Sandvik H6800 Dust Seal Figure 1

Sandvik H6800 Dust Seal Improvement

One of our customer import two sets of  Sandvik H6800 cone crushers in the 2015 year. After using the new cone crusher, the crushing efficiency has been greatly improved and the production capacity has been further improved. However, there are still some problems need to solve. Such as the dust seal problem: After several years of use, it was found that the dust seal of the H6800 single-cylinder hydraulic cone crusher wears faster and consumes more. Each crusher needs to replace about 4 dust seals per year, worth about 140,000 yuan, and the equipment has high operating costs.

Cause Analysis

The dust seal is supported under the moving cone, and the dust cover can move and slide freely, as shown in Figure 1.

Sandvik H6800 Dust Seal Figure 1

  • 1.Dust seal     2.Gear ring     3.Support ring    4.Rubber scraper     5.Dust cover

Due to the relative movement between the dust seal and the dust cover, the wear is faster. After about 3 to 4 months, the gap between the dust seal and the dust cover exceeds the allowable clearance and must be replaced.

Improvement

Aiming at the problem of large wear of the dust seal, a comprehensive analysis was carried out, and corresponding transformation and utilization were carried out.

  • To measure the dust seal that needs to be replaced with excessive wear, find a groove with a width of 8 mm and a depth of 7.8 mm on the inner working surface, see Figure 2.
  • Insert a rubber ring of φ 8.5 mm in this groove, and press and connect the joint.
  • After inserting the rubber ring, clean the burrs of the groove and press the rubber ring. Be careful not to let the rubber ring undulate when lifting.

Sandvik H6800 Dust Seal Figure 2

Notices

  • Always check for leaks during operation and replace the rubber ring regularly. The rubber ring is usually replaced periodically when the moving cone liner is replaced.
  • Pay attention to the wear of the dust ring. If the wear is large, replace the dust seal. Replace approximately one dust seal per year.

The Result

The modification of the dust seal of the Sandvik H6800 crusher can effectively prevent dust and dirt from entering the broken lubrication system, which can meet the requirements of equipment operation, and only use one dust seal per year, which can save 105,000 yuan than before the transformation.

 

 

 

Nordberg GP300 Top Bearing Seal Structure

Nordberg GP300 Top Bearing Seal Structure Improvement

One of our customers started to use Nordberg GP300 cone crusher since the 2004 year. The machine has the characteristics of large processing capacity, simple operation, convenient maintenance, and high automation. However, after several years of use, some problems have arisen, requiring frequent maintenance and replacement of parts, which not only wastes a lot of labor and material resources, but also requires the entire production system to be shut down, which affects normal production.

The Problems

The feed plate of the GP300 cone crusher and the upper frame are fixed by four M20 screws with O-rings for sealing the end faces between the end faces. Check the following picture:

Nordberg GP300 Top Bearing Seal Structure

  • 1. Feed Plate       2.4- M20 Screws       3.O-rings      4.The Upper Frame       5. The Upper Bushing    6.Mainshaft

The fixing of the upper frame and the distribution plate of the GP300 cone crusher is unreasonable. Under the vibration of the ore impact and the crushed ore of the equipment, the bolts are subjected to large force, which is easy to loose or even sheared, resulting in the separation of the ore. The disc and the rack are loose and create a gap. The O-ring seal loses its sealing effect, and mud, slurry and dust enter the upper cavity through the gap (the grease is stored in the cavity), causing rapid wear of the upper shaft (with the jacket) and the upper bearing. The separation disc is located in the feeding chamber of the crusher. It is difficult to find that the distribution disc is loose when the equipment is running, so it cannot be processed in time.
When the wear reaches the limit, the equipment vibrates greatly, the upper part of the main shaft is not effectively supported, and the crushing capacity is greatly reduced. The equipment has to be shut down for repair; when the wear exceeds the limit, the large axial force generated by the crushing causes the main shaft to tilt too much, crushing the eccentricity The upper part of the copper sleeve causes the copper sleeve of the frame to rupture. In recent years, an average of one upper bearing needs to be replaced every month. Every two months, the upper bearing housing and the parts such as the separation plate need to be replaced. In less than one year, the eccentric copper sleeve and the frame copper sleeve need to be replaced.
After a series of accessories such as the upper bearing are worn, the moving cone is excessively vibrated, causing the matching cone surface of the upper frame and the lower frame to wear.

