A Comprehensive Guide to Crusher Parts and Spares

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Specialized Article: A Comprehensive Guide to Crusher Parts and Spares

An in-depth look at the types of parts, materials, maintenance principles, and increasing the lifespan of crushing equipment.

Introduction

In the mining and road construction industries, crusher parts play a vital role as the beating heart of aggregate production lines in the mineral crushing process. These machines operate under intense pressure and abrasion, and crusher spare parts wear out over time. A precise understanding of spare parts, the materials used, maintenance principles, and warning signs of failure is essential for any technical manager and investor in this field.

In this article, we will comprehensively review the types of crusher parts (Jaw, Kobit, Hydrocone), the metallurgy of the parts, a guide to purchasing crusher spare parts, and key tips for extending the lifespan of the equipment.

Part 1: Classification of Crusher Parts

Crusher parts are divided into two main categories:

  1. Critical Parts

    Parts that play a fundamental role in the machine’s operation, and their failure can cause severe damage to the entire machine. Replacing these crusher spare parts is very costly and sometimes impossible. Examples:

    • Machine Body and Chassis: The backbone of the crusher, through which impact pressure, vibration, and continuous stresses are transmitted.
    • Pulley: Plays a fundamental role in all crushers (Jaw, Kobit, Hydrocone).
    • Toggle (in Jaw Crusher): A critical part that may split under sudden pressure.
    • Rotor (in Kobit): Located at the center of impacts; any crack or warp in it is very dangerous.
    • Screen Decks and Chassis.
    • Main Shaft and Housing (in Hydrocone).

  2. Wear Parts

    Parts that gradually wear down during operation and have a specific lifespan. These crusher spare parts must be replaced periodically. Examples:

    • Hammer and Liner in Kobit.
    • Jaw Plate in Jaw Crusher (Fixed and Moving).
    • Screen Mesh (typical lifespan of 4 to 5 months).
    • Paddle in Sand Washer (lifespan of 7 to 8 years).
    • Mantle and Concave in Hydrocone.
    • Anvil and Hammer Box.

Part 2: Jaw Crusher Parts

Introduction and Application

The Jaw Crusher is used as a primary crusher in crushing lines and is designed for crushing large and hard rocks (up to 320 MPa resistance). Jaw Crusher spare parts include the following:

Main Parts of the Jaw Crusher:

  • Fixed Jaw Plate: Made of manganese steel, provides a stationary surface for crushing.
  • Moving Jaw Plate: Made of manganese steel, a moving surface for applying pressure.
  • Jaw Fixer: Made of alloy steel, holds the jaw plate.
  • Toggle: Made of cast iron or steel, transmits force and protects the machine from overload.
  • Main Shaft: Made of alloy steel, transmits rotational force.
  • Bearings: Made of chrome steel, withstand radial and axial loads.
  • Pulley: Made of cast iron, transmits power from the motor to the machine.
  • Electric Motor: Provides motive power.

Important Points in Jaw Crusher Inspection:

  1. Body and Chassis: Check for micro-cracks that are sometimes not visible to the naked eye.
  2. Toggle: Ensure there are no cracks, as breakage can damage the jaw plate and body.
  3. Pulley: Check for cracks, warping, or excessive play on the shaft.
  4. Jaw Plate: Inspect the extent of wear and the need for replacement.

Part 3: Kobit (Impact) Crusher Parts

Introduction and Application

The Impact Crusher (Kobit) is used for crushing medium to high hardness materials and crushes rocks using hammer impacts. Kobit crusher spare parts include the following:

Main Parts of the Kobit Crusher:

  • Hammer: Made of manganese steel or molybdenum manganese steel, strikes the rocks.
  • Rotor: Made of alloy steel, holds the hammers and is the center of impact.
  • Anvil: Made of manganese steel, provides a stationary surface for rock impact.
  • Liner: Made of manganese steel or Ni-Hard cast iron, protects the body from abrasion.
  • Hammer Box: Made of steel, holds the hammer in the rotor.
  • Rotor Shaft: Made of alloy steel, the main axis of the rotor.

Critical Points in Kobit Crushers:

  1. Rotor: The most important part of the Kobit. It must be checked for cracks, absence of additional welding, and balance.
  2. Timely Replacement of Hammers: If hammers are not replaced on time, excessive impacts will occur, increasing pressure on the body and even damaging the motor.
  3. Rotor Balancing: Imbalance causes severe vibration and premature failure of the bearings.

Part 4: Hydrocone (Cone) Crusher Parts

Introduction and Application

The Cone Crusher (Hydrocone) is used for crushing high-hardness minerals in the secondary and tertiary stages. Hydrocone crusher spare parts include the following:

Complete List of Hydrocone Crusher Parts:

  • Mantle: Made of manganese steel, the moving conical part that moves towards the Concave.
  • Concave: Made of manganese steel, the stationary part against which the Mantle presses.
  • Top Shell: Made of cast steel, the upper part of the body.
  • Bottom Shell: Made of cast steel, the lower part of the body.
  • Main Shaft: Made of alloy steel, performs the crushing operation and adjusts the Mantle-Concave gap.
  • Eccentric Bushing: Made of bronze or steel, transmits power to the crusher’s center and adjusts output size.
  • Head Center: Made of steel, holds the Mantle on the shaft.
  • Cranville and Pinion Gears: Made of alloy steel, transmit torque.
  • Piston and Piston Plate: Made of carbon steel, control the hydraulic system.
  • Bearings: Made of chrome steel, reduce friction and withstand load.
  • Dust Collar: Made of steel, protects against dust.
  • Bowl: Made of carbon steel, transmits force between parts.

