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HEAVY.
All rights reserved. Any form of copy of this document without prior approval of Shaorui Heavy
Industries Co. Ltd is prohibited. All the data and information in this manual are subject to change
without prior notice.
Fax: 0751-8136871
Website: : www.sgsrzg.cn
Contents
1. Introduction
1.1 Equipment Information
1.1.1 Document Information
1.2 Operational Principle
1.2.1 Descriptions
2. Safety Precautions
2.1 Signals of Dangers
2.1.1 Warning Signs
2.1.2 Classification of Dangers
Chapter One
Introduction
To ensure safety, please read the safety precautions in chapter 2 before carrying out
any work or adjustment on the machine.
1.1 Equipment information
Application purpose
The crushing and screening devices or plants made by Shaorui Heavy Industries
Co. Ltd at the mining sites can reduce the dimensions of rocks, ores and other
materials, which is also the basis of our designs. Shaorui Heavy Industries Co.
Ltd is not liable for the whole mining operation unless crushers are part of our
delivered production line. Nor is it liable for any damage to equipment or people
due to improper operation, use or refit of our equipment.
Maintenance
Please contact the nearest agents or representatives of Shaorui Heavy Industries
Co. Ltd or directly contact the factory.
Tel: 0751-8136739
Fax: 0751-8136871
Crusher nameplate
The picture below is an example of our crusher nameplate, which includes the
information related to a specific device that needs to be rendered to us when
contacting Shaorui Heavy Industries Co.
Ltd for
servicing.
Model is a sign for product series.
Nameplate:
1. Model
2. Factory code
3. Local series number
4. Order number
5. Mass(kg)
6. ID code
7. Manufacturer
8. Year of production
9. CE mark
10. Dimensions
11. Cavity type
12. Eccentricity(mm)
Marks on the oil tank compartment
The picture below is an example of the marks of oil tank compartment, which
include the information related to a specific device that needs to be rendered to us
when you contact Shaorui Heavy Industries Co. Ltd for servicing.
16. Model
17. Part number
18. Series number
19. Quality
20. Order number
21. Manufacturer
22. Year of production
23. CE mark
CE mark
This equipment conforms to the environment and safety regulations of the EU and European
economic zone. Shaorui Heavy Industries Co. Ltd will no longer be liable for such
Document information
Keep this manual carefully within the service life of this machine.
When the user or owner of this machine is changed, this manual must be
handed over at
1.
2.
3.
4.
5.
6.
Arm bearing
Upper frame
Concave
Mantle
Eccentric assembly
Main shaft
1 arm cap
2 upper frame liner
3 main shaft nut
4 mantle
5 concave
6 head
7 wear ring
8 lower frame liner
9 eccentric
10 eccentric bushing
11 main shaft
bushing
12 hydraulic piston
13 countershaft box
14 countershaft
15 dust-proof cover
16 locating block
17dust-proof ring
18 lower frame
assembly
19 upper frame
20 filler ring
22 inspection gate
23 feed hopper
24 observation cover
25 pressure fan
26 pressure regulator
27 oil tank
28 water/oil radiator
29 air/oil radiator
30 inflatable kit of energy
accumulator
Chapter Two
Safety Precautions
In order to ensure safety, please read this book carefully before carrying out any work or making
any adjustment on the crusher.
2.1 Signs of dangers
2.1.1 Warning signs
2.2 Personnel
The operation of this machine must be done by trained or authorized personnel.
trained refers to personnel who have fully understood how to perform all kinds of tasks after
receiving practical guidance offered by authorize personnel.
authorized refers to personnel who have passed the theoretical and practical knowledge test
organized by Shaorui Heavy Industries and thus have acquired necessary knowledge and
competence for performing tasks of a specific position.
We have divided all the tasks related to our production equipment into three job positions
according to different requirements for experience background, namely installation, operation and
maintenance.
We have provided proper documents for the three job positions.
We offer technical documents for job tasks related to our machine, excluding job tasks involved
in other machines at the job site or in the daily activity.
The equipment management personnel should assign the following responsibilities
Production machines and working areas around them
All the personnel near the machines
Conformation to the national and local safety regulations
check and make sure that all the safety devices are working well.
We are not liable for any damage caused by failure to observe the instructions in this manual.
Prior to operation of the machine, check, repair or replace all defective safety guards and dustproof elements.
2.3.2 Electric safety
The electric operation can only be carried out by electricians in accordance with European
EN 50110 standard or equivalent standards.
Electric danger
Operators must pay attention to all electric devices until the electricity is cut off.
Before operating the equipment, check, repair or replace any broken or damaged cable or
connector.
The control cabinet must have a lock.
2.3.3 Welding
Related regulations in this manual must be observed when carrying out welding on the crusher.
Please consult our local maintenance personnel when carrying out welding on the crusher.
The welding on the crusher is only allowed to be carried out by welders in accordance with EN
287 standard or equivalent standards.
The welded parts must be earthed during welding. If a part of the crusher is to be welded, it
must be earthed at a nearest possible place to the welding area.
Toxic gas
It is harmful to health to inhale welding smoke, so please always follow the instructions
provided by the supplier of the welding machine. Some parts of the crusher are made of
manganese steel, so manganese oxide is produced during welding. Constant exposure to
manganese oxide will have a negative impact on the nervous system.
2.3.4 Hydraulic system
Only personnel that have passed the examination are allowed to operate the hydraulic system.
Oil pressure
If the pressurized oil is released incorrectly, it may incur a danger. Therefore, please release all
the pressure before carrying out maintenance or repair work on the hydraulic system.
Do not exceed the recommended value when adjusting the safety valve.
Oil temperature
During operation, the temperature of hydraulic oil will increase. Therefore, the hydraulic oil
must be cooled down before carrying out any work on the hydraulic system.
Before operation of the equipment, please check, repair and replace all defective hoses, valves
or accessories.
2.3.5 Lifting and moving load
The lifting operation shall be carried out by trained personnel.
Lifting load
Do not stand below the crane when it is lifting items. Please keep a safety distance from the
crane.
Make sure that the crane has a adequate capacity and is in good condition.
If the lifting rigging is composed of separate components, make sure that connectors are
reliable and have the same lifting capacity as other lifting components.