Improvement Measures

The mine has improved the bearing seal structure of the cone crusher, as shown in Figure 2. Machining 1 piece of M440×8 mm×55 mm left-hand locking sleeve and welding on the upper frame. The left-hand locking sleeve and the moving cone rotate in opposite directions. Only the locking will not loosen during operation. A sealing groove is formed on the upper surface of the locking sleeve, and the oil hole is opened on the side for lubrication. Install a lock nut on the lock sleeve and tighten to fix the splitter disc. Even if the splitter disc is loose, the slurry will not enter the grease chamber at the top of the spindle.

Figure 2

  • 1. Feed Plate       2.4- M20 Screws       3.O-rings      4.The Upper Frame       5. The Upper Bushing    6.Mainshaft

After the improvement, the vibration of the equipment is reduced, the wear caused by the vibration of the upper and lower frames is reduced, and the local axial pressure of the moving cone to the eccentric copper sleeve and the copper sleeve of the frame is also reduced, and the crusher is operated more. It is stable and avoids cracking of the eccentric copper sleeve and the frame copper sleeve.

The Result

The mine improved the top bearing seal structure of the GP300 cone crusher in November 2009. The equipment has been operating normally, and the parts have not been replaced, saving a lot of maintenance time and achieving good economic benefits. 1 year can save 10 pieces of upper bearing, totaling 50,000 yuan; 4 bearing blocks, totaling 20,000 yuan; 3 pieces of main shaft sheath, totaling 15,000 yuan; 4 pieces of mining plate, totaling 20,000 yuan; eccentric copper sleeve 1 A total of 90,000 yuan; a rack of copper sleeves, a total of 110,000 yuan. The total cost savings is 315,000 yuan. The improvement of the sealing system is only 28,000 yuan.

 

 

Change Cone Crusher Liner

When And How To Change Cone Crusher Liner?

When Need To Change Cone Crusher Liner?

Cone crusher liner needs to be changed well before they are cracked, broken, loose, or have holes in them! If cone crusher liner pushed too long can and will lead to mechanical many problems with the Crusher:

  • A thinning mantle and thinning bowl liner will flex.
  • Flexing liners will crack out the backing material.
  • Continued flexing will “powder out” the backing material.
  • The flexing deteriorates the head and bowl seating surfaces.
  • The seating surfaces eventually will need reconditioning as liners will no longer stay tight.

In our experience that too many people lean towards too late, the optimum time to change a liner really depends on how much money you are prepared to lose to production losses to get the maximum use out of a wear component.

The first condition that is optimum is that the liner change happens when you planned it. This gives you the opportunity to have all of the required parts on-hand before starting. This also allows you to perform other maintenance work on other equipment when the change is being conducted. These days it’s tough to get screen media and manganese on a moment’s notice and you will need to plan things if you need to rent a crane.

The second condition is changing the liner before you start to suffer significant production losses. 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 30% of feed size. This is less of an issue with hydrocodones as the feed size remains constant throughout the life of the manganese.

You should have a pretty good idea when you will need to change manganese and 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.

What is the threshold for a liner change? We believe the maximum threshold for a liner change is as follows: Change your liners no later than a 10% decline in production.

