Comprehensive guidelines for a new installed HP cone crusher initial operation

Checklist when starting up a newly installed HP cone crusher

1. Checks prior to start-up

● Have the wooden chocks between the bowl liner and mantle been removed

● HP cone crusher adjustment measured at certain size

● Drive tension and alignment

● Position of the countershaft bushing’s oil groove in relation to the drive

● If the eccentric was delivered dismantled, check the play between the pinion or crown teeth

● Lateral play of countershaft

● HP cone crusher’s anchorage and fastening bolts

● Does the design of the concrete block or dead-bed under the crusher allow the free flow of crushed material?

● Lubrication:

a. Slope of return pipes at least 10% between the HP cone crusher and the tank

b. Check the make and quality of the oil used and check the oil level

c. Pipes are installed according to the plans

d. Accessories such as filters, fan, unit heater, immersion heater, pressure relief valves, thermostats or temperature sensors, pressure switches and breathers are correctly mounted

e. Alarm device, pressure switches, level controller and thermostat are correctly connected

f. The pressure limiter and related pipes are properly mounted

g. The pump rotates in the right direction

h. Hydraulic couplings on the unit are correct

i. Clean filter

j. Breathers in the countershaft housing and breather in tank correctly fitted

k. Oil supply and return pipes do not contain foreign bodies. Before connecting, check the condition and cleanliness of the insides of the pipes

● Hydraulic device

a. The right make and type of oil in the oil tank; check the oil level

b. The retaining system’s accumulators are properly filled with nitrogen

c. All connections between the hydraulic unit and the crusher are correct

d. Pipes have been blasted and tested for leaks

e. At least one adjustment should be made to ensure that the adjusting system and locking cylinders are working properly

2. Starting up the oil pump

Oil temperature should be at least 16℃ or 60℉.

3. Starting up the HP cone crusher’s hydraulics

The countershaft rotates in the right direction.

4. Starting up the HP cone crusher

● The HP cone crusher must run idle for roughly 1 hour, until the temperature of the return oil reaches 27℃ or 80℉

● Crusher rotation speed, keep a record

● Seals underneath the crusher have been checked

● Absorbed current running idle, keep a record

● Alarm devices like pressure switches, thermostats or temperature sensors have been checked and conform

● The HP cone crusher has run at 50% load for 2 hours

● The HP crusher has run at 75% load for 4 hours

● The HP cone crusher has run at 100% load for 1 hour

● The shut-off valve stopped returning oil to the tank, keep a record

● Is the material evenly distributed in the cavity?

● The crusher shuts down in how many seconds, keep a record

5. Six hours after initial start-up

● Keep a record for the temperature difference between the oil supply and return

● The customer has been apprised of any recommendations regarding possible modifications to his installation

● The crusher has run at 75% capacity for 6 hours

Preparations prior to start-up

Carrying out inspections as a matter of routine will go a long way to ensuring optimal operation of the HP cone crusher for many years. Never rely on your memory when planning regular maintenance, use a maintenance logbook.

Regular checks and inspections will avert stoppages and prolong the HP cone crusher’s lifetime. Before starting up the HP cone crusher, carry out the following operations:

● Check that the right lubricating oil is used and that the lubrication system is properly fitted as explained in the lubrication manual.

● Start the oil pump motor. Open the inspection hatch on the tank and check the oil return pipe to make sure the oil is circulating. In normal operation, the oil flowing out of the return pipe should fill half to two-thirds of the pipe.

● Remove the wooden chocks between the liner and mantle for transportation.

● Check the play at the end of the countershaft. The countershaft must be able to move leftwards and rightwards by 1.0 mm to 1.5 mm.

● Carry out a final check to ensure there are no tools or mechanical obstacles on the crusher.

All joints must be properly fitted.

Check for any leaks.

Check for any other reasons that may prevent the HP cone crusher from starting.

● Rotate the countershaft by hand to check that the mantle does not touch the bowl liner and that there are no other mechanical hitches. If the mantle touches the bowl liner, refer to the bowl adjusting instructions in this section.

● Use the checklist at the beginning of this section to ensure all the important points have been checked.

● When all these points have been checked, start the HP cone crusher following the detailed instructions "Initial start-up".

Countershaft speed

Speed or revolutions per minutes is essential to the proper functioning of the HP cone crusher.

