Crusher Maintenance: Essential Tips for Jaw, Cone & Impact Crusher Repairs

Crusher maintenance is critical for ensuring the longevity and efficiency of heavy equipment. This guide covers key maintenance strategies for jaw, cone, and impact crushers to prevent breakdowns and minimize downtime.

Learn more about the maintenance practices that ensure crushers perform efficiently and effectively, including how to repair and maintain jaw, cone and impact crushers. We will also cover checklists, common repairs and tips for extending the lifespan of your equipment.

Why Crusher Maintenance is Essential

The importance of regular maintenance in all machines, especially rock crushers and concrete crushers is vital. The idea is to maintain so that you don’t have to repair. Proper concrete crusher maintenance may allow you to avoid expensive repairs and machine failures.

Taking preventative crusher maintenance seriously will pay dividends. It’s crazy to think that people will wait for failures before doing basic crusher maintenance. Routine crusher maintenance will ensure maximum uptime and prevent unnecessary costly repairs.

Check out the video below to learn more about crusher maintenance and what it’s like.

Jaw Crusher Maintenance and Repair

A jaw crusher is one of the most rugged machines known to exist. Jaw crushers are used to crush some of the hardest material on the planet. Often used as primary crushers after blasting, jaw crushers take the brunt of the raw large material and reduce the stones or rock into a more manageable size to be further reduced by secondary crushers.

A daily visual inspection can be quite useful. Inspect the whole machine while it’s operating, and make sure it appears to be consistent each day.

Daily Maintenance Checklist for Jaw Crushers

1. Look at the position of flywheels and flywheel weights to be sure nothing has moved or changed. Flywheels can loosen over time and move on the main crusher shaft. Flywheels cannot only spin on the shaft if loose but can also move side to side.
   • If drive V-belts become loose or cannot maintain true drive alignment, the flywheels may be loose.
2. Check jaw die bolts and fasteners to be sure they are in place and not loose.
3. Check the toggle plate and toggle seat areas to be sure the toggle plate hasn’t moved and is on the stationary as well as the moving toggle seat.
4. Grease Jaw crusher Pitman bearings as well as the Jaw crusher main frame bearings. A total of four spherical roller bearings may be present on most overhead eccentric jaw crushers. Be sure to follow the factory guidelines for grease type, frequency of grease and quantity of grease.
5. Check drive V-belt tension to ensure belts are tensioned properly.
6. Listen for any unusual noises that may not be consistent with normal operation.
7. If hydraulically driven, check the hydraulic pressure gauge when the machine is operating with and without material in the crushing chamber. High pressure could indicate a mechanical problem, or it could indicate that there is an uncrushable obstruction inside the jaw crushing chamber.
8. If electrically driven, you should check the amp gauge when the machine is operating with and without material in the crushing chamber. High amperage could indicate a mechanical problem, or it could indicate that there is an uncrushable obstruction inside the jaw crushing chamber.
9. It is vital to check the jaw crusher flywheel RPM both crushing and empty. The Jaw crusher RPM may have a factory recommended range. It’s important to maintain the jaw crusher RPM guidelines to ensure maximum crushing power, efficiency and inertia. The flywheel RPM translates into crushing power along with the horsepower of the jaw crusher motor.
10. Check the jaw crusher pitman assembly from time to time to be sure it hasn’t moved on the jaw crusher main shaft. If the pitman has become loose on the shaft it may move to one side and rub on the mainframe or mainframe bearing caps.
11. The jaw crusher jaw dies, or jaw plates will wear. Check for uneven wear which could be attributed to a variety of factors including improper feed. Material should be fed into a jaw crusher evenly and as close to the center as possible.
12. Jaw dies may wear more at the top or bottom so routine visual inspection may allow you to adjust the machine or feed method to maximize jaw die life and reduce wear.
13. In addition, jaw dies in some machines are the same part number. If so, operators may choose to flip or swap the jaw dies. Flipping the jaw dies so the bottom is now on the top can maximize jaw die life. In addition, swapping the moveable jaw die for the stationary jaw die may produce similar results to flipping. Flipping or swapping jaw dies in a timely manner can maximize jaw die life rather than wait until one of them is worn too badly and must be replaced.
14. Check the jaw crusher side liners inside the crushing chamber, aka cheek plates and replace as required. Waiting to replace the cheek plates can be costly if they wear through and expose the main frame. The cheek plates are designed to wear and be replaced and protect the main frame.

