Analysis problem

There are some reasons that may lead to the crusher overheating:

1. Damaged pump Inadequate throughput
2. Bowl liner and mantle unsuited to the application.
3. A special feed generates too much heat in the crusher.
4. Insufficient lubrication of the crusher.
5. V-type drive belts are too taut.
6. Lubrication is too contaminated.
7. No axial play on the countershaft
8. The upper thrust washer has worn out
9. The crusher absorbs too much power.
10. Crusher adjustments are too narrow.
11. The lubrication holes in the shaft are clogged with mud or rubble.
12. The unit heater is clogged up with mud or rubble or block on the outside (curtains).
13. The lower head bushing is warped.
14. Eccentric bushing surface warped.

Corresponding solutions

1. Check the backflow of oil returned by the pump (l/min)
2. Too much fine materials fins in the crusher cavity, entailing excessive input power.
3. An oil cooler must be fitted.
4. Check the pressure relief valve, which may be faulty due to wear. It may be bypassing the crusher. Check the quality of the oil used.
5. Adjust belt tension.
6. Replace the lubricant as per the specification.
7. Axial play of the countershaft.
8. The lubricating grooves are worn, preventing proper lubrication of the surface and causing the temperature to rise. Replace the washer.
9. Poor feed conditions, too much fine product, or crusher working too hard. Tramp iron causes overload.
10. Do not adjust the crusher below its minimum gradation setting. Check bounce on the adjusting ring.
11. Clean the vertical and horizontal holes in the shaft with compressed air.
12. Clean the unit heater.
13. Crushing with insufficient mechanical force, power under 40%. The crusher remains without feed for too long, too many fines in the feed. Oil pressure too low, high temperature, wrong oil viscosity (too low) Oil contaminated due to the presence of foreign particles upstream of the filter, or filter obstructed.
14. Lubricating failure due to too high a temperature of the oil, incorrect oil viscosity (too low). Incorrect feed, the excessive quantity of fines in the feed or crusher gradation set too fine. Large amounts of impurities in the feed, cause overload. Insufficient film of oil. The surface of the main shaft was damaged earlier. Play between the main shaft and the eccentric bushing. Incorrect adjustment between the shaft and the frame. Check it with a thickness gauge.

Analysis problem

There are some reasons that may lead to the sleeve unlocked:

1. The sleeve screws broke. Play between the sleeve and the shaft due to wear.

Corresponding solutions

1. Check the gap between the shaft and the sleeve. If necessary recondition the sleeve by hard-surfacing and machining, to achieve maximum screw adjustment or if the shaft is damaged, mount a sleeve with a smaller bore. Replace the screws using the correct thread torque, tighten after cooling the assembly

Analysis problem

There are some reasons that may lead to the crusher using too much oil:

1. The T and/or U seals are worn or damaged.
2. Faulty pressure relief valve.
3. The oil is too cold.
4. The oil in the crusher is too viscous.
5. The crusher is not properly ventilated.
6. Oil return blocked with mud or rubble.
7. Oil return unsuitable.

Corresponding solutions

1. Replace the seals.
2. The relief valve is incorrectly set or the spring remains in the closed position. Replace the relief valve. Too much oil flow in the crusher.
3. Fit an immersion heater to heat the oil to 27°C.
4. Use the right oil.
5. Clean the breathers at the countershaft housing or on the cover.
6. Inspect the oil return and clean if necessary.
7. Check the oil return gradient (minimum 25 mm for 300 mm) or if the diameter of the oil return tube is too small. Replace the return tube with a suitable one.

Analysis problem

There are some reasons that may lead to the problem that production is reduced:

1. Too fine a feed causes irregular wear on the bowl liner and mantle that when corrected reduces grip.
2. Too low or high an operating speed.
3. Much too much debris in the feed (wood, roots, etc.).
4. Materials are too large at the feed, preventing correct feed.
5. Too much sticky material in the feed, blocking the bowl liner and mantle inlet.
6. Incorrect feed distribution.
7. The bottom of the mantle has a “duckbill” shape.
8. The bowl liner and mantle in the parallel zone area have worn too quickly.

