Mobile crushers (tracked mobile jaw, cone and impact crushers) and mobile screens are machines that can be brought to site and start producing quickly without installation work, and are widely used in quarries, construction and demolition waste recycling and temporary projects. This flexibility, however, brings extra maintenance responsibilities: besides the crusher and screen, a mobile machine also has a diesel engine, an extensive hydraulic system, a tracked undercarriage and folding conveyors. A failure in any of these systems means the whole machine stops.
In this guide we cover best-practice maintenance of mobile crushers and screens under the headings of daily checks, engine, hydraulics, tracks, conveyors, wear parts, transport, winter conditions and long-term parking. For choosing between mobile and fixed plants, see our mobile or fixed guide.
Types of Mobile Crusher and Their Applications
| Machine | Duty | Typical Application |
|---|---|---|
| Mobile jaw crusher | Primary crushing | Quarries, concrete and demolition waste recycling |
| Mobile cone crusher | Secondary and tertiary crushing | Chippings production from hard, abrasive rock |
| Mobile impact crusher | Primary or secondary crushing | Limestone, asphalt and concrete recycling |
| Mobile screen | Classification | Product fractioning, pre-screening |
| Mobile scalper | Heavy pre-screening | Soil, overburden, demolition waste |
The crushing principle of each machine is the same as its fixed equivalent, so our jaw crusher, cone crusher, impact crusher and vibrating screen guides also apply to mobile machines.
Daily Checklist
| System | Check |
|---|---|
| Diesel engine | Oil level, coolant level, fuel, air filter indicator, leaks, belt condition |
| Hydraulics | Oil level and temperature, hose and fitting leaks, filter indicators |
| Coolers | Dust build-up on radiator and oil cooler cores |
| Crusher | Wear parts, setting, lubrication (oil temperature and pressure on cone crushers) |
| Conveyors | Belt tracking, scrapers, idlers, material build-up |
| Screen | Screen surfaces, tension, springs, bearing temperature |
| Tracks | Tension, loose bolts, damage |
| Safety | Emergency stop buttons, guards, warning systems |
| Lubrication | Grease points or the automatic lubrication system reservoir |
Diesel Engine Maintenance
- Air filter: In a crushing environment the air filter is the most critical maintenance item. A dirty filter reduces engine power and increases fuel consumption; a holed or incorrectly fitted filter lets dust into the engine and causes heavy damage in a short time.
- Oil and filters: Engine oil and filters should be changed at the manufacturer’s intervals. Oil analysis allows dust ingress to be detected early.
- Fuel system: Use clean fuel, drain the water separator regularly and change fuel filters.
- Cooling system: Keep radiator cores clean and check the antifreeze ratio.
- Exhaust after-treatment systems: Newer engines may have diesel particulate filters and exhaust fluid systems; follow the maintenance instructions for these systems.
Hydraulic System
On mobile machines the hydraulic system is used for the track drive, conveyor and screen drives, feeder, crusher setting and folding mechanisms. The cleanliness of the hydraulic oil determines the life of the system. Filter changes, the tank breather filter, hose checks and cleaning of the oil cooler should be carried out regularly. For detailed information see our hydraulic system maintenance guide.
Tracked Undercarriage
- Track tension: Over-tight tracks increase wear and fuel consumption; slack tracks can come off. Tension should be set to the manufacturer’s value.
- Rollers and wheels: Carrier rollers, track rollers, the idler and the sprocket should be checked for wear and oil leaks.
- Cleaning: Stone and mud building up inside the tracks causes damage, especially in freezing conditions.
- Travel gearbox: Track the oil level and change interval.
- Travel distance: Mobile crushers are not designed to track long distances; use a transporter for long moves on site.
Conveyors and Folding Mechanisms
The product, side and main conveyors of mobile machines consist of the belt, idlers, pulleys, scrapers and hydraulic drive motors. The pins and bushings of the folding mechanisms should be greased regularly. For belt tracking and scraper adjustment see our belt conveyor guide and belt scrapers guide.
Wear Parts
| Machine | Main Wear Parts | Guide |
|---|---|---|
| Mobile jaw crusher | Jaw plates, cheek plates, toggle plate | Jaw plates |
| Mobile cone crusher | Mantle, concave, feed plate | Mantle and concave replacement |
| Mobile impact crusher | Blow bars, apron liners, side liners | Blow bars |
| Mobile screen | Screen wire, polyurethane panels, tensioning rubbers | Screen surface selection |
| Feeder | Grizzly bars, hopper liners | Feeder types |
In recycling applications, rebar in concrete can damage wear parts and conveyors; the mobile machine’s magnetic separator and belt protection arrangement should be checked (magnetic separator guide). On mobile cone crushers, mantles and concaves that need backing are best re-seated with our own Aurox backing compound.
Transport and Moving on Site
- Before transport, conveyors must be folded and secured and hopper extensions lowered.
