Manual Trio Primaria

TRIO E N G I N E E R E D

P R O D U C T S

JAW C CRUSHER P PLANT-WJ3254A

INSTRUCTION A AND P PARTS M MANUAL

SERIAL N NUMBER -- _ _______________

Trio Engineered Products TRIO E N G I N E E R ED

P R O D U C T S

12823 Schabarum Ave. Irwindale, CA 91706

To THE OWNER: Congratulations on your selection of a Trio Jaw Crusher Plant. The plant is designed to provide you with years of profitable and dependable service. To ensure optimum performance, it is mandatory that you, and all personnel working with this machine, thoroughly study the Instruction Manual and follow its recommendations. Proper operation and maintenance are essential to prevent injury or damage and to maximize machine life. It is the owner’s responsibility to: o Operate and maintain this plant in a safe manner and in accordance with all applicable local, state and federal codes, regulations and/or laws and in compliance with on-product labeling and Instruction Manual instructions. o

Make sure that all personnel have read the Instruction Manual and thoroughly understand safe and correct installation, operation and maintenance procedures.

o

Make sure the machine is installed correctly before being placed into service, and at regular intervals thereafter, serviced in accordance with procedures outlined in the Instruction Manual.

o

Fulfill all warranty obligations so that the warranty is not not voided. Please refer to the warranty statement to determine the conditions of Trio Engineered Products warranty.

Trio Engineered Products reserves the right to make product improvements to the equipment at any time.

Trio Engineered Products TRIO E N G I N E E R ED

P R O D U C T S

12823 Schabarum Ave. Irwindale, CA 91706

To THE OWNER: Congratulations on your selection of a Trio Jaw Crusher Plant. The plant is designed to provide you with years of profitable and dependable service. To ensure optimum performance, it is mandatory that you, and all personnel working with this machine, thoroughly study the Instruction Manual and follow its recommendations. Proper operation and maintenance are essential to prevent injury or damage and to maximize machine life. It is the owner’s responsibility to: o Operate and maintain this plant in a safe manner and in accordance with all applicable local, state and federal codes, regulations and/or laws and in compliance with on-product labeling and Instruction Manual instructions. o

Make sure that all personnel have read the Instruction Manual and thoroughly understand safe and correct installation, operation and maintenance procedures.

o

Make sure the machine is installed correctly before being placed into service, and at regular intervals thereafter, serviced in accordance with procedures outlined in the Instruction Manual.

o

Fulfill all warranty obligations so that the warranty is not not voided. Please refer to the warranty statement to determine the conditions of Trio Engineered Products warranty.

Trio Engineered Products reserves the right to make product improvements to the equipment at any time.

Trio Engineered Products 12823 Schabarum Ave. Irwindale, CA 91706

TRIO E N G I N E E R ED

P R O D U C T S

FOREWORD Illustrations Illustrations and instructions instructions in this Manual guide the operator and maintenance personnel through correct procedures for checking, starting and operating the plant and its accessories. Operating techniques techniques outlined in in this book book are not all-encompassing. all-encompassing. Operating skills and additional maintenance techniques will develop as the operator gains knowledge of the machine machine and its capabilities. capabilities. The description and specifications in this manual were in effect at the time this manual was printed. Trio Engineered Products reserves the right to discontinue models at any time and to change specifications or design, without notice and without incurring obligation.

Whenever a question arises regarding your machine or this instruction manual, please consult Trio Engineered Products for the latest information.

SAFETY BE ABSOLUTELY CERTAIN THAT ALL PERSONNEL READ THIS INSTRUCTION MANUAL, THE QUICK REFERENCE GUIDE, AND ALL RELATED LITERATURE, AND FULLY UNDERSTAND SAFE AND PROPER INSTALLATION, OPERATION, AND MAINTENANCE MAINTENANCE PRACTICES! UNSAFE PRACTICES OR IMPROPER USE OF THIS MACHINE CAN RESULT IN SERIOUS BODILY HARM OR DEATH!

BASIC RULES REGARDING SAFETY IS OUTLINED IN SECTION 0, “SAFETY”. OPERATOR SAFETY AND THE SAFETY OF OTHERS DEPENDS UPON REASONABLE CARE AND JUDGM JUDGMENT ENT IN THE OPERATIO OPERATION N OF THIS MACHIN MACHINE. E.

RECOGNIZING HAZARDS AND TAKING STEPS TO AVOID THEM CAN PREVENT MOST ACCIDENTS ACCIDENTS BEFORE THEY BEFORE THEY OCCUR! REGARDLESS OF THE CARE USED IN THE DESIGN AND CONSTRUCTION OF THIS TYPE OF EQUIPMENT, UNEXPECTED CIRCUMSTANCES MAY OCCASIONALLY ARISE THAT CANNOT BE ANTICIPA ANTI CIPA TED OR COMP LETE LY PREVENT PRE VENT ED WITHOUT WITH OUT INTERFER INTE RFERING ING WITH REASONABLE ACCESSIBILITY AND EFFICIENT OPERATION. WARNINGS ARE INCLUDED IN THIS INSTRUCTION MANUAL (AND THE QUICK REFERENCE GUIDE) TO HIGHLIGHT SOME OF THESE CONDITIONS.

TABLE OF CONTENTS SAFETY AND GENERAL INFORMATION................................................................................. . 1 A-I

SAFETY..................................................................................................................................................1

A-II

GENERAL INFORMATION ...............................................................................................................8

INSTALLATION & OPERATION DETAILS................................................................................ 9 B-I

MACHINE DESCRIPTION AND SPECIFICATION........................................................................9

B-II

INSTALLATION INFORMATION...................................................................................................10

B-III

OPERATING INSTRUCTIONS ........................................................................................................12

B-IV

LUBRICATION...................................................................................................................................14

B-V

MAINTENANCE SCHEDULE ..........................................................................................................15

B-VI

TROUBLE SHOOTING......................................................................................................................16

B-VII

JAW CRUSHER ..................................................................................................................................16

B-VIII

PLANT TRANSPORTATION............................................................................................................17

ASSEMBLY INSTRUCTION & MAINTENANCE ............................................... ...................... 18 C-I

PLANT LAYOUT................................................................................................................................18

