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TELSMI

TH
Models 38, 44, 52, 57 and 68 H/SBS
Cone Crushers
Wear Liner Replacement

ISSUE DATE: 07/09 (Rev 1)

TP401

SAFETY
Be sure to read and fully understand the precautions shown on the inside front cover of this manual before
operating or servicing your Telsmith product. Also refer to Chapter 1 for important safety information.

! WARNING
Failure to follow the safety precautions shown below may result
in serious personal injury or death!

Never attempt to work on quarry equipment while it is in operation. Always stop the machinery, lockout power
and tag controls:
1. Before performing any lubrication, maintenance, adjustment, or repairs.
2. Before removing spilled materials.
3. Before clearing jams or working inside the machinery.
4. If any unusual noises or sudden changes in operation are noticed.

Stay clear of feed and discharge areas and other places where falling rock is present. Keep away from loading
vehicles. Wear and use personal protective equipment in accordance with all applicable health and safety
regulations. Safety goggles, hard hat, ear plugs and steel-toed shoes are mandatory when working near
machinery. Wear and use additional personal protective equipment as required.

Stay clear of springs and other pinch points. Never reach in-between vibrating equipment and its support
structure. Keep a safe distance from all moving components.

Never attempt to enter the crushing chamber when tramp iron or other uncrushable objects are wedged inside.
These materials are under tremendous pressure and may be propelled upward through the feed opening at any
time. On crushers not equipped with hydraulic clearing, use a pole, hook, grappling device, or breaker bar to
safely dislodge uncrushable objects.

Do not make equipment modifications that will result in a safety hazard or create a dangerous situation. Never
remove or disable safety devices. Maintain all machinery in accordance with manufacturers instructions and
maintenance schedules.

Read the operators manual for the equipment that you operate. Be sure that you fully understand all phases of
operation for each machine. A careful and well-trained operator is the best insurance against an accident.

Refer to Chapter 1, Safety, for important quarry safety information. If your copy is missing, replacement
copies may be obtained from your local Telsmith Dealer or the Telsmith Parts Department.

All rotating power products are potentially dangerous and must be properly guarded. Placement of guards and
other safety equipment is the users responsibility. Such equipment must be installed wherever appropriate and
maintained as required.

It is the purchasers responsibility to ensure that quarry equipment is installed and used in a safe and lawful
manner. All machinery must be operated in compliance with applicable health and safety laws and general
standards of reasonable care.

Foreword
INTRODUCTION

ORDERING REPLACEMENT PARTS

This manual will help you achieve optimum performance


from your Telsmith SBS Cone Crusher. It contains complete
repair and overhaul instructions for all SBS-Series models.

For replacement parts information, please refer to the SBSSeries Cone Crusher Drawings. These drawings contains
exploded diagrams and parts lists to help you quickly identify
the major components used on your crusher.

The data and instructions contained in this manual are based


on the latest information at the time of publication. Telsmith's
policy of continuous improvem ents, features and
specifications are subject to change without notice.
Actual dimensions, weights, and clearances may be different
than shown, due to fabrication variables, custom engineering
or optional equipment.
Please note that some features shown in this manual may not
be present on your machine. Some equipment described may
be optional at extra cost, or available only on selected
models.

If your prints have been lost or damaged, new copies are


available from your local approved Telsmith Distributor or
the Telsmith Parts Department.
To ensure that you receive the correct parts for your machine,
always include the model number and serial number when
ordering.

MODEL and SERIAL NUMBER PLATE


LOCATION

HOW TO CONTACT TELSMITH INC.


Use the following information when you wish to contact
Telsmith:

General: Phone (262) 242-6600 (24/7)


FAX
(262) 242-5812

Parts:

Written: Telsmith, Inc.


10910 N. Industrial Drive
P.O. Box 539
Mequon, WI 53092-0539
U.S.A.

Send all e-mail to:


parts@telsmith.com

Phone (800) 688-6601 (24/7)


FAX
(262) 242-7861

REQUESTING SERVICE ASSISTANCE


If service assistance is required or you have questions about
maintenance or repair procedures in this manual, please
contact your local approved Telsmith Distributor. If
additional assistance is necessary, contact the Telsmith
Service Department.
Service technicians are available by telephone 24 hours a day,
seven days a week. To ensure faster response, always have
your machines model and serial numbers ready when
calling.
Model and serial numbers are located on a data plate attached
to the machine main frame. Always lockout power and tag
controls before reading data plate!

07/09 (Rev 1)

Foreword

OPERATION AND MAINTENANCE


INSTRUCTIONS
This manual includes procedures for cone crusher repair and
overhaul only. For detailed operation and maintenance
instructions, please refer to the SBS-Series O peration and
M aintenance M anual.
The Operation and Maintenance Manual is provided with all
new SBS-Series cone crushers. Replacement copies, if
needed, may be ordered from your local Telsmith dealer or
the Telmith Parts Department.

SERVICE BULLETINS
Telsmith periodically issues service bulletins to inform
customers of the latest repair and maintenance procedures.
Service bulletins may have been included separately with this
manual. Always read and understand all service bulletins
before starting any maintenance or service work.

SAFETY
All quarry personnel operating or servicing the machine must
read and fully understand the information included in
Chapter 1, Safety of this manual.

ILLUSTRATIONS
This manual contains some illustrations in which guards,
access panels and other safety equipment have been removed
for instructional purposes or to provide greater clarity.
However, to prevent serious personal injury or death, always
be sure all such equipment is installed before operating the
product.

Wear Liner Replacement


Telsmith SBS Cone Crusher

CONTACTS
TELSMITH PARTS DEPARTMENT CONTACTS

Name:
Phone (Office):
Phone (Cell):
FAX:

Name:
Phone (Office):
Phone (Cell):
FAX:

TELSMITH SERVICE DEPARTMENT CONTACTS

Name:
Phone (Office):
Phone (Cell):
FAX:

TELSMITH APPROVED DISTRIBUTOR CONTACTS

Name:
Phone (Office):
Phone (Cell):
FAX:

INSTALLATION & ASSEMBLY DRAWINGS


Installation and assembly drawings (blueprints) are provided
with all new Telsmith products. These drawings are normally
included with the technical manuals but may be shipped
separately for some orders.
The drawings include specifications, dimensions and other
information for use during installation and assembly
procedures. Contact your local Telsmith dealer or the
Telsmith Service Department if you have any questions about
information contained on the drawings.
If the drawings are lost, replacement copies may be ordered
from your local Telsmith dealer or the Telsmith Parts
Department.

OTHER CONTACTS

Name:
Phone (Office):
Phone (Cell):
FAX:

Name:
Phone (Office):
Phone (Cell):
FAX:

07/09 (Rev 1)

Table of Contents
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUPPORT BOWL AND CONCAVE RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANTLE AND HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A - Torque Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1


Appendix B - Conversion Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Appendix C - Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Appendix D - Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Appendix E - Sealants and Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Appendix F - Removal Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
Appendix G - Wear Liner Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

(Continued on next page)


07/09 (Rev 1)

Table of Contents

12

Wear Liner Replacement


Telsmith

07/09 (Rev 1)

Wear Liner Replacement


Telsmith Silver Bullet Series Gyrasphere

Chapter 1

Chapter 1
Safety
Page
SAFETY OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
HAZARD AND ADVISORY STATEMENTS . . . . . . . . . . . . . . . . . . . . . . 1-2
LOCKOUT/TAGOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

GYRASPHERE SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5


QUARRY SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
MACHINERY INSTALLATION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . 1-8
MAINTENANCE AND REPAIR SAFETY. . . . . . . . . . . . . . . . . . . . . . . . 1-9
HOISTING AND HANDLING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . 1-11
TRANSPORTING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

7F

07/09 (Rev 1)

11

Safety

SAFETY OVERVIEW
It is the responsibility of the quarry management team to
develop a comprehensive safety awareness program, and to
ensure that all quarry workers and support personnel receive
appropriate safety training as required by federal, state and
local regulations.

Wear Liner Replacement


Telsmith SBS Cone Crusher
A Note is a basic informational statement or helpful
suggestion. An Important is used to draw attention to a
procedure that must be observed to prevent machine damage
or malfunction.

Safety is basically common sense. There are standard safety


rules, but each situation has its own peculiarities which can
not always be covered by rules. Therefore, quarry personnel
must continually watch for possible safety hazards and be
prepared to take prompt corrective action when necessary.

! DANGER

Failure to observe the precautions contained in this chapter


can result in serious personal injury and even loss of life. As
with most industrial work environments, a careful operator is
the best insurance against an accident.

! WARNING!!!
DANGER

Hazard
Statements

The complete observance of one simple rule would prevent


many unnecessary injuries and deaths each year. This rule is:
Never attempt to clean, lubricate, repair or adjust any
machinery unless it is stopped and properly locked out.
Please note that this chapter is only intended as a brief review
of basic quarry safety precautions and procedures. The
general guidelines included in the following paragraphs
should not be considered in lieu of a quarrys official safety
procedures, insurance company requirements, or applicable
federal, state and local regulations.

! CAUTION
DANGER !!!

Important
Note

Advisory
Statements

HAZARD AND ADVISORY STATEMENTS


Throughout this manual, the use of hazard and advisory
statements have been emphasized. Examples of these are
shown in Figure 1-1.

7F

Hazard Statements
The Caution, Warning and Danger statements are hazard
statements used to alert workers of unsafe practises and
potentially harmful or life-threatening situations. Each of
these statements is preceded by the Safety Alert Symbol.
Failure to follow the instructions contained in a Caution
statement may result in MINOR PERSONAL INJURY.
Failure to follow the instructions contained in a Warning
statement could result in SERIOUS PERSONAL
INJURY or DEATH.
Failure to follow the instructions contained in a Danger
statement will result in SEVERE PERSONAL INJURY
or DEATH.

Advisory Statements
The Note and Important statements are advisory statements
which relate to equipment operation, maintenance and
service procedures. They are used to draw attention to proper
procedures and practises.
12

Figure 11. Hazard and Advisory Statements

LOCKOUT/TAGOUT
Who Must Use Lockout/Tagout?
Quarry owners, managers, and safety officers must be aware
of OSHAs lockout/tagout standard: CRF Section 29
1910.147, The Control of Hazardous Energy. This standard is
also recognized by MSHA.
All mechanics, maintenance personnel, operators, and
electricians must fully understand and comply with this
standard to ensure the safety of all employees.

What is Lockout/Tagout?
Lockout/tagout is a means to ensure that personnel who
install, operate, repair, maintain, service or otherwise disable
machines, equipment, or electrical energy systems are
protected from harm due to unexpected energizing, or the
release of stored energy by...
1. Lockout Placing a disconnect switch, circuit breaker,
valve, or other energy-isolating mechanism in the off or
safe position and securing it with a lock so the energyisolating mechanism cannot be activated.
07/09 (Rev 1)

Wear Liner Replacement


Telsmith SBS Cone Crusher

Safety

2. Tagout A prominent written warning (tag or label)


placed on the energy-isolating mechanism indicating the
name of the individual placing the mechanism out-ofservice, and stating that the energy isolating mechanism
cannot be activated until the tagout device is removed.

When Must Lockout/Tagout Occur?


Lockout/tagout must occur whenever service or maintenance
is performed, and injury could occur due to the unexpected
start-up of equipment, or the release of stored energy. See
Figure 1-2.
In general, lockout/tagout procedures must be performed
under the following circumstances:
Before cleaning, lubricating, adjusting or repairing
machinery or equipment.
Before working on electrical, hydraulic or pneumatic
circuits or devices.
Before clearing jammed mechanisms, machinery or
equipment.
Before removing guards or other protective devices.
Whenever a machine or its controls will be left
unattended.

How is Lockout/Tagout Performed?


OSHA has identified the following step-by-step lockout/
tagout procedure:

1. Prepare for shutdown Before shutting down a piece


of equipment, know the type and magnitude of the energy
that powers it, the hazards of that energy, and how to control
it. Warn all employees that the machinery is about to be shut
down.
2. Shutdown the equipment After warning all
employees, shut down the machine, equipment, or electrical
system by the normal stopping procedure.
3. Control stored energy any potentially hazardous
stored energy (electrical, mechanical, hydraulic, pneumatic,
etc.) that remains must be released, dissipated, restrained, or
otherwise rendered safe. If stored energy reaccumulates,
monitor it until the possibility of accumulation no longer
exists.
4. Isolate the equipment Disengage all isolating
devices, both primary and secondary, so that the equipment
is isolated from all of its energy sources (electrical,
mechanical, hydraulic, pneumatic, etc.).

5. Apply lockout/tagout devices Attach lockout tagout


devices (according to your companys safety program) in
such a manner that the isolating device (circuit breaker,
control, etc.) will be held in a safe or off position. Attach tags
to alert others that the machinery is being serviced.
6. Verify that equipment is isolated After warning all
employees to stay clear, engage the start button to confirm
the machine is inoperable. Return the control to the off
position before proceeding with servicing.

LOCKOUT / TAGOUT POWER...


Before making inspections or adjustments.

7F

Before performing any lubrication, maintenance or repairs.


Crusher lockout/tagout summary:
1.

Always lockout/tagout power to crusher drive motor.

2.

Always lockout/tagout controls for diesel engine (If equipped).


Disconnect batteries and shut-off fuel supply.

3.

Always lockout/tagout power to crusher lubrication and hydraulic


systems.

4.

Always lockout/tagout power to all crusher feed and discharge


equipment, such as feeders, conveyors and screens.

! WARNING!!!
DANGER
Failure to perform lockout/tagout procedures can result
in serious personal injury or death!
Figure 12. Lockout/Tagout
07/09 (Rev 1)

13

Safety

When Can Lockout/Tagout Devices be


Removed?
Lockout/tagout devices can only be removed after the
following conditions are met:
All guards and protective devices are properly reinstalled.
All tools and repair equipment are removed from the
equipment and the immediate area.
All mechanics and other personnel are clear of the
equipment and its immediate area.
All personnel have been warned that the equipment is
about to be restarted (sound warning horn and activate
warning lights).

After removing lockout/tagout devices, always use the


normal start-up procedure as described in the operators
manual for the machinery.

Lockout/Tagout Devices
Lockout/tagout devices include:
1) locks
2) tags and labels
3) multiple lockout devices
A lock must be sufficiently durable, so it can withstand the
environmental conditions (heat, cold, moisture, etc.) around
it. A lock must also be strong enough so that it cannot be
easily removed or forced open.
A tag or label must be affixed to each lock to alert others that
service work is in progress. Each tag or label must have the
following characteristics:

7F

Be sufficiently durable to withstand wear and abuse, even


if used in dirty or damp environments.
Be securely attached with a cable that is difficult to
remove, cut or tear.
Contain the name of the person that applied it.
Contain a warning or other precautionary statement that
briefly indicates why the machine is locked out and what
hazards could result if the equipment is started while
service work is in progress.
When two or more people are working on a piece of
equipment, a multiple lockout device must be used. This
allows each person to install their own lock, preventing
accidental start-up.

Lockout/Tagout Rules
Always lockout/tagout any machinery before performing
any adjustment, inspection, lubrication, maintenance or
repair procedures. Failure to observe this precaution may
result in serious personal injury or death.
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Telsmith SBS Cone Crusher
Your companys lockout/tagout program may be
somewhat different than described in this manual. If so, be
sure to completely follow your companys official
policies and procedures when lockout/tagout is necessary.
Consult your companys safety officer if you have any
questions.
A lock must have only one user and one key. Anyone who
installs a lock must keep the key in their possession at all
times. Except in an emergency situation, only the person
that installs a lock is authorized to remove it.
To prevent accidental start-up, never give your lock or its
key to another employee.
Your key must open your lock only. Your key should not
be capable of opening any other locks. Keys for other
locks should not be capable of opening your lock.
Except in an emergency situation, never attempt to
remove anyone elses lock. Do not allow others to remove
your lock.
When disconnecting power, be sure that the circuit
breaker handle (or other isolating device) is in the OFF
position. Accidentally locking a control in the ON
position could result in serious personal injury or death.
If two or more people are working on a machine, a
multiple lockout device must be used to prevent
accidental start-up in the event that one person finishes
working before another.
Each lock must have a tag. If two or more people are
working on a machine, each person must attach a separate
tag to their lock. Never attach a lock without a tag.
Never use tags alone. A tag should always be
accompanied by a lock which prevents the isolating
device from becoming energized.

Additional Lockout/Tagout Requirements


Be sure that the power is COMPLETELY turned off. A
motor may be stopped and locked out. However,
interlocks, starters, and other supplemental electrical
components may still be energized. Use a voltmeter and/
or ammeter to verify that all electrical circuits are
completely dead.
Always be sure that all peripheral equipment, such as feed
conveyors, grizzly feeders and discharge conveyors, is
also tagged and locked out. Serious personal injury or
death can result if any of these items starts unexpectedly
while the crusher is being serviced.
Although lockout/tagout procedures are most commonly
associated with electrical systems, be aware that
hydraulic, pneumatic and mechanical systems must also
be tagged and locked out before servicing. This may
involve the lockout/tagout of valves, levers and other nonelectrical devices.
07/09 (Rev 1)

Wear Liner Replacement


Telsmith SBS Cone Crusher
For machinery powered by internal combustion engines
(diesel, gas, etc.), always disconnect batteries and shut-off
fuel supply before servicing the machinery. Lockout/
tagout engine controls to ensure that engine is not
accidentally started while the machinery is being
serviced.
Always be sure that all hydraulic or air pressure is
completely relieved before working on hydraulic or
pneumatic systems. Dangerous pressures can be present,
even when equipment is turned off and locked out.
After maintenance or repairs are completed, always warn
all employees that the machinery is about to be restarted.
Be sure no one is on or near the equipment before a lock
and tag is removed.
As a precaution, always activate a warning horn or light
before restarting the machinery. This will provide
additional warning for personnel to stay clear of
machinery that is about to be started.

GYRASPHERE SAFETY
Perform a complete walk around inspection before
starting the crusher. Be sure that no persons are on, inside
or under the crusher. Refer to the Operation and
Maintenance Manual for crusher daily start-up
procedures.
Be sure that all guards and other safety devices are
correctly installed and tightly secured before starting the
crusher. Stay clear of rotating or moving parts during
crusher operation.
Do not allow personnel to be on or near the crusher during
operation. Stay clear of feed and discharge areas to
prevent being injured or killed by flying or falling rock.
Rock projected upwards through the feed opening can
injure or kill. Do not look directly into the feed opening
while the crusher is operating. Use mirrors or closedcircuit cameras if close observation of the feed
arrangement is necessary for troubleshooting or
evaluation purposes.
Never attempt to clear jammed material from the crushing
chamber while the crusher is operating. Serious injury or
death could result if you are pulled into, or fall inside, the
crushing chamber.

07/09 (Rev 1)

Safety

Never attempt to manually clear jammed material from


the crushing chamber while the upper frame is in the
lowered (clamping) position. Any material lodged in the
chamber could release without warning, and may be
propelled upward through the feed opening. Serious
injury or death could result. Refer to the Operation and
Maintenance Manual for jam removal procedures.
Do not tamper with crusher alarm components. Never
attempt to defeat electrical interlocks or to disable crusher
protective devices.
Never place hands on cylinder rods. Stay clear of pinchpoint area between the upper and main frames.
Never stand on hydraulic hoses or use them as steps. If
hoses rupture, serious injury or death could result. As
required, use a safety harness during servicing.
Always lockout/tagout power to the crusher drive motor,
crusher oil lubrication system and crusher hydraulic
system before performing any inspection, adjustment
lubrication, maintenance or repair procedures. Also
lockout power to all crusher feed and discharge
equipment. Be sure pressure is fully relieved before
servicing the hydraulic system.

If the crusher is powered by a diesel engine, always


disconnect batteries and shut-off fuel supply before
performing any inspection, adjustment, lubrication,
maintenance or repair procedures. Lockout/tagout
engine controls to prevent the engine from being
accidentally started while the crusher is being serviced.
Support the crusher upper frame with hardwood blocking
or steel safety spacers before entering the crushing
chamber for service work. Never rely on hydraulic
pressure to keep the upper frame raised. You could be
crushed and killed if the upper frame lowers
unexpectedly.
Always stop the crusher immediately if any gauges show
abnormal readings, or if there is a sudden obvious change
in operation. Be alert for noises that might indicate
trouble.
Inspect, lubricate, maintain and repair the crusher in
accordance with the instructions contained in this manual
and any additional manuals or documentation provided
with the crusher.

15

7F

Safety

QUARRY SAFETY SUMMARY


Know Your Machinery
Read the manufacturers operation and maintenance
manuals for all machinery and equipment that you
operate. Be sure that all hazard statements contained
within the manuals are completely understood.
Become familiar with the controls, functions and settings
of each machine. Fully understand all phases of each
machines operation.
Be sure that you completely understand and follow all
start-up and shut-down procedures as described in the
manufacturers manuals.

Be familiar with the safety signs on your equipment, and


the hazards against which they warn.
Check the legibility of all safety signs every day. Order
new signs from the machinery manufacturer if they
become illegible or worn.

Be Prepared for Emergencies


Know the proper emergency shut-down procedures for
the equipment you operate.
Know where fire extinguishers are kept and how to use
them. Be sure that fire extinguishers are properly rated,
and that they remain fully charged and ready for use at all
times.
Know the procedure for contacting emergency medical
personnel. Keep a list of emergency phone numbers
handy at all times.

7F

Know where first-aid kit, stretcher and other emergency


supplies are kept. Be sure that first aid supplies are
properly maintained and ready for use.
Make sure that a clear path to emergency equipment and
exits is always maintained. Do not allow equipment,
spilled materials or other obstructions to get in the way.
Know how to report accidents. Always report all
accidents immediately to the appropriate supervisor.

Wear Personal Protective Equipment


(PPE)
Wear safety glasses or goggles whenever outside of an
approved operator s enclosure. Failure to wear
appropriate eye protection can result in permanent eye
injuries and loss of sight.
Wear appropriate ear protection when working within 50
feet of any operating quarry machinery, and in other areas
where noise levels are high. Prolonged exposure to high
noise levels can cause permanent hearing loss.

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Telsmith SBS Cone Crusher
Wear steel-toe safety boots, heavy-duty gloves and a hard
hat. This equipment is mandatory in most areas of the
quarry.
Use respirators in dusty locations and when working with
hazardous substances. Prolonged exposure to rock dust or
chemical fumes can cause permanent respiratory illness.
Other personal protective equipment may be necessary for
your specific job assignment, such as a full face shield and
safety harness. Wear or use these items when necessary
and as required by applicable federal state and local
regulations.

Observe Personal Safety Precautions


Never wear loose or ragged clothing when working on or
around rotating power equipment. Avoid wearing
necklaces, rings or other jewelry. These items can become
caught or tangled in the machinery, resulting in severe
personal injury or death.
Keep hair short, if possible. Keep long hair securely tiedup to prevent it from becoming caught in the machinery.
Be especially careful whenever using wet walkways,
platforms, or ramps. The combination of rock dust and
wet metal can create an extremely slippery surface. Keep
all walkways and other access structures clean, dry and
free of grease or oil.
Use walkways and ladders when working near machinery,
or observing its operation. Use a safety harness when
necessary. Keep handrails and machine contact surfaces
clean.
To avoid back injuries, always use proper lifting
techniques to safely lift heavy objects. Lift with your legs
and keep your back straight. Keep the materials or object
close to your body. Have a co-worker assist you if the load
cannot be lifted safely by one person.
Never attempt to catch falling materials or objects.
Be aware of flammable liquids and other potential fire
hazards. Do not smoke when refilling engines or using
cleaning solvents.
Do not stand under equipment or components that are
being hoisted or suspended. Never allow other quarry
personnel to do so.
Before you assemble, operate, clean, lubricate, or adjust
machinery, be sure to read and understand all procedures
contained in the machinery manufacturers manual.
Be sure to operate quarry machinery in compliance with
current OSHA and MSHA regulations, and all applicable
state and local regulations.

