Equipment Manual

HOISTING EQUIPMENGT

HOISTING EQUIPMENT

MANUAL

ABMC 10000 TPD CEMENT PRODUCTION LINE

Submitted by
CHINA NATIONAL BUILDING MATERIAL EQUIPMENT CORP., LTD

May, 2009

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Contents

1 Technical number………….……………………. 3

2 Working principle………………………………. 4

3 Technical data…………………...………………. 5

4 Installation………………………………………. 6

5 Commissioning & operation……………………. 11

6 Maintenance…………………..………………… 15

7 Lubrication………………...…………………… 21

8 Trouble shooting…………...…………………… 25

9 Drawings…………………...…………………… 33

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1 Technical number

表一

Section Type Technical No.

General use Overhead Crane 62/10t-15.3m 1011
20/5t-14.9m 1416

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2 Working principle

1 Main purpose

Electric Overhead Cranes are usually used to move materials or install and maintain equipments at factories,
power station, and storehouse and goods yard. According to requirement, the equipment can be divided into
following types:

2 Main Performance Data and Structure of Crane

Parameters show the crane work ability. The main parameters including lifting weight, lifting height,
span, working
The structure of overhead crane mainly includes bridge, crane traveling mechanism and trolley with
hoisting and traveling mechanism.
The bridge is composed of weld-box main girder, end girder platform and so on. Above the main
girder there is the steel track and there is the platform for installing the electric box and electric conductor
device, connecting with the outer flank of the two main girders.
Bridge traveling mechanism use independent drive. There are four or eight wheels (maybe more) in
the bridge. And the wheels and angle bearing box (45°structure bearing box) are installed in the end girder
or equalizing truck.
Trolley includes hoisting mechanism with limit safety switch and trolley traveling mechanism.
Power supply of trolley is suspension electric conduction and the track of the trolley is I-shaped steel
track or channel steel track with involute margins.

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3 Technical data
3.1 Temperatures on Site
The Factory site is located at subtropics. The winter is from November to May of next
year .The hottest season is from July to August.
Temperatures：
Yearly Average： 37℃
Average of the hottest month： Max 46℃ (July/Aug)
Average of the coldest month： 7℃ (January)
Max. Temperature considered for design： 50℃.
3.2 Technical data
1011 1416

Loading capacity（t） 62/10 20/5

Fly-past(m） 15 14.9

Lifting height（m） 15.3 13

Main lifting speed（m/min） 4.48 7.2

Secondary lifting speed（m/ming） 8.5 9.23

Crab running speed（m/ming） 22.6 19.8

Running speed（m/min） 35.8 31.6

Wheel-pressure (max.)（KN） 422 178

Lifting motor power（KW) 52 26

Secondary lifting motor power（KW) 17 9

Crab wheeling motor power（KW） 8.5 2.5

Wheeling motor power（kw） 2x9 2x2.5

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4 Installation

4.1 preparation for erection and notes

Before the erection, erection persons with the deputies of Erection Company and manufacture should
open the box to check the number of the crane, components and spare parts that listed on the packing list
and attached documents, to see if there is any shortage or damage, then read the erection drawing and
technology requirement carefully to ensure the detailed erection procedure.
While unloading, especially avoid wresting, bending or striking to the crane. While lifting the crane,
two lifting points is necessary and there must be underlay in the lifting point. If there is any shortage or
damage to the crane, the adjustment or reparation must be done before erection. And any damage to metal
structure part must be corrected on the floor. Erection is not allowed without doing that.
4.2 erection of bridge
Bridge is the main body of crane. There is strict technology requirement and measure method to erect
and assembly the bridge.
4.2.1 method and requirement for erection
A） Requirement for Crane erection: the crane lifting weight under 75t will be assembled on the floor.
The crane will be putted on the shelves built for this machine. If steel track can be put on the shelves, the
crane wheels can be put on the track. If not, the shelves should be put under the bottom flange plate near
two ends of main girder. No matter which method is used, the gradienter must be used.
B） quality requirement
Support point on the bridge should be under the wheel. According to the regulation of 2-1table, check
the erection quality item by item.
4.3 erection of trolley
Manufacture has assembled and finished commission to middle and small tonnage trolley before
delivery. Only do some checks and adjustment, can install the trolley to bridge. To big tonnage trolley
needed disassembly, according to detailed drawing to reassembly, then lift to the bridge.
4.4 traveling mechanism of Crane
Crane traveling mechanism has been assembled to the bridge and has accepted commission to
ensure gain acceptable quality. Crane traveling mechanism should accord to following requirement to
check after finishing crane assembly.
A） Check benchmark: put the outer flank of driving wheel as benchmark, while checking the
traveling mechanism.

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B） The level deflexion of end surface of each wheel is less than 1/1000L (L means measure length).
C） measure the span
D） Rectify wheel: parallel, uprightness, level height difference between several wheels
a. Parallel: Draw two parallel 0.6～1.0mm nylon lines under the wheels to see if the parallel lines
equally contact with the four wheels. If it is, it tell us that the four wheels are parallel and on the same lines.
If there is certain clearance, firstly we can ensure whether the error is in stated scope. If not, we should
adjust it through loosening the bolts of fixed angle bearing box.
b. Uprightness: Deflexion of wheel in vertical direction should be less than 1/400L (L means the
measures length)
c. Level height difference between several wheels under same end girder: less than 2mm while there
is two wheels, less than 3mm while there is three wheels or more.
table 2-1
No. Item Allowable Deviation（mm）

Difference between driving wheel span and driven wheel

1 Span Deviation
span is less than 5mm

2 Beam camber after assembly (0.9/1000～1.4/1000)S

3 Diagonal deviation of bridge ≤5

Symmetry box girder: f≤1/2000S
Level lateral flexure of main others
4 girder (after the walkway and end
girder have been installed) s≤19.5m，f≤5
s≥19.5m，f≤8
Symmetry box girder in the end of span：±2
5 Trolley gauge deviation in the middle part of span
：s≤19.5m，+5
+1
S＞19.5m，+7
+1
other girder：±3
6 Height difference of trolley track
K≤2m，△h≤3
on the same floor
2m≤K≤6.6m
△h≤0.0015K
K＞6.6m △h≤10

4.5 Principal of electric control

The circuit consists of main circuit of each system, control circuit, light signal circuit and protective
circuit.

