TROUBLESHOOTING OF cement plant mechanical and electrical equipment

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TROUBLESHOOTING OF cement plant mechanical and electrical equipment


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  • Jaw crusher trouble shooting


Common malfunctionscauseMethod of exclusion
1After vigorous splitting sound, swing the movable jaw is stopped, continued rotation of the flywheel, the spring rod slack.Crushing cavity into the material can not be broken or otherwise damaged so that the thrust plate.Turn on the tie rod nuts, remove the rod spring, the movable jaw suspended, replacement thrust plate.
2Breaker plate shake and impact sound is generated.1、  Crushing plate fixing bolt loosening.

2、    Crushing plate fixing bolt breakage.

1、Crushing a fastening plate fixing bolt, such as a resilient locking insufficient replacement.

2、  Replace the bolt.

3Flywheel rotary, crushing is stopped, the thrust plate from coming out of the holder.Spring rod or rod breakage.Replace the damaged parts.
4Generating thrust plate bearing a crash or other abnormal sounds.1、  Insufficient tightness or broken spring.

2、  The thrust plate bearing wear or loose.

3、  The thrust plate elbow head badly worn.

4、    Squaring means spout squaring unevenly, causing inconsistent around thrust plate difficult.

1、Tightening springs or replace the spring.

2、Replace the thrust plate holder.

3、Replace the thrust plate.

4、  Re-align the discharge opening adjustment device.

5Flywheel loose.1、Too loose with the key, the key and keyway wear serious.

2、  The shaft locking device loose.

1、The key matter, replacement or re splined key.

2、  The tightening shaft locking device.

6Crushed product particle size increases.Bottom jaw badly worn.Adjustment means to adjust the discharge opening, narrow discharge opening, such as when not, the jaw plates may be swapped or replaced with new jaws.
7Crushing chamber blocked, the main motor current is higher than the normal operating current.1、 Large stones entering the top of the crushing chamber, but not crushed clogging.

2、 The following crusher belt failure, blocked discharge opening.

3、 Into the viscous material and other debris clogging the discharge port

4、   Feeding too big.

1、After stopping, large stones and then tethered wire rope crane lifted out large stones crusher.

2、Stop feeding, troubleshooting belt machine, then stop crusher as possible.

3、Stop feeding material, and clear the discharge port, stop at this time as the crusher.

4、  Feeder slow the speed and reduce the volume of feed.

8,Bearing fever (more than permissive temperature).1、Tubing plug, poor lubrication oil flow.

2、Oil pump, insufficient supply pressure.

3、Lubricating oil is dirty, mixed with debris.

4、Small clearance between the pads and the shaft.

5、Inappropriate selection of lubricants, the viscosity is too large or too small.

6、Before winter starts without opening the oil heater, oil is too viscous.

7、In summer, the lubricating oil from the oil pump is not hit by the oil cooler, an oil cooler, or failure, such as clogging of pipes, poor water, water.

8、Bearing cooling water circulating device failure, such as clogging.

9、The discharge port is set too small (too thrust plate) eccentric shaft too much force.

10、          Pull drive belt too tight, bearing load is too large.

1、Clear, clean tubing.

2、Repair of pumps.

3、Cleaning bearings, oil change.

4、Open bearings, re-scraping increase watt mouth pad, adjust the gap.

5、Replacement for oil.

6、Open oil heater.

7、Troubleshooting for oil cooling, the lubricating oil through the cooler.

8、Bearing failure to exclude the cooling water circulating means.

9、Appropriate relaxation of the discharge opening.

10、          Loosen the belt, not so tight.

9Bearing oil (mainly in the bearing structure, the oil passes through the gap between the pad and the joystick, the permeate from the middle to both sides).1、Deformation processing or use bush imprecise, resulting in loose fitting between the pad and the joystick.

2、  Small clearance between the shaft and the bearing bush, the hydraulic pressure is increased between the two pads.

1、Replace the bearing.

2、  Adjusting the gap, the gap is preferably slightly larger than the gap of the two middle.

10Failure top seat adjustment wedgeTop level wedge seat forward movement distance is too large.The wedge-shaped top seat back rearward.
11Eccentric shaft fracture.Withstand large loads suddenly (e.g., iron fall).Control large loads, measures to strengthen the iron.
12Movable jaw fracture.1、Withstand large loads.

2、Poor materials.

3、  Poorly designed or defective casting.

1、To prevent excessive load (particle size control, into the anti-iron).

2、Improved materials.

3、  Improve the design, improve manufacturing quality.

13Hydraulic pressure is lowered to the oil system.1、Pump is defective.

2、Oil too cold.

3、  Fuel supply valve failure.

1、Overhaul pumps.

2、Heating oil.

3、  Supply valve repair or replacement.

14A hydraulic oil supply system increases, a corresponding increase in the oil temperature.Part of the tank or pipe plug clogging.Cleaning pipe, tank, or replace the filter.


  • Hammer crusher trouble shooting

No.Common malfunctionscauseMethod of exclusion
1Larger initial startup vibration.Rotor imbalance, loose bolts coupling housing, sandwiching hammer rotor imbalance.By weight of optional re-hammer so that the hammer with a symmetrical row of a row is equal to the weight of the hammer (with at most 30 g); Check coupling bolts, and re-tightening; hammer stop treatment.
2Bearing temperature exceeds the specified range.Grapefruit curved so that the main pad uneven force; insufficient oil or dirty.In other spindle or spindle straightening; cleaning bearings, replaced with new oil, such as changing pad worn pad.
3Fever motor bearing temperature exceeds a predetermined range.Insufficient amount of oil bearing, V-belt pulled too tightly.The bearing screw unloading points, check the bearing wear, if no damage, add a little oil, V-belt adjustment appropriate.
4Crusher abnormal noise, excessive vibration.Iron into the crusher, hammer bolts or the liner broken.Parking remove iron, replace bolts.
5The particle size is large, and a multi-material discharge.Grate discharge head surfacing too high, hammer wear too much.Replace the discharge grate, replace the hammer, an appropriate increase in the height of the feed grate.
6Have abnormal crash the crusher.Feed grate high welding head, mounted out of true.Removing portions collide with oxygen welding, adjusting the position of a good segment of the grate.
7The material could not row, row, or very little.An upper feed grate holding material too; badly worn hammer.Renewal hammer, the upper portion of the material emptied, then gradually feed.
8Large pulley slow speed, large vibration motor, current is high.Feeding too uneven, V-belt slack, the material is too wet, forming “turn lost.”To feed a uniform, reduced feeding, until the current returns to normal, then feeding, the motor anchor bolts tightened.
9The material falling or breaking grate bars.Layering bad welding, weld badly worn.Replacement of grate bars, and the bead firmly welded.
10V-belt from the floor.Pull too tight; belt aging.Cut off from the floor fall out section, adjust the belt tightness.
11Loose superstructure bearing, bearing hear the sound.Bearing bolt break; loose bolts.Check parking; replace or tighten bolts.
  • Mill trouble shooting

No.Common malfunctionscauseMethod of exclusion
1Bearing overheating or melting; off motor overload.1、Lubricating oil supply disruption or too little.

2、Impure or inappropriate lubricating viscosity.

3、The bearing into the material.

4、The main bearing is installed incorrectly.

5、Barrel or shaft bending.

6、Journal bearing bad.

7、  Lack of main bearing cooling water or high temperature.

Stop and identify the causes and take specific case of increasing the amount of oil, replace dirty oil, cleaning bearings, trim barrel and journal bearing position adjustment, re-scraping bush, increased water supply, reduce water temperature and other measures.
2When the starter motor has overload phenomenon.After prolonged stop, the barrel wet material form lumps, starting mill, a ball carrier can not fall into the falling or diarrhea, difficult to start the motor load increases.A partial discharge from the mill balls, steel balls and then for the remaining loose mix.
3Mill discharge quantity reduction, hour production is too low.1、Feeder jam or damage.


3、Infeed material size and fragility of the blend ratio changes.

4、Excessive or insufficient number of media wear.

5、Dry grinding material into the mill water is too large.

6、  Dry grinding mill poor ventilation grate clogging.

1、Feeding equipment service and repair.

2、Address the causes underfeeding.

