Manual de Instalacion de Cono (Chancadora)

Users manual of SG160C cone crusher
Copyright 2009 SHAORUI
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.
Shaorui Heavy Industries Co. Ltd.

Science and technology park, Wujiang district, Shaoguan, Guangdong.
Tel: 0751-8136739
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
2.1.3 Prohibitive Signs

2.1.4 Instructive Signs
2.2 Personnel
2.2.1 Personal Protection
2.3 General Safety Precautions
2.3.1 Safety Guards
2.3.2 Electrical Safety
2.3.3 Welding
2.3.4 Hydraulic System
2.3.5 Lifting and Moving Load
2.3.6 Feed and Blockage
2.4 Discharge
2.4.1 Dust
2.4.2 Noise
2.4.3 Radioactive
3. Technical Data
3.1 General Data
3.2 Processing Data
4. Start-up
4.1 Overview
4.2 Running-in
4.2.1 Checking the Settings with a Lead Block
4.2.2 Starting the Main Oil Pump
4.2.3 Expel Air from the Hydraulic System
4.2.4 Maximum Load
4.2.5 Starting the Crusher under Extremely Low Temperature
5. Operation of the Cone Crusher
5.1 Start-up and Stop
5.1.1 Starting the Crusher
5.1.2 Stopping the Crusher
5.2 Checking the Settings
5.3 Change oil
5.3.1 Normal Operational Conditions
5.3.2 Operation under High Temperature
5.3.3 Operation under Low Temperature
5.4 Checking the Tension of Belts
5.5 Energy Accumulator
5.6 Clearing the Cavity
6. Inspection and Maintenance
6.1 Daily Inspection and Maintenance
6.1.1 Daily Maintenance
6.1.2 Weekly Maintenance
6.1.3 Monthly Maintenance

6.1.4 Semi-annual Maintenance
6.1.5 Annual Maintenance
6.2 Standard Tool Box
6.3 Upper Frame and Main Shaft Assembly
6.3.1 Dust-proof Ring
6.3.2 Scraper
6.4 Belts
6.4.1 Rotating Direction
6.4.2 Belt Tension
6.5 Upper Frame Assembly
6.6 Hydraulic and Lubricating System
6.7 Dust-proof Seal
6.7.1 Dust-proof Sealing Principle
6.7.2 Air Blower
6.7.3 Adjustment Device of Compressed Air
7. Lubrication
7.1 Requirements of Lube Oil
7.1.1 Miscibility
7.1.2 Low Temperature
7.1.3 High Temperature
7.2 Lube Oil in the Lubricating System
7.3 Lube Oil in the Hydraulic System
7.4 Lube Oil of Pinion
7.5 Grease for Arm Bearings
8. Hydraulic and Lubricating System
8.1 Overview
8.1.1 Oil Tank Compartment
8.1.2 Machine Cabinet
8.2 Main Lubricating System
8.2.1 Cleaning the Oil Tank
8.2.2 Magnetic Plug
8.2.3 Filter Element
8.2.4 Oil Pump
8.2.5 Pressure Gauge
8.2.6 Indicator of Oil Pressure Decrease
8.2.7 Thermometer
8.2.8 Safety Valve
8.2.9 Switch of Return Oil
8.2.10Filtering Mesh
8.2.11 Temperature Control Switch
8.2.12 Oil Heating
8.3 Changing the Main Lube Oil

8.3.1 Drain the Main Lubricating System
8.3.2 Cleaning the Magnetic Plug
8.3.3 Replacing the Filter Elements
8.3.4 Cleaning the Return Oil Mesh and Oil Tank
8.3.5 Purifying Air/ Oil Radiator (Optional)
8.3.6 Refill the Main Lubricating System
8.4 Water/ Oil Radiator (Optional)
8.5 Air/ Oil Radiator (optional)
8.6 Hydraulic System
8.6.1 Hydraulic Pump
8.6.2 Filter Element
8.6.3 Magnetic Plug
8.6.4 Control Valve
8.6.5 Pressure Gauge
9. Energy Accumulator
9.1 Overview
9.2 Meters
9.3 Inflatable Kit
9.3.1 Checking the Air Pressure
9.3.2 Fill the Nitrogen
10.Upper Frame Assembly
10.1 Replacing the Arm Cap
10.1.1Removing the Arm Cap
10.1.2 Inspection of Arm Cap Disassembly
10.1.3 Installation the Arm Cap
10.2 Checking the Cavity
10.3 Arm Bearings
10.3.1Inspection of the Arm Bearings
11.Inspection of Settings
11.1Overview
11.1.1 Checking the Settings with a Lead Block
12.Trouble Shooting
12.1 Faults and Remedies
Appendix A: Inspection
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
conformation if any change to the configuration of the cone crusher is made by

customers.
1.1.1
Document information
The usage of this users manual

This users manual is aimed to provide information concerning how to handle and operate the
equipment to operators.
Important notice:
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
the same time.
Illustrations in this manual

The illustrations in this manual are made based on SG160 cone crusher. Though it is similar
to GP280, there are still some differences in designs at a few insignificant places.
Document conformation
Instructions in this document are based on the latest design and structure of the machine.
Technical publication document
Technical publication document related to the installation and operation of this machine
includes:
Users manual
When subscribing technical publication document, please specify the
language and equipment ID code. This technical publication document is for
trained operators and maintenance personnel only. Shaorui Heavy Industries Co. Ltd
can provide sufficient training and competent service personnel.

Please refer to personnel in chapter 2.2 for more information about the
document and related job positions.
Number of pages
This document has 113 pages.
1.2 Operational principle of the cone crusher
The feed material is compressed between the two hard surfaces. The action of the moving
surfaces is determined by the load of the crusher. The crushing action is realized by the
eccentric rotation of the main shaft (6).
The feed material (such as rocks or ores) is clamped, compressed and crushed between the
movable mantle (4) and concave (3).
The quality and quantity of processed material are determined by the interaction between
the crusher and feed material. The eccentric rotation, the dynamics of the crusher and the
properties of feed material are the most important factors.
The geometric shape of the cavity is determined by the positions of the mantle, concave,
eccentric assembly and pivot. The driving motor of the crusher drive the eccentric assembly
evenly through gears. The rotation of the eccentric causes the upper part of the main shaft to
rotate. On the top of the main shaft is the arm bearing (1), which is the pivot point of the
rotation. The mantle is fixed on the main shaft and the concave is fixed on the upper frame
(2). The rotation of the main shaft means that the distance between the mantle and concave is
constantly changing. When the distance decreases, the feed material will be compressed and
crushed and when the mantle moves away from the concave from the concave, the feed
material can flow downward in the cavity.
As the mantle and concave are under constant wear, they need to be replaced regularly. The
wear rate depends on the properties of the feed material. See more details in the checking the
cavity in the chapter 10.2.
1.
2.
3.
4.
5.
6.
Arm bearing
Upper frame
Concave
Mantle
Eccentric assembly
Main shaft
Adjustment of the discharge opening

