Trio Engineered Products, Inc.

• 12823 Schabarum Avenue • Irwindale, CA 91706 USA • Telephone 626-851-3966 • Fax 626-851-9526

STANDARD JOB PROCEDURES

FOR
TC CONE CRUSHERS

Cone Standard Job Procedures ENG (FEB-2014)

Copyright © 2014 Trio Engineered Products, Inc. All rights reserved.
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treaties and may not be copied without the express permission of Trio Engineered Products, Inc., which
reserves all rights. All Content is copyrighted as a collective work under the U.S. copyright laws, and Trio
Engineered Products, Inc. owns a copyright in the selection, coordination, arrangement and enhancement
of such Content.
Re-use of any of our Content for any purpose other than stated commercial use is strictly prohibited. You
may not modify, publish, transmit, participate in the transfer or sale, create derivative works, or in any way
exploit, any of the Content, in whole or in part. You may not upload, post, reproduce or distribute content
protected by copyright, or other proprietary right, without obtaining permission of the copyright owner.
 Cone Standard Job Procedures

To the Owner & Operator

We have tried to provide information that gives our customers a clear understanding of equipment
construction, function, capabilities and requirements. This information is based on the knowledge and
experience of qualified people at our company and in our field organization. Proper use of this information
provides users of our equipment with high efficiency, maximum service life and low maintenance costs.
That is why we strongly recommend that anyone using our equipment be familiar with this manual.
Information presented here should not be considered authoritative in every situation. Users will as a matter
of course encounter problems and circumstances that raise questions not anticipated here. Such questions
should be directed to their distributor or the manufacturer.
Anyone who uses this equipment for any purpose other than that for which it was intended assumes sole
responsibility for dangers encountered and injuries sustained as a result of such misuse.

DANGER
Federal, state and local safety regulations aim to protect both people and property from
accident, injury and harmful exposure. When complied with, such regulations are often
effective. Hazards to personnel and property are further reduced when this equipment is
used in accordance with all operation and maintenance instructions. Generally:

(1) Read and heed all danger, warning, caution, and notice decals. Know what guards and protective
devices are included and see that each is installed and in operational condition. Additional guards and
protective devices may be required and must be installed by the user (owner) before operating.
(2) Never attempt to maintain, lubricate or adjust this equipment while it is running. Lock out and tag
out all energy sources before doing maintenance, cleaning, adjusting or repairing this equipment. Make it
impossible for anyone to start this machine while others are working on it or in it.
(3) Wear personal protective equipment such as hard hats, ear plugs, safety glasses and safety shoes
when operating this equipment. Do not wear loose clothing or long hair.
(4) Think safety and act safely. Stay alert at all times. Eliminate or neutralize potential hazards as soon
as you spot them. Never allow anyone to engage in horseplay when near this equipment.

DANGER
Failure to take these precautions will result in death or severe personal injury.

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Cone Standard Job Procedures

The following warning applies to equipment supplied with lead-acid batteries:

WARNING
Battery posts, terminals and related accessories contain lead and lead compounds,
chemicals known to the State of California to cause cancer and reproductive harm.
Wash hands after handling.

The following warning applies to equipment supplied with diesel powered engines:

WARNING
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.

NOTICE

Product Registration:
All equipment must be registered within 14 days of start-up to receive warranty coverage.
Registration information will only be accepted from the end-users of the equipment, however dealers can
register the equipment for the end-user provided the information registered is the end-user’s information.
In addition to this registration, all cone crushers, vertical shaft impact crushers, and all screens using
urethane media must have an application data sheet on file and approved by Trio.
After completion of the registration and application data sheet, if required, all submitted information will
be reviewed and a confirmation e-mail sent to the e-mail address provided to Trio.
Warranty will be fully enforced upon confirmation of payment and receipt of the above information.
Register online at: http://www.trioproducts.com/register/form
or call Trio at +1 626 851 3966.

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 Cone Standard Job Procedures

