operation manual of overhead crane english
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Manual of Overhead CraneTRANSCRIPT
General UseOverhead Crane
Operation Manual
Weihua Group. Henan Weihua Heavy Machinery CO., Ltd
Contents1.General………………………………………………………………………………………21.1 chief use of cranes…………………………………………………………………………21.2 basic performance data and structure…………………………………………………22. erection and commissioning……………………………………………………………2
2.1 preparation for installation and attentions……………………………………………2~3
2.2 bridge assembly…………………………………………………………………………32.3 trolley assembly……………………………………………………………………………32.4 crane traveling mechanism………………………………………………………………3
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3. electric control principle and installation………………………………………………33.1 control principle……………………………………………………………………………3
3.2 installation………………………………………………………………………………3~6
4. running test of the crane………………………………………………………………64.1 no-load test…………………………………………………………………………6
4.2 load test…………………………………………………………………………………6~7
5. maintenance, protection and lubrication……………………………………………75.1 inspection of steel structure………………………………………………………7
5.2 inspection and maintenance of mechanisms………………………………………7~8
5.3 maintenance of control system and electrical parts…………………………………8~
9
5.4 lubrication of cranes………………………………………………………………9 ~ 10
6. common troubles and disposal………………………………………………………106.1 steel structure……………………………………………………………………………11
6.2 parts…………………………………………………………………………………11~ 17
6.3 control system………………………………………………………………………18~19
7. notice for operation………………………………………………………………………19
7.1 technical safety rules………………………………………………………………19~20
7.2 duty of driver…………………………………………………………………………20~22
1. General The manual is used for guidance of erection, operation and
maintenance for erection, operation and maintenance persons.
1.1 chief uses of cranes
Electric Overhead Cranes are usually used to move materials or install and
maintain equipments in fixed span at factories, power station, and storehouse and
goods yard.
1.2 basic performance data and structure
1.2.1 Main performance data
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Lifting weight, span, lifting height, working grade, wording speed of each
mechanism, working limit of the crab, maximum wheel pressure, grab volume and
material density, model of electromagnetic plate, exterior dimensions, explosion-proof
grade and so on. For detailed values, see general diagram of the crane and table of
function data.
1.2.2 Structure
The Overhead Crane consists of bridge, crane traveling mechanism and trolley
with hoisting, traversing mechanisms.
a. bridge
This part is composed of main girder, end carriages, walkway etc..
b. crane travel mechanism consists of motor, brake, reducer, transmitting axis,
couplings, wheel group. Majority of cranes are driven intensively and the trolley are
usually driven respectively.
c. trolley
The trolley consists of hoisting mechanism and trolley traversing mechanism. The
hoisting mechanism is equipped with limit switches.
2. Erection and commissioning
2.1 Preparation for Installation and AttentionsBefore erection work started, erection supervisor together with user’s
representative should open the package of equipment, check everything actually
received with the packing list to see if there are any loss and damage to the goods.
Unloading from vehicle should be specially paid attention, when hoisting up, there
should be at least two hanging points, and cushion should be used. The hanging point
is suggested to be the ends of the main girder.
2.2 Bridge assembly
Bridge is main part of the crane; here are the requirements for bridge assembly as
follows.
a) The bridge is assembled on ground, the main girder shall be put on provisional
supports and emend by gradienter; the end carriage should be connected with
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main girder as prescribed in the drawing before checking gradient.
b) All data can be inspected when support point under wheels, if support points
are under main girder, the camber can’t be inspected.
2.3 Trolley assembly
Assembly two parts of trolley together as prescribed in the drawing then hoist it onto
the bridge.
2.4 Crane traveling mechanism
The crane traveling mechanism has been installed and tested, user should take
under mentioned tests:
a) Check the benchmark of traveling mechanism to see if it is the exterior of
the driving wheel;
b) Check the horizontal deflexion of wheel;
c) Check the span of crane;
d) Check the centricity of wheels to see if their exteriors are on one same
plane;
e) The max. vertical deflexion of wheels is 1/400 of span;
3. Electrical Control Principle and Installation
3.1 Control principle
The circuit consists of main circuit of each system, control circuit, light control
circuit and protection circuit.
