How to replace cone crusher wear parts？

Cone crushers are widely used in mining, quarrying, and aggregate production for reducing large rocks into smaller, uniform sizes. However, due to continuous crushing operations under heavy load and abrasive conditions, critical wear parts such as mantles, concaves, liners, and bowl liners experience gradual wear. Timely replacement of cone crusher wear parts is essential not only to maintain high crushing efficiency and consistent product size, but also to extend the overall lifespan of the equipment and reduce unplanned downtime.

Replacing a cone crusher's wear parts, primarily the mantle and concave (bowl liner), is a multi-step process that requires careful attention to safety and manufacturer guidelines. These parts are typically made of high-manganese steel due to its durability and wear resistance.

Cone Crusher Wear Parts Replacement

Safety First!

Lock Out/Tag Out: Before starting any maintenance, always ensure the crusher's power is disconnected and locked out to prevent accidental startup.

Personal Protective Equipment (PPE): Wear appropriate PPE, including hard hat, safety glasses, gloves, and steel-toed boots.

Read the Manual: Always consult your specific crusher's operation and maintenance manual for detailed instructions and safety procedures.

Steps to Replace Wear Parts

1. Preparation and Disassembly:

Clear the Crusher: Ensure the crusher is empty of any material.

Remove the Top Shell (if applicable): Depending on your crusher model, you might need to remove the top shell to access some wear parts. This usually involves unbolting and carefully lifting it with appropriate lifting equipment.

Remove the Bowl (Concaves/Mantle):

Loosen Bowl Nuts: Use a specialized tool or impact wrench to loosen the large nuts that hold the bowl liner (concaves) in place.

Lift the Bowl: Use a crane or other lifting device to carefully lift and remove the bowl.

Remove Old Concaves: Once the bowl is off, the old concaves can be unbolted or pried out. They are often backed with epoxy or zinc, which will need to be broken away.

2. Replacing the Mantle:

The mantle is the wear part on the cone head.

Remove Old Mantle: This usually involves heating the mantle to expand it, or using specialized tools to break the epoxy or zinc backing. Some mantles are threaded and can be unscrewed.

Clean the Cone Head: Thoroughly clean the cone head surface, removing any old backing material, dirt, or debris.
Install New Mantle:

Position: Carefully lower the new mantle onto the cone head.

Backing Material: Fill the gap between the mantle and the cone head with a suitable backing material (epoxy or molten zinc is common). Ensure it's evenly distributed and cures properly according to the manufacturer's instructions.

Curing: Allow sufficient time for the backing material to cure before proceeding.

3. Replacing the Concaves (Bowl Liner):

Clean the Bowl: Clean the inside surface of the bowl thoroughly, removing any old backing material.

Install New Concaves:

Position: Carefully place the new concaves into the bowl.

Secure: Depending on the design, they will either be bolted in place or held by a backing material.

Backing Material: If using backing material, pour it into the gap between the concaves and the bowl, ensuring it fills completely and cures properly.

4. Reassembly:

Lower the Bowl: Carefully lower the bowl back onto the crusher assembly.

Tighten Bowl Nuts: Securely tighten the bowl nuts to the manufacturer's specified torque.

Replace Top Shell (if removed): Reattach the top shell, ensuring all bolts are properly tightened.

5. Inspection and Testing:

Visual Inspection: Perform a thorough visual inspection to ensure all parts are correctly installed and all fasteners are tightened.

Clearance Checks: Check for proper clearances between the mantle and concaves.

Test Run: Before putting the crusher back into full operation, perform a no-load test run to check for any unusual noises or vibrations. Gradually introduce material and monitor performance.

Understanding the correct replacement cycle, choosing high-quality wear parts, and following proper installation procedures can significantly improve crusher performance. Using durable materials like manganese steel or customized alloys ensures better resistance against abrasion, impact, and stress. In addition, scheduled inspections and preventive maintenance play a crucial role in maximizing productivity and minimizing operating costs.

Whether you operate a primary, secondary, or tertiary cone crusher, a well-planned wear parts replacement strategy helps achieve smoother production, reduced maintenance costs, and reliable long-term operation.