3、Grinding ratio adjustment.

4、Supplementary grinding bodies.

5、Reduce the temperature of the material into the ground or water.

6、  Cleaning grate plate hole and vent line.

4Cylinder liner bolt hole leakage of material.1、Liner bolts loose.

2、Gasket wear.

3、  Liner bolts break.

1、Tighten or replace bolts pad new gasket, if necessary, replace the liner.

2、  After replacing the bolt, nut washers use an outer cylinder mill waste belt better seal.

5Current is too high, the current instability.1、Loading capacity of the mill is too high.

2、Lack of bearing lubrication oil.

3、Transmission failure or excessive wear.

4、  Weight variation liner four weeks.

1、Adjust the load.

2、Increase the amount of oil.

3、Check bearings, shafts, gears and other transmission parts and repair.

4、  Regulating liner.

6Gear knocking.1、Excessive gear wear or poor lubrication.

2、A gear processing or assembly does not meet the quality requirements.

3、  Bearing or bearing bolt loose.

Down to check and eliminate hidden dangers.
7Lubrication system oil pressure is too high or too low.1、Tubing plug.

2、Tank fuel shortage.

3、Pump or tubing penetrate air or oil spills.

4、  Oil pump failure.

Stop grinding, check the oil, to solve the problem.
8Drive gear tooth wear.1、Long-term operation, material fatigue.

2、Gear vibration, increasing the dynamic load gear.

3、Transmission parts bolts loose.

4、Large bearing clearance

5、  The drive shaft at the center line curved or skewed.

1、Wear more than 30%, the replacement gear; minor wear, the size gear used upside down.

2、Identify the cause of vibration, excluded.

3、Fastening bolt.

4、Reduce or replace bearing pads bearing the mouth.

5、  Straighten alignment.


  • Drying grinding trouble shooting

No.Common malfunctionscauseMethod of exclusion
1Full mill (grinding boring, full of grinding) grinding feed back.1、 Or excess amount into the mill feed particle size, hardness.

2、 Grinding of materials into the water large, poor ventilation.

3、 Inadequate drying heat.

4、 Ball grading inappropriate.

5、 Diaphragm plate damage, channeling grinding compartment.

6、   Classifier meal back more than expected.

1、Timely adjustment of the volume of feed.

2、Reduce moisture or forced ventilation.

3、Increase the amount of hot air, raising the temperature.

4、Gradation adjustment.

5、Stop changing compartment plate.

6、  Cyclic load adjustment, maintenance selected feeder.

2And ringAfter grinding full discovery and treatment is not timely.Reduced feeding, increase the hot air, the tap open chute rotary screen shutter, slagging.
3Liner material leakage out of the bolt holes in the mill.1、Fracture bolt.

2、A small gap between the lining, thermal expansion caused by falling.

3、Drop wedge ring slot liner to iron.

4、  Drive preheating, uneven heating, rapid expansion of certain components such as the backing card compartment plate pressing down bolts.

Stop grinding reinstall liner.
4Drying Chambers steel ball smashing hit sound.Compartment wear plate heat deformation, ball fleeing drying chambers.Downtime to replace the damaged diaphragm plate.
5Feeding loose spiral tube, friction impact sound.1、Fixing bolts loose.

2、Large stones card in the blade, damaging the bolts.

3、  Hot flue is tilted, helical tube by friction.

Find out the reasons for processing.
6Mill bearing fever.1、Insufficient cooling water pipes clogged or inadequate water pressure.

2、Cooling water quality does not comply, the residue impurities.

3、High-temperature hot air into the mill without water or hot air non-stop.

4、Protective insulating hollow shaft asbestos rope is disengaged.

5、  Bad, not properly installed.

Identify the cause symptomatic treatment.
7Starting mill large load.1、Long-term stop grinding material deposition, carrying the ball is not thrown down.

2、  The hollow shaft surface oxidized.

1、Discharge of the discharged balls, loose slug.

2、  After refueling stop grinding without water descaling the hollow shaft.


  • Separator trouble shooting

No.Common malfunctionscauseMethod of exclusion
1,Gearbox fever or “smoke.”1、Gear boxes short of oil, poor lubrication, poor oil quality.

2、Overload use.

3、  Transmission failure itself.

1、Improved fuel or lubricating oil change.

2、Load control or improve drive design.

3、  Press the “burning oil”, specific analysis of “glue”, “thermoplastic deformation” and symptomatic treatment.

2Of gearbox vibration and noise.1、Bad tooth contact surface.

2、With a suitable backlash, there is an axial runout.

3、  Bevel gear precision tolerance.

1、Adjust the contact surface.

2、Adjusting backlash elimination ran.

3、  Replace the bevel gear.

3Bevel gear tooth root cracks or Duanzhe.1、Support rigidity difference, bearing damage, axial movement.

2、Two or excessive wear tooth thickness of gear teeth difference is too thick, too thin a break.

3、  Gear hardening issued a “fragile.”

1、Accordingly excluded.

2、Improved analysis of reasons, such as material.

3、  Improved heat treatment.

4Cemented gear and plastic deformation.1、Poor lubrication, less oil, oil-free.

2、  High-speed overload use.

1、Cleaning the tank, fuel oil change.

2、  Speed ​​control, load control, or improve the design.

5Gear severe pitting and spalling.1、Bearing gap is too large, serious bearing wear.

2、Bad material or heat treatment.

3、  Overload use.

1、Repair or replace bearings.

2、Improved materials, improved heat.

3、  The control load.

6Badly worn gear.1、Adverse protective seal.

2、Bad oil, oil impurities.

3、  Bad material.

1、Strengthen the protection seal.

2、Cleaning oil change.

3、  Selection of wear-resistant material.

7Rolling fever Abnormal sound.1、Poor lubrication, wear a serious lack of oil.

2、The horizontal axis end flange bolts loose slip teeth.

3、Loose fit, clearance increases.

4、  Adjusting nut threaded upper slip teeth.

1、Come on in time, short-term increase oil production.

2、Tapping again change large bolts.

3、Removable repair.

4、  Processing head shaft, re-threading, for the nut.

8Separator blade swing body broke or dropped.1、Poor leaf quality, inconsistent weight.

2、Blade fixing bolts loose.

3、  Not properly installed, an upward or downward deflection.

1、Replacement blades, uniformly weighing installation.

2、Check the bolts, tighten the bolt plus washers.

3、  Adjust the mounting position.

9Separator current suddenly increases.1、Lower or upper roller bearing burn.

2、Cuff deformed, broken off stuck.

3、Feed mixed with chunks of debris plug dead Caesar upper tray outlet.

4、  Large lower vertical shaft nut loose, spreader hub lowered.

1、Check and replace bearings.

2、Check and replace the snap ring.

3、Clear debris.

4、  Tighten the large nut.

10Fan bearing housing vibration.1、 Two fan and motor shaft misalignment.

2、 Impeller imbalance.

3、 Fans import and export throttle out of position.

4、 Not strong enough foundation stiffness.

5、 Anchor bolts loose.

6、   Fan impeller fouling.

1、The two concentric to the axis alignment.

2、Correction balance.

3、Regulate the throttle position.

4、Strengthening the foundation, increased stiffness.

5、Check tightening bolts.

6、  After cleaning stop open access door.


  • Vertical mill trouble shooting

No.Common malfunctionscauseMethod of exclusion
1Main gear bearing temperature limit.Pipe length, elbow, large resistance, pressure oil separator oil shortage.The tubing from the brass φ16mm φ11mm to reduce elbow.
2Roller hydraulic system leak.Coupling a threaded pipe joints, threaded lead to leaks and low machining accuracy.The tubing threaded coupling to flange connection.
3Scum (scum production).1、Grinder gas into the negative pressure is too low.

2、Millstone thin material.

3、Excessive material into the mill.

4、Insufficient pressure roller.

5、  A small amount of wind into the mill, low wind speed wind ring.

1、Maintaining the slag discharge port is not clear product material, reducing slagging leakage; and periodic replacement of the seal roller and the cylinder.

2、Establish a stable layer material, materials to increase the humidity.

3、Appropriate to reduce the volume of feed.

4、An appropriate increase in disc height gauge ring.

