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A Complete Introduction of Crane Maintenance Standards
A complete introduction of crane maintenance standards, crane is a heavy machinery, in daily work wear will be more serious. Crane maintenance can offer a reference for crane daily maintenance standard. To bring us crane maintenance standard complete introduction for your reference.
Crane maintenance standards: part of the project and technical standards
1. The hook maintenance of crane maintenance standard
(1) Remove check hook, beams, pulley, shaft, bearing, and clean and smooth, hook, beams and slide shaft,No crack,Threaded portion should not be loose, bearing in good condition, turn the pulley, thread tool marks or cracks relief groove should be replaced;
(2) Check the dangerous section and wear condition, the dangerous section wear more than 10% of the original height should be done to change;
(3) The hook test, after overhaul, hook test should be done, to 1.25 times the rated load of suspended for 10 minutes, hook mouth is elastic volume should not exceed 0.25% of the hook dimensions, should not have permanent deformation after unloading and crack;
(4) Board hook overhaul, board hook after riveting, the clearance between the plate and plate, should not be greater than 0.3 mm.
2. Crane rope maintenance
(1) Broken wires check: broken wires within one lay length of more than 10% of the total number of steel wire should be scrapped by the standard;
(2) Radial wear: Steel wire radial wear more than 40% of the original diameter, the cable should be scrapped;
(3) Deformation inspection: Wire diameter shrinkage is fine amount to 70% of kink rope, rope place, should be scrapped in new broken strands wire rope;
(4) Wire lubrication: Before the lubrication, to clean with wire brush， kerosene, etc,With hemp rope grease (Q/SY1152-65) or synthetic graphite calcium base grease means (SYA1405-65) dip-coating saturation is advisable.
3. Crane pulley block maintenance
(1) Unpick and wash maintenance pulley block, check the crack, sliding shaft can not have crack, may not wear the shaft neck diameter 30%, conicity is not more than 5%, more than the value that should be replaced;
(2) For the maintenance of pulley groove, using sample to check pulley groove, radial wear should not exceed 30% of the wall thickness, otherwise should be scrapped.Shall not exceed the standard can be mended, with sample check after overhaul, the bottom and side clearance should not be greater than 0.5 mm, the center line of the wheel groove and the roller center line deviation should not be greater than 0.2 mm, end of the rope groove center for contour deviation should not be greater than 1 mm;
(3) The shaft hole inspection, after overhaul, axle hole is allowed no more than 0.25 CM2 defects, depth should not be more than 4 mm;
(4) Assembly, After assembly, should use flexible rotation, sideways motion not exceed D / 1000.D - diameter in the name of the pulley.
4. Crane drum maintenance
(1) Drum rope groove, wire rope wear more than 2 mm should be back to the car, after overhaul rope groove should meet the drawing requirements, but the thickness of the wall thickness should not be less than the original 81%;
(2) The surface of the drum, the drum surface should not have crack, there should be no apparent loss of roundness, linking piece screws should not loose;
(3) Drum shaft, on the drum shaft can not have crack, should meet the drawing requirements, after the big repair wear and tear more than 5% of nominal diameter, should replace new pieces;
(4) The assembly and installation, the center line of the drum shaft bearing surface to parallel with the car frame, the deviation is not thrown 1 mm/m, after the installation of two drum shaft end centerline deviation should be no greater than 0.15 mm.
5. Crane wheels maintenance
(1) The wheel tread wear, more than 15% of the original thickness of the wheel tread wear new parts should be changed, no more than this value, to system, heat treatment to repair the car.Wheel diameter shall be within the limits of tolerance, surface quenching hardness HB300 ~ 500, the wheel diameter greater than 400 mm Φ quenching layer thickness should be greater than 20 mm;Φ less than 400 mm, the hardening layer should not be less than 15 mm thick;
(2) The wheel diameter deviation between two matching, active wheel diameter deviation shall not be more than 0.1% of nominal diameter, driven wheel should not exceed 0.2%, electric hoist wheel diameter deviation shall not be more than 1% of nominal diameter, driven wheel should not exceed 0.2%;Electric hoist wheel diameter deviation should not exceed 1% of the nominal diameter;
(3）Flange wear and broken, deformation: 50% of the original thick rim wear or break area of more than 30mm² was should be scrapped, bending deformation of the flange thickness thickness of 20% should be scrapped;
(4) Wheel crack: wheel found crack should be scrapped;
(5) Tread ovality: ovality wheel tread up to 1 mm should be scrapped;
(6) The wheel group assembly: wheel installed components, should be good flexible rotation, installed on the same balance on the shelf a few wheels in the same vertical plane, allowable deviation of 1 mm.
