The effective and safe operation of the autohydro lift (AHP) directly depends on the state of its main working body - the arrow. It is this unit that is subjected to enormous mechanical loads, vibrations and aggressive influence of the external environment during operation. Well-chosen grease-truck It is not just an expendable material, but a critical element that ensures the durability of hinge joints and smoothness of the telescopic sections.
Ignoring routine lubrication work or using poor-quality materials inevitably leads to accelerated wear of bushings, the appearance of backlashes and, in the worst case, to jamming mechanisms at height. This poses a direct threat to the lives of operators and people in the area of work. In this article, we will discuss in detail what types of lubricants are necessary for various nodes of the boom, how often you need to carry out maintenance and what technological nuances should be taken into account when applying the composition.
Modern requirements for maintenance of special equipment dictate strict standards, violation of which can lead to expensive repairs and downtime of the machine. Understanding the physicochemical properties of lubricants allows you to optimize the cost of maintaining the fleet and ensure the smooth operation of the equipment in any climatic conditions. Let’s look at the key aspects of the selection and application of lubricants for AGP.
Criteria for the selection of lubricant for AGP
The choice of lubricant for the elements of the boom of the tower is a complex engineering process that requires considering many factors. The main parameter is the type of load that a particular node experiences: sliding friction in telescopic sections or rolling friction in hinge joints. For the former, adhesion and the ability to form a strong protective film that prevents direct contact of the metal are critically important. For the second - penetrability (penetration ability) and resistance to extrusion under high pressure.
The temperature of the operation also plays a crucial role. In the Russian climate grease-truck should retain its rheological properties both in severe frost and with strong heating of the nodes in summer. Thickening of the material at low temperatures can lead to the inability to fold the arrow, and excessive liquefaction - to the flow of lubrication and bare rubbing surfaces. Therefore, the use of all-season compounds with a wide temperature range is the industry standard.
⚠️ Attention: It is strictly forbidden to mix lubricants on different bases (for example, lithium with calcium or synthetic with mineral). The chemical reaction between the components can lead to the stratification of the composition, loss of lubricating properties and the formation of solid abrasive inclusions that will destroy the bushings in a matter of hours of operation.
Another important criterion is water resistance and anticorrosion protection. Because work is often done outdoors, moisture, dust and reagents from roads constantly attack the exposed parts of the boom. A quality material should create a sealed barrier, displace water and prevent the oxidation of the metal. Use of compounds with graphite or molybdenum disulfide (MoS2) significantly increases the load-bearing capacity of the lubricant layer under extreme conditions.
Classification of lubricants for telescopic and hinge joints
The market of industrial lubricants offers a wide range of products, each of which is tailored for specific tasks. To service the boom of the car tower, plastic lubricants are most often used, classified by thickener and base oil. Understanding these differences avoids mistakes when purchasing fuel. The most common types are:
- 🔹 Lithium lubricants: Classical materials (e.g. Litol-24 or their modern analogues), having good mechanical stability and water resistance. They are universal, but have limitations in temperature range and loads.
- 🔹 Integrated lubricants: They contain special additives (often molybdenum disulfide), which makes them ideal for nodes with high impact loads. They work perfectly in the hinges of the arrow, where the pressure can reach critical values.
- 🔹 Polyurethane lubricants: Modern solution with extended service life and excellent compatibility with various metals. They have a high oxidative stability, which prolongs the intervals between services.
- 🔹 Graphite pastes: They are used mainly for open gears of rotary mechanisms and large threaded joints, where protection from corrosion and prevention of fitting of parts are required.
Special attention should be paid to sprays and penetrating compositions. They are not designed to permanently lubricate loaded nodes, but are indispensable in preparation for maintenance. With their help, you can effectively clean old contaminants and develop acidic compounds before applying the main layer. grease. However, they cannot be relied on as the main means of protection – they quickly wash out and evaporate.
When choosing a lubricant, pay attention to the value of NLGI (National Lubricating Grease Institute). For hinges of arrows of a car tower, NLGI 2 class lubricants are optimally suited, having a balance between softness and the ability to hold in the node.
Technology of applying lubrication to arrow nodes
The process of lubricating the arrow of the tower requires strict adherence to technological discipline. It is not enough to just squeeze a little material out of the syringe – it is important to ensure that it penetrates all the gaps. Before starting work, it is necessary to carefully clean the oil presses (tavotnitsa) and adjacent surfaces from dirt, old lubricant and sand. The entry of abrasive particles into the node during lubrication is equivalent to the introduction of sandpaper between rubbing parts.
For telescopic sections that do not have oil presses, the method of applying lubrication manually or using special spatulas on the guide surfaces is used. It is important to cover the entire running section of the rod or inner section with a uniform layer. When the boom is extended, the lubricant must be distributed along the entire length, creating a continuous protective film. If you notice that when working, a metal creak or knock is heard, this is a sure sign of oil starvation.
In the hinge joints, lubrication is fed through a syringe until the fresh composition begins to protrude from the gaps, displacing the spent material. This ensures that the entire working cavity is filled with fresh product. Special attention should be paid to the fingers of the cradle attachment and the main supports of the arrow, since they carry the maximum load.
☑️ Lubrication preparation checklist
Service regulations and lubrication frequency
The frequency of lubrication of the nodes of the arrow of the car tower is determined by the manufacturer of equipment and is prescribed in the operating manual (RE). However, the real working conditions often make adjustments. Intensive operation, work in dusty quarries, on the seashore or at extreme temperatures require shorter service intervals. On average, hinge lubrication is done every 40–60 hours or weekly, whichever comes first.
