INSTRUCTION MANUAL

SPRING CONE CRUSHER

CHYI MEANG MACHINERY CO., LTD.

NO.535, CHIEH SHOU RD. SEC.2, PATE CITY
TAOYUAN HSIEN TAIWAN R.O.C.
Tel:886-3-3666167 6 LINES
Fax:886-3-3668366
EMAIL:webmaster@chyimeang.com
 INSTRUCTION MANUAL
FOR
SPRING CONE CRUSHER
CONTENTS

CHAPTER 1 INTRODUCTION .......................................................................1-1

CHPATER 2 EQUIPMENT DESCRIPTION ....................................................2-1

CHPATER 3 INSTALLATION ..........................................................................3-1

CHPATER 4 TRIAL RUN .................................................................................4-1

CHPATER 5 OPERATION ................................................................................5-1

CHPATER 6 MAINTENANCE AND TROUBLE SHOOTING.......................6-1

CHPATER 7 AUXILIARY EQUIPMENT.........................................................7-1

CHPATER 8 LUBRICATION SYSTEM ...........................................................8-1

CHPATER 9 PARTS LIST .................................................................................9-1

CHPATER 10 PARTS REPLACEMENT ..........................................................10-1

 CHPATER 1 INTRODUCTION

1.1 GENERALITY.............................................................................................1-1

1.2 HOW TO READ THIS INSTRUCTION MANUAL ..................................1-1

1.3 SAFETY INSTRUCTIONS .........................................................................1-2

1.4 THE PROCESS OF SAFETY CRUSHES/SCREEN AND

RELATIVE EQUIPMENTS ........................................................................1-2

1.4.1 PERSONAL SAFETY ........................................................................1-2

1.4.2 SAFETY AND RULES ......................................................................1-3

1.4.3 WORK AREA SAFETY.....................................................................1-4

1.4.4 EQUIPMENT AND TOOLS SAFETY ..............................................1-4

 CHAPTER 1 INTRODUCTION

1.1 GENERALITY：
AT FIRST, WE DO APPRECIATE YOU TO CHOOSE CHYI-MEANG’S SERIES CRUSHING
AND SCREENING EQUIPMENTS.
ALL THE PERSONNEL OF CHYI MEANG DO KEEP A AUSTERE WORKING ATTITUDE
IN ORDER TO REACH EASY MAINTENANCE AND OPERATION, WE HOPE TO OFFER THE
BEST SERVICE FOR YOU.

1.2 HOW TO READ THIS INSTRUCTION MANUAL：

THIS INSTRUCTION MANUAL IS CLASSIFIED INTO CHAPTERS BY SUBJECTS. AND
SINCE EACH CHAPTER FORMS AN INDEPENDENT INSTRUCTION MANUAL FOR THE
SUBJECT CONCERNED, YOU CAN USE IT SEPARATELY FROM OTHER CHAPTERS. SINCE
EACH CHAPTER HAS THE CONTENT RELATED TO ONE ANOTHER, WE WOULD
SUGGEST YOU TO READ THROUGH ALL CHAPTER FROM BEGINNING.
THE CONTENTS OF EACH CHAPTER ARE SHOWN BELOW：

CHPATER TOPIC CONTENTS

GENERALITY, HOW TO READ THIS INSTRUCTION
1 INTRODUCTION
MANUAL
EQUIPMENT MODELS, CONSTRUCTION AND CRUSHING
2
DESCRIPTION MECHANISM
PROCEDURE, CAUTIONS (INCLUDING FOUNDATION
3 INSTALLATION
FEED HOPPER, MOTOR UNIT)
TRIAL RUN PROCESS, PRELIMINARY WORKS,
4 TRIAL RUN CAUTIONS (INCLUDING LOAD & UNLOAD TRIAL
RUN) ANALYSIS OF TRIAL RUN RESULT
CAUTIONS BEFORE OPERATION. OPERATION PROC-
5 OPERATIONS -EDURE, AUXILIARY EQUIPMENT OPERATION, AD-
-JUSTMENT OF DISCHARGE SETTING
MAINTENANCE AND CHECK ITEMS, TROUBLE SHOO-
6 MAINTENANCE
-TING
AUXILIARY
7 MODELS, CONSTRUCTION, PART LIST
EQUIPMENT
LUBRICATION SPECIFICATION, FILLING & DRAINING OIL,
8
SYSTEM QUANTITY, REPLACEMENT SCHEDULE
PART LIST OF PRINCIPLE UNIT, SECTIONAL
9 PART LIST
ELEVATION
PARTS
10 REPLACEMENT PROCEDURE FOR WEAR PARTS
REPLACEMENT

1-1
1.3 SAFETY INSTRUCTIONS：
THE OPERATION OF CHYI MEANG MACHINERY IS SUBJECT TO STATUTORY
SAFETY AND ACCIDENT PREVENTION REGULATIONS.
OUR MACHINERY COMPLIES WITH THE FOLLOWING SAFETY REGULATIONS:
CNS-LAW ON TECHINICAL WORKING FACILITY.
CNS-GENERAL ACCIDENT PREVENTION REGULATIONS.
CNS-ACCIDENT PREVENTION REGULATION-WORKING MACHINERY.
USERS IN THE R.O.C. ARE OBLIGED TO IMPLEMENT THE ABOVE-MENTIONED LAWS
AND REGULATIONS AND TO SEE THAT THEY ARE OBSERVED. USERS IN THE ABROAD
MUST OBSERVE THE SAFETY LAWS IN FORCE IN THE COUNTRY IN QUESTION. THE
CNS SAFETY REGULATIONS SHOULD BE TAKEN AS THE BASIC RULES WHICH SHOULD
BE ADAPTED TO LOCAL SAFETY REGULATIONS AS QPPOOPRIATE. UNLESS
OTHERWISE STIPULATED IN THE CONTRACT OF SALE, THE NECESSARY ADAPTATION
IS TO BE CARRIED OUT BY THE USER. THE LOCAL REGULATIONS ON ESCAPE ROUTES
MUST BE STRICTLY ADHERED TO FOR THE ERECTION AND OPERATION OF THE
RANGE.

1.4 THE PROCESS OF SAFETY CRUSHE/SCREEN AND RELATIVE EQUIPMENTS:

1.4.1 PERSONAL SAFETY
EQUIPMENT IS DESIGNED WITH THE SAFELY OF ALL PERSONNEL IN MIND.
DO NOT ATTEMPT TO CHANGE, MODIFY, OR ELIMINATE THE ACCIDENT
PREVENTION DEVICES INSTALLED AT THE FACTORY. MAKE SURE THAT ALL
PERSONNEL WHO REGULARLY WORK OR WHO MIGHT DO WORK IN THE AREA OF
THE EQUIPMENT ARE FAMILIAR WITH THE SAFETY PRECAUTIONS.
GUARDS, COVERS, AND SHIELDS ARE INSTALLED AROUND MOVING PARTS
AT THE FACTORY WHENEVER NECESSARY TO PREVENT ACCIDENTAL INJURY TO
OPERATORS AND OTHERS WORKING ON OR NEAR THE EQUIPMENT. DO NOT
REMOVE THEM.
WARNING: WHENEVER YOU SEE “WARNING SYMBOL” IT MEANS THAT
PERSONAL BODY INJURY MAY RESULT FROM IMPROPER PROCEDURES. EACH
WARNING NOTE IS ACCOMPANIED BY, AN INTERNATIONAL ALERT SYMBOL TO
HELP CALL YOUR ATTENTION TO SITUATIONS IN WHICH DANGER OF BODY
HARM MAY BE PRESENT. READ ALL WARNING NOTES CAREFULLY TO PREVENT
SOMEONE BEING HURT.
CAUTION: WHENEVER YOU SEE “CAUTION” IN THIS MANUAL, IT MEANS
THAT IF PROPER PROCEDURES ARE NOT FOLLOWED, SERIONS AND EXPENSIVE
DAMAGE TO YOUR MACHINE MAY RESULT.

1-2
1.4.2 SAFETY AND RULES
CRUSHES, SCREENING AND RELATIVE EQUIPMENTS RECOMMENDS THE
FOLLOWING BASIC SAFETY PRACTICES.
1. READ ALL WARNING, CAUTION, AND INSTRUCTION SIGNS.
2. NEVER LUBRICATE THE EQUIPMENT WHICH IT IS IN MOTION.
3. DO NOT REMOVE ANY GUARDS, COVERS, OR SHIELDS WHEN EQUIPMENT IS
RUNNING.
4. REPLACE ANY GUARDS, COVERS, OR SHIELDS AFTER ADJUSTMENT OR
MAINTENANCE.
5. ALWAYS ESTABLISH A POSITIVE LOCKOUT OF THE INVOLVED POWER
SOURCE BEFORE PERFORMING MAINTENANCE, CLEANING, ADJUSTING, OR
REPAIR. SECURE THE POWER SOURCE LOCKOUT TO PREVENT START-UP BY
OTHER PERSONS.
6. BLOCK PARTS AS NECESSARY TO PREVENT UNEXPECTED MOTION WHILE
PERFORMING MAINTENANCE, ADJUSTMENTS, OR PERAIR.
7. DO NOT ATTEMPT TO REMOVE JAMMED PRODUCT OR OTHER BLOCKAGE
FROM RUNNING EQUIPMENT. POWER MUST BE SHUT OFF AND LOCKED OUT
WHILE DOING SO.
8. USE ADEQUATE HEARING PROTECTION DEVICES WHENEVER THE NOISE
LEVEL IS ABOVE ACCEPTABLE LIMITS.
9. WEAR AN ADEQUATE PROTECTIVE BREATHING MASK WHEN DUST AND
FUMES ARE ABOVE ACCEPTABLE LIMITS.
10. WEAR ADEQUALE EYE PROTECTION GOGGLES OR SAFETY GLASSES WITH
SIDE SHIELDS TO PREVENT FLYING PARTICLES FROM ENTERING EYES.
11. HARD HATS ARE A GOOD IDEA IN ALL WORK SITES AND REQUIRED AT MOST.
WEAR YOURS.
12. MAINTAIN SAFE WORK HABITS BY DRESSING OPPROPRIATELY FOR THE JOB.
DO NOT WEAR LOOSE SLEEVES, FLOWING HAIR, LONG COAT TAILS, WRIST
WATCHES OR BRACELETS, OR POCKETS FULL OF TOOLS, WHICH COULD GET
CAUGHT IN MOVING MACHINERY. THIN-SOLED SHOES WITHOUT TREAD
COULD CAUSE UNEXPECTED FALLS OR ROOT INJURY. WEAR SAFE SHOES.
13. ALWAYS LOOK AROUND EQUIPMENT BEFORE STARTUP TO MAKE SURE NO
ONE IS NEAR MOVING PARTS, MAKING ADJUSTMENTS, OR PERFORMING
MAINTENANCE. KEEP ALERT TO WHERE YOUR CO-WORKERS ARE.
14. REPORT DEFECTIVE MACHINERY AND UNSAFE CONDITIONS TO YOUR
SUPERVISOR.
15. SAVE YOUR BACK. IF THE LOAD IS MORE THAN 40 1BS., GET HELP OR PROPER
LIFTING PROCEDURES. USE YOUR LEG MUSCLES, NOT YOUR BACK, FOR
LIFTING. KEEP LOADS CLOSE TO YOUR BODY. AVOID TWISTING MOTIONS
AND OVER-EXTENSIONS WHEN MOVING LOADS.

1-3
 16. MOST OF ALL, KNOW YOUR EQUIPMENT. UNDERSTAND THE MACHINE AND
THE CONDITIONS UNDER WHICH IT OPERATES. DON’T LIMIT PLAYING IT
STAGE TO ONLY THESE FEW RULES. THINK AND ACT SAFETY FOR YOUR
SPECIFIC WORK ENVIRONMENT AND YOUR PARTICULAR EQUIPMENT.
1.4.3 WORK AREA SAFETY
1. KEEP THE WORK AREA NEAT AND CLEAN.
2. KEEP ALL WARNING AND CAUTION SIGNS CLEAR AND UP TO DATE.
3. MAKE CERTAIN THAT ALL ELECTRICAL EQUIPMENT IS PROPERLY GROUNDED.
WET SPOTS NEAR ELECTRIC CURRENT ARE DANGEROUS.
4. STORE HAZARDOUS MATERIALS IN RESTRICTED ACCESS AREAS AND MARK
THEM CLEARLY.
5. MAKE CERTAIN ENOUGH VENTILATION IS PRESENT TO SAFETY RUN ENGINES.
DO NOT START AN ENGINE IN AN ENCLOSED SPACE WITHOUT PROPERLY
VENTED EXHAUST. EXHAUST FUMES FROM GASOLINE OR DIESEL CAN KILL!
6. DO NOT SMOKE OR ALLOW SMOKING NEAR FLAMMABLE FUELS OR
SOLVENTS. USE NON FLAMMABLE SOLVENTS WHEN POSSIBLE FOR
CLEANING PARTS AND EQUIPMENT.
7. AVOID ELECTRICAL AND STATIC SPARKS AND ANY OPEN FLAME WHEN
HANDING, MOVING OR POURING FUELS, BATTERY ELECTRICITIES,
HYDRAULIC FLUIDS, OR COOLANTS.
8. CHECK FOR LEAKS IN TANKS OR TUBING WITH FLASHLIGHTS OR OTHER
PROPER EQUIPMENT. NEVER USR AN OPEN FLAME TO CHECK FOR LEAKS.
9. KNOW WHERE FIRE EXTINGULSHERS AND OTHER FIRE SUPPRESSION
EQUIPMENT ARE LOCATED. LEARN TO USE THEM.
10. BE ALERT AND WARY AROUND ANY PRESSURIZED SYSTEM: HYDRAULIC OR
AIR. HIGH PRESSURE GASES AND OILS CAN BE VERY DANGEROUS. KNOW
YOUR EQUIPMENT AND OPERATE IT PROPERLY.
1.4.4 EQUIPMENT AND TOOLS SAFETY
1. CLEAN AND PROPERLY LABELES TOOLS ARE SAFER TOOLS. KEEP YOUR
EQUIPMENT AND TOOLS IN ORDER.
2. ALWAYS USE HOISTING EQUIPMENT FOR HEAVY LOADS. REGULARLY CHECK
HOOKS, CABLES, SHACKLES, AND CHAINS FOR STRETCH AND WEAR. NEVER
OVERLOAD THE LIFTING CAPCAITY OF HOISTS, CRANES, AND LIFTING
DEVICES.
3. KEEP V-BELTS AND SHEAVES IN GOOD CONDITION. FRAYED BELTS OR
CRACKED SHEAVES CAN BE DANGEROUS AND CAUSE DOWNTIME.
4. KEEP EQUIPMENT CLEAN AND FREE OF DIRT AND GREASE SO IT CAN BE
CHECKED FOR LOOSE, CRACKED, OR BROKEN PARTS. REPLACE DEFECTIVE
PARTS AS SOON AS DISCOVERED.

1-4
 CHAPTER 2 EQUIPMENT DESCRIPTION

2.1 INTRODUCTION ........................................................................................2-1

2.2 MODEL AND OTHER DESCRIPTION .....................................................2-2

2.3 FEED MATERIAL SIZE AND OTHER......................................................2-3

2.4 CONSTRUCTION OF PRINCIPLE UNIT .................................................2-3

2.4.1 LOWER FRAME ASSEMBLY ..........................................................2-3

2.4.2 UPPER FRAME ASSEMBLY............................................................2-5

2.4.3 ECCENTRIC SLEEVE ASSEMBLY.................................................2-7

2.4.4 SOCKET ASSEMBLY........................................................................2-9

2.4.5 COUNTERSHAFT BOX ASSEMBLY ..............................................2-10

2.4.6 FEED HOPPER ASSEMBLY.............................................................2-12

2.4.7 MANTLE CORE ASSEMBLY...........................................................2-13

2.5 CRUSHING MECHANISM ........................................................................2-15

 CHAPTER 2 EQUIPMENT DESCRIPTION

2.1 INTRODUCTION
THIS CHAPTER ONLY DESCRIBES CONSTRUCTION OF PRINCIPLE UNIT, AS FOR DETAIL
SPECIFICATION, QUANTITIES ETC. OF EACH PARTS IS SHOWN IN CHAPTER 9.
CHYI MEANG SPRING CONE CRUSHER DIVIDE INTO 3 TYPES ACCORDING TO DIFFERENT
APPLICATION. THEY ARE RELATIVELY COARSE CRUSHING TYPE (NCC OR CC), MEDIUM AND FINE
CRUSHING TYPE (NCF OR CF), SHORT HEAD TYPE FOR FINE CRUSHING (NCSH OR CSH)
RESPECTIVELY. BE SURE TO CHOOSE THE SUITABLE MODEL ACCORDING TO CAPACITY AND
APPLICATION. (COARSE CRUSHING OR FINE CRUSHING ETC) PLEASE REFER TO BELOW TABLE
(TABLE 2-1) FOR DETAIL INFORMATION.

FIG 2-1

FIG 2-2

FIG 2-3

2-1
2.2 MODEL AND RELATED CAPACITY, PRODUCT SIZE ETC.