5、  Appropriate to reduce the air ring area, controlling the wind speed 50-70m / S.

4Scum (start-stop Scum).1、Roll pressing down time is later than the feeding drive causing scum.

2、  Roll ahead of the decompression stop feeding time, resulting in parking scum.

1、        Normal start pressurizing have stable and fast, 1 minute is added to the desired pressure of the pressure roller; After no downtime disc drive first feed roller is not pressing down, the material thickness to be increased when gradually pressurized 50-60mm, 3 minutes in the process of completing the press.

2、        30 seconds after stopping feed roller lift and then gradually reduced, synchronization can be avoided.

5vibration.1、High temperature gas into the mill, too dry material into the mill.

2、Pressure roller inappropriate.

3、Into the grinding material particle size is too large.

4、Uneven material into the mill, clay blanking.

5、Millstone thin material.

6、  Out of the mill pressure value increases.

Controlling the grinding gas temperature 110-1250C.

Reducing the pressure roller, due to lower yields.

To prevent large pieces of material into the mill. Limestone <25mm, clay <50mm.

Ensure continuous feeding balanced, non-card material, blanking.

The proper use of spray disc, holding the material thickness of 50–65mm.

Adjustment loop material mill, the mill is reduced in the resistance of the control pressure value -7.0-7.6KPa.


  • ATOX vertical mill trouble shooting

No.Common malfunctionscauseMethod of exclusion
1Stretching rod breakage.1、 No protective cover above the stretching rod, stretching rod operation against the material, resulting in wear and tear.

2、   Since the screw head root stress concentration, the increase in diameter in the middle, the impact toughness is reduced in the long-term alternating stresses, plus three different heights, the roller plate, causing fracture (middle stretching rod off).

1、In the stretching rod welded on the protective sleeve, and to avoid touching operation.

2、  Improved stretching rod structure.

2And a connector joint with the internal disengaged from the roller mill.1、Shall replace the air seal ring and the joint bearing with the connector pulled out from the roller mill, multiple operations, the shaft surface is strained.

2、Low surface hardness of the shaft, the upper half of the pressure receiving surface is deformed.

3、Bearing inner ring and the bearing shaft locking relative movement.

4、When installing the bearing inner ring end face of the left distance is not in place.

For these reasons the bearing and the shaft by the interference fit becomes loose fit, then broken bolt, connector prolapse.

1、Improved air sealing ring, the sealing ring to facilitate replacement.

2、Brush the bearing inner ring, shaft diameter required to recover.

3、The top end surface of the bearing inner ring in place.

4、  The bearing cover bolt strength.

3Rolling mill liner cracks.Improperly installed, the bottom surface of the liner in contact with the roller surface uneven, resulting in the vibration plate.Correct installation of a new liner.
4Disc liner shift.When mounting the compact disc to contact the bottom surface, the inclined surface is not in contact with the liner.The bottom surface of the compact car to an appropriate thickness. Lining the inner surface of the card into the card slot of the disc, the outer surface of the card is caught by the compact surface of the card 3, each compact disc bolted.


  • Troubleshooting HRM vertical mill hydraulic system of exclusion

No.Common malfunctionscauseMethod of exclusion
1Air suction pump.Inlet pipe bad seal leakage.

Pump itself bad seal leak.

Fuel shortage, improper fluid consistency.

Tighten the nut conduit.

Replacing defective seal.

Add enough oil, oil plus a suitable consistency, such as wear hydraulic oil # 32 or # 46.

2Insufficient hydraulic pressure or no pressure.Motor connection is reversed or under motor power, speed is not enough.

Pump oil inlet reverse, poor oil absorption.

1、Motor exchange line, the test voltage, the current size.

2、  The pump oil out of the oil port connected properly to ensure smooth oil absorption.

3Hydraulic component failure.1、To pump large gap.

2、Insufficient amount of oil.

3、Copper sleeve pump, gear damage or other elements of poor accuracy.

4、  Wear and pressure plate.

Timely repair or replacement of parts, serious when changing gear pump.
4Control valve failure.1、 Valve regulating spring permanent deformation, distortion or damage.

2、 Seat wear, poor sealing.

3、 Spool nap, deformation, does not move freely, stuck, damping clogged.

4、 Spool valve hole with the large gap.

5、   Valve opening is small, a large flow rate, the generation of cavitation.

Timely maintenance, adjustment, replacement of components, to minimize pressure drop.
5Mechanical vibration.Tubing vibration or impact each other.Plus support tube clamp.
6Hydraulic cylinder failure.1、Assembly or installation accuracy is poor.

2、Piston ring damage.

3、Clearance seal piston wear and cylinder wall, the leakage more.

4、Head of the seal friction is too large.

5、  At the piston rod seals badly worn or damaged, crawling movement.

Timely maintenance, adjustment and replacement of defective seal element.
7Hydraulic shock.1、The hydraulic cylinder cushion failure.

2、  Back pressure valve to adjust the pressure variation.

Timely maintenance, adjustment of the replacement element.
8Hydraulic components rust wear faster.The oil is mixed with water, milky white liquid.The oil was allowed to stand for 30 minutes, the mixture was discharged from the bottom portion of the water tank; severe replaced with new oil.
9Pumps, valves and other moving parts in the death of the card member, a slit orifice clogging.Oil was mixed with the chips, sand, ash and other impurities.1、Before filling the oil tank cleaning.

2、You need to add the filter when refueling.

3、  Regularly replaced with new oil, cleaned the filter.

10Vibration noise, oil deterioration.Oil in the invaded air.1、Replacing defective seal.

2、  Check hydraulic fittings and connection elements, the fastening and loosening of the bolts in a timely manner.


  • Kiln trouble shooting

No.Common malfunctionscauseMethod of exclusion
1Red brick kiln off1、Hanging kiln skin poorly.

2、Kiln inlay puzzle quality or fails to be replaced after thinning.

3、Severe wear plate and belt, the gap is too large, radial deformation so that the cylindrical body is increased.

4、Cylinder centerline is not straight.

5、  Local overheating deformable cylindrical inner wall irregularities.

1、 Work to strengthen the ingredients and baking operations.

2、 Use high-quality kiln lining, inlay puzzle improve the quality of life cycle strictly controlled kiln lining, thick brick timely inspection, timely replacement of worn lining of the kiln.

3、 Strictly control the gap with tire burning zone near the pad; must be promptly replaced or padded adjustment plate when the gap is too large, in order to prevent and reduce the wear and tear of long-term relative motion between the plate produced, between the belt and the plate plus lubricant.

4、 Periodic calibration cylinder centerline, the adjustment idler position.

5、   Red kiln will stop must be done; excessive deformation timely repair or replacement of the barrel.

2Roller broken shaft.1、Cylinder center line is not straight, so that the idler excessive force, overload.

2、Torr axle poor material, internal defects; insufficient strength, fatigue resistance difference.

3、  Journal stress concentration at the transition.

1、Periodic calibration cylinder centerline.

2、For internal testing of the new shaft, check for internal defects.

3、  Appropriate choice of transition radii (fillet), to improve the surface finish.

3Cracks or fractures occur belt.1、Cylinder center line is not straight, belt excessive force, overload.

2、Roller adjustment is not correct, skew is too large, resulting in a local tire overload.

3、Poor material, strength is insufficient, fatigue resistance difference.

4、Section complex and difficult to cast, there are pores, slag.

5、  Structure is irrational, poor heat dissipation conditions, a large thermal stress.

Periodic calibration cylinder centerline.

Roller correctly adjusted so belt force uniform.

High quality steel casting.

Use a simple cross-section, improve casting quality.

Selection of a rational structure.


4Roller surface cracks, spoke breakage.With two, 1.

Roller adjusted correctly, the skew is too large; uneven force so that the idler, localized overloads.

Poor material, strength is insufficient, fatigue resistance difference.

Poor casting quality, trachoma, slag.

Roller misalignment and the rear axle assembly.

When asked wheel assembly, excessive interference.

1、With two, 1.

2、Roller correctly adjusted.

3、Made of high quality material casting.

4、Improve the quality of casting.

5、Turning again after assembly.

6、Choose a reasonable amount of interference.


5Vibration kiln.1、Excessive bending cylinder, idler void.

