Introduction
Cone crusher, as secondary or tertiary crushing equipment in mining and sand and gravel aggregate production, are widely used due to their high crushing ratio, high efficiency, and fine particle size. However, over time, cone crushers can experience various malfunctions. Failure to promptly identify and address these malfunctions can not only affect production efficiency but also lead to equipment damage and downtime. This article, based on practical production experience, summarizes common cone crusher malfunctions and troubleshooting methods to help users improve equipment operational stability.
Summary table
| No. | Fault Symptom | Possible Cause | Troubleshooting Method |
| 1 | The oil pump is hot | The oil is thick, or the oil temperature is low. | Change to thinner oil or increase the temperature. |
| 2 | The oil pump is working, but the oil pressure is low. | 1. Oil suction pipe clogged.2. Oil pump gears worn.3. Inaccurate pressure gauge. | 1. Clean the oil pipes.2. Replace the oil pump.3. Replace the pressure gauge. |
| 3 | The oil pump is operating normally, the pressure indicator is normal, but there is no oil return. | Oil return pipe clogged.Oil return pipe slope is shallow.Oil viscosity or low temperature. | Clean the oil return pipe.Increase the slope.Change to thinner oil and heat it. |
| 4 | The oil level indicator is empty or the oil flow is interrupted, and the oil pressure is dropping. | Oil pipe clogged.Low oil temperature.Oil pump malfunctioning. | Clean the oil pipe system.Heat the oil.Inspect and repair the oil pump. |
| 5 | The oil return is decreasing, and the oil in the tank is also decreasing. | Oil leak under the crusher.Oil drain clogged, oil leaking from the seal. | Shut down the machine to inspect and eliminate oil leaks.Adjust the oil supply and clean or deepen the oil drain ditch.Open the sluice gate and supply water normally. |
| 6 | The cooler is not functioning or is not functioning effectively. | No cooling water or insufficient water supply.Cooling system clogged. | Open the sluice gate and supply water normally.Check the water pressure gauge and clean the cooler. |
| 7 | The return oil temperature is too high (>60°C). | Harmful friction on the eccentric shaft sleeve friction surface.Bearing malfunctioning.Insufficient oil groove cross-section or clogged. | Stop the machine to inspect and clean the friction surfaces of the oil supply and cooling systems. |
| 8 | There is oil in the water, or water in the oil. | Cooling water pressure exceeds oil pressure.Broken water pipes, water seeping into the oil. | Reduce the cooling water pressure to 0.05 MPa below the oil pressure.Check the cooler water pipe joints for leaks. |
| 9 | The drive shaft is rotating unevenly, making unusual noises, and the pulley is rotating while the movable cone is not moving. | Defective bevel gear tooth installation, excessive axial play on the drive shaft during operation, causing wear or damage.Damaged pulley or gear key.Shaft breakage caused by indestructible objects. | Shut down the machine to change gears and adjust meshing clearance.Replace the main shaft and strengthen the iron removal system. |
| 10 | The crusher is vibrating strongly, and the movable cone is rotating faster. | No oil or uncleanliness between the main shaft and bushing.Sinking of the movable cone or damaged spherical bearing.Small clearance between the cone bushing. | Shut down the machine to inspect, identify the cause, clean, and oil.Repair or replace.Adjust clearance. |
| 11 | There is an increase in large crushed products. | Worn movable cone. | Reduce the discharge opening and replace the liner. |
| 12 | Severe vibration during operation. | Insufficient spring pressure, excessive fine and sticky material, uneven ore feeding, insufficient spring elasticity. | Tighten or replace the spring and adjust the ore supply. |
| 13 | A crackling sound is heard during rotation. | Loose liners (movable and fixed), damaged screws or lugs, loose liners causing impact. | Stop the machine to inspect, repair, or replace. |
| 14 | There is no water in the water seal. | Abnormal water seal water supply pipe. | Stop the machine to identify the cause of the water supply interruption. |