The cast steel spider cap has been designed to serve as a feed distribution plate for coarse materials. It is recessed on the 22, 30, 36 and 48-in. crushers. For fine materials, the wobble plate feeder a more effective means of distributing the feed is recommended.
The annealed cast steel top shell and spider are made in one piece. The spider is of the three arm type, equipped with a self-aligning, Scor-Proof plastic ball and socket bearing in crusher sizes 22 to 48-in., and with an hourglass type bearing in sizes above 48-in. The lubricant is sealed in with a garter type oil seal. Bearings can be lubricated from outside the topshell on the 51, 60 and 84-in. crushers through oil holes in spider caps of the four smaller sizes.
The mainshaft is of high grade forged steel, annealed for stress relief. It is tapered to gauge for head center fit. The bottom of the shaft is fitted with a polished bronze step bearing. The journal for the spider bearing is formed by a sleeve shrunk on the shaft on the 51, 60 and 84-in. crushers. Short, heavy mainshaft design results in long life.
The step bearing consists of a bronze mainshaft step, a bronze piston wearing plate, and an alloy steel washer between the two. The washer is drilled for oil cooling and lubrication. Both the mainshaft step and the piston wearing plate are made of high lead bronze, selected to give the best bearing surface. The washer and plate are pinned in place, and the bearing surfaces are grooved to permit distribution of the lubricating oil.
The Mantalloy head mantle of this cone crusher is a replaceable wearing surface. It is made of alloyed manganese steel, and is held in place with a self-tightening head nut. On the 51-in. Hydrocone crushers and larger, the bottom portion of the mantle is ground to gauge to fit the head center, and the top portion is zinced. For crushers smaller than 51-in., the entire inner surface of the mantle is ground to gauge and no zincing is required.
The Mantalloy concave ring, or the stationary crushing surface, is available in three standard types, coarse, intermediate and fine. Helices, cast into the bottom of the concave ring, engage similar helices on the top of a cast steel concave support ring. The support ring is held by a key to the top shell to facilitate assembly, after which it is supported on the bottom shell. The helical surfaces make the concave ring self-tightening; no zincing is required.
The dust seal is a plastic ring suspended in a housing from the head center and encircling the dust collar. It is designed to accommodate the vertical adjustment and the gyrating and rotating motion of the head. All wearing parts are replaceable. The crusher is fitted with a connection for introducing low pressure air inside the seal for additional dust protection.
The eccentric is made of high carbon cast steel and fitted with a bronze inner wearing sleeve. The eccentric turns in a bronze bottom shell bushing. Both sleeve and bushing are replaceable. The eccentric throw can be changed in the field by installing a different sleeve.
The alloy steel pinion is mounted on a turned shaft. The cast steel pinionshaft housing is bolted to the machined opening in the bottom shell. It is equipped with anti-friction bearings sealed inside and out, and has separate pool lubrication in all sizes except the 36 and 48-inch machines. The 36 and 48-inch Hydrocone crushers have sleeve type counter-shaft bearings which are lubricated by the external oiling system.
The annealed cast steel bottom shell is of the three arm, open discharge type, bored to gauge for the top shell and eccentric bushing. It is bored and faced for the bottom plate, pinionshaft bearing and dust collar.
The external oil conditioning system furnished with Hydrocone crushers consists of a large oil storage tank on which are mounted a condenser type cooler, pressure type filter, motor, and a pump which pumps the lubricant to the crusher automatically. These units both cool and filter the oil. The accumulator and tank for the Automatic Reset are mounted separately from the oil storage tank.
All oil conditioning systems are equipped with oil flow and temperature safety switches which are adjusted to open the motor circuit and stop the crusher if the temperature becomes too high or if there is not a sufficient flow of oil. Flexible hose connects the lubricating unit to the crushers, greatly reducing the number of pipe fittings required and simplifying the installation.
Oil for the tank is pumped through the filter and cooler to the step bearing and up the inner eccentric bearing. It flows down the outer eccentric bearing, lubricates the gear and pinion, then returns to the tank. Tank capacities vary from 30 gallons for the 22-in. Hydrocone crusher to 240 gallons for the 84-in. machine.
23. Feed Plate 24. Screw 25. Torch Ring 26. Locking Bolt 27. Dust Shell 28. Clamp Ring 29. Adjustment Ring 30. Mainshaft Pin 31. Pin 32. Socket Liner 33. Socket 34. Eccentric 35. Eccentric Bushing 36. Counterweight 37. Counterweight Guard 38. Gear 39. Thrust Bearing 40. Countershaft Box 41. Countershaft Box Guard 42. Oil Finger Cover 43. Oil Finger 44. Countershaft Bushing 45. Countershaft 46. Pinion
CRUSHING CHAMBER may be any one of three standard types (Fine, Intermediate and Coarse) designed to assure a cubical, well-graded product. Shape of mantle and concave ring, and the range of adjustment available, results in maximum life and minimum scrap when replacing parts. Special crushing chambers also available.
