HPT Series Efficient Hydraulic Cone Crushers

User manual

Warning!
Read and follow all safety precaution instructions throughout this manual and on
safety signs attached to this equipment.

SBUM-0418-0201
Shanghai Shibang Machinery Co., Ltd
Shanghai Shibang Machinery Co., Ltd. can provide customers with a full range of technical support, so you
can contact your local SBM office or directly contact the SBM headquarters.

Shanghai Shibang Machinery Co., Ltd

Address: No.416, Jianye Road, South Jinqiao District, Pudong New Area, Shanghai, China
Postcode: 201201

International Marketing Department

Customer service telephone: 0086-021-58385683
Customer service fax:0086-021-38910000
Website：www.sbmchina.com

Domestic Marketing Department

Customer service telephone: 0086-021-58385683
Customer service fax: 0086-021-38910000
Website: www.shibangchina.com

All copyright © 2015 Shanghai Shibang Machinery Co., LTD

All rights reserved. Any organization or individual shall never extract, reproduce, copy or spread
this document in whole or part in any form without prior written consent of this Company.

And other SBM trademarks all belong to Shanghai Shibang Machinery Co., LTD. All
other trademarks or registered trademarks mentioned in this document are owned by individual
owners.
The Chinese version is the original version of this document. Other versions are translated ones.

Attention
Due to product upgrade or other reasons, this document will have its contents updated irregularly.
Unless otherwise agreed, this document is only used for reference, and any statement,
information or advice in this document shall never constitute any explicit or implied guarantee.
Valid For
Name Model Remarks
HPT Series Efficient HPT100 -
Hydraulic Cone HPT200
Crushers HPT300
HPT400
HPT500
Update Log

Document (Modified) (Modified) Signature Date Remarks

version Sections and Contents
Page Numbers
V01 - - - 2015-01-09 -
Introduction
This manual aims to provide guidance to new cone crusher operators and technical program
references to skilled ones. Read, study and save this manual for future reference.
The illustrations and instructions in this manual can guide operators to use correct
procedures for inspection, installation, operation and maintenance of the crusher and its auxiliary
equipment.
This manual only provides the most basic operation technology. Other operation skills and
technologies need operation personnel’s exploration and accumulation based on full
understanding of the crusher and its performance. Constant improvement and update of the
product design may bring your new products new changes not covered in this manual, but each
version of the manual is subject to constant review and revision, with appropriate change
contents updated and added in the latest version as required.
The descriptions and technical characteristics in this manual are effective when it is
approved for printing. SBM shall reserve the right to suspend the products of a certain type,
change the technical characteristics or design at any time subject to no prior notice or any
responsibility accordingly.
If you are doubtful about your crusher or the version of your manual, please consult any SBM
representative for the latest information.
This manual has provided a comprehensive guidance to relevant technical information. All
technical information necessary for correct installation of your crusher must come from the
installation drawings and technical data specifically available for you.

Safety
The first chapter “Safety” in the cone crusher manual has summarized the basic safety rules
in and around a crushing plant.
The operation safety and other safety affairs depend on the rational prevention and
judgment during operation of the crusher. Prudent operators should be good guarantee for
reduction of accidents.
Most of the accidents have resulted from ignorance to simple and basic safety rules or
precautions. As a result, most of the accidents can be prevented in advance by means of high
safety awareness and preventive measures.
We have been careful enough during design and production of this equipment, but, under
certain conditions, the equipment reasonable accessibility and effective interference-free
operation still can not be fully ensured. “Warnings” are used in this manual to emphasize such
conditions.

I
Contents
HPT Series Efficient Hydraulic Cone Crushers .................................................................................................... I
User manual .......................................................................................................................................................... I
Introduction ........................................................................................................................................................... I
Contents................................................................................................................................................................. I
Chapter 1 Safety............................................................................................................................................ 1
1.1 Personal safety.............................................................................................................................. 1
1.1.1 General rules......................................................................................................................... 1
1.1.2 Nip in the bud!...................................................................................................................... 1
1.1.3 Are you familiar with the safety rules of the factory? .......................................................... 1
1.1.4 Do you wear in accordance with the job requirements? ....................................................... 1
1.1.5 Do you understand your machine? ....................................................................................... 2
1.1.6 Are you familiar with the job site? ....................................................................................... 2
1.1.7 Are you ready for any potential accident? ............................................................................ 2
1.1.8 Inspection before starting ..................................................................................................... 2
1.1.9 Safe start ............................................................................................................................... 3
1.1.10 Machine fault report ............................................................................................................. 3
1.1.11 Safe shutdown ...................................................................................................................... 4
1.2 Essentials for safety maintenance ................................................................................................. 4
1.2.1 Read and understand ............................................................................................................ 4
1.2.2 Warning signs ....................................................................................................................... 4
1.2.3 Cut off the power supply ...................................................................................................... 4
1.2.4 Dressing - safe operation ...................................................................................................... 4
1.2.5 No alcoholic beverage or drug is permitted.......................................................................... 5
1.2.6 Workspace ............................................................................................................................ 5
1.2.7 Equipment ............................................................................................................................ 5
1.2.8 Fire protection ...................................................................................................................... 5
1.2.9 Compression system - hydraulic or pneumatic..................................................................... 6
1.2.10 Use high-quality parts .......................................................................................................... 6
1.2.11 Report necessary maintenance contents ............................................................................... 6
1.3 Factory safety rules ...................................................................................................................... 6
1.3.1 General rules......................................................................................................................... 6
1.3.2 Drive protection device ........................................................................................................ 6
1.3.3 Operation platform ............................................................................................................... 7
1.3.4 Cut off the power supply ...................................................................................................... 7
1.3.5 Crane .................................................................................................................................... 7
1.3.6 Mobile crane ......................................................................................................................... 8
1.3.7 Welding Equipment .............................................................................................................. 8
1.3.8 Lifting drive unit .................................................................................................................. 8
1.3.9 Belt conveyor belt ................................................................................................................ 8
1.3.10 Mobile crushing plant........................................................................................................... 8
I
 1.3.11 Crushing plant “noise” ......................................................................................................... 9
1.3.12 Epoxy resin and zinc fillers .................................................................................................. 9
1.3.13 Crushing plant “dust” ......................................................................................................... 10
1.3.14 Routine maintenance .......................................................................................................... 10
1.3.15 Thermalization process....................................................................................................... 10
Chapter 2 Overview of crusher ................................................................................................................... 11
2.1 Introduction ................................................................................................................................ 11
2.2 Crusher specifications ................................................................................................................ 11
2.3 Initial check ................................................................................................................................ 11
2.4 Information provided .................................................................................................................. 11
2.5 Parts maintenance ....................................................................................................................... 11
2.6 Crusher terminologies ................................................................................................................ 12
2.7 Prediction of crusher production capacity .................................................................................. 13
2.8 Choose right liners...................................................................................................................... 13
Chapter 3 General installation instructions ................................................................................................. 15
3.1 Installation drawing .................................................................................................................... 15
3.2 Configuration ............................................................................................................................. 15
3.2.1 Equipment installation ........................................................................................................ 15
3.2.2 Seal ..................................................................................................................................... 15
3.3 Feeding configuration................................................................................................................. 15
3.4 Discharge configuration ............................................................................................................. 17
3.5 Drive mode ................................................................................................................................. 18
3.6 Initial installation of V-belt drive unit ........................................................................................ 18
3.7 Tension of V-belt drive unit ....................................................................................................... 21
3.7.1 Tension deflection method ................................................................................................. 21
3.7.2 Elongation method ............................................................................................................. 23
3.8 V-belt protective measures ......................................................................................................... 25
3.9 Initial calibration of flexible coupling ........................................................................................ 25
3.10 Crusher motor ............................................................................................................................. 28
3.11 Piping descriptions ..................................................................................................................... 28
3.12 General assembly and disassembly instructions ......................................................................... 29
3.13 General maintenance instructions............................................................................................... 29
3.14 List for minimal spare parts as recommended ............................................................................ 30
3.15 Special tools ............................................................................................................................... 31
3.16 Prevent crusher corrosion ........................................................................................................... 31
Chapter 4 Operation instruction .................................................................................................................. 34
4.1 Check list for a new crusher before started ................................................................................ 34
4.2 Preparation before starting ......................................................................................................... 37
4.3 Countershaft speed ..................................................................................................................... 37
4.4 Rotation direction of the countershaft ........................................................................................ 38
II
 4.5 Operation of the hydraulic power unit........................................................................................ 38
4.6 Steps for initial starting and running-in ...................................................................................... 38
4.7 Procedures for daily startup and shutdown................................................................................. 39
4.7.1 Daily startup ....................................................................................................................... 39
4.7.2 Daily shutdown................................................................................................................... 40
4.8 Adjust the crusher discharge gate ............................................................................................... 40
4.9 Turn the adjusting ring ............................................................................................................... 41
4.9.1 Use the hydraulic regulating mechanism to turn the adjusting ring ................................... 41
4.9.2 Use a wire rope to rotate the moving cone ......................................................................... 41
4.10 Minimum discharge gate ............................................................................................................ 42
4.11 Check crusher discharge opening ............................................................................................... 42
4.11.1 Operation suggestions for standard crushers ...................................................................... 43
4.12 Ring motion ................................................................................................................................ 44
4.13 Determine the liner wear ............................................................................................................ 45
4.14 Thread lubrication ...................................................................................................................... 48
4.15 Adjusting ring and support bushing thread wear ........................................................................ 48
4.16 Difficulty in turning the adjusting ring ....................................................................................... 50
4.17 Crusher chamber cleaning .......................................................................................................... 52
4.18 Adjusting ring removal and installation ..................................................................................... 53
4.19 In-plant overhauling ................................................................................................................... 53
4.20 Periodical maintenance............................................................................................................... 54
Chapter 5 Inspection and maintenance cycle .............................................................................................. 55
Chapter 6 Crusher operation ....................................................................................................................... 64
6.1 Adjusting ring, bowl liner and feed hopper assembly ................................................................ 64
6.1.1 Overview ............................................................................................................................ 64
6.1.2 Assembly instructions ........................................................................................................ 64
6.1.3 Maintenance ....................................................................................................................... 67
6.1.4 Feed hopper replacement and adjustment .......................................................................... 69
6.2 Moving cone, mantle and cone head assembly .......................................................................... 70
6.2.1 Overview ............................................................................................................................ 70
6.2.2 Installation of the moving cone assembly .......................................................................... 70
6.2.3 Maintenance ....................................................................................................................... 73
6.3 Socket liner assembly ................................................................................................................. 87
6.3.1 Overview ............................................................................................................................ 87
6.3.2 Assembly instructions................................................................................................................ 87
6.3.3 Maintenance ....................................................................................................................... 90
6.4 Eccentric bushing assembly ....................................................................................................... 91
6.4.1 Overview ............................................................................................................................ 91
6.4.2 Assembly instructions ........................................................................................................ 92
6.4.3 Maintenance ....................................................................................................................... 94
6.5 Countershaft frame, countershaft and pulley assembly ............................................................ 105
III
 6.5.1 Overview .......................................................................................................................... 105
6.5.2 Maintenance ..................................................................................................................... 109
6.6 Main frame/support bushing and iron release assembly........................................................... 121
6.6.1 Overview .......................................................................................................................... 121
6.6.2 Assembly instructions ...................................................................................................... 122
6.6.3 Maintenance ..................................................................................................................... 126
Chapter 7 Hydraulic system ...................................................................................................................... 145
7.1. Overview .................................................................................................................................. 145
7.2. Operation of the hydraulic power unit...................................................................................... 145
7.2.1 Hydraulic oil characteristics ............................................................................................. 145
7.2.2 Locking hydraulic cylinder assembly ...................................................................................... 146
7.2.3 Hydraulic adjusting mechanism assembly ....................................................................... 147
7.2.4 Hydraulic hose and crusher coupling ............................................................................... 147
7.2.5 Accumulator precharging and charging checks ................................................................ 148
7.2.6 Discharging and pressurization test of the hydraulic system............................................ 150
7.2.7 Pressurize the crushing chamber releasing circuit ............................................................ 152
7.3 Maintenance ............................................................................................................................. 152
Chapter 8 Typical Problems of a Crusher ................................................................................................. 153

IV
Chapter 1 Safety

will have the word “warning” marked for

1.1 Personal safety
hazardous or adventurous operation.

1.1.1 General rules

No matter how safe the equipment is, you also
This Chapter is mainly to illustrate the basic safety
need to operate carefully, familiarize yourself with
rules. To achieve the safe operation of the crusher,
its technical performance and fully comply with
other measures still needs to be taken. The
the safety rules.
contents of this manual cannot replace the safety
rules, safety measures and relevant governmental
Remember that the safety mainly depends on
laws, rules and regulations at all levels.
yourself in any case and that earnest safety
The safety of the operation and maintenance
protection not only can protect the people around
personnel is of great importance. This manual
you, but also can protect yourself most reliably.
mainly provides guidance to equipment installation
Please learn this manual and all other operation
personnel for some problems possibly occurring in
manuals prepared by the manufacturer and related
their daily work.
to your equipment in service. Read all warnings
and precautions. Be sure to achieve safe operation.
The operators shall have the responsibility to
familiarize themselves with the specific
Urge your co-workers also to comply with the
requirements, precautions and unsafe factors
safety rules. Alert to all unknown dangers. Do
existing in the working area, and discuss these
remember: Safety is your responsibility!!!
issues with the managers in a timely manner. Only
if all personnel have reached a consensus in this 1.1.3 Are you familiar with the safety
respect can the safety operation be ensured. rules of the factory?
The safety records of the company show that most
Operators are of great importance for excellent accidents resulted from ignorance to simple safety
performance in safety work, so they should have rules. Therefore, you must be familiar with and
the opportunity to learn the safety considerations abide by all provisions and ask the executives for
and know about the basic safety measures, in order relevant provisions before starting your work.
to prevent serious personal casualties and property
losses.
1.1.4 Do you wear in accordance with
the job requirements?
1.1.2 Nip in the bud!
For your personal safety, you should carefully
In order to remind you (users and relevant choose and correctly wear safety helmets, safety
operation and maintenance personnel), this manual

1
shoes, goggle, goggles, protective gloves, ear
protection devices and other supplies.
Wide clothes are easy to get stuck in rotating parts.
Please tie your cuffs reliably, tighten your blouse
carefully and wear all safety products correctly.
Pay attention to warm keeping, but permit no
interference with your actions. Watches and rings
may bring about dangers. Never put anything in
your pocket that may slip out.
1.1.5 Do you understand your
machine?
Please read the onboard manual, familiarize
yourself with equipment operation and
maintenance essentials, understand the production
capacity and application scope of the machine, and
understand the positions, functions and alarm
prompts of all controllers, indicators and alarm
devices. Learn to recognize the alarm and safety
devices of the machine. The alarm device will
warn you of dangers if operation continues under
the condition of low pressure and high
temperature.
1.1.6 Are you familiar with the job
site?
Try to know more about your work site ahead of
time:
Always keep the floor clean and free of oil, grease,
cloth waste, rope, chain, hopper, rocks and other
obstacles. Place the scattered parts in a toolkit.
Never use flammable solution for cleaning.
Be aware of the bearing capacity of the workplace
ground.
2
Be familiar with the workplace clearance. Use a
little time to check workplace surrounding and top
clearance, including power supply, which can
reduce a lot of future troubles.
Watch for dust, smoke or fog, which might
interfere with your line of sight.
1.1.7 Are you ready for any potential
accident?
Take preventive measures in advance, keep
watchful at any time, operate in an elaborate
manner, and you can prevent personal injuries and
equipment failures. If any accident happens due to
slightest negligence, you should use your handy
tools and skilled technology for emergent
treatment as quickly as possible. Be familiar with
the location and usage of the fire extinguisher and
first-aid kit.
Know where to get emergency aid.
Dial the service telephone as quickly as possible
for immediate emergency aid.
The safety work should not only be confined to
these regular rules, and at the same time, it should
also be noted that some preventive measures
should be additionally taken in specific working
conditions and for the specific device you are
using.
1.1.8 Inspection before starting
Any equipment is unsafe if no full preparation has
been made for operation. Check carefully in time
of work shifts. If any problem is found worth
sufficient attention, take it into careful
consideration again and again before deciding to
“let it be this time”. Even a tiny mechanical failure
may also cause personal injuries and major
accidents.
1. Never allow anyone unauthorized to operate
the crusher!
2. Make sure that all the safety covers and other
protective devices are located and fixed
correctly in place, free of damages.
3. Check whether the oil system is at the level,
free of leakage.
4. Check each discharge cock, valve and pipe
joint to make sure that they are located and
fixed correctly in place.
5. Serious hydraulic failures may result from
insufficient pressure due to a low oil level.
6. The crusher block-out occurring due to thin
oil or insufficient grease may be one of the
troubles leading to failures.
7. Never adjust the reducing valve to increase
the operating oil pressure. The oil pressure
recommended by the manufacturer can
provide the longest service life and the safest
performance.
8. Never modify any safety device without
authorization.
9. Check the crusher thoroughly to see if there is
any visible defect, such as leakage, worn hose
or loose part.
10. Check your machine in accordance with the
operation manual and management
personnel’s instructions.
11. Check your machine around before driving.
Make sure that nobody is near, on or below
the equipment. Remind nearby personnel
before starting.
Any accident should be reported to your
manager.
3
1.1.9 Safe start
1. Check the warning signs of the equipment.
2. Follow the start-up procedures as
recommended in Chapter 3: Operation
Instructions.
3. After a crusher is started, check all indicators
and instruments to make sure that they are
working normally.
4. If any reading is found abnormal, stop
immediately.
5. Test all controllers to ensure normal
functions.
6. Monitor and report any abnormal noise.
7. Check the alarm or other warning and safety
devices.
8. Never stand on the support bushing of the
crusher in operation.
9. When a crusher is working, never lean against
or put your hands on the safety cylinder or
between the support bushing and the main
frame.
10. Never start any faulty machine by luck.
Report the real conditions to the manager.
11. When a crusher is working, never observe the
crushing chamber inside in the absence of
protective measures.
1.1.10 Machine fault report
Check the machine every day to see whether there
is any loose, worn or damaged part, report or
correct unsafe conditions immediately and never
operate the machine before equipment
troubleshooting.
Even a small failure will also become a serious
accident, so any equipment failure should be
reported to the manager.
1.1.11 Safe shutdown
Make sure the crusher has shut down before
cleaning, maintenance, oil filling, belt tension
checks, tank cover opening, hydraulic system
checks, crushing chamber repairing or cleaning
and other relevant work contents. When a crusher
is working, no inspection, adjustment or repair
work is permitted.
1.2.3 Cut off the power supply
1. Before the crusher is subject to any
maintenance, cut off all electrical controllers.
2. When any hydraulic power equipment is in
maintenance, cut off all electrical power
sources, because only the motor can be
stopped when the “STOP” button is pressed.
3. Provide an independent padlock and a unique
key to each maintenance operator.

1.2 Essentials for safety

1.2.4 Dressing - safe operation
maintenance
1. Keep your hands and clothes far away from
Do well in maintenance work in an elaborate
moving parts. Never wear clothes with loose
manner.
sleeves, sagging ties, watches or rings by
luck.
2. When exposed to fuel oil, cleaning fluid, oil
1.2.1 Read and understand
or brake fluid, you should wear glasses to
1. Rear part “Inspection and Maintenance
protect your eyes against injuries.
Instructions” of Chapter 4 “Operation
3. Wear a respirator when necessary.
Instructions”
4. When drilling, grinding, or forging any metal,
2. Onboard warning nameplates
you should wear goggles.
3. Warning instructions in the manual
5. Never put pocket anything that may fall out
4. Chapter 5 Lubrication guidelines for regular
into the machine.
maintenance
6. Wear safety helmet and safety shoes when

1.2.2 Warning signs necessary.

7. When replacing any steel cable, you should
Before working in the crusher, mount a warning
wear gloves to protect your hands.
sign and cut off all electric controllers so that
8. When using high-pressure air, you should
nobody could start it.
wear goggles and protective clothing.
9. When operating any molten metal, such as
Mount a warning sign to prevent accidents:
zinc, babbitt and lead, you should wear
1. If the crusher can't be operated safely.
goggles and protective clothing.
2. If the controller is in maintenance.
10. You should wear ear protectors or have your
3. If the machine is in maintenance.
ears subject to shorter exposure as required.

4
1.2.5 No alcoholic beverage or drug is
permitted
1. Before or during working, you shall not drink
any alcoholic beverage.
2. Beware of taking any medicine, tranquilizer
or other narcotic drug possibly to make you
sleepy or less alert.
1.2.6 Workspace
1. As advocated, have the workspace floor kept
clean, dry and free of debris and tools.
Slippage may happen more easily due to
greasy and wet ground, pedals, steps and
handrails. Beware of ice and snow in winter.
Wet ground, especially near the electrical
equipment, is very dangerous.
2. Never place or stockpile any material on or
around the crusher.
3. Store any dangerous liquid at a suitable place
far away from unauthorized personnel.
No smoking in any workspace!
4. Never start any diesel or gasoline engine in an
airtight place, but keep it well ventilated
because the exhaust fumes may be fatal.
5. In time of gas cutting or welding, take
appropriate protective measures. Any
personnel to perform such operations should
avoid breathing dust and smoke, because it
may harm your health. Therefore, perform
such operations at a well-ventilated place
configured with relevant facilities to provide
the machine with pure air independently or
exhaust smoke. Please refer to the MAHA or
OSHA applicable standards.
1.2.7 Equipment
1. Use the right tools; deal with tools and heavy
parts in a flexible manner.
5
2. Have all tools and equipment kept free of dirt
and grease. Never abandon or throw any tool
at will.
3. Use lifting equipment for large parts. Take care
to look behind at any time.
4. Lower but never casually drop any part.
5. Clear the grease on the operating lever and
handle to prevent slippage.
6. Never use any belt pulley with its rim or spoke
cracked.
7. Check the V-belt speed loss, cracks and edge
wear.
8. Check and replace any damaged, defective or
missing part. Have the equipment kept clean
and free of dust and oil stains, in order to find
any loose or defective part.
9. When using a steel rope to move heavy objects,
make sure of the competent specifications and
replace any worn steel rode subject to serious
abrasion, cleavage or twist. Check whether
any end connector is worn.
1.2.8 Fire protection
1. No smoking when filling oil or transporting
any oil container.
2. Shut down the engine when filling oil and
take special care when the engine is still hot
enough.
3. When refueling, have the funnel or nozzle
kept close to the fuel tank and ground it
reliably to prevent electrostatic sparks.
4. Never use petrol or diesel to clean parts.
You’d better use high-quality industrial
nonflammable solvents.
5. Smoking is forbidden when any cleaning
agent is used.
6. Never stack oily rags and other flammables in
a poorly ventilated place but at a safe place.
7. Never use open fire when checking the fuel,
battery electrolyte or coolant level; use a
flashlight to find any sign of hydraulic oil
leakage.
8. Make sure where the fire extinguisher is
stored, how it is used and what kind of fire it
can be competent for. Check it regularly at
least once a month and make sure it is stored
within the workspace.
9. In case of fires, shut down the crusher
hydraulic unit and lubricating oil system on
the premise of safe operation.
1.2.9 Compression system - hydraulic
or pneumatic
1. Release the pressure completely before
opening or moving any hydraulic or
pneumatic pipe, valve and joint, etc.
2. Check whether any hose is worn or any pipe
is damaged.
3. The high pressure oil is dangerous.
4. Any device equipped with a
hydraulic-pneumatic accumulator should
comply with the provisions on gas pressure
containers in the French decree issued on
November 24, 1982 about
hydraulic-pneumatic accumulators.
1.2.10 Use high-quality parts
When any part is abandoned, the part for
replacement must be identical to the original one in
specification, type and quality.
1.2.11 Report necessary maintenance
contents
6
In daily inspection, if some parts are found in need
of elaborate repair, replacement or adjustment, a
timely report should be delivered!
If the equipment is in operation, even minor
defects can also cause serious faults.
Implement any task authorized but never try to do
what you don't understand.
You can only work on such equipment you have
fully understood. For any part mounted with
pressure, personal injuries may happen if the
pressure is released due to carelessness.
Keep in mind that the equipment whose operation
and maintenance you are responsible for is
expensive. Treat it carefully!
1.3 Factory safety rules
1.3.1 General rules
The safety rules mentioned here can't rule out all
potential safety hazards in the crushing plant, and
moreover, in the long-term production practice,
people have summarized some safety rules, which
have improved the safety situations around the
crusher and the crushing plant. SBM welcomes
users’ any suggestion on the safety rules for use of
the crusher and relevant equipment.
1.3.2 Drive protection device
When a crusher is being installed, pay attention to
appropriate safety measures. The crusher can be
driven by a V-belt or directly by a coupler.
Protection devices should be provided around the
drive belt or coupler.

The crusher pulley is specially designed according
to the maximum speed of its rim, so the pulley
may rupture if beyond its maximum speed to result
in serious accidents or personal casualties.
The crusher speed is essential to its normal
working. Therefore, most V-belts usually have a
small hole cut on the safety covers against the
center of the countershaft, so that a tachometer
could be put in for regular inspection of the shaft
speed. The hole is covered with an access door or
lattice door.
1.3.3 Operation platform
Each crusher must need regular inspection and
maintenance, so an applicable operation platform
should be set up at a proper height, so that the
operating personnel could complete inspection on
the crusher. The high-quality operation platform
built on a whole floor should provide handrails and
steps, as well as wire net or metal net between the
platform and the handrails to prevent tools falling
down from the platform to hurt the working staff
on the ground. Never fix the operation platform
together with the support bushing, because the
whole support bushing will be raise up quickly
when any iron piece goes through the crusher.
1.3.4 Cut off the power supply
No matter what time it is, cut off the power supply
of the crushing equipment as long as someone is
working on the crusher.
Each maintenance personnel working normally on
the crusher should have his own special lock and
the only key. When working on any part of the
7
crusher, he should use his own padlock to lock the
power control device of the crusher. More
importantly, this lock only has one key and this
key also must be kept in the pocket of the operator
working on the crusher. If more than one person is
working on the crusher at the same time, then
everyone should have their own padlocks and keys
used for the lock positions on the crusher
controller.
1.3.5 Crane
Like other types of machinery equipment, if you
want to get the best economic efficiency from a
crusher, you must complete normal and regular
maintenance. One of the most serious safety
violation events for a crusher is to use incompetent
and unsafe lifting equipment. The crusher does not
need precise adjustment like a car engine, but
lifting equipment must be used for assembly and
disassembly of its interior parts. The competent
crane should be able to lift and lower down the
crusher parts smoothly and slowly for final
assembly. When a crane is used, it must be
working within its rated load. The safe rated load
of a crane includes the weight of its hook, pulley
block and suspension system, such as steel wire
ropes, slings and levers. Only after the weight of
such devices is deducted can you determine the
real safe load. The chain hoist is just the most
unavoidable means used for crusher assembly and
disassembly.
Anything related to safety shall need the best
protective measures.
1.3.6 Mobile crane
When a mobile crane is used, it must be working
within its rated load in case of cargo boom
deformation or overturn. The safe rated load is
calculated on the condition that a crane is kept on a
solid horizontal ground. Have its cantilever rack
stretch out appropriately and put it as low as
possible. Avoid rapid rotation, lifting or sudden
braking; otherwise, the crane may suffer from
overload. Never lift any heavy loads in the case of
high winds.
First check the bridge load before a mobile crane
crosses any bridge and check the height limit when
going through under a bridge, for example,
whether there are overhead wires or any other
obstacles.
Before lifting, check the environment around you
and confirm that no obstacle is around the cargo to
be lifted. Make sure that the crane is firmly
connected with the cargo to be lifted.
1.3.7 Welding Equipment
In time of gas cutting or welding, you generally
need to take appropriate protective measures,
because many metals are dangerous to human
health. Any personnel to perform such operations
should avoid breathing dust and smoke. Such
operationgs shall be performed outdoors or at a
well-ventilated place equipped with relevant
facilities to provide the machine with pure air
independently or exhaust smoke. Please refer to
the MAHA or OSHA applicable standards. Cutting
torches are one of the most widely used tools for
crushers. In time of welding or cutting operations,
release the pressure in all hydraulic components of
8
the crusher equipped with hydraulic devices, and
cover such components with fireproof materials to
prevent welding sparks or splashes. If any
high-pressure hydraulic pipeline is broken, the
internal liquid will vaporize quickly in the
atmosphere. This vaporization liquid can quickly
burn to result in serious burns of the neighboring
persons. If a hydraulic component is located near
the working area, make sure to notify all the staff
using gas cutting equipment and then take
necessary measures to avoid contact with such
parts. The cutting equipment can only be used for
normal maintenance in the workshop, not for
rubber-lined hoses.
1.3.8 Lifting drive unit
Use a lifting drive unit to lift all crusher parts
slowly and steadily and have the drive unit move
within its maximum rated load. Remember that the
safe rated load includes the weight of the crusher
and such lifting accessories as chains and hooks.
1.3.9 Belt conveyor belt
Never use the conveyor belt as a channel. There
shall be pedestrian passageways arranged beside
the belt conveyors from and to the crusher, with
handrails provided along the channel of the
conveyor as additional safety measures.
1.3.10 Mobile crushing plant
If the crusher is composed of mobile equipment,
that is to say, the crushing and screening
equipment is installed on a trailer, then the trailer
base or support is very important for safe
production. Check the base of the trailer and have
all equipment installed on a base as solid and flat
as possible. Use thick cushions under the trailer, so
that its wheels could be kept off the ground.
Arrange a screw jack at or near each of the trailer
four corners respectively. The four jacks must be
kept identical in distance of the angle tips. Adjust
the height of the jacks to have the unsupported part
of the trailer beam stop vibrating or minimize the
vibrations. Never park the trailer at any low-lying
area where the rain water can wash its base.
Regularly check the trailer base to ensure of its
firmness.
Before driving a trailer across a bridge, first check
whether the bridge can bear the weight of the
equipment. When driving through a tunnel, check
the overhead clearance under the bridge, such as:
elevated lines or other obstacles. Never have any
weight crossing a bridge if it is heavy enough to
reach the bridge bearing capacity. Check local
regulations, especially the weight limit.
When driving on a highway, make sure that the
headlamps, brake lights and tail lights can work
normally. Use correct transport warning flags and
signs.
1.3.11 Crushing plant “noise”
Any crushing equipment will naturally have noises.
Such ancillary equipment around the crusher as the
chutes, transshipment points and sieves are much
noisier than the crusher.
The sound power level is typically between
100-130DBA when a crusher is working. If the
noise is greater than that of the scope of legal
permission, ear protection devices should be used.
If the ear protection devices still can not have the
noise lowered to the regulated level, then
consideration should be taken into reducing the
time duration of the post workers or maintenance
9
personnel in the noise, namely, shortening the
working hours.
It is not feasible in economy to lower the noise
level by changing the machine itself. Many
operators have found that the noise can be reduced
by construction of a relatively inexpensive
operation room. In the operation room, the
operator can see the equipment in operation, while
installation of insulation bricks, double-layered
windows and air-conditioning equipment can
protect the operator from noise hazards. These
working conditions can inevitably improve
operation efficiency and reduce potential noise
hazards.
Many crushing plant operators have found that to
build a control tower higher than most of the
equipment can provide the operating personnel
with a safe place and also improve the working
efficiency of the crushing plant.
1.3.12 Epoxy resin and zinc fillers
All crushers need some kind of fillers when
components are replaced. Resin (for example,
epoxy resin) fillers can avoid the possibility of
staff’s accidental burns due to splash and
explosion when the molten zinc contacts with the
wet surface. Plastic fillers feature greater
convenience and a bigger safety coefficient, so
molten zinc has been out of date if used as crusher
lining fillers.
If epoxy resin fillers are used, take great care when
removing crusher liners by means of gas welding
cutting. The working area must be well ventilated,
because the flue gas of epoxy resin makes people
sick and also have stimulation to eyes and skin.
1.3.13 Crushing plant “dust”
The crushing equipment, chutes, transshipment
points, sieves and other auxiliary equipment
naturally will produce dust, which will float in the
air if not collected. Excessive inhalation of dust
will do harm to the operators or workers on or
around the equipment. In general, atmospheric dust
of a high concentration may cause lung diseases
and its danger coefficient depends on the dust
concentration, the time of exposure to dust and the
kind of the material to be crushed. SBM highly
recommends you use dust-proof equipment, for
example, any worker exposed to airborne dust
should wear a dust mask. OSHA, MSHA or local
laws may require the use of dust-proof equipment
and dust alarm devices. It should be up to the
operators to determine under which conditions
such dust-proof equipment and dust alarm devices
should be used. Provide dust-proof equipment and
dust alarm devices and ensure they can be used as
required.
If some changes can be made to the crushing
network, for example, add a dust collection system
or use spray nozzles at the inlet and /or discharging
conveyor, the airborne dust can be significantly
reduced. If a corner funnel is used during crushing
operations, the dust from the crusher itself can also
be reduced. Each crusher may have different
configurations from others, so SBM suggests that
operators should consult SBM or dust reduction
adviser to see which measures can be adopted to
reduce dust.
1.3.14 Routine maintenance
In daily operation, some maintenance work must
be executed around the crusher. The following
10
items should be regarded as part of the rules for
normal operation of the crusher, here indicating
what should be done and what should not be done.
1. No maintenance work is permitted on any
working machinery equipment, including
lubricating oil or grease filled in the crusher
parts in operation.
2. When a crusher is working, never put your
hands or feet on the safety cylinder of the
crusher. This device is used to protect the
crusher in operation in case of iron passing.
3. Maintain the equipment according to the
preventive maintenance programs as
recommended by the manufacturer. Such
maintenance programs are provided not only
to avoid damage to equipment, but also avoid
operators’ injuries.
4. Prevent broken stone flying out from the
crusher because excessively large stone
blocks are fed into the crusher chamber. The
workshop operators should ensure that no
broken stone fly out of the crusher to hurt
defenseless passers-by.
5. When a crusher is in operation, never look
into the crusher chamber if no reliable
measures have been taken to prevent material
flying.
6. When using a crane to lift or lower a load,
ensure that no one is in the work place.
7. Never walk, stand, ramble or lie down under
any load hanging on the crane boom.
1.3.15 Thermalization process
To cool various parts of the crusher, take
appropriate safety measures to deal with dry ice,
liquid nitrogen or any other low-temperature
refrigerant. Please refer to the MAHA and OSHA
applicable standards. If no correct preventive
measures have been taken, serious body harm may
happen.
Chapter 2 Overview of crusher
2.1 Introduction
This manual is prepared for users and operators
during installation, operation and maintenance of
the HPT cone crusher.
The information in the manual will help you
understand the structure of the crusher and get
knowledge about effective operation and
maintenance.
Each crusher has been assembled and tested before
delivery. Even so, certain safety protection
measures should be taken during operation. Such
measures will be introduced to you in later
chapters to help you prevent failures due to
incorrect operation or maintenance.
What needs to be stressed is that you should first
read and understand the contents of this manual
and put them into practice before installation and
during operation of the crusher.
2.2 Crusher specifications
In general, this manual covers all smaller cone
crushers.
2.3 Initial check
When receiving a crusher, check it carefully as
soon as possible to find any possible damage
during the process of transportation and confirm
whether any part is missing and whether all
11
Please keep in mind that safety is your
responsibility!
mentioned on the bill of lading, shipping list or
packing list have been received. If any part is
found lost or damaged, notify relevant traffic unit
immediately for necessary claims timely.
2.4 Information provided
The following drawings and data of the crusher
you purchased will be provided in the form of
separate installation atlas.
1. Foundation drawing
2. Oil circuit diagram of the crusher and
lubricating system
3. Drawings and data for auxiliary equipment
not manufactured by SBM
4. All other drawings or information necessary
for specific installation
5. Atlas for quick-wear crusher parts, available
for part ordering or replacement
2.5 Parts maintenance
SBM will try to provide adequate inventory of
spare parts, in order to provide fast and efficient
service for such users ordering parts for
maintenance or replacement.
To avoid delaying and providing inaccurate parts,
please provide such information as follows:
1. Crusher specifications
2. Serial number on the crusher nameplate and
the parts manual cover
3. Accurate quantity of each kind of parts to be
ordered
4. Full name and serial number marked in the
part manual for each part
5. Complete requirements for transportation:
by mail, express delivery, land/ water
transportation or air transportation
If your crusher parts manual is lost or damaged, we
can send another copy for free if you demand in
your letter. For normal operation, only the parts
and components produced by the original factory
can be used to ensure the accuracy, processing
technology and materials.
2.6 Crusher terminologies
In the manual, certain terminologies are used to
describe the crusher and its operation. To avoid
confusion and misunderstanding, such
terminologies as follows are defined in this manual
according to the usage:
Feeding: Raw materials to be crushed
Lining: bowl liners, mantles, main frame liners and
main frame installation liners, which are all
crushing parts and known as lining.
Crushing chamber: Internal space formed by two
crushing parts
Parallel band: It refers to such area between two
parallel liners within a certain range when the
adjusting ring is closest to the lower part of the
mantle in a cycle of suspension motion.
Tension side feeder inlet: It refers to the upper
minimum distance when two crushing parts move
to the nearest end.
12
Slack side feeder inlet: It refers to the upper
maximum distance when two crushing parts move
to the farthest end. The slack side feeder inlet will
decide the maximum feeding size. According to
the general rule, the maximum feeding size shall
never exceed the tension side feeder inlet.
Discharge gate: It refers to the distance between
two points on the bottom when two crushing parts
move to the closest position. The discharge gate
can adjust the product granularity.
Tension side discharge gate: It refers to the
minimum distance permitted between two points
on the bottom when two crushing parts move to
the closest position.
Slack side discharge gate: It refers to the distance
between two points on the bottom when two
crushing parts move to the farthest position. This
wide gate can have the crushed material
discharged rapidly.
Feeding granularity: It refers to the size of the
material able to go through the square hole on the
sieve (for example: when the feeding granularity is
50mm (2"), then the materials can completely go
through a 50 mm (2") sieve).
Product granularity: It refers to the granularity of
the materials crushed and screened.
Capacity: crusher processing capacity calculated
by tons per hour
Open-circuit production: This operation mode does
not mainly consider the uniformity of the product
granularity, but whether the feeding materials can
go through the crusher for once only.
Closed-circuit production: This operation mode
mainly considers the uniformity of the product
granularity. The products refer to the materials
under the sieve and such materials on the sieve
need to be fed back into the crusher again.
2.7 Prediction of crusher
production capacity
The crusher is just one part of the process.
Therefore, its performance partially depends on
proper selection and operation of the feeder, belt
conveyor, sieve, bearing components, motor, drive
components and buffer bin. When this kind of
crusher is used, its capacity and performance can
be improved if attention is paid to such factors as
follows:
1. Correctly select the crushing chamber
according to the materials to be crushed.
2. The feeding granularity is appropriately
proportioned.
3. Control the feeding quantity.
4. The feeding is evenly distributed within 360°
of the crushing chamber.
5. The discharge conveyor has its specifications
corresponding to the maximum processing
capacity of the crusher.
6. Select appropriate specifications of the sieves
for prescreening and closed-circuit screening.
7. Automatic control
8. The crusher can discharge material smoothly.
Such factors as follows will reduce the capacity
and performance of the crusher:
1. The feeding contains viscous materials.
13
2. The fine materials smaller than the discharge
gate in the feeding exceed 10% of the crusher
capacity.
3. The feeding is too wet.
4. The feeding segregation appears in the
crushing chamber.
5. The feeding is unevenly distributed around
the crushing chamber.
6. The feeding is insufficiently controlled.
7. The recommended power has not been fully
used.
8. The conveyor is less competent.
9. Prescreening and closed-circuit screening is
less competent.
10. The crusher discharging is not smooth.
11. The materials are too hard or tough.
12. The crusher countershaft works below its
full-load speed as recommended.
The crusher capacity and product granularity is an
average based on the results during crushing of
various ores and rocks by world-wide crushers
installed. For any rare case, please consult SBM.
2.8 Choose right liners
Through extensive exploration and research, SBM
has developed various types of crushing parts to
adapt to all kinds of feeding and product
granularity. The conditions and operation modes
are variable, so it is rather difficult to separately
list each kind of liners suitable for each special
situation and operation mode.
If the liner you are using has no ideal wear life for
some reason, it is recommended that you use gas
cutting to the adjusting ring and mantle, trace the
outline of the adjusting ring and mantle onto a
piece of cardboard or hard paper and then send the
skeleton maps to the manufacturer, so that the 5. Part numbers of the adjusting ring and mantle
wear concentrated area could be accurately currently in operation
determined as shown in Figure 2-1. 6. Crusher driving power
7. Crusher capacity
We will recommend you another kind of adjusting 8. Crusher series number
rings and mantles different in outline according to 9. Crusher discharge gate
the wear locations. 10. Crusher load hours
11. Speed of the crusher pulley (RPM)
In order to accurately answer your questions,
please provide such information as follows: Continuous use of such liners not suitable for the
1. Feeding granularity. crushing chamber and the operating conditions will
2. Feeding type (for example, granite) lead to liner wear and lower crushing efficiency
3. Product granularity as required and, in some cases, even lead to damages to the
4. Settings of the crushing circuit as well as all crusher.
screening meshes and the crusher

