For the maintenance and upkeep of emulsion cranes, a systematic plan should be constructed from three dimensions: daily inspection, periodic maintenance, and deep maintenance of key components. The maintenance strategy should be optimized based on the characteristics of the emulsion operation environment (such as humidity, chemical corrosion, etc.). The specific implementation points are as follows:

1、 Daily inspection: Building the first line of defense for safe operation

The following core inspection items need to be completed before daily homework to ensure that the equipment meets the real-time status standards:

Structural component safety inspection

Check whether there are cracks, deformations, or rust in the metal structures such as the main arm, support legs, and turntable (especially pay attention to the corrosion situation in the contact area with the emulsion).

Confirm the tightness of bolts, pins, and other connecting components, and use a torque wrench to verify the pre tightening force of key parts (such as slewing bearing bolts).

Observe the breakage, wear, and twisting of the steel wire rope. Lubrication should cover the entire length of the rope, with a focus on the contact section with the pulley.

Hydraulic system status monitoring

Check the hydraulic oil level and cleanliness. Emulsification work environment can easily cause oil emulsification, which requires dual verification through visual inspection (turbidity) and test paper detection (water content ≤ 0.1%).

Observe the leakage at the pipeline joints and oil cylinder seals, and use fluorescent leak detectors to locate small leakage points.

Test the stability of hydraulic actions (such as telescopic arm and rotation) after startup, and record the delay time of actions (normally ≤ 2 seconds).

Functional verification of safety devices

Test the accuracy of the alarm threshold of the overload protection system (torque limiter), and the error should be controlled within ± 3%.

Confirm the triggering sensitivity of limit switches (such as lifting height and amplitude limits) and conduct analog signal triggering tests.

Check the functions of the anemometer, dashboard indicator lights, and alarm devices in the driver's cabin. Additional verification of waterproof performance is required during the rainy season.

2、 Periodic maintenance: hierarchical management improves equipment reliability

Develop monthly, quarterly, and annual three-level maintenance plans based on equipment usage frequency and environmental conditions:

Monthly maintenance (every 30 days)

Clean the radiator and filter element to prevent blockages in the oil circuit (especially pay attention to the clogging of the filter element caused by residual emulsion).

Add lithium based grease (NLGI grade 2) to the slewing bearings, pulley systems, and other parts to form a waterproof protective film.

Check the electrolyte level and electrode cleanliness of the battery, and add dehumidification treatment during the rainy season (with cab humidity<60%).

Quarterly maintenance (every 90 days)

Replace the hydraulic oil filter element and check the oil contamination level (particle counter detection, ISO 4406 standard ≤ 18/16).

Calibrate the torque limiter and adjust the brake clearance (if the brake pad thickness wears out more than 50%, it needs to be replaced).

Check the insulation of the electrical circuit (megohmmeter test, insulation resistance ≥ 2M Ω), and focus on addressing the aging of the waterproof tape at the harness joints.

Annual major overhaul (every 365 days)

Thoroughly disassemble key components (such as reducers and hoisting mechanisms), replace worn bearings and gears (if the tooth surface pitting area exceeds 30%, it needs to be replaced).

Perform non-destructive testing on metal structures (ultrasonic testing for welds, magnetic particle testing for surface cracks).

Re calibrate the performance parameters of the entire machine (lifting capacity, amplitude, rotation speed) to ensure compliance with the GB/T 6067.1 standard.

3、 Deep maintenance of key components: the core strategy for extending equipment lifespan

Hydraulic system maintenance

Replace the hydraulic oil every 2000 hours or every year, and prioritize choosing branded oils with high wear resistance (such as ISO VG46 anti-wear hydraulic oil).

Regularly clean the fuel tank, use magnetic filters to absorb metal debris, and avoid oil pollution.

When an abnormal increase in oil temperature (>80 ℃) is detected, it is necessary to investigate the problem of radiator blockage or pump valve leakage.

Wire rope and hook management

According to the GB/T5972 standard, when the diameter wear of the steel wire rope exceeds 7% or there is a concentration of broken wires (more than 10% of broken wires within one twist), it should be replaced immediately.

The opening deformation of the hook needs to be checked (if it exceeds the original size by 15%, it needs to be scrapped), and the rotational flexibility needs to be tested (without jamming or abnormal noise).

When the wear depth of the pulley groove exceeds 20% of the diameter of the steel wire rope, it needs to be replaced and tested using a sample comparison method.

Electrical system optimization

Regularly upgrade the controller software to avoid program errors that may cause misoperations (such as overloading without alarm).

Clean the contacts of sensors (such as angle sensors and pressure sensors) and verify signal stability using a contact resistance tester.

Strengthen the waterproof treatment of the line during the rainy season, and use silicone sealing rings to enhance the protection of sensor components.

4、 Special maintenance of emulsification working environment

In response to the characteristics of emulsion corrosion and moisture, the following measures need to be strengthened:

Corrosion prevention of steel structures

Rinse the frame, legs, and boom with a high-pressure water gun every week, with a focus on removing emulsion residue.

Apply epoxy primer and polyurethane topcoat to the areas where the paint has peeled off, and use WD-40 rust inhibitor for special protection at the welds.

Electrical system waterproofing

Install a dehumidifier in the cab, wrap waterproof tape around the wiring harness joints, and install a rain cover on the controller.

The insulation value of the circuit should be checked weekly, and the standard should not be lower than 2M Ω. Additional review is required after rain.

Lubrication system upgrade

Replace with NLGI grade 2 waterproof grease and implement periodic management for all 32 lubrication points on the vehicle (refill every 50 hours).

Apply lithium based grease to key parts such as the bearing seat of the pulley system and the piston rod of the hydraulic cylinder to form a protective film.

5、 Maintain records and manage data

Establish equipment maintenance files, record the content of each maintenance, replaced parts, and discovered problems, collect real-time data through IoT sensors (such as hydraulic oil temperature, wire rope tension), and combine predictive maintenance algorithms to warn of faults in advance, achieving scientific management.

The main equipment produced by Hebei Makita: stage electric hoist, electric chian hoist, wire rope electric hoist，Hand chain hoist, lever hoist, pneumatic hoist and other lifting equipment