I. General Provisions

1. These specifications apply to the operation and management of vertical chain crushing equipment in fertilizer production workshops, covering the entire process of pre-production preparation, production operation, and maintenance.
2. Operators must pass training before taking up their posts. Before operation, they shall become familiar with the equipment structure and the contents of these specifications. Operators should work from the side. Operating after drinking alcohol is strictly prohibited. Operators with long hair must wear work caps.
3. The vertical chain crusher mainly consists of a lower frame, casing, upper and lower shaft seats, main shaft, rotor disc, chains (hammers), pulley, motor frame, feed hopper, etc. Power is transmitted through the V-belt to drive the main shaft to rotate. The main shaft is equipped with a rotor disc and chains. After material enters from the feed inlet, it collides with the high-speed rotating chains. After multiple impacts, it becomes powder or particles below 3 mm and is discharged from the lower part. This machine has strong adaptability to materials with a moisture content of 20%–50% and is not easily blocked. It is especially suitable for crushing fermented organic fertilizer, compost, and other raw materials.

II. Pre-Production Preparation Stage

2.1 Pre-Startup Inspection

1. Equipment integrity inspection: Check whether all parts are installed securely and whether fasteners are loose, especially easily loosened parts such as chains and hammers. Check whether there are foreign objects in the casing; clean them promptly if present. Before restarting equipment that has been out of service for a long time (over 30 days), test the motor insulation with a megohmmeter.
2. Lubrication system inspection: The bearings bear the entire load of the machine, and good lubrication directly affects bearing life. Bearings should be greased once per shift with No. 3 calcium-based grease. The fill amount should be 1/3–1/2 of the bearing housing volume. Replace with new lubricating grease periodically, and clean the bearings during replacement. Check whether the oil/grease quantity at each lubrication point is sufficient.
3. Transmission system inspection: Check whether the transmission belt is installed correctly and whether the tension is suitable. If too loose, it will slip; if too tight, it will increase motor load and belt wear. If there is oil on the belt or sheave, wipe it clean promptly with a clean rag.
4. Electrical inspection: Power connections should be firm and reliable, insulation should be good, and grounding should be correct. Check whether the power socket, plug, and power cord are damaged or detached.
5. No-load trial run: For newly installed or overhauled equipment, before startup, rotate the rotor by hand to check whether it rotates flexibly and whether there is any collision inside the casing. After connecting power, run without load for 2–3 minutes first, check whether the rotation direction is correct, and feed material only after confirming smooth operation and no abnormal noise.

2.2 Material Preparation

1. Confirm that the material to be crushed contains no hard foreign matter such as iron blocks or stones, so as to avoid damaging the chains or causing accidents.
2. Materials with a moisture content of 20%–50% can be crushed normally, but the feed speed should be controlled during feeding. Wet materials easily stick and form lumps, so even greater attention should be paid to uniform feeding.

III. During Production Operation

3.1 Startup Sequence

1. This machine must be started under no-load conditions. Startup with material is strictly prohibited.
2. Connect the power, start the motor, and let the equipment run idle for 2–3 minutes to confirm normal operation.
3. After the equipment runs smoothly, begin slow and uniform feeding.

3.2 Operation Monitoring

1. Feeding operation: Material should be added slowly and uniformly into the feed inlet. The feed speed must not be too fast; otherwise, the crushing chamber will be blocked. The operator should stand at the side to prevent hard objects from being ejected from the feed inlet and causing injury.
2. Operation monitoring:
   • Always observe the operating condition of the equipment and listen for abnormal noise (such as metal collision or friction). If abnormality is found, stop immediately and inspect.
   • Observe the ammeter reading. Excessive current may indicate too much material in the crushing chamber or entry of foreign objects.
   • Observe the discharge condition to ensure smooth discharge and that the crushed material particle size meets requirements.
   • Check the bearing oil temperature. If it rises, stop immediately to inspect the cause and eliminate it.
3. Safety discipline:
   • It is strictly prohibited to put hands into the feed inlet or force feeding, and strictly prohibited to use wooden sticks or similar objects to assist feeding.
   • Do not arbitrarily increase the main shaft speed during operation, so as to prevent machine damage and personal injury caused by high-speed rotation.
   • Guards for transmission parts must always remain installed.
   • During work, the operator must not leave the post. If it is urgent to leave, stop the machine and disconnect power.

