User Manual Cone Hpc220

HPC Series High-Effiency Hydraulic Cone Crusher
User Manual
Warning
Read and follow all safety precaution instructions throughout this
manual and on safety signs attached to this equipment.
SBUM-0402-0202
Shanghai Shibang Machinery Co., Ltd
Shanghai Shibang Machinery Co.,Ltd provides customers with comprehensive support and service.
Please feel free to contact our local office or company headquaters.
Shanghai Shibang Machinery Co.,Ltd

Address:416 Jianye Road, South Jinqiao Area, Pudong, Shanghai, People’s Republic of China
Postal Code:201201
International Trade Department

Tel.:0086-021-58385683
Fax:0086-021-38910000
Website:www.sbmchina.com
National Trade Department

Tel.:0086-021-58385683
Fax:0086-021-38910000
Website:www.shibangchina.com
Copyright © 2013 Shanghai Shibang Machinery Co.,Ltd

All rights Reserved.No part of this document may be reproduced or copied in any form or by any means
without written permission from Shanghai Shibang Machinery Co.,Ltd.
and other Shibang trademarks are trademarks belonging to Shanghai Shibang Machinery
Co.,Ltd. All other trademarks or trade names mentioned in this document are the property of their
respective holders.
The Chinese language version contains the original instructions. All other language versions are
translations of the original instructions.
Notice
The information in this document is subject to change without notice.Every effort has been made in the
preparation of this document to ensure accurancy of this contents, but all statements, information, and
recommendations in this document do not constitute the warranty of any kind, express or implied.
Contents
1 Safety Rules ................................................................................................................................................ 1
2 Basic Technical Information ....................................................................................................................... 9
3 Installation ................................................................................................................................................ 14
4 Lubrication................................................................................................................................................ 23
5.Hydraulic system ................................................................................................................................. .... 29
6 Operation Guidance .................................................................................................................................. 32
7 Glossary of Terms ..................................................................................................................................... 75
Appendix A HPC series Cone Crusher Hydraulic Lubricant Oil Station User Guide.................................. 77
i
1 Safety Rules
Before installation, please read this manual carefully. Any indifference of the
instruction in this manual may cause danger to you and your colleagues and also
bring damage to the machine.
1.1 Brief Introduction
Shanghai Shibang Machinery is a professional manufacturer of crushing,

screening , feeding and grinding machineries as well as mobile crushing and screening
plant used in mineral processing and all kinds of construction program. During design
and manufacture, many efforts have been paid to avoid danger to human safety and
health.
Because our machines are mainly used for handling some minerals and other
material which may do harm to human or animals, the operator should strictly obey
the rules for avoiding hurts. For example, the rules made specially for asbestos,
quartzite and radon.
The machines we provide are usually used as part of a whole mineral processing
line. Therefore, as a supplier, we are not able to provide operation instruction for the
control system in every working condition.
This manual mainly introduces knowledge of safe installation, operation and
maintenance rather than a detailed user manual for a specific model. It mainly
introduces some general danger that the user, operator, and maintenance people may
encounter in a crushing plant.
This manual could provide detailed instruction for certain machine. However,
extra training from Shanghai Shibang is still necessary. Thus, please keep contact with
our after sales services for information of training.
According to experience, in a crushing or screening plant, most accidents happen
during maintenance such as examining working components or cleaning out blockage.
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Therefore, this manual emphasizes on the safety precautions during the above working
conditions.
In order to avoid potential accident, please must note:
A. Please operate as instructed in the manual. Read carefully and obey the rules.
B. Regular maintenance for the machine and regular safety training for workers
must be provided.
C. Please obey universal and official safety rules.
D. Mark dangerous areas with warnings mark.
E. Prepare all necessary equipments and tools.
F. Factory owner and administration staff should be responsible for the
carrying‐out of the current safety rules. Make sure the workers will obey these
rules.
1.2 Basic Safety Precaution
The following introduces some basic safety precautions and do not include all
possible conditions and variations in operating the machines. Basic safety precaution
aims at making all staff aware of the common dangers at the working site.
1.2.1 Personal Safety
1. Read and comprehend every cautions and instructions in this manual and all
the instruction marks on or around the machines.
2.Once there is accident, please report to site manager; If someone gets hurt,
please turn to doctor as soon as possible.
3. Please put emergency call list beside the telephone and give notice to
everybody at site about the place of emergency call list.
4. Please don’ t operate the equipment or work around it when you have alcohol,
medicine, sedative or other medicine which will affect your vigilance or judgment.
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5.Please keep the handrails, guard railings, ladders and platforms clean, dry and
free from grease. Put machine components and tools in designated place when you
don’t use them.
6. Protect avoid your hair and loose cloths being hooked up by working
components of crusher or control elements.
7. Please wear protective glasses in places where the stone chips, ashes or dusts
etc may do harm to your eyes or when the operation rules requires you to do so.
Please protect your eyes and put on the protecting glasses as rules require.
8. Please put on gloves to protect your hands or fingers from danger of cutting,
scraping, burning and corrosion.
9. Please put on protective hat and shoes if the local working condition requires
or the country law requires. Please put suitable warning mark at material transporting
place ( from belt conveyor/ feeder to jaw crusher or below the crushers) because the
material may fall down.
10.Please take off rings, watches, necklaces and bracelets before entering the
factory.
11. Please put on ear‐protecting device at places where noise level is high.
12. Please put on respirator or mask in places where oil paint, chemical substance,
erosion substance or other substances may do harm to health. Please note, people
may suffer from silicosis where there are silica ash in the air.
13. Don’t carry too much. Use the hoisting equipment or transporting equipment
to help.
1.2.2 Safety at the working site.
1. Please keep the working site tidy and clean from all stone chips. Make sure the
stones or other material will not pile on the footpath, platforms, ladders or conveyos.
2. Without permission, anyone is not allowed to enter the working site or around
the working site. Please check the workers at the working site and it is necessary to list
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their names.
3. For all machine surfaces where your hand and feet might contact, please keep
them clean, dry and free from grease.
4. Please put protecting devices in designated place. Make sure that everyone at
the working site know the place and can use these devices correctly.
5. Check and start the warning devices at the working site every day. Make sure
that all the warning devices can work normally before the crushing equipments start
running.
6. Do not allow everyone to stand below the uplifted machines. When machines
are hoisted, please use safe hook or the hook with safety latch. Use spreading wooden
poles when necessary.
7. Be familiar with the weight limit and their error range of the machines used at
or around the working site.
8. Walking path is for walking and cannot be used for transporting equipments.
Therefore, please don’t overload the walking path.
9. Please be alert when your eye‐sight is blocked when supervising the working
site or around area.
10. Please cut off the driving motor of the equipment before moving away the
protecting devices,or before examination or maintainance.
1.3 Electrical safety
Only trained and qualified persons could undertake jobs regarding electrical
components.
1. Only when special test can prove that the electrical return circuit is cut, the
electrical circuit will be considered to be electrified.
2. Before examining, maintaining, greasing or adjusting machines, start the
safety disconnecting switch or main circuit‐breaker, and put warning mark
“Repair In Progress” at suitable place.
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3. Repair or change the broken wires, cables and connectors.
4. Check the ground wire and make sure that the motor and power cables are
connected correctly and safely before starting any machine.
5. Make sure that you know where the power circuits and underground cables
are placed. Please be extremely careful when working at these places. Please
keep in mind where electrical isolator switches are placed.
6. Make sure that you know the power has been cut, otherwise don’t do any job
related to electrical equipments in rainy days or when you stand in water or
wet surface.
7. Please be alert when you are near or handling the electrical equipments. Once
you notice any danger related to electrical equipments, inform the person in
charge immediately.
1.4 Safety for Combustible items and Dangerous items
1. Please put Combustible, explosive and other dangerous items in safe places.
Boxes for these items should be specially made and marked according to rules.
2. According to country or local law and rules, put the used or grease‐spotted
cloth into special box and keep them away from those combustible and explosive
items.
3．Please don’t put combustible and explosive items into, on or around the
equipments, electrical system or personal belongings.
Smoking or firing is strictly forbidden around the oil tank or other boxes with
combustible or explosive items inside.
4. Put several full fire‐extinguishers in different places of the working site. Make
sure everybody knows their places and usage. Fire‐extinguisher should be at working
state when adding fuel or when other fire dangers exist. Check the fire‐extinguisher
capacity at least once a month or handle according to rules.
5. When filling in the fuel or transporting combustible, explosive or other
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dangerous items, please stop all engines and motors. Please follow the procedures
SBM recommended when filling in the fuel or transporting combustible, explosive or
other dangerous items.
6. Fill the oil tank with oil or other explosive items in draughty condition. Keep
away from the equipments with sparkles or combustible items.
7. Prepare a shower pipe when filling in the fuel or transporting combustible,
explosive or other dangerous items to avoid spark discharges caused by static charges.
8. Please don’t start diesel or gasoline engine in a closed area, only when the
place is draughty.
Warning: Discharged smoke is toxic.
9. Please do not use combustible, explosive items such as gasoline, kerosine or
diesel. Please use noncombustible solvent as detergent remover.
10. Please follow the steps and precautions recommended by manufacturer when
using epoxy resin material.
Warning: Please mix or pour epoxy resin material in draughty condition. Please
don’t burn the solid resin in bad draft conditions. Protect your skin from the uncured
epoxy resin.
11. Change and check the battery in open and draughty places.It is forbidden to
fire or smoke around battery.
12. Please strictly obey country or local stipulations in environment, safe
transportation or other rules that stipulate how to handle waste material, emission, or
dangerous items. Make sure everybody is familiar with these rules.
13. Please put on protecting clothes and devices when operate combustible,
explosive or other dangerous items. Follow the recommended steps when handling
these items.
1.5 Pressure system (Air, hydraulic)
Please release all the pressure in pressure system before maintaining the
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components in pressure system.
1. Please release all the pressure in pressure system before checking the
hydraulic system. If pressure is released incorrectly, pressurized air and oil will
be dangerous to human beings. Oil and air under pressure are very hot so
please be extremely careful. Only when the air and oil cools down, you can
start maintenance work.
2. Don’t take any air pipeline or hydraulic pipeline off from the hydraulic cylinder
before pressure in the system is completely released.
3. Don’t operate pressure system if rubber pipe, pressure valve or fasteners get
worn or broken. Please first change the broken components before pressurize
the system.
4. Don’t take the air pressure or hydraulic oil cylinder’s clevis off from the system
accessory before pressure in the system is completely released. Don’t try to
take air pressure or hydraulic oil cylinder off if you are not specially trained or
authorized to maintain the oil cylinder.
5. Don’t adjust overflow valve pressure above the recommended value.
6. Please follow the recommended ways to check and maintain the pressure
system. Make sure that the workers are always in safe working condition.
7. Please watch out when handling hydraulic accumulator. They cannot be
heated, welded or mechanically handled.
1.6 Safety in welding.
1. Any welding or cutting job must be completed by experienced welder because
they are familiar with welding machines and the materials to be welded.
2. Take all necessary measures to prevent welding sparkles from splashing to belts,
rubber pipes, oil tanks, other machine components and human body. Caution for fire.
3. Please put ground cable of welding machine near the welding workpieces to
prevent machines from being damaged and human being hurt.
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4. Consult to the welding machine manufacturer before operation.
5. Please don’t weld the pressurized containers or pipes.
1.7 Safety Rules.
1. Try your best to protect your safety and health at the working site.
2. Be responsible for your and other people’s safety.
3. Check the tools and protecting machines regularly to make sure that they are in
normal working state.
4. Provide safety education to everybody regarding their work to build their safety
awareness.
5. Please learn the dangers and the protective mrasures of unfamiliar working
procedures in advance in order to protect workers and the machine.
6. Before starting any project, please carefully consider the possibility of accidents
and make precaution plans for you and others. Improve the working process
regularly.
7. When you find others in unsafe working conditions or in potential danger,
please warn them of the possible accidents and dangers.
8. Please be alert of the changes of the working conditions or procedures.
9. Please report the unsafe operation or working condition to superior without
delay.
10. Keep the working site and the tools tidy. All tools and materials, after being
used, should be put away in fixed place.
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2 Basic Technical Information
2.1 Introduction
This machine adopts multi-layer crushing theory. Reasonable structure parameter

and working parameter matched with the reasonable cavity design can realize selective
crushing, which means materials could be crushed along the threads of concave. Such
crushing method can save power, ensure the best final products shape, reduce the
possibility of over-crushing, improve crushing principles, and ensure the best
performance. At the same time, by reasonable definition of crusher’s inner structure and
mechanical parameter, the crusher can be equipped with a larger-power motor to make
better performance. Therefore, it represents the developing trend of modern cone
crusher.
This machine is mainly made up of transmission part, frame, eccentric sleeve part,
bowling part, concave part, supporting sleeve, adjusting ring and safety device.
When the crusher is working, material will be fed into the crushing cavity (formed
by mantle and concave) from the feeding tank. Motor will drive the transmission shaft
and a pair of bevel gears to make eccentric sleeve rotate. Eccentric sleeve force the shaft
axis to swing to make the concave surface close to the mantle surface from time to time.
In this way, material fed into the cavity will be crushed by continuous compressing
force and bending force.
Please note: Only when the cavity is full of material, the multi-layer crushing
between materials could be realized. To fill the cavity with full material can realize
larger output, smller product size, better shape and less power consumption.
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Naming mode
HPC is SBM’s high‐efficiency hydraulic cone crusher. Its naming mode is as
follows:
HPC 220/C
Cavity type (EC=extra coarse、C=coarse、M=medium、F=fine)
Max. power (160kW、220kW、315kW、400kW)
High efficiency （High Performance Cone Crusher）
For example HPC 220/C

