Lubrication and hydraulic

of
HP new generation cone crushers

This presentation covers the

ranges :
- HP100 to HP500 (range HPX00)
- HP3 to HP6 (range HPX)
with 24V DC voltage
 The proper lubrication conditions guarantee the crusher a perfect reliability
for many years. The trainee will learn what are the optimal conditions for oil
temperature, pressure, cleanliness and et specification necessary for a troublefree
long term operation.
The hydraulic functions for setting adjustment, clamping, clearing and
protection involve many components and a bit complex circuits. The trainee will
understand how work the components and the whole circuits.

• Know the various components involved in the lubrication

circuit, and understand its global working and behavior.
PURPOSES • Know the required conditions for a good lubrication :
of the temperature, pressure, cleanliness and et oil specification.
• Acquire the good control practices to regularly achieve.
COURSE • Know the various components involved by the hydraulic
functions and understand the working principles of tramp
release, clamping, clearing and setting adjustment circuits.
• Be able to detect a dysfunction in a circuit, and to fix it.
p. 2 © Metso
 Lubrication Hydraulic
Click on a button to
- Description of components (p.61)
access the topic
- Study of the circuits (p.109)

- Use of the unit (p.137)

- Maintenance (p.151)

p. 3 © Metso
 Units

• The units used in this presentation are METRIC :

- Dimension : meter
- Volume : liter
- Temperature : ° Celcuis
- Pressure : bar
- Power : Watt (or kW)
- ….

p. 4 © Metso
 Lubrication
of HP new generation cone crushers

Back to front page

p. 5 © Metso
 Generalities
Conditions for a good lubrication
Oil temperature
Oil pressure
Oil specification
Oil cleanliness
Description of tank and accessories
Installation

p. 6 © Metso
 The lubrication functions is are provided by the LUBRICATION UNIT, which
gathers on the same package the functions for :

hydraulic

Lubrication

This presentation only covers the

LUBRICATION topics.

HP400 package,
p. 7 © Metso Without the covers
Functions provided by the lubrication :

Bronze bushings lubrication

Pinion & gear lubrication

Crusher cooling

70 of the oil flow is used to cool down the crusher and

its oil, and 30 % for actual lubrication.

p. 8 © Metso
 Circulation in the crusher

Circulation

Click for the animation

p. 9 © Metso
 Crusher
Lubrication circuit
Manometer

Pressure
switch Relief valve

Radiator
Cooler relief Fan
valve Return
Clogging temperature
indicator sensor or swtich

Check
Pump + motor valve
Tank
temperature
sensor or
switch
Filter
Immersion heaters

p. 10 © Metso
 Lubrication plate Breather

Motor

Filter

Level switch

p. 11 © Metso Pump
 Conditions for a good lubrication

Oil temperature
Oil pressure
Oil specification
Oil cleanliness

p. 12 © Metso
 Conditions for a good lubrication

3 switches, or…
Oil temperature
2 temperature sensors
Oil pressure Immersion heaters
Oil specification Fan cooler
Oil cleanliness Water cooler
‘Winter’ mode
Heating coil Option

p. 13 © Metso
 The temperatures are measured by :

3 switches :
Case of HPX00 if no automation.
The switch is set at a certain value, an electric contact
closes or opens when temperature is reached.
or

2 sensors :
Case of HPX00 with automation, and all HPX
The sensor measures the actual temperature and gives the
value to an automation which processes the information.

p. 14 © Metso
 Case of the 3 switches
• One located on the tank, which controls the immersion heaters :
- Stop them when temperature (T°) reaches 25 °C
- Start them if T° is below 20 °C
- The switch is set at 25 °C, the 20 °C level is determined by the 5°C
hysteresis.

• One on the return block, which controls the fan cooler :

- Starts it if return oil is over 45 °C
- Stops it when return oils drops back to 35°C.

• An other one also on the return block which controls the crusher emergency
stop
- Stops the crusher if return oil reaches 65 °C.
p. 15 © Metso
 Location of the 3 temperature
switches

p. 16 © Metso
 Case of the temperature sensors

• One located on the tank, which controls the immersion heaters :

- Stop them when temperature (T°) reaches 25 °C
- Start them if T° is below 20 °C

• One located on the return block, which :

- Authorizes the crusher start if T° > 16 °C
- Authorizes the crusher feeder if T° > 25 °C (and if crusher has turned for 2
min)
- Starts the cooler if return T° > 45 °C
- Stops the cooler if return T° < 35 °C
- Stops the crusher feeder if T° > 55 °C ( restarts the feeder at 50 °C )
- Stops the crusher (HPX00) if return T° > 65 °C
(stops an HPX if return T°> 60° C )

p. 17 © Metso
 Case of the temperature sensors
• 2 sensors PT100 type
- 4-20 mA built-in converter, voltage 24V DC
- Outpout at 0°C : 4 mA
- Output at 100°C : 20 mA

Return line sensor

Tank sensor

p. 18 © Metso
 Immersion heaters

Ambiant T°

Thank to their ‘power’ of 2 Watt per sqcm,

they bring the tank oil at 25 °C :
Required time
• in about 20 minutes if ambiant T° is 10 to reach 25 °C
°C
• in about 45 minutes if ambiant T° is 0
°C
• with very low T°, it is advised to
implement a clock to anticipate the oil
p. 19 © Metso
heating.
 Immersion heaters

• Depending on the country of destination, 3 types of heaters can be provided :

- Type 1 : 220/380 V – 230 / 400V – 240/415 V – 255/440 V- 265/460 V – 280/480 V
- Type 2 : 115/200 V – 130/220 V
- Type 3 : 300/525 V – 320/550V – 330/575 V

One phase 3 phases ‘Delta’ 3 phases ‘star’

Immersion heaters HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5

Quantity 2 3 ? 2 3

Total heating power (kW) 8,5 12,8 ? 8,5 12,8

p. 20 © Metso
(power pour 230/400V voltage)
 Heaters start / stop conditions

• MUST START :
- If tank oil T° < 20 °C

• MUST STOP :
- if tank oil T° > 25 °C
- if return oil > 45 °C
- in case of oil level fault
- in case of sensor fault
- if fan cooler is working

p. 21 © Metso
Unit Converter
 p. 22

Fan cooler
• Sized for a 40° C ambiant T°.
- Above, use the water cooling option.
• Starts when return T° reaches 45°C and stops at 35°C
• Installed on the lubrication unit (HP100 to HP300) or beside (HP400, HP500, HP4
and HP5)

© Metso
Unit Converter
p. 23

Fan cooler

1: radiator
2: frame
3: pedestal
4: fan
5: protection grid
6: motor

© Metso
 Fan cooler
• Motor power

Fan cooler HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5

Motor power (kW) 1,1 4 2,2 ? 5,5

• The motor must be

wired so that the fan
turns in the correct
direction : air must be
sucked through the
radiator

p. 24 © Metso
Unit Converter
 Fan cooler
• Equiped with a relief valve which protects the radiator small
tubes in case of cold / thick oil, which generates higher
pressure.
• The valve starts to open at 3 bar, and fully opened at 6 bar.
- Warm oil fluide low pressure the valve stays
closed oil goes through the radiator.
- Cold oil thick high pressure the valve opens
oil is directed toward the radiator exit without passing
through.

p. 25 © Metso
 p. 26

Water cooling
• When ambiant temperature is too high (above 45°C), air cooling is no longer
efficient water cooling .
- Water T° for maximum efficiency : 25°C
- Required water flow :
Water cooler HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5

Water flow requirement (L/min) 89 79 ? ? ?

(indicative flow for a 25° C water)

1 1 Oil outlet
2 2 Oil inlet
4 3 Water inlet
4 Water outlet
5 3 5 Water bleeding
6 6 Oil bleeding

© Metso
 Winter mode
• Function : allows the piping to stay warm during the coldest
periods, keeping the tank T° between 20 and 25°C O O
O
C F
• This mode is only available with an automation controlling the 50 120

crusher. 40
30
100
80

• Method : keep the lub pump turning 10 min every 30 min. 20

10
60
40

• Only works when : 0

10
20
0

- Crusher stopped 20
30
20
40
40
- Tank T° > 20°C 50 60

- No oil level fault.

- No countershaft pressure fault
- No tank sensor fault
- Heaters properly interlocked with the tank sensor

p. 27 © Metso
Unit Converter
 Heating coil option
• Copper coil immersed in the tank.
• Warm water circulation in the coil.

