This chapter only explains basic safety regulations. Other precautions are necessary for the safe operation of the crusher. The content of this manual cannot replace safety regulations, safety measures, or relevant laws, rules, and regulations of governments at all levels.
The safety of operating and maintenance personnel is paramount. This manual is available for equipment installers and presents some problems they may encounter in their daily work.
Operators are responsible for familiarizing themselves with specific requirements, precautions, and unsafe factors in the work area and discussing these issues with management promptly. All personnel must reach a consensus in this regard to ensure operational safety.
Operators are key to safety work. They should learn safety precautions and understand basic safety measures to prevent serious personal injury, death, and property damage.
To remind you—the user, and relevant operation and maintenance personnel—the term "Warning" is used throughout this manual to mark dangerous or risky operations.
The safest equipment requires careful operation and familiarity with its technical performance. Safety regulations must be fully complied with.
Remember, in any case, you are the key to safety. Taking safety seriously not only protects those around you but is also the best protection for yourself. Please study this manual and all operating manuals related to the equipment you use provided by the manufacturer. Read all warnings and precautions. Be sure to achieve safe operation.
Urge your coworkers to also comply with safety regulations. Be vigilant of all unknown dangers. Always remember: Safety is your responsibility!!
Company safety records show that the vast majority of accidents are caused by neglecting simple safety rules. Therefore, be familiar with and comply with all regulations, and understand the relevant regulations from supervisors before work begins.
For your personal safety, you should select and wear safety helmets, safety shoes, safety glasses, goggles, protective gloves, and hearing protection as needed.
Loose clothing can easily get caught in rotating parts. Fasten cuffs, tuck in shirts, and wear all safety equipment properly. Keep warm, but do not let clothing hinder your movement. Watches and rings can be dangerous. Do not carry items in pockets that could fall out.
Read the manual provided with the machine. Familiarize yourself with the equipment's operating methods and maintenance requirements. Understand the machine's production capacity and application range. Know the location and function of all controllers, indicators, and alarm devices, as well as alarm prompts. Learn to recognize the machine's alarm and safety devices. Alarm devices will warn you of the dangers of continuing operation under low pressure or high temperature conditions.
Try to learn as much as possible about your work site in advance:
Be a good housekeeper. Always keep the ground clean, free of oil, grease, rags, ropes, chains, buckets, stones, and other obstacles. Place loose parts in toolboxes. Do not use flammable solutions for cleaning.
HP100/200/300/400/500 Cone Crusher Operation Manual
Be familiar with the load-bearing capacity of the workplace ground.
Be familiar with the clearance at the work site. Taking a moment to check the clearance around and above the work area, including power sources, can prevent many future problems.
Be wary of dust, smoke, or fog, which may obstruct your view.
Measures in advance—constant vigilance—careful operation—you can prevent personal injury and equipment failure. If an accident occurs due to slight negligence, use the tools at hand and skilled techniques to resolve it quickly. Know the location and use of fire extinguishers and first aid kits.
Know where to get emergency assistance.
Call the accident number immediately for rapid assistance.
Safe work is not limited to these conventional regulations. Also, pay attention to additional precautions required under specific working conditions and for the specific equipment you use.
Equipment not fully prepared for operation is unsafe equipment. Perform a careful check when taking over a shift. If you find a problem that should be noted, be sure to consider it carefully before deciding "let it go this time." Even a small mechanical failure can cause personal injury and major accidents.
Do not allow unauthorized personnel to operate the crusher!
Confirm all safety covers and other protective devices are in the correct position, secure, and undamaged.
Check the oil system: Is it at the correct level? Are there any leaks?
Check every drain cock, valve, and pipe connection to ensure they are in the correct position and secure.
Insufficient pressure due to low oil level can cause serious hydraulic failure.
Crusher seizure due to insufficient thin oil or grease can be one of the problems leading to failure.
Do not adjust the pressure relief valve to increase working oil pressure. The manufacturer's recommended oil pressure provides the longest service life and safest performance.
Do not arbitrarily modify safety devices.
Thoroughly inspect the crusher for visible defects, such as: leaks, worn hoses, or loose parts.
Check your machine according to the operation manual and management instructions.
Walk around the machine before starting it. Ensure no one is near, above, or below the equipment. Alert nearby personnel before starting.
Report any accident to your manager.
Check the equipment's warning signs.
Execute the start-up procedure suggested in Chapter 3 Operating Instructions.
After the crusher starts, check all indicators and gauges to confirm everything is running normally.
If any reading is abnormal, stop immediately.
Test all controllers to ensure they function properly.
Listen for and report any abnormal noises.
Recheck alarms or other warning and safety devices.
Do not stand on the adjustment ring while the crusher is running.
Do not lean or place hands on the tramp release cylinders or between the adjustment ring and main frame while the crusher is running.
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Do not start a problematic machine. Report the specific situation to management.
Do not observe the crushing cavity without protective measures while the crusher is running.
Inspect the machine daily to identify loose, worn, or damaged parts. Immediately report or correct unsafe conditions. Do not operate the machine until it is repaired.