3.2 Installation
All installation and wiring should be done according to the drawing;
Check all electrical parts before installation;
Check the insulation condition of motor, brake, carbon brush, contactor,
resistor and so on, if the insulation resistor is lower than 0.5mohm, desiccate
the part;
Check the pressure between motor carbon brush and slip ring, all pressure
in the same motor should be equal;
The joystick shall move flexible;
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Check the pressure of electronic contact of each controller, contactor and
relay;
The control panel, resistor supposed to be put on platform should be firmly
fastened on the frame, the resistor should be parallel to the main girder;
The max. gradient of control panel 5°, the space in front of the panel should
be more than 500mm(600mm recommended);
The conduction insulator must be complete and not have cracks, and fixed
firmly on electric conduction. The electric conduction must tightly press on
the electric contact conductor. When there is spark occurring, it shows that
they don’t contact well. The reason may be because the electric conduction
and the electric conduction contact conductor don’t contact well or the active
face is not clean, or the two exist at the same time.
To install the trolley electric conduction device, first straighten out the electric
cables, eliminate the torsion, then arrange end point clamps, the electric
cable pulley and festoon pulley in order according to the drawings. Drive the
trolley to the limited position opposite the driver’s cab, then let go electric
cables, adjust the position of festoon pulley to keep the length of every
period consistent basically and maintain certain relaxation, the sagging angle
maintains about 120°, after adjustment, uses cable cleat to fix electric cables
in the end point clamps and festoon pulleys firmly. Then drive the trolley to
the limited position near the driver’s cab, adjust electric cables to keep the
length of every period consistent basically, uses cable cleat to fix electric
cables in the end point clamps and festoon pulleys firmly. Weave and clamp
the electric cables with the iron sheet every 500 ~ 700 millimeters. Do
guarantee all electric cables are clamped tightly. For such a reason, rubber
must be put under the cable clamps. Then install towing wire-rope, adjust its
length to guarantee wire-ropes bear force during running, finally connect the
two terminals of cables to the junction boxes on the bridge and trolley
separately.
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Check the wiring of limit switch to ensure it can work when the hook hoisting
to the limit height;
The working temperature is -25℃~45℃;
Use electric welding to fix the electric wire tube.
Rubber or wooden drivepipe should be padded at the end of the wire tube
where the wire comes out. For those crane used in the open-air, seal their mouth
with asphalt and make the tube mouth bend downward. If condition permits,
insert the wire tube in the wire inlet hole. The wire outlet hole in the driver’s cab
should be opened on the side plate, do not open on the top.
After all the wires are laid well, use megameter to measure the insulating
performance in the whole electric circuit. It can be judged qualified only when
three dielectric resistances exceed regulated standard and the resistance value
difference is not big between all insulation.
The curving radius should not be smaller than 5 times the pipe diameter
when bending the tube. All curving angles should not be smaller than90°
The wire tube body should all reliably earth for all the cases of electric
equipments on the crane. The trolley rail and driver’s cab should be welded with
the main girder to earth. The end at the low voltage side of the transformer.
The earth wires can be flat steel with section not smaller than 75 square
millimeters, 10 square millimeter copper wire or 30 millimeters round steel. 4×40
millimeter or above galvanized flat steel should be used for driver’s cabin and the
crane body to earth not less than two points. The earth wires should be fixed by
electric welding or with earth screws in the equipment. Clear off rust and clean
the surface at the fixed points.
The resistance should not be more than 4Ω from any point on the crane to
the neutral point in electrical network.
