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Tower crane maintenance small knowledge


Release time:

2019-02-07

金属结构件的维修与保养1.严格执行起重机钢结构件报废标准。2.对主要受力的结构件应检查金属疲劳强度、焊缝裂纹、结构变形、破损等情况,对主要受力结构件的关键焊缝及焊接热影响区的母材应进行检查,若发现异常,应进行处理。结构件的检查应按下列程序进行。   (A)日常检查:塔机每工作80小时应进行一次日常检查。塔机司机在交接班时,应检查各连接部位螺栓的紧固情况,如有松动应及时紧固。   (B)当塔机出现异常声响,或出现过误操作,或发现塔机安全保护装置失灵等情况时,应进行检查,并作好记录。   (C)当一个工程完成,塔机拆卸后,应由工程技术人员和专业维修人员进行详细检查,并作好记录。   3.在运输过程中应尽量设法防止结构件变形和碰撞损坏。   4.每半年至一年喷刷油漆一次。油漆前应除尽金属表面的锈斑、油污及其它污物。   钢丝绳及其维护保养   1.钢丝绳在使用过程中,应防止钢丝绳打环、扭结、弯折或粘上杂物,防止与机械或其他杂物相摩擦。   2.塔机安装完毕(使用前)应对钢丝绳进行润滑,用石墨润滑脂涂抹一遍,以后对钢丝绳的润滑按“起重机润滑表“进行。   3.塔机的总体设计不允许钢丝绳具有无限期的寿命,有下列情况之一应予以报废:   a. 钢丝绳6×19―d(d钢丝绳直径)在6d长度内断丝数量超过5根,在30d长度内断丝数量超过10根。   b. 钢丝绳6×37―d(d钢丝绳直径)在6d长度内断丝数量超过10根,在30d长度内断丝数量超过19根。   c. 钢丝绳紧靠在一起,即使在6d长度内断丝数量没超过5根,也应报废。   d. 钢丝绳虽然没有断丝,但钢丝绳磨损达到其直径的40%,或钢丝绳相对于公称直径减小7%甚至更多时,或钢丝绳明显弯曲等。   e. 钢丝绳失去正常的形状,产生畸形,如波浪、笼状畸变、绳股挤出、钢丝挤出、绳径局部变大、扭结、绳径局部变小、部分被压扁、弯折。   f.钢丝绳径受了特殊热力作用,外部出现了可识别的颜色时。   注:当吊运熔化或炽热金属、酸溶液、爆炸物、易燃物时,钢丝绳断丝报废数量减半。本说明书未提及情况按GB5972的规定执行。   机械部分的保养和修理   1.日常保养   (1)经常保持各机构的清洁,及时清扫各部分灰尘;   (2)检查各减速器的油量,如低于规定油面高度应及时加油;   (3)检查各减速机的透气塞是否能自由排气,若阻塞,应及时疏通;   (4)检查各制动器的效能,如不灵敏可靠应及时调整;   (5)检查各连接处的螺栓,如有松动和脱落应及时紧固和增补;   (6)检查各种安全装置,如发现失灵情况应及时调整;   (7)检查各部位钢丝绳和滑轮,如发现过度磨损情况应及时处理;   (8)检查各润滑部位的润滑情况,及时添加润滑脂。   2.小修(塔机工作1000小时以后进行)   (1)进行日常保养的各项工作;   (2)拆检清洗减速机的齿轮,调整齿侧间隙;   (3)清洗开式传动的齿轮,调整后涂抹润滑脂;   (4)检查和调整回转支承装置;   (5)检查和调整制动器和安全装置;   (6)检查吊钩、滑轮和钢丝绳的磨损情况,必要时进行调整、修复和更改。   3.中修(塔机工作4000小时以后进行)   (1)进行小修的各项工作;   (2)修复或更改各联轴器的损坏件;   (3)修复或更换制动瓦;   (4)更换钢丝绳、滑轮等;   (5)检查回转支承部分各连接螺栓,必要时更换,注意:更换时采用高强螺栓;   (6)除锈、油漆。   4.大修(塔机工作8000小时以后进行)   (1)进行小修和中修的各项工作;   (2)修复或更换制动轮、制动器等;   (3)修复或更换减速机总成;   (4)修复或更换回转支承总成。   其它主要部件的维护和保养   1.制动器零件有下列情况之一的应予报废:   (1)裂纹;   (2)制动块摩擦衬垫磨损量达原材料厚度的50%;   (3)制动轮表面磨损量达5mm ~2mm;   (4)弹簧出现塑性变形;   (5)杠杆系统空行程超过其额定行程约10%。   2.吊钩禁止补焊,有下列情况之一的应予报废:   (1)用20倍放大镜观察表面有裂纹及破口;   (2)钩尾和螺纹部分等危险断面及钩筋有永久性变形;   (3)挂绳处断面磨损量超过原高的10%;   (4)心轴磨损量超过其直径的5%;   (5)开口度比原尺寸增加15%。   3.卷筒和滑轮有下列情况之一的应予报废:   (1)裂纹和轮缘破损;   (2)卷筒壁磨损量达原壁厚的10%;   (3)滑轮绳槽底的磨损量超过相应钢丝绳直径的25%。   4.车轮有下列情况之一的应予报废:   (1)裂纹;   (2)车轮踏面厚度磨损量达原厚度的15%;   (3)车轮轮缘厚度磨损量达原厚度的50%。   5.操作司机必须经常检查安全限制器灵敏程度及有效情况,如发现失灵应及时调整或维修,决不允许将限制器线路拆掉。   回转支承装置的维护保养   (1)回转支承的安装支座(支承齿圈下底面的座子和置于内座圈上表面的座子)必须有足够的刚性,安装面要平整。装配回转支承以前支座应进行去应力处理,减少回转支承支座的变形。装配时支座和回转支承的接触面必须清理干净。   (2)使用中应注意噪音的变化和回转阻力矩的变化,如有不正常现象应拆检。   (3)回转支承必须水平起吊或存放,切勿垂直起吊或存放,以免变形。   (4)在螺栓完全拧紧以前,应进行齿轮的啮合检查,其啮合状况应符合齿轮精度的要求:即齿轮副在轻微的制动下运转后齿面上分布的接触斑点在轮齿高度方向上不小于25%,在轮齿长度方向上不小于30%。   (5)齿面工作10个班次应清除一次杂物,并重新涂上润滑脂。   (6)为确保螺栓工作的可靠性,避免螺栓预紧力的不足,回转支承工作的第一个100 小时和500小时后,均应分别检查螺栓的预紧扭矩。此后每工作1000小时应检查一次预紧扭矩。   (7)连接回转支承的螺栓和螺母均采用高强螺栓和螺母;采用双螺母紧固和防松。   (8)拧紧螺母时,应在螺栓的螺纹及螺母端面涂润滑油,并应该用扭矩扳手在圆周方向对称均匀多次拧紧。最后一遍拧紧时,每个螺栓上预紧扭矩应大致均匀。   (9)在回转支承的齿圈上表面对准滚道的部位均布了4个油杯,由此向滚道内添加润滑脂。在一般情况下,回转支承运转50小时润滑一次。每次加油必须加足,直至从密封处渗出油脂为止。

