MANUAL DE INSTALACION DE CONO (CHANCADORA)

7/24/2019 MANUAL DE INSTALACION DE CONO (CHANCADORA)

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Users manual of SG160C cone crusher

Copyright 2009 SHAORUI HEAVY.


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All rights reserved. Any form of copy of this document without prior approval of Shaorui Heavy

Industries Co. Ltd is prohibited. All the data and information in this manual are subject to change

without prior notice.

Shaorui Heavy Industries Co. Ltd.

Science and technology park !ujiang district Shaoguan "uangdong.

#el$ %&'()*(+,&+- a/$ %&'()*(+,*&(

!ebsite$ : www.sgsrzg.cn

Contents1. Introduction

1.1 Equip!nt In"or#tion

1.1.1 $ocu!nt In"or#tion

1.2 Op!r#tion#% &rincip%!

1.2.1 $!'cription'

2. S#"!ty &r!c#ution'

2.1 Sign#%' o" $#ng!r'

2.1.1 (#rning Sign'

2.1.2 C%#''i"ic#tion o" $#ng!r'


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2.1.) &rohi*iti+! Sign'

2.1., In'tructi+! Sign'

2.2 &!r'onn!%

2.2.1 &!r'on#% &rot!ction

2.) -!n!r#% S#"!ty &r!c#ution'2.).1 S#"!ty -u#rd'

2.).2 E%!ctric#% S#"!ty

2.).) (!%ding

2.)., Hydr#u%ic Sy't!

2.). /i"ting #nd o+ing /o#d

2.). !!d #nd 3%oc4#g!

2., $i'ch#rg!

2.,.1 $u't

2.,.2 5oi'!2.,.) R#dio#cti+!

). 6!chnic#% $#t#

).1 -!n!r#% $#t#

).2 &roc!''ing $#t#

,. St#rt7up

,.1 O+!r+i!8

,.2 Running7in

,.2.1 Ch!c4ing th! S!tting' 8ith # /!#d 3%oc4

,.2.2 St#rting th! #in Oi% &up

,.2.) Ep!% Air "ro th! Hydr#u%ic Sy't!

,.2., #iu /o#d

,.2. St#rting th! Cru'h!r und!r Etr!!%y /o8 6!p!r#tur!

. Op!r#tion o" th! Con! Cru'h!r

.1 St#rt7up #nd Stop

.1.1 St#rting th! Cru'h!r

.1.2 Stopping th! Cru'h!r

.2 Ch!c4ing th! S!tting'

.) Ch#ng! oi%

.).1 5or#% Op!r#tion#% Condition'.).2 Op!r#tion und!r High 6!p!r#tur!

.).) Op!r#tion und!r /o8 6!p!r#tur!

., Ch!c4ing th! 6!n'ion o" 3!%t'

. En!rgy Accuu%#tor

. C%!#ring th! C#+ity

. In'p!ction #nd #int!n#nc!

.1 $#i%y In'p!ction #nd #int!n#nc!

.1.1 $#i%y #int!n#nc!.1.2 (!!4%y #int!n#nc!


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.1.) onth%y #int!n#nc!

.1., S!i7#nnu#% #int!n#nc!

.1. Annu#% #int!n#nc!

.2 St#nd#rd 6oo% 3o

.) Upp!r r#! #nd #in Sh#"t A''!*%y.).1 $u't7proo" Ring

.).2 Scraper

., 3!%t'

.,.1 Rot#ting $ir!ction

.,.2 3!%t 6!n'ion

. Upp!r r#! A''!*%y

. Hydr#u%ic #nd /u*ric#ting Sy't!

.: $u't7proo" S!#%

.:.1 $u't7proo" S!#%ing &rincip%!.:.2 Air 3%o8!r

.:.) Ad;u't!nt $!+ic! o" Copr!''!d Air

:. /u*ric#tion

:.1 R!quir!!nt' o" /u*! Oi%

:.1.1 i'ci*i%ity

:.1.2 /o8 6!p!r#tur!

:.1.) High 6!p!r#tur!

:.2 /u*! Oi% in th! /u*ric#ting Sy't!

:.) /u*! Oi% in th! Hydr#u%ic Sy't!

:., /u*! Oi% o" &inion

:. -r!#'! "or Ar 3!#ring'


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Ch#pt!r On! Introduction

#o ensure safety please read the safety precautions in chapter 0 before carrying out

any work or adjustment on the machine.

(.( 12uipment information

Application purpose

#he crushing and screening devices or plants made by Shaorui Heavy Industries

Co. Ltd at the mining sites can reduce the dimensions of rocks ores and other

materials which is also the basis of our designs. Shaorui Heavy Industries Co.Ltd is not liable for the whole mining operation unless crushers are part of our

delivered production line. 3or is it liable for any damage to e2uipment or people

due to improper operation use or refit of our e2uipment.

4aintenance

5lease contact the nearest agents or representatives of Shaorui Heavy Industries

Co. Ltd or directly contact the factory.

#el$ %&'()*(+,&+-

a/$ %&'()*(+,*&(

Crusher nameplate

#he picture below is an e/ample of our crusher nameplate which includes the

information related to a specific device that needs to be rendered to us when

contacting Shaorui Heavy Industries Co. Ltd for

servicing.

64odel7 is a sign for product series.

3ameplate$

(. 4odel

0. actory code

+. Local series number8. 9rder number


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'. 4ass:kg;

,. I< code

&. 4anufacturer

*. =ear of production

-. C1 mark

(%. uality

0%. 9rder number

0(. 4anufacturer

00. =ear of production

0+. C1 mark

C1 mark#his e2uipment conforms to the environment and safety regulations of the 1? and 1uropean

economic @one. Shaorui Heavy Industries Co. Ltd will no longer be liable for such

conformation if any change to the configuration of the cone crusher is made bycustomers.

(.(.(


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Illustrations in this manual

#he illustrations in this manual are made based on S"(,% cone crusher. #hough it is similar

to "50*% there are still some differences in designs at a few insignificant places.


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Adjustment of the discharge opening #o compensate wear and produce products of different si@es the crusher is e2uipped with a

control system. It is mainly composed of a solid hydraulic called adjustment cylinder which

supports and adjusts the position of the main shaft. #o move the main shaft up and down can

change the discharge settings and thus change the si@es of crushed material. See more detailsin 6settings measurement7 in chapter ((

educe the settingD smaller product si@e

Lubricating system5lease refer to 6main lubricating system7 in the chapter *.0 for more details about the circulating

lubricating system.

(.0.(


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Cone crusher)) profile

9il tank compartment and au/iliary devices

1 arm cap

2 upper frame liner

3 main shaft nut

4 mantle

5 concave

6 head

7 wear ring

8 lower frame liner9 eccentric

10 eccentric bushing

11 main shaft

bushing

12 hydraulic piston

13 countershaft box

14 countershaft

15 dust-proof cover

16 locating block17dust-proof ring

18 lower frame

assembly

19 upper frame

20 filler ring

21hub of material level

indicator

22inspection gate

23 feed hopper

24 observation cover


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Ch#pt!r 68o S#"!ty &r!c#ution'

In order to ensure safety please read this book carefully before carrying out any work or making

any adjustment on the crusher.

0.( Signs of dangers

0.(.( !arning signs

25 pressure fan

26 pressure regulator27 oil tank

28 water/oil radiator

2 air/oil radiator

!" inflatable kit of energy

accumulator


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0.(.0 Classification of dangers

In this manual dangers are classified as 6danger7 6warning7 and 6caution7. 6


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0.0.( 5ersonal protection

!e strongly recommend that personnel near the machines should always wear personalprotective devices which include$

0.+ "eneral safety precautions

alling stones

5lease clear all the feed material in the hopper before carrying out any

maintenance work inside or under the crusher to avoid falling stones.

