A systematic and applicable plan covering operating specifications, maintenance, emergency response to faults, and safety management can be developed for pneumatic hoists in operation, as follows:

1、 Operation standard scheme

Pre startup inspection

Air source system: Confirm that the compressed air pressure is stable (6-8 bar), there are no leaks in the gas supply pipeline, and the filters, pressure regulating valves, and oil mist devices are working properly.

Equipment status: Check if the chain, hook, and limiter are intact, if the brake clearance meets the standard (such as 0.5-1mm), and if there is no oil leakage between the motor and gearbox.

Environmental safety: Ensure that the workspace is spacious, obstacle free, and the hanging points are firm and reliable (such as a 6-ton hoist that requires at least 2 anchor cables).

Running operation

Load control: Overloading is strictly prohibited, with a safety upper limit of 90% of the rated load to avoid emergency stops and starts. The principle of "slow start, slow stop" is adopted.

Stable operation: Maintain a stable connection between the hook and the object, conduct a brake test when the heavy object is 30cm off the ground, and confirm the reliability of the brake.

Real time monitoring: Pay attention to abnormal sounds, vibrations, or temperature increases during operation (such as hydraulic oil temperature ≤ 70 ℃), and immediately stop the machine if any abnormalities are found.

Post shutdown processing

Equipment return: Place the hoist on a dedicated gantry to avoid chain entanglement, and ensure that the controller air pipe is wound neatly.

Data recording: Fill in the operation log, record the load, time, and fault phenomena, and provide a basis for maintenance.

2、 Maintenance plan

routine maintenance

Cleaning: Wipe off the oil stains on the surface of the equipment after homework, and clean the condensation water in the gas supply pipeline.

Lubrication: Add 20ml of specialized lubricating oil to the motor air inlet daily, and add lithium based grease to the sprocket and bearings weekly.

Inspection: Check the tightness of bolts, sensitivity of brakes, and reliability of limit switches.

regular maintenance

Monthly maintenance: Start idle equipment and run it without load for 10 minutes to check the pressure stability of the pneumatic system.

Quarterly maintenance: replace air filter element, clean brake wheel rust, calibrate speed control valve.

Annual maintenance: Disassemble and inspect the wear of gears and bearings, replace aging sealing rings.

Spare Parts Management

Inventory list: Reserve commonly used spare parts (such as brake springs, chains, seals) to ensure that the inventory meets the demand for 3 months.

Supplier cooperation: Establish long-term cooperation with original or authorized suppliers to ensure the quality of spare parts.

3、 Emergency plan for malfunction

Sudden interrupt handling

Air source failure: Check the pressure of the air compressor and the leakage of the gas supply pipeline. After restoring the gas source, conduct a no-load test run.

Brake failure: Immediately stop the machine, check the brake spring and brake disc for wear, and replace damaged parts.

Abnormal control: Verify the control handle speed regulating valve, clean the valve body of foreign objects, and recalibrate the limit switch.

Maintenance Process

Fault declaration: The operator fills out a fault report, describing the phenomenon, time, and environmental conditions.

On site diagnosis: Maintenance personnel bring tool kits (including pressure gauges and torque wrenches) to the site and make a preliminary diagnosis of the fault within 10 minutes.

Repair verification: After repair, conduct three-level tests with no load, half load, and full load to confirm that the braking and limit functions are normal.

4、 Security Management Plan

personnel training

Operation training: New employees need to pass theoretical exams (such as pneumatic principles, safety regulations) and practical assessments (such as no-load operation, fault handling).

Maintenance training: Maintenance personnel need to master skills such as disassembling pneumatic systems, replacing seals, and pressure testing.

Annual refresher training: Organize safety regulations, case analysis training, and update emergency response procedures every year.

safety protection

Personal protection: Operators should wear safety helmets, non slip shoes, gloves, and are prohibited from wearing loose clothing.

Regional isolation: Set up warning lines and hang "No Entry" signs in the work area to prevent unrelated personnel from approaching.

Emergency equipment: equipped with fire extinguishers, first aid kits, and regularly checked for expiration dates.

risk assessment

Hazard identification: Conduct monthly inspections of risk points such as gas source leaks, brake failures, and chain breaks.

Risk classification: Divide the risk level based on the severity of the consequences (such as personal injury or equipment damage) and develop control measures.

Emergency drill: Simulate scenarios such as gas supply interruption, overload and falling every quarter, and drill the emergency response process.

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