What is a Double Jaw Crusher Mobile Crushing Plant?
The plant adopts a two-stage crushing process: PE series jaw crusher for primary crushing and PEX series fine jaw crusher for secondary crushing. It features a four-in-one integrated design that assembles four core components—vibrating feeder, primary jaw crusher, secondary fine jaw crusher and vibrating screen—on a single heavy-duty frame.
This all-in-one structure enables fast movement, quick site relocation and instant commissioning for production. Simple to operate and highly flexible, it perfectly meets the on-site crushing needs of sand and gravel mines, aggregate yards and construction waste recycling projects with mobile operation demands.
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Working Principle of Double Jaw Crusher Mobile Crushing Plant
The double jaw crusher mobile crushing plant relies on the coordinated operation of four core components integrated on a single frame to complete the crushing and processing of sand and gravel raw materials through a continuous process of uniform feeding → primary crushing → secondary fine crushing → classification screening. The whole process is fully automated. Thanks to its integrated design, the plant requires no on-site assembly and commissioning after relocation and can start production immediately upon startup. Its core lies in the two-stage progressive extrusion crushing of PE primary jaw crusher + PEX secondary fine jaw crusher, combined with the precise classification of the vibrating screen, to realize the integrated processing of raw materials from large stone blocks to qualified finished aggregates.
Its specific working process is completed in 5 steps, with seamless connection between all components, adapting to the mobile crushing needs of mines, sand and gravel yards, and infrastructure sites:
Vibrating Feeder: Uniform Feeding + Pre-screening, Control Feeding Rhythm
Raw stone materials are transported to the hopper of the vibrating feeder by a loader/excavator. Driven by a vibration motor, the feeder conveys the raw materials evenly, quantitatively and continuously to the feed inlet of the PE primary jaw crusher, avoiding material jamming and overload shutdown of the primary crushing chamber caused by excessive feeding. Meanwhile, some feeders are equipped with a simple pre-screening function, which can screen out soil, fine powder or small-grained stone from the raw materials in advance, reduce the load of subsequent crushing processes, and improve the overall processing efficiency.
PE Series Primary Jaw Crusher: Primary Crushing, Crush Large Stones into Medium Granularity
This is the first-stage crushing of the process. Large stone blocks enter the crushing chamber between the moving jaw and fixed jaw of the PE primary jaw crusher. Through the reciprocating swing of the moving jaw, the raw materials are crushed by extrusion and splitting, breaking large stone blocks of tens or even hundreds of centimeters into medium-grained stone that meets the feeding requirements of the PEX fine jaw crusher (the general discharge granularity can be adjusted to 50-150mm). The crushed stone is directly transported to the subsequent PEX fine jaw crusher by a conveyor belt.
PEX Series Fine Jaw Crusher: Secondary Fine Crushing, Process Medium Stone to Near-finished Granularity
This is the second-stage crushing of the process. The medium-grained stone after primary crushing enters the narrow crushing chamber of the PEX fine jaw crusher. With a smaller discharge opening and higher crushing frequency, the PEX fine jaw crusher performs secondary extrusion and fine crushing on the stone, processing it to a near-finished granularity range (the discharge granularity can be adjusted to 10-50mm as needed), meeting the fine crushing processing needs of sand and gravel aggregates. The finely crushed stone is then sent to the vibrating screen for classification by a conveyor belt.
Vibrating Screen: Multi-layer Classification Screening, Screen Qualified Finished Aggregates
The finely crushed stone enters the high-frequency vibrating screen, which is designed with a multi-layer screen mesh (2-3 layers as standard). According to the customer’s requirements for the specification of finished aggregates (such as 0-5mm stone powder, 5-10mm, 10-20mm, 20-31.5mm, etc.), the stone can be precisely classified and screened to separate qualified finished aggregates of different specifications. If there is a small amount of over-grained stone, it can be sent back to the PEX fine jaw crusher for re-crushing through the return conveyor belt, realizing full utilization of raw materials with no waste residue (the return channel is an optional design, adapting to the demand for high finished product rate).
Finished Product Discharge & On-site Stockpiling, Continuous Operation Throughout the Process
The qualified finished aggregates of various specifications after screening are directly discharged through the conveyor belt/chute built into the mobile plant, which can be directly stockpiled on the job site, or the finished products can be transported to the silo for storage with a conveyor belt. The entire crushing-screening process is fully automated and continuous, without manual transshipment, greatly saving on-site labor and material transportation costs.
Core Operational Advantages (Adapting to On-site Operation Needs)
- Integrated linkage of four components: Feeding, primary crushing, fine crushing and screening are integrated on the same frame, with precise connection between all components, no on-site assembly link, and quick startup and production after relocation;
- Controllable granularity of two-stage crushing: The combination of PE primary crushing and PEX fine crushing can adjust the discharge openings of the two jaw crushers respectively, flexibly control the granularity of finished aggregates, and adapt to different sand and gravel processing needs;
- High operation efficiency: Automated continuous feeding-crushing-screening with no waiting for material transshipment, and the double screening process of pre-screening and classification screening further improves the quality and processing efficiency of finished materials;
- Easy operation: The whole plant is centrally controlled, enabling one-key startup/shutdown, requiring only a small number of on-site operators. In addition, the mobile plant is equipped with traction/travel devices and can be directly towed during relocation without disassembly.