Item Name
Use gas cutting to cut a seam on the moving cone or cone
1
liner;
Mark the wear contour line on the cardboard or thick plate
2
inserted into the cutting;
3 Contour line marked on the wear plate
Figure 2-1 Determine the wear contour line
14
Chapter 3 General installation instructions
3.1 Installation drawing
The specific installation drawing is provided in the
attachment of this document. Concrete or metal
bases must be calculated and verified in
accordance with the size and load as indicated in
this figure.
The concrete blocks or metal bases must be
designed and calculated in accordance with the
previous research results and the elastic mechanics
on the ground in time of pouring and layout.
3.2 Configuration
3.2.1 Equipment installation
The stand surface must be flat and level.
And ensure that:
- The adequate height is reserved for removal
of the moving cone and adjusting ring
components;
- The adequate height is reserved for removal
of the countershaft components;
- Sufficient space is reserved for the feeding
funnel, chute and other auxiliary equipment,
as well as for discharging of the crushed
materials and maintenance of the hopper, belt
conveyor and crusher, etc.
3.2.2 Seal
If this equipment is installed on a concrete base, a
number of anchor bolts shall be used to fix the
equipment on the base.
15
These bolts will transmit their traction to the
concrete grouting seal.
The sealing concrete will transmit the torque from
the bolts to the concrete base. The force will be
transmitted between concrete blocks through the
interface layer.
If any anchor wrench is used, it can only be used
as a support bushing between the bolt and the
sealing element, and should be removed after
sealing or concrete curing is completed. Any tall
and narrow structure subject to the wind effect
(e.g., belt conveyer) must be sealed as soon as
possible before test run. In fact, the anchor bolt not
sealed only has 1/12 resistance of the sealed one.
The anchor wrench doesn't work in anchoring
resistance and only the sealing concrete can ensure
the strength of the hook anchorage.
In general, concrete must conform to the
reasonable operation procedure and accept the
official stress experiment in the local country.
Note: Crushers and crushers on steel structures
will have their space size and weight given by
SBM in relevant technical data.
3.3 Feeding configuration
Whether a crusher can obtain the highest
efficiency directly depends on the feeding
configuration. If the materials are fed appropriately
and distributed evenly in the crushing chamber, the
crusher can achieve its maximum efficiency. If
carefully checking the foundation drawing and the during overhauling of the crusher. Therefore,
crusher space size, you can take some measures in before the final construction, a thorough plan
advance to installation of the feeding equipment. should be prepared.
This feeding device should be easy to dismantle

Incorrect feeding method Correct feeding method

The materials are fed from the feeding inlet to Have the feeding appropriately fall onto the cone
result in uneven distribution. Consequences of head.
uneven feeding: Consequences of even feeding:
1. Reduction of the production capacity 1. Maximum production capacity
2. Excessively larger particle size of the product 2. Even particle size of the product
3. Excessive displacement of the support 3. Have the support bushing subject to the
bushing minimum displacement.
4. Maximum bearing pressure. 4. Minimum bearing pressure
5. Maximum power consumption. 5. Minimum power consumption.

Figure 3-1 Feeding configuration

A feed box should be equipped at the top of the
hopper, so that the materials from the funnel can
first fall down onto the dead angle and then fall
vertically onto the cone head more evenly. If the
correct feeding method is combined with the cone
crusher head, the feed box will help ensure that
16
after the materials fully mixed could be fed evenly
along the whole crushing chamber. Try to
minimize the fine and coarse material segregation,
in order to minimize liner wear. In order to have
the crusher achieve the ideal effect, the feeding
should need to be adjusted, so that the materials
could be accumulated at 3''-4'' (full feeding) above
the crushing chamber and rise evenly along the The correct and incorrect feeding methods, as well
whole crushing chamber. as the feeding box structure, are shown in the
figure 3-1
The crusher should be fed fully and evenly. In this
way, it can achieve greater yield, finer and more
3.4 Discharge configuration
uniform product granularity, and obviously lower
energy consumption. The feed box structure and The discharge configuration varies with each

material depends on feeding method, so no feed device, so no discharge chamber or funnel is

box is delivered with the crusher. provided together with the crusher. But, its
structure should meet the requirements of the

No matter which kind of crusher is used, you’d foundation drawing. The discharge chamber can be

better use prescreening to remove the fine and made from metal or wood. The discharge chamber

viscous materials in the feeding, so that material should have an inspection hole reserved to

blockage, support bushing excessive motion and facilitate inside cleaning and inspection. A baffle is

lower production efficiency could be avoided. provided in the discharge chamber to “pad” the

Moreover, a metal detector also should be crushed materials and bear the impact of the falling

installed in order to remove any metal object ore. This baffle can absorb most of the impact

causing motion of the support bushing. before the material has dropped onto the
transportation equipment, thus increasing the

The feeding equipment must be large enough in service life of the equipment.

specifications to ensure the maximum feeding of

the crusher. If a funnel is used, it should have its gradient
greater than 45° to the horizontal surface; if the

It is very important to control the speed to feed material is rather sticky, the dip angle should be

the crusher. The materials falling from high further increased. Enough space should be left

into the crusher almost can be forced through between the main frame and the bottom of the

the open side of the crushing chamber. The discharge chamber as well as between the

materials not crushed but directly dropped into discharge gate or hopper and the belt conveyor or

the bottom of the crushing chamber will cause hoister. Enough space left at such places can

abnormal beating of the support bushing to prevent materials blocking the discharge channel

result in serious damages to the main frame and and having impact on the crusher operation due to

support bushing contact surfaces. If the material accumulation on the moving cone, so that

materials are fed into a 36'' or larger crushing the crushed products could be discharged freely.

chamber, then trapezoid blanking, corner

stockpiling or similar reduction devices should
be used.

17
3.5 Drive mode
If the motor pulley is mounted under the
countershaft or within 30° to the vertical centerline
of the crusher, you should inform the manufacturer
of the position for installation of the drive pulley,
so as to properly install the outer countershaft
Item Name bushing of the countershaft.
1 Single V-belt
2 Serial V-belts A crusher can be driven by an electric motor or a

Figure 3-2 Belt cross section drawing diesel engine.

V-belts are standard configurations for crusher A crusher can be directly driven, namely,

driving. V-belts are specifically required for connected with an electric motor or a diesel engine

crusher driving because: firstly, the V-belt can by means of a coupler.

prevent the impact load of the crusher transmitting

to its motor due to the born characteristics of such Any problem relevant to crusher driving shall be

belts; secondly, it can withstand the pulsating load submitted to the manufacturer for suggestions.

without damage to the crusher speed.

3.6 Initial installation of V-belt

The V-belt driving device can be a single narrow
belt or serial V-belts as shown in Figure 3-2. drive unit
During initial installation or reassembly of a V-belt
If a narrower belt is used as designed, the driving drive unit, you should follow such procedures as
device will be more compact and economical, able follows:
to reduce the cantilever load. The serial V-belt is 1. Clean the oil, grease or rust in the pulley
made up of several single belts connected by a groove.
common coupling layer, in order to prevent the 2. Make sure the pulley is aligned and parallel to
belt shaking or overturning. The serial V-belts are the shaft.
suitable for various standard pulleys, but they can
only have two or four separate belts connected
together.

18
 Item Name
1 Crusher pulley
2 Shortened center-to-center distance after V-belt installation
3 Motor pulley
4 Elongated center-to-center distance due to V-belt tension
5 Center-to-center distance
Figure 3-3 V- belt installation
Minimum allowance (mm/inches) when a belt smaller than the center-to-center distance is installed
V-belt cross section Minimum allowance when the
crusher is equipped with an
Belt length * mm
elongated and worn belt
(inches) 8V 8 V in series SPC
bigger than the
center-to-center distance
2000(79)-2749(108) 40(1 1/2) 85(3 3/8) 35(1 3/8) 40(1 1/2)
2750(108)-3499(138) 40(1 1/2) 85(3 3/8) 35(1 3/8) 45(1 3/4)
3500(138)-4499(177) 40(1 1/2) 85(3 3/8) 35(1 3/8) 55(2 1/8)
4500(177)-5499(216) 45(1 3/4) 90(3 1/2) 35(1 3/8) 65(2 1/2)
5500(216)-6499(256) 45(1 3/4) 90(3 1/2) 40(1 1/2) 85(3 3/8)
6500(256)-7999(315) 45(1 3/4) 90(3 1/2) 40(1 1/2) 95(3 1/2)
8000(315)-9999(394) 50 100 45(1 3/4) 110(4 3/8)
10000 (394) and above 50 100 45(1 3/4) 140(5 1/2)
Table 3-1 V-belt installation and tensioning allowance
3. Never force a belt on the pulley. Usually shorten or lengthen the center-to-center
shorten the center-to-center distance until the distance.
belt can be easily mounted onto the pulley. See To facilitate installation without damage to the
table 3-1 to determine the minimum range to belt, follow the numerical values in the table
below to shorten the center-to-center distance

19
 after worked out according to the standard
length. Similarly, due to manufacturing errors,
belt elongation and abrasion, you can also
elongate the center-to-center distance based on
the calculated distance according to the
numerical values given in the column of the
table.
4. Always use matching new belts produced by
the same manufacturer. Never use old and new
belts together.
5. After the belt is mounted on the pulley, rotate
this drive unit for a few minutes, and then
tension the belt until the belt slack side only
becomes loose or droops slightly when the
drive unit is working. The belt tension and
slack sides are exemplified in Figure 3-4. The
belt slack side depends on the position of the
motor.

Item Name
1 Crusher pulley
2 Tension side
3 Motor pulley
4 Pay attention to the radian and sag of the slack side.
Figure 3-4 Determine the slack side of the V-belt drive unit

20
 1. Place a ruler at the top of the two pulleys
3.7 Tension of V-belt drive unit
horizontally as shown in Figure 3-5.
2. Measure the span length.
3.7.1 Tension deflection method
3. Place a spring meter at the point in the center of
The drive unit tension is a term. When a force is
the span length vertical to the belt. Exert
exerted on the V-belt somehow to produce a
enough force on the spring meter to have one of
wedge-caulking effect between the V-belt and the
the belts deflect a distance equivalent to 0.016
pulley, this is known as tension. The wedge-caulking
X span length (mm) (0.016 X span length:
effect can have the V-belt transmit power from the
inches)
motor pulley to the crusher pulley.
4. For any drive unit moderately tensioned, the
The V-belt can be tensioned in a variety of methods.
force exerted on it should be roughly equal to
Here are two simple methods as follows: tension
that as shown in Table 3-2.
deflection method and elongation percentage method.
One of the two methods can achieve satisfactory
result of belt tension. Each has its advantages.
Follow the steps below to tension the drive unit by
means of the tension deflection method:

Item Name
1 Ruler
2 1/2 span
3 Span length
4 Deflect by 0.4 mm (1/64'') every 25 mm (1'') span length
5 Pull direction
6 Motor pulley
21
 7 Belt
8 Spring meter
9 Pull (based on the numerical values in the table)
10 Crusher pulley
Figure 3.5 Tension deflection method

22
For example
V-belt cross section = standard 8V belt
Span length (center-to-center distance) = 1575 mm
(62'')
Deflection force (see the table) = 15-22 kg
(34-50Ibs)
Deflection = 1575 mm (62'') x 0.016 = 25 mm (1'')
Therefore, when a new standard 8V sectional belt is
installed with the span length of 1575 mm (62''), for
a drive unit moderately tensioned, the V-belt
deflection should be 25 mm (1'') and the spring
tension should be 15-22 kg (34-50Ibs).
4. After 2-4 hours’ working, the drive unit should
be tensioned again approximately to its
maximum tension status.
5. After 24-48 hours’ working, you’d better check
the drive unit to see whether the force applied
on the belt is in the middle of the minimum and
maximum forces as shown in Figure 3-2. When
necessary, tension it once again. Too high or
too low tension will affect the service life and
operation of the V-belt.
3.7.2 Elongation method
Follow the steps below to tension the belt by means
of the elongation percentage (%) method. This
special method for tension of V-belt drive unit is
mainly used to tension serial belts.
1. Eliminate the belt relaxation.
2. Use a 15-metre-long (50 ft) measuring tape
around the belt periphery, measure its outer
perimeter accurate to mm (1/16 inch), and
record the length, with the details as shown in
Figure 3-6.
3. Use the recorded length multiplied by the
percentage of the elongation coefficient as
given in Table 3-3, plus the initial value.
4. Stretch the belt to this new reading value.

After a narrow V-belt is appropriately tensioned,

it may feel not as tight as expected. Therefore,
you’d better use a spring meter to check the belt
Item Name
tension.
1 Tape reading
2 Steel tape
3 Belt
Figure 3-6 Tension elongation percentage method

23
 Belt cross section Standard belt Serial V-belts
Minimum tension Maximum tension Minimum tension Maximum tension
8V kg (lb) kg (lb) kg (lb) kg (lb)
15.4(34) 22.7(50) 18.1(40) 27.2(60)
SPC 10.4(23) 15.4(34) 11.8(26) 18.1(40)
* Use the number of belts in the serial belts multiplied by the value in the table.
Table 3-2 Deflection force
For example
V-belt = standard 8V belt
Tape initial reading = 3 m 48 mm (120 inches)
Elongation coefficient (see the table) = 0.009 (coefficient), namely, 0.9% (percentage)
New length reading = 3 m 48 mm (120 inches) initial reading x 1.009 elongation coefficient = 3 m 48 mm
(120 inches) + 27 mm (1-1/16 inch) or 3 m 75 mm (121-1/16 inch)

Belt Coefficient Percentage (%)

8V 0.009 0.9
Table 3-3 Elongation coefficient

24
Therefore, when a 8V belt is installed and its outer
peripheral measuring length is 3 meters 48 mm (120
inches), the motor pulley should move away from
the direction of the crusher pulley, until the steel
tape reading reaches 3 m 75 mm (121-1/16 of an
inch), and at this point, the drive unit has been
appropriately tensioned.
5. Regularly check the belt tension and repeat the
tensioning steps mentioned above if necessary.
It must be pointed out that the tension deflection
method is the best way to tension V-belts.
In general, the sign for most urgent belt tension is
belt creeping. The belt and pulley grooves are
seriously worn. In this case, the belt often “screams”,
with the belt and pulley overheated. Moreover, you
can easily see, hear and feel such conditions.
3.8 V-belt protective measures
For V-belt drive operation, the dos and don’ts are as
follows:
1. Dos - Check the tension of the belt during the
commissioning of the first few days. When any
belt is found falling into the pulley groove,
tension the belt again; any new belt has certain
initial elongation, so it needs additional
tensioning.
2. Don’ts - excessive tension Excessive tension
will shorten the service life of the belt and
bearings. Maintain tension consistent all the
time. During shutdown, the belt should be kept
moderately or slightly tight, while during
working, its slack side should be kept slightly
sagging.
3. Dos – Have the drive unit well ventilated.
When the temperature is higher than 60℃
(140℉),the be ltw illha ve a shor ter service life,
25
so the air around the belt protective cover
should circulate sufficiently. On this occasion,
you’d better use pore or steel plates as
protective covers.
4. Don’ts – Never have the belt stained with oil or
grease, because excessive oil stains will cause
belt expansion and make the belt prematurely
fail.
5. Dos – Comprehensively check the V-belt on a
regular basis. The following points should be
observed in time of each check:
a. Crusher stalling - Check the belt tension.
b. Unequal elongation - Check whether any
internal crack occurs.
c. Excessive elongation - Check whether
overload occurs.
d. Belt softening or expansion - Checks
whether there is any oil or grease.
e. Belt hardening or fracture - Check
whether overheating occurs.
3.9 Initial calibration of flexible
coupling
When installing or reinstalling flexible coupling for
the first time directly on the drive system, adjust the
coupling as accurately as possible to reach its
maximum life expectancy and minimum vibration.
After the half couplings are installed on the shaft,
connect the two half couplings together and follow
the steps below to adjust it.
1. Measure the distance between the half
couplings at four points around the coupling
spaced by 90° to check the clearance and align
the gradient as shown in Figure 3-7. To
measure the clearance, you can use a feeler,
 caliper gauge or dial indicator with a magnetic 3. When a flexible coupling is adopted to drive
base. The half couplings must be centered to the crusher, the clearance, gradient and
have the deflection of the four points measured parallelism alignment is of great importance.
no more than 0.38 mm (0.015'').
If any point of the four points measured has its A safe locating ring must be installed on the
deflection greater than 0.38 mm (0.015''), then countershaft of the crusher, so that the countershaft
it suggests that the gradient suffers from could have a proper axial clearance, or its rotation
excessive adjustment. clearance could be ensured.
2. Place a ruler horizontally onto the outer
diameters of the two half couplings at four
points around the coupling spaced by 90° to
check the parallelism. See Figure 3-7 for more
details. The method for alignment is as follows:
place the ruler flat on the two half couplings
and use a feeler gauge or dial indicator for
checks. The parallel deflection should be no
more than 0.38 mm (0.015'').

26
 Correct parallelism
adjustment
Correct clearance and gradient
adjustment

Incorrect parallelism
Incorrect clearance and gradient adjustment
adjustment

Item Name Item Name

Have the ruler here close to the half
1 Equal clearance 8
coupling.
Use a feeler gauge here to check the
2 Use the key to check the clearance. 9 parallelism of the other half coupling -
check at the interval of 90°.
3 Have the key here close to the half coupling 10 Clearance
Use a feeler gauge here to check the clearance
4 and gradient of the other half coupling - 11 Gradient not aligned
check at the interval of 90°.
0.38 mm (0.015'') maximum clearance and
5 Drive half coupling 12
gradient not aligned
0.38 mm (0.015'') maximum parallelism not
6 Drive half coupling (motor) 13
aligned
7 Ruler
Figure 3-7 Coupling alignment
27

3.10 Crusher motor
A squirrel cage induction motor (or collector ring) is
adopted as the electric drive motor, and during
continuous operation, when the voltage variation is
+ 10%, it can achieve the normal starting torque
(about 125%) and normal locked-rotor torque (about
200%).
Wear-resisting insulation materials and stator
thermostat (internal protection device) are
recommended. The motor can be an open drip-proof
type or a fully enclosed air-cooled type.
In order to keep the working power as recommended
on the foundation drawing, it requires a motor with
the service life coefficient of 1.15. If you use a
motor with the service life coefficient of 1.0, then
the rated power value marked on the power
nameplate should be about 15% higher than the
recommended power value. However, the traction
power of the crusher should keep consistent with the
power given on the foundation drawing.
If a drive V-belt is used, make sure whether the
motor bearing specifications can sufficiently sustain
the weight of the pulley and the tension of the belt in
time of ordering. The motor must also be able to
withstand 360° radial belt pull. The motor shaft
diameter should be able to withstand the peak torque
and the bending caused by the belt tension and
pulley weight. The motor shaft should be long
enough to adapt to the total length of the bush and
hub in the motor pulley, with a clearance left
between the motor shell and the pulley rim.
When a drive V-belt is used, it requires a slideway
arranged under the motor to provide an adjustment
amount for belt tension and installation.
28
If direct drive is used, make sure whether the motor
shaft extension range and bearing size can be
suitable for direct drive when ordering a motor. The
motor shaft diameter must be able to withstand the
peak torque.
All power ratings given on the foundation drawing
are based on the electric power. Therefore, when a
diesel generator is used as a drive unit, you must get
in touch with the manufacturer to determine how
much power of a diesel engine can be equivalent to
the electric power in the speed (RPM) conditions
given on the foundation drawing.
3.11 Piping descriptions
The “Lubrication System manual” details the right
oil type, temperature and adjustment, as well as the
equipment used or to be used in the lubrication
system of the crusher. It should be pointed out that
the maximum working pressure is 0.86 Mpa (125PSI)
in the lubrication system.
The piping drawing gives the pipes and pipe fittings
delivered together with the crusher and other
lubrication equipment, and in order to adapt to the
local conditions, the piping arrangement can be
changed. When arranging oil supply and drainage
pipes, two impact factors should be considered: The
pipe should be kept as short and straight as possible,
free of oil blockage or other obstacles; the discharge
pipe should have its minimum gradient of 25 mm (1'')
every 305 mm (12'').
Check whether all pipelines inside are clean and
clear all cuttings on the chamber threaded ends to
ensure safe operation of the oil pump.
Install a union at the right place to facilitate removal
of any lubrication equipment, oil pump, filter and
cooler, etc. Check whether any pipe joint suffers
from leakage. It is very important to ensure absolute
sealing of the oil suction pipe between the oil pump
and the fuel tank, because the suction pipe leakage
will lead to reduction of the oil pump efficiency,
namely, obvious decrease of the oil level and oil
pressure, and may endanger lubrication of the
crusher. The oil suction pipe leakage can not be
exposed like pressure oil pipe leakage, so it is more
dangerous.
3.12 General assembly and
disassembly instructions
According to the crusher specifications, the HPT
cone crusher can be shipped wholly or partially. For
domestic shipping, small-sized crushers in
specifications are often wholly delivered directly to
the destination foundations. In some cases, such
small-sized crushers can also be partially shipped for
export or to such regions subject to domestic
transportation and lifting limits. The vast majority of
large-sized crushers are partially shipped.
The following chapters will detail assembly and
disassembly of all crusher parts and components.
Let’s first detail the moving cone; other parts will be
detailed according to the normal disassembly
sequence. Any crusher can be assembled in
accordance with the instructions in all chapters
based on the disassembly range no matter whether it
is disintegrated for shipment or delivered wholly.
Before installing any crusher part, check whether the
protective coating on the machined surface is
removed during transportation, whether all parts
29
especially oil circuits and pipes are clean, and
whether there are metal filings and stains.
During transportation, some machined surfaces and
threads may be damaged, so proper repair must be
needed before installation. After cleaned, all bearing
surfaces and the machined surfaces of all matching
parts must be coated with a thin layer of lubricating
oil.
During assembly and disassembly of some parts,
special preventive measure shall be taken. Ensure
compliance with all applicable safety rules about
lifting devices, including correct hand signals. In
addition, it should also be ensured that all such
lifting devices and auxiliary equipment as ropes,
cables, hooks and hardware are capable enough to
support the component weight.
All chapters in this manual have provided repair
instructions for lifting devices. Handle the parts in
accordance with the illustrated instructions in
corresponding chapters. Never handle the parts by
any other means before consulting SBM.
3.13 General maintenance
instructions
When any maintenance is given to the crusher, the
following general precautions should be taken:
1. When removing any part with a machined or
bearing surface possibly subject to rustiness,
coat it with oil or antirust agent no matter how
long such part will be kept after removed.
2. Take great care when handling such part with a
bearing or machined surface featuring a rather
small fit tolerance.
3. When removing any part with a bearing or
machined surface, use wooden blocks to
prevent its surface touching the ground.
4. Take great care when handling copper bushes
or sleeves. Excessive hammering or heavy
knocking on such soft metal may have these
components deflected or bulged.
5. Before reassembled to the crusher, all machined
parts shall be thoroughly cleaned and oiled.
Any bearing surface not coated with oil shall
never be reassembled into the crusher.
6. When reassembling two matching parts in need
of press or sliding fit, coat their contact surfaces
with a thin layer of oil, which can be used as
lubricating oil and may prevent rust here.
7. The moving cone and eccentric bushing liners
should be vertically stored. If stored in any
other way, the eccentric bushing will be out of
round or become elliptical. Then, when loaded
on the crusher, there will be a lot of difficulties
and even it can't be installed.
8. All thread surfaces of the adjusting ring,
support bushing, lock nuts and moving cone
should be scoured with a cloth filled with
molybdenum disulfide powder, and then coated
with oil or grease. If there is no molybdenum
disulfide powder, then coat them with enough
grease
9. Any part in need of heat treatment may be
damaged if improper technology is used.
During thermalization, the following protective
measures should be taken.
a. At any time, an oiled bath or temperature
control furnace must be used for
thermalization treatment.
b. Never exceed the specified temperature, or
the part will be damaged.
30
c. Any heater element can not use cutting
torches due to its born characteristics
because the local overheating due to
concentrated heat from the cutting torches
may cause deformation or have a negative
impact to induction hardening parts. Local
heating may also produce tiny stress
cracks.
d. You must use propane or acetylene
equipment specially designed for
thermalization.
e. If flame heating has to be used to assemble
the drive unit, please avoid direct contact
of the flame with induction hardened parts.
Heat its center and surface, so that the heat
could evenly spread out.
f. Heat such parts to be removed quickly and
evenly. And then quickly remove the
heated parts to minimize the heat
transferred to the matrix.
g. Never use liquid to have any thermalized
part “cool down rapidly”. If a rapid
cooling is a must as specified, then only
the air transfer method (use the fan or
compressed gas evaporation) can be used.
3.14 List for minimal spare parts
as recommended
In order to ensure the shortest downtime, the
following spare parts often should be stored:
1. Bowl liner
2. Bowl liner bolts
3. Mantles
4. Torch ring
5. Feeding cones + screws
This list includes only the minimal spare parts. If a
crusher is installed in a remote area or a few
crushers are installed at the same time, the contents 2.
of such list should be expanded. Therefore, please
consult the manufacturer for a specific spare parts
list according to your own conditions. Before storing
any spare part, check whether its protective layer has
been damaged during shipment.
Finally, a running-in test is recommended after any
bush, bearing or main component is replaced and
when a crusher is started for the first time. See the
data titled as operational guidelines in Chapter 3.
3.15 Special tools
Only such tools not easy to buy in industrial supplies
stores are delivered with the crusher.
These special tools include eyebolts as handling
equipment requires, moving cone lifting plates,
helium bottle connectors, ball bowls – ball bowl
alignment screws, accumulator meter and pneumatic
components (standby), eccentric bushing lifting
rings, and jack screws, etc. For quick identification,
all tools are coated with the same color as the
crusher and separately shipped in a package.
3.16 Prevent crusher corrosion
3.
During seasonal downtime, overseas shipment or
outdoor storage (in winters or summers), the
following protective measures are suggested to
prevent corrosion of your crusher:
1. Remove the adjusting ring, feeding plate,
moving cone, ball bowl and eccentric
components. Disconnect the oil drain pipe at
the bottom of the main frame and the oil
pressure inlet at the bottom of the main shaft,
and ensure that pipe stoppers are used to seal
all pipes and holes at the bottom of the main
shaft.
31
Use a wide paint brush to coat all inner surfaces
of the main shaft with anti-rust oil.
Please use the lubricating oil containing
corrosion inhibitor. This kind of oil is used to
protect the internal parts of such enclosed
equipment as engines, compressors, pumps,
gear banks and hydraulic components. The
function of corrosion inhibitor is to rule out the
water on the surface of metal, form a strong
waterproof film on the metal surface and
generate water-in-oil emulsion by absorbing the
water in the system. The rust resistance of these
products is 30 to 40 times stronger than
high-quality lubricating oil without special
preparation.
Residual rust-preventative oil film on these
products don't have to wash away, or in other
words, such anti-rust oil film will disappear
when the crusher is filled with lubricating oil
and put into normal operation.
Usually 208 liters (55 American gallons) of oil
is enough to coat a crusher. The oil viscosity
should be 150-300SSU at 38℃ (100℉ ).
Use a paint brush to coat the lower thrust
bearing, outer surface of the main shaft and all
exposed pinion surfaces with anti-rust oil.
Remove the countershaft frame oil supply hose
from the top or side of the countershaft frame,
then place a funnel onto the filler of the
countershaft frame, turn the countershaft frame
and pour oil into it at the same time. Coating
the entire countershaft frame will need about 20
liters (5 American gallons) of oil. It is normal
that some oil flows out from the drive end of
the countershaft frame.
 Then, remount the oil supply hose to the
countershaft frame.
4. Fill oil into the lubricant filler on the main shaft
and then drain such oil again.
5. Coat anti-rust oil on the eccentric bushing outer
surface, eccentric bushing liner hole, gears and
upper friction disk.
6. Coat a layer of special oil on the moving cone
ball bearing, moving cone upper and lower
bushes and all moving cone surfaces adjacent
to the “T” seal.
7. Remount the eccentric components and ball
bowl components. Coat a layer of special oil on
the bearing and exposed surfaces of the socket
liner. Then, mount the moving cone
components and feed plate.
8. Fill the oil tank of the power unit with similar
anti-rust oil with the viscosity of 150SSU at
38℃ (100℉ ). The whole hydraulic system
requires 95 liters (25 American gallons) of oil.
It should be ensured that the oil is suitable for
such hydraulic equipment made from poly
chloroprene rubber, polyurethane, bronze,
nickel, chromium, iron and steel materials.
The hydraulic safety mechanism, as well as
locking and adjusting rings must act, in place to
ensure that all power units and hydraulic
components are all coated with rust inhibitor.
9. Brush or spray a layer of mild viscous oil
solvent on the adjusting ring, support bushing
and lock nut screws. This solvent contains a lot
of polarity antirust additive featuring a strong
affinity with metal surfaces.
Under water-rich conditions, this additive
should be competent to wet metal surfaces, so it
can effectively prevent water subsiding from
such surfaces; moreover, this solvent can
evaporate fast, only leaving a thin layer of
32
transparent grease film. This kind of material
should be suitable for mild and moderate
service situations, for example, outdoor storage
protection. The solvent can be applied in any
way (brushing, rolling or spraying) under
conditions of factory operating temperature,
and when a crusher is put into production, the
solvent film also don't have to be removed.
Hereafter, coat plenty of lithium grease (NLGI
No.1) on the thread. This lubricating grease
contains 5.10% molybdenum disulfide.
10. Remount the adjusting ring components, use a
1/8000-inch-thick black PU film to cover the
whole adjusting cap and funnel to prevent
adjusting ring and support bushing thread
corrosion due to water invasion into the crusher.
This film is delivered in the form of plate rolls
at 20 feet / 100 feet. The aging speed of
transparent films is 4 times faster than that of
the black films, so black films are
recommended. The countershaft and its frame
ends should also be covered. It is an ideal
method to use a steel band or bar to fix the
polyurethane film.
11. Fit the oil inlet and discharge pipe again. The
oil stuck to the metal surface is necessary for
appropriate rust prevention.
If the above-mentioned suggestions are followed, the
antirust period can be up to 6-12 months for outdoor
storage of a crusher.
Wherever a crusher must be disintegrated for
shipment or storage, all kinds of parts must be
protected more thoroughly, because such steps
mentioned above are only applicable to such metal
surfaces not only directly exposed to the natural
environment (such as sunlight, wind, rain and snow).
If a crusher must be disintegrated for shipment or
storage with all kinds of parts compulsorily exposed
to the natural environment, the following measures
should be taken as suggested.
1. Use black PU film to cover the ball bowl and
main shaft outer surface, and encase the
countershaft frame with this kind of film
tensioned across the support bushing port.
This covering film can protect the interior of the
crusher coated with anti-rust oil as mentioned above.
This kind of film must be tightened to prevent
sagging.
2. Use bituminous materials (liquid mixed with oil
solvent) after special treatment to coat or paint
the machined surfaces of various components,
such as adjusting rings, feed plates, moving
cones, ball bowls and eccentric bushings. This
is a kind of medium-thick black liquid able to
be used at room temperature in any convenient
form. After evaporation of the solvent, a layer
of hard, solid, dry and acid-proof film. In the
open air and unprotected harsh conditions full
of corrosive smoke, this coating can have
long-term protection, especially suitable for
such outer surfaces not painted. The parts after
treatment can stand obvious scratches and mild
rough handling, but serious damages should be
avoided, because such hard and dry oil film
cannot fix itself somewhat similar to
semi-permanent paint and can be rubbed out if
forcefully by means of a cloth dipped into
solvent after long-term use.

