A Comprehensive Guide to Hydrocone Crusher Parts and Spares

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Specialized Article: A Comprehensive Guide to Hydrocone Crusher Parts and Spares

An in-depth look at the types of parts, materials, maintenance principles, and increasing the lifespan of parts in cone crushers.

Introduction

The Hydrocone Crusher is one of the most widely used types of cone crushers in the mining and road construction industries, used for crushing high-hardness minerals in the secondary and tertiary stages. This machine, utilizing an advanced hydraulic system, is capable of precise adjustment of the discharge opening and rapid removal of uncrushable materials.

Due to exposure to severe pressure and abrasion, Hydrocone parts require periodic inspection and timely replacement. A precise understanding of Hydrocone crusher parts, the alloys used, and their maintenance principles plays a vital role in increasing the machine’s lifespan, reducing repair costs, and improving production line efficiency.

In this article, we will comprehensively review the types of Hydrocone spare parts, the metallurgy of the parts, a purchasing guide, and key tips for extending the equipment’s lifespan.

Part 1: Understanding the Structure of the Hydrocone Crusher

The Hydrocone crusher consists of two main sections: the Top Shell and the Bottom Shell, which are connected by 12 steel bolts. Inside this chamber are the main crushing parts: the Mantle and the Concave.

How it Works:

The feed material enters through the openings at the top of the machine and is positioned in the space between the Concave and the Mantle. As the main shaft rotates and the Mantle moves eccentrically, the gap between the Mantle and the Concave opens and closes, subjecting the rocks to pressure and crushing them.

Part 2: Main Parts of the Hydrocone Crusher

  1. Hydrocone Mantle

    The Hydrocone Mantle is a cone-shaped part that sits on the main shaft inside the Concave and rotates around its axis. This part bears the primary responsibility for crushing rocks and is held in place by a tightening nut at the top.

    • Material: Manganese steel or Molybdenum manganese steel.
    • Weight: Approximately 400 kg.
    • Common Models: Mantle 2 and Mantle 4 are among the most frequently used types.

  2. Hydrocone Concave

    Unlike the Mantle, which has a rotational movement, the Hydrocone Concave acts as a stationary part. It is installed within the Top Shell and Bottom Shell and performs the crushing operation along with the Mantle.

    • Material: Manganese steel and Molybdenum manganese steel.
    • Role: Provides a stationary surface for rock impact.

  3. Hydrocone Top Shell

    The Hydrocone Top Shell is the upper part of the machine’s body where the Concave is installed, forming the crushing chamber. This part is made of carbon steel and is connected to the Bottom Shell by 12 bolts.

  4. Hydrocone Bottom Shell

    The Hydrocone Bottom Shell is the lower part of the machine, housing essential components like the shaft and bushings. This part is also made of cast steel.

  5. Main Shaft & Housing

    The main shaft of the Hydrocone is responsible for the crushing operation and adjusting the distance between the Mantle and Concave. This part is made of alloy steel and is subjected to very high pressures.

    The shaft housing is located inside the housing assembly and supports the main shaft. Bearings, spacers, the machine’s pulley, and the pinion gear are mounted on this component.

  6. Hydrocone Head Center

    The Hydrocone Head Center is cone-shaped and is mounted on the main shaft. This part rotates with the shaft and Mantle to perform the crushing operation and adjust the Mantle-Concave gap.

  7. Eccentric Bushing

    The Hydrocone Eccentric Bushing transmits the necessary power to the center of the crusher and is responsible for adjusting the output size and increasing efficiency. This part transfers the eccentric rotational movement to the main shaft.

    • Material: Bronze or alloy steel.

  8. Cranville & Pinion Gear

    The Cranville and Pinion gears transmit torque from the electric motor to the main shaft. These parts are made of steel alloy and play a vital role in power transmission.

  9. Hydrocone Dust Collar

    The Hydrocone Dust Collar is responsible for adjusting the cone’s height and protecting the crusher from dust ingress.

