工程编号：

PROJECT NO： M8A

项目名称:
Subjec： MQ4040 Gantry Luffing Crane

港 口 机 械
DECK CRANE
机 械 部 分
MACHINERY EQUIPMENT

培 训 手 册

TRAINING MANUAL

编 制 资料编号
EDITED FILE NO
校 核
Total 共 22 页 Page
CHECKED
批 准 备 注
APPROVED REMARK
地址：中国湖北省武汉市青山区武东街九号
Add：N0.9Wudong Street Qingshan Wuhan HuBei China
Fax：（027）68867461 Tel：（027）68867393
E-mail：[email protected] Code：430084
Wuhan Marine Machinery Plant Co., Ltd. Training Manual

Table of contents
1. General ....................................................................................................2

2. Main technical performance ...................................................................2

3. Major mechanism ...................................................................................3

4. Major metal structure ..............................................................................6

5. Safety facilities .......................................................................................7

6. Lubrication ..............................................................................................8

7. Operation and setting ..............................................................................9

8. Attentions for different mechanisms .....................................................10

9. Usage and maintenance ........................................................................14

10. Common faults and troubleshooting...................................................18

11. Notice before leaving the shift and operation program ......................22

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1. General

The crane belongs to the port portal crane in handling type.

As the type with double-link jib system, the crane is able to carry out non-working
operation along the trace and mainly used for handling the bulk goods and groceries
in pieces, with 40t grab bucket of rated capacity, 40t lifting hook and 30.5t lifting
appliance. The rotary mechanism of crane can rotate in 360degrees in positive and
negative direction successively. The replacement trace of grab bucket during luffing
process can get access to the horizontal line. In addition, luffing mechanism is in
gear-rack amplitude-change type.

The rotation support device adopts three-row roller rotary support, which is able to
bear axial load, radial load and overturning moment. Rotary bearing is used to
connect the rotary table and gantry of crane and able to make crane rotate in
360degrees in the positive and negative direction.

The crane consists of four mechanisms, i.e. lifting mechanism, luffing mechanism,
rotary mechanism and travlling mechanism, all of which adopt variable-frequency
speed-regulating three-phase asynchronous motor.

The major metal structure of the crane is mainly divided to Boom system,
Frame&equalizing system, Slewing platform and cylinder gantry.

The working personnel can reach at the driver’s cab through cylinder gantry, Slewing
platform and machine room through the staircase, which is set on the plane of rotary
table to reach at the top of machine room and propeller strut.

The supply power of the crane adopts diesel engine generator. The electric control
cabinets, resistance cabinets and other equipment of lifting, luffing and rotary
mechanisms are installed in the machine room while the electric control cabinet of
travlling mechanism in the electric chamber of Main girder..

The safety facilities of the crane include load moment limiter (including load indicator
and luffing indicator), limiting device of different mechanisms, wind speed indicator,
electric iron wedge and anchor device, etc.

2. Main technical performance

Lifting altitude +25m~-12m Maximum wheel 25t

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Maximum rotary
90m/min
Hoisting mechanism 45/min radius diameter in the 9m
Working (empty)
tail
speed of

mechanis Maximum overall

Luffing mechanism 36m/min 58.2m
m height

Swing mechanism 0.8r/min、1.3 r/min Clear headway 8.582m

Travelling mechanism 30m/min Pivoting support 132.50.4000
Hoisting mechanism M8 YTSZ355M2-8x2 Trace model A100
Luffing mechanism M7 YTSZ315S-8x1 Travelling distance
Total
Working Swing mechanism M8 YTSZ280S-6 x2 48
wheels
level and
Travell Number of
electromo Travelling mechanism M5 DV112M4x24 24
ing driving
tor
wheel
Wheel
Complete appliance A7 555KW φ440
diameter

Steel wire rope 36NAT6*36WS + IWR- 1770 Power 380V 50HZ

Gauge/base distance 10.5m/12.5m Total weight 628t

3. Major mechanism

3.1Lifting mechanism

Lifting mechanism, installed in the machine room, consists of single motor system,
high-speed coupling, reducer, low-speed coupling, winding drum and steel rope,
without which, the goods can be lifted or dropped. Brake is in electric hydraulic wheel
type. Different lifting speeds under different loads can be realized by controlling the
rotation speed of variable frequency motor through the frequency converter. The
winding drum is winded in single layer with the guiding and pressing device of steel
rope with excellent performance set to prevent the steel rope from loosening or
skipping from the groove. The steel rope is in 6x36 multi-layer type and the winding
system of steel rope is in reasonable arrangement without bending in negative
direction. Both ends of the steel rope are fixed effectively. The lifting mechanism is

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able to lift 40t (lifting hook), 40t (grab bucket) and 30.5t (lifting appliance) within
45m range.

