Note: When lifting the entire crusher, use wire ropes of sufficient strength with correct lifting points on the lifting lugs of the main frame.
Lift from the main frame assembly.
Note: Main frame liners and armor plates should be inspected regularly, at least during each liner change.
Main frame liners for HP700, HP800
Main frame liner clamps
Note: HP700 and HP800 main frame liners are bolted in place.
Note: Main frame liners and armor plates should be inspected regularly, at least during each liner change. Do not patch worn plates; replace them.
Note: New "U" seals on the main frame must be properly positioned. Test fit the seal before applying adhesive to ensure correct alignment. Do not force the seal into the groove.
Use Loctite adhesive No: 20252.
Main Frame "U" Seal
Note: The HP100 "U" seal consists of two flat plastic straps that glue into their respective grooves of the main frame center casting. The adhesive used is Loctite Depend No: 20252.
BROUILLON DE PIEU PRINCIPAL
Results of main frame pin wear
Note: Wear on the main frame seat cone surface, main frame pin, and main frame pin bushing will eventually exert force on the tramp release cylinder rods, causing cylinder oil leakage.
Seal oil leakage
Note: Main frame seats are used on all crusher models. Made of bronze material to protect the steel main frame seat surface and steel adjustment ring seat surface from wear.
Determining main frame seat wear
Note: Measure the original dimension after installing or replacing the main frame seat. If this dimension has decreased by 8 mm, it should be replaced immediately.
Worn main frame seat
Note: Frequent crushing force overload (adjustment ring bouncing) will cause wear on the main frame pin bushing and main frame seat.
Most HP crushers tramp release system
Tramp release system
Tramp release pressure release pressure
Note: Nitrogen pre-charge pressure should be checked every 30 days. Allowable deviation is ±50 PSI from the values in the table.
Crusher nitrogen pre-charge pressure
Note: During installation, the release cylinder rod must be pulled out the correct distance to avoid the piston hitting the cylinder bottom. Apply Loctite 242 to the spherical nut.
Crusher screw extension length inches (mm) flush with spherical nut top surface
Release cylinder installation 3/4" (20 mm) 9/16" (15mm) HP100
Note: Threads must be cleaned with non-oily cleaner. Apply Loctite 242 to threads.
Note: When the locking cylinder is pressurized, the locking hydraulic cylinder expands the locking ring to disengage from the adjustment ring, thus locking with the bowl threads.
HP (except HP100) pump start @ 2400 PSI pump stop @ 2800 PSI
Omnicone pump start @ 2100 PSI pump stop @ 2500 PSI
HP100 pump start @ 235 PSI pump stop @ 365 PSI locking tube bladder HP100
HP100 pump start @ 235 PSI pump stop @ 365 PSI
Dust collar adjustment ring main frame tramp release cylinder
Note: Lubricate set screws. Heat the sheave evenly from the outside.
Note: The main frame needs to be heated to 100°F (55°C) above ambient temperature to loosen the interference fit between the horizontal shaft housing and the main frame.
Note: Horizontal shaft bushings can be removed from the housing using the methods shown above. After removal, check the housing bore dimensions.
Horizontal shaft bushing removal
Note: Outer bushings can be removed using custom puller devices. After removal, check housing bore dimensions.
Horizontal shaft bushing removal
Note: Inner bushings can be removed by hammering using a center rod/plate device. After removal, check housing bore dimensions.
Note: Horizontal shaft bushings must be shrunk with dry ice for at least 2 hours, requiring 50 lbs (22 kgs) of dry ice.
Horizontal shaft bushing installation
Note: Horizontal shaft bushings must be shrunk with dry ice for at least 2 hours. Do not forget to install set screws, which require Loctite 242.
Note: The horizontal shaft can be removed using a horizontal shaft wrench and pinion wrench. The pinion has right-hand threads screwed onto the horizontal shaft.
Threaded pinion
Note: The horizontal shaft can be removed using a horizontal shaft wrench and pinion wrench. The pinion has right-hand threads screwed onto the horizontal shaft.
Note: The oil groove of the inner bushing is always installed at the highest point of the housing (12:00 position). No exceptions.
Inner bushing horizontal shaft housing inner bushing 12:00 position
Horizontal shaft bushing oil groove position 45º 45º
Note: Outer bushings are normally installed at the bottom of the housing (6:00 position). If the drive motor is mounted below the horizontal shaft, the oil groove needs to be at the 12:00 position.
6:00 position 12:00 position outer bushing
Pinion horizontal shaft bushing oil slinger horizontal shaft
Note: Axial oil clearance must be provided when assembling the horizontal shaft housing. Proper axial oil clearance prevents heat buildup in horizontal shaft bushings during operation.
Axial oil clearance
Crusher axial clearance (mm)
Step 1
How to provide axial oil clearance
Note: Heat the oil slinger to 50°F (27°C) above ambient temperature. Using leather gloves, push it onto the horizontal shaft. Use a feeler gauge set to the appropriate thickness to set the axial oil clearance.
How to provide axial oil clearance
Note: After the oil slinger cools, remove the feeler gauge and carefully install the oil slinger seat and lip seal. Make sure not to disturb the set axial oil clearance.
