| S.No | Code | Fault | Cause | Corrective Action |
|---|---|---|---|---|
| 1 | CF-01 | Rotor Tips worn out or damaged | Normal wear of rotor tips. | "The tips must be replaced when they are worn 95% in the centre. Replace the rotor tips when the thickness of the carbide insert is less than 5 mm in the centre. Mounting the backup tip will protect the rotor structure against damage, so that a backup tip can be used under these conditions for a shift more. Replaced the tip with new one." |
| Off Centre Wear | "The rotor tips are wearing at the top or bottom not in the centre. Trail plates may require adjustment." | |||
| Fragments of ferrous or non-ferrous material in the feed. | "Remove tramp iron. Install a permanent magnet or magnetic detector over the conveyor" | |||
| Insufficient build-up will result in tip exposure. | "Correct Rotor build-up Note : Insufficient build-up of material will expose the supporting metal of the rotor tips. This will also lead to premature failure of the inserts by direct abrasion from the stone flow through the rotor. This can also result in the rotor tips wearing in front of the inserts which will eventually lead to their falling out of the carrier plate. " | |||
| Cracking of Tungsten carbide insert due to feeding oversized material/foreign material. | "Reduce the feed size. Install a permanent magnet or magnetic detector over the conveyor" | |||
| 2 | CF-02 | Tip Cavity Wear Plates Worn out or Broken | Cavity Tips Broken - Tramp Iron in the feed | "Reduce the feed size. Install a permanent magnet or magnetic detector over the conveyor" |
| Excessive accumulation of wet or sticky material, or uneven contact with weldment plate. | "Reduce the water content in the feed. Check for surface contact between the tip cavity wear plate and the weldment plates." | |||
| Normal wear of cavity tips. | "Replace with new one. Note: The cavity wear plates should be replaced before wear progresses to the body of the rotor. Remove the bolts holding the wear plate to the rotor body and replace. " | |||
| Off Centre Wear | "The rotor tips are wearing at the top or bottom not in the centre. Trail plates may require adjustment. | |||
| "Uneven wear due to excessive accumulation within the rotor. Premature wear on the top may indicate feed eye ring wear." | "Clean the accumulation on the rotor. Refer CF-07" | |||
| Premature wear on the tip cavity wear plate on the bottom may indicate excessive accumulation on the base of the rotor. | "Remove the excessive accumulation on the base of the rotor. Replace the cavity tip with new one." | |||
| 3 | CF-03 | Distribution Plate Wear | Wear due to excessive feed size | Reduce the feed size. |
| Normal wear | Replace with new one. | |||
| Premature Wear | "Adjust the spreader plate if your model is attached with one. Reduce the feed size. Replace the distributor plate with new one." | |||
| 4 | CF-04 | Upper Wear Plate Wear | The rapid wear of the upper wear plate is an indication that the feed tube and feed eye ring is worn. | "Periodic inspection of feed tube and feed eye ring wear. Replace the feed tube and feed eye ring along with the upper wear plate." |
| Incorrectly profiled trail plates. | Trail plates may require adjustment. | |||
| 5 | CF-05 | Lower Wear Plate Wear | The rapid wear of the lower wear plate is an indication that the distribution plate is worn. | Replace distribution plate and lower wear plate. |
| Incorrectly profiled trail plates. | Trail plates may require adjustment. | |||
| 6 | CF-06 | Feed Tube worn out / cracked | "Premature wear due to feed tube not centralized. Note: The tube is worn on one side." | Ensure the feed tube is properly centralized. |
| The feed tube is cracked in the lower edge as there is an excessive accumulation within the rotor and is near the feed tube causing overheating. | "Replaced the Feed Tube with new one. Check if there is no gap between the lower end of the feed tube and the upper part of the feed eye ring." | |||
| Rocks wedged in between feed tube and feed eye ring, eventually causing the feed tube or the feed eye ring to break. | The feed tube should go into the feed eye ring by 50 - 70 mm for proper feeding of the rotor. | |||
| Feeding is high | Reduce the feed. | |||
| 7 | CF-07 | Feed Eye Ring worn out / Broken | Premature Wear | Ensure the feed tube is properly positioned. |
| Feed Eye Ring Cleavage | It occurs when feed material is jammed between the feed tube and the feed eye ring. Check the accumulation of the rotor. | |||
| Feed Eye Ring is Loose | Check if the fasteners are tight. | |||
| As the feed tube is worn, the feed eye ring is exposed to more wear. | "Periodic checking of feed tube for wear. Note: The life of the feed eye ring can be increased by rotating the ring clockwise to allow for new surface to wear out." | |||