To compensate wear and produce products of different sizes, the crusher is equipped with a
control system. It is mainly composed of a solid hydraulic called adjustment cylinder, which
supports and adjusts the position of the main shaft. To move the main shaft up and down can
change the discharge settings and thus change the sizes of crushed material. See more details
in settings measurement in chapter 11
Reduce the setting= smaller product size
Lubricating system
Please refer to main lubricating system in the chapter 8.2 for more details about the circulating
lubricating system.
1.2.1 Descriptions
The following graphics display all the parts and their names. The grey parts are cross sections
Cone crushersectional view
Cone crusher-- profile
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
21 hub of material level

indicator
22 inspection gate
23 feed hopper
24 observation cover
Oil tank compartment and auxiliary devices
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
2.1.2 Classification of dangers

In this manual, dangers are classified as danger, warning and caution. Danger and
warning signs are labeled on the crusher.
Please follow strictly to the danger and warning signs, or it may cause damage to people
and/ or equipment.
Please follow caution sign to avoid damage to the equipment.
2.1.3 Prohibitive signs
2.1.4 Instructive 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.
2.2.1 Personal protection

We strongly recommend that personnel near the machines should always wear personal
protective devices, which include:
2.3 General safety precautions

Falling stones
Please clear all the feed material in the hopper before carrying out any
maintenance work inside or under the crusher to avoid falling stones.
Please cut off the electricity and lock the device before carrying out any
maintenance work. Besides, make sure no one will turn on the electricity during
the maintenance work
Do not stay on the crusher except unless carrying out necessary maintenance work.
Compaction danger
Do not stay on the crusher when it is running. Moving parts pose risks of
compaction. Falling into the crusher will cause compaction.
Compaction danger
If the crusher is installed on a rubber buffer, there is compaction danger between the
vibrating parts and stationary main frame.
Spurt
Do not look into the crusher when it is running. The rubbles and harmful substances may
spurt out.
2.3.1 Safety guards
Do not remove the safety guards
Check and make sure that all arm guards are in position and function well to avoid damage
from flying rubbles and rotating parts. Do not operate the equipment until the safety guards
are installed.
Rotating parts
Safety guards should be installed to avoid exposure to rotating parts. Install safety guards after
maintenance work is finished
Flying rubbles
Rubbles that spurt upward may fall around the crusher. Please install enough safety guards
within a proper range around the crusher and put up a warning notice.
A platform with handrails should be installed around the feed opening. The passages, staircases
and ladders must be designed properly. (These parts are excluded from the standard
specifications of the crusher.)
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
When the cavity is empty, do not put in a whole piece of boulder.

Do not feed in flammable industrial material.
Flying rubbles
Do not use a wooden wedge to clear the stuck material in the feed opening. Rocks and
rubbles may be thrown out from the cavity in a high speed.
Blast
Do not use the blasting method to clear the stuck boulder. Otherwise it will cause damage to
people, bearings or other parts. We are not liable for any damage to people or equipment due
to blasting.
Crushing danger
Do not stand inside the crusher to clear the blocked material. Or it may suddenly be put
downward and people will fall down into the cavity along with the feed material and get
crushed.
In some circumstances, temporary increase of CSS can be used to clear the blocked material.
Please abide by the local regulations when clearing the blocked material.
2.4 Discharge
2.4.1 Dust
Health danger
Dust will arise during crushing and processing. It may incur damage to a certain extent to
human health. So please wear a mask.
We strongly recommend that a extra device should be used to control the dust. For instance,
spray water or bubbles to absorb dust or install a dust-proof cover. Such devices are not
included in the standard specifications of the crusher.
We are not liable for any damage caused by the dust produced during the production process.
2.4.2 Noise
Health danger
Noise will be produced by crushing and processing the material. It will more or less do harm
to hearing. Therefore please wear goggles.
2.4.3 Radioactivity
.
Health danger
Radon is a natural radioactive gas formed in the bedrock, which may cause lung cancer.
Categories of ores, ventilation and water are the main factors that influence the content of
radon.
We are not liable for any damage to human health caused by radon or any other harmful
substances produced during production process.
Chapter Three Technical Data

To ensure safety, please read carefully safety precautions in the chapter 2 before carrying out
3.1 General data
The data provided below is typical. Specific data may vary due to installation and device
configuration.
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
3.2 Processing data

Features (depends on cavity shape)
Maximum feed size
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
This chapter introduces how to start the cone crusher.

4.1 Overview
Assembly, test-run and inspection have been done before delivery of each cone crusher. Test-run
is carried out without load to find out any possible mechanical fault.
4.2 Running-in
The content of this paragraph is also applicable for repaired machines and machines with new
parts.
a) Start the main oil pump
b) Start the driving motor when you get the ready to start signal.
c) Check and adjust settings. Please refer to check the settings with a lead block in chapter
4.2.1.
d) Start feeding the crusher. Gradually increase the load until it reaches the drawbar power or
around 75% of the maximum hydraulic power. Please refer to maximum load in chapter
4.2.4.
Caution! If possible, the cavity should be full of material as the crusher cannot run in without load.
Running-in will be finished after about 16 hours of operation with 75% load. After that, increase
the load to the maximum. The running-in time may be longer due to different feed materials and
engineering designs. During the process of running-in, the following rules must be observed:
e) Regularly check the temperature of return oil to see if it is between 40C (104 F) and 45 C
(113 F).
f) Make sure that the cooling system is on and off at correct temperatures. Please refer to oil
temperature switch in chapter 8.2.11.
Caution! If the operational conditions are not normal (oil=ISO VG viscosity 150), please follow
the instructions in temperature control switch in the chapter 8.2.11 and temperature control
switch of oil heating device.
g) Regularly check and clean the filter mesh. Please refer to filter mesh in the chapter 8.2.10.
in the initial running-in period, some fine steel and copper particles are usually on the filter
mesh.
h) Expel air from the hydraulic system. Please refer to expel air from the hydraulic system in
the chapter 8.6.5.
i) Check and make sure that there is no relative movement between the upper frame and lower
frame. Put your finger between the upper frame and lower frame to feel possible vibration.
j) Check and make sure that there is no oil leakage.
k) Check and make sure that the pointer of the hydraulic pressure gauge moves steadily. Please
refer to pressure gauge in the chapter 8.6.5.
l) Use a proper thermometer such as an IR camera to check the temperature on the external
surface of the pinion box. The normal temperature should be between 50-60C (122-140
F)
m) Check and make sure that feed material is evenly distributed around the circumference of the
cavity.
n) Check the power consumption and hydraulic pressure. Please refer to maximum load in
chapter 4.2.4 and pressure gauge in chapter 8.6.5.
o) Check and record the main hydraulic pressure. Please refer to main lubricating system in
chapter 8.2.
p) Please
q) Check if there is grease leakage from the arm bearing.
r) Check the oil level in the pinion box when the crusher completely stops. Please refer to lube
oil of the small shaft.
s) After running-in is completed, check the tightness of all the bolts and retighten the belts.
Please refer to belt tension in chapter 6.4.2.
4.2.1 Check the settings with a lead block

