Targeted preventive measures should be taken for hydraulic winches at different stages of use to ensure safe and efficient operation of the equipment and extend its service life. The following is a detailed explanation of the phased precautions:

1、 Installation and debugging phase

1. Environmental adaptability inspection

Temperature control:

Ensure that the installation environment temperature is within the allowable range of hydraulic oil (usually -20 ℃ to+60 ℃). Preheat the hydraulic oil to above 15 ℃ in low-temperature environments to avoid difficulties in starting due to high viscosity; High temperature environments require the installation of heat dissipation devices or the use of high-temperature resistant hydraulic oil (such as HV46).

Example: When working outdoors in winter in the north, it is necessary to install an electric heater on the hydraulic oil tank and set a temperature controller to automatically start and stop.

Dustproof and Waterproof:

Hydraulic winches should be installed in dry and ventilated areas to prevent rainwater or dust from entering. If outdoor use is required, a protective shed should be built or motors and electrical control boxes with IP65 or higher protection levels should be selected.

Regularly clean the dust on the surface of the radiator (once every 3 months) to prevent blockages from affecting heat dissipation efficiency.

2. Sealing test of hydraulic system

Stress testing:

After installation, add hydraulic oil to the system to the calibration level, start the hydraulic pump and slowly increase the pressure to 1.25 times the rated pressure, hold the pressure for 10 minutes, and check whether there is any leakage at each connection.

Focus on inspecting high-pressure pipelines (such as pump outlet to winch inlet), joint threads, and seals (such as O-rings and combination washers).

Vacuum testing:

For closed hydraulic systems, a vacuum pump can be used to evacuate to -0.08MPa, and the pressure gauge can be observed for rebound to detect leakage points in the system (such as stuck valve cores or scratched cylinder walls).

3. Electrical safety verification

Grounding protection:

The motor, electrical control box, and metal casing of the hydraulic winch must be reliably grounded with a grounding resistance of ≤ 4 Ω to prevent electric shock accidents caused by leakage.

Example: Use a grounding resistance tester to regularly check and record data.

Insulation test:

Measure the insulation resistance of the motor winding to ground with a 500V megohmmeter, and the value should be ≥ 1M Ω; if it is lower than the standard, it needs to be dried or the insulation material needs to be replaced.

2、 Daily operation phase

1. Operating standards

Load limit:

Overloading operation is strictly prohibited, and the load weight must not exceed 90% of the rated lifting weight of the winch (with a safety margin reserved).

Example: If the rated lifting weight of the winch is 10 tons, the actual load should be controlled within 9 tons.

Start stop control:

When starting, run at low speed without load for 2-3 minutes, and gradually load after the system pressure stabilizes; Unload to an unloaded state before stopping the pump.

Avoid frequent starting and stopping (no more than 10 times per hour) to reduce hydraulic shock and motor overheating.

2. Parameter monitoring

Pressure and temperature:

Install pressure gauges and thermometers to monitor system pressure (normal range: 80% -100% of rated pressure) and oil temperature (normal range: 40 ℃ -60 ℃) in real-time.

If the pressure fluctuates abnormally or the oil temperature exceeds 70 ℃, the machine should be stopped immediately for inspection.

Oil level and cleanliness:

Check the hydraulic oil tank oil level daily to ensure it is within the calibration range; Take oil samples every week to test cleanliness (NAS1638 standard ≤ level 9). If it exceeds the standard, replace the filter element or oil.

3. Emergency response

Leakage response:

If the oil pipe is found to be broken or the joint leaks, immediately stop the pump and close the shut-off valve, temporarily seal it with a leak sealing tool, and then replace the damaged parts.

Example: Wrap the leakage point with a quick connector plug or rubber gasket.

Overload protection:

The winch should be equipped with overload protection devices (such as pressure relays or electronic scales), which will automatically shut down and sound an alarm when the load exceeds the set value.

Regularly test the sensitivity of the protective device (once a month) to ensure its reliable operation.

3、 Maintenance phase

1. Regularly replace vulnerable parts

Sealing element:

Replace O-rings, oil seals, and combination washers every 6-12 months, preferably using fluororubber or polyurethane materials to adapt to high temperature and high pressure environments.

Example: In humid environments such as mines, hydrogenated nitrile rubber (HNBR) seals that are resistant to hydrolysis can be used.

filter element:

The oil suction filter should be replaced every 3 months, and the oil return filter should be replaced every 6 months; If the oil cleanliness is poor, the replacement cycle needs to be shortened.

When replacing, pay attention to the installation direction of the filter element to avoid reverse direction causing filtration failure.

2. Hydraulic oil management

Oil replacement:

The first maintenance period is 500 hours, and the hydraulic oil should be replaced every 2000 hours or 1 year thereafter (whichever comes first).

Thoroughly clean the fuel tank and pipelines during replacement to avoid performance degradation caused by mixing new and old oil.

Oil testing:

Every year, samples are sent to a professional laboratory to test the viscosity, acid value, and moisture content of the oil. If the viscosity changes by more than ± 15% or the moisture content exceeds 0.1%, it needs to be replaced in advance.

3. Component maintenance

Hydraulic pump and motor:

Disassemble and inspect the clearance between the gear pump teeth (standard value ≤ 0.1mm) or the wear of the plunger pump sliding shoes every 2 years, and replace them if they exceed the tolerance.

Example: For an axial piston pump, measure the wear depth of the contact surface between the sliding shoe and the inclined plate. If it is greater than 0.05mm, it needs to be repaired or replaced.

Hydraulic valve:

Clean the directional valve, overflow valve and other control valves once a year, and check whether the valve core is stuck or worn; For solenoid valves, it is necessary to test the coil resistance (the normal value should deviate from the nominal value by ≤ 10%).

4、 Long term disuse phase

1. Rust prevention treatment

Pipeline and components:

After draining the hydraulic oil, inject anti rust oil (such as L-HM32 anti-wear hydraulic oil mixed with anti rust agent in a ratio of 10:1) into the system and run it in a cycle for 10 minutes to cover all inner surfaces with anti rust oil.

Apply butter or anti rust paint to exposed metal parts such as cylinder blocks and valve blocks.

2. Protective storage

Environmental requirements:

The winch that has been out of use for a long time should be stored in a dry and ventilated room, avoiding direct sunlight and rain.

If outdoor storage is required, the equipment should be covered with waterproof cloth and raised by more than 20cm to prevent water accumulation.

3. Regular activation

Moisture resistant operation:

Start the hydraulic pump every 3 months and run it without load for 30 minutes to drive the hydraulic oil circulation to prevent internal rust or condensation of water vapor.

Before starting, check the insulation resistance of the motor (value should be ≥ 1M Ω). If it is lower than the standard, it needs to be dried.

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