CLOSED
SIDE FEED PRODUCT HOURLY POWER PULLEY WEIGHT
MODEL SETTING SIZE SIZE CAPACITY
(m/m) (m/m) (m/m) (T/H) (HP) R.P.M. (KG)

14 18~50 0~34 61~91

CSH900 75~100 630 10,500
18 20~60 0~39 63~95

20 30~80 0~44 69~103

CF900 23 37~92 0~49 79~118 75~100 630 10,500

28 40~110 0~60 96~144

40 50~150 0~70 128~192

CC900 75~100 630 10,500
65 70~170 0~100 179~269

14 18~50 0~32 92~138

CSH1200 150~250 560 22,400
18 20~70 0~37 97~146

20 23~80 0~43 102~153

CF1200 23 25~92 0~48 118~177 150~200 560 22,400

28 30~112 0~59 144~216

45 50~210 0~69 230~346

CC1200 150~250 560 22,400
80 90~250 0~111 307~461

60 70~260 0~89 384~576

NCC1600 200~250 510 42,000
80 90~280 0~119 486~730

TABLE 2-1

2-2
2.3 FEED MATERIAL SIZE AND OTHERS：
IN ORDER TO FEED MATERIAL SMOOTHLY AND AVOID GETTING STUCK IN CRUSHING
CHAMBER, PLEASE BE SURE TO FOLLOWING THE “FEED SIZE” IN TABLE 2.1. MOREOVER, THE MUD
CONTENT IN FEED MATERIAL IS AS LESS AS BETTER. TOO MUCH MUD WILL AFFECT THE CRUSHING
EFFECT AND LOWER DOWN CAPACITY.

2.4 MAIN CONSTRUCTION OF PRINCIPLE UNIT：

CHYI MEANG SPRING CONE CRUSHER HAS THE FEATURES OF SIMPLE, BUT ROBUST
CONSTRUCTION, USING EXCELLENT MATERIAL AND PARTICULARLY SUITABLE FOR HEAVY DUTY
APPLICATION. IT IS DIVIDED INTO SEVEN ASSEMBLY, i.e. LOWER FRAME ASSEMBLY, UPPER FRAEM
ASSEMBLY, ECCENTRIC SLEEVE ASSEMBLY, SOCKET ASSEMBLY, COUNTERSHAFT BOX ASSEMBLY,
FEED HOPPER ASSEMBLY AND MANTLE CORE ASSEMBLY.

2.4.1 LOWER FRAME ASSEMBLY：

IT IS THE MAIN PART OF SPRING CONE CRUSHER AND THERE ARE SEVERAL HYDRANLIC
CYLINDERS EQUIPPED AROUND IT. IT IS INTEGRALLY FABRICATED BY CO2 WELDING OF
OUTER BUSH HOLDER IN CENTRAL, A CASTING STEEL AND ROLLED THICK STEEL PLATE
OUTSIDE. THEN IT IS ANNEALED TO RELEASE STRESS. THE MAIN PARTS ARE SHOWN AS
BELOW TABLE AND ALSO REFER TO FIG 2-4 FOR CONSTRUCTION.

PART NO PART NAME FIXING METHOD

FIXED WITH UPPER FRAME BY SPRINGS,
1 LOWER FRAME
SPRING BOLTS/NUTS
LOWER FRAME
2 FIXED TO LOWER FRAME BY BOLTS
CAP
HYDRAULIC FIXED AROUND LOWER FRAME BY
3
CYLINDER PUSHING RODS
4 PUSHING ROD WELDED WITH HYDRAULIC CYLINDER
SUPPORTED BY UPPER & LOWER SPRING
5 SPRING
SEGMENT AND SPRING BOLTS
TO BE USED TO FIXED SPRING AND
6 SPRING BOLT
LOWER/UPPER FRAME
TABLE 2-2

2-3
FIG 2-4

2-4
 2.4.2 UPPER FRAME ASSEMBLY：
THE MAIN PART IS TOP CELL USED TO SUPPORT CONCAVE AND CONNECT WITH
ADJUSTMENT CAP, WITH FUNCTION OF ADJUST UPWARD/DOWNWARD MOVEMENT OF
CONCAVE BY MEAN OF THREAD.
THEREFORE, THE MAIN FUNCTION OF UPPER FRAME ASSEMBLY IS TO ADJUST THE
DISCHARG SETTING. THE MAIN PARTS ARE SHOWN AS BELOW TABLE AND PLEASE REFER TO
FIG 2-5 FOR CONSTRUCTION.

PART NO PART NAME FIXING METHOD

SUPPORTED BY UPPER FRAME BY MEANS
1 TOP CELL
OF THREAD
2 CONCAVE FIXED TO TOP CELL BY U-BOLTS
ADJUSTMENT FIXED TOP CELL BY ADJUSTMENT
3
CAP BOLTS AND TAPER KEYS
ADJUSTMENT USED TO FIX TOP CELL AND
4
BOLT ADJUSTMENT CAP
TO LOCK ADJUSTMENT RING DURING NORMAL WORKING
5 STOPPER CONDITION AND TO UNLOCK ADJUSTMENT RING WHILE
ADJUSTING DISCHARGE SET.
FIXED TO LOWER FRAME BY SPRINGS &
6 UPPER FRAME
SPRING BOLTS
TABLE 2-3

2-5
2-6
FIG 2-5
2.4.3 ECCENTRIC SLEEVE ASSEMBLY：
AN ECCENTRIC STRUCTURE WHICH IS DRIVEN BY PINION OF COUNTERSHAFT TO MAKE
MANTLE & SHAFT PRODUCE A GYRATORY MOTION. THE MAIN PARTS ARE AS BELOW AND
PLEASE PEFER TO FIG 2-6 FOR CONSTRUCTION.

PART NO PART NAME FIXING METHOD

1 GEAR FIXED TO ECCENTRIC SLEEVE BY KEY
ECCENTRIC SUPPORTED BY OUTER BUSH AND UPPER
2
SLEEVE STEP BEARING PLATE
FIXED TO ECCENTRIC SLEEVE BY MEANS
3 INNER BUSH
OF FILLING BABBITT METAL
UPPER STEP
4 FIXED TO ECCENTRIC SLEEVE BY PIN
BEARING PLATE
USED TO CONNECT ECCENTRIC SLEEVE
5 PIN
AND UPPER STEP BEARING PLATE
TABLE 2-4

2-7
FIG 2-6

2-8
2.4.4 SOCKET ASSEMBLY：
IT IS USED TO SUPPORT MANTLE’S GYRATORY MOTION WITH SHAPE LIKE BALL AND
SUPPORTED BY LOWER FRAME. THE MAIN PART IS AS BELOW AND PLEASE REFER TO FIG 2-7
FOR CONSTRUCTION.

PART NO PART NAME FIXING METHOD

1 SOCKET FIXED TO LOWER FRAME BY BOLTS
SOCKET FIXED TO SOCKET BY MEAN OF FILLING
2
LINEAR BABBITT METAL
TABLE 2-5

FIG 2-7

2-9
2.4.5 COUNTERSHAFT BOX ASSEMBLY：
THE MAIN FUNCTION OF THIS ASSEMBLY IS TO TRANSFER POWER FROM MOTOR TO
ECCENTRIC SLEEVE. THE COUNTERSHAFT IS DRIVEN BY MOTOR VIA PULLEYS AND BELTS,
AND THEN TRANSFERS POWER FROM COUNTERSHAFT TO ECCENTRIC SLEEVE VIA PINION
AND GEAR TO DRIVE ECCENTRIC SLEEVE ROTATE. THE MAIN PARTS ARE SHOWN AS BELOW
AND PLEASE REFER TO FIG 2-8 FOR CONSTRUCTION.

PART NO PART NAME FIXING METHOD

1 PULLEY FIXED TO COUNTERSHAFT BY KEY
SUPPORTED & POSITIONED INSIDE OF
2 COUNTERSHAFT
COUNTERSHAFT BOX BY BEARINGS
3 BEARING FIXED INSIDE COUNTERSHAFT BOX
4 PINION FIXED TO COUNTERSHAFT BY KEY
COUNTERSHAFT
5 FIXED TO LOWER FRAME BY BOLTS
BOX
TABLE 2-6

2-10
FIG 2-8

2-11
 2.4.6 FEED HOPPER ASSEMBLY：
THE MAIN FUNCTION OF THIS ASSEMBLY IS TO CONTAIN FEED MATERIALS AND GUIDE
THEM INTO CRUSHING CHAMBER. THE MAIN PARTS ARE AS BELOW AND PLEASE REFER TO FIG
2-9 FOR CONSTRUCTION.

PART NO PART NAME FIXING METHOD

ROLLED STEEL AND THEN FOLLOWED BY
1 FEED HOOPPER
WELDING. PUT ONTO ADJUSTMENT CAP
TOP CELL
2 WELDED ONTO FEED HOPPER
LINER
TABLE 2-7

FIG 2-9

2-12
 2.4.7 MANTLE CORE ASSEMBLY：
MANTLE CORE ASSEMBLY IS DRIVEN BY ECCENTRIC TO MAKE A GYRATORY MOTION TO
CRUSH METERIAL. THE MAIN PART IS AS BELOW AND PLEASE REFER TO FIG 2-10 FOR
CONSTRUCTION.

PART NO PART NAME FIXING METHOD

FIXED TO MAIN SHAFT BY MEANS OF
1 MANTLE CORE TWO TAPER SURFACE OF MAIN SHAFT
AND ITSELF RESPECTIVELY.
SHRINK FITTED INTO INNER HOLE OF
2 MAIN SHAFT
MANTLE CORE BY TWO TAPPER SURFACE
DUST SEAL SUPPORTED BY DUST SEAL PLATE AND
3
FING SOCKET
FIXED TO MAIN SHAFT BY MEANS OF
4 LOCKING CAP
THREAD
SUPPORTED BY LOCKING CAP AND
TIGHTING
5 LOCKING RING, IN POSITION BETWEEN
COLLAR
ABOVE TWO
SUPPORTED BY TIGHTING COLLOR AND
6 LOCKING RING MANTLE IN POSITION BETWEEN ABOVE
TWO
FIXED TO MANTLE CORE BY ABOVE PART
7 MANTLE
NO. 5, 6, 7
TABLE 2-8

2-13
FIG 2-10

2-14
2.5 CRUSHING MECHANISM
2.5.1 OPERATING PRINCIPLE：
THE OPERATING PRINCIPLE OF CRUSHING MECHANISM IS AS DESCRIBED BELOW.
THE POWER GENERATED BY MOTOR IS TRANSFERRED TO COUNTERSHAFT VIA V-PULLEYS
AND V-BELT AND CAUSE THE PULLEY ON COUNTERSHAFT ROTATE CLOCKWISE VIEWED FROM
OUTSIDE.
THE REVOLUTION OF SAID V-PULLEY CAUSES THE BEVEL PINION TO ROTATE VIA
COUNTERSHAFT, WHICH IN TURN CAUSES THE GEAR FIXED TO ECCENTRIC SLEEVE TO
ROTATE.
THE ECCENTRIC SLEEVE IS SUPPORTED BY UPPER STEP BEARING PLATE AND OUTER BUSH,
WHILE THE MAIN SHAFT AND MANTLE CORE ARE SUPPORTED BY INNER BUSH IN THE RADIAL
DIRECTION AND BY SOCKET LINER IN THE THRUST DIRECTION, THEREFORE, THE MANTLE
CORE ASSEMBLY WILL DO A GYRATORY MOTION DUE TO THE ROTATION OF ECCENTRIC
SLEEVE. THE GYRATORY IS COUNTERCLOCKWISE AS ONE VIEWS FROM ABOVE.
EXCEPT THE ABOVE GYROTORY MOTION, THE MANTLE IS CAUSED TURN
COUNTERCLOCKWISE BY THE VISCOUS RESISTANCE OF THE LUBRICATING OIL BETWEEN
MAINSHAFT AND INNER BUSH AT THE TIME OF NO-LOAD OPERATION. DURING A LOAD
OPERATION, THE MANTLE REVOLVES CLOCKWISE DUE TO REACTION FORCE OF
TO-BE-CRUSHED MATERIAL.
THE GYRATORY MOVEMENT OF MANTLE CORE CAUSES MANTLE TO PERFORM A
SWINGING MOTION IN THE DIRECTION ALMOST RECTANGULAR TO CONCAVE.
CONSEQUENTLY THE CLEARANCE BETWEEN MANTLE AND CONCAVE CHANGES ON THE
ENTIRE CIRCUMFERENCE BY FIXED AMOUNTS, THEREBY ACHIEVING THE FUNCTION OF
CRUSHING.

2-15
2.5.2 CRUSHING CHAMBER：
THE CRUSHING CHAMBER CONSISTS OF A MANTLE WHICH IS A MOVABLE CRUSHING PLATE
AND A CONCAVE WHICH IS A FIXED CRUSHING PLATE. THE MATERIAL USED IS A HIGH
MANGANESE STEEL HAVING EXCELLENT WEAR RESISTANCE AND TOUGHNESS. SINCE THE
MANTLE IS CONTACTED CLOSELY ON THE MANTLE CORE VIA THE MACHINED SURFACE AND
LOCKED UP WITH LOCKING CAP, LOCKING RING ETC., NO FILLER IS NEEDED.
ALSO THE CONCAVE IS CONTACTED CLOSELY ON THE TOP CELL VIA THE MACHINE SURFACE
AND LOCKED UP WITH U-BOLT.

2-16
 CHAPTER 3 INSTALLATION

3.1 INTRODUCTION........................................................................................3-1

3.2 INSTALLATION PROCEDURE.................................................................3-1

3.2.1 FOUNDATION...................................................................................3-1

3.2.2 FEED HOPPER ..................................................................................3-2

3.2.3 MOTOR BASE ...................................................................................3-3

3.3 MAIN POINT OF INSTALLATION ...........................................................3-4

3.4 V-BELT INSTALLATION ...........................................................................3-6

3.5 INSTALLATION THE LUBRICATION OIL TANK..................................3-10

3.6 INSTALLATION THE HYDRAULIS OIL TANK AND OTHERS ...........3-12

 CHAPTER 3 INSTALLATION

3.1 INTRODUCTION
A GOOD INSTALLATION IS CLOSE RELATED TO MACHINE SERVICE LIFE. THE
MAJOR POINT TO REACH MACHINE’S EFFECT IS TO INSTALL IT RIGHT.
3.2 INSTALLATION PROCEDURE
3.2.1 FOUNDATION：(AS SHOWN IN FIG 3-1)
3.2.1.1 CHECK WHETHER THE FOUNDATION IS HORIZONTAL AND FIRM. (BE SURE
THAT THE FOUNDATION IS HORIZONTAL BEFORE GROUTING)
3.2.1.2 IF THERE IS NOT HORIZONTAL AND FIRM, MODIFY AND REENFORCE IT.
3.2.1.3 MAKE SURE THE FOUNDATION BOLTS HAS BEEN TIGHTED.

FIG 3-1

3-1
3.2.2 FEED HOPPER：
3.2.2.1 FEED HOPPER SHOULD BE ADJUSTABLE AND CONSIDER THE HEIGHT AND
SPACE FOR REPLACEMENT OF MANTLE & CONCAVE.
3.2.2.2 FEED HOPPER & CHUTE SHOULD BE MATCHED WITH CRUSHER INLET AND
KEEP 70~80% FULL MATERIAL IN CRUSHING CHAMBER. ALSO IT SHOULD
AVOID OBLIQUE TO CAUSE UNEVEN WEAR OF CONCAVE/MANTLE,
LOWER DOWN EFFICIENCY AND SERVICE LIFE. (AS SHOWN IN FIG 3-2)

FIG 3-2

3-2
3.2.3 MOTOR BASE：
3.2.3.1 MOTOR SHOULD BE ADJUSTABLE ON MOTOR BASE, SO MOTOR PULLEY
AND MACHINE PULLEY COULD BE ALIGNED TO A STRAIGHT LINE AND
V-BELT COULD BE ADJUSTED TO SUITABLE TIGHTNESS (REFER TO
SECTION 3.4)
3.2.3.2 THE REVOLUTION DIRECTION OF MACHINE PULLEY IS AS BELOW.

