O&M Manual (English Version)

Before the Erection
and Operation of the

Crane, Please Read the
Manual Carefully
Operation and Maintenance Manual

800/125t-38m Fixed Slewing Crane
No.：A190700013MS
Dalian Huarui Heavy Industry Group Co., Ltd.

August, 2017
Operation and Maintenance Manual for 800/125t-38m Fixed Slewing Crane
Preface
Our respected clients:
Thank you for selection of our product!
In order to correctly assemble and safely operate 800/125t-38m fixed slewing crane, you must carefully
read this Operation and Maintenance Manual.
This Operation and Maintenance Manual should be kept in an accessible place so that it may be timely
consulted if any doubt.
This Operation and Maintenance Manual is submitted to the equipment user and its all rights are
reserved by DHHI Group Co., Ltd. Reproduction of the specifications, drawings and schematic diagrams
given in this manual and/or transmittal thereof to third parties, as well as utilization or disclosure of the
contents thereof, are not permitted unless express authorization is given in writing.
This Operation and Maintenance Manual should be kept safe for future reference during life cycle of
equipment.
This Operation and Maintenance Manual includes the following parts:：
——Overview of Product;
——Safety;
——Erection and Commissioning;
——Operation;
——Maintenance and Repair;
——Others；
——Electrical System (see Booklet for Electrical System)
If the solution cannot be found in this text for your doubt, please make contact with us. We are very glad
to help you.
The way you can make contact with us is as follows:
Address: 169, Bayi Road, Xigang District, Dalian, P.R. China
Postcode: 116013
Website: http://www.dhidcw.com
Telephone (Reception Center): 0411-86852188 E-mail:gsbw@dhidcw.com
Customer Service Center: 0411-62999688
Fax: 0411-86852553 E-mail: fwzx@dhidcw.com
I
General Contents
Part one Product Overview ............................................................... 4
Product Overview........................................................................ 5
1.1 Product Features ...................................................................... 5
1.2 Main purpose and scope of application .................................................... 5
1.3 Technical Features .................................................................... 5
1.3.1Model ............................................................................. 5
1.3.2 Main technical parameters............................................................. 6
1.3.3Load - amplitude curve ............................................................... 8
1.4 SITE CONDITION ................................................................... 8
1.5 Operation condition ................................................................... 9
1.6 Impact on the environment and energy .................................................... 9
1.7 Structural features and working principle ................................................. 10
1.7.2 The structure, function and working principle of the main part or functional unit ................. 13
Part 2 Safety ........................................................................... 39
2.3 Instructions for indicating hazardous areas and entering dangerous areas……… ................... 39
2.1 Items to be observed and forbidden ...................................................... 40
2.1.1Genaral Precautions ................................................................. 40
2.1.2Crane Foundation ................................................................... 42
2.2Warning signs and definition and location of signs .......................................... 42
2.3Instructions for indicating hazardous areas and entering dangerous areas ......................... 42
2.5 Faults handling methods............................................................... 43
2.6 Measures to prevent unqualified personnel from operating the crane ............................ 43
2.7Disposal of deleterious material ......................................................... 43
2.8 Other safety notes and methods ......................................................... 43
Erection and Adjustment (or Commissioning) ................................................. 45

1
3.1 transportation and storage ............................................................. 45
3.1.1Items to be observed and forbidden ..................................................... 45
3.1.2Storage conditions, storage period and precautions ......................................... 45
3.1.2.1Mechanical parts .................................................................. 45
3.1.2.2Electrical parts .................................................................... 45
3.2 Unpack and check ................................................................... 45
3.2.1 Unpack matters need attention ........................................................ 45
3.2.1Checking items ..................................................................... 45
3.3Equipment foundation, erecting condition and technical requirement of erection ................... 45
3.4 Erection procedure, methods and matters need attention ...................................... 46
3.5Commissioning procedure, methods and matters need to be observed ............................ 46
3.6 Acceptance test items after installation, adjustment (or commissioning), method and criteria ......... 46
3.7 Preparation before the commissioning, start of commissioning, commissioning. ................... 46
Operation ............................................................................. 48
4.1 Prepare and check before operation ...................................................... 48
4.2 Safety and safety protection, safety signs and instructions before and during the operation. .......... 48
4.3Operational methods and precautions ..................................................... 48
4.4 Operations and records in operation ...................................................... 48
4.5Procedures and precautions for operating procedures for shutdown .............................. 48
4.6Malfunction analysis and problem shooting ................................................ 49
4.6.1Classification of common faults of lifting machinery ....................................... 49
4.6.2Failure cause and trouble shooting ...................................................... 52
4.7Faults handling procedures and methods .................................................. 56
Part V Service and Maintenance ........................................................... 57
Service and Maintenance ................................................................. 58
5.1Routine Service and Maintenance ........................................................ 58
5.2Maintenance and inspection ............................................................ 60
5.2.1Maintenance, inspection and repair requirements .......................................... 60
5.2.2Maintenance and inspection record ..................................................... 61

2
5.3Preparation of the crane operation........................................................ 68
5.4Maintenance of the main parts .......................................................... 69
5.4.1motor ............................................................................ 69
5.4.2 High speed shaft plum coupling ....................................................... 69
5.4.3Low speed shaft gear coupling ......................................................... 69
5.4.4 Reducer .......................................................................... 69
5.4.5High speed shaft brake ............................................................... 70
5.4.5safety brake ....................................................................... 72
5.4.6 Drum ............................................................................ 72
5.4.7 Roller ............................................................................ 73
5.4.8 Open gear ........................................................................ 73
5.4.9 Pulley............................................................................ 73
5.4.10 Wire rope ........................................................................ 73
5.4.11Hook assembly .................................................................... 75
5.4.12 Maintenance of main structural parts .................................................. 76
5.5Crane lubrication ..................................................................... 78
5.5.1 Methods of lubrication .............................................................. 78
5.5.2The model and lubrication cycle of lubricating oil (grease) ................................... 78
3
Part I Product Overview
1.1 Product Features ............................................................................................................................................. 9
1.2 Main purpose and scope of application .......................................................................................................... 9
1.3 Technical Features.......................................................................................................................................... 9
1.3.1 Model .......................................................................................................................................................... 9
1.3.2 Main technical parameters......................................................................................................................... 10
1.3.3 Load - amplitude curve ............................................................................................................................. 12
1.4 Site condition ............................................................................................................................................... 12
1.5 Operation condition ...................................................................................................................................... 13
1.6 Impact on the environment and energy ........................................................................................................ 13
1.7 Structural features and working principle .................................................................................................... 14
1.7.1 Overall structure and its working principle, working features .................................................................. 17
1.7.2 The structure, function and working principle of the main part or functional unit ................................... 17
4
Product Overview
1.1 Product Features
800/125t-38m fixed slewing crane is specially designed and manufactured ship unloading equipment for
Pakistan's Karachi nuclear power plant heavy cargo wharf.
The crane is fixed on the heavy cargo wharf and the lower part is connected with the pier foundation
through the cylinder steel structure. The upper part of the rotary part includes the main hoisting, auxiliary
lifting, luffing and slewing mechanisms.
The crane is 360°full circle slewing and achieve the loading and unloading operations and cargo
handling in the circular area through the main, auxiliary hoisting and wire rope luffing mechanism.
The crane adopts variable frequency control, and the brake is stable and accurate with perfect safety
protection function. It has the features of easy operation, safe and reliable, easy maintenance and so on.
1.2 Main purpose and scope of application
The crane use hooks to for lifting large and other items of nuclear power equipment.
Suitable ship type is 5000t deck barge.

1.3 Technical Features
1.3.1Model
Crane model：800/125t-38m
800 indicates the main hook rated lifting capacity800t；
125 indicates the auxiliary hook rated lifting capacity 125t；
38 indicates the maximum operating range of the crane 38m.
The following signs and regulations are used in the operation and maintenance
manual to indicate the degree of importance:
"DANGER" means a high degree of danger to be vigilant, emphasizing industrial

safety, the consequences may lead to personal injury or equipment damage.
"Warning" means to be alert to moderate risk, stressing that the consequences may
cause damage to the equipment or other items.
Attention"Attention" indicates that attention should be paid to minor hazards, mainly related to
the economics of the use of the crane.
5
1.3.2 Main technical parameters
Crane main technical parameters in Table 1:

Table 1 Main technical parameters
Crane classification group A4
Max. Lifting Moment（t.m） 16740
main hook auxiliary hook

classification group
M4 M4
Max. rated lifting capacity（ t） 800 620 125
Minimum radius（ m） 15 15 17.5
Max. radius（ m） 19 27 38
hoisting
lifting height above the wharf
mechanism 32m（R=25m）
surface
Lowest hook position under the

-10m（R=25m）
wharf surface
lifting speed full load 2 6
（m/min） empty load 4 12
slewing classification group M4
mechanism speed（r/min） 0.125
classification group M4
luffing Average full load 2
mechanism speed
empty load 3
（m/min）
in-service condition 250

wind pressure（N/m2）
out of service condition 1400
minimum allowable temperature -0.6°C
maximum ambient temperature 47.7°C
Humidity 65%
Crane service life ≥30 years
Rear Swing Radius ≤17m
6
Lower clearance of slewing part ≥12m
7
1.3.3Load - amplitude curve

The load-amplitude curve of the crane is shown in Figure 1:
Figure 1 Load-amplitude curve

The lifting is ALLOWED in the range below the load-amplitude curve corresponding
to the main hoisting mechanism and the auxiliary hoisting mechanism
The lifting is FORBIDDEN within the range above the load-amplitude curve
corresponding to the main hoisting mechanism and the auxiliary hoisting mechanism.
1.4 SITE CONDITION
——Ambient temperature
Extreme highest47.7°C
Extreme minimum-0.6°C
——Design wind speed
In service wind speed：20m/s
Out of service wind speed：60m/s
——Relative humidity： 65％；
——the basic earthquake intensity is 7 degrees, and the basic earthquake acceleration value is
0.1g；
——The service life of the crane is not less than 30 years.
8
1.5 Operation condition

The crane is allowed to be lifted within the range below the crane load-amplitude curve specified in 1.3.3
and is prohibited from lifting within the range above the crane load-amplitude curve specified in 1.3.3.
The crane only allows work to be carried out below the operating wind speed specified in 1.4.
The crane only allows the operation within the maximum working speed, amplitude of the mechanisms
specified in 1.3.2; overloading, overspeed and other over-limit work are prohibited.
Main lifting and auxiliary hoisting mechanism are not allowed to work simultaneously. The main lifting
and luffing mechanism are not allowed to work simultaneously.
1.6 Impact on the environment and energy
The crane uses power supply; there is no waste residue, waste water, waste gas and other harmful
substances emissions, which is safe and environmental protection.
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1.7 Structural features and working principle

1.7.1 Overall structure and its working principle, working features
The overall structure of the crane as shown in figure 2, is mainly composed of cylindrical steel structure, boom,
shaft bracket, turntable, machine room, main hoisting mechanism, auxiliary hoisting mechanism, luffing
mechanism, slewing mechanism, main hook, hook, cab, counterweight, wire rope system, the ladder platform
system, and electrical and safety protection system.
Figure 2 General structure drawing of crane