1: coil
2: connecting nuts
3: support
4: support
5: fixation
6: inlet / outlet

p. 28 © Metso
 Conditions for a good lubrication

Pump
Oil temperature
Crusher pressure
Oil pressure Relief valve
Oil specification Pressure switch
Oil cleanliness Air blower
Air breather

p. 29 © Metso
 p. 30

Lubrication pump assembly

Motor
• The assembly is composed of :
- A motor
- An elastic coupling Elastic
- A spacer coupling
- A pump
Spacer
• Data on the pump assembly :

Pump

Lubrication pump HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5

Pump capacity (L/min) 76 107 128 194 218 ? 128 222

Motor power (kW) 4 5,5 7,5 7,5 7,5 ? 7,5 7,5

© Metso
Unit Converter
(Power for a 230/400V voltage and capacities for a 50 Hz,1450 RPM motor)
 p. 31

Lubrication pump assembly

• Pump starting conditions :
- Receive the starting authorization
- No ‘winter mode‘ activation
- Discharge conveyor is on operation
- Tank T° > 20°C
- Oil level OK
- Countershaft pressure OK
- T° Sensors are OK
(for the whole description, see at the end of the instruction
manuals the ‘TD3-B107’ and ‘TD3-B108’ for HPX00 and TD5-
B111 for HPX)
Pump
• Remind : a pump generates a flow, not a pressure !
The pressure is generated by the resistance to flow.
• The pump is gear type.
© Metso
Unit Converter
 p. 32

Relief valve To the countershaft

To the pressure
• Installed on the crusher near the switch and
countershaft box, it limits the oil manometer

pressure entering the crusher at

a pre-set value of 2.4 bar (for a
40 °C oil) .
• Ifthe pressure exceeds the pre-
set one, part of the flow goes
back to the tank.
• In cas of wrong setting, a bit too
high pressure is not harmful, but
could generate leakages in the
crusher. But a much too high To the main shaft Drain line
pressure can lead the pump
motor to stall.
Feed line

© Metso
Unit Converter
 p. 33

Pressure switch
•A too low pressure leads to unefficient lubrication, so a real danger for the
crusher.
• A pressure switch monitors the pressure, and trips whenP < 0.8 bar (0.8 bar
measured at the countershaft is the minimum pressure which guarantees a
correct lubrication of all the bushings).

• The pressure switch must be wired so

that it stops at once the crusher and
feeder : emergency case !

• The pressure switch is pre-set, there is

normally no need to adjust it.

© Metso
Unit Converter
 p. 34

Pressure switch Pressure switch

front view
• However, if needed to adjust :
- Open the small cover
- Turn the red screw (1) to bring the cursor at 1.1 bar on
the red scale.
- Turn the green screw (2) to adjust the differential at 0.3
bar on the green scale.
- This determines the 0,8 bar setting. If below, the crusher 1,1 bar
must stop.

0,3 bar
• The pressure switch has 2 electric contacts :
- The ‘Normally Opened’ contact is used (terminals 13 and 14)
- The contact stays closed if P > 1.1 bar.
- The contact opens if P < 0.8 bar.

Pressure switch, top view

© Metso
Unit Converter
 p. 35

Air blower
Blower
• In some cases, dust may Take out the air
penetrate the crusher through breather, to
the ‘U & T’ seals. insert the hose
• A blower is then used to blower
Air filter
generate a positive pressure
inside the crusher to keep the
dust particles out, which would
contaminate the oil.
• Air is sucked through a filter and turbine
blown in the countershaft box by
the air breather piping which has
been beforehand taken out.

inlet
outlet

© Metso
 p. 36

Air blower
• The blower is standard delivery for HPX
• It is a recommanded option for HP500 operating in secondary (low
rotation speed of the counterweight, so less efficiency of ‘U&T’ seals)
• It must be connected so that it starts/stops with the lubrication pump.
- blower motor :
• rotation speed at 50 Hz = 2640 RPM
• power :
– HP4 = 0.25 kW. - the air extraction
HP5, HP500 = 0,55 kW must be distant from
the crusher if its
environment is dusty.
- Must be vertical

© Metso
Unit Converter
 p. 37

Air blower : siphon

• The blower is always associated to a siphon
implemented on the collecting block.
• Function : in case the air over-pressure cannot freely get
out through the U&T seals, avoids the air to be blown in
the tank which would generate turbulences and
sprinkling through the air breather filter.

The air turbulences are

stopped in the first siphon
chamber.

© Metso
 p. 38

Air breathers
• Due to the large oil flow circulating in the crusher and lubrication unit, and to
allow a free draining to the tank, it is important that the circuit stays at the
atmospheric pressure.

• Two air inlets are provided :

- One one the lubrication plate to ventilate the sealed tank.
- One at the countershaft for a free return to the tank

• An air filter ( 10 microns ) equips each air inlet to

retain the dust particles which could be sucked and
contaminate the oil.

© Metso
 Conditions for a good lubrication

Oil temperature
Oil pressure
Oil specification
Oil cleanliness

p. 39 © Metso
 Oil specification
• Use an EP (Extreme Pressure) Lubricant which provides:
- High oil film strength
- High adhesiveness to metal surfaces
- Stable chemical and physical properties

• Moreover, the oil must have :

- High viscosity index
- Good water separation properties
- Low lather production,
- Good corrosion protection properties,
- Resistance against oxidation
- Anti-wear agents.

p. 40 © Metso
 Oil specification
• The lubricant must have a viscosity of:
- – 135 to165 cSt at 40°C
- – 13 cSt or more at 99°C
• Moreover it must have a viscosity index of :
- 90 or more.
• Several systems of classification are used to describe the viscosity
characteristics. Our specifications for the lubricant are:
- – ISO Grade 150
- – AGMA Grade 4 EP

• Note : The SAE system of classification covers the motor oils, not the gear
lubrication oils used in the crushers.

p. 41 © Metso
Unit Converter
 Oil specification

• Choose an oil among the below recommendations :

- BP Energol GRXP 150
- CASTROL Alpha SP 150
- ESSO Spartam EP150
- MOBIL Mobilgear 600 XP150
- SHELL Omala 150
- TEXACO Meropa 150
- TOTAL Carter EP 150

• Or any other compying with the norm ISO CC 150

p. 42 © Metso
 Conditions for a good lubrication

Oil temperature
Oil pressure Filter
Oil specification Return line strainer
Oil cleanliness Contamination

p. 43 © Metso
 Filter
• Installed between pump and cooler, it retains the small size
contaminants (filtration fineness= 60 microns).
• A clean filter increases the life span of bronze bushings and
oil.
• The cartridge can be cleaned few times by ultra-sound but
then must be changed.

Magnet

60 µm cartrigde

By-Pass

p. 44 © Metso HP400 cartridge

 Filter : clogging indicator
• When the cartridge becomes dirty, the pressure in the body
increases.
• When the pressure difference between inlet and oulet reaches 1,2
bar, the cartridge must be cleaned or replaced, which is shwon by
the clogging indicator
• The indication is both visual and electrical :
- Visual : a bicolor ring, green and red, moves upward in front of a
window, when the red stripe is visible, change the cartridge .
- Electrical : a double contact open/close switches. The information is
used at the user’s choice in its control cabinet.

p. 45 © Metso
 Filter : clogging indicator
• If the cartridge is not changed even though the clogging indicator has tripped,
the pressure in the filter body continues to increase.
• The safety is provided by a b-pass located in the bottom of the body : when
the pressure difference between inlet and outlet reaches 1.5 bar, the cartridge
moves downward, squeezing a spring, and oil no longer passes through the
cartridge.

6 Cartridge
7 By-pass spring
9 Nut
10 Pin

• By cold temperature, it is possible that the clogging indicator trips while the
cartridge is still clean : only check the clogging when oils has started to warm
up (30°C).
Unit Converter

p. 46 © Metso
Filter : strainer on the return line
• The tank is equiped with a strainer which filters the oil return line and collects
the coarse particles on a 0.63 mm mesh. The pivoting hatch allows an
easy access to check the
cleanliness
• From all the elements the bronze is
made up of, lead is the one melting at
the lowest temperature, and can
sometimes weeps from the bushing
surface. Strainer

A magnet retains the

ferrous particles

p. 47 © Metso
Unit Converter
 Oil contamination

• In the latest generation cone crushers, like HPs are, the oil film providing the
lubrication between the pieces in movement is mistreated by the huge forces
and tight clearances.
• If metallic particles are too numerous in the lubricant, the risks for the crushers
become serious :
- Tearing of the oil film
- Deterioration of parts

Clean oil Oil slightly contaminated Oil very

p. 48 contaminated
© Metso
 Oil contamination
• A regular oil analysis should be included in the crusher preventive
maintenance program.
• Metso Minerals recommends this analysis to be done every 6 weeks or 250
hours of operation.
• The percentage of each contaminate level found is reported on an analysis
log.
• The trend observed after several analysis is more imortant than the value by
itself. For instance a slow but steady increase of the copper %, even though
the value is high, is not as worrying as a sudden raising.
• Reminder : though the oil composition is still right in term of contamination, it
must be changed every 2000 hours as it may have lost its mechanical
properties.

p. 49 © Metso
 Oil contamination
• The quantities of contaminants are expressed in PPM (Part Per Million, or 1 mg
per kg), water and solid residues in %.

