1200 LSOps

Crusher Startup Checklist
an Astec company
JCI, Inc.
86470 FRANKLIN BLVD EUGENE, OR 97405
TEL. (800) 314-4656 FAX (541) 988-9401
________________________ ________________________ ___________________________

Model No. Startup Date / Hour meter Serial No.
_______________________________________ _________________________________________
Customer Distributor
_______________________________________ _________________________________________
Address Address
_______________________________________ _________________________________________
City/State/Zip City/State/Zip
_______________________________________ _________________________________________
Delivery Date to Customer Delivery Date to Distributor
EQUIPMENT INITIAL INSPECTION CHECKLIST

Yes No
___ ___ Was equipment received in good physical condition?
___ ___ Were any parts missing?
___ ___ Was equipment received as ordered by the customer (Sales order sheet)?
___ ___ Were operations and parts manual(s) received with the equipment?
EQUIPMENT SETUP CHECKLIST

___ ___ Were safety precautions reviewed with customer? Safety issues to cover are:
Lockout/Tagout; Hearing protection; Hard hat protection; Eye protection; Crusher decals
___ ___ Was crusher mounted level in all directions and supported evenly on all four mounting pads?
___ ___ Was the support structure and cribbing sufficient to prevent excessive vibration?
___ ___ Was belt tension correct and sheaves in alignment correct on crusher drive?
___ ___ Was crusher guard(s) in place?
___ ___ Was customer instructed of need to remove dust buildup from crusher sheave daily?
___ ___ Was oil level at the full position on the dipstick?
___ ___ Do the oil seals leak the correct amount of oil?
___ ___ Was customer instructed on proper oil sampling and change frequency?
Time: _______ Temp: _____ Dots upper_______ Dots Lower________ (3" pattern @ 1 min.)
Page 1 of 2 081503
Crusher Startup Checklist
an Astec company
JCI, Inc.
86470 FRANKLIN BLVD EUGENE, OR 97405
TEL. (800) 314-4656 FAX (541) 988-9401
Yes No
___ ___ Was customer instructed how to make manganese closed side setting changes?
___ ___ Was customer instructed on inspection of wear parts?
___ ___ Was customer instructed to keep crusher discharge area clear of obstructions?
___ ___ Was customer instructed how to check and service the tramp iron relief system?
___ ___ Was the hydraulic system operating properly and pressures checked?
___ ___ Was the oil flow meter functioning properly. Flow reading __________ gpm? Trip set: ____________
___ ___ Was the warning system(s) and interlocks properly wired in?
___ ___ Was in-feed material centered in feed hopper?
___ ___ Was the customer cautioned on the causes and effects of bowl float? At ______ CSS
___ ___ Was cone head spinning on startup?
___ ___ Was crusher input shaft rotating clockwise. Input shaft speed ______ RPM.
APPLICATION
___ ___ Does the liner configuration and speed fit the application? Liner size: __________ Brand: _________
___ ___ Have the operating parameters been discussed with the customer?
___ ___ Is there a magnet or metal detector installed in the circuit?
Crusher feed size ______________ Target product _______ CSS _______ Closed Circuit Y / N
Material type __________________ Pit Run/Shot Rock TPH _______ (actual/estimated)
Dealer Rep (print): ___________________________ Date: ________ X____________________________
Customer (print): ____________________________ Date: ________ X____________________________
Page 2 of 2 081503
Crusher Checklist
an Astec company 30 Day Inspection
JCI, Inc.
P.O. BOX 40277 EUGENE, OR 97404
TEL. (541) 736-1400 FAX (541) 988-9401
________________________ ________________________ ___________________________

Model No. Inspection Date Serial No.
_______________________________________ _________________________________________
_______________________________________ _________________________________________
Address Address
_______________________________________ _________________________________________
_______________________________________ _________________________________________
Startup Date Approximate Hours
EQUIPMENT CHECKLIST
Yes No
___ ___ Is crusher mounted level in all directions and supported evenly on all four mounting pads?
___ ___ Is belt tension correct and sheaves in alignment correct on crusher drive?
___ ___ Is crusher guard in place?
___ ___ Has customer removed dust buildup from crusher sheave daily?
___ ___ Is oil level at the full position on the dipstick?
___ ___ Any indications of oil leakage at Pinion Shaft or Seal Rings?
If yes, how much oil added, how often? _________________ (i.e. 1 gal/day)
___ ___ Has customer been sampling and changing oil as frequently as instructed?
___ ___ Is warning system properly wired in?
___ ___ Is the manganese wearing evenly?
___ ___ Are Baseframe Strut Guards and Rock Shelves in place and in good condition?
___ ___ Are all counter weights in place and in good condition?
___ ___ Is there any indication of build-up in discharge area?
___ ___ Has customer checked oil and nitrogen gas pressures in tramp iron relief system?
Page 1 of 2 010204
Crusher Checklist
an Astec company 30 Day Inspection
JCI, Inc.
TEL. (541) 736-1400 FAX (541) 988-9401
Tramp Iron relief pressure __________ psi
Yes No
___ ___ Is there any evidence of leakage in the tramp iron relief system or clamp system?
MACHINE CHECKLIST
___ ___ Is oil flow meter functioning properly? Flow reading ________________ gpm
___ ___ Is in-feed material centered in feed hopper?
___ ___ Is in-feed material dropping from a height of less than 36” to the hopper?
___ ___ Is the crusher exhibiting bowl float or evidence of seat damage?
___ ___ Is cone head spinning?
___ ___ Is crusher input shaft rotating clockwise? Input shaft speed ________ RPM
___ ___ Is the Crusher correctly balanced and running smoothly?
___ ___ Is the Crusher being choke fed?
Customer Signature ____________________ Company Rep. Signature _______________
Page 2 of 2 010204
an Astec company Crusher Checklist
JCI, Inc. 90 Day Inspection
TEL. (541) 736-1400 FAX (541) 988-9401
________________________ ________________________ ___________________________

Model No. Inspection Date Serial No.
_______________________________________ _________________________________________
_______________________________________ _________________________________________
Address Address
_______________________________________ _________________________________________
_______________________________________ _________________________________________
Startup Date Approximate Hours
EQUIPMENT CHECKLIST
Yes No
___ ___ Is crusher mounted level in all directions and supported evenly on all four mounting pads?
___ ___ Is belt tension correct and sheaves in alignment correct on crusher drive?
___ ___ Is crusher guard in place?
___ ___ Has customer removed dust buildup from crusher sheave daily?
___ ___ Is oil level at the full position on the dipstick?
___ ___ Any indications of oil leakage at Pinion Shaft or Seal Rings?
If yes, how much oil added, how often? _________________ (i.e. 1 gal/day)
___ ___ Has customer been sampling and changing oil as frequently as instructed?
___ ___ Is warning system properly wired in?
___ ___ Is the manganese wearing evenly?
___ ___ Are Baseframe Strut Guards and Rock Shelves in place and in good condition?
___ ___ Are all counter weights in place and in good condition?
___ ___ Is there any indication of build-up in discharge area?
___ ___ Has customer checked oil and nitrogen gas pressures in tramp iron relief system?
…Forms\Crushers\Crusher90insp.doc Page 1 of 2 011300

an Astec company Crusher Checklist
JCI, Inc. 90 Day Inspection
TEL. (541) 736-1400 FAX (541) 988-9401
Tramp Iron relief pressure __________ psi
Yes No
___ ___ Is there any evidence of leakage in the tramp iron relief system or clamp system?
MACHINE CHECKLIST
___ ___ Is oil flow meter functioning properly? Flow reading ________________ gpm
___ ___ Is in-feed material centered in feed hopper?
___ ___ Is in-feed material dropping from a height of less than 36” to the hopper?
___ ___ Is the crusher exhibiting bowl float?
___ ___ Is cone head spinning?
___ ___ Is crusher input shaft rotating clockwise? Input shaft speed ________ RPM
___ ___ Is the Crusher correctly balanced and running smoothly?
Customer Signature ____________________ Company Rep. Signature _______________
…Forms\Crushers\Crusher90insp.doc Page 2 of 2 011300