Even a small fault can become a serious accident, so report any equipment malfunction to management.
Always confirm the crusher has stopped before performing any work such as cleaning, maintenance, refueling, checking belt tension, opening covers, inspecting hydraulic systems, repairing, or clearing the crushing cavity, etc.
Do not perform any inspection, adjustment, or repair work while the crusher is running.
Perform maintenance work carefully.
The user manual provided with the machine, especially Chapter 11 "Operating Instructions".
The latter part of Chapter 3 "Operating Instructions", "Inspection and Maintenance Instructions".
The warning nameplates on the machine.
The warning instructions in the user manual.
Chapter 4, Lubrication Guide for Periodic Maintenance.
Before starting work on the crusher, always hang warning signs, disconnect electrical controls, so that no one can start it.
Hanging warning signs prevents accidents:
If the crusher cannot be operated safely.
If the controls are under maintenance.
If the machine is under repair.
Before performing any type of maintenance operation on the crusher, all electrical controls must be disconnected.
When maintaining hydraulic equipment, disconnect all electrical power. Because pressing the "STOP" button only stops the motor.
Provide each maintenance person with their own independent lock and unique key.
Keep hands and clothing away from moving parts. Never侥幸 wear clothes with loose sleeves, loose hanging ties, watches, and rings.
Wear eye protection when handling fuel, cleaning fluids, oils, or brake fluid, as these items can injure your eyes.
Wear a respirator when needed.
Wear safety glasses when drilling, grinding, or chipping metal.
Do not carry items in pockets that could fall out and enter the machine.
Wear a safety helmet and safety shoes when needed.
Wear gloves to protect your hands when replacing steel cables.
Wear safety glasses and protective clothing when using high-pressure air.
Wear goggles and protective clothing when handling molten metals, such as zinc, babbitt, and lead.
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Wear ear muffs when needed, or reduce ear exposure time as required.
Do not consume alcoholic beverages before or during work.
Beware of drugs, sedatives, or other anesthetics that can make you drowsy or reduce alertness.
Promote a good work area. Keep the ground clean, dry, free of debris and tools. Oily and wet floors, pedals, steps, and handrails are slippery. Beware of ice and snow in winter. Wet areas, especially near electrical equipment, are very dangerous.
Do not place or store materials on or around the crusher.
Store hazardous liquids in appropriate locations. Keep them away from unauthorized personnel. No smoking in the work area!
Do not start diesel or gasoline engines in enclosed spaces. Ensure good ventilation. Exhaust fumes can be fatal.
Take appropriate protective measures when performing gas cutting or welding. Anyone performing such operations should avoid breathing fumes, as they may pose health hazards. Therefore, such operations should be performed outdoors in well-ventilated areas equipped with machinery to provide clean air separately or with local fume extraction facilities. Please refer to applicable OSHA or MSHA standards.
Use the correct tools; handle tools and heavy parts flexibly.
Keep all tools and equipment free of dirt and grease. Do not throw them around.
Use lifting equipment for large items. Watch your back.
Lower parts down, do not throw them down.
Wipe grease off levers and handles to prevent slipping.
Do not use pulleys with cracked rims or spokes.
Check V-belts for slippage, cracks, and edge wear.
Check and replace damaged, substandard, or missing parts. Keep equipment clean, free of dust and oil stains, to spot loose or defective parts.
When using steel ropes to move heavy objects, ensure the rope specification is suitable, and replace ropes that are worn, severely scratched, broken, or twisted. Check end fittings for wear.
No smoking when refueling or handling fuel containers.
Turn off the engine when refueling. Be especially careful if the engine is hot.
When refueling the fuel tank, keep the funnel or nozzle close to the tank and ground it to prevent static sparks.
Do not use gasoline or diesel to clean parts. Preferably use high-quality industrial non-flammable solvents.
No smoking when using cleaning agents.
Do not pile oily rags in poorly ventilated areas. Place oily rags and other flammable materials in a safe place.
Never use an open flame to check fuel, battery electrolyte, or coolant levels. Use a flashlight to find hydraulic oil leaks.
Know the location, use, and applicable fire type of fire extinguishers. Check them regularly, at least monthly, to ensure they are in the work area.
In case of fire, shut down the crusher's hydraulic and lubrication systems if it is safe to do so.
Always release all pressure before opening or moving any hydraulic or pneumatic line, valve, fitting, etc.
Check for hose wear or line damage.
High-pressure oil is dangerous.
Equipment equipped with hydro-pneumatic accumulators must comply with the regulations for gas pressure vessels in the French decree concerning hydro-pneumatic accumulators issued on November 24, 1982.
When any part is scrapped, the replacement part must be equivalent to the original part in specification, model, and quality.
During daily inspections, if you find areas that require serious repair, replacement, or adjustment, report it promptly!
If the equipment is running, even a small defect can cause a very serious failure.
Perform authorized work only. Do not attempt maintenance work you do not understand.
Only work on equipment you fully understand. Careless release of pressure on pressure-loaded parts may cause personal injury.
Remember, you are responsible for operating and maintaining an expensive piece of equipment. Treat it with care!