2、Small gears meshing gap is not correct.

3、The cylinder and the gear for the spring plate interfaces bolts loose, broken off.

4、Drive bearing with the gap is too large with the journal bearing or housing coupling bolt loosening.

5、The drive pinion have shoulder.

6、Roller excessive skew.

7、  Anchor bolts loose.

Roller correctly adjusted, cylinder correction.

Resize engagement clearance.

Coupling bolts fastening, riveting re good loose rivet, build up to stop the kiln bricks.

Good fit with the journal bearing clearance adjustment, the fastening bolt bearing housing coupled.

Chisel platform shoulder.

Readjust Roller.

Sturdy anchor bolts.

6Supporting Shaft tile overheating.1、Kiln center line is not straight, so that the idler excessive force, the local overload.

2、Roller skew is too large, too large thrust bearing.

3、The bearing cooling pipes blocked or leaking.

4、  Deterioration of grease or dirty lubrication device failure.

Periodic calibration cylinder centerline.

Roller adjustment.

Repair water pipes.

Cleaning, maintenance and Bush lubricating device, an oil change.

7Roller Axle Wala Si.Bearing hard pox or slag.

Iron fall within the lubricating oil, or other hard clinker pieces debris.

1、Replace the bearing.

2、  Cleaning and lubricating device pad, oil change.

8Current increases.1、Thick skin and long kiln.

2、Kiln ring formation.

3、Roller adjustment is not correct, a “figure eight.”

4、Roller bearing lubrication, poor cooling.

5、Tube bending.

6、  Motor failure.

1、Reduce wind, coal, materials, process kiln skin.

2、Ring formation process.

3、Redeployment roller, maintaining consistent thrust direction.

4、Maintenance lubrication, cooling means.

5、The cylindrical projecting portion or boom portion to tilt at the top, an appropriate time to stop a little, cylindrical correction own weight.

6、  Motor maintenance.

9Barrel cracking.1、Vibration kiln.

2、Red kiln burning kiln strength weakened.

3、A top idler gear force is too high.

4、Steel weld defects or poor quality interfaces.

5、Thin steel plate.

6、Foundation uneven subsidence, causing the cylinder to bend.

7、  Cylinder surface temperature exceeds 4000C, the strength of the steel sheet to reduce creep.

1、See “Five.”

2、Kiln repair, reinforcement cylinder.

3、Roller correctly adjusted, to reduce the load.

4、A flaw defect inspection inside, around the defective portion by a rivet to live, to prevent spreading.

5、Select the appropriate plate thickness.

6、Adjusting the position of the idler mount and maintain linearity kiln.

7、  Take measures to reduce kiln shell temperature.

10The contact surface of the transmission gear has a shoulder.1、Kiln ran poor flexibility.

2、  Gear wheel and the left wheel band gap is too large or too small.

1、 Keep flexibility ran the kiln.

2、   Shoulder cutting platform, according to specifications of the kiln, the adjustment wheel between the gear wheel and the band gap.

11Roller bearing block leakage of lubricating oil.1、Improperly installed or worn seals.

2、Seal gland bolts loose.

3、  Inadequate or excessive grease supply.

1、Inspection equipment, the replacement of the new oil seal.

2、Tighten the bolts.

3、  Adding oil as required.



  • Grate cooler trouble shooting

No.Common malfunctionscauseMethod of exclusion
1Grate plate turned up, a large number of material leakage.1、Roller chain from the connecting plate, the fixing plate touch the chain grate plate row from the top, overturned.

2、  T-shaped projections windshield thermal deformation, the fixing plate blocked, the rows of grate plates inverted.

1、The chain idler is reset, off tightening bolts, tightening ring fight, tighten the top wire.

2、  After the T-shaped flap formation roasted red, severe deformation, it should be updated.

2Small shaft bending, breakage of a large number of grate plates.1、Dingfan the grate plate, robbed cards live crushed material, small shaft bending.

2、Curvature of the guide plate, the length does not meet the requirements, a wrong adjustment, or even fall off, causing grate plate “fight into saddle” shape, the whole grate board live crushed small shaft bending.

3、The gap between the feed plate and the grate grab too large, hot material falls into the gap, extrusion grate plate.

4、Direct impact on bulk clinker, crushed grate plate, hit the small shaft bending.

1、Analysis Grate plate Dingfan reason, the processing described above.

2、Correcting the curvature and length of the guide plate, the opening degree of fine-tuning gradually, the guide plate are off, you must immediately refitted.

3、Adjusting the mounting position of the grab plate material, and a bottom surface edge to grab feed grate bed gap control about 5 mm.

4、  Into the bulk material or should be prohibited local hit, plot thick layers, cushioning the impact of large pieces of material.

3Grate bed deviation.1、Three round a chain does not correspond to the position of the groove.

2、Three guide pulley diameter error is too large.

3、Each upper and lower error tread diameter idler wheels and chains pressure too.

4、Lin large error connecting plate section, the installation is not optional, resulting in a great difference in the total length of the three rows of the chain.

5、Unilateral replacement coupling plate, resulting in the total length of the chain vary greatly.

6、First, the end of the shaft, the vertical axis and the chain holder mounting positions are not parallel finale.

1、Turning again chain groove, corresponding to the same.

2、Optional tread close to the diameter of the guide wheel, the roller, and the idler wheel compression chain, each of the three matched sets should be used.

3、Pitch control connecting plate manufacturing error, installation optional use.

4、When replacing the unilateral coupling plate, wear old should be based on the coupling plate hole, drilling connecting plate processing new pitch and aperture.

5、All axes should be carefully mounted, parallel to strive, should not replace the reference to the size of the line.

6、  Adjust the mounting position of each part, of the corresponding parallel.

4Semi-sealed spur gear, large and small gear tooth breakage.1、Grate severe deviation, from the coupling plate and first idler chains, small shaft, snap into the sleeve sprocket Valley grate blocked, load surge, bad pull grate, tooth breakage.

2、  Grate small shaft ring off shaft, a small shaft outer channeling, the other end of the coupling plate disjointed, stuck on a round teeth.

1、Found grate deviation must be timely adjustment, adjustment method can be found on the strip.

2、  Small ring ends of the shaft must be firmly welded found loose ring, firmly welded in time.

5Zipper pull off the chain plate, open gear tooth breakage.1、Discharge improper operation, while eight winds suddenly discharge, zipper surge load.

2、Grate plate Dingfan or seriously damaged, the red material poured into the zipper, the pitch of the link plates heated elongated, small axial tube stuck on the head wheel.

3、Head, tail shaft is not parallel to the chain link plates on both sides or unequal length, the chain link plates serious deviation to the edge, even stuck in the groove of the adapter housing.

4、  Grate plate pieces fall into the collar or fastener machine, the wedge into the small shaft portion, the chain link plates card refuses to move.

1、Avoid too much wind scoop plot material, the first once every twenty minutes to put the material, you should head winds start, one by one turn.

2、Grate plate Dingfan prevented, replace damaged grate plate to prevent material falling red.

3、Adjusting the tail shaft, to be parallel to the first axle, when partial replacement link plates, link plates in accordance with an optional pitch.

4、  Grate plate to prevent debris falling into the zipper, found small shaft loose ring, timely weld to prevent falling.

6Pop intermittent rotation shaft, or even rotated.1、Roller chain severe tooth wear, and even polished.

2、Card Pinto wheel side edges.

3、On the pipe shaft and wherein the shaft is bent Tropsch.

4、  Small radial sliding off the bearing gap is too small, or incorrectly installed and excessive force.

1、Replace the chain idler.

2、Pinto adjustment wheel size.

3、Pipe shaft length size appropriate adjustments should take too short.

4、  Correction on the steel shaft and the prop shaft alignment sliding off the small bearing installation location, and scrape good bush.

7Of axle spindle, severe side bearing outer ring can be crushed.1、Installing the master, both sides of the link between the driven shaft must be parallel to and perpendicular to the driven shaft, if the parallelogram, the drive shaft will be subject to an axial force, bearing its free positioning step, the shaft will channeling.

2、  Activities grate easy road, even when the main installation, the driven shaft is strictly rectangular, can also cause the driven shaft ran after grate easy road, rectangular is destroyed, advancing spindle runout.