Those parts stored outdoors without protection can

have their antirust period up to 24 months after
treated as recommended above.

33
Chapter 4 Operation instruction

4.1 Check list for a new crusher before started

Satisfied Dissatisfied
Checks before a crusher is started
1. Check whether the wedges added in time of transportation between the mantle and the
bowl liner has been removed.
2. The checked crusher discharge opening is mm(〃 )
3. V-belt tension and/or coupling correction
4. Mutual relation between the oil groove of the countershaft bushing and the position of
the driving device
5. If the eccentric bushing has its components forced loose during transportation, check
the clearance between the big gear and the pinion.
6. The axial clearance of the countershaft should be 1.0m (1/32″) - 1.5mm (1/16″). See
Chapter 5.
7. Grouting and fastening between the crusher and its foundation
8. The foundation should be so designed that there is a sufficient discharge space for
free falling of the material, in order to avoid material accumulation under the crusher.
9. Lubrication system:
a. 25mm drop per 305 mm (namely, 1:12), so the tubing slope is enough.
b. Check the trademark, brand and level of the lubricant in the oil tank and record
its name and brand in detail.
Trademark Brand
c. Install the pipelines according to manufacturer’s drawings.
d. Make sure that all auxiliary devices have been installed reliably, such as filter,
cooler, immersion heater, pressure switch, temperature switch and air breather of
the countershaft.
e. Make sure that the alarm system (pressure switch, temperature switch border line)
has been reliably connected according to the wiring diagram.
f. The safety valve (if provided) and pipelines are accurately located.
g. The pump rotation direction is correct.
h. The pipelines and the pump are connected correctly.
i. The filter has been exhausted (if provided).
j. You have correctly installed the vent hood of the crusher and oil tank.
k. The oil supply and return pipelines have been cleaned.
10. The grease as recommended has already been filled in the oiler of the support
bushing.

34
Hydraulic pressure Satisfied Dissatisfied
a. Check the trademark, brand and level of the
hydraulic oil in the oil tank of the hydraulic station.
Record its name and brand in detail.
b. The release system accumulator has been inflated.
c. You have correctly connected all hoses from the
hydraulic station to the crusher.
d. The hydraulic circuit has accepted leakage test.
e. The adjustment test should be made at least once
to ensure normal working of the adjusting ring and
the locking cylinder.
Start the oil pump:
1. Before a crusher is started, the oil temperature should
at least reach 25℃ (80℉) in the oilreturn pipe.

Start the hydraulic power unit.

Crusher inching:
1. The countershaft rotates in the right direction.
Start the crusher:
1. The crusher will at least spend 2 hours from its
load-free idling until the oil temperature has reached
27℃ (80℉ ) in the oil return pipeline.
2. The crusher countershaft rotates at the speed of
RPM.
3. Check whether the crusher is suffering from oil
leakage.
4. Load-free idle current: A.
5. Check the alarm system (pressure, temperature and
flow switches).
6. The crusher should be working at least 2 hours under
the condition of its 50% full power.
7. In time of °, the main safety valve will stop oil
returning to the oil tank.
8. The crushing chamber feeding is distributed
correctly.
9. Coasting stop duration: seconds

35
After six hours’ initial running: Satisfied Dissatisfied
1. Oil feed and return temperature difference ____℃
2. Any suggestion for improvement offered to the user
for installation
3. The crusher should be working at least 6 hours under
the condition of its 75% full power.

Mobile crushing station:

1. The chassis has been installed well.
2. When a rubber blanket is used for fixation, its
maximum thickness should be 12mm (1/2″) and the
crusher can move freely.

Comments:

36

4.2 Preparation before starting
A good habit of inspection can ensure perennial
normal working of a crusher. Make regular
maintenance with accurate written records kept but
never carry out pre-start and regular maintenance
only based on memory, so that costly shutdown
could be reduced and simultaneously the crusher
could have a longer service life. Preparations should
be made as follows before a crusher is started.
1. Check whether all lubricating oil is correct and
whether the lubrication system has been
installed as required in the Lubrication System
manual.
2. Start the oil pump motor. Open the access cover
on the oil tank and check the return oil pipe in
the oil tank to confirm the oil has already been
circulating.
3. Remove the wooden wedges forced between
the crusher liners for transportation.
4. Check for no axial clearance. The countershaft
should be able to move freely in and out
between 1.0m (1/32″) and1.5mm (1/16″) along
the axial direction. See Chapter 5 Crusher
Pulley Installation.
5. Check it for the last time to ensure that there is
no tool or obstacle left on or around the crusher,
and ensure that all connectors and fasteners
Crusher
HPT100 HPT200
specifications
Full-load speed
750-1200 750-1200
(RPM)
Table 4-1 Countershaft speed
37
have been firmly tightened, free of oil leakage
and other factors hindering the crusher startup.
6. Rotate the countershaft by hand to check
whether the crushing and bowl liners touch
each other and whether any other mechanical
obstacle occurs. If any collision is found, see
the adjusting ring instructions in the rear part of
this Chapter.
7. Check item by item according to the checklist
in the front of this Chapter, and confirm that all
crusher devices and auxiliary equipment have
been checked with everything ready.
8. After completing all checks as mentioned
above, start the crusher according to the
following instructions in the steps for first
start-up and commissioning.
4.3 Countershaft speed
The correct speed (RPM) of the countershaft is
important for normal crushing. Table 4-1 gives the
speed of different crushers. The pulley specification
of a crusher is designed based on its full-load
operation, so the countershaft speed will be slightly
higher in case of no-load operation. Experience
shows that a crusher can achieve its maximum
capacity and deliver evenly-crushed products if
working at its correct speed.
HPT300 HPT400 HPT500
700-1200 700-1000 700-950
A crusher has its countershaft speed depending on Attention:
the amount of the material through the crushing Before the belt is mounted on the pulley, it is
chamber and the times of impacting particles. If a extremely important to check the motor rotation
crusher is not working at its correct speed, you direction. The rotation direction should be
should have it working at a slightly higher speed clockwise, consistent with the direction seen from
(within 10% of the correct speed), because if the the drive end.
crusher has its countershaft speed much slower than
its recommended speed, its performance will be
4.5 Operation of the hydraulic power
significantly reduced due to excessive cramming of
the crushing chamber and the crusher will be stalling unit
accordingly.
To keep the locking pressure of the adjusting ring
and the pressure of the foreign matter or crushing
For example: If a crusher with the countershaft
chamber release hydraulic cylinder, the hydraulic
speed recommended as 1020 RPM works at any
power unit should have its oil pump motor
speed between 1020 and 1122RM
connected to the power supply during operation of
(1020RPM+10％,-0％), there will be no impact on
the crusher to have the support bushing kept on the
its crushing performance. In some use cases, a speed
main frame. In addition, before starting the crusher,
higher than normal is recommended to improve the
have the oil pump motor of the hydraulic power unit
particle size and (or) shape without reduction of the
working continuously when adjusting the crushing
crusher throughput. In this case, please consult the
chamber or compressing the crushing chamber after
manufacturer for correct speed of the countershaft.
it is released and when operating chamber cleaning
circuit.
Due to high operating speed, the crusher and motor
Refer to the User manual for complete operating
pulleys must be made from nodular cast iron.
instructions of the hydraulic power unit.

4.4 Rotation direction of the

4.6 Steps for initial starting and
countershaft
running-in
All HPT cone crushers have their countershafts
The crusher has experienced its running-in process
designed to rotate clockwise. You can face the drive
in the factory, but it is advisable to have it working
end of the countershaft to determine its rotation
for several hours without loads or at a smaller load
direction and the countershaft shall never rotate
than usual when the crusher is started for the first
counterclockwise. The mantles are kept pressing on
time or after a new bearing is installed, so that the
the moving cone automatically by the self-locking
crusher can have a period for basic running-in and
bolt and only the countershaft direction is correct
have all its parts lubricated fully and working well.
such self-locking feature can function, so the
In the meanwhile, check the oil temperature
rotation direction is very important.

38
frequently. See the oil temperature in the 8. Establish and keep the daily operation records
Lubrication System manual. of the crusher according to the format at the
end of this Chapter.
When the HPT cone crusher is started for the first
time and after a new moving cone sleeve or
4.7 Procedures for daily startup and
eccentric bushing liner is installed, the start-up steps
are as follows: shutdown
After running-in, it is also important to keep steps
1. Start the lubrication system before the crusher
for daily startup and shutdown.
starts working.
Tell all operators the operating steps and show them
To provide adequate lubricating oil to the
which parts of the equipment they should pay
crusher bearings, the oil temperature in the
attention to.
return oil pipe must reach at least 16℃
(60℉) before the crusher is started.If
necessary, use an immersion heater to heat 4.7.1 Daily startup
the lubricating oil.
1. Before starting a crusher, start its lubrication
2. The hydraulic power unit must be put into
system at first and make sure that the oil
operation before the crusher starts working.
temperature in the return oil pipe has reached
3. Start the crusher and have it idling for 2 hours.
least 27℃ (80℉ ).
Make sure the oil temperature has reached 27℃
(80℉) atleast.
Provide the crusher bearings with sufficient
4. After 2 hours’ idling, have the crusher
lubricating oil and simultaneously have the
continuously working again for at least 4 hours
oil temperature in the return oil pipe at least
at the feeding rate when the current has reached
up to 16℃ (60℉ ). I f the oil temperature is
50% of the rated current on the motor
below 16℃ (60℉ ) during shutdown, use an
nameplate.
immersion heater to heat the lubricating oil.
5. After 6 hours’ operation (Step 3 and Step 4),
When the crusher works in extremely cold
have the crusher continuously working again
ambient conditions, it is also necessary to
for at least 8 hours at the feeding rate when the
have the heater and oil pump kept running
current has reached 75% of the rated current.
continuously even the crusher is not working.
6. After completion of the above-mentioned Step
If the lubricating oil can not satisfy the
3, Step 4 and Step 5, the crusher can work at its
requirements in case of continuous heating,
full load until its current has reached 100% of
it is suggested using such lubricating oil with
its rated current or the support bushing is on the
the viscosity of ISO150 all the year round.
brink of floating.
7. After running-in, take an oil sample and sent it
2. The lubricating oil must be circulating for at
to the test factory.
least 1 minute before the crusher starts.

39
 If the return oil pipe in the oil tank has no oil
flowing out, never have the crusher working
more than 15 seconds, or the crusher may be
seriously damaged. Many conditions may
result in reduction of the oil flow, such as
insufficient lubricating oil, oil pump failure,
oil pump performance reduction, oil supply
pipe blockage or improper setting of the
overflow valve. See the lubrication system in
the manual.
3. Start the hydraulic power unit before the
crusher is started. Check the remote control
button indicators on the control cabinet to
confirm that the hydraulic power unit has been
working with the circuit pressure kept normal.
If the pressure release of the crushing chamber
is not normal, pressurize the circuit as
instructed in the Hydraulic System manual.
4. Start the crusher and have it working with no
load for about 5 minutes.
5. Feed the crusher at a feeding rate at first and
gradually feed it faster up to its maximum
power level (its current has reached 100% of its
rated current or the support bushing is on the
brink of floating).
4.7.2 Daily shutdown
1. Stop feeding the crusher and let it idling
continuously for 2-3 minutes.
2. Let the crusher slow down until stop working.
The minimum time is about 45 seconds for
speed reduction.
3. After completion of Step 2, you can stop the
lubrication system (See Step 1: Daily Startup;
under an extremely cold environment, take care
40
to have the heating and/or circulation system
continue to work).
4. Stop the hydraulic equipment.
4.8 Adjust the crusher discharge gate
The crusher discharge gate depends on the product
particle size as required. In many cases, the
adjusting ring needs adjustment to have the tension
side opening between the liners slightly smaller than
the maximum product granularity as expected. To
change the product particle size, you should readjust
the adjusting ring. In addition, in order to make up
for the crusher liner wear, you should also need to
adjust the adjusting ring.
The discharge gate initially determined according to
the desired product size will not necessarily be
absolutely guaranteed, and the best discharge gate is
the one able to provide the maximum yield. This
often depends on the nature of the material to be
crushed, the driving power of the crusher motor or
the pulsation conditions of the support bushing.
The crusher discharge gate is changed to lowering
(turn the adjusting ring assembly clockwise) or
rising (turn the adjusting ring assembly
counterclockwise).
Lower the adjusting ring to reduce the discharge
gate, but have the adjusting ring rise to increase the
discharge gate. See Figure 3-1.
Adjust the crusher discharge gate in accordance with
crusher discharge gate adjustment in the HPT
Hydraulic System manual.
After completion of adjustment, see whether the
pinion on the hydraulic adjustment device fits the
adjusting gear disc on the adjustment cap. If not, the
adjusting ring may suddenly drop and the discharge
gate may become tighter during crushing.
Item Name
1 Bowl liner
2 Adjusting ring
3 Support bushing
4 Parallel band
5 Mantles
6 Moving con
Figure 4-1 Adjust the crusher discharge gate
4.9 Turn the adjusting ring
4.9.1 Use the hydraulic regulating
mechanism to turn the adjusting ring
Use the hydraulic adjustment device and you can
screw the adjusting ring into the support bushing
until the discharge gate as expected; see this chapter
“Adjusting Ring Disassembly and Installation
Instructions”.
41
4.9.2 Use a wire rope to rotate the
moving cone
If there is no suitable crane lifting equipment, you
can use a wire rope to rotate the adjusting ring
alternately and screw it in or out of the support
bushing. Follow the steps below to remove and
install the adjusting ring by means of a wire rope:
1. To screw the adjusting ring into the support
bushing until the discharge gate is as expected,
follow the instructions for adjusting ring
disassembly and installation in this chapter to
release the pressure in the locking circuit.
2. Fasten a 20mm (3/4″) wire rope onto a
rotating/lifting hook of the adjusting cap at its
right side to obtain the revolutions as expected.
3. Let the wire rope winding around the adjusting
cap for a few circles and have the other end
engaged to a loader, tractor, hoist, truck or any
other suitable traction device. Confirm that the
wire rope is pulled in a parallel straight line.
Besides, a pulley or pulley block may need to
be mounted onto a certain fixed structure,
through which the wire rope can pull the
adjusting cap on the same level.
4. Pull the wire rope carefully until the winding
wire rope is completely released and then
rewind the wire rope for several circles
necessary for installation and removal of the
adjusting ring to repeat the steps mentioned
above.

4.10 Minimum discharge gate
In any case, the crusher discharge gate can not be
adjusted to result in motion (beating and striking) of
the support bushing. Striking of the support bushing
will lead to abnormal stress within the crusher and
excessive damage of the main shaft.
Table 4-2 shows the recommended minimum
discharge gates, but such values are only references,
which can be slightly larger or smaller depending on
the crushing material to ensure no striking of the
support bushing.
4.11 Check crusher discharge
opening
Fasten a lead block to one end of a strong and soft
metal wire, slowly put it into the crushing chamber
with the crusher idling, and make sure that the lead
block has gone through the parallel band of the
crushing chamber as shown in Figure 4-1, so that the
discharge gate could be checked in this way. In the
same way, quickly take out the lead block and
measure its thickness, through which you can obtain
the size of the crusher discharge gate. If the crusher
is started when no material is kept in the crushing
42
Item Name
Release or rotation
1
state
2 Floating state
3 Crushing state
4 Adjusting ring
5 Support bushing
Figure 4-2 Meshing between the adjusting ring
thread and the support bushing
chamber, the moving cone will rotate at 300 RPM
counterclockwise.
When the crushing chamber is fed with materials,
the moving cone will stop and rotate clockwise at
the speed of about 10 RPM.
In order to obtain the accurate size of the crusher
discharge gate, the speed of the moving cone must
be kept as low as possible in such two ways as
follows:
1. Just when the crushing operation starts, namely,
before the crusher countershaft has reached its
normal speed, with the moving cone starting to
speed up, you can insert the lead block into the
parallel band to measure the discharge gate.
2. Have the machine continue crushing but stop
feeding. Then, put the lead block into the
parallel band just when the feeding is removed
from the crushing chamber.
Zinc is not easy to be compressed, so do not use any
zinc block to check the crusher discharge gate. If a
zinc block is used, the support bushing may slightly
rise to give an incorrect measurement result.
In order to determine whether the discharge gates
are identical around the crushing chamber, it is
suggested that you place lead blocks at four different
locations spaced by 90°. Compare the four thickness
results and you can completely know whether the
support bushing is kept horizontally on the main
frame or whether the support bushing leans sideward
due to unilateral wear of the crusher from uneven
feed distribution. The right feeding is as shown in
Figure 3-1.
If working with the support bushing tilting, the
crusher throughput may be significantly reduced and
the support bushing may suffer from excessive
beating.

Recommended minimum
Crusher specifications Crushing chamber type
discharge gate
Super-small-sized type 4mm(3/16″)
Small-sized type 6mm(1/4″)
HPT100 standard type Medium-sized type 9mm(3/8″)
Big-sized type 13mm(1/2″)
Large-sized type 21mm(13/16″)
Small-sized type 13m(1/2″)
HPT200 Standard type Medium-sized type 16mm(5/8″)
Big-sized type 19mm(3/4″)
Small-sized type 14mm(9/16″)
Medium-sized type 17mm(11/16″)
HPT300 Standard type
Big-sized type 19mm(3/4″)
Large-sized type 25mm(1″)
Small-sized type 16m(5/8″)
HPT400 Standard type Medium-sized type 22mm(7/8″)
Big-sized type 25mm(1″)
Small-sized type 16m(5/8″)
HPT500 Standard type Medium-sized type 22mm(7/8″)
Big-sized type 30mm(1-3/16″)
Table 4-2 Minimum discharge gate
never have a crusher working more than a few
4.11.1 Operation suggestions for standard seconds at its lower power. During crushing
crushers operations, the driving power should at least be kept
The crusher can be controlled by changing its more than 40% of the rated power. A lower power
feeding amount. A larger feeding amount requires a may occur during the transient period of feeding
higher driving power, while a smaller feeding intervals, so try to avoid such conditions. If a crusher
amount requires a lower driving power. According will be free of feeding in more than 30 minutes, you
to the circuit design and control system capacity, try should shut down the crusher until material feeding
to make the practical working power of the crusher is started. In addition, if the feeding exceeds the
close to its full rated power. Never have the peak volume capacity of the crushing chamber, the
power up to 110% of the rated power. To have the materials will pile up at the upper part of the
power peak kept within its safe range, the set crushing chamber.
throughput may need to be reduced. In any case,
43
Faster feeding will have the materials rising more
quickly in the crushing chamber while slower
feeding will have the materials rising more slowly in
the crushing chamber, and if such a lower rate
continues, then the material level in the crushing
chamber will start to decline.
The best operating conditions for a crusher is that
the material level in its crushing chamber is kept at
300 millimeters (12 inches) above the cone head,
which is known as “full feeding conditions”. Under
this condition, it can be guaranteed that the feeding
can be evenly distributed around the crushing
chamber and the power can be prevented reaching
the peak value due to subtle changes of the feeding.
Its alternate ultrasonic crushing chamber material
level converter can be used to detect the material
level in the crushing chamber or used as the input
signal of the crusher feeding control circuit.
The use of the crushing chamber selector switch
(moving cone and bowl liner design) and the tension
side discharge gate can create the “full feeding
conditions” for the crusher (The material level in the
crushing chamber is kept at 300 millimeters (12
inches) above the cone head) and have the driving
power kept stable between 75% and 100%.
Once the “full feeding conditions” has been
achieved, you can use the crusher discharge gate to
optimize the driving power and increase the gate to
reduce the driving power for a given material level
in the crushing chamber and simultaneously increase
the feeding amount necessary to keep the material
level in the same crushing chamber while decrease
the gate to increase the driving power for a given
material level in the crushing chamber and
simultaneously decrease the feeding amount
44
necessary to keep the material level in the same
crushing chamber.
Of course, a smaller discharge gate means that the
crusher product size distribution should be adjusted
to a smaller size.
The crusher discharge gate system is adjusted by
means of a hydraulic motor when no feeding is
given.
It is suggested that the crusher is mainly controlled
by changing its feeding amount but alternatively by
means of its discharge gate. It is suggested that you
adjust the discharge gate to compensate for liner
wear and keep a stable product particle size.
The discharge gate should not be adjusted more than
once per hour.
4.12 Ring motion
The ring moves only when iron passes by. If the
support bushing moves and keeps on moving, it
suggests an excessive load, which may result in
lower screening efficiency, feeding segregation or
unequal distribution. Sufficient measures can be
taken to prevent motion of the support bushing:
expand the discharge gate, reduce the feeding or
replace the base plate, etc.
Item Name
The support bushing is at the location
1
of suspension.
2 Main frame
Figure 4-3 Ring motion
Benefits from no ring motion:
 Longer lifespan of the crusher parts
 Continuous stable production
 Longer life of the liner
 Relatively stable driving power
 Lower maintenance cost
The loss caused by ring beating is not in the scope of
guaranty.
4.13 Determine the liner wear
When trying to determine whether the liner has been
so seriously worn to be replaced, the following
information is very helpful. Accurate records can
help you determine the degree of wear without
shutdown. For the initial set of liners, the records
can be made as follows:
1. After it has reached the crusher discharge gate,
make an identification sign on the adjusting
gear disc of the adjustment cap at the joint
between the hydraulic adjustment device and
the adjusting gear disc, and this sign will
indicate the initial discharge gate. When the
adjusting gear disc turns to the next tooth, then
the adjusting ring will have a slight adjustment
along the vertical direction. See Figure 4-4.
2. In day-to-day operations, accurately record the
actual number of teeth used by the first set of
liners and then record the number of teeth at
every position from the first position to the end
of liner use.
No two crushers work identically and the liners
feature more types, greater thickness changes and
more significant casting errors, so for a particular set
of liners, it is impossible to determine how many
45
teeth the adjusting gear disc will go across in
advance before they have been actually used.
As estimated, under the condition of standard
operation, about 50% of the liner weight will be
worn down at the end of its use. The numerical
values may be higher or lower when a crusher is
used in a specific environment. Never adjust the
adjusting ring low enough to have any interference
or contact between the adjustment cap and the
support bushing.
3. Record the number of teeth before turning the
adjusting ring in the support bushing after a set
of liners has been used. And mark a horizontal
short line along the lower edge of the
adjustment cap on the scraper seal.
4. Install a new liner and record the number of
teeth on the adjusting gear disc. Compare with
that after the first set of liners has been used
and you can determine the degree of the liner
wear. As the discharge gate changes, the
adjustment cap will move down a bit and the
mark on the scraper seal will also tell you when
the liner will reach its wear limit. No two sets
of liners wear exactly the same, so in order to
estimate a more accurate average, please follow
the steps for several times.
As an auxiliary tool for operators, Table 4-3 gives
the number of teeth necessary for each circle of the
adjusting ring as well as its vertical stroke and the
discharge gate changes for each tooth. When a liner
is worn to its limit, the roughly minimum height
from the adjustment cap to the top of the support
bushing is indicated in Figure 4-5 and Table 4-3.
 Item Name
1 Vertical key pad
2 Adjusting gear disc
3 Hydraulic adjusting mechanism
4 Pinion gear tooth
5 Narrow the discharge gate
Mark the initial position on the adjusting
6
gear disc
Count and record the initial position of
the first liner record the initial positions
7
of the first set of liners and record the
number of teeth passing by.
8 Enlarge the discharge gate
9 Adjustment cap
Figure 4-4 Teeth positions of pinion and
adjusting gear disc

46
Item Name
1 Adjustment cap
2 Adjusting ring
3 Position of the adjustment cap for a new liner
4 For size "A", see Table 3-3.
Position mark on the scraper seal at the bottom of the adjustment cap after the
5
liner has been worn
6 Support bushing
7 Scraper seal
Figure 4-5 Position of the adjustment cap after the liner has been worn

47
 Vertical stroke Changes of the Changes of the “A” -
Number of teeth
of the adjusting crusher crusher Approximate
on the adjusting
Crusher ring for each discharge gate discharge gate minimum height
gear disc for
specific tooth the for each tooth for 1/4 circle the of the
every circle of
ations adjusting gear the adjusting adjusting gear adjustment cap
the adjusting
disc has passed gear disc has disc has passed after the liner
ring rotation
by passed by by has been worn
0.36mm 0.27mm 7.1mm
HPT100 106
(0.014″) (0.009″) (1/4″)
0.28mm 0.18mm 6.3mm 54mm
HPT200 138
(0.011″) (0.007″) (1/4″) (2-1/8″)
0.33mm 0.23mm 8.73mm 50mm
HPT300 150
(0.013″) (0.009″) (0.014″) (2″)
0.29mm 0.20mm 8.9mm 29mm
HPT400 176
(0.011″) (0.008″) (11/32″) (1-1/8″)
0.26mm 0.18mm 8.5mm 30mm
HPT500 190
(0.010″) (0.007″) (0.344″) (1.18″)
Table 4-3 Number of the adjusting gear disc teeth and stroke of the adjusting ring

4.14 Thread lubrication

The adjusting ring is a crusher part for adjustment,
so it is very important to grease the adjusting ring
and support bushing threads on a regular basis so
that the adjusting ring could rotate freely in the
support bushing.
Lubricating nipples are evenly distributed around the
side of the support bushing, able to lubricate the
threads when the adjusting ring is kept in the support
bushing. See Figure 4-6.
Item Name

The adjusting ring shall need to be greased by force 1 Lubricating nipple

from the oil fillers no matter whether the crushing or 2 Support bushing

release state functions. Set up a regular maintenance Figure 4-6 Lubricating nipple

plan for timely lubrication. Use lithium base grease,
for example, NLGI No.1 or equivalent grease,
preferably with 5-10% (by volume) molybdenum
disulfide powder mixed in advance. In such a high
temperature operation condition, it is also
satisfactory to mix such powder with thin oil.
4.15 Adjusting ring and support
bushing thread wear
Check the wear status of the adjusting ring and
support bushing threads every time a liner board is
replaced. Check the differences at the vertical

48
positions when the adjusting ring is locked and
unlocked to determine the wear status. Measure the
height “H” from the top of the support bushing to
the bottom of the adjustment cap when the adjusting
ring is locked and unlocked. See Figure 4-7.
Item Name
1 Adjustment cap
2 Dust shell
3 Locking cylinder
4 Height - “H”
5 Gasket
6 Support bushing
Figure 4-7 Support bushing to adjustment cap
The motion of a new crusher should be 2.75 mm
(0.108″), namely, the motion before the thread is
free of damage. Any additional motion will indicate
that the thread has been worn. When the vertical
motion reaches 7.5mm (0.295″), it indicates that the
thread has 4.75mm (0.187″) worn. This is the
maximum motion allowed, before which relevant
measures should be taken.
49
When the vertical motion reaches 7.5mm (0.295″), it
indicates that the thread has 4.75mm (0.187″) worn
and that the locking cylinder and lock nut should be
filled with the pads of such thickness to ensure that
there is an enough stroke in the cylinder to lock the
adjusting ring. In addition, the pipe washer fastened
by the cap screw should be 4.75mm (0.187″) long.
See Figure 4-8.
The cylinder can be padded only once. If the vertical
motion again reaches 7.5 mm (0.295″) between the
locked thread and the unlocked thread after the
cylinder has been padded once, the adjusting ring
thread or support bushing or both must be machined
again.
Item Name
1 Flat washer
2 Locknut
3 Washer
4 Support bushing
Figure 4-8 Pipe washer
 1. Turn the adjusting ring. Using a crane or other
lifting equipment to lift the adjusting ring up to
4.16 Difficulty in turning the
the position as indicated in Figure 4-2, so that

adjusting ring the support bushing could be kept suspending.

When the adjusting ring is kept at a suspending
If the adjusting ring is difficult to turn, then the
position, two people can work together to
adjusting ring or support bushing or their thread
adjust the adjusting ring up and down in the
surfaces may be abraded or scratched. When a single
support bushing until the discharge gate as
wire rope tied to the adjustment cap is used to “pull”
expected. After the adjusting ring has been
the adjusting ring for a discharging port as expected,
turned every a quarter circle, lower or lift it, so
the new adjusting ring in the support bushing will
that it could be kept free in the support bushing.
frequently suffer from thread damages. When this
In this way, turn the adjusting ring assembly for
method is used for adjustment, usually use a trailer
at least two full circles.
or loader to pull the wire rope to have the adjusting
-Or-
ring rotating.
Use a pair of wire ropes to drag the adjusting ring
assembly to screw in or out.
If a single wire rope is used to screw the adjusting
-Or-
ring assembly in the support bushing, the adjusting
Use a hydraulic adjustment device to rotate the
ring will be loaded aslant within the support bushing
adjusting ring until it has rotated for at least two
thread. Especially when the traction is not kept
complete circles.
horizontal, then the point contact will happen
After the adjusting ring assembly has been screwed
accordingly between the outer diameter of the
in the support bushing for at least two circles, a
adjusting ring and the thread plane of the support
single wire rope can be used to drag the adjusting
bushing in the direction of traction. When the
ring to rotate. It should be ensured that the adjusting
adjusting ring is pulled “misaligned” and tilted, the
ring assembly is dragged to move slowly (about one
thread may suffer from grinding injuries or scratches.
circle per minute). Follow the reverse steps to
Such injuries often happen to the first lap of threads
remove the adjusting ring.
on the adjusting ring and the support bushing and on
the thread plane. The adjusting ring is screwed into
In order to “prevent” the adjusting ring becoming
the support bushing, so the metal filings from thread
loose in the support bushing, a great force may be
scratches may damage the remaining threads. If the
exerted. Any one or more errors below will make the
adjusting ring is removed in this way, similar thread
adjusting ring difficult to rotate in the support
damages may occur, too.
bushing.
1. Incorrect thread grease is applied when
If wear and scratches have already occurred, the
crushing such hot materials as slag and
thread damages can be minimized if it is installed
sintering materials.
and removed as follows.

50
2. The adjusting ring and support bushing threads
are not lubricated at the interval as
recommended.
3. The scraper seal has been worn or improperly
installed, as shown in Figure 4-9.
4. The crusher has been working too long subject
to the same discharge gate (Note: The
discharge gate has not been adjusted for a long
period of time).
5. The crusher is placed somewhere without
proper protective measures: some parts are
exposed and especially in the rain.
In order to avoid difficult rotation of the adjusting
ring in the support bushing, frequent operations as
follows are recommended.
1. Periodically loosen the adjusting ring and let it
rotate backward at the crushing state.
2. Fill the oil nipples around the support bushing
with grease as recommended in the section
“Thread Lubrication” of this chapter when the
adjusting ring is kept in the support bushing in
accordance with a regular lubrication plan.
3. During the first installation or at any time
before the adjusting ring is reassembled, clean
the thread and apply the lubricating grease as
recommended in Section 6.1 for parts
assembly.
4. Check the wear status of the adjusting ring seal
frequently.
51
Item Name
1 Adjustment cap
2 Sealing element
3 Adjusting ring
4 Locknut
5 Dust shell
6 Support bushing
7 Main frame
Figure 4-9 Dust shell and seal
If the adjusting ring is stuck in the support bushing
and can't rotate as usual, follow the steps below fro
troubleshooting:
1. During operation of the crusher, feed it with a
certain amount of materials when the adjusting
ring is kept loose.
2. Fill penetrating oil or curing resistant agent into
the whole circle of the adjusting ring thread and
fill the same solvent in the lubricating nipple on
the support bushing. The penetrating oil and
curing resistant agent will loosen any dirt
possibly seeping and concreting in the thread,
as well as the existing rust. Try your best to
turn the adjusting ring. If this step is not
 immediately effective, let the crusher stop occurs due to failures of the hydraulic
working for a few hours, apply penetrating oil pipeline/pump or hydraulic cylinder. See Figure
and curing resistant agent repeatedly along the 4-10.
thread, and then repeat the previous step. Warning!
Before starting to clear the crushing chamber
manually, all safety blocks must be reliably put
4.17 Crusher chamber cleaning
between the main frame and the support bushing.
In case the crusher stops with load, never attempt to
When the hydraulic system has failed, this is a kind
restart the crusher before its crushing chamber has of safety measures to prevent your hands or arms or
been completely cleaned. If you attempt to start the
the equipment getting stuck in the crushing chamber.
crusher with its crushing chamber filled with
materials, the crusher and its motor may suffer from
serious damages.
Warning!
If a crusher stops with load, some of the reasons are
Never put your hand or foot between the main frame
as follows: The crusher or engine stops due to
and the adjusting ring. When iron is being cleared
electrical fault or oil shortage; excessive materials
and the adjusting ring is kept at its rising position,
are fed into the crushing chamber to result in stalling;
the safety blocks should always be located between
the discharge conveyer stops to lead to material
the main frame and the adjusting ring.
accumulation and crusher blocking, or any iron part
gets stuck in the crushing chamber.
To clear the materials or iron parts stuck between the
4. When the “Supercharge” button is pressed, the
moving cone and the bowl liner, the following steps
support bushing and adjusting ring assembly
must be followed, and at the same time, the motor of
will immediately start to drop onto the safety
the hydraulic power unit must be kept working. See
block. All equipment and persons must be far
the Hydraulic System manual.
away from the support bushing until it has
landed on safety block smoothly.
1. Turn the selector switch on the electric cabinet
to the “Adjustment” position. Press the
Warning!
“Chamber Clear” button and hold it until the
Never try to remove any material before a safety
safe-keeping cylinder has fully stretched out.
block is inserted. The compression force from the
2. In most cases the materials can fall through the
iron release cylinder and the accumulator has been
crushing chamber and be cleared simply. If low
released, but hydraulic failures still may happen to
release pressure occurs, the red indicator will
result in serious injuries due to falling of the heavy
light up.
adjusting ring and adjusting ring assembly.
3. If the crushing chamber is not cleared, put a
safety block between the support bushing and
5. Clear the hard chunks of materials or iron parts
the main frame so that the support bushing and
through the feeding port of the crushing
the adjusting ring still could be kept at their
chamber.
rising positions when sudden pressure drop
52
6. When clearing all materials in the crushing
chamber, press the “Chamber Clear” button
until the safety cylinder has completely
stretched out. At this point, the support bushing
and adjusting ring parts will be jacked up away
from the safety block, and then remove the
safety block. Make sure that all equipment and
persons are kept far away from the support
bushing so that it could fall onto the main frame
and the compression system seat.
7. See whether the support bushing all around is
installed smoothly. If not, lift the support
bushing again and then drop it. If the support
bushing is not installed steadily, never
pressurize the safety cylinder or it may be Item Name
damaged. 1 Main frame
2 Frame pin
It is very important to remove excessive 3 Safety block
miscellaneous iron. The safety cylinder can make 4 The support bushing is at the highest
position.
miscellaneous iron go through easily, but excessive
Figure 4-10 Safety block use
miscellaneous iron will cause damages to the main
frame seat. If the feeding contains a lot of 4.18 Adjusting ring removal and
miscellaneous iron, an iron remover must be
installed. Any damage to the main frame due to installation
excessive iron is not within the scope of the crusher Follow the steps below to remove the adjusting ring
warranty. assembly to create conditions for removal of the
mantles or other components:
1. Lock and unlock the adjusting ring (see the
Hydraulic manual).
2. According to the method mentioned earlier in
this chapter, use a crane or rope to install the
adjusting ring. Install the adjusting ring into the
support bushing and rotate it clockwise; remove
the adjusting ring and rotate it
counterclockwise.