5lease cut off the electricity and lock the device before carrying out any

maintenance work. esides make sure no one will turn on the electricity during

the maintenance work


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5rior to operation of the machine check repair or replace all defective safety guards and dust)

proof elements.

0.+.0 1lectric safety

#he electric operation can only be carried out by electricians in accordance with 1uropean

13 '%((% standard or e2uivalent standards. 1lectric danger

9perators must pay attention to all electric devices until the electricity is cut off.

efore operating the e2uipment check repair or replace any broken or damaged cable orconnector.

#he control cabinet must have a lock.

0.+.+ !elding elated regulations in this manual must be observed when carrying out welding on the crusher.

5lease consult our local maintenance personnel when carrying out welding on the crusher.

#he welding on the crusher is only allowed to be carried out by welders in accordance with 130*& standard or e2uivalent standards.

#he welded parts must be earthed during welding. If a part of the crusher is to be welded itmust be earthed at a nearest possible place to the welding area.

#o/ic gas It is harmful to health to inhale welding smoke so please always follow the instructions

provided by the supplier of the welding machine. Some parts of the crusher are made of

manganese steel so manganese o/ide is produced during welding. Constant e/posure tomanganese o/ide will have a negative impact on the nervous system.

0.+.8 Hydraulic system

9nly personnel that have passed the e/amination are allowed to operate the hydraulic system.

9il pressure

If the pressuri@ed oil is released incorrectly it may incur a danger. #herefore please release all

the pressure before carrying out maintenance or repair work on the hydraulic system.


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!hen the cavity is empty do not put in a whole piece of boulder.


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+.0 5rocessing data

eatures :depends on cavity shape;

4a/imum feed si@e '% to(-% mm

CSS minimum)ma/imum , to +*mm

Capacity 8' to 00% tonsFhour

Above is typical data. #he capacity of the cone crusher depends on cavity shape eccentricitysettings and density of feed material crushability fractions and moisture etc please consult us if

you need more information about applications.

eatures


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Ch#pt!r our St#rt7up

#his chapter introduces how to start the cone crusher.

#o ensure safety please read carefully 6safety precautions7 in the chapter 0 before carrying out


8.( 9verview Assembly test)run and inspection have been done before delivery of each cone crusher. #est)run

is carried out without load to find out any possible mechanical fault.

8.0 unning)in

#he content of this paragraph is also applicable for repaired machines and machines with newparts.

a; Start the main oil pump

b; Start the driving motor when you get the 6ready to start7 signal.c; Check and adjust settings. 5lease refer to 6check the settings with a lead block7 in chapter

8.0.(.

d; Start feeding the crusher. "radually increase the load until it reaches the drawbar power oraround &' of the ma/imum hydraulic power. 5lease refer to 6ma/imum load7 in chapter8.0.8.

CautionJ If possible the cavity should be full of material as the crusher cannot run in without load.

unning)in will be finished after about (, hours of operation with &' load. After that increasethe load to the ma/imum. #he running)in time may be longer due to different feed materials and

engineering designs.


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8.0.( Check the settings with a lead block

A very simple way to check the CSS is to tie a lead block on a iron wire and then slowly put itinside the discharge area of the cavity. #he lead block will be s2uee@ed out and its thickness is the

setting. 4ake sure the lead block is big enough so that it is easy to measure the thickness.

=ou may also check the CSS at four different points around the cavity circumference. If you find

uneven wear the performance of the feeding device is not satisfactory. 5lease refer to 6settingsmeasurement7.

CautionJ #he CSS should not be too small or it will cause the drawbar power or hydraulic

pressure to e/ceed the upper limits in chapter 8.0.8.

8.0.0 Start the main oil pump

Check the oil level before starting the main oil pump. After the oil pump starts the oil tank must

be full of oil to ensure sufficient oil supply.

8.0.+ 1/pel air from the hydraulic system

#he upper air outlet valve is installed on the throat of energy accumulator.

a; ?se the /1button bo/ to raise the main shaft by a few millimetersb; 9pen the upper air outlet valve with a 'mm he/agon spanner to e/pel all the air.c; aise the main shaft by another few millimeters.d; ?se a 'mm he/agon spanner to open the air outlet valve in the hydraulic cylinder to

e/pel the air.e; aise and lower down the main shaft several times.

f; epeat the above procedures until the oil flows out with no bubble.

8.0.8 4a/imum load


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Average power

#he following are the typical values of average drawbar power measured on the motor shafts

which are determined by eccentricity and cavity shape. If the average drawbar power is even andhas no peak its value may be relatively higher but it should not e/ceed the ma/imum average

power and hydraulic pressure value.

8.0.' Start

the crusher at an e/tremely low temperature

If the main oil pump is started at an e/tremely low temperature the lube oil may overflow fromthe dust)proof frame.

a; epeatedly start and stop the oil pump at an interval of (%s until the 6Ready for start7signal appears. #hen start the crusher and run it without load. Check if the oil flow 2uantity is

normal.

Ch#pt!r i+! Op!r#tion o" th! Con! Cru'h!r #his chapter introduces the basic procedures of using the cone crusher.

#o ensure safety please read carefully 6safety precautions7 in chapter 0 before carrying out any

work or adjustment on the crusher.

'.( Start)up and stop ?sually the crusher is controlled by a control system to regulate the starting of the crusher.

5lease refer to the supplementary information provided by the manufacturer of the

control system. However follow)up or inspection is needed to make sure that the

control system follows the start)up and stop procedures below.CautionJ 5lease refer to 6running)in7 in chapter 8.0 for information about running)in after

maintenance or installation of new parts.

CautionJ ollow the instructions in 6daily inspection and maintenance7 in chapter ,.( to carry outdaily inspection and maintenance work.

'.(.( Start the crusherCautionJ 5lease refer to 6start the crusher at an e/tremely low temperature7 in chapter 8.0.' for

information about starting the crusher at an e/tremely low temperature.

b; Start the main oil pump

c; !hen the indicator light 6ready to start7 is on start the driving motor.d; Check and adjust the settings. 5lease refer to 6check the settings with a lead block7.

e; Start the feeder. #he crusher should be fed evenly with full load.CautionJ #he CSS should not be too small or it will cause the drawbar power or hydraulicpressure to e/ceed the upper limits in chapter 8.0.8.

power(k

Cavity shape

Eccentri

EF F MF M MC C EC

*6 mm 67 7" 7%

* mm 7! 77 8* 85

22 mm 75 7 8! 87 2 7

25 mm

8! 88 2 7 *"2 *"8

2mm % % *"5 **" **6 *2!

!2mm *"2 *"2 108 **% *2" *27 *!2

!% mm

*"8 *"8 **% *2" *26

!6mm **! **! *2" *27 *!2


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'.(.0 Stop the crusher

a; Stop feeding but continue to run the crusher until there is no material in the cavity.b; Stop the driving motor of the crusher.

c; Stop the main oil pump.

CautionJ 9il heating device should be on 08 hours a day. #he heating element is automatically

controlled by the temperature control switch.

'.0 check the settings

Check the CSS following the procedures in 6check the settings with a lead block7 in chapter 8.0.(and 6settings measurement7 in chapter ((.

'.+ oil replacement


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and the magnetic plug needs to be cleaned. 5lease refer to 6filter element7 in chapter *.,.0 and

6magnetic plug7 in chapter *.,.+.

d; eplace the oil in the pinion bo/. ?se the same oil with the main lubricating system. 5leaserefer to 6lube oil of pinion bo/7 in chapter &.8.

e; If the temperature control switches #"(.#"0 and #"+ are not yet set up according to normal

operational conditions please reset them following the instructions in 6temperature control

switch7 in chapter *.0.& and 6oil heating7 in chapter *.0.(0.

