Document No.

D01081800032

Document version 1

HPT
HPT Series Multiple Cylinder Cone Crusher(01)

User Manual

Edit
Check
Auditing
Standardization

Notice:
 Due to the product update or other issues, this file may renew constantly. This file is for
installation references only, unless otherwise specified. All the statements、
information and advice within this file don’t constitute any express or implied
guarantees.

 We are free of responsibilities to any equipment losses or personnel injuries caused by

without following the instructions of this manual book.
 Foreword
This instruction manual works as the guidance for cone crusher operational personnel for
the first time, meanwhile it will work also as a technical reference for a mature crusher operator.
Please read-analyze-and keep it for further reference.
The illustrations and instructions in the manual can guide operator to examine, install,
operate and maintain the crusher as its accessories by correct procedure. Besides the main
manual for cone crusher, individual instructions for accessories as lubrication system, hydraulic
system and crusher drive system also give out thorough explanation.
What this manual offers is ground basic operation method, operation skill and other skills
need operators to develop after fully grasp the gist of the crusher and fully understanding of its
traits. As the product are ceaselessly developing and update, which might brought some
uncovered change in the manual, but, we insist constantly examining, revising and adding and
updating what is necessary for the newest version.
The description and technic in this manual are valid during printing period, Kefid
Mechanical retain the authority right to put in new model, and changing technic traits and
design, while without notice ahead and avoiding corresponding responsibility generated by this
gesture. If you have any questions regarding to your crusher and the very version of manual,
please enquiry us Kefid Mechanical for further information.
This manual has provided comprehensive guide on related technical details. All the
necessary correct crushing installation technical information must come from the installation
drawing and technical data we provided.

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 CATALOGUE
HPT Series Multiple Cylinder Cone Crusher
Maintenance guide book
Chapter 1 Safety
1.1 personal safety...........................................................................................................................................7
1.1.1 general rules...................................................................................................................................7
1.1.2 against the rainy day / nip it in the bud！.....................................................................................7
1.1.3 are youfamiliar with the factory safety proticol？........................................................................ 7
1.1.4 is your dressing up to the work requests？.................................................................................. 7
1.1.5 are you familiar with your machine？...........................................................................................8
1.1.6 are you familiar with the work site？............................................................................................8
1.1.7 are you prepared for the underlying accidents?........................................................................... 8
1.1.8 examine before start...................................................................................................................... 8
1.1.9 safe boot.........................................................................................................................................9
1.1.10 report machinery breakdown...................................................................................................... 9
1.1.11safe shut-down............................................................................................................................10
1.2 safety maintenance gist........................................................................................................................... 10
1.2.1 read and comprehend..................................................................................................................10
1.2.2 warning sign................................................................................................................................. 10
1.2.3 power off......................................................................................................................................10
1.2.4 dress code -- safe operation.........................................................................................................10
1.2.5 pick-me-updrink and drug is forbad............................................................................................ 11
1.2.6 working area.................................................................................................................................11
1.2.7 equipment....................................................................................................................................11
1.2.8 fire prevention proticol................................................................................................................ 12
1.2.9 pressure increase system – hydraulic pressure or air pressure.................................................. 12
1.2.10 choose good quality accessory.................................................................................................. 12
1.2.11 report necessary repair items....................................................................................................12
1.3 factory safety regulations........................................................................................................................ 13
1.3.1 general rules.................................................................................................................................13
1.3.2 drive security device.................................................................................................................... 13
1.3.3 working platform..........................................................................................................................13
1.3.4 power off......................................................................................................................................13
1.3.5 crane.............................................................................................................................................14
1.3.6 mobile crane.................................................................................................................................14
1.3.7 welding equipment...................................................................................................................... 14
1.3.8 lifting gearing............................................................................................................................... 14
1.3.9 belt conveyor strap...................................................................................................................... 15
1.3.10 mobile crushing factory............................................................................................................. 15

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 1.3.11 ”noise” from the crushing factory............................................................................................. 15
1.3.12 ethoxyline resin padding and zinc filling................................................................................... 15
1.3.13 “dust” in the crushing factory....................................................................................................16
1.3.14 routine maintenance work........................................................................................................ 16
1.3.15 thermalization process...............................................................................................................16
Chapter 2 Crusher Summary
2.1 foreword.................................................................................................................................................. 17
2.2 crusher specification................................................................................................................................17
2.3 initial check............................................................................................................................................. 17
2.4 providing data..........................................................................................................................................17
2.5 examine spare part...................................................................................................................................17
2.6 crusher term.............................................................................................................................................18
2.7 crusher capacity predict.......................................................................................................................... 18
2.8 chossing the right lining plate................................................................................................................. 19
Chapter 3 General installation instruction
3.1 installation drawing.................................................................................................................................21
3.2 configuration........................................................................................................................................... 21
3.2.1 equipment installation.................................................................................................................21
3.2.2 seal............................................................................................................................................... 21
3.3 feeding configuration.............................................................................................................................. 21
3.4 discharge configuration...........................................................................................................................23
3.5 drive mode...............................................................................................................................................24
3.6 belt drive unit initial installation.................................................................................................................
3.7 tensioning of belt drive unit........................................................................................................................
3.7.1 tensioning deflection method..................................................................................................... 28
3.7.2 stretching method........................................................................................................................29
3.8 how to maintain the belt..............................................................................................................................
3.9 initial calibration flexible coupling.............................................................................................................
3.10 motor.........................................................................................................................................................
3.11 piping explanation.................................................................................................................................34
3.12 general assemble and dismount explanation.........................................................................................34
3.13 general repair explanation.....................................................................................................................35
3.14 recommeded minimum spare part list...................................................................................................36
3.15 exclusive-use tool..................................................................................................................................36
3.16 prevent it from rusty..............................................................................................................................37
Chapter 4 Operation Guide
4.1 check list before start a new crusher....................................................................................................... 40
4.2 preparison before start.................................................................................................................................
4.3 transmission shaft rotate speed...................................................................................................................
4.4 transmission shaft rotate direction.......................................................................................................... 43
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4.5 hydraulic station operation......................................................................................................................43
4.6 first time run and running-in procedures................................................................................................ 44
4.7 procedure after everyday start and stop.................................................................................................. 45
4.7.1 everyday start...............................................................................................................................45
4.7.2 everyday stop............................................................................................................................... 46
4.8 adjust crusher discharge opening............................................................................................................ 46
4.9 rotate adjusting ring.................................................................................................................................48
4.9.1 using Hydraulic regulating mechanism to rotae the adjusting ring............................................ 48
4.9.2 using wirerope rotate the movable cone.................................................................................... 48
4.10 minimum discharge opening.................................................................................................................48
4.11 check the crusher discharge......................................................................................................................
4.11.1 standard crusher operate advices............................................................................................. 50
4.12 ring movement...................................................................................................................................... 51
4.13 confirm lining plate abrasion................................................................................................................ 52
4.14 whorl lubrication.......................................................................................................................................
4.15 adjusting ring and support sleeve whorl abrasion.....................................................................................
4.16 what if it is hard to trun the adjusting ring?..............................................................................................
4.17 empty crusher chamber.............................................................................................................................
4.18 how to dismount and install adjusting ring...............................................................................................
4.19 Plant overhaul............................................................................................................................................
4.20 periodic maintenance................................................................................................................................
Chapter 5 Inspection and Maintenance Period 63
Chapter 6 Crusher Operation 73
6.1 adjusting ring、concave and hopper assembly...................................................................................... 73
6.1.1 summary.......................................................................................................................................73
6.1.2assmbel explanation..................................................................................................................... 74
6.1.3 repair............................................................................................................................................ 75
6.1.4 change and adjust feeding hopper.............................................................................................. 78
6.2 movable cone、mantle and cone head assembly................................................................................... 79
6.2.1 summary.......................................................................................................................................79
6.2.2 install movable cone assembly.................................................................................................... 79
6.2.3 repair............................................................................................................................................ 81
6.3 socket liner /Ball type tile assembly....................................................................................................... 94
6.3.1 summary.......................................................................................................................................94
6.3.2 assemble illustration.................................................................................................................... 94
6.3.3 repair............................................................................................................................................ 98
6.4 eccentric locking collar assembly......................................................................................................... 100
6.4.1 summary.................................................................................................................................... 100
6.4.2 assemble illustration.................................................................................................................. 101
6.4.3 repair.......................................................................................................................................... 103
6.5 transmission shaft frame、transmission shaft andpulley assembly..................................................... 115
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 6.5.1 summary.................................................................................................................................... 115
6.5.2 repair................................................................................................................................................
6.6 main frame／support sleeve and iron block pass and release assembly..............................................133
6.6.1 summary.................................................................................................................................... 133
6.6.2 assemble illustration.................................................................................................................. 135
6.6.3 repair................................................................................................................................................
Chapter 7 Hydraulic System
7.1 summary......................................................................................................................................................
7. 1.1 hydraulic station operate.......................................................................................................... 161
7. 1.2 hydraulic oil traits............................................................................................................................
7. 1.3 lock the hydraulic cylinder assembly..............................................................................................
7. 1.4 hydraulic adjusting system assembly..............................................................................................
7. 1.5 hydraulic hose and crusher connection..........................................................................................
7. 1.6 energy accumulator pre-pressure- charge and charging test.................................................. 166
7.1.7 hydraulic system discharge and inflating test..................................................................................
7.1.8 release crushing chamber circuit inflating................................................................................ 169
7.2 repair......................................................................................................................................................170
Chapter 8 Lubrication System
8.1 summary................................................................................................................................................ 171
8.2 lubricating oil traits............................................................................................................................... 172
8.3 oil temperature...................................................................................................................................... 173
8.4 oil pressure and flow rate...................................................................................................................... 174
8.5 air breather.............................................................................................................................................174
Chapter 9 Tipical problems regarding crusher

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 Safety
In the manual Chapter 1 which concludes the basic safety regulations regarding inside the
crusher factory and surrounding the crusher factory.
Operation safety and other safety, which utterly depends on the rational precaution and judge
during operation. A cautious operator is a fine guarantee of lesser accident.
Actually most of the accidents are all caused by neglecting the basic safety rules. So, which also
means most of them could be prevented by higher safety awareness and earlier steps taken
before the accidents.
Even though during the designing and machine making process, we are more than careful, but
under certain circumstances we still can not guarantee that the there is no disturb of
equipments accessibility and functional operation. So in the manual we will use “warning ” to
emphasis these terms.

Chapter 1. Safety
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1.1 Personal Safety

1.1.1General Introduction
This chapter is just the explanation of the basic safety rules. In order to achieve a safe operation, there should
be extra precautionary measures. This manual can’t replace safety regulation, safeguard measures and laws,
principles and regulations made by the governments at all levels. The operator and maintenance worker’s
safety is matter of importance and this manual is for these workers to provide them some prevention
measures to common problems they will meet during the operation.

The operators have the responsibilities to know about the specific requirements, precautionary measures and
unsafe factors at the working zone very well and to discuss those matters with their supervisors. To ensure a
safe operation, all the operators and supervisors should have the consensus on these factors.

The operator is always key persons of the safe operation. So it is very necessary to let the operators to learn
about the safety regulations very well and grasp the basic safety measures to prevent and avoid personal
injury and property loss.

1.1.2 Precautionary Measures

In order to warn the operators, maintenance works and related workers, if the operation is dangerous and
risky, it will be marked with “Warning”.
No matter how safe the equipment is, it is still very necessary for the operators to operate carefully, to know
about the technical features and to grasp the safety regulations.

Please be noticed in any cases, the worker himself is always the key person of safe operation. Keeping with
the safety regulations not only can protect the people around you, but also can provide you the best
protection. Please learn and grasp this manual and all the manuals provided by supplier related to the safe
operation, and please read all the warning and notice matters so that to achieve a safe operation.

To supervise people who work with you to obey all the safety regulations and be alert of any unknown
dangers. Please keep it in your mind---Safety Is Your Responsibility!!!!!

1.1.3 Are you familiar with the factory’s safety regulation?

According to the safety record, most accidents are caused by ignorance of the simple safety regulations.
Therefore, it is very necessary to grasp and obey all the safety regulations and learn about the related
regulations from the supervisors.

1.1.4 Does all your wearing meet the working requirements?

For your own safety, you should chose the suitable protective wearing such as helmet, safety shoes, safety
glasses, goggle, safety gloves, and earmuff as requested and wear them seriously.

Fat clothes will be much easier to be drawn into rotation parts, so please fasten your cuff, bind up your jacket
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and wear all the safety wearing. Keep warm is necessary, but make sure all your clothes won’t obstruct your
work. It maybe bring danger to wear ring and watch. And do not put any goods into your pocket which is easy
to slid out.

1.1.5 Do you know about your machine?

Please read the manual to learn about the operation and maintenance ways, about the machine’s capacity
and applied range, and about the functions, position and alert signals of all the controllers, indicators, alerts.
Please grasp how to distinguish the alert devices and the safety devices of the machine. The alert devices will
alert you all the dangers that will be caused by a operation under low-pressure or high temperature.

1.1.6 Are you familiar with the working condition?

Please try to know about your working condition beforehand as possible as you can:

Be a good operator, you should keep the ground clean and no greasy dirt, oil, rocks, chain or other barriers.
Put all the parts and tools into the suitable tools boxes and do not use inflammable solution to clean them.

Please learn about the carrying capacity of the ground at working site.

It is necessary to know about the clearance situation of the working site. Take you a little time to check the
surrounding and clearance situation, including the power unit can reduce a lot of danger.

Be noticed of dust, smoke, and fog cause it maybe obstruct your sight.

1.1.7 Are you always prepared for the accident?

Grasping the regulations, keeping vigilant and operating carefully, then you can protect yourself from injury
and prevent the machine from breakdown. However, if there is a accident due to ignorance, you can stop it by
the tools at hand and skills at mind as soon as possible. Please know the position of the fire extinguisher and
first-aid case and how to use them accurately.

You should know where you can get the first-aid very well.

Make a emergency phone call for help immediately.

Safety works doesn’t only means this regular rules, you also should know at certain condition and with certain
equipment, there should be some precautionary measures.

1.1.8 Inspection before start.

Without good operation preparation, then the equipment will be in danger. Please check the equipment up
very carefully when change the shifts. If there is a problem need to be noticed of, please consider and check it
again and again before “letting it go”. Even if a very small breakdown may arouse an injury and serious
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accident.
1. Without professional training, people are not allowed to operate the equipment!
2. Make sure all the safety covers and protective devices at the right please, fixed and complete without
damage.
3. Check the oil system to make sure the oil level is correct and there is no leak.
4. Check every discharging cock, valve, and pipe joint to make sure them at right place and fixed.
5. Underpressure caused by lower oil level will bring serious breakdown of the hydraulic system.
6. Jam of the crusher due to insufficient lubrication oil maybe one of the reasons that cause breakdown.
7. It is strictly prohibited to adjust the reducing valve to increase the working oil pressure. The oil pressure
provided by the manufacturer can guarantee the longest service life and safest performance.
8. It is strictly prohibited to change the safety devices.
9. Check up the crusher completely to see if there are some visible problems like leaked, damaged pipe,
and loose parts.
10. Check up the equipment should follow the manual and the instructions of the supervisors.
11. Before start, walk around the machine to see if there are people near the machine and warn them the
machine will be start immediately.
Any accident you should report it to your supervisor in time.

1.1.9 Safe Start

1. Check up the warning mark of the equipment.
2. Follow all the procedure showed at Chapter 3.
3. After starting the machine, check up all the indicators to ensure everything is fine.
4. If there is any abnormality of the indicator, stop the machine immediately.
5. Test all the controllers to make sure every function is fine.
6. Listen and report whether there is abnormal noise of not.
7. Re-check up all the alert and other warning and safety devices.
8. During the operation, it is not allowed to stand on the support covers.
9. During the operation, it is not allowed to lean or put your hands on the insurance cylinder or between
the support covers and the main frame.
10. It is strictly prohibited to start up a machine with problems. The operator should report the problem to
the supervisors in time.
11. During the operation, it is not allowed to observe inside the crushing chamber without any protective
measures.

1.1.10 Report the Problems.

Check up the machine everyday to see if there are loose, worn and damaged parts. If there is, the operator
should report the problem to the supervisor and fix the unsafe condition immediately. The machine can’t be
started up until all the problems are solved.

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Even if a very small breakdown will cause a very serious accident, therefore, any breakdown should report to
the supervisor in time.

1.1.11 Safe Stop

Only after ensuring the crusher has been stopped, then the operator can do the cleaning, maintenance,
refueling, check the v-belt tension, open the cover and check the hydraulic system, maintain and clean the
crushing chamber, etc. During the operation, it is strictly prohibited to do any inspection, adjustment, and
maintenance.

1.2 Tips of Safe Maintenance.

All the maintenance should be done carefully.

1.2.1 Reading and Comprehending

1. ”Inspection and maintenance instruction” at the latter half of Chapter 4- Operation Instruction.
2. All the warning nameplate on the machine.
3. All the warning instructions at the manual.
4. Chapter 5-- Instruction on regular lubrication.

1.2.2 Warning Mark

Before entering into the crushing chamber, it is very necessary to hang the warning mark and cut the power
so that nobody can start it up.

The warning mark should be hanged for the following situation：

1. The crusher can not be operated safely.
2. The controller is fixing.
3. The machine is checking and maintaining.

1.2.3 Power Cut

1. Before any maintenance of the crusher, it should turn off all the electric controllers.
2. When doing the maintenance of the hydraulic system, it should cut off all the power because the “stop”
button can only stop the motor.
3. Provide every maintenance worker their own private lock and the only key.

1.2.4 Wearing-- Safe Operation

1. Keep clothes and hands away from the running parts. Don’t wear fat clothes, loose tie, watch or ring.

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2. Wear the protective glasses when touching fuel, cleaning fluid, and brake fluid cause it will harm your
eyes.
3. Wear the respirator when it is necessary.
4. Wear the protective glasses when drilling, grinding or forge the metals.
5. Don’t put any goods in the pocket which will slid down into the machine.
6. Wear the hamlet and safety shoes when it is necessary.
7. Wear gloves when changing the steel wire rope.
8. Wear the protective glasses and protective clothes when using the high-pressure air.
9. Wear goggle and protective clothes when melting metal like zinc, babbit metal, and lead, etc.
10. Wear earmuff or reduce the exposure time of ear as requested when it is necessary.

1.2.5 Don’t drink alcoholic drinks and take medicines.

1. During the shift, it is prohibited to drink alcoholic drinks.
2. During the shift, it is prohibited to take the medicines, sedative, and anesthetics which will make you
sleepy.

1.2.6 Working Zone

1. 1. Keep a good working zone which is dry and clean and without dust and tools. If the ground, footstep,
stairs, and handrail are wet or covered by oil, they will be very slippery. For wet working zone, it will be
very dangerous especially the place near to the electric equipment.
2. At the top or around the crusher, it is not allowed to place or stock materials or goods.
3. Put the highly dangerous liquid at the right place and keep it far from the unauthorized people.
No smoking at the working zone!
4. Don’t start the diesel or gasoline engine at a airtight place and keep a good ventilated condition cause
the exhaust gas may cause a death.
5. When doing the gas cutting and welding, it is necessary to take some protective measures. People
whoever doing the gas cutting and welding should avoid to breath the dust and smoke which will bring
injury. Therefore, the operator should accomplish all these work at outdoor zone where has the facility
can provide the equipment clean air or can eject the smoke and dust. For suitable standard, please refer
to OSHA or MSHA.

1.2.7 Equipment
1. Use the right tools to take care of the heavy parts and tools neatly.
2. Keep all the tools and equipment clean and without dirt or grease. Don’t throw them about.
3. Moving the big part need to use the lifting equipment, and when lifting, watch out your back.
4. Put down the part carefully, not just throw them away.
5. Clear the grease out on the action bars and hand shanks to avoid slipping.
6. Don’t use the fly wheel with crack on the side or spoke.
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7. Check up the v-belt to see the working condition.
8. Check and replace the worn, unqualified, or lost parts. Keep the equipment clean, no dirt or grease so that
you can find the loose or damaged part at first time.
9. When using the steel wire rope, make sure the standard of the rope is suitable and make sure it is qualified
and undamaged.

1.2.8 Fire Proof

1. No smoking when refueling or moving the tank with oil in it.
2. Shut down the motor when refueling. If the temperature of the motor is high, then the operator should
be much more careful.
3. When refueling, keep the funnel or glib tight with the tank. Make sure the tank contact with the ground
to avoid the static.
4. Use high quality industrial nonflammable solvent to clean the parts, and don’t use gasoline or diesel.
Don’t smoke when using the solvent.
5. No smoking while using detergent.
6. Put the mop with oil and other flammable goods at the safe place, not at the place with bad ventilation.
7. Don’t use open fire to check the liquid level of the fuel oil, electrolyte or coolant, and use flashlight to
check the hydraulic oil leak.
8. Knowing where to get the fire extinguisher, how to use it and what kind of fire it can put out. Check the
extinguisher at least for very month, and make sure it at the right place.
9. When there is a fire, under a condition of safe operation, try to shut down the hydraulic system and the
lubrication system.

1.2.9 Compression System---hydraulic pressure or air pressure.

1. Release all the pressure before opening or moving any hydraulic or barometric pipe, valve or joint.
2. Check to see if there any damage of the tube or pipeline.
3. The high pressure oil is dangerous.
4. The energy accumulator contains hydraulic or air pressure should meet the standard of the Act
promulgated by the government at November 24th, 1982.

1.2.10 Using the High Quality Parts

When replacing parts, the new parts should have the exact same standard, model and quality as the old ones.

1.2.11 Report the Necessary Maintenance Projects

When doing the daily inspection, if the inspector find there are some parts that need to be maintained,
replaced or adjusted, please report to the supervisors in time.

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If the equipment is operating, even if a small flaw will cause a serious breakdown.

Do the maintenance works that you are authorized to do and don’t do the works that you don’t know.

Operate and maintain the equipment that you know about very well. For some part that with high pressure, if
release the pressure carefully, it will cause injury.
Keep it in mind, the equipment you are operate and maintain is a very expensive one, please take a good care
of it.

1.3 Working Site Safety Regulations

1.3.1 General Introduction

The safety regulations here can not cover all the safety hidden danger at the working site, besides, people has
summarized some safety regulations based on long term production practice which can promote the safety
working condition of the crusher and the surrounding of the working site. Therefore, LIMING always welcome
the suggestion and advice at safety aspect from clients or others.

1.3.2 Driving Protective Device

At the beginning of the installation, it should take the suitable safety measures. The crusher can be driven by
v-belts or couplings, but no matter the v-belts or couplings, it is necessary to install the protective device
around them.
The flange of the fly wheel is specially designed according to the max speed, if it is over speed, it will break
and cause some injury.

The speed of the crusher is very important to a normal operation. So normally, at the place that facing the
center of transmission shaft on the protective cover, there will be a hole where can place a velocity meter to
measure the speed of the shaft. The hole should be covered by a maintenance gate or lattice gate.

1.3.3 Working Platform

Since it is necessary to check up every crusher periodically, so there should be a some kind of working
platform at certain height which is easy for the workers to do the inspection and maintenance. A high quality
working platform should owns handrail and footstep, also there should be iron netting or metal meshes
which can prevent the tools from falling and hurting the people on the ground. Don’t connect the working
platform with the support sleeve cause the sleeve will rapidly rise when there is an iron passing through the
crushing chamber.

1.3.4 Cut Off the Power

Anytime there is someone working on the crusher, the power should be cut off.
People who work on the crusher have their own private lock and the only key. When they work on the crusher,
they should cut off the power and lock the power controlling device by their own lock. The point is the lock
13
only has one key which should be kept by the people who working on the crusher. If there are more than one
person working on the crusher, then each of them should take their own lock and key to lock the controlling
device. Those who are responsible to the accident usually are those who think the crusher is absolutely safe.

1.3.5 Crane
Like all the mechanical equipment, crusher also need to be maintained periodically if you want to make good
profits. And one of the most serious danger is to use the crane which is unqualified and unsafe. Though the
crushers are not like automobile engines that need precise adjustment, but the inside parts of the crusher
need to be assembled and disassembled by crane. And the crane should be able to lift up and put down all
the part to assemble the crusher. When using the crane, all the work load should be below the rated load.
And the rated load also includes the weight of the parts on the crane like lifting hook, pulley block, and
hanging device such as steel wire rope, etc. Minus these weight, then it is the real rated load of the crane. The
hand chain block and lever is the most have-to way when there is no suitable lifting equipment.
Anything related to safety should take the best measure.

1.3.6 Mobile Crane

When using the mobile crane, it should work under the rated load to avoid damage to crane boom or
turnover. The safe rated load should be at a precondition that the crane are working at the solid and level
ground. The cantilever shalving should extend rightly and keep low as possible. Try to avoid rapid rotation, or
sudden lifting or stopping, otherwise, it will be over load. Don’t lifting the heavy goods when there is a big
wind.

Before the mobile crane crossing the bridge, it is necessary to check the rated load of the bridge, the limited
height, and if there are some barriers such as electric wire.
Before lifting, check around to ensure there is no barrier and ensure the lifted good is connected with the
crane solidly.

1.3.7 Welding Equipment.

Since many metal are harmful to people’s health, so before doing the gas cutting or welding, the operator
should take some protective measure. People whoever doing the gas cutting and welding should avoid to
breath the dust and smoke which will bring injury. Therefore, the operator should accomplish all these work
at outdoor zone where has the facility can provide the equipment clean air or can eject the smoke and dust.
For suitable standard, please refer to OSHA or MSHA. Gas cutting touch is one of the most used tools. When
doing the welding or cutting, the operator should remove the hydraulic parts and cover them with fire-proof
cover to avoid welding spark.
If the high pressure hydraulic pipe rupture, the liquid will be vaporized quickly and the vaporized liquid will be
fired rapidly which will cause serious burn to surrounded people. So if the welding or cutting zone is very near
to the hydraulic parts, the operator should take necessary measure to avoid these parts.

1.3.8 Lifting and Transmission Device

All the parts of the crusher should be lifted smoothly by the lifting and transmission device, and it shouldn’t
14
over the rated load. Be noticed that the safe rated load includes the weight of the crusher and the parts on
the device such as chain, hoist hook, etc.

1.3.9 The Belt Of the Belt Conveyor

Don’t take the belt of the belt conveyor as a passageway. Beside the belt conveyor, there should be
pedestrian passageway as the safety measure. And along the passageway, there should have the handrail.

1.3.10 Mobile Crushing Plant

If the crushing line are composed by the mobile equipment which means the crushing and screening plant
installed on the chassis, then the bottom seat and support frame of the chassis are very important for safe
operation. Check the bottom seat of the chassis to ensure the equipment installed on the solid and level
bottom seat. If it is needed, putting some sleepers under the chassis to keep the wheels us and away from the
ground. Place one screw jack at each corner(4 corners total) of the chassis, and the distance between the jack
and the corner should be same. Then adjust the height of the jack to stop or reduce the shake of the support
part. Never park the chassis at the low-lying place where rain can scour the bottom seat. Check up the
bottom seat periodically to ensure it stable.

Before crossing the bridge,it is necessary to check whether the bridge can stand the weight, and check the
limited height, and if there are some barriers such as electric wire. If the weight of the equipment is very
close to the rated load of the bridge, then the equipment mustn’t cross the bridge. Pay attention to the local
regulations especially the one about the weight limit.

When driving on the high way, make sure the front and back light, brace light are fine and use the right
transportation flags and marks.

1.3.11 The Noise

It is natural that the crusher has noise. And the noise of the auxiliary equipment such as chute, transmission
point, screen will be much louder.

During the operation, the noise of the crusher will be from 100-130DBA. If the noise is higher than the legal
limit, then the worker should wear the ear protective device. If the ear protective device still can not meet
the requirement, then it should reduce the working time of workers.

It is unacceptable to try to change the inside structure to reduce the noise. However, according to some
operators, they find that building a cheap operation room will be very useful to reduce the noise. In the
operation room, for one hand, the operator can watch the running equipment, for other hand, the
noise-proof bricks, double glazed windows, and air conditioner will protect the operator from noise. In this
case, it can not only promote the efficiency, but also reduce the harm of noise.
Also, most operator find that building a operation tower in a higher place can not only provide the workers a
safe work place, but also improve the efficiency,

1.3.12 Epoxy Filler and Zinc Irrigation

For all the crusher, when replacing the parts, it need to use some filler. And the epoxy filler can reduce or
avoid the danger of unexpected burn injury. With more convenient process, and higher safety factor, the
15
epoxy filler can replace the melted zinc totally.

When using the epoxy filler, the operator should be very carefully when disassembling the liner by gas
welding and cutting methods. Also the working zone should have a good ventilation cause the smoke of the
epoxy can make people sick and irritate people’s eyes and skin.

1.3.13 The Dust

The crusher and the auxiliary equipment like chute, transportation point, screen will product the dust. If there
is not suitable measure to collect the dust, it will cause the harm to worker’s health. Therefore, LIMING highly
recommend to use the dust-collecting equipment and the workers should wear the dust mask when exposing
in the dust for long time. The OSHA, MSHA or some local laws may require to use dust-proof equipment and
dust alert. It should be decided by the operator to use what kind of dust-proof equipment or dust alert and
make sure the required dust-proof equipment and dust alert have been provided.

By doing some change of the crushing line such as add a dust collecting system or water sprayer can reduce
the dust effectively. During the operation, using the dead funnel can also reduce the dust. Since the installation
configurations of each crusher are different, so LIMING suggest the operator need to ask about the
professional advice for dust proof from LIMING or dust-proof counselor.

1.3.14 Daily Maintenance Work

For daily operation, it is necessary to do some maintenance work around the crusher. Below is a important
part of the daily operation regulations which shows what should do and which shouldn’t.
1. Don’t do any maintenance work if the machine is running, even refuel the lubrication oil or grease into
the crusher.
2. When the machine is running, don’t put your hand or foot on the hydraulic cylinder used as insurance
cylinder when iron passing through.
3. Maintain the equipment periodically according to the manufacturer’s advice.
4. If the stone in the crushing chamber is over big, then there will be gravel splash out. So the operator
should make sure there is no splashing to avoid hurting people.
5. When the machine is running, it there is no measure to prevent stone from splashing, then do not look
into the crushing chamber.
6. Making sure there is no people around when using the crane.
7. Never walking, standing, rambling, lying below the crane when it is working.

1.3.15 The Thermalization Process

When cooling the parts of the crusher, please take the suitable measure to deal with the dry ice, liquid
nitrogen, and other refrigerating fluid. For more standard, please refer to MAHA and OSHA. Incorrect
precaution taken may cause serious body injury.

PLEASE KEEP IN MIND THAT SAETY IS ALWAYS YOUR RESPONSIBILITY.

16
 Chapter 2 Crusher Introduction

2.1 Foreword 2.4 Document

This book is written for users and operators who The following drawing and date of the crusher
install, operate and maintain the HPT Cone you’ve bought will be provided in a separated
Crusher. installation brochure.
1. Foundation drawing
It will help you to know the structure of crusher 2. Oil circuit drawing of crusher and lubrication
and the common sense of efficient operation and system
maintenance. 3. Drawings and data of the associated
equipment that are not made by Liming.
Before delivery, all the crushers has been 4. Other drawing and data probably used in the
assembled and tested. Despite all this, safety installation.
precautions should be taken during the operation.
These precautions will be introduced in the The parts manual will be sent after the crushers are
following chapters, to help you avoid breakdowns delivered. The parts manual introduces all the part
by wrong operation or maintenance. used in the crusher assembly and can be used for
parts ordering or changing.
To be highlighted, the operators cannot install or
run the crusher until they have read and understand
2.5 Parts maintenance
this introduction and take it into effect.
Liming will have enough parts in stock so that we
2.2 Crusher specification can serve faster and more efficiently for those
Generally, this introduction is suitable for all the users who order the parts.
smaller type cone crusher.
In order to provide the right parts fast, please
provide the following specification:
2.3 Initial Inspection
After the arrival, the goods should be taken a 1. Crusher model
careful inspection, as soon as possible to find any 2. Name board of crusher and the serial number
possible damage in transit. The purpose of of the parts manual
inspection is also to confirm whether there are 3. Quantity of each part
parts lost. Make sure that all terms on bill of lading, 4. The full name and no. of this part in the Parts
bills of lading and packing list are all received. Manual
Found lost or damaged, it shall be notified 5. Complete transportation requirement, by
immediately to the transportation company and express, post, shipping or air.
claim in time.

