What safety regulations apply to crusher maintenance in Australia?

Crusher maintenance in Australia must comply with the WHS Act 2011 and WHS Regulations 2011 (Chapter 5), which require that plant is maintained in a safe condition with documented records by competent persons. AS 4024 (Safety of Machinery) covers guarding requirements for rotating equipment, nip points and access to crushing chambers. State mining safety regulations (e.g. NSW WHS (Mines and Petroleum Sites) Regulation) impose additional obligations for mining and quarrying operations, including mechanical engineering control plans (MECPs), risk assessments for maintenance activities and reporting requirements for incidents involving plant failures.

How often should a crusher be inspected?

Daily operator checks should cover oil levels, temperatures, pressures, vibration, noise, guard condition and CSS. Weekly inspections should include detailed wear part measurement, drive system checks and lubrication system servicing. Monthly major inspections should cover bearing assessment, structural integrity, overload system testing and comprehensive safety checks. Liner replacement intervals depend on the material being crushed and typically range from 200 hours (impact crusher blow bars in highly abrasive applications) to 4,000 hours (cone crusher mantles in moderately abrasive applications).

What is a closed-side setting and why does it need to be checked?

The closed-side setting (CSS) is the minimum gap between the fixed and moving crushing surfaces at the closest point of their stroke (jaw and cone crushers) or the gap between the blow bars and impact aprons (impact crushers). The CSS determines the maximum product size from the crusher. As wear parts erode, the CSS opens, producing coarser material that may not meet the product specification. Checking and adjusting the CSS regularly ensures consistent product quality. For jaw crushers, the CSS is adjusted using shims or a hydraulic toggle. For cone crushers, the CSS is adjusted by raising or lowering the mantle. CSS should be verified daily or at the start of each production shift.

What is the difference between maintaining a jaw crusher and a cone crusher?

Jaw crushers have fewer moving parts and simpler maintenance requirements: the main wear items are the fixed and swing jaw plates, cheek plates, toggle plate and bearings. Cone crushers are more complex, with additional maintenance items including the mantle and concave liners, main shaft, spider bushing or top bearing, eccentric assembly, hydraulic clamping system, tramp iron release system, and a more sophisticated lubrication system with higher oil flow requirements. Cone crushers also require CSS adjustment as the mantle wears, whereas jaw crushers use shim or hydraulic toggle adjustment. Cone crusher liner changes are more labour-intensive and typically require a crane, while jaw plate changes can often be completed with the crusher in-built lifting equipment.

Is this crusher maintenance checklist free to download?

Yes. This crusher maintenance checklist is completely free to download and use. Open the template in your browser and print or save as PDF. No account or sign-up is required. If you want to digitise inspections with automatic scheduling, photo capture and compliance dashboards, MapTrack can help. Book a free demo to see how it works for your operation.

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Free crusher maintenance checklist (PDF-ready). Covers jaw, cone and impact crushers, liners, bearings, drive systems, lubrication and safety guards.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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What is a crusher maintenance checklist?

A crusher maintenance checklist is a structured document used to systematically inspect and maintain rock crushers (jaw crushers, cone crushers, impact crushers and gyratory crushers) used in mining, quarrying, construction materials and recycling operations. The checklist covers crusher liner and wear part condition assessment (jaw plates, mantle and concave, blow bars, cheek plates), crusher chamber geometry and closed-side setting (CSS) verification, main shaft and eccentric bearing condition, drive system inspection (motor, belts, couplings, flywheel), lubrication system checks (oil level, temperature, filtration, flow rates), hydraulic system inspection (adjustment cylinders, tramp iron release, clamping systems), feed system and hopper condition, discharge conveyor and screening integration, structural frame and mounting bolt integrity, guard and safety device inspection, and dust suppression and environmental controls.

Crushers are among the most heavily loaded machines in any processing operation, subjected to continuous impact forces, abrasive materials and high vibration levels. Wear parts such as jaw plates, mantles and blow bars are consumable items that must be monitored and replaced before they wear through to the backing material or crusher body, causing catastrophic and expensive damage. Bearings operate under extreme loads and must be kept clean and correctly lubricated to achieve their design life. Drive systems transmit enormous torque through belts, couplings and flywheels that require regular tension checks and alignment verification. A missed maintenance item on a crusher can escalate rapidly from a minor wear issue to a multi-week shutdown costing hundreds of thousands of dollars in lost production and emergency repairs. Regular documented maintenance using a standardised checklist ensures that all wear points, lubrication systems, safety devices and structural components are assessed systematically, reducing unplanned downtime and extending crusher service life.

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Benefits of using this crusher maintenance checklist

Reduced unplanned downtime: systematic monitoring of liner wear, bearing condition and drive components identifies items approaching replacement before they fail during production, avoiding costly emergency shutdowns.
Extended component life: correct lubrication, proper CSS setting and timely liner rotation maximise the service life of wear parts and protect the crusher body from damage.
Product quality: maintaining the correct CSS and monitoring liner profile ensures the crusher produces material within the required specification, reducing reprocessing and waste.
Safety: inspecting guards, lockout points, access platforms, feed chutes and dust suppression systems reduces the risk of injuries from entanglement, falling rock, dust inhalation and noise exposure.
Cost control: planned liner changes, scheduled bearing replacements and proactive drive system maintenance are significantly cheaper than reactive emergency repairs and the associated production losses.
Compliance: documented maintenance records demonstrate that the crusher is maintained to WHS requirements and manufacturer specifications, supporting insurance claims, environmental licence conditions and regulatory audits.

