From Drawings to Finished Products: Non-standard Slewing Bearing Customization Process Details

Non-standard slewing bearings are crucial components in various heavy machinery and precision equipment, designed to handle significant axial, radial, and moment loads in highly specialized applications. Unlike standard bearings, their customization process is intricate, involving close collaboration between the client and the manufacturer to meet unique operational demands.

Non-standard slewing bearing customization process

slewing bearing

1. Initial Consultation and Requirement Gathering

The process begins with a comprehensive understanding of the client’s needs. This involves:

Application Analysis: Understanding the specific machine or system where the slewing bearing will be used. This includes factors like the type of equipment (cranes, excavators, wind turbines, medical equipment, robotics, etc.), its operating environment (marine, high/low temperature, dusty, corrosive), and overall performance requirements.

Load Analysis: Detailed information on the static and dynamic loads the bearing will endure, including axial, radial, and overturning moment loads, as well as shock loads and vibration.

Dimensional Constraints: Precise dimensions of the mounting space, including outer diameter, bore size, width, and any specific mounting hole configurations.

Performance Specifications: Required rotational speed, precision (runout tolerances), stiffness, torque requirements, and expected service life.

Environmental Factors: Exposure to moisture, saltwater, chemicals, dust, extreme temperatures, and the need for specialized sealing or corrosion protection.

Special Features: Any unique requirements such as integrated gearing (internal, external, helical, worm gears), lubrication systems, control devices, or monitoring systems.

Material Preferences: While manufacturers often recommend materials, clients may have specific preferences or requirements for certain alloys (e.g., high-strength steel, stainless steel, specialized alloys like 42CrMo4, 50Mn, or even aluminum for lightweight applications).

Compliance and Certifications: Any industry-specific standards (e.g., ISO, AGMA, DEF STAN) or certifications required for the bearing.

2. Design and Engineering

Once the requirements are thoroughly understood, the engineering team commences the design phase:

Conceptual Design: Engineers develop initial concepts based on the gathered data, considering different slewing bearing types (e.g., four-point contact ball bearings, crossed cylindrical roller bearings, triple-row roller bearings, combined roller/ball bearings) that best suit the application.

Detailed CAD Modeling: Using advanced 3D modeling software, a detailed design of the non-standard bearing is created. This includes precise geometries of the inner and outer rings, raceways, rolling elements, cages/spacers, gearing, and sealing systems.

Material Selection: Based on load, environment, and performance requirements, appropriate materials are selected for the rings, rolling elements, and other components. This often involves specialized heat treatments to achieve desired hardness, wear resistance, and fatigue strength.

Structural Analysis (FEA): Finite Element Analysis (FEA) simulations are performed to validate the design’s integrity under various load conditions, predict stress distribution, deflection, and stiffness, and optimize the design for maximum performance and lifespan.

Lubrication System Design: Designing or recommending a suitable lubrication system (grease or oil) and specifying lubricants based on operating conditions. This includes determining lubrication intervals and potential for advanced lubrication systems.

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How Slewing Bearings Withstand Radial Loads

Slewing bearings withstand radial loads through a combination of their internal geometry, the distribution of force across multiple rolling elements, and the structural rigidity of their rings.

How Slewing Bearings Withstand Radial Loads

Slewing bearings

1. The Foundation: What is a Radial Load?

First, let’s be clear on the force we’re talking about. In the context of a slewing bearing (like the one on a crane), a radial load is a force that pushes or pulls on the bearing from the side, perpendicular to the central axis of rotation.

Example: The force of the wind pushing against the side of a long crane boom.

Contrast with other loads:

Axial (or Thrust) Load: A force acting parallel to the axis of rotation (e.g., the weight of the crane’s cabin and boom pushing straight down).

Moment (or Tilting) Load: A force that tries to tip or overturn the bearing (e.g., the weight of a heavy object lifted at the end of the crane boom).

Slewing bearings are remarkable because they are designed to handle all three types of loads simultaneously. Their ability to handle radial loads is a direct result of this multi-load design.

2. The Core Mechanism: Raceway Geometry and Contact Angle

The “magic” happens inside the bearing, specifically in the way the rolling elements (balls or rollers) make contact with the inner and outer rings (the raceways).