Cone Crusher Maintenance: Key Practices

Cone crushers handle high-impact workloads and regular maintenance is essential for reducing downtime and operational costs. Cone crushers are used to further reduce medium sized stones and rocks into a more saleable product. Cone crushers are more efficient than jaw crushers in reducing material into saleable products and therefore exist to handle hard rock and stones while producing the finished products we see in concrete or asphalt.

A daily visual inspection can be quite useful. Look over the machine to ensure consistent operation every day.

Daily Maintenance Checklist for Cone Crushers

1. Look at the position of the flywheel and flywheel weights (if applicable), to be sure nothing has moved or changed. The flywheel can loosen over time and move on the cone crusher countershaft and/or drive shaft.
   • If drive V-belts become loose or cannot maintain true drive alignment, the flywheel may be loose.
2. Check cone crusher manganese mantle and bowl liner bolts and fasteners to be sure they are in place and not loose. Various cone crusher manufacturers fasten their wear parts differently. Adhere to factory guidelines when inspecting cone crusher wear parts.
3. Check the cone crusher lubrication oil level, flow and pressure.
4. Check the cone crusher lubrication pump for direction and be sure it is operating at the correct RPM.
5. Check drive V-belt tension to ensure belts are tensioned properly.
6. Listen for any unusual noises that may not be consistent with normal operation.
7. If hydraulically driven, check the hydraulic pressure gauge when the machine is operating with and without material in the crushing chamber. High pressure could indicate a mechanical problem, or it could indicate that there is an uncrushable obstruction inside the cone crushing chamber.
8. If electrically driven, you should check the amp gauge when the machine is operating with and without material in the crushing chamber. High amperage could indicate a mechanical problem, or it could indicate that there is an uncrushable obstruction inside the cone crushing chamber.
9. It is vital to check the cone crusher flywheel RPM both crushing and empty. The cone crusher RPM may have a factory recommended range. It’s important to maintain the cone crusher RPM guidelines to ensure maximum crushing power, efficiency and inertia. The flywheel RPM translates into crushing power along with the horsepower of the cone crusher motor.
10. Various cone crushers require head spin RPM checks while operating and coast down. Follow factory guidelines to reduce potential costly repairs. Excessive head spin can be an early indication of main bearing or bushing wear as well as other issues.
11. Check for uneven wear which could be attributed to a variety of factors including improper feed. Material should be fed into a cone crusher evenly and as close to the center of the feed plate as possible.
12. Check the cone crusher side liners or main frame liners if applicable. inside the crushing chamber, aka cheek plates and replace as required. Waiting to replace the main frame liners can be costly if they wear through and expose the main frame. Main frame liners are designed to wear and be replaced to protect the main frame.
13. There are a variety of cone crusher configurations. Each manufacturer has different designs and therefore different inspection points and maintenance tips and intervals. Overall, a cone crusher has a head and shaft that rotates vertically vs a jaw crusher than has a horizontal shaft.
    • Cone crushers can have roller bearings, bronze bushings or a combination thereof.

Cone crushers can be very expensive to purchase and costly to repair. Routine inspections and maintenance will ensure longevity and rescue overall operating costs.

Best Lubrication Practices for Cone Crushers

• Be sure to follow all cone crusher manufacturer lubrication guidelines.
• Using only factory recommended oil manufacturers as well as specifications is critical.
• Oil level must be checked and within tolerances.
• Oil filters must be routinely checked and replaced.
• Replace oil as recommended and/or if contamination is present.
• Check cone crusher lubrication oil for contaminants routinely.
• Maintain proper cone crusher lubrication oil temperature and service lubrication oil cooler as required.

