Key Measures to Extend the Service Life of Cone Crusher Wear Parts

I. Material Pre-Treatment: Minimize "Destructive Impact" from the Source

1. Strict Impurity Removal to Prevent Hard Foreign Objects from Entering

• Install magnetic separators (strong magnetic or electromagnetic type) before the crusher’s feed inlet to remove metal debris (e.g., steel bars, scrap iron) from the material. This prevents hard metal impurities from causing chipping, cracking on the crushing mantle/concave liner, or jamming the crushing chamber, which would lead to overload wear.

• Equip vibrating screens to sift out fine powder (e.g., dust with particle size < 5mm) from the material. This avoids fine powder adhering and scaling on the inner wall of the crushing chamber—scaling causes uneven material extrusion stress, intensifies local wear, and impairs crushing efficiency.

2. Control Material Particle Size and Moisture to Avoid Blockage/Unbalanced Loading

• The feed particle size must strictly match the crusher’s "feed inlet size" (e.g., if the feed inlet is designed for 200mm, the maximum feed particle size should not exceed 180mm). Forcing oversized bulk materials into the crusher is prohibited, as this may cause instantaneous overload of the mantle/concave liner, leading to eccentric bushing wear or bolt loosening.

• For wet and sticky materials (e.g., ore with moisture content > 15%), install drying equipment or "anti-clogging liners" to prevent materials from adhering in the crushing chamber and forming "material arches" (blockages). Blockages cause prolonged static friction between the crushing mantle and materials, accelerating local wear.

II. Optimization of Operating Parameters: Avoid "Overload" and "Unreasonable Stress"

1. Control Processing Capacity and Avoid "Overload Production"

• The actual processing capacity should be controlled at 80%-95% of the equipment’s design capacity. Avoid forced overload operation to pursue output (e.g., if the design capacity is 200 t/h, long-term operation at 250 t/h is not recommended). Overload drastically increases the axial pressure on the eccentric bushing and thrust bearing, which easily damages the lubricating film and causes "dry friction". Meanwhile, the extrusion impact force between the crushing mantle and materials increases significantly, accelerating the wear rate of the wear-resistant layer by 30%-50%.

2. Dynamically Adjust Crushing Gap to Match Material Hardness

• Adjust the "discharge gap" according to material hardness (e.g., Protodyakonov hardness coefficient f): For hard rocks (f > 12, such as granite), slightly increase the gap (e.g., 15-20mm) to reduce the contact time between materials and the crushing mantle, minimizing impact wear. For soft rocks (f < 6, such as limestone), reduce the gap (e.g., 8-12mm) to avoid "repeated impact" of materials in the crushing chamber, which causes ineffective wear.

• Inspect the discharge gap regularly (once a week). If the gap increases due to wear (e.g., from 15mm to 25mm), fine-tune it promptly using the "adjustment ring" to ensure uniform stress in the crushing chamber.

3. Ensure Uniform Feeding to Avoid "Unbalanced Wear"

• Use a material distributor (e.g., conical hopper) to feed materials evenly into the center of the crushing chamber. Unilateral feeding is prohibited—unilateral feeding causes the mantle to bear uneven stress on one side, leading to "unbalanced wear" of the main shaft cone bushing and spherical bearing. Additionally, it results in excessive wear on one side of the crushing mantle while the other side remains almost unworn, significantly shortening the overall service life.

III. Lubrication System Management: Prevent "Dry Friction" and Protect Transmission/Support Parts

1. Strictly Select Suitable Lubricating Oil and Replace It Regularly

• Choose the lubricating oil type as required by the equipment manual: For high-speed rotating parts such as the main shaft and eccentric bushing, use extreme-pressure industrial gear oil (e.g., ISO VG 320 or 460, depending on the equipment’s temperature conditions). For load-bearing parts such as the thrust bearing and spherical bearing, use lithium-based grease (e.g., Grade 2 or 3, which is high-pressure resistant and anti-aging). Mixing different grades of lubricating oil is prohibited (as it reduces the stability of the oil film).

• Establish a fixed oil change cycle: Replace lubricating oil every 2,000-2,500 operating hours (approximately 3 months of continuous operation) and replenish grease every 1,000-1,500 operating hours. Thoroughly clean the oil tank and oil pipes before oil replacement to prevent residual metal debris (e.g., iron filings from wear) in the old oil from scratching the part surfaces again.