- Loading onto and unloading from a low-loader should be done on flat, firm ground, with a suitable ramp and an experienced operator.
- The machine must be secured with chains and tensioners during transport.
- Transport height and weight must comply with road regulations.
- When tracking on site, check ground slope and firmness, and keep pedestrians away from the machine.
Winter Conditions
- Use engine and hydraulic oils, antifreeze and fuel suitable for cold weather.
- Hydraulic oil must warm up before work begins; running under high load with cold oil damages the pump.
- At the end of the day, empty the conveyors and screen to stop wet material freezing.
- Clean mud from the tracks and conveyors.
- Check battery condition.
Long-Term Parking and Preservation
- Clean the machine and empty all material from the crusher and screen.
- Keep the fuel tank full to prevent condensation.
- Disconnect the battery or keep it on charge.
- Protect exposed hydraulic cylinder rods.
- Run the machine briefly at intervals to prevent false brinelling and corrosion in the bearings.
- Before returning to service, check all fluids, filters and safety systems.
Best Practice: Increasing Productivity
- Correct feeding: Feed the crusher opening with suitably sized material, continuously; the excavator operator should keep the feed even.
- Pre-screening fines: Fines should bypass the crusher through the feeder’s pre-screen grizzly or a pre-screen.
- Crusher setting: Check the setting regularly against product requirements.
- Telematics: Remote monitoring systems on many modern machines allow fuel consumption, operating hours, fault codes and maintenance times to be tracked (automation and remote monitoring).
- Maintenance records: Record all maintenance and failures; these records also increase resale value.
Frequently Asked Questions
What is the most critical maintenance item on a mobile crusher?
Because of the dusty environment, the air filter, cooler cleanliness and hydraulic oil cleanliness are the most critical issues.
How far can a mobile crusher be tracked?
Mobile crushers are designed for short distances on site; over long distances they should be moved on a low-loader.
Are wear parts on a mobile crusher different from a fixed crusher?
The crushing principle is the same; the parts are specific to the machine model. Material should be selected according to rock type.
What is the most common problem on mobile screens?
Screen surface blinding, wire breakage due to incorrect tension and material build-up on conveyors are common problems.
Critical Spare Parts List for Mobile Crushers
| Group | Parts | Note |
|---|---|---|
| Crusher wear parts | Jaw / cheek plates, mantle–concave, blow bars, apron liners | Metallurgy suited to the rock |
| Crusher mechanical parts | Toggle plate, tension springs, bearings, seals | By model and serial number |
| Engine service parts | Air, oil and fuel filters, belts | A set for each service interval |
| Hydraulics | Filters, hoses, cylinder seal kits | Frequently replaced hose sizes in stock |
| Conveyors | Belt, idlers, scrapers, drive pulleys | For product and side conveyors |
| Screen | Screen wire or panels, springs, tensioning parts | For each deck |
| Feeder | Grizzly bars, hopper liners | Impact wear |
| Tracks | Track chains, rollers, sprocket | May have long lead times |
For wear and mechanical parts for your mobile crushers, see our jaw crusher, cone crusher and impact crusher spare parts pages; for conveyor and screen parts see our belt conveyor and vibrating screen spare parts pages. For the toggle plate and tension system, see our toggle plate and tension springs guides.
Example Periodic Maintenance Plan
| Interval | Tasks |
|---|---|
| Daily / every shift | Visual inspection, fluid levels, grease points, cooler cleaning, wear parts |
| Weekly | Belt tension and tracking, screen tension, track tension, bolt checks |
| By engine hours (manufacturer intervals) | Engine oil and filters, fuel filters, air filter |
| Hydraulic interval | Hydraulic filters, oil analysis, oil change if required |
| Annual | Comprehensive inspection, bearing checks, electrical system, safety systems |
Glossary
- Tracked chassis: The undercarriage of a mobile machine.
- Scalper: A heavy-duty coarse pre-screen.
- Bypass conveyor: A side conveyor that carries fines around the crusher.
- Telematics: Remote monitoring of machine data.
- Low-loader: A trailer for transporting heavy machinery.
More Questions
Why is maintenance by engine hours important on a mobile crusher?
Maintenance intervals for mobile machines are usually set by engine operating hours; tracking hours ensures maintenance is done on time.
How should a mobile crusher and mobile screen be set up together?
Conveyor heights and distances should be set so that material flows between the machines without interruption, and stockpile areas and loading routes should be planned in advance.
What should be done to protect a mobile crusher in recycling?
Correct operation of the magnetic separator, removing large steel in advance and choosing suitable wear parts are important.
CSP Mühendislik Support
CSP Mühendislik supplies wear and mechanical spare parts and provides service, maintenance and repair for mobile jaw, cone and impact crushers and mobile screens. For your parts requirements, see our jaw crusher spare parts, cone crusher spare parts, impact crusher spare parts and vibrating screen spare parts pages.