Warranty Terms & Conditions

Seller warrants all new equipment manufactured or imported by Trio Engineered Products, Inc. (Trio) against defects
in material or workmanship attributed to the original machine manufacturing. No other warranties are expressed or
implied.
Warranty claims must be made through the dealer or agent responsible for the original equipment sale, as the
equipment will have been registered with them at the time of sale from Trio. Claims must be made within twelve (12)
months or 2,000 working hours, whichever occurs first, from the date of readiness for operation, but not more than
fifteen (15) months from the date of shipment from Trio. All parts claimed to be defective shall be returned to Trio,
freight prepaid, for inspection to determine that the said part or parts are defective.
If it is determined that the fault lies with Trio, Trio will ship a replacement part or parts at no cost, but freight charges
will be paid by customer. If it is determined that the fault does not lie with Trio, a replacement part or parts will be
shipped, freight collect, to the customer with the receipt of a purchase order from the dealer or agent. Trio will not be
responsible for freight costs associated with warranty claims.
When petitioning for a warranty item, the serial number of the equipment must be referenced. The serial number must
be clearly identifiable on the Trio nameplate on the equipment. This warranty is void if:
The serial number plate and/or other markings identifying the machine as Trio have been altered or removed.
The machine was not sold under the Trio brand name or another brand name approved by Trio.
Parts have been used other than those supplied by Trio.
Trio makes no warranty with respect to damages or defects in any product caused by improper installation, operation,
maintenance, and storage or caused by negligence or accident. In addition, any product repaired or altered in any way
as reasonably determined by Trio, that affects the performance or purpose for which the equipment was originally
manufactured, will not be covered under this warranty.
Under this warranty, the buyer will not be entitled to any labor charges involving the repair of the equipment involving
warranty items, unless authorized by Trio in writing.
Warranties of merchantability or of fitness for any particular purpose or arising from the course of dealing or usage of
trade are specifically excluded. Any affirmation of fact, description of goods, or sample or model referred to in this
agreement or elsewhere, whether or not the same relate to production or capability of the goods to perform, are not the
basis of this agreement, unless specifically made a party of the agreement in writing.
Under no circumstances will Trio be responsible for consequential or punitive damages of any nature, whether based
on contract or tort, including but not limited to lost profits, loss of production, delays or other expenses. Under no
circumstances shall the liability of Trio exceed the purchase price of the equipment furnished.
The laws of the state of California shall govern the warranty. The parties agree that exclusive jurisdiction for any claim
for breach of this warranty shall rest in the Los Angeles County Superior Court in the State of California.

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 Cone Standard Job Procedures
Table of Contents

About These Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Bowl Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bowl Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Epoxy Backing Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Bowl Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Bowl Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Pouring the Bowl Liner Backing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bowl Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cone Head Mantle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cone Head Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mantle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Welding Lugs To Mantle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lifting Mantle Off Cone Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Mantle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pouring the Mantle Backing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cone Head Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Socket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Socket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Socket Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Socket Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Socket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Eccentric Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Eccentric Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Eccentric Assembly Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Eccentric Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Checking Backlash and Root Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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About These Instructions
These instructions are designed to give Trio
equipment owners and operators general guidance
and considerations for certain maintenance
procedures.
Bowl Liner Replacement
To replace the bowl liner, it will be necessary to
remove the bowl assembly from the adjustment
ring/locking ring.
Bowl Assembly Removal
1) Depressurize the hydraulic locking ring
cylinders. Pressure gauge must read zero.
2) Turn the bowl counter-clockwise to screw it
out of the adjustment ring/locking ring until
the threads become disengaged.
3) With a suitable lifting device and slings, lift
the bowl and adjustment cap assembly from
the machine and place it on the ground on top
of stable blocking.
4) Remove the feed hopper from the bowl
assembly.
5) Remove the adjustment cap from the top of
the bowl assembly.
6) Inspect the adjustment cap seal for damage or
wear. Replace if necessary.
7) Clean grease, dirt, and any other debris from
the threads on the adjustment ring, locking
ring, and bowl.
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Cone Standard Job Procedures
About These Instructions
NOTICE
Use gloves to protect hands and avoid
metal slivers when cleaning the thread
surfaces.
Epoxy Backing Description
Epoxy is a tough, resilient, non-metallic backing
material which is readily available in kit form in
various sizes. The use of epoxy requires no special
equipment, preparation or handling. The epoxy
material is not reusable and, therefore, is
expendable with the worn liner. With epoxy, the
backing can be mixed right at the job site as mixing
and pouring requires no special training. Follow
the simple directions supplied with each kit. Once
mixed, the epoxy must be poured without delay.
Subsequent mixes that may be required to
completely fill the cavity, can be poured at any
convenient time.
The epoxy kits and the parts that require backing
should be at 15° to 32°C (60° to 90°F) prior to
pouring.
NOTICE
If too cold, epoxy will harden slowly and
will be too viscous to fill a small space with
certainty. If too hot, there is the risk of the
mixture setting in the can before it can all
be poured. Should this situation arise, the
unopened cans should be immersed in cool
water before mixing to bring to
temperature noted above. Do not use
epoxy where the feed to the crusher
exceeds 79.4°C (175°F).
1
Cone Standard Job Procedures
Bowl Liner Replacement

Bowl Liner Removal 1) Remove the rectangular U-bolt lock washers

from the nuts.
See (Figure 1)
2) Remove the U-bolt nuts.

10 3) Lift off all the U-bolt washers.

4) Remove the U-bolts.

9 5) Lift the bowl off the liner. If bowl sticks to the

bowl liner, it may be necessary to hit vertically
on top of the bowl liner hooks to break the
backing material loose and release the bowl
liner.

6 6) With the bowl released from the bowl liner,

lift the bowl clear and chip off any backing
material that might remain on the bowl.
5
Bowl Liner Installation
4
8
7 3 1) Remove any rust, paint, or debris from seating
surfaces of bowl and new bowl liner.

2) Apply a light coat of lube oil to the inside of

2
the bowl to prevent backing material from
sticking to the bowl. Insure there is no oil on
1 liner seating surfaces.