FIG 3-3

3-3
3.3 MAIN POINT OF INSTALLATION
3.3.1 USE THE SUITABLE HOIST & OTHER ACCESSORIES TO MATCH THE WEIGHT OF
MACHINE WHILE INSTALLATION. THE MACHINE SHOULE BE HORIZONTAL AND
TIGHTLY FIXED ONTO STEEL STRUCTURE OR CONCRETE FOUNDATION. (NOTE
THAT IF CONCRETE FOUNDATION IS USED, PLEASE GROUTE IT 30 DAYS BEFORE
INSTALLATION TO ENSURE THE STRENGTH OF CONCRETE FOUNDATION)
3.3.2 MOTOR PULLEY AND MACHINE PULLEY SHOULD BE ALIGNED IN A STRAIGHT
LINE. MOTOR BASE SHOULD HAVE ENOUGH SAPCE TO ADJUST THE TIGHTNESS
OF V-BELT.
3.3.3 LUBRICATION OIL TANK SHOULD BE PUT BELOW THE COUNTERBOX SIDE AND
AVOIDED FALLING STONE COLLISION & DIRECT SUNSHINE, ALSO KEEPED IN
PLACE OF GOOD VENTILATION.
3.3.4 HYDRAULIC OIL TANK SHOULD BE PUT IN EASY OPERATION PLACE OF
MACHINE-SIDE AND ALSO AVOIDED FALLING STONE COLLISION & MIX OF
WATER.
3.3.5 CONSIDER THE SPACE FOR PART REPLACEMENT OR MAINTENANCE WHILE
INSTALLATION, FOR EXAMPLE, THE HEIGHT NEEDED TO LIFT MANTLE CORE
ASSEMBLY, AND THE SPACE FOR REMORAL OF COUNTERSHAFT BOX ETC.
REGARDING THE DIMENSION FOR YOUR INSTALLATION REFERENCE; PLEASE
REFER TO FIG SHOWN BELOW.

3-4
MODEL A B C D E F G H I J

900 1070 1800 924 1776 495 1300 1500 1660 1580 780

1200 1361 2300 1426 2050 593 1600 1800 2065 2060 1164

1300 1410 2650 1420 2070 605 1726 1950 2200 2050 900

REMARK：THE DIMENSION TABLE ABOVE IS MADE FROM THE STANDARD LAYOUT. AT

THE ACTUAL INSTALLATION WE WILL SUBMIT THE DETAILED DRAWING
SEPARATELY.

3-5
 3.3.6 INSTALLATION OF FEED AND OUTLET CHUTE
3.3.6.1 FEED CHUTE SHOULD BE MATCHED WITH FEED HOPPER ASSEMBLY OF
CRUSHER AND FIXED TO FEED HOPPER ABOVE. AN ADJUSTABLE GATE IS
USED TO CONTROL THE FEEDING RATE. BE NOTED TO AVOID OBLIQUITY
OF FEED CHUTE SO AS TO FEED MATERIAL EVENLY IN THE FULL
CIRCLMFERENCE WHILE INSTALLING.
3.3.6.2 OUTLET HOPPER SHOULD BE RIGHT BELOW CRUSHER OUTLET AND
CONSIDERED TO FORM A STONE BED TO AVOID OUTPUT MATERIAL
DIRECTLY COLLIDE ONTO CONVEYOR. ALSO THERE SHOULD BE ENOUGH
SPACE FOR OUTLET HOPPER TO AVOID OUTPUT MATERIAL STACKED
INSIDE HOPPER OR EVENLY WORSELY UP TO INSIDE OF CRUSHER,
THEREBY CAUSED SEVERELY DAMAGE.
3.3.7 CHECK THE SPECIFICATION OF ELECTRIC POWER AND MOTOR BEFORE
ERECTION OF WIRINGS.
3.3.8 CHECK THE SPECIFICATION OF LUBRICANT AND HYDRAULIC OIL BEFORE
FILLING INTO TANK.

3.4 INSTALLATION OF V-BELT

PLEASE FOLLOW PROCEDURES SHOWN BELOW WHILE INSTALLATION OF V-BELT
3.4.1 CLEAN THE GREASE OR RUST IN THE GROOVES OF MOTOR PULLEY AND
MACHINE PULLEY.
3.4.2 ASCERTAIN MOTOR PULLEY AND MACHINE PULLEY ARE IN THE SAME STRAIGHT
LINE AND MOTOR SHAFT AND COUNTERSHAFT ARE PARALLEL. MOTOR BASE
SHOULD HAVE ENOUGH SPACE TO ADJUST TIGHTNESS OF V-BELT. THE CENTRAL
DISTANCE OF TWC PULLEYS SHOULD BE 2.5~3 TIMES OF DIAMETER OF
MACHINE PULLEY.
3.4.3 DON’T INSTALL V-BELT FORCELY, INSTEAD REMOVE MOTOR AND MOTOR
PULLEY TO SHORTEN THE CENTRAL DISTANCE OF TWO PULLEY UNTIL V-BELT
COULD BE EASILY SLIP INTO THE GROOVES. THE SHORTENING DISTANCE IS
SHOWN IN TABLE 3-3.

3-6
 CONVENTIONAL “ABCDE” V-BELTS
Minimum Allowance Below Center Minimum Allowance
Belt Above Center Distance
Distance for installation of Belts
Length For Stretch and Wear
A B C D E All Sections
26 to 28* 3/4 1 1
36 to 60* 3/4 1 1-1/2 1-1/2
60 to 90* 3/4 1-1/4 1-1/2 2
90 to 120* 1 1-1/4 1-1/2 2-1/2
120 to 158* 1 1-1/4 1-1/2 2 3
158 to 195* 1-1/4 2 2 2-1/2 3-1/2
195 to 240* 1-1/2 2 2 2-1/2 4
240 to 270* 2 2-1/2 2-1/2 4-1/2
270 to 330* 2 2-1/2 3 5
330 to 420* 2 2-1/2 3 6
420 and over 3 3-1/2 1.5% of Belt Length
NARROW “3V, 5V, 8V” V-BELTS
Minimum Allowance Below Center Minimum Allowance
Belt Above Center Distance
Distance for installation of Belts
Length For Stretch and Wear
3V 5V 8V All Sections
25 to 50* 1/2 1
50 to 80* 3/4 1 1-1/4
80 to 112* 3/4 1 1-1/2 1-1/2
112 to 140* 3/4 1 1-1/2 1-3/4
140 to 180* 1 1-1/2 2-1/4
180 to 224* 1 1-3/4 2-1/2
224 to 250* 1-1/4 1-3/4 2-3/4
250 to 280* 1-1/4 1-3/4 3-1/4
280 to 315* 1-1/4 1-3/4 4
315 to 400* 1-1/4 2 4-1/2
400 to 500* 2 5-1/2
*In each group the range is to, but not including, the second length.
All dimensions in inches.
V-BELT INSTALLATION AND TAKE-UP ALLOWANCES
TABLE 3-3

3-7
3.4.4 ADJUSTMENT OF TIGHTNESS OF V-BELT
IN CASE OF TOO TIGHT V-BELT, THE LOAD OF MOTOR SHAFT AND
COUNTERSHAFT OF MACHINE WOULD BE INCREASE, SO THE BEARINGS AND
V-BELTS ARE EASILY DAMAGED OR BROKEN. ON THE CONTRARY, THE POWER
TRANSMISSION EFFICIENCY WOULD BE LOWERED DOWN IN CASE OF LOOSE
V-BELT. THEREFORE, HOW TO ADJUST THE SUITABLE TIGHTNESS OF V-BELT IS
VERY IMPORTANT.
3.4.4.1 PUT A STRAIGHT STEEL BAR ACROSS THE MOTOR AND MACHINE PULLEY
AS FIG 3-4 SHOWN

FIG 3-4

3-8
 3.4.4.2 MEASURE THE SPAN LENGTH BETWEEN OUTERS OF TWO PULLEYS
(AS SHOWN FIG 3-4)
3.4.4.3 EXERT A FORCE ON POSITION OF 1/2 SPAN LENGTH WITH DIRECTION
VERTICAL TO STEEL BAR BY A SPRING SCALE. ALSO THE FORCE EXERTED
SHOULD CAUSE THE DEFLECTION OF V-BELT EQUAL TO 1/64 OF SPAN
LENGTH.
3.4.4.4 THE SUITABLE TIGHTNESS OF V-BELT IS THE DEFLECTION FORCE OF
ABOVE SAID SPRING SCALE EQUAL TO BELOW TABLE 3-4. THAT IS ALSO
MEAN THE TENSION OF V-BELT.
BELT NORMAL 1-1/2 TIMES 2 TIMES
SECTION TENSION NORMAL TENSION NORMAL TENSION
(IN POUNDS) (IN POUNDS) (IN POUNDS)
A 2 3 4
B 4 6 8
C 8 12 14
D 12 22 26
E 21 35 40
3V 4 7 9
5V 9 12 15
8V 20 30 40
DEFLECTION FORCES TABLE 3-4
REMARKS：THE V-BELT SECTION OF SPRING CONE CRUSHER IS “C” TYPE
3.4.4.5 THE TENSION OF NEW BELT SHOULD BE TWICE OF NORMAL TENSION TO
COMPENSATE THE LOSS FOR INTIAL RUN-IN AND STRETCH.
3.4.4.6 ADJUST BELT TENSION TO 11/2 NORMAL TENSION AFTER 2-4 hrs
OPERATION.
3.4.4.7 AFTER 24-28 hrs RUNNING, CHECK WHETHER V-BELT TENSION IS SAME AS
NORMAL TENSION. ADJUST IT IF NECESSARY.
3.4.5 CAUTIONS:
3.4.5.1 FOR STORAGE OF V-BELTS, PLEASE PUT ON SHELF OR HANG ON THE
WALL. DON’T TOUCH WITH OIL, PUT UNDER SUN SHINE OR NEAR HEAT
SOURCE.
3.4.5.2 IT’S BETTER TO SET UP A GUARD OUTSIDE V-BELTS WHILE THEY ARE
RUNNING.
3.4.5.3 DON’T APPLY BELT WAX ONTO PULLEY OR V-BELT.
3.4.5.4 BESURE TO REPLACE ALL THE BELTS ONE TIME WHILE ANY BELT IS
BROKEN DURING USE TO ENSURE THE TENSION OF BELTS ARE SAME.
3.4.5.5 INSPECT THE WEAR CONDITION OF V-BELT & PULLEY FREQUENTLY.

3-9
3.5 INSTALL THE LUBRICATION OIL TANK
3.5.1 THE ELECTRICAL WIRING INSTALLATION PROCESS OF LUBRICATION OIL TANK
SHOULD REFER TO THE FIG 3-5A/3-5B/3-6 IN ORDER TO MAKE SURE THE SAFETY
INTERLOCK IS ACTUATED TO PROTECT THE MACHINE.
3.5.2 THE RETURN LUDRICANT PIPE SHOULD BE HIGHER THAN THE RETURN SCREEN
OF LUBRICANT OIL TANK TO PREVENT LUBRICANT TO BLOCK UP THE
CIRCULATION PIPE PLEASE REFER TO FIG 3.6.
3.5.3 FOR THE CIRCULATION PIPING DISTANCE, THE SHORTER WILL BE BETTER.
3.5.4 ALL THE CONNECTION OF PIPES SHOULD BE ADAPTED FLANGE TYPE OR OTHER
JOINT, BUT NEVER ADAPT WELD METHOD. ALSO A SECTION OF HOSE SHOUD BE
ARRANGED IN BOTH INLET & RETURN PIPING IN ORDER TO ABSORBE SHOCK
FROM CRUSHER.
3.5.5 THE AIR COOLER IS CONTROLLED BY A TEMPERATURE CONTROLLER, SO THAT
THE FAN OF AIR COOLER WILL BE STARTED ONLY WHEN OIL TEMPERATURE
REACHED PRE-SET TEMPERATURE. THIS WILL SAVE THE COST OF ELECTRICILITY.
PLEASE REFER TO 7.5 FOR THE DETAILED SETTING OF TEMPERATURE
CONTROLLER.

3-10
F1 F2
1A 1A

575V 460V 440V 415V 400V 380V 0V

220V

1 0

1
L u b r ic a tio n S W
WL P o w e r I n d i c a to r
V U
M1 L u b ric a tio n P u m p
M1 2 P r e - L u b r i c a t i o n T im e r
T

T 3
GL C r u s h e r r u n I n d i c a to r

F lo w C o n tro l
4 F lo w C o n tro l
R1
T e m p e ra tu r e C o n tro l
5 T e m p e ra tu re C o n tro l
R2
R1 6
YL In te rlo c k o n A la rm
3
R2

10
R3
M T -4 8
A i r C o o l e r C o n tr o l
Ta Tb TB
A ir C o o le r C o n tr o l
( 4 8 * 4 8 T e m p e r a tu r e C o n tro l)

R3 U
M2

1 0

M a in M o to r Y - △ C o n tro l C irc u it

R2 R1 O F F (G ) O N (R )
8
M
9 7
M
R M a in M o to r C o n tr o l T

R S T U1 V1 W1 U2 V2 W2 3 4 3 5 Ta Tb TB 7 9

G 1 2 3 4 5 6 7 8 9
Temperature Control

Main Motor Control

Ground Connection
Power

PT100 Temperature Sensor

Lubrication Motor

Air Cooler Motor

Flow Control

FIG 3-5a

3-11
 MCD

OCR
MCM
MCS
R U X

S
V

W
M Y

Z
T

GL T

RL
RT MCD

ON
RT
OFF

R MCM

RT
RT
MCS
OCR
MCD

MCM MCD

MCS

MAIN MOTOR Y-△ CONTROL CIRCUIT

FIG 3-5b

3-12
3-13
FIG 3-6
3.6 INSTALL THE HYDRAULIC OIL TANK
3.6.1 THE PIPING INSTALLATION PROCESS OF HYDRAULIC OIL TANK PLEASE REFER
TO FIG 3-7.
3.6.2 NOTICE ANY HIGH PRESSURE PIPING SYSTEM HAVE TO PREVENT FOLDING OR
BENDING; ONCE THE PIPING FOLDED OR BENDED MAY CAUSE THE DAMAGED
OF PIPING AND ACCIDENT.

FIG 3-7

3-14
 CHAPTER 4 TRIAL RUN

4.1 INTRODUCTION........................................................................................4-1

4.2 PRELIMINARY WORKS............................................................................4-2

4.3 PROCEDURE FOR TRIAL RUN ...............................................................4-3

4.4 ANALYSIS OF TRIAL RUN RESULTS ....................................................4-8

 CHPATER 4 TRIAL RUN

4.1 INTRODUCTION
4.1.1 THIS CHAPTER DESCRIBES THE OPERATION AND TRIAL RUN PROCEDURE OF
PRINCIPLE UNIT AND AUXILIARY EQUIPMENTS. ALSO IN ORDER TO MAKE SURE THE
CONE CRUSHER IS PROPERLY WORKING UNDER DIFFERENT SITUATION. A TRIAL RUN
BEFORE COMMERCIAL OPERATION IS NECESSARY SO AS TO EIMINATE THE PROBLEM
BEFORE OPERATION.

4.1.2 TRIAL RUN PROCEDURE

PLEASE FOLLOW BELOW STEP

INSPECTION & PREPARATION BEFORE TRIAL RUN

NO LOAD TRIAL RUN

LOAD TRIAL RUN

COMMERCIAL OPERATION

4-1
4.2 PRELIMINARY WORKS
4.2.1 INSPECTION OF ELECTRICAL WIRING
THE CHECK ITEMS IS AS FOLLOWING
4.2.1.1 CHECK WHETHER WIRING CONNECTION BETWEEN MOTOR AND CONTROL
PANEL IS OK OR NOT?
4.2.1.2 IS THERE ANY NAKED OR LOOSE WIRING?
4.2.2 CLEAN LUBRICATION OIL TANK & HYDRAULIC OIL TANK.
ALTHOUGH AN ANTI-CORROSION TREATMENT IS APPLIED TO BOTH LUBRICANT &
HYDRAULIC OIL TANK, HOWEVER DUST AND WATER INFILTRATE INTO TANKS
SOMETIMES, IF IT IS STORED FOR A LONG PERIOD. IN SUCH A CASE, DISCONNECT THE
FLANGE BOLT AT THE CHECK HOLE COVER ON THE FRONT SURFACE (LUBRICATION
OIL TANK) OR FILLING PORT (HYDRAULIC OIL TANK) AND CLEAN INSIDE WITH
FLUSHING OIL OR THE LIKE.
4.2.3 GREASE SUPPLYING
SUPPLY THE SPECIFIED GREASE AS DESIGNATED BY CHAPTER 8 TO THREAD PARTS
OF TOP CELL AND UPPER FRAME. FILL GREASE INTO GREASE NIPPLE OF UPPER
FRAME UNTIL GREASE OVER FLOW.
4.2.4 CLEAN
4.2.4.1 LUBRICATION SYSTEM
FOLLOWING THE PROCEDURE SHOWN BELOW TO PRECEDE CLEAN JOB.
4.2.4.1.1 FILL A CERTAIN AMOUNT OF FLUSHING OIL INTO LUBRICATION OIL
TANK.
4.2.4.1.2 TURN ON THE LUBRICATION PUMP FOR ABOUT 30 MINUTES AND
CLEAN THE RETURN SCREEN.
4.2.4.1.3 TURN THE LUBRICANT PUMP IN OPPOSITE DIRECTION FOR ABOUT
20~30 SECOND.
4.2.4.1.4 KEEP THE PUMP TURNING FOR ANOTHER 30 MINUTES AND INSPECT
WHETHER ANY FOREIGN MATTER IN RETURN SCREEN. IF THERE IS
ANY FOREIGN MATTER, KEEP PUMP RUNNING UNTIL NO FOREIGN
MATTER OCCURS.
4.2.4.1.5 WHEN FOREIGN MATTER HAS BEEN STOPPED TO INCREASE IN RETURN
SCREEN, DRAIN THE CLEAN OIL IN LUBRICATION TANK AND FILL THE
SPECIFIED QUANTITY OF LUBRICANT TO TANK.
4.2.4.2 COUNTERSHAFT
CLEAN COUNTERSHAFT SHOULD BE PROCEED IN SAME TIME OF 4.2.4.1
4.2.4.2.1 FILL A CERTAIN AMOUNT OF CLEAN OIL TO COUNTERSHAFT BOX.
4.2.4.2.2 DRAIN THE CLEAN OIL IN THE SAME TIME OF 4.2.4.1 CLEAN
PROCEDURE FINISH. THEN FILL THE SPECIFIED AMOUNT OF
LUBRICANT INTO COUNTERSHAFT BOX.