HPC high-efficiency hydraulic cone crusher, max. power 220kw, coarse cavity.
Figure 2.1-1 Crusher terms
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2.2 Technical parameter
Chart 2.2-1 Technical Parameter
Model Cavity type Min. Feed Capacity Recommended

discharge opening （t/h） max. power
opening （mm）（KW）
（mm）
F（Fine） 13 95 120～200
HPC160 M（Medium） 16 120 140～220 160
C（Coarse） 19 190 160～250
F（Fine） 13 105 150～210
M（Medium） 16 150 170～250
HPC220 C（Coarse） 19 210 185～300 220
EC（Extra 25 230 220～400
Coarse）
F（Fine） 14 110 185～230
M（Medium） 20 196 255～320
HPC315 C（Coarse） 25 251 295～370 315
EC（Extra 30 295 325～430
Coarse）
F（Fine） 16 135 260～400
M（Medium） 22 210 330～450
HPC400 C（Coarse） 30 290 400～500 400
EC（Extra 38 330 440～550
Coarse）
Note:
• Capacity in this chart is the typical value based on 1.6t/m3 loose degree, proper
feeding ratio and at least 80% power consumption. The real capacity should be based
on material property, feeding mode and material components.
• Min. discharge opening value in this chart is the value when supporting sleeve
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doesn’t jitter. Min. discharge opening value will change according the different
material property.
• Feed opening matches with the min. discharge opening.
• Max. feeding size is based on the machine specifications and material shapes. Max.
feeding size is about 80%-100% of the feeding opening size.
Figure2.2-1 Particle sizes diagram

(Vertical: passing through rate Horizontal: sieve pore size)
Particle size in this diagram is typical values. They will change based on the
manganese steel plate abrasion, material gradation, cavity type, feeding materials’
moisture content and anti-press strength, crushing performance and other factors.
HPC high-efficiency hydraulic cone crusher has different cavity type. Generally,
you could choose the cavity from chart 2.2-1 and figure 2.2-1 based on material size,
material abrasion and requirements for final products sizes.
Crusher is only a part of crushing line. Therefore, the performance will be decided
partly by the selection and operation of feeder, conveyor, screens and small hopper.
When operating, the following factor can help to improve the crusher capacity and
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performance.
1. Select the suitable cavity according to the material.
2. Raw material gradation ratio should be proper. The raw material whose sizes
are smaller than the crusher’s closed discharge opening should be less than
10% of the total feeding material.
3. Control the feeding quantity. To make the cavity full of material will be better
and this is highly recommended.
4. Material should be evenly fed into cavity by 360°
5. Discharge conveyor specification should match with the max. capacity of the
crusher.
6. Select proper specification of the pre-sieving screen and close-circuit screen.
7. Automatic control system.
8. Keep the discharge opening unobstructed.
The following factors will bring damage to the performance of crusher :

1. There is sticky material in the feeding material.
2. Fine material (whose size is smaller than the discharge opening) takes more than
10% of crusher’s capacity.
3. The moisture content is high in the feeding material.
4. The feeding method is not correct.
5. The feeding materials are not evenly distributed.
6. The feeding process lacks control.
7. The recommended power is not fully used.
8. The capacity of belt conveyor is small.
9. The capacity of screen is small.
10. The material discharging is not smooth.
11. The feeding material is too hard or too tough.
12. The rotation speed of transmission shaft is smaller than recommended full-load
speed.
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3 Installation
3.1 Attention
The crusher must be installed in a horizontal surface. If not, the working life and
working efficiency will be shortened.
If the crusher is installed in the concrete base, please make sure the strength of the
base can bear the total weight of the machine and the feeding material.
If the crusher is installed on mobile chassis, the chassis must be supported by
crosstie or lifting jack, and the tires must be above the ground. If the tires are on the
ground, vibration will deform the tires and damage the bearing.
To avoid the crash of the mantle and concave during transportation and installation,
there should be fixed wedges on each side of the discharge opening. After installation
and before test running of the machine, please make sure that the wedges are taken out.
3.2 Crusher dimensions
Well planed installation is very necessary for the proper operation of crushers, and
during base building and installation, the dimensions of crusher is one of the important
considerations. Above the crusher, there should be enough space for dissembling the
mantle and concave. Sufficient room should also be saved on one side of the concrete
base to dissemble the transmission shaft. Space for feeding device (e.g. hopper) and
discharging device (e.g. discharging room, belt conveyors) shall also be considered. For
accurate dimensions, please refer to Figure 3.2-1 and Table 3.2-1.
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Figure 3.2-1 Dimensions

Table 3.2-1 Dimensions (please refer to Figure3.2-1)
Model A B C D E F G H I J K
HPC160 1927 1630 2135 1160 1840 1810 950 832 970 875 1750
HPC220 2182 1991 2726 1382 2232 2491 1095 965 1220 975 1950
HPC315 2295 2055 2775 1645 2470 2530 1210 1085 1410 1185 2370
HPC400 2977 2580 3447 1755 2595 2970 1385 1281 1574 1415 2830
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3.3 Weight of crusher and crusher components
设计基础应考虑的一个因素，也是计划上布置起吊设备时应考虑的一个因素
是破碎机重量。在安装期间或在更换破碎机衬板或其他磨损件时，必须使用适宜
的起吊设备。表 3.3-1 列出了整机的重量和需要经常吊运的部件的重量。参照表
3.3-1 计算提升设备，包括钢丝绳、吊具和所需吊钩的规格大小。必须记住，无论
如何，当吊索处于非垂直的任何角度时，它能承受的载荷急剧的减小了。例如：
每个起吊装置的吊索处于与水平呈 60°角度时，只能承受它的安全起吊能力的
85%；在与水平呈 30°角度时，它的承载能力仅是其垂直起吊能力的 50%。
When designing the concrete base and in choosing the lifting equipments, the
weight of crusher needs to be considered. Suitable lifting devices must be chosen
according to crusher’s weight during installation or when changing the spare parts.
Figure3.3-1 shows the total weight of crusher and the weight of some crusher
components. You can choose suitable lifting devices such as wire ropes, slings, lifting
hooks by referring to Figure 3.3-1. Please note that when the sling is not vertical, its
bearing load decreases sharply. For example, when the sling forms an angle of 60
degree to the horizontal plane, its lifting capacity is only 85% of the normal capacity. If
the angle is 30 degree, the capacity is 50% of normal capacity.
Table 3.3-1 Weight of crusher and its components
Model Total weight Transmissio Machine Eccentric Crushing Ball Supporting Adjustable Safety
(excluding n assembly frame sleeve cone bearing sleeve ring device
motor and device
control box)
HPC160 13110 548 3004 882 1308 61 2205 2590 587
HPC220 18900 892 3920 1123 2220 110 2725 3682 820
HPC315 29700 925 7530 2054 4127 215 5123 6227 1323
HPC400 36600 950 9295 2493 5076 251 6280 7673 1548
The above weight is subject to ±5% variation. All weight is calculated in

kilograms.
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3.4 Feeding
The feeding device will directly influence the working efficiency of crusher. If the
feeding material is evenly distributed in the crushing chamber, the crusher will achieve
highest efficiency.
Above the hopper, there should be a feeding box (the height should not exceed
1.5m). The material in the hopper will fall down evenly onto the distributing plate. If
proper feeding method and the distributing plate are used together, the feeding box will
ensure that the feeding materials are evenly distributed in the crushing chamber. To
reduce the wearing of lining plate, please keep a reasonable proportion of fine and
coarse material. To achieve the best performance, feeding should be adjustable. The
material should be piled 75mm-100mm above the crushing cavity (full cavity). To adopt
this feeding method, the capacity will be larger, the final product size will be finer, and
power consumption will be less. Since the structure and material of feeding box depends
on the feeding method, the feeding box is not supplied together with the crusher.
For every kind of crusher, it is strongly recommended that the materials are sieved
first to get rid of fine or sticky material. This will avoid blockage, over-moving of
supporting sheath, and low production efficiency. One set of metal detector should be
installed to get rid of metals that cause moving of supporting sheath.
The capacity of feeding device should match the largest capacity of crushers.
Controlling the feeding speed is very important. If the feeding material falls from a
high place, the material will all go through the opening of crushing cavity. The
uncrushed material that falls onto the bottom of crushing cavity will cause the moving
of supporting sheath. This will lead to severe damage of the contact surface of
mainframes and the supporting sheath. If >900mm or larger material falls into the
crushing chamber, you should adopt ladder-shaped feeding or install speed-reducing
device.
For correct and incorrect feeding method and the structure of feeding box, please
refer to Figure3.4-1.
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Incorrect Feeding Correct feeding method

The feeding materials are not evenly The feeding materials falls evenly
distributed. onto the distributing plate
The damage would be: The benefits would be:
1. Lower capacity 1. Large capacity
2. Larger size of final products 2. Even product size of final products
3. Moving of supporting sheath 3. Smallest moving of supporting
4. Huge pressure of bearing sheath
5. Large power consumption 4. Lowest pressure of bearing
6. Crusher damage 5. Lowest power consumption
For the above damages caused by
incorrect feeding method, our
company does not take
responsibilities.
Figure 3.4-1 feeding method
3.5 Discharging
Since the discharging configuration is different for each machine, the discharging
room or hopper is not supplied together with crusher. However, the structure should
meet the demands of the foundation drawing. The discharging room could be made by
metal or wood. An inspection hole should be saved in the discharging room for the
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convenience of cleaning and inspection. There should be clapboard in the discharging

room to form a material liner. This clapboard can bear the impact force of falling
material so that the service life of crusher is prolonged.
If you use the hopper, it should form a 45 degree with the horizontal plane. If the
materials are sticky, the angle should be larger.
Enough space should be saved between the mainframe and the bottom of the
discharging room, and also between the discharge opening/hopper and the belt
conveyor/elevator. The space can avoid material blockage.
3.6 Piping
In chapter 4, lubrication system, there is detailed introduction of oil types,

temperature and necessary equipments used in the lubrication system. Please note that
the largest working pressure of lubrication system is 8.6 bar.
In piping diagram, we listed the pipe fittings supplied with crusher and lubrication
device. The piping diagram could also be adjusted to local conditions. Two factors need
to be considered when designing the oil feeding pipe and the oil discharging pipe: the
pipes should be short and straight, without dead angles or other oil blockage; the error
of oil discharging pipelines for every 305 mm should be 25mm.
Please check if the inside of pipes is clean. To ensure the safe running of oil pump,
please clear all the metal cuttings of screw.
Install joints in suitable place for the convenience of dissembling lubrication
device, oil pump, filter, cooler, etc.
Check if the pipe joints are leaking. It is very important to ensure the sealing of oil
sucking pipe which connects the oil pump and oil tank because leakage of oil sucking
pipe will cause low efficiency of oil pump, i.e. the oil level and oil pressure will be
apparently lower, which will affect the lubrication of crushers. The leaking of oil
sucking pipe is very dangerous since the leakage of oil sucking pipe is not as obvious as
the leaking of pressure oil pipe.
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3.7 Assembly and disassembly
Small crushers are usually delivered as a whole unit. Large crusher, most of the
time, are first dissembled and then delivered considering the restricts of transportation
and lifting.
Before installing crusher components, please first check if the protective layer of
the machined surface has been removed, and also check if all the components,
especially the oil pipes are clean without metal cuttings and dirt.
During transportation, some machined surface or threads might be damaged. They
must be repaired before installation. After cleaning, the surface of all bearings and the
machined surface of bearing’s matching part must be lubricated.
3.8 Instructions for maintenance
During maintenance, the following protective measure should be adopted:

1. When disassembling the machined surface or the supporting surface and the
their components that will rust, these surfaces and components need to be
coated with lubrication or anti-rust oil no matter for how long they are
disassembled.
2. When processing the machined surface and the supporting surface with their
corresponding components with very small deviation, you must be extra
cautious.
3. When disassembling any components of the machined surface, use wooden
wedges to avoid their interaction with the ground.
4. Be careful when handling the cooper bush or sleeve. Excessive impact on such
soft metal will cause bending.
5. Before assembling the crusher components, all mechanically processed
components need to be cleaned and oiled. Without oiling, the components
cannot be installed in the crusher.
6. When assembling two components that are force fitted or slide fitted, please
lubricate these components, which can also protect these components from
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getting rusted.
7. The moveable cone and the eccentric bush should be restored vertically. Other
methods of storing will make them deformed so that they cannot be installed.
8. The thread surface of the supporting sheath, the adjustable ring, the locknut, the
movable cone and the press cap must first be wiped by cloth with molybdenum
disulfide powder, and then coated with oil or lubricant. If you don’t have
molybdenum disulfide powder, enough oil is also okay.
3.9 Minimum recommended spare parts list
To ensure normal working of the machine, the following spare parts should be prepared.
1. Mantle 2. Concave 3. Press ring 4. Thrust bearing gasket (one set)
The above list is the minimum spare parts list. If the crusher is used in remote area or
you buy several sets of crusher at one time, this list should be enlarged.
3.10 Installation
If the crusher or crusher frame needs to be installed on concrete base, the

mainframe must be fixed by grouted concrete. There are usually two kinds of materials
for grouting: concrete and epoxy resin. The most commonly used is concrete.
1. Keep the verticality and horizontality of the machine frame. Use the gradienter
and overhang to examine the central line of the base.
2. After adjusting the levelness of the base by the adjustable iron pad, fasten the
anchor bolts and do the grouting for another time.
3. After the second grouting is hardened, take away the adjustable iron pad and
fill the gap with cement and then check the verticality and horizontality as in
step 1.
4. Keep the horizontality and verticality of the machine base to ensure its reliable
performance. Otherwise, the eccentric bushing will be worn.
21
If the crusher is placed on steel frame or mobile chassis, the machine must be fixed
by gaskets. The steps are as follows:
1. Remove the welding slags on top of the steel frame and rub the unsmooth
welding spot.
2. Cut four steel plates 6×305×305 by gas cutting. In the middle of the steel
plate, there should be a hole for installing the bolts.
3. Lift the machine frame carefully and place it on top of the four steel plates.
4. Insert U-shape gaskets 305*305 around the anchor bolts to keep the crusher
level. The thickness of the gaskets can be adjusted.
5. After adjusting crusher’s levelness, measure the gap between the machine frame
flange and the steel frame referring to the 3 areas in Figure 3.10-1. The 3 areas
must have gaskets to enhance the support between the machine frame and the
steel frame. The thickness of gaskets varies according to crusher models, and its
width is about the same with the machine flange, 610-915mm.
6. When the gaskets are fixed appropriately under the crusher, weld the gaskets
onto the frame or the mobile chassis to ensure its fixation under vibration.
7. After fixing the machine onto the steel frame, check again the levelness of
crusher.
If the crusher is installed on the mobile chassis, the chassis should be supported
by crosstie or jack lift. The tires must be above the ground. If the tires are on the
ground, the vibration will cause deformation of tires and thus damage the
bearing.
Figure 3.10-1 gaskets place

