HP Series Cone Crusher Common Faults Analysis and Solutions

Main Unit Section

The main unit section is prone to the following problems:

Eccentric bushing burning

Moving cone bushing burning

Counterweight damage

Main frame seat damage

Common Faults - Main Unit Section:

Eccentric Bushing Burning

There are two main reasons for eccentric bushing burning:

Overload

Poor Lubrication

Main Unit Section:

Eccentric Bushing Burning - Overload

Overload can cause serious damage to the crusher. The main causes of overload are:

Tramp iron

Overly fine feed

Feed segregation

Overly wet feed

Discharge opening too small

Main Unit Section:

Eccentric Bushing Burning - Overload Symptoms:

When tramp iron is present:

Instantaneous current is too high

Adjusting ring jumps violently

When feed is too fine, segregated, too wet, or discharge opening is too small:

Prolonged high current

Frequent adjusting ring jumping

Main Unit Section:

Eccentric Bushing Burning - Poor Lubrication

Incorrect lubricant grade (Correct should be ISO Grade 150)

Insufficient lubricant quantity (Check lubrication pump capacity)

Contaminated lubricant (Dust ingress. Check breather)

Main Unit Section:

Eccentric Bushing Burning - How to judge damage:

High no-load current

Coasting time less than 45 seconds

High return oil temperature

Metal debris on return oil filter screen

Main Unit Section:

Moving Cone Bushing Burning

Reasons for moving cone bushing damage:

Intermittent feeding

Excessive no-load operation time

Poor lubrication

Main Unit Section:

Moving Cone Bushing Burning

Intermittent feeding can cause damage to the lower moving cone bushing.

During no-load operation, the moving cone and eccentric sleeve rotate rapidly in the same direction. After feeding, the moving cone rotation direction changes to slow rotation opposite to the eccentric sleeve. Frequent intermittent feeding causes the moving cone to frequently change direction and speed, leading to collision and damage between the moving cone bushing and the eccentric sleeve.

Main Unit Section:

Moving Cone Bushing Burning

Excessive no-load operation can damage the upper moving cone bushing.

Under load, the upper moving cone bushing rolls against the spherical seat, resulting in line contact.

During no-load operation, the moving cone swings due to its large weight. The collision between the upper bushing and the spherical seat can damage the upper moving cone bushing.

Main Unit Section:

Counterweight Damage

Reason:

Counterweight damage is mainly caused by poor discharge, material buildup on ribs and horizontal shaft. The buildup wears out the counterweight guard plate, which is not replaced in time.

Phenomenon:

After counterweight wear, imbalance occurs, causing severe crusher vibration.

Consequence:

Long-term use can cause serious damage to the crusher.

Main Unit Section:

Counterweight Damage

Reasons for material buildup:

Overly wet feed easily causes buildup.

Foreign objects in feed (wood, roots, belts, etc.) easily cause buildup.

Adding 4 square steels outside the counterweight guard plate is a simple and easy method for protection.

Main Unit Section:

Main Frame Seat Damage

Reason

Frequent adjusting ring jumping.

Main Unit Section:

Main Frame Seat Damage - Repair:

Many customers report that the main frame seat is difficult to weld onto the main frame, mainly due to not mastering the welding process. Pay attention to the following points:

Thoroughly clean the welding area.

Preheat before welding (100°C).

Weld from the center towards both sides.

Must keep warm after welding.

Hydraulic Section

PS1A PS2A Safety Valve Manual Valve Pressure Gauge

Hydraulic Section:

Release Cylinder Circuit

Problems:

Cannot maintain pressure:

Cylinder and pipeline seals

CL3 and VAL2 seals

Insufficient pressure:

Cylinder and pipeline seals

RLV3 setting

RLV4 setting

RLA6 setting

Solenoid valves SOL-4, SOL-7 - Check if operating correctly.

POMPE

Hydraulic Section:

Release Cylinder Leakage

Hydraulic Section:

Clamping Cylinder Circuit

Problems:

Cannot maintain pressure:

Cylinder and pipeline seals

CL1 and VAL1 seals

Insufficient pressure:

Cylinder and pipeline seals

RLV1 setting

RLV5 setting

Solenoid valve SOL-1 - Check if operating correctly.

POMPE

Hydraulic Section:

Clamping Cylinder Leakage

Oil stains, Joints, Plugs

Hydraulic Section:

Discharge Opening Cannot Be Adjusted

Problems:

Cannot increase discharge opening:

Solenoid valve SOL-3 not operating

Solenoid valve SOL-4 not operating

Solenoid valve SOL-5 not operating

Safety valve RLV-2 setting

Safety valve RLV-3 setting

Two-position valve CL-2 not operating

Hydraulic pump not running

Cannot decrease discharge opening:

Solenoid valve SOL-3 not operating

Solenoid valve SOL-4 not operating

Solenoid valve SOL-6 not operating

Safety valve RLV-2 setting

Safety valve RLV-3 setting

Two-position valve CL-2 not operating

Hydraulic pump not running

Hydraulic Section:

Safety Valve Settings

RLV5: 250Bar

RLV6: 300Bar

Hydraulic Section:

Safety Valve Settings

Remember: Always adjust RLV-3 first, then adjust RLV-4.

Hydraulic Section:

Pressure Switch Settings

Clamping cylinder circuit

Release cylinder circuit

Hydraulic Section:

Hydraulic Oil

The correct oil should be ISO Grade 32, Viscosity: 20-40 cSt (40°C) or 6 cSt (100°C). Viscosity index should reach 140 or higher.

Recommended brands:

BP - Energol HLP 32

MOBIL - Mobil DTE 24

SHELL - Tellus S 32

Or other hydraulic oil meeting ISO 32 standard.