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general overhead crane maintenance guide manual
All crane standard reference German DIN standard, europe FEM standard or other equivalent
international standards, China and India standards are not accepted.
Main DIN and FEM standards are as follows
DIN15018 and related standards
Hoisting mechanism follows the FEM calculation standard
DIN & VDE electrical standards
DIN EN 5817 Welding Standard
DIN EN ISO 9001 Standard
IEC Standard
IEC 60079 for electrical equipments for explosive gas atmospheres
2.1 Tech specification and requirements of GT House double beam bridge crane
NO. Item Description Remark
1 Installation site and GT House,1 set
quantity
2 Work group A3
3 Explosion proof grade N/A
4 Size( Length / width / 136866mm/8244mm/2144
height ) mm
5 Main/ Aux hook Max. 120t+35t,Gq≤120t
capacity
6 Main/ Aux Hook Point move N/A
distance
7 Driver side:
main hook :3150 mm
Hook center distance to aux hook:1550 mm
track center limit Busbur:
main hook :2050 mm
aux hook:3650 mm
8 Height of the rail top 17m
9 Span 13.3m
10 Maximum hoisting height 16.5/17.1m
(main hook / aux hook)
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general overhead crane maintenance guide manual
2.2 燃机房辅助行车技术规格参数及要求
序
项目 内容 备注
号
1 安装地点及数量 燃机厂房上,共 1 台
2 工作级别 A3
3 防爆等级 无
4 外形尺寸(长/宽/高) 13582mm/6596mm/181
9mm
5 主钩/副钩最大起重量 35t/5t
6 主/副钩点动距离 无
7 吊钩中心距轨道中心极限位置 司机侧:主钩 2630 mm
副钩 1400 mm
滑线侧:主钩 1600 mm
副钩 2830mm
8 行车轨顶标高 17m
9 跨度 13.3m
10 最大起升高度(主钩/副钩) 16.5/16.8m
11 起升速度(主钩/副钩) 主副钩均为 0.2-4 m/min
12 起升电动机功率(主钩/副钩) 主钩:30KW (JC=25%)
副钩:5.5KW (JC=25%)
13 运行速度(Crane/Trolley:) Crane:1.25-25m/min
Trolley::0.5-10 m/min
14 运行电动机功率(Crane/Trolley:) Crane:2*3KW
Trolley::2*1.1KW
15 选用轨道型号 Trolley::70*50 方钢
Crane:A65
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general overhead crane maintenance guide manual
序
项目 内容 备注
号
16 工作电源 三相四线制交流 400,
50Hz
17 控制方式 司机室+备用手操
18 轨顶至吊车最高点高度 1928mm
19 司机室侧 A 排柱侧:司机室(带空 与 120/35t 燃机房主吊
调) 车同轨
B 排柱侧:滑线侧
20 司机室高度 2225 mm
21 轨顶至司机室底部距离 2500mm
22 缓冲器中心至轨顶距离 200mm
23 司机室侧至 Crane 轨道中心距离 1200mm
24 Crane 轨道中心至端梁外端距离 141mm
25 轮数及轮距(Trolley:/Crane) 单 侧 轮 数
(Trolley:/Crane):3/4
轮距 :900mm/4590mm
26 重量(Trolley:/Crane/总重) 6.3t/12.2t/18.5t
27 最大轮压 105KN
28 燃机厂房长度 74m
29 油漆及年限 满足 EN ISO 12944 C4
标准,保证 15 年使用寿
命,并提供现场补漆用
漆。
30 土建安装要求 承轨梁厚度按照 45mm
考虑
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general overhead crane maintenance guide manual
3.3 Control:
All movement for cross & crane travel are controlled by frequency inverter.
The wire pendants, which can be move freely along the crane girder, is as the back-up controller for the
cranes.
The status of the remote controller and wire pendant is interlocking, this means that there is only one
control type during the fixed time (remoter control or wire pendant). If one is used and the another is
unavailable to avoid the control disorder and the safety of the lifting process.
Emergency control
Mobile control pendant and remote control both has the emergency push button, when the push button are
pushed, the whole crane will be power-off and stop.
4 General Overview
The design and manufacture of the crane is in accordance with the safe operation, we use advanced design,
reasonable layout, compact structure, simple operation, easy maintenance principles , The overall
technological level reached the advanced level of the similar products. The Steel,mechanical systems,
electrical systems and safety devices of cranes is in strict accordance with norms and standards on existing.
Cranes have sufficient strength, rigidity, stability and rollover resistance, the company uses a lot of
advanced technology during the design of cranes,For example , we use conduct repeated computer
simulations to product in order to ensure product safety.
The vibration, noise, environmental protection, fire and security agencies of our product are in compliance
with existing standards, The crane design drawings and technical documents of Mapping methods, size,
tolerances, symbols, adopted the metric system, is in line with ISO or F.E.M existing standards.
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general overhead crane maintenance guide manual
4.1 Trolley:
Double girder trolley use a modular design, a combination of technology, standardization designed
to improve the versatility of parts, shorten the delivery cycle, the post maintenance can be more secure,
convenient and efficient.