Original data of QR1-3Y series time relay
QR1Y QR2Y QR3Y
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code K01 K02 K01 K02 K01 K02 K03 K04 K05
time/S 3 1.5 3 1.5 1.5 3 1.5 6 6
Original data of QR2S series time relay
series K040 K041 K042 K043 K044 K045
4class resistor /S 0.6 0.7 0.4 0.6 0.3
5class resistor /S 0.6 0.7 0.4 0.6 0.3 0.15
4. Running test
4.1 No-load Test
a) Turn the braking wheel of each system, wheel shaft and drum shaft manually to
see if they can move flexible;
b) Operate each system at slow speed first, then at rated speed, watch the system
to see if there are any abnormal condition;
c) Operate the crane to run along the rail for three times, checks each traveling
mechanism;
d) Check each switch, limit switch, door switch etc, and check if everything is in
condition;
4.2 Load Test
a) Operate the crane to hoist small load(0.5~0.75 of rated load) for several times,
then hoisting rated load, run the trolley along the girder back and forth, then stop it on
the middle of the girder, get the datum mark. Raise the load up to 1.25 rated load, lift
100m~200m from the ground, hold for 100min, the unload it, check the deflection to the
datum mark. Repeat this test for three times, after that the girder shouldn’t have any
permanent distortion, move the trolley to the end of main girder, the actual camber
should be 0.75/1000~1.5/1000 of span. At last, hoist rated load, lift 1m up from the
ground, check the deflection, it shouldn’t exceed 1/700 of span;
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b) Hoist 1.1 of the rated load, run each system, repeat each movement and
function, the test should last for one hour, after the test, there shouldn’t be any damage
and loose, then the whole crane is eligible.
5. Maintenance, Protection and Lubrication
5.1 Inspection of the steel structure
Check the steel structure 1 or 2 times each year, see if there is any loose, cast,
distortion, craze or cauterization. Here is the inspection standard as follows:
Item Standard
Main girder
distortion deflection ≤ 1/700 of span
structureNo crack, loose, cast, distinct distortion, craze or
cauterization
Trolley
frame
structureNo crack, loose, cast, distinct distortion, craze or
cauterization
others No paint flaking away, no rustiness
Connection between
cabin and main girderFastened and reliable
5.2 Inspection and Maintenance of mechanisms
Item Standard
Brake brake Enough oil, no leaking, no crack
Drum
group
DrumNo crack, loose, cast, distinct distortion, craze or
cauterization
Shaft and
bearing
No crack, loose, cast, distinct distortion, craze or
cauterization, well lubricated
Pulley
group
PulleyNo crack, loose, cast, distinct distortion, craze or
cauterization
Shaft and
bearing
No crack, loose, cast, distinct distortion, craze or
cauterization, well lubricated
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wire rope
structure Two or more safe loop
conditionless than 10% cores of each lay break, the actual
diameter is larger than 93% of rated diameter
Assembly No rubbing with other things, no distinct abrasion
Hook
grouphook
No crack, loose, cast, distinct distortion, craze or
cauterization, well lubricated
5.3Maintenance of control system and electrical parts
Item Standard
motor
resistor No crack, loose
BearingInsulated resistor under confine, no abnormal
heating
Sliding ring Well lubricated, no abnormal noise
Carbon
brush
No loose, distinct abrasion, sparking, proper
voltage
Contact
contractor
Contact
contractor
No crack, loose, cast, distinct distortion, craze or
cauterization
switch switchNo crack, loose, cast, distinct distortion, craze or
cauterization
contactor contactorNo crack, loose, cast, distinct distortion, craze or
cauterization
relay relayNo crack, loose, cast, distinct distortion, craze or
cauterization
cable cableNo crack, loose, cast, distinct distortion, craze or
cauterization
Maintenance of electrical parts
a) Daily inspection: eliminate dust, sludge and the oil etc. adhere to electrical
equipments. Survey with hand the heat situation of electric motor, the electro-magnet,
the controller contact, the resistor and so on, inspect whether there is oil leak
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phenomenon on the bearing, whether the connect terminal is tight on the chief
equipments, when opening the observation hole cover or the case, the dust, the iron
filings and so on should be prevented invading in the winding. Record all discovered
peculiar circumstance.
b) annual: Disassemble each electrical equipment to clean up, overhaul the support
of each equipment, clean the rolling bearing in the electric motors and exchange new
grease, survey space between the stator and rotor, change for new rolling bearing if
uneven phenomena is discovered. Survey dielectric resistance, dry if necessary. Repair
any kind of problems when carrying out annual overhaul. Replace those parts which
can’t be repaired. Annual overhaul and large-scale repair both depend on the actual
attrition and obsolete degree of all equipments.
Only dry-type fire extinguisher must be equipped on the crane. And carbon
tetrachloride fire extinguisher is commonly used. Foam fire extinguisher is forbidden.
Dry sand is only used to put out lead fire but not fire in the electric motor.
