Maximising the lifespan of a crusher is crucial for optimising operational efficiency and reducing maintenance costs. By implementing proper maintenance practices, ensuring correct operation, and wear-prevention strategies, crushers can perform at their best for longer periods. Regular inspections, servicing and the timely replacement of wear parts are essential for extending your equipment’s service life, reducing downtime, and improving overall productivity.

Check out our tips and tricks below to help maximise your crusher’s lifespan.

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Feed Material & Loading Best Practices

· Consistent feeding prevents stress on the main shaft and bearings and helps avoid dumping large, uneven loads.

· Where suitable, pre-screen to remove fines andreduce wear inside the crushing chamber.

· Oversized rocks cause excessive wear, so consider pre-crushing or using a scalping screen and carefully selecting oversize material.

· Monitor moisture content. Wet or sticky materials can cause blockages, so look at pre-drying options.

Regular Jaw Crusher Maintenance Tips

· Inspect jaw plates daily as uneven wear may indicate feeding issues.

· Rotate or replace jaw and side plates before they become too thin to avoid damage to the crusher frame.

· Check toggle plate tension to ensure proper jaw alignment.

· Lubricate bearings regularly but avoid over-greasing, which can cause heat build-up.

· Inspect the pitman arm and bushings for cracks, excessive play, or leaks.

Cone Crusher Maintenance Tips

· Monitor liner wear (mantles & concaves) and make sure to rotate and replace at the appropriate intervals.

· Closed Side Setting (CSS) adjustments can impact performance. If they are too tight it will create excessive liner wear, too wide and you’ll have poor crushing efficiency.

· Check oil quality and levels regularly as dirty oil can lead to overheating and bearing failure.

· Replace oil filters as needed. Clogged filters may indicate excessive contamination in the system.

Impact Crusher Wear Prevention Tips

· Inspect blow bars and rotor wear plates regularly and rotate or replace before they wear too thin.

· Keep the rotor balanced as unbalanced rotors can cause excessive vibration and bearing damage.

· Monitor bearing temperatures as high heat can indicate misalignment, overloading, or lubrication issues.

· Prevent material build-up inside the chamber as sticky materials and excessive fines can lead to blockages.

Crusher Conveyor & Discharge Maintenance

· Monitor belt tension and alignment to catch any misaligned belts that may cause excessive wear and slippage.

· Check conveyor rollers for material spillage to prevent belt damage and tracking issues.

· Keep discharge chutes clear as blockages can overload the crusher and cause damage.

Keep a Predictive Maintenance Schedule

· Follow daily, weekly, and monthly maintenance schedules to avoid major breakdowns.

· Use telematics and remote monitoring to help track vibration, oil levels, and operating hours.

· Maintain detailed maintenance logs to identify wear trends and plan proactive replacements.

· Book Onetrak’s skilled service technicians to regularly inspect and service your plant.

As always, you can contact our skilled service technicians to help maintain your crusher and to offer expert advice for maintaining your machines for longer.