Selecting a primary crusher can have far-reaching and sometimes unexpected consequences. Choose correctly, and material flow from the pit to the plant will most likely proceed efficiently and without excessive maintenance or downtime. Choose incorrectly, and a number of unpleasant consequences can follow. These can range from increased costs due to secondary drilling, blasting and rehandling of rock fragments too big for the crusher, to over-production of troublesome fines that can degrade plant efficiency.

Conversely, changes in upstream conditions — such as modifications to established blasting practices or changes in raw material characteristics — could decrease the performance of even a properly sized crusher. In a stationary application, problems of this type can generally be solved by careful analysis of current mining practices, as well as by mine-to-mill optimization studies. On off-site jobs that require mobile units, adjustments to crusher settings may be the only viable option until the job is completed.

However, when crusher replacement becomes the only alternative to meet performance objectives, manufacturers continue to make it easy to choose the appropriate equipment. In addition to their mature crusher product lines — some of which have been around for several decades — they've introduced a flurry of models that range from compact units designed for mobile applications, to large crushers that are suited for both stationary and mobile settings. Most of these recent products have been in the jaw-crusher sector.

Other recently introduced models from Telsmith and Lippmann-Milwaukee incorporate design changes that also focus on quicker, simpler adjustment features and higher capacity. Lippmann-Milwaukee's line of large-capacity jaw crushers includes models that range from the 63,000-pound 3048 to the 211,500-pound 5062. It offers production ranging from the 200-horsepower 3048's 685 tons per hour at a 10-inch closed-side setting to the 300-horsepower 5062's 1,800 tons per hour at a 16-inch closed-side setting. All models include features designed for long service life including oversized heat-treated eccentric shafts, extra-large radial thrust tapered roller bearings, a robust stress-relieved frame, and hydraulic setting adjustment and overload protection.

Telsmith's model 3258 jaw crusher, for example, employs two oversized hydraulic cylinders behind a traveling toggle beam to make all closed-side setting adjustments — no shims are needed. The crusher's design provides hydraulic release for overload protection and eliminates the tension rod and spring. The 3258's hydraulic system automatically sets the proper tension between the pitman and toggle beam, securing the toggle in place without excessive wear. Telsmith says that it has built in certain features on the 3258 that speed up toggle removal and reduce long-term maintenance. The 60,000-pound unit is powered by a 200-horsepower motor, and offers output ranging from 300 to 485 tons per hour at 3-inch closed-side setting, to 455 to 705 tons per hour at 7-inch closed-side setting.

Metso Minerals' Nordberg C3054 wide jaw crusher was developed to provide high crushing capacity in a unit that can be used in both stationary and mobile applications. The C3054 — latest in the long-running C series — is designed to increase crushing capacity while allowing a reduction in product top size. The C3054's vital statistics include a nominal feed opening of 30 × 54 inches, closed-side setting range of 1½ to 8 inches, crusher speed of 260 rpm, weight of 62,820 pounds, and capacity rating of 660 tons per hour using the maximum closed-side setting.

New design features of the C3054 include:

• A jaw retention system with protection plates behind the jaws.
• Thicker cheek plates.
• An upgraded hydraulic setting djustment system.
• Capability of mounting a hydraulic jack cylinder on the front frame of the crusher to assist with removing the stationary jaw.
• An integral motor base.
• Mounting brackets with rubber dampers and stoppers.

Metso installed the C3054 in its NW3054 mobile jaw plant, a tire-mounted unit with triple axles and air-ride suspension. Set-up and tear-down times are shortened because the feeder hopper and support structure are fitted into a self-contained unit mounted on hydraulic cylinders, which can be raised or lowered into position quickly. Metso's upgraded C145 jaw crusher, which measures 55 inches wide with a 44-inch feed opening, shares design features with the C3054. A hydraulic setting adjustment is used to move the setting wedges, eliminating any need for shims and reducing the time to accomplish the adjustment. A new hydraulic tension rod holds the toggle plate in place, a new mounting system speeds installation, and improved damping allows the C145 to run more smoothly than its predecessor.