How to provide axial oil clearance
Note: Carefully install the crusher sheave taper bushing, which will finally lock the axial oil clearance. Do not lubricate the taper bushing.
Crusher sheave sheave taper bushing pinion oil slinger horizontal shaft Step 4
Crusher sheave self-locking QD taper bushing Type 1
Crusher sheave sheave taper bushing horizontal shaft
Crusher sheave spacer ring
Crusher sheave sheave taper bushing horizontal shaft Type 2 self-locking taper bushing
Note: Coupling alignment is very important, and the two coupling halves should not contact during operation. In direct drive mode, the bushing oil groove position is always outer bushing at 6:00 position and inner bushing at 12:00 position.
Note: The inner side of the horizontal shaft housing is sealed by an "O" ring. This "O" ring should be replaced every time the horizontal shaft housing is removed.
Frame ring main frame "O" ring
Note: Inner and outer contact surfaces must be cleaned and lubricated. Heat the frame to 55°C above ambient temperature. Jacking bolts are needed in this step to pull the housing in until the bolts are tight. Lubricate jacking bolt threads to prevent over-tightening.
Horizontal shaft housing installation
Note: When the jacking bolts reach their limit, remove the bolts, add some shims, and further pull the housing into the main frame until the jacking bolts again reach their limit.
Horizontal shaft housing installation
Note: Finally, remove the jacking bolts and use the original bolts to tighten the housing into position. When completed, the housing flange and main frame flange should be tight together.
Assemblage excentrique
Note: The eccentric should be lifted using eccentric lifting rings, with two eye bolts screwed into the thick and thin sides of the eccentric. Before disassembling the eccentric assembly, the spherical seat must be removed first.
Note: After drilling out the locking compound, the bushing can be removed.
Eccentric bushing removal
Note: Turn the eccentric upside down, and the bushing can be hammered or pressed out.
Note: Significant heat is required to blacken the bushing. Regardless of the reason, if the bushing is overheated as shown, the overheating will certainly damage the eccentric bore. For this reason, before installing a new bushing, the eccentric bore dimensions and any cracks must be checked.
Note: Check the eccentric bore with an inside micrometer. If the bore is found to be deformed, contact rock machinery for confirmation.
Note: Eccentric bushings need to be cooled with dry ice for at least 2 hours, requiring about 90 kg of dry ice. When pouring locking compound, the eccentric and bushing must be at room temperature of about 70°F (21°C). The oil holes of the eccentric and bushing must be aligned.
Original groove depth minimum groove depth
Crusher original dimension minimum dimension
Minimum groove width original groove width
Crusher original dimension minimum dimension
Note: The currently used counterweight guard and plate structure is shown. When replacing, simply loosen the bolts for removal.
Counterweight guard and plate
Note: Counterweight guards and plates should be inspected daily for wear. The light side of the counterweight can be filled with foam material to prevent dust accumulation.
Note: Counterweight "T" and "U" seals are part of the counterweight. Previously designed seals were glued to the counterweight. Currently, the "U" seal on the main frame and the "T" seal on the head are still glued.
Note: The goal is to achieve proper backlash while maintaining tip clearance not less than the minimum tip clearance.
Gear & pinion meshing
Note: The goal is to achieve proper backlash while maintaining tip clearance not less than the minimum tip clearance.
Crusher backlash actual tip clearance maximum tip clearance minimum tip clearance mm mm mm mm
Note: When the oil groove wears to a depth of 2.5 mm, the spherical seat should be replaced. The oil groove depth of a new spherical seat is 6 mm. Check the oil groove depth during each liner change.
Note: Spherical seat life can be measured in years. Lifespan depends on many factors including whether the lubricating oil is clean.
Spherical seat removal
Note: The spherical seat needs to be heated to above ambient temperature (as shown in the table above) to loosen the interference fit.
Crusher above ambient temperature
Note: The spherical seat must be uniformly heated to above ambient temperature (temperature as shown in the table above).
Crusher above ambient temperature
Make sure the spherical seat is tight! Note: After the spherical seat housing is installed in place, use a feeler gauge to check if the spherical seat is installed correctly. There should be no gap between the lower surface of the spherical seat housing and the top surface of the main shaft.
Spherical seat installation
Note: The spherical seat needs to be shrunk with dry ice for at least 2 hours, requiring 22 kg of dry ice.
Note: Eye bolts must be screwed into the high side of the head. The high side of the head corresponds to the thick side of the eccentric.
Eye bolts
Eye bolts thick side of eccentric
Note: Eye bolts must be on the same side as the thick side of the eccentric. The high side of the head corresponds to the thick side of the eccentric.
Note: The cutting torch should be at an angle to the locking ring to avoid damaging the threads of the lock nut.
Note: The split nut is an old design lock nut.
Feed distributor locking ring bolts (600 ft lbs) lock nut feed distributor bolts bolts old design HP lock nut lock nut feed distributor current design feed distributor bolts silicone rubber
Note: The lock nut is one piece. The lock nut, locking ring, and head liner need to be welded together.