Core Advantages of Double Jaw Crusher Mobile Crushing Plant
As an integrated and mobile sand and gravel crushing equipment, the double jaw crusher mobile crushing plant relies on the two-stage extrusion crushing process of PE primary jaw crusher + PEX fine jaw crusher and the four-in-one frame integrated design, which perfectly solves the pain points of traditional fixed crushing production lines such as difficult relocation, complex assembly and poor adaptability. Its core advantages focus on four dimensions: high mobility, high-quality process, easy operation and controllable cost, adapting to the mobile crushing needs of mines, sand and gravel yards, infrastructure projects, construction waste recycling and other scenarios, and is the preferred equipment for on-site aggregate processing outdoors.
Integrated Design, Ultra-fast Relocation and Commissioning
The whole machine highly integrates four core components: vibrating feeder, PE primary jaw crusher, PEX fine jaw crusher and vibrating screen on a heavy-duty steel structure frame, realizing a true four-in-one integration, without on-site assembly, splicing, pipeline docking and other processes. Equipped with traction/travel devices, it can be directly towed for relocation by a trailer. After arriving at the operation site, it only needs simple leveling and power connection, and can start production in 1-2 hours, which greatly saves the time and labor cost of site planning and equipment installation, and adapts to the mobile operation needs of scattered construction points and tight construction periods.
Two-stage Progressive Crushing, Controllable Finished Aggregate Quality
Adopt the special two-stage extrusion crushing process of PE series primary crushing + PEX series fine crushing. The primary crushing efficiently crushes large raw stones into medium granularity, and the fine crushing completes fine processing through a narrow crushing chamber + high crushing frequency. The discharge openings of the two jaw crushers can be independently and flexibly adjusted, and the finished product granularity can be controlled on demand (conventional discharge 10-50mm). The crushed aggregates have regular particle shape, low content of needle and flake, and uniform gradation, meeting the quality requirements of finished aggregates for construction sand, road infrastructure, concrete mixing and other scenarios. At the same time, the two-stage crushing has a clear division of labor, avoiding overloading of a single equipment, improving crushing efficiency and extending the service life of the equipment.
Full-process Automated Operation, Easier Operation and Maintenance
Realize the continuous and automated closed-loop operation of feeding – primary crushing – fine crushing – screening, without manual material transshipment. The whole machine is operated by a centralized electric control cabinet, supporting one-key start/stop and remote monitoring. Only 1-2 on-site operators are needed to complete the whole process control, which greatly reduces labor costs. All core components of the equipment are designed with convenient access holes and hoisting positions. Daily maintenance and replacement of wearing parts do not require large dismantling tools, the maintenance operation is simple, reducing the downtime and maintenance time of the equipment, and ensuring continuous on-site operation.
Extremely Strong Site Adaptability, Flexible Operation Without Infrastructure Requirements
Unlike fixed crushing lines, it does not need to build concrete foundations or harden the site. The operation site only needs simple ground leveling, and the equipment can be directly put into operation, adapting to complex, remote and temporary operation sites such as mountainous areas, hills, mine scrap yards, and construction waste stacking points. The frame is welded with thickened section steel, with strong seismic and impact resistance, and can adapt to harsh outdoor operating environments. At the same time, the equipment has a compact layout and a small floor area, and can operate normally even in narrow sites.
Full Utilization of Materials Without Wastage, Double Improvement of Operation Efficiency and Income
The vibrating feeder is equipped with a pre-screening function, which can screen out soil and fine powder from raw materials in advance, reducing the subsequent crushing load; the vibrating screen adopts multi-layer screen mesh for precise classification, screening out qualified finished aggregates of various specifications, and a small amount of over-grained materials can be sent back to the PEX fine jaw crusher for re-crushing through the return conveyor belt, realizing 100% full utilization of raw materials with no waste residue. There is no material transshipment loss in the whole process, crushing and screening are completed integrally, and a single equipment can realize “raw stone in, finished product out”, which greatly improves the on-site processing efficiency, directly reduces the additional cost of material transshipment and waste treatment, and increases the overall income of the project.
Stable Overall Performance, Safe and Reliable Operation
All core components are equipped with heavy industry-grade configurations. The moving jaw and fixed jaw of the jaw crusher are made of high wear-resistant alloy materials, and the screen mesh of the vibrating screen and the idler of the conveyor belt are reinforced, adapting to the crushing needs of hard materials such as mine raw stones and construction waste, with low equipment failure rate and stable operation. The whole machine is designed with multiple safety protection devices, such as jaw crusher overload protection, conveyor belt anti-deviation, and hopper anti-blocking, which effectively avoid equipment jamming, overload shutdown and other problems, ensure the safety of on-site operation, and reduce the economic loss caused by equipment failure.
50 TPH mobile stone crusher plant setup for Cebu, Philippines
Application Scenarios of Double Jaw Crusher Mobile Crushing Plant
Relying on the core advantages of four-in-one integrated design, rapid relocation and commissioning, controllable particle size of two-stage crushing, and foundation-free site adaptability, the double jaw crusher mobile crushing plant has become a core sand and gravel aggregate equipment for on-site crushing and mobile processing. It can realize the integrated on-site processing of raw stone from “feeding – crushing – screening – finished product”, and is perfectly adapted to the mobile aggregate processing needs in various fields such as mine mining, infrastructure construction and solid waste recycling. It especially solves the crushing pain points of scattered construction sites, complex sites and the need for local material taking. It is widely used in core scenarios such as sand and gravel mines, road infrastructure, construction waste recycling, water conservancy and hydropower, and can also meet the flexible processing needs of emergency projects and rural infrastructure.
