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Call : 1800 571 464
Screenmasters Australia’s National Sales Manager, Ciaran Lagan, shares his effective maintenance practices, designed to minimise downtime and maximise productivity.
Mobile crushing and screening equipment has revolutionised material processing across the mining, quarrying, construction and recycling industries. These machines provide flexibility, mobility, and the ability to process materials on-site, reducing transportation costs and improving efficiency.
Increased Complexity Also Comes With the Risk of Costly Breakdowns
Too often, operators only learn the real value of preventative maintenance after a critical failure. After speaking with field operators, maintenance technicians, and service managers, we’ve compiled a series of lessons from the front lines – insights that every crushing operator should understand to prevent the next unplanned shutdown.
Preventative Maintenance is Always Cheaper than Emergency Repairs
One of the most common regrets among operators is neglecting regular maintenance due to time pressure. In high-output environments, there’s always a push to “just get the job done.” Unfortunately, skipping scheduled maintenance can quickly lead to catastrophic failure.
Operators often share stories of production being halted for days due to avoidable issues – failed bearings from lack of grease, worn-out belts and skirting rubbers, or clogged air filters. Small warning signs often go unnoticed until they snowball into equipment-destroying problems.
Best Practices:
Vibration and Noise Are Early Warning Signs – Don’t Ignore Them!
In mobile crushers and screens, excessive vibration or unusual noise is rarely a good thing. These machines are designed to run smoothly; when something starts rattling, squeaking or grinding, it’s usually a signal that something’s about to fail.
Several operators admitted to ignoring “small” issues – thinking they could deal with it later. Later often came in the form of unwanted breakdowns.
Commonly Overlooked Signs:
Training Makes or Breaks the Machine
A surprising number of crushing and screening breakdowns can be traced to operator error or lack of training. These machines are powerful, precise and unforgiving when used improperly.
Some of the most damaging mistakes include overloading the crusher, using incorrect feed materials, bypassing safety interlocks or improper warm-up/cool-down procedures.
Training isn’t a one-off task; it should be ongoing. Even experienced operators benefit from refresher training as technology and machine designs evolve.
Training Recommendations:
Don’t Skimp on Spare Parts or Tools
In remote or high-production environments, waiting 2–3 days for a spare part can cost thousands of dollars in downtime. Many operators now keep a critical parts kit on-site, including wear plates, screens, drive belts, filters and fast-moving consumables.
Equally important is having the right tools for diagnostics and repair. Several operators emphasised the importance of having torque wrenches, grease guns, digital thermometers and multimeters on hand at all times.
Spare parts to consider stocking:
OEMs Who Prioritise Serviceability Save You Time and Money
Keestrack and GIPO have developed their mobile crushing and screening equipment with real-world service conditions in mind. These manufacturers understand that easy maintenance is more than a convenience – it’s a cost saver and downtime reducer.
Smart Design Features that Operators Love:
Regular Maintenance Prolongs Equipment Lifespans – and Productivity
Design matters. Machines that are built for easy maintenance make it more likely that maintenance gets done properly and on time.
Modern crushing operations are about intelligent data. Tools like Sensortechnik belt scales and Keestrack telematics have become essential in tracking performance, maximising efficiency and catching issues early.
Sensortechnik Scales
These precision belt scales provide real-time production data, which allows operators and managers to:
Keestrack Telematics
Keestrack’s proprietary telematics system, Keestrack-er, allows remote monitoring of:
Real Data Improves Decision Making
The ability to make decisions based on real data, rather than relying on gut feeling, transforms how operators maintain and manage their equipment.
Every Failure is a Chance to Learn.
And every avoided breakdown is a quiet success that adds to your bottom line. The smartest crushing operators today aren’t just reacting to problems – they’re using smartly-designed machines, intelligent data and proactive maintenance strategies to stay ahead.
Keestrack and GIPO are examples of OEMs designing machines that respect the realities of field work. They integrate practical service features, durable engineering, and real-time intelligence tools like Keestrack-er and Sensortechnik to support better decisions and longer machine life.
To find out more about Screenmasters Australia’s range of intelligently-designed crushing solutions, contact us today and let’s set up a meeting.