TRAINING MANUAL

SELLING CRUSHER WEAR PARTS

 TABLE OF CONTENTS

SECTION 1 3

SELLING CRUSHER WEAR PARTS 3

SECTION 2 8

CRUSHING HISTORY AND PRINCIPLES 8

SECTION 3 24

A GLOSSARY OF ROCK CRUSHING DEFINITIONS AND TERMINOLOGY. 24

SECTION 4 29

JAW CRUSHER WEAR PARTS 29

SECTION 5 50

GYRATORY AND CONE CRUSHERS 50

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 SECTION 1

SELLING CRUSHER WEAR PARTS

Selling wear parts is a growing process: you must crawl before you walk. The effective
salesman must learn basic fundamentals before he is ready to walk into a crushing operation
and ask for any ordering, you will be a more effective salesman, your customers will be glad
to see you when you call, and the result will be more repeat ord.

First, a word about what we do and why we’ve been successful. You must clearly
understand that we manufacture wear parts for crushing equipment manufactured by other
companies. We function independently of these firms, usually called Original Equipment
Manufacturers (OEM).

Virtually all crushers are designed to be capable of producing a wide range of crushed
product sizes. In stationary plants, crushers are often assigned very specialized roles,
producing the same size product, day in and day out. In a portable plant, the same crusher
may be called upon to produce various sized products.

Crusher manufacturers have taken these different needs into consideration, so their standard
manganese liner designs are suited to handle this range of crushing requirements. Often,
crushers equipped with “original” designs operate quite well. In other cases, liner designs
should be – or must be – changed to give the customer optimum performance.

The foundry offers a large number of wear part designs dimensionally equal to original
equipment. More important to many of our customers, we have engineered a wide range of
custom profile wear parts which may be suitable for consideration by other crushing plants.

Needs for additional designs continue to present themselves. As a general rule, we charge
separately for new patterns unless there is a reasonable potential for usage. Consult with
your supplier’s Sales Department for additional information.

Gathering equipment information is basic to any sale. This relationship dictates that
supplier representatives – engineers, district managers, and distributor salesmen – must be
our “eyes and ears”. You must gather information about all the crushers a customer /
prospect operates, before you ask for the order or opportunity to quote.

Start with an Equipment Survey. We call the first step “doing a survey” of an operation’s
equipment. You might compare it to the way your local auto parts store works.

Suppose you need a carburetor kit for your car. The counterman will begin by asking “What
make, year, engine, horsepower rating? Does it have air conditioning?” and so on. Only
then does he start his search for the item’s number, availability and price. Why is he so
thorough?

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Because when you tear down your carburetor, you expect the replacement parts to fit and
perform properly. If they do, you’re a satisfied customer. If they don’t you take them back,
curse the parts house, and vow never to buy there again. Failure to get all the information
can lose a valuable customer. It might be the world’s best carburetor kit, but if it isn’t
properly specified, it’s useless.

Our customers expect wear part fit and performance, too. But the crusher operator has a lot
more at stake when he changes parts. The parts are costly and plant downtime can cost
hundreds or even thousands of dollars an hour. If you follow a consistent, orderly procedure
to survey customer equipment, we all prosper.

Rule 1: If in doubt, don’t guess, ask! Our simplified, easy to do Equipment Survey is
based on the premise that you know nothing about your customer’s crushing equipment.
Here’s what you must establish and record:

A: Make, size, model and serial number of crushers.

B: OEM part numbers or other foundry pattern numbers of the wear parts you hope
to replace with non-genuine Items.

After these basic, information on the customer’s plant design, material crushed, end product
and wear life experience with present parts can round out your knowledge of the operation.

How to get the information. You have to build enough rapport with your prospect that he
will be willing – even eager- to help you. If you’re new on the account, and the customer
feels he’s just your “meal ticket”, he may be reluctant to give you the information you need.
You must stress that the goal is to lower his cost per ton of material processed.

In other words, the customer has nothing to lose by cooperating, and his operation stands to
gain a great deal by helping you get information so the supplier can quote proper parts.

Of course, a friend of the customer could be supplying the current parts, so one facet of your
job is to get to know customers and prospects on a personal basis. When you become a
trusted friend, the whole selling process becomes much easier. Remember this: although the
sales transaction may be technically between your company and the customer’s corporation,
successful selling is based on person to person relationships.

Look for a Crusher Parts List and Maintenance Manual. If your customers’ crushers
were purchased new, the OEM usually supplies a “parts list” and maintenance manual with
the equipment. Of course, you should still verify that any copies of manuals given you
actually go with the crushers out in the plant.

If the equipment is old, or was purchased used, the parts list may not be available. And there
are those days when the customer just can’t take the time to find his manual. Rule of Thumb:
Be patient and tactful…but persistent.

Go out to the crusher, measure and record. As the salesman, you have the number one job of
properly identifying what crusher wear parts are currently in use.

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Here’s a tip: Your new car’s standard equipment (OEM) tires were probably 2-ply bias
belted. After you have experienced rapid wear and generally poor performance, you’ll
probably replace them with 4-ply, radial belted tires guaranteed for 40,000 miles. The same
idea holds true for crusher wear parts.

Your customer may have changed liner designs for better performance after the OEM set
wore out. You usually won’t find any evidence of this in his parts list – customers don’t
seem to keep very good records of details like this. (But, oh, do they keep records of tons
crushed per set of manganese liners!) So, your job is to identify what is in the crusher
currently, and to keep track of it’s performance, its wear life, and when it is due for
replacement.

Be on top of OEM and Competitor’s parts. After all, your customer does have the right to try
competitive parts – and he often does. Competitors out there trying to improve part designs,
too. Competition is good for the industry – it improves the quality of the product and weeds
out companies who can’t compete.

Again, if you have developed a friendly, trusting relationship with your customer, you can
usually find out what competitive parts they are trying.

Staying abreast maintains your credibility. One good argument for staying on top of your
customers’ part usage is this: If you waste his time, or make a poor recommendation, you
lose your credibility as a wear parts expert. It is your responsibility to keep your customer
currently informed.

Here’s an example. One of your customer’s many crushers is a 1934 vintage “Offbrand” jaw
crusher. There are few of these units in existence, and your supplier lists only standard style
jaws for it. The customer uses special heavy duty anti-slab jaws from competitive wear
parts source.

If you jump in and “ask for the order”, and promise the moon, you’ll be left with two
undesirable alternatives – telling the customer you can’t supply the parts he needs after all, or
worse yet, selling him a wear part which obviously will not perform to his expectations.

This embarrassment can be avoided if you do your homework. Never give your customer the
feeling you can fill all his wear parts needs unless you have double-checked availability. It is
far better to tell your customer that your supplier is not able to furnish a certain item at that
time and keep your credibility.

Observation of details makes the difference. The professional wear parts salesman keeps
his eye out for details. When looking at competitive castings, he jots down all numbers
either cast-in or painted on. The experienced salesman also takes measurements of key
thicknesses and exterior dimensions, and records them systematically, with his other data on
that part.

This way, he can stay abreast of what the OEM or competitive manufacturer is furnishing.
He can also note for later use what problem areas the competition has. Two common

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examples are casting flaws and poor machining. Another surprisingly common occurrence
are erroneous weights painted on castings by some manufacturers.

The good salesman knows what he is competing against and anticipates questions. He is
prepared to get answers for his customers.

And he carries a camera to record the part’s shapes, features and wear contours to
supplement his reports. One tip: Never take pictures without “asking” permission first.

Working as part of the “maintenance world”. Regardless of who writes the purchase
order for wear parts, your customers are the maintenance and plant superintendents who keep
the crusher plant running. Their job is to minimize downtime for re-lining and to maximize
production.

Few purchasing agents, remote from the crushing plant, have hands-on experience with
crusher maintenance – although many will try to keep the wear parts salesman from visiting
the shop or crusher plant. You must persist in reaching the responsible operations personnel.
They have the feel and knowledge of their wear parts needs. They know that a “cheaper”
part is no bargain if it wears rapidly or fails prematurely, causing unscheduled downtime.
And they will listen to your suggestions for improvements, because a better running plant
makes their job easier.

Cautious, incremental re-designs work best. Every crushing operation and site comprise a
unique and complex situation. Over the years, we have followed the practice of selling
designs dimensionally equivalent to those currently being used by new customers – rather
than barging in with, “Have I got the parts for you!” We never wish to make arbitrary wear
part revisions that may cause more problems than they solve.

This allows you time to look over the situation carefully, consult this manual and the
supplier’s engineering department on any problems, and then make proper wear part
recommendations. This approach poses less risk, avoids crises and gives you time to develop
your customer.

Involve the customer in new part testing. Once you have identified an existing part that
could improve wear life, or after the engineering department has proposed a custom liner
profile, don’t say, “This part will give you additional tons of production.” Instead, discuss
the proposed change with your customer. Show him what the part is intended to do, and
propose that he purchase a set and carefully monitor its performance and life. Say, “We
believe that this design may be an improvement for you.”

If the new part performance to expectations, you get the credit. If it doesn’t, you have not
made a commitment on what is properly a research and development test. Avoid the use of
the word “will”, because it implies exactness or certainty.

Taking the order and “creative selling.” All your work does pay off. Now- your customer
decides to place an order. Don’t miss a real chance to serve him – and increase the size of
the order, too.

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At change-out time, your customer will have a specific need for certain parts. Be prepared in
advance. Know what parts your supplier has available for his equipment. Then, when the
customer is ready to order, you’ll be able to take care of the specifics:

Proper part identification,

delivery required,
price, as well as those “other”
accessory parts.

Our experience and surveys reveal that most orders placed are singular in content - generally
only for the heavy items like bowl liners, mantles and jaws. Don’t forget to ask about the
other items your customer will be needing for his change-out. Because so little attention has
been devoted to selling these accessory items, we often find they are purchased from other
sources. When we later ask, the customer often says, “Oh, we didn’t know you could supply
that!”

Rule of thumb: You can never remind your customers too often precisely what you can
supply. Memories are short, and your customers have many other things to keep track of.
Remind them verbally, by direct mail – and ask for the order.

Follow these guidelines and you’ll be on your way to being a professional wear parts
salesman. . The rest of this manual is devoted to information to help you do the job.

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 SECTION 2

CRUSHING HISTORY AND PRINCIPLES

Crushing as we know it today is relatively new. For thousands of years, all mining and
quarrying operations relied on hand labor. However, the industrial revolution of the late 18th
century created demand for greater quantities of minerals, which spurred development of
mechanical means of ore reduction.

The first patent for a crushing device in the U.S. was issued in 1830. This crusher operated
on the drop hammer principle, and was likely the predecessor of the stamp mill used as a
finishing crusher in mines of the period.

The Blake jaw. Other crushing devices followed, but none proved popular until Eli Whitney
Blake patented his double-toggle jaw crusher in 1858. The Blake type crusher, still in use
today, can generate tremendous compressive forces, making it suitable for crushing very hard
materials. Production capacity was earthshaking by 1858 standards, but the Blake crusher’s
slow reciprocating action and relatively small discharge area limited capacity.

The Gates gyratory. Several gyratory designs were patented through the 1860’s and 70’s,
culminating in the 1881 patent for the Gates Gyratory Breaker. The gates crusher included
the basic features found in today’s primary gyratory crusher. It was quickly proven more
productive than the Blake jaw, winning an 1883 production contest by crushing 9 cu.yd. of
stone in 20-1/2 minutes, one-third the time of the Blake.

The gyratory crusher reigned supreme until about 1908, when primary jaw crushers attained
sizes of 84 x 60 inches – producing up to 400 tons per hour of 10” minus product. (Gyratory
crushers of the day had only 48 inch maximum feed openings, but were soon to grow and
regain their production advantage).

Single toggle overhead eccentric jaw. Small mining operations and far-flung construction
operations throughout the world needed a crusher that was lower in cost, portable, and simple
to operate. This need led to the introduction of the single toggle overhead eccentric jaw
crusher in 1879.

Most early crushers were quite small by today’s standards, with feed openings ranging from
6 to 12 inches to accommodate hand loading.

During this period other crusher types appeared, including hammermills, sledging rolls for
primary crushing and smooth faced rolls as finishing crushers for mining operations.

Demand for fine product grows. Before the turn of the century, plants produced mostly
coarse macadam stone and ballast. The demand for crushed stone and ballast. The demand
for crushed stone in the late 19th and early 20th century ranged from 2-1/2” to 1-1/2” sizes
with the ¼ minus material removed. Many of America’s early highways were paved with
this coarse material and hand-sledged stone.

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Two fundamental construction breakthroughs changed crusher design radically. First, the
steam shovel made loading larger material possible, dictating much wider feed openings. By
1910, gyratory crusher feed sizes quickly grew from 18” to 48” and jaw crushers to 84 x 60”.
To handle the larger feed and produce higher volumes, the gyratory crusher soon grew larger
in height and diameter, becoming the larger primary gyratory crusher to know today.

