As we saw in 91������ Service Manager John’s recent Service Questions, a common area on rock crushing equipment that leads to constant questions is the conveyors. From conveyor belts not staying aligned to head pulley slippage, there are various items on the conveyors that require preventative maintenance and routine checks. Service Technician, Dakota, will run through the various questions that come from conveyor maintenance.

Conveyor Maintenance at a Glance

Common issues with conveyors involve the belt. For this Service Question, we will focus on the conveyor belt itself and not the motors or bearings involved in the pulleys. A common issue is the conveyor belt not staying centered. This can be caused by:

• Uneven Loading
  • To fix this, you should adjust the loading to be more even by dumping from a chute to the center of the conveyor belt.
• Worn or Misaligned Components (Pulleys, Idlers)
  • Check for worn or misaligned components by inspecting all pulleys and idlers to ensure they are free of any built-up material and ensure that the pulleys and idlers are properly aligned.
• Incorrect Tension or a Crooked Belt Splice

��How often should conveyor belts be inspected or spliced?

Conveyor belts should be inspected daily to ensure the health and performance of the conveyor. You should be looking for various types of conveyor belt damage, such as cuts, frays, cracks, and wear. Make sure to clean off any debris buildup on the belt, pulleys, and rollers. Also, do a visual inspection to see if the conveyor belt is tracking straight and the splice is in good condition. Listen for unusual noises while in operation, such as grinding or squeaking, which could be misaligned or failing components.

How do I set proper belt tension?

Put marks on the nontensioned belt at exactly 1000 mm from the splice. The marking must be done on the left and right side of the conveyor belt. Tension the belt and let it turn a few times to equally divide the tension. Then, measure the elongation and adjust the belt tension if necessary. See your owner’s manual for the recommended elongation of the conveyor belts.

What is causing slippage at the head pulley?

To drive a conveyor belt without slippage, and to track it in a proper way, a certain tension of the conveyor belt is necessary. See your owner’s manual for the recommended tension.

Built up materials such as fines material will increase the friction between the conveyor belt and the head pulley, so it is very important to clean your conveyor properly. If slippage continues the belt could damage the lagging of the head pulley by rubbing it smooth, causing it to struggle to grip the conveyor belt.

An example of a head pulley that is missing half the lagging.

How can I reduce material buildup under the conveyor belt?

You can reduce the buildup under a conveyor belt by ensuring the belt flashing or skirting is in good condition and making good contact with the conveyor belt. The skirting is adjustable by clamp plates. To adjust the skirting to avoid gaps in the flashing, simply loosen the clamp plates and pull the skirting down. If you can no longer pull the skirting down, you need to order new belt skirting.

After you have made sure your belt skirting is adjusted properly, inspect your belt scrapers and ensure they are making good. If the belt scrapers are not making good contact, adjust the scraper toward the belt by loosening the tensioner retainer screw and put tension on the scraper. You can do that by using a wrench to build tension, then tightening the retainer screw back down.

Don’t Let the Tension Get to You – Reach Out!

As you already know, a simple-looking part in rock crushing equipment doesn’t always mean it’s immune to preventative maintenance. What is simple is knowing the resources available to you. Not only do you have your owner’s manual, but you have a network of authorized dealers, a team of 91������ parts experts, and 91������ Service Technicians ready to help keep your tension to a minimum.

The post The Tension with Conveyor Belt Maintenance appeared first on 91������.

It’s been a year since John stepped into the role of Service Manager. Throughout this time, he has established relationships with various authorized dealers and customers by answering their burning crusher questions. While answering these questions, he noticed several questions were recurring. To celebrate his first year as Service Manager, join John as he answers the top five frequently asked questions he’s received.

1. Why is my clutch fusible plug leaking fluid?
   • Your impactor may be getting overloaded and therefore overheating the clutch. The plug has a solder compound in it so that if the fluid in the clutch gets too hot, the fluid will leak out. This is done to prevent overheating and the possibly of causing permanent damage to the clutch.
   • Another solution would be to learn the proper flow of material for your machine to avoid overloading your impactor. Overloading your impactor causes a variety of issues, so it’s important to start with good practice to avoid any unnecessary downtime.

An example of good material flow.

2. Why isn’t my machine running evenly? Why are my conveyor belts wearing unevenly?
   • One of smallest differences that can cause significant issues in your machine is your machine not being level. If your machine is not level, it will cause material to shift and not run evenly through the plant. This can lead to belts leaking materials, flashings being worn out, wear plates and blow bars wearing unevenly and will affect the performance of the feeder and screen.

