1. Spider Bushing Wear/Failure‌

• ‌Problem‌: Excessive wear in the spider bushing (top bearing) due to misalignment, contamination, or inadequate lubrication. Leads to increased vibration, metal-to-metal contact, and catastrophic failure.
• ‌Causes‌:
  • Dust/lubricant contamination.
  • Improper lubrication flow/quality.
  • Excessive crusher load or “ring bounce”.
• ‌Fix‌:
  • Monitor lube oil purity (filtration, regular sampling).
  • Ensure correct oil flow/psi (per OEM specs).
  • Install condition monitoring (vibration sensors, temperature probes).

‌2. Eccentric Wear & “Ring Bounce”‌

• ‌Problem‌: Wear in the eccentric bushing or gear causes the main shaft to oscillate erratically (“ring bounce”). Results in uneven crushing, product inconsistency, and mechanical stress.
• ‌Causes‌:
  • Feed segregation (uneven material distribution).
  • Overloading or fluctuating feed rates.
  • Worn/damaged eccentric components.
• ‌Fix‌:
  • Use rotating distributors for even feed.
  • Install load sensors to prevent overfilling.
  • Regularly inspect eccentric assembly wear.

‌3. Dust Contamination in Lubrication System‌

• ‌Problem‌: Dust ingress into the lube oil system accelerates bearing wear and degrades oil performance. Common in dry/dusty environments.
• ‌Causes‌:
  • Worn/damaged seals (e.g., dust collar seals).
  • Negative pressure in the crushing chamber.
• ‌Fix‌:
  • Maintain air seal systems (positive air pressure).
  • Replace seals during liner changes.
  • Use high-efficiency oil filters.

‌4. Liner Wear & Fastening Failures‌

• ‌Problem‌: Uneven liner wear reduces crushing efficiency. Loose liners cause movement, leading to cracks or catastrophic detachment.
• ‌Causes‌:
  • Incorrect alloy selection for material hardness.
  • Poor feed distribution (e.g., “direct feed” hitting one zone).
  • Loose backing material or broken bolts.
• ‌Fix‌:
  • Rotate/flip liners periodically for even wear.
  • Use laser scanning to track liner profiles.
  • Apply thread-locking compounds on bolts + regular torque checks.

‌5. Oil Leaks & Hydraulic System Issues‌

• ‌Problem‌: Hydraulic oil leaks from cylinders, hoses, or accumulator systems. Causes loss of pressure, adjustment failures, and fire hazards.
• ‌Causes‌:
  • Damaged seals/hoses from abrasion.
  • Overpressurization or thermal cycling.
• ‌Fix‌:
  • Inspect hoses/seals quarterly.
  • Use protective sleeving on hydraulic lines.
  • Monitor hydraulic pressure gauges.

‌6. Tramp Metal Damage‌

• ‌Problem‌: Uncrushable metal (e.g., drill bits, bucket teeth) enters the chamber, damaging liners, shafts, or eccentric components.
• ‌Causes‌:
  • Ineffective metal detection upstream.
  • Poor quarry cleanup practices.
• ‌Fix‌:
  • Install metal detectors/electromagnets on feed conveyors.
  • Implement “last chance” traps before the crusher.

‌7. Main Shaft Fracture‌

• ‌Problem‌: Rare but catastrophic failure of the main shaft due to fatigue cracks or overload stress.
• ‌Causes‌:
  • Undetected cracks from ring bounce events.
  • Over-tightened bushings causing stress points.
• ‌Fix‌:
  • Non-destructive testing (UT/MPI) during major shutdowns.
  • Avoid “emergency stops” under load.

‌Prevention Checklist‌

‌Key Takeaway‌

Gyratory crushers thrive on ‌consistency‌:

• ✔️ ‌Stable feed rates‌ prevent ring bounce.
• ✔️ ‌Immaculate lubrication‌ extends bearing life.
• ✔️ ‌Proactive liner management‌ avoids unplanned downtime.

Example: A copper mine reduced downtime 30% by switching to ‌real-time oil debris monitoring‌ and *automated feed control – addressing bushings and ring bounce simultaneously.

Need help troubleshooting a specific issue? Share symptoms (e.g., unusual noise/vibration) for targeted solutions! ⚙️