PE (X) Jaw Crusher

Shanghai Zenith Mining and Construction Machinery Co.,Ltd

 We
We Pursue
Pursue the
the Zenith
Zenith of
of
Technology
Technology and
and Quality
Quality

Shanghai Zenith Mining and Construction Machinery Co.,Ltd

Add: No.416 Jianye Road,South Jinqiao Area,
Pudong New District,Shanghai,China
Telesales: 021-58386256 58386258
After-sale phone: 021-58385616
Fax: 021-58385887
P. C : 201201 1008-V1-P2
Preface ..............................................................................................................1

Product Characteristic ........................................................................................1

Product Application .............................................................................................1

Specifications and Technical Parameter .............................................................2

Structure Description and Assembly ...................................................................3

Installation Operation and Maintenance ............................................................10

Safety Regulation for Operation .......................................................................16

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PE (X) JAW CRUSHER

Please read the user manual carefully before operation

Warning: * Please read the user manual carefully before using the machine
* Please preserve this instruction and documents of the machine
I. Preface

Thanks for choosing and using “Zenith’s product, which are excellent in quality and performance, in order

to facilitate your use, please read the manual carefully, and operate as per the manual.

In order to ensure your service information is dealt with in time, please contact in our factory’s hot-line, our

factory will offer the unified and standard service.

After the installation and commissioning by technician, please fill in “Service Feedback Report”, if you are

dissatisfied with the service, please feedback to our factory directly. Our factory will deal with in time, and

guarantee your satisfaction.

From the beginning to the end, the satisfactory service of “Zenith” will follow you, thank you for using the

products of our company again. The improvement of our products is continuous, so maybe there will be some

changes of specification without notice.

II. Product characteristic

High reduction ratio Simple structure Reliable operation Convenient maintenance.

III. Product application

PE(X) series Jaw crusher, whose size reduction ratio up to 4—6 and the final products are even, can be

widely used in crushing hard, medium-hard, soft ore, and various kinds of ore, the solvent, slag, building

stones, marble, etc. Compression strength does not exceed 320 Pa. This machine is suitable for mining,

building construction, highway, railway, water conservancy and chemical industry.

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PE (X) JAW CRUSHER

IV. Specifications and technical parameter

Name and Model 400×600 600×900 500×750 750×1060

Feed Opening
600×400 900×600 750×500 1060×750
˄mm˅

Max.Feed Size
350 480 425 630
˄mm˅
Range of Discharge
Opening 40-100 75-200 50-100 80-140
˄mm˅

Speed of Mainshaft
250 250 250 250
(r/min)
Capacity (t/h) 15-50 45-110 45-100 105-195
Model for Motor Y225m-6 Y280m-6 Y280M-6 Y315S-8
Motor Power
(KW) 30 55 55 110

Dimension(length,
width, height) 1732×1656×1586 1840×2305×2298 1890×1916×1020 2472×2450×2848
˄mm˅
Weight ˄mm˅ 6.5 15.5 4.9 28

Name and Model 900×1200 1000×1200 250×1000 250×1200

Feed Opening
1200×900 1200×900 1000×250 1200×250
˄mm˅

Max.Feed Size
750 850 210 210
˄mm˅
Range of Discharge
Opening 95-165 192-265 25-60 25-60
˄mm˅

Speed of Mainshaft 250 250 330 330

(r/min)
Capacity (t/h) 220-450 315-550 15-50 20-60
Model for Motor JR3 126-8 Y315S-8 Y225M-6 Y225M-6
Motor Power
(KW) 110 110 30 37

Dimension(length,
width, height) 3800×3166×3045 3800×3166×3045 1992×1964×1870 2192×1900×1950
˄mm˅
Weight ˄mm˅ 52 57 10.1 7.7

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PE (X) JAW CRUSHER

V. Structure description and assembly

4 3 2 1 12 11 10 9 8

5 6 7
Diagram 1 Structure of Jaw Crusher
1. Fixed jaw plate 2. Side plate（Up）　 　3. Movable jaw plate 4. Jaw 5.Toggle Plate
6. Tension device（spring and tension rod） 7. Side plate（lower） 8. Pulley 9.Bearing
10.Bearing 11.Eccentric Shaft 12. Fly wheel
Jaw Crusher uses motor as its power. Through the motor’s wheels, the eccentric shaft is driven by V-belt and
groove wheel to make the movable jaw move by a regulated track. Therefore, the materials in the chamber that
consists of fixed jaw, movable jaw and side- plate can be crushed and discharged through the discharge opening.
1. The frame
The frame of jaw crusher has heavily impulsive load during work. So it must be of high intensity and
rigidity. The frame is welded (the small jaw crusher is cast -steel). The fixed jaw fastening by high-strength
bolt is installed at the front frame. The up and lower side-plate is installed at the left and right side of the
frame.