4-2
 4.2.5 CHECK FOLLOWING ITEMS
4.2.5.1 WHETHER THE BOLTS ARE TIGHT OR NOT.
4.2.5.2 WHETHER THE LUBRICANT IN COUNTERSHAFT BOX RIGHT OR NOT?
ALSO IT’S QUANTITY RIGHT OR NOT?
4.2.5.3 CHECK MOTOR SPECIFICATION (HORSE POWER. POLE)
4.2.5.4 WHETHER THE MOTOR PULLEY AND MACHINE PULLEY ARE PARALLEL OR
NOT.
4.2.5.5 CHECK WHETHER THERE IS ANY INTEREFENCE FOR RUNNING.
4.2.5.6 WHETHER THE TIGHTNESS OF V-BELTS IS SUITABLE OR NOT.
4.2.5.7 WHETHER THE DISCHARGE SETTING IS SUITABLE OR NOT.
4.2.5.8 WHETHER TENSION OF THE SPRINGS IS SUITABLE.

4.3 THE PROCESS OF TRIAL RUN

4.3.1 UNLOADING TRIAL RUN
4.3.1.1 BE SURE THE NECESSARY INSPECTED PROCEDURES OF THE PRELIMINARY
WORK IN NORMALLY CONDITIONS OTHERWISE DON’T DO IT.
4.3.1.2 MAKE SURE ALL THE ELECTRICAL CIRCUITS IS CORRECT AND IN THE SAFETY
CONDITIONS.
4.3.1.3 BE SURE THE LUBRICATION OIL FLOW CONTROL INTERLOCK IS SET
CORRECTLY.
4.3.1.3.1 TURN ON THE LUBRICATION PUMP SWITCH.
4.3.1.3.2 SET THE PRESSURE SWITCH SET VALUE OF 1.2kg/c ㎡ (THIS VALUE
MEANS UNDER THIS FLOW PRESSURE, MAIN MOTOR WILL BE
STOPPED) THE SET METHOD IS TO ADJUST THE SCREW ABOVE
PRESSURE SWITCH BY SCREW DRIVER BE SURE TO TIGHT THE NUT
AFTER SETTING IS COMPLETE TO AVOID SET VALUE VARIES LATE ON.

4-3
4.3.1.3.3 CHECK THE INTERLOCK FUNCTION O.K. OR NOT. BY ADJUST THE
RETURN VALUE UNTIL THE FLOW PRESSURE REACH 1.2kg/c ㎡ (SEE
THE PRESSURE GAUGE INSIDE TANK), THE MAIN MOTOR SHOULD BE
STOPPED.

FIG 4-1

4-4
FIG 4-2

4-5
 4.3.1.4 SET UP THE UPPER LUBRICANT TEMPERATURE LIMITATION.
4.3.1.4.1 ROTATE THE THEMOMETER (A) BLACK KNOB TO SET THE RED
INDICATOR IN THE TEMPERATURE OF 55℃.
4.3.1.4.2 ROTATE THE BLACK KNOB TO PUSH RED INDICATOR TO BE
CLOSE TO BLACK INDICATOR, I.E. THE CURRENT TEMPERATURE
READING UNTIL BOTH INDICATORS TOUCH. THEN THE MAIN MOTOR
SHOULD BE STOPPED.
4.3.1.4.3 NOTE: THE TEMPERATURE DIFFERENCE BETWEEN THERMOMETER A &
B SHOWS THE COOLING CAPACITY OF OIL COOLER. IN CASE THE AIR
COOLER WAS COVERED TOO MUCH DUST, THE CAPACITY OF OIL
OOLER WIL BE REDUCED. CLEAN DUST BY AIR SPRAY.
4.3.1.5 SET UP THE TEMPERATURE WHICH STARTS AIR COOLER FAN. REFER TO
7.5. FOR DETAIL.
4.3.1.6 TURN ON LUBRICATION PUMP BEFORE TURNNING ON THE MAIN MOTOR AND
CHECK IF THERE IS ANY FOREIGN MATTERS OR METAL CHIPS EXISTED ON
SCREEN. CLEAN THE FOREIGN MATTERS AND METAL CHIPS AND CONTINUE
RUNNING PUMP UNTIL NO FURTHER FOREIGN MATTER EXISTED ON SCREEN.
THEN CHECK IF THERE ARE NO ANY OTHERNESS, LIKE WOOD STONE INSIDE
CRUSHING CHAMBER. SWITCH ON THE MAIN MOTOR IN THE TURNING
SITUATION.
4.3.1.7 SETTING UP THE SPACE BETWEEN THE CONCAVE AND MANTLE.
4.3.1.7.1 HANGING THE LEAD BLOCK IN TO THE MACHINCE IN 5 SECOND THEN
HANG UP THE LEAD BLOCK AND MEASURE THE THICKNESS. THE
THICKNESS IS THE DISCHARGE SET WHICH IS RELATED TO PRODUCT
SIZE.
4.3.1.7.2 PLEASE REFER TO THE CHAPTER 2-1 THE STANDARD OF PRODUCTS
SIZE LISTS.
4.3.1.7.3 IF CAN NOT REACH THE PRODUCT SIZE THEN TURN THE ADJUSTMENT
CAP BY ACTUATING ADJUSTMENT CYINDER VIEWS FROM TOP.
IF ADJUST BY CLOCKWISE THE TOP CELL GO DOWN. IF ADJUST BY
COUNTER-CLOCKWISE THE TOP CELL GO UP SO THAT IT MAY ADJUST
TO THE REQUIRED PRODUCET SIZE.
4.3.1.7.4 WHEN THE ADJUSTMENT CAP MOVES ONE PITCH, THE DISCHARGE
SETTING PACES ABOUT 1.27MM. (FOR MODEL 1200 & 1600) AND 0.95MM
(FOR MODEL 900)
4.3.1.8 RECORD THE TEST RUN DATA LIKE AMPERE, TEMPERATURE.
4.3.1.9 JUDGE WHETHER THE NO LOAD TRIAL RUM IS O.K.
4.3.2 LOADING TRIAL RUN:
4.3.2.1 ONCE COMPLETED THE UNLOANDING TRIAL RUN; THE LOADING TRIAL RUN
MAY BE PROCEEDED. OTHERWISE DON’T DO IT.
4-6
4.3.2.2 THE MACHINERY SHOULD BE UNDER UNLOADING SITUATION.
4.3.2.3 FEEDES IN BY JOG PROGRESS AND INSPECTED THE WORKING CONDITION IN
NORIMALLY ALSO NOTICE THE UPPER & LOWER HOPPER FUNCTION
NORMATLLY.
4.3.2.4 CONTINUOUS FEEDING IN 70%~80% FULL MATERIALS IN CRUSHING CHAMBER
THEN CHECK THE MACHINENY RUNNING CONDITIONS.
4.3.2.5 RECORD THE TRIAL RUN DATA.
4.3.2.6 THE FULL LOAD CURRENCY DATA SHOULD BE RECORDED FOR THE FUTURE
MACHINERY ADJUSTMENT REFERENCE. DURING THE COMMERCIAL
APPLICATION, IF THE POWER CURRENCY IS LOWER THAN THE CURRENT
DESCRIBED ABOVE THAT MEANS THE DISCHARGE SETTING ENLARGE DUE TO
WEAR OF CONCAVE AND MANTLE. ADJUST THE DISCHARGE SETTING UNTIL
THE LOAD CURRENT BACK TO THE VALUE DESCRIBED ABOVE, THAT MEANS
THE REQUIRED SETTING IN NORMALLY SITUATION.
4.3.2.7 THE LOAD CURRENT VALUE IS ABONT 75-85% OF MOTOR RATED CURRENT
WHILE THE HIGHEST LOAD CURRENT SHOULDN’T EXCEED 90% OF MOTOR
RATED CURRENT.
4.3.2.8 JUDGE WHETHER THE LOAD TRIAL RUN IS O.K.

4-7
4.4 ANALYSIS OF TRIAL RUN RESULTS：

PHENOMENON REASON COUNTERMEASURE

1 MOTOR POWER TOO LOW . CHECK AND REPLACE IT
2 WIRING PROBLEM . CHECK AND REPAIR
UNABLE TO
3 INTERFERENCE IN CRUSHING CHAMBER . CLEAR IT
RUN
4 INNER OR OUTER BUSH IS STUCK . REPAIR OR REPLACE IT
5 INSUFFICIENT LUBRICATION . ADJUST OIL FLOW
1 LOOSE FRAME BOLTS . TIGHTEN THEM
ABNORMAL 2 MANTLE OR CONCAVE LOOSEN . TIGHTEN AGAIN
VIBRATION OR 3 LOOSE V-BELT AND CAUSE TO SLIP . ADJUST IT
NOISE 4 FEED HOPPER AREN’T FIXED OR . FIX IT OR ADJUST IT
INSTALLED PROPERLY
1 CAP LOOSEN . TIGHTEN AGAIN
2 COUNTERSHAFT WEAR IN V-PULLEY . REPAIR OR REPLACE IT
LOOSE
CONTACT PORTION . REPLACE IT
V-PULLEY CAP
3 THREAD OF CAP OR COUNTERSHAFT
WEAR
1 LOW CAPACITY OF LUBRICATION PUMP . CHECK OR REPLACE IT
2 RETURN FLOW OF LUBRICANT IS NOT . ADJUST THE HEIGHT OF
SMOOTH LUBRICATION OIL TANK
3 LUBRICANT TEMPERATURE IS TOO HIGH . CHECK IT
4 WRONG LUBRICANT USED . CHANGE THE SPECIFIED ONE
ABNORMAL
5 V-BELT IS TOO TIGHT . ADJUST IT
TEMPERATURE
6 INSUFFICIENT LUBRICANT . ADJUST OIL FLOW
7 OVER FEEDING OR TOO MUCH MUD . CHECK AND ADJUST
8 TOO SMALL DISCHARGE SETTING . ADJUST IT
9 MUD OR WOOD STUCK IN OUT- . CLEAR IT
LET OF CRUSHER
1 TOO SMALL DISCHARGE SETTING . ADJUST IT
ABNORMAL 2 TOO BIG FEED MATERIAL . CONTROL THE SIZE OF
CURRENT 3 UNCRUSHABLE MATERIAL FED FEED MATERIAL
INTO CRUSHING CHAMBER . CLEAR IT
1 UPPER FRAME MOVES UP AND DOWN . ADJUST SPRINGS’ TENSION
OTHERS 2 ADJUSTMENT CAP MOVES UP . ADJUSTMENT BOLTS LOOSEN.
AND DOWN CHECK AND TIGHTEN AGAIN
TABLE 4-1

4-8
 CHAPTER 5 OPERATION

5.1 INTRODUCTION........................................................................................5-1

5.2 CHECK ITEMS BEFORE OPERATION....................................................5-1

5.3 DESCRIPTION OF OPERATION ..............................................................5-3

5.3.1 PRELIMINARY WORK ....................................................................5-3

5.3.2 OPERATION OF LUBRICATION DEVICE.....................................5-5

5.3.3 DISCHARGE SETTING ADJUSTMENT.........................................5-7

5.3.4 FEEDING CONTROL........................................................................5-8

5.4 PROCEDURE OF OPERATION.................................................................5-9

 CHAPTER 5 OPERATION

5.1 INTRODUCTION
THIS MANUAL PROVIDES DESCRIPTION SURROUNDING THE MATTERS THAT ARE
NEEDED IN ACTUALLY OPERATING THE CONE CRUSHER. THE OPERATOR IS
REQUESTED TO READ THIS CHAPTER THROUGHLY, ESPECIALLY SPEIFICATIONS AND
CAUTIONS IN ORDER TO OPERATE RIGHT AND EFFICIENTLY.

5.2 CHECK ITEMS BEFORE OPERATION

5.2.1 CHECK WHETHER THERE IS ANY BOLTS LOOSEN AND TIGHTEN AGAIN TO
AVOID DAMAGE.
5.2.2 AVOID ANY UNCRUSHABLE MATERIAL MIX INTO CRUSHING CHAMBER. CHECK
IF THERE IS ANY FOREIGN MATTER IN FEED MATERIAL AND CLEAR IT.
5.2.3 FEED MATERIAL SIZE SHOULD BE WITHIN 0.8 TIMES OF CRUSHING CHAMBER
OPENING TO AVOID MATERIAL BEING STUCK AND CAUSE DAMAGE. (REFER TO
FIG 5.1)
5.2.4 FEED CHUTE SHOULD NOT BE OBLIQUE TO AVOID UNEVEN FEEDING SO AS TO
LOWER DOWN CAPACITY AND CAUSE UNEVEN WEAR OF CONCAVE AND
MANTLE. ADJUST FEED CHUTE IN CASE OF ABOVE PROBLEM OCCUR.
5.2.5 CLEAR THE REMAINING MATERIAL IN CURSHING CHAMBER BEFORE STARTING
CRUSHER. ACTUALLY, YOU SHOULD CRUSH ALL THE MATERIAL COMPLETELY
BEFORE STOP CRUSHER.
5.2.6 CHECK WHETHER THE OIL LEVEL OF LUBRICANT IS BELOW LOWER LIMIT OR
NOT. FILLING LUBRICANT AS IT IS BELOW LOWER LIMIT. ALSO WHETHER
LUBRICATION OIL FLOW IS ENOUGH TO AVOID MAIN POWER SHUT OFF
FREQUENTLY.

5-1
5.2.7 CHECK DISCHARGE SETTING AND ADJUST IF NECESSARY. PLEASE REFER TO
TABLE 2-1 FOR DETAIL.

FIG 5-1

5-2
5.3 DESCRIPTION OF OPERATION
5.3.1 LUBRICATION DEVICE
MAIN SHAFT, MANTLE CORE AND ECCENTRIC SLEEVE ARE ALL SUPPORTED
TO TURN BY COPPER BUSH OR LINER, THEREBY A FORCE LUBRICATION
SYSTEM IS NECESSARY. THE LUBRICATION FLOW SCHEME IS SHOWN IN FIG 5-2.
BE SURE TO TURN ON LUBRICATION PUMP TO SEND LUBRICANT TO LUBRICATE
GEAR, PINION, COPPER BUSH OR LINER BEFORE TURNING ON MAIN MOTOR.
SOME SAFTY DEVICES, LIKE FLOW CONTROL VALVE AND THERMOMETER
CONTROL ETC. ARE EQUIPPED IN THE LUBRICATION SYSTEM TO ENSURE
SUFFICIENT LUBRICANT IS OFFERED TO CRUSHER, BUT BE SURE TO CHECK THE
FUNCTION OF SAFTY DEVICE BEFORE OPERATION.
THE PRESSURE OF LUBRICANT SHOULD BE SET WITHIN 0.5~2kg/cm DUE TO
THE KIND OF LUBRICANT USED AND TEMPERATURE AT SITE. IT IS
RECOMMENDED TO JUDGE BY THE RETURN OIL FLOW RATE TO TANK.

5-3
5-4
FIG 5-2
5.3.2 PROCEDURE OF ADJUSTMENT OF DISCHARGE SETTING
THE ADJUSTMENT METHOD OF DISCHARGE SETTING OF CHYI MEANG
SPRING CONE CRUSHER IS TO LIFT AND LOWER DOWN TOP CELL BY
HYDRAULIC DEVICE TO ACHIEVE A LARGER OR SMALLER DISCHARGE SETTING
NEEDED.
PROCEDURES ARE AS BELOW：
5.3.2.1 LOOSEN FIXING BLOCK.
5.2.2.2 LOOSEN ADJUSTMENT BOLT SLIGHTLY.
5.3.2.3 SET UP THE ADJUSTMENT HYDRAULIC CYLINDER ON TO UPPER FRAME
AND CONNECT THE PIPING TO HYDRAULIC OIL TANK. (REFER TO FIG 5-3
FOR DETAIL)
5.3.2.4 OPERATE THE MANUAL SWITCH OF HYDRAULIC OIL TANK TO DRIVE THE
ADJUSTMENT HYDRAULIC CYLINDER SO AS TO MOVE THE ADJUSTMENT
CAP.
5.3.2.5 WHEN THE ADJUSTMENT CAP MOVES ON PITCH, THE DISCHARGE
SETTING PACES ABOUT 1.27mm. (FOR MODEL 1200 & 1600) AND 0.95MM
(FOR MODEL 900)
5.3.2.6 TIGHTEN THE ADJUSTMENT BOLTS AFTER ADJUSTING TO THE DESIRED
DISCHARGE SETTING.
5.3.2.7 INSERT THE FIXING BLOCK BACK.