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(1) Light signal circuit and protective circuit

A. System short circuit use breaker to protect and control circuit and light signal circuit use breaker or
fuse.
B. Except some special requirement, main contractor use running contractor.
C. The wound rotor motor is protected by current circuit breaker.
D. The protect cabinet matched with cam control, using for kinds of protection system.
E. There are key switch, startup button, stop button and there is urgency stop button for cutting the
breaker and main contact in urgency situation.
（2） electric control
For 5-125/32t electric double-girder crane, please see the attached electric drawing to finish the
electric control of crane.
4.6 Installation and adjustment
（1）. Installation of electric equipment
● All installation and wiring should be done according to the drawing
● In order to well know the problem ，check all electrical parts drawing and technology condition
before installation and be familiar with the control principal.
● Check all electrical parts before installation, to ensure that all parts are no defect, running well, no
lock or loosen phenomena. Model and specification of electric parts should accord with the drawing. Any
adjustment should also accord with the drawing.
● Check the insulation condition of motor, brake, carbon brush, contactor, and 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. And carbon brush and slip ring should completely contact.
● Fill the hydraulic brake wit hydraulic oil.
● Check the pressure between contact points of control, contractor and relay.
● The joystick shall move flexible.
● Installation of the electric equipment and parts should accord with the general drawing of electric
and other erection drawing.
● The control cabinet and resistor and other heavier equipment on the walkway supposed to be put
on the main frame. And the resistor should be parallel to main girder in order to reduce shake and benefit
for aeration.
● The max. gradient of control panel 5°, the space in front of the panel should be more than
500mm(600mm recommended);

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● 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.
● The working temperature is -25℃~50℃;

● 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 cranes 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 should also earth.
The earth wires can be flat steel with section not smaller than 75 square millimeters, 10square
millimeter copper wire or 30 millimeters round steel. 4×40 millimeter or above galvanized flat steel should

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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

Item QR1Y QR2Y QR3Y

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

Item 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

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5 Commissioning and operation
For the newly erected crane, it must have the commissioning and test. It can be done
usually.
5.1 preparation and inspection before testing
In order to operate the crane safely and smoothly, carefully inspection must be done before the test,
making fully preparation for it.
Turn done the power, checking whether all the connections are fastened
B) Checking whether all the traveling mechanism is precise and flexible, any inflection of the steel
structure, and the winding of wire ropes in wheels and winding drum.
C) Check the circuits, electric equipment and insulated resistance with Megohm device. Make sure
that they are eligible.
D) Turn down the engineering circuit; check the operating circuit and all the transmission parts.
E) Add lubrication to the lubrication points, such as reducer, brake, hydraulic bumper.
F) Pay more attention to the magnetic iron, limit switch, safety switch and emergence switch.
G) Clear up all the obstacles on the crane and long traveling rail.
H) Prepare the loading test items, such as steel ingot, billet, bar steel, pig iron or mass rough cast.
Weigh them carefully and pack them safely.
5.2 Test without load
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, check each traveling mechanism;
D) Moving speed of cable should be coordinate with the traveling mechanism.
E) Check each switch, limit switch, door switch etc, check if everything is in condition;
5.3 test with load
test with dead weight
The purpose of test with dead weight is checking the capacity of crane and all parts
Firstly, 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

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should be 0.75/1000~1.5/1000 of span. At last, hoist rated load, lift 1000mm up from the ground, check the
deflection, it shouldn’t exceed D/700 of span;
B) The purpose of test with moving weight is checking the braking ability of crane parts
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.
5.4 Crane operation notice
（1）technical safety rules
A） do abide by the following safety technical rules
Ⅰ、 To operate the crane, must having professional workers
Ⅱ、 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
Ⅲ、 During the operating time, no person is allowed on the working spot except the control cabin.
Ⅳ、 Must keep power off While doing the inspection and reparation.
Ⅴ、 While crane running without load, the height of the hook from the floor is 2.5 meters (as over the
height of a person).
Ⅵ、 While crane operating loaded, the weight traveling over the head of the person is strictly
forbidden.
Ⅶ、 While crane operating loaded, the height from the lowest point of the weight to the highest point
of barrier is 0.5 meters at least.
Ⅷ、 Using the hook to deliver and hoist person is strictly forbidden
Ⅸ、 Any way to drop goods from crane is forbidden.
Ⅹ、 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.
Ⅺ、 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.
Ⅻ、 Store the flammable good on the crane is not allowed and good fireproofing work is necessary.
ⅤⅢ、 With the crane working in the open air, stop work while the wind power is larger than six
degree.
ⅩⅣ、 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.
ⅩⅤ、 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

Ⅰ、 Only the electric professionals can duty the electric repair work.
Ⅱ、 The pocketed spotlight whose voltage is below 36V should be used when doing repair work.
Ⅲ、 While doing some work regarding electric, the worker must wear rubber gloves, rubber shoes,
and use tools with insulated handle. 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

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electricity should be enclosed with barrier

Ⅳ、 The metal shell of the electromotor and electrical equipment and other metal parts should be
grounding
（2）duty of driver

A） Be Familiar with the function, method of operation and maintenance rules.