• The next page table gives the average and maximum values for each contaminate
level: the figures are given for indication and if some elements in the oil exceed
the maximum, the crusher is not necessarily in danger. See below some possible
corrective actions :

- Some contaminate elements are more serious than others, like copper, lead,
tin, iron and silica.
- Presence of aluminium, chromium, silver, nickel or sodium is often not critical.
These elements are also sometimes present in the crushed rock.
- Silica comes from the crushed material; possible cause : defective U&T seal,
clogged air breather, dirty filter, tank hatch not sealed. Too much silica leads to
p. 50 a rapid wear of the moving pieces.
© Metso
 p. 51

Oil contamination
- Copper, lead and tin are some of the bronze components. Reason of
their presence in oil : heavy wear of bushings
- Iron comes from the steel parts on contact with the bronze (shaft, socket,
eccentric…)
- Water can come from defective U&T seals, not sealed tank hatch, or
condensation in the tank if this one is exposed to the sun.
Avg. High
Contaminants
PPM PPM
Copper 100 210
Aluminum 5 10
Iron 20 50
Silica 25 65
Chromium .5 1.5
Lead 70 190
Silver 0 5
Nickel 5 15
Tin 15 30
Sodium 30 60
Water .1% 1%
© Metso
Total Solids .1% .2%
 The tank and its accessories
• The tank is separated in 2 parts,
lubrication and hydraulic, as their oils are Hydraulic
not compatible. Lubrication
• Necessary volume of lubrication oil:
- HP100/200/300 = 275 liters (maxi 300 l)
- HP4 = 275 liters ‘’
- HP400 & HP500 = 480 liters (maxi 500 l)
- HP5 = 480 liters ‘’
Level gauges
• After the first sart-up, refill the tank. The
actual volume depends on the lenght of
connection between lubrication unit and
crusher.

p. 52 © Metso

Drain valves
 The tank and its accessories
The sliding float is equiped with a magnet.
When in bottom position, it :
• opens a contact which stops the pump
• closes a contact which illuminates the lamp ‘Oil
level’

interlocking
Pump

Sliding
float
Level switch

p. 53 © Metso
 The tank and its accessories
• A check valve is installed between the filter and the cooler.
• Purpose of this device is to prevent feed line oil from draining back to the tank
when the operator opens the filter to change the cartridge

To the cooler

Filter
Check valve
p. 54 © Metso
 Piping
Feed line
• The lubrication unit is delivered with all the
necessary connection hoses

• Standard lenght = 4m ( option for 6,8 and10 m )

• Feed line & relief valve return line :

- HP100 = 1 inch
- HP200,300 and HP4 = 1 ½ inch
- HP400,500 and HP5 = 2 inch

• Main return line :

- HP100 and 200 = 3 inch
- HP300 to 500 = 4 inch Main return line
- HP4 and 5 = 4 inch relief valve
p. 55 © Metso
return line Unit Converter
 Piping
HP100 to HP300

Connections made with JIC 3/4- 16 female

swivel hose-unions :

Feed

Main return line

Relief valve retrun line

p. 56 © Metso
 Piping
HP400 and HP500
Made with SAE connections :
.

Relief valve return line

Main return line

p. 57 © Metso
 Piping
Raising pump option

When the lubrication unit

cannot be installed below the
crusher (mobile crushers on
wheels or tracks).
Comprises an additional tank
and a raising pump.

From relief valve to tank Feed line

Main return line

From additional to main tank

p. 58 © Metso
 Piping : Installation
• The Pipeline should be as short and as direct as possible.
• Avoid dead pockets or other flow obstruction
• Drain line must have a minimum slope of 10 °
• Avoid vertical drop section in drain line ( risk of dust succion through the
U & T seals )
• Check the piping for internal cleanliness ( chips, cuttings, etc .. ) before
connection, to safeguard the oil pump.

Oil succion line between tank and pump must be

absolutely air-proof : a leakage will lower the pump
efficiency and endanger the crusher lubrication.

p. 59 © Metso
 Page left blank
p. 60 © Metso
 Hydraulic components
of Metso Minerals
‘HP’ cone crushers

This presentation covers the

ranges :
- HP100 to HP500 (range HPX00)
- HP4 and HP5 (range HPX)
with 24V DC voltage

p. 61 Back
© Metso to front page
• Control components
- Control box and relays
- Pressure sensors
- Relief valves
- Directional valves
- Accessories :
• Level switch, check valves, filter

• Power components
- Pumps
- Cylinders
- Accumulators
- Hydraulic motor
p. 62 © Metso
 Control components

p. 63 © Metso
 Control box and relays for HPX00

1: ON / OFF button 8
1
2: « light test » button
2
3: « Oil level fault » light
9
4: « Compensation mode » light
5: « Compensation mode » button 3
10
6: « Manual mode » button
7: « Clearing » button 4
11
8: « Power On » light 5
9: « Oil Presure fault » light
6 12
10: « Pressurizing » button
11: « Close setting » button
7
12: « Open setting » button
p. 64 © Metso
 Control box and relays for HPX00
• Due to the new features (manual or compensation mode switched by
simple push buttons, pressure sensors, etc…) a total of 9 relays are
now needed.
• 4 relays inside the control box
• …

p. 65 © Metso Inside the control box

 Control box and relays for HPX00
• … and 5 in the terminal box

p. 66 © Metso
 Control box and relays for HPX00
• Functions of the 9 relays

Relay Localiaation Function

KA1 Control Box swap from a mode to another (compensation <--> manual)
KA2 Control Box swap from a mode to another (compensation <--> manual)
KA3 Terminal Box controls the feeder according to clamping pressure (PS1B)
KA4 Control Box controls the pump according to clamping pressure (PS1A)
KA5 Terminal Box controls the feeder according to release pressure (PS2B)
KA6 Control Box controls the pump waccording to release pressure (PS2A)
KA7 Terminal Box When oil level is low : send warning to PLC, and desactivate KA9
KA8 Terminal Box When filter is clogged, send warning to PLC
KA9 Terminal Box When oil level is low, prevents the pump from starting

p. 67 © Metso
 Control box and relays for HPX
1: ON / OFF button
2: « light test » button 8
3: « Oil level fault » light 1

4: « Compensation mode » light

2 9
5: « Compensation mode »
button
3
6: « Manual mode » button 10

7: « Clearing » button 4
11
8: « Power On » light 5
9: «Tooth counter » display
6 12
10: « Oil Presure fault » light
11: « Pressurizing » button 7
13
12: « Maintenance » light
13: « Close setting » button 1 15
4
14: « Open setting » button
p. 68 © Metso
15: « Maintenance » button
 Control box and relays for HPX
• 4 relays and a timer inside the control box
• 6 relays in the terminal box.

Inside the control box

p. 69 © Metso
The back side of the door
p. 70

Control box and relays for HPX

• Function of the 10 relays

Relay Localiaation Function

KA1 Control Box swap from a mode to another (compensation <--> manual)
KA2 Control Box swap from a mode to another (compensation <--> manual)
KA3 Terminal Box controls the feeder according to clamping pressure (PS1B)
KA4 Control Box controls the pump according to clamping pressure (PS1A)
KA5 Terminal Box controls the feeder according to release pressure (PS2B)
KA6 Control Box controls the pump waccording to release pressure (PS2A)
KA7 Terminal Box When oil level is low : send warning to PLC, and desactivate KA9
KA8 Terminal Box When filter is clogged, send warning to PLC
KA9 Terminal Box When oil level is low, prevents the pump from starting
KA10 Terminal Box activated when closing the crusher, to give PLC the direction of rotation

© Metso
p. 71

Control box and relays for HPX

• Timer
- As soon as the push button ‘open’ or ‘close’ is pressed, the clamping pressure
starts to drop down, and a timer set at 2 second is started.
- It is only after this time that the pump will start and actually opens / closes the
crusher.
- So we are sure that the clamping pressure is actually 0, and the clamping ring is
protected against pinching.

The timer inside the

remote control box

© Metso
 Pressure sensors

• 2 electronic pressure sensors

- Direct reading of the pressure on the display
- 1 in the tramp release circuit and 1 in the clamping circuit
- Each sensor controls 4 levels of pressure, adjustable independantly :
• To stop the pump
• To restart the pump
• To stop the feeder
• To restart the feeder
- Once a level is reached a light is switched, indicating the state
(ON / OFF) of the output.

p. 72 © Metso
 Pressure sensors

1 Green LED, indicating the set unit (bar, Mpa or PSI)

2 Yellow LED, switching status. ON if output has switched

3 Digital display, showing the pressure, or the parameter value

4 Set button : scrolling by holding pressed, or incremental by pressing

briefly
p. 73 © Metso
5 Mode/Enter button : selection of the parameter
 p. 74

Pressure sensor in the tramp release circuit

• 1 sensor is equivalent to 2 pressure switches (PS2-A and PS2-B) which control
each a low level and a high level (The difference between the 2 levels is called
hysteresis).
• PS2-A controls the pump to repressurize
• PS2-B controls the feeder

PS2-A

PS2-B

ON
Feeder OF OF
F F
ON ON
© Metso Pump OF
F
 Pressure sensor in the tramp release circuit

• Pressure values of the pump and feeder Start / Stop

Tramp release circuit HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5
Pump stop Sp1 115 b 160 b ? 154 b 130 b
PS2-A
Pump start Rp1 105 b 150 b ? 140 b 120 b
Feeder start Sp2 100 b 145 b ? 130 b 110 b
PS2-B
Feeder stop Rp2 95 b 140 b ? 125 b 100 b

Sp1
Rp1

Sp2
Rp2

p. 75 © Metso Unit Converter

 p. 76

Pressure sensor in the clamping circuit

• 1 sensor is equivalent to 2 pressure switches
(PS1-A and PS1-B) which control each a low level
and a high level
• PS1-A controls the pump to repressurize
• PS1-B controls the feeder

PS1-A

PS1-B

ON
Feeder OF OF
F F

ON ON
Pump OF
© Metso F
 p. 77

Pressure sensor in the clamping circuit

• Pressure values of the pump and feeder Start / Stop

Clamping circuit HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5

Pump stop Sp1 25 b 190 b ? 25 b 25 b

PS1-A
Pump start Rp1 20 b 175 b ? 20 b 20 b
Feeder start Sp2 16 b 165 b ? 16 b 16 b
PS1-B
Feeder stop Rp2 14 b 160 b ? 14 b 14 b

Sp1
Rp1

Sp2
Rp2

© Metso
Unit Converter
 Run mode : Normal operating mode
At power on the unit is in the Run mode. It carries out its measurement and evaluation
functions and provides output signals according to the set parameters.
The display shows the current system pressure. The yellow LEDs indicate the switching
state of the outputs.