The safety regulations mentioned here cannot eliminate all safety hazards in the crushing plant area. Moreover, people have summarized some safety regulations through long-term production practice, improving safety around crushers and crushing plants.
Appropriate safety measures should be considered from the beginning of crusher installation. The crusher can be driven by V-belts or directly by a coupling. Guards should be installed around belt drives or couplings.
The crusher sheave is specifically designed for the maximum rim speed. If the maximum speed is exceeded, the sheave may rupture, leading to serious accidents causing personal injury or death.
Crusher speed is crucial for normal crusher operation. Therefore, most V-belt guards usually have a small opening in the center opposite the drive shaft to allow a tachometer to be inserted to frequently check the drive shaft speed. This opening is covered with an access door or grid door.
Since each crusher must be inspected and maintained periodically, some form of operating platform should be installed at an appropriate height to facilitate inspection work on the crusher. A high-quality personnel platform built with solid flooring should have handrails and treads, and wire mesh or perforated metal mesh between the platform and handrails to prevent tools from falling off the platform and injuring ground personnel. Do not fix the operating platform to the adjustment ring, as the entire adjustment ring will be quickly lifted when tramp material passes through the crusher.
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Whenever someone is working on the crusher, the power to the crushing equipment must be disconnected.
Each maintenance person performing normal work on the crusher should have his own dedicated lock and unique key. When he is working on any part of the crusher, he should lock the crusher's power control device with his own lock. The key point is that the lock has only one key, and this key must be kept in the pocket of the operator working on the crusher. If more than one person is working on the crusher at the same time, each person should have their own padlock and key for the locked positions on the crusher controller. Those responsible for accidental start-up accidents are often those who think the crusher is "safe".
Like other types of mechanical equipment, if you want to obtain the best economic benefits from using a crusher, normal, regular maintenance is required. One of the most serious safety violations for crushers is the use of insufficient capacity and unsafe lifting equipment. Although crushers are not precision-adjusted equipment like car engines, the internal parts of the crusher must be assembled and disassembled using lifting equipment. The crane should be able to lift and lower various parts of the crusher smoothly and slowly to assemble the crusher. When using a crane, always work within the crane's rated load. The safe rated load of the crane includes the weight of the hook, pulley block, and suspension devices, such as wire ropes, slings, and levers. Subtract the weight of these devices to determine the true safe load weight. Chain hoists are only a last resort for disassembling and assembling crushers.
Where safety is concerned, the best measures should be adopted.
When using a mobile crane, the crane must operate within its rated load to avoid boom deformation or overturning. The safe rated load is based on the premise that the crane is working on firm, level ground. The boom should be properly extended and lowered as much as possible. Avoid rapid rotation, lifting, or sudden braking, as this can overload the crane. Do not lift large heavy objects in high wind conditions.
Before a mobile crane crosses a bridge, first check the bridge load capacity. Check clearance under bridges, such as for overhead power lines or any other obstacles.
Check your surroundings before lifting. Ensure there are no obstacles around the object to be lifted. Ensure the connection between the crane and the object is secure.
Appropriate protective measures are generally required when performing gas cutting or welding because many metals pose dangers to human health. Anyone performing such operations should avoid breathing fumes. Such operations should be performed outdoors or in well-ventilated areas equipped with machinery to provide clean air separately or with local fume extraction facilities.
Please refer to applicable OSHA or MSHA standards. One of the most used tools for crushers is the cutting torch. When performing welding or cutting operations, depressurize hydraulic components on crushers equipped with hydraulic devices and cover them with fire-resistant materials to prevent welding sparks or spatter from contacting these components. If a high-pressure hydraulic line ruptures, the liquid will rapidly vaporize in the atmosphere. This vaporized liquid can ignite quickly, causing severe burns to nearby personnel. If hydraulic components are near the work area, be sure to notify all
personnel using cutting equipment, then take necessary measures to avoid contact with these components. Cutting equipment is for normal workshop maintenance and should not be used for rubber hoses.
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All parts of the crusher must be lifted slowly and smoothly by lifting gear and moved within the maximum rated load of the lifting gear. Remember the safe rated load includes the weight of chains, hooks, and other lifting accessories, and the weight of the crusher.
Do not use conveyor belts as walkways. Pedestrian walkways should be provided alongside conveyors to and from the crusher. As an additional safety measure, handrails should also be installed along the conveyor access.
If the crusher consists of mobile equipment, that is, crushing and screening equipment mounted on trailers, then the trailer's foundation or support is extremely important for safe production. Check the trailer's foundation. The equipment should be mounted on as firm and level a foundation as possible. Use cribbing as needed to raise the trailer's wheels off the ground. Place a screw jack at each of the four corners or near the four corners of the trailer. The four jacks must be equidistant from the corners. Adjust the jack heights so that the trailer beam support stops vibrating or minimizes vibration. Never park the trailer in low-lying areas where rainwater can wash away the foundation. Regularly复查 the trailer foundation to ensure it is stable.