4.19 In-plant overhauling

Such parts already seriously worn after used long or
usually difficult to repair can be repaired manually
53
or machined again by means of the in-plant special maintenance cycle according to your operation
facilities. Facts proved that it should be desirable experience.
and beneficial to have your crusher repaired by its
manufacturer. Timely thorough overhauling is more
economical than only replacement of some worn
parts. Completely dismantle the crusher to check its
all parts so as to determine whether such parts can
still be further used and use the parts of the original
manufacturer to replace worn parts, so that the
crusher could work normally.

Please send such worn parts as moving cones,

adjusting rings, support bushings or main frames for
in-plant overhauling and machining before
abandoned, which can save a lot of spending.

4.20 Periodical maintenance

After a crusher has been installed and kept working

for a period of time, preventive maintenance is the
best way to have it working normally. It is suggested
that you complete regular checks and adjustment and
replace worn parts before severe damages occur. See
Chapter 5 for necessary maintenance contents and
maintenance cycle. These maintenance contents are
used for reference only. To determine whether the
maintenance needs to be brought forward or
postponed, some adjustment must be made at first.

The frequency of the maintenance depends on

material type, environment and operating conditions.

The crusher should be kept clean with no paint

damage.

The maintenance time changes to the application and

site conditions, and you’d better select the

54
Chapter 5 Inspection and maintenance cycle
Logs for crusher operators
Check
The indicator
whether the
for lower lock
Tension discharge
Oil Driving Inertial and release
Initials of Environment Oil temperature ℃ (℉ ) side Alarm checks port is
pressure power running pressure
operators’ temperature ℃ discharge unobstructed
BAR KW time should light
names (℉) port mm (has materials
(PSI) (AMPS) (seconds) up.
(inch) accumulated).
Gear Driving Return
Normal Abnormal OFF ON
chamber shaft oil

55
Daily checks and maintenance

Item Check results Normal conditions

Within the scope of the oil level
1 Check the tank oil level.
indicator
Return oil:
2 Check the temperature of the return oil.
35℃-57℃(95℉ -135℉)
Check the oil pressure of the countershaft oil
3 0.14-0.28MPa（1.4-2.8Bars）
tank.
Check the differential pressure of the oil
4 0.03-0.3MPa（0.3-3Bars）
filter.
Check the driving power and the material
5
level in the crushing chamber.
6 Check the discharge port at the tension side.
Check the release pressure of the crushing See the appendix “Hydraulic
7
chamber. System”.
8 Check the locking pressure. 16.5-19MPa(165Bars-190Bars)
9 Check the feeding distribution.
Check whether the crusher discharge area is
10 unobstructed and clear away the materials
bonded on the large steel bar.
Check the wear status of the counterweight
11
guard and cover.
12 Check the inertial stop time. More than 45 seconds
Check whether any fastener or connector is
13
loose.
Check any abnormal noise indicating that the
14 crusher parts are worn or excessively
damaged.
Check whether the crusher liners (moving
cone and bowl liner) are loose, fractured or
15
worn through or have reached their wear
limits.
Check the motion status of the support
16
bushing.
17 Check the oil flow and filter screen.
Table 5-1 Periodical checks and maintenance

56
Weekly checks and maintenance

Check Normal
Item
results conditions
1 Clean the countershaft frame and fuel tank ventilation device.
2 Check whether any pipeline has oil leakage.
Check the fastening and wear status of the bowl liners and cone
3
heads.
Fill oil into the support bushing threads both when the adjusting
4
ring is unlocked and locked successively.
5 Check the metal and debris in the filter of the oil tank.
6 Check the motion of the support bushing.
7 Check the V-belt tension and alignment.
8 Check the lubricating oil leakage.
Check whether the pulley has any crack and whether the shaft is
9
fastened reliably.
10 Check whether the cone head bolts are fastened reliably.
Check the working conditions of the indicator on the remote
11
control button box.
Check the wear status of the countershaft, large steel bar fender,
12
balance weight, moving cone and main frame liners.
Table 5-2 Periodical checks and maintenance (to be continued)

Monthly checks and maintenance

Item Check results Normal conditions

Check the precharged pressure of the accumulator and add See the attachment
1
more nitrogen if necessary. “Hydraulic System”.
Check the meshing status of the small gear and adjusting
2
gear disc of the adjustment device.
Check the motor and lubricating oil according to
3
manufacturer’s suggestions.
Loosen the adjusting ring assembly and turn it back and
4
forth when the crushing state functions.
Check dirt and impurities in the lubricating oil and replace
5
the oil if necessary.
See the oil pollution
6 Analyze the pollution status of the oil.
guidelines.
7 Check for no axial clearance.
Table 5-3 Periodical checks and maintenance (to be continued)
57
Annual checks and maintenance

Normal
Item Check results
conditions
Completely disassemble the crusher and check the wear
1 status of all bearing surfaces (adjusting ring sleeves,
eccentric bushing liners and socket liners) and all gears.
Check whether there is any fatigue crack on the main
2 frame and moving cone adjusting ring (especially the main
frame flange and reinforcing rib root).
Check the fastening conditions of all fasteners and pipe
3
connectors.
4 Check the wear status of the moving cone head bowl.
5 Check the wear status of big and small gears.
6 Check the status of the scraper seal.
Replace the lubricating oil in the hydraulic drive gear
7
reducer.

Liner replacement and checks

Normal
Check
Item condition
results
s
Check the matching surface between the adjusting ring and the moving
1 cone liner.
Rub away any nick or burr on the moving cone and the adjusting ring.
Check the wear status of the mantle, moving cone head bowl, socket
liner, eccentric bushing liner and scraper seal. Use a feeler gauge to
2
check the fitting clearance between the moving cone liner and the
adjusting ring.
Check the wear status of the mantle locknut and cone head, and replace
3
it if necessary.
Check the wear status of the large steel bar, countershaft frame and fan
4
frame fenders.
Check the wear status of the adjusting ring, support bushing and locknut
5
threads.
6 Check whether any hydraulic hose suffers from leakage or damage.
7 Check the fastening status of the liner wedges and bolts.
8 Check the fastening status of the balance weight bolts.
9 Check the wear status of the counterweight guard.
Table 5-4 Periodical checks and maintenance (to be continued)

58
8 hours (daily checks) 40 hours (weekly 200 hours (monthly 2000 hours (annual
checks) checks) checks)
1. Check the tank oil 1. Check the V-belt 1. Loosen the adjusting 1. Check the wear
level. tension, wear and ring assembly from status of the moving
rupture. its crushing cone and eccentric
positions and turn it bushing.
back and forth.
2. Check the 2. Check whether any 2. Check the dirt and 2. Check the wear
temperature of the oil pipe, hose, guide sediment in the status and tip
crusher return oil, pipe or joint suffers lubricating oil. clearance of
gear chamber and from oil leakage. Replace the big/small gears.
countershaft. lubricating oil when
necessary.
3. Check the oil 3. Check whether the 3. Check the metal 3. Check the wear
pressure of the mantle and bowl (bronze) debris on status of the socket
countershaft frame. liner are fastened the oil filter in the liner.
reliably. oil tank. It is normal
to have some
occasionally.
However, a large
amount of debris
indicates that the
pressure is too high
on the bearing
surface or damages
4. Check the driving 4. Check crusher have happened.
power of the motor. discharge opening 4. Check the wear 4. Check the spherical
status of the moving wear of the moving
cone and bowl liner. cone.
5. Clean the ventilation 5. Check the cone head
5. Check the release devices on the wear. 5. Check the wear
pressure of the countershaft frame status or scratches
crushing chamber. and the oil tank. of the adjusting ring,
locknut and support
6. When the adjusting 6. Check the wear bushing threads.
6. Check whether any ring is at the status of the balance 6. Check the gasket,
fastener or position for weight, moving feeding materials
connector is loose. crushing, lubricate cone, main frame and O-shaped ring.
the support bushing and countershaft
and adjusting ring frame.
threads through the
lubricating nipple
59
 mounted on the
support bushing.
7. Check the motion of 7. Check whether the
7. Check any abnormal the support bushing. alarm system 7. Check the wear
noise indicating (pressure switch, status of the main
wear or deformation temperature switch, frame liner.
of the crusher parts. etc.) is normal.
8. Check the pulley 8. Check for no axial
8. Daily checks shall dust, spoke cracks clearance. 8. Check the wear
be necessary when and shaft fastening status of the support
the crushing parts status. arm and
are close to their countershaft frame
wear limits. 9. Check the fastening 9. Check the wear fenders.
9. Check the oil flow status of the cone status of the balance
back into the tank head screws. weight liner and 9. Check whether any
from the crusher and cover. crack has happened
main safety valve. to the weld joints on
Check whether there the main frame.
is any abnormal
fragment on the
strainer of the return
oil pipe in the oil
tank. 10. Check the working 10. Check the
10. Check whether the conditions of the precharged pressure
feeding is alarm lamp on the in the accumulator. 10. Replace the
reasonably hydraulic power lubricating oil in the
distributed in the unit. oil tank when
crusher. necessary.

11. Check whether the

crusher discharge is 11. Check the wear
unblocked. status of the dust
shell and scraper
12. Check the inertial seal.
stop time of the
crusher.

60
Feeding granularity
- No than 10% is permitted for such material smaller than the tension side discharge port (C.S.S).
- The granularity must be uniform.

Benefits: * more smooth driving power - more productive - better particle shape - more even liner wear

Item Name
1 Percentage of accumulative output weight
2 Feeding of uniform granularity
Up to 10% through 20 mm - 3/4 inch C.S.S (tight side
3
discharge port)
Figure 5-1 Feeding granularity

61
Feeding distribution Benefits: * more smooth driving power - more
- It must be evenly distributed around the crushing productive - better particle shape - more even liner
chamber. wear

Figure 5-2 Feeding distribution

62
Material level in the crushing chamber
Full feeding in the crushing chamber is
recommended during operation, but it often can
not be achieved due to liner design, crushing ratio,
power limitation and other relevant factors.
In most cases, a standard crusher can not be fully
fed during operation.
Discharge port
a. Open-circuit process
- Select the discharge port according to the
requirements of products.
b. Closed-circuit process
-When the HPT cone crusher is 3.2mm (1/8
inch)-6.5mm (1/4 inch) larger than the screen hole
size, the initial discharge port determined
according to the desired product granularity is not
certainly the most productive and best discharge
port. It depends on the nature of the material to be
crushed, crusher motor or engine driving power or
status of the support bushing. You would have to
adjust the discharge port a little to achieve the
highest yield of qualified products yield.
Driving power
Under the condition of no support bushing
beating, 75%-95% of the maximum power is
advisable for medium-hard and hard materials
during operation.
Benefits: * longest service life of the crusher parts
- highest yield

Item Name
1 Power (drive power)
Figure 5-3 Driving power

63
Chapter 6 Crusher operation
dead angle, so as to prevent the continuous material
6.1 Adjusting ring, bowl liner and
flow wearing the surface of the hopper.

feed hopper assembly

In the adjusting ring at the bottom of the feed hopper,
6.1.1 Overview there are several fork-type cantilevers, disc springs
and bolt components, which can fix the replaceable
This Chapter includes: adjusting ring, bowl liner and
mantles firmly on the adjusting ring. As a fixed
feed hopper assembly. Threads are machined on the
crushing part, the bowl liner is adjustable.
outer diameter of the adjusting ring supported in the
support bushing by meshing with the heavy-load
threads in the sleeve. Turn the adjusting ring in the
6.1.2 Assembly instructions
support bushing anticlockwise or clockwise, and the
Before installation, follow the steps below to
up-and-down adjustment can be achieved. Adjust the
dismantle, clean and reassemble such components as
adjusting ring and you can adjust the size of the
the adjusting ring, mantle and hopper detached for
feeding and discharging ports.
separate shipment due to load or transportation
limits.
The adjustment cap placed on the adjusting ring has
1. First remove the adjustment cap so that the
a lip seal contact with the dust shell fastened on the
threads on the adjusting ring could be
support bushing; the adjustment cap only provides a
completely exposed. Take down the bolts and
protective cover for the adjusting ring and lock nut.
washer to fasten the adjustment cap onto the
Several elastic load locking cylinders are distributed
adjusting ring, hang the lifting rope and anchor
around the top of the support bushing, able to push
ring around the lug of the adjustment cap and
the lock nut move upward. Lift the adjusting ring up
then lift the adjustment cap away from the
to the crushing position. When a heavy-duty
adjusting ring. See Figure 6-1.
hydraulic motor adjusting mechanism installed on
2. Thoroughly clean the adjusting ring, support
the support bushing is adopted to rotate the
bushing and lock nut threads to remove all dirt
adjustment cap, the adjusting ring will rotate
and antirust agents.
together with the adjustment cap.
3. Use a cloth filled with molybdenum disulfide
powder to scour the adjusting ring, support
The feed hopper bolted on the top flange of the
bushing and lock nut thread surfaces. (This step
adjusting ring mainly guides the feeding into the
can have the metal surface coated with a layer
crushing chamber. The mantle top around is sealed
of lubricant film so that the adjusting ring could
with asbestos material to prevent the crushing dust at
rotate more freely; the molybdenum disulfide
the bottom of the hopper, so that a flat bottom plate
lubricant film on the initial threads is painted
can be formed between the hopper bottom and the
by the manufacturer).
hopper walls for material accumulation to create a

64
4. Coat the threads with plenty of lubricant – a
mixture of oil and 5-10% molybdenum
disulfide powder.

When crushing sinter and slag or other similar

materials, you should use a kind of high-temperature
resistant grease mixed with 5-10% (by volume)
molybdenum disulfide power. Moreover,
satisfactory results also can be achieved when
lubricating oil is mixed with 5-10% molybdenum
disulfide power.

5. Assemble the adjustment cap and other parts

onto the adjusting ring.
6. Use the same lifting procedures as described in
the first step to lift the whole part already
assembled onto the lock nut. Before screwing
the adjusting ring parts into the lock nut and
support bushing, follow the method as stated in
Section 4.1 8 “Adjusting Ring Removal and
Installation” to decompress the locking
cylinder.
7. Follow the method as stated in the “Operation
Instructions” of Section 4.9 “Adjusting Ring
Rotation” to screw the adjusting ring into the
lock nut and support bushing.

65
Item Name
1 Feed Hopper
2 Sling
3 Lifting Eye
4 Adjustment cap lug
5 Adjustment cap
6 Mantles
7 Adjusting ring
8 Wood cushion

Figure 6-1 Lifting of adjusting ring assembly

66
 4 Small gear
6.1.3 Maintenance
5 Hydraulic motor
6.1.3.1 Adjusting ring removal
6 Support bushing
To check and replace any part, follow the steps
7 Main Frame
below to remove the adjusting ring parts:
Figure 6-2 Hydraulic adjusting mechanism
1. Before the adjusting ring parts are unscrewed
from the crusher, follow the method as stated in
Section 4.18 “Adjusting Ring Removal and
Installation” to decompress the locking
cylinder.
2. Use the hydraulic motor adjusting mechanism
to unscrew the adjusting ring counterclockwise
out of the support bushing as shown in Figure
6-2 and follow the method as described in
Section 4.9 “Adjusting Ring Rotation”.
3. Hang the lifting rope and ring around the lug of
the adjustment cap, lift the adjusting ring across
feed plate, and then place it on the wood
cushion as shown in Figure 6-1. Item Name
1 Nut
2 Disc spring
3 Gasket
4 Bolt
Figure 6-3 Disc spring components

6.1.3.2 Remove the bowl liner

Follow the steps below to remove the mantle:
1. Remove the adjustment cap from the adjusting
ring according to “Assembly Instructions” as
stated earlier in this Chapter.
2. Thoroughly clean the support bushing, lock nut
and adjusting ring threads to remove all dirty
marks, rusty spots and residual grease.
Item Name 3. Lift the feed hopper from the adjusting ring, so
1 Adjustment cap that the disc spring components to fix the bowl
2 Adjusting gear disc liner can be exposed. See Figure 6-3.
3 Protection cover
67
4. Use a wrench to remove the nut, disc spring,
gaskets and bolts. See Figure 6-4.

Item Name
1 Adjusting ring
2 Disc spring assembly
3 Bowl liner
4 Wood cushion
Figure 6-4 Bowl liner disassembly

5. Lift the adjusting ring away from the liner. If
the bowl liner and the adjustable ring are lifted
together, hammer the upper rim of the bowl
liner.
6. Check whether the bowl liner has caused burrs
on its mounting surface in the adjusting ring. If
slight burrs are found, grind away to ensure that
the entire cone surface is smooth and
continuous, free of any burr. If deeper burrs are
68
found, please follow the “Adjusting Ring
Installation Surface” in the latter part of this
section for treatment accordingly.
The mounting surfaces of different bowl liners
are different in length, so the burrs on the
adjusting ring mounting surfaces may have the
bowl liners unable to be correctly located on
the adjusting ring.

If so, during the crushing operations, the bowl
liners may become loose to cause further
damages to the mounting surfaces of the
adjusting ring.
6.1.3.3 Bowl liner installation
Follow the steps below to install the bowl liner:
1. Place the bowl liner on an appropriate wood
cushion and make sure that the adjusting ring
can be completely pressed on the bowl liner
after put in place.
2. Install the disc spring components reliably but
do not tighten the nuts. In order not to let the
bowl liner tilting inside the adjusting ring, use a
steel tape to measure the size “B”; it requires
that the sizes should be identical at six points
on the circumference. See Figure 6-5.
Item Name
1 Adjusting ring
2 Disc spring components
3 Size "B"
4 Bowl liner
69
5 Wood cushion
6 Feeler
Figure 6-5 Placed at the highest point of the
spiral line
3. Use an open end wrench to tighten all the nuts
alternatively in a symmetric manner. Use a
feeler check around the mating face between
the adjusting ring and the liner to see whether
the bowl liner has been tightly pressed on the
adjusting ring, with the in-between clearance
no greater than 0.025 mm (0.010″).
4. Reinstall the feed hopper,
5. Follow the procedures as recommended in the
“Assembly Instructions” earlier in this Chapter
to lubricate the threads on the adjusting ring,
lock nut and support bushing. This is the most
important step to ensure that the adjusting ring
can rotate freely in the support bushing.
6. Reassemble the rest of the parts.
6.1.4 Feed hopper replacement and
adjustment
When the bowl liner changes from one type to
another or the crusher changes from the current
standard type to a short head type, the feed hopper
specifications must be changed. All bowl liners need
such feed hoppers specific in shapes.
6.1.4.1 Mounting surface of the adjusting ring
After used for long, the bowl liner mounting surface
will need calibration by means of machining or bead
welding and fine reprocessing. If the mounting
surface of the adjusting ring needs reprocessing,
please contact the SBM service department to get
the manual for treatment instructions.
 the eccentric bushing. During eccentric or cycling
6.2 Moving cone, mantle and cone
movement of the eccentric bushing, the moving cone

head assembly is driven only with the aid of the contact between its
lower head bushing and eccentric bushing.

6.2.1 Overview
During the process of load-free operation, the upper
head bushing of the moving cone will contact with
This Chapter includes moving cones, mantles and
the socket liner to have the ball bearing kept in the
cone heads. The moving cone and replaceable
ball bowl.
mantle constitute the rotating or driving parts of a
crusher, and further form a crushing chamber
The oil way will go through the main shaft to
together with the adjusting ring and bowl liner.
directly lubricate the upper head bushing, lower
head bushing and socket liner.
Install a torch ring at the top of the mantle. The two
parts are fixed on the moving cone by means of a
The molded non-metallic T seal ring stuck in the slot
pressure cap.
below the moving cone forms a labyrinth seal
together with the U seal ring at the top of the balance
The mantle is firmly fixed on the moving cone
weigh to prevent oil leakage and protect the gear and
directly through the pressure cap screw threads. The
bearing surfaces against dust invasion. Under the
pressure cap can also support the cone head. The
moving cone cast a petticoat oil baffle plate to
cone head can rotate with the moving cone,
prevent the splashing oil bleeding out from the
undertaking to evenly distribute the feeding around
labyrinth seal.
the crushing chamber. There is a lock stud at the
lower part of the pressure cap and both form
double-nut locking to prevent the pressure cap
6.2.2 Installation of the moving cone
becoming loose.
assembly
See Figure 6-6.
At the lower part of the moving cone, there are
inverted countersinks used to install the ball bearing,
Follow the steps below to install such parts as the
upper head bushing and lower head bushing of the
moving cone, mantle and cone head removed before
moving cone. The head bowl of the moving cone is
shipment due to weight limits:
fixed on the moving cone with the aid of static
matching; the upper head bushing and lower head
1. If the cone head is usually installed on the
bushing of the moving cone are positioned with the
moving cone, then it must be removed before
aid of static fitting, keys and screws.
the moving cone assembly is mounted into the
crusher (See “Moving Cone Removal” in the
The ball bearing seat of the moving cone is fitted on
latter part of this Chapter).
the socket liner at the top of the main shaft while the
2. Thoroughly clean the eccentric bushing, upper
lower head bushing of the moving cone is fitted on
head bushing and lower bush hole of the
70
 moving cone, as well as ball bearing and socket
liner of the moving cone. Check the glossiness
of all surfaces and use a fine emery cloth to
grind off scratches or collision damages.
Check and make sure that all oil ways have
been completely cleaned.
3. Use conventional crusher lubricating oil to fully
lubricate the external surface of the eccentric
bushing, surface of the moving cone bush, ball
bearing of the moving cone and ball bearing
surface.
4. Take out the circular moving cone hanger plate
from the toolkit, and screw appropriate lifting
bolts into the offset threaded hole on the plate.
Fix the moving cone hanger plate onto the
pressure cap. Use the bolts of appropriate
length in the kit to fix the hanger plate and the
pressure cap together.
5. Use a suitable lifting device to lift the moving
cone and align it to the ball bowl. The
eccentricity of the lifting bolt will result in a
slight imbalance so that the moving cone could
be hanging at a certain angle. This is needed so
that the moving cone and eccentric bushing
could be hanging at the same angle. Turn the
moving cone to have its higher side (namely,
upswept side) aligned to the thicker side of the
eccentric bushing as far as possible.
71
6. Carefully lower the moving cone above the
socket liner.
7. The top edge of the eccentric bushing has been
chamfered to help the moving cone and the
eccentric bushing aligned. Slowly lower the
moving cone onto the eccentric bushing; if
necessary, gently push the moving cone and lift
it up where it can fit the eccentric bushing.
Lower the moving cone until it has been seated
correctly on the socket liner.
8. When the moving cone is correctly positioned
with its head bowl completely lowered onto the
socket liner, lift the moving cone by 6 mm
(0.25″) - 10 mm (0.39″) again and let the
moving cone hanging here.
Then start the lubrication pump and let it
working for 6-10 minutes.
This will help to wash away all the dust
gathering when the crusher is opened. At the
same time, the bearings are lubricated in
advance, which can help to start the machine.
And then turn off the pump, let the moving
cone fall back onto the socket liner and
dismount the hanger from the pressure cap.
Item Name
1 Lifting bolt
2 Sling
3 Moving cone hanger plate
4 Moving con
5 Minimum clearance
6 Equal clearance
7 Maximum clearance
8 Ball bowl
9 Thicker edge of the eccentric bushing
Remove the moving cone assembly:
1) Lift the moving cone assembly until the lower head bushing has detached from the outer
10
diameter of the eccentric bushing.
2) Align the moving cone above the ball bowl and continue to lift it.
Installation of the moving cone assembly:
1) Align the moving cone above the ball bowl;
11
2) Move the moving cone to the thicker edge of the eccentric bushing and then let it
continue to fall.
Figure 6 -6 Installation or removal of the moving cone assembly

72
9. Use larger screws and washers to fix the cone
head onto the top of the pressure cap as shown
in Figure 6 -7.
After the screws are tightly hammered, seal the
screws and lock washer tops around with silicone in
order to protect the pressure cap against water
infiltration and erosion.
Item Name
1 Cone head screw
2 Cone head
3 Pressure cap
4 Lock stud
5 Lock screw
Figure 6-7 Lock screw assembly
6.2.3 Maintenance
6.2.3.1 Removal of the moving cone
Follow the steps below to dismantle the moving
cone assembly for checks or replacement of parts:
1. Remove the cone head from the pressure cap.
2. Screw lifting bolts into the offset holes on the
moving cone hanger plate (taken from the
toolkit), use a set of matching holes to place the
hanger plate onto the pressure cap, have the
offset lifting bolts aligned to the higher side of
the moving cone (namely, the side facing
upward) and take out appropriate screws from
the toolkit to fix the moving cone hanger plate
onto the pressure cap.
73
3. Tie the moving cone hanger plate onto
appropriate lifting equipment and slowly lift the
moving cone until the lower bush of the
moving cone has left from the eccentric
bushing. At this position, move the lifting
equipment to have the moving cone lower bush
aligned to the socket liner and then lift it up
vertically.
If improper operation occurs in this step, the
moving cone parts may swing severely and
cause damages to the lower bush of the moving
cone.
4. Place the moving cone onto an appropriate
wood cushion.
6.2.3.2 Replacement of mantles
Remove and replace the mantles as follows.
1. Remove the moving cone hanger plate.
2. Grind the pressure cap the two weld joints
between the torch ring and the mantle.
Item Name
1 Pressure cap wrench
2 Sledge hammer
3 Pressure cap
4 Lock stud
5 Tighten direction
6 Loosen direction
Figure 6-8 Removal and pressure cap (HPT100)
 During crushing, the liner often swells, so it is
difficult to remove the cone head screw. If this
is the case, use gas cutting to cut off the torch
ring between the liner and the pressure cap, in
order to reduce stress and tension of the screw
(as shown in Figure 6-9). When gas cutting is
used to cut the torch ring, measures should be
taken, so as not to damage the moving cone.
Cutting must be aimed at the tangent of the
torch ring and cut a groove around before
finally cutting. Then the pressure cap can be
rotated and removed.
Item Name
1 Circular groove
Use a welding torch for cutting this
2 way to protect the moving cone
against damages.
Figure 6-9 Slot the torch ring
3. Use a wrench to loosen the lock screw between
the pressure cap and the lock stud, as shown in
Figure 6-7.
4. Put the pressure cap wrench (a tool provided in
the toolkit) in the corresponding slot of the
pressure cap. Hammer the wrench and loosen
the pressure cap clockwise, as shown in Figure
6-8.
74
Item Name
1 Mantles
2 Hanger hook cast with the liner
3 The lifting lug is welded the mantle.
4 Sling
Figure 6-10 Lift the mantle
Figure 6-11 Lifting lug (HPT100)
Warning!
When a hanger ring is welded on the liner to lift the
mantle, it must be determined that the hanger ring is
strong enough to bear the lifting load and use such
welding electrodes suitable for welding of
manganese steel.
The size of the hanger ring is as shown in Figure
6-11. Follow the steps below to weld the hanger ring
onto the liner.
A. Use chromium-nickel-magnesium alloyed (Efe
Mn - A) electrodes.
B. No preheating is needed – Have the
temperature of the mantle kept as low as
possible.
C. Clean up the part on which a hanger ring will
be welded (at least use a wire brush to clean it).
D. Weld the hanger hook bilaterally with the weld
as high as 6 mm (1/4″).
E. Repair any arc crater in the weld joints.
5. Check the moving cone and pressure cap screw
threads, remove any burr or nick possibly in
existence and thoroughly clean the threads.
Coat the threads with lubricating grease or oil.
6. It is very important to install the mantle
correctly; looseness or cocking may damage the
mantle seated on the moving cone. Follow the
steps below to install the mantle:
a. Before lowering the mantle onto the
moving cone, coat the lower edge of the
moving cone mounting surface with a
25mm(1″)-wide circle of dry oil.
b. Lower the mantle onto the moving cone.
c. Place the torch ring on the top of the liner.
d. If the pressure cap is not replaced, check
whether it is just pressed on the torch ring.
If placed incorrectly, the pressure cap or
moving cone will crack and the mantle
cannot be fixed on the moving cone.
e. Screw the pressure cap onto the moving
cone. The clearance must be equal
between the pressure cap and the torch
ring. During assembly, the mantle must be
75
correctly positioned and aligned to the
moving cone before bolts are tightened.
Never correct the mantles only by tightening the
screws. The clearance between the pressure cap and
the torch ring must be measured as illustrated in
Figure 6-12. Hammer the top or lift the bottom and
you can correct the positioning of the mantle. Before
tightening the pressure cap, have the deviation kept
within 1 mm (0.040″) or less.
7. Use a sledge hammer to knock and tighten the
pressure cap, so that the liner could be aligned
to the moving cone in place.
8. Use a feeler along the liner fitting surface as
shown in the figure to check whether the liner
is closely pressed onto the moving cone with
the clearance no greater than 0.25 mm (0.010″).
9. Use a wrench to fully tighten the pressure cap.
 Item Name
1 Mantles
2 Pressure cap
3 Equally spaced
4 Torch ring
5 Moving con
Figure 6-12 Mantle in place

10. After the pressure cap is tightened onto the
moving cone, make 4 x50mm weld joints
between the mantle and the torch ring as well
as between the torch ring and the pressure cap
in a completely opposite way.
Warning!
Welding shall not interfere with the cone head
pressed on the lock bolt.
18 8 35 SAFINOX (312 stainless) electrodes should
be used.
11. Install the moving cone assembly as instructed
in “Moving Cone Assembly Installation”
earlier in this Chapter.
6.2.3.3 Replace the moving cone head bowl
The moving cone head bowl seated on the socket
liner usually features smaller spherical wear. If the
head bowl surface has wear pits due to lubrication
76
failure or lubricant contamination, the head bowl
must be replaced as shown in Figure 6-13. The steps
are as follows:
1. Remove the set screw between the head bowl
and the moving cone. This screw is installed
with anaerobic adhesive, so before loosening it,
you must use gas cutting to heat it up to about
205℃ (400℉).
2. Follow the steps below to loosen the
countersink hole (transitional fitting) between
the ball bearing and the empty chamber of the
moving cone:
a. Arrange a sleeper frame under the ball
bearing of the moving cone at such an
appropriate height that the ball bearing has
no large clearance to drop and the moving
cone bush may not be hurt. But the height
should be kept so proper that the ball
bearing, if dropped, can be completely
 separated from the countersink hole in the needed. Measure the outer diameter of the ball
moving cone. bearing and the inner diameter of the bearing
b. Insert a 50 mm x 50 mm wood stick seat on the moving cone to determine when the
(2″×2″) between the dead plate of the ball bearing can have been fully cooled.
welded ball bearing and the moving cone
hole, and then hammer the stick until the Warning!
spherical body has been removed. Wear thick insulation gloves when handling dry ice,
or your skin will be seriously burned due to direct
3. After the ball bearing is removed, invert the contact with the dry ice.
moving cone and then clean the ball bearing
seat surface on the moving cone.
4. Put the ball bearing to be installed into dry ice
for 4-6 hours, so that it could be cooled down
enough to “fall into” the bearing seat on the
moving cone. About 23 kg (50 lb) of dry ice is

Item Name
1 Screws and spring washers
2 Ball bearing dead plate
3 Ball bearing
77
4 Moving con
5 Lower bush
6 Wood cushion
7 Upper head bushing
8 6 mm (1/4″) weld joints
9 Pin
Figure 6-13 Ball bearing seat disassembly
5. Use the lifting bolt screwed on the center hole
to hang the contracted ball bearing on an
appropriate lifting device as shown in Figure
6-14 (installation of moving cone ball bearing),
mount it as quickly as possible into the
installation position in the moving cone and
ensure that it is aligned and completely seated
on the bottom of the countersink hole on the
moving cone. Use a feeler to check the contact
status between the ball bearing and the moving Item Name

cone in all directions (at least at four points)! 1 Moving cone ball bearing

Confirm that the pin hole on the ball bearing 2 Lifting bolt

has already been aligned to the pin on the Figure 6-14 Moving cone ball bearing installation

moving cone.
6. Insert a proper bolt in the ball bearing dead 6.2.3.4 Remove the lower bush of the moving

plate welded in the moving cone hole, screw it cone

into the threaded hole on the ball bearing and (Figure 6-15)

then tighten the bolt. The lower bush stationarily fitting the moving cone

7. After the ball bearing has reached the is positioned by means of bolts.

environment temperature, remove the If you need to remove and replace the lower bush of

pre-installed bolt, use non-oily solvent to clean the moving cone, invert the moving cone and follow

the screw thread and the threaded hole on the the steps below to remove the bolts;

ball bearing, then coat the thread with 277

anaerobic adhesive, apply a proper spring 1. Use a heavy-load industrial circular saw fitted

washer, remount the bolt and finally tighten it.
with a saw blade suitable for metal cutting (the
moving cone bush is made from lead bronze) to
cut through the bush wall at least at two places.
Adjust the circular saw so that its blade could
touch the bush inner wall when placed in the
bush. Put the circular saw where cutting is
needed and adjust it properly, so that its base

78
 rear could be aligned to the bush end. See
Figure 6-16.
2. Measure the distance between the circular saw
base bottom to the intersection point between
the saw blade elongation cord and the bush
outer diameter. Deduct a little distance from
this distance. Deduct a little uneven distance
from this distance so that the saw blade will not
cut the moving cone.
3. Adjust the blade cut depth equal to the distance
as determined in Step 2.
Warning!
When cutting the bush, wear appropriate protective
devices. For safety, wear a plastic mask resistant to
high temperature impact during cutting.
4. Complete experimental cutting at first to have
the maximum outer diameter of the circular saw
cut in, then check whether the blade has been
adjusted to the correct cutting depth, and if
necessary, readjust it.
5. Cut along the full length of the bush.
6. Repeat this step opposite to the first incision.
After the second incision is completed, the bush
will break and fall down.

