In-depth interpretation of crane maintenance plan, to build a solid foundation for stable operation of equipment

1. Maintenance purpose
Ensure the safe operation of the crane, extend its service life, improve work efficiency, reduce the occurrence of failures and accidents.
2. Maintenance scope
Including the metal structure of the crane, mechanical transmission system, electrical system, lifting mechanism, operating mechanism, braking system, safety protection device, etc.
Three, maintenance cycle
Daily maintenance: daily before and after work.
Level 1 maintenance: every 200 hours of operation.
Secondary maintenance: once every 1000 hours of operation.
Level 3 maintenance: once every 3000 hours of operation.
Iv. Maintenance contents and requirements
(1) Daily maintenance
Visual inspection
Check the appearance of the crane for obvious damage, deformation, paint removal, etc.
Clean the surface of the crane dust, oil and debris.
Mechanical transmission system
Check the connecting parts of each transmission part, such as bolts, pins, keys, etc., to ensure that they are tight and not loose.
Check the lubrication of each transmission part, and add or replace lubricating oil in time.
Electrical system
Check the appearance of the electrical equipment for damage, deformation, moisture and other conditions.
Check the electrical connection parts, such as terminal, plug, socket, etc., to ensure that the connection is firm, no loosening, oxidation and other phenomena.
Check whether control buttons, switches, indicators, etc. work properly.
Lifting mechanism
Check whether the hook has cracks, deformation, wear and other defects, and replace it if necessary.
Check whether the anti-decoupling device of the hook is in good condition and effective.
Check the wear, broken wire, deformation and other conditions of the wire rope to ensure that it is in a safe state.
Check whether the wire rope on the drum is arranged neatly, if there is a disorderly rope phenomenon should be adjusted in time.
Operating mechanism
Check the wear condition of the wheel and track, and deal with it in time if there is any abnormality.
Check the rim and tread of the wheel for wear, cracks and other defects.
Check the fixed condition of the track, whether there is loosening, displacement and other phenomena.
Brake system
Check brake pads for wear and replace them if necessary.
Check whether the surface of the brake wheel is smooth, there is no oil, scratches, etc.
Check the performance of the brake spring, whether there is deformation, fracture, etc.
Safety protection device
Check whether safety protection devices such as lifting weight limiter, travel limiter, and height limiter are sensitive and reliable.
Check whether the sound and light alarm, emergency stop button, etc. are working properly.
(2) First level maintenance
Complete all the contents of daily maintenance.
Mechanical transmission system
Carry out comprehensive lubrication maintenance for each transmission part, clean the lubrication system, and replace the lubricating oil.
Check the gear, shaft, bearing and other parts of the reducer wear, repair or replace if necessary.
Check the coupling connection, adjust the coaxiality and clearance.
Electrical system
Check the insulation resistance of the motor, clean the dust and debris inside the motor.
Check the wear of the motor brush, slip ring and other parts, and replace them if necessary.
Check the wiring of the electrical control system, arrange the wiring, and replace the aging wires and cables.
Lifting mechanism
Check the drum for wear and repair or replace it if necessary.
Check the lubrication of the wire rope and reapply grease.
Complete inspection and maintenance of hook, pulley and other parts, repair or replace damaged parts.
Operating mechanism
Check the wear of axle and bearing, clean and lubricate.
Adjust the clearance between the wheel rim and the track to ensure smooth running.
Check the joints of the track and make the necessary adjustments and fastening.
Brake system
Adjust the clearance between brake disc and brake wheel to meet the specified requirements.
Check the hydraulic or pneumatic components of the brake system, such as oil pumps, cylinders, cylinders, etc., to ensure that they are working properly.
(3) Two level maintenance
Complete all contents of Level 1 maintenance.
Metal structure
A comprehensive inspection of the metal structure of the crane, including the main beam, end beam, leg, etc., focusing on checking whether there are cracks in the weld and whether the structure is deformed.
The metal structure shall be treated with anti-corrosion and repainted with anti-rust paint and topcoat.
Mechanical transmission system
Disassemble and inspect the reducer, clean the internal parts, and replace the gear, shaft, bearing and other parts that are seriously worn.
Check the coaxiality and runout of the drive shaft, and make necessary adjustments and repairs.
Check the thickness of the drum wall of the drum, and repair or replace it if it becomes thinner.
Electrical system
Conduct a comprehensive inspection and commissioning of the electrical control system, check the performance of various electrical components, and replace aging and damaged components.
Check the insulation of the electrical circuit and make necessary repairs and replacements.
Carry out comprehensive inspection and maintenance of the motor, including stator, rotor, winding, etc., and repair or replace it if necessary.
Lifting mechanism
Carry out non-destructive inspection on the hook to ensure that there are no internal defects.
Check the wear condition of the pulley block and replace the severely worn pulley.
Check the drum shaft of the lifting drum. If it is bent, it should be corrected or replaced.
Operating mechanism
Check the tread hardness of the wheel, if there is wear should be repaired or replaced.
Inspect the track for wear and tear and repair or replace it as necessary.
Check the gearbox of the operating mechanism and replace the badly worn gears and bearings.
Brake system
Replace the brake pads and brake wheels to ensure good braking performance.
Check the brake valve, brake cylinder and other parts of the brake system, and carry out necessary maintenance and replacement.
(4) three level maintenance
Complete all contents of Level 2 maintenance.
Carry out comprehensive performance testing and evaluation of the crane, including lifting weight, lifting height, running speed, working accuracy, etc.
According to the test results, the necessary technical transformation and upgrading of the crane are carried out to improve its performance and safety.
Summarize and analyze the use and maintenance of the crane, formulate improvement measures and preventive measures, and provide reference for future maintenance work.
5. Maintenance records and files
After each maintenance is completed, the maintenance personnel should fill in the maintenance record, and record the maintenance content, time, replacement parts and other information in detail.
Establish crane maintenance files, and archive maintenance records, maintenance records, test reports and other information for inquiry and analysis.
Six, maintenance personnel requirements
Maintenance personnel should have the corresponding professional knowledge and skills, familiar with the structure, performance and working principle of the crane.
Maintenance personnel should strictly follow the maintenance plan and operating procedures for maintenance work to ensure maintenance quality and safety.
Please note that in the actual maintenance process, the maintenance content and cycle should be properly adjusted according to the specific model of the crane, the use of the environment and work intensity and other factors. At the same time, the maintenance work should be carried out by professionals, and strictly abide by the relevant safety regulations and operating procedures.