A very simple way to check the CSS is to tie a lead block on a iron wire and then slowly put it
inside the discharge area of the cavity. The lead block will be squeezed out and its thickness is the
setting. Make sure the lead block is big enough so that it is easy to measure the thickness.
You may also check the CSS at four different points around the cavity circumference. If you find
uneven wear, the performance of the feeding device is not satisfactory. Please refer to settings
measurement.
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.
4.2.2 Start the main oil pump
Check the oil level before starting the main oil pump. After the oil pump starts, the oil tank must
be full of oil to ensure sufficient oil supply.
4.2.3 Expel air from the hydraulic system
The upper air outlet valve is installed on the throat of energy accumulator.
1 air outlet valve

2 air outlet valve
3 L1 button box
Use the L1 button box to raise the main shaft by a few millimeters
Open the upper air outlet valve with a 5mm hexagon spanner to expel all the air.
Raise the main shaft by another few millimeters.
Use a 5mm hexagon spanner to open the air outlet valve in the hydraulic cylinder to
expel the air.
e) Raise and lower down the main shaft several times.
f) Repeat the above procedures until the oil flows out with no bubble.
a)
b)
c)
d)
4.2.4 Maximum load

During operation, the drawbar power and hydraulic pressure of the crusher depend on cavity
shape, eccentricity, settings and crushability, fractions and moisture of feed material etc.
-the maximum average drawbar power of the crusher should not exceed 155KW.
-the maximum average hydraulic pressure should not exceed the following values.
Cavity shape
EF
F
MF
M
MCC
EC
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
Operation of the Cone Crusher
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.
5.1.2 Stop the crusher

a) Stop feeding but continue to run the crusher until there is no material in the cavity.
b) Stop the driving motor of the crusher.
c) Stop the main oil pump.
Caution! Oil heating device should be on 24 hours a day. The heating element is automatically
controlled by the temperature control switch.
5.2 check the settings
Check the CSS following the procedures in check the settings with a lead block in chapter 4.2.1
and settings measurement in chapter 11.
5.3 oil replacement
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! Do not mix grease of different brands or types. Improper mixture will cause precipitation
and oil failure. Please consult the grease manufacturer for more details.
Usually the old lube oil should be cleaned before filling in the new oil. Please consult lube oil
manufacturer for more information about whether the lube oils can be mixed.
5.3.1 Normal operational condition
Ambient temperature
Normal operational condition

Maximum 32(90F)
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
Operation under high temperatures

Maximum 40 C( 104F)
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.
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
5.3.3 Operation under low temperatures
Ambient temperature
Operation under low temperatures

Lower than 0C( 32F)
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.
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
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
Inspection and Maintenance
This chapter introduces general knowledge about daily inspection and maintenance of the cone
crusher.
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
Check and make sure that there is no material deposit

on the lower frame arm.
Before starting the crush

er
Check the oil level of lube oil tank.

Check the oil level of hydraulic oil tank.
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.
Run the machine without

load.
Listen and make sure there is no abnormal noise inside

the crusher.
Listen and make sure there is no abnormal noise inside
lubricating system.
During crushing process

Before and during crushi
ng
8.2
4.2.1
Check the temperature of the return oil.
Check the current, power and oil consumption of the

driving motor.
8.2.7
4.2.4
Check and make sure the damping of hydraulic and

pressure gauges is correct.
8.6
Check the temperature of the pinion box. Use an IR

camera or just feel it above the box to. If it is very
hot, do not touch it. The normal temperature should be During crushing process
50-60 C (122-140 F).
6.1.2
Check the oil temperature of the main lubricating

system under normal operational temperatures.
Check and make sure that there is no leakage.
Check if the bolts are loose.
Check and make sure that the oil heater works well.
When the crusher stops
Check the distance between the top nut and the bottom
of arm frame.
When the crusher stops
8.2.12
10.2
Check and make sure that there is no more dirt, i.e

.metal particles, on the filter mesh.
When the crusher and oil

pump stop.
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
Clean the damper valve of the hydraulic gauge.

Check the air pressure of the dust-proof seal
(when fan or pressure regulator is running).
Check the hose and filter element of the dustproof seal and sealing condition of the cap of
oil tank.
Reference
When the crusher and

8.2.3 8.3.3
lubrication stop.
When the crusher and 8.2.18.2.2
lubrication stop.
Check if the crusher liners are worn or

When the crusher
damaged.
stops.
When the crusher is
Measure frames at the four corners in the cavity
running without
and see if there is uneven wear.
load.
Check if the pump is worn or has abnormal
During crushing
noise.
Check the tension and wear condition of the
When the crusher
belts.
stops.
When the crusher
Check the oil level in the pinion box.
stops.
Check the cooler core in the air/oil radiator
When the crusher and
(optional).
lubrication stop.
6.1.3
8.2.5
When the crusher

stops.
When the crusher is
running without
load.
When the crusher
stops.
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
Clean the nozzle on the pinion box.
Person in cha Reference

rge
Operator
7.4
Check of the dust-proof seal is worn.
Operator
6.3.1
Check the condition of the scraper rotating on

the dust-proof frame.
Operator
6.3.2
Check the tightness of all the bolts.
Operator
Check the end-play between the main shaft bushing

and pipe connector.
Operator
10.110.3
Check the grease level in the arm bearing.
Operator
7.5
Clean the air channel in the arm frame cap and

upper frame.
Check the quality of lube oil.
Operator
10.1
Operator
7.2
Action
Check the function of the return oil flow control Operator

switch.
Check the clearance between the pinion and gear.
Maintenance p
ersonnel
Check the mantle, mantle liner, upper frame and

fixed cone liner.
Maintenance
personnel
Check if the arm bearing is worn.
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.
Check the air pressure of energy accumulator.
Person in char Reference

ge
Operator
9.3
Clean the oil tank.
Operator
8.2.18.3
Check the filter element and clean the magnetic

plug of the hydraulic system.
Operator
8.6.28.6.3
Check the clearance of the arm bearing.
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
Check if the main shaft bushing is worn or rusted.
Maintenance
personnel
Maintenance
Check if the seal is worn.
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
Check if the eccentric is worn or scratched.

Check if the eccentric wear plate is worn.
Check if the lower frame liner is worn or scratched.
Maintenance
personnel
Check the thickness of the components of upper thrust bearing

and
If
they are worn or scratched.
Maintenance
personnel
Check if the gear is worn.
Maintenance
personnel
Maintenance
personnel
Check if the hydraulic cylinder sleeve is worn or scratched.