Sand and Gravel Mine Mining: On-site Processing of Small and Medium-sized Mines/Mine Scrap
Suitable for scenarios such as mining of small and medium-sized sand and gravel mines, open-pit mines, and recovery of mine scrap. For scattered mining points of mines and unused raw stone of scrap, the double jaw crusher mobile crushing plant can directly enter the mining site without building a fixed crushing production line, and complete the two-stage crushing and screening of raw stone on site to process qualified sand and gravel aggregates for construction and infrastructure.
Core Adaptability: No mine site infrastructure is required, the operation position can be flexibly adjusted with the movement of mining points, and the finished product particle size (10-50mm) can be adjusted on demand through two-stage crushing. It not only improves the utilization rate of mine raw stone, but also reduces the transportation cost of raw stone from mining points to fixed crushing plants, which is suitable for the low-cost and high-efficiency mining needs of small and medium-sized mines.
Road and Municipal Infrastructure Engineering: Local Material Taking to Process Engineering Aggregates
Widely used in infrastructure construction such as highways, railways, bridges and municipal roads, especially engineering scenarios with scattered construction sites and inconvenient transportation such as mountain roads, intercity highways and rural roads. It can directly enter the construction site, crush and screen the raw stone and blasting materials around the site on site, and process them into cushion materials, subgrade aggregates and concrete aggregates required for the project.
Core Adaptability: Realize “local material taking, local processing and local use”, which greatly saves the freight and time for transporting stone materials from external stockyards to the construction site. The convenient relocation can move flexibly with the construction bid section, and put into production quickly in 1-2 hours, adapting to the characteristics of tight construction period and multi-bid section construction of infrastructure projects.
Construction Waste Recycling and Regeneration: Manufacturing Recycled Aggregates at Urban Demolition Sites
Suitable for construction waste recycling scenarios such as urban demolition, old city reconstruction and construction engineering demolition. For construction waste such as concrete blocks, brick residue and gravel generated at demolition sites, it can directly enter the demolition site for on-site crushing and processing, and convert construction waste into recycled sand and gravel aggregates for road cushion, square pavement, recycled concrete production, etc.
Core Adaptability: No need to transport construction waste to a fixed recycling plant, reducing urban transportation pressure and environmental protection costs. Integrated crushing and screening can directly produce qualified recycled aggregates. The equipment has a compact layout and can operate in the narrow site of urban demolition sites, complying with the environmental protection requirements of green construction and solid waste regeneration.
Water Conservancy and Hydropower Engineering: Sand and Gravel Aggregate Processing in Remote Reservoir Areas/Rivers
For water conservancy and hydropower projects such as reservoirs, dams, river regulation and hydropower station construction, most of these projects are located in remote mountainous areas and around reservoir areas with complex sites, inconvenient transportation and poor infrastructure conditions. The double jaw crusher mobile crushing plant can directly enter the project site and crush river pebbles and raw stone around reservoir areas on site.
Core Adaptability: No need to pour concrete foundations on site, and it can operate with simple ground leveling. The whole machine is shock and impact resistant, adapting to the harsh operating environment of outdoor mountainous areas. The processed aggregates can be directly used for dam filling, river bank protection and hydropower station plant construction, solving the aggregate transportation problem of remote water conservancy projects.
Emergency Rescue Projects: Rapid Aggregate Supply for Road Rush Repair/Post-disaster Reconstruction
As a standby crushing equipment for emergency rescue and post-disaster reconstruction, it is suitable for scenarios such as road collapse rush repair, post-earthquake/flood post-disaster reconstruction and temporary engineering construction. It can be quickly deployed to the rescue site, crush surrounding stone materials on site, and provide emergency sand and gravel aggregates for road rush repair and temporary building construction.
Core Adaptability: Fast relocation speed and high commissioning efficiency, no complex debugging is required, and it can operate by connecting to the power supply. It can quickly form aggregate processing capacity in emergency sites without perfect infrastructure, meeting the emergency material demand of rescue projects.
Rural Infrastructure and Small Aggregate Processing: Small Site/Flexible Demand Processing
Suitable for rural infrastructure projects such as rural roads, rural resettlement houses and small farmland water conservancy, as well as the flexible processing needs of small sand and gravel yards in towns. These scenarios have moderate material demand, small sites and high requirements for equipment flexibility. The double jaw crusher mobile crushing plant has a small floor area and simple operation, and can meet the small-batch and multi-specification aggregate processing needs.
Core Adaptability: The whole machine is centrally controlled and only needs 1-2 operators to operate. The equipment investment and operation cost are lower than the fixed crushing production line. The finished product particle size can be flexibly adjusted according to the material demand of rural infrastructure, which is suitable for the small-scale aggregate processing scenario in town and township areas.
Temporary Processing/Outsourcing Processing of Stone Factories: Supplementing Capacity and Flexible Order Taking
For large and medium-sized stone factories, it can be used as a supplementary equipment for fixed crushing production lines. When raw material transportation is tight and the demand for finished aggregates surges, it can enter the raw material stacking site for temporary processing to quickly increase production capacity; it can also be used as an outsourcing processing equipment for stone factories to undertake crushing orders from surrounding construction sites and small mines, and flexibly move to the partner’s site to complete processing, improving the business coverage of stone factories.