A. For Four-Point Contact Ball Bearings (The Most Common Type)

This is the classic design. Imagine cutting a slewing bearing in half. You would see that the groove (raceway) the balls run in is not a simple semi-circle. It’s shaped like a gothic arch or two shallow V’s.

How it Works: When a radial load pushes the inner ring sideways, the balls are forced up the angled raceways of both the inner and outer rings.

The Contact Angle: The force is transmitted through the balls at an angle (the “contact angle”). This angle means that a single radial force is resolved into two components: one that is axial and one that is radial.

The Key Takeaway: Because the ball contacts the raceway on an angle, it can resist forces from both the side (radial) and top/bottom (axial) simultaneously. A single ball acts like two separate bearings pushed against each other at an angle, all in one compact design.

B. For Crossed Roller Bearings

This design is even more explicit in how it handles loads from different directions.

How it Works: Cylindrical rollers are arranged in a crisscross pattern, with each roller oriented at 90 degrees to the one next to it.

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What about the welding process for wind tower welding rotators

Wind tower fabrication is a highly specialized and welding-intensive industry that relies heavily on automation due to the massive size and thick steel components involved. Welding rotators play a crucial role in this process by enabling precise and efficient welding of cylindrical wind tower sections.

Wind Tower Welding Rotator Welding Process

Here’s a breakdown of the welding process for wind tower welding rotators:

wind tower welding rotators

1. Wind Tower Fabrication Process (where rotators fit in):

Plate Rolling: Large steel plates (often exceeding 80mm thick) are rolled into cylindrical “cans.”

Longitudinal Welding: Individual cans are seam-welded along their length. This often involves manipulators and column-and-boom systems.

Circumferential Welding (where rotators are key): Once individual cans are formed, they are aligned and joined to each other with circumferential welds to form tower sections. This is the primary application for welding rotators. Rotators hold and rotate the heavy, cylindrical sections, allowing a stationary welding head (typically on a column and boom manipulator) to perform the circular weld.

Flange Welding: Flanges are attached to the ends of sections, also by circumferential welds, for on-site assembly.

Door Frame Welding: Door frames are welded, typically using mechanized flux-cored or metal-cored arc welding.

2. Key Welding Process for Wind Towers:

Submerged Arc Welding (SAW): This is the dominant welding process for both longitudinal and circumferential seams in wind tower fabrication.

High Deposition Rate: SAW can deliver extremely high weld metal deposition rates and the necessary heat for the thick steel used in wind towers.

Automation: SAW is highly adaptable to automation, which is critical for consistent quality and productivity on large, repetitive welds.

Multi-wire SAW: To further increase productivity, multi-wire SAW systems (e.g., twin arc, tandem arc, tandem twin arc) are commonly used, where multiple welding torches feed the same weld pool.

Flux Shielding: The arc is submerged under a blanket of granular flux, protecting the weld pool from atmospheric contamination. This also makes it less susceptible to environmental factors like wind.

Orientation: SAW typically requires gravity to hold the weld metal and flux in place, meaning the parts must be reoriented (e.g., rotated by rotators) to maintain a flat or horizontal welding position.

Other Processes (for specific applications):

Gas Metal Arc Welding (GMAW or MIG) and Flux Cored Arc Welding (FCAW): Used for various applications, including door frame welding or in conjunction with SAW for certain passes.

Electrogas Arc Welding (EGW): A high-efficiency vertical automatic welding process used for thick plates, especially in offshore wind power generation facilities. A newer variant, SESLA, offers advantages like minimal spatter and fumes and excellent wind resistance.

Narrow Gap Welding: Applied to reduce weld volume, utilizing special flat welding heads and single or tandem wire heads.

wind tower welding rotators

3. The Role of Welding Rotators:

Precise Rotation: Welding rotators (also known as turning rolls) use wheels to align and rotate cylindrical workpieces, such as the “cans” of a wind tower, at a uniform and controlled speed.

Types of Rotators:

Conventional Rotators: Simple, solid, and widely used for internal welding, long seam welding, surface treatment, and internal equipment installation.

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How To Choose Wind Tower Welding Rotator

Choosing the right welding rotator for wind tower fabrication is crucial for ensuring efficient, high-quality welds and safe operations. Wind towers are large, heavy, and often have varying diameters, requiring robust and adaptable equipment.

