Dynamic Compactor Maintenance: Gear Oil Replacement for All Gearboxes

Dynamic Compactor Maintenance: Gear Oil Replacement for All Gearboxes

Dynamic compactors operate under heavy loads for extended periods, which often leads to various faults. Regular maintenance and servicing can prevent some faults from occurring, extend the service life of the machine, and create greater value for customers. However, some customers neglect maintenance, waiting until problems arise before repairing, and then complain about product quality as well as the downtime and costs incurred during repairs. Therefore, doing a good job of maintenance is very important.

　　The dynamic compactor should be kept clean at all times. After each operation, wipe the mud off the cab windows. Apply grease to exposed machined surfaces to prevent rust; lubricate all lubrication points with grease as required by the lubrication chart; and keep the wire rope lubricated and clean. Routine inspections of the compactor's working components include: whether there is any leakage in the hydraulic system oil lines and whether the oil pipe connections are loose; whether the oil pump connections are tight and reliable; whether the wire rope is severely damaged; whether the main winch leaks oil; and whether all instruments, indicator lights, and safety devices are working properly. Regularly check the structural connecting bolts, welded parts, and structural components for damage, deformation, or looseness. Check whether all parts of the travel device are normal; whether the gear oil level in the travel gearbox is appropriate; whether the track shoes are cracked or deformed; whether the travel motion is normal; and whether the idler, track rollers, carrier rollers, and drive sprocket are normal and free of oil leakage.

　　The dynamic compactor also requires regular replacement of the gear oil in all gearboxes.

　　First: Oil level check and oil change for the (main winch) hoisting gearbox

　　The first oil change is after 150 hours, and thereafter every 500 hours. The oil level of the main winch gearbox is checked at a plug on the side. To change the oil, first lower the wire rope from the drum until the fill hole and drain hole are exposed, then remove the drain plug directly below the gearbox drum, then remove the plug directly above to vent, allowing normal draining. Then reinstall the drain plug, pour the specified amount of heavy-duty vehicle gear oil through the fill port, and finally reinstall the fill plug.

　　Second: Oil level check and oil change for the travel gearbox

　　The first oil change is after 150 hours, and thereafter every 1,500 hours. Filling method: rotate the gearbox so that the oil plugs are at the horizontal and lowest positions. Then remove the lower oil plug, then remove the oil plug at the horizontal position to drain the oil. Then rotate the gearbox so that the oil plugs are at the horizontal and topmost positions. Then pour an appropriate amount of heavy-duty vehicle gear oil through the top oil plug; once gear oil flows out from the horizontal oil plug, reinstall the horizontal plug. Then add an appropriate amount of gear oil.

　　Third: Oil level check and oil change for the slewing gearbox and luffing gearbox

　　Change the oil every 1,500 hours. First remove the breather plug and fill plug, then remove the drain plug to drain the oil. Then reinstall the drain plug, pour an appropriate amount of heavy-duty vehicle gear oil through the fill port, and finally reinstall the fill plug and breather plug.

　　The service life of the gearbox can be considerably extended through proper maintenance and servicing measures. Perform a visual inspection daily, with particular attention to the sealing of the gearbox. Regularly check the gearbox for abnormal noise. Regularly check the gearbox oil level.

　　Selection and replacement of hydraulic oil: Select hydraulic oil according to ambient temperature. If the ambient temperature is low, use hydraulic oil with lower viscosity; conversely, use hydraulic oil with higher viscosity. Generally, the oil grade is L-HL32 in winter and L-HL46 in summer. Hydraulic oil is generally replaced after 12 months of use or 2,000 hours of operation. Each time the oil is changed, carefully clean the oil tank and filter, and fill the oil through the fill strainer.

　　The above is the correct maintenance knowledge for dynamic compactors. Only by carrying out proper maintenance and servicing can the service life of dynamic compaction equipment be maximized and maximum value created.