To do a good job in the maintenance of electric winches, it is necessary to start from six aspects: daily inspection, regular maintenance, special maintenance, safety protection, operation standards, and fault handling, combined with scientific management systems and record keeping systems, to ensure the long-term stable operation of the equipment. The following are specific implementation points:

1、 Daily check: prevent problems before they happen

Pre operation inspection

Appearance inspection: Check for cracks, deformations, or corrosion in the winch casing, drum, and wire rope to ensure there are no foreign objects obstructing them.

Lubrication system: Confirm whether the oil level is within the normal range (such as the gearbox oil level needs to be between the upper and lower limits of the oil gauge), and whether the oil quality is clear and free of impurities.

Braking system: Manually test whether the brake action is flexible and whether the clearance between the brake shoe and the brake wheel meets the requirements (such as ≤ 0.7-0.8mm).

Electrical system: Check whether the cables, plugs, and control box connections are secure, without damage or aging.

Safety devices: Verify whether overload protection, speed limit protection, rope loosening protection and other devices are sensitive and reliable.

Monitoring during operation

Abnormal sound: Listen for any abnormal sounds (such as friction or impact) from the motor, gearbox, bearings, and other parts.

Temperature monitoring: Touch the motor casing, gearbox, and other parts with your hand to sense if the temperature has increased abnormally (be alert if it exceeds the ambient temperature of 30 ℃).

Vibration observation: Pay attention to whether there are any abnormal vibrations during equipment operation, especially the drum and transmission components.

Parameter recording: Record operating parameters such as current, voltage, and speed, and compare and analyze them with reference values.

2、 Regular maintenance: precise maintenance in stages

Weekly maintenance

Cleaning equipment: Remove dust and oil stains from the surfaces of motors, gearboxes, and drums to prevent blockage of heat dissipation holes.

Tighten bolts: Check and tighten all connecting bolts, especially key parts such as motor base and gearbox fixing bolts.

Lubrication and oil replenishment: Supplement lubricating grease (such as ZL-3 lithium grease) to lubrication points such as bearings and gears to ensure the integrity of the oil film.

Monthly maintenance

Brake adjustment: Measure the clearance between the brake shoe and the brake wheel, and adjust the brake spring pressure or replace worn brake shoes if necessary.

Wire rope inspection: Check whether the wire rope has broken wires, wear or rust, record the number of broken wires and evaluate the remaining strength.

Electrical testing: Use a megohmmeter to test the insulation resistance of the motor (≥ 1M Ω) and check if the grounding resistance (≤ 4 Ω) meets the standard.

Quarterly maintenance

Gearbox oil change: Drain the old oil and clean the oil tank, replace with gear oil that meets the requirements (such as winter gear oil or saturated cylinder oil).

Load test: Run the winch at rated load to verify whether the braking performance, motor temperature rise, and other indicators meet the standards.

Safety device verification: Simulate overload, overspeed, rope loosening and other working conditions to test the reliability of the protective device action.

annual maintenance

Comprehensive disassembly and inspection: Disassemble core components such as motors and gearboxes, check the wear of bearings, gears, seals, etc., and replace aging components.

Anti corrosion treatment: Apply anti rust coating to metal parts such as equipment casings and drums to extend their service life.

Performance evaluation: Entrust a professional organization to conduct a comprehensive inspection of the winch and issue a performance evaluation report.

3、 Special maintenance: for key components

Motor maintenance

Heat dissipation maintenance: Clean the dust on the motor air inlet and heat sink to ensure smooth ventilation.

Bearing maintenance: Add lubricating grease every 5000 hours of operation, and replace the bearing immediately if overheating or increased noise is found.

Winding protection: Strictly record the original parameters when replacing the winding to avoid performance degradation caused by arbitrary changes.

Brake system maintenance

Hydraulic system maintenance: Check for leaks in the brake cylinder, regularly replace hydraulic oil, and clean the filter screen.

Spring calibration: Use a spring tester to test the elasticity of the brake spring and ensure that the braking torque meets the design requirements.

Friction plate replacement: When the thickness of the brake shoe wears down to one-third of its original thickness, a new plate must be replaced.

Maintenance of steel wire rope

Lubricating coating: Use specialized steel wire rope lubricating grease (such as calcium based grease) to evenly apply to the rope body, reducing wear and corrosion.

Rope end fixing inspection: Confirm whether the fixing devices such as the rope head pressure plate and wedge-shaped joint are firm and free of looseness.

Wire breakage monitoring: Establish a record file of broken wires, and replace them immediately when the number of broken wires exceeds the standard (such as 12 broken wires when 6 × 19+1 steel wire rope is alternately twisted).

4、 Security Protection: Building Multiple Barriers

Installation of protective devices

Protective cover: Install protective covers for exposed components such as motors, gearboxes, and drums to prevent foreign objects from entering.

Limit device: Install travel limit switches at both ends of the drum to prevent the wire rope from slipping out of the groove or over winding.

Warning signs: Post warning signs such as "Do Not Touch" and "High Voltage Danger" in hazardous areas of the equipment.

Operating environment management

Moisture and dust prevention: Install the winch in a dry and ventilated room, or build a rain shelter to prevent rainwater erosion.

Temperature control: Ensure that the operating environment temperature is between -10 ℃ and+40 ℃ to avoid overheating of the motor caused by high temperatures.

Space layout: Maintain an operating space of at least 1 meter around the equipment for easy maintenance and emergency shutdown.

5、 Operation standard: cultivate good habits

Preparation for starting

No load test run: First run the equipment at low speed for 1-2 minutes without load to check if it runs smoothly.

Load confirmation: Check whether the actual load exceeds the rated value, and overloading is strictly prohibited.

Signal communication: Confirm instructions such as lifting direction and speed with the operator to avoid misoperation.

Precautions during operation

Uniform speed operation: Avoid sudden acceleration or deceleration and reduce the impact on the motor and transmission system.

Prohibition of diagonal pulling: Ensure that the steel wire rope is perpendicular to the load to prevent further wear and tear caused by diagonal pulling.

Observe the load: closely monitor the load status and immediately stop the machine for inspection if any abnormalities are found.

Post shutdown processing

Cut off power supply: Immediately disconnect the main power supply after shutdown to prevent accidental startup.

Steel wire rope return: Wrap the steel wire rope evenly around the drum to avoid tangled ropes.

Cleaning and tidying up: Clean up the debris around the equipment and keep the work area clean.

6、 Fault handling: rapid response and prevention

Common faults and their solutions

Motor not starting: Check if the power supply, control circuit, and thermal relay are working, troubleshoot and reset.

Brake failure: Adjust the pressure of the brake spring, replace worn brake shoes, or repair hydraulic system leaks.

Wire rope breakage: Immediately stop the machine and replace the new rope, and analyze the cause of the breakage (such as overload, wear, etc.).

Abnormal vibration: Check whether the drum, gears, bearings and other components are loose or damaged, tighten or replace the components.

Fault prevention mechanism

Establish a fault file: record the symptoms, causes, and handling measures of each fault, and analyze the fault patterns.

Spare parts management: Reserve commonly used vulnerable parts (such as bearings, brake shoes, wire ropes, etc.) to shorten maintenance time.

Training Enhancement: Regularly organize operators to participate in maintenance training to improve their ability to identify and handle faults.

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