Reactive maintenance is the most costly type of maintenance and should be avoided at all costs. This maintenance is performed when the machine is not operating within its specifications and a determination is made that maintenance is needed. This will not only involve cost for an individual repair and/or part, but will involve the downtime of the machine. This type of maintenance can be costly; it should be seen as a last resort to the problem.

Lastly, remember that operators should always consider safety as a part of their routine. Every job you do has the potential to result in serious injury, so make sure all maintenance plans ensure safety is the top priority. Identify all hazards and make sure all operators know what their role is in the safety of maintenance procedures. Block out all components against movement and tag out equipment when necessary. Always use a “what-if scenario” to anticipate every possibility, and make sure all operators are trained in this and have a plan for each event. Most importantly, make certain the team always uses proper safety equipment and is trained in that equipment. Using a crusher maintenance program will not only save you money and time, but quite possibly a life. It’s that important. AM

Cone Crusher Guidance

Bowl float (aka: ring bounce or upper frame movement) — Most cone crushers employ a tramp iron relief (TIR) system to allow the passing of an “un-crushable” should it enter the crushing chamber. This is typically accomplished by absorption of the energy through hydraulic cylinders, accumulators, springs, or relief valves. These systems are NOT designed for continuous overloading. This is all too often seen due to misapplication of the crusher outside of its designed operating parameters, such as reduction ratio, liner configuration, excessive fines, etc. The most common problem is simply operating the crusher at too small of a closed-side setting.

Horizontal Shaft Impactor (HSI) Do’s and Don’ts

• Do check the rotor for wear after making a speed adjustment. Checking the rotor for wear will ensure that you are not over-penetrating and wearing the rotor.

• Do check for excessive horsepower draw or loss of production after making an apron (curtain) adjustment. Improper curtain settings can cause high horsepower demand and low production rates.

• Do provide well-graded input feed to the crusher. This will maximize production while minimizing wear costs.

• Do properly prep the feed when crushing recycled concrete with steel. This will reduce plugging in the chamber and blow bar breakage.

• Do monitor the wear in the crusher daily. Abrasive material, tight settings, and uncrushables can accelerate wear.

• Do make adjustments for the aprons in small increments. Smaller adjustments allow you to achieve the desired results quicker.

• Do lubricate crusher bearings daily per the manufactures recommendations. New grease keeps dirt out of the bearings and extends bearing life.

• Do flip the blow bars before they are less than 3/4-inch above the rotor. Be sure to readjust the aprons before operating the crusher.

• Don’t exceed a reduction ratio of 12:1 to 18:1. Excessive reduction ratios reduce production rates and shorten crusher life.