A detailed Jaw Crusher MONTHLY preventive maintenance Inspection checklist
1. General Inspection
2. Lubrication System
- Remove the reservoir cap.
- Check the oil level using the dipstick or sight glass.
- Add suitable oil to reach the recommended level.
- Replace the cap securely after topping up.
- Examine lines for cracks, abrasions, or leaks.
- Check connections for tightness and integrity.
- Use a flashlight to inspect hard-to-see areas.
- Clear any blockages using appropriate cleaning tools.
- Locate all grease fittings on the machinery.
- Use a grease gun to apply lubricant.
- Ensure each fitting is filled but not overfilled.
- Wipe off excess grease to prevent contamination.
- Drain old oil completely from the reservoir.
- Replace with new oil that meets specifications.
- Use a funnel to avoid spills during refilling.
- Dispose of old oil in accordance with local regulations.
- Remove the reservoir cap.
- Check the oil level using the dipstick or sight glass.
- Add suitable oil to reach the recommended level.
- Replace the cap securely after topping up.
- Examine lines for cracks, abrasions, or leaks.
- Check connections for tightness and integrity.
- Use a flashlight to inspect hard-to-see areas.
- Clear any blockages using appropriate cleaning tools.
- Locate all grease fittings on the machinery.
- Use a grease gun to apply lubricant.
- Ensure each fitting is filled but not overfilled.
- Wipe off excess grease to prevent contamination.
- Drain old oil completely from the reservoir.
- Replace with new oil that meets specifications.
- Use a funnel to avoid spills during refilling.
- Dispose of old oil in accordance with local regulations.
- Locate the oil filter and check for signs of clogging.
- Remove the filter using the appropriate tools.
- Install a new filter, ensuring proper sealing.
- Check for leaks after installation.
- Perform a visual inspection of all connections.
- Look for oil spots or residue under the equipment.
- Tighten loose fittings or replace faulty components.
- Document any repairs in the maintenance log.
- Remove a sample of oil for analysis.
- Check for unusual color, smell, or particles.
- If contamination is detected, replace the oil.
- Record findings in the maintenance log.
- Check the operation of the automatic lubrication timer.
- Inspect for proper delivery of lubricant to components.
- Listen for unusual noises that may indicate malfunction.
- Calibrate or repair the system as needed.
- Use a clean cloth to wipe each fitting.
- Purge old grease by applying new grease until clean.
- Ensure that no dirt or debris enters the fitting.
- Repeat for all grease fittings on the machine.
- Record the date and type of maintenance conducted.
- Note any observations or issues found during inspection.
- Include quantities of oil or grease used.
- Ensure entries are clear and legible for future reference.
3. Electrical System
4. Mechanical Components
- Check for visible wear patterns.
- Measure thickness using a caliper.
- Look for cracks or breaks.
- Replace if thickness is below minimum specification.
- Inspect for cracks or excessive wear.
- Ensure proper fit and alignment.
- Check for any unusual movement during operation.
- Replace if any damage is found.
- Inspect the flywheel surface for cracks.
- Check for signs of wear or deformation.
- Ensure mounting bolts are secure.
- Replace if any structural integrity issues are found.
- Check for excessive play by manually rotating.
- Listen for unusual noises during operation.
- Inspect for signs of lubricant leakage.
- Replace any bearings showing wear or noise.
- Remove the jaw plates carefully.
- Check for cracks, chips, or excessive wear.
- Measure the thickness against specifications.
- Replace if wear exceeds allowed limits.
- Reinstall securely, ensuring proper alignment.
- Inspect for cracks or significant wear.
- Ensure the toggle plate is not excessively worn.
- Check the toggle seat for proper fit.
- Replace components if wear is evident.
- Lubricate before reassembly as needed.
- Inspect the flywheel surface for cracks.
- Check for any unusual wear patterns.
- Ensure the flywheel is securely mounted.
- Test for any abnormal vibrations during operation.
- Replace if any damage is found.
- Check for any lateral or axial play.
- Listen for any unusual noises during operation.
- Lubricate bearings adequately as per specifications.
- Replace bearings if signs of wear are present.
- Ensure proper housing alignment during checks.
5. Safety Features
6. Operational Checks
- Start the crusher and observe its operation.
- Listen for any grinding, rattling, or irregular sounds.
- Pay attention to vibrations that feel different than normal.
- Shut down if any concerning noises are detected.
- Measure the output material size with calipers or a screen.
- Compare measurements to specified output size requirements.
- Adjust the settings on the crusher to achieve desired size.
- Retest output size after adjustments.
- Use a thermometer or infrared gun to check key areas.
- Monitor temperatures of bearings, motors, and hydraulic fluid.
- Record any temperatures exceeding normal operational ranges.
- Investigate and remedy any overheating issues.
- Inspect the conveyor belt for wear and tear.
- Check for proper alignment and tension of the belt.
- Observe the discharge flow of material.
- Listen for any unusual noises during operation.
- Examine the feed material visually and physically.
- Measure particle sizes to confirm they meet specifications.
- Remove any oversized or unsuitable material immediately.
- Document the condition of the feed material.
- Watch for any interruptions in the flow of material.
- Look for signs of material buildup around the jaws.
- Stop the machine if a blockage is detected.
- Clear any jams carefully following safety protocols.
- Visually inspect the jaw plates while the crusher is running.
- Look for signs of uneven wear or misalignment.
- Make adjustments if misalignment is observed.
- Ensure bolts are tight and secure.
- Inspect hoses and connections for signs of leaks.
- Check pressure gauges for normal operating ranges.
- Tighten any loose fittings and replace damaged parts.
- Document any abnormalities for follow-up.
- Observe the toggle mechanism during operation.
- Check for smooth movement and listen for grinding noises.
- Inspect for signs of wear or damage.
- Lubricate if necessary and replace worn parts.
- Inspect all safety guards and covers for integrity.
- Ensure all guards are securely fastened.
- Test functionality to confirm they operate correctly.
- Replace any damaged or missing guards immediately.
- Inspect the hydraulic oil level against recommended levels.
- Check for signs of contamination or discoloration.
- Top up oil if low and replace if contaminated.
- Document oil condition and levels.
- Pay attention to the sound of the crushing cycle.
- Note any variations in the operational rhythm.
- Investigate any disruptions or changes in performance.
- Document findings for future reference.
- Check the operation of the dust suppression system.
- Observe if dust is being effectively controlled.
- Inspect spray nozzles for clogs or malfunctions.
- Document any issues and corrective actions taken.
- Monitor the feed rate visually and via controls.
- Ensure it remains within specified limits.
- Adjust as necessary to maintain optimal performance.
- Document any deviations from normal feed rates.
Use in Manifestly