CLEANLINESS IS KEY.
Keep oil systems free of contamination. Clean out any sludge buildup in the tank to prevent contamination of the new oil. Also, changing the oil requires clean buckets, clean rags, and storage in a clean environment. Keep the breathers clean as well; and keep the right gaskets and oil filters on hand. Don’t run oil filters into the “red.” Always have the right replacement parts and cleaning components set aside and ready to go.
Wash out the toggle seats and plates daily, as wet material buildup results in a gritty compound that grinds down components, causing premature wear.
Remove dirt and debris from crusher frame surfaces and from areas around the machine. Monitor discharge chutes for obstructions and check for material buildup under the jaw to avoid excessive wear on the pitman.
CONDUCT REGULAR INSPECTIONS.
Conduct daily, weekly, and/or monthly recommended inspections. Check jaw dies daily, making sure that bolts are kept tight. Check cheek plates for any excessive wear that may affect the mainframe of the jaw. Monitor flywheels for cleanliness, tightened bolts, and potential cracks; and make sure drive belts aren’t worn or cracked.
MONITOR OPERATIONS & LOG DATA.
Log amperage draw to see if it changes from day to day. If amperage exceeds normal levels, it could be a signal of bearing problems or loose belts. Log coast-down times daily. How long does it take the machine to come to a dead stop? If the time starts to shorten, this could indicate a bearing problem. Check all indicators and switches daily for proper operation – as they are integral to proper shut-down in the event of issues such as high temperatures or low hydraulic pressures.
DON'T OVER-EXTEND WEAR PARTS.
Avoid running jaw dies until they become too thin. You may find that you can no longer flip them over – and now, you've lost half the wear. To get the full life of the manganese, change them out sooner than later.
UPDATE YOUR EQUIPMENT.
As an example, Macini points to modern crusher designs (such as the Telsmith 3258), which incorporate hydraulic tensioning cylinders that replace conventional toggle tension rods and springs. As a result, the tension cylinders automatically maintain the proper tension on the toggle, eliminating the need for spring adjustment. With proper tensioning being automatic, producers save time as well as reduce wear and tear on parts. Furthermore, two oversized hydraulic cylinders behind a moving toggle beam enable all closed side setting (CSS) adjustments. A flip of a switch extends or retracts the cylinders and the adjustment is complete – and made safely without shims being needed at any time.
DEVELOP A MAINTENANCE DISCIPLINE.
Ditch the shortcuts! As with anything, you get out of it what you put into it. Learn to do maintenance jobs right the first time, and continue the discipline throughout the life of the equipment. The payoff is time and cost savings, and a far safer working environment.