Top 5 Signs Your Crusher Needs Servicing (And How to Avoid Downtime)
Crushers are the pillars of numerous business sectors, from mining and construction to recycling and material handling. Crushers deal with abrasive conditions daily by crushing hard, wear-resistant material. Like all the heavy machinery, the Crusher requires consistent servicing and maintenance to function at its best. Neglecting minor issues will translate to unexpected breakdowns, hence costly repairs and poor productivity.
What We’ve Seen at ProTrack: Straight Stories from the Field
We’ve seen it all at ProTrack. From equipment so dry it almost squealed itself to death (although we did fix it up, of course), to crushers that cut out in mid-job because a bolt was left loose for too long. We don’t just sell and lease crushers—we fix them. And so, we’ve fixed more than our fair share of equipment that isn’t ours.
Too often, we get the call after the damage is done.
⬇️ Here we are, servicing an emergency at midnight on a Wednesday.
One customer called us distressed when their entire production line reached a standstill. When we arrived, their jaw crusher had locked up, with rock-solid bearings ripped, a motor burnt out, and a jammed feed that had been left for weeks. A simple vibration monitoring system and personnel training on warning signs would have prevented the $30,000+ downtime loss. We’ve now set them up with a maintenance schedule, predictive monitoring tools, and on-site operator training—and they haven’t missed a beat since.
One day, a crusher we were on was overheating every day and needed shutdowns that took an entire mining operation behind. No one had serviced the coolers or lubricated them in over a month. Our team cleaned the system, replaced filters, adjusted the feed rate, and added automatic warnings. Simple upkeep that had an enormous difference.
We do not share these stories to intimidate you—we share them because they are preventable.
That’s why every ProTrack customer doesn’t just get a machine; they get ongoing training, a tailored service plan, and service that keeps their business running at full speed. We allow our customers to catch the warning signs before they cause shutdowns. Even if your equipment isn’t ours, we treat it like it is—because uptime is everything in this business.
Crusher Servicing Sign 1: Unusual Sounds and Vibrations
One of the first and most obvious symptoms that your crusher requires service is abnormal vibration or noise under operating conditions. When it has been properly serviced, your crusher will operate smoothly and silently, with nothing but the usual rattle of material being crushed. Grind, rattle, or thump, though, are indications of trouble.
Likely causes:
- Loose or worn bearings
- Internal misalignment
- Debris build-up in the machine
- Overwear of the crushing chamber
How to Avoid It:
- Carrying lubrication from time to time to avoid wear and tear.
- Periodic tightening of bolts and fasteners and inspection.
- Vibration analysis using predictive maintenance technology.
- Ensuring the crushing chamber remains free of any waste that would choke it.
If not identified, these symptoms can lead to disastrous failure, with associated extended downtime and replacement costs.
Crusher Servicing Sign 2: Decline in Crushing Efficiency
If your crusher isn’t breaking down material as efficiently as before, you must maintain it. Reduced throughput and poor product quality are symptoms of the machine not running its best.
Common Causes for Decrease in Crushing Efficiency:
- Tired jaw plates or liners affecting material breaking
- Clogging or blockage of material within the feed zone
- Hydraulic failure due to pressure shortage
- Improper settings leading to ineffective material handling
Preventive Measures:
- Replace wear parts, including hammers and liners, regularly.
- Monitor feed size and material properties to avoid jamming.
- Check the hydraulic system for leakage and pressure.
- Adjust the crusher setting according to the material’s specifications.
Maintaining the crushing efficiency maximises ensures maximum productivity with minimum power consumption.
Crusher Servicing Sign 3: Excessive Heat and Overheating
Heat generation and overheating are some of the major warning signs that your crusher needs to be repaired. Overheating leads to lubrication failure, bearing damage, and engine shutdown.
Common Causes of Overheating:
- Degraded or Lacking Lubricant
- Blind coolers or heat exchangers
- Excessive wear on moving parts
- Overloading of the motor due to overfeeding of material
Preventing Overheating:
- Maintain and change oil and lubricants periodically.
- Check the coolers and the fans frequently for blockage and accumulation of dust.
- Do not overcharge the crusher, and provide good material flow.
- Monitor temperature sensors and warn of excessive heat.
Avoiding excessive heat shields your precious parts and allows the crusher to operate safely under full loads.
Crusher Servicing Sign 4: Increased Power Consumption
A strange surge in power consumption is one of the most neglected red flags that your crusher is operating at capacity. If your machine requires more power than usual to perform the same operation, it could be a sign of wear and tear within or mechanical inefficiencies.
Reasons for Higher Power Consumption:
- Faulty motor parts or worn transmission belts
- Friction caused by inadequate lubrication
- Physical barriers are placing undue stress
- Deterioration of power transmission due to poor electrical connections
Crusher Maintenance Tips:
- Check the drive belts for wear and slippage.