07/09 (Rev 1)

Wear Liner Replacement


Telsmith SBS Cone Crusher

Safety

Help Prevent Accidents

Practice Good Housekeeping

Do not allow unauthorized personnel in or near the work


area. Never allow unauthorized personnel to operate,
adjust, maintain or repair machinery.

Do not store tools or equipment on walkways.

Allow only properly trained and experienced personnel to


operate machinery. Be sure inexperienced operators are
carefully supervised at all times.
Before start-up, visually check that no personnel are
inside, on, under or beside the machinery. Alert all
workers that start-up is about to occur. Always sound
warning horn before starting the machinery.
Do not allow personnel to be near loading areas, or
anywhere else that falling or ejected material could hit
them.
Use extreme caution if the machinery must be operated
for inspection or observation purposes. Stay a safe
distance from the machinery and wear appropriate
personal protective devices.
Before making repairs to the machinery, always clear all
quarry material from the feed and discharge devices
(feeders, conveyors, chutes, etc.).
In areas which present a danger of falling, use an
appropriate fall protection device, such as a safety harness
and lifeline.
Always report any unsafe conditions or defective
equipment to the appropriate supervisor.

Avoid Alcohol and Other Drugs


Do not operate or work near quarry machinery when
under the influence of alcohol or other drugs. These items
can result in reduced alertness and impaired judgement.
Serious personal injury or death could result.
Some prescription and non-prescription medications can
cause drowsiness or other adverse side effects. Do not
operate or work near quarry machinery when under the
influence of such medications.

Be Aware of Your Surroundings


The quarry environment contains many situations that are
potentially hazardous. Use extreme caution to avoid being
struck by haul trucks, loaders and other quarry mobile
equipment.
Be aware of idle machinery that could start-up without
warning. Stay clear of such machinery and the immediate
area.

Be sure that all walkways, platforms, stairs and ramps are


kept free of spilled material and trash. A build-up of
material in these areas can cause slips and falls. Make
repairs as required in areas where spillage is present.
Do not allow machinery to become buried under piles of
spilled material. This will make the machinery more
difficult to inspect and may hide broken welds, loose
fasteners and other serious problems that could cause a
safety hazard.
Keep the areas around control panels and machinery free
of spilled material. Free access must be maintained at all
times. In the event of an emergency, quick access to
controls could prevent injury or death.
Clean up spilled fuel or oil immediately to eliminate
slipping hazards. If necessary, use an oil absorbent.
Always be sure that power is tagged and locked out before
cleaning spilled material or oils. Never clean-up these
items while the machinery is operating.

Inspect And Maintain Machinery


Always perform a safety inspection at the beginning of
each shift. Refer to the machinery manufacturers
operation and maintenance manuals for detailed pre-startup inspection and maintenance procedures.
Test all warning devices before starting the machinery to
ensure that they are working properly. Never disable or
bypass any alarm systems or interlocks.
Be sure that any defective components or systems are
properly repaired by a qualified technician before the
machinery is started. Immediately report any serious
problems to the appropriate supervisor.
Before performing inspections or maintenance, always
lock out power and tag controls to the machine drive, and
to all feed and discharge equipment. Warn all personnel
that the equipment is being serviced. Refer to the Lockout/
Tagout section of this chapter for additional information.
Maintenance inspection procedures are included
throughout this manual. Although maintenance is not
typically a safety concern, machinery that is regularly
maintained and in proper working condition will
minimize the occurrence of safety hazards and emergency
situations.

Be aware of overhead obstructions, such as conveyors,


support structures or power lines.

07/09 (Rev 1)

17

7F

Safety

MACHINERY INSTALLATION SAFETY


Foundations
Proper foundations and support structures are essential to
ensure the safe and efficient operation of quarry equipment.
Crushing machinery needs a firm foundation on which to
operate. This does not need to be a poured pad, but it must
not be unstable ground. When selecting the location, be
sure that the entire area is as level as possible.
Follow all manufacturers installation drawings and
specifications when constructing the base pads for
permanent plants.

If any questions arise regarding foundation requirements


or modifications necessary for Telsmith machinery, please
contact the Telsmith Service Department.
Customer-designed support structures for Telsmith
equipment must meet Telsmiths engineering standards.
All plans must be submitted in advance to the Telsmith
Engineering Department for approval.

Guarding
Quarry management is responsible for the proper
installation and placement of guards to prevent personnel
from coming in contact with rotating or moving parts.
In addition to the guards supplied with the machinery,
additional guards and related safety equipment may be
required to comply with OSHA, MSHA and any
applicable local regulations. The proper fabrication,
installation and placement of these items is the users
responsibility.

7F

When fabricating guards, refer to MSHAs Guide to


Equipment Guarding at Metal and Nonmetal Mines.
Additional information can also be provided by the safety
officer at your worksite.

Wear Liner Replacement


Telsmith SBS Cone Crusher

Electrical Hook-up

! WARNING!!!
DANGER
When installing any electrical equipment, be sure
t o c o m p l e t e l y f o l l o w t h e m a n u f a c t u r e r s
instructions. Failure to observe this precaution
could result in a dangerous electrical shock hazard.
Be sure that all electrical equipment is properly grounded.
Lay out the power lines, especially those for portable
plants, so that contact with standing water is minimized.
Do not place power lines in an area where they will be
driven over by transport vehicles or other quarry
equipment. If it is absolutely necessary to extend a power
line across a traffic area, protect the cable with properly
rated bridging.
Be sure that all auxiliary control panels or power supply
panels can be securely locked out. This type of panel is
mandatary.
Maintain adequate overhead clearance from power lines
or other obstructions, particularly when planning to use
stacking conveyors for stockpiles.
Be sure that electrical power supplies are located in an
area that will be safe from accidental contact during
crushing operations.
All Telsmith machinery is designed with electrical
components of the proper size and voltage. Any
modifications to these components or to the power supply
must be approved in writing by the Telsmith Engineering
Department.
Be sure that all connections are in accordance with the
National Electric Code and any applicable state or local
codes.

Never remove guards until the machinery is stopped,


power is locked out, and controls are tagged. Be sure that
guards are properly re-installed before reconnecting
power.

Customer Modifications
Do not modify quarry machinery in any way without prior
approval from the manufacturer. Such modifications may
include (but are not limited to) changing machine speed or
direction of rotation, drilling additional holes and welding
or bolting additional equipment to the machinery.
All customer modifications to Telsmith machinery must
be approved in writing in writing by the Telsmith
Engineering Department.

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MAINTENANCE AND REPAIR SAFETY

! WARNING!!!
DANGER
Always lockout/tagout power to machinery and
conveying equipment before performing any
maintenance or repairs. Warn all personnel that the
machinery is being serviced.

General Precautions
To help ensure safe machine operation, use only genuine
OEM replacement parts that are sold or approved by the
machines manufacturer. Use of non-OEM parts may
adversely affect machine operation and could result in an
a hazardous situation.
Always tighten all fasteners to the proper torque as
described in the repair procedures. When torque
specifications are not listed, use the values in the torque
chart at the back of this manual. Refer to Appendix A of
this manual.
Be sure all replacement fasteners are of the proper grade
and specifications. Replace any worn or damaged
fasteners.

Electrical Systems
Always read, understand and follow appropriate electrical
system troubleshooting, maintenance and repair
instructions in the machinery manufacturers manuals.
Allow only trained and licensed electricians to install,
troubleshoot and repair electrical equipment. All
procedures must be in compliance with the National
Electric Code and any applicable state or local
regulations.
When servicing an electrical system, work with the power
locked out and tagged. Always assume that an electrical
system is live until it has been locked out.
Always tag and lockout power before removing cables
with quick-disconnect plugs.
Repair any obviously worn or damaged wires and
connectors.
Inspect power cables and connections daily for signs of
wear, cracked insulation and worn or damaged
connectors. Repair or replace as required.
Do not store tools inside electrical cabinets.
Verify that all tools are grounded with a three wire plug or
double insulated. Be sure that all extension cords are
grounded with a three wire plug.

07/09 (Rev 1)

Safety

Pressurized Systems (hydraulic and air)


Adjust, maintain and repair all pressurized systems only
in accordance with the instructions contained in the
manufacturers manuals provided with the machinery.
Never attempt to work on a pressurized system while it is
pressurized or in operation.
Before performing maintenance or repairs on any
pressurized system:
- Cycle the controls through all operating positions to
relieve any trapped pressure.
- Check that ALL pressure is relieved from the system.
Pressure gauges must read zero (0) PSI.
- Lockout and tag all controls. Be sure electrical power is
properly locked out and tagged.
Allow time for hot hydraulic oil to cool before performing
any maintenance or repairs. Hot oil can cause burns.

Before loosening fittings or removing components,


always recheck that ALL pressure is relieved from the
system. Pressure gauges must read zero (0) PSI.
Never attempt to crack a hydraulic fitting while a
hydraulic system is pressurized. You could be injured or
killed by a stream of high pressure oil.
Never have your face near, or stand directly in front of a
hydraulic line when cracking a fitting, even after system
pressure has been relieved. Always assume that the line
has pressure.
Use a piece of cardboard to check for hydraulic oil leaks,
not your hand. Escaping fluid under pressure can
penetrate the skin, resulting in serious personal injury.
Clean-up any spilled hydraulic fluid. Hydraulic fluid is
extremely slippery, and can be especially dangerous if
spilled on an elevated walkway or platform.
Repair any leaks immediately. Always relieve system
pressure and lockout/tagout power before tightening
fittings or making repairs.
Never attempt to adjust pressure relief valves to above the
machinery manufacturer s recommended settings.
Serious personal injury and/or equipment damage could
result.
Do not operate any hydraulic or air system with obviously
worn or damaged, or leaking components. Always replace
any defective components immediately.
Never place hands on hydraulic cylinder rods while
equipment is in operation. Do not step on the hydraulic
relief cylinder hoses when climbing on the crusher.

19

7F

Safety

Refer to manufacturers instructions when recharging


hydraulic accumulators or checking accumulator
pressure. Allow only trained and certified hydraulic
system technicians to depressurize, recharge or repair
hydraulic accumulators.

Welding On Machinery
Be sure to provide adequate ventilation when welding
inside enclosed areas to prevent the buildup of hazardous
fumes. Special concern should be exercised when welding
chromium, manganese, cadmium, copper, cobalt, lead and
nickel, as these materials are considered to be potentially
carcinogenic.
Be sure to wear the proper welding shield, welding gloves
and clothing. Do not wear synthetic fabric clothing or
clothing which could be easily ignited by sparks.

Always follow all standard safety procedures when


welding. Be sure that all systems are shut down, power is
locked out, and controls are tagged. Provide welding
screens to protect other employees working in the area.
Relieve all hydraulic pressure before welding near
hydraulic components and lines. Cover hydraulic
components to protect them from weld spatter and sparks.
Do not weld near flammable liquids or hydraulic oils.
Welding lifting eyes or hooks to manganese steel castings
is strongly discouraged, and should be done only if
absolutely necessary. Always use a stainless steel or
manganese weld rod. Never allow personnel to walk or
work underneath castings being lifted or supported.

7F

Never ground the welder so that the electrical power will


flow through bearings, hydraulic components or electrical
equipment. Serious damage could result.
Be sure all compressed gas cylinders are stored upright,
chained and capped. Turn-off all cylinders when not in
use.

Clearing Jammed Material


If material becomes jammed in the machinery:

Wear Liner Replacement


Telsmith SBS Cone Crusher
Always remove all jammed material before restarting the
machinery. To prevent damage, never attempt to restart a
stalled machine without first removing the jammed
material.
Never use dynamite or other explosives to clear jams.
Explosives are dangerous and can injure or kill personnel.
Damage to machinery could also occur.

Hazardous Materials
Be aware potentially hazardous chemicals or materials.
Such items can be harmful if they are improperly used,
stored, mixed or transported, or if they are inhaled,
swallowed or allowed to contact the skin.
Consult your employers hazard communications plan for
instructions regarding the proper handling and use of
hazardous materials. Read and understand the labels
attached to the product containers. Always follow the
instructions carefully.
Consult the manufacturers material data sheet (MMD)
for potential hazards and appropriate medical procedures
should an accident occur.
Store hazardous materials only in approved containers. Be
sure containers are clearly labeled.
To avoid potential health hazards, persons in regular
contact with hydraulic oils must be aware of the
importance of thorough hygiene, and the proper methods
for handling mineral oils.
Mineral-based hydraulic oils act as solvents on the natural
oils of the skin. Frequent and prolonged skin contact can
cause dermatitis or severe irritation.
Always wear suitable protective clothing when handling
hydraulic oil.
Be sure protective clothing and proper wash-up facilities
are available to all personnel that may come in contact
with mineral-based hydraulic oils.
Always dispose of used rags or paper towels in the correct
and safe fashion.

- Immediately stop the machinery.


- Lockout/tagout power. Warn others that the machinery is
being serviced.
- Follow the instructions in the operation and maintenance
manual of the affected equipment. (The jam removal
procedure for Silver Bullet Series crushers is located in
the Operation and Maintenance Manual).
To prevent serious personal injury or death, never attempt
to remove jammed material while the machinery is in
operation.

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Disposal Of Excess Fuels, Lubricants And


Liquids
Quarry personnel are responsible for the proper disposal of
unused fuels, used lubricating oils, used hydraulic oils, and
other toxic materials. DO NOT dispose of these materials in
an unapproved manner. Follow all applicable federal, state
and local regulations.

Flammable and Combustible Liquids


Store flammable liquids in a safe place, away from quarry
machinery and personnel. Use approved safety containers
and be sure that they are clearly marked. Containers must
be covered when not in use.

Safety

Wire Rope
Wire rope requires careful use, handling and maintenance to
ensure long life and safe operation. Always observe the
following precautions.
Be sure to use the correct wire rope for the application.
Be sure that the wire rope is inspected regularly following
the manufacturers guidelines.
Avoid sudden loading in cold weather. Never use frozen
wire rope.
Use suitable padding to protect wire rope from sharp
corners or edges.

Keep flammable liquids away from sparks, open flame,


and other ignition sources. Do not smoke around
flammable liquids. Always obey posted no smoking
signs.

Avoid dragging wire rope underneath loads or over


obstacles.

Be familiar with the locations of fire extinguishers


throughout the quarry. Be sure they remain accessible at
all times, and are not blocked by obstructions.

Avoid reverse bends.

Do not use gasoline or other flammable liquids to clean


tools or parts. Use only approved non-flammable
solvents.

Use thimbles in eye fittings at all times.

Always shut-off engines before refueling. Ground fuel


spout against the filler neck to prevent static electricity.
Never smoke while refueling.

Follow the manufacturers instructions for lubrication if


using wire rope for lifting purposes.

Use only approved safety containers for storing and


transporting small quantities of flammable liquids. Keep
containers covered when not in use.

When connecting or clamping wire ropes, use one of the


following:

HOISTING AND HANDLING SAFETY


General Precautions
Do not allow personnel to work or walk under loads
supported by a crane or hoist.
Use appropriate lifting devices to secure the load to the
crane. See the following paragraphs of this section for
additional information.
Use the correct lifting hooks to support the load. Refer to
the Operation and Maintenance Manual for crusher
lifting points and procedures.
Use extreme caution when operating a crane near power
lines or electrical equipment.
Do not exceed the cranes rated load capacity. Always
subtract the weight of the hook block, slings, chains,
spreader bars and any additional equipment to determine
the maximum load that can be safely lifted.

Never use wire rope that is cut, badly kinked, frayed or


crushed.

Be sure that rope ends are properly sized.

Watch for local wear. Reposition or shorten wire rope to


remove the worn section from the area of lifting tension.

Connecting Or Clamping Wire Ropes

Clamp and thimble connections combine both the


clamp and thimble in one unit. Clamp and thimble
connections are capable of supporting 80% of the rated
wire rope load.
Cable clips are the most common way to secure a rope to
a piece of equipment or to make an eye. The cable clip or
Crosby Clip is made of a U-bolt and saddle. If this type
of clip is used to make an eye, the use of a properly sized
thimble is mandatory. If not, the cable may kink, forming
a permanent weak spot.

Chains
Chains require careful use, handling and maintenance to
ensure long life and safe operation.
Be sure that the correct size chain is being used for the
application.
Be sure that the chain is inspected regularly following the
manufacturers guidelines.
Avoid sudden or shock loading (DO NOT jerk load
upright).

07/09 (Rev 1)

111

7F

Safety

Wear Liner Replacement


Telsmith SBS Cone Crusher

Use suitable padding to protect the chain from sharp


corners or edges.

Use the proper fittings at all times.

Be sure that all tractor-trailer components are working and


in good condition. Test all systems (brakes, steering,
lights, etc.) for proper operation and/or adjustment before
beginning the move. Check air pressure in all tires and
replace any tires that are worn or damaged.

Watch for local wear. Reposition or shorten chain (as


required) to remove the worn section from the area of
tension.

After the machinery has been transported, block the tires


if the trailer will remain stationary for an extended period
of time.

Avoid dragging the chain under loads or over obstacles.

Inspect links to determine the amount of wear. Refer to


manufacturers specifications for wear tolerance ranges.
Be sure that all connections between chain sections are
completed with properly sized hardware and lifting
hooks.

! CAUTION
DANGER !!!
Always follow proper rigging procedures as provided by the chain manufacturer. The angle of rigging
may decrease the rated lifting capacity.

Fiber Or Synthetic Slings


Slings require careful use, handling and maintenance to
ensure long life and safe operation.
Be sure that slings are rated or coded for the hitch or
application.
Be sure that slings are inspected regularly following the
manufacturers guidelines.
Slings may be safely used in a temperature range of 20 to
180 F (-6 to 82C) without decreasing load limits. For
temperatures beyond this range or for wet/frozen slings,
follow manufacturers instructions for load reductions.

7F

Do not use synthetic slings in temperatures exceeding


180F (82C).
Avoid sudden or shock loading (DO NOT jerk load
upright).

TRANSPORTING MACHINERY
Be sure that the machinery is properly secured so that it
cannot vibrate or move during transport. Remove any dirt,
stones or other loose material from the machinery.
Install shipping brackets, wood blocking or other shipping
materials as directed in the machinery manufacturers
manuals. Perform any shipment preparation procedures as
indicated in the manuals.
Plan your route carefully. Know the clearance height of
the machinery. Be aware of bridges, power lines and steep
or uneven grades. Be aware of any other conditions which
may present hazards or obstructions.

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Telsmith Silver Bullet Series Gyrasphere

Chapter 2

Chapter 2
General Instructions
Page

WORK SAFELY AND USE COMMON SENSE . . . . . . . . . . . . . . . . . . . . 2-2


TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
LUBRICANTS & SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

PART IDENTIFICATION & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 2-2


HANDLING SEALS & MACHINED PARTS . . . . . . . . . . . . . . . . . . . . . . 2-2
HANDLING BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
USING HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
HYDRAULIC SYSTEM SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . 2-3
DISCONNECTING HYDRAULIC LINES . . . . . . . . . . . . . . . . . . . . . . . . 2-3
DEPRESSURIZING THE POWER ROTATOR CIRCUIT . . . . . . . . . . . . . . . 2-4

7F

07/09

21

General Instructions

WORK SAFELY AND


USE COMMON SENSE
Refer to Chapter 1 of this manual for important quarry
safety information. Also refer to the Telsmith Quarry
Equipment Safety Guide for additional safety precautions.
Observe all precautionary statements (DANGER,
WARNING, CAUTION, IMPORTANT, and NOTE) that
are included within the repair and overhaul procedures.
Be sure all lifting devices, slings and supports are in good
condition and of adequate rated capacity. Refer to
Appendix C for component weights.
Keep cleaning solvents and other combustibles away from
heat and open flame. Do not smoke around flammable
liquids.

PART IDENTIFICATION & INSPECTION


Tag and mark all parts during removal and disassembly
procedures.
Clean all parts as removed. Verify that they are free of
cracks, nicks, burrs and other imperfections.
Check clearances and dimensions as instructed in the
procedures.
Replace any excessively worn or damaged parts.
If possible, take reference photographs of the machinery
as it is disassembled. During reassembly, use the
photographs to verify that all parts are correctly
reinstalled.

HANDLING SEALS & MACHINED PARTS

Wear appropriate personal protective equipment (PPE).


Keep the work area clean and well organized.

Be careful not to cut or damage seals during installation.

If service assistance is needed, contact your local Telsmith


dealer or the Telsmith Service Department.

Handle shafts carefully to prevent damage. Do not nick or


mar finished surfaces.

TOOLS AND SUPPLIES


The following common tools, shop equipment and supplies
are required to complete the repair and overhaul procedures
in the following chapters of this manual:
Impact wrench with a 3/4 inch drive minimum, 1 inch
preferred.
Set of sockets and breaker bars, minimum 3/4 inch drive
with sockets up to 3-1/2 inches.
Cold chisel, 3/4 inch.
Hammers (various sizes).

7F

Wear Liner Replacement


Telsmith SBS Cone Crusher

Cables, slings, and chains.


Crane or hoist of adequate capacity.
(Refer to Appendix C for component weights)
Feeler gauge and inside/outside micrometers.

If shafts, bearings or other machined items are to be


removed from the machinery for more than a few days,
cover them with a protective coating of rust-preventative
lubricant.

HANDLING BEARINGS
Remove any loose dirt from the machinery before
exposing bearings. Handle bearings with clean, dry hands.
Use only clean lint-free rags. Use clean tools in clean
surroundings. Use clean solvents and flushing oils.
Install new bearings as removed from packaging without
washing. Do not remove bearings from packaging until
ready to use.
Soak used bearings in solvent. Then wash the bearings
and blow them dry with filtered, moisture-free
compressed air. Dip the bearings in oil immediately after
drying to prevent rust.

Cleaning solvent.
Flushing oil.
Refer to the Tools and Supplies Required heading at the
beginning of each chapter for additional items needed to
perform specific repair and overhaul procedures.

LUBRICANTS & SEALANTS

! WARNING!!!
DANGER
Always wear eye protection and face shield when
using compressed air.
To prevent bearing damage, do not spin the bearings by
hand or with compressed air after the bearing surfaces
have dried.

Required lubricants and sealants are listed at the beginning of


each chapter under the Tools and Supplies Required heading.
Detailed specifications for these items are located in
Appendixes D and E.

22

07/09 (Rev 1)

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Telsmith SBS Cone Crusher

USING HEAT
When using an oil bath, avoid contact with hot oil.

General Instructions

Clean-up any spilled hydraulic oil. Hydraulic oil is


extremely slippery, and can be especially dangerous if
spilled on an elevated walkway or platform.

Use an acetylene torch if heat is required to remove an


interference-fit part and it is not practical to use hot oil.
Keep flame moving continuously. Do not let flame touch
the part being removed.

Refer to Chapter 1 for additional safety precautions and


warnings which apply to pressurized systems and related
machinery.

If a part is to be destroyed by heat, be careful not to


damage other reusable parts nearby.

Refer to the crusher operation and maintenance manual


for complete hydraulic system operation, maintenance
and troubleshooting procedures.

Be careful when using heat and handling hot parts. To


prevent burns, always wear appropriate hand, face and
eye protection.

DISCONNECTING HYDRAULIC LINES

HYDRAULIC SYSTEM SAFETY SUMMARY

! WARNING!!!
DANGER
Lockout/tagout power to the hydraulic control
console before performing any hydraulic system
maintenance or repairs.