The admissible speed range is given in the following table. The recommended dimensions of the pulleys driving the HP cone crusher are calculated for operation at full capacity.

The countershaft will rotate a little faster when the crusher is running idle.

Experience shows that running the HP cone crusher with the correct countershaft rotation speed produces a maximum amount of material at a constant grade.

The HP cone crusher's countershaft speed determines both the amount of material and the number of impacts a particle sustains in the cavity.

If the HP cone crusher cannot run at the right speed (rpm), a higher rotation speed is preferable (no more than 10% over the rated speed), because if countershaft speed is reduced to much lower that the recommended rotation speed, performance will be greatly impaired due to jamming in the crushing chamber, which could block the HP cone crusher.

Countershaft rotation

All HP cone crushers are designed in such a way that their countershaft rotates clockwise, as viewed when facing the countershaft.

The direction of rotation is important because the locking nut keeps the mantle tight against the head, we rely on correct rotation to ensure its self-clamping capacity.

Operation of the hydraulic unit

The unit should always be powered up when the HP cone crusher is running to ensure adequate retaining and support pressure.

It should also be powered up for adjustment and clearing operations prior to starting up the HP cone crusher itself.

Initial start-up of the HP cone crusher

Although the HP cone crusher has been tested in Deya Machinery’s workshop, we recommend first running the HP cone crusher idle then at reduced capacity for several hours after the initial start-up or after fitting new rings.

This runs in the HP cone crusher and ensures that all the parts are working properly and are well oiled. It is also advisable to check oil temperature more often during this period.

The initial start-up procedure after fitting a new head bushing or eccentric thrust bearing is as follows:

● Before starting up the HP cone crusher, start up the lubrication system.

For proper lubrication of the bushings, the temperature of the return oil should be at least 16℃ or 60℉ before starting up the HP cone crusher.

If necessary, immersion heaters will heat up the oil.

● The hydraulic unit should also be powered up before the HP cone crusher.

● Start up the HP cone crusher and let it run idle for 1 hour. Make sure the return oil temperature reaches at least 27℃ or 80℉.

● After one hour of operation, start steadily feeding the HP cone crusher for 2 hours up to 50% of the amperage indicated on the motor’s nameplate.

● After 3 hours of operation, feed the crusher for 2 hours up to 75% of the amperage.

● After completing the instructions, the HP cone crusher can now run at full capacity up to 100% of the amperage or the adjusting ring’s bounce limit.

● Take an oil sample after initial start-up and send it to the factory for analysis.

● Start keeping and updating a "HP cone crusher event log".

Daily HP cone crusher start-up and shutdown procedures

It is important to consult the logbook when the HP cone crusher has not been in use for a while.

Note down all operations and post them up so that all personnel are apprised of them.

Daily start-up

● Before starting up the crusher, start up the lubrication system and make sure the return oil temperature is at least 16℃ or 60 ℉.

● The oil takes at least 1 minute to circulate before the HP cone crusher can start up.

Note:

Do not let the crusher run for more than 15 seconds if the oil does not appear in the collector unit on the oil tank, because this could cause serious damage in the HP cone crusher.

Normally there should be enough oil flowing through the return pipe to fill it up to between one third and one half.

Lack of oil may be due to several conditions:

Lack of oil in the lubrication system, a broken oil pump, a priming failure in the pump, a blocked suction pipe or an incorrectly adjusted bypass valve.

● The hydraulic unit should be powered up before the HP cone crusher.

Check all the indicators on the control box to ascertain that the hydraulic unit is indeed powered up and the pressure in its circuits is normal.

If holding pressure is abnormal, adjust the pressure of the circuit as instructed in the hydraulics manual.

● Start up the HP cone crusher and let it run idle for 5 minutes.

● Gradually start feeding the HP cone crusher until its maximum power requirement is reached.

Daily shutdown

● Stop the feed and let the HP cone crusher run for 2 to 3 minutes.

● Shut down the HP cone crusher and check how long it takes to stop; this should be at least 30 seconds.

● After shutting down the HP cone crusher, the oil pump should continue operating for 2 minutes.

● Shut down the hydraulic unit.

Remeber, always operate according to the operation manual provided by Deya Machinery, feel free to contact our technical team if there are any questions.

HP Cone Crusher by Deya Machinery

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