Cone crusher common 9 kinds of faults and solutions

1. Why Does My Cone Crusher Keep Overloading or Stalling?

An overload situation stops your crusher and production. What usually leads to this disruptive cone crusher fault?

Frequent cone crusher overloads are often caused by feeding oversized material, an excessive feed rate, a discharge setting (CSS) that’s too tight for the conditions, or worn liners changing the crushing chamber volume.

An overload occurs when the crushing force required exceeds the crusher’s design limits or motor capacity. Understanding the specific cause is crucial for resolving this cone crusher fault.

Deeper Dive into Overload Causes and Solutions:

• Oversized Feed: Check the upstream screening process. Ensure the top size of the material entering the cone crusher is within the manufacturer’s recommended limit for that specific machine and liner configuration. Worn screen media on your Vibrating Screen could be letting oversized particles through.
• Excessive Feed Rate: The crusher needs time to process material. Too much material entering too quickly overwhelms the chamber. Adjust the feed rate from the upstream feeder (like a belt feeder or vibrating feeder) to match the crusher’s capacity. Aim for a steady, controlled “choke feed” condition where the crushing chamber is kept full, but not overloaded.
• Closed Side Setting (CSS) Too Tight: The CSS determines the minimum gap between the mantle and concave. If it’s set too small for the feed size or type, the crusher will struggle and may overload. Verify the CSS using a lead slug test or the crusher’s hydraulic system calibration, and adjust it according to operational requirements and manufacturer guidelines.
• Worn Liners: As the mantle and concave wear, the chamber volume increases, and the crusher’s ability to nip and break rock changes. Paradoxically, sometimes specific wear patterns can decrease the effective volume or lead to packing, increasing overload risk. Regularly inspect wear liners and replace them when they reach the end of their service life. Using high-quality ZONEDING replacement liners ensures proper fit and performance.
• Tramp Material: Uncrushable objects like metal (excavator teeth, bolts) entering the crusher can cause sudden stalls and severe damage. Ensure upstream magnets and metal detectors are functioning correctly.

2. What Causes the Head or Bowl to Spin Uncontrollably on a Cone Crusher?

Seeing the head or bowl spin without effectively crushing rock is a clear sign of trouble. What triggers this specific cone crusher fault?

A spinning head or bowl on a cone crusher usually indicates insufficient crushing force being applied, often due to low or intermittent feed rate, feed segregation (too many fines), or an excessively large closed side setting (CSS).

This cone crusher fault, sometimes called “idling,” means there isn’t enough resistance from the rock feed to keep the head assembly firmly engaged against the eccentric drive mechanism.

Addressing the Spinning Head/Bowl Issue:

• Insufficient Feed (Lack of Choke Feed): The cone crusher operates most efficiently and stably under choke feed conditions, where the crushing chamber is consistently full. A low or intermittent feed rate means the head isn’t constantly pushing against material, allowing it to spin freely with the eccentric motion instead of gyrating against the rock. Ensure a steady, adequate feed rate from the upstream equipment.
• Feed Segregation: If the feed material entering the crusher is segregated (e.g., fines accumulating on one side, coarse on the other), it creates uneven crushing pressure. Pockets of fines offer little resistance, contributing to spinning. Improve feed distribution into the crusher opening, perhaps by adjusting the feed box or trajectory from the feed conveyor.
• Closed Side Setting (CSS) Too Large: If the gap between the mantle and concave is too wide for the feed size, the rock pieces may not be properly nipped and held for crushing. This lack of engagement reduces resistance. Verify and adjust the CSS to a setting appropriate for the feed material and desired product size.
• Incorrect Liner Profile: Using a mantle and concave liner combination not suited for the application or feed type can sometimes lead to poor nipping and contribute to spinning. Consult ZONEDING for the optimal liner selection for your specific needs.

3. Why is My Cone Crusher Oil Temperature Running Too High?

Overheating lubrication oil is a serious cone crusher fault that can lead to bearing failure. What are the common culprits?

High cone crusher oil temperature often results from problems with the cooling system (dirty cooler, low coolant flow/airflow), incorrect oil type or viscosity, internal friction from failing components (like bearings), or very high ambient operating temperatures.

The lubrication system is vital for protecting the internal bearings and gears. Addressing high oil temperature promptly prevents catastrophic failure.