C-II

DISCHARGE CONVEYOR ASSEMBLY.........................................................................................20

C-III

HYDRAULIC SYSTEM......................................................................................................................22

C-I V

SAFETY DECAL KIT.........................................................................................................................22

GENERAL TECHNICAL INFORMATIONS.......................................................................... ..... 25 D-I

TERMINOLOGY ................................................................................................................................25

APPENDIX-A

BOLT TORQUE SPECIFICATION........................................................................................26

APPENDIX - B

OIL VISCOSITY CLASSIFICATION ....................................................................................27

APPENDIX-C

GENERAL DIMENSION (TRANSPORTATION) ................................................................28

APPENDIX-D

GENERAL DIMENSION (OPERATION)..............................................................................30

APPENDIX-E

ELECTRICAL SCHEMATIC.................................................................................................30

WARRANTY TERMS AND CONDITION...............................................................................................................32


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1

JAW CRUSHER PLANT WJ3254A

SAFETY

SAFETY AND GENERAL INFORMATION A-I

A

SAFETY

TABLE OF CONTENTS PERSONNEL SAFETY •

GENERAL......................................................................................................................................................

•

STOP ACCIDENTS BEFORE THEY STOP YOU............................................................................................

•

KNOW YOUR EMPLOYER’S SAFETY PROGRAM! .......................................................................................

•

DRESS PROPERLY FOR THE JOB..............................................................................................................

•

READ THE MANUAL AND UNDERSTAND YOUR MACHINERY.................................................................

•

ARE YOU PREPARED FOR EMERGENCIES? ............................................................................................

•

BEFORE STARTING CHECK.........................................................................................................................

•

IMMEDIATELY AFTER STARTING CHECK...............................................................................................

•

DURING

•

STOPPING

•

LOCKOUT ELECTRICAL SERVICE.................................................................................................................

•

WARNING TAGS...........................................................................................................................................

•

USE OF EPOXY RESIN.....................................................................................................................................

•

ALCOHOLIC BEVERAGES AND MEDICATION...........................................................................................

•

WORK AREA.........................................................................................................................................................

•

EQUIPMENT..................................................................................................................................................

•

FIRE

•

PRESSURIZED SYSTEMS — HYDRAULIC OR AIR....................................................................................

•

USE QUALITY PARTS.....................................................................................................................................

•

REPORT NECESSARY REPAIRS..................................................................................................................

OPERATION..................................................................................................................................... SAFELY........................................................................................................................................

HAZARDS..............................................................................................................................................

PLANT SAFETY •

GENERAL......................................................................................................................................................

•

DRIVE GUARDS...........................................................................................................................................

•

OPERATOR’S PLATFORM..........................................................................................................................

•

ELECTRICAL LOCKOUT.............................................................................................................................

•

CRANES.......................................................................................................................................................

•

MOBILE CRANES........................................................................................................................................

•

CUTTING TORCH AND WELDING EQUIPMENT......................................................................................

•

CONVEYOR BELTS.....................................................................................................................................

•

CLEARING THE MACHINE.........................................................................................................................

•

GENERAL MAINTENANCE WORK.............................................................................................................


P R O D U C T S

1


SAFETY

PERSONNEL SAFETY GENERAL

This portion of the instruction manual is intended to illustrate only basic safety procedures.

The information in this manual is not intended to replace safety codes, insurance requirements, federal, state and local laws, rules and regulations. These sections are presented as a helpful guide and show some of the daily problems that may be encountered.

STOP ACCIDENTS BEFORE THEY STOP YOU In order to alert you, as operators and maintenance personnel, dangerous or hazardous operations are shown in this instruction manual with BOLD and ITALIC notes. Study this manual, the quick reference guide and any other manufacturer’s literature covering your specific equipment. READ ALL WARNING INSTRUCTIONS. Practice safe operation.

KNOW YOUR EMPLOYER'S SAFETY PROGRAM! Company safety records show that the greatest percentage of accidents is caused by disregard of simple safety rules. Consult your supervisor for specific instructions when starting a job.

DRESS PROPERLY FOR THE JOB Protective clothing is essential to protecting one’s self. Be aware that loose clothing can become entangled in moving parts! Keep warm without restricting movement. Wrist watches, rings, and other jewelry can be dangerous. Keep your pockets free of objects that may fall out. Proper clothing is required while running this machine: 1. 2. 3. 4. 5. 6. 7.

HARD HAT SAFETY EYE WEAR (Glasses or goggles) SAFETY SHOES EAR PLUGS RESPIRATOR (When required) GLOVES PROTECTIVE CLOTHING

Other safety equipment may be required for maintenance of this machine. Find out what items are required and wear them!


P R O D U C T S

2


SAFETY

READ THE MANUAL AND UNDERSTAND YOUR MACHINERY Have everyone READ THE MANUAL (and all related literature) furnished with your equipment to learn its operating and maintenance characteristics, capacities, and limitations. Learn the location and function of ALL CONTROLS, indicators, warning devices and WARNING instructions. READ and OBSERVE the SAFETY DECALS! Replace the decals when it becomes necessary.

ARE YOU PREPARED FOR EMERGENCIES? Know the location of, and how to use a fire extinguisher and a first aid kit. Know where to get prompt assistance. An emergency calls for fast action.

BEFORE STARTING CHECK Equipment not properly maintained and prepared for operation is unsafe equipment. Perform a careful check at the beginning of your shift. WALK COMPLETELY AROUND THE PLANT AND INSPECT IT. Check for warning and lockout tags! If something needs attention now, do not run the machinery until it is fixed. Do not let unauthorized personnel operate the Machine! DO NOT START ANY MACHINE WITH FEED MATERIAL INSIDE THE MACHINE! 1. 2. 3. 4.

Walk completely around the machine. Be absolutely certain that no one is in, on, under, next to, or near the Machine! Look for lockout tags, warning tags, and notices. Observe all safety decals on the Machine. Warn all nearby personnel that you are starting the Machine!

IMMEDIATELY AFTER STARTING CHECK 1. Check all instruments and gauges to be sure everything is operating properly. 2. Test all controls for proper functioning. 3. Listen for any unusual noises or vibrations.


