Common Jaw Crusher Problems and Solutions: Your Complete Maintenance Checklist

1. Uneven Jaw Plate Wear

Symptoms: 30-50% faster wear on one side
Solutions:

• Rotate plates every 200 operating hours
• Check feed distribution with laser alignment
• Upgrade to asymmetric tooth profiles for mixed materials

2. Excessive Vibration

Symptoms: Structural shaking >5mm/s RMS
Root Cause:

• Worn bearings (85% of cases)
• Unbalanced flywheel (12%)
• Loose foundation bolts (3%)

Fix:

1. Torque all bolts to 350 N·m specification
2. Replace tapered roller bearings using proper installation techniques

3. Low Production Output

Symptoms: Throughput drops >20%
Diagnosis:

4. Hydraulic System Overheating

Symptoms: Oil temperature >80°C
Solutions:

• Clean clogged radiator fins weekly
• Replace hydraulic filters every 500 hours
• Upgrade to synthetic high-temp oil (ISO VG 68)

5. Abnormal Noise During Operation

Sound Types & Meanings:

• Metallic grinding: Worn toggle seats
• Loud banging: Broken toggle plate
• High-pitched squeal: Dry bearings

Action Plan:

1. Immediately stop operation
2. Inspect components using diagnostic checklist
3. Replace damaged parts before restarting

6. Frequent Bearing Failures

Prevention Strategy:

• Use laser alignment for perfect shaft positioning (±0.05mm)
• Implement automatic lubrication systems
• Monitor temperature with wireless IoT sensors

7. Oil Contamination Issues

Contamination Sources:

Daily Tasks

• Check oil levels and contamination (use patch test)
• Inspect belt tension (deflection ＜15mm)

Weekly Actions

• Measure CSS with laser gauge
• Test safety interlocks

Monthly Priorities

• Perform vibration analysis (2-5mm/s limit)
• Inspect structural welds for cracks