1.main hook2.auxiliary hook3.embeded parts of foundation 4.Cylindrical steel structure 5.slewing mechanism 6.slewing support
device 7.auxiliary hoisting mechanism 8.main hoisting mechanism9.luffing mechanism10.slewing platform 11.boom assembly
12.A bracket assembly 13.machine room14..erection of operator’s cabin15.rope winding 16.ladder platform system17.lubrication
device 18.limit switches19. Lightning Protection System 20.lable 21.cable wiring 22.power unit 23.counterweight
24.electric-controlling system
——Cylindrical steel structure is bolted with the dock foundation embedded parts, is a fixed
part of the crane;
——the upper part of the cylinder is equipped with the rotary roller running track, the counter
roller track, the center pivot bearing block and the rotary drive pin shaft;
——the rotating part of the crane is rotated 360 degrees on the upper circular track of the
cylinder;
------the boom with truss form is connected with the turntable through the root hinge point,
and the boom rotates around the hinge；
10
——the head of the boom is equipped with a main, auxiliary hoisting and a luffing wire rope
guide pulley, and the boom is pulled by the wire rope to move;
——The turntable is the main supporting structure of the upper rotary part, and the welded
box girder structure is adopted；
——When it is out of service condition, the turntable can be anchored to the cylinder steel
structure, to prevent the wind blowing, and the anchor limit switch is interlocked with
the movement of the mechanism;
——The boom and the A-bracket are hinged on the turntable；
——A-bracket. The top of the A-bracket is equipped with a main, auxiliary hoisting and a
luffing wire rope guide pulley to guide the wire rope to the head of the boom;
——A protruding bracket structure is set on A-bracket, the head is equipped with two buffers that
absorb impact energy to prevent the boom from leaning back slightly during the small luffing;
——The operator’s cab is fixed on the front of the turntable；

——The counter weight is fixed on the rear of the turntable;
—— The main and auxiliary hoisting mechanism, luffing mechanism, slewing mechanism are all
mounted on the turntable；
——The main and auxiliary hoisting mechanism, luffing mechanism are arranged in the machine room;
—— The machine room is fully enclosed, spacious and bright, with convenient maintenance；
——there is a closed electrical room in the machine room, and the electric room is equipped
with a control cabinet；
——There is a super winding electric hoist and a chain block in the machine room；
——There is a ring I-track on the top of the machine room, the maintenance crane’s operation covers
the entire equipment area；
——There is a maintenance hatch on the ground of the machine room, and the service parts
can reach the pier floor through the hatch；
——The rotary supporting device adopts vertical roller and vertical anti-roller to bear axial
force and overturning moment, and the central pivot is subjected to horizontal force；
——A set of safety hooks are provided on the boom side and the opposite side of the boom to
prevent the turntable from tipping off；
——The swing drive adopts the pin-gear drive of the motor-driven vertical planetary gear
reducer, and equipped with ultimate torque coupling to protect the driving device；
11
——with load torque limiter (including load indicator and amplitude indicator), anemometer,
etc., to ensure safe operation；
——The power supply of the crane is AC11kV ,50Hz，the center collector ring is adopted to
supply power.
The instruction of joint action of crane：

The main hoisting and slewing and auxiliary hoisting and slewing, auxiliary hoisting
and luffing, slewing and luffing mechanism are ALLOWED to be interlocked.
The main hoisting and auxiliary hoisting, the main hoisting and luffing mechanism are
FORBIDDEN to be interlocked.
It is WARNED that during the slewing of crane, the tail of the turntable will go
beyong the pier 2m,pay attention to the interference with the hull and other buildings (turntable
tail radius is 17m).
12
1.7.2 The structure, function and working principle of the main part or functional unit
1.7.2.1 Main hoisting mechanism
The arrangement of main hoisting mechanism is shown in Fig.3. The mechanism is installed in the middle
of the machine room, which consists of variable frequency motor, high speed shaft brake disc plum coupling, a
set of disc brakes, horizontal parallel shaft reducer, low speed shaft drum-gear coupling, open gear, broken
wire reel group, low speed belt brakes, and drum bearing block and other components.
Fig. 3 Main hoisting mechanism arrangement

1.Variable frequency motor 2.brake disc plum coupling 3.disc brake 4.horizontal parallel shaft reducer
5.low speed shaft drum-gear coupling 6.operan gear 7.broken wire reel group 8.belt brake 9.drum bearing block
——The motor is AC inverter motor which meets the IEC standard, and the overload capacity
is strong, the torque is smooth at low speed, no crawling phenomenon, and has good
speed regulating performance；
——The motor shaft is connected to the reducer input shaft through the brake disc type plum
coupling. The coupling drive is stable, reliable and easy to maintain;
——A set of disc brakes are set on the high-speed shaft, and the safety factor of the brake is
not less than 1.7, which improves the reliability of the brake;
——The disc brake is normally closed type of the electric hydraulic push rod drive, when the
brake is powered off; the brake disc is clamped by the spring force and brake. When
13
energized, the brake is released by the action of the electrohydraulic push rod to release
the brake disc. Therefore, when there is no power failure or not energized due to other
reasons, the brake can quickly brake by clamping the brake disc. The brake is equipped
with a switch that detects whether the brake is fully open, and the motor can only be
energized when the limit switch is fully open. The brake is with the manual release
device and brake clearance self-compensation mechanism；
——The gear reducer is a full-closed hard surface parallel shaft reducer with carburizing and
quenching process and good lubrication. the installation position of the oil level gauge
and drain hole on the reducer is convenient for daily maintenance and inspection;
——A drum gear coupling is set between the output shaft of the reducer and the open pinion
shaft. The coupling capacity is large, the work is stable and reliable, and the installation
error can be compensated effectively;
——The drum is made of Q345-B.II steel plate, and the surface is a folding rope groove
suitable for multi-layer winding, which can ensure the correct winding of the wire rope.
The drum has a safety ring of at least 3 loops, and the end of the wire rope is fixed by
pressing plate. The two ends of the drum are supported on the bearing pedestal. The
bearing adopts the aligning roller bearing;
——The main hoisting wire rope adopts multi-layer winding, the drum has a maximum of 6
layers;
——The drum is driven by open gear, and the large gear ring is bolted to the side plate of the
drum；
——The drum is set with normal close belt brake as a low-speed shaft brake. The brake
adopts a special compression spring to brake and equip with a hydraulic station to drive
release device. The brake has the characteristics of simple structure, compact size, large
Angle and large braking torque, and equipped with the opening limit switch, suitable for
multi-layer winding low speed shaft brake.

——Oil drip pan is equipped below the drum to prevent the oil on the wire rope dripping to
the ground. The oil drip pan needs to be cleaned up regularly.
——Main lifting speed gear stage is set as per the lifting tonnage. Please refer to the
description of the electrical section for the specific operation sequence and operation
14
method.
——The drum shaft is equipped with hoisting height meter, cam limit switch and over speed
switch as safety protection device;
——The hoisting height meter is an absolute value encoder for real-time detection of lifting
height, displaying on the control panel and providing signals for the control system；
——When the crane is in operation, the hook can move up and down within the lifting height
range. In the lifting and falling process, it can control the deceleration of the upper and
lower end points, stop and provide various interlocking signals through the CAM limit
switch.
——When the transmission chain of the mechanism is abnormal, the speed of the drum may
increase significantly. When the speed exceeds the normal value and reaches to 1.1 times
of the normal speed, the over speed switch mounted on the drum shaft is activated to
make the motor brake, and the brake of the low speed shaft brake the drum.
The performance parameters of the main hoisting mechanism are shown in Table 2:
15
table 2Main hoisting mechanism performance parameters

Item Unit Description Manufacturer
Lifting capacity t 800/620
diameter of wire rope mm 46
Wire rope tension kN 398
Drum diameter mm 1200
lifting height Above wharf m When the range is 25m，32m
surface
Below wharf m When the range is 25m，-10m
lifting speed m/min full load2m/min，empty load4m/min
motor model YZPFMC450L3-8 Changjiang
rated power kW 400

Hangyun
rated speed r/min 742
reducer model M2PSF90 SEW
drive ratio 18.056
brake model YP31-2000 Jiangxi Hua
braking torque Nm 6600

Wu
Pusher model Ed2000-60
high speed shaft model MLPK12-710x30 Ningbo Wei

rated torque Nm 11200
coupling Long
low speed shaft model GIICL16 Ningbo Wei
rated torque kNm 250

coupling Long
Open pinion teeth number 17
mode number mm 20
Open large gear teeth number 130
mode number mm 20
Open gear drive ratio 7.647
Belt brake model BB2500-900HH Jiangxi Hua
braking torque kNm 900

Wu
16
1.7.2.2 Auxiliary hoisting mechanism

Auxiliary hoisting mechanism arrangement refer to figure 4.The mechanism is installed in the front of the
machine room, which is composed of variable frequency motor, high speed shaft brake disc plum coupling, a
set of disc brake, horizontal parallel shaft reducer, low speed shaft drum gear coupling, open gear, drum group,
low-speed shaft brake and drum bearing block and other components.
Figure 4 Auxiliaryhoisting mechanism arrangement

1.variable frequency motor 2.brake disc plum coupling 3.disc brake 4.horizontal parallel shaft reducer 5.low speed shaft
drum gear coupling
6.open gear 7.drum group 8.belt brake 9.drum bearing block
——the motor is ac variable frequency motor which meets the IEC standard, with strong
overload ability, smooth torque at low speed, no crawling phenomenon, and good speed
regulating performance;
——The motor shaft is connected to the reducer input shaft through the brake disk plum
coupling. The coupling drive is stable, reliable and easy to maintain;；
——a set of disc brake is set on the high-speed shaft, and the safety factor of brake is not less
than 1.7, which improves the braking reliability；
——The disc brake is normal closed type of electric hydraulic push rod, and when the brake
is power off, the brake disc is clamped with spring force. When the power is energized,
the brake disc is released by opening the brake by the action of the electric hydraulic
push rod. Therefore, when there is a power failure or no electricity caused by other
reasons, the brake can quickly clamp the brake disc.The brake is equipped with a switch
17
that detects whether the brake is fully open and only when the limit switch is fully open,
the motor can operate.Brake is equipped with manual release device and brake clearance
automatic compensation device；
——the reducer is a full-closed hard-tooth surface parallel axis reducer with the carburizing
and quenching process, which is well lubricated, and the installation position of the oil
level gauge and drain hole in the reducer facilitates daily maintenance and inspection；
—— The drum gear coupling is set between the reducer output shaft and the open pinion
shaft. The coupling bearing capacity is large, the work is stable and reliable, and the
installation error can be compensated effectively.；
——The drum is made of Q345-B.II steel sheet, and the surface is a folding rope groove
The drum has a safety ring of at least 3 rings, and the end of the wire rope is fixed by
bearing adopts the aligning roller bearing；
——the Auxiliary hoisting wire rope adopts multi-layer winding, the drum will have a
maximum of 3 layers；
drum.；
——The drum is set with normal closed belt brake as the low speed shaft brake. The brake
adopts a special compression spring brake with a hydraulic station drive release device.
The brake has the characteristics of simple structure, compact size, large angle and high
braking torque, and equipped with the opening limit switch, suitable for multi-layer
winding low speed shaft brake；
——Auxiliary lifting speed gear stage is set as per the lifting tonnage. Please refer to the
description of the electrical section for the specific operation sequence and operation
method.
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switch.
The performance parameters of the Auxiliary hoisting mechanism are shown in Table 3:
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Table 3Auxiliaryhoisting mechanism performance parameter