Benefits of digitising forms in MapTrack

When you digitise crusher checklists in MapTrack, you get:

Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
Automatically get alerts when faults are identified.
Link every form digitally as a PDF to the relevant asset, location or person.
Receive a digital PDF copy with every submission to your email.
Ability to share forms digitally.
Build conditional logic (show or hide questions based on answers).
Take pictures or attach photos. Not possible with a paper-based form.
Electronic signatures.
Edit forms later without reprinting.
Restrict permissions (who can view, complete or approve).
Build forms with AI (describe what you need and MapTrack suggests the form).
Trigger work orders automatically when a fault is logged during an inspection.
Track service intervals by hours, kilometres or calendar date in one place.
Attach supplier invoices and parts receipts to each maintenance record.

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What to include in a crusher maintenance checklist

This crusher maintenance checklist covers 9 key areas:

Wear parts: measure jaw plate thickness (jaw crusher), mantle and concave profile (cone crusher), blow bar thickness (impact crusher), cheek plate condition, feed plate or distributor plate wear.
Crusher chamber: verify closed-side setting (CSS) using a lead or plastic plug method, check chamber geometry and profile for uneven wear patterns indicating feed distribution issues.
Main shaft and bearings: check main shaft run-out (cone crusher), inspect eccentric bearing housing for temperature anomalies, check main bearing oil temperatures and pressures, inspect spider bushing or top bearing condition.
Drive system: inspect drive motor condition (winding temperature, bearing noise), check belt tension and condition (V-belts or synchronous belts), inspect coupling alignment, check flywheel for cracks and key condition.
Lubrication system: check oil reservoir level and condition, verify oil temperature is within range, check oil filter differential pressure, verify oil flow to all bearing points, inspect oil cooler for blockage.
Hydraulic system: check hydraulic oil level and condition, test tramp iron release (TIR) or overload protection system, check adjustment cylinder operation, verify clamping system pressure (cone crushers).
Feed system: inspect feed hopper for liner wear and build-up, check feeder or grizzly condition, verify feed distribution into the crusher chamber is centred and consistent.
Structural: inspect crusher frame for cracks (particularly at bearing housings and mounting points), check foundation bolts and mounting pads, inspect discharge chute and conveyor interface.
Safety and environment: inspect all guards and access covers, verify lockout/tagout points are accessible and labelled, check dust suppression spray nozzles and water supply, inspect noise enclosures.

How to use this crusher maintenance checklist

Lock out and tag out the crusher, feeder and all associated conveyors. Allow the crusher to empty completely and cool before entering the crushing chamber or accessing rotating components.: Isolate the crusher drive motor, feeder, discharge conveyor and any associated equipment at their local isolators. Apply personal lockout devices and danger tags. Verify isolation by attempting to start each piece of equipment. Allow the crusher to run empty until no material remains in the chamber. Allow hot components (bearings, lubrication lines, hydraulic cylinders) to cool to a safe temperature. Confirm the area is safe for entry and that no material is bridged above the chamber that could collapse.
Measure wear part condition: check jaw plate thickness (jaw crusher), mantle and concave profile (cone crusher), or blow bar thickness (impact crusher). Measure the closed-side setting.: For jaw crushers, measure the thickness of fixed and swing jaw plates at multiple points and compare against the minimum specification (typically 20 to 25 mm remaining triggers replacement). For cone crushers, measure the mantle and concave profile using a template or direct measurement at multiple heights around the chamber. For impact crushers, measure blow bar thickness at the impact face. Use a lead or plastic plug to measure the CSS and compare against the target product specification. Note any uneven wear patterns that indicate feed distribution issues.
Inspect the main shaft, bearings and drive system: check bearing temperatures and oil pressures from operating data, inspect bearing housings, check drive belt tension and condition, inspect coupling alignment and flywheel.: Review the bearing temperature and oil pressure trend data from the last operating period to identify any anomalies. Inspect bearing housings for oil leaks, unusual heat discolouration or vibration marks. For cone crushers, check main shaft run-out if accessible. Inspect drive belts for cracking, glazing, cord exposure and correct tension (measure deflection against the specification). Check coupling alignment with a straight edge or laser alignment tool. Inspect the flywheel for cracks, particularly at the keyway and spoke junctions.
Service the lubrication system: check oil level and condition, replace oil filter if differential pressure is high, clean the oil cooler, verify oil flow rates and temperature are within range.: Check the oil reservoir level on the sight glass and top up if required with the specified grade (typically ISO VG 150 or 220 for crusher bearings). Inspect the oil condition visually for discolouration, water contamination (milky appearance) or metallic particles. Take an oil sample for laboratory analysis if the sampling schedule requires it. Check the oil filter differential pressure gauge and replace the element if it exceeds the specified limit. Clean the oil cooler fins with compressed air. Verify that oil flow indicators at each bearing point show adequate flow.
Test the hydraulic system and overload protection. Inspect the feed system, structural frame, safety guards, dust suppression and environmental controls. Record all findings and create maintenance work orders.: Test the tramp iron release (TIR) system by cycling the hydraulic cylinders through their full range and verifying the crusher opens to the correct tramp release gap. For cone crushers, verify the clamping system pressure and check for ring bounce indicators. Inspect the feed hopper liners, grizzly bars and feeder for wear. Check the crusher frame at bearing housings, mounting bolt locations and welded joints for cracks. Inspect all guards, access covers and lockout points. Check dust suppression spray nozzles for blockage and water supply pressure. Record all findings with measurements, photographs and severity ratings. Create maintenance work orders for any items requiring attention before the next scheduled inspection.