3.3 Shutdown Operation

1. Normal shutdown:
   • Stop feeding first, let the crusher continue running, and shut it down only after the material inside the machine is completely discharged.
   • Turn off the motor power and cut off the main power of the control cabinet.
   • Hang a “Stopped / Do Not Operate” warning sign.
2. Emergency shutdown (abnormal shutdown):
   • Immediately press the emergency stop button or cut off power to perform emergency shutdown.
   • Handling after emergency shutdown: The cause of the fault must be identified and eliminated before restarting according to the startup sequence. It is strictly prohibited to force startup before the fault is eliminated. At the same time, the emergency shutdown time, cause, and handling process should be recorded in detail in the Equipment Operation Record.
3. Post-shutdown on-site handling (mandatory):
   • Clean residual material inside and outside the crusher to prevent caking from affecting the next use.
   • Close and lock the inspection door to prevent dust entry.
4. Shift-change shutdown requirements:
   • Before handover, the equipment must be stopped and cleaned, and the Equipment Operation Record and Shift Handover Record must be truthfully filled in, noting the equipment operation status during the shift, abnormalities, and countermeasures.
   • Before startup, incoming shift personnel must re-confirm the equipment status against the inspection requirements in the “Pre-Production Preparation Stage.”

IV. Maintenance and Care

4.1 Daily Maintenance (Each Shift)

1. Equipment cleaning: After daily work is finished, clean residual fertilizer, mud, etc. on the equipment surface and inside the equipment to prevent corrosion and blockage.
2. Lubrication management: Regularly check and replace lubricating oil to ensure that rotating parts (such as bearings and gears) are fully lubricated.
3. Fastener inspection: Check whether all screws and nuts are loose, and tighten them when necessary.
4. Electrical system inspection: Confirm that wiring connections are firm and undamaged, and that switches and sensors work normally.
5. Check the operation status of the spray device.

Regular Maintenance

1. Lubrication maintenance cycle:
   • Regularly lubricate support rollers, thrust rollers, and transmission gears.
   • The injected lubricating oil must be clean, and seals must be good.
   • (Note: For detailed lubrication guidance, see the equipment lubrication nameplate.) Transmission system maintenance:
2. Fastener inspection: Regularly check whether all fasteners are tight. If looseness is found, handle it promptly. Newly installed riding rings are prone to loosening and must be checked frequently.
3. Wearing parts inspection and replacement: Pay attention to checking the wear degree of wearing parts (chains, hammers, etc.), and replace worn parts at any time. After the crusher has operated for a certain period, severely worn chains or hammers should be replaced in time.
4. Guard inspection: Regularly check whether guards are intact.
5. Electrical system: Regularly inspect power and cable lines to ensure electrical safety.

4.3 Long-Term Shutdown Maintenance

When the equipment is out of service for more than 30 days, thoroughly clean the inside and outside of the equipment, and apply anti-rust grease to exposed rotating parts. During long shutdown, remove the transmission belt. Before restarting, test the motor insulation with a megohmmeter, trial run according to the no-load trial run requirements, and only feed production after confirming normal operation.

4.4 Fault Handling Principles

1. If abnormal sound, excessive bearing temperature, severe vibration, etc. are found, stop immediately; restart only after the cause is identified and the fault is eliminated.
2. It is strictly prohibited to run equipment with faults, and strictly prohibited to perform maintenance or cleaning while the equipment is running.
3. When repairing transmission parts or entering the crushing chamber, cut off power and hang a “Do Not Close Switch” warning sign.

V. Common Faults and Remedies