6. Crane locomotive axle and bearing maintenance
(1) Journal of maintenance: journal after overhaul of ovality, conicity should not be greater than 0.03 mm;
(2) The crack repair: with magnetic or ultrasonic flaw detector check shaft, shaft can not have crack, scratch depth shall not be more than 0.03 mm;
(3) For the maintenance of rolling bearing, tapered roller bearing inner and outer circle between 0.03 ~ 0.18 mm are allowed within the scope of the axial clearance.Bearing gland to adjust gap should be within the range of 0.5 ~ 1.5 mm.
7. Crane gear and reducer maintenance
(1) Disassembling reducer cleaning and check gear grinding conditions;
(2) The tooth surface inspection: Reducer on the first shaft hoist gear wear amount should not exceed 10% of the tooth thickness, the rest should be less than 20%;Big car run institutions first shaft reducer gear wear should not be more than 15%, the rest should be less than 25%.Tooth surface corrosion damage on the surface of the mesh, 30% 10% of the original tooth thickness and depth should be scrapped gear, gear tooth should not have cracks or not has a broken tooth.Or replacement;
(3) Shaft repair: shaft shall not have cracks, the axis of bending length should not be more than 0.03 mm/m, excessive alignment;
(4) Gear reducer box joint surface (subdivision surface) is not permitted in any part in hit, touch and serious scratch, edge highs, flanging, and subdivision surface after joint clearance should be no more than 0.03 mm, and ensure no leakage.Parallelism in 1 m or more shall not be greater than 0.5 mm;
In no-load cases, with 1000 r/min drag operation, positive &negative each not less than 10 minutes, there should be no vibration of the motor when starting, impact and intense or intermittent abnormal sound;
The casing temperature rise shall not exceed 70 ℃, and the absolute temperature is not higher than 80 ℃;The bearing temperature rise shall not exceed 40 ℃, the absolute value should not exceed 80 ℃.
8. Crane coupling maintenance
(1) Coupling tooth surface maintenance;
(2) The internal and external gear ring end face the centerline of the throwing test;
(3) When the shaft centerline, no tilt, check coupling installation radial displacement;
(4) No radial displacement, due to the difference of two coupling heart caused by outer car line of skew Angle inspection;
(5) With the tooth forms of the intermediate shaft coupling coupling radial displacement (1) part for reference.
9. Crane brake maintenance
(1) brake lining maintenance: the wear amount should not exceed 50% of the original thickness, rivet should be sink ≥2mm;
(2) brake wheel repair: brake wheel working surface roughness is not lower than Ra = 16μm, HRC not less than 50, depth of 2 mm is not lower than HRC40;
Work surface dent or unilateral radial wear quantity of 1.5 mm should be back to the car and heat treatment.
Processing after the thickness of the brake wheel: the lifting mechanism should not be less than 70% of the original thickness, the operation should not be less than 50% of the original thickness of the brake wheel after overhaul, D≤200 mm or less radial runout should not be more than 0.05 m, D > 200 mm radial runout should not be more than 0.1 m.
10. Crane hoisting mechanism and car maintenance
(1) The lifting mechanism of axis: inspection check of the main shaft and the shaft hoist, there is no crack;
(2) Displacement of the motor and reducer check: should conform to the requirements for the installation of the coupling;
(3) Drum and reducer axis deviation: deviation should not be allowed in bearing seat is greater than 3 mm/m.