At the other end of the scale, the adoption of reinforced concrete as a building material
created a demand for accurately-sized small stone and gravel. Well suited for efficient
primary crushing, the slow-speed gyratory crusher encountered difficulties with choking
when called upon to produce fine material.

Secondary crushing and the specialized fine reduction crusher. Up to this time,
aggregate and mining operations generally achieved secondary reduction by simply adding a
stage of smaller crushers of the same class as the primary. In small plants, the single toggle
jaw crusher was popular for secondary crushing because of its ability to function at close
discharge settings. But the demand for larger volumes of smaller product forced
manufacturers to develop more efficient units, known as fine reduction crushers. A number
of these were designed between 1916 and 1920. Two of these – the Telsmith reduction
crusher and the Superior McCully fine reduction crusher – are still encountered in plants
today. Soon after these two followed the high speed Newhouse crusher by Allis Chalmers.

Non-choking concaves. All of the crushers mentioned to date were outfitted with straight
liner profiles. Beveled concaves – flared outward at bottom – were first tried in the fine
reduction gyratory crushers as a means of improving wear distribution. The success of these
first efforts gave rise to further experiments in cavity design and the curved, or “non-
choking” concave resulted. Naturally, this same principle was soon applied to jaw crushers,
giving us the various styles of curved jaw plates available today.

The introduction of curved, non-choking designs was one of the most significant advances in
jaw and gyratory crusher development. They increased crusher capacities; improved wear
distribution; produced a finer, more uniform product and allowed smaller discharge settings.

The cone crusher. The reduction gyratory crushers we have discussed above still fell short
in producing very fine, consistently sized product. They were low speed class crushers
(except the Newhouse) with vertical (cylindrical) concaves, flared mantles and short
eccentric throws.

In 1928, the Symons cone crusher was introduced. This crusher, with its high speed, large
eccentric throw and widely flared cavity, opened up a range of crushing capabilities not
possible from any other type of crusher. It is available today in three classes: Standard, Fine
and Very Fine, each having a variety of liner options which will yield crushing cavities from
extra coarse to fine.

Shortly after the introduction of the Symons cone crusher, the Telsmith Gyrasphere crusher
came on the market. In 1938, Allis Chalmers introduced their Type R crusher, the
predecessor of the Hydrocone crusher.

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Today’s many versatile cone crushers, depending on the liner profiles chosen, are capable of
reduction crushing with large reduction ratios, as well as high volume fine crushing.

The modern crushing plant. As the previous discussion suggests, the crushing plant of
today is usually comprised of two, three or even four or more stages of reduction. The
number of stages, and the types of crushers used will vary radically depending on the type of
operation and material being crushed. Crushing plants fall into two general groups, each
with a different crushing goal.

Maximum reduction is the purpose of most ore reduction plants, that is, to reduce the
material to a size suitable for pulverization. Intermediate sizing is not important, and the
incidental production of fines during reduction crushing is quite acceptable. Most ore
reduction of fines during reduction crushing is quite acceptable. Most ore reduction plants
use only three crushing stages to reach a particle size of 5/8” to ½”, the common size for ball
mill feed.

Sized reduction is the goal of aggregated plants, which are designed to reduce the feed
material to specific sizes or into a graded product. In most cases, fines are undesirable and
the finished product is a cleaned, fully-fractured cubic material accurately screened to size.
Aggregated plants may employ four or more stages of reduction with screening to separate
the various sizes of product.

Types of crushers and their applications. Types of crushers vary in the way they apply
breaking force to feed material. The two basic methods of applying crushing force are
compression and impact. The normal crushing process also effects some reduction by
attrition and shear. While no crusher relies purely on a single crushing action, here are the
basic crushing actions, and their application by various crusher types.

Maximum compression, Twin roll crushers

Low impact….. Blake type jaw crushers
To…… Gyratory crushers
Single toggle jaw crushers
Cone crushers
Single roll crushers
Vertical shaft impactors
….maximum impact, Hammermills
low compression. Impact breakers.

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The Blake type jaw crusher. These are most suited to breaking hard, tough, abrasive rocks.
Because of this and the ability to handle coarse blocky material, the Blake jaw continues on
today principally as a primary breaker in hard to very hard materials. It is not suited to wet,
sticky or slabby materials.

Figure 2-1:
The Blake Jaw Crusher
A good hard rock primary breaker that generates great compressive forces.

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The Gyratory Crusher. A primary (and sometimes secondary) breaker, the gyratory
crusher is capable of handling the same hard material as the Blake jaw, but with higher
production capacity for a given feed opening. Because of its curved crushing surfaces, the
gyratory crusher reduces slabby materials well. Clays and other sticky materials will reduce
throughput or even plug the gyratory crusher, just as they will jaw crushers.

Figure 2-2:
A typical Primary Gyratory Crusher
Hall, high in capacity, efficient and effective against slabs.

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The Single Toggle/Overhead Eccentric Jaw Crusher. The Overhead Eccentric (or Single
Toggle) jaw crusher performs well as a secondary crusher because of its ability to work at
narrow discharge settings. It is also a common primary breaker in aggregate plants. The
Overhead Eccentric crusher performs well in medium hard to hard materials – approaching
the Blake crusher’s capabilities except in those materials with extremely high compressive
strengths. Because of the downward “wiping” action of the Over-head Eccentric’s movable
jaw, highly abrasive materials will tend to cause rapid jaw plate wear.

Figure 2-3:
An Overhead Eccentric Jaw Crusher
A versatile reduction or primary crusher, reasonably portable and
straightforward in design.

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The Cone Crusher. Usually found in the second, third and succeeding stages of reduction,
Cone crushers are designated as Standard, Fine and Very Fine crushers. The Standard
crusher can be used as a primary breaker in operations where the top size of feed material is
relatively small.

The cone crusher is in the middle on the compression-impact scale because its crushing
action is a combination of both. The top of the crushing chamber works more in a
compression mode, with light impact progressively increasing down through the chamber.

It is capable of handling hard, tough and abrasive materials. Liner wear, however, can
increase greatly with material abrasiveness. Clays and sticky materials should not be fed to
Cone crushers.

Figure 2-4:
A typical Cone Crusher
High efficiency, good production capacity, and excellent design versatility.

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The Twin Roll Crusher. Predominately a compression type crusher, the Twin Roll is
usually used as a finishing crusher. It is suitable for soft to medium hard rocks, including
damp and sticky material. The Twin Roll has been used in hard, abrasive materials, but
maintenance costs have been high in some applications.

Figure 2-5:
A Twin Roll Crusher
Accurate product sizing, but limited capacity.

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The Single Roll Crusher. Because it uses both impact and compression in reducing
material, the Single Roll Crusher can reduce soft and sticky materials without clogging. It
can serve as a primary breaker in reduction of soft to medium hard rock and performs well in
limestone, shale and phosphate rocks. Hard abrasive materials can cause a high rate of wear.
It is one of the best performers in wet, sticky material.

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The Hammermill. Depending on whether or not it is equipped with grates for product
sizing, the Hammermill can be classed as a primary or finishing crusher.

As a primary crusher without grates, the Hammermill is strictly an impact crusher. With
grates as a finishing crusher, initial reduction is by impact, followed by sheering and attrition
until the material is small enough to pass through the grate openings.

The Hammermill should be used on soft to medium hard material that is relatively friable and
non-abrasive. Hammermills with grates are poor performers in clays or wet, sticky materials.
In these cases a Non-clogging Hammermill with movable breaker plates and wipers should
be used to eliminate build-up of sticky materials.

Figure 2-6:
A typical Hammermill.
Good performer in relatively soft, friable, non-abrasive material.

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The Impact Breaker. Horizontal shaft impeller breakers are effective as primary and
secondary breakers of very friable, non-abrasive materials. The impeller bars strike the feed
material and drive it against the impact bars or plates. After several impacts the material is
able to exit between the rotor and breaker plate or breaker bards. The product is generally
well-graded and cubical.

Figure 2-7:
An Impact Breaker
The crusher of choice for very friable, non abrasive materials.

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The Vertical Shaft Impactor. The most recently developed impact crusher type in general
use, the Vertical Shaft Impactor can be a secondary or finishing crusher. It slings the
material against impact blocks which line the inside of the chamber. Vertical shaft impactors
work best in non-abrasive friable materials. They are often used in hard abrasive materials,
however, but at the expense of rapid wear to both the flinger shoes and impact blocks.

Figure 2-8:
A Vertical Shaft Impactor
Reduces friable material to a uniform, cubical product.

Other Crushers. One may encounter other types of crushers we have not mentioned here.
Their omission from this manual does not mean that your supplier does not supply wear parts
for them. For information on any crusher or part not discussed, contact the supplier’s Sales
Department.

Material properties. Rock crushing is not an exact science, largely because of the wide
range of characteristics of the world’s vast array of geologic formations. Even within the
same pit, rock will vary considerably.

The following are some material properties that affect crushability. This is not an attempt to
cover this broad subject in detail, for which we recommend further independent study.

Elasticity,
Compressive strength,
Hardness,
Friability,
Abrasiveness,
Flowability, and
Stickiness, related to moisture content of the feed material or presence of clays in the
formation.

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While all of these factors determine the best choice of crushing equipment (and also dictate
the optimum wear part profiles) for a specific plant – abrasiveness is probably the single
most important factor. Deposits which are high in silica are far more abrasive than other
materials. For crushing to be economically feasible, abrasive deposits must be crushed by
correct equipment.

Here are a few examples of material characteristics in ascending order of crushing difficulty.

Soapstone (Talc): Low abrasion, friable.

Limestone, cement rock, shale, dolomite: Mildly abrasive, friable and free flowing.

Marl, raw and wet: Mildly abrasive, friable, but sticky with sluggish flow.

Superphosphate: Mildly abrasive, friable, but sticky with sluggish flow.

Sand, gravel, dross, glass cullet: Very abrasive, free flowing and mildly friable.

Aluminium oxide, basalt, manganese ore, tungsten carbide: Very abrasive and tough.

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Crushing plant design.

Wear parts are simply one of the many variables in the crushing plant. It is valuable for the
wear parts salesman to understand the layout, function and material flow in his customer’s
plants for two reasons:

Firstly, to identify plant design areas which may be the cause of crusher wear parts
problems; and

Second, to note non-crusher parts that you could supply such as chute wear plates, grizzly
bars and grates.

A few basics. As mentioned earlier in this chapter, crushing plants can have one of two
goals: maximum reduction as in cement and ore dressing plants, or sized reduction as in
aggregate plants.

Where sizing is not critical, a crusher may be run Open Circuit, that is, material passes
through the crusher once, without recirculation.

Where sizing is important, a crusher may be operated Closed Circuit. Screens after the
crusher remove oversized material, and send it back through the crusher via a conveyor until
it meets size requirements. The crusher operator must achieve the optimum relationship
between the crusher discharge setting and percentage of recirculated material for best
production and liner wear.

Some rules of thumb on plant design. Your supplier’s years of experience serving varied
crusher plants confirm these basic principles.

1. It is cheaper to screen than to crush. At every stage, from truck dumping to the
finishing crusher, it is always more economical to remove undersized material from the
crushing circuit. Consider the effects of excessive amounts of fines in feed material: they
Help produce more fines through attrition;
Reduce crusher capacity;
Create high power draw;
Can cause packing and eventual choking;
Can lead to toggle breakage or damage to the crusher shafts and frame; and
Increase liner wear.

This suggests that it is always worth your while to investigate crusher plant screening before
responding to a complaint about wear part life.

Excessive reduction ratios are self-defeating. In a desire to cut costs, some crusher
operators may use too few crushers. As a general rule, lower crusher reduction ratios yield
higher production, require less power, and give longer wear part life.

If the crusher operator calls upon each crusher to deliver its absolute maximum reduction
ratio, he may get by with three stages instead of four. This will lower initial plant cost.

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However, each crusher will be operating near its design limits. Each stage will be highly
stressed and struggling. The output will be limited. Liner wear may seem excessive. And
the likelihood of crusher failure is increased.

It is far better to design the plant within “comfortable” limits, so that each crushing stage is
working at a reduction level that gives high production with maximum wear part and crusher
component life. Any capital cost savings from fewer crushing stages will probably be offset
by higher operating costs.

Crusher type is critical. Selecting adequate and proper equipment to do the job, and fitting
it with the most efficient wear parts is the secret of successful crushing operations.
Attempting to run sticky material through a cone crusher or slabby material through a jaw
crusher will ensure headaches throughout the life of the plant.

Within limits, crusher liner designs can compensate for crusher mis-application. However, if
a customer continues to experience production and wear problems even with special liners,
suggestion of another type of crusher may be the best service you can render.

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A crushing plant example. Here is an example of a crushing plant flow to show a typical
operation you may encounter in the field.

