The operation, maintenance and upkeep of the electric winch after installation need to be carried out from eight core modules: operating environment management, motor special maintenance, lubrication system maintenance, braking system maintenance, electrical system maintenance, safety device maintenance, wire rope maintenance, and regular inspection and testing. The specific methods are as follows:

1、 Operating environment management

Maintain dryness and cleanliness: The surface and surrounding environment of the electric motor should be regularly cleaned to prevent dust, fibers, and other blockages from entering the air outlet, and to avoid electrical components from short circuiting or rusting in humid environments.

Temperature and ventilation control: Ensure that the operating environment temperature of the equipment is within a reasonable range (usually -10 ℃ to+40 ℃), avoiding high temperature causing motor overheating or low temperature affecting lubricating oil fluidity.

2、 Special maintenance of motor

Thermal protection monitoring: If the thermal protection of the motor continues to operate, the cause of the fault (such as motor overload, low setting value of the protection device) needs to be investigated, and the fault must be eliminated before resuming operation.

Bearing maintenance:

Lubrication cycle: After running the motor for about 5000 hours, it is necessary to replenish or replace the lubricating grease (such as ZL-3 lithium grease). If the bearing is found to be overheated or the lubrication has deteriorated, it should be replaced immediately.

Clearance inspection: When the vibration and noise of the bearing increase significantly, it is necessary to check the radial clearance and replace the bearing when it reaches the specified value.

Winding protection: When replacing the winding, it is necessary to record the original winding form, size, number of turns, and wire gauge to avoid performance deterioration caused by arbitrary changes.

3、 Lubrication system maintenance

Lubrication point inspection: Regularly check the oil level and quality of lubrication points such as gearbox, gear meshing parts, bearings, etc., to ensure smooth oil flow and no deterioration or sedimentation.

Oil pump maintenance: Check the operation status of the lubricating oil pump to ensure that the oil ring rotates normally and the oil temperature is within a reasonable range, and adjust any abnormal situations in a timely manner.

Oil replacement: The reducer should be lubricated with winter gear oil or saturated cylinder oil, and should be replaced once a year; The main shaft bearings and the output shaft end bearings of the reducer should be replaced with No. 4 calcium based grease every two years.

4、 Brake system maintenance

Inspection of brake wheels and brake shoes: Regularly check the wear of brake wheels, brake discs, and brake shoes to ensure that the gap between the brake block and brake disc meets the regulations (such as when the brake is released, the gap between the brake shoe and brake wheel is ≤ 0.7-0.8mm).

Maintenance of transmission mechanism: Check whether the brake system transmission mechanism (such as hydraulic station, transmission rod) is flexible and reliable, and whether the safety brake operates normally.

Spring and counterweight inspection: Check whether the disc-shaped spring of the disc brake has failed, whether the brake counterweight is cushioned by foreign objects, and ensure the reliability of the braking system.

5、 Electrical system maintenance

Grounding and insulation inspection: Regularly check the grounding resistance (≤ 4 Ω) and insulation resistance (≥ 1M Ω) of the equipment to ensure electrical safety.

Controller and contact maintenance: Check the burning condition of the main controller, electromagnetic contactor, relay and other contacts, and promptly repair or replace the contacts to ensure good contact.

Signal device testing: Test signal devices such as deceleration alarm bells and over roll protection switches to ensure sensitive and reliable operation.

6、 Maintenance of safety devices

Over roll protection test: Simulate the situation where the lifting container exceeds the normal terminal stop position by 0.5 meters to verify the automatic power-off and safety brake braking functions.

Overspeed protection test: When the lifting speed exceeds 15% of the maximum speed, verify the automatic power-off and safety brake braking function.

Speed limit device inspection: winches with lifting speeds exceeding 3m/s must be equipped with speed limit devices to ensure that the speed of the lifting container does not exceed 2m/s when it reaches the terminal position.

Loose rope protection test: The winding electric winch needs to be equipped with a loose rope protection device to verify the automatic power-off and alarm function when the steel wire rope is loose.

Gate gap protection test: When the gate gap exceeds the specified value, verify the automatic alarm or automatic power-off function.

7、 Maintenance of steel wire rope

Regular inspection: Check whether the steel wire rope is wound neatly on the drum, whether the rope head is firmly fixed, and check the records of broken wires and wear.

Lubrication and rust prevention: The steel wire rope needs to be coated with special grease to reduce friction and rust. If the wear exceeds the technical safety specification limit, it should be replaced immediately.

8、 Regular inspection and testing

No load test run: After installation, conduct a no-load test run to check the smoothness of operation, smooth switching between forward and reverse directions, and no abnormal vibration or noise.

Load test: Load in stages to 50%, 75%, and 100% of the rated load, run for 10 minutes each time, and observe the equipment's operating status and parameters (such as current and temperature).

Overload test: Conduct a 110% rated load test (duration ≤ 5 minutes) in a safe environment to verify the structural strength of the equipment and the reliability of the braking system.

Braking performance test: Emergency braking under rated load, measuring braking distance and time to ensure compliance with design requirements (such as braking distance ≤ 0.5m/s ² deceleration).

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