When fire happens, try to cut off the power supply first. At this moment, cut off the
power supply with emergency switch or knife switch on the protection plate. When fire
happens to the lead in front of the protection plate, cut off the knife switch on the lead.
For those cranes which have fired, they can’t be used again until clean and clear
up, dry and check all electrical equipments and wire layout, repair to be qualified.
5.4 Lubrication
Lubrication point:
hook shaft and bearing;
fixed pulley shaft;
wire rope;
gearbox;
coupling;
bearing base;
motor bearing;
brake;
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Lubrication material for typical parts
Item name Circle period condition material
1 wire rope 15~30 days
heat the grease up to 50~100℃
daub without heating
calcium—sodium base grease
2 gearbox3 months (early
days)6~12 months
circular spouting
L-CKC100 、 L-
CKC150L-CKC220
3 Open gear15days
Cleanout every 6 months
Gear grease
(HG1-26-73)
4 Gear coupling 30 days
Working temperature -20~120℃
General Purpose Lithium Lubricating Grease GB7624-1994low-temperature grease No.54
5Rolling bearing
3~6 days
6Sliding bearing
Considering the actual condition
7 Drum Overhauling
8 Motor OverhaulingPurpose Lithium Lubricating Grease No 3
9 brake 30 days
6. Common troubles and disposal
6.1 steel structure
trouble Possible reason solution
Web or cover
plate have crack
Long time overload If the crack width is under
0.1mm, just mill it down, for
others, drill one ¢8 hole at
each end of the crack, beveling
60°groove along each side of
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the crack, then take repair
welding, for some important
parts where the stress is large,
use strengthen plate to ensure
the intensity.
Web of main
girder have
distortion
overload Flame emendation
Main girder
bendingStress superposition Flame emendation
Main girder
deflectionStress superposition Flame emendation
6.2 parts
trouble Possible reason solution
hook
Crack
overload
replace
abrasion
Replace when
abrasion is more
than 10%
Permanent distortion replace
wire rope abrasion replace
Pulley Asymmetrical
abrasion
improper assembly,
rope doesn’t fully fit
Replace when wall
abrasion more than
10%,or radial
abrasion more than
20%
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Pulley doesn’t turnDamage on shaft or
bearing
Replace shaft and
bearing, reinforce
lubrication
Loose, deflexion Fastener loose, rope
jump out of groove
Fasten all fastener,
check drum groove
Crack Damage on pulley replace
drum
Crack Damage to drum replace
Shaft & key abrasion
Stop working, check
shaft and key,
replace when needed
Groove abrasion,
rope jump out of
groove
replace
Gear
Tooth breakWorking Impact and
libration replace
evident abrasion improper assembly replace
Crack Damage to gear
Check hoisting
system, replace
when needed
Damage to Key
Check hoisting
system, replace
when needed
desquamation replace
Shaft
Crack replace
inflected replace
Damage to Key
Check hoisting
system, replace
when needed
wheel Crack replace
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Asymmetrical
abrasionReplace in pairs
Wheel tread abrasion
15%Replace
Wheel flange
abrasion 50%Replace
coupling
Crack Replace
Bolt abrasion
Hoisting system:
replace
Traveling system:
repair welding
Gear abrasion
Hoisting system:
replace when
abrasion reach 15%
Traveling system:
Key inflected
Hoisting system:
replace
Traveling system:
repair
Rubber ring abrasion replace
Rolling
bearing
overheat No oil or over lubricated
Replace bearing,
check lubrication
condition
Abnormal noise Bearing smeary Clean bearing
Metal milling noise Lack of oil Add oil
Impact noise Damage to bearing replace
Sliding
bearing overheat
Bearing deflected, over
pressed, lack of oil or oil
not qualified
Adjust, add oil or
change oil
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brake
Can’t brake
Can’t brake
Chain is blockedcheck the chain,
lubricate
Braking wheel and shoe
smearyClean
Magnetic moving
distance too shortAdjust
Braking wheel and shoe
abrasion Replace shoe
Main spring loose or
damage
Replace main spring
or fasten nut
Fasten nut loose or
push bar looseFasten nut
Brake can’t open
Magnetic burn Replace
Cable loose reconnect
Shoe stock on braking
wheelClean with kerosene
Gemel stock Adjust
Main spring over
pressedAdjust
Push bar inflected Adjust or replace
Wrong oil Change
Wheel stock Adjust
