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Crusher Wear Parts Reference Guide: Powerscreen
Crusher Wear Parts Reference Guide: Powerscreen
www.powerscreen.com
CONTENTS
WEAR PARTS OVERVIEW PAGES 4 - 11
• Metallurgy Options & Facts
• Wear Lifetime & Costs
• Test Methods & Terminology
ROCK TYPES
Medium & Soft & Non-
Manganese Hard & Hard & Non- Medium & Soft &
Non-Abrasive Abrasive
Content Abrasive Rock Abrasive Rock Abrasive Rock Abrasive Rock
Rock Rock
14% Manganese
18% Manganese
22% Manganese
NON ABRASIVE
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WEAR PARTS OVERVIEW
Manganese is added to steel to improve strength, durability • Liners work harden by compressive forces and at any What is wear? A primary factor in wear for crushing applications is abrasion.
and toughness. given time the work hardened face is only about 2-3mm. Material fatigue is also a factor as the jaw liners are subject
Wear is produced when two elements press against each to numerous pressure and impact stresses.
The strength of a jaw liner is the ability to withstand • The speed at which the liner work hardens increases as other, such as a jaw liner and crushing material. During
crushing forces without failure and is dependent on the the percentage of manganese content increases. For this process, small materials from each element become The diagram below summarizes factors that affect the wear
metals microstructure. Manganese steel has high-hardness example, 12-14% of manganese content work hardens detached, causing the surface to wear away. lifetime of crusher wear parts.
properties and is wear resistant. slower than 20-24% of manganese content.
• The work hardened face has a higher Brunel value if the
percentage of manganese content is lower. For example,
Work hardening once work hardened, steel with 12-14% manganese
Work hardening of a jaw liner, is the strengthening of the liner content will be more wear resistant than steel with 16-
as it is pounded by rock forces inside the crushing chamber. 18% content.
This strengthening occurs because of permanent changes
within the microstructure of the material on the liner surface. TYPE WEAR
Before work hardening, the molecular structure of the liner is How do I optimize liner wear life? Abrasive, Fatigue
a regular, defect-free pattern. As the liner is pounded by rock,
the microstructure dislocates and the structure becomes • Reduce the amount of fine and wet material allowed
denser. The denser structure provides more resistance to into the crushing chamber by using a correct choice of
forces and is observed as strengthening or work hardening. feeder.
• Run the chamber at an optimum speed. Running it too
fast will hinder the liners ability to ‘bite’ the material and
Through hardening pull it into the chamber, resulting in material rubbing WEAR MATERIAL
against the liners, promoting premature wear. Chemical Composition - ENVIRONMENTAL
Through hardening is when the core of the manganese loses 18%, 22% etc FACTORS
its ductility. For manganese to work the skin has to be very • Tight Closed Side Settings (CSS) can hinder the liners Wear part manufacturing Moist Temperature
hard and abrasive resistant but the core needs to be as ductile ability to sufficiently work harden. By initially running the quality
and as soft as chewing gum. If manganese is misapplied,
there is a serious risk of losing this innate ductility that must
chamber at a larger CSS for a day or two this could help
increase liner wear life.
WEAR
be at the core.
• Rotating jaw liners prematurely allows the crushing faces LIFETIME
to work harden more effectively.
Manganese liner facts:
• Manganese liners are used because of their ability to
work harden while crushing, which extends their wear life
dramatically.
