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Prepare the crusher for safe change-out
Before handling new blow bars, lock out the HSI circuit and isolate all power. Check the rotor is blocked and cannot rotate. Remove the worn bars using approved lifting lugs and the correct bakkie-mounted crane or workshop hoist. Never work under a suspended load. Clean the rotor seats thoroughly, removing any old backing compound or crushed fines, and inspect for cracks or damage before installing new bars.
- Full lockout, tag out, and power isolation
- Correct lifting lugs and rated slings
- Clean rotor and check for scoring
Installing and seating the new bars
Fit the new blow bars as a balanced set, following the marked sequence for your rotor. If backing compound is specified for your chamber, mix and apply it only after a dry fit confirms alignment. Use the correct torque for all liner bolts, as per the OEM manual. Do not reuse old bolts if they show thread stretch or corrosion. Confirm mass balance and rotor free rotation after fitment, before closing up the crusher.
- Follow sequence and mass matching
- Use new bolts if in doubt
- Check rotor turns freely by hand
Setting up for the first tonnes
After installation, reset the gap or curtain settings to the OEM closed side spec. Rotate the rotor by hand to check for drag or fouling. Start the crusher on no load and monitor for vibration. Run a short warm-up, then check liner bolts for movement. After the first 20 tonnes, pause and check bolt torque again, and inspect for seat settling or backing compound extrusion. Document the new bar’s starting profile for future wear tracking.
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