17
If your Parts Manual is lost or destroyed, please
contact us for a new one for free. For regular
operation, we only allow the parts made by
original factory to make sure the accuracy,
material and processing technic.
2.6 Crusher terms
In this Introduction, some fixed terms are used for
description of crusher and operation. For avoiding
the confusion and misunderstanding, we describe
the following terms according to their usage:
Feeding: the raw material waiting for crushing
Liner plate: Mantle, concave, liner plate of main
frame, installation plate of main frame are all
called liner plate.
Crushing cavity: the space between the mantle and
concave
Parallel zone: During the rotary, when the
adjusting ring is close to the mantle bottom, they
are paralleled in some degree, this space is parallel
zone.
Tight side feeding mouth: When the mantle and
concave reach the closest point, the space upon
this point is called tight side feeding month.
Loose side feeding mouth: When the mantle and
concave reach the distant point, the space upon this
point is call loose side feeding mouth. The feeding
mouth on loose side decides the max. feeding size.
Generally speaking, the max. feeding size cannot
exceed the loose size.
Discharging outlet: When the mantle and concave
move to the closest point, the distance between
18
their bottoms are call discharging outlet. It can
adjust the final product size.
Tight side discharging outlet: When the mantle and
concave move to the closest point, the distance
between their bottoms are call discharging outlet.
And the smallest distance is called tight side
discharging outlet..
Loose side discharging outlet: The one opposite
the tight side discharging outlet is loose side
discharging outlet.
Feeding size: it is the size of the mesh holes that
the stone can pass through.
Final product size: The size of final stones after
crushed.
Capacity: how many tons per hour the crusher can
produce.
Open circuit producing: in this solution, all the
feeding material only be crushed by once, without
requirement on the
Close circuit: in this solution, the size evenness of
the product is considered. The product are those
stones go though the screen. The stones that stay
on the screen have to return to the crusher.
2.7The prediction on the crusher’s
capacity
Crusher is only a part in the whole solution.
Therefore, its performance is depended on the
selection of feeder, belt conveyors, screen,
supporting structure, motors, driving parts and the
hopper. The following factors will improve the
2.8 Choose the suitable liner plate
capacity and performance of the crusher.
1. Choose the right cavity according to the raw After extensive exploration and research, Liming

material has developed many kinds of crusher parts to adapt

2. Feeding proportion should be suitable. different feeding size and output size. Because of

3. Feeding quantity controlling the alterable condition and operation method, it is

4. Feeding evenly to the cavity very hard to make list of every kind of liner to

5. The belt conveyor that transferring the match with each special case and operation mode.

discharging stones should match with the

maximum capacity of the crusher. If somehow, your liner plate cannot be used for a

6. Choose the suitable screen for pre-screening reasonable time, we suggest you to cut the

and close circuit screening adjusting ring and mantle by the gas cutting, so

7. Automatic control that you can outline the adjusting ring and mantle

8. Discharging is smoothly on the stiff paper or paperboard and deliver the

drawing to the manufacturer. In this way, they can

The following factors will decrease the crusher’s estimate the wear parts precisely. (See figure 2)

capacity and performance

1. There are clay material in feeding Then we will recommend the different adjusting

2. The quantity of material smaller than ring and mantle based on the outline of the wear

discharging size are 10% more than the parts.

crusher’s capacity In order to give you the right answer, please

3. The moisture of feeding material is too high confirm the following information:

4. Feeding inclined to one side 1. feeding size

5. The feeding are not evenly in the cavity 2. stone type

6. Feeding without control 3. final product size

7. Ignore the recommended power 4. The set point of crushing circuit, all the

8. belt conveyors are not capable screening mesh hole size and crusher.

9. Screens for pre-screening and close circuit 5. The number of the adjusting ring and mantle

screening are not capable that you are using

10. Discharging is not smoothly 6. crusher driving power

11. The raw material is too hard or tough 7. crushing capacity

12. The transmission shaft of crusher is running 8. series number of crusher

under the recommended chuck loading 9. discharging size of crusher

10. time of electricity load of crusher

The capacity and product size of crushers are the 11. The RPM of crusher’s belt pulley

average data that we got based on the crushers that

is processing many kinds of stones in the world. It will increase the liner’ wearing and decrease the

For the special case, please consult Liming. crushing efficiency even damage the crusher if the
crushing cavity doesn’t match with the liner.
19
Item Name
1 cut a slit on the movable cone or cone liner by the gas cutting
Insert the paperboard or stiff paper in the slit and outline the
2
wear part.
3 label the outline
2-1 Determine the wear profile

20
 Chapter 3 General Installation Instruction
3.1 Installation Drawing
The detailed installation drawing is in the
attachment. Concrete block and metal base should
be calculated, checked and ratified according to the
size and loading in this figure.
The design of concrete block and metal backing
should be based on the consideration of previous
research results and the elastic mechanics of the
ground.
3.2 Configuration
3.2.1 Installation
The ground should be flat and remain level.
And
promise:
-Leave enough height for the disassembly of
movable cone and adjusting ring components
-Leave enough height for the disassembly of
transmission components
- Leave enough height for the feeding of the funnel,
chute and other associated equipment, as well as
the for material discharging, funnel, belt conveyor
and the maintenance of the crusher.
3.2.2 Sealing
If the machines are installed on the concrete base,
please fix the machine on the base by some bolts.
These bolts will transfer the traction to the
grouting seal concrete.
21
Sealed concrete will transmit the torque coming
from the bolt to the concrete base. The force will
be passed between concrete blocks through the
interface layer.
If the anchoring wrench is needed, it should just be
the fixture between the bolt and sealing element
and will be removed after seal or concrete
resistance. Those narrow and high structures (like
belt conveyor) should be sealed as soon as possible
before the testing. In fact, the resistance of those
unsealed bolts is 1/12 of those sealed bolts.
Anchoring wrench plays no important role in
anchoring the resistance. It only seals the concrete
to ensure the strength of the hook anchorage.
Generally, the concrete must conform to the
reasonable operation procedure, and do the official
stress experiment in its country.
Attention: Crushers, crushers with steel structure,
spatial size and weight will be given by Liming.
3.3 Feeding Device
The efficiency of crusher is depended on the
feeding device directly. If feeding properly
spreading the cavity, the crusher can reach high
efficiency. By studying the layout and crusher
space, we can take some precautions on the
feeding device. The feeding device should be easy
to assembly. Therefore, a careful planning should
be made before the execution of works.
Wrong Feeding Right Feeding
1. Material is fed into one side of the mouth, the 1. Material is falling on the cone head.
material doesn’t spread equally ： 2. material spread evenly
2. decrease the capacity 3. capacity is the largest
3. product size is too large 4. product size distribution is uniform
4. supporting sleeve moving too much 5. supporting sleeve moves a little
5. bearing pressure is too large 6. power consumption is small
6. power consumption is too large
Figure 3-1Feeding device

22
There is a feeding box on the top of hopper. Th
e stones fall down through the hopper to the bl
ind side and then fall down straightly, spread o
n the cone head evenly. By combing the right f
eeding with the cone head, the feeding box wil
l help those mixed stones to be fed along the w
ho crushing cavity evenly. In order to ease the
liner abrasion, you should keep the asymmetry
of fine and coarse materials feeding as little as
possible. For the perfect performance of the cr
usher, the feeding should be adjustable and ma
ke sure the cavity is chuck feeding. The materi
al position goes up evenly.
Crusher should take chuck feeding. By this fee
ding method, the production capacity will be l
arger, product size will be finer, more evenly a
nd the power consumption will be less. Since t
he feeding box is depended on the feeding met
hod, it cannot be provided along with crushers.
No matter what kind of crusher, it is better t
o do pre-screening for sorting out the fine p
articles and clay. Prescreening will avoid m
aterial blocking, supporting sleeve moving t
oo much or low production capacity. Beside,
a metal detector for removing the metal obj
ect that will make the supporting sleeve mo
ving.
Feeding device should be large enough to reac
h the maximum feeding capacity of the crusher
. eserved between the machine frame and the di
It is important to control the feeding speed
of the crusher. Falling down from a great he
23
ight, all the material almost can go through
the opening size of the cavity. Falling down
to the cavity bottom without being crushed,
these materials will cause the supporting sle
eve jump abnormally, which will damage th
e touching space between the main frame a
nd the supporting sleeve. If the cavity is 36”
or bigger, it needs trapezoidal falling, piling
materials in the blink site or similar speedi
ng cut device
Right and wrong feeding method as well as the
feeding box structure is in the figure 3-1.
3.4 Discharging device
Since the discharging device changes from diff
erent crushers, the discharging chamber or fun
nel are not provided along with crusher. But its
structure should satisfy the foundation layout.
Discharging chamber can be made of metal or
wood. There should be a inspection hole reser
ved in the discharging chamber for inside chec
king and cavity clearing. In the discharging ch
amber, there is a clapboard which will develop
a “stones bedding” for bearing the impact fro
m falling stones. The clapboard absorbs most i
mpact before the stones fall down the machine,
to lengthen the service life of the machine.
If adopts funnel, the gradient should be over 4
5°; if the material is very sticky, the gradient h
as to increase. There should be enough space r
scharging room bottom as well as the dischargi
ng outlet or funnel and the belt conveyor or ele
vator, which will keep the discharging channel
from being blocked and make sure the crushin
g product discharged smoothly.
3.5 Driving Mode
Item Name
1 Single Belt Conveyor
2 Joint Belt Conveyors
3-2 Belt Conveyor Transaction
The standard driving mode is by the V-belt. Th
e reason is : No.1 the V-belt can stop passing t
he impact load to the crusher’s motor; No.2 it
can bear the pulsating load and won’t affect th
e crusher speed.
V-belt driving can be consist of one narrow bel
t as well as banded belts. Please check the figu
re 3-2.
The narrow belt makes the driving device mor
e tighter, economic and ease the cantilever loa
d. The banded belt is the joint of some single b
elts by a common connection layer, which will
avoid the belt shaking or overturn. The bande
d belt is suitable for all kind of belt pulley, but
it only accepts the joint of 2 or 4 single belts.
24
If the motor belt pulley is fixed right under the
transmission shaft or the 30° to the vertical ce
nterline of crusher, you should notify the suppl
ier the position of the driving pulley so that the
y can install the shaft sleeves of transmission s
haft exactly.
Only if you know the position of driving pulle
y, you can install the shaft sleeve correctly.
As for the driving power, both electricity and d
iesel engine are ok.
Crusher can adopt direct driving mode, which
is connected by the coupler and driving motor
or diesel engine.
Any problem of crusher, please contact the ma
nufacturer
3.6 Belt drive unit initial
installation
The engineer should according to the
following procedures to install or reassemble
of the V-belt transmission device.
1. Cleaning up the oil, grease or rust in the
groove of the belt pulley.
2. Making sure the belt pulley keep balance
with the flywheel and the main shaft should
keep parallel.
 Item Name
1 Belt pulley of the crusher
2 The shortened center distance after install the V-belt
3 Motor pulley
4 The lengthened center distance tension by the V-belt
5 Center distance
Picture 3-3 V-belt installation

The minimum allowance quantity when install the belt that less than the center distance mm（inch）
V-belt cross section The minimum allowance
quantity when install the
Belt length*mm（inch） lengthened and abrasion belt
8V 8V group SPC
that more than the center
distance
2000(79)-2749(108) 40(1 1/2) 85(3 3/8) 35(1 3/8) 40(1 1/2)
2750(108)-3499(138) 40(1 1/2) 85(3 3/8) 35(1 3/8) 45(1 3/4)
3500(138)-4499(177) 40(1 1/2) 85(3 3/8) 35(1 3/8) 55(2 1/8)
4500(177)-5499(216) 45(1 3/4) 90(3 1/2) 35(1 3/8) 65(2 1/2)
5500(216)-6499(256) 45(1 3/4) 90(3 1/2) 40(1 1/2) 85(3 3/8)
6500(256)-7999(315) 45(1 3/4) 90(3 1/2) 40(1 1/2) 95(3 1/2)
8000(315)-9999(394) 50 100 45(1 3/4) 110(4 3/8)
Above 10000(394) 50 100 45(1 3/4) 140(5 1/2)
Table 3-1 V-belt installation and tension allowances quantity
3. Don’t force to install the belt on the belt distance first until the belt can easily install
pulley. Generally we should shorten the center onto the belt pulley. Please refer to the picture

25
3-1 to make sure the minimum range of
shorten or lengthen the center distance
After calculate the center distance according to
the standard length, in order to install easily
and not damage the belt, the center distance
should be shorten based on the numerical
value given by the form bellow. As well,
because of the manufacture errors, belt
stretched and wearing, the engineer can turn
up the center distance according to the last
column numerical value given by the picture
3-1.
Item
1 Belt pulley of the crusher
2 Tight side
3 Motor pulley
26
4. Always adhere to using a matching belt and
using the new belts that produce by the same
factory. Do not mixes use the new and old
belts at the same time.
5. When install the belt onto the belt pulley,
you should rotate this device for several
minutes, then strain the belt until the slack side
of the belt just show up little loose or droop
during the operation. The example of the tight
side and the slack side of the belt please see
picture 3-4. The slack side of the belt depends
on the location of the motor.
Name
4 The slack side’s radian and sag should pay special attention
Picture 3-4 the slack side picture of the v-belt drive device

27
3.7 Tensioning of belt drive unit
3.7.1 Tensioning deflection method
The strain of drive device is a terminology. When
apply the force into the belt and generate a strain
role between belt and belt pulley, this is called strain.
This kind of strain effect can let the belt transmit the
power from motor pulley to crusher belt pulley
easily.
The strain of the v-belt can use many methods. Here
are two simple methods. One is deflection method;
the other is percentage elongation method. Either of
them can reach a very satisfactory result and each
one has their own advantages.
Tensioning deflection method is adopted tension
transmission device, complete the following steps:
1. At the top of the two pulley placed horizontally a
ruler, as shown in figure 3-5
2. Measure the span length.
3. In the center of the span length at right angles
point in spring
To spring meter exert enough force, make one belt
offset distance is equivalent to 0.016 X span length
(mm) (0.016 X span long inches)
4. For tensioning the moderate transmission device,
should be imposed on the force and the force shown
in table 3-2 roughly equal.

Item Name
1 Ruler
2 1/2Span
3 Long span
4 Every 25 mm (1 ") span long offset of 0.4 mm (1/64 ')
5 Pull the direction
6 Motor pulley
7 The belt
8 Spring meter
9 Tensile force (by number)
10 Belt pulley of the crusher
Picture 3-5 The tensioning offset
For example, The V belt section = the standard 8 v belt
28
Long span (center distance) = 1575 mm (62 '')
Offset (look-up table) = 15-22 kg (34-50Ibs)
Offset = 1575 mm (62 '') x 0.016 = 25 mm (1 ")
Therefore, when the newly installed a standard
section 8 v belt and the span length of 1575 mm (62
''), for tensioning the moderate drive, v-belt should
offset the 25 mm (1 "), spring tension for 15-22 kg
(34-50Ibs).
5. 2-4 hours after transmission device should tension
to approximately maximum tension state again.
6. On 24-48 hours later, the best inspection on
transmission device, is used as a force on the belt in
3-2 shown in the middle of the smallest and most
strongly. When necessary, it should be to tension.
Tension is too high or too low will affect the service
life of v belt and operation.
3.7.2 Stretching method
The elongation percentage (%) method is adopted
tension belt steps are as follows. This kind of special
v-belt drive tensioning method is mainly used for
tensioning transmitted belt.
1. Eliminate belt relaxation.
2. The peripheral along the belt around a 15 metres
(50 ft) of measuring tape, measure the outer
perimeter, accurate to mm (1/16 inch), record the
length. As shown in the figure 3-6.
3. Use the record length multiplied by the percentage
of elongation coefficient in table 3-3, coupled with
the initial value.
4. pull the belt to the new value.

When the narrow v-belt is properly tightened, it

may not be as tight as expected. Therefore, it is
best to check the tension of the belt by spring.

Item Name
1 Tape reading
2 Steel measure tape
3 Belt
Picture 3-6 tensioning elongation
percentage method

Belt cross section Standard belt Joined v-belt

The minimum The maximum The minimum The minimum
8V tension kg (lb) tension kg (lb) tension kg (lb) tension kg (lb)
15.4(34) 22.7(50) 18.1(40) 27.2(60)
SPC 10.4(23) 15.4(34) 11.8(26) 18.1(40)
* With the joint belt in the belt multiplied by the number of values in the table
Table 3-2 Decentering force
For example,
29
The V belt section = the standard 8 v belt
The original tape reading =3 m 48 mm (120 inches)
Elongation factor (see table) =0.009 (coefficient), that is, 0.9% (percentage)
New length reading =3 m 48 mm (120 inch) initial reading x 1.009 elongation coefficient =3 m 48 mm (120
inches) +27 mm (1-1/16 inches) or 3 m 75 mm (121-1/16 inches).
Belt Coefficient
8V 0.009
Table 3-3 Elongation coefficient
Therefore, when install the 8V belt, and the outer
perimeter measuring 48 mm in length 3 meters (120
inches), motor pulley should be in the direction of
moving away from the crusher pulley until the
reading reaches 3 meters steel tape measure 75 mm
(121-1 / 16 ) , at this time, the tension transmission
is very suitable.
5. You must periodically check belt tension, if you
need to re-tension, repeat the previous tensioning
step.
It must be noted, the tension offset method is the
best way to tension the V-belt.
Typically, most in need of re-tensioning belt sign
belt slippage. Belt and pulley groove wear serious.
This is often accompanied by a belt of "scream",
while the belt and pulley fever. This is a very clear
need to simply observe, listen and feel can be found.
3.8 How to maintain the belt
For V-belt drives operate, things to do and not do as
follows:
1. Things should do - During commissioning the
first few days, you should always check the belt
tensioned situation. When they find there is a belt
pulley groove has fallen, should be re-tensioned
belts, new belt has a certain amount of initial
extension, the need for additional tensioning.
30
Percentage（%）
0.9
2. Things should not do - Too much tension.
Excessive belt tensions only shorten life, but also
shorten the life of the bearing. To maintain
uniformity in tension. When not working,
moderately or slightly elastic belt was tight state,
when in operation, the loose side with a slight droop.
3. Things should do - keep the drive means having
good ventilation. Because the temperature exceeds
60 ℃ (140 ℉) will shorten the life of the belt, belt
guard four weeks should be sufficient air circulation.
In this case, the ideal is to use as protective cover
plate or plates.
4. Things should do - Belt oil or grease. Because too
much grease can cause the belt expands, so that
premature failure of
5. Things should do - V-belts regularly conduct a
comprehensive inspection. Each inspection should
check the following points:
a. Crusher stall - Check the belt tension.
b. Elongation range - check for internal cracks.
c. Excessive elongation - Check overload.
d. Belt softening or swelling - Check whether
there is oil or grease.
e. Hardened or broken belt - Check whether
overheating.
 coupling requires adjustment as accurately as
3.9 initial calibration flexible possible to reach the longest life expectancy,
minimal vibration. When the coupling halves
coupling properly installed in the rear axle, the two
When first install or re-install a flexible coupling halves together, according to the
coupling on the direct transmission, the following steps to adjust the coupling.
1. Using the coupling periphery 90 ° apart four
points method to check the clearance between
the coupling halves measure distances, find the
right tilt. See Figure 3-7 To measure taken gap
can feeler, dial gauge inside calipers or
magnetic base. Coupling halves must be in
order to make four points measured offset is
not greater than the size of 0.38mm (0.015 '').
If any of the four points of measurement point
offset is greater than 0.38mm (0.015 ''), it
indicates that the tilt adjustment is too large.
2. Couplings along the periphery, separated by
90 ° around the cross on a ruler on the outer
diameter of the coupling halves, check
parallelism. See Figure 37. Alignment method
is straight ruler placed on the coupling halves,
a check with a feeler or dial gauge. Parallelism
deviation should not exceed 0.38mm (0.015 '').
3. When using the flexible coupling drive
crusher. Alignment gap, tilt and parallelism is
very important.
You must install a safety retaining ring on the
shaft crusher to allow proper shaft axial gap,
or ensure rotation clearance.

31
Item Name Item Name
1 Equal gap 8 Here the ruler against the coupling halves
Here, with the other half of the coupling
2 Check the gap using a key material 9
feeler parallelism - Check 90 ° intervals.
Here, the material will be built close to the
3 10 Gap
coupling halves
Here the use of feeler coupling half gap and
4 11 Not looking for a positive tilt
inclination - Check 90 ° intervals.
0.38mm (0.015 '') maximum clearance and
5 Drive coupling half 12
inclination not find positive
0.38mm (0.015 '') the maximum degree of
6 Driver coupling half (motor) 13
parallelism is not looking positive
7 Straightedge
Picture 3-7 Coupling Alignment

3.10 Motor
Electric drive motors are squirrel-cage induction motor (or slip rings), continuous operation, the
voltage change of + 10%, with a normal starting torque (approximately 125%) and normal stall
torque (about 200%).

Recommend wear and stator insulation material thermostat (internal protection). The motor can be
both open drip-proof, it can be totally enclosed air-cooled.

32
In order to continue to maintain the base figure shows the recommended operating power
requirements of the motor service life coefficient of 1.15. If you use the service life of the motor
factor of 1.0, then the motor nameplate power rating should be higher than the recommended
operating power value about 15% higher. However, the crusher traction power should remain
consistent with the foundation drawing power given.

If V-belt drive, when ordering the motor must pay attention to the motor bearing specifications are
sufficient to withstand the weight of the suspension pulley and belt tension. The motor must also
have to withstand 360 ° radial belt pull capacity. Motor shaft diameter should be able to withstand
the peak torque and bending of the belt tension and the pulley weight due cause. The motor shaft
should be long enough to accommodate the total length of the motor pulley bush and the hub, and
a gap between the motor housing and the pulley edge.
When using V-belt drive, requiring the laying of rails in the motor, so that the belt tensioning and
installation provides adjustment.

If the direct drive motor must be noted when ordering the motor shaft and bearing size is projected
amount for direct drive. The diameter of the motor shaft must be able to withstand the peak
torque.

All power ratings are given on the basis of electric power base. Therefore, when a diesel generator
as a driving device, you must get in touch with the manufacturer to determine how much diesel
power equivalent to a given speed (rev / min) conditions of electric power.

33
3.11 Piping Explanation
The Lubrication System Manual detailedly states the suitable oil type, oil temperature and
adjustment, and the equipment maybe used in the lubrication system. Should note that, the
MWP(maximum working pressure) of the crusher lubrication system is 0.86Mpa(125PSI).

In the piping diagram, there are pipes and pipe fittings which will be delivered together with
crusher and other lubrication equipment. For adapting the local condition, we can change the
pipe arrangement. When arranging the oil-supply pipe and oil-hold pipe, you should consider
about two influence factors: pipelines should be short and straight, no dead oil or oil flow
barriers; every 305mm (12'') pipeline should have minimum slope 25mm(1'').

Must check the inside of all the pipes, make sure the cleanness, clean the cuttings in the screw
threads. Make sure the safe operation of the oil pump.

Installing the movable joints at the proper positions so that easily tear down all the lubrication
equipment, oil pump, filters, and coolers, etc. Check all the pipe joints whether have leakage or
not. Make sure the oil suction pipe between the oil pump and oil tank be sealed up. Because the
oil suction pipe’s leakage will lead to oil pump’s lower efficiency, oil mass and oil pressure will be
go down obviously and maybe will imperil the crusher’s lubrication. Because the oil suction pipe’s
leakage is not easily to be found as that of pressure oil pipe, so it is more dangerous.

3.12 General Assemble and Dismount Explanation

According to crusher’s specifications, HPT cone crusher can be delivered in a complete machine
or in part. For domestic transportation, small crushers usually are delivered in a complete
machine and can be installed directly on the foundation. In some situations, export or domestic
transportation, lifting transport are restrict in some areas, these small crushers also can be
delivered in part.

Following charts will detailedly describe the assembly and disassembly process of every crusher’
spare parts. First is about Moving Cone. Other part’s disassembly will be described one by one.
No matter the crusher will be delivered in a whole machine or not, you can assemble it according
to the charts’ description.

Checking the protective cover painted on the cover of the equipment off or not, oil pipes clean or
not.

Some equipment covers and screw threads will be damaged during the transportation. So they
must be repaired before installation. After being cleaned up, all bearings and concerned parts
should be pained some lubrication oil.

Assembly and disassembly of some part need to take special precautionary measures. Make sure
obey all the safety rules and right gestures of lifting devices. Besides, make sure all the lifting

34
devices and associated equipment can bear the weight with suitable ropes, lifting hook, etc.

All charts in this manual offer the detailed repair instructions for lifting devices. Must obey the
concerned captions when transferring the equipment part. Do not carry the equipment part
without consulting with the manufacturer.

3.13 General Repair Explanation

Taking following precautionary measures before repairing any parts of the crusher:
1.
Disassembling mechanical part surface or bearing surface with rusty, you must paint oil or
corrosion inhibitor. No matter how long you will keep those parts.
2.
Be careful about handling the bearing surface or mechanical part surface.
3.
Using wooden heel block when disassembling any the bearing surface or mechanical part
surface.
4.
Be careful when handling the copper bush or sleeve. Excessive hammer or pounding on the
soft metal will cause deflection or bulging.
5.
Cleaning and oiling all the disassembled equipment part before installing them again.
Bearing surface can’t be installed without painting oil.
6.
Painting a little oil when reassembling two press fit or sliding fit matching parts. Both can be
used as lubricating oil, and may prevent the rust.
7.
Dynamic cone and eccentric sleeve lining should be vertical state. Stored in any other way
can result in eccentric set of loss of circular or elliptical shape. When it loaded on the crusher,
encountered great difficulties.
8.
All the thread surfaces of adjusting ring, support, lock nut, moving cone and lock nut, should
be handled with the cloth impregnated with mos2 powder grinding, and then apply oil or
grease.
9.
Need to heat treatment parts, such as improper use of technology will lead to damage of
components. Thermalization needs following safeguard procedures.
a. Any time must use oiled thermalization processing bath or furnace temperature
control.
b. Can ‘t exceed the specified temperature, otherwise it will damage parts.

35
 c. Because of the characteristic of the heating element, not suitable for use cutting torch.
Because of concentrated heat from the cutting torch cause local overheating may cause
deformation or have a negative impact to the induction hardening parts. Local heating
may also produce tiny stress cracks
d. Must use specially designed for thermalization propane or acetylene equipment.
e. If you must use the flame heating to assemble the actuator, please avoid direct contact
with induction hardened parts flame. Heating center and surface, let the heat evenly
spread out.
f. When heated to remove parts, it needs fast and uniform heating. And then quickly
remove the heating parts, minimizing heat transferred to the mother's.
g. Do not use liquid thermalization parts' rapid cooling. If you specify a rapid cooling is
required, then only to transfer air (use the fan or compressed gas evaporation).

3.14 Recommended Minimum Spare Part List

In order to ensure the shortest downtime, often should store the following spare parts:
1. concave
2. concave bolt
3. mantle
4. compression ring
5. The feeding cone head + bolt
The list includes only the minimum spare parts. If the crusher is installed in remote areas or many
crushers are installed at the same time, the content of the list should be expanded. Therefore,
please consult the factory, so that factory provide spare parts list according to your specific
situation. Before storing the spare parts, check whether the protective layer is damaged or not
before shipment.

Finally, when replacing bushings, bearings or major components and when starting the crusher
for the first time, we suggest to undergo the first test run do the run-in test run. Referring to
Chapter 3 General installation instruction.

3.15 Exclusive-use Tool

Only these tools can be delivered with the crusher, which are not easily to be bought in the
industrial products store.
These special tools include handling equipment needed for eye bolt eyebolt, dynamic cone lifting
plate, helium bottle interface, ball bowl - seat adjustment screw, accumulator table and
pneumatic components (standby), eccentric sleeve ring, jack screws, etc. In order to quickly
identify, all tools and crusher are coated with the same color, with a package shipped separately.

36
3.16 Prevent It from Rusty

During the seasonal downtime, or shipped overseas, or when the outdoor storage (winter or
summer), in order to prevent the crusher from rust, we suggest you following protective measures:
1. Remove the adjusting ring, feeding plate, moving cone, ball seat and eccentric components.
Off the oil drain at the bottom of the main frame and the bottom of the main shaft of oil
imports. Make sure all the pipes and holes at the bottom of the main shaft sealed up by the
tube plugs.
2. With wide paint brush, coating all inner surface of the main shaft with anti-rust oil.

Please use the lubricating oil containing corrosion inhibitor. This oil is used to protect the
enclosed equipment such as engines, compressors, pumps, gear set and the internal parts of
the hydraulic components. The function of corrosion inhibitor is to rule out the water on the
surface of the metal, and to became a strong waterproof membrane. By absorbing the water
in the system, to generate a water-in-oil emulsion.The rust resistance of the products is30 to
40 times that of the high quality lubricating oilwithout special preparation.

No need to wash down the residual rust-preventative oil membrane on these products. The
crusher filled with oil can be used normally, the anti-rust oil will get off itself.

Usually painting a crusher needs 208 liters (55American gallons). Oil viscosity in 38 ℃
(100 ℉) should be 150-300SSU.
3.
Use a paint brush brushes anti-rust oil on the exposed surface of thrust bearing, the outer
surface of the main shaft and pinion. From the top of the shaft frame or side unload the shaft
frame for oil hose, then put the funnel on the mouth of transmission shaft and pour the oil
into transmission shaft while it is running. Covered the entire shaft frame takes about 20 liters
(5 American gallons) of oil. It is normal to some leak from the shaft’s drive end. Then
reinstall the oil feeding soft pipe on the transmission shaft.
4.
Oil the lubrication holes on the main shaft until the holes are full of oil. Then drain out the
oil.
5.
Coating rust-proof oil on the outer surface of the eccentric sleeve lining, eccentric sleeve hole
and gear and friction plate.
6.
Coating special oil on the dynamic cone ball bearing, movable cone’s upper and lower
bushings and neighbouring "T" shape moving cone surfaces.
37
7.
Remounted eccentric component and ball seat components. Coating a layer of special oil on
the ball bearing surface and the exposed surface. Then, install the dynamic cone components
and feed plate.
8.
Pour the power device within the tank filling 38 ℃ (100 ℉) under the condition of similar
rust-proof oil viscosity 150 SSU. The whole hydraulic system requires 95 litres (25 American
gallons) of oil. Should ensure that the oil is suitable for poly (chloroprene rubber,
polyurethane, bronze, nickel, chromium, iron and steel material of hydraulic equipment.

Hydraulic iron separation system, lock and adjusting ring rotating mechanism must be in
action, in place to ensure that all power device and hydraulic components are all coated with
rust inhibitor.
9.
In the adjusting ring, support on the set of the screw and lock nut brush or spray a layer of
mild viscous oil solvents. The solvent contains a lot of metal surface has a strong affinity
polarity antirust additive.

Under the condition of water, the additive should have good wetting ability on the surface of
the metal. So it has a strong resistance to the role of water from the surface subsidence, the
solvent evaporation fast, volatilization, leave a thin, transparent film, grease. The material
shall be suitable for mild and moderate service situation, such as outdoor storage protection.
Solvent can operating temperature conditions in the factory, in any way (brush, roller,
spraying), when the crusher is put into production, the film also don't have to get rid of. Since
then, on the thread with plenty of lithium grease base NLGI no. 1. The grease containing
5.10% molybdenum disulfide.
10.
To pack good, adjusting ring components with a 8000th of an inch thick piece of black pu
membrane cover the whole adjustment cap and funnel, prevent water leaking into the crusher
corrosion adjusting ring and support thread. The film is at 20 feet / 100 feet plate volumes.
Because of the transparent film aging speed is 4 times of that of the black film, so it is
recommended to use black film. The end of the shaft frame and the shaft should be covered.
With steel band or steel to fix polyurethane film is ideal method.
11.
To pick up good inlet and exhaust pipe. Oil sticking to the metal surface is necessary for rust
proof.

If using the above Suggestions, outdoor storage of crusher antirust period is up to 6 to 12

months.
38
The crusher which must be in division of shipment or in storage place. Various emails must be a
more thorough protection, because of the above steps for not only directly exposed to the natural
environment (such as sunlight, wind, rain and snow) metal surface.