3. Why is there a gap in the flashing?
   • Flashing is adjusted to the belts when the unit is built and tested in the factory. Once material is on the belts, they have weight added onto them, causing the belt to sag. That is why you see gaps between the belts and flashing. After your first couple of runs, the skirtboard clamps will need to be loosened, and the flashing adjusted accordingly.

4. Why did my feeder shut off, and my code says low voltage? Is it because there’s too much material on my screen?
   • When it comes to the feeder shutting off, most of the time the drive belt just needs to be tightened or replaced. If the drive belt looks to be good, a worn-out drive sheave could also cause a low voltage code.
   • When it comes to the level of material on your screen and feed issues, it’s important to adjust the feeder belt speed to accommodate the screen. Once the machine is up and crushing, watch the material flow on the belts and screen. If there seems to be a small amount of material on the belts and the screen isn’t loaded, you can turn the feeder up to feed more material to the impactor. On the other hand, if the belts look overloaded and screen is backing up or getting material over the sides turn the feeder down to decrease the flow.

5. Why does one blow bar have more material above the locking rod pocket when I pull them to flip?
   • If there is extra material in the pocket, it might have been from the wedge being loose. When replacing the blow bars, you need to tighten the wedge screws in each wedge. When flipping or replacing the blow bars, do not torque and insert set screw and glue at first. Once everything is properly set, and the lid is properly closed, turn on the crusher and let it get up to speed. Doing this allows the blow bars to “seat” or pull out as far as they can against the locking rod. If the bar moves when the impactor is started, you may hear a loud bang. That is the bar moving into place as the rotor gets up to speed. After it has been run at full speed for a little bit, follow the proper lock out / tag out procedures prior to opening the lid again. At this point, retighten the wedge bots and torque to the recommended setting.
   • As a side note, when you insert the set screws, you can insert a small amount of paper towel to help keep the hex in the cap screw from filling with glue.
   • For more information about flipping blow bars, check out this previous Service Question with James.

Knowing Who to Call

The last year of being in the service manager position has been an interesting year. John spent the previous 12 years as 91������’s Assembly Supervisor, spent time as the assembly team leader, and helped build impactors and jaws for several years. Going from the various positions, he has had the opportunity to learn even more about the equipment 91������ builds. Throughout this past year, John has been able to go to jobsites with the service technicians to get some hands on in the field experience to accentuate this experience in the shop.

“In the areas I don’t excel in, on the service side, I have listened and have learned a lot in the last year and know that I still have a lot to learn. Working with our service technicians, I am also learning from them, and I am happy to join you in your journey to learning more about rock crusher maintenance.”

Looking back at the past year, it has been a year of learning not only for John as the new service manager, but for everyone following along on this “Service Questions” journey. It’s important to always stay curious and ask questions before servicing your machine instead of causing unnecessary downtime.

When you have questions or concerns about the operation of your machine, it’s important to know the resources available to you to find that answer. If you cannot find the answer you’re looking for in your owner’s manual, you can reach out to your local, authorized dealer or reach out to 91������’s Service Team.

The post Top 5 Frequently Asked Service Questions appeared first on 91������.

Thank you for following along in another year of our “Service Questions” series. We are always happy to share our expertise when it comes to our rock crushers and how to maintain them and can’t wait to share more information next year. For now, take a break and refresh your knowledge with 2025’s Service Questions.

General Safety

This year let’s make it our resolution to stay vigilant about protecting ourselves with the knowledge of rock crusher safety.

During start-up, it’s important to always follow the instructions the factory field service technician provides or the instructions in your operator’s manual along with your employer’s site approved plan. While the plant is in operation, it’s imperative that you follow all safety procedures for the safety of yourself and the machine. As with any piece of equipment, rock crushers are also in need of regular maintenance. To ensure that maintenance is done correctly, make sure you follow the instructions that were given at start-up by your field service technician and the information in the operator’s manual.

Read more about general safety with rock crushers.

Looking Back at over 35 Years of Eagle Service

Join us in honoring BC’s 15 years of being 91������’s Service Manager with 15 facts, stories, and challenges he faced over the years.

For over 35 years, Bill Compton (BC) has been the backbone of 91������, setting the standard for exceptional service, leadership, and innovation. As we celebrate his retirement, we reflect on his unwavering dedication, the countless challenges he has turned into opportunities, and the lasting impact he has had on our team and customers alike. BC’s passion and commitment have not only shaped our company’s success but has inspired us all to aim higher every day. BC worked at 91������ for a total of 42 years, serving as Group Leader over the Jaw Crusher assembly, Cobey composter assembly, and small crushing plant assembly at the previous Galion facility in 1986; temporary Plant Manager at the new, and current, Bucyrus location from 1994 to mid-1995; Service Technician starting in 1991; and finally awarded the title of Service Manager in 2010. Join us in honoring BC’s 15 years of being 91������’s Service Manager with 15 facts, stories, and challenges he faced over the years.

