Wash Plant Maintenance: Keep It Running

The Cost of Downtime

A properly maintained wash plant can run for 10+ years with minimal issues. A neglected one will cost you more in repairs and downtime than a new machine. Based on feedback from operations worldwide — from Alaska's harsh conditions to Africa's dusty environments — here's your complete maintenance guide to keep your wash plant running profitably.

Daily Maintenance (5-10 Minutes)

These quick daily checks prevent most major problems:

Before Starting:

• Visual inspection: Walk around entire plant, look for obvious damage
• Check fluid levels: Engine oil, hydraulic fluid, coolant
• Water system check: Verify adequate water supply and pressure
• Screen inspection: Remove any large debris caught overnight
• Belt tension: Quick visual check — belts should be tight but not over-tensioned
• Electrical connections: Look for loose wires or damaged cables

During Operation:

• Monitor temperatures: Engine temperature gauges should stay normal
• Listen for unusual noises: Grinding, squealing, or knocking sounds
• Watch vibration: Excessive vibration indicates wear or imbalance
• Check water flow: Maintain proper flow rates throughout system

End of Day:

• Clean screens: Remove built-up material from all screens
• Grease fittings: A few pumps on key grease points
• Secure equipment: Lock electrical panels, fuel caps
• Record hours: Track operating hours for scheduled maintenance

Weekly Maintenance (30-60 Minutes)

More thorough weekly maintenance prevents major problems:

Engine/Motor Service:

• Oil level check: Check with engine warm but stopped
• Air filter inspection: Clean or replace if dusty/damaged
• Belt inspection: Check tension, wear, and alignment
• Cooling system: Clean radiator screens, check coolant level
• Fuel system: Drain water from fuel tank, check lines

Water System Service:

• Pump inspection: Check for leaks, unusual vibration
• Hose inspection: Look for cracks, abrasion, loose clamps
• Spray nozzles: Clean plugged nozzles, check spray patterns
• Water tank cleaning: Remove sediment from water storage tanks

Screening System:

• Screen wear check: Look for holes or excessive wear
• Screen tensioning: Tighten or replace worn screen panels
• Support structure: Check for cracks or loose bolts
• Vibrating motors: Check mounting bolts and electrical connections

Monthly Maintenance (2-4 Hours)

Monthly service prevents major failures and extends equipment life:

Engine Service (Diesel Models):

• Oil change: Every 100-150 hours or monthly
• Oil filter replacement: With every oil change
• Fuel filter replacement: Every 200-300 hours
• Air filter cleaning/replacement: As needed based on conditions
• Coolant check: Level, condition, freeze protection

Hydraulic System:

• Hydraulic fluid check: Level and condition
• Filter replacement: Every 500 hours or as indicated
• Cylinder inspection: Check for leaks or damage
• Hose inspection: Replace any damaged hydraulic hoses

Lubrication Service:

• Grease all fittings: Pump fresh grease into all zerk fittings
• Chain lubrication: Clean and lubricate drive chains
• Bearing inspection: Check for wear or overheating
• Pivot points: Lubricate all pivot and hinge points

Maintenance Level	Frequency	Time Required	Key Focus Areas
Daily	Every operation	5-10 minutes	Visual inspection, fluid levels
Weekly	Every 40-50 hours	30-60 minutes	Engine service, water system
Monthly	Every 150-200 hours	2-4 hours	Oil changes, filters, lubrication
Seasonal	2-4 times per year	4-8 hours	Major inspection, parts replacement

Common Wear Items and Replacement Intervals

These parts wear out during normal operation and should be replaced proactively:

High-Wear Items (Replace Every 500-1,000 Hours):

• Screen mesh: $200-500 per screen, varies by size
• Water pump impellers: $150-300, especially in sandy conditions
• Drive belts: $50-150 per belt, critical for reliability
• Spray nozzles: $20-50 each, get plugged or worn
• Hose clamps: $5-15 each, prevent expensive leaks

Medium-Wear Items (Replace Every 1,000-2,000 Hours):

• Water pump seals: $100-200, prevent major pump failure
• Hydraulic hoses: $50-200 each, replace before failure
• Engine air filters: $30-80, critical in dusty conditions
• Sluice box riffles: $100-300, affects gold recovery
• Bearing assemblies: $50-200 each, critical for smooth operation

Long-Term Items (Replace Every 2,000-4,000 Hours):