Troubleshooting High Oil Temperature:

• Cooling System Issues: This is the most frequent cause.
  • Air Coolers: Check if the cooler fins are blocked by dust or debris. Clean them thoroughly. Ensure the cooling fan is operating correctly (correct speed, blades intact, airflow direction).
  • Water Coolers: Verify adequate water flow rate and ensure the inlet water temperature is within specifications. Check for scale buildup or blockages inside the cooler tubes. Clean or descale as needed.
• Incorrect Oil: Using oil with the wrong viscosity grade for the ambient temperature or operating conditions can lead to overheating. Too thin, and it doesn’t provide adequate film strength; too thick, and it creates excess drag and heat. Confirm you are using the oil type and grade recommended by the manufacturer (like ZONEDING) for your specific model and climate.
• Internal Friction: Worn or failing bearings (main shaft, eccentric, countershaft) or damaged gears can generate excess heat, which transfers to the oil. If cooling and oil type are correct, suspect internal mechanical issues. This may require inspection during scheduled maintenance or based on vibration analysis.
• High Ambient Temperature: In very hot climates, the standard cooling system might struggle. Consider options like larger coolers, supplemental cooling, or using a higher viscosity grade oil if recommended by the manufacturer.
• Low Oil Level: While less common for high temperature (more often causing low pressure), a critically low oil level reduces the volume available for heat dissipation. Always maintain the correct oil level.

4. What Should I Do If My Cone Crusher Has Low Oil Pressure?

Steps to Address Low Oil Pressure:

1. STOP THE CRUSHER IMMEDIATELY: Prevent catastrophic damage.
2. Check Oil Level: Verify the oil level in the reservoir is within the operating range. Top up if necessary with the correct grade of oil.
3. Check for Leaks: Inspect the crusher base, lubrication lines, filter housings, and cooler for any signs of oil leakage. Repair any leaks found.
4. Verify Oil Viscosity: Ensure the correct oil type and viscosity grade are being used, especially considering ambient temperature changes. Oil that is too thin (e.g., wrong grade or diluted by fuel/coolant) can cause low pressure.
5. Inspect Filters and Strainers: A clogged suction strainer or main filter can restrict oil flow to the pump, causing low pressure. Check and clean/replace filters as part of routine maintenance. A suddenly clogged filter might indicate an internal component failure shedding debris.
6. Check Oil Pump: The oil pump itself might be worn or damaged, reducing its efficiency. Check pump pressure output directly (if possible) or inspect the pump drive (coupling, motor). Consider pump replacement if wear is suspected.
7. Check Pressure Relief Valve: A malfunctioning pressure relief valve stuck partially open can bleed off pressure. Inspect and service the valve.
8. Bearing Clearances: As bearings wear over time, clearances increase. This can lead to lower oil pressure as more oil escapes through the larger gaps. This usually happens gradually and requires internal inspection.

5. How Can I Reduce Excessive Wear on Cone Crusher Liners (Mantle/Concave)?

Replacing mantle and concave liners is a significant operating cost. What causes them to wear out too quickly, and how can you extend their life?

Excessive wear on cone crusher liners is often due to highly abrasive feed material, improper feed distribution, selecting the wrong liner profile for the application, operating outside optimal choke feed conditions, or an incorrect CSS.

While wear is inevitable, managing it effectively reduces costs and maintains crusher performance. Understanding the wear pattern is key to diagnosing this cone crusher fault.

Strategies to Minimize Liner Wear:

• Optimize Feed Distribution: Uneven feed distribution causes localized wear on one side of the chamber. Ensure material enters the crusher centrally and evenly. Use appropriate feed box designs or rotating distributors if necessary.
• Maintain Choke Feed: Operating under consistent choke feed ensures crushing occurs throughout the chamber, utilizing the entire liner surface and promoting rock-on-rock crushing, which can reduce direct liner abrasion. Avoid trickle feeding.
• Select Correct Liner Profile: Different liner profiles (mantle and concave combinations) create different crushing chamber shapes (e.g., fine, medium, coarse, extra coarse). Using a profile designed for your feed size, reduction ratio, and product requirements is crucial. An incorrect profile can lead to poor nipping, excessive scrubbing, and rapid wear. Consult ZONEDING for recommendations.
• Use Quality Liners: The material composition (e.g., manganese steel content and hardening process) significantly impacts wear life. Use high-quality replacement liners from reputable suppliers like ZONEDING, designed for your specific crusher model.
• Verify CSS: Operating at a CSS that is too small can sometimes increase abrasive wear due to excessive compaction and scrubbing. Ensure the CSS is appropriate for the liner profile and application.
• Manage Feed Abrasiveness: While often uncontrollable, be aware if your feed material is particularly abrasive (e.g., high silica content). This will inherently lead to faster wear, making other optimization strategies even more important.