Read more about BC’s journey at 91������.

Parts that Require Regular Replacement

The regular placement of parts is not just a best practice; it’s a necessity for keeping heavy equipment running smoothly and safely.

Heavy equipment is the backbone of industries like construction, agriculture, and mining. These machines, such as rock crushing equipment, take on demanding tasks daily, making their reliability crucial for productivity and safety. However, without regular maintenance, even the most robust equipment can break down unexpectedly, leading to costly repairs, project delays, and safety hazards. Implementing a consistent maintenance routine ensures that your heavy machinery operates efficiently, extends its lifespan, and minimizes downtime—ultimately saving your business time and money.

Read more about Parts that Require Regular Replacement.

Bearings and Shafts

Explore the best practices for maintaining bearings and shafts to keep your heavy equipment running optimally.

Bearings and shafts are fundamental components of heavy machinery, playing a crucial role in ensuring smooth operation and efficiency. Bearings reduce friction between moving parts, allowing machines to run with minimal wear and tear, while shafts serve as the backbone, transmitting power and rotational motion. Proper maintenance of these components is essential to prevent breakdowns, extend machinery lifespan, and reduce costly repairs. Neglecting them can lead to premature failure, decreased performance, and even hazardous working conditions.

Read more about Bearings and Shafts.

What to Check Before Buying Used Crushers

Get crucial tips for purchasing used crushing equipment. Our used rock crusher checklist helps you find the best used crusher for your needs.

When it comes to investing in rock crushing equipment, buying used can be a smart way to save money without sacrificing performance, if you know what to look for. Whether you’re expanding an existing operation or just getting started in the rock crushing business, used crushers can offer reliable service at a fraction of the cost of new machines.

However, the key to making a sound purchase lies in knowing which features and conditions to inspect.

Read more about What to Check Before Buying Used Crushers.

Ensuring Your Rotor Lasts

With proper care and timely maintenance, a rotor can stand the test of time.

When it comes to keeping your rock crusher performing at its peak, the rotor is the heart of the operation. Responsible for generating the crushing force and managing material flow, the rotor takes on intense wear and impact with every cycle. That’s why consistent servicing of your rotor is critical. Not only to avoid downtime, but to ensure your equipment’s longevity. With proper care and timely maintenance, a rotor can stand the test of time and serve your operation for generations.

Read more about Ensuring Your Rotor Lasts.

Component Inspections

By committing to thorough and timely crusher inspections, you’re investing in the long-term reliability of your operation.

When it comes to keeping your rock crusher running at peak performance, component inspections are one of the most effective tools in your preventative maintenance arsenal. Regular inspections of critical parts like bearings, belts, liners, and rotors can help identify wear and tear long before it leads to costly downtime. These routine check-ups not only extend the lifespan of your crusher but also support safer operation and better production quality. By committing to thorough and timely inspections, you’re investing in the long-term reliability of your crushing operation.����

Read more about Component Inspections.

Understanding Variable Frequency Drives (VFDs)

When you understand the role your VFD plays, you’re not just protecting a single component, but your entire crushing operation.

Variable Frequency Drives (VFDs) are becoming an essential component in modern rock crushing operations, offering improved control, efficiency, and protection for your equipment. By precisely regulating motor speed and torque, VFDs help reduce mechanical stress, optimize energy usage, and adapt crusher performance to varying feed conditions. But beyond their operational benefits, understanding how your VFD functions, and the early signs of potential issues, is key to implementing effective preventative maintenance. A well-monitored VFD can extend the lifespan of your crusher, minimize costly downtime, and ensure consistent production output.

Read more about Understanding Variable Frequency Drives.

Training on Your Equipment’s Operation and Safety

Here at 91������, we offer both onsite equipment training and classroom training at our Headquarters in Galion, Ohio.

When it comes to operating heavy equipment, there’s no substitute for the knowledge of those who designed and built it. A manufacturer’s service team doesn’t just know the machine, they understand its engineering, its limits, and the best practices to keep it running at peak performance. Listening to their advice and taking advantage of equipment-specific training ensures that your team is not only using the machinery correctly but also maximizing its lifespan, efficiency, and safety.��

Read more about Training on Your Equipment’s Operation and Safety.

Tools Needed to Work on Your Rock Crusher

From heavy-duty wrenches to safety gear, every tool plays a critical role in keeping your crusher running smoothly and safely.