! WARNING!!!
DANGER
Before disconnecting the power rotator hoses, be
certain that any trapped pressure is completely
relieved.

! WARNING!!!
DANGER
Up to 3000 PSI (206 bar) may remain trapped in the
power rotator circuit even when the hydraulic
pump is off and the pressure gauge indicates zero
(0) PSI. Before disconnecting the power rotator
hoses, be certain that pressure is completely
relieved. Refer to the following section of this
chapter for procedure.

! WARNING!!!
DANGER

Refer to the following sections of this chapter for additional


information.

Failure to relieve pressure before disconnecting


the power rotator hoses may result in the sudden
release of pressurized hydraulic oil. Serious
personal injury or death can occur if pressurized
hydraulic oil penetrates the skin.

Observe the following precautions when performing


hydraulic system maintenance or repairs:

Observe the following precautions when disconnecting


hydraulic lines during maintenance and repair procedures:

Allow only qualified hydraulic service technicians to


perform hydraulic system troubleshooting and repairs.
All persons working on the hydraulic system must have
appropriate training and certification.

Lockout/tagout power to the hydraulic control console


before disconnecting hydraulic lines. Be certain that
trapped pressure is completely relieved before loosening
any hydraulic fittings (see next section of this chapter).

Allow only licensed electricians to troubleshoot and


repair hydraulic system electrical components and wiring.

Wear appropriate eye, face and hand protection, when


disconnecting hydraulic hoses or loosening hydraulic
fittings. Wear or use additional personal protective
equipment (PPE) as required.

Use common sense when observing hydraulic system


operation. Be aware of potential hazards at all times. Stay
clear of all moving or rotating parts.
Wear appropriate eye, face and hand protection, when
troubleshooting or repairing the hydraulic system. Wear
or use additional personal protective equipment (PPE) as
required.
Use a piece of cardboard to check for hydraulic oil leaks,
not your hand. Escaping fluid under pressure can
penetrate the skin.
Avoid unnecessary contact with hydraulic oil.

07/09 (Rev 1)

Always assume that the system is pressurized, even if


pressure appears to have been relieved. Some residual
pressure may remain trapped within the system even
when the pressure gauge indicates zero (0) PSI.
Before disconnecting a hydraulic hose, verify that it is
relaxed and not stiff. A stiff hose indicates that pressure
has not been relieved.
Never have your face directly in front of a hydraulic line
when loosening a fitting, even after system pressure has
been relieved. Always assume that the line has pressure.

23

7F

General Instructions

Wear Liner Replacement


Telsmith SBS Cone Crusher

As hydraulic lines are disconnected, catch any oil leakage


in an appropriate container.
To prevent contamination, cap all ports and hose fittings
immediately after hydraulic lines are disconnected.

11. To verify that pressure has been relieved, check that both
power rotator hoses are relaxed and not stiff. A stiff hose
indicates that high pressure remains trapped in the circuit.

OFF

ON

DEPRESSURIZING THE POWER ROTATOR


CIRCUIT

CRUSH

CLEAR

MANUAL

EXTRACT
HIGH
SPEED

AUTO

START

CLOSE

STOP

OPEN

Crush/Clear
High Speed
Switch

! WARNING!!!
DANGER

38/44 Models

Up to 3000 PSI (206 bar) may remain trapped in the


power rotator circuit even when the hydraulic
pump is off and the pressure gauge indicates zero
(0) PSI. Be sure that the power rotator circuit is
completely depressurized before disconnecting
the power rotator hoses or servicing any hydraulic
components in the power rotator circuit.

Old Style Models


52/57/68

The power rotator hoses must be disconnected before


performing some repair and overhaul procedures in this
manual. Before disconnecting hoses, depressurize the power
rotator circuit as described in the following steps:
1. Stop the crusher. Lockout/tagout power to the crusher
drive and to all feed and discharge equipment (Refer to
Chapter 1 for complete lockout/tagout procedures).
2. Stop the hydraulic pump. Lockout/tagout power to the
hydraulic control console.
3. Jog the Crush/Clear/High Speed switch on the
Hydraulic Control Panel (Fig. 2-1) between CLEAR and
CRUSH several times. Then allow the switch to return to the
CRUSH position.

New Style Models


52/57/68

4. Check the hydraulic pressure gauge or sensor readout.


Verify that the gauge indicates zero (0) PSI. See Figure 2-1.

7F

(Pressure Sensor)

5. Locate counterbalance valve A. Refer to Figures 2-3


and 2-5 for valve locations.
6. Loosen the pressure adjustment screw locknut. Refer to
Figure 2-2.
7. Turn the pressure adjustment screw CLOCKWISE
about three turns. Listen for a hissing sound. This indicates
that pressure is being relieved.
8. After relieving pressure, reset the pressure adjustment
screw to its original setting (turn the pressure adjustment
screw COUNTERCLOCKWISE the same number of turns
as in step 6).
9.

Figure 21. Hydraulic Pressure Gauge Locations

Pressure Adjustment
Screw

Re-tighten the pressure adjustment screw locknut.

10. Repeat steps 5 through 8 for counterbalance valve B.


Refer to Figures 2-4 and 2-6 for valve locations.
IMPORTANT: Pressure must be relieved at both
counterbalance valves to ensure that all pressure in the
power rotator circuit is completely relieved.
24

Locknut
Figure 22. Counterbalance Valve Details
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Telsmith SBS Cone Crusher

Counterbalance
Valve A

Figure 23. Counterbalance Valve A


(Models 38 and 44)

General Instructions

Counterbalance
Valve A

Figure 25. Counterbalance Valve A


(Models 52, 57 and 68)

7F
Counterbalance
Valve B
Counterbalance
Valve B

Figure 26. Counterbalance Valve B


(Models 52, 57 and 68)
Figure 24. Counterbalance Valve B
(Models 38 and 44)

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Telsmith SBS Cone Crusher

NOTES

7F

26

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Chapter 3
Support Bowl and Concave Ring

CONTENTS
Page
GENERAL SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
TOOLS AND SUPPLIES REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Type A Support Bowl and Concave Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Type B Support Bowl and Concave Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Type C Support Bowl and Concave Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-6
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
SUPPORT BOWL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Type A and B Bowl Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Type C Bowl Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
CONCAVE RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Old Style TypeA and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
New Style Type C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
CONCAVE RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Old Style Type A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
New Style Type C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
SUPPORT BOWL PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
SUPPORT BOWL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Old Style A and B Support Bowl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
New Style C Support Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
RECEIVING HOPPER INSTALLATION (Old Style A and B) . . . . . . . . . . . . . . . . 3-36
DRIVE RING COVER INSTALLATION (New Style C). . . . . . . . . . . . . . . . . . . . . . . 3-38
MIXING AND POURING SMITHBOND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

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Concave Ring

32

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Support Bowl and Concave Ring

GENERAL SHUTDOWN PROCEDURE

TOOLS AND SUPPLIES REQUIRED

Prior to Working On Crusher


1. Stop the material feed. Operate the SBS Crusher until the
crushing chamber is completely empty. If necessary, use the
hydraulic clearing function to clear the crushing chamber.
2. Lockout/tagout power to the crusher drive motor. Refer
to Chapter 1 for detailed lockout/tagout information and
procedures.
3. Lockout/tagout power to all crusher feed and discharge
equipment.
4. Lockout/tagout power to the crusher oil lubrication
system.
5. Jog the CLEAR/CRUSH/HIGH SPEED switch on the
Hydraulic Control Panel (Fig. 3-1) between CLEAR and
CRUSH several times. Then allow the switch to return to the
CRUSH position.
6. Lockout/tagout power to the crusher hydraulic control
console.

Suitable rigging and hoisting equipment

5 pound hammer
Sledge hammer
Extension brackets (special tools - provided with crusher)
Eyebolts 3/4-10 UNC 2B (quantity = 3)
Crowbar
Hand grinder
Feeler gauge
Tape measure
Cold steel chisel
Cleaning solvent
Putty
Moly-based EP-2 grease (refer to Appendix D)
Smithbond backing compound (refer to Table 3-1)

7. Check that the hydraulic system pressure gauge on your


unit is registering zero (0) psi.

Crush
Clear Extract
High Spd

Start

Manual Auto

Stop

Close

Open

Figure 31. SBS Hydraulic Controls

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C
A

B
D
E
F
G

Type A

Crushers with slotted concave


ring lugs only

W
K
X

J
N

L
M

Model 38 only

T
Q
X
O
U
R

Figure 32. Support Bowl and Concave Ring Assembly, Type A


A. Capscrew
F. Flatwasher
K. Concave Ring
P. Extension Bracket
U. Locknut Ring

34

B. Flatwasher
G. Support Bowl Driver
L. Filler Ring
Q. Nut
V. Ring Gear

C. Outer Receiving Hopper


H. Inner Receiving Hopper
M. Felt Seal
R. Nut
W. Tapered Key

D. Felt Seal
I. Support Bowl
N. Capscrew
S. Drive Ring
X. Wedge

E.Socket Head Capscrew


J. Smithbond Compound
O. Flatwasher
T. Upper Frame

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Support Bowl and Concave Ring

Type B
D

Crushers with slotted concave


ring lugs only
E

F
G

V
H
W
I

Model 38 only

K
J

A
M

B
O

L
B

N
R
S
P
Q

T
U

Figure 33. Support Bowl and Concave Ring Assembly, Type B


A. Capscrew
F. Socket Hd Capscrew
K. Concave Ring
P. Flatwasher
U. Ring Gear

07/09

B. Flatwasher
G. Flatwasher
L. Extension Bracket
Q. Nut
V. Tapered Key

C. Outer Receiving Hopper


H. Support Bowl Drive Key
M. Filler Ring
R. Drive Ring

D. Inner Receiving Hopper


I. Support Bowl
N. Nut
S. Upper Frame

E. Felt Seal
J. Smithbond Compound
O. Felt Seal
T. Locknut Ring

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B
A

Type
B
TYPE
C

38 SBS
Non-Rimmed Wedge

44/52/57/68 SBS
Rimmed Wedge

E
F

K
L
M

Figure 34. Support Bowl and Concave Ring Assembly, Type C


A. Drive Ring Cover
F. Extension (3)
K. Pin Retainer

36

B. Cover Fastener (12)


G. Support Bowl
L. Thrust Pin Bushing

C. Drive Ring
H. Felt Seal
M.Upper Frame

D. Keeper
I. Locknut
N. Felt Strip

E. Felt Seal
J. Felt Strip

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Support Bowl and Concave Ring

DESCRIPTION
The concave ring is a replaceable casting that forms the upper
surface of the crushing chamber. It is made from manganese
steel, a wear-resistant alloy that work hardens during
crushing.

The concave ring is mounted inside the crusher support bowl.


Rotation of the support bowl raises or lowers the concave
ring, allowing the crusher discharge setting to be adjusted as
needed.
During crushing, the support bowl is held stationary by a
series of hydraulic locking cylinders and a threaded locknut
ring. The locknut ring is located just above the upper frame.

B
C

When energized, the locking cylinders exert an upward force


on the locknut ring that is transmitted to the support bowl.
This force lodges the slanted buttress threads of the support
bowl tight against the slanted buttress threads of the upper
frame, preventing any support bowl movement. See Fig. 3-5.

Depressing the open or close pushbutton on the hydraulic


control console partially de-energizes the hydraulic locking
cylinders. This unlocks the support bowl, allowing it to be
turned in the desired direction. See Figure 3-6.
The open pushbutton rotates the support bowl counterclockwise, increasing the discharge setting. The close
pushbutton rotates the support bowl clockwise, decreasing
the discharge setting. Adjustments can be made at any time,
even while crushing. Full locking force resumes immediately
when either pushbutton is released.

Figure 35. Support Bowl, Locked Position


A. Support Bowl
C. Locking Cylinder

Support bowl rotation is achieved by one or two power


rotators (depending on crusher model) mounted on the upper
frame. A large ring gear transmits force from the power
rotator(s) to a drive ring weldment which engages and turns
the support bowl.

B. Locknut Ring
D. Upper Frame

On models 44, 52 and 57, one full rotation of the support bowl
changes the discharge setting approximately 1-1/2 inches. On
Model 68 only, a full rotation changes the discharge setting
approximately 2 inches.

B
C

To facilitate concave ring replacement, a special high-speed


extract function allows the support bowl to be quickly
unthreaded from the upper frame.

The concave ring is tightly secured to the support bowl by a


series of tapered steel wedges. Smithbond, a special epoxybased backing compound, fills the void area between the
concave ring and the support bowl. Smithbond must be repoured whenever the concave ring is replaced.
Concave ring replacement intervals will vary, depending on
the amount and type of material being crushed. However,
replacement should always be performed before the concave
ring becomes cracked or excessively worn. Refer to
Appendix G for additional information.

07/09

Figure 36. Support Bowl, Unlocked Position


A. Support Bowl
C. Locking Cylinder

B. Locknut Ring
D. Upper Frame

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SUPPORT BOWL REMOVAL

Remove the support bowl from the crusher upper frame as


described in the following steps. Refer to Figures 3-2, 3-3 and
3-4 for exploded views and parts designations. Refer to other
figures as indicated.

1. Lockout/tagout power. Perform the General Shutdown


Procedure as described earlier in this chapter. Refer to
Chapter 1 for complete lockout/tagout instructions.

2. Remove chutes, conveyors or other feeding devices above


the crusher.
3. Verify that there is adequate clearance above the crusher
for support bowl removal. Refer to Appendix F for removal
clearances.

Type A and B Bowl Removal


1. Remove capscrews (A) flatwashers (B), and nuts securing
the outer receiving hopper (C) to the drive ring (Figs. 3-2 &
3-3).

! WARNING
Always use suitable rigging and hoisting equipment
to stabilize and lift heavy objects. Lifting heavy
components with inadequate hoisting apparatus
can damage machinery and may result in serious
personal injury or death. Refer to Appendix C for
weights.

Figure 37. Extension Bracket


(Type A Support Bowl Assemblies Only)
A. Capscrew
C. Extension Bracket (3)

B. Flat Washer
D. Nut

2. Using an appropriate lifting device and cables, carefully


lift the outer receiving hopper (C, Fig. 3-2 & 3-3) straight up
and remove it from the support bowl (I, Fig. 3-2 & 3-3). The
hopper is sealed with a felt seal and rope caulk, so some effort
may be required to loosen it.

B
C

3. Remove any loose dust and dirt from the area between the
support bowl and the inner receiving hopper (H, Fig. 3-2 &
D, Fig. 3-3).
4. Using an appropriate lifting device and cables, carefully
lift the inner receiving hopper straight up and remove it from
the support bowl (I, Fig. 3-2 & 3-3).
5. Install the extension brackets (C, Fig. 3-7 & C, Fig. 3-8)
on the drive ring. Secure with capscrews, flatwashers and
nuts.

Figure 38. Extension Bracket


(Type B and C Support Bowl Assemblies Only)
A. Capscrew
C. Extension Bracket (3)

38

B. Flat Washer
D. Nut

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Support Bowl and Concave Ring

Cutaway
View

Moly-Based
EP-2
Figure 39. Buttress Thread Lubrication
6. Apply a generous amount of moly-based EP-2 grease at
each of the four grease fittings around the upper frame. See
Figure 3-9. Refer to Appendix D for grease specifications.
7. Be sure that power to the hydraulic power unit is lockedout, and that the hydraulic pressure gauge indicates zero (0)
PSI.
8. Disconnect the hydraulic locking cylinder hose at the
hydraulic power unit. Leave all other hoses connected. See
Figure 3-10.

10. Visually check that no personnel are on, under, inside or


beside the crusher.
11. Connect power to the hydraulic control console. Move the
function selector switch to EXTRACT-HIGH SPEED. See
Figure 3-11 for typical control console diagram.
12. Depress the START button. The hydraulic pump will
start.

Hydraulic Locking
Cylinder Hose

Function
Selector
Switch

Figure 310. Hydraulic Locking Cylinder Hose

Figure 311. Hydraulic Control Console

9. Check the oil level in the hydraulic reservoir. Be sure that


the oil level is up to the black line of sight gauge. Add oil if
oil level is low. Refer to Appendix D for oil specifications.
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3
B

Figure 312. Unthreading Support Bowl


A. Support Bowl

B. Drive Ring

13. Depress and hold the OPEN button. Visually check that
the ring gear (C, Fig. 3-12) begins turning slowly
counterclockwise. On some crushers, there may be a brief
delay before the gear starts turning.

C. Ring Gear

D. Upper Frame

14. Depress and hold the OPEN button. Allow the support
bowl (A, Fig. 3-12) to become completely unthreaded from
th e u pp e r fr a m e ( D , F i g . 3 - 12 ) a nd lo c k n ut r i n g.
Approximately 7 to 10 revolutions will be required,
depending on the initial position of the support bowl.
15. Depress the STOP button after the support bowl becomes
completely unthreaded. Lockout/tagout power to the
hydraulic control console.
16. Type A support bowl assemblies only: Install 3/4 inch
eyebolts in the three lifting holes on the support bowl driver.
Secure the eyebolts with jamnuts.
17. Type B support bowl assemblies only: Install 3/4 inch
eyebolts in the three lifting holes on the top edge of the
support bowl (Fig. 3-13). Secure the eyebolts with jamnuts.
18. Using an appropriate lifting device and cables, carefully
lift the support bowl straight up and remove it from the upper
frame. See Figure 3-13.
19. Suspend the support bowl over a clean, flat work area.

Figure 313. Support Bowl Lifing Arrangement


310

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Support Bowl and Concave Ring

Figure 314. Support Bowl on Blocking (cutaway view)


20. Arrange four evenly spaced hardwood blocks directly
beneath the outer edge of the support bowl. Each timber
should be exactly the same height (approximately 3 inches
(7.6 cm). See Figure 3-14.

IMPORTANT:
Do Not place timbers beneath the lower lip of the
concave ring. This area must remain unobstructed to
allow room for the concave ring removal.
21. Slowly lower the support bowl onto the timbers.

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Type C Bowl Removal


1. Remove the nine hex head capscrews and washers bolting
the drive ring cover (A, Fig. 3-15) to the drive ring (B, Fig. 315).

A
D

3
C

A
C

D
A

Figure 316. Drive Key Extension Mounting Points


A. Drive Key Extension (3)
C. Drive Ring

B. Support Bowl
D. Drive Keys (3)

! CAUTION

Figure 315. Drive Ring Cover Removal


A. Drive Ring Cover
C. Drive Ring Lift Points

B. Drive Ring

2. Install lift eyes or lift hooks and a lifting harness of


sufficient capacity to the three lift eyes cast in the cover (Fig.
3-15). (Drive ring covers weigh in a range from 675 lbs (306
Kg) on 38SBS to 1330 Lbs (603 Kg) on 68 SBS). Lift the
cover straight up off the drive ring to remove.
3. Transfer the drive ring cover capscrews and washers from
the points on the cover with three adjacent fasteners to the
three drive key extensions (Fig. 3-16) supplied loose with
your crusher. (Drive key extensions are pn BE-272-2174W).
Bolt the drive key extensions to the top of the drive ring with
three fasteners per extension as shown in Fig. 3-16.

312

If you are using the EXTRACT HIGH SPEED mode to


remove the support bowl, make certain all hydraulic
pressure is released from the locking cylinder
circuit. Failure to disconnect the hydraulic pressure
line to the cylinders could result in damage to the
support bowl or locking nut threads if the control
switch was inadvertently returned to the CRUSH
position with hydraulic pressure still connected to
the locking cylinders.
4. Move the control switch to the EXTRACT HIGH SPEED
position (Fig. 3-11) and press the OPEN button. Hold both
switches in this position while the support bowl unthreads
from the threaded portions of the main frame and locknut. DO
NOT allow the control switch to return to the CRUSH
position while the bowl is unthreading, as this could damage
the threads. As the support bowl rises, watch for thread
disengagement and release the switch from the EXTRACT
HIGH SPEED position when the end of the thread on the
support bowl becomes visible.
5. Press the STOP button on the hydraulic control panel and
disconnect power to the hydraulic unit pump.
6. Before removing the support bowl from the crusher, mark
the point on the upper rim with paint where the external
threads end at the bottom of the bowl. Mark the
corresponding position on the locking ring where the internal
threads start. This will help correctly position components
and start thread engagement when replacing the support
bowl.
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Telsmith SBS Cone Crusher

Support Bowl and Concave Ring

7. Thread three 3/4 lift eyes fully into the upper rim of the
support bowl (A, Fig. 3-17) and attach a lift harness and hoist
of sufficient capacity to lift the bowl (bowls range in weight
from 2700 lbs (1225 Kg) on the 38SBS to 13,000 lbs (5,900
Kg on the 68 SBS). Make certain the external threads on
the support bowl are fully disengaged from the threads on
the lock ring. Lift the support bowl straight up out of the
drive ring until the drive keys (D, Fig. 3-16) clear the drive
key extensions (A, Fig. 3-16).

Figure 318. Felt Seal Installation.


A. Felt Seal
B. Support Bowl Upper Lip
C. Rough Side Facing Out D. Smooth Side Facing Up

Figure 317. Support Bowl Lift Eyes


A. Lift Eyes (3)
B. Support Bowl External Thread
C. Upper Frame Internal Thread

8. Lower the support bowl onto blocking, making certain the


blocking is placed under the support bowl casting, not the
maganese concave liner.
9. Examine the condition of the drive keys (D, Fig. 3-16). If
keys are deformed, cracked or excessively worn replace them
at this time.
10. Inspect the felt seal on the inside upper lip of the support
bowl. If it is worn, torn, damaged or heavily contaminated
with metal filings or debris, remove it and replace with new
felt. All SBS crushers with the exception of the Model 68,
require 5/8 in. square felt approximately 15 feet long. Model
68 crushers will require 3/4 in square felt approximately 20
feet long. Install new felt into groove with the smooth side
facing up, and the rough side facing out (Fig. 3-18). Use a
rubber faced mallet to seat felt in groove. Trim felt to size so
that ends meet square and no material is bulging from the
groove. Just prior to installation of the support bowl, coat the
rough face with moly based EP#2 grease.

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CONCAVE RING REMOVAL

Remove the concave ring from the support bowl as described


in the following steps. Refer to Figures 3-1, 3-2 and 3-3 for
exploded views and component designations. Refer to other
figures as indicated.

Old Style Series A and B Removal


1. Place the support bowl on timbers as described in the
previous section of this chapter. Be sure that the timbers are
located only under the concave ring outer edge. The timbers
must not extend beneath the concave ring lower lip. See
Figure 3-14.
2. Clean the area around the concave ring mounting lugs.
Remove all accumulated dust and dirt.

! CAUTION
The concave ring can release and drop at any
time after the mounting lugs are cut. To prevent
serious personal injury, be sure that all
personnel are clear of the area between the
concave ring lower lip and the ground.
3. Using a torch or air-arc, cut the concave ring mounting
lugs. The number of lugs will vary depending on crusher
model. Refer to Figure 3-19.
4. Using a sledge hammer, strike the top edge of the
concave ring until it breaks loose and drops from the support
bowl.
5. Units with standard concave ring lugs (Fig. 3-19): Using
a torch, remove the cut-off lug ends from the taper wedge
segments. Save the taper segments for later use.

CUT LUG HERE

6. Units with slotted concave ring lugs (Fig. 3-2 & 3-3):
Using a torch, remove the cut-off lug ends from the tapered
keys (W, Fig. 3-2). Save the keys and taper wedge segments
(X, Fig. 3-2) for later use.

