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Views: 0 Author: Site Editor Publish Time: 2026-01-23 Origin: Site
The crushing chamber of a jaw crusher is the core component responsible for the actual crushing process. It consists of a moving jaw and a fixed jaw. The moving jaw is typically cast from high - manganese steel, with a manganese content ranging from 12% to 14%. This material provides excellent wear resistance and impact resistance. The surface of the jaw is designed with a toothed pattern, and the angle of the tooth crest is usually between 60° and 70°. This tooth design enhances the splitting effect on the ore, enabling more efficient crushing.
The fixed jaw liner and the moving jaw liner form a "V - shaped" crushing chamber. The width of the upper feeding port determines the processing capacity of the jaw crusher. For example, the PE - 600×900 type jaw crusher has a feeding port size of 600×900mm, which allows it to handle a processing capacity of 50 - 160 tons per hour. The deep - cavity design of the crushing chamber extends the residence time of the ore in the chamber by 15% compared to traditional designs. Coupled with the tapered chamber shape (wider at the top and narrower at the bottom), it achieves a crushing ratio of 4 - 6, making it highly suitable for primary crushing operations in underground mining projects.
The eccentric shaft assembly is a crucial part of the jaw crusher's transmission system. Made from 42CrMo alloy forged steel, the shaft undergoes quenching and tempering treatment, resulting in a hardness of HB280 - 320. The eccentricity of the shaft varies according to different models. For instance, in the PE - 1200×1500 type jaw crusher, the eccentricity is 30mm, which determines the swing amplitude of the moving jaw. This precise design ensures the stable operation of the crusher and the effective transmission of power.
The bearing and lubrication system is essential for the smooth running of the jaw crusher. Double - row self - aligning roller bearings, such as the 23240CA type, are commonly used. These bearings are equipped with an automatic thin - oil lubrication system. When the oil temperature exceeds 60°C, the cooler automatically activates to maintain the optimal operating temperature. This advanced lubrication system ensures that the bearing life can reach more than 20,000 hours, reducing the frequency of maintenance and replacement.
The discharge opening adjustment mechanism is a key feature of jaw crushers, allowing for flexible control of the product particle size. The wedge - type adjustment mechanism, available in both manual and hydraulic versions, enables stepless adjustment within a range of 5 - 200mm, with an adjustment accuracy of ±2mm. This feature allows operators to meet different crushing requirements, whether it is for coarse crushing in the early stages of mining or for more refined crushing in specific processes.
The overload protection system of the jaw crusher is designed to safeguard the main components from damage. The toggle plate is deliberately designed as the "weak link" of the system, usually made of HT300 material. When foreign objects enter the crushing chamber, the toggle plate will break first, protecting critical components such as the eccentric shaft and the moving jaw. Replacing the toggle plate can be completed in less than 30 minutes, minimizing downtime and repair costs.
Lubrication management is of utmost importance in daily maintenance. Operators need to regularly check the oil level of the thin - oil station, ensuring it remains between one - half and two - thirds of the oil level gauge. When the oil temperature exceeds 70°C, the crusher should be shut down immediately for inspection. For manual lubrication points, such as the tie - rod nuts, lithium - based grease of NLGI 2 grade should be applied 1 - 2 times per shift. This regular lubrication reduces friction, prevents wear, and ensures the smooth operation of moving parts.
Fastener inspection is another critical daily task. Using a torque wrench, operators should check the tightness of the frame bolts. The pre - tightening torque varies according to the model; for example, for the PE - 600×900 type, it should be 450 - 500N·m. Any loose bolts should be tightened promptly to avoid increased vibration, which can lead to damage to the crusher and affect the quality of crushing.
Liner wear detection is a key aspect of regular maintenance. A feeler gauge should be used to measure the thickness of the liners. When the remaining thickness is less than one - third of the original thickness (for example, when the original thickness of the moving jaw liner is 120mm and it wears down to 40mm), the liners should be replaced. It is important to replace the left and right liners simultaneously to ensure the symmetry of the crushing chamber, which is crucial for uniform crushing and the longevity of the equipment.
Bearing condition monitoring is also essential. A vibration detector should be used to measure the amplitude of the bearing seat. The amplitude in the vertical and horizontal directions should be no more than 0.15mm/s. If the value exceeds the standard, the bearing clearance should be checked. For new bearings, the clearance is typically 0.12 - 0.18mm, and the wear limit is 0.4mm. Early detection of bearing problems can prevent serious failures and costly repairs.
Eccentric shaft flaw detection is a major task during the overhaul. Ultrasonic flaw detection should be carried out on the shaft neck and eccentric parts. Any cracks deeper than 2mm require the replacement of the shaft. The detection sensitivity for new shafts should be no less than that of a Φ2mm flat - bottomed hole. This thorough inspection ensures the safety and reliability of the key transmission component.
The gearbox also needs comprehensive maintenance during the overhaul. After opening the gearbox, the tooth surface wear should be checked. The allowable tooth thickness wear is no more than 15%, and the meshing clearance should be maintained at 0.15 - 0.3mm. Additionally, the lubricating oil should be replaced. The viscosity grade of the oil is usually ISO VG 220, and the oil change cycle is 80,000 hours. Proper gearbox maintenance is vital for the smooth transmission of power and the overall performance of the jaw crusher.
When the production capacity of the jaw crusher decreases, it is often due to liner wear or an enlarged discharge opening. The solution is to replace the worn - out liners in a timely manner and readjust the discharge opening to the standard value. Abnormal vibration may be caused by damaged bearings or uneven feeding. In this case, the bearings should be replaced, and the feeding device should be adjusted to ensure uniform feeding. If the toggle plate breaks, it is usually a result of overloading or the use of a toggle plate that does not meet the material requirements. The solution is to remove foreign objects from the crushing chamber and replace the toggle plate with a high - strength one, such as ZG310 - 570.
The stable operation of jaw crushers depends on the rational design of key components and regular maintenance. From liner wear management to bearing lubrication, each maintenance link is crucial for extending the service life of the equipment and reducing downtime costs. For mining enterprises, establishing a standardized maintenance process, such as the "5S" management method, can reduce the failure rate by more than 30%. Properly maintained jaw crushers can continuously provide reliable crushing performance, supporting the efficient operation of underground mining trucks and the entire mining production line.
Hambition Drivetrain Components & Parts Co., Ltd. provides original accessories for jaw crushers, such as high - manganese steel liners and eccentric shafts, as well as professional maintenance training services. If you need to obtain the "Jaw Crusher Maintenance Manual" or on - site maintenance support, please visit our website at www.hambition.net. Our technical team is dedicated to ensuring the optimal performance of your mining equipment, helping you achieve efficient and stable mining operations.