Display mode : Indication of parameters and the set parameter values

When the "Mode/Enter" button is pressed briefly, the unit passes to the Display mode
which allows parameter values to be read. The internal sensing, processing and output
functions of the unit continue as if in Run mode.
• The parameter names are scrolled with each pressing of the "Mode/Enter" button.
• When the "Set" button is pressed briefly, the corresponding parameter value is displayed
for 15s. After another 15s the unit returns to the Run mode.

Programming mode : Setting of the parameter values

While viewing a parameter value pressing the "Set" button for more than 5s causes the
unit to enter the programming mode. You can alter the parameter value by pressing the
"Set" button and confirm the new value by pressing the "Mode/Enter" button. The internal
sensing, processing and output functions of the unit continue as if in Run mode with the
original parameter values unless a new value is confirmed.
The© Metso
unit returns to the Run mode when no button has been pressed for 15 s.
p. 78
p. 79

Pressure sensors : programming

See
© Metso page 167 more complete information
 Refief valves
• Control the pressure in a line at a set value.
• When the pressure in line P exceeds the set value, a valve opens and
drains a controled volume of oil in line T as long as the pressure has not
reached back the set value.
• All the relief valves are directly fitted on the connecting block

P T
Pressure line Return line

p. 80 © Metso
p. 81

Refief valves
• Setting values of the relief valves

HP200…
Relief valves HP100 HP500 HP3 HP4 HP5
HP400
RLV1 Maxi pressure in clamping circuit 28 b 210 b 210 b ? 28 b 28 b
RLV2 Residual clamping pressure for setting X 15 b 15 b ? X X
RLV3 Maxi pressure in setting adjustment 230 b 230 b 230 b ? 210 b 210 b
RLV4 Maxi pressure in tramp release circuit 135 b 135 b 175 b ? 170 b 150 b
RLV5 Security pressure in clamping circuit 35 b 250 b 250 b ? 35 b 35 b
RLV6 Security pressure in tramp release circuit 320 b 320 b 250 b ? 250 b 250 b
RLV7 Maxi pressure when maintenance mode X X X ? 110 b 110 b

© Metso
Unit Converter
 p. 82

Directional valves
Controls the flow direction according to the position of a slide.
The slide is moved by an electro-magnet ( solenoid )

The activation status is indicated

by a green LED.

SonenoÏd non activated Solenoïd activated

Depending on the crusher type, up to 5 different directional valves are used.

© Metso
 p. 83

Directional valves
SOL
4
• Beside, the connecting block
of HPX00, with :
SOL
- 6 directional valves
7
- 8 solenoids.
SOL
• See the function of each 8
solenoid in the chapter SOL
« hydraulic circuits» 6
SOL
5

SOL
1
SOL
© Metso
3
 p. 84

Directional valves
SOL
• Beside, the connecting block 9
of HPX, with :
- 7 directional valves
- 9 solenoids.
• SOL 9 = additional solenoid,
activated by the ‘maintenance’
mode.
• See the function of each
solenoid in the chapter
« hydraulic circuits»

© Metso
 Level switch

L/S 1

Symbol :

The sliding float is equiped with a magnet.

When in bottom position, it :
• opens a contact which stops the pump
• closes a contact which illuminates the lamp ‘Oil level’ Sliding
p. 85 © Metso
float
 Check valves

• Allows flow in only one

direction

• Pilot operated check valve : • Pilot operated check

- Allows flow in only one direction valve :
when pilot line pressure is OFF
- Allows flow in only both
directions when pilot line
pressure is ON

p. 86 © Metso
 p. 87

Filter
• The hydraulic filter is installed in a pressure line (after the n° 2 pump, for
tramp release and setting adjustment).
• Clogging indication is visual (LED) and electrical (contact which activates
KA8 relay).

• Filter and clogging indicator are fitted on the

connection block.
• Fineness of filtration is 10 microns (the
cartridge cannot be cleaned).
• To know is the cartridge is dirty, switch the unit
in « manual » mode and press the button
« pressurisation ».
• If the diode illuminates, change the cartridge.

© Metso
 Power components

p. 88 © Metso
 Pompes
• The 3 pumps are connected together, and
powered by the same motor.
• The number of pumps depends on the crusher
type :

• Range HPX00 : Pump 2

Pump 1
- 1 pump (n°1) for the clamping circuit.
- 1 pump (n°2) for the tramp release and setting
adjustment circuits.

• Range HPX :
- 1 pump (n°1) for the clamping circuit. Pump 3
Pump 2
- 1 pump (n°2) for the tramp release and setting
Pump 1
adjustment circuits.
- 1 pump (n°3) for the maintenance mode
p. 89 © Metso
 Pumps
Range HPX00 Range HPX

To circuits

From tank
p. 90 © Metso
From tank To circuits
p. 91

Pumps
• capacity (L/min) of hydraulic pumps (for a 1475 RPM / 50 Hz motor) :

Pump capacity (L / min) HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5

Pump 1 : clamping 6,7 ? 6,7

Pump 2 : tramp release /setting adjust. 20 ? 14,7

Pump 3: maintenance mode (no maintenance mode) ? 20

© Metso
Unit Converter
 Tramp release cylinders
• 6 double acting cylinders :
- Tramp release function : opposed to the crushing force
qui tend to lift bowl and rings. Downward force which
provides the contact between adjustment ring and main
frame.
- Clearing function : lifts the bowl and rings to free the
material stuck between the liners. Upward action.
Adjustment
ring

Tramp release Tramp

circuit release
cylinder

Clearing
circuit
Accumulator
p. 92 © Metso
p. 93

Tramp release cylinders

• Table of data on the

tramp release cylinders :

(HP4 crusher)

Tramp release cylinders HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5
Pressure (bar) 105 à 115 150 / 160 ? 140 / 154 120 / 130
Force per cylinder (daN) 15 500 18 000 24 300 31 400 42 300 ? 36 000 51 500
Clearing stroke (mm) 65 70 85 105 125 ? 92 135
© Metso
Unit Converter
 Clamping function
• The clamping function consists of preventing the bowl from turning during
crushing, and so keeping constant the setting.
• The clamping is permanently provided by the hydraulic unit, and the bowl is
automatically unclamped for a setting adjustment.
• The clamping function is achieved differently depending on the HP type :
- HP200 to HP500 : several cylinders, at high pressure.
- HP100, HP4 and HP5 : one oil chamber, at low pressure.
• When the clamping device (cylinders or chamber) is pressurized, it raises the
clamping ring from the adjustment ring, and then eliminates the clearance in
the threads.

p. 94 © Metso
 Clamping cylinders and oil chamber

3 4 1) Clamping ring
2) Adjustment ring
3) Clamping cylinder
4) Oil chamber

• HP200 to HP500 HP100, HP4, HP5

p. 95 © Metso
 Clamping cylinders and oil chamber

p. 96 © Metso
p. 97

Clamping cylinders and oil chamber

• Table of data on the clamping cylinders :

Clamping cylinders HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5
Type chamber cylinders chamber
Quantity 1 8 8 8 12 1
Clamping pressure (bar) 20 to 25 175 to 190 20 to 25
Residual pressure (bar) 0 15 0

© Metso
Unit Converter
 p. 98

Accumulators

• The accumulators in the tramp release circuit give the

necessary softness for the cylinders raising when a
tramp iron passes through the cavity.
• The association cylinder + accumulator beheaves like a
spring.

• See the animation

Rubber
bladder not
pressurized

© Metso
p. 99

Accumulators
• Pre-charge :
- The accumulators receive before installation on the crusher a pre-charge of
NITROGEN (example : HP 100 to 400 = 83 bar)
- The rubber bladder occupies all the volume inside the accumulator, and the inner
gas pressure is 83 bar.
- Then the accumulator is connected to the hydraulic circuit, which is afterward
pressurized : (example HP 100 to 400 , the oil pressure in the tramp release
cylinders is 115 bar)
- The oil pressure being more than the gas pre-charge, oil partly squeezes the bladder
untill the two pressures are balanced :
- If oil pressure = 115 b, then nitrogen pressure = 115 b

- Hence the need to drop

83 b 115 b
down the oil pressure to
check the gas pre-charge
value !

