Jaw Crusher Troubleshooting Guide: From Cause to Solution

Jaw crusher, also known as jaw stone crusher, is mainly suitable for crushing various ores and rocks with medium hardness and below. It is widely used in industries such as mining, metallurgy, building materials, highways, railways, water conservancy, and chemical engineering. When using a jaw crusher, it is necessary to comply with relevant safety operating procedures, regularly inspect and maintain the equipment, and periodically replace wearing parts to ensure that the equipment operates normally and stably.

Common causes and solutions for jaw crusher faults are as follows:

1. Failure phenomenon: feed inlet blockage.

Failure reason 1: Excessive or uneven feeding, resulting in material blockage at the feeding port.

Solution: To avoid excessive input at one time, control the reasonable amount of material input. Adjust the feeding method to ensure that materials are fed evenly.

Failure reason 2: It can also easily cause blockages at the feeding inlet when the feeding material is too large or too hard

Solution: The materials are coarsely crushed or screened in advance to make them meet the processing capacity of the jaw crusher; If the material has a higher hardness, you can consider using more wear-resistant jaw plates and hammerheads.

Failure reason 3: The design of the feed port is unreasonable. The width of the feed port is too small or the shape is not suitable for material flow, which can also easily cause blockage.

Solution: Optimize the design of the feed port to ensure appropriate width and smooth shape, which is conducive to the smooth flow of materials; Clean the feed port regularly to avoid clogging due to long-term use.

2. Failure phenomenon: The jaw plate is loose or damaged

Failure reason 1: The fixing bolts of the jaw plate are loose, causing the overall jaw plate to become loose.

Solution: Check the condition of the jaw plate fixing bolts and tighten them to the specified torque; Regularly check the tightening condition of the jaw plate fixing bolts, and tighten them in time if they are found to be loose.

Failure reason 2: The jaw plate is severely worn and cannot complete the crushing task normally.

Solution: Regularly check the wear of the jaw plate. If serious wear is found, the jaw plate needs to be replaced in time. When replacing the jaw plate, please choose a jaw plate that meets the specified size and material, and replace it according to the manufacturer's requirements.

3. Fault phenomenon: The discharge port is blocked

Failure reason 1: Wet or sticky materials tend to form blocks near the discharge port and block the discharge port.

Solution: Clean up the accumulation of materials around the discharge port, and use appropriate tools to remove the blocking materials. If you encounter wet materials, you can consider heating or drying them to make them flow easier during the crushing process.

Failure reason 2: The design of the discharge port is unreasonable, the width is too small or the shape is poor, which can easily cause material blockage.

Solution: Re-evaluate and optimize the design of the discharge port to ensure that the width is appropriate and the shape can smoothly guide the flow of materials; Clean the discharge port regularly to avoid long-term accumulation of materials and blockage.

Failure reason 3: The material in the crushing cavity is not discharged in time, causing the blockage.

Solution: Check whether the feeding system and discharging system are working properly to ensure that materials can enter and exit the crushing cavity smoothly, ensure that the crushing parameters of the crusher are reasonable, and avoid excessive fine crushing that makes it difficult for materials to be discharged smoothly.

4. Fault phenomenon: After a sudden violent cracking sound occurs during the operation of the main machine, the movable jaw does not move, the flywheel continues to rotate, and the pull rod spring relaxes.

Failure reason 1: The jaw plate is cracked or broken. The cracking sound and the immobility of the movable jaw may be caused by the cracked or broken jaw plate. This may be caused by overloading, excessive clamping, or abnormal materials.

Solution: Stop the machine and check the status of the jaw plate. If rupture or breakage is found, the jaw plate needs to be replaced in time and the cause should be found to avoid similar problems from happening again.

Failure reason 2: It may be that the tension rod spring is relaxed due to the rupture or breakage of the jaw plate. When the jaw plate is damaged, the tension rod spring loses its supporting role, resulting in relaxation.