'.+.+ 9peration under low temperatures

9peration under low temperatures

Ambient temperature Lower than %MC: +0K;

#he viscosity will increase under low temperatures. However as there is a heating element in the

oil tank it is not necessary to replace the oil with another type with lower viscosity. In addition

there are several methods to reduce the risk of oil free@ing such as keeping a proper temperatureand heating.

3evertheless sometimes oil with lower viscosity is still recommended under e/tremely low

temperatures.

a; Choose the main lube oil used for operation under low temperatures according to 6lubricatingsystem7 in chapter &.0.

b; eplace the main lube oil according to 6replacing the main lube oil7 in chapter *.+. besides

the filter element also needs to be replaced and the magnetic plug return oil mesh oil tankand airFoil radiator need to be cleaned.

c; Choose the hydraulic oil according to 6hydraulic system7 in chapter &.+ and replace the oil in

the hydraulic system. esides the filter element also needs to be replaced and the magneticplug needs to be cleaned. 5lease refer to 6filter element7 in chapter *.,.0 and 6magnetic plug7

in chapter *.,.+. ?sually the hydraulic oil doesnt need to be changed. However if the

condition is so harsh that the oil tank needs oil with lower viscosity or a heater please consult

us.d; eplace the oil in the pinion bo/. ?se the same oil with the main lubricating system. 5lease

refer to 6lube oil of pinion bo/7 in chapter &.8.e; 5lease consult the grease producer and refer to 6lube oil in the arm bearing7 in chapter &.' for

more information about the grease used in the arm bearing under e/treme ambienttemperatures.

f; If the temperature control switches #"(.#"0 and #"+ are not yet set up according to low

operational temperatures please reset them following the instructions in 6temperature controlswitch7 in chapter *.0.& and 6oil heating7 in chapter *.0.(0.

'.8 Check the belt tension

Check the belt tension according to instructions in 6belt tension7 in chapter ,.8.0.

'.' 1nergy accumulator

5lease refer to 6inflatable kit7 in chapter -.+ for procedures of check the air pressure andpumping.

'., Clear the cavity

If the crusher stops with a full cavity please take the following steps to clear it.a; 4ake sure that the feeding device has been turned off.

b; If there is material deposit in the discharge chute under the crusher please remove it.

CautionJ If there is A Si system please turn it off to avoid raising or lowering down the mainshaft.

c; 9pen the tamper valve connected with the hydraulic pressure gauge. 5lease refer to 6pressure

gauge7 in chapter *.,.'.

d; ?se L( button bo/ to lower down the main shaft and meanwhile pay attention to the hydraulicpressure.

e; If the hydraulic pressure is lower than %.+4pa raise the main shaft again until the reading ofpressure gauge at least reaches %.'4pa. :If the pressure drops below @ero the thrust plate of


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the main shaft may lose contact with the upper thrust pad.;

f; Start the crusher

CautionJ Check if there is material deposit on the lower frame arm. If moist material blocks thecavity please operate the machine under a larger setting.

CautionJ Check the interlock between the feeding device and discharge system. 9nce the

discharge system stops working there should be enough space under the crusher for the material

remaining in the cavity and hopper.CarefulJ If the crusher stops due to some uncrushable materials :metal wood etc.; do not restart

the crusher. 4anually clear the cavity or remove the bolts on the upper frame so that all the

material can be released from the cavity.CarefulJ


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!hec" the tem$erature of the return oil. &urin% crushin% process 8.2.7!hec" the current, $ower and oil consum$tion of thedrivin motor.

&urin% crushin% process 4.2.4

!hec" and ma"e sure the dam$ing of h#draulic and$ressure gauges is correct.

&urin% crushin% process 8.6

!hec" the temperature of the pinion bo#. Use an )'camera or *ust feel it above the box to. )f it is ver#hot, do not touch it. +he normal tem$erature should be50-60 C (122-140 F).

&urin% crushin% process

!hec" the oil tem$erature of the main lubricatings#stem under normal o$erational tem$eratures.

&urin% crushin% process 8.2.5

!hec" and ma"e sure that there is no lea"age. &urin% crushin% process

!hec" if the bolts are loose. &urin% crushin% process

!hec" and ma"e sure that the oil heater wor"s well. When the crusher stops 8.2.12!hec" the distance between the to$ nut and the bottomof arm frame.

When the crusher stops 10.2

!hec" and ma"e sure that there is no more dirt, i.e.metal $articles, on the filter mesh.

When the crusher and oil$um$ sto$. 8.3.4

,.(.0 !eekly

9perators are responsible for carrying out these inspections every week or every 8% hours.

Action i!e "e#erence

!hec" the filter element chec" if the redbutton on the $ressure sensor has bulged-

When the crusher andlubrication sto$.

8.2.38.3.3

!lean the magnetic $lug and chec" the oil tan" When the crusher and 8.2.18.2.2

uricatin% syste!. lubrication sto$. 8.3

!hec" if the crusher liners are worn or When the crusher 10.2

easure frames at the four corners in the cavit#and see if there is uneven wear.

When the crusher isrunning withoutload.

4.2.1.11.1

!hec" if the $um$ is worn or has abnormal &urin% crushin% 8.2.4 8.6.1

!hec" the tension and wear condition of the When the crusher

!hec" the oil level in the $inion box. When the crusher 7.4

!hec" the cooler core in the air/oil radiatoro$tional-.

When the crusher andlubrication sto$.

8.5

!lean the dam$er valve of the h#draulic gauge. When the crusher 8.6.5

!hec" the air $ressure of the dust0$roof sealwhen fan or $ressure regulator is running-.

When the crusher isrunning withoutload.

6.7

!hec" the hose and filter element of the dust0$roof seal and sealing condition of the ca$ ofoil tan".

When the crushersto$s.

6.7

,.(.+ 4onthly9perators are responsible for carrying out these inspections when the crusher stops everymonth or every (,% hours


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Action Person in cha "e#erence

!lean the nozzle on the $inion box. *perator 7.4

!hec" of the dust0$roof seal is worn. *perator 6.3.1

!hec" the condition of the scra$er rotating onthe dust0$roof frame.

*perator 6.3.2

!hec" the tightness of all the bolts. *perator

!hec" the end0$la# between the main shaft bushingand $i$e connector.

*perator 10.110.3

!hec" the grease level in the arm bearing. 1$erator

7.5

!lean the air channel in the arm frame ca$ andu$$er frame.

1$erator 10.1

!hec" the 2ualit# of lube oil. 1$erator 7.2

!hec" the function of the return oil flow controlswitch.

1$erator 8.2.9

!hec" the clearance between the $inion and gear.aintenance personne+

!hec" the mantle, mantle liner, u$$er frame andfixed cone liner.

Maintenancepersonne+

!hec" if the arm bearing is worn.Maintenancepersonne+

,.(.8 Semiannual9perators are responsible for carrying out these inspections when the crusher stops every half

year or every (%%% hours.

Action Person in char "e#erence

!hec" the air $ressure of energ# accumulator. *perator 9.3

C+ean the oi+ tank. *perator 8.2.18.3

!hec" the filter element and clean the magnetic$lug of the h#draulic s#stem.

*perator 8.6.28.6.3

!hec" the clearance of the arm bearing. *perator 10.1 10.3

,.(.' Annual9perators are responsible for carrying out these inspections when the crusher stops every year

or every 0%%% hours.

