In asphalt pavement paving construction, the vibratory rammer (also known as the compaction mechanism) is a core component of the screed assembly in the paver. It performs preliminary compaction of the asphalt mixture through high-frequency vertical impact, directly determining the flatness, density, and final construction quality of the pavement.
However, due to prolonged exposure to harsh conditions such as high temperatures (asphalt mixture temperatures typically exceed 150°C), high impact, and severe wear, the rammer is often the component that wears out the fastest. Many operators report issues like the paver “lacking power” or “producing loose pavement,” which are frequently attributed to inadequate rammer maintenance. This article will systematically outline the entire maintenance process for vibrating rammers.
1、 Core lubrication: the “golden cycle” of lubricating grease
vibrating compaction hammers bears enormous impact loads during operation. If lubrication is inadequate, the bearings can burn out in a very short time due to high temperatures and wear.
- Lubrication cycle and timing:
- High frequency refueling: According to equipment maintenance standards, the lubrication interval between the rammer and the vibration bearing is usually every 30-50 hours of operation. If the construction task is heavy and the working conditions are poor, it is recommended to shorten the cycle appropriately.
- Hot car filling: Be sure to add lubricating grease while it is still hot after stopping the machine. At this time, the old grease inside the bearing has good fluidity, making it easier to be squeezed and discharged by new grease, and can also carry away the iron filings generated by wear.
- Oil selection：
- Composite calcium based high-temperature grease or high-temperature resistant grease specified in the equipment manual must be used. Ordinary lithium based grease will quickly soften and lose at high temperatures, and cannot provide effective protection.
- Operation method:
- Add to ‘Old Oil Out’: When adding new oil, it is necessary to continue adding until the color of the squeezed oil becomes new and there are no impurities. This means that the old oil and impurities inside have been completely replaced.
- Exhaust operation: If air enters the centralized lubrication system pipeline, it will cause the butter pump to idle and unable to discharge oil, and in severe cases, it may damage the bearings. Once air is detected entering, manual exhaust must be carried out.
2、 Daily cleaning: eliminate “grinding paste”
Asphalt mixture is a highly abrasive substance. If not cleaned in a timely manner, the cooled asphalt will wrap around the sand and gravel, forming a substance similar to “grinding paste”, which will severely wear down the hammer and guide mechanism during the next start-up.
- Remove while hot:
- After completing daily homework, the ironing board should be lifted before the entire machine has completely cooled down (the asphalt has not solidified).
- Use a specialized tool (shovel) to remove all residual asphalt attached to the rammer, ironing board bottom plate, guard plate, and guide column.
- Auxiliary cleaning:
- For stubborn asphalt that is difficult to remove, a small amount of diesel can be sprayed for softening and cleaning, but the following taboos must be strictly followed.
3、 Regular inspection: wear and fastening
The state of the rammer directly affects the compaction effect, and regular “physical examinations” are essential.
- Check for wear and tear (cycle: monthly or every 500-1000 square meters of material):
- Check the wear in the middle: If it is found that the wear in the middle of the rammer is significantly greater than that at both ends, it usually vibrating compaction hammers has undergone twisting deformation (not straight) and needs to be corrected or replaced immediately.
- Check edge wear: If frequent “hot to cold” (hot to cold) paving operations are carried out, the outer edge of the hammer will wear abnormally. Because the rammer crushed the hardened edge of the cold road surface.
- Check related components: If the rammer is severely worn, the ironing plate bottom plate and pressure beam often wear out quickly. The status of these components is linked and needs to be checked together.
- Check fastening (cycle: daily):
- Vibration and impact can cause bolts to loosen. After daily cleaning, it is important to inspect the fastening bolts of the vibration and vibration devices. Once looseness is found, it should be tightened immediately. If the bolt falls off, it should be repaired in a timely manner to prevent the machine from breaking due to uneven stress.
4、 Adjustment and Maintenance: Maintain ‘Precise Strike’
In addition to cleaning and refueling, proper mechanical adjustment can significantly extend the lifespan of the rammer.
- Adjust height and travel:
- If using a telescopic ironing board, it is necessary to ensure that the height of the telescopic section is consistent with that of the basic section. If the height of the expansion section is not appropriate, it will cause the hammer behind the basic section to bear additional loads, exacerbating wear and tear.
- Prohibit empty vibration:
- Although this usually refers to small flat compactors, the principle of pavers is the same: it is strictly prohibited to frequently turn on the compactor on hardened road surfaces or in the absence of materials, otherwise it will produce a “hard impact”, which can easily cause cracks or bearing fractures in the compactor.
5、 Shutdown, sealing and maintenance
If the device needs to be parked for a long time (such as in winter or rainy season):
- Rust prevention treatment: After thorough cleaning, apply rust proof grease to the surface of the hammer and all exposed shaft surfaces.
- Release load: Place the ironing board steadily on the wooden pad, and it is strictly prohibited to let the rammer hang in the air or be in a state of deformation under stress.
- Electrical protection: Pay attention to protecting electrical components and wiring harnesses during cleaning, and strictly prohibit high-pressure water guns from directly flushing bearing seals and solenoid valves.
summary
The vibrating compaction hammers of the asphalt paver is like a “printer nozzle”, and its state directly determines the “image quality” of the finished product. Ten minutes of maintenance during shutdown is better than ten days of repair after shutdown. Adhering to the principle of “daily cleaning, hot car lubrication, and mandatory exceptions” is the key to keeping your equipment in the best working condition and creating higher economic benefits.
Ma’anshan Datai Machinery Technology Co., Ltd. specializes in the production and sales of vibration compaction beams for VOGLE BOMAG DYNAPAC VOLVO (ABG) and other brands of asphalt pavers, VOGLE AB500-3TV ironing plate repair kit (2202733 2202847 2202970 2203022) VOGLE AB600-3TV ironing plate repair kit (2203109 2203136 2203171 2203200). The product quality is very reliable and the price is also very favorable. Welcome to contact our sales engineer Mr. Li Chao
