Full Analysis of Wearing Parts of Jaw Crusher: Types, Replacement Cycles and Tips for Extending Service Life

As the core equipment in mining, building materials and other industries, the jaw crusher's operating status is directly related to production efficiency and economic benefits. However, due to the harsh environment of crushing operations and long-term use, the jaw crusher is subject to high-intensity impact and friction, and its wearing parts are prone to wear, breakage and other problems. This will not only affect the performance and efficiency of the equipment but also may cause production line shutdown. Therefore, timely and regular inspection and replacement are required to ensure the normal operation and production efficiency of the equipment.

1. Types and replacement cycles of wearing parts for jaw crushers

The wearing parts of the jaw crusher include a movable jaw plate, fixed jaw plate, side guard plate, toggle plate, bearings, spring tension rods and spring components, etc.

(1). Fixed and movable jaw plate:

The jaw plate is the main working component of the jaw crusher and bears huge impact loads. During the crushing process, serious wear will occur on the edge of the fixed and movable jaw plate, and the wear is mostly concentrated in the middle and lower parts. This is due to the repeated impact and friction of the materials during the crushing process. The shape of the fixed and movable jaw plate is designed to be symmetrical up and down, so when one end of the fixed jaw plate is worn, it can be turned around and used. To extend its service life, the fixed and movable jaw plate is generally made of high manganese steel and other materials with good hardness and wear resistance, such as ZGMn13 material. The replacement cycle of the fixed and movable jaw plate is generally about a few months to half a year, depending on factors such as usage conditions, stone hardness, and equipment load.

(2). Side guard plate:

The side guard plates are located on the left and right inner sides of the jaw crusher rack and are used to protect the jaw crusher body. The side guard plate will wear away from material impact. When the wear of the side guard plate reaches a certain level, it needs to be replaced with a new one. The replacement cycle of the side guard plate is generally longer, usually about half a year, depending on the usage conditions and the working intensity of the crusher.

(3). Toggle plate:

The toggle plate is an important component of connecting the movable and fixed and movable jaw plates. It is also an insurance part of the crusher. When unbreakable materials fall into the crusher and the machine exceeds the normal load, the toggle plate will break immediately and the crusher will stop working, thereby avoiding damage to the entire machine. Toggle plates need to be inspected and replaced regularly, and the replacement cycle is usually about half a year. The toggle plate and toggle plate pad adopt a sliding contact method. There is little friction under normal use. It is enough to apply a layer of grease on the contact surface.

(4). Spring tension rods and spring components:

As an important component of the jaw crusher, the spring pull rod mainly plays the role of connecting the adjustment seat and the back support plate. It can also adjust the size of the ore discharge port and maintain the stability of the jaw plate. The spring component and the spring tension rod are matched and have the main function. It is a fixed toggle plate to prevent the toggle plate from falling off and absorbs and buffers the vibration and impact during the crushing process. It has a good buffering and vibration-damping effect and can effectively reduce the impact damage to the machine during the crushing process. In actual operation, if the spring tension rod and the spring components are found to be damaged or failed, they need to be replaced in time to ensure the normal operation of the equipment. The replacement cycle of spring rods and the spring components is generally about half a year. The specific replacement cycle depends on factors such as usage conditions, work intensity, and maintenance.

(5). Bearings:

The jaw crusher's bearings use 4 sets of spherical roller bearings, which have good load-bearing and self-aligning properties. The bearings of the jaw crusher mainly bear the radial load when the equipment is working. Under long-term high-load operation, the bearings will wear and need to be inspected and replaced regularly. The turning eccentric shaft and jaw mandrel are replaced, the Babbitt alloy on the upper part of the connecting rod head is cast, and the worn parts are replaced or repaired. To increase the service life of the bearing, bearing materials with higher durability and load-bearing capacity can be used. The replacement cycle of bearings is generally more than one year, depending on bearing quality, usage conditions and maintenance.

2. How to extend the service life of the wearing parts of the jaw crusher?

(1). Optimize the crushed materials: Different materials crushed by the jaw crusher will have different wear conditions of wearing parts. The crushed materials should be optimized as much as possible to reduce the use of materials with high hardness and many impurities.

(2). Use the correct operating method: The correct operating method can reduce the wear of the liner. For example, the feeding should be kept uniform to avoid too much or too little feeding; Overloading should be avoided during operation to prevent excessive damage to the equipment with a big load.

(3). Regular inspection and maintenance: Regularly check the wearing parts of the crusher. If any serious wear or damage is found, they should be replaced in time. In addition, the inside of the equipment should be cleaned regularly to prevent the accumulation of impurities and cause additional wear and tear.

(4). Reasonable installation and adjustment: When installing and adjusting the jaw crusher, ensure the correct installation position and reasonable adjustment of each component to avoid additional wear caused by deviations and instability.

(5). Proper maintenance and lubrication: Keep the lubricating oil clean, and replace and replenish the lubricating oil in time to ensure that the equipment operates under normal lubrication conditions.

(6). Pay attention to safe operation: When using the jaw crusher, you must strictly follow the operating procedures, pay attention to safety matters, and avoid equipment damage caused by human factors.

(7). Choose high-quality wearing parts: Choose high-quality wearing parts suppliers and purchase original or high-quality certified wearing parts to ensure the quality and service life of wearing parts and reduce equipment failure rates.

In summary, the types and replacement cycles of wearing parts will vary depending on factors such as equipment model, manufacturing process, usage environment, and operating methods. Therefore, in actual production, the jaw crusher should be inspected and maintained regularly, and problems should be discovered and dealt with in a timely manner to ensure normal operation of the equipment and improve production efficiency. At the same time, users also need to standardize the use of crushing equipment, perform maintenance and repair of wearing parts, strengthen the inspection process, and replace them in time if wear and tear is found, to ensure the normal operation of the entire gravel production line.