! WARNING
Always use suitable rigging and hoisting equipment
to stabilize and lift heavy objects. Lifting heavy
components with inadequate hoisting apparatus
can damage machinery and may result in serious
personal injury or death. Refer to Appendix C for
weights.
7. Using an appropriate lifting device, move the support
bowl to a suitable work area where it can be thoroughly
cleaned and inspected.
8. If present, remove the filler rings (M, Fig. 3-3) from the
old concave ring. Save the filler rings for later use.
314

Note: Quantity of
lugs varies by
crusher model

Figure 319. Cutting Concave Ring Lugs

New Style Series C Removal


1. When the support bowl is removed from the upper frame,
suspend it over a clean, flat work area.
2. Arrange four evenly spaced hardwood blocks directly
below the support bowl on the work area. Each timber must
be the same height. Timbers at least 3 inches (7.6 cm) tall are
required.

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Telsmith SBS Cone Crusher

Support Bowl and Concave Ring

3. Slowly lower the support bowl onto the timbers (Fig. 320) Make certain the support timbers are placed beneath the
lower ring of the support bowl only. If timbers protrude in and
reach under the concave ring, they will prevent the concave
ring from dropping during removal.

C
B

Figure 320. Blocking Up Support Bowl


A. Support Bowl

B. Concave Ring Lip

C. Hardwood Mounting Blocks (4)

! CAUTION
Removing the tapered wedges that support the concave ring may require standing inside the support
bowl. Make certain your feet are not below the concave ring lower lip when driving out wedges. The
concave liner could drop suddenly as the tapered
wedges are driven out. Serious personal injury
could result if all personnel are not clear of the area
beneath the concave ring lower lip and the ground
as the liner is prepared for removal.
4. Torch or grind off the welds holding the tapered wedges
in place at the concave ring ears (B, Fig. 3-21). If possible, Do
Not cut through the wedges, as they will be reused when
mounting the new concave ring.
5. Use a sledge and driver bar to drive the tapered wedges
out from beneath the mounting ears. The concave ring should
drop down of its own weight as the final tapered wedge is
driven out.

07/09

Figure 321. Wedge Removal


A. Tapered Wedge

B. Weld

C. Concave Ear

6. If the concave liner does not drop down after the wedges
are removed, it will be necessary to strike the top edge of the
liner and the ears with a sledge hammer to free the liner.
7. When the liner has dropped, use a torch to remove the
wedges (and keys if used) from the torched off mounting ear
segments. If wedges and keys are not damaged they can be
reused in the new liner installation.

315

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! WARNING

Always use suitable rigging and hoisting


equipment to stabilize and lift heavy objects.
Lifting the support bowl or concave ring with
inadequate hoisting apparatus can damage
machinery and may result in serious personal
injury or death.
8. Using a hoist and crane of suitable rating, lift the support
bowl a slight distance off the concave ring and check for the
location of the filler rings (if your crusher is equipped with
filler rings). If filler rings (L, Fig. 3-2) are stuck to the support
bowl by Smithbond, remove them before they drop and cause
damage. If all filler rings have remained seated on the old
concave ring, continue to lift the support bowl free of the
concave ring.

! WARNING
When grinding, cutting or breaking up pieces of
old Smithbond filler it is mandatory to wear a
respirator that prevents inhalation of toxic
fumes. Failure to provide adequate ventilation
and filter toxic fumes could cause injury to
personnel working on the crusher.
9. Move the support bowl to a suitable stand or work area
where it can be cleaned and examined. Clean any remaining
Smithbond backing material from the bowl with a handheld
grinder. Use a grinder to remove any weld in the area where
the wedges were removed. Be careful not to nick or scratch
the machined seat of the support bowl while cleaning or
grinding on the bowl. Check that the mounting surfaces for
the concave support ears are clean and flat. Check that the
exterior threads on the bowl are undamaged. If support bowl
is reusable, remove the old grease from threads, as
contamination in the grease could cause problems during
reassembly.
10. Remove the filler rings from the old concave ring and
clean any Smithbond filler from the rings. Check the filler
rings (Fig. 3-22) for signs of damage, particularly at the lower
seating surface and at the mounting holes. If a filler ring is
bent, shows signs of chatter marks on the surface or has
damaged mounting holes or broken or bent mounting feet,
replace it.

316

Figure 322. Filler Ring Inspection


A. Filler Ring
C. Locator Mounting Hole

B. Lift Hole
D. Mounting Feet (4)

CONCAVE RING INSTALLATION


Old Style Series A and B
1. Place a new concave ring on hardwood blocking so it is
raised about 3 or 4 inches (7.6 - 10.1 cm) off the ground. The
ring must be evenly supported and completely level (Fig. 323).

Figure 323. Concave Ring on Blocking


2. Inspect the machined seat area on both the support bowl
and the new concave ring (Fig. 3-24). Remove any burrs or
rough spots with a grinder. The seating surfaces must be
clean, dry and with a uniform surface free of rust, paint etc. to
promote a proper seal.

07/09

Wear Liner Replacement


Telsmith SBS Cone Crusher

Support Bowl and Concave Ring

Coat With
Heavy
Gear Oil
(ISO 150)

No Lube

No
A

No

Lu
be

Lu
be

Figure 325. Lubricant Application Area


6. Install 3/4 inch eyebolts into the three lifting holes on the
top edge of the support bowl. Secure the eyebolts with
jamnuts.
Figure 324. Seat Inspection
A. Concave Ring

B. Support Bowl

3. Apply a coat of heavy gear oil (ISO 150) to the curved


upper surface of the support bowl (Fig. 3-25). DO NOT apply
any lubricant to the machined seat at the bottom.

IMPORTANT:
DO NOT apply any lube to the concave ring.
4. Apply a thin coat of heavy gear oil to the complete surface
of each filler ring. (Lubricant is applied to help prevent
adhesion of filler compound.).
5. Lift each filler ring up into position on the concave ring
with a suitable lifting device. Position the filler ring locator
mounting hole (C, Fig. 3-22) over the mounting stub on the
concave ring and lower into position.

07/09

! WARNING
Always use suitable rigging and hoisting
equipment to stabilize and lift heavy objects.
Lifting heavy components with inadequate
hoisting apparatus can damage machinery and
may result in serious personal injury or death.
Support bowls range in weight from 2,600 lbs
(1179 Kg) on the Model 38 to 12,000 lbs (5443 Kg)
on the Model 68.
7. Slowly lower the support bowl onto the concave ring (Fig.
3-26. Align the support bowl so that the support bowl slots
align with the concave ring lugs. Lower the support bowl so
the slots pass down over the lugs.

317

Support Bowl and Concave Ring

Wear Liner Replacement


Telsmith SBS Cone Crusher

A
B

Figure 327. Positioning The Concave Ring


A. Take Measurement at 4 places 90o apart
B. Space lugs evenly between support bowl cutouts

11. If necessary, shift the concave ring with a crowbar so that


it is centered within the support bowl (Fig. 3-28).

Figure 326. Lowering the Support Bowl onto the


Concave Ring
8. When the support bowl slots are approximately 1/2 (1.2
cm) below the lugs, stop lowering the support bowl. Rotate
the support bowl so that the lugs on the concave ring are
centered between the slots (Fig. 3-27). Finish lowering the
support bowl down onto the concave ring when the lugs are
correctly aligned.
9. Remove the lifting cables from the support bowl.
10. When the concave ring lugs are correctly positioned in
relation to the cutouts, check that the concave ring is centered
in the support bowl. Measure the distance from the inner edge
of the support bowl to the top edge of the concave ring at four
l o c a t i on s 9 0 o d e gr e e s a p a r t ( F i g . 3 - 2 7 ) . A l l f o ur
measurements must be equal.

Figure 328. Center Concave Ring


12. Install the wedges under the concave ring lugs. On models
with slotted lugs, install the keys (W, Fig. 3-2).

318

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Telsmith SBS Cone Crusher

Support Bowl and Concave Ring

13. Using a hammer, alternately tap all wedge segments into


place until they are snug against the machined surface of the
support bowl.
14. Switch to a sledge hammer and drive bar and alternately
drive the wedge segments tight until they will not move (Fig.
3-29). Follow the sequence in Figure 3-30 when tightening
the wedges on your model crusher.

38, 44 & 52

Figure 329. Tightening Wedge Segments


57 Only

IMPORTANT:
Be certain that all wedge segments are driven as tight
as possible. Failure to fully tighten wedge segments
could allow the concave ring to loosen during crushing.
15. Re-check the concave ring position in the support bowl
when all wedges are tight. Check that the ring is still centered
in the bowl and has not shifted. If measurements are unequal
(Fig. 3-27), it will be necessary to drive the wedge segments
back out and re-center the ring in the bowl.

68 Only
Figure 330. Wedge Tightening Sequence per Model
16. Using a feeler gauge check that the machined seat of the
concave ring is TIGHT against the machined seat of the
support bowl. Move completely (360o) around the lower edge
of the support bowl checking the clearance (Fig. 3-31). There
should be no clearance at any point.

07/09

319

Support Bowl and Concave Ring

Wear Liner Replacement


Telsmith SBS Cone Crusher

Figure 331. Checking Ring to Bowl Clearance

IMPORTANT:
Make certain the concave ring is properly installed as
described in the previous steps. Serious damage to the
support bowl will occur if the concave ring is loose or
cocked when the crusher is put into production.
17. If any clearance is detected in Step 16, check again that
the concave ring is centered in the support bowl, and that all
wedges are fully seated. If the concave ring is correctly
seated, any clearance may indicate that the support bowl has
wear on the machined seat. Any worn areas will need to be
sealed with putty before pouring the Smithbond sealant. This
will prevent any of the backing sealant from leaking out
through the worn areas.

Figure 332. Welding Wedge Segments


19. For crusher models equipped with a tapered key and a
tapered wedge (Fig. 3-33), tack weld the wedge to the tapered
key.

! CAUTION
DO NOT weld the tapered wedges to the support
bowl. Concave ring lugs may break if tapered
wedges are welded to the support bowl.
18. For crusher models using a tapered wedge only (Fig. 332), tack weld the taper wedges to the concave ring lugs.

Figure 333. Welding Taper Key Models

320

07/09

Wear Liner Replacement


Telsmith SBS Cone Crusher

Support Bowl and Concave Ring

20. Before mixing and pouring Smithbond epoxy backing


compound, determine the amount of Smithbond required for
your crusher model using Table 3-1. Make certain you have
an adequate amount of compound to complete the job.
Table 31. Smithbond Required Quantities (22 Pound Containers)
Fine
Concave

Medium
Fine
Concave

Medium
Concave

Medium
Coarse
Concave

Coarse
Concave

Extra
Coarse
Concave

38S

N/A

N/A

N/A

38FC

N/A

N/A

N/A

44S

N/A

N/A

N/A

44FC

N/A

N/A

N/A

52S

N/A

N/A

N/A

52FC

N/A

N/A

N/A

57S

N/A

N/A

15

N/A

10

57FC

18

16

15

12

14

N/A

68S

N/A

N/A

16

N/A

16

16

68FC

24

N/A

22

N/A

22

N/A

Crusher
Model

NOTE: Quantities shown are approximate. Actual quantities required may vary. Consult Telsmith if your
liner configuration is not shown above.
21. Mix each pail of Smithbond one-at-a-time as described in
the Mixing and Pouring Smithbond section of this chapter.
After mixing, pour the Smithbond mixture through the
support bowl slots as shown in Figure 3-34.

22. Continue mixing and pouring Smithbond until the


Smithbond is level with the bottom of the support bowl
vertical face (Fig. 3-35). Do Not overfill the slots with
Smithbond and allow the level to rise up and overflow onto
the wedge seating surfaces. Correct Smithbond level can be
determined by measuring Dimension A between the
bottom of the support bowl vertical face and the machined
wedge seating surface. The pour dimension is model specific
as outlined in the dimension chart of Figure 3-35. Pouring
time can be reduced if more than one individual pours
Smithbond, allowing the pour to occur at multiple locations
around the top of the support bowl at one time.

Figure 334. Pouring Concave Ring Smithbond

07/09

321

Support Bowl and Concave Ring

Wear Liner Replacement


Telsmith SBS Cone Crusher

New Style C

1. Place a new concave ring on hardwood blocking so it is


raised about 3 or 4 inches (7.6 - 10.1 cm) off the ground. The
ring must be evenly supported and completely level (Fig. 336).

A
B

D
E

Dimension A (Backing Fill Level):


38 SBS: 0.88 (2.2 cm)
44 H/SBS: 1.00 (2.5 cm)
52 H/SBS: 1.38 (3.5 cm)
57 H: 1.61 (4.0 cm)
57 SBS: 1.00 (2.5 cm)
68 H: 2.38 (6.0 cm)
68 SBS: 1.38 (3.5 cm)

Figure 335. Support Bowl Backing Fill Level

Figure 336. Blocking Up New Concave Ring


2. Inspect the machined seat area on both the support bowl
and the new concave ring. (Fig. 3-37). Remove any burrs or
rough spots with a grinder. The seating surfaces must be
clean, dry and with a uniform surface free of rust, paint etc. to
promote a proper seal.

A. Fill Dimension (Concave Ring) B. Smithbond Backing Levels


C. Support Bowl
D. Concave Ring
E. Mantle
F. Head

23. Allow adequate time for Smithbond to harden. In most


climates, at least four hours will be required. In colder
climates, allow at least eight hours or let Smithbond harden
overnight.
24. Prepare and install the support bowl in the upper frame
following the instructions in this chapter when the Smithbond
has fully hardened.

322

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Wear Liner Replacement


Telsmith SBS Cone Crusher

Support Bowl and Concave Ring

IMPORTANT:
DO NOT apply any grease or gear oil to the concave
ring.

NO GREA

SE

NO GREA
S
NO

GR

EA

SE

Figure 337. Seat Inspection


3. Apply a thin coat of NLGI#2 grease, or a generous coating
of heavy gear oil to the curved upper surface of the support
bowl including the lug pockets (Fig. 3-38). DO NOT apply
any grease or gear oil to the machined seat at the bottom.

Figure 338. Greasing the Support Bowl


4. Apply a thin coat of grease to the complete surface of each
filler ring. (Grease is applied to help prevent adhesion of filler
compound.)
5. Lift each filler ring (if used) up into position on the
concave ring with a suitable lifting device (Fig. 3-39).
Position the filler ring locator mounting hole over the
concave mounting stub (B, Fig. 3-39) and lower into position.

07/09

323

Support Bowl and Concave Ring

Wear Liner Replacement


Telsmith SBS Cone Crusher

A
B
C

Figure 339. Concave Ring Installation


A. Filler Ring
C. Concave Ring

B.Concave Mounting Stub


D. Lift Hole

6. Install 3/4 inch eyebolts into the three lifting holes on the
top edge of the support bowl. Secure the eyebolts with
jamnuts.

! WARNING
Always use suitable rigging and hoisting
equipment to stabilize and lift heavy objects.
Lifting heavy components with inadequate
hoisting apparatus can damage machinery and
may result in serious personal injury or death.
Support bowls range in weight from 2,600 lbs
(1179 Kg) on the Model 38 to 12,000 lbs (5443 Kg)
on the Model 68.
7. Slowly lower the support bowl onto the concave ring (Fig.
3-40). Align the support bowl so that the support bowl slots
align with the concave ring lugs. Lower the support bowl so
the slots pass down over the lugs. Lower the support bowl
until it is resting on the machined lip of the concave ring. DO
NOT rotate the support bowl, the support bowl cutout slots
must remain aligned with the ears on the concave ring.

Figure 340. Lowering the Support Bowl onto the


Concave Ring
8. Remove the lifting cables from the support bowl.
9. Measure the distance from the inner edge of the support
bowl to the top edge of the concave ring at four locations 90o
apart (Fig. 3-41). All four measurements must be equal.

324

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Telsmith SBS Cone Crusher

Support Bowl and Concave Ring

IMPORTANT:
2
1

The taper wedges used on Model 38 liners differ from


the wedges used on 44/52/57/68 liners. Model 38
wedges do not have a rim. Wedges are not
interchangeable (see Fig. 3-44 & 3-45).
12. Switch to a sledge hammer and drive bar and alternately
drive the wedge segments tight until they will not move (Fig.
3-43). Follow the sequence in Figures 3-44 & 3-45 when
tightening the wedges on your model crusher.

Figure 341. Concave Ring Centering Measurements


10. If necessary, shift the concave ring with a crowbar so that
it is centered within the support bowl (Fig. 3-42). When the
concave ring is correctly centered, check to make sure that the
ears are still located directly above the support bowl slots. If
not, rotate the concave ring until ears are above the slots.

Figure 343. Tightening Wedge Segments

Non-Rim
Wedge

MODELS 38
Figure 344. Wedge Tightening Sequence Model 38
Figure 342. Centering The Concave Ring.
11. Using a hammer, alternately tap all taper wedge segments
into place until they are tight beneath the concave ring ears
and have bridged the slots in the support bowl.
07/09

325

Support Bowl and Concave Ring

Wear Liner Replacement


Telsmith SBS Cone Crusher

IMPORTANT:
Make certain that all wedge segments are driven as
tight as possible. Failure to fully tighten wedge
segments could allow the concave ring to loosen during
crushing.

3
4

3
Rimmed
Wedge
2

14. Using a feeler gauge, check that the machined seat of the
concave ring is TIGHT against the machined seat of the
support bowl. Move completely (360o) around the lower edge
of the support bowl checking the clearance (Fig. 3-46). There
should be no clearance at any point.

MODELS 44 & 52

13. Re-check the concave ring position in the support bowl


when all wedges are tight. Check that the ring is still centered
in the bowl and has not shifted. If measurements are unequal
(Fig. 3-41), it will be necessary to drive the wedge segments
back out and re-center the ring in the bowl. When retightening the wedges, make certain to alternate wedges
every few blows to prevent the bowl from shifting to one side.

2
1
Rimmed
Wedge
3

MODEL 57

1
6

Figure 346. Measuring Seat Clearance


4

IMPORTANT:

Rimmed
Wedge

5
2

MODEL 68
Figure 345. Wedge Tightening Sequence per Model

326

Make certain the concave ring is properly installed as


described in the previous steps. Serious damage to the
support bowl will occur if the concave ring is loose or
cocked when the crusher is put into production.
15. If any clearance is detected in Step 14, check again that
the concave ring is centered in the support bowl and that all
wedges are fully seated. If the concave ring is correctly
seated, any clearance may indicate that the support bowl has
wear on the machined seat. Any worn areas will need to be
sealed with putty before pouring the Smithbond sealant. This
will prevent any of the backing sealant from leaking out
through the worn areas.

07/09

Wear Liner Replacement


Telsmith SBS Cone Crusher

Support Bowl and Concave Ring

16. Tack weld the taper wedges to the concave ring lugs (Fig.
3-47).

! CAUTION
DO NOT weld the tapered wedges to the support
bowl. Concave ring lugs may break, if tapered
wedges are welded to the support bowl.
17. Before mixing and pouring Smithbond epoxy backing
compound, determine the amount of Smithbond required for
your crusher model using Table 3-2. Make certain you have
an adequate amount of compound to complete the job.

Figure 347. Welding Tapered Wedge Segments


Table 32. Smithbond Required Quantities (22 Pound Containers)
Crusher
Model

#1

#2

#3

#4

#5

#6

#7

#8

#9

38SBS

N/A*

N/A*

N/A*

NA*

NA*

NA*

N/A*

N/A*

N/A*

44SBS

N/A

N/A

52SBS

N/A

57SBS

N/A

16

11

11

11

68SBS

N/A

18

18

18

16

16

16

16

NOTE: Quantities shown are approximate. Actual quantities required may vary. Consult Telsmith if your liner
configuration is not shown above.
*Model 38 SBS crushers use non-numbered liners. Use the 38S quantities in Table 3-1 when determining
quantities for the SBS.
18. Mix each pail of Smithbond one-at-a-time as described in
the Mixing and Pouring Smithbond section of this chapter.
After mixing, pour the Smithbond mixture through the
support bowl slots as shown in Figure 3-48.

07/09

327

Support Bowl and Concave Ring

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Telsmith SBS Cone Crusher

3
A
B

D
E

Figure 348. Pouring Smithbond Backing


19. Continue mixing and pouring Smithbond until the
Smithbond is level with the bottom of the support bowl
vertical face (Fig. 3-49). Do Not overfill the slots with
Smithbond and allow the level to rise up and overflow onto
the wedge seating surfaces. Correct Smithbond level can be
determined by measuring Dimension A between the
bottom of the support bowl vertical face and the machined
wedge seating surface. The pour dimension is model specific
as outlined in the dimension chart of Figure 3-49. Pouring
time can be reduced if more than one individual pours
Smithbond, allowing the pour to occur at multiple locations
around the top of the support bowl at one time.

Dimension A (Backing Fill Level):


38 SBS: 0.88 (2.2 cm)
44 H/SBS: 1.00 (2.5 cm)
52 H/SBS: 1.38 (3.5 cm)
57 H: 1.61 (4.0 cm)
57 SBS: 1.00 (2.5 cm)
68 H: 2.38 (6.0 cm)
68 SBS: 1.38 (3.5 cm)

Figure 349. Support Bowl Backing Fill Levell


A. Fill Dimension (Concave Ring) B. Smithbond Backing Levels
C. Support Bowl
D. Concave Ring
E. Mantle
F. Head

20. Allow adequate time for Smithbond to harden. In most


climates, at least four hours will be required. In colder
climates allow at least eight hours or let Smithbond harden
overnight.
21. Prepare and install the support bowl in the upper frame
following the instructions in this chapter when the Smithbond
has fully hardened.

328

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Wear Liner Replacement


Telsmith SBS Cone Crusher

Support Bowl and Concave Ring

SUPPORT BOWL PREPARATION


Prepare the support bowl for installation as described in the
following steps.
1. Be sure that power remains locked-out. Refer to
Chapter 1 for complete lockout/tagout instructions.

2. Replace the concave ring if it is cracked, damaged or


worn beyond its useful life. Refer to the procedures earlier in
this chapter for concave ring removal and installation
procedures.
3. Remove all dirt, rust and old grease from the buttress
threads of the support bowl (Fig. 3-50), the locknut ring and
the upper frame..

Figure 350. Cleaning the Buttress Threads


4. Use a wire brush on the buttress threads. File any rough
areas. Remove any nicks, burrs or scratches.
5. After cleaning, carefully inspect all buttress threads for
signs of damage or excessive wear. Make repairs as required.
6. Inspect the support bowl felt seal. On Type A
assemblies, the seal is located inside the support bowl driver.
On Type B & C assemblies, the seal is located near the top
of the support bowl. Replace the seal if it is worn or damaged.
Refer to Figure 3-51 for seal lengths. See Figure 3-52 for seal
orientation.
7. Inspect the felt seal at the bottom of the upper frame.
Replace the seal if it is worn or damaged. Refer to Figure 351 for seal lengths. See Figure 3-52 for seal orientation.

07/09

329

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Telsmith SBS Cone Crusher

3
A
B

Crusher Model
Seal Length in
feet/(cm)
Seal Thickness in
inches/(mm)

38

44

52

57

68

11.0
(335.3)

12.5
(381.0)

14.4
(438.9)

16.3
(496.8)

18.4
(560.8)

5/8
(16)

5/8
(16)

5/8
(16)

5/8
(16)

5/8
(16)

Note: All dimensions shown above are approximate


Figure 351. Felt Seal Installation (Support Bowl)
A.Type A Support Bowl Felt Seal

B. Type B & C Support Bowl Felt Seal

8. Type A support bowl assemblies only: If removed,


reinstall the support bowl driver. Secure with socket head
capscrews and flatwashers. Apply thread locking compound
to capscrews as installed. Refer to Appendix E for thread
locking compound specifications. See Appendix A for torque
specifications.