(4) The car wheel track deviation: due to the small wheels measuring car track deviation: when the gauge≤2.5m 2.5m, allowable deviation is±2mm, and the master-slave pulley relative difference is not greater than 2 mm, when the gauge is > 2.5 m, allowing its deviation is not more than±3mm, and the drive wheel relative difference is not more than 3 mm;
(5) The car track elevation deviation: when the small car gauge≤2.5mm, the allowable deviation to 3 mm;Gauge > 2.5 m, the allowable deviation for 5 mm;
(6) The center line of the orbit deviations from the center line of the support rail beam design: box beam deviation is allowed, shall not be more than 1/2δ, δ - web thickness (mm), single beam web allowable deviation is: not less than 10 mm, box double girder allowable deviation for: 2 ~ 3 mm;
(7) The car rail joint deviation: rail junction elevation deviation and the centerline deviation of 1 mm or less;
(8) The small wheels end face level deviation: deviation should not be more than 1/1000, and the two driving wheel deflection master to the contrary, 1 - to measure length;
(9) The small wheels end face deviation shall not be greater than D / 400;
(10) Small Wheel tread deviation: all wheel tread must be on a plane, deviation should not be greater than 0.5 mm;
(11) The car wheel track deviation: allow relative deviation is 4 mm.
11. The crane cart operation maintenance
(1)The wheel deviation: cart wheels of horizontal and vertical deviation with small wheels are the same;
(2) The same wheel to check on the balance beam: the same symmetric plane of the two wheels on the balance beam should be in the same vertical plane, allowable deviation should not be greater than 1 mm;
(3) Track inspection: track should not have crack, rail top, such as rail head side abrasion quantity should not be more than 3 mm;Crane rail longitudinal slope should not be more than 5/1000;
Two rail relative elevation deviation within the same section of ≤10mm;
(4) Clamping rail maintenance: jaw wear is more than 40% of the original thickness should be replaced, electric device clamp rail often should pay attention to adjust the safety rule, make the position of the cursor within the prescribed;
(5) Measured by wheel crane span deviation: when the span lengthL≤30m, span deviation should not be greater than 5 mm, when L > 30 m, span deviation should not be greater than 8 mm.
(6) by the wheels of diagonal deviation: when the span ≤30m, deviation should not be greater than 5 mm, when L < 30 m, its deviation should not be greater than 10 mm.
Above introduction of crane maintenance standards including the hook, rope, gear and gear reducer, a lot of hoisting machinery parts, when maintenance crane for you to provide a reference standard, hope to be of help.
Crane maintenance standards: part of the project and technical standards
1. The hook maintenance of crane maintenance standard
(1) Remove check hook, beams, pulley, shaft, bearing, and clean and smooth, hook, beams and slide shaft,No crack,Threaded portion should not be loose, bearing in good condition, turn the pulley, thread tool marks or cracks relief groove should be replaced;
(2) Check the dangerous section and wear condition, the dangerous section wear more than 10% of the original height should be done to change;
(3) The hook test, after overhaul, hook test should be done, to 1.25 times the rated load of suspended for 10 minutes, hook mouth is elastic volume should not exceed 0.25% of the hook dimensions, should not have permanent deformation after unloading and crack;
(4) Board hook overhaul, board hook after riveting, the clearance between the plate and plate, should not be greater than 0.3 mm.
2. Crane rope maintenance
(1) Broken wires check: broken wires within one lay length of more than 10% of the total number of steel wire should be scrapped by the standard;
(2) Radial wear: Steel wire radial wear more than 40% of the original diameter, the cable should be scrapped;
(3) Deformation inspection: Wire diameter shrinkage is fine amount to 70% of kink rope, rope place, should be scrapped in new broken strands wire rope;
(4) Wire lubrication: Before the lubrication, to clean with wire brush， kerosene, etc,With hemp rope grease (Q/SY1152-65) or synthetic graphite calcium base grease means (SYA1405-65) dip-coating saturation is advisable.
3. Crane pulley block maintenance
(1) Unpick and wash maintenance pulley block, check the crack, sliding shaft can not have crack, may not wear the shaft neck diameter 30%, conicity is not more than 5%, more than the value that should be replaced;
(2) For the maintenance of pulley groove, using sample to check pulley groove, radial wear should not exceed 30% of the wall thickness, otherwise should be scrapped.Shall not exceed the standard can be mended, with sample check after overhaul, the bottom and side clearance should not be greater than 0.5 mm, the center line of the wheel groove and the roller center line deviation should not be greater than 0.2 mm, end of the rope groove center for contour deviation should not be greater than 1 mm;
(3) The shaft hole inspection, after overhaul, axle hole is allowed no more than 0.25 CM2 defects, depth should not be more than 4 mm;
(4) Assembly, After assembly, should use flexible rotation, sideways motion not exceed D / 1000.D - diameter in the name of the pulley.