Working on and operating rock crushing equipment requires more than just skill, it demands the right tools for the job. From heavy-duty wrenches and torque tools for maintenance to gauges, diagnostic devices, and safety gear for daily operation, every tool plays a critical role in keeping your crusher running smoothly and safely. Understanding what’s needed and how to use each piece properly can mean the difference between efficient production and costly downtime.

Read more about the Tools Needed to Work on Your Rock Crusher.

The post Service Questions: 2025 Recap appeared first on 91������.

In the world of construction, aggregates, and material recycling, equipment reliability is everything. When a machine goes down, production stops, deadlines slip, and costs rise.��It’s��easy to assume every issue is major or expensive, but the truth is that many common heavy equipment problems have simple solutions if you know what to look for. Many times, if you catch and��address��issues when they are small, you can prevent them from becoming��major issues��that require extended down time. Understanding the difference between a major breakdown and a minor maintenance fix can save your team time, money, and unnecessary headaches. Today,��let’s��learn with 91������ Service Technician, Louis, about the common causes and solutions to abnormal vibrations that come from your machines.��

Common Causes of Abnormal Crusher Vibrations��

• Feeding Issues: Oversized materials and��uneven feeding can cause abnormal vibrations.��

• Improper Wear and Tear: Impactor Plates,��Jaw Dies, and Blow Bars in Impact Crushers, are going to wear, but uneven wear on the liners can cause abnormal vibrations. Additionally, bearings that are worn can overheat and create noise.��

• Loose Components:��After hours of usage,��bearings, shafts, fasteners, and more can become loose.��

• Misalignment: The imbalanced rotor can cause material buildup and uneven wear. Fluid couplings being misaligned can cause failure in the bearings, seals, and the coupling itself.��

Common Solutions of Abnormal Crusher Vibrations��

• Feeding Issues: While the machines will react to the addition of feed materials,��it’s��important to not add oversized materials and to evenly space out your feed loading.��You can reach out to the manufacturer, or the owner’s manual, for��recommendations on feed size and timing.����

• Improper Wear and Tear:��Add regular inspections to your schedule. The faster you can catch improper wear and tear, the less down time you will have in replacing the wear plates.��

• Loose Components:��After completing your regular inspections, make��sure to tighten or replace��any��components.��

• Misalignment:��Clean any build up in the impactor or jaw crusher and replace wear parts in sets. An uneven replacement could cause more issues.��
• Lubrication:��During your regular inspection, make sure all items, such as hydraulic lines and bearings, are properly lubricated.��

Preventative Maintenance is the Key��

When equipment is��maintained��regularly, troubleshooting becomes faster and more��accurate. Routine inspections help catch the simple problems before they escalate into costly downtime. Proper lubrication,��timely��filter changes, and��a��regular system��check��all reduce the chance of a small issue turning into a major failure.��

If��you’re��unsure what to include in your routine maintenance, check out the variety of places you have at your disposal:��

• Owner’s Manual��

• Authorized Dealer��

• Check out the list of 91������’s Authorized Dealers

• Manufacturer��

• Reach out to 91������’s Service Team

Learning from the Professionals��

While many equipment issues are simple, some problems truly require a trained technician. If��you’ve��worked through the basic checks and the machine is still malfunctioning, a deeper issue��may be at play. The key is to start with the easy fixes first before assuming the worst��because heavy equipment issues are inevitable, but they��aren’t��always a sign of catastrophic failure.����

With a little knowledge, a keen eye, and a structured approach to troubleshooting, many problems can be resolved��by��you,��quickly and affordably. Understanding the difference between a major breakdown and a simple fix empowers your operators, minimizes downtime, and keeps your equipment working hard on the jobsite.��

Service Questions Featured in AsphaltPro

The journey of learning about crusher maintenance has expanded to the Asphalt Pro community! Check out the article this blog inspired by clicking searching theasphaltpro.com/articles/crusher-vibration-fixes/, or by checking out the February 2026 physical copy of AsphaltPro.

The post Abnormal Crusher Vibrations�� appeared first on 91������.

Working on and operating rock crushing equipment requires more than just skill, it demands the right tools for the job. From heavy-duty wrenches and torque tools for maintenance to gauges, diagnostic devices, and safety gear for daily operation, every tool plays a critical role in keeping your crusher running smoothly and safely. Understanding what’s needed and how to use each piece properly can mean the difference between efficient production and costly downtime. 91������ Service Technician James will run down some of the common tools needed for 91������ equipment. As always, make sure you lock out/tag out whenever you are performing maintenance on your rock crushing equipment and to wear the appropriate personal protective equipment (PPE) such as hardhats, safety glasses, steel toe boots, ear plugs, high-vis clothing, sunscreen, and more.

