how to assemble a cone crusher?

In the fine crushing part of mining crushing plant, the performance of the cone crusher directly affects the overall production efficiency. The installation quality of the equipment is the core factor that determines whether it can operate stably and extend its service life. The wrong installation method may cause abnormal vibration of the equipment, accelerated wear of components, and even cause safety accidents. This article will provide you with a complete set of cone crusher installation solutions from the preparatory work before installation to the installation steps of each core component, and then to the trial operation and commissioning. ​

Preparation before installation

The installation of the cone crusher is a systematic project. Whether the preliminary preparation is sufficient directly affects the quality of subsequent installation. ​

Equipment and accessories inspection

• Appearance inspection: focus on checking whether the core components such as the fixed cone, moving cone, and main shaft have bumps, deformations or cracks caused during transportation, and ensure that the key working surfaces are intact. ​
• Dimension verification: use precision tools such as calipers and micrometers to measure key dimensions such as the main shaft diameter, the inner diameter of the eccentric sleeve, and the tolerance of the bearing seat to ensure consistency with the design drawings and avoid assembly difficulties due to dimensional deviations.​
• Accessories inventory: Check the quantity and model of hydraulic cylinders, high-strength bolts, seals, lubrication pipelines and other accessories one by one against the equipment packing list. Missing or inconsistent accessories need to be replaced in time. ​

Foundation acceptance and treatment ​

• Check whether the concrete strength of the equipment foundation meets the standard (usually more than 80% of the design strength is required), and the surface flatness error of the foundation should be controlled within 5mm/m. ​
• If the anchor bolt fixing solution is adopted, the position, verticality and extension length of the embedded bolts need to be checked; if the embedded iron solution is adopted, it is necessary to ensure that the surface of the embedded iron is flat and firmly connected to the foundation. ​
• Clean up the debris, oil and slurry on the surface of the foundation, and polish the area where the chassis is installed to ensure that the contact surface is flat. ​

Tool and personnel preparation ​

• Prepare special installation tools: including level (accuracy not less than 0.02mm/m), torque wrench, hydraulic puller, heating equipment (for hot installation of bearings), lifting equipment (load-bearing capacity must meet the component weight requirements), etc.​
• Establish a professional installation team: Installers need to be familiar with the structural principles of the equipment, have relevant installation experience, and have a clear division of labor (such as hoisting command, technical debugging, record monitoring, etc.). ​

Core component installation steps:  ​

Chassis installation: ​

The chassis is the foundation that supports the entire equipment, and its levelness directly affects the dynamic balance performance of the equipment. ​

• Hoist the chassis to the specified position of the foundation, and preliminarily adjust the position so that it is aligned with the installation reference line. ​
• If anchor bolts are used for fixing, secondary grouting is required according to the foundation drawing: clean up the debris in the bolt hole before grouting, and ensure that the concrete fills the gap during grouting and vibrates and compacts it. After the strength of the grouting layer reaches more than 70%, tighten the anchor bolts. ​
• Use a level to check the levelness of the upper surface of the chassis, and adjust the gaskets (no more than 3 gaskets per group) to control the horizontal deviation within 0.1mm/m. Polish the contact area of the chassis vibration damping pad to ensure a tight fit.​

Note: The horizontality of the chassis installation is the key to avoid additional torque when the equipment is running, and it must be strictly controlled. ​

Transmission component installation:

The transmission component is responsible for transmitting the motor power to the crushing mechanism, and the installation accuracy directly affects the transmission efficiency. ​

• The bearing adopts the hot installation process: put the bearing into the heating oil tank (temperature controlled at 80-100℃) and heat it to the specified time. After taking it out, quickly put it into the specified position of the transmission shaft to ensure that the inner ring of the bearing fits tightly with the journal. ​
• After the transmission shaft is installed, use a dial indicator to check the axial movement, and its value should not exceed 0.1mm. ​
• When installing the gland and the main engine pulley, evenly apply sealant (such as Loctite 587) on the contact surface and the flat key surface to ensure reliable sealing and prevent oil leakage. ​
• The removal of the main engine pulley requires the use of a special hydraulic device. It is forbidden to use a hammer to hit it hard to avoid damaging the shaft and pulley.​

