1、 Mechanical structure maintenance

1. Blade inspection and replacement
   • Wear monitoringCheck the blade edge after daily shutdown. If there is any breakage, curling or wear to 1/3 of the original thickness, it needs to be replaced immediately.
   • Dynamic balance calibrationAfter replacing the blade, use a dynamic balance meter to check the rotor balance to avoid vibration during high-speed rotation, which may cause damage to the bearings or shaft.
   • Material matchingSelect blade materials based on material hardness (such as high manganese steel, alloy steel), and shorten the replacement cycle for hard materials.
2. Bearing maintenance
   • Lubrication management：
     • Add lithium based grease (such as NLGI No.2) to the bearing seat every 500 hours of operation, with a filling amount not exceeding 2/3 of the bearing chamber.
     • The high-speed shaft bearings adopt thin oil circulation lubrication, and the oil level needs to be maintained above the oil standard centerline. The lubricating oil (such as ISO VG 46 anti-wear hydraulic oil) should be replaced every 3 months.
   • Temperature monitoringInstall an infrared thermometer and stop the machine for inspection when the bearing temperature exceeds 80 ℃. Common reasons include insufficient lubrication, bent shaft, or material jamming.
3. Transmission system maintenance
   • Belt tension adjustmentUse a belt tension meter to test, and the tension should meet the requirements of the equipment manual (such as the initial tension of the V-belt being the width of the belt multiplied by 10N/mm), to avoid excessive looseness, slippage, or wear on the bearings.
   • Coupling alignmentCheck the coaxiality of the motor and reducer coupling every quarter, with a deviation of ≤ 0.1mm, to prevent shaft seal leakage caused by vibration transmission.

2、 Electrical system maintenance

1. Motor and control cabinet inspection
   • Temperature rise monitoringThe surface temperature of the motor should not exceed the ambient temperature+40 ℃, and the temperature inside the control cabinet should be ≤ 50 ℃. When the temperature exceeds the limit, clean the dust in the ventilation opening or add a cooling fan.
   • insulation testEvery six months, use a megohmmeter to test the insulation resistance of the motor winding. A value of ≥ 0.5M Ω is considered qualified. If it is lower than this value, it needs to be dried or the winding needs to be replaced.
   • Tightening of wiringCheck the wiring terminals inside the control cabinet. Loose connections may cause increased contact resistance, leading to local overheating and even fire.
2. Sensors and protective devices
   • overload protectionRegularly test the operating current of the thermal relay to ensure that it trips within the range of 1.1-1.2 times the rated current of the motor.
   • locked-rotor protectionSimulate material jamming and verify whether the torque limiter or current transformer can cut off the power supply within 5 seconds.
   • metal detectorIf handling materials containing metal, calibrate the detector sensitivity daily to avoid metal entering the crushing chamber and damaging the blades.

3、 Lubrication and cooling system

1. Lubricating oil management
   • Oil replacementChoose the viscosity of the lubricating oil based on the ambient temperature (such as ISO VG 32 in winter and ISO VG 68 in summer), and replace it every 2000 hours of operation or 1 year.
   • Oil circuit cleaningClean the lubricating oil filter screen every quarter to prevent impurities from entering the bearings and causing increased wear.
2. Cooling system maintenance
   • water coolerCheck the water pump flow rate (≥ 90% of the design value), cooling water temperature ≤ 35 ℃, and water quality in accordance with GB/T 1576 "Industrial Boiler Water Quality" standard.
   • Air cooled equipmentClean the dust on the heat sink, ensure that the fan airflow is ≥ 80% of the design value, and prevent the motor from overheating.

4、 Safety operation standards

1. Pre startup inspection
   • Confirm that there are no foreign objects in the crushing chamber, the protective cover is installed in place, and the emergency stop button function is normal.
   • Manually turn the rotor 2-3 times to confirm that there is no jamming or abnormal noise.
2. Monitoring during operation
   • Overloading operation is prohibited, and the feed rate must be controlled within 80% of the rated value.
   • Listening to the sound of equipment operation, abnormal vibration or noise may indicate loose blades, damaged bearings, or material jamming.
3. Post shutdown processing
   • After the rotor stops, turn off the power to avoid residual material jamming the blade.
   • Clean up residual materials at the inlet and outlet to prevent clumping from affecting the next start-up.

5、 Environmental adaptability maintenance

1. Anti corrosion treatment
   • If dealing with materials containing salt, acid and alkali, the equipment casing needs to be coated with epoxy resin anti-corrosion paint with a thickness of ≥ 120 μ m.
   • The sealing ring of the bearing seat should be replaced every six months to prevent corrosive gases from entering the lubrication system.
2. Dust and moisture prevention
   • In dusty environments such as mines and metallurgy, motors and control cabinets should adopt IP55 protection level and be equipped with air filters.
   • In humid environments (such as coastal areas), desiccants should be placed inside the control cabinet and the moisture absorption should be checked monthly.

6、 Spare parts management and recording

1. Key spare parts reserve
   • Reserve vulnerable parts such as blades, bearings, belts, etc., and the inventory level must meet at least one major overhaul requirement (such as blade reserve ≥ 20% of the total number of equipment blades).
   • Spare parts should be stored in a dry and ventilated warehouse to avoid rusting or deformation.
2. Maintenance Record
   • Establish equipment maintenance records, recording the maintenance time, content, replacement parts model, and quantity for each maintenance.
   • Predicting spare parts lifespan through data analysis, developing procurement plans in advance, and reducing unplanned downtime.