Checking and Replacing Worn Parts for Cone Crushers

1. One way to check cone crusher wear is to notice the finished product variations in size and/or quality.
2. As mantle and bowl liners wear crushed material will become larger or less consistent in shape or size.
3. Check to be sure the mantle is meeting the bowl liner in the appropriate locations. If the mantle or bowl liner are not aligned and/or the liners wear unevenly, the efficiency of the machine will suffer.
4. In addition, production rates may suffer if wear liners are not replaced as required.
5. More frequent adjustments may ensure a more consistent product and allow ear parts to maximize their life by using a higher percentage of their surface and meeting each other across their entire surface rather than at a pinch point.
6. Be sure to use the proper manganese backing material per the manufacturer guidelines. Some cone crusher designs utilize a chemical backing that is similar to a filler and secures the liner after liner bolts are tightened.

Impact Crusher Maintenance and Efficiency

Impact crushers deal with high-impact and abrasive materials, making maintenance crucial for performance and safety. An impact crusher is mostly used in softer rock or asphalt crushing applications. It can be a primary or secondary in various rock crushing or concrete or asphalt crushing operations as well.

Its unique design and operation contain a crushing explosion essentially. Impact crushers typically operate at higher RPMs and reduce material by impacting it as it’s fed into the crushing chamber. The impact particles may either be thrown down and out of the crusher or up and against impact curtains and then dropped down and out of the machine. All of these surfaces require maintenance from time to time.

The frequency of impact crusher maintenance may be greater than that of other types of crushers. Due to its explosion style of crushing, the wear may be greater, more frequent and more complicated than jaw crusher or cone crushers.

Daily Maintenance Checklist for Impact Crushers

1. Look at the position of the flywheel(s) to be sure nothing has moved or changed. Flywheels can loosen over time and move on the main crusher shaft.
2. Flywheels cannot only spin on the shaft if loose but can also move side to side.
   • If drive V-belts become loose or cannot maintain true drive alignment, the flywheels may be loose.
3. Check the blow bar and curtain liner fasteners to be sure they are in place and not loose.
4. Check the rotor and blow bar wedges if any on a frequent basis.
5. Check the wear liner and curtain fasteners and curtain liners on a frequent basis.
6. Grease impact crusher pillow block bearings and be sure to follow the factory guidelines for grease type, frequency of grease and quantity of grease.
7. Check drive V-belt tension to ensure belts are tensioned properly.
8. Listen for any unusual noises that may not be consistent with normal operation.
9. If hydraulically driven, check the hydraulic pressure gauge when the machine is operating with and without material in the crushing chamber. High pressure could indicate a mechanical problem, or it could indicate that there is an uncrushable obstruction inside the impact crushing chamber.
10. If electrically driven, you should check the amp gauge when the machine is operating with and without material in the crushing chamber. High amperage could indicate a mechanical problem, or it could indicate that there is an uncrushable obstruction inside the impact crushing chamber.
11. It is vital to check the impact crusher flywheel RPM both crushing and empty. The impact crusher RPM may have a factory recommended range. It’s important to maintain the impact crusher RPM guidelines to ensure maximum crushing power, efficiency and inertia. The flywheel RPM translates into crushing power along with the horsepower of the impact crusher motor.
12. Check the impact crusher rotor assembly from time to time to be sure it hasn’t moved on the impact crusher main shaft. If the rotor has become loose on the shaft it may move to one side and rub on the mainframe or mainframe liners.
13. The Impact crusher rotor, blow bars as well as blow bar wedges and fasteners will wear. Check for uneven wear which could be attributed to a variety of factors including improper feed. Material should be fed into an impact crusher evenly and as close to the center as possible.
14. Adjusting the impact crusher curtains can also reduce overall ear and maximize production.
15. In addition, blow bars in most impact crushers are the same part number. If so, operators may choose to flip or swap the blow bars. Flipping the blow bars so the bottom is now on the top can maximize blow bar life.
16. If blow bars become chipped, broken or cracked, it is important to rotate or replace them. Blow bars should be similar in size and weight to ensure the spinning rotor is balanced. If the rotor is operated out of balance premature bearing failure can occur.
17. Check the impact crusher side liners inside the crushing chamber, aka wear liners and replace as required. Waiting to replace the wear liners can be costly if they wear through and expose the main frame. The side wear liners are designed to wear and be replaced and protect the main frame.
18. Impact crushers may have hydraulic curtain adjustments. Periodically check hydraulics for leaks and make sure hydraulics are fully operational.
19. Impact crushers may also have hydraulic mainframe cylinders that open and close the main frame for inspection and repair purposes. Maintain hydraulic cylinders and routinely inspect.
20. The rotor houses the blow bars and is positioned on the impact crusher main shaft. The rotor will wear over time. Similar to blow bars, the wear on both sides and/or the circumference of the rotor must be similar. Rotos that wear unevenly can cause the crusher to become out of balance and cause premature bearing failure.
21. Some manufacturers allow and suggest that the rotor be hard faced from time to time to maximize longevity. Be sure to evenly apply the same amount of hard face to all sides to ensure the rotor is balanced.

