The magnetic separator fails to remove the reinforcement due to incorrectly selected magnet settings, contamination of the magnet’s surface, an excessively fast flow of raw material, design faults and the low magnetic properties of the reinforcement material.
The condition of industrial bearings is assessed on the basis of temperature and vibration. Equipment is shut down if thresholds are exceeded, if there is an abnormal increase in readings, or if squeaking or knocking is detected; regular monitoring prevents costly downtime.
Hydraulic oil overheating is a common fault in hydraulic systems; it has both obvious and indirect signs, frequent causes, and requires a step-by-step diagnostic process; ignoring the problem leads to costly repairs, whilst preventative maintenance extends the service life by a factor of 2–3.
Conveyor belt misalignment is caused by load displacement, wear and tear on components, etc. Regular inspections, quick troubleshooting methods and preventative maintenance help to avoid production stoppages.
Clogging of the screens on a mobile screen brings its operation to a standstill. There are seven easily remedied causes: high moisture content in the raw material, unsuitable mesh size, screen wear, excessive feed rate, incorrect vibration settings, sticky impurities, and a lack of regular cleaning.
The blades of a rotary crusher are replaced when they show signs of wear down to 10–15 mm, cracks, poor crushing performance or vibrations. Their service life depends on the raw material and the load; all blades should be replaced at the same time, and balancing and inspection carried out every 100–120 hours to extend their service life.
Uneven wear of crushing plates is a common fault in crushing equipment, arising from installation errors, irregularities in the feed of raw materials, incorrect gap adjustment and operational errors, which reduces productivity and shortens the service life of components.
A drop in crusher performance is a sign of a problem: there are warning signs, common causes, simple diagnostic checks, methods for restoring performance, and preventative measures to reduce breakdowns on the 70%.
The reliability of a crusher over 1,000 operating hours is assessed using the MTBF (mean time between failures). This is influenced by the assembly, raw materials, maintenance and workload. A high MTBF reduces downtime and improves profitability; compliance with maintenance schedules helps to increase it.
The article analyses the operation of crushers in hot weather (a 12–15% reduction in productivity, a 22% increase in downtime) and during the rainy season (an 18% increase in energy consumption and a 31% increase in downtime), and provides practical recommendations for stable operation.