22
4 Lubrication
4.1 Brief introduction
The lubrication system provides lubricant with adjustable temperature and pressure.
The lubricant is filtered and the quantity is pre-determined and thus is widely used in
crusher lubrication. The unitary lubrication system applies to all kinds of weather and
atmospheric conditions. The system has automatic alarming which alarms when the oil
temperature is too high or too low. Through inspecting the oil meters, you can clearly
see the working conditions of all parts including the temperature of cooler inlets and
outlets, return oil temperature, oil pump pressure, oil supply pressure, and pressure loss
of the filter.
For the oil flow, please refer to figure 4.1-1 Oil flow
Figure 4.1-1 Inner Oil flow
23
The cooler of the lubrication system has two types. The most commonly used is
water cooler. In some water lacking area or for the mobile crusher, you can use air
cooling. This cooling method uses a large radiator similar to car radiator, to cool the hot
oil in the crusher. The fan installed on the radiator will cool the surrounding air, the
radiator and thus cool the oil. The structure of cooler depends on the highest
environment temperature and the crusher model, thus the cooler should be designed
according to local condition. The air cooling can achieve the same effects with water
cooling. The normal supply with crusher is the air cooler.
The lubricant, under certain pressure, will go up through the main shaft to the
eccentric bushing, the moveable cone, and then up to bearing of bowl liners. The oil
overflow will flow to the oil hole of movable cone and then to the large and small gears.
Meantime, for another oil flow, the oil goes through the transmission shaft to the
bushing and is finally collected in the return oil tank and then goes to the oil tank
through oil pipe automatic flow.
4.2 Features of lubrication oil
Use the linear alkyl carbonate (not naphthene) with standard viscosity. This kind of
oil has the feature of high oil film strength, good adhesiveness to metal and stable
physical and chemical properties.
The lubricant must include the extreme pressure additives such as phosphate sulfur
and anti-adhesive that can be used for crusher metals (such as bronze, Babbitt metal,
cast iron and steel). In addition, the lubricant must have a high viscosity index and has
the following features: quick separation with water, no bubbles, anti-rust, anti-corrosion,
anti-oxidant, anti-wearing. Compared with clean industrial oil, the extreme pressure
lubricate has a much lower freezing point. Thus, the extreme pressure oil worth a higher
price.
The suitable lubricant is ISO 150 grade.

The lubricant should meet the following viscosity:
24
Under40℃, 135～165cst
Under 100℃, 13cst or higher
In addition, the viscosity index must reach 90 or higher
The recommended lubrication oil is as follows:
1、Temperature >30℃（very hot）
BP Energol GR-XP 220
ESSO Spartan EP 220
MOBIL Mobilgear 630
SHELL Omala Oil 220
2、Temperature +5～+35℃（summer）
ESSO Spartan EP 150
MOBIL Mobilgear 629
SHELL Omala Oil 150
3、Temperature -25℃～+10℃（Winter）
BP Energol GR-XP 100
ESSO Spartan EP 100
MOBIL Mobilgear 627
SHELL Omala Oil 100
4、Temperature -34℃～-25℃(very cold)
Mobilgear SHC 150
Please note: do not mix lubricant from different producers. It is recommended that
the ISO150 oil is used all year round.
When choosing the lubricant, please meet the above demands to protect the
crushers. If inappropriate lubricant is used, the crusher quality cannot be guaranteed.
4.3 Oil temperature
The oil temperature should be within 25-60 ℃ . However, the optimum

temperature should be 38-54℃. If the oil temperature is above 60℃ or below 25℃, the
crusher should not be allowed to work.
Slightly higher oil temperature can guarantee the normal oil flow. But if the
25
discharging oil is higher than 60 degrees, cooling system must be used.

When the oil temperature is below 25℃ in cold weather, we suggest to use a
electric heater with constant temperature control.
At any time, if you suspect the crusher temperature is too high, you can check the
thermometer installed on the oil inlet and outlet pipe to check the temperature difference
between oil inflow and outflow. The difference should be within 3-5 ℃. If the
difference is larger than 5℃, this might be caused by the damage of bowl liner. It must
be pointed out that the actual difference might be larger than 3-5℃ considering the
length of oil pipes, use of heater or coolers. Normally, the difference is constant. If the
difference changes sharply, the cause might be damage of be bowl liner by high oil
temperature.
4.4 Oil pressure and flow rate
The pump capacity, pipe size and safety valve model have been selected and well
adjusted, which can offer enough lubrication oil to crusher to ensure the normal
operation of cooler. Thus, please install and use the lubrication system following the
user’ manual of lubrication station, and operate the lubrication station and crusher
properly following this manual.
Table 4.4-1 listed lubrication oil flow rate and working pressure in transmission shaft of
all models of HPC cone crusher's.
Table 4.4-1 Lubrication oil flow rate and working pressure
Recommended
The lowest flow Normal working
Model flow
rate( Litre/Min)） pressure（Mpa）
rate( Litre/Min)
HPC160 95～114 60 0.14～0.35
HPC220 114～132 80 0.14～0.35
HPC315 204～222 150 0.14～0.35

HPC400 227～246 170 0.14～0.35
26
4.5 Start and shutdown of Lubrication station
Lubrication station must be started before the start of crusher, so that

the lubricant can be firstly transported to the compoments which need
to be lubricated. And please do not start the crusher until there is a
steady flow of oil in the oil-return pipe. Similarly, only after the crusher
stops working can we power off the lubrication station. Please ensure
that before the start of crusher’s driving motor, the oil pump has been
operating for at least 2 minutes, so that all bearing surfaces are covered
with oil film.
4.6 Ventilation device
Install a ventilation device on the transmission shaft frame or the oil

trap of the transmission shaft’s belt pulley, which can maintain
atmospheric pressure within the crusher, to ensure that the lubrication
oil can be discharged smoothly.
To check if the crusher ventilation is normal or not, we can put a
tissue on the elbow of the ventilation device. If the tissue twitched
gently to the inside, the ventilation is good. However, if the tissue is
blown off, there is something wrong with the crusher ventilation.
If the ventilation device is not ventilated, the reason might be: the long
core hole in the transmission shaft frame connected to the ventilation
device has been clogged by the impurities. Measures shall be taken to
remove the impurities: please remove the ventilation device as well as
pipes and use compressed air to clean the holes. Normally, you don't need to
dissemble the transmission shaft frame to clean the impurities.
27
4.7 Positive pressure dust-proof device
The positive dust-proof device is used to prevent dust coming into lubrication
station of crusher, which is installed around ventilation device of the transmission shaft
frame, replacing the gas filter of ventilation device.
28
5. Hydraulic system
5.1 General introduction
All HPF220 hydraulic cone crushers are equipped with Iron pass-by or crushing
cavity hydraulic release and cleaning system. Insurance cylinder is connected with the
lower part of frame as well as fixed together with the supporting sleeve, which ensures
the solid connection between the supporting sleeve and the frame in order to bear
normal crushing force. The extra large crushing force generated by abnormal operating
or non-braking material (iron) will rise the supporting sleeve up, which can push the
piston rod of in the upper part of hydraulic cylinder to move upward. then the hydraulic
oil in the hydraulic cylinder will be squeezed into the accumulator, and then compress
the nitrogen in the accumulator. Once the overload disappears or the Iron (or extra hard
material that cannot be crushed) goes through the crushing cavity, the crushing force
goes back to normal, compressed nitrogen pushes hydraulic oil back to hydraulic
cylinder, and supporting sleeve is back to its original place. To clear the crusher,
pressurize the lower half of hydraulic cylinder to push the piston, thus pushing the
supporting sleeve off the main frame.
In addition to the release and clearance system of the hydraulic cylinder, the
crusher is also equipped with a concave hydraulic locking and adjusting system. A series
of hydraulic locking cylinders between locknuts and supporting sleeve can lift the
locknuts on upper part of the supporting sleeve, so that the concave will be in crushing
position when the hydraulic cylinder is pressurized. When locking hydraulic cylinder's
pressure is relieved, hydraulic motor adjusting system fixed on the supporting sleeve
will turn the adjustive ring assembly to change discharge size.
All HPF220 hydraulic cone crushers are equipped with hydraulic station to control
all hydraulic functions.
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5.2 Characteristics of hydraulic oil
Oil used in hydraulic system must be chain alkyl (not cycloalkyl) high-grade industrial
oil with the required viscosity, which should have a higher film strength, strong
adhesiveness to metal surfaces and stability of physical and chemical properties.
Oil used in lubrication system must have the following feature: high viscosity index,
quich separation with water, no bubbles, anti-rust, anti-corrosion, antioxidant, and
containing anti-wear additives.
Recommendation: ISO 32 lubrication
Viscosity of oil:
40℃ 20～40cst
100℃ 6cst or higher
But at most 68 cst.
It is very important to use suitable lubrication oil as stated above to protect crushers.
Improper lubrication oil will damage the crushers and make any guarantees about
crushers ineffective.
There should be sufficient oil in the hydraulic oil tank to make sure that you can see the
oil level in oil gauge. When adding and releasing oil or pressurize the releasing system,
the oil level should be in the middle of the oil gauge window.
5.3 Maintenance
Pressure relief
Maintenance of hydraulic system, the pressure of relevant circuits must be relieved to

ensure that any circuit pressure is "0", which is very important for workers' safety.
When the crusher stops working, normally many circuits' pressure will be relieved and
only when the crusher operates can we compress. However, as a safety precaution,
before circuit operation, we should use pressure gauge to confirm there is no residual
pressure in the circuit.
30
Please clean the hydraulic station as follows:
a) Empty the entire system. Oil samples can be sent to the laboratory to check the
status of the hydraulic oil. Please clear all used oil as carefully as possible,
because even after you have emptied the oil tank of hydraulic station, perhaps
there is oil residue in the locking system, the accumulator and the pipelines,
etc.
b) Please remove the oil suction tube filter from the connecting point of the oil
pump. Please check the filter to see if there is any dirt accumulation around
filter or on the filter magnet. The naked eye can detect peeling paint, rust, wear
particles, hair or other similar items. If you find wear metal particles, please
identify the cause of the wear and tear. Clean the filter in solvent and then
air-dry.
c) Please wash the inside of oil tank with solvent or clean light oil. Wipe the inner
surface with lint-free cotton.
d) Fill the hydraulic system with oil of suitable specification and quantity. Please
refer to the recommended hydraulic oil in the previous part of this chapter.
Troubleshooting of hydraulic station
Most faults of hydraulic system render one of the following symptoms: graudual or
sharp decrease of high pressure which decrease the energy or reduce the speed of the
hydraulic driving system or the releasing cylinder. The major form is oil leakage.
The pressure loss may cause blockage or immobility of hydraulic driving system or the
releasing cylinder. Any of the major components - pumps, safety valves, control valves,
locking valves and iron pass-by or crushing cavity release cylinder may have some
problems. Before any troubleshooting, you should check the following items:
a) Oil level of hydraulic station is appropriate.