Solution: After replacing the damaged jaw plate, check and adjust the tension of the tie rod spring to ensure that it can provide sufficient support.

Failure reason 3: The cause of sudden violent sound may also be caused by damage or failure of other parts, such as broken bearings, damaged transmission devices, etc.

Solution: Carry out a comprehensive inspection after shutdown to determine whether there are other component failures. If faulty parts are found, they need to be repaired or replaced according to the specific situation.

5. Fault phenomenon: The host suddenly shuts down (commonly known as Blocking run).

Failure reason 1: The discharge port is blocked, causing the cavity to be full of material.

Solution: Clear the blockage at the discharge port to ensure smooth discharge, or appropriately reduce the feed speed to ensure smooth material supply.

Failure reason 2: The V-belt that drives the sheave to rotate is too loose, causing the belt to slip.

Solution: Check the tightness and wear of the V-belt, and make appropriate adjustments or replace the V-belt with a new one in time.

Failure reason 3: The tightening bushing of the eccentric shaft is loose, resulting in no clearance on both sides of the bearing seat of the rack, causing the eccentric shaft to become stuck and unable to rotate.

Solution: Check the looseness of the eccentric shaft tightening bushing and reinstall the tightening bushing; Check the condition of the bearing seat of the rack to determine whether there are wear and other problems. If there is any problem, you can try to replace the bearing seat with a new one; adjust appropriately. The position of the eccentric shaft avoids problems such as excessive looseness or jamming.

Failure reason 4: The voltage at the work site is too low, and the host is unable to break when encountering aniseed.

Solution: Check whether the voltage is stable or too low. If this situation exists, adjust it; If the power line is aging or too long, it may also cause the voltage to drop. It is recommended to replace the power line with a new one to ensure that the connection of the new line is stable and reliable; If the voltage is too low for a long time, you can consider installing a voltage regulator to stabilize the voltage of the equipment to ensure that the voltage is stable when the equipment is working.

Failure reason 5: Bearing damage.

Solution: After confirming that the bearing is damaged, you need to stop the machine immediately for inspection and replace the bearing with a new one in time.

6. Fault phenomenon: Broken toggle plate

Failure reason 1: When the jaw crusher exceeds its rated power or the hardness of the material processed is too high, the toggle plate will break.

Solution: Strictly abide by the rated power requirements of the jaw crusher and do not exceed the power range specified by its design; Select the appropriate crusher model and specification according to the hardness of the material to ensure that the equipment can process the material normally; For materials with higher hardness, pretreatment measures can be considered to reduce the impact of the jaw crusher on the material.

Failure reason 2: There are material defects or poor welding problems in the manufacturing of the toggle plate, which may cause the toggle plate to break.

Solution: Replace the broken toggle plate according to the specific situation.

Failure reason 3: Long-term use and wear may cause the strength of the toggle plate to decrease and eventually break.

Solution: Check and maintain the equipment regularly, check whether the toggle plate has obvious damage or wear, and repair or replace it in time; Operate the equipment in accordance with the manufacturer's guidance and specifications, avoid excessive or improper use, and reduce damage and wear to the toggle plate; Select the appropriate crusher model and specifications based on the characteristics of the material to avoid additional wear and damage to the toggle plate caused by the use of unsuitable equipment.

Failure reason 4: The toggle plate and toggle plate pad are not parallel and skewed, which may cause abnormal operation and failure of the jaw crusher.

Solution: Check and replace the toggle plate to ensure proper alignment and tightening; Check the toggle plate pad for wear and replace if necessary.

7. Failure phenomenon: eccentric shaft bent or broken

Failure reason 1: Overload or foreign matter entering may cause the eccentric shaft to bend or break due to excessive pressure.

Solution: Make sure to comply with the rated load when using the equipment, and clean foreign objects in the crushing cavity in time.

Failure reason 2: Equipment aging or wear. Long-term use and wear may cause the strength of the jaw crusher components to decrease, including the eccentric shaft.