9. Type B & C support bowl assemblies only: If removed,


reinstall the support bowl driver keys. Secure with socket
head capscrews and flatwashers. Apply thread locking
compound to capscrews as installed. Refer to Appendix E for
thread locking compound specifications. See Appendix A for
torque specifications

B
A

Figure 352. Seal Orientation (all felt seals)


A. Rough Side Faces OUT

330

B. Smooth side faces UP

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Wear Liner Replacement


Telsmith SBS Cone Crusher

Support Bowl and Concave Ring

IMPORTANT: Use only moly-based EP-2 grease in the


following steps. Refer to Appendix D for grease
specifications. Before applying grease, be certain that
the buttress threads are clean, in good condition and
completely free of any rust, nicks or burrs.

10. Coat the buttress threads of the locknut ring and the upper
frame with moly-based EP-2 grease (Fig. 3-54).
11. Coat the buttress threads of the support bowl with molybased EP-2 grease (Fig. 3.54).
12. Coat the smooth lower surface of the support bowl with
moly-based EP-2 grease.
13. Coat both felt seals with moly-based EP-2 grease.
IMPORTANT: Failure to apply grease as described in
the previous steps may result in thread damage and/or
excessive thread wear.

Crusher
Model

Seal Length
feet/(cm)

Seal Thickness
inches/(mm)

38

12.3
(374.9)

5/8
(16)

44

13.3
(405.3)

5/8
(16)

52

16.4
(499.8)

5/8
(16)

57

18.0
(548.6)

5/8
(16)

68

20.0
(609.6)

3/4
(16)

Note: All dimensions shown are approximate

Figure 353. Felt Seal Installation (Upper Frame)

07/09

331

Support Bowl and Concave Ring

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Telsmith SBS Cone Crusher

Figure 354. Greasing Threads and Seals


A. Grease Buttress Threads

332

B. Grease Machined Surface

C. Grease All Felt Seals

07/09

Wear Liner Replacement


Telsmith SBS Cone Crusher

Support Bowl and Concave Ring

SUPPORT BOWL INSTALLATION


Old Style A and B
Install the support bowl as described in the following steps:

6. If removed, reinstall the extension brackets onto the drive


ring (Fig. 3-55). Secure the extension brackets with
capscrews, flatwashers and nuts. Refer to Figures 3-7 and 38 for installation details.

1. Be sure that power remains locked-out. Refer to Chapter


1 for complete lockout/tagout procedures.

! WARNING

3. Type A support bowl assemblies only: Install 3/4 inch


eyebolts into the three lifting holes on the support bowl driver
. Secure the eyebolts with jamnuts.

Always use suitable rigging and hoisting equipment


to stabilize and lift heavy objects. Lifting heavy
components with inadequate hoisting apparatus
can damage machinery and may result in serious
personal injury or death. Refer to Appendix C for
weights.

4. Type B support bowl assemblies only: Install 3/4 inch


eyebolts into the three lifting holes on the top edge of the
support bowl (Fig. 3-55). Secure the eyebolts with jamnuts.

7. Using an appropriate lifting device and cables, suspend


the support bowl several inches over the threaded bore of the
locknut ring (Fig. 3-55).

5. If not done previously, disconnect the locking cylinder


hose at the hydraulic power unit. Leave all other hoses
connected. Refer to Figure 3-10.

2. Prepare the support bowl for installation as described in


the Support Bowl Preparation section of this chapter.

C
D

Figure 355. Positioning The Support Bowl


A. Support Bowl Buttress Threads

07/09

B. Locknut Ring Threads

C. Allow 6 inches clearance between thread starts D. Extension Bracket

333

Support Bowl and Concave Ring

8. Slowly rotate the support bowl until the leading end of the
support bowl buttress thread is positioned about 6 inches
(15.2 cm) behind the start of the locknut ring buttress thread.
See Figure 3-55.

9. Visually check that no personnel are on, under, inside or


beside the crusher.
10. Connect power to the hydraulic control console. Move the
function selector switch to EXTRACT-HIGH SPEED. Refer
to Figure 3-11 for control console diagram.
11. Depress the START button. The hydraulic pump will
start.
12. Type A support bowl assemblies only: Depress and
hold the OPEN or CLOSE pushbutton until the keys on the
extension brackets become aligned with the keyways on the
support bowl driver.
13. Type B support bowl assemblies only: Depress and hold
the OPEN or CLOSE pushbutton until the keyways on the
extension brackets become aligned with the support bowl
drive keys.
IMPORTANT: Be sure that the support bowl remains
level as it is lowered in step 14 or 15. On some crushers,
it may be necessary to loosen the extension brackets
slightly to allow key engagement.

Wear Liner Replacement


Telsmith SBS Cone Crusher

20. Depress and hold the CLOSE button. Verify that the
support bowl begins turning slowly clockwise.
21. Allow the support bowl to become threaded within the
bore of the locknut ring and the upper frame (Fig. 3-56). The
support bowl will move slowly downward as it rotates.
22. Type A support bowl assemblies only: Continue to
depress the CLOSE button until the keys on the drive ring
become fully engaged in the keyways of the support bowl
driver.
23. Type B support bowl assemblies only: Continue to
depress the CLOSE button until the support bowl drive keys
become fully engaged in the keyways of the drive ring.
24. Depress the STOP button. Lockout/tagout power to
the hydraulic control console. Refer to Chapter 1 for
complete lockout/tagout procedures.
25. Remove capscrews, flatwashers, nuts and extension
brackets.
26. Install the inner and outer receiving hoppers. Refer to the
Receiving Hopper Installation section of this chapter for
procedure.
.
B

14. Type A support bowl assemblies only: Slowly lower the


support bowl. Allow the keys on the extension brackets to
enter the keyways in the support bowl driver. Continue
lowering the support bowl until its bottom buttress thread is
resting on the top buttress thread of the locknut ring .
15. Type B support bowl assemblies only: Slowly lower the
support bowl. Allow the drive keys to enter the keyways of
the extension brackets. Continue lowering the support bowl
until its bottom buttress thread is resting on the top buttress
thread of the locknut ring .

16. Measure the support bowl height at all three extension


brackets. Measurements must be approximately equal in all
three locations.
IMPORTANT: Be sure that the support bowl is not
cocked. To ensure proper thread engagement, the
support bowl must be completely level as it is threaded
into the locknut ring.

Figure 356. Threading Support Bowl


A. Extension
C. Drive Ring

B. Support Bowl

17. Disconnect the lifting cables and remove the eyebolt.


18. Visually check that no personnel are on, under, inside or
beside the crusher.
19. With the function selector switch in the EXTRACTHIGH SPEED position, depress the START button. The
hydraulic pump will start.

334

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Support Bowl and Concave Ring

New Style C
1. Apply Moly-based EP#2 grease to the support bowl felt
seal as shown in Figure 3-57.

3
D

Figure 357. Felt Seal Installation.


A. Felt Seal
B. Support Bowl Upper Lip
C. Rough Side Facing Out D. Smooth Side Facing Up

2. Apply a liberal amount of Moly-based EP#2 grease to the


internal threads of the locknut and upper frame. Also apply
grease to the external threads of the support bowl and the
machined area beneath the threads (Fig. 3-58).
3. If your upper frame requires new inner or outer felt seals,
install them at this time (Fig. 3-57), and coat outer face
liberally with Moly-based EP#2 grease.

Figure 358. Assembly Grease Points


IMPORTANT: Failure to properly grease adjuster
component threads prior to assembly can result in
thread damage and/or rapid thread wear.
4. Install the three 3/4 inch threaded lift eyes fully in the
support bowl as shown in Figure 3-59. Attach a lift device and
cables or chain of sufficient capacity to the lift eyes.
NOTE: It is recommended that a lift device with a hook
or lift eye that can rotate 3600 be used to ease the rethreading of the support bowl. The lifting device will
need to rotate without binding or putting excess strain
on the lift chains or cables while engaging the threads.
5. Carefully lift the support bowl and suspend a few inches
above the drive key extensions. Make certain the support
bowl is completely level. Rotate the support bowl until the
match marks you made previously on the support bowl and
the locking ring are aligned .

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335

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Telsmith SBS Cone Crusher

9. Hold the control switch in the Extract High Speed


position and activate the Close button. The support bowl
should rotate slowly down into the upper frame. If any
grinding, jerking or slowing of the rotation is noted, STOP the
rotation immediately by releasing the Close button. If the
bowl does not rotate smoothly, this could be a sign of cross
threading, damaged threads or resistance created by the lift
apparatus.

NOTE: If the lift apparatus remains attached while the


bowl is descending into the upper frame, continue to
provide additional slack in the lift harness. Failure to
provide sufficient slack could result in the support bowl
threads being pulled up against the upper frame
threads, creating resistance to rotation.

RECEIVING HOPPER INSTALLATION

Figure 359. Orienting Support Bowl


A. Drive Key (3)
C. Locking Ring Match Mark
E. Lift Eye (3)

10. When the support bowl has rotated completely to the


bottom of the upper frame, stop the rotation and remove the
lift eyes and lift apparatus from the bowl if not removed
previously. Unbolt the drive key extensions (B, Fig. 3-59)
from the drive ring.

B. Drive Key Extension (3)


D. Support Bowl Match Mark

6. Rotate the support bowl back (counterclockwise) from the


locking ring mark until the drive keys on the support bowl are
aligned with the drive key extensions. (Rotating the bowl
back will help ensure that the threads engage properly in step
7). Lower the support bowl down, engaging the drive keys in
the drive key extensions.

Old Style A and B


Reinstall the inner and outer receiving hoppers as described
in the following steps. Refer to Figures 3-2 and 3-3 for
exploded views.
1. Be sure that power remains locked-out. Refer to Chapter
1 for complete lockout/tagout procedures.
2. Reinstall the support bowl as described in the Support
Bowl Installation sections earlier in this chapter.

! WARNING

7. Manually rotate the support bowl clockwise a small


amount to ensure the support bowl threads engage correctly
with locking ring threads. (Using a long bar as a lever on top
of the bowl may be necessary to rotate the bowl). If any
resistance is felt or the bowl refuses to turn, back up and start
over. Any resistance is an indication the threads are cross
threaded or jammed.

Always use suitable rigging and hoisting equipment


to stabilize and lift heavy objects. Lifting heavy
components with inadequate hoisting apparatus
can damage machinery and may result in serious
personal injury or death. Refer to Appendix C for
weights.

8. Restore hydraulic and electrical power to the crusher.


Provide some slack in the lift apparatus to allow the bowl to
rotate down.

3. Using an appropriate lifting device and cables, slowly


lower the inner receiving hopper straight down into the
support bowl.

NOTE: When the support bowl has rotated several


rotations and the threads have moved through the
locking ring and down into the upper frame, it is
permissible to stop the rotation and remove the lift
apparatus and lift eyes from the bowl.

4. Clean the top surface of the drive ring and the mating
surface of the outer receiving hopper. Apply a bead of caulk
completely around the drive ring. See Figure 3-60.

336

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Telsmith SBS Cone Crusher

Support Bowl and Concave Ring

Figure 360. Caulk Application


A. Caulk

B. Drive Ring Upper Flange

5. If not done previously, coat the felt seal with moly-based


EP-2 grease. Refer to Appendix D for grease specifications.
6. Using an appropriate lifting device and cables, slowly
lower the outer receiving hopper into the concave ring (Fig.
3-61). Be sure that bolt holes are aligned.

Figure 361. Outer Receiving Hopper Installation


7. Remove the lifting cables from the outer receiving
hopper.
8. Using a mallet, evenly tap completely around the edge of
the outer receiving hopper until it is firmly seated against the
top of the drive ring. Secure the hopper with capscrews
flatwashers and nuts. Torque fasteners to 150 ft. lb. (203 nm).
9. Reconnect the locking cylinder hose at the hydraulic
power unit.
10. Restore power to the crusher, and rotate the support bowl
open and closed to check adjusting assembly operation. If the
unit is working correctly, set your crusher final discharge
setting by following the instructions in your Operation and
Maintenance Manual.
11. Install any conveyors, chutes, hoppers or any other feed
equipment that was removed to gain access to the support
bowl.

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337

Support Bowl and Concave Ring

DRIVE RING COVER INSTALLATION


New Style C

Wear Liner Replacement


Telsmith SBS Cone Crusher

6. Install any conveyors, chutes, hoppers or any other feed


equipment that was removed to gain access to the support
bowl.

1. Install the support bowl following the instructions in


Adjuster Assembly Support Bowl Installation in this chapter.
2. Remove drive key extensions and store for future use.
3. Install lift eyes and lift apparatus of sufficient capacity to
the drive ring cover and lift cover into position above drive
ring (Fig. 3-62). Align mounting holes with the threaded
holes in the drive ring where the drive key extensions were
removed. Install nine (9) hex head cap screws and washers
and torque to 150 Ft. lb. (203 Nm).

Figure 362. Install Drive Ring Cover


4. Install the clamping cylinder hydraulic hoses at the
hydraulic power unit manifold.
NOTE: If the hydraulic clamping cylinder hydraulic
circuit was opened (cylinder replaced, cylinder hoses
disconnected etc.) during adjusting assembly service, it
will be necessary to bleed the hydraulic clamping
cylinder circuit. Follow the instructions in Upper Frame
Hydraulic System Service in this chapter.
5. Restore power to the crusher, and rotate the support bowl
open and closed to check adjusting assembly operation. If the
unit is working correctly, set your crusher final discharge
setting by following the instructions in your Operation and
Maintenance Manual.
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Support Bowl and Concave Ring

MIXING AND POURING SMITHBOND


The epoxy based material required to fill the voids between
the concave ring and support bowl of the crusher is
Smithbond. This compound provides a solid backing surface
that helps prevent the concave ring from becoming deformed
during crushing. New Smithbond is required whenever the
concave ring is replaced.

Smithbond Safety Precautions

! WARNING
Failure to observe the following safety
precautions may result in serious personal
injury or death.

Mix and pour Smithbond only in a well ventilated area.


Avoid inhaling fumes.

Wear rubber or plastic gloves when working with


Smithbond. Always wear eye protection.

Avoid contact with Smithbond. Use soap and water to


remove any Smithbond that comes in contact with the
skin. Immediately flush eyes with running water if eye
contact occurs.

Clothes soiled with Smithbond must be laundered before


being re-worn.

Provide adequate ventilation when removing parts backed


with Smithbond. Wear an airline grade respirator to
prevent inhalation of fumes when torch cutting, grinding
or chopping Smithbond.

Figure 363. Smithbond Kit Components


A. Hardener Can
C. Cover
E. Stirring Rod

Read the labels on the Smithbond pail and the Smithbond


hardener can (Fig. 3-63) for additional warnings,
directions and safety precautions.

B. Plastic Partition
D. Resin
F. Pail

For best results, crusher parts should be between 65oF


(18oC) and 90oF (32oC) during pouring.

Tips for Handling Smithbond

The Smithbond kit is shipped in a plastic pail. Each kit


contains a pre-measured amount of liquid resin. Included
separately inside the pail is a small can of liquid hardener
and a stirring rod (Fig. 3-63)

Subsequent batches required to completely fill the cavity


may be mixed and added at any time. Newly poured
Smithbond will adhere to any Smithbond that has already
hardened.

The required quantities of Smithbond are listed in the


Tables under Concave Ring Installation in this chapter. It
is recommended that one extra pail of Smithbond be
ordered as a precaution when preparing to pour concave
ring backing.

Do not mix Smithbond in batches larger than 22 pounds.


For best results, mix and pour each pail one at a time. Do
Not re-use stirring rods.

Store Smithbond at temperatures below 100oF (38oC).


Smithbond is stable for at least 12 months after the date of
manufacture. Smithbond can be used up to 24 months
after manufacture, but hardening times will increase as
the kit grows older.

Ensure that Smithbond is at room temperature (about


70oF (21oC)) before mixing. If Smithbond is too cold, it
can become viscous and have difficulty flowing into small
spaces. If the Smithbond is too warm, it may harden
before it is completely poured.

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Mixing Smithbond
1. Read and understand all safety precautions on the
Smithbond pail and hardener before proceeding with mixing.

2. Mix the resin using the stirring rod and a low speed
electric drill. Continue stirring the resin for about 5 minutes.
If any crust has formed on the top of the resin use a sharp tool
to break it up.
3. As stirring continues, add the entire contents of the
hardener can into the pail at a slow, continuous rate. Mix until
a uniform color is obtained. Be sure all settled material is
thoroughly mixed (Fig. 3-64).
4. Pour Smithbond IMMEDIATELY after mixing in
hardener. DO NOT allow Smithbond to stand. Hardening
begins quickly and the mixture will remain pourable for only
about 15 minutes.

! CAUTION
Smithbond may become hot when mixed,
especially if pouring occurs during high ambient
temperatures. To avoid burns, use gloves when
handling the Smithbond pail. Avoid contact with
the concave ring while pouring Smithbond.
5. Mix and pour additional batches of Smithbond as required
to completely fill the cavity.

Figure 364. Mixing Smithbond

340

07/09

Chapter 4
Mantle and Head

CONTENTS

Page
EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
TOOLS AND SUPPLIES REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
MANTLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
MANTLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
HEAD and SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Mantle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
HEAD and SHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
HEAD and SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Mantle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Installation - Crushers Without Anti-Spin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Installation - Crushers With Anti-Spin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

FINAL INSTALLATION and ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

07/09 (Rev 1)

41

Mantle and Head

Wear Liner Replacement


Telsmith SBS Cone Crusher

Shaft Nut Cap


Mantle

Head

42

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Wear Liner Replacement


Telsmith SBS Cone Crusher

Mantle and Head

4
A

Figure 41. Exploded View, Head and Shaft Components (Type A)


A. Main Shaft
B. Taper Head

07/09 (Rev 1)

C. Mantle
D. Burn Ring

E. Shaft Nut (FC Only) G. Feed Plate (FC Only)


F. Shaft Nut (S Only)
H. Shaft Nut Cap (S Only)

I. Inner Piston Ring

43

Mantle and Head

Wear Liner Replacement


Telsmith SBS Cone Crusher

J
B

Figure 42. Exploded View, Head and Shaft Assembly (Type B)


A. Main Shaft
B. Taper Head

44

C. Mantle
D. Burn Ring

E. Shaft Nut
F. Spacer (FC Only)

G. Feed Plate (FC Only)


H. Shaft Nut Cap (S Only)

I. Inner Piston Ring


J. Smithbond
K. Shaft Nut Wrench

07/09 (Rev 1)

Wear Liner Replacement


Telsmith SBS Cone Crusher

Model 38

Mantle and Head

Models 44-68
I
H
B
G

4
Figure 43. Exploded View, Head and Shaft Components (Type C)
A. Main Shaft
B. Taper Head

07/09

C. Mantle
D. Burn Ring

E. Shaft Nut
F. Shaft Nut Cap

G. Washer
H. Hex Head Capscrew Gr5

I. Bolt Locking Plate

45

Mantle and Head

Wear Liner Replacement


Telsmith SBS Cone Crusher

DESCRIPTION
The mantle (C, Fig. 4-1, 4-2 & 4-3) is a replaceable coneshaped maganese steel casting that forms the lower surface of
the crushing chamber.
The mantle is secured by a shaft nut (E, Fig. 4-1, 4-2 & 4-3)
located on the upper threaded portion of the main shaft.
Before the nut is loosened for removal, a burning ring (D)
located between the mantle and the nut must be cut away with
a torch. A special wrench supplied with the special tools kit
is required to remove the nut. Nuts come in several styles. A
matching wrench is required for loosening and tightening
each style nut.
Smithbond, a special epoxy based backing compound, fills
the void area between the top surface of the taper head (B)
and the underside of the mantle (C).

Mantle replacement intervals will vary, depending on the


amount and type of material being crushed. Replacement
should always be performed before the mantle becomes
excessively worn or cracked.
A

Mantle replacement can be performed in two ways. One


method involves leaving the shaft and taper head in the
crusher and removing only the mantle. The second method
involves removing the mantle, taper head and shaft assembly
as a unit before removing the mantle. Both methods are
covered in this chapter. It is recommended that the complete
assembly be removed at every other mantle change to allow
the shaft, taper head skirt, the inner piston ring and the upper
thrust bearing to be completely inspected.

Figure 44. Type C Mantle Nuts and Wrenches


A. New Style Nut & Wrench (44-68)
C. Model 38 Nut & Wrench

46

B. Old Style Nut & Wrench

07/09

Wear Liner Replacement


Telsmith SBS Cone Crusher

SHUTDOWN PROCEDURE

Mantle and Head

TOOLS AND SUPPLIES REQUIRED

Suitable rigging and hoisting equipment

Standard open-end and socket wrenches

Standard hex wrenches

Sledge hammer

Shaft nut wrench*

Shaft nut cap lift lug*

Eyebolt, 1-1/4 inch or 1-1/2 inch

2. Lockout/ tagout power to the crusher drive motor. Shut


off fuel supply and disconnect batteries if the crusher is
powered by a diesel engine. Refer to Chapter 1 for detailed
safety procedures and lockout/tagout information.

Crowbar

Hand grinder

Tape measure and feeler gauge

3. Lockout /tagout power to all crusher feed and discharge


equipment.

Cold steel chisel

Cleaning solvent, clay and putty

4. Lockout/tagout power to the crusher oil-lubrication


system.

Shaft nut burning ring (new)

NLGI #2 grease

Lubricating oil

Smithbond backing compound

! WARNING
Always lockout/tagout power before performing
any maintenance, adjustments, lubrication or
repairs. Failure to lockout/tagout power may
result in serious personal injury or death!
1. Stop the material feed, operate the crusher until the
crushing chamber is completely empty. If necessary, use the
hydraulic clearing function to clear the crushing chamber.

IMPORTANT:
Be sure that power remains connected to the hydraulic
control console during the next step.

* Supplied with crusher special tools

5. Depress the STOP button on the hydraulic control


console. Then jog the function selector switch between
CLEAR, CRUSH, EXTRACT HI-SPEED positions several
times.
6. Check that all hydraulic pressure gauges and indicators
indicate zero PSI (0 bar). Repeat step 5 if any pressure is
indicated.
7. Lockout/tagout power to the crusher hydraulic control
console.

8. If you will be disconnecting the power rotator hoses or


servicing the hydraulic components in the power rotator
circuit, depressurize the power rotator circuit following the
instructions in Chapter 10 of your SBS Operation and
Maintenance manual.

! WARNING
Pressures of up to 4000 PSI (276 bar) may remain
trapped in the power rotator circuit even when
the hydraulic pump is off and the pressure
gauge indicates zero PSI (0 bar). Relieve
pressure as described in Chapter 10 of your
Operator Manual before disconnecting the
power rotator hoses or servicing any hydraulic
components in the power rotator circuit.

07/09

47

Mantle and Head

MANTLE REMOVAL
1. Lockout/tagout power. Perform the Shutdown Procedure
described earlier in this chapter. Refer to Chapter 1 for
complete lockout/tagout instructions.
2. Remove chutes, conveyors or other feeding devices from
above the crusher.
3. Remove the complete upper frame assembly from the
crusher following the instructions in Chapter 3 of this
manual.

Wear Liner Replacement


Telsmith SBS Cone Crusher

7. On Model 38 crushers the shaft nut cap can be lifted off


and removed by hand as it weighs approximately 20 lb. (9
kg). It is suggested that model 44-68 shaft nut caps be lifted
off using appropriately sized lift apparatus. The new C style
shaft nut cap on models 44-68 can be lifted off using the lift
lug supplied in the special tools kit. Insert the lifting lug (Fig
4-6) through the slot in the shaft nut cap and turn 90o to
engage the lifting lug tangs in the pockets of the cap. Use a
properly rated lift device to lift the lug and cap off the shaft
nut.