The crusher which must be in division of shipment or in storage place, and all parts must be
exposed to the natural environment, following suggestions:

1 With black pu film covering tile ball and spindle lateral, to encase the shaft frame by the
membrane, and across the fixture mouth taut. Crusher after rust-proof oil described earlier, the
covering film can protect the interior of the crusher. The film must tighten, prevent sagging.

2 Using special processing of bituminous material (add oil solvent liquid) coat the machining
surfaces and various elements. Such as the adjusting ring, feeding plate, moving cone, ball seat
and eccentric sleeve. This is a kind of medium thick black liquid, can be at room temperature,
using any kind of a convenient way. After the solvent evaporation, leaving a layer of hard, solid,
dry acid membrane. In most unprotected in open air and corrosive smoke harsh conditions, the
coating can be long-term protection, especially suitable for the outer surface of the paint. The
processed parts can stand the rough handling of obvious scratches and mild, but avoid serious
injury. Because of this hard dry oil film can't fix itself. The oil film is similar to paint. Although it
is a permanent, but after long-term use can rub with it with solvent rags rub out.

For those who are in outdoor parts without protection, antirust period can be up to 24
months after the above recommended practice treatment.

39
 Chapter 4 Operation Guide

4.1check the list before start a new crusher

Check before starting a crusher Yes No
1. Wedge between the mantle and concave is off or not.
2. Discharge size checked of the crusher is mm (″).
3. V belt tension and/or coupling correction.
4. Position relationship between the drive shaft’s sleeve oil groove
5. and drive device.
6. If eccentric sleeve component loose in transit, check the big
7. bevel gear and small gear tooth gap.
8. Drive shaft axial clearance is from 1.0 m (1/32 ') to 1.5 mm (1/16 ").
9. Referring to chapter 5.
10. Grouting and tighten between the crusher and the foundation.
11. Designed foundation leaves enough space for discharging
12. material, in case of material stockpiling.
13. Lubrication system：
a. Minimum Every 305 mm by 25 m(1:12), Tubing slope
b. is enough.
c. Check the lubricating oil in the tank trademark and brand，
d. Check the oil level in gas, detailed record the name and number.
Trademark No.
e. Piping installation according to the factory drawings
f. Filter, cooler, immersion heater, pressure switch,
g. temperature switch and the shaft air breathing apparatus and
h. other auxiliary equipment has been installed.
i. Alarm system (pressure switch, temperature switches lines)
j. has good according to the wiring diagram.
k. Accurate location of the relief valve (if provided) and pipes.
l. The rotation of the pump in the right direction
m. Pipe and pump link correctly.
n. The filter has exhaust (if provided)
o. Crusher and fuel tank vent hood installed correctly.
10. For oil and oil return pipeline has been cleaned.
11. All support the oiler is already loaded recommended set of grease.

40
 a. Check the hydraulic oil in the tank of the hydraulic pressure
b. station of trademark and brand, check the oil level in tank.
c. Detailed record the name and number.
d. The accumulator has inflated with release system.
Yes No
e. Hydraulic station all the hose is connected to the crusher.
f. Leakage of hydraulic circuit for inspection.
In order to ensure the adjustment ring device and the locking cylinder
works well, at least for an adjustment test.
start-up oil pump：
Before starting the crusher, return pipe in the oil temperature at
least 25 ℃（80℉）
Start the hydraulic station：

Crusher inching：
The drive shaft in the right direction.

Start the crusher：

1. Crusher run empty load, until the return pipe inside the oil
temperature to 27 ℃ (80 ℉) - at least 2 hours.
2. Crusher shaft rotates at RPM.
3. Check whether the crusher is leaking.
4. Idle load current is ampere.
5. Check the alarm system (pressure switch, temperature switch, flow switch).
6. Crusher under the condition of 50% at full power operation at least 2 hours.
7. At°，the main safety valve end to the oil tank。
8. Crushing cavity feed distribution is correct.
9. Crusher inertia parking time is second.

Six hours after the first run:

1. Supply oil and return oil temperature℃.
2. Give the user any Suggestions for improvement on the installation
3. Crusher run at least six hours under 75% at full power.

Mobile crushing station:

1. The chassis has been installed.
2. Using fixed rubber mat, rubber gasket thickness 12 mm (1/2 "), the crusher
3. moving freely uninhibited.

Make commentary and annotation：

41
4.2 preparation before starting
The good habit of checking machines will ensure the crusher work normally. Make the
maintenance regularly and make detailed the written record, please don’t pre-boot according to
your memory. Regular maintenance will reduce the stopping time and prolong the lifetime of the
crusher. Please do as follows before you start the crusher.
1. Check whether all the lubrication oil is right model, whether the lubrication system is
installed as the manual book.
2. Start the motor of the oil pump. Open the checking cover on the oil tank cover. Check the oil
return pipe in the tank, and ensure the oil is working in its circle.
3. Take out the wooden wedges which are huddled between the crushing lining plate when
transportation.
4. Check the axial internal clearance. It should can move smoothly from 1.0m (1/32 ″ ) to
1.5mm(1/16 ″ ) in axial of transmission shaft. Please refer to Chapter 5 installation of the
belt pulley.
5. Check again, ensure there is no tools or stumbling block, all the connectors and fasteners are
well fastened, no oil leak or other elements which will affect the crusher starting.
Move the transmission shaft by hand to check whether the mantle and concave bump against

4.2 preparation before starting

The good habit of checking machines will ensure the crusher work normally. Make the
maintenance regularly and make detailed the written record, please don’t pre-boot according to
your memory. Regular maintenance will reduce the stopping time and prolong the lifetime of the
crusher. Please do as follows before you start the crusher.
6. Check whether all the lubrication oil is right model, whether the lubrication system is
installed as the manual book.
7. Start the motor of the oil pump. Open the checking cover on the oil tank cover. Check the oil
return pipe in the tank, and ensure the oil is working in its circle.
8. Take out the wooden wedges which are huddled between the crushing lining plate when
transportation.
9. Check the axial internal clearance. It should can move smoothly from 1.0m (1/32 ″ ) to
1.5mm(1/16 ″ ) in axial of transmission shaft. Please refer to Chapter 5 installation of the
belt pulley.
10. Check again, ensure there is no tools or stumbling block, all the connectors and fasteners are
well fastened, no oil leak or other elements which will affect the crusher starting.
Move the transmission shaft by hand to check whether the mantle and concave bump against

42
 Mode of the
HPT100 HPT200 HPT300 HPT400 HPT500
crusher
Speed for the shaft
under full load 750-1200 750-1200 700-1200 700-1000 700-950
(RPM)
Form 4-1 Transmission shaft speed

The speed of the transmission shaft is determined by the material quantity in the crushing cavity
and the impact frequency. If the crusher can not running at the right speed, you can try to adjust
the speed to the higher level instead of lower level(10% higher is acceptable) . The over
compression in the crushing cavity will cause crusher stoppage and severely damage of the
crusher running.

For example, If the recommended speed for the transmission shaft is 1020RPM, When the
transmission speed is between 1020RPM and 1122RM(1020RPM+10％，-0％), the transmission
shaft speed will not influence the performance of the crusher , Under certain circumstance, It is
recommended to adopt slightly higher speed to change the material size or the shape of the final
products while keeping the crusher’s passing through capacity. Please confirm with the seller on
the details if you want to adjust the transmission shaft speed.

Because the speed of the shaft is very high, the pulley of the crusher and the motor must be made
of nodular cast iron.

4.4 Rotation direction of the transmission shaft.

The rotation direction of the HPT Series hydraulic cone crusher is clockwise rotation. The
rotation direction is confirmed when you face the driving part of the transmission shaft , The
rotation direction is very important because the mantle is compressed on the moving cone by
automatic self-locking bolts, Only when the rotation direction is correct, the self-locking will
play a role.
Note: Before you set the v-belt, Please check the rotation direction of the motor, the rotation
direction should be clockwise rotation..

4.5 Operation of hydraulic station.

In order to keep the locking pressure of adjusting ring and the released pressure of cylinders, and
keep the support sleeve t the main frame, the motor of hydraulic station oil pump should be
plugged in the power source when the crusher is in operation. And it should be done before
starting the crusher. When adjusting crushing cavity, or forcing after loose the crushing cavity, or

43
operating the return circle of clear the cavity, the motor of oil pump of hydraulic station also
should be operating continuously.
The operation of hydraulic station, please refer to the manual book.

4.6 First run and running-in process

Although crusher has been tested in factory, for the first start up or first time running after
installing new bearing, The crusher should run under empty load or under lower load for several
hours. This will ensure that all the components can be lubricated, During this period of time, to
check the temperature for the lubrication oil frequently is necessary. Please refer to the chapter
lubrication oil for lubrication manual.

The step for first start up and the start up after you change the new inner bushing and outer
bushing is as follows:
1.
Start the lubrication system before you start up.

In order to guarantee that the bearing can get enough lubrication oil, before you start
production, the temperature for the return oil should be not less than 6 ℃ (77 ℉ ), If
necessary, Use the submerged heater to heat the oil.
2.
Hydraulic station should start up before the crusher running.
3.
Start the crusher and run it under empty load for two hours and make sure that the oil
temperature can get 27℃(80℉)
4.
After the 2 hours running under empty load, start feeding material and keep the electric
current reach 50% of the rated current on the motor’s nameplate. And keep the crusher
running for four hours.
5.
After the 6 hours running (step three and step four) Keep the electric current at 75% of the
rated current for 8 hours.
6.
After finishing step 3 , 4, 5, the crusher can run under full load, the current can get 100% of
the rated current or the supporting sleeve is about to lift.
7.
After the trail run finish, please take the sample of the oil and take to the testing lab.
8.
Take daily records according to the method mentioned in the last chapter.

44
4.7.1 Daily start up
1.
Before starting the crusher, please confirm that the return oil temperature is not less than
27℃(80℉)

You need to guarantee that the bearing is fully lubricated, at the same time, the return
oil temperature should be not less than 16℃(60℉), If the return oil temperature is less
than 16℃ (60℉ ) when you stop the machine, Please use submerged heater to heat the
lubrication oil, If the circumstance for the site is extreme cold, no matter whether the
stone crusher is running , you need to keep the heater and the oil pump is running , If it
is still not functional, Please change to adopt the ISO150 lubrication oil.
2.
Before stating the crusher, lubricant should cycle for at least 1 minute.

If there is no oil discharged from pipe for return oil, the crusher should not be allowed
to run for more than 15 seconds. Otherwise it may cause serious damage for the crusher.
Decrease of oil flow might caused by many factors, such as insufficient lubrication oil,
oil pump failure, performance failure for the oil pump, improper setting for the relief
valve and blockage of oil pipe.

3.
You need to start the hydraulic station before you start the crusher. Check the Indicator light on
the control panel and make sure the hydraulic station is running and the pressure for

4.7 Daily start-up and shut –down procedures

After the test running, the daily start up and shut down procedures are very important

4.7.1 Daily start up

4.
Before starting the crusher, please confirm that the return oil temperature is not less than
27℃(80℉)

You need to guarantee that the bearing is fully lubricated, at the same time, the return
oil temperature should be not less than 16℃(60℉), If the return oil temperature is less
than 16℃ (60℉ ) when you stop the machine, Please use submerged heater to heat the
lubrication oil, If the circumstance for the site is extreme cold, no matter whether the
stone crusher is running , you need to keep the heater and the oil pump is running , If it
is still not functional, Please change to adopt the ISO150 lubrication oil.
45
5.
Before stating the crusher, lubricant should cycle for at least 1 minute.

If there is no oil discharged from pipe for return oil, the crusher should not be allowed
to run for more than 15 seconds. Otherwise it may cause serious damage for the crusher.
Decrease of oil flow might caused by many factors, such as insufficient lubrication oil,
oil pump failure, performance failure for the oil pump, improper setting for the relief
valve and blockage of oil pipe.
6.
You need to start the hydraulic station before you start the crusher. Check the Indicator light
on the control panel and make sure the hydraulic station is running and the pressure forreturn
oil is normal. If the chamber for the release improper pressure, Pressurize the return circle
according to the manual for hydraulic system.
7.
Start the crusher and operate for five minutes with empty load.
8.
Start from small amount of feeding material and gradually increase feeding until the current
can get 100% of the rated current or the supporting sleeve is about to lift.

4.7.2 Daily shut down

1.
Stop feeding and keep the crusher running for 2-3 minutes under empty load.
2.
Stop the crusher and the minimum deceleration time is about 45 seconds.
3.
After you finish step two, you can stop the lubrication system, If the circumstance for the site
is extreme cold, you need to keep the heater and the oil pump is running
4.
Stop the hydraulic system.

4.8 Adjust the discharge opening

The discharge opening is not totally determined by the final product size needed. Sometimes, you
need to adjust close side opening between the mantle and concave and make it smaller than the
max output size needed, When you want to get different output size, you need to readjust the
supporting sleeve , At the same time , you need to adjust the adjusting ring when the mantel and
concave is ware.

46
The best discharge opening is to guarantee the crusher can get the largest passing through capacity.
This is determined by the raw material’s characteristics, and the motor’s driving power or
supporting sleeve’s moving.

You can get the discharge opening adjusted by lifting or lower the adjusting ring, the supporting
sleeve falls when it is rotates clockwise, and it will rise when rotating counter-clockwise.

Adjusting ring going down and reduce the discharge outlet, adjusting ring go up and increase the
discharge outlet, please referring to Chart 3-1

When the adjusting ring falls, the discharge opening decrease, and when the adjusting ring raise,
the discharge opening increase.

After finish the adjustment, check whether the pinion in the hydraulic motor and the tooth plate
match with each other completely, If not, the adjusting ring might fall during the operation.

Number Name
1 Concave
2 Adjusting ring
3 Supporting sleeve
4 parallel band
5 Mantel
6 moveable cone
Adjust the discharge opening

47
4.9 rotating the adjusting ring

4.9.1 Adjust the adjusting ring with the hydraulic system.

Use the hydraulic adjusting system to make the adjusting ring screw in the support sleeve part, and
set up the discharge opening. Refer to the following chapter of instruction for adjusting,
disassembly and installation.

4.9.2 Using wire rope to rotate movable cone

If there is no crane lifting equipment, you can use the steel wire rope to rotate the adjusting ring
alternatively to rotate in or rotate out the support sleeve part. The step is as follows:
1. In order to let the adjusting ring screw in the support sleeve part and get the discharge
opening you want, please refer to the disassembly and installation instruction after this
chapter, release the pressure of locking returning circle.
2. Fasten a piece of steel wire rope to one lifting hook of the adjusting cap, in order to get the
revolution you wanted, fasten the steel wire rope to a suitable side of the adjusting cap.
3. Wind the steel wire rope on the adjusting cap for a few circles, and fasten the other end to the
loader, tractor, winch, truck or other traction equipment. Ensure the steel wire rope is
dragged by straight line in parallel. Maybe there need pulley or pulley block to somewhere of
the machine, and the wire rope through them to drag the adjusting cap in the same level.
4.
Pull the steel wire rope carefully until all of the twining wire rope loose, twin the wire rope
again according to the times of install or disassemble the adjusting ring need.

4.10 Minimum discharge outlet

In any case, please do not adjust the discharge opening to make the support sleeve bounced (ring
bounced). The support sleeve bounce will cause the abnormal internal stress of crusher, and
damage the main shaft.

48
There is suggesting minimum close site setting(discharge opening) in table 4-2, for your reference,
you can adjust it according to your raw stone, but ensure the support sleeve will not bounce or
strike.
Item Name
condition of Release or
1
rotation
2 condition of float
3 Condition of crushing
4 Adjusting ring
5 Support sleeve
Figure 4-2 mesh of adjusting ring thread and support sleeve

Model Cavity Min CSS

Extra fine 4mm(3/16″)
Fine 6mm(1/4″)
HPT100 Medium 9mm(3/8″)
Coarse 13mm(1/2″)
Extra coarse 21mm(13/16″)
Fine 13m(1/2″)
HPT200 Medium 16mm(5/8″)
Coarse 19mm(3/4″)
Fine 14mm(9/16″)
Medium 17mm(11/16″)
HPT300
Coarse 19mm(3/4″)
Extra coarse 25mm(1″)
Fine 16m(5/8″)
HPT400 Medium 22mm(7/8″)
Coarse 25mm(1″)
Fine 16m(5/8″)
HPT500 Medium 22mm(7/8″)
Coarse 30mm(1-3/16″)
Form 4-2 Min CSS

4.11 Inspecting the discharge opening

Fasten a lead at the end of a strong and soft metal wire, then put it into crusher cavity slowly
when the crusher is running with empty load and confirm the lead has passed through parallel
strip of crushing cavity. In the same way, put the lead block into crusher quickly and measure its
thickness. Through this method, you will know the discharge opening of the crusher. When the
crusher is running with empty load, the moveable cone is running counter clockwise with the
speed of 300RPM.

49
When the materials are fed into the crushing cavity, the movable cone will stop and rotate in
clockwise direction, its speed is approximate 10RPM. In order to get the accurate discharge
opening, the speed of the movable cone should be as low as possible. There are two ways to
realize it.
1. When starting, that is when the driven shaft reach its normal rotation speed, before
movable cone self-rotation speed increasing, insert the lead to the parallel strip to measure
the discharge opening.
2. Keep crusher working, but stop feeding it. Then at the moment of materials are cleared from
the crushing cavity, put the lead to the parallel strip.
Because the zinc can not be pressed easily, please do not use zinc to check the crusher discharge
opening. Using zinc to check it may get wrong result because the support sleeve maybe uplifted
slightly.

In order to confirm whether the discharge opening around the crushing cavity is same, we
suggest to put leads to four different positions of every 90° interval. Compare the four thickness,
you will see whether the support sleeve inclined because of uneven wear of the crusher caused
by materials feeding unevenly. The right feeding method refers to figure 3-1.
If operating the crusher when support sleeve is inclined, the processing capacity of crusher will
decrease much and the spring will bounce excessively.

4.11.1 Suggestion for standard crusher operation

Through to vary the feeding capacity to control the crusher. Bigger feeding capacity will request
bigger driven power. And smaller feeding capacity request lower power. According to the design
of return circle and control system, you should try to make the actual operation power be close to
the full rated power. And avoid the peak to reach 110% of rated power. In order to keep the power
peak in a safety range, it may need to reduce the capacity. Anyhow, the crusher should not be
operated more than a few seconds in the low power. When crushing, the driven power should be
more than 40% rated power at least. In the short period of start and stop, it may appear lower
power. If the crusher will be not fed the materials more than 30 minutes, you should stop it until it
will be fed. Besides, once the feeding capacity exceed the volume of the crushing cavity, the
materials will begin to pile up upon the crushing cavity.

Higher feeding speed will increase rising speed of materials level of the crusher cavity, and lower
feeding speed will reduce the rising speed of materials level of the crusher cavity. If keep the
lower feeding speed, the feeding capacity will be lower than the volume of crushing cavity, and
the materials level in crushing cavity will drop.

The best operation condition is the materials level is 300 mm(12 inches) higher than the cone head
of the cone crusher. It is called “fully feeding condition”. Under this condition, the feeding

50
materials will be uniform distributing in the crushing cavity, avoiding the power to reach peak
because of the small change of the feeding capacity.
The spare ultrasound material level convertor can be used for detecting the material level of
crushing cavity, or the input signal of controlling the return circle of feeding capacity.

Use the option switch of crushing cavity(design of concave and mantle) and close side setting to
create the operation condition of “fully feeding”(the materials level is 300 mm(12 inches) higher
than the cone head of the cone crusher), and make the driven power between 75%-100% of rated
power. Once it is in the condition of fully feeding, the driven power can be optimized by the
discharge opening, when you enlarge the discharge opening, the driven power for feeding
materials to the materials level will be reduced, but the feeding capacity to keep the materials level
will be increased. When you decrease the discharge opening, the driven power for feeding
materials to materials level will be increased, but the feeding capacity to keep the materials level
will be reduced.

Smaller discharge opening means the outputs size is smaller.

The discharge opening is adjusted by the hydraulic motor. Adjust it when there is no feeding. We
suggest to control the crusher by varying the feeding capacity, and minor control the crusher by
discharge opening. Suggest to make up the wearing of lining plates by adjusting discharge
opening to keep the outputs size.

Discharge opening should not be adjusted more than once in an hour.

4.12 movement of adjusting ring

Only there is iron or metal going through, the adjusting ring will move. If the support sleeve
moved and keep continuous movement, it shows the crusher is overloaded. It may lead to the low
efficiency of screening, uneven distribution of materials feeding, and other problems. The
solutions for supporting sleeve movement are to enlarge the discharge opening, reduce feeding
capacity, or replace the base plate.

51
 Item Name
support sleeve, in the
1
suspension position.
2 main frame
Figure 4-3 movement of adjusting ring
benefits of no movement of ring:
 prolong the lifetime of the crusher parts
 continuously stable capacity
 longer lifetime of lining plates
 more steady driving power
 lower maintenance cost

The loss caused by the movement of adjusting ring is not in the purview of guarantee.

4.13 confirm the worn of lining plates

When you want to confirm whether the lining plates are worn to the limitation and need to replace,
please refer to the follows. Exact record can help to confirm the lining plates wearing without stop.
According to the first set of lining plates, please make the record as follows:

1. When the discharge opening is set well, make the mark on the teeth which is located in mesh
of the hydraulic adjusting device and adjusting gear plate, and the mark shows the initial
discharge opening. When the adjusting gear plate rotate to next tooth, the vertical shaft of the
adjusting ring will be a small adjustment. Refer to Figure 4-4.
2. In the daily operation, make the exact record of the actual teeth used by the first set of lining
plates, from the first position to the end of the lining plate service life, record the teeth of
every position.
Because there is no completely same operation of two sets of crusher, and there are the various
types of lining plates and thickness variation, casting error, for one set of lining plates, before its
service life ending, we cannot know the teeth numbers of the adjusting gear plate rotated.
52
Under the standard operation condition, when the service life of the lining plate is ended,
approximate 50% weight of the lining plates may be consumed. The data may change to higher or
lower when it in the certain surroundings. Do not adjust the adjusting ring down to the position
where may contact with the obstruction between adjusting cap and support sleeve.
3. After a set of lining plates using up, record the teeth of adjusting gear plate rotated before
rotate the adjusting ring in the support sleeve, and paint a short horizontal line on the scraper
seal located the lower edge of adjusting cap.
4. Install the new lining plates and record the teeth numbers the adjusting gear plate moved.
Compare with the teeth numbers when the first set of lining plates worn out, you can confirm
the wearing level of the lining plates. Along with the changing of discharge opening,
adjusting cap will move down a little, and the mark on the scraper seal also will indicate
when will the lining plates will worn out. Because there are no lining plates can be worn
same, you can do this for several times in order to get a more accurate average level.

Note: in general, when the thickness of the bottom of lining plates located the discharge
opening is less than 25mm, you need to replace the lining plates. It is just for your reference,
because for different raw materials, the wearing location will be different. After using, you
need to make maintenance regularly, ensure the lining plates will be replaced in time.

As a tool of operator, table 4-3 lists the teeth numbers of the adjusting gear disk when adjusting
ring rotates one circle, the vertical stroke and the discharge opening size changing when the
adjusting ring rotates one tooth. When the wearing of the lining plates reaches its limitation, the
approximate
minimum height of the adjusting cap and support sleeve is shown in figure 4-5 and table 4-3.

Item Name

53
1 key seat
2 adjusting gear disk
3 hydraulic adjusting system
4 teeth of pinion
5 minimum discharge opening
make initial position mark in the
6
adjusting gear disk
Count and record the initial position of
7 the first set of lining plate, record the
teeth numbers they rotated.
8 maximum discharge opening
9 adjusting cap
Figure 4-4 pinion and teeth position of adjusting gear disk

54
 Item Name
1 Adjusting cap
2 Adjusting ring
3 Adjusting cap position when the lining plate is new
4 size“A”，refer to table 3-3
Position mark in the scraper seal in the bottom of adjusting cap when the lining
5
plate is worn.
6 Support sleeve.
7 Scraper seal
Figure 4-5 adjusting cap position when the lining plates are worn

“A”—
teeth numbers Vertical stroke discharge discharge
approximate
of the adjusting of adjusting ring opening size opening size
minimum height
Crusher gear disk when when the changing when changing when
of the adjusting
model adjusting ring adjusting gear the adjusting the adjusting
cap when the
rotates one disk rotates one ring rotates one gear disk rotates
lining plates are
circle tooth tooth 1/4 circle.
worn.
0.36mm 0.27mm 7.1mm
HPT100 106
(0.014″) (0.009″) (1/4″)
0.28mm 0.18mm 6.3mm 54mm
HPT200 138
(0.011″) (0.007″) (1/4″) (2-1/8″)
0.33mm 0.23mm 8.73mm 50mm
HPT300 150
(0.013″) (0.009″) (0.014″) (2″)
0.29mm 0.20mm 8.9mm 29mm
HPT400 176
(0.011″) (0.008″) (11/32″) (1-1/8″)
0.26mm 0.18mm 8.5mm 30mm
HPT500 190
(0.010″) (0.007″) (0.344″) (1.18″)
Table 4-3 teeth numbers of adjusting gear disk and stroke of adjusting ring

55
4.14 Screw-thread’s lubrication
Since adjustment ring is the adjustment part of cone crusher, we should termly smear grease on
the adjustment ring’s screw thread and support sleeve’s screw thread. This lubricant method will
ensure the important point: the adjustment ring can rotate swimmingly in the support sleeve.

There are several grease zerk around the side face of adjustment ring, so the grease can be
injected into the thread of adjustment ring inside the support sleeve. See chart 4-6

No matter what adjustment ring is in crushing condition or in release condition, the grease must
be injected into the zerk. Set up a regular maintenance plan to feed the zerk. Use lithium base
grease, for example, NLGI No.1 or same specification. Under this condition of high-temperature
working, It is better to mixed grease with 5-10%(by volume) molybdenum disulfide powder,
because we already found this mixing way could get satisfied effect.

Item Name
1 Grease zerk
2 Support house
Chart 4-6 Grease zerk

4.15 Adjustment ring and support sleeve’s thread abrasion

Please check the adjustment ring and support sleeve’s screw thread abrasion when replacing the
bowl liner and mantle. To confirm the abrasion level, we should check the vertical distance
difference between locking and unlocking the adjustment ring. Measure the size “H” from the
top of support sleeve to the bottom of adjustment cap in both condition: when unlocking
adjustment ring; when locking adjustment ring. See chart 4-7.
Item Name
1 Adjustment cap
2 Dust shield
3 Locking cylinder
4 “H”size
5 Gasket
6 Support sleeve
Chart 4-7 Support sleeve to adjustment cap

New crusher has movement distance 2.75mm(0.108”) without any screw thread abrasion. Any
additional movement distance said screw thread has been wear and tear. That means screw
thread has been worn off 4.75mm (0.187”) when vertical movement is maximum 7.5mm(0.295”).
We must adopt corresponding measures before this movement distance is expanded to 7.5mm.
When this movement distance is expanded to 7.5mm (0.295”), that is screw thread has been
worn off 4.75mm(0.187”). At this time, we must add the gasket with same worn thickness

56
between the lock cylinder and lock nut, this action will ensure the lock cylinder has enough
movable distance to lock the adjustment ring. Moreover, the tube washer should be added
length 4.75mm(0.187”) under the big cap bolts. See chart 4-8.
We only have once to add the gasket on the lock cylinder. After adding gasket on the lock cylinder,
if the vertical movement distance is expanded to 7.5mm(0.295”) because of abrasion between
locking and unlocking. Then we must reprocess the screw thread of adjustment ring or support
sleeve, even reprocess both of these two parts.
Item Name
1 Flat washer
2 Lock nut
3 Washer
4 Support sleeve
Chart 4-8 Tube washer
4.16 Adjustment ring rotate in difficulty
If the adjustment ring can’t be rotated, the reason may be the screw threads’ surface has been worn
badly or scratched on the adjustment or support sleeve or both of them. There is single wire rope
tied to adjustment cap. When we use this wire rope to pull the adjustment ring and then get the
adjustment of discharge opening, the new adjustment ring often happen this abrasion of screw
threads inside the support sleeve. When using this way for adjustment, as usual, we will use trailer
or loader which drags the wire rope to rotate the adjustment ring.

If we use the single wire rope to screw the adjustment ring in the support sleeve, adjustment ring
tends to tilt inside the support sleeve’s screw threads. Especially, if the dragging is not level, this
tilt will lead that outside diameter of adjustment ring’s screw threads may have point contact with
the flat surface of support sleeve’s screw threads in screw threads may be worn or scratched. This
damage only happens at the first lap screw thread’s flat surface of adjustment ring and support
sleeve. Since the adjustment ring is screwed in the support sleeve, the screw threads are scratched
to produce metal scrap, these metal scrap may damage the rest of screw threads. If we adopt this
way to disassemble the adjustment ring, it may lead to similar damage on screw threads.

If the abrasion and scratches were happening, please check the following way to install and
disassemble the adjustment ring, this way will reduce the screw threads’ abrasion to minimum.

1. Rotate the adjustment ring. Please use overhead crane or other hoisting equipment and then lift
the adjustment ring to the position shown in chart 4-2, adjustment ring is in a condition of
suspension. Under this condition of suspension position, two persons can move up and down the
adjustment ring to get the suitable discharge opening. Once the adjustment ring is rotated a quarter
circle, we should lift or drop down it a little to ensure that the adjustment ring can keep freedom in
the support sleeve. Use this way to rotate the adjustment ring two circle at least.

57
Or, use a pair of wire rope to drag the adjustment ring for screwing in or screwing out.
Or, use hydraulic adjusting device to rotate the adjustment ring two circle at least. .
After the adjustment ring has been screwed two circles in the support sleeve, we can use single
wire rope to drag the adjustment ring for the rest of rotation. Please ensure the adjustment ring will
be dragged slowly and evenly (about rotate a circle per minute). All the steps are on the contrary
when disassembling the adjustment ring.
To prevent that adjustment ring become loose in the support sleeve, it needs apply big active force.
It will cause the adjustment ring rotate with difficulty in the support sleeve, if we do one or several
wrong operating conditions as following:
1. Crush heated material, slag, sintered material and so on, use improper lubricating grease of
screw thread.
2. Not lubricate the screw thread of adjustment ring and support sleeve in accordance with the
recommended time period.
3. Dustband has been worn or installed improperly, see chart 4-9 .
4. For long time, no adjust the discharging opening.
5. Crusher is placed in some place without proper protection, the spare parts are exposed out,
especially suffer the rain.
To avoid this condition: adjustment ring rotate with difficulty in the support sleeve, our advice is:
often does the following operant behavior:
1. Termly loosen the adjustment ring from crushing condition then rotate it forward and
backward.
2. Inject the grease into the zerks around the adjustment ring. Set up a regular grease adding plan.
Use the lubricating oil type we have recommended in this chapter (screw thread lubrication
section).
3. During the first installation or when being ready to install the adjustment ring after
disassembly, please clean the screw thread and smear lubricating grease. The grease must be
the type we recommend in part 6.1 component assembly.
4. Often check the seal’s abrasion of adjustment ring.

58
 Item Name
1 Adjustment cap
2 Seal part
3 Adjustment ring
4 Lock nut
5 Dust shield
6 Support sleeve
7 Main frame
Chart 4-9 Dust shield and sea
If the adjustment ring is stuck in the support sleeve and can’t be rotated when using the former
method. Please take measures according to the following way:
1. During crusher working, feed some material into the crusher when the adjustment ring is
loosened.
2. Inject the penetrating oil or anti- solidification agent, and inject the same solvent into the
grease zerks around the support sleeve. Penetrating oil or anti- solidification agent can
loosen any concrete dirt which come into the screw thread, and also loosen the rust. Rotate
the adjustment ring with largest strength. If this step can’t work, let the crusher parking a
few hours. Smear the penetrating oil or anti- solidification agent around the screw thread ,
then do the former step again.

