Level 1 maintenance is performed when the beam pumping unit has been operating for one month (720-800 hours). It is carried out by the production unit's maintenance team with the assistance of on-site personnel. The maintenance interval should be at least 25 days, and includes the following tasks:
(1) Perform all routine maintenance procedures.
(2) Inspect the gears in the reducer: Open the inspection port on the top of the gearbox, check the gear meshing condition, and inspect for gear damage and wear. Analyze the causes of any damage or wear. Check and clean the breather.
(3) Check the oil level in the gearbox of the Beam pumping unit: The upper oil level should not exceed 2/3 of the capacity, and the lower level should not be below 1/3. Ideally, the intermediate shaft gear teeth should be just submerged. Add oil to the specified level if necessary. Inspect the gearbox for any leaks, determine the cause, and repair or control as needed.
(4) Check the lubrication of the pumping unit: Apply grease to all bearings, ensuring they are sufficiently and fully lubricated. If the grease has deteriorated, replace it entirely. For the center bearing housing, if grease replacement is needed, attach the grease gun to the filling port, open the drain port, and continue pumping grease until the old grease is expelled and new grease emerges from the drain port.
(5) Check the balance of the pumping unit: Use a clamp-on ammeter to measure the current, observing the peak current variations during upstroke and downstroke. The balance rate should be between 85% and 115% to be considered satisfactory. If the balance rate does not meet requirements, adjust the counterbalance.
(6) Inspect the tightness of the pumping unit: Check and tighten all bolts individually. Critical areas such as the crank pin, center bearing housing, tail shaft, base bolts, and gearbox mounting bolts must be tightened and marked with new safety inspection lines.
(7) Check the condition of the brake system: Clean the brake pads and inspect them for wear. Replace the brake pads if they are severely worn or cracked. Check the brake travel and clearance, and adjust the brake tension. The brake locking pawl should engage between 1/3 and 2/3 of the brake slot. Inspect the pull rod and brake pivot shaft.
(8) Inspect the belt wear: Check for any damage to the belts. Ensure the motor pulley and gearbox pulley faces are aligned and at the appropriate distance. The tension of each individual belt should be consistent.
(9) Check the alignment of the horse head center with the wellhead center: If misaligned, make necessary adjustments promptly.
(10) Inspect the wire rope slings. Replace if there are signs of fraying or broken strands. Check the cable clamps; both upper and lower clamps should be in good condition. Wire rope slings with three broken wires in the same location need replacement. If the wire rope diameter is inconsistent, it should be replaced. If significant rust is found on the wire rope, apply oil lubrication or coat the exterior with grease.
(11) Inspect the electrical equipment: Check the motor for unusual sounds and temperature rise. Inspect the motor shaft and fan. Examine the distribution box wiring, starter, overcurrent protection devices, and instruments. Inspect the grounding system and cables.
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