A systematic solution is provided for possible defects in the support points of hydraulic winches, such as wear, looseness, deformation, or leakage, covering fault diagnosis, repair methods, and preventive measures

1、 Common support point defects and diagnosis

Wear of support points

Performance: Scratches, dents, or metal peeling on the surface of the supporting shaft, bearing, or fixed seat.

Reason: Long term exposure to heavy loads, insufficient lubrication, invasion of impurities, or material fatigue.

Diagnosis: Locate the worn area through visual inspection, ultrasonic testing, or vibration analysis.

Loose support points

Performance: Abnormal noise, vibration, or unstable torque transmission during operation.

Reason: Loose bolts, deformed fixing seats, or cracked welding points.

Diagnosis: Use a torque wrench to check the tightening force of bolts, or use a laser alignment instrument to detect the offset of support points.

Support point deformation

Performance: The supporting structure bends, twists, or cracks, causing the winch to run skewed.

Reason: Overload, impact load, or insufficient material strength.

Diagnosis: Use a coordinate measuring instrument or strain gauge to detect deformation.

Hydraulic system leakage

Performance: Oil leakage near the support point may cause lubrication failure or environmental pollution.

Reason: Aging of seals, rupture of oil pipes, or loose joints.

Diagnosis: Use fluorescent leak detector or pressure test to locate the leak point.

2、 Targeted repair plan

1. Wear and tear repair of support points

Surface Treatment

Minor wear: Use electric brush plating or laser cladding technology to restore surface dimensions.

Severe wear and tear: Replace the supporting shaft or bearing and use high hardness alloy materials (such as chromium molybdenum steel).

Lubrication optimization:

Regularly replace lubricating grease and choose synthetic lubricants that are resistant to extreme pressure and high temperature (such as lithium based composite grease).

Install an automatic lubrication system to ensure a continuous supply of lubricating oil.

2. Loosening treatment of support points

Tightening and reinforcement:

Retighten the bolts to the specified torque and use anti loosening glue (such as Loctite 243) or spring washers.

Weld or locally reinforce the fixed seat to enhance structural rigidity.

Dynamic monitoring:

Install vibration sensors to monitor the loosening trend of support points in real time and provide early warning and maintenance.

3. Deformation correction of support points

Mechanical correction:

Use hydraulic jacks or presses to cold straighten the bent parts, and then perform stress annealing treatment after correction.

Structural replacement:

If the deformation is severe, the entire support frame needs to be replaced and the design optimized (such as adding reinforcement bars or using a box structure).

4. Leakage control of hydraulic system

Seal replacement:

Select high-pressure and corrosion-resistant seals (such as fluororubber O-rings) and ensure correct installation direction.

Oil pipe repair:

Cold press sleeve repair or replacement of high-pressure hydraulic hose (such as SAE 100R12 standard) for ruptured oil pipes.

Joint fastening:

Use double sleeve or welded joints to avoid loose threads.

3、 Preventive measures and maintenance recommendations

Regular inspection:

Develop a maintenance plan and conduct quarterly checks on support point wear, bolt tightening, and hydraulic system sealing.

Load management:

To avoid overloading operation, install torque limiters or overload protection devices.

Environmental control:

In damp or corrosive environments, apply anti rust paint or use stainless steel material to the support points.

Operation training:

Train operators to standardize starting, braking, and reversing operations to reduce impact loads.

Spare parts reserve:

Reserve key spare parts (such as support shafts, bearings, seals) to shorten downtime due to malfunctions.

4、 Case reference

Repair of wear on the support shaft of a hydraulic winch in a certain mine:

Using laser cladding technology to repair worn surfaces, the hardness is increased to HRC55 or higher, and the service life is extended by three times after repair.

Deformation treatment of hydraulic winch support seat in a certain port:

Optimizing the support structure through finite element analysis, using Q345B steel and adding reinforcement bars, reducing deformation by 80%.

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