Also, there are some other notices:

  • Change the cone crusher liner sat the same time each time by watching the adjustment cap height. Some customers measure the distance between the underside of the adjustment cap and the top of the adjustment ring. This creates a reference point for the next liner change. Such as Nordberg GP series cone crusher, When the dimension is 10mm-15mm, the GP cone crusher liner needs change.
  • Change the cone crusher liner at the same time each time by watching the total number of crushing hours on the liners. Some customers watch and record the total number of crushing hours on a set of liners. Once established, this creates a benchmark for the next set of liners. Such as Nordberg MP series cone crusher, most of the original crusher liners can work around 755 hours.
  • Change the cone crusher liner at the same time each time by watching the total tons of material that passed through the set of liners. Some customers watch and record the total tons of feed material that passed through the liners. Once established, this creates a benchmark for the next set of liners.
  • Change the cone crusher liner at the same time by watching for a reduction in throughput caused by the closing off of the liners feed opening.The volumetric area of the liner decreases late in liner life as the feed opening closes off. This results in lower throughput and a substantial loss in salable product. An excellent time to change liners is when a 10% loss of product is noticed.

How To Change Cone Crusher Liner?

  • On the initial set of new liners, place a mark on the adjustment cap driver ring where the pinion tooth makes contact with a driver ring tooth when the target crusher setting has been achieved.
  • Keep an accurate record of the number of teeth used to compensate for liner wear on this set of liners.
  • After the initial set of liners have worn out, but before moving the bowl, record the total number of teeth the driver ring has moved and also paint a horizontal liner on the side of the dust shell just below the bottom of the adjustment cap. This will be the baseline for determining how close the next liner sets are to being worn out.
  • When a new liner set has been installed, keep a record of the number of teeth the driver ring has moved and compared this number to the total number from the initial set of liners. This will give an estimation of the liner wear. The horizontal mark painted on the dust shell will also be indicated when the liners are approaching the wear limit. The approximate minimum heights of the adjustment cap (A-dimension) with worn liners are listed in the attached tables.

When changing liners and determining liner wear, follow the instructions in the related cone crusher instruction manual.

Extend Crusher Liner Life

Extend Crusher Liner Life Tips

There are some tips to extend crusher liner life:

1. When changing the new crusher liners, you need following these steps

  • Operate 50% rated power (65% amps) with a full cavity for 6 hours.
  • Operate 75% rated power (80% amps) with a full cavity for 2 hours.
  • Operate at or near 100% rated power (100% amps) from this point on.
  • The Crusher normally operates near full power draw
  • Increasing the Crusher setting in order to operate at the lighter power levels does not affect the crushing circuit.

2. Limit the quantity of water used to control dust!

  • Many times water is used above the Crusher to control dust.
  • Too much water can cause fines to be washed down the face of the mantle which can cause premature liner wear.

3. Keep a material load on the Crusher all day!

  • When feed enters the crushing cavity, it rubs against the fast-moving mantle and if done frequently throughout the day (switching from load to no load), it may prevent the liners from work hardening properly.
  • Liners will work harden and get tougher if you can maintain a steady feed rate to the crusher all day long.

4. Change New Material Crusher Liner, Such as the TIC Insert Cone Crusher Parts

When changing to TIC insert cone liner and bowl liner, the span life can be 2-3 times than normal manganese cone liner and bowl liner. Titanium carbide (TiC) cone crusher wear parts are designed to increase the wear life of wear parts in abrasive environments. Titanium carbide columns are cast within proprietary alloys for added strength and durability.

 

Nordberg MP Series Cone Wear Parts Selection Guide

Nordberg MP Series Cone Wear Parts Selection Guide

The Nordberg MP Cone crusher is a compressive crusher in which feed material is crushed between a fixed bowl liner and a moveable mantle. Bigger rock particles are crushed directly between the surfaces of the mantle and bowl liner. This is called single layer crushing. Smaller rock particles are crushed between other rock particles, which is termed multi-layer crushing or inter-particle comminution. Multi-layer crush-ing plays a significant role in the MP cavity. This improves the reduction through the crusher and end product shape.

Each MP Cone Crusher has sever-al cavity options with different feed openings and setting ranges. The correct cavity can be selected based on the feed size, setting, and application. Standard liners are typically used in secondary applications. Secondary applications don’t necessarily need to be operated in the closed circuit, but preferably choke fed. Short head liners are used in tertiary or quaternary stage applications for fine crushing and may be in closed circuit returning to the crusher. Liners are manufactured from XT510,XT515, XT520, XT525, XT710, XT750 or XT770 material depending on the application and material characteristics.