4. Remove any built-up dirt or debris from inside the


crusher.
5. Using a torch, cut through the perimeter of the burn ring
(Fig. 4-5). Move completely around (360o) the burn ring
while cutting. Use the groove in the center of the ring as a
guide while cutting the ring in half. The ring will collapse
when cut, relieving pressure on the shaft nut.

! CAUTION
To avoid heat damage when cutting the burn
ring, direct the cutting torch away from the taper
head and the shaft nut (Fig. 4-3).

Figure 46. C Style Shaft Nut Cap Removal


A. New Style Shaft Nut Cap

B. Shaft Nut Cap Lift Lug

8. Type A head and shaft assemblies only: Secure the shaft


nut wrench to the shaft nut with capscrews, flatwashers and
nuts (Fig. 4-1).
9. Type B head and shaft assemblies only: Secure the shaft
nut wrench to the shaft nut with capscrews (Fig. 4-2).
10. Note that the Type C 38 model shaft nut removal
wrench, requires four 3/4 x 11/4 shoulder screws to bolt the
wrench to the shaft nut. The new style shaft wrench used on
Type C 44-68 models must be clamped around the shaft nut
and tightened down into the pockets on the nut as shown in
Figure 4-4.

11. Use a sledge hammer to loosen the shaft nut (Fig. 4-7 &
4-8). Drive the wrench COUNTERCLOCKWISE to loosen
the nut.
Figure 45. Burn Ring Removal
6. Use a torch to cut the welds holding the bolt locking plate
(I, Fig. 4-1) to the shaft nut cap (F, Fig. 4-1). Remove the
locking plate, the hex head cap screw (H) and the flat washer
(G) from the shaft nut cap.

48

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Telsmith SBS Cone Crusher

Mantle and Head

Figure 47. Shaft Nut Removal (Style A)

Figure 49. Breaking Mantle Loose

Figure 48. Shaft Nut Removal (New Style C)

13. Lifting of the worn mantle from the taper head is most
commonly done by welding lifting eyes to the mantle in three
places. Weld three pieces of mild steel stock that can be bent
to conform to the mantle surface into place using stainless
steel welding rod AWSE3091L-17 (Fig. 4-10). Cut lift holes
in the steel stock to mount lift eyes.

12. When the shaft nut is successfully removed, use the


sledge hammer to strike the mantle in several places to break
it loose from the taper head (Fig.4-9). If the mantle will not
break loose using the sledge hammer, it may be necessary to
use the cutting torch to cut the mantle in half so it can be
removed in two pieces.

! WARNING
You must provide adequate ventilation when
removing parts backed with Smithbond with a
torch. Wear a properly rated respirator to
prevent inhalation of fumes when torch cutting,
grinding or chopping maganese and Smithbond.

Figure 410. Mantle Lift Eye Installation

07/09

49

Mantle and Head

Wear Liner Replacement


Telsmith SBS Cone Crusher

! CAUTION
Welding lift eyes to the mantle maganese must
be done carefully with the correct equipment.
Welds have a tendency to pull out of the surface
of worn maganese if the lift eyes are not
correctly welded into place with maganese
compatible welding rod. Stainless steel rod
AWSE309L-17 is recommended.
14. Using a suitable lifting device of correct capacity, lift the
mantle a short distance off the taper head. Place blocking
around the circumference of the mantle to hold it in the lifted
position. Remove the lift device and cables from the lift eyes.
15. Install mantle U hooks at three points around the lower lip
of the mantle (Fig. 4-11). Transfer the lift device and cables
to the U hooks (Fig. 4-11).

16. Using a hammer, chisel and hand grinder, remove all old
Smithbond and any accumulated debris from the surface of
the taper head. Do not nick or scratch the machined seat at the
bottom of the taper head.

! WARNING
Provide adequate ventilation when removing
Smithbond debris. Wear a certified respirator to
prevent inhalation of fumes when torch cutting,
grinding or breaking up Smithbond or
components backed with Smithbond.

MANTLE INSTALLATION
1. Inspect the machined seat on the taper head and the new
mantle (Fig. 4-12). No paint, dirt, grease or rust should be
present on either machined surface. Remove any rough spots
or burrs with a grinder.

4
B

Figure 411. Mantle Lifting Arrangement


A. U Hook (3)
B. Mantle

C. Cable or Lift Harness


D. Lift Device

NOTE:
If U hooks are not available, it is possible to sling
through the mantle (running the slings through the shaft
mounting hole at the top) at several places. When
installing slings that run up the inside of the mantle, be
aware of pieces of Smithbond backing that could break
off and fall to the ground.
410

Figure 412. Seat Inspection


A. Mantle Machined Seat

B. Taper Machined Seat

07/09

Wear Liner Replacement


Telsmith SBS Cone Crusher

Mantle and Head

2. When both the taper head and the new mantle are clean
and dry, apply a coat of heavy gear oil (ISO 150) to the
unmachined upper surface of the taper head (Fig. 4-13). Do
Not apply any oil to the machined seat of the taper or any
portion of the new mantle.

Apply ISO 150


Gear Oil

NO LUBE ON SEAT

Figure 414. Burning Ring Installation


Figure 413. Taper Head Lubrication Area

A. Mantle
C. Shaft

B. Burn Ring

! WARNING
Always use suitable rigging and hoisting when
lifting the mantle into place. Lifting heavy
components with inadequate or incorrectly
stabilized hoisting apparatus could damage
components or result in serious injury or death
to personnel.
3. Install U hooks at three points around the mantle (Fig.411). Install an appropriate lift device and cables and lower the
new mantle down into the crusher onto the taper head.

! CAUTION
Do Not weld lifting eyes to a new mantle. Welding
on the new maganese could damage the new
mantle if the lift eyes were to fail. Use only lift U
hooks or lift harnesses to install the new mantle
on the taper head.
4. Remove the lifting apparatus and the U-hooks from the
mantle.
5. Place a new burning ring around the threaded portion of
the main shaft (Fig. 4-14). Center it on the upper lip of the
mantle. If the new burn ring will not drop down into position,
it may be necessary to use a pry bar to center the top of the
mantle in relation to the main shaft (Fig. 4-15).

07/09

Figure 415. Centering Mantle


6. Measure from the shaft to the inside edge of the mantle at
four positions 90o apart as shown in Figure 4-16. All four
measurements must be equal; if they are not, continue using
the pry bar to position the mantle.

411

Mantle and Head

Wear Liner Replacement


Telsmith SBS Cone Crusher

C
D
E

F
G

Figure 416. Mantle Measurements

IMPORTANT:
Telsmith introduced a new style tapered shaft nut for all
sizes of H/SBS cone crushers in 2008. When replacing
your burn ring, it will be necessary to use the new style
nut, a new style cap and a new style shaft nut wrench
for the installation (Fig. 4-17).

Figure 417. Required New Parts and Tool

A. Cap Bolt Locking Plate


B. Shaft Nut Cap Bolt
C. Washer
D. Cap Lifting Lug
E. Shaft Nut Cap
F. Shaft Nut Wrench
G. Tapered Shaft Nut
H. Burn Ring
I. Mantle/Head and Shaft Assembly

7. Secure the shaft nut wrench (F, Fig. 4-17) to the shaft nut
(G), and hand thread the shaft nut onto the shaft until it is snug
against the burn ring (H).
8. Final tighten the shaft nut using a sledge hammer to strike
the shaft nut wrench (Fig. 4-18). Tighten the nut
CLOCKWISE until it stops turning. To prevent the mantle
from loosening during crushing, the shaft nut must be as tight
as possible against the burning ring.

412

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Telsmith SBS Cone Crusher

Mantle and Head

Figure 418. Tightening Shaft Nut


9. Remove the shaft nut wrench and all mounting hardware
and store for future use.
10. Using a feeler gauge, check that the machined seat of the
mantle is tight against the machined seat of the taper head.
Check clearance at multiple points moving 360o around the
taper head (Fig 4-19). There should be no clearance at any
point.

IMPORTANT:
Carefully inspect the joint between the mantle and the
taper head. Seal any worn areas that create a gap with
putty to prevent Smithbond leakage during backing
installation. If any major clearance is detected, check
that the mantle is not cocked, or the shaft nut not fully
tightened.

Figure 419. Checking Mantle to Taper Clearance


11. Install the shaft nut cap using the lift lug (D, Fig. 4-17) to
lower the cap into position. Install the washer and Grade 5
hex head capscrew torquing to specification.
Table 41. Shaft Nut Torque Values
Cone Model

Torque Specification

38

840 Ft-lb. (1138 N-m)

44

840 Ft-lb. (1138 N-m)

52

1500 Ft-lb. (2033 N-m)

57

1500 Ft-lb. (2033 N-m)

68

1500 Ft-lb. (2033 N-m)

NOTE:
It is possible to use a new style shaft nut cap on an old
style shaft nut on models 44, 52 and 57 cone crushers.
To use the new style cap, grind off the locating lug (Fig.
4-20) until it is smooth with the surrounding surface.

07/09

413

Mantle and Head

Wear Liner Replacement


Telsmith SBS Cone Crusher

A
A

Figure 420. Modifying a New Style Cap


A. Grind Lug Flush With Surface

12. The void between the mantle and the taper head will now
need to be filled with Smithbond epoxy-based backing
compound. Refer to Table 4-2 for the approximate amount of
Smithbond needed for your particular model crusher. Be sure
that an adequate supply of Smithbond is available before
beginning the pour.
Table 42. Smithbond Quantities - Mantle*
Crusher Model

Quantity

Figure 421. Mantle Pouring Holes


A. Pour equal amounts of Smithbond through each access hole.

14. Mix a pail of Smithbond as described in the Mixing and


Pouring Smithbond section in Chapter 3.
15. Slowly pour the Smithbond mixture into the clay pouring
funnel at one of the pouring holes (Fig. 4-22). Allow the
Smithbond to flow into the cavity between the mantle and
taper head. Continue pouring until the pail is completely
empty.

(22 Pound Container)

38S/FC

44S

44FC

52S/FC

57S

57FC

68S/FC

*Quantities are approximate, actual quantities may vary

13. Form a clay funnel around each of the two pouring holes
near the top of the mantle (Fig. 4-21).
Figure 422. Pouring Smithbond
16. Mix another pail of Smithbond and pour into the opposite
funnel from the first pour. Continue pouring until the pail is
completely empty. Pouring should be alternated between the
two pouring holes.

414

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Telsmith SBS Cone Crusher

Mantle and Head

17. Mix and pour additional pails of Smithbond until the level
just reaches the lower edge of the pour hole on the mantle
(Fig. 4-23). DO NOT fill the holes so that backing compound
backs up into the clay funnels. If this occurs, quickly remove
the clay funnels and allow backing compound to drain down
to the correct level.

23. Weld the shaft nut cap to the burning ring using stainless
steel weld rod E (R) 309L. Apply 2 welds in four places as
shown in Figure 4-24.

WEL

WELD

C
A
B

Figure 423. Smithbond Fill Level


A. Mantle Fill Level
C. Taper Head

B. Mantle
D. Shaft

18. Check for Smithbond leakage at the joint between the


mantle and the taper head (Fig. 4-19). Seal any leaks with
putty.

WELD

Figure 424. Installing Shaft Nut Cap and Locking


Devices
A. Shaft Nut Cap Bolt
B. Washer
C. Shaft Nut Cap Bolt Locking Plate

19. Allow Smithbond to fully harden. In most climates, at


least four hours will be required. In cold climates allow 8
hours.

20. After the Smithbond has fully hardened, remove the clay
pouring funnels and any clay putty that was used at the mantle
joint. Grind off any excess Smithbond residue.
21. Tack weld the shaft nut locking plate to the shaft nut cap
(Fig. 4-24) using stainless steel weld rod E (R) 309L.

IMPORTANT:
If the shaft nut cap bolt locking plate is not welded to the
shaft nut cap, the bolt could loosen and cause damage
to the shaft nut cap or crusher. If you have further
questions on how or where to weld the shaft nut, shaft
nut cap or burning ring, contact Telsmith Service.
22. Weld the burning ring to the mantle using stainless steel
weld rod E (R) 309L. Apply 2 welds in four places as shown
in Figure 4-24.
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Telsmith SBS Cone Crusher

HEAD and SHAFT REMOVAL


If removal of the mantle also requires removal of the shaft
and head assembly, remove the complete assembly as
follows:
1. Lockout/tagout power. Perform the Shutdown Procedure
described earlier in this chapter. Refer to Chapter 1 for
complete lockout/tagout instructions.
2. Remove chutes, conveyors or other feed devices from
above the crusher.
3. To provide access, remove the complete upper frame
assembly as detailed in Chapter 4 of this manual.
4. Verify that there is adequate space above the crusher to
allow head and shaft removal.

NOTE:
Perform steps 5 and 6 ONLY if your crusher is equipped
with the anti-spin option (4-25). If your crusher is not
equipped with anti-spin, skip steps 5 and 6.

Figure 426. Bottom of Head Skirt to Frame Arm


Measurement

With Anti-Spin

6. At a point near the Step 5 match marks, place additional


match marks on the taper head skirt, the rotary seal ring, the
main frame hub and the main frame liner (Fig. 4-27). These
marks will be used during reassembly.

Without Anti-Spin
Figure 425. Anti-Spin Option Check
5. At one of the crusher arms, measure the distance between
the top of the frame arm and the bottom of the taper head
skirt. (Fig. 4-26). Record this measurement for further use. It
will be checked again during reassembly procedures.

416

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Mantle and Head

A
C

Figure 428. Shaft Nut Cap Removal (New Style)


A

A. New Style Shaft Nut Cap

10. Thread an eyebolt of suitable capacity to support the head


and shaft assembly into the tapped hole at the top of the shaft
(Fig. 4-29). Make certain the eyebolt is threaded completely
into the hole until it is tight. Install a suitable lift device
through the eyebolt.

Figure 427. Match Marks


A. Main Frame
C. Head Skirt

B. Shaft Nut Cap Lift Lug

B. Rotary Seal Ring

7. Remove the shaft nut cap bolt, washer and shaft nut
locking plate from the shaft nut (Fig. 4-24). It will be
necessary to use a cutting torch to remove the weld holding
shaft nut locking plate to the shaft nut cap.

! WARNING
Always use suitable rigging and hoisting
equipment to stabilize and lift heavy objects.
Lifting heavy components with inadequate
hoisting apparatus can damage machinery and
may result in serious personal injury or death.

8. Use a torch to cut the weld holding the shaft nut locking
plate (Fig. 4-24) to the shaft nut cap. Remove the locking
plate, the hex head cap screw and the flat washer from the
shaft nut cap.

9. On Model 38 crushers, the shaft nut cap can be lifted off


and removed by hand as it weighs approximately 20 lb. (9
kg). It is suggested that the new style shaft nut cap on models
44-68 be lifted off using the lift lug supplied in the special
tools kit. Insert the lifting lug (Fig 4-28) through the slot in
the shaft nut cap and turn 90o to engage the lifting lug tangs
in the pockets of the cap. Use a properly rated lift device to
lift the lug and cap off the shaft nut.

07/09

417

Mantle and Head

Wear Liner Replacement


Telsmith SBS Cone Crusher

B
C

D
B

E
C

Figure 430. Head and Shaft Removal (C Style)

Figure 429. Head and Shaft Removal (A Style)


A. Shaft and Mantle Assembly
C. Bearing Cage
E. Rotary Seal Ring

B. Upper Bearing Race


D. Lower Bearing Race
F. Bakelite Seals

A. Shaft and Mantle Assembly


C. Bearing Cage
E. Eccentric Assembly

B. Upper Bearing Race


D. Lower Bearing Race

IMPORTANT:
The upper bearing race (B, Fig. 4-29 & 4-30) may
temporarily stick to the inside of the taper head due to
oil adhesion. To prevent bearing damage, do not lift the
taper head more than 2 inches off the eccentric before
determining if the upper bearing race has detached
from the head.
11. Slowly lift the head and shaft assembly approximately
two inches off the eccentric. Stop and wait several minutes
while listening for the upper race to drop. A distinctive
clunk should be audible when the race drops down out of
the taper head.

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Telsmith SBS Cone Crusher

! WARNING
Do Not reach or work under the taper head while
it is suspended. If the race remains stuck to the
underside of the taper head, use a sling to retain
it as described below. Serious personal injury or
death will result if the race loosens and falls on
personnel.
12. If there is a question whether the race has dropped, lift the
head and shaft assembly up several more inches and check
visually with a mirror to see if the race has dislodged. Do Not
under any circumstances place any portion of your body
under the shaft assembly while checking for the position of
the upper race.

Mantle and Head

Mantle Removal
Remove the mantle from the head and shaft assembly as
detailed in MANTLE REMOVAL in this chapter.

! CAUTION
Make certain the head and shaft assembly is
securely supported when removing the mantle
(Fig. 4-31). A sledgehammer will be required to
break the mantle free. The head and shaft
assembly must be securely blocked to prevent
the head and shaft assembly from moving while
the mantle is being broken loose.

! WARNING

NOTE:
Hitting the side of the mantle with a sledge hammer may
help loosen a stuck upper race.
13. If the race still has not dropped down, loop a sling around
the lower end of the main shaft to form a noose. Do Not reach
under the taper head while positioning the noose. Secure the
loose end of the sling to the eyebolt at the upper end of the
shaft.
14. Using the lift device, slowly lift the head and shaft
assembly completely from the crusher and place on suitable
work supports (Fig.4-31).

If the mantle must be removed by cutting with a


torch, provide adequate ventilation when
removing Smithbond debris. Wear a certified
respirator to prevent inhalation of fumes when
torch cutting, grinding or breaking up
S m i t h b o n d o r c o m p o n e n ts b a c k e d w i t h
Smithbond.

HEAD and SHAFT INSPECTION


When the head and shaft assembly is removed from the
crusher, the following checks and inspections should be
made. It is recommended that during the inspection
procedures the head and shaft assembly be turned over to
allow a more complete inspection of the underside of the
taper head.
1. Inspect the entire surface of the main shaft (Fig. 4-32) for
cracks, grooves, scratches, score marks, burn marks, pits or
rust. Attempt to polish out burn marks, scratches, rust and
scoring with an emery cloth or sandpaper.

IMPORTANT:
The shaft assembly has a 16 RMS finish that can be
damaged if handled improperly. NEVER attempt to
remove nicks, scratches or burrs by working in a vertical
motion with sandpaper, emery cloth or a file. If attempts
are made to remove imperfections, use only a fine file
and work horizontally when attempting to repair the
surface. If the shaft will not be reused immediately, coat
it with grease or oil to prevent rust.

Figure 431. Supporting the Head and Shaft Assembly

2. If the shaft shows cracks, vertical grooves or surface


checking (fine cracks in an area on the surface) it is
recommended that the shaft be replaced.

15. If the upper bearing race remains stuck in the head, again
rap on the mantle with a sledgehammer to loosen the race and
get it to fall into the noose wrapped around the head.
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Wear Liner Replacement


Telsmith SBS Cone Crusher

B
A

E
C

Figure 432. Shaft and Taper Head Inspection


A. Taper Head Machined Surface
C. Main Shaft

B. Taper Head Flange

3. Check the taper head on both the inside and outside for
signs of cracks or other damage. Cracking on the taper head
will typically be visible on the flange (B, Fig. 4-32) or on the
inside of the taper at the main shaft junction. Check the inside
of the taper for signs of scoring that could indicate the upper
bearing has spun. If the taper head is cracked or badly scored,
it must be replaced.
4. Check the machined surface of the taper flange for
denting or gouging. Remove any surface imperfections with
a grinder.
5. Check the taper flange for dents or caved in areas that
could cause the flange to hang up on the eccentric assembly.
If it is not possible to bend the flange back into position or
into the correct shape, it will be necessary to replace the taper.
6. Inspect the upper bakelite seals (D, Fig. 4-33) for wear.
Replace the seals if worn or damaged.

420

Figure 433. Eccentric Assembly Components


A. Upper Bearing Race
C. Lower Bearing Race
E. Rotary Seal Ring
G. Eccentric

B. Bearing Roller Cage


D. Bakelite Seals
F. Inner Piston Ring

7. Inspect the inner piston ring (F, Fig. 4-33) for cracks or
damage. File or sand any rough areas on the ring and clean
out the piston ring groove thoroughly. If the piston ring is
cracked or damaged, it must be replaced.
8. Inspect the upper thrust bearing components (A, B and C,
Fig. 4-33) for wear, scratches, score marks, cracks in the
cages, roller wear or damage, pitting in rollers or races, rust,
etc. Replace the bearing if any damage is present or wear is
evident.
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Telsmith SBS Cone Crusher

9. Inspect the inner bronze sleeve (located inside the


eccentric) for wear, burn marks, gouging or cracks. Replace
the sleeve if damage is evident or the sleeve shows extensive
wear.

HEAD and SHAFT INSTALLATION

IMPORTANT:
If the main shaft, taper head, bearing components or the
bronze sleeve in the eccentric were replaced with new
components after the inspection procedure, it will be
necessary to check head and shaft tolerances before
re-installing the head and shaft in the crusher. Refer to
the H or SBS service manual for the correct procedures
on measuring tolerances.

Mantle and Head

3. Prefit the inner piston ring in the groove on the eccentric


assembly to check for fit. If the ring is a loose fit in the
groove, it will be necessary to shim the ends of the ring. Braze
material on the ends of the ring to tighten the fit. If the ring is
a tight fit and does not enter the groove and seat correctly at
all points around the circumference, it will be necessary to
file the ends of the ring to gain clearance.
4. Thoroughly clean the underside of the taper head making
certain the labyrinth grooves are free of dust and dirt. Remove
the piston ring from the eccentric and fit it in the groove on
the underside of the taper head (Fig. 4-34).

Mantle Installation
Install a new mantle on the taper head following the
instructions in MANTLE INSTALLATION in this chapter.

IMPORTANT:
Before installing the new mantle on the taper head,
make certain all old Smithbond and other debris has
been removed from the taper head. If it is necessary to
remove material using a grinder or hand chisels, be
careful not to nick or scratch the machined seat at the
bottom of the taper head.

C
B

Installation - Crushers Without Anti-Spin


1. Make certain that power to the crusher remains locked
out. Refer to Chapter 1 for complete lockout/tagout
instructions.

2. If the upper thrust bearing was removed from the


eccentric, install it at this time. Make certain the races are
aligned correctly with the large bevel facing away from the
roller cage (Fig. 4-34). The roller cage must be oriented with
the notched side of the cage facing down (Fig.4-34).
NOTE: Thrust bearings are supplied in two styles, TYPE 1
and TYPE 2. If you have questions on bearing type and
installation procedure, refer to the H or SBS service manual.

! CAUTION
Failure to properly install and align bearing
components will result in bearing failure which
could damage other components on the crusher.

Figure 434. Bearing Component Orientation


A. Top Race Large Bevel Facing Up
B. Bottom Race Large Bevel Facing Down
C. Notches In Roller Cage Facing Down
D. This Side Of Cage Facing Up
E. This Side Of Cage Facing Down

5. If the eyebolt was removed, reinstall the eyebolt into the


tapped hole at the top of the main shaft.
6. Lubricate the mating surfaces of the main shaft and the
inner bronze sleeve with crusher lube oil.

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Mantle and Head

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Telsmith SBS Cone Crusher

NOTE:

! WARNING
Always use suitable rigging and hoisting
equipment to stabilize and lift heavy objects.
Lifting heavy components with inadequate
hoisting apparatus can damage machinery and
may result in serious personal injury or death.
7. Attach a lift cable or chain to the eyebolt. Using a properly
rated lifting device, carefully suspend the head and shaft
assembly over the crusher.
8. Align the bottom of the main shaft with the bore of the
bronze sleeve in the eccentric (Fig. 4-35). Slowly lower the
head and shaft assembly into the crusher. DO NOT rotate the
assembly as it is being lowered into the sleeve.

