general overhead crane maintenance guide manual

General Overhead Crane Maintenance

Guide Manual

1
 general overhead crane maintenance guide manual

First Section Crane overview

1、 1、Standards and specifications for crane design and acceptance

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、crane program description

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)

2
 general overhead crane maintenance guide manual

NO. Item Description Remark

11 Hoisting speed (main hook / Mian and Mux, hook:
aux hook) 0.2-4 m/min
12 Mian hook:
Hoisting motor power (main 90KW (JC=25%)
hook / aux hook) aux hook：
30KW (JC=25%)
13 Travelling speed( crane/ Crane：1.25-25m/min
trolley) Trolley:：0.5-10 m/min
14 Travelling motor( crane/ Crane：2*7.5KW
trolley) Trolley:：2*3KW
15 Trolley:
80*60
Selection rail model
Square steel crane:
A100
16 Three-phase four wire
Working power supply system lternating
current 400，50Hz
17 Type of control Cab+spare hand control
18 Height of the rail top to the 2144mm
apogee of the crane
19 A：Cab（air conditioner）
Cab side
B：Busbur
20 Cab height 2225mm
21 Distance from rail top to 2500mm
bottom of the cab
22 Distance from buffer center 200mm
to rail top
23 Distance from cab side to 1200mm
crane rail center
24 Distance from crane rail 193mm
center to beam to end of beam
25 Number of wheels and wheel Single side wheel ( trolley/
distance ( crane/ trolley) crane) :5/4
Wheel distance:
1400mm/10500mm
5600mm
26 Weight(trolley/crane/total 15.9t/23.5t/39.4t
weight)
27 Max wheel load 309KN
28 Single side workshop length 74m
29 Paint and its life Meet the EN ISO 12944 C4

3
 general overhead crane maintenance guide manual

NO. Item Description Remark

standard, guaranteed 15
years of service life and
provide on-site repair
paint.
30 Building install requirement thickness of beam 45mm
31 Cantilever weight 15t
32 Cantilever hoisting height 13.134m
33 Cantilever Hoisting speed 4/0.67m/min
34 Height of the rail top to the 2535mm
apogee of the cantilever lower
border
35 Hook center distance to 468mm
track center limit
36 Cantilever move length 6000mm

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

4
 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

3 Construction conditions and equipment run conditions

3.1 Plant site and weather condition

Plant address: Power plant is in Punjab, Pakistan. 12KM of Southwest of Lahore, in the south
of the town of BHIKKI shekhupura
3.2The characteristic values of the main meteorological elements are as follows：
Maximum outdoor ambient temperature：50℃
Minimun outdoor ambient temperature：5℃
Maximum indoor ambient temperature：55℃
Minimum indoor ambient temperature：10℃
the average high temperature from May to July,：31-34℃
the average high temperature from January to December：13-14℃

5
 general overhead crane maintenance guide manual

Average relative humidity：70 %

Outdoor maximum relative humidity 87%
designing wind speed：160km/hr
The project area is in ZONE 2A,designing earthquake acceleration is 0.15g.

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.

6
 general overhead crane maintenance guide manual

4.1 Trolley:

Double girder 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.

4.1.1 Hoisting mechanism

Trolley lifting mechanism respectively by compact geared motor brake drive units, reel device, rope
guide , wire rope, pulley, hook, lifting limit switch and other components
a. Hoisting motor adopts squirrel cage Frequency conversion motor starting, no impact, aluminum
shell, fast heat dissipation, protection class IP54, class F insulation, electrical sustained rate of 40% (also
available frequency conversion motor and protective, higher insulation grade according to user
requirements).
b. Hoisting gear uses the professional brand SIEMENS etc, which acknowledged as the European
standard. These gears distinctive in its design practice high-ratio, high-torque low-noise, high
reliability, maintenance-free. The body of t gearbox shall be forged by welding or casting. Gears comply

7
 general overhead crane maintenance guide manual

with 18CrNiMo7-6 and comply with Germany standard DIN 6.