79
Item Name
1 Ball bearing dead plate
2 Moving cone ball bearing
3 Upper head bushing of the moving cone
4 Moving con
5 Press cake
6 Positioning screw HPT200/HPT300
7 T seal
8 Bush stop key
9 Bolt
10 Lower bush of the moving cone
11 Screws and spring washers
12 Positioning pin
Figure 6-15 Installed moving cone bush

Item Name
1 Circular saw
2 Lower bush of the moving cone
3 Circular saw base
4 Saw blade used for metal cutting
5 Cutting depth
Figure 6-16 Use a circular saw to remove the moving cone bush

6.2.3.5 Another way for removal of the moving upper head bushing of the moving cone, you must
cone bush remove the lower bush of the moving cone. To save
and reuse the lower bush of the moving cone, invert
The lower bush stationarily fitting the moving cone the moving cone and operate according to the
is positioned by means of bolts. When replacing the following steps:
80
1. Remove the positioning screw or bolt which fix
the lower bush of the moving cone liner onto
the moving cone.
2. Take out the removal tool for moving cone
bushes (in the onboard toolkit), as shown in
Figure 6-17.
3. Let the narrow part of the disc vertically go
through the countershaft bushing until it is as
indicated in the figure. Turn the disc by 90° and
have its outer edge leaning against the Item Name
1 Center disc
countershaft bushing.
Weld a 24 or 27 mm (1″) hexagonal nut on
4. Locate the disc and simultaneously have a 2
the disc.
screw rod with the diameter of 24 or 27 mm (1″)
Figure 6-17 Center disc
screwed into the nut welded in the center of the
disc. This screw rod must be slightly longer
than the countershaft bushing and its both ends
must have threads machined.

5. Place a 25 mm x 75 mm (1″×3″) flat steel bar at

the other end of the screw rod and use a
hexagonal nut to fix the screw rod firmly.
6. As indicated in Figure 6-19, put a wooden
frame between the flat steel bar and the moving
cone bottom.
7. Fill in the bush hole with dry ice to have it
contracted about two hours.
8. Use a threaded screw rod as a screw jack and Item Name
Have the center disc through the bush and
tighten the hexagonal nut until the bush flange 1
rotate by 90° in order to support the bush.
has been pulled to the steel bar. Or, a hydraulic
2 Bush
jack can be applied along the wooden frame.
3 Center disc
9. Unscrew the hexagonal nut, add a cushion
Figure 6-18 Center disc
block under the steel bar and tighten the
hexagonal nut until the countershaft bushing
has been pulled to the steel bar again.
10. Repeat this step until the countershaft bushing
has detached.

81
 Item Name
1 Steel plate
2 Threaded screw rod
3 Wooden frame
4 Lower bush of the moving cone
5 Withdrawal tool for lower bushes of moving cones
Figure 6 -19 Remove the lower bush of the moving cone

6.2.3.6 Check the inner, upper and lower holes due to heat dissipation. Measure the inner hole of the
on the moving cone. moving cone from the bottom up.
Before installing a new bush, invert the moving cone
and check whether the inner hole suffers from nicks, 6.2.3.7 Install the lower bush of the moving
cross ditches or rough blotches (all of which must be cone
smoothed). (See Figure 6-20)
1. Follow the steps below to install a new moving
Besides, check and confirm that the inner hole has cone bush:
not become larger due to grinding or become smaller
82
2. Use a wire brush to clean the inner hole of the
moving cone and the outer diameter of the
bush.
3. Put dry ice in the bush to be installed for
thermal contraction; if something is filled in the
central part of the bush, about 90 kilograms
(200 pounds) of dry ice should be needed to fill
the bush completely, for example use a 100 mm
x 100 mm (4″×4″) wood stick to occupy the
ineffective room in the center, with enough dry
ice filled around for thermal contraction of the
bush. Coat the bush with several layers of
insulating glass fiber to prevent the outer wall
from frosting. Otherwise, it will be more
difficult to mount the bush into the inner hole
of the moving cone. The wrapper also can help
to achieve more sufficient cooling, and the
cooling time should be about 2 hours.
Never force any bush into an excessively small
inner hole of the moving cone in this way.
Warning!
Wear thick insulation gloves when handling
dry ice, or serious burns will happen.
4. Measure the outer diameter of the bush and the
hole diameter of the moving cone to determine
when the bush will have been satisfactorily
cooled.
5. Install two lifting bolts (taken from the toolkit)
in the threaded hole at the bottom edge of the
bush.
6. Lift the bush above the inner hole of the
moving cone and have it aligned. Quickly
lower the bush, install it into the inner hole of
the moving cone and calibrate the mounting
hole until the flange has landed on the moving
cone.
7. Immediately confirm whether the hole is
aligned so well that the bolt can be screwed into
the moving cone. If not aligned, rotate the bush
slightly until the bolt can be screwed into the
moving cone.
8. Insert a bolt into the bush flange hole and screw
it into the threaded hole of the moving cone.
Then tighten the bolt to its 50% torque as
shown in Table 6-3. Use a feeler to check the
contact status between the bush flange and the
moving cone in all directions (at least at four
points)!

Item Name Crusher Bolt size Torque N·m

specifications and length (inch·Lbs)
1 Bolt
HPT300 M12x40 81(60)
2 Anaerobic adhesive 277
HPT500 M20x40 385（284）
3 Lower bush of the moving cone
Table 6-3 Bolt size and torque
4 Moving con
Figure 6-20 Flanged bush installation
83
9. After the bush has heated the environment
temperature, remove the pre-installed bolt and
use non-oily solvent to clean the bolt and the
threaded hole in the moving cone. Then coat
the thread surface with 277 anaerobic adhesive,
install and screw the bolt to the ultimate torque
as specified in Table 6-3.
10. Install the moving cone according to the
instructions related to moving cone assembly
installation in this Chapter. When reassembling
the cone head, confirm that the clearance has
been blocked between the screw head and the
spring gasket, which is very important to
prevent dirt and water seeping into the threads
of the cone head bolt and the pressure cap.
After a new moving cone has had its lower
bush installed, follow the steps as stated in
Section 4.6 to have it run in.
6.2.3.8 Remove the upper head bushing of the
moving cone
(See Figure 6-21)
The moving cone stationarily fits its upper head
bushing subject to a positioning key. If the upper
head bushing of a moving cone needs to be replaced,
invert the moving cone and handle it as the follows:
Remove the lower bush at first and then lift the
upper head bushing out of the moving cone. Refer to
another way outlined earlier in this Chapter for
removal of the moving cone lower bush.
1. Before disassembly, carefully read the
instructions for removal of the moving cone
lower bush in this Chapter; the removal and
84
installation of the upper head bushing is
identical in such steps as “sawing” and
“thermal contraction”.
2. Remove the four press cakes between the bush
and the moving cone, and abandon any old
press cake.
3. Saw and remove the bush.
4. Check whether the inner hole of the moving
cone has nicks, cross ditches or rough points.
Besides, check and confirm that the inner hole
has not become larger due to grinding or
become smaller due to heat dissipation.
6.2.3.9 Install the upper head bushing of the
moving cone
(See Figure 6-21)
Follow the steps below to install the upper head
bushing of the moving cone:
1. Use a wire brush to clean the inner hole of the
moving cone and the outer wall of the upper
head bushing.
2. Make the bush subject to thermal contraction at
least 2 hours in dry ice.
3. Use a lifting bolt to lift the bush above the inner
hole of the moving cone.
4. Quickly lower the bush into the moving cone
and then mount the press cake until the bush
“bottom” has landed onto the convex circle of
the inner hole in the moving cone.
5. Weld the two moving cones on both sides of
the press cake together.
Follow the relevant instructions of the moving cone
lower bush earlier in this Chapter to install a new
lower bush of the moving cone. After a new moving
cone has had its upper head bushing installed, follow
the steps as stated in Section 4.6 to have it run in.
Item Name
1 Press cake
2 Weld the press cake onto the moving cone.
3 Upper head bushing
Figure 6-21 Install the upper head bushing of the moving cone

6.2.3.10 Identify the connecting bolts of the cone Check the wear status of the cone head and its bolt,
head and when necessary, renew or replace it.

Check the wear status of the cone head and the
center bolt, and when necessary, replace the bolt.
Serious damages may happen due to falling of the
cone head into the crushing chamber. Regularly
check the tightness of the bolt attached to the
cone head. If not sure enough, replace the bolt
preferably.
6.2.3.11 Check the cone head bolt
During operation, the crusher may be damaged
due to falling of the cone head into the crushing
chamber, and serious damages may happen if the
cone head is left across the crushing chamber.
During operation, regularly check the cone head
bolt and ensure that it is firmly tightened and not
worn. If not sure enough, replace the bolt
preferably.

85
6.2.3.12 Replace the sealing ring ensure that less adhesive is squeezed out during
(See Figure 6-22) bonding.
The “T” seals installed around the bottom of the 6. Put the sealing strip after coated with adhesive
moving cone will generally not contact or wear. But into the groove and press the T seal as tight as
if the sealing ring has any damage, replace it possible so that the sealing strip is sufficiently
immediately, which is very important. The seals can pressed on the groove bottom. It will take about
prevent oil leakage and protect the gear, the finish 3 minutes to complete adhesive bonding.
machined surfaces of the small gear and bearing Warning!
against harmful dust. Follow the steps below to When adhesive and chemicals are used to
replace the sealing ring: replace a seal, adequate ventilation shall be
a must and no smoke can be breathed.
1. Remove the damaged sealing element and
thoroughly remove the residual adhesive in the
seal slot. Use a sharp chisel and a hard putty
knife to cut open the sealing ring and clear the
adhesive left in the slot.
2. Use non-oily solvent (for example, alcohol or
acetone) to thoroughly clean the groove and dry
it in the air.
3. Take out a new “molded” seal from the goods
container and use a sandpaper to thoroughly
roughen the T seal bottom to remove the
shining surface layer before bonded. The
sealing strip surface is coated with a layer of
mold release agents, so that the sealing strip can
be separated out from the mould during
manufacturing; in order to make adhesive stick Item Name
the T seal tightly into the groove of the moving 1 Moving con
cone, such layer of mold release agents must be Before applying activator and adhesive
fully cleared. If the release agents are not to the groove bottom of the moving
2
completely cleared, the sealing strip is likely cone, use a sandpaper to remove the
to fall off during operation. “shining” surface layer of the T seal.
4. Smear a very thin layer of activator in the 3 T seal
bottom of the sealing strip. If too much is Figure 6-22 Replacement of sealing elements
coated, then local concretion may occur.
5. Coat the groove button of the moving cone
with an appropriate amount of adhesive to

86
6.3 Socket liner assembly
Warning!
Wear thickened gloves featuring good heat
insulation when installing any heated part.
6.3.1 Overview
This Chapter mainly introduces the socket liner
assembly. The socket liner with a ball bearing
Lower the ball bowl on the main shaft along the
supports the moving cone and transmits the crushing
positioning pin and make sure that it is closely
force to the main frame. The ball bowl is fixed on
seated on the top of the main shaft. Have a feeler
the main shaft by means of interference fit and
gauge through the access hole on the ball bowl side
several bolts installed around the bearing frame.
to check and confirm the spherical surface.
The socket liner is fixed on the top of the bearing
4. The ball bowl has been seated horizontally on
frame with pins to provide a bearing surface for the
the main shaft (free of clearance) as shown in
ball bearing fixed below the moving cone with bolts.
Figure 6-4.
The socket liner has its surface sufficiently
5. Remove the positioning pin and screw the bolt
lubricated by the lubricating oil conveyed by the oil
padded with a lock washer into the screw hole
pump pressure through the connection oil hole
on the main shaft through the ball bowl.
between the main shaft and the bearing frame.
Tighten the bolts alternately once by a bit until
the torque value is as specified in Table 6-5.

6.3.2 Assembly instructions Note: Review the screw torque value after the part is
cooled.
See Figure 6-23.
b. Install the socket liner
If the ball bearing and socket liner have been
Install a new socket liner by means of socket liner
removed when the eccentric bushing is removed for
contraction or ball bowl expansion.
convenient transportation, in time of assembly,
Heating means: Reheat the ball bowl to have it
install the eccentric bushing assembly first and then
heater than the environment temperature as specified
follow the steps below to install other parts:
in Table 6-4 before a socket liner is installed.
a． Install the ball bowl.
Cooling means: Cool the ball bowl to have it cooler
1. Take out three positioning pins from the toolkit
than the environment temperature as specified in
and screw them into the screw hole at the top of
Table 6-5 before a socket liner is installed.
the main shaft.
Screw the lifting bolts into the threaded holes on the
2. Install two lifting bolts on the ball bowl and
edge of the ball bowl as shown in Figure 6-25.
hang them on a lifting device with an
Hang the lifting bolts on the socket liner on
appropriate lifting capacity.
appropriate lifting devices.
3. Heat the ball bowl based on the temperature
Align the socket liner, have the through-holes at the
(above the environment temperature) specified
bottom of the socket liner engaged in the positioning
in Table 6-4 and install it onto the main shaft as
pins on the ball bowl and then lower the socket liner
soon as possible.
onto the ball bowl.

87
Item Name
1 Ball bowl
2 Key
3 Main shaft
4 Positioning pin for ball bowl mounting
5 Spring washer
6 Bolt
Figure 6-23 Ball bowl installation

Higher than the environment temperature Ball bowl bolt

Crusher type Centigrade degree Specifications and
Fahrenheit (℉) Torque N.m (FP)
(℃) length
HPT200 80 145 M16×80mm 260(192)
HPT300 70 125 M16×90mm 260(192)
HPT400 94 168 M20×100mm 470(345)
HPT500 83 150 M20×100mm 470(345)
Table 6-5 Ball bowl preheating temperature and bolt torque requirements

88
Item Name
1 Compress Item Name
2 Feeler 1 Socket liner
3 Ball bowl 2 Ball bowl
4 Main shaft 3 Main shaft
Figure 6-24 Check the ball bowl contact 4 Bolt and washer
Figure 6-25 Socket liner installation
Higher than the environment
temperature
Crusher type
Centigrade
Fahrenheit (℉)
degree (℃)
HPT200 45 80
HPT300 45 80
HPT400 45 80
HPT500 45 80
Table 6-4 Temperature for ball bowl “reheating”

Below the environment

Crusher type temperature
Centigrade (℃) Fahrenheit (℉)
HPT200 45 80
HPT300 45 80
HPT400 45 80
HPT500 45 80
Table 6-5 Socket liner cooling temperature

89
 2.5 mm (0.098 inch) minimum oil
6.3.3 Maintenance 4
groove depth
Figure 6-26 Measure the oil groove depth
The oil groove on the ball bearing surface can be
used to determine when the ball bearing needs to be
4. Hang it on a suitable lifting device and remove
replaced. Measure the ball bearing as shown in
the worn ball bearing.
Figure 6-26, and when the ball bearing surface is so
5. Cool the new ball bearing before installed. Cool
seriously worn that the oil groove depth has been
the ball bearing lower than the environment
reduced to 2.5 mm (0.098 inch), then replace the ball
temperature as specified in Table 6-5; the ball
bearing.
bearing will contract to facilitate correct
It is also normal that slight looseness occurs between
installation into the bearing frame.
the ball bearing and the ball bowl, because the pins
6. Align the through-hole at the bottom of the ball
can prevent the ball bowl rotating.
bearing to the positioning pin on the ball bowl
Replace the ball bearing according to the following
and lower the ball bearing into the concave
steps:
chamber of the ball bowl. Note: Confirm that
1. Install three jack bolts (taken from the toolkit)
the ball bearing has been completely seated on
into the screw holes on the ball bearing as
the ball bowl.
shown in Figure 6-27.
2. Screw the jack bolts alternately once by a bit,
and if necessary, heat the upper part of the ball
bowl to facilitate removal of the ball bearing.
3. Remove the jack bolts and install the lifting
bolts on the ball bearing outside.

Item Name
1 Ball bearing
2 Ball bowl
3 Main shaft
If necessary, heat the upper part of the
Item Name 4
ball bowl.
1 Initial outline of the ball bowl
5 Jack bolt
2 Worn ball bowl
Figure 6-27 Remove the ball bearing
3 Oil groove

90
 bottom of the eccentric bushing and the static lower
6.4 Eccentric bushing assembly
steel thrust bearing is bolted onto the frame. The top
and side clearance between the gear and the small
6.4.1 Overview
gear is kept by adding or reducing gaskets under the
This Chapter mainly describes the eccentric bushing
lower thrust bearing.
assembly, including eccentric bushing, eccentric
bushing liner, gear and balance ring. The eccentric
The balance weight on the eccentric bushing has a
hole of the eccentric bushing enables the moving
light side and a heavy side relatively positioned to
cone to follow the eccentric motion curve in each
reduce the unbalanced force caused by crusher
circle. The eccentric bushing liner is fixed within the
rotation.
eccentric bushing as the bearing surface of the main
shaft. The gear fixed at the bottom of the eccentric
The U-T sealing ring around the bottom and top of
bushing with screws is driven by the small gear on
the balance weight can provide a labyrinth seal to
the countershaft. The eccentric bushing rotates
prevent oil leakage and dust invasion for protection
around the static main shaft. The whole eccentric
of the big and pinions as well as the bearing surface.
device is supported by a group of thrust bearings, the
upper copper thrust bearing is bolted onto the

Item Name Item Name

1 Lifting wire rope 7 Pinion
2 Lifting bolt 8 Main Frame
3 Eccentric bushing lifting plate 9 Lower thrust bearing
4 Main shaft 10 Upper friction plate
5 Balance weight 11 Eccentric bushing
6 Gear 12 Balance ring
Figure 6-28 Lifting of eccentric bushing assembly

91
 layer of oil on the main shaft, eccentric shaft
6.4.2 Assembly instructions
liner and two thrust bearings.
6.4.2.1 Install the eccentric bushing assembly
4. Hang the lifting bolt on a suitable lifting device
See Figure 6-28.
and then slowly lower the eccentric bushing
onto the main shaft. Use the bevel edge of the
If the eccentric bushing is removed from the crusher,
eccentric bushing liner to align the center of the
due to the weight limits, follow the steps below to
part and lower the eccentric bushing until the
assemble various components in this assembly:
bottom of the upper friction plate has landed on
1. Thoroughly clear the outer wall and top of the
the lower thrust bearing. Gently turn the
main shaft, the gear chamber on the frame and
eccentric bushing if necessary to have the large
the inner wall of the eccentric bushing liner to
and small gear teeth meshed completely to
remove nicks, scratches and burrs. Clean the
ensure that the eccentric bushing has
upper surface of the upper friction plate on the
completely landed on the lower thrust bearing.
main frame and the lower surface of the upper
5. Ensure that the large and pinions are meshed
friction plate bolted at the bottom of the
correctly and reliably as shown in Figure 6-29,
eccentric bushing.
calibrate the gear side and top clearance in
2. Make sure that the bolts and spring gasket for
accordance with Table 6-6, and you can remove
the upper friction plate and lower thrust bearing
the eccentric bushing lifting plate after suitable
have been fixed reliably.
side and top clearance has been achieved.
3. Use the threaded hole at the top of the eccentric
bushing to fix its lifting plate (taken from the
toolkit) onto the eccentric bushing assembly
and then screw the two lifting bolts (taken from
the toolkit) onto the hanger rings. Coat a thin

Crusher Gear side clearance Minimum gear top clearance

specifications mm inch mm inch
HPT100 0.560-0.710 0.022-0.028 1.670 0.066
HPT200 0.457-0.813 0.018-0.032 1.905 0.075
HPT300 0.508-1.016 0.020-0.040 2.388 0.094
HPT400 0.640-1.150 0.025-0.045 3.454 0.136
HPT500 0.890-1.400 0.035-0.055 3.480 0.137
Table 6-6 Gear side and top clearance

Thickness of gasket Side clearance change

92
 HPT100 HPT200 HPT300 HPT400 HPT500
mm inch mm inch mm inch mm inch mm inch mm inch
3.0 0.1181 1.90 0.075 1.87 0.073
1.7 0.0669 1.03 0.040 1.00 0.039
0.4 0.0157 0.17 0.007 0.15 0.006
Table 6-7 Thickness of gasket

The burrs at the end of the gear teeth can be rubbed

Item Name
1 Pinion
2 Gear
3 Side clearance
4 Top clearance
Figure 6-29 Check the gear top and side
clearance
6.4.2.2 Check the gear top and side clearance
See Figure 6-29.
The right method for adjustment of a series of gears
on a new or old crusher is to achieve the gear side
clearance as recommended. If the top clearance
reaches its lowest limit when the eccentric bushing
is lowered to reduce the gear side clearance, then the
top clearance will be a limit factor to ensure that the
gear teeth will not fall to the lowest point.
away by hand without dismantling the complete part,
but rust peeling may bring extra pressure to the parts,
so replacement may be the only option.
Follow the steps below to check and adjust the gear
top and side clearance:
1. Position a big center pin into the balance
weight right above the small gear or remove the
balance weight from the eccentric bushing.
2. Pull the countershaft toward the drive end until
the small gear is closely pressed on the inner
sleeve of the countershaft, as indicated in the
chapter “Countershaft, Countershaft Frame and
Pulley Assembly”.
Note: Loosen the V-belt before measurement.
3. Gently rotate the countershaft to have some
tooth of the gear turned to the vertical position,
as shown in Figure 6-29.
4. Push or pry the heavy side of the eccentric
bushing assembly to the main shaft, eliminate
the clearance between the eccentric bushing
and the main shaft, have the gear teeth and the
pinion located at a right place, keep the gear at
this location and then carry out measurement.
Push the eccentric bushing towards the main
shaft with appropriate strength, or the eccentric
bushing may lean sideward to give incorrect
results.
5. Rotate the countershaft to have the large and
pinion teeth just “contact” each other for

93
 convenient measurement of the gear side
clearance; use a feeler gauge to measure and
record the side clearance of the gear teeth
un-meshed side at the position as shown in
Figure 6-29.
6. Then measure and record the gear top clearance
as shown in Figure 6-29.
7. If the measured gear top and side clearance
values are smaller than those listed in Table 6-6,
you should remove the eccentric bushing
assembly and add more metal gaskets of
appropriate thickness again under the lower
thrust bearing according to the instructions in
“Lower Thrust Bearing and Gasket Installation”.
If more gaskets are added, the eccentric
bushing assembly will rise accordingly to
enlarge the distance between the big and
pinions, and thus to increase the gear top and
side clearance. If the measured results are
greater than those listed in the table, you should
take out some metal gaskets of appropriate
thickness.
Note: When a crusher is delivered, the gaskets
mounted on the lower thrust bearing reaching the
thickness as required, correct gear top and side
clearance can be provided. However, such
gaskets initially mounted in the crusher for gear
side clearance adjustment can be used to
compensate the initial wear.
See the maintenance contents stated in this
Chapter.
6.4.3 Maintenance
6.4.3.1 Remove the eccentric bushing assembly
For parts maintenance and replacement, follow the
steps below to remove the eccentric bushing
assembly from the crusher:
1. Use the threaded holes on the eccentric bushing
to fix its lifting plate (taken from the toolkit) on
94
the top of the eccentric bushing assembly,
install two lifting bolts on the hanger ring and
hang them on suitable lifting equipment as
shown in Figure 6-28.
2. Take care to lift the eccentric bushing assembly
vertically away from the main shaft.
3. Take care to lift the eccentric bushing parts
completely out from the crusher and put them
on a suitable wooden frame.
6.4.3.2 Balance ring protection
A deep chamber is designed in the frame to avoid
wear due to contact between the balance ring and the
materials as shown in Figure 6-28 and Figure 6-48.
The outer ring of the balance ring protection
chamber has a shaft aligning seat fender, whose
outer ring is welded with a wear-resistant rod to
improve its wearability.
Note: Check the thickness of the surfacing layer
every day, and if it is seriously worn, surface it
timely to avoid impact on the balance ring
protection chamber because the shaft aligning
seat fender has been worn through; if worn
through, surface it again in a timely manner.
Replace the shaft aligning seat fender: Check the
thickness of the surfacing layer on the outer ring of
the shaft aligning seat fender every day, and within
the life cycle of the liner, if the shaft aligning seat
fender has been worn through, replace the liner and
the shaft aligning seat fender at the same time.
Check the discharge area of the crusher every day to
ensure that materials can be discharged freely from
the bottom of the crusher. When wood sticks and
other materials are collected across the crusher arm
and discharging hopper, material accumulation will
occur to result in rapid wear of the balance weight
components.
The U and T-shaped seals at the top and bottom of the gear bank and bearings could be protected
the balance weight will not contact or wear, so that against intrusion of harmful lime sand.

Item Name
1 Main shaft
2 Floating sealing device
3 Shaft aligning seat fender
4 Balance ring protection chamber
5 U-shaped seal
6 Lower thrust bearing plate
Figure 6-30 Balance ring protection chamber

6.4.3.3 Upper friction plate
Whenever the eccentric bushing assembly is
removed from the crusher, you should check
whether the thrust bearing suffers from scratches,
scoring signs and wears. If the upper friction plate is
worn, two operation troubles will occur:
Firstly, the eccentric bushing assembly will lower to
result in too deep meshing between the large and
pinion teeth. In this case, adjust it by adding more
gaskets under the lower thrust bearing. See Section
6.4.2.2 “Gear Side and Top Clearance Checks or
Adjustment”.
Secondly, the oil groove on the contact surface of
the upper friction plate will become smaller.
If the oil groove is smaller than the minimum width
or depth as shown in Table 6-8, the friction disc
should be replaced. In emergency situations, you can
machine the oil groove to increase its depth or
width.

95
Note: The ultimate wear limit is that the contact
surface of the upper friction plate is parallel to the
surface of the bolt head.
Item Name
1 Oil groove
2 Upper friction plate
3 Original groove depth
4 Minimum groove depth
Figure 6-31 Wear limit of the upper friction plate
Crusher Groove depth
Model Original
HPT100 8mm(5/16″)
HPT200 8mm(5/16″)
HPT300 10mm(25/64″)
HPT400 11mm(7/16″)
HPT500 11mm(7/16″)
Table 6-8 Groove depth
bowl, eccentric bushing assembly and floating
sealing device. See the contents in relevant
sections for removal of such parts.
2. Invert the eccentric bushing assembly to have
the thrust bearing kept upward.
3. Remove the countersunk head screw and spring
washer to fix the eccentric bushing.
4. Screw the lifting bolts into the two screw holes
on the thrust bearing.
5. Hang the eyebolt on an appropriate lifting
device and take care to lift the eccentric
bushing away. The clearance mesh is adopted
between the upper friction plate and the
eccentric bushing.
6. Check the thrust bearing for replacement and
make sure that no burrs or abnormal edges
occur, or the bearing may not completely
contact the surface of the eccentric bushing.
7. Remove the lifting bolts on the upper friction
plate and install them on the new bearing, put
the upper friction plate in place and ensure that
all holes are aligned to those on the eccentric
bushing for appropriate installation.
8. Place a new spring gasket on each hole of the
upper friction plate, have proper bolts through
Minimum the spring washers and then tighten the bolts
6.7mm(17/64″) alternately one by one in a cross manner to the
6.7mm(17/64″) torque as shown in Table 6-9.
8.7mm(11/32″)
9.7mm(3/8″)
9.7mm(3/8″)

6.4.3.4 Replace the upper friction plate

See Figure 6-32.
Follow the steps below to replace the damaged or
worn upper friction plate:
1. In order to get access to the thrust bearing, first
dismantle the adjusting ring, moving cone, ball
96
 6.4.3.5 Eccentric bushing liner
Whenever the eccentric bushing is removed, you
should check whether its liner is loose and
excessively worn. If the eccentric bushing liner is
found loose, check and confirm whether it is loose in
the eccentric bushing. If not, you should relocate the
liner and then cast zinc-base alloy again as required.

Note: Under normal conditions, the eccentric

bushing liner has its heavy side worn more
seriously, which is normal as expected, so take it
easy. If the bush is excessively worn or cracked,
replace it.

6.4.3.6 Remove the eccentric bushing liner

The zinc-base alloy is located at the top of the bush,
namely, several groups of chutes made up of the
eccentric bushing and bush, with locking mixture
filled in the chutes to prevent the bush rotating. To
replace the bush, follow the steps below:
1. As shown in Figure 6-33, drill several holes on
Item Name the locking materials in each chute.
1 Upper friction plate
2 Eccentric bushing
3 Bolt
4 Spring gasket
Figure 6-32 Upper friction plate

Bolt torque
Crusher Upper friction plate
N.m
Model Bolt size Item Name
(FP)
HPT100 M8×20 45(34) 1 Eccentric bushing
HPT200 M8×20 45(34) Drill a group of holes on the locking
2
HPT300 M10×25 90(66) materials in the chute.
HPT400 M10×25 90(66) 3 Eccentric bushing liner
HPT500 M14×35 250(185) Figure 6-33 Remove the zinc-base alloy
Table 6-9 Requirements for torques of the upper
friction plate bolts 2. Tunnel the adjacent hole walls and remove the
locking fillers so that there should be no
97
 locking materials preventing the bush removal. Item Name
As shown in Figure 6-34, invert the eccentric 1 Wood block
bushing and put it on a wood frame, so that the 2 Disc
3 Wooden block
bush could be forced off from the eccentric
4 Eccentric bushing liner
bushing.
5 Eccentric bushing
3. Cut a piece of 25mm (1 inch)-thick circular
Figure 6-34 Remove the eccentric bushing liner
steel plate slightly smaller than the outer
diameter of the bush, rub down the outer edge
6.4.3.7 Check the inner chamber of the
of the steel plate and glue it with an adhesive
eccentric bushing
tape to prevent rough edges from scratching the
Before installing a new eccentric bushing liner,
inner wall of the eccentric bushing.
check whether any scratch or rough point occurs on
4. Put the steel plate on the bush and ensure that it
the eccentric bushing liner, and if any, polish it.
is aligned without contact with the inner wall of
the eccentric bushing.
Besides, check and confirm that the inner chamber
5. Use a 100mm×100mm (4″×4″) stick to tamper
has not become larger due to grinding or become
the steel plate until the bush has completely
smaller due to heat dissipation. Measure the inner
separated from the eccentric bushing. It may be
chamber of the eccentric bushing from the bottom
difficult to tamper the bush away from the
up.
eccentric bushing, so you can use a heavy-load
industrial circular saw to cut the bush into two
Contact the manufacturer for correct diameter of the
or more pieces along the bush wall. See the
inner chamber.
method for bush cutting as recommend in
“Removal of Moving Cone Bush”.
At the same time, rotate a micrometer by 90° to
check its circular degree and measure the diameter
each spaced by 45° to the previous point.

The inner chamber often contracts unevenly, so you

can machine it to the drawing size, but take great
care to arrange the parts to be machined.

6.4.3.8 Check the main shaft

When the eccentric bushing liner is replaced due to
bearing failure and especially when it gets stuck by
the main shaft, you should check the main shaft
accordingly. Use a fine emery cloth to remove all
lead and copper particles from the main shaft only in
the horizontal and circular directions. Consult the

98
manufacturer to decide whether the main shaft
should be replaced.
If the eccentric bushing liner gets stuck on the main
shaft, you can remove it according to the following
steps:
1. A longitudinal slot lies between the bush inner
diameter and the large oilhole. Use a
heavy-load industrial circular saw fitted with a
saw blade suitable for metal cutting (the
moving cone bush is made from lead bronze) to
cut through the bush wall. Adjust the saw blade
depth to 20 mm (0.75 inches), but no more than
25 mm (1 inch).
2. Cut the bush along the longitudinal slot.
3. Place a pry bar at the cut to pry the bush
outward so that it could eject from the cut.
4. Note: Never have the circular saw blade leaving
any scratch on the main shaft, or it will bring
negative impact on the performance of the new
eccentric bushing liner.
Attention
Note: When removing lead and copper
cuttings, never leave any scar on the main
shaft.
6.4.3.9 Install the eccentric bushing liner
Metal-to-metal clearance fit or a few tenths
millimeters’ (parts per thousand) should be kept
between the machined eccentric bushing liner and its
inner chamber. Improper storage or transportation
may have the bush subject to metal-to-metal fit or
out-of-round, so the following steps are recommend
for use of dry ice.
Follow the steps below to use dry ice for installation
of a new bush:
1. Make sure that the locking materials in the
chute at the top of the eccentric bushing have
been completely cleared and that the inner
99
chamber surface of the eccentric bushing is
clean, free of any rough point.
2. Thoroughly clear all surfaces of the whole bush,
remove any rough point on the surface and
have the bush ready.
3. Fill the bush inner chamber with dry ice to have
the bush contract. If some kind of fillers are
placed in the center of the bush, about 90
kilograms (200 pounds) of dry ice should be
enough to fill the bush inner chamber. For
example, place a 100×100 mm (4″×4″) wooden
stick in the center, enough free space should be
left for filling sufficient dry ice to have the bush
subject to thermal contraction.
Warning!
Wear thickened gloves featuring good heat
insulation when handling the dry ice; if not,
serious burns will happen.
4. Coat the bush with several layers of insulating
glass fiber to prevent the outer wall from
frosting. Otherwise, it will be more difficult to
mount the bush into the eccentric bushing. The
wrapper also can help to achieve more
sufficient cooling, and the cooling time should
be about 2 hours.
Note: Never force any bush into an eccentric
bushing with a relatively smaller inner diameter
in this way.
5. Measure the outer diameter of the bush and the
inner diameter of the eccentric bushing to
determine whether the bush has been
sufficiently cooled. Screw two lifting bolts
(taken from the toolkit) in the top of the bush.
6. Draw or scratch marker lines along both sides Note: After a new eccentric bushing liner has been
of the two oilholes (large and small) outside the installed, follow the steps in Chapter 4 to let it run
bush as shown in Figure 6-35. And then draw in.
or scratch marker lines along both sides of the RE
oilholes on the eccentric bushing to its top
surface, and such lines will ensure that the
eccentric bushing could be aligned to the oil
holes on the bush.
7. Use lifting bolts and gaskets (taken from the
toolkit) to lift the bush in place and align it to
the inner chamber of the eccentric bushing
above as shown in Figure 6-36. Put the
contracted bush into the inner chamber of the
eccentric bushing as quickly as possible and
align it to the groove and oil holes.

Note: The lubricating oil fillers on the bush must

be completely aligned to the corresponding holes
through the wall of the eccentric bushing, the
groove at the outer top of the bush should be
aligned to that on the eccentric bushing, and the
groove can allow for a tiny displacement, but the Name
Item
lubricating oil fillers shall be strictly aligned.
Draw or scratch lines along the edges
8. When the bush has been installed, its top should 1
of the oilholes.
be parallel to that of the eccentric bushing. 2 Small hole
9. According to the instructions on each barrel, 3 Eccentric bushing liner
mix the locking materials and pour the mixture 4 Big hole
into the grooves at the top of the eccentric Figure 6-35 Align the eccentric bushing liner
bushing and the bush, with each groove
sufficiently filled.
10. Before the locking materials are poured, the
eccentric bushing, bush and locking materials
should be kept at the room temperature between
16℃(60℉)~32℃(90℉).
11. After the lock materials are completely
hardened, grind off any protruding locking
material.