4.17 Clean the crushing chamber

In case the crusher park with load, please never restart crusher before thoroughly cleaning the
crushing chamber. When the crushing chamber filled with material, try to restart crusher will
damage the crusher and electricity motor.
There are some reasons which lead to crusher’ parking with load, as following: because of
electrical fault or engine oil shortage; feed overmuch material into crusher leads to crusher stall;
under the discharging opening, belt conveyor parking leads to material accumulation and
59
blocking the crusher; iron come into the crusher chamber.
When cleaning the material or iron between the movable cone and concave, please note the
following steps, at the same time the electricity motor must be working in the hydraulic station.
Please check the instruction manual of hydraulic station.
1. Turn the selector switch to adjusting position in the electric control cabinet. Pressing the
cleaning button without loosening till insurance cylinder completely comes out.
2. In most condition, material will fall down and crushing chamber will be cleaned thoroughly.
Low release pressure, the red indicating light is on.
3. If the crushing chamber is not cleaned completely, put the security block between the main
frame and support sleeve. This will ensure the support sleeve and adjustment ring still keep
rising, in case the pressure suddenly fall because the hydraulic pipe or pump or hydraulic
cylinder get fault. See chart 4-10.
Caution:
All security blocks should be put firmly between main frame and support sleeve before
employees are ready to clean the crushing chamber. In case the hydraulic system gets faults, this
one measure to prevent that hand or arm are caught.
Caution:
Do not put the hand or leg between main frame and adjustment ring. Security should always be
located between main frame and adjustment ring when cleaning the iron and adjustment ring is
in the rising position.
4. Press pressurization key, support sleeve and adjustment ring will fall down to security block.
All equipment and persons should be away from support sleeve till support sleeve meet the
security block.
Caution:
Never try to clean the material in the chamber before putting the security block in. Although we
eliminate the compressing force which are from energy accumulator and cylinder, the hydraulic
fault might still happen. The hydraulic fault will lead that the adjustment ring fall down and big
damage.

5. Eliminate the big material and iron which can not pass the crushing chamber.
6. When cleaning all material in the crushing chamber, please press down the cleaning button
till insurance cylinder completely hold out. At this moment, support sleeve and adjustment
ring are raised away from security block, then take away the security block. Ensure all
equipment and persons are standing away from the support sleeve, let support sleeve fall
down to main frame and then increase the pressure.
7. Check if the installation is steady around the support sleeve. If not, please lift up the support
sleeve again, then fall it down. If support sleeve is installed unsteady, please never increase
the pressure of insurance cylinders (if increase the pressure, it will get damages).
Eliminate too much miscellaneous iron is much important. Insurance cylinders can let iron pass
easily, but much iron will lead that main frame seat gets damages. If there is much iron in the
feeding material, we must install the iron separator. If the main frame is damaged because of too
much iron passing, this will be not guaranteed within quality guarantee.

60
 Item Name
1 Main frame
2 Pin bolt of main frame
3 Security block
4 Support sleeve is located at top position
Chart 4-10 put the security block

4.18 Disassembly and installation of adjustment ring

To create the requirements to disassemble the mantle or other parts, please disassemble
the adjustment ring assembly according to the following steps.
1. Adjustment ring loosens locking (see the instruction of hydraulic system).
2. According to the ways in the front part of this chapter, use overhead crane or mooring
rope dragging way to install the adjustment ring. When adjustment ring is installed in
the support sleeve, please rotate it by clockwise sense. For disassembling it, please
rotate it by anti-clockwise direction.
4.19 Thorough repair
For the heavy abrasion and the parts which is difficult to follow a routine maintenance after
long time working, we can let technician use professional facilities to check and repair the
complete crusher machine or process some parts again in manufactory. Reality proves that
sending crusher machines back to manufactory for repairing is desirable and beneficial. Get
the thorough repair in time is more economical than just replace some worn parts. The
crusher will be disassembled thoroughly, then all parts will be checked to ensure whether
the parts can be continued to use, and use the parts from manufactory instead of the worn
parts. This will ensure the crusher can run well.
Before abandoning movable cone, adjustment ring, support sleeve or main frame and other

61
 worn parts, please send machine to manufactory for thorough repair. It will save much cost
by processing these parts again.
4.20 Periodic maintenance
After the crusher have been installed well and working a period, please check and repair the
crusher, this will keep the crusher work well and continuously. We advise it is necessary to
check and repair crusher before heavy damage happening. The content of maintenance and
maintenance period is in the 5th chapter. The content of maintenance is only for reference.
To ensure whether you should repair it in advance or delay the maintenance, a few time
adjusting is necessary.
The material type crushed, environment and operation condition will decide the frequency
of maintenance.
Please keep crusher is clean and the pain is in good condition. Generally, one clean crusher
can work well must get the careful maintenance, and will never damage soon like crusher
without maintenance or misused.
The maintenance time should be changed with the application and site condition, then
maintenance period had better be decided from actual operating experience.

62
 Chapter 5 Check and repair period
Daily record of crusher operator
If discharging
Lock and release
Environ- Oil Inertial opening is
Oil temperature℃(℉) Driving Close Alarms check the low pressure
Worker ment press running unblocked
power discharging indicator light
name’s tempera- -ure time （blocked）
KW opening
initial ture℃ Gear Oil BAR （secon
Drive (AMPS) mm(inch) Norm- Abnor
(℉) cham return (PSI) d） off on
shaft al -mal
-ber

63
64
 Daily check and maintenance

Item Result Normal condition

1 Check the tank oil level Within the scope of oil level meter
Returning oil：
2 Check the temperature of returning oil
35℃-57℃(95℉-135℉)
3 Check the oil pressure of drive shaft oil box 0.14-0.28MPa（1.4-2.8Bars）
4 Check the oil pressure difference of oil filter 0.03-0.3MPa（0.3-3Bars）
Check driving power and material lever in
5
crushing chamber
6 Check close discharging opening
Check the release pressure of crushing See the appendix of hydraulic
7
chamber system
8 Check the lock pressure 16.5-19MPa(165Bars-190Bars)
9 Check the material distribution
Check if it’s unblocked at the discharging
10
opening area, clean the bonding material.
Check the counterweight guard plate and
11
guard cover’s abrasion condition.
12 Check inertial stop time >45 seconds
Check if the fastening parts and joint are
13
loose.
Check the abnormal noise that proves the
14
crusher parts excessive wear or abrasion.
Check if the crushing plate (mantle and
15 concave) reach the wear limit, if it is loose,
break, or wear out.
Check the movement condition of support
16
sleeve
17 Check the oil flow and filter screen
Chart 5-1 Regular check and maintenance

Weekly check and maintenance

Normal
Item Result
condition
1 Check the driving shaft frame and oil tank’s ventilation device
2 Check if the oil pipe is leaking
3 Check concave, cone head, and concave fastening and abrasion
65
 condition.
Inject grease into the screw thread of support sleeve when
4
unlocking. Then inject grease when locking.
5 Check the metal and debris in the filter screen of oil tank.
6 Check the movement condition of support sleeve
7 Check the tension and correction of V-belt.
8 Check leakage situation of lubricated oil
9 Check if flying wheel has crack, if the shaft is fastening.
10 Check if cone head fastening.
Check if the indictor light is working well in the remote control
11
button box.
Check the abrasion condition for driving shaft, guard plate of
12 large steel rib, counter weight, movable cone and main frame
lining plate.
Chart 5-2 Regular check and repair (continued)

Monthly check and maintenance

Item Result Normal condition
Check the pre-charge pressure of energy accumulator, if See the appendix of
1
need, add nitrogen. hydraulic system
Check the meshing between small gear and adjusting gear
2
disk in the adjusting device.
Check motor and lubricated oil according to the advice of
3
manufacturer.
From crushing condition, loosen the adjustment ring
4 assembly and rotate the adjustment ring forward and
backward.
Check the dirt and impurity inside the lubricated oil, if
5
need, change new oil.
6 Analyze the pollution level of lubricated oil See oil pollution guide
7 Check the axial clearance
Chart 5-3 Regular check and maintenance (continued)

Yearly check and maintenance

Item Result Normal condition
1 Thoroughly disassemble the crusher, check the surface of

66
 all bearings (bushing of adjustment ring, eccentric sleeve
lining, and head bowl), and the abrasion of all gears.
Check if main frame, movable cone, adjustment ring have
2 fatigue crack (especially, the main frame flange and
reinforcing rib. )
Check all fastening parts and pipes’ joints’ fastening
3
condition
4 Check the spherical bearing abrasion of movable cone.
5 Check the abrasion of big and small drive gears.
6 Check the dust sealing condition.
Change the lubricated oil in the hydraulic driving gear
7
reducer.

Lining plates’ replacement and checking

Normal
Item Result
condition
Check the fitting surface of lining plate on the adjustment ring and
1 movable cone. Grind any nick and burrs on the movable cone and
adjustment ring.
Check the abrasion of the mantle, spherical bearing of movable
cone, head bowl, eccentric sleeve lining and dust sealing. Use feeler
2
gauge to check the fit clearance between movable cone bushing and
adjustment ring.
Check the locking nuts’ abrasion of mantle, and cone head’s
3
abrasion. If it is necessary, please use new one instead of worn parts.
Check the abrasion of the following parts, guard plate of large steel
4 rib, guard plate of driving shaft frame, and guard plate of fan
machine.
Check the abrasion of following parts, adjustment ring, support
5
sleeve, and screw thread of lock nuts.
6 Check the leakage and damage of all hydraulic soft pipes.
7 Check lining plates’ wedge block and nut fastening condition.
8 Check the fastening condition of counterweight parts.
9 Check guard plate abrasion of counterweight parts.

Chart 5-4 Regular check and maintenance (continued)

67
 Table 5-4 Regular Check and maintenance（Supplement）
8 hour（Daily 40 hour（weekly 200 hour（monthly 2000 hour（Annual
Checking） Checking ） Checking ） Checking ）
1. Check the tank oil 1. Check the tension, 1. Loose the adjusting 1. Check movable
level wear and tear of ring assembly from cone and eccentric
V-belt crushing position, sleeve wearing
turn back and forth conditions.
2. Check crusher 2. Check all the oil 2. Check lubrication 2. Check big/small
return oil pipe, flexible pipe, oil pollution and gears wearing
temperature, gear conduit, connector sediment, change conditions and gear
chamber have fluid leakage new oil when tip clearance
temperature and or not necessary
drive shaft
temperature
3. Check drive shaft 3. Check concave and 3. Check metal 3. Check ball tile
oil pressure mantle fastening or (bronze) debris on wearing conditions
not oil filter of tank.
Little debris is
normal, if much, it
means the bearing
surface pressure is
too high, or already 4. Check movable
broken. cone ball surface
4. Check driving 4. Check crusher 4. Check movable wearing conditions.
power of motor discharge opening cone and concave
wearing conditions
5. Check release 5. clear the ventilation 5. Check cone head 5. Check adjusting
pressure of crushing device of drive shaft wearing conditions ring, fasten nut and
chamber frame and oil tank support sleeve screw
thread wearing
conditions and
scratch situation
6. Check the fastener 6. When adjusting ring 6. Check balance 6. Check gasket,
and the connector is on crushing weight, movable filling” O” ring
loose or not position, oiling the cone, main structure leakage or not
support sleeve and and drive shaft
adjusting ring screw frame wearing
thread with the oil conditions
nipple on support
sleeve.
7. Check and show 7. Check movement of 7. Check alarming 7. Check main frame
abnormal noise due support sleeve system( pressure liner wearing
to the crusher stitch, temperature situation
wearing parts switch) good or not
68
 wearing or
deformation
8. Daily Check should 8. Check dust on belt 8. Check axial 8. Check support
be done when the wheel, spoke clearance sleeve guard board
wearing parts cracking or not and and drive shaft
approach wearing shaft fastening or guard board wearing
limitation not situation
9. Check the return oil 9. Check cone head 9. Check balance 9. Check all the weld
flow from crusher screw fastening or weight liner and joint on main frame
and main safety not cover plate wearing cracking or not
valve to oil tank conditions
10.Check crusher 10.Check working 10.Check other 10.Change the
feeding distribution conditions of pre-charge pressure lubrication oil when
suitable or not hydraulic station of energy necessary
alarming light accumulator
11.Check crusher 11.Check dust cover
discharging good and dust seal
ore not wearing situation
12.Check crusher
inertial stopping
time

Feeding size
-Material less than the （C.S.S）take up less than 10%.
-Feeding must be evenly

Advantages：*more stable driving powers –higher capacity-better products shape-evenly wearing of liners.

69
Items Name
1 Cumulative passing weight percentage
2 Evenly feeding material
3 Less than 10% pass 20mm -3/4 inches C.S.S
Figure 5-1 Feeding Size

70
Feeding Distribution Advantages：*more stable driving powers –higher
-must uniform distribute to all the circle of capacity-better products shape-evenly wearing of
crushing chamber. liners.

Figure 5-2 Feeding Distribution

71
Crushing chamber material level

Better fully feeding when operating, but due to the

liner designation, crushing ratio, limitation of
powers, can’t make it for all the times. Standard
models crusher are not fully fed for most
situations.

Discharging opening
a. Open circuit
-choose suitable CSS 。
b. Close circuit
-HPT Cone crusher discharging opening will
be 3.2mm(1/8 inch) to 6.5mm(1/4 inch) bigger
than vibrating screen mesh. Theoretical CSS
based on final products size may not be the best.
This is decided by the material, motors, driving
powers or support sleeve situation. Better to
adjust the CSS and find the best CSS that can
have best performance.

Driving Powers

If support sleeve don’t make any shaking ， for

middle hard and hard material, better to operate
crusher as 75-95% of the maximum power.

Advantages：*longest using life-highest capacity。

72
 Items
1 Power （driving power）
Figure 5-3 Driving power
Chapter 6 Crusher operation
6.1 Adjusting ring, concave and
feeding hopper assembly
6.1.1 Introduction
This chapter including：Adjusting ring, concave and
feeding hopper assembly. There are screw thread
on outer of adjusting ring, it mesh the heavy screw
thread in the support sleeve. Adjusting ring can be
turned back or forth, up and down, thus can change
the feeding and discharge opening size.
Adjust cap is placed on adjusting ring，and have a lip
seal contact with the dust cover on support sleeve.
73
Name
Adjust cap just offer a protect cover for adjusting
ring and the locking nut. Some locking cylinder
that bearing the elastic load distribute on the top
of support sleeve, and push the locking nut
upward, list the adjusting ring to crushing position.
When using a heavy hydraulic motors to drive
adjust system, turning the adjust cap, the adjusting
ring will turn around with the cap.
Feeding hopper was fixed on the adjusting ring top
flange by bolt, its function is to feed the material to
crushing cavity. The hopper is sealed by asbestos
material on top of mantle, and it block the dust
processed by crushing in the bottom. There will
form a flat plate between the hopper bottom and its
wall, thus material shall be blocked here and avoid good performance in this situation.
the wearing to hopper. 5. Install the adjust cap and other parts on the
adjusting ring.
Some fork type cantilever, disk spring and bolt are in
6. Hung the installed assembly on the locking nut
the adjusting ring, these parts will fixed the
as step 1. Before the adjusting ring parts
changeable mantle on the ring. Mantle is adjustable
and it is a fixed crushing parts. installed into the locking nut and support
sleeve, must decompression the locking
6.1.2 Install Introductions cylinder as chapter 4.18
If the adjusting ring, mantle and feeding hopper are 7. Install the adjusting ring into locking nut and
dismantled shipped separately due to the limitation support sleeve as introduction of chapter 4.9
of shipping, before installing, these parts must be
dismantled and cleaned as followed:
1. To uncover all the thread on the adjusting ring,
adjust cap should be dismantled firstly.
Dismantle the nut and gasket on top of
adjusting ring, put the crane steel wire rope
and anchor ring on the lifting lug of adjust cap,
then hung it away the adjusting ring. See on pic
6-1
2. Clean the adjusting ring, support sleeve and
locking nut thread entirely, remove all the dirt
and corrosion inhibitor.
3. Clean the adjusting ring, support sleeve and
locking nut thread with a piece of cloth and
molybdenum disulfide powder.( this step can
make a layer of lubricant film on surface of the
metal and make the adjusting ring turns freely.
The primary molybdenum disulfide lubricant
film was painted when in factory.)
4. Coat enough lubricant on the thread, this
lubricant was mixture of oil and 5-10%
molybdenum disulfide powder.

When crushing sinter and furnace slag, should

use mixture of high temperature resistance
lubricating grease and 5-10% molybdenum
disulfide powder. Same amount of mixture of
high temperature resistance lubricating oil and
molybdenum disulfide powder can also have

74
 Item Name
1 Feeding Hoper
2 Sling
3 Rings
4 Adjust cap lifting cap
5 Adjust cap
6 Mantle
7 Adjusting ring
8 Sole timber

Figure 6-1 Lifting adjusting ring assembly

2. Use hydraulic motor adjust the adjusting

6.1.3 Maintenance
ring(anticlockwise) and dismantle the support
6.1.3.1 Dismantle adjusting ring
sleeve see in figure 6-2, operate as chapter 4.9.
If checking and changing wearing parts, dismount
3. Put the lifting steel wire rope and lifting ring on
adjusting ring as followed:
adjust cap lifting lug, hung up the adjusting ring,
1. Before the adjusting ring was back out, should
over the feeding plate, then placed the ring on
decompress the locking cylinder as chapter 4.18
sole timber, see as figure 6-1

75
Item Name
1 Adjust cap
2 Adjust gear disk
3 Guard cover plate
4 Small gears Items Name
5 Hydraulic motor 1 Nut
6 Support sleeve 2 Disk spring cover
7 Main frame 3 Disk spring
Figure 6-2 hydraulic adjust system 4 Gasket
5 Bolt
H Compression height of disk spring
Figure 6-3 Disk spring parts

6.1.3.2 Dismantle concave

Dismantle the concave as followed；
1. Dismantle the adjust cap from adjusting ring as
former “ installation introduction”
2. Clean the support sleeve, locking nut and
adjusting ring thread entirely, remove all the
dirt marks, rusty spot and residual grease.
3. Hung up the feeding hopper from adjusting
ring, uncover the disk spring parts of concave.
See as Figure 6-3

76
4. Dismantle the nut, remove the disk spring, Note ： Watch out the installation model of disk
gasket and bolt with a wrench. spring, three for a group, alternately stacked
together.

Items Name
1 Adjusting ring
2 Disk spring assembly
3 mantle
4 Sole timber

Figure 6-4 dismantle of concave

5. Hung the adjusting ring away from liner. If the Due to the different fitting surface of concave, the
mantle was up with adjusting ring, knock the embossment of adjusting ring will make the concave
tope of mantle with a hammer. be placed on adjusting ring improperly. If so,
6. Check the concave, whether there is bourre on concave may loose when working, thus will damage
surface of concave. If slight bourre, remove it the adjusting ring fitting surface.
to keep he cone type install face smoothly,
continuously and non bourre. If heavy bourre,
solve it as followed chapter” adjusting ring
install surface”.

77
6.1.3.3 Install the concave
Installation steps：
1. To put the concave onto the suitable stow wood
and press the adjusting ring against the
concave. 4. Assemble the feeding chute.
2. Assemble the disc springs first and leave the 5. According to the assemble instruction to
bolts loose. Use the steel tape measure the lubricate the adjusting ring, locking bolts and
distance B, and make sure the six points in the the screw threads on the supporting bracket.
round the same. Check photo 6-5. This is the very important step.
6. Assemble the rest parts.

6.1.4 Replace the feeding chute

The feeding chute must be replaced once the
concave type is changed. Each concave has different
feeding chute.

6.1.4.1 The mounting surface of the adjusting

ring.
The mounting surface of the concave needs to be
regulated by the mechanical treatment. Please
contact us to get the handling brochure if you need
this work.

Item Name
1 Adjusting ring
2 Disc springs
3 Distance“B”
4 Concave
5 Stow wood
6 feeler gauge
图 6-5 put on the spiral line highest spot

3. Screw the bolts up symmetrically. To use the

feeler gauge to make sure the distance between
the concave and adjusting ring smaller than
0.025mm（0.010″）

78
6.2 Moving cone, mantle and cone
head assembly
6.2.1Summary
This chapter includes the moving cone, mantle and
cone head assembly. The movable cone and
changeable mantle composes the cone crusher drive
system and composes the crushing cavity with
adjusting ring and concave.
There is a pressing ring on the top of the mantle. The
mantle and pressing ring are fixed onto the movable
cone by pressing nut.
The mantle is fixed onto the movable by the
pressing nut’s screw threads. The pressing nut also
supports the cone head. The cone head rotates
together with the movable cone and distribute the
materials to the crushing cavity equally. There is
locking bolt on the bottom of pressing nut. This
makes it a double bolts locking system to make sure
the locking of pressing nut.
There is a inverted hole to install the ball bearing on
the bottom of movable cone, and a hole to install the
floating bush and bottom bush of the movable cone.
The ball bearing is fixed by the stationary fit and the
floating bush & bottom bush is fixed by stationary
fit, key and bolts.
The ball bearing is installed on the concavity of the
spherical tile, which sits the top of the main shaft. It
drives the movable cone by the friction between the
bottom bush and eccentric bush, while the eccentric
bush moving or rotation.
The friction between floating bush and spherical tile
will keep the ball bearing inside the spherical tile,
while trial run.
79
The oil way is to cross the main shaft and lubricate
the floating bush, bottom bush and the spherical tile
directly.
The T shape sealed ring is attached to the
indentation of the moving cone, and composes the
labyrinth seal system with the U shape sealed ring to
protect the gear and bearings.
6.2.2 Assemble of the movable cone
Please check the photo 6-6
The steps to detach the movable cone, mantle and
cone head part are as follows:
1. The cone head must be detached before the
movable cone is installed into the crusher, if the
cone head is assembled onto the movable cone.
2. Wash the eccentric bush, floating bush, bottom
bush, ball bearings Spherical tile as clean as
you can. Check the smooth of all the surfaces
and use the fine sand cloth to clean the damage.
Check all the oil way and make sure they are
cleaned completely.
3. Lubricate the outside of eccentric bush, the
surface of floating bush, the ball bearing and
the surface of the spherical tile by the regular
crusher lubrication oil.
4. Take out the round lifting plate from the tool
cabinet and use the correct eyebolt to fix the
lifting plate to the pressing nut. Use the correct
bolts in the tool cabinet to fix the lifting plate
with the pressing nut.
5. Use the correct lifting device to lift the movable
cone and make it centring with the seat of
Spherical tile.
6. Lower the movable cone carefully.
7. Lower the movable cone to the eccentric bush
slowly, and push the movable cone carefully if
needed. Then land the movable cone until it
seats onto the spherical tile correctly.
8. While the movable cone seats correctly onto
the spherical tile, lift the movable around
6mm(0.25″)-10mm(0.39″) and then open the
lubrication pump for 6-10’. This will clean the
dust and the bearings are lubricated first, it is
good to operate the machine. Then stop the
pump and lower the movable cone to the right
place.

Item Name
1 eyebolt
2 sling
3 Lifting plate
4 Movable cone
5 minimum clearance
6 equal clearance
7 Maximum clearance
8 seat of the spherical tile
9 thicker side of the eccentric bush
disassemble the movable cone
10 1）Lift the movable cone assemble until bottom bush leaves the external diameter of the eccentric bush.
2）Make the movable cone centring above the spherical tile and keep lifting work.
Assemble the movable cone
11 1）make the movable cone centring above the spherical tile.
2）lower the movable cone to the thicker part of the eccentric bush and keep lowering.
6-6 Assemble or disassemble the movable cone
80
9. Use big diameter bolts and washers to fix the
cone head to the top of pressing nut. Please 6.2.3.2 Change the concave
check photo 6-7.
10. use the silicon resin to seal the pressing nut. Please follow the steps to replace the concave.
1. disassemble the lifting plate
2. Remove the welding materials between the
pressing nut & pressing ring, and the pressing
ring & concave.

item Name
1 cone head bolts
2 Cone head
3 pressing nut
4 locking pins
5 locking bolts item Name

6-7 locking bolts assemble 1 wrench for pressing nut

2 hammer
6.2.3 maintenance 3 Pressing nut
4 locking pins
6.2.3.1disassemble the movable cone 5 locking direction
Please follow the steps to disassemble the movable 6 loosing direction
cone: 6-8Disassemble the pressing nut
1. Take the cone head off from the pressing nut.
2. Put the eyebolt on the movable cone lift plate, If it is hard to detached the cone head bolt, use
and then fix the lift plate onto the pressing nut. the gas cutting to cut off the pressing ring.
3. Use the correct lifter to lift the movable cone, Please check photo 6-9.
until the bottom bush leaves the eccentric bush.
Please make sure the bottom bush centring
above the spherical tile, and then keep lifting
work. It may damage the bottom bush if the
wrong work step.
4. Put the movable cone on the suitable stow
wood.
81
 6-11 lift ear

Attention:
Make sure to use the Use EfeMn-A
welding rod. Make sure the welding
item name
work is strong enough to lift the
1 Circular groove mantle.
2 Gas cutting direction Check photo 6-11. The following steps:
6-9 A. Use (Efe Mn-A) welding rod
B. Keep the mantle’s temperature as low
3. Use the wrench to loose the locking bolts
as possible.
between the pressing nut and locking pins,
C. Clean the welding point.
please check photo 6-7.
D. 2 sides welding, and the welding
4. Use the wrench to loose the pressing nut height should be >6mm(1/4″).
clockwise. See photo 6-8. E. Check and weld the defects.

5. Check the screw threads of the movable cone

and pressing nut, clean and lubricate them.
6. Assemble the mantle as following steps:
a. Daub the bottom of movable cone with a
width 25mm dry oil.
b. Put the mantle onto the movable cone.
c. Put the pressing ring on the top of the
Item 名称
liners.
1 mantle
d. Check the pressing nut, if not correct, then
2 hanger
need change a new one.
3 lift ear
e. Screw the pressing nut onto the movable
4 sling
cone. The distance between the pressing
6-10 lift the mantle
nut and ring must be equal. The mantle
must be assembled right position. The
distance must be measured as the photo
6-12.

82
 Use hammer to knock the top of the
mantle to correct the position. The 8. use the feeler gauge to check if the liner is
deflection should be less than pressed against the movable cone tightly, and
1mm(0.040″). the distance should be smaller than
7. Use hammer to know the pressing nut and 0.25mm(0.010″).
make sure the liners centring and in the 9. Use the wrench the pressing nut tightly.
correction position.

item name
1 mantle
2 pressing nut
3 equal clearance
4 pressing ring
5 movable cone
6-12 the correct position of the mantle

10. After the pressing nut is screwed tightly, weld

the distance between the mantle & pressing
ring, as well as the distance between pressing 6.2.3.3replace the spherical bearings
ring and pressing nut with 4x50mm thickness.

Attention The steps are as follows, and please refer to the

Welding work should make sure that the cone photo 6-13.
head is pressed onto the locking pin.
1. Remove the fixed bolts between the spherical
bearing and movable cone. It must be heated up
Welding should use 18 8 35 SAFINOX welding rod. to 205 ℃ (400 ℉ ), as the bolts is fixed by the
11. Please refer to the assemble the movable cone Anaerobic adhesive
part. 2. Disassemble the spherical bearing of the
movable cone:
83
 a. The stow wood should be prepared in the 3. Convert the movable cone, an clean the surface
correct height to make sure the safe of the of the spherical bearing seat.

movable cone bush, and also there is
enough height for the bearing leaves the
inverted hole.
b. Use a 50mm×50mm(2″×2″) wood bar in
the distance between the spherical bearing fixed
plate and the movable cone hole. Use the
hammer to knock the wood, until the bearing
leaves the pin.
4. Put the new spherical bearing into the solid
carbon dioxide 4-6 hours, and make it be able
to sit correctly into the bearing seat. Around
23kg solid carbon dioxide is needed. Measure
the bearing and seat’s diameter to control the
process.
Attention: Be careful when using the solid carbon
dioxide.

item Name
1 bolts and washers
2 fixed plate
3 spherical bearing
4 movable cone
5 bottom bush
6 stow wood
7 floating bush
8 6mm(1/4″)weld seam
9 pin
6-13 disassemble spherical bearing
84
5. Use the eyebolt to connect the spherical bearing with the lifter, please refer to photo 6-14, and assemble it
into the correction position quickly. Use the feeler gauge to check the touch situation between the bearing
and the movable cone. At least 4 points should be checked. Meanwhile make sure the pin and pin hole is
in the proper position.
6. Use the right size bolts and screw it tightly into the screw threads on the spherical bearing.
7. While the temperature of the spherical bearing rises to the ambient temperature, remove the bolt and use
the Non oily solvent to clean the screw threads of the bearing, and daub the 277 Anaerobic adhesive.
Then use the washers and screw the bolts tightly.

item name
1 spherical bearing
2 hanger bolt
6-14 assemble spherical bearing

6.2.3.4 Remove the cone sleeve

(Pic 6-15)
The cone sleeve is located by bolts.
If the cone sleeve needs changing to a new one, make the cone upside down and remove the bolts according to
the following steps:

1. Use one heavy duty industrial circular saw which is quipped with metal cutting blades(cone sleeve is lead
bronze) to cut through at least 2 places on the sleeve liner. Adjust the saw so that the blade can get the
sleeve inner liner when it is put in the sleeve. Put the saw on the cutting position and adjust the saw
location to make the the back of the saw base aligned with the end of the sleeve. As shown in Pic 6-16.
2. Measure the distance between the saw base bottom and the intersection point of saw blade extension line
and the sleeve external diameter. Deduct a little distance from this distance. Deduct a little uneven
quantity from this distance to make sure the blade will not saw the cone.
3. Adjust the blade cutting depth to be the distance of step 2.
Caution
85
Wearing appropriate protective product is a must when cutting sleeve. For security, make sure wear a high
temperature resistant plastic mask in the process of cutting.
4. Do an experiment cutting to make the max. external diameter is cut in and then check if the blade is
adjusted to a proper cutting depth. Readjust if needed.
5. Blade along the whole length of the sleeve.
6. Repeat this step opposite to the first incision. The sleeve will crack down when the second incision is
finished.

Item Name
1 Ball bearings fixed plate
2 cone ball bearing
3 cone floating sleeve
4 cone
5 Briquetting
6 Anti-dust ball ring
7 T-type seal
8 Sleeve locking key
9 Bolt
10 cone sleeve
86
11 Bolt and spring washer
12 Locating pin
Pic 6-15 installed cone sleeve

87
 in the picture. Rotate the disk 90 ° and let the
external side of the disk beside the sleeve.
4. Screw a lead screw of 24 or27mm(1’’) diameter
in the nut which is melt on the disk center. This
lead screw must be longer than the cone sleeve
and both ends with screws.

5. Put a 25mm ×75mm(1″× 3″ ) flat steel bar

on the other end of the lead screw. Fix the lead
screw with hex nut.
6. As shown in pic6-19, put a wood support
between the flat steel bar and bottom line of the
cone.
7. Fill the sleeve hole with dry ice to contract the
sleeve. The contract time is about 2 hours.
Item Name
8. Use the lead screw as screw jack, screw the hex
1 Circular saw
nut till the sleeve flange pulling to the steel bar.
2 cone sleeve
Or you can use the hydraulic jack along the
3 Saw base
wood support.
4 Metal cutting blades
9. Loose the hex nut, put a heel block under the
5 Cutting depth
steel bar and then screw t the hex nut tight till
Pic 6-16 remove the cone sleeve with the saw
the sleeve pulling to the steel bar again.
10. Repeat this step till the sleeve tripped out.
6.2.3.5 Another method to remove

the cone sleeve

The cone sleeve is located by bolts.

The cone sleeve must be removed if you want to
exchange the cone floating sleeve. To save and reuse
the cone sleeve, make the cone upside down and
remove the bolts according to the following steps:
1. Remove the locating bolt or bolt which is used
to fix the cone sleeve on the cone.
2. Take out the cone sleeve withdrawal tools.(in
the toolkit). As shown in Pic6-17.
Item Name
3. Penetrate the sleeve with the narrow part of the
1 Central disk
disk till the disk slides to the sleeve as is shown
2 Meld 24 or 27mm(1″) hex nut on the disk
88
 Pic 6-17 central disk

Name
Steel plate
Lead screw with thread
Wood support
cone sleeve
cone sleeve withdrawal tools
Pic 6-19 remove the cone sleeve

6.2.3.6 Check cone inner hole, upper

Item Name

1
Penetrate the sleeve with the central disk hole and lower hole
and then rotate 90°to support the sleeve
Before installing the new sleeve, put the sleeve
2 Sleeve
3 Central disk upside down and check if there is nick, cross ditch or
Pic 6-18 central disk rough blotch on the inner hole. All of these should
be rub down.

