The maintenance of mobile crushers is a vital part of ensuring their long-term performance, efficiency, and safety, especially when dealing with different chassis types such as wheeled and tracked systems. Mobile crushers are widely used in mining, quarrying, and construction projects because of their flexibility and mobility, allowing them to process materials directly on-site without the need for additional transportation. However, this same mobility brings unique challenges during maintenance. Each chassis type—tracked or wheeled—requires specific safety considerations due to its structure, stability, and operational mechanism. Proper understanding of these differences can help prevent accidents, extend machine life, and reduce maintenance downtime.

Understanding the Role of Chassis in Mobile Crusher Maintenance​

Before performing maintenance of mobile crushers, it’s essential to understand the role that the chassis plays. The chassis serves as the supporting framework for the entire crusher, housing key components such as the power unit, crusher chamber, conveyor belts, and hydraulic systems. In a tracked chassis, mobility is achieved through a crawler system that allows the crusher to move across rough terrain, making it ideal for mining or large-scale quarry applications. On the other hand, a wheeled chassis provides better maneuverability on paved or semi-solid surfaces, making it easier to transport between job sites using trucks or trailers.

When planning maintenance, operators must assess how the chassis type affects accessibility and stability. For example, tracked mobile crushers often have more complex hydraulic systems that need regular inspection for leaks and pressure calibration. Meanwhile, wheeled mobile crushers might require more attention to tire condition, braking systems, and frame balance.

Conducting Safety Inspections Before Maintenance​

Safety inspections are the foundation of effective maintenance of mobile crushers. Before beginning any maintenance work, operators should always perform a thorough inspection of the crusher. This includes checking the engine, hydraulic systems, conveyor belts, lubrication points, and electrical circuits. Importantly, the stability of the chassis must be verified.

For tracked crushers, ensure the crawler tracks are securely positioned on stable ground before initiating maintenance. If the surface is uneven or sloped, use additional support blocks or wheel chocks to prevent movement. For wheeled crushers, always engage the parking brake and use wheel stoppers to prevent accidental rolling. Hydraulic systems should be depressurized, and power sources should be turned off and locked out according to the Lockout/Tagout (LOTO) procedure.

Additionally, visual inspections can reveal wear and tear in vital components. Cracks in the chassis frame, loose bolts, or corroded parts can pose serious safety risks. Addressing these early can prevent accidents during repair or reassembly.

Personal Protective Equipment (PPE) and Safe Work Practices​

No matter the type of mobile crusher, maintenance should always be conducted with the proper personal protective equipment (PPE). Workers should wear helmets, gloves, safety boots, high-visibility vests, and eye protection. When working near hydraulic systems or engines, hearing protection and fire-resistant clothing may also be necessary.

Moreover, teams should follow standard safety practices. Maintenance should never be conducted alone; there should always be at least one other worker present in case of emergencies. Communication systems, such as radios, should be checked beforehand. When accessing high areas of the crusher, use stable ladders or scaffolding with guardrails instead of makeshift supports.

Special Considerations for Tracked Mobile Crushers​

Tracked crushers offer exceptional off-road mobility, but their maintenance procedures demand special caution. The hydraulic tracks are powerful systems that can cause serious injuries if inadvertently activated. Before maintenance, the control system must be fully shut down and the hydraulic pressure released. It’s advisable to place warning tags on the control levers to prevent accidental engagement.

In addition, the undercarriage of tracked crushers is prone to accumulation of mud, rocks, and debris, especially after working in rough terrain. Cleaning the tracks regularly helps prevent mechanical strain and extends their lifespan. The rollers and idlers should be inspected for uneven wear, and lubrication must be performed according to the manufacturer’s schedule.

When performing maintenance underneath the tracked chassis, always ensure the machine is adequately supported using heavy-duty jacks or steel stands rated for the crusher’s weight. Never rely solely on the hydraulic system to hold the chassis elevated, as pressure loss can result in sudden drops.

Maintenance Safety for Wheeled Mobile Crushers​

For wheeled mobile crushers, stability during maintenance is equally critical. The vehicle’s handbrake and parking brake must be firmly engaged, and wheel chocks should be placed under the tires. When working near the wheels or under the chassis, avoid positioning the body directly beneath unsupported areas.

One key aspect of wheeled crusher maintenance is the inspection of tires. Over time, heavy loads and uneven terrain can lead to tire damage or pressure imbalances, affecting stability during operation and maintenance. Ensure all tires are properly inflated and that rims are free of cracks. Additionally, check the steering and braking systems to ensure they respond correctly.

If maintenance involves electrical systems, such as lighting or control panels, the power supply should be disconnected to prevent electric shock. Similarly, when working on conveyors or rotating parts, mechanical guards should remain in place until maintenance is complete and the system has been tested for safe operation.

Hydraulic and Electrical System Maintenance​

Both tracked and wheeled mobile crushers rely heavily on hydraulic and electrical systems. Regular inspection of hydraulic hoses, connectors, and pumps is vital. Small leaks can lead to pressure drops, overheating, and even fire hazards. Therefore, maintenance teams should use leak detection tools and ensure that hydraulic fluid levels are adequate and free from contamination.

For electrical systems, all cables and connectors should be inspected for wear or fraying. Grounding systems must be intact to avoid static discharge during operation. Any damaged wiring must be replaced immediately, and only qualified technicians should handle electrical repairs.

Conclusion​

Ensuring safety during the maintenance of mobile crushers requires a combination of careful planning, the right tools, and disciplined adherence to safety procedures. Different chassis types—whether tracked or wheeled—demand distinct approaches to stability and accessibility. Proper pre-maintenance inspection, lockout procedures, and the use of suitable personal protective equipment significantly reduce the risk of accidents. Regular cleaning, lubrication, and monitoring of hydraulic and electrical systems further ensure reliable operation. By understanding and addressing the specific maintenance needs of each chassis type, operators can not only keep the work environment safe but also maximize the crusher’s performance and lifespan. In the end, consistent safety practices are not just about compliance—they are the foundation of sustainable and efficient mobile crusher operation.