Please use lifting rigging in line with local conditions.
Make sure that the insurance clamp is always connected with the lifting hook to avoid the
lifting rigging from falling off.
When fixing or moving a load, please use cables or a sliding bar. Do not use your hands or feet.
Before lifting a load, make sure that there is no obstacle in the way. And descend the load
quickly and safely to the ground in a emergency case.
When piling up the loads, please keep the lifting device in the position until you make sure that
the load is stable.
2.3.6 Feed and blockage
Features
Model
Data
SG160
Name
Cone crusher
Application
Ore processing
Gross weight
12985 kg
length
2.1m
width
1.8m
height
2.73m
Rotating speed of
pinion
1475 rpm
Maximum power of
motor
155 kW
Transmission
Belts
50 to190 mm
CSS minimum-maximum
6 to 38mm
Capacity
45 to 220 tons/hour
Above is typical data. The capacity of the cone crusher depends on cavity shape, eccentricity,
settings and density of feed material, crushability, fractions and moisture etc, please consult us if
you need more information about applications.
Chapter Four
Start-up
Pressure
4.0 MPa (580 p.s.i.)
4.0 MPa (580 p.s.i.)
3.8 MPa (551 p.s.i.)
3.8 MPa (551 p.s.i.)
3.6 MPa (522 p.s.i.)
3.4 MPa (493 p.s.i.)
Average power
The following are the typical values of average drawbar power measured on the motor shafts,
which are determined by eccentricity and cavity shape. If the average drawbar power is even and
has no peak, its value may be relatively higher, but it should not exceed the maximum average
power and hydraulic pressure value.
power(k
W)
Eccentri
city
Cavity shape
EF
MF
16 mm
19 mm
MC
EC
67
70
74
73
77
81
85
22 mm
75
79
83
87
92
97
25 mm
83
88
92
97
102
108
105
110
116
123
127
29mm
94
94
99
32mm
102
102
108
114
120
34 mm
108
108
114
120
126
36mm
113
113
120
127
132
132
4.2.5 Start
the crusher at an extremely low temperature
If the main oil pump is started at an extremely low temperature, the lube oil may overflow from
the dust-proof frame.
a) Repeatedly start and stop the oil pump at an interval of 10s until the Ready for start"
signal appears. Then start the crusher and run it without load. Check if the oil flow quantity is
normal.
Chapter Five
This chapter introduces the basic procedures of using the cone crusher.
To ensure safety, please read carefully safety precautions in chapter 2 before carrying out any
work or adjustment on the crusher.
5.1 Start-up and stop
Usually the crusher is controlled by a control system to regulate the starting of the crusher.
Please refer to the supplementary information provided by the manufacturer of the
control system. However, follow-up or inspection is needed to make sure that the
control system follows the start-up and stop procedures below.
Caution! Please refer to running-in in chapter 4.2 for information about running-in after
maintenance or installation of new parts.
Caution! Follow the instructions in daily inspection and maintenance in chapter 6.1 to carry out
daily inspection and maintenance work.
5.1.1 Start the crusher
Caution! Please refer to start the crusher at an extremely low temperature in chapter 4.2.5 for
information about starting the crusher at an extremely low temperature.
b) Start the main oil pump
c) When the indicator light ready to start is on, start the driving motor.
d) Check and adjust the settings. Please refer to check the settings with a lead block.
e) Start the feeder. The crusher should be fed evenly with full load.
Caution! The CSS should not be too small, or it will cause the drawbar power or hydraulic
pressure to exceed the upper limits in chapter 4.2.4.
a) Choose the main lube oil used in operational condition according to lube oil used in the
lubricating system in chapter 7.2.
b) Replace the main lube oil according to instructions in chapter 8.3. Besides filter elements also
need to be replaced and the magnetic plug, return oil mesh, oil tank and air/oil radiator need to
be cleaned.
c) Choose hydraulic oil according the instructions in hydraulic system in chapter 7.3 and
replace the oil in the hydraulic system. In addition, the filter elements should also be replaced
and the magnetic plug needs to be cleaned. Please refer to filter element in chapter 8.6.2 and
magnetic plug in chapter 8.6.3.
d) Replace the oil in the pinion box. Use the same oil with the main lubricating system. Please
refer to lube oil of pinion box in chapter 7.4.
e) If the temperature control switches TG1.TG2 and TG3 are not yet set up according to normal
operational conditions, please reset them following the instructions in temperature control
switch in chapter 8.2.7 and oil heating in chapter 8.2.12.
5.3.2 Operation under high temperatures
Ambient temperature
If the ambient temperature is so high that the cooling system cannot keep the return oil
temperature below 50C( 120F), it may necessary to permit operation under a high temperature.
In this case, please consult us timely. At the same time, replace the lube oil with another type with
higher viscosity.
a) Choose the main lube oil used in operational condition according to lube oil used in the
lubricating system in chapter 7.2.
b) Replace the main lube oil according to instructions in chapter 8.3. Besides filter elements also
need to be replaced and the magnetic plug, return oil mesh, oil tank and air/oil radiator need to
be cleaned.
c) Choose hydraulic oil according the instructions in hydraulic system in chapter 7.3 and
replace the oil in the hydraulic system. In addition, the filter elements should also be replaced
and the magnetic plug needs to be cleaned. Please refer to filter element in chapter 8.6.2 and
magnetic plug in chapter 8.6.3.
d) Replace the oil in the pinion box. Use the same oil with the main lubricating system. Please
refer to lube oil of pinion box in chapter 7.4.
e) If the temperature control switches TG1.TG2 and TG3 are not yet set up according to normal
operational conditions, please reset them following the instructions in temperature control
switch in chapter 8.2.7 and oil heating in chapter 8.2.12.
5.3.3 Operation under low temperatures
Ambient temperature
The viscosity will increase under low temperatures. However, as there is a heating element in the
oil tank, it is not necessary to replace the oil with another type with lower viscosity. In addition,
there are several methods to reduce the risk of oil freezing, such as keeping a proper temperature
and heating.