How To Choose Wind Tower Welding Rotator

I. Key Factors to Consider:

Load Capacity:

Wind tower sections are incredibly heavy, ranging from tons to hundreds or even thousands of tons.

The rotator’s load capacity is paramount. Ensure it significantly exceeds the maximum weight of your heaviest wind tower section to maintain safety and prevent damage to the equipment or workpiece.

Manufacturers offer rotators with capacities from a few tons up to 2000 tons or more.

Workpiece Diameter Range:

Wind tower sections vary in diameter along their length.

Self-aligning rotators (SARs) are highly recommended for wind towers as they automatically adjust their roller cradles to accommodate different diameters. This saves time and effort compared to manual adjustments.

Conventional (adjustable) rotators require manual adjustment of the roller spacing to suit different diameters. While often more economical for fixed-diameter workpieces, they can be less efficient for wind towers.

Fit-up rotators are specifically designed to align multiple cylindrical sections for circumferential welding, often used in conjunction with other rotators. They frequently feature hydraulic up/down and left/right adjustments for precise alignment.

Welding Application and Type:

Longitudinal welds: These run along the length of the tower sections. Rotators ensure stable rotation while a welding head (often a column and boom manipulator with Submerged Arc Welding (SAW)) moves along the seam.

Circumferential welds (girth welds): These join tower sections together. Rotators provide precise, consistent rotation for continuous welding.

Internal welding: Some rotators are designed to facilitate internal welding processes.

Surface treatment/blasting/painting: Rotators are also used for rotating sections during these processes to ensure uniform application.

Welding process: Consider the welding process you’ll be using (e.g., SAW, MIG/MAG, FCAW). The rotator’s speed control and stability should be compatible with your chosen process. Wind tower welding often relies heavily on SAW for its high deposition rates.

Roller Type and Material:

Polyurethane (PU) wheels: Often favored for their grip, ability to prevent slippage, and suitability for various operating temperatures and wall thicknesses. They also reduce the risk of scratching or damaging the workpiece surface.

Steel wheels: Suitable for extremely heavy loads and high-temperature applications, but may require protective measures to prevent damage to the workpiece.

Rubber wheels: Common for general-purpose applications but may not be as durable or suitable for the heavy loads and demanding conditions of wind tower fabrication.

Control System and Features:

Variable speed control: Essential for optimizing welding parameters and accommodating different welding processes.

Remote control (wired or wireless): Enhances operator safety and convenience, allowing control from a safe distance.

Anti-drift systems: Crucial for preventing axial movement (drifting) of the workpiece during rotation, especially important for long welds and precise alignment.

These systems dynamically adjust to keep the section centered.

Traversing capability: Allows the rotators to move along rails, providing flexibility for positioning and material handling in a production line.

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How to Choose the Model of Lead Screw Welding Rotator

Lead screw welding rotators are specialized pieces of equipment designed to support and precisely rotate cylindrical workpieces for welding, polishing, assembly, and other fabrication processes. Their defining feature is the lead screw mechanism, which allows for accurate adjustment of the roller distance to accommodate a wide range of workpiece diameters.

Choosing the right model of lead screw welding rotator is crucial for optimizing your welding operations, ensuring efficiency, quality, and safety.

Lead Screw Welding Rotator Model Choose

Lead Screw Welding Rotator

1. Understand Your Workpiece Specifications:

Weight Capacity: This is the most critical factor. Determine the maximum weight of the cylindrical workpieces (pipes, tanks, vessels, etc.) you will be welding.

Welding rotators are typically rated in tons (e.g., 2T, 5T, 10T, up to hundreds of tons). Ensure the rotator’s capacity comfortably exceeds your heaviest workpiece.

Diameter Range: Identify the minimum and maximum diameters of the workpieces you need to rotate. Lead screw rotators offer adjustable roller distances to accommodate various diameters. Make sure the chosen model’s adjustment range covers your needs.

Length of Workpiece: For very long workpieces, you might need multiple sets of rotators (one drive unit and multiple idler units) to provide adequate support and

prevent sagging. Consider synchronization features if you plan to use multiple units.