Replace the oil in the small shaft box.
Check the function of the thermometer.
Check the functions of temperature control switch TG 1 and
the radiator temperature control switch TG2.
Operator
Operator
7.4
8.2.7
Operator
8.2.11
6.2 Standard tool box

The following is a list of all the items in a standard tool box for maintenance.
Tool
Lifting hook
Lifting plate
Dimensions Part number

SG160-15-02
SG160-15-04
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
To assemble and disassemble the plunger of

adjustment cylinder
Plunger baffle ring

Eyebolt
Eyebolt
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
To lift the eccentric assembly and dust-proof

frame
Eyebolt
M10
GB825-88
To lift the lower frame sleeve and eccentric

bushing
Eyebolt
M8
GB825-88
To lift the main shaft bushing
double offset ring spanner
41 x46
GB4388-95 -01
Bolt and nut M30 to install adjustment

cylinder

adjustable spanner
32 x36
22 x24
300 x36
GB4388-95 -02
GB4388-95 -03
GB4440-98-01
Bolt and nut M24 to install concave

Bolt and nut M16 to install dust-proof
frame
Bolt
and nut M20 to install arm frame cap
adjustable spanner
200 x24
GB4440-98-02
Bolt and nut M12install eccentric pressure

pad
inner hexagon spanner

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
cheese head screw M16 to install gear

cheese head screw M12 to install wear
ring
cheese head screw M8 to install locating
block
To lift the upper frame assembly
To install upper frame bolt M42
6.2 Lower frame and main shaft assembly

There are on the lower frame assembly two spy holes, through which we can check the
dust-proof seal ring, dust-proof frame, liner and seal ring and oil leakage condition.
Do not remove the hole cover/guard plate
When the equipment is running, do not open the cover. During the operation of the
crusher, do not put your hands in it.
1. Spy hole
6.3.1 Dust-proof seal ring

The dust-proof ring (3) under the mantle can move freely and it is installed on the dust-proof
frame through sliding fit. It is the most important seal in the lubricating system. The dust-proof
circle is composed of the dust-proof ring (3) and dust-proof end cap (2), which is fixed on the
mantle by screws.
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
2 dust-proof ring end cap

3 dust-proof ring
4 dust-proof frame
5 scraper
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.
Recommended deflection loadF

F kp/belt(pound /belt)
Belt section
Normal
Maximum new belt
SPC
7 (15.4)
12.0 (26.5)
8V
9 (19.8)
14.0 (30.9)
Check the deflection load with a tension meter.

a) Measure the span of the belt (W) as shown in the picture below, unit: m
b) Get the deformation (D)of the belt by multiplying the span by 1.5, unit : cm
c) Set a correct deflection for the O ring on the dial of the instrument, unit: cm
d) Push the O ring to the bottom side of the external sleeve.
e) Put the instrument at the middle of the belt and then push it downward to make the top of the
ring level with the belt.
f) Remove the instrument and read the load, unit: kp (pound). The reading on the instrument
should conform to the load value in the table.
g) If the load is too low or high, please tighten or loosen it.
1 F scale
2 D scale
D =deformation
W =belt span
F =deflection load
6.5 Upper frame assembly

Please refer to upper frame assembly in chapter 10 for more detailed information about the
inspection and maintenance of the upper frame assembly.
6.6 Hydraulic and lubricating system
Please refer to hydraulic and lubricating system in chapter 8 for more detailed information
about the inspection and maintenance of hydraulic and lubricating system.
6.7 Overpressure dust-proof seal
This crusher uses dust-proof seal (SG160-05-03) to prevent dust and absorb air with a slight
overpressure because the lube oil with air that returns the oil tank may have a little negative
pressure. This negative pressure will absorb dust into the crusher and form a dust film inside
the dust-proof frame. Then lube oil transmit the dust around the lubricating system and thus
cause blockage of filter element and accelerate the wear of components of upper thrust
bearing and precipitation of the

the oil tank. Other components in
dirt in
the
SG160-04-01 dust-proof frame

SG160-04-02 oil baffle ring
SG160-05-03 dust-proof ring
SG160-05-04 dust-proof ring end
cap
SG160-05-05 scraper
1 dust
crusher may also suffer excessive
Over-pressurized air (white
can be provided by air blower or
compressed air system.
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
6.7.3 Adjustment device of compressed air

There is a pressure gauge for measuring the overpressure at the entry of the crusher in the
adjustment device.
Chapter Seven
Lubrication
This chapter introduces the requirements for lube oil of the cone crusher.
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.
7.1.2 Low temperature

Under low temperatures, the viscosity will increase. However, it is not necessary to changer the
oil for another type with lower viscosity in the winter because there is a heater in the oil tank.
Besides, there are several ways to reduce the risk of oil freezing, such as keeping a proper
temperature and heating. Please refer to installation manual and consult us when necessary.
Nevertheless, sometimes it is still recommended to use oil with lower viscosity when the
temperatures are extremely low. Please refer to operation under low temperatures.
7.1.3 High temperatures
If the ambient temperature is so high that the cooling system cannot keep the return oil
temperature below 50C (1220 F), 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.
7.2 Lube oil used in the lubricating system

We recommend that neutral EP additive should be added to lube oil and the oil should conform to
the requirements in the table.
Usually ISO VG 150 viscosity lube oil is used.
General descriptions
Lube oil should conform to the requirements about viscosity in DIN 51 517-CLP and should
contain additive to prevent oxidization and froth and anti-wear additive as well. The bearing of the
crusher is made of copper alloy, so the lube oil should not do harm to the material.
The table below specifies different types of lube oils used under various operational conditions.
Requirements for lube oil under different operational conditions
Operational conditio
n
Normal
High temperatures
Low temperatures
Maximum 32C (89.6F)

ISO VG 150
DIN 51 517-CLP 150
Requirement
Maximum 40C (104F)

ISO VG 220
DIN 51 517-CLP 220
Requirement
Below OC (32F)
ISO VG 100
DIN 51 517-CLP 1
00
Requirement
220
100
DIN ISO 2 100

909
DIN 51354 12
100
100
12
DIN ISO 3 -9 C (15.8F)

016
sulfur / phosphorus
-6 C (21.2F)
-12C (10.4F)
sulfur / phosphorus
sulfur / phosphoru
s
Ambient temperature
Viscosity
Specifications
Performance
Test method
40' C (104'basic oil

viscosityunit mm2/s DIN 51 519 150
(cSt)
Viscosity index
FZG
Lowest flow point
EP-additive
Examples of lube oil

The examples below are lube oil that conform to our requirements.
The local conditions may vary in different countries. For your own safety, please choose the right
lube oil supplier.
Besides the lube oils listed below, some other brands of oil may also be used as long as they
conform to our quality standards.
Mineral oil
Operation under normal conditions:
BP Energol GR-XP 150
Molub-Alloy Tribol 1100/150
ESSO Spartan EP 150
Shell Omala 220
Kltiber Kltiberoil GEM 1-150 Statoil LoadWay EP 220
Mobil Mobilgear 629
Tocaxe Meropa 220
Operation under high temperatures
ESSO Spartan EP 220
Shell Omala 150
Mobil Mobilgear 630
Texaco Meropa 150
Operation under low temperatures
ESSO Spartan EP 100
Shell Omala 100
Kltiber Kltiberoil GEM 1-100
Statoil LoadWay EP 100
Mobil Mobilgear 627
Texaco Meropa 100
Bio-degradable lube oil
If bio-degradable lube oil is used, we recommend that you only choose 100% Ester type
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
DIN ISO 2909

