1、 Daily inspection and basic maintenance (daily/shift)

1. Check before startup

• lubrication system：
  • Check the oil level of the reducer (above the centerline of the oil gauge). If the oil level is too low, supplement L-CKC220 industrial gear oil (viscosity grade 220, suitable for temperatures of -10 ℃~60 ℃).
  • Check the bearing grease (such as lithium based grease), press the grease gun 3-5 times per shift (ensure that the grease covers the bearing raceway).
• fastener：
  • Use a torque wrench to check the bolt of the tool holder (the torque value should meet the requirements of the equipment manual, such as the M16 bolt torque of 200-220N · m), to avoid loosening and causing the blade to fall off (which may cause machine jamming or equipment damage).
• safety device：
  • Test the emergency stop button (response time ≤ 0.5 seconds), safety light barrier (automatic stop when blocked), and protective cover (no damage or displacement) to ensure proper functionality.

2. Monitoring during operation

• Abnormal noise and vibration：
  • Use a vibration detector (such as Fluke 810) to monitor the spindle vibration value (normal range ≤ 5mm/s). If it exceeds 8mm/s, stop the machine for inspection (possibly due to bearing wear or blade imbalance).
• temperature control：
  • Use an infrared thermometer to measure the surface temperature of the motor and reducer (normal ≤ 70 ℃). If it exceeds 85 ℃, stop the machine for cooling (possibly due to excessive load or poor heat dissipation).
• discharge particle size：
  • 10% of the discharged materials (such as shredded metal plates with a particle size ≤ 100mm) are randomly inspected per shift. If the particle size exceeds the standard (such as>150mm block like objects), the blade gap needs to be adjusted or worn blades need to be replaced.

3. Cleaning after shutdown

• Residual materials：
  • Use high-pressure gas (pressure 0.6-0.8MPa) to clean the residual boards (especially metal shavings and wood fibers) inside the knife box to prevent jamming (accumulation of residues may cause motor overload).
• cooling system：
  • Check the water level in the water tank (cover the suction port of the water pump). If the water level is too low, add softened water (hardness ≤ 8 ° dH) to avoid scale blocking the waterway (heat transfer efficiency decreases by 30%).
• electrical cabinet：
  • Use dry compressed air (pressure 0.2-0.3MPa) to blow away dust inside the electrical cabinet (especially pay attention to the contactor and frequency converter heat sink), to prevent short circuits (dust accumulation may increase the electrical failure rate by 40%).

2、 Regular maintenance (weekly/monthly/quarterly)

1. Deep maintenance of lubrication system (weekly)

• Gearbox oil change：
  • Replace the gear oil (such as L-CKC320 industrial gear oil) every 200 hours of operation, and discharge the old oil when changing the oil (avoid mixing different viscosity oils).
• Bearing cleaning：
  • Disassemble the bearing (such as SKF 6206-2RS) every 500 hours of operation, clean it with kerosene, and apply lithium based grease (filling amount accounts for 1/2-2/3 of the bearing cavity). Adjust the clearance (radial clearance 0.01-0.03mm) when reinstalling.

2. Blade maintenance (monthly)

• Wear detection：
  • Measure the thickness of the blade with a vernier caliper (new blade thickness 20mm, wear limit 15mm). If the thickness is ≤ 16mm, it needs to be flipped for use (double-sided blades can extend their lifespan by 50%).
• Blade repair：
  • Use a portable grinding wheel (grit 80 #) to polish the blade edge (with an angle of 30 °± 2 °), and after repair, conduct a dynamic balance test (unbalance ≤ 0.5g · cm) to avoid excessive vibration during high-speed rotation.
• Blade replacement：
  • When replacing the blade, tighten the bolts in diagonal order (to prevent deformation of the blade seat) and apply thread locking adhesive (such as Loctite 243) to avoid loosening of the bolts.