B） Strictly abide by the safety technical rules.
C） Following step should be done before the crane starting to work
Ⅰ、 Check condition of power supply, the crane will not be started when the voltage of power supply
is under 90% of the rated value
Ⅱ、 Check condition of every main parts to ensure the connecting and running condition and adjust
separate mechanism
Ⅲ、 Check if there are any tools or other good left behind, prevent from bodily injury or damage to
equipment
Ⅳ、 Oiling the lubricating point according to the rules.
Ⅴ、 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
operating, keep the bridge and rail clean all the time.
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, 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, turning 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

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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 not allowed to apart from
control cabin.
O） Lift the hook on high position, controller is on zero bit and the main switch is turned off after
finishing the work.
P） Turn off the main switch and electric lock after finishing the work.
Q） Cleaning and re-checking after finishing work, preparing for the next work.
R） When handing over the work, get the note book ready to the next driver, and any trouble be found
must be notified to related department and the next driver
S） When the driver departs from the crane, the crane must be stopped on the given points and be
fastened.

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6 Maintenance

In order to make crane working well and postpone its using time, must examine the crane
frequently.
6.1 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:
Table 6-1 Inspection of the steel structure
Item content determinant Standard

distortion Check the main girder. deflection ≤ 1/700 of span

Main
girder Check metal parts have any crack, cast,
No crack, loose, cast,
structure distinct distortion, craze
distinct distortion, craze or cauterization
or cauterization

others Check surface of metal parts No paint flaking away, no rustiness

Trolle
Check there is any crack, cast, distinct
frame No crack, loose, cast, distinct
structure distortion, craze
distortion, craze or cauterization
or cauterization
Connection between
Fastened and reliable
cabin and main girder

6.2 Inspection of the mechanism

A） The examination of lifting mechanisms: check items refer to table 5-2. the examination for the
same parts in lifting and traveling mechanisms, such as motor, couplings, reducer, shaft and bearing, etc,
can refer to the relevant contents and standards in table 5-2
Table 6-2
Item Standard

Brake Brake Enough oil, no leaking, no crack

Drum No crack, loose, cast, distinct distortion, craze or

group cauterization

Drum group
Shaft and No crack, loose, cast, distinct distortion, craze or
bearing cauterization, well lubricated

No crack, loose, cast, distinct distortion, craze or

Pulley group Pulley
cauterization

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Shaft and No crack, loose, cast, distinct distortion, craze or

bearing cauterization, well lubricated

structure Two or more safe loop

wirerope less than 10% cores of each lay break, the actual
condition
diameter is larger than 93% of rated diameter

Assembly No rubbing with other things, no distinct abrasion

No crack, loose, cast, distinct distortion, craze or

hook cauterization, well lubricated

hoist No crack, loose, cast, distinct distortion, craze or

Hook group board, cauterization, well lubricated
connections
No crack, loose, cast, distinct distortion, craze or
grab cauterization, well lubricated

B）
Table 6—3 Maintenance of control system and electrical parts

check item standard

motor Fixing base without crack and loose.

Key and key Check the key without loose, out of slot Without loose, crack and
slot and damage. damage.
Without obvious radial
Transmission move couplings without radial jumping.
jumping and moving.
gear
can not be beyond the reject
couplings Rubber spring check the damage.
limitation.
Check the condition of lubrication as proper oil without abnormal
gear coupling
well the oil. sound.
bolts and
Check bolts and nuts, whether there is any without loose or coming off.
nuts
loose and coming off.
arrester brake check the condition of the brake.
Work well
feet-push check the space normal or not and the
proper space, without loose
brake lever system loose or not.
Check the liquid surface
Check the function, damage and leakage. The proper oil, without
Hydraulic
Check whether there is the lever bending obvious bend and leakage.
arrester
or not, the condition of the oil.
Electromagnetic
Check electromagnetic without abnormal sound.
arrester

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Check fuel and oil spills, connecting with the

fastener installation Inspection of hydraulic
components and disk condition, and none proper oil.
Disk brake
other than normal wear and tear injury. without damage.

without obvious damage,

Disk brake Check the condition of disk brake.
loose and sound
Brake wheel without loose, palling and
check the installment of brake wheels,
and brake damage. The space should
and whether there is any damage.
holding follow the standard.
check any abnormal in brake torque
traveling and
system, as well as any crack, bend and Proper regulator, without
brake torque
damage in stick, pin and bolts. crack, deformation and wear.
check whether there is any loose among
without loose.
Bolts and pin screw, nuts and pin.

check the crack, deformation and Without crack, obvious

gears
damage, as well as the quality of the oil. deformation and damage,
proper oil without pollution.
Check any abnormal sound, heat and
reducer without abnormal sound,
gear vibration, without damage in gear surface
heat, lubrication
and the condition of lubrication.
without crack, obvious
gear cover check the crack, damage and any loose.
deformation and damage.
moving shaft,
without damage, abnormal
core shaft and
shaft check wearing, loose and crack. sound and heat, and good
transmission
lubrication
shaft
without damage, abnormal
rolling check the crack, damage and the
sound and heat, and good
bearing condition of lubrication.
lubrication
Bearing without obvious damage,
check the damage， if there any burning
slide bearing burning and obvious
and heat.
temperature change
check the crack, damage and without deformation and
flange
deformation. damage.
check the crack, damage and without deformation and
wheel tread
cartwheel deformation damage.
and axle check the crack, damage and the
inside normal
condition of lubrication.
wheel and
check the frication and precision.
end carriage Without frication and damage.