DIN 51354
DIN ISO 3016
Hydraulic oil examples

The examples below are the oils that conform to our requirements.
lube oil supplier.
Besides the lube oils listed below, some other brands of oil may also be used as long as they
Mineral oil
BP Energol GR-XP 68
ESSO Spartan EP 68
Shell Omala 68
Mobil Mobilgear 626
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
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.
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
40C (104)basic viscosityunit mm2/s (cSt)
400
Additive
Silver or uranium
Drop point
140C (284F)
DIN ISO 2176
Anti-corrosive
Approved
DIN 51 802 SKF Emcor
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.
grease supplier.
Besides the greases listed below, some other brands of grease may also be used as long as they
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.
Check and replace the grease

During the first few weeks of operation, remove the plug in the lower arm frame cap to check the
grease level.
Check the grease level in the arm frame cap:
a) Stop the crusher
b) Remove the plug in the lower arm frame cap
c) Insert your finger into the spy oil to feel the grease level or use a torch to shine the hole and
observe the grease level. If grease is found on the main shaft under the arm bearing, the seal
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
Hydraulic and Lubricating System
This chapter introduces the maintenance procedures of the hydraulic and lubricating system of
the cone crusher.
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.
1 oil tank cap

2 lubricating
oil tank cap
3 namepalte
4 cabinet
8.1.2 Cabinet
Components of the main lubricating system and hydraulic system are installed inside the cabinet.
Main lubricating system
hydraulic system
Temperature control switch and heater
8.2 Main lubricating system

In the lubricating circuit, oil is pumped to the main inlet of the crusher from the oil pump through
filter element and radiator. After entering the crusher, oil is pressed upward through upper thrust
bearing into the space between the eccentric bushing, main shaft and the lower frame sleeve to
lubricate the bearings. The oil will lubricate the wear plate and bevel wheel before returning to the
oil tank due to gravity.
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)
8.2.1 Clean the oil tank

Pollutants such as stone dust, water etc can, to some extent, deposit at the bottom of the oil tank,
so it has to been cleaned at least twice every year. The regular inspection can avoid mud being
pumped up from the bottom with the oil. Please refer to clean return oil mesh and oil tank in
chapter 8.3.4.
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
8.2.3 Filter element

The filter element used is full-flow type, which can filter all the lube oil from the pump to the
crusher. The filter element can be used only once. Please refer to replace filter element in
chapter 8.3.3.
Under normal operational temperatures, if the oil pressure decreases more than 0.22MPa (32psi)
after passing through the filter element, the filter element must be changed.
There is a by-pass valve on the filter element. If the oil pressure decrease exceeds 0.35MPa
(51psi), the valve will be open. Then part of oil will not pass through the filter element.
Caution! If the filter element must be replaced frequently, please check the dust-proof sealing
system of the crusher.
8.2.4 Oil pump
Under normal conditions, the lube oil pump doesnt need special attention. However, if the oil
contains stone dust or similar pollutants, special attention must be paid to it. The most common
sign of the wear of oil pump is the decrease of oil flow quantity.
14 drain plug, lube oil tank
15 end caplube oil tank
16 end cap hydraulic oil
tank
17 drain plug hydraulic oil
tank
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
Power source frequency 50 H

z
Power source frequency 60 H
ty
z
ty
Normal capacity
Minimum capaci
Liter /mi gallon/min

33
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
8.2.6 Pressure drop sensor

The pressure drop sensor (6) monitors the pressure drop after passing through filter element and
send a signal if the pressure drop exceeds 0.22 MPa (32 psi ). The signal means that the filter
element needs to be replaced.
The signal is transmitted electronically to the pressure drop indicator light (1) and the red button
will pop up from the top of the sensor (about 4mm).
Caution! During cold start, as the oil is very viscous, the indicator may give a wrong signal.
When the working temperature is achieved, the electric signal will automatically reset, but the
mechanical signal (red button) must be reset manually. If the red button automatically popes up
again after reaching the working temperature or if the light is still on, the filter element must be
replaced.
8.2.7 Thermometer
The thermometer (2) monitors the temperature of the return oil. The temperature of return oil
depends on the load of the crusher, ambient temperature and oil viscosity. Please refer to
temperature control switch in chapter 8.2.11.
Inspection
Calibrate the thermometer every year to ensure the correctness of its reading. Carry out the
inspection when the oil temperature is 40-50 C (104-122 F)
8.2.8 Safety valve
The safety valve (10) is installed between the filter element (7) and radiator. Its function is to
lower down the pressure on the oil pump (4) and radiator when the crusher is started under a low
temperature with highly viscous oil.
Caution! Do not change the setting of the valve. The valve is set at 0.7 MPa (102 psi)
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
8.2.9 Switch of return oil flow

The return oil flow is monitored by the oil flow switch in the return oil chamber in the oil tank.
The connection method of the switch of return oil flow ensures that the driving motor of the
crusher can only be started when there is enough oil pumped to the crusher and then returning to
the crusher through the switch of return oil flow. Besides the lube oil pump (4) can only be started
when the switch of return oil flow is working well.
The switch of return oil flow is connected to float (20) in the return oil chamber (24) to monitor
the rise or fall of the float. There are an adjustable lower outlet (22) and a overflow baffle plate
(21) in the oil return chamber.
Caution! The lower outlet has been adjusted before leaving factory and the setting should not be
changed.
After oil return to the oil tank, the oil level in the return oil chamber should at least 5mm (0.20")
higher than the baffle plate. When the oil level is at that position, the float is completely immersed
in the oil and the buoyancy of the oil will push the float to the baffle plate.
If the oil flow decreases, the oil level in the return oil chamber will drop. When the oil level
decreases about 15mm (0.59"), the float will be at 5mm below the baffle plate. At this position, the
switch will be on and the driving motor of the crusher will stop.
Inspection
Push the float downward from the baffle plate by 5mm (0.20) below the baffle plate, and check
the oil level monitor. Then the driving motor of the crusher must be stopped.
20 float
21 baffle plate
22 adjustable lower outlet
23 filter mesh
24 return oil chamber
8.2.10 filter mesh

The filter mesh (23) separates the dirt from the oil and expels the air from the oil as well.
Inspection
Check carefully the filter mesh. Especially during running-in period, it has to be checked every
day. If there is metal particles on the mesh, there may a fault. Check it and locate the cause to
avoid possible risks.
8.2.11 Temperature control switch

Two sensing heads of the temperature control switch is in the return oil chamber (24). The
temperature control switch TG2 of the cooler controls the cooling of the oil pumped to the crusher
whereas the protective temperature control switch TG1 shuts down the driving motor of the
crusher when the oil temperature is too high.
26 protective temperature
control switch TG1

27 temperature control switch
TG2 of the cooler
28 oil heater TG 3
29 heating element
30 oil level indicatorlube oil tank
Caution! It is very important to use the correct temperature setting. Set the temperature control
switch under different operational conditions according to the table below.
TG1 shuts down the driving motor of the crusher
Operational
conditions
conditions
Normal operational Operation under
Operation under
condition
High temperatures
Low temperatures
Ambient temperature
Maximum 32 C
Maximum 40 C
Lower than 0 C
Viscosity of lube oil
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)
Maximum 40 C (104 Lower than 0 C

F)
(32 F)
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
Temperature control switch of

the radiator TG2
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
Normal operational Operation under