BEVEL PINION AND GEAR are of the spiral design in the larger sizes provide greater tooth contact and smooth, trouble-free operation under most severe conditions. Bevel spur and pinion gears are used on smaller size Hydrocone crushers.
INNER CRUSHING CONE or mantle is one-piece Mantalloy casting held in place by a self-locking head nut. Complete contact of the ground inner surface with steel head center eliminates need for zincing in all but the larger sizes.
OUTER CRUSHING RING or concave ring is one-piece Mantalloy casting. Necessity of zincing or clamping concave ring in place is eliminated by ground-to-fit finish on outer surface and the use of an effective self-locking device.
3-PIECE STEP BEARING accommodates gyrating motion of main shaft and transmits crushing pressure to hydraulic piston. Designed to withstand bearing pressures much greater than those encountered in actual service.
While it is one of the major parts in the machine, there are few essential differences between the adjustment ring in the 10 ft. crusher and in the smaller machines, except as to size. Material of the ring which weighs 70,000 pounds is cast steel. Rigidity of the adjustment ring cross-section is essential. In this case, increased section thickness, with ordinary carbon steels, results in a reduction in deflection.
This part, which is screwed into the adjustment ring, is the means of setting of the machine. Adjustment is performed by rotating the bowl relative to the adjustment ring. In the 10 ft. machine provision has been made to adjust the setting during crushing. This increases the availability of the crusher substantially. Past practice had been to stop feed to the crusher during adjustment.
During crushing the position of the bowl and adjustment ring is maintained on the slant flank of the threads by means of the crushing force. The slant flank helps in centering the two elements. The clamp ring acts somewhat like a locking device to take up clearances. Ideally, the clamping cylinders do not have to have any greater capacity than is necessary to overcome the weight of the bowl. Practically, the clamp ring capacity is many times higher to withstand tramp passage.
To adjust the setting of the machine, hydraulic rams are used to rotate or counter-rotate the bowl in the adjustment ring. The seal between the adjustment cap and hopper is a simple, continuous, tightly fitting flap which allows free, relative rotation but prevents intrusion of dust into the thread area. The lower end of the thread connection between bowl and adjustment ring is also sealed. The hopper assembly, which is actually a part of the bowl assembly, including the hopper, hopper liner and cap closure, comprises the section in which the feed is introduced. It includes a dead bed, reducing wear and shock from the fall of the feed from the feeder above.
The adjustment rams are pressurized hydraulically and provide a setting adjustment. For normal adjustment of setting due to wear, installation and removal of the bowl is made through a swivel sheave and a cable turn applied around the adjustment cap. The bowl is then rotated by use of the maintenance crane.
The crushing head, similar in section to that of the 7 ft. machine, had three-dimensional photoelastic studies made using the technique of freezing stresses into a loaded plastic model, sectioning the model and examining the slices under polarized light. As a result of these techniques, stresses have been reduced. The core of the head consists of six massive ribs to support the crushing forces on the surface of the head. The head is cast steel.
The main shaft is of turbine rotor steel of high quality and refinement, the chemistry of which is low carbon to reduce the possibility of heat checking. It includes chrome nickel additions for deep hardening, notch toughness and resistance to fatigue. The shaft extension is provided to reduce the relative strain between the head and shaft and thereby reduce fretting in the fit, which has a heavy press. The shaft diameter is 50 percent greater than the 7 ft. crusher shaft. As a result, the shaft operates at lower values of bending stress and deflection. Reduced deflection produces distinct benefits in bearing behavior because of uniformity of oil film under load. Reduced stresses assure longer life and resistance to overloads.
The head-shaft assembly is supported by the socket and socket liner which is, in essence, a spherical thrust bearing. The function is to carry the vertical component of the crushing force while allowing the head to oscillate around the theoretical center of rotation.
The socket of carbon steel is of dowelled design. The forces between the head and the socket are normal to the spherical surface of the head and pass through the theoretical center. The line of action of these forces is such that practically pure compression is applied to the socket and liner, reducing deflection and stress to a minimum and promoting good bearing performance.
The force distribution throughout the crusher is based on a vector diagram of the cavity forces during crushing and the reactions at various associated loading points in the crusher. The vector diagram establishes their relative magnitude, direction and points of application. The actual magnitude of these forces is established by the crushing force necessary to lift the adjustment ring off the frame seat. This condition represents the maximum allowable force for normal crushing.
