桥式起重机维护及保养.doc

起重机日常维护与保养Routine Care and Maintenance of Crane（一）机构的润滑 Lubrication of Mechanism起重机设备润滑情况的好坏直接影响起重机各机构的正常运转，同时与延长机件的寿命和促进安全生产有密切的关系。因此，使用和维修人员必须经常检查各润滑点的润滑情况，按时用油枪通过各润滑点的油杯加油。The lubrication condition of crane equipment directly affects the normal operation of crane mechanisms and is closely related to extending the service life of the mechanics and promoting safety in production. Therefore, the use and maintenance personnel must carry out regular checks on all lubrication points and fuel on time with oil gun through oil cups of the lubrication points.1起重设备各润滑点的分布1. Distribution of lubrication points of hoisting equipment 吊钩滑轮轴；Hook pulley spindle 固定滑轮轴（小车架上）；Fixed pulley spindle (on the dolly frame) 钢丝绳；Steel rope 各减速器；Reducers 各齿轮联轴器；Gear couplings 各轴承箱（包括车轮组、卷筒组）；Bearing boxes (including group wheel and group reel) 电动机轴承；Motor bearing 制动器各节点和轴栓；Nodes and axle bolts of brake 电缆导电中滑车的轴承；Pulley bearing of electric cable 抓斗各铰点的轴。Shafts of grab hinge joints2润滑条件与润滑材料2. Lubricating condition and materials起重设备必须采用合适的润滑油脂，定期润滑和及时更换，润滑装置和各润滑点必须保持清洁。下表所列为各机构主要零部件润滑时间的一般规定和推荐用的润滑材料：Appropriate lubricant grease must be used for hoisting equipment, which should be regularly lubricated and timely replaced; lubrication equipment and the lubrication points must be kept clean. The following table lists the general regulation on lubrication interval time of major components of various mechanisms and lubricating materials recommended to use.序号No.易损零部件Wearing parts规 则Regulation 润滑条件Lubricating condition润滑材料Lubricating materials1钢丝绳Steel rope一般1530天一次，根据实际使用中的润滑情况决定Lubricated once 1530 days in general, according to lubrication condition in the actual use把润滑脂加热到80100浸泡至饱和为宜不加热涂沫Heat lubricant grease to 80100, soaked to saturationLiniment not heated 钢丝绳麻心脂(Q/SY1152-65)涂合成石墨钙基脂(SYB1405-65)或其它钢丝绳润滑脂Steel rope hemp core grease (Q/SY1152-65)graphite calcium base grease (SYB1405-65) or other steel rope lubricant grease2减速器Reducers使用初期每季换一次，以后可根据油的清洁情况半年一年换一次Replaced once every quarter in the early use period and 6-12 months later according to the cleanness of oil夏 季summer用HL30齿轮油(SYB1103-62)With HL30 gear oil (SYB1103-62)冬 季（不低于-20）Winter(not lower than -20)用HL20齿轮油(SYB1103-62)With HL20 gear oil (SYB1103-62)3齿轮联轴器Gear couplings每月一次Once a month工作温度-2060Service temperature -2060高于50Higher than 50低于-20Lower than -20 可采用以任何元素为基体的润滑脂，但不能混合使用。冬季宜用1.2号，夏季宜用3.4号。Lubricant grease adopting any element as the base can be used but cannot be mixed. No.1.2 is preferred in winter and No.3.4 in summer. 用工业锂基润滑脂(QSY1110-65)冬季用1号，夏季用2号。Industrial lithium base grease (QSY1110-65); No.1 for winter and No.2 for summer采用1、2号特种润滑脂(Q/SY1119-70)No.1 and No.2 special lubricant grease (Q/SY1119-70)4滚动轴承Rolling bearing36个月一次Once 36 months 5滑动轴承Sliding bearing酌情Case by case6卷筒内齿盘Inner fluted disc of reel每大修时加满Top up in every heavy maintenance7电动机Motor年修或大修Annual overhaul or heavy maintenance一般电动机 General motorH级绝缘和湿热地带H-grade insulation and hot and humid zone复合铝基润滑脂(Q/SY1105-66)Compound aluminum base grease (Q/SY1105-66) 3号锂基润滑脂No.3 lithium base grease注：表中所列Q/SY系列系辽宁省营口市润滑油脂厂厂标代号；SYB系石油部部颁标准代号。Note: the listed Q / SY series is the blem code of Lubricating Oil and Grease Factory in Yingkou City, Liaoning Province; SYB is the ministerial standard code of the Petroleum Department.（二）机构设备的维护和保养 Care and Maintenance of Mechanical Equipment1钢丝绳1. Steel rope报废标准：按GB6067-85起重机械安全规程中有关规定执行。