Operation under
condition
High temperatures Low temperatures
Ambient temperature
Maximum 32C
(90F)
Maximum 40C
(104F)
Low er than 0C
(32 F)
ISO VG 150
ISO VG 220
ISO VG 100
Proper temperature before

starting the crusher
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
Oil heater and radiator TG3
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.
12 lube oil inlet

(From crusher)
13 lube oil outlet

(To crusher)
31 L1button box
h)remove the drain plug at the bottom of the lube oil tank to drain the lube oil tank.
14 drain pluglube oil tank

15 drain end caplube oil tank
16 drain end caphydraulic oil tank
17 drain plughydraulic oil tank
8.3.2 clean the magnetic plug

a) Close the stop valve before the magnetic plug.
b) Prepare a bucket to collect the overflowing oil.
c) Loosen the screw of the plug.
d) Remove and clean the gauze element.
e) Install the gauze element and plug.
f) Open the stop valve.
18 gauze element
19 plug
8.3.3 Replace the filter element

a) Close the stop valve (1) between the filter element (7) and radiator.
b) Close the stop valve (9) between the oil tank and magnetic plug (8).
c) Replace the filter element.
d) Check the oil filter element to see if there are large particles on the filter element. If yes, some
part must be worn or damaged in the lubricating system.
e) Open the stop valve between the oil tank and magnetic plug.
f) Open the stop valve between the filter element and radiator.
Inspection
Regularly check the pressure drop after passing through the filter element (7) to prepare for
purchasing new filter elements.
Caution! When the fan of the cooler is running, the pressure in the oil system will usually.
Therefore it should be avoided to read the pressure during the period.
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
8.3.4 Clean the return oil mesh and oil tank

a) Remove the cap on the lube oil tank.
b) Raise and take out the filter mesh (23).
c) Clean the filter mesh with diesel or petroleum solvent.
d) Clean the filter mesh with compressed air.
Caution! If the filter mesh is damaged, it should be replaced.
f) Put the filter mesh back to the return oil tank.
8.3.5 Refill the main lubricating system
Caution! Before refilling the oil tank, wash the oil tank, oil pipes and radiator with clean new oil.
a) Reinstall the bolt on the drain plug at the bottom of the lube oil tank.
b) Remove the cap on the lube oil tank.
c) Connect the hose with the oil bucket.
d) Refill the oil tank with new oil (150liters) through the filter mesh (23).
e) Check there is leakage at the connectors and valves.
f) Remove the hose from the lube hub.
g) Reinstall the cap of lube oil hub and tighten the flynut.
8.4 Electric cooler
Clean the electric cooler with compressed air every 5-10 hours to ensure its working
efficiency. If vibration is found in the cooler, the fan in the cooler has to be
clean or replaced to avoid damage to the cooler.
To ensure optimal cooling effect, it must be installed in a well-ventilated room and an
exhaust fan must be installed as well.
The electric cooler is controlled by the cooler temperature control switch TG2. Please
refer to temperature control switch in chapter 8.2.11.
1 cooler fan
8.5 Hydraulic system
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
8.5.1 Hydraulic pump

The hydraulic pump (3) is a reversible gear pump. Before the pump is started, the oil tank must
be filled with oil to a correct oil level.
8.5.2 Filter element
The filter element is full flow type and has the capacity to filter all the lube oil passing
through it. The filter element can be used only once.
Replace the filter element
Replace the filter element when changing the hydraulic oil or every six months.
a) Use the L1 button box (8) near the crusher to lower down the main shaft and
hydraulic piston to the lowest position to release the pressure in the system..
b) Remove the filter element (2) and install a new one.
8. L1 button box
8.5.3 Magnetic plug
The magnetic plug (6) is used to clear the magnetic particles in the system.
Cleaning
Clean the magnetic plug when changing hydraulic oil or every six months.
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.
8.5.5 Pressure gauge

The pressure gauge (1) shows the hydraulic pressure measured by the control valve (5).
When the crusher is running, the damping valve (4) between the hydraulic pipes and pressure
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
This chapter introduces the maintenance of energy accumulator.

9.1 Overview
Danger of explosion
Damaged energy accumulator may have a risk of explosion, so it should be protected against
any mechanical or heat damage (impact, welding etc.).
Energy accumulator (1) is a conical pressure container, which has a rubber gasbag fixed at the
top of the container by gas charging valve. The rubber gasbag is filled with nitrogen.
The setting increases due to overpressure

Oil is squeezed from hydraulic cylinder to energy accumulator, which allows the mantle to fall
deep enough to pass the iron chips from the cavity. After the obstacles leave the cavity, the air
pressure in the energy accumulator immediately push the oil back to the hydraulic cylinder.
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.
9.3.2 Fill nitrogen

Charging pressure of energy accumulator
Tolerence
No ASRbut with ASRPlus
4.2 MPa (610 p.s.i.)
5%
With ASRi
6.0 MPa (870 p.s.i.)
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
Upper Frame Assembly
This chapter introduces procedures of maintenance of the upper frame assembly.

10.1Replace arm frame cap
Replaceable parts:
Part
Code
Quantity
Bolt M2055
SG160-06-0
2
SG160-06-0
3
GB5783-86 4
Spring washer 20
GB93-97
Arm frame cap

0 seal ring
Remarks
Weight 135 kg
8.8grade full thread
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
10.1.1 Remove the arm frame cap

a) Clear the material in the arm frame cap (SG160-06-02).
b) Remove the four bolts M2055 and spring washers 20 that fix the arm
frame cap on the upper frame assembly (SG160-06-17).

c) Put the hook of a crane just above the arm frame cap (SG160-06-02).
d) Put the hook into the lifting eye of arm frame cap (SG160-06-02).
e) Lift up the hanging part of the cable.
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 liners to avoid:

a) Excessive wear of the contacting surface of upper frame and mantle.
b) Loss of production due to decrease of capacity, unqualified product or unexpected downtime.
If the fractions of feed material are not even, similar problems will arise as those in the case of
improper feed device. If most of the feed material is close to the maximum feed size, the crushing
will happen in the upper part of the cavity, which could incur an annular groove (B groove) in the
cavity. If there is much fine material in the feed, the crushing will mainly take place in the lower
part of the cavity (C groove).
The foregoing disadvantages will far outweigh the benefits of using worn liners. Optimal cost
efficiency can be achieved by changing liners at proper times.
Besides, if the main shaft is raised due to maintaining the desired setting and the distance (A
dimension) between the head nut and the bottom of the arm frame is less than 15mm (0.6"), the
liner must be replaced.
The main shaft is raised by hydraulic device to compensate the wear and thus maintain the
desired setting.
A dimension shows the position of main shaft in the crusher.
Caution! The main shaft cannot be raised so high that the A dimension is less than 15mm (0.6").
If the main shaft is raised further, the arm frame bearing in the upper frame may be damaged.
Caution! Every cavity design has a specific setting interval when the liners are within wear limit.
E.G.:
MF (medium fine) cavity

The theoretical setting interval is 6-16 mm (0.24-0.63").
If the crusher runs with the 6 mm (0.24") setting, the rate of reaching the minimum A dimension
15 mm (0.6) is faster than running with the setting 16 mm (0.63"). So when the setting is larger,
the wear rate of the liner is slower.
As the wear of liners depends on the cavity shape, it is hard to predict where is the A dimension.
Therefore operation and visual inspection experience is a must for determining the right time for
changing liners.
10.3 Arm frame bearing
10.3.1 Check the arm frame bearing

Maximum clearance and distance allowed above the pivot
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
This chapter introduces the measurement of the CSS setting.