Summary of Core Advantages of Scenario Application
The application of the double jaw crusher mobile crushing plant in various scenarios focuses on the three characteristics of “mobility, localization and high efficiency”, solving the pain points of difficult relocation, high infrastructure cost and high transportation cost of the traditional fixed crushing production line. At the same time, the high-quality crushing process of the two-stage jaw crusher ensures the particle shape and gradation of finished aggregates, which not only meets the aggregate quality requirements of various industries, but also can greatly reduce the comprehensive cost of on-site processing. It is a cross-scenario and highly adaptable core equipment for mobile crushing.
Maintenance and Servicing Methods for Double Jaw Crusher Mobile Crushing Plant
(PE + PEX Four-in-One Integrated Model)
The double jaw crusher mobile crushing plant features a four-in-one integrated design of vibrating feeder + PE primary jaw crusher + PEX fine jaw crusher + vibrating screen. With strong interconnection of all components and complex outdoor working conditions, the core of its maintenance and servicing adheres to the principle of “Prevention First, Regular Inspection, Graded Maintenance, and Interconnected Protection”. Standardized daily patrols, regular maintenance, and dedicated care for core components can effectively reduce the equipment failure rate (target ≤3%), extend the service life of wearing parts by more than 30%, and ensure continuous and stable operation of the entire unit. Meanwhile, it also covers the maintenance of exclusive mobile components such as the hydraulic, traveling, and electric control systems, adapting to outdoor operational needs in mines, infrastructure construction, demolition and other scenarios.
The following servicing methods are divided into six modules: Daily Basic Maintenance, Regular Graded Maintenance, Dedicated Maintenance for Core Components, Maintenance for Mobile Exclusive Systems, Seasonal/Working Condition Adaptive Maintenance, and Fault Prevention & Emergency Maintenance. They are highly practical and can be directly used as a standardized manual for equipment operation and maintenance.
I. Daily Basic Maintenance (Performed per shift/daily by operators)
Focus on three key nodes: pre-startup inspection, in-operation patrol, and post-shutdown cleaning & reset. It covers basic status checks of the core components of the entire unit to avoid immediate faults caused by material jamming, oil shortage, loosening, and deviation. The time required for a single maintenance session is ≤30 minutes.
1. Pre-startup Inspection (10 minutes before startup)
- Fasteners of all components: Check bolts and nuts of the jaw crusher frame, vibrating screen box, feeder hopper, and conveyor belt support for no loosening or falling off (focus on the connecting bolts of the jaw crusher’s moving jaw and main shaft, with torque meeting the equipment’s calibrated value);
- Lubrication system: Check the oil level of the main shaft bearings, eccentric shafts of PE/PEX jaw crushers, vibrating screen exciters, and feeder vibration motors to ensure the lubricating oil is between the upper and lower limits of the oil gauge, with no oil leakage or shortage;
- Wearing parts status: Quickly check for no large-area falling off of the jaw crusher’s jaw plates and guard plates, no damage or blockage of the vibrating screen mesh, no tearing or deviation of the conveyor belt, and no jamming of the idlers;
- Traveling/support system: For tire-type units, check normal tire pressure and no air leakage, and smooth hydraulic lifting of the outriggers; for crawler-type units, check the tightness of crawlers and no chain off; ensure the outriggers are firmly grounded and the frame is not tilted;
- Electric control/safety system: Ensure the electric control cabinet door is closed tightly with no water/dust ingress, emergency stop buttons are reset, wiring of all motors and sensors is firm, indicator lights are normal; and safety guardrails and shields are complete.
2. In-operation Patrol (Once every 1-2 hours, all-round observation)
- Operation sound: No abnormal noise or metal impact sound during the operation of jaw crushers, vibrating screens, and feeders (abnormal noise in jaw crushers is mostly caused by material jamming/loose toggle plates, and that in vibrating screens by spring breakage/exciter faults);
- Temperature control: The working temperature of jaw crusher bearings, motors, and exciters is ≤75℃ (not hot to the touch); stop the machine immediately for inspection if the temperature exceeds 80℃;
- Material flow: Uniform feeding with no off-center feeding, no over-sized feed into the jaw crusher (≤ the calibrated maximum feeding size of the equipment), no deviation or slipping of the conveyor belt, and no mesh blockage or material accumulation at the discharge of the vibrating screen;
- Hydraulic/pneumatic system: No oil leakage from hydraulic outriggers and conveyor belt deviation-correcting oil cylinders, and the pressure gauge shows normal pressure (within the calibrated range);
- Dust removal/noise reduction: The spray dust suppression system and silencing device work normally with no dust overflow or sudden increase in noise.
3. Post-shutdown Cleaning & Reset (After the end of the shift operation)
- Material cleaning: Thoroughly remove residual stone materials from the jaw crusher crushing chamber, feeder hopper, vibrating screen surface, and conveyor belt rollers; it is strictly forbidden to stop the machine with materials inside overnight to prevent material caking and chamber jamming;
- Surface cleaning: Clean dust and soil from the electric control cabinet, motors, and bearing blocks to avoid dust entering the interior and causing wear/short circuit;
- Component reset: Lift and lower the hydraulic outriggers slightly once to ensure no jamming; reset the conveyor belt to the center position; turn off the main power of the electric control cabinet and take rain and dust protection measures;
- On-site recording: Fill in the Daily Maintenance Ledger, recording equipment operation time, fault signs (e.g., slight abnormal noise, high temperature), and wear of wearing parts to achieve “early fault detection”.