an Astec company
1200LS Crusher
Operation Manual
an Astec company
1200LS CRUSHER OPERATION MANUAL
TABLE OF CONTENTS
INTRODUCTION ...................................................................................................................... 1
NEW PARTS AND EQUIPMENT WARRANTY ............................................................................ 2
INSTALLATION ........................................................................................................................ 3
Mounting ........................................................................................................................................... 3
Clearance ........................................................................................................................................... 3
Control feed material velocity ........................................................................................................... 6
Remove transport blocks ................................................................................................................... 6
ELECTRICAL ............................................................................................................................ 9
Oil flow meter ................................................................................................................................... 11
Heater ................................................................................................................................................ 12
START-UP AND MAINTENANCE CHECKLIST ........................................................................... 13
Before start-up .................................................................................................................................. 13
After start-up, running empty ........................................................................................................... 13
After crushing begins ........................................................................................................................ 14
Regular maintenance ........................................................................................................................ 14
LUBRICATION SYSTEM ........................................................................................................... 17
Oil level ............................................................................................................................................ 17
Viscosity ........................................................................................................................................... 18
Oil sampling ..................................................................................................................................... 18
Changing oil ..................................................................................................................................... 19
Oil type ............................................................................................................................................. 19
Oil filter ............................................................................................................................................ 20
TRAMP IRON RELIEF SYSTEM ................................................................................................ 23
Bowl float ......................................................................................................................................... 23
Checking tramp iron relief system pressure ..................................................................................... 24
Charging the 5-gallon accumulators with nitrogen .......................................................................... 26
Charging the tramp iron relief system .............................................................................................. 27
CHANGING MANGANESE ....................................................................................................... 29
Preparation ........................................................................................................................................ 29
Changing manganese bowl liner ....................................................................................................... 33
Changing manganese cone mantle .................................................................................................... 35
Installing new liner ........................................................................................................................... 37
Backing material ............................................................................................................................... 40
Installing upper assembly ................................................................................................................. 41
CLOSED SIDE SETTING ........................................................................................................... 45
Capacities .......................................................................................................................................... 45
Gradation chart ................................................................................................................................. 46
Selecting closed side setting ............................................................................................................. 47
Changing closed side setting ............................................................................................................ 48
Adjusting shims ................................................................................................................................ 50
Clamp system accumulator ............................................................................................................... 52
Charging the 1-gallon accumulator .................................................................................................. 53
CONE BRAKE SYSTEM ............................................................................................................ 55
STORAGE ............................................................................................................................... 57
TRANSPORT ........................................................................................................................... 57
OM2009704
an Astec company
INTRODUCTION
The JCI 1200LS cone crusher is designed with numerous features for improving
durability, serviceability and performance. It has anti-friction roller bearings, spiral
bevel gears, heavy-duty replaceable strut guards, a modular tramp iron relief manifold
beam, and a self-contained oil reservoir. The oil lubrication pump, meter, and filter are
mounted in a separate enclosure for easier placement on stationary or portable plant
set-ups. The crusher has an interchangeable standard/fine chamber configuration.
This manual covers the information an experienced crusher operator needs to
successfully and safely operate the JCI 1200LS cone crusher. Read it carefully to
insure you get the most from your new crusher. Make sure that all personnel are aware
of, and use, proper safety precautions when working around the crusher and related
equipment.
This manual does not cover major service items, such as changing roller bearings. For
information on service, call your JCI dealer or the JCI service department. Contact JCI
at 541-461-8101, 541-461-8480 fax, or P.O. Box 40277, Eugene OR 97404.
OM2009704 1
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NEW PARTS AND EQUIPMENT WARRANTY

JOHNSON CRUSHERS INTERNATIONAL, INC.
1. Johnson Crushers International, Inc. (JCI) Warranty:
JCI warrants to the Distributor and Distributor’s customers on resale with respect to
JCI products sold that the new equipment will be free from defect in material and
workmanship under normal use for a period of one year after the date of start-up or
2,000 hours of operation, whichever first occurs. JCI further warrants to the Distributor
and Distributor’s customers on resale that any and all parts supplied by JCI will be free
from defect in material and workmanship under normal use (excluding ordinary wear)
for a period of six months after installation. The sole and exclusive remedy for any
breach of warranty, breach of contract, or any claim in tort (including, but not limited
to, strict liability and negligence) shall be the repair or replacement (at JCI’s option) of
any defective part, parts or equipment at JCI’s manufacturing plant in Lane County,
Oregon. Any part(s) and/or equipment claimed to be defective shall be returned, freight
prepaid, to JCI’s manufacturing plant in Lane County, Oregon, following the receipt
of JCI’s returned goods authorization. Written notice of any claimed defect must be
provided to JCI within sixty (60) days of the discovery of any claimed defect(s).
2. Disclaimer/Limitation of Warranties:
The express warranty described above is expressly in lieu of other warranties, express
or implied AND ANY AND ALL IMPLIED WARRANTIES, INCLUDING, BUT
NOT LIMITED TO, ANY AND ALL IMPLIED WARRANTIES OR
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE
HEREBY EXPRESSLY DISCLAIMED AND EXCLUDED.
NO PERSON(S), INCLUDING, BUT NOT LIMITED TO, EMPLOYEES AND
AGENTS OF JCI AND/OR ITS DISTRIBUTORS ARE AUTHORIZED TO MAKE
ANY REPRESENTATION OR WARRANTY CONCERNING JCI PRODUCTS
THAT ARE IN ANY WAY INCONSISTENT WITH THE FOREGOING
WARRANTY.
JCI MAKES NO WARRANTY OR WARRANTIES, EXPRESS OR IMPLIED,
WITH RESPECT TO ANY ACCESSORIES, COMPONENTS OR PARTS NOT
MANUFACTURED BY JCI, AND THE INSTALLATION OF ANY PARTS OR
COMPONENTS NOT MANUFACTURED OR SUPPLIED BY JCI, AND ANY
ALTERATION OF EQUIPMENT OR PARTS SUPPLIED BY JCI WITHOUT JCI’S
EXPRESS WRITTEN CONSENT SHALL VOID THE WARRANTY GRANTED
HEREBY.
UNDER NO CIRCUMSTANCES SHALL COMPANY BE RESPONSIBLE FOR
ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING, BUT
NOT LIMITED TO, LOST PROFITS OR LOSS OF USE.
3. Address for Notices:
Any and all inquiries and/or warranty claims should be reduced to writing and
submitted to JCI at the following address:
Johnson Crushers International, Inc., P.O. Box 40277, Eugene OR 97404
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an Astec company
INSTALLATION
It is important that the JCI 1200LS be properly mounted. This includes leveling, proper
clearance to lubrication components and adjusting shims, correct electrical hookups
including proper interlocks, correct drive motor orientation, proper oil level, proper
relief system pressures, and proper clearance between crusher discharge and under-
crusher hopper.
A new JCI crusher is shipped with transport blocks in place, which need to be removed.
It is shipped with oil, and the accumulators and hydraulic systems are charged, but
these must be checked before operating for the first time. Refer to the start-up and
maintenance checklist on page 13.
Mounting
For best results, the crusher must be mounted on a structurally sound stand or portable
chassis. The substructure should be level in the east-west and north-south directions.
The 1200LS weighs approximately 29,800 pounds. It has mount dimensions similar to Notice: Operating
other 45" cone crushers, and should fit the same envelope. See Figure 1 for the the crusher out-of-
dimensions. level could reduce
its life and
Clearance operating
effectiveness.
It will be necessary to adjust the closed side setting often during the course of a
crushing season. To make the adjustment as easy as possible, allow adequate room for
workers to gain access to the adjustment shim stacks. We suggest that a minimum of
18 inches be planned for this operation. See Figure 1 for the location of critical
components. It is important to allow access to the adjustment ports for connecting the
Y-27 pump, and to the accumulator area for connecting the nitrogen bottle used in
changing the closed side setting and servicing the tramp iron system.
OM2009704 3
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Pinion housing
Direction of
rotation
(clockwise)
5-1/2" clearance
required for
tramp iron
relief system
movement
Upper section
Accumulators
Bonnet
Shim stacks
Oil Fill (not

shown)
Adjustment
ports
Discharge area
Oil heater
Oil drain
Figure 1 - Mounting dimensions
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an Astec company
Adequate clearance must also be provided for the lubrication system components.
They are mounted in an enclosure which may be located remotely away from the cone
crusher itself. The enclosure should be located in an area which is accessible for
personnel to perform maintenance and for visual observation of the oil flow meter
gauge and oil filter indicator. The enclosure should be securely mounted as close to the
crusher as practical, but no farther than the supplied hoses will reach, with no sharp
bends or kinks. Make sure that the hoses are protected from falling rock, sharp edges,
moving machinery, and other hazards. Connect the hoses as shown in Figure 2 for
proper oil flow. The suction side uses a 1" I.D. hose with a maximum length of 9 feet,
and the pressure hose is 1/2" I.D.
Figure 2 - Oil flow
In the event the pinion housing assembly needs to be removed from the crusher, a
minimum of 27 inches of clearance must be provided.
When performing a manganese change or crusher tear-down, the upper section of the
crusher must be removed. This operation requires a minimum of 25 inches of vertical
clearance. In addition, there should be no permanent structures in place that would
interfere with lifting cables being used to remove the upper section from the crusher.
In the event tramp iron enters the feed material and finds its way into the crushing
chamber, the bonnet will rise a maximum of 5-1/2 inches to allow the uncrushable
material to pass through the chamber. Allow clearance for this, and be aware that it can
happen at any time the crusher is running.
Do not let personnel get in a position where this movement may pinch them between WARNING: The
the crusher and nearby mounts, or throw them off the machine. bonnet can rise
suddenly during
operation.
OM2009704 5
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Control feed material velocity

It is important to control the feed size being fed to the crusher as well as the velocity
of the material. If the feed is falling from a height greater than 36 inches, a rock box or
rock ladder should be installed. If the velocity of the feed is great enough, damage to
the mantle nut cap can occur, possibly sending the cap through the crushing chamber.
If rock enters the crushing chamber at too great a speed, some material may pass
through the chamber without being crushed.
For maximum crushing effectiveness, productivity, and product gradation, the
crushing chamber should be full while in operation. To accomplish this “choke” feed
condition, a surge bin may need to be inserted somewhere in the circuit to keep the
crusher chamber full at all times.
Remove transport blocks

