How to Determine Whether the Hammer, Liner and Other Parts of the Impact Crusher Need to Be Replaced?

In industrial production, whether the core components of the impact crusher, such as the liner and hammer, need to be replaced is mainly judged by comprehensively observing the operating status, wear characteristics and production efficiency of the equipment. In daily operation, technicians need to focus on abnormal phenomena during equipment operation. For example, if metal collision noises frequently occur in the crusher cavity, it may be that the liner fixing bolts are loose or the liner itself is broken and displaced; when the vibration amplitude of the machine body increases abnormally, it is necessary to check whether the hammer has a dynamic imbalance caused by severe wear. These signs are often early warnings of component failure.

Visual inspection of the degree of wear of components is particularly critical. When shutting down for maintenance, it is necessary to focus on the wear form of the hammer working surface: when the hammer head edges are rounded to more than 1/3 of the original size, or a pit with a depth of more than 5mm appears on the working surface, its crushing kinetic energy will be significantly reduced, and at this time, phenomena such as uneven crushing particle size and increased return rate of materials will appear simultaneously. The wear of the liner needs to be judged by observing its contour changes. If the height of the protective ridge is reduced to less than 50% of the original design, or a through crack appears on the surface of the liner, the material guiding function will fail and the risk of machine body wear will be increased.

Dynamic monitoring of production efficiency parameters is an important basis. When the continuous operating current of the equipment increases by 10%-15% compared with the normal value, and the processing volume per unit time decreases by more than 20%, it often indicates that the hammer and liner can no longer effectively crush the material, and the energy loss increases significantly. At this time, even if the appearance of the parts is not seriously damaged, the overall replacement should be considered to restore the performance of the equipment. In addition, regularly measuring the thickness changes of wearing parts and establishing wear files, combined with the cumulative working time of the equipment for preventive replacement, can effectively avoid downtime losses caused by sudden failures.

The balance between safety and economic benefits is the core consideration of replacement decisions. Excessively worn parts not only reduce production efficiency, but are also likely to cause structural damage to the crushing chamber, and even cause secondary failures such as bearing overheating and spindle deformation. When the maintenance cost exceeds 70% of the value of a new part, or the time taken for a single repair exceeds 30% of the normal production cycle, timely replacement can not only ensure safe production, but also maintain a stable production rhythm, achieving optimal cost control throughout the life cycle of the equipment.