1 - U-bolt 5 - Lock Washer NOTICE

2 - Thick Steel Washer 6 - Hex Nuts
3 - Rubber and Fabric 7 - Bowl
Use plastic or non-porous gloves when
Composition 8 - Bowl Liner
handling fiberglass insulation. Without
Washers 9 - Feed Hopper
protection, skin irritation could result.
4 - Thin Steel Washer 10- Adjustment Cap

Figure 1 Typical Bowl and Liner Assembly

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 Cone Standard Job Procedures
Bowl Liner Replacement

3) Cut U-shaped inserts using shears from

fiberglass insulation. The paper backing 1 - Bowl
should be left on the insulation while cutting 2 - Bowl Liner U-bolt
and protective non-porous gloves should be 3 - Fiberglass Packing
used when handling this material. Cut the 4 - Bowl Liner
length of the inserts so as to provide a 5 - Fiberglass Insert
minimum clearance of 1/2 inch between the 6 - Area for Backing Material to be Poured
insert and the edge of the bowl liner seat.
Chamfer the corners of the inserts to allow the 1
backing material to flow easily around the 6
inserts. Remove the paper covering and
position the inserts around the liner hooks
making sure the inserts will not interfere with
the seating of the bowl liner on the bowl.
2
4) Place the bowl liner on wood blocking,
making sure the blocking will allow the bowl
to fully seat on the bowl liner. 3

5) Lower the bowl in position on the bowl liner,

being careful not to disturb any of the inserts.
When the bowl is properly seated and
centered, fill all clearances and voids around 5
4
the hooks with loose insulation and pack
Figure 2 Preparation of Bowl and Bowl Liner
firmly in place using wooden wedge or
something similar. See (Figure 2).

NOTICE

Should any backing material be allowed to

seep in and harden around the liner hooks,
a worn liner will be difficult to remove.

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Cone Standard Job Procedures
Bowl Liner Replacement

6) Install the U-bolts and then assemble the thick Pouring the Bowl Liner Backing Material
steel washer followed by the rubber and fabric
The amount of backing material needed is based
composition washers followed by the thin
upon what size machine and what type of liners are
steel washer. Now assemble the nuts and
being utilized. See (Table 1)
tighten them securely so the rubber and fabric
composition washers are firmly compressed.
Table 1 Approximate Number of Backing Material
7) Check that the bowl liner bears tightly against 7.5 liter (2 Gallon) Kits Needed for Bowl Liners
the bowl by using feeler gauge all around the
Model Standard Head Short Head
liner seat. Should any opening exist due to
wear on this area of the bowl, pack these TC36 1 - 1/2 1 - 1/2
openings with silicone caulk or clay to keep
TC51 4 - 1/2 2 - 1/2
the backing from leaking out during pouring.
TC66 7 - 1/2 6
8) The liner should be even all the way around
TC84 15 9
the bowl. Take measurements in four places
about 90° apart, so the liner is as even as
NOTE: Requirements may vary depending on the
possible all around the perimeter.
type of liners used. If user is changing liner
See (Figure 3)
configuration, consult the Parts Manual because
filler blocks (packing) may need to be added or
1 - Bowl removed.
2 - Bowl Liner
3 - Measurements to Center Bowl on Liner 1) Prepare and mix the backing material per
instructions supplied with the material kit.
1
2) Pour backing material immediately after
mixing filling entire cavity between bowl and
bowl liner. See (Figure 4)

3 2 3

Figure 3 Center Bowl on Liner

9) If liner is not even, loosen U-bolts, re-position

the liner, and then re-tighten U-bolts.
Liner should now be ready to have backing
material poured.

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 Cone Standard Job Procedures
Bowl Liner Replacement

4) Re-install the feed hopper and adjustment cap

1 - Bowl back onto the top of the bowl assembly.
2 - Bowl Liner
3 - Backing Material 5) Lubricate the bowl, locking ring, and
adjustment ring threads using a spray dry film
3 lubricant that contains a mixture of
molybdenum disulfide and graphite on all
1 surfaces of the threads. Make sure all surfaces
are thoroughly coated. For best results, allow
film to dry before assembly.

6) Liberally coat the threads with lithium base

NLGI No. 2 grease.

7) With a suitable lifting device and slings, lift

2 the bowl assembly back above the adjustment
ring/locking ring to engage the threads on the
Figure 4 Pour Bowl Liner Backing Material
bowl.
Bowl Assembly Installation
8) Make sure the hydraulic locking ring cylinders
are depressurized. Pressure gauge must read
1) Re-check all bowl liner U-bolts after the
zero.
backing material has hardened making sure
they are all tight.
9) Turn the bowl clockwise to screw it into the
adjustment ring/locking ring until the threads
2) Place the rectangular lock washers over the
are engaged completely.
bolt nuts.
10) Turn the bowl assembly to the desired
3) Place layers of 50mm (2 inch) thick, or
crushing chamber setting.
thicker, unfaced fiberglass insulation around
and over the U-bolts to keep the dust and dirt
from building onto the assemblies and thus
making it easy to remove the nuts in the
future.

