Level 2 maintenance is performed by the production unit maintenance team when the beam pumping unit has accumulated 4000 hours of operation (once every six months). It includes all Level 1 maintenance tasks and is conducted simultaneously with the last Level 1 maintenance. The maintenance includes:
(1) Performing all first-level maintenance tasks.
(2) Brake system: Remove and inspect the brake drum for severe wear, replacing if necessary. Check if brake pad thickness meets braking requirements. Ensure the cam moves consistently when pulling the brake rocker arm. Inspect brake shoe springs for damage or breakage, replacing if needed. Check if both brake shoes operate uniformly. Adjust the brake travel to be between 1/2 and 2/3.
(3) Using a level, check the beam pumping unit's longitudinal and lateral levelness (measure 1 point each on the left and right of the support frame and gearbox longitudinally, with error not exceeding 3mm per meter; measure 3 points laterally across the support frame front and gearbox front and back, with error not exceeding 0.5mm per meter). If requirements are not met, use shims to level, ensuring standards are met. When adjusting, loosen fixing bolts, use a jack to lift the base before adding shims, avoiding direct force that could damage the cement foundation.
(4) Inspect gearbox gears and bearings: Check oil quality, replace if unsatisfactory by draining, cleaning with kerosene, removing metal particles with a magnet, cleaning sediment, and refilling with appropriate oil (use lower viscosity oil in winter). Remove and clean the gearbox breather valve. Check gears for severe wear, peeling, or cracks, replacing if found. Ensure bearings are not severely worn and radial clearance meets standards. Check for loose intermediate shaft helical gears. Inspect sealing rings and gaskets, replacing if severely damaged. Verify all fixing bolts are tight.
(5) Check alignment of horse head with wellhead, adjusting front, back, left, and right using set screws on the central bearing housing. Error should not exceed standard requirements.
(6) Inspect crank pins: Check grease quantity and quality. Inspect bearing wear and radial clearance. Check oil seal wear, replacing if necessary. Verify tightness of crown nut and connecting rod bolts.
(7) Ensure both connecting rods are of equal length, with error not exceeding 3mm.
(8) Lubrication of middle and tail shafts: Check lubricant quality and quantity. Listen for abnormal noises during operation. Check for loose fixing bolts. Ensure the walking beam is centered on the unit's centerline.
(9) Check belt tension and "four-point alignment". Adjust if not meeting requirements.
(10) Electrical equipment maintenance: Check motor grounding wire security and insulation. Inspect AC contactor points for burning, sand down if slightly burnt, or replace if severely damaged. Clean the distribution box. Add grease to the motor. Remove the pulley, fan, and end cover to add molybdenum disulfide.
(11) Inspect electrical equipment: Check motor for unusual sounds and temperature rise. Examine motor shaft and fan. Inspect distribution box circuitry, starter, overcurrent protection devices, and instruments. Check grounding devices and cables.
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