Installation of exciter components:

The exciter generates crushing force through the rotation of the eccentric block. The quality of its installation determines the crushing efficiency and equipment stability. ​

• Eccentric block assembly: The exciter includes upper and lower eccentric blocks and the middle eccentric block. There are three sets of keyways on the shaft sleeve. The life of the shaft sleeve can be extended by replacing the keyway position. According to the required crushing force, adjust the relative angle between the middle eccentric block and the upper and lower eccentric blocks. ​
• Eccentric block loading and unloading skills: Use a small angle wedge to slightly expand the opening of the eccentric block for easy loading and unloading; during installation, ensure that the long key is fully embedded in the keyway to ensure uniform force transmission. ​
• Bolt tightening requirements: Use high-strength steel structure bolts (such as grade 10.9) to lock the eccentric block, and the nut must sink into the opening groove. If an alternative bolt is used, it is necessary to ensure that the nut does not rotate 90° after sinking, and weld a thin iron plate limiter if necessary. After tightening the nut until the two planes at the opening are parallel, tighten it again by 15-30° with a 1-meter-long force rod, apply pre-tightening force and lock the nut. ​
• Installation of locking plate: After installing the locking plate, if there is a gap between the locking plate and the upper surface of the keyway of the shaft sleeve, a thin iron plate can be used to compensate, and then the fixing bolts can be tightened to prevent loosening. ​

Assembly of exciter and dynamic cone support:

The matching accuracy of the dynamic cone support and the exciter affects the force distribution of the equipment. ​

• Spherical bearing scraping: In conjunction with the dynamic cone support steel bearing, scrape the auxiliary bearing spherical bearing to ensure that there are 10-15 contact points in every 25mm×25mm area of the outer ring of the spherical bearing, and retain a small amount of annular gap in the inner ring to ensure lubrication and heat dissipation. ​
• Assembly process: Lay the exciter flat on the ground, place the dynamic cone support, insert the flange, cone sleeve and retaining ring, and ensure that the retaining ring is completely embedded in the keyway of the shaft sleeve and the step of the cone sleeve. Slowly lift the dynamic cone support, tighten the 8 bolts on the flange symmetrically one by one (tighten in 3-4 times, tighten 1/3 torque each time), and finally lock the bolts in pairs with wire. ​

Installation of dynamic cone components:

The dynamic cone is a component that directly contacts the material, and pollution and damage should be avoided during installation. ​

• Surface treatment: remove the protective oil layer on the main shaft, spherical surface and conical surface, apply yellow dry oil on the main shaft surface to prevent rust, and apply thin oil (such as No. 32 mechanical oil) on the spherical surface and conical surface for easy assembly. ​
• Moving cone liner installation: weld symmetrical lifting rings on the outer surface of the dynamic cone liner, hoist the liner to the dynamic cone, and install the small liner, gasket and left-handed cap nut in turn. Use a special wrench and a sledgehammer to tighten the nut to ensure that the liner fits tightly with the dynamic cone. Use a feeler gauge to check that the gap should be ≤0.1mm and uniform around.​
• Moving cone hoisting: Hang the hoist at the cap nut, slowly put the moving cone main shaft into the exciter sleeve, ensure that the moving cone spherical surface is in uniform contact with the spherical tile, avoid the tongue ring or the outer edge from being suspended, and prevent the sealing ring from being damaged. ​

Adjustment ring installation:

The adjustment ring is used to adjust the size of the discharge port. Its installation affects the particle size of the crushed product and the life of the fixed cone. ​