Figure 2-9:
A typical Crushing plant

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 SECTION 3

A GLOSSARY OF ROCK CRUSHING DEFINITIONS

AND TERMINOLOGY.

We recommend this section to those new to crushing and to the experienced, too – because
terms are occasionally used loosely or inaccurately in the field.

These terms focus on crushing action and wear parts, rather than crusher mechanical systems.
Most terms relate to the common crushers for whichthe manufacturersupplies parts.

Attrition. The reduction of material by a grinding or rubbing action between materials

and/or hard surfaces.

Belching. The spitting back of feed material from a crushing cavity. Usually caused when
friction between the material and crusher liners is insufficient to effectively nip the material.

Blocking. Stoppage of material flow into a crusher by a single piece of material too large to
enter the crusher.

Blow Bar. See Impeller Bar.

Bonnet. See Bowl/Concave Support Bowl.

Bowl/Concave Support Bowl. In gyratory type and cone crushers, the supporting member of
the upper crushing liner – Bowl Liner, Concave or Concave Ring.

Breaker Bar or Anvil. On impact type crushers, a bar separates from the Rotor for crushing
and sizing of material. May be fixed or adjustable.

Breaker Bar Sleeve. On impact type crushers, a tubular wear member that covers and
protects the Breaker Bar.

Breaker Plate. A member against which material is crushed on impact type crushers. May
be fixed or adjustable.

Bridging. Stoppage of material flow into a crusher by one piece or multiple pieces of
material wedged together covering the feed opening.

Cheek Plate. A replaceable crusher wearing surface, usually of manganese steel. Found on
jaw and roll crushers, cheek plates confine the rock or ore between crushing members and
protect the frame from wear.

Choke Feed. Feeding a crusher so the crushing cavity is kept full and covered with feed
material.

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Choke point or choke zone. The level in a crushing cavity where the capacity is minimum.

Choking. The complete or nearly complete stoppage of material through the crusher. May
be caused by too much fine material in the choke zone, which can result from too many fines
in the feed or from crushing extremely friable material at too tight a discharge setting.

Choking may also result from a material flow problem after discharge from the crusher
causing material to back up into the crushing zone.

Closed Circuit. The use of screens and conveyors to recirculate oversize material back
through the crusher as many times as needed to crush to size.

Concaves. Segmented gyratory crusher wear liners.

Concave/Concave Ring. A one-piece gyratory crusher stationary wear liner. See also Bowl
Liner.

Cone. See Head.

Compression Crushing. The reduction of material by the comparatively slow application of

pressure.

Crushing Cavity or Chamber. The area of any crusher where the material reduction
occurs.

In jaw and gyratory type crushers, it is the volume between the crushing tools. The crushing
cavity extends from the top of the liners to the lowest point of the liners where crushing
occurs.

CSS: Closed Side Setting.

Discharge Setting. The setting between the movable and stationary members at the
discharge opening of the crushing chamber. The setting is in accordance with the desired
product size and is measured on the open side or closed side depending on the type of
crusher. In roll crushers it is the narrowest space between the rolls.

Feed Opening. The inlet opening of the crushing cavity. Because of the gyratory type
crusher’s eccentric action, may be given as two dimensions, Closed Side (CS) and Open Side
(OS).

Fines. Material of a particle size smaller than a specified opening.

Friable. Easily fractured.

Grate or Block Grate. In hammermills, a screening section with specified openings for
passing sized material.

Grate Bar. See Screen Bar.

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Grizzly. A heavy duty stationary or vibrating screening surface comprised of parallel bars
spaced to pass a given size material. Usually used to scalp fine material from primary
crusher feed.

Hadfield’s Manganese Steel. The most common alloy used for crusher wear parts in high
impact and abrasive applications. It is a ductile material that work hardens under impact,
forming a tough wear-resistant surface layer.

Hammer. On hammermills, the crushing element attached to the Rotor, usually free-
swinging.

Hammer-Bullhead. See Hammer T-Head.

Hammer Circle. On hammermills, the diameter of the circle described by the Hammer tip
with Hammer extended.

Hammer-Slugger or Stirrup. On hammermills, a bar-type Hammer with multiple shanks.

Hammer T-Head. On hammermills, a Hammer with a head wider than its shank.

Head (Head Centre). In gyratory type and cone crushers, the supporting member for the
lower (moving) crusher liner – the Mantle.

Head Nut. In gyratory type and cone crushers, a threaded nut used to secure the Mantle to
the Head.

Hold Down Nut. See Head Nut.

Hold Down Washer. See Torch/Burning Ring.

Impact Crushing. The reduction of material by striking of one moving object against
another moving or fixed object.

Impeller Bar. In impactors, a bar rigidly attached to and extending the full width of the
Rotor, used as the main crushing element.

Impeller Shoe. In vertical shaft impact crushers, the flinger on the Impeller Table.

Locking Nut. See Head Nut.

Main Shaft Nut. See Head Nut.

Mantle. On gyratory type crushers, the lower crushing wear part which covers the crusher
Head. Usually cast of manganese steel.

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Mantle Nut. See Head Nut.

Mohs Scale. A scale of relative hardness of material as compared to: 1-Talc; 2-Gypsum; 3-
Calcite; 4-Fluorite; 5-Apatite; 6-Feldspar; 7-Quartz; 8-Topaz; 9-Corundum; 10-Diamond.

Nip Angle. The angle between the two crushing surfaces of gravity fed compression type
crushers. This angle will vary depending upon the size of crusher and style of liners.

Nominal. A description of crushed product size, denoting that at least 90% of the product is
smaller than stated size.

Open Circuit Crushing. Material passes through a crusher only once.

OSS. Open Side Setting.

Packing. The compaction of fine material which cakes in or near the choke zone, restricting
flow through the crusher. Sticky material may also contribute to packing.

Close discharge settings and high reduction ratios may result in the absence of voids in the
material, with packing as the result.

Parallel Zone. The lower portion of cone crusher cavities, at which point the Mantle and
Bowl Liner surfaces are parallel at the closed side.

Coarse reduction cone crushers feature a comparatively short parallel zone near the discharge
point, while fine crushers devote most of their crushing cavity to a long parallel zone.

Plugging. Any blockage that restricts flow of material through the crusher.

Reduction Ratio or Ratio of Reduction. Generally defined as the ratio of maximum feed
size to maximum discharge size. For maximum capability of any given size crusher, it is
defined as the ratio of the feed opening to the discharge opening – either open or closed side,
depending on crusher specification. Maximum reduction ratios range from 4:1 for small
crushers to 9.5:1 for large primary crushers.

Regulated Feed. Feeding at a controlled rate usually under the maximum capacity of the
crusher.

Ring Hammer. On hammermills, a ring-shaped member, either smooth or toothed on the

external surface, supported by hammer pins. The Ring Hammer is free to rotate through the
material while crushing by impact and compression.

Rotor. In hammermills or impactors, a rotating assembly with crushing elements which

imparts the crushing force required to reduce feed material.

Scapling. Removing most undersize material before feeding to a crusher.

Screening. Grading and separating material with Screens or Grizzlies.

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Screen Bar. In impact type crushers, bars arranged to control product size. Also know as
Grate Bars.

Screen Section. See Grate.

Top Shell. See Bowl/Concave Support Bowl.

Top Size. The largest particle size in crusher feed or crushed product.

Torch/Burning Ring. On gyratory type and cone crushers, a ring located between the
Mantle Nut and the Mantle. Designed to be torch cut to relieve the extreme force on the nut
when removing Mantles.

Voids. The space between crushed particles. Large, irregularly shaped material has a high
percentage of voids. This space is necessary to allow crushed material to fall freely down the
crushing cavity. As material is reduced in size, voids become smaller in relation to the
material volume. In fine crushing, voids reached a minimum. Many fines can result in the
near absence of voids and consequent packing of material, resulting in crusher overload.

Wear Parts. Those parts in a crusher that channel material, protect structural members or do
the actual crushing.

Page 28 of 89
 SECTION 4

JAW CRUSHER WEAR PARTS

Crushing principle. The jaw crusher is predominantly a compression breaker. A movable

jaw approaches a stationary jaw, crushes the rock or ore, and then recedes, allowing the
material to fall farther into the crushing chamber. When broken to final size by repeated
crushing, the material falls through the discharge opening at the bottom of the chamber.

Common jaw crusher brands for which the foundry can supply wear parts include Allis
Chalmers, Baxter, Cedarapids, Champion, Roxon Pegson, Jaques, Kue-Ken, Pacific, Pioneer,
Nordberg/Rogers, Telsmith, Traylor, Universal and Vickers Rouwolt. A complete list of
current parts will be found in Section J.

Non-standard Wear Parts for jaw crushers. Stationary Jaws, Swing or Movable Jaws, in
a variety of profiles; Cheek, Key or Wearing Plates, Toggle Plates and Toggle Seats,
Securing hardware including Jaw Wedges or Keeper Plates.

Jaw Crusher size designations. Jaw crushers are designated by the size of the feed
opening, viewed from the top of the crusher. For example, a “20 x 36” indicates a crusher
that is 20” between the top of the two jaws, and 36” between cheek or key plates.

The dimensions between the jaw plates is usually given first and is measured from the top of
the corrugations, that is, peak to peak.

Some manufacturers list width between cheek plates first in their nomenclature, but in any
case, the larger figure is usually the width of the crushing chamber.

Page 29 of 89
 Figure 4-1:
Measurement points of jaw crusher feed Openings & discharge setting

Jaw Crusher types. There are basically two types of jaw crushers in common use today:
The Blake type and the Single Toggle or Overhead Eccentric type.

Other types of jaw crushers have been developed but have not gained wide acceptance
because of factors that limit their use in today’s high production plants.

The Blake Type Jaw Crusher. This is the earliest jaw crusher developed, and is used
predominantly as a primary breaker. Blake crushers are low capacity crushers, but generate
extremely high crushing forces. This makes them most suitable for the reduction of very
hard rock and ore.

As the drawing below shows, the principle is a simple one. The swing jaw-double toggle
design yields a mechanical advantage which produces the heavy crushing forces.

Jaw Motion. The pure swinging action of the swing jaw minimizes abrasive action so jaw
plate life is relatively long.

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The speed of the large Blake type primary breakers is generally slow – ranging between 90 to
200 RPM – so product size is based on the open side discharge setting.

Figure 4-2:
Blake type Jaw Crusher

Smaller Blake style crushers usually operate at higher speeds – up to 300RPM. Some Blake
style variations operate at considerably higher speeds. One example is the Kue
Ken/Pennsylvania crusher which operates at speeds ranging from 225 to 425 RPM. At these
speeds, product size and crusher capacity are usually based on the closed side discharge
setting.

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Single Toggle/Overhead Eccentric Jaw Crushers. This type is by far the most popular of
the jaw crushers. It is generally simpler, more compact and lighter in weight than the Blake
type jaw. The movable jaw – the counterpart of the Blake crusher’s swing jaw – is hung
from an eccentric on the main drive shaft. Thus, the jaw action is significantly different than
the Blake swing jaw.

Jaw motion. The movable jaw motion is complex, varying from top to bottom in both
horizontal and vertical movement. The horizontal movement is maximum at the top of the
jaw and minimum at the bottom. This action gives the Overhead Eccentric crusher the
capability for high ratios of reduction.

Figure 4-3:
Overhead Eccentric Type Crusher

In addition, the downward (vertical) motion of the movable jaw gives a forced feeding
action. Combined with higher operating speeds, the action yields greater productive
capacities for the Over-head Eccentric crusher compared to the Blake type. Although the
vertical movement is an asset in this respect, more rapid jaw wear results from slippage of
material against the jaw faces.

Because of the high speed of the Overhead Eccentric crusher, product size and crusher
capacity are based on the closed side discharge setting.

Being a high capacity machine capable of tight discharge settings, the Overhead Eccentric
jaw was originally used for secondary crushing or for primary crushing in small or single
stage operations. However, today’s high strength eccentric shafts and heavy duty roller
bearings allow larger primary sizes to be manufactured for use in quarry and large gravel
operations.
Page 32 of 89
Overhead Eccentric Crusher Variations. One variation occasionally encountered is the
Twin or Matched jaw crusher. It has two opposed moving jaws, both having the eccentric
action described earlier.

Figure 4-4:
Matched Overhead Eccentric Crusher.

Jaw Crusher discharge settings. Discharge settings for most jaw plate designs are
measured at the bottom of the jaws, generally from the top of the corrugations to the bottom
of the corrugations directly opposite (peak to valley).

One exception to peak to valley measuring is with “High Tooth” jaws. The depth of teeth
may preclude minimum discharge settings, or at wider settings result in a product size that is
inconsistent with the peak to valley measurement. Usually with this type of jaw, experience
or a series of trials near the desired setting will be required for precise sizing.