Item Unit Description manufacturer
Lifting capacity t 125
wire rope diameter mm 36
wire rope tension kN 229
drum diameter mm 1200
lifting height Above wharf m Range of main hook is 25m，32m
surface
Below wharf m Range of main hook is 25m，-10m
surface
lifting speed m/min full load6m/min，empty load12m/min
motor model YZPFMC355M1-8 Changjiang
rated power kW 160

Hangyun
reducer model MC2PLSF06 SEW
drive ratio 6.817
brake model YP21-800-630×30 Jiangxi Hua

Wu
high speed shaft model MLPK10-630x30 Ningbo Wei

rated torque Nm 4500
coupling Long
low speed shaft model GICL11 Ningbo Wei
rated torque kNm 35.5

coupling Long
open pinion teeth number 17
mode number mm 10
open large gear teeth number 213
mode number mm 10
open gear drive ratio 12.53
safety brake model BB1600-400HH Jiangxi Hua

Wu
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1.7.2.3 Luffing mechanism

The arrangement of luffing mechanism refers to figure 5, The machine is mounted on the rear of the
machine room, which consists of variable frequency motor, high speed shaft brake disc plum coupling, a set of
disc brake, horizontal parallel shaft reducer and low speed shaft drum gear coupling, open gear, luffing drum,
low speed shaft belt brake and drum bearing block and so on.
Figure 5 luffing mechanism arrangement

1.variable frequency motor 2.brake disc plum coupling 3.disc brake 4.horizontal parallel shaft reducer 5.low speed shaft
drum gear coupling
6.open gear 7.luffing drum 8.belt brake 9.drum bearing block
——the motor is ac variable frequency motor which meets the IEC standard, with strong
overload ability, smooth torque at low speed, no crawling phenomenon, and good speed
regulating performance;
——The motor shaft is connected to the reducer input shaft through the brake disk plum
coupling. The coupling drive is stable, reliable and easy to maintain;；
——a set of disc brake is set on the high-speed shaft, and the safety factor of brake is not less
than 1.7, which improves the braking reliability；
——The disc brake is normal closed type of electric hydraulic push rod, and when the brake
is power off, the brake disc is clamped with spring force. When the power is energized,
the brake disc is released by opening the brake by the action of the electric hydraulic
21
push rod. Therefore, when there is a power failure or no electricity caused by other
reasons, the brake can quickly clamp the brake disc. The brake is equipped with a switch
that detects whether the brake is fully open and only when the limit switch is fully open,
the motor can operate. Brake is equipped with manual release device and brake clearance
automatic compensation device；
——the reducer is a full-closed hard-tooth surface parallel axis reducer with the carburizing
and quenching process, which is well lubricated, and the installation position of the oil
level gauge and drain hole in the reducer facilitates daily maintenance and inspection；
—— The drum gear coupling is set between the reducer output shaft and the open pinion
shaft. The coupling bearing capacity is large, the work is stable and reliable, and the
installation error can be compensated effectively.；
——The drum is made of Q345-B.II steel sheet, and the surface is a folding rope groove
The drum has a safety ring of at least 3 rings, and the end of the wire rope is fixed by
bearing adopts the aligning roller bearing；
——the luffing wire rope adopts multi-layer winding, the drum will have a maximum of 4
layers；
drum.；
——The drum is set with normal closed belt brake as the low speed shaft brake. The brake
adopts a special compression spring brake with a hydraulic station drive release device.
The brake has the characteristics of simple structure, compact size, large angle and high
braking torque, and equipped with the opening limit switch, suitable for multi-layer
winding low speed shaft brake；
——Luffing speed gear stage is set as per the lifting tonnage. Please refer to the description of
the electrical section for the specific operation sequence and operation method.
22
switch.
The performance parameter of luffing mechanism refer to table 4：
23
Table 4luffing mechanismperformance parameter

wire rope diameter mm 46
wire rope tension kN 351
luffing drum diameter mm 1200
luffing speed m/min full load2m/min，empty load3m/min
motor model YZPFMC450L2-8 Changjiang
rated power kW 355

Hangyun
reducer model M2PSF80 SEW
drive ratio 18.056
brake model YP31-2000-630×30 Jiangxi Hua

Wu
high speed shaft model MLPK12-710×30 Ningbo Wei
coupling rated torque Nm 11200 Long

low speed shaft model GIICL15 Ningbo Wei
rated torque kNm 180

coupling Long
open pinion teeth number 16
mode number mm 20
open large gear teeth number 125
mode number mm 20
open gear drive ratio 7.8125
safety brake model BB2500-900HH Jiangxi Hua

Wu
24
1.7.2.4 Slewing mechanism

The slewing mechanism is shown in figure 6, and the mechanism is installed on the turntable. The
mechanism consists of two rotary drive devices, rotary supporting roller, reaction wheel, central pivot and
safety hook.
Figure 6slewing mechanismarrangement

1.slewing drive 2.rotary supporting roller3.reaction wheel4.central pivot5.safety hook
——Two sets of rotary drive are arranged on both sides of the rotary centerline；
——there are 206 rotary supporting rollers in total, evenly arranged on two circumferences
with the diameter of φ13m and 13.8m to bear the axial force and overturning moment；
——Reaction wheels are arranged on the side of the boom and the machine room and both
sides of the boom. There are 8 in the front side and 24 in the rear side, 1 in the left and
right side to withstand the overturning moment;
——The central pivot is set at the center of rotation, bearing the horizontal force;；
——A set of safety hooks are provided on the side and the opposite side of the boom on the
turntable to prevent the turntable from accidentally tipping over.
25
1.7.2.4.1 Slewing drive device

The slewing drive arrangement is shown in FIG. 7,
installed on the turntable. The slewing drive adopts the
pin gear drive. The driving device consists of variable
frequency motor, limit torque coupling, hydraulic block
brake, planetary reducer, pinion and pin gear
—— the motor is ac
variable frequency motor which meets the IEC standard,
with strong overload ability, smooth torque at low speed,
no crawling phenomenon, and good speed regulating
performance;
—— The motor shaft is
connected with the planetary reducer shaft with the limit
torque coupling. The limit torque coupling can bear all
load( including the dynamic load)that on the slewing
mechanism;
—— Normal close
hydraulic block type brake is equipped, controlled by
hydraulic pump. The brake device is composed by the
hydraulic station, pipe system and control solenoid valve;
——The planetary reducer is a full-closed hard-tooth surface vertical type reducer with the
carburizing and quenching process, which is well lubricated, and the installation position
of the oil level gauge and drain hole in the reducer facilitates daily maintenance and
inspection；
——Pin tooth shaft is installed on the cylinder steel structure, and achieve the turntable swing
by engaging with the pinion. Two fixed pressing plate groove of the pin tooth shaft are
set and arranged at 90°angle. The pin tooth shaft which is worn seriously can continue to
be used after rotating 90°.
Figure 7 Slewing drive unit
1.variable-frequency motor 2.limit torque coupling

3.hydraulic block brake4. Planetary reducer 5.pinion 6.pin
gear shaft 7.turntable 8.Cylinder steel structure
26
When a storm (above strong gale) is received, the slewing mechanism brake should be
opened manually to prevent the storm from damaging the slewing mechanism and
reverting the brake when the storm is canceled.
27
1.7.2.4.2Slewing bogie wheel

The arrangement of slewing bogie wheel refer to figure 8, which is composed by top rail, bottom rail,
roller and self-lubricated bearing, roller shaft, cage and connecting shaft.
Figure 8 Slewing bogie wheel arrangement

1.turntable 2.top rail 3.Connecting shaft 4.roller 5.Roller shaft 6.self-lubricated bearing 7.botom rail 8cylinder steel
structure 9.cage
——The turntable and cylinder steel structures are respectively installed with top circular rail
with the diameter of 13m and the bottom rail with the diameter of 13.8.
——The top and bottom circular rails adopt Q690 steel. The rail connecting end is fixed by
the connecting plate;
——the roller is floating between the top and bottom rails and connected by the cage；
——When the turntable rotates, the rollers roll between the top and bottom rails；
——the roller pass through the shaft, and the self-lubricated bearing is equipped between the
shaft and the roller to reduce the running friction resistance
——the cage is made in sections, and connected with the connecting shafts and bolts；
——The cage has sufficient strength and stiffness to ensure the relative position of the rollers；
——The roller bearing uniform pressure is ensured by the advanced design and
manufacturing process, which can improve the service life of the roller.
The rail must be coated with molybdenum disulfide lithium grease.
28
1.7.2.4.3Reaction wheel and safety hook

The reaction wheel and safety hook arrangement refer to figure 9, it is mainly composed by the support,
reaction wheel shaft, reaction wheel, self-lubricated bearing, rail and safety hook, etc.
Figure 9Reaction wheel and safety hook arrangement

1.turntable 2.Cylinder steel structure3.support 4.reaction wheel shaft 5.reaction wheel 6. Selft-lubricated bearing 7.rail
8.safety hook
——The circular reaction wheel rail is installed on the cylinder steel structure and fixed by
the bolts.
——The whole crane is installed with 24 reaction wheels, 8 of which are installed on the
boom side, 12 of which are installed on the opposite side of the boom, 2 are installed on
the both sides of the boom;
——The support is welded on the turntable;；
——Between the reaction wheel and reaction wheel shaft, there is equipped with the
self-lubricated bearing to reduce the running friction resistance;
——There are 10m of adjustment of eccentricity for the reaction wheel to adjust the gap
between the shaft and the rail；

——The safety hook is steel structure. A set of safety hook is installed on the side and
opposite side of the boom to prevent the turntable from unexpected tip-over.。
The reaction wheel must be adjusted after the installation，the reaction wheels
compress the rail under in-service condition；
29
The clearance between the safety hook and the rail on the cylinder must be adjusted into
20mm;
The track must be coated with molybdenum disulfide lithium grease.
30
1.7.2.4.4 Central pivot

The arragement of central pivot is shown in figure 10. It is mainly composed of the upper bracket,
lowerbracket and spherical bearing,etc.
Figure 10Central pivotarrangement

1.turntable 2.upper bracket 3.spherical bearing 4.lower bracket5.cylinder steel structure
——The upper bracket and lower bracket are respectively installed on the turntable and
cylinder steel structure and fixed by the bolts;
——The spherical bearing is installed between the upper and lower brackets, the bearing has
good self-aligning;
The internal hole of the upper bracket is the access of the cable on the machine; all the cables enter
the turntable through here.
The spherical bearing must be coated with molybdenum disulfide lithium grease.
The performance parameter of slewing mechanism in shown in table 5：
31
Table 5slewing mechanismperformance parameter

Slewing speed r/min 0.125
motor model YZPFM250M2-8（vertical ） Changjiang
rated power kW 37×2