4. Crane drum maintenance
(1) Drum rope groove, wire rope wear more than 2 mm should be back to the car, after overhaul rope groove should meet the drawing requirements, but the thickness of the wall thickness should not be less than the original 81%;
(2) The surface of the drum, the drum surface should not have crack, there should be no apparent loss of roundness, linking piece screws should not loose;
(3) Drum shaft, on the drum shaft can not have crack, should meet the drawing requirements, after the big repair wear and tear more than 5% of nominal diameter, should replace new pieces;
(4) The assembly and installation, the center line of the drum shaft bearing surface to parallel with the car frame, the deviation is not thrown 1 mm/m, after the installation of two drum shaft end centerline deviation should be no greater than 0.15 mm.
5. Crane wheels maintenance
(1) The wheel tread wear, more than 15% of the original thickness of the wheel tread wear new parts should be changed, no more than this value, to system, heat treatment to repair the car.Wheel diameter shall be within the limits of tolerance, surface quenching hardness HB300 ~ 500, the wheel diameter greater than 400 mm Φ quenching layer thickness should be greater than 20 mm;Φ less than 400 mm, the hardening layer should not be less than 15 mm thick;
(2) The wheel diameter deviation between two matching, active wheel diameter deviation shall not be more than 0.1% of nominal diameter, driven wheel should not exceed 0.2%, electric hoist wheel diameter deviation shall not be more than 1% of nominal diameter, driven wheel should not exceed 0.2%;Electric hoist wheel diameter deviation should not exceed 1% of the nominal diameter;
(3）Flange wear and broken, deformation: 50% of the original thick rim wear or break area of more than 30mm² was should be scrapped, bending deformation of the flange thickness thickness of 20% should be scrapped;
(4) Wheel crack: wheel found crack should be scrapped;
(5) Tread ovality: ovality wheel tread up to 1 mm should be scrapped;
(6) The wheel group assembly: wheel installed components, should be good flexible rotation, installed on the same balance on the shelf a few wheels in the same vertical plane, allowable deviation of 1 mm.
6. Crane locomotive axle and bearing maintenance
(1) Journal of maintenance: journal after overhaul of ovality, conicity should not be greater than 0.03 mm;
(2) The crack repair: with magnetic or ultrasonic flaw detector check shaft, shaft can not have crack, scratch depth shall not be more than 0.03 mm;
(3) For the maintenance of rolling bearing, tapered roller bearing inner and outer circle between 0.03 ~ 0.18 mm are allowed within the scope of the axial clearance.Bearing gland to adjust gap should be within the range of 0.5 ~ 1.5 mm.
7. Crane gear and reducer maintenance
(1) Disassembling reducer cleaning and check gear grinding conditions;
(2) The tooth surface inspection: Reducer on the first shaft hoist gear wear amount should not exceed 10% of the tooth thickness, the rest should be less than 20%;Big car run institutions first shaft reducer gear wear should not be more than 15%, the rest should be less than 25%.Tooth surface corrosion damage on the surface of the mesh, 30% 10% of the original tooth thickness and depth should be scrapped gear, gear tooth should not have cracks or not has a broken tooth.Or replacement;
(3) Shaft repair: shaft shall not have cracks, the axis of bending length should not be more than 0.03 mm/m, excessive alignment;
(4) Gear reducer box joint surface (subdivision surface) is not permitted in any part in hit, touch and serious scratch, edge highs, flanging, and subdivision surface after joint clearance should be no more than 0.03 mm, and ensure no leakage.Parallelism in 1 m or more shall not be greater than 0.5 mm;
In no-load cases, with 1000 r/min drag operation, positive &negative each not less than 10 minutes, there should be no vibration of the motor when starting, impact and intense or intermittent abnormal sound;
The casing temperature rise shall not exceed 70 ℃, and the absolute temperature is not higher than 80 ℃;The bearing temperature rise shall not exceed 40 ℃, the absolute value should not exceed 80 ℃.