Nordberg MP Series Cavities Selection

Part Number Description Crusher Type Weight
1048315201 BOWL LINER STANDARD MEDIUM MP800 4,132.000
1048315250 BOWL LINER SHORT HEAD – FINE MP800 3,908.000
1048315255 BOWL LINER SHORT HEAD – MEDIUM MP800 4,451.000
1050143900 MANTLE STANDARD MP800 4,347.000
1050143950 MANTLE SHORT HEAD MP800 4,987.000
1050143953 MANTLE SHORT HEAD MEDIUM INTERMEDIATE MP800 4,700.000
10P1018901 BOWL LINER MODIFIED, SH HD MEDIUM MP800 4,414.000
MM0314033 BOWL LINER SHORT HEAD COARSE MP800 3,561.000
1048315559 BOWL LINER STANDARD MP1250 6234
MM0366360 MANTLE STANDARD MP1250 5383

Terex Cone Wear Parts Selection Guide

CCP offers all Terex Cone Wear Parts profiles, it includes kinds of materials cone liners and bowl liners.  Ask our experts for advice on the correct Terex cone liners and bowl liners for your specific application to help maximize your productivity and wear life.  Our range of crusher cone liners and bowl liners ranges from the smaller Terex C1540 cone liners up to the huge Terex C1554 cone crusher. CCP also offers a variety of manganese contents, from 14% up to 22% and Tic insert jaw plates for the more demanding applications.

Different cavities need different kinds of cone liner and bowl liner to suit. There are some cavities: Auto sand chamber, Fine chamber, Medium Coarse chamber, Coarse chamber, Extra Coarse chamber, and Heavy Duty Chamber.

Auto Sand Chamber

Auto Sand Chamber

Coarse Chamber

Coarse Chamber

Extra Coarse Chamber

Extra Coarse Chamber

Heavy Duty Chamber

Heavy Duty Chamber

Medium Coarse Chamber

Medium Coarse Chamber

Terex Cone Wear Parts’ Part Number

Terex C1540 Cone Crusher Parts
Material Description Medium Coarse Coarse Extra Coarse Fine Auto Sand Heavy Duty
Mn18Cr2 Mantle 31.12.0252 31.12.0252 31.12.0252 N.A 31.12.0252 603/9273E
Concave 31.12.0316 31.12.0315 603/9053E N.A 31.12.0317 603/9274E
Mn22Cr2 Mantle 31.12.0355 N.A 31.12.0355 N.A 31.12.0355 603/9273TT
Concave 31.12.035B N.A 603/9053TT N.A 603/9071TT 603/9274TT
Terex C1545 Cone Crusher Parts
Mn18Cr2 Mantle CW023-006-MN180 N.A CW023-006-MN180 CW023-006-MN180 N.A CW023-007-MN180
Concave CW023-003-MN180 N.A CW023-005-MN180 CW023-002-MN180 N.A CW023-008-MN180
Mn22Cr2 Mantle CW023-006-MN220 N.A CW023-006-MN220 CW023-006-MN220 N.A CW023-007-MN220
Concave CW023-003-MN220 N.A CW023-005-MN220 CW023-002-MN220 N.A CW023-008-MN220
Terex C1550 Cone Crusher Parts
Mn18Cr2 Mantle 603/1508E N.A N.A N.A 603/1508E 603/1617E
Concave 603/1416E N.A N.A N.A 603/1407E 603/1618E
Mn22Cr2 Mantle 603/1508TT N.A N.A N.A 603/1508TT 603/1617TT
Concave 603/1416TT N.A N.A N.A 603/1407TT 603/1618TT
Terex C1554 Cone Crusher Parts
Mn18Cr2 Mantle 054003002001E 054003002001E 054003002001E 054003002001E 054003002001E N.A
Concave 0540030015E 0540030016E 0540030018E 0540030018E 0540030019E N.A
Mn22Cr2 Mantle 054003002001TT 054003002001TT 054003002001TT N.A N.A N.A
Concave 0540030015TT 0540030016TT 0540030017TT N.A N.A N.A