How can we reduce the failure rate of jaw crushers to minimize losses

Jaw crushers are widely used in sand and gravel aggregate production due to their simple structure, reliable operation, easy maintenance, and low production costs. They are extensively employed for coarse crushing of ores and large bulk materials. Since jaw crushers primarily handle coarse crushing tasks, they process relatively hard materials under complex feeding conditions. The sand and gravel aggregate market continuously raises performance expectations for these machines. However, certain operational details are often overlooked during use, which can negatively impact production efficiency. To ensure stable and reliable operation, understanding proper daily procedures is crucial. Below are key operational guidelines for jaw crushers.

A. Pre-Startup Preparations

1. Inspect all major components for integrity. Check for loose bolts or fasteners and verify safety devices are intact.

2. Confirm feeding equipment, conveying systems, and electrical components are in good working order.

3. Ensure cooling water valves are open.

B. Startup and Normal Operation

1. Start the machine according to operating procedures, following the reverse sequence of the production process;

2. When starting the main motor, monitor the current meter on the control cabinet. After 20-30 seconds, the current should drop to normal operating levels;

3. Adjust and control feeding to ensure uniform material supply. Material particle size should not exceed 80%-90% of the feed opening width;

4. Generally, sliding bearing temperatures should not exceed 60°C, and rolling bearing temperatures should not exceed 70°C;

5. If electrical equipment trips automatically and the cause is unknown, forcibly restarting is strictly prohibited;

C. Precautions During Shutdown

1. The shutdown sequence is the reverse of startup, following the production process direction;

2. Lubrication and cooling systems must only be stopped after the crusher has come to a complete halt. In winter, drain circulating cooling water from bearings to prevent freezing damage;

3. After shutdown, perform thorough cleaning and inspect all machine components.

D. Lubrication

1. The connecting rod bearings, eccentric shaft bearings, and thrust plate pivot points of the jaw crusher are lubricated with oil. No. 70 machine oil is suitable for summer use, while No. 40 machine oil is recommended for winter. If the crusher operates continuously, has oil heating equipment in winter, and faces moderate ambient temperatures in summer, No. 50 machine oil may be used year-round.

2. An oil temperature heater can preheat lubricating oil for use during winter.

3. If the oil pump suddenly fails, the crusher requires 15-20 minutes to stop due to its large oscillating force. In this case, manually operate the oil pump to supply oil, ensuring bearings remain lubricated and preventing bearing burnout.

E. Inspection and Maintenance

The inspection and maintenance of jaw crushers primarily include the following points:

1. Monitor bearing temperature. Bearing alloy bushings function properly only below 100°C. If temperatures exceed this threshold, immediately shut down the machine for inspection and troubleshooting.

2. Verify lubrication system functionality. Listen for abnormal noises (e.g., knocking) from the gear oil pump, check oil pressure gauge readings, inspect oil tank levels, and examine the lubrication system for leaks. Replenish oil promptly if levels are insufficient.

3. Inspect the return oil line for contaminants like metal filings. If present, immediately stop the machine and open the bearings and other lubricated areas for inspection.

4. Check for loosening of connecting components such as bolts and flywheel keys.

5. Inspect the wear condition of jaw plates and transmission components. Check the tie rod springs for cracks and ensure they function normally.

6. Maintain equipment cleanliness at all times, ensuring no accumulated dust, oil stains, oil leaks, water leaks, electrical leaks, or ash leaks. Pay particular attention to preventing dust and debris from entering the lubrication system and lubricated areas. Such contaminants can disrupt the lubricating oil film, causing equipment to lose lubrication and increasing wear. Additionally, dust and debris act as abrasives, accelerating equipment wear and shortening its service life.

To reduce the failure rate of jaw crushers, strictly adhere to the operational guidelines outlined above. This will minimize losses caused by equipment malfunctions. Click to contact our website customer service for a free consultation.