When the crusher is to be moved to a new crushing site, the cone head must be blocked
to prevent damage to the crusher bearings. The roller bearings are designed to handle
heavy crushing loads but not the sharp impact load caused from the cone head
bouncing during transportation. Moves of even short distances can cause brinelling
marks leading to reduced bearing life. See page 57 for information on installing
transport blocks when moving the crusher. The crusher is shipped from the factory
with two transport blocks in place. See Figure 3 for their location.
Feed opening
Transport blocks
Figure 3 - Location of the transport blocks
To remove the transport blocks you must raise the upper section with the Y-27 pump.
Connect the hoses from the Y-27 hydraulic pump as shown in Figure 4.
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Clamp cylinder
accumulator valve
Adjusting jack
Clamp cylinder
manifold valve
Adjusting jack
manifold
Pressure gauges
Line from port A
Line from port B
Shim guard
Handle in neutral
position
Figure 4 - Connecting the Y-27 hydraulic pump
Close the clamp cylinder accumulator valve. Open the clamp cylinder manifold valve.
Put the pump handle in position B. See Figure 5.
Handle in position A Handle in position B
Figure 5 - Pump handle positions A and B
OM2009704 7
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This will pressurize the adjusting jack cylinders and raise the upper assembly off the
shim stacks. Carefully reach into the feed opening and pull out the 2 wedge-shaped
wooden blocks. Lower the upper section by slowly moving the 3-way control valve on
the adjusting pump to position A.
With the control valve on the adjusting pump still in position A, recharge the clamp CAUTION: Make sure
cylinder system to 1800 psi. Close the clamp cylinder manifold valve. Open the clamp all workers have
cylinder accumulator valve. Re-pressurize the system if the hydraulic pressure drops their hands and
below 1800 psi. Retract one adjusting jack ram 2 inches to allow for thermal expansion fingers out of the
of the hydraulic system. Disconnect the hydraulic hoses from the quick couplers. Raise shim area before
and secure the shim guard. lowering the upper
section back into
If you are going to be moving the crusher again, store the blocks and reinstall them at place.
that time. See the Transport section (page 57) at the end of this manual for instructions.
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ELECTRICAL
Components requiring electrical power are the oil flow meter, oil pump motor, oil
heater, thermostat, and warning horn. Standard voltage for the oil flow meter,
thermostat, and warning horn is 120 Volt, 60 Hertz. Wires from these devices
terminate in the junction box located on the remote lubrication panel. See Figure 6 for
details of the junction box terminal strip.
Figure 6 - Junction box terminal strip
The 1200LS has the capability of supplying lubricant to the crusher bearings prior to
machine start-up. Your control panel must include a pre-lube circuit with a relay timer.
The timer is a 2 to 180 second relay. The recommended setting for the relay is 30
seconds. When the circuit has been properly set up, the main crusher motor can not be
started until the relay timer has timed out. Once the relay timer reaches 30 seconds,
electrical power is supplied to the main crusher motor.
Figure 1 shows a typical wiring diagram for the entire system. Figure 7 shows the Notice: Failure to
crusher drive and prelubrication control wiring schematic. pre-lubricate the
crusher bearings
may lead to prema-
ture problems in-
cluding bearing
failure.
OM2009704 9
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21
19
Figure 1 - Typical wiring diagram
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Figure 7 - Crusher drive and prelubrication control circuit
Oil flow meter

An oil flow meter has been provided as a safety device to protect the crusher
components in the event of a lubrication system failure. Should the flow meter detect
a flow of oil less than its preset value, the electrical control circuit will activate the
warning horn alerting crusher operators that the machine needs to be shut down
immediately so as to prevent permanent damage to crusher components. In addition, it
is strongly suggested that the control circuit be wired such that when the warning
system is activated the feed device feeding the crusher is shut down. The crusher
should be shut down immediately after the rock has cleared the crushing chamber (less
than 10 seconds). This will prevent personnel from having to dig out the crushing
chamber.
Oil flow meter wiring is shown in Figure 8. Notice: Always

have the oil flow
meter and warning
horn properly
connected to help
prevent crusher
damage.
Figure 8 - Oil flow meter wiring diagram
OM2009704 11
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Heater
All JCI crushers are supplied with an oil heater to help keep the oil viscosity at an
acceptable level during cool weather start-ups. It is important to keep the oil pump
from cavitating, which would prevent adequate amounts of lubricant from reaching the
bearings. The oil heater and thermostat are mounted on the cover plate on the underside
of the reservoir. The thermostat turns the heater on when the temperature of the oil falls
below 60°F and turns the heater off when the temperature of the oil reaches 80°F. If
your crusher will be operating in consistently cold weather, the factory recommends an
additional timer relay be added to the circuit in the control panel. This circuit will cycle
the crusher oil pump on every 15 to 30 minutes keeping warm oil flowing through the
lines and distributing warm oil from around the heater to the back of the oil reservoir.
See Figure 9 for an electrical schematic of this circuit.
Figure 9 - Oil heater wiring diagram
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START-UP AND MAINTENANCE CHECKLIST

For optimum crusher performance and safety, site personnel should observe the
following start-up procedures each time the crusher is started.
Before start-up
Check oil level with the dipstick. Fill as needed with an approved oil. See Table 2 on
page 19 for a list of approved oils. Check the condition and viscosity visually and by
taking regular oil samples. See page 17 for details. In cold weather, check that the oil
heater is working and the oil flows easily.
Check oil lines for signs of damage, and fittings for leaks. Replace hoses or retighten
fittings if necessary.
Check the crusher hydraulic systems for leaks. Areas to check are the tramp iron relief
system and clamp cylinder system. See the Tramp iron relief system section, page 23,
and the Closed side setting section, page 45, for maintenance instructions.
Check stop blocks for cracks or sheared bolts. They keep the bonnet from rotating, and
can be damaged by bowl float. See page 23 in this manual for instructions on stopping
bowl float.
Check inside the crusher for missing or worn counterweights. Replace as necessary.
The condition of the manganese needs to be checked daily starting when the lower DANGER: Before
shim stack height is reduced to 1-1/2 times the closed side setting. Thin manganese can entering the
develop cracks leading to potential structural casting damage. See the Manganese crusher via the
section, starting on page 29, for more information on checking manganese, along with product belt, be
instructions for changing the manganese. sure to lock out the
power source of
Check the under-crusher discharge area for obstructions that would cause material to the crusher and
build up leading to excessive wear in the lower wedge plate area. product conveyor!
Check the crusher drive for dirt buildup or excessive wear. If the drive belt is flush with DANGER: Before
the top of the sheave, it is time to replace the sheave. Check drive belts for signs of wear working on the
or damage. crusher drive, be
sure to lock out the
Check that all safety devices are in place and in good condition. power source!
After start-up, running empty

You can make an approximate determination of the closed side setting by passing some
easily deformed object, such as a ball of tinfoil, through the crusher when it is running
empty. Attach a piece of string or wire to the ball of foil and holding the string, lower
the ball into the crushing chamber and keep it in the manganese parallel zone for a few
revolutions. Measure the flattened foil to determine your CSS. See the Closed side
setting section, page 45, for details on adjusting CSS.
Check to see that the flow switch is reading the proper flow, 4 gallons per minute
(minimum) for the 1200 series machines.
Check the oil filter indicator on the filter housing for signs of restricted flow. Change
the oil filter if the needle is in the red area.
OM2009704 13
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Check that the cone head is not spinning. If the cone head spins while running empty,
stop and check the shear bolts in the over-running clutch. See the Cone brake system
section, page 55, for more information.
DANGER: Before Check machine balance. If vibration is excessive, stop the crusher and look for the
entering the cause of imbalance. Possible causes are excessively worn or damaged counterweights,
crusher via the dirt build-up in the crusher sheave or brake mechanism, or an inadequate or damaged
product belt, be structural mount.
sure to lock out the
power source of After crushing begins
the crusher and
product conveyor. Check the feed stream. Is it centered? If not, adjust feed.
Check the level of feed in crusher hopper. Is crusher being choke fed? If not, consider
adding a surge bin to the feed system.
Check for rock spillage between the under-crusher hopper and the discharge conveyor.
Listen to the crusher run. Notice any unusual sounds which may be an indication of
potential problems.
Check for bowl float. Bowl float can cause excessive wear and component failure. For
information on the causes and ways to prevent it, read page 23 in the Tramp iron relief
system section of this manual. Do not allow bowl float to continue. Doing so may void
your warranty.
Check for excessive temperature. The normal operating temperature should be 185°F
or below. Excessive temperature can be caused by low oil viscosity, low oil flow,
outside air temperature, or too small a closed side setting. See the Lubrication and
Closed side setting sections for more information.
Regular maintenance
The following list covers areas that need regular attention and scheduled maintenance.
Take oil samples regularly, and when the oil appears dirty or burnt, have it analyzed
for total acid number (TAN), contaminants, and viscosity.
Change oil every 1000 hours, or more often depending on conditions and the results of
oil analysis. Change the filter at the same time, and when the filter indicator needle is
in the red area.
DANGER: Lock out Change the manganese bowl liner and mantle. Check the condition of the manganese
the power source daily starting when the lower shim stack height is reduced to 1-1/2 times the closed side
to the crusher and setting. Replace the manganese when there are thin spots, cracks, holes, or they are too
related conveyors worn to allow proper adjustment of CSS. Abnormal wear can cause bowl float. See the
before beginning Manganese section, page 29, for instructions.
service.
Check the bonnet support skirt thickness when you are changing the manganese. It
begins at about 1-1/4" thick. The bonnet support needs to be replaced when the skirt is
worn down to 1/2" thick. If it is only partly worn (3/4" to 1") you can install a liner kit
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to extend its life. Install liners if the bonnet skirt continues to have excessive wear. See
Figure 10.
Bowl liner
Mantle liner
Bonnet
support skirt
Bonnet
support liners
(optional)
Counter-
weights
Strut guard
Base tub
Pinion tunnel
guard
Figure 10 - Cross-section of the 1200LS DANGER: Before

entering the
Check the strut guards and pinion tunnel guard for excessive wear. If allowed to wear crusher via the
out, you may compromise the structure of the crusher. Replace as necessary. product belt, be
Check for excessive wear on the base tub, struts, and pinion tunnel. sure to lock out the
power source of
Check the hydraulic and nitrogen pressure in the tramp iron relief system and the clamp the crusher and
cylinder system. Recharge as needed. Replace accumulators if there are any signs of product conveyor!
external damage.
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LUBRICATION SYSTEM
Oil is stored in a sump in the crusher, and is drawn from it by the external oil pump
mounted in a separate enclosure. See Figure 11. The oil is then sent through the oil
filter (with attached filter indicator), and the oil flow meter. The pressurized oil is then
sent back to the crusher where it is pumped up the base frame spindle to the bearings.
The oil drains down through the bearings to the sump.
Sampler valve Filter Filter indicator Suction line
from crusher
Warning Oil flow Pump Pump Pressure line