Double girder trolley has the advantages of compact structure, stable running, accurate positioning, limit
the size of the smaller, so that users can get the larger work space, At the same time , combination of low
lift mechanism of modular design allows the user to reduce the height of plant, increase the use of space
more, Users can make less investment to get higher returns. The mechanism of smooth operation, long
service life, low noise, greatly improve the working environment. Gourd contains lifting mechanism,
operation mechanism and an electrical control mechanism.
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general overhead crane maintenance guide manual
hook objects. Hook with safety card sling, prevent collapse, the pulley cover exquisite workmanship, the
overall appearance of coordination, not bite edges or burrs, safe operation.
/limit switches: The design of crane must be compliant to the relevant stipulations of the FEM 1.001
《Federation European de la Manutention 》,good sealing performance, high protection level, ensure the
limit position weight lifting falling, prevent accidents top brought. Hoist lifting the lifting mechanism is
composed of four level limit switch limit::
a. First level: at the maximum lifting height of -Cmm (top safety switch)
b. Second level: at the maximum lifting height (at work, you can set the C
size needed)
c. Level third: at the maximum lifting height of +Cmm (low speed near,
C size can be adjusted according to the user process)
d. Level four: avoid the contact with the ground (hook installation can be
set)
Overload protection device: High reliability, sensor has 1.5 times overload
ability, good stability, high accuracy, strong anti-interference ability, sensitive
reaction.
a. Warning: when lifting weight reaches the 90% (able to adjust)of
rated lifting weight, emits intermittent alarm sound (sound), display the
weight’s.
b. Immediate action points: when the weight reaches the 110% (able
to adjust) of the rated lifting weight, immediately cut off the rising power
contactor, ban lifting action, also issued a ringing the alarm and alarm
indicator lamp high frequency flicker, display the weight
Cross-traveling Mechanism : Operation mechanism of high performance, low energy consumption and
high efficiency operation, work, the warranty period of trouble free
operation, lighter wheel pressure, small wheel diameter to ensure
structural investment cost much less, a higher rate of return, the use of
long cycle,. The running mechanism of variable frequency speed
regulation, stable running, accurate positioning load, reducing swing
lifting objects, increase safe operation in the process of safety and
comfort. The Cross Traveling movement drive system is controlled by One Central al compact geared
motor brake drive units , wheels and other components
Compact geared motor brake drive units:
The compact geared motor brake drive units with foreign brands, is an operation drive system mechanism.
Respectively by the reducer, motor, brake, light weight, high transmission efficiency, energy saving, it has a
larger starting and ultimate moment, double safety brake, braking, no vibration, through a standard
interface and simple assembly
a. The motor adopts squirrel cage motor, the inverter, the maximum improve motor performance, it
can start with no impact and it is a stable operation; expand speed ratio; using aluminum shell, heat faster,
Insulation class F, electrical sustained the rate of 40% (can also according to user requirements to provide
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general overhead crane maintenance guide manual
4.2 Bridge :
Structural design of the bridge crane is reasonable, compact layout, advanced design means.The design and
manufacture of crane must be compliant to the relevant stipulations of the FEM 1.001 《Federation
European de la Manutention 》 , meet the strength, stiffness and stability requirements, and design the full
considering the field working environment; design of steel structure manufacturing, inspection, considering
the transport, installation and maintenance of operational process. To meet the demand and standard
conditions, by optimizing the design, to minimize the weight of steel structure, reduce the cart wheel
pressure, get rid of the traditional domestic crane heavy, big volume, high energy consumption of the
disadvantages, the maximum for customers to save plant investment cost and device with the cost.
The main beam, end beam and other components into bridge; The crane girders are of welded box girder
construction, the end beam type structure for single box; connection between the main end beams,
connected by hinge and bolt, with high strength to ensure the assembly accuracy and smooth running.
Other components use the bolt connection to reduce the field welding inconvenience to customers, but it
also can increase the security equipment installation, shorten the cycle of installation of crane, the crane
also beautify the appearance of. The use of heavy equipment working level to consider fully the design
process, the working environment temperature, speed and type of goods handling.
Use high quality steel plate and steel domestic from well-known manufacturers. material used material
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general overhead crane maintenance guide manual
report and certificate. The processing sequence of strict implementation of production process of main
girder of the company. Steel cutting, welding equipment, fully automated, to ensure weld thickness
requirements and weld appearance. The quality inspector
using the ultrasonic equipment advanced, carries on the
examination to each of the weld beam. The key force structure
by butt welding and taking sides welding process, according to
the provisions of the visual inspection and nondestructive
testing, welding personnel holding welding certificates.
nondestructive inspection of weld, and provide the inspection
report.
Strict implementation of the new F.E.M standard, the main girder, plate local flatness, the horizontal
direction of bending, inspection personnel to carry out strict inspection. For example:
The girder midspan camber values≥0.7S, and the largest arch camber must be controlled within the range
of midspan S/10.(S- The crane span)
The lateral deviation value of top flange plate on the box beam and single plate web beam:C≤B/200
B-The width of the top cover plate girder
Other requirements must implement the 1.001 Federation European de la Manutention “mechanical
handling association.
