Large gyratory crushers are the heart of many mines and quarries. When they break down, repairs are costly, time-consuming, and often dangerous. How to prevent the failures? This short guide shows you what to do when trouble appears, and how to prevent it.
The most common problems are:
Oil system issues – high temperature, low pressure, or dirty oil.
Tramp metal (digger teeth, drill bits, tools) entering the crushing chamber.
Worn liners that crack or fall off.
Blocked crusher from overfeeding or a downstream conveyor stopping.
Excessive vibration or unusual noise.
How to prevent failures – 4 simple rules
1. Watch the oil condition
Check oil temperature, pressure, and flow every shift.
Change oil on schedule – dirty oil kills bearings.
Make sure the cooling system works (hot oil = trouble).
2. Stop metal before it stops your crusher
Install a metal detector on the feed conveyor.
Use a magnetic separator if possible.
Train loaders and dozer operators: no metal objects near the feed point.
3. Feed the crusher the right way
Never flood the chamber – keep it full but not packed.
Use a level sensor or acoustic alarm to warn operators before overfeeding.
If the discharge conveyor stops, stop feeding immediately.
4. Inspect liners and wear parts weekly
Look for cracks, loose bolts, or liners thinner than 1/3 of new.
Replace liners before they break – a broken liner can damage the main frame.
Quick action guide: what to do if a failure happens
| Problem | What to do |
| Oil temperature too high | Clean the cooler, check water flow, add oil if low. |
| Metal in crushing chamber | Open the discharge setting, remove metal, check for damage. |
| Crusher stops under load | Lock out power, clear chamber, inspect for tramp metal or broken parts. |
| Heavy vibration | Stop immediately – likely a loose mantle or broken bearing. |
| Oil pressure zero | Stop the crusher. Do not restart until the pump or oil line is fixed. |
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