FEED CRUSHER
Rock type, Size, Shape, SETTINGS
Hardness and Toughness Speed, CSS
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WEAR PARTS OVERVIEW
ABRASIVENESS
CLASSIFICATION FRENCH ABRASIVENESS ( G/TON) ABRASION INDEX
Non Abrasive 0 - 100 0.0 - 0.1
Slightly Abrasive 100 - 600 0.1 - 0.4
Medium Abrasive 600 - 1200 0.4 - 0.6
Abrasive 1200 - 1700 0.6 - 0.8
Very Abrasive 1700 + 0.8 +
MATERIAL PROPERTIES
ROCK NAME CRUSHABILITY ABRASIVENESS
Amphibolite 25 - 46 30 - 1600
Basalt 20 - 44 500 - 2300
Diabase 18 - 44 450 - 2300
Diorite 20 - 36 400 - 1700
Dolomite 30 - 56 20 - 450
Gabbro 27 - 34 800 - 1700
Gneiss 30 - 67 600 - 1600
Granite 28 - 90 900 - 1900
Gravel 30 - 55 300 - 2500
Limestone 30 - 62 0 - 500
Rhyolite 16 - 56 700 - 1900
Sandstone 32 - 60 300 - 2200
Quartzite 22 - 65 1400 - 2400
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JAW CRUSHER
TERMINOLOGY
Open Side Setting (OSS) Jaw Plates
Maximum distance between jaw plates for a given setting (the Replaceable liner plates available with different profiles
distance when the jaw is at rest). for certain applications. They help achieve required output
grading whilst protecting jaw stocks from wear.
Close side setting (CSS)
Minimum distance between jaw plates derived from the OSS Fixed Jaw
and the stroke. Replaceable liner plate attached to the fixed frame.
Flywheel Wedges
Large wheels used as part of the crusher drive and to store The design of some jaw crushers requires wedges, to ensure
inertia. that the jaw plates are held firmly in position. These are also
a wear part that can be replaced when worn down.
Nip Angle
Angle between jaw plates which is indicative of the crushers
ability to crush and draw rock.
JAW
CRUSHERS
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JAW CRUSHERS
4. Required Output
Multi-Tooth
• Recycling applications
• Available in 18%
• Available in 18%
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JAW CRUSHERS CASE STUDY
Jaw Fitted with Fixed Heavy Duty Liner & Super Tooth Swing Liner
THE RESULTS
Previously standard 18% Super Tooth liners had a wear life of
10,000MT. With a newly designed Heavy Duty Fixed Jaw Liner
with Swing Super Tooth, wear life increased to 17,250MT.
This is an improvement in wear life of 70% which means
a large improvement in machine uptime.
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JAW CRUSHERS
NB: The crusher must not be operated at a CSS using below measurement guidelines smaller than stated in the ‘Technical
Information’ section of the manuals.
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JAW CRUSHERS
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JAW CRUSHERS
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CONE CRUSHER
TERMINOLOGY
Mantle Open Side Setting (OSS)
Covers the cone head of the crusher to protect it from wear. The maximum distance between concave and mantle at a
It is the inner sacrificial wear liner that sits on the cone head. given close side setting.
CONE
CRUSHERS
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CONE CRUSHERS
There are a few key points that you need to consider when selecting the correct crushing chamber:
1. Feed Size
Each chamber configuration has a maximum feed size that it can accept.
2. Feed Grading
The maximum feed size is important as if there are a lot of fines in the feed or a lot of single size in the feed, it can cause issues
with wear and output.
Attention should also be given to recirculating stone for the following reasons:
• It has a tendency to be a lot more abrasive and harder than virgin stone
• Depending on the amount recirculating, it can cause issues with segregated feed
1000 Auto Sand Chamber 1000 Medium Coarse Chamber
3. Output required
This takes into account output and grading required, which can affect which crushing chamber you should select
Chamber 1000 Maxtrak / 1150 Maxtrak 1300 Maxtrak 1400 Maxtrak 1500 Maxtrak
1000SR
Auto Sand 63mm N/A 63mm See Page 30 N/A
Fine N/A 110mm N/A 150mm
Medium Coarse 160mm 180mm 220mm N/A
Coarse 175mm N/A N/A 320mm
Extra Coarse 195mm 210mm N/A N/A
Heavy Duty 160mm 180mm 220mm N/A 1000 Coarse Chamber 1000 Extra Coarse Chamber
On the following pages you will see Cone Chamber Configurations by model.
