In heavy material handling operations, high-load operation of equipment is the norm. However, if abnormally high oil temperature (commonly known as "tank burning"), accelerated oil deterioration, or excessively rapid wear of hydraulic components occurs, it's often not due to the equipment reaching the end of its lifespan, but rather a chain reaction caused by mismatched selection, heat dissipation failure, or improper maintenance.
This practical guide to preventing overheating and reducing wear will help you reduce equipment maintenance costs and extend its lifespan.
I. Diagnosing the Root Cause: Why is Equipment Prone to "Tank Burning" and Rapid Component Wear?
In the process of converting energy into hydraulic energy in a hydraulic system, any unnecessary overflow and friction will directly become heat. When the rate of heat generation significantly exceeds the rate of heat dissipation, the oil temperature will naturally soar.
- When equipment is subjected to prolonged overload or extreme operating conditions, frequent opening and overflow of hydraulic valves means that a large amount of energy is not used for work but is converted into heat.
- In dusty environments like stone factories and mines, radiator fins are particularly prone to accumulating dust and oil, causing a sharp drop in heat dissipation efficiency.
- Using hydraulic oil of unsuitable viscosity, or oil contaminated with impurities that wear down pumps and valves, creates metal shavings that further exacerbate friction and heat generation.
These problems can easily lead to fuel tank burnout and rapid component wear.
II. Avoiding Pitfalls and Reducing Costs: Four-Step Overheat Prevention Guide
1. Choose a Model with Sufficient Margin; Don't Overload Equipment
When frequently performing high-level lifting and heavy-tonnage handling operations, ensure that the equipment's rated load and hydraulic system have reasonable margins. For high-intensity continuous operation, prioritize models equipped with large-capacity radiators or independent hydraulic cooling systems.
2. Develop a Cleaning Habit; Don't Let the Radiator "Suffocate"
In dusty working conditions, it is recommended to develop a habit of cleaning the radiator fins with a high-pressure air gun every day after get off work. Keeping the radiator unobstructed ensures efficient heat dissipation.
Choose the right hydraulic oil and change the filter on time.
Select anti-wear hydraulic oil according to different seasons and ambient temperatures. Never use inferior oil to save money. Change the filter on time and check the oil quality regularly. If you find the oil is black or has an unusual odor, check and replace it immediately.
Improve your skills and reduce unnecessary work. Optimize operating habits and reduce unnecessary work.
Remind operators to avoid pushing the control lever all the way down (cylinder-mounted operation) to reduce unnecessary overflow and heat generation. Plan the transportation route reasonably and avoid idling the equipment for long periods of time.
III. Spend two minutes each day performing these four small checks:
Check the radiator: Before starting work each day, take a look to see if the fins are blocked by dust and oil.
Check the hydraulic oil: Check if the oil level is sufficient, and also check if the oil is clear and has no unusual odor.
Check the lines: Check the hydraulic lines and joints weekly for oil leaks or wear and tear.
Change the filter: Change the filter on the scheduled maintenance period, and check for metal shavings inside when removing it.
Excessive hydraulic oil temperature can significantly increase maintenance costs and shorten equipment lifespan. Regular inspections, standardized operations, and periodic maintenance can effectively prevent "oil tank burning" problems and ensure stable and continuous operation of the equipment under high-intensity conditions.