The multiplying power of the trolley group of lifting hook is 1 and the fluctuation
limit position of lifting hook is installed on the output axle on one end of the winding
drum and controlled by limit switch. The weighing of lifting load and lifting torque
can be controlled by the Qverload limiter at the top of propeller strut and the
amplitude inspection device near the lower hinged point of Main boom structure.

3.2 Luffing mechanism

Luffing mechanism is installed in luffing platform in the middle of Frame and consists
of single motor, high-speed coupling, reducer, low-speed coupling, gear-rack cradle,
so as to make the Main boom structure move backward and forward. The brake is in
electric hydraulic wheel type. Different luffing speeds can be realized by controlling
the rotation speed of variable frequency motor through the frequency converter. The
luffing is in double-link jib compensation way, so as to make the goods under nearly
horizontal movement during the luffing process.

Amplitude sending device is set near the hinged point at the root of crane arm rest and
issues amplitude signal.

The amplitude limit is controlled by the limit switch installed on the output axle of
Gear shaft.

AC variable frequency motor makes luffing mechanism in stable brake through

variable frequency control.

3.3 Rotary mechanism

The rotary mechanism is installed in the machine room and consists of vertical motor,
coupling, gear and Slewing Bearing. It can make the rotary table rotate continuously
in 360° in positive and negative direction. The brake is in pedal hydraulic block type,
and manual brake and non-working manual rotary locking device are set to lock the
Slewing platform and Cylinder gantry. The locking device is in flexible and
convenient operation.

Several plate frication limit torque couplings are installed on the output axle of motor
so as to be preventive from the overload of machine parts.

The rotation mechanism is in variable-frequency speed regulation, which can make

brake stable and obtain better speed-regulating performance.

3.4 Travlling mechanism

The travlling mechanism consists of four sets. The machine includes respective 24
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driving wheels and driven wheels. The wheel is in type of flat tread and double-wheel
rolling bearing, with the material of 42CrMo. Thermal treatment is made to the wheel
tread and wheel edge and the surface hardness shall be HB300-380 while the depth of
hardening layer shall be no smaller than 20mm; the equalizer beam is in container
welding structure and connected with Bogie through cardinal axle.

The mechanism is in AC variable-frequency motor. The variable-frequency electric

control results in stable brake. To prevent the crane from damaging due to the
collision, buffers are installed on both ends of the travlling mechanism. Besides, two
limit switches are installed on the driving frame near both ends of the travlling
mechanism which is on one side of the trace.

3.5 Driver’s cab

The driver’s cab is installed in the front of Slewing platform and is in framing
thin-plate structure. The external wall is color plate while the internal wall in light
heat-insulated sandwich panel. The shutter-proof glass and safety grid are applied to
the glasses on both sides and the positive side. Wiper is set in the positive surface. The
driver’s cab is in totally enclosed structure and rubber gasket is set on the ground with
excellent heat-insulation, noise-insulation and water-proof performance. The driver’s
cab boasts excellent vision and set with cooling and heating air conditioner, so as to
guarantee that the temperature in driver’s cab is between 15℃ and 30℃. The linkage
platform with adjustable aero seat and other operation systems, integral control
linkage console, inspection display instrument and device, as well as microcomputer
torque limiter which can display weight and amplitude value are set inside the driver’s
cab. Horn and project lamp are installed on the external side of the driver’s cab.
Loudspeaker and other communication equipment are set within the driver’s cab.

3.6 Machine room

Machine room is installed on the Slewing platform and is in framing structure. The
external wall of it is in light heat-insulated color steel laminboard, which will not be
affected by the climate and weather conditions and able to resist fire, rain, dust,
corrosion and strong wind. The top of machine room is in sloped structure, which can
discharge rainwater in time. The steel runs through the top of machine room forcefully,
with anti-rainwater enclosing measures. Lifting mechanism, secondary lifting
mechanism, rotary mechanism and enclosed electric chamber are set in the machine
room while all the control cabinets as well as some auxiliary devices and maintenance
tools are set in the electric chamber.