The discharge setting will affect the output of the crusher – minimum discharge settings
reduce throughput considerably. Minimum settings also accelerate jaw plate wear,
especially at or near the lower ends.

The crusher manufacturer specifies minimum discharge settings as the safe limit for
operation under normal conditions. Operators should consult the crusher manufacturer
before using smaller than recommended discharge settings.

Feeding jaw crushers. Feed requirements may vary with the design of the jaw crusher and
the characteristics of the feed material, such as toughness, friability and shape of particles.
The following procedures, however, will effect the most efficient crushing.
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Scalping. Good crushing practice dictates that all fines smaller than the jaw crusher
discharge setting be scalped from the feed material. Abundant fines in the feed material can
cause production of more fines through attrition, reduce capacity, high power draw, choking
and accelerated wear.

An exception to scalping all fines from primary crusher feed is in quary operations where
generally the volume of fines is insufficient to cause problems.

Maximum size feed. The largest particle fed to jaw crushers should not exceed 80 to 90% of
the maximum feed opening with the straight jaws, nor 80 to 90% of the effective feed
opening with curved jaws. Larger feed can cause bridging, restricting the feed opening and
even plugging the crusher.

Choke feed. In most cases, the ideal feed to jaw crushers is a controlled choke feed that will
keep the crushing cavity full. This will result in the most efficient operation of the crusher.
A choke fed crusher will usually produce to maximum capacity with minimum jaw plate
wear. With a full cavity, the jaw plates do not have to do all the crushing – some reduction is
accomplished by rock against rock. Also, a full cavity maintains pressure on the smaller
particles at the bottom of the chamber, reducing slippage and thus minimizing wear.

Choke feeding may not always be possible. The composition of the feed material as well as
the fracture characteristics may preclude it. Or, a primary crusher which has been selected on
the basis of feed opening may have a greater capacity than is needed. What-ever the reason,
the feed should be controlled, effecting a partial choke feed condition – if at all possible – or
at least an even distribution of material across the cavity to avoid irregular jaw wear.

Jaw wear patterns. Many variables affect the wear of stationary and movable jaws. Most
wear takes place on the lower portion of the jaws, so most jaws are designed to be reversible
for maximum metal utilization. In Overhead Eccentric crushers, the stationary jaw usually
experiences the greater wear. Some of the variables effecting jaw plate wear are:

Physical characteristics of feed material;

Size of feed;
Method of feeding, choke or dribble;
Discharge setting;
Style of jaw plates

A full discussion of the effect of jaw plate design follows.

Jaw Plate design and applications. There are many different types and styles of jaw plates
– smooth, corrugated – fine, - medium and wide, full curved, curved with straight ends,
straight and so on as the drawings below show. Some large jaw crushers use two or more
jaw plate segments per jaw, which keeps jaw plates to easily handled sizes and allows
changing only the worn segments.

Page 34 of 89
 Figure 4-5:
Common Crusher Jaw Tooth Forms

Figure 4-6:
Common Crusher Jaw Styles (Profiles)

Page 35 of 89
Smooth Jaws. The first jaw plates used in the original Blake jaw crusher were smooth
faced, and this style of jaw was used in subsequent crusher for many years.

Today, except for use in primary Blake type crushers, smooth jaws are generally used for
relatively fine crushing. They perform well in the softer, friable materials.

Smooth jaws require more power than do corrugated jaws because breaking forces are
imposed upon a larger surface area, which exerts smaller unit pressures.

Because a smooth jaw has nearly twice the wear metal of a corrugated jaw of equal
thickness, service life will be considerably greater.

Corrugated Jaws. These jaw styles concentrate crushing power into high unit forces (psi) at
the tooth ridges. This reduces the load on the crusher and lowers power requirements
compared to smooth jaws. Standard variations include the following:

Wavy Tooth. The original corrugated jaw was the wavy tooth style, designed to minimize
passage of large slabs through the crusher. (Note that slabby material is best processed by a
gyratory crusher, because of its curved crushing surfaces).

Like the smooth jaw, wavy tooth designs are most suited to primary crushing in mining and
quarrying operations.

Sharp Tooth. When crushing of gravel and large boulders became more prevalent, and
when jaw crushers were introduced as secondary crushers, medium and fine pitched jaws
were developed. These narrow pitched jaws with sharp teeth are most suited to fine crushing
of non-abrasive rock.

Given suitable material, sharp tooth jaws may be used successfully in primary crushers where
a maximum ratio of reduction is required, as in single or two-stage plants.

Tooth pitch usually relates to desired product: the finer the product, the finer the pitch.

Sharp tooth jaw plate life is relatively short, especially in abrasive materials. The tooth point
wears rapidly, taking on the appearance of a blunt, shallow tooth.

Round Tooth. Because it has more wear metal at the tooth/rock interface, the round tooth
design performs better in abrasive material, giving longer service life.

The round shallow tooth and the wavy tooth designs perform better in soft, tough rock, which
tends to pulverize locally instead of fracturing. Sharp teeth can work grooves into this type
of material, delaying fracture and restricting the flow of material through the crusher.

High Tooth. For years, the tooth depth of most jaws was shallow, approximately 1/2 the
pitch. The crushing efficiency of the corrugated jaws was lost when the jaw wore down to a
smooth base. The high tooth jaw was developed to avoid this loss of efficiency and to reduce
the high throw away weight of worn out jaw plates. High tooth depth is about 2/3 the pitch.

Page 36 of 89
High tooth jaws have performed well, giving efficiency and long tooth life in both primary
and secondary crushers. Where maximum feed opening is critical, consideration should be
given to the possible loss of feed opening. In some cases, it has been necessary to increase
the thickness of the jaws to accommodate the additional tooth height.

A word of caution: High tooth jaws work well in most hard and friable materials; they
should not be used for materials containing clays or tough resilient rock or ore. These
materials will tend to fill or wedge between the teeth, restricting or even stopping flow.

Jaw Profiles. Standard jaw profiles are the three basic designs – straight, straight with
curved ends, and full curved. To discuss the advantages and disadvantages of each, a little
background in the principles of crusher cavity design is necessary.

Nip Angles. As we have described, gravity is the primary method of feeding jaw crushers.
As the rock enters the crushing cavity it is nipped between the two jaws. It is the weight of
the rock particle coupled with the resulting friction forces which keep it from slipping and
ultimately allow it to be crushed. The angle between the two crushing surfaces is, therefore,
a design criterion, and is referred to as the nip angle.

Since the angle of nip will vary with the size and weight of rock or ore particle, the angle
between the jaws must be held within a range which will nip the smallest particle in the feed.
The best nip angles are under 24o, and crushers are usually designed with angles in the range
of 18o to 24o with straight jaws. Larger nip angles, ranging from 22o to 28o, will be found in
some medium to large primary jaw crushers. (Some authorities specify 33o as a maximum
nip angle for ordinary rock.) These larger angles, of course, will only be effective on the
large, softer, friable rocks or ores.

Figure 4-7:
Measurement of jaw crusher nip angles

Page 37 of 89
Choke Point. The choke point of a crushing cavity is a zone of minimum capacity. It is that
point or zone in the chamber where the volume of material can approach a solid mass. The
material upon entering the crushing cavity is composed of large particles with numerous
voids. As it is crushed the particles become smaller, as do the voids. This process continues
down through the cavity until the voids are essentially non-existent. The material can then
compact, restricting progress down to the next crushing zone, drastically reducing capacity.
This, then, is the choke point, and its location in the crushing cavity is a function of jaw plate
profile.

Figure 4-8:
Location of typical choke points
With various jaw profiles

Page 38 of 89
Choking will only occur when there are enough fines present, either in the feed material
and/or produced in the crushing process, to eliminate most of the voids in the choke zone.

Straight Jaws. This type of jaw is best suited to primary crushing where maximum effective
feed opening is required and discharge settings are relatively large. The nip angle is at the
minimum design angle for any given crusher and will nip and crush any rock of a size which
will just enter the crushing cavity. See Feeding Jaw Crushers for recommended maximum
feed size.

The choke point of straight jaws is at the discharge opening. Choking can be a problem at
close discharge settings when numerous fines are present. The wide discharge settings
generally used in primary breakers usually preclude choking.

When operating straight jaws at close discharge settings, as might be done for reduction
crushing or in an attempt to get a large ratio of reduction, rapid end wear can be expected.
The concentration of fine material causes this rapid wear. If fine material is sufficient to
cause some choking or near-choking, cupping of both jaws just above the discharge point
will be evident.

Full Curved Jaws. This style of jaw can be used successfully in operations where feed size
is relatively small compared to the crusher feed opening. The drawing below shows the same
size nip angle for both the straight and the curved jaws. Assuming this is the maximum angle
of nip for the material being crushed, then the difference in effective feed opening will be as
shown.

The effective feed opening for curved jaws will b dependent upon the amount of curve – the
greater the curvature, the smaller the effective feed opening.

Page 39 of 89
 Figure 4-9:
Nip angle related to feed opening with
straight and curved jaw plates

Page 40 of 89
Advantages of curved jaws. Curved jaws offer the following advantages:

Better distribution of wear. The circles shown in the drawing are the same size. Thus, for
any given size rock, crushing will begin higher in the cavity with the curved jaws.
Reduced possibility of choking. The choke point for curved jaws is above the point of
discharge, and therefore at a point less prone to compaction.
Increased production (throughput). An increased volume of material can pass through the
higher choke point of the curved jaws, so restriction of material flow is reduced.
A more uniform product. Generally, curved jaws generate less fine material through
attrition.
Smaller discharge settings. Smaller discharge settings are possible – a result of the raised
choke point. (This is not to suggest any deviation from the manufacturer’s recommended
minimum settings).

Straight with Curved Ends. Jaws of this design are a compromise between straight and full
curved jaws. They will usually accept larger feed size than is possible with the full curved
jaw – while realizing most of its benefits. As with curved jaws, there will be a loss of feed
opening. The maximum feed size depends on the maximum angle of nip for the material
being crushed.

Wear distribution will be similar to that of a straight jaw for a given feed, except for the
discharge end wear, which will be comparable to the full curved jaw’s.

Straight/Curved Jaw Combinations. Depending on the wear patterns of any existing

operation, any combination of straight, straight with curved ends, or full curve jaw plates to
give desired effective feed opening and optimum wear characteristics is permissible.

Special designs. The foundry produces some jaw styles for special applications. Before
recommending use of these designs, a careful study of the operation and consultation with
the supplier’s Engineering Department are recommended.

Anti-slab Jaws. This style of jaw has a combination of high and low teeth. The high, or
slab, teeth are superimposed upon two or more of the standard teeth, and are usually tapered
from standard tooth height at the feed opening to a maximum height at the discharge end, so
they will overlap when the crusher is set for the desired product. Large slabs, then, cannot
pass through the crusher without being broken.

Page 41 of 89
 Figure 4-10:
Cross-sectional views of anti-slab jaw plates

These jaws are suitable for crushing large slabs only. Small slabs will pass between the
teeth. It is not possible to design a jaw without slab teeth spaced close enough to break the
small slabs without restricting throughput. If slabby material is a major problem, a gyratory
or cone crusher may be more suitable.

Concave/Convex Jaws. This combination is comprised of a stationary jaw with an extreme

full curve and a concave movable jaw, both having smooth crushing faces.

The crushing cavity is unique in that the nip angle continuously decreases from the feed
opening to the discharge end like that of full curved jaws – but unlike full curved jaws, a high
ratio of reduction is maintained throughout the cavity.

Because of this high ratio of reduction and the low choke point (at the point of discharge),
scalping the feed of all material smaller than the discharge setting is a must! Excessive
fines can cause choking and packing sufficient to break the toggle plate and/or damage the
crusher. For the same reasons, these jaws should not be used at tight discharge settings when
crushing extremely friable rock.

Ideally, the maximum feed size for hard rock should be small compared to the feed opening
of the crusher – small enough to allow the crushing action to begin at or below the center of
the cavity. The nip angle, however, is generally adequate for an occasional large rock, and
larger feed is permissible in the softer materials.

Concave/convex jaws are most suitable to secondary crushing, but have been used in primary
crushers where the feed material is relatively small.

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Users report that these jaws produce a finer product (less over-size with better gradation),
have greater capacity and give longer service life than standard jaws. When properly
applied, they have been considered quite an asset.

Figure 4-11:
Cross-sectional view of concave/convex jaw plates

Competitive Jaw Plate Designs. The above jaw plate designs cover the full range of needs
of most crusher operations. Our competitors offer variations on these basic jaw designs,
often under proprietary brand names. Here is a partial list of competitors’ jaws you may
encounter in the field.

Peen Slot. This is a smooth faced jaw with 90mm x 90mm grooves in a diamond pattern
across the face. The grooves help grip the rock and allow cold flow of the metal with
minimal warpage. Baker jaws are at least as thick as corrugated jaws, and because of the
additional wear metal, service life is usually long.