Discard standard: according to the relevant provisions in GB6067-85 “Hoisting Machinery Safety Regulations”.钢丝绳使用的安全程度由下列项目判定（见2.5.12.5.10款）The security level of steel rope is determined by the following items （refer to 2.5.12.5.10）a、 断丝的性质和数量；Nature and number of filament breakageb、 绳端断丝；Rope-end filament breakagec、 断丝的局部聚集；Partial aggregation of filament breakaged、 断丝的增加率； Increasing rate of filament breakagee、 绳股断裂；Strand breakagef、 由于绳芯损坏而引起的绳径减小；Reduction of rope diameter caused by the damage of rope coreg、 弹性减小；Reduction of elasticityh、 外部及内部磨损；External and internal wear and teari、 外部及内部腐蚀；External and internal corrosionj、 变形；Deformationk、 由于热或电弧造成的损坏。Damages caused by heat or electric arc所有的均应考虑以上各项因素并遵循各自的标准。然而，钢丝绳的损坏往往是由各个因素综合积累造成的，这就应由主管主管判别并决定钢丝绳是报废还是继续使用。All the above factors should be taken into account and follow their respective standard. However, the damage of steel rope is often caused by the accumulation of various factors, which requires the superintendent to judge and decide to discard or continue to use the rope.在所有情况下，检验人员应弄清钢丝绳的损坏是否由机构上缺陷所造成，如果是这样，应建议在换新钢丝绳之前消除这缺陷。In all cases, inspectors should ascertain whether the rope damage is caused by mechanism defects; if so, it should be recommended to eliminate the defect before replacing the rope.2.5.1绳端断丝 Rope-end filament breakage当绳端或其附近出现断丝时，即使数量很少也表明该部位应力很高，可能是由于绳端安装不正确造成的，应查明损坏原因。如果绳长允许，应将断丝的部位切去重新合理安装。When filament breakage occurs at the rope end or nearby, even if there is only a small number, it also indicates that the stress of that part is very high, which may be because of the incorrect installation of rope end; the cause of damage should be identified. If the rope length allows, cut out the site where filament breakage occurs and conduct a reasonable re-installation.2.5.2断丝的局部聚集Partial aggregation of filament breakage如果数年丝紧靠一直形成局部聚集，则钢丝绳应报废。如这种断丝聚集在小于6d的绳长范围内，或者集中在任一支绳股里，那么，即使断丝数比表列的数值少，钢丝绳也应予以报废。If for years the filaments gather forming partial aggregation, the rope should be scrapped. If the filament breakage aggregates within the scope of rope length less than 6d, or concentrates in any one strand, even if the number of broken wires is less than the value listed in the table, the steel rope should also be scrapped.2.5.3断丝的增加率Increasing rate of filament breakage在某些使用场合，疲劳是引起钢丝绳损坏的主要原因，断丝则是在使用一个时期以后才开始出现但断丝数逐渐增加，其时间间隔越来越短。在此情况下，为了判定断丝的增加率，应仔细检验并记录断丝增加情况。判明这个“规律”可用来确定钢丝绳未来报废的日期。In some use occasions, fatigue is the main reason causing the damage of steel wire rope; filament breakage begins to occur after a period of time, but the number of broken wires gradually increases and its interval time becomes shorter and shorter. In this case, in order to determine the increasing rate of broken wires, carefully inspect and record the increase of broken wires. Identifying this law can be used to determine the future scrapping date of steel rope.2.5.4绳股断裂Strand breakage如果出现整根绳股的断裂，则钢丝绳应报废。If the breakage occurs to a whole strand, the steel rope should be scrapped.2.5.5由于绳苡损坏而引起的绳么减小Reduction of rope diameter caused by the damage of rope core当钢丝绳的纤维芯损坏或钢芯（或多层结构中的内部绳股）断裂而造成绳显著减小时，钢丝绳应报废。When the fiber core of steel rope is damaged or steel core (or the internal strand in multi-layer structure) fractures and it causes significant reduction of rope diameter, the rope should be scrapped. 微小的损坏，特别是当所有各绳股中应力处于良好平衡时，用通常的检验方法可能是不明显的。然而这种情况会引起钢丝绳的强度大大降低。所以，有任何内部细微损坏的迹象时，均应对钢丝绳内部进行检验予以查明。一经证实损坏，则该钢丝绳就应报废。