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Cone Standard Job Procedures
Cone Head Mantle Replacement
Cone Head Mantle Replacement
The cone head is assembled to the main shaft by an
interference fit and is supported by the concave
bearing surface of the socket liner. The tapered
portion of the main shaft extends down into the
inner bushing in the eccentric assembly. Covering
the head is the replaceable mantle. Some mantles
may come in two pieces, an upper and lower.
When this type mantle is used, it may only be
necessary to replace one portion until the other
portion has worn enough to warrant replacement.
See (Figure 5)
1 - Main Shaft Nut - Standard Head Type
2 - Main Shaft Nut - Short Head Type
3 - Torch Ring
4 - Mantle - (May be comprised of 2 pieces)
5 - Cone Head
6 - Main Shaft
1
2
3
Figure 5 Cone Head and Main Shaft Assembly
Cone Standard Job Procedures ENG (FEB-2014)
Cone Head Assembly Removal
To remove the cone head and shaft assembly for
mantle replacement, it is necessary to have the
bowl assembly removed. See the previous
instructions on Bowl Assembly Removal and
Bowl Assembly Installation.
1) Determine the heavy or thick side of the
eccentric by noting the discharge opening
before the bowl is removed. The low side of
the head indicates the heavy side of the
eccentric.
2) When the bowl assembly is removed and set
aside, fasten the cone head lifting tool
(supplied with the machine) to the main shaft
nut as shown. See (Figure 6)
1 - Cone Head Lifting Tool
2 - Main Shaft Nut
2
Figure 6 Cone Head Lifting Tool Installed
6

WARNING
Do not attempt to lift the cone head
assembly by the bolt holes on the feed plate
or by a rod inserted through the main shaft
nut. This would not be strong enough to
lift the entire weight of the head assembly.
Serious personal injury or severe damage
to the equipment could result.
3) With a suitable lifting device and slings,
carefully lift the cone head assembly out of
the crusher at a slight angle from vertical to
prevent damaging the sealing arrangement on
the underside of the head and on the socket.
4) With the cone head assembly out of the
crusher, examine the machined surfaces of the
head, shaft, inner eccentric bushing, and
sealing arrangement. Smooth any scratches or
score marks as well as remove any rust,
pitting, or debris. Also check the grease in the
socket sealing ring and replace with clean
grease as well as check the rubber support
pipe condition. See Socket Assembly later in
this section.
5) Lower the cone head assembly onto suitable
blocking to prevent damaging the seal area.
Mantle Removal
1) Remove the main shaft nut from the shaft by
turning it counter-clockwise. Use a sledge
hammer to hit against the lugs cast on the nut
or place a 1 - 3/4 inch diameter steel rod of
sufficient length through the hole in the nut
and hit on the rod.
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Cone Standard Job Procedures
Cone Head Mantle Replacement
2) If difficulty is encountered in removing the
nut, the torch ring, located below the nut, may
be torch cut to relieve the pressure on the nut.
In most instances it is not necessary to cut
completely through the torch ring, but a
groove cut in the ring around the entire
circumference will cause the ring to collapse.
If the torch ring must be cut all the way
through, be extremely careful not to damage
the shaft or cone head. See (Figure 7)
1 - Torch Ring
2 - 1 - 3/4 Inch Rod
3 - Main Shaft Nut
4 - Cutting Torch - Notice the cutting direction
3
2
1
4
Figure 7 Main Shaft Nut Removal
WARNING
When it is necessary to use a cutting torch
to remove parts with epoxy backing
material behind them, provide adequate
ventilation. Avoid inhaling fumes or dust.
Personnel removing parts are to wear
appropriate personal protective equipment
when torch cutting, grinding, or chipping.
3) With the main shaft nut removed, the worn
mantle is ready to be lifted off the cone head.
7
Cone Standard Job Procedures
Cone Head Mantle Replacement

4) To lift the worn mantle, weld two fabricated

steel lugs to the mantle in the general location
as shown in the following illustration. See WARNING
(Figure 8) and (Figure 9)
When lifting the mantle using lugs that
Chamfer 45° 50mm were welded on, be absolutely certain lugs
Both Sides (2”) Diameter are strong enough to carry the load safely.
50mm (2”)
The lifting lugs must be welded onto the
mantle by an experienced welder, using the
100mm proper welding rod and procedure for
(4”) welding structural steel (ASTM A36) to
manganese steel.

Radius Failure to do so can result in serious injury

50mm 50mm (2”) to personnel.
(2”)
Welding Lugs To Mantle
Use 13mm (1/2”) thick,
ASTM A36 structural steel plate. 1) Prepare lugs to fit snugly against mantle
surface at the proper location. Grind 45°
Figure 8 Fabricated Lifting Lug
chamfers on the lugs as shown.
See (Figure 8)
1 - Lifting Lugs Welded to Worn Mantle
2 - Lifting Slings 2) Clean mantle surface at lug base contact area
by grinding.
2
3) No preheat is necessary unless mantle
1 temperature is below 15°C (60°F). If below
this temperature, preheat to a range of 24° to
38°C (75° to 100°F).

4) Tack weld lugs to mantle using AWS E309

electrodes or AWS ER309 wire.

5) Complete welding of lugs to mantle using

6mm (1/4”) fillet welds. See (Figure 9)

6) Avoid excessive heating of weld area. If

necessary, skip weld or cool the welded area
Both Sides with a wet cloth or water spray.
6mm (1/4”)
7) Visually examine welded area for any defects.
Figure 9 Lifting Worn Mantle

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 Cone Standard Job Procedures
Cone Head Mantle Replacement

1 - Lifting Hooks Cast in Lower Edge of Mantle

WARNING 2 - Lifting Slings
2
Do not pull lugs with the lifting device or
crane to break the mantle loose from the
cone head.