High Tooth. This is a deep tooth style jaw which many designate as “High Tooth”.

High Flow. These liners are essentially a high tooth design with deepened grooves in the
tooth valleys to allow fine material to fall away without contributing to liner life.

Securing Movable and Stationary Jaws. Jaws plates, like compression crusher liners, must
fit tightly and securely to avoid damage to the wear part and crusher frame or pitman.
Manufacturers use two principle methods to secure the jaw plates in the crusher.

Page 43 of 89
Bolts. In many large crushers, both the movable and stationary jaws are held in place by
bolts (countersunk) extending through the face of the jaws.

Wedges. In small crushers and some large crushers, the jaws are wedge held. Usually the
movable jaw is held by a bolted jaw wedge. The stationary jaw may be held either by a
bolted jaw wedge, or it may be wedged in place by the crusher cheek/key plates.

As the drawing below shows, if the jaw wedge bottoms before it wedges the jaw plate, a
shim may be needed.

Figure 4-12:
Typical Movable/Stationary Jaw Installation

Pioneer crushers (excepting the early models and the very large crushers) use the wedge head
and clamp bar arrangement shown below. The wedge head should not touch the jaw plate,
nor should the camp bar bottom against the pitman. If either occurs, shimming of the wedge
clamp bar is necessary.

Page 44 of 89
 Figure 4-13:
Movable Jaw Installation, Pioneer Jaw Crushers

Seldom is it necessary to shim cheek or key plates. If it is needed to wedge the jaw plate
tightly, shims can be placed between the cheek/key plate and stationary jaw.

The exceptions are those crushers designed with a system which will compensate for casting
variations, such as the Pivot Block and Shim found on pioneer crushers.

Figure 4-14
Stationary Jaw Installation, Pioneer Crushers

Page 45 of 89
It may also be necessary to further shim the stationary jaw against vertical movement. Even
though the cheek/key plates are tight, vertical forces may be sufficient to move the jaw up
and down. This action, of course, will wear the bearing surface of the base and cause further
loosening.

Cedarapids suggests shimming between the jaw flange and the top of the base as shown.

Figure 4-15:
Stationary Jaw Shim

Universal, on the other hand, suggests similar shimming at the bottom of the base, and
Pioneer at top, bottom or both, depending on crusher size and model.

Toggle Plates and Toggle Seats. The toggle plate has two functions. It acts as a
compression member which imparts the movement to the lower end of the swing or
moveable jaw. It is also the “fuse” of the crusher.

As the fuse, the toggle plate is designed to fail when an overload condition exists. Should
uncrushable material enter the crushing cavity, or if packing were to occur, the crusher frame
or other components would be damaged were it not for this toggle plate feature. (Note: The
Kue Ken/Pennsylvania crusher is an exception. Its toggle plates do not provide overload
relief, which comes from a spring mechanism on the drive pulley).

There are principally two types of toggle plates: the “S” type and the straight type. Usually
“S” type toggle plates are made of cast iron and are used in single toggle crushers. Straight
plates are generally of semi-steel or steel, and are designed to bend or break when
overloaded. The straight type is used in all Blake crushers and some single toggle crushers.

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Most crushers allow the use of toggle plates to compensate for jaw wear and to give a range
of product sizing, so it is important to know the toggle plate length on replacement orders.

The well-run crushing plant will maintain a stock of spare toggle plates in the lengths it
commonly uses to avoid lengthy downtime and panic orders.

Toggle ends are of two types: round and rocker.

Figure 4-16:
Round and rocker toggle ends

Round ends have considerably shorter life than the rocker type because of the constant
sliding action against the seats. The rocker type has a rolling action so the rate of wear is
minimal.

In some crushers, all toggle seats are replaceable. In others – mostly single toggle types –
only the pitman seat is replaceable. When replacing a toggle plate, the seats should be
carefully inspected for wear and replaced if necessary. Usually, when a toggle plate must be
replaced because of wear, the seat will also be badly worn and need replacing. In most cases,
a worn seat will have an irregular surface which, when paired with a new toggle plate, will
cause high localized stresses resulting in early toggle plate failure.

After installing a new toggle plate or seat, it is advisable to run the crusher without load for a
short break-in period to allow the toggle to seat itself. This will minimize these early
localized stress failures.

Page 47 of 89
 Figure 4-17:
Toggle Plate Installation

Proper installation. A cause of toggle plate failure which probably occurs more than
anyone cares to admit is inverted installation of the toggle plate. It is possible to install the
S-shape toggle plate upside down or backwards, resulting in bending stresses that cause
premature failure.

Cheek Plate Identification for Replacement. Cheek, Heel or Key Plates protect the sides
of the crusher frame from wear. With normal wear, the cheek plates on both sides of the
crusher should be replaced at the same time. However, crusher operators will occasionally
order only a single cheek plate.

The customer should be able to identify the left or right side part he needs by part number or
from his crusher manual, but unfortunately, many customers cannot locate this information at
the time of ordering.

Jaw crusher manufacturers differ on their nomenclature for left and right crusher parts. In
some instances, left and right cheek plates are common parts, so there is no problem. As a
general guide, the illustrations below offer a partial listing of manufacturers and their method
of designating left and right.
Page 48 of 89
 Figure 4-18:
Group A: left and right hand sides identified
By standing at stationary jaw

Figure 4-19:
Group B: left and right hand sides identified
By standing at moving jaw

Whenever a customer orders a single cheek plate, be certain to check that he is using proper
left or right nomenclature to avoid ordering and shipping the wrong part.

Page 49 of 89
 SECTION 5

GYRATORY AND CONE CRUSHERS

A word about nomenclature. Both Gyratory and Cone crushers are gyratory crushers in
type. In this manual, gyratory crusher refers to the primary, secondary and reduction
crushers with comparatively vertical crushing cavities.

Cone crusher refers to those gyratory-type crushers with cone-shaped, widely flared
crushing cavities and higher rotational speeds.

The gyratory crusher

Crushing principle. The gyratory crusher is a pressure type crusher which uses a gyrating
action to reduce material. Its outer, fixed crushing member is an inverted, conical shell.
Inside it the conical movable crushing member, or head, gyrates.

The head’s gyration is smallest at its top (feed) end and greatest at its bottom (discharge) end.

Rock ore is gravity fed, falling progressively farther between the two crushing members as
the head moves away, being crushed as the mantle gyrates to the “closed side”, and falling
again as the head recedes.

Because this eccentric action is comparatively slow, most material that has been reduced to
the open side setting (maximum discharge opening) can fall from the crusher on the open
side. Therefore, all performance data for the gyratory crusher is based on the open side
setting.

This crushing action continuously moves around the crushing cavity – unlike the Blake jaw
crusher which uses an intermittent, reciprocating action. This continuous action, plus the
gyratory’s larger discharge area, gives gyratory crushers generally higher capacities than jaw
crushers of similar feed size capabilities.

The gyratory head is also free to rotate slowly about its own axis, which allows the mantle to
roll against the material being crushed. If the head could not turn, a sliding action would
result, causing rapid wear to the crusher liners.

Common gyratory crusher brands for which the manufacturer can supply wear parts
include:

Allis Chalmers, Gyratory;

Nordberg, Gyratory;
Telsmith, Gyratory; and
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 Fuller/Traylor, Gyratory and Reduction Gyratory.
Wear parts for gyratory crushers. One-, Two- and Three Piece Mantles, Sectional
Concaves, Rim Liners, Spider Arm Shields, plus Crusher Backing Material.

Gyratory crusher sizes and applications. The gyratory crusher is principally used as a
Primary breaker in mining and quarry operations. Some manufacturers make a group of
smaller gyratory crushers which are classed as Secondary crushers. Also for secondary
crushing is the Reduction gyratory crusher, with its flared mantle and concaves which flare
outward at the discharge end.

Figure 5-1:
Gyratory Crusher Wear Parts

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Gyratory crusher size designations. Very early gyratory models were numbered (4, 5, 6
and so on) as a rough indication of feed opening.

Primary gyratory crushers of the modern era are designated by the feed opening in inches.
This dimension is measured horizontally from the top of the concave to the top of the mantle.
More recently, manufacturers have included the maximum diameter of the mantle, as the
accompanying drawing shows. For example, the 60-109 has a 60” feed opening and a 109”
mantle diameter.

Figure 5-2:
Gyratory crusher size designation.
Feed opening is given first, mantle diameter also on recent models.

Primary gyratory crushers are made with feed openings from 30” to 72”, with mantles up to
109” in diameter.

Secondary crushers are available with feed openings from 11” to 30” and mantle diameters to
70”.

Reduction crushers are designated by the diameter of the mantle at the discharge point.
Each size of reduction crushers may have several possible feed openings, depending on the
concaves used.
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Gyratory crusher capabilities. As a primary or secondary breaker, the gyratory can handle
hard, tough and abrasive materials well. Because of its curved crushing surfaces, it easily
reduces the large slabby material which the jaw crusher cannot.

Gyratory crushers, with their large feed openings and deep chambers, usually offer large
reduction ratios with high efficiency. Depending on the size of crusher, the apparent
reduction ratio (feed opening to minimum discharge setting) ranges from 7:1 to 10:1. The
actual maximum ratio will be somewhat less because the recommended maximum feed size
for gyratories is about 85% of the nominal feed opening.

Effective nip angles for these large crushers range from 27o to 30o, while smaller crushers
including secondaries will have from 21o to 24o. As discussed in other sections of this
manual, lighter materials and smaller particles demand smaller nip angles.

Feeding the gyratory crusher. A steady, regulated feed is ideal for efficient operation –
and for attaining maximum capacity. The gyratory crusher can be fully choke fed (buried).

Choke feeding also ensures more uniform concave and mantle wear. If the crusher cannot
be choke fed, the feed material should be distributed evenly around the chamber. Some
manufacturers suggest feeding the crusher from two sides, but if this is impossible, the spider
arms should be in line with the single feed source so material is distributed between the two
openings.

Feed size. As mentioned, a maximum feed size should be about 85% of the nominal feed
opening. The gyratory can nip and crush any rock that can enter the chamber, but material
larger than then recommended 80 to 90% can bridge, restricting the flow of material,
particularly when choke feeding.

The feed to a primary gyratory crusher normally need not be scalped of the fine material.
Usually these crushers are used in quarries or mining operations where the amount of fine
material is small and has little effect on crusher operation or product.

There are exceptions, however. If there is a substantial volume of material smaller than the
crusher discharge setting, scalping is definitely recommended. An abundance of fine
material can accelerate liner wear, create choking problems and reduce throughput.

The curved (non-choking), lower liners used in today’s crushers reduce the possibility of
choking. However, given the right conditions, choking can still occur. See page 4.7 of the
Jaw Crusher section for a discussion of the choke point and its effects. The same principles
apply to the gyratory crusher.

Gyratory crusher discharge settings. Early gyratory crushers had no means of adjusting
the discharge setting to compensate for liner wear. Then, only liner design and resetting
lower concaves closer to the mantle controlled product sizing.

Today, the main shaft of gyratory crushers can be adjusted vertically a limited amount,
through mechanical or hydraulic jacking. Still, the initial discharge setting is a factor of liner
design, as the accompanying figure shows.
Page 53 of 89
 Figure 5-3:
Lower concaves of varying thickness.
Replacement with thicker concaves or oversize mantles can compensate for wear.

The crusher’s vertical head adjustment can then maintain this setting for some time.

When all adjustment is used, oversize mantles or concaves can be installed, restoring the full
range of adjustment. The practice of alternating standard and oversize parts can effectively
use all possible wear metal before scrapping wear parts.

Gyratory wear part design and replacement. The drawing above shows a typical gyratory
crusher mantle and concave cross section.

Concaves. Four rows of concaves are shown. The number of rows will vary, depending on
the size of the crusher – from 2 rows on smaller crushers to 6 on the largest.

The lower rows experience greater wear. The bottom row, where final sizing is done, has the
highest rate of wear, so it is thicker than the rest. Even so, the lower rows may need to be
replaced more often than the upper rows to maintain discharge settings or because they are
worn out.

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Mantles. The mantle shown above is a One-piece design. Two-and Three-piece mantles are
also available for large crushers. Mantle wear is also greatest on the lower surfaces. A
multiple-piece mantle allows replacement of only the lower mantle sections when it is worn
through, or needs to be replaced with an oversized mantle to restore product sizing. The
upper and middle sections may last the life of several lower mantles. This results in
considerable savings to the crusher operator. Mantle sections are also easier to cast, ship and
handle.

Backing material. Gyratory wear parts must mate firmly with the crusher frame or head.
Molten zinc was traditionally poured as a backing material between the mantle and head, and
to set the concaves. Epoxies such as Megapoxy are well suited for this task, and in most
operations have replaced zinc.