Low voltage Check
Brake Break overheat, shoe
burnt and abrasion
Shoe can’t fully
disengage braking
wheel
Adjust
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Asymmetrical distance
from shoe to braking
wheel
Adjust
Supporting spring
damage
Replace or repair the
spring
Braking wheel tread not
smoothMachine the wheel
Braking torque not
steady
Fasten nut loose Fasten nut
Screw damage Replace
Magnetic overheat,
abnormal noise
Main spring over
pressedAdjust
Push bar stock Check and lubricate
gearbox
Seasonal libration Reinstalled
noiseReinstalled or
replace gear
Bearing overheat
Bearing damage replace
Shaft stock check and adjust
Gear abrasion Maintain the gear
Lack of oil Lubricate
Leak of oil
No longer hermetic Change seal
Outer proof inflected Repair or change
Some plane not flat Repair these plane
Connection bolt loose Fasten bolt
Gearbox libration on
base
Connection bolt loose adjust
Improper installation adjust
Base damage fasten
Gearbox overheat Too much oil Adjust oil
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motor
Whole motor
overheat
Overload caused by
heavy duty
Reduce working duty
or change proper
motor
Low voltage
Stop working when
voltage is lower than
10% rated
Wrong type of motor Change motor
Change of crane
working conditionChange motor
Stator overheat Stator short circuit
Check and eliminate
short
libration
Motor shaft and gearbox
shaft not concentricreinstall
Bearing abrasion or
damageReplace
Mover distortion Check and repair
Abnormal noise
Stator phase move Check and repair
Stator steel core over
pressedCheck and repair
Bearing abrasion Replace
Motor stator rub with
mover
Bearing end wiring short
circuit
Check and eliminate
short
Wrong connection Check and repair
Spark on motor
carbon brush
Brush loose adjust
Brush and ring smeary Clean
Ring face not flat, brush jump
Machine the ring, smooth the face
Low pressureAdjust pressure to
18~20kPa Wrong brush Change
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Asymmetric current Check and adjust
Contactor
and relay
Loop overheat Loop overloadReduce contact
pressure
Contactor noise Loop overloadReduce contact
pressureLoop dirty clean
Contactor burnt Low contact pressure Adjust pressureContact dirty Clean
Main contactor can’t
switch on
knife switch open, emergency switch open
Close
Door switch open CloseNo zero adjustment to
controllerzero adjustment
Control circuit breaker burnt
replace
No current Check the voltage
Power-off protection
happens frequently
Low contact pressure Adjust pressureContact burnt Replace or repairContact dirty Clean
Large current caused by overload
Reduce load
Current collector and contract conductor(DSL
system) contact problem
Repair contact conductor
6.3 control system
trouble Possible reason solution
Breaker burnt when the
protective knife-switch shut
off
The relative phase
contact ground
Check with ohmmeter,
eliminate the earthing.
Protective relay works when
certain system running
Improper of relay
Initialization Reset Initialization
Certain parts of the
system stock Check and repair
Motor can’t work after One phase power off Check and rewire it
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controller switched on
Mover circuit wire loose Check and rewire it
No circuit voltage Check and rewire it
Contact doesn’t contact
to each otherRepair the controller
Brush broken repair
Brake can’t open repair
Motor can only run in one
direction
Contact problem Check and repair
Wiring failure Check and repair
Limit switch open Reset limit switch
Limit switch problemCheck the limit switch
and repair
Contactor fail after limit
switch open
Switch circuit problem Check and eliminate
Wiring problem Check and eliminate
Controller can’t work during
crane working
Positioning system
failureAdjust pressure
Contact burnt repair contact
Protective contactor failure
after power off
Short circuit or earthing
in control circuitCheck and eliminate
Contact burnt repair contact
7. Crane operation notice
7.1 technical safety rules
a) do abide by the following safety technical rules
Having professional workers to operate the crane.
The label plate which gives clear indication of maximum hoisting weight, span,
working system and manufactory must be hung on the flank of the crane.
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During the working time, no person is allowed on the working spot except the
control cabin.