Hangyun
reducer model JVP316CB-339-M Jujing
drive ratio 348.23

Transmission
Rated output kNm 170
torque
brake model YWW400-800 Jiangxi Hua
Diameter of mm 400
Wu
brake pulley
braking torque Nm Adjusted into 950
limit torque model G350008408 Ningbo Wei
Separation Nm 950
coupling Long
torque
Exposed drive Pinion teeth 9
Pin tooth teeth 156

number
Pin tooth shaft mm 110
number
diameter
Total drive ratio of mechanism 6035.99
32
1.7.2.5Turntable and machine room

Turntable and machine room are the core of the crane, a number of mechanical and electrical
equipmentare installed there. The arrrangement is shown in figure 11.
Figure 11 Turntable and machine roomarrangement

1.slewing drive deivce 2.Auxiliaryhoisting mechanism 3. Main hoisting mechanism 4.luffing mechanism 5.hatch
6.maintenance crane rail 7.counter weight 8.E-room 9.Operator’s cabin
——The operator’s cabin is fixed on the front of the turntable;
——The counter weight is fixed on the rear of the turntable;
——Two sets of slewing drive units are arranged two sides of the rotation centerline with a symmetry
layout.
——The main and auxiliary hoisting mechanism, luffing mechanism and slewing mechanism are all
arranged in the machine room;
——The machine room is an insulated room with the frame made of the square steel tube and sandwich
structure as the skirt plate;
——The machine room is a totally enclosed, large and bright room, with easy maintenance and repair;
——The machine room is installed with enclosed e-room. The structure of the e-room is sandwich type,
which has good performance of thermal insulation, sealing and heat preservation;
——The e-room is installed with control cabinet and air conditioner;
——The e-room is installed with a set of super winding electric hoist and a hand hoist, their lifting weights
is 5t respectively;
——Circular I steel rail is installed on the top of the machine room , the operation of the maintenance crane
covers the whole equipment area;
33
——A hatch is set on the machine room ground. The maintenance parts can reach on the wharf ground
through the hatch;
——Ventilating system is equipped in the machine room. Two sets of axial flow fan inlet the air, two axial
flow fan outlet the air to keep the positive pressure in the machine room;
——a large enough drainage gradient is equipped on the top of the machine room;
——fire extinguisher is installed in the machine room;
34
1.7.2.6Main hoisting rope reeving system
Figure 12 Main hoisting rope reeving system drawing

——Wire rope model is 6xK36WS-IWRC-φ46-1870，1490m。
——The wire rope is fixed on the main hoisting double drum with the pressing plate. The rope pass through
the rope hole, through the guide pulley on one side of A-bracket end and directly reach to the bend
pulley on one side of the boom end, and then through the head block assembly on one side of the boom
end, and wind with the moveable pulley of the hook group, the returning rope successively pass
through the bend pulley on the boom end and A-bracket end, wind the other side of the A-bracket in
reverse until the pulley on the other side of the boom end. The rope returns to the boom end through the
hook pulley group and return back through A- bracket, and then pass through the rope mouth on the top
roof of the machine room, then fixed on the main hoisting double drum with the pressing plate;
——On the first installation, the lead rope is used to pass the route as per the rope reeving drawing, the end
of the lead rope is connected with the working wire rope which is driven by the lead rope until the front
end of the operating rope reaches the drum and fix it;
——After each change of the rope, the fixation of wire rope needs to be done after adjusting
the hook level. The fastening of the fixed ends of the wire rope should strictly follow the
relevant specifications, meet the required torque requirements and ensure uniform force.
——The pin-type sensor is mounted on the A-bracket end to measure the lifting load.
35
Note: The winding system has only one wire rope, and the rotation of the wire rope
is independent of the rotation of the drum groove.
36
1.7.2.7AuxiliaryHoisting Rope Reeving System
Figure 13AuxiliaryHoisting Rope Reeving System
—— Wire rope (non-rotating wire rope)model is 35（W）xK7-φ36－1770MPa，
420m.
——The wire rope is fixed on the Auxiliary hoisting single drum with the pressing plate，the
wire rope passes through the rope access on the top of the machine room, reaches to the
boom end bend pulley through A-bracket end guide pulley, and then bypass boom end
pulley block, multi ratio reeving with the hook group, the return rope is fixed on the
boom end.
——On the first installation, the lead rope is used to pass the route as per the rope reeving
drawing, the end of the lead rope is connected with the working wire rope which is
driven by the lead rope until the front end of the operating rope reaches the drum and fix
it;
——The fastening of the fixed ends of the wire rope should strictly follow the relevant
specifications, meet the required torque requirements and ensure uniform force.
——The tension sensor is mounted on the wire rope end to measure the lifting load.
37
1.7.2.8 Luffing Rope Reeving System
Figure 14luffing rope reeving system

——Wire rope model is 6×K36WS-IWRC-φ46－1770MPa，1160m.
——The wire rope is fixed on the luffing double drum with the pressing plate，the wire rope
passes through the rope access on the top of the machine room, reaches to the boom end
luffing pulley block with multi ratio reeving through A-bracket end guide pulley, the
return rope bypass A-bracket equalizer pulley and then pass through the equalizer pulley
on the other side, perform symmetry multi ratio reeving of luffing rope, and pass through
the rope access on the top of the machine room and then fixed on the other side of the
luffing drum;
——The boom should be leveled up during the rope installation. The lead rope is used to pass
the route as per the rope reeving drawing, the end of the lead rope is connected with the
working wire rope which is driven by the lead rope until the front end of the operating
rope reaches the drum and fix it;
——The fastening of the fixed ends of the wire rope should strictly follow the relevant
specifications, meet the required torque requirements and ensure uniform force.；
38
Part II Safety
2.1 Items to be observed and forbidden ............................................................................................................. 44
2.1.1 Genaral Precautions................................................................................................................................... 44
2.1.2 Crane Foundation ...................................................................................................................................... 46
2.2 Warning signs and definition and location of signs ..................................................................................... 46

2.3 Instructions for indicating hazardous areas and entering dangerous areas……………………....................46
2.4 Safety device ................................................................................................................................................ 46
2.5 Faults handling methods............................................................................................................................... 46
2.6 Measures to prevent unqualified personnel from operating the crane.......................................................... 46
2.7 Disposal of deleterious material ................................................................................................................... 47
2.8 Other safety notes and methods..................................................................... Error! Bookmark not defined.
39
Safety
2.1 Items to be observed and forbidden
2.1.1Genaral Precautions
The crane is designed and manufactured in accordance with the corresponding technical specifications.
Incorrect use will cause the user and the third person's life and physical hazards, and the mechanical and other
materials may be damaged. In order to ensure the safe use of the crane, observe the following safety
precautions:
——The crane can only be used under specified conditions of use; the crane should be
operated by an operator who has a good knowledge of the hazards of the crane and any
technical failure affecting the safety of the crane should be repaired in time；
——Users should not only understand the service regulations of equipment, but also
understand the necessary rules to prevent accidents and general applicable law；
——The maintenance of the parts of the crane shall be carried out by the person who has been
trained on the corresponding parts；
——The safety protection device installed on each device shall not be dismantled at will, and
the action of each safety protection device shall always be fully checked, and whether its
function meets the requirements；
——Under the wind speed below 20m/s, the crane has sufficient wind resistance to ensure
normal operation;
——The rotary anchoring device is interlocked with the rotary motor, so the anchoring device
must be released before starting the crane. If the crane has not been used for a long time
or it is expected a storm or hurricane, the crane's anchoring device must be used to fix
the crane to the cylinder structure;
——After long-term disengagement of the crane or reassembly, the empty load operation
should be carried out first, while observing the running state, the reducer and bearing are
fully lubricated and then the load operation is started；
——In order to ensure that the crane can function normally in the best condition, it is
necessary to check the mechanical action and the wear condition of the parts, the
lubrication condition and so on. In the daily inspection, if something improper is found,
immediate measures must be taken to properly repair it and make it to the best working
condition；
40
——The operator should have a comprehensive understanding of the crane's technical
performance, structure, signal rules and safety technical procedures before operating the
crane;
——It is forbidden to lift if the weight of goods is unknown or the night lighting is
insufficient;
——When the crane is operating in the air, the spreader or cargo position shall not be less
than 2m from the wharf surface；
——The motor’s reverse is forbidden to be used as the brake of the mechanism, this braking
method is allowed to be used only when extremely unexpected events occur;
——The air light must be open during the night operation；
——the inner ladder platform in the cylinder is used only for the maintenance center of the
electric power, which is only allowed to be used in the case of high voltage and power
failure; High Voltage Risk；
——Strictly follow the relevant crane transport equipment operating safety specifications
issued by State or Ministries；
—— When the wind speed has been over 20m/s for a long
time, the crane is forbidden to work. In order to prevent the the displacement
or tipping of the crane caused by occurrence of storms or hurricanes, to
recognize the possibility of this phenomenon, It is necessary to turn the crane
back to the anchor position, insert the anchor pin, and hold the arm frame to
the maximum, and release slewing mechanism brake manually;
—— It is forbidden to lift materials that exceed the allowable load curve of
crane；
—— The spreader is forbidden to pull the cargos at a titled angle;
—— It is forbidden to lift the goods over the human body；
—— It is forbidden to use the crane to pull out any objects buried in the
41
ground；
—— It is prohibited to use the limit switch to control the action of the mechanism. The limit
switch only works when the device has an accident or the operator is negligent.
—— The internal ladder platform of the cylinder is only allowed to be used in

high voltage cut –off state;
The manufacturer is not responsible for any damage caused by any contravention use of the
operating procedures of the crane, which is only the responsibility of the crane driver and the
operator.
2.1.2Crane Foundation
—— The crane foundation is one of the most important parts to ensure
the normal operation of the crane. After prolonged use of the crane, due to the
base sinking and the base displacement, there may be the basis of the level of
error and other undesirable phenomena, it is possible to have a base level
error and other undesirable phenomena, so check the base size regularly. If
you exceed the allowable value, you must adjust the base immediately.
—— The slewing track must keep the planeness and circular degree, the
height difference of the track joint is adjusted to a minimum. In addition,

when the crane is used for a long time, it may cause the loose of the rail fixed
bolt. If it is loose, it must be fastened immediately.
2.2Warning signs and definition and location of signs

The crane has a number of warnings and attention signs, respectively, at the gate, the platform entrance, the
operator’s room, machine room, electrical room and other locations, see the nameplate installation drawings.
2.3Instructions for indicating hazardous areas and entering dangerous areas
When the crane is operating, the following areas are strictly prohibited：
—— Boom, A-bracket, machine room top, counterweight top；
—— new the running gear inside the machine room
42
—— below the crane boom;
—— between the boom end and the machine room;
—— Under the turntable tail part；

