Free crusher maintenance checklist

• The MapTrack crusher maintenance checklist contains 37 checks across 6 sections. Sections covered: Wear Parts, Hydraulic System, Drive System, Lubrication, Bearings & Seals, Structure & Safety.
• 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.

Learn more about maintenance and work orders in MapTrack.

• 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.

• 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.

1. 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.

2. 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.

3. 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.

4. 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.

5. 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.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

• 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

• Model Code of Practice: Managing risks of plant in the workplace (Safe Work Australia)
• Model WHS Regulations (Safe Work Australia)
• Model Work Health and Safety Act (Safe Work Australia)
• AS 4024 series, Safety of machinery (Standards Australia listing)

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

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