Gyratory wear part precautions and problem solving. Gyratory crushers are heavy,
rugged machines capable of withstanding the rigorous punishment imposed by hard rock and
ores. There are comparatively few wear part problems, but there are two areas that demand
attention: wear distribution, and regular inspection/maintenance.

Wear distribution and service life. If your on-site inspection shows that the gyratory
crusher is being properly fed and operated, problems related to wear distribution and service
life can often be resolved through proper engineering. Improved distribution of wear metal
(thicker or thinner sections as needed) or use a better alloy for the application are two ways
engineers have improved wear part life. If you encounter such questions in the field, refer
them to the supplier’s Sales Department.

Inspection and maintenance. The crusher operator must be aware of the condition of his
gyratory crusher wear parts at all times to avoid damage from normal crusher operation.

As detailed in the metallurgy section of this manual, “work hardening” manganese steel alloy
is one of the better materials for wear resistance in compression type crushers – but it does
have a tendency to “cold flow”. This cold flow can become critical in operations where the
rock is hard, non-abrasive and the wear rate slow.

Keep mantle tight. Manganese cold flow can increase the diameter of the mantle slightly in
high pressure areas, causing it to loosen, and work (move) on the head. When this occurs,
inordinate stresses can ultimately cause cracking of the mantle and failure. At the first sign
of loosening, the mantle nut should be checked for tightness. If the problem persists, the
mantle should be removed and reinstalled on a head using fresh backing material. If regular
inspection catches this problem in time, the reset mantle can realize its normal wear life
without failure.

Maintaining concave spacing. Cold flow can cause problems with concaves, too.
Particular attention should be paid to proper spacing – that is, not too close- at installation.
This gap between concaves should be watched so that it does not close from work hardening
and flow.

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Once all spaces in a row of concaves close completely – and if the metal is allowed to flow
uncorrected – immense forces can build up. Overstressing or breakage of the crusher top
shell can result.

In extreme cases when crushing hard and non-abrasive materials, it may be necessary to
allow slightly greater than normal spacing between concaves, as well as horizontally between
each row.

Periodic trimming away of excess metal at the joints by arc-air may also be necessary.

Experience in a given pit, or a study of the rock hardness and abrasiveness will determine
how much extra care is needed to avoid problems.

Page 56 of 89
The Cone crusher.

Crushing principle. The cone crusher operates on the same principle as the gyratory
crusher. A conical mantle moves in an eccentric motion inside a fixed crushing member that
flares outward. The speed and eccentric throw are considerably greater than that of the
gyratory. This adds a different dimension to the crushing action.

Whereas the gyratory crushes mainly by compression throughout its chamber, the cone
crusher reduces material by compression or light impaction at the top of its chamber, with
increased impacting as the material progresses lower. When feed material enters the top of
the chamber, it is squeezed by the shorter stroke at the top. The mantle then moves away
rapidly, leaving the crushed material free to drop to a lower point in the crushing chamber.
The material is then lifted on the next upward cycle of the mantle, which brings it smartly in
contact with the stationary liner.

These light to moderate impacts continue down through the crushing chamber, usually giving
material 4 to 5 blows before it exists.

Distinctive design characteristics. The cone crusher differs from the gyratory crusher in
several important ways.

Sizes at C.S.S. The cone crusher’s high speed and flared crushing cavity cause most of the
material to be sized by multiple blows before it can leave the crushing cavity. Therefore, the
maximum one-way dimension of the material is established by the closed side setting – so all
performance data for the cone crusher is based on the closed side setting.

Smaller nip angles with parallel zone. Because the feed material is smaller and falls at an
angle through the crushing cavity, cone crusher nip angles are generally smaller than the
gyratory’s. The lowest portion of the mantle and liner is usually parallel to ensure final
product sizing.

Greater range of cavity options. Virtually all cone crushers have a spring, hydraulic or
pneumatic release system to allow tramp metal to pass through the crusher. This is necessary
because items such as bolts, hammerheads and fragments of bucket teeth can usually pass
through a large gyratory crusher, but are large enough to cause damage with the cone’s
smaller discharge settings.

Very Fine Crushers differ. The newcomer to the gyratory type crusher is the Very Fine
Cone Crusher. The crushing action deviates considerably from the above description. These
crushers use attrition and inter-particle reaction to reduce material to size. Unlike gyratory
and conventional cone crushers, the product size is smaller than the discharge setting. Sizing
depends primarily on the gradation of the feed material and its volume in the crushing
chamber. Very fine crushers will be discussed separately later in this section.

Page 57 of 89
 Figure 5-4:
Typical Cone Crusher Wear Parts

Common cone crusher brands for which the foundry can supply wear parts include:

Allis Chalmers, Hydrocone;

El Jay/Cedarapids, Rollercone;
Kue Ken, Gyratory and Cone Type (CT);
Nordberg/Symons, Standard, Short Head and Gyradisc;
Telsmith, Gyrasphere, Intercone and Very Fine Crusher (VFC).

Wear parts for cone crushers. Mantles, Bowl Liners, Concave Rings, Concaves, Feed
Plates, Feed Cones, Torch or Burning Rings, Head Nuts, Locking Nuts and Covers, Mantle
Hold Down Nuts and Washers, Nut Protectors and Protector Caps, Main Shaft Sleeves, Arm
Guards, Countershaft Box Guards, Head Wear Rings and Attachment Hardware, plus
Megapoxy Backing Material.

Conce crusher types and applications. Cone crushers are used mostly for intermediate
crushing. The Standard cone is usually found as a secondary crusher, the Fine crusher as a
tertiary. Occasionally, a Standard cone crusher will be found as a primary breaker in gravel
operations, or in other cases where feed sizes are small.

The Very Fine Crusher was designed for the production of sand, and is also used as a
finishing crusher to produce finer products required in graded construction materials.

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Cone crusher size designations. Cone crushers are designated by the approximate mean
diameter of the discharge area (or annulus). It may be given in feet or inches, depending on
the manufacturer. (Examples: 7ft Symonds, 54” El Jay).

Some special coarse cone crushers with fixed feed openings will also include the size of the
feed opening along with the annulus diameter. (Example: 489 Telsmith Gyrasphere with 48”
mean discharge annulus and 9” feed opening).

Very fine crushers are designated by the diameter of the head in inches.

Cone crusher capabilities. Since its inception in 1928, the cone crusher has become one of
the most popular crushers in both the mining and construction industries. The range of cavity
designs available has made this crusher a very versatile unit. Cone crushers function well in
the same hard, tough and abrasive materials as the gyratory crusher.

Cone crusher nip angles will vary considerably, depending on the style of liner used. The
largest effective nip angles will be in the same range as jaw crushers (Section 4).

In the Standard crusher, the nip angle will be greatest at the feed opening, diminishing
rapidly to zero at the sizing or parallel zone. The coarse liners in larger crushers can have a
maximum nip angle of 24o to 26o. More effective nip angles will be in the range of 18o to
22o.

Fine crushers equipped with coarse liners will have a smilar decrease in nip angles, but
designed for smaller size feed. Some fine liners for the Nordberg/Symons crushers have a
zero nip angle – forming essentially one long parallel zone.

The largest effective ratio of reduction for the Standard Cone Crusher will be from 6:1 to 8:1.
Standard practice for the Fine Crusher is approximately 4:1 to 6:1.

Page 59 of 89
 Figure 5-5:
Comparison of Coarse, Medium and Fine Liners.

Standard and Fine cone crusher liner design. As we have mentioned, the shape of the
cone crushing cavity is defined by the mantle and bowl liner (or concave ring), allowing
somewhat more freedom in designing the cavity than with gyratory crushers.

Unlike gyratory crusher liners, cone crusher mantles and liners are not usually changed out in
alternating sequence. It is far more efficient and economical to match mantles with liners
that give equal wear life, so when down time is necessary, both parts will be nearly worn
through – and can be replaced together.

There are four basic classes of crusher liners: Extra Coarse, Coarse, Medium and Fine.
Figure 5-5 shows a comparison of three of these for a typical Standard crusher. The principle
differences between them are the volume of the crushing chamber and the size of the feed
opening.

In addition to these basic designs, the supplier has available several variations and special
designs which can offer greater efficiency and economy to many operations.

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Extra Coarse liners (not shown) are usually of the step design. Within the same confines as
the Coarse liner, this liner allows a slightly larger crushing chamber and feed opening. A
step mantle is usually used as well, to further effect a coarse chamber. Step liners also effect
better nip angles. Wet, sticky feed material (at best hard to crush in a cone crusher) may
require using a smooth mantle.

Basic cone liner selection. Because of the many variables in materials and operations, it is
impossible to specify a given liner for a given application in this manual. However, the
following principles can be used as a guide for liner selection.

Four basic factors must be considered.

1. Size of material entering the crusher.
2. Desired product size to be discharged from the crusher.
3. Efficient utilization of liner wear metal.
4. maximum productivity

These factors are interrelated, and each is dependent on the other. For example, final product
size depends on the discharge setting, which can effect the maximum allowable feed size and
the rate of liner wear – all of which require a liner with a specific profile for optimum
performance.

Feed size. As cone crusher liners wear, normally the shape of the crushing cavity changes.
Most wear takes place in the lower regions of the liners near the sizing or parallel zone. As
the crusher is adjusted to maintain the discharge setting, the cavity feed opening narrows.
Liner feed openings must be sufficient to accept the maximum feed size not only when
new, but throughout the liner life.

Figure 5-6 shows three Standard crusher liner options available to a crusher operator with a
specific feed size indicated by the three circles.

Obviously, the Fine liner is unsuitable, because any wear will make the feed opening too
small to handle top size material.

The operator then has the choice of the Medium or Coarse liner.

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 Figure 5-6:
New liner options for a given feed size.
Discharge setting is shown for profile comparison only, and could vary with style of bowl
liner.

By looking at the new liner profiles in Figure 5-6, Medium appears ideal. However, we must
consider what the liner feed openings will be like near the end of liner life.

Figure 5-7:
Feed openings of nearly expended liners.
To simplify the comparison, the lower parallel zone is not shown.

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The superimposed profiles of worn liners shown in Figure 5-7 suggest that only the Coarse
liner will continue to accept the original size feed material throughout its life. Assuming the
feed size remains constant, this particular coarse liner will keep an adequate feed opening
until the lower portion is worn through. In fact, this liner will accept a larger feed size than
shown. (The feed size shown in this example was selected on the basis of that which would
first enter the Fine chamber).

The medium liner will allow better wear metal utilization because the crushing action will
start higher in the cavity. However, feed restriction and reduced capacity are possible,
depending upon the amount of wear to the upper regions of the liners. (Usually, Standard
cone liners receive comparatively little wear at the feed opening).

It is even possible that an alternate liner with a feed opening between the two shown is
available. If not – and if the feed size is fixed and cannot be adjusted up or down – then a
wear study for determination of the most suitable liners may be in order. This could result in
the selection of a liner combination which would yield optimum performance and wear metal
utilization.

Standard and Fine cone discharge settings. As mentioned, cone crusher discharge settings
are measured at the closed side setting (C.S.S.) of the lower parallel zone. All performance
data is based on this setting.

All crusher manufacturers recommend minimum safe discharge settings for each class of
liner, diminishing from Coarse to Fine. Although a coarse liner/mantle combination
designed to operate at a minimum discharge setting of ¾” could be set to produce a ½”
product, this would probably be damaging to the crusher. Some material and operational
variables could allow slightly smaller settings – but one should consult the manufacturer
before deviating from these recommendations.

Small discharge settings will cause more rapid wear in the sizing zone and lower region of
the crushing chamber. This is pronounced when crushing abrasive materials. As you would
expect, smaller settings reduce crusher capacity appreciably.

Feeding the Standard cone crusher. Proper feeding of cone crushers is essential for high
production, efficiency and wear part life.

Scalping. For most efficient operation, the feed material should be scalped of all fines
smaller than the discharge setting or finished product. An abundance of fine material in the
feed can result in accelerated liner wear, reduced capacity and choking – with its potential to
damage the crusher.

Distribution. The feed material should be distributed evenly around the crushing cavity.
Unevenly distributed or segregated materials can result in reduced capacity and a coarser
product. It can also cause uneven wear around the liner, which in some cases can become so
bad that accurate product sizing is impossible at any discharge setting. Early replacement of
the partially worn liner is the only – and costly – solution.

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Feed size. The ideal maximum feed size – for acceptance throughout the liner life – is
approximately 2/3 of the feed opening with new liners, depending on the make of the
crusher and style of liner. Remember in computing this top feed size that the intended
discharge setting has an effect. The feed opening will increase or decrease with the discharge
setting.

Choke feeding. Most manufacturers recommend choke feeding the cone crusher for
maximum efficiency. Those crushers having feed or distributor plates should be fed at a rate
that keeps a “head” of material above the feed opening – but below the feed plate. The
advantages of choke feeding are: maximum capacity; a finer, more uniform product and
efficient liner utilization.

