How to quickly resolve common faults in hammer crushers

Hammer crushers are primarily used for stone crushing in the building materials industry, highway and railway construction, and other industrial applications requiring crushed stone. They are suitable for crushing medium-hard and softer materials. During operation, overlooked minor details can lead to machine malfunctions. When a fault occurs, the machine must be shut down for inspection and troubleshooting, inevitably delaying production progress. So how can we quickly identify where the machine is malfunctioning? What are the likely causes? And how can we resolve them?

First, let's understand the structure of a hammer crusher. The PC series hammer crusher features large feed particle size and low over-crushing rate, making it particularly suitable for crushing limestone and medium-hard materials. It primarily consists of the machine body, rotor, and adjustment mechanism. The body features a maintenance door and is bolted together in an upper and lower section, forming a spiral-shaped, straight-through crushing chamber fully lined with wear plates. The rotor comprises a main shaft, pulley, hammer discs, hammers, hammer shafts, and bearing housings. The adjustment mechanism primarily regulates discharge particle size by altering the distance between the impact plate and the circular path of the hammers, thereby changing the output particle size. Low-power series models are directly driven by the motor via a belt. High-power series models (1620 and above) incorporate an additional transmission assembly. (Technical parameters and data mentioned herein are subject to updates with product upgrades. Click website customer service for the latest equipment specifications.)

1. Cause of Failure: During operation, the hammer crusher may produce oversized discharge particles. This could result from excessive hammer wear or broken screen bars.

   Solution: Replace hammer heads and screen bars.

2. Cause: Bearing overheating during operation. Possible causes include insufficient lubricant, excessive lubricant, contaminated or degraded lubricant, or bearing damage.

   Solution: Add appropriate grease; ensure grease fills 50% of bearing cavity volume; clean bearings and replace grease; replace bearings.

3. Cause: Internal knocking sounds. Possible causes include non-crushable objects entering the machine, loose liner fasteners causing hammers to strike liners, or broken hammers/parts.

   Solutions: Stop the machine and clean the crushing chamber; inspect liner fastening and clearance between hammers and screen bars; replace broken parts.

4. Cause: Reduced output may result from clogged screen bar gaps or uneven feeding.

   Solution: Stop the machine, clear obstructions from screen bar gaps; adjust the feeding equipment.

5. Cause of Failure: Excessive vibration. Possible reasons include: rotor static imbalance after hammer replacement or due to cone head wear; broken hammers causing rotor imbalance; bent or broken pins; cracks in the triangular plate; loose anchor bolts.

   Solution: Remove hammer heads and select replacements by weight to achieve static balance; replace hammer heads; replace pins; weld repairs or replace components; tighten anchor bolts.

During crusher operation, pay attention to detailed procedures to minimize machine failures. Understanding these operational insights helps quickly identify issues, resolve them promptly, and avoid production delays.

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