P R O D U C T S

3


SAFETY

DURING OPERATION •

•

NEVER STAND ANY CLOSER THAN FIVE (5) FEET (1.5 meters) FROM THE MACHINE WHEN IT IS RUNNING! NEVER LOOK IN THE FEED HOPPER WHILE THE MACHINE IS RUNNING.

STOPPING SAFELY Be sure the Machine is stopped before: • • • • • • • •

Cleaning Servicing Lubricating Checking belt tension Opening inspection covers Adjusting Machine setting Making repairs Attempting to clear a plugged Machine

MAKE NO CHECKS, ADJUSTMENTS OR REPAIRS OF ANY KIND WHILE MACHINE IS IN OPERATION!

LOCKOUT ELECTRICAL SERVICE 1. ALL MAINTENANCE PERSONNEL MUST BE PROVIDED WITH A PERSONAL PADLOCK WITH ONLY ONE (1) KEY.

2. Always lockout all electrical controls before performing any type of maintenance work on the Machine.

WARNING TAGS Before working inside a Machine, be sure to tag and lockout the electrical controls, so no one else can start it. Attach warning tags to prevent accidents: • • •

If the Machine is unsafe for operation If controls are being serviced or replaced If the machine is being repaired

USE OF EPOXY RESINS In those areas where epoxy materials/compounds are used, care should be taken when using a cutting torch or when grinding. THE AREA SHOULD BE WELL VENTILATED BECAUSE EPOXY FUMES CAN CAUSE NAUSEA OR POSSIBLE EYE OR SKIN IRRITATION.

ALCOHOLIC BEVERAGES AND MEDICATION - DO NOT use alcoholic beverages before coming to work or while on the job. - BEWARE of medicines, tranquilizers or other drugs that can make you sleepy or less alert.


P R O D U C T S

4


SAFETY

WORK AREA 1. KEEP the floor clean and dry and free of debris and tools. Oily and wet floors, steps and handrails are slippery. In winter, watch out for ice and snow. Wet spots, especially near electrical equipment, are dangerous. 2. DO NOT let material lie or build up on or around the Machine.

EQUIPMENT 1. Use the proper tools. Handle tools and heavy parts sensibly. 2. Keep all tools and equipment free of dirt, oil and grease. Do not drop or toss them. 3. Use hoisting equipment for heavy lifting. Save your back. 4. Lower parts. Do not drop them. 5. To prevent slipping, wipe hand levers and knobs clean of oil or grease. 6. Do not use sheaves with rims or spokes that are cracked. 7. Check for missing, cracked or frayed V-belts. 8. Check for broken, defective, worn or missing parts and replace them. 9. When using cables to move a load, be sure the cables are of adequate size. Replace any worn, badly frayed, broken or kinked ones. Check end connections for wear.

3. STORE dangerous fluids in a suitable place away from unauthorized personnel. ALLOW NO SMOKING IN THE AREA! Use only nonflammable solutions for cleaning. 4. NEVER start a diesel or gasoline engine within an enclosed area unless there is adequate ventilation. Exhaust fumes can kill!

FIRE HAZARDS 1. DO NOT SMOKE while refueling — or when handling fuel containers 2. DO NOT SMOKE while using cleaning solvents. 3. WHEN pouring fuel into the tank, ground the funnel or spout against the filter neck to avoid static electric spark. 4. DO NOT use gasoline or diesel fuel for cleaning parts. Good commercial, non-flammable solvents are preferred. 5. SHUT OFF engine when refueling — and use extra caution if engine is hot. 6. DO NOT let greasy, oily rags accumulate in a poorly ventilated area. Store oily rags and other combustible material in a safe place. 7. NEVER use an open flame to check fuel, battery electrolyte or coolant levels — or to look for hydraulic leaks anywhere on the equipment. Use a sealed flashlight! 8. KNOW where fire extinguishers are kept —and how they operate — and for what type of fire. Check regularly — at least monthly — to be sure they are in the working area.

PRESSURIZED SYSTEMS - HYDRAULIC OR AIR • • •

Relieve ALL pressure before opening or removing any hydraulic or air pressure lines, valves, fittings, etc. Check for worn hoses or damaged lines. High pressure oil can be dangerous!

USE QUALITY PARTS A replacement part for any item should always be of comparable SIZE, TYPE AND QUALITY — as the part being discarded. USE GENUINE FACTORY PARTS.

REPORT NECESSARY REPAIRS • • • •

If your daily check uncovers any item that needs attention — repair, replacement or adjustment — REPORT IT NOW! The most minor defect could result in more serious trouble — IF THE MACHINE IS OPERATED. Only perform the work you’re AUTHORIZED to do. Only work on equipment you THOROUGHLY understand.

5 TRIO E N G I N E E R ED

P R O D U C T S


SAFETY

PLANT SAFETY

GENERAL The safety procedures mentioned in this manual do not eliminate all safety hazards found in the area of crushing plants. Trio welcomes inquiries regarding other suggested safety procedures for use around their Machines and related equipment.

DRIVE GUARDS Proper safety precautions start with the initial installation of the Machine. Machines are driven by V-belts or by direct couplings to electric motors or diesel engines. THE BELT DRIVE OR COUPLING SHOULD HAVE A GUARD AROUND IT. Since the speed of the Machine is quite important for proper operation, most V-belt drive guards usually have a small opening immediately opposite the center of the Machine drive shaft so that a tachometer can be inserted to occasionally check the speed. This opening should be covered with an access door.

OPERATOR’S PLATFORM Since periodic inspection and maintenance must be performed on each Machine, IT IS IMPORTANT THAT SOME TYPE OF PLATFORM BE ERECTED AT A LEVEL CONVENIENT FOR MAINTENANCE PERSONNEL WHO MUST INSPECT AND WORK ON THE MACHINE. Do not fasten the operator’s platform to the Machine

ELECTRICAL LOCKOUT T H HE E E L LE E C C T T R R I I C C A L P O OW W E E R R S O OU U R R C C E E F O OR R T H HE E C R RU U S S H H I I N N G G E Q QU U I I P P M M E E N N T T S H HO O U U L L D D B E E L O OC C K K E E D D O U UT T W H HE E N N E E V V E E R R W O OR R K K I I N N G G O N N I T T. . Each maintenance worker who normally works on a Machine should be provided with a personal padlock with only one (1) key. When working on any assembly of the Machine, use this padlock to lock out the electrical controls for the Machine. It is most important that only one key be provided for the lock, and that key must be in the pocket of the person who is working on the Machine.