Impactor Supplies

• Socket/Wrench
• Allen Wrench
• Torque ratchet
• Basic glue gun with glue sticks
• Roll of paper towels to protect Allen head
• Hammer
• Pry bar

For information on how to flip your blow bars, check out this previous Service Questions.

Supplies for Adjusting Conveyors on 91������ Equipment

• Socket
• • When adjusting take-ups, we recommend using a ratchet instead of an impact, so the threads do not get stripped on the take-up
• Tape measure
• Hammer

Feeder/Hopper Supplies

• Socket/Wrench
• Alignment pins
• Pry bar
• Hammer

Supplies for Screens

• Socket
• Ratchet Wrench
• Pry bar
• Alignment pin
• Hammer

Supplies for Grease Lines

• Deep well socket
• Wrenches

General Tools Needed to Work on a Rock Crusher

• Sockets
• Wrenchs
• Impact
• Torque wrench
• Vise grips
• Channel locks
• Side cuts
• Hammers/Dead blow
• Screwdrivers
  • flat head/ Philips
  • insulated screw drivers for electrical work
• Come along
• Allen sockets
  • normal Allen wrenches will work as well
• Bar wedges
• Glue gun with glue sticks
• Alignments pins
• Pry bars
• Grease guns
• Level
• Meter for electrical trouble shooting
• Safety Supplies
  • Lock out Tag out kit
  • First aid kit

Having the Proper Equipment

Having the proper tools on hand ensures your team can work confidently, efficiently, and safely, no matter the size or type of crushing system you run. Taking the time to equip your operation with the right maintenance and operational tools is an investment in performance and longevity. When your tools and your team work in sync, your crusher can deliver the reliability and results your business depends on.

91������’s Service Team is another tool that is always available to you. If you have questions about general maintenance, check out our previous Service Questions. For more information, reach out to our Service team.

The post Tools Needed to Work on Your Rock Crusher appeared first on 91������.

When it comes to operating heavy equipment, there’s no substitute for the knowledge of those who designed and built it. A manufacturer’s service team doesn’t just know the machine, they understand its engineering, its limits, and the best practices to keep it running at peak performance. Listening to their advice and taking advantage of equipment-specific training ensures that your team is not only using the machinery correctly but also maximizing its lifespan, efficiency, and safety.��

While these Service Questions blogs are a great start to understanding your equipment, taking advantage of personalized training is the best way to truly know what your specific equipment requires.����

��

Offered Training��

Here at 91������, we offer both onsite training and classroom training at our Headquarters in .��

��

Onsite Trainings��

Onsite training starts with standard classroom training that covers a variety of topics from general safety to plant specific maintenance. These onsite trainings allow you to include as many members of your team as you would like.��

The advantage of the service team coming to your facility is that we can also look over your system to see if we can possibly find any issues that may cause disruptions to your production. It is hands-on training so that you and your team know your plant inside and out.��

Additionally, we will meet your needs in any way possible. This could be by creating training that fits your schedule and needs or in any way that will benefit you.��

Headquarters Trainings��

Headquarters training allows you to connect with other 91������ equipment owners and learn about equipment safety, operation, and more. These classroom training sessions can be either a one-day event or two-day event depending on your needs. It also allows you to get a custom tour of the manufacturing facility located 15 minutes away in to see how equipment like yours is built.����

��

What Does the Training Cover��

Our Service Department has the knowledge and experience to come to you and talk about safety, proper operation, and fine tuning of your 91������ units. We can cover items from our combined years of experience on all our units.��

During the classroom training we will cover these items and more, depending on timing and your needs:��

Electrical Panel��

• This includes what the purpose that each component serves in your operation, trouble shooting of electrical issues, and more equipment specific information.��

Plant Operation��

• Training will cover the steps from start to finish��

Plant Safety��

• Keeping your equipment in one piece while also protecting your team��

Plant Specific Preventative Maintenance��

• Such as adjusting belts and curtains��

• Lubrication points����

• More��

Blow Bar Installation and Maintenance��

• Onsite training can include hands-on experience��

��

Schedule Your Training��

At the end of the day, your equipment is only as effective as the people operating it. By trusting the guidance of the manufacturer’s service experts and investing in training tailored to your machine, you’re protecting your investment, boosting productivity, and fostering a safer work environment. The knowledge gained at those trainings pays dividends for years to come, making training and expert advice one of the smartest moves your team can make.��

If you are interested in scheduling 91������ Service Training, please contact Service Manager John Griffith at servicedept@eaglecrusher.com.��

The post Training on Your Equipment’s Operation and Safety�� appeared first on 91������.