horn meter motor to crusher
Figure 11 - External lubrication panel
Operating the crusher with oil at the proper level, with the correct viscosity and
acceptable cleanliness is essential.
Oil level
The 1200LS has an approximate oil capacity of 17 gallons. Use the dipstick to check
for proper level. See Figure 12. Clean off any dirt that may have accumulated around
the fill pipe/dipstick area before removing the dipstick. Unscrew the dipstick from the
fill pipe, wipe the stick clean, and replace it lightly on the fill pipe- do not re-thread.
Remove the dipstick by pulling it straight up. If the level is too low, add oil before
starting crusher.
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Dipstick
Full
Add
Run Level
Figure 12 - Dipstick
Viscosity
Observe the viscosity of the oil. If the oil does not readily drip from the dipstick it may
be too viscous to flow through the system and lubricate the bearings. Oil pump
cavitation may occur. Check to see that the oil heater, located under the crusher in the
main oil reservoir, is in proper operating condition. In cold weather, steps should be
taken to warm the oil and keep it fluid before starting the crusher. See page 12 for the
heater wiring schematic.
When the crusher is running, check that the gauge on the flow switch is reading the
correct flow of 4 gallons per minute (minimum).
Oil sampling
Observe the condition of the oil on the dip stick. If it appears dirty, turn on the pump
and pull an oil sample from the sampler plug located near the oil filter.
Have the oil analyzed. An oil sample will tell you your TAN (total acid number),
concentrations of wear metal in part-per-million (ppm), and the viscosity. Take regular
samples to monitor the effectiveness of your oil. Generally, a 100% increase in TAN
or an increase of 20% in viscosity over a baseline sample taken when the oil was fresh,
or a ppm that exceeds the maximums listed in Table 1, indicates that it is time to change
oil.
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NORMAL LEVEL MAXIMUM

METAL
(PARTS PER MILLION) (PARTS PER MILLION)
Aluminum 0-10 -
Copper 0-15 50
Nickel 0-5 10
Chrome 0-5 10
Lead 0-20 50
Iron 30-50 150
Silicon (dirt) 10-30 75
Table 1 - Concentrations of wear metal in oil
Changing oil
Oil should be changed every 1000 working hours, or more frequently depending on
your use and environment, or when a problem is discovered through sampling and
observation.
The oil drain plug is under the crusher on the rectangular oil sump cover. The 1200LS WARNING: Lock out
crusher has an oil capacity of approximately 17 gallons. But use the dipstick to check the power source
for the correct level. Always replace with the proper oil type. before performing
any maintenance.
Oil type
See Table 2 for a listing of the proper oils. The crusher uses ISO 150 oil with extreme
pressure (EP) additives.
SUPPLIER BRAND NAME AND GRADE
Amoco Amogear EP 150
Chevron Ultra Gear 80W-90
Exxon Spartan EP 150
Gulf Gulf EP HD 150
Mobil Mobilgear 629
Shell Omala 150
Texaco Meropa 150
Table 2 - Proper oils
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At the normal operating temperature of 185°F the oil should have the following
specifications:
• Minimum viscosity of 100 SUS
• Minimum viscosity index of 90
• Minimum Timkin OK load of 55 pounds.
If your crusher operates at a temperature higher than 190° to 200°F, an ISO 220 grade
will help to protect the bearings. If you operate in sub-zero temperatures an ISO 68
fluid may be used as long as the oil temperature does not exceed 150 degrees.
Oil filter
Check the filter indicator for signs of restricted flow and change the oil filter if the
needle is in the red area. It is also a good idea to change the filter when the oil is
changed.
To change the filter, first flip the hinged lid on the enclosure out of the way. Unscrew
the cover of the oil filter housing. Figure 13 shows the internal parts of the filter. The
oil can be drained from the filter housing by removing the plug on the bottom. Remove
the spring and insert assembly. Unscrew the insert assembly from the bypass assembly
to remove the old element. Clean the parts and the filter housing.
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Cover
Cover 0-ring
Top spring
Insert assembly
Insert O-ring
Bypass seal
Bypass seal gasket
Element
Element O-ring
Bypass assembly
Filter housing
Plug
Figure 13 - Exploded view of oil filter
Replace the bypass seal and gasket and install the new filter element. Put the assembly
and spring back in the filter housing. Replace the cover and fold the lid back down. Run
the pump to fill the filter with oil before starting the crusher. Check the oil level and
top it off. Once the crusher is running, check for leaks. Check the oil level again after
shut down and refill as needed.
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TRAMP IRON RELIEF SYSTEM

The hydro-pneumatic system used on the 1200LS provides great hold down force to
the bonnet. This system also provides a measure of safety to the crusher bearings and
steel castings. When tramp iron passes through the crushing chamber, the crushing
force exceeds the hold down pressure in the relief system. The uncrushable material
causes the bonnet to raise to allow the object to pass through the chamber. The system
accommodates this movement by stroking the relief cylinder pistons upwards, which
pushes the hydraulic fluid out of the relief cylinder and into the 5 gallon accumulator
network. As soon as the uncrushable has passed through the chamber, the nitrogen gas,
which is also under pressure, pushes the hydraulic fluid back into the cylinders. See
Figure 14.
Bleeder valve
Tramp iron relief

manifold beam
Pressure valve
Relief cylinder
5-gallon
accumulator
Nitrogen gas
bladder
Push rod
Bonnet
Vee seat
Nitrogen charging
valve
Bonnet support
Crushing chamber
Figure 14 - Cross-section of the tramp iron relief system
Bowl float
The minimum closed side setting (CSS) is the closest setting possible that does not
produce bowl float. The actual minimum CSS at a given crushing site can vary widely
depending on the nature and condition of the material.
Bowl float is defined as the periodic separation of the bonnet from the bonnet support.
This area is also known as the vee seat. Metal transfer will occur if the float condition
is allowed to persist.
Bowl float may not be visible without careful observation. Movement may be detected
by observing metal filings at the rotation stop blocks or at the joint between the bonnet
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and bonnet support. Failure to correct the problem causing the bowl float could lead to
nullifying the crusher warranty.
One of the major causes of bowl float is too small a closed side setting. Other causes
of bowl float are:
• tramp iron
• excessive near-size or fines in the feed
• soft material that can form “pancakes”
• rock with a very high compressive strength
• low relief system pressure
• air in the relief system.
Notice: Do not Some possible solutions to bowl float are:

correct for bowl • open up the closed side setting
float by increasing • increase screening area to remove excessive fines
system hydraulic • wash infeed material to remove some of the mud
pressure beyond • check the nitrogen and hydraulic pressures frequently to ensure they are kept at the
2300 psi. Damage factory settings.
to the bearings
and/or structural Checking tramp iron relief system pressure
members will likely
occur. The accumulator bladders contain nitrogen gas at a nominal pressure of 1950 psi. The
relief system hydraulic pressure is pumped up to 2300 psi. This provides reserve
energy in the accumulator to keep the cylinders under continuous pressure. The
hydraulic fluid capacity of the system is about 10 gallons.
Notice: The relief The hydraulic fluid and nitrogen gas pressures work together in the tramp iron relief
system does not system, but need to be checked separately. Usually, you check the overall system
tolerate hydraulic (hydraulic) pressure first and if it is low, check the nitrogen pressure in the
fluid or gas leaks. accumulators. Checking the nitrogen pressure requires draining (and later recharging)
Integrity of the the hydraulic system, so plan your service accordingly.
system would be
diminished and Check the overall pressure of the system with a nitrogen pressure gauge, shown in
bowl float would Figure 16, connected at the pressure valve shown in Figure 15.
become even more
prevalent. Check
for signs of
leakage daily.
T-handle
Nitrogen pressure
gauge
Figure 15 - Nitrogen pressure gauge
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Tighten the T-handle to open the valve. The pressure should read 2300 psi. If the WARNING: Wear
pressure is correct, close the valve and remove the gauge. goggles or a face
shield when
If the pressure is low, you need to check the nitrogen pressure in each of the 5-gallon working around
accumulators. Check early in the day, as pressure builds up with a rise in air pressurized fluids.
temperature.
To check the nitrogen pressure you first need to drain the hydraulic fluid from the relief WARNING: Never
system. Attach a hose to the pressure valve and put the other end of the hose into a clean charge the tramp
container which can hold up to 20 gallons. Slowly open the valve and drain the fluid. iron relief system
See Figure 16. Close the valve and remove the hose. without first
checking all of the
accumulator’s
nitrogen pressure.
Excess pressure
can cause system
failure or
Pressure valve explosion.
Figure 16 - Location of the pressure valve
Remove the cap from one of the nitrogen charging valves, located on the bottom of the WARNING: Wear
5-gallon accumulators, and attach the nitrogen pressure gauge as shown in Figure 17. goggles or a face
shield when
working around
pressurized fluids.
5-gallon accumulator
T-handle
Nitrogen pressure
gauge
Figure 17 - Nitrogen pressure gauge connected to a 5-gallon accumulator
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Tighten the T-handle to open the valve. The pressure should read between 1900 and
2000 psi. If the pressure is correct, close the valve and remove the gauge. Put a little
silicone sealer on the edge of the protective cap, to help seal water out of the valve, and
install the cap.
Repeat this procedure for both accumulators. If either accumulator reads too low it will
need to be charged with nitrogen. If the pressure reads higher than 2100 psi the
accumulator may have a bad port valve spring. Have an authorized service person
check the accumulator. Faulty accumulators can be dangerous.
DANGER: Do not If both of the 5-gallon accumulators have the correct nitrogen pressure, charge the
attempt to repair hydraulic fluid pressure in the tramp iron relief system as described on page 27.
an accumulator
without proper Charging the 5-gallon accumulators with nitrogen
training.
Before charging the accumulators with nitrogen, the hydraulic system must be drained
as described in the preceding paragraphs.
WARNING: Do not To charge the accumulators with nitrogen gas, you will need several full nitrogen
charge the relief bottles and a charging gauge with hose. See Figure 18.
system without
first checking the
pressures.
Figure 18 - Charging gauge with hose
Remove the cap from the bottom of the accumulator and connect the gauge to the
nitrogen charging valve. Tighten the T-handle to open the valve on the accumulator.
The gauge will show the current nitrogen pressure. Open the valve on the nitrogen
bottle, and the gas pressure will rise. Close the valve on the nitrogen bottle when the
pressure in the accumulator bladder reaches 1950 psi. Loosen the T-handle on the
gauge to close the accumulator valve before removing (or changing) the nitrogen
bottle. Remove the gauge from the accumulator and repeat the procedure with the other
5-gallon accumulator if necessary. Once both of the 5-gallon accumulators are checked
and charged, it is time to recharge the hydraulic fluid pressure in the tramp iron relief
system.
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Charging the tramp iron relief system