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How often should you complete this checklist?

Crusher maintenance frequency depends on the machine type, material hardness, throughput and operating hours. Daily operator checks should cover oil levels, temperatures, pressures, unusual vibration or noise, guard condition and CSS verification. Weekly inspections should include detailed wear part assessment, drive system checks and lubrication system servicing. Major inspections including bearing assessment, structural checks and overload system testing should be performed monthly.

Liner replacement intervals vary widely based on the application: jaw plates may last 500 to 2,000 hours, cone crusher mantles and concaves 1,500 to 4,000 hours, and impact crusher blow bars 200 to 800 hours depending on feed material abrasiveness. Oil changes are typically performed every 1,000 to 2,000 hours or when oil analysis indicates degradation. In MapTrack, configure meter-based maintenance triggers linked to the crusher hour meter for scheduled inspections, and calendar-based triggers for weekly and monthly checks to ensure no inspection is missed during continuous production campaigns.

Frequently asked questions

What safety regulations apply to crusher maintenance in Australia?: Crusher maintenance in Australia must comply with the WHS Act 2011 and WHS Regulations 2011 (Chapter 5), which require that plant is maintained in a safe condition with documented records by competent persons. AS 4024 (Safety of Machinery) covers guarding requirements for rotating equipment, nip points and access to crushing chambers. State mining safety regulations (e.g. NSW WHS (Mines and Petroleum Sites) Regulation) impose additional obligations for mining and quarrying operations, including mechanical engineering control plans (MECPs), risk assessments for maintenance activities and reporting requirements for incidents involving plant failures.
How often should a crusher be inspected?: Daily operator checks should cover oil levels, temperatures, pressures, vibration, noise, guard condition and CSS. Weekly inspections should include detailed wear part measurement, drive system checks and lubrication system servicing. Monthly major inspections should cover bearing assessment, structural integrity, overload system testing and comprehensive safety checks. Liner replacement intervals depend on the material being crushed and typically range from 200 hours (impact crusher blow bars in highly abrasive applications) to 4,000 hours (cone crusher mantles in moderately abrasive applications).
What is a closed-side setting and why does it need to be checked?: The closed-side setting (CSS) is the minimum gap between the fixed and moving crushing surfaces at the closest point of their stroke (jaw and cone crushers) or the gap between the blow bars and impact aprons (impact crushers). The CSS determines the maximum product size from the crusher. As wear parts erode, the CSS opens, producing coarser material that may not meet the product specification. Checking and adjusting the CSS regularly ensures consistent product quality. For jaw crushers, the CSS is adjusted using shims or a hydraulic toggle. For cone crushers, the CSS is adjusted by raising or lowering the mantle. CSS should be verified daily or at the start of each production shift.
What is the difference between maintaining a jaw crusher and a cone crusher?: Jaw crushers have fewer moving parts and simpler maintenance requirements: the main wear items are the fixed and swing jaw plates, cheek plates, toggle plate and bearings. Cone crushers are more complex, with additional maintenance items including the mantle and concave liners, main shaft, spider bushing or top bearing, eccentric assembly, hydraulic clamping system, tramp iron release system, and a more sophisticated lubrication system with higher oil flow requirements. Cone crushers also require CSS adjustment as the mantle wears, whereas jaw crushers use shim or hydraulic toggle adjustment. Cone crusher liner changes are more labour-intensive and typically require a crane, while jaw plate changes can often be completed with the crusher in-built lifting equipment.
Is this crusher maintenance checklist free to download?: Yes. This crusher maintenance checklist is completely free to download and use. Open the template in your browser and print or save as PDF. No account or sign-up is required. If you want to digitise inspections with automatic scheduling, photo capture and compliance dashboards, MapTrack can help. Book a free demo to see how it works for your operation.

Applicable regulatory standards

This template aligns with the following regulations and standards:

WHS Act 2011 (Duty to maintain plant in safe condition)
WHS Regulations 2011, Chapter 5 (Plant and Structures)
AS 4024 (Safety of Machinery series, including guarding requirements)
Mining safety regulations (state-specific, e.g. NSW WHS (Mines and Petroleum Sites) Regulation)
Safe Work Australia Code of Practice: Managing Risks of Plant in the Workplace

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