Material of Workpiece: While most rotators are designed for general metals, consider if your material has specific requirements (e.g., very thin walls, sensitive surfaces that might need specialized roller coatings).

2. Consider the Type of Lead Screw Welding Rotator:

Lead Screw Adjustable (Manual or Motorized): This is the defining characteristic. The lead screw mechanism allows for precise adjustment of the roller distance to accommodate different workpiece diameters.

Manual Lead Screw: More economical, suitable for workshops with less frequent changes in workpiece diameter or when precise manual positioning is acceptable.

Motorized Lead Screw: Offers quicker and more precise adjustment, ideal for dynamic fabrication environments with frequent changes in workpiece sizes, reducing setup time and enhancing efficiency.

Self-Centering vs. Conventional (within Lead Screw Type):

Self-Centering Lead Screw Rotators: These are an enhanced version where the lead screw mechanism automatically centers the workpiece by moving both roller brackets equally in opposite directions. This is highly beneficial for varying diameters and frequent job changes, saving significant setup time and improving alignment accuracy.

Conventional Lead Screw Rotators: While still using a lead screw for adjustment, they might require more manual intervention for precise centering.

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How to Improve Welding Efficiency of Welding Positioner

Welding positioners are invaluable tools for significantly improving welding efficiency. They do this by allowing the workpiece to be rotated, tilted, and held in optimal positions, reducing the need for manual manipulation, awkward welding postures, and frequent repositioning. Here’s a breakdown of how to maximize their efficiency.

How to Improve Welding Efficiency of Welding Positioner

Welding positioners

1. Proper Selection of the Welding Positioner:

Match to Workpiece: Choose a positioner that can safely and effectively handle the size, weight, and shape of your typical workpieces. Consider load capacity (vertical and horizontal), rotation speed, and tilt capabilities.

Application-Specific Types:

Tilting Positioners: Best for complex angles and intricate applications.

Headstock & Tailstock Positioners: Ideal for long and heavy workpieces like pipes or beams, ensuring balanced support.

Turntable Positioners: Great for smaller, circular components, offering 360-degree rotation.

Ferris Wheel Positioners: Excellent for robotic welding, allowing loading/unloading on one side while welding occurs on the other, maximizing arc-on time.

Control Features: Look for adjustable rotation and tilting speeds, programmable settings, and remote control capabilities for enhanced precision and ease of use.

2. Optimize Setup and Operation:

Secure Workpiece: Always ensure the workpiece is firmly and stably attached to the positioner. Consider the center of gravity to maintain balance, especially for large or irregularly shaped parts. Use appropriate clamps and fixtures.

Ergonomics: Position the workpiece at an optimal height and angle that allows the welder to maintain a comfortable, natural posture. This reduces physical strain, fatigue, and the risk of musculoskeletal injuries, leading to more consistent and higher-quality welds over longer periods.

Downhand Welding: The primary goal of a positioner is to bring the weld joint into the “downhand” or “flat” position (1F or 2F). These positions allow for higher deposition rates, better penetration, and easier control of the weld pool, leading to faster and higher-quality welds.

Minimize Repositioning: Plan the welding sequence to minimize the number of times the workpiece needs to be repositioned. A good positioner allows a single setup for multiple passes or joints.

Streamline Multi-Pass Welding: For thick materials requiring multiple passes, a positioner ensures smooth transitions between passes, reducing delays and improving consistency.

3. Integration and Automation:

Robotic Integration: If applicable, integrate the welding positioner with robotic welding systems. This allows for fully automated processes, significantly increasing travel speed, consistency, and overall throughput, especially for repetitive tasks and large-scale production.

Fixture Compatibility: Ensure that fixtures used to secure the workpiece are compatible with the positioner and provide adequate stability. Custom fixtures can be designed to maximize efficiency for specific parts.

Consistent Welding Parameters: Standardize welding parameters (speed, heat settings, rotation times) for similar jobs to ensure uniform results and reduce errors.

Welding positioners

4. Maintenance and Monitoring:

Regular Maintenance: Implement a routine maintenance schedule. Inspect motors, gears, clamps, and electrical connections regularly. Lubricate moving parts to reduce wear and tear and extend the lifespan of the equipment.

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Single shaft mixer vs. double shaft mixer, how to choose?