CRANES This machines, like any other type of mechanical equipment, require normal periodic maintenance. Internal parts of a machine should be assembled and disassembled with crane facilities that have the capability of gently and slowly lifting and lowering the various parts that make up a machine. CHAIN HOISTS should be considered only as a LAST resort to assemble and disassemble a machine. Personnel working with cranes must know proper hand signals.

MOBILE CRANES WHEN USING A MOBILE CRANE, ALWAYS OPERATE WITHIN THE RATED CAPACITY OF THE MACHINE TO AVOID BUCKLING THE BOOM OR TIPPING. Safe ratings are based on operating the crane on firm, level ground. Outriggers should be properly extended and/or lowered whenever possible.

CUTTING TORCH AND WELDING EQUIPMENT During the use of the cutting torch on, machines which are equipped with hydraulic components should have these components depressurized and adequately covered with flame-proof material so that sparks, weld spatter, etc., cannot reach these areas. Ruptured high pressure hydraulic lines will quickly vaporize the hydraulic fluid as it reaches the atmosphere. This vaporized fluid can quickly become a mass of flames, resulting in severe burns for personnel in the immediate area. ALL MAINTENANCE PERSONNEL WHO NORMALLY USE CUTTING TORCH EQUIPMENT SHOULD BE ADVISED IF THERE ARE HYDRAULIC COMPONENTS IN THE IMMEDIATE AREA IN WHICH THEY ARE WORKING. Rubber lined hoses are not immune to the cutting torch equipment.


P R O D U C T S


SAFETY

CONVEYOR BELTS Conveyor belts leading to and from the machine should be provided with walkways ALONG SIDE the conveyor. ALWAYS PROVIDE HAND RAILS along the conveyor belt walkway.

DO NOT USE CONVEYOR BELTS AS WALKWAYS.

CLEARING THE MACHINE There are many events such as power failures, sudden surge of materials, etc., which can cause a machine to become plugged with material and stall. UNPLUGGING THE MACHINE CAN BECOME A VERY SERIOUS POTENTIAL SOURCE OF ACCIDENTS. PROCEED WITH CAUTION! In many instances, the only way in which the machine can be restarted is to dig the material out of the crushing cavity by hand.

GENERAL MAINTENANCE WORK The following points cover some of the basic do's and don’ts when performing maintenance work. 1.

DO NOT perform maintenance on moving machinery. This includes adding lubricating oil or greasing parts of a machine while it is in operation.

2. DO lockout and tag the equipment before performing maintenance work. 3. DO NOT look into the machine while the machine is in operation without protection. 4. DO avoid spillage around the machine. Plant operators should make it a habit to keep the area immediately adjacent to the machine free from this type of spillage which could cause unsuspecting personnel to trip and fall.


P R O D U C T S


GENERAL INFORMATION

A-II

GENERAL INFORMATION

INTRODUCTION

This Instruction book has been prepared to assist you, the user, in the installation, operation and maintenance of your machine. This information will serve to acquaint you with the construction of the machine and as an aid in gaining the general knowledge necessary for efficient operation and maintenance. It is strongly recommended that the contents of this book be read, understood and put in practice prior to both installation and operation of the machine.

INITIAL INSPECTION It is recommended that as soon as possible, after receipt of the machine, a careful check be made for any possible damage which might have occurred during transit. A careful check should also be made to be sure that nothing has been lost and that all items on the Bill of Lading, Freight Bill or Manifest can be accounted for.

PARTS MANUAL This manual along with other manuals also illustrates and identifies the major parts used in the assembly of the machine and is to be used when ordering spare or replacement parts.

REPAIR PARTS For proper operation, only genuine factory parts should be installed. To avoid delay and the possibility of incorrect parts being furnished, the following information should be provided when ordering: 1. Model Number 2. The Serial Number of the machine, which is stamped on th e nameplate, as well as on the cover of th e parts manual. 3. Complete name and part number as show n in the parts manual. 4. Exact quantit y of each part ordered. 5. Complete shipping instr uctions.


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APPLICATION AND OPERATION GUIDE LINES

INSTALLATION & OPERATION DETAILS B-I

B

MACHINE DESCRIPTION AND SPECIFICATION

PLANT DESCRIPTION Plant consist of following main equipments,

Trailer

Providing the firm support frame for the all other equipments and provides the ability to transport on the road.

Jaw Crusher

Main crushing equipment for the material.

Feeder

Feeding the material to Jaw crusher.

Conveyor

Conveying the crushed material from the jaw crusher for the next operation.

Hydraulic Power Unit

Provides the hydraulic power to Jaw crusher and trailer.

PLANT SPECIFICATIONS

1 1.1 1.2 1.3 2 2.1 2.2 3 3.1 3.2 4 4.1 4.2 4.3 4.4 4.5 5 5.1 5.2 5.3

JA W CRUSHER PLANT – WJ3254A Plant WJ3254A Total Horse power 257 HP 192 Kw Total Weight 131582 Lbs 59810 Kg Capacity (TPH) Refer Crusher Manual Jaw crusher CT 3254TA ( Refer Machine Manual) Motor Power 200 HP 132 Kw Operating Speed 230 RPM F5220YB ( Refer Machine Manual) Feeder Motor Power 40 HP 30 Kw Operating Speed 800 RPM Discharge Conveyor CCA4830H Motor Power 15 HP 10 Kw Gear box size / Ratio 515 /1:15 Belt Size 48” Conveyor Length 30’ Speed 315 FPM 96 MPM Hydraulic Power Unit Motor Power 2 HP 1.5Kw Oil tank capacity 10 Gallon 38 Liter Maximum pressure 3000 psi 21 Mpa


P R O D U C T S


INSTALLATION INFORMATIONS

B-II

INSTALLATION INFORMATION

GENERAL INFORMATION The washer can be shipped either as a complete unit or in sub-assemblies. Instructions are provided for the assembly and disassembly of the machine components in the various sections of this manual.

