Jaw crushers, the pioneers of primary crushing in industries like mining, building materials, and road construction, have a significant impact on the profitability of the entire production line. However, under long-term, high-load conditions, jaw crushers are inevitably prone to malfunctions and even breakdowns. Mastering the troubleshooting and solutions for common faults is essential for every equipment manager and operator.
This article will delve into the most common jaw crusher operational issues, analyze their underlying causes, and provide practical solutions to help you quickly troubleshoot and maximize equipment utilization.
1. Abnormal Vibration During Operation
This is one of the most obvious and dangerous signs, requiring immediate equipment shutdown and inspection.
• Possible Cause 1: The material hardness or toughness exceeds the specified range for the equipment, resulting in "over-iron" or overload.
• Solution: Strictly control the feed size and properties, and install and effectively use an iron remover.
• Possible Cause 2: Loose anchor bolts, bearing housing, or toggle plate fastening bolts. • Solution: Immediately shut down the machine, thoroughly inspect, and retighten all bolts at all connections.
• Possible Cause 3: There is a balance problem with the sheave or sheave counterweight.
• Solution: Professional technicians are required to perform corrections or replacements, and rebalance the machine.
• Possible Cause 4: Severe wear or damage to core components such as bearings.
• Solution: Replace the bearings with new ones and ensure proper lubrication.
2. Significant Decrease in Crushing Output
Production efficiency is vital, and decreased output means direct economic loss.
• Possible Cause 1: Severe wear of the jaw plates. The meshing angle between the movable and fixed jaws increases, reducing the effective volume of the crushing chamber.
• Solution: Reverse the jaw plates or replace them promptly. During installation, ensure that the peaks of the movable and fixed jaw teeth align with the valleys of the teeth to maintain the optimal crushing ratio.
• Possible Cause 2: The material has too much moisture, which is sticking to the crushing chamber and causing blockage.
• Solution: Reduce the material moisture content or pre-dry or sun-dry the material. • Possible Cause 3: Improper discharge opening adjustment, too small.
• Solution: Readjust the discharge opening to the appropriate size based on product particle size requirements.
3. Uneven product particle size, too coarse or too powdery
Product quality is core competitiveness, and uneven particle size will affect subsequent processes and product value.
• Possible Cause 1: Severe wear of the jaw plate, flattening the tooth peaks and losing effective splitting and breaking properties.
• Solution: Replace the jaw plate.
• Possible Cause 2: Irrational feed particle size distribution, with excessive fines or a high proportion of large lumps.
• Solution: Pre-screen the raw materials to ensure that the feed meets equipment requirements.
• Possible Cause 3: The discharge opening has become larger due to wear.
• Solution: Regularly check and readjust the discharge opening clearance.
4. Unusual noises during equipment operation
Unusual metallic clashing or grinding sounds are the "painful groans" of the equipment. • Possible Cause 1: Loose jaw plate fasteners, causing impact with other parts of the machine body.
• Solution: Check and tighten the jaw plate clamping bolts and toggle plate support bolts.
• Possible Cause 2: Bearing damage or poor lubrication, resulting in dry friction.
• Solution: Check the lubrication system and add or replace the lubricant. If the bearing is damaged, replace it immediately.
• Possible Cause 3: The tension spring is broken or has lost its elasticity.
• Solution: Replace the tension spring with a new one.
V. Abnormally High Bearing Temperature
Bearings are the heart of the equipment, and high temperatures are their "fatal killer."
• Possible Cause 1: Insufficient, excessive, deteriorated, or incorrect type of lubricant.
• Solution: Use the correct type of lubricant as specified in the equipment manual, and maintain an appropriate amount and cleanliness.
• Possible Cause 2: Improper or damaged bearing installation.
• Solution: Reinstall or replace the bearing.
• Possible Cause 3: Prolonged overload operation.
• Solution: Adjust the feed rate to ensure operation within rated load.
Prevention is worse than cure: Daily maintenance is key.
Instead of panicking after a malfunction occurs, it's better to establish a scientific preventive maintenance system:
1. Regular Lubrication: Strictly lubricate according to the schedule, oil type, and dosage specified in the maintenance manual.
2. Regular Tightening: Regularly inspect all fasteners, especially the anchor bolts and jaw plate bolts.
3. Regular Inspection of Wear Parts: Keep an inspection record of wear parts such as the jaw plate and side guards to ensure proactive and planned replacement.
4. Pre-Startup Inspection: Before each startup, check the crushing chamber for residual material and confirm that all components are functioning properly.
Mastering common jaw crusher troubleshooting methods will not only help you quickly resume production, but also effectively extend the equipment's service life and reduce operating costs. Remember, when encountering complex malfunctions that cannot be identified, always contact professional maintenance personnel. Avoid blindly operating to avoid further losses.
We hope this guide will be a valuable aid in your equipment management journey!
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Our complete after-sales service system guarantees long-term, stable operation of your machinery with minimal downtime.
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