1、When installed, the main, bearing two link passive adjusted to strict rectangles.

2、The use of anti-bias measures grate bed.


8Crusher grate frangible off easily.Unreasonable grate welded structure, the overall strength insufficient.Using Mn13G2Making the whole cast steel grate.
9Crusher bearings easily burned.In the high-temperature operating conditions, both sides of the bearing lubricant easily dry out after burning bearing lubrication failure.1、Each plus a small axial fan at the bearings on both sides to enhance the cooling.

2、  Add oil as required.

10Frequent failures flap valve “as release rod, bolts off of axle stuck, and serious leakage.”1、Flap valve structure is irrational, the link structure is too complicated, wear easily pull off.

2、Flap valve undesirable material.

3、  Maintenance space is too small, not easy to replace and repair.

1、The drive to cam.

2、The valve flap plate material used IG18Ni9Ti.

3、  The zipper to cover a straight convex.

11Tertiary air settling chamber clogging lumps.1, the tube design and installation of the settling chamber below unreasonable feed tube to the fastener machine body side cooler, the material is difficult to machine away the fastener, it is easy to agglomerate blockage.The settling chamber is provided in the feed pipe zipper tail middle position.
12Activities grate plate snowman.
13Activities such as burnout grate high frequency warping deformation.Grate plate mobility, although beneficial to promote clinker blanking point, reducing snowmen, but easily damaged grate plate, the grate so that warping deformation, the gap increases, the short-circuit air passage, the cooling effect deteriorate, frequently burned grate plate.In the case does not affect the grate plate installed in the grate additional board stiffener, in order to raise grate plate deformation resistance, improve their life.
14Winter low temperatures cooling fan does not start properly, automatically switching frequency operation.Air automatic switch incorrectly rated capacity of design choice, cold winter temperatures without considering the effects of regions of equipment operation, and therefore, when the load current increases, the cooling fan starts difficult.1、Note where the enterprise design selection climatic conditions, the rated capacity to leave a large surplus.

2、  Larger capacity of the air replacement automatic switch.

15Cooler actual production efficiency is not high.1、Uneven grate bed cloth.

2、Improper cooler air volume.

3、  The poor sealing around the cooler.

1、Improved dosing device.

2、Adjusting the air flow rate.

3、  Improved grate plate material, improve the sealing property.


  • Kiln trouble shooting

No.Common malfunctionscauseMethod of exclusion
1The combustion chamber temperature is too high.1、C1, C2, C3One of three preheater clogging.

2、Reducing the amount of feed raw material or feed off abruptly.

3、A small amount of secondary air, or dusting device bad material.

4、Cadogan manual feed coal combustion chamber, when the failure of self-control.

5、Thermocouple failure.

1、Poke stop blocking material.

2、Less time looking for material reasons for automation, reduce coal when manual.

3、Increase the amount of secondary air, to stop the kiln repair material spreading device.

4、Save for the amount of coal when the coal fed, manually, when controlled, to find the meter repair personnel.

5、  Repair or replacement of the thermocouple.

2Combustion temperature is reduced.1、C1, C2Two feed preheater collapse.

2、Coal bin empty or shed material.

3、Kiln coal too.

4、Lack of secondary air.

5、Secondary air is too large.

6、Wind pipe large ash leakage.

7、Skinning or unplug the thermocouple.

1、Collapse stabilize small quantity fixed, maximum feed reduction slow play.

2、Blowing cartridge, or to knock coal bin.

3、Reduce coal kiln.

4、Increase the amount of secondary air.

5、Reduce the amount of secondary air.

6、  Crust upper cleaning thermocouple, mounted in place.

3Decomposition chamber and C4There are a lot of spark barrel.1、Secondary air duct product material, small throttle opening.

2、Secondary air temperature is too low.

3、A large number of secondary air duct leakage.

4、Pulverized coal is too rough, too low volatile coal.

5、  Wind wing damage.

1、Instant throttle once the second big move, slightly open throttle.

2、Gradually adjust the secondary throttle.

3、Cha Du air leakage.

4、Pressure coal fineness, the amount of primary air in accordance with the coal volatiles adjusted.

5、  Replace the air wing.

4C1Preheater outlet temperature is high.1、Feeding too, blanking.

2、Coal combustion is not good, C3, C4There are sparks.

3、Within a damaged tube stage preheater.

4、C4After the exit of air leakage phenomenon rarely reduce the machine before the negative pressure.

5、Thermocouple damage, one-way temperature changes.

1、Check blanking reasons, recovery feed, humidification by the water pump control.

2、3 with reference to the failure processing.

3、Replacement of the inner tube.

4、Normal should be maintained.

5、  Replace thermocouple.

5Kiln temperature decreases more.1、C1, C3 collapsed material, kiln-return fire, smoke down.

2、Flat collapsed pipe material.

3、Volatile coal at high, short black attempting.

4、After Kiln ring, kiln increased negative pressure.

5、After the kiln forming a large ball, the negative pressure rises kiln, and to swing.

6、Necking serious kiln crust.

7、Preheater part of a serious leakage.

8、  Crust thermocouple, the above-described adjustment is invalid.

1、Fixed hold small material collapse, the maximum feed reduction kiln slow play, check the solenoid valve.

2、Do not adjust the amount of wind suddenly tune.

3、Appropriate to increase the kiln exhaust.

4、Reduce the primary air, large changes in the coal pipe, with the exhaust variable, ring formation after treatment.

5、Changes in ventilation, tube feeding amount and location of coal and let the ball come out and try to restore the kiln temperature.

6、Crust necking process.

7、Clear air leakage points.

8、  Inspection, replacement of the thermocouple.

6Kiln temperature is too high.1、A stage preheater clogging.

2、Small high volatile coal content of fixed carbon black attempting long kiln.

3、Thermocouple failure.

4、Pull the wind kiln, kiln negative growth.

5、  Kiln-coal amount, not added into the coal combustor (controlled).

1、Coal feed barrel block stop stop.

2、Appropriate to reduce the amount of primary air and kiln exhaust and replace coal.

3、Replace thermocouple.

4、Damper, reducing the kiln exhaust.

5、  Kiln-reduced coal.

7Kiln negative pressure increased.1、Kiln with too much wind.

2、Kiln ring formation, fire ball.

3、  Vacuum table failure, changes in throttle invalid.

1、 Adjusted so that the entire damper is proportional.

2、 Processing and ring and ball.

3、   Repair vacuum table.

8Kiln negative pressure is too low.1、Negative pyrolysis furnace crust serious necking.

2、Three throttle opening too wide, a total small throttle opening.

3、System-wide severe leakage.

4、Tertiary air duct leakage has just been processed.

5、  Negative pressure tube plugging, vacuum table pointer does not move.

1、Crust necking process.

2、Three small off throttle, adjusting the total throttle.

3、Cha Du air leakage.

4、Three off a small damper.

5、  Clean up the negative pressure tube.

9A sudden increase in temperature stage preheater.1、On a warm jam.


3、C1 has a blockage.

4、  Thermocouple failure, normal process.

1、Coal feed barrel block stop stop.

2、Identify the cause immediately sent material.

3、Activity gradually clogging flashing valve.

4、  Check and replace the thermocouple.

10Tertiary air negative pressure is too small.1、Negative sample point to the combustion chamber section of the pipeline blockage or severe leakage.

2、Negative sample points to grate cooler flow duct outlet section, air leak.

3、Tertiary air amount is too small.

4、  Vacuum tube blockage.

1、Plugging at the first check, post-processing.



4、  Bypassed negative pressure tube.

11Lower yields when the lift pump material surface height unchanged.1、Roots blower to enhance the lack of wind between the pump source, duct leakage.

2、The check ball is damaged or the nozzle plate, damage or leakage canvas.

3、Kiln ring formation.

4、Cooler grate slow speed.

5、  Meter card hopper or failure.

1、Check piping, clogging, check fan.

2、Material Parts replacement parking.

3、Ring formation process.

4、Not necessarily the reason.

5、  Repair meter.

12Conditioning tower outlet temperature.1、C1 outlet temperature is high.

2、The spray nozzle is not damaged.

3、There nozzle clogging.