Corresponding solutions

1. Replace the bowl liner and mantle or adjust the bowl for a bigger opening.
2. Check countershaft speed.
3. Remove the debris.
4. Reduce the dimensions of the materials at the feed.
5. Remove sticky products.
6. Correct feed distribution.
7. Contact us. Replace the bowl liner and mantle.
8. Replace the bowl liner and mantle, and use another type of profile.

Analysis problem

There are some reasons that may lead to the problem that the crusher is blocked:

1. V-type drive belts are too slack.
2. Electric problems on the motor.
3. Clogging under the crusher.
4. The countershaft speed is too slow.
5. The oil pressure is too low.
6. Feed opening problem. Since crushing only occurs at the bottom of the chamber, motor power take-off.
7. The bowl liner and mantle look like a “duckbill”.
8. The bowl liner and mantle wear out quickly in the parallel zone.

Corresponding solutions

1. Tauten the V-type belts.
2. Check the crusher’s off-load power rating and power absorbed by only the motor (without the belts). If both readings are similar, have the motor tested by an electrician.
3. Check the passage of materials in the sheet metal work under the crusher. Fit a rotation checker on the discharge conveyor and have it driven by the crusher feed.
4. Check countershaft speed.
5. Check to have the correct pressure.
6. Check the profile of the bowl liner and mantle.
7. Cut the “duckbill”. Replace the bowl liner and mantle.
8. Replace the bowl liner and mantle with suitable profiles.

Analysis problem

There are some reasons that may lead to the oil leak problem:

1. The T and/or U seals are worn or damaged.
2. The O-ring or lip seals are damaged or worn (countershaft housing).

Corresponding solutions

1. Replace the seals.
2. Replace the joints and thoroughly clean the pinion side interlocking, lag with silicone.

Analysis problem

There are some reasons that may lead to the countershaft being jammed or broken:

1. The belts are too tight.
2. No lubrication or not enough oil on the countershaft bushings.
3. The lubrication grooves in the bushing are incorrectly positioned.
4. No play at the end of the countershaft.
5. The countershaft is bent, generally due to excessive vibrations at the end of the countershaft.
6. The oil grooves in the outer countershaft bushing are clogged up with mud or debris.
7. Crown or pinion teeth were broken.
8. Incorrect play between teeth or at the bottom of the teeth between the crown and the pinion.

Corresponding solutions

1. Check the tension of the belts and the alignment of the bull wheels.
2. Check the connection between the main oil pipe and the oil inlet in the countershaft box. Remove any valve or other device restricting the countershaft oil supply pipe.
3. The belt drive should not pull the countershaft against the lubrication groove.
4. Adjust axial play to suitable mm.
5. Replace the countershaft.
6. Clean the oil grooves.
7. Replace the crown or pinion.
8. Adjust the play between and at the bottom of the teeth.

Analysis problem

There are some reasons that may lead to the problem that water is mixed with oil:

1. Accumulation of water coming through the imbalance cover.
2. Breather blocked on the oil tank.

Corresponding solutions

1. Drill holes and weld return tubes.
2. Replace the breather.

Analysis problem

There are some reasons that may lead to the problem that the bowl being blocked:

Accumulation of dust or rust in the thread of the bowl adjusting ring du bowl due to:

• Too hot a feed.
• Insufficient lubrication of the threading.
• The adjustment cap cover is worn or the dust prevention collar is damaged.
• No weather protection.
• The crusher has run too long for the given settings.
• Bowl or adjusting ring threads damaged.
• The threads are broken.

Corresponding solutions

Try any of the following solutions:

• Put penetrating oil in the threads.
• Relieve the pressure in the holding and locking cylinders and let the products pass through the crusher.
• Feed small pieces of wood through the crusher.
• Throw small pieces of soft steel into the crusher.
• Heat the adjusting ring.
• Heat the adjusting ring and cool down the bowl.

