Hydraulic Lifting System for Bearing Replacement on a 470-Ton Stacker Reclaimer
Industry: Mining
Location: Open-pit Mining Site, Southeast Asia
Year: 2025
Application: Maintenance & Heavy Equipment Lifting
Overview
In modern open-pit mining operations, stacker reclaimers play a vital role in material handling. These massive machines are responsible for stacking and reclaiming bulk materials such as coal, iron ore, and bauxite. A typical stacker reclaimer can weigh several hundred tons and move thousands of tons of aggregate per hour—making its operational reliability critical to production continuity.
One of Yongjian’s mining clients encountered a serious issue: a major bearing in a 470-ton stacker reclaimer required replacement due to fatigue failure. The bearing supported a critical slewing motion component. Any downtime would directly impact the material loading process and overall productivity.
The Challenge
To replace the bearing safely, the maintenance team needed to lift the main frame of the stacker reclaimer by approximately 400 mm (15.74 inches). This task presented several technical challenges:
Enormous Load: Lifting a 470-ton structure in a balanced and controlled manner
Center-of-Gravity Sensitivity: Uneven loading could risk structural distortion or equipment failure
Operator Safety: Personnel needed to be at a safe distance during the entire lifting operation
Precise Synchronization: Simultaneous control of multiple lifting points to avoid twisting or misalignment
Yongjian’s Solution
Yongjian partnered with the site’s maintenance contractor to design and implement a synchronized hydraulic lifting system, incorporating the following key components:
1. Enerpac EVO Split Flow Pump System
A high-capacity hydraulic control solution enabling precise, synchronized movement of multiple cylinders. This system ensured real-time feedback and correction across each lifting point, maintaining perfect parallelism during the lift.
2. Custom-Configured Yongjian Heavy-Duty Hydraulic Cylinders
Four ultra-high-pressure lifting cylinders (700 bar rated) were deployed at critical load-bearing points. Each cylinder was equipped with integrated locking collars and load sensors, enabling real-time monitoring and locking after lifting.
3. Remote Control & Monitoring
The lifting system was operated via a centralized control unit positioned 30 meters (98 feet) away from the equipment. This allowed the technicians to perform the lift without exposure to load risk, ensuring personnel safety.
4. Support Accessories & Engineering Supervision
Load distribution mats were installed under each cylinder to protect ground stability
All connections were secured using Yongjian’s quick-lock hydraulic fittings for leak-free operation
A senior Yongjian hydraulic engineer remained onsite throughout the lift to provide technical oversight
Results
The lifting operation was completed safely, efficiently, and ahead of schedule. Key outcomes included:
Zero safety incidents reported during the 3-day operation
Precise 400 mm lift achieved with less than 2 mm deviation across four points
Successful bearing removal and replacement in one working shift
Minimized downtime for the mining client—normal operation resumed within 48 hours
Why It Matters
This project exemplifies Yongjian’s ability to deliver custom-engineered hydraulic solutions for mission-critical maintenance in extreme environments. Through the integration of precision control systems, robust cylinder design, and on-site technical support, Yongjian helped the client:
Avoid the cost of dismantling the entire reclaimer arm
Reduce downtime from weeks to days
Improve maintenance efficiency and safety protocols
Conclusion
In the high-stakes world of mining, where every hour of downtime can cost thousands of dollars, fast and reliable maintenance solutions are essential. Yongjian’s deep experience in hydraulic system integration enables heavy-industry clients to perform complex repairs with speed, safety, and precision.
This case further highlights how our hydraulic lifting systems can be adapted for use in other heavy-equipment applications, such as dragline maintenance, bucket wheel replacements, or conveyor drive systems.
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