  10. Hydrocone Bowl

    The Hydrocone Bowl is made of carbon steel and has a bowl-like shape. Its function is to transmit force between the various parts of the Hydrocone crusher.

Part 3: Hydraulic and Lubrication System Parts

  1. Piston & Piston Plate

    The Hydrocone piston is a critical component in the hydraulic system, playing a significant role in controlling electrical force, speed, and pressure, as well as in adjusting and discharging materials. The Piston Plate generates hydraulic pressure for the piston’s movement within the cylinder.

    • Piston Material: Alloy steel.
    • Piston Plate Material: Carbon steel.

  2. Lubrication Tank

    The lubrication tank is responsible for delivering oil to the head of the shaft, the shaft housing, bushings, and the main components of the jack. By lubricating other components, this part increases efficiency and reduces repair and maintenance costs.

  3. Hydrocone Cooler

    The Hydrocone cooler is one of the most important consumable parts, responsible for dissipating the high heat generated in the machine and preventing the control pump of the hydraulic jack from melting.

  4. Various Bushings

    Different types of bushings play a significant role in lubrication within the Hydrocone:

    • Bronze Bushing (Grooved): Made of bronze alloy with channels on its surface for oil transfer.
    • Steel Bushing.
    • Spider Bushing: Located at the upper part of the shaft and acts as a guide.
    • Step Bearing: Distributes load uniformly and reduces wear at the contact point between the body and the shaft.

Part 4: Auxiliary and Consumable Parts

  1. Bearings

    Hydrocone bearings are essential components that improve efficiency and withstand heavy impacts. These parts are installed in various locations of the machine, such as the housing and the main shaft.

  2. Hydrocone Dust Seal Ring

    The Hydrocone Dust Seal Ring is used to protect and securely hold the gears. This part is resistant to pressure and torque, ensuring balance and stability in the machine.

  3. Shaft Head Sleeve

    The Hydrocone Shaft Head Sleeve is located inside the cone and is installed on the central shaft. Its function is to reduce friction and regulate the movement of the central shaft.

  4. Housing Shell

    The Hydrocone Housing Shell is cylindrical and is responsible for protecting internal components from dust.

  5. Housing Spacer

    The Hydrocone Housing Spacer acts as a filler for the empty space between the bearing and the shaft housing.

  6. Bolts and Nuts

    Hydrocone bolts and nuts are made of steel and play the primary role in connecting various parts. Twelve of these bolts are used to connect the Top Shell and the Bottom Shell.

Part 5: Metallurgy and Material of Hydrocone Parts

The quality of Hydrocone spare parts directly depends on their material and manufacturing process.

Types of Alloys Used:

  • Manganese Steel (Hadfield): Used in Mantle, Concave – Feature: High wear resistance, high work hardening.
  • Molybdenum Manganese Steel: Used in Mantle, Concave (higher quality) – Feature: Greater wear resistance, high toughness.
  • Bronze: Used in eccentric, step, and spider bushings – Feature: Self-lubricating, wear resistance.
  • Alloy Steel: Used in the main shaft, Cranville gear – Feature: High strength, torsional resistance.
  • Carbon Steel: Used in Top Shell, Bottom Shell, Bowl – Feature: Good strength, reasonable price.
  • Cast Iron: Used in some stationary parts – Feature: High compressive strength.

Manufacturing Process:

  1. Casting: Most Hydrocone crusher parts are produced by casting.
  2. Heat Treatment: To achieve desired hardness and toughness.
  3. Precision Machining: For precise parts like shafts and bushings.

Part 6: Guide to Purchasing Hydrocone Spare Parts

Key Points in Purchasing Parts:

  • Source from Reputable Suppliers: Purchase from actual manufacturers, not intermediaries.
  • Compatibility with Crusher Model: Parts must precisely fit the Hydrocone model (e.g., 36-2, 36-4, 36-5, etc.).
  • Check Material and Alloy: Request material analysis and quality certificates.
  • Standardized Parts: Compliance with international standards.
  • Warranty and After-Sales Service: Parts must have a warranty.
  • Parts Availability: Ensure availability of frequently consumed parts.