Seasonal maintenance (S) is a mandatory stage of preparing equipment for the winter or summer period. At this time, it is recommended to completely update the lubricant in all nodes, even if the resource of the previous one has not yet been exhausted. This is due to the fact that the properties of the material can change under the influence of temperature, moisture and time changes. Ignoring seasonal lubrication is one of the main reasons for winter failures of hydraulics and AGP mechanics.
The state of the lubrication should be monitored visually before each shift. The operator is obliged to inspect the open parts of the boom for the presence of a lubricating layer, the absence of leaks and damage to seals. If you see that the lubricant has turned black, acquired the smell of burning or metal splashes (glitters) are visible in it, this is a signal of critical wear of the node and the need for immediate diagnosis.
| Arrow knot | Type of lubricant | Interval (motoclock) | Method of application |
|---|---|---|---|
| Section hinges | Lithium with MoS2 (NLGI 2) | 40-50 | Lubricant syringe |
| Telescopic surfaces | Adhesive paste/Lithium | 80-100 | Manual application |
| rotational axis of the rotating platform | Transmission / Special | 250-500 | Replacement/Doliv |
| Winch cables (if any) | Cable lubrication | Once a month | Impregnation |
Compliance with the lubrication regulations increases the life of the boom of the tower by 30-40% and reduces the risk of emergency stops at the facility.
Typical errors in the maintenance of the arrow
One of the most common mistakes is “re-sweeping”. Many operators believe that the more lubricant, the better, and pump it until the seals burst or the lubricant begins to drip to the ground. The excess lubrication in telescopic sections causes it to work as a magnet for dust and sand, forming an abrasive porridge that destroys the metal faster than the lack of lubrication at all.
The second critical mistake is to ignore cleaning before lubrication. Pumping new lubricant over a dirty oil drives the abrasive inside the knot. Use of used oils or materials not intended for this purpose (for example, solidol in high-speed or high-temperature units where required) is also common. heat-resistant). This leads to coking of the material and jamming.
⚠️ Attention: Never use diesel fuel or aggressive solvents to flush the nodes immediately before lubrication unless it is possible to remove them completely. Residues of the solvent destroy the structure of fresh lubricant and can damage rubber seals (cuffs, gums).
Another problem is the late replacement of damaged oils. If the tavotnik is broken or clogged, it is impossible to lubricate the knot qualitatively. Operators often try to pierce the hole with a needle or simply pour lubrication on top, which does not give effect. All elements of the lubrication system must be serviceable and accessible.
What to do if the lubricant does not pass into the node?
If the syringe does not grease, and the pressure increases, it is possible that the channel is filled with old fossilized lubricant or dirt. In this case, you can not press to the victory - you can damage the omentum. It is necessary to gently clean the channel with thin wire, warm the knot (if the temperature allows) or use special penetrating compounds to soften the lubricant before retrying.
The influence of climate and operating conditions on the choice of lubricant
The climatic conditions of Russia dictate special requirements for lubricants. In northern regions where temperatures drop below -40°C, conventional lithium lubricants can freeze to become a solid mass. For such conditions, synthetic formulations based on polyalphaolefins (PAO) or esters are required, which retain mobility at extremely low temperatures. Using the wrong material in winter can cause the hydraulic cylinders to break when trying to fold the arrow.
In hot climates or when working in conditions of high thermal loads (for example, near metallurgical furnaces), the priority is thermal stability. The lubricant should not spread and flow out of the nodes, losing its properties. Here, formulations with high drop temperatures are used, often on a complex aluminum or barium basis. It is also important to take into account humidity: to work on water or in high humidity conditions, lubricants with enhanced anticorrosion additives are required.
Work in dust conditions (cement plants, grain terminals) requires the use of sticky, viscous compounds that are firmly held on the metal and do not splash when moving. Often in such cases, graphite lubricants are used, which create a dry sliding layer that does not attract dust as much as oily films. The right selection grease-truck under specific conditions - the pledge of saving the budget for repairs.
Can I use Litol-24 to lubricate the boom of a tower in winter?
The use of classic Lithol-24 at temperatures below -20°C is not recommended, as it thickens and loses its lubricating properties. For winter operation, it is better to choose frost-resistant analogues with a temperature range of up to -40 ° C and below, or special synthetic lubricants.
How often should the lubricant be completely changed in the hinges?
Full replacement (washing and laying a new one) is usually carried out during major repairs or once every 2-3 years of active operation. In the usual mode, regular replenishment (refilling) of fresh lubricant is made, which displaces the old through the gaps.
What is the danger of working a tower without lubrication?
Work without lubrication leads to dry friction, rapid heating of the nodes, destruction of bushings and fingers, the appearance of backlashes. In critical cases, it is possible to jam the arrow in the raised position, which requires a complex and dangerous operation to save equipment and people.
Do I need to wash off the old lubricant before applying a new one?
If the old lubricant does not contain abrasive and is compatible in composition with the new, it is enough to remove the top contaminated layer. If the lubricant is blackened, contains metal shavings or you change the type of lubricant - you need a complete cleaning and washing of the unit.
Which lubricant is better for telescopic sections: spray or paste?
For telescopic sections, thick adhesive pastes or plastic greases applied by a spatula are better suited. Sprays are too liquid, drain quickly and do not provide long-term protection when sliding large surfaces.