Nevertheless, sometimes oil with lower viscosity is still recommended under extremely low
temperatures.
a) Choose the main lube oil used for operation under low temperatures according to lubricating
system in chapter 7.2.
b) Replace the main lube oil according to replacing the main lube oil in chapter 8.3. besides
the filter element also needs to be replaced and the magnetic plug, return oil mesh, oil tank
and air/oil radiator need to be cleaned.
c) Choose the hydraulic oil according to hydraulic system in chapter 7.3 and replace the oil in
the hydraulic system. Besides, the filter element also needs to be replaced and the magnetic
plug needs to be cleaned. Please refer to filter element in chapter 8.6.2 and magnetic plug
in chapter 8.6.3. Usually the hydraulic oil doesnt need to be changed. However, if the
condition is so harsh that the oil tank needs oil with lower viscosity or a heater, please consult
us.
d) Replace the oil in the pinion box. Use the same oil with the main lubricating system. Please
refer to lube oil of pinion box in chapter 7.4.
e) Please consult the grease producer and refer to lube oil in the arm bearing in chapter 7.5 for
more information about the grease used in the arm bearing under extreme ambient
temperatures.
f) If the temperature control switches TG1.TG2 and TG3 are not yet set up according to low
operational temperatures, please reset them following the instructions in temperature control
switch in chapter 8.2.7 and oil heating in chapter 8.2.12.
5.4 Check the belt tension
Check the belt tension according to instructions in belt tension in chapter 6.4.2.
5.5 Energy accumulator
Please refer to inflatable kit in chapter 9.3 for procedures of check the air pressure and
pumping.
5.6 Clear the cavity
If the crusher stops with a full cavity, please take the following steps to clear it.
a) Make sure that the feeding device has been turned off.
b) If there is material deposit in the discharge chute under the crusher, please remove it.
Caution! If there is A SRi system, please turn it off to avoid raising or lowering down the main
shaft.
c) Open the tamper valve connected with the hydraulic pressure gauge. Please refer to pressure
gauge in chapter 8.6.5.
d) Use L1 button box to lower down the main shaft and meanwhile pay attention to the hydraulic
pressure.
e) If the hydraulic pressure is lower than 0.3Mpa, raise the main shaft again until the reading of
pressure gauge at least reaches 0.5Mpa. (If the pressure drops below zero, the thrust plate of
the main shaft may lose contact with the upper thrust pad.)
f) Start the crusher
Caution! Check if there is material deposit on the lower frame arm. If moist material blocks the
cavity, please operate the machine under a larger setting.
Caution! Check the interlock between the feeding device and discharge system. Once the
discharge system stops working, there should be enough space under the crusher for the material
remaining in the cavity and hopper.
Careful! If the crusher stops due to some uncrushable materials (metal, wood etc.), do not restart
the crusher. Manually clear the cavity or remove the bolts on the upper frame so that all the
material can be released from the cavity.
Careful! Do not start the crusher while the upper frame is loose.
Chapter Six
This chapter introduces general knowledge about daily inspection and maintenance of the cone
crusher.
To ensure safety, please read carefully safety precautions in the chapter 2 before carrying out
any work or adjustment on the machine.
6.1 Daily inspection and maintenance
Every cone crusher must receive regular systematic inspection. It can reduce maintenance
frequency, narrow down maintenance range and reduce downtime and thus lower down the
overall operation cost.
Caution! Frequent inspections must be carried out during the initial operation period of a new
crusher and then gradually increase the interval until a proper inspection frequency.
Keep a daily record of the detailed information about operational conditions, load, important
data, adjustment and maintenance of the crusher. Please refer to the appendix inspection for the
format of the record table.
As the crusher can operate under completely different conditions, it is impossible to come up
with a daily inspection table of inspection and maintenance for all crushers. However, regular
inspection is very necessary. See some examples in the following table.
6.1.1
Daily
Operators are responsible for carrying out these inspections every day or every 8 hours.
Action
Time
Reference
Check and make sure that all the stop valves between
the oil tank and oil pump are completely open.
Before starting
er
Before starting
er
Before starting
crusher and oil
the crush
the crush
8.2
8.6
the
pump.
Check and make sure the oil returns to the oil tank and After starting the oil
it is clean.
pump
Check and make sure that there is no leakage on the
After starting the oil
pipes.
pump
Run the machine without
Check css.
load.
Check and make sure that the hopper and spreader plate
are not stuck and the feed opening is not blocked.
8.2
4.2.1
8.2.7
4.2.4
8.6
6.1.2
Check and make sure that the oil heater works well.
Check the distance between the top nut and the bottom
of arm frame.
8.2.12
10.2
8.3.4
Weekly
Operators are responsible for carrying out these inspections every week or every 40 hours.
Action
Check the filter element (check if the red
button on the pressure sensor has bulged)
Clean the magnetic plug and check the oil tank
of the main
Lubricating system.
Time
Reference
6.1.3
8.2.5
8.3
10.2
4.2.1.11.1
8.2.4 8.6.1
7.4
8.5
8.6.5
6.7
6.7
Monthly
Operators are responsible for carrying out these inspections when the crusher stops every
month or every 160 hours
Operator
6.3.1
Operator
6.3.2
Operator
Operator
10.110.3
Operator
7.5
Operator
10.1
Operator
7.2
Action
Maintenance p
ersonnel
Maintenance
personnel
Maintenance
personnel
8.2.9
6.1.4 Semiannual
Operators are responsible for carrying out these inspections when the crusher stops every half
year or every 1000 hours.
Operator
8.2.18.3
Operator
8.6.28.6.3
Operator
10.1 10.3
Action
6.1.5 Annual
Operators are responsible for carrying out these inspections when the crusher stops every year
or every 2000 hours.
Action
Person in charge Reference
Check if the upper frame and lower frame assembly are Maintenance
worn.
personnel
Check if the adjustment cylinder seal is worn.
Check the conical contact surface between the upper
frame and
Maintenance
personnel
Maintenance
lower frame.
personnel
Maintenance
personnel
Maintenance
personnel
Maintenance
Check the end-play between the reference column and gear hub.
