A standard woven wire mesh has a certain wire diameter, a square woven mesh with a crisscross pattern. As it wears, the openings become greater, going from a 3/4 inch opening to 1 inch in size. That will cause the aggregate to fall out of spec.

Also, as the wire diameter gets smaller and smaller, the mesh becomes weaker and more prone to breaking, causing the openings to become 1 3/4 inches by 3/4 inches, and again, the material is out of spec. Look for worn and broken wires and damaged crimps within the wire that are causing the screen mesh to move and allow larger material to pass through. Check the tension of the mesh. If the mesh is not tensioned properly, it will bounce around inside the screen deck and cause damage to itself and the surrounding screen box.

7. Engines and hydraulics

The engines and hydraulics systems should be maintained according to schedule. For example, greasing the bearings of the crusher, conveyor belts, screens, and feeders should be taken care of periodically to keep the machine in shape.

Frequency of service depends on the item. It could be weekly for greasing, 500 hours for an engine service, and 2,000 hours, depending on the manufacturer, for hydraulic service. These all should be done regularly, by schedule, as their need is not evident during visual inspection.

The manual will contain the specified intervals for lubrication or replacement of a certain part. Instead of having to hunt for a manual, many companies have their own maintenance logs, with their own servicing capabilities and trucks. If an interval checklist is posted inside a door to the machine, it can be reviewed on a daily basis, with a summary of what oil types are needed in what quantities and what the intervals are.

If the work is done by a dealer, the dealer will track the average number of hours on customer’s machines and visit the machines to carry out the service. Ultimately, the dealer should know more about what long-term maintenance is required, while the operator can keep track of the daily maintenance. There is no substitute for a dealer’s in-depth knowledge via a qualified, trained mechanic who can give the machine a complete health check.

If your manufacturer offers training classes, so much the better. Operational and maintenance training should be part of the initial commissioning of the plant, but the operator should attend a formal training program sponsored by the manufacturer to truly optimize maintenance and service.

Summary

Maintenance of mobile crushers for optimum production is not only about when the task is performed, but also how it is performed.

Unless the person making the checks has the training and knowledge to effectively take care of the machine, downtime will be increased and production decreased.

For optimum uptime, a thorough maintenance program will ensure a dependable machine for years to come.

Paul McLaren is product support manager for Kleemann.