C) Check crane and trolley rails for 2-4 times one year. And make all the structure work well. See
table 5—4。
Table 6—4 rail item, content and standard
Check item Check content Determinant standard
Check crack, distortion, or any No crack, evidence cave in,
rail
runway damaged on side face. distortion or seriously damaged.

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Check anchor bolts/nuts lose or fall

Rail anchor bolts/nuts No lose or fall off
off
connecting panel and
Check all bolts/nuts loss or fall off, No lose or moving,bug or fall
pads
connecting panel moving or fall off off
end stoppers, and
Check any damage or join missing; No damage or join missing,
pads
setting loss or fall off No loss or fall
化 Check rail tie-in damaged or
Rail tie-in No in evidence join damaged or
space between is not fitting space between not fitting
Rail welding and
Check welding line crack No crack or craze
build on

geometry dimension Check warp of gauge, center

no warp over ordain range
error line,

6.3 maintenance of control system and electrical system

A） power supply and control system
The item refer to the table 5.5

Table 6-5 crane electrical system and content as well as standard

Check item Check content Determinant
standard
Check insulated no abnormal
resistor resistance: any heating
glow
check lubrication, any good lubrication
bearing
noise and no noise
any change in color, any no obvious change
motor
Sliding ring crack, any loose color, no scar, crack
connection and loose,
any abrasion and loose; No obvious abrasion,
press or carbon power, loose, proper press,
Brush and lead
any loose in rotating no carbon power, no
shaft spark.
Collector Sliding Any inflection, No obvious
device wire and Sliding wire, abrasion, damage, the inflection, abrasion,
pulley rail electricity track connection of sliding damage, good
wire and sliding block. connection. No loose
No abrasion,
Any abrasion and
inflection, enough
inflection, check
Hull, cover, mantle gap between sliding
protection
wire.

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check insulated Reliable connection

Insulated collector collector between cable and
hull
isolator any loose, break, or no loose, break
dirty and dirt
no obvious
any abrasion, check the
collector mechanism abrasion, damage,
lubrication
good lubricaion
any inflection, erosion, no inflection, no
spring
abrasion erosion, abrasion
Connection and Check any break of wire, No break, damage,
isolation any dirt or damage dirt
tie-in bolt any loose no loose
cable insulated layer any abrasion no abrasion
joint any loose no loose
cable and Any inflection, No inflection,
direction-guider distortion, abrasion. distortion, abrasion.
A） maintenance of electricity equipment
Establish the regulation of electricity equipment. All the following regulations apply for the common
condition of crane.
Daily maintenance is done by crane drivers when shift.
An elimination electrical equipment place dust, the sludge and the oil class and so on, with the hand
survey electric motor, the electro-magnet, the controller contact, the resistor and so on gives off heat the
situation, whether there is inspects the bearing oil leak phenomenon, the main equipment splice is whether
close, when opens the observation or the outer covering, should prevent the dust, the iron filings and so on
invade in the winding. Will observe the obtained each kind of peculiar circumstance to record.
Ten-day maintenance is done electrician or crane driver.
Clean the dust, dirt and oil of the electricity equipments, check any abrasion of brush frame, carbon
brush, any abnormal noise from motor, electromagnetic iron, relay and electro switch, check and repair
controller and switch.
Annual maintenance is done by electrician.
Disassembles each item of electrical equipment to carry on the cleaning up, overhauls each item of
equipment the support, cleans the electric motor the rolling bearing and exchanges in addition grease,
surveys the stator with the crevice, when discovery non-uniformity needs to replace the rolling bearing.
Survey dielectric resistance, when necessity carries on dryly, each kind of problem repairs when the year
should completely fix, is unable the part which repairs to be supposed to replace, the year repairs or the
overhaul scope decided by each item of equipment actual attrition and the obsolete degree. Must have on
the hoist crane moreover only permits with the doing-like fire extinguisher.

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HOISTING EQUIPMENGT
Most commonly used is the carbon tetrachloride fire extinguisher, does not permit the use foam fire
extinguisher, does the sand only to be able to use for to suppress the wire the fire, but cannot use for to
suppress the electric motor the fire. When has the fire, first should try the dump, this time or protects on the
plate with the emergency switch the knife switch to begin the dump. When protects in front of the plate the
wire fire, should shutoff on the lead the knife switch. Is going too far the hoist crane must pass through
clear scratches. Dryly with the inspection all electrical equipment and the electrical wiring, repair qualified
later will be able again to use.

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 Equipment Manual
HOISTING EQUIPMENGT

7 Lubrication of crane

Lubrication Schedule for ABMC

Technical No. 1011
Equipment Name Bridge Crane 62/10t-15.3m
Replacement
Lubricant Name
Period
Part No. of Filling Initial Supplement Supplement
Item Remark
Description point(s) Summer season Winter season method Filling period Quantity
Initial Standard
>10℃ <10℃

1,Heating
lubrication to
Calcium-sodium Calcium-sodium Inspect and 50-100
1 Steel wire 1 by hand 15-30 days
base grease base grease complement ℃then
apply.2 apply
without
According to
LICKC100、 LICKC100、
Full Inspect and three reducer
2 Reducer L-CKC150、 L-CKC150、 Oil cup One week One year
felling complement month operation
L-CKC220 L-CKC220 menu

Opening Rear grease Rear grease Full Inspect and 3

3 by hand 15days Half year
type gear (HG1-26-73) (HG1-26-73) felling complement months