Check if the eccentric bushing is worn or scratched.
personnel
Maintenance
personnel
Maintenance
personnel
Maintenance
personnel
Maintenance
personnel
Maintenance
personnel
Maintenance
personnel
Maintenance
personnel
Operator
Operator
7.4
8.2.7
Operator
8.2.11
M30 bolt
M30x600
SG160-15-06
Use
To lift the plunger wear plate
To lift lower frame liner
To assemble and disassemble the plunger of
adjustment cylinder
M30 nut
M30
GB6170-86
M42
M20
SG160-15-05
GB825-88
GB825-88
To fix plunger
To lift the mantle
To lift the end cap of dust-proof seal
Eyebolt
M16
GB825-88
Eyebolt
M10
GB825-88
Eyebolt
M8
GB825-88
41 x46
GB4388-95 -01
32 x36
22 x24
300 x36
GB4388-95 -02
GB4388-95 -03
GB4440-98-01
adjustable spanner
200 x24
GB4440-98-02
14 mm
10 mm
GB5356-85-01
GB5356-85-02
6 mm
GB5356-85-03
Cable
M42 bolt wrench
SG160-15-03
SG160-15-01
1. Spy hole
Use a clearance gauge to check the clearance between the dust-proof ring and main shaft.
The maximum clearance allowed between the dust-proof ring and main shaft is
mm (inch)
1.3 (0.51)
6.3.2 Scraper
To keep dust and material etc off the surface of the dust-proof frame (4), a scraper (5) is installed
under the dust-proof ring end cap (2) of the crusher. It is composed of rubber and fixing plate. The
fixing plate is attached to the bottom of the keeper ring by bolts.
The scraper (5) ensures that there is always space for the main shaft to move up and down. If
there is swing motion, the iron will enter the cavity.
Regularly check the condition of the scraper (5). Clean the dust-proof frame and lower frame arm
if necessary.
6.4 Belts
Do not move the fixing plate.
Do not run the cone crusher before installing the fixing plate around the movable parts.
6.4.1
Rotating direction
6.4.2
Belt tension
In the first few of running, the belt tension needs to be checked frequently because the new belts
can be stretched. If the belts are not fully stretched, they may be slippery and their service lives
will be shortened.
The proper belt tension can be determined by deflection load-bearing stress with a gauge such
spring scale, tension meter and the like.
Normal
SPC
7 (15.4)
12.0 (26.5)
8V
9 (19.8)
14.0 (30.9)
dirt in
the
wear.
arrow)
GP380-04-01
GP380-04-02
GP380-05-03
GP380-05-04
1
GP380-05-05
6.7.1 Dust-proof sealing principle
The condition of the dust-proof ring determines the function of the dust-proof frame. If the dustproof ring is worn or becomes oval, it will increase the clearance of dust-proof frame and increase
the possibility of ingress of dust.
A plastic hose is installed between the crusher and oil tank to balance the pressure. One end is
connected to the T shaped connector (2) on the crusher, which is just above the pinion shaft box
and the other end is connected to the sleeve (5) welded on the outside surface above the oil level
in the oil tank.
Caution! The cap of the oil tank should have air tightness. Adjust or change the seal ring if
necessary.
Overpressure in the crusher and oil tank is to prevent dust from entering the crusher. The
overpressure is realized by supplying compressed air with air blower or pressure adjustment
device. Please refer to air blower in chapter 6.7.2 and adjustment device of compressed air in
chapter 6.7.3. the crusher get the overpressure air by the same connector T (2) used for balancing
the pressure between the hose and oil tank.
Inspection
When the crusher is running, the air pressure at the feed opening should be 600-1000Pa (60-100
mm w.g.).
6.7.2
Air blower
The capacity of the air blower should be no less than 0.3 m3/min under the pressure of 600
Pa (60 mm w.g).
Inspection
The air filter of the air blower has a replaceable paper-core. Please regularly check the filter
element and replace it if necessary.
4 air blower
6 filter element
3pressure gauge
7pressure
adjustment
device
8filter element
9compressed air
2 T shaped
connector
connector
4 air blower
5 sleeve
Chapter Seven
Lubrication
This chapter introduces the requirements for lube oil of the cone crusher.
To ensure safety, please read carefully safety precautions in the chapter 2 before carrying out
any work or adjustment on the machine.
7.1 Requirements for lube oil
In order to optimize the performance of the crusher, the lube oil used in the crusher must be
strictly restricted.
Caution! During warranty period, it is not allowed to use lube oil that doesnt conform to our
requirements.
Danger of fire and toxic gases
Oil products may cause environmental pollution and fire. Inhale or skin contact with
oil may cause damage to human body. Please follow the safety instructions of the
manufacturer when handling the oil or grease.
Caution! Replace oil according to instructions in replacing oil in chapter 5.3.
Inspection
If the color of the lube oil has changed, it shows that there may be water or dirt in the oil. In this
case, it needs to be replaced.
7.1.1 Miscibility
Caution! Do not mix lube oils of different brands or types unless they are suitable for mixing. Or it
will cause poor mixing or precipitation and thus lose its lubricating features.
Usually before replacing the oil, the old lube oil should be thoroughly cleaned. The oil
manufacturer can provide information about miscibility.
Normal
High temperatures
Low temperatures
Below OC (32F)
ISO VG 100
DIN 51 517-CLP 1
00
Requirement
220
100
100
100
12
-6 C (21.2F)
-12C (10.4F)
sulfur / phosphorus
sulfur / phosphoru
s
Ambient temperature
Viscosity
Specifications
Performance
Test method
synthetic oil because this type of oil has a high viscosity. Usually the ISO VG 150 viscosity oil can
be used all year round.
If the ambient temperature exceeds 32 C (90 F), it may be necessary to follow instructions in
operation under high temperatures to reset temperature control switches TG1 and TG2. Or TG1
may trip due to high temperature thus stop the crusher. Please refer to temperature switch in
chapter 8.2.11.
E.g.: Tribol Bio Top 1418/150 (VI> 170)
Quantity of lube oil
Capacity
Lube oil tank
150 liters (40 gallons)
When the crusher is running, the oil level must be above the marked lowest level. Please observe
the oil level indicator in the oil tank.
When the crusher stops, some lube oil may remain in the crusher and oil pipes, so after test-run,
the oil tank should be filled. To avoid oil overflow after the oil in the crusher return to the oil tank,
if the oil pipe between the oil tank and crusher is very long, the oil filling should be strictly
controlled.