8. Crane coupling maintenance
(1) Coupling tooth surface maintenance;
(2) The internal and external gear ring end face the centerline of the throwing test;
(3) When the shaft centerline, no tilt, check coupling installation radial displacement;
(4) No radial displacement, due to the difference of two coupling heart caused by outer car line of skew Angle inspection;
(5) With the tooth forms of the intermediate shaft coupling coupling radial displacement (1) part for reference.
9. Crane brake maintenance
(1) brake lining maintenance: the wear amount should not exceed 50% of the original thickness, rivet should be sink ≥2mm;
(2) brake wheel repair: brake wheel working surface roughness is not lower than Ra = 16μm, HRC not less than 50, depth of 2 mm is not lower than HRC40;
Work surface dent or unilateral radial wear quantity of 1.5 mm should be back to the car and heat treatment.
Processing after the thickness of the brake wheel: the lifting mechanism should not be less than 70% of the original thickness, the operation should not be less than 50% of the original thickness of the brake wheel after overhaul, D≤200 mm or less radial runout should not be more than 0.05 m, D > 200 mm radial runout should not be more than 0.1 m.
10. Crane hoisting mechanism and car maintenance
(1) The lifting mechanism of axis: inspection check of the main shaft and the shaft hoist, there is no crack;
(2) Displacement of the motor and reducer check: should conform to the requirements for the installation of the coupling;
(3) Drum and reducer axis deviation: deviation should not be allowed in bearing seat is greater than 3 mm/m.
(4) The car wheel track deviation: due to the small wheels measuring car track deviation: when the gauge≤2.5m 2.5m, allowable deviation is±2mm, and the master-slave pulley relative difference is not greater than 2 mm, when the gauge is > 2.5 m, allowing its deviation is not more than±3mm, and the drive wheel relative difference is not more than 3 mm;
(5) The car track elevation deviation: when the small car gauge≤2.5mm, the allowable deviation to 3 mm;Gauge > 2.5 m, the allowable deviation for 5 mm;
(6) The center line of the orbit deviations from the center line of the support rail beam design: box beam deviation is allowed, shall not be more than 1/2δ, δ - web thickness (mm), single beam web allowable deviation is: not less than 10 mm, box double girder allowable deviation for: 2 ~ 3 mm;
(7) The car rail joint deviation: rail junction elevation deviation and the centerline deviation of 1 mm or less;
(8) The small wheels end face level deviation: deviation should not be more than 1/1000, and the two driving wheel deflection master to the contrary, 1 - to measure length;
(9) The small wheels end face deviation shall not be greater than D / 400;
(10) Small Wheel tread deviation: all wheel tread must be on a plane, deviation should not be greater than 0.5 mm;
(11) The car wheel track deviation: allow relative deviation is 4 mm.
11. The crane cart operation maintenance
(1)The wheel deviation: cart wheels of horizontal and vertical deviation with small wheels are the same;
(2) The same wheel to check on the balance beam: the same symmetric plane of the two wheels on the balance beam should be in the same vertical plane, allowable deviation should not be greater than 1 mm;
(3) Track inspection: track should not have crack, rail top, such as rail head side abrasion quantity should not be more than 3 mm;Crane rail longitudinal slope should not be more than 5/1000;
Two rail relative elevation deviation within the same section of ≤10mm;
(4) Clamping rail maintenance: jaw wear is more than 40% of the original thickness should be replaced, electric device clamp rail often should pay attention to adjust the safety rule, make the position of the cursor within the prescribed;
(5) Measured by wheel crane span deviation: when the span lengthL≤30m, span deviation should not be greater than 5 mm, when L > 30 m, span deviation should not be greater than 8 mm.
(6) by the wheels of diagonal deviation: when the span ≤30m, deviation should not be greater than 5 mm, when L < 30 m, its deviation should not be greater than 10 mm.
Above introduction of crane maintenance standards including the hook, rope, gear and gear reducer, a lot of hoisting machinery parts, when maintenance crane for you to provide a reference standard, hope to be of help.