b) All soft tube fittings are installed properly in the hydraulic station and crusher .
c) Accumulator is filled with appropriate nitrogen.
31
d) Air in all oil tubes connecting the hydraulic station and crusher has been
released
e) No visible oil leakage in hydraulic station or crusher.
f) Oil pump is running.
Accumulator pre-charge pressure (crushing cavity release system and hydraulic

station)
All accumulators should not be connected to the hydraulic circuits until the pre-charge
pressure meets required pressure value. The pre-charge pressure value is 8-8.3Mpa of
all accumulators.
6 Operation Guidance
6.1 Preparatory work before start-up
Good inspection habits will keep the proper crusher operation all year round,
Regular maintenance and accurate record should be taken. Pre-start-up and routine
maintenance inspection can reduce the crusher stopping time and extend the life of the
crusher. Before start, you should make the following preparation:
a) Check if the suitable lubrication oil is used, and if the lubrication system is
correctly installed.
b) Start oil pump motor, check the oil return pipe of the oil tank to ensure the oil
circuits. The discharged oil should at least fill half of the oil return pipe.
c) 3. Remove the wooden wedges squeezed between crushing liners for the
purpose of transportation.
d) Check the axial clearance. The transmission shaft must be able to run from
inside to outside freely along the axial direction. Please check axial clearance
in table 6.1-1.
Table 6.1-1 Axial clearance
Model Axial clearance
32
HPC160 1.0～1.5 ㎜
HPC220 0.8～1.5 ㎜
HPC315 0.8～1.5 ㎜
HPC400 0.8～1.5 ㎜
e) Final inspection should be taken to ensure that there are no tools or other
mechanical obstructions within the crusher, all wedge heads and fasteners are
tightened. There is no oil leakage, and no other factors that hinder the crusher
start-up.
f) Use your hand to rotate the transmission shaft to check if the mantle and
concave will clash and if there are other mechanical obstacles.
g) Please check one by one according to the attachment Check list before start-up
to ensure all equipments and other auxiliary equipments have been inspected
and ready to start.
h) After finished all inspections listed above, please start crusher according to 6.2
First start up and test running.
Speed of transmission shaft
The accurate speed of transmission shaft (or RPM) is very important for proper
working of crusher. The speed of all models of HPF220 series cone crusher is listed in
the following table 6.1-2. The specifications of crusher pulley is designed for full load.
Thus, when the crusher is under empty load operation, the transmission speed will be
slightly higher. Experiences have shown that correct speed of crusher will reach the
largest capacity and best product shape.
Table 6.1-2 Speed of transmission shaft
Model Speed at full load（RPM）
HPC160 1120～1232r/min
HPC220 1020～1122r/min
HPC315 910～1000r/min
HPC400 865～952r/min
The speed of transmission shaft is determined by the material quantity in the
crushing cavity and the impact frequency. If the crusher is running at improper speed,
33
(10% higher is acceptable). If the speed of transmission shaft is much lower than
recommended, the over compression in the crushing cavity will cause crusher stoppage
and severely damage the crusher running.
Under certain circumstances, it is recommended to adopt slightly higher speed to
change the material size or shape while keeping the crusher’s capacity
Rotation direction of transmission shaft
The rotation direction of all models of hydraulic cone crusher is designed for
clockwise rotation. The rotation direction is decided by the driving part of the
transmission shaf. The mantle is compressed on the moving cone by automatic
self-locking bolts. Only when the rotation direction is right, can it have self-locking
function. Thus, the rotation direction is very important.
6.2 First start-up and test running
Although crusher has been tested in factory, for first start-up or first-time running after
installing new bearing, the crusher should run under empty load or under reducing load
for several hours. In this way, the crusher can go through the breaking-in period, and all
components can be lubricated and operate properly. During this period, you should also
check the oil temperature frequently. Please refer to the oil temperature part in Chapter
4.
Steps for first start-up or first time starting after installation of new movable cone
bushing or eccentric sleeve bushing:
a) Before start-up, start the lubrication system.
In order to supply sufficient oil to the crusher’s bearing, the oil temperature of
return oil pipe must reach 25 ℃ before start. If necessary, use submerged heater
to heat oil.
b) Hydraulic station should start operating before the crusher runs.
c) Start crusher and run under empty load for half an hour, to ensure that return oil
temperature reaches at least 25 ℃.
d) After operating under empty load for half an hour, while feeding, please keep
the electric currenct reach 50% of rated current on the motor’s nameplate,and
34
keep the crusher operate for at least eight hours.

e) After completing steps 3 and 4, keep the electric currency reach 60% of rated
current on the motor’s nameplate, and keep the crusher operates for another 8
hours.
f) After completing step 3, 4, and 5 , the crusher can run under full load condition.
The currency will reach 70-80% of the rated currency (coarse cavity), or
80-90% of the rated currency (for fine cavity), or the supporting sleeve is about
to lift.
g) After trial operation,please check the lubrication oil and take daily records.
6.3 Daily start-up and shutdown procedures
After the test running, the daily start-up and shutdown procedures are also very
important.
Daily start‐up
a) Before starting the crusher, first start the lubrication system and make sure the
oil temperature in return oil pipe is no less than 25℃.
b) Before starting the crusher, lubricant must have been cycling for at least two
minutes.
If there is no oil discharged from return oil pipe in the oil tank, the crusher
should not be allowed to operate for more than 15 seconds, because it may
cause serious damage.to crusher. Under normal circumstances, the oil flow
discharged from the oil return pipe should at least fill half of the return pipe.
Decrease of oil flow might be caused by many factors, such as insufficient
lubrication oil, oil pump failure, performance degradation of oil pump,
blockage of oil pipe or improper setting of relief valve.
c) Hydraulic station must operate before crusher’s start-up.
d) Start crusher and operate for about 5 minutes with empty load.
e) Start from small amount of feeding material and gradually increase feeding
until achieving the maximum power level. (At most can reach 70%-80% of
rated electrical current or the supporting sleeve is about to be lifted.)
35
Daily shutdown
a) Stop feeding and continue operating for 2-3minutes without feeding.
b) Stop the crusher and let it slow down to stop running. The minimum
deceleration time is about 45 seconds.
c) When you finish step 2, lubrication system can be shut down after 10 minutes.
d) Stop hydraulic station.
6.4 Adjusting the discharge opening
Discharge opening is not totally determined by the required product size..

Sometimes, we need to adjust the closed side openings between the liners slightly
smaller than the max. desired product size. When you want to change the product size,
please re-adjust the fixed cone. In addition, the fixed cone needs to be adjusted to
compensate for wearing of the crusher liner.
In the open cycle design, please set the discharge opening according to the required
product size. In a closed cycle, the discharge opening can be 3-6 mm than the pore size
of screen.
Setting the discharge opening by desired final product size may not be the best
option. The best choice is the optimal discharge opening which can ensure the largest
capacity. This is usually determined by the raw materials characteristics, the motor’s
driving power or supporting sleeve’s moving.
The discharge opening changes with the place of the adjustive ring in the
supporting sleeve. The supporting sleeve falls when the it rotates
clockwise, and it rises when rotating counter-clockwise. When the adjustive ring falls,
the discharge opening decreases, and when the adjustive ring rises, the opening
increases.
Adjusting fixed cone with hydraulic equipments
After pressure in the locking cylinder decreased, the hydraulic motor mounted on
the supporting sleeve will start, gears on the hydraulic motor drives the adjustive ring
assembly to rotate to adjust the discharge opening. Table 6.4‐1 shows the change of
discharge opening when the motor rotates one tooth pitch.
36
Table 6.4-1 Discharge opening adjustment
Change of discharge Change of discharge

opening when the opening when the
Model
adjustive ring rotates adjustive ring rotates
one tooth pitch 1/4 round
HPC160 0.18mm 6.3mm
HPC220 0.23mm 8.5mm
HPC315 0.20mm 8.9mm
HPC400 0.18mm 8.5mm
Adjusting the adjustive ring (fixed cone) with crane
If crane and other equipments can be used, more skills are needed to rotate the
adjustive ring in the locking nut and the supporting sleeve.
Before rotating, release the pressure in the locking circuits. Hang up the suitable lifting
cable between the adjustive ring’s lifting hook and the overhead crane’s hook and
then slightly lift the fixed cone upwards. By this small lifting force, the adjustive ring
will suspend in the threads of supporting sleeve. Then two people adjust the adjustive
ring upward or downward for the required discharge opening.
Table 6.4‐1 shows the change of discharge opening when the adjustive ring rotates 1/4
round.
Minimum discharge opening
Do not adjust the discharge opening to a certain extent that will casue moving or
clashing of the supporting sleeve. Clashing of supporting sleeve will lead to abnormal
stress within the crusher and excessive damage to the main shaft.
Table 6.4‐2 shows the recommended minimum discharge opening. These values are
only for reference. The actual opening can be slightly larger or smaller than
recommended based on different types of raw material. The main principle for
adjustment is to make sure the supporting sleeve does not clash.
37
Table 6.4-2 Minimum discharge opening
Model Cavity Discharge setting min

（mm）
F（fine） 13
HPC160 M（Medium） 16
C（Coarse） 19
F（Fine） 13
M（Medium） 16
HPC220
C（Coarse） 19
EC（Super coarse） 25
F（Fine） 14
M（Medium） 20
HPC315
C（Coarse） 25
F（Fine） 16
M（Medium） 22
HPC400
C（Coarse） 30
Inspecting the discharge opening
Method for inspecting the discharge opening: Fasten a lead at the end of a strong
and soft metal wire, put it into crusher cavity slowly when the crusher is operating with
empty load and confirm the lead has passed through parallel strip of crushing cavity.
In the same way, put the lead into crusher quickly and measure its thickness, which you
can know the discharge opening size of the crusher. To get a correct value, the speed of
fixed cone must be very slow. The correct time for measurement is: at the beginning of
crusher operation, that is, the speed of crusher transmission shaft has reached its normal
speed, or when the material feeding has just been stopped, or when the rotation speed of
the movable cone begins to increase. If necessary, re-adjust the fixed cone assembly to
get the desired closed side discharge opening.
To confirm if the discharge opening of crushing cavity circumference are the same,
38
we suggest you put four leads in different positions (Interval:90 degrees). Compare the
thickness of these leads, and then you can find clearly if the supporting sleeve is
horizontal on main frame or the sleeve is leaning caused by uneven wearing of crusher
because of inappropriate feeding. For correct feeding methods, please refer to Chapter 3,
figure 3.4-1.
Confirming the wearing condition of liners
When trying to determine if the liner has worn and need to be changed, the
following data are very helpful. Accurate records can help you determine the wearing
condition of the lining plates without stopping the crusher. For the first set of linings,
the methods of recording the wearing condition are as follows:
a) Set the discharge opening to the required size, and then make a mark on the
adjustive gear of the anti-dust cover. After the liners has been used for a period
of time, the discharge opening will become larger because of wearing, rotate
the adjustive gear to re-adjust the opening size to the original discharge
opening size, and make another mark on the gear. Each time you adjust the gear,
make a record.
b) In daily operation, make a record of the wearing condition of the first set of
liners. From the first running of the machine to when the liners are worn and
replaced, carefully make a record each time you adjust the gear.
Considering different operating conditions of crushers, different types of liners,
variation in liners’ thickness, and errors in casting, we cannot predict how
many teeth will be rotated before the using of liners.
c) After finish using one set of liner plates and before turning the adjustive ring in
the supporting sleeve., count the total number of teeth that has been rotated on
the gear, and mark a horizontal line on the anti-dust ring as shown in Figure
6.4-1.
d) Install new liner plates and record the number of gears rotated each time you
adjust the discharge opening. By comparing with the using record of first set of
liner , you can know the wearing degree. Each time you adjust the discharge
opening, the anti-dust cover will move downward a little. From the mark line
on the anti-dust ring , you can also determine the maximum wearing of the liner.
Since no two liners are worn exactly the same, , you can repeat the above step
39
to estimate an average wearing level.
Figure 6.4-1 The place of anti-dust cover after wearing of liners