11.1 Overview
Set up the adjustment system to compensate the wear of mantle and concave as well as to change
the CSS of the crusher.
Generally the frequency of checking CSS depends on the wear rate of the liners. Abrasive rocks
require more frequent inspections while non-abrasive material only needs periodical inspections.
It is recommended to check the concave regularly to make sure that it doesnt suffer from uneven
wear or become oval. Besides, also check if there is partial wear or damage in the cavity. If liners
are worn, the mantle cannot be raised to contact the concave and the main shaft head nut has a risk
of contacting hub bottom of the arm frame. This condition will happen very soon when the crusher
is crushing abrasive material with a large CSS.
Caution! Do not raise the main shaft to A dimension 15 mm (0.6"). if the main shaft is raised
further, the arm frame bearing in the upper frame may be damaged. Please refer to check the
cavity in chapter 10.2.
11.1.1 Check the setting with a lead block
Please refer to chapter 4.2.1.
Chapter Twelve
Trouble Shooting
This chapter introduces how to tackle various problems in the operation.

The operator should not take actions by himself. Instead the operator should find the fault or
error timely and then report it to the supervisor. The supervisor shall decide what to do.
12.1 Faults and recommended remedies
The table below shows various faults, probable causes and recommended remedies.
Numbe Fault
Inspection
Remedy
r
No ready for start signal or Check the circuit and the starter of the oil pump
the oil pump doesnt work.
motor and then start the pump.
If the return oil flow is too low, wait a few
minutes to see if it is stable.
Check and make sure that the oil doesnt
No ready for start signal, overflow from the dust-proof frame. Check the
the lube oil flow is very low. 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
1
The
crusher
level.
cannot start.
The lube oil flow is normal, Check the switch of return oil flow.
but there is no ready for
start signal.
If the protective temperature control switch
TG1 shut down the crusher, check the switch
according to instructions in chapter 8.2.11.
The oil pump is running and Check the starter of the crusher motor and other
there is ready for start circuits.
signal.
The oil doesnt return to the
oil tank (low temperature).
The oil pump doesnt work.

The lube oil flow is too low.
The
crusher
stops when it
is running at
idle speed or
there
is
material in the
cavity.
The lube oil flow is normal.

The oil temperature is too
high and the belts are
slippery.
The crusher
overloaded.
motor
is
The cavity is blocked.

There is iron chip in the
cavity or the cavity is
blocked.
The protective temperature

control switch TG1 shuts
down the crusher.
The
temperature of
lube oil is too
high.
The radiator is continuously

working.
The lube oil flow is too low.
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 hydraulic pressure is too

low.
There is leakage in the
system.
The safety valve is leaking.

The increase of setting
causes the oil level in the
hydraulic oil tank to rise.
The
crusher
doesnt
maintain
a
constant CSS
or the product
size is too
large.
The hydraulic control valve

is leaking. Please refer to
8.6.4. The increase of the
setting causes the oil level in
the hydraulic oil tank to rise.
The hydraulic seal is leaking.
The air pressure in the
hydraulic system or energy
accumulator is too low. The
CSS
increases
during
crushing process but restore
to the preset valve when
there is no feed.
The air bag of energy

accumulator is damaged.
When the crusher is running
without load, the main shaft
rises to a position where the
liners contact each other.
The feed distribution in the
crusher is uneven. The
hydraulic pump reaches its
pressure peak and it cannot
reduce the CSS.
The liners are worn
The liners become oval.
The mantle is loose.

The internal and external
temperatures of the pinion
shaft box are too high.
Clean the magnetic plug. Please refer to 8.3.2.

If necessary, replace the filter element
according to 8.3.3.
Check the capacity of the oil pump and oil
level.
Check the capacity of the hydraulic pump. If
necessary, replace it.
Check the oil pipes. If possible, raise the main
shaft until the liners contact each other. Do not
exceed the maximum hydraulic pressure.
Check the hydraulic meter to see if the pressure
has dropped.
If there is overload peak pressure, change the
feed device. The crusher should be sufficiently
and evenly fed.
Clean or replace the hydraulic control valve.
Check if the lube oil tank is leaking. Replace

the hydraulic seal. Check the hydraulic cylinder
sleeve and replace it if necessary.
Expel air from the hydraulic system. Please
refer to 4.2.3.
Charge the energy accumulator to a proper

pressure. Please refer to 9.3. Replace the air
bag or the whole energy accumulator when
necessary.
Change the air bag or the whole energy
accumulator. Expel air in the hydraulic system.
Please refer to 4.2.3.
Change the feed device. The crusher should be

sufficiently and evenly fed.
Check if the liners are worn or loose.

Check the setting at four evenly distributed
points along the circumference of the crusher,
as stated in 4.2.1. The difference between the
maximum and minimum readings is the ovality.
Check if the clearance between the mantle and
main shaft is too large.
Check and make sure that there is no leakage at
the oil level pipe or drain plug. Please refer to
7.4. Check and make sure there is no other
leakage.
Inspections of
the
pinion
shaft device
Oil leaks from the external

bearing cover.
There is abnormal noise
inside the pinion shaft
device.
The crusher or pinion shaft
box is vibrating.
The clearance in the bearing

is too large due to excessive
wear of the balls and seat
ring.
There
is
abnormal
noise
inside
the crusher.
The conical gear is installed

correctly or the wrong
engagement of gear teeth
causes
abnormal
noise.
Insufficient
clearance
between the teeth will incur
high
frequency
impact
sound.
Excessive wear of eccentric
wear plate causes decrease
of
teeth
clearance.
Insufficient
clearance
between the teeth will incur
high
frequency
impact
sound.
The liners are loose.
During feeding, the arm
frame bearing will make
abnormal noise.
The upper thrust bearing

components make friction
noise.
If the oil level in the pinion shaft box is too

low, fill it to the correct oil level. If the oil level
continuously drops, it shows that the internal
seal is damaged. Recheck please refer to 7.4.
Remove the pinion shaft device for inspection.
If necessary, replace worn bearings and sealing
components.
Check if the external seal ring, the or O ring is
worn or damaged. Remove the pinion bearing
for inspection. If necessary, replace the worn
bearing and sealing components.
components.
Check the pulley. Clean the dust and check the
belt tension. Then check if the belts are waxed.
components.
Frequently check the noise and temperature
inside the pinion shaft device. Remove and
replace the bearing at a convenient time.
Replace the oil inside the pinion shaft box.
Please refer to 7.4.
Remove the pinion shaft device and measure
the adjust the teeth clearance.
Disassemble the crusher, change the eccentric

wear plate. Readjust the teeth clearance. If the
wear of eccentric wear plate increases, the wear
of bearing components will increase as well.
Check and tighten the bolts on the liners. Check
the clearance between the mantle and concave.
Frequently check the oil level and fill it when
necessary. Please refer to 7.5 and 10.3.
Measure the clearance at the pivot. If it is larger
than the allowed valve, replace the pipe
connection and/or main shaft bushing. If it is
much larger than the allowed clearance, the
eccentric may also needs to be changed. Please
refer to 10.1 and 10.3.
Reduce the load of the crusher and prolong the
running-in time. Please refer to 4.2.
If the dirt on the return oil mesh increases,
check if the bearing is faulty. Please refer to
8.2.10 and number 8.
Check if the liners have become oval.
The cavity is blocked or the

liners contact each other.
Check the operational conditions and CSS.