While doing the inspection and reparation, the crane must keep power down.
While crane running without load, the height of the hook from the floor is 2.5
meters (over the height of a person).
While using the crane to handle the weight, the weight traveling over the head of
the person is strictly forbidden.
While crane handling weight, the height from the lowest point of the weight to
the highest point of barrier is 0.5 meters at least.
Using the hook to deliver and hoist man is strictly forbidden.
Any way to cast the goods from crane is forbidden.
Tools, spare parts, fastener, sundries and so on must be kept in the special box,
in order to avoid the body injury and harm to equipment, put on the crane is
forbidden.
While hoisting the liquid metal, harmful liquor and important goods, no matter
how much weight is it, firstly, one should hoist the weight to 150~200mm from
the floor in order to examine and certify the reliability.
Store the flammable good on the crane is not allowed and good fireproofing
work is necessary.
With the crane working in the open air, stop work while the wind power is larger
than six degree.
The crane working in the open air must be well fasten when it stop work (for
example, the hook with ground anchor fastened and wheel with slanting iron
stopped) in order to prevent accident.
Regular safety check must be done with the crane, including static load and
dynamic load test, and the test result should be recorded in the equipment files.
b) Safety technical rules to examine and repair electrical equipment
Only the electric professionals can duty the electric repair work.
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The pocketed spotlight whose voltage is below 36V should be used when doing
repair work.
While doing some work regarding electric, the worker must wear rubber gloves,
rubber shoes, and use tools with insulated handhold. And have special person
to control the electric switch, once there is some accident, the person can cut off
the power at the first time, and places close with the electricity should be
enclosed with barrier.
The metal shell of the electromotor and electrical equipment and other metal
parts should be grounding.
7.2 duty of driver
a) Familiar with the function, method of operation and maintenance rules.
b) Strictly abide by the safety technical rules.
c) Following work should be done before the crane starting to work
Check situation of power supply, the crane will not be started when the voltage
of power supply is under 90% of the rated value.
Check situation of every main parts to ensure the connecting and running
situation and adjust separate mechanism.
Check if there are any leaving tools and other good, prevent from bodily injury or
damage to equipment.
Oiling the lubricating point according to rules.
To the crane working in the open air, some measures prevent from the damage
of the wind should be taken.
d) Before turning on the main switch, the entire controller should be in zero
position. During working time, no one is allowed on bridge and rail.
e) Before starting up the crane, warning alarm should be sent out.
f) The weight of the good would not heavier than the rated load-lifting capacity.
g) The driver must cooperation well with hook worker. Moving or hoisting weight
should accord with the sigh of hook worker, but the sign of stop no matter who send out,
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the driver must stop the crane.
h) Hoist the weight to upright, move the crane or trolley to drag the weight is not
allowed.
i) While the crane and trolley having a small distance with the edge position, with
slow motion gradually close to the block and without hitting the block.
j) The controller should be started step by step. Before the mechanism completely
stop, putting the controller from veering to reversing is not allowed, but in emergence
situation to stop the accident, this method also can be used with the controller
k) Driver assures that the crane will not run against another crane. Only in the
position that one fail to operate then use another to push and both of then should have
no load and remove in the lowest speed.
l) In the situation of voltage drop markedly or power is cut off, the main switch must
be turn off and all controller should be in zero position.
m) While the motor’s power is suddenly cut off or voltage of circuitry drop suddenly,
the entire controller should be in zero position, the main switch should be cut off
immediately and driver should notice the hook worker promptly.
n) While handing the weight and lowing downing the weight, driver is now allowed
to apart from control cabin.
o) The hook is on high position, controller is on zero bit and the main switch is
turned off after finishing the work.
p) Turns off the main switch and electric lock after finishing the work.
q) Does the cleaning and re-checking after finishing work, preparing for the coming
work.
r) While handing over the work, the note book also is handed over to the next
driver, and any trouble be found must be notified to related department and the next
driver.
s) While the driver departs from the crane, the crane must be stopped on the given
points and be fastened.
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Address: Industrial Zone, Wenming West Road,
Changyuan County, Henan Province
Fax: 086-373-8887665
Technical Consultation Tel: 086-373-8887681
Sales Tel: 13903807662
http://www.whgroup.com.cn
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