| 8 | CF-08 | Trail Plate Wear | Normal wear | "Change the trail plate periodically such that to keep the accumulation constant. Note: The trail plates are the heart of the rotor. The size, position and angle of the trail plate control the size of accumulation in the the rotor and the material flow through the rotor. " |
| 9 | CF-09 | Top protection plate Wear | The feed tube has worn out and the material is being unloaded from the top of the rotor. | "Change the feed tube If the protection plate can be used for couple of shifts more, hard face the top of the protection plate. If the protection plate is worn out completely, replace with new one. Note: Top protection plate although it is made up of mild steel, should not wear out quickly. Review the wear profile of the protection plate before it damages the top plate of the rotor. If rapid wear occurs, it may be necessary to hard face the protection plate whenever required. " |
| 10 | CF-10 | Rotor Top edge Wear | Worn-out due to wearing of feed tube or cavity wear plate | Replace the feed tube and cavity wear plate. |
| 11 | CF-11 | Rotor Bottom edge Wear | Worn-out due to high tonnage operation or excessive accumulation near the base of the rotor. | "Reduce the accumulation. Reducing the moisture content of the feed to reduce the buildup of material. " |
| 12 | CF-12 | Bottom Protection Plate Wear | Worn-out due to high tonnage operation or excessive accumulation near the base of the rotor. | "Reduce the accumulation. Reducing the moisture content of the feed to reduce the build-up of material. " |
| 13 | CF-13 | Channel wear | Channel wear due to the fine, wet / or very abrasive, feed and is caused by feed moving around the tip cavity wear plate. | The effects can be reduced by sealing the space between the upper and lower edges of the tip cavity wear plate and the rotor with silicone or urethane rubber. |
| 14 | CF-14 | Rotor Unbalance | Cavity Wear plate worn out | "Refer CF-02 Balance the Rotor after replacement of parts." |
| Distribution Plate worn out | "Refer CF-03 Balance the Rotor after replacement of parts." | |||
| Improper rock formation inside the rotor. | "Trail plates may require adjustment. Select suitable trail plates based on application. Check the moisture the content of the feed. Reduce the water in case of excessive moisture or sticky feed." | |||
| Rotor Tip worn out | "Refer CF-01 Balance the Rotor after replacement of parts." | |||
| Rotor Structure Worn Out | "The wear from the cavity tips, rotor tips may have creeped into the rotor and have damaged the rotor structure. Replace the entire rotor. New Rotor is recommended. Balance the Rotor after replacement of parts." | |||
| 15 | CF-15 | Bearing Temperature increasing | Insufficient grease on the cartridge assembly. | "Grease the bearing cartridge. For greasing quantity refer maintenance sticker on the machine or the manual." |
| Usage of non recommended grease. | Recommended to use MOBIL SHC 100. Refer the manual for other alternative greases. | |||
| Over greasing of the bearings | Remove excess grease from the cartridge. | |||
| Due to leak/blockage of grease. | "Ensure any leakage from hose or nipple. Ensure the delivery of grease to top and bottom bearings. Ensure that the hoses from the progressive block to the bearing cartridge are not damaged. Remove any blockages and seal leakages" | |||
| O-Rings on Flinger top has damaged | Replace the O-Rings | |||
| V seal damaged | Replace the V Seal | |||
| Bearings damaged | "Replace the bearings. Refer CF- 21" | |||
| 16 | CF-16 | Vibration is too high. | Rotor unbalance. | Refer CF- 14 |
| Play in shaft | Replace the shaft. | |||
| Free movement of the machine body is arrested | "Field modification by the user such as welding of chutes into the machine. Ensure no objects touching the body of the crusher." | |||
| Anti-Vibration Mount is not properly installed | "Ensure the anti-vibration mount is free Ensure the transportation bolts in the anti-vibration mount is removed." | |||
| Improper rock formation inside the rotor. | "Trail plates may require adjustment. Select suitable trail plates based on application. Check the moisture the content of the feed. Reduce the water in case of excessive moisture or sticky feed." | |||
| 17 | CF-17 | Bearing Noise. | Grease delivery to the bearings are not proper / Inadequate grease | "Ensure grease is passing to bearing properly by Ensure that there is no air lock in the grease gun and the grease is pumped out. Ensure that the progressive block is working correctly. Ensure that the hoses from the progressive block to the bearing cartridge are not damaged. Replace the damaged parts. Grease extra grease into the cartridge" |
| Bearings worn out | Replace the bearings. | |||