Minor damage, especially when the stress of all the strands is in good balance, may be unobvious with the usual test method. However, this may greatly reduce the strength of steel wire rope. Therefore, when there are any signs of internal slight damage, the interior of steel rope should be inspected to make clear the signs. Once the damage is proven, the rope should be discarded.2.5.6弹性减小Reduction of elasticity在某范些情况下，钢丝绳的弹性会显著减小，若继续使用则是不安全的。In some cases, the elasticity of steel rope will be significantly reduced and continued use would be unsafe.钢丝绳的弹性减小是较难发觉的，如检验人员有任何怀疑，则应征询钢丝绳专家的意见。然而弹性减小通常伴随下述现象：It is rather difficult to find the reduction of the wire rope elasticity; if inspectors have any doubts, they should consult the rope expert. However, the reduction of elasticity is usually accompanied by the following phenomenon:a、 绳径减小；Reduction of rope diameterb、 钢丝绳捻距伸长；Prolonged lay length of steel ropec、 由于各部分相互压紧，钢丝之间和绳股之间缺少空隙；As various parts are compressed against each other, there is lack of gap among wires and strands.d、 绳股凹处出现细微的褐色粉末；Fine brown powder appears in the place of strand cavity. e、 虽未发现断丝，但钢丝绳明显的不易弯曲和直径减小比起单纯是由于钢丝磨损而引起的也要快得多。这种情况会导致在动载作用下突然断裂，故应立即报废。Although broken wires are not found, the elasticity reduction caused by obvious difficulty of bending and diameter reduction is quicker than that simply caused by wear and tear of wires. This situation will result in a sudden fracture under dynamic load, so the rope should be immediately scrapped.2.5.7外部及内部磨损External and internal wear and tear产生磨损的两种情况：The two situation causing wear and tear:a、 内部磨损及压坑Internal wear and indentation这种情况是由于绳内各个绳股和钢丝之间的摩擦引起的，特别是当钢丝绳经受弯曲时更是如此。This situation is due to the friction among strands and wires in the rope, especially when the wire rope is subject to bending.b、外部磨损 External wear钢丝绳外层绳股的钢丝表面的磨损，是由于它的压力作用下与滑轮和卷筒的绳槽接触摩擦造成的。这种现象在吊载加速和减速运动时，钢丝绳与滑轮接触的部位特别明显，并表现为外部钢丝磨成平面状。The wear on the wire surface of the outer strands in the rope is caused by the friction in the contact with the rope groove of pulley and reel under its pressure. When the suspended load is acceleration and deceleration movements, this phenomenon is particularly evident at the contact area of wire rope and pulley and it is shown that the external wires are worn into a planar.润滑不足，或不正确的润滑以及还存在灰尘和砂粒都会加剧磨损。Lack of lubrication, improper lubrication, or the existence of dust and grit will accelerate the wear.磨损使钢丝绳的断面积减小因而强度降低。当外层钢丝磨损达到其直径的40%时，钢丝绳应报废。The wears reduce the sectional area of steel rope and thus reduce the strength of the rope. When the wear of outer wire reaches 40% of its diameter, the rope should be scrapped.当钢丝绳直径相对于公称直径减小7%或更多是，即使未发现断丝，该钢丝绳也应报废。When the diameter of steel rope decreases by 7% or more compared to the nominal diameter, even if no broken wire is found, the wire rope should also be scrapped.2.5.8外部及内部腐蚀 External and internal corrosion腐蚀在海洋或工业污染的大气中特别容易发生。它不公减少了钢丝绳的金属面积从而降低了破断强度，而且还将引起表面粗糙并从中开始发展裂纹以致加速疲劳。严重的腐蚀还会引起钢丝绳弹性的降低。Corrosions will happen very easily in the sea or in the atmosphere subjecting to industrial pollution. It not only reduces the metal area of the wire rope and thus reduces the breaking strength, but also will cause a rough surface which may be developed into cracks accelerating fatigue. Serious corrosion can also reduce the reduction of rope elasticity. 2.5.8.1外部腐蚀 External corrosion外部钢丝的腐蚀可用肉眼观察。当表面出现深坑，钢丝相当松弛时应报废。The corrosion of external wires can be observed with the naked eye. When there is deep pit on the surface and the wire is quite loose, the rope should be scrapped.2.5.8.2内部腐蚀 Internal corrosion内部腐蚀比经常伴随它出现的外部腐蚀较难发现。