——On the circular passage of the upper part of the cylinder
2.4 Safety device
All of the movements of the crane are provided with limit switch interlocks, please refer to section 1.7.
2.5 Faults handling methods
Please operate the crane in strict accordance with the maintenance operation manual, for the accidents
caused by the illegal operation; the appropriate measures should be taken immediately. As for the mechanisms,
press the emergency stop button, the relevant action of the mechanisms should not be done to avoid further
expansion of the accident. And the equipment manufacturer should be contacted immediately and coordinated.
2.6 Measures to prevent unqualified personnel from operating the crane
The crane operator’s cabin, machine room, electrical room and other important places are equipped with locks,
the key should be responsible for the custody of the staff, after the operation of the crane, the operator should
lock the corresponding parts of the door to avoid unrelated personnel to enter and operate the crane, resulting
in unnecessary accidents.
2.7Disposal of deleterious material
The crane has no emissions of waste gas, waste gas and other harmful substances.
2.8 Other safety notes and methods
Please strictly observe the manual during the operation and follow the relevant laws and regulations.
43
Part III Erection and Adjustment (or Commissioning)
3.1 transportation and storage ............................................................................................................................ 45
3.2 Unpack and check ........................................................................................................................................ 45
3.3Equipment foundation, erecting condition and technical requirement of erection ........................................ 45
3.4 Erection procedure, methods and matters need attention ............................................................................. 46
3.5Commissioning procedure, methods and matters need to be observed ......................................................... 46
3.6 Acceptance test items after installation, adjustment (or commissioning), method and criteria ................... 46
3.7 Preparation before the commissioning, start of commissioning, commissioning. ....................................... 46
44
Erection and Adjustment (or Commissioning)

3.1 transportation and storage
3.1.1Items to be observed and forbidden
The crane is a turnkey and field erection project.
3.1.2Storage conditions, storage period and precautions
3.1.2.1Mechanical parts
The management of the spare parts should be fully prepared and ready to be used at any time, so pay
attention to the following matters and keep the custody management.
——Storage of spare parts should avoid high humidity, direct sunlight and air circulation,
place it in the shade of the house；
——Now the spare equipment is covered with anti-rust oil, but it can't guarantee the rust
effect for a long time. Therefore, it should be inspected every three months and put on
new anti-rust oil；
——When coated with anti-rust oil, wrapped with plastic cloth, so that it avoid contact with
the outside air.

3.1.2.2Electrical parts
——Storage of spare parts should avoid high humidity, direct sunlight and air circulation,
place it in the shade of the house；
——now spare parts are coated with electrical anti-rust agent, but it cannot guarantee
long-term anti-rust effect, so every three months to conduct a comprehensive inspection,
coated with a new anti-rust agent;
——When coated with rust inhibitor, put a sufficient desiccant and wrap it with a
polyethylene film to keep it from direct contact with the outside air.
3.2 Unpack and check
3.2.1 Unpack matters need attention
3.2.1Checking items
3.3Equipment foundation, erecting condition and technical requirement of erection
——Roller track grade after installation≤1/500
——Height difference of track≤5mm
——Bend in the direction of up and down≤1mm
——Bend in the direction of right and left ≤1mm
——Stagger at the track splicing place (top and bottom, side) ≤1mm
45
——Gap at the track splicing place≤5mm( will not be together in summer)

——Wornness of track head≤10％ of original size
3.4 Erection procedure, methods and matters need attention
3.5Commissioning procedure, methods and matters need to be observed
The crane is a turnkey project.
3.6 Acceptance test items after installation, adjustment (or commissioning), method and criteria
Procedures, methods and acceptance test requirements of Crane installation, commissioning and test run see
the relevant documents
3.7 Preparation before the commissioning, start of commissioning, commissioning.
The crane is a turnkey project. The crane should be prepared according to the requirements of section 4
before operation
46
Part IV Operation
4.1 Prepare and check before operation ............................................................................................................. 52
4.2 Safety and safety protection, safety signs and instructions before and during the operation ....................... 52
4.3 Operational methods and precautions .......................................................................................................... 52
4.4 Operations and records in operation ............................................................................................................. 52
4.5 Procedures and precautions for operating procedures for shutdown ............................................................ 52
4.6 Malfunction analysis and problem shooting................................................................................................. 53
4.6.1 Classification of common faults of lifting machinery ............................................................................... 53
4.6.2 Failure cause and trouble shooting ............................................................................................................ 56
4.7 Faults handling procedures and methods ..................................................................................................... 60
47
Operation
4.1 Prepare and check before operation
Before the operation of the crane, the operator will fully check the follow, so that the crane can be
operated in the best condition.
——Confirm whether there is any obstacle unrelated to the crane touch the crane, or the
obstacle is placed near the range of the crane’s working range.；If so, these obstacles
must be removed.
——Confirm whether the rotary anchor device is out of service；
——Confirm whether the rotary roller and the reaction wheel are in normal condition；
——Check whether the lubrication of each mechanical device is sufficient；
——Check the switch of each electrical device and the joystick are in the normal position;；
——Confirm the power supply and voltage are normal；
——Start with the empty load operation of the crane，confirm all parts of the safety device
and each limit switch are normal.

4.2 Safety and safety protection, safety signs and instructions before and during the operation.
When the wind speed is above 20m / s, the crane is prohibited from working.
Prohibit the lifting of goods over the human body;
Prohibit the use of cranes to pull any objects buried in the ground;
It is forbidden to use the limit switch to control mechanism action. The limit switch only works when the
device has an accident or the operator is negligent.
Before use, check whether the action of the limit switches is normal and whether the brake action is
normal.
The operation must be carried out in accordance with the Electrical Part of Maintenance Manual.
4.3Operational methods and precautions
4.4 Operations and records in operation
4.5Procedures and precautions for operating procedures for shutdown
——According to the need of the ship’ s departure from the shore, The boom is placed in the
maximum radius and slewing anchored position, where the spreader does not allow the
material to be suspended and lift the spreader to the upper limit and the crane is anchored；
——Return each lever of the control room and the switch to the specified position；
——Return the necessary switches, such as in the machine room and control cabinet, back to
OFF position；
——In order to prevent unauthorized personnel from entering the machine room and the cab,
48
these two parts should be managed and should be locked；
——Confirm the air obstruction lights mounted on the boom and A-bracket end have been
fully displayed.
4.6Malfunction analysis and problem shooting
4.6.1Classification of common faults of lifting machinery
Crane is a machinery used in industrial production for lifting and handling. It is an important device in
modern industrial production, transportation and basic construction
However, when the crane has been used for a certain period of time, it is often not safe to operate due to
the wear of the parts and the increase of clearance. Even some mechanisms failure are caused due to the
fatigue of some major components or parts, serious failure will also cause the occurrence of major accidents,
endangering equipment and personal safety, causing significant losses to the enterprise and bringing
misfortune to the family.
Therefore, the crane operator must learn to correctly judge the crane’s common faults. And according to
the abnormal phenomenon of the crane, the operator can analyze the situation, determine the fault, find out the
reasons, timely repair to use, to ensure the safe operation of the crane, and play the best role of the crane.
4.6.1.1Mechanical failure
——Any mechanical equipment is composed of several assemblies and parts. The cranes are
not excepting.；
—— the faults of the crane mechanical parts are mainly from the motor, brake, reducer,
pulley group, drum, hook, coupling, wheels and other major parts；
——During the use of the parts, the contact part of the parts produces surface wear in the
relative motion, which can affect the normal operation and of the mechanism after to be
worn to a certain extent and result in failure；
——Brake is one of the indispensable important component in crane, the braking
performance of the brake in each mechanism directly affect the accuracy of the
movement of each mechanism and the safety of the work. Especially, the braking
performance of hoisting mechanism and luffing mechanism must be absolutely reliable.
——The failure of brake directly endangers safe production. Every workshop should inspect.
If the clearance is too large, adjustment or maintenance must be carried out；
——The brake failure are mostly from the improper adjustment of the brake pads and brake
disc gap；sometimes, sometimes due to hydraulic push rod failure or brake specification
selection does not conform to requirements, the braking torque is too small also can
cause brake failure or work unreliable
49
——In cranes, reducer is mainly used in hoisting mechanism, luffing mechanism and slewing
mechanism, used to transmit torque and reduce the speed；
——Reducer quality directly affects the safe operation of the crane. After a certain time, the
gear surface of the reducer often causes abnormal noises due to the corrosion and wear of
the fatigue points, and there are unsteady, vibration and hot phenomenon on the drive；
Therefore, if the gear box is found to be defective, immediately remove the defects.
——The coupling is usually flexible coupling, and the crane is usually installed with the plum
or dental coupling；
——The dental coupling often has serve gear wear during the operation; the main reason is
the poor installation accuracy. there is a large offset between the two axes that are
connected and lacks good lubrication, resulting in the tooth surface grease unable to
replenish itself after being squeezed out (There is no meshing form of relative motion)；
The gear on the whole gear ring is sharpened and bald to reach the degree of scrapping.
——Severe wear of the coupling can also cause mechanical drive failure, and sometimes a
serious accident may occur；
——The pulley and the drum are both parts of the transmission, so the friction of the bearing
should be as small as possible and must be lubricated frequently；
——The pulley and the drum are the load-carrying parts of the wire rope, and the common
damage form is the wear of the rope grooves. The main reason is that when it is empty
load, the wire rope is in a loose state in the rope groove; and when it is with load, the
wire rope is tightened and produces a certain pressure on the wheel groove. The relative
slip between the wire rope and the pulley or drum is produced during the lifting or
lowering. In addition, due to the deflection of the rope grooves, the peak part of the drum
groove is worn down. The pulley or drums with the cracks or the Wheel groove wear
size to the scrap level are not allowed to continue use, which is because the serious wear
of the drum groove is easy to cause the wire rope out of the groove and deviate, and the
broken pulley rim will cause the wire rope napping or out of the groove and jammed, and
finally pulled off and cause the accident.
4.6.1.2Failure of metal structure
50
——Crane metal structure quality directly affects the safety of the crane, such as metal
structure once damaged, it will lead to serious accidents, therefore, the design of the
crane metal structure must meet the requirements of strength, stiffness and stability at the
same time；
——Similarly, crane metal structure deformation (distortion) and structure connecting bolt
with different tightness can make the connection bolt fracture due to load; Or because the
weld quality does not meet the requirements and cause cracks which will cause the crane
cannot run properly, affecting the safety of production.
4.6.1.3Failure of electrical part
——According to the characteristics of lifting machinery, motor is required with high
mechanical strength and large overload capacity, and can withstand the frequent
mechanical vibration and shock, but also requires a small moment of inertia and can
quickly start and brake；
——Motor should not have friction sound, screams or other noise in the operation, if any
abnormal sound is detected, the crane should be stopped and checked in time, to
eliminate the fault before they can continue to run, No water or oil is allowed inside the
motor during the operation of motor.；
——The main failures of the motor are: unable to start; temperature rise is too high; the load
power is less than the rated value and so on.
——The electrical equipment is a more complicated part of the crane. It works under shock
and oscillation conditions and is prone to failure. Especially the cranes work in high
temperature, dusty, humid environment is more prone to failure. Failure of electrical
equipment will not only cause parking to affect production, but also may cause accidents；
——Electrical equipment mainly includes motor, electromagnet, controller, resistor,
protective disk and other equipment, conductor and slick line device and control circuit,
and the electrical equipment failure details refer to the electrical manual.
4.6.1.4Hydraulic system failure
——The hydraulic system will inevitably fail during operation. These faults can be divided
into sudden and abrasive；
51
——For sudden, such as the burning loss of the pump, the damage of the parts, the pipe
rupture, etc. are often related to whether the manufacturing, assembly and operation are
in compliance with the rules and other factors, These failures often occur in the early and
middle stages of the system operation.
——For wear failure, such as the failure of the sealing parts, the slow working speed, etc.
These failures usually occur in the later stages of system operation under the normal use
of machinery, mainly due to the natural wear and tear of the mechanical parts. The
frequency of its occurrence is closely related to the quality of daily maintenance.
——In order to improve the service life of hydraulic transmission system and make a
hydraulic mechanical maintain a long-term good performance, in addition to strict
compliance with operating procedures, the maximum prevention of early and
medium-term sudden accidents, it also needs to establish and improve the necessary
daily maintenance system to reduce the late wear out failure. Refer to the hydraulic
manual for the breakdown of this hydraulic equipment.