The tramp iron relief system has a capacity of about 10 gallons of hydraulic fluid. Use
a premium, medium viscosity, anti-foaming fluid with additives to reduce oxidation
and wear, such as Chevron AW46.
To charge the system, connect the line from port A on the Y-27 hydraulic pump to the WARNING: Wear
pressure valve as shown in Figure 19. Open the pressure valve. Move the handle on the goggles or face
pump to position A and switch the pump ON. See Figure 20. shield when
working with
pressurized fluids.
WARNING: The Y-27

pump is capable of
Tramp iron relief beam
producing up to
Bleeder valve (the 10,000 psi of
second valve is 180° pressure. Hoses
opposite) and fittings should
be inspected
Pressure valve before attempting
Line from port A
this operation.
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Open the bleeder valve closest to the pressure valve and release the air from the system.
Stop the pump and close the bleeder valve once fluid with no air bubbles comes out.
Repeat this process for the second bleeder valve.
Notice: Do not let Re-start the pump and carefully watch the pressure rise. The pressure will appear to
the hydraulic stop rising once it equals the nitrogen pressure, but it will continue to rise very slowly.
pump run out of When the system reaches 2300 psi, stop the pump. Close the pressure valve. Move the
fluid. This could handle on the Y-27 pump to position B and remove the hose. The tramp iron relief
damage it. system is now ready to work.
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CHANGING MANGANESE
During the crushing process, the manganese mantle and bowl liner experience wear
leading to the need to change the liner set. As the closed side setting is changed during
the course of crushing rock to compensate for wear, the number of shims in the lower
stack will be reduced. Crusher operators will need to pay close attention to the
condition of the manganese as the stack gets shorter. Daily observation of the
manganese condition should begin when the lower shim stack is 1-1/2 times the closed
side setting (CSS). For example, for a CSS of 1-1/2" begin observation of the liners
daily when the shim stack is 2-1/4" high.Visual observation is a must as thin
manganese can develop cracks leading to potential structural casting damage.
For maximum production and manganese wear profiles, JCI recommends changing the
manganese in sets. To change the manganese set, follow the instructions listed below.
Preparation
Remove or swing out of the way any feed devices or other structural members which WARNING: Lock out
have been mounted directly overhead. This allows the crusher upper section to be lifted the power source
vertically. before performing
any maintenance.
Remove the crusher feed hopper by removing the hopper bolts and attaching lifting
cables to the two lifting eyes located in the hopper gussets as shown in Figure 21.
Lifting eyes
Remove
hopper bolts
Figure 21 - Lifting the hopper
Lower the shim guard and connect the Y-27 hydraulic pump to the quick couplers at
the clamp cylinder manifold valve and adjusting jack manifold block as shown in
Figure 22.
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Notice: When
connecting the Y-
Clamp cylinder
27 hydraulic pump
accumulator valve
hoses to the quick
couplers, clean the Adjusting jack
dirt from all
connectors and Clamp cylinder
fittings. Make manifold valve
certain the threads Adjusting jack
are clean and in manifold
good shape. To
allow hydraulic Pressure gauges
fluid to pass
through the Line from port A
fittings, make Line from port B
certain the fittings
are fully threaded Shim guard
together and are
tight. Handle in neutral
position
Close the clamp cylinder accumulator valve. Open the clamp cylinder manifold valve.
Put the pump handle in position B (see Figure 23) and raise the pressure to 10,000 psi.
This will drive the clamp ring down and away from the bonnet support skirt and
compress the clamp cylinder assemblies.
Notice: Do not use

excessive force Handle in position A Handle in position B
when closing the
clamp cylinder
accumulator valve.
Closing it too
tightly can damage
the seat or twist
off the cap.
Lower the upper section by slowly moving the 3-way control valve on the adjusting
pump to position A.
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Turn off the pump and close the clamp cylinder manifold valve. Disconnect the hoses. CAUTION: Make sure
all workers have
Remove the O-ring from the split coupler. Remove both split coupler halves, shown in
their hands and
Figure 24. fingers out of the
shim area before
Split coupler lowering the upper
section back into
O-ring place.
Upper spherical
seat washer
Upper shim stack
Aligning Washer
Figure 24 - Split coupler
Remove the upper spherical seat washers, the upper shim stacks, and the aligning
washers.
Attach shackles and cables to the bonnet lifting ears. See Figure 25. Lift the upper
section. (If the clamp ring is holding the upper section, it may help to reconnect the
hydraulic pump and pressurize the adjusting jacks.) Lift the upper section slowly until
the bottom edge of the bonnet support clears the top of the cone head and the adjusting
bolts. Move the upper section laterally and place on the ground or other suitable
surface.
Notice: Be sure the

quick couplers are
disconnected from
the manifold
blocks.
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Clamp cylinders
Bonnet support
25" minimum
distance
required to
remove upper
section
Adjusting bolts
Shim stacks
Figure 25 - Lifting the upper section
Remove the lower shim stacks keeping each stack separate. Set aside for later
reassembly.
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Changing manganese bowl liner

Remove the welds holding the bowl wedge stop blocks to the bowl wedges, shown in
Figure 26.
Bowl liner loop
Wedge
Wedge stop block
Figure 26 - Bowl wedge
Drive the wedges out from the manganese loops. If the liner does not drop, drive it
down with a steel bar and a sledge hammer. If attempts to drive out the liner fails, a
manganese press may be used as shown in Figure 27.
Manganese press
Hydraulic jack
Wooden block
Loop eyes
Block
Figure 27 - Manganese press
When the liner has been removed, clean all remnants of the backing material from the
inside of the bonnet. Ensure that the seating surface is clean and smooth. If this seating
surface is severely worn and would prevent the bowl liner from seating level, the
surface should be built up with weld material and re-machined to factory
specifications. Coat the inside of the bonnet down to the bowl liner seat with a thin film
of grease. Use care not to leave excessive amounts of grease, which can cause voids in
the backing material.
Notice: Do not
grease bowl liner
seat.
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Wrap the new bowl liner loops with tape as shown in Figure 28. Inspect the bowl liner
seating surface making sure it is clean and smooth.
Figure 28 - Taping the bowl liner loops
With the new bowl liner sitting on a level surface, lower the upper assembly over the
bowl liner. Raise the new liner into place using a steel ring or beam larger than the liner
feed opening.
Insert the wedges through the liner loop eyes. The loop eyes are tapered so the wedges
must be inserted the way they came out. See Figure 29. Tap the wedges lightly until
the liner is held snugly but not too tightly as the final leveling must take place.
Loop on
manganese
bowl liner
Wedge
Bonnet
Figure 29 - Inserting the bowl wedges
WARNING: Be sure With one person inside the upper assembly checking the evenness of the liner/bowl, a
the bowl liner is second person taps the wedges until the liner is even all around the circumference of
secured from the bonnet. See Figure 30.
falling before
allowing anyone to
climb inside.
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Wedges
Equal all around
Person inside
checking
Figure 30 - Centering the bowl liner
When the liner is in the proper position, drive the wedges tight by striking them Notice: If the bowl
alternately so they tighten up evenly. Alternate from one side to the other as is done liner is not
when tightening lug nuts on an automobile wheel. Use a long, heavy bar as a punch to properly centered,
reach the wedges so there is room to swing a sledge hammer. When the wedges are the crusher will
tight enough, the bar, not the hammer, bounces back. have an uneven
closed side setting.
Weld bowl wedge stop blocks onto the bowl wedges to secure them in place.
Push paper or oakum down around the liner loop eyes to prevent backing material from
flowing out of the top of the pocket. Do not pour the bowl liner until the cone is also
ready to pour.
Changing manganese cone mantle
Remove the mantle nut protector cap bolt, using the allen wrench supplied with the Notice: Do not
machine, and cut the three welds holding the cap to the mantle washer. See Figure 31. remove the cone
Keep the cone head from rotating by placing a bar between a cone strut and a base head from the
frame strut. crusher to change
the mantle. Change
the mantle with
the cone head in
place to prevent
entry of dirt or
possible damage to
the bearings.
Figure 31 - Removing the mantle nut protector cap bolt
Cut the mantle washer using an oxyacetylene torch or an arc-air torch. See Figure 32.
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Notice: If cutting After cutting the mantle washer 360 degrees, the mantle nut should be free to turn.
with an arc-air
torch, electrically
ground the mantle.
To ground the cone
head, replace the
protector cap bolt
and place the allen
wrench in the bolt
head. Attach the
grounding strap to
the allen wrench.
Figure 32 - Cutting the mantle washer
Remove the protector cap bolt and allen wrench if they had been reinstalled.
Insert the mantle nut wrench into the mantle nut and secure with a bolt as shown in
Figure 33.
Figure 33 - Removing the mantle nut
Notice: The mantle Use a heavy sledge hammer to turn the mantle nut clockwise. If the cone head turns
nut has a left-hand freely while loosening the mantle nut, place a bar between a cone strut and the inside
thread. of the base frame.
Prepare the mantle for removal by welding two lifting ears to the manganese mantle.
Make the ears from 1/2" mild steel plate. They each measure 6" by 6", with a 3"
diameter hole. Position the top of the ears level with the top of the mantle. See Figure
34.
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Notice: Ground the