Before a trailer crosses a bridge, check whether the bridge can bear the weight of the equipment. When passing under bridges, check the clearance height under the bridge, such as: overhead lines, or other obstacles. Heavy loads approaching the bridge's capacity must never cross the bridge. Check local regulations, especially weight restrictions.
When driving on highways, ensure headlights, brake lights, and taillights are working properly. Use correct transport warning flags and signs.
Crushing equipment naturally produces noise. Auxiliary equipment around the crusher, such as chutes, transfer points, screens, etc., can produce noise many times greater than the crusher itself.
Typical crusher sound power levels during crushing operations are between 100-130 DBA. If the noise exceeds legally permitted levels, hearing protection should be used. If hearing protection still does not meet requirements, consider reducing the time maintenance personnel or operators stay in the noise. In other words, shorten working hours.
Attempting to reduce noise by changing the machine itself is economically unfeasible. Many operators find that building a relatively inexpensive operator's cabin can improve noise conditions. In this cabin, the operator can see the operating equipment, and installing soundproof tiles, double-glazed windows, air conditioning equipment, etc., can protect the operator from noise hazards. These working conditions inevitably improve operating efficiency and reduce the potential harm of noise.
Many crushing plant operators find that building an operator's tower above most equipment provides a safe place for operators and improves the efficiency of the crushing plant.
All crushers require some kind of filler when replacing crushing components. Resins like epoxy filler can avoid the possibility of accidental burns to staff caused by splashing and explosion when molten metal contacts damp surfaces. Using plastic filler is convenient and has a high safety factor, making the use of molten metal for crusher liner filler obsolete.
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When using epoxy filler, operate carefully when disassembling the crusher using gas cutting methods. The work area must be well ventilated because epoxy fumes are nauseating and irritating to the eyes and skin.
Crushing equipment and auxiliary equipment such as chutes, transfer points, screens, etc., themselves generate dust, which will affect the air if not extracted. Inhaling large amounts of dust can be harmful to the health of operators or personnel working above or around the equipment. Generally speaking, high concentrations of atmospheric dust may lead to lung diseases. The degree of risk depends on the dust concentration, exposure time, and the type of material being crushed. It strongly recommends the use of dust control equipment, and anyone exposed to airborne dust should wear dust masks. OSHA, MSHA, or local laws may require the use of dust control equipment and dust alarms. The operator should decide under what circumstances to use such dust control equipment and dust alarms. Ensure that dust control equipment and dust alarms are used as required.
By making some changes to the crushing circuit, such as adding a dust collection system or using water spray pipes at the feed inlet and/or discharge conveyor, the amount of airborne dust can be reduced. Using a dead zone hopper during crushing operations can also reduce the amount of dust coming from the crusher itself.
During daily operation, certain maintenance work must be performed in the area around the crusher. The following items should be considered part of the normal operating rules for the crusher, indicating what should and should not be done.
Do not perform maintenance work on running machinery. This includes adding lubricating oil or grease to running crusher components.
Do not place hands or feet on the crusher's tramp release hydraulic cylinders while the crusher is running. This device is used to protect the crusher when tramp material occurs during operation.
Maintain equipment according to the manufacturer's recommended periodic inspection procedures. These procedures are not only to avoid damaging the equipment but also to avoid injuring the operator.
Prevent the crusher from throwing rocks around, which is caused by feeding overly large rocks into the crushing chamber, etc. Plant operators must ensure there is no rock splash around the crusher to avoid injuring unprepared passersby.
Absolutely do not look into the crushing chamber while the crusher is running if measures have not been taken to prevent material splash.
Ensure the work area is clear of people when using a crane to lift or lower a load.
Do not walk, stand, stroll, or lie under a load suspended by a crane.
When cooling various parts of the crusher, take appropriate safety precautions when handling dry ice, liquid nitrogen, or any other cryogenic refrigerant. Please refer to applicable MSHA and OSHA standards. Failure to take correct precautions may result in serious physical injury.
Remember—Safety is Your Responsibility!
HP100/200/300/400/500 Cone Crusher Operation Manual 0-8
The HP cone crusher is a compression type crusher, typically used in secondary, tertiary, or quaternary crushing stages in the aggregate and mining industries. The HP cone crusher is known for its high capacity and excellent product shape.
Whether you are involved in just starting up, operating, or servicing an HP cone crusher, this manual provides valuable information to help you achieve the best possible results from your crusher.
The HP cone crusher series is designed to provide:
High performance - Higher capacity and better quality
Low operating costs - Easy maintenance and wear part replacement
Versatility - A wide range of crushing cavities for different applications
Advanced automation - Possibility to fully automate the crusher operation
Reliability - Robust design with quality components
The main components of the HP cone crusher are:
Main frame
Adjustment ring
Head
Bowl
Eccentric assembly
Socket assembly
Pinion shaft housing
Pinion shaft and sheave assembly
Lubrication system
Hydraulic system
Drive system
Each component plays a vital role in the crusher's operation and will be described in detail in subsequent chapters.
The HP cone crusher utilizes the compression crushing principle. Rock is compressed between a stationary bowl liner and a gyrating mantle. The crushing action is caused by the closing of the gap between the mantle line (movable) mounted on the central vertical spindle and the concave liners (fixed) mounted on the main frame of the crusher.