3.7 Power supply device

Diesel engine power supply system is the input device for power supply, control and
communications of crane power: the electricity is introduced to the equipment by
power supply cable and the inspection signal of crane is sent to the central control

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room. The power device used for connecting the rotary and non-rotary part of the
crane adopts central slip-ring current collector which is installed in the upper part of
cylinder.

3.8 Electric iron wedge, anchor device and Tied down device

Electric iron wedge and anchor device can guarantee the crane in stable condition
under any circumstances. With the wind speed below 20m/s, the equipment can work
normally. In case the wind speed is above it, the vehicle can enter the anchored
position by going against the wind. When the wind speed is 42m/s, crane can remain
stable status with the efforts of electric iron wedge, anchor device and Tied down
device.

3.9 Lubrication and sealing

1) The crane is stuffed with the relatively central lubrication system and inspection
platform is set for the trolley group in each hinged point.

2) Complete set of products are used for the central lubrication system of crane.

3) Different reducers are set with excellent sealing devices to be preventive from oil
leakage.

4. Major metal structure

The metal structure of crane is in container structure and pipe big-pole structure, all of
which can be used in cranes in the same type for several years, with the strength,
stiffness and stability all satisfying the design code and usage requirements of crane.

1) Boom system

Boom system is in double-link combined type. Main boom structure is in container

cross-section welding structure, with its lower part hinged with Slewing platform and
end hinged with the middle part of Fly jib. The hinged points all adopt rolling bearing.
The middle part of Main boom structure is hinged with luffing rack and Small tension
bar. The Fly jib is in self-aligning rolling bearing while Big tension bar hinge in
rolling bearing. The Fly jib is in truss structure consisting of container type and
H-typed beam and both ends of it are set with lifting trolley group and steel rope roller
in the middle. Big tension bar is in container structure with lightening hole. Both ends
of it are hinged with Fly jib and the end of Frame and the hinged points are in rolling
bearing.

2) Frame&equalizing system

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The lower part of Frame&equalizing system is in door type structure while the upper
part in rectangular variable cross-section container structure. Its bottom is in rigid
connection withSlewing platform. Platform and rack luffing structure are set in the
middle part, with load force device in the upper part and Equalizing boom and
hinged support of Big tension bar at the top of the platform, so as to guide to the
trolley group. The Equalizing boom is in double-container structure with the tail
connected with weight box and head hinged with Small tension bar. Small tension bar
is hinged with Main boom structure while concrete casting is used for balancing
weight. Some weight blocks are set to adjust the activity weight.

3) Slewing platform

The mixed structure consisting of main and secondary container beam and auxiliary
H-typed beam is adopted and integral flange of cylinder is set in the middle. As for
the bottom, thick flange board is set and connected with Slewing Bearing through
bolts in high strength.

4)Cylinder gantry

The gantry is in cylinder H-typed and consists of cylinder, Main girder and Sill beam ,
among which, the cylinder is in thick-wall structure. Thick flange board is set in the
upper side and connected with Slewing Bearing through bolts in high strength. while
drip pan is set at the bottom of flange board. Jacking support is set in the upper part of
cylinder to change Slewing Bearing. H-typed gantry is in container welding structure.
The lower part of Sill beam is hinged with Up equalizer beam of Travlling mechanism
through flange hinged support, so as to ensure sufficient integral rigidness of the crane,
reduce the horizontal shaking of crane when it works and brakes and benefit the
comfortable operation by the driver.

5. Safety facilities

1)Protection device of lifting overload torque: the electric signals output by the load
force device installed in the upper part of Frame and the one by luffing sending device
installed near the lower hinged point of Main boom structure can be used for overload
torque protection through the calculation of microcomputer torque limiter.

2)Stroke protection and electric interlocking

a.Lifting and dropping limit protection: stroke switch is installed in the end of drum
shaft of crab.

b.The final point limit of luffing limit protection and pre-warning switch near the final
point (Rmax-0.5m，Rmin+0.5m) are installed on the output axle of Gear shaft.

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c.The brake of rotary mechanism is in electric interlocking with rotation motor. When
the brake is clasped, the power of rotary motor can be connected by cutting of the
motor power and loosening the brake.

d.Travlling limit protection: installed with final point limit switch and final point
buffering device.