Action Person in char%e "e#erence

!hec" if the u$$er frame and lower frame assembl# are Maintenance

personne+

!hec" if the ad*ustment c#linder seal is worn. Maintenance

!hec" the conical contact surface between the u$$er Maintenance


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lower frame. personne+

!hec" if the main shaft bushing is worn or rusted. Maintenance

personne+

!hec" if the seal is worn. Maintenance

personne+

Maintenance

personne+

Check if the eccentric bushing is worn or scratched. 4aintenance

personnel

Check if the eccentric is worn or scratched. 4aintenance

personnel

Check if the eccentric wear plate is worn. 4aintenance

personnel

Check if the lower frame liner is worn or scratched. 4aintenance

personnelCheck the thickness of the components of upper thrust bearing 4aintenance

If they are worn or scratched. personnel

Check if the gear is worn. 4aintenance

personnel

Check if the hydraulic cylinder sleeve is worn or scratched. 4aintenance

personnel

eplace the oil in the small shaft bo/. 9perator :.,

Check the function of the thermometer. 9perator


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double offset ring spanner 8( /8, "8+**)-' )%(olt and nut 4+% 3to install adjustmentcylinder4

double offset ring spanner +0 /+, "8+**)-' )%0 olt and nut 408 3to install concave4

double offset ring spanner 00 /08 "8+**)-' )%+ olt and nut 4(, 3to install dust)proof

adjustable spanner +%% /+, "888%)-*)%( olt and nut 40%3

to install arm frame cap4

adjustable spanner 0%% /08 "888%)-*)%0olt and nut 4(03install eccentric pressurepad4

inner he/agon spanner (8 mm "'+',)*')%( cheese head screw 4(, 3to install gear4

inner he/agon spanner (% mm "'+',)*')%0 cheese head screw 4(0 3to install wear

inner he/agon spanner , mm "'+',)*')%+cheese head screw 4* 3to install locatingblock4

Cable S"(,%)(')%+ #o lift the upper frame assembly

480 bolt wrench S"(,%)(')%( #o install upper frame bolt 480

,.0 Lower frame and main shaft assembly

#here are on the lower frame assembly two spy holes through which we can check the

dust)proof seal ring dust)proof frame liner and seal ring and oil leakage condition.


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,.+.(


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,.8.0 elt tension

In the first few of running the belt tension needs to be checked fre2uently because the new belts

can be stretched. If the belts are not fully stretched they may be slippery and their service lives

will be shortened. #he proper belt tension can be determined by deflection load)bearing stress with a gauge such

spring scale tension meter and the like.

'ecommended deflection load3F4

$ kp/belt$ound /belt-

$e+t section ,or!a+ aximum 5new belt6

+(, 7 )*5&% *2&" )26&5

8. )*&8 *%&" )!"&

Check the deflection load with a tension meter.a; 4easure the span of the belt :!; as shown in the picture below unit$ m

b; "et the deformation :


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bearing and precipitation of the dirt in

the oil tank. 9ther components in the

crusher may also suffer e/cessive wear.

9ver)pressuri@ed air :white arrow;can be provided by air blower or

compressed air system.

,.&.(


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CautionJ #he cap of the oil tank should have air tightness. Adjust or change the seal ring if

necessary.

9verpressure in the crusher and oil tank is to prevent dust from entering the crusher. #heoverpressure is reali@ed by supplying compressed air with air blower or pressure adjustment

device. 5lease refer to 6air blower7 in chapter ,.&.0 and 6adjustment device of compressed air7 in

chapter ,.&.+. the crusher get the overpressure air by the same connector # :0; used for balancing

the pressure between the hose and oil tank.Inspection

!hen the crusher is running the air pressure at the feed opening should be ,%%)(%%%5a :,%)(%%

mm w.g.;.

,.&.0 Air blower

#he capacity of the air blower should be no less than %.+ m+Fmin under the pressure of ,%%

5a :,% mm w.g;.Inspection

#he air filter of the air blower has a replaceable paper)core. 5lease regularly check the filter

element and replace it if necessary.

,.&.+ Adjustment device of compressed air

#here is a pressure gauge for measuring the overpressure at the entry of the crusher in theadjustment device.

2 T sha$edconnector

4 air blower

5 sleeve

4 air blower

6filter element

3$ressure gauge

7$ressure

ad*ustment

device

8filter element

9com$ressed air

connector


31/62

Ch#pt!r S!+!n /u*ric#tion

#his chapter introduces the re2uirements for lube oil of the cone crusher.#o ensure safety please read carefully 6safety precautions7 in the chapter 0 before carrying out


&.( e2uirements for lube oil

In order to optimi@e the performance of the crusher the lube oil used in the crusher must bestrictly restricted.

CautionJ


32/62

&.0 Lube oil used in the lubricating system

!e recommend that neutral 15 additive should be added to lube oil and the oil should conform to

the re2uirements in the table. ?sually IS9 " ('% viscosity lube oil is used.

"eneral descriptions

Lube oil should conform to the re2uirements about viscosity in


33/62

synthetic oil because this type of oil has a high viscosity. ?sually the IS9 " ('% viscosity oil can

be used all year round.

If the ambient temperature e/ceeds +0K C :-%K ; it may be necessary to follow instructions in6operation under high temperatures7 to reset temperature control switches #"( and #"0. 9r #"(

may trip due to high temperature thus stop the crusher. 5lease refer to 6temperature switch7 in

chapter *.0.((.

1.g.$ #ribol io #op (8(*F('% :IQ (&%; >uantity of lube oil

Capacity

Lube oil tank ('% liters :8% gallons;

!hen the crusher is running the oil level must be above the marked lowest level. 5lease observe

the oil level indicator in the oil tank.

!hen the crusher stops some lube oil may remain in the crusher and oil pipes so after test)run

the oil tank should be filled. #o avoid oil overflow after the oil in the crusher return to the oil tankif the oil pipe between the oil tank and crusher is very long the oil filling should be strictly

controlled.

CautionJ


34/62

4obil 4obilgear ,0, #oca/e 4eropa ,*

CautionJ uantity of lube oil

Capacity

Hydraulic oil tank 8% liters :(%.&gallons;

!hen filling oil to the hydraulic oil tank the main shaft must be at the lowest position. If it is at

the highest position the oil tank may not have enough space to hold all the oil when it lowersdown.

9il replacement !hen changing lube oil the oil in the hydraulic system should also be changed. 5lease refer to

6oil replacement7 in chapter '.+ and 6lube oil used in the lubricating system7 in chapter &.0.

&.8 Lube oil for the pinion shaft!hen the crusher leaves the factory there is a label near the pinion shaft to indicate the type of

oil used in the pinion shaft bo/. uantity of lube oil

>uantity of lube oil

5inion shaft bo/ %.* liter :%.0(gallon;


35/62

Per#or!ance "e-uire!ents est !etho'

iscosity 0 or "" /01

%"3, )*"%3-basic viscosit#unit mm2/s )c+t- /%""

A''itive i+ver or uraniu!

&rop point /*%"1, )28%3$ 4/ + 2*76

Anti2corrosive Approve' 4/ 5* 8"2 +$ #mcor

9ther properties

))must have 15 additive))can be pumped

ecommended operational temperature is between )(%KC to R(%%KC :(8K to 0(0K;. if the

operation is under e/treme ambient conditions please contact the lube oil supplier.

"rease e/amples

#he e/amples below are the greases that conform to our re2uirements.

#he local conditions may vary in different countries. or your own safety please choose the right

grease supplier. esides the greases listed below some other brands of grease may also be used as long as they

conform to our 2uality standards.

4obil 4obilith SHC %%& :,8+',-; Statoil "rease!ay LiCaP-%4olub)Alloy #ribol +%0%F(%%%)%% #e/aco 4arfak %% :%(-%&;

>uantity of grease

>uantity of grease

Arm bearing +)8 kg :,.,)*.* pounds;

#he arm bearing must be filled with grease to the correct level which is close to the 2uantity

stated in the table above. !hen filling the grease the main shaft must be at the lowest position.

