Busbar machine hydraulic oil replacement cycle and maintenance specifications

The replacement cycle of the hydraulic oil of the busbar machine needs to comprehensively consider the equipment working conditions, oil type and monitoring results. The common principles are as follows:

1. **First replacement cycle**
After the new equipment is put into use, it is recommended to replace the hydraulic oil for the first time after half a year of operation. Although the oil has not completely deteriorated at this time, it may be contaminated by residual metal particles during the running-in period. Timely replacement can remove impurities and lay the foundation for subsequent operation.

2. **Regular replacement cycle**
– **Ordinary hydraulic oil**: It is recommended to replace it once a year, which is suitable for medium and low intensity operation environments.
– **Synthetic hydraulic oil**: The replacement cycle can be extended to 3 years, and its anti-oxidation and anti-wear properties are better, but regular testing and verification are required.
– **Low-frequency equipment**: If the average annual operation time of the busbar machine is less than 500 hours, it can be appropriately extended to 2 years for replacement, but it needs to be confirmed by oil quality testing.

3. **Dynamic adjustment mechanism**
For equipment with harsh environment (high temperature, high dust) and continuous high-load operation, the replacement cycle should be shortened to 6 months; on the contrary, equipment with clean environment and intermittent operation can be appropriately extended, but the longest period shall not exceed the recommended cycle.

To avoid blind replacement or delayed maintenance, the following scientific methods can be used to evaluate the oil status:

1. **Visual oil change method** Intuitive judgment through vision and smell:
– The oil color becomes significantly darker (dark brown), turbid or milky white emulsified;
– Odor (burnt smell, rancid smell);
– Visible metal particles or fiber impurities are suspended. This method relies on experience and is suitable for emergency judgment, but it is highly subjective.

2. **Regular oil change method** is suitable for equipment-intensive enterprises, and forced replacement is performed according to a preset cycle (such as once a year) to ensure the standardization of batch equipment maintenance, but it may lead to resource waste or excessive maintenance due to “one size fits all”.

3. **Sampling test method** is the most scientific method. Regularly extract oil samples to test the following indicators:
– **Viscosity**: deviation from the standard ±15%;
– **Acid value**: more than 0.5mgKOH/g;
– **Water content**: more than 0.1%;
– **Particle contamination**: ISO 4406 standard exceeds 18/15 level;
– **Corrosion test**: copper sheet corrosion level ≥ 2 level. Replace immediately when the test result exceeds the standard. It is suitable for key equipment and high-precision busbar machines.

To ensure the safety of equipment and personnel, the following regulations must be strictly followed during the oil change process:

1. **Equipment shutdown and protection**
– Before replacement, shut down the machine completely, cut off the power supply and hang a warning sign;
– Set blocks in front and behind the wheels, and insert lock pins in the slewing mechanism to prevent accidental movement;
– When disassembling hydraulic components, confirm that the system is pressure-free to avoid high-pressure splashing and injuring people.

2. **Oil discharge and cleaning**
– After the oil tank is emptied, flush the oil tank and pipelines with clean diesel or special cleaning agents to remove deposited impurities;
– Replace the filter element and check the seals, and replace aging parts simultaneously.

3. **Oil filling and exhaust**
– Select hydraulic oil that meets the equipment specifications (refer to the manual) and slowly inject it into the oil tank;
– Before starting the equipment, manually operate each actuator to exhaust air to ensure that there is no air residue in the hydraulic pump and motor cavity. (Note: 3 in 1 busbar machine does not need to be exhausted.)

1. **Environmental control** Keep the machine room clean, clean the dust filter regularly to prevent dust from invading the system; install cooling devices in high-temperature environments to control the oil temperature below 60℃.

2. **Oil filter management** Regularly (every 3 months) replace the return oil filter element, and use high-precision filters (β≥200) for key equipment.
3. **Oil monitoring** Establish an oil sample file, conduct a comprehensive test every six months, and dynamically adjust the replacement cycle.

Notes:
●The replacement cycle needs to be adjusted according to the actual working conditions of the equipment, and the cycle should be shortened in harsh environments.
●The performance of hydraulic oils of different brands varies greatly, and the model recommended by the original manufacturer of the equipment is preferred.
●When the oil test exceeds the standard, it should be replaced immediately regardless of whether the cycle has been reached.

Scientific replacement of busbar machine hydraulic oil is the core of preventive maintenance. Users should combine equipment conditions, oil characteristics and monitoring data, and flexibly use visual inspection, regular or laboratory testing to determine the replacement time, while strictly following safety operating procedures. Through systematic maintenance, the equipment life can be significantly extended, the failure rate can be reduced, and the dual guarantee of production efficiency and safety can be achieved.

Related Quality Articles > Busbar Machine Maintenance Guide: Replacing Hydraulic Oil

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