3)Electric iron wedge and wind-resistance anchor device

The crane is set with four sets of electric iron wedges and two sets of anchor devices.
When the travlling mechanism of crane is interrupted, the electric iron wedge will
immobilize the wheel. The gantry is also set with anchor device which can prevent the
crane from falling due to strong wind. The anchor device consists of lever-typed blank
with balanced weight, anchor pin and anchor seat.

The crane will be driven to the anchor area in case of strong wind or when the worker
leaves the shift. Use anchor pin to fix the blank and anchor seat so as to fix the crane,
aiming to make sure the safety of non-working status. The electric iron wedge and
anchor device are set with limit switch and loop interlocking of travlling mechanism.
The power of travlling motor will be interrupted when the brake wheel of electric iron
wedge or the anchor blank is inserted in the anchor seat.

6. Lubrication

1) Refer to the table below for the crane lubricant and lubrication cycle:

No. Type and name of Lubricant Lubrication Cleaning

lubricated parts cycle cycle
1 Crane reducer Based on the product Adding oil Once a
sample based on year
demand
2 Open gear No. 00 reducer lubricating Adding oil
When
grease based on
inspecting
demandit
3 Rolling bearing General lithium lubricating Once When a
grease month inspecting
it
4 Steel rope SY1577-78S steel rope Every half a Once a
surface grease month year
5 Vertical gear Based on the product Adding oil Once a
reducer of rotary sample based on year
mechanism demand
6 Gear coupling HL-30 gear oil Inspecting Once a

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every week year

Adding oil
based on
demand
7 Sliding bearing General lithium lubricating Once a week When
grease inspecting
it
8 Hinged point and No. 00 reducer lubricating Once a When
trolley group of grease month inspecting
arm rest it

2) The filling quantity of lubricating grease within the rolling bearing is generally
1/2~3/5 of the internal cavity and 1/2~2/3 in the cover on both ends.

3) The lubricating grease of open gear is coated on the gear surface by brush and
the lubricating consumption quantity for one time is:

Q grease =0.15DB (g)

Where: D— wheel diameter (cm), B— gear width (mm)

4) Lubrication of steel rope during working time: the steel rope lubricating grease
with the brand number “SY1577-78S steel rope surface grease” listed in Table 1
shall be used; alternatively, the one mixed with calcium grease and 15% graphite
can be used. The consumption quantity of lubricant: surface coating: 5g/m with the
diameter/mm.

7. Operation and setting

1) Preparations before operation

a.Open anchor device

b.Loosen the manual spiral brake of rotary mechanism

c.Switch on the main power knife switch and automatic switch

d.Switch on the main loop and control loop power switch in the control box of
different mechanisms and the switch of illumination box in order.

Different mechanisms are operated on the operator control station.

2)The setting of installation position of different stroke limit switches are adjusted by
combining the setting of electric system.

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8. Attentions for different mechanisms

1) Attention for operation mechanism (general attentions)

Operate in empty load first and then in load when trial operation is carried out.

Items and cycle for maintenance and inspection

All the parts:

(1)Whether the fixing bolts are loosened

The importance of fixing bolt connection shall be fully understood. Fasten the bolts in
bolt loosening inspection when they operate initially in the first week and every
month after that. Proper wrench shall be used for fastening.

Maintenance cycle: weekly and monthly

(2)Lubricating oil

Add oil according to the lubricating oil table.

Maintenance cycle: weekly

(3) Three-in-one reducer

a)The wearing of carbon brush, whether the abnormal sound exists inside it and the
temperature rise of bearing

b)Whether the oil quantity is proper

c)Whether oil leaks

d)Whether the temperature rise is abnormal? If the enclosure temperature is above

85℃, the internal reducer shall be inspected accordingly.

e)Whether there is abnormal sound inside it

f)Whether the bolt is loosen

g)Whether the bearing temperature is higher than 85℃

h)Maintenance cycle: always

(4) Wheel

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a)Whether the wheel has axial movement? If so, the check ring or the bearing is
damaged.

b)Whether the wheel tread is peeled or there is other damage.

Important attentions

The travlling mechanism is set with whole brake system (brake of driving wheel and
electric iron wedge of driven wheel) so as to brake the crane and make it operate
continuously with the wind speed less than 20m/s. The braking force is designed
based on 35m/s wind speed.

2) Attention for lifting mechanism

(1)Whether the fixing bolt is loosened

Inspect the fastening of bolts particularly when it is operated for one week for the
very first time and each month afterwards. Inspect all the bolts carefully and fasten
them again. Use proper wrench when fastening the bolts.