#he grease is pumped in through a channel in one arm frame of the upper frame.

Check and replace the grease


36/62

of arm bearing may be damaged. 4ake sure that there is no oil or stone dust on the main shaft

to prevent the dirt from entering the arm bearing through the arm bearing seal :8;when the

main shaft is raised. re2uently check the grease level and replace it when necessary. If thearm bearing seal is damaged replace it as soon as possible.

#here is a label along the grease no@@le on the arm frame of upper frame for showing the type

of grease in the arm bearing before delivery.


37/62

4ain lubricating system hydraulic system

#emperature control switch and heater

*.0 4ain lubricating system

In the lubricating circuit oil is pumped to the main inlet of the crusher from the oil pump through

filter element and radiator. After entering the crusher oil is pressed upward through upper thrustbearing into the space between the eccentric bushing main shaft and the lower frame sleeve to

lubricate the bearings. #he oil will lubricate the wear plate and bevel wheel before returning to the

oil tank due to gravity.


38/62

*.0.( Clean the oil tank

5ollutants such as stone dust water etc can to some e/tent deposit at the bottom of the oil tank

so it has to been cleaned at least twice every year. #he regular inspection can avoid mud beingpumped up from the bottom with the oil. 5lease refer to 6clean return oil mesh and oil tank7 in

chapter *.+.8.

1pressure indicator

2 thermometer

)pressure gauge

,lubricating oil pump

pressure gauge

connector

pressure sensor

:filter element


39/62

emove the drain plug :(8; to clean the precipitate. 5erform the action regularly to avoid too

much water in the oil.

CautionJ !hen the oil level drops to just above the oil inlet stop the pump immediately or it maybe damaged because the pump cannot run without oil.

*.0.0 4agnetic plug

4agnetic plug :*; protects the oil pump and it is installed before the oil pump.CautionJ egularly clean the magnetic plug. If it is blocked the pump will fail. 5lease refer to

6clean magnetic plug7 in chapter *.+.0.

CautionJ ?nder any circumstance the gau@e element is indispensible and it cannot be replaced byother types with different apertures.

*.0.+ ilter element #he filter element used is full)flow type which can filter all the lube oil from the pump to the

crusher. #he filter element can be used only once. 5lease refer to 6replace filter element7 in

chapter *.+.+.

?nder normal operational temperatures if the oil pressure decreases more than %.0045a :+0psi;after passing through the filter element the filter element must be changed.

#here is a by)pass valve on the filter element. If the oil pressure decrease e/ceeds %.+'45a

:'(psi; the valve will be open. #hen part of oil will not pass through the filter element.CautionJ If the filter element must be replaced fre2uently please check the dust)proof sealing

system of the crusher.

*.0.8 9il pump ?nder normal conditions the lube oil pump doesnt need special attention. However if the oil

contains stone dust or similar pollutants special attention must be paid to it. #he most common

sign of the wear of oil pump is the decrease of oil flow 2uantity.

14drain plug, lube oil tan"

15end ca$lube oil tan"

16 end ca$ h#draulic oil

tan"

17drain plugh#draulic oil

tan"

18gauze element

19$lug


40/62

CautionJ !hen starting the oil pump the oil tank must be filled with oil. Check and make sure

that the stop valve before the magnetic plug is on before starting the oil pump.

eplacement

#he capacity of the pump under standard operational temperatures and pressures is shown in the

following table. :if the motor is connected with power source with the fre2uency of ,%H@ not

'%H@ the capacity will be 0% higher and the oil flow will increase as well.;If the oil flow drops to the minimum value in the table the oil pump should be replaced.

:low rate of lube oil iter 3!i

%a++on3!in

Power source #re-uency 5"Hz

,or!a+ capacity !! 8&7

Mini!u! capaci

27 7&*

Power source #re-uency6"Hz

,or!a+ capacity %" *"&6

Mini!u! capaci 27 7&*

Inspection

Check the oil supply condition by measuring the oil flow 2uantity. 5ut a bucket with a specificcapacity under the opening of the return oil chamber and then measure the time needed for filling

the bucket.1.". if it takes 0% minutes to fill a bucket with a capacity of (% liters the oil flow rate is

:(%P,%;F0% D +% liters Fmin

*.0.' 5ressure gauge #he pressure gauge :+; shows the pressure value measured by the pressure gauge connector :';

between the oil pump :8; and filter element :&;.

Inspection

egularly check the pressure and record the readings. ?nder normal operational temperatures the

pressure in the main system is usually %.(')%.' 45a :0(.*)&0.'psi;. the value depends on the

installation of the oil tank. If the pressure increases before the filter element the filter elementneeds to be replaced. 1/tremely low pressures may show that the pump is worn or the magnetic

plug is blocked.

1$ressure indicator

light

2thermometer

3$ressure gauge

4lube oil $um$

5$ressure gauge

connector

6$ressure dro$

sensor

7filter element

8magnetic $lug

9sto$ valve

10safet# valve

11sto$ valve


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*.0., 5ressure drop sensor

#he pressure drop sensor :,; monitors the pressure drop after passing through filter element and

send a signal if the pressure drop e/ceeds %.00 45a :+0 psi ;. #he signal means that the filter

element needs to be replaced. #he signal is transmitted electronically to the pressure drop indicator light :(; and the red button

will pop up from the top of the sensor :about 8mm;.

CautionJ


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*.0.- Switch of return oil flow

#he return oil flow is monitored by the oil flow switch in the return oil chamber in the oil tank. #he connection method of the switch of return oil flow ensures that the driving motor of the

crusher can only be started when there is enough oil pumped to the crusher and then returning to

the crusher through the switch of return oil flow. esides the lube oil pump :8; can only be startedwhen the switch of return oil flow is working well.

#he switch of return oil flow is connected to float :0%; in the return oil chamber :08; to monitor

the rise or fall of the float. #here are an adjustable lower outlet :00; and a overflow baffle plate

:0(; in the oil return chamber.CautionJ #he lower outlet has been adjusted before leaving factory and the setting should not be

changed.

After oil return to the oil tank the oil level in the return oil chamber should at least 'mm :%.0%;higher than the baffle plate. !hen the oil level is at that position the float is completely immersed

in the oil and the buoyancy of the oil will push the float to the baffle plate.If the oil flow decreases the oil level in the return oil chamber will drop. !hen the oil level

decreases about ('mm :%.'-; the float will be at 'mm below the baffle plate. At this position theswitch will be on and the driving motor of the crusher will stop.

Inspection 5ush the float downward from the baffle plate by 'mm :%.0%; below the baffle plate and check

the oil level monitor. #hen the driving motor of the crusher must be stopped.

*.0.(% filter mesh

#he filter mesh :0+; separates the dirt from the oil and e/pels the air from the oil as well.

Inspection

Check carefully the filter mesh. 1specially during running)in period it has to be checked every

day. If there is metal particles on the mesh there may a fault. Check it and locate the cause to

avoid possible risks.

20 float

21baffle plate

22 adjustable lower outlet

2) filter mesh

2, return oil chamber


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*.0.(( #emperature control switch

#wo sensing heads of the temperature control switch is in the return oil chamber :08;. #he

temperature control switch #"0 of the cooler controls the cooling of the oil pumped to the crusherwhereas the protective temperature control switch #"( shuts down the driving motor of the

crusher when the oil temperature is too high.

26protective temperature

control switch #"(

27 temperature control switch

#"0 of the cooler

28 oil heater TG 3

29 heating element

30 oil level indicatorlube oil tan"

CautionJ It is very important to use the correct temperature setting. Set the temperature controlswitch under different operational conditions according to the table below.