Tower crane maintenance small knowledge

Repair and maintenance of metal structural parts

1. Strict implementation of crane steel structure scrap standards.

2. The metal fatigue strength, weld crack, structural deformation and damage shall be checked for the main stressed structural parts. The key weld of the main stressed structural parts and the base metal of the welding heat affected zone shall be checked. If any abnormality is found, it shall be treated. The inspection of structural parts shall be carried out according to the following procedures.

(A) daily inspection: tower crane every 80 hours should be a daily inspection. Tower crane driver in the shift, should check the connection parts of the bolt fastening, such as loose should be timely fastening.

(B) When the tower crane has abnormal sound, or misoperation, or the failure of the tower crane safety protection device is found, it should be checked and recorded.

(C) When a project is completed and the tower crane is disassembled, it should be inspected in detail by engineering technicians and professional maintenance personnel, and records should be made.

3. Try to prevent structural deformation and collision damage during transportation.

4. Spray paint once every six months to a year. Before painting, rust spots, oil stains and other dirt on the metal surface shall be removed.

Wire Rope and Its Maintenance

1. During the use of the wire rope, the wire rope should be prevented from being looped, kinked, bent or stuck to debris to prevent friction with machinery or other debris.

2. After the tower crane is installed (before use), the steel wire rope shall be lubricated and daubed with graphite grease. After that, the steel wire rope shall be lubricated according to the "crane lubrication table.

The overall design of the tower crane does not allow the wire rope to have an indefinite life, and one of the following situations should be scrapped:

A. wire rope 6 × 19-d(d wire rope diameter) has more than 5 broken wires in 6d length and more than 10 broken wires in 30d length.

B. wire rope 6 × 37-d(d wire rope diameter) has more than 10 broken wires in 6d length and more than 19 broken wires in 30d length.

C. wire rope close together, even if the number of broken wires within 6d length does not exceed 5, should also be scrapped.

D. although the wire rope is not broken, the wire rope is worn to 40% of its diameter, or when the wire rope is reduced by 7% or more relative to the nominal diameter, or the wire rope is obviously bent.

e. The wire rope loses its normal shape and produces deformities, such as waves, cage distortion, strand extrusion, steel wire extrusion, local enlargement of the rope diameter, kink, local reduction of the rope diameter, and partial flattening and bending.

f. When the wire rope diameter is affected by special heat and a recognizable color appears on the outside.

Note: When lifting molten or hot metal, acid solution, explosives and inflammables, the scrap quantity of broken wire rope will be halved. The situation not mentioned in this manual shall be implemented according to the provisions of GB5972.