Caution! During operation, please make sure that heating elements and oil control switches are
always immersed in the lube oil so that overheat of heating elements could be avoided.
Oil replacement
To ensure good condition of lube oil, it is recommended to send oil sample to the supplier every
month to work with them to set a proper interval for replacing the oil.
If the oil is changed to another brand or type, all the oil in the system needs to be replaced. This
is especially important when the oil is changed from leaded oil to oil with sulfur / phosphorus
additive. The remaining oil in the crusher should be drained by cutting the oil supply pipe
between the crusher and oil tank at a proper point. After the oil is drained, the main shaft must
be raised to the highest position to let the oil in the hydraulic plunger overflow.
7.3 Lube oil used in the hydraulic system
Requirement descriptions
Oil used in the hydraulic system must be easy to mix with lube oil and conform to the same
requirements. But its viscosity must conform to requirements of ISO VG 68 and oil is in
accordance with DIN 51 517-CLP 68.
Requirements for hydraulic oil
Performance
40C (104)basic oil
viscosity, unit mm
(cSt)
Viscosity index
FZG
Lowest flow point
EPadditive
Requiremnts
Test method
68
DIN 51 519
100
12
-15C (5F)
sulfur / phosphorus
Tocaxe Meropa 68
Caution! Do not use oil that is more viscous than ISO VG 68 or ordinary hydraulic oil.
Under extremely low temperatures, problems may arise when the crusher is operating in the open
air with recommended oil. If that is the case, please contact us to get information about changing it
to another type of oil with lower viscosity.
Bio-degradable lube oil
If bio-degradable lube oil is used, we recommend that you only choose 100% Ester type
synthetic
oil
E.G. Tribol Bio Top 1448/68
Quantity of lube oil
Capacity
Hydraulic oil tank
40 liters (10.7gallons)
When filling oil to the hydraulic oil tank, the main shaft must be at the lowest position. If it is at
the highest position, the oil tank may not have enough space to hold all the oil when it lowers
down.
Oil replacement
When changing lube oil, the oil in the hydraulic system should also be changed. Please refer to
oil replacement in chapter 5.3 and lube oil used in the lubricating system in chapter 7.2.
7.4 Lube oil for the pinion shaft
When the crusher leaves the factory, there is a label near the pinion shaft to indicate the type of
oil used in the pinion shaft box. Do not mix oils of different types.
The oil used for pinion shaft should be the same with the oil used in the main lubricating system.
Please refer to lube oil used in the lubricating system in chapter 7.2.
Quantity of lube oil
Quantity of lube oil
Pinion shaft box
0.8 liter (0.21gallon)
Drain plug (4) and oil level pipe (3) are installed at the bottom of pinion shaft box, when filling
oil, the drain plug must remain at the original position. The quantity of filled oil is slightly more
than that of required. After the oil level in the pinion shaft box becomes stable, remove the drain
plug to discharge excess oil in the oil level pipe.
Caution! Every time when your check the oil level, it should be filled full and excess oil should be
discharged. Or some oil will overflow from the oil level pipe, which give people a false
impression that the oil level is too high.
Oil replacement
Regularly check the oil level and replace the lube oil every 2000 hours or every year. Remove the
oil level pipe and drain plug to drain the old oil.
Air nozzle is installed on the filler plug at the top of pinion shaft box. It must be cleaned about
every two months, or it may cause damage to the seal and thus lead to leakage.
7.5 Grease for arm bearing
The main shaft rotates in the arm bearing and the pressure is very high although the rotating
speed is relatively low. It is very important to use the correct type of grease to make sure that the
grease can permeate to the bearing surface.
Requirements descriptions
The grease should meet the requirements in the table below to make sure that the arm bearing is
constantly lubricated under vibration and heavy load. Besides, the grease should also provide good
anti-corrosive protection. The arm bearing contains alloy, cast iron and nitrile rubber. Therefore
grease must do no harm to these materials.
Requirements for grease in arm bearing
Requirements
Test method
Viscosity
0 or 00
NLGI
400
Additive
Silver or uranium
Drop point
140C (284F)
Anti-corrosive
Approved
Performance
Other properties
--must have EP additive
--can be pumped
Recommended operational temperature is between -10C to +100C (14 F to 212F). if the
operation is under extreme ambient conditions, please contact the lube oil supplier.
Grease examples
The examples below are the greases that conform to our requirements.
The local conditions may vary in different countries. For your own safety, please choose the right
grease supplier.
Besides the greases listed below, some other brands of grease may also be used as long as they
conform to our quality standards.
Mobil Mobilith SHC 007 (643569)
Statoil GreaseWay LiCaX90
Molub-Alloy Tribol 3020/1000-00
Texaco Marfak 00 (01907)
Quantity of grease
Arm bearing
Quantity of grease
3-4 kg (6.6-8.8 pounds)
The arm bearing must be filled with grease to the correct level, which is close to the quantity
stated in the table above. When filling the grease, the main shaft must be at the lowest position.
1 grease pipe
2 grease level
3 spy hole
4 arm bearing seal
5 ventilation pipe
The grease is pumped in through a channel in one arm frame of the upper frame.
of arm bearing may be damaged. Make sure that there is no oil or stone dust on the main shaft
to prevent the dirt from entering the arm bearing through the arm bearing seal (4)when the
main shaft is raised. Frequently check the grease level and replace it when necessary. If the
arm bearing seal is damaged, replace it as soon as possible.
There is a label along the grease nozzle on the arm frame of upper frame for showing the type
of grease in the arm bearing before delivery. Do not mix different types of grease together.
When installing the new mantle liner and/or concave liner, please carefully clean the arm bearing
and seal then fill in fresh grease. To avoid downtime, it is recommended to change the arm bearing
seal (4)when the liner is changed.
Chapter Eight
This chapter introduces the maintenance procedures of the hydraulic and lubricating system of
the cone crusher.
To ensure safety, please read carefully safety precautions in the chapter 2 before carrying out
any work or adjustment on the machine.
8.1 Overview
8.1.1 Oil tank
The oil tank is composed of a pump with a driving motor, a cabinet with filters etc and there are
lubricating and hydraulic tanks.