As an example of the compact-mobile variety, Fintec recently introduced to the North American market the Fintec 1107, a track-mounted primary-crushing unit equipped with Sandvik's J11 single-toggle jaw crusher. Fintec says the 1107 is designed for recycling and contract crushing, but a wider range of applications is possible when the machine is combined with screening units.

Sandvik owns 49% of Fintec, and the 1107 was jointly designed by the venture partners. Throughput of the machine is rated at 80 to 400 tons per hour, with a feed opening of 44 × 28 inches. The 1107 also has a heavy-duty Sandvik feeder and a three-ply, extra heavy-duty main conveyor. The unit's 50-ton nominal weight allows it to be transported on a low-bed trailer.

The 31,500-pound crusher is powered by a 125-horsepower motor and allows the user to interchange the fixed and swing jaw. It also features pre-drilled, threaded and bolted holes that allow customers to tailor the machine to specific requirements by adjusting or adding optional equipment. These adjustments and optional features include:

• Alternative mounting points to install the crusher at different inclinations to fit an existing chassis.
• A wedge-type setting system that offers push-button control for setting regulation.
• An hydraulic control unit that integrates the crusher's setting system into an existing system.
• A deflector plate to protect the conveyor belt against rebar damage.
• An extra shim plate to decrease the nip angle.
• An integrated motor bracket that saves space and ensures that the motor and crusher move as a single unit.

Earlier this year, Terex Pegson launched its X400 crushing plant. This model was initially introduced into Europe and was scheduled for global availability later this year. The X400 series is available in both hydraulic-adjustable (XA400) and hydraulic-release (XR400) versions.

Pegson says the XA400 has an aggressive crushing action with hydraulic crusher-setting adjustment. The high-swing jaw eases material entry into the crushing chamber and the hydraulic adjustment allows for quick changes to the crusher setting over a wide range. The adjustment is activated without the need to release the drawback mechanism and this system is particularly suitable for applications where regular jaw-setting adjustments are required.

The XR400 with hydraulic release has been specifically designed to alleviate problems associated with crusher overload, which can be encountered when tramp metal enters the crushing process. The hydraulic-release feature is fully adjustable, quick and easy to reset, and makes blockage clearance a simple process.

Additional features on the X400 series include a hydraulically folding feed hopper constructed of 15-millimeter Hardox steel for extended service life; a newly designed crusher drive access system; an easy-access power-pack canopy; 2,000-hour hydraulic and oil filter change intervals; and improved under-crusher access provided by a hydraulic tilting conveyor system. Options on the X400 series include a dirt conveyor with a new troughing system, over-band magnet, radio remote control and under-feeder screen.

The X400 series' introduction followed Terex Pegson's release of the tracked 1165 HA Premiertrak crusher with hydraulic setting adjustment, and the 1165 HR Premiertrak with a hydraulic release system. According to the company, the 1165 HA is a high-output, hydraulically adjustable version of the M series single-toggle jaw crusher. The hydraulic-release version of the 1165 is designed for applications in which tramp metal or rebar (maximum length of 8 inches) may enter the crushing chamber. This plant also has a hydraulic setting adjustment system similar to the 1165 HA.

The company also upgraded its 24- × 36-inch Metrotrak M series single-toggle jaw crusher and claims the aggressive crushing action of the newer, bigger Metrotrak enables high output in recycling and aggregates applications, even at tight settings. The tracked unit allows fast setup and is built for long service life, with a heavy-duty chassis and track frame.

Standard equipment includes a two-step, self-cleaning grizzly with under-screen option; a fully skirted product conveyor; grizzly bypass and fines chute; dust-suppression sprays; and an hydraulic folding Hardox feed hopper that measures 13 feet 2 inches long by 5 feet 11 inches wide, with capacity up to 4.7 cubic yards. Also standard are a magnetic separator, radio remote control, hydraulic adjustment of the crusher setting, and hydraulic folding dirt and side conveyor. The Metrotrak M is powered by a Caterpillar 3126 diesel engine generating 175 horsepower at 1,800 rpm.

Reader Service

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Name	RSN
Astec Mobile Screens	176
Fintec	177
Lippmann-Milwaukee	178
Metso Minerals	179
Telsmith	180
Terex Pegson	181