6. Where Do Oil Leaks Commonly Occur on Cone Crushers and How to Fix Them?

Oil spots under your crusher are messy and can lead to low oil levels. Identifying the source is the first step in fixing this common cone crusher fault.

Common cone crusher oil leak points include dynamic seals (like the pinion shaft seal, countershaft box seal, main shaft seals near the dust collar), static seals (filter housings, inspection covers), hydraulic adjustment/clamping cylinder seals, and pipe fittings or hoses.

Addressing leaks promptly prevents oil loss, contamination ingress, and potential environmental issues.

Finding and Fixing Oil Leaks:

1. Clean the Area: Thoroughly clean the suspected leak area to pinpoint the exact source. Oil can travel, making a dirty machine hard to diagnose.
2. Identify the Source:
   • Shaft Seals: Look for oil around the pinion shaft where it enters the eccentric assembly or around the main shaft base (dust seal area). These rotating seals wear over time.
   • Static Seals/Gaskets: Check covers, filter housings, and connection points for weeping or dripping. Bolts may need tightening, or gaskets/O-rings may need replacement.
   • Hydraulic System: Inspect hydraulic cylinders (tramp release, adjustment, clamping) for leaks around rod seals or hose connections.
   • Fittings and Hoses: Check all lubrication and hydraulic line connections for tightness and hose condition. Vibration can loosen fittings over time.
3. Implement the Fix:
   • Tighten Fittings: Often, a loose fitting is the culprit. Tighten carefully to the correct torque.
   • Replace Seals/Gaskets: Worn seals, O-rings, or gaskets require replacement. This might involve some disassembly. Ensure correct part numbers and proper installation. Check shaft surfaces for grooves or damage that could compromise the new seal.
   • Replace Hoses: Damaged or aged hydraulic hoses should be replaced.
4. Monitor: After repair, monitor the area to ensure the leak has stopped.

7. What Causes Excessive Vibration or Noise in a Cone Crusher?

While crushers are inherently noisy, a sudden increase or change in vibration or noise level indicates a potential cone crusher fault.

Excessive cone crusher vibration or noise can stem from loose mounting bolts, an unbalanced rotating assembly (mantle/head, often due to uneven wear or incorrect installation), worn bearings, damaged gears, or structural issues like cracks.

Investigating unusual vibration or noise is crucial for preventing major mechanical failures.

Diagnosing Vibration and Noise Issues:

• Check Mounting: Ensure all foundation bolts and crusher assembly bolts are tightened to the correct torque specifications. Loose components are a common source of vibration.
• Inspect Rotating Assembly Balance: The main head/mantle assembly must be balanced. Uneven wear on liners, incorrect backing material application, or improper installation can cause imbalance. Sometimes, balance weights on the countershaft assembly may need checking.
• Check Bearings: Worn or damaged bearings (main shaft, eccentric, countershaft) are a primary cause of increased vibration and noise. Regular lubrication analysis and vibration monitoring can help detect bearing issues early. Bearing failure often produces a distinct rumbling or grinding noise.
• Inspect Gears: Damage to the main drive gear and pinion (e.g., chipped teeth, excessive wear, incorrect backlash) can cause loud clanking or grinding noises and vibration. Check gear mesh and condition during maintenance shutdowns.
• Look for Structural Damage: In rare cases, cracks in the main frame, bowl, or adjustment ring can cause vibration. Perform visual inspections, especially around welds and high-stress areas.
• Check Drive System: Issues with the drive motor bearings or V-belt drive (slipping, damaged belts) can also transmit vibration.

8. Why Does Material Bridge or Block the Feed Opening of My Cone Crusher?

Material flow stopping at the crusher inlet severely impacts production. What causes this frustrating cone crusher fault?

Material bridging or blocking a cone crusher feed opening typically occurs when oversized rocks lodge in the opening, or when sticky/clay-like material compacts and refuses to flow into the crushing chamber.

Preventing blockages ensures continuous operation and avoids potentially hazardous manual clearing procedures.