3 namepalte
4 cabinet
8.1.2 Cabinet
Components of the main lubricating system and hydraulic system are installed inside the cabinet.
hydraulic system
1 pressure indicator
2 thermometer
3 pressure gauge
4 lubricating oil pump
5
pressure
gauge
connector
6 pressure sensor
7 filter element
8 magnetic plug
9 stop valve
10 safety valve
11 stop valve
12 lube oil inlet (from crusher)
13 lube oil outlet (to crusher)
Remove the drain plug (14) to clean the precipitate. Perform the action regularly to avoid too
much water in the oil.
Caution! When the oil level drops to just above the oil inlet, stop the pump immediately, or it may
be damaged, because the pump cannot run without oil.
8.2.2 Magnetic plug
Magnetic plug (8) protects the oil pump and it is installed before the oil pump.
Caution! Regularly clean the magnetic plug. If it is blocked, the pump will fail. Please refer to
clean magnetic plug in chapter 8.3.2.
Caution! Under any circumstance, the gauze element is indispensible and it cannot be replaced by
other types with different apertures.
18 gauze element
19 plug
Caution! When starting the oil pump, the oil tank must be filled with oil. Check and make sure
that the stop valve before the magnetic plug is on before starting the oil pump.
Replacement
The capacity of the pump under standard operational temperatures and pressures is shown in the
following table. (if the motor is connected with power source with the frequency of 60Hz, not
50Hz, the capacity will be 20% higher and the oil flow will increase as well.)
If the oil flow drops to the minimum value in the table, the oil pump should be replaced.
Flow rate of lube oil
Normal capacity
Minimum capaci
ty
z
ty
Normal capacity
Minimum capaci
8.7
27
7.1
40
10.6
27
7.1
Inspection
Check the oil supply condition by measuring the oil flow quantity. Put a bucket with a specific
capacity under the opening of the return oil chamber and then measure the time needed for filling
the bucket.
E.G. if it takes 20 minutes to fill a bucket with a capacity of 10 liters, the oil flow rate is
(10X60)/20 = 30 liters /min
8.2.5 Pressure gauge
The pressure gauge (3) shows the pressure value measured by the pressure gauge connector (5)
between the oil pump (4) and filter element (7).
Inspection
Regularly check the pressure and record the readings. Under normal operational temperatures, the
pressure in the main system is usually 0.15-0.5 MPa (21.8-72.5psi). the value depends on the
installation of the oil tank. If the pressure increases before the filter element, the filter element
needs to be replaced. Extremely low pressures may show that the pump is worn or the magnetic
plug is blocked.
1 pressure indicator
light
2 thermometer
3 pressure gauge
4 lube oil pump
5 pressure gauge
connector
6 pressure drop
sensor
7 filter element
8 magnetic plug
9 stop valve
10 safety valve
11 stop valve
1 pressure drop
indicator light
2 thermometer
3 pressure gauge
4 lube oil pump
5 pressure gauge
connector
6 pressure drop
sensor
7 filter element
8 magnetic plug
9 stop valve
10 safety valve
11 stop valve
20 float
21 baffle plate
22 adjustable lower outlet
23 filter mesh
24 return oil chamber
26 protective temperature
Operation under
condition
High temperatures
Low temperatures
Ambient temperature
Maximum 32 C
Maximum 40 C
Lower than 0 C
ISO VG 150
150VG 220
ISO VG 100
Basic setting
54 C
60 C
52 C
Turn off at
Turn on at
Different settings
54 C
57 C
1
60 C
63 C
1
52 C
55 C
1
Protective temperature
control switch TG1
Caution! When the oil temperature is too high due to a serious fault in the lubricating system, such
as failure of cooling system, the protective temperature control switch TG1 will stop the crusher.
Therefore it is very important that no element should split the current. Before restarting the
crusher, check the lubricating system and locate the cause then solve it.
TG2 controls the oil cooling
Operational
conditions
Normal operational
condition
Operation under
High temperatures
Operation under
Low temperatures
Ambient temperature
Maixum 32 C
(90F)
ISO VG 150
150VG 220
ISO VG 100
Basic setting
38 C46 C
42 C50 C
33 C 42 C
Turn off at
46 C
50 C
42 C
Turn on at
38 C
42 C
33 C
Different settings
Inspection
Put a thermometer near the sensing heads to check the temperature control switch of the radiator
TG2 and record the start and stop temperature of the air conditioner and cooling fan.
Slowly put the sensing heads and thermometer into the oil tank that is being heated and check the
protective temperature control switch TG1. Record the temperature at which the contact point
separates and then wait until the oil cools down and then record the temperature at which the
contact point closes.
8.2.12 Heating the oil
Before starting the crusher, the oil should be heated to the given temperature in the table F, which
can prevent the oil from overflowing from the dust-proof frame.
TG3 oil temperature
Operational conditions
Ambient temperature
Maximum 32C
(90F)
Maximum 40C
(104F)
Low er than 0C
(32 F)
ISO VG 150
ISO VG 220
ISO VG 100
20C (86 F)
30C (99F)
16C (77 F)
Basic setting
20 C (86 F)
30 C (99 F)
16C (68 F)
Turn off at
20 C (86 F)
30 C (99 F)
16 C (68 F)
Turn on at
27 C (95 F)
35 C (108 F)
20 C (77 F)
Different settings
Caution! The oil heater should be working 24 hours a day. The heating element is controlled by
the oil temperature control switch.
Inspection
During operation, check and make sure that the heating element and sensors of the oil
temperature control switch are always immersed in the oil.
8.3Replace the lube oil
Caution! Please follow the procedures below.
8.3.1 Drain the main lubricating system
a) Disconnect the oil pipe from the outlet on the oil tank.
b) Drain all the oil in the crusher.
c) Push the L1 button box near the crusher to raise the main shaft and drain the oil from the piston
d) Reconnect the oil pipe to the outlet.
e) Disconnect the oil pipe at the lowest position to drain oil in the radiator.
Caution! The lowest position is usually the connection on the oil tank.
f) Drain all the oil in the radiator.
g) Reconnect all the pipes.