4、Wrong open water valve phenomenon.

5、The number of nozzles less than normal.

6、  Insufficient pump pressure.

1、Increasing the number of nozzles.

2、Replace the bad nozzle.

3、Clear tip.

4、Check line relationship with the nozzle.

5、Increase the nozzle.

6、  In other standby pump.


  • Fault exclusion of MFC calciner

No.Common malfunctionscauseMethod of exclusion
1Abnormally low temperature of the inner layer.1、The actual amount of small coal supply, the temperature is low.

2、  The amount of material in the furnace is too large, three air damper into the furnace temperature is too low, resulting in low temperatures.

1、Check the coal supply system, appropriate to add coal.

2、  With air adjusted by the grate cooler, tertiary air temperature increase, the amount of fluidizing air damper appropriately reduced.

2Laminated abnormalities and death bed.1、Furnaces quantity is too large, the air chamber pressure (lamination) high.

2、Chamber pressure is high, the material crushed in the fluidized bed dead on the bed.

1、To reduce the quantity.

2、  Shutdown, closing shutter dosing, through the bed scum discharging the crushed material, a laminate according to the display, determining whether or furnace casting.

3Fluidized fan stop jumping.Quantity of coal fed ones.Stop feeding coal furnace, a raw material dispensing flap is fully closed, reducing the feed preheater until the required value, if the temperature is higher cold openable door, the main adjustment kiln exhaust fan speed, the valve control system, to control the temperature of each part, timely adjustment kiln kiln speed and feed before.
4The furnace temperature is low.Coal feeding system failure, such as a sudden stop or abnormal coal under coal.Save suitable material (repair before firing system) until the layer normal temperature, to adjust the amount of coal feed systems using air and kiln.
5Fluidizing nozzles deformation, wear, the top of the hood release layer temperature decreases the air chamber pressure is reduced.Material by repeated impact, as well as high temperature duration of action, resulting in bad fluidizing nozzles, other joint failure.1、A small amount of damage to the nozzle, is not necessary to stop the kiln process.

2、  Large number of nozzles damage (more than 30), the replacement process must be shutdown.


XI, belt conveyor trouble shooting

No.Common malfunctionscauseMethod of exclusion
1Slip tape.1、Between the drive rollers and a small friction coefficient or a tape wrap angle is too small.

2、The tensioning device pulling force is too small.

3、  Carrying capacity at design capacity.

1、Improved friction coefficient, increasing the wrap angle.

2、Proofreading adjust tension.

3、  Reduce the amount of carrier so as not to overload.

2Tape a certain part of a sudden deviation.1、Tape has a curved portion.

2、  Joint center misalignment.

1、When replacing severe bending section.

2、  Re-connection.

3No-load deviation.Bad tape into the slot.Replaced with a groove or a tape having good self-adjusting roller.
4Tape edge wear too much.1、 Excessive adherent roller and the drum.

2、 Roller or guide roller adjustment is not good.

3、 Bracket injustice.

4、 Automatically adjust the roller and guide rollers poor.

5、 Bulk material into the tape and between brackets.

6、   Unloader is not correct.

1、Means effective scavenger.



4、Adjustment or replacement.


6、  Maintenance, adjustment unloader.

5Long distance fragmented longitudinal upper gum.Chute pretend to be bad.Re-adjust the assembly.
6Upper gum abnormal wear.1、When the discharge chute, limestone and other materials inconsistent acute angle speed tape speed.

2、Return roller is not rotated.

3、  Chute plug.

1、Adjust the chute, the material down to change the speed.

2、Replace the cleaning roller.

3、  Improved chute.

7Band edge wear to strip bars.Striker plate errors.Adjust the striker plate.
8Lower gum abnormal wear.1、Slip tape.

2、Debris intrusion return section.

3、Material moisture large, the friction coefficient decreased.

4、  Roller does not rotate.

1、Check the tensioning device.

2、Clean carrier and check segment.

3、Reduce material moisture.

4、  Cleaning roller adjustment.

9Tape wrinkled.Roller skid.Improved tape engraved or increase the coefficient of friction.
10Roller bearings abnormal sound.1、Bearings used for too long.

2、  Poor lubrication.

1、Check bearing replacement.

2、  After cleaning grease.


Twelve, HL-bucket elevator trouble shooting

No.Common malfunctionscauseMethod of exclusion
1Upper and lower bearings hot.1、Lack of grease.

2、Grease dirt.

3、  Poor installation.

1、Make up the grease.

2、Cleaning bearings, inject new grease change.

3、  Recheck, adjust the alignment.

2Hopper severely deformed or scratched.1、Hopper coupling bolts loose or fall off.

2、Under sprocket chain off the road.

3、Tractor parts badly worn, overstretched.

4、  The bottom falls non-transportation thereof.

1、Check coupling bolts fastening the hopper.

2、Clear the chain off road failure.

3、Adjusting the length of the traction member.

4、  Clear bottom product material and foreign matter.

3The material back to the material.1、Bottom material buildup.

2、Hopper fill too much.

3、  Unloading endless.

1、Adjust the feed rate.

2、Adjust the feed rate.

3、  In an additional discharge opening plate material can be adjusted.

4The occurrence of chain sprocket off road.1、Winding axis of the shaft is not level.

2、  Joint board of the chain and sprocket wear serious, so that the two different pitches.

1、Adjust the nose on both sides of the main bearings, sprockets on the shaft level.

2、  Replace worn chain and sprocket.

5Under sprocket chain occurs off road (slip).1、The degree of traction means tensioning is too slack.

2、Two inconsistent chain length, the chain tightness inconsistent.

3、  The bottom of the excessive accumulation of materials.

1、Adjusting tensioning device.

2、Adjusting the length of the two chains, so consistent.

3、  Clear plot material, adjust the feed rate.


XIII, efficient bucket elevator trouble shooting

No.Common malfunctionscauseMethod of exclusion
1Driving drum failure.1、Fixing roller and the hub flange bolts loose, broken.

2、  Rubber bonded on the roller off, unglued.

1、The drum and the hub bore with a wire fixing bolt connected in series.

2、  The rubber on the drum with tape switch from line canvas layer 5, again, the two roller borehole with the fixed tape adhered to the drum adjacent to each other.

2Out fighting.1、 Douzi fixing bolt insufficient strength.

2、   Douzi fixing bolt breakage.

Replacing larger diameter bolts or bolts greater intensity.
3Tape joint disconnected.1、Joint bar uneven, resulting in uneven force the joint portion of the tape.

2、Tape joints have more bolt holes or bolt holes is too large, the multi-band wire breakage.

3、  Pressing the tape tab clamp bolt preload or compression plastic deformation of mainly the bolt.

Tape joints to improve and increase the central support plate and stiffener plate.
4Round off the block header.The first wheel with the overall structure of cast iron, the mutation occurs when an impact load to fall apart as the rear wheel bearings stuck, and from the bolt hole broken off the block.First reinforcing insert positioned wheel, the wheel head to separate the whole cast steel member.
5Pulling off the shelf member.1、U-shaped connector ring hook Douzi no reinforcement plates.

2、  Ring hook brittleness.

1、U-shaped additional reinforcing ring hook strip tapered.

2、  Improve the quality of the ring hook.


XIV screw conveyor trouble shooting

No.Common malfunctionscauseMethod of exclusion
1Flash.1、Material in the debris clogging the spiral hanging bearing.

2、Material moisture large, and gradually build the thickened suspension on the spiral bearing, so that incoming easily through.

3、  A transmission failure, not recognizing.

1、Stop the machine clear of debris.

2、Strengthening the raw material drying.

3、  Downtime, repair gear.

2Suspension bearing temperature rise too high.1、Location improper installation.

2、  Hard chunks mixed into the object locally generated abnormal friction coupling shaft.

1、Adjust the position of the bearing of the suspension.

2、  Clear foreign objects, test to normal.

3Cabinet shake.When mounting the helical center line is different in each heart, the eccentric housing rub during operation, the housing shaking.Reinstall the alignment centerline.
4Hanging bearing wear.Material surrounded by hanging bearing operating conditions poor.Ground inspection, the timely replacement of hanging bearing.
5Drive motor burned.1、Delivery material has a hard segment blocks or mixing small iron, stuck cutter, the current surge, burning motor.