Thread lubricating
Adjustive ring is crusher’s adjustment components,.It is very important to lubricate
the the threads of the adjustive ring and the supporting sleeve to ensure the smooth
moving of of the adjustive ring inside the supporting sleeve .
Each time you change the liners of the fixed cone, lubricate threads of adjustive
ring, the supporting sleeve , lock nut. When using lithium base oil NLGI NO. 1 or
similar oil, it is better to mixed in advance 5 to 10% (by volume) of Molybdenum
disulfide powder. Even in hot working conditions, it is also satisfactory to mix this
powder in thin oil.
6.5 Cleaning the crushing cavity
In case of crusher’s stoppage with loads, do not try to restart the crusher until the
crushing cavity is cleaned completely. If the crushing cavity is filled with materials,
starting crusher will cause serious damage to crusher and motor.
The reason of stoppage with loads are as following：electrical faults or engine’s lacking
40
of oil ; excessive feeding material in the crushing cavity material accumulation under
the discharge opening because of the stoppage of belt conveyor; or iron is stuck in the
crushing cavity.
In order to clear the materials or iron blocked between the mantle and concave, start the
hydraulic station as in the following steps:
a) Start the clearing function of the hydraulic station, and keep operating until the
piston of the hydraulic cyclinder completely opens In most cases, the material
in crushing cavity will be completely cleaned.
b) If the crushing chamber is not completely cleaned, insert iron pads (with the
same height) between the supporting sleeve and the machine frame, and then
take back the hydraulic cylinder piston, until the supporting sleeve and the
adjustive ring assembly falls on the iron pad.
Before start manual cleaning of the crushing cavity, you must firmly insert iron
pads (with the same height) between the supporting sleeve and the main frame.
In case of hydraulic system failure, this is a security measure to prevent the
hands or arms or equipments from being stuck in the crushing cavity
When you do not insert the iron pads, do not try to manually clear the jammed
material. Though the pressure in the hydraulic cyclinder and the accumulator is
relieved, there is still possibility of hydraulic faults, which will cause the
supporting sleeve and the adjustive ring to fall down and casuse serious serious
personal injury.
c) Clear the large material or iron in the crushing cavity.
d) When all material in the crushing cavity is cleared, start the hydraulic
station,and keep operating until the piston of hydraulic cyclinder completely
opens. Then remove the iron pads, lower the supporting sleeve onto the main
frame and then pressurize the hydraulic cyclinder. Check if the circumference
of supporting sleeve is level. If not, lift the supporting sleeve and let it fall back
on the mainframe. If the supporting sleeve is not level, do not pressurize the
hydraulic cylinder.
Excessive iron will cause damage to crusher. If the raw material contains large
41
amount of iron, you must install the iron separator. If the crusher is damaged by
excessive amount of iron, it is not within our quality guarantee.
6.6 Replacing the manganese plate
Please follow the following instructions when dismantling the wearing liners and
installing new ones.
a) Loose the pressure cap and the puller bolt on the locking bolt after dismantling
cone head so to unlock the pressure cap and the cone.
b) Use a hammer to knock the professional wrench to rotate the pressure cap.
It will be hard to unlock the pressure cap because of the extending of mantle
during the crushing process.In this case, please cut off the ring at the bottom of
the pressure cap to release the pressure.
Usually it's not necessary to cut the ring.You only need to cut a notch on the
ring to make it change the shape. If you do not want to change the shape of the
ring, pierce it and don't damage the pressure cap and the cone.At this time,
pressure can be unscrewed from the cone.
c) To remove the wearing liners from the cone, it is suggested to weld two rings
on the liners which can bear the liner’s weight. Use suitable welding rod for
manganese steel, such as Nickel chrome manganese.
d) Remove any left padding on the cone. Usually padding will stick to the liners.
Remove all of them.
e) Check the thread of cone and pressure cap. Remove any burr or nick, and
carefully clean the thread. Lubricate or grease the threads.
f) The cone’s outer surface and the adjustive ring’s inner surface must be coated
with a layer of lubricant to prevent padding from sticking to the movable cone
or the adjustive ring.
g) It's very important to install the mantle correctly. The loose or tilting of mantle
may damage the connecting surface between cone and liner.
For installing the mantle, please refer to the following steps:
• The cone and lower surface of liner must be coated with a layer of 25mm dry oil
42
before the mantle is installed on the cone
• Set the liner on the cone and install pressure ring on the top of liner.
• Check if there is any damage on the surface of the pressure cap if you are using the
original cap. If it' is damaged, it will have a contact point with pressure ring, which
will cause the pressure cap, cone threads, or even liners to loosen.
• Tighten the pressure cap to the top of pressure ring so that the space
between pressure cap and pressure ring is same if the liners are properly
installed. During installation, new liner plate must be placed and stand in
line with cone before screwing the pressure cap.
Don't adjust the leaning plates by the pressure cap. If the space is not the
same between the pressure cap and the ring, it's suggested to strike the top
of the liners, or strike or lever the the lower side of plate upward.
• Use hammer to strike the wrench to tighten pressure cap to make the liner
plates in place in cone.
• Use feeler gauge to check if liner plate is firmly attached to the cone
around the circumference. The space should be smaller than 0.15mm.
If there is gap on the cone because of wearing, it's suggested to use clay,
fibre or mixed material to block it so that it won't leak during pouring.
• Mark a line between the pressure cap and ring. Then use gas cutting to heat
the lower part of liner plate (which is connected to the cone) to about 55℃.
Do not press your hand on the liner.
• Use the wrench and use the hammer to strike it until the pressure cap is
tight. Check the mark and the pressure cap should rotate for about 25mm.
43
6.6-1 Installation of liner plate

• After tightening the pressure cap to the cone, tighten the pressure bolt to
the moment of force shown as 6.6-1. It's very important to fasten the
pressure bolt in the cone, otherwise, it will cause loosening of liner plate
and damage pressure bolt/cone/plate/liner seat.
The bottom of the puller bolt cannot touch the pressure cap, and there
should be 1mm to 5mm gap between them. If not, the thread cannot be
fixed and the plate will loosen.
Table 6.6-1 Specification of puller bolt and moment of force
Crusher model Puller bolt model Suitable moment of force (N.m)
HPC160 M16x130 165
HPC220 M16x130 165
HPC315 M20x180 310
HPC400 M20x180 310
44
• After the cooling of plate, fill the empty cavity with padding until the level
is a little lower the than the upper curve. The following is the procedure:
i Prepare to fill padding. The following is the estimated amount of a
crusher.
6.6-2
Crusher model Epoxy resin back glue
HPC160 21kg
HPC220 20kg
HPC315 25kg
HPC400 30kg
Note: The compressive strength of epoxy resin back glue should be at
least 110 MPa, and the contractibility rate should be smaller
than 0.01%.
ii The epoxy resin back glue usually have two components: resin
(Group A) and firming agent (Group B) will get mixed before
pouring. Note that the whole process should be completed within
10 minutes, otherwise the fluency of the resin will reduce sharply.
The temperature of pouring should be within 15-25 ℃ . The
hardening time of resin will change according to the temperature
(usually the resin will become solid after 7-24 hours),
iii Note:
• Wipe grease on the connecting surface of cone and epoxy resin.
• Be careful and don't get the epoxy resin on hand. Put on mask
and glove when pouring.
Replacing the Concave
a) Dismantle the adjustive ring from the supporting bush.
b) Clean the supporting bush, adjustive ring and the threads of the
locknut.Remove all the dirt, rust and remaining grease.
c) Hang up the feeding box from the adjustive ring, and then you can see the
wedges to fix the concave. These wedges are on the top of the assistant ring
which is fixed on the adjusting ring by dowel.
d) Dismantle the cotter that fixes the tighten plate to wedge.Then hang out the
45
tighten plate to expose the sphere bolt to loose the wedge. Loosen the spherical
nuts on the square head bolt. These nuts peak the wedges on the concave. Use a
chisel without edge and a hammer to knock out wedges.
e) Hang the adjustive ring out of the liner plate. If the original ring is not treated
properly, the plate will get stick to the adjustive ring occasionally. In this case,
it's suggested to knock the top of plate to loosen padding.
f) Remove all the remaining padding on the adjustive ring.
Install the concave according to the following steps:
• Put the concave on the skid to ensure that it can perfectly adhere to plate.
Wipe a layer of grease on the inner side of adjustive ring in case the
padding adheres to the adjustive ring.
• After installing the assistant ring to the adjustive ring, lower the adjustive
ring downward to the concave. To ensure the close fixation of the
ring, ,please make sure that the place of wedges is in line with the highest
point of concave’s spiral line as shown in picture 6.6-2.
Figure 6.6-2
• Firstly, install square-head bolt, the spherical nuts and wedges, as shown in
Figure 6.6-3, we must let the spherical nut put on top of the wedge.
46
• Put the wedge component placed in the upper part of the auxiliary ring and
placed in the welded stopper block around the inside of the adjustment ring.
At the same time, the wedge components should be installed between the
stop block for the welding of the upper part of the adapter ring. These stop
blocks are to prevent the wedge moving to different sides, movements of
the wedge will cause rolling concave loosening.
• Use an open-end wrench, turn each spherical nut behind the wedge, until
the wedge top meet the spiral line of concave.
• Use a symmetry method, alternately tighten the nut until all the wedge
compression to the spiral line of the concave. Must make wedge
components pressed firmly and correctly installed inside the adjustment
ring. Use a feeler to check along the adjustment ring and concave to see if
concave has been firmly attached to the adjustment ring, the gap between
the two should not be greater than 0.15mm. If adjustment ring parts has
some holes due to wear and existence, application of clay, fillers or glass
mud filling the holes, prevent pouring packing leakage, shown in Figure
6.6-4.
Figure 6.6-3 Installation of concave
47
Figure 6.6-4 Checking the surface of liner

If there are tolerances due to casting, the wedge might be in contact with the side
of the concave, and then we should put several gaskets under the wedge, make the slope
part of wedge in contact with the liners. As shown in Picture 6.6-3. If using gasket to
adjust, the welding point should be on the auxiliary ring.
Put the filling into the filling cavity behind the concave, the specific operations are
as follows:
1) Prepare to fill, the following is a approximate usage of one crusher.
Table 6.6-3
Crusher model Epoxy back rubber lining
HPC160 32.5kg
HPC220 30kg
HPC315 37kg
HPC400 47kg
Note: Epoxy back rubber lined compressive strength of at least

110MPa; the shrinkage is less than 0.01%
2) Finished epoxy back rubber lining is generally of 2 component glues, resin
48
(component A) and hardener (component B) need rapid mixing and stirring

well before pouring. .Note stirring after adding hardnener and poured into,
the process should be completed within 10 minutes, otherwise the resin
flow will be greatly reduced; pouring fashionable ambient temperature is
generally between 15-25 ℃; resin curing time with the ambient
temperature changes, generally all hardened will harden 7-24 hours after
mixing. The specific methods of operation and procedures please refer to
the instructions supplied with the choice of back rubber lining.
3) Notes
a) Before pouring, the contact face of the adjustment ring and the epoxy
resin should be coated with a layer of grease.
b) Pay attention to safety, do not stick epoxy in their hands and wear
masks and gloves when pouring.
4) If the fillings becomes curing, should re-check all wedges and spherical
nut tighten.
5) The locking board should be put in the spherical nut, use a long open cotter
pin to fix the locking board fastening on the wedge. The locking board can
be adjusted to avoid ring liner loose due to the spherical nut shock.
6) A 12mmx12mmx40mm long steel bolt stop block welded on the
adjustment ring, you should just weld in the square head bolt’s head, as
shown in Figure 6.6-3. The stop block will avoid the bolt to slide up when
crusher working, thus avoiding the cause rolling acetabular wall loosening
7) Use a cloth dipped in a molybdenum disulfide powder to rub the support
sets, adjustment ring and locking nuts’ threaded surface. Make threads
coated with plenty of lubricant or grease, the lubricant is a mixture of
grease and 5% to 10% (volume) of molybdenum disulfide powder.
This step is the most important step to ensure that the adjustment ring can
rotate freely inside the support cover.
8) Reassemble the remaining parts.
49
6.7 Installation and disassembling of spare part
Installation and Disassembling of adjusting ring
In order to replace the concave and mantle, or to create the conditions to
disassemble other components, the demolition of adjustment ring assembly is needed,
the following are these steps:
1) Turn off the hydraulic station, unload the pressure of the locking loop.
2) The method described earlier in this chapter, use a hydraulic adjusting device
or overhead traveling crane. When put the support cover into the adjustment
ring, it should be clockwise turn, while the demolition of the adjustment ring is
counterclockwise rotation.
3) After the adjustment ring put into the crusher, adjust the adjustment ring to
achieve the desired opening of discharge. Start the hydraulic station, and add
pressure of the locking loop.
Replacement of auxiliary ring
When concave changes from one type of another type, you must change the
specifications of the auxiliary ring. All concaves needs a corresponding auxiliary ring.
Since the auxiliary ring is fixed on adjustment ring by pin, therefore, in
replacement of the auxiliary ring, the first is to take the adaptation ring from the pin, and
then install the new auxiliary ring. New auxiliary ring has welded stopper block, so
there is no need to dissemble the old block from the old auxiliary ring, as shown in
Figure 6.6-3.
Replacement of eccentric bushing liner
Whenever remove of the eccentric bushing, check if eccentric bushing liner is
loose or excessive wearing. When finding out the eccentric bushing liner is loosen in the
eccentric bushing, pu some filling into the bushing to tighten. Usually heavy side
bushing wears much more, which is the expected normal circumstances, do not worry.
The eccentric bushing and bush liner surrounds a by a group of chute, tank full of
locking filler to prevent the bushing rotation. the bushing needs to be replaced as
following step:
50
1) Drill a few holes in each slot on the locking filler.

2) Make the adjacent hole through with each other, and remove locking filler.
So there is not tight packing to prevent the demolition of the bush.
3) As shown in Figure 6.7-1, put the eccentric bushing down on the upside
down on pieces of wood shelves so that the bushing will be able to play
down in sets. Ram style of play will bush removed from the eccentric
sleeve. When the removal of difficulties, along the wall of the bush to bush
cutting in half or more blocks of heavy industrial circular saw.
Figure 6.7-1 Dismantle of eccentric bushing

4) Before installing a new eccentric sleeve bushing, check the eccentric
bushing inner wall scratches or rough points, they must be polished smooth.
In addition, check the cavity size does not worn too large or too small due
to thermal contraction. Measure from the bottom to the top of the eccentric
comprising a cavity.
5) Install the eccentric bushing
Finishing eccentric sleeve bushing and eccentric comprising a chamber to
maintain the clearance fit. Inappropriate storage or transport may bush lost
the round to produce the interference effect to be installed directly
51
recommend the use of dry ice method to install the bushing, the following
steps:
a) Convinced that locking filler in the eccentric sleeve in the top of the
chute has been cleaned up, eccentric comprising a cavity surface clean,
without any rough at.
b) Thoroughly clean all surfaces of the bush, to remove surface
irregularities, and ready bush.
c) fill in the bushing cavity dry ice to make the bush contraction.
d) In the bush outside wrapped across the layers of glass fiber pads, avoid
the bushing external frost. The frost will prevent the bushing load
eccentric sleeve. The parcel layer also helps to achieve adequate
cooling. Expand and contract time takes about 2 hours.
It's forbidden to install the liner into the bushing with smaller inner
diameter.
e) Measuring the bushing's outside diameter and inside diameter of the
eccentric sleeve, and determine the bushing whether full cooling. Two
eyebolt screwed into the top of the bushing.
f) In the bush external along both sides of the painting or the designated
mark line of the two hole (large hole and small hole), as shown in
Figure 6.7-2, and then on both sides of the eccentric sleeve along the
hole to the top of the eccentric sleeve surface painting or draw the mark
line, these lines will ensure that the eccentric sleeve and the bushing on
the hole on the positive.
52
Figure 6.7-2 Aiming at eccentric bushing

g) Bush lift eye bolt and gasket in place and aligned above the eccentric
sleeve and comprising a chamber, rapidly expand and contract the
bushing into the cavity of the eccentric sleeve, and aligned with slots
and hole.
Lubricant on the bushing holes must cross the corresponding hole of
the eccentric sleeve wall completely, bushings of the outer wall of the
slot at the top of the eccentric sleeve slot. Slot can have a slight
dislocation of the lubricating oil hole must be strictly positive.
h) When the bushing is installed, the bushing top should be completely
flush with eccentric sleeve top.
i) Will be ready for locking filler into the eccentric and bushes at the top
of the slot and filled each slot.
j) When locking the filler completely hardened, according to the previous
section of this chapter lists the car steps running.
Demolition and installation of cone under the bush
If you need to remove the moving cone bushings replaced with new bushings,
dynamic cone upside down and press the following steps:
1) Remove the screws and tabs.
53
2) A computer with suitable heavy-duty industrial metal cutting saw blade

circular saw, at least in the two bushing wall is pierced with incisions.
Adjust circular saw to put it in the bush, the blade can come into contact
with the inner wall of the bushing. Circular saw into the cutting position
and adjust the position of the circular saw, circular saw the back-end and
bushing ends aligned. Shown in Figure 6.7-3.
6.7-3 Dismantle movable shaft busing by circular saw