4.6.2Failure cause and trouble shooting
General mechanical failure reasons and troubleshooting methods of Crane parts and metal structure are
shown in Table 6 and Table 7, respectively.
52
Table 6 Common Faults and Solutions
Fault Possible Cause of Fault Method of Correction Note

High temperature occurred ---Lack of lubricating grease or less ---The rolling bearing is fully filled
in rolling
lubricating grease in rolling bearing with lubricating grease.
---Dirt exists in rolling bearing ---The rolling bearing is cleaned up

with kerosene and filled with
lubricating grease.
Noise being increased in ---Seizure exists due to poor assembly, The bearing is checked for correct
rolling bearing during assembly and adjusted or replaced by
operation deflection of bearing or too tightly new one.
tightening up
---Damage and abrasion of parts of

bearing
Periodic noise occurred Pitch error of gears is too great and side The gears are repaired and
due to wobbling of gears play of gears exceeds the standard. reassembled.
in reducer, especially
driven gears
Intense grating just like Too little gap between driving gears, gear The gears are repaired and
metal filing occurred in being not aligned to the center, crest reassembled or changed.
reducer as result in chink having sharp edge and uneven tooth
due to vibration of reducer surface after wearing (minor groove and
wale mark)
Uneven but continuous Defective flank (lamellar structure) The gears are changed.
knocking occurred during
engagement of gears in
reducer and vibration of
gear box can be heard and
felt anywhere on gear box
Knocking occurred in Too large axial play of bevel gear or teeth The gears are changed or repaired
bevel gear reducer. of bevel gear being worn out severely. and reassembled.
Alternate periodic heavy Pitch circle of gear being not aligned to
and light sound being axle and accumulated error occurring on
coincident with periodic circular pitch of gear
sound produced during
rotary motion of gears
Heating of reducer Too much lubricating oil
53
The oil quantity is controlled on the

specified oil level.
Too heavy sound ---Excessive worn gears ---The gears are changed.
occurring in gear reducer,
which is accompanied by ---Foreign material exists in gearbox ---The foreign material is removed.
impulsive sound ---Damaged bearing ---The bearing is changed.

Too hot bearings in ---Dirt entering into bearing ---The bearing is unpicked and
reducer
---Too little gap washed.
---Too much quantity of heat or lack of ---The gap of bearing is adjusted.

oil
---Reducer is filled with oil
according to the oil level.
Heavy load being not ---Turning joints in lever system being - The brake is cleaned up and -
stopped by means of brake
seized seizure is eliminated;
---Oil existing on brake disk - The turning joints are filled
---Excessive worn brake disk and brake with oil.
shoes - The brake disk and brake
---Too small tension due to damage or shoes are washed up with
loosening of main spring kerosene.
---Lever locking nut being loose and play - The brake shoes or bands are
of lever
changed.
- The spring is changed or the
nut is adjusted so that the
spring has proper tension.
The locking nut of lever is adjusted.

Brake being not released ---Too large tension of main spring of ---The pre-tightening force is
brake adjusted.
---Damaged hydraulic thruster ---The hydraulic thruster is repaired

or changed.
Brake being easy to be Adjusting nut being not tightened up or The brake is adjusted, the nut and
deflected from its locknut not tightened up or damaged lock nut are tightened up and the
adjustable position thread of nut defective nut is changed.
“Skew traveling” during ---Deviation occurring in installation of - The deviations of levelness, -
running of crane
wheels verticality and diagonal of
54
---Deviation occurring in laying of rails wheels are adjusted.
---Oil or water existing on rails - Errors of elevation, span and
---Too large deviation of driving system parallelism of rails are
---Deflection and deformation of wheels adjusted.
- The rails are cleaned up.
- The motors and brakes are
matched reasonably and the
shaft keys are checked and
repaired.
---The wheels are changed.

Sheave being not rotated - No lubricating grease between axle - The lubricating parts are -
and bush unpicked and washed and
Damaged bearings filled with lubricating grease.
Wire rope being quickly Dirt or insufficient lubrication The wire rope is washed or filled
worn out or often broken with lubricating oil.
Rated load being not lifted Failure in motor or circuitry and overload Being checked, eliminated and
up device being not adjusted properly adjusted.
Brake being started too ---Too great resistance to all hinges of ---All the hinges of brake are cleaned
long
brake up and filled oil. They should be
---Oil leaking inside of brake, too low oil acted flexibly.

pressure or oil circuit being obstructed
---Being filled with oil according to
the requirements. The hydraulic
thruster is checked for noise and
washed.
---The damaged parts are timely
changed.
The duration for release of The distance between the control bar and Slightly tighten the nut at the top of
hydraulic thrust bar is the spray nozzle is too short the cross spring.
over-long or the residual The diameter of the nozzle hole is too Enlarge the hold diameter
pressure is too high small.
No pressure is generated The damping hole of the overflow valve Clean the overflow valve
by the hydraulic thrust bar, is blocked. Adjust the wiring of the coil
so it’s impossible to brake The coil of the power supply device is Clean the filter.
connected wrongly; the control bar Tighten the connection of the vane
cannot go downwards. pump.
55
The oil filter is blocked.

The connection of the vane pump is not
tightened.
The oil pressure of the During the assembling, the plane of the Find out the failure points and install
hydraulic thrust bar cannot control rod for the overflow adjusting correctly.
reach the working device is not flat; the center of the control Adjust the current value in the
pressure; the braking time rod is not aligned with the center of the permitted range. The clearance
is too long. nozzle. should be adjusted within 0.5 ～
The current of the coil of the 1.5mm.
electro-hydraulic adjusting device is too
less, the clearance of the brake shoes is
too much.
Table 7 Common Faults and Solutions of Metal Structure

Fault Possible Cause of Fault Method of Correction Note
The severe down-warping of Improper transport storage Carry out the transportation
the boom affects the normal Frequent overload and storage work according to
operation of the crane. operation the regulations
In accordance with the
regulations,
The serious down-warping
should be corrected.
Welding cracks are generated local stress concentration Check metal structure 1~2
in important parts of the Violent vibration (positive times every year
metal structure and negative operation) The load test is conducted
frequent overloaded every two years.
Conduct safety technical
identification
4.7Faults handling procedures and methods
If an abnormal sound or oil leak is detected in the operation, or if an emergency occurs, the operation must be
stopped and the spreader should be removed immediately for maintenance.
56
Part V Service and Maintenance

5.1Routine Service and Maintenance ........................................................ 58
5.2Maintenance and inspection ............................................................ 60
5.2.1Maintenance, inspection and repair requirements .......................................... 60
5.2.2Maintenance and inspection record ..................................................... 61
5.3Preparation of the crane operation........................................................ 68
5.4Maintenance of the main parts .......................................................... 69
5.4.1motor ............................................................................ 69
5.4.2 High speed shaft plum coupling ....................................................... 69
5.4.3Low speed shaft gear coupling ......................................................... 69
5.4.4 Reducer .......................................................................... 69
5.4.5High speed shaft brake ............................................................... 70
5.4.5safety brake ....................................................................... 72
5.4.6 Drum ............................................................................ 72
5.4.7 Roller ............................................................................ 73
5.4.8 Open gear ........................................................................ 73
5.4.9 Pulley............................................................................ 73
5.4.10 Wire rope ........................................................................ 73
5.4.11Hook assembly .................................................................... 75
5.4.12 Maintenance of main structural parts .................................................. 76
5.5Crane lubrication ..................................................................... 78
5.5.1 Methods of lubrication .............................................................. 78
5.5.2The model and lubrication cycle of lubricating oil (grease) ................................... 78
57
Service and Maintenance

5.1Routine Service and Maintenance
——All the electrical devices are in an advanced class mode of operation, so they must be
operated in the sequence as stated in the electrical system in the Instruction Manual for
Operation and Maintenance of Crane.
——Before operation, it should be confirmed whether the limit switches that are mounted in
each of the mechanical devices are acted normally
——If the runway rails exceed the tolerance range specified in 3.2 Technical requirements of
equipment foundation”, the foundation must be trimmed so that they can be kept in the
tolerance range.
——It is sufficiently noted whether all the fastening bolts of each of the mechanical devices
are loosened. Especially the fastening bolts that are fixed on the main and auxiliary
hoisting mechanism and the luffing mechanism, because they are subjected to heavy load,
the fastening bolts fixed on those mechanisms must be more carefully checked.
——Compared with other components, the brake disks and brake lining of the brakes that are
mounted in each of the mechanical devices are easier to wear out, so special attention
must be paid to them.
——In addition, it is feasible for the gap between the brake disk and the brake lining is 0.5～
1.0 mm.
——It must be often checked whether three (3) dead turns of wire rope for purpose of safety
are kept on the drums.
——If the bolts that fixing the ends of wire ropes, are loose, they will lead to rope sliding
down, so the bolts must be often checked sufficiently.
——In case where the irregular location of limit switch is caused by elongation of wire rope,
the limit switches must be adjusted. After the wire rope has been replaced by new one,
the elongation of wire rope exists, so the new wire rope must be more carefully checked
at the early days of change of wire rope.
——In order to prevent the wire ropes from being not lubricated, they must be lubricated in
time.
58
——During the oil change, all the old oil should be out. The oil should not be mixed,
especially the grease. The use of inconsistent concentrations of grease will cause the old
grease block, resulting in the consequences of burned bearings;
——Wear deformation within a certain limit does not affect the use. If abrasion of any
component exceeds the limit of abrasion of crane components as stated in this manual,
the component must be replaced immediately. The specifics refer to section 5.4 of this
manual; Regular check the reducer gear and other important components that are related
to the normal operation and the performance maintenance of the crane, meanwhile, it is
also required to submit a repair plan or an immediate replacement within the cycle of the
next inspection based on the degree of wear and tear.
——The anchor pit that is fixed on the foundation is provided to prevent the crane against
movement during storm, so the fastening bolts and structural members of anchor pit must
be often checked.
——When the wire ropes are changed, attention must be paid to not damaging the threads of
fastening bolt of rope clip. If the threads have been damaged, the bolt is difficult to
tighten up and can’t come up to the tightening torque and the fastening effect. So do the
fastening bolts used in general mechanical devices. Therefore, attention must be paid to
not damaging the threads of bolt.
——After the erection has been completed or the disassembly and reassembly have been
completed, the bolts fixed on the main components must be retightened up during the
actual operation. If the bolts have loose, they should be tightened up again. For example
the fixed bolts on the slewing gear ring, the tightening torque value must be rechecked
after three month use.
——After completing the installation and repair, if the actual operation is performed,
Retightening of Bolts and Nuts can be performed as per the date listed in table 8.
Table 8Retightening of Bolts and Nuts
One Half a One Three Six One
week month month months months year Note
later later later later later later
Bolts for fastening the
○ ○ ○
motor
59