Lifting Mantle Off Cone Head

Once lugs are welded to the worn mantle, proceed
to lift the mantle from the cone head.

1) Using a suitable lifting device and slings, lift

worn mantle from the cone head and set aside.

2) Usually the backing material will adhere to the

mantle and it will release from the cone head.

3) Chip off any backing material which might

remain on the cone head. 1

Mantle Installation Figure 10 Lifting New Mantle

1) Remove any rust, paint, or debris from seating
surfaces of cone head and new mantle.
2) Apply a light coat of lube oil to the cone head
to prevent backing material from sticking to
the cone head. Insure there is no oil on seating
surfaces.
3) With a suitable lifting device and slings, lift
new mantle and lower onto the cone head
using lifting hooks cast into the lower edge of
the new mantle. See (Figure 10)
If no lifting hooks are cast into the mantle,
follow the steps outlined above for welding
lifting lugs on mantle. See (Figure 9) These
lugs will have to be taken off and the welds
ground flush with the mantle surface after it is
in place on the cone head.
4) Center the mantle on the cone head using a
0.127mm (0.005”) feeler gauge around the
perimeter of the mantle.
5) Position the torch ring onto the top of the
mantle.
6) Screw on the main shaft nut clockwise and
tighten it securely against the torch ring
making sure the mantle is seated properly.
NOTICE
A loose or cocked mantle can result in
damage to the mantle or the seat on the
cone head. Properly seating is important
both for pouring the backing material and
the self-tightening feature of the nut.

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Cone Standard Job Procedures
Cone Head Mantle Replacement

7) Re-check that the mantle is tight against the Pouring the Mantle Backing Material
cone head by using a feeler gauge around the
The amount of backing material needed is based
perimeter of the seat. If any opening exists
upon what size machine and what type of liners are
due to wear on the cone head, fill with silicone
being utilized. See (Table 1)
sealant to keep backing material from leaking
out during pouring. See (Figure 11)
Table 2 Approximate Number of Backing Material
8) Some replacement mantles may have backing 7.5 liter (2 Gallon) Kits Needed for Mantle
material pour holes. If the mantle has this, it
Model Standard Head Short Head
is not necessary to remove the main shaft nut
as described below. You may proceed to TC36 2 - 1/2 1 - 1/2
Pouring the Mantle Backing Material.
TC51 4 2
9) If the mantle does not have pour holes, TC66 7 - 1/2 3 - 1/2
unscrew the main shaft nut counter-clockwise
TC84 12 6 - 1/2
and remove it from the shaft taking care not to
move the torch ring.
NOTE: Requirements may vary depending on the
type of liners used. If user is changing liner
configuration, consult the Parts Manual.
1
1) Prepare and mix the backing material per
instructions supplied with the material kit.

2 2) Pour backing material immediately after

mixing filling the cavity between mantle and
3 cone head to about 25mm (1”) below the top
of the mantle. See (Figure 11)

3) Screw on the main shaft nut clockwise and

tighten securely down against torch ring.
4
4) Once the backing material has sufficiently
hardened, the lifting lugs, that may have been
welded to the mantle, should be removed by
grinding off the welds.
1 - Area to Pour Backing Material
2 - Mantle Cone head and main shaft assembly is now ready
3 - Feeler Gauge to be re-installed into crusher.
4 - Cone Head Before assembly, make sure the socket sealing ring
has an adequate amount of clean grease and the
Figure 11 Cone Mantle Installation
rubber support pipe is in good condition and in
The mantle is now ready to have backing material place. See Socket Assembly later in this section.
poured.

Cone Standard Job Procedures ENG (FEB-2014) 10

 Cone Standard Job Procedures
Cone Head Mantle Replacement

Cone Head Assembly Installation 2) Apply a light coating of oil (not grease) to the
main shaft and spherical surface of the bottom
1) Fasten the cone head lifting tool (supplied of the cone head.
with the machine) to the main shaft nut as
shown. See (Figure 12) 3) With a suitable lifting device and slings,
carefully lift the cone head assembly at a
1 - Cone Head Lifting Tool slight angle from vertical and lower into the
2 - Main Shaft Nut crusher taking care to prevent damaging the
sealing arrangement on the underside of the
head, the socket contact area, and the inner
2 eccentric bushing.

4) After the cone head assembly has been

installed into the crusher, remove the lifting
tool from the main shaft nut.
The bowl assembly should now be ready to be re-
1 installed back on the crusher. See the previous
instructions on Bowl Assembly Installation.

Figure 12 Cone Head Lifting Tool Installed

WARNING

Do not attempt to lift the cone head

assembly by the bolt holes on the feed plate
or by a rod inserted through the main shaft
nut. This would not be strong enough to
lift the entire weight of the head assembly.
Serious personal injury or severe damage
to the equipment could result.