2. The movable jaw

(1) Structure characteristic
Movable jaw is made of high-quality casting steel. Its holes and troughs are made through
precision machining and tested strictly, which can make sure that they can work safe and credible.
The eccentric shaft is made of the excellent forging steel. Its precision machining, heat treatment
and inspection make it be of high intensity and rigidity.
Bearing adopts four sets self-aligning roller bearing and it has excellent loading capacity and auto
self-aligning performance.

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Both the fixed and movable jaw is made of high-quality manganese-steel. In order to extend
its working time, it is designed symmetrically. So if one end is frayed, an other end also can
be used. Flywheel and groove wheel are made of good casting iron. Their weight and structure
can ensure the crusher work balanceable. The flywheel on the eccentric shaft can be exchanged
and connected by the power lock.
(2) Installation of the movable jaw parts
a. Installation of the eccentric shaft subassembly.
The eccentric shaft and the bearing must be washed by karaffin oil, then install the Oil Partition
at two ends of the eccentric shaft. Put the two bearings into the oil of 80-100 degree for 15
minutes. When the hole is bigger than the eccentric shaft at 0.15, then put it on the ends of the
eccentric shaft pressure the bearing so it would close to the shoulder of bearing, until the bearing
become cool, the clearance must be lower than 0.05mm. After clearing, you should put grease at
50 percent to 70 percent.

1.Eccentric Shaft

2.Installation of Oil Partition

3. Installation of Bearing

4.Diagram After above Step 3

Diagram 2 Installation Process of Eccentric Shaft Subassembly

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PE (X) JAW CRUSHER

b. Install eccentric shaft into movable jaw

After fasten the unclosed cap and the paper gasket into the movable jaw with bolts, make sure
the end down with the unclosed cap. Then put the eccentric shaft parts into the movable jaw.
When lift it please pay attention to make sure that the eccentric shaft and the movable jaw’s
center line be consistent. Put the bearing sleeve well slightly, then strike and press gradually
when the pressing amount is even. (do not hammer the bearing directly, put copper bar on the
bearing and hammer the cooper bar), The procedure is the same as pressing the second bearing
after the first one bears pressure, then pour into 50%-70% lubricating grease in the bearing,
afterwards put on another side unclosed cap, paper gasket, etc., fasten with bolts, and should
also make bearing outer surface with cover surface have 0.2~0.4 gap.

unclosed cap eccentric shaft

subassembly

1.install unclosed cap on one end of 2.install eccentric shaft subassembly

movable jaw palte into the movable jaw plate

XQFORVHG
FDS

4.complete the installation 3.install unclosed cap on the

other end of movable jaw plate

Diagram 3 Install Jaw Crusher Subassembly into Jaw Crusher Hole

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PE (X) JAW CRUSHER

c. Install of external bearing

Put every key into the keyway of eccentric shaft, then pack the cover of inner loop of
the maze, pay attention to the direction, fetch other two bearings, wash clean with the
kerosene, put the adapter sleeve into the hole of the bearing, install on the eccentric shaft,
fasten into the round nut according to the structure chart. Note that the whorl is on the
eccentric shaft, with the purpose that eccentric shaft can m a ke round nut fasten urgent
when rotating Fasten the round nut on the eccentric shaft first, make inner ring of the
bearing close to the sealed ring, repeated for several times, make the axle bush fasten
finally and make round nut of bush withdraw, make the interval between round nut and
inner circle is about 1mm. Press the lon g - short teeth of gasket into the slot of round
nut and fasten them, then pour 50%¬70% lubricant into bearing, then put into the inner
loop of the cover respectively.