AS FOR THE ADJUSTING PORTION AND METHOD, REFER TO FIG 5-3 FOR DETAIL.

5-5
FIG 5-3

5-6
5.3.3 AUTOMATICAL DISCHARGE DEVICE
IN CASE OF POWER FAILURE OR EMERGENT STOP, THERE WOULD BE MANY
RAW MATERIALS BEING STUCK IN CRUSHING CHAMBER AND CRUSHER CAN’T
BE STARTED AGAIN, A HYDRAULIC DISCHARGE DEVICE COULD BE USED TO
PUSH THE UPPER FRAME ASSEMBLY UP TO DISCHARGE MATERIAL SO AS TO
START CONE CRUSHER AGAIN. PLEASE REFER TO FIG 5-4 FOR DETAIL.

FIG 5-4

5-7
5.3.4 FEEDING CONTROL
FEEDING MATERIAL SHOULD BE EVENLY DISTRIBUTED AROUND THE
CIRCUMFERENCE OF CRUSHING CHAMBER INLET. IN CASE OF FEED MATERIAL
IS OBLIQUELY CONCENTRATE IN THE SAME PORTION OF CRUSHING CHAMBER
AS SHOWN IN FIG 5-5, NOT ONLY THE CAPACITY WOULD BE LOWERED DOWN,
BUT ALSO CAUSED MANTLE CORE ASSEMBLY OR ECCENTRIC SLEEVE
ASSEMBLY EASILY TO DAMAGE.
70%~80% FULL OF FEED MATERIAL SHOULD BE KEPT IN CRUSHING
CHAMBER AS SHOWN IN FIG 5-5 TO ATTAIN A BETTER CRUSHING EFFICIENCY
AND MORE CUBICAL SHAPE.

FIG 5-5

5-8
5.4 OPERATION PROCEDURE
ITEM OPERATION PROCEDURE
CHECK ITEMS BEFORE
1
OPERATION
2 START THE LUBRICATION PUMP
AFTER 4 MINUTES, START
3 MAIN POWER TO ENSURE
LUBRICATION COMPLETELY
4 FEEDING MATERIAL
5 STOP FEEDING MATERIAL
6 STOP LUBRICATION PUMP
7 STOP MAIN POWER
CAUTIONS
1 BOLTS ARE TIGHT OR NOT?
2 IS THERE ANY REMAINING MATERIAL
IN CRUSHING CHAMBER?
3 IS THE LUBRICANT ENOUGH?
1 IS THE AMPERES NORMAL
2 IS THE RUNNING OF MANTLE CORE
ASSEMBLY NORMALLY
3 IS THERE ANY ABNORMAL NOISE OR
PHENOMENON
4 IS THE LUBRICANT PRESSURE NORMAL
1 WHETHER THE LOAD CURRENT IS BELOW 80%
OF RATE CURRENT OF MAIN MOTOR
2 IS THE FEEDING CONDITION GOOD
3 IS THE CRUSHING CONDITION GOOD
1 CHECK WHETHER ALL THE MATERIALS ARE
CRUSHED COMPLETELY
1 CLEAN FEED STRAINER AND RETURN SCREEN,
CHECK IS THERE ANY FOREIGN MATTER MIXED
2 REPLENISH GREASE
3 CHECK IS THERE ANY BOLT LOOSE
5-9
 CHAPTER 6 MAINTENANCE

6.1 INTRODUCTION........................................................................................6-1

6.2 DAILY MAINTENANCE AND CHECK ITEMS ......................................6-1

6.3 TROUBLE SHOOTING LIST.....................................................................6-3

6.4 CHECK POINT OF LUBRICATION OIL TANK ......................................6-6

6.4.1 TROUBLE SHOOTING OF LUBRICATION OIL TANK ...............6-8

 CHPATER 6 MAINTENANCE

6.1 INTRODUCTION
THIS CHAPTER DESCRIBE ABOUT ROUTINE MAINTENANCE AND TROUBLE
SHOOTING. CORRECT MAINTENANCE WILL HAVE HIGHEST CAPACITIES, SO
MAINTENANCE IS THE MOST IMPORTANT POINT FOR ANY MACHINE. BUT OPERATOR
NEGLECTS ROUTINE MAINTENANCE FREQUENTLY. THUS NOT ONLY CAPACITY
DECREASE BUT ALSO CAUSE FATAL DAMAGE FROM THESE TINY PROBLEMS, WHICH
WASN’T DISCOVERED, SO YOU MUST READ THIS CHAPTER OVER AND OVER AND
PERFORM ROUTINE MAINTENANCE, BESIDE, WHEN PROBLEM OCCURRED, HOW TO
KNOW THE REASON AT INITIAL STAGE AND REPAIR IT IN THE SHORTEST TIME,
THAT’S THE VERY POINT. THE SECOND PART OF THIS CHAPTER WILL SHOW YOU
HOW TO SOLVE PROBLEM(S) AND FIND THE REASON(S).

6.2 DAILY MAINTENANCE AND CHECK ITEMS

DAILY MAINTENANCE AND CHECK IS THE BEST WAY TO OPERATE MACHINE
SAFELY AND EFFICIENTLY. THE MAINTENANCE PERIODS WOULD BE DIFFERENT BY
THE APPLIED CONDITION. BELOW PERIODS IS A REFERENCE TO OPERATION PEOPLE.

A. CHECK AND MAINTENANCE PER 8 HOURS：

1. LUBRICATION OIL QUANTITY OF LUBRICATION OIL TANK.
2. TEMPERATURE OF LUBRICANT.
3. LUBRICATION OIL PRESSURE.
4. ELECTRICAL CURRENT AND VOLTAGE OF MAIN MOTOR.
5. CHECK WHETHER THE U-BOLTS OF TOP CELL LOOSEN OR NOT.
6. IS THERE ANY BOLTS OR ANY CONNECT PORTION LOOSE.
7. IS THERE ANY ABNORMAL NOISE HAPPENED?
8. CHECK WEAR CONDITION OF CONCOVE AND MANTLE WHILE THEY ARE
NEARLY TO BE REPLACED.
9. CHECK THE FUNCTION OF SAFETY DEVICE IS NORMAL OR NOT.
10. IS THE FEEDING CONDITION NORMAL.
11. IS THE MATERIAL STUCK IN THE OUTLET.

B. CHECK AND MAINTENANCE ITEMS PER 48 HRS：

1. TIGHTNESS OF V-BELTS AND ALSO ANY BREAK OF V-BELTS.
2. ANY LEAKAGE IN LUBRICATION OR HYDRAULIC OIL PIPINGS.
3. ARE DISTRIBUTOR, MANTLE OR CONCAVE LOOSE?
6-1
 4. ANY ABNORMAL PHENOMENON IN FRAME.
5. LUBRICANT CONDITION OF COUNTERSHAFT BOX.
6. GREASE REPLENISHED OF THREADS OF TOP CELL AND UPPER FRAME.
7. SPRINGS’ TIGHTNESS.
8. CHECK IS THERE ANY DUST OR SAND ENTERED INTO SHAFT, GEAR AND OTHER
TURNING PARTS.

C. CHECK AND MAINTENANCE ITEMS PER 240 HRS：

1. THE DETERIORATION CONDITION OF LUBRICANT, REPLACE IT IF NECESSARY.
2. FUNCTION OF PUMP, SAFETY VALVE, FLOW CONTROL VALVE, FEED STRAINER
AND RETURN SCREEN OF LUBRICATION SYSTEM.
3. WEAR CONDITION OF DISTRIBUTOR, MANTLE AND CONCAVE.
4. WEAR CONDITION OF FEED HOPPER, TOP CELL LINER AND OUTLET CHUTE.
5. CHECK IS THERE ANY METAL CHIPS ON RETURN SCREEN. A FEW METAL CHIPS
IS ACCEPTABLE. IN CASE OF A LOT METAL CHIPS, THEN INNER BUSH, OUTER
BUSH OR SOCKET LINER MAY BE DAMAGED.

D. YEARLY CHECK AND MAINTENANCE ITEMS：

1. WEAR CONDITION OF MIDDLE STEP BEARING PLATE.
2. WEAR CONDITION OF INNER BUSH AND OUTER BUSH.
3. WEAR CONDITION AND BACKLASH OF GEAR AND PINION.
4. WEAR CONDITION OF SOCKET LINER.
5. WEAR CONDITION OF DUST SEAL RING.
6. WEAR CONDITION OF THREADS OF TOP CELL AND UPPER FRAME.
7. ANY LEAKAGE OF O-RING, OIL SEAL ETC.
8. WEAR CONDITION OF MAIN FRAME LINER.
9. WEAR CONDITION OF ARM GUARD AND COUNTERSHAFT BOX GUARD.

6-2
6.3 TROUBLE SHOOTING LIST
PHENOMENON POSSIBLE CAUSES COUNTERMEASURE
1 DEFICIENT PUMP 1 OPEN RETURN BOX COVER TO CHECK
EFFICIENCY RETURN OIL AMOUNT, REPLACE PUMP IF
NECESSARY
2 LUBRICANT DOESN’T 2 RECONSIDER THE RELATIVE HEIGHT
RETURN SMOOTHLY ALLOCATION OF PRINCIPLE UNIT AND
LUBRICATION OIL TANK
3 HIGH RETURN OIL 3 CHECK THE AMOUNT OF COOLING WATER.
TEMPERATURE ALSO ANY CLOG IN COOLING PIPE, IF YES,
REPLACE OR REPAIR COOLING PIPE
4 WRONG LUBRICANT USED 4 CHANGE THE SPECIFIED ONE
ABNORMAL 5 DEFICIENT LUBRICANT 5 CHECK ALL PIPINGS AND LUBRICANT
TEMPERATURE QUANTITY IN TANK
6 V-BELT TOO TIGHT 6 ADJUST THE TIGHTNESS OF V-BELT
7 ABNORMAL CRUSHING 7 UNEVENLY FEEDING OR OVERLOAD
FEEDING, ADJUST FEEDING EVENLY OR
CONTROL FEEDING AMOUNT
8 TOO SMALL DISCHARGE 8 ADJUST IT
SETTING
9 MUD, WOOD ETC. ARE 9 CLEAN IT IMMEDIATELY TO AVOID DUST
CLOGGED IN OUTLET OF SEAL RING BREAK AND DUST ENTER INTO
CRUSHER OIL PATH SO AS TO CAUSE CLOG IN OIL
PATH OR DETERIORATION OF LUBRICANT
1 MANTLE AND CONCAVE 1 CHECK AND REPLACE
WEAR AND NEED TO
CHANGE
LOW CAPACITY 2 TOO BIG DISCHARGE 2 CHECK & ADJUST TO SPECIFICATION
SETTING
3 R.P.M. TOO LOW 3 CHECK R.P.M. MOTOR V-BELTS, REPAIR OR
REPLACE IF NECESSARY
CRUSHING 1 V-BELT LOOSEN 1 TIGHTEN TO SUITABLE TIGHTNESS
EFFECT
WEAKEN
1 SLANT V-BELT OR IT IS TOO 1 ADJUST TIGHTNESS OF V-BELT AND ALIGN
TIGHT THE MOTOR PULLEY AND MACHINE
COUNTERSHAFT
PULLEY TO A STRAIGHT LINE AGAIN
STICK
2 CHECK BEARINGS, LUBRICATION SYSTEM
AND BEARING SEAT
1 LOCKING CAP OF MAIN 1 CHECK AND TIGHTEN AGAIN
SHAFT LOOSEN
2 WRONG TURNING 2 CORRECT IT
MANTLE OR DIRECTION OF MAIN
CONCAVE FALL SHAFT
OFF 3 U-BOLTS LOOSEN 3 REMOVE TOP CELL, CHECK U-BOLTS AND
TIGHTEN AGAIN
4 MANTLE AND CONCAVE 4 REPLACE THEM
BREAK
1 DISCHARGE SETTING IS 1 ADJUST DISCHARGE SETTING TO NORMAL
TOO SMALL CONDITION
2 FEED MATERIAL IS TOO 2 ADJUST DISCHARGE SETTING OF
BIG FORE-CRUSHER TO MAKE FEED MATERIAL
ABNORMAL IS WITHIN SPECIFICATION
CURRENT 3 UNCRUSHABLE MATERIAL 3 CONTROL FEED MATERIAL TO EXCLUDE
MIX INTO FEED MATERIAL UNCRUSHABLE MATERIAL
4 MANTLE AND CONCAVE 4 REPLACE NEW MANTLE AND CONCAVE
WEAR AND BREAK
5 FOREIGN MATTERS STACK 5 CLEAN FOREIGN MATTER BY ENTERING
6-3
 IN OUTLET OF CRUSHING INTO BOTTOM OF LOWER FRAME
CHAMBER
1 UPPER FRAME MOVES UP & 1 THE COMPRESSION AMOUNT OF SPRING IS
DOWN NOT ENOUGH, ADJUST IT
OTHERS 2 ADJUSTMENT CAP MOVES 2 ADJUSTMENT BOLT LOOSEN OR FIXING
UP & DOWN BLOCK LOOSEN. CHECK AND TIGHTEN IT
AGAIN
1 FOUNDATION BOLTS 1 TIGHTEN AGAIN
LOOSEN
ABNORMAL
2 UNCRUSHABLE MATTER 2 CLEAR IT AND CONTROL FEED MATERIAL
VIBRATION OF
MIX INTO CRUSHING CONDITION
LOWER FRAME
CHAMBER
3 FOUNDATION LOOSEN 3 REPAIR AND FIX AGAIN
OIL LEAKAGE 1 LUBRICANT IS TOO MUCH 1 REDUCE IT
FROM AIR 2 DRAIN PIPE IS CLOGGED 2 CLEAN IT
BREATHER OF
COUNTERSHAFT
BOX
OIL LEAKAGE OF 1 OIL SEALS OR COLLARS 1 REPLACE THEM
COUNTERSHAFT DAMAGE
BOX 2 BEARINGS DAMAGE 2 REPLACE THEM
1 BEARINGS ARE DAMAGED 1 REPLACE THEM
COUNTERSHAFT
2 PINION DAMAGE 2 REPLACE IT
STICK
3 V-BELT IS TOO TIGHT 3 ADJUST IT
1 OIL SEAL DAMAGE 1 REPLACE IT
OIL LEAKAGE 2 PISTON OR INNER WALL OF 2 REPLACE IT
OF HYDRAULIC CYLINDER WEAR
CYLINDER 3 MUD & DUST STACK
AROUND CRUSHER
1 U-BOLT LOOSEN 1 TIGHTEN AGAIN
2 TOP CELL MACHINING 2 REPAIR OR REPLACE IT
SURFACE WEAR
3 CONCAVE WEAR OR 3 REPAIR OR REPLACE IT
CONCAVE UNMATCHING INCINATION
LOOSEN ANGLE WHILE MATCHING
WITH TOP CELL
4 BAD ASSEMBLY OR 4 ADJUST OR REPAIR IT
INTEREFENCE BY FOREIGN
MATTER
1 LOCKING CAP LOOSEN 1 TIGHTEN IT AGAIN
2 MANTLE CORE WEAR 2 REPAIR OR REPLACE IT
MANTLE
3 BAD ASSEMBLY OR 3 ADJUST OR REPAIR IT
LOOSEN
INTEREFENCE BY FOREIGN
MATTER
1 INNER BUSH IS BURNT AND 1 REPAIR OR REPLACE IT
STUCK
2 MAIN SHAFT BREAK OR 2 REPAIR OR REPLACE IT
REVOLUTION LOOSEN
OF MANTLE IS 3 SOCKET LOOSEN 3 TIGHTEN IT AGAIN
TOO FAST 4 SOCKET LINER WEAR TOO 4 REPLACE IT
MUCH
5 WEAR BETWEEN SOCKET 5 REPAIR AND REPLACE IT
AND LOWER FRAME
OIL LEAKAGE 1 O-RING WEAR 1 REPLACE IT
BETWEEN 2 SIDE HOLE OF LOWER 2 REPAIR IT
COUNTERSHAFT FRAME WEAR
BOX AND 3 COUNTERSHAFT BOX 3 REPAIR IT
LOWER FRAME WEAR
ABNORMAL 1 FOUNDATION BOLTS 1 TIGHTEN AGAIN
6-4
NOISE DURING LOOSEN
RUNNING 2 SPRINGS BETWEEN UPPER 2 ADJUST THEM
AND LOWER FREME
LOOSEN
3 GEAR AND PINION WEAR 3 REPAIR OR CLEAR
OR INTEREFERED BY
FOREIGN MATTERS
4 UNCRUSHABLE MATTER 4 CLEAR IT
ENTER INTO CRUSHING
CHAMBER
5 OUTLET IS STUCK 5 CLEAR IT
1 DUST SEAL RING WEAR 1 REPLACE IT
2 O-RING OF SOCKET 2 REPLACE IT
DAMAGE
3 SOCKET AND LOWER 3 REPAIR OR REPLACE IT
FRAME WEAR
FOREIGN
4 DUST COVER WEAR 4 REPAIR OR REPLACE IT
MATTERS, LIKE
5 DUST SEAL EFFECT OF 5 IMPROVE IT
DUST, PEBBLE
LUBRICANT OIL TANK IS
ENTER INTO
BAD
OIL PATH
6 FOREIGN MATTERS (LIKE 6 CLEAR THEM
CLOTH, WOOD) ARE STUCK
IN OUTLET
7 OIL PIPES BREAK OR 7 REPAIR OR REPLACE THEM
DAMAGE
1 OUTLET IS STUCK BY 1 CLEAR IT
CLOTH, WOOD
OUTLET OF
2 MUD CONTENT OF 2 IMPROVE IT
CRUSHER IS
MATERIAL IS TOO HIGH
NOT SMOOTH
3 WRONG ALLOCATION OF 3 ADJUST IT
CONVEYOR
1 TOP CELL IS COLLIDED OR 1 REPAIR IT
DEFORMED
TOP CELL AND 2 FOREIGN MATTERS EXIST 2 CLEAR IT
UPPER FRAME IN THREADS OF TOP CELL
ARE HARD TO OR UPPER FRAME
ASSEMBLE 3 THREAD OF TOP CELL OR 3 REPAIR IT
UPPER FRAME ARE
DAMAGED
1 FEED HOPPER IS NOT 1 REPAIR IT
FEEDING INSTALLED WELL
MATERIAL IS 2 FEED HOPPER WEAR 2 REPAIR IT
OBLIQUE 3 INTERFERED BY FOREIGN 3 CLEAR IT
MATTER
1 INNER BUSH BURNT AND 1 REPAIR OR REPLACE IT
DEFORMED
2 OUTER BUSH BURNT AND 2 REPAIR OR REPLACE IT
CRUSHER IS DEFORMED
STUCK DURING 3 ECCENTRIC SLEEVE WEAR 3 REPAIR OR REPLACE IT
RUNNING 4 SOCKET LINEAR WEAR 4 REPAIR OR REPLACE IT
5 COUNTERSHAFT DAMAGE 5 REPAIR OR REPLACE IT
6 STEP BEARING PLATES 6 REPAIR OR REPLACE IT
WEAR