Increase the setting.
Check if the liners have become oval.
Relative movement occurs

between the flanges of the
upper frame assembly and
lower frame assembly.
If there is clearance between the flanges,

measure it with a clearance gauge. Tighten the
bolts. If there is still relative movement
between the flanges, the conical connectors
need to be machined. Please contact us.
Check if skiing channel appears on the
mantle and concave. Replace the liners.
Check the feed device. Make sure that the
crusher is sufficiently fed. Check the
dimensions at the top and bottom of the feed
material. It is not allowed that the size of most
of the material is smaller than CSS. Please refer
to 10.2.
Check the clearance. Please refer to 10.1 and
10.3. if the clearance is too large, check the
condition of the eccentric.
Adjust the belt tension. Replace the belt when
necessary, check the grooves of the pulley.
The change of length or hardness of the
material may incur changes of the capacity.
Check the height of the feed tube. If possible,
restrict the top dimension of the feed tube.
Regularly check the condition of lube oil.
Periodically clean the oil tank and replace the
oil. Please refer to 8.3.
Replace the filter element. Please refer to 8.3.3.
If the clearance between the dust-proof frame
and dust-proof seal ring exceeds the value
given in 6.3.1, the dust-proof seal ring should
be replaced.
Check the whole overpressure system and
check the operation.
Disassemble the crusher and check the bearing
components.
The hydraulic cylinder reacts

too frequently.
Skiing channel appears on
the liners
The capacity
of the crusher
drops down.
The wear of
bearing
components
increases.
The bearing in
the crusher is
faulty.
The clearance in the arm

frame bearing is too large.
The belts are slippery.
The feed material or the
fraction has changed.
Material piles up in or block
the cavity.
The lube oil is contaminated
and thus the wear of
eccentric increases.
The filter element is blocked.
The dust-proof seal ring is
worn or damaged.
The overpressure dust-proof
sealing system doesnt work.
The main shaft assembly is
rotating at a high speed or its
speed is the same with that
of eccentric. The main shaft
and eccentric is stuck
together.
The pinion shaft cannot
rotate. The eccentric and
lower frame sleeve is stuck
together.
The pinion shaft cannot
rotate. The bearing in the
pinion shaft assembly is
faulty.
The quantity of chips on the
return oil mesh increases.
The upper thrust bearing or
bushing is stuck.
Needle particles appear on
If possible, remove the bolts that fix the dustproof frame. Disassemble the main shaft
assembly and the whole eccentric assembly.
Disassemble the upper thrust bearing, remove

the burrs on the rim of oil grooves, polish the
bearing surface of the bushing and the
components of the upper thrust bearing. If
necessary, replace the components of the upper
thrust bearing.
10
The lube oil is

contaminated.
the return oil mesh. Bevel

wheel is stuck or worn.
Tin or lead particles appear
on the return oil mesh. The
bushing or upper thrust
bearing components have a
high temperature or they are
partially overheated or stuck.
Copper particles appear on
the return oil mesh.
The temperature of return oil
is too high.
high.
Dust and dirt
11
The hydraulic
bolts
are
broken.
The torque is wrong.

high.
12
13
The bolts of
concave
are
broken.
The
oil
capacity drops
down, even to
zero.
The upper frame is worn.
The bolts are not properly

tightened.
The pump takes in air at the
leakage.
The rotating direction of the
pump is wrong.
Because a wrong type of
lube oil is used, the capacity
is still too low under high
pressure
The pump is drained.
The inlet pipe is blocked.
The temperature of lube oil is too high.
Check if the bearing is faulty. Please refer to

8.2.10 and number 8.
Please refer to 4. The crusher doesnt maintain
a constant CSS setting or the product size is too
large.
Check the dust-proof seal. The wear of dustproof seal may cause dust to enter the system.
If any defects of bolts are found, replace them
timely. Only special hydraulic bolts can be used
and they should be tightened to the
recommended torque.
If there are too many metal chips in the cavity,
the hydraulic bolts may become loose and fall.
The metal chips should be removed from the
feed material before entering the crusher.
Check the seat of concave when changing the
concave. Remove any metal obstacles that
hinder the concave from correctly seating on
the upper frame.
Tighten the bolts properly.
Change the absorbing pipes (if there is
leakage).
Change the shaft seal (if there is leakage).
Change the rotating direction.
Change the oil. Please refer to 8.3.
Add oil in it.

Remove the blockage.
Replace the pump.
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.
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Remarks

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Users manual of SG160C cone crusher

Copyright 2009 SHAORUI

Shaorui Heavy Industries Co. Ltd.

2.1.3 Prohibitive Signs

6.1.3 Monthly Maintenance

8.3 Changing the Main Lube Oil

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

The usage of this users manual

the same time.

Illustrations in this manual

can provide sufficient training and competent service personnel.

Adjustment of the discharge opening

Cone crusher-- profile

21 hub of material level

Oil tank compartment and auxiliary devices

2.1.2 Classification of dangers

2.1.4 Instructive signs

2.2.1 Personal protection

2.3 General safety precautions

When the cavity is empty, do not put in a whole piece of boulder.

Chapter Three Technical Data

3.2 Processing data

Maximum feed size

This chapter introduces how to start the cone crusher.

4.2.1 Check the settings with a lead block

1 air outlet valve

4.2.4 Maximum load

Operation of the Cone Crusher

5.1.2 Stop the crusher

Normal operational condition

Operation under high temperatures

Operation under low temperatures

Inspection and Maintenance

Check and make sure that there is no material deposit

Before starting the crush

Check the oil level of lube oil tank.

Run the machine without

Listen and make sure there is no abnormal noise inside

During crushing process

Check the temperature of the return oil.

During crushing process

Check the current, power and oil consumption of the

During crushing process

Check and make sure the damping of hydraulic and

During crushing process

Check the temperature of the pinion box. Use an IR

50-60 C (122-140 F).

Check the oil temperature of the main lubricating

During crushing process

Check and make sure that there is no leakage.

During crushing process

Check if the bolts are loose.

During crushing process

When the crusher stops

When the crusher stops

Check and make sure that there is no more dirt, i.e

When the crusher and oil

Clean the damper valve of the hydraulic gauge.

When the crusher and

Check if the crusher liners are worn or

When the crusher

Clean the nozzle on the pinion box.

Person in cha Reference