Cone Standard Job Procedures ENG (FEB-2014) 11

Cone Standard Job Procedures
Socket Assembly
Socket Assembly
The socket with the socket liner supports the cone
head and main shaft assembly and transmits the
crushing force to the main frame. The socket is
held into the frame by an interference fit and either
a series of capscrews bolted to the frame, or a
sereis of dowels holding it to the frame.
See (Figure 13)
Cone Standard Job Procedures ENG (FEB-2014)
The socket liner, mounted on top of the socket,
provides the bearing surface for the cone head.
The spherical bearing surface is thoroughly
lubricated from an oil passage through the center
of the main shaft and through the head. A retaining
ring on the socket prevents the oil circulating on
the surface of the socket liner from spilling into the
sealing arrangement. Grooves and holes in both
the socket and socket liner allow the oil to drain
back inside the crusher.
A sealing ring packed with grease and held against
the head wipers by means of a rubber support pipe
under it allows the dust particles that enter the seal
to become trapped and embedded in the grease.
Some seal ring types have helical springs for
support instead of the rubber support pipe.
12
 Cone Standard Job Procedures
Socket Assembly

4
3
5

Bolted Socket

2 6

1
4
3 5

Dowelled Socket

2 6

1 - Main Frame 4 - Socket Liner

2 - Socket 5 - Socket Sealing Ring
3 - Oil Retaining Ring 6 - Rubber Support Pipe

Figure 13 Typical Cone Socket Assembly Types

Cone Standard Job Procedures ENG (FEB-2014) 13

Cone Standard Job Procedures
Socket Assembly

Socket Assembly Removal

To be able to remove the socket assembly, it is
necessary to first have the bowl assembly and the
cone head and main shaft assembly out of the
machine. See previous procedures for their
removal.
NOTICE
Heating the frame is required to protect it
from damage when removing the socket.

1) Remove the sealing ring from the socket by 5) Alternately tighten each jackscrew in small
placing eyebolts into the tapped holes in the increments to prevent the socket from binding
ring and, with a suitable lifting device and in the frame.
slings, lift sealing ring off of the socket and set
aside. See (Figure 14) 6) Continue tightening until the socket is free
from the frame. This may require backing the
jackscrews out and placing spacer blocks
1 - Socket Sealing Ring
under the screws to completely pull the socket
2 - Rubber Support Pipe
from the frame.
3 - Socket Assembly
1 2 3 7) Remove the socket from the frame by placing
eyebolts into the tapped holes used for the
jackscrews and, with a suitable lifting device
and slings, lift the socket out of the frame.
The socket is now ready to have the liner removed
for replacement.

Figure 14 Socket Sealing Ring Removal

2) Remove the rubber support pipe and discard.

This is made from a straight section of rubber
pipe which is cut to the proper length to fit the
circumference of the socket area under the
sealing ring.

3) Install three jackscrews into the threaded holes

in the socket flange.

4) Uniformly heat the frame around the socket

where it fits into frame to 38° C (100° F)
above the ambient temperature.

Cone Standard Job Procedures ENG (FEB-2014) 14

 Cone Standard Job Procedures
Socket Assembly

Socket Liner Removal 2) Place a wooden block against the socket liner
and hit against the block with a heavy
1) Place the socket assembly upside down onto hammer, moving around the bore and
timbers or other suitable supports. alternately hitting the liner at one point, then
See (Figure 15) at a point on the opposite side until the liner
drops free.
1 - Socket Liner
2 - Socket 3) Set the worn socket liner aside.

1 2 4) Make sure the liner seating surfaces on the

socket were not damaged during liner
removal. Any dents, nicks, or other damage
will need to be smoothed and the surface flush
before a new liner is installed.

5) Make sure the dowels in the socket are in

good condition. Replace if necessary.

6) Turn the socket back over on the blocking.

Figure 15 Socket Liner Removal
The socket is now ready to have the liner installed.

Cone Standard Job Procedures ENG (FEB-2014) 15

Cone Standard Job Procedures
Socket Assembly

Socket Liner Installation

1 - Socket Liner
1) Center the new liner over the dowels in the 2 - Socket
socket. To prevent the liner from turning
should it lose its interference fit, babbitt will 1
be poured in the holes of the socket liner and
socket after the liner is seated. 2
See (Table 3) for the proper amount of
interference fit between the socket and the
socket liner.

Table 3 Socket Liner to Socket Interference

Model Minimum Maximum

TC36 0.00mm 0.08mm Figure 16 Socket Liner Installation
(0.000”) (0.003”)
3) With the liner seated, pour molten babbitt into
TC51 0.005mm 0.102mm the holes in the socket liner.
(0.0002”) (0.004”) See (Figure 17)
TC66 0.127mm 0.229mm
1 - Socket Liner
(0.005”) (0.009”)
2 - Socket
TC84 0.022mm 0.14mm 3 - Socket Dowel
(0.00086”) (0.0055”) 4 - Babbitt
5 - Smooth babbitt poured in this area to blend
2) Place a wooden block directly over the top the into the spherical surface of liner.
socket liner and hit against the block with a 5
heavy hammer, moving around the bore and
alternately hitting the liner at one point, then
at a point on the opposite side until the liner is
moved into place. See (Figure 16) 1
4

2
3
Figure 17 Socket Liner Babbitt Pour Installation

4) Thoroughly clean and lightly oil surface of the

liner.
Socket and liner assembly is now ready to be re-
installed back into crusher frame.