2、  Incoming is too large, motor overload and fever burned.

1、Prevent small iron entering.

2、And a cutter housing to maintain a certain gap.

3、Feeding balanced.

4、  Stop before the material while supplies last.


Fifth, the air compressor trouble shooting

No.Common malfunctionscauseMethod of exclusion
1A sudden drop in oil pressure.1、Lack of body oil.

2、Filter, clogging of the filter element.

3、Oil pressure gauge malfunction.

4、Lubricating oil pipe blockage or rupture.

5、  Pumps out of action, oil return valve malfunction, short circuit oil through the oil return valve back to the oil tank.

1、Come on now.


3、Replace the oil pressure gauge.

4、Clean or replace.

5、  Overhaul pumps, oil return valve.

2Oiler is not oiled.1、Oiler suction strainer clogging.

2、Tubing blocked or ruptured oil pipeline spill.

3、  Pump check valve and the valve sleeve, and a spring opening the ball valve and valve seat wear hammer stuck or inoperative.

1、Clean the screen.

2、Dredge pipe or replacing a ruptured pipeline.

3、  Replacement of badly worn parts, spotting the ball valve, spring seat.

3Safety valve failure.1、Safety valve opening is not timely.

2、Valve open process to achieve their height.

3、  Safety valve closed lax.


2、Detachable wash, maintenance.

3、  Remove dirt, re-off valve.

4Stuffing box is not tight, leak.1、Small damage or stretch the spring, the piston rod so that it can not be completely sealed.

2、The metal seal tank string can not move with the piston rod there is a gap.

3、Piston ring wear, strain, have worn impartial circle and so on.

4、The inner diameter of the metal seal plate wear and piston sealing leakage in the stuffing box.

5、  Inadequate supply of lubricating oil, part of the deterioration of the airtightness of the stuffing box, leakage is formed.

1、Replace spring.

2、Re-assembly metal sealing plate packing box, so that the string in the box can be freely movable with the piston rod seal.

3、Repair or replace the piston rings.

4、Replace the sealing disk.

5、  Packing box to ensure adequate lubricant.

5Oiler oiling is not normal.1、Excessive wear and piston pump, pressure below standard.

2、Oiler inappropriate regulation, so that too much or too little oil.

3、  Table 2 refer to the contents of the fault.

1、Replacement or repair.

2、Readjust the stroke of the injection pump.

3、  Table 2 refer to the contents of the fault.

6Abnormal sound occurs operation.1、Screamed:

1        Clearance is too small.

2        Piston nut loose.

3        Cylinder water.

4        Valve loose.

5        Cylinder gas line or a foreign body.

6        Valve, spring deterioration.


1        Tile size of the first rod, crosshead pin bushing, slide badly worn, large gaps.

2        Journal through the large oval.

3        Excessive bearing play.

4        Loose belt pulley or loose.

1、Screamed exclusion:

1        Adjusted clearance.

2        Remove tightened.

3        Tightness check cooling system.

4        Tighten the bolts brake valve.

5        Remove foreign bodies.

6        Remove debris, replace it.

2、Muffled exclusion:

1        Conduct repair or replacement.

2        Grinding.

3        Replace the bearings.

4         Tight tight belts or pulleys.



XVI electric precipitator common fault exclusion

No.Common malfunctionscauseMethod of exclusion
1Back Corona.1、 Dust specific resistance higher than a predetermined value.

2、   Precipitation is not timely cleaning fouling board.

1, in advance of the specific resistance of gas conditioning, humidification method may be employed.

2, the cleaning plate precipitation fouling.

2Extreme precipitation fracture.1, since the internal electric field leakage or condensation when open stop, so that the exhaust gas SO2 plate corrosion.

2, high wind speed, air volume so that the plate is worn dust.

1, the plate use corrosion-resistant materials.

2, passing hot air into the electric field the field is maintained at a temperature of 20-30 degrees above the dew point before and after the start and stop.

3Rapping drive motor burned.1, when cold, each bearing a different shaft core centerline, or axial deformation of the motor shaft sprocket sprocket flat plane is not coincident, resulting in torque increase.

2, when hot, due to the action of temperature, changes in the rotation axis, or because of uneven temperature, the centerline of each bearing out of alignment, resulting in a sharp rise in resistance.

1, adjust the concentricity.

2, an enlarged bearing clearance.

3, each shaft for axially set point.

4, multiple adjustments.

5, plus motor overload protection.

6, note that the uniformity of the air distribution in order to ensure a uniform temperature.

4Corona electrode line relaxed.1, since the corona electrode line is too long, the surface portion of each corona electrode temperature unevenness.

2, each of the discharge electrodes of different tightness.

3, electrostatic precipitator start stop frequently.

1, the corona electrode length to make it shorter.

2, corona wires enameled available after relaxation was tied.

3, with the plate line tool, the slack was tied corona wires.

5Corona wire breakage.1, since the rapping a gap, so that the hanging hook and loop connector and the frame structure of the corona wire arc discharge is generated, and the hook attached to the ring at the blow.

2, the corona wire relaxation, is generated during the rapping wobble, causing an arc discharge, corona wire blown.

3, due to air leakage into the condensate, causing corrosion.

4, the rapping force is too large, so that the source line fatigue.

6Corona closed.1, imported dust concentration of more than 35 g / cubic meters.

2, not timely corona electrode cleaning.

1, the control dust concentration at the inlet.

2, rapping, fouling the purge corona electrode.

7Rapping failure.1, rapping means of axle shaft, card hammer, anvil off, off rapping hammer and anvil offset from center.

2, electrode fouling seriously.

1, the rapping mechanism to the side arm portions pouring hammer rapping mechanism.

2, splint profiling hammer to hammer, anvil and striking lever connection coupled welding rivets or bolts.

3, universal joints and special support provided on the drive shaft, and the reduction of axle shaft card. Transmission means to periodically refuel, and add rain cover.

4, a reasonable rapping system, generally the thickness of the fouling of the anode plate when the transducer is appropriate to play 5-10 mm.

8The anode plate in bending.1, cinder poor, fouling enter between the plates, electric short-circuit, the anode plate is deformed reheat.

2, flue gas temperature is too high or the electric field caused by deformation of the explosion.

1, remove the plastic plate (this method is not good).

2, plus the belt between the plates, the anode plate will deform in time with a small hoist tools such as oxygen straightened After brazing heating, put flat belts, but to prevent the belt cathode discharge.



XVII electrostatic precipitator common fault exclusion

No.Common malfunctionscauseMethod of exclusion
1Current increases, the voltage booster does not move or just on the trip.1, broken wire pole.

2, high-voltage cable breakdown anode plate.

3, quartz tube wear contaminated or rupture.

1 down into the field maintenance.
2No current voltage or current is small.1, more fouling on the electrodes.

2, a high specific resistance.

Shutdown, cleaning, changing the resistance.
3Current and voltage are unstable and prone to tripping.After stabilization adjusted too large or small.Properly adjusted.
4Voltage rises tripped.Low temperature electric field.Appropriate heating.
5Voltage rise is not high, a small current or voltage does not rise, or rises rapidly meter trip immediately.1, the wind speed is too high electric field.

2, the electrode vibrates.

3, the cathode, anode spacing small.

4, the electric field fouling too much.

5, hanging hanging loose bolts.

Stop checking into the field. For reasons to be addressed.
6Short-circuit high-pressure circuit, the corona wire close to the positive electrode plate breakage.1, using a longer time.

2, the corona wire corrosion loss.

Stop into the field to check and replace the corona wire.
7Quartz tube cracking breakdown.1, quartz tube corrosion.

2, fouling more.

Shutdown, cleaning, replacement.
8High voltage circuit shorted.1, plate by rapping and wind impact deformation.

2, sealing off shift.

Stop into the field to check for Cause.
9Rapping failure.RBI rapping bearing and vibration displacement.Stop checking into the electric field correction.
10Rapping motor burned out.1, a mechanical jam.

2, marbles wear.

3, eat items.

Stop into the field to check for Cause, replace the motor.
11Ruled wheel jammed.Electric field objects have fallen into the hopper.Stop checking door open, clean up.
12Ruled wheel current is large.1, the excessive amount of ash.