A baffle ring attached to the head is sub-merged around its entire periphery in a water trough resting on the socket. Dust tends to settle into the trough and must be continuously removed to prevent caking. For this reason, water is continuously fed through specially designed nozzles which scour the trough. Overflow water is carried off by internal piping and passages. The seal chamber is vented to atmosphere to prevent siphoning which may cause oil contamination of the water or vice versa.
The gears are straight tooth bevel gears and are designed to AGMA standards using a computerized program which, upon input of the basic information, such as DP, diameters, gear ratio, material properties, tooth type, provides a complete printout of the rated power on the basis of tooth strength and surface durability of the gear. The factor of safety on the gear is in excess of three on the strength basis and in excess of two on the durability basis.
With over 100 years of experience and our knowledge of crushers and different minerals processes, we know how crusher wear parts fit and function within a crusher to provide maximum performance. Our cone crusher wear parts are designed to the same specifications and standards as our cone crusher equipment, ensuring equipment compatibility for reliable and safe operation.
We have complete control over quality at every step of the process, from the selection of raw materials to final production. Metso Outotec cone crusher wear parts are made of high-quality manganese in a continuously monitored process at our own foundries and manufacturing facilities.
Our selection of cone crusher wear parts ensures that there is a solution for your application. We have the expertise to select both the chamber and the material to fit your crushing process. The right wear profile improves crusher performance and extends wear life, leading to less downtime and fewer liner replacements, which in turn increases safety and reduces the cost per ton. Our cone crusher wear parts are available for all Metso Outotec crushing equipment, but we also offer crusher wears for non-Metso Outotec crusher models.
Our premium cone crusher wears are designed to provide extended life, lower cost per ton, and optimized capacity and performance even in the most challenging conditions. Our selection of premium cone crusher wear parts has solutions for every type of application. We also have the expertise and tools to offer customized solutions and chamber optimization services to find the optimal crusher wear parts that will bring your specific crushing application improved crushing performance and lower cost per ton.
Get the maximum potential out of your size reduction process to achieve improved crushing performance and lower cost per ton. By using our unique simulation software, our chamber optimization experts can design an optimized crushing chamber that matches the exact conditions you are operating under.
Maintain control of your daily operation at an affordable cost with Metso Outotec O-Series crusher wear parts. We offer O-Series crusher wear parts for Nordberg HP, GP and Symons crushers. These O-Series crusher wear parts are designed by original equipment manufacturer (OEM), so you can trust that they fit and function with your Metso Outotec crusher.
With multiple fabrication options and upgrades to choose from, Metso Outotec's cone crusher spare parts are eliminating the risk that the replaced part becomes the weak point in your crusher. They offer stable production without unexpected downtime.
Contender Series spare and wear parts are designed to fit and perform with Sandvik CH, CS and CJ crushers. The premium spare parts are designed using our OEM know-how. Selected spare parts are enhanced with better safety, easier maintenance and longer life. Wear parts are designed to meet OEM standards, going well together with Contender Series spare parts. Wear parts for CH430 and CH440 crushers are further complemented with lifting tools.
When it comes to Replacement Cone Crusher Parts, Qiming Casting has been crushing the market for decades. If you demand the peace of mind that comes with ISO 9001-certified, fully-guaranteed, and warranted replacement parts for your cone crusher. Qiming Casting can supply cone crusher wear parts and cone crusher spare parts with the best quality and suitable price. Cone crusher wear parts include cone liners, bowl liners; Cone crusher spare parts include: cone crusher spider cap, top shell, and spider, cone crusher main shaft, head center, cone crusher step bearing, cone crusher dust seal, cone crusher eccentric bushings, cone crusher bottom shell and so on.
Qiming Casting is Your SuperStore for Cone Crusher Parts! All Qiming Casting Replacement Parts are backed by ISO9001:2015 quality control system and are shipped only after meeting our rigorous quality standards. We are committed to meeting your replacement parts needs in a professional and efficient manner. Our Customer Support Department is ready to help you with a quote, to check inventory, or simply answer a technical question. Talk to your Qiming Casting professional today about your specific needs!
A Cone crusher is a type of compression crusher, which reduces material by squeezing or compressing it until it breaks. Specifically, the material is compressed between an eccentrically rotating piece of steel, the mantle, and a stationary piece of steel, the bowl. The material works its way down along the crushing chamber as it gets smaller, until the crushed material discharges at the bottom of the machine.
