Production line overload surges and frequent breakdowns? Listen to what DMAC mechanical engineers ha

                                          
When a stone crushing production line is operating at full capacity to meet order demands and supply materials to construction projects, the crushing equipment is most prone to malfunctions: severe vibrations, jaw plate jamming, conveyor belt tearing, and so on. If these issues are not addressed promptly, even a one- or two-day downtime can result in significant production losses and repair costs.

Below are six of the most common problems encountered with stone crushing equipment during tight deadlines, summarized by DMAC mechanical engineers, along with corresponding solutions and upgrade suggestions to ensure quarries can continue operating smoothly during periods of high pressure.
1. Excessive Vibration and Unusual Noise
Signs:

1. Unusual vibration of the machine base, conveyor belt, and screen
2. Continuous "rattling" or "clunking" noises when running under load
3. Loose foundation bolts and support bolts, requiring constant tightening

1. Wear and imbalance in the rotor, shaft, rollers, and pulleys
2. Incorrect centering or alignment of the production line
3. Worn, dry, or seizing bearings

1. Periodic inspection of the entire screen, conveyor belt, pulley, roller, and bearing assembly
2. Replace excessively worn parts promptly
3. Readjust the entire production line if vibration persists to prevent frame cracking and beam breakage

1. The motor makes a loud noise but the crushing shaft doesn't rotate, or rotates very heavily
2. Abnormally high current, circuit breaker trips repeatedly
3. The hopper is "stuck" with rocks, preventing them from entering the crusher

1. Rocks are too hard or too large for the machine's design
2. The discharge opening is narrow or clogged due to rock fragments
3. The feeding system is uneven, causing load shock

1. Adjust the discharge and inlet doors, check the vibration amplitude of the feed chute
2. Use a vibrating feeder and primary screen with the correct capacity
3. Consult with DMAC engineers to replace jaws and optimize the crushing chamber

1. Uneven stone size output, many stones too flat or with cracked corners
2. Cracks, breaks, or chipping detected on liners and jaw plates
3. Frequent jaw plate rotation and liner replacement

1. Prolonged operation with hard rocks (granite, basalt, etc.) without upgrading wear-resistant materials
2. Incorrect discharge slot adjustment, causing concentrated impact
3. Using jaw plates/liners of the wrong steel grade or poor quality

1. DMAC provides jaw plates and liners cast from high-wear-resistant alloys
2. Products designed specifically for each machine model and rock type
3. Upgrading with correct materials increases lifespan and reduces replacement downtime

1. A "roaring" sound when the shaft rotates, or looseness when shaking the shaft
2. Unusually hot bearings, requiring machine shutdown for cooling
3. Grease leakage, or dried-out grease

1. Using the wrong type of bearing, unsuitable load capacity for the quarry environment
2. Incorrect installation technique, misalignment, clearance/overlapping
3. Using the wrong type of grease or insufficient maintenance cycles

1. Replace with specialized bearings for stone crushers (SKF, NSK, depending on configuration)
2. DMAC provides consulting support to select correct bearing code, load, and speed
3. Professional guidance on proper alignment and lubrication

1. Belt rubbing against the frame, material falling from both sides
2. Belt surface cracked, torn, or fabric layer peeling off
3. Previous belt breaks requiring multiple splicing/crimping

1. Using the wrong cable or thickness for the load
2. Uneven wear of rollers, pulleys, and bearings causing belt misalignment
3. Sharp objects and steel falling onto the belt

1. Replace rubber rollers and pulleys, adjust anti-misalignment rollers
2. Install additional belt guide channels
3. Use heavy-duty rubber conveyor belts specifically designed for quarries

1. The output is too large, requiring multiple re-crushing cycles
2. Or the stone is too fine, with many small particles, difficult to sell at correct price
3. High machine operating intensity but no increase in commercial output

1. Incorrect machine configuration chosen for the desired stone type and size
2. Inadequate sorting screen, worn or torn screen mesh
3. Suboptimal coordination ratio between jaw crusher, cone crusher, VSI, and vibrating screen

1. DMAC engineers can optimize the crushing plant's technological diagram
2. Advise on machine upgrades, add VSI, replace vibrating screens
3. Adjust discharge gate to achieve correct commercial stone size and reduce backturn