The gap is opened and closed by an eccentric assembly that causes the central vertical spindle to gyrate. The vertical spindle is free to rotate around its own axis. The crusher is set by determining the smallest distance between the mantle and bowl liner at the bottom of the crushing chamber (closed side setting).
The crushing chamber is the area between the concave liners and the mantle. The shape of the crushing chamber has a significant impact on capacity, product gradation, power draw, and wear life. HP cone crushers are available with several different crushing chamber profiles to match the specific application, from extra coarse to extra fine.
The selection of the right crushing chamber and eccentric throw is essential for optimizing crusher performance. The crusher should always operate with a full crushing chamber for best results.
Crusher performance is measured by capacity, product gradation, power consumption, and wear life. The HP cone crusher is designed to deliver high performance in all these areas. The performance depends on:
Feed material characteristics (hardness, gradation, moisture content)
Crusher setting (closed side setting)
Crusher speed (rpm)
Crushing chamber selection
Feed arrangement
Power available
The capacity of an HP cone crusher is affected by the crusher setting, the crusher speed, the size and shape of the feed material, and the characteristics of the rock itself. Capacity tables in Chapter 5 provide estimated capacities for different crusher settings and chamber configurations under specific conditions.
It is important to note that these capacities are approximate and can vary significantly based on actual operating conditions. The crusher should be operated with a full crushing chamber to achieve maximum capacity and the best product shape.
The power required to operate an HP cone crusher depends on the hardness of the feed material, the crusher setting, the crusher speed, and the crushing chamber design. The crusher motor must be sized to provide sufficient power for the expected operating conditions.
The power draw of the crusher is monitored to ensure the crusher is operating within its designed power range. Overloading the crusher can lead to premature wear and potential damage, while underloading can result in poor product shape and reduced capacity.
The HP cone crusher can be driven by either V-belts or a direct drive coupling. The drive system transmits power from the motor to the crusher's pinion shaft, which in turn drives the eccentric assembly.
Proper belt tension is critical for efficient power transmission and long belt life. The crusher sheave is designed for a specific maximum rim speed. Exceeding this speed can cause the sheave to rupture, leading to serious accidents.
A forced-feed, closed-loop lubrication system is used to lubricate the crusher's internal components. The system includes a pump, filters, a heat exchanger, and various safety devices. The lubrication system is critical for crusher operation and must be properly maintained.
The correct type and grade of lubricating oil must be used, and the oil must be kept clean and at the proper operating temperature. Chapter 4 provides detailed information on lubrication requirements and maintenance.
The hydraulic system is used for several functions, including:
Adjusting the crusher setting
Clearing the crushing chamber in the event of a power failure or mechanical overload (tramp release)
Locking the adjustment ring during operation
Supporting the upper section of the crusher during liner changes
The hydraulic system is powered by an electric motor and pump. System pressure is maintained by accumulators. Chapter 6 provides detailed information on the hydraulic system.
The crusher setting is the closed side setting (CSS), which is the smallest distance between the mantle and the bowl liner at the bottom of the crushing chamber. The CSS determines the product size and has a major influence on capacity, power draw, and wear life.
The CSS can be adjusted by rotating the bowl or the main shaft, depending on the crusher model. The adjustment is made using the hydraulic system. It is important to check and adjust the CSS regularly to compensate for liner wear and to maintain consistent product quality.
Modern HP cone crushers can be equipped with advanced automation systems that monitor and control crusher operation. These systems can optimize crusher performance, protect the crusher from damage, and provide valuable operating data.
Basic crusher controls include:
Main drive motor start/stop
Lubrication system controls
Hydraulic system controls
Setting adjustment controls
Safety interlocks
Automation systems can add features such as:
CSS measurement and control
Power draw monitoring
Crusher overload protection
Wear part tracking
Remote monitoring and control
Proper use of crusher controls is essential for safe and efficient operation.
2.1 - Foundation
2.1 - Foundation
2.2 - Crusher Assembly
2.3 - Lubrication System Installation
2.4 - Hydraulic System Installation
2.5 - Electrical Installation
2.6 - Pre-Startup Checks
A solid foundation is essential for the stable operation of the crusher. The foundation must be designed to support the weight of the crusher and the dynamic loads generated during operation. The foundation should be made of high-quality concrete and should be isolated from the surrounding structure to minimize vibration transmission.
The foundation drawing provided with the crusher must be followed precisely. The foundation bolts should be of the correct size and grade and should be properly grouted into the foundation. Allow the concrete to cure fully before tightening the foundation bolts.
The crusher is typically shipped in several major assemblies. The assembly sequence is critical for correct installation. The main steps in crusher assembly are:
Place the main frame on the foundation and align it.
Install the eccentric assembly into the main frame.
Install the socket assembly and head.
Install the bowl and adjustment ring assembly.
Install the pinion shaft housing and pinion shaft.
Install the drive sheave and V-belts or coupling.
Install the lubrication system components.
Install the hydraulic system components.