Important Points in Hydrocone Crushers:

  1. Adjustment of Mantle and Concave Gap: Directly affects the size of the output product.
  2. Lubrication System: Hydrocone requires an advanced lubrication system.
  3. Inspection of Bushings: Bronze bushings are subject to wear and must be replaced promptly.
  4. Hydraulic System: Used for adjusting the discharge opening and rapid removal of uncrushable materials.

Part 5: Screen and Sand Washer Parts

Screen Parts:

  • Screen Mesh: Separates materials into different sizes (lifespan 4-5 months).
  • Vibrating Motor: Creates vibration for sizing.
  • Springs: Suspend the screen and absorb vibrations.
  • Decks: Support the meshes.
  • Eccentric Shaft: Creates vibration in mechanical models.

Sand Washer (Classifier) Parts:

  • Helical Paddles: Convey and wash materials (lifespan 7-8 years).
  • Main Shaft: Transmits power to the screw.
  • Gearbox: Reduces speed and increases torque.
  • Paddle Rubber: Reduces wear on the plate and increases lifespan.
  • Tub: The basin holding water and materials.

Part 6: Metallurgy and Material of Parts

The quality of crusher spare parts directly depends on their material and manufacturing process.

Types of Alloys Used:

  • Manganese Steel (Hadfield): Used in jaw plates, hammers, mantles, concaves – Feature: High wear resistance, high work hardening.
  • Molybdenum Manganese Steel: Used in Kobit hammers – Feature: Greater wear resistance, high toughness.
  • Ni-Hard 4 Cast Iron: Used in liners, parts under severe wear – Feature: Very high hardness, limited impact resistance.
  • High Chrome Cast Iron: Used in rotors, parts under wear – Feature: Excellent wear resistance.
  • Carbon Steels: Used in bodies, chassis, structural parts – Feature: Good strength, reasonable price.
  • Bronze: Used in Hydrocone bushings – Feature: Self-lubricating, wear resistance.

Manufacturing Process:

  1. Casting: Most crusher spare parts are produced by casting.
  2. Heat Treatment: To achieve desired hardness and toughness.
  3. Machining: For precise parts like shafts and bushings.

Part 7: Guide to Purchasing Spare Parts

Key Points in Purchasing Parts:

  • Source from Reputable Suppliers: Purchase from actual crusher part manufacturers, not intermediaries.
  • Compatibility with Machine Model: Crusher spare parts must precisely match the crusher model.
  • Check Material and Alloy: Request material analysis and quality certificates.
  • Warranty and After-Sales Service: Spare parts must have a warranty.
  • Parts Availability: Ensure availability of frequently consumed crusher parts.

Factors Affecting Part Prices:

  • Type of alloy and raw materials.
  • Manufacturing process (casting, machining).
  • Exchange rates and market conditions.
  • Manufacturer brand.
  • Part dimensions and weight.

Part 8: Maintenance Principles and Increasing Part Lifespan

Periodic Inspection:

  1. Daily Inspection: Check hammers, jaw plates, screens, and signs of wear on crusher spare parts.
  2. Weekly Inspection: Check bearings, lubrication, bolts, and nuts.
  3. Monthly Inspection: Inspect the body, chassis, and potential cracks.

Warning Signs:

  • Unusual Vibration: May indicate an unbalanced rotor or a warped body.
  • Unusual Noise: Indicates damaged bearings or loose crusher parts.
  • Reduced Efficiency: Indicates excessive wear of hammers or jaw plates.
  • Increased Energy Consumption: Indicates a problem with the crusher spare parts.

Golden Tips for Increasing Part Lifespan:

  1. Timely Replacement of Consumables: Before they damage main parts.
  2. Regular Lubrication: Use appropriate oil and grease.
  3. Precise Machine Adjustment: Adjust clearances according to the material type.
  4. Uniform Feeding: Prevent the sudden entry of very large rocks.
  5. Adhere to Rated Capacity: Avoid overloading the machine.

Part 9: Conclusion and Final Recommendations

Parts Management Checklist in the Mine:

  1. Identify Critical Parts: Determine crusher parts whose failure will stop the production line.
  2. Strategic Inventory: Maintain at least one set of critical spare parts in stock.
  3. Scheduled Replacement Program: Create a replacement calendar for consumable spare parts based on operating hours.
  4. Collaborate with Reputable Suppliers: Establish long-term relationships with crusher part manufacturers.
  5. Staff Training: Train operators and maintenance personnel for early problem detection.

Concluding Remarks

Crusher parts are the beating heart of aggregate production lines and mining industries. Investing in high-quality crusher spare parts is not an expense, but a smart move to ensure production continuity, reduce unscheduled downtime, and increase productivity. A precise understanding of spare parts, their materials, and maintenance principles is the winning advantage for technical managers in today’s industrial competition.

KOBESH MACHINE – Specialized Supplier of Crusher Parts

With over 3 decades of experience in designing and manufacturing crushing equipment, Kobesh Machine is proud to offer various genuine crusher spare parts with the best quality and international standard alloys (Manganese Steel, Ni-Hard, High Chrome Steel) to our customers across the country and the region.

Available Parts:

  • Fixed and Moving Jaw Plates for all Jaw Crusher models.
  • Kobit Hammers (HS, Kobit 120, 180, Behringer).
  • Hydrocone Mantle and Concave in various types.
  • Liners, Anvils, Hammer Boxes, and Rotors.
  • Screen Meshes with various apertures.
  • Sand Washer Paddles with rubber lining.
  • Genuine Bearings and Alloy Shafts.

Immediate Shipping Nationwide and to Regional Countries.

Contact Us:

Alipour Brothers – Kobesh Machine

Amir Alipour: +989121943801 Yousef Alipour: +989123657790 Abdolhossein Alipour: +989126614519

Kobesh Machine – Powering Your Production.