Cone Standard Job Procedures ENG (FEB-2014) 16

 Cone Standard Job Procedures
Socket Assembly

Socket Assembly Installation 5) Alternately tighten each mounting cap screw a

small amount to prevent binding.
For installation of the socket and liner assembly
into the crusher frame, proceed as follows.
6) Tighten all cap screws until the socket is
firmly seated in the main frame.
1) With a suitable lifting device and slings, lower
the socket and liner assembly into the
7) Install rubber support pipe or, springs and pins
approximate position on the crusher main
if so equipped, onto the socket. See (Figure
frame and align the holes in the socket with
18)
the dowels in the frame.

2) Insert mounting cap screws through the holes NOTICE

in the socket then into the tapped holes in the
frame.
3) As the socket has an interference fit with the
frame, See (Table 4) for proper interference fit
between the socket and frame.
It is very important the rubber support pipe
be stored properly to assure the rubber is
not kinked, bent, or otherwise in a
condition that would not fit properly once
installed.

Table 4 Socket to Main Frame Interference

Model Minimum Maximum

Rubber
TC36 0.05mm 0.152mm
Support
(0.002”) (0.006”)
Pipe
TC51 0.010mm 0.152mm
(0.0004”) (0.006”)
TC66 0.127mm 0.229mm
(0.005”) (0.009”)
TC84 0.022mm 0.14mm
(0.00086”) (0.0055”)
Springs
and
4) Uniformly heat the frame around the socket Pins
where it fits into frame to 38° C (100° F)
above the ambient temperature.

NOTICE

Heating the frame is required to protect it

from damage when installing the socket.
Figure 18 Socket Sealing Ring Rubber Support Pipe or
Springs and Pins

Cone Standard Job Procedures ENG (FEB-2014) 17

Cone Standard Job Procedures
Socket Assembly

8) There is either an o-ring or a wool felt packing 12) Lightly oil the surface of the socket liner and
on the socket sealing ring flange. Make sure coat both sealing ring wipers with a liberal
this is lubricated and installed in the groove on amount of grease.
the sealing ring.
The cone head and shaft assembly is now ready to
be re-installed back into the crusher onto the
9) With a suitable lifting device and slings,
socket and socket liner assembly with the sealing
carefully align the sealing ring with the
ring. See cone head assembly installation
locking keys or the guide pins in the socket
procedures described previously in this section.
and lower the socket sealing ring down into
the socket and onto the support pipe or,
springs and pins if so equipped.

10) Remove the lifting eyebolts used on the

sealing ring and seal the tapped holes with
cotton waste saturated with oil or grease.
Some sealing rings may be supplied with
plastic plugs to place in these holes.

11) Pack the sealing ring chamber with a lithium

base NLGI No. 1 grease or equivalent to the
level shown in the following illustration. See
(Figure 19)

Figure 19 Socket Sealing Ring Grease Chamber

Cone Standard Job Procedures ENG (FEB-2014) 18

 Cone Standard Job Procedures
Eccentric Assembly

Eccentric Assembly
1 - Upper Step Bearing Plate Tool
The eccentric assembly, which has a tapered,
2 - Eccentric Assembly
offset bore, provides the means for the head and
3 - Eyebolts
main shaft to follow an eccentric path during each
cycle of rotation. An inner eccentric bushing
locked into the eccentric bore provides the bearing
surface for the main shaft. The upper and lower 3
step bearing plates with shims under the main 2
frame cap positions the eccentric assembly gear 1
contact with the pinion gear. Backlash and root
clearance between eccentric gear and pinion gear
are maintained by the addition or subtraction of
step bearing plate shims.

Eccentric Assembly Removal

To remove the eccentric assembly, it is necessary
to have first removed the bowl and liner assembly,
cone head and main shaft assembly, socket and
socket liner assembly, and the socket sealing ring Figure 20 Eccentric Assembly Removal
assembly. Once these assemblies have been
removed as described previously, proceed as 2) Install the two eyebolts into the top of the
follows: eccentric assembly.

1) Attach the upper step bearing tool to the upper 3) With a suitable lifting device and slings,
step bearing plate to hold it together with the carefully lift the eccentric assembly out of the
eccentric. See (Figure 20) main frame.

4) Set eccentric aside and inspect gear and

bearing surfaces.

5) Install lower step bearing plate eyebolt tool.