100

Item Name
Lifting bolts and gasket for bush
1
fixation
2 Eccentric bushing
3 Zinc-base alloy
4 Eccentric bushing liner
Figure 6-36 Bush and eccentric bushing liner
6.4.3.10 Perfuse the zinc base alloy again.
The bush can rotate automatically in the eccentric
bushing due to the wear of the zinc-base alloy, so
you need to perfuse zinc-base alloy again. Drill, cut
off and clean the alloy in the groove successively for
reperfusion. Take care to align the oilholes on the
eccentric bushing and the bush. See Figure 6-35 and
Figure 6-33.
Note: Before reperfusion, check whether the bush
is correctly installed as stated in “Eccentric
bushing Liner Installation”.
6.4.3.11 Adjust the side clearance of the gear
after worn
When the thrust bearing can’t keep a suitable gear
side clearance any longer with the gear teeth due to
101
wear to a certain extent, you must increase or
decrease the gasket assembly to adjust the gear side
clearance to achieve the suitable gear side clearance
as shown in Table 6-6. Increase a gasket to have the
eccentric bushing assembly higher, and the distance
between the big and pinions will increase.
Oppositely, remove a gasket to lower the whole
assembly, and the big and pinions will be closer.
Ensure to reassemble the thrust bearing and gasket
correctly.
Note: Collision shall be prevented between the
teeth tops and roots of the big and pinions at any
time. No matter whether a gear is worn or not, its
root should have sufficient clearance reserved.
Therefore, when the gear teeth can have correct
side clearance after worn to a certain extent but
the top clearance can not reach the minimum
value as listed in Table 6-6, then the gear side
clearance value can be ignored.
6.4.3.12 Replace the gear
When the eccentric bushing is removed whether for
maintenance of related parts or for fear of broken
teeth and excessive wear, you should check the
bevel gear installed at the bottom of the large
eccentric bushing.
The roughness and pits on the gear surface indicate
excessive wear of gears due to inappropriate number
of the lower gaskets of the lower thrust bearing,
crusher overload or use of particularly dirty oil. If it
is ensured that the gear has been so seriously worn
that it must be replaced, follow the instructions in
“Removal of Balance Weight and Gear” to remove
the gear.
6.4.3.13 Remove the balance weight and gear.
See Figure 6-37.
Lift and remove the eccentric bushing assembly
from the crusher as stated in “Eccentric bushing
Assembly Installation”, and then follow the steps
below to remove and replace any part excessively
worn or damaged.
1. Put the entire assembly on a wood cushion and
remove the hexagonal screws to fasten the
balance weight and the eccentric bushing flange;
anaerobic adhesive has been applied to such
screws during installation, so gas cutting should
be used to heat them to about 205℃ (400℉)
before unscrewed.
2. Screw the four lifting bolts (taken from the
toolkit) into the flange of the balance weight.
3. Remove the bolts screwed into the gear screw
holes through the eccentric bushing flange.
Anaerobic adhesive has been applied to such
screws during installation, so gas cutting should
be used to heat them to about 205℃ (400℉)
before unscrewed.
4. The countersink on the top of the gear features
light interference fit with the flange of the
eccentric bushing. Screw the two lifting bolts
into the hanger ring (taken from the toolkit) and
then screw the ring onto the top of the eccentric
bushing.
5. Lift the whole part at about 40mm (1-1／2″)
above the wood cushion and use gas cutting to
102
heat the gear evenly until its diameter has
become larger and fallen from the eccentric
bushing.
6. Place the machined surface of the eccentric
bushing on a hardwood block.
7. Remove the countersunk head screws and the
spring gasket from the upper friction plate and
then remove the thrust bearing.
6.4.3.14 Assemble the balance weight and gear
Follow the steps below to reassemble the eccentric
bushing:
1. Take care to invert the eccentric bushing and
place it on a suitable wood cushion.
2. Place the upper friction plate at the bottom of
the eccentric bushing and ensure that all holes
are aligned. Apply a new spring gasket and
tighten the countersunk head screws.
3. Place the gear down onto an appropriate wood
cushion as shown in Figure 6-37.
4. Invert the eccentric bushing again, then screw
two lifting bolts on the hanger ring and fix the
hanger ring to the top of the eccentric bushing.
Item Name
1 Balance ring
2 Eccentric bushing
3 Positioning pin
4 Gear
Figure 6-37 Lift the balance weight and eccentric bushing
5. Use appropriate lifting equipment to lift the
eccentric bushing above the gear. Make sure
that the eccentric bushing is vertically aligned
to the gear.
6. Use gas cutting to heat the gear evenly to
45℃(80℉) higher than the environment
temperature.
Note: It is very important to heat the gear evenly
but never focus on one area to form a “hot spot”,
103
Item Name
5 Wood block
6 Upper friction plate
Coupling screws between the eccentric
7
bushing and the gear
8 Eccentric bushing liner
or heat treatment of the gear will be damaged.
Use a standard chemical component softening
once at a predetermined temperature to ensure
even and safe heating.
7. Measure the outer diameter of the eccentric
bushing and the countersink inner diameter of
the heated gear to ensure the countersink inner
diameter is slightly larger than the eccentric
bushing. Then put the eccentric bushing into
 the countersink of the gear as quickly as
possible and have the mating holes aligned.
There is no special requirement for alignment
due to equal hole pitch. Check and confirm that
the eccentric bushing has closely fitted the gear.
8. Use non-oily solvent (alcohol or acetone) to
clean the threads of the long and short bolts and
the screw holes on the gear and then coat the
thread surfaces with 271 anaerobic adhesive.
9. Screw the short bolts for coupling of the
eccentric bushing and the gear into the gear
through the holes on the eccentric bushing
flange, and then successively tighten the bolts
alternately in a cross manner up to the torque as
shown in Table 6-10.
10. If the eccentric bushing is installed in the
crusher with no balance weight assembled after
the gear is replaced, it can be easier to check
the side and top clearance of the big and
pinions. See the instructions in “Gear Side and
Top Clearance Checks or Adjustment” earlier
in this Chapter.
11. Screw the two lifting bolts (taken from the
toolkit) into the inner flange of the balance
weight.
12. Take care to lower the balance weight onto the
eccentric bushing and then install it on the
flange plate of the eccentric bushing according
to Figure 6-37. Have the pin hole on the
balance weight aligned to the pin rod on the
eccentric bushing.
13. Screw the long coupling bolts of the balance
weight and the gear into the threaded holes of
the gear through the screw holes on the
eccentric bushing.
14. Tighten such long bolts alternately one by one
in a cross manner to the torque values listed in
Table 6-10.
15. Before installing the eccentric bushing parts on
the crusher, rotate the countershaft to check
whether the pinion has had its teeth worn or
damaged.
16. Install the eccentric bushing assembly as
instructed earlier in this Chapter.
Note: After removing the moving cone for bush
replacement, you should check the tightness of the
bolts connecting the gear to the eccentric bushing
and the balance ring.

Specifications and length Specifications and length Higher than the

of the bolts connecting the of the bolts connecting Tightening environment temperature
Crusher gear to the eccentric the gear to the balance torque
Model bushing weight N.m Centigrade Fahrenheit
(FP) (℃) (℉)

HPT100 M12×70 M12×70 135(100) 45 80

HPT200 M14×70 M14×70 167(124) 45 80
HPT300 M16×70 M16×70 260 (192) 45 80
HPT400 M20×100 M20×120 470(345) 34 61
HPT500 M24×100 M24×140 810(600) 32 57
Table 6-10 Torque and heating requirements of gear bolts
104
 countershaft frame with the help of the centrifugal
6.5 Countershaft frame, countershaft
force.

and pulley assembly The oil slinger enclosed in the end cover can have
the oil return to the oil tank for recycling. Driving

6.5.1 Overview shaft

This Chapter includes the countershaft frame,

The countershaft frame is pressed to the main frame
countershaft and crusher pulley assembly. The
and fixed by means of bolts large in diameter. An
power source is transmitted to the countershaft by
O-ring or lip seal is equipped between the matching
means of a V-belt or directly-coupled drive device.
surfaces of the dive shaft frame and the main frame
The countershaft of the helical tooth pinion subject
to provide oil seal. The countershaft frame fender
to a press fit assembly will successively drive the
can protect the exposed parts of the shaft frame
gear on the eccentric assembly again. The
against wear damages due to falling materials.
countershaft is supported in the two shell sliding
bearings or countershaft bushings, and the
6.5.1.1 Countershaft frame installation
countershaft bushing is fixed on the countershaft
frame by a key to prevent the bearing rotating. The
See the maintenance contents in this Chapter for the
flange on the countershaft bushing bears the axial
whole process of components assembly. If the
thrust load from the pinion or oil slinger. The oil
countershaft frame is removed due to transportation
slinger fixed by a key to or pressed on the drive end
reasons, then it should be mounted on the main
of the countershaft will discharge the oil out of the
frame according to the following procedures.

Item Name
105
1 O ring
2 Main Frame
3 Countershaft frame
Figure 6-38 Countershaft frame
1. Coat the large diameter O-ring taken from the countershaft assembly into the frame hole as
package with clean grease and expand it onto deep as possible. Place the inner flange at the
the machined diameter at the small gear end of small gear end of the countershaft frame
the countershaft frame. See Figure 6-38. The temporarily on the sliding plate or the
O-ring can prevent oil leakage between the sliding plate frame. Put down a chain hook
countershaft frame and the main frame. from the inside of the main frame to lift the
2. Apply a long pipe around the pulley end of the small gear end of the countershaft frame and
countershaft to balance the small gear end simultaneously slide into the fit mechanism
weight much heavier than the assembly, as of the inner frame.
shown in Figure 6-39.
Note: If no long pipe can be used to balance
it due to space limitations, then push the

Item Name Item Name

1 O ring
2 Countershaft frame
3 Sling
4 Balance weight pipe
Figure 6-39 Countershaft assembly installation
5 Countershaft alignment flange
6 Main frame guide plate
7 Pinion

106
3. Use a crane or other appropriate lifting device
to carefully place the countershaft frame on the
guide plate of the main frame with the flanged,
and then slide the assembly inward as far as
possible.
4. Screw the three special hexagonal jack bolts
(taken from the toolkit) into the threaded holes
on the main frame through the screw holes on
the shaft frame flange with the interval of 120°
in accordance with the first step as shown in
Figure 6-40.
5. Interference fit is adopted between the two
flanges of the countershaft frame and the main
frame, so, to prevent stress unevenness, you
should tighten each jack bolt successively bit
by bit until the bolt has reached the bottom of
the threaded hole on the main frame.
Step 1
Step 2
107
6. Remove the jack bolt, add a gasket or spacer
between the jack bolt head and the flange as
shown in Step 2 (Figure 6-40) and tighten each
jack bolt bit by bit until it has reached the
bottom of the threaded hole.
7. Remove the jack bolts, use normal hexagonal
bolts and lock washers and fix the shaft frame
onto the main frame.
8. Take turns to tighten such bolts continuously to
press the countershaft frame into the main
frame until the shaft frame is closely pressed on
the outer flange and the main frame as shown in
Step 3 (Figure 6-40).
9. Place the countershaft frame fender onto the
countershaft frame, with the fender opening
aligned to the flange on each side of the
countershaft frame. See Figure 6-41.
Step 3
Item Name Item Name
1 Main frame 4 Gasket / washer
2 Jack bolt 5 Washer
3 Countershaft frame 6 Bolt
Figure 6-40 Press the countershaft frame in the main frame

6.5.1.2 Check the axial clearance

See Figure 6-42.
If a crusher is shipped as a whole, then its axial
clearance has be well calibrated in the factory, but
the axial clearance is very important to the normal
operation of a crusher, so it still should be checked
again to ensure that the countershaft can move in
and out freely. See the numerical values as provided
in Table 6-11.
Crusher
Axial clearance (clearance)
Dimensions
Item Name
HPT100 0.8mm(0.031″)-1.2mm(0.047″)
1 Countershaft frame fender
HPT200 0.8mm(0.031″)-1.5mm(0.062″)
2 Countershaft frame fender
HPT300 0.8mm(0.031″)-1.5mm(0.062″)
Flange cast on the side of the
HPT400 0.8mm(0.031″)-1.5mm(0.062″) 3
countershaft frame
HPT500 0.8mm(0.031″)-1.5mm(0.062″) 4 Countershaft frame
Table 6-11 Axial clearance Figure 6-41 Install the countershaft frame fender

108
 Item Name
1 Pinion
2 Countershaft bushing
3 Axial clearance
Figure 6-42 Axial clearance
6.5.2 Maintenance
6.5.2.1 Remove the countershaft frame
To replace the bush, small gear or any other
wear-out part, follow the steps below to remove the
countershaft frame and the countershaft:
1. Remove all oil pipes that may hamper removal
of the countershaft frame. Block or cover all
openings.
2. Remove the crusher pulley here as stated in the
part for removal of the crusher belt pulley in
order to protect the pulley against damages or
destruction during removal of the countershaft.
3. Remove the bolts to fix the countershaft frame
to the main frame.
109
Item Name
4 See Figure 6-11.
5 Compress
4. Mount the dedicated onboard jack bolts in the
three equally-spaced threaded holes on the
outer flange of the countershaft frame.
5. Tighten each jack bolt alternately bit by bit to
prevent stress unevenness on the frame.
Note: If the countershaft frame fits too tight, you can
first heat the main frame at the fitting surface outside
the countershaft frame. Have the frame shell heated
to 55℃ (100℉) higher than the environment
temperature.
6. Continue to screw the jack bolts until the
countershaft frame has separated from the main
frame.
7. Apply a pipe around the pulley end of the
countershaft to balance the assembly. Then use
 a crane or other appropriate lifting device to
remove the assembly (see Figure 6-39).
8. Remove the end cover or cover plate of the oil
slinger.
9. Have the oil slinger heated to about 27℃ (50℉)
higher than the environment temperature.
Warning!
Wear thick insulation gloves when
unscrewing the heated oil slinger.
10. Place a pinch bar between the oil slinger and
the countershaft frame with proper pressure
applied. Once the oil slinger starts to become
loose, hold both sides of the oil slinger and pull
it off directly from the shaft.
11. Pull out the countershaft assembly from the
shaft frame.
6.5.2.2 Small gear replacement
When removing the countershaft frame for checks or
part replacement, check the wear status or crushing
teeth of the small gear at the same time. If pitting or
chafing occurs on the tooth surface, it indicates
excessive wear. The reasons may be as follows: a
wrong number of spacers are placed under the lower
thrust bearing to result in poor contact between the
teeth; the crusher is overloaded, or too dirty oil is
used. The small gear wear will more easily lead to
crushing teeth. In addition, if a worn small gear is
used during operation, damages will happen to the
structure of other parts due to vibration. Any small
gear seriously worn should be replaced. To give full
play to the benefit of new parts, it is recommended
that you replace the gear and the small gear at the
same time, and if a new small gear is used together
with a gear already worn, you must check the root
clearance according to the requirements for “checks
110
of tooth clearance” in the section of the eccentric
bushing assembly. Follow the steps below to replace
the small gear:
1. Remove the countershaft assembly from the
countershaft frame. Put the countershaft on an
appropriate wood block.
2. To remove the small gear, lower the thermal
intensity of a cutting torch to heat the small
gear to about 100℃ (180℉) higher than the
environment temperature. Constantly move the
torch around the small gear and simultaneously
use a heavy wooden hammer to knock on the
small gear repeatedly. Once the small gear
starts to move, seize both sides of the small
gear and pull it out directly from the shaft.
Wear thick insulation gloves when handling the
small gear already heated.
3. To replace a new small gear, use a cutting torch
to heat it up to the temperature higher than the
environment temperature as specified in Table
6-14 or to about 215℃ (385℉) higher than the
environment temperature in an oil pool. When
the small gear is heated to the required
temperature, put it at the shaft end as quickly as
possible and push it onto the shaft so that the
shaft end could be aligned to the small gear
end.
Note: If the small gear gets stuck on the shaft
without motion due to cooling, use a cutting torch
to heat it again and simultaneously use a wooden
hammer to knock on it. Remember to
continuously move the torch around the small
gear to avoid heat concentration on one point.
 2. Take out the withdrawal tool for countershaft
bushing from the toolkit. See Figure 6-44.
3. Let the narrow part of the disc vertically go
through the countershaft bushing as indicated in
the figure. Turn the disc by 90° and have its
outer edge leaning against the countershaft
bushing.

Item Name
1 Small gear
2 Driving shaft
Alignment of the small gear end to the
3
shaft end
Figure 6-43 Small gear location

6.5.2.3 Remove the countershaft bushing

When a countershaft bushing needs to be replaced
due to wear, it should be loose in the countershaft
frame. Similarly in this case, the countershaft
bushing may easily slip out from the countershaft
frame, free of any difficulty. However, if the
manufacturing tolerance is the ultimate limit value,
the countershaft may have mild interference fit in
the shaft frame. If this happens, it will be more
difficult to remove the countershaft bushing. If the
countershaft bushing subject to a press fit gets stuck
Item Name
to the countershaft frame due to inadequate 1 Countershaft bushing
lubrication, crusher overload or overtemperature, Withdrawal tool for countershaft
2
follow the steps below to replace it: bushing
1. Remove the countershaft frame from the main 3 M24mm hexagonal nut
frame as stated in “Removal of the Have the center plate slide into the
4 countershaft bushing and turn it by
Countershaft Frame” and then remove the
90° so that it could be leaning against
countershaft from the countershaft frame.
111
 the countershaft bushing end.
Figure 6-44 Center disc
4. While positioning the tooling, take out the
double-thread screw (M24) from the toolkit and
mount it into the nut of the center disc.
5. Place a 25mm * 75mm * 305mm (1″×3″×1 2″)
flat steel bar at the other end of the screw rod
and use a hexagonal nut to fix it firmly.
6. Insert a long wood stick or steel pipe into the
other end of the countershaft frame to hit the
center disc. See Figure 6-45. If the bush is still
kept rather tight in the countershaft frame, push
it out by force as recommended and remove it
as shown in Figure 6-46. The steps are
specifically as follows:
Name
Item
1 Wood
2 Countershaft frame
Withdrawal tool for countershaft
3 7
bushing
4 Screw rod
112
7. Use the same center position as described
earlier in the same way, but the screw rod is
much longer than the flat steel bar, so place a
wood block between the steel bar and the
countershaft frame flange.
8. Use a threaded screw rod as a screw jack and
tighten the hexagonal nut until the bush flange
has been pulled to the steel bar.
9. Unscrew the hexagonal nut, add a cushion
block under the steel bar and tighten the
hexagonal nut until the countershaft bushing
has been pulled to the steel bar again.
10. If necessary, repeat Step 9 until the
countershaft bushing has detached.
Item Name
5 Flat steel
6 Countershaft bushing
Pin
Figure 6-45 Remove the countershaft bushing with a hammer
Item Name Item
Withdrawal tool for countershaft
1 4
bushing
2 Screw rod 5 Countershaft bushing
3 Cushion block
Figure 6-46 Push out and remove the countershaft bushing
Check 6.5.2.4 Check the countershaft bushing
before installation
Before a new countershaft bushing is installed,
check the bore diameter of the countershaft frame as
a precaution.
The countershaft bushing is machined in accordance
with the tightness of 0.03 mm (0.001″) to the
looseness of 0.065 (0.002″) for assembly. You
should check the bore inner diameter and the outer
diameter of the countershaft bushing to ensure that
their diameters meet such tolerances. If the
113
Name
Flat steel
interference size is greater than 0.030mm (0.001″),
the countershaft frame must be machined again, in
order to satisfy the limit requirement. Too much
interference will have the countershaft bushing
damaged or the inner bore become smaller, so that
the clearance between the countershaft and the
countershaft bushing will be narrower accordingly.
If it is found that the inner bore size is smaller than
the original, it usually results from overheating.
Check the straightness or radial runout of the
countershaft itself. The countershaft between the two
round holes should not have its total radial runout
more than 0.102 mm (0.004″), and if more than this bushing related the countershaft frame as
value, replace the shaft. follows:
When pressed in a too small inner hole on the
countershaft frame, the countershaft bushing may
get stuck to the shaft if the countershaft bushing
inner hole becomes smaller due to excessive
pressure or the countershaft has bent. If the shaft is
found distorted, abandon it and use a new one
instead.

6.5.2.5 Install the countershaft bushing

After overhauling, if the countershaft and the

countershaft frame can meet the relevant
requirements, then a new countershaft bushing can
be installed. If a loose fit is adopted between the
countershaft bushing and the countershaft frame, Item Name
you only need to slide the countershaft bushing into 1 Countershaft frame
and around the positioning pin, but you should 2 Countershaft bushing
3 Steel guide rod
determine the position of the oil groove in the inner
Figure 6-47 Install the countershaft bushing
hole as stated in Step 3. If interference fit occurs,
follow Step 4 to fill the new countershaft bushing
a. The longitudinal oil groove on the small
with dry ice and install it as follows:
gear end countershaft bushing of the
1. Remove the positioning pin on the flange
countershaft should be located at the top of
surface of the countershaft.
the countershaft, as shown in Figure 6-49.
2. Insert two steel bars identical to the pins in
b. The outer countershaft bushing of the
diameter into the holes of the two positioning
countershaft is usually installed at the
pins. The steel bar should be slightly longer
bottom together with the longitudinal oil
than the countershaft bushing.
groove as shown in Figure 6-49. However,
See Figure 6-47. The role of two steel bars is to
if the motor pulley is located under the
ensure that the holes of the countershaft
crusher, just under the crusher pulley or
bushing flange be aligned to the positioning
within the range of 45° at any side of the
pins on the countershaft frame.
crusher vertical centerline, its position will
3. The countershaft has two identical countershaft
be different as shown in Figure 6-49. Note:
bushings, but their positions in the inner holes
At this point, the countershaft outer
are not actually the same. Determine the correct
sleeve must be turned to the top center.
position of the oil groove on the countershaft
In this way, rotate the countershaft

114
 bushing and it can prevent the countershaft
pressing onto the oil groove.

Item Name 3 Motor pulley

1 Crusher vertical centerline Figure 6-48 Downward pull of the vertical driver
2 Crusher pulley

115
 Item Name
1 Pinion end countershaft bushing
The oil groove is located at the 12:00 o'clock position on the pinion countershaft
2
bushing.
In time of upward pull by horizontal or vertical drivers, the pulley countershaft bushing
3
is normally at the 6:00 o'clock position.
4 Oil groove
In time of downward pull by the horizontal driver, the pulley countershaft bushing is at
5
the 12:00 o'clock position.
6 Pulley countershaft bushing
7 Countershaft frame
Figure 6-49 Position of the countershaft bushing oil groove in the countershaft

116
4. Fill the countershaft bushing to be installed
with dry ice and keep it for 2-3 hours to have
the sleeve contract, so that it could be more
easily installed into the countershaft frame. The
two countershaft bushings of the countershaft
need about a total of 22 kg (50 lb).
Note: Coat the countershaft bushing with
several layers of insulating glass fiber to
prevent the outer wall from frosting, so that
the countershaft bushing could be more
easily installed into the countershaft frame,
which could also facilitate more thorough
cooling.
Warning!
Wear thickened gloves featuring good
heat insulation when handling the dry
ice; if not, serious burns will happen.
bushing for protection and knock it in place. In
this way, the guide bar functions significantly.
Note: Never knock it too fiercely because the
countershaft bushing may cock in the inner hole
of the countershaft frame to result in more
difficult installation.
7. Remove the guide rod and remount the
positioning pins originally removed.
6.5.2.6 Countershaft frame assembly
See Figure 6-38 and Figure 6-50.
When removing the countershaft frame assembly for
checks or parts replacement, it is suggested that you
replace the O-ring between the countershaft frame
and the main frame as well as the spacer or sealant
between the cover plate and the countershaft frame
at the same time.

Note: If the temperature of the crusher countershaft

In a few years, these parts may lose their elasticity
frame is 24℃ (75℉) or higher, ordinary ice can be
and compressibility necessary for effective sealing
used instead of dry ice. Measure the outer diameter
due to permanent deformation. The O-rings and
of the countershaft bushing and the inner diameter of
sealants are not rather expensive, so not worth
the countershaft frame to determine when the
unforeseen oil leakage.
countershaft bushing will been sufficiently cooled.
The procedure for assembly is opposite to that of
disassembly, with the differences as follows:
5. Use the steel bar inserted into the countershaft
frame as a guide rod to have the countershaft
1. Insert the countershaft assembly into the
bushing quickly slide into the inner hole of the
countershaft frame.
countershaft frame.
2. To fix the horizontal shaft steadily, you can
6. If the countershaft bushing has expanded only
arrange a big “C”-shaped clamp, so that the
when part of it has been installed in the inner
small gear could be fixed to the countershaft
hole due to slow operation, or if it can not be
frame flange as shown in Figure 6-51. You can
installed in place by means of thermal
also have the small gear leaning against a
contraction, you can place a piece of wood
strong supporting wall or similar upholders to
horizontally on the surface of the countershaft
fix the countershaft.

117
3. Heat the oil slinger to about 27℃ (50℉) higher 6. Before installing the transparent cover onto the
than the environment temperature and mount it countershaft frame, check to make sure that its
on the countershaft as soon as possible. two sides (which closely contact the sealing
4. If you encounter resistance, put a wood block ring) are smooth! If the surface is worn,
on the surface of the oil slinger and hit the machine and polish it.
block to force the oil slinger on the shaft. When
the oil slinger has been appropriately installed,
it should be closely leaning against the special
feeler on the surface of the countershaft
bushing. The feeler thickness or axial clearance
is shown in Figure 6-42 and Table 6-11.

Item Name
1 C-shaped clamp
2 Countershaft frame
3 Pinion
Figure 6-51 Fix the countershaft assembly

7. Before using bolts to fix the transparent cover

to the countershaft frame, place a gasket on the
surface of the countershaft frame. Then screw
the bolts into the threaded holes on the
countershaft frame through the cover plate
Item Name holes.
1 Countershaft frame 8. Mount the sealing ring at the outer side of the
2 Oil flinger transparent cover.
3 Transparent cover
4 Sealing ring
6.5.2.7 Oil leakage occurs at the drive end of
Figure 6-50 Oil flinger, sealing ring
the countershaft frame

5. When the oil flinger has been cooled to the

If oil leaks from the oil slinger cup plate at the drive
room temperature, mount the first sealing ring
end of the countershaft frame, then the inner and
on the countershaft with its lip outward and
outer sealing rings of the transparent cover may be
with the side closely against the oil flinger.
118
damaged or worn, and immediate replacement
should be needed. See Figure 6-50.
Check whether there is dirt in the long hole on the
countershaft frame under the countershaft. Dirt
build-up will limit the oil flow from the oil slinger.
Besides, if the oil can not be discharged from the
crusher as quickly as possible, oil leakage may also
occur, especially when the oil temperature is rather
low. The minimum gradient should be a 25mm (1″)
drop every 305mm (1 2″)-long oil drain pipe.
You should also check whether there is any obstacle
in the main oil discharge hose or pipe, for example,
there is dirt accumulated or the hose is flattened,
which may limit the oil flow.
119
Any one of the reasons described above can cause
oil flow back and oil leaking from the oil trap area.
6.5.2.8 Remove the crusher pulley
See Figure 6-52.
Follow the steps below to remove the crusher pulley:
1. Unscrew the hub clamping screws at first.
2. Insert a screw into the hub drain hole.
Warning!
If it is difficult to separate the pulley from the
removable hub, knock it gently with a hammer and
have the pressure maintained on the thrust screw.
 Item Name
1 Driving shaft
2 Key
3 Pulley taper sleeve
4 Belt Pulley
5 Decorative plate coupling bolt
6 Decorative plate of the countershaft pulley
7 Pulley tension screw
Figure 6-52 Pulley assembly

120

6.6 Main frame/support bushing
and iron release assembly
6.6.1 Overview
This Chapter includes the main frame, support
bushing and iron release device.
The main frame bolted on the foundation can
transfer the crushing force to the foundation, thus
providing a strong support for other crushing parts.
The main frame liner and stiffened plate welded or
bolted in the frame can be replaceable and can
prevent the frame inner wall wearing. There is a
deep chamber (balance ring protection chamber) cast
in the frame, so the balance ring can be fully isolated
from the outside to achieve reliable protection if
placed in. The balance ring protection chamber is
equipped with a replaceable fender around to
prevent the chamber from wearing during
production. See Figure 6-53.
121
Item Name
1 U seal ring
2 Balance ring
3 Balance ring protection chamber
4 Floating ring support
5 Floating sealing ring
6 Shaft aligning seat fender
Figure 6-53 Balance ring protection
The support bushing seated on the machined taper
surface at the top of the main frame has threads
tapped on its inner wall used to adjust the adjusting
ring assembly. The lock nuts supported on the
support bushing by a set of lock cylinders also have
threads tapped on the inner walls used to lock the
adjusting ring assembly in the support bushing at the
position for crushing operation.
There is a scraper seal provided on the top of the
support bushing used to cover the threads of the lock
cylinder and the adjusting ring to prevent dust and
dirt.
The hydraulic cylinder is installed at the bottom of
the main frame and bolted on the support bushing.
The hydraulic cylinder fixes the support bushing
firmly to the main frame, so that the normal crushing
force could be borne. When excessive stress occurs
due to improper operation or passing of uncrushable
materials, the support bushing will rise to pull the
piston rod in the hydraulic cylinder upward
accordingly, drain the oil in the hydraulic cylinder
into the accumulator and then compress the nitrogen
in the accumulator. Once the overload ends or the
tramp iron passes through the crusher, the crushing
force will become normal, the compressed nitrogen
will have the oil return to the hydraulic cylinder, the
piston rod will retract and the support bushing will
be seated again onto the main frame.
The main frame pin extending from the bottom of
the support bushing (depending on the size of the
crusher) can prevent the support bushing from
rotating and also can be used as a guide to have the
support bushing come back to its original place
when it rises or leans sideward.
The thrust bearing is bolted to the main frame
around the spindle seat to support the rotating
eccentric bushing. The base plate inserted under the
thrust bearing is used to determine the gear side and
top clearance of the big and pinions.
The double seal can effectively prevent dust
intrusion:
1. The floating sealing ring device equipped on the
balance ring protection chamber in the frame can
work effectively with the dustproof ball ring
installed under the moving cone to achieve good
sealing performance.
2. On the crusher, the two bronze bushes support the
countershaft. In the grooves around the main frame
gear well block, molded and non-metallic stationary
U-shaped sealing elements are set to form a
labyrinth seal together with the rotatory T-shaped
sealing elements at the bottom of the balance ring, to
prevent oil leakage and protect the big and pinions
as well as the bearing surface against dust intrusion.
The main shaft is firmly installed on the center hub
of the main frame to have the eccentric bushing turn
around it and support the ball bowl.
6.6.2 Assembly instructions
6.6.2.1 General rules
In most cases, the main frame, support bushing and
iron release parts have been assembled before
122
transportation. But in rare cases, such parts may
need to be disassembled due to transportation and
space limits. Refer to the part of maintenance in this
Chapter for the whole process of the main frame
parts assembly.
6.6.2.2 Crusher installation
6.6.2.2.1 Concrete foundation installation
If the main frame assembly or the whole crusher is
to be seated on a concrete foundation, the main
frame must be fixed by means of grouting.
Now there are two types of grouting materials
available, namely, concrete and epoxy fillers. Over
the years, concrete has been considered as the only
grouting material, but for most crushers recently
installed, the epoxy fillers have replaced the
concrete grouting. Due to the nature of the concrete,
a lot of preparation shall be made in advance,
including relevant equipment in most cases, so the
epoxy fillers have become more popular. As a kind
of viscous, elastic and aseismatic material, epoxy
fillers are separately barreled in different
specifications for sale, and each barrel contains
epoxy fillers and curing agents, which you can just
mix at the work site. Besides, simple use instructions
are provided on each barrel. If epoxy fillers are used,
no special equipment, preparation or treatment is
needed. The epoxy fillers once mixed must be
poured immediately, but the materials not mixed can
be mixed at any convenient time for continuous
pouring.
 Item Name
1 Crusher profile
2 Foundation
3 Epoxy filler grouting after the wood mould is removed
4 Bay bolt
5 Wood mould
Figure 6-54 Crusher grouting

Install the main frame assembly or the whole crusher

onto the concrete foundation or have the steel 2. Take care to lift the main frame and coat its
structure embedded into the concrete slab as shown flange bottom with a little oil to prevent epoxy
in Figure 6-54, with the operation steps as follows: fillers from getting stuck to the crusher.
1. Cut four large diameter gaskets from a 3. Place the upper frame on the 10 mm (3/8”)
10mm-thick (3／8″) steel plate and place them thick pad on the foundation.
on the foundation bolts. Hang an appropriate
sling on the lifting hook near the bottom of the
frame. See Figure 6-54.
Warning!
Never use lifting lugs on the adjusting cap to lift
the whole machine, because such lugs are not
strong enough to lift the whole crusher;
otherwise, serious personal injuries or crusher
damages will occur.