2. Monitor Lubrication Status in Real Time to Avoid "Oil Shortage/High Temperature"

• Install oil level sensors and oil temperature alarms: Replenish oil promptly when the oil level is below the standard line (e.g., 2/3 of the oil tank volume) to prevent "dry friction due to oil shortage". When the oil temperature exceeds 60°C (normal temperature should be ≤ 55°C), check if the cooling system (e.g., cooling fan, cooling water pipe) is blocked. High temperatures reduce the viscosity of the lubricating oil, break the oil film, and drastically accelerate wear.

• Conduct oil sample testing regularly (once a month): Use professional equipment to test the iron content and moisture content in the oil. If the iron content exceeds the standard (e.g., > 100 ppm), it indicates abnormal wear of internal parts, requiring disassembly and inspection. If the moisture content exceeds the standard (e.g., > 0.1%), replace the lubricating oil immediately (moisture damages the oil film and causes part rusting).

IV. Operating and Maintenance Standards: Reduce Damage Caused by "Human Error"

1. Start-Stop Operation: Avoid "Loaded Start/Stop" and "Emergency Stop"

• Run the equipment without load for 3-5 minutes before starting to allow full circulation of the lubricating oil and formation of an oil film, then feed materials. Before stopping, stop feeding first and wait for all materials in the crushing chamber to be discharged before shutting down. "Loaded start/stop" is prohibited—loaded starting causes instantaneous impact load on parts, easily leading to bushing displacement; loaded stopping leaves materials squeezing the crushing mantle for a long time, potentially causing local deformation.

• Frequent emergency stops (e.g., more than 2 times per hour) are prohibited: Emergency stops cause inertial rotation of the eccentric bushing, damaging the lubricating film. Additionally, materials get stuck in the crushing chamber, which may cause overload when the equipment is restarted.

2. Regular Inspection: Detect "Minor Damage" in Advance

• Daily inspection (twice a week): Focus on checking for cracks or chipping on the crushing mantle and concave liner, and whether the fixing bolts (e.g., U-bolts) are loose (use a torque wrench to test the tightening torque—if it drops from the original 500 N·m to below 400 N·m, re-tighten immediately).

• In-depth inspection (once a quarter): Disassemble the equipment to inspect the gap between the main shaft cone bushing and eccentric bushing (measured with a feeler gauge; the normal gap should be ≤ 0.8mm, and replacement is required if it exceeds 1mm). Check for pitting or wear on the thrust bearing surface—if "step-like" wear occurs, replace it promptly to avoid increased axial movement.

3. Proper Installation: Ensure "Fit Degree" and "Concentricity"

• When replacing wear parts (e.g., crushing mantle, concave liner), clean impurities (e.g., residue from old liners, rust) on the fitting surface, apply "anaerobic adhesive" (e.g., Loctite 243), and then tighten the bolts to ensure tight fitting. This avoids "vibration wear" caused by poor fitting.

• When installing the main shaft and eccentric bushing, use a "dial indicator" to calibrate concentricity (the deviation should be ≤ 0.05mm). Excessive concentricity deviation causes unbalanced wear of parts, shortening their service life by more than 40%.

V. Quality Control of Wear Parts: Select "Suitable and Wear-Resistant" Components

1. Core Wear Parts: Prioritize "High-Chromium Cast Iron + Optimized Heat Treatment"

• For crushing mantles and concave liners, select high-chromium cast iron materials (e.g., Cr26, Cr28). Their hardness (HRC ≥ 58) is more than twice that of ordinary high-manganese steel (Mn13, HRC ≤ 25), and their wear-resistant service life can be extended by 50%-80%. For extremely hard materials (e.g., basalt), "bimetallic composite liners" (wear-resistant outer layer of high-chromium cast iron, impact-resistant inner layer of high-manganese steel) can be used to balance wear resistance and crack resistance.

• Inspect the heat treatment process: High-quality liners should undergo "quenching + tempering" treatment to ensure uniform hardness distribution (hardness difference between the surface and inner layer ≤ 3 HRC). Avoid purchasing liners with uneven hardness (e.g., local soft spots), as they will wear rapidly at weak points.

2. Transmission/Support Parts: Focus on "Material Toughness" and "Precision Machining"

• For main shafts, eccentric bushings, and thrust bearings, select alloy steel materials (e.g., 42CrMo) with high toughness (impact toughness ≥ 60 J/cm²) to resist impact and fatigue. Avoid using ordinary carbon steel parts, which are prone to deformation or cracking under heavy load.

• Check the machining precision: The inner/outer diameter tolerance of bushings should comply with ISO H7/f6 (close fit), and the surface roughness should be ≤ Ra 0.8 μm. Poor machining precision (e.g., rough surface, excessive tolerance) will damage the lubricating film and accelerate wear