If the taper head will not turn in Step 11 or is difficult to


turn, the inner piston ring (F, Fig. 4-33) may not have
seated correctly in the bore of the rotary seal ring.
Attempt to seat the piston ring by rapping on the mantle
with a sledge hammer at several points on the
circumference. Check again for free rotation of the
head. If the taper head is still difficult to turn, raise the
head and shaft and re-center the piston ring within its
groove. Re-seat the head and shaft assembly.
12. Remove the eyebolt from the shaft and store for future
use.
13. Install the shaft nut cap and secure with a capscrew and
flatwasher (Fig. 4-17). Torque the shaft nut to the correct
torque for your model crusher (Table 4-1).
14. Install the shaft nut bolt locking plate and weld the plate,
the burn ring and the shaft nut cap as shown in Figure 4-24.
A stainless steel weld rod E (R) 309L is required when
making these welds.
15. Install the complete upper frame assembly to the crusher
following the instructions in Chapter 4 of this manual.

C
B

16. Install any chutes, conveyors or other feeding devices that


were removed previously.

Installation - Crushers with Anti-Spin


1. Make certain that power to the crusher remains locked
out. Refer to Ch. 1 for complete lockout/tagout instructions.

4
D

2. If the anti-spin assembly was removed, install it on the


lower frame at this time. Make certain the slider plate is
aligned with the input shaft and the inspection plug hole
(units built after 3/09 have inspection holes) on the front of
the anti-spin housing when bolting the unit to the bottom of
the crusher (Fig. 4-36).

Figure 435. Lowering Head and Shaft Assembly


A. Lift Eyebolt
C. Eccentric Assembly
E. Taper Head

B. Main Shaft
D. Bronze Sleeve
F.Thrust Bearing Upper Race

9. Continue lowering the head and shaft assembly until the


underside of the taper head is seated on the top race of the
thrust bearing.

10. Remove the lifting apparatus from the eyebolt when the
taper and shaft assembly is fully seated.
11. Block the flywheel sheave so it cannot move. Attempt to
turn the taper head by hand. The assembly should turn freely
and smoothly in both directions.

Figure 436. Aligning the Slider Plate


A. Slider Plate Groove

422

B. Front Inspection Hole

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Telsmith SBS Cone Crusher

3. If the upper thrust bearing was removed from the


eccentric, install it at this time. Make certain the races are
aligned correctly with the large bevel facing away from the
roller cage (Fig. 4-34). The roller cage must be oriented with
the notched side of the cage facing down (Fig. 4-34).

Mantle and Head

6. Thoroughly clean the underside of the taper head making


certain the labyrinth grooves are free of dust and dirt. Remove
the piston ring from the eccentric and fit it in the groove on
the underside of the taper head (Fig. 4-37).

! CAUTION
Failure to properly install and align bearing
components will result in bearing failure which
could damage other components on the crusher.
4. Place a long bar down through the bore of the eccentric.
Using the bar, shift the slider plate from side to side until the
rectangular center hole is aligned with the round center hole
of the adapter plate (Fig.4-37).

Figure 438. Taper Head Labyrinth Grooves


A. Piston Ring Groove

NOTE:
Crushers built after 3/09 have two threaded inspection
plugs on the anti-spin cover. These plugs should be
removed and used to help visually align anti-spin
components when installing the shaft drive tang into the
slider plate groove. Best results can be obtained by
shining a light in through the side hole (A, Fig. 4-39) and
viewing the tang and slider plate through the front
inspection hole (B).

Figure 437. Centering the Slider Plate


5. Prefit the inner piston ring in the groove on the eccentric
assembly to check for fit. If the ring is a loose fit in the
groove, it will be necessary to shim the ends of the ring. Braze
material on the ends of the ring to tighten the fit. If the ring is
a tight fit and does not enter the groove and seat correctly at
all points around the circumference, it will be necessary to
file the ends of the ring to gain clearance.

Figure 439. Anti Spin Inspection Plugs


A. Side Inspection Plug

07/09

B. Front Inspection Plug

423

Mantle and Head

Wear Liner Replacement


Telsmith SBS Cone Crusher

7. Manually turn the eccentric until the highest and lowest


points are aligned with the end of the slider plate tang groove
(Fig. 4-40). When the alignment is correct, the oil duct (52 &
57 models only) will be centered directly below the eccentric
high point and the counterweight will be centered over the
input shaft.
ECCENTRIC
HIGH POINT

9. Lubricate the mating surfaces of the main shaft and the


inner bronze sleeve with crusher lube oil.

! WARNING
Always use suitable rigging and hoisting
equipment to stabilize and lift heavy objects.
Lifting heavy components with inadequate
hoisting apparatus can damage machinery and
may result in serious personal injury or death.
10. Attach a lift cable or chain to the eyebolt. Using a properly
rated lifting device, carefully suspend the head and shaft
assembly over the crusher (Fig. 4-41).

C
A

ECCENTRIC
LOW POINT

Figure 441. Aligning The Head and Shaft


A. Drive Tang

B. Main Shaft

11. Align the bottom end of the main shaft with the bore of the
inner bronze sleeve. With the shaft suspended above the bore,
slowly rotate the head and shaft assembly until the drive tang
is precisely aligned with the drive tang groove on the slider
plate (Fig. 4-42).

4
A

Figure 440. Aligning the Eccentric and Tang Groove


A. Align Tang Groove
C. Counterweight
E. Eccentric High Side

B. Oil Duct
D. Countershaft

8. If the eyebolt was removed, reinstall the eyebolt into the


tapped hole at the top of the main shaft.

424

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Telsmith SBS Cone Crusher

Mantle and Head

1
Turn

1/4
Turn

Figure 443. Rotation Check


17. Rotate the taper head slowly clockwise by hand. Verify
that it turns freely for at least 1/4 turn. Due to a one-way valve
inside the anti-spin unit, the amount of effort required will
increase gradually as the head is rotated in this direction.
D

NOTE:
Figure 442. Aligning Drive Tang with Groove
A. Adapter Plate
C. Drive Tang

B. Slider Plate Groove


D. Inspection Hole (New Style Covers Only)

12. Slowly lower the head and shaft assembly into the
crusher. To ensure drive tang engagement, DO NOT rotate
the assembly as it is being lowered into the bronze sleeve.
13. Continue lowering the head and shaft assembly until the
underside of the taper head is seated on the top race of the
upper thrust bearing.
14. Remove the lifting chain from the eyebolt. Rock the head
slightly to check that the tang has seated in the tang groove.
15. Block the flywheel sheave so that the eccentric assembly
cannot turn.
16. Rotate the taper head slowly counter-clockwise by hand.
Verify that it turns freely for at least one full turn (Fig. 4-43).

If the taper head is difficult to turn in steps 15 and 16,


raise the taper head and shaft and make the following
checks:
- Check that the slider plate is properly positioned.
- Verify that the piston ring is correctly centered in the
groove on the inside of the taper head.
- Make certain the drive tang is aligned with the slider
plate groove (Fig. 4-39).
18. Remove the blocking from the flywheel sheave.
19. From under the crusher, locate the match marks that were
made prior to head and shaft removal (Fig. 4-27).
20. Verify that all match marks are aligned. If necessary,
rotate the taper head and rotary seal ring so that match marks
on these components are aligned with match marks on the
crusher main frame.
21. At the frame arm nearest the match marks, measure the
distance between the top of the frame arm and the bottom of
the taper head skirt (Fig. 4-26). Compare this measurement
with the measurement taken earlier during disassembly.

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425

Mantle and Head

Wear Liner Replacement


Telsmith SBS Cone Crusher

22. If the new measurement matches the measurement taken


earlier this indicates that the head and shaft assembly is fully
seated and the drive tang is engaged in the slider plate groove.

IMPORTANT:
If the drive tang has not engaged the slider plate groove,
the measurement made in step 20 will be approximately
1
/2 to 1 inch (1.25 to 2.5 cm) longer than the earlier
measurement. If the measurement is too long, raise the
shaft and head assembly and install the assembly again
re-aligning the drive tang and the slider plate groove
(Fig. 4-39).

27. When the shaft nut cap is correctly installed, install the
shaft nut cpascrew locking plate and weld the plate, the burn
ring and the shaft nut cap as shown in Figure 4-45. A stainless
steel weld rod E (R) 309L is required when making these
welds.

WEL

WELD

C
A
B

! CAUTION
Never reach between the rotary seal ring and the
underside of the taper head to check clearance.
Serious personal injury will result if the rotary
seal ring is lowered onto hands or fingers.
23. Tang engagement can also be checked at the top of the
crusher. Lay a long straight edge or bar across the top of the
main frame (Fig. 4-44) parallel to the tang direction. Observe
the bar in relation to the taper head. The bar to head should
show a 3o gap on the eccentric low point side. If no gap is
present, this is an indication that the shaft tang has not
correctly seated in the slider groove.
WELD

Figure 445. Shaft Nut Welding Requirements


A. Capscrew
C. Capscrew Locking Plate

B. Flat Washer

FINAL INSTALLATION and ASSEMBLY

Figure 444. Tang Engagement Check


A. Check Gap At This Point

B. Straight Bar

24. On units with a new style anti-spin cover, re-install the


inspection plugs (Fig. 4-39) that were removed to visually
determine drive tang engagement.
25. Remove the lifting eyebolt from the shaft and store for
future use.

1. On Anti-Spin equipped units, make certain all hydraulic


lines are correctly installed and that the anti-spin hydraulic
system has been successfully bled (See SBS Operation and
Maintenance Manual or TP405 Anti Spin Unit - Installation,
Operation and Troubleshooting manual).
2. Re-install the upper frame assembly following the
instructions in Chapter 3 of this manual. Restore hydraulic
and electrical power to the crusher.
3. Install all chutes, hoppers and feed equipment that were
removed previously to provide access to the crusher.
4. Adjust the crusher discharge setting and resume crushing
with a normal feed of material.

26. Install the shaft nut cap, flatwasher and capscrew. Torque
the shaft nut capscrew to specification (Table 4-1).

426

07/09

Appendix A - Torque Tables

Wear Liner Replacement


Telsmith SBS Cone Crusher

Fastener Information
Size

Thread
Type

Threads
Per Inch
(n)

Major Dia.
(in)

SAE J429 Grade 2

SAE J429 Grade 5

(in2)

Torque
Dry
in-lb/ft-lb
(Nm)

Torque
Lubricated
in-lb/ft-lb
(Nm)

Torque
Dry
in-lb/ft-lb
(Nm)

Torque
Lubricated
in-lb/ft-lb
(Nm)

Tensile
Stress
Area

1/4

UNC
UNF

20
28

0.2500
0.2500

0.0318
0.0364

66 (7.4)
75 (8.4)

49 (5.5)
56 (6.3)

100 (11.2)
120 (13.5)

76 (8.5)
87 (9.8)

5/16

UNC
UNF

18
24

0.3125
0.3125

0.0524
0.0581

11 (14.9)
13 (17.6)

8 (10.8)
9 (12.2)

17 (23.0)
19 (25.7)

13 (17.6)
14 (18.9)

3/8

UNC
UNF

16
24

0.3750
0.3750

0.0775
0.0878

20 (27.1)
23 (31.1)

15 (20)
17 (23)

31 (42.0)
35 (47.4)

23 (31.1)
26 (35.2)

7/16

UNC
UNF

14
20

0.4375
0.4375

0.1063
0.1187

32 (42.3)
36 (48.8)

24 (32.5)
27 (36.6)

49 (66.4)
55 (74.5)

37 (50.1)
41 (55.5)

1/2

UNC
UNF

13
20

0.5000
0.5000

0.1419
0.1600

49 (66.4)
55 (74.5)

37 (50.1)
41 (55.5)

75 (101)
85 (115)

57 (77.2)
64 (86.7)

9/16

UNC
UNF

12
18

0.5625
0.5625

0.1819
0.2030

70 (94.9)
78 (106)

53 (71.8)
59 (79.9)

110 (149)
120 (162)

82 (111)
91 (123)

5/8

UNC
UNF

11
18

0.6250
0.6250

0.2260
0.2560

97 (131)
110 (149)

73 (98.9)
83 (112)

150 (203)
170 (230)

110 (149)
130 (176)

3/4

UNC
UNF

10
16

0.7500
0.7500

0.3345
0.3730

170 (230)
190 (258)

130 176)
140 (188)

270 (366)
300 (407)

200 (271)
220 (298)

7/8

UNC
UNF

9
14

0.8750
0.8750

0.4617
0.5095

170 (230)
180 (244)

120 (163)
140 (190)

430 (583)
470 (630)

320 (434)
360 (488)

UNC
UNF

8
12

1.0000
1.0000

0.6057
0.6630

250 (339)
270 (366)

190 (258)
210 (285)

640 (868)
710 (963)

480 (651)
530 (719)

1 1/8

UNC
UNF

7
12

1.1250
1.1250

0.7633
0.8557

350 (474)
400 (542)

270 (366)
300 (407)

800 (1085)
890 (1207)

600 (813)
670 (908)

1 1/4

UNC
UNF

7
12

1.2500
1.2500

0.9691
1.0729

500 (677)
550 (746)

380 (515)
420 (569)

1,100 (1491)
1,200 (1627)

840 (1139)
930 (1260)

1 3/8

UNC
UNF

6
12

1.3750
1.3750

1.1549
1.3147

660 (895)
740 (1003)

490 (664)
560 (760)

1,500 (2033)
1,700 (2304)

1,100 (1491)
1,300 (1762)

1 1/2

UNC
UNF

6
12

1.5000
1.5000

1.4053
1.5810

870 (1179)
980 (1328)

650 (881)
730 (989)

2,000 (2711)
2,200 (2982)

1,500 (2033)
1,600 (2169)

ASTM A307 Grade A

ASTM A449

1 3/4
1 3/4

UNC
UN

5
12

1.7500
1.7500

1.8995
2.1873

1,400 (1898)
1,600 (2169)

1,000 (1355)
1,200 (1627)

2,300 (3118)
2,600 (3525)

1,700 (2304)
2,000 (2711)

2
2

UNC
UN

4 1/2
12

2.0000
2.0000

2.4982
2.8917

2,100 (2847)
2,400 (3254)

1,500 (2033)
1,800 (2440)

3,400 (4609)
4,000 (5423)

2,600 (3525)
3,000 (4067)

2 1/4
2 1/2
2 3/4
3

UNC
UNC
UNC
UNC

4 1/2
4
4
4

2.2500
2.5000
2.7500
3.0000

3.2477
3.9988
4.9340
5.9674

3,000 (4067)
4,100 (5559)
5,600 (7592)
7,400 (10033)

2,300 (3118)
3,100 (4203)
4,200 (5694)
5,600 (7592)

5,000 (6779)
6,900 (9355)
9,400 (12745
12,000 (16270)

3,800 (5152)
5,200 (7050)
7,000 (9491)
9,200 (12473)

Torque Coefficients

07/09

Dry: 0.20
Lubricated: 0.15

A1

7F

Wear Liner Replacement


Telsmith SBS Cone Crusher

Torque Tables
Fastener Information
Size

7F

Thread
Type

Threads
Per Inch
(n)

Major Dia.
(in)

SAE J429 Grade 8

Alloy Socket Head Cap


Screws ASTM A574

(in2)

Torque
Dry
ft-lb
(Nm)

Torque
Lubricated
ft-lb
(Nm)

Torque
Dry
ft-lb
(Nm)

Torque
Lubricated
ft-lb
(Nm)

Tensile
Stress
Area

1/4

UNC
UNF

20
28

0.2500
0.2500

0.0318
0.0364

12 (16.2)
14 (18.9)

9 (12.2)
10 (13.5)

14 (18.9)
16 (21.6)

10 (13.5)
12 (16.2)

5/16

UNC
UNF

18
24

0.3125
0.3125

0.0524
0.0581

25 (33.8)
27 (36.6)

18 (24.4)
20 (27.1)

29 (39.3)
32 (43.3)

22 (29.8)
24 (32.5)

3/8

UNC
UNF

16
24

0.3750
0.3750

0.0775
0.0878

44 (59.6)
49 (66.4)

33 (44.7)
37 (50.1)

51 (69.1)
58 (78.6)

38 (51.5)
43 (58.3)

7/16

UNC
UNF

14
20

0.4375
0.4375

0.1063
0.1187

70 (94.9)
78 (106)

52 (71.8)
59 (79.9)

82 (111)
91 (123)

61 (82.7)
68 (92.1)

1/2

UNC
UNF

13
20

0.5000
0.5000

0.1419
0.1600

110 (149)
120 (163)

80 (109)
90 (122)

120 (162)
140 (188)

93 (126)
110 (149)

9/16

UNC
UNF

12
18

0.5625
0.5625

0.1819
0.2030

150 (203)
170 (230)

120 (162)
130 (176)

-----

-----

5/8

UNC
UNF

11
18

0.6250
0.6250

0.2260
0.2560

210 (285)
240 (325)

160 (217)
180 (244)

240 (325)
270 (366)

180 (244)
200 (271)

3/4

UNC
UNF

10
16

0.7500
0.7500

0.3345
0.3730

380 (515)
420 (569)

280 (379)
320 (433)

420 (569)
470 (637)

320 (434)
350 (474)

7/8

UNC
UNF

9
14

0.8750
0.8750

0.4617
0.5095

610 (827)
670 (908)

460 (624)
500 (677)

680 (922)
750 (1017)

510 (691)
560 (759)

UNC
UNF

8
12

1.0000
1.0000

0.6057
0.6630

910 (1234)
1,000 (1356)

680 (922)
750 (1017)

1,000 (1350)
1,100 (1491)

770 (1044)
840 (1139)

1 1/8

UNC
UNF

7
12

1.1250
1.1250

0.7633
0.8557

1,300 (1762)
1,400 (1898)

970 (1315)
1,100 (1491)

1,400 (1898)
1,600 (2169)

1,100 (1491)
1,200 (1627)

1 1/4

UNC
UNF

7
12

1.2500
1.2500

0.9691
1.0729

1,800 (2440)
2,000 (2711)

1,400 (1898)
1,500 (2003)

2,000 (2711)
2,300 (3118)

1,500 (2003)
1,700 (2305)

1 3/8

UNC
UNF

6
12

1.3750
1.3750

1.1549
1.3147

2,400 (3254)
2,700 (3660)

1,800 (2440)
2,000 (2711)

2,700 (3660)
3,000 (4068)

2,000 (2711)
2,300 (3118)

1 1/2

UNC
UNF

6
12

1.5000
1.5000

1.4053
1.5810

3,200 (4338)
3,600 (4881)

2,400 (3254)
2,700 (3660)

3,600 (4881)
4,000 (5423)

2,700 (3660)
3,000 (4068)

ASTM A354 Grade BD


1 3/4
1 3/4

UNC
UN

5
12

1.7500
1.7500

1.8995
2.1873

5,000 (6779)
5,700 (7728)

3,700 (5017)
4,300 (5830)

5,600 (7592)
6,400 (8677)

4,200 (5694)
4,800 (6508)

2
2

UNC
UN

4 1/2
12

2.0000
2.0000

2.4982
2.8917

7,500 (10169)
8,700 (11796)

5,600 (7593)
6,500 (8813)

8,400 (11389)
10,000 (13588)

6,300 (8541)
7,300 (9897)

2 1/4
2 1/2
2 3/4
3

UNC
UNC
UNC
UNC

4 1/2
4
4
4

2.2500
2.5000
2.7500
3.0000

3.2477
3.9988
4.9340
5.9674

11,000 (14914)
15,000 (20338)
18,000 (24405)
24,000 (32540)

8,200 (11118)
11,000 (14914)
13,000 (17626)
18,000 (24405)

12,000 (16270)
17,000 (23049)
23,000 (31184)
30,000 (40676)

9,300 (12609)
13,000 (17626)
17,000 (23049)
23,000 (31184)

Torque Coefficients

A2

Dry: 0.20
Lubricated: 0.15
07/09

Wear Liner Replacement


Telsmith SBS Cone Crusher Appendix B

Appendix B - Conversion Tables

Appendix B - Conversion Tables


LINEAR MEASURE

SQUARE MEASURE

To Convert

Info

Multiply by

To Convert

Info

Multiply by

Inches
Feet
Centimeters
Millimeters
Meters
Meters

Centimeters
Meters
Inches
Inches
lnches
Feet

2.54
0.3048
0.3937
0.0394
39.37
3.2808

Sq. Inches
Sq. Miles
Sq. Centimeters
Sq. Meters
Sq. Meters

Sq. Centimeters
Sq. Kilometers
Sq. Inches
Sq. Inches
Sq. Feet

6.452
2.59
0.15499
1549.9
10.763

CUBIC MEASURE

WEIGHT

To Convert

Info

Multiply by

To Convert

Info

Multiply by

Cu. Inches
Cu. Feet
Cu. Centimeters
Cu. Meters
Cu. Meters

Cu. Centimeters
Cu. Meters
Cu. Inches
Cu. inches
Cu. Feet

16.387
0.0283
0.06102
610233779.0
35.314

Kilograms
Pounds
Pounds/Sq.
Inch
Pounds/Sq.
Foot

Pounds
Kilograms
Kilograms/Sq.
Centimeter
Kilograms/Sq.
Meter

2.2046
0.4536
0.0703
4.8824

DEGREES FAHRENHEIT TO DEGREES CENTIGRADE

07/09

-30
-28
-26
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
+1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

-34.44
-33.33
-32.22
-31.11
-30.00
-28.89
-27.78
-26.67
-25.56
-24.44
-23.33
-22.22
-21.11
-20.00
-18.89
-17.78
-17.22
-16.67
-16.11
-15.56
-15.00
-14.44
-13.89
-13.33
-12.78
-12.22
-11.67
-11.11
-10.56
-10.00
-9.44
-8.89
-8.33
-7.78
-7.22

+20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54

-6.67
-6.11
-5.56
-5.00
-4.44
-3.89
-3.33
-2.78
-2.22
-1.67
-1.11
-0.56
0.00
+0.56
1.11
1.67
2.22
2.78
3.33
3.89
4.44
5.00
5.56
6.11
6.67
7.22
7.78
8.33
8.89
9.44
10.00
10.56
11.11
11.67
12.22

F
+55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89

C
+12.78
13.33
13.89
14.44
15.00
15.56
16.11
16.67
17.22
17.78
18.33
18.89
19.44
20.00
20.56
21.11
21.67
22.22
22.78
23.33
23.89
24.44
25.00
25.56
26.11
26.67
27.22
27.78
28.33
28.89
29.44
30.00
30.56
31.11
31.67

+90
91
92
93
94
95
96
97
98
99
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220

+32.22
32.78
33.33
33.89
34.44
35.00
35.56
36.11
36.67
37.22
37.78
40.55
43.33
46.11
48.89
51.67
54.44
57.22
60.00
62.78
65.56
68.33
71.11
73.89
76.67
79.44
82.22
85.00
87.78
90.55
93.33
96.11
98.89
101.67
104.44

F
+225
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395

C
+107.22
110.00
112.78
115.56
118.33
121.11
123.89
126.67
129.44
132.22
135.00
137.78
140.55
143.33
146.11
148.89
151.67
154.44
157.22
160.00
162.78
165.56
168.33
171.11
173.89
176.67
179.44
182.22
185.00
187.78
190.55
193.33
196.11
198.89
201.67

B1

7F

Appendix B - Conversion Tables

Wear Liner Replacement


Telsmith SBS Cone Crusher

NOTES

7F

B2

07/09

Appendix C - Weights

Wear Liner Replacement


Telsmith Silver Bullet Series Gyrasphere

Appendix C - Weights

Model 38 Weights Pounds (Kilograms)


Item
Crusher - complete and assembled w/o Anti-Spin
Crusher - complete and assembled with Anti-Spin

26,912 (12207)
27, 275 (12371)

Crusher - Base Unit


Including Mantle, Nut and Cap, Anti-Spin and Flywheel
Including Mantle, Nut and Cap, Bottom Plate and Flywheel

16,389 (7433)
16,026 (7269)

Crusher - Upper frame


Includes upper frame assembly, rotator, support bowl and
concave ring.

