operation manual of overhead crane english

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

2


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;

3


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.

4


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



7


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



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


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

8


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;

9


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


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%

11


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

12


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

13


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

14


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

15


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

16


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


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

17


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.

18


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.

19


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,

20


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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http://www.whgroup.com.cn/

operation manual of overhead crane english

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