How To Maintain An Intensive Mixer Properly?

Maintaining an intensive mixer is essential to ensure its longevity and efficient operation. Here’s a comprehensive guide to help you keep your intensive mixer in top condition:

Intensive mixers
Intensive mixers
Intensive mixers

Maintenance Guide

1. Lubrication Guidelines:

Lubricate critical components such as discharge door shaft, storage hopper door shaft, weighing hopper door shaft, pressure wheel, belt conveyor supporting wheel, bearings, rollers, transmission chain, and large gear to prevent friction damage, ideally every 100 operating hours or monthly, whichever comes first.

Gearbox maintenance should be performed every three months or after every 200 operating hours, whichever occurs earlier. This includes checking oil levels, inspecting for leaks, and replacing transmission fluid if necessary.

2. Cleaning Procedures:

Before cleaning the mixer, ensure all power sources are disconnected to prevent accidental startup.

Wear appropriate personal protective equipment (PPE) such as gloves, safety goggles, and waterproof clothing to protect against high-pressure water and potential chemical exposure.

Use caution when operating pressure washers to avoid injury from high-pressure water spray.

Clean the mixer daily with a hose to prevent concrete buildup.

Utilize a pressure washer to remove concrete buildup if it occurs, and resort to cutting if necessary.

Keep the motor clean to prevent loose particles from damaging internal components.

Regularly inspect and clean the door seal to prevent buildup.

3. Checking Intensive Mixer Parts:

Regularly check and adjust the sealing gap of the discharge door.

Monitor the wear of the large gear and replace if necessary.

Conduct daily inspections of the water supply and admixture systems to detect and address any leaks promptly.

Verify the integrity of electrical contacts on the relay and replace if damaged.

Monitor the tension and wear of the main machine belt to ensure proper operation.

Common faults and solutions

Leakage:

Cause: Wear or damage to the door seal.

Solution: Replace the door seal if leakage occurs to prevent further loss of materials and ensure a tight seal.

Oil Level Too Full:

Cause: Excessive oil filling beyond the recommended level.

Solution: Use the dipstick to check the oil level and adjust accordingly to prevent overfilling, which can lead to leakage or damage to internal components.

Emulsification and Contamination of Transmission Fluid:

Cause: Failure to change transmission fluid regularly.

Solution: Change the transmission fluid at recommended intervals to prevent emulsification and contamination, ensuring smooth operation of the mixer.

Mixer Cannot Start or Shuts Down and Trips:

Causes:

Excessive material feed causing increased mixer load.

Increased resistance due to gap between blades and lining plate.

Poor tensioning of material transmission belt leading to reduced efficiency.

Disconnection of maintenance switch due to vibration.

Solutions:

Verify that all electrical connections are secure and that there are no loose wires or damaged components.

Monitor material feed to prevent overloading the mixer.

Regularly inspect and adjust the gap between blades and lining plate to maintain optimal mixing conditions.

Ensure proper tensioning of the material transmission belt to improve transmission efficiency.

Check and secure the maintenance switch to prevent unintended shutdowns.

Slow Feeding Speed of Powder:

Causes:

Blockage in the powder tank unloading system.

Deformation or damage to screw conveyor blades.

Solutions:

Clear any blockages in the powder tank unloading system to restore proper material flow.

Inspect and replace damaged or deformed screw conveyor blades to ensure smooth feeding of materials.

intensive mixer-2
Glass Raw Material Intensive Mixer
Welding Flux Intensive Mixer

Importance of Regular Inspections and Maintenance:

Regular inspections and maintenance are crucial for ensuring the optimal performance and longevity of the intensive mixer.

Scheduled maintenance helps to identify potential issues early, preventing costly breakdowns and minimizing downtime.

Proper lubrication and cleaning procedures reduce wear and tear on components, extending the lifespan of the mixer and minimizing the risk of unexpected failures.

Investing time and resources in routine maintenance not only improves efficiency but also enhances safety for operators and prolongs the overall lifespan of the equipment.

By following these guidelines and conducting regular maintenance, you can ensure your intensive mixer operates efficiently and reliably for years to come.

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