Pre-charged
accumulator, before
© Metso installation 115 b
Unit Converter
p. 100

Accumulators in the release circuit (HPX00)

• In case of tramp iron in an HPX00 :
- The mantle movement is transmited to the bowl liner through the tramp iron.
- The bowl liner can move upward as the oil in the upper chamber of the cylinder can
be pushed in the accumulator, which squeezes the bladder.
- As soon as the tramp iron has passed, the gas over-pressure pushes back the oil
in the cylinder, untill having back the contact between adjustment ring and main
frame.
- The forces ans stresses generated by the tramp iron are proportional to the piston
extension needed to free it (contrarily to the HPX).

© Metso Pressures = 115 b Pressures = 200… 300 b Pressures = 115 b

 p. 101

Accumulators in the release circuit (HPX)

• HP4 case :
- These machines are equiped with a connection
block, comprising :
• 1 x 1 liter, Nitrogen pre-charge = 130 b
• 2 x 10 L in parallel, pre-charge = 200 b
- Oil pressure in the cylinders = 154 b

• HP5 case:
- These machines are equiped with 3 connection
blocks, comprising each :
• 1 x 0.6 liter, Nitrogen pre-charge = 120 b
• 1 x 13 L, Nitrogen pre-charge = 170 b
- Oil pressure in the cylinders = 130 b

© Metso
Unit Converter
 p. 102

Accumulators in the release circuit (HPX)

FORCE

• Protection against the ring bouncings

involves the small accumulator, which the
small volume brings a ‘rigid’ behavior : a
large increase in force leads to a small
movement.
Tramp irons :
large accumulators,
• Protection against tramp irons involves NORMAL soft behavior
RETAINING
first the small accumulator, then when its FORCE
inside pressure reaches the pre-charge Ring bouncings :
value of the large accumulators, these small accumulator,
ones start to be filled with oil. They large rigid behavior
volume gives ‘softness’ to the circuit : a
force increase leads to a large stroke.
STROKE

© Metso
 p. 103

Accumulators in the release circuit (HPX)

Large
Small
movement
vibrations

Normal case : Ring bouncings : Tramp irons :

The pressure in the circuit is between 140 and The movements coming from the crusher A large movement of the piston is needed to
154 bar, which is more than the pre-charge gas overload push some oil in the small allow the tramp iron to escape out of the cavity.
pressure in the small accumulator (130 bar) accumulator. A high force is needed for a The small accumulator absorbs the first
and less than the pre-charge gas pressure in small piston movement, as the small millimeters of this displacement, then, when the
the large accumulators. accumulator is rigid : the crusher is well pressure in the circuit reaches 200 bar (which is
protected against ring bouncings. the large accumulator pre-charge), the large
So the small accu bladder is slightly
accumulators start to be compressed. As these
compressed by the pressure difference, and the The large accumulators are not involved.
accumulators are ‘soft’ because large, the
large accumulator bladders are not
© Metso crusher is well protected
compressed.
p. 104

Accumulators in the release circuit

• Nitrogen pre-charge values :

Tramp release accumulators HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5

Quantity of accumulators 3 6 ? 3 6
1 x 1L 3 x 0,6L
Unit volume (L) 4 10 ?
2 x 10 L 3 x 13 L
130 120
Nitrogen pre-charge (bar) 83 105 ?
200 170
Tramp release pressure (bar) 115 160 ? 154 130

© Metso
Unit Converter
p. 105

Accumulator in the clamping circuit

• Function :
- Possible vibrations between clamping and
adjustment rings make shaking the pressure at
the same frequency as the vibrations.
- There is so a risk of erractic tripping of the
pressure sensor.
- The accumulator filters filtre and damp down
these pressure variations.

• Quantity : 1 for all HP sizes

• Volume : 4 liters for all HP sizes
• Nitrogen pressure :
- 16 bar for HP100, HP4 and HP5
- 83 bar for HP200 to HP500

© Metso
Unit Converter
 Hydraulic motor
Maximum pressure in the setting adjustment circuit : 210 bar (110 bar when
the maintenance mode of HPX is activated).
Controled by RLV 3 (or RLV 7 if maintenance mode of HPX is activated)
Shown on manometer G1, or G4 for HPX in maintenance mode.
The motor assembly is equiped with a mechanical brake released by an
hydraulic pressure.
Usual pressure range : about 50 to 100 bar, depending on the threads
lubrication condition.
Hydraulic motors capacities:
HP100 82 cm3
HP200/300 100 cm3
HP400/500 250 cm3
HP4 125 cm3
HP5 160 cm3
p. 106 © Metso
Unit Converter
 Hydraulic motor Hydraulic
Hydraulic Motor
Motor

2 position
valve in the Gear reducer
motor
3 hoses 2 hoses
Brake

CL 2 2 position
valve in the
Motor
unit

SOL 6 SOL 5
SOL 6 SOL 5

Connections for
HP200 to HP500 : HP100, HP4 and HP5 : setting
1 hose to open 1 hose to open adjustments
1 hose to Close 1 hose to Close
Release the brake
1 hose to release the brake The valve is built-in in the motor

p. 107 © Metso
p. 108

Hydraulic motor
• Information on screwing / unscrewing the bowl:

Bowl screwing / unscrewing HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5

Setting adjustment pump (L/min) 20 ? 14,7 / 34,7

Hydraulic motor capacity (cm3) 82 100 250 ? 125 160

Gear reducer ratio 24,5 19,5 ? 22,5

Pinion speed (mode normal / 5,22 / 4,08 /
9,95 8,16 4,10 ?
maintenance) (tr/min) 12,33 9,64
Time to turn the bowl by 1 turn, in
normal mode (min)
53 s 1mn 25s 1mn 35s 3mn 35s 4 mn ? 2mn 30s 3mn 45s
Time to turn the bowl by 1 turn, in
maintenance mode (min)
X X X X X ? 1 mn 1 mn 35s

© Metso
Unit Converter
 Hydraulic Circuits
of ‘HP’ cone crushers

This presentation covers the

ranges :
- HP100 to HP500 (range HPX00)
- HP4 and HP5 (range HPX)
with 24V DC voltage

p. 109 Back
© Metso to front page
 • First part : HPX00 range
- 4 configurations are studied :
• Unit power OFF
• Normal working situation
• Clearing
• Setting adjustment

• Second part : HPX range

- 5 configurations are studied :
• Unit power OFF
• Normal working situation
• Clearing
• Setting adjustment
• Bowl unscrewing in maintenance mode

p. 110 © Metso
 Hydraulic circuits
Range HPX00

p. 111 © Metso
p. 112

• Activation status of the solenoids

MODE MANUAL MODE COMPENSATION MODE

Clamping Release
FUNCTION Pressurize Open Close Clearing
pressure pressure
Sol 1 1 1
Sol 2 1 1
Sol 3 1 1
Sol 4 1 1 1 1 1
Sol 5 1
Sol 6 1
Sol 7 1 1
Sol 8 1
Sol 9 1 if SB9 1 if SB9 1

© Metso
 Case study # 1 : Power OFF

p. 113 © Metso
 Case study # 1 : Power OFF
(drain valves opened)

p. 114 © Metso
 Case study # 2 : Normal working
situation ‘compensation mode’
activated
ON / OFF button
pulled

p. 115 © Metso No solenoids activated All relays activated

 Case study # 2 :
Normal working
situation

Click to start the

corresponding
animation

- The pumps do not turn

- None solenoid activated
- All pressures are correct

p. 116 © Metso
 Case study # 3 : Clearing
‘manual’ mode activated :
‘Clear’ button
pressed KA1 and KA2 disactivated
ON / OFF button
pulled

Solenoids 4 and 8 activated Release pressure = 0

p. 117 © Metso
Relays KA5 and KA6
disactivated
 Case study # 3 :
Release
Clearing pressure =
0

Sol 4 and Sol 8

activated

Click to start the

corresponding
animation

p. 118 © Metso
 Case study # 4 : ‘manual’ mode activated :
KA1 and KA2 disactivated
Setting adjustment ‘Close’ button
pressed

Solenoids 2,3,4 and 6 activated Clamping pressure = 0

p. 119 © Metso

Relays KA3 and KA4

 Case study # 4 :
Setting adjustment

Solenoids
2 and 3
activated

Solenoids
4 and 6 activated

Click to start the

Clamping corresponding
animation
pressure 15
bar

p. 120 © Metso
p. 121

Hydraulic circuits
Range HPX

© Metso
p. 122

• Activation status of the solenoids

MODE MANUAL MODE COMPENSATION MODE

Clamping Release
FUNCTION Pressurize Open Close Clearing
pressure pressure
Sol 1 1 1
Sol 2 1 1
Sol 3 1 1
Sol 4 1 1 1 1 1
Sol 5 1
Sol 6 1
Sol 7 1 1
Sol 8 1
Sol 9 1 if maint. 1 if maint. 1

© Metso
 Case study # 1 : Power OFF
The ON / OFF button is pushed :
The unit is out of tension, nothing is activated.

p. 123 © Metso
 Case study # 1 : Power OFF

If the drain valves are

opened, there is no
pressure in the crusher and
in the hydraulic unit.
p. 124 © Metso
 Case study # 2 : The unit is switched ON
ON / OFF button is pulled :
-If pressures are OK, nothing is activated (solenoid, lamp, pump…) except the white lamp
and relays KA3 to KA8
- If no button is pressed, the unit is in manual mode.

p. 125 © Metso
 … then the ‘Compensation’ button is pressed : normal working
configuration
• The ‘Compensation’ button is pressed once :
- The unit is in compensation mode,
- The green light is ON,
- All the relays are activated.

p. 126 © Metso

As long as pressures are OK, the pump does not turn.