the cover of inner bearing eccentric shaft

loop of the maze XSSHUURXQGQXW

adapter sleeve adapter sleeve XSSHU

URXQGQXW

Diagram 4 Installation of external bearing

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PE (X) JAW CRUSHER

d. Installation of flywheel and grooved pulley

Put flywheel, grooved pulley and power lock on the eccentric shaft and have flywheel, grooved
pulley close to sealed ring. Then fasten the bolt of power lock after making sure that the mark
of flywheel and grooved pulley be correspond to the mark of eccentric shaft. Installation of
power lock follows this instruction, then install shaft end baffle ring. (note: flywheel and
grooved pulley are cast iron parts, avoid heat when installation). A routine is to install grooved
pulley on the left end of eccentric shaft (face to feed opening), and also can exchange groove
pulley’s position according to spot’s requirement.

power lock

1.lift the pulley(flywheel) 2.press the power lock into the

on the eccentric shaft eccentric shaft
˄loseen the bolt of power lock˅

Lock ring

3.tight the bolt of power lock to fasten the pulley(flywheel),

then installa lock ring at the end of shaft

Diagram5 installation of pulley and flywheel(include power lock)

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PE (X) JAW CRUSHER

3. The toggle plate and adjustment parts

(1) The toggle plate is made of accurate casting iron. It is not only the component that spreads the strength,
but also the insurance part of crusher, the toggle will break up immediately and the crusher will stop
working when some unbreakable materials go into the crusher. Toggle and toggle mat adopt rolling
contact way, which can reduce attrition during the normal operation, so the user only needs to put
some lubrication grease on the contact surface. Change the toggle plate as soon as it’s broken, and
the change method please see diagram 6
(2) Adjusting parts are used for adjusting the discharge size and reducing the attrition among jaw plate,
toggle plate and shim.
Note: Make sure that there is lifting device and reinforcing wire before change the toggle plate.

1. Hanging the end of movable jaw with 2.start crane installationēmake the
reinforcing wire ēthe upper end of

Diagram6 installation the toggle plate

movable jaw plate rotating slowly till it
reinforcing wire hanging on the suspender next to fixed jaw plate tightly
of lifting equioment

3.take off adjusting device 4.install the new toggle plate

and tension device at the right place

5.install adjusting device and 6.put down the movable jaw

tension device slowlyēlet the toggle plate tight at
both ends and adjust tension device
appropriately.

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PE (X) JAW CRUSHER

(3) Adjustment of discharge opening

The shims are fixed on adjusting base or movable jaw by angle steel and bolts; shims are between
adjusting base and frame, above supporting frame; lifting bolt (or header and hydraulic jack) push
adjusting base through bolt or shim, adjusting base connects with frame directly or through wedge,
lifting bolt or heading and hydraulic jack can play adjusting role independently.
When adjusting and arranging the discharge opening, unscrew the nut of tension rod which strains
the part appropriately at first, unclamp spring, unclamp wedge a bolt, unclamp the wedge one, tighten
the jack bolt, it push forward the toggle seat and achieve some space, then take out the shim reaching
the needs of discharging opening; if add more shim, it can reduce the opening; when reaching the
needs, unscrew the jack bolt and the toggle seat with shims will be back to the frame under the weight
of movable jaw. Pls note that the toggle seats should not contact with frame, then tighten the bolts and
firm the framework, tighten the tension rod nut appropriately and tighten up the spring, namely finish
adjustment.

2.loosen strain wedge bolt

loosen wedge
3.turning lifting bolt
impulse lifting adjusting
base

4.add or reduce gasket

1.loosen the bolt properly

loosen the spring and
tension rod
adjusting base toggle plate

Diagram 7Adjustment of Discharge Opening

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PE (X) JAW CRUSHER

4. The tension part

It is used for guaranteeing the combination of whole configuration closely and balancing the mass force
in working time.
The assembling process:
The end of tension rod connects to the earring on the low part of movable jaw plate, another end is on
the low part of rear frame through washers. The spring is clamped by the washers and nuts of two sides.
It needs some pretightening force when crusher works to avoid the draw down. But the force can’t be
so big that the spring fracture.
5. The rail
The rail is fastened on the basis of reinforced concrete through the foundation bolts. Motor is installed on
the rail, the motor base imbeds in the rail, adjust the distance from crusher according to the length of
V belt. When the distance is confirmed, use the adjusting
rod to fasten the motor base.
6. Safety device.
Safety devices are made and installed on working site with relative mark.

