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Mobile Crusher Maintenance and Operation Guide

I. Pre-Operation Preparation

As an efficient crushing equipment, the mobile crusher requires a comprehensive inspection before startup to ensure it is in a safe operating state. The specific steps are as follows:

1. Equipment Appearance Inspection: Check if the machine body has deformation, cracks, or loose parts. Focus on inspecting the integrity of the feed inlet, crushing chamber, and discharge conveyor belt. Remove debris and residual materials attached to the equipment surface.
2. Oil and Lubrication Inspection: Check if the oil levels in the hydraulic oil tank and gearbox meet the standard scale. The oil should be clear, free of turbidity and impurities. Ensure that all lubrication points (such as bearings and transmission parts) are filled with grease as required to avoid component wear caused by dry friction.
3. Electrical System Inspection: Check if the connections of power cables and control lines are secure, and if there is any damage or aging. Test the sensitivity and effectiveness of safety controls such as emergency stop buttons, overload protection devices, and indicator lights. Ensure the electrical system is properly grounded.
4. Material and Site Preparation: Confirm that the hardness and particle size of the materials to be crushed meet the rated processing range of the equipment (preventing ultra-hard materials such as metal blocks from entering the crushing chamber). Clean the work site to ensure no obstacles around the equipment, reserve sufficient space for operation and maintenance, and check the smoothness of the feed hopper and discharge area.

II. Operation Process and Specifications

Following the correct operation process is the core of ensuring the efficiency and safety of the mobile crusher. The following steps must be strictly implemented:

1. Startup Sequence: Adopt the "back-to-front" startup principle. First start the discharge conveyor belt, wait for it to run stably, then start the crushing main machine, and finally start the feeding device (such as a vibrating feeder). Avoid overloading the equipment due to starting with a load.
2. Operation Monitoring: During the operation of the equipment, the operator must observe the following indicators in real time:
   • Sound of the crushing chamber: During normal operation, it should be a uniform "crushing sound". If there is a sharp abnormal noise or jamming sound, it may be due to material blockage or loose parts, and the machine must be shut down immediately for inspection.
   • Temperature of motor and bearings: Regularly detect the temperature of the motor and main shaft bearings with a temperature detector. The normal temperature should be ≤70℃. If it exceeds 80℃, the machine must be shut down for cooling and the cause (such as insufficient lubrication, overload, etc.) must be investigated.
   • Material processing capacity and particle size: Adjust the crushing gap (such as the jaw plate gap of the jaw crusher, the gap between the fixed cone and moving cone of the cone crusher) according to the required discharge particle size to ensure uniform discharge particle size. At the same time, avoid equipment congestion caused by excessive feeding volume.
3. Shutdown Process: First stop the feeding device, wait for all materials in the crushing chamber to be discharged, then turn off the crushing main machine, and finally stop the discharge conveyor belt. After shutdown, clean the residual materials on the equipment surface and in the crushing chamber, turn off the main power supply, and make operation records (such as operation time, fault conditions, etc.).

III. Daily Maintenance Key Points

Daily maintenance can extend the service life of the mobile crusher and reduce the incidence of faults. The following maintenance work must be performed regularly on a daily, weekly, and monthly basis:

1. Daily Maintenance

• Clean the residual materials on the equipment surface, feed inlet, and discharge outlet. Check if the seals (such as dust covers and sealing rings) are intact to prevent dust leakage.
• Check if the connecting bolts (such as the main machine base bolts and conveyor belt support bolts) are loose. Tighten them in time if there is any looseness.
• Replenish the grease at each lubrication point. Check if there is any leakage in the oil pipeline to ensure the lubrication system is unobstructed.

2. Weekly Maintenance

• Check the wear of crushing components (such as jaw plates, blow bars, and liners). If the wear amount exceeds the specified standard (such as the jaw plate thickness is reduced by 1/3), replace or repair them in time to avoid the worn components affecting the crushing efficiency or damaging other parts.
• Clean the filter element of the hydraulic system and check the cleanliness of the hydraulic oil. If the oil is turbid, replace it with new oil (the hydraulic oil replacement cycle is usually 6 months, subject to the equipment manual).
• Check the tension and deviation of the conveyor belt. Adjust the conveyor belt rollers to ensure the conveyor belt runs smoothly without slipping or deviation. If the conveyor belt surface is damaged, repair or replace it in time.

3. Monthly Maintenance

• Conduct a comprehensive inspection of the motor and reducer. Test the insulation performance of the motor (the insulation resistance should be ≥0.5MΩ). Check the meshing condition of the reducer gears. If there is abnormal wear or abnormal noise, disassemble and overhaul it.
• Check the safety protection devices of the equipment (such as overload protectors and limit switches) and conduct simulation tests to ensure their sensitive and reliable triggering.
• Inspect the structural parts of the equipment (such as the frame and feed hopper) to check for cracks in welding points and structural deformation. Reinforce or repair them in time if any problems are found.

IV. Common Fault Handling

Various faults may occur during the operation of the mobile crusher. It is necessary to quickly identify the cause of the fault and take correct handling measures to avoid fault expansion. The common faults and handling methods are as follows:

Fault Phenomenon	Possible Causes	Handling Methods
Failure to start the crushing main machine	1. Insufficient power supply voltage or line open circuit; 2. Motor fault (such as winding burnout); 3. Material blockage in the crushing chamber; 4. Overload protector triggered	1. Check the power supply voltage and repair the open circuit line; 2. Detect the motor windings and replace the damaged motor; 3. Shut down the machine to clean the blocked materials in the crushing chamber; 4. Reset the overload protector and investigate the cause of overload (such as excessive feeding volume)
Uneven or excessive discharge particle size	1. Improper adjustment of the crushing gap; 2. Severe wear of crushing components (such as jaw plates, blow bars); 3. Excessive feeding volume or uneven material particle size	1. Readjust the crushing gap to meet the discharge requirements; 2. Replace the worn crushing components; 3. Control the feeding volume, screen the material particle size, and prevent materials with excessive particle size from entering
Severe vibration or abnormal noise during equipment operation	1. Loose bolts