How to maintain and maintain the traditional hydraulic station?

The maintenance and upkeep of the traditional hydraulic station is the key to ensuring its stable operation and extending its service life. It needs to start from oil management, component inspection, system cleaning, daily operation specifications and other aspects. The following are the detailed maintenance points:

I. Management and maintenance of hydraulic fluids 

 Hydraulic oil is the "blood" of the hydraulic system. Its state directly affects the performance of the system. It should be paid attention to: 

 1. Check the oil status regularly. 

 - Fuel level: Check the fuel level of the fuel tank every day before starting up to ensure that the fuel level is between the "highest" and "minimum" scales of the liquid level meter. A low oil level will cause the pump to absorb air and produce air erosion; too high oil level may cause excessive oil temperature. 

 - Oil quality: 

 - Observe the color of the oil: the normal hydraulic oil is light yellow or amber. If it turns dark brown, milky white (emulsified) or contains impurities, it needs to be replaced in time. 

 - Detection of viscosity: oil viscosity varies with temperature. If the ambient temperature varies greatly, the corresponding viscosity level of hydraulic oil (such as high viscosity in summer and low viscosity in winter) needs to be replaced according to the season. 

 - Regular testing: after 1000 hours of testing of oil every year or operation, check the moisture content (should be ≤0.1%), particle pollution (need to meet the system cleanliness level, such as ISO 18/15), etc.

2. Regular replacement of hydraulic fluids and filter elements 

 - After the first operation for 3 months or 500 hours, the hydraulic oil absorption filter element and oil return filter element need to be replaced; after that, it needs to be replaced every 6-12 months or 2000-3000 hours of operation (adjusted according to the oil quality condition). 

 - When changing oil, it is necessary to completely empty the old oil, clean the interior of the fuel tank (scrub with a lint-free cloth, avoid using cotton yarn, and prevent fiber residue), and then add new oil. 

 - When refueling, it needs to be filtered through the oil filter to avoid impurities in the new oil directly entering the system. 

 3. Prevent oil pollution 

 - The lid of the fuel tank should be well sealed to avoid dust, moisture, metal debris, etc.; the refueling port should be equipped with a filter. 

 - After disconnecting the pipeline during repair, the connector should be closed immediately with a plug to prevent pollutants from entering.

II. Inspection and maintenance of core components

1. Hydraulic pump 

 - Operating status: Listen to the running sound of the pump after starting up. Normally, it should be a stable "buzzing" sound. If there is abnormal noise (such as sharp noise and impact sound), it may be wear and tear, air absorption or insufficient oil in the pump, and it needs to be stopped for inspection. 

 - Leakage and temperature: check whether the shaft seal and joints of the pump are leaking; the temperature of the pump body should not exceed 60°C (not felt hot), and if overheating, it may be improper oil viscosity, wear or overload. 

 - Check the internal parts of the pump (such as the gear of the gear pump and the blade of the blade pump) regularly (every 1-2 years), and replace them in time when it is seriously worn. 

 2. Hydraulic valve 

 - Action flexibility: Check whether the spool of the direction valve, pressure valve and flow valve is smooth and stuck (can pass the manual adjustment test). 

 - Pressure stability: Observe the pressure of the system through the pressure gauge. If the pressure fluctuation is too large or cannot reach the set value, it may be a fault of the overflow valve and pressure relief valve, and the valve spool needs to be disassembled and cleaned or the spring needs to be replaced. 

 - Leakage inspection: If there is an oil leak between the valve block and the pipeline joint, the joint needs to be tightened or the seals (such as O-ring, combination pads) need to be replaced.

3. Actuator (cylinder/oil motor) 

 - Cylinder: check whether there are scratches and corrosion on the surface of the piston rod, if it needs to be repaired (such as chrome-plated polishing); whether the seals at both ends of the cylinder are leaking oil, and the sealing rings are replaced when leaking; whether there is crawling or jamming during operation, which may be air or piston wear in the cylinder. 

 - Oil motor: observe whether the output speed is stable and whether there is abnormal noise. If the rotation speed drops or abnormal noises, it may be worn on internal parts and need to be disassembled and overhauled. 

 4. Auxiliary components 

 - Oil filter: Regularly check the pollution degree of the oil-absorbing filter element and the oil-return filter element. If the surface is seriously blocked (if the pressure difference exceeds the specified value), it needs to be replaced immediately to avoid excessive oil absorption resistance or oil filtration failure. 

 - Cooler: If the oil temperature of the system is too high (more than 55°C), it is necessary to check whether the cooler (such as the water-cooled water pipe is blocked and the air-cooled fan is working), and the dust and grease on the surface of the cooler should be cleaned regularly to ensure heat dissipation efficiency. 

 - Pressure gauge: The pressure gauge is calibrated once a month to ensure that the reading is accurate. If the pointer is beating or not displayed, a new pressure gauge needs to be replaced.

III. Maintenance of pipelines and sealing systems 

 1. Pipeline inspection 

 - Regularly check the oil pipe for deformation, aging and cracks, especially near the bends and joints, and replace them immediately if problems are found (avoid temporary splicing of broken pipes). 

 - The pipe joint should be tightened in place to avoid loosening and oil leakage; sealant (such as Letai 554) can be applied to the threaded joint to enhance the sealing, but it should be noted that the glue should not enter the system. 

 2. Seal maintenance 

 - Seals (O-rings, lip-shaped seals, combination pads, etc.) are wearable parts and need to be replaced regularly (recommended every 1-2 years). When replacing, choose materials that are compatible with oil and liquids (such as nitrile rubber is suitable for mineral oil, and fluororubber is suitable for high temperature or special media). 

 - When installing the seal, it should be kept clean to avoid scratches; the groove size should be matched to prevent the seal from being squeezed, deformed or loose.