Jaw Crusher Emergency Fault Quick-Reference Table
High-Frequency Operational Issues and Corrective Actions
| No. | Fault Condition | Primary Causes | Corrective Actions |
|---|---|---|---|
| 1 | Abnormal sharp noise; movable jaw stops while flywheel rotates | • Tension spring fatigue or fracture • Tie rod failure under excessive load • Non-crushable material causing toggle plate displacement or fracture | • Stop equipment immediately • Replace damaged tension spring and tie rod • Secure movable jaw and inspect toggle plate • Reinstall or replace toggle plate as required • Perform no-load test before restart |
| 2 | Material accumulation in crushing chamber with high motor current | • Oversized material lodged in chamber • Discharge conveyor malfunction • Excessive feed rate or cohesive material | • Stop crusher operation • Remove blocked material using lifting tools • Restore downstream conveying system • Clear discharge opening and reduce feed rate |
| 3 | Excessive vibration and impact noise from jaw plates | • Loose or missing jaw plate bolts • Failed locking components • Broken fastening bolts | • Inspect all fastening bolts • Tighten or replace damaged fasteners • Replace worn locking springs • Adjust discharge opening and jaw alignment |
| 4 | Discharge opening blockage due to adjustment system failure | • Adjustment wedge out of operating range • Non-compliant toggle plate or seat • Loose adjustment seat bolts • Structural defects in adjustment seat | • Reset adjustment wedge position • Replace non-compliant components • Tighten or replace fastening bolts • Replace defective adjustment seat |
| 5 | Movable jaw fracture | • Long-term overload operation • Casting defects in movable jaw • Ineffective toggle plate protection • Jaw-frame interference • Loss of tie rod spring tension • Discharge opening set below limit • Uneven material feeding | • Replace movable jaw assembly • Install compliant toggle plate and seat • Reassemble eccentric shaft and bearings accurately • Restore tie rod spring tension • Adjust discharge opening to specification • Optimize feed distribution |
| 6 | Eccentric shaft deformation or fracture | • Improper lifting or installation • Material strength exceeding limits • Continuous overload operation • Toggle plate protection failure • Improper heat treatment | • Replace eccentric shaft • Standardize lifting and installation process • Match crusher to material properties • Use compliant toggle assemblies • Select shafts with verified heat treatment |
| 7 | Toggle plate failure | • Overload or oversized feed material • Entry of non-crushable objects • Misalignment between toggle plate and seat • Casting defects | • Replace toggle plate • Control feed size and improve screening • Replace worn toggle seats • Ensure parallel and correct installation |
| 8 | Sudden main unit shutdown; unable to restart | • Severe discharge blockage • V-belt slippage due to low tension or wear • Loose eccentric shaft locking bushings • Insufficient or unstable voltage • Main bearing failure | • Stop feeding and clear blockage completely • Adjust or replace V-belts • Reinstall or replace locking bushings and reset clearances • Stabilize power supply voltage • Replace damaged bearings and check lubrication |