Solutions for Feed Bridging/Blocking:

• Control Feed Top Size: The most common cause is rock pieces larger than the crusher’s recommended feed opening (gape). Improve upstream primary crushing and screening to eliminate oversized material before it reaches the cone. Ensure screen apertures are correct and not blinded or damaged.
• Manage Sticky Material: Wet, clay-like, or sticky feed can compact easily, especially in tapered feed chutes or the upper part of the crusher chamber.
  • Improve Feed Flow: Ensure feed chutes have steep enough angles and possibly low-friction liners. Avoid designs where material impacts directly onto flat surfaces.
  • Control Moisture: If possible, manage the moisture content of the feed. Blending with drier material might help.
  • Scalping Screen: Using a scalping screen before the crusher can remove sticky fines that often contribute to bridging.
• Rock Breaker: Installing a hydraulic rock breaker near the crusher feed opening allows operators to safely break oversized rocks or dislodge blockages without stopping the entire plant. Use with care to avoid damaging the crusher.
• Proper Feed Chute Design: Ensure the chute delivering material into the crusher promotes central feeding and doesn’t encourage segregation or hang-ups.

9. Why is My Cone Crusher Producing the Wrong Product Size?

If your crushed product doesn’t meet size specifications, it can cause problems downstream or fail quality control. What leads to this cone crusher fault?

Incorrect product size from a cone crusher is usually due to an improperly set or drifting Closed Side Setting (CSS), worn liners significantly changing the chamber profile, inconsistent feed conditions (non-choke feed), or operating at the incorrect crusher speed.

Consistently achieving the target product gradation is essential for meeting customer requirements and optimizing downstream processes like screening or milling.

Correcting Product Size Issues:

• Verify and Adjust CSS: The Closed Side Setting is the primary control for product size. Regularly measure the CSS using appropriate methods (lead slug, electronic sensor, calibrated hydraulics) and adjust as needed. Remember that the CSS can drift during operation due to liner wear or hydraulic system changes.
• Account for Liner Wear: As liners wear, the crushing chamber volume and geometry change, which directly impacts the product size distribution (gradation). You may need to progressively tighten the CSS as liners wear to maintain a consistent product size. A severely worn or incorrect liner profile makes consistent sizing difficult. Replace worn liners.
• Maintain Consistent Feed: Operating under choke feed conditions generally leads to a more consistent product size and shape. Fluctuating or low feed levels can increase the proportion of coarser particles.
• Check Crusher Speed: Cone crushers are designed to operate at a specific countershaft speed. Running too fast or too slow can affect the crushing action and product gradation. Verify the speed is correct according to the manufacturer’s specifications. Check V-belt tension and condition.
• Review Downstream Screening: Ensure the screens separating the final product sizes are functioning correctly with intact screen media and proper tension. Sometimes perceived crusher problems are actually screening issues.

Common Questions about Cone Crusher Faults

Question 1: How often should I perform maintenance checks to prevent these faults?

Regular preventative maintenance is key. Daily checks (visual inspection, listening for odd noises, checking lube temps/pressures), weekly checks (bolt tightness, liner inspection), and major inspections during liner changes or annually are recommended. Follow the ZONEDING maintenance schedule for your specific model.

Question 2: What exactly is the Closed Side Setting (CSS)?

The CSS is the minimum gap between the mantle and the concave liners at the bottom of the crushing chamber, measured when the mantle is at its closest point to the concave during its gyration. It’s the primary adjustment for controlling crusher product size.

Question 3: How critical is the lubrication oil quality for cone crusher health?

Extremely critical. The correct type, grade, cleanliness, and quantity of lubricating oil protect vital components like bearings and gears from extreme pressures and heat. Regular oil analysis can detect potential problems like contamination or component wear before they cause major cone crusher faults.

Question 4: Can I weld worn cone crusher liners (mantle/concave)?

Generally, welding manganese steel liners is not recommended. It can alter the material properties, lead to cracking, and potentially cause catastrophic failure. It’s safer and ultimately more cost-effective to replace worn liners with high-quality replacements from ZONEDING.

Question 5: What should I do if I can’t diagnose a cone crusher fault myself?

If you’ve gone through basic troubleshooting and the problem persists, or if you suspect a major internal issue, it’s best to contact the manufacturer or a qualified service technician. ZONEDING offers expert support. Contact us for assistance.

Conclusion

Understanding these 9 common cone crusher faults allows you to react quickly, minimize downtime, and maintain optimal crusher performance. Proactive maintenance and using quality parts are your best defense against unexpected failures.

ZONEDING MACHINE is dedicated to providing reliable Cone Crushers and comprehensive support. If you’re facing persistent issues or need expert advice, don’t hesitate to reach out.