10, 885
(4937)

Main (lower) frame only

8440
(3828)

Thrust bearing (each)

175
(79)

Rotary seal ring with lead

453
(205)

Inner bronze sleeve

40
(18)

Outer bronze sleeve

96
(44)

Eccentric

859
(390)

Main drive gear

263
(119)

Bottom cover plate (units without anti-spin only)

121
(55)

Anti-spin unit - Includes bottom plate, gearbox, hydraulic


motor, adapter plate, slider plate and gearbox cover.

508
(230)

Upper frame only

4070
(1846)

Hydraulic relief cylinder (each)

94
(43)

Receiving hopper, outer

557
(253)

Receiving hopper, inner

223
(101)

Locknut

1431
(649)

Hydraulic locking cylinder (each)

30
(14)

Support bowl with inner hopper and concave ring

4360
(1977)

Concave ring

1300
(590)

Smithbond for concave ring


(Typical - Refer to Chapter 3 for exact quantities)

44
(20)

Head and shaft assembly, with mantle and nut.

07/09

38

7F

3083
(1398)

C1

Appendix C - Weights

Wear Liner Replacement


Telsmith Silver Bullet Series Gyrasphere

Model 38 Weights Pounds (Kilograms)


Item
Taper head only

1290
(585)

Main (tapered) shaft only

545
(247)

Mantle only

1022
(464)

Smithbond for mantle


(Typical - Refer to Chapter 4 for exact quantities)

44
(20)

Countershaft box assembly w/flywheel

7F

38

1,475
(669)

Countershaft

125
(57)

Bevel pinion gear (countershaft)

60
(27)

Flywheel sheave

162
(73)

Power rotator assembly, including motor, gearbox and


adapter plate.

200
(91)

Power rotator mounting bracket

54
(24)

Power rotator pinion gear

35
(16)

Crusher ring gear

780
(354)

Support Bowl Driver Forging (early models only - if equipped)

326
(148)

Drive ring weldment

509
(231)

Oil lubrication system with water cooler (empty - no oil in tank)

1380
(626)

Oil lubrication system with air-oil cooler (empty - no oil in tank)

1880
(853)

Hydraulic power unit (empty - no oil in tank)

600
(272)

V-belt drive guard

520
(236)

Important: All weights shown are estimated and may vary by +/-5 percent.
When available, always refer to the bill-of-lading or packing list for actual weights.

C2

07/09

Wear Liner Replacement


Telsmith Silver Bullet Series Gyrasphere

Appendix C - Weights

Model 44 Weights Pounds (Kilograms)


Item
Crusher - complete and assembled w/o Anti-Spin
Crusher - complete and assembled with Anti-Spin

32,818 (14885)
33,178 (15049

Crusher - Base Unit


Including Mantle, Nut and Cap, Anti-Spin and Flywheel
Including Mantle, Nut and Cap, Bottom Plate and Flywheel

20,436 (9269)
20,074 (9105)

Crusher - Upper Frame


Includes upper frame, locknut, locknut cover, support bowl,
concave ring, feed hoppers, Smithbond, and hyd. unlock cylinders.

12,744
(5780)

Main (lower) frame only

9010
(4087)

Thrust bearing (each)

185
(84)

Rotary seal ring with lead

1041
(472)

Inner bronze sleeve

40
(18)

Outer bronze sleeve

130
(59)

Eccentric

1069
(485)

Main drive gear

263
(119)

Bottom cover plate (units without anti-spin only)

121
(55)

Anti-spin unit - Includes bottom plate, gearbox, hydraulic


motor, adapter plate, slider plate and gearbox cover.

508
(230)

Upper frame only

3320
(1506)

Hydraulic relief cylinder and manifold (each)

150
(68)

Receiving hopper, outer

732
(332)

Receiving hopper, inner

263
(119)

Locknut

1664
(755)

Hydraulic locking cylinder (each)

30
(14)

Support bowl with inner hopper and concave ring


Concave ring - S
Concave ring - FC
Smithbond for concave ring S & FC
(Typical - Refer to Chapter 3 for exact quantities)

07/09

44

7F

4791
(2173)
1600 (726)
1700 (771)
110 (50)

C3

Appendix C - Weights

Wear Liner Replacement


Telsmith Silver Bullet Series Gyrasphere

Model 44 Weights Pounds (Kilograms)


Item
Head and shaft assembly, including mantle and nut

4380
(1986)

Taper head only

2280
(1034)

Main (tapered) shaft only

640
(290)

Mantle only

1325
(601)

Smithbond for mantle


(Typical - Refer to Chapter 4 for exact quantities)

44
(20)

Countershaft box assembly w/flywheel

7F

44

1,519
(689)

Countershaft

125
(57)

Bevel pinion gear (countershaft)

60
(27)

Flywheel sheave

320
(145)

Power rotator assembly, including motor, gearbox and


adapter plate.

234
(106)

Power rotator mounting bracket

54
(24)

Power rotator pinion gear

35
(16)

Crusher ring gear

385
(175)

Drive ring weldment

960
(435)

Oil lubrication system with water cooler (empty - no oil in tank)

1380
(626)

Oil lubrication system with air-oil cooler (empty - no oil in tank)

1880
(853)

Hydraulic power unit (empty - no oil in tank)

600
(272)

V-belt drive guard

520
(236)

Important: All weights shown are estimated and may vary by +/-5 percent.
When available, always refer to the bill-of-lading or packing list for actual
weights.

C4

07/09

Wear Liner Replacement


Telsmith Silver Bullet Series Gyrasphere

Appendix C - Weights

Model 52 Weights Pounds (Kilograms)


Item
Crusher - complete and assembled w/o Anti-Spin
Crusher - complete and assembled with Anti-Spin

50,053 (22074)
50,454(22886)

Crusher - Base Unit


Including Mantle, Nut and Cap, Anti-Spin and Flywheel.
Including Mantle, Nut and Cap, Bottom Plate and Flywheel

31,857(14,454)
31,465 (14,272)

Crusher - Upper Frame


Includes upper frame, locknut, locknut cover, support bowl,
concave ring, feed hoppers, Smithbond, and hyd. unlock cylinders.

16740
(7593)

Main (lower) frame only

13500
(6123)

Thrust bearing (each)

350
(159)

Rotary seal ring with lead

1426
(647)

Inner bronze sleeve

125
(57)

Outer bronze sleeve

173
(78)

Eccentric

1550
(703)

Main drive gear

486
(220)

Bottom cover plate (units without anti-spin only)

173
(78)

Anti-spin unit - Includes bottom plate, gearbox, hydraulic


motor, adapter plate, slider plate and gearbox cover.

570
(259)

Upper frame only

4080
(1851)

Hydraulic relief cylinder and manifold (each)

202
(92)

Receiving hopper, outer

875
(397)

Receiving hopper, inner

229
(104)

Locknut

1663
(754)

Hydraulic Locking Cylinder (each)

30
(14)

Support bowl, with inner hopper and concave ring

8503
(3857)

Smithbond for concave ring S


Smithbond for concave ring FC
(Typical - Refer to Chapter 3 for exact quantities)

176 (80)
132 (60)
(80)

Head and shaft assembly, including mantle and nut.

07/09

52

7F

8405
(3812)

C5

Appendix C - Weights

Wear Liner Replacement


Telsmith Silver Bullet Series Gyrasphere

Model 52 Weights Pounds (Kilograms)


Item

7F

52

Taper head only

5196
(2357)

Main (tapered) shaft only

1258
(571)

Mantle only

1626
(738)

Smithbond for mantle


(Typical - Refer to Chapter 4 for exact quantities)

88
(40)

Countershaft box assembly w/flywheel

2310
(1048)

Countershaft

223
(101)

Bevel pinion gear (countershaft)

160
(73)

Flywheel sheave

540
(245)

Power rotator assembly, including motor, gearbox and


adapter plate.

200
(91)

Power Rotator Mounting Bracket

54
(24)

Power rotator pinion gear

35
(16)

Crusher ring gear

355
(161)

Drive ring weldment

1367
(620)

Oil lubrication system with water cooler (empty - no oil in tank)

1880
(853)

Oil lubrication system with air-oil cooler (empty - no oil in tank)

2465
(1118)

Hydraulic power unit (empty - no oil in tank)

1280
(581)

V-belt drive guard

778
(353)

Important: All weights shown are estimated and may vary by +/-5 percent.
When available, always refer to the bill-of-lading or packing list for actual weights.

C6

07/09

Wear Liner Replacement


Telsmith Silver Bullet Series Gyrasphere

Appendix C - Weights

Model 57 Weights Pounds (Kilograms)


Item
Crusher - complete and assembled w/o Anti-Spin
Crusher - complete and assembled with Anti-Spin

70,078 (31989)
70, 523 (31787)

Crusher - Base Unit


Including Mantle, Nut and Cap, Anti-Spin and Flywheel
Including Mantle, Nut and Cap, Bottom Plate and Flywheel

44,739 (20293)
44,294 (20091)

Crusher - Upper Frame


Includes upper frame, locknut, locknut cover, support bowl,
concave ring, feed hoppers, Smithbond, and hyd. unlock cylinders.

29102
(13200)

Main (lower) frame only

19708
(8940)

Thrust bearing (each)

475
(215)

Rotary seal ring with lead

2342
(1062)

Inner bronze sleeve

280
(127)

Outer bronze sleeve

280
(127)

Eccentric

2800
(1270)

Main drive gear

1040
(472)

Bottom cover plate (units without anti-spin only)

283
(128)

Anti-spin unit - Includes bottom plate, gearbox, hydraulic


motor, adapter plate, slider plate and gearbox cover.

734
(333)

Upper frame only

9187
(4167)

Hydraulic relief cylinder and manifold (each)

210
(95)

Receiving hopper - outer

1292
(586)

Receiving hopper - inner

569
(258)

Locknut

5700
(2586)

Hydraulic locking cylinder (each)

7F

30
(14)

Support bowl with inner hopper and concave ring

13,589
(6164)

Concave ring

4000
(1814)

Smithbond for concave ring (S & FC)


(Typical - Refer to Chapter 3 for exact quantities)

07/09

57

330 (150)

C7

Appendix C - Weights

Wear Liner Replacement


Telsmith Silver Bullet Series Gyrasphere

Model 57 Weights Pounds (Kilograms)


Item
Head and shaft assembly, including mantle and nut.

10,662
(4,836)

Taper head only

5883
(2668)

Main (tapered) shaft only

1713
(777)

Mantle only

2653
(1203)

Smithbond for mantle


(Typical - Refer to Chapter 4 for exact quantities)
Countershaft box assembly with flywheel

7F

57

176
(80)
2,243
(1,018)

Countershaft

240
(109)

Bevel pinion gear (countershaft)

200
(91)

Flywheel sheave

750
(340)

Power rotator assembly, including motor, gearbox and


adapter plate.

234
(106)

Power rotator mounting bracket

78
(35)

Power rotator pinion gear

35
(16)

Crusher ring gear

1240
(562)

Drive ring weldment

1725
(782)

Support bowl driver forging (early models only - if equipped)

569
(258)

Oil lubrication system with air-oil cooler (empty - no oil in tank)

2680
(1216)

Hydraulic power unit (empty - no oil in tank)

1280
(581)

V-belt drive guard

506
(230)

Important: All weights shown are estimated and may vary by +/-5 percent.
When available, always refer to the bill-of-lading or packing list for actual weights.

C8

07/09

Wear Liner Replacement


Telsmith Silver Bullet Series Gyrasphere

Appendix C - Weights

Model 68 Weights Pounds (Kilograms)


Item
Crusher - complete and assembled w/o anti-spin
Crusher - complete and assembled w/ anti-spin

106,643 (48372)
107,102 (48581)

Crusher - Base Unit


Including Mantle, Nut and Cap, Anti-Spin and Flywheel
Including Mantle, Nut and Cap, Bottom Plate and Flywheel

65,783 (29838)
65,324 (29630)

Crusher - upper framey


Includes upper frame, locknut, locknut cover, support bowl,
concave ring, feed hoppers, Smithbond, and hyd. unlock cylinders.

40460
(18352)

Main (lower) frame only

29564
(13410)

Thrust bearing (each)

750
(340)

Rotary seal ring with lead

748
(339)

Inner bronze sleeve

265
(120)

Outer bronze sleeve

345
(156)

Eccentric

4400
(1996)

Main drive gear

3270
(1483)

Bottom cover plate (units without anti-spin only)

296
(134)

Anti-spin unit - Includes bottom plate, gearbox, hydraulic


motor, adapter plate, slider plate and gearbox cover.

755
(342)

Upper frame only

11509
(5220)

Hydraulic relief cylinder and manifold (each)

225
(102)

Receiving hopper - outer

1543
(700)

Receiving hopper - inner

306
(139)

Locknut

4896
(2221)

Hydraulic unlock cylinder (each)

7F

122
(55)

Support bowl with Inner Hopper and Concave Ring

20,485
(9,292)

Concave ring

5120
(2322)

Smithbond for concave ring 68S


Smithbond for concave ring 68FC
(Typical - Refer to Chapter 3 for exact quantities)

07/09

68

352 (160)
484 (220)

C9

Appendix C - Weights

Wear Liner Replacement


Telsmith Silver Bullet Series Gyrasphere

Model 68 Weights Pounds (Kilograms)


Item
Head and shaft assembly, including mantle and nut.

15882
(7177)

Taper head only

7412
(3362)

Main (tapered) shaft only

2949
(1338)

Mantle only

3280
(1488)

Smithbond for mantle


(Typical - Refer to Chapter 4 for exact quantities)
Countershaft box assembly with flywheel

7F

68

154
(70)
3,728
(1,691)

Countershaft

373
(169)

Bevel pinion gear (countershaft)

480
(218)

Flywheel sheave

870
(395)

Power rotator assembly, including motor, gearbox and


adapter plate.

234
(106)

Power rotator mounting bracket

78
(35)

Power rotator pinion gear

35
(16)

Crusher ring gear

2934
(1331)

Drive ring weldment

647
(293)

Support bowl driver forging (early models only - if equipped)

647
(293)

Oil lubrication system with water cooler (empty - no oil in tank)

2760
(1252)

Oil lubrication system with air-oil cooler (empty - no oil in tank)

3660
(1660)

Hydraulic power unit (empty - no oil in tank)

1280
(581)

V-belt drive guard

739
(335)

Important: All weights shown are estimated and may vary by +/-5 percent.
When available, always refer to the bill-of-lading or packing list for actual weights.

C10

07/09

Wear Liner Replacement


Telsmith SBS Cone Crusher

Appendix D - Lubricants

Appendix D - Lubricants

Lubricating Oil Specifications


Ambient Temperature
Below 40 F
(4.5 C)

Above 40 F
(4.5 C)

Viscosity ISO Grade

C-100

C-150

Viscosity AGMA Grade #250.04

3 EP

4 EP

Viscosity SUS @ 100 F

469 to 575

709 to 871

Viscosity SUS @ 210 F

61 to 67

74 to 82

Viscosity Index

95 Min.

95 Min.

Timken OK Load (lbs)

60 Min.

60 Min.

Extreme Pressure Agent (EP)

Yes

Yes

Rust and Oxidation Agent

Yes

Yes

Anti-Foaming Agent

Yes

Yes

Copper Strip Corrosion Test

Pass

Pass

NOTE: Oil must not be corrosive to metals generally used in bearings, gears, shafts,
pumps and housings. Oil must have the least possible effect on rubber seals, synthetic
seals, packings and hoses. Refer to the Gyrasphere Operation & Maintenance Manual
for detailed crusher lubrication procedures and oil capacities.

7F
Hydraulic Oil Specifications
Viscosity ISO Grade

68

Viscosity SUS @ 100 F

317

Viscosity SUS @ 210 F

53 to 57

Viscosity Index

95 Min.

API Gravity

29 Min.

Pour Point, F

-10 to +10

Flash Point, F

400 to 425

Anti-Wear Agent

Yes

Anti-Foaming Agent

Yes

Rust and Oxidation Inhibitor

Yes

NOTE: Refer to the Gyrasphere Operation and Maintenance Manual for detailed
hydraulic system maintenance instructions and oil capacities.
07/09

D1

Appendix D - Lubricants

Wear Liner Replacement


Telsmith SBS Cone Crusher

NLGI #2 Grease Specifications


NLGI Grade Number

Worked Penetration @ 77 (60 Strokes)

285

Worked Penetration @ 77 (100,00 Strokes)

300

Dropping Point F

365

Copper Corrosion Test, 14 Days

Pass

Wheel Bearing Test @ 275 F

Pass

Timken OK Load (lbs)

50

NOTE: The above grease must contain an extreme pressure (EP) agent that is not
harmful to bronze, brass or lead. For satisfactory lubrication, grease must be
absolutely free from any ingredients which could cause corrosion, and from gritty
material which could produce wear. Grease should also be uniform in texture,
consistency, structure, stability, flow characteristics and lubricating characteristics.

MOLY
EP-2

Moly Based EP-2 Grease Specifications


(Aluminum Complex with Molybdenum Disulfide)
Worked Penetration

7F

265/295

Dropping Point F

510

Rust Prevention (ASTM D-1743)

Pass

Corrosion Prevention (ASTM D-1261)

Pass

Oxidation Stability (ASTM D-942)


Oxygen Absorption (PSI)
After
100 Hours
200 Hours
300 Hours
Oil Viscosity, SUS @ 100 F
Extreme Pressure Performance
Timken OK Load (lbs)
Four Ball Weld Point
Wear Scar
Type of Soap
Operating Temperature
MoS2 % by Weight

D2

<3
<4
<5
1000
65
800
0.51 mm
Aluminum Complex
0 to 450 F
3.0

07/09

Wear Liner Replacement


Telsmith SBS Cone Crushers

Appendix E - Sealants and Compounds

Appendix E - Sealants and Compounds


The following sealants and compounds are used throughout the repair procedures of this manual. These items
or their equivalents are commonly available at most local supply houses or distributors. Always read and
understand manufacturers directions and safety precautions before using any items shown.

Pipe Sealant
Description
Loctite 592 PST Pipe Sealant, Medium
Strength, Slow Cure, Anti-Galling.
Part No. 59241.

Manufacturer
Loctite Corp

Thread Locking Compound


Description

Manufacturer

Loctite 242 Threadblocker, Removable


Strength. Part No. 24241.

Loctite Corp.

Loctite 271 Threadlock, Permanent


Strength. Part No. 10T77.

Loctite Corp.

7F

Spray Primer
(for use with Loctite 242 thread locking compound)

07/09

Description

Manufacturer

Loctite 7471 Locquic Primer T, Aerosol,


Part No. 22477.

Loctite Corp.

E1

Appendix E - Sealants and Compounds

Wear Liner Replacement


Telsmith SBS Cone Crushers

Anti-Seize Compound
Description

Manufacturer

Bostik Never-Seez, Regular Grade,


Copper Formula. Meets MIL SPEC A907E.

Bostik Corp.

Silicone Sealant
Description

Manufacturer

Red Devil RD ProTM 100% Silicone Sealant.


Meets MIL SPEC 46106A.

Red Devil, Inc.

Shellac

7F

E2

Description

Manufacturer

Bulls Eye Shellac, Clear Sealer & Finish


(Conforms to federal spec. TT-S-300A)

Wm. Zinsser & Co., Inc.

07/09

Wear Liner Replacement


Telsmith SBS Cone Crusher

Appendix F - Removal Clearances

Appendix F - Removal Clearances

Type A Gear
Arrangement

Type B Gear
Arrangement

Note: Check crusher


gear arrangement
before using the table
below.

7F
Support Bowl Removal Clearances
Dimensions in inches (centimeters)

Crusher

Crushers With Type A Gear Arrangement


Dimension A

Crushers With Type B Gear Arrangement

Dimension B

Dimension C

Dimension A

Dimension B

Dimension C

Model 38

104 (264)

67 (170)

5 (13)

106 (269)

67 (170)

5 (13)

Model 44

N/A

N/A

N/A

104 (264)

67 (170)

5 (13)

Model 52

N/A

N/A

N/A

116 (295)

76 (193)

5 (13)

Model 57

133 (338)

87 (221)

5 (13)

125 (318)

83 (211)

5 (13)

Model 68

144 (366)

96 (244)

5 (13)

142 (361)

94 (239)

5 (13)

NOTE: Measurements shown above are typical. Actual measurements may vary, due to product changes, custom engineering
or fabrication variables. See the inset views above to determine gear arrangement.

07/09

F1

Appendix F - Removal Clearances

Wear Liner Replacement


Telsmith SBS Cone Crusher

A
B
C

Type A Upper
Frame Assembly

Type B Gear
Arrangement

Note: Check crusher


gear arrangement
before using the table
below.

7F
Head and Shaft Removal Clearances
Dimensions in inches (centimeters)

Crusher

Crushers With Type A Gear Arrangement

Crushers With Type B Gear Arraangement

Dimension A

Dimension B

Dimension C

Dimension A

Dimension B

Dimension C

Model 38

136 (345)

130 (330)

5 (13)

136 (345)

130 (330)

5 (13)

Model 44

N/A

N/A

N/A

141 (358)

132 (335)

5 (13)

Model 52

N/A

N/A

N/A

161 (409)

151 (384)

5 (13)

Model 57

182 (462)

169 (429)

5 (13)

177 (450)

164 (417)

5 (13)

Model 68

203 (516)

188 (478)

5 (13)

201 (511)

186 (472)

5 (13)

NOTE: Measurements shown above are typical. Actual measurements may vary, due to product changes, custom
engineering or fabrication variables. See the inset views above to determine gear arrangement.
If crusher is NOT equipped with anti-spin, Dimensions A and B will be approximately 6 inches less than shown.
F2

07/09

Wear Liner Replacement


Telsmith SBS Cone Crusher

Appendix G - Wear Liner Wear Limits

Appendix G - Wear Liner Wear Limits

7F
CONCAVE RING WEAR MEASUREMENT
1. Stop the crusher. Lockout/Tagout power to the crusher drive.
2. Raise the upper frame using the hydraulic clearing feature. Place hardwood blocks or safety spacers
between the upper and main frames. Refer to the crusher operators manual for instructions.
3. Lockout/Tagout Power to the hydraulic power unit.
4. At the bottom lip of the concave ring, measure dimension A.
5. Place a straight edge along the concave ring wear surface. Measure Dimension B.
6. Subtract Dimension B from Dimension A. This measurement should be 3/4 to 1 inch minimum.
7. If measurement is less than 1 inch, the concave ring should be replaced.

07/09

G1

Appendix G - Wear Liner Wear Limits

Wear Liner Replacement


Telsmith SBS Cone Crusher

7F

MANTLE WEAR MEASUREMENT


1. Stop the crusher. Lockout/Tagout power to the crusher drive.
2. Raise the upper frame using the hydraulic clearing feature. Place hardwood blocks or safety spacers
between the upper and main frames. Refer to the crusher operators manual for instructions.
3. Lockout/Tagout Power to the hydraulic power unit.
4. At the bottom lip of the mantle, measure dimension A.
5. Place a straight edge along the mantle wear surface. Measure Dimension B.
6. Subtract Dimension B from Dimension A. This measurement should be 3/4 to 1 inch minimum.
7. If measurement is less than 1 inch, the mantle should be replaced.

G2

07/09