See (Figure 21)

Cone Standard Job Procedures ENG (FEB-2014) 19

Cone Standard Job Procedures
Eccentric Assembly
1 - Lower Step Bearing Plate Tool
1
Figure 21 Lower Step Bearing Plate Removal
6) With a suitable lifting device and sling, lift
the lower step bearing plate from crusher.
7) Set plate aside and inspect bearing surface for
wear.
Cone Standard Job Procedures ENG (FEB-2014)
8) Remove shims from crusher which are under
the lower step bearing plate. Take note the
amount of shims.
NOTICE
Shims installed at the factory are of the
required thickness to provide proper
backlash and root clearance. Additional
shims may be required for wear
compensation.
With all components removed from crusher,
inspect outer eccentric bushing for wear or
damage. If the outer eccentric bushing requires
replacement, see the removal and installation
procedures later in this section.
20
 Cone Standard Job Procedures
Eccentric Assembly

Eccentric Assembly Measurement

The eccentric assembly thrust bearing plates along Table 5 Eccentric Assembly Dimensions
with the shims set the eccentric overall height
Dimension (mm) Shims
dimensions. See (Figure 22). The quantity of Model
shims and the dimensions for a new eccentric are A B C Thickness (mm) Qty.
shown in the table below. See (Table 5) 1 2

TC36H 59.5 16 747.7 1.5 2

3 1

1 2

TC51 31.75 19.05 911.4 1.5 2

3 2
1
1 2

C TC66 95.25 19.18 1200.15 1.5 2

3 1
2 1 2
TC84 1.5 2
& 96 20 1505
3 TC84X 2 1

3 1
4
A

B
1 - Eccentric
2 - Upper Step Bearing Plate
3 - Lower Step Bearing Plate
4 - Shim Set

Figure 22 Eccentric Assembly

Cone Standard Job Procedures ENG (FEB-2014) 21

Cone Standard Job Procedures
Eccentric Assembly
Eccentric Assembly Installation
Carefully inspect the pinion gear to assure there is
no excessive wear or damage. If it is required to be
replaced, see the removal and installation
procedures later in this section.
When ready to install eccentric assembly back into
crusher, proceed as follows:
1) Install the amount of shims into the crusher
that were removed as noted previously.
2) Install the lower step bearing plate using the
eyebolt tool with a suitable lifting device and
sling. See (Figure 23)
1 - Lower Step Bearing Plate Tool
Figure 23 Lower Step Bearing Plate Installation
3) Remove the lower step bearing plate eyebolt
tool from the plate.
Cone Standard Job Procedures ENG (FEB-2014)
4) With a suitable lifting device and slings and
with the upper step bearing plate tool still
holding the upper step bearing plate to the
eccentric, carefully lower the eccentric
assembly into the bore of the outer eccentric
bushing.
1 - Upper Step Bearing Plate Tool
2 - Eccentric Assembly
3 - Eyebolts
3
2
1
Figure 24 Eccentric Assembly Installation
5) Continue lowering the eccentric assembly
until it sets on the lower step bearing plate and
making sure the eccentric gear teeth engage
with the pinion gear teeth.
6) Remove upper step bearing plate tool from the
eccentric assembly.
22
 Cone Standard Job Procedures
Eccentric Assembly

7) Root clearance and backlash should be set as

indicated in the following table.

Table 6 Gear Root Clearance and Backlash

Backlash Root Clearance

Model
Minimum Maximum Minimum Maximum
TC36 0.51 mm (0.020”) 1.00 mm (0.040”) 2.38 mm (0.094”) 3.20 mm (0.125”)
TC51 0.76 mm (0.030”) 1.27 mm (0.050”) 2.38 mm (0.094”) 3.96 mm (0.156”)
TC66 1.1 mm (0.040”) 1.52 mm (0.060”) 3.20 mm (0.125”) 4.60 mm (0.183”)
TC84 1.1 mm (0.040”) 1.60 mm (0.063”) 4.00 mm (0.160”) 10.2 mm (0.400”)
NOTE: Measurement to be taken at outer end of teeth only.

Checking Backlash and Root Clearance 3) Remove all clearance between between the
eccentric and the outer eccentric bushingby
1) Position the heavy side of the eccentric pushing the eccentric toward the pinion. This
assembly near the pinion. puts the eccentric gear teeth in the closest
relationship to the pinion gear teeth.
2) Turn the countershaft slightly until an
eccentric gear tooth is in a vertical position. 4) Hold the gear in this position while taking the
See (Figure 25) measurements. Use only enough force
required to maintain this position. Excessive
1 - Backlash Measurement force may tip the eccentric and cause incorrect
2 - Eccentric Gear Tooth Must Be Vertical readings.
3 - Root Clearance Measurement
4 - Pinion Gear 5) Rotate the countershaft until the pinion gear
5 - Eccentric Gear tooth just touches the eccentric gear tooth.

6) Measure the clearance on the opposite side of

1
the teeth with a feeler gauge for the backlash
5
reading as shown.

7) Measure the root clearance between the two

meshing teeth as shown.

3 2
4

Figure 25 Gear Backlash and Root Clearance

Cone Standard Job Procedures ENG (FEB-2014) 23

Cone Standard Job Procedures
Eccentric Assembly
8) Repeat this several times to find average
readings. If the average readings are less than
or more than specified in the above table, then
the eccentric assembly should be removed to
add or remove appriate amount of shims to
attain the specified measurements.
NOTICE
The backlash measurement of the gears
takes priority when doing this check.
Cone Standard Job Procedures ENG (FEB-2014)
9) When installing shims, place the thinnest shim
at the bottom and the thickest at the top. Use
the thickest shims possible and make sure they
are flat without burrs, kinks and bends.
10) Adding shims will raise the eccentric
assembly and move the eccentric gear away
from the pinion gear which increases root
clearance.
Once the backlash and root clearance is set, the
crusher is now ready to be re-assembled with the
components previously removed.
24