Layered by shift (daily), 200 hours of first level maintenance, monthly, 4000 hours of second level maintenance, and annual maintenance, covering all dimensions of cleaning, lubrication, vulnerable parts, transmission, electrical, and unloading systems, suitable for working conditions such as concrete, refractory castables, ceramics, graphite, etc.
1、 Maintenance must be done every shift (before startup, during operation, and after shutdown, daily)
1. Pre startup inspection (power off+emergency stop button pressed)
Turning inspection: Manually rotate the revolving bracket without any jamming or abnormal noise from scraping the cylinder wall; It is strictly prohibited to forcefully start with materials.
Tightening inspection: All connecting bolts of the cylinder, mixing arm, blades, discharge door, foundation, and reducer should be visually inspected. If they become loose, tighten them immediately and replace the rusted nuts.
Gearbox oil level: Observe the oil gauge, and the oil level should not be lower than 1/3 of the viewing window; Immediately stop the machine and change the oil if the oil turns white, emulsified, and contains metal debris.
Sealing inspection: There is no oil or material leakage in the revolving shaft oil seal, discharge door seal, and revolving bearing dust ring.
Electrical safety: Emergency stop button and safety door interlock are effective; The motor wiring terminals are not loose or dusty.
Lubrication pre injection: Add a small amount of 0 # lithium grease to the discharge door shaft and cylinder pin shaft.
2. Real time monitoring during operation
The motor current is stable within the rated range, without sudden high or low overload;
The whole machine has no sharp friction, impact, or periodic gear noise;
The temperature of the gearbox housing is ≤ 75 ℃, and if it exceeds 85 ℃, the machine will be shut down for maintenance;
The cylinder has no severe shaking, and the vibration value is less than 4.5mm/s;
The unloading cylinder and hydraulic unloading switch are stable without any jamming or pressure relief.
3. Clean thoroughly after shutdown (the most important thing is to prevent material accumulation and jamming)
Cleaning inside the cylinder: add water and run with crushed stones for 10-15 minutes to flush the inner wall and drain the sewage; Manually clean the dead corners and clumps of the bottom lining plate, side lining plate, and mixing arm root
Cleaning of easily accumulated material points
Remove the accumulated material on the back of the mixing blade, bottom scraper, and side scraper;
Clean the sealing surface and door edge of the discharge door to prevent material leakage due to loose door closure;
Aggregate/powder feeding inlet, observation cover sealing groove cleaning.
External cleaning: Clean the surface dust and mortar of the reducer, motor, and rotary bearing to prevent dust from entering the oil seal.
Power off lock: Disconnect the main power supply, press the electronic emergency stop button, and close the maintenance door.
2、 First level maintenance (every 200 hours of operation)
After completing all maintenance tasks for each shift, add the following items:
Gap calibration (core)
Gap between mixing blade and bottom wear-resistant plate: 8-10mm;
Gap between the side scraper and the inner wall of the cylinder: 8-10mm;
Excessive gaps result in many dead corners and decreased efficiency in mixing; Too small will scratch the lining plate.
Partial lubrication and filling
Add L-CKC220 heavy-duty gear oil to the reducer;
Open the top observation cover and add 0 # lithium based grease to the upper chamber of the revolving body;
Open the side cover of the revolving body and add 2 # lithium grease to the lower chamber;
The electric lubrication pump continuously supplies oil to the slewing support for 3 minutes, and confirms that the oil circuit is unobstructed.
Unloading system maintenance: The cylinder seal is leak free, the unloading door roller and guide block are not worn, and the door body is adjusted for fit.
Sealing inspection: Replace the oil seal and dust ring of the revolving body skeleton if they are hardened or damaged.
3、 Monthly maintenance (every 30 days, regardless of working hours)
Wear measurement of vulnerable parts
If the wear thickness of the stirring blade is greater than 15mm, it must be replaced;
Replace the side scraper and bottom lining plate with local wear and depression depth exceeding 10mm;
The mixing arm should have no bending or cracks, and any deformation should be corrected or replaced immediately.
Tighten the bolts of the entire machine: Use a torque wrench to tighten the anchor bolts, reducer base, cylinder flange, and high-strength bolts of the planetary arm to the standard torque.
Motor maintenance: Clean the dust from the fan cover and check for any abnormal noise from the bearings; Add about 20g of 2 # lithium grease to the motor bearings.
Electrical system: Clean the dust in the control cabinet, tighten the wiring terminals, check the stability of the contactor and sensor signals; Calibrate current and temperature instruments.
Lubrication pipeline: unclog the grease pump oil pipe, clean the filter to prevent oil blockage and dry grinding.
Additional hydraulic model: Check the hydraulic oil level, check for black impurities, and clean the return oil filter element.
4、 Secondary deep maintenance (every 4000 working hours)
1、Complete all first level maintenance tasks and disassemble the transmission system for inspection.
2、Thoroughly replace the gearbox with oil: drain the old oil, clean the diesel tank, and replace with new L-CKC220 gear oil; Check for gear pitting, broken teeth, and peeling.
3、Disassemble the revolving assembly: Disassemble the revolving support and planetary gear carrier, clean the oil stains, and check the wear of the gears and raceways; Replace as a whole if the wear exceeds the limit.
4、Complete seal replacement: All shaft end oil seals, O-rings, and discharge door seals should be replaced at once.
5、Comprehensive inspection of lining plates: Replace all the bottom and side lining plates of the cylinder that have worn out more than 1/3 of their thickness to avoid wearing through the cylinder.
6、Whole machine balance check: After replacing the blades and mixing arms, conduct a no-load test run to eliminate eccentric vibration.
7、Disassemble and inspect the motor, clean the dust accumulation on the stator, check the friction marks on the stator and rotor, and replace the motor bearing grease.
5、 Annual overhaul and maintenance (annual shutdown maintenance)
1、All secondary maintenance items;
2、Cylinder inspection, checking for cracks and deformations in the welding areas;
3、Ultrasonic testing of the gear surface and raceway of the slewing bearing, replacement of worn out bearings exceeding the limit;
4、Inspect all internal gears and bearings of the reducer and replace any damaged parts;
5、Replacement of aging cables, contactors, and PLC batteries in the electronic control system;
6、Rust removal and repainting of the entire machine, rust prevention and anti-corrosion treatment;
7、No load+full load test, record current, temperature, and noise for archiving.
6、 Maintenance taboos (to avoid rapid equipment damage)
1、It is prohibited to forcefully start with hard lumps or large pieces of metal, which can easily break the mixing arm and damage the gearbox gears;
2、Do not mix lubricating grease and gear oil, as different types of grease may react and block the oil circuit;
3、Long term failure to clean the accumulated material in the cylinder is prohibited, as it increases the load and causes motor overload and gear breakage in the reducer;
4、The gap should not be less than 6mm, as the blade scraping plate will quickly wear through the wear-resistant parts;
5、Prohibit the gearbox from running out of oil and burning gears due to high temperatures in a short period of time;
6、It is prohibited to continue production if the safety door interlock fails, as there may be mechanical safety hazards involved.
7、 Reference cycle for replacement of vulnerable parts
1、Mixing blades and scrapers: 6-12 months (3-6 months for refractory materials and high wear conditions)
2、Wear resistant lining plate for cylinder: 12-24 months
3、Shaft end oil seal and sealing components: 6-12 months
4、Rotary bearing: 2-3 years
5、Gearbox gear bearings: 3-5 years (can be extended with proper maintenance)