(2) Lubrication

The lubricating oil of reducer and hydraulic push rod shall be upgraded every six
months.

(3)Rolling bearing:

Including the bearings in motor, reducer and rolling bearing.

a. Whether abnormal temperature rise occurs.

Upper limit of bearing temperature rise: 40℃ higher than the ambient temperature

Maintenance cycle: always

b. Whether there is abnormal sound.

Maintenance cycle: on an often basis

(4) Steel rope

Whether the pressing plate at the end of steel rope is loosen

Whether excessive wearing and filament breakage exist

Maintenance cycle: always

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(5) Limit switch and encoder

Inspect whether the action and position of pulse encoder and limit switch are normal

3) Attention for luffing mechanism

(1) Whether the fixing bolt is loosened

Attention shall be paid to bolt loosening particularly it needs fastening again for the
first week and each month afterwards. Use proper wrench for fastening.

Maintenance cycle: always and once a week

(2) Lubrication

Correct lubrication shall be made to motor, brake, reducer, coupling, bearing of

bearing pedestal and cam limit switch transmission according to the lubrication table.

Maintenance cycle: always

(3) Motor

a. Inspect heating and check whether the bearing is in abnormal heat.

b. Whether there is abnormal sound inside the motor.

c. Inspect the wearing of carbon brush.

Maintenance cycle: always

(4) Reducer

a. Use oil pointer to measure whether the oil quantity is proper

b. Whether the oil temperature rises?

The internal parts need inspecting when the temperature of enclosure is 40℃ higher
than the surrounding temperature.

c. Whether there is abnormal sound inside it.

Maintenance cycle: always

(5) Dental coupling

a. Bolt fastening of cover on both sides of the internal gear.

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b. Mesh and wearing of internal and external gear.

c. The center offset of coupling is less than 0.03mm with angle deviation less than
<15’.

Maintenance cycle: once a month.

(6) Bearing

a. Whether the temperature rises abnormally?

The temperature rise of bearing is not allowed to be 40℃ higher than the surrounding
temperature.

b. Whether there is abnormal sound;

c. Whether the fixing bolt is loosened.

Maintenance cycle: always

(7) Command limit switch

Whether the action is correct

Maintenance cycle: once a month

(8) Brake

a. The clearance between brake clamp and brake disc shall be 0.5~1.0mm;

b. Inspect the wearing condition of brake friction plate;

c. Heat inspection;

4) Attention for rotary mechanism

1) Whether the fixing bolt is loosened

Inspect the fastening of bolts particularly when it is operated for one week for the
very first time and each month afterwards. Inspect all the bolts carefully and fasten
them again. Use proper wrench when fastening the bolts.

2) Lubrication

The lubricating oil of reducer and hydraulic push rod shall be upgraded every six
months.

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3) Rolling bearing:

Including motor, reducer and slewing bearing, etc.

a. Whether there is abnormal temperature rise

Upper limit of bearing temperature rise: 40℃higher than the ambient temperature

Maintenance cycle: on an often basis

b. Whether there is abnormal sound

Maintenance cycle: on an often basis

9. Usage and maintenance

9.1 Attentions for safe use

1) Clear the trace and the barriers surrounding the gantry before starting the crane;

2) Inspect the crane appearance, and make sure no usage faults exist in the metal
structure of crane and no damage occurs to the paint;

3) Inspect whether barriers exist in the transmission part of crane, safety hood and
whether the brake and coupling are fastened;

4) Lubricate according to the lubrication regulations;

5) Inspect and loosen anchor device and screw and anchor the rotary mechanism by
hands;

6) The driver shall fully understand the technical performance and structure, safety
operation rules and signal rules of the crane;

7) Stop working upon the problem occurs to the crane;

8) The load weight is unclear, the tying is not proper, the hook is incorrect,
illumination at night is insufficient and lifting becomes impossible;

9) When the crane is used, the driver is not allowed to leave the driver’s cab and
irrelevant personnel are prohibited to get on the crane;

10) The operation in excessive load and pulling load with lifting hook diagonally are
prohibited; the unobvious weights buried in mud, rubbish, snow or water or the
weight pressed by other object are prohibited to be lifted;

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11) The weight or lifting hook is not allowed to run over the head of personnel or to
lift people with weight or lifting hook. When the weight or lifting hook surpasses the
object, it shall be 2m higher than the object;

12) Mud, ice and oil dirt on ladder, platform and rail shall be always cleared and
remain tidy. When the load or lifting hook is higher than any objects, they shall be 2m
higher than the object;

13) Electric equipment can not be repaired until the main power switch is interrupted;

14) When the lifting mechanism is operated quickly, the hoisting capacity shall be
controlled by strictly following the regulated value of technical parameter;

15) The crane shall stop working when the wind speed is faster than 20m/s; the
anchor device in marine and land groups shall be used to fix the crane on the
foundation.