II. Regular Graded Maintenance (Performed by maintenance personnel and operators in cooperation according to cycles)
Divided into weekly, monthly, quarterly, and annual overhauls, it involves in-depth inspection, replacement, calibration, and tightening of wearing parts, lubrication systems, transmission systems, and structural parts to avoid long-term faults caused by fatigue wear of components, which is the core link of equipment maintenance.
1. Weekly Maintenance (50 cumulative operating hours, time required ≤2 hours)
- Comprehensive tightening: Perform secondary tightening on all fasteners of the entire unit (focus on vibrating components such as jaw crushers, vibrating screens, and exciters) and tighten them with a torque wrench according to the calibrated torque;
- Lubrication supplement: Fill dry friction parts such as jaw crusher toggle plates, conveyor belt roller bearings, and feeder lifting lugs with lithium-based grease (Model: ZL-3, temperature range: -20~60℃) to ensure “adequate lubrication without dry friction”;
- Wearing parts inspection: Measure the jaw crusher discharge opening gap to confirm no excessive gap caused by jaw plate wear; check the tightness of the screen mesh and repair minor damage in a timely manner;
- Traveling system: For tire-type units, check hub bearings and connecting pins of the traction device and fill with grease; for crawler-type units, check no jamming of carrier rollers and top rollers, and clean gravel inside the crawlers.
2. Monthly Maintenance (200 cumulative operating hours, time required ≤4 hours)
- Lubricant replacement: Perform the first replacement of lubricating oil for vibrating screen exciters and feeder vibration motors (replaced quarterly thereafter); drain the old oil and fill with new oil (Model: N220/N320 medium-load industrial gear oil);
- Wearing parts evaluation: Detect the wear of jaw plates and liner plates; make a replacement plan if the wear exceeds 1/2 of the thickness; check the wear of the upper and lower rubber surfaces of the conveyor belt and adjust the roller position if deviation is severe;
- Transmission system: Check the tightness of jaw crusher V-belts and couplings; ensure no cracking or slipping of V-belts and no damage to coupling elastic gaskets;
- Hydraulic system: Check the hydraulic oil level and oil quality for no emulsification or turbidity; clean the hydraulic oil filter element, check no oil leakage from oil cylinders and pipelines, and replace aging gaskets;
- Electric control system: Open the electric control cabinet, clean internal dust with compressed air, and check no burning of contacts of contactors, relays and sensors, and firm wiring terminals.
3. Quarterly Maintenance (800 cumulative operating hours, time required ≤8 hours)
- In-depth lubrication: Replace the lubricating oil of the main shaft bearings and eccentric shafts of PE/PEX jaw crushers (Model: 320# extreme pressure gear oil), clean the bearing blocks, and check the bearing clearance for no looseness or burning;
- Wearing parts replacement: Replace jaw plates, guard plates and toggle plates with excessive wear (it is recommended to replace jaw plates in pairs to ensure even force bearing); replace damaged screen mesh and aging conveyor belt idlers;
- Structural part detection: Check cracks and deformation of the jaw crusher frame, vibrating screen box and frame main beam; repair minor cracks with welding in a timely manner and reinforce them, and correct deformed parts;
- Vibration system: Check the elasticity of vibrating screen springs for no breakage or permanent deformation; adjust the angle of the exciter eccentric block to ensure consistent vibration amplitude; ensure no loosening of the anchor bolts of the feeder vibration motor and intact shock absorption pads;
- Seal inspection: Replace aging seals of the jaw crusher crushing chamber, bearing blocks and exciters to achieve “no oil leakage and no dust ingress”.
4. Annual Overhaul (3000 cumulative operating hours/12 months, performed by a professional team)
Comprehensive disassembly, detection, repair and replacement of the entire unit to restore the designed performance of the equipment, taking 1-2 days, suitable for implementation during the shutdown season/equipment major repair:
- Core component disassembly: Disassemble the main shaft, eccentric shaft and moving jaw assembly of PE/PEX jaw crushers, detect the wear of shaft necks and bearings, and replace if exceeding the tolerance; disassemble the vibrating screen exciter, clean internal impurities, and replace bearings and lubricating oil;
- Structural part flaw detection: Conduct ultrasonic flaw detection on the frame main beam, jaw crusher frame and vibrating screen box to check for internal hidden cracks; cut and weld cracked parts and perform stress relief treatment;
- Comprehensive system replacement: Replace all aging hydraulic oil pipes, seals, conveyor belts and V-belts; replace aging contactors, cables and sensors in the electric control cabinet;
- Traveling/support system major repair: For tire-type units, replace aging tires and hub bearings and overhaul the traction device; for crawler-type units, replace worn crawler plates, carrier rollers and tension oil cylinders; overhaul oil cylinders and pump stations of hydraulic outriggers and replace hydraulic oil;
- Accuracy calibration: Recalibrate the jaw crusher discharge opening gap, vibrating screen amplitude and conveyor belt deviation to ensure the interconnection accuracy of all components meets the factory standards of the equipment;
- Whole unit anti-corrosion: Perform derusting and painting on metal parts such as the frame, stand and hopper (it is recommended to use heavy anti-corrosion paint to adapt to harsh outdoor working conditions).
III. Dedicated Maintenance for Core Components
(PE Primary Jaw Crusher + PEX Fine Jaw Crusher + Vibrating Feeder + Vibrating Screen)
The core crushing and screening components of the double jaw crusher mobile station are high fault-prone areas, requiring component-specific maintenance with a focus on four key indicators: lubrication, wear, clearance and vibration. The maintenance of PE and PEX jaw crushers is consistent, with only differences in discharge opening gap and lubricant dosage.