Analysis problem

There are some reasons that may lead to the problem that the bowl mantle or liner being detached:

1. The thread torque of the nut’s locking bolt is not correct, nor is the play between the head of the screw and the locking nut.
2. Wrong position of the locking nut on the spacer ring.
3. The locking nut knocks against the top of the head.
4. Liner/mantle or head spans damaged.
5. Insufficient play for the seal between the mantle and the head.
6. Cylindricality defect.
7. The mantle is not secured to the head.
8. The mantle is not centered on the head.
9. Mantle-The crusher rotates too long without feed.
10. The mantle is too thin.
11. The old sealant resin was not completely removed before the new mantle was installed.
12. The tightening lugs of the bowl liner touch the outer diameter of the liner or the screws have worked loose.
13. The Bowl liner is too thin.
14. Too much tramp iron passes through the crusher.
15. The span on the bowl liner or bowl is damaged.
16. The old sealant resin was not completely removed before the new bowl liner was installed.

Corresponding solutions

1. Apply the correct thread torque.
2. Change the locking nut.
3. Insufficient play between the bottom of the locking nut and the top of the head. This should be about 10 mm.
4. Remake the spans.
5. The play should be between 6 mm and 10 mm.
6. This should not exceed 3 mm.
7. Check at the bottom of the mantle with a gauge. The gap should not exceed 0.1 mm.
8. Dismantle the mantle and reinstall it correctly.
9. The maximum time without feed should not exceed 30 minutes.
10. Wear should not exceed 2/3 of the mantle.
11. Remove all the old sealant resin.
12. Wedge the lug or tighten the screw.
13. Wear should not exceed 2/3 of the bowl liner.
14. Too much tramp iron will loosen the bowl liner.
15. Remake the spans to the original dimensions.
16. Remove all the old sealant resin.

Analysis problem

There are some reasons that may lead to the problem of the oil leak at the end of the countershaft housing, bullwheel side:

1. The crusher is not at atmospheric pressure.
2. Not enough oil returns from the countershaft housing or oil deflector, above all when the oil is cold.
3. Defective lip seals.
4. The crusher is not level.

Corresponding solutions

1. Clean the breather of the countershaft housing.
2. Clean the oil inlet hole in the countershaft housing.
3. Replace the lip seals.
4. Level the crusher.

Analysis problem

There are some reasons that may lead to the excessive vibrations problem:

1. Imbalance or imbalance liner is worn.
2. Play incorrectly adjusted at the bottom of the teeth.
3. Bent countershaft.
4. The crusher’s bullwheel turns with difficulty.
5. If the crusher is mounted as a mobile unit, the ground should be correctly prepared.
6. Unsuitable foundations.
7. Bowl liner loose or worn.
8. The countershaft speed is too high.
9. The imbalance liner missing.

Corresponding solutions

1. Remake the imbalance, consult us. Replace the imbalance line.
2. Reassemble the eccentric and wedge it.
3. Replace the countershaft.
4. Remove the accumulated dust on the spokes of the bullwheel.
5. Check the seating.
6. Check the foundations.
7. Dismantle the bowl liner and replace or change it.
8. Use the correct speed.
9. Replace the liner, and contact us.

Analysis problem

There are some reasons that may lead to the problem that wear on the head span and bowl:

1. The crusher runs with the bowl liner and mantle loose.
2. The crusher runs with damaged bowl liner and mantle.
3. The crusher runs with worn bowl liner and mantle.
4. The mantle and bowl liner broken.
5. Intermittent feed while the new bowl liner and mantle are being run in.

Corresponding solutions

1. Make sure the bowl liner and mantle are properly mounted and that the locking nut is tight enough.
2. Excessive wear on the bowl liner and mantle accelerates wear on the bowl and head spans.
3. Excessive wear on the bowl liner and mantle accelerates wear on the bowl and head spans.
4. Running with broken bowl liner and mantle accelerates wear on the bowl and head spans.
5. For crushers without the freewheeling clutch, starting the feed loosens torque when the feed slows down head rotation. Avoid intermittent feed when new bowl liner and mantle are mounted.

Analysis problem

There are some reasons that may lead to the problem that dust enters the lubrication system:

1. No breather on the crusher.
2. The breathers on the crusher or the oil tank do not work properly.
3. The crusher bullwheel sends dust toward the breather.
4. Dust penetrated the crusher when parts were being dismantled.
5. The oil return between the crusher and the tank is too vertical.
6. No seal between the oil tank and its cover.
7. The hose between the fan and the countershaft housing is damaged or disconnected.
8. The breather hose or couplings are damaged or disconnected.