In the current economic climate, decrease cost and increase profit are the most important, and cost base is a major factor in managing a successful quarrying business, crusher replacement costs associated with cone crushers can be a major cost center. This post explains a method to reduce crusher replacement costs by casting crusher liners. However, the process has been perfected in recent years and can work well in the right applications. Cone crushers operate by having stone fed into the top of the crusher chamber. The chamber is lined with crusher replacement, namely the mantle and bowl liners. As the stone drops through the choked chamber, crushing is achieved when the motion of the mantle causes compressive and abrasive forces to act upon the stone and bowl liner, causing the stone to break. Liners are manufactured from manganese steel rather than normal steel as the manganese content provides protection against abrasion (normal steel generally has a lower tolerance to wear than crushing duties require). Depending on the stone being crushed, the percentage of manganese in the liners can vary from around 12% to 23%, so we can find the materials Mn14, Mn18, and Mn21. The below are the major factors we need analytics:
Once again, selection depends upon the product required and the feedstock. Consultation with manufacturers is essential, some of whom will provide computer design facilities and offer wear-analysis services on both their own and other makes of crusher, such as the level of competition.
Cone crusher liners that exceed their intended operating life will cause mechanical problems with the crusher. A liner that is pushed too long will flex and crack, and the flexing of a thin or cracked mantle will cause severe seat surface damage.
If the liner is wearing evenly throughout the chamber, you should consider changing it when it has worn down to about 1 (2.5 cm) thick at the bottom. At about 3/4 to 5/8 (1.9 cm to 1.6 cm) thick, the liner will crack, causing the backing material to begin to disintegrate. This will cause the liners to break loose. If the liners break loose, the continued operation could destroy the seat on the support bowl or the head of the Cone Crusher.
Some Cone Crushers feature an automatic liner change reminder. When new mantle and concave liners are installed, the automatic reminder is reset. As the crusher operates, the system tracks production capacities and calculates the liner wear rate. When the cone liners reach the maximum wear point, the system sends a flashing reminder to Change Cone on the cone setting meter. After the wear parts are changes, reset the automatic reminder system and continue efficient and reliable crushing.
An important item to note: You should never place a new concave liner in a crusher with a worn mantle or a new mantle in a crusher with a worn concave liner. Mating new and worn components will change the profile of the crushing chamber and restrict the feed from entering the crushing chamber, which will reduce the tons per hour produced.
On top-adjust/screw adjust cones this is especially true as the feed size starts to shrink pretty dramatically as soon as you get to the last 1/3 of life and as you near the end the feed size can get very small, losing as much as 30% of feed size. This is less of an issue with hydrocones as the feed size remains constant throughout the life of the manganese.
You should have a pretty good idea when you will need to changemanganeseand be able to have all of the parts on hand prior to needing to change. By having an accurate belt scale, you can know to the day when your production starts to tail off to the threshold and schedule the change immediately.
Therefore a 10% reduction in production results in a loss of $2,000 per day in gross profit. All of the other fixed and variable costs of labor and fuel keep adding up at the same rate. At $10,000-12,000 per week it doesnt take too long to rack up serious losses, in two weeks you could afford at least two new sets of liners!
Some may say that times are tough and we cant sell everything we can produce so why not get the last ton out of that set of manganese? If you conduct four liner changes per year and you delayed each change by two weeks, you add forty-four hours of operation time to your season, thats a whole week of wages and fuel!
There are 5 key points that you need to consider when selecting the correct crushing chamber: 1. Feed size Each chamber configuration has a maximum feed size that it can accept. 2. Feed grading The maximum feed size is important as if there are a lot of fines in the feed or a lot of single size in the feed, it can cause issues with wear and output. Attention should also be given to recirculating stone for the following reasons: It has a tendency to be a lot more abrasive and harder than virgin stone; Depending on the amount recirculating, it can cause issues with segregated feed 3. Output required This takes into account output and grading required, which can affect which crushing chamber you should select.
The closed side setting (CSS) defines the reduction ratio in cone crushers and has a significant effect on product gradation, capacity, and power draw. The closed side setting is measured from the bottom of the mantle to the bottom of the bowl liner at their closest point during the gyrating cycle.
Generally, a higher speed creates a finer product gradation curve and better product shape, which is important when producing the end product for most construction applications, while operating the cone crusher at the lower end of its speed range will increase the cavity volumetric throughput and the product gradation curve can be altered to produce fewer fines. Crusher operating speed is adjusted by changing the diameter of the crusher and motor sheaves.
Each cone crusher has several cavity options with different feed openings and setting ranges. The correct cavity can be selected based on the feed size, setting, and application. Overall, it is essential to keep in mind that the crusher is just one part of a crushing circuit. Its performance depends on the proper selection and operation of feeders, conveyors, screens, electric motors, drive components, and feed silos which are part of the circuit. All the elements should be examined as part of an entity to get the most out of the production.
