Yearly / 2000h Maintenance
Perform yearly maintenance after every 2000 hours of operation (or annually, whichever comes first). Estimated time: 4–8 hours. Some tasks may require specialized tools or external service providers.
Hydraulic System
| Task | Details |
|---|---|
| Complete hydraulic oil change | Always perform yearly regardless of oil analysis results. Use OEM-approved grade and quantity. |
| All filter elements replacement | Replace suction, return, high-pressure, and off-line filter elements. |
| Tank cleaning | Open tank manhole, clean all internal surfaces, magnetic rods, and baffles. |
| Hydraulic pump overhaul (if indicated) | Replace shaft seal, bearings, and wear plate if pump running hours exceed OEM recommended interval (typically 15000–20000h). |
| Valve overhaul | Inspect servo-proportional valves. Replace pilot filters, O-rings. Perform null bias calibration. |
| Cylinder seal replacement | Replace all cylinder rod seals and wiper rings preventatively. |
| Hose replacement | Replace all flexible hydraulic hoses (max service life 5–6 years per ISO 8331). |
| Accumulator overhaul | Replace bladder/diaphragm, check shell integrity. |
Electrical System
| Task | Details |
|---|---|
| Controller backup battery | Replace lithium battery on controller CPU module and servo drives. |
| Main contactor replacement | Preventative replacement of main power contactors. |
| Servo drive capacitor check | Measure DC bus capacitance or replace per OEM schedule (typically 5–7 years). |
| Full megger test | Test all motor windings, heater circuits, and DC bus to ground. |
| Cable replacement | Replace high-flex cables in drag chains showing wear. |
| Cleaning / overhaul of main breaker | Check main breaker mechanism, torque all terminals. |
Mechanical System
| Task | Details |
|---|---|
| Tie bar inspection for cracks | Perform magnetic particle (MT) or ultrasonic (UT) inspection on all four tie bars. |
| Screw and barrel inspection | Remove screw, inspect flight wear pattern, measure barrel I.D. Replace if worn beyond tolerance. |
| Non-return valve (check ring) | Inspect check ring and seat for wear. Replace if gap > 0.1 mm. |
| Clamp toggle bushing replacement | Replace all toggle joint brass bushings. |
| Platen surface inspection | Check platen surface flatness. Re-surface if damaged. |
| Guide rail replacement (if worn) | Measure guide rail clearance. Replace gibs or guide shoes. |
Safety System
| Task | Details |
|---|---|
| Safety relay test | Test all safety relay modules per manufacturer procedure. |
| Door switch replacement | Replace safety door switches (preventative, regardless of condition). |
| E-stop button check | Verify all E-stop buttons function and have correct labels. |
| Light curtain test (if equipped) | Perform full light curtain function test. |
| Hydraulic safety valve test | Test hydraulic dump valve / safety block functionality. |
| Ground bonding verification | Verify all panels, doors, and machine frame bonded to ground. |
Yearly maintenance is the ideal time to perform machine upgrades — such as retrofitting IoT sensors, upgrading the controller software, or replacing older servo drives with current-generation models.