c. The normally closed double safety brake disc brake has the functions of high safety factor, non
asbestos, reliable performance, high rate of closing, automatic braking power, braking safety and no
vibration, little abrasion, wear gap automatic adjusting.
Drum device: The drum device consists of a reel, end flanges and other components. The coaxial after
each assembly is good, the connection between components is safe and reliable, the whole assembly drum
device has the advantages of high precision, and are good to ensure the service life of the transmission
system.
a. The drum is made of high strength low -alloy steel, the use of high-quality seamless steel pipe is
formed by processing high precision CNC machine tool, it guarantees the coaxial drum drum, high strength,
and good abrasion resistance
b.After the end flange mold, forming a flange, to ensure the perfect combination of drum device and
transmission system
Rope guide(if necessary by the design):
Rope guide is to ensure that the wire rope around the drum correctly and prevent important parts of wire
rope is wound into the grooves of adjacent error. It is made of special engineering
plastics, strong wear resistance, self-lubrication performance, leading technology,
advanced technology, with a high quality and inexpensive, do not need
maintenance. Steel wire rope and drum rope groove, greatly reducing the wear of
the steel wire rope guide, enhance the security items, prolonging the service life of
wire rope at the rate of 20%.
Wire rope:Steel wire core rope are foreign galvanized, eliminate the formation of
pre-stressed, high breaking strength (2160N/m m) and high flexibility, and has
good corrosion resistance; wire rope winding with parallel mode, has the smallest
tensile deformation, high safety coefficient. So it can reduce the high strength steel wire rope and stiff
resistance. The structure is using the line contact type bearing, interacts with a twist, can effectively avoid
the phenomenon of resistance, the wire rope are made of galvanized surface, corrosion resistant, so in the
high temperature conditions ,it do not have the liquid drop, and will not affect
the work of safety.
Sheaves： The p u l l e y is made of special materials, high
strength, advanced technology, applicable to all kinds of conditions, safe and
reliable, with high wear resistance, light weight, good cushioning effect, low
working noise, long service life, maintenance free, also prolongs the service
life of wire rope at the rate of 20%, and can reduce the weight of the whole
mechanism.
Hook Block : Hook carry on the implementation of the requirements of DIN
strictly, the custom mold forging high strength alloy steel hook, antifriction roller
bearing, pulley of the pulley is made of special material, with high wear
resistance, light weight, good cushioning effect, low working noise, maintenance
free, and hook group also extended the wire rope of 20% service life. Using the
latest patented technology to ensure the angle steel wire rope and pulley close to
0 °, the lateral wear pulley rim and the wire rope. The hook can rotate 360
degrees, the vertical direction can rotate 180 degrees, each angle convenient

8
 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

4.1.2 Trolley: traveling Mechanism

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

9
 general overhead crane maintenance guide manual

protection, higher levels of insulation level)

b. Running gear uses the professional brand SIEMENS etc., which is acknowledged as the European
standard. These gears is distinctive in its design practice high-ratio, high-torque, low-noise, high reliability,
maintenance-free. The body of the gearbox shall be forged by welding or casting.
c. The normally closed double safety brake disc brake, it has a high safety factor, non-asbestos,
reliable performance, high rate of closing,
automatic braking power, braking safety
and no vibration, little abrasion, wear gap
automatic adjusting.
Wheels:
Modularized design is adopted when
choosing wheels. Its high reliability and
wearing quality has been approved by a
long term indoor experiment and practice.
The wheel is made of 40Cr or 42CrMo steel
material, possessing excellent fatigue value,
shock resistance capacity and good low temperature impact ductility. The bearing adopts 40Cr heat refining,
possessing good low temperature impact ductility and outstanding harden-ability, preventing cracks。

4.1.3 Trolley: frame

Frame of trolley by running end beams and beams connected by high strength bolts, avoid the welding
deformation caused by small frame, the wheel rail gnawing phenomenon, prolong the service life of the
wheel and rail. The design and manufacture of crane must be compliant to the relevant stipulations of the
FEM 1.001 《Federation European de la Manutention》 structure the service life of elements and weld
reliability, safety is accurately calculated, through CNC lathes and other advanced equipment for precision
machining of steel, the structure of the assembly, beautiful. Welding each structures on operating table,
avoid distortion caused by welding
a.The carrier adopts the European concept of design, its short time production, long working life and
simple maintenance open up to customers the a great of advantages by using this standard. Based on
accurate calculation, the carrier’s box-type structure is made up with rectangular pipe welded with other 4
steel plates. The carrier adopts overall fabrication, final machine tooling ensures the precision of the
assembly. The rigidity is no less than 1/1000L, L is wheel center distance of carriers. Otherwise we adopt
linking carriers when crane’s capacity is bigger or special requirement for linking carriers exists. This kind
of carriers can diminish the pressure on tread to a half of the value on the tread of carriers of standard
double-girder cranes.
b.Standard beam, the alloy steel high strength welded by cutting, shaping, cutting surface are smooth
and beautiful. By using the method of optical calibration apparatus for measuring specific and machining
the parts surface, it can ensure the accuracy and parallelism is connected to ensure accuracy and smooth
running of the crane. After the completion of welding, shot penning, grade of Sa2.5, to eliminate welding
stress, epoxy zinc rich paint, long service life, the appearance of color can have users determine. With
mounting bolt hole end beam with drilling, the use of high strength bolt connection and end beam
combination, novel structure type, safety, and the lifting hoist assembly has a simple form.

