The hammer crusher is the core equipment for mining and stone crushing. It has a simple structure, can be used for both dry and wet materials, and has high crushing efficiency, making it an essential crushing equipment for many mineral processing plants and cement factories. However, under long-term high-load production environments and the influence of materials, the hammer crusher inevitably experiences various faults that affect your production.
We have summarized the 9 most common faults and provided solutions to help you quickly troubleshoot the issues.
1.Equipment Vibrates Strongly
When your hammer crusher starts or operates, the equipment experiences severe shaking, and the connecting bolts become loose or fall off. You need to stop the machine immediately for inspection. Continuing to operate the equipment may cause your crusher components to crack, affecting the operation of related equipment.
Cause: Unbalanced installation of hammers; loose bearing seat due to poor foundation construction; pin roll bending.
Solution: ① Stop the machine, disassemble the hammers, replace broken and severely worn parts; weigh each hammer to ensure equal weight for each group. ② Conduct a thorough inspection of the connecting bolts and reinforce the concrete foundation. ③Replace the worn pins and check components such as the triangular disk and circular plate. ④ You can also control the feed size to avoid large materials impacting the crushing chamber.
2.Abnormal Bearing Temperature
A burnt smell, a bearing temperature surpassing 70°C, and lubricating oil that has darkened or begun to leak are all red flags. These symptoms point directly to a problem with the hammer crusher’s bearing, a critical component.
The underlying causes? They could be a breakdown in lubrication—too little, too much, or contaminated oil. Dust infiltrating the bearing is another possibility, as is simply the aging or physical damage of the bearings themselves.
Solution: ① Stop the machine to cool the bearing, check the oil level and type. Regularly inspect and replace the lubricating oil without delay. ② To minimize dust-related harm to the bearings, install or fix the bearing dust seals. ③ To keep the hammer crusher’s essential parts functioning correctly, swap out any bearings that are old or damaged.
3.Hammer wear is too fast
When you frequently replace hammers and costs remain high, you need to consider several other influencing factors.
Causes: Material hardness exceeds standards; impurities like iron blocks wear down the hammers; hammer material does not meet production requirements; oversized feed blocks the crushing chamber; equipment speed is too high.
Solutions: ① Screen out materials with excessive hardness and high impurity content. ②Replace the hammer heads with high-hardness, wear-resistant materials. ③ Optimize the feeding method to ensure uniform feeding. ④ Adjust the hammer crusher speed according to the requirements of the crushed material.
4.Uneven discharge particle size
During the crushing process, you may encounter issues where the particle size of the crushed material does not meet production requirements, and some materials are not sufficiently crushed.
Causes: Hammer wear can lead to uneven crushing force. An incorrect hammer installation angle, a poorly adjusted discharge port, or an unstable rotor speed can also contribute, all of which result in a less effective crushing process.
Solutions: First, inspect the hammer heads for wear. They should all be roughly the same weight and degree of wear. Next, tweak the hammer head’s installation angle. This is crucial for even force distribution when the machine is crushing. After that, you’ll want to set the discharge port gap. This determines the size of the final product. Finally, inspect the motor and transmission system. This is to make sure the rotor speed remains consistent.
5.Motor shutdown
If the motor current exceeds the rated value while the hammer crusher is running, overload protection will activate, shutting down the motor.Ultimately, this leads to the motor tripping and the equipment shutting down.
Causes: Blockage in the crushing chamber leading to motor overload; excessive hardness of the crushed material requiring the motor to output greater power for crushing; motor circuit issues; motor malfunctions such as coil aging or short circuits.
Solution: First, halt the machine to remove whatever’s jammed in the crushing chamber, and then adjust how much you’re feeding it. Second, get rid of anything that’s too hard; this will prevent the motor from getting overloaded. Third, check the motor’s wiring, tighten any loose connections, and fix any mistakes in how it’s wired. Fourth, take a look at the bearings and rotors, clear away any blockages, and swap out any bearings that are stuck. Finally, if the motor itself is the problem, you’ll need to call in a professional to either fix it or replace it.
6.Discharge Port Blockage
When the discharge amount of the equipment significantly decreases, the discharge port of your hammer crusher is blocked by the crushed materials. To avoid overloading the equipment, you need to promptly inspect and clean the discharge port.
Causes: The discharge port is too small; the material moisture is too high; the discharge port is blocked by debris or large chunks; discharge device malfunction.
Solution: ① Adjust the discharge port gap of your equipment according to the particle size of the crushed material. ② Pre-treat materials with high moisture content to avoid sticking to the inner wall of the discharge port. ③ Promptly clean the debris and materials from the discharge port to ensure smooth discharge. ④ Check your discharge device, repair or replace damaged parts.
7.Equipment Abnormal Noise
Performance: During the operation of the hammer crusher, abnormal sounds such as impact noise, friction noise, and screeching noise may occur; abnormal noise accompanied by increased vibration can cause the equipment to fail to operate normally in severe cases.
Cause: The hammerhead is loose or broken and collides with the crushing chamber; the rotor is unbalanced; bearing wear.
Solution: You need to stop the machine immediately, then check the hammerhead, pin shaft, rotor, bearings, and lubrication oil levels. If there are any damaged parts, you need to replace them immediately. Cleaning out hard materials and impurities from the crushing chamber can also help you resolve equipment noise issues.
8.Decreased Output
When the moisture content of your materials is too high or the feed is uneven, the output of your hammer crusher will significantly decrease. The occurrence of this problem will directly affect the interests of your mineral processing plant.
Solution: Shut down the machine to clear blockages in the discharge gap; strictly control the moisture content of the material, and adjust the speed and quantity of the feeder to ensure continuous and uniform feeding.
9.Belt Issues
In high-load working environments, the hammer crusher may also experience problems such as belt loosening, damage, and aging. Belt failures not only reduce crushing efficiency but can also cause equipment shutdown in severe cases.
We recommend that you adjust the belt tension to ensure it is neither too loose nor too tight. If the belt is damaged or broken, promptly clean and replace it with a high-quality belt. Finally, regular inspection and maintenance of the belt is fundamental work.
Summary
The hammer crusher is the core crushing equipment of mineral processing plants. Its operating condition is closely related to your profits. I hope the common faults of the 9 types of hammer crushers introduced in the article can help you solve practical problems in production.
If you need to learn more solutions and maintenance strategies, contact Sandreck immediately!