○ ○ ○
brake
Bolts for connection disk
○ ○ ○
of brake
○ ○ ○
gearbox
○ ○ ○
shafting
○ ○ ○
mechanical base
Bolts for fixing the wire
○ ○ ○ ○ ○
rope on the drum
Bolts for fixing the rope
○ ○ ○ ○ ○ ○
clip
Bolts for fixing the
○ ○ ○
electric reel
Bolts for fixing the
○ ○ ○ ○ ○
grating of resistor
Joints of the grating of
○ ○ ○
resistor
Connectors in the control
○ ○ ○
cabinet
Connectors in the
○ ○ ○
operating box
Connectors of limit
○ ○ ○
switch
Slew bearing bolts ○ ○ ○
The above items with the mark “○” will be checked for retightened up at the specified time. In
addition, if it has been found out that the bolts were loosened indeed during the last inspection, the
inspection frequency may be shortened between inspection periods. In a word, the maintenance and
management of bolts and nuts must be strengthened. No loosening is allowed.
5.2Maintenance and inspection

The maintenance of the crane is to ensure the performance of the crane and the measures taken to prevent
accidents.
The responsible person of the crane shall pay special attention to the maintenance and inspection,
propose the suggestion for repairing or replacement of parts according to the circumstances, and assume the
responsibility for preventing the occurrence of accidents.
Maintenance is divided into routine maintenance items and regular inspections. In addition, when
listening to typhoon warning or earthquake prediction, it is necessary to confirm the precautionary measures,
as well as post-inspection and so on.
5.2.1Maintenance, inspection and repair requirements
60
——The operation instruction, inspection record, etc. provided by the manufacturer shall be
fully understood prior to the operation of the crane；
——Coordinate the relevant department when it is planned to carried out maintenance, check
or repairing;
——In case there is another crane or other equipment in the adjacent position, special
personnel is required to supervise the travelling, rotation, luffing movements, etc to
prevent from collision. Or set a barrier in the contact area of the crane to keep it from
approaching.
——When carrying out inspection and repairing, a mark shall be provided at an obvious
position identifying “Inspection in process” or “Repairing in process” to avoid people
not related to access to the area under the crane and accident of personnel due to
dropping of items from the machine.
——When carrying our inspection and repairing with power off, an obvious mark shall be
provided at the disconnected switch identifying “Inspection in process” or “Repairing in
process” to avoid risk due to unguarded power on. Unallowed remove of the mark or
switching on by people not related shall be strictly prohibited. (The mark shall be
removed by the one setting it.) People shall confirm whether it is allowed to switch on
before power on and keep an eye up on safety;
——In case inspection will be carried out during operation, special attention shall be paid to
avoid people from standing and passing through under the cargo.
5.2.2Maintenance and inspection record
The instruction includes maintenance and inspection record, in which the result is useful for repairing
and reconstruction. Therefore, the record shall be well prepared.
——Routine maintenance item；
——Weekly maintenance items；
——Monthly maintenance items；
——Annual inspection record；
——Maintenance record after storm.
5.2.2.1Routine Inspection Item
The purpose of daily inspection is that the person in charge (mainly the operator or maintenance staff
arranged by the person in charge) to carry out the following work to prevent the accident in the first place.
Inspection items and methods are shown in Table 9 to Table 11, respectively.
——The performance and the safety of the surroundings are confirmed before the operation；
61
——To strengthen the monitoring in the operation, stop operation immediately if the
abnormal condition was found;
——After the operation, the crane stops at the right place, confirm whether there is any
abnormality.
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Table 9 inspection items and methods before the operation

Inspection items Methods
—— Obstacles within the range of movement of the crane visual

visual
—— obstacles in the rotating track visual
—— Jumping from groove of the wire rope on the drum or the pulley. visual
—— Oil-break of wire rope, broken strand, and the loose of the wire rope grips. visual
—— Check for brake pads motion
—— Repair after a failure the previous day start
—— the check and movement of the main brake (main lifting, auxiliary lifting, luffing and start
slewing) start
—— Various kinds of instrument panel and indicator start
—— Operation of each joystick and push button switch (close, open, emergency stop, etc.)
—— Main limit switches (Main lifting, Auxiliary lifting, luffing, slewing )
Table 10 Check items and methods in operation
Inspection items inspection
method
—— Abnormal sound, smell, heat, vibration visual

visual
—— Abnormal condition of current and voltage
Table 11 Check items and methods after the operation

Inspection items inspection
method
—— Hook inspection visual

visual
—— whether the operating levers have all returned to the stop position visual
—— whether there is oil leakage in the oil supply action

visual
—— bearings, gears and other lubricating parts visual
—— abnormal heat start

start
—— cracking and damage of various parts visual
—— shutdown of power supply switch visual

motion
—— cleaning of the parts motion
—— lock of the cab
—— whether the aviation obstruction light is on
—— The motion of an anchor device
—— Operation diary, transfer record of loading and unloading
5.2.2.2Weekly inspection items

The weekly inspection is carried out by the people in charge (mainly refers to the operator appointed by
63
the person in charge or maintenance personnel) prior to the monthly inspection to try to find the badness. The
inspection items and methods refer to table12.
Table 12 Weekly Inspection Items and Methods
Inspection Time Inspection Item Inspection Method
—— Damage of all bearing and looseness visual

visual
of bolts. visual
—— Looseness and dropout of for all pin, motion
key and stop plate on bearing end.
—— Twisting, surface damage and

After completion
crazing of cable and looseness,
of operation
corrosion, etc. of connection
terminal.
—— Motion of electromagnetic
contactor, knife switch and
indicating lamp.
5.2.2.3Monthly and annual inspection items

The periodic inspection is carried out by the people in charge (mainly refers to the inspector appointed by
the person in charge) for detailed inspection to important parts as required and to request for disassembly
inspection and repair for the imperfect not found in the daily and weekly inspections. The periodic inspection
includes monthly inspection (once a month) and annual inspection (once a year)。Inspection items see table
13~table 15
Table 13 Wharf foundation inspection items
Monthly inspection Annual inspection
Inspection item Inspection item
—— Damage on the foundation —— Roller track Slope
—— Looseness of fixing bolt or crazing —— Vertical bending
on welding part —— Traversal bending
—— The loose of the fixing bolt and the —— Interlacement of rail junction
cracking of the welded part —— Gap on rail junction
—— looseness of the track hold down —— Wearing on rail end
plate
—— Height difference of rails
Table 14Inspection items of steel structure

64
Monthly inspection Annual inspection

Inspection item Inspection item
—— Looseness and dropout of fixing bolt —— Corrosion of steel
—— Crazing of welding part —— Peel-off of coating
—— Deformation and crazing of steel —— Wearing of parts such as pin
—— Lubrication of parts such as pin and and shaft
shaft
—— Looseness and dropout of ladder,
handrail, platform and fixing bolt
Table 15 Mechanical Inspection part items

Classificatio Monthly inspection Annual inspection
n Inspection item Inspection item
Reducer and —— Abnormal sound, heat, —— Crazing of casing
gear
vibration —— Looseness of key
—— Engagement of gear —— Deformation of key slot
—— Lubrication —— Oil turbidity
—— Oil volume and leakage
—— Looseness of fixing bolt
1 Abnormal sound, heat 1 Foreign material

2 Breakage damage or crazing of the body 2 Gap between pin and sleeve
Bearing
3 Looseness of fixing bolt 3 Wearing of bearing
1 Wearing and crazing

2 Looseness of key
Shaft
3 Deformation of key slot
Pin tooth —— Engagement —— Abrasion and crack
Baffle Looseness of fixing bolt Damage

plate on
shaft end
Key Deformation
1 Abnormal sound, heat 1 Coaxility of two half teeth
2 Oil volume 2 Oil supply
3 Leakage 3 Looseness of key
coupling
4 Looseness of fixing bolt 4 Deformation of key slot
5 Damage and crazing of tooth form
65
1 Wearing and discoloration of brake 1 Heat generation and discoloration of brake

2 Gap between brake hold block and brake disc holder block and brake disc
3 Wearing and roughness of brake hold block 2 Looseness of brake disc and key
4 Crazing of brake hold block 3 Dust accumulation
5 Lubrication condition of all rods and pin shaft 4 Aging of electric oil pressure push rod
6 Braking torque (device with spring) reaches 5 Aging of electric hydraulic power unit
required value?
7 Looseness and damage of parts such as rod, pin
Brake and screw, etc. on the body
8 Oil pressure of electric oil pressure push rod
brake and electric hydraulic power brake
9 Oil volume and oil level of electric oil pressure
push rod brake and electric hydraulic power brake
10 Stroke of electric oil push rod
11 Abnormal sound, smell, heat, vibration
Roller —— Wearing and deformation of
wheel flange and wheel tread
—— Looseness of bolt
Roller —— Damage on each part

holder
—— Abrasion of connection pin
1 Looseness of clamp plate for wire rope Wearing of wire slot

Drum 2 Damage of fixing bolt of drum
3 Crazing of welding
1 Rotating condition
2 Crazing
Sheave 3 Wearing of wire slot
4 Damage of rope guard
1 Wire breaking of strand

2 Wearing and surface damage
3 Bending and deformation
Wire 4 Slack strand
rope 5 Applying and controlling condition of grease
6 Rusting and corrosion
7 Fixing condition of wire rope
Hook —— deformation and cracking of —— Wear of the pin and shaft

assembly —— hook body opening size
66
steel structures
—— Damage and wear of hooks,
hook beams and nuts
1 Turbidity, aging and discoloration of grease

Oil
2 Oil supply of lubricated parts
supply
3 Damage and leakage of oil pipe
system
Fire Setting CO2 valid for one year

extinguisher
1 Oil volume and turbidity
2 Cleaning of filter
3 Pressure
4 Abnormal sound and heat of oil pump and
motor
Hydrau
5 Adjustment and movement of valve
lic system
6 Movement of hydraulic cylinder
7 Damage of oil pipe
8 Oil leakage on each part
9 Looseness of fixing bolt
Mainte The inspection shall be implemented according to The inspection shall be implemented according to
nance crane the standard of the machine. the standard of the machine.
1 Confirmation of movement Movement and condition of wind velocity
Safety 2 Confirmation of movement and position of indicator
device limit switch
5.2.2.3Inspection item after cyclone

After the storm or major earthquake, the crane may be damaged, therefore, the person in charge (mainly
refer to the maintenance personnel appointed by the person in charge) shall carry out adequate inspection to
the machine.
5.2.2.3.1Inspection items
——Whether the rail and other infrastructure meets the criteria
——Damage or distortion of roller device
——Crack of track
——Soaking of rotating motor and brake
——Damage of steps, walkway, handrail and so on
——Deformation and crazing of welding part on steel structure
——Movement of wire rope on Sheave and deflecting roller
67
——Damage of wire rope
——Open circuit and drop-off of oil supply system on each part
——Rain leakage and damage of operator cab, machine room and e-house
——Abnormal condition of power cable and power supply device
——Decreasing of insulation resistance
——Damage and drop-off of lumination, device and so on
5.2.2.3.2 Precautions after inspection
——The rotary brake should be reset in time
——Oil filling at all supply points
——Operation of every movement without load
——Confirm the movement of each limit switch
——The formal operation of the machine shall be started after confirming no obstruction for
operation
5.3Preparation of the crane operation
——Before the operation of the machine, it is necessary to perform the operation with the
empty load, check the motion of the brake, the bolt loose and so on.；
——In order to operate the operating lever easily, pay attention to regular check and keep it
clean. In addition, frequently re-lubricate the sliding parts.
——Contact of the electromagnetic contactor will be worn due to the impact of the electric
arc, so the finishing should be checked frequently to make the surface keep smooth.
When the thickness of the contact member reaches 1/2 of its original size, it should be
replaced immediately. Because if you use a contact sheet that exceeds its wear limit, it
can cause an excessive amount of pitting corrosion and a bad contact. In addition, when
the arc grating appears to be damaged, if it is not replaced immediately, there is a risk of
short circuit and other accidents. The sliding part of the contactor should also be refueled,
adjusted so that it can keep the action light.
——Always check the back of the panel, the resistor, the joystick terminal, and do not let it
loose. The temperature of the resistance is very high, so the vicinity cannot be placed
flammable materials. Besides, the damage to grille, loose bolts, loose contact sheet and
so on should be checked frequently

68
5.4Maintenance of the main parts

5.4.1motor
——check whether the motor is hot；
——Check whether the bearing is unusually hot, and whether there are abnormal noises
inside the motor.

