How to maintain a hammer crusher

A hammer crusher is widely used in mining, cement, coal, metallurgy, and construction industries for crushing brittle materials such as limestone, slag, and coal. To ensure stable operation, extend equipment life, and reduce downtime, proper maintenance is essential.Maintaining a hammer crusher is crucial for its optimal performance, longevity, and safe operation. 

Hammer Crusher Maintenance

I. Regular Inspections (Daily, Weekly, Monthly, Annually):

Hammers and Hammer Rods:

Visual Inspection: Look for rounded, blunted, chipped edges, cracks, or fractures.

Rotation: Hammers often have multiple striking edges (2-way or 4-way reversible). Rotate them to a new edge when the current one becomes worn. This maximizes their lifespan.

Replacement: Replace hammers when all cutting edges are rounded or if they show excessive wear or damage. Replace hammers in factory-balanced sets to prevent imbalance.

Hammer Rods: Inspect for grooving or wear. Replace if grooving is present, especially when replacing hammers in a row.

Screens/Sieve Plates and Bar Grates:

Wear and Damage: Check for holes, tears, excessive clogging, or elongated perforations.

Cleaning: Regularly remove material buildup to ensure better efficiency.

Replacement: Replace screens or bar grates when worn or damaged, as worn-out openings lead to inconsistent particle size.

Wear Plates/Liners:

Thinning: Inspect regularly for signs of thinning, particularly around the bolts.

Replacement: Replace wear plates when they show signs of thinning to protect the main housing.

Bearings:

Signs of Wear: Check for signs of wear, overheating (excessive heat, unusually high temperature), or vibration. Listen for unusual whines or squeaks.

Lubrication: Proper lubrication is critical. Refer to the manufacturer's guidelines for the recommended lubricant type and schedule. Avoid over-lubrication.

Replacement: Replace any damaged or worn bearings promptly, often in pairs.

Motor Coupling:

Alignment: Check the motor coupling and its alignment every 6-12 months. Misalignment can cause vibrations.

Fasteners: Ensure mounting and coupling bolts are tightly fastened.

Belts:

Tension: Check the tension of drive belts regularly. Adjust as needed to prevent slipping and ensure proper power transmission.

Wear: Inspect for cracks or signs of wear.

Fasteners (Bolts, Nuts):

Tightness: Regularly check and tighten all bolts, nuts, and fasteners to the recommended torque values. Loose fasteners can lead to vibration and damage.

Airflow:

Cleanliness: Ensure proper airflow through the mill. Poor airflow can reduce product speed and overall efficiency.

Filters: Maintain and check air filters.

Flow Directors:

Abrasion: Inspect for signs of abrasion or wear, as circulating materials can wear them down. Replace as needed (typically every 18-48 months).

Screen Carriages:

Wear and Impact: Inspect for wear and impact damage, especially in specific applications (e.g., pet food grinding). Replace if damaged to prevent leaks and maintain performance.

Motor:

Overload: Ensure the motor load does not exceed its rated value.

Electrical Connections: Check for good electrical contact.

II. Lubrication:

Follow Manufacturer's Recommendations: This is paramount. Different machines and components require specific types and amounts of lubricants.

Regular Lubrication: Lubricate bearings and other moving parts regularly to reduce friction and wear, extending their lifespan.

Avoid Over-Lubrication: Too much grease can also cause issues like overheating. Generally, fill bearing chambers to 1/3 to 1/2 of their volume.

Cleanliness: Clean old grease from bearings and seals before adding fresh lubricant.

III. Cleaning:

Regular Cleaning: Keep the machine clean by regularly removing dirt, dust, and debris. Accumulation can cause damage, reduce performance, and even lead to failure.

Clear Cloggings: If clogs occur (e.g., between sieve strips), stop the machine and clean them out.

IV. Replacement of Worn Parts:

Timely Replacement: Replace worn-out or damaged parts immediately to prevent further damage to the machine, maintain efficiency, and ensure product quality.

Genuine Parts: Use genuine replacement parts to prevent damage and ensure compatibility.

Balanced Sets: When replacing hammers, always replace them in balanced sets to maintain rotor balance and prevent vibration.

V. Monitoring Performance:

Particle Size Distribution: Monitor the output particle size to ensure consistency. Inconsistent particle size can indicate worn hammers or screens.

Power Consumption: An increase in power consumption can signal issues like worn parts, blockages, or an overloaded machine.

Overall Efficiency: Track the machine's overall efficiency to detect problems early.

Vibration and Noise: Pay attention to any unusual vibrations or sounds, which can indicate issues like unbalanced rotors, loose bolts, or worn bearings.

VI. Safety Procedures:

Lock-out/Tag-out: Always implement lock-out/tag-out procedures before performing any maintenance or repair work to prevent accidental startups.

Follow Manual: Familiarize yourself with and strictly follow the manufacturer's instructions for operation and maintenance.

Safe Distance: Keep bystanders at a safe distance from the machine during operation.

Foreign Objects: Strictly forbid feeding metal foreign objects into the crusher. If found, stop immediately and remove them.

Do Not Exceed Capacity: Never exceed the machine's recommended capacity to avoid overloading and potential damage.

VII. Long-Term Maintenance Considerations:

Preventive Maintenance Schedule: Establish and adhere to a regular preventive maintenance schedule that includes routine inspections, lubrication, and proactive replacement of wear parts.

Spare Parts Inventory: Keep a stock of common wear parts (hammers, screens, bearings, hammer rods, wear plates) on hand to minimize downtime.

Training: Ensure operators and maintenance personnel are properly trained on the correct operation, inspection, and maintenance protocols.

By following these guidelines, you can significantly extend the lifespan of your hammer crusher, improve its efficiency, and ensure a safer working environment.