Variable Frequency Drives (VFDs) are becoming an essential component in modern rock crushing operations, offering improved control, efficiency, and protection for your equipment. By precisely regulating motor speed and torque, VFDs help reduce mechanical stress, optimize energy usage, and adapt crusher performance to varying feed conditions. But beyond their operational benefits, understanding how your VFD functions, and the early signs of potential issues, is key to implementing effective preventative maintenance. A well-monitored VFD can extend the lifespan of your crusher, minimize costly downtime, and ensure consistent production output.

Where are VFDs Usually Found on Rock Crushers

VFDs are used on rock crushers and are usually found controlling the feeder speed to offer adjustability to target a nominal material feeding into the crusher. They can also be found on closed circuit plants controlling the return conveyor. Offering a speed adjustment on a return conveyor via potentiometer (speed pot) allowing you to speed up or slow down the conveyor to ensure proper loading and conveying of the product. VFD controllers are usually found in the main control panel.

VFD Faults and Alarms

A VDF fault is an error detected by the drive that indicates something is preventing it from operating correctly. When a VFD fault occurs, it will have a fault code associated with it to lead you to potential errors. Faults can occur from both mechanical issues and electrical issues but may not always occur together.

During a VFD fault, it may open the circuit and de-energize the motor it relates to. Once you read the fault code, the associated fault with the code can be found in the manufacturer’s operating manual. The VFD operating manuals will offer possible causes of the fault, helping you to find the issue and resolve it quickly.

VFDs can also present alarms, which are different from faults. Depending on the way the VFD is configured, an alarm may have a code associated with it but may not enter a shutdown condition.

An image of the VFD controller where the code will display.

Common VFD Faults

One of the most common VFD faults seen is output overcurrent. This fault is often found associated with either the acceleration time being programmed too short or the feeder could be rubbing the hopper. If a feeder is rubbing against the hopper, it can cause an excessive amp to draw on the feeder motor and in turn enter a fault condition to protect the motor.

An example of a poorly maintained VFD and control panel.

Maintaining Your VFD

When it comes to the maintenance of any VFD, you will first need to lockout/tagout the main control panel and wait at least 5 minutes for the stored electrical energy to dissipate before performing any maintenance task.

Some general maintenance items would include:

• Inspecting the cooling fans to ensure there is no dirt buildup
  • Dirt buildup can damage the cooling system, leading to catastrophic VFD failure.
  • When it comes to the cooling system, there are fan change intervals, and you will need to refer to the specific VFD manufacturers’ guidelines found in their manual.
  • Dirt buildup can be reduced by keeping your control doors shut other than when performing maintenance.
• VFD’s can be damaged by vibration
  • It’s best to remove the main control panel from the plant before you start crushing.

Always refer to your operator’s manual for your equipment’s specific maintenance needs and requirements.

Knowing Who’s Got Your Back

When you understand the role your VFD plays and incorporate it into your preventative maintenance program, you’re not just protecting a single component, you’re safeguarding your entire crushing operation. Regular inspections, performance monitoring, and proper troubleshooting can keep your VFD running at peak efficiency, which in turn helps your crusher perform reliably day after day.

If you have VFD issues that you cannot resolve with your operator’s manual, you can always reach out to 91������’s Service Team or their network of authorized dealers.

The post Service Questions: Understanding Variable Frequency Drives (VFDs) appeared first on 91������.

When it comes to keeping your rock crusher running at peak performance, component inspections are one of the most effective tools in your preventative maintenance arsenal. Regular inspections of critical parts like bearings, belts, liners, and rotors can help identify wear and tear long before it leads to costly downtime. These routine check-ups not only extend the lifespan of your crusher but also support safer operation and better production quality. By committing to thorough and timely inspections, you’re investing in the long-term reliability of your crushing operation.����

Check out Service Technician Louis’s list of recommended daily, weekly, and monthly inspections to add to your preventative maintenance routine. While this list is a good start, it’s important to review your owner’s manual for model specific inspection requirements. As always, remember to lock out and tag out your equipment before inspecting and working on it.����

��

Daily inspections��

Check oil coolant and for any fluid leaks��

• Engine��
• Hydraulics��
• Gearbox��
• Motorized head pulley��

Look for signs of wear or damage��

• Belts��
• Liners��
• Guards��

Inspect for clogging or material build up��

• Screens��
• Chutes��
• Transfer points����

Check for cracks or abnormal wear��

• Impactor��
• Blow bars / jaw dies��
• Wear plates����

��

Weekly Inspections��

Inspect frame welds and bolts for cracks or looseness��

Check grizzly bars and screen mesh for excessive wear��

Inspect conveyor belts for damage or mis tracking��

Check pulley alignment and lagging condition��

Grease all lube points per manufacturer recommendations��

• Look for signs of grease purging which may indicate over-lubrication or bearing issues.����

