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.

Inspect Regularly

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
• Filters
• Fluids
• Safety relays
• Fuses
• Tyres, track plates
• Wear parts
• Jaw plates, cheek plates, toggle plate
• Cone liners, backing compound
• Blow bars, tiles, wedges
• Drive belts
• E-stops
• Hydraulic motors
• Skirt rubber
• Conveyor rollers

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.

‍