#"( shuts down the driving motor of the crusher

CautionJ !hen the oil temperature is too high due to a serious fault in the lubricating system such

as failure of cooling system the protective temperature control switch #"( will stop the crusher.

#herefore it is very important that no element should split the current. efore restarting the

crusher check the lubricating system and locate the cause then solve it.

#"0 controls the oil cooling

9perationalconditions

3ormal operational9peration under

9peration under

condition High temperatures Low temperatures

9perational 3ormal operational 9peration under

9peration under

conditions condition High temperatures Low temperatures

Ambient temperature 4a/imum +0K C 4a/imum 8%K C Lower than %K C

iscosity of lube oil IS9 " ('% ('%" 00% IS9 " (%%

5rotective temperature

control switch #"(

asic setting '8K C ,%K C '0K C

#urn off at '8K C ,%K C '0K C

#urn on at '&K C ,+K C ''K C


44/62

Ambient temperature4ai/um +0K C

:-%K;

4a/imum 8%K C :(%8K

;

Lower than %K C

:+0K ;

iscosity of lube oil IS9 " ('% ('%" 00% IS9 " (%%

#emperature control switch ofthe radiator #"0

asic setting +*K CT8, K C 80K CT'% K C ++K C T80K C

#urn off at 8,K C '%K C 80K C

#urn on at +*K C 80K C ++K C


45/62

5roper temperature beforestarting the crusher

0%KC :*,K ; +%KC :--K; (,KC :&&K ;

9il heater and radiator #"+

asic setting 0%K C :*,K ; +%K C :--K ; (,KC :,*K ;

#urn off at 0%K C :*,K ; +%K C :--K ; (,K C :,*K ;

#urn on at 0&K C :-'K ; +'K C :(%*K ; 0%K C :&&K ;


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*.+.0 clean the magnetic plug

a; Close the stop valve before the magnetic plug.

b; 5repare a bucket to collect the overflowing oil.c; Loosen the screw of the plug.

d; emove and clean the gau@e element.e; Install the gau@e element and plug.

f; 9pen the stop valve.

*.+.+ eplace the filter element

a; Close the stop valve :(; between the filter element :&; and radiator.

b; Close the stop valve :-; between the oil tank and magnetic plug :*;.c; eplace the filter element.

d; Check the oil filter element to see if there are large particles on the filter element. If yes some

part must be worn or damaged in the lubricating system.e; 9pen the stop valve between the oil tank and magnetic plug.

f; 9pen the stop valve between the filter element and radiator.

Inspectionegularly check the pressure drop after passing through the filter element :&; to prepare for

purchasing new filter elements.

CautionJ !hen the fan of the cooler is running the pressure in the oil system will usually.

#herefore it should be avoided to read the pressure during the period.

14 drain $luglube oil tan"

15 drain end ca$lube oil tan"

16 drain end ca$h#draulic oil tan"

17 drain $lugh#draulic oil tan"

18 gauze element

19 $lug


47/62

*.+.8 Clean the return oil mesh and oil tank

a; emove the cap on the lube oil tank.

b; aise and take out the filter mesh :0+;.c; Clean the filter mesh with diesel or petroleum solvent.

d; Clean the filter mesh with compressed air.CautionJ If the filter mesh is damaged it should be replaced.

f; 5ut the filter mesh back to the return oil tank.

*.+.' efill the main lubricating systemCautionJ efore refilling the oil tank wash the oil tank oil pipes and radiator with clean new oil.

a; einstall the bolt on the drain plug at the bottom of the lube oil tank.

b; emove the cap on the lube oil tank.c; Connect the hose with the oil bucket.

d; efill the oil tank with new oil :('%liters; through the filter mesh :0+;.

e; Check there is leakage at the connectors and valves.

f; emove the hose from the lube hub.g; einstall the cap of lube oil hub and tighten the flynut.

*.8 1lectric cooler Clean the electric cooler with compressed air every ')(% hours to ensure its working

efficiency. If vibration is found in the cooler the fan in the cooler has to be

clean or replaced to avoid damage to the cooler.

#o ensure optimal cooling effect it must be installed in a well)ventilated room and ane/haust fan must be installed as well.

#he electric cooler is controlled by the cooler temperature control switch #"0. 5lease

refer to 6temperature control switch7 in chapter *.0.((.

( cooler fan*.' Hydraulic system

pressure dropindicator light

2 thermometer

) pressure gauge, lube oil pump

pressure gauge connector

pressure drop sensor

: filter element

< magnetic plug

9 stop valve

10 safety valve

11 stop valve


48/62

#he setting of the crusher can be changed by the hydraulic system.. the adjustment of setting is

reali@ed by raising :to decrease the setting; or lowering down :to increase the setting; the

hydraulic piston and main shaft assembly :including the mantle liner; which is supported by thehydraulic piston. !hen the setting decreases the oil is pumped to the hydraulic cylinder and when

the setting increases the oil is pumped back to the hydraulic oil tank. #here is pressure gauge :(;

on the oil tank to show the pressure in the hydraulic system.

*.'.( Hydraulic pump

#he hydraulic pump :+; is a reversible gear pump. efore the pump is started the oil tank must

be filled with oil to a correct oil level.

*.'.0 ilter element

#he filter element is full flow type and has the capacity to filter all the lube oil passingthrough it. #he filter element can be used only once.

eplace the filter element

eplace the filter element when changing the hydraulic oil or every si/ months.

a; ?se the L( button bo/ :*; near the crusher to lower down the main shaft andhydraulic piston to the lowest position to release the pressure in the system..

b; emove the filter element :0; and install a new one.

*. L( button bo/

*.'.+ 4agnetic plug #he magnetic plug :,; is used to clear the magnetic particles in the system.

CleaningClean the magnetic plug when changing hydraulic oil or every si/ months.

1 $ressure gauge

2 filter element

3 h#draulic $um$

4 dam$er

5 control valve

6 magnetic $lug

7 h#draulic connector


49/62

a; ?se L( button bo/ :*; to lower down the main shaft and hydraulic piston to the lowest

position to release the pressure in the system.

b; 5repare a bucket to collect the oil.c; emove and clean the magnetic plug.

*.'.8 Control valve

#here is a control valve :'; between the crusher and hydraulic pump and it a one)way valve thatcontrols the oil flow to protect the pump.

1mergency manual start of the valve

#he control valve :'; has a manual start device for emergency use. !hen the dirt in the oil blockthe valve and the setting cannot be increased by the electric method carry out the following steps$

a; Loosen the cap :((;.

b; 5ush in the pin :(%;. If it is hard to do that put a (%mm bead on the cap

c; Start the pump to increase the setting :useL(button bo/ to lower down the main shaft to aproper position.;.

d; Stop the pump.

CautionJ If the valve is improperly operated remove and clean it. If it still doesnt work the capmust be replaced. Always keep the hydraulic system clean to reduce the risk of blockage of the

valve by dirt.

*.'.' 5ressure gauge #he pressure gauge :(; shows the hydraulic pressure measured by the control valve :';.

!hen the crusher is running the damping valve :8; between the hydraulic pipes and pressure

gauge helps to provide a more accurate pressure reading.Cleaning

9pen the damping valve :8; to clean the needle valve every week. After that close the damping

valve until the pointer of pressure gauge :(; can move freely.

Ch#pt!r 5in! En!rgy Accuu%#tor

#his chapter introduces the maintenance of energy accumulator.#o ensure safety please read carefully 6safety precautions7 in the chapter 0 before carrying out


-.( 9verview


50/62

top of the container by gas charging valve. #he rubber gasbag is filled with nitrogen.

#he setting increases due to overpressure

9il is s2uee@ed from hydraulic cylinder to energy accumulator which allows the mantle to falldeep enough to pass the iron chips from the cavity. After the obstacles leave the cavity the air

pressure in the energy accumulator immediately push the oil back to the hydraulic cylinder.