Frequently Asked Questions (FAQs)

How often should crusher maintenance be performed?

Crusher maintenance should be performed regularly based on the type of crusher and its usage. Every manufacturer has factory recommended service intervals for their particular rock crusher. For most machines, this includes daily inspections like checking oil levels and wear parts.

More extensive servicing should be performed based on servicing hours. Establishing a consistent maintenance schedule, including predictive maintenance, helps reduce the risk of breakdowns and extends the equipment’s service life.

Grease intervals could be daily or based on the hours, factory guidelines and/or the severity of the environment.

If the rock crusher is diesel powered, adhering to the diesel manufacturer guidelines is imperative. Maintaining air filters, fuel filters, oil and oil filters is cheap insurance. Simple and routine maintenance on any crusher will translate into more uptime and add to the longevity of the machine.

How can I extend the life of cone crusher liners?

To extend the life of cone crusher liners, ensure the machine is choke-fed, avoid overfeeding and maintain proper lubrication. Operators should also monitor wear patterns and replace liners before they are excessively worn to prevent damage to other components.

What is the recommended maintenance for an impact crusher?

Impact crusher maintenance includes regular inspection of blow bars, rotors, and aprons for wear and damage. Additionally, operators should monitor oil levels, belt tension and feed alignment. Overheating and contamination in the oil system can lead to mechanical failure. This makes regular oil changes and system checks essential.

Why is a crusher maintenance checklist important?

A crusher maintenance checklist ensures all necessary inspections and tasks are performed consistently, reducing the risk of unplanned downtime. Regularly following a checklist helps identify potential problems before they escalate. Creating a rigid and defined maintenance schedule will also allow all operators to understand exactly what should be done and what has been done.

Maximize Crusher Longevity with Regular Maintenance

We can’t stress enough the importance of preventative maintenance for rock crushers, concrete crushers and asphalt crushers. Operators who adopt regular maintenance schedules and follow checklists can maximize uptime, reduce costs, and extend the lifespan of their equipment.

It may sound like common sense, but experience has shown that many operators do not follow the crusher factory guidelines for maintenance. It defies all logic, but it is true. Many operators are so busy that they forego the maintenance in the hopes the crusher will continue to run. This is a mistake and eventually will lead to more serious issues.

As stated throughout this blog, having checklists and a routine maintenance schedule that’s’ easy to adhere to and understand, will ensure the longevity of the wear parts as well as the entire machine. If you have questions about a maintenance schedule or need help completing maintenance, feel free to contact us.