Impact crushers are widely used in mining, construction, and recycling industries for crushing various materials. However, like any machinery, the impact crusher can encounter operational faults. Below are common faults, faults, and solutions for impact crushers:
1. Crusher Not Starting or Sudden Shutdown
Possible faults:
Power supply failure or voltage instability.
Electrical control system malfunction.
Overload protection triggered (blocked rotor, excessive feed).
Belt slippage or breakage.
Solutions:
Check power supply and voltage stability.
Inspect circuit breakers, fuses, and wiring.
Clear blockages in the crushing chamber.
Adjust or replace V-belts if loose or damaged.
2. Excessive Vibration or Abnormal Noise
Possible faults:
Loose or worn-out blow bars/hammers.
Imbalanced rotor (broken or unevenly worn parts).
Loose foundation bolts or bearing damage.
Foreign objects in the crushing chamber.
Solutions:
Tighten or replace blow bars/hammers.
Check rotor balance and replace damaged parts.
Tighten foundation bolts and inspect bearings for wear.
Remove foreign materials from the crushing chamber.
3. Reduced Crushing Efficiency & Output
Possible faults:
Worn-out blow bars/hammers or impact plates.
Improper feed size (too large or uneven).
Low rotor speed (due to belt slippage or motor issues).
Material moisture causing clogging.
Solutions:
Replace worn impact parts (hammers, liners).
Adjust feed size to meet crusher specifications.
Check belt tension and motor performance.
Pre-dry wet materials or reduce moisture content.
4. Bearing Overheating
Possible faults:
Insufficient or contaminated lubrication.
Bearing damage or misalignment.
Excessive load or prolonged operation.
Solutions:
Replenish or replace lubricant (use recommended grease).
Replace damaged bearings and ensure proper alignment.
Avoid overloading and allow cooling intervals.
5. Material Blockage in Crushing Chamber
Possible faults:
Overfeeding or oversized material.
Moisture or sticky materials clogging the chamber.
Worn or broken components affecting flow.
Solutions:
Control feed rate and pre-screen oversized materials.
Reduce moisture or use a pre-drying process.
Clear blockages and inspect wear parts.
Preventive Maintenance Tips:
✔ Regularly inspect blow bars, liners, and bearings.
✔ Lubricate bearings as per manufacturer guidelines.
✔ Monitor feed size to avoid overloading.
✔ Check belt tension and alignment periodically.
✔ Clean dust and debris from the machine.
Luoyang Dahua Heavy Industry is a high-tech enterprise with research & development production, sales, and service. The mobile crushing station has been successfully applied in domestic and foreign mine crushing projects. The company has a professional R & D team, a strong after-sales team, from the equipment selection, site inspection, equipment manufacturing, installation, commissioning, delivery and other aspects for your service.