Beam welded by CO2 gas shielded arc welding. The connecting webs, cover plate girder using automatic
submerged arc welding, the other position of welding welded by hand.
The weld grooves shall conform to the provisions of AWS the special joints shall be marked out in the
drawings. Nondestructive inspection shall be made in the butt weld between the flange plate and
abdominal plate of the tensile region in the main beam. Radiographic inspection shall not be lower than
Grade II stated inAWS, and ultrasonic inspection shall not be lower than GradeⅠstated in AWS.
The trolley track with square steel, in order to improve the wheel tread effective contact area and reduce the
weight of the steel rail track, the material for the 16Mn, requirements of good flatness, ensure quality of
welding, welding defects such as deformation is not allowed.
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general overhead crane maintenance guide manual
d. Running on the same track crane, they adopt a photoelectric limited switch, this is used to prevent
the risk of collision. And they were installed near the two sets of equipment, capable of active anti-collision
protection.
safety distance to bus bar is 200mm. To ensure ease of maintenance, washboard height shall be more than
100mm. Flooring 5mm rubber insulation board on the bottom of the cage.
All electrical cabinets of the crane are placed on the main girder platform and flooring rubber insulation
board on the passageway. Because motor with resistor will lead to high temperature which need dissipate
4.4Cabin
The cab is full closed structure with steel plate. The cab’s window shall be wide vision, in order to
convenient the operation. The cab must be safe and reliable. The connection with the suspension or support
section must be securely attached. Cab should be guaranteed can be safe withdrew from accident. Cab’s
front and side shall be installed steel window frame and tempered laminated glass. Cab’s front shall be
installed straight through to the end large size glass. In the front of the glass with safety railing for
protection. Glass mounting form under foot pedal should convenient the cleaning work in the cab safely.
The ground in the cab shall be floored on composite floor and insulating rubber.
Linkage console is set in the cab. The operating handle and buttons are simple, thoughtful, easy operation.
There is also need protection measures against operation mistake and false action. Linkage console can
operate any couple of the mechanisms at the same time. During operating single or double mechanisms the
neighboring control pieces shall not collided. The left hand side of the cab’s seat control the trolley and
crane travelling, while the right hand side control the hoisting mechanism.
Cab shall have completely display and control function of working condition. There are power supply
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socket and lighting etc. set in the cab. Left and right, up and down adjustable fixed seat, wall mounted
emergency lamp, door lock, fire extinguisher, power supply socket, and a pedal horn or a electric bell etc.
shall be equipped in the cab. The driver can conveniently and reliably shut off the general crane power
wheels :
The wheels are made of alloy steel forging, precision machining CNC
machine tools, wheels are made of 42CrMo, the quenching and
tempering treatment.
a. Running wheel tread has the function of high wear resistance,
low noise. It has certain plasticity and toughness, good shockproof effect, and good cutting performance,
the splice shaft way is connected with a gear, can ensure that walking is connected between the wheel and
axle are firm and reliable, convenient disassembly, installation.
b. The machining process using the most advanced processing equipment and high standards of the
wheel, the processing and assembling precision, can realize the smooth operation of the good.
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general overhead crane maintenance guide manual
not self-action, as the controller is set back to zero, institutions can restart
Voltage loss protection Crane power supply interruption, relating to the electric equipment safety or
not open automatically are in the off state, avoid the equipment run automatically after the power recovery
Motor stator power failure protection the hoisting mechanism of motor stator power failure protection
function, when the speed control device or forward and reverse fault in the motor contactor control, shall be
immediately brake motor
Accurate calculation, selection of suitable working environment of polyurethane buffer or buffer springs, so
that the operation mechanism of crane in operation to achieve the end position, can buffer capacity to
absorb crane operation is very good, are respectively arranged at the end of the large car. Long service life
and good cushioning properties are all its features.
5. Oil paint
In factory before manufacturing ,
sand-blasting SA 2,5 or use steel plate shot
blasted,Structure after shot peening treatment,
immediately primer painting , After
manufacturing (after welding),1 coating epoxy
40 microns , 1 coating epoxy 40 microns, 1
coating of polyurethane 40 microns, Average
thickness : about 120 microns , The paint
appearance inspection conclude wet film may
shrink, shrink, foaming, pale, no light, paint
sagging. For dry film, there are no subtle
cracking peeling phenomenon. Finish should
be uniform, smooth, and uniform in color, with no leakage of paint, paint cracks, pinhole, flow, such as
delimitation defects.
6 Packing
Electric system and electric wire rope hoist will whole package, the car overall container transportation, site
installation are more convenient. Packaging used to dust, moisture-proof packaging design, small volume,
convenient loading and unloading.
Motor siemens
Gear’ siemens
1 Hoisting
brake zpmc
limit switch GG
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general overhead crane maintenance guide manual
wirerope BRIDON
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general overhead crane maintenance guide manual
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