6-5
6.4 LUBRICANT TANK CHECK POINT

CHECK ITEMS CHECKING PROCEDURE COUNTERMEASURE

LUBRICANT QUANTITY CHECK BY OIL METER ATTACHED ON
IN TANK TANK
COMPARED WITH NEW OIL IN GLASS
CHECK THE DIRTINESS VESSELS FOR FOUL SMELL, REFER BELOW TABLE FOR
OF LUBRICANT TRANSPARENCY, WATER MIXING OR DETAIL
SOLID MATTER MIXING
VISUAL ASSESSMENT

APPEARANCE SMELL CONDITION REMEDY

TRANSPARENT
AND NO CHANGE GOOD GOOD USE IT AS IT IS
IN COLOR
TRNSPARENT A DIFFERENT TYPE
CHECK VISCOSITY AND IF
BUT COLOR IS GOOD OF OIL MAY HAVE
NO PROBLEM, USE IT
THIN MIXED IN
AIR BUBBLES AND HAVE THE WATER CONTENT
HAS TURNED
GOOD WATER HAVE MIXED SEPARATED BY OIL MAKER
MILK-WHITE
IN OR REPLACE THE OIL
HAS TURNED BAD HAS OXIDIZED AND
REPLACE IT WITH NEW OIL
BLACKISH BROWN SMELL DETERIORATED
TRANSPARENT
EITHER USE IT AFTER FILL
BUT FINE FOREIGN FOREIGN MATTERS
GOOD TRATED OR REPLACE IT
MATTERS HAVE HAVE MIXED IN
WITH NEW OIL
MIXED IN

LISTEN TO PUMP RUNNING SOUND TO

JUDGE THE EXISTENCE OF
FOLLOWING
SOUND OF LUBRICATION 1 OIL TEMPERATURE IS TOOL LOW 1 HEAT OIL
PUMP WHILE 2 AIR IS SUCKED INTO PUMP 2 CHECK WHETHER THE
RUNNING PIPING LOOSEN
3 CLOG INSIDE PIPES 3 TEAR DOWN AND CLEAR
IT
4 GEAR OR BEARING ETC. DAMAGE 4 CHANGE A NEW PUMP
OIL BLOCKADE WHILE 1 WHETHER OUPUT PRESSURE RAISE REMOVE RETURN SCREEN
TRANSPORTING FROM OR NOT AND WASH IT
PUMP 2 CHECK RETURN SCREEN
OIL TEMPERATURE RAISE OR NOT CHECK COOLING WATER
COOLING WATER QUANTITY, INCREASE IT IF
QUANTITY NECESSARY

6-6
 CHECK ACCORDING TO RETURN OIL
TEMPERATURE METER
1 DEFICIENT LUBRICANT
IS THE RETURN
OIL TEMPERATURE TOO 2 DEFICIENT COOLING WATER
HIGH
3 OVER LOAD
4 INNER BUSH BURNT
REMOVE THE SCREENS AND CHECK
RETURN SCREEN OR
STRAINER
6-7
1 SUPPLY LUBRICANT TO
SPECIFIED VALUE
2 SUPPLY COOLING WATER
TO SPECIFIED VALUE
3 ADJUST THE FEEDING
RATE
4 REPAIR OR REPLACE IT
1 CLEAN THE SCREEN
2 WHEN A LOT METAL
CHIPS ARE FOUND
EXISTING ON SCREENS,
SOCKET LINER,
INNER/OUTER BUSH AND
STEP BEARING PLATE
DAMAGE OR WEAR.
REAPIR OR REPLACE
THEM.
 6.4.1 TROUBLE SHOOTING OF LUBRICATION OIL TANK：

PHENOMENON POSSIBLE CAUSES COUNTERMEASURE

. TURNING DIRECTION OF PUMP IS . CHANGE DIRECTION
NO OIL COME OUT WRONG . CLEAN THE SCREEN
FROM PUMP . SCREEN IS STUCK . CHECK PIPING AND IT’S
. AIR IS SUCKED INTO PUMP CONNECTION
. SCREEN IS STUCK . CLEAN THE SCREEN
. AIR IS SUCKED INTO PUMP . CHECK PIPING AND IT’S
ABNORMAL NOISE . BUBBLE MIXED INTO OIL CONNECTION
OF PUMP . GEAR OR BEARING WEAR . EXCLUDE THE BUBBLE.
. OIL TEMPERATURE IS TOO LOW . CHANGE A NEW PUMP
. HEAT OIL
HIGH TEMPERATURE . ABNORMAL SHAFT OF PUMP . TEAR DOWN AND CHECK
OF PUMP BEARING . STRAINER OR RETURN SCREEN IS . CLEAN THE SCREEN OR
1 SUDDENLY RISE STUCK STRAINER
WHILE RUNNING . DEFICIENT COOLING WATER OR . SUPPLY COOLING WATER TO
2 PUMP BECOMES BEING STUCK IN PIPING SPECIFIED QUANTITY
HOT AFTER LONG
TERM RUNNING
. DEFICIENT COOLING WATER OR . SUPPLY COOLING WATER TO
BEING STUCK IN PIPING SPECIFIED QUANTITY
. HIGH TEMPERATURE OF COOLING . CHECK AND CLEAN PIPES OF
HIGH TEMPERATURE WATER COOLING WATER
OF RETURN OIL . OVERLOAD OF PRINCIPLE UNIT . CHECK DISCHARGE SETTING OR
FEED METERIAL RATE
. IS THE MAIN MOTOR CURRENT
WITHIN SPECIFICATION OR NOT

6-8
 CHAPTER 7 AUXILIARY EQUIPMENTS

7.1 INTRODUCTION........................................................................................7-1

7.2 LUBRICATION OIL TANK ........................................................................7-1

7.3 HYDRAULIC OIL TANK ...........................................................................7-3

7.4 ADJUSTMENT HYDRAULIC CYCINDER..............................................7-5

7.5.TEMPERATURE CONTROLLER OF AIR COOLER…………………7-10

 CHAPTER 7 AUXILIARY EQUIPMENTS

7.1 INTRODUCTION
THERE ARE THREE AUXILIARY EQUIPMENT AS DESCRIBED BELOW：
LUBRICATION OIL TANK：THE MAIN FUNCTION IS TO SUPPLY LUBRICANT INTO OIL PATH OF
PRINCIPLE UNIT SO AS TO LUBRICATE INNER PARTS.
HYDRAULIC OIL TANK：INCORPORTING WITH HYDRAULIC CYCINDERS EQUIPPED AROUND
LOWER FRAME TO RAISE UPPER FRAME AND ENLARGE THE
DISCHARGE SETTING SO AS TO DISCHARGE THE REMAINING
MATERIAL WHILE POWER SUDDENLY SHUT DOWN OR EMERGENT
STOP. IT IS MUCH EASIER COMPARED WITH MANUAL DISCHARGE.
ADJUSTMENT HYDRAULIC CYLINDER：USED TO ADJUST THE DISCHARGE SETTING TO WHAT
WE DESIRED. ALSO IT SHOULD BE USED TOGETHER
WITH HYDRAULIC OIL TANK.
TEMPERATURE CONTROLLER OF AIR COOLER: CONTROL THE ACTUATION TEMPERATURE OF
AIR COOLER.
7.2 PARTS OF LUBRICATION OIL TANK

PART NO. PART NAME REMARK

1 PUMP
2 COUPLE
3 MOTOR
4 STRAINER
5 OIL COOLER
6 THERMOMETER
7 PRESSURE GAGE
8 FLOW CONTROL VALVE
9 OIL METER
10 AIR BREATHER
11 STOP VALVE (DRAIN)
12 RETURN SCREEN
13 THERMOMETER A
14 ELECTRIC BOX WITH AIR COOLER TEMPERATURE CONTROLLER
15 RELIEF VALVE
TABLE 7-1

7-1
FIG 7-1

7-2
 TWO DEVICES OF ABOVE SHOULD BE INTERLOCKED WITH MAIN MOTOR, i.e. MAIN MOTOR
WILL STOP AS LONG AS THE TWO DEVICE REACH THE PRESET VALUE IN ORDER TO PROTECT
CRUSHER AND AVOID DAMAGE.
7.2.1 THERMOMETER A (PART NO.13)：WHEN THE RETURN OIL TEMPERATURE REACH THE
PRESET VELUE (AS THE INDICATOR SHOWN), THE MAIN
MOTOR WILL BE STOPPED.
7.2.2 PRESSURE VALVE：WHEN OIL PRESSURE IS LOWER THAN THE SET VALUE OF FLOW
PRESSURE, THE MAIN MOTOR WILL BE STOPPED.

7.3 PART OF HYDRAULIC OIL TANK

PART NO. PART NAME REMARK

1 MOTOR
2 COUPLER
3 PUMP
4 OIL SCREEN
5 CHECK VALVE
6 OIL METER
7 PIPE (DRAINING)
8 PLUG (DRAINING)
9 DUAL MANUAL VALVE
OIL FILLER WITH AIR
10
BREATHER
TABLE 7-2

NOTE: THE CHECK VALVE (PART NO.5) WILL NEED TO RELEASE AIR BEFORE ACTUATING THE
HYDRAULIC SYSTEM. THIS IS BECAUSE THAT THE PIPING LINE AND HYDRAULIC
CYLINDERS FULL OF AIR BEFORE OIL BE SENT TO ALL SPACE. PLEAES REFER TO FIG 7-2A
FOR DETAIL.

7-3
FIG 7-2

7-4
Release Check
air Valve

FIG 7-2A

7-5
7.3.1 DUAL MANUAL VALVE

PLEASE REFER TO FIG 7-3 FOR THE STUCTURE OF DUAL MANUAL VALVE AND NAME OF
EACH PARTS:
1. PUSH ROD:
THIS IS USED TO ACTUATE THE HYDRALIC OIL TO THE HYDRALULC
CYLINDERS. ONE ROD IS SET FOR ADJUSTMENT HYDRAULIC CYLINDER. THE OTHER
ONE IS FOR DISCHARGE HYDRAULIC CYINDERS SURROUNDING THE LOWER FRAME.
2. OIL INLET AND OUTLET PORT:
THESE ARE ONLY OIL IN AND OUT PATH
3. PRESSURE REGULATOR:
THIS IS USED TO ADJUST THE HYDRAULIC PRESUURE WHILE ACTUATING THE
CYLINDERS. MOVE THE CAP OUT BEFORE ADJUSTING THE SET SCREW. PLEASE REFER
TO FIG 7-4 FOR THE DETAIL STUCTURE. SCREW THE SET SCREW IN, i.e. CLOCKWISE BY
VIEW FROM THE ABOVE OF NUT BY USING INNER HEXAGON SPANNER, THE PRESSURE
WILL BE INCREASED. SCREW THE SET SCREW OUT, i.e. COUNTER-CLOCKWISE BY VIEW
FROM THE ABOVE OF NUT, THE PRESUURE WILL BE DECREASED. NORMALLY, THE
ADJUSTMENT CLINDERS FOR THE DISCHARGE SET ADJUSTMENT DOES NOT NEED HIGH
PRESSURE. ONLY THE DISCHARGE CYLINDERS SURROUNDING LOWER FRAME NEEDS
HIGH HYDRAULIC PRESSURE DURING ACTUATION. SO, IT SHOULD BE CAREFULLY
WHEN THE DISCHAGE CYLINDERS ARE ACTUATED TO DISCHARGE THE MATERIAL
INSIDE CRUSHING CHAMBER AS THE OPERATING PRESSURE IS HIGH. FOLLOWINGS ARE
THE POINTS TO BE CAUTIONED.
1. THE HYDRAULIC PRESSURE SHOULD NOT OVER 180KG/CM2 WHILE ACTUATING
THE ROD.
2. ALSO, IT IS VERY IMPORTANT TO RELIEVE THE PRESSURE BY PUSH BACK THE ROD
VERY OFTEN DURING THE ACTUATION OF HYDRAULIC CYLINDERS. IN OTHER
WORD, IT IS NECESSARY TO PUSH FORWARD – BACK-FORWARD –BACK WHILE
OPERATING THE ROD TO AVOID THE HOT HYDRALIC OIL WHICH MAY CAUSE THE
DISCHARGE CYLINDERS CAN NOT BE ACTUATED.

7-6
 ROD

OIL OULET PORT

OIL INLET PORT

PRESSURE
REGULATOR

FIG 7-3

7-7
 CAP

SET SCREW

FIG 7-4

7-8
 7.4 PART LIST FOR ADJUSTMENT HYDRAULIC CYCINDER

ITEM PART NAME QTY REMARK

1 HYDRAULIC CYLINDER 1
2 ROD 1
3 PISTON 1
4 RETURN PIPE 1
5 BRACKET 1
6 OIL SEAL 1
7 O-RING 1
8 O-RING 1
9 OIL SEAL 2
10 O-RING 1
11 O-RING 1
TABLE 7-3

7-9
FIG 7-5

7-10
7.5 TEMPERATURE CONTROLLER OF AIR COOLER
THE TEMPERATURE CONTROLLER TO CONTROL THE START OPERATION OF AIR COOLER FAN
AS DESCIBED IN 3.5.5 HAS THE OPERATION MANUAL AS ENCLOSED LEAFLET. THE PICTURE OF THE
DEVISE IS SHOWN IN

FIG 7.6.

7-11
 CHAPTER 8 LUBRICATION SYSTEM

8.1 INTRODUCTION........................................................................................8-1

8.2 FILLING AND DRAINING OF LUBRICANT ..........................................8-3

8.3 LUBRICANT SPECIFICATION AND REPLACEMENT SCHEDULE ...8-5

8.4 VISUAL ASSESSEMENT...........................................................................8-6

 CHAPTER 8 LUBRICATION SYSTEM

8.1 INTRODUCTION
THE LUBRICATION METHODS AND PORTIONS OF SPRING CONE CRUSHER CAN BE
DIVIDED INTO 3 KINDS.
8.1.1 FORCE LUBRICATION
FORCE LUBRICATION IS APPLIED TO LUBRICATE PRINCIPLE UNIT BY PUMP
SENDING OIL FROM TANK FORCELY INTO OIL PATH OF CRUSHER. THE
LUBRICANT LUBRICATES INNER BUSH, OUTER BUSH, SOCKET LINER, GEARS,
STEP BEARING STEPS AND THEN RETURN BACK TO TANK TO FORM A
CIRCULATION. THE DETAIL OIL FLOW IS SHOWN ON FIG 8-1 & 8-2.

