Intro
Unplanned downtime and high repair cost have always been big pain points for concrete batching plant owners across global construction industry. Irregular cleaning, neglected lubrication and untimely component inspection easily lead to measuring inaccuracy, blocking failure, air leakage and sudden shutdown, severely delaying infrastructure construction progress.
Based on decades of after-sales service experience on stationary & mobile concrete mixing equipment, our engineering team sorts out a full standardized maintenance manual covering general daily upkeep, aggregate feeding, weighing, mixing, powder supply and pneumatic system. Following this systematic maintenance plan can effectively stabilize hourly output, guarantee concrete quality, extend machine service life and cut long-term operation expense for batching plant operators.
General Daily Routine Maintenance
Daily maintenance is the foundation of stable running, operators must finish below checks per shift:
1.Keep the whole machine and surrounding site clean; clear residual material inside weighing hopper for accurate sensor zero reset.
2.Check lubricating oil volume of all lubrication points, ensure sufficient oil inside air oil mist unit of pneumatic system.
3.Inspect all motors and electrical components for overheating or abnormal noise; verify instrument reading and signal alarm system in good condition.
4.Adjust cylinder, butterfly valve and solenoid valve to guarantee flexible opening & closing as designed. Repair air leakage, oil leakage, dust leakage and electric leakage instantly once found.
5.Clean main mixer and discharge hopper every 4 hours to avoid solidified leftover concrete blocking discharging.
6.Drain accumulated water inside air compressor, air tank and filter after each shift, troubleshoot existing faults timely.
7.Follow original equipment manual to service butterfly valve, mixer, solenoid valve, air filter and oil mist device periodically.
Aggregate Feeding Conveyor System Maintenance
Aggregate belt conveyor is vulnerable to sticky mud and material blocking, implement shift & periodic maintenance as below:
1.Pre-operation no-load inspection per shift: remove sundries and sticky mud, fasten loose bolts, adjust conveyor belt deviation to ensure flexible rotation of all rolling parts.
2.Replace lubricant of electric drum regularly complying with factory specification.
3.After 6-month running, refill grease for all rotating bearing positions; fully disassemble and change grease once per year afterwards.
4.Frequently check and adjust scraper cleaner to make scraper closely fit belt surface for efficient residual material removal.
Weighing & Dosing System Maintenance
Precise dosing decides finished concrete strength, focus on these maintenance items:
1.Check and adjust flexible connectors of all weighing hoppers every shift, reserve proper margin to secure weighing precision.
2.Drain all residual water inside water & admixture pipeline after shutdown in cold winter to prevent pipe freeze crack.
3.Complete reverse flushing for admixture pump during seasonal idle period to avoid additive precipitation and pipeline blockage.
Core Mixing System Maintenance
Main mixer is the heart of batching plant, detailed maintenance refers to MAO Twin-shaft Mixer Official Manual with key highlighted items:
1.Check shaft-end sealing cavity, distributor ports and sealing pipeline unobstructed with full grease filling; confirm enough lube oil in reducer case every shift.
2.Check grease storage barrel of automatic electric lubrication pump; refill grease before empty to forbid no-oil dry running.
3.Thoroughly clean mixing drum interior & exterior plus discharge gate after each shift, wash with water and chisel off stubborn solid concrete regularly.
4.Fasten and adjust mixing blades once per week to prevent blade falling off and equipment accident.
Powder Supply & Screw Conveyor Maintenance
Cement silo and screw conveyor often get blocked by agglomerated cement, regular weekly maintenance required:
1.Start silo top dust remover vibrator multiple times weekly to shake off dust stuck on filter bags and keep smooth ventilation.
2.Fully clean inner wall of feeding pipeline and screw outlet weekly to avoid lump blocking and insufficient discharging.
3.Empty residual cement inside screw conveyor if equipment keeps idle for long period.
4.Inject grease every four hours for head outer spherical bearing and middle support bearing of standard WAM-type screw conveyor; first reducer oil replacement after 500 working hours, then annual grease change with No.00 lithium base grease.
Full Pneumatic System Maintenance (Air Compressor+Cylinder+Solenoid Valve+Air Treatment Unit)
Pneumatic system controls all pneumatic gates, systematic maintenance divides into four modules:
- Air Compressor Maintenance
- Pre-use: Fix compressor on level ground with good ventilation, avoid rain wash and direct sunlight exposure; set upper & lower limit of automatic pressure switch properly to prevent slow cylinder action or seal damage; check oil level between upper/lower scale mark and replenish oil timely; adjust belt tightness (around 10mm depression by finger press), replace whole belt group together when changing.
- Running period: Monitor working pressure under rated value, stop machine for inspection once oil leakage, air leakage or abnormal noise occurs.
- Periodic service: Drain condensate water from air tank drain valve after shutdown; change lubricant every 1000 working hours or 4 months; clean filter cartridge (blow paper filter from inside out with compressed air, wash sponge filter with detergent and dry completely) to avoid cylinder abrasion and carbon deposit caused by dusty intake air.
- Pneumatic Cylinder Maintenance
Cylinder converts compressed air into mechanical power; rely on oil mist unit for inner lubrication. Install extra oil mist between aggregate bin air pipes for far-end cylinder insufficient lubrication. Coat butter on piston rod against rust; repair inner/outer air leakage by replacing worn piston sealing and rod packing promptly.
- Solenoid Valve Maintenance
Solenoid valve controls air flow direction. Disassemble and clean all spare parts with clean diesel when exhaust port leaks under standard air pressure, daub thin machine oil after drying; replace spare part for seriously worn piston or damaged sealing ring.
- Water-Oil Separator & Oil Mist Unit Maintenance
Water-oil separator drains moisture and impurity from compressed air; drain sewage in water cup manually regularly. Use regular diesel engine oil for oil mist device, replace oil every 100 working hours based on 100ml oil cup capacity. Pressure regulating valve stabilizes output air pressure matching actual demand of each pneumatic component.
Conclusion
Scientific periodic maintenance lowers unexpected repair cost by over 30% and prolongs whole plant service life effectively. Our technical team provides free after-sales maintenance consultation and customized maintenance plan for all mobile & stationary concrete batching plants including HZS, YHZS, Mobile120 series. If you have equipment breakdown or maintenance confusion, feel free to leave message or contact us directly.
