Shantou Hetian Machinery Manufacture Co.,Ltd

Core principles of maintenance and upkeep

• Prevention oriented: Identify potential hazards (such as wear, looseness, and oil leakage) in advance through daily inspections to avoid the escalation of faults.

• Institutionalized implementation: Develop standardized maintenance procedures (such as daily/weekly/monthly inspection forms) and assign responsibilities to individuals.

• Targeted maintenance: Adjust maintenance plans based on equipment types (such as construction machinery, processing machines, conveying equipment) and operating conditions (heavy load, high temperature, humidity).

Specific measures for daily maintenance

1. Cleaning and dust removal

• Surface cleaning: Use a cloth and compressed air daily to remove dust, oil stains, and metal debris from the surface and gaps of the equipment, to avoid poor heat dissipation or component corrosion caused by dust accumulation (such as motors and control panels).

• Key parts cleaning:

• Radiators and fan blades: Use a brush or high-pressure air gun to remove clogged fibers and dust (suitable for injection molding machines and air compressors).

• Guide rail and screw: Wipe off oil stains and remove iron filings to prevent jamming (such as machine tool equipment).

2. Lubrication management

• Fixed point lubrication: Regularly add lubricating oil/grease to the lubrication points (such as bearings, gearboxes, chains) marked in the instruction manual. Common tools include grease guns and oil pots.

• Lubrication standard: Observe the oil level of the gearbox and hydraulic oil tank through the oil window, and replenish it when it is insufficient (such as in the hydraulic system of an excavator); Replace the lubricating oil according to the running time (e.g. every 500 hours) to avoid oil oxidation and failure (e.g. crane gearbox).

• Special scenario: Use high-temperature resistant lubricating grease in high temperature environments, and choose waterproof lubricating oil in humid environments.

3. Tightening and anti loosening

• Key bolt inspection: Daily visual or wrench inspection of foundation bolts, coupling bolts, drive shaft nuts, etc., and timely tightening if loose (such as crusher base bolts) is found.

• Anti loosening measures: For parts with high vibration (such as punching machines), use anti loosening washers, locking nuts, or apply thread glue (such as Loctite).

4. Running status monitoring

The Four Step Method of "Listen, Touch, Look, Smell":

• Listen: Abnormal noise (such as bearing noise, gear tooth sound) indicates wear or misalignment.

• Touch: Temperature of bearings and motor casing (shutdown inspection is required if it exceeds 60 ℃), vibration amplitude (measured quantitatively with a vibration meter).

• Check: Instrument data (whether voltage, current, pressure are within the rated range), pipeline leaks (hydraulic oil, coolant).

• Smell: There is a burning smell of electrical components and a strange smell of oil deterioration. Check for short circuits or overloads in a timely manner.

Regular maintenance plan (divided by cycle)

1. Weekly maintenance

• Thoroughly inspect lubrication points and replenish missing grease;

• Test the effectiveness of safety devices such as emergency stop buttons and overload protection;

• Clean the dust-proof net of the electrical cabinet and check the burning condition of the contactor contacts.

2. Monthly maintenance

• Replace the air filter and hydraulic oil filter (shorten the cycle according to the working conditions);

• Measure the insulation resistance of the motor and record the trend of data comparison;

• Perform oil sampling analysis on key components (such as reducers) to detect iron content and moisture.

3. Annual maintenance

• Disassemble and clean the main components (such as hydraulic pump and gearbox), replace all seals;

• Calibrate instruments (pressure gauges, thermometers) and entrust third-party testing equipment for accuracy;

• Repaint the rust proof layer of the equipment and repair worn rails or workbenches.

Safety regulations and management requirements

1. Operational Security

• Before maintenance, power must be cut off, tags must be hung and locked, hydraulic equipment needs to be depressurized, and pneumatic equipment needs to be emptied of air pressure;

• Use anti-skid platforms and wear safety belts for high-altitude operations (such as tower crane maintenance).

2. Record and Trace

• Establish an "Equipment Maintenance Ledger" to record maintenance time, items, consumable models, and fault handling (which can be done using digital management systems such as Excel or equipment management apps);

• Save spare parts replacement records and predict the replacement cycle of vulnerable parts (such as bearings and belts).

3. Personnel training

• Operators need to master the "three understandings and four skills" (understanding structure, principles, performance, and being able to use, maintain, inspect, and troubleshoot);

• Regularly organize emergency training (such as equipment overload and fire handling procedures).

Special working condition response strategy

High temperature environment: Increase the motor cooling fan and use high-temperature lubricating grease (such as lithium grease) to avoid continuous full load operation during noon hours.

Damp/dusty environment: Install waterproof covers on electrical components, regularly use insulation testers to test circuits, and lay moisture-proof pads at the bottom of equipment.

Heavy load impact condition: Strengthen the anti loosening measures of fasteners (such as using anti loosening nuts), increase buffering devices (such as shock pads), and shorten the inspection cycle of key components.

Through systematic maintenance and upkeep, the failure rate of large equipment can be reduced by 40% to 60%, and the lifespan can be extended by 20% to 30%. It is recommended to develop personalized maintenance plans based on equipment manuals and manufacturer technical guidance, and use IoT technology (such as vibration sensors and oil monitoring sensors) to achieve predictive maintenance, further improving management efficiency.