• Assembly of fixed cone liner: The fixed cone liner contacts the thread ring through the conical surface. After the fixed cone liner is placed correctly, the thread ring is placed on it, and the flange and the clamping ring are installed. The clamping ring needs to clamp the outer ring of the neck of the fixed cone liner. Tighten the flange bolts symmetrically one by one, and clamp the clamping ring to ensure that the fixed cone liner is firm and not loose. ​
• Accessory installation: Install the pressure iron, sealing ring and hopper in sequence. The sealing ring must ensure good sealing to prevent dust from entering the equipment.​

Locking mechanism installation:

The locking mechanism locks the adjustment ring through a disc spring to prevent loosening during operation. ​

• Positioning and adjustment: Determine the relative position of the locking mechanism and the support ring according to the positioning pin, and screw in the adjustment ring to the required discharge port gap (which can be measured by a feeler gauge). ​
• Hydraulic locking: Open the high-pressure pump station, adjust the pressure to 13MPa, and tighten the locking jack jack rod symmetrically one by one until it is dead. Close the pump station and remove the remaining pressure to ensure reliable locking. ​
• Important reminder: It is strictly forbidden to open the high-pressure pump when the equipment is running to avoid destroying the locking state. ​

Lubrication device installation:

The lubrication system provides lubrication for each moving part. The installation must ensure that the oil circuit is unobstructed and the pressure is stable. ​

• Pipeline layout: Install the oil tank, oil pump, filter and pipeline according to the assembly drawing. The oil pipe adopts the HG4-761-74 specification, and the oil inlet hose pressure resistance must be greater than 10MPa. The pipeline layout should be neat, avoid crossing and sharp bends, and the joints should be sealed reliably. ​
• System debugging: After installation, add the specified brand of lubricating oil (such as N320 extreme pressure gear oil) to the oil tank, start the oil pump to check whether the oil circuit is unobstructed and whether the oil volume of each lubrication point is sufficient. Debug the temperature and pressure control system to ensure that the electric contact pressure gauge, temperature gauge and electric control cabinet are linked reliably, and can automatically alarm when the oil temperature exceeds 60℃ or the pressure is lower than 0.2MPa. ​

Trial operation and debugging:

No-load trial operation ​

• Check before trial operation: Confirm that all bolts are tightened, the lubrication system works normally, the motor turns correctly, and the safety cover is installed in place. ​
• Operation requirements: No-load operation time is not less than 2 hours, check whether there is any abnormal sound in each component during operation, the bearing temperature rise does not exceed 40℃ (above ambient temperature), and the vibration intensity is ≤1.8mm/s.​

Load test run​

• Gradually add material: first add a small amount of material, observe the crushing situation, and gradually increase to the rated load after the equipment runs stably. The load test run time is not less than 4 hours. ​
• Parameter monitoring: record parameters such as discharge particle size, motor current, bearing temperature, etc. to ensure that the discharge particle size meets the requirements, the current is stable within the rated range, and the bearing temperature does not exceed 70℃. ​
• Adjustment and optimization: If the discharge particle size is unqualified, fine-tune the discharge port through the adjustment ring; if abnormal vibration or sound occurs, stop the machine immediately for inspection, and continue to operate after troubleshooting. ​

Precautions and maintenance suggestions after installation​

• After the installation is completed, clean up the debris on site, organize the installation records and debugging data, and archive them for reference. ​
• Regularly check the tightening of the bolts of each component, especially the bolts of the force-bearing parts such as the vibrator and the moving cone to prevent loosening. ​
• Regularly replace the lubricating oil according to the requirements of the equipment manual, keep the lubrication system clean, and avoid oil contamination and component wear.​
• During daily operation, pay close attention to the operating status of the equipment, and stop the machine in time to deal with abnormalities to avoid small faults from expanding into big problems. ​

The installation of cone crusher is a delicate work, and every link must strictly follow the specifications. Correct installation can not only ensure the efficient operation of the equipment, but also significantly extend its service life. If you encounter special problems during the installation process, please share them in the message area, and we will provide you with professional answers.