In industrial processing, achieving a consistent, high-quality blend of materials is crucial. The choice of mixer is a fundamental decision that impacts efficiency, product quality, and operational costs. Among the most common horizontal mixers are the single-shaft and double-shaft (or twin-shaft) designs.

While both are used for blending solids, sludges, and pastes, their internal mechanics create vastly different mixing environments. Choosing between a single shaft mixer and a double shaft mixer depends heavily on your specific mixing needs. Both types have distinct advantages and are suited for different applications.

Single Shaft Mixer vs Double Shaft Mixer

double shaft mixer

Single Shaft Mixer

Design: Features one rotating shaft equipped with mixing paddles or blades.

Mixing Action: Generally provides a gentler, more consistent mixing action. The paddles lift the material and allow it to fall, creating cross-mixing.

Ideal for:

Dry powders and granular materials: Think spices, flour, coffee beans, animal feed, fertilizers, etc.

Light pastes and some liquid applications: Where a homogenous blend without excessive shearing is desired.

Delicate blending: Materials that can be easily damaged or degraded by aggressive mixing.

Applications requiring low maintenance and operational costs: Simpler design generally means less to go wrong.

Key Features:

One central shaft with attached paddles or blades.

Uniform mixing for homogeneous products.

Lower initial investment and easier to maintain.

Can often mix down to a lower percentage of its rated capacity effectively.

Lower horizontal profile, which can be beneficial if height is a limitation.

Double Shaft Mixer (also known as Twin Shaft Mixer)

double shaft mixer

Design: Features two horizontal shafts rotating in opposite directions. These shafts often have overlapping paddles or blades.

Mixing Action: Creates a counter-rotating motion that provides intensive, high-shear mixing. The two shafts and their intermeshing blades actively displace, shear, and distribute the material, resulting in faster and more thorough blending. It also creates a “fluidized bed” effect for optimal mixing.

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What are the maintenance tips for double shaft mixer

A double shaft mixer, often called a twin-shaft mixer or pugmill, is a high-intensity, industrial mixing machine designed to blend a wide variety of materials quickly and homogeneously.

Its core feature is the presence of two parallel, counter-rotating shafts equipped with multiple paddles, blades, or arms. These shafts are housed within a W-shaped or U-shaped trough. This design creates a powerful and efficient mixing action that is ideal for demanding applications, especially those involving aggregates, sludges, powders, and pastes.Maintaining a double shaft mixer is crucial for its longevity, efficiency, and safe operation.

Double Shaft Mixer Maintenance Tips

Double Shaft Mixer

I. Daily/Per Shift Maintenance:

Cleaning is Paramount:

Thorough Washout: After every use, especially with concrete or sticky materials, thoroughly clean the mixer. Use water, and for stubborn buildup, consider adding gravel to the water and running the mixer for 5-30 minutes.

Remove Residue: Scrape off any remaining material from the interior, especially the mixing arms, blades, and shaft. Hardened concrete or material buildup reduces mixing efficiency and can damage components.

Discharge Door: Clean deposits around the discharge door to ensure smooth opening and closing.

Non-Wetted Parts: Be careful when cleaning non-wetted components to avoid damage from liquids.

Lubrication Checks:

Central Lubrication System: Ensure the central lubrication pump is working properly. Check for any leaks in connection points and refill the lubricant if necessary.

Shaft End Seal: This is a critical area. Check the lubricating oil pump for normal oiling daily. Ensure there’s oil in the oil pump oil cup and the pump’s cartridge is normal. If there’s an issue, stop immediately and troubleshoot. If manual oiling is needed, do it every 30 minutes to keep the shaft end sufficiently lubricated.

Other Lubrication Points: Check other lubrication points like spindle bearings, discharge door bearings, motor bottom plate rotating shaft, and hydraulic cylinder rotating shaft.

Visual Inspection:

Leaks: Look for any oil, grease, or other fluid leaks, which could indicate seal or gasket problems.

Unusual Noises/Vibrations: Listen for any strange sounds or vibrations, which can be early indicators of a problem. Stop operation immediately if detected.

Loose Bolts/Connections: Check for any loose bolts on blades, stirring arms, and lining plates, and tighten them.