All components must be clean and free of damage before assembly. Use the correct lifting equipment and follow the recommended procedures to avoid injury and damage to the equipment.
The lubrication system includes the oil tank, pump, filters, heat exchanger, and piping. The system must be installed according to the provided drawings. All piping should be clean and free of obstructions. Use the recommended type and grade of oil.
After installation, fill the system with oil and check for leaks. Prime the pump and ensure that oil flows to all lubrication points. Check the oil pressure and temperature gauges for proper operation.
The hydraulic system includes the hydraulic power unit, cylinders, accumulators, and piping. Install the system according to the provided drawings. All hydraulic components must be clean during assembly. Use the recommended hydraulic fluid.
After installation, fill the system with fluid and bleed air from the cylinders and piping. Check for leaks and ensure that the system operates smoothly. Set the relief valves to the specified pressures.
The electrical installation must be performed by qualified electricians in accordance with local electrical codes. The crusher motor, lubrication pump motor, and hydraulic pump motor must be connected to the power supply with the correct voltage and phase.
All control wiring should be installed according to the wiring diagrams. Safety interlocks must be connected and tested to ensure they function correctly. Ground all electrical components properly.
Before starting the crusher for the first time, perform the following checks:
Verify that all foundation bolts are tight.
Check that all crusher components are properly assembled and tightened.
Ensure that the lubrication system is filled with oil and that oil flows to all points.
Ensure that the hydraulic system is filled with fluid and that all functions operate correctly.
Check the V-belt tension or coupling alignment.
Rotate the crusher by hand to ensure that it turns freely.
Verify that all guards are in place and secure.
Check that all electrical connections are tight and correct.
Ensure that the crusher setting is correct.
Review the operating manual with all personnel who will operate the crusher.
Only after all pre-startup checks are completed satisfactorily should the crusher be started.
3.1 - Pre-Startup Procedure
3.2 - Startup Procedure
3.3 - Operation Monitoring
3.4 - Shutdown Procedure
3.5 - Emergency Shutdown
Before starting the crusher each day, or at the beginning of each shift, perform the following checks:
Walk around the crusher and visually inspect for any obvious problems, such as oil leaks, loose parts, or damaged components.
Check the oil level in the lubrication system tank. Add oil if necessary.
Check the hydraulic system fluid level. Add fluid if necessary.
Check the drive belt tension or coupling condition.
Ensure that the crushing chamber is empty. Never start the crusher with material in the crushing chamber.
Check the crusher setting (CSS) if possible.
Ensure that all guards are in place and secure.
Verify that the area around the crusher is clear of personnel and obstacles.
Start the crusher in the following sequence:
Start the lubrication system pump and allow it to run for at least 5-10 minutes to circulate oil to all bearing surfaces. Verify that oil is flowing and that the oil pressure is within the specified range.
Start the hydraulic system pump and verify that the system pressure is correct.
Start the main crusher drive motor.
Allow the crusher to run empty for at least 2-3 minutes to ensure that everything is operating normally. Listen for unusual noises and monitor the ammeter for abnormal power draw.
Begin feeding material into the crusher slowly and gradually increase the feed rate to the desired level. The crusher should always be operated with a full crushing chamber for best performance.
WARNING: Never start the crusher without first starting the lubrication system. Severe damage to the crusher will occur.
During operation, continuously monitor the following parameters:
Oil pressure: The lubrication system oil pressure should remain within the specified range. A drop in oil pressure may indicate a problem with the pump, a clogged filter, or a leak.
Oil temperature: The oil temperature should be maintained within the specified range. High oil temperature may indicate a problem with the heat exchanger or overloading of the crusher.
Hydraulic pressure: Monitor the hydraulic system pressure to ensure it is correct for the current operation.
Power draw: The ammeter reading indicates the power being used by the crusher. A sudden increase may indicate an overload condition, while a sudden decrease may indicate a loss of feed.
Product size: Regularly sample the crusher product to ensure it meets specifications. Adjust the crusher setting if necessary.
Feed rate: Maintain a consistent and appropriate feed rate to keep the crushing chamber full without overloading the crusher.
Unusual noises: Listen for any unusual noises such as knocking, grinding, or squealing, which may indicate a problem.
Record operating parameters regularly to track crusher performance and identify trends that may indicate developing problems.
Shut down the crusher in the following sequence:
Stop feeding material to the crusher.
Allow the crusher to run empty for at least 2-3 minutes to clear the crushing chamber of all material.
Stop the main crusher drive motor.
Allow the lubrication system to continue running for at least 5-10 minutes after the crusher has stopped to cool the bearings and circulate oil.
Stop the lubrication system pump.
Stop the hydraulic system pump if it is not needed for other functions.
NOTE: In cold climates, it may be necessary to use oil heaters to maintain the oil temperature during shutdown periods to facilitate easy starting.
In case of an emergency, such as a person caught in the crusher, a serious oil leak, or other immediate danger, use the emergency stop buttons to shut down the entire crusher system immediately.
Emergency stop buttons are located at strategic points around the crusher. Know the location of these buttons before operating the crusher.