8-1
8-2
FIG 8-1
 8.1.2 OIL BATH
OIL BATH METHOD IS APPLIED TO LUBRICATE BEARINGS OF COUNTERSHAFT.
BY FILLING SAME LUBRICATION OIL AS ONE INSIDE LUBRICATION OIL TANK TO
THE HEIGHT OF PLUG, BEARINGS ARE THEREFORE LUBRICATED. IN CASE OF
FILLING TOO MUCH OIL, IT WILL FLOW TO DRAINING PIPE CONNECTED TO
RETURN OIL PIPE AND BACK TO TANK. (REFER TO FIG 8-1)
8.1.3 GREASE LUBRICATION
THE THREADS OF TOP CELL AND UPPER FRAME IS LUBRICATED BY GREASE TO
AVOID RUSTING AND STICKING. (REFER TO FIG 8-1)

8.2 FILLING AND DRAINING OF LUBRICANT

8.2.1 FORCE LUBRICATION
THE LUBRICATION OIL TANK AND OIL PATH OF PRINCIPLE UNIT ARE FORMED A
CIRCULATION. OIL QUANTITY COULD BE JUDGED FROM OIL METER OF TANK.
THE LUBRICANT IS FILLED THROUGH RETURN BOX AND DRAINED THROUGH
DRAINING VALVE. (FIG 8-2)
8.2.2 OIL BATH
PLEASE REFER TO FIG 8-1 FOR FILLING AND DRAINING PORT POSITION. FILLING
OIL UNTIL OIL OVERFLOW FROM “A” PORT (PLUG DEVICE) AND THEN TIGHTEN
THE PLUG. IF OIL IS FILLED TOO MUCH, IT WILL CAUSE OIL LEAK OUT FROM AIR
BREATHER OR RETURN BACK TO OIL TANK THROUGH RETURN PIPE. THE
ABOVE PHENOMENON IS NORMAL. AS FOR DRAINING OIL, IT IS SIMPLY TO
DRAIN OIL THROUGH DRAINING PORT.
8.2.3 GREASE LUBRICATION
REPLENISHING GREASE THROUGH GREASE NIPPLE OF UPPER FRAME UNTIL
GREASE OVERFLOW FROM GREASE NIPPLE. BE SURE TO REPLENISH GREASE
REGULARLY TO AVOID STICKING BETWEEN TOP CELL AND UPPER FRAME.

8-3
8-4
FIG 8-2
8.3 LUBRICATION OIL SPECIFICATION AND REPLACEMENT SCHEDULE

REPLACEMENT
METHOD OIL SPECIFICATION OIL QUANTITY
SCHEDULE
1ST: 400 HRS FROM
HD-220 REFER TO OIL BEGINMING OF
FORCE OR MOBIL DTE OIL BB METER OF COMMERCIAL
LUBRICATION OR ESSO SPARTAN EP220 LUBRICATION OIL OPERATION
OR SHELL OMALA 220 TANK (SEE FIG 8-2) THEN FOR EVERY
700HRS REPLACE ONCF
SAME AS “FORCE SAME LEVEL OF SAME AS “FORCE
OIL BATH
LUBRICATION” PLUG POSITION LUBRICATION”
FILLING OR
REPLENISHING
GREASE REPLENISHING
GREASE NO.2 UNTIL GREASE
LUBRICATION GREASE WEEKLY
OVERFLOW
GREASE NIPPLE
CPC AW68 or REFER TO OIL
CASTROL AWS68 or METER OF
HYDRAULIC One year or 3000Hrs,
Mobil DTE26 HYDRAULIC OIL
OIL whichever comes first
or Shell Tellusk 68 or TANK
ESSO Nuto 68
TABLE 8-1

8-5
8.4 VISUAL ASSESSMENT OF LUBRICATION OIL
BELOW IS A SIMPLE JUDGEMENT OF OIL DETERIORATION FOR REFERENCE

APPEARANCE SMELL CONDITION REMEDY

TRANSPARENT
AND NO CHANGE GOOD GOOD USE IT AS IT IS
IN COLOR
TRANSPARENT A DIFFERENT TYPE
CHECK VISCOSITY AND
BUT COLOR IS GOOD OF OIL MAY HAVE
IF NO PROBLEM, USE IT
THIN MIXED IN
HAS TURNED AIR BUBBLES AND HAVE THE WATER CONTENT
MILK-WHITE GOOD WATER HAVE MIXED SEPARATED BY OIL MAKER
IN OR REPLACE THE OIL
HAS TURNED BAD HAS OXIDIZED AND REPLACE IT WITH NEW
BLACKISH BROWN SMELL DETERIORATED OIL
TRANSPARENT
EITHER USE IT AFTER
BUT FINE FOREIGN FOREIGN MATTERS
GOOD FILTRATED OR REPLACE
MATTERS HAVE HAVE MIXED IN
IT WITH NEW OIL
MIXED IN
TABLE 8-2

8-6
 CHAPTER 9 PARTS LIST

9.1 INTRODUCTION........................................................................................9-1

9.2 PART LIST ...................................................................................................9-1

 CHAPTER 9 PARTS LIST

9.1 INTRODUCTION
THE MAIN PURPOSE OF THIS CHAPTER IS TO OFFER A CLEAR LIST OF ALL PARTS
OF PRINCIPLE UNIT IN ORDER TO MAKE YOU CONVENIENT TO INQUIRE OR ORDER
PARTS. AS FOR AUXILIARY EQUIPMENTS, PLEASE REFER TO CHAPTER 7 FOR DETAIL.

9.2 PARTS LIST

FEED HOPPER ASSEMBLY

PART NO. PART NAME QTY’S REMARKS

101 FEED HOPPER 1
102 TOP CELL LINER 1
TABLE 9-1
UPPER FRAME ASSEMBLY

PART NO. PART NAME QTY’S REMARKS

201 TOP CELL 1
202 CONCAVE 1
203 U-BOLT 4 WITH A NUT 16 PIECES
204 COMPRESSED SHIM 8
RUBBER SHIM;
205 16
U-BOLT
206 UPPER FRAME 1
207 DUST RING 1
208 DUST RUBBER 1
209 DUST COLLAR 1
210 ADJUSTMENT CAP 1
211 ADJUSTMENT BOLT 6
212 BRACKET 2
213 FIXING BLOCK 1
PIN;
214 1
FIXING BLOCK
215 GREASE NIPPLE 2
216 PIN; UPPER FRAME 4
STOPPER PIN;
217 1
FIXING BLOCK
TABLE 9-2
MANTLE CORE ASSEMBLY

PART NO. PART NAME QTY’S REMARKS

301 MAIN SHAFT 1
302 KEY, MAIN SHAFT 1
303 MANTLE CORE 1
304 MANTLE 1
305 TIGHTING COLLAR 1
306 LOCKING RING 1
307 LOCKING CAP 1
308 DUST SEAL RING 1
309 SPRING, DUST SEAL RING 12
310 KEY, DUST SEAL RING 2
TABLE 9-3

SOCKET ASSEMBLY

PART NO. PART NAME QTY’S REMARKS

401 SOCKET 1
402 SOCKET LINER 1
403 O-RING 1
404 BOLT; SOCKET LINER 4
405 BOLT; SOCKET 12
406 KEY 2
407 BOLT 2
TABLE 9-4
ECCENTRIC SLEEVE ASSEMBLY

PART NO. PART NAME QTY’S REMARKS

501 ECCENTRIC SLEEVE 1
502 GEAR 1
503 INNER BUSH 1
504 KEY 1
505 PIN,; ECCENTRIC SLEEVE 1
TABLE 9-5
COUNTERSHAFT BOX ASSEMBLY

PART NO. PART NAME QTY’S REMARKS

601 COUNTERSHAFT BOX 1
602 COUNTERSHAFT 1
603 BEARING COVER 2
604 BOLT, BEARING COVER 16
605 ASBESTOS SHIM 2
606 OIL SEAL 2
607 O-RING 1
608 BEARING 2
609 BEARING 1
610 COMPRESSION NUT 1
611 COMPRESSION WASHER 1
612 MACHINE PULLEY 1
613 KEY; MACHINE PULLEY 1
614 PULLEY CAP 1
615 PINION 1
616 KEY, PINION 2
617 LONG COLLAR 1
618 SHORT COLLAR 1
619 END PLATE; COUNTERSHAFT 1
620 BOLT SHIM 1
621 BOLT; END PLATE 2
622 PLUG 1
623 PEA-COCK 1
624 AIR-BREATHER 1
625 BOLT; HEXAGON 8
626 BOLT; HEXAGON 4
627 NUT; HEXAGON 4
628 GUARD; COUNTERSHAFT BOX 1
TABLE 9-6
LOWER FRAME ASSEMBLY

PART NO. PART NAME QTY’S REMARKS

701 LOWER FRAME 1
702 OUTER BUSH 1
703 LOWER FRAME CAP 1
704 LOWER STEP BEARING PLATE 1
705 MIDDLE STEP BEARING PLATE 1
706 UPPER STEP BEARING PLATE 1
707 SPRING BOLT 26
708 SPRING 36
709 LOWER SPRING SEGMENT 12
710 PUSHING ROD 10
711 HYDRAULIC CYLINDER 10
712 SEAT, HYDRAULIC CYLINDER 10
713 LOWER FRAME LINER (UPPER) 1
714 LOWER FRAME LINER (LOWER) 1
715 HOSE; HIGH PRESSURE 10
716 FOUNDATION BOLT 4 WITH 3 NUTS
TABLE 9-7
FIG 9-1
 CHAPTER 10 PART REPLACEMENT

10.1 INTRODUCTION......................................................................................10-1

10.2 WEAR PART SERVICE LIFE...................................................................10-1

10.3 REPLACEMENT OF LINER....................................................................10-5

10.4 REPLACEMENT OF MANTLE & CONCAVE ....................................10-11

10.5 REPLACEMENT OF DUST SEAL RING.............................................10-14

10.6 REPLACEMENT OF SOCKET LINER ................................................10-15

10.7 REPLACEMENT OF INNER BUSH.....................................................10-17

10.8 REPLACEMENT OF MIDDLE STEP BEARING ................................10-24

10.9 REPLACEMENT OF OUTER BUSH....................................................10-25

10.10 REPLACEMENT OF COUNTERSHAFT BOX BEARINGS ............10-32

 CHAPTER 10 PART REPLACEMENT

10.1 INTRODUCTION
THIS CHAPTER DESCRIBES THE REPLACEMENT PROCEDUCE FOR WEAR PART,
FOR EXAMPLE MANTLE, CONCAVE ETC. IN ORDER TO REPLACE PARTS PROMPTLY,
ACCURATELY AND SAFELY, PLEASE READ THIS CHAPTER THROUGHLY.

10.2 SERVICE LIFE OF WEAR PART

10.2.1 TOP CELL LINER, LOWER FRAME LINER (UPPER), LOWER FRAME LINER
(LOWER) AND COUNTERSHAFT BOX GUARD ETC.
(CHECK WHETHER THERE IS ANY HOLE BROKEN THROUGH BY VISUAL
INSPECTION. IF YES, THEN IT SHOULD BE CHANGED WITH A NEW ONE)

10-1
10.2.2 MANTLE AND CONCAVE (REFER TO FIG 10.1)
MANTLE OR CONCAVE SHOULD BE CHANGED WHILE EITHER THICKNESS OF
MAMTLE OR CONVARE REACHES 20-25MM BY VISUAL ASSESSMENT.

REMARK：CUTTING RING SHOULD BE CHANGED IN THE MEANTIME OF

CHANGING MANTLE, WHILE REPLACEMENT OF LOCKING CAP,
TIGHTEN COLLAR AND DISTRIBUTOR IS PENDING ON THE WEAR
CONDITION.

FIG 10-1

10-2
10.2.3 DUST SEAL RING
IF THE DUST SEALING RING IS EXCESSIVELY WORN TO THE POINT WHERE IT
HAS LOST ITS EFFECTIVENESS AS A SEAL, IT SHOULD BE REPLACED. IF ANY OF
THE SPRINGS HAVE BECOME WEAKENED AND NO LONGER CAN EXERT
NECESSARY FORCE TO KEEP CONTACT OF DUST SEAL RING AND MANTLE
CORE, THEY ALSO SHOULD BE REPLACED.

FIG 10-2

10.2.4 SOCKET LINER AND INNER BUSH

WHEN SOCKET LINER WEARS, THE GAP BETWEEN MAIN SHAFT AND INNER
BUSH WOULD BE SMALLER, IE SOCKET LINER HAS CLOSE RELATON WITH THE
GAP BETWEEN MAIN SHAFT AND SOCKET LINER. THEREFORE, SOCKET LINER
AND INNER BUSH SHONLD BE REPLACED IN SAME TIME WHEN SOCKET
LONER LOSS 1-3~2-/5 DIMENSIONS (REFER TO FIG 10-3)

FIG 10-3
10-3
10.2.5 WHEN THE GAP BETWEEN MAIN SHAFT AND INNER BUSH ENLARGE TO 2.3~2.5
M/M DUE TO WEAR, SOCKET LINER, INNER BUSH, MIDDLE STEP BEARING
PLATE SHOULD BE REPLACED IN THE SAME TIME.
10.2.6 ONCE THE GAP BETWEEN OUTER BUSH AND ECCENTRIC IS MORE THAN
1.6~1.8M/M, THE OUTER BUSH SHOULD BE REPLACED.
10.2.7 ONCE THE DITCHES ON MIDDLE STEP BEARING PLATE TO 1/2 DIMENSION
BELOW, IT SHOULD BE REPLACED.
10.2.8 THE WEAR OF UPPER, MIDDLE AND LOWER STEP BEARING PLATE ARE
RELATED TO BACKLASH OF GEAR SET, SO THE BACKLASH SHOULD BE
ADJUSTED WHILE THEY WEAR. PLEASE REFER TO FIG 10-4 FOR ADJUSTMENT
METHOD AND ALSO THE ADJUSTING TRAVEL IS ABOUT 6~7 M/M AS FOR
BACKLASH OF GEAR SET, A SIMPLE JUDGEMENT IS TO SHAKE MACHINE
V-PULLEY IN CIRCUFERENCECE DIRECTION AND CHECK THE TRAVEL IS IN 6~7
M/M.

FIG 10-4

10-4
10.3 REPLACEMENT OF LINER
10.3.1 TOP CELL LINER
HANG UP FEED HOPPER ASSEMBLY DIRECTLY AND CUT THE BROKEN LINER
BY TORCH. THEN, REPLACE A NEW ONE AND WELD. (REFER TO FIG 10-5)

FIG 10-5

10.3.2 LOWER FRAME LINER (UPPER & LOWER)

10.3.2.1 REMOVE THE STOP PIN OF BRACKET AND TURN THE STOPPER
OUTWARD TO LEAVE THE ADJUSTMENT TEETH OF ADJUSTMENT CAP,.
(REFER TO FIG 10-6)
10.3.2.2 TURN THE ADJUSTMENT BOLTS LOOSE SLIGHTLY. (REFER TO FIG 10-6)
10.3.2.3 CLEAN THE MUD ADHERED TO FRAME BY USING AIR COMPRESSOR.
10.3.2.4 SET UP THE ADJUSTMENT HYDRAULIC CYLINDER ON TO UPPER FRAME
AND CONNECT OIL PIPING TO HYDRAULIC OIL TANK. TURN THE
ADJUSTMENT CAP TILL IT LOOSEN BY OPERATING THE DUAL MANUAL
SWITCH OF HYDRAULIC TANK TO PUSH THE PISTON ROD OF
ADJUSTMENT HYDRAULIC CYLINDER. (REFER TO FIG 10-7)

10-5
FIG 10-6

FIG10-7

10-6
10.3.2.5 AFTER LOOSENING ADJUSTMENT CAP, CONNECT WIRING POPE TO
ADJUSTMENT CAP AND HANG UP ADJUSTMENT CAP AND TOP CELL BY
HOIST. (REFER TO FIG 10-8)

FIG 10-8

10-7
10.3.2.6 WELD A SUSPENSION HOOK PING ONTO DISTRUBUTOR AND THEN
CONNECT WIRING POPE BY PUTTING THROUGH THE SUSPENSION
HOOK. HANG UP THE MANTLE CORE ASSEMBLY. (REFER TO FIG 10-9)

FIG 10-9

10-8
10.3.2.7 CUTTING THE BROKEN LOWER FRAME LINER (UPPER & LOWER) AND
REPLACE WITH NEW ONE, THEN WELD IT. (REFER FIG 10-10)

FIG 10-10

10-9
 10.2.2.8 ASSEMBLING ALL THE TEAR DOWN PARTS ACCORDING TO THE
OPPOSITE SEQUENCE OF 10.3.2.1~10.3.2.6 (NOTE TO APPLY GREASE ON
TO THREADS OF TOP CELL BEFORE ASSEMBLY)
10.3.3 COUNTERSHAFT BOX GUARD REPLACEMENT
10.3.3.1 REMOVE THE BELTS BETWEEN COUNTERSHAFT BOX AND LOWER
FRAME. PUTTING THROUGH WIRING POPE THROUGH PULLEY HANG UP
THE MACHINE PULLEY AND REMOVE OUT HORIZONTALLY.
10.3.3.2 PUTTING THE REMOVED COUNTERSHAFT BOX TO A SUITABLE PLACE
AND THEN CUTTING THE STEEL ROD (5/8”), REMOVE COUNTERSHAFT
BOX GUARD. (REMARK: COUNTERSHAFT BOX GUARD IS FIXED TO
COUNTERSHAFT BOX BY SIMPLY USING STEEL ROD AND INS’T
WELDED ITSELF). REPLACE A NEW COUNTERSHAFT BOX GUARD AND
STEEL ROD AND WELD THE STEEL ROD ONTO COUNTERSHAFT BOX
(REMARK: STEEL ROD SHOULD BE IN TOUCH WITH COUNTERSHAFT
BOX ON END IN ORDER TO FIX COUNTERSHAFT BOX GUARD). (REFER
TO FIG 10-11)
10.3.3.3 ASSEMBLING COUNTERSHAFT BOX ASSEMBLY ACCORDING TO THE
OPPOSITE SEQUENCE OF STEP STEP 3.1.

