To extend the service life of a pneumatic hoist (or similar lifting equipment) in operation, system maintenance needs to be carried out from six aspects: daily inspection, periodic maintenance, key component maintenance, environmental control, operating standards, and maintenance strategies. The following are specific methods and analysis:

1、 Daily inspection: the "first line of defense" to prevent hidden dangers

Structural component inspection

Before daily homework, check whether the metal structures such as the main arm, support legs, and turntable have cracks, deformations, or rust, and whether the connecting parts such as bolts and pin shafts are loose.

Analysis: Metal fatigue or loose connections may lead to structural failure and cause safety accidents. For example, at a construction site, the crane overturned due to failure to tighten the leg bolts in a timely manner.

Hydraulic system monitoring

Check the hydraulic oil level and cleanliness, and observe whether there is any leakage at the pipeline joints and cylinder seals.

Analysis: Hydraulic oil contamination or leakage can reduce system efficiency and even damage pump valves. In a certain case, the failure to replace the hydraulic oil in a timely manner resulted in wear and tear of the pump body, increasing maintenance costs by tens of thousands of yuan.

Verification of safety devices

Test whether the overload protection system, limit switch, anemometer, etc. are sensitive, and confirm that the dashboard indicator lights and alarm devices are normal.

Analysis: Failure of safety devices is one of the common causes of accidents. Due to the failure to calibrate the torque limiter in a certain project, a suspended object fell and injured people.

2、 Periodic maintenance: "scientific planning" for graded maintenance

Monthly maintenance

Clean the radiator and filter element to prevent oil blockage; Add lubricating grease to the slewing bearing and pulley system; Check the electrolyte level and electrode cleanliness of the battery.

Analysis: Filter blockage can cause hydraulic system overheating and shorten component life. A certain enterprise has extended the filter replacement cycle by 30% through monthly cleaning.

Quarterly maintenance

Replace the hydraulic oil filter element and check the degree of oil contamination; Calibrate the torque limiter and adjust the brake clearance; Check the insulation of electrical circuits.

Analysis: Excessive oil contamination can accelerate hydraulic pump wear. In a certain case, the quarterly inspection found that the oil particles exceeded the standard, and timely replacement of the filter element prevented damage to the pump body.

Annual major overhaul

Disassemble key components such as reducers and hoisting mechanisms, replace worn bearings and gears; Perform non-destructive testing on metal structures; Re calibrate the performance parameters of the entire machine.

Analysis: Annual major repairs can detect hidden faults and extend the overall lifespan of equipment. A certain enterprise replaced the main arm with cracks in advance through annual inspection, avoiding major accidents.

3、 Deep maintenance of key components: the "core link" of precise maintenance

hydraulic system

Replace hydraulic oil every 2000 hours or annually, and prioritize selecting branded oils with high wear resistance; Regularly clean the fuel tank to prevent metal debris from contaminating the oil circuit.

Analysis: Deterioration of hydraulic oil can lead to aging of seals. In a certain case, due to the use of inferior oil, the sealing ring of the hydraulic cylinder failed prematurely, resulting in severe oil leakage.

Wire rope and hook

According to the GB/T5972 standard, the steel wire rope should be replaced immediately when the diameter wear exceeds 7% or when there is a concentration of broken wires; The opening deformation of the hook exceeds 15% of the original size and needs to be replaced.

Analysis: Wire rope breakage is one of the main causes of lifting accidents. Due to the failure to replace worn steel wire ropes in a timely manner, a suspended object fell from a construction site, resulting in casualties.

Electrical system

Regularly upgrade controller software, clean sensor contacts, and prevent signal interference; Strengthen the waterproof treatment of the line during the rainy season.

Analysis: Electrical faults may lead to misoperation. In a certain case, the oxidation of sensor contacts resulted in incorrect angle detection, causing a collision with the crane arm.

4、 Environmental control: the key measure to reduce intangible wear and tear

Anti corrosion treatment

Outdoor work equipment needs to be coated with anti rust paint and regularly cleaned of surface dirt; When not in use for a long time, do a good job of cleaning, plastic surgery, matching, and anti-corrosion.

Analysis: Corrosion can reduce the strength of metals. Due to the lack of rust prevention treatment, the structural strength of equipment at a coastal construction site decreased by 40% after 3 years of use.

temperature control

Take cooling measures in summer (such as installing sunshades) and adjust the electrolyte density of the battery in winter to prevent difficulty in starting at low temperatures.

Analysis: High temperature can cause a decrease in hydraulic oil viscosity, while low temperature can cause lubricating grease to solidify. In a certain case, the electrolyte density was not adjusted during winter, resulting in the battery freezing and cracking.

5、 Operational norms: the "basic guarantee" for standardized use

Avoid overloaded work

Strictly use according to the rated load and prohibit long-term overloading operation.

Analysis: Overloading can accelerate structural fatigue. Due to frequent overloading, the service life of equipment in a certain enterprise has been shortened by 50%.

Smooth operation

When starting and braking, the action should be gentle to avoid sudden stop and start, which may cause impact loads.

Analysis: Impact loads can damage components such as gears and bearings. In a certain case, due to rough operation, the gear of the gearbox was worn out prematurely, resulting in an increase of tens of thousands of yuan in maintenance costs.

6、 Maintenance Strategy: Efficiency Enhancement of Scientific Maintenance

Adopting state monitoring

Real time collection of hydraulic oil temperature and vibration data using IoT sensors to predict fault trends.

Analysis: Condition monitoring can reduce maintenance costs by 25% to 50%. A certain enterprise replaced the hydraulic pump with hidden dangers in advance through sensor warning, avoiding downtime losses.

Choose professional maintenance

Entrust qualified maintenance units to use original parts to ensure the quality of repairs.

Analysis: Non professional maintenance may lead to the recurrence of faults. In a certain case, due to the use of aftermarket parts, the equipment frequently malfunctioned after maintenance, resulting in a threefold increase in maintenance costs.

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