After an emergency shutdown, investigate and correct the cause of the emergency before restarting the crusher.
WARNING: Do not attempt to clear a jammed crusher or perform any maintenance until the crusher is completely stopped and the power is locked out.
4.1 - Daily Inspection
4.2 - Weekly Inspection
4.3 - Monthly Inspection
4.4 - Lubrication Maintenance
4.5 - Liner Change Procedure
4.6 - Seasonal Maintenance
Perform these checks at the beginning of each shift or daily:
Check for oil leaks in the lubrication and hydraulic systems.
Check oil level in the lubrication system tank.
Check hydraulic fluid level.
Check drive belt tension and condition.
Listen for unusual noises during operation.
Monitor oil pressure and temperature.
Check for excessive vibration.
Inspect the product size and adjust the setting if necessary.
Perform these checks weekly:
Check the condition of the lubrication system filters. Change if necessary.
Inspect the hydraulic system for leaks and proper operation.
Check all guards for security and damage.
Inspect the crushing chamber liners for wear (if possible).
Check the condition of the drive sheave and belts.
Lubricate all grease points as specified.
Perform these checks monthly:
Take oil samples from the lubrication system for analysis.
Check the crusher setting and adjust if necessary.
Inspect the internal components through inspection openings if available.
Check the condition of the eccentric bushing and other wear parts.
Inspect the foundation bolts for tightness.
Check all electrical connections for tightness.
Proper lubrication is critical for crusher longevity. Follow these guidelines:
Use only the recommended type and grade of oil.
Change the oil and filters at the recommended intervals, or based on oil analysis.
Keep the oil clean and free of contamination.
Maintain the proper oil level in the tank.
Ensure that the oil cooler is functioning properly.
Refer to the lubrication guide in the manual for specific intervals and specifications.
Liners will need to be replaced when they are worn. The procedure for changing liners varies by crusher model but generally involves the following steps:
Shut down and lock out the crusher.
Drain the lubrication and hydraulic systems if necessary.
Remove the feed hopper and distribution plate.
Use the hydraulic system to loosen the bowl and adjustment ring.
Use a crane to remove the bowl assembly.
Remove the old liners and install new ones.
Reassemble the crusher in reverse order.
Refill with oil and check for leaks.
Always use the correct lifting equipment and follow the detailed procedures in the manual.
In addition to regular maintenance, perform these tasks seasonally or during scheduled shutdowns:
Thoroughly inspect all crusher components for wear and damage.
Check the alignment of the crusher and drive.
Inspect and repair the lubrication and hydraulic systems as needed.
Check and tighten all bolts and fasteners.
Paint exposed surfaces to prevent corrosion.
Update maintenance records and plan for future parts replacements.
A well-maintained crusher will provide years of reliable service with minimal downtime.
5.1 - Bowl, Bowl Liner, and Feed Hopper Assembly
5.1 - Bowl, Bowl Liner, and Feed Hopper Assembly
5.2 - Head, Head Liner, and Distributor Plate Assembly
5.3 - Socket Assembly
5.4 - Eccentric Assembly
5.5 - Pinion Shaft Housing, Pinion Shaft, and Sheave Assembly
5.6 - Main Frame, Adjustment Ring, and Tramp Release Assembly
5.7 - Lubrication System
The bowl is the stationary part of the crusher that holds the bowl liner. The bowl liner is the wearing surface that comes into contact with the rock. The feed hopper directs material into the crushing chamber.
Key points for operation:
Ensure that the bowl liner is properly seated and locked in place.
Use the correct bowl liner for the application (coarse, medium, fine).
Check the bowl liner regularly for wear and replace when necessary.
Keep the feed hopper clear of obstructions.
The head is the moving part of the crusher that holds the mantle (head liner). The head gyrates within the bowl, compressing the rock. The distributor plate helps to distribute the feed evenly around the crushing chamber.
Key points for operation:
Ensure that the mantle is properly seated on the head.
Use the correct mantle for the application and bowl liner.
Check the mantle regularly for wear and replace when necessary.
Ensure that the distributor plate is in good condition and properly installed.
The socket assembly provides a bearing surface for the gyrating head. It is lubricated under pressure from the lubrication system.
Key points for operation:
Ensure that the lubrication system is providing adequate oil to the socket assembly.
Monitor for unusual noises that may indicate socket wear.
The socket liner should be replaced if worn beyond specifications.
The eccentric assembly causes the head to gyrate. It consists of an eccentric bushing, eccentric throw, and various bearings.
Key points for operation:
The eccentric throw determines the crusher's stroke and affects capacity and product gradation.
Ensure that the lubrication system is providing adequate oil to the eccentric bearings.
Monitor for excessive vibration that may indicate eccentric problems.
The pinion shaft is driven by the motor (via belts or coupling) and drives the eccentric assembly. The sheave is part of the drive system.
Key points for operation:
Check the pinion shaft bearings for proper lubrication.
Monitor the drive belts for proper tension and wear.
Ensure that the sheave is securely attached to the pinion shaft.
Check the alignment of the drive system.