FIG 10-11

10-10
10.4 REPLACEMENT OF MANTLE AND CONCAVE
10.4.1 CONCAVE
10.4.1.1 REMOVE THE ADJUSTMENT CAP, TOP CELL TO A SUITABLE PLACE
ACCORDING TO STEP 10.3.2.1~10.3.2.5 OF PARAGRAPH 10-3.
10.4.1.2 REMOVE THE FEED HOPPER ASSEMBLY. (REFER TO FIG 10-12)
10.4.1.3 REMOVE ALL THE U-BOLTS AND HANG ADJUSTMENT CAP & TOP CELL
UP ABOUT 5CM, KNOCK CONCAVE BY HAMMER TO SEPARATE IT.
(REFER TO FIG 10-12)

FIG 10-12
10-11
 10.4.1.4 REPLACE A NEW CONCAVE AND ASSEMBLE THE TEAR DOWN PARTS
BACK ACCORDING TO OPPOSITE SEQUENCE OF STEP 10.4.1.1~10.4.1.3.
10.4.2 MANTLE
10.4.2.1 REMOVING FEED HOPPER ASSEMBLY, ADJUSTMENT CAP, TOP CELL AND
MANTLE CORE ASSEMBLY BY FOLLOWING STEP 10.3.2.1~10.3.2.6 OF
PARAGRAPH 10.3.
10.4.2.2 MELTING TIN OF TIGHTING COLLARS BY FLAME. (REFER TO FIG 10.13)
10.4.2.3 LOOSENING LOCKING CAP CLOCKWISELY BY KNOCKING WITH
HAMMER. (REFER TO FIG 10.13)
10.4.2.4 REMOVE TIGHTING COLLAR. (REFER TO FIG 10.13)
10.4.2.5 REMOVE LOCKING RING. (REFER TO FIG 10.13)
10.4.2.6 WELDING TWO SUSPENSION HOOKS ON TO MANTLE AND HANG UP IT
BY HOIST. (REFER TO FIG 10.13)
10.4.2.7 REPLACE A NEW MANTLE AND TIGHTING COLLAR.
(REMARK：TIGHTING COLLAR SHOULD BE REPLACED WHENEVER
MANTLE IS CHANGED, WHILE REPLACEMENT OF LOCKING CAP, AND
LOCKING RING IS PENDING ON THE WEAR CONDITION)
10.4.2.8 ASSEMBLING THE TEAR DOWN PARTS BY FOLLOWING THE OPPOSITE
SEQUENCE OF ABOVE STEP 10.4.2.1~10.4.2.7.

NOTE：AFTER REPLACEMENT OF MANTLE, THE MAIN SHAFT & MANTLE

SHOULD BE HUNG UP TO INSPECT WHETHER SOCKET BOLTS ARE
LOOSE OR NOT, TIGHT THEM IF NECESSARY AND CLEAN THE FOREIGN
MATTER.

10-12
FIG 10-13

10-13
10.5 DUST SEAL RING
10.5.1 HANG UP MANTL CORE ASSEMBLY BY FOLLOWING STEP 10.3.2.1~10.3.2.6 OF
PARAGRAPH 10-3. THEN IT REMAINS DUST SEAL RING, LOWE FRAME AND
OTHERS AS BELOW FIG.(REFER TO FIG 10-14)

FIG 10-14

10.5.2 HOOK ON TWO EYE BOLTS INTO THE SIDES OF DUST SEAL RING AND USE
CRANE TO HANG IT UP. (NOTE: THE DUST SEAL RING IS ONLY SUPPORTED BY
SPRINGS UNDER WITHOUT TIGHTEN BY ANY BOLTS)

10-14
10.6 SOCKET LINER
10.6.1 REMOVE FEED HOPPER ASSEMBLY, ADJUSTMENT CAP, TOP CELL, MANTLE
CORE ASSEMBLY BY FOLLOWING STEP 2.1~2.6 OF PARAGRAPH 10.3.
10.6.2 LOOSEN BOLTS OF SOCKET BY USING SPANNER, HEXAGON.
10.6.3 FIXING EYEBOLT TO SOCKET ASSEMBLY AND HANG IT UP. (REFER TO FIG 10-15)

FIG 10-15

10.6.4 MELTING AND CLEARING THE BABBITT METAL BY FLAME, THEN LOOSENING
BOLTS OF SOCKET LINER BY USING SPANNER, HEXAGON. (REFER TO FIG 10-16)

FIG 10-16

10-15
10.6.5 REMOVE SOCKET LINER AND REPLACE A NEW ONE, THEN TIGHTEN BOLTS OF
SOCKET LINER.
10.6.6 PUT THE BABBITT METAL INTO AN OVEN AND THEN HEATEN IT TO LIQUID.
10.6.7 FILL THE LIQUID BABBITT METAL TO THE BOLT HOLES OF SOCKET LINER, AND
TAKE OUT THE REDUNDANT BABBITT METAL AFTER FROZENING TO MAKE
SURE THE SURFACE OF SOCKET LINER IS SMOOTH. (REFER TO FIG 10-17)
10.6.8 ASSEMBLE THE TEAR DOWN PARTS ACCORDING TO THE OPPOSITE SEQUENCE
OF ABOVE STEP 10.6.1~10.6.3.

FIG 10-17

10-16
10.7 INNER BUSH
10.7.1 REMOVE FEED HOPPER ASSEMBLY, ADJUSTMENT CAP, TOP CELL, MANTLE
CORE ASSEMBLY AND SOCKET ASSEMBLY BY FOLLOWING STEP 10.6.1~10.6.3 OF
PARAGRAPH 10.6.
10.7.2 FIX EYEBOLT TO ECCENTRIC SLEEVE ASSEMBLY AND HANG UP IT. (REFER TO
FIG 10.18)

FIG 10-18

10-17
10.7.3 REMOVE UPPER STEP BEARING PLATE AND KEY OF INNER BUSH (REFER TO FIG
10-19)

FIG 10-19

10-18
10.7.4 REVERSE THE ECCENTRIC SLEEVE ASSEMBLY AND HANG IT UP. (REFER TO FIG
10-20)

FIG 10-20

10-19
10.7.5 PAD WOOD IN BOTTOM OF ECCENTRIC SLEEVE ASSEMBLY AND PUT A STEEL
PLATE WITH DIAMETER BETWEEN OUTER AND INNER DIAMETER OF INNER
BUSH. THEN CONNECT A JIG AS SHOWN IN BELOW FIG AND PUT A JACK ONTO
TO STEEL PLATE TO PUSH THE INNER BUSH OUT OF ECCENTRIC SLEEVE
ASSEMBLY. (REFER TO FIG 10-21)

FIG 10-21

10-20
10.7.6 CLEAN THE INNER BUSH AND ECCENTRIC SLEEVE.
10.7.7 HANG THE INNER BUSH INTO ECCENTRIC SLEEVE AND NOTE THAT THE
CHANNELS OF INNER BUSH SHOULD BE COINCIDED WITH THOSE OF
ECCENTRIC SLEEVE. ALSO BE NOTICED ABOUT THE POSITION OF OIL HOLE OF
INNER BUSH. (REFER TO FIG 10-22)

FIG 10-22

10-21
10.7.8 CONNECT A JIG AS SHOWN IN BELOW FIG ONTO ECCENTRIC SLEEVE AND
ALSO PAD WOOD IN BOTTOM OF ECCENTRIC SLEEVE. THEN PUT A ROUND
STEEL PLATE ON ABOVE OF INNER BUSH AND ALSO PUT A JACK ON TO THE
STEEL PLATE, THEN PUSHING INNER BUSH INTO ECCENTRIC SLEEVE BY USING
JACK. (SEE FIG 10-23)

FIG 10-23

10-22
10.7.9 INSTALL KEY AND BOLT OF KEY INTO INNER BUSH AND ECCENTRIC SLEEVE
(REFER TO FIG 10-24)

FIG 10-24

10.7.10 ASSEMBLING UPPER STEP BEARING, ECCENTRIC SLEEVE ASSEMBLY, SOCKET

ASSEMBLY, MANTLE CORE ASSEMBLY, TOP CELL, ADJUSTMENT CAP, FEED
HOPPER ASSEMBLY BACK ACCORDING TO THE OPPOSITE SEQUENCE OF
ABOVE STEP 10.7.1~10.7.3

10-23
10.8 MIDDLE STEP BEARING
10.8.1 REMOVE FEED HOPPER ASSEMBLY, ADJUSTMENT CAP, TOP CELL, MANTLE
CORE ASSEMBLY, SOCKET ASSEMBLY AND ECCENTRIC SLEEVE ASSEMBLY BY
FOLLOWING STOP 10.7.1~10.7.2 OF PARAGRAPH 10.7.
10.8.2 USE A JIG AS SHOWN IN FIG 10-25 (IT IS COMPSED OF A ROUND STEEL PLATE
WITH DIAMETER A LITTLE BIT BIGGER THEN HOLE DIAMETER OF MIDDLE &
LOWER STEP BEARING PLATE AND WELDED A STEEL ROD ONTO THE STEEL
PLATE). THEN PUT THE JIG THROUGH CENTRAL HOLE OF MIDDLE AND LOWER
BEARING STEPS WITH AN INCLINATION ANGLE. HANG UP MIDDLE & LOWER
STEP BEARING PLATE AFTER THE JIG PUTTING THROUGH.
10.8.3 REPLACE A NEW MIDDLE STEP BEARING PLATE. ASSEMBLING ECCENTRIC
SLEEVE ASSEMBLY, SOCKET ASSEMBLY, MANTLE CORE ASSEMBLY, TOP CELL,
ADJUSTMENT CAP, FEED HOPPER ASSEMBLY BACK BY FOLLOWING THE
OPPOSITE SEQUENCE OF ABOVE STEP 10.8.1~10.8.2.

FIG 10-25

10-24
10.9 OUTER BUSH
10.9.1 REMOVE FEED HOPPER ASSEMBLY, ADJUSTMENT CAP, TOP CELL, MANTLE
CORE ASSEMBLY, SOCKET ASSEMBLY, ECCENTRIC SLEEVE ASSEMBLY
ACCORDING TO STEP 10.7.1~10.7.2 OF PARAGRAPH 10.7.
10.9.2 TEAR DOWN THE FLANGE OF ALL OIL PIPE AND FOUNDATION BOLTS TO
ISOLATE LOWER FRAME ASSEMBLY. HANG UP LOWER FRAME ASSEMBLY TO
SUITABLE PLACE.
10.9.3 FIX A SUSPENSION HOOK ONTO ONE SIDE OF LOWER FRAME AND CONNECT
WITH WIRING ROPE. (REFER TO FIG 10.26)

FIG 10-26

10-25
10.9.4 ALSO FIX ANOTHER SUSPENSION HOOK ONTO THE BOTTOM OF THE OTHER
SIDE AND CONNECT WITH WIRING POPE, THEN REVERSE THE LOWER FRAME
ASSEMBLY BY HOIST. THEN PUT WOOD UNDER BOTTOM OF LOWER FRAME.
(REFER TO FIG 10.27)

FIG 10-27

10-26
10.9.5 LOOSEN BOLTS OF LOWER FRAME CAP. FIX EYEBOLT ONTO IT AND HANG IT UP,
THEN REMOVE MIDDLE STEP BEARING PLATE. (REFER TO FIG 10.28)

FIG 10-28

10-27
10.9.6 REMOVE THE KEY AND BOLT OF KEY OF OUTER BUSH (REFER TO FIG 10-29)
10.9.7 CONNECT A JIG AS SHOWN BELOW TO LOWER FRAME. THEN PUT A STEEL
PLATE WITH DIAMETER BETWEEN THE OUTER AND INNER DIAMETER OF
OUTER BUSH, THEN PUSH THE OUTER BUSH OUT OF LOWER FRAME BY
HYDRAULIC JACK. (REFER TO FIG 10-29)

FIG 10-29

10-28
10.9.8 TAKE A NEW OUTER BUSH AND GRIND THE BLACK PORTION OF OUTER BUSH
BY HAND GRINDER IN ORDER TO PUT IT INTO LOWER FRAME SMOOTHLY.
(NOTE：THE OUTER BUSH SHOULD BE DRAWN 12 PARALLEL LINE ALONG THE
EDGES OF SIX RAISED BLOCKS SO AS TO IDENTIFY THE POSITION OF THOSE
SIX RAISED BLOCK AND MAKE IT EASY TO COINCIDE THEM WITH CHANNEL
OF LOWER FRAME. (REFER TO FIG 10-30)

FIG 10-30

10-29
10.9.9 HANG UP OUTER BUSH AND PUT IT INTO LOWER FRAME. (NOTE：LOWER
FRAME NEED TO BE REVERSED FIRST) MAKE THE RAISED BLOCKS OF OUTER
BUSH COINCIDES WITH CHANNELS OF LOWER FRAME ACCORDING TO THE 12
PARALLEL LINES. (REFER TO FIG 10-31)

FIG 10-31

10-30
10.9.10 CONNECT A JIG AS SHOWN IN BELOW DRAWING TO LOWER FRAME. PUT A
STEEL PLATE WITH DIAMETER BETWEEN THE INNER AND OUTER DIAMETER
OF OUTER BUSH AND THEN PUSH OUTER BUSH INTO LOWER FRAME TIGHTLY
BY USING HYDRAULIC JACK. (REFER TO FIG 10-32)

FIG 10-32

10.9.11 INSTALL KEY INTO OUTER BUSH AND ECCENTRIC SLEEVE.

10.9.12 ASSEMBLE ALL THE TEAR DOWN PARTS BACK ACCORDING TO THE OPPOSITE
SEQUENCE OF THE ABOVE STEP 10.9.1~10.9.5.

10-31
10.10 COUNTERSHAFT BOX BEARINGS
10.10.1 REMOVE BOLTS CONNECTED COUNTERSHAFT BOX AND LOWER FRAME AND
PUT A WIRING POPE THROUGH V-PULLEY. THEN REMOVE THE
COUNTERSHAFT BOX ASSEMBLY BY USING HOIST TO MOVE IT OUT
HORIZONTALLY. (REFER TO FIG 10-33)

FIG 10-33

10-32
10.10.2 REMOVE THE COUNTERSHAFT BOX ASSEMBLY TO A SUITABLE PLACE AND
PAD WOOD TO SUPPORT IT. (REFER TO FIG 10-34)

FIG 10-34

10.10.3 REMOVE END PLATE OF COUNTERSHAFT AND IT’S BOLTS.

10.10.4 REMOVE PINION OUT OF COUNTERSHAFT BY USING HYDRAULIC JACKET
AND SPECIAL JIG AS SHOWN BELOW. (REFER TO FIG 10-35)

FIG 10-35

10-33
10.10.5 REMOVE BEARING COVER, SHORT COLLAR, OIL SEAL. (REFER TO FIG 10-36)

FIG 10-36

10.10.6 LOOSEN V-PULLEY CAP AND REMOVE V-PULLEY. (REFER TO FIG 10-37)
10.10.7 REMOVE COMPRESSION NUT, WASHER OIL SEAL, BEARING COVER, ASBESTOS
SHIM. (REFER TO FIG 10-37)

FIG 10-37

10-34
10.10.8 KNOCK OUT COUNTERSHAFT FROM PINION END BY A LARGE WOODEN
HAMMER. (REFER TO FIG 10-38)

FIG 10-38

10-35
10.10.9 REMOVE THE BEARINGS LOCATED ON COUNTERSHAFT OR INSIDE
COUNTERSHAFT BOX BY KNOCKING WITH HAMMER. (REFER TO FIG 10-39)

FIG 10-39

10.10.10 CHANGING NEW BEARINGS AND ASSEMBLING BACK ALL THE TEAR DOWN
PARTS BY FOLLOWING THE OPPOSITE SEQUENCE OF ABOVE STEP
10.10.1~10.10.9
(NOTE TO HEAT BEARING UP TO 120℃ AROUND BY PUT IT INTO OIL AND
HEAT OIL BEFORE ASSEMBLING BEARING)

10-36
Attachment

INSTRUCTION MANUAL
AI TEMPERATURE CONTROLLER

10-37
10-38
10-39
10-40
10-41
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10-46