In some crushing plants, choke feeding may be impossible. Choke feeding will be successful
only if liners suited to the feed size and discharge setting are used. If liners with a crushing
cavity too large for the average feed size are used, excessive power draw and near choking
conditions may result. It will then be necessary to regulate the feed for the maximum
acceptable power draw.

Feeding the Fine cone crusher. Most fine cone crushers equipped with Extra Coarse,
Coarse and Medium liners can be fed according to the above guidelines for standard
crushers. The following is an important exception for some liners.

Maximum feed size required. Some Fine and Medium liners may require a maximum feed
size of approximately 80% of the maximum feed opening (or the open side). These liners
usually have long parallel zones and require the larger feed to keep the feed opening
adequate.

Generally, the Fine cone crusher is operated in a closed circuit, where it is always choke fed.

The Very fine Crusher.

As we have mentioned, the Very Fine crusher, such as the Nordberg Gyradisc, Telsmith VFC
and El Jay Sandcone, is of the cone crusher class, but operates on an entirely different
principle.

In conventional cone crushers, the presence of fines and the rubbing together of particles
(attrition) are considered undesirable because they interfere with flow through the crusher –
reducing efficiency.

The Very Fine crushers use this inter-particle action – crushing by attrition and inter-particle
reduction.

Feeding the Very Fine crusher. Normally this crusher is operated in closed circuit, with
new feed material scalped of all fines under the desired product size. For the production of
sand, the maximum feed size can range from ¾” to 1-1/2”, depending on the size of crusher.
For coarse crushing, the top size can range from 1-1/2” for the 36” crusher to 4” for the 84”
crusher.

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Choke feeding required. The crushing principle requires a constant volume of material in
the crushing chamber.

Feed gradation important. In some cases, feed gradation can have an appreciable effect on
the final product. Refer to the manufacturer’s recommendations for ideal feed distribution.

Very Fine crusher discharge settings. Unlike Standard and Fine crushers, the discharge
setting is not indicative of the final product size. For most applications, the closed side
setting will range from1/4” to ½” depending on the desired product and the fracture
characteristics of the material being crushed. For the coarser feeds and coarse crushing,
discharge settings may be up to 1”.

Final adjustments will be obtained through screen analyses, with changes in discharge
settings and/or recirculation adjustments.

Cone crusher troubleshooting and liner wear problems.

Because of the relatively complex crushing action of the cone crusher, analysis of wear
patterns and wear part life problems requires somewhat more expertise and experience than
other crushers.

Sometimes the difficulty may lie in the part itself, but often the causes are operationally
fostered. Each case must be evaluated on the basis of the specific conditions.

The supplier’s Sales Department and Engineering Departments have many years of
experience solving cone crusher problems, including those relating to liner wear, production
and installation. Rather than trying to list the potential problems and their solutions in this
manual, we suggest you call your Representative.

Here is the information you should be ready to provide when you call for an inquiry:

1. Type of material crushed.

2. Abrasiveness.
3. Hardness.
4. Compressive strength.
5. Size and gradation of feed.
6. Discharge settings.
7. Part numbers of liners currently in use, along with the manufacturer’s name. If
a recognised part, the serial number of the liner should also be included.
8. A statement as to the nature of the problem.
9. Photographs showing the problem area and a plotted or traced wear pattern
where wear is the problem.

The liner in question should be saved – not scrapped – in case sections or a complete
examination are required.

Page 65 of 89
Gyratory and Cone Crusher Wear parts by Make and Model.

The following illustrated pages give important points to note regarding common gyratory and
cone crushers for which the supplier makes wear parts. Call your supplier’s Sales
Department for additional information or data on less common crushers.

Allis Chalmers Hydrocone Crushers.

The Hydrocone Crusher has been produced in eight sizes from 22” to 84”. Most sizes are
also available in three models – Fine, Intermediate and Coarse – which are designated by the
size of the feed opening. For example, the designations 236, 436 and 736 represent 36”
crushers with top shells allowing maximum feed openings of 2”, 4” and 7” respectively.

Figure 5-8:
Allis Chalmers Hydrocone Crusher.
A top supported concave machine is shown.

Each model also accepts a range of concave rings which give finer cavities with smaller feed
openings. For example, for the 736 concave rings are available with feed openings from 7”
to 4”.

There are two systems of securing the Hydrocone concave ring. The new system shown in
Figure 5-8 uses bolts to secure the liner at top and poured backing material between liner and
frame.

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 Figure 5-9:
Hydrocone Ring Concave Support.
This is the old style, bottom-supported machine.

The old system uses a bottom support ring as shown in Figure 5-9. The support ring has
several helical jaws which mate with like jaws on the concave ring. The crushing process
rotates the concave ring up these helix until it seats firmly. It is then held in place by friction,
being continually tightened by crushing action.

The seat and annular rings on the old style concave ring are fully machined and fit firmly
against the top shell. Therefore, no backing material is required.

Feed distribution around the Hydrocone cavity is critical. Adjustment for sizing and wear is
made by hydraulically raising or the lowering the head while the concave ring remains
stationary. Thus, imbalanced feed to one side of the cavity will result in differential wear –
with eventual loss of sizing capability.

Hydrocone crushers were designed for choke feeding, which will give maximum efficiency
and best wear part life.

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El Jay Crushers.

The El Jay/Cedarapids crusher is manufactured in three models –the Standard and Fine Head
(fine crusher) in five sizes from 36’ to 72’ and a Sand Cone (very fine crusher) in the 49”
size only. A limited number of Sand Cones have been produced to date and.

Figure 5-10:
El Jay Standard Rollercone.
This is the late style, available in 36” to 54”.

El Jay Standard Rollercone. The supplier produces three basic styles of Rollercone bowl
liners: Fine (which El Jay calls Medium Fine), Medium (or Medium Coarse) and Coarse –all
of which are used with the same mantle. In addition, we have available Heavy Duty bowl
liners and mantles for some sizes.

Filler blocks. When using the Medium or Fine bowl liners, filter blocks should be used.
These are aluminum castings tapered to fit between the bowl liner and bonnet (bowl liner
support member). Use of filler blocks reduces the amount of epoxy backing material
required.

Mantle hold down nuts. There are two types of threads. The earlier models use the
American Standard thread – either right or left hand. Current models use the Buttress
thread, left hand only. All 54” Standard Hold Down Nuts have the same external shape,
which allows the use of a common Mantle Nut Protector Cap.

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The 45” Standard crusher has two distinct nut shapes. One, which is used on the earlier
crushers, has the American Standard thread and a nut protector which fits in the wrench
socket. The other, on current models, has the Buttress thread and uses the same mantle nut
protector cap arrangement as the current 54” crusher.

Note: Older style crushers can be converted to use a later style nut by replacing the hold
down bolt – therefore, be sure to confirm type of thread or part number.

El Jay Fine Head Rollercone. For the 54” Fine Head crusher, there are two styles of liners
available: Coarse and Fine. These liners are usually used in matched sets, that is, Coarse
Bowl Liner with Coarse Mantle and Fine with Fine.

Figure 5-11:
El Jay Fine Head Rollercone.
Typical of 36” to 54” sizes.

The 45” Fine Head crusher has been made in two models. The liners for both are quite
similar in appearance, but neither the bowl liner nor mantle for one will fit the other. You
must exercise caution and obtain part numbers from the parts book, from previous liners, or
the bonnet and head before ordering.

Like the 54”, Coarse and Fine liners are made for the 45”. . These wear parts for the 45”
Rollercone are a special design developed for long life and maximum metal utilization.
The early Standard and Fine Head Rollercones were equipped with right hand Mantle Hold
Down Nuts and mantles with lugs on the inside surface. Most of these old crushers have

Page 69 of 89
been converted to left hand nuts. However, for those still using right hand nuts, be sure to
specify mantles with lugs.

Rollercone Bowl Liner Securement. On current 36”, 45” and 54” Rollercones, the bowl
liner is attached and secured with wedges as shown in Figure 5-12. A set of 4 or 6 wedges is
required, depending on the size of crusher. For added strength, liners with heavier loops can
be produced, and for ease of assembly, wedges are one-piece. These wedges are directly
interchangeable with the OEM two-piece design.

Dimensional variations in bowl liners and bonnets can result in insufficient wedging to
secure the liner. Should this condition be experienced, place shims of suitable thickness
under the wedge.

The 66” and 72” Rollercones use a threaded attachment system. The threaded member is
attached to the bowl liner with a pin. The very early 36” and 45” models use square or hex
head bolts through slots in the lower edge of the bowl liner to secure it to the bonnet.

Rollercone feed. Choke feeding of the El Jay crushers – or an evenly distributed regulated
feed – is necessary for efficient liner wear. The bonnet does not rotate when changing the
discharge setting – it moves vertically. If one side of the crushing chamber receives greater
volume, differential wear will occur.

Page 70 of 89
 Figure 5-12:
Loop Wedges for El Jay Rollercone.

Page 71 of 89
Kue Ken Crushers.

The Kue Ken Gyratory Crusher has been produced in three sizes: 18”, 28” and 36”. Each
of these accepts mantles and concaves which will create two (or more) cavity designs.
Unlike most cone type or reduction crushers, the mantles for Kue Ken crushers are
designated Coarse or Fine. These two are usually paired with appropriate concaves to
produce fine, medium or coarse crushing cavities.

There are two concave holders for the 36” crusher. One is a Coarse holder for use with the
Coarse concave only. The other will accommodate either Medium or Fine concaves.

Concave securement. The Kue Ken Gyratory concaves are secured to the concave holder
with a square head bolt through lugs on the periphery of the concave. Four or six bolts are
required, depending on the size of crusher.

Feed distribution. The Keu Ken Gyratory must have even feed distribution. Like the El Jay
crusher, the concave only moves vertically when adjusting the discharge setting. Uneven
feed distribution will result in uneven wear around the part.

Figure 5-13:
Kue Ken Gyratory Crusher.

The new Kue Ken C.T. (Cone Type) crusher is produced in two models – the C.T.C.
(Coarse) and the C.T.F. (Fine). Both of these are made in three sizes: 28”, 36” and 51”, with
three cavity designs available for each. The C.T.C. crusher cavities are classed as Coarse,
Medium Coarse and Fine. Those for the C.T.F. are Medium Fine, Fine and Extra Fine.

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Concave securement. The concave holder for the Kue Ken C.T. crusher rotates on threads
to adjust discharge settings. This feature tends to even out small irregularities in wear caused
by minor un-eveness in feed distribution. However, even distribution of feed material is still
a must for efficient operation.

Figure 5-14:
Kue Ken C.T. Cone Type Crusher

Page 73 of 89
Nordber/Symons Cone Crushers.

There are seven sizes of Nordberg/Symons cone crusher currently produced. These range
from 2’ to 10’, with two models in each size – Standard and Short Head (Fine Crusher).

Figure 5-15:
Nordberg/Symons Standard cone crusher

Nordber/Symons Standard. This widely-used crusher is found in many vintages and

variations so part numbers must be checked carefully.

Standard Bowls (Bowl Liner Support Members). There are several bowls available for
each size crusher. Exercise caution when considering liners other than those being used or
shown in the parts book for that particular crusher.

The crushers can be equipped with from two to four styles of bowls, depending on the size
and model. They range from Fine to Extra Coarse (to XX-Coarse on the 7’ Standard). In
addition to current models, there are old style crusher bowls in which bowl liners attach
differently – see the later section on Bowl Liner Attachment.

The Parts Catalog usually indicates which bowl a given bowl liner will fit. Even so, it is
always advisable to obtain bowl part numbers for reference and confirmation of fit.

Page 74 of 89
Standard Filler Pieces (Filler Blocks). You can usually fit finer liners into coarser bowls.
Because there is excess room, tack welding Filler Pieces into the bowl is more economical
than filling the large space with backing material alone at each changeout.

When changing back to a coarser liner in such a bowl, some or all of the Filler Pieces must
be removed for proper fit of the liner.

Standard Bowl Liners. There are several different styles of bowl liners for the various sizes
of Standard crushers, including the usual OEM equivalents: Extra Coarse, Coarse, Medium
and Fine – plus many special designs the supplier has developed for special applications and
solving wear or performance problems. Again, before specifying special liners, contact
your Representative.

Standard Mantles. Like bowl liners, mantles are available in standard and special designs.
No single mantle is compatible with all bowl liners – there are standard acceptable
combinations which work well together. Mismatched parts can cause a poor wear pattern,
loss of sizing capability, reduction in capacity and possible premature replacement of both
parts. Call when considering mixing unknown combinations of bowl liners and mantles.

Standard Bowl Liner Attachment. All current Nordberg/Symons Standard crusher models
use “U” bolts through hooks on the backing surface of the bowl liner to secure it to the bowl,
as in Figure 5-15.