| 18 | CF-18 | Over Heating of pulley | Drive Misalignment. | "Ensure the pulleys aligned correctly. Ensure proper belt tension." |
| 19 | CF-19 | Machine does not start | Power Failure | Ensure that the control panel is working correctly and incoming power supply is proper |
| Motor Failure | "Ensure the motor is not seized and runs freely. Remove the belts from the motor and check if it running. If the motor runs without belts on, then check the belt tensioning. Set proper belt tensioning. If the motor does not run without the belts on, then the motor is faulty. Contact authorised service centre." | |||
| Excessive build at the base of the crusher | Clear the build up | |||
| Panel trips due to high belt tension | Set proper belt tension. | |||
| 20 | CF-20 | Worn-out of Rotor / Rotor Broken | Worn-out of Tip cavity wear plates. | Refer CF-02 |
| Worn-out of Top Protection Plate. | Refer CF-10 | |||
| Worn-out of Bottom Protection Plate. | Refer CF-11 | |||
| Worn-out of Weldment Plate. | Refer CF-22 | |||
| Incorrect feed size | Reduce the feed size. | |||
| Tramp iron in the feed | "Remove tramp iron. Install a permanent magnet or magnetic detector over the conveyor" | |||
| Premature worn-out due to incorrect direction of rotation | "Check the Direction of Rotation. Ensure rotor balance after replacement of parts." | |||
| 21 | CF-21 | Bearing failure | Insufficient grease on the cartridge assembly. | "Grease the bearing cartridge. For greasing quantity refer maintenance sticker on the machine or the manual." |
| Usage of non recommended grease. | Recommended to use MOBIL SHC 100. Refer the manual for other alternative greases. | |||
| Due to leak/blockage of grease. | "Ensure any leakage from hose or nipple. Ensure the delivery of grease to top and bottom bearings. Ensure that the hoses from the progressive block to the bearing cartridge are not damaged. Remove any blockages and seal leakages" | |||
| Due to prolonged usage of Unbalanced Rotor. | Balance the rotor at regular intervals. | |||
| Anti-Vibration Mount is not properly installed | "Ensure the anti-vibration mount is free Ensure the transportation bolts in the anti-vibration mount is removed." | |||
| Usage of contaminated grease. | "Make sure the grease pump is properly sealed. Pack the grease with proper handling equipment." | |||
| 22 | CF-22 | Worn-out of Weldment Plate | Excessive wear of the rotor tips or cavity tips | "Patch the worn-out area if possible or replace the entire rotor structure. Inspect the rotor tips and cavity tips in regular intervals." |
| Incorrect feed size | Reduce the feed size. | |||
| Tramp iron in the feed | "Remove tramp iron. Install a permanent magnet or magnetic detector over the conveyor" | |||
| Improper rock formation inside the rotor. | "Trail plates may require adjustment. Select suitable trail plates based on application. Check the moisture the content of the feed. Reduce the water in case of excessive moisture or sticky feed." | |||
| 23 | CF-23 | Outer surface of the Crushing Chamber is damaged or holes appear | Cavity Ring assembly worn-out | "Replace the cavity ring assembly Periodically inspect the rock formation in the cavity ring assembly." |
| 24 | CF-24 | Rotor stopped abruptly | V Seal damaged | Change the worn out of V Seal. |
| Bearing seized on shaft | Disassemble the cartridge and replace the bearings | |||
| 25 | CF-25 | Output is too fine | Rotor tip velocity is high | "Reduce the speed by changing the output frequency in the VFD if available. In case of Star Delta Starter, Change the pulley in order to reduce the speed." |
| 26 | CF-26 | Output is too coarse | Rotor tip velocity is low | "Increase the speed by changing the output frequency in the VFD if available. In case of Star Delta Starter, Change the pulley in order to increase the speed." |
| 27 | CF-27 | Low production | Rotor worn out | Refer CF-20 |
| Feed size is high | Reduce the feed size. | |||
| Feeding is not regulated | Feed should be regulated. Ensure the feeding of the machine | |||
| 28 | CF-28 | Excessive material build up at crusher base | Moisture content of the feed too high | Reduce the moisture content in the feed |
| High percentage of fine material in feed | Check feed gradation. Reduce the fine material in the feed if possible. | |||
| 29 | CF-29 | No Grease discharge | Grease discharge is blocked | Check and clear the blockage. |
| 30 | CF-30 | Low Build up in Crushing Chamber | Feed size is high | Reduce the feed size. |
| Feed is very dry | Add water to the feed | |||
| 31 | CF-31 | Excessive build up in Crushing Chamber | Feed moisture too high | Reduce the moisture content in the feed |
| High percentage of fine material in feed | Check feed gradation. Reduce the fine material in the feed if possible. |
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