- Lubricate all the moving parts.
- Remove material obstructions and ensure equal feed distribution.
- Check and maintain the electrical connections for efficient supply of electricity.
You can decrease operating costs and maximise your crusher’s performance by removing power inefficiencies.
Crusher Servicing Sign 5: Leakage of Lubricants and Fluids
Hydraulic oil, lubricant, or coolant leaks are severe conditions that must be addressed immediately. The fluids perform vital duties of avoiding friction, excessive heat, and mechanical damage.
Typical Crusher Leak Sources:
- Faulty hydraulic seals or gaskets
- Burst or leaking oil hoses
- Cooling system leaks
- Over-charging or under-servicing lubrication systems
Preventive action:
- Check the hoses and seals regularly for wear and replace them whenever necessary.
- Check fluid levels while performing the daily maintenance routine.
- Check the hydraulic system pressure for sluggish leaks in advance.
- Employ top–quality lubricants that are up to manufacturer standards.
Early leak fixing prevents complete breakage, minimizes the possibility of contaminants, and makes the machine long-lasting.
5 Ways to Avoid Your Crusher Shutting Down
Avoiding unscheduled downtime is essential to achieve optimum productivity and profitability. The following are the key maintenance routines to keep your crusher running smoothly:
1. Practice Preventive Crusher Maintenance Schedule
- Do daily, weekly, and monthly inspections.
- Follow the supplier & manufacturer’s maintenance guidelines.
- Monitor the performance with condition monitoring software.
2. Practice Crusher Operator Training
- Train staff in the earliest stages before signs of failure.
- Train staff on proper feeding and loading practices.
- Encourage frequent reporting of abnormal noise or loss of performance.
3. Use Proper Spare Parts
- With Original Equipment Manufacturer (OEM) parts.
- Avoid low-cost, low-quality parts that cause further breakages.
4. Invest in Predictive Maintenance Technology
- Use thermal imaging, vibration analysis, and oil sampling to find issues early on.
- Utilise automatic monitoring systems for real-time machine health monitoring.
5. Prepare Spare Parts & Solutions
- Hold spares such as bearings, belts, and filters in inventories.
- Schedule periodic replacements to avoid extended periods of downtime.
Having your crusher serviced regularly will prevent costly breakages, maximize equipment longevity, and sustain productivity.
Wrapping up
A properly maintained crusher is the secret to efficient operation, reduced downtime, and lower repair bills. If you listen to these top 5 warning signs and adopt good maintenance practices, you will prevent breakdowns and prolong the life of your crusher.
Regular inspection, constant maintenance, and proper training would significantly boost productivity, with your operation humming in peak condition. Don’t break down—get ahead of proactive crusher maintenance!
Join Pro Track for Professional Crusher Servicing and Support
At ProTrack, we realise the importance of your crusher to your business. Being a Canadian seller, renter, and servicer of heavy equipment, including crusher equipment, we sell the machinery, but not just that—we support it with skilled service, maintenance, and support. From scheduled wear and tear to scheduled downtime, our factory-certified technicians and field service work get your equipment running less, with more equipment life to show for it.
At ProTrack, we realise the importance of your crusher to your business. Being a Canadian seller, renter, and servicer of heavy equipment, including crusher equipment, we sell the machinery, but not just that—we support it with skilled service, maintenance, and support. From scheduled wear and tear to scheduled downtime, our factory-certified technicians and field service work get your equipment running less, with more equipment life to show for it.
Why choose ProTrack for Crushing Equipment and Servicing?
- Full Service Support: From inspection and breakdown repair to complete overhaul.
- Parts in Inventory: OEM and performance aftermarket parts in inventory and available to ship.
- Flexible Rental & Purchase Options: Stay operational while your crusher is down for repairs.
- Expertise: Our staff help you design a preventive maintenance plan for your crushing business uniquely suited to your situation.
Don‘t wait for a breakdown. Call ProTrack today to book a crusher inspection or learn more about our maintenance and servicing packages built to minimize downtime and optimise your productivity.
FAQs Crusher Maintenance
- How frequently should I service my crusher?
Routine maintenance must be performed every 500-1,000 hours, depending on the application. Periodic lubrication and inspection are still suggested. - What is the most common cause of crusher failure?
Poor maintenance and inadequate lubrication are the root causes of failure, which result in overheating, wear, and failure of parts. - Can I perform maintenance on my crusher?
Simple internal maintenance, like lubrication and inspections, can be performed, but skilled mechanics must do intricate repairs. - What would make my crusher over-vibrate?
Excessive vibration may result from loose parts, worn bearings, or poor rotor balancing. - What will happen if my crusher is not serviced?
Neglecting to keep your crusher in top condition may result in unforeseen breakages, costly repairs, and even long-term equipment destruction.