5 Signs Your Rock Crusher Needs a Rebuild

Avoid Downtime and Costly Failures With These Early Warning Signs

At Marion Machine, we know that a rock crusher is the backbone of any aggregate or mining operation. But even the toughest equipment has its limits. Recognizing the signs of wear and addressing issues early can mean the difference between a routine rebuild and a catastrophic failure.

Here are five critical signs your rock crusher may be due for a rebuild—and what you can do about it.

1. Excessive Vibration or Unusual Noise

If your crusher is rattling, thumping, or vibrating more than usual, something’s off.
These symptoms often point to worn bearings, misaligned components, or structural cracks. Left unaddressed, these issues can lead to premature failure of internal parts or even catastrophic machine damage.

What to Do: Schedule a diagnostic inspection. At Marion Machine, we offer precision measurement and vibration analysis to locate the root of the issue.

2. Visible Cracks in the Frame or Welds

Over time, the constant crushing of hard materials puts stress on structural components. Cracks in the mainframe, side plates, or welds are serious indicators that the crusher is no longer structurally sound.

What to Do: Frame damage often requires specialized welding and stress-relief procedures. We perform both in-house and can restore the structural integrity of your crusher.

3. Irregular Product Size or Reduced Output

If your product gradation has changed or throughput has dropped, worn liners, misaligned components, or damaged internals may be to blame. These issues don’t just hurt productivity—they can strain downstream equipment as well.

What to Do: A rebuild often includes realigning components, replacing worn liners, and machining critical surfaces to restore proper function and efficiency.

4. Frequent Breakdowns and Increased Maintenance

Are you constantly shutting down for repairs? Increasing downtime and spare parts usage are signs that your crusher’s major systems are failing—and patchwork fixes may no longer be effective.

What to Do: A full rebuild can replace all worn components, restore like-new performance, and provide a reset point for your maintenance schedule.

5. Excessive Oil Leakage or Contamination

Hydraulic and lubrication systems are vital to your crusher’s operation. Oil leaks, discoloration, or metal shavings in the oil can signal internal damage to gears, bearings, or shafts.

What to Do: These signs often require teardown and inspection. At Marion Machine, we have the machining and rebuild capabilities to replace damaged parts and restore system reliability.

Why Choose Marion Machine for Your Crusher Rebuild?

Located in Marion, NC, Marion Machine is one of the nation’s premier rock crusher repair and machining facilities. With over 80 years of experience and the ability to handle the largest of crushers and equipment, we’re trusted by operations across North America to restore their equipment to OEM or better-than-OEM standards.

Whether it’s a cone crusher, jaw crusher, or gyratory, our expert technicians, in-house and field machining, welding, and stress-relief capabilities ensure the job gets done right—the first time.

Don’t Wait for Failure. Plan Your Rebuild Now.

If you’re seeing any of the warning signs above, it’s time to act. Contact us today to schedule a crusher inspection or request a free rebuild quote.

📞 Call: 1-800-627-1639
📍 Serving North Carolina and customers across the U.S.
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