General General
Purpose Lithium Purpose Lithium Full Inspect and One
4 Gear wheel by hand One month One year
Lubricating Grease Lubricating Grease felling complement month
GB7624-1994 GB7624-1994

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General General
Roller Purpose Lithium Purpose Lithium Full Inspect and 3-6
5 by hand 3-6 months One year
axletree Lubricating Grease Lubricating Grease felling complement months
GB7624-1994 GB7624-1994
General General take the
Sliding Purpose Lithium Purpose Lithium Full Inspect and 3-6 circumstances
6 by hand 3-6 months One year
bearing Lubricating Grease Lubricating Grease felling complement months into
GB7624-1994 GB7624-1994 consideration
General General
Drum fluted Purpose Lithium Purpose Lithium Full Inspect and Apply when
7 by hand One month One year
disc Lubricating Grease Lubricating Grease felling complement heavy repair
GB7624-1994 GB7624-1994

（SH/T0378-1992） （SH/T0378-1992）
Full Inspect and Apply when
8 Motor Purpose Lithium Purpose Lithium by hand One month One year
felling complement heavy repair
Lubricating Grease Lubricating Grease
No 3 No 3
General General
Purpose Lithium Purpose Lithium Full Inspect and One
9 Break point by hand One month One year
Lubricating Grease Lubricating Grease felling complement month
GB7624-1994 GB7624-1994

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 Equipment Manual
HOISTING EQUIPMENGT

Lubrication Schedule for ABMC

Technical No. 1416
Equipment Name Elevator 62/10t-14.9m
Replacement
Lubricant Name
Part No. of Filling Initial Supplement Supplement Period
Item Remark
Description point(s) Summer season Winter season <10 method Filling period Quantity
Initial Standard
>10℃ ℃
1,Heating
lubrication to
Calcium-sodium Calcium-sodium Inspect and
1 Steel wire 1 by hand 15-30 days 50-100 ℃
base grease base grease complement
then apply.2
apply without
According to
LICKC100、 LICKC100、
Full Inspect and three reducer
2 Reducer L-CKC150、 L-CKC150、 Oil cup One week One year
felling complement month operation
L-CKC220 L-CKC220 menu
Opening Rear grease Rear grease Full Inspect and 3
3 by hand 15days Half year
type gear (HG1-26-73) (HG1-26-73) felling complement months
General General
Purpose Lithium Purpose Lithium Full Inspect and One
4 Gear wheel by hand One month One year
Lubricating Grease Lubricating Grease felling complement month
GB7624-1994 GB7624-1994
General General
Roller Purpose Lithium Purpose Lithium Full Inspect and 3-6
5 by hand 3-6 months One year
axletree Lubricating Grease Lubricating Grease felling complement months
GB7624-1994 GB7624-1994
General General take the
Sliding Purpose Lithium Purpose Lithium Full Inspect and 3-6 circumstances
6 by hand 3-6 months One year
bearing Lubricating Grease Lubricating Grease felling complement months into
GB7624-1994 GB7624-1994 consideration

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HOISTING EQUIPMENGT
General General
Drum fluted Purpose Lithium Purpose Lithium Full Inspect and Apply when
7 by hand One month One year
disc Lubricating Grease Lubricating Grease felling complement heavy repair
GB7624-1994 GB7624-1994

（SH/T0378-1992） （SH/T0378-1992）
Full Inspect and Apply when
8 Motor Purpose Lithium Purpose Lithium by hand One month One year
felling complement heavy repair
Lubricating Grease Lubricating Grease
No 3 No 3
General General
Purpose Lithium Purpose Lithium Full Inspect and One
9 Break point by hand One month One year
Lubricating Grease Lubricating Grease felling complement month
GB7624-1994 GB7624-1994

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 Equipment Manual
HOISTING EQUIPMENT

8 Trouble shooting
While Lifting equipment operating, Machine parts、electric control and hydraulic pressure system
parts would inevitably have abrasion or damaged,and it’s conduce malfunction, the causation of malfunction
possibility not *******.
⑴
Table 8.1 metel structure faults
faults reasons methods
malfunction reason Obviate method
Breadth is 0.1mm or under crack,use grinder grind it
Under-part panel and welding.big crack drill ￠8 hole at each end of the
or cover board Long overload use. crack and grind the crack between the holds then
wear out crack. welding.
Under-part panel
or cover board Fiery redress,remove distortion, strictly prohibit
Overload use.
wavilness overloading operation.
distortion
be caused by working
main girder side stress pile up,
Fiery redress,remove distortion.
bend distortion. transportation or
storage.

be caused by girder
Girder go do frame stress, distortion Redress and remove distortion.the pin up use trough
down. or transportation or steel.
storage.

⑵ faults and Obviate method (table 8-2 . table 8-3. table 8-4)
Table 8.2
parts Obviate method
malfunction Reason and results
1. crack 1.overload 1.replace
2. abrasion 2. hook easy to break off, 2.replace
Foundry 3. Permanent distortion causes accident 3.replace at once
hook 3.Long time overload
1.hook inflection 1.Long time overload 1. replace
2.crack 2.Overtime overload hook 2.replace
Plank 3.abrasion damage 3.replace
hook 4.abrasion 3.hook break off 4.replace
4. dangler break off 5.replace
5. bad load