Note any unusual vibrations or noises while running��

��

Monthly inspections��

Prior to putting the plant back in service, remove guards to check internal wear parts��

• Cheek plates��
• Liners��
• Rotor��

Measure wear tolerances and compare them to OEM specs��

Check shaft and pulley alignment��

Inspect the electric panel and VFD panels for heat damage or loose connections.����

Thoroughly inspect for metal fatigue stress fractures by inspecting foundations or mounting platforms for cracks.��

��

Adding Routine Inspections to Your Plan��

Preventative maintenance is about building a proactive culture that protects your equipment, your team, and your bottom line. Don’t wait for warning signs to appear; instead, make inspections a scheduled part of your operation. The time and resources you invest today will return as increased uptime, reduced repair costs, and improved crusher performance for years to come.��

91������ is always there to help you. From our network of authorized dealers to our parts department and our Service Technicians, 91������ will help you keep your equipment up and crushing it.��

��

The post Service Questions: Component Inspections�� appeared first on 91������.

When it comes to keeping your rock crusher performing at its peak, the rotor is the heart of the operation. Responsible for generating the crushing force and managing material flow, the rotor takes on intense wear and impact with every cycle. That’s why consistent servicing of your rotor is critical. Not only to avoid downtime, but to ensure your equipment’s longevity. With proper care and timely maintenance, a rotor can stand the test of time and serve your operation for generations.

Properly Removing Blow Bars

The first step for the removal of the existing blow bars is to lock out/tag out your equipment.�� Then, lock the rotor by carefully rotating it so that the safety pin can be inserted. This is to ensure the rotor will not spin while maintenance is being performed.

Install the blow bar removal tool that is located on the side of the impactor lid. Make sure you have a little tension so the blow bar will not move while removing the wedges.

Once the tool is in place, remove the glue from the wedges to expose the jam screw. Remove the jam screw to expose the wedge screws. Loosen the wedge screws. Next, hit the wedges downward to knock them loose, then remove the wedge and set aside.

Once all the wedges are removed for that bar you are working on, you can take some tension off your blow bar tool and slide your blow bar forward so that the locking bar can be removed.

If you need more advice on installing blow bars, check out this previous Service Questions with James.

Cleaning the Rotor Prior to Reinstalling

Clean the locking bar with a wire wheel or sanding disk to ensure there is no mud or dirt on the locking rod.

Clean the slot where the locking bar sits on your rotor. The locking bar must sit correctly when reinstalled.

Clean wedges so they will last.

Clean the faces of the rotor.

The reason these steps are so important is because if your blow bars do not sit flat on the rotor, the locking bar will not lock correctly and cause a mushroom effect on the bottom of the top rotor face. If it is not corrected, the blow bar can shift and sit incorrectly. It’s imperative to take the extra couple minutes to clean your rotor while doing a blow bar change or flip.

Maintenance Now or Costly Downtime Later

Neglecting rotor maintenance can lead to costly repairs, decreased efficiency, and shortened equipment life. By taking a proactive approach of inspecting for wear, balancing regularly, and following manufacturer guidelines, you can extend the life of your crusher while protecting your investment. With consistent servicing, your rotor can continue doing what it was built to do: crush with precision and power for years to come.

Need more help? Reach out to 91������’s Service Team or authorized dealers for any questions you may have.

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Bearings and shafts are fundamental components of heavy machinery, playing a crucial role in ensuring smooth operation and efficiency. Bearings reduce friction between moving parts, allowing machines to run with minimal wear and tear, while shafts serve as the backbone, transmitting power and rotational motion. Proper maintenance of these components is essential to prevent breakdowns, extend machinery lifespan, and reduce costly repairs. Neglecting them can lead to premature failure, decreased performance, and even hazardous working conditions. 91������ Service Technician Dakota will explore the best practices for maintaining bearings and shafts to keep your crushers running optimally.

Bearing Inspection

Proper bearing lubrication and inspection are crucial for maintaining your equipment efficiency and preventing costly failures. As always, when you are performing any maintenance on your equipment, start off by locking and tagging out.

• Visual Inspection:��Regularly inspect bearings for signs of wear, damage, or excessive heat.
• Temperature Monitoring:��Track bearing temperatures to detect overheating or excessive friction.
• Noise and Vibration Analysis:��Monitor noise and vibration levels to identify potential problems.

Always refer to your lubrication list for intervals and grease amounts. If you cannot find your lubrication list, reach out to a certified 91������ dealer or Service Technician for help.