123
 the flange, have the mould kept close to the
Item Name foundation side and the bottom of the main
2 Sling frame flange. See Figure 6-53 for more details.
3 Main frame All mould plates should be coated with
4 Main frame hook
ordinary dewaxing for three times to prevent
Figure 6-54 Lift the crusher.
the battens from adhering to the grouting
materials. All joints and gaps must be sealed
Note: When concrete is used for pouring, the
with joint mixture to prevent epoxy fillers
main frame should have its four corners padded
flowing out in the case of full infusion.
with hardwood blocks but not steel rings; in this
6. Mix and pour the epoxy fillers as instructed on
case, the wood will contract together with the
the barrel. During operation at a low
concrete pouring materials. The main frame
temperature, heat the epoxy fillers and the
should be padded about 50mm~60mm (2″-l／2″)
crusher flange up to 18℃～27℃(65℉-80℉).
higher than the concrete foundation by means of
For the best effect, store the filler barrel where
wood blocks so that the concrete for pouring
it is warm enough before the materials are
could be thick appropriately. Have the
mixed. To have no air trapped under the crusher,
foundation surface with concrete mortar poured
an area of about 0.6 meters (2 feet) around each
kept rough and take care to clean the chamber
pouring spot should be covered before later
before pouring operation. This surface should
pouring continues from the spot where the
also be fully watered so that the water in the
pouring mixture has stopped flowing. Repeat
grouting mixture could not be absorbed quickly.
until the pouring operation has ended.
But the excessive water on the surface of the
Note: No more than one spot can be poured once
foundation should be drained before grouting.
when epoxy fillers are used either 12 mm or 20 mm
The grouting mixture containing unshrinkable
(1／2″ or 3／4″) in thickness.
additive should be used to reduce shrinkage as
See Table 6-17 for the average weight of the epoxy
much as possible.
fillers for crusher grouting.
4. Insert “C”-shaped gaskets around the
7. In time of pouring operation, if the foundation,
foundation bolts and at the top of the steel
crusher and epoxy fillers are all heated to
washer to level the crusher and leave a
2l℃(70℉), the epoxy fillers will harden in 6
12mm-20mm(1／2″-3／4″)-thick grouting
hours for next working procedure.
layer between the main frame and the
8. The pouring materials after hardened will fix
foundation, which is properly thick for use of
the crusher firmly to the foundation.
epoxy fillers.
5. Then, prepare a mould along the inner and
Crusher Required epoxy Kg *
outer circles of the main frame flange to
Specification 12mm(1／2") 20mm(3／4")
accommodate the epoxy fillers in time of
HPT100 35(77) 35(77)
pouring; such mould is made from
HPT200 45(99) 65(143)
25mm-50mm (1×2″) battens. Fix the battens at
HPT300 45(99) 65(143)
12mm(1／2″) outside the crusher flange and in
124
HPT400 45(99) 65(143)
HPT500 85(187) 130(286)
*The total amount includes the pouring layer beyond
12mm (1/2″) thick between the mould and the frame
flange. If the foundation is irregular, add 10% more.
Table 6-l2 Required epoxy grouting material
If the crusher is placed on a steel structure or trailer
chassis, the main frame should be fixed by adding
gaskets due to deformation or irregularity of the
steel structure or crusher frame.
Follow the steps below to install the crusher on a
steel structure:
1. Clear the welding slags and spatters at the top
of the steel structure and under the main frame
flange, and then rub down any welding spot
likely higher than the plane around.
2. Tie a sling on the lifting hook near the main
frame bottom as shown in Figure 6-54.
Never use lifting lugs on the adjusting cap to
lift the whole machine, because such lugs are
not strong enough to lift the whole crusher;
otherwise, serious personal injuries or
crusher damages will occur.
3. From a 6mm (0.25″)-thick steel plate, use a
cutting torch to cut four base plates identical in
shape or contour as the cushion blocks for the
machined surface of the main frame. In the
center of each base plate, there is a hole for a
foundation bolt going through to have the plate
engaged to the foundation bolt or steel
structure.
4. Take care to lift the main frame and place it on
the top of the four base plates on the steel
structure.
125
5. Insert a gasket with the shape identical to the
base plate in Step 3 to level the crusher. The
U-shaped notch on the gasket can keep it away
from where the foundation bolt is placed. The
machined surface of the whole main frame
flange can be evenly supported by means of the
gaskets different in thickness. Level the crusher
in two directions from the top of the main shaft.
6. When the gasket is properly positioned under
the crusher flange, fix the gasket on the steel
structure by means of spot welding so that it
could not move out due to vibration.
7. Once the crusher is leveled, measure the gap or
distance between the crusher frame flange and
the steel structure in the three areas as shown in
Figure 6-55; in such three areas, gaskets should
be added to strengthen the support between the
crusher frame and the steel structure. According
to the crusher specifications, the gasket
thickness should be different, its width should
be about the same as the main frame flange and
the length should be 400mm-915mm (16″-36″).
The base plates of 915rpm(36″) long are
usually adopted on HPT400 and HPT500.
8. When the gasket is properly positioned under
the crusher flange, fix the gasket on the steel
structure by means of spot welding so that it
could not move out due to vibration.
9. Have the crusher firmly fixed onto the steel
structure. The anchor bolts used should be long
enough to pass through the full depth of the
whole support beam (net length: 18″or longer).
10. After the crusher has been firmly fixed onto the
steel structure, check again whether the crusher
is kept level.
11. Check the tightness of the anchor bolts and
tighten again in one week, one month, six
 months and one year respectively after Note that welding will produce abundant heat, which
installation. will melt the rubber spring away from the steel plate
to result in damages. Avoid continuous welding, or
excessive heat will be produced.

Item Name
1 Square wood cushion
2 Gasket Item Name
3 Crusher main frame flange 1 Floating steel frame
4 Steel structure or trailer 2 Rubber spring
5 Bolt hole for crusher installation 3 Junction plate
Figure 6-55 Base plate location 4 Embedded steel plates
5 Steel rod
6.6.2.2.2 Installation of floating steel frame 6 Concrete foundation
foundation Figure 6-56 Rubber spring installation

To put a crusher equipped with a floating steel frame

6.6.3 Maintenance
on a concrete foundation, first embed a steel plate on
the concrete foundation, put the assembled floating 6.6.3.1 Main frame liner and stiffened plate

steel frame on the embedded steel plate on the See Figure 6-57.

concrete foundation and weld the junction plate and When stopping a crusher for liner replacement,

the embedded steel plate together after leveled. See check the wear status of the upper frame liner

Figure 6-56. and stiffened plate.

126
After the moving cone is removed from the crusher,
you can put the stiffened plate on the rib top of the
main frame from above. When the moving cone is
kept in situ, the stiffened plate can also slide in place
from below the crusher, but it's very difficult.
The spare main frame liner is usually divided into
several sections for shipment to simplify its
installation. To get a whole liner, its two sides must
be overlapped until the liner diameter has become
smaller than the inner diameter of the support
bushing thread. Use a heavy-load “C”-shaped clamp
to tightly fix the overlapped end sockets, then put
the liner into the frame and remove the clamp to
have the liner restore its original shape. By means of
the weld mark on the old liner, it is easy to see how
high the liner is welded into the frame. Only weld a
liner on the top.

Item Name
1 Main frame
2 Weld point on the main frame liner
3 Main frame liner
4 Stiffened plate
5 Floating sealing device
6 Temperature sensor
Figure 6-57 Main frame liner and stiffened plate

127
6.6.3.2 Replace the main shaft additional gasket should be placed on the top of
The main shaft rarely needs to be replaced. It is very the existing one. To install a new thrust bearing,
important to properly assemble the main shaft and remove the eyebolt from the old bearing and
the frame hub, so the main shaft should be install it on the new one. Put down the thrust
disassembled and installed by manufacturers’ bearing, ensure all holes are aligned to those on
representatives who are well trained and holding the main frame hub and confirm the bearing
suitable equipment. contacts with the gasket correctly.
7. Place a new spring washer on each hole of the
6.6.3.3 Replace the lower thrust bearing and thrust bearing. Insert bolts through the spring
base plate washer, lower the thrust bearing and gasket and
See Figure 6-58. put the bolts in the threaded holes on the frame.
Then tighten each hexagonal bolt alternately bit
Follow the steps below to replace the damaged or by bit until all are completely tightened.
worn lower thrust bearing or add a base plate to
restore appropriate top and side clearance of the big
and pinions:
1. To replace the thrust bearing, first dismount the
adjusting ring, moving cone, ball bowl and
eccentric bushing assemblies in accordance
with the instruction in relevant sections for
removal of such assemblies.
2. Remove the bolts and spring washer to fix the
thrust bearing to the main frame.
3. Screw a lifting bolt respectively into the two
threaded holes on the thrust bearing.
4. Hang the lifting bolts on a suitable lifting
device and lift the thrust bearing carefully
above from the main shaft.
5. Check the thrust bearing and its base plate for
replacement and make sure that no burrs or Item Name
abnormal edges occur and place the bearing or 1 Lower thrust bearing
base plate horizontally on the main frame with 2 Inner hexagonal bolt
3 Spring gasket
the surface in full contact.
4 Base plate
6. Refer to the part of “Check the Gear Top and
Figure 6-58 Lower thrust bearing assembly
Side Clearance” in the section for eccentric
bushing assembly to determine the right
number of the gaskets to be assembled. Any

128

6.6.3.5 Sealing element replacement
See Figure 6-59.
The U-shaped sealing element at the gear groove on
the frame usually will not contact or wear. However,
it is very important to replace such sealing element if
damaged in any way. This sealing element is used to
prevent oil leakage and protect the precision
machined surfaces of the big and pinions and
bearings against harmful dust. Follow the steps
below to replace the sealing element:
5. Coat the bottom of the seal groove on the main
frame with a small amount of curing agent
enough to ensure that the extrusion output is as
little as possible.
6. After coated with adhesive, mount the sealing
element into the seal groove as quickly as
possible to keep sufficient strength at its bottom
and have its seal groove bottom closely pressed,
which will take about 3 minutes.

1. Remove the damaged sealing element and clear

anything adhesive in the seal groove. Use a
sharp scraper knife or rigid putty knife to cut
off the sealing element and scrape off the old
adhesive from the groove.
2. Use non-oily solvent (alcohol or acetone) to
clean the seal groove thoroughly and have it
dried.
3. Take out a new “molded” sealing element from
the shipping carton and use a sandpaper to
thoroughly roughen the element bottom to
remove the shining surface layer before bonded
and fixed. In the process of manufacturing, the
sealing element is coated with a layer of release
agent to facilitate its demoulding. In order to
make the sealing element firmly stick to the Figure 6-59 Replace the sealing element
adhesive and in the groove of the main frame,
such layer of release agents must be fully 6.6.3.4 Replace the main frame pin.
cleared. See Figure 6-60.

Note: If the release agents are not completely
cleared, the sealing element will become loose
during operation.
4. Apply a thin layer of curing agent at the bottom
of the sealing element. Too much curing agent
will lead to local curing and cementation.
The main frame pin is used to prevent the support
bushing rotating relatively to the main frame. In
addition, the main frame pin also can be used as a
guide to have the support bushing come back to its
original place when it rises because the crushing
chamber has miscellaneous iron passing through or

129
is plugged with materials. It is abnormal for the
support bushing to jump up repeatedly, but the
sleeve usually can return to normal by means of
proper material distribution and adjustment of the
crusher discharge port. The improper operation
(excessive support bushing movement) will have the
frame pin worn and elongate the hole on the support
bushing or frame pin bush. Check around the bottom
frame pin of the support bushing and you can find
the wear status. The moving cone rotation is related
to the adjusting ring, so the support bushing will
rotate with the machine, which only functions on the
support bushing along the same direction, so that the
main frame pin and the pin hole or pin bush on the
support bushing could have one side tend to be
worn.
Follow the steps below to replace the worn frame
pin:
1. Release the pressure of the safety cylinder to
ensure that the zero pressure appear on the
pressure gauge in the release-charging circuit of
the crushing chamber.
2. Unscrew the spherical nut at the top of the
support bushing from above the piston rod of
the safety cylinder. This nut is coated with
anaerobic adhesive, so it should be heated to
about 205℃(400℉) before unscrewed.
3. Fix all safety cylinders on the outer ring of the
main frame.
4. Use a crane or other suitable lifting equipment
to lift the support bushing assembly (including
the lock nut and lock cylinder) so that it could
separate from the main frame.
5. Remove the bolt from the top of each pin to be
replaced.
6. Use a cutting torch to heat the taper pin seat
and simultaneously knock at the worn pin out
130
from the bottom of the support bushing or cut
open the pin center, heat its seat and force the
pin out.
7. Place the cone pin for replacement in dry ice
for about two hours before installation.
Warning!
Wear thickened gloves featuring good heat
insulation when handling the dry ice; if not,
serious burns will happen.
8. Use a cutting torch to heat the support bushing
about 10 minutes before installed. Then insert
the cold pin upward into the support bushing as
quickly as possible and tap the pin until it is
seated on the bottom of the flat base
chambering. Reinstall the screws and washers.
9. Install the support bushing assembly on the
main frame. Coat the support bushing with
NLGI No.1 lithium-base grease mixed with 3%
molybdenum disulfide powder.
10. Reinstall the spherical nut of the safety cylinder
according to the method for installation of the
iron release or crushing chamber safety
cylinder as introduced in the rear part of this
Chapter.
11. Pressurize the safety cylinder again.
 anaerobic adhesive, so it should be heated to
about 205℃ (400℉) before unscrewed.
3. Fix all safety cylinders on the outer ring of the
main frame.
4. Use a crane or other suitable lifting equipment
to lift the support bushing assembly (including
the lock nut and lock cylinder) so that it could
separate from the main frame.
5. Remove the bottom fixing ring from the pin
bush groove.
6. Tap to remove the worn pin bush and
simultaneously use a cutting torch to heat the
pin seat of the main frame.
7. Place the pin bush for replacement in dry ice
for about two hours before installation.
Warning!
Wear thickened gloves featuring good heat
insulation when handling the dry ice; if not,
serious burns will happen.

Item Name
1 Bolt and lock washer
2 Support bushing
3 Taper pin 8. Before installing the pin bush, use a cutting
4 Main Frame torch to heat the frame pin seat about 10
5 Pin bush minutes. And then insert the cold pin bush into
Figure 6-60 Replace the taper pin
the pin seat hole as quickly as possible with the
pin bush flange contact with the pin seat.
9. Install the fixing ring at the base of the bush.
6.6.3.5 Replace the pin bush of the main frame
10. Install the support bushing assembly on the
See Figure 6-60.
main frame. Coat the support bushing with
NLGI No.1 lithium-base grease mixed with 3%
Replace the pin bush of the main frame as follows:
molybdenum disulfide powder.
1. Release the pressure of the safety cylinder to
11. Reinstall the spherical nut of the safety cylinder
ensure that the zero pressure appear on the
according to the method for installation of the
pressure gauge in the release-charging circuit of
iron release or crushing chamber safety
the crushing chamber.
cylinder as introduced in the rear part of this
2. Unscrew the spherical nut at the top of the
Chapter.
support bushing from above the piston rod of
the safety cylinder. This nut is coated with
131
6.6.3.6 Main frame seat

6.6.3.6.1 Overview
Check the wear status of the main frame seat on a
regular basis. The crusher feeding is of irregularity
and the support bushing suffers from slight friction
with the main frame seat, so certain wear is
somewhat inevitable. If the support bushing is
subject to excessive movement, more serious wear
may occur. Each standard HPT cone crusher has its
frame welded with a bronze main frame liner as
shown in Figure 6-61. Taking the bronze alloy as the
contact surface of the crusher support bushing can
offer a replaceable wear surface. The bronze alloy is
softer than the metal of the frame and support
bushing, so only this liner will be worn if any.
Item Name
1 Bolt and spring washer
2 Support bushing
3 Measure this distance.
4 Main Frame
5 Pin bush
6 Taper pin
7 Copper liner
Figure 6-62 Mark the pin hole flange to
determine the wear status of the installation
surface.

Follow the procedures below to accurately

determine the wear status of the frame copper liner:
1. From the first main frame pin on the left of the
countershaft frame forward clockwise, paint or
mark 1, 2, 3, 4, 5 and 6 or 1, 2, 3 and 4 (subject
to the number of frames) on the surface of the

Item Name support bushing or the main frame pin hole.

1 Copper liner 2. As shown in Figure 6-62, measure the distance
2 Seat surface between the support bushing and the flange of
3 Main frame the main frame pin hole. Write it down.
Figure 6-61 Main frame seat surface

132
3. Measure these points regularly and compare the
results with the distance. Compare two
measurement results and you can see whether it
is evenly worn. Due to casting and machining
errors, this is the only method for accurate
determination of the wear status.
4. When any measurement result has reached the
numerical value as listed in Table 6-13, the
copper liner needs to be replaced.
In time of regular checks, when the difference value
is equal to or greater than 6mm (1／4″) between two
checkpoints, it shows that the copper liner has had
one side worn to have the support bushing slantly
seated on the main frame due to feeding
concentration on one area in the crushing chamber,
so that the impact of the support bushing has been
increased on the frame seat to result in excessive
wear of the copper liner accordingly. If the
difference value between two checkpoints has
changed from 6mm(1/4″) to 10mm(3/8″), the main
frame should have its copper liner replaced.
To solve this problem, you should adjust the crusher
feeding configuration to have the feeding into the
crusher evenly distributed around the crushing
chamber as mentioned in Chapter 2.
Note: Before a copper liner is mounted to an old
crusher with no liner provided, the matching surface
between the frame and the support bushing should
be restored to its original status.
Crusher
Minimum value
specifications
HPT100 7mm(0.28″)
HPT200 12mm(0.5″)
HPT300 20mm(0.79″)
133
HPT400 20mm(0.79″)
HPT500 20mm(0.79″)
Table 6-13 Copper liner wear
6.6.3.6.2 Install the frame copper liner
Follow the steps below to install the copper liner:
1. Release the pressure in the safety cylinder as
instructed in previous sections about pressure
release in the attachment of the hydraulic
system.
2. Unscrew the spherical nut at the top of the
support bushing from above the piston rod of
the safety cylinder. This nut is coated with
anaerobic adhesive, so it should be heated to
about 205℃(400℉) before unscrewed.
3. Fix all safety cylinders on the outer ring of the
main frame.
4. Use a crane or other suitable lifting equipment
to lift the support bushing assembly (including
the ring and lock cylinder) so that it could
separate from the main frame.
5. Disassemble the old copper liner.
6. Fix the copper liner to the main frame seat by
means of sequence welding, but never butt the
vertical joints. Adopt spot and full welding
respectively to the top as well as the slotted and
vertical joints (see Figure 6-63). Preheat the
main frame and seat liner to be welded
respectively up to 20℃(70℉) and 40℃(100℉),
which can surely eliminate all moisture to
achieve correct weld penetration. Please use
such welding rods as AMPCOTRODE 10.
7. Install the support bushing assembly on the
main frame. Coat the support bushing with
NLGI No.1 lithium-base grease mixed with 3%
molybdenum disulfide powder.
8. Reinstall the spherical nut of the safety cylinder
according to the method for installation of the
iron release or crushing chamber safety
cylinder as introduced in the rear part of this
Chapter.

Figure 6-63 Welding

134
6.6.3.7 Remove the iron release or crushing
chamber safety cylinder
See Figure 6-65 and Figure 6-64.
Immediate attention shall be paid to the leakage of
the hydraulic cylinder, because the support bushing
may suffer from excessive movement no matter
whether the oil leakage occurs around the piston rod
of the hydraulic cylinder or outside the end cover
seal or on both sides of the pistons in the hydraulic
cylinder. The external oil leakage can be seen
around the piston rod at the top of the hydraulic
cylinder or the joint between the hydraulic cylinder
and its end cover. Either external or internal oil
leakage will be displayed on the pressure gauge of
the crushing chamber release system. If the system
pressure requires repeated pressurization due to
pressure drop, then oil leakage should have
happened. Follow the steps below to remove the
hydraulic cylinder for replacement or repair:
1. Cut off the power supply of the hydraulic
power unit motor to stop the motor and then
release the pressure according to the
requirements in the section of pressure release
in “Hydraulic System manual”. Force the
pressure oil at the accumulator side of the
hydraulic cylinder back into the oil tank to
ensure that the crushing chamber
release-pressurization circuit have its gauge
pressure reach zero.
Warning!
Never attempt to remove any hydraulic joint
under any circumstance before you can confirm
the system has had its pressure released. The
ejective oil has a fast speed and the free end of the
swinging hose may cause collision, so it is
dangerous to disconnect any high-stress hose.
135
2. Remove the crushing chamber
release-pressurization circuit hose connected to
the top of the safety cylinder and the chamber
cleaning circuit hose installed at the bottom of
the hydraulic cylinder. Add covers or pistons to
all pipe fittings and hoses.
3. Connect the hydraulic cylinder to be replaced
with a suitable lifting device by means of a
sling.
4. Unscrew the spherical nut at the top of the
support bushing from the piston rod. This nut is
coated with anaerobic adhesive, so heat it to
about 205℃ (400℉) before unscrewed.
5. Remove the split cotters from both sides of the
pin bolt at the bottom fork lever of the
hydraulic cylinder.
6. The pin bolt adopts mild clearance fit in fork
lever. Use a hammer to tap the pin bolt of the
fork lever out from the side most convenient.
Never tap the pin bolt directly; otherwise, the
pin bolt end will become mushroom and can
not be removed any more. Align a circular steel
or brass rod to the pin surface. Then tap the rod
until the pin bolt has been forced out.
7. After the piston rod has been drawn out from
the hole of the support bushing, lift the
hydraulic cylinder and the accumulator away
from the crusher. Take care not to damage any
hose or pipe fitting.
8. See the “Hydraulic System manual” for
reinstallation instructions of the iron release or
chamber cleaning hydraulic cylinder.
 Item Name
1 Support bushing
2 Iron release circuit
3 Oil discharge circuit
4 Fork lever pin bolt
5 Hexagonal nut
6 Round knurled nut
7 Safety cylinder
8 Accumulator
9 Main frame reinforced rib
10 Piston rod
Figure 6-64 Iron release assembly

136
 Item Name
1 Piston rod
2 Support bushing
3
4 Safety cylinder
5 Regular hexagonal nut
6 Round knurled nut
Figure 6-65 Hydraulic cylinder piston end
coupling

6.6.3.8 Install iron release or crushing chamber

safety cylinder
See Figure 6-65 and Figure 6-64.
Follow the steps below to install a new or repaired
hydraulic cylinder:
1. Push the piston rod downward and push the
piston to the bottom of the hydraulic cylinder.
2. Screw the round knurled nut on the piston rod.
And then, turn this nut downward to the bottom
of the piston rod thread.
3. Use a lifting device to lift the hydraulic
cylinder vertically to have the piston rod end
upward. Let the piston rod upward through the
hole of the support bushing and lift the
hydraulic cylinder. Install the smooth plug rod
and pin.
4. Check the pin bolt of the fork lever and remove
the burrs or scratches (if any) on the machined
outer surface.
5. Align the main frame to the pin bolt hole of the
fork lever. Coat the pin bolt with oil and then
use a hammer to tap the round steel or brass rod,
so that the pin bolt could be forced into the fork
lever and the main frame. Mount a split cotter
on the pin bolt.
6. Make sure that the piston rod has reached the
bottom of the hydraulic cylinder. Measure the

137
 distance from the top of the support bushing to
the top of the piston rod.
7. Mount a spherical gasket on the piston rod,
screw the hexagonal nut on the piston rod and
then pull the piston rod out from the hydraulic
cylinder at the length as shown in Table 6-14.
When the piston rod has been pulled out to the
required length from the hydraulic cylinder,
remove the hexagonal nut from the piston rod.
8. Use non-oily solvent (alcohol or acetone) to
clean the 100mm (4″) threads at the top of the
piston rod. Then, use a clean brush to coat the
screw thread with anaerobic adhesive.
Crusher
Set value
specifications
HPT200 12mm(1/2″)
HPT300 23mm(1″)
HPT400 25mm(1″)
HPT500 25mm(1″)
Table 6-14 Pull-out distance of the piston rod
9. Screw the hexagonal nut on the piston rod until
it has touched the spherical gasket.
10. Review the distance from the top of the support
bushing to the top of the piston rod. The
measurement results must be kept in the range
as given in Step 7 and Step 8.
11. Use non-oily solvent to clean the piston rod
thread under the support bushing. After
cleaning, coat the piston rod thread with
anaerobic adhesive 242 at 20 mm (0.79″) away
to the bottom of the support bushing. Then
screw the round knurled nut towards the top of
the piston rod until the distance has reached 20
mm (3/4″) between the top of the round knurled
nut and the bottom of the support bushing.
138
12. Connect all hoses of the hydraulic power unit
and the accumulator.
13. After the hydraulic cylinder has been installed
with all joints connected, exhaust the air
trapped in the system. Then, pressurize the
system and check whether any leakage occurs.
See the Hydraulic System manual for system
exhaust, inflation and checks instructions.
14. After the iron release circuit has been
pressurized, check the distance between the top
of the round knurled nut and the bottom of the
support bushing as required in Step 11. If the
distance is not correct, decompress the circuit.
Adjust the lower hexagonal nut so that it could
reach the exact set value. Then, pressurize the
circuit, check the distance again, and if
necessary, adjust it again.
6.6.3.9 Replace the accumulator
See Figure 6-66.
For any defective accumulator, whether nitrogen
leaks into the atmosphere or inner leakage occurs, it
should be a serious condition in need of immediate
attention. In either case, the accumulator will be
filled with oil. Moreover, the iron release device will
not work properly because the gas or precharged gas
has run away or left out from the tank.
When anything unable to be crushed or overload
occurs, the hydraulic oil squeezed into the
accumulator from the iron release safety cylinder
thus cannot compress the nitrogen in the tank of the
accumulator, so that excessive crushing force will be
produced in the crushing component.
The precharging pressure of the accumulator should
be checked once every 200 hours (1 month). The
accumulator should be removed and replaced if its
gas pressure is not kept at the normal level of
precharging or can't maintain the recommended
pressure level for normal operation. Follow the steps
below to replace the defective accumulator:

1. Cut off the motor power of the hydraulic power

unit to stop the motor and then release the
pressure according to the requirements in the
section of pressure release in “Hydraulic
System manual”. In this way, the hydraulic oil
at the accumulator side of the hydraulic
cylinder can then be forced back into the oil
tank to ensure that the crushing chamber
cleaning-pressurization circuit have its gauge
pressure reach zero.
Warning!
Never remove any hydraulic joint under any
circumstance before you can confirm the
system has had its pressure released, because Item Name
the leaking oil has a fast speed and the free Accumulator press frame bolted on the
1
end of the swinging hose may cause collision. main frame
2 Accumulator clamping piece
3 Accumulator
4 Big oil distributor
Figure 6-66 Replace the accumulator

2. Remove the valve protection plug from the top

of the accumulator. Remove the aerator/tester
to ensure its bottom coupler matches the
accumulator valve. Loosen the knurled knob on
the aerator/tester completely and confirm that
the vent plug is shut off. Use the knurled knob
at the bottom of the aerator/tester to screw the
aerator/tester onto the accumulator. Screw the
knurled knob onto the aerator/tester.

Remount the valve protection plug and open the

vent screw until nitrogen gas has been
completely discharged (with the pressure gauge
139
 reading displayed as “0”). Remove the
aerator/tester.
3. Remove the hexagonal nut of the clamp piece
on the accumulator housing, lock the washer
and bolt, and then, again remove the clamp
piece on the clamp frame of the accumulator.
Apply a sling around the accumulator and
connect the sling to an appropriate lifting
device.
4. Mount a big pipe or adjustable wrench on the
top joint of the accumulator and turn the
accumulator clockwise until it can be easily
removed.
5. Apply appropriate thread sealant on the pipe
joint thread and the internal thread of the
accumulator repaired or to be replaced. Then,
screw the pipe joint into the accumulator.
6. Take great care when the accumulator and pipe
joint for replacement are close to the big oil
distributor. When screwing the accumulator
coupler into the thread joint of the big oil
distributor, have the accumulator kept vertical
and never have the screw threads dislocated.
Then, tighten it completely.
7. Install the supporting structure and accessories.
8. Precharge the new accumulator as instructed in
“Hydraulic System manual”. If pressure is
applied before nitrogen is correctly precharged,
the accumulator may be damaged.
9. After the accumulator has been installed with
all joints connected, exhaust the air trapped in
the system, then pressurize the system and
check whether any leakage occurs.
6.6.3.10 Remove the lock nut
Follow the procedures below to remove the lock nut
for parts checks or replacement:
140
1. Remove the adjusting ring as stated in the
section “Remove of the Adjusting Ring”.
2. Remove the lock nut hexagonal head bolt and
locking nut. Screw this bolt through the lock
nut to the top of the support bushing, in order to
prevent the lock nut accidentally rising during
removal of the adjusting ring and
simultaneously protect the lock cylinder against
damages due to compression when the
adjusting ring assembly is not installed in place.
3. Make sure that the locking circuit has been
decompressed and then remove the hose
between the first lock cylinder and the support
bushing bend.
4. Screw the lifting bolt into the top of the lock
nut and use a suitable lifting device to lift the
lock nut and the lock cylinder out of the support
bushing.
5. At this time, you can remove any or all
cylinders from the lock nut for repair or
replacement. Disconnect the hoses at both sides
of the hydraulic cylinder, remove the
countersunk head positioning screws to fix the
hydraulic cylinder and then take out the
hydraulic cylinder from the lock nut.
6.6.3.11 Install the lock nut
Follow the method below to mount the lock nut onto
the support bushing:
1. Thoroughly clean the lock nut, adjusting ring
and support bushing threads. Clean the hole on
the lock nut for installation of the lock cylinder
and polish the burrs (if any).
2. As shown in Figure 6-67, install the lock
cylinder into the hole of the lock nut. Install the
check ring at the right position on the lock
cylinder and connect the hose.
3. Screw the lifting bolt into the threaded hole at
the top of the lock nut. Fasten a sling between
the eyebolt and the appropriate lifting device to
lift the lock nut above the support bushing. See
Figure 6-68.
4. Turn the lock nut to have the oil pipe hole on Item Name
the lock nut aligned to the corresponding hole 1 Locking cylinder
on the support bushing. 2 Check ring
3 Locknut
4 Support bushing
Figure 6-67 Installation of lock cylinder

141
Item Name Item Name
1 Locknut 6 Locking cylinder
2 Sling 7 Lifting Eye
3 Lock nut stop screw 8 Sling
4 Washer 9 Oil pipe hole
5 Support bushing 10 Lock cylinder hole
Figure 6-68 Holes for alignment markers

5. Place the lock nut slowly on the support cylinder is pressurized, the lock nut should be
bushing. Make sure that the lock cylinder has able to move vertically.
already had its pressure released.
6. Insert the lock nut stop screw into the lock nut
hole and screw it into the support bushing.

Keep a proper clearance as shown in Figure

6-69 between the screw head and the lock nut
top. A clearance must be left between the screw
head and the lock nut top. When the lock

142
 ring is installed into the machine, for HPT400
and HPT500 crushers, increase the system
pressure to the maximum pressure 19.5 Mpa
(195 bar), hold it for 10 minutes and check
whether any lock cylinder or hose coupler
suffers from leakage.
8. Use a cloth filled with molybdenum disulfide
powder to scour the lock nut, adjusting ring and
support bushing screw thread surfaces, so that
the metal surface could be coated with a layer
of lubricant film to have the adjusting ring able
to rotate more freely. The threads for the first
time have been coated with molybdenum
disulfide by the manufacturer.
9. Coat the threads with plenty of lubricant – a
mixture of grease and 5-10% (by volume)
molybdenum disulfide powder.

Note: When crushing sinter and slag or

Item Name other similar materials, you should use a

1 Lock nut stop screw kind of high-temperature resistant grease
2 Clearance mixed with 5-10% (by volume) molybdenum
4 Lock nut disulfide power.
5 Support bushing
Figure 6-69 Installation of stop screw 10. Install an adjusting ring in the crusher as stated
in the section “Remove of Adjusting Rings”.
7. Connect the first lock cylinder and the bend on Release the pressure in the lock cylinder
the support bushing by means of a hose, (loosen the lock cylinder) before installation.
through which all lock cylinders can be
connected to the hydraulic power unit. See
Figure 6-70.
After the hydraulic cylinders and hose couplers
have been assembled but before the adjusting

143
 Item Name
1 Locking cylinder
2 90° bend
Pipe hole on the support bushing for connection of the lock cylinder with
3
the hydraulic power unit
4 No. 1 hydraulic cylinder
5 Hose
6 Support bushing
7 Tee joint
Figure 6-70 Lock cylinder hose coupling

144
Chapter 7 Hydraulic system
7.1. Overview
All HPT cone crushers are equipped with iron
release or crushing chamber hydraulic release and
chamber cleaning systems. The hydraulic cylinder is
connected to the lower part of the main frame and
fixed with the support bushing, so that the support
bushing could steadily contact with the main frame
to overcome the normal crushing force. When
excessive crushing force occurs due to abnormal
operation or passing of uncrushable materials (iron),
the support bushing will rise to pull the piston rod in
the hydraulic cylinder upper to rise accordingly,
force the oil in the upper half chamber of the
hydraulic cylinder into the accumulator and then
compress the nitrogen in the accumulator. Once the
overload disappears or the tramp iron passes through
the crusher, the crushing force will become normal,
the compressed nitrogen will have the hydraulic oil
return to the hydraulic cylinder, the piston rod will
retract and the support bushing will be seated again
onto the main frame. In order to clean the crusher
chamber, the lower half chamber of the hydraulic
cylinder should be pressurized to push its piston rod
upward to force the support bushing away from the
main frame.
In addition to hydraulic cylinder release and
chamber cleaning, the crusher is also equipped with
adjusting ring hydraulic lock and adjustment
systems. A series of locking hydraulic cylinders
between the lock nut and the support bushing can
support the lock nut at the upper part of the support
bushing to ensure that the adjusting ring could be
located at the crushing position in the support
bushing when the hydraulic cylinder is pressurized
145
in the process of crushing. When the locking
hydraulic cylinder has had its pressure reduced, the
motor installed in the support bushing will start, and
the gears on the motor will have the adjusting gear
disc meshed with the adjustment cap so that the
adjusting ring assembly could rotate to automatically
adjust the size of the crusher discharge port.
All HPT cone crushers are equipped with a
hydraulic power unit to control all their hydraulic
functions.
7.2. Operation of the hydraulic
power unit
When a crusher is in operation, the hydraulic power
unit must be in its working state to maintain the
locking pressure and pressurize the iron release or
crushing chamber safety cylinder to press the
support bushing onto the main frame.
Refer to the hydraulic system manual and the
operation instructions in Chapter 7 Crusher
Adjustment, Chamber Cleaning and Adjusting Ring
Disassembly and Installation.
7.2.1 Hydraulic oil characteristics
Hydraulic locking and adjustment mechanisms must
use chain alkyl (rather than naphthenic base)
high-grade industrial oil with the viscosity as
required; this kind of oil features higher oil film
strength, stronger adhesion to metal surfaces and
stable physical and chemical properties. All
lubricants must have a high viscosity index, able to
quickly separate from water, produce no bubbles and
prevent part rust and corrosion, with antioxidant and should be maintained at the central part of the
anti-wear additives contained. glass window on the oil level gauge.
The ISO 32 lubricating oil is practical for use. About 100 liters (26 U.S. gallons) should be needed
The viscosity of the oil must be: in the fuel tank of the hydraulic power unit, iron
20-40cSt (Centistokcs) at 40℃; 6cSt or higher release safety cylinder, accumulator, lock cylinder
at 100℃ and coupling hoses.
Or:
135-165SUS (Saybot, UnwcrsaI Seconds) at
100℉; 45SUS or higher at 210℉.
In addition, the oil viscosity index should be 140 or
higher.

The lubricating oil in accordance with the

above-mentioned conditions is extremely necessary
for protection of the crusher during operation. This
kind of lubricating oil can be available from all big
oil companies. Improper lubricating oil will damage
and disable any warranty to your crusher.
Note: Never use any flame resistant hydraulic agent
because the hydraulic system is not so designed to
use such agent.