mantle before
doing any welding
to it. Failure to do
so could send an
arc through the
crusher bearings.
Figure 34 - Lifting ears
Weld the lifting ears to the mantle using McKay’s Chrome Mang or an equivalent
product.
Make a first-pass weld on each side of the ears. Repeat for a total of three passes to WARNING: Never
form a 1/4" fillet on each side of the ears. Do not weld across the ends of the ears. Weld use low hydrogen
the second ear 180 degrees apart from the first. or other mild steel
rods or hard facing
Attach a lifting chain to each ear as shown in Figure 34. Lift the old mantle off, rapping rods to weld to
the lower rim if necessary to break it loose from the cone head. manganese steel.
Remove the lifting ears from the mantle for use at a later time. DANGER: Do not
allow anyone to
Installing new liner stand, walk, or
work underneath
Invert and clean the new mantle. To turn the mantle over, rest one edge of the mantle the mantle while it
on a block to provide clearance for a lifting chain. Pass the chain through the hole in is in the air. Severe
the top of the mantle and secure the shackle near the base of the mantle as shown in personal injury or
Figure 35. Take up all slack in the circle of chain. death can occur.
Figure 35 - Inverting the mantle
Lift the mantle to a vertical position. As you lift the mantle, move the chain slightly in WARNING: Do not
a horizontal direction so the base of the mantle pivots in place. Continue moving allow any slack in
horizontally while lowering the mantle to the upside-down position. Rest the chained the chain as the
side on a block. Unfasten the shackle and remove the chain. mantle rolls over.
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Clean the mantle’s cone head seating surface using a scraper to remove all protective
coatings and then sand or grind to assure a smooth, clean surface.
Turn the mantle right side up using the same chaining procedure used to invert the
mantle, but put the shackle on the outside near the center hole of the mantle.
Weld two lifting ears to the new mantle using McKay’s Chrome Mang or an equivalent
product.
WARNING: Never Make a first-pass weld on each side of the ears. Repeat for a total of three passes to
use low hydrogen form a 1/4" fillet on each side of the ears. Do not weld across the ends of the ears. Weld
or other mild steel the second ear 180 degrees apart from the first.
rods or hard facing
rods to weld to Fit a new mantle washer into the top of the mantle. It should fit flat with no gaps. Check
manganese steel. for any interference’s or rocking motion. Enlarge the smaller notch in the top of the
mantle if necessary to get a good fit with the washer lug. Make sure all mating surfaces
are clean and smooth.
Inspect the pour hole in the top of the mantle with the washer in place. Enlarge this
opening if necessary to provide an adequate space to pour the backing material in.
Thoroughly clean the old backing material from the cone head. Clean the cone head
seating surface. Use a scraper, then grind or sand until the surface is clean and smooth.
Coat the outside of the cone head down to the cone seat with a thin film of grease. Use
care not to leave excessive amounts of grease, which can cause voids in the backing
material.
Notice: Do not Attach lifting chains to each of the ears on the mantle.
grease cone seat.
DANGER: Do not Lift the mantle into position over the cone head. Lower the mantle onto the cone head
allow anyone to and bump the mantle with a hammer to center it on the cone head. Remove the lifting
stand, walk, or ears.
work underneath
the mantle while it Put a heavy coat of grease on the inside edge of the mantle hole.
is in the air. Severe Roll foam-rubber into a ring and tape the ends together. Insert the foam-rubber between
personal injury or the mantle and cone head to form a seal. See Figure 36. This will prevent backing
death can occur. material from contacting the mantle hold down nut and allow the nut to tighten as the
mantle wears.
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Mantle nut
Mantle washer
Foam strips
Mantle nut seal
Pour notch
Figure 36 - Foam rubber between the mantle and cone head
Inspect the mantle nut seal (O-ring) and replace if damaged. Apply a coating of anti-
seize lubricant to the O-ring after it is in place. Install the mantle washer. Apply a coat
of grease on the exposed angled surface of the washer.
Lubricate the threads on the mantle hold-down bolt and threads and outside surface of
the mantle hold-down nut using thread grease.
Drive the nut counterclockwise to the point of refusal using the mantle nut wrench and Notice: The mantle
a sledge hammer. See Figure 33. Keep the cone head from rotating by placing a bar nut has left-hand
between a cone strut and a base frame strut. threads.
Center punch a hole on the joint line between the mantle nut and mantle washer. Drill
a small pilot hole. Drill a 1/2" diameter hole 1-1/4" deep parallel to the seat angle of
the nut and washer. Drive a 1/2" diameter pin the full depth of the hole. Cut off any
excess pin protruding from joint. See Figure 37.
Pin
Figure 37 - Locking pin
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Backing material
Prepare the backing material for pouring according to the instructions on the container
label. To minimize waste, pour the liner and mantle at the same time. See Table 3 to
determine the quantity of backing material required for your set of manganese.
CHAMBER TOTAL WEIGHT (POUNDS) LINER MANTLE
Coarse 145 95 50
Medium 140 90 50
Fine 175 85 90
Table 3 - Backing material quantity
WARNING: Wear Build a pouring spout using clay or commercial Damtite around the pour notch in the
protective top of the mantle.
goggles when
mixing or pouring
When pouring backing material into the cone mantle cavity, tap the liner around its
backing material. perimeter with a hammer to help settle the backing material to obtain a denser pour.
Notice: If pouring After completing the pour of the mantle, pour the bowl liner cavity. Pour material in
in cold weather, one spot until the backing material flows into sight. Continue to pour as you move
warm the parts to around the bowl. Stop when the backing material is level with the top of the bonnet or
approximately liner, whichever is lower. See Figure 38.
60oF before
pouring. Cold
weather can
prevent the
Backing material
backing material
from hardening Loop eyes with
properly. wedges in place
Oakum or paper
Figure 38 - Backing material level
After pouring the backing material, you need to replace the mantle nut protector cap on
the mantle. Insert the mantle nut protector cap bolt. Tighten bolt using the allen
wrench.
Attach grounding strap to the allen wrench while it is still in the bolt head.
Weld the mantle nut cap to the washer in three places using McKay’s Chrome Mang
or equivalent. See Figure 39.
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Mantle (top view)
Welds
Mantle washer lug
Mantle washer
Mantle nut cap
Weld
Pour notch
Figure 39 - Position of welds on mantle nut cap to mantle washer
Installing upper assembly Notice: Ground the

mantle before
Attach shackles and cables to the bonnet lifting ears. Lift the upper section slowly until
doing any welding
the bottom edge of the bonnet support clears the top of the cone head and the adjusting
to it. Failure to do
bolts. Move it into position over the lower assembly. The upper and lower halves of the
so could send an
rotation stop block nearest the pinion are marked to maintain proper alignment during arc through the
reassembly. Rotate the upper assembly to align the marks. crusher bearings.
Slowly lower the upper assembly into place, pausing just above the bonnet support. Put DANGER: Do not
the 8 shim stacks in place and then lower the upper assembly until it rests on the shim allow anyone
stacks. Check the closed side setting and adjust. See Figure 40. under the upper
assembly while it is
in the air.
CAUTION: Make sure

all workers have
their hands and
fingers out of the
shim area before
lowering the upper
section back into
place.
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Figure 40 - Lowering upper assembly
Put the O-ring on the aligning washers and anti-seize lubricant on the seats. Replace
the washers, the upper shim stacks, and the upper spherical seat washers. See Figure
41. Install the split couplers and O-rings.
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Split coupler
O-ring
Upper spherical
seat washer
Upper shim stack
Aligning Washer
Figure 41 - Split coupler
Connect the hoses from the Y-27 hydraulic pump as shown in Figure 42.
Clamp cylinder
accumulator valve
Adjusting jack
Clamp cylinder
manifold valve
Adjusting jack
manifold
Pressure gauges
Line from port A
Line from port B
Shim guard
Handle in neutral
position
OM2009704 43
an Astec company
Open the clamp cylinder manifold valve. With the adjusting pump handle in position
A, turn on the pump. See Figure 43. Stop the pump when the pressure reaches 1800 psi.
Open the clamp cylinder accumulator valve. If the pressure drops, turn on the pump
until the pressure is back at 1800 psi. Turn off the pump and close the clamp cylinder
manifold valve.
Move the pump handle to position B to release pressure. Use a pry bar to raise one of
the adjusting jack rams about 2". Disconnect the pump hoses and store the pump. Raise
the shim guard and clamp it.
Attach cables to the hopper lifting eyes and lift it into place. Bolt it down. Replace any
conveyors and supports that had to be moved, and check the that the feed is still correct.
44
an Astec company
CLOSED SIDE SETTING