 Case study # 2 : Normal working configuration

Click to start the

corresponding
animation
110
The clamping and b
release pressures are
present on the crusher, As long as pressures are
and kept by the check OK, the pumps do not
valves. turn.
p. 127 © Metso
 Case study # 3 the « pressure fault » light is ON
• In this example :
- Clamping pressure is a bit too low, PS1A trips
- The unit is in ‘compensation’ mode
- The pumps turn to repressurize

p. 128 © Metso
 Case study # 3 the « pressure fault » light is ON
No change in
the release
PS1A has tripped circuit, which
stays
pressurized.

Click to start the

corresponding
animation

Pumps 2 and 3
turn in ‘closed
110
b circuit’ 3
-SOL1 is activated
2
Pump 1
pressurizes the
1
p. 129 © Metso clamping circuit.
 Case # 4 : closing the crusher setting
-Maunual mode is activated the ‘compensation’ light is OFF and KA1 & KA2 are
disactivated.
- ‘Close’ button is pressed : SOL 2,3,4 & 6 are activated clamping pressure drops
down KA3 & KA4 relays are disactivated.
- IMPORTANT : The pumps start after a 2 second delay.

p. 130 © Metso
 Case # 4 : closing the crusher setting
No changes in the
release circuit.

Click to start the

corresponding
animation

After 2 seconds the

pumps start.
- pumps 1 and 3 turn in
‘closed circuit’
- pump 2 powers the
110 motor through SOL 4 and
6
b 3

1
p. 131 © Metso Clamping pressure flows back to the
tank.
 Case # 5 : clearing the crusher
-When a clearing is required, the ‘maintenance’ mode is automatically activated :
SOL 9 and orange light are activated.
- the clearing can only be done in ‘manual’ mode.

p. 132 © Metso
 Case # 5 : clearing the crusher

No changes in the
clamping circuit.

Click to start the

corresponding
animation

- as SOL 9 is activated, the oil flow

coming from pump 3 is added to the
one from pump 2 :
* the flow is more than doubled
* So the clearing speed
* But the maximum pressure must be
reduced (110 b RLV7)
110
b 3

1
p. 133 © Metso
 Case study # 6 : complete bowl unscrewing for liner change
- switch in manual mode : disactivation of relays KA1 and KA2
- ‘maintenance’ button pressed activation of SOL 4 and 9
- this button is kept pressed and the ‘open’ button is also pressed
activation of SOL 2, 3 and 5, and pump starts after 2 seconds.

p. 134 © Metso
 Case study # 6 : complete bowl unscrewing for liner change
Clamping pressure No changes in the
drops to 0 release pressure.

Click to start the

corresponding
animation

As SOL9 is activated,
pump 3 flow is added
to pump 2 one.

110
b 3

1
p. 135 © Metso
 Use of the
Hydraulic Unit
of ‘HP’ cone crushers

This presentation covers the

ranges :
- HP100 to HP500 (range HPX00)
- HP4 and HP5 (range HPX)
with 24V DC voltage

p. 136 Back
© Metso to front page
 Use of HPX00 control box

1: ON / OFF button
8
2: « light test » button 1
2
3: « Oil level fault » light
4: « Compensation mode » light 9

5: « Compensation mode » button

3
10
6: « Manual mode » button
7: « Clearing » button 4
11
8: « Power On » light 5
9: « Oil Presure fault » light
6 12
10: « Pressurizing » button
11: « Close setting » button
7
12: « Open setting » button
p. 137 © Metso
 Use of HPX00 control box

• ON / OFF button :
- Pull : the hydraulic unit is powered ON. Push : powered OFF
- The unit must stay powered during the crusher operation, to see
the ligth indications, and to allow any hydraulic operation.

• White light :
- Indicates that the unit is under current. It is the only light which
should be ON during normal operation.

• Red light :
- Indicates that the oil level in the tank is too low. In this case the
pumps cannot start.

p. 138 © Metso
 Use of HPX00 control box

• Red light :
- Indicates a too low pressure in either the clmaping pressure or
the release pressure.
- A re-pressurization of the circuits is needed, either in ‘manual’ or
in ‘compensation’ mode.
- This re-pressurization can be done when the crusher works .

• Green light :
- When illuminated, indicates that ‘compensation’ mode is
activated.

• Pressurization button :
- Provides a manual re-pressurization of the circuits, if ‘manual’
mode is activated (green light OFF).
- Presse this button until the pressure fault red light is OFF.
p. 139 © Metso
 Use of HPX00 control box

• ‘Light test’ button

- To check if the 4 lights actually work.
• ‘Manual mode’ button
- When this button has been pressed, the unit is in manual mode
and green light is OFF.
- Just after starting, the unit is always in manual mode.
- This mode is required for all hydraulic functions (setting
adjustment, clearing).
• ‘Compensation mode button :
- When this button has been pressed, the unit is in compensation
mode and green light is ON
- In normal working situation, it is advised to activate this mode
just after the starting of the unit.
- Then in case of pressure drop, the pumps will automatically
start and stop.
p. 140 © Metso
 Use of HPX00 control box
• ‘Clearing’ button :
- The clearing is always done when the crusher is stopped.
- Prior to achieve the clearing, set the unit in ‘manual’ mode (green
light OFF)
• The cylinders get ou as long as the button is kept pressed. As soon
as it is released, the bowl starts to move down. If the bowl should stay
in high position, install the safety blocks around the main frame pins.
- When the buttuon is pressed, the ‘presseure fault’ red light is ON
because the release pressure is nile.
• ‘Open’ button’ :
- commutate the unit in manual mode (green light OFF)
- The button activates the hydraulic motor in the unscrewing
direction.
- The clamping pressure is dropped down : the ‘pressure fault’ red
light is ON
• ‘Close’ button :
- commutate the unit in manual mode (green light OFF)
p. 141 © Metso
- The button activates the hydraulic motor in the screwing direction.
 Use of HPX control box
In red : the new functions that HPX00 don’t
have:
1: ON / OFF button 8
1
2: « light test » button
3: « Oil level fault » light
2 9
4: « Compensation mode » light
5: « Compensation mode » 3
button 10

6: « Manual mode » button 4

7: « Clearing » button 11
5
8: « Power On » light
9: «Tooth counter » display 6 12
10: « Oil Presure fault » light
13
11: « Pressurizing » button 7
12: « Maintenance » light
13: « Close setting » button 1 15
4
14: « Open setting » button
p. 142 © Metso
15: « Maintenance » button
 Use of HPX control box

• Dispaly of the teeth counter :

- Displays how many teeth the bowl has turned.
- Recieves the information from one of the 2 proximity
sensorss located in front of the pinion. Every time a tooth
passes in front of the sensor, an impulse is sent to the
counter which increments.
- The pinion rotation direction, so the information of opening
or closing the crusher, is given by the status of activation of
solenoid 5 (see the hydraulic circuits). When the crusher
setting increases (SOL 5 activated) le number of teeth is
decremented.
- The counter is reset every time the unit is switched OFF. A
manual reset button is also provided on the dispaly.

p. 143 © Metso
 Use of HPX control box

• Maintenance mode :
- When this mode is activated the flow of pump number 3 is
added to the one of pump 2, and the oil flow sent to the
motor goes from 15 to 35 litres per minute.
- The rotation speed of the motor increases in the same
proportion, which allows a quicker bowl unscrewing
(example : total time for an HP4 bowl complete rotation in
normal mode = 28 min, in maintenance mode = 12 min).
- Use this mode only for complete bowl screwing /
unscrewing (for liner change for example ), not for setting
adjustment.
- During the screwing / unscrewing, keep the finger on the
button. The yellow light indicates the maintenance mode
activation (solenoid 9 activated, see the hydraulic circuits).
- When a clearing is required, it is done automatically in
maintenance mode, so the cylinder rods get out quickly.
- When maintenance mode is activated, the maximum
p. 144 © Metso
pressure in the setting adjustment circuit is limited at 110
bar (relief valve RLV 7) instead of 210 bar. Unit Converter
 Using the crusher
• Daily start-up:
- Pull the black button to switch the unit ON --> the white light
is illuminated.
- Test the correct functioning of the lights by pressing the blue
button on the control box side : all the lights must be
illuminated..
- Switch the unit in the « compensation » mode : the green
light switches ON.
- A pressure on the crusher (clamping or release) may have
dropped during the night, and the red light « pressure fault »
is ON. In this case, if ‘comensation’ mode is activated, the HPX00
pumps startfew seconds then stop automatically when the
right pressures are reached.
- If the ‘compensation’ mode has not been activated, the unit
is still in ‘manual’ mode and it will be necesary to press the
« pressurization » button until the red light has switched
OFF (keep the finger on the button for few more seconds).