31 L1button box
h)remove the drain plug at the bottom of the lube oil tank to drain the lube oil tank.
18 gauze element
19 plug
pressure drop
indicator light
2 thermometer
3 pressure gauge
4 lube oil pump
5 pressure gauge connector
6 pressure drop sensor
7 filter element
8 magnetic plug
9 stop valve
10 safety valve
11 stop valve
The setting of the crusher can be changed by the hydraulic system.. the adjustment of setting is
realized by raising (to decrease the setting) or lowering down (to increase the setting) the
hydraulic piston and main shaft assembly (including the mantle liner) which is supported by the
hydraulic piston. When the setting decreases, the oil is pumped to the hydraulic cylinder and when
the setting increases, the oil is pumped back to the hydraulic oil tank. There is pressure gauge (1)
on the oil tank to show the pressure in the hydraulic system.
1 pressure gauge
2 filter element
3 hydraulic pump
4 damper
5 control valve
6 magnetic plug
7 hydraulic connector
a) Use L1 button box (8) to lower down the main shaft and hydraulic piston to the lowest
position to release the pressure in the system.
b) Prepare a bucket to collect the oil.
c) Remove and clean the magnetic plug.
8.5.4 Control valve
There is a control valve (5) between the crusher and hydraulic pump and it a one-way valve that
controls the oil flow to protect the pump.
Emergency manual start of the valve
The control valve (5) has a manual start device for emergency use. When the dirt in the oil block
the valve and the setting cannot be increased by the electric method, carry out the following steps:
a) Loosen the cap (11).
b) Push in the pin (10). If it is hard to do that, put a 10mm bead on the cap
c) Start the pump to increase the setting (useL1button box to lower down the main shaft to a
proper position.).
d) Stop the pump.
Caution! If the valve is improperly operated, remove and clean it. If it still doesnt work, the cap
must be replaced. Always keep the hydraulic system clean to reduce the risk of blockage of the
valve by dirt.
9 pressure limit
valve
10 pin
11 cap
gauge helps to provide a more accurate pressure reading.
Cleaning
Open the damping valve (4) to clean the needle valve every week. After that, close the damping
valve until the pointer of pressure gauge (1) can move freely.
Chapter Nine
Energy Accumulator
top of the container by gas charging valve. The rubber gasbag is filled with nitrogen.
1 energy accumulator
2 automatic switch valve
3 air release valve
4 flow meter
Everyones responsibility
If the energy accumulator is suspected to have been damaged, it must be rechecked by authorized
personnel. It is recommended to buy new ones from our factory.
9.2 Flow meter
9.3 Inflatable kit (optional)
Danger of explosion
Mixture of air and oil with high pressure has a risk of explosion. Energy accumulator can
only be filled with nitrogen (N2).
The inflatable kit (FPU-1) can be used to check the air pressure in the energy accumulator
and nitrogen should be added when necessary. The inflatable kit is composed of air
release valve with pressure gauge and connecting device as well as hoses and
connectors for connecting with energy accumulator.
9.3.1 Check the air pressure
Install the inflatable kit
a) Loosen the he screw of protective cap (1) and (2) on the air charging valve of energy
accumulator.
b) Loosen the inner hexagon bolt (6) so that its sectional opening can be seen from the top of the
adaptor (5).
c) Close the vent valve (8).
d) Connect the air charging connector (3) of the energy accumulator to the adaptor (5). Tighten it
to avoid air leakage.
e) Put a thread connector (7) on the adapt (5) or and tighten it to avoid air leakage.
f) Tighten the valve rod (9) so that the valve inside the energy accumulator can open.
g) Read the charging pressure on the pressure gauge.
Remove the inflatable kit
h) Loosen the screw of valve rod (9).
i) Open the vent valve (8).
j) Loosen the threaded connector (7) and remove the inflatable kit(FPU-1 ).
k) Loosen the adaptor (5) and remove it from the air charging connector (3) of energy
accumulator.
l) Check and make sure that the valve has no leakage. This can done with the help of soapy
water.
m) Reinstall the protective cap on the air charging valve of energy accumulator.
Tolerence
5%
With ASRi
5%
a) Install the threaded connector (12) and air charging hose (11) on the nitrogen cylinder.
b) Loosen the he screw of protective cap (1) and (2) on the air charging valve of energy
accumulator.
c) Loosen the inner hexagon bolt (6) so that its sectional opening can be seen from the top of the
adaptor (5).
d) Close the vent valve (8).
e) Connect the air charging connector (3) of the energy accumulator to the adaptor (5). Tighten it
to avoid air leakage.
f)
g)
h)
i)
Put a thread connector (7) on the adapt (5) or and tighten it to avoid air leakage.
Tighten the valve rod (9) so that the valve inside the energy accumulator can open.
Carefully open the valve on the nitrogen cylinder to
Close the valve on the nitrogen cylinder and wait for 5 minutes an then check the pressure. If
the pressure is too high, release some air through the vent valve (8) to achieve a proper
pressure.
j) Loosen the screw of the valve rod (9).
k) Open the vent valve (8).
l) Loosen the screw connector (7) and remove the inflatable kit(FPU-1).
m) Loosen the adaptor (5) and remove the adaptor from the charging connector of energy
accumulator (3).
n) Check and make sure that the valve has no leakage. This can be done with the help of soapy
water.
o) Reinstall the protective cap (1) and (2) back to the charging valve of energy accumulator.
p) Remove the inflatable kit from the nitrogen cylinder.
Caution! Recheck the pressure after one, two and three weeks and then recheck it every 6 months.
Chapter Ten
Code
Quantity
Bolt M2055
SG160-06-0
2
SG160-06-0
3
GB5783-86 4
Spring washer 20
GB93-97
Remarks
Weight 135 kg
Caution! Before removing the arm frame cap, disassemble the feed distributor (if installed), and
clear the material in the feed tube.
Reommended tools
Lifting rigging
and
chains
Lifting cables
Mobile crane
Clearance gauge
rugs
24mm pen-end wrench
Lifting load
Please mind the weight of the arm frame cap as shown in the table above. Handle it
carefully. The cables should be tight, but the lifting should not start right away.