10
 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.

4.2.1 The girder：

Use high quality steel plate and steel domestic from well-known manufacturers. material used material

11
 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.

4.2..2 End Truck :

The design of end beam give full consideration to the crane's working level, environment temperature,
bearing capacity building users, building space and transporting goods type, Advanced end beam
processing technology, uses the large-scale NC machine tools for machining small tolerances, Geometric
tolerance small, high-precision assembly, effectively avoid the deviation caused by the deviation of wheels,
factors such as the large span of the wheel gnawing rail, the wheel does not work at the same time. The end
beams with the function of light weight, strong rigidity, compact appearance.
a. The assembly accuracy wheel group and the end of the beam is guaranteed by the processing
precision, convenient replacement wheels, can realize maintenance simple and quick
b. For the important parts, their steel material shall be derusted by the means of pill spraying before
coating, and the derusting shall meet the grade of Sa21/2 ; and the rest members shall meet grade of Sa2 or
St2 (manual derusting).
c. The end beams set the bumpers for mechanical impact to prevent accidental impact，The bumper
usually is made from polyurethane JHQ-A or JHQ-C, this type of bumper is well shockproof, compressive,
corrosion-preventive and of minimum rebound. It can fully absorb collision energy, minimize the damage
to steel structures.

12
 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.

4.3 Walkway and Handrails :

There is safety, convenient repair platform set driven along the side of electric double beam bridge crane
(electric control box and channel, a cart running mechanism mounting platform above), let the staff safely
and smoothly get into the repair site, and can provide enough working space. In addition, where operation,
inspection is needed, ladders, platforms and walkways are provided for safe and reliable, relevant
dimensions according to the relevant provisions of the state standard
The height of handrail sonthe walking platform shall be 1200mm.Two crossbars with the upper distance of
400mm shall be installed.The bottom shall be installed with the protection board with the height no less
than100mm.Any part of the handrail shall be able to receive load of 1 kN with out permanent deformation.
Crane also equipped with power supply maintenance cage. The cage height is more than 1600mm and its

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

heat, the motors shall be placed out of the electrical cabinets.

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

13
 general overhead crane maintenance guide manual

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

supply in the cab (except lighting signal).

Cab used the end to side entry.

4.3 Long Travelling Mechanism

The crane with high performance traveling mechanism, 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. Crane operation were
respectively three in one transmission, wheels and other components. Crane driver were driven by 1/2,
according to the customer plant capacity is insufficient, also can take 4/8 or 2/8 drive mode, greatly reduce
the wheel pressure (25 tons and above the road with the double end beam special design of the connection
end beams, each side is provided with 4 wheels, effectively dispersed the wheel pressure, reduce vehicle
the bearing rail beam plant structure requirements).
Compact geared motor brake drive units with foreign brands,drive system operation mechanism for.
Respectively by the reducer, motor, brake, light weight, high transmission efficiency, energy saving, has a
larger starting and ultimate moment, double safety brake, braking, no vibration, through a standard
interface and simple assembly
a. The operation of the motor adopts squirrel cage type frequency conversion motor, inverter, step less
speed regulation, start with no impact, aluminum shell, fast heat dissipation, protection class IP54,
insulation class F, electrical sustained rate of 60%. (also available frequency conversion motor and
protective, higher insulation grade according to user requirements).
b. The gear with big transmission ratio transmission, Sealed gearbox housings are made of aluminum.
Good heat dissipation，Small volume，Light weight，Low noise，minimum of maintenance，no leakage。
c. Brake is a normally closed type double safety brake, with high safety factor, non-asbestos, reliable
performance, high rate, closing, automatic braking power, braking
safety and no vibration, little abrasion, wear gap automatic adjusting.