PREPARE THE SITE Refer to your site plan or contact your Trio for guidance in determining the best location and required clearances for the plant and related equipment. Prepare the operating site so as to provide level and stable ground conditions, particularly in those areas that need cribbing and stabilizing. Make sure the soil is compacted enough to provide good support to the plant considering the plant vibrations. Use crushed rock, if needed, to establish a firm base.

INSTALLING TRAILER NOTICE: TO PREVENT DAMAGE TO THE TRAILER, RAISE ALL PLANT WEIGHT OFF THE SUSPENSION WHILE OPERATING USING HYDRAULIC JACKS AND FOOT PADS. During operation, all the plant weight must be put on the support legs provide on the trailer frame and conveyor(s). Be sure the jack footpads rest on a firm surface of the proper height to match related equipment. You may need timbers under the jacks to increase the bearing surface on soft ground. Place the footpads and screw jacks under the plant legs, including any front folding legs. When the plant is properly supported, remove the dolly or haul the tractor from under the kingpin. Diagram shows the operation of the Hydraulic jacks. There are four (4) hydraulic jacks, 1 each on the front right and left side and one each on the back right and left side. Each jack can be moved down or lifted up using the hydraulic control valve levers. Make sure to control the levers so as to move the jack in equally controlled motion.

INSTALLING OTHER PLANT EQUIPMENTS Install the ladder if provided. Normally, the ladder is strapped to the plant for transport. For safety and convenience, Do not remove any equipment that were installed at the factory. Set up or install any other handrails or any other equipment if provided with your plant. Handrails not only make operating the plant safer but make movement around the plant faster and easier. Before start-up, install all other equipment that was banded down for transport.

INSTALLING V-BELT DRIVES For Installing V-Belt drives on particular machine, refer the operation manual of corresponding machine.


P R O D U C T S


INSTALLATION INFORMATIONS

PLANT MAIN EQUIPMENTS WEIGHTS Another facto to be considered when designing the foundation, and planning overhead lifting equipment, is the machine weight. A overhead crane, a mobile crane, a chain hoist or other suitable equipment must be provided for handling heavy machine components during erection or replacement of worn parts. Size requirements for hosting equipment including cables, slings and hooks can be calculated by referring toTable below. DESCRIPTION

POUNDS

KILOGRAMS

131582

59810

Trailer

42126

19148

Jaw crusher

65934

29970

Feeder

16425

7466

7097

3226

Plant (COMPLETE)

Discharge Conveyor

The weights shown above are approximate.

GENERAL PRECAUTIONS DURING INSTALLATION / MAINTENANCE When performing any maintenance work on the machine, the following general precautions should be observed: 1. 2. 3. 4. 5. 6.

When removing parts with machined or bearing surfaces that may rust, they should be well oiled or covered with a rust preventative if they are to be kept out of the machine for any length of time. Use additional care when handling any parts that have bearing surfaces or machined surfaces that have close tolerances. When disassembling any parts with bearing or machined surfaces, protect these surfaces from coming in contact with the ground by using wooden blocking. Bronze liners or bushings should be handled with extreme care. Excessive ramming or pounding on this soft material may cause warping or springing of the part. Clean thoroughly and oil all machined parts before installing them in the machine. Do not replace a bearing surface without coating it with oil. When assembling two mating parts that require either a press or sliding fit, coat the contacting surfaces with a light coating of oil. This will act as a lubricant and prevent rusting when in place.

SPECIAL TOOLS Special tools have been furnished with your machine. Additional tools are available as an option.

RECOMMENDED SPARE PARTS CONTACT TRIO FOR A SUGGESTED LIST OF SPARE PARTS FOR YOUR PARTICULAR OPERATION. BEFORE STORING ANY SPARE PARTS, CHECK THAT THE PROTECTIVE COATING A PPLIED BEFORE SHIPMENT IS STILL INTACT.

BOLT TORQUE CHART Refer A pp endi x-A. B OLTS TORQUE SPECIFICATION


P R O D U C T S


OPERATING INSTRUCTIONS

B-III


TRIO MACHINE ARE SHIPPED WITHOUT OIL IN THE GEAR REDUCERS, MAKE SURE TO FILL THE RECOMMENDED OIL BEFORE OPERATING ANY MACHINE.

MOTOR SPEED AND DIRECTION OF ROTATION The correct speed or revolutions per minute (RPM) is most important for the proper throughput. The speed and direction of rotation should be checked to confirm with the data provided in the machine manuals. For conveyor, refer the section “ Discharge Conveyor”.

INTIAL START-UP AND RE START-UP CHECKS KEEP AN ACCURATE WRITTEN RECORD OF PERIODIC MAINTENANCE. Before initially starting the machine, or starting the machine after rework, perform the following operations: 1. Check that the Drive System is functioning properly. Be sure that the Drive system Gear boxes have been filled with the correct lubricating oil. 2. Make a final inspection of the machine to be certain that there are no mechanical obstructions, that all fasteners and pipe connections are properly tightened, and that there are no leaks. 3. After all the previous steps have been completed, perform the checks described next, under "BEFORE STARTING CHECK". 4.

If the plant has been stored for a period of time, inspect and grease any non-sealed bearings and oil seals, as required. Refer to your Machines Owner/ Operator Manual for the correct procedure.

BEFORE STARTING CHECK Equipment not properly maintained, and prepared for operation is unsafe equipment. Perform a careful check at the BEGINNING of your shift. Check for warning and lockout tags! If something needs attention now, do not run the machinery until it is fixed. Do not let unauthorized personnel operate the machine! notices. Observe all safety decals on the 1. Walk completely around the machine. machine, and related components. 2. Be absolutely certain that no one is in, on, 4. Warn all personnel nearby that you are under, next to, or near the machine! starting the machine! 3. Look for lockout tags, warning tags, and 1. Check the screw speed and direction of DO NOT START THE MACHINE WITH FEED rotation. MATERIAL INSIDE THE MACHINE!

DURING OPERATION •

NEVER STAND CLOSER TO THEMACHINE WHEN IT IS RUNNING!

•

DO NOT LEAN OR PLACE YOUR HANDS AGAINST MACHINE WHILE IN OPERATION.