1. Dedicated Maintenance for PE/PEX Jaw Crushers (Core: Lubrication + Wear + Clearance Control)
- Lubrication requirements: The main shaft bearings and eccentric shafts use 320# extreme pressure gear oil; replace with new oil after the first 50 hours of operation, and then every 800 hours; fill hinged parts such as toggle plates and thrust plates with ZL-3 lithium-based grease weekly to achieve “adequate lubrication without oil dripping”;
- Wear control: Jaw plates, liner plates and guard plates are made of high wear-resistant alloy materials; it is strictly forbidden to crush hard foreign objects such as metals and steel bars during operation, and the feeding particle size is ≤ the calibrated value of the equipment (e.g., the maximum feeding size of PE600×900 is 500mm) to reduce abnormal wear;
- Clearance adjustment: Measure the discharge opening gap regularly; calibrate by adjusting the toggle plate gaskets and jacking screws when the gap is excessive due to jaw plate wear to ensure the finished product particle size meets the requirements; it is strictly forbidden to hard squeeze with no clearance to avoid frame deformation;
- Overload protection: The jaw crusher is equipped with an overload protection device that automatically stops when material jamming or overload occurs; do not force startup; remove materials from the crushing chamber first and check for no component damage before restarting.
2. Dedicated Maintenance for Vibrating Feeder (Core: Vibration Damping + Anti-off-center Feeding + No Jamming)
- Vibration damping system: Check the lifting lug damping pads and anchor damping springs for no breakage or permanent deformation; replace in a timely manner if deformed to avoid vibration transmission to the frame causing fastener loosening;
- Anti-off-center feeding: Install a material distribution plate in the hopper to ensure raw materials fall evenly to the middle of the feeder, avoiding one-sided wear and abnormal vibration of the feeder caused by off-center feeding;
- Cleaning maintenance: Timely clean soil and caked materials on the feeder grate to prevent grate blockage and affect the pre-screening effect and feeding efficiency.
3. Dedicated Maintenance for Vibrating Screen (Core: Exciter + Spring + Screen Mesh + Amplitude)
- Exciter maintenance: Fill with N220/N320 medium-load gear oil to the middle line of the oil gauge, replace every 600 hours, and clean internal impurities; the exciter bearing temperature is ≤75℃; stop the machine for inspection of oil quality and bearings if exceeding the limit;
- Spring and amplitude: Check the consistent elasticity of springs on both sides of the screen box for no breakage, otherwise it will cause screen box tilting and material deviation; adjust the angle of the exciter eccentric block according to screening requirements, and control the amplitude at 5-8mm to avoid screen box cracking caused by excessive amplitude;
- Screen mesh maintenance: The screen mesh is fixed with a tension type; repair minor damage with iron sheet/bolts and replace in a timely manner if severely damaged; clean residual materials on the screen surface after operation to prevent mesh blockage; multi-layer screen meshes for classified screening shall be placed according to specifications to avoid misalignment.
IV. Maintenance for Mobile Station Exclusive Systems
(Hydraulic + Traveling + Electric Control, Different from Fixed Crushing Lines)
The hydraulic system, traveling system and centralized electric control system are the core of the mobile characteristics of the double jaw crusher mobile station and also the focus of outdoor maintenance. It is necessary to do a good job in leakage prevention, dust prevention, anti-freezing and short circuit prevention to avoid system faults caused by mobile relocation.
1. Hydraulic System (Outriggers + Conveyor Belt Deviation Correction + Crawler Tension, Core: Leakage Prevention + Oil Quality + Filter Element)
- Hydraulic oil management: Use 46# anti-wear hydraulic oil (32# in winter); the oil level is between the marked lines of the oil tank with clear oil quality and no emulsification or impurities; replace the hydraulic oil every 1200 hours and clean the oil tank at the same time;
- Leakage and seal prevention: Check the gaskets of hydraulic oil pipes, oil cylinders and joints for no aging or oil leakage, and the oil pipes for no bending or damage; take protective measures for oil pipes during relocation to avoid collision;
- Filter element cleaning: Clean the hydraulic oil suction filter element and return oil filter element every 3 months and replace every 6 months to prevent filter element blockage leading to insufficient pressure of the hydraulic system;
- No-load operation: Start the hydraulic system for 2-3 times of no-load lifting/tensioning for the first time after relocation to discharge air in the pipeline and ensure smooth system operation.
2. Traveling System (Tire-type/Crawler-type, Core: Relocation Protection + Daily Inspection)
Tire-type (Suitable for flat roads and short-distance relocation)
- Tire pressure control: The outriggers are grounded during operation and the tires are no-load to avoid long-term pressure deformation; check the tire pressure (according to the equipment calibrated value) before relocation for no air leakage or bulging, and replace aging tires;
- Traction device: Check the firmness of the traction hook and connecting pin, and sensitive braking system; limit the speed to ≤30km/h during relocation to avoid component displacement of the equipment caused by sudden braking;
- Hub maintenance: Fill the hub bearings with lithium-based grease monthly to prevent bearing jamming and burning.