VI. Installation Operation and Maintenance

1) Installation Jaw Crusher
This machine is the big machine which is assembled by factory and shipped by parts after trial run
without load. The user must check the amount after receiving this product so as to discover some
problems form transportation.
1） Because this machine vibrates largely when working, it must install on the ferroconcrete foundation.
The weight of the foundation is 8-10 times than the machine. The depth of foundation must be bigger
than the depth of freeze ground. The dimension and other data on the foundation drawing are for
reference, not the construction drawing. It must set aside the preformed hole in order to install the
ground bolts. The height of chute of discharge opening is up to the situation of location.
2） In order to lighten vibration, put not less than 10mm rubber as amortize cushion between crusher
and concrete foundation when installation. After the cement curdle of second grouting, please screw
down ground bolts. In this process you should determine level degree with gradienter, make sure the
difference of level degree below 2mm. Machine frame’s level degree is very important, it can avoid
the occurrence unilateral feeding in working, and avoid the damage due to uneven burden.
3） When install the motor, check the distance to the main unit, and ensure the center of motor wheel
and center of groove wheel are parallel.
4） The size of discharge opening is adjusted as the need sizes and capacity. Dismantle spring before
adjusting discharge opening. After adjustment, properly adjust spring tighten degree in case of draw.
Details see adjusting part.

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2) Operation Jaw Crusher

After installment and adjustment, you can do trial run:
1. Trial run without load
a. Continuous running 2 hour, bearing temperature increase less than 30C
b. All fasteners must be tight.
c. Flywheel and grooved pulley run smoothly.
d. No abrasion, filings and attrition in all friction parts, no abnormal noise.
e. The range of discharge opening is according to the specification.
2. Trial run with load.
Do trial run with load after first successful trial run.
a. No periodical or obvious impact sound in crusher.
b. The biggest size of the feeding material must accord to specification.
c. Constant running 8 hours for the first time, bearing temperature increase no more than 30C
3. The checking before the start-up
1） Check-up the lubrication of bearing, toggle plate and movable jaw, check the contact situation of
toggle plates gasket, and check if there is enough lube between toggle plate and toggle plate gasket.
2） Adjust all fasteners firmly.
3） Check if flywheel and groove pulley’s center position are right. The center of flywheel shaft is on
same line (180 degrees) with pulley’s shaft center.
4） Check if the transmission belt is installed right, if there is some attrition, change it in time. Clean
the belt and wheel if they are dirty.
5） Check if safety device is ok or not, if there is any insecurity; clear it as soon as possible.
6） Ensure crusher chamber hasn’t any material and other things.
7） Ensure the shims are installed rightly and compactly.
4. Start-up of the crusher
(1) You can start-up after ensuring the machine ad transmission parts are all right.
(2) This machine must start-up without feeding.
(3) Stop the machine if it’s abnormal. After solving the problem, you can start-up the crusher.
5. Usage of the crusher
1) Begin to feed materials after running well.
2) Feed materials to crushing chamber evenly, avoid side feeding or stack feeding in case of unilateral
overload, load sudden change or block.
3) Stop feeding before stop the crusher, after all the material is discharged, switch off the motor.
4) Crusher stops due to block inside, switch off motor immediately, start the crusher after remove all
the materials.
5) If one end of the fixed jaw plate and movable plate is worn-out, reverse and use another end.
6) Fasten all parts periodically.