The main frame supports the entire crusher. The adjustment ring holds the bowl and allows for setting adjustment. The tramp release system protects the crusher from damage due to uncrushable material.
Key points for operation:
Check the main frame for cracks or damage.
The adjustment ring threads should be kept clean and lubricated.
The tramp release system should be tested regularly to ensure it functions correctly.
Know the procedure for resetting the crusher after a tramp release event.
The lubrication system is critical for crusher operation. It provides oil to all bearing surfaces.
Key points for operation:
Monitor oil pressure and temperature continuously.
Change oil and filters at recommended intervals.
Keep the oil clean and free of water and contaminants.
Ensure that the oil cooler is functioning properly.
Know the location of all lubrication points and check them regularly.
6.1 - System Overview
6.2 - Setting Adjustment
6.3 - Tramp Release Function
6.4 - Locking Function
6.5 - Maintenance
The hydraulic system on the HP cone crusher is used for several important functions:
Adjusting the crusher setting (closed side setting)
Releasing tramp material to protect the crusher from damage
Locking the adjustment ring during operation
Supporting the upper assembly during liner changes
The system consists of a hydraulic power unit, cylinders, accumulators, valves, and piping. System pressure is maintained by nitrogen-charged accumulators.
The crusher setting is adjusted by rotating the bowl or the main shaft hydraulically. The procedure is:
Ensure the crusher is running and the hydraulic system is pressurized.
Use the control valve to activate the setting adjustment cylinders.
Monitor the setting indicator to achieve the desired CSS.
Lock the adjustment ring in place after adjustment.
Always check the CSS with lead or measurement tools after adjustment to verify the setting.
The tramp release system automatically protects the crusher if uncrushable material enters the crushing chamber. When excessive force is applied, the hydraulic cylinders allow the adjustment ring to lift, opening the crusher setting and releasing the material.
After a tramp release event, the crusher must be reset:
Stop the crusher and ensure the crushing chamber is empty.
Use the hydraulic system to lower the adjustment ring back to its operating position.
Check the crusher setting and adjust if necessary.
Resume operation.
WARNING: Never attempt to clear a jammed crusher or perform any maintenance until the crusher is completely stopped and the power is locked out.
The hydraulic system is used to lock the adjustment ring during operation to prevent movement and maintain a consistent setting. The locking cylinders apply force to keep the adjustment ring securely positioned against the main frame.
Ensure that the locking system is engaged before operating the crusher.
Regular maintenance of the hydraulic system is essential for reliable operation:
Check hydraulic fluid level regularly.
Inspect hoses and fittings for leaks and damage.
Check accumulator precharge pressure periodically.
Change hydraulic fluid and filters at recommended intervals.
Keep the system clean and free of contaminants.
7.1 - Low Oil Pressure
7.2 - High Oil Temperature
7.3 - Excessive Vibration
7.4 - Unusual Noises
7.5 - Power Draw Problems
7.6 - Product Quality Issues
7.7 - Hydraulic System Problems
Possible causes:
Low oil level in the tank
Clogged oil filter
Faulty oil pump
Leak in the oil system
Worn bearings
Incorrect oil viscosity
Actions:
Check oil level and add oil if necessary.
Check and replace the oil filter.
Inspect for leaks and repair.
Check oil pump performance.
Use the correct grade of oil.
Possible causes:
Insufficient oil flow
Faulty oil cooler
High ambient temperature
Crusher overload
Incorrect oil viscosity
Actions:
Check oil flow and pressure.
Clean or repair the oil cooler.
Reduce crusher load if necessary.
Use the correct grade of oil.
Possible causes:
Unbalanced rotating parts
Worn bearings
Loose components
Incorrect crusher setting
Improper feed distribution
Actions:
Check and tighten all bolts.
Inspect bearings for wear.
Check crusher setting.
Ensure even feed distribution.
Balance rotating parts if necessary.
Possible causes:
Loose or broken parts
Worn liners
Foreign material in crushing chamber
Lack of lubrication
Actions:
Stop the crusher immediately if serious noises are heard.
Inspect the crushing chamber for foreign objects.
Check liners for wear and damage.
Check lubrication system.
Tighten or replace loose or broken parts.
High power draw:
Overloading the crusher
Too small crusher setting
Hard feed material
Mechanical problems
Low power draw:
Loss of feed
Too large crusher setting
Soft feed material
Actions:
Adjust feed rate.
Adjust crusher setting.
Check for mechanical issues.
Oversize product:
Crusher setting too large
Worn liners
Incorrect liner type
Poor product shape:
Incorrect crusher setting
Improper feed distribution
Worn liners
Actions:
Check and adjust crusher setting.
Inspect liners and replace if worn.
Ensure even feed distribution.
Select the correct liner profile for the application.
Low hydraulic pressure:
Low fluid level
Faulty pump
Leaks in the system
Faulty relief valve
Slow operation:
Low fluid level
Contaminated fluid
Faulty pump
Actions:
Check fluid level and add if necessary.
Inspect for leaks and repair.
Check and replace filters.
Test pump performance.
Use the correct hydraulic fluid.
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