Solution: Check the equipment regularly and replace worn parts as necessary to ensure normal operation of the equipment.

Failure reason 3: Improper installation or maintenance of the eccentric shaft may also cause it to bend or break.

Solution: Make sure the eccentric shaft is installed correctly and perform regular maintenance according to the maintenance guidelines provided by the manufacturer.

Failure reason 4: Quality problems with the eccentric shaft. There may be quality problems with the eccentric shaft during the manufacturing process, such as material defects or poor processing.

Solution: It is recommended to contact the equipment manufacturer to ensure that the manufacturer strictly abides by the production process and quality requirements, takes quality control measures to ensure material quality, and uses high-quality materials to produce eccentric shafts.

8. Failure phenomenon: movable jaw fracture

Failure reason 1: Overload or material hardness is too high. When the jaw crusher is overloaded or handles materials that are too large and too hard, the movable jaw is subjected to pressure that exceeds its bearing capacity, causing it to break.

Solution: Avoid overload operation, control the hardness and size of the material, and ensure operation within the normal working range of the equipment.

Failure reason 2: Material or quality problems of the movable jaw. The material of the movable jaw is inappropriate or has quality problems, such as containing pores, inclusions, etc., which may cause its strength to be insufficient or easy to break.

Solution: Use high-quality, reliable materials to manufacture the movable jaw, and conduct necessary quality inspection and control.

Failure reason 3: Equipment wear or aging. Long-term use and wear will reduce the strength and durability of the movable jaw and increase the risk of breakage.

Solution: Regularly check the wear and tear of the equipment and replace seriously worn parts in time to maintain the normal operation of the equipment.

Failure reason 4: Improper installation or maintenance. The movable jaw is not installed correctly or maintained improperly, such as loose fastening bolts, insufficient lubrication, etc., which may cause it to break.

Solution: Make sure the movable jaw is installed correctly and perform regular maintenance according to the manufacturer's recommendations to ensure the normal operation of the equipment.

9. Fault phenomenon: The movable jaw plate and the fixed jaw plate vibrate and produce impact sounds.

Failure reason 1: The wear of the movable jaw plate and the fixed jaw plate results in poor coordination between them, resulting in vibration and impact sounds.

Solution: Check and replace the severely worn movable jaw plate and fixed jaw plate.

Failure reason 2: The support structure or bearings may be loose, damaged or worn, causing the movable jaw plate and fixed jaw plate to be unstable, causing jitter and impact sounds.

Solution: Inspect and repair or replace damaged support structures or bearings.

Failure reason 3: The clearance between the movable jaw plate and the fixed jaw plate is improperly adjusted. If it is too large or too small, it will cause shaking and collision sounds.

Solution: Adjust the clearance between the movable jaw plate and the fixed jaw plate to ensure proper working conditions.

Failure reason 4: The presence of foreign matter or blockage in the crushing cavity will interfere with the normal movement of the movable jaw plate and the fixed jaw plate, causing shaking and impact sounds.

Solution: Clean the foreign matter or blockage in the crushing cavity.

The above are some common faults and emergency solutions. The specific situation needs to be analyzed according to the specific fault, and corresponding measures should be taken to solve the problem and ensure the normal operation of the equipment. At the same time, equipment should be maintained and maintained regularly, inspection and repair work should be strengthened, and the reliability and service life of the equipment should be improved to ensure production efficiency and safe operation.

Vanguard Machinery has an experienced technical team to provide customers with all-around technical support from equipment selection, installation and commissioning to maintenance. The company always insists on selecting high-quality raw materials and paying attention to product details to ensure that the equipment is durable and can also be used. According to customer needs, we provide personalized customized services to meet customers' special operating needs. In the future, the company will continue to be committed to the development of the field of machinery and equipment and provide customers with better products and services. At the same time, the company will continue to expand the international market and actively participate in international competition to achieve greater development and breakthroughs.