89
Besides, check that if the inner hole is larger by
grinding or smaller by contracting. Measure the cone item name
inner hole from the bottom up. 1 Bolt
2 Anaerobic adhesive277
3 cone sleeve
6.2.3.7 Install the cone sleeve
4 cone
（As shown in pic6-20）
Pic 6-20 install the flange sleeve
1. Install and exchange cone sleeve according to
the following steps: Caution
2. Use wire brush to clean cone inner hole and Wear thick insulated gloves when carrying dry ice
sleeve external diameter. and serious burn will occur if there is no protective
3. Put dry ice in the sleeve inner hole to be measures.

installed to contract . If fill something in the

central of the sleeve, 90Kg (200 pounds) fry ice
will be needed to fill the sleeve fully. For 4. Measure sleeve external diameter and cone hole

example, use a 100mm × 100mm(4 ″ × 4 ″ ) diameter to confirm when the sleeve will cool

wood stick to occupy the void space and put well.

enough dry ice surrounding to contract the 5. Install 2 lifting bolts(in the toolkit) in the

sleeve. Surrounding several layers of insulating threaded hole on the sleeve bottom line.

glass fiber on the sleeve to prevent the frost of 6. Lift the sleeve above the cone inner hole and

outer wall. Frost will prevent sleeve going into align them. Lower the sleeve rapidly and install

the cone inner hole. Layers will do good to it in the cone inner hole. Adjust the installing

sufficient cooling. hole till the flange falls on the cone.

Cooling time is about 2 hours. 7. Immediately check if the hole is aligned well

Do not use this method to install sleeve and is able to make the bolt screwed in the cone.

compulsively in the extra small cone inner hole. If it is not aligned well, rotate the sleeve
slightly till the bolt can be screwed in the cone.
8. Insert the bolt in the hole of the sleeve flange
and screw it in the cone threaded hole. Then
screw the bolt to 50% torque according to table
6-3. Using feeler to check the contact
conditions between sleeve flange and the cone
in every direction. Check at least 4 directions!

Bolt Torque
Crusher
dimension newton·meter
model
and length （inch·pound）
HPT300 M12x40 81(60)
HPT500 M20x40 385（284）

90
 Table 6-3 bolt dimension and torque of the cone floating sleeve, such as sawing and
contracting, are the same.
9. When the sleeve is heated to environment 2. Remove the 4 briquettings and the old
temperature, remove the pre-installed bolt, use abandoned briquettings between the sleeve and
none-oily solvent wash bolt and the threaded the cone.
hole in the cone. The smear 277 anaerobic 3. Saw the sleeve apart and remove it.
adhesive on the thread surface. Install the bolt 4. Check that if the cone inner hole has nick, cross
and screw the bolt to the regulated final torque ditch or rough point. Check and confirm that
as is shown in table 6-3. the inner hole diameter is not grinded larger or
10. Install the cone according to cone installation contracted smaller because of the site
instruction in the former section in this chapter. temperature.
When re-assembly the cone head, make sure
6.2.3.9 Install the cone floating sleeve
that the gap between the bolt head and the
spring gasket is blocked. This step is very (as shown in pic 6-21)

important, which will prevent the dirt and water Install the cone sleeve according to the following

penetrating in the thread of the cone head bolt steps:

and the pressing cap. 1. Clean the cone inner hole and floating sleeve

After finishing installing the new cone sleeve, ektexine with a steel brush.

do the running-in according to the steps in 2. Cool the sleeve in dry ice for at least 2 hours.

chapter 4.6.
6.2.3.8 Remove the cone floating
sleeve
(as shown in pic 6-21)
cone floating sleeve and cone are stationary fit and
located by key If the cone floating sleeve needs
exchanging, make the cone upside down and go on
with the following steps:
The cone sleeve has to be removed to lift out of the
cone. Refer to another method to remove the cone
sleeve in the former part of this chapter.
3. Lift the sleeve above the cone inner hole with a
lifting bolt.
4. Lower the sleeve rapidly and install it in the
cone till the sleeve bottom fall on the convex
circle of the cone inner hole.
5. Install the briquetting. Using electro welding to
weld 2 sides of the electro welding on the cone.
Install the cone sleeve according to the cone
installation instruction in the former part of this
chapter. After finishing installation of the cone
floating sleeve, do the running-in according to
chapter 4.6.

1. Read the instruction of removing the cone

sleeve in the former part of this chapter before
removing. The steps of removing and installing

91
item name
1 Briquetting
2 Weld the briquetting on the cone
3 Floating sleeve
Pic 6-21 Install the cone floating sleeve

92
6.2.3.10 Identify the connection between cone head and bolt

Check the wear pattern between cone head and center bolt, it should replace the screw when necessary.
It would cause badly damage if the cone head fall into crushing chamber. Regular check the tight degree
of the screw on cone head. It should replace the screw if uncertain.

6.2.3.11Check cone head and screw

Check the wear pattern between cone head and its screw, it should replace the screw when necessary.
It may damage crusher if the cone head fall into crushing chamber when operation, and if may cause
badly damage if the cone head crossly stay in crushing chamber. Regular check cone head screw when
operation, in order to make sure that the screw has been tighten up and no abrasion. It should replace
the screw if uncertain.

6.2.3.12 Replace sealing ring

（see figure 6-22）
Generally, the ‘T’ shape sealing element that installed around the bottom of movable cone would not be
contacted and wore. But it is very important to replace the sealing ring if there has any damage on it. This
sealing would prevent oil leakage, and protect the finished surface of bevel gear wheel, pinion and bearing
from the invasion of harmful dust. Replace sealing ring as following steps:
1. Remove the damaged sealing element and thoroughly remove the residual adhesive in the seal groove.
Use a sharp chisel and hard putty knife to cut the sealing ring and scratch off the original adhesive in the
groove.
2. Use non-oleaginous solvent (alcohol or acetone) to thoroughly clean and air drying the groove.
3. Take out the “moulding” seal that use for replacement, and firstly use flint paper to thoroughly roughen
the bottom of ‘T’ shape sealing element to remove the surface layer. There has a layer of releasing agent
on the surface of sealing strip, which is used to make sealing strip demould of the
mouldduring manufacture. In order to firmly stickup ‘T’ shape sealing into the groove of movable cone
with adhesives, it should totally know about this lay of releasing agent.
The sealing strip would fall off when operation if there has no thoroughly clearing with releasing
agent.
4. There has a thin layer of activator at the bottom of sealing strip. It would cause partial consolidation if
smear too much.
5. Use a bit of adhesive (with right amount) at the bottom of cone head groove, and make sure the adhesive
squeeze out less as far as possible.
After coating adhesive, put sealing strip into the groove as soon as possible, and impact the ‘T’ shape
sealing with enough pressure, making sealing strip and bottom of the groove are compacting contact. It
needs 3 minutes to finish the splice work.

warning
when using chemical agent and
adhesive to replace sealing parts,
sufficient air must be provided, in
case breathing in smoke.

93
 |item Name
1 Movable cone
Before smear in the movable cone
groove bottom activating agent and
2 adhesive, use coarse mesh gauze to
polish the T type sealing surface, in
order to remove surface “shining” layer
3 T type sealing
Pic 6-22 Replacing sealing parts

6.3 Socket liner assembly

6.3.1 summary
This chapter is the introduction of socket liner assembly. Assemble the base with socket liner to support the
movable cone, and transfer the crushing force to the mainframe. The socket liner base is fixed on the main
shaft by interference fit and several bolts that surrounding the socket liner frame.
The socket liner is fixed on the top of the frame with pin, which provides a bearing surface for the ball bearing
that fixed by bolts under the movable cone. It uses lubricating oil that delivered by oil pump pressure to
through the connecting oil hole between the main frame and socket liner frame to make adequately lubrication
for the surface of socket liner.

6.3.2 assemble illustration

See figure 6-23

94
If removed the socket liner and its base for the convenience of transport, then it should assemble the eccentric
locking collar assembly at first, and then assemble other parts according to the following steps:
a．socket liner base assembly
1. Take out three positioning pins from toolkit, and screw them into the screw hole on the top of the main
shaft.
2. Install two lifting bolts on the socket liner base, and hang them in the lifting appliance with suitable lifting
capacity.
3. Heating socket liner base with specified temperature (higher than ambient temperature) according to the
table 6-4, and install it on the main shaft as soon as possible.

Caution!
It should use thickening insulated
gloves when install the parts that being
heated.

Fall the socket liner base along the positioning pin on the main shaft, and make sure the socket liner base is
sitting closely on the top of main shaft. Use a feeler gauge to through the side inspection hole of the socket
liner base to check and confirm the surface of socket liner.
4. The socket liner base is flat sitting on the main shaft (without interval), as shown in figure 6-4.
5. Remove the positioning pins, and make the bolts with lock washer through socket liner base, then screw
the bolts into the screw hole on main shaft. Tighten bolts alternately, and screw into a little until tighten to
the torque value given in table 6-5.
Notice: it should recheck the torque value of bolts after components cooling.
b. socket liner assembly
It could use shrink socket liner or swell socket liner base to install a new socket liner.
Heating means: before installing the socket liner, reheating socket liner base to make its temperature higher
than the specified ambient temperature on table 6-4.
Cooling means: before installing the socket liner, cooling socket liner base to make its temperature lower than
the specified ambient temperature on table 6-5.

Screw lifting bolts into the bolt hole surrounding the periphery of socket liner base, as shown in figure 6-25.
Hang the lifting bolts of socket liner in the suitable lifting appliance.
Aligning socket liner, and set the through hole at the bottom of the socket liner on the positioning pin of socket
liner base, and then install the socket liner on socket liner base.

95
 Item Name
1 Socket liner base
2 Key
3 Main shaft
4 Dowel pin for socket liner base
5 Spring washer
6 Bolt
Figure 6-23 Installation of socket liner base
Higher than ambient temperature Socket liner base screw
Model Centigrade degree Fahrenheit degree Torque Newton
Standard & length
（℃） （℉） meters（FP）
HPT200 80 145 M16×80mm 260(192)
HPT300 70 125 M16×90mm 260(192)
HPT400 94 168 M20×100mm 470(345)
HPT500 83 150 M20×100mm 470(345)
Table 6-5 Socket liner base preheating temperature and screw torque requirement

96
 Item Name
1 Compress
2 Feeler gauge
3 Socket liner base
4 Main shaft
Figure 6-24 Check the contact situation of the socket liner base

Higher than ambient temperature

Model Centigrade degree Fahrenheit degree
（℃） （℉）
HPT200 45 80
HPT300 45 80
HPT400 45 80
HPT500 45 80
Figure 6-4 Socket liner base re-heating temperature

Lowe than ambient temperature

Model Centigrade degree Fahrenheit degree
（℃） （℉）
HPT200 45 80
HPT300 45 80
HPT400 45 80
HPT500 45 80
Figure 6-4 Socket liner cooling tempreture

97
 Item Name
1 Socket liner
2 Socket liner base
3 Main shaft
4 Bolt and washer
Figure 6-25 Installation of socket liner

6.3.3 Repair

It could determine the time of replacing socket liner by the oil groove on its surface.
Measure socket liner as it shown in figure 6-26, it should replace the socket liner when its bearing surface is
worn until the oil groove depth reduce to 2.5 mm (0.098 inch).
It is normal even there has slightly looseness between socket liner and its base, because the dowel could avoid
turning of socket liner.
Replace socket liner as following steps:
1. Install three jack bolts (take out from toolkit) into the bolt hole on socket liner, as it shown in figure 6-27.
2. Tighten jack bolts alternately, and screw into a little every time to disassemble socket liner. If necessary,
heat the upper part of socket liner base with convenience of disassembling socket liner.
3. Remove jack bolt, and install lifting bolts
on the periphery of socket liner base.

98
 Item Name
1 Initial contour of socket liner base
2 Abrasive socket liner base
3 Oil groove
2.5 mm （ 0.098 inch ） minimum oil
4
groove depth
Figure 6-26 measure oil groove depth

4. Hang it on a suitable lifting device and remove the worn socket liner.
5. Install a new socket liner by cooling it. Cooling socket liner and make its temperature is lower than the
ambient as shown in figure 6-5. Then socket liner will shrink, and it could be installed into its frame
accurately
6. Aligning through hole at bottom of socket liner with the positioning pin on socket liner base, and fall the
socket liner into the cavity of its base. Notice: make sure the socket liner has completely sitting on the
socket liner base.

99
 Item Name
1 Socket liner
2 Socket liner base
3 Main shaft
Heating upper part of the socket liner
4
base if need
5 Jack bolt
Figure 6-27 dismantle socket liner

6.4 Eccentric locking collar assembly

6.4.1 Summary
This chapter is taking about eccentric locking collar assembly, which includes eccentric locking collar, liner,
bevel gear wheel and balance ring. Eccentric hole of eccentric locking collar makes the movable cone comply
with the eccentric motion trajectory in turning of each circle. The liner is fixed inside of eccentric locking
collar, worked as the bearing surface of main shaft. The bevel gear wheel that fixed at bottom of eccentric
locking collar by bolt is driven by the pinion in transmission shaft. eccentric locking collar revolves around
static main shaft.

The whole eccentric locking collar is supported by a group of thrust axis, and the up-thrust cooper bearing is
bolted at the bottom of eccentric locking collar, and the static down-thrust steel bearing is bolted on the frame.
100
It is to keep gear backlash and tip clearance between the big bevel gear and small bevel gear by increasing or
reducing the gasket below the down thrust bearing.

There have light wedge and heavy wedge on the counter weight of eccentric locking collar, and they are
relative positioning, in order to lower the unbalanced force that made by crusher rotation. Guard board and
cover plate that welded on the counter weight is to avoid impact of the falling material.

U-T seal surrounds the top and bottom of the counter weight, which makes a labyrinth seal to avoid oil leak
and dust, also it protects the bearing surface of big and small bevel gear.
Item Name Item Name
1 Lifting wire rope 7 Small bevel gear
2 Lifting screw 8 Rack
3 Hoisting plate 9 Down thrust bearing
4 Main shaft 10 Upper friction disk
5 Counter weight 11 Eccentric locking collar
6 Big bevel gear 12 Balance ring
Figure 6-28 hoisting eccentric locking collar assembly

6.4.2 assemble illustration

6.4.2.1 install eccentric locking collar assembly
See figure 6-28

If eccentric locking collar is removed from the crusher, because of weight limit, all the parts of this assembly
should be assembled as following steps:
1. Completely clear the exterior and top surface of the main shaft, gear cavity of the rack, inner wall of
eccentric locking collar liner, and eliminate the nick, scratch and barb. Clear the upper surface of upper
friction disk on the main rack and lower surface of upper friction disk that bolting at the bottom of
eccentric locking collar.
2. Confirm that the screw and spring gasket of upper friction disk and down thrust bearing have been
fastened well.
3. Use the screw hole on the top of eccentric locking collar to fix the hoisting plate (take from toolkit) on
eccentric locking collar assembly, and screw the two lifting screws (take from toolkit) on the lifting ring.
On the main shaft, it needs to coat with a thin layer of oil on the eccentric locking collar and two thrust
bearings.
4. Hang the lifting screw on the suitable lifting device, and slowly fall down the eccentric locking collar
above the main shaft. Bevel edge of the eccentric locking collar will help to align centre of the part,
falling down eccentric locking collar until the bottom of upper friction disk falling over the down thrust
bearing. It would need to slightly turn the eccentric locking collar, and make the big gear completely
meshed with the small gear, and make sure that the eccentric locking collar could completely fall over the
down thrust bearing.

101
5. Make sure that the big gear could be correctly meshed with the small gear, see figure 6-29. Gear backlash
and tip clearance should be checked according to the table 6-6. It could remove the lifting plate of
eccentric locking collar after getting suitable gear backlash and tip clearance.

Gear backlash Minimum gear tip clearance

Model
Millimeter Inch Millimeter Inch
HPT100 0.560-0.710 0.022-0.028 1.670 0.066
HPT200 0.457-0.813 0.018-0.032 1.905 0.075
HPT300 0.508-1.016 0.020-0.040 2.388 0.094
HPT400 0.640-1.150 0.025-0.045 3.454 0.136
HPT500 0.890-1.400 0.035-0.055 3.480 0.137
Table 6-6 backlash and tip clearance

Backlash change
Gasket thickness
HPT100 HPT200 HPT300 HPT400 HPT500
mm inch mm inch mm inch mm inch mm inch mm inch
3.0 0.1181 1.90 0.075 1.87 0.073
1.7 0.0669 1.03 0.040 1.00 0.039
0.4 0.0157 0.17 0.007 0.15 0.006
Table 6-7 gasket thickness

2 Big bevel gear

3 Backlash
4 Tip clearance
Figure 6-29 check backlash and tip clearance of
the gear

Item Name
1 Small bevel gear
102
 generals lead to eccentric tilt, and give incorrect
6.4.2.2Check gear backlash and
results.

headspace 5. Rotate the drive shaft, and make the teeth with
the large bevel gear pinion teeth just "touch" on
As shown in figure6-29
to check gear backlash, according to the
The correct way to adjust a series of large bevel gear
position shown in Figure 6-29 with a feeler and
on the new or old crusher is try the best to obtain the
recorded a non-engaging side teeth backlash.
recommended backlash. If the gear headspace reach
6. Measure and record tooth tip clearance as
lowest limit when you put down the eccentric to
shown in Figure 6-29
reduce gear backlash, the headspace will become the
7. If the measured backlash and headspace values
limiting factor to ensure that the tooth will not
are less than those listed in Table 6-6, the
bottom out of.
eccentric assembly should be removed, and
The burr at the end of the teeth can be manually
then add a metal appropriate thickness shim
rubbed off without loosening the entire part.
under the lower thrust bearing according to the
However, flaking rust may bring additional pressure
explanation of "Install the lower thrust bearing
to the parts. Thus, the replacement may be the only
and shim". Increase gasket elevates the
alternative.
eccentric assembly so that the distance large
Backlash and headspace should be checked and
bevel gear and pinion increase thereby increase
adjusted according to the following steps:
the gear tip clearance and backlash. If the
1. Place a large center pin pinion being positioned
measured result is greater than the data listed in
above the counterweight, or removed from the
the table, it should remove the appropriate
eccentric sleeve counterweight.
thickness metal shim.
2. Pull the drive shaft to the drive end until close
Note: When the crusher leave factory, shims
to the pinion shaft on the inner sleeve, see "rack
under the thrust bearing coat has reached the
shaft, drive shaft and pulley assembly frame"
required thickness, and can provide the correct
section below.
backlash and headspace. And the shims for the
Note: Before measuring, you must loosen the
adjustment of the backlash for the first time
V-belt.
installed in the crusher can be used to
3. Gently turn the shaft, make the large bevel gear
compensate for initial wear.
teeth to a vertical position, as shown in Figure
See chapter Maintenance section.
6-29.
4. Push or lever the eccentric weight assembly 6.4.3 Repair
side to the spindle, eliminating the eccentric
bushing and the spindle between all the gaps, so
6.4.3.1Removing the eccentric
that large bevel gear teeth of the pinion is in the
assembly
right position, make the large bevel gear held in
this position, then measure. When push To repair and replacement parts, according to the

eccentric sleeve toward the main shaft, the following steps to remove the eccentric assembly

strength should be appropriate, excessive force from the crusher:

103
1. Fix the eccentric lifting plate (from the Toolbox) this seal protection gear sets and bearings from
at the top of the eccentric assembly with harmful lime sand intrusion.
threaded hole of the eccentric sleeve, install
two lifting bolts at the lifting ring, and hang it
to the appropriate lifting equipment, shown as
Figure 6-28.
2. Hang the eccentric vertical from the spindle
assembly carefully.
3. Lift out the eccentric parts thoroughly crusher,
and put it on the right wooden support
carefully.

6.4.3.2 Protection of balance circle

Designed with a deep cavity, it avoids balance circle
contact with the material, which led to wear and tear,
shown as figure 6-28,6-48.In the outer circle of
protection chamber there is the shaft seat heart guard,
there are wear-resistance welding around it, which
improve the wear resistance.
Note: Check the thickness of welding cladding
layer everyday. If the wear and tear is serious,
should repair timely to avoid shaft seat center
guard ring worn affect the balance cavity
protection. If worn, need timely patching.

Replace the shaft seat center guard: In addition to

checking the shaft seat center guard welding
cladding layer thickness per day, if the shaft seat
center guard has been worn in a fender liner cycle,
then replace it when replace the liner plate.
Crusher discharging area should be checked daily to
ensure that the material drain freely from the bottom
of the crusher. If the sticks or other things hang on
crusher arm and the discharge cone, it can cause
accumulation of materials, which will lead to rapid
wear of the weight member.
U-shaped, T-shaped seal on the top and at bottom of
counterweight do not come into contact and wear,
104
Items Name
1 Main shaft
2 Floating seal
3 Shaft seat heart guard
4 Balance circle protection cavity
5 U-shaped seal
6 Lower thrust bearing plate
Figure 6-30 Balance circle protection cavity

105
6.4.3.3 Upper friction plate
Whenever remove the eccentric sleeve assembly
from the crusher, you should check whether the
thrust bearing scratches, scratches and wear. Wear
on the upper friction plate will causes two
operational issues:
First, wear make the eccentric sleeve assembly
declined, resulting the meshing between a large
bevel gear meshing and the small bevel gear is too
deep. In this case it should be adjusted by increasing
shims to the next lower thrust bearing. See Section
6.4.2.2 "Checking or adjusting the gear backlash and
headspace."
Second, the wear on the upper friction plate decrease
the oil groove on the upper friction plate.
If the oil groove is less than the minimum width or
minimum depth shown in Table 6-8, should replace
the upper friction plate. In emergency situations can
enhance the depth or breadth of the oil groove.
Note: The final wear limit is the flush contact
surface between the upper friction plate and bolt.
Items Name
1 Oil groove
2 Upper friction plate
3 Original groove depth
4 Minimum groove depth
Figure 6-31 friction plate wear limit
Crusher Groove depth
Model Original Minimum
HPT100 8mm(5/16″) 6.7mm(17/64″)
6.4.3.4 Replace upper friction plate
Shown as figure 6-32
Replace damaged or worn upper friction plate, as
follows:
1. In order to close the thrust bearing, first need to
remove the adjustment ring, moving cone, ball
bearing seat, and eccentric and floating seal
assembly. See dismantle the contents of these
components relevant sections.
2. Place upside down the eccentric sleeve
assembly to make the thrust bearing upward.
3. Remove the countersunk head screws and
spring washers fixed with eccentric sleeve.
4. Screwed screw rings into the thrust bearing two
screws.
5. Hang the eye bolts onto suitable lifting
equipment lift off the eccentric bushing
carefully. It’s a clearance fit between the upper
friction plate and the eccentric bushing.
6. Check the thrust bearing that to be put on, make
sure there are no burrs or abnormal curling;
they will hinder full contact between the
eccentric bushing surface and bearing.
7. Remove the lifting bolt on upper friction plate
and install it on the new bearings, the upper
friction plate in place and make sure that all the
holes of eccentric bushing hole on the positive
place, to ensure proper installation.
8. Put a new spring washer on the upper part of
upper friction plate, the screw through a spring
washer, then tighten each screw in a cross way

HPT200 10mm(25/64″) 6.7mm(17/64″) alternately. Achieve torque as shown in Table

HPT300 8mm(5/16″) 8.7mm(11/32″) 6-9.
HPT400 11mm(7/16″) 9.7mm(3/8″)
HPT500 11mm(7/16″) 9.7mm(3/8″)
Figure6-8 Groove depth

106
 Items Name
1 Upper friction plate
2 Eccentric bushing
3 Screw
4 Spring washer
Figure 6-32 Upper friction plate

Crusher Upper friction plate Screw torque

Model Screw size N • m（Ft • lb）
HPT100 M8×20 45(34)
HPT200 M8×20 45(34)
HPT300 M10×25 90(66)
HPT400 M10×25 90(66)
HPT500 M14×35 250(185)
Figure 6-9Upper friction plate screw torque
requirements

107

6.4.3.5Eccentric bushing
Whenever remove the eccentric, eccentric sleeve
should be checked for loose and excessive wear. If
find eccentric sleeve has been loosened, check
whether the sleeve is loose in the eccentric bushing.
If no loose, it should be repositioned to the bush, and
then do following the re-cast zinc alloy.
Note: Under normal circumstances, the heavy
sides eccentric bushing wear serious, this is the
expected normal circumstances, do not worry.
Eccentric bushing wears too thin or when an
existing cracks, should replace it.
6.4.3.6 Removing the eccentric
bushing lining
Zinc-based alloy at the top of the liner is eccentric
and bushes surrounded by several groups chute and
tank are full of lock mixture to prevent rotation of
the bushing. The bushing needs to be replaced, as
follows:
1. As shown in Figure 6-33, on each locking
groove material drill a few holes.
Items Name
1 Eccentric bushing
Drill a series of holes the tank locking
2
material
3 Eccentric bushing lining
Figure 6-33 Removing zinc base alloys
108
2. Drill through the adjacent holes wall, and
remove the locking material. In this way the
locking material will not hinder the demolition
of the lining.
3. As shown in Figure 6-34, put the eccentric
bushing upside down on a wooden frame, so
you can fight off the eccentric bushing lining.
4. Cut a piece of 25 mm (1 inch) thick circular
steel plate, which is slightly smaller than the
outer diameter of the liner, polish steel plate
and glue the outer edge of the tape, so that no
rough edges will scratch eccentric bushing
inner wall.
5. Put the plate on the liner and ensure it in the
middle location but does not touch on the inner
wall of the eccentric.
6. Pound the steel with a 100mm × 100mm (4 "×
4") sticks until the lining completely out of the
eccentric bushing. It may be very difficult to
remove the lining from the eccentric bushing
with a pounding way, may cut the lining into
two or more pieces with aindustrial circular saw.
See "Removing the movable cone lining"
section of the instructions recommended
method of cutting bushes.

Items Name
1 Wood brick
2 Plate
3 Wood Pad
4 Eccentric bushing lining
5 Eccentric bushing
Figure 6-34Removing the eccentric bushing lining
6.4.3.7 Check the eccentric bushing
cavity
Before installing a new eccentric lining, check the
eccentric inner wall whether has scratches or rough
spot, they must be sanded smooth.
Also, check the inner cavity and make sure it’s not
worn too big or too small due to the heat shrinkage.
Measure the eccentric bushing cavity from the
bottom to the top.
Contact with the manufacturer to obtain the correct
diameter of the inner cavity.
At the same time, check its roundness by rotating the
micrometer 90 °, space 45 ° before compared with
last measurement point when checking the diameter.
Due to uneven shrinkage cavity can be machined to
size paper maps. However, must be extra careful
when arrange machined parts.
6.4.3.8 Checking main shaft
When the eccentric bushing linings need to be
replaced due to bearing failure, especially when the
eccentric shaft liner is stuck, the main shaft should
be checked. Remove all the lead and copper from
the main shaft with a very thin gauze. Note that we
109
can only erase it in the lateral and upward direction.
Consult the manufacturer to decide whether it should
replace the main shaft.
If the eccentric bushing lining was stuck on the
spindle, can be demolished by following steps:
1. There is a longitudinal groove between the
bushing inner diameter and the large hole. Cut
through the liner wall with a metal cutting
blade (dynamic cone bushing is lead bronze)
heavy industrial circular saw. Adjust the blade
depth to 20 mm (0.75 inches), but not more
than 25 mm (1 inch).
2. Cut the bushing lining in the longitudinal slot
position.
3. Place a pry bar in the cutting department; pry
out hard, so the lining is ejected from the
cutting position.
4. Note that the saw blade should not leave
scratches on the spindle, or will give new
eccentric bushing lining a negative impact on
performance.
Note: When clearing lead and copper
scrap and do not leave any scars on
the main shaft.
6.4.3.9Installation eccentric bushing
lining
The eccentric bushing lining and inner cavity should
remain tenths of a millimeter (thousandths) of
clearance fit. Improper storage or transportation may
cause the liner to produce the metal-to-metal fit or
lose a round; we recommend the following steps to
use dry ice.
The following steps are how to use fry ice to install
new lining:
1. Make sure clean up all the locking material at
the top of the chute eccentric, the surface
 eccentric bushing cavity is lean and without any
rough place.
2. Clean all surfaces of the bushing thoroughly,
remove surface irregularities, and make the
lining ready.
3. Fill in the inner cavity of the dry ice in the
bushing to make it contraction. If put some kind
of filler in the center of the bushing, it’s about
90 kilograms (200 pounds) of dry ice filled
inner cavity lining. For example, put a 100 ×
100mm (4 "× 4") stick, leaving enough space
to fill in plenty of ice cold shrinking bushing.
Warning: When handling dry ice need
to take a good thick, insulated glove
good. Dry ice pick and place without
protection can cause severe burns.
4. Wrap several layer of glass fiber insulation
outside of bushing to avoid the bush outside
frost. Frost would prevent the lining put into the
eccentric bushing. Wrapped layer also helps to
achieve a more sufficient cooling, shrink time
should to be about two hours.
Note: Do not use this method to install the lining
to the inner diameter of the small eccentric
bushing.
5. Measure the lining outside diameter and
eccentric bushing inside diameter, and
determine whether the lining is sufficiently
cooled. Screw two bolts (from the toolbox) into
the top of the liner.
6. Make lines outside the bushing along two holes
(large hole small hole) on both sides of the
lining, shown in Figure 6-35.Then paint or
draw eccentric mark lines along the hole on
110
both sides of the eccentric bushing to the top
surface of the eccentric bushing, these lines will
ensure that the hole on the eccentric bushing
and lining on the positive position.
7. Lift the bushing in place with screws and
gasket rings (from the kit)and align with the
eccentric upper place and eccentric inner cavity,
as shown in Figure 6-36. Put the shrink
eccentric bushing into the inner cavity quickly,
and align the grooves and oil hole.
Note: The lining lubrication holes must align with
traverse eccentric wall holes, the groove on
outside and top of the lining should align with the
eccentric bushing groove. Grooves may have a
slight dislocation, but the lubrication hole must
be strictly positive.
8. When the lining is installed, the lining top
should be flush with the eccentric bushing top.
9. Mix the locking material according to the
instructions of each barrel, and pour them into
the groove at top of the eccentric and bushing,
and filled every groove.
10. Before pouring the locking material, the room
temperature should be 16 ℃ (60 ℉ ) to 32
~ ℃ (90 ℉).
11. When the locking material is completely
hardened, polish the protruding locking
material.
Note: After installing the new eccentric bushing
lining, breaking in according to Chapter 4.
RE
Items Name
1 Rings, bolt and washers fixed bushing
2 Eccentric bushing
3 Zinc Alloy
4 Eccentric bushing lining
Figure 6-36Lining in the eccentric bushing

6.4.3.10 Refilled zinc base alloys

Due to zinc-based alloy wear, lining in the eccentric
bushing can rotate automatically, need re-perfusion
zinc base alloys. Need drilling, cutting out, clear
cavity tank epoxy filler, and refilled. Note bushing
and eccentric holes need to be aligned, Figure 6-35
and Figure 6-33.

Note: Before pouring again, check bushing part

Items Name whether is correctly installed according to

1 Draw a line along the oil hole edge
2 Small hole
3 Eccentric bushing lining
4 Big hole
Figure 6-35 Alignment eccentric lining
"eccentric lining installation" instructions.
6.4.3.11 Adjusted wear backlash
When the thrust bearing and tooth wear to a certain
extent and can no longer maintain the proper
backlash, must increase or decrease the backlash
shim for portfolio adjustments, and achieve the
appropriate backlash as shown in Table 6-6.Increase
the gasket, elevate eccentric assembly so that the
distance between the gear and the pinion increase;
remove the gasket; reduce the whole assembly, so
that the distance between the teeth increases. Make
sure the thrust bearing and washer reassembled
correctly.
Note: At any time must prevent large and small
gear tooth tip collide with tooth root. Regardless
of whether the gear wears, tooth roots must be a
gap. Therefore, when the teeth wear to a certain
extent to maintain the correct backlash and the

111
addendum can not achieve the minimum installation, use gas cutting in front of the loosen
clearance listed in Table 6-6, then you can ignore screw to be heated to about 205 ℃ (400 ℉).
the backlash value. 4. The big bevel gear with eccentric sleeve flange at
the top of the sink hole for the light interference fit.
The two rings set screws into the rings on the (taken
6.4.3.12Replacing the large bevel
from the toolkit), will the rings twist to the top of the

gear eccentric sleeve.

