Crane Walking Mechanism Lubrication and Maintenance Manual

Proper lubrication and maintenance of the crane’s walking mechanism are critical for ensuring the equipment’s longevity, reliability, and safe operation. This document provides comprehensive guidance on the lubrication and care of the crane’s walking components, including the reduction gears, wheel bearings, and open gear systems.

Initial Setup and Reduction Gear Lubrication

When the walking mechanism of a crane is first put into service, specific steps must be taken to ensure the system operates optimally:

1. Opening the Vent Cap: Before the crane is operated for the first time, it is essential to open the vent cap of the reduction gear. This allows for adequate ventilation and helps mitigate internal pressure buildup, which could otherwise lead to oil leaks or compromised gear performance.
2. Checking Lubricant Levels: Prior to each work session, inspect the lubricant level in the reduction gear. Use the designated oil level gauge or visual inspection ports to verify whether the lubricant is at the recommended height. If the lubricant is found to be below the acceptable level, add the same type and grade of oil specified for the system.
3. Using the Correct Lubricants: Always use high-quality gear oils that meet the manufacturer’s specifications. The correct type and viscosity of oil will depend on the operating conditions, such as ambient temperature and load capacity. Failure to use the appropriate oil may result in accelerated wear or damage to the gears.
4. Ventilation Maintenance: Regularly inspect the vent cap for blockages caused by debris or hardened oil residues. Proper airflow is essential for maintaining internal pressure equilibrium within the reduction gear housing.

Wheel Bearing Maintenance

The wheel bearings of the crane’s walking mechanism play a pivotal role in supporting the load and ensuring smooth operation. Proper lubrication and care of these components include the following:

1. Initial Lubrication: During the assembly of the crane’s walking mechanism, all wheel bearings are pre-filled with an adequate amount of calcium-based grease. This initial lubrication ensures the bearings are ready for operation without requiring immediate maintenance.
2. Routine Grease Checks: While daily greasing is not necessary, it is recommended to inspect the condition of the grease every two months. Grease should be replenished through the designated grease injection ports or by removing the bearing covers if necessary.
3. Annual Maintenance: Once a year, the wheel bearings should be fully disassembled, thoroughly cleaned, and re-lubricated. This process involves:
   • Removing old grease to eliminate contaminants.
   • Inspecting the bearings for signs of wear or damage.
   • Applying a fresh layer of calcium-based grease before reassembly.
4. Environmental Considerations: Ensure that the lubrication process is conducted in a clean environment to prevent contamination of the grease. Dust and debris can significantly reduce the efficacy of the lubricant and the lifespan of the bearings.

Open Gear Lubrication

Open gears are exposed components that require regular lubrication to ensure smooth operation and prevent wear caused by metal-to-metal contact. The following practices are recommended:

1. Weekly Grease Application: Open gears should be coated with a layer of high-quality grease at least once a week. This practice minimizes friction and provides a protective barrier against corrosion and debris accumulation.
2. Inspection Before Lubrication: Before applying grease, inspect the gear teeth for visible signs of wear, misalignment, or damage. Addressing these issues promptly can prevent further deterioration and potential system failures.
3. Choosing the Right Grease: Use a lubricant specifically designed for open gear systems, which typically contains additives for extreme pressure and anti-wear properties. These greases are formulated to adhere well to gear surfaces, even in challenging operating conditions.
4. Application Techniques: Apply the grease evenly across the entire contact surface of the gears. This can be achieved manually using a brush or through automated lubrication systems equipped with grease applicators. Ensure all gear teeth receive adequate coverage.

Additional Guidelines for Lubrication and Maintenance

To ensure the walking mechanism operates at peak efficiency, adhere to the following best practices:

1. Regular Inspections: Conduct routine inspections of all lubrication points, including reduction gears, wheel bearings, and open gears. Look for signs of oil leakage, grease contamination, or insufficient lubrication.
2. Temperature Monitoring: Monitor the operating temperature of the reduction gear and wheel bearings. Elevated temperatures may indicate insufficient lubrication or excessive friction, warranting immediate attention.
3. Maintaining a Clean Environment: Keep all lubrication areas clean and free from dirt, dust, and moisture. Contaminants can compromise the performance of lubricants and lead to premature component wear.
4. Documentation and Scheduling: Maintain a detailed log of all lubrication and maintenance activities. This includes recording the type and quantity of lubricants used, inspection findings, and any corrective actions taken. Establish a clear schedule for routine maintenance tasks.

Troubleshooting Common Issues

Below are some common issues related to the lubrication of the walking mechanism, along with potential solutions:

1. Oil Leakage from Reduction Gear:
   • Cause: Blocked vent cap or overfilled oil level.
   • Solution: Clean the vent cap and verify the oil level.
2. Noisy Bearings:
   • Cause: Insufficient grease or contamination.
   • Solution: Replenish or replace the grease and inspect for foreign particles.
3. Uneven Wear on Open Gears:
   • Cause: Misalignment or inadequate lubrication.
   • Solution: Align the gears properly and ensure even grease application.
4. Overheating:
   • Cause: Excessive friction due to poor lubrication.
   • Solution: Inspect and replenish lubricants as needed.

By adhering to these guidelines and maintaining a proactive approach to lubrication and maintenance, the walking mechanism of the crane can achieve reliable performance and a prolonged operational lifespan. Regular care not only enhances safety but also minimizes downtime and reduces long-term maintenance costs.