Noise failure elimination method of jaw crusher

Noise failure elimination method of jaw crusher

Jaw crusher abnormal noise is one of the common on-site faults. Continuous harsh noise not only harms the operating environment and operators’ hearing, but also implies hidden mechanical damage. This article sorts out typical noise sources, judgment methods and elimination solutions for reference of mine and aggregate production line maintenance teams.

1. Noise from crushing chamber (rattling, heavy impact sound)

Root causes

  1. Hard unbreakable foreign matter (iron block, drill bit, steel bar) enters the crushing cavity.
  2. Too large feed size; materials hit jaw plates violently.
  3. Loose jaw plates, toggle plate or toggle seat; liner shakes during crushing stroke.
  4. Uneven feeding, material arching and intermittent falling impact.

Elimination methods

  • Stop the machine immediately, cut off power, lock out/tag out, then clean foreign objects inside the cavity.
  • Control feeding particle size strictly according to equipment parameter requirements; install iron remover on the feeding belt.
  • Retighten jaw plate fixing bolts; check and replace failed toggle plate and toggle seat.
  • Adjust feeder speed to realize uniform continuous feeding.

2. Transmission part noise (clicking, buzzing, regular knocking sound)

Root causes

  1. Loose or worn V-belts, uneven belt tension; pulley eccentricity.
  2. Damaged coupling elastic buffer pad, coupling misalignment.
  3. Worn pulley keyway, loose flat key.

Elimination methods

  • Adjust belt tension to consistent level; replace cracked, aged belts in groups.
  • Recalibrate the coaxiality of motor and crusher shaft; replace damaged coupling buffer parts.
  • Check key and keyway; re-fit or replace flat key if it is deformed or worn.

3. Bearing & eccentric shaft noise (humming, continuous grinding noise)

Root causes

  1. Insufficient lubricating oil, deteriorated oil, or oil mixed with dust and impurities.
  2. Bearing clearance abnormal, rolling elements or raceway pitting and peeling.
  3. Eccentric shaft bending, bearing preload improper.
  4. Bearing seal damaged, dust enters the bearing chamber.

Elimination methods

  • Drain old lubricant thoroughly, clean bearing housing, refill with specified grease / lubrication oil to standard volume.
  • Disassemble and inspect bearings; replace bearings once pitting, ablation or excessive clearance appears.
  • Check straightness of eccentric shaft; repair or replace bent shaft.
  • Renew oil seal and dust seal regularly to prevent dust intrusion.

4. Frame and foundation noise (low-frequency resonance, rumble)

Root causes

  1. Anchor bolts loose; crusher frame shakes on the foundation.
  2. Foundation cushion damaged, foundation sinking unevenly.
  3. Adjacent steel structure or guard plate loose, resonating with equipment vibration.

Elimination methods

  • Tighten all anchor bolts according to torque requirement; add lock washers.
  • Check concrete foundation and base pad; re-shim and level the machine if settlement occurs.
  • Fasten guard plates, dust covers and connecting brackets; add rubber damping pads between steel parts.

5. Toggle plate and tension rod noise (light clatter when swinging)

Root causes

  1. Tension spring fatigue, spring force insufficient.
  2. Tension rod nut loose; toggle plate cannot keep close contact with toggle seat.
  3. Toggle plate contact surface lack of lubrication or worn.

Elimination methods

  • Replace fatigue tension spring; adjust spring preload properly.
  • Lock tension rod nut; ensure toggle plate fits tightly on both ends.
  • Clean contact surfaces of toggle plate and toggle seat, apply lubricant as required.

6. On-site auxiliary noise & reduction tips

  1. Install sound insulation cover or sound barrier around the crusher station.
  2. Add rubber damping pads between crusher base and concrete foundation.
  3. Regularly inspect all fasteners as routine maintenance items.
  4. Form daily patrol mechanism: record noise change trend, so early abnormal signal can be captured before severe failure.

Safety Reminder

All inspection and maintenance inside the crusher must be carried out after complete power cut and LOTO (Lockout Tagout). Never open the inspection cover or reach into the crushing cavity when the equipment is running.