Preparation before replacing the roller of a road roller

1. List of tools and materials

- Necessary tools: hydraulic jack (load bearing ≥ 10 tons), wrench set, crowbar, wire rope, grease (NLGI grade 2 lithium grease is recommended).

- Safety equipment: non-slip gloves, goggles, safety rope (refer to OSHA standards).

- New roller parameters: must be consistent with the original specifications, such as diameter 1.2m±0.05m (according to “GB/T 8511-2017 Technical Conditions for Road Rollers”).

2. Safety inspection

- Stop the machine and cut off the power supply to ensure that the equipment is on a level ground.

- Check the wear of the roller bearing. If the radial clearance exceeds 0.5mm (according to ISO 281 standard), the bearing needs to be replaced simultaneously.

Detailed steps for replacing the drum

1. Disassembly of the old drum

- Step 1: Lift the machine body with a jack and place wooden blocks on both sides of the drum to keep it stable.

- Step 2: Remove the fixing bolts (usually M24 specifications, the torque must reach 450N·m), and use a crowbar to slowly separate the drum and the bracket.

- Step 3: When hoisting the old drum, the wire rope angle should be less than 60° to avoid lateral force (refer to “Crane Safety Regulations GB 6067.1″).

2. Installation of the new drum

- Step 1: Clean the installation surface and apply grease to reduce friction.

- Step 2: Align the shaft holes and tighten the bolts in stages (pre-tighten to 200N·m first, then cross-tighten to 450N·m).

- Step 3: After installation, manually rotate the drum 3-5 times to check if it is stuck.

Debugging and maintenance suggestions

1. Trial operation and debugging

- Run without load for 10 minutes and observe whether the vibration frequency is normal (single steel wheel roller is usually 28-33Hz).

- Check the drum temperature. The surface temperature should be ≤70℃ after 1 hour of continuous work (according to “JB/T 10749-2018 Vibratory Roller”).

2. Tips for extending the life of the drum

- Replenish grease every 50 hours of work, and the amount is 1/3 of the bearing cavity volume (about 80-100g).

- Avoid working on gravel roads for a long time to prevent hard objects from scratching the drum surface.

Common problem handling

- Problem 1: Abnormal vibration after drum installation

Possible reasons: The bolts are not tightened or the bearings are not aligned. The torque and coaxiality need to be re-calibrated (error ≤0.1mm).

- Problem 2: Drum oil leakage

Check whether the seal ring is aging (the recommended replacement cycle is 2 years or 2000 working hours).

Through the above steps, the roller replacement can be completed efficiently and the construction safety can be ensured. Regular maintenance can significantly reduce the failure rate. It is recommended to conduct a comprehensive inspection every quarter.

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