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Crushing Equipment Maintenance Guide

Regular maintenance is essential for keeping crushing equipment running reliably and extending its service life. This guide covers the maintenance tasks required at different intervals and provides tips for maximizing crusher uptime.

Daily Maintenance Tasks

Operators should perform these checks at the start of each shift:

Visual Inspection:

• Check for oil leaks under the crusher
• Inspect belts for cracks, tears or improper tension
• Check for material buildup around crusher and feed hopper
• Verify all guards are in place
• Check hydraulic fluid level (if equipped)

Operational Checks:

• Listen for unusual sounds during startup
• Monitor oil pressure and temperature gauges
• Verify CSS adjustment operates smoothly (if adjustable)
• Check that safety devices (emergency stops) function correctly

Lubrication:

• Grease toggle plate bearings (jaw crushers)
• Check oil level in reservoir
• Verify grease cups are filled

Weekly Maintenance Tasks

Mechanical Inspection:

• Measure belt tension and alignment
• Check pulley condition and alignment
• Inspect jaw dies/cone mantles for wear patterns
• Check toggle plate and seat condition
• Inspect hopper and feedbox for wear

Operational Testing:

• Record power draw during normal operation
• Check vibration levels with crusher running empty
• Test all emergency stops
• Verify alarm systems function

Monthly Maintenance Tasks

Comprehensive Inspection:

• Complete visual inspection of all components
• Check foundation bolts for tightness
• Inspect and clean oil coolers
• Check electrical connections for tightness and corrosion
• Inspect conveyor belts for damage
• Lubricate all grease points (if missed daily)

Documentation:

• Review and record all inspection findings
• Update maintenance log
• Plan any repairs needed
• Order replacement parts if necessary

Scheduled Wear Part Replacement

Jaw Crushers:

• Jaw dies: Replace at 70% wear or when cracked
• Cheek plates: Rotate or replace when worn
• Toggle plate: Inspect for cracks, replace if elongated
• Toggle seat: Replace when worn or cracked

Cone Crushers:

• Mantle and concave: Replace at 50% remaining thickness
• Drive belt: Replace at 70% wear or when cracked
• Oil filter: Replace every 250-500 hours
• Lubricating oil: Change every 500-1000 hours

Impact Crushers:

• Blow bars: Replace at 50% remaining thickness
• Apron liners: Replace when worn through
• Side liners: Replace when worn
• Anvils: Adjust or replace when worn

Tips for Extending Crusher Life

Operate Correctly:

• Avoid feeding oversized material
• Maintain consistent feed rate
• Use correct CSS settings for product requirements
• Don't run empty after last feed — clear material first

Maintain Properly:

• Follow lubrication schedules exactly
• Replace wear parts before catastrophic failure
• Keep records of wear rates and maintenance performed
• Train operators on proper operation and early problem detection

Use Quality Parts:

• Genuine OEM wear parts last longer than counterfeit parts
• Proper lubricant grades specified by manufacturer
• Quality replacement components

When Problems Occur

If you notice any of these warning signs, investigate immediately:

• Metal-on-metal grinding sounds
• Excessive vibration
• Oil discoloration or metal particles in oil
• Sudden drop in throughput
• Excessive heat from bearings or hydraulic system
• Cracked or broken wear parts visible

WSHT offers comprehensive aftermarket support including genuine wear parts, lubricants and maintenance services. Our technicians can provide operator training and maintenance procedure development for your operation.