The crusher is the first machine in the cement process, so when it stops, everything downstream eventually starves. Liners and blow bars wear, bearings run warm, hydraulics leak and tramp metal arrives without notice. Most of these problems can be caught on a planned round long before they interrupt the kiln feed. This checklist gives crushing crews a repeatable preventive routine with clear limits and escalation steps, and maintenance management software keeps each inspection and repair traceable to the asset.
Quarry and Crushing Reliability
Cement Crusher Preventive Maintenance Checklist
Field checks, condition indicators and maintenance actions for jaw, impact, hammer and gyratory crushers in cement plants.
Every shiftSound, temperature, leaks, feed and choke checks
WeeklyWear parts, belts, guards, lubrication points
MonthlyBearings, fasteners, hydraulics, vibration route
OutageLiner change, shaft and frame inspection
Know Your Machine
Where Each Crusher Type Usually Fails
Use the manufacturer manual for limits. This table shows where to focus checks by crusher type.
| Crusher type | Wear focus | Common problems |
|---|---|---|
| Jaw crusher | Jaw plates, toggle plate, cheek plates | Wear, wedge bolt loosening, bearing heat, flywheel issues |
| Impact crusher | Blow bars, impact aprons, side liners | Rotor imbalance, loose wedges, uneven wear, blockage |
| Hammer crusher | Hammers, grate bars, pins | Grate plugging, hammer wear, rotor imbalance |
| Gyratory crusher | Mantle, concave, spider, eccentric | Oil system faults, wear, hydraulic adjustment problems |
Inspection frequency key
SEvery shift
WWeekly
MMonthly
OOutage
Section 01
Feed, Operation and Safety Checks
Feed condition observed for oversize rock, tramp metal, sticky material and uneven loading across the chamber.
Escalate if: oversize or metal reaches the crusher. Stop, clear and report the source.
Motor current, throughput and product size compared with normal range. A rising current at the same feed rate points to wear or a setting issue.
Escalate if: current trends up or product gets coarse. Check settings and liners.
Metal detectors, magnets and protective devices confirmed working, along with emergency stops and pull cords.
Escalate if: any device is faulty. Do not run without it.
Guards, walkways and access points in place. Clear spillage around the crusher, and confirm isolation and lockout points are readable.
Escalate if: a guard is missing or damaged. Restore before operation.
Section 02
Wear Parts and Liners
NewRoutine checks
WornOrder parts, plan change
LimitReplace at next window
Jaw plates, blow bars, hammers, mantle or concave measured for remaining thickness and compared with the wear limit and last reading.
Escalate if: wear is ahead of plan. Order parts and schedule the change.
Fixing wedges, bolts and clamps checked for looseness or damage. Loose liners can move and damage the frame.
Escalate if: a liner has moved or a bolt is missing. Stop and reset.
Closed side setting or gap measured and recorded, with adjustment done by procedure after wear.
Escalate if: the setting cannot be held. Inspect the adjusting mechanism.
Wear pattern reviewed for uneven or accelerated wear, which may indicate poor feed distribution or a wrong material grade.
Escalate if: a pattern repeats. Raise a reliability review.
Schedule Crusher Rounds Without the Paper Trail
Oxmaint turns preventive routines into scheduled work orders with mobile checklists, wear readings and photos attached to each crusher.
Section 03
Bearings, Shaft, Flywheel and Lubrication
Bearing housing temperatures recorded or scanned and compared with baseline at similar load.
Escalate if: a bearing runs hotter than its trend. Check lubrication and vibration.
Grease points or circulating oil system checked for correct lubricant, level, flow and leaks. Record quantities applied.
Escalate if: a point is dry or oil flow is low. Stop and correct.
Vibration measured on bearings and frame, watching for rotor imbalance, looseness or bearing defects.
Escalate if: readings rise against baseline. Analyse and plan inspection.
Flywheels, pulleys and V-belts inspected for cracks, wear, tension and guard fit. Check that belts are matched sets.
Escalate if: cracks, glazing or slipping is found. Replace before failure.
Main shaft, eccentric or rotor assembly inspected during outages for cracks, wear and seal condition.
Escalate if: cracks or scoring are found. Involve engineering before restart.
Section 04
Hydraulics, Frame and Dust Control
Hydraulic hoses, cylinders, accumulators and oil level checked for leaks, damage and pressure loss.
Escalate if: pressure will not hold or a hose is damaged. Isolate and repair.
Frame, welds, foundations and anchor bolts inspected for cracks, movement and corrosion.
Escalate if: a crack is found. Stop and assess.
Dust extraction, sprays and seals working, with covers intact. Dust ingress shortens bearing and seal life.
Escalate if: dust escapes or extraction is weak. Check filters and ducting.
Discharge conveyor, apron feeder and chutes inspected for blockage, wear and spillage that could back up into the crusher.
Escalate if: build-up is frequent. Raise a corrective job for the chute or feeder.
Measure It
Crusher Reliability KPIs
PM complianceTasks done on time against plan
Unplanned stopsHours lost to breakdowns and blockages
Wear part lifeTonnes crushed per set of liners
Repair backlogOpen corrective jobs by age
Oxmaint capabilities for crusher maintenance
- Recurring preventive maintenance schedules by running hours or calendar.
- Mobile inspections, work orders and photo evidence.
- Asset history for liners, bearings and hydraulic components.
- Spare parts tracking and dashboards for overdue and repeat work.
Frequently Asked Questions
How often should a cement crusher be inspected?
Operators check each shift, with weekly wear checks and monthly deeper inspections. Set intervals by duty.
What causes premature liner wear?
Uneven feed, wrong material grade, abrasive rock and poor settings are common causes.
Should crusher PM follow hours or dates?
Running hours suit wear items. Calendar tasks suit inspections. Try Oxmaint to use both.
How do we reduce tramp metal damage?
Keep magnets and detectors working and log every event with its source for follow-up.
Can this checklist be used on mobile?
Yes. Book a demo to see mobile checklists for quarry and crushing assets.
Keep the First Machine in the Process Running
Use Oxmaint to schedule crusher inspections, track wear parts and turn every finding into a planned work order.