• Water pumps: $800-2,000, rebuild or replace
• Electric motors: $500-1,500, rewind or replace
• Structural components: As needed, inspect regularly

Essential Spare Parts Inventory

Stock these parts to minimize downtime:

Critical Spares (Must Have):

• Complete set of drive belts: $200-400 total investment
• Water pump repair kit: $150-300, includes seals and impeller
• Screen panels: 1-2 spare panels for each size
• Basic electrical supplies: Fuses, contactors, wire, connectors
• Hydraulic hoses: 2-3 of each critical size

Important Spares (Should Have):

• Engine filters: Oil, fuel, air filters for 6 months
• Spray nozzles: Complete set of replacements
• Bearing assemblies: For critical rotating components
• Hydraulic cylinders: Seal kits for all cylinders

Troubleshooting Low Gold Recovery

When gold recovery drops, these are the most common causes:

Water Flow Issues:

• Insufficient water: Check pump capacity, intake screens
• Incorrect pressure: Too high = gold washed away, too low = poor classification
• Plugged nozzles: Clean spray nozzles throughout system
• Uneven flow: Check for damaged or missing spray tips

Screening Problems:

• Worn screens: Holes allow oversized material through
• Plugged screens: Reduce effective screening area
• Poor vibration: Check vibrating motor and mountings
• Wrong screen size: Verify correct mesh for your material

Sluice Box Issues:

• Worn riffles: Reduce gold capture efficiency
• Incorrect slope: Too steep = gold washes out, too flat = poor flow
• Overloading: Too much material overwhelms capture ability
• Clay buildup: Prevents gold from reaching riffles

Seasonal Maintenance and Storage

End of Season Storage:

• Complete cleaning: Remove all material from screens and sluices
• Fluid changes: Fresh oil, fuel stabilizer, coolant check
• Corrosion protection: Spray exposed metal with rust preventative
• Battery maintenance: Remove and store in warm location
• Tire care: Block up equipment to prevent flat spots

Winterization (Cold Climates):

• Drain water systems: Prevent freeze damage to pumps and pipes
• Antifreeze protection: Ensure adequate freeze protection
• Covered storage: Protect from snow and ice accumulation
• Monthly start-up: Run engine monthly to circulate fluids

Start of Season Preparation:

• Complete inspection: Check for winter damage or wear
• Fluid checks: All levels, change if contaminated
• System testing: Test all systems before first operation
• Screen inspection: Repair or replace any damaged screens
• Calibration check: Verify proper water flows and pressures

Maintenance Records and Tracking

Good record keeping prevents problems and supports warranty claims:

Track These Key Metrics:

• Operating hours: Daily hours and cumulative total
• Maintenance performed: Date, hours, what was done
• Parts replaced: Part numbers, dates, costs
• Problems noted: Issues found during inspections
• Performance data: Throughput, recovery rates

When to Call for Professional Service

Some maintenance requires experienced technicians:

Call us for:

• Major engine problems: Overheating, excessive noise, power loss
• Hydraulic system failures: Major leaks, pump failures
• Electrical issues: Motor failures, control problems
• Structural damage: Cracked welds, bent components
• Performance problems: Consistent low recovery despite maintenance

Maintenance Cost Budgeting

Plan these maintenance costs into your operating budget:

Annual Maintenance Costs (Typical):

• M50 wash plant: $3,000-5,000 annually
• M100 wash plant: $5,000-8,000 annually
• M200 wash plant: $8,000-12,000 annually
• Emergency repairs: Budget additional 50% for unexpected issues

These costs assume normal operating conditions and proper maintenance. Neglected maintenance can easily double these figures.

Climate-Specific Maintenance Tips

Hot, Dusty Conditions (Africa, Southwest US):

• Clean air filters weekly instead of monthly
• Check radiators daily for dust buildup
• Use higher-grade lubricants for extreme heat
• Inspect electrical connections more frequently

Cold, Wet Conditions (Alaska, Canada):

• Use winter-grade fluids and fuels
• Pre-heat engines before starting
• Check for ice formation in water systems
• Inspect for corrosion from road salt exposure

Tropical Conditions (PNG, South America):

• Increase lubrication frequency due to humidity
• Watch for accelerated corrosion
• Use fungicide treatments in fuel during storage
• Check electrical systems for moisture intrusion

Need maintenance support? Call Chase at (888) 868-2650 for maintenance schedules, parts identification, or troubleshooting help. Proper maintenance is the key to profitable wash plant operation.