Example of a bearing lubrication chart

If the bearings do not pass your inspection that you followed in the above list, let’s look at potential causes of bearing issues.

Causes of Bearing Misalignment:

• Incorrect installation procedures can lead to misalignment, imbalance, and other issues.
• Out-of-Square Components can cause misalignment.
• Bent shafts can lead to misalignment.
• Dirt on shaft or housing shoulders can cause misalignment.

Signs of Bearing Misalignment and Damage

• Excessive Noise
  • Grinding, humming, whining, or squealing sounds, especially when the shaft is in motion or under load, can indicate bearing issues.
• Vibrations
  • Excessive or unusual vibrations, especially when the shaft is in motion, can indicate bearing problems.
• Unusual Heat
  • Overheated bearings and couplings can indicate poor lubrication or misalignment.
• Visible Damage
  • Look for signs of wear, damage, or contamination on the bearing surface, including pitting, scoring, scratches, or discoloration of the lubricant.
• Reduced Performance
  • Reduced efficiency reduced rotating movement, or difficulty in operation can indicate bearing issues.
• Lubricant Contamination
  • The presence of metal particles or discoloration of the lubricant can suggest bearing wear.

Shaft Inspection

Similarly to the bearings, it’s important to inspect the shafts regularly, keeping an eye out for the following:

• Visual Inspection: Scratches, gouges, pitting, corrosion, rust, cracks, fractures, and wear patterns on the shaft’s surface.

Signs of Shaft Misalignment and Damage

• Balancing Techniques:
  • Check the sheave with a dial indicator for signs of damage.
• Vibration Analysis
  • Analyzing vibration patterns can help identify imbalances and other issues that need to be addressed.
• Field Balancing
  • This involves adding or removing weight to the rotating components to achieve balance.

Knowing Who Has Your Back

Regular maintenance of bearings and shafts is not just a recommendation, it’s a necessity for ensuring the longevity and reliability of heavy machinery. By implementing proper lubrication, routine inspections, and timely replacements, you can prevent costly downtime and improve overall efficiency. Prioritizing the care of your machine is an investment in the performance and durability of your equipment, ensuring productivity and profitability for years to come.

You are not alone on this journey. 91������ has a wide network of dealers and technicians ready to assist you with anything you need. You can reach out to any Team Eagle member or check out our previous Service Questions blogs where our certified technicians talk about the various maintenance items you may experience with your rock crusher.

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Heavy equipment is the backbone of industries like construction, agriculture, and mining. These machines, such as rock crushing equipment, take on demanding tasks daily, making their reliability crucial for productivity and safety. However, without regular maintenance, even the most robust equipment can break down unexpectedly, leading to costly repairs, project delays, and safety hazards. Implementing a consistent maintenance routine ensures that your heavy machinery operates efficiently, extends its lifespan, and minimizes downtime—ultimately saving your business time and money.

Top Five Parts That Require Frequent Replacements

It’s recommended that you inspect every part of your equipment prior to use. If any wear parts, such as the following, or any other part of the equipment is broken, bent, cracked, or otherwise not to standard, it’s recommended that you replace it before operating.

• Wear Liners
  • Replace wear liners when liners are worn down to ¼ inch thick
  • This also applies to secondary curtain liners

• Impactor Primary Curtains
  • Primary curtains are typically two sided and should be flipped when worn down to 1 inch from the mounting ear

• Blow Bars
  • Blow Bars can be worn down to 7/8 of an inch before flipping them the first time.
    • 
  • The second side can be worn down to ¼ inch before bars need to be replaced
  • Always replace cracked or broken blow bars

• Jaw Dies
  • Jaw Dies are one sided and can be flipped from top to bottom
  • Worn down, or smooth, jaw dies may not properly grip and crush the rock to the size required so it’s best to flip them before that happens.

• Screen Cloth
  • Screen cloths can be manufactured from a variety of materials, like wire cloth
  • Always refer to the screen cloth manufacturer’s guide for replacement

Making Regular Maintenance Part of Your Day

In the long run, regular maintenance is not just a best practice—it’s a necessity for keeping heavy equipment running smoothly and safely. A proactive approach to inspections, servicing, and repairs helps prevent major failures, reduces operational costs, and maximizes productivity. Whether it’s checking fluids, replacing worn-out parts, or following manufacturer recommendations, staying on top of maintenance ensures that your equipment remains a reliable asset rather than an expensive liability. Investing in upkeep today means avoiding costly breakdowns tomorrow.

91������’s team of experts is always available to assist. Whether you’re looking for parts or looking for maintenance suggestions, 91������ has the answers for you. Additionally, you can check out previous Service Questions where we cover a range of topics to help keep you up and crushing it!

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