Proper jaw crusher operation requires pre-start inspections, controlled feeding, and regular maintenance. Before putting the machine into production, operators should inspect the lubrication system, crushing chamber, jaw plates, drive components, and safety guards to confirm that everything is in proper working condition.
During operation, operators should also monitor feed size, machine load, bearing temperature, and operating noise. Any abnormal condition should be addressed promptly. Jaw crusher models may differ in bearing arrangements, lubrication methods, and temperature monitoring systems. Actual operating procedures should always follow the machine manual and manufacturer's specifications.
Jaw crusher operating instructions
Pre-start inspection
Before starting the machine, inspect the main mechanical components, electrical system, and safety devices. This helps prevent equipment damage caused by loose components, insufficient lubrication, or foreign material entering the crushing chamber.
Check the lubrication system
Confirm that the eccentric shaft bearings and other lubrication points are receiving the required amount of lubricant. Check the condition and quantity of grease or oil. For machines equipped with centralized lubrication systems, make sure the lubrication pump, pipelines, and control devices are working properly.
Remove foreign material from the crushing chamber
Inspect the crushing chamber and feed passage to make sure they are free of leftover rock, metal pieces, and other uncrushable materials. Foreign objects entering the chamber may cause the moving jaw to jam, damage the jaw plates, or overload the machine.
Inspect the moving jaw and drive components
Check the moving jaw, eccentric shaft, flywheel, toggle plate, and related connections for abnormal wear, looseness, or damage. When manual inspection of flywheel rotation is required, disconnect the power supply first and make sure the machine cannot start unexpectedly. Follow the manufacturer's inspection procedure.
Check all fastening bolts
Inspect the frame anchor bolts, jaw plate bolts, motor mounting bolts, and other major connections. Confirm that they are properly tightened to prevent loosening, excessive vibration, or component displacement during operation.
Confirm the motor rotation direction
Check that the motor wiring and rotation direction comply with the crusher specifications. For equipment requiring rotation direction verification, follow the electrical wiring diagram and manufacturer's instructions to prevent reverse rotation from affecting normal crushing operations.
Inspect safety guards and devices
Make sure inspection doors, drive belt guards, flywheel guards, and other protective components are securely installed. Check the emergency stop buttons and relevant safety interlocks. Confirm that no personnel are in hazardous areas before starting the machine.
Startup and test running
After completing the pre-start inspection, start the crusher and auxiliary equipment according to the specified operating procedure.
For newly installed equipment, machines that have undergone maintenance, or crushers being restarted after an extended shutdown, conduct a no-load test run as required by the manufacturer. Observe the flywheel, eccentric shaft, bearings, and moving jaw. Check for abnormal vibration, metallic knocking sounds, or excessive bearing temperature.
For production lines equipped with feeders, conveyors, and magnetic separators, follow the prescribed control sequence. Make sure the conveying and material receiving systems are ready before introducing material into the crusher.
Once the machine runs normally, gradually increase the feed rate. Avoid introducing a large quantity of material immediately after startup, as this may overload the crushing chamber.
Operating precautions for jaw crushers
Prevent metal and other uncrushable materials from entering the crushing chamber
During production, prevent iron pieces, steel bars, and other uncrushable materials from entering the crushing chamber. These objects may damage the jaw plates, toggle plate, and other mechanical components. Severe cases can cause the crusher to jam.
Depending on the feed material and production conditions, magnetic separators or metal detectors can be installed in the feeding system to reduce the risk of metal contamination.
Control feed size and material hardness
The maximum feed size must comply with the crusher specifications. Oversized rock may become trapped at the feed opening or inside the crushing chamber, increasing the load on the moving jaw, eccentric shaft, and motor.
Material compressive strength must also be within the design capacity of the equipment. The value of 320 MPa stated in some equipment descriptions should not be treated as a universal limit for all jaw crushers. The actual material strength limit depends on the crusher model, jaw plate configuration, and manufacturer's technical specifications.