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.

14
 general overhead crane maintenance guide manual

4.4 Crane runway adopts DIN standard track

4.5 Method of Control

The control method of bridge crane is divided into ground control, remote control,and cabin control，the
user can choose the control mode according to the using environmental factors of the crane. When the crane
with two kinds of control mode, the crane is provided with a locking device, the user can only use one kind
of control mode operation of a crane, the prevention of accidents.
Pendant control station hanging in the crane through cable, Pendant control station of good quality, high
protection level.
The remote control transmitter completely adopts frequency wireless remote control operation, with strong
signal, the other lifting equipment signal without interference, far distance control, high protection level,
long service life are the features of our remote .

4.6 ELECTRICAL EQUIPMENT

The goal of electrical design is: to meet customer specifications and
functional requirements and service environment. This design will be based
on the standard and application experience, the design is according to the
requirements of the actual use. The related characteristics of the product such
as shock and vibration, wear resistance and safety have been tested. Series of
products and the standardization of parts can ensure quality standards for
high performance.
The key electric components with Schneider and other brand products,
product safety protection class IP55
The power supply voltage 415V/50HZ; 48V low voltage control
Inverter adopts YASKAWA, Schneider, Siemens etc.. Overload capacity is high, and it is not affected by
load limiting control of walking and lifting characteristics, frequency converter with variable speed
control, makes the motor output power can be fully utilized. Starting current by limiting, reducing motor
with gearbox torque, so as to protect any mechanical components (including crane, crane rail), load
transportation smooth, simple operation, fast debugging, can adapt to the harsh working environment.
It has the set of emergency stop switch, when there is an emergency situation,
it can quickly stop all movement mechanism.
The lack of protection error and phase the lack of protection
mechanism of crane have the structure of wrong and dangerous to avoid the
dangerous of wrong phase and phase lead
Line protection all lines have a short circuit or grounding caused by
over current protection, short-circuit or grounding line occurs, the
instantaneous protection device can quickly break the circuit
Motor protection t h e motor has the corresponding protection function,
protection mode is determined by the motor and its control method
Zero protection the transmission mechanism is provided with a crane
zero protection, operation if due to failure or loss of pressure to stop running, regain power, mechanism is

15
 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.

7 Main configuration list

content name manufacturer

Motor siemens

Gear’ siemens
1 Hoisting
brake zpmc

limit switch GG

16
 general overhead crane maintenance guide manual

wirerope BRIDON

Trolley travel （3 in 1）motor、reducer SIEMENS

2
mechanism limit switch Schneider/GG
Travelling
3 （3 in 1）motor、reducer SIEMENS
Mechanism
4 Bearing Travelling mechanism bearing SKF

5 Operating system remote control(key type) HBC

contactor Schneider /SIEMENS

6 Electrical system
frequency converter Schneider /SIEMENS

Section II Crane Installation

Chapter 1 Parts Lifting
1 Prepare work before hoisting
1.1 Environment
Notice the weather conditions before lifting, strong winds, heavy rain, high temperature and other
harsh weather conditions can not be lifted.
1.2 Check rails
Recheck the crane rail gauge, rail straightness, height difference and other technical conditions
meets the design requirements before lifting.
table of personnel required for lifting ( project manager, cable command, construction
personnel, driver, Emergency personnel, etc. ) , emergency plan, vehicle ( 50t truck crane for 1,
5t forklift for 2, etc.) etc..
1.3 lifting rigging and installation tools
1.3.1 eight 10t supporting leg lifting discharge buckle and four ¢32* 4m lifting wire rope
1.3.2 four 12.5t main girder lifting discharge buckle and four ¢36*4m lifting wire rope
1.3.3 sixteen 5t wind cable discharge buckle and sixteen ¢20*25m wire rope
1.3.4 3t four to eight manual hoist
1.35 four 10t lifting jack and 2 sets special installation tool

17
 general overhead crane maintenance guide manual

1.4 erection area

Reserve enough area for the crane parts transportation tools and truck crane. The area shall be
fenced to ensure the safety of irrelevant personel. Refer tofigure 1 for the require space above the
crane rail.
1.5 Capability of lifting area
The lifting area capability must be inspected before lifting to verify that it can carry crane
components, transport vehicles and truck crane. Pay attention to truck crane supporting leg
maximum load.

Figure 1 Requirements for lifting area of lifting a truck crane

18