1. Lifting eye
3. O ring
4. hexagon bolt
5. spring washer
6. arm frame cap
Please keep away from the load.
f) Carefully lift the arm frame cap from the upper frame assembly.
g) Remove the O ring (SG160-06-03) from the arm frame cap (SG160-06-02).
h) Put the arm frame cap (SG160-06-02) on the ground.
i) Clear all the grease in the arm frame bearing.
3
M2055
20
GP380-06-02
10.1.2 Disassembly and inspection of arm frame cap
Check the clearance, make a record and compare it with the previous measurement.
Clean and check the rim of arm frame cap (SG160-06-02 ) and O ring (SG160-06-03), then install
the upper frame of O ring. If the O ring is damaged, replace it timely.
Check if the arm frame cap (SG160-06-02) is worn. If yes, weld t
10.1.3 Install the arm frame cap
a) Locate the hook of the crane right above the arm frame cap (SG160-06-02 ).
b) Put the hook into the lifting eye of arm frame cap (SG160-06-02).
c) Lift up the hanging part of the cable.
Please mind the weight of the arm frame cap as shown in the table above. Handle it carefully. The
cables should be tight, but the lifting should not start right away. Please keep away from the load.
d) Lift up the arm frame cap from the ground carefully.
e) Grease the O ring (SG160-06-03) and locate it on the arm frame cap.
f) Put the arm frame cap on the upper frame and install four hexagon M2055 bolts and spring
washer 20.
g) Fill in grease. Please refer to grease for arm bearing in chapter 7.5.
10.2 Check the cavity
Check the liners at a proper interval. Please refer to daily inspection and maintenance in
chapter 6.1. new machines must be inspected more frequently. After the liners are replaced twice,
the inspection interval can be longer.
Daily inspection can help to decide the right time to replace the liners. It is hard to tell the wear
limit of a liner. Decrease of capacity or thickness, nicks and cracks are all signs of wear.
During harsh operational conditions, the liners may need to be replaced before they are worn.
One possible reason for this is improper feed, which leads to excessive wear on one side of the
mantle. It also shows that the setting may differ due to different measurement positions on the
circumference of the cavity.
A A dimension
B groove
C groove
Check the clearance of the arm frame bearing when changing the liners or twice every year
(1000hours). If the feed material is very abrasive, the inspection frequency should be increased.
If the clearance (S) is close to the maximum value allowed, and the old bushing continues to be
used, the frequency of filling grease should be increased.
When measuring the clearance (8), push the main shaft toward the direction of main shaft
inclination and then measure with the clearance gauge at the other side. The clearance gauge
should be parallel with the pivot. It is included in the tool box delivered along with the crusher.
Caution! Make sure that the clearance gauge will not damage the oil seal of arm frame bearing or
the scraper.
If the clearance exceeds the maximum value allowed, the pipe connection and/or main shaft
bushing must be replaced. When removing the bearing, the old parts should be measured to make
a comparison with new ones so that the worst worn part can be found and then the replacement of
the one part can help to achieve a proper clearance.
If the clearance is much larger than the maximum value, abnormal inclination of the main shaft
occurred in the crushing process and the wear angle of the eccentric is incorrect.
Chapter Eleven
Setting Measurement
Chapter Twelve
Trouble Shooting
signal.
The oil doesnt return to the
oil tank (low temperature).
The
crusher
stops when it
is running at
idle speed or
there
is
material in the
cavity.
motor
is
The
temperature of
lube oil is too
high.
Start the oil pump and let it run for about 30s.
Connect the return oil flow switch to get ready
for start signal. Start the crusher and run it for
about 20s. After about 40s disconnect the
switch. If the crusher still cannot start. Wait for
a few minutes and repeat the procedures.
Check the circuit and starter of the oil pump
motor. Start the pump.
Check and make sure that the oil doesnt
overflow from the dust-proof frame. Check the
oil pipe. If the blockage of return oil pipe is
found, clear the blockage timely.
Clean the magnetic plug. If necessary, replace
the filter element.
Check the capacity of the pump and the oil
level.
Check the switch of return oil flow.
Please refer to number 3.
Adjust the belt tension and if necessary, replace
the belts.
Reduce the load of the crusher.
Check and make sure that the eccentricity and
cavity shape are correct regarding the chosen
CSS and feed material. If the CSS is too small,
increase the setting timely.
Check if there is anything wrong with the
bearing. Please refer to number 9.
Please refer to 5.6.
Lower down the main shaft to release the
blockage. Check all the liners to see if they are
worn or loose. Reset the motor and overload
protection. Check the belt tension and adjust it
if necessary.
If lowering down the main shaft doesnt help, it
may be necessary to loosen the bolts on the
upper frame.
Check the oil cooling system and the
temperature control switch of the radiator TG2.
Please refer to 8.2.11.
As for water/oil radiator, check the fan motor
and starter. Clean the radiator core. Check and
make sure there is enough cool air. Please refer
to 8.5.
The radiator and oil tank compartment should
be avoided from direct sunlight.
Check and make sure that the safety valve has
no leakage. Please refer to 8.2.8
If the dirt on the return oil mesh increases,
check if the bearing is faulty. Please refer to
8.2.10.
Please refer to the content above.
If the viscosity of the lube oil is incorrect,
please change the oil. Please refer to 7.2 and
8.3.
Check the oil pipes and remove the obstacles.
The
crusher
doesnt
maintain
a
constant CSS
or the product
size is too
large.
leakage.
Inspections of
the
pinion
shaft device
There
is
abnormal
noise
inside
the crusher.
The capacity
of the crusher
drops down.
The wear of
bearing
components
increases.
The bearing in
the crusher is
faulty.
If possible, remove the bolts that fix the dustproof frame. Disassemble the main shaft
assembly and the whole eccentric assembly.
10
11
The hydraulic
bolts
are
broken.
13
The bolts of
concave
are
broken.
The
oil
capacity drops
down, even to
zero.
Appendix A: Inspection
Replicate the inspection list and the inspection record in this appendix and use them in
accordance with the instructions in daily inspection and maintenance in chapter 6.1.
To ensure safety, please read carefully safety precautions in the chapter 2 before carrying out
any work or adjustment on the machine.
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Remarks