The following will elaborate on practical tips for setting the maintenance schedule of combined mobile crushing plant from five key aspects, providing comprehensive guidance for equipment operators and maintenance managers.


Base on Equipment Manual and Working Conditions to Determine Maintenance Frequency

The primary premise of setting the maintenance schedule of combined mobile crushing plant is to take the equipment manual as the basic guide and adjust it according to the current working conditions. The official manual of the combined mobile crushing plant usually provides the basic maintenance cycle and content, such as daily inspection items, weekly lubrication requirements, monthly parts inspection, and annual comprehensive maintenance. These standard cycles are formulated based on the general working environment and load, and are the foundation of the maintenance schedule. However, the current working conditions of the combined mobile crushing plant are often more complex—for example, crushing hard materials (such as granite, basalt) will increase the wear of the crushing chamber and hammer head; working in high-dust areas will accelerate the blockage of the cooling system and air filter; Long-term continuous operation (more than 10 hours a day) will shorten the service life of bearings, motors, and other components. Therefore, it is necessary to adjust the maintenance frequency appropriately according to the current working conditions.

It is recommended to establish a working condition record system, recording the daily working hours, crushed material type, ambient temperature, and dust concentration of the combined mobile crushing plant, so as to provide data support for adjusting the maintenance frequency. At the same time, for new equipment in the running-in period (usually the first 500 working hours), it is necessary to formulate a more intensive maintenance schedule, such as increasing the frequency of oil change and parts tightening, to ensure the smooth running-in of components.

Classify Maintenance Levels to Clarify Core Maintenance Content

The maintenance of combined mobile crushing plant can be divided into different levels according to the scope of maintenance, difficulty, and cycle, including daily maintenance, periodic maintenance (weekly, monthly, quarterly, annual), and fault maintenance. Setting a scientific maintenance schedule requires clarifying the content and focus of each level of maintenance to ensure that all key components are covered without redundancy. Daily maintenance is the most basic and frequent maintenance work, which should be completed before and after the daily operation of the combined mobile crushing plant. The core content includes checking the tightness of fasteners (such as bolts of the crushing chamber, connecting bolts of the frame), inspecting the oil level and oil quality of the hydraulic system and lubrication system, cleaning the surface of the equipment and the dust on the air filter, and checking the operation status of the motor, reducer, and other components (such as whether there is abnormal noise or overheating).

Periodic maintenance is a targeted maintenance work carried out according to a fixed cycle, and the content should be gradually in-depth with the extension of the cycle. Weekly maintenance focuses on lubrication and partial inspection—for example, adding lubricating oil to the rotating parts (such as the bearing of the vibrating screen, the conveying roller), checking the wear of the crushing hammer head and liner, and inspecting the tightness of the belt conveyor. Monthly maintenance needs to conduct a comprehensive inspection of key components, such as disassembling and inspecting the air filter and replacing it if necessary, checking the wear of the hydraulic cylinder and sealing ring, and testing the performance of the electrical control system (such as the sensitivity of the emergency stop button, the normal operation of the sensor). Quarterly maintenance focuses on the inspection and adjustment of the core system, such as adjusting the clearance of the crushing chamber, checking the alignment of the motor and reducer, and testing the pressure of the hydraulic system. Annual maintenance is a comprehensive overhaul work, which requires disassembling key components (such as the crushing rotor, bearing seat) for inspection and replacement, comprehensively cleaning the hydraulic system and cooling system, and testing the overall performance of the equipment. It should be emphasized that fault maintenance should be incorporated into the maintenance schedule as a supplementary item, and the causes of faults should be analyzed in time after troubleshooting, and the maintenance schedule should be adjusted if necessary to prevent the recurrence of similar faults.

Focus on Key Components to Formulate Targeted Maintenance Plans

The combined mobile crushing plant is composed of multiple components, and the importance and wear characteristics of different components are different. Therefore, when setting the maintenance schedule, it is necessary to focus on key components that affect the operation of the whole machine and formulate targeted maintenance plans. The core components of the combined mobile crushing plant include the crushing system (jaw crusher, impact crusher, cone crusher), screening system (vibrating screen), conveying system (belt conveyor), hydraulic system, lubrication system, and electrical system. For the crushing system, the hammer head, liner, and crushing plate are easily worn parts, and their wear status should be checked regularly. For example, the wear of the hammer head should be checked weekly, and the replacement should be arranged when the wear amount exceeds the limit (usually 10-15mm). The liner should be checked monthly, and the position should be adjusted or replaced in time to ensure the crushing effect.

For the hydraulic system, which is the "power source" of the combined mobile crushing plant, the maintenance focus is on preventing oil leakage and ensuring the cleanliness of hydraulic oil. The hydraulic oil should be sampled and tested every 3 months to check its viscosity, water content, and impurity content, and the oil should be replaced completely when it fails to meet the requirements. The hydraulic cylinder, hydraulic pump, and hydraulic valve should be inspected monthly for oil leakage and abnormal noise. For the lubrication system, it is necessary to ensure that all rotating parts are adequately lubricated, and the lubricating oil should be replaced according to the working hours (usually every 2000-3000 working hours). The air filter of the lubrication system should be cleaned weekly to prevent dust from entering and polluting the lubricating oil. For the electrical system, the wiring terminals, sensors, and control cabinet should be inspected monthly for loose connections, moisture, and dust accumulation. The battery of the mobile unit should be checked regularly for voltage and charging status to ensure that the equipment can be started normally. In addition, for vulnerable parts such as the belt of the conveyor and the screen mesh of the vibrating screen, a regular replacement plan should be formulated according to their service life, and spare parts should be prepared in advance to avoid downtime due to parts damage.

Integrate Operation Data and Fault Records to Optimize Maintenance Schedule Dynamically

A scientific maintenance schedule of combined mobile crushing plant is not static, but needs to be dynamically optimized based on long-term operation data and fault records. In the process of equipment operation, it is necessary to establish a complete maintenance and fault record system, recording the time, content, and effect of each maintenance, as well as the type, occurrence time, cause, and handling method of each fault. By these analyzing data, we can find out the regularities of equipment failure and the rationality of the maintenance schedule. For example, if the bearing of the vibrating screen frequently fails before the scheduled maintenance cycle, it may indicate that the maintenance frequency of the bearing is too low, or the lubrication method is improper. At this time, it is necessary to shorten the maintenance cycle of the bearing and optimize the lubrication process.


Formulate Emergency Maintenance Plans and Supporting Measures

In addition to regular maintenance, the maintenance schedule of combined mobile crushing plant should also include emergency maintenance plans to deal with sudden faults. Sudden faults (such as sudden damage of the crushing hammer head, leakage of the hydraulic system) will cause the equipment to stop suddenly, affecting the construction progress. Therefore, it is necessary to predict possible sudden faults in advance, formulate corresponding emergency maintenance plans, and clarify the handling process, responsible personnel, and required tools and spare parts. For example, for the sudden damage of the hammer head, the emergency plan should specify the steps of disassembling the crushing chamber, replacing the hammer head, and testing the equipment, as well as the time limit for handling (such as completing the replacement within 4 hours).