16) When the crane lifts, measures shall be taken to prevent the load from swing and
rotating;

17) When two cranes lift one object together, necessary safety measures shall be taken
and operation can be made when the safety is guaranteed;

18) The driver can not control the action of mechanism by depending on the limit
switch only; instead, the driver shall stop action before the mechanism reaches the end
point;

19) Switch the handle to “0” position when the power is interrupted in operation;

20) When two cranes operate next to each other, they shall rotate in small amplitudes
as to avoid the collision of arm rests of two cranes;

21) When operating luffing mechanism, the driver shall gradually move the handle to
avoid impacting;

22) Turn on the aviation lamp at night;

23) Prevention shall be made and the anchor device of crane shall be properly
anchored in case of typhoon warning;

24) Place the crane in safe area, turn off the main power and place different operation
handles to “0”, close the doors and windows, put the anchor push plate of anchor
device in the anchor seat and plug the pin before the workers leave the shift

9.2 Regular inspection

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Category Monthly inspection Annual inspection

Loosening and falling of fixing Corrosion of steel
bolt materials
Cracking of welded parts Coating peeling
Deformation and cracking of
Pin and axle lubrication
Metal steel materials
Steel structure
structure Grease lubrication of pin and
axle
Loosening and falling of stair
tread, rail, platform and fixing
bolt
Abnormal sound, heat and
Enclosure cracking
vibration
Lubrication status Key loosening
Reducer
Oil quantity and oil leakage Deformation of key way
device
Loosening of fixing bolt Oil dirt
Status of mesh surface of
gear
Whether the smear metal
Abnormal sound and heat
is mixed in oil
Bearing Clearance of pin and
Ontology damage or cracking
bushing
Loosening of fixing bolt Bearing wearing
Wearing and cracking
Axis Key loosening
Deformation of key way
End plate Loosening of fixing bolt Damage
Machinery
Loosening of the fixed part of
steel rope
Damage of steel rope guidance
Winding drum
Damage of fixing bolt of
winding drum
Cracking in welding parts
Alignment with axle
Abnormal sound and heat
center
Oil quantity Oil supply
Oil leakage Back lash
Coupling
Loosening of fixing bolt Key loosening
Deformation of key way
Damage or cracking of
tooth profile
Wearing and deformation of Pedal wearing, peeling and
Wheel
flange and pedal cracking

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Damage of different parts Inspect in the same month

Wearing of connection pin Inspect in the same month
Tooth wearing Inspect in the same month
Brake
Stroke confirmation Inspect in the same month
Lubrication status of different
Inspect in the same month
parts
Rotation status Inspect in the same month
Cracking Inspect in the same month
Trolley Groove wearing Inspect in the same month
Damage of anti-jumping device
Inspect in the same month
of steel rope
Breaking of odd lot Inspect in the same month
Wearing and external damage Inspect in the same month
Buckling and deformation Inspect in the same month
Odd lot Inspect in the same month
Steel rope Coating and friction status of oil
Inspect in the same month
grease
Rust and corrosion Inspect in the same month
Processing and fixing status in
Inspect in the same month
the end of steel rope
Oil dirt, aging and discoloration Inspect in the same month
Oil supply of lubrication part Inspect in the same month
Oil supply
Damage and oil leakage of
lubrication Inspect in the same month
tubing
system
Central lubrication system of big
Inspect in the same month
vehicle
Oil quantity and oil dirt Inspect in the same month
Clearing filter Inspect in the same month
Oil pressure Inspect in the same month
Abnormal sound and heat of oil
Inspect in the same month
Oil pressure pump and motor
device system Valve adjustment and action Inspect in the same month
Action of oil pressure cylinder Inspect in the same month
Damage of oil pipe Inspect in the same month
Oil leakage in different parts Inspect in the same month
Loosening of fixing bolt Inspect in the same month
Loosening and falling of fixing
Corrosion of steel material
bolt
Cracking of the welded parts Coat peeling
Operation
Machinery Deformation and cracking of
mechanism
steel material
Oil supply of pin and axle
Cleaner damage