wirerope abrasion break off Replace wirerope

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1.Asymmetrical abrasion 1.improper assembly, rope 1.Replace when wall abrasion
2.Pulley doesn’t turn doesn’t fully fi more than 10%,or radial abrasion
3.Loose, deflexion 2.Damage on shaft or more than 20%
4.Crack bearing 2.Replace shaft and bearing,
pulley
3.Fastener loose, rope jump reinforce lubrication
out of groove 3.Fasten all fastener, check drum
4.Damage on pulley groove
4．replace
1.crack 1.drum crack 1.replace drum
2. drum abrasion 2.Shaft broken, lifting item 2.Stop using, check and repair
drum 3.15%~20% falls down 3.replace drum
15%~20% abrasion of drum 3.Easy to break, wire rope
groove winding out of order
1.gear tooth break 1.Impact and vibration 1.replace gear
2.15%~20% gear abrasion destroy the transmission 2.replace gear
reach 15%-20% thickness of 2.exceeding use and proper 3. repair
gear installation cause vibration 4.repair
3. crack in gear and abnormal noise 5.replace
gear
4.groove damage 3. gear damage
5. the area of flake off 4. falling of lifting item
reaches 30%, the depth 5.exceeding use, bad heat
reaches 10%, the abrasion treatment
reaches 80%
1.crack 1. bad quality 1.replace
2.0.5mm/nCurving 0.5mm/n 2.shaft neck abrasion, cause 2.replace or rectify
shaft
3.groove damage vibration 3.replace lifting and traveling
3. no transmission mechanism
1.crack 1.abrasion 1.replace
2.abrasion 2.Wheel gnawing, crane 2.replace double
3.abrasion reach 15% decline, vibration 3.replace
wheel
thickness of wheel 3. wheel damage 4.replace
4.Wheel edge abrasion reach 4.run off rail due to crane
50% thickness of wheel declining, wheel gnawing
1.Push bar Crack 1.brake fail 1.replace
2.spring crack 2.brake fail 2.eplace
Brake
3. 3. brake fail 3.replace
parts
4. 4.slip 4.replace
5. 5.in braking 5.replace coat
1.crack 1.coupling damage 1.change
2.bolt abrasion 2.Vibration when starting 2.replace parts, weld the
3.gear abrasion and braking, bolt break, fall traveling mechanism
4. key inflection down of lifting item 3.replace
coupling 5.Rubber ring abrasion 3.Lack of lubrication, heavy 4. replace
duty, coupling damage 5.replace abrasion parts
4.Off key, no transmission
5.Vibration when starting
and braking
1.overheat 1.No oil or over lubricated 1.i ， Replace bearing, check
2.Abnormal noise 2.Bearing smeary lubrication condition
Rolling 3.Metal milling noise 3.Lack of oil 2.Clean bearing
bearing 4.Impact noise 4.Damage to bearing 3.Add oil
4.replace

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HOISTING EQUIPMENT
1.Bearing deflected, , lack 1.reasonable fasten
of oil or oil not qualified 2.adjust gap
sliding 2.over pressed 3.add oil
over heating.
bearing 3.lack of oil 4.change proper oil
4.oil not qualified

Table 8.3

Faults malfunction Reasons reason Methods Obviate method

1.Chain is blocked 1.check the chain, lubricate
2.Braking wheel and shoe smeary 2.Clean the smeay
3.Magnetic moving distance too 3.Adjust brake
short 4.Replace shoe
4.Braking wheel and shoe 5.Replace main spring or fasten
Can’t brake abrasion nut
5.Main spring loose or damage 6.Fasten nut
6.Fasten nut loose or push bar 7.inspect the electric part of push
loose bar.
7.push bar can not rotate
smoothly

1.Magnetic burn 1.Replace

2.Cable loose 2.reconnect
3.Shoe block on braking wheel 3.Clean with kerosene
4. Gemel stock 4.Adjust it
5.Main spring over pressed 5.Adjust main spring
6.Push bar inflected 6.Adjust or replace push bar
brake Brake can’t open
7.Wrong oil 7.Change oil according to
8.Wheel stock working condition
9.85% lower than the rated 8.Adjust push bar and check the
voltage. Not enough magnet electric part
9.Find out the reason, eliminate
the obstacle
1.Shoe can’t fully disengage 1.Adjust clearance
braking wheel 2.Adjust clearance
Break overheat, shoe 2.Asymmetrical distance from 3.Replace or repair the spring
burnt and abrasion shoe to braking wheel 4.Turning the surface of brake
3.Supporting spring damage
4.Braking wheel tread not smooth
Braking torque not 1.Fasten nut loose 1.Fasten nut
steady 2.Screw damage 2.Replace
1.Main spring over pressed 1.Adjust main spring
Magnetic overheat,
2.Push bar stock 2.Find out the reason and
abnormal noise
lubricate
Gap of Gag bit and iron core Reinstalled
Seasonal libration distance too big.
Reducer Reinstalled or replace gear
strong grating, vibration 1.Gap of Transmission gears too 1、2replace the gear
of brake, noise of small, non-parallel gears, sharp
machine cover gears
Knocks of gear 2. rough working face of gear
joggling, vibration of Defectiveness of gear working
machine cover face.