The closed side setting (CSS) is the minimum distance between the mantle and the
bowl liner. It determines the product size produced by the crusher. It also affects the
crusher’s production capacity, and the selection of mantle and liner.
You can make an approximate determination of your current setting by passing some
easily deformed object, such as a ball of tinfoil, through the crusher when it is running
empty. Attach a piece of string or wire to the ball of foil and holding the string, lower
the ball into the crushing chamber and keep it in the manganese parallel zone for a few
revolutions. Measure the flattened foil to determine your CSS.
The minimum closed side setting is the closest setting the crusher can maintain without
bowl float. Bowl float is hazardous to the integrity of the crusher. Once the minimum
setting has been determined where no bowl float is observed, notify other crusher
operators so that they will not set the crusher below that number. See page 23 in the
Tramp iron relief system section for more information on bowl float.
It is important to note at this time that the conditions at each crushing site determine
the minimum closed side setting. Actual minimum closed side setting and production
numbers will vary from pit to pit and are influenced by such factors as nature of feed
material, ability to screen out fines, manganese condition, and low relief system
pressure.
Capacities
Open circuit capacities in tons-per-hour.
Closed side
1/2" 5/8" 3/4" 7/8" 1" 1-1/4" 1-1/2" 1-3/4" 2"
setting
Gross 125-165 140-195 165-220 180-245 200-270 220-320 240-345 260-365 270-385
throughput
Closed circuit capacities in tons-per-hour.
Closed side setting 1/4" 5/16" 3/8" 1/2" 5/8" 3/4" 7/8" 1"
Recirculating load 15% 15% 16% 20% 20% 20% 26% 28%
Gross throughput 75-90 90-105 115-145 145-190 165-220 185-250 205-275 225-300
Net product 64-77 77-90 97-122 116-152 132-176 148-200 152-204 162-216
OM2009704 45
an Astec company
Gradation chart
Product
Crusher closed side setting
size
5/16" 3/8" 7/16" 1/2" 5/8" 3/4" 7/8" 1" 1-1/4" 1-1/2" 1-3/4" 2"
4" 100
3-1/2" 100 96
3" 100 95 90
2-3/4" 98 92 86
2-1/2" 100 95 88 81
2-1/4" 97 91 83 74
2" 100 94 86 76 65
1-3/4" 100 97 88 79 66 55
1-1/2" 100 96 91 80 68 56 45
1-1/4" 100 97 90 83 70 56 46 38
1" 100 99 90 82 72 58 45 36 29
7/8" 100 99 93 86 74 64 48 38 30 25
3/4" 100 97 94 87 80 65 54 40 32 26 21
5/8" 98 94 87 80 69 55 46 34 28 22 18
1/2" 100 95 88 80 69 58 47 39 28 23 19 16
3/8" 91 84 73 63 52 44 37 28 21 17 14 12
5/16" 85 74 63 54 46 37 31 25 19 15 13 10
1/4" 74 61 50 44 36 32 26 21 16 13 11 9
4M 58 48 42 35 32 26 21 18 14 11 9 7
5/32" 50 41 36 30 28 23 18 15 12 10 8 6
8M 40 35 30 26 24 20 16 12 9 7 5 4
10M 35 31 26 22 20 18 14 10 8 6 4 3
16M 28 24 21 17 15 13 10 8 6 4 3 2
30M 20 18 15 11 9 8 6 5 4 3 2 1.5
40M 18 15 14 10 8 7 5 4 3 2 1.5 1
50M 14 12 12 8 7 6 4 3 2 1.5 1 0.8
100M 11 9 9 7 6 5 4 3 1.5 1 0.5 0.5
200M 8 7 6 6 5 4 3 2 1 0.5 0.5 0.3
Estimated product gradation percentages at setting shown.
46
an Astec company
Selecting closed side setting

The following table shows the relationship of typical input to output sizes for various
chamber (mantle and liner) configurations. The closed side setting shown is for
reference only. Actual minimum closed side setting is the closest setting the crusher
can maintain without bowl float.
Coarse chamber
Medium chamber
Fine chamber
JCI 1200LS CHAMBERS A B CLOSED SIDE SETTING
Coarse chamber 7-1/2" 5" 1"
Medium chamber 4" 2" 3/4"
Fine chamber 2" 1" 3/8"
OM2009704 47
an Astec company
Changing closed side setting

The JCI 1200LS series machine is equipped with stacks of adjusting shims. The
position of these shims determines the size of opening between the mantle and liner and
thus determines product size produced by the machine. The shim stacks are held in
position by the adjusting bolts and clamp cylinders. When the clamp cylinders are
pressurized by the crushers hydraulic system during normal operation, the cylinder
pistons pull up on the adjusting bolts applying a clamping force to the shim stacks and
a squeezing pressure to the clamp ring. The clamp ring keeps the bonnet support
centered which is important to the closed side setting and also provides resistance to
the upper assembly from moving upwards during the crushing action.
To change the closed side setting, the pressure exerted by the clamp cylinders on both
the shim stacks and the clamp ring must be relieved. Using the Y-27 pump, the
adjusting jack cylinders are pressurized to push down on the clamp ring to release its
contact with the bonnet support skirt and to lift the upper assembly off of the shim
stacks. See Figure 44.
Adjusting jack
cylinder
Adjusting bolt
Shim stack
(upper portion)
Brass sleeve
(hidden)
Clamp cylinder
Shim stack (lower

portion)
Figure 44 - Shim stack and adjusting boltHow to change the closed side setting
Lower the shim guard. Plug the Y-27 hydraulic pump unit to an appropriate electrical
outlet. Connect the line from port B to the adjusting jack manifold. Connect the line
from port A to the clamp cylinder manifold valve. Both of these items are located on
the bonnet support flange. See Figure 45.
48
an Astec company
Notice: When
connecting the Y-
Clamp cylinder
27 hydraulic pump
accumulator valve
hoses to the quick
Adjusting jack couplers, be
certain to clean
Clamp cylinder dirt from all
manifold valve connectors and
Adjusting jack
fittings. Make
manifold certain the threads
are clean and in
Pressure gauges good shape. Make
certain the fittings
Line from port A are fully threaded
Line from port B together and are
tight.
Shim guard
Handle in neutral
position
Figure 45 - Connecting the Y-27 pump
Move the pump handle to position A. See Figure 46. Close the accumulator valve at
the bottom of the clamp system accumulator.
OM2009704 49
an Astec company
Notice: Do not use By closing the valve on the accumulator, fluid not required for this operation is trapped
excessive force inside the accumulator and will not have to be replaced later on. Slowly open the clamp
when closing this cylinder manifold valve. Move the handle on the Y-27 hydraulic pump to position B.
valve. Closing too Move the toggle switch on the pump to ON. This will pressurize the adjusting jack
tightly can damage cylinders and extend the rams. Continue to apply pressure until the clamp cylinders are
the valve seat or completely collapsed and the brass sleeve can no longer be seen. Turn the toggle switch
twist off the cap. to the OFF position.
WARNING: The Y-27 Through the above process, the upper assembly has been lifted upward releasing the
pump is capable of clamping pressure on the adjusting shims. The shims are now free and can be moved
producing up to up or down depending on the closed side setting change you wish to make.
10,000 psi of
pressure. Hoses Adjusting shims
and fittings should
be inspected Determine the closed side setting desired.
before attempting
this operation.
Notice: The The shim stacks between the base frame and the bonnet support control the closed side
minimum closed setting. Each of these stacks must contain an equal number of the same color shims to
side setting is the enable the upper assembly to sit flat and maintain a constant closed side setting the full
closest setting the 360 degrees of the crushing chamber. The shims in the upper portion of the stack, those
crusher can on top of the clamp cylinders, do not figure into the closed side setting but are being
maintain without stored there for later use. See Table 4 for thickness of shims in the stacks and their
bowl float. Bowl colors, and the amount of change one can expect if a particular shim is added or
float is hazardous removed from the bottom stacks.
to the well being
of the crusher.
50
an Astec company
APPROXIMATE CHANGE
COLOR NUMBER THICKNESS
IN CSS
Green 1/16" 3/64"
White 1 1/8" 3/32"
Yellow 2 3/16" 9/64"
Black 3 1/4" 3/16"
Red 4 5/16" 15/64"
Blue 5 3/8" 9/32"
Orange 6 1/2" 3/8"
Brown 7 5/8" 15/32"
Purple 8 3/4" 9/16"
Grey 9 7/8" 21/32"
Green 10 1" 3/4"
White 11 1-1/2" 1-1/8"
Table 4 - Shim Thickness
Based on the information found in Table 4, determine which shims needs to be moved.
To decrease the amount of opening in the crushing chamber, remove the appropriate WARNING: Before
shims from the lower shim stacks. Slowly move the pump handle to position A. The lowering the upper
upper assembly should quickly lower onto the shim stacks. Place the shims that were assembly back on
removed from the lower stacks into the upper shim stacks. the shim stacks,
make certain all
To adjust to a wider opening in the crushing chamber, move shims from the upper hands and tools
stacks to the lower stacks. Move the pump handle to position A. This releases the are out of the way.
pressure on the upper shim stacks. Remove the desired shims from the upper stacks.
Move the handle back to position B and jog the pump. This will increase the space
between the bonnet support and the base frame. Insert the shims into the lower stacks.
Move the handle back to position A to re-pressurize the system.
Re-pressurize the adjusting clamp cylinders. With the Y-27 pump handle still at
position A, start the pump and pressurize the system to 1800 psi. Stop the pump when
this value has been reached. Open the relief valve on the clamp system accumulator.
With this valve open, system pressure must still be 1800 psi. If it is not, restart the
pump and continue to run the pump until 1800 psi is reached. Close the clamp cylinder
manifold valve. Move the Y-27 pump handle to position B to depressurize the
hydraulic lines. Using a pry bar, raise one adjusting jack ram 2 inches to allow for
thermal expansion in the hydraulic system. Remove the hydraulic hoses and store the
Y-27 hydraulic pump unit. Place the protective caps on the hydraulic connectors.
OM2009704 51
an Astec company
Clamp system accumulator