Monitor operating noise and vibration
Operators should listen for changes in operating noise and observe the frame and drive components for abnormal vibration.
If continuous metallic knocking, unusual friction noise, or excessive vibration occurs, stop feeding and shut down the machine according to the specified procedure. Inspect the jaw plate fasteners, toggle plate and toggle seats, bearings, and flywheel connections. Check for foreign material, component looseness, or mechanical damage.
Do not restart the crusher until the fault has been identified and corrected.
Monitor bearing temperature
The eccentric shaft bearings are important load-bearing components of a jaw crusher. Their temperature should be monitored during extended operation.
Some machines are equipped with platinum resistance thermometers, temperature sensors, or other monitoring devices. These systems can display bearing temperature continuously and trigger alarms or shutdown protection when preset limits are reached.
The sensor measuring range, alarm threshold, and shutdown threshold are different parameters. Monitoring settings must be determined according to the actual bearing arrangement, lubrication system, and manufacturer's requirements. Values such as an alarm at 85°C and shutdown at 90°C should not be applied as universal settings for all jaw crushers.
If bearing temperature continues to rise or exceeds the permitted operating range, inspect the lubrication condition, bearing clearance, mounting fit, and actual machine load. Shut down the crusher for maintenance when necessary.
Maintain proper bearing lubrication
Jaw crusher bearings generally require grease or oil lubrication according to the equipment specifications. Lubricant selection should take account of bearing type, operating temperature, rotational speed, and working environment. Use the lubricant specified or approved by the equipment manufacturer.
Routine maintenance should include checking lubricant quantity, condition, contamination, deterioration, and leakage. For grease-lubricated machines, replenish or replace grease according to the specified quantity and maintenance interval. For machines with centralized lubrication systems, inspect the pump, pipelines, and lubricant supply.
Adding more grease does not necessarily improve bearing performance. Excessive grease can increase internal churning resistance and raise bearing temperature, while insufficient lubrication accelerates friction and wear. The correct filling quantity and replacement interval must follow the maintenance manual for the specific machine.
Jaw crusher shutdown and routine maintenance
Follow the correct shutdown sequence
At the end of normal production, stop feeding first. Allow the material inside the crushing chamber to discharge before stopping the crusher. For continuous production lines, wait until the material has cleared the conveyors before stopping the related conveying equipment.
If the crusher becomes jammed, overloaded, or develops another serious fault, follow the emergency shutdown procedure. Do not continue operating the machine simply to empty the crushing chamber.
Inspect wear parts and the drive system regularly
The jaw plates are exposed to repeated compression and friction, so their working surfaces gradually wear. Inspect the moving and fixed jaw plates regularly. Adjust or replace them according to the equipment requirements.
The eccentric shaft, bearings, toggle plate, flywheel, and drive belts should also be checked to confirm that they remain correctly installed and operate normally. For belt-driven equipment, inspect belt tension, pulley groove wear, and pulley alignment.
Maintain equipment service records
Record operating hours, bearing temperature, lubrication condition, jaw plate wear, discharge opening settings, and equipment faults or repairs.
For newly installed machines or equipment that has undergone major maintenance, increase inspection frequency during the initial operating period. Pay particular attention to loose bolts, liner displacement, and abnormal bearing temperature. Maintenance intervals should be determined according to the manufacturer's recommendations and actual operating conditions.
Follow personnel safety requirements
Operators should wear the required personal protective equipment, including safety helmets, safety glasses, hearing protection, and suitable respiratory protection.
Never open protective guards or inspection doors while the machine is running. Do not place hands or tools near the crushing chamber, drive mechanism, or other moving components. Before removing blocked material, inspecting internal components, or replacing wear parts, stop the machine, isolate all relevant energy sources, and apply lockout/tagout (LOTO) procedures.
Reliable jaw crusher operation depends on proper operating practices and regular maintenance. Operators must understand the machine structure, rated operating limits, and safety requirements. Feed rates and operating parameters should be adjusted according to material conditions to prevent overloading, foreign material entry, and lubrication failure.
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