3) Measuring circular saw base surface to the blade to extend the distance
between the point of intersection of line with the bushing outside diameter.
A small amount of uneven amount deducted from this distance, to ensure
that the blade will not be sawn to cone.
4) Adjust the blade cut into the depth equal to the distance determined in Step
2.
5) Along the bush full-length cut.
6) Repeat this step 6. Opposite the first incision. The second incision cut the
bush will be breaking off.
7) Before installing the new bushing, check the dynamic cone bushing hole
nicks, program ditch or rough sweat stain, all of which must be polished.
Another check to make sure the hole is not grinding or heat dissipation or
cooling smaller. Measurement from the bottom to the hole in the moving
cone.
Follow these steps to install the moving cone bushing:
1) A wire brush to clean the fixed cone hole and bushing outside diameter.
54
2) The bushing to be installed into the dry ice Lengsu. Quilt outsourcing
insulating layers of glass fiber, to prevent the outer wall of frost, frost will
prevent the bushing loaded cone hole. The parcel layer also helps to
achieve adequate cooling.
Do not use these methods will be too small cone inside the hole to force
the installation of the bushing.
3) Measuring the bushing diameter and the cone aperture to determine the
bush when it is cooled.
4) Threaded holes built in the edge of the bushing end of the first of the two
ring bolts.
5) The bush hanging to the cone at the top and hole pair.
6) Install the moving cone bushing and alignment with the bottom edge of the
moving cone.
7) With non-oily solvent such as ethanol or acetone cleaning bolt holes and
screw, coated with Loctite 277, countersunk head screws screwed into the
threaded hole.
8) Installation location, non-oily solvent such as ethanol or acetone
positioning key bolt holes and screw, coated with Loctite 277, countersunk
head screws screwed into the threaded hole.
9) The new dynamic cone bushing installed, tuning, car steps described
earlier in this chapter.
55
6.8 Maintenance
Daily inspection and maintenance
Item Result Daily inspection and maintenance

1. Check the oil level in the oil tank. When supply oil, please make sure the oil
level indicator within the range
2. Check the temperature of supply and
38℃~54℃；Return oil is 3℃~5℃
return temperature.
higher than supply oil.
3. Check the oil pressure of transmission
0.1 MPa ~ 0.4MPa
shaft.
4. Check the differential pressure of oil filter.
0.035 MPa ~ 0.24MPa
5. Check the drive power and the amount of
crushing chamber material.
6. Check the release pressure of crushing
cavity.
10.5 MPa ~ 12MPa
7. Check the locking pressure.
16.5 MPa ~ 19MPa
8. Check the distribution of feeding material.
9. Check whether the discharge region is
smooth, and remove the sticking material
from the frame.
10. Check the wearing condition of weight
and protective cap.
11. Check the inertia stopping time.
12. Check the speed of moving cone rotation
30 S ~ 60S
13. Check whether fasteners and connectors
are loose.
14. Check the abnormal noise of wearing
parts.
15. Check the movement of adjusting ring.
16. Check the oil flow and coarse strainer.
56
Weekly inspection and maintenance
Item Result Normal condition

1. Clear the transmission shaft and breather of
oil tank.
2. Check whether the oil pipes leak.
3. Check the wearing situation and fastens of
concave and mantle and cone head.
4. Check the metal and debris in the oil filter.
5. Check the movement of adjusting ring.
6. Check the fastening and straightening of
V-belt.
7. Check whether the lubrication oil leak.
8. Check whether the pulley is tight and
without flaw.
9. Check whether the bolt of cone is tight.
10. Check the wearing situation of transmission
frame/ frame plate/ bob-weight/ cone.
57
Monthly inspection and maintenance

1. Check the pressure of accumulator, and add 8.3MPa
nitrogen when it needs.
2. Check all the alarms and pressure,
temperature, flow switch of lubrication and
hydraulic systems.
3. Check the motor and lubrication oil as
manufactures’ suggestion.
4. Release the adjusting ring and then adjust it
ahead and back.
5. Check the dirt and impurities in oil.
6. Analyze the pollution degree.
7. Check the axial clearance.
Yearly inspection and maintenance

1. Completely disassemble the crusher, and
check all the surface of bearing (Main shaft
bushing/eccentric bushing/Socket liner), and
also the big and small gears.
2. Check whether there is fatigue crack on
main frame, cone and adjustment ring.
3. Check all the tight situation of fastens and
connectors.
4. Check the wearing situation of bearing
surface.
5. Check the wearing situation of big and small
gears.
6. Check the dust ring.
58
The inspection and maintenance of liner plate
Item Result Normal situation

1. Check the contact surface of adjustment
ring and liner plate on the cone, then
remove all the nick or burr.
2. Check the wearing situation of bushing/
bearing/ socket liner/dust seal. And then
use a feeler gauge to check the gap
between the movable cone’s bushing and
cone’s inner hole.
3. Check the wearing situation of mantle
locking nuts and the cone head. Renew
it if it needs.
4. Check the wearing situation of frame
protect plates/transmission protect
plates/main frame liners.
5. Check the wearing situation of
supporting bushing/adjusting
ring/locking ring.
6. Check whether the hydraulic oil pipes
leaking or damaged.
7. Check the fastening of liner plate wedge
and bolts.
59
Common problems and solutions
Problems Possible Reasons Instruction

The crusher 1. Oil pump damaged——lack of oil 1. Check whether the amount of
is supply return oil is normal.
overheating. 2. Oil can’t be discharged normally 2. Check the gradient of return oil
（Min 1：12）.
Clear transmission shaft
frame and vent hood.
3. The liner plates are not proper. 3. In the lower part of the
crushing cavity, too much
crushing leads to driving
power goes too high.
4. Hot or hard material caused it. 4. Use lubricating oil cooler.
5. Oil supply lack. 5. Check whether the safety valve
is not working because of
spring wearing, metal stuffed,
so the oil returns in the side
pipe. Check the oil level in oil
tank if the level is normal or
not.
6. The belt is too tight. 6. Adjust the belt.
7. The type of lubricant is wrong. 7. Use suitable lubricant Suggest
to use extreme pressure
lubricant.
8. No axial clearance 8. Adjust it as list 6.1-1.
9. The upper thrust bearings wear. 9. The oil tank damaged, and the
lubricant oil cannot go
through the bearing
10. The output power is too high. 10. Normally caused by the
60
inappropriate feeding
materials. There are two
much powder in the material,
or the discharging opening
sets too small, or too many
iron material in the feeding
material leads to too much
pressure on the cone crusher.
11. The discharging opening is too small. 11. It can’t be smaller than which
we suggest.
12. The oil cooler is blocked by dust, or 12. If it’s water cooler, use a brush
other scraps. to clear it. If it’s air cooler,
clear the dust and other
sewage on the cooling fin.
13. The oil cooler is blocked by dust, or 13. If it’s water cooler, use a brush
other scraps. to clear it. If it’s air cooler,
clear the dust and other
sewage on the cooling fin.
14. The clearance between movable cone 14. a. The bottom of moveable
bushing and eccentric bushing is too cone bushing is
small. damaged—the feeding
material is too small and the
below crushing cylinder
usually work. When there is
no feeding material the
crusher can’t work more than
30 minutes.
b. The top and bottom of
moveable cone bushing is
damaged—the feeding
61
material is too big in flake