5. Lift the parts above stow-wood about 40 mm
Whether it is maintenance-related parts, or suspected
(1-1/2 "), uniform heating with gas welding big
broken teeth and excessive wear and remove
bevel gear, until the diameter of the big bevel gear,
eccentric, you should check the bevel gear mounted
falling off the eccentric sleeve.
on the bottom of a large eccentric.
6. The eccentric set of machine on the hardwood
Pits and rough tooth surfaces are a good indicator of
block.
excessive wear gear, the next number of shims under
7. Remove the friction disc on the countersunk head
the thrust bearing is inappropriate, or crusher
screw and spring washer, then remove the thrust
overload or particularly dirty oil can cause this
bearing.
condition. If it is determined to a serious degree
wear then the large bevel gear must be replaced,
6.4.3.14Assembly weight and big bevel gear
dismantle large bevel gear according to "dismantle
Follow these steps to reassemble the eccentric sleeve
the counterweight and large bevel gear".
assembly:
1. Carefully packed the eccentric sleeve backwards,
6.4.3.13Remove the weight and big bevel gear
and placed it in the right pad on the wood.
See Figure 6-37
2. The friction plate is placed in the bottom of the
Do as the "installation the eccentric sleeve assembly”
eccentric sleeve; make sure that all the holes are at
described in part of lifting method after the eccentric
the right place. Mat new spring gasket and tighten
sleeve assembly down crusher, press the following
the countersunk head screws.
steps to remove and replace the excessive wear or
3. The big bevel gear placed on the appropriate
damage of parts.
stow-wood down, as shown in figure 6 to 37.
1. The entire assembly on stow-wood, removed the
4. Put the eccentric sleeve up and then ring on the
counterweight and the eccentricity of hex flange
two lifting bolt, screw in and put the rings fixed to
fastening screw, because these screws using
the top of the eccentric sleeve.
anaerobic adhesive when installation. use gas cutting
in front of the loosen the screw to be heated to about
205 ℃ (400 ℉).
2. The four lifting bolt (from toolkit) screw in
weight in the flange.
3. Remove screw in big bevel gear screw in the
screw hole the through the eccentric flange. Because
the bolt using the anaerobic adhesive when
112
 item name itemheating treatment. Adopt a softening of
gear
1 balance ring 5
chemical standard components at a
2 Eccentric sleeve 6
predetermined temperature reached, in order to
3 alignment pin ensure
7 uniform heating and safety.

4 Big bevel gear 8

6-37 Lifting weight and eccentric sleeve

7. Measurement of eccentric sleeve diameter and big

5. Use appropriate lifting equipment, the eccentric
sleeve hoisted to the top of the big bevel gear.
Convinced that eccentric sleeve and big bevel gear
alignment and vertical.
6. with uniform heating gas welding big bevel gear
to the higher ambient temperature 45 ℃ (80 ℉).
Note: uniform heating big bevel gear is very
important, don't focus on one area heating in the
form "hot spots", this will destroy the big bevel
113
bevel gear after heat sink whole diameter, and
ensure the sink whole diameter slightly larger than
eccentric gear sets. Then quickly put eccentric
sleeve in big bevel gear sink hole and alignment
with holes. Because the whole spacing is equal, so
there is no special claim to is. Check and confirm the
eccentric sleeve and big bevel gear work closely
together
8.Clean with non oily solvents (alcohol or acetone)
long or short of screw thread and the screw hole on
the big bevel gear, and then thread surface coated
anaerobic adhesive 271.
9. The short link of eccentric sleeve and big bevel
gear screw, through the eccentric hole on the flange
screw into the big bevel gear, the cross way of
successive tighten the screws. As shown in table
6-10.
10. If replacement after the big bevel gear, not
assembly counterweight, the eccentric set into the
crusher, can be easy to check the big and small gear
side clearance and tip clearance. See this chapter in
front of the "check or adjust the tooth tip clearance"
lateral clearance and part of the explanation.
11. The two lifting bolt (from the toolkit) screw in
weight in the flange.
12. Carefully to lower counterweight to the eccentric
sleeve, according to the figure 6 to 37 to re-install
the eccentric sleeve of the flange plate. To maintain
the pin hole on the counterweight and the eccentric
sleeve pin shaft alignment.
13. The counterweight and the big bevel gear of the
screw hole on the connection screw through the
eccentric sleeve, and turned into the threaded hole of
the big bevel gear.
14. In a cross way long successive tighten the screw
to the torque values listed in table 6-10.
15. Before the eccentric sleeve parts installed on the
crusher, rotating shaft check the small gear tooth
wear or damage.
16. According to the eccentric sleeve assembly
installed in front of the instructions in this chapter.

Note: take dynamic cone after replacing the

bushing should be to link eccentric sleeve and big
bevel gear and balance ring and the degree of
tightness of screw of big bevel gear check.

114
 Link weight and big Tightening Higher
Link of the specifications of the
Crusher gear of the torque Newton temperature
eccentric sleeve and big bevel gear
size specifications of the meters (feet,
screw and length (℃) (℉)
screw and length pounds)
HPT100 M12×70 M12×70 135(100) 45 80
HPT200 M14×70 M14×70 167(124) 45 80
HPT300 M16×70 M16×70 260 (192) 45 80
HPT400 M20×100 M20×120 470(345) 34 61
HPT500 M24×100 M24×140 810(600) 32 57
Picture 6-10 Big bevel gear screw torque required and heating requirements

6.5The transmission shaft, drive shaft and the pulley assembly

6.5.1overview
This chapter includes the transmission shaft, drive shaft and crusher pulley assembly.
Through the v belt or straight league drive transfer power from the power source to drive shaft. With a press fit
of helical pinion shaft assembly, in turn, to drive the eccentric big bevel gear assembly. Shaft bearing in two
sets of sliding bearing or sleeve, collar with a key to the shaft frame, to prevent bearing rotation. The shaft
collar on the flange from the pinion or under lubricating ring axial thrust load. With key or compression
loading on the shaft drive lubricating ring by means of centrifugal force the oil discharge shaft frame. Cover
within the end cover of the lubricating ring can make oil returns to the fuel tank, recycling use. The shaft frame
and frame for the press fit, through large diameter screw. In the shaft frame and frame of the matching between
the surface with a o-ring or lip seal, oil seal. Drive shaft wearing armor can protect the shaft frame exposed
parts from the wear and tear of falling material.

6.5.1.1Install the transmission shaft frame

The whole process of components assembly to see the maintenance section of this chapter. If the shaft frame
will be removed due to transportation reasons, so the shaft frame according to the following procedure should
be loaded on the rack.

115
 item name
1 o-rings
2 frame
3 The transmission shaft frame
Picture 6-38The transmission shaft frame

1. In the package to find the large diameter of the o-ring with clean grease, and expandingplaced on the pinion
shaft frame end machining diameter. As shown in figure 6 to 38. O-ring can avoid the shaft frame and main
frame between the spills.
2. The pulley end of a long tube set in the shaft, in order to balance a much heavier than the assembly weight
pinion end, as shown in figure 6-39.

116

Attention: If the long pipe can not be balanced
due to the space limit, please try to put the
drive shaft assembly into the rack hole. Put the
inner flange of the transmission shaft rack on the
sliding plate or on the holder. Put down a grabs
from inner frame, and sling the end of pinion,
and slip into the copula of inner frame.
Item Name
1 O-ring
2 Transmission shaft rack
3 Sling
4 bob-weight
Picture 6-39 Install drive shaft assembly
1. Carefully aim transmission shaft rack to the
reeding and put it on the guide plate of mainframe
with crane or other lifting device, and then slide
assembly to the inner part to the greatest extent.
2. Screw the three dedicated hex head screws into
the screw hole in the frame with angle of 120 ° .
Picture 6-40 for reference, the first step.
3. As the two flange on the transmission shaft rack
and mainframe is interference fit, please tightening
each screws to avoid uneven loading until the reach
to the bottom of the threaded holes.
4. Take off the jack bolt and set spacer between head
part of the jack bolt and flange like Picture 6-40, the
second step. And then tightening each jack bolt until
the reach to the bottom of the threaded holes.
5. Take off the jack bolt and put on common
Item hexagonal head screw and lock washer to fix shaft
5 bracket on the mainframe.
6 6. Keep on tightening these bolts to push
7
transmission shaft rack into the mainframe until the
outward flange cling the mainframe tightly. Picture
6-40, the third step for reference.
7. Put the guard board on the transmission shaft rack
and make sure the opening of the guard board align
at margin of the shaft rack.
117
 第一步：the first step 第二步：The second step 第三步：the third step
Item Name Item Name
1 mainframe 4 lock washer
2 Jack bolt 5 washer
3 transmission shaft rack 6 Bolt / screw
Picture 6-40 Compress the transmission shaft rack into the mainframe

6.5.1.2 Check the Axial Play

Picture 6-42 for reference
The Axial play is stated in the factory if the crusher is integral transportation. As the Axial play is important
for the normal running, please check it again before running to make sure the transmission shaft rack can move
smoothly.

Model of
Axial Play
Crusher
HPT100 0.8mm(0.031″)-1.2mm(0.047″)
HPT200 0.8mm(0.031″)-1.5mm(0.062″)
118
 HPT300 0.8mm(0.031″)-1.5mm(0.062″)
HPT400 0.8mm(0.031″)-1.5mm(0.062″)
HPT500 0.8mm(0.031″)-1.5mm(0.062″)
Form 6-11 Axial Play

Item Name
1 guard board
2 guard board
reeding pouring on the edge of the
3
transmission shaft rack
4 The transmission shaft frame
Picture 6-41 Install the guard board

119
Item Name Item Name
1 Bevel pinion 4 Form 6-11
2 Shaft sleeve 5 Compress
3 Axial Play
Picture 6-42Axial Play

120
6.5.2 Maintenance

6.5.2.1The procedure of disassemble transmission shaft frame

To replace lining, gears, or other wear parts, the procedure of disassemble transmission shaft frame and
transmission shaft as following:
1. Remove all of the lubrication tubes which may hamper the disassembly. Block or cover all the openings.
2. Refer to the procedure of disassemble crusher belt wheel, disassemble the belt wheel. The purpose is
preventing damage the belt wheel during the process of disassemble transmission shaft.
3. Remove the screws which fix the transmission shaft on main frame.
4. Use the customized lifting screws which in the cone crusher tool package, installing in the three screwed
holes which located at the flange out of transmission shaft frame.
5. Should evenly screw down every lifting screw to prevent the screws load unevenly on the frame.
Attention: If the transmission shaft connection is too tight, may heating the connection surface out of
transmission shaft frame to help disassembly. Should heat the surface 100℉(55℃) higher than the
environment temperature.
6. Keep screwing down the lifting screws, until the transmission shaft frame leave the the main frame.
7. Put a section of tube on the belt wheel end, and keep the assembly balance. Use crane or other lifting
appropriate equipment remove the assembly. (Refer to diagram 6-39)
8. Remove the lubricating ring end cover or cover plate.
9. Heat the lubricating ring to 50℉(27℃) higher than environment temperature.

。
When screwing the heated lubricating
ring, should wearing a pair of thick
enough and heat-insulated glove.

10. Put a crowbar between lubricating ring and transmission shaft frame, and press appropriate pressure on it.
If the lubricating ring start to loose, grasp the two sides of lubricating ring and pull it out from the shaft.
11. Draw the transmission shaft assembly out from the shaft frame.

6.5.2.2 The procedure of replacing the transmission shaft gear

When disassemble the transmission shaft frame to inspect or replace parts, at the same time it supposed to
inspect the transmission shaft gear’s wearing or damaging condition. If there appeared hard spots or worn
much on the gear surface, it means the gear was over worn. The reasons perhaps are: First, the wrong quantity
of spacer which installed under lower thrust bearing caused the bad gear connection. Second, the crusher

121
overloaded work. Finally, the lubrication oil is too dirty. The transmission shaft gear is easier get broken if
worn. In addition, because the vibration caused by the crusher operating with worn transmission shaft gear,
other component and structures will get influenced and worn. The over worn transmission shaft gear should be
replaced. To fully utilize a component’s capability, it supposed to replace the main shaft gear and transmission
shaft gear together. If the crusher operating with a brand new transmission shaft gear and a worn main shaft
gear, it must inspect the gap between gears root according to the requirement of “The procedure of inspect the
gap between gears” in the chapter: Eccentric bushing assembly. The procedure of replace transmission shaft
gear as following:
1. Remove the transmission shaft assembly from transmission shaft frame. Put the transmission shaft on an
appropriate wooden board.
2. To withdraw the transmission shaft gear, use a low intensity heat torch heating the gear to 180℉ (100 ℃)
higher than environment temperature. During constantly shifting the heat torch heating the gear, use a
heavy wooden hammer to hammerblow the gear repeatedly. Once the gear start loosing, grasp the two
sides of the gear, pull it out from the shaft.

Warning!
When touching and pulling the heated
gear, should wearing a pair of thick
enough and heat-insulated glove.
Warning!

3. To put a brand new transmission shaft gear, use a heat torch heating the gear to a specific degree
according to form 6-14 higher than environment temperature., or put it in oil-bath heating to
approximately385℉(215℃) higher than environment temperature. When the heated gear reached the
temperature, rapidly put the gear on the shaft end and push it on, and align the gear end with shaft end.
Attention: If the gear cooled down and stucked on the shaft, use a heat torch heating the gear again and
use wooden hammer to hammerblow the gear at the same time. Must constantly shift the heat torch
around the gear to prevent the heat point focus on just one position.

122
 Term Name
1 Transmission shaft gear
2 Transmission shaft
3 Gear end and shaft end aligning
Form 6-43 Transmission shaft gear position

6.5.2.3 The procedure of disassemble transmission shaft sleeve

The sleeve will be loosing in transmission shaft frame when the shaft sleeve was worn and needed to be
replaced. In the condition, the sleeve will be easily drew out of transmission shaft frame. But if the
manufacturing tolerance is the ultimate maximum value, the transmission shaft sleeve may be a mild form of
interference fit in the shaft frame, and in the condition to disassemble the shaft sleeve will be difficult. To
change the press fitted transmission shaft sleeve, or the sleeve which stuck in the transmission shaft frame
because the sleeve temperature is too high which caused by insufficient lubrication or crusher overload, the
procedure as following points:
1. Refer to the description of “The procedure of disassemble transmission shaft frame” disassemble the shaft
frame, and then remove the transmission shaft from frame.
2. Take the transmission shaft sleeve disassembling tool from tool box. Refer to Form 6-44.
3. Thread the narrow part of the disassembling tool into the sleeve, until the circular plate slip to the position
behind sleeve according to the form. To rotate the circular plate 90 degrees, and make the edge rely on the
sleeve.

123
 Term Name
1 Transmission shaft sleeve
Transmission shaft sleeve
2
disassembling tool
3 M24mm Hexagon nut
To slip the circular plate into the
4 sleeve and rotate 90 degrees, and then
rely on the sleeve edge.

Form 6-44 Central circular plate

4. When positioning the tool, at the same time, take the double armed bolt rod (M24) and install it into the
nut in the central circular plate.
5. Put a 25×75×305mm(1”×3”×12”) flat steel stick on the other end of the bolt rod.
6. Insert a long wooden rod or a steel tube into the other end of transmission shaft frame, and hit the central
circular plate.
7. If the inside of the frame is still tight, it is recommended to use push-out method to disassemble sleeve.
Refer to Form 6-46. The procedure as following:

124
8. Use the same method and central device with previously description, but the bolt rod and flat steel stick
supposed to be longer, and put a wooden block between steel stick and transmission shaft frame flange.
9. Use the bolt rod with screw thread as screw jack, screw down the hexagon nut until the sleeve flange is
pulled to steel stick.
10. unscrew the hexagon nut, put a support block below the steel stick, and screw down the hexagon nut
again until the sleeve is pulled to steel stick again.
11. If necessary, redo the step 9 until the sleeve loosed.

Term Name Term Name

1 Wooden rod 5 Flat steel stick
2 Transmission shaft frame 6 Transmission shaft sleeve
Transmission shaft sleeve
3 7 Pin
disassembling tool
4 Bolt rod
Form 6-45 Use hammering method to disassemble transmission shaft sleeve

125
 Term Name Term Name
Transmission shaft frame
1 4 Flat steel stick
disassembling tool
2 Bolt rod 5 Transmission shaft sleeve
3 Support block
Form 6-46 Use push-out method to disassemble transmission shaft sleeve
6.5.4.4 The inspection procedure before install sleeve

Have the inspection before installing new shaft sleeve. As a preventive measure, the bore diameter of
transmission shaft frame should be inspected

The shaft sleeve is machined according to the tolerance0.03mm (0.001”) tightness to 0.065mm (0.002”)
looseness. Should inspecting the inner diameter of bore and outer diameter of shaft sleeve, to ensure the
diameters meet the tolerance. If the interference size greater than 0.030mm (0.001”), the transmission shaft
frame must be re-machined to meet the maximum requirement. Over-interference will cause the sleeve broken
or the inner bore shrunk thus the gap between transmission shaft and shaft sleeve will be shorten. If found the
inner bore size became smaller than original machining, the inner bore shrunk usually caused by overheating.

To inspect the straightness and diameter run out of transmission shaft. The diameter run out amount between
two bores should not exceed 0.102mm (0.004”), and the shaft should be replaced if the amount exceeded. If
install the shaft sleeve to undersize transmission shaft frame bore or the transmission shaft curved, the shaft
sleeve may stuck on the shaft. If found the shaft twisted, the shaft should be scraped and then replacing a new
shaft.

126
6.5.2.5 The procedure of install transmission shaft sleeve

After totally inspected the transmission shaft and shaft frame, install the new shaft sleeve if the inspection
considered as meet requirement.
1. Remove the locating pin on the surface of transmission shaft frame flange.
2. Insert two steel sticks which the diameter same with locating pin bore. The steel sticks is supposed to be
longer than shaft sleeve.

Refer to Form 6-47. The two steel sticks’ function are to ensure the shaft sleeve flange’s bore align with
transmission shaft frame’s locating pin.

3 It has two same shaft sleeves in the transmission shaft, but their position in the inner bore are different.
Refer to following method to confirm the correct position of shaft sleeve lubrication groove which relates
to transmission shaft frame.

Term Name
1 Transmission shaft frame
2 Transmission shaft sleeve
3 Oriented steel stick
Form 6-47 Installing transmission shaft sleeve

a. The shaft sleeve’s longitudinal lubrication groove which on the the transmission shaft gear end is
supposed to be located on the top of transmission shaft.
127
b. The transmission shaft outer sleeve is usually installed at the bottom with longitudinal lubrication groove,
refers to form 6-49. But, its position will be changed if the motor drive wheel is under crusher drive wheel,
or in the either one side of crusher’s vertical center line45 degrees range. Attention: The transmission
shaft outer sleeve must be rotated to top center position. When utilize this transmission method,
rotating the shaft sleeve can prevent the transmission shaft press on the lubrication groove.

Term Name
1 Crusher vertical center line
2 Crusher drive wheel
3 Motor drive wheel
128
 Form 6-48 Vertical drive downward traction

Term Name
1 Shaft sleeve on the shaft gear end
Lubrication groove is on the 12 o’clock direction of sleeve on the transmission shaft
2
gear end
When horizontal drive or vertical drive upward traction, the drive wheel shaft sleeve’s
3
regular 6 o’clock position
4 Lubrication groove
When vertical drive downward traction, the shaft sleeve on the drive wheel end’s 12
5
o’clock position
6 The shaft sleeve on the drive wheel end
7 Transmission shaft frame
Form 6-49 The shaft sleeve lubrication groove’ position in transmission shaft

4. Slip dry ice into the prepared shaft sleeve and keep 2-3 hours, to shrink the shaft sleeve to be smoothly
installed in the transmission shaft frame.
129
Attention: Wrap a few of glass fibre cloth on the outside of shaft sleeve to keep warm and prevent
outside frosting which may influence install the shaft sleeve into transmission shaft frame. The method
is also beneficial to totally cooling down.

Warning
When carry the dry ice, should
wearing thick enough and heat-pre
vented gloves. Carrying the dry ice
without protection will cause serious
frostbite.

Attention: If the crusher transmission shaft frame temperature is 75℃ (24℉) or higher, it can use regular ice
to replace dry ice. To measure shaft sleeve’s outer diameter and shaft frame’s inner bore to check whether the
shaft sleeve totally cooling down.

5. To take the steel stick which inserted in the shaft frame as oriented rod, slipping the shaft sleeve into shaft
frame inner bore.
6. If the installation speed not fast enough caused the shaft sleeve swell back when just a part of shaft sleeve
installed in the inner bore, or it cannot use the cooling shrink method to install; it can put a wooden block
as protection on the surface of shaft sleeve, and then knock the shaft sleeve onto position. When utilizing
this method, the oriented rod will be highly effective.

Attention: Do not knock the sleeve too hard, because the shaft sleeve may up wrap in the shaft frame
inner bore, and it will cause the installation be more difficult.

7. Remove the oriented rod, and then installing locating pin which removed before.

6.5.2.6 Transmission shaft frame assembly

refer to figure 6-38,6-50
When disassembling the transmission shaft frame assembly for checking and replacing the parts, O-shape ring
between the transmission shaft frame and main frame and the gasket or sealant between the cover plate and
transmission shaft frame are suggested to be replaced.
These parts may be deformed permanently after years and lose the elasticity and compressibility needed by the
effective seal. The O-shape ring and sealant are both not expensive and it is not worth for that to happn the
unpredictable phenomenon of oil leak.
the procedure of assembly and disassembly are opposite, the difference as follows:
1. Plug the transmission shaft assembly into the transmission shaft frame.

130
2. For firmly fix the horizontal shaft, place one big C-shape clamp to make the small gear fixed on the the
flange of the transmission shaft frame, refer to figure 6-51. Another way for fixing the transmission shaft
is to lean the small gear on the firm supporting bulkhead or similar upholder.
3. Heat the oil slinger to the temperature about 27℃(50℉) higher than ambient temperature and install it
quickly on the transmission shaft.
4. If the resistance is encountered, place one piece of wood block on the surface of the oil sling, through
knocking the wood block, force the oil slinger loaded on the shaft. When the oil slinger installed properly is to
lean on the special feeler gauge on the surface of transmission shaft sleeve. The thickness of feeler gauge or
axial play refer to figure 6-42 and 6-11.

item name
1 transmission shaft frame
2 oil slinger
3 penetrating cover
4 seal ring
table 6-50 oil slinger, seal ring
5. When the oil flinger is cooled to the room temperature, install the first seal ring on the transmission shaft,
the lip side outside and another side close to the oil flinger.
6. Before install the penetrating cover on the transmission shaft, check two sides of the penetrating cover(the
side close to the seal ring), which must be smooth! If the surface is worn, it must be processed smoothly.

131
 item name
1 C-shape clamp
2 transmission shaft frame
3 small gear
Table 6-51 fixed transmission shaft assembly

3. Before fix the penetrating cover with bolts on the transmission shaft frame, place the gasket on the shaft
surface. Penetrate the screw into the cover board hole and screw into the threaded hole of shaft frame.
4. Install the seal ring outside the penetrating on.

6.5.2.7 Oil leak from the drive end from the transmission shaft frame
If the oil leaks from oil slinger light plate of the shaft drive end, maybe the seal ring in and out of transparent
cover is damaged or worn, need to be changed. As shown in figure 6-50.
Check the long hole of drive shaft frame below the drive shaft to see if there is dirt. Dirt build-up will limit oil
amount from the oil slinger.
The reason for oil leak may also be that the oil can not discharge from crusher rapidly, especially when the oil
temperature is low. Minimum slope should be every 305 mm (12 ")long line tubing falling 25 mm (1"). Should
also check whether there is obstacles in main oil discharge hose or the pipe , such as dirt stored or hose
flattening, these may limit the flow of oil.
Above any one of the reasons described could lead to oil back-flow and oil leakage from the oil trap area.

6.5.2.8 Remove the crusher pulley

As shown in figure 6 to 52
According to the following steps to remove the breaker belt pulley:
1. First unscrew the hub, clamp the screw tightly.
2. Insert the screw into the hub, dish out hole.

warning 132
If the pulley and removable hub are separated apart difficulty, knock gently with
hammer, and maintain the pressure on the thrust screw
 item name
1 transmission shaft
2 key
3 pulley taper sleeve
4 pulley
5 decorating plate connection bolt
6 drive shaft pulley decorative board
7 pulley tighten screw
Table 6- 52 pulley assembly

6.6 main frame／support sleeve and iron block pass and release assembly

6.6.1 summary
This chapter includes main frame, support sleeve and iron block pass and release assembly.

133
With bolts tightened on the basis of the main frame, pass the crushing force to the foundation, to provide
strong support for other broken parts.
Main frame plate and stiffened plate that welded within the rack or bolted within the frame can be replaced,
and can prevent frame inner wall wear and tear. Inside the frame casting a deep cavity called balance ring
protection cavity, balance ring put in is isolated completely with the outside, has played a very good protection
effect. The cylindrical of balance ring protection cavity is equipped with replaceable sheeting, prevent balance
ring protection cavity is worn during the production. As shown in figure 6-53.

item name
1 U- shape seal ring
2 balance ring
3 balance ring protection cavity
4 The floating ring bearing
5 The floating seal ring
6 Shaft seat heart guard
Table 6-53 balance ring protection

The support sleeve on the taper machining surface on the top of the main frame with its internal thread is used
to adjust the adjusting ring assembly. The lock nut on the support sleeve supported a set of lock cylinder
bearing , in its wall also tapping screw thread, used to lock the adjusting ring assembly in supporting sleeve
tightly on the broken position.
At the top of the support sleeve, equipped with a scraper seal, cover lock the thread of the cylinder and the
adjusting ring, prevent dust and dirt to enter.

134
。 The hydraulic cylinder is installed on the bottom side of the main frame, bolted onto the support sleeve.
Hydraulic cylinder support set is firmly fixed to the main frame, bearing normal crushing force. Due to
improper operation or caused too much stress by not broken material, make the support sleeve raised, which
will pull up the hydraulic cylinder piston rod, discharge the oil in the hydraulic cylinder cavity into the
accumulator, and then compress nitrogen gas in the accumulator. Once the load or miscellaneous iron through
the crusher finish, the crushing force turns into normal, compressed nitrogen will make oil returned back to the
hydraulic cylinder, piston rod will retract, support sleeve is placed back to the main frame.
From the bottom of support sleeve(depends on the size and specifications of the crusher) out of the main frame
of pin, can prevent the support set rotated, and can be used as a guide, when support rises or tilts, the support
sleeve comes back in place.
。 The thrust bearing is bolted on the main frame around the main shaft seat to support the eccentric sleeve
bearing rotated. The base plate inserted under the thrust bearing is used to determine the big bevel gear and
small gear tooth clearance and tooth tip clearance.

Double seal prevents dust intrusion:

1、Floating seal ring device is mounted on balance ring protection cavity of the frame, matched well with dust
proof ball ring below the dynamic cone have good sealing effect.

2、On the crusher, two bronze bushings support the shaft. In the groove around the main frame gear well block,
tied with non-metallic stationary u-shaped seal, together with the spinning T seal form at the bottom of balance
ring forms labyrinth seal, prevent oil leaking and protect large bevel gear and small gear and bearing surface,
so as to avoid the dust intrusion.

Spindle is firmly installed hub in the center of the main frame of the plate, let the eccentric sleeve turned
around it, and supporting the ball seat.

6.6.2 Assemble illustration

6.6.2.1 General rules

In most cases, the main frame, support sleeve, and iron release parts are assembled to transport. But in rare
cases, because of the limit transportation and space, that may need to be disassembled for transportation. Main
frame assembly of different parts of the whole program, see the maintenance section of this chapter.

6.6.2.2 Crusher installation

6.6.2.2.1 Concrete foundation installation

135
If the host frame assembly or the whole crusher is placed on concrete foundation, main frame must be grouted.
Now there are two types of filling materials can be used, i.e., concrete and epoxy filler. Over the years,
coagulation is thought to be the only grouting material, However, most of the recent installation crusher, epoxy
resin filler has replaced the concrete grouting. Due to the nature of concrete, it is necessary to do a lot of
preparation work and in most cases it is related with the equipment used, As a result, the epoxy resin filling
material becomes more popular. Epoxy resin filler is a kind of viscous, elastic and shock-resistant epoxy resin
materials, stored in different specifications of the small sale barrels for sale, including epoxy resin and curing
agent in the bucket, just can be mixed at the scene of the work. There are simple instructions in each barrel.
Using epoxy resin does not need special equipment, preparation and processing. Once epoxy resin is mixed,
must immediately pouring, but not mixed material can be in any convenient time after mixing and then
continue casting.

item name
1 Crusher appearance
2 foundation
3 Wood pattern removed after filling grouting epoxy filler
4 anchor bolt
5 wood pattern
Table 6-54 crusher grouting
Install the main frame assembly or the whole crusher on the concrete or steel structure perfusion to the
concrete slab, as shown in figure 6-54, its operation steps as follows:
1. Cut four large diameter gasket from 10 mm thick (3/8 ") steel plate , drop it on foundation bolt. Near the
bottom of the racks hook hung on the appropriate line. As shown in figure 6-54.

warning
Can't use the lug on the adjusting cap to lift the whole machine. Because the lug
strength is not enough to lift the whole crusher, Otherwise, it will cause serious
personal injuries or serious crusher damaged.

136
2. Carefully lift main frame and smear the bottom of the main frame flange with a little oil, prevent stick
epoxy filler tied to the crusher.
3. Put the upper frame on 10 mm (3/8 ") thick pads of the basis.

item name
2 sling
3 main frame
4 main frame lifting hook
Table 6-54 lifting crusher
Note: when using concrete, should mat hardwood block under the four corners of the main frame, not mat steel
ring. Because in this case, when concrete pouring material shrinks, wood shrinks with the wood. The main
frame should be based by the block about 50 mm ~ 60 mm (2 "- l) / 2" higher than the concrete foundation , in
order to make the concrete perfusion with proper thickness. Keep the surface of the basis poured concrete
mortar rough, carefully clear the cavity before filling. The surface should also be full of water, keep wet,
prevent the water in the grouting mixture be absorbed quickly. However, before the grouting, the excess water
on top of the basis should be discharged. The grout mixture containing no shrinkage additive should be used,
trying to reduce shrinkage.
4. Around the foundation bolt, insert "C" type gasket into the top of the steel washer, make the crusher
leveling .This will a 12 mm - about 20 mm (1/2 ", 3/4 ") perfusion layer thickness between the main frame and
basis, the proper thickness is that of epoxy filler used.
5. Then, inside and outside the main frame flange making a mold, in order to be filled with the epoxy resin
filler when pouring, the mold is made of 25 mm to 50 mm (1 x 2 ") wood planks. Fix the wood planks outside
the crusher flange 12 mm (1/2 "), inside the flange, lean the mold close to the basic profile and the bottom side
of the host flange. Refer to figure 6-5. All the moulds must be painted three times with ordinary wax melting,
prevent grouting and wood adhesion. All joints and cracks must use gap agent seal, in case of epoxy resin filler
leaks when full filled.