•

NEVER LOOK IN THEFEED HOPPER WHILE THE MACHINE IS RUNNING.


P R O D U C T S



STOPPING SAFELY STOP FEED BEFORE STOPPING MACHINE. Be sure the machine is stopped before: - Cleaning

- Repair and Servicing

- Checking belt tension

- Adjusting machine setting

- Lubricating

- Attempting to clear a plugged machine

MAKE NO CHECKS, ADJUSTMENTS OR REPAIRS OF ANY KIND WHILE MACHINE IS IN OPERATION!

LOCKOUT ELECTRICAL SERVICE 1.

ALL MAINTENANCE PERSONNEL MUST BE PROVIDED WITH A PERSONAL PADLOCK WITH ONLY ONE KEY.

2.

Always lockout all electrical controls before performing any type of maintenance work on the machine.

WARNING TAGS Before working inside a machine, be sure to tag and lockout all electrical controls, so no one else can start it. Attach warning tags to prevent accidents: 1.

If the machine is unsafe for operation.

2.

If controls are being serviced or replaced.

3.

If the machine is being repaired.

MACHINE SETTING The machine setting depends on the size of product and throughput required.

Refer to machine manuals for proper setting of the equipments.

Conveyor Belt Tracking Before a plant leaves the factory, all test runs and adjustments are done on all conveyors so they “track true.” That is, the belt runs straight without rubbing any part of the conveyor frame. When the plant arrives at the job site, the tracking may not be true due to product loading, vibration during travel, or belt stretch. As the belt wears in, or product loading changes, you may need to adjust the belt to keep it centered in the conveyor frame. A properly adjusted belt: • Carries the product load in center of the belt. • Rides and fits smoothly on the troughing rolls • Accurately delivers the product to the discharge or head end, • has a slight “belly” (droop or sag) in the return loop, and does not slip at the pulleys. A properly adjusted belt provides excellent service over a long operating life. If possible, make adjustments to the Conveyor belt when it is empty.


P R O D U C T S


LUBRICATION

B-IV

LUBRICATION

LUBRICATION CHART Proper lubrication is extremely important in the operation and maintenance of the equipment on your plant. Check the oil level in the crusher, feeder and all other equipments before start-up. Individual machine Operation Manual has a description of the lubricating oil capacity, specifications for your particular equipment. Conveyor bearings are lubricated and sealed at the factory with a supply of grease. Do not lubricate sealed bearings. If the plant has been stored for a period of time, inspect and grease any non-sealed bearings and oil seals, as required. Refer to your crusher’s Owner/ Operator Manual for the correct procedure. Location Lubricant 1 Interval

Oil; ISO 220 (1100 SUS @ 100ºF) for ambient temperature from 50º-100ºF. EP Grade Gear Oil. First change after 80 hrs of initial operation, subsequent change every 2000 hours or if found dirty (see Contamination Limit table)

Qty.

1 gallons

Location

Jaw Crusher

Lubricant

Refer Jaw Crusher Manual

2 Interval Qty.

3

Conveyor Drive Gear Box

Refer Jaw Crusher Manual Refer Jaw Crusher Manual

Location

Feeder

Lubricant

Refer Feeder Manual

Interval Qty.

Refer Feeder Manual Refer Feeder Manual

TO COMPARE DIFFERENT GRADES OF OIL, PLEASE REFER TO ANNEXURE ‘B’.

TRIO EQUIPMENTS ARE SHIPPED WITHOUT OIL IN THE GEAR REDUCERS, MAKE SURE TO FILL THE RECOMMENDED OIL BEFORE OPERATING THE ANY EQUIPMENT.


P R O D U C T S


MAINTENANCE SCHEDULE

B-V

MAINTENANCE SCHEDULE

8 HOURS •

Check belt alignment and tension.

•

Check the power draw on the motor.

•

Check oil level at the drive Gear box.

•

Check for loose fasteners or connections.

•

Check conveyor belt tensioning and tracking.

•

•

Check for Hydraulic oil leaks.

Check for unusual noise, indications of wear or undue strain on machine parts.

•

Check that feed to machine is proper.

•

Check the bearing temperatures.

80 HOURS •

Change drive gear box lubrication oil.

•

Check V-belts for wear or cracks.

•

Check belt alignment and tension.

•

Check machine settings.

•

Check conveyor belt tensioning and tracking.

•

Check the bearing temperatures.

•

Check V-belts for wear or cracks.

•

Check machine settings.

Every 300 HOURS •

•

•

•

Check belt alignment and tension. Check oil level and the contamination level at the drive Gear box. Check the bearing temperatures.

•

Check for unusual noise, indications of wear or undue strain on machine parts.

Adjust conveyor belt tensioning and tracking.


P R O D U C T S


TROUBLE SHOOTING

B-VI

TROUBLE SHOOTING

PLANT VIBRATION PROBABLE CA USES Plant not grouted and leveled

COMMENTS/CORRECTIVE ACTIONS Check the level and grouting for any cracks and vibration.

Footpad support not rigid

Check the support under the footstep and soil compactness.

Incorrect Jaw crusher RPM

Check and adjust RPM as specified in the manual.

PRODUCT SPILLAGE PROBABLE CA USES Improper Conveyor belt alignment.

COMMENTS/CORRECTIVE ACTIONS Check belt tracking on the conveyor.

Worn out skirts and wipers

Check and replace the skirts and wipers.

Machine or conveyor overloading

Check material feed and blocking in the crusher or conveyor.

LOW OUTPUT (TONNAGE) PROBABLE CA USES

COMMENTS/CORRECTIVE ACTIONS

Low operating speed (RPM).

Check and adjust the speed according to the output desired.

Lack of Power

Check for Motor and drives.

Low Feed

Check the feed from the feeder or to the feeder.

Incorrect crusher settings

Check and adjust the setting on crusher.

LOW PORDUCT QUALITY PROBABLE CA USES

COMMENTS/CORRECTIVE ACTIONS

Incorrect Crusher setting

Check and adjust the settings

Incorrect feed

Check for the feed size and quaity

B-VII

JAW CRUSHER

CHANGING SWING DIE As the Jaw Crusher is installed at 10° inclined position, precaution should be taken while changing Swing Jaw die. Following steps could be exercised during the replacement of swing Jaw die. 1.

