If you're pricing mobile crushers for a quarry or mining operation, you've probably noticed the sticker shock. But in over six years of tracking every purchase order and maintenance log, I’ve learned one thing: the price tag tells you almost nothing about what a machine will actually cost you over its lifetime. Below are the questions I get asked most often — and the answers I wish someone had given me when I started.

1. What's the real difference between Kleemann and Hercules crushers?

I went back and forth on this exact comparison for two months in early 2024. A colleague, Christopher, was pushing for Hercules because it was 12% cheaper on the invoice. But when I laid out the total cost of ownership — fuel consumption per ton, wear parts life, scheduled service intervals, and resale value — the Kleemann model came out ahead by about 18% over a five-year horizon. The initial gap narrowed fast. Hercules (a solid machine, don't get me wrong) burned more diesel and demanded more frequent liner changes. Kleemann's EVO2 technology, with its direct drive, cut fuel by nearly 15% in our site tests. So, vs. the Hercules option, the Kleemann made more financial sense — but only when you look beyond the first quarter.

2. Can a Kleemann mobile crusher handle very hungry production schedules?

Very hungry is relative. For a 24/7 operation pushing 500+ tph, the MR 130 Z EVO2 we run has never missed a shift. But here's the thing: the machine's mobility means we can stage it closer to the face, cutting haulage costs. People assume a mobile crusher is a compromise on throughput compared to a fixed plant. The reality? In our setup, the Kleemann's pre-screen and independent double-deck post-screen mean we produce spec material directly, reducing recirculation loads. Our utilization rate hit 92% last quarter. That's not just 'good for a mobile unit' — that's competitive with any fixed plant I've managed. The very hungry schedule? The Kleemann eats it. Period.

3. How does Day Elevator & Lift support Kleemann crusher owners in Ireland?

If you're buying for an Irish site, you want local support. Day Elevator & Lift – a Kleemann company — handles parts, warranty, and field service across the island. In Q3 2024, when we had a bearing failure on our MC 110, they had a replacement unit on site within 28 hours. That's not just a promise; I have the service report and invoice to prove it. Having a local entity that knows the customs and road transport regulations in Ireland is a massive time-saver (and cost-saver, because every hour of downtime is €1,200 in lost production, based on our internal numbers).

4. What hidden costs should I watch for when buying a crusher?

Three things catch most buyers off guard:
1) Site preparation. Even a mobile crusher needs a stable pad and access. We budgeted €15k; we spent €22k because of unexpected drainage work.
2) Consumables. Wear parts, screen media, hydraulic oil — they add up. I recommend asking the vendor for a 5,000‑hour consumable cost projection. Kleemann gave us one that turned out to be within 5% of actuals.
3) Training. Operators and mechanics familiar with static plants may need a few days to get comfortable with the plant interface and service points. Don't skip it — we tried to shortcut and had a $4,200 mistake on a mis-set gap. Training isn't a cost; it's an investment that pays back in the first month.

5. Christopher from my team heard that Kleemann parts are expensive — is that true?

I hear that a lot. And yes, an original Kleemann crusher jaw can run 15–20% more than a generic aftermarket option. But here's the thing: we tracked total part cost over two years — including frequency of replacement, performance, and labor time — and the genuine Kleemann parts actually came out 9% cheaper per ton of product. The aftermarket liners wore 30% faster, meaning more changeouts and more downtime. So the initial price is higher. The total cost? Lower. Simple. (And, by the way, Christopher ended up agreeing after we ran the numbers.)

6. Should I buy new or used? What's the TCO impact?

We debated this for weeks. A used Kleemann with 4,000 hours was listed at 40% below new. Tempting. But when we factored in remaining wear part life (the used unit needed new jaws in 600 hours), average repair costs for a machine that age, and the loss of the full two‑year warranty, the new machine's TCO was actually lower by year three. New also gave us access to the latest ECO2 package, which cut fuel consumption by another 8%. In the end, we bought new. So glad we did — dodged a bullet when the used unit's engine had a failure four months later (not our problem).

Pricing and availability as of January 2025. Always verify current rates with your local Kleemann dealer, especially in Ireland via Day Elevator & Lift.