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Buffer damage
Anti-climbing wedge block
Control of rail clamping device
and hydraulic system
Fixing of steel rope Inspect in the same month
Wearing of steel rope Inspect in the same month
Lifting hook
Damage of rope retainer Inspect in the same month
(grab bucket)
Damage of lifting hook (grab
Inspect in the same month
bucket)
Extinguish The validity of carbon
Extinguisher Equipment condition
ing device dioxide lasts for one year
Emergency Action status of
Action confirmation
stop limit anemoscope
switch, control
Safety device and
device other electric Confirmation of action position
appliance of limit switch
protection
device
Illuminati
Whether the lamps are damaged Inspect in the same month
on
Inspect whether the
Earthing earthing resistance of
resistance crane complies with the
requirements
Accessorie Maintenance Inspect according to the crane Inspect according to the
s crane standard standard of the machine
Rated load of lifting shall be subject to the lifting of rated
Load test speed, luffing compound action, secondary lifting and
travlling.
Inspect the wearing of wheel every three months and inspect and clean the open gear.

10. Common faults and troubleshooting

1) Refer to the table below for the causes of common faults and troubleshooting of
crane.

Faults Causes Troubleshooting

Totally lack of or less lubricating Add enough lubricating oil to
grease the bearing
Heat occurs to rolling
Use kerosene to clean the
bearing
Dirt in bearing bearing and inject lubricating
oil
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Poor assembly, the bearing is

Inspect the correctness of
inclined or blocked due to the
The noise in roller bearing assembly and adjust it then
excessive fastening
increases when it works
The bearing parts are damaged or
Change bearing
worn
The reducer has
The pitch error of tooth is too
periodical vibration sound
large and the clearance along the Repair and install it again
particularly in the driving
teeth has surpassed the standard
wheel
The clearance of transmission
gear is too small, the wheel and
The reducer has strong
center are not in alignment, there
metal friction noise Repair, install again or
is sharp and thin edge on the gear
which makes reducer upgrade
top and the tooth surface is not
vibration seriously
even after wearing (small groove
and convex mark)
The gear mesh of
reducer is not even but
successive striking
Faults at the tooth side (zonal
sound can be heard from Upgrade it
structure)
the reducer. The
enclosure of reducer is
vibrated
The internal oil temperature
of cylinder gear and bevel
gear reducer shall be lower
than 60 ℃ while that of
Reducer becomes heat Excessive lubricating oil
worm reducer lower than
75℃. The oil surface shall
remain between the two
marks of the indicator.
Clean the brake, eliminate
The active joints in lever system the blocking phenomenon
are blocked and add oil to the active
joints
The brake can not stop Use kerosene to clean the
Oil on brake disc
heavy things (for brake disc and friction lining
travlling mechanism, the Excessive wearing of friction
Change friction lining
sliding distance after lining of brake valve
brake is too long) Change the spring or adjust
Smaller tension due to the damage
the screw to make the spring
or loosening of major spring
tension proper
The lever locking nut is loosened Fasten the screw after
and lever is moved adjusting lever
Line is broken or burnt in coil, the
tension of main spring in
Change coil or adjust the
Failing to open the brake short-stroke brake is excessive
spring or heavy hammer
and the heavy hammer of
long-stroke brake is tightened