Place the wooden block between the Jaw dies.

2.

Remove the Swing Jaw die wedge.

3.

Hold the Swing Jaw die with chain or rope suitable for the job.

4.

Remove the wooden block and cautiously lift the Swing jaw die.

FOR OTHER JAW CRUSHER OPERATION, PLEASE REFER JAW CRUSHER MANUAL.


P R O D U C T S


PLANT TRANSPORTATION

B-VIII

PLANT TRANSPORTATION

PREPARE THE PLANT FOR TRAVEL Before the plant is moved, protect the equipment and prepare the plant for transport. 1.

Clean any rock material buildup off the trailer frame.

2.

Disconnect electrical and any pipe connections as necessary, to ensure the plant can be transported without damage to equipment. Mark each part, if needed, to make reassembly easier. Properly store the loose items duly marked.

3.

Remove any conveyor that extends above or beyond to meet road transportation requirements.

4.

Make sure the plant meets the overall height requirement, • position the conveyer(s) and other equipment in the as-delivered configuration. Also measure the plant from the highest point to the ground to ensure the requirements • include in your measurements any modifications you have made to your plant since the initial delivery. • review the road limits and requirements for the public roads and highways along the route you plan to take. • consider any special limitations, such as a low overpass, that may exist on private roads or property you intend to cross.

PREPARATION FOR TRANSPORT 1.

Remove and stow the ladder and other portable equipments.

2.

Position a tractor or dolly under the trailer and install the kingpin. Connect the tractor’s electrical cables and air hoses to the trailer. Make sure the trailer’s brakes are locked.

3.

Raise front and rear legs and locked them in position.

4.

Lower the trailer onto its wheels by raising the hydraulic jacks. Lock all the jacks.

5.

Remove and stow cribbing, braces and blocks.

6.

Check trailer lights and brakes before rolling.

TRANSPORT 1.

Observe speed or other special limits for transport (such as travel only during certain hours) set by each state. Exceeding limits may cause damage to the plant or its components, delay transport, or cause a road hazard.

2.

Take extra precautions when crossing an abrupt changes in road elevation, such as a railroad crossing, to avoid “high-centering” the truck frame. High-centering can damage undercarriage accessories.


P R O D U C T S


ASSEMBLY INSTRUCTIONS AND MAINTAENACE

ASSEMBLY INSTRUCTION & MAINTENANCE C-I

C

PLANT LAYOUT

18


PLANT LAYOUT

PLANT LAYOUT

ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

PART NO. WJ3042D.1 WJ3254A.1 WJ3254A.2 WJ3254A.3 F5220YB.00 WJ3254A.4 WJ3254A.5 WJ3254A.6 C3254TA.00 WJ3254A.7 CCA4830H.00 WJ3254A.8 WJ3254A.9 WJ3254A.10 WJ3254A.11 WJ3254A.12 WJ3254A.13 WJ3254A.14 WJ3254A.15

DESCRIPTION

QTY.

Support Leg Feeder Hopper Hopple Frame Electric Control Box Support Vibrating Grizzly Feeder Main Frame Vibrating Grizzly Feeder Discharge Chute Feed Box Jaw Crusher Walkway 48” X30’ Discharge Conveyor Rubber Plate Baffle-Plate Flywh eel Guard Jaw Crusher Drive Guard Jaw Crusher Baffle-Plate (LH & RH Each) Feeder Drive Guard Axle Assembly F5220+CT3254 Hydraulic s System

4 1 1 1 1 1 1 1 1 1 1 2 1 1 1 Total 2 1 1 1


P R O D U C T S


DISCHAGE CONVEYOR ASSEMBLY

C-II

DISCHARGE CONVEYOR ASSEMBLY

20



ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

PART NO. CCA4830E.1 GB5783/ M12X20 GB96/12 CCA2460F-3 CCA2480A.10 BTA48X12-39A/48” CCA4830D.2 CI20-48/20º-48” IB20-48-A/20º-48” CCA4830H.1 CCA4830H.2 C20-48/20º-48” GB5782M16X55 GB6170/M16 GB96/16 GB97.1/16 GB93/16

DESCRIPTION Pulley Guard Bolt M12X20 Washer 12 Adjustment Bolt Tail Pulley Seat 48” Tail Pulley Side Plate (I) (LH & RH Each) Impact Idler Impact Pad Side Plate (I) (LH & RH Each) Side Plate (II)(LH & RH Each) Idler Bolt M16X55 Nut M16 Washer 16 Washer 16 Lock Washer16

QTY. 1 70 70 2 2 1 Total 2 4 1 Total 2 Total 2 6 76 76 60 72 76


ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 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

PART NO. CCA4830E.1 GB5783/ M12X20 GB96/12 CCA2460F-3 CCA2480A.10 BTA48X12-39A/48” CCA4830D.2 CI20-48/20º-48” IB20-48-A/20º-48” CCA4830H.1 CCA4830H.2 C20-48/20º-48” GB5782M16X55 GB6170/M16 GB96/16 GB97.1/16 GB93/16 BCT-48/48” CCA4830D.7 CCA4830H.3 GB1230/16 CR-48/48” NN300 CCA4830E.3 GB5782/M14X40 GB97.1/14 GB93/14 GB6170/M14 254T GB5783/M12X55 GB93/12 GB97.1/12 GB6170/M12 TXS515 /1:15 B-2B5.8-SDS MB15P-SDS GB5783/M6X35 GB93/6 GB11544 B-2B7.0-SK RB5-SK GB5783/M8X45 GB93/8 BHB48X12-47/48” CCA4830F-1 CCA4830F-2 CCA4830E.4 CCA4830H.4 CCA4830D.10 CCA4830H.5