2, or hot melt fuse.

Down to check.

The lower the ash content the ash content at proper adjustment.

Replace the fuse.

13Lo transport machine full of ash blocked the trip.1, kiln dust pipe blockage.

2, excessive ash content.

3, spiral transport blade deformation or desoldering.

4, the trip unit transport screw, ruled wheel in turn.

Clear the pipeline.

Adjusting the amount of ash.

Stop to check for problem solving.



stationary packing machine trouble shooting

No.Common malfunctionscauseMethod of exclusion
1Run bags.1, the paper is not inserted in place.

2, the bag clip is pressed bags is not tight.

3, improper disk position facing the bag.

1, identify the reasons for exclusion.

2, the replacement of worn rubber pressing, rubber pressing surface to adjust the gap and the discharge nozzle.

3, the adjustment plate and the bag opposite the discharge nozzle pitch.

2Drain large quantity of ash.1, a gate and static discharge nozzle bore

A large gap or misregistration.

2, the frit sealing mat cover both sides of the boss, anti-dust barrier gray cotton or cannula clamp wear.

3, the cover material or the material worn seat cover.

1, over which the adjustment bolts and the bracket, seat and nozzle resorted discharge opening coincides with the center line, and then transferred the packaging frame bolts and lower end of the screw, resorted to two nozzle discharge port and the parallel plane, and held a distance (3-5 mm).

2, replacement of seals, filling the filler.

3, the replacement of worn parts.

3,Broken bags.Pressed sheet discharge mouth side are not synchronized.Check the pressing plate, so that act simultaneously on both sides.
4Discharge or slow discharge nozzle clogging.1, mechanical causes rotation of the impeller seat ① slid on the spindle. ② blade wear or bending. ③ discharge port and the tap center misalignment.

2, the cement material reasons ① dilated humidity. ② packaging machine feed tank material level is too full or in space. ③ volume of cement bags and cement volume does not match.

3, the discharge port or the discharge nozzle has a blockage.

Identify the reasons, excluded one by one.
5Feeder does not turn.1, the cement silo and long residence compacting the feeder resistance increases.

2, with the body to have jammed between the hopper.

1, the pressing pressure rollers or to increase the friction with the drive belt plus the oil.

2, shut down, a large hand movable pulley disk, disk inverted several weeks, as the rotation resistance is still large, the bearing cases should be checked.

6Main bearing fever.1, bearing installation errors.

2, bearing short of oil.

3, bearing into the dust.

1, to adjust the horizontal position of the bearing so that the bearing centerline concentric holding.

2, come on.

3, regular inspection, cleaning, refueling, gray cotton barrier interposed regularly add fillers to enhance the seal the shaft hole.

7Package weight sudden changes in care package shelf sink slowly.1, with fine slag particles trapped between the discharge port and the discharge nozzle housing.

2, a lower frame bracket link from the packet.

3, each frame fixed weight hindered knife edge seat and the disengagement or damage.

4, mutual friction between the bag frame bracket.

Find out the reasons, be excluded.
8The shutter opening and closing inflexible.1, dross stuck, iron particles (blocks) and other debris.

2, gate liner wear.

3, gate installed incorrectly.

1. Always check the sieve screen, find timely repair damage.

2, gate sets the timely replacement of worn.

3, to make the shutter, rod, holding the handle at the junction in a straight line during installation.

9Spindle fragile.1, often mixed with bagasse cement, iron slag, etc., is stuck in the shaft sealing parts, wear of the main.

2, an elongated spindle, pliable when subjected to torque, increased degree of wear.

1, replacement of bad shaft.

2, take measures to prevent damage to the spindle.




 rotary packaging machine trouble shooting

No.Common malfunctionscauseMethod of exclusion
1Rubber hoses ineffective closing.1, loss of elasticity of the rubber hose.

2, the platen rubber hoses screw loose.

1, replacement of rubber hose.

2, the upper plate is pressed against the screws.

2Free access to the rollers.Positioning spring soft or broken.Replace the spring.
3The material is not smooth.1, the discharge port blockage or outlet tube.

2, down time is longer, the cement plug the discharge port.

3, inflatable down, fluidized bad.

1, the elimination of foreign body.

2, clear or thin rods with compressed air.

3, increase inflation pressure.

4Bags not working out.1, out of the bag out of the bag guide the control mechanism sinks.

2, the discharge elbow tight fit face.

1, to adjust the bag off the rail.

2, adjustment of the gap surface anastomosis.

5Run bags.1, the bag clip position is too high.

2, pocket too shallow.

1, to adjust the position of the bag clip.

2, an improved pocket operation.

6Broken bags and more.1, playing bags location and time are incorrect.

2, the bag hit the arm rotation is not flexible.

1, to adjust the position of the arm hit the bag.

2, the bag hit check and replace the spring arm.

7Overflowing the cartridge ash.1, the drum level control malfunction.

2, the feed cylinder operation of the pneumatic valve failure.

3, insufficient supply line pressure or severe leakage, resulting in a discharge failure pneumatic valve operation.

1, inspection, repair level control.

2, repair or replacement of the piston ring.

3, check the gas supply system repair.

8Package weight instability.1, weighing system weight properly.

2, the feeding mechanism malfunction.

1, to adjust the weight balance weight weighing mechanism according to test results.

2, inspection or adjustment of the discharge means, check for blockage.

9Light package or filling does not go.1, improper packaging machine speed.

2, paper size selection improper.

3, good fluidized state.

1, adjust the speed.

2, using the appropriate paper.

3, increase the inflated amount.


WKB series of cement packing machine trouble shooting

No.Common malfunctionscauseMethod of exclusion
1No computer display.1, such as a power interruption fuse damaged, is not plugged in a power interruption or the like.

2, a display circuit problem.

1, the insurance overhaul, plugs, power, power supply and so on.

2, the inspection display circuit.

2Display disorder.1, electromagnetic interference, vibration interference.

2, a low voltage or unstable (interference power).

3, the power supply line and its associated virtual connection.

4, a display circuit damage.

1, remove sources of interference.

2, automatic re-supply, or power supply.

3, repair the internal circuits.

4, repair and replacement display circuit.

3Heavy bags instability.1, mechanical repeatability bad.

2, improper operation, with the external force operating instability.

3, install the equipment in question.

1, the first movable member is not fixed, the movable member and then adjusted to the optimum state.

2, eliminate the interference, the right to cheer.

3, adjust the electrical system, improve equipment, installation resolve the remaining issues.

4No alarm counter is not counting.1, the power supply out of the question.

2, the interrupt signal line.

3, the counter element is damaged.

1, power system maintenance troubleshooting.

2, the internal inspection signal line.

3, replacement of the damaged element.

5Show negative growth when weighed.Sensor input-output polarity reversed.Re-connected, and proofreading.
6Weighing, force increases with no change or show abnormal changes.1, line break or connection errors.

2, the sensor amplifier is damaged or broken.

3, for the bridge voltage out of the question.

4, host internal fault.

1, temporarily connect a good sensor to help determine the failure point.

2, inspection sensors, amplifiers and signal wires or load host.

3, maintenance for the bridge, and the main amplifier output display circuit troubleshooting.

7Solenoid does not pull, weighing more than the set value.1, the line break.

2, internal hosts out of the question.

3, solenoid coil burnout.

4, mechanical failure.

1, overhaul the internal circuits and components.

2, the fault position and the exclusion assay.

3, to see if the electromagnet is energized signs, such as blown coil, should be replaced, while the detection magnet protector.

4, rule out mechanical jamming.

8It shows the number is not zero cleared. (Display -FF.F or not cleared).1, internal hosts out of the question.

2, clear switch damage.

3, line break or connection errors.

4, beyond the zero offset tracking range, preload overrun.

1, remove the computer, using the clear signal applied to internal shorting, determine the fault in the machine or in the switch.

2, replacement of repair clear switch.

3, and the connection line fault repair.

4, the mechanical adjustment means is in particular a reed levelness adjusting the reference potential or the like.


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1 thought on “TROUBLESHOOTING OF cement plant mechanical and electrical equipment”

  1. Great Post. Thanks for sharing this. Really helpful.

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