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1.Bearing damage 1、2replace bearings
2.Shaft stock 3.check and adjust gears
Bearing overheat
3.Gear abrasion 4.replace oil
4.Lack of oil
1.No longer hermetic 1. replace oil seals
2.box inflected 2.check box, replace it when
Leak of oil 3.Some plane not flat heavy damaged
4.Connection bolt loose 3. flat the plane
4.fasten bolt
1.Connection bolt loose 1.adjust bolt
Gearbox libration on
2.Improper installation 2.adjust
base
3.Base damage 3. fasten base, make rigid
Gearbox overheat Too much oil adjust the oil
1. short diameter of wheel and 1.Replace wire ropes. Use bigger
drum wheel or drum
2.rope unsuitable to drum 2.replace proper wheel and drum
wire rope abrasion and –ark 3.clean, lubricate
Wirerope
damage 3.smeary or lack of lubrication 4.adjust
wheel
system 4.Lifting limit grind the rope
5. groove not smooth
Some wheel can not Lack of oil, smeary or rusty lubricate and clean
rotate

Table 8.4
trouble Possible reason solution
1. 1.Measure, machining or replace
Different diameter of two main wheel
wheel 2.Bigger the diameter of small
crane traveling

2.Main wheel do not touch the rail wheel

Bridge deflection, overall 3.check and eliminate the decline
gnawing rail 3. improper axes 4.improve
4. inflection of steel structure 5. adjust rail
5.bad quality of rail installation 6.clean dirty and frost
6.rail top smeary or frost
1.smeary 1.clean
2. odds in wheel pressure 2.adjust pressure
trolley traveling

3.violent start or brake 3. mend start method, use winding

slippery motor

1. main wheel hang in the air 1.adjust

crane sway 2. gnawing rail 2.solve gnawing

（3）overhead crane electrical parts’ faults as well as settlement

Table 8.5 overhead crane electrical parts’ faults as well as settlement
name reason solution

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1.Overload due to heavy JC% 1.Lower the load, replace
2.working in low voltage proper motor
3. improper motor 2.lower the rated voltage, stop
Whole motor 4.Changed the parameter after working.
overheat inspection 3. use proper motor
4.Maintenance, keep the
designed parameter
Short of stator eliminate the short, coated
part of Stator the repaired part with
overheat insulated lacquer
1. connection fault 1.Check and eliminate the
Winding part of
2. short with the cover fault
stator overheat
2.repair the windings
1.Winding End, neutral or 1.detecting welding and
indirect access to undesirable troubleshoot.
parallel windings 2.detecting wiring point
rotor overheat, stator
2.Winding and slip rings access 3.deteting brush
heavy current
to undesirable 4.detecting and repairing，
impact, motor can
3.Brush Apparatus Department replace
not reach full speed have access to undesirable
with rated load 4.Rotor circuit has access to
undesirable Department

1.Motor reducer shaft axis and 1.Re-installation of lines

Motor vibration different heart 2.Replacement
Alternating when working 2.Bearing damage and wear 3.Overhaul
current motor 3.Rotor deformation
1. stator wrong position 1.Check connection and
2. stator impact rectify
motor makes 3.bearing abrasion 2.check stator and repair
abnormal noise 4.groove wedge expands 3.replace bearing
4.Saw off expanded wedge or
replace
rotating speed 1.short on rotor 1.eliminate grounding
becomes slower with 2.rotor loop grounding 2. check loop, eliminate short
load
stator rubs with the 1.Short on bearing connection 1. replace bearing
rotor when motor 2.improper winding 2.check loop
working
1. not good grinded brush 1. grind brush
2.Brush loose 2.Machine the ring, smooth
3.Brush and ring smeary the face
4.Ring face not flat, brush jump 3.
5.Low pressure Clean with spirit
Spark on motor 6.Wrong brush 4. turning and polishing slide
carbon brush 7.Asymmetric current ring
5.（18~20KPa）Adjust pressure
to 18~20kPa
6.replace
7.check and rectify brush
slide ring open
dirty slide ring and brush clean
circuit

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HOISTING EQUIPMENT
1. overload 1. adjust spring
2.oving part and stationary part 2. eliminate gap
loop overheat
can not touch 3.Replace loop or change
3. improper voltage connection way
1. electromagnetic iron overload 1.adjust spring
Electromagnetic Big noise when 2.some dirt is on magnetic-way 2.remove dirt
Iron working 3.magnetic system runout 3.adjust machanism
1.electromagnetic iron overload 1、2Adjust main spring
Can not over come 2. bigger spring 3. suspend working
spring action 3.low voltage

1.loop overload 1. reduce pressure

loop heating 2.moving part and stationary 2. eliminate decline, block,
part can not touch dirty or replace loop
1. loop overload 1.Reduce contact pressure
Bigger noise of 2.Loop dirty 2.clean loop
contactor 3.block in automatic adjusting 3.eliminate the block
system
contactor overheat 1.Low contact pressure 1. adjust pressure
or burnt 2. smeary contactor 2.check and replace
1.knife switch open, emergency 1、2close switch
switch open 2、3zero adjustment
2.Door switch open 3、4Check and replace fuse
Main contactor can
3.No zero adjustment to
Contactor and not switch on 4、5Check voltage
controller
relay
4. Control circuit breaker burnt
5. No current
1.Low contact pressure 1. Adjust pressure
2.burnt contactor point 2.replace or file the contactor
3.smeary contactor point
Power-off protection 4.Overloaded causes heavy 3. clean
happens frequently electricity 4. reduce load
5. unparallel slide-wire, 5.Repair rail or tunnel slide
collector and slide-wire do not wire
touch well
1.Gap of polar fronts too big 1. shorten gap of polar front
Slow suction
2.mechanical boarding project 2.put the item upright
1. push bar tuck 1. eliminate the tuck
2. 85% lower than the rated 2. raise the voltage
voltage 3.Adjust the delaying relay
3. delaying relay delay too short t≈0.5s
Hydraulic magnet Push bar can not 4. commute device can not work 4.repair or replace
contactor and work when switch 5. break down of commute 5.repair or replace
relay on device 6. repair the touching point
6. Touch point of Timing relay 7.Repair the airproof device ,
can not work add oil
7. no oil or heavy oil leaking
1. push bar tuck 1. eliminate the tuck
2. 85% lower than the rated 2. raise the voltage
voltage 3.Adjust the delaying relay
3. delaying relay delay too short t≈0.5s
4. commute device can not work 4.repair or replace
Push bar can not
5. break down of commute 5.repair or replace
work when switch
device 6. repair the touching point
on

