Подземные скалы are designed to withstand harsh conditions of underground mining, and are subjected to great wear and tear throughout the course of a long day of breaking hard rock in confined spaces. Wet and dirty conditions can greatly exacerbate this type of wear, and the majority of underground maintenance-related delays are caused by simple avoidable mistakes made by the operator and maintenance staff. With proper maintenance, an Underground Rock Breaker such as the new CHSJ-500 model can provide years of efficient underground mining production.
Mistakes that shorten equipment life and cause unnecessary expenses for repairs are covered in this article. Techniques that working underground crews use to keep breakers running for years are also included.
Mistake 1: Inadequate or Incorrect Greasing
Don’t destroy your rock breaker. Greasing the tool bushing and front head with the correct grease on a regular basis is a priority for the safe operation of your rock breaker. Many operators only grease once per shift and do not use the correct grease. Fresh grease should be applied every 2 to 3 hours of operation, depending on application.
Lack of grease causes metal-to-metal contact which generates heat and wear. A recent case in South America where a breaker’s front head seized after only 800 hours of operation could have been avoided by following a greasing schedule and likely doubling the life of the front head.
Best Practice:
- Use high-quality molybdenum disulfide grease
- Grease after every 2–3 hours of hammering
- Always grease with the tool bit in place
- Check grease ports for blockages regularly
Mistake 2: Ignoring Chisel Wear Patterns
The chisel (or moil point) are the hardest working bits and often are run until they are totally worn out or have mushroomed out completely. Excessive vibration caused by these very worn bits are transferred to the breaker body and the hydraulic system.
Change chisels often enough so that they wear evenly before wear becomes too extreme. Extremely dull tools put a lot of pressure on the piston and bushings and can cause them to fail prematurely.
Signs it’s time to change the chisel:
- Rounded or mushroomed tip
- Visible cracks
- Uneven wear on one side
- Increased vibration felt by the operator
Replacing chisels at the right time is one of the lowest cost protection for your entire breaker.
Mistake 3: Poor Hydraulic Oil Management
Hydraulic oil is the essence of an Underground Rock Breaker. In most cases dirty oil or the wrong oil causes the most damage to the internal parts of a Rock Breaker. Mines operating in a hot and dusty environment have to be extra careful with their choice of lubricant.
Common issues include:
- Running the same oil too long
- Using standard hydraulic oil instead of specialized anti-wear formulas
- Not changing filters on schedule
A mid size gold mine in Canada have changed to more strict oil analysis and now change all filters every 500 hours. Breaker repair frequency have decreased with almost 60% in the last 12 months.
Recommended Practices:
- Use manufacturer-specified hydraulic oil
- Change oil and filters according to hours, not calendar time
- Install high-quality return line filters
- Keep oil samples for trend analysis
Mistake 4: Operating Without Proper Carrier Matching
The operator can be put under undue stress by using a breaker that is either too large for the carrier or too small for the carrier. The large breaker on a light duty carrier will produce excessive vibrations and create many problems. The small breaker requires the operator to work long and arduous hours.
Be sure to choose a breaker that matches the specified operating weight and impact energy required by the carrier. Boart & Lucas’ CHSJ-500 is designed for optimal performance with 12-18 ton class underground carriers and represents an ideal solution for many applications.
Mistake 5: Skipping Daily Visual Inspections
Despite being under a lot of pressure to hit production targets, it’s important to never rush a pre-shift inspection even if it seems like a quick visual once over. What may seem like a minor issue that can be dealt with later can end up being an expensive failure if not caught beforehand.
Daily Checklist Items:
- Look for hydraulic leaks
- Check tool bit retainer pins
- Inspect hoses for chafing or damage
- Listen for unusual noises during operation
- Check mounting bolts for tightness
How Good Design Makes Maintenance Easier
The CHSJ-500 underground rock breaker was designed with maintenance in mind. The ground-level service points, grease points and other components are easily serviced with the appropriate tools to allow for quick and safe work to be done. The robust design means it can withstand hard use and requires minimal servicing.
Yantai Chi Hong Machinery Co., Ltd. as a Trusted Underground Mine Truck Supplier
Yantai Chi Hong Machinery Co., Ltd. is more than 12 years experienced and professional manufacturer of underground mining machinery. We have very good reputation in mining machinery industry. Our main products of underground mining equipment are all kinds of trackless underground mine machinery, such as underground loading and hauling LHDs, underground mine trucks, and also other specific подземные горнодобывающие машины, like underground rock breakers, which are especially design for narrow-vein and low-profile mines.
All the equipment we supply is rugged enough for underground work, easy to maintain while still delivering good performance. Our equipment is designed with a focus on the real world needs of mines. With ISO9001 and CE approval we have a lot of experience of providing equipment that is maintained quickly to minimize downtime and keep costs under control. We get a lot of repeat business from customers all over the world because our equipment is designed to work in mining environments and is backed up by good technical support.
Заключение
Most Underground Rock Breaker failures are caused by 5 simple mistakes that can be prevented by proper greasing, timely chisel changes, good management of hydraulic oil, proper matching of carriers and daily checks to identify any potential problems.
Managing breaker maintenance as a routine task, can keep repair costs down and increase the utilization of the breaker. In these days of mining on a tight margin, paying attention to details like this can be the difference between running an efficient mine and not.
Часто задаваемые вопросы
How often should I grease an Underground Rock Breaker?
Every 2 to 3 hours of actual hammering time is the general rule. In very dusty or wet conditions, grease even more frequently.
When does a chisel need to be replaced?
Chisel tips can develop heavy rounding, mushrooming, cracks or even unequal wear and tear. Worn chisel tips can severely damage an Underground Rock Breaker’s internal parts.
Can poor hydraulic oil really destroy an Underground Rock Breaker?
Yes. Dirty or incorrect oil is one of the leading causes of internal wear, valve failures, and reduced performance.
Why is carrier matching important for Underground Rock Breakers?
Using the wrong size breaker can create excessive vibration and stress putting excessive wear on the carrier as well as the Underground Rock Breaker causing premature failure.
What daily checks help prevent major problems with Underground Rock Breakers?
Check for hydraulic leaks, loose bolts, damaged hoses, and unusual noises. A 5-minute visual inspection before each shift catches most emerging issues.
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