Note: The housing, sealing elements, accumulator

tank, hoses and other components in the
hydraulic system may not be suitable for use of
any flame resistant hydraulic agent. If such agent
is used, the oil pump will have a shorter service
life and the oil tank inside coating will become Item Name
soft and fall off. 1 Positioning screw
2 Locking cylinder
3 Locknut
Note: When the hydraulic cylinder and pipelines
4 Support bushing
are filled with oil or drained for the first time, the
Figure 7-1 Installation of lock cylinder
hydraulic oil in the tank of the hydraulic power
unit will be pumped out, so enough hydraulic oil
should be filled to ensure that the oil level can be 7.2.2 Locking hydraulic cylinder assembly
seen in the oil level gauge. After the system has
been refilled with oil or drained and after the
When installing the locking hydraulic cylinder,
release system has been pressurized, the oil level
please refer to “Instructions for Lock Nut
146
Installation - HPT200 / HPT300 / HPT400 /
HPT500”, “Main Frame, Support bushing and Iron
Release Assembly” in Chapter 5 as well as Figure
7-1 and Figure 7-2.
Item Name
1 Locking cylinder
2 90° bend
Pipe hole on the support bushing for
3 connection of the lock cylinder with the
hydraulic power unit
4 No. 1 hydraulic cylinder
5 Hose
6 Support bushing
7 Tee joint
Figure 7-2 Lock cylinder hose coupling
7.2.3 Hydraulic adjusting mechanism
assembly
It is rather rarely seen to repair hydraulic drive
assembly. In view of the component complexity in
the hydraulic drive assembly, only manufacturer’s
representatives after proper training can remove,
replace, adjust and reinstall the components by
means of special tools as required.
147
7.2.4 Hydraulic hose and crusher
coupling
See Figure 7-3.
Once the hydraulic power unit is installed in place,
mount the hydraulic adjusting mechanism on the
crusher, connect the hoses with the hydraulic motor,
lock cylinder and crushing chamber safety cylinder,
and then follow the steps below to connect the
crusher.
The six hoses from the hydraulic power unit are all
the same.
To facilitate connection of the hoses among the
hydraulic power unit, crusher and hydraulic motor,
the manufacturer has clearly marked all outlets and
hose couplers with such numbers as 1, 2, 3, 4, 5 and
6.
1. Connect the hose coupler for down adjustment
of the discharge port on the hydraulic power
unit with the outlet on the right of the hydraulic
motor.
Note: In the process of connection, protect the hoses
and couplers against any dirt.
2. Connect the hose coupler for up adjustment of
the discharge port with the outlet on the left of
the hydraulic motor.
3. Connect the brake release hose from the
corresponding coupler on the hydraulic power
unit to the outlet of the brake above the
hydraulic motor.
Note: Check whether the hydraulic pipelines to
the hydraulic motor and the brake are so
properly located that no impact occurs on any
other moving part.
4. Connect the lock cylinder hose from the
corresponding coupler on the hydraulic power
unit to the screw hole on the support bushing.
5. Connect the chamber cleaning circuit hose
from the corresponding coupler on the
hydraulic power unit to the chamber cleaning
circuit on the oil distributor of the crusher. This
Item Name
1 Big oil distributor
2 Hydraulic Cylinder
3 Chamber cleaning oil-way interface
4 Safety pressurization interface
5 Accumulator
Figure 7-3 Safety cylinder coupling
7.2.5 Accumulator precharging and
charging checks
(Crushing chamber releasing system)
148
circuit is connected to the lower part or bottom
cover of the hydraulic safety cylinder.
6. Connect the pressurization circuit hose to the
pressurization hose on the crusher oil
distributor and this hose is connected with the
upper part of the safety cylinder or the end of
the piston rod. See Figure 7-3.
Check the precharging pressure of the accumulator
once every 200 hours (one month). Fill the
accumulator with nitrogen in advance, have the
pressure in the release circuit kept at 0 before the
start of the test and then enable the corresponding
valve in the hydraulic power unit.. During test, make
sure that the accumulator is not kept in the sun and
that the outdoor temperature should be about 20℃
(70℉).C onne ctthe testdevice as follows in order to
check the precharged pressure in the accumulator:
1. The pressure in the crushing chamber cleaning
system and the accumulator must be completely
released. See the Hydraulic System manual.
Item Name
1 Air valve plug
2 Accumulator
3 Valve housing
4 Valve cover
Figure 7-4 Accumulator valve
2. As shown in Figure 7-4, remove the valve
housing at the top of the accumulator and
remove the valve cover from the valve plug.
3. Take out the nitrogen charger from the crusher
toolkit.
The nitrogen charger is made up of a pressure
gauge, vent plug, round handle, main body and
hose; the hose has one of its ends connected to
the nitrogen cylinder. The coupling nut below
the main valve body is directly connected with
the valve plug on the accumulator.
149
4. Completely loosen the round button of the
charger and make sure that the vent plug is shut
down.
5. Screw the coupling nut below the main valve
body on the accumulator.
6. Connect the nitrogen charger hose onto the
nitrogen cylinder.
7. Tighten the round handle onto the nitrogen
charger. The pressure value is displayed on the
pressure gauge.
8. When the pressure is greater than the specified
value, loosen the vent plug until the required
pressure is obtained.
9. When the pressure is smaller than the specified
value, open the valve of the nitrogen cylinder
so that the pressure could be regulated to the
required value.
10. Close the nitrogen cylinder valve and
disconnect.
11. Unscrew the round handle on the nitrogen
charger.
12. Remove the nitrogen charger from the
accumulator.
13. Use soap solution to check whether the valve
seal is in good conditions, and if any leakage
occurs, check the pressure again. If the leakage
is kept as usual, replace the valve.
14. Remount the valve protection plug.
15. Repeat the above operations on other
accumulators.
16. Shut off the needle valve of the hydraulic
power unit.
17. Pressurize the releasing circuit.
Warning!
Only nitrogen can be used to pressurize the
accumulator because other compressed gas might
explode or produce explosive substances inside
the system. Never use oxygen!

7.2.6 Discharging and pressurization
test of the hydraulic system
After the system is connected for the first time or
whenever any part needs replacing or repairing due
to failures, some circuits ever exposed in the air
should be deflated to discharge the air trapped in the
hydraulic circuit or circuit devices. A small amount
of air in the system won't have harmful impact on
operation, so the air should not necessarily be
discharged completely. If the crusher is initially put
into use, all circuits should be discharged before
pressurization.
Note: When the hydraulic cylinder and pipelines
are filled with oil or drained for the first time, the
hydraulic oil in the tank of the hydraulic power
unit will be pumped out. Add more hydraulic oil
as required to ensure that the oil level can be seen
on the glass window in the oil level gauge at the
side of the hydraulic power unit. After the system
has been refilled with oil or drained and after the
release system has been pressurized, the oil level
should be maintained at the central part of the
glass window on the oil level gauge.
Start the hydraulic power unit. Before discharging
the whole system or any circuit, you need to have an
oil flow force the air to be discharged from the
interface selected for emissions at first, then start the
hydraulic power unit according to the hydraulic
system service manual and get ready for discharging
and pressurization test.
Note: Before the accumulator is precharged with
nitrogen, never pump the oil into the crushing
chamber safety circuit; otherwise, the
accumulator should have to be replaced due the
damages to the gasbag.
7.2.6.1 Lock cylinder circuit
Follow the steps below to carry out discharging and
pressurization test of the lock circuit.
1. Start the hydraulic power unit. See the
Hydraulic System manual.
2. The pressure lock cylinder circuit should be
kept at the “0” position. See the Hydraulic
System manual.
Warning!
Never discharge any circuit when fully
pressurized. Personal injuries may happen due to
cracks of loose couplers or high-pressure oil
leakage. When discharging the circuit, you
should wear suitable goggles.
3. Screw the screwed nipple of the lock cylinder
circuit hose into the discharging screw hole on
the support bushing side. Slightly open the
nipple just to have some oil flowing out. When
there is clear oil flowing out from the cylinder
block free of bubbles or splash, tighten the
rotating joint.
4. Increase the locking pressure. See the
Hydraulic System manual.
7.2.6.2 Crushing chamber cleaning-cleaning
circuit
The crushing chamber cleaning-cleaning circuit
consists of several crushing chamber safety
cylinders and accumulators. These cylinder blocks
are connected by hoses around the main frame.
Follow the steps below to discharge the air trapped
in each cylinder chamber and hose:

150
1. Start the hydraulic power unit. See the
Hydraulic System manual.
2. Adjust the pressure to 1.4Mpa(14bar). See the
Hydraulic System manual.
3. Loosen the chamber cleaning hose nipple
connected to the bottom or the end cover of the
safety cylinder at about 1-1/2 circle. When
there is clear oil flowing out from the cylinder
block free of bubbles and splash, tighten the
nipple. Repeat this step until all nipples are
tightened.
4. Press the “Chamber Cleaning” button, place the
support bushing at its maximum lift with the
pressure up to the maximum of 21Mpa（210
bars). Check whether there is leakage on any oil
hose or pipe network connector. Tighten all
loose connectors.
Warning!
Keep all personnel and equipment far away
from the adjusting ring when it is in its
rising state to avoid personnel injuries and
equipment damages due to accidental falling.
Press the “Cleaning” button when checking
and correcting the leakage. Loosen the
“Cleaning” button and the adjusting ring
will fall.
5. Release the “Chamber Cleaning” button and
install the support bushing on the main frame
around the crusher.
7.2.6.3 Crushing chamber
cleaning-pressurization circuit
The crushing chamber cleaning-pressurization
circuit consists of several crushing chamber safety
cylinders and accumulators connected around the
main frame by hoses.
Follow the steps below to discharge the air trapped
in each hydraulic cylinder and accumulator:
151
1. Start the hydraulic power unit. See the
Hydraulic System manual.
2. Adjust the pressure to 1.4Mpa(14bar) according
to the hydraulic system manual.
3. Loosen each nipple on the safety cylinder or the
piston rod hose at about 1-1/2 circle, only if the
air and hydraulic oil can be discharged. When
there is clear oil flowing out from the cylinder
block free of bubbles or splash, it indicates that
the air has been completely discharged. Tighten
the rotating joint.
4. Repeat the above-mentioned operations for the
rest hydraulic cylinders and accumulators.
5. Follow the steps in the section of “Crushing
Chamber cleaning Circuit Pressurization” later
in this document to pressurize the system.
Check whether there is any oil leakage on all
hoses and pipe joints. Tighten all loose
connectors.
6. The hydraulic power unit connected to the
crusher should work through two complete
crushing chamber cleaning-release
pressurization cycles, thus to drive the air
trapped in the system back to the oil tank.
7.2.6.4 Brake release circuit
The brake release circuit is related to the operation
of the discharging port circuit for up and down
adjustment. Follow the steps below to discharge the
brake release circuit:
1. Connect the brake release circuit hose to the
outlet on the side of the brake, which is a
component of the hydraulic drive assembly
installed on the support bushing. Slightly open
the hose nipple just to have some oil flowing
out. When there is clear oil flowing out free of
bubbles and splash, tighten the nipple. When
 there is clear oil flowing out from the cylinder 3. Follow the hydraulic system manual to
block free of bubbles or splash, tighten the pressurize the release circuit of the crushing
rotating joint. chamber.

When the pressure is too low, never start the crusher

7.2.7 Pressurize the crushing chamber so as to avoid damages to the main frame base due
releasing circuit to impact of the support bushing. Readjust the
pressure according to the hydraulic system manual.
After all connections have been completed and each
system has been discharged with no leakage visible,
pressurize the crushing chamber cleaning circuit for
7.3 Maintenance
initial startup. The crushing chamber cleaning circuit
should have its pressure maintained within the scope Before any device of the hydraulic system is subject
of the recommended value, so that safe and to any maintenance, properly decompress related
sufficient overload protection could be provided to circuits. It is of great importance for safety of the
the iron release and crushing chamber safety operation personnel on the machine. During
cylinders. The circuit pressure should be kept crushing, generally many circuits will be
between the maximum and minimum pressure decompressed but pressurized only when the
values (see the hydraulic manual). operation functions are enabled. But for reliable
safety, before any circuit operation, you should
If the circuit pressure goes beyond the upper limit as check its pressure with a pressure gauge to ensure
recommended, refer to the steps in the section for that no residual pressure is left in the circuit.
pressure release in the maintenance contents of this However, even if the oil pump has been disabled for
Chapter. After initial installation or repair or the a period of time, the crushing chamber
circuit pressure is too low, follow the steps below to cleaning-pressurization circuit will still have
pressurize the circuit: pressure due to action of the accumulator. Before
1. Check whether there is sufficient hydraulic oil any operation of the hydraulic system, read the
in the oil tank. hydraulic system manual at first.
Note: Before the accumulator is charged with
nitrogen, never pump the hydraulic oil into the
releasing circuit of the crushing chamber. Otherwise,
the accumulator tank may have to be repaired or
replaced due to damages.
2. Check the precharged pressure of the
accumulator and further charge it if necessary.
See the contents in the section of “Check the
precharged pressure and accumulator
pressurization” in this Chapter.

152
Chapter 8 Typical Problems of a Crusher
References
Relevant
chapters
and
Faults Possible reasons Instructions/Troubleshooting
sections Attachment
of the
service
manual
1. Oil pump is worn. –oil 1. Check whether the oil return 5 Lubrication
supply is insufficient liter/minute (gallon/ minute) system
is normal in the oil return
2. An inappropriate crusher pipe.
liner is used. 2. Excessive working media 1
gathering at the bottom of the
3. The crusher is overheated crushing chamber leads to
due to hot or exceptionally excessive driving power.
hard materials. 3. A large-scale lubricating oil Lubrication
4. The oil supply is cooler is needed in this case. system
insufficient. 4. Check whether the main Lubrication
safety valve has failed due to system
wear, metal blockage or
spring blockage, with the
lubricating oil bypassed back
The to the oil tank.
crusher is 5. The V-belt is excessively 5. Readjust the tension status of
overheated. tensioned. the V-belt.
6. The crusher has used 6. Use appropriate lubricant 5 Lubrication
inappropriate lubricating instead, and extreme pressure system
oil. lubricant is recommended.

7. There is no axial 7. Readjust the axial clearance 5

clearance. from 0.8 mm (0.031 inch) to
1.2 mm (0.047 inch) for
HPT100 models but from 0.8
mm (0.031 inch) to 1.5 mm
(0.062 inch) for other
crushers.
8. Heat accumulation occurs 5
8. The upper friction disk is because the lubricating oil
worn. can not flow through the
bearing due to excessive wear
153
 of the oil groove. Replace the
upper friction disk.
9. Use a right-angle ruler to 5
9. The upper or lower thrust check it and consult the
bearing is no longer flat manufacturer if it is not flat
due to winding. any more.
10. Usually due to improper 1
10. The crusher has an feeding, excessive feeding
excessively high output powder or too small discharge
power. opening Excessive iron
materials in the feeding lead
to crusher overload.
11. Check the movement of the 3
11. The discharge port is too support bushing. The
small. discharge port shall never be
adjusted lower than the
minimum value as
recommended.

154

Crusher
Possible reasons
faults
12. The lubrication oil hole
inside the main shaft is
blocked by dirt or debris.
13. The oil cooler is blocked
by dirt, dust and other
debris.
14. The moving cone has its
lower bush surface worn.
The
crusher is
overheated.
15. The eccentric bushing has
its liner surface worn or
charred.
References
Relevant
chapters
and
Instructions/Troubleshooting
sections Attachment
of the
service
manual
12. High-pressure air shall be
used to clean the inner
vertical and horizontal holes
in the main shaft.
13. If it is a water cooler, use a Lubrication
wire brush to clean it, but if it system
is an air cooler, clear the dust
or other contaminants on the
hot fins.
14. During crushing operation,
there is no enough driving
power - less than 40% of the
rated power.
The crushing part is excessively
located downward in the crushing
chamber and too fine materials are
fed.
The pressing cap gets stuck by
excessively larger sheet materials.
15. Lubrication system failure -
excessively low oil pressure,
excessively high oil
temperature and incorrect oil
viscosity (excessively low oil
viscosity)
Oil pollution – The impurity
particles penetrate through or 5 Lubrication
block the filter. system
Lubrication system failure – The
oil temperature is too high and the
155
oil viscosity is not correct (too low
viscosity).
Usually due to improper feeding,
excessive feeding powder or too
small discharge opening
Excessive iron materials in the
feeding lead to crusher overload.
The main bearing surface has been
damaged due to insufficient oil
film.
The space for normal operation has
been reduced between the main
bearing and the eccentric bushing
liner because the eccentric bushing
hole has been drawn.
The static fitting loss occurs
between the bearing and the frame.
Use a feeler to check the static
fitting.

156
 References
Relevant
chapters
Crusher
Possible reasons Instructions/Troubleshooting and
faults Attachment
sections of
the service
manual
1. The ball bush seat has its 1. Check whether the static 5
bolt cut. The static fitting fitting is normal between the
has failed between the main main shaft and the ball bowl.
shaft and the bearing holder If necessary, adopt repair
due to wear. welding and machining to
The ball have the ball bowl hole
bush achieve the maximum static
seat fitting. If the main shaft has its
becomes upper part damaged, buy a
loose. small ball bowl and machine it
for appropriate static fitting.
Replace the bolt and screw it
to the appropriate torque:
After the part is cooled, check
the torque again.
1. The “T” and “U”-shaped 1. Replace the sealing elements. 5
sealing rings are damaged
or worn.
2. The safety valve has failed. 2. The safety valve is not set Lubrication
correctly or its spring gets system
stuck where it is compressed.
Replace the safety valve.
3. The oil is too cold. 3. Install an immersion heater Lubrication
and heat the lubricating oil up system
Crusher to 27℃ (80℉).
oil is 4. The crusher uses improper 4. Use suitable lubricating oil 5 Lubrication
slinging lubricating oil - The oil is instead. system
too heavy.
5. The crusher exhaust is not 5. Clean the vent hood connected 5 Lubrication
normal. to the countershaft frame. system
6. The return pipeline is 6. Check the oil return pipe and No
blocked by dirt or other clean it if necessary.
debris.
7. The return oil is abnormal. 7. Check the slope of the return No
pipeline from the crusher to
the oil tank. The minimum
157
 gradient decreases by 25 mm
(1 inch) per 305 mm (12
inches) or the oil return pipe is
too small.

Use an appropriate oil return

pipe instead.

1. The feeding port of the 1. Replace the liner or enlarge 1

mantle has become smaller the feeding port.
because it is subject to
limited wear of the
The materials.
capacity 2. The speed (RPM) is too 2. Check whether the 3
has low. countershaft speed (RPM) is
reduced. 3. The material flow speed has correct. 2
been reduced due to 3. Avoid excessively larger
excessively large feeding materials fed in the crusher.
(wood, roots and rebars,
etc.).

158
 References
Relevant
chapters
Crusher and
Possible reasons Instructions/Troubleshooting
faults sections Attachment
of the
service
manual
4. The largest feeding 4. Decrease the feeding
particle size is too large. particle size. 2
5. The feeding contains 5. Remove the lay or No
too much clay. viscous materials in the
6. The materials are fed feeding. 2
sideward in the crushing 6. Correct the
chamber due to unequal configurations of the
distribution and feeding feeding hopper.
segregation.
The
7. The mantle or its No
capacity
bottom collides at the
has
bottom of the parallel 7. Cut off the protruding
reduced.
band. part to hinder material
discharging at the
8. The mantle or its bottom of the adjusting 1
parallel band is worn ring or mantle.
too fast. 8. Use an adjusting ring or
mantle different in
chamber specifications.
Consult the
manufacturer.
1. The V-belt is too loose. 1. Tension the V-belt. Drive
2. The drive motor suffers 2. Check the idle power of No
from electrical faults. the crusher. Compare it
with the power when
the motor rotates on its
The own (with the driving
crusher belt not engaged). If the
is two counts are basically
stalled identical, then the motor
should be tested by
electricians.
3. The crusher is fed with 3. Install a water jet to No Lubrication
wet and sticky flush the materials system
materials. through the crusher to
159
 prevent cementation in
the chamber.
4. Material accumulation 4. Check whether the 2
below the crusher discharge is
unobstructed in the
foundation. Check the
mud pump. 3
5. The countershaft speed 5. Check whether the
is too low. countershaft speed
(RP1D) is correct. 5
6. The oil pressure Bar 6. Check whether the
(PSI) is too low. working pressure is 2
normal.
7. The drive motor or 7. The motor or engine has
diesel engine is not a rather low power 1
suitable. service coefficient.
8. Due to incorrect (too 8. Check and choose a
large) feeding port of suitable liner plate.
the crushing chamber,
the crushing is mostly
completed at the lower
part of the crushing
chamber so the power
consumption has been
increased.
9. The mantle or its 9. Cut off the protruding No
bottom collides at the part to hinder material
bottom of the parallel discharging at the
band. bottom of the adjusting
ring or moving cone.
Replace the moving 5
cone and the mantle. 1
10. Use a moving cone and
10. The mantle or its a mantle different in
parallel band is worn chamber specifications
too fast. instead. Contact the
manufacturer.

160
 References
Relevant
chapters
Crusher and
Possible reasons Instructions/Troubleshooting
faults sections Attachment
of the
service
manual
1. The “T” and “U”-shaped 1. Replace the sealing elements. 5
sealing rings are
damaged or worn.
2. Wear or damages have 2. Replace the sealing elements 5
Oil leakage
happened to the flange or thoroughly clean the inner
occurs.
O-rings or lip seals in the flanges of the main and
countershaft and main countershaft frames and
frames. apply silicone for sealing at
the joints.
1. The V-belt is excessively 1. Tension the V-belt again and
tensioned. check the calibration of the
belt pulley.
2. The driving sleeve has no 2. Check to see whether there is No
or insufficient oil. any limiting factor on the
pipeline between the main oil
feed pipe and the oil supply
hole on the countershaft
frame. Remove any valve or
eliminate other factors or
obstruction in the fuel feed
The pipe.
countershaft 3. The countershaft has the 3. At no time, the V-belt pulley 5
is stuck or oil groove of its outer can pull the countershaft
broken. bush misplaced. towards the oil groove.
4. No axial clearance 4. Readjust the axial clearance 5
from 0.8 mm (0.031 inch) to
1.2 mm (0.047 inch) for
HPT100 models but from 0.8
mm (0.031 inch) to 1.5 mm
5. The countershaft is bent. (0.062 inch) for other
Usually, the countershaft crushers.
has its shaft end vibrating 5. Replace the countershaft. 5
or the broken belt pulley
is swinging.
6. The outer countershaft 6. Clean the oil groove. 5
161
 bushing of the
countershaft has had its 5
oil groove stuck with dirt
or other debris. 7. Replace the big cone gear or 5
7. The big cone gear or pinion.
pinion has teeth broken. 8. Check and correct the
8. Inappropriate backlash addendum and circular tooth
occurs between the backlash.
addendum and/ or the
circular tooth of the big
gear and pinion.
1. Ponding occurs at the top 1. Replace the vent hood.
of the balance weight
cover.
Lubricant is
2. The vent hood at the top 2. Repair or replace the heat
contaminated
of the oil tank is blocked. exchanger.
with water.
3. Water erosion or
damages to the heat
exchanger tube

162

Crusher
Possible reasons
faults
1. Dirt or rust is
accumulated between the
threads of the adjusting
ring and its support
bushing. The specific
reasons are shown below:
Overheated feeding (slag)
The thread is not well
lubricated;
The
adjusting
The scraper seal or dust
ring can not
sealing is worn.
rotate.
No rainproof facilities are
provided.
It has been running too
long at a certain fixed
discharge opening;
Scratches occur to the
adjusting ring and/or
support bushing threads.
Threads are broken.
References
Relevant
chapters
and
Instructions/Troubleshooting
sections Attachment
of the
service
manual
1. Try such steps as follows: 5
Add anticoagulants to the
thread;
Release the pressure in the
lock cylinder and the iron
release safety cylinder and
start the crusher to have
materials passing through.
Let a wood block through the
crusher;
Throw small “soft” steel
pieces in the crusher and let
such pieces pass through.
Heat the support bushing;
Heat the support bushing and
cool the adjusting ring.
Don't remove the support
bushing from the main frame.
163
 References
Relevant
chapters
Crusher and
Possible reasons Instructions/Troubleshooting
faults sections Attachment
of the
service
manual
1. The pressure cap of the 1. The weld joint may have 5
mantle can’t be broken from the mantle to the
automatically tightened. pressure cap.
2. The wear of the pressure 2. Grind off the protruding part 5
cap bottom leads to or install a new pressure cap.
contact with the mantle or
protruding welds.
3. The pressure cap contacts 3. The clearance is not enough
the top of the moving between the lock screw
cone. bottom and the moving cone
top, and the minimum
clearance is about 10 mm
(3/8 inch).
4. Restore the mating surface No
4. The mantle or moving back to its design size.
cone has its matching
The
surface worn or
adjusting
incorrectly machined. 5. The maximum out-of-round No
ring or
5. The mantle is out of degree should be 3 mm (1/8
mantle
round. inch).
becomes
6. Use a feeler to check the 5
loose.
6. The mantle center is not bottom of the mantle and the
aligned to that of the clearance should be no
moving cone. greater than 0.25 mm (0.010
inch).
7. Remove the liner plateliner 5
7. During the initial plate and install again
installation, the mantle correctly.
was not completely
tightened on the moving
cone. No
8. Mantle - The crusher has 8. The longest idle time should
been running too long be 30 minutes.
without material fed. No
9. The mantle is too thin. 9. The mantle shall never be
worn more than two thirds of
its thickness.
164
 References
Relevant
chapters
Crusher and
Possible reasons Instructions/Troubleshooting
faults sections Attachment
of the
service
manual
1. The mantle-wedge top has 1. Add a gasket to the wedge or 5
touched the excircle of the tighten the mantle bolts.
mantle or the bolts have
become loose.
2. The mantle is too thin. 2. The mantle shall never be
The worn more than two thirds of No
adjusting 3. The crusher has too much its thickness.
ring can not iron fed. 3. Too much iron will have
rotate. impact on the support 2
bushing and have the mantle
4. The mantle or adjusting become loose.
ring has its matching 4. Restore the mating surface
surface worn or back to its design size. No
incorrectly machined.
1. The crusher exhaust is not 1. Clean the vent hood of the 5
good. countershaft frame.
2. The oil is rather slowly 2. Clean the long through-hole No
discharged in the in the countershaft frame
The
countershaft frame or the under the countershaft.
countershaft
oil slinger chamber,
belt pulley
especially when the
has one side
lubricant is cold. 3. Replace the piston ring. 5
suffering
3. The piston ring seal
from oil
between the oil slinger
leakage.
and bolt cover has been 4. Adjust the crusher to be
worn. horizontal.
4. The crusher is not kept
horizontal.

165
 References
Relevant
chapters
Crusher and
Possible reasons Instructions/Troubleshooting
faults sections Attachment
of the
service
manual
1. The balance weight or 1. Negotiate with the 5
counterweight guard and manufacturer to repair the
cover are worn. balance weight. Replace the
counterweight guard and
cover or replace the balance
weight.
2. The big and pinions have 2. The gear is directly pressed 5
their teeth roots contact. on the pinion due to
inappropriate modulus of the
gear. Add a washer to raise
the eccentric bushing
3. The countershaft is bent. assembly.
4. The crusher has its belt 3. Replace the countershaft. 5
pulley seriously 4. Remove the dirt on the belt 5
imbalanced. pulley rim and spokes.
Too serious 5. If the crusher is installed
vibration in a mobile crushing 5. Check the stow-wood or 0
appears. station, probably foundation conditions.
stow-wood or foundation
is not appropriate.
6. The base and foundation
has an inappropriate 6. Check the base or foundation 2
bearing capacity. conditions.
7. The mantle is loose or
excessively worn. 7. Remove the mantle, and 5
reinstall or replace it.
8. The countershaft speed
(RPM) is too high. 8. Check whether the 5
9. The balance weight is countershaft speed (RPM) is
lost. correct. 5
9. Negotiate with the
manufacturer to make up for
the missing balance weight.

166
 References
Relevant
chapters
Crusher and
Possible reasons Instructions/Troubleshooting
faults sections Attachment
of the
service
manual
1. The crusher is still 1. In time of assembly, make 5
working when the bowl sure that the crusher parts and
liner is loose. related parts are assembled
properly and that the pressing No
cap has been fully tightened
before operation.
2. The crusher is still 2. Weak plane bending of the No
working when the moving crusher parts has accelerated
cone or bowl liner are the wear of the mating
excessively worn. surface between the moving
cone or adjusting ring and the
liner plate.
The mating 3. The crushing depends on 3. Weak plane bending of the No
surface is the moving cone or crusher parts has accelerated
worn adjusting ring because the the wear of the mating
between the moving cone or mantle surface between the moving
moving has been completely worn cone or adjusting ring and the
cone or through. liner plate.
adjusting 4. The mantle or adjusting 4. Bending of the crusher parts No
ring and the ring liner is broken. has accelerated the wear of
liner plate. the mating surface between
the moving cone or adjusting
ring and the liner plate.
5. Intermittent feeding
happens during the 5. For any crusher provided 5
running-in period of the with no anti-rotation
new liner. mechanism, a loose torque
will appear at the start of
feeding and the feeding will
prevent the moving cone
rotating. Intermittent feeding
should be avoided when a
new liner is used.

167
 References
Relevant
chapters
Crusher and
Possible reasons Instructions/Troubleshooting
faults sections Attachment
of the
service
manual
1. There is no vent hood on 1. Install the vent hood on the 5 Lubrication
the crusher. countershaft frame. system
2. Dysfunctions happen to 2. Clean the vent hoods at such Lubrication
the vent hood mounted on two places. When the crusher system
the countershaft frame or is working, the paper put
fuel tank. above the vent pipe should
slightly move inward.
3. The crusher belt pulley 3. Use a hose to install the vent 5 Lubrication
brings dust into the vent hood at another place, so that system
hood. it could be kept far away
from the belt pulley.
4. In time of dismantling for 4. In time of crusher No
inspection or repair, dust overhauling, use canvas or
The
has fallen into the crusher. polyethylene (plastic) film to
lubrication
cover the head bowl and the
system
eccentric bushing.
suffers from
5. Excessive vertical drop 5. The U and T sealing elements No
dust or dirt
occurs to the return oil are contaminated with dust
invasion.
pipeline between the and dirt. Add another vent
crusher and the oil tank. hood onto the oil return pipe
to reduce dust invasion.
6. No seal or washer is 6. Replace the seal or washer. Lubrication
provided between the oil system
tank and its cap.
7. The hose from the air 7. Check the hose and
blower to the countershaft connection.
frame is broken or
disconnected.
8. The hose or vent hood 8. Check the hose and
connector is broken or connection.
disconnected.

168
 References
Relevant
chapters
Crusher and
Possible reasons Instructions/Troubleshooting
faults sections Attachment
of the
service
manual
1. Lubricant is too dirty. 1. Replace the lubricant and Lubrication
clean the oil tank. 5 system
2. Teeth worn parts are too 2. The thrust bearing is worn, so
low. gaskets should be added to
jack up the eccentric bushing.
3. Teeth worn parts are too 3. Reduce a washer under the 5
high. lower thrust bearing to lower
The big the eccentric bushing.
cone gear 4. The crusher is overloaded. 4. It is generally characterized 1,5
and pinion by beating of the support
teeth are bushing. Reduce the crusher
worn. feeding.
5. The axial clearance is 5. Readjust the axial clearance 5
excessively large. from 0.8 mm (0.031 inch) to
1.2 mm (0.047 inch) for
HPT100 models but from 0.8
mm (0.031 inch) to 1.5 mm
(0.062 inch) for other
crushers.
1. Gear backlash and/ or tip 1. Check the gear backlash and 5
clearance is not tip clearance.
appropriate.
Noise
2. The crusher is working 2. No 5
occurs from
when a new big cone gear
big and
and a worn pinion or a
pinions.
worn big cone gear and a
new pinion are used
together.

169
 References
Relevant
chapters
Crusher and
Possible reasons Instructions/Troubleshooting
faults sections Attachment
of the
service
manual
1. Beating of the support 1. Feed distribution is not 2 Hydraulic
bushing has the main appropriate in the crushing system
frame top and/or the chamber. Adjust the support
mating surface of the bushing by 180°.
support bushing unevenly Checked whether the iron 5
worn (in this condition, release safety cylinder suffers
the crusher warranty will from an excessively low
The support become invalid.) pressure and pressurize the
bushing hydraulic cylinder.
leans 2. Continuous overload or 2. If the feeding contains too
sideward. inappropriate liner plate much fine material, refer to
has the support bushing the section “Appropriate 1
continuously impacting Liner Options” and the table.
the mating surface of the Feed the crusher more.
main frame. Adjust the crusher discharge
port to be larger.
Add more water to the 3
feeding if it is too sticky.

170
 References
Relevant
chapters
Crusher and
Possible reasons Instructions/Troubleshooting
faults sections Attachment
of the
service
manual
1. The support bushing and 1. If the thread is not seriously No Hydraulic
adjusting ring threads worn, machine the thread system
have been worn. bevel (45°) again to have the
screw pitches kept uniform.
2. The lock cylinder 2. Compress the locking 5
pressure is too low during cylinder to an appropriate
operation. pressure.
3. The crusher discharge 3. Adjust the crusher
opening is too small in discharging port larger until 3
size. the adjusting ring stops
Mantles beating.
occur. 4. The moving cone or bowl 4. Too narrow thread
liner is too thick. engagement occurs between No
the adjusting ring and the
support bushing. A thinner
plate is needed.
5. The crusher discharge 5. Too narrow thread
opening is too large in engagement occurs between 3
size. the adjusting ring and the
support bushing. Adjust the
crusher discharge port
smaller.
Adjusting 6. Check whether the hose 6. When the hydraulic station is Hydraulic
ring connection is normal from working, the hose between system
becomes the hydraulic station to the hydraulic station and the
loose. (to be the locking cylinder. locking cylinder should be
continued) felt somewhat stiff.
1. Leakage may occur in the 1. If the indicator lights up more Hydraulic
The low
hydraulic power unit or than once every 10 minutes, system
locking
locking circuit. check whether there is any
pressure
leakage in the hydraulic
indicator
power unit and the locking
lights up.
circuit.

171
 References
Relevant
chapters
Crusher and
Possible reasons Instructions/Troubleshooting
faults sections Attachment
of the
service
manual
1. Leakage may occur in the 1. If the indicator lights up more Hydraulic
The low
hydraulic power unit or than once every 3 hours, system
release
release circuit. check whether there is any
pressure
leakage in the hydraulic
indicator
power unit and the release
lights up.
circuit.
1. The crusher chamber is 1. Reduce the crusher feeding. 1
excessively fed. 2. Reduce the feeding particle 1
2. Sheet materials are fed. size or change the liner plate
to increase the material inlet.
3. Wear happens to the 3. Weld and machine the 5
matching surface between mating surface of the
the cone head and the pressing cap again. Replace
The taper
lock nut. the cone head.
screw is
4. The taper screw is too No
broken.
loose. 4. Tighten the bolt so that it
5. Excessive fall happens to could fit closely. No
the massive materials fed 5. This problem usually occurs
to the cone top. in standard crushers. Reduce
the height from the feeding
hopper, funnel or belt
conveyor to the cone head.

172
 References
Relevant
chapters
Crusher and
Possible reasons Instructions/Troubleshooting
faults sections Attachment
of the
service
manual
1. Overload or inappropriate 1. If the feeding contains too 1
liner plate much fine materials, refer to
the section “Appropriate
Liner Options” and the table.

Feed the crusher more. 3

Adjust the crusher discharge

port larger.

The material may be sticky,

2. Operation continues when so add water to the feeding.
the iron release safety
cylinder suffers from an 2. The iron release safety Hydraulic
excessively low pressure. cylinder has its seal faulty. system

The support
The hydraulic power unit can Hydraulic
bushing is
not automatically pressurize system
beating.
the iron release safety
cylinder (pressure switch
failure).

The hydraulic power unit has Hydraulic

the valve of its internal system
releasing circuit suffer from
leakage.

The iron release safety Hydraulic

cylinder has its pressure system
safety valve open or suffer
from leakage.

Any hose or part fails or Hydraulic

suffers from leakage. system

173
174