Daily Maintenance of Impact Crushers: Targeted Solutions for Greater Efficiency

Operating outdoors near mining sites for extended periods, impact crushers inevitably encounter malfunctions. Any downtime due to failure delays project schedules and incurs significant losses. To enhance maintenance efficiency, we've compiled the following tips for swift, targeted troubleshooting to promptly resolve issues with impact crushers.

1. Impact Crusher Fails to Start

Check if vibration during shutdown caused material from the belt feeder to fall into the crushing chamber, jamming the rotor. Clear the material from the chamber and restart the machine to resolve the issue.

2. Overheating bearings

Verify proper lubrication—lubricant should fill 50% of the bearing housing volume under normal conditions. If lubricant has deteriorated or thickened, clean the bearings and replace the lubricant.

3. Abnormal equipment vibration

Possible causes: oversized feed material; uneven wear of wear parts requiring hammer replacement; rotor imbalance requiring adjustment and balancing; or loose foundation bolts needing tightening and reinforcement.

4. Belt Reversal in Impact Crusher

Primarily caused by belt damage requiring replacement with high-quality V-belts. Alternatively, improper pulley alignment necessitates adjusting the drive and driven pulleys to the same plane.

5. Bent or Broken Machine Bearings

Primary causes include prolonged overload operation of the main unit, improper heat treatment of bearings, or excessive hardness of crushed materials. Address by replacing bearings with new ones and ensuring timely maintenance during subsequent operation.

6. Impact Crusher Stalling

Sudden shutdowns during operation can result from multiple causes, including discharge port blockage, belt slippage, low voltage, or bearing damage. Address each issue individually: clear discharge obstructions, tighten the belt, increase and stabilize voltage, or replace bearings.

7. Broken Spring Components

This failure typically occurs when springs are not released before reducing the discharge opening. Replace any broken springs immediately.

8. Abnormal Noise Inside Crushing Chamber

Immediately shut down the machine. Inspect the crushing chamber for metallic contaminants or broken components, then clean the chamber. Inspect the tightness of internal liner plates and the clearance between impact plates and liners. Excessively small clearances can also cause abnormal noises.

9. Flywheel rotation without crusher operation

This is primarily caused by damaged tie rod springs or tie rods, tie rod nuts coming loose causing the toggle plate to disengage from the support slider, or toggle plate fracture and detachment. Investigate the cause and replace damaged components.

10. Rubber odor during operation

This issue primarily stems from belt slippage, causing friction and heat generation with the pulley that produces a pungent rubber smell, or from rotor jamming. Inspect the rotor condition inside the chamber and resolve promptly.

11. Excessively large discharge particle size

This indicates severe wear on the impact crusher's hammer plates or impact liners, causing excessive clearance between the hammer plates and impact plates. Adjust the gap between the front and rear impact frames, or replace the liners and hammer plates. Adjust the position of the impact frame to ensure uniform clearance between both sides and the frame liners. If the frame liners are severely worn, replace them promptly.

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