DESCRIPTION Pulley Guard Bolt M12X20 Washer 12 Adjustment Bolt Tail Pulley Seat 48” Tail Pulley Side Plate (I) (LH & RH Each) Impact Idler Impact Pad Side Plate (I) (LH & RH Each) Side Plate (II)(LH & RH Each) Idler Bolt M16X55 Nut M16 Washer 16 Washer 16 Lock Washer16 48” Wiper Side Plate (V) Frame Washer 16 48”Return Idler Belt 1.2X4-5.1-3, 1200X21000 Drive Guard Bolt M14X40 Washer 14 Lock Washer 14 Nut M14 Motor 15HP, 1760RPM, 60HZ Bolt M12X55 Lock Washer 12 Washer 12 Nut M12 Gear Box (1:15) Sheave 15HP Taper Sleeve Bolt M6X35 Loc k Washer 6 V-Belt SPB-1800 Sheave Taper Sleeve 1-15/16 Bolt M8X45 Loc k Washer 8 48” Head Pulley Scratch Board Clamp Plate Motor Mount Front Support Leg Suspend Bar Cross Bar


P R O D U C T S

QTY. 1 70 70 2 2 1 Total 2 4 1 Total 2 Total 2 6 76 76 60 72 76 1 10 1 20 5 1 1 6 6 6 6 1 13 13 13 13 1 1 1 3 3 2 1 1 3 3 1 1 1 1 1 2 2


SAFETY DECAL

C-III


P R O D U C T S

HYDRAULIC SYSTEM

22


SAFETY DECAL

ITEM NO. 1 2 3 4 5 6 7

PART NO. WJ2436D.7-1

WJ2436D.7-3

DESCRIPTION Handle Sign Plate Hand valve Hoses and Fittings Pump unit Distributor & Pressure Lock fro Jaw Mountin g Plate Hydraulic Cylinders

QTY.

UNIT WEIGHT Kgs Lbs.

1 1 1 Set 1 1 1 4

Hydraulic Pump Specification: Motor Power Speed Tank Volume Max. Pressure


P R O D U C T S

1.5kw 1750RPM 38 Liter (10 Gallon) 21Mpa (3000Psi)

23


SAFETY DECAL

C-IV

SAFETY DECAL KIT

Sample Figure

ITEM NO.


P R O D U C T S

PART NO.

DESCRIPTION

SDK-001

Safety Decal Kit and Charts

24

QTY.


D

GENERAL TECHNICAL INFORMATION

GENERAL TECHNICAL INFORMATIONS D-I

TERMINOLOGY

CAPACITY: The output of the machine in tons per hour, checked on machine DISCHARGE belt. DRIVE: Any device used to transmit rotating force from the electric motor or diesel engine to the machine countershaft; V-Belt or Flexible Coupling. DRIVE GUARD: Safety enclosure for the drive with small opening (opposite countershaft with cover) for tachometer. FEED: The raw material which is to be processed. FINISHED PRODUCT: The resultant material after it has been processed. GRADATION: The range of sizes contained in a sample of rock.


P R O D U C T S


APPENDIX A – BOLT TORQUE SPECIFICTIONS

APPENDIX-A

BOLT TORQUE SPECIFICATION

GENERAL RULES : 1. Values shown below are for Dry unplated condition, for lubricated plated condition torque shou ld be 75% of the values shown below.

METRIC BOLTS DIAMETER

GRADE 8.8

GRADE 10.9

SOCKET HEAD

FT-LB

N-M

FT-LB

N-M

FT-LB

N-M

6 mm (M6)

9

12

12

16

14

19

8 mm (M8)

22

30

29

39

34

46

10 mm (M10)

44

60

57

77

66

89

12 mm (M12)

78

106

99

134

117

159

14 mm (M14)

123

167

158

214

185

251

16 mm (M16)

192

260

245

332

290

393

20 mm (M20)

345

468

480

651

560

759

24 mm (M24)

600

816

830

1125

960

1302

30 mm (M30)

1190

1613

1650

2237

1920

2603

36 mm (M36)

2080

2820

2880

3905

3360

4556

SAE (iNCH) BOLTS DIAMETER

GRADE 5

GRADE 8

SOCKET HEAD

FT-LB

N-M

FT-LB

N-M

FT-LB

N-M

1/4-20

8

11

12

16

14

19

5/16-18

17

23

24

33

29

39

3/8-16

30

41

45

61

49

66

7/16-14

50

68

70

95

76

103

1/2-13

75

102

110

149

113

153

9/16-12

110

149

150

203

163

221

5/8-11

150

203

210

285

230

312

3/4-10

260

353

380

515

400

542

7/8-9

430

583

600

814

640

868

1-8

640

868

910

1234

980

1329

1 1/4-7

1120

1519

1820

2468

1710

2319

1 1/2-6

1910

2590

3160

4285

2920

3960


P R O D U C T S


APPENDIX B –OIL VISCOSITY CHART

APPENDIX - B

OIL VISCOSITY CLASSIFICATION


P R O D U C T S


GENRAL DIMENSIONS

APPENDIX-C

GENERAL DIMENSION (TRANSPORTATION)

28


GENRAL DIM

GENRAL DIM

GENRAL DIMENSIONS

APPENDIX-D

GENERAL DIMENSION (OPERATION)

GENRAL DIMENSIONS

APPENDIX-D

GENERAL DIMENSION (OPERATION)

30


GENRAL DIMENSIONS

APPENDIX-E ELECTRICAL SCHEMATIC

GENRAL DIMENSIONS

APPENDIX-E ELECTRICAL SCHEMATIC

31


WARRANTY TERMS

WARRANTY TERMS AND CONDITION Seller warrants all new equipment manufactured or imported by Trio Engineered Products, Inc. (Trio) against defects in material or workmanship attributed to the original machine manufacturing. No other warranties are expressed or implied. Warranty claims must be made through the dealer or agent responsible for the original equipment sale, as the equipment will have been registered with them at the time of sale from Trio. Claims must be made within twelve (12) months or 2,000 working hours, whichever occurs first, from the date of readiness for operation, but not more than fifteen (15) months from the date of shipment from Trio. All parts claimed to be defective shall be returned to Trio, freight prepaid, for inspection to determine that the said part or parts are defective. If it is determined that the fault lies with Trio, Trio will ship a replacement part or parts at no cost, but freight charges will be paid by customer. If it is determined that the fault does not lie with Trio, a replacement part or parts will be shipped, freight collect, to the customer with the receipt of a purchase order from the dealer or agent. Trio will not be responsible for freight costs associated with warranty claims.

Manual Trio Primaria

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