Corresponding solutions

1. Fit a breather on the top of the countershaft housing.
2. Clean the breathers on the countershaft and the oil tank. To check, with the crusher running, a sheet of paper placed on the breather pipe should be sucked slightly inwards.
3. Position the breather further away from the bullwheel.
4. Cover the sleeve and the eccentric with a plastic sheet.
5. Dust may have been sucked towards the sleeve; add another breather on the oil return pipe.
6. Fit a seal or apply silicone.
7. Check the hose and the couplings.
8. Check the hose and the couplings.

Analysis problem

There are some reasons that may lead to the problem that wear on the crown and pinion teeth:

1. The oil is dirty.
2. The tooth wear is too low.
3. The tooth wear is too high.
4. Crusher overworking.
5. Too much play at the end of the countershaft.

Corresponding solutions

1. Replace the oil and clean the tank.
2. Defective eccentric thrust washers, adjust the eccentric assembly with spacer rings.
3. Lower the eccentric assembly by removing the spacer rings.
4. Generally revealed by adjusting ring bounce. Reduce the amount of feed.
5. Adjust play to the right sizes.

Analysis problem

There are some reasons that may lead to the problem that Noise on the drive gear and pinion:

1. Incorrect play between the teeth and at the bottom of the teeth.
2. The crusher runs with a new crown and an old pinion, or vice versa.

Corresponding solutions

1. Adjust play.
2. No need to change.

Analysis problem

There are some reasons that may lead to the problem that the adjusting ring is tilted:

1. Contact surfaces were damaged between the frame and adjusting ring, due to ring bounce.
2. Too frequent overload or unsuitable bowl liner and mantle profiles, causing the adjusting ring to bounce.

Corresponding solutions

1. Feed incorrectly distributed in the crusher cavity. Turn the ring 180°. Check the pressure in the holding cylinders. If too low, increase it.
2. Too many fine products in the feed, refer to paragraph “bowl liner and mantle selection”. Increase the feed in the crusher. Increase the gap between the bowl liner and mantle. Materials clogged, water the feed.

Analysis problem

There are some reasons that may lead to the Bowl bounce problem:

1. Wear on the adjusting ring and bowl threads.
2. lack of pressure in the locking cylinders.
3. Crusher adjustments are too narrow.
4. Bowl liner and mantle are too thick.
5. Gap adjustment is too wide.
6. Check that the hydraulic hoses and locking cylinders are correctly connected.

Corresponding solutions

1. Re-machine the surface of the threads at 45° to achieve a uniform slope, provided the threads are not irreparably damaged.
2. Restore normal pressure in the locking cylinders.
3. Increase the gap until the bowl no longer jumps.
4. Not enough threads engaged. Mount thinner bowl liner and mantle.
5. Not enough threads engaged. Reduce the gap.
6. When the hydraulic unit is running, the hose between the cabinet and the locking cylinders must be “taut”.

Analysis problem

There are some reasons that may lead to the problem that Locking bolts on the feeder cone are broken:

1. Too much feed in the crushing chamber.
2. Feed contains large pieces of product.
3. The contact surfaces between the feeder cone and the locking nut are worn.
4. The feeder cone bolts are loose.
5. Drop too high.

Corresponding solutions

1. Reduce the amount of feed.
2. Reduce the size of the input products or increase the admission opening by changing the bowl liner and mantle.
3. Hard-surface and re-machine the locking nut. Replace the feeder cone.
4. Tighten the bolts to their thread torque.
5. Reduce the drop between the feed box/belt and the feeder cone.

Analysis problem

There are some reasons that may lead to the problem that Bounce on the adjusting ring:

1. Overload or incorrect profile of the bowl liner and mantle.
2. Operation with too little cylinder pressure.

Corresponding solutions

1. The excessive quantity of fines in the feed. Too much feed. Opening too narrow. Sticky materials.
2. Cylinder seal defect. The unit does not repressurize the cylinders automatically (faulty pressure switch). Leak in the cylinder circuit valve inside the unit. Leak in the cylinder pressure relief valve or valve left open. Leak or defect on the hose or coupling…