Mainframe: The main frame of the cone crusher is composed of an upper frame and a lower frame, which are connected by hydraulic cylinders, with wear-resistant liners and protective covers: the upper frame is a welded part, and the upper part is welded with wear copper plate and the lower frame are integral steel castings.
Main shaft assembly: The main shaft and the center wheel of the lower frame of the main frame are assembled with a small interference fit on the cone surface. The main shaft has axial and radial lubricating holes.
Eccentric shaft sleeve assembly: The eccentric shaft sleeve is equipped with a high-lead bronze bushing fixed by screws; the lower part is equipped with a large bevel gear and a thrust bearing through bolts. The upper thrust bearing is forged steel, and the lower thrust bearing is a high-lead bronze piece; in addition, a counterweight component fixed by bolts is installed on the eccentric shaft sleeve, and the inside is filled with lead and a wear-resistant protective liner is installed.
Moving cone assembly: The upper part of the moving cone is bolted to fix the feed plate assembly, and the lower part is equipped with a spherical bearing bush, which can be matched with the spherical steel tile installed in the sleeve; the outside of the moving cone is installed with high manganese steel. The movable cone lining board, the gap between the movable cone body and the lining board is filled with epoxy resin; the upper and lower high lead bronze bushings are installed inside the movable cone.
Fixed cone assembly: the upper part of the fixed cone is fitted with a feeding hopper; the inner part is fitted with a high manganese steel wear-resistant liner fixed with large diameter bolts; the fixed cone is also filled with epoxy resin between the fixed cone and its liner; the outer part of the fixed cone is a trapezoidal thread matching the adjusting ring.
Adjusting ring: Adjusting ring is a component consisting of adjusting ring, clamping ring, cam follower, hydraulic motor, etc. It has a trapezoidal thread in the clamping ring and can be connected with fixed cone. Fixing pin and guide rod are installed on the upper part of the adjusting ring to prevent the adjusting ring from rotating in the main frame.
Unit lubrication device: composed of lubrication oil tank, motor oil pump, filter, cooling device and control device. For example, the cone crusher of Yantai Xinhai Mine Machine adopts dry oil or water sealing methods, which makes it impossible for dust and impurities to enter the human body and ensures the cleanliness of lubricating and cleaning oil.
Horizontal drive shaft assembly: a high-power main drive motor, small bevel gears on the horizontal shaft drive large bevel gears, and eccentric bushings through triangular pulley drive device: the box of the horizontal shaft is an integral cast iron part, which is bolted to the mainframe.
Adjustment mechanism assembly: use a hydraulic motor to drive pinion and pinion to drive large ring gear on adjusting cap, so as to drive fixed cone rotation to achieve the purpose of adjusting the clearance between fixed cone liner and movable cone liner.
Hydraulic control station: control station includes an oil tank with an oil gauge, motor oil pump, filter, energy storage device, control device, pressure switch, safety protection device, etc. Terminal box and push-button control cabinet are also installed beside the crusher.
Our commitment to improving design and ease of use comes first. If we can improve and manufacture a crusher component that helps our customers achieve longer-lasting parts, reliability, and ease of use we follow through. Our Quality standards are very strict. We have inspectors that make sure throughout the process that we hold tight tolerances and provide exceptional high-quality parts.
Qiming Casting is one of the largest manganese steel, chromium steel, and alloy steel foundry in China. Products include crusher wear parts, Crusher spare parts, mill liners, shredder wear parts, apron feeder pans, and electric rope shovel parts.
By understanding all the various factors that impact your crushers operating performance, we are always looking to make improvements. For selected parts, additional enhancements have been made such as adding extra lifting points for safer change outs or using improved materials and alloys for longer parts life.
You can find most parts with reference numbers in the tables below. If you are interested in buying parts or want to know more about them, please send us an inquiry by filling the contact form in the end of the page.
CMS Cepcor is the aftermarket cone crusher experts and the range of replacement cone crusher parts held in stock is unrivaled. CMS Cepcor replacement parts are specified by mining and quarrying operators worldwide.
The CMS Cepcor product range of mechanical spare parts for cone crushers is unrivaled. CMS Cepcor stocks precision-machined UK manufactured main shafts, head centers, socket liners and eccentric bushings for popular cone crushers.
CMS Cepcor has heavily invested in new technology in order to set the standard for aftermarket quality assurance, reverse engineering and metallurgy, resulting in the continual and rapid growth of our product range, especially for those parts normally only associated with the original equipment manufacturers (OEM).