Pressure is maintained in the clamp system with the 1 gallon clamp system
accumulator. It is charged with nitrogen to 1000 psi. Since it works with the hydraulic
fluid, the nitrogen pressure can only be checked when the hydraulic system is drained,
so plan service accordingly.
While changing closed side setting, overall clamp cylinder system pressure can be
relieved through the use of the Y-27 pump as described in the preceding pages, or you
can drain the hydraulic fluid through the clamp cylinder manifold valve and the clamp
cylinder accumulator valve.
Once the hydraulic pressure has been relieved, check the accumulator pressure with a
nitrogen pressure gauge, shown attached to the nitrogen charging valve in Figure 47.
Nitrogen pressure
gauge
T-handle
1-gallon accumulator
Clamp cylinder
accumulator valve
Figure 47 - Nitrogen pressure gauge connected to the 1-gallon accumulator
Remove the cap from the nitrogen charging valve, located on the top of the 1-gallon
accumulator, and attach the nitrogen pressure gauge.
WARNING: Wear Tighten the T-handle to open the valve. The pressure should read 1000 psi. Check early
goggles or a face in the day, as pressure goes up with the air temperature. If the pressure is correct, close
shield when the valve and remove the gauge. Re-install the protective cap. Re-charge the clamp
working around cylinder hydraulic system as described in adjusting the closed side setting.
pressurized fluids.
If the pressure is low, the accumulator will need to be charged with nitrogen. If the
pressure reads higher than 1150 psi the accumulator may have a bad port valve spring.
Have an authorized service person check the accumulator. Faulty accumulators can be
dangerous.
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an Astec company
Charging the 1-gallon accumulator DANGER: Do not

attempt to repair
Before charging the accumulator the hydraulic system must be drained as described in
an accumulator
the preceding paragraphs.
without proper
To charge the 1-gallon accumulator with nitrogen requires a full nitrogen bottle and a training.
charging gauge with hose. See Figure 48.
Figure 48 - Charging gauge with hose
Remove the cap from the top of the accumulator and connect the gauge to the nitrogen
charging valve. Tighten the T-handle to open the valve on the accumulator. The gauge
will show the current nitrogen pressure. Open the valve on the nitrogen bottle, and the
gas pressure will rise. Close the valve when it reaches 1000 psi. Loosen the T-handle
on the gauge to close the accumulator valve before removing (or changing) the
nitrogen bottle. Remove the gauge from the accumulator. Put a little silicone sealer on
the edge of the protective cap, to help seal water out of the valve, and replace the cap.
Recharge the hydraulic fluid in the clamp cylinder system as described on page 51.
OM2009704 53
an Astec company
54
an Astec company
CONE BRAKE SYSTEM

The anti-spin brake prevents the cone head from spinning while the crusher is running
empty. Damage to the crusher bearings could result from bringing a spinning cone
head to an abrupt halt. In addition, manganese steel does not hold up well under sliding
abrasion. Its life would be greatly reduced. The brake mechanism allows the cone to
rotate slowly clockwise during crushing but does not allow rotation counterclockwise
at any time. This resistance to spinning is supplied by an overrunning clutch. The
clutch mounts to a guide ring with 3 shear bolts, which in turn mounts to the base frame
spindle.
Operators should include daily checks to make sure the cone head is not spinning. If it
is, investigate the cause at the first opportunity. Replace the bolts if they are found to
be sheared. See Figure 49.
DANGER: Lock out

Cone stem the power source
to the crusher and
Torque bar
related conveyors
before beginning
service.
Floating plate
Brake bar
Upper Key
Brake shaft
Base frame
spindle
Overrunning
clutch
Grade five shear

bolts
Guide ring
Brake cover plate
Figure 49 - Cross-section of the cone brake system
OM2009704 55
an Astec company
56
an Astec company
STORAGE
If the crusher is to sit idle for extended periods of time, steps should be taken to rotate
the bearings to minimize the chance that rust will develop between the bearing rollers
and bearing races. The bearings can be rotated by using the crusher motor or by turning
the crusher sheave by hand. The oil lubrication system should be activated for a
duration of 30 seconds. The above steps should be repeated every 14 days during
crusher inactivity.
TRANSPORT WARNING: Lock out

the power source
When the crusher is to be moved to a new crushing site, the cone head must be blocked
before performing
to prevent damage to the crusher bearings. The roller bearings are designed to handle
any maintenance.
heavy crushing loads but not the sharp impact load caused from the cone head
bouncing during transportation. Moves of even short distances can cause brinelling
marks leading to reduced bearing life. The crusher was shipped from the factory with
transport blocks in place. Use them to block the cone head, or make new ones by
cutting two wedge shaped wooden blocks, each about 30" long, from a 4 by 4.
Place the blocks side by side in the widest part of the opening between the cone mantle
and the bowl liner, and hammer the wedges in place. See Figure 50.
Feed opening
Transport blocks
Figure 50 - Position of the transport blocks
OM2009704 57
an Astec company
58

1200 LSOps

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Crusher Startup Checklist

________________________ ________________________ ___________________________

EQUIPMENT INITIAL INSPECTION CHECKLIST

___ ___ Were any parts missing?

EQUIPMENT SETUP CHECKLIST

___ ___ Was crusher guard(s) in place?

___ ___ Was customer instructed on inspection of wear parts?

___ ___ Was in-feed material centered in feed hopper?

___ ___ Was cone head spinning on startup?

___ ___ Is there a magnet or metal detector installed in the circuit?

Material type __________________ Pit Run/Shot Rock TPH _______ (actual/estimated)

Dealer Rep (print): ___________________________ Date: ________ X____________________________

Customer (print): ____________________________ Date: ________ X____________________________

________________________ ________________________ ___________________________

___ ___ Is crusher guard in place?

___ ___ Is oil level at the full position on the dipstick?

___ ___ Is warning system properly wired in?

___ ___ Is the manganese wearing evenly?

___ ___ Is there any indication of build-up in discharge area?

Tramp Iron relief pressure __________ psi

___ ___ Is in-feed material centered in feed hopper?

___ ___ Is cone head spinning?

___ ___ Is the Crusher correctly balanced and running smoothly?

___ ___ Is the Crusher being choke fed?

Customer Signature ____________________ Company Rep. Signature _______________

________________________ ________________________ ___________________________

___ ___ Is crusher guard in place?

___ ___ Is oil level at the full position on the dipstick?

___ ___ Is warning system properly wired in?

___ ___ Is the manganese wearing evenly?

___ ___ Is there any indication of build-up in discharge area?

…Forms\Crushers\Crusher90insp.doc Page 1 of 2 011300

Tramp Iron relief pressure __________ psi

___ ___ Is in-feed material centered in feed hopper?

___ ___ Is the crusher exhibiting bowl float?

___ ___ Is cone head spinning?

___ ___ Is the Crusher correctly balanced and running smoothly?

Customer Signature ____________________ Company Rep. Signature _______________

…Forms\Crushers\Crusher90insp.doc Page 2 of 2 011300

NEW PARTS AND EQUIPMENT WARRANTY

Oil Fill (not

Figure 1 - Mounting dimensions

Figure 2 - Oil flow

Control feed material velocity

Remove transport blocks

Figure 3 - Location of the transport blocks

Line from port A

Line from port B

Figure 4 - Connecting the Y-27 hydraulic pump

Handle in position A Handle in position B

Figure 5 - Pump handle positions A and B

Figure 6 - Junction box terminal strip

Figure 1 - Typical wiring diagram

Figure 7 - Crusher drive and prelubrication control circuit

Oil flow meter

Oil flow meter wiring is shown in Figure 8. Notice: Always

Figure 8 - Oil flow meter wiring diagram

Figure 9 - Oil heater wiring diagram

START-UP AND MAINTENANCE CHECKLIST

After start-up, running empty

Figure 10 - Cross-section of the 1200LS DANGER: Before

Warning Oil flow Pump Pump Pressure line

Figure 11 - External lubrication panel

___

_ _ Were any parts missing?

_ _ Was crusher guard(s) in place?

_ _ Was customer instructed on inspection of wear parts?

_ _ Was in-feed material centered in feed hopper?

_ _ Was cone head spinning on startup?

_ _ Is there a magnet or metal detector installed in the circuit?

Material type ____________ Pit Run/Shot Rock TPH _ (actual/estimated)

Dealer Rep (print): _ Date: X__

Customer (print): Date: X

___

_ _ Is crusher guard in place?

_ _ Is oil level at the full position on the dipstick?

_ _ Is warning system properly wired in?

_ _ Is the manganese wearing evenly?

_ _ Is there any indication of build-up in discharge area?

_ _ Is in-feed material centered in feed hopper?

_ _ Is cone head spinning?

_ _ Is the Crusher correctly balanced and running smoothly?

_ _ Is the Crusher being choke fed?

Customer Signature ______ Company Rep. Signature _

___

_ _ Is crusher guard in place?

_ _ Is oil level at the full position on the dipstick?

_ _ Is warning system properly wired in?

_ _ Is the manganese wearing evenly?

_ _ Is there any indication of build-up in discharge area?

_ _ Is in-feed material centered in feed hopper?

_ _ Is the crusher exhibiting bowl float?

_ _ Is cone head spinning?

_ _ Is the Crusher correctly balanced and running smoothly?

Customer Signature ______ Company Rep. Signature _