Terex C1540 Cone Crusher Operation Manual

The Terex C1540 Cone Crusher is engineered for precise crushing and consistent output in quarry and aggregate operations. This Operation Manual explains feed control, cone chamber behavior, hydraulic adjustment, tramp release mechanisms, and conveyor operation. Operators gain insight into how material flow, chamber pressure, and cone speed interact to determine final product size.

Applications & Use Cases

Daily startup and shutdown routines
Adjusting cone settings for different material profiles
Monitoring chamber pressure and wear indicators
Diagnosing feed irregularities or output size issues
Ensuring proper lubrication and cooling flow

FAQ
Does the manual cover hydraulic adjustment systems?
Yes, with step-by-step operation guidance.

Is it useful for new crusher operators?
Very. It explains how the crusher responds to load changes.

Safety Note
Never attempt to clear blockages manually; use the chamber release system as instructed.

📘 Show Index

Terex C1540 Cone Crusher Index:

SECTION 1 : SAFETY
SAFETY INTRODUCTION
SAFETY SIGNS ON YOUR MACHINE ………………………..
WORKAREA SAFETY
HYDRAULIC
ELECTRICALAND ENGINE SAFETY ….. ..
SAFETY BEFOREAND DURING OPERATION ……….„ ..
SAFETYBEFOREANDDURING …
SAFETY BEFOREAND DURING TRANSPORT …………………………….
INFORMATION SIGNS……
REMOTE STOPS ON YOUR MACHINE
SAFETY GUARDS ON YOUR
NOISE LEVELS AROUND YOUR
SECTION 2 : TECHNICAL INFORMATION
FAMILIARISATION..„ .
KEY COMPONENTS ………………„..
TECHNICAL .
GLOSSARY OF CONE PARTS …..
MACHINE CONTROLS
TRANSPORT POSITION …„……..
WORKING POSITION DIMENSIONS
CORRECT USE OF MACHINE
SECTION 3: INSTALLATION ..m
SAFETY INTRODUCTION ………… .
STARTING ENGINE
ENGINE INFORMATION DISPLAY
TRACKING
TRACKING USING REMOTE HANDSET (Option)…………………….
TRACKING USING WANDERLEAD
FEEDER SKIRTING EXTENSIONS..
PLACING WARNING BEACON INTO WORKING POSITION.
PLACING FEEDER INTO WORKING POSITION.
SETUP FOR PRE-SCREEN (OPTION).
PLACING THE CONE SENSOR INTO THE WORKING POSITION.
DUST SUPPRESSION
FITTING ACCESS ..
METAL PURGE
PRIOR TO WELDING

SECTION 4 : OPERATION ………………..„
SAFETY INTRODUCTION .
SAFETY BEFORE AND DURING OPERATION………………..
SAFE OPERATION OF THE CONE UNIT ………….
CONE OPERATION .
CRUSHING MODES……….
PRE-OPERATION CHECK…………..
CONE SETUP .
CONE spEED
AUTOSET/ MAXSET
OPERATING MACHINE .
MANUAL PLANT MODE
AUTO MODE…………………………………….
INITIAL START-UPAND RUNNING
STOPPING THE MACHINE ……….
METAL DETECTION .
BLOCKED CRUSHER PROCEDURES ………..
DETACHING THE SCREENAND FINES PROCEDURE
ATTACHING THE SCREEN AND FINES PROCEDURE …„…..
SECTION 5 :
SAFE-TYINTRODUCTION…………….
SAFETYBEFOREAND DURING MAINTENANCE …….
HYDRAULIC SAFETY……………………………..„…
ELECTRICALAND ENGINE SAFETY ..
WEIGHT OF CRUSHING COMPONENTS …………………. …….„ .
HYDRAULIC SYSTEM…….
HYDRAULIC
FILTRATION
LUBRICATION .„..
BELT
BELTADJUSTMENT ON MAIN
BELTADJUSTMENT ON FEED CONVEYOR
BELTADJUSTMENT ON FINES CONVEYOR …
BELT ADJUSTMENT ON OVERSIZE, MIDDLE & RECIRC CONVEYOR „
CHANGING PRESCREEN MESHES..
LOWERING SCREEN PRIOR TO CHANGING MESHES ….„…
CHANGING SCREEN MESHES…CHANGING HYDRAULIC FILTERS & OIL …..
CHANGING LUBRICATION SUCTION FILTERS & OIL
DIESEL ENGINE
CHANGING ENGINE FILTERS & OIL
CHANGING FEEDER GEARBOX
TRACK MAINTENANCE ………………
CRUSHER MAINTENANCE…
CHANGING THE .
WEDGE RING
OUT OF ROUND MANGANESE – CAUSES AND EFFECTS ………….. ..
METAL DETECTOR MAINTENANCE…..
HYDRAULIC .
RECOMMENDED LUBRICANTS
GREASING
MAINTENANCE ..
SECTION 6 : TRANSPORT
SAFETY BEFOREAND DURING TRANSPORT
STOPPING THE
PREPARING FOR .
METAL PURGE CHUTE
ACCESS UDDER…
DUST SUPPRESSION
PLACING CONE SENSOR INTO TRANSPORT POSITION
PLACING WARNING BEACON INTO TRANSPORT POSITION
FEEDER SKIRTING EXTENSIONS.
PLACING FEEDER INTO TRANSPORT POSITION…………………………„..
PLACING PRE-SCREEN INTO TRANSPORT POSITION (OPTION). ..
PLACING FINES INTO TRANSPORT POSITION (OPTION) .
PLACING SCREEN INTO TRANSPORT POSmON (OPTION) …
PLACING OVERSIZE CONVEYOR INTO TRANSPORT POSITION ………
PLACING RECIRCULATING CONVEYOR INTO TRANSPORT
POSITION
MIDDLEGRADE CHUTES-NON DISCHARGE CONVEYOR SIDE
READY FOR TRANSPORT
PRIOR TO HAULAGE