• The crusher is ready to work.

p. 145 © Metso
HPX
 Using the crusher
• Setting adjustment :
- Can only be done in ‘manual’ mode, green light OFF.
- As soon as the ‘Open’ or ‘Close’ button is pressed, the
clamping pressure drops down (to 0 or 15 bar, depending on
the crusher type).
- HPX case : when a setting adjustment button is pressed, the
pumps only start after a 2 seconds delay (timer in the control
box), to give time for the clamping chamber to be empty
before the bowl turns.
- A setting adjustment should be done crusher empty (feeder
stopped), but turning.
- However, it could be possible to adjust the setting under the
load if the material is easy to crush and if the setting is large.
- HPX case : the number of teeth the bolw has turned is
shown on the display on the control box.
- Once the setting adjustment is done, re-pressurize by
switching ON the ‘compensation’ mode.
p. 146 © Metso
 p. 147

Using the crusher

• Setting adjustment :
- Bowl direction of rotation when the setting is tightened :
• HP100, HP4 and HP5 : counterclock wise (left hand threads).
• HP200 to HP500 : clock wise (right hand threads).

• Setting variation :

Setting variation HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5

Gear teeth number 106 138 156 176 192 ? 159 185

Setting variation per tooth (mm) 0,27 0,18 0,23 0,20 0,18 ? 0,17 0,21
setting variation for 1 bowl turn
(mm)
28,6 24,8 35,9 35,2 34,5 ? 27,0 38,9

© Metso
 Using the crusher

• Clearing :
- The clearing is done when the crusher is STOPPED.
- The unit must be set back in ‘manual’ mode (green light OFF). The clearing cannot
be done in COMPENSATION mode as the release pressure (provided by the
same cylinders) must stay nile during the clearing, without the automatic pressure
compensation.
- Press the button ‘clearing’ : the adjustment ring and bowl rise.
- The ‘pressure fault’ red light is ON.

Clearing HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5

Vertical clearing stroke (mm) 65 70 85 105 125 ? 92 135

- When the clamping ring is empty, re-pressurize the circuits to press back the
adjustment ring on the frame.

p. 148 © Metso
 Using the crusher

• Clearing :
- If the bowl must stay in high position, instal the safety block (delivered with the tool
kit) around the frame pins.

1) Adjustment ring raised

2) Safety block
3) Frame
4) Frame pin

p. 149 © Metso
 Maintenance
of the ‘HP’ cone crusher
hydraulic unit

This presentation covers the

ranges :
- HP100 to HP500 (range HPX00)
- HP4 and HP5 (range HPX)
with 24V DC voltage

p. 150 Back
© Metso to front page
 Maintenance : sommaire

• Oil specification
• De-pressurization
• Filter cleaning
• Oil change and unit cleaning
• Check and refill of the accumulators
• Circuit bleeding
• Relief valve setting
• Pressure sensor setting
• Troubleshooting
• Start-up checks

p. 151 © Metso
 Maintenance : Specification of hydraulic oil

The proper oil to use is ISO Grade 32, with a viscosity of :

20 to 40 cSt ( centistokes ) at 40 °C
and 6 cSt at 100 °C
In addition, the oil must have a viscosity index of 140 or higher

Select your hydraulic oil within our oil recommendation :

BP Energol HLP 32 MOBIL Mobil DTE 24

CASTROL Hyspin AWS 32 SHELL Tellus S 32
TEXACO Rando HD 32 TOTAL Azolla ZS 32
ESSO Nuto HP 32

OR ANY OTHER OIL COMPLYING WITH THE ISO HM 32

Approximate oil volume necessary to fill the tank and circuit :

HP100 to HP300 100 litres
HP400 & HP500 150 litres
p. 152 © Metso
Unit Converter
 Maintenance : depressurization
• Even after a long period of non operation, the crusher stays pressurized !
Prior to any maintenance on the crusher, it is essential to drop down the
clamping et the release pressures.

- Set the unit in ‘manual’ mode (green light OFF).

- Open the doors of the unit cover.
- Localize the tramp release pressure sensor (PS2) and
the drain valve (VAL2).
- Fully open the valve in the counterclock direction, allow
enough time for the oil to flow back to the tank, untill the
pressure drops to 0 bar.
- Localize the clamping pressure sensor (PS1) and the
drain valve (VAL1).
- Fully open the valve in the counterclock direction, allow
enough time for the oil to flow back to the tank, untill the
pressure drops to 0 bar.

p. 153 © Metso
 Maintenance : filter cleaning
• To know if the cartridge is clogged, start the unit in ‘manual’ mode et press
the button « pressurization ».
• If the LED of the indicator lights ON, change the cartridge :

- Switch OFF the unit.

- Unscrew the filter cover.
- Take out the cartridge et replace it by a new one.
- The fineness of filtration is 10 microns (the
cartridge cannot be cleaned).

p. 154 © Metso
 Maintenance : cleaning the unit and changing the oil
• The oil must be changed at least once a year. Take the opportunity to clean
the inside of the unit.
• Reasons for cleaning the hydraulic system :
- Deposits in the tank or on any component
- Erratic operation or high oil temperature
- Poor oil condition (dark color, cloudy appearance, « burnt oil » or rancid odor, etc…
- Presence of emulsions or oil contamination
• Cleaning :
- Drain the system. Try to drain the oil left in the
cylinders, accumulators, etc…
- If necessary, send a sample to your oil supplier for
analysis.
- Remove the cover above the unit, and the hydraulic
hoses connected on the left side.
- Remove the screws fitting the hydraulic plate on the
tank and lift it, using the eye bolts.
- Clean the inside of the tank with solvent and wipe
with rags
- Reinstall the hydraulic plate on the tank.
p. 155 © Metso
- Refill the tank through the air breather
 Maintenance : Check and refill of the accumulators
• For the crusher safety in case of tramp irons, it is mandatory to to check the
accumulator pre-charge .
• Reminder of the correct pre-charges :

Tramp release accumulators HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5

Quantity of accumulators 3 6 ? 3 6
1 x 1L 3 x 0,6L
Unit volume (L) 4 10 ?
2 x 10 L 3 x 13 L
130 120
Nitrogen pre-charge (bar) 83 105 ?
200 170

• A charging kit is supplied

(option depending on the 1. Accumulator
country) with the tool kit. 2. Gas valve
stem
3. Valve cap
4. Valve guard
p. 156 © Metso
5. Washer
 Maintenance : Check and refill of the accumulators
• How to check the nitrogen pressure ? : Adaptator
Upper
- Drop down the oil pressure to check the gas ring
pressure.
- Unscrew (counterclockwise) the lower ring, so
that the accumulator valve does open when fitting
the charging kit.
- Fit the kit on the accumulator by screwing the
upper ring through the 7/8’’ or 5/8’’ adaptor
- Fit the hose on the nitrogen bottle. A specific
adaptor is supplied according to the country of
use.
- Turn the lower ring. The pressure value appears
on the gauge..
- The pressure is too high : slowly turn on the drain
tap to release some gas until the pressure is
correct.
- The pressure is too low : slowy open the valve on
the nitrogen bottle to allow the gas to enter the
accumulator Lower ring To Nitrogen
- Close the nitrogen bottle, unscew Drain tap
bottle
(counterclockwide) the lower ring, close the drain
p. 157 © Metsotapremove the hose,

- Remove the charging kit from the accumulator,

 Maintenance : Circuit bleeding
• After initial connection or whenever the circuit has been broken to replace a
component, this circuit must be bled to remove the air that has likely entered
the circuit
• Before bleeding, first start the hydraulic unit to have oil flow forcing out the air.
- Do not start the hydraulic unit before all the accumulators are pre-charged with nitrogen
(could dammage the bladder)
- Under no circumstances attempt to bleed a pressurized circuit

• Bleeding the clamping circuit

- Untighten the fitting of the clamping hose near the crusher
- Start the hydraulic unit in MANUAL mode, hold the button PRESSURIZING pressed
- Open the drain valve VAL1 to start the circuit depressurization
- When the oil is flowing freely without bubbles or spitting, tighten the fitting
- Close the drain valve VAL1 and press the PRESSURIZING button
- Check the pressure on the sensor digital display : must be 190 bar for HP200 to
HP500 (25 for HP100 and HPX), and then the pump must stop.
- Check the hoses and fittings for oil leaks
p. 158 © Metso
 Maintenance : Circuit bleeding
Release
• Bleeding the clearing circuit :
Clearing
- Untighten the hose connected at the bottom of the
cylinder
- Start the hydraulic unit in MANUAL mode, press the
button CLEARING and hold it
- Open the drain valve VAL2 to depressurize the
circuit until the pressure drops to approximately 15
bars
- When the oil is flowing freely without bubbles or
spitting, tighten the fitting.
- Close the drain valve VAL2 and hold the
CLEARING button pressed
- Wait several minutes until the adjustment ring
reaches its maximum lift
- Check the hoses and fittings for oil leaks
p. 159 - Hold the PRESSURIZING button pressed until the
© Metso

adjustment ring is seated on the main frame liner.

