Common Crusher Problems and How to Fix Them: Real Cases from the Field

Every crusher operator knows: no matter how good your machine is, issues will come up. The real skill is knowing how to spot problems early and fix them fast before they slow down your whole operation.

Here are some common crusher headaches—plus how teams on site solved them, so you can avoid downtime and costly repairs.

Problem 1: Crusher Jammed by Oversized Material

What happened:
On a quarry site, the jaw crusher suddenly stopped working. Investigation showed a massive boulder stuck inside the crushing chamber, blocking output completely.

How they fixed it:
The operator safely opened the crusher and manually removed the boulder. They then adjusted the vibrating feeder settings to prevent oversized rocks from entering the crusher next time. Installing a grizzly screen upstream also helped filter out large stones.

Lesson: Always monitor feed size and use proper screening to protect crushers.

Problem 2: Excessive Wear on Crusher Liners

What happened:
A crushing plant noticed frequent replacement of jaw plates and liners, driving up maintenance costs and downtime.

How they fixed it:
The maintenance team switched to higher-grade manganese steel liners with better wear resistance. They also optimized the crusher’s settings to reduce crushing force where possible and improved feeding consistency to avoid shock loads.

Lesson: Invest in quality wear parts and adjust operational parameters for longevity.

Problem 3: Dust Overflow Causing Air Filter Clogging

What happened:
Dust from the crusher was so heavy that dust collectors clogged repeatedly, causing air system failures and production halts.

How they fixed it:
The site installed a water spray dust suppression system around transfer points and enclosed conveyors. Regular cleaning schedules for dust collectors were set up, and operators were trained on early dust buildup signs.

Lesson: Proactive dust control prevents system failure and keeps production smooth.

Problem 4: Noise Complaints from Nearby Residents

What happened:
A crushing operation faced complaints from local communities due to loud noise disrupting nearby neighborhoods.

How they fixed it:
Management built sound barriers and planted vegetation as natural noise buffers. They also adjusted crusher operating hours to avoid early morning or late night noise. New crushers with soundproof enclosures were installed during upgrades.

Lesson: Community relations matter—address noise issues early with engineering and operational solutions.

Final Tips for Crusher Troubleshooting

• Regular inspections catch wear and tear before failures occur.

• Training operators on problem signs speeds up response time.

• Keeping good records of issues helps identify recurring problems and trends.

• Working with equipment suppliers ensures you get the best technical support.

No crusher runs perfectly forever, but with the right approach, you can keep problems small and downtime minimal.

Need help diagnosing your crusher issues? Our experienced team can offer fast, practical solutions tailored to your machine and site conditions.