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6. Touch point of Timing relay 7.Repair the airproof device ,
can not work add oil
7. no oil or heavy oil leaking
1. push bar tuck 1. eliminate the tuck
2. 85% lower than the rated 2. raise the voltage
voltage 3.Adjust the delaying relay
3. delaying relay delay too short t≈0.5s
Push bar can not 4. commute device can not work 4.repair or replace
work when switch 5. break down of commute 5.repair or replace
on device 6. repair the touching point
6. Touch point of Timing relay 7.Repair the airproof device ,
can not work add oil
7. no oil or heavy oil leaking
1. push bar tuck 1. eliminate the tuck
2. 85% lower than the rated 2. raise the voltage
voltage 3.Adjust the delaying relay
3. delaying relay delay too short t≈0.5s
Push bar can not 4. commute device can not work 4.repair or replace
work when switch 5. break down of commute 5.repair or replace
on device 6. repair the touching point
6. Touch point of Timing relay 7.Repair the airproof device ,
can not work add oil
7. no oil or heavy oil leaking
1. push bar tuck 1. eliminate the tuck
2. 85% lower than the rated 2. raise the voltage
voltage 3.Adjust the delaying relay
3. delaying relay delay too short t≈0.5s
Push bar can not 4. commute device can not work 4.repair or replace
work when switch 5. break down of commute 5.repair or replace
on device 6. repair the touching point
6. Touch point of Timing relay 7.Repair the airproof device ,
can not work add oil
7. no oil or heavy oil leaking

Table 8.6 electric fault ande

faults reasons Obviate method
Breaker burnt when the
Check with ohmmeter,
protective knife-switch shut off The relative phase contact ground
eliminate the earthing
1. Adjust the relayⅠ额定=（2.25～
1. improper relay
Protective relay works when 2.5）Ⅰ额
2. transmission part blocked causes
certain system running 2.Check the transmission part,
motor overloaded
eliminate the block.
fuse burnt when main
grounding eliminate grounding
contactor switch on
1. Noise from motor when one phase
power off 1.Check and rewire it
2. rotor electricity break off 2.Check and rewire it
Motor cannot work after 3. no voltage 3.Check and rewire it
controller switched on 4. Contactor doesn’t contact to each 4.check the controller
other 5.check the brush
5. Brush broken 6.check the brake
6. the brake can not open

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1 、 Controller’s reversal contactor 1 、 Inspect and adjust the
point can not work well or some contactor point
wrong with the rotor mechanism 2、Using the short method to find
Motor can only run in one 2、electric fault out the fault and eliminate it.
direction
3、 break the limit when working 3、eliminate fault
mechanism travel to the end 4 、 check the limit switch,
4、fault in limit switch eliminate the fault
Contactor fail after limit switch 1. short of end switch 1. eliminate the short
open 2.wiring fault 2.rectify the fault of wiring
Tuck and bump when controller 1.limit fault 1.eliminate fault
working 2.contactor point located in camber 2.adjust the position
1. limit faults
1.adjust press
Controller can not pull 2.contactor point burnt and stick
2. clean the contactor point
together
1. checking the excite loop line
1. excite loop-line break
motor can not excite 1.adjust two phase of driving
2.motor rotating oppositely
motor rotor
1. Control loop-line grounding or 1.Find out grounding and short,
Protective contactor failure after short eliminate the faults
power off 2.weld the contactor, supply the 2.file the burnt contactor point,
electricity for loop better the connection

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HOISTING EQUIPMENT

9 Drawing list

Technical
No Name Drawing No.
No.
1 GENERAL DRAWING QD200751 1461
2 CRAB QD200751.2 1461
3 TROLLEY QD200751.3 1461
GENERAL SYSTEM PRINCIPLE
4 QD200751.1-D 1461
DRAWING
5 WRING DIARAM OF CRAB QD200751.1-D 1461
6 WRING DIARAM OF TROLLEY QD200751.1-D 1461
WRING DIARAM OF
7 QD200751.1-D 1461
DISTRIBUTION PROTECTION
WITING DIAGRAM OF MAIN
8 QD200751.1-D 1461
LIFTING
9 ELECTRIC COMPONENT TABLE QD200751.5-D 1461
10 PRINCIPLE FIG.OF MAIN LOOP QD200751.1-D 1461
PRINCIPLE FIG.OF CONTROL
11 QD200751.1-D 1461
LOOP
WIRING DIAGRAM OF
12 QD200751.1-D 1461
AUX.LIFTING
13 GENERAL DRAWING QD62049 1011
14 CRAB QD62049.2 1011
15 TROLLEY QD62049.3 1011
GENERAL SYSTEM PRINCIPLE
16 QD62049.1-D 1011
DRAWING
WRING DIAGRAM OF
17 QD62049.1-D 1011
DISTRIBUTION PROTECTION
18 WRING DIAGRAM OF CRAB QD62049.1-D 1011
19 PRINCIPLE FIG.OF MAIN LOOP QD62049.1-D 1011
20 ELECTRIC COMPONENT TABLE QD62049.5-D 1011
WIRING DIAGRAM OF
21 QD62049.1-D 1011
AUX.LIFTING
22 PRINCIPLE FIG.OF CONTROL LOOP QD62049.1-D 1011
WRING DIAGRAM OF MAIN
23 QD62049.1-D 1011
LIFTING
24 WRING DIARAM OF TROLLEY QD62049.1-D 1011
25 PRINCIPLE FIG.OF CONTROL LOOP QD62049.1-D 1011

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