Wear and Tear: Quickly inspect for any obvious signs of damage, cracks, or corrosion on external components like the motor, drive shafts, and blades.

Control Panel: Check the alarm status on the control panel.

II. Weekly Maintenance:

Lubrication:

Check the oil level of the reducer and hydraulic pump.

Belt Tension:

Check and adjust the tension of the driving belt using the belt stretching unit. Ensure proper tension to avoid premature wear or slippage.

Wear Parts:

Visually inspect seals, bearings, and couplings for wear or damage. Replace any seals that show cracks or damage.

Check the alignment of mixing blades and adjust as needed.

Material Buildup:

Perform a longer, more thorough cleaning with water and rock to remove any deeper buildup.

Double Shaft Mixer

III. Monthly Maintenance:

Gearbox: Check the oil level in the gearbox.

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How to adjust the belt conveyor deflection

Belt conveyor deflection, also known as mistracking or misalignment, is a common issue that can lead to increased wear on components, material spillage, and costly downtime. Adjusting it effectively requires understanding the causes and applying the appropriate solutions.

Common Causes of Belt Conveyor Deflection

Belt conveyor

Improper Installation:

Misaligned support structures, pulleys (head, tail, drive, snub), and idlers.

Non-perpendicularity of roller axes to the belt’s centerline.

Skewed conveyor frame.

Incorrect belt splicing (not straight or uneven tension).

Operational Issues:

Uneven or off-center material loading.

Material build-up on pulleys, idlers, or the belt itself.

Insufficient or uneven belt tension.

Seized, worn, or damaged rollers/idlers.

Worn or damaged belt (e.g., uneven wear, aging deformation, edge damage).

Foreign objects stuck in the system.

Environmental factors (e.g., wind).

Vibration during operation.

General Principles for Adjusting Deflection

Start with a clean conveyor: Remove any material buildup from rollers, pulleys, and the belt.

Conduct adjustments during no-load operation: This allows for clear observation of the belt’s natural tracking.

Adjust gradually and one side at a time: Small adjustments are key to avoiding overcorrection.

Work from the head/discharge end backwards: Often, issues at the head end can cause problems further down the line.

Allow time for the belt to react: After an adjustment, let the belt run for several minutes (at least 4-5 full belt revolutions) to see the effect before making further changes.

Confirm with a load: Once the belt tracks well under no-load, test it with a load to ensure continued stability.

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How to Replace Impact Crusher Wear Parts

Replacing wear parts on an impact crusher is a crucial maintenance task to ensure optimal performance, efficiency, and safety. The main wear parts in an impact crusher are the blow bars, breaker plate liners (or impact plates), and side wear plates (or side liners). The specific procedure can vary slightly depending on the crusher model and manufacturer, but here’s a general guide for each.

Impact Crusher Wear Parts Replacement

impact crusher

General Safety Precautions (ALWAYS follow these!):

STOP THE CRUSHER: Completely shut down the crusher and any associated equipment (feeders, conveyors).

DISCONNECT POWER: Ensure all power sources are disconnected and locked out/tagged out to prevent accidental startup. This is non-negotiable.

SECURE THE ROTOR: If replacing blow bars, the rotor must be secured to prevent it from rotating unexpectedly.

CLEAR THE CRUSHING CHAMBER: Remove any remaining material from the crushing chamber.

USE APPROPRIATE PPE: Wear hard hats, safety glasses, steel-toed boots, gloves, and any other required personal protective equipment.

USE PROPER LIFTING GEAR: Wear parts can be very heavy. Always use appropriate lifting equipment (hoists, slings, etc.) and ensure they are rated for the weight.

WORK WITH A TEAM: Never attempt wear part replacement alone. A minimum of two people is usually recommended for safety and efficiency.

REFER TO THE OPERATOR’S MANUAL: Always consult your specific crusher’s operator’s and maintenance manual for detailed instructions, diagrams, and torque specifications.

1. Replacing Blow Bars

impact crusher

Blow bars are the primary impact elements and typically wear out the fastest.

When to replace/turn blow bars:

When one face is worn down to its limit. Many blow bars are symmetrically shaped and can be flipped to use the other side, effectively doubling their lifespan.

Before they are worn through to prevent damage to the rotor.

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