Maintenance and repair of mechanical parts

1. Daily maintenance

(1) Always keep the institutions clean and clean all parts of the dust in time;

(2) Check the amount of oil in each reducer. If it is lower than the specified oil level, add oil in time;

(3) Check whether the vent plug of each reducer can exhaust freely. If it is blocked, it should be cleared in time;

(4) check the effectiveness of the brake, if not sensitive and reliable should be adjusted in time;

(5) Check the bolts at each connection. If they are loose and fall off, they should be tightened and supplemented in time;

(6) check all kinds of safety devices, such as failure should be adjusted in time;

(7) check the various parts of the wire rope and pulley, if found excessive wear should be dealt with in a timely manner;

(8) Check the lubrication of each lubrication part and add grease in time.

2. minor repairs (after 1000 hours of tower crane operation)

(1) the daily maintenance of the work;

(2) disassemble and clean the gear of the reducer, and adjust the tooth side clearance;

(3) Clean the gears of the open transmission and apply grease after adjustment;

(4) Check and adjust the slewing bearing device;

(5) Check and adjust brakes and safety devices;

(6) Check the wear of hooks, pulleys and wire ropes, and adjust, repair and change if necessary.

3. Medium repair (after 4000 hours of tower crane operation)

(1) the work of minor repairs;

(2) Repair or change the damaged parts of each coupling;

(3) Repair or replace the brake shoe;

(4) Replace wire ropes, pulleys, etc;

(5) Check the connecting bolts of the slewing bearing and replace them if necessary. Note: high-strength bolts are used for replacement;

(6) Derusting and painting.

4. Overhaul (after 8000 hours of tower crane operation)

(1) to carry out the work of minor repair and intermediate repair;

(2) Repair or replace brake wheels, brakes, etc;

(3) Repair or replace the reducer assembly;

(4) Repair or replace the slewing bearing assembly.

Maintenance of other major components

1. Brake parts shall be scrapped in one of the following cases:

(1) Cracks;

(2) The wear amount of the brake pad friction lining reaches 50% of the thickness of the raw material;

(3) the brake wheel surface wear amount of 5mm ~ 2mm;

(4) Plastic deformation of the spring;

(5) The idle stroke of the lever system exceeds its rated stroke by about 10%.

2. Repair welding is prohibited for the hook, and one of the following conditions shall be scrapped:

(1) Use a 20-fold magnifying glass to observe cracks and breaks on the surface;

(2) Hook tail and thread part and other dangerous section and hook bar have permanent deformation;

(3) The wear of the section at the lanyard exceeds 10% of the original height;

(4) The wear of the mandrel exceeds 5% of its diameter;

(5) The opening degree is increased by 15% compared with the original size.

3. Drums and pulleys shall be scrapped in one of the following situations:

(1) Cracks and rim damage;

(2) The wear of the drum wall is 10% of the original wall thickness;

(3) The amount of wear at the bottom of the pulley rope groove exceeds 25% of the diameter of the corresponding wire rope.

4. The wheel shall be scrapped if it has one of the following conditions:

(1) Cracks;

(2) The wear amount of the wheel tread thickness is 15% of the original thickness;

(3) The wear amount of the wheel flange thickness is 50% of the original thickness.

5. The operator must always check the safety limiter sensitivity and effective situation, such as failure should be timely adjustment or maintenance, never allow the limiter line removed.

Maintenance of slewing bearing device

(1) The mounting support of the slewing bearing (the seat on the lower bottom surface of the ring gear and the seat on the upper surface of the inner seat ring) must have sufficient rigidity, and the mounting surface must be flat. Before assembling the slewing bearing, the bearing should be treated with stress relief to reduce the deformation of the slewing bearing. The contact surface between the support and the slewing bearing must be cleaned during assembly.

(2) In use, attention should be paid to the change of noise and the change of rotation resistance torque. If there is any abnormal phenomenon, it should be disassembled and inspected.

(3) The slewing bearing must be lifted or stored horizontally, and must not be lifted or stored vertically to avoid deformation.

(4) Before the bolts are completely tightened, the meshing inspection of the gears should be carried out, and the meshing condition should meet the requirements of gear accuracy: that is, the contact spots distributed on the tooth surface after the gear pair is running under slight braking are not less than 25% in the height direction of the gear teeth, and not less than 30% in the length direction of the gear teeth.

(5) The sundries shall be removed once for 10 shifts of tooth surface work, and grease shall be applied again.

(6) In order to ensure the reliability of bolt work and avoid insufficient bolt pre-tightening force, the bolt pre-tightening torque should be checked separately after the first 100 hours and 500 hours of slewing bearing work. The pre-tightening torque shall be checked every 1000 hours thereafter.

(7) The bolts and nuts connecting the slewing bearing are all high-strength bolts and nuts; double nuts are used for fastening and anti-loosening.

(8) When tightening the nut, the thread of the bolt and the end face of the nut should be coated with lubricating oil, and the torque wrench should be used to tighten the nut several times symmetrically and evenly in the circumferential direction. When tightening the last time, the pre-tightening torque on each bolt should be approximately uniform.

(9) 4 oil cups are evenly distributed on the upper surface of the ring gear of the slewing bearing aligned with the raceway, thus adding grease to the raceway. In general, the slewing bearing is lubricated once every 50 hours. Fill the oil every time until the grease seeps from the seal.

Tag:

Huaxia Heavy Industry

Mainly engaged in the production and sales of tower cranes, lifts and related accessories.

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