Generally, the jaw crusher will encounter the following types of problems during operation: "What to do if the jaw crusher is stuck", "Why the jaw plate wears too fast", "How to deal with the heating of the jaw crusher bearing", "Daily maintenance manual of the equipment”.

The jaw crusher is a common coarse crushing equipment in the mining, building materials and other industries. Its stable operation is crucial to production efficiency. The following is a troubleshooting and maintenance guide for the jaw crusher to help you quickly solve problems and extend the life of the equipment: Common problems in actual use require quick solutions, and maintenance costs affect the life of the equipment.

Common jaw crusher faults and troubleshooting methods

1. Abnormal vibration or noise

​Possible causes:

• Loose anchor bolts or unstable foundation;

• Loose jaw plate fixing bolts;

• Bearing wear or poor lubrication;

• Uncrushable foreign objects enter the crushing chamber

​Solutions:

• Check and re-tighten the bolts and reinforce the foundation;

• Replace worn bearings and add or replace lubricating oil;

• Clean the crushing chamber and check whether the jaw plate is misaligned.

2. Uneven discharging particle size

​Possible causes:

• Severe wear of the jaw plate causes changes in the meshing angle;

• Improper adjustment of the clearance between the movable jaw and the fixed jaw;

• Too high material hardness or uneven feeding.

​Solutions:

• Replace the worn jaw plate (recommended to replace in pairs);

• Readjust the gap of the discharge port (by adding or removing gaskets or adjusting the screw);

• Control the feed particle size (not exceeding the equipment rating) and feed evenly.

3. Overheating of the bearing (＞70℃)

​Possible causes:

• Insufficient or contaminated lubricating oil;

• Improper installation or excessive wear of the bearing;

• Overtightening of the belt causes additional load.

​Solution:

• Clean the bearing and add an appropriate amount of grease (lithium-based grease is recommended);

• Correct the bearing installation position and replace the bearing if necessary;

• Adjust the belt tension to a moderate level.

4. ​The equipment cannot start or stops suddenly

​Possible reasons:

• Power failure or motor overload protection is triggered;

• Belt slippage or breakage;

• Blockage of the crushing chamber causes a sudden increase in load.

​Solution:

• Check the circuit and voltage, reset the thermal relay;

• Replace the damaged belt and adjust the tension;

• Clear the blocked material and check whether the motor is burned.

Daily maintenance points of jaw crusher

1. ​Lubrication management

• Regularly check the lubrication of bearings, elbow plates and other parts, and add grease every 8 hours;

• Replace the lubricating oil every 3 months and clean the impurities in the oil circuit;

​Note: Avoid mixing greases of different types to prevent lubrication failure.

2. Inspection of key components

• Jaw plate: Check the wear weekly, and replace when the wear exceeds 20%;

• Toggle plate (thrust plate): Replace immediately if cracks or deformation are found to prevent accidents caused by breakage;

• Spring and pull rod: Check the preload to prevent breakage due to fatigue.

3. Operation specifications

• Feeding control: It is strictly forbidden to allow super-hard materials (such as metal blocks) or materials that exceed the size of the feed port to enter;

• Load monitoring: Observe the motor load through the ammeter, and stop the machine immediately for inspection when abnormal;

• Regular cleaning: Clear the residual materials in the crushing chamber after each shift to prevent agglomeration.

4. Preventive maintenance plan

• Daily: Check the tightness of the bolts, the belt status, and the lubrication points;

• Monthly: Measure the wear of the jaw plate and check the bearing clearance;

• Half a year: Fully calibrate the levelness of the equipment and check whether the foundation structure has settled.

Safety precautions for jaw crushers

• Always cut off the power supply and lock out the machine (LOTO) before maintenance;

• Use special tools when replacing the jaw plate to avoid direct knocking;

• Do not adjust the discharge port or clean the material during operation, and the machine must be stopped for operation;

• Wear goggles and earplugs to prevent splashes and noise damage.

Improvement suggestions for extending the life of jaw crushers

• Optimize the material of the jaw plate: use high manganese steel or composite alloy jaw plate to improve wear resistance;

• Install a buffer device: add a rubber shock-absorbing pad between the foundation and the equipment to reduce vibration transmission;

• Intelligent monitoring system: add temperature and vibration sensors to achieve predictive maintenance.

Through systematic maintenance and rapid fault response, the mean time between failures (MTBF) of the jaw crusher can be increased by more than 30%. It is recommended to formulate a personalized maintenance plan in combination with the equipment manual, and contact professional technicians for in-depth maintenance when necessary.