1veryones responsibilityIf the energy accumulator is suspected to have been damaged it must be rechecked by authori@ed

personnel. It is recommended to buy new ones from our factory.

-.0 low meter

-.+ Inflatable kit :optional;


51/62

b; Loosen the inner he/agon bolt :,; so that its sectional opening can be seen from the top of the

adaptor :';.

c; Close the vent valve :*;.d; Connect the air charging connector :+; of the energy accumulator to the adaptor :';. #ighten it

to avoid air leakage.

e; 5ut a thread connector :&; on the adapt :'; or and tighten it to avoid air leakage.

f; #ighten the valve rod :-; so that the valve inside the energy accumulator can open.g; ead the charging pressure on the pressure gauge.

emove the inflatable kith; Loosen the screw of valve rod :-;.

i; 9pen the vent valve :*;.

j; Loosen the threaded connector :&; and remove the inflatable kit:5?)( ;.

k; Loosen the adaptor :'; and remove it from the air charging connector :+; of energyaccumulator.

l; Check and make sure that the valve has no leakage. #his can done with the help of soapy

water.m; einstall the protective cap on the air charging valve of energy accumulator.

-.+.0 ill nitrogen

a; Install the threaded connector :(0; and air charging hose :((; on the nitrogen cylinder.

b; Loosen the he screw of protective cap :(; and :0; on the air charging valve of energy

accumulator.c; Loosen the inner he/agon bolt :,; so that its sectional opening can be seen from the top of the

adaptor :';.

d; Close the vent valve :*;.

e; Connect the air charging connector :+; of the energy accumulator to the adaptor :';. #ighten itto avoid air leakage.

Charging pressure of energy accumulator #olerence

3o ASbut with AS5lus 8.0 45a :,(% p.s.i.; ; '

!ith ASi ,.% 45a :*&% p.s.i.; ; '


52/62

f; 5ut a thread connector :&; on the adapt :'; or and tighten it to avoid air leakage.

g; #ighten the valve rod :-; so that the valve inside the energy accumulator can open.

h; Carefully open the valve on the nitrogen cylinder toi; Close the valve on the nitrogen cylinder and wait for ' minutes an then check the pressure. If

the pressure is too high release some air through the vent valve :*; to achieve a proper

pressure.

j; Loosen the screw of the valve rod :-;.k; 9pen the vent valve :*;.

l; Loosen the screw connector :&; and remove the inflatable kit:5?)(;.

m; Loosen the adaptor :'; and remove the adaptor from the charging connector of energyaccumulator :+;.

n; Check and make sure that the valve has no leakage. #his can be done with the help of soapy

water.

o; einstall the protective cap :(; and :0; back to the charging valve of energy accumulator.p; emove the inflatable kit from the nitrogen cylinder.

CautionJ echeck the pressure after one two and three weeks and then recheck it every , months.

Ch#pt!r 6!n Upp!r r#! A''!*%y

#his chapter introduces procedures of maintenance of the upper frame assembly.

#o ensure safety please read carefully 6safety precautions7 in the chapter 0 before carrying outany work or adjustment on the machine.

(%.(eplace arm frame cap

eplaceable parts$

5art Code >uantity emarks

Arm frame cap S"(,%)%,)%

!eight (+' kg

% seal ring S"(,%)%,)%

olt 40%U'' "'&*+)*, 8 *.*grade full thread

Spring washer 0% "-+)-& 8

CautionJ efore removing the arm frame cap disassemble the feed distributor :if installed; andclear the material in the feed tube.

(%.(.( emove the arm frame cap

a; Clear the material in the arm frame cap (SG160-06-02).b; emove the four bolts 40%U'' and spring washers 0% that fi/ the arm

'eommended tools

(ifting rigging and

chains

(ifting cables

obile crane

!learance gauge

rugs

2%mm $en0end wrench


53/62

frame cap on the upper frame assembly :S"(,%)%,)(&;.

c; 5ut the hook of a crane just above the arm frame cap(SG160-06-02).d; 5ut the hook into the lifting eye of arm frame cap :S"(,%)%,)%0;.

e; Lift up the hanging part of the cable.

Lifting load

5lease mind the weight of the arm frame cap as shown in the table above. Handle itcarefully. #he cables should be tight but the lifting should not start right away.

5lease keep away from the load. f; Carefully lift the arm frame cap from the upper frame assembly.

g; emove the 9 ring :S"(,%)%,)%+; from the arm frame cap :S"(,%)%,)%0;. h; 5ut the arm frame cap :S"(,%)%,)%0; on the ground.

i; Clear all the grease in the arm frame bearing.

(%.(.0


54/62

washer 0%.

g; ill in grease. 5lease refer to 6grease for arm bearing 7 in chapter &.'.

(%.0 Check the cavity Check the liners at a proper interval. 5lease refer to 6daily inspection and maintenance7 in

chapter ,.(. new machines must be inspected more fre2uently. After the liners are replaced twice

the inspection interval can be longer.


55/62

4 :medium fine; cavity

#he theoretical setting interval is ,)(, mm :%.08)%.,+;.

If the crusher runs with the , mm :%.08; setting the rate of reaching the minimum A dimension(' mm :%.,7; is faster than running with the setting (, mm :%.,+;. So when the setting is larger

the wear rate of the liner is slower.

As the wear of liners depends on the cavity shape it is hard to predict where is the A dimension.

#herefore operation and visual inspection e/perience is a must for determining the right time forchanging liners.

(%.+ Arm frame bearing

(%.+.( Check the arm frame bearing

4a/imum clearance and distance allowed above the pivot

Check the clearance of the arm frame bearing when changing the liners or twice every year

:(%%%hours;. If the feed material is very abrasive the inspection fre2uency should be increased.

If the clearance :S; is close to the ma/imum value allowed and the old bushing continues to beused the fre2uency of filling grease should be increased.

!hen measuring the clearance :*; push the main shaft toward the direction of main shaft

inclination and then measure with the clearance gauge at the other side. #he clearance gauge

should be parallel with the pivot. It is included in the tool bo/ delivered along with the crusher. CautionJ 4ake sure that the clearance gauge will not damage the oil seal of arm frame bearing or

the scraper.

If the clearance e/ceeds the ma/imum value allowed the pipe connection andFor main shaftbushing must be replaced. !hen removing the bearing the old parts should be measured to make

a comparison with new ones so that the worst worn part can be found and then the replacement of

the one part can help to achieve a proper clearance.

If the clearance is much larger than the ma/imum value abnormal inclination of the main shaftoccurred in the crushing process and the wear angle of the eccentric is incorrect.

Ch#pt!r E%!+!n S!tting !#'ur!!nt


56/62

#his chapter introduces the measurement of the CSS setting.

#o ensure safety please read carefully 6safety precautions7 in the chapter 0 before carrying out


((.( 9verview

Set up the adjustment system to compensate the wear of mantle and concave as well as to change

the CSS of the crusher. "enerally the fre2uency of checking CSS depends on the wear rate of the liners. Abrasive rocks

re2uire more fre2uent inspections while non)abrasive material only needs periodical inspections.

It is recommended to check the concave regularly to make sure that it doesnt suffer from unevenwear or become oval. esides also check if there is partial wear or damage in the cavity. If liners

are worn the mantle cannot be raised to contact the concave and the main shaft head nut has a risk

of contacting hub bottom of the arm frame. #his condition will happen very soon when the crusher

is crushing abrasive material with a large CSS.CautionJ


57/62

signal.

#he oil doesnt return to theoil tank :low temperature;.

