Způsob výměny a bezpečnostní opatření pro kyvné ložisko rypadla

Kyvná ložiska se hojně používají v mnoha velkých stavebních strojích a zařízeních, jako jsou například běžně používaná rypadla. Vzhledem k vysokému pracovnímu zatížení a složitému pracovnímu prostředí rypadel je poškození ložisek po delším provozu nevyhnutelné. Poškození kyvného ložiska rypadla se obvykle projevuje abnormálním hlukem, zvýšenou vůlí, únikem oleje na těsnícím zařízení atd. Pokud se po vyšetření potvrdí, že je ložisko poškozené, je třeba jej včas vyměnit.

Comprehensive Guide to Replacing an Excavator Swing Bearing

The swing bearing, also known as a slewing ring, is a crucial component of an excavator that enables the upper structure to rotate smoothly on the undercarriage. Over time, the swing bearing may experience wear and tear, necessitating its replacement to maintain the excavator’s efficiency and performance. This detailed guide covers the step-by-step process of replacing an excavator swing bearing, from disassembly of the old bearing to the assembly and installation of the new one.

1. Disassembly Method of the Old Kyvné ložisko

Preparation and Safety Measures

Before beginning the disassembly process, it’s essential to take several preparatory steps to ensure safety and efficiency:

• Safety Gear: Ensure that all personnel involved in the disassembly are equipped with appropriate safety gear, including gloves, safety glasses, and hard hats.
• Workspace Preparation: Clear the working area around the excavator to provide ample space for the disassembly process. Ensure that the ground is stable and level to prevent accidents.
• Tools and Equipment: Gather all necessary tools and equipment, including wrenches, cranes, plastic bags for sealing oil pipes, and torque wrenches.

Disconnecting Hydraulic and Electrical Systems

1. Hydraulic System: Begin by disconnecting all hydraulic lines attached to the slewing motor. This involves:
   • Removing all oil pipes connected to the slewing motor.
   • Sealing the ends of the oil pipes with clean plastic bags to prevent contamination and leakage.
2. Electrical System: If applicable, disconnect any electrical connections that may interfere with the disassembly process.

Lifting the Upper Structure

1. Crane Setup: Position a crane to lift the upper structure of the excavator. Ensure that the crane has sufficient capacity to handle the weight of the upper structure.
2. Lifting Process:
   • Attach the crane to designated lifting points on the upper structure.
   • Carefully lift the upper structure, ensuring it is stable and balanced during the lift.

Removing the Old Swing Bearings

1. Loosening Bolts: With the upper structure lifted, proceed to loosen and remove the bolts connecting the outer ring of the swing bearing to the upper structure. This step may require considerable effort due to the size and torque of the bolts.
2. Separation: Once all bolts are removed, carefully separate the upper and lower structures. The old swing bearing should now be accessible for removal.

2. Assembly Method of the New Swing Bearings

Cleaning and Preparation

1. Cleaning Components: Thoroughly clean the inner and outer races of the new swing bearing, including the raceways, isolation sleeves, steel balls, and bolt holes. Use a degreaser or cleaning solvent to remove any contaminants.
2. Kontrola: Inspect all components for any defects or damage. Ensure that the raceways are smooth and free of debris.

Assembling the Swing Bearings

1. Aligning Races: Place the outer race on a stable surface and align the inner race above it so that the raceways of both races are in the same plane.
2. Inserting Rolling Elements:
   • Insert the steel balls and isolation sleeves into the raceways through the radial hole.
   • Fill the raceway in sequence, ensuring that the steel balls are evenly distributed.
   • Once filled, plug the radial hole and securely install the cone pin to lock the components in place.

Sealing and Lubrication

1. Sealing Device:
   • Apply a suitable sealant to the parts of the sealing device that contact the sealing groove.
   • Carefully install the sealing device, ensuring a proper seal to prevent contaminants from entering the bearing.
2. Mazání:
   • Rotate the swing bearing to ensure smooth and flexible operation.
   • Fill the raceway with grease (butter) to ensure adequate lubrication.
   • Additionally, fill the oil pool of the swing pinion and the swing bearing ring gear with grease.

3. Installation Method of the New Swing Bearings

Lifting and Positioning

1. Crane Setup: Use the crane to lift the new swing bearing assembly.
2. Positioning:
   • Align the lower edge of the slewing platform with the outer race of the slewing support.
   • Use tools such as round steel bars to precisely align and position the upper and lower structures.

Securing the Swing Bearings

1. Bolt Assembly:
   • Begin by inserting bolts in a triangular pattern to ensure even distribution of force and stability.
   • Apply anti-loosening adhesive to the threads of the bolts to prevent them from coming loose during operation.
2. Tightening Bolts:
   • Initially, do not fully tighten the bolts. Instead, insert and loosely secure all bolts to ensure proper alignment.
   • Once all bolts are in place, use a torque wrench to tighten them sequentially, following the manufacturer’s recommended torque specifications.

Testing and Final Adjustments

1. Operational Testing:
   • Start the excavator and perform various movements, including rotation, to check for any abnormalities.
   • Pay attention to any unusual noises, vibrations, or resistance during the operation.
2. Final Adjustments:
   • If any issues are detected, stop the machine and recheck the alignment and tightness of the bolts.
   • Make necessary adjustments to ensure smooth and efficient operation of the swing bearing.

Preventive Maintenance Tips for Swing Bearings

To extend the lifespan of the new swing bearing and ensure optimal performance, it’s essential to implement a regular maintenance routine. Here are some preventive maintenance tips:

Pravidelné kontroly

1. Vizuální kontrola: Conduct regular visual inspections of the swing bearing for signs of wear, damage, or leaks. Look for any cracks or deformation in the raceways and seals.
2. Lubrication Checks: Regularly check the lubrication levels and quality. Ensure that the grease is free from contaminants and topped up as needed.

Torque Checks

1. Bolt Tightness: Periodically check the tightness of the bolts securing the swing bearing. Use a torque wrench to ensure they remain within the recommended torque specifications.

Cleaning and Sealing

1. Cleanliness: Keep the area around the swing bearing clean to prevent dirt and debris from entering the bearing assembly.
2. Seal Integrity: Check the condition of the seals regularly and replace them if they show signs of wear or damage.

Operational Monitoring

1. Performance Monitoring: Monitor the performance of the swing bearing during operation. Pay attention to any changes in the smoothness of rotation, unusual noises, or increased resistance.
2. Temperature Checks: Check the temperature of the swing bearing during operation. Excessive heat can indicate lubrication issues or internal damage.

Opatření pro výměnu kyvných ložisek rýpadel

1. Vyberte vhodné místo: Při výměně kyvného ložiska vyberte místo s velkým prostorem a rovným terénem, abyste usnadnili oddělení a zvednutí horní a dolní části.

2. Obezřetné zvedání: Při demontáži nebo montáži ložisek je třeba lano správně zavěsit, aby bylo zajištěno bezpečné zvedání.

3. Utáhněte šrouby a namažte je na místě: Při výměně otočného ložiska by měly být vyměněny také šrouby, aby se předešlo případnému poškození, a vyměněné šrouby by měly být dotaženy; naneste dostatečné množství mazacího oleje, aby se snížilo vnitřní tření ložiska.

The above is our summary of replacement methods and precautions for excavator swing bearings, hoping to be helpful to you. During daily maintenance and upkeep of excavators, it is important to focus on checking the operation of the slewing bearing and promptly handle any abnormalities found. This can extend the service life of the bearings and save you operating costs. If you have any other questions or needs, please feel free to kontaktujte nás at any time!