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CONE CRUSHERS
1500 MAXTRAK
(Coarse standard fit from factory)
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CONE CRUSHERS
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CONE CRUSHERS
INCREASED WEAR AVAILABLE HEAVY DUTY LINERS CHAMBER PROFILE AND DUMP CLEARANCE
v STANDARD LINERS The new Heavy Duty cone liners have been designed around The reduction in dump clearance means that the machines
Pin Centre 1000 Maxtrak 1150 Maxtrak 1300 Maxtrak the popular medium coarse chamber and as such accepts need to have a metal detector working to ensure that no
Measurement the same feed size as the medium coarse chamber. Due to uncrushable material can enter the chamber.
Standard Heavy Duty Standard Heavy Duty Standard Heavy Duty the thicker liners there is a Reduction in Dump Clearance
New 765 mm 788 mm 869 mm 897 mm 907 mm 927 mm on all the crushing chambers. This clearance will increase
Worn 680 mm 680 mm 775 mm 775 mm 805 mm 805 mm proportionally as the Liners wear.
Vertical Travel 85 mm 108 mm 94 mm 122 mm 102 mm 122 mm
Wear 50 mm 66 mm 60 mm 80 mm 60 mm 80 mm
Increased Wear + 16 mm + 20 mm + 20 mm
Cone liners must be changed when the hydraulic rams cannot be fully closed. The pin to pin centre distance is detailed below and
worn pin centre measurements are outlined in the table above.
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CONE CRUSHERS CASE STUDY
THE RESULTS
Standard 18% Manganese liners were lasting on average This is an improvement of + 45% over the standard
42hrs in this application. Newly designed 18% Heavy Duty liners which made a massive difference to the Site
cone liners and the wear life increased to 62hrs on the same productivity.
application.
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CONE CRUSHERS
IMPACT
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CRUSHERS Crusher Wear Parts Reference Guide - 37
IMPACT CRUSHERS
Aprons
Primary and Secondary aprons are used to reduce rock down 2 Bar is Standard fit from the Factory
to the required product size. 4 Bar is an option – Only used when feed size small
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IMPACT CRUSHERS
Medium Chrome & Medium Chrome Ceramic lie between Martensitic variants and High Chrome variants as an added option. CERAMIC INSERTS
CERAMIC INSERTS
Ceramic inserts can be provided for both Martensitic and Chrome Blow bars
See some examples below of ceramic inlays in the basic material of Martensitic or Chrome:
Ceramic inserts can be provided for both Martensitic and Chrome Blow bars
These examples show ceramic inlays in the basic material of Martensitic or Chrome:
Benefits:
NB: The ceramic inlay will not be visible when the blow bar is new
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IMPACT CRUSHERS
Blow bar needs changed or rotated when the wear limit “Z” is reached otherwise considerable damage will occur to rotor.
Always refer to Machine Specific Operational manual for Correct Wear Limits
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IMPACT CRUSHERS
• If the bar is not turned before the recommended specified limit , then once changed the bar will not be in a stable position
when working.
• This may lead to the bar becoming loose and falling out of the rotor.
• The figure below shows how a blow bar has been worn excessively past its recommended limit.
Excessively worn
Rotor
Due to excessive
wear to the blow
bar, the locking
wedge has now
come in contact Feed Material is the most important factor for selecting the correct blow bar.
with material
resulting in its To increase the life of blow bars the following guidelines should be adhered to:
dislodgement
Blow bar worn on Maintain and clean chamber daily
from its seat.
one face only, has Inspect blow bars for premature wear or damage
not been turned.
Select correct blow bars depending on application
Adjust machine parameters
The result of this negligence has led to the blow bar not being able to be turned
More severely is the fact that the machine will now need a new rotor
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IMPACT CRUSHERS
A gentle radius on the blow bar shows that the feed material is the correct size Problem
It shows that the rotor penetration and rotor speed are correct Poor penetration on the blow bar means the top of the blow bar is worn down flat
The correct blow bar for the feed material is being used
The machine parameter is correctly set up Causes & Issues
The rotor speed is too high
Solution
Reduce the rotor speed
Change configuration to 2 high and 2 low blow bars
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IMPACT CRUSHERS
Solution
Solution
Reduce speed of feeder so wear becomes
even across the surface of the blow bar Select correct blow bar
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IMPACT CRUSHERS
EXAMPLES OF APPLICATIONS FOR
CHROME / CHROME CERAMIC
BLOWBAR SELECTION
There are a few key points that you need to consider when selecting the correct blow bar for an application:
1. Feed Size
This has a direct link to what blow bars should be selected for each application.