137
6. Mix and pour the epoxy resin filler according the introduction on the barrel. When operating at the low
temperature, heat the epoxy resin filler and crusher flange to 18℃～27℃(65℉-80℉). To gain the best results,
before mixing, place the barrel of epoxy resin at the warm place and stored. To prevent the entrapped air under
the crusher, every time pouring the epoxy resin filler at one place and make the surrounding of pouring spots
covered about 0.6 m( 2 inches) area, then move to the last place that the pouring filler stopped and continue to
pour. The process is repeated until the pouring is finished.
Note: when pouring the epoxy resin filler, each time will not exceed one place.
Whatever the pouring thickness is 12mm or 20mm(1／2″or 3／4″), the average weight of epoxy resin filler
needed by the crusher refer to the figure 6-17.
7. When pouring, the base, crusher and epoxy resin are all heated to 2l℃(70℉), the epoxy resin will harden
after 6 hours and next process is allowed to do.
8. After the pouring materials harden, the crusher is firmly fixed to the base.

epoxy resin needed kg*

crusher model
12mm(1／2") 20mm(3／4")
HPT100 35(77) 35(77)
HPT200 45(99) 65(143)
HPT300 45(99) 65(143)
HPT400 45(99) 65(143)
HPT500 85(187) 130(286)
*Total amount includes that amount for more than 12mm(1/2”) grouting layer between the mould and frame
flange. If the foundation is irregular, that amount will add another 10%.
Table 6-12 the required amount of epoxy resin grouting agent
If the crusher is placed on the steel structure or the trailer chassis, because of the deform or irregular steel
structure or crusher frame, the main frame must be fixed by adding the gaskets.
：the procedure that the crusher is installed on the steel structure as follows:
1. Clear the welding slag or spatters on the top of steel structure and at the bottom of main frame flange,
besides, grind the welding spots smoothly which are higher than the surrounding surface.
2. Tie the sling on the lifting hook near the bottom of main frame, refer to the figure 6-54.

warning
The lifting lug on the adjust cap must not be used to lift the whole machine.
Because the strength of the lifting lug is not enough to lift the whole crusher,
otherwise, that will cause serious personal injuries or the crusher damaged
seriously.

138
3. Gas cutting four same shape or outline of base plates from 6mm(0.25”) steel plate as that of machining
surface of main frame. There are the holes for through the foundation anchor bolts in the middle of base
plate, covering the base plate on the foundation anchor bolts or steel structure.
4. Carefully lift the main frame and plate it on the neck of four base plates upper the steel structure.
5. Plug the gasket same as the base plate in process 3 in to level the crusher. The gasket has the U-type
breach to avoid the foundation bolts and be put in the position. Different thickness gaskets is used to
support evenly on the machining face of the whole main frame flange. Level the crusher from two sides
using the neck of main shaft.
6. After properly position the gasket under the crusher flange, spot weld the gasket on the steel structure,
make it not be removed for the vibration.

7. Once the crusher is level. Measure the gap or distance between the crusher frame flange and steel
structure in the three areas shown in figure 6-55, and add gaskets on these three positions, to reinforce the
supporting of crusher frame and steel structure. According to the crusher size, the thickness of gasket is
different, and its width is nearly same with the main frame flange; according to the model of the crusher, the
length is 400mm-915mm(16″-36″). HPT400 and HPT500 always use the base plate with the length of
915ram(36″).
8. After properly position the gasket under the crusher flange, spot weld the gasket on the steel structure, make
it not be removed for the vibration.
9. Fix the crusher firmly on the steel structure. The anchor bolt used should be long enough to through the
depth of the whole bearing bars(net length 18″or much longer).
10. Fix the crusher firmly on the structure and check the crusher again in parallel or not.
11.Respectively check anchor bolts loose or not and tight them again a week, a month, 6 months and 1 year
after the installation.

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 item name
1 Square stow-wood
2 gasket
3 flange of crusher main frame
4 steel structure or trailer
5 crusher installation bolt hole
Table 6-55 the position of base plate

6.6.2.2.2Floating steel base installation

If it is equipped with a floating steel into concrete crushing confidential basis, on the basis of previously buried
in concrete on embedded steel, the assembled floating steel plates embedded into the concrete foundation,
school level after the connecting plate and pre-buried steel plate welded together. Figure 6-56.

Note that during welding, soldering will produce a lot of heat that would melt rubber springs and rubber
springs out of steel cause damage. Do not weld continuous welding to prevent a lot of heat.

Item Name
1 Floating steel
2 Rubber spring
3 Webs
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4 Embedded steel
5 Round
6 Concrete foundation

Figure 6-56 Rubber spring mount

6.6.3 Maintenance
6.6.3.1 liner and bars lining the main frame
Figure 6-57
When the crusher downtime replace liner, liner wear and bars lining the racks should be checked on.
Split out from inside the cone crusher, the can from the top of the bar into the main frame bars on top of the
liner. When moving cone in place, reinforced liners can also be slipped into place from the bottom of the
crusher, but very difficult.
Pull the main frame lining replacement parts shipped generally divided into paragraphs, making installation
more convenient to work some of the liner. If the claim must be made whole liner, the liner must overlap at
both ends until the liner diameter smaller than the inner diameter of the support sleeve screw up. Heavy "C"
shaped clamp firmly overlapping ends of the card owner, then the liner into the rack, removed the clip, so that
the liner bounce back to its original shape. With the old liner welding marks, it is easy to see that the liner is
welded to a height within the rack. Only to the top of the welding liner.

141
 Item Name
1 Main Frame
2 Host shelf liner welding points
3 Main Frame Liner
4 Bars lining
5 Floating seal
6 Temperature Sensor
Figure 6-57 and bars lining the main frame liner

6.6.3.2 Replace the spindle

Spindle rarely need to be replaced. Because between the spindle and the rack assembly suitable hub is very
important, therefore, removing and installing the spindle factory representatives should be, the representative
of well-trained and have the right equipment.

6.6.3.3 Replace the lower thrust bearing and plate

Figure 6-58

Steps to replace damaged or worn under or additional thrust bearing pad, restore large and small gear right
headspace and backlash as follows:
1. In order to replace the thrust bearing, you first need to remove the adjustment ring, moving cone, ball
bearing seat and eccentric assembly, please refer to the relevant sections of removal of these assembly
instructions.
2. Remove the thrust bearing is fixed to the main frame of the screw and spring washer.
3. In the two threaded holes in each thrust bearing rings screwed into a screw.
4. Place the screw rings linked to the appropriate lifting device from above carefully lift shaft thrust bearing.
5. Check to be put on the thrust bearing or thrust bearing plate, ensure that no burr or curling, the bearing or
pad flat on the main frame, its surface full access.
6. Reference eccentric assembly section "Check the tooth tip and the backlash" section to determine the correct
number to install the gasket. Any additional shims should be placed on top of the existing gasket. If you install
a new thrust bearings, remove the eye bolts from the old bearing, which is mounted on a new bearing. The
thrust bearing down, to ensure that all the holes are on the hole being the hub of the main frame, bearings and
gaskets confirm proper contact.
7. Place the new spring washer into each hole on the thrust bearing. Insert screws through the spring washer,
thrust bearings and gaskets fall screws into the threaded hole of the rack. Then, a few alternately tighten each
hex bolts, until they are completely tight.

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Item Name
1 Lower thrust bearing
2 Socket head cap screws
3 Spring washer
4 Backing

Figure 6-58 lower thrust bearing assembly

6.6.3.4 Replace the seals

U-shaped gear rack recess seal is usually no contact and wear. However, if the seal is damaged in any way,
replace the seals are very important. The seal to prevent leakage and protect large bevel gears, pinion bearings
and precision machined surface from harmful dust and damage. Follow these steps to replace the seals:

1. Remove the damaged seal, and remove remaining in the sealing of any adhesions bad thing. With a sharp
blade or putty knife to cut off the rigid seals, scrape the old adhesive from the tank.
2. Use non-oily solvents, alcohol or acetone, thoroughly clean the seal groove, and allowed to dry.
3. Remove the molded seal from the shipping carton before seal adhesive attachment, beat bottom with coarse
sandpaper to completely seal the hair to get rid of surface light. In the manufacturing process for the seal to
facilitate the release, a release agent layer of the sealing member Xu. In order to make a good seal and
adhesive bonding, the seal is firmly bonded to the main frame of the tank, the release agent must be thoroughly
cleaned.
Note: If the release agent is not completely removed during the operation, the seal will be loose.
4. At the bottom seal coated with a thin layer of a curing agent. If applied too much hardener can cause partial
curing adhesive.

143
5. At the bottom of the main frame of the seal groove Apply a small amount of a curing agent. Adhesive
coating can be enough to ensure that the extrusion amount as small as possible.
6. After applying adhesive, the seal is loaded as soon as the seal groove, holding the bottom of the seal has
enough power, the seal is pressed against the contact seal groove bottom. The bonding process takes about
three minutes.

Figure 6-59 Replacing the U-ring

6.6.3.5 Replace the floating seal ring, round rubber tubes and dust apron
Floating seal device floating seal ring, round rubber tubes and dust apron to be replaced, otherwise it will cause
excessive oil pollution.

Every time you replace the liner time to check dust apron and circular rubber tube be replaced if damaged. As
shown in Figure 6-60

Time to check each replacement liner floating seal ring "H", replace float if "H" reaches the minimum value
Table 6-13 sealing ring

144
Figure 6-60 Replacing the dust apron and circular rubber tube
Item Name
1 Floating seal ring
2 Circular rubber tube
3 Floating ring holder
4 Dust Aprons

Figure 6-61 floating seal ring

Crusher
H. minimum
Specifications
HPT300 40mm
HPT500 45mm
Table 6-13

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6.6.3.6 Replace the main frame pin
Figure 6-62.

Usefulness of the main frame pins are set relative to the main frame to prevent rotation of the support. In
addition, when the crushing cavity by miscellaneous iron or blockage material leaving the support sleeve lift,
but also as a guide, the support sleeve back to original position. Support sleeve repeatedly bounce is not
normal, it can usually return to normal by appropriate adjustment of the fabric and the crusher discharge
opening. Non-operating support sleeve correct excessive movement will cause the rack to wear the pin, and the
support sleeve or bushing hole on the rack pins are elongated. By looking at the site of the support sleeve
around the bottom of the rack pin wear can be found. Due to the rotation of the adjustment ring movable cone
related support units will rotate in the machine direction of rotation. Because this effect is only one direction in
the supporting sleeve, and therefore, the pin hole of the main frame pin and the support sleeve or pin bushing
wear only on one side of the trend.

Follow these steps to replace worn rack pins:

1. Release of insurance over iron cylinder pressure. Ensure the release of the crushing chamber pressurized
loop pressure gauge reaches zero.
2. Remove the support sleeve nut from the top of the sphere of insurance through iron cylinder rod. As the nuts
are coated with anaerobic adhesives, therefore, to loosen the nut before. It must be heated to about 205 ℃ (400
℉).
3. All over the insurance iron cylinder mounted on the main frame of the outer ring.
4. Use a crane or other suitable lifting equipment, lifting support sleeve assembly (including nut and locking
cylinder) to disengage the main frame.
5. From the top of each pin to be replaced Remove the screws.
6. torch heating taper pin seat while worn by tapping the top of the pin from the bottom of the support units.
After the addition center or, cut spending and sell hot seat ejection.
7. The installation replaces the previous taper pin placed in dry ice for about two hours.

Warning

8. Before installing the pin support sleeve with torch heating for about 10 minutes. Then quickly cold pin
inserted up support sets, tap until the pin sitting on the bottom of the counter-bore.
9. Re-install the screws, washers.
10. In the main frame mounting support sleeve assembly. Mixed with 3% molybdenum disulfide powder
NLGI No. 1 lithium-based grease applied to the support socket.
146
11. Re-install Insurance cylinder spherical nut over iron or crushing chamber in accordance with the insurance
cylinder installation method described later in this chapter.

Item Name
1 Bolts and lock washers
2 Supporting sleeve
3 Taper pin
4 frame
5 Pin sleeve
Figure 6-62 Replacing the taper pin

6.6.3.7 Host mountings

6.6.3.7.1 Overview

147
Check the host should regularly wear seat frame. Since the feed feed irregular crusher and support sleeve and
the main frame of the seat has a slight friction, therefore, there will be some wear and tear. If the support cover
excessive exercise, the wear will increase. It is in the main frame chassis welded bronze liners on all standard
HPT cone crusher, as shown in Figure 6-63 bronze alloy crusher supporting the contact surface sets, providing
a replaceable wear surface. Since bronze alloy are softer than a metal frame and a support sleeve, wear only
when the liner wear.

Item Name
1 Copper pad
2 Seat surface
3 Main Frame
Figure 6-63 seat surface of the main frame

148
Item Name
1 Screws, spring washers
2 Support sleeves
3 Measuring the distance
4 frame
5 Pin sleeve
6 Taper pin
7 Copper pad
Figure 6-64 mark pin hole flange mounting surface to measure wear

Accurately determine the status of the rack copper pad wear procedures are as follows:
1. From the first frame of the main frame pin shaft from the left, clockwise, on the outside of the main frame
supporting sleeve or pin hole method painted or printed and marked 1,2,3,4,5 6 or 2, 3 and 4, depending on the
number numeral rack pins.
2. Figure 6-64 shows that the measured distance between the support sleeve and the main frame pin hole
between the flanges. Note its size.
3. Regular measurement of these points, and compared with the size. Comparison of two measurements of the
size, it can be seen whether or not wear a uniform. Due to reasons of casting and machining error, this is the
only method capable of accurately determining the wear.
4. When an inspection of any size to the size of the measured values of given in Table 6-14, copper pads need
to be replaced.

Periodic inspection, from one checkpoint to another checkpoint difference is equal to or greater than 6mm (1/4
"), it indicates that copper pad on one side is worn, causing support sleeve tilt seat to the main frame. The tilt is
from the crushing chamber feed concentrated in one area. This uneven distribution of feed to make the most

149
crushing concentrated in a certain range, increasing the support base of the rack set in potency, resulting in
excessive copper liner for this region wear when from one checkpoint to another checkpoint if the difference
between the change in 6mm (1/4 ") to 10mm (3/8"), the main frame copper pads need to be replaced.

To solve this problem, you should adjust the crusher feed configuration, so to feed into the crusher as
described in the second chapter, evenly distributed along the crushing chamber around.

Note: Before the copper liner is attached to the liner is not installed an old crusher, and the supporting frame
must be restored to the original sets of mating surfaces.
Crusher
Minimum
Specifications
HPT100 7mm(0.28″)
HPT200 12mm(0.5″)
HPT300 20mm(0.79″)
HPT400 20mm(0.79″)
HPT500 20mm(0.79″)
Table 6-14 copper pad wear

6.6.3.7.2 Installation of Frame Copper Liner

Copper liner installation as followings:

1. In accordance with hydraulic system accessories’ pressure release introduction to release over iron insurance
cylinder pressure.
2. Screw down the top of support sleeve’s sphere nut from over iron insurance cylinder’s piston rod. As the
nuts are coated with anaerobic adhesives, therefore, before unscrewing the nut, it must be heated to about
205 ℃ (400 ℉)
3. All of the insurance iron cylinders are fixed on outer ring of the main frame.
4. Use a crane or other suitable lifting equipment, lifting support sleeve assembly (including ring and locking
cylinder) to disengage it from main frame.
5. Disassemble the old copper liner.
6. Sequence welding the copper liner to the main frame. Do not butt joint vertical seam. Use spot welding for
the top, and taking full welding for slot seam and vertical seam welding (picture6-65). Preheat the main frame
portion and the seat liner to 20 ℃ (70 ℉) and 40 ℃ (100 ℉) before welding. This can ensure the elimination
of all moisture and thus achieve correct penetration depth. Please use AMPCOTRODE 10 welding rods.
7. Install support sleeve assembly to the main frame. Coated support sleeve with mixed 3% molybdenum
disulfide powder, lithium-based grease NLGI No.1 pool.
8. Reinstall insurance cylinder’s spherical nut in accordance with installation methods of over iron or crushing
chamber in later chapter.

150
 Picture 6-65 welding

6.6.3.8 Disassemble Insurance Cylinder of Over Iron or Crushing Cavity

Picture 6-67 and picture 6-66.

To pay attention of hydraulic cylinder oil leakage, no matter which parts concerned. It will be displayed on the
gauge of crushing cavity release system whether it is external or internal oil leakage. If the pressure system
drops and requires repeated pressurization, oil leakage should be occurred. Disassemble and repair the
hydraulic cylinder oil leakage as followings:
1. Disconnect power supply of hydraulic station motor, stop the motor, and then follow the "Hydraulic System
Manual" section to release the pressure. To release pressure oil of hydraulic cylinder accumulator back to oil
tank. Make sure the crushing cavity pressure gauge at zero.
2. Disassemble crushing cavity release pressurizes hose and cavity cleaning circuit hose which connected onto
over iron insurance cylinder and bottom of hydraulic cylinder. Covered or piston all pipe fittings and hose.
3. Install a sling for replaced hydraulic cylinder and connect to a suitable lifting device.
4. Screw down sphere nut in the top of the support sleeve from piston rod. Before unscrewing the nut, it must
be heated to about 205 ℃ (400 ℉) for coated with anaerobic adhesives.
5. Disassemble cotter pin from both sides of hydraulic cylinder bottom end clevis.
6. Pin use mild clearance fit within fork. Use hammer and gently knock the pin from the most convenient side.
No directing hit pin, otherwise, the pin will become mushroom-shaped tip, no longer unload down. Stick
surface alignment pins with round steel bars or brass. Then, tap the bar, until the pins are knocked up.
7. Unload piston rod out from the support sleeve, and then hanging the hydraulic cylinder and the accumulator

151
from the crusher. Be careful not to damage any hoses or hose device.
8. Reinstall instructions over iron and cavity clean cylinder, refers to "Hydraulic System Operation Manual."

Warning:
Before making sure the system has release the pressure, in any case, do not attempt to disassemble any
hydraulic connecting fitting. Disassemble hose from high pressure state is dangerous due to the high speed
ejection of oil and exists free end collision possibility of swinging hose

Item Name
1 Support sleeve
2 Over iron release circuit
3 Oil drain circuit
4 Clevis pin
5 Hex nuts
6 Roundness flower nut
7 Over iron Insurance cylinder
8 Accumulator
9 Main frame stiffening ribs
10 Piston rod

Picture 6-66 over iron release assembly

152
 Item Name
1 Piston rod
2 Support sleeve
3
4 Over iron Insurance cylinder
5 Hex nuts
6 Roundness flower nut
Picture 6-67 top piston connection of hydraulic cylinder

6.6.3.9 Installation of Over Iron or Crushing Cavity’s Insurance Cylinder

Picture 6-67 and picture 6-66
Install a new or repaired hydraulic cylinder as followings:
1. Push down piston rod into the bottom of the hydraulic cylinder.
2. Screw roundness flower nut onto piston rod. Then, move down the nut to the thread bottom of piston rod.
3. Lifting hydraulic cylinder vertically by lifting device, and make the piston rod end head-on. And penetration
piston rod into support sleeve hole, and then lifting the hydraulic cylinder. Install the piston rod and pin.
4. Check the fork pin, it should be disposed if there are burrs or scratches on the outer surface,.
5. Align the main frame and fork pin holes. Oil the pin, then use a hammer gently tapping round steel bars or
brass rods, put the pin into fork rod and the main frame. Install cotter pin on the pin.
6. Make sure that the piston rod reaches the bottom of the hydraulic cylinder. Measuring distance between
support sleeve to the top piston rod.
7. Install spherical mat on the piston rod, then tighten the hex nuts onto the piston rod, then pull out the length
of the piston rod as shown in Table 6-15 from the hydraulic cylinder. Disassemble hex nuts when pull the
153
required length of piston rod from the hydraulic cylinder.
8. Use non-oily solvent cleaning rod tip 100mm (4 ") of the threaded portion, you can use alcohol or acetone.
Then, painted anaerobic on thread with a clean brush

Crusher Model Setting

HPT200 12mm(1/2″)
HPT300 23mm(1″)
HPT400 25mm(1″)
HPT500 25mm(1″)
Table 6-15 pulling length of piston rod
.
9. Screw the hex nut onto the piston rod until reach near to spherical mat.
10. Re-check the distance from top support sleeve to top piston rod. Be sure the distance range results are
within steps 7 and 8.
11. Cleaning the support sleeve threaded rod with non-oily solvent. After cleaning, smear piston rod thread
with anaerobic 242 away from support sleeve 20mm (0.79 "). Then tighten roundness flower nut in upper
piston rod until the distance is 20mm (3/4 ") from top roundness flower nut to support sleeve’s bottom surface.
12. Connect all hoses of hydraulic station and accumulator.
13. After installation of hydraulic cylinder, and all connectors connected, release any air left in the system.
Then, pressurize the system and check leakage. Refer to the hydraulic system manual about holding gas, air
inflation and checking.
14. After pressurize for over iron release circuit, in accordance with the requirements of the 12th procedure,
check the distance between roundness flower nut to support sleeve. Release pressure of circuit if the distance is
incorrect. Achieve accurate setting by adjusting lower hex nut. Then, pressurize the circuit, check the distance
again, re-adjusting if necessary.

6.6.3.10 Accumulator Replacement

Picture 6-68.

Faulted accumulators of nitrogen leakage into the atmosphere or liner leaking need immediate attention, for
they are very serious situation. In either case, the accumulator will full oil. Over iron release system will not
work properly since the gas or pre-charge gas run away or been missing from the bladder.

When faced with unable crushed material or overloaded, over iron insurance cylinder hydraulic oil can’t
compress accumulator liner’s nitrogen, resulting in large crushing force in crusher’s inner element.

Pre-charge pressure in the accumulator should be checked in every 200 hours (1 month).If the accumulator gas
pressure is not in its normal pre-charge level, or can’t maintain normal operation recommended pressure level;
the accumulator should be disassembled and replaced. Replacement steps as followings:
1. Disconnect power supply of hydraulic station motor, stop the motor, and then follow the "Hydraulic System
Manual" section to release the pressure. To release pressure oil of hydraulic cylinder accumulator back to oil
tank. Make sure the crushing cavity pressure gauge at zero.
154
Warning:
Before making sure the system has release the pressure, in any case, do not attempt to disassemble any
hydraulic connecting fitting. Disassemble hose from high pressure state is dangerous due to the high speed
ejection of oil and exists free end collision possibility of swinging hose

Item Name
Accumulator intensify frame bolted in
1
frame
2 Accumulator intensify mat
3 Accumulator
4 Large oil passing distributor
Picture 6-68 accumulator replacement

2. Disassemble the valve plug from the top of the accumulator. Remove aerator / test machine to ensure that
the bottom of the coupler and the accumulator valve to match. Completely loosen the knurled knob, make sure
to put the air lock is closed. Use lower portion screwed onto the accumulator of aerator / test machine. Screw
knurled knob onto the aerator / test machine.

Put valve protection plug back and open exhaust valve screw until nitrogen is empty (pressure gauge reads
"0"). Disassemble aerator / test machine.
3. Disassemble hex nut of accumulator shell’s intensify mat, lock mat loop and screw, and then, disassemble
intensify mat in accumulator intensify frame. Loading a sling around the accumulator and connected sling to a
suitable lifting device.
4. Put a large pipe and or wrench at the top of the accumulator, and clockwise to the accumulator, until the
accumulator can be easily removed.
5. Apply a suitable thread sealant on the screw thread and replacement parts or repaired accumulator’s inner
screw thread. Then, screw pipe joints into the accumulator.
6. Be careful when seated accumulator and pipe joints in which near to the big passing distributor. When screw
the accumulator joints into large passing oil distributor’s screw thread joints, should pay attention to make
155
accumulator vertically, not to let screw dislocation. Then, make it fully tightened.
7. Installation of fixed frame and accessories.
8. Follow "Hydraulic System Manual" to pre-charge new accumulator. It may damage the accumulator if press
the oil pressure before pre-charge with nitrogen properly.
9. After installation of accumulator and all joints connected, system gas drain, to get rid of trapped air, then
pressurize the system is and make leakage check.

6.6.3.11 Disassembly of the locknut

The procedures to check or replace parts and disassemble locknut are as follows:
1. Disassemble the adjustment ring according to Chapter 4.18.
2. Remove the hex head screw and locknut. The screw is through the locknut, and screwed into the top of the
support sleeve, its usage is to prevent accidental increase of locknut when disassemble the adjustment ring,
and to prevent from the damage of locking cylinder due to pressure when the adjustment ring assembly is
not seated.
3. Make sure that locking circuit finishes relief, then remove the hose between the first locking cylinder and
the elbow above support sleeve.
4. Screw the rings screw into the locknut, lift the locknut and locking cylinder from support sleeve with
suitable lifting devices.
5. Until now, can remove any parts or all the locking cylinder from the locknut to repair or make replacement.
Disassemble the hoses on both sides of hydraulic cylinders, remove the countersunk screws which fix cylinder,
and remove the cylinder from locknut.

6.6.3.12 Installation of locknut

The method to assemble locknut to the support sleeve is as follows:
1. Thoroughly wash the threads of locknut, adjustment ring and support sleeve. The Installation holes on the
locknut to install locking cylinder should be cleaned with burrs polish.
2. Check Figure 6-69, install locking cylinder in the hole of locknut. Fix the collar to the corresponding position
of locking cylinder and connect the hose.
3. Insert the screw rings into the threaded holes on top of locknut. Fasten slings between eyebolts and a
suitable lifting device; lift the locknut above the support sleeve. Details in Figure 6-70.
4. Turn the locknut and make positive of the tubing holes on locknut and the corresponding holes on support
sleeve.

156
Item Name
1 Lock cylinder
2 Collar
3 Locknut
4 Support sleeves
Figure 6-69 Installation of lock cylinder

157
 Item Name Item Name
1 Locknut 6 Lock cylinder
2 Hanging Sling 7 Hanging Rings
3 Limit screw of locknut 8 Hanging Sling
4 Spacer 9 Oil pipe hole
5 Support sleeves 10 The hole of locking cylinder
Figure 6-70 Positive signs of holes

5. Place locknut slowly to supporting sleeve. Ensure locking cylinder has been depressurized.

6. Align the limit screw of locknut and hole to insert locknut, and screw into support sleeve.

Keep the proper gap between the head of screw and locknut top, details in Figure 6-70. Leave a gap between
the head of the screw and locknut top.

158
When pressure the locking cylinder, the locknut should be able to move vertically.

Item Name
1 Limit screw of locknut
2 Clearance
4 Tightening nut
5 Support sleeves
Figure 6-70 Installation of Setscrews

7. Connect No.1 locking cylinder with elbow of support sleeve with hose. This hose will connect all the
locking cylinders to hydraulic station. Details in Figure 6-72.
After assembly of hydraulic cylinder and hose fittings, but before fix the adjustment ring with the
machine, pressure HPT400 and HPT500 crusher system to the maximum pressure 19.5Mpa (195 bar) for
10 minutes and check all locking cylinders and hose fittings for leaking.
8. Rub the threaded surface of lock nut, adjustment ring and the support sleeve by the cloth soaked with
molybdenum disulfide powder so that a lubricating film will be formed on the metal, which makes the
adjustment ring rotates more flexibly. The first time coated molybdenum disulfide has been completed at
factory.
9. Coat the threads with sufficient lubricant which is mixture of grease and 5-10% (by volume) disulfide
aluminum powder.

159
Note: When crushing sintered ore, slag or other hot material, should use a mixture of high-temperature
grease with 5-10% (by volume) molybdenum disulfide powder.
10. Install the adjustment ring of crusher as the description in Chapter 4.18. Ensure to relief pressure of
locking cylinder (loose the lock cylinder) before installation.

Item Name
1 Locking cylinder
2 90°elbow
3 Holes on support sleeve to connect lock cylinder with hydraulic station
4 No.1 Hydraulic cylinders
5 Hose
6 Support sleeves
7 Three-way valve
Figure 6-72 Hose connection of locking cylinder

160
 Chapter 7 Hydraulic System
7.1 General introduction
All HPT hydraulic cone crushers are equipped with Iron pass-by or crushing cavity hydraulic release and
cleaning system. Hydraulic cylinder is connected with the lower part of frame as well as fixed together with
the supporting sleeve, which ensures the solid connection between the supporting sleeve and the frame in
order to bear normal crushing force. The extra large crushing force generated by abnormal operating or
non-braking material (iron) will rise the supporting sleeve up, which can push the piston rod of in the upper
part of hydraulic cylinder to move upward. then the hydraulic oil in the hydraulic cylinder will be squeezed
into the accumulator, and then compress the nitrogen in the accumulator. Once the overload disappears or
the Iron (or extra hard material that cannot be crushed) goes through the crushing cavity, the crushing force
goes back to normal, compressed nitrogen pushes hydraulic oil back to hydraulic cylinder, and supporting
sleeve is back to its original place. To clear the crusher, pressurize the lower half of hydraulic cylinder to push
the piston, thus pushing the supporting sleeve off the main frame.

In addition to the release and clearance system of the hydraulic cylinder, the crusher is also equipped with a
adjustment ring hydraulic locking and adjusting system. A series of hydraulic locking cylinders between
locknuts and supporting sleeve can lift the locknuts on upper part of the supporting sleeve, so that the
adjustment ring will be in crushing position when the hydraulic cylinder is pressurized. When locking
hydraulic cylinder's pressure is relieved, hydraulic motor adjusting system fixed on the supporting sleeve will
turn the adjustment ring assembly to change discharge size.

All HPT hydraulic cone crushers are equipped with hydraulic station to control all hydraulic functions.

7. 1.1 Operation of hydraulic station

When the crusher in operation, the hydraulic station must be running to keep the locking pressure, and
pressurize the iron protection device or insurance cylinder of crushing chamber, in order to press the
supporting sleeve on the main frame.
Referring to the hydraulic system manual and Chapter 7 of crusher adjustment, cavity clearance, and the
operating instructions to remove and install the adjustment ring.

7.1.2 Characteristics of hydraulic oil

Oil used in hydraulic system must be chain alkyl (not cycloalkyl) high-grade industrial oil with the required
viscosity, which should have higher film strength, strong adhesiveness to metal surfaces and stability of
physical and chemical properties.
Oil used in lubrication system must have the following feature: high viscosity index, quick separation with
water, no bubbles, anti-rust, anti-corrosion, antioxidant, and containing anti-wear additives.

Recommendation: ISO 32 lubrication

Viscosity of oil:
40℃ 20～40cst
100℃ 6cst or higher.
161
Or:
100℃ 135～165 SUS (Saybot, UnwcrsaI Seconds)：
210℃ 45 SUS or higher
What’s more, viscosity of oil: 140 or higher.

It is very important to use suitable lubrication oil as stated above to protect crushers, which is easy to buy
from world famous oil companies. Improper lubrication oil will damage the crushers and make any
guarantees about crushers ineffective.

Be careful not to use fire resistant hydraulic fluids, hydraulic systems are not designed to use the fire resistant
hydraulic fluids.

NOTE: The hydraulic system frame, seals, accumulator tank, hoses and other components may not be suitable
for fire resistant hydraulic fluids. If use, it will shorten the lifespan of pump and make the inside wall coating
of fuel tank soften and fall off.

NOTE: During the first time fueling and releasing of hydraulic cylinder and pipes, hydraulic oil in hydraulic
station tank can be pumped out. There should be sufficient oil in the hydraulic oil tank to make sure that you
can see the oil level in oil gauge. When adding and releasing oil or pressurize the releasing system, the oil
level should be in the middle of the oil gauge window.
Hydraulic station fuel tank, iron insurance cylinders, accumulators, locking cylinders and connecting hoses
take about 100 liters (26 US gallons).

162
Item Name
1 Positioning screw
2 Locking cylinder
3 Locknut
4 Support sleeve
Figure 7-1 Installation of locking cylinder

7. 1.3 Lock the hydraulic cylinder assembly

Installation of locking cylinder refers to the "locking nut installation instructions -HPT200 / HPT300 / HPT400 /
HPT500", and Chapter 5, "the main frame, the support sleeve and iron release assembly" and Figure 7-1 &
Figure 7 - 2.

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Item Name
1 Locking cylinder
2 90°elbow
Holes on support sleeve to connect lock
3
cylinder with hydraulic station
4 No.1 Hydraulic cylinders
5 Hose
6 Support sleeves
7 Three-way valve
Figure 7-2 Hose connection of locking cylinder

7. 1.4 Hydraulic adjusting system assembly

There are rare circumstances for maintenance of the hydraulic drive unit. Given the complexity of the drive
components of hydraulic assembly, only properly trained factory representatives with necessary tools, can do
the work of disassembly, replacement parts, adjusting parts and reinstallation.