The older style crushers – many of which are still in service – use a square head bolt through
lugs around the lower outside edge adjacent to the seat of the liner.

Page 75 of 89
 Figure 5-16:
Nordberg/Symons Short Head Cone Crusher

Nordberg/Symons Short Head crusher. These Fine crushers have a number of similarities
to the Standard crusher.

Short Head Bowls. Like the Standard crusher, there are different bowls for the Short Head.
Except for the 7’ Short Head, there are two basic bowls: Coarse and Fine.

The 7’ Short Head Bowl is produced in Coarse and Fine plus Heavy Duty, Extra Heavy Duty
and Special Heavy Duty designs. The fit detail may differ, so the bowl and bowl liner must
be checked closely for compatibility.

As with the Standard crusher, it is recommended that bowl part numbers be obtained for
reference and for assurance of proper fit.

Model 4800 Short Head. The foundry may not have liners for this crusher, but some have
been converted to use Short 4’ or 4-1/4’ Short Head liners.

Pay special attention to the revised parts list for these altered crushers. There is a list of
recommended liner combinations – but what may be classed as a Medium liner for the 4’ or
4-1/4’ Short Head will be classed as Coarse for the altered 4800 Short Head.

Page 76 of 89
Model 5100, 4’ and 4-1/4’ Short Heads. These crushers will accept the same bowl liners
and mantles. The 4’ Short Head is the earlier model, succeeded by the 4-1/4’ and then the
5100.

Short Head Bowl Liners and Mantles. As with Standard Crushers, the manufacturer offers
many styles. Check with us before specifying special parts.

Short Head Bowl Liner Attachment. Most bowl liners attach with U-bolts as shown in
Figure 5-16 except the 2’, original 4800 and 4’ crushers. The 2’ Short Head bowl liner is
secured with square head bolts like the 2’ Standard. (The 4800 and 5’ bowl liners use the
same attachment system as the Gyradisc crushers .

Short Versus Long liners. The Nordberg/Symons Short Head crushers can use either Long
or Short liners. Experimentation has shown that Medium and Fine liners tend to size many
materials when first impacted in the parallel (sizing) zone. Additional time in the parallel
zone does little additional sizing – either by impact or attrition. Also, some materials tend
to pack in the parallel zone, causing excessive and irregular wear. If the desired product can
be obtained with short liners, the crusher will perform more efficiently and economically.

Head Wear Ring. Using Short Liners leaves the lower part of the head seat exposed. A
Head Wear Ring, tack welded to the head, should be used to protect the seat from abrasion.

Spacing must be sufficient between the mantle and wear ring to allow the mantle to stretch
and move downward during its life. If the wear ring interferes with this downward
movement, the mantle will tend to loosen on the head – requiring premature replacement.
This can also damage the head seat. See Figure 5-17 for minimum recommended spacing.

Page 77 of 89
 Figure 5-17:
Nordberg/Symons Short Head Wear Ring minimum spacing

Nordberg Gyradisc crusher. The Gyradisc is currently produced in four sizes: 36”, 48”,
66” and 84”. There was also a 54” Gyradisc produced for a period, which is now replaced by
the 48” crusher.

Gyradisc liners. There are two styles of liners: Long and Short. The Upper Liners are
classed by the size of the throat opening – the feed opening dimension between Upper and
Lower liners – rather than fine, medium or coarse.

Generally a single Lower Liner can be used universally with the various Upper Liners of its
style (Short with Short, Long with Long).

Heavy Duty Liners are the same style and class as OEM liners, but are thicker and generally
yield longer service life.

The foundry also produces special liners for the Gyradisc that have shown superior
performance in many operations, giving longer service life and improved metal utilization.
Contact your representative for recommendations before specifying special designs.

Page 78 of 89
 Figure 5-18:
Gyradisc Crusher

Wedge Blocks can bottom out before wedging the liner – requiring shimming. If necessary,
place a steel shim thick enough to ensure tightening between the wedge block and the bowl.

Backing material. Epoxy backing is required for the 84” Gyradisc only, behind both Upper
and Lower Liners.

Page 79 of 89
Telsmith Cone Crushers.

The Standard Telsmith Gyrasphere is made in four sizes from 24” to 66”. In each size
there are two concave support bowls: Coarse and Extra Coarse. The Coarse bowl
accommodates the standard group of liners – Extra Coarse, Coarse, Medium and Fine.

Figure 5-19:
Telsmith Series Gyrasphere

The Extra Coarse support bowl accepts only an Extra Coarse style of concave ring which
gives a larger feed opening than the Extra Coarse used in the Standard Coarse support bowl.
This Extra Coarse crusher has an additional digit in its size designation.

For example, a 24S is a 24” crusher with a support bowl in which the standard Extra Coarse,
Coarse, Medium or Fine liners will fit. A 244S is a 24” crusher with a 5” feed opening – this
model crusher (Extra Coarse) will only accept only a 245S concave ring.

Concave rings. The foundry makes concave rings for the Standard Gyrasphere in equivalent
OEM designs and heavy duty or special designs. All Standard concave rings (except for the
Extra Coarse mentioned above) will fit all Standard models “A” through “D”.

Mantles. The foundry offers OEM style mantles for use with OEM style concave rings,
including those Extra Coarse crushers.

Page 80 of 89
The foundry also has heavy duty and specially designed lower mantles for the 36” and 48”
crushers.

There are two styles of lower mantles available for the 6614S Gyrasphere – one smooth, and
one with a ribbed crushing surface. This is a two-piece mantle design, and requires the
corresponding Upper and Lower Mantle – either both smooth or both ribbed.

The foundryhas available two OEM style lower mantles for 24”, 36” and 48” sizes – one top
pour and one bottom pour (of backing material).

With the old style Bottom Pour Mantle, the backing material was poured through slots in the
head and mantle seats. This required removing and inverting the head and main shaft
assembly. Not only was this inconvenient, but the slots weakened the mantle, frequently
resulting in sufficient stretching to cause the mantle to loosen on the head. A Bottom Pour
Mantle is still available for our customers who prefer it.

We recommend using the Top Pour Mantle. This can be accomplished by damming the slots
in the head with clay or a similar compound. Preferably, for a permanent fix, the head seat
can be reworked by welding and remachining.

Use of the Top Pour Lower Mantle requires the new style Top Pour Upper Mantle and Nut.
Because the top pour arrangement has been in use for several years, most crushers will be
equipped with the new style Top Pour Upper Mantle and Nut – if not, new ones will be
required.

Selecting Heavy Duty and Special Designs. Before specifying special liners for the
Gyrasphere crusher, contact the supplier for recommendations.

Concave ring securement. All Standard Gyrasphere concave rings (except on Extra Coarse
models) are attached to the support bowl with bolts as shown in Figure 5-19. All models
(excepting model D) use a standard square head bolt. Model D bolts have a tapered square
head as shown in the inset.

Concave rings in the Extra Coarse crushers 245, 367, 489 and 6614 are secured with wedges
the same as the FC crusher shown in Figure 5-20.

The Telsmith Gyrasphere FC (Fine Crusher), like the Standard crusher, is made in four
sizes from 24” to 66”.

Page 81 of 89
 Figure 5-20:
Telsmith FC Gyrasphere

The Concave Rings are graded similarly: Coarse, Medium and Fine. As with most crushers,
special designs may be available for special applications. Their application should be cleared
with an engineering representative.

Mantles, too, are used universally with Coarse, Medium and Fine concave rings.

Upper Mantles for both 36” and 48” crushers are made in two styles: new and old. The old
style Upper Mantles goes with the old style Nut, which is smaller in diameter than the new
style nut. See Figure 5-21 for differences in the Upper Mantles.

Page 82 of 89
 Figure 5-21:
New and old style Upper Mantles on Telsmith FC

Concave Ring securement. Concave rings for all FC crushers are secured with wedges
under lugs protruding from the top of the concave as shown in Figure 5-20.

Burning Ring. Some 66FC and 48FC Gyrasphere crushers may use a burning ring located
between the Upper Mantle and Main Shaft Nut. Use of this burning ring should be
confirmed, because many of the older crusher did not require it.

Telsmith E Series Gyrasphere. Telsmith produces this crusher in five metric sizes: 1100,
1300, 1500, 1700 and 1900mm. Each of these sizes comes in three models: Extra Coarse
(SX), Standard (or Coarse – S) and Fine (FC).

Page 83 of 89
 Figure 5-22:
E Series Gyrasphere

Concave Rings. Original equipment concave rings range from Coarse to Medium for the
SX; Extra Coarse to Medium for the S; and from Coarse to Fine for the FC.

This crusher is relatively new and it appears liner design is still under development by the
manufacturer.

Mantles. The mantles for the E series are common to all concave rings. That is, for each
size of crusher, a single mantle serves for all models – SX, S and FC – and with all concave
rings – Fine, Medium and so on. Of course, the mantles and concave rings both must be of
the same design – either both Short or both Long.

Burning Ring. The same burning ring is used for all three models of a given size.

Mantle Cap. A Mantle Cap protects the Nut on the Standard crushers (SX and S). (A
Mantle Nut and Feed Plate are used on the FC crushers).

Concave Ring Securement. Hex head bolt and “T” nut secure the concave ring to the
support bowl on all E series models as shown in Figure 5-23.

Page 84 of 89
 Figure 5-23:
Gyrasphere E Series Concave Ring Securement

Telsmith VFC (Very Fine Crusher). The Telsmith VFC crusher is relatively new. It is
presently produced in four sizes: 24”, 36”, 48” and 1410mm. To date, the 48” appears to be
the most popular.

Concave Ring securement. The FVC has large lugs at the top of the concave ring. A set of
wedges under these lugs secure the liner to the Concave Ring Support Bowl. These wedges
are drawn together by a bolt and nut, as shown in Figure 5-25. These concaves to not require
backing material.

Page 85 of 89
 Figure 5-24:
Telsmith VFC

Figure 5-25:
Telsmith VFC Wedge Block Detail

Telsmith Intercone Crusher. The Intercone is one of the earlier reduction crushers made in
18” and 28” sizes. OEM equivalent concave rings and mantles are available for both sizes.

Page 86 of 89
Traylor TY Crushers.

The Traylor TY Reduction Crusher is not of the cone crusher class. Being a reduction
crusher, however, it is mostly used as a secondary crusher. Like the cone crusher, it is
occasionally used as a primary crusher in operations with small material.

Sizes. There are six sizes of TY crusher, ranging from 1’-3” to 5’-6”. Each size (except the
1’-3” crusher) may have two or more designated feed openings.

Concaves. The different openings result from alternate concaves, which can give smaller
crushing chambers much like those of standard cone crushers (Figure 5-3). The smaller
crushing cavities give the same benefits as they do in cone crushers: they raise the crushing
action, improve wear distribution and reduce power requirements – all of which are affected
by feed size.

Figure 5-26:
Traylor Type TY Reduction Crusher

The concaves for the 1’-3” and 1’-8” crusher are one-piece. The 2’-4” through 4’-0”
crushers use a one-piece Lower Concave Ring with Sectional Upper Concaves. The 5’-6”
crusher requires three rows of sectional concaves.

Mantles. 1’-3” and 1’-8” crushers use One-piece Mantles. One or Two-piece Mantles are
available for the larger crushers. Because most wear takes place on the Lower Mantle, it can
be replaced alone for economy. The Upper Mantle can be reused several times.

Page 87 of 89
Oversize Mantles and Concaves. TY adjustment for sizing and wear compensation is
accomplished by raising and lowering the head like a primary gyratory. The vertical
movement of the Suspension Nut may not be sufficient to fully expend the lower wear metal.
For this reason, First and Second Oversize Concaves and Mantles are available. They can be
alternated with standard parts as described earlier in this section under Gyratory Crushers for
full wear metal utilization.

Liner securement. Concaves in all but the 5’-6” crushers are held in place by zinc or epoxy
backing and Lower Concave Ring is clamped between the Bottom and Top Shells. The
concaves in the 5’-6” crusher are held in place by zinc or epoxy as on a primary gyratory
crusher.

Feeding the Traylor TY Crusher. As with all crushers in which the stationary member
does not rotate during adjustment, distribution of feed material around the crushing chamber
is critical. If distribution is uneven, excessive wear on one side will make proper product
sizing impossible.

Page 88 of 89
MANGANESE LINER PERFORMANCE QUESTIONNAIRE

Customer: Contact:

Site: Phone:

Feed Size mm

Feed Gradation F80

Feed Tonnes Per hour

Life of the Liner hours

Closed Side Setting mm

Product Size mm

Product Gradation P80

Other Information (Liners compared to OEM, tones crushed and product characteristics)

Is the customer able to supplyeither a cut-out section of used liners or the complete used
liners (The foundry will pay scrap value at current market rate).

Page 89 of 89