Start the oil pump and let it run for about +%s.Connect the return oil flow switch to get 6ready

for start7 signal. Start the crusher and run it for

about 0%s. After about 8%s disconnect theswitch. If the crusher still cannot start. !ait for

a few minutes and repeat the procedures.

0

#he crusher

stops when itis running at

idle speed or

there is

material in thecavity.

#he oil pump doesnt work. Check the circuit and starter of the oil pumpmotor. Start the pump.

#he lube oil flow is too low. Check and make sure that the oil doesnt

overflow from the dust)proof frame. Check theoil pipe. If the blockage of return oil pipe is

found clear the blockage timely.

Clean the magnetic plug. If necessary replace

the filter element.

Check the capacity of the pump and the oillevel.

#he lube oil flow is normal. Check the switch of return oil flow.

#he oil temperature is toohigh and the belts are

slippery.

5lease refer to number +.Adjust the belt tension and if necessary replace

the belts.

educe the load of the crusher.

#he crusher motor is

overloaded.

Check and make sure that the eccentricity and

cavity shape are correct regarding the chosen

CSS and feed material. If the CSS is too smallincrease the setting timely.

Check if there is anything wrong with thebearing. 5lease refer to number -.

#he cavity is blocked. 5lease refer to '.,.

#here is iron chip in the

cavity or the cavity isblocked.

Lower down the main shaft to release the

blockage. Check all the liners to see if they areworn or loose. eset the motor and overload

protection. Check the belt tension and adjust itif necessary.

If lowering down the main shaft doesnt help it

may be necessary to loosen the bolts on theupper frame.

+

#he

temperature oflube oil is too

high.

#he protective temperaturecontrol switch #"( shuts

down the crusher.

Check the oil cooling system and thetemperature control switch of the radiator #"0.

5lease refer to *.0.((.

As for waterFoil radiator check the fan motorand starter. Clean the radiator core. Check and

make sure there is enough cool air. 5lease referto *.'.

#he radiator and oil tank compartment should

be avoided from direct sunlight.

Check and make sure that the safety valve hasno leakage. 5lease refer to *.0.*

If the dirt on the return oil mesh increases

check if the bearing is faulty. 5lease refer to*.0.(%.

#he radiator is continuouslyworking.

5lease refer to the content above.

If the viscosity of the lube oil is incorrect

please change the oil. 5lease refer to &.0 and

*.+.#he lube oil flow is too low. Check the oil pipes and remove the obstacles.


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Clean the magnetic plug. 5lease refer to *.+.0.

If necessary replace the filter elementaccording to *.+.+.

Check the capacity of the oil pump and oil

level.

8 #he crusher doesnt

maintain a

constant CSS

or the productsi@e is too

large.

#he hydraulic pressure is too

low.

Check the capacity of the hydraulic pump. If

necessary replace it.

#here is leakage in the

system.

Check the oil pipes. If possible raise the main

shaft until the liners contact each other.


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' Inspections of the pinion

shaft device

leakage.

If the oil level in the pinion shaft bo/ is too

low fill it to the correct oil level. If the oil level

continuously drops it shows that the internalseal is damaged. echeck please refer to &.8.

emove the pinion shaft device for inspection.If necessary replace worn bearings and sealingcomponents.

9il leaks from the e/ternalbearing cover.

Check if the e/ternal seal ring the or 9 ring isworn or damaged. emove the pinion bearing

for inspection. If necessary replace the worn

bearing and sealing components.

#here is abnormal noise

inside the pinion shaft

device.

emove the pinion shaft device for inspection.

If necessary replace worn bearings and sealing

components.

#he crusher or pinion shaft

bo/ is vibrating.

Check the pulley. Clean the dust and check the

belt tension. #hen check if the belts are wa/ed.

emove the pinion shaft device for inspection.If necessary replace worn bearings and sealing

components.

#he clearance in the bearingis too large due to e/cessive

wear of the balls and seat

ring.

re2uently check the noise and temperatureinside the pinion shaft device. emove and

replace the bearing at a convenient time.

eplace the oil inside the pinion shaft bo/.

5lease refer to &.8.

, #here is

abnormal

noise inside

the crusher.

#he conical gear is installed

correctly or the wrong

engagement of gear teethcauses abnormal noise.

Insufficient clearance

between the teeth will incurhigh fre2uency impact

sound.

emove the pinion shaft device and measure

the adjust the teeth clearance.

1/cessive wear of eccentricwear plate causes decrease

of teeth clearance.

Insufficient clearancebetween the teeth will incur

high fre2uency impact

sound.


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#he cavity is blocked or the

liners contact each other.

Check the operational conditions and CSS.

Increase the setting.

Check if the liners have become oval.

elative movement occursbetween the flanges of the

upper frame assembly andlower frame assembly.

If there is clearance between the flangesmeasure it with a clearance gauge. #ighten the

bolts. If there is still relative movementbetween the flanges the conical connectors

need to be machined. 5lease contact us.

#he hydraulic cylinder reacts

too fre2uently.

Check if 6skiing channel7 appears on the

mantle and concave. eplace the liners.

&

#he capacity

of the crusherdrops down.

6Skiing channel7 appears on

the liners

Check the feed device. 4ake sure that the

crusher is sufficiently fed. Check the

dimensions at the top and bottom of the feedmaterial. It is not allowed that the si@e of most

of the material is smaller than CSS. 5lease refer

to (%.0.

#he clearance in the arm

frame bearing is too large.

Check the clearance. 5lease refer to (%.( and

(%.+. if the clearance is too large check thecondition of the eccentric.

#he belts are slippery. Adjust the belt tension. eplace the belt when

necessary check the grooves of the pulley.

#he feed material or the

fraction has changed.

#he change of length or hardness of the

material may incur changes of the capacity.

4aterial piles up in or blockthe cavity.

Check the height of the feed tube. If possiblerestrict the top dimension of the feed tube.

* #he wear of

bearingcomponents

increases.

#he lube oil is contaminated

and thus the wear of eccentric increases.

egularly check the condition of lube oil.

5eriodically clean the oil tank and replace theoil. 5lease refer to *.+.

#he filter element is blocked. eplace the filter element. 5lease refer to *.+.+.

#he dust)proof seal ring isworn or damaged. If the clearance between the dust)proof frameand dust)proof seal ring e/ceeds the value

given in ,.+.( the dust)proof seal ring should

be replaced.

#he overpressure dust)proof

sealing system doesnt work.

Check the whole overpressure system and

check the operation.

- #he bearing in

the crusher is

faulty.

#he main shaft assembly is

rotating at a high speed or its

speed is the same with thatof eccentric. #he main shaft

and eccentric is stuck

together.


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the return oil mesh. evel

wheel is stuck or worn.

#in or lead particles appear

on the return oil mesh. #he

bushing or upper thrustbearing components have a

high temperature or they arepartially overheated or stuck.

#he temperature of lube oil is too high.

(% #he lube oil iscontaminated.

Copper particles appear on

the return oil mesh.

Check if the bearing is faulty. 5lease refer to

*.0.(% and number *.

#he temperature of return oilis too high.

5lease refer to number +.

#he hydraulic pressure is toohigh.

5lease refer to 8. #he crusher doesnt maintaina constant CSS setting or the product si@e is too

large.


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eplicate the inspection list and the inspection record in this appendi/ and use them in

accordance with the instructions in 6daily inspection and maintenance7 in chapter ,.(.

#o ensure safety please read carefully 6safety precautions7 in the chapter 0 before carrying outany work or adjustment on the machine.

3umber emarks

(

0

+

8

'

,

&

*

-

(%

((

(0

(+

(8

('

(,

(&

(*

(-

MANUAL DE INSTALACION DE CONO (CHANCADORA)

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Transcript of MANUAL DE INSTALACION DE CONO (CHANCADORA)