shape.
c. The medium and all of
moveable cone bushing is
damaged—oil pressure is too
low，oil temperature is too
high，Oil viscosity is not
correct.( viscosity is too
low）
Socket liner The bolt of the Socket liner seat is cut Use welding machine to make sure
seat is down. Because of abrasion, the main shaft the main shaft and Socket surface
loosening loses close connection with socket liner match well. If the upper part of
seat. main shaft is broken, please
purchase a small ball bearing seat
to process it to a proper one. And
then change the bolts.
Crusher 1. “T” and “U” seal ring is damaged or 1. Change the seal ring.
throw oil wear
2. Safety valve out of order. 2. Safety valve setting is not
correct or safety valve spring
card at the pressing position,
replacing the safety valve
3. Oil is too cool 3. Install oil immersion heater,
and heat the lubricant to 27℃.
4. The lubricant is not proper. It’s too 4. Choose the suitable lubricant
heavy. oil.
5. The exhaust is not normal. 5. Clear the exhaust on
transmission and oil slinger.
6. The return oil pipe is blocked. 6. Check and clear the return oil
62
pipe.
7. The return oil is not normal. 7. Check the slope of oil pipe
from crusher to oil tank. The
min slope is (descend 25mm
per 305mm). Or change a
bigger oil pipe.
Low 1. The feeding chute is wear and becomes 1. Replace the liner and enlarge
capacity smaller. the feeding opeing.
2. Low RPM 2. Check the transmission shaft
rpm is normal or not according
to the figure6.1-2.
3. Crossed connection of liner on the top 3. Reduce the feeding size of raw
of feeding opening. material.
4. In the feeding opening, there are big 4. Such kind material should be
size impurities influencing the flow of fed freely, cannot be jamming
material. feeding.
5. The maximum feed size of raw material 5. Reduce the feeding size of raw
is big. material.
6. High proportion of dust and soil in the 6. Remove the dust and soil in
raw material. the raw materials.
7. The distribution of feeding material is 7. Correct the location of the
not good, the inclination of feeding feeding chute.
chute cause material goes to one side of
cavity.
8. The parallel area between the mantle 8. Cut the nib area of the mantle
and concave strikes. and concave bottom.
9. The parallel area between the mantle 9. Replace different type cavity’s
and concave wears quickly. mantle and concave.
Low Rotation 1. V belt is too loose. 1. Tighten the v-belt.
Speed 2. The motor’s electric failure occurs. 2. Check the power of crusher
63
working with no material, and the
power of motor rotating with no
belts. Compare the two figures, if
they are close, a electrician is
needed to check the motor.
3. Feeding materials are wet and sticky. 3. Install a water spraying nozzle,
wash the material when crushing to
avoid the material sticky in the
cavity.
4. Material accumulate at the bottom of the 4. Check whether the discharging is
crusher smooth in the base; install indicator
of buffer positions and install zero
speed switches on the tail wheel of
discharging belt.
5. The driving shaft speed is too low. 5. Check whether the driving shaft
speed is normal according to Table
6.1-2.
6. Oil pressure is too low 6. Check whether the working
pressure is normal
7. The driving motor or diesel engine is 7. Motor's or engine's power
inappropriate coefficient is too low.
8. Feeding opening of cavity is not correct (too 8. Check and use suitable lining
large). Most crushing job is done at the lower boards.
part of cavity, increasing the power
consumption.
9. Parallel areas at lower part of concave and 9. Cuts off the protruding part
mantle have collision. impeding material discharging at
the lower part of concave and
mantle.
10. Parallel areas of concave and mantle are 10. Change concave and mantle of
64
worn too fast. different cavity.
Oil Spill "T" and "U" type seal-rings are broken or worn. Change the seals.
The O seal-rings of flange in driving shaft frame Change seals or clean thoroughly
and main frame are broken or worn. flanges in driving shaft fram and main
fram and coat the junction with silicone
to seal.
Dring shaft is 1. 1. V-belt is too tight.. 1. Tension V-belt again and check the
stuck or calibration of pulley.
broken. 2. Drive shaft sleeve has no oil or hasn't enough 2. Check whether there is some
oil. limiting factor on the pipe between
the main oil-supply pipeline and
the input oil-hole of driving shaft
frame. Remove any type of valve
or slashing of other limiting factors.
3. The outer sleeve of driving shaft's oil groove 3. Any time the v-belt pulley should
has been worn to the limit. not pull the driving shaft toward the
oil groove
4. No axial clearance 4. Adjust the axial clearance again
according to Table 6.1-1
5. Driving shaft is bending, which usually 5. Change the driving shaft
performs as the end of driving shaft vibrates
or the crushing pulley swings.
6. Oil groove of driving shaft's outer sleeve is 6. Clean the oil groove.
clogged by dirt or other debris.
7. Teeth of big gear or pinion are broken 7. Change the big gear or pinion.
8. The gap between teeth top and teeth side of 8. Check and adjust the gap between
big gear and pinion is not appropriate. teeth top and teeth side.
Water comes 1.Stagnant water on the top of weigh-cover 1.Drill and weld the drain pipe
into the 2.Ventilation hood on top of oil tank is blocked 2.Change the ventilation hood
lubricating
65
oil.
The Dirt or rust accumulates between the threads of Try the following steps:
adjustment adjustment ring and support sleeve. Reasons are as Add anticoagulant into the threads;
ring cannot follows: Release the locking cylinder and the
rotate Feeding material is too hot (slag, etc.); pressure in it, run the crusher and let
Lubrication of threads are not adequate; materials pass through;
Moisture-proof ring or dustproof seals are worn; Make wood blocks pass through the
No rain-proof; crusher;
Working too long time at a fixed discharging Throw small pieces of mild steel into the
opening; crusher and let them pass through;
Threads of support sleeve and adjustment ring are Heat the support sleeve;
scratched; Heat the support sleeve and cool the
Threads are broken. adjusting ring;
Don't remove the support sleeve from
the main frame.
Mantle or 1. Tightening torque of pressure cap's tightening 1. Screw the tightening screws to the
concave is screws is not enough or there is no cap stuitable torque or change
loose between tightening screw's top and pressure tightening screws.
cap.
2. The underside of the pressure cap is worn, 2. Install a new pressure cap.
resulting in its contact with the pressure ring
spot
3. The surface between pressure cap and 3. Return the dimension of surface
movable cone is worn or is processed between pressure cap and movable
incorrectly. cone to the original designed
dimension.
4. The clearance between materials filled 4. The clearance between materials
between mantle and movable cone. should be 6mm-10mm at least.
5. Mantle is not round any more. 5. The biggest loss of round should be
3mm.
66
6. Mantle's center and movable cone's center do 6. Use a feeler to check the bottom of
not coincide with each other. mantle. The clearance should not
larger than 0.15mm.
7. During the first installation, mantle is not 7. Dismantle lining board and
screwed tightly on movable cone. re-install correctly.
8. Mantle-the crusher has been working for long 8. Longest idle time is 30 minutes.
time without material.
9. Mantle is too thin 9. The worn amount of mantle should
not be more than 2/3 of its
thickness.
10. The old materials in the cavity have not been 10. Clear all old materials in the cavity
cleared completely before installing new to assure the new lining board can
mantle. be put correctly on the movable
cone.
11. The top of a wedge of concave has touched 11. Add shim to the wedge or screw
the ex-circle of concave or bolts have been tightly the bolts of concave.
loose.
12. 12.
13. Concave is too thin 13. The worn amount of concave
should not be more than 2/3 of its
thickness.
14. Too much iron pass through crusher. 14. Too much iron passing throng will
impact the adjustment ring and
result in loose of concave.
15. The surface of concave or fixed cone is worn 15. Return the dimension of surface to
or processed incorrectly the original designed dimension.
The pulley 1. Crusher's ventilation is not good. 1. Clean the driving shaft frame or the
end of driving gas hood at the top of oil chamber.
shaft fram has 2. Discharge of oil is too slow in the 2. Clean the long through-hole below
oil leak. transmission shaft frame or oil chamber, the transmission shaft.
67
especially when the lubricating oil is cold.
3. Oil plug or lip seal has been worn between 3. Change the lip seal or piston ring.
oil slinger ring and oil slinger ring cover, or Re-process the oil chamber.
between oil slinger ring cover and oil
chamber.
Vibrating is 1. The crusher weight changed caused by the 1. Cone head or pressure cap is worn
too strong worn parts. excessively.
2. Weight or weight shielding board and cover Increase the weight of cone head or
are worn. change worn parts.
3. Teeth of large gear and pinion gear conflicts 2. Discuss with manufacturer to
with each other. restore the weight. Change weight
4. Driving shaft bends shielding board and cover or
5. Crusher's pulley loses the balance greatly. change weight.
6. If the crusher is installed on portable track, it 3. The gap between gears is not
is possible that the skid wood or the appropriate. Large gear pressed
foundation is not appropriate. directly on the pinion gear. Use
7. The carrying capacity of basis and foundation shim to block up the eccentric
is not appropriate. sleeve assembly.
8. Concave is loose or is worn excessively 4. Change the driving shaft
9. RPM of driving shaft is too high. 5. Clear the filth bonded on the pulley
10. Weight block get lost edge and spoke.
6. Check the skid wood or foundation
situation.
7. Check the situation of basis or
foundation.
8. Dismantle the concave and
re-install it or change a new one.
9. Check whether the RPM of driving
shaft is correct.
10. Discuss with the manufacturer to
68
install the weight block which is
lost.
The surface 1. The crusher is working when the concave is 1. When assembling, make sure that
between loose. the parts of crusher and related
movable cone parts are assembled correctly and
and lining the pressure cap has been screwed
board or tightly before working.
between fixed 2. The crusher is working under the situation 2. weak side of crusher parts bent,
cone and that movable cone or concave is worn which accelerate the worn of
lining board excessively. surface between movable cone and
is worn. lining board or between fixed cone
and lining board
3. Movable cone or concave is completely worn 3. weak side of crusher parts bent,
out. which accelerate the worn of
surface between movable cone and
lining board or between fixed cone
and lining board
4. Matle or concave is broken. 4. weak side of crusher parts bent,
which accelerate the worn of
surface between movable cone and
lining board or between fixed cone
and lining board
Dust or dirt is 1. There is no ventilation hood on the crusher 1. Install ventilation hood on the top
into the of frame or oil chamber.
lubrication 2. Ventilation hood installed on the tope of 2. Clean the ventilation hood of these
system driving shaft frame or oil chamber or oil tank places. When the crusher is
has malfunction. working, paper on ventilation tube
should be slightly moved to the
inside.
3. Pulley of crusher brings the dust into the 3. Install ventilation hood to another
69
ventilation hood. place by hose to make it away from
the pulley of the crusher.
4. Crusher is open for inspection or 4. When maintain the crusher, use
maintenance, the dust falling into the crusher. canvas or polyethylene (plastic)
film to cover the spherical bearing
and the eccentric sleeve.
5. The vertical drop of oil return pipe between 5. Dust and dirt are sucked into
crusher and fuel tank is too large. spherical bush area. Add a
ventilation hood to the level pipe of
oil return pipe under driving shaft
frame, closely next to the elbow of
level pipe.
6. No seal or gasket between the oil tank and 6. Change the seal or gasket.
tank cover
Teeth of large 1. Lubricating oil is too dirty 1. Change the lubricating oil and
gear and clean oil tank.
pinion gear 2. Worn part of teeth is too low 2. The thrust bearing is worn. Add
are worn pads, block up eccentric sleeve
3. Worn part of teeth is too high 3. Reduce the pads under thrust
bearing and lower the eccentric
sleeve.
4. Over-load of crusher 4. It usually manifests as adjustment
ring beats. Reduce the feeding of
crusher.
5. Axial clearance is too large 5. Re-adjust axial clearance according
Table 6.1-1
Large gear 1. Gear side clearance and gear top clearance is 1. Check the gear side clearance or
and pinion inappropriate. gear top clearance.
gear have 2. Crusher is working under the condition that
noise new large gear is used together with worn
70
pinion gear or new pinion is used large gear
is worn.
Adjustment 1. Adjustment ring’s beating caused the top of 1. The distribution of Feeding
ring tilts the main frame, and (or) adjustment ring’s materials in crushing cavity is
surface are worn not evenly. (under this inappropriate. Adjust the
condition, crushing machine guarantee will adjustment ring by 180 °. Check
be invalidated.) whether the insurance cylinder’s
pressure is too low. Pressurize the
hydraulic cylinder.
2. Continuous overload or inappropriate lining 2. Too much fine material in feeding
board result in that adjustment ring hit material; adjust larger the crusher
continuously the surface of main shaft. discharging opening; feeding
material may be too sticky, add
water to the feeding material.
Fixed cone is 1. Threads of adjustment and fixed cone are 1. If the threads are not worn too
loose worn. seriously, re-process the slant of the
thread, maintain uniform pitch.
2. Locking pressure is too low during operation. 2. Pressurize locking cylinder to
appropriate pressure.
3. Discharging opening of crusher is too large. 3. Adjust crusher’s discharging
opening until the fixed cone stops
beating.
4. The movable cone or concave is too thick. 4. Thread engagement part is too little
of fixed cone and adjustment ring.
Need thinner lining board.
5. The discharging opening of crusher is too 5. Thread engagement part is too little
large. of fixed cone and adjustment ring.
Reduce the discharging opening.
6. Check whether the hose connection from the 6. When hydraulic station is working,
hydraulic station to the locking cylinder is the hose between the hydraulic
71
normal station and locking cylinder should
feel a little stiff.
7. The locking ring bolt prevents the locking 7. Adjust those bolts to make the
ring from going down tightening during the 100mm clearance between bolts’
scheduled demolition of the process due to top and locking ring’s tope. Install
vibration. Limit the locking ring to locknut on the bolt, and screw it to
non-locking position. the adjustment ring.
Cone-head 1. Too much material are fed into crushing 1. Reduce the amount of feeding
screw cavity. material.
fracture 2. Feeding material shows in plate shape. 2. Reduce the particle size of feeding
material or enlarge the feeding size
by changing lining board.
3. Cone-head screw is too tight. 3. Do not screw the screws too tightly.
4. Surface between cone head and pressure cap 4. Surfacing and re-processing
is worn. pressure cap’s surface. Change
cone head.
5. Cone head bolts are too loose. 5. Tighten bolts to coordinate closely
with each other.
6. Material fed to the top of cone-head is too 6. This problem usually occurs to
large. standard-type cone crusher. Reduce
the height from feeding box, funnel
or belt conveyor to cone-head.
Adjustment Over-load or lining board is inappropriate. Too much fine material in the feeding
ring beats material; adjust larger the crusher
discharging opening; feeding material
may be too sticky, add water to the
feeding material.
72
6.9Lubrication
1. Lubricating part Crusher circulating lubricating oil
Lubricant Lubricating oil. ISO150
Fuel charging cycle Change every 2000 hours if needed
Lubricating way Circulating
2. Lubricating part Hydraulic iron release cylinder and locking cylinder
Fuel charging cycle Change every 2000 hours if needed
Lubricating way Circulating
3. Lubricating part "U" shaped clip pin
Lubricant Dry oil. Lithium based NLGI NO.1 with 5% to 10%
molybdenum disulfide powder (by volume)
Fuel charging cycle 200 hours
Lubricating way Hand-smear
4. Lubricating part Filling material contact surface of fixed cone and
movable cone
73
Fuel charging cycle Every time changing the lining board
Lubricating way Hand brushing
5. Lubricating part Fixed cone, locking ring and adjustment ring
threads (Loosen the fixed cone before refueling)
Fuel charging cycle 40 hours and every time changing the lining board
6. Lubricating part Movable cone and pressure cap’s thread
7. Lubricating part Contact surface of main frame and adjustment ring
8. Lubricating part Flange O-ring in the horizontal axis
Fuel charging cycle During installation
9. Lubricating part Main frame pin
Molybdenum disulfide powder
Fuel charging cycle 2000 hours
74
7 Glossary of Terms
The whole manual adopts some fixed terms to describe the crusher and its
operation. In order to avoid confusion and misunderstandings, in this manual, we define
the following terms according to their use.
Feeding material: Raw materials going to be crushed.
Lining board: concave and mantle are both crushing parts, which are generally
called lining board or lining plate.
Crushing cavity: the space formed between the two crushing parts.
Parallel zones: during the swing cycle, when the fixed cone is most close to the lower part of
the concave, the two lining board are parallel to each other in a certain area. That area is called
parallel zone.
Tight side of feeding opening: when the two crushing parts spin to the closest distance, the
minimum distance of their upper part is called the tight side of feeding opening.
Loose side of feeding opening: when the two crushing parts spin to the farthest position, the
maximum distance of their upper part is called the loose side of feeding opening. Loose side
decides the maximum feeding size. Conventionally, the maximum feeding size should not be
larger than the tight side size of feeding opening.
Discharging opening: when the two crushing parts spin to the closest distance, the distance
between two points at their bottoms is called discharging opening. Discharging opening adjusts
the final product size.
Minimum discharging opening: when the two crushing parts spin to the closest distance, the
minimum distance allowed to reach between two points at their bottoms is called minimum
discharging opening.
Loose side of discharging opening: when the two crushing parts spin to the farthest position,
the maximum distance allowed to reach between two points at their bottoms is called maximum
discharging opening. This loose opening can discharge the crushed materials fast.
75
Feeding size: feeding size is the size of materials that can pass through the sieve of mesh.
Final product size: the material size after being crushed and screened.
Capacity: the processing capacity of crusher counted by tons per hour.
Open circle production: this way of production is not considering mainly the uniform of final
product size, but feeding material passing through the crusher for only once.
Closed circle production: this way of production is considering mainly the uniform of final
product size. Final product is the material screened out under the screen. The material on the
screen will be sent back to the crusher to be re-crushed.
Iron passing throng: iron entering the crushing cavity, such as bolts, bulldozer teeth, canned
food and other metal objects that can not be broken.
Insurance cylinders: hydraulic oil tank which is pressurized by accumulator. It will keep the
supporting sleeve being down to resist the crushing force, but it can release into the accumulator
(to allow pressure to escape) and to lift the supporting sleeve when non-broken materials (such
as iron) passing through the crushing cavity.
76
Appendix A HPC series Cone Crusher

