Our National Product Support Manager for Crushing and Screening has provided some cost saving tips on parts and maintenance for your equipment.
Operating heavy machinery is no small task; it involves countless moving parts that must work in perfect harmony to ensure smooth operation. Maintaining these machines can be a daunting task, but it's critical for the longevity of your equipment and the safety of your staff. Here are some ideas to help you keep your heavy machinery in top condition. Our National Product Support Manager for Crushing and Screening Jason MacDonald has provided some cost saving tips below. Follow him on Linkedin for further insight on running your equipment.
Given the high operational costs associated with heavy machinery, regular safety and operational inspections are crucial. These inspections help detect potential problems early, preventing costly repairs and downtime.
Here are a few tips on how to carry out adequate inspections:
Inspect all parts of the machinery or equipment, not just the visible ones
Pay attention to any unusual noises or vibrations
Look for any signs of wear and tear, such as cracks or chipped paint
Check for any loose bolts or other fasteners
Take note of any oil or fluid leaks
Remember, every piece of equipment will eventually need repairs, and if you're not proactive about catching problems, the damage can become extensive. So, make it a habit to perform regular inspections on your machinery.
Replace Parts When Needed
Maintaining optimum equipment performance heavily depends on replacing old and damaged parts when necessary. Any delay in this regard can escalate the situation, posing financial and safety risks to your business.
By replacing smaller parts before they fail, you extend the life of your assets and avoid even more expensive repairs or replacements down the line. However, when replacing parts, ensure to use only high-quality components designed for your equipment’s specific make and model. Using substandard parts can lead to further problems down the road.
Have Critical parts on hand:
Nuts and bolts, washers
Tyres, track plates
Jaw plates, cheek plates, toggle plate
Cone liners, backing compound
Blow bars, tiles, wedges
JAW CRUSHER - Wear liners
In order to maintain maximum production you should only run your jaw liners down to 10-20% of its original profile height. You might think you're getting your moneys worth but if the face is smooth you are losing production and putting extra stress on the crusher.
CONE CRUSHER - Wear liners
Change them out when you start see a >=10% loss in production.
If the liners have worn evenly it is time to change out the liners when there is about 25mm left at the bottom of the liner. Once it wears down to <19mm or <16mm you will generally see cracking of the liner, causing the backing material to start breaking up and this can lead to the liner coming loose. If the liner comes loose and the cone continues to operate, the head of the cone or the seat on the support bowl can be badly damaged.
On some cones wear can be determined by the pin to pin centre distance on the tramp cylinders. Liners must be changed when the hydraulic rams cannot be fully closed.
Other cone crushers have automatic liner changeout reminders. The reminder is reset when a new set of liners are installed and then tracks the wear and sends an "alarm" when it is time to change the liners.
It is not productive or efficient to try and get the last bit of wear out of your liners once they have passed their useful life. Best to change it out in a planned situation and not in a breakdown situation where there could be damage to the crusher parts.
IMPACT CRUSHER - Blow Bars
Many impactors require the bars to be changed or turned when there is a minimum of 25-30mm sitting proud of the rotor. If you try to wear them further in most models, it will result in wear to the rotor which can be a very expensive repair, requiring welding to build up the worn sections and dynamic balancing afterwards of the rotor.
Before doing a Blow Bar change
Read the manual to make sure all safety procedures are understood
Determine whether you will be running all high bars or high and low bars combination
Lock Out / Isolate the engine
Undo all fastening bolts for the moveable lid
Lock the rotor to prevent unwanted movement
Lock the lid to prevent crush injuries
Make sure that the weights of the bars are known and that the difference in weight is 1 kilogram or less for bars opposite each other
Label / Number the bars so that they are put into the correct position
Ensure you have the correct tools for lifting the bars - slings, chains, d-shackles, lifting bar and that they are rated correctly for the job
Never work under a suspended load
Pull aprons back
Check behind aprons for build-up of material - clear if necessary
Check side liners and aprons for wear or damage - replace if necessary
Undo and remove wedges
Fit new bars, fit wedges and tighten
Check skirts / rock box under crusher for signs of wear or damage
Close lid, lock lid, open inspection door
Make apron adjustments
Turn rotor by hand to ensure the new bars don't hit the aprons or rub on the edges.
Close and lock inspection door
Fire it up and start production
The result of not scheduling preventative maintenance is that the equipment will usually choose the least appropriate time for a breakdown.
When taken on its own, 1 piece of equipment probably doesn't cause too many issues but in the case of a crushing train it may result in 8 or more pieces of equipment parked up and enormous losses of production and revenue.
The true cost of running unreliable / unmaintained equipment is usually 4-15 times more than the repair cost. Contact our Product Support Manager for Crushing and Screening Jason MacDonald for help with required parts and advice for your machines. We also have a National Parts and Service team in 8 locations around Australia.