7. 1.5 Connection of hydraulic hose and crusher

Detail in Figure 7-3.
Once hydraulic station seated, hydraulic adjustment device mounted on the crusher, connect hose with
hydraulic motor, locking cylinder and insurance cylinder of crushing chamber, then take the following steps to
connect with the crusher.
• The six hoses taking out of hydraulic station are all the same.
• For easy hose connection of hydraulic station, crusher and hydraulic motor, the factory makes clearly marks
for all exported goods. In many places it is marked numbers 1,2,3,4,5,6 .
1. Connect the hydraulic station hose fittings to decrease CSS with the right discharge outlet of hydraulic
motor.
NOTE: During the connection process, should avoid any dirt into the hoses and fittings.
2. Connect the hydraulic station hose fittings to increase CSS with the left discharge outlet of hydraulic motor.
3. Connect the brake release hose from corresponding connector of hydraulic station with the brake outlet
164
above the hydraulic motor.
NOTE: Check the position of the hydraulic pipelines to the hydraulic motor and brakes; ensure no effect to any
other moving parts.
4. Connect the locking cylinder hose from the hydraulic station to the corresponding terminal holes at the
side of the support sleeve.
5. Connect the clear cavity circuit hose from the corresponding connector of hydraulic station to the clear
cavity circuit of the oil distributor. The circuit is connected to the lower part of the hydraulic insurance
cylinder or the bottom cover.
6. Connect the decompression circuit hose to the decompression circuit hose of the oil distributor, this return
hose is connected to the top of insurance cylinder or rod ends. Refer to Figure 7-3.

Item Name
1 Big oil passage distributor
2 Hydraulic cylinders
3 Clear cavity passage Interface
4 Insurance pressurized Interface
5 Accumulators
Figure 7-3 Connection of Insurance Cylinder

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7.1.6 Energy accumulator pre-pressurization and pressurization inspection.
(Crushing Cavity Releasing System)
Energy accumulator pre-pressurization should be inspected every 200 hours (Every month).
Energy accumulator should be pre-charged with nitrogen gas, and before inspection, make the
pressure 0 in the releasing circuit. Then open the relative valve in the hydraulic station. Make sure
that energy accumulator is not under the sunshine, and the outdoor temperature is around
20 ℃(70℉) when inspection. In order to inspect the Pre-charge pressure in the energy
accumulator, the way of connecting inspection equipment is as follow:
1. The pressure in the crushing cavity releasing system and energy accumulator must be
evacuated. See hydraulic system instruction manual.

Item Name
1 Air valve plug
2 Energy accumulator
3 Valve shield
4 Valve cover
Diagram 7-4 Energy accumulator valve

2. As picture 7-4 shows, take down the valve shield in the upper part of energy accumulator,
take valve cover away from valve plug.
Take the charging-nitrogen tools from the crusher kit. Charging-nitrogen tools consists of
pressure gage, relief plug, circular handle, main valve, tubes. Connect the tube with nitrogen
gas cylinder. The connecting nut in the lower part of main valve with valve plug on the
energy accumulator.
3. Fully open circular button the nitrogen-charging tool and make sure venting plug is closed.
4. The connecting nut in the lower part of valve is fastened on the energy accumulator.
5. The tube of Nitrogen tool should be connected with nitrogen gas cylinder.
6. The circular handle is fastened on the nitrogen-charging tool. The pressure value is on the
pressure gage.

166
7. If the pressure is bigger than the threshold value, open the vent plug and reach the qualified
pressure.
8. If the pressure is smaller than the threshold value, open the nitrogen cylinder valve and reach
the qualified pressure.
9. Close the nitrogen gas cylinder valve, and disconnect.
10. Open the circular handle on the nitrogen-charging.
11. Take down the nitrogen-charging tool from the energy accumulator.
12. Inspect if valve is sealed or not by soap lye. If valve leaks, repeat the pressure inspection
operation. If it still leaks, change the valve.
13. Put the valve protection plug.
14. Repeat the same action for other energy accumulator.
15. Close the needle valve of hydraulic valve.
16. Inflating releases circuit.

Warning
The charging air must be nitrogen, other
compressed gas may explode or create
other explosive substances. Oxygen is
prohibited!

7.1.7 Emission and Inflating Test of Hydraulic System

After system is connected at first time, or breakdown happens at any time and some part need to
be changed or fixed, some circuit that is exposed in the air must be deflated in order to exhaust air
in the hydraulic circuit or circuit device. A little air in the system has no influence on the operation,
so there is no need to exhaust all the air. If the crusher is used first time, all the circuit must be
exhausted before inflating.

Notes: When oil is charged and discharged for hydraulic tank and pipe at first time, the
hydraulic oil in the hydraulic station will be pumped out. The increase of hydraulic oil is up
to the demand in order to make sure the oil level can be seen in the oil level indicator in the
hydraulic station side. After charging, discharging and releasing system, the oil level should
be kept in the middle of the indicator window.

Start Hydraulic station。Before discharging in any circuit or in the system, at first prepare the oil
to force the air to exhaust via some connector. Start the hydraulic station according to instruction
manual, and ready to exhaust and inflating test.

167
Notes: Before energy accumulator pre-charges nitrogen gas, the oil is prohibited to be
pumped into crushing cavity insurance circuit, in order to avoid damaging gasbag and
changing energy accumulator.

7.1.7.1 Locking Cylinder Circuit

Locking circuit discharging and inflating test should be done as follow:
1. Start Hydraulic station, see hydraulic system manual.
2. Pressure locking cylinder circuit must be at 0 level, see hydraulic system manual.

Warning
Discharging action can not be done
for any circuit when inflating. The
crazing of loose connection and
escaping of high pressure oil will
damage workers. When discharging
circuit, eye protection device need to
wear.

3. Connect screwed joint of locking tank’s circuit tube with the screw hole for discharging in
the supporting sleeve side. Open the connector a little bit, in order to let oil come out. When
the oil is clean, no foam, and no splashing, close the connector.
4. Increase the locking pressure, see hydraulic system manual.

7.1.7.2 Crushing Cavity Releasing Cleaning Circuit

There are some crushing cavity safety tanks and accumulators in the crushing cavity releasing
cleaning circuit. Connect these tanks with tubes and the tanks are around the frame. The air in
every tank cleaning cavity side and tube should be exhausted as follow:
1. Open hydraulic station. See hydraulic system manual.
2. Adjust pressure into 1.4Mpa(14bar). See hydraulic system manual.
3. The cavity-cleaning tube connector under safety bottom or cover part is loosened about 1-1/2
lap. When the oil is clean, no foam, and no splashing, close the connector. Repeat this action
until tightening all the connectors.
4. Press the cavity-cleaning button until the supporting sleeve reaches the Max. lift condition,
pressure reaches max. 21Mpa(210Bar). Inspect if there is leak between tube and tube net
connector. Tightening all the connectors.
Warning
hen the adjustment ring is lifted, all
the staffs should keep away from it in
order to avoid that the ring may fall
down and damage staffs and
equipment. Inspecting and correcting
leakage should control the cleaning
168
button. Loosening cleaning button,
the adjustment ring will come down
5. Loosening cavity-cleaning button and the supporting sleeve will install around the frame.

7.1.7.3 Crushing Cavity Releasing Inflating Circuit

There are some crushing cavity safety tanks and accumulators in the crushing cavity releasing
inflating circuit. They are connected by tubes and around the frame.
Exhausting the air in the hydraulic tank and energy accumulator as follow:
1. Open hydraulic station. See hydraulic system manual.
2. Adjust pressure into 1.4Mpa (14bar). See hydraulic system manual.
3. The connector on every safety tank top or piston tube is loosened about 1-1/2 lap. If the oil is
clean, no foam, and no splashing, close the connector.
4. Repeat this action for the rest hydraulic tanks and energy accumulators
5. The method of inflating system is based on the crushing cavity releasing inflating circuit
parts. Inspect oil leakage in all tubes and connectors. Tightening all the connectors.
6. The hydraulic station connected with the crusher should run via 2 complete crushing cavity’s
releasing cavity and crushing cavity releasing inflating recycling, in order to return the air
into oil tank in the system.

7.1.7.4 Braking Releasing Circuit

Braking releasing circuit is connected with discharging open adjustment circuit. The operation of
braking releasing circuit is as follow:
1. Connect the tube of braking releasing circuit with the exit of brake side, and brake is the main
component which is installed on the supporting sleeve on the hydraulic drive assembly.
Loosening the connector a little bit until the oil can come out. If the oil is clean, no foam, and
no splashing, close the connector.

7.1.8 Crushing Cavity Releasing Circuit Inflating.

Complete all the connection, and after all the system should exhaust the air for avoiding leakage,
inflate crushing cavity releasing circuit and prepare to do initial start. The pressure value of
crushing cavity releasing circuit must be in control. It will supply the safe and enough over-load
protection for iron passing and crushing cavity safety tank. Circuit pressure must be between the
Max. value and Min. Value.(See hydraulic system manual)

169
If the circuit pressure value is above the Max. Value, please fix it according to the releasing
section in the maintenance part. If installation or fix at the first time, or circuit pressure is very low,
please inflating circuit as follow.
1. Inspect the hydraulic oil in the tank is enough or not.
Note: Before the energy accumulator is not inflated by nitrogen gas, hydraulic oil can not be
pumped into crushing cavity releasing circuit. Or it will cause the damage of the energy
accumulator liner and the accumulator will have to be fixed or changed.
2. Inspect the pre-pressure in the energy accumulator, and if necessary, inflate it. See how to
inspect pre-pressure and energy accumulator in this part.
3. Inflate the crushing cavity release circuit according to the hydraulic system manual.

When the pressure is low, the crusher can not start because it supporting sleeve will hit and the
frame chassis may break. Adjust the pressure again according to the hydraulic system manual.

7.2 Maintenance

When maintain any parts in the hydraulic system, the relative circuit shoud reduce pressure. It is
very important for the operator. When crusher works, some circuits will reduce pressure, and
they will increase pressure when their function work. However, precaution should be
considered. Before operate the circuit, circuit pressure should be inspected by pressure meter
in order to make sure there is not rest pressure in the circuit. However, even though the oil
pump is closed for a while, due to the energy accumulator’ function, there is remanent
pressure in the crushing cavity releasing inflating circuit. Please read the hydraulic system
first before operate the hydraulic system.

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Chapter 8 Lubrication System

8.1 Summary
The integral lubrication system equipped with crusher is called thin Oil Lubrication Station for
short. Because it can supply lubrication oil which can be changed its temperature and pressure,
and be filtrated, and changed its quantity in advance to the lubrication cycle system, so it is widely
used in the crushers. The integral lubrication system is suitable for all kinds of climates and
atmospheric conditions, and this system owns automatic alarm system when the oil temperature is
too high or low. You can see the working condition of each part directly by observe the meter on
the lubrication system, including inlet and outlet temperature of cooler, oil returning temperature,
oil pump pressure, crusher oil supplying pressure and the pressure loss of filter. Crusher inside oil
flow See picture 8-1

Diagram 8-1 Inside Oil Flow

There are 2 kinds of cooler for lubrication system. The most popular kind is to use the recycled
water in the cooler to cool. In the hydropenic area or mobile crusher situation can use air to cool
lubrication oil. This cooling method is to use the large radiator like truck radiator, and make the
hot oil cool by recycling. The electric fan installed on the radiator makes the air around go through
radiator center and cooling fin in order to cool oil. Because air cooler's structure is based on

171
environment highest temperature and crusher model, so under some circumstances, its structure
should be designed by crusher model in order to meet the special needs on site. This kind of
cooling system can reach the same effect of water cooler. The air cooler is the general
configuration.

Lubrication oil will go through interface channel in the main shaft and go up to eccentric bush
under pressure, and then reaches bearing top of eccentric and moving cone bush, and then goes
through ball liner chassia and reaches ball liner and pinion's teeth surface. At the same time, in the
other oil flow, the oil will go through transmission shaft frame and reach transmission shaft sleeve,
finally the oil will be collected in the oil pool under the frame, and return the oil tank by oil return
pipe.

8.2 Lubrication Oil Character

Advanced chain alkyl industry oil (Not naphthene). This type oil owns some characters such as
high strength of oil slick, good adhesiveness with metal surface, and stable physical and chemical
properties etc.
The lubricant should includes stalled pressure additive, such as parkerising and other anti-adhesive
which is suitable for crusher metal(E.g. bronze, babbitt metal, cast iron and steel etc.) In addition,
this lubricant also owns the characters such as high viscosity index, quick separation speed with
water, not foaming, rust protection, antiseptic, antioxidant, including antifraying additive etc.
Compared with the industry oil, stalled pressure lubricant's freezing point is much lower.
Therefore, a little higher price is worthy.
Lubricant is ISO 150 class
：This lubricant’s adhesiveness is required as follow:
40℃ 135～165cst 135～165cst in 40℃
100℃ 13cst or higher in 100℃
In addition, this lubricant’ viscosity index should reach 90 or more.
Lubricant is recommended as follow:

1、Environment temperature>30℃ (Hot environment)

MOBIL Mobilgear 600XP 220
ESSO Spartan EP 220
BP Energol GR-XP 220
SHELL Omala Oil 220

2、Environment temperature +5～+35℃ (Summer)

MOBIL Mobilgear 600XP 150
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ESSO Spartan EP 150
SHELL Omala Oil 150

3、Environment temperature -25℃～+10℃ (Winter)

MOBIL Mobilgear 600XP 100
ESSO Spartan EP 100
BP Energol GR-XP 100
SHELL Omala Oil 100
4、Environment temperature -34℃～+25℃ (Cold environment)

Mobilgear SHC 150

Notes: The lubricant from different companies can not be combined for usage, and advise to use
ISO 150 lubricant all the year around.

The lubricant which must meet the needs above can be used to maintain the components of
equipment. The improper lubricant will damage crusher. At the same time, the relative guarantee
will lose efficacy.

8.3 Oil Temperature

The temperature of lubricant out of crusher is between 25℃ and 60℃ . However, the optimum
temperature of lubricant is between 38℃ and 54℃. The oil temperature is not allowed to be more
than 60℃ or lower than 25℃.
A little higher oil temperature can insure its flow ability and normal character. However, when the
environment temperature or operation condition lead the oil temperature more than 60 ℃ , the
cooling equipment must be used.
In cold weather, when the oil temperature is lower than 25 ℃ , electric heater controlled by
constant temperature is advised.
At any time, if suspect that the crusher overheat, temperature difference between inlet and outlet
lubricant can be checked by thermometer installed in the oil tube. The temperature difference
should be between 3℃ and 5℃. If the temperature difference is more than 5℃, the reason
may be the damage of ball liner caused improper operation. The temperature difference
checked by the inlet and
outlet thermometer in the lubrication station decides the oil tube length, the usage of cooler or
electrical heater according to lubrication location. The actual temperature difference will be
beyond this value, but it will be relatively constant in one equilibrium point. If the temperature
difference in the equilibrium point is changed suddenly, it may be caused by the worn ball liner in
the crusher.
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8.4 Oil Pressure and Flow

The capacity of oil pump, pipeline model, and bypass safety valve in the lubrication station have
been chosen and well adjusted, this station can supply enough lubricant and make sure the good
working condition of cooler. Therefore, please install and use lubrication station according to the
"Lubrication Station Operation Manual", and choose the suitable lubricant and operate crusher
accordingly.

See lubricating oil flow and working pressure of transmission shaft bracket of all kinds of the
crusher in Table 8-1 lists

Crusher lubricating oil flow and working pressure

Recomme Min. （ Mpa ）
Crusher ndatory Working Normal
model flow flow working
(L/Min) (L/Min) pressure
HPC160 95～114 60 0.14～0.35
HPC220 114～132 80 0.14～0.35
HPC315 204～222 150 0.14～0.35
HPC400 227～246 170 0.14～0.35
Lubrication Start up and stop

Start lubrication station first and then crusher, in this way, the lubrication oil will be sent to
the places where need it, and the crusher should be started when the oil returning volume us
stable. In the same way, the lubrication station is closed after crusher. The pump in the
lubrication station should run at least 2 minutes before the crusher's motor runs in order to
make lubricant cover all the bearing surface.

8.5 Venting Device

Install one venting device on the transmission shaft bracket or transmission shaft bracket belt
pulley side's oil collector, this venting device keep the air pressure in the crusher and insure
the lubricant to discharge successfully. Inspect crusher ventilation is normal or not. Put a
piece paper on the venting device 's elbow, and if the paper twitches a litte bit, it indicates ok;
if the paper blows off from the elbow, it indicates problem inside. If the venting device is
stuffiness, the hole connected with the venting device in the shaft bracket may be blocked by
impurity. The venting device and its pipe should be taken apart and the compressed air will
174
blow the hole clearly. Generally, it is not necessary to take apart the venting device to blow
the hole.

175
 Chapter 9 Tipical Problems Regarding Crusher

Typical Reference
Reason Solution
Problem Chapter Affix
1. The bolt of ball seat is 1. Check whether the 6
cut. The main shaft lost connection between the
connection with the main shaft and the ball
frame because of the seat. If necessary,
worn out. welding and machining
the ball seat in order to
reach the max
Ball seat connection. If the upper
becomes of the main shaft is
loose broken, please buy a
ball seat and adjust it to
the suitable connection.
Replace the bolt and
adjust it to the suitable
torque. Double check
the torque when the
components cool down.
1. “T” or “U” type seal is 1. Replace the sealing 6
broken or worn out. element.
2. Safety valve 2. Safety valve setting is Lubrication
malfunction. incorrect or safety System
3. Temperature of oil is valve spring is blocked
too low. at the compress
4. Unsuitable lubrication position. Replace the Lubrication
oil is applied. safety valve. 8 System
5. Exhaust is abnormal. 3. Install oil tank heater
6. Oil return pipe is and heat the lubrication 6 Lubrication
jammed oil to 27℃ (80℉). System
Oil Shed
7. Oil return is abnormal. 4. Use the suitable NA
lubrication oil. Lubrication
5. Connect the cleaner to NA System
the transmission shaft
exhaust shield.
6. Check the oil return
pipe. If necessary,
please clean the cavity.
7. Check the gradient of
the oil return pipe from
the crusher to oil tank.
176
 The minimum gradient
is 25mm (1”) lower and
305mm (12”) longer, or
the oil return pipe is
too small.
Replace the suitable oil
return pipe.
1. The feed open becomes 1. Replace the line board 6
smaller because of the or enlarge the feed
mantle feed open is opening.
worn out. 2. Check whether the 4
Capacity 2. Rotate speed (RPM) is transmission shaft
is Lower too low. rotate speed (RPM) is 3
3. Large size material correct.
(wood stick, rebar) is 3. Avoid this material
fed into which slow when feeding.
down the speed.

Typical Reference
Reason Solution
Problem Chapter Affix
4. Feeding size is too 4. Decrease the feeding 3
large. size. NA
5. Too much clay in the 5. Remove the clay in the
feeding material. material. 3
6. Distribution of the 6. Adjust the feeding
feeding is not good. hopper.
Feeding segregation 7. Cut the bulge part of the NA
causes fine material are adjust ring or the mantle
fed to one side of the bottom. 2
cavity. 8. Replace another
7. The mantle or the different adjust ring and
bottom of mantle crash mantle.
at the bottom of
parallel band.
8. The mantle or the
parallel band is worn
out.
1. V-belt is too loose. 1. Tensioning the V-belt. Drive
2. Malfunction on the 2. Check the power NA
Crusher
drive motor. without load, and
becomes
3. Damp raw material is compare with the power
Slower
fed into crusher. when the motor
4. Stones stocked under autorotation (without NA
177
 the crusher. driving belt). If the
5. Speed of transmission powers are similar, 3
shaft is too low. please check the motor.
6. Oil pressure is too low. 3. Install a water spray, 4
7. Drive motor or diesel clean the material
motor is not suitable. before feeding into 8 Lubrication
8. Feed open is incorrect crusher, in case that the 3 System
(too large). Most of the material bond in the
crushing is processed cavity. 2
under the cavity, which 4. Check whether the
increase the power output is smoothly.
consumption. Check the slush pump.
9. The mantle or the 5. Check whether the NA
bottom of mantle crash transmission shaft rotate
at the bottom of speed (RPM) is correct. 6
parallel band. 6. Check whether the 2
10. The mantle or the working pressure is
parallel band is worn normal.
out. 7. The power of motor or
engine is too low.
8. Check and choose
suitable liner board.
9. Cut the bulge part of the
adjust ring or the mantle
bottom. Replace the
main shaft and mantle.
10. Replace different main
shaft and mantle.
Contact with the
factory.

Typical Reference
Reason Solution
Problem Chapter Affix
1. “T” or “U” type seal 1. Replace the sealing 6
is broken or worn out. element.
2. The O ring in flange 2. Replace the sealing 6
inside the element or clean the
Oil Leakage transmission shaft flange in main frame
and main frame is and transmission shaft
worn out. and smear silicon resin
at the connection and
seal it.
178
 1. V-belt is too tight. 1. Tension the V-belt
2. There is no or not again, and check the
enough oil on the drive wheel. NA
transmission shaft 2. Check the pipe between
sleeve. the oil supply pipe and
3. The oil groove of the the transmission shaft.
transmission shaft Remove the valve, and
sleeve is incorrect. remove the jam. 6
4. No axial play. 3. Do not pull the
5. The transmission transmission shaft to the 6
shaft is curve. oil groove direction by
Transmission
General is the V-belt.
shaft is
transmission shaft 4. Adjust the axial play.
jammed or
vibrates, or drive HPT100 from
broken
wheel vibrates. 0.8mm(0.031”) to 6
6. The oil groove of the 1.2mm(0.047”), other
transmission shaft crusher from
sleeve is blocked by 0.8mm(0.031”) to 6
chippings. 1.5mm(0.062”)
7. The gear is broken. 5. Replace the 6
8. The gap of gear is not transmission shaft. 6
suitable. 6. Clean the oil groove.
7. Replace the gear.
8. Check and correct the
gap.
1. There is water on the 1. If there is no hole, drill
top of balance weight a hole and weld the
There is
cap. drain pipe.
Water in
2. The vent hood of oil 2. Replace vent hood.
Lubrication
tank is jammed. 3. Repair or replace heat
Oil
3. Water erosion or heat exchanger
exchanger is broken.

Typical Reference
Reason Solution
Problem Chapter Affix
1. There is dust or rust 1. Steps as below： 6
between the supporting Add anticoagulation in
Adjust
sleeve and the adjust the thread.
Ring
ring thread. Reasons as Remove the pressure of
cannot
below: the tramp release
Move
Over heater cylinder and the
material(slag) insurance cylinder for
179
 There is no enough passing iron. Operate the
lubrication on the crusher and make stones
thread. pass through.
Scraper seal or dust seal Let the wood block pass
is worn out through.
No rain proof equipment Throw soft steel in the
Some place of the outlet crusher and let it pass
works too long time. through.
There is scratch on the Heat the supporting
adjust ring or support sleeve.
sleeve. Heat the supporting
Thread is broken. sleeve and cool down the
adjust ring.
Do not remove the
supporting sleeve from
the main frame.
1. Pressing cap of the 1. The welding of mantle 6
mantle cannot self tight. pressing cap may be
2. The bottom of pressing broken. 6
cap is worn out, which 2. Grind and remove the
makes it touches mantle top or replace a new
or welding point. pressing cap.
3. Pressing cap touches the 3. The gap between the
top of head of main bottom of lock bolt and
shaft top of main shaft is not NA
4. Mantel or the main shaft enough, the smallest gap
is worn out or processed is 10mm(3/8”)
incorrectly. 4. Recover the matching 6
Mantle 5. Mantle is out of round. surface size to original
or 6. Center of mantle and the size.
Concave main shaft center do not 5. The max out of round is NA
is loose match. 3mm(1/8”)
7. At the first installation, 6. Check the bottom or 6
the mantle is not mantle, and gap should
fastened on the main not larger than NA
shaft tightly. 0.25mm(0.010”)
8. Mantle-crusher operates 7. Disassemble the liner NA
without load for too long board and install it
time. correctly.
9. The mantle is too thin. 8. The longest operation
without load is 30
minutes.
9. The wearing capacity
cannot larger than 2/3 of

180
 its thickness.

Reference
Typical Problem Reason Solution
Chapter Affix
10. Mantle-decrement of 10. Compress the disc 6
disc spring is not spring to the
enough, and the required height, and
preload of bolt is not replace it in time.
enough. 11. The wearing 3
11. The concave is too capacity of concave
thin. cannot larger than
12. Too much iron passes 2/3 of its thickness.
Mantle or through. 15. Too much iron
Concave is loose 13. Matching surface of passes through
mantle or concave is makes the mantle
processed incorrectly. loose.
14. Supporting sleeve 12. Recover the
vibrates, the matching surface
adjustment of outlet is size to original size.
too small and too 13. Enlarge the outlet
much load. and keep the load in
a reasonable range.
1. Exhausting is not 1. Clean the vent hood 6
good. of the transmission NA
2. The oil extraction is shaft.
too slow in the 2. Clean the hole at
transmission shaft or the bottom of 6
the oil cavity, transmission shaft.
Transmission
especially the 3. Replace the piston
shaft drive
lubrication oil is too ring.
wheel one side
slow. 4. Keep the crusher
leak oil
3. The piston ring horizontal.
between the oil
slinger and the cap is
worn out.
4. The crusher is not
horizontal.
1. Additional weight or 1. Consult the 6
additional weight supplier, repair the
plate and cap are additional weight.
Over Vibrating
worn out. Replace the 6
2. Dedendum of pinion additional weight
and gear is plate and cap or
181
 contradicting. replace additional 6
3. Transmission shaft is weight. 6
bent. 2. The module of hear
4. Belt pulley of crusher is not suitable, the 1
lost balance. dedendum press on
5. The skid or the base the pinion directly.
is not suitable. Add gasket to 3
6. Foundation and increase the
foundation capability eccentric sleeve. 6
is not suitable. 3. Replace the
7. Mantle is loose or transmission shaft 6
over worn out. 4. Clean the dust of
8. Rotation of belt pulley. 6
transmission shaft 5. Check the gasket or
(RPM) is too high. the foundation.
6. Check the base or
the foundation.
7. Disassemble the
mantle, assemble it
again or replace it.
8. Check whether the
rotation of
transmission shaft
(RPM) is correct.

Reference
Typical Problem Reason Solution
Chapter Affix
1. The crusher 1. When assembling, 6
operates when ensure that the crusher
the mantle is components are
loose. assembled correctly, NA
Matching
2. The crusher and the caps are
surface between
operates when tightening before
main shaft adjust
the main shaft operating. NA
ring and liner
and mantle is 2. The weak surface of
board is worn
over worn out. crusher components
out
3. The main shaft are bent, which makes NA
or mantle is the main shaft or
totally worn match surface between 6
out, the crusher adjust ring and liner

182
 operates by board wear out.
main shaft or 3. The weak surface of
adjust ring. crusher components
4. The mantle or are bent, which makes
adjust ring liner the main shaft or
board is broken. match surface between
5. Feeding interval adjust ring and liner
when the new board wear out.
liner board is 4. The crusher
replaced. components are bent,
which makes the main
shaft or match surface
between adjust ring
and liner board wear
out.
5. Avoid interval feed
when new liner board
is replaced.
1. There is no vent 1. Install a vent hood at 6 Lubrication
hood on the the transmission shaft. System
crusher. 2. Clean these two vent Lubrication
2. The vent hood hoods. The card on the System
on the vent pipe should move 6
transmission inside a little when
shaft or oil tank operating. NA Lubrication
is malfunction. 3. Install the vent hood to System
3. The belt pulley other position with a
brings dust into soft pipe, to keep it NA
vent hood. away from the belt
4. Dust enters the pulley.
Dust enters
crusher when do 4. When doing
Lubrication
the maintenance, cover the
System
maintenance. ball bearing and
5. Vertical throw eccentric shaft with a Lubrication
of the oil return canvas or plastic. System
pipe between 5. Add another vent
the crusher and hood.
oil tanks is too 6. Replace seal or gasket.
large. 7. Check soft pipe and
6. There is no seal connection.
or gasket 8. Check soft pipe and
between the oil connection.
tank and the
cover.

183
 7. The soft pipe
from the fan to
transmission
shaft is broken.
8. Soft pipe or
vent hood
connection is
broken.

Reference
Typical Problem Reason Solution
Chapter Affix
1. Lubrication oil is 1. Change lubrication Lubrication
dirty. oil and clean oil 6 System
2. Worn out place of tank.
dedendum is too 2. Thrust bearing is 6
low. worn out. Add
3. Worn out place of gasket to increase 2,2
dedendum is too the height of
high. eccentric shaft. 6
4. Crusher is 3. Decrease the
overloaded. height of eccentric
Dedendum of
5. Axial play is too shaft by taking off
pinion and gear is
large. gasket.
worn out
4. Decrease the
feeding capacity.
5. Readjust the axial
play. HPT100
from
0.8mm(0.031”) to
1.2mm(0.047”),
other models from
0.8mm(0.031”) to
1.5mm(0.062”)
1. Gap between 1. Check the gap 6
dedendum is not 2. No.
suitable. 6
2. Crusher operates
Too much noise of
when use new
gear and pinion
gear and worn out
pinion, or use
worn out gear and
new pinion.
184
 1. Supporting sleeve 1. Feeding is not 3 Hydraulic
vibrates which suitable in the System
causes the cavity. 6
matching surface Adjust the support
between main sleeve 180°. 2
frame and the Check whether the
supporting sleeve pressure in the
worn out(in this passing iron safety
condition, the cylinder is too 4
guarantee of low. Pressurize the
crusher lost cylinder.
efficacy) 2. Feed in too many
Supporting Sleeve
2. Overload fine material.
is Slant
continuously or Refer to “choose
unsuitable liner suitable liner
board causes the board” chapter and
supporting sleeve the chart.
hits the matching Increase the
surface of main feeding capacity
frame. Enlarge the outlet.
The feeding
material may be
too sticky. Add
water when
feeding.
1. Supporting sleeve 1. If the thread is not NA Hydraulic
and adjust ring worn out badly, System
thread are worn process the
out. 45°bevel of the 6
2. The pressure in thread and keep
lock cylinder is the thread distance 4
too low during balance.
operation. 2. Add the pressure NA
3. The outlet is too in lock cylinder to
Mantle small. suitable pressure. 4
4. The main shaft or 3. Increase the outlet
mantle is too until the adjust
thick. ring stops
5. The outlet is too vibrating.
large. 4. The mate between
adjust ring and
supporting sleeve
is too little, which
needs a thin liner

185
 board.
5. The mate between
adjust ring and
supporting sleeve
is too little.
Decrease the
outlet.

Typical Reference
Reason Solution
Problem Chapter Affix
6. Check whether the 6. When the hydraulic Hydraulic
soft pipe connection station operates, the System
Adjusting between hydraulic soft pipe between
ring loose station and the lock hydraulic station and
cylinder is normal. the lock cylinder is
stiff.
1. There may be leakage 1. If the indicator is on Hydraulic
Low lock in the hydraulic more than 1 time in 10 System
pressure station or the lock minutes, check whether
indicator loop. there is leakage in the
is on hydraulic station or the
lock loop.
1. There may be leakage 1. If the indicator is on Hydraulic
Low
in the hydraulic more than 1 time in 3 System
release
station or the release hours, check whether
pressure
loop. there is leakage in the
indicator
hydraulic station or the
is on
release loop.
1. Feed too much into 1. Reduce the feeding 2
cavity. capacity. 2
2. Feeding material is in 2. Reduce the feeding
flake. capacity or increase the 6
3. Matching surface feed opening by replace
between main shaft liner board. NA
head and lock nut is 3. Weld and process the NA
Main shaft
worn out. cap matching surface
head bolt
4. Main shaft bolt is too again. Replace the
is broken
loose. main shaft head.
5. The big size material 4. Tighten the bolt until
has a large fall to match closely.
main shaft head. 5. This problem often
happens in the standard
crusher. Reduce the
feeding hopper or the
186
 height from belt
conveyor to the main
shaft head.
1. Overload or the liner 1. Too much fine material 2
board is not suitable. in feeding. Refer to
2. Operate when the iron “choose suitable liner
passing cylinder board” and chart. 4
pressure is too low. Increase the feeding
capacity.
Enlarge the outlet.
The feeding material
may be too sticky. Add
water when feeding.
2. Iron passing cylinder Hydraulic
Supporting sealing is malfunction. System
sleeve The hydraulic station Hydraulic
vibrating cannot add pressure to System
iron pressure cylinder Hydraulic
automatically (pressure System
switch is broken). Hydraulic
Inside release loop System
valve in the hydraulic Hydraulic
station is leak. System
Iron passing cylinder
safety valve is leak or
open.
Soft pipe or parts is
leak or broken.

187