3. Transmission system maintenance (quarterly)

• Belt tension adjustment：
  • Use a belt tension meter (such as BTL-01) to detect the belt tension (such as the tension of A-type belt needs to reach 80-100N). If the tension is insufficient, adjust the motor base (to avoid belt slippage and a 15% decrease in transmission efficiency).
• Coupling alignment：
  • Using a laser alignment instrument (such as Easy Laser XT660) to detect the alignment of the motor and reducer coupling (radial deviation ≤ 0.05mm, axial deviation ≤ 0.1mm), poor alignment can lead to a 60% reduction in bearing life.
• Gear wear inspection：
  • Disassemble the gearbox and inspect the gear tooth surface (without pitting, bonding, or broken teeth). If the wear of the tooth surface exceeds 20% of the module (such as the wear of a 5mm module gear>1mm), the gear needs to be replaced.

3、 Special maintenance of key components

1. Maintenance of hydraulic system (if equipped with hydraulic pushing device)

• Hydraulic oil detection：
  • Every six months, hydraulic oil is sampled and tested (including viscosity, moisture, and particle contamination). If the NAS level is greater than level 8, the hydraulic oil (such as HM46 anti-wear hydraulic oil) needs to be replaced.
• Hydraulic cylinder seal：
  • Check the sealing ring of the hydraulic cylinder piston rod (no leakage, no aging cracks). If any leakage is found, replace the sealing ring (such as Parker O-Ring 70 Shore A).
• Overflow valve pressure regulation：
  • Use a pressure gauge to measure the system pressure (in accordance with the equipment manual requirements, such as a fluctuation range of ± 0.5MPa for a 16MPa system pressure). If the pressure exceeds the standard, adjust the preload force of the overflow valve spring.

2. Electrical system maintenance

• Backup of frequency converter parameters：
  • Backup the parameters of the frequency converter (such as acceleration time, deceleration time, V/F curve) every six months to avoid parameter loss that may cause the equipment to fail to start.
• Motor insulation testing：
  • Use a megohmmeter (such as Fluke 1508) to measure the insulation resistance of the motor (insulation resistance ≥ 0.5M Ω for motors with rated voltage below 500V). If the insulation resistance is less than 0.5M Ω, it needs to be dried (temperature 80-100 ℃, drying time 8-12 hours).
• Tightening of wiring terminals：
  • Use a torque wrench to tighten the wiring terminals inside the electrical cabinet every quarter (the torque value should meet the requirements of the equipment manual, such as M10 bolt torque 18-20N · m), to avoid poor contact and heat generation (terminal temperature exceeding 90 ℃ may cause a fire).

4、 Safe operation and emergency maintenance

1. Safety operation standards

• protective equipment：
  • Operators must wear anti cutting gloves (such as Kevlar material), goggles (to prevent splashing particles), and dust masks (with a filtration efficiency of ≥ 95%).
• Prohibited acts：
  • It is strictly prohibited to open the protective door during equipment operation (which may cause mechanical injury);
  • It is strictly prohibited to directly clean the residue inside the knife box by hand (special tools such as long handled iron hooks should be used).
• Shutdown sequence：
  1. Stop the feeder;
  2. Stop the main motor after the materials in the knife box are emptied;
  3. Shut down the hydraulic system (if equipped);
  4. Cut off the power and hang a "Do Not Close" sign.

2. Emergency handling of common faults

5、 Maintenance records and data analysis

1. record content：
   • Record the equipment operation time, maintenance items (such as oil change and blade change), fault types, and handling results for each shift.
2. data analysis：
   • Monitor the fluctuation of failure rate through control charts (such as P chart) (such as the standard deviation of monthly failure frequency should be ≤ 1 time), and if it exceeds the standard, analyze the root cause (such as improper operation, poor quality of spare parts).
3. optimization objective：
   • Realize the "three reductions": reducing downtime due to faults (target ≤ 8 hours/month), reducing spare parts consumption costs (target ≤ 2% of equipment value/year), and reducing energy consumption (target ≤ 85% of rated power).