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excessively
Adjust the stroke of
The armature is attached on the armature, scrap the armature
circuit core incorrectly, lever and the attached surface of
Heating or sound of
system is blocked and the tension iron core on short stroke
electromagnet
of main spring is excessive (refer magnet, eliminate the
to short-stroke brake) blocking phenomenon and
adjust the spring
The clearance of brake disc and
friction lining is not even and Adjust the clearance to
Focal spot is generated friction occurs when leaving separate friction lining
in friction lining, which mutually. The brake disc is evenly
makes the brake band overheated
wear quickly The auxiliary spring is damaged
or bended (refer to short-stroke Change auxiliary spring
brake)
The brake easily isolates Either the nut or back nut is not Adjust the brake, fasten nut
from the adjusted fastened and the nut tread is and back nut or change the
position damaged nut with faults
Adjust the levelness,
Wheel installation deviation verticality and diagonal
deviation of the wheel
Adjust the trace elevation,
Trace pavement deviation
span and parallel error
Excessive friction in the
Oil or water on trace (ice in
vehicle operation Clearing the trace
winter)
Match motor and brake
Too large deviation of
reasonably and inspect the
transmission system
axle key
Wheel deflection and deformation Wheel frame correction
Inspect once-three times a
Invalid usage, overload or
year and upgrade it when
material faults
fatigue crack is found
Fatigue cracking occurs When the wearing of the
to the forged lifting hazard section is more
point and surface of the The wearing height of the serious than the one
lifting hook; it may dangerous section in the outlet of regulated in the standard,
cause breaking. lifting hook is 10% greater than static load can be added to
that of the section carry out load test and
determine the new
application load.
Select the diameter of trolley
The diameter of trolley and
and winding drum and the
winding drum and the groove
rope groove distance of
distance on the winding drum are
Fast wearing or frequent winding drum correctly and
too small for the steel rope in such
cracking of the lifting install the steep rope with
type
steel rope standard diameter
Clean and lubricate the steel
With dirt but without lubricating
rope and adjust the retaining
oil
wall
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Dismantle lubricating parts

No lubricating oil available
The trolley fails to rotate and guarantee the required
between bearings
lubricating oil
Faults occur to motor or circuit
Failing to lift rated load system and overload device is not Inspect, clear and change it
adjusted properly
Add oil after cleaning
different joints of brake and
The joint resistance of brake
different joints shall be
becomes larger
added with oil according to
The starting time of brake
the requirements
is too long (hydraulic
Clean and inspect whether
brake)
Oil leakage inside it, the oil the hydraulic releaser has
pressure is low or the oil circuit is abnormal sound, damaged
unsmooth parts; if so, change the
damaged parts.
The damping hole of overflow
Clean the overflow valve
valve is blocked
The coil of voltage device is in
The brake does not have
reverse connection and the control Adjust the line
pressure and brake thus
rod can not be lower.
becomes impossible
The oil filter is blocked Clean the oil filter
Failing to fasten blade oil pump
Fasten blade oil pump joint
joint
The plane of control rod is not
even and the nozzle center of
Install the position correctly
control rod is inclined when the
The oil pressure of brake after finding the faults
control rod of overflow
fails to reach the
adjustment device is assembled
working oil pressure and
The coil current of battery
the brake time is too Increase the current value
solution adjustment device is too
long within the allowable range
small
Adjust the brake clearance
Too large shoe clearance
between 0.6~1.0mm
The distance between control rod Fasten the bolt in the upper
Too long time for brake
and nozzle is too small end of cross spring
release and too large
Too small diameter of nozzle
residual pressure Enlarge the aperture
aperture
Too large reducer box or Serious gear wearing Change gear
impact sound can be Foreign substances in the box Get the foreign substance
heard Bearing is damaged Change the bearing
Dismantle and wash the
Dirt enters the bearing
bearing
Overheat of reducer
Too small clearance Adjust the bearing clearance
bearing
Add oil according to the oil
Excessive oil or oil supply cut
scale
2) Refer to the table below for the causes and troubleshooting of metal

structure.

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Faults Causes Troubleshooting

(1) Carry out transportation and
The main beam is in
storage according to the
serious
(1) Improper transportation regulations
down-wrapping, which
and storage (2) Use it reasonably based on
influences the normal
(2) In overload use always the regulation
operation of crane (big
(3) Correct it in case of serious
vehicle)
down-wrapping
(1) The local stress shall be
(1) Inspect the metal structure for
central
Crack occurs to the once or twice a year
(2) Intensified vibration
important welded part (2) Carry out load test for once in
(positive and negative
of metal structure the second year and safety
operation)
technical identification
(3) Overload always

11. Notice before leaving the shift and operation program

The driver shall deal with the crane according to the following rules after finishing
using it.

1. The lifting hook shall be lifted to a higher position, without hindering the actions of
personnel on the ground; no rack or lifted materials are allowed to be hanged on the
lifting hook.

2. Drive the big vehicle to the fixed parking position.

3. Set the controller handle of different mechanisms to zero, switch out emergency
circuit breaker and pull off the main operation switch handle of the protection cabinet;
record the conditions in lifting, operation and inspection in the handover log and get
off the vehicle after closing the driver’s door.

4. The crane working outdoors shall be parked stably after finishing using it.

5. Hand over work with the driver in next shift.

-END-

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