但下列现象可供识别：The internal corrosion is difficult to find than the external corrosion often accompanying the internal corrosion. However, the following phenomena can be identified:a、钢丝绳直径的变化。钢丝绳在绕过滑轮的弯曲部位直径通常变小。但对于静止段的钢丝绳则常由于外层股出现锈积而引起钢丝绳直径的增加。The change of wire rope diameter: The diameter of the bending part through the pulley usually decreases. But the diameter of steel rope in the still part usually increases due to rust accumulation of the outer strands.b、钢丝绳外层绳间的空隙减小，还经常伴随出现个层绳股之间断丝。The gap reduction between the outer wire ropes is also often accompanied by filament breakage in the single strand.如果有任何内部腐蚀的迹象，应由高度重视人员对钢丝绳内部检验。若确认有严重的内部腐蚀，则钢丝绳应立即报废。If there are any signs of internal corrosion, the inspection of the steel rope interior should be attached great importance to by testing personnel. If serious internal corrosion is identified, the rope should be immediately scrapped.2.5.9变形 Deformation钢丝绳失去正常形状产生可见的畸形称为“变形”。这种变形部位可能引起变化它会导致钢丝绳内部应力分布不均匀。Loss of normal shape and visible malformation of wire rope are known as deformation. This kind of deformation may cause the uneven distribution of internal stress in the steel rope.钢丝绳的变形从外观上区分，主要可分下述几种：Distinguished from the appearance, the deformation of steel rope can be mainly classified as the following types:2.5.9.1波浪形 Wave-type波浪形的变形是：钢丝绳的纵向轴线成螺旋线形状。这种变形不一定导致任何强度上的损失，但是变形严重即会产生跳动造成不规则的传动。时间长了会引起磨损及断丝。Wave-shaped deformation is: the vertical axis of the rope turns into the spiral shape. This deformation does not necessarily lead to any loss of strength, but serious deformation will lead to jumpiness and cause irregular transmission. Such deformation for a long time can cause wear and filament breakage.出现波浪形时，在钢丝绳长度不超过25d的范围内，若d1，则钢丝绳应报废。When the wave shape occurs and the length of the rope is no more than 25d, if d1 , the rope should be scrapped.式中d为钢丝绳的公称直径；d1钢丝绳变形后包络直径。In the formula d is the nominal diameter of steel rope; d1 refers to enveloping diameter after steel wire rope deforms. 2.5.9.2笼关畸变 Cage-type deformation这种变形出现在具有钢芯的钢丝绳上。当外层绳股发生脱节或者变得比内部绳股长的时候就会发生这种变形。笼状畸变的钢丝绳应立即报废。This deformation appears in the wire rope with steel core. When the outer strands become detached or become longer than the internal strands, the kind of deformation will occur. The rope deformed into cage shape should be immediately scrapped.2.5.9.3绳股挤出 Strand extrusion此种状况通常伴随笼状畸变一直产生。绳股被挤出说明钢丝绳不平衡。绳股挤出的钢丝绳应立即报废。This situation usually occurs accompanying cage-type deformation. The strand extrusion means the imbalance of steel rope. The rope whose strand is extruded should be immediately scrapped.2.5.90.4钢丝挤出 Wire extrusion此种变形是一部分钢丝或钢丝束在钢丝绳背着滑轮槽的一侧拱起形成环状。这种变形常因冲击载荷而引起。若此种变形严重时，则钢丝绳应报废。This kind of deformation is because part of the wires or wire tendons hog forming into ring shape on the side against the pulley groove. This distortion is often caused by impact load. If such deformation is severe, the rope should be scrapped.2.5.90.5绳径局部增大Partial increase of rope diameter钢丝绳直径有可能发生局部增大，并能波及相当长一段钢丝绳。绳径增大通常与绳芯畸变有关（如在特殊环境中，纤维芯因受潮而膨胀），其必然结果是外层绳股产生不平衡，而造成定位不正确。绳径局部严重增大的应报废。There is possibly partial increase of rope diameter and can spread to quite a long rope. The increase of rope diameter is usually associated with the distortion of the rope core (for example, in a special environment, the fiber core will inflate due to damp), and it will definitely lead to the imbalance of outer strands and incorrect positioning. The rope whose partial diameter is severely enlarged should be scrapped.2.5.9.6扭结Kink扭结是由于钢丝绳成环状在不可能绕其轴线；转动的情况下被拉紧而造成的一种变形。