To extend the service life of hydraulic winches, maintenance measures need to be systematically implemented from seven aspects: oil management, seal maintenance, pressure control, temperature management, operating standards, regular maintenance, and professional training. The specific measures are as follows:

1、 Oil management: Cleaning and adaptation are the core

Oil selection and replacement

Choose hydraulic oil models that match the equipment and avoid changing brands at will. It is recommended to use No. 4 calcium based grease or No. 70 engine oil in summer, and No. 2 calcium based grease or No. 50 engine oil in winter to ensure that the oil viscosity adapts to temperature changes.

Check the viscosity, acid value, and moisture content of the oil every quarter, and replace it immediately if it exceeds the standards. The oil level should be maintained at 80% -90% of the tank capacity to avoid cavitation caused by too low or abnormal oil temperature caused by too high.

pollution control

Thoroughly clean the fuel tank every six months, use dough to adhere metal shavings, and prohibit wiping with cotton cloth to produce fibers. Check the pressure difference of the return oil filter every 500 hours, and replace the filter element when the pressure difference exceeds 0.3MPa.

Use a three-stage filtering device when refueling, and equip the refueling port with an air filter to prevent impurities from entering.

2、 Sealing maintenance: details determine lifespan

Seal replacement

Regularly check the elasticity of the sealing components and replace them immediately if they age or are damaged. Choose high temperature resistant and wear-resistant polyurethane or fluororubber seals, avoid twisting or squeezing during installation, and apply lubricating oil to reduce friction damage.

Install a bellows protective sleeve on the exposed part of the hydraulic cylinder piston rod to prevent dust from entering the seal.

Joint fastening

Use professional tools to check the pipeline joints, ensuring that the connections are firm and not loose. Immediately replace cracked or deformed pipelines and joints, and install anti vibration fixtures on the pipelines to reduce external impact.

3、 Pressure control: Stability is key

stress regulation

By adjusting the overflow valve, the system pressure is controlled within the design range (not exceeding 80% of the rated value), and the peak impact pressure is controlled within 1.5 times the working pressure.

Regularly check the performance of the pressure valve to ensure its normal working condition and prevent hydraulic oil leakage caused by excessive pressure.

Components Detected

After 2000 hours of operation, the hydraulic pump's volumetric efficiency is tested. If the efficiency is below 85%, it is disassembled for maintenance, with a focus on checking the wear of the distribution plate. If the flatness error exceeds 0.005mm, it is ground and repaired.

4、 Temperature management: Avoid extreme environments

Cooling system optimization

Control the oil temperature within the safe range of 30-60 ℃. Before starting the cooling system in summer, check the tension of the fan belt. Use compressed air to blow the radiator fins in reverse every month.

When the oil temperature is below 10 ℃ before starting the equipment in winter, use an electric heating device to preheat it to above 15 ℃.

Environmental protection

Pay attention to the freezing problem of the fuel tank breathing valve in winter in the north, and switch to antifreeze breathing devices in environments below -15 ℃.

5、 Operation standard: Reduce human damage

load control

Strictly follow the rated load of the equipment and avoid overloading operation. When lifting heavy objects, the operation should be gentle and stable, and should not be raised or rapidly lowered. Emergency braking in the air should be avoided as much as possible.

It is prohibited to use it beyond the rated load and rated closing times per hour (120 times).

Signal and Command

Concentrate on the operation, see the signal clearly, follow the command, and the operator is not allowed to leave the post. If there is abnormal noise or brake failure during the operation of the winch, it should be stopped immediately for inspection.

6、 Regular maintenance: preventive maintenance

Graded maintenance

Daily maintenance: Check the steel wire rope, brake, lubrication points, clean the machine body, and clear the pipes every shift.

First level maintenance: After working for 100-300 hours, thoroughly clean the machinery, re lubricate and inspect the brakes and gearbox.

Secondary maintenance: Measure the insulation resistance of the motor after 600 hours of operation, dismantle and inspect the gearbox and brake, and check for wire rope breakage.

Overhaul and improvement

Long term shutdown equipment is operated without load every month, with the oil cylinder reciprocating 10 times throughout its full stroke to prevent seal adhesion and failure.

Organize monthly system operation analysis meetings, calculate component failure rates, and make special improvements to component types with a failure rate increase of more than 5%.

7、 Professional Training: Enhancing Operational Literacy

Skill Enhancement

Operators need to master the correct start-up, shutdown, and operation procedures to avoid oil leakage or component damage caused by misoperation.

Strengthen skills such as identifying abnormal sounds and troubleshooting pressure gauge pointer shaking during training. Delay of more than 0.5 seconds in the action of the actuator is considered a precursor to a malfunction.

Tool equipment

The maintenance team is equipped with professional tools such as infrared thermometers, ultrasonic leak detectors, and oil particle size analyzers to improve the efficiency of fault diagnosis.

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