2. Uncrushable Material
This is material such as steel/rebar that can cause blow bar breakages
3. Feed Material
The type of feed material can have a large impact due to the different abrasiveness of materials
Blow Bar Type Recommended For Not Recommended For Risk Of Breakage
Primary blasted quarry rock
Building rubble & Concrete
Martensitic High Abrasive Material Very large feed size
Limestone
Larger feed sizes
Secondary Crushing
Large feed size
Chrome Smaller feed sizes
Abrasive Materials
Low Abrasive Material
Steel content EXAMPLES OF APPLICATIONS FOR
Asphalt MARTENSITIC / MARTENSITIC CERAMIC
Natural stone
Martensitic Ceramic Building rubble & concrete Low Abrasive Material Large feed size
with small to medium iron
content
Medium abrasive material
Secondary crushing with
natural stone
Large feed size
Chrome Ceramic Asphalt in the case of small Low Abrasive Material
Steel content
feed size without any iron
content
Low abrasive material Large feed
Toughened Chrome Concrete recycling
Oversize feed Excess steel content
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Feed Size (mm)
Note
Nat Re c
u ra
LOW
HIGH
ylin
l Sto
ne g
0
200
400
600
800
1000
Key Factors
• Size of feed
• Abrasiveness
100
M
AR
200
TE
N SIT
300
Limestone
Slate
Dolomite
400
500
Sandstone
AR
IMPACT CRUSHERS
TE
N S
600
ITI
C/
C E
Diabase
700
RA
M
IC
800
900
• Martensitic steels offer good Impact resistance for Larger feed sizes
BLOW BAR GUIDE
Abrasiveness (g/t)
CH
1000
RO
Basalt
M
• Chrome Steels offer good Abrasiveness properties for High wear applications
E
1100
1200
• Above Guide provides an Overview for selecting Appropriate blow bar for your application .
1300
Asphalt
Always refer to Operations Manual for Maximum Feed Size Limitations per Crusher Model
1400
Greywacke
Toughened Chrome Bars
Granite
CHR
River Gravel
OM
Gabbro
1500
E/
CER
An increase in Steels Wear Resistance (Hardness) E.G. Chrome is normally associated with a reduction in Toughness (Impact Resistance) of the material.
1600
AM
IC
1700
HIGH
1800
XH320 MODEL
The XH320 machines with the unclamped blow bars are the
machines manufactured before September 2012. The design
of these blow bars remain the same but we are introducing new
part numbers for clarity. The last serial numbers for the old
design of machines are:
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www.powerscreen.com
Email: sales@powerscreen.com
POWERSCREEN SOCIAL
CONTACT DETAILS NETWORKING
Dungannon Become a Powerscreen fan on Facebook by visiting:
200 Coalisland Road, Dungannon, www.facebook.com/powerscreenofficial
Co Tyrone, BT71 4DR, Northern Ireland
Tel: +44 (0) 28 87 718 500 Follow Powerscreen on Twitter by visiting:
Fax: +44 (0) 28 87 747 231 www.twitter.com/powerscreen
The material in this document is for information only and is subject to change without notice.
Powerscreen assumes no liability resulting from errors or omissions in this document, or from the use of the information contained herein.
Due to continual product development we reserve the right to change specifications without notice. Product performance figures given in
this brochure are for guidance purposes only, this information does not constitute an expressed or implied warranty or guarantee, but shows
test examples provided by Dealers. These results will vary depending on crusher chamber settings, screen media and sizes, feed source
and types of material being processed.
Photographs are for illustrative purposes only, some or all of the machines in the illustrations may be fitted with optional extras.
Please check with your Dealer for details on optional extras.
Powerscreen® is a registered trademark of Terex GB Limited in the United States of America and many other countries.
Copyright 2019 Terex GB Limited. Published and Printed in February 2019.
All machines are CE Approved.