Rock crusher equipment is put through a great deal of wear and tear, and proper maintenance is essential to ensure it functions efficiently. Regular maintenance checks and services are necessary to keep your rock crusher in excellent condition. But what exactly needs to be done to keep your equipment operating at peak performance?
Rock Crusher Maintenance
Rock crushers, especially those found in quarries, break down materials through pressure or impact. The surfaces that come in contact with the materials must be extremely strong, so the crushing chambers are lined with steel strengthened with manganese.
Manganese is used because of this element’s unique property: the harder it is struck, the harder it becomes. This means that manganese parts can take a lot of stress and wear over the years without cracking or breaking down.
However, these steel/manganese liners eventually wear through, so keeping an eye on them and replacing them when necessary is essential.
So, what does that mean? Should you wait until the liners are completely worn out before you replace them? While it might seem like the most cost-effective option, you’ll find that the decline in production and efficiency when your liners are worn is much more expensive than replacing them.
Instead, it’s recommended that you change out the manganese liners as soon as you notice a 10% drop in production. Also, ensure you have all the parts you need before you begin work on exchanging the old liners. Otherwise, the downtime and delays could cost you even more money.
Other Rock Crusher Maintenance Tasks
Besides keeping an eye on the manganese liners, there are other things you should do to keep your rock crusher in good condition, such as:
- Regularly inspecting parts such as wear plates, blow bars, and shoes and anvils for wear and tear.
- Lubricating the moving parts, such as bearings and shafts, with grease to ensure proper functioning.
- Checking oil and filters daily and changing them based on the manufacturer’s recommendations.
Screening Equipment Maintenance
Screens are a critical component of your rock crusher equipment system, as they separate aggregates based on size. Like rock crushers, screens must be regularly maintained to ensure efficient operation and peak performance.
Since they use intense vibrations to do their work, they’re prone to becoming unbalanced and wearing out over time. The most important thing to watch out for is the integrity of the screen media.
Changing Screen Media
Screen media refers to the part of the screen that separates the aggregates, and it wears out over time. The time it takes to wear out will depend on what the media is made from: wire cloth, rubber, or urethane.
If you wait too long, worn media can damage the other components of the screening equipment, so follow the manufacturer’s recommended schedule. You can extend the life of the screen media by ensuring that it is adequately supported and tensioned.
Other Screening Equipment Maintenance Tasks
Besides changing out media, there are other tasks you should do to keep your screening equipment in top condition, including:
- Checking and changing the oil by following the manufacturer’s recommendations.
- Cleaning the equipment to prevent dust and stone from accumulating and contaminating the oil or damaging components such as support springs and pivot motor bases.
Conveyor Maintenance
Conveyors are integral to rock crusher equipment systems because they keep the material moving from one processing stage to the next. Without proper maintenance, conveyors can become clogged or jammed and cause unplanned downtime.
Belts and Rollers
The most critical components of a conveyor system are the belts and rollers, which move the material along. To keep them working optimally, you should inspect them regularly for any signs of wear or damage. If you find any problems, replace the worn parts immediately to prevent further damage.
Note that belts must rarely be changed completely unless they’ve suffered significant damage. However, the belts must be cleaned regularly to keep the system working efficiently. Scraping is usually the preferred method. You can make rubber scrapers in-house for the operation.
Another option is to install special belt scraping assemblies on the conveyor to make this process easier. With one of these systems, all you have to do is change out the scraping blades once they become worn.
Just as belts must be kept clean, the rollers must also be cleaned and lubricated regularly. Otherwise, dirt and debris accumulates in the grooves and causes premature wear.
Maximize Rock Crusher Equipment Performance with Expert Maintenance Services from Mellott
Regular maintenance ensures your rock crusher equipment remains in peak working condition. Checking manganese liners, lubricating moving parts, changing screen media, and cleaning conveyor belts and rollers are all essential elements of a maintenance program for rock-crushing systems. Taking care of these tasks regularly ensures your equipment operates at its best and continues to provide your business with high-quality materials.
However, if all these tasks seem too daunting, you can trust Mellott’s maintenance services to keep your rock crusher equipment in top condition. Our team of experts has repaired and rebuilt thousands of crushing systems and is dedicated to helping you maximize your equipment’s performance. Contact us today at (855) 554-1606 for more information or to schedule a service appointment.