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3) Operation Jaw Crusher

1. Lubrication
1) To guarantee normal operation of machine and lengthen service life, add grease periodically.
2) Grease in bearing housing takes 50-70% of total volume, change once every 3-6 months. Wash the
inside of bearing with clean petrol or kerosene when change grease, Open oil outlet hole under
bearing housing when washing.
3) The grease depends on local area, and weather condition. Generally use calcium base, sodium base
or calcium sodium base grease. When the grease is dry, pls mix with thin oil.
4) Add grease on the connection surface of toggle pad and toggle plate only when assembling or
overhauling.
5) The lubrication points are the places through which you put the grease into the machine conveniently.
This machine has four Lubrication points on the bearings. (See Diagram 8)

Molybdenum disulfide complex calcium-based grease (No.3)

add every eight hours change every three month

Diagram 8 Lubrication Position and Lubrication Grease

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2. Normal trouble and trouble shooting

Trouble Main reason Trouble shooting

1.Spring broken 1.change Spring
1.The flywheel reverse, crushing stops,
2. tension rod broken 2.change tension rod
the toggle plate draw down
3. toggle plate broken 3.change toggle plate
1.Set bolt of crushing plate loose 1.Fastenning the set bolt, change it
2.The broken board shakes,
2.Set bolt of crushing if anti-loose spring not works well
produce strike sound
plate ruptures 2.Change set bolt of crushing plate
1. Tighten the spring or change the
1. The spring doesn’t strain enough
spring
2. The seat is worn and torn or loose
3.Bump sound or other abnormal 2. Change the toggle seat
3. The end of toggle plate is worn
sound from toggle seats 3. Change toggle plate, re-adjust
4. Adjusting device of discharge opening
adjusting device
not adjusted even

1. The key is cooperated too loose, the key
4.The flywheel loose and keyway are worn and torn
2. lock device of shaft end is loose
5.Output size increases Bottom of jaw plate is worn seriously
1. Big stone enter the side of crushing
chamber, cannot be crushed.
6.Crushing chamber blocked,
2. Trouble in belt conveyor that under
electric current of the main motor is
crusher, discharge opening blocked
higher than normal electric
3. Viscous and other things block
current
discharge opening
4. Over feeding
1. The lubricant is insufficient
7.Bearing temperature is too high 2. The lubricant is dirty
3. Bearing damaged
Tighten key, or open keyway and
change key, lock axle end device
tight
Adjust discharge opening small, if
not ok, exchange jaw plate ends or
change new jaw plate
1. Stop crusher, fasten the stone with
steel wire and hang out with crane.
2. Stop feeding, get rid of belt machine
trouble, don’t stop crusher if not
necessary
3. Stopping feeding, clear discharge
opening, don’t stop crusher if possible
4. Adjust down rotation speed of the
feeder, reduce feeding amount
1. add lubricant as needed
2. Clean bearing and change
lubricant
3. change bearing

3. Wearing part
6 3 5 8

7
9

1 2 4
Diagram 9 Wearing Parts Position

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Details of Wearing Parts˖

NO. Name Picture Useful Life Material 　

1 6

2 6

3 4

4 4

5 4

6 4

7 2 　

8 6

9 4

Note: 1.The above useful life is based on theory; please change them according to your actual situation timely.
2. Different model of the jaw crushers, the wearing parts maybe different, please refer to actual appearance.

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PE (X) JAW CRUSHER

MAINTENANCE REQUIREMENT

MAINTENANCE REQUIREMENT AS NEEDED MONTHLY WEEKLY DAILY

Check that the dies are tight and are not worn too thin. ƹ

Check that the cheek plates are tight and are not worn
ƹ
too thin.

Check the discharge chute to ensure it is clear of

ƹ
debris,steel,slabs,etc.

Inspect all the bolts to see if they are tight. ƹ

Inspect the toggle plate stops ƹ

Check the toggle plates for cracks ƹ

Check the toggle springs, make sure they are not

ƹ
broken and are adjusted equally.

Listen to the crusher running empty. Tighten toggle

ƹ
springs if a thumping sound is heard.

Check the flywheels for cracks. ƹ

Check the coast down time at the end of each day, log
ƹ
in the equipment file and watch for downward trends

Check the bearing temperatures periodically. Log in

ƹ
the equipment file and watch for upward trends.

Check that the belts are tight and not worn. ƹ

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PE (X) JAW CRUSHER

VII. Safety Regulation for Operation

User can operate the machine after safety training

Read and understand instruction manual before using or maintaining this

machine.
Failure to follow operating instructions may result in death or serious injury.

Risk of head injury.

Use of a helmet required.

Lubrication

Lifting position

Moving parts can crush and cut. Do not insert tools in the crusher cavity
when the motor is running.

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Jaw Crusher indicative gradation curves

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