Factors Affecting Part Prices:

  • Type of alloy and raw materials.
  • Manufacturing process (casting, machining).
  • Exchange rates and market conditions.
  • Manufacturer brand.
  • Part dimensions and weight.

Part 7: Maintenance Principles and Increasing Hydrocone Part Lifespan

Periodic Inspection:

  1. Daily Inspection: Check lubrication, machine temperature, and unusual noises.
  2. Weekly Inspection: Check bushings, bearings, and signs of wear.
  3. Monthly Inspection: Inspect the Mantle, Concave, main shaft, and potential cracks.

Lubrication System:

Excellent lubrication is a key feature of the Hydrocone machine. Bronze bushings with special channels transfer oil to both sides of the bushing, providing cooling and lubrication.

Warning Signs:

  • Increased Oil Temperature: Indicates a problem with the lubrication or cooling system.
  • Unusual Vibration: May indicate imbalance or worn bushings.
  • Unusual Noise: Indicates damaged bearings or loose parts.
  • Reduced Efficiency: Indicates excessive wear of the Mantle and Concave.
  • Oil Leaks: Indicates damaged O-rings and seals.

Golden Tips for Increasing Part Lifespan:

  1. Timely Replacement of Consumables: Before they damage main parts.
  2. Regular Lubrication: Use high-quality hydraulic oil.
  3. Precise Machine Adjustment: Adjust the Mantle-Concave gap according to the material type.
  4. Check Cooling System: Prevent overheating of the machine.
  5. Uniform Feeding: Prevent the sudden entry of very large rocks.
  6. Adhere to Rated Capacity: Avoid overloading the machine.

Part 8: Conclusion and Final Recommendations

Hydrocone Parts Management Checklist in the Mine:

  1. Identify Critical Parts: Mantle, Concave, main shaft, bushings.
  2. Strategic Inventory: Maintain at least one set of main parts in stock.
  3. Scheduled Replacement Program: Create a replacement calendar for consumable parts based on operating hours.
  4. Collaborate with Reputable Suppliers: Establish long-term relationships with manufacturers.
  5. Staff Training: Train operators and maintenance personnel for early problem detection.
  6. Monitor Lubrication System: Regularly check oil quality and temperature.

Concluding Remarks

Hydrocone crusher parts are the beating heart of aggregate production lines and mining industries. Investing in high-quality Hydrocone spare parts is not an expense, but a smart move to ensure production continuity, reduce unscheduled downtime, and increase productivity. A precise understanding of parts, their materials, and maintenance principles is the winning advantage for technical managers in today’s industrial competition.

KOBESH MACHINE – Specialized Supplier of Hydrocone Parts

With over 3 decades of experience in designing and manufacturing crushing equipment, Kobesh Machine is proud to offer various genuine Hydrocone impact crusher spare parts with the best quality and international standard alloys (Manganese Steel, Ni-Hard, High Chrome Steel, Bronze) to our customers across the country and the region.

Available Parts:

  • Hydrocone Mantle in types 2, 4, 5.5, 6.5, and 8.
  • Hydrocone Concave in various types.
  • Hydrocone Top Shell and Bottom Shell.
  • Main Shaft and Shaft Housing.
  • Head Center and Bowl.
  • Eccentric, Step, and Spider Bushings (Bronze and Steel).
  • Cranville and Pinion Gears.
  • Dust Collar and Dust Seal Ring.
  • Piston and Piston Plate.
  • Genuine Hydrocone Bearings.
  • Lubrication Tank and Cooler.
  • Pulley Bushing and Shaft Head Sleeve.

Immediate Shipping Nationwide and to Regional Countries.

Contact Us:

Alipour Brothers – Kobesh Machine

Amir Alipour: +989121943801

Yousef Alipour: +989123657790

Abdolhossein Alipour: +989126614519

Kobesh Machine – Powering Your Production.