Seven common faults of impact crusher and their solutions

Impact crushers, essential crushing equipment in industries like mining, building materials, and cement, are subject to long-term, high-intensity operation and can develop various malfunctions due to wear, operating errors, or inadequate maintenance. Pioneer Heavy Industry has carefully summarized seven common impact crusher malfunctions and their solutions to help users quickly resolve them and ensure efficient equipment operation.

1. Bearing Overheating
   Causes: This could be caused by insufficient or excessive grease, contaminated or deteriorated grease, bearing damage, overtightening of the bearing, or improper bolt adjustment.
   Solution: First, check the grease level to ensure it is adequate. If the grease is faulty, clean the bearing and replace with fresh, clean grease. If the bearing is damaged, replace it. Also, adjust the bearing gland bolts to ensure they are properly tightened.
2. Abnormal Vibration
   Causes: This is usually caused by factors such as excessive feed material size, uneven wear of the hammer or liner, rotor imbalance, loose equipment foundation, or untightened anchor bolts.
   Solution: Check and control the feed material size to ensure it meets equipment requirements. If the hammer or liner is severely worn, replace them promptly. Also, reinstall the blow bar and perform rotor balancing. Finally, reinforce the equipment foundation and tighten the anchor bolts.
3. Belt Twistover or Wear
   Causes: This could be caused by an aging or poor quality belt, unevenly mounted pulleys, or improper belt tension. Solution: If the belt is aging or of poor quality, replace it with a V-belt that meets quality standards. If the pulleys are improperly positioned, adjust them to ensure the driving and driven pulleys are aligned. Also, regularly check and adjust the belt tension.
4. Excessively Large Discharge Particles
   Cause: This may be due to severe wear of the hammers or impact plate, excessive clearance between the hammers and the impact plate (usually adjusted to 15-20mm), or feed particle size exceeding the equipment’s handling range.
   Solution: Replace or re-use the worn hammers and liners. Adjust the impact plate clearance to the standard range. Strictly control the feed particle size to prevent oversized material from entering the crushing chamber.
5. Knocking Sounds Inside the Machine
   Cause: This may be due to uncrushable material (such as metal blocks) entering the crushing chamber, loose liner fasteners causing the hammers to strike the liner, or breakage of the hammers or other components. Solution: Stop the machine to clean out foreign matter from the crushing chamber; inspect and tighten the liner bolts, and adjust the clearance between the hammer and liner. If any hammer or parts are broken, replace them promptly.
6. Casing Oil Leakage
   Cause: This may be caused by aging or damage to the seal, excessive lubricant, or a clogged oil line.
   Solution: If the seal is defective, replace it with a new one. Clean the oil line and control the lubricant level to an appropriate level.
7. Impact Plate Fracture
   Cause: Long-term high impact loads may cause fatigue damage to the impact plate, or the material and manufacturing process may not meet standards.
   Solution: Replace the impact plate promptly with a high-quality one and regularly inspect its condition. If necessary, replace it in advance to prevent further failure.