其结果是出现捻距不均而引起格外的磨损，严重时钢丝绳将产生扭曲，以致只留下极小一部分钢丝绳强度。Kink occurs when the rope is tensed up in the rotation because the ring-like rope cannot wind around its axis. This will result in the unevenness of lay length and extra wear. When this situation is severe, the rope will be distorted and only a very small part of the rope strength remains. 严重扭结的钢丝绳应立即报废。The steel rope having severe kinks should be immediately scrapped.2.5.9.7绳径局部减小Partial decrease of rope diameter钢丝绳直径的局部减小常常与绳芯的断裂有关。应特别仔细检验靠绳端部位有无此种变形。The partial decrease of rope diameter is often related to the fracture of rope core. Carry out particularly careful examination to check whether there is such deformation in the rope-end part. 绳径局部严重减小的钢丝绳应报废。The steel rope whose partial diameter severely decreases should be scrapped.2.5.10.8部分被压扁 Parts flattened钢丝绳部分被压扁是由于机械事故造的。严重时，则钢丝绳应报废。The parts of steel rope are flattened due to mechanical accident. If it is severe, the rope should be scrapped.2.4.9.9弯折 Bending弯折是钢丝绳在外界影响下引起的角度变形。Bending is the angle deformation of steel rope caused under the outside influence. 这种变形的钢丝绳应立即报废。The steel wire rope having such deformation should be immediately scrapped.2.4.10由于热或电弧的作用而引起的损坏Damages caused by heat or electric arc 钢丝绳经受了特殊热力的作用其外表出现可资识别的颜色时，该钢丝绳应报废。If influenced by special heat the steel wire rope shows identifiable color, the rope should be scrapped.维护：钢丝绳应定期检查，必须特别注意钢丝绳末端的固定情况。为了避免钢丝绳迅速磨损，应保持钢丝绳处于良好的润滑状态。润滑前须用钢丝刷子刷去钢丝绳上的污物并用煤油清洗，再按规定用热油润滑。Maintenance: wire rope should be regularly checked and special attention should be paid to the fixation situation of the rope end. In order to avoid rapid wear of steel wire rope, wire rope should be maintained in good lubrication. Before lubrication, use steel wire brush to rod the dirt on the rope, wash it with kerosene, and then conduct lubrication with hot oil according to the regulation.更换：更换新的钢丝绳必须符合原设计型号、规格及钢丝绳公称抗拉强度等要求。钢丝绳禁止接起来使用。钢丝绳压板绳夹等处螺检必须坚固牢靠。Replacement: The new wire rope must be consistent with the original design model, specifications, nominal tensile strength of wire rope and other requirements. It is prohibited to use the connected steel rope. The bolts at pressure pad, rope clamp, etc. must be firm and solid.2传动轴2. Propeller shaft 轴的弯曲度不得超过1（1为轴的有效长度），超过此值时应校直或换新轴。尤其是高速轴，弯曲度过大会产生振动。但允许低速轴的弯曲度超过1（1为轴的有效长度）或超过1mm才予以更换。The curvature of the shaft should not exceed 1 (1 represents the effective length of the shaft), and the shafts should be aligned or replaced if the curvature exceed the value, especially the high-speed shaft, vibration will appear when the curvature is too big. But the curvature of low-speed shaft is allowed to exceed 1 (1 represents the effective length of the shaft) or the shaft should be replaced only when the curvature exceeds 1mm. 3轴承3. Bearing 轴承应保持良好的润滑状态。重新涂油前，轴承应当用汽油洗净，注意涂油量应为轴承体空腔的三分之二。正常情况下，轴承温升不超过6070，轴承的音响均匀。当轴承的温升过高、噪音很大时，必须检查，如发现轴承内外圈滚道、滚珠（柱）表面产生磨损条、剥落小坑、裂纹或轴承径向间隙增大到0.2毫米时，应予以更换。The bearing should be kept in lubrication state. Before re-oil, the bearing should be cleaned with petrol, and the oil amount should be 2/3 of the cavity of bearing. Under normal circumstances, the elevated temperature should not exceed 6070，and the sound of bearing should be even. The bearing must be inspected when the temperature is too high and the noise is too big and should be replaced when feather wear, point co