Crawler-type (Suitable for mountainous areas, muddy and complex terrain; flatbed trucks are required for long-distance relocation)
- Tightness adjustment: The proper tightness of the crawler is that “the upper and lower gap is 10-20mm when the crawler plate is pulled by hand”; excessive looseness easily causes chain off, and excessive tightness increases the load of the traveling motor;
- Crawler cleaning: Timely clean gravel and soil inside the crawlers and on carrier rollers to avoid gravel wearing crawler plates and carrier rollers;
- Traveling motor: Check the firm wiring of the traveling motor, fill the reducer with gear oil for no oil leakage or shortage, and avoid forcibly climbing steep slopes and obstacles during relocation.
3. Centralized Electric Control System (Core: Dust Prevention + Rain Prevention + Short Circuit Prevention + Remote Monitoring)
- Basic protection: The electric control cabinet is designed with rainproof, dustproof and explosion-proof features; the cabinet door is closed tightly during operation with intact sealing strips to avoid rain and dust ingress; cover with a rain cover when parked outdoors;
- Line inspection: Check the firm wiring terminals of motors, sensors and cables monthly for no oxidation or burning, and the cables for no damage or aging; wrap damaged parts with insulating tape and fix them;
- Heat dissipation and dehumidification: Install cooling fans and dehumidifiers in the electric control cabinet; ensure the fans work normally in high temperature in summer, and prevent short circuit caused by condensation in the cabinet in winter/rainy season;
- System debugging: Debug functions such as one-key startup/shutdown, remote monitoring and overload protection quarterly to ensure the normal operation of sensors and controllers and accurate data transmission.
V. Seasonal/Working Condition Adaptive Maintenance (Adjust according to seasons + operation scenarios for targeted protection)
The double jaw crusher mobile station is mostly operated outdoors and in the open air, with great differences in operating environments in different seasons (winter/summer/rainy season) and different working conditions (mining/construction waste/water conservancy). Adaptive maintenance is required to avoid equipment faults caused by environmental factors.
1. Seasonal Adaptive Maintenance
Summer (High temperature and heavy dust, Focus: Cooling + Dust Prevention)
- Cooling protection: Install heat dissipation covers on motors, bearing blocks and exciters to avoid direct sunlight; avoid operating at high noon temperatures if necessary; cool the bearing blocks with cold water when needed (it is strictly forbidden to directly spray motors and electric control cabinets);
- Enhanced dust prevention: Install dustproof nets at the air inlets of the electric control cabinet and motors, and clean dust on the dustproof nets every day; seal the filling ports of the hydraulic system and lubrication system to prevent dust from entering the oil;
- Oil quality inspection: High temperature easily causes oxidation of hydraulic oil and lubricating oil; check the oil quality weekly and replace the oil in a timely manner if it is turbid or has an unusual odor.
Winter (Low temperature and freezing, Focus: Anti-freezing + Preheating)
- Anti-freezing protection: Replace with low-temperature hydraulic oil (32#) and low-temperature gear oil; fill the water tank (if equipped) with antifreeze (the ratio is based on the local minimum temperature); install thermal insulation layers on hydraulic pipelines and water pipes to avoid freezing and cracking;
- Pre-startup preheating: Before starting the equipment, run all motors no-load for 5-10 minutes to preheat the hydraulic system and lubrication system; start feeding only after the oil temperature and motor temperature rise to normal;
- Water drainage and moisture proof: After operation, drain residual water in the hydraulic system and water pipes to prevent freezing at night; turn on the dehumidifier in the electric control cabinet to prevent condensation and short circuit.
Rainy Season (Humid and rainy, Focus: Rain Prevention + Rust Prevention + Anti-slip)
- Rain protection: Park the equipment at a high terrain and ensure good drainage; cover the electric control cabinet, motors and bearing blocks with rain covers and check for no water leakage in the seals;
- Enhanced rust prevention: Apply anti-rust oil to metal parts such as the frame, stand and fasteners; timely clean water and soil on the equipment surface after rain and do a good job in derusting;
- Anti-slip protection: The working surfaces of vibrating screens and conveyor belts are prone to slipping when wet; anti-slip rubber sleeves can be installed on the conveyor belt rollers and the tightness of the conveyor belt can be adjusted to avoid material slipping and deviation.
2. Working Condition Adaptive Maintenance
Sand and Gravel Mine Working Condition (Heavy dust and hard rock, Focus: Dust Prevention + Wear Resistance)
- Enhanced dust removal: Install a high-pressure spray dust suppression system and keep spraying during operation to reduce dust entering the equipment interior;
- Thickened wearing parts: Replace with high wear-resistant jaw plates, screen mesh and conveyor belts, and shorten the inspection cycle of wearing parts (from weekly to every 3 days);
- Lubrication upgrade: Use high-viscosity extreme pressure grease to reduce dry friction caused by dust entering the friction surface.
Construction Waste Recycling Working Condition (Including steel bars and concrete blocks, Focus: Anti-jamming + Iron Removal)
- Install iron removal device: Install a permanent magnet iron remover between the feeder and the jaw crusher to timely remove steel bars and metals in construction waste and avoid entering the crushing chamber to cause jaw plate damage and material jamming;
- Overload protection: Ensure the sensitivity of the jaw crusher overload protection device, which automatically stops when metal jamming occurs to avoid frame deformation caused by forced crushing;
- Frequent inspection: Check the jaw crusher crushing chamber every hour, timely remove residual metals and large concrete blocks to prevent chamber jamming.