Note: Do not use the lock nut to compact misaligned head liners. Before starting to tighten the nut, measure the gap between the locking ring and lock nut to ensure it is even. After the liners are tightened, heat the head contact surface to the following temperature before tightening the lock nut. HP100 crusher does not require heating.
130°F (55°C) - HP200 & HP300
150°F - 175°F (66°C - 79°C) - All Omnicone & HP400 to HP800
Counterclockwise = tight Clockwise = loose
Note: Before installing new head liners, apply lubricating oil to the head surface to prevent the compound from sticking to the head. HP100 crusher does not require compound.
Filling hole locking ring maximum gap 0.25 mm maximum gap 0.25 mm
Note: Remove the safety bolts. Hammer or press out the worn or damaged head ball assembled with the head. If the head ball is difficult to remove, heat the head area just outside the head ball to approximately 100°F (55°C) above ambient to relieve the interference fit.
Note: Remove the head ball bolts. Ram or press worn or damaged head ball out of the head fit area. If the head ball is difficult to remove, warm the head area just outside the head ball to approximately 100°F (55°C) above ambient to relieve the interference fit.
Note: Cool the head ball in dry ice for a minimum of 2 hours. About 22 kg of dry ice is required. After cooling, check the inner diameter of the head and the outer diameter of the head ball to ensure sufficient clearance for installation. Do not forget to install the safety bolts; the threads need to be coated with Loctite 272.
Note: Cool the head ball in dry ice for a minimum of four to six hours. 50 lbs (22 kgs) of dry ice is required. After cooling, measure the bore of the head and the outside of the head ball to make sure that it has sufficiently cooled to drop right in. Don't forget to re-install the head ball bolts. The threads of these bolts should be coated with Loctite 277.
Note: The lower head bushing can be sawn off, but ensure not to damage the head bore. The head bushing can also be pulled out using the method shown in the figure. Cooling the bushing with dry ice can speed up the pulling process.
Note: Cool the head bushing with dry ice for at least 2 hours, 90 kg dry ice. When sufficiently cooled, lift the bushing with a lifting ring, using flat washers under the lifting ring to ensure the bushing edge is completely flush with the bottom edge of the head.
Head bushing lifting ring
Note: Set screw length 5/8-11 x 1.5" (HP700 length 5/8-11 x 2"). The screw needs to be coated with Loctite 277, tapped and screwed into the hole.
Concasseur
Head bushing locking
Note: When the bushing temperature returns to room temperature, install the locking screws, apply Loctite 277, and tighten to the proper torque level using a cross-tightening pattern.
Bolts and torque crusher
Note: The upper head bushing can be sawn off, but ensure that the saw blade or angle grinder does not touch the head bore. It can also be removed by pulling after cooling with dry ice. The lower head bushing must be removed before removing the upper head bushing (except HP100).
Note: Cool the upper head bushing with dry ice for at least 2 hours, about 22 kg dry ice. When sufficiently cooled, hoist it into position. Apply Loctite 277 to the locking bolt threads.
Upper head bushing lifting ring
Note: The HP100 head assembly differs from other HP models. It features a unique design with upper and lower bushings as one piece and a bronze head ball. Head bushing and head ball assembly and disassembly are the same as other crusher models.
Note: Before installing new head liners, wear and damage to the head seat must be checked. Any raised areas should be ground down.
Note: New head "T" seals need to be glued. Dry fit the seal before applying adhesive to ensure correct alignment. Do not force the seal into the seal groove. Use Loctite 000207 adhesive.
Note: The new head seal is glued into position. Dry fit the seal before gluing it in to assure proper fit up. Never force the seal into the groove. The adhesive used is Loctite Depend No: 000207.
Note: When lifting the bowl assembly, use the lifting lugs on the adjustment cap. Use proper wire ropes. Never use these lifting lugs to lift the entire crusher.
Lifting lugs blocking wood
Note: Wedges must be installed at the spiral high point position. The spiral high point position needs to be marked with a pen on the upper edge of the bowl liner before installation.
Bowl liner retention
Note: Thread wear on the bowl, adjustment ring, and locking ring can be checked using a template. Hold the template, push it flush to the bottom, and measure and record (if any) the gap between the template's bevel and the thread bevel.
Template No: 7046600101 - HP100 & HP200 79624000 - Other models.
Note: Grease should be applied to bowl threads every 40 hours. Use NLGI #1 with at least 3% molybdenum disulfide. There are 4 grease fittings on the adjustment ring.
Note: Cams on HP series crushers should be lubricated every 40 hours. Use multi-purpose EP2 grease.
Lubricant return oil temperature must be above 16ºC before starting crusher.
Run crusher without load for 2 hours. Return oil temperature should reach at least 27ºC.
Then, with sufficient feed, run crusher under load for 2 hours, achieving 50% of motor power or 65% of current.
Then, with sufficient feed, run crusher under load for 4 hours, achieving 75% of motor power or 80% of current.
After completing these 4 steps, the crusher can operate normally.
When new bushings are installed, the following steps are required:
Horizontal shaft wrench, head lock nut wrench, eye bolt, flat washer, safety block, inflation tool, head lifting plate pin, set screw
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