 Maintenance : Circuit bleeding
• Bleeding the release circuit :
- Start the hydraulic unit in MANUAL mode, press the button
CLEARING and hold it
- Open the drain valve VAL2 to depressurize the circuit until
the pressure drops to approximately 15 bars
- Loosen the bled screw at the bottom of the accumulator.
When the oil is flowing free without bubbles or spitting,
tighten the bleed screw.
- Loosen the hose fitting at the top of the cylinder. When the
oil is flowing free without bubbles or sputterings, tighten
the hose fitting.
- Repeat above procedure for the 6 accumulators /
cylinders.
- Close the drain valve VAL2 and hold the PRESSURIZING
button pressed
- Check the hoses and fittings for oil leaks
Proceed with TWO complete cycles of cavity clearing and cavity pressurizing
to force any entrapped remaining air back to the tank
p. 160 © Metso
 Relief valve setting
• The relief valves, originally fitted or spare ones, are preset by the supplier :
normally no need to adjust. Setting adjustment is given for information.
• A modification of the factory settings will annul the warranty !
• Reminder of the original settings :
HP200…
Relief valves HP100 HP500 HP3 HP4 HP5
HP400
RLV1 Maxi pressure in clamping circuit 28 b 210 b 210 b ? 28 b 28 b
RLV2 Residual clamping pressure for setting X 15 b 15 b ? X X
RLV3 Maxi pressure in setting adjustment 230 b 230 b 230 b ? 210 b 210 b
RLV4 Maxi pressure in tramp release circuit 135 b 135 b 175 b ? 170 b 150 b
RLV5 Security pressure in clamping circuit 35 b 250 b 250 b ? 35 b 35 b
RLV6 Security pressure in tramp release circuit 320 b 320 b 250 b ? 250 b 250 b
RLV7 Maxi pressure when maintenance mode X X X ? 110 b 110 b

p. 161 © Metso
Unit Converter
 Relief valve setting
• Setting procedure :
- Switch ON the unit, in ‘manual’ mode (green light
OFF).
- Press the button corresponding to the relief valve
to set (table next page).
- To obtain the setting, turn the screw after having
unblock the counter nut. Read the pressure on
the sensor display.
- When a relief valve is adjusted in a circuit
(clamping or clearing/pressurizing), better to
release the pressure in the other circuit by Setting screw
opening the corresponding valve.. Locking nut

p. 162 © Metso
 Relief valve setting

relief Valve Function Valve VAL 1 Valve VAL 2 Button to press Read the pressure on :

Maxi clamping
RLV 1 Closed Opened Pressurize pressure sensor PS1
pressure
Residual clamping
RLV 2 (HPX00) Closed Opened Open pressure sensor PS1
pressure
Maxi setting pressure
RLV 3 Opened Closed Open Manometer G1
in normal mode
Maxi setting pressure
RLV 7 (HPX) Opened Closed Open Manometer G4 (HPX)
in maintenance mode

RLV 4 maxi release pressure Opened Closed Pressurize pressure sensor PS2

p. 163 © Metso
 Relief valve setting
• Function of RLV-5 and RLV-6 :
- Safety devices.
- They are used to limit the pressure when accumulators have no, or not enough,
nitrogen pressure. In this case they are filled with oil, and the crusher is no longer
protected in case of tramp iron.
- Setting of RLV-5 :
• HP100, HP4 and HP5 = 35 bar
• HP200 to HP500 = 250 bar
- Setting of RLV-6 :
• HP100 to HP400 = 320 bar
• HP500, HP4 and HP5 = 250 bar

- If a cylinder rod is pulled upward by a tramp

iron and the accumulator is full of oil, the
pressure exceeding 320 bar is drained to the
tank.
- The settings of RLV-5 and RLV-6 are higher
than the maximum pressure the pump can
p. 164 © Metsogenerate. So it is not possible to check their

settings.
 Pressure sensor setting
• Reminder of the settings :

Tramp release circuit HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5
Pump stop Sp1 115 b 160 b ? 154 b 130 b
PS2-A
Pump start Rp1 105 b 150 b ? 140 b 120 b
Feeder start Sp2 100 b 145 b ? 130 b 110 b
PS2-B
Feeder stop Rp2 95 b 140 b ? 125 b 100 b

Clamping circuit HP100 HP200 HP300 HP400 HP500 HP3 HP4 HP5
Pump stop Sp1 25 b 190 b ? 25 b 25 b
PS1-A
Pump start Rp1 20 b 175 b ? 20 b 20 b
Feeder start Sp2 16 b 165 b ? 16 b 16 b
PS1-B
Feeder stop Rp2 14 b 160 b ? 14 b 14 b

p. 165 © Metso
Unit Converter
 Pressure sensor setting (extracts from the manufacturer instruction
manual)

p. 166 © Metso
 Pressure sensor setting (extracts from the manufacturer instruction
manual)

p. 167 © Metso
 Pressure sensor setting (extracts from the manufacturer instruction
manual)

p. 168 © Metso
 Pressure sensor setting (extracts from the manufacturer instruction
manual)

p. 169 © Metso
 Pressure sensor setting (extracts from the manufacturer instruction
manual)

p. 170 © Metso
 Problems with the hydraulic unit
• Most of the hydraulic failures come from a gradual or sudden loss of high
pressure, resulting in loss of power or speed of the hydraulic functions :
clamping – unclamping – setting adjustment – cavity clearing – cavity
pressurizing..

• Prior to any troubleshooting procedure, the following items should be checked :

- Oil level is satisfactory ?
- Hoses properly located on hydraulic unit and crusher ?
- Accumulators properly charged with nitrogen ?
- Whole hydraulic circuit properly bled ?
- No visible leaks in the unit or at the crusher ?
- Pump is operating ?

• Even with no knowledge in hydraulic, it is possible to fix a problem by using the

hereafter sketches, where are mentioned the components which could be
p. 171 © Metso
involved and checked depending on the type of problem faced.
Trouble shooting
MOTOR RELEASE
1) the unit cannot clamp the bowl CLAMPING

The only components involved are :

Pump and motor assembly

Solenoid vavle SOL-1

Solenoid valve SOL-3

Relief valve RLV-1

Pressure Switch PS1

Manual Valve VAL-1

Check Valve CL 1

p. 172 © Metso
 Trouble shooting MOTOR RELEASE
CLAMPING
2) the unit cannot unclamp the bowl

The only components involved are :

Solenoid valve SOL-3

Relief valve RLV-2

p. 173 © Metso
Trouble shooting MOTOR RELEASE
CLAMPING
3) the unit cannot adjust the
setting

The only components involved are

:

Pump and motor assembly

Solenoid valve SOL-3

Solenoid valve SOL-4

Solenoid valve SOL-5 and SOL-6

Relief valve RLV-2

Relief valve RLV-3

Shuttle Valve CL-2

p. 174 © Metso
 Trouble shooting
MOTOR RELEASE
4) the unit cannot keep the release CLAMPING
pressure

The only components involved are :

Pump and motor assembly

Solenoid valve SOL-4

Solenoid valve SOL-7

Solenoid valve SOL-8

Relief valve RLV-3

Relief valve RLV-4

Relief valve RLV-6

Manual Valve VAL-2

p. 175 © Metso
 Trouble shooting
MOTOR RELEASE
CLAMPING
5) the unit cannot clear the crusher

The only components involved are

:

Pump and motor assembly

Solenoid valve SOL-4

Solenoid valve SOL-7

Solenoid valve SOL-8

Relief valve RLV-3

Pilot operated valve CL-3

p. 176 © Metso
 Contrôles à la mise en route

• Vérification du bon fonctionnement du mode compensation :

- Mettre la centrale en mode compensation
- Ouvrir légèrement la vanne VAL1 pour créer un léger débit de fuite dans le circuit
de blocage.
- Observer la chute de pression sur l’afficheur du capteur de pression.
- Repèrer à quelle pression la pompe se met en route,
- Et a quelle pression elle s’arrête.
- Faire de même avec VAL2 pour le circuit de maintien.

• Vérification de l’asservissement de l’alimentateur :

- Mettre la centrale en mode manuel
- Ouvrir la vanne VAL1 pour créer un débit de fuite dans le circuit de blocage.
- Observer la chute de pression sur l’afficheur du capteur de pression.
- Repèrer à quelle pression l’alimentateur s’arrête,
- Faire de même avec VAL2 pour le circuit de maintien.
p. 177 © Metso
 Start-up controls

• Check if the compensation mode works properly:

- Set the unit in the compensation mode
- Slightly open the drain valve VAL1 to create a small pressure drop in the clamping
circuit.
- Watch the pressure drop on the pressure sensor display.
- Notice at what pressure the pump starts,
- And at what pressure it stops.
- Do the same with VAL2 for the release circuit.

• Check the interlocking of the feeder :

- Set the unit in manual mode.
- Open the drain valve VAL1 to create a large pressure drop in the clamping circuit.
- Watch the pressure drop on the pressure sensor display.
- Notice at what pressure the feeder stops.
- Do the same with VAL2 for the release circuit.
p. 178 © Metso
 • End of the presentation « lubrication & hydraulic of HP crushers »

p. 179 © Metso
 Appendice : definition of hysteresis
A switch (for temperature, pressure, ..) which reacts according to a fluctuating
temperature or pressure will not trip at the same value when it decreases or
increases.
The gap between the 2 levels is called hysteresis. It can be adjustable, or fixed.

The electric contact of

the trigger only trips
High level
(opens / closes) when the
value gets out of the Low level
hystereris strip.

back
p. 180 © Metso