Water Conservancy/Reservoir Area Working Condition (Muddy, humid and waterlogged, Focus: Rust Prevention + Anti-slip + Anti-sinking)
- Frame protection: Install mud guards at the bottom of the frame, timely clean mud on the frame and traveling system, and do a good job in rust prevention;
- Support reinforcement: Lay steel plates and sleepers under the hydraulic outriggers during operation to prevent the outriggers from sinking;
- Motor protection: The motor is of waterproof design, and the wiring terminals are sealed against water to avoid motor burning caused by water ingress.
VI. Fault Prevention and Emergency Maintenance (Common Faults + Prevention Methods + Emergency Solutions)
Daily maintenance focuses on “prevention”. In case of sudden minor equipment faults, rapid emergency treatment is required to avoid fault expansion leading to the shutdown of the entire unit. The following are the prevention methods and emergency solutions for 8 high-frequency faults of the double jaw crusher mobile station, which can be directly applied by operators.
| High-frequency Fault | Common Causes | Daily Prevention Methods | Emergency Solutions |
|---|---|---|---|
| Jaw Crusher Jamming | Over-sized feed, large hard foreign objects, excessive feeding speed | Strictly control the feeding particle size, install iron removal devices, and feed evenly with the feeder | Stop the machine immediately, cut off the power supply, remove materials from the crushing chamber with a crowbar (it is strictly forbidden to clean by hand), and restart after checking for no damage to jaw plates and toggle plates |
| Vibrating Screen Deviation | Inconsistent spring elasticity, deviated angle of exciter eccentric block, off-center material feeding | Regularly check springs and replace damaged ones in a timely manner; adjust the angle of eccentric blocks; feed evenly with the feeder | Stop the machine, adjust the spring height on both sides of the screen box, calibrate the angle of the exciter eccentric block, clean off-center materials on the screen surface, and run no-load until the screen surface is centered |
| Conveyor Belt Deviation/Slipping | Deviated roller position, insufficient conveyor belt tightness, off-center material feeding, material sticking to rollers | Regularly adjust the roller position to maintain conveyor belt tightness; timely clean material sticking to rollers; feed evenly | Deviation: Adjust the roller deviation-correcting bolts to reset the conveyor belt; Slipping: Tension the conveyor belt, clean material sticking to rollers, and install anti-slip rubber sleeves on rollers if necessary |
| Excessively High Bearing Temperature (>80℃) | Oil shortage, deteriorated oil quality, bearing wear, insufficient clearance | Regularly check the oil level and oil quality, and supplement/replace lubricating oil in a timely manner; regularly detect the bearing clearance | Stop the machine immediately to cool the bearings, check and replace the oil quality, detect the bearing wear, and replace the bearing if exceeding the tolerance and adjust the bearing clearance |
| Insufficient Hydraulic System Pressure | Low oil level, blocked filter element, oil leakage from oil pipes, pump failure | Regularly check the oil level and clean the filter element, and replace aging oil pipes and seals in a timely manner | Supplement hydraulic oil, clean the filter element, check for no oil leakage from oil pipes; stop the machine for repair and replace the pump immediately if the pump fails |
| Abnormal Vibration of the Entire Unit | Loose fasteners, broken springs, exciter faults, frame tilting | Regularly tighten fasteners, check springs and exciters, and ensure the outriggers are firmly grounded and the frame is level during operation | Stop the machine, comprehensively tighten fasteners, replace broken springs, overhaul the exciter, adjust the hydraulic outriggers to level the frame, and run no-load until the vibration is normal |
| Vibrating Screen Mesh Blockage/Damage | Material caking, excessive soil content, excessive impact force of feeding | Timely clean the screen surface after operation, install a buffer plate on the feeder, and remove soil by pre-screening | Clean blocked materials on the mesh, repair minor damage, replace the screen mesh if severely damaged, and adjust the feeder height to reduce the impact force of feeding |
| Electric Control Cabinet Tripping/Short Circuit | Dust ingress, water ingress, motor overload, aging lines | Take dust and rain protection measures for the electric control cabinet, install a dehumidifier, regularly check lines, and avoid motor overload | Cut off the main power supply immediately, clean dust and accumulated water in the electric control cabinet, check for no aging or short circuit of lines and no motor overload, and restart after reset |
VII. Core Points of Maintenance Management (Ensure the Implementation of Maintenance and Reduce Human Errors)
- Establish an equipment maintenance ledger: Record in detail the daily/regular maintenance content, replacement time of wearing parts, fault handling, and equipment operation time to achieve “one ledger for one machine, with traceable records”;
- Operator training: All operators must take professional training before taking up their posts, be familiar with the equipment structure, maintenance methods and emergency handling procedures, and it is strictly forbidden to operate without a license and operate in violation of regulations;
- Spare parts reserve: Reserve common wearing parts (jaw plates, screen mesh, conveyor belts, grease, seals, filter elements) and general parts (bolts, nuts, V-belts) on site to ensure quick replacement of minor faults and reduce downtime;
- Regular professional patrol inspection: Invite professional engineers from the equipment manufacturer to conduct a comprehensive patrol inspection of the entire unit every six months to check for hidden faults, calibrate the equipment accuracy, and put forward suggestions for maintenance optimization;
- Special maintenance for relocation: Before equipment relocation (transport by trailer/flatbed truck), conduct special tightening and protection for the entire unit, fix vibrating components such as jaw crushers and vibrating screens, take protective measures for oil pipes, cables and conveyor belts to avoid collision and displacement during relocation; conduct a comprehensive inspection and no-load test run before startup after relocation, and start feeding only if there is no abnormality.
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