Hydraulic Lubricant Oil Station User Guide
77
Contents
1. General Description of HPC series Cone Crusher Oil Station............................................................... 1
2. HPC Cone Crusher Lubrication System ................................................................................................ 2
3. HPC series Cone Crusher Oil Station Hydraulic System....................................................................... 3
4. Analysis of Malfunction ........................................................................................................................ 4
5. Maintenance........................................................................................................................................... 5
Appendix: The Overall Dimension of Oil Station ......................................................................................... 7
i
1. General Description of HPC series Cone Crusher Oil
Station
This equipment is used as an assorted machine of HPC series cone crusher. The
Hydraulic station main function is: use oil pump to extract the lubricant oil in the oil tank,
after filtering, cooling, temperature checking, pressure adjustment, the lubricant oil will
goes to the oil feeding from the discharging of the lubricant oil station for the lubrication
and cooling of different parts of cone crusher. The returning oil will be collected at the
returning opening of lubrication station, after flow checking, filtering wastes and iron scrap,
the oil goes back to the oil tank. The hydraulic station includes the hydraulic oil tank, motor,
gear pump, piezometer and other hydraulic and electric elements and parts,
HPC series Cone Crusher Lubricant Oil Station
HPC220 Parameters
Setting Flow Flow of Setting Setting

Hydraulic of Lubrication Hydraulic Pressure of Pressure of
Lubricant Oil
Oil System system Lubrication Hydraulic
System system
ISO VG150 ISO VG32

150L/min 13.6ml/r 2.2Mpa 21Mpa
Accuracy of Accuracy of
Lubricant Oil Tank Lubricant Hydraulic
Cooler Hydraulic
Filtering Oil Volume Motor Motor
Filtering Oil
2AH2590G 60μm 5μm 180L+650L 5.5KW 5.5KW
HPC400 Parameters
Setting Flow Flow of Setting Setting Pressure

of Lubrication Hydraulic Pressure of of Hydraulic
Lubricant Oil Hydraulic Oil
System system Lubrication system
System
ISO VG150 ISO VG32 250L/min 13.6ml/r 2.5MPa 21Mpa
Accuracy of Accuracy of
Lubricant Oil Tank Lubricant Hydraulic
Cooler Hydraulic
Filtering Oil Volume Motor Motor
Filtering Oil
2AH25120G 60μm. 5μm 180L+650L 7.5KW 5.5KW
1
2. HPC Cone Crusher Lubrication System
1. Working Principle of Lubrication
2. Composition of Lubrication system and working principle
2.1 By pump units, oil pumps out of the tank, and then goes through a device with pressure
differential indicator and a bypass valve for the secondary filtering. Then open the
one-way valve, through the soft pipe, the oil will go to wind cooler, then it goes the cone
crusher, oil will come back to the oil tank after lubricating all the parts of cone crusher.
2.2 This system has temperature switch, pressure switch, oil level switch, flow switch and
other electric parts, it can work automatically after connected with the electric control
panel.
2.2.1 In the system, there are three temperature switch, one is used to control the heater
(25℃-35℃), one is used to control the cooling fan（40℃-45℃）,one is used to
2
control the main machine（60℃）.
2.3 The oil tank is equipped with a oil lever meter, it is easy to check the oil level and the
temperature inside the oil tank.
2.4 The cooler is installed independently by an individual frame, connected with the
hydraulic station with soft pipe. The cooler is parallel connected with a bypass valve
(0.7Mpa) to protect the cooler. Behind the cooler, there installs piezometer, safety
valve, pressure switch and cooler together, the returning oil will come back to the oil
tank by the soft pipe.
3. HPC series Cone Crusher Oil Station Hydraulic System

1. Working Principle Drawing of Hydraulic System
2. Composition of Hydraulic System and Working Principle

The motor pump group of hydraulic system is controlled by electric elements. The
pump group will feed oil to different hydro-cylinder. The system’ main relief valve
3
controlling system’s highest pressure is 21MPa. Different solenoid directional valve
relatively controls hydro-cylinder’s oil feeding and discharging.
Insurance cylinder loop: stacked hydraulic control one-way valve can make
insurance oil cylinder has rod chamber to maintain pressure, and when the pressure
drops to insurance oil cylinder pressure relay setting pressure, the system will
automatically add pressure to oil cylinder. When filling pressure makes to achieve
insurance oil cylinder pressure setting, pump will automatically stop adding pressure
(through the time control). When clearing the cavity, solenoid directional valve reverse
charged, supply oil to no-stem cavity. On Rod cavity there’s a stop valve, can be used
for manual pressure relief.
Lock oil cylinder loop: there are two pressure relay on the the returning wayway
back with two pressure relay, and when the pressure drops to insurance oil cylinder
pressure relay setting pressure, the system will automatically add pressure to oil
cylinder. When filling pressure makes to achieve insurance oil cylinder pressure setting,
pump will automatically stop adding pressure. When solenoid directional valve reverse
charged, the lock cylinder will discharge oil by gravity. On Rod cavity there’s a stop
valve, can be used for manual pressure relief.
Hydraulic motor loop: electromagnetic reversing valves of the pros charged,

change the spin of oil motor to adjust the discharging opening size.
4. Analysis of Malfunction
Low flow and low temperature of pump

1. The pump inhale air from the inlet line leakage.
2. The pump inhale air from the sealing elements of bearings.
3. The inlet line is partly blocked or wholly blocked.
4. The rotation direction of the pump is wrong.
5. The pressure is too high, and the model of oil is wrong, thus the flow is low.
6. The manual stop switch is not turned off in the insurance cylinder loop or the lock cylinder
loop.
The pump does not absorb oil.

1. Pump is too dry when feeding oil.
2. The pump inhale air from the sealing elements of bearings.
3. The rotation direction of the pump is wrong.
4. The inlet line is blocked or the switch of stop valve is turned off.
Abnormal noise inside the pump

1. Gas hole formed inside the pump.
2. The oil is mixed with some air because of leakage in the inlet line or the bearing sealing
elements are abraded.
3. The tooth of gear inside the pump is abraded.
4
4. The inlet line’s contaminant separation net is blocked, result in the air hole.
5. The pump is not leveled correctly.
5. Maintenance
1. Working principle refers to the working drawing of hydraulic system
2. Operation Method
Preparation
Check if all the joint and coupling screw are tightened;

If the electric ligature is stable or not
Add oil to the 2/3 height of liquid thermometer (should not exceed the highest oil level),
when adding oil, the Shortening Filter should be applied, and also ensuring the cleanness of
the oil.
Initial Settings:
①System Pressure Setting
Before switch on the hydraulic pump, please pay attention to the rotation direction of the
hydraulic pump. Observe over the motor fan blade, to make sure if the motor is rotating
clockwise. Before starting the motor, set the main relief valve pressure to be 0MPA,
clockwise direction means adding pressure, anticlockwise means reducing pressure. Do
not use high voltage to start, or the motor pump will be burned.
Start the pump, make it operate for five minutes without load, set the relief valve to the
required pressure.
3. Maintenance
Maintenance
① Fasten at regular intervals

Every connecting screw and joint should not only checked daily, but also should be
fastened once a month.
② Make a sealing ring replacement schedule for regular changing sealing ring.
③ Make a cleansing schedule for regular oil tank cleaning.
④ Regularly change or filter the oil, make a required time interval to change or filter the oil.
A: There is a high pressure filtering machine at the oil pump discharging opening of the
hydraulic system, it is needed to be cleaned about once in two months generally, but the exact
time depends on the observation of the oil. If this filtering machine’s filtering core is blocked,
it will lead oil stuffed, the hydraulic system might not work if the situation is not so serious,
if too serious, the core might be broken by the high pressure oil, then the broken core will go
directly into the system valves, cylinder or pipes, the whole system will not work in order.
(Note: In the beginning of using the filtering machine, clean it every week, after 2 or 3
months, clean the filtering machine once in 2 weeks.)
Care and cleaning

5
① Before starting, check whether all the hydraulic parts are at the original location or not,
and also the oil level.
② If the machine stops for 4 hours, before switch on the machine, start the hydraulic pump
working for 5 minutes.
③ Keep the cleanness of the machinery, avoid dust, cotton velvet and dirts get into the oil
tank and the system.
Note: Every time starting the machine, be sure to observe the oil level if it is at the
required level, otherwise do not start the machine. If the level is not enough, and
machine is started, the bump will insert air, which will result in the air turbid, and burn
the motor and oil pump.
6
Appendix: The Overall Dimension of Oil Station
1. HPC series Cone Crusher Oil Station Overall Dimension
7
2. Parts list of HPC Cone Crusher Oil Station Drawing
1 . Hydraulic Motor Oil Pump Group 10. Thermograph

2. Hydraulic Filter 11. Liquid Thermometer
3. Single-way valve 12. Light Oil Supplying Pipe
4. Hydraulic integrated package 13. Electrical junction boxes
5. Hydraulic relay 14. Light Oil Returning Opening
6. Air filter 15. Safety Valve Oil Return Opening
7. Lubricant motor oil pump group 16. Light Oil Returning Tank
8. Oil filter 17. Cleansing Window
9. Single-way valve
8
3. The Hydraulic Oil Channel integrated package parts list
1.Lock Cylinder Valve Set 7. Insurance cylinder loop stop valve (15-2)
2.Hydraulic Motor Valve Set 8. System Pressure Adjusting Valve(13-1)
3. Insurance Cylinder Valve Set 9. Lock cylinder loop Pressure Relay (14-2)
4.Lock cylinder loop relief valve (13-2) 10. Lock cylinder loop Pressure Relay (14-1)
5. Lock cylinder loop stop valve (15-1) 11. Insurance cylinder loop Pressure Relay
6. Insurance cylinder loop relief valve (13-4) (14-3)
12. Insurance cylinder loop relief valve (13-3
9
4. Wind-cooler assembly drawing
10
5. Connection Drawing of Oil Station and Wind Cooler
HPC400 Oil Station Wind Cooler Joint Thread
1、 Oil supplying opening joint M42*2 outside trace
2、 Wind cooler oil feeding joint M60*2 outside trace
3、 Wind cooler oil discharge joint RC2
4、 Safety valve oil leaking opening joint M52*2 outside trace
5、 Safety valve joint M52*2 outside trace
6、 System Oil returning opening joint RC4
7、 Oil discharging soft pipe, two ends, M52*2 even mouth inside trace joint
8、 Oil supplying soft pipe, two ends, M60*2 even mouth inside trace joint
11
HPC220 Oil Station Wind Cooler Joint Thread
1、Oil supplying opening joint M60*2 outside trace
2、Wind cooler oil feeding joint M42*2outside trace
3、Wind cooler oil discharge joint RC1 1/4
4、Safety valve oil leaking opening joint M42*2 outside trace
5、Safety valve joint M42*2 outside trace
6、System Oil returning opening joint RC3
7、Oil discharging soft pipe, two ends, M42*2 even mouth inside trace joint
8、Oil supplying soft pipe, two ends, M42*2 even mouth inside trace joint
12
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HPC Series High-Effiency Hydraulic Cone Crusher

Shanghai Shibang Machinery Co.,Ltd

International Trade Department

National Trade Department

Copyright © 2013 Shanghai Shibang Machinery Co.,Ltd

2 Basic Technical Information ....................................................................................................................... 9

5.Hydraulic system ................................................................................................................................. .... 29

6 Operation Guidance .................................................................................................................................. 32

7 Glossary of Terms ..................................................................................................................................... 75

1.1 Brief Introduction

Shanghai Shibang Machinery is a professional manufacturer of crushing,

1.2 Basic Safety Precaution

1.2.1 Personal Safety

1.2.2 Safety at the working site.

1.3 Electrical safety

1.4 Safety for Combustible items and Dangerous items

1.5 Pressure system (Air, hydraulic)

1.6 Safety in welding.

1.7 Safety Rules.

2 Basic Technical Information

This machine adopts multi-layer crushing theory. Reasonable structure parameter

For example HPC 220/C

Figure 2.1-1 Crusher terms

2.2 Technical parameter

Chart 2.2-1 Technical Parameter

Model Cavity type Min. Feed Capacity Recommended

on material property, feeding mode and material components.

• Feed opening matches with the min. discharge opening.

feeding size is about 80%-100% of the feeding opening size.

Figure2.2-1 Particle sizes diagram

The following factors will bring damage to the performance of crusher :

3.2 Crusher dimensions

Figure 3.2-1 Dimensions

3.3 Weight of crusher and crusher components

(excluding n assembly frame sleeve cone bearing sleeve ring device

motor and device

HPC160 13110 548 3004 882 1308 61 2205 2590 587

The above weight is subject to ±5% variation. All weight is calculated in

Incorrect Feeding Correct feeding method

convenience of cleaning and inspection. There should be clapboard in the discharging

In chapter 4, lubrication system, there is detailed introduction of oil types,

3.7 Assembly and disassembly

3.8 Instructions for maintenance

During maintenance, the following protective measure should be adopted:

3.9 Minimum recommended spare parts list

If the crusher or crusher frame needs to be installed on concrete base, the

Figure 3.10-1 gaskets place

4.1 Brief introduction

Figure 4.1-1 Inner Oil flow

4.2 Features of lubrication oil

The suitable lubricant is ISO 150 grade.

4.3 Oil temperature

The oil temperature should be within 25-60 ℃ . However, the optimum

discharging oil is higher than 60 degrees, cooling system must be used.

4.4 Oil pressure and flow rate

HPC160 95～114 60 0.14～0.35

HPC220 114～132 80 0.14～0.35

HPC315 204～222 150 0.14～0.35

4.5 Start and shutdown of Lubrication station

Lubrication station must be started before the start of crusher, so that

4.6 Ventilation device

Install a ventilation device on the transmission shaft frame or the oil

4.7 Positive pressure dust-proof device

5.1 General introduction