Refer to the maintenance manual for the use and maintenance of the motor。
5.4.2 High speed shaft plum coupling
——Whether the right or left half coupling is eccentric, the eccentricity should be within
0.1mm of the middle；
——Whether the elastomer is damaged and aging.

The use and maintenance of high-speed shaft plum couplings refer to its maintenance manual.
5.4.3Low speed shaft gear coupling
——check whether the fastening bolts are loose；
——When the coupling bolt hole is worn seriously, the actuator will start to beat, or even cut
off the bolt, therefore, the serious worn bolt hole which cannot be repaired should be
scrapped.；
——Whether the right or left half coupling is eccentric, the eccentricity should be within
0.1mm of the middle；
——when the tooth thickness wear exceeds more than 15% of the original teeth, it should be
scrapped；
——When the flat key groove is worn, the key is easy to loose or even fall off. It can be
rotated 90°or 180°to re-open the new keyway on the original key groove on the shaft,
or add a pad that does not exceed 15% on the key.
——Repair welding the key groove is not allowed; it is not allowed to repair the key groove
of the hoisting mechanism and luffing mechanism;
——When any part of the coupling is cracked, it should be scrapped; when there is a broken
tooth, it should be scrapped.

The use and maintenance of low-speed shaft gear coupling refer to its maintenance manual.
5.4.4 Reducer
——The oil gauge is applied to check whether the oil amount is appropriate.
——Whether there is oil leakage.
——Whether there is an abnormal increase in temperature
69
——If the difference between the enclosure temperature and the ambient temperature exceeds
50 ° C, check the inside.
——Whether there is an abnormal sound inside.
——If the sound is unusually loud, check inside.

The following items should also be noted while maintaining the vertical planetary reducer：
——All parts must be well marked before disassembly, especially the relative meshing
position between the sun wheel, planetary gear and the fixed internal gear. The
installation should be installed according to the mark and cannot be misaligned；
——If you want to replace the bearing of the planetary gear, it must replace three groups, not
only for one or one group;
——The replacement of planetary wheels due to wear and tear must be performed in groups.
The ones with close tolerance of common normal line are selected into a group.
Deviation between the length of the common normal line of the three planetary gears is
not allowed to exceed 0.03mm;
——To prevent collision when the main component is removed, prevent the
burr on the gear tooth surface. Once there is burr, the fine oil stone can be
used to sleeking. It is absolutely not allowed to assemble without grinding

Refer to the maintenance manual for the use and maintenance of the reducer。
5.4.5High speed shaft brake
——Whether the motion of the brake is normal；
——Keep the gap between the brake disc and the brake pad between 0.5 and 1.0mm；
——Whether the wear of the brake pad has exceeded the limit；
——If the wear exceeds 3mm, replace it;
——Whether there is any damage on the fastening bolt;
——The gradual decrease of the torque is caused by the wear of brake pad, the gradual
relaxation of the main spring, or the excessive wear of the holes or shafts of the hinge
points of the brake. Replace the brake pad if it wears more than half of the original
thickness and the wear of the pin is more than 5% of the original diameter and the ovality
is over 1mm.When the hole’s wear extent exceeds 5% of the original aperture, the
reamer (milling cutter) can be used to ream and reused with the corresponding pin shaft.
70
if the hole is very worn, it can be repaired by covering after the reaming or processing
the hold after repair welding;
——The sudden failure of the brake, which may be due to the serious wear of the brake pad
or removed, the hydraulic push rod press on the shell, the spring failure or the damage of
the brake frame and other reasons, so the brake pads cannot hold the brake disc (brake
wheel).
——In addition to replacing and repairing damaged parts, adjust the brake；
——Brake (disc) wheel temperature is too high and the brake pad is smoking, which is
mainly due to the poor installation adjustment.
——Sometimes the brake is open, but there is a brake band that does not leave the brake (disc)
wheel and they are rubbing against each other during the operation, so that the
temperature of the brake (disk) wheel rises to 300 ~400 C in a short time, and the brake
pad is smoking. The brake frame should be adjusted so that the center of the brake belt
coincides with the center of the brake wheel and the clearance on both sides is equal. It
should be noted that the brake pad must be parallel to the brake surface of the brake disc.
——The temperature rise of the brake wheel used in the crane is generally not higher than the
ambient temperature of 120 ° C and its surface temperature is usually below 50 ° C in
winter (-20 ° C). The best way to cool the high-temperature brake (wheel) is to run the
hoisting mechanism with empty hook for one or two times within the limit range, from
300 ° to 400 ° C to about 70 ° C (ambient temperature is at 20 ° C). it should be noted
that the brake is tight at high temperature but may become very loose after cooling, the
brake need to be re-adjusted;
——The brake cannot open because the hinge points are jammed and cannot rotate. The force
of the main spring is too large, the hydraulic push rod is lack of oil or the air was not
exhausted, the coil or rectification element is burned, the line is broken, the voltage is too
low, and after finding out the reason, it should be repaired in time.
——Each hinge of the brake frame is applied with thin oil once a week to reduce wear and
allow flexible rotation；
——It is easy to disengage the adjusted position. The hydraulic push rod brake is rotated by
71
the motor in the push rod, which causes the oil to generate upward thrust and lift the
piston rod to open the brake. The hydraulic push rod brake is rotated by the motor in the
push rod, which causes the oil to generate upward thrust and lift the piston rod to open
the brake.
——After power failure, under the action of the main spring on the brake frame, the push rod
is returned to its original position. During adjusting the push rod, 1/3 of the stroke should
be kept for the compensative stroke after the brake pad wear.
The parts of brake should be scrapped when one of the following conditions occurs：
——Cracks ；
——The friction pad thickness of the brake band is 50% of the original thickness；
——The spring appears plastic deformation;
——The wear of the small shaft or diameter of the shaft hole reach 5% of the original
diameter;
Brake (disc) wheel should be discarded when one of the following conditions occurs：
——Cracks ；
——The brake wheel flange friction thickness of the hoisting, luffing mechanism reach20%
of the original thickness；
——The brake wheel flange friction thickness of the other mechanisms reach 50% of the
original thickness.
——When (disc) wheel surface ruggedness reaches 1.5mm, if it can be repaired, the flange
thickness after being repaired should meet the requirements, if not, it should be scrapped.
The use and maintenance of brake refer to its use maintenance instruction.
5.4.6 safety brake
——Whether the hydraulic system is normal, whether the cylinder is overheating, whether
there is oil leakage in the hydraulic system, whether there is abnormal noise；
——Oil leakage of tubing and joints in hydraulic components；
——Whether the brake action is abnormal；
——Whether the wear of brake band has exceeded the limit；
——Whether the fastening bolts are damaged.

The use and maintenance of safety brake refer to its use maintenance instruction.
5.4.7 Drum
72
——Whether the pressing plate of the wire rope is loose；
——If there are any cracks in the drum, it should be scrapped；
——the thickness of the drum after wear should not be less than 90% of the original wall
thickness；
——There must be no crack on the flange, and the connection screw on it should be fastened.
5.4.8 Roller
A regular and comprehensive check on the roller should be performed; the roller should be repaired if it
appears the following conditions:
——Roller diameter deviation is greater than 1.5mm；
——The exfoliation of rolling surface, the scratch area is greater than200mm2，the depth is
greater than3mm；
——Replace the roller when the rim wear is more than 30% of the original thickness, the rim
of the wheel is partially cracked, or the deflection is 20 at the beginning of the vertical
position；
——The roller rotation is flexible and must not be stuck

5.4.9 Open gear
——Gear contact spots: the height is not less than 30% and the width is not less than 50%.
——Pitting corrosion of the tooth surface is 30％ of the meshing surface, and the depth is 10%
of the tooth thickness, the gear should be replaced.

5.4.10 Pulley
All pulleys should rotate flexibly. In the process of use, the pulley should be discarded as follows：
——The wear part of the rope groove reaches 0.15d（d is wire rope diameter）；
——The wear of the wall thickness of the wheel groove is 20% of the original thickness or
there is fracture condition；
——Cracks appear in the pulley;
——Other defects that damage the wire rope.

5.4.11 Wire rope
The safe service life of wire rope is largely determined by the quality of maintenance, so the proper use
and maintenance of wire rope is an important work, the following should be done generally：
——The wire rope leave the factory with coil packaging, the original roll of the wire rope
should be open as per the correct method; the distortion or knot is not allowed.
——When the wire rope is cut off, there should be measures to prevent the rope strand from
73
scattering；
——When installing a wire rope, it should not be dragged in an unclean place, nor should it
be wrapped around other objects. It should be protected from grinding and over-bending；
——The wire rope should be kept well lubricated. Lubricate at least twice a month. Firstly,
wash the old oil with a cloth soaked with kerosene, then dip the wire rope with the
lubricating oil which was heated above 80°C to make the oil into the rope core. Special
attention should be paid to the parts which are not visible and inaccessible, such as the
wire rope at the balance pulley. The use of metal brushes or other sharp instruments to
clean the wire rope is forbidden, and it is forbidden to lubricate it with acid or other
highly corrosive lubricants；
——The wire rope for daily use should be inspected every day, including the fixed
connection to the end, the inspection on the equalizer pulley, and make a safety judgment；
——The new rope must be replaced with the original design of the model, diameter, nominal
tensile strength and qualified wire rope, must check the wire rope to ensure that the
mechanical properties, specifications and the original design of the provisions of the wire
rope；
——The wire rope should be protected against the reduced performance caused by damage,
corrosion, or other physical and chemical reasons.
The check and change of wire rope shall be carried out as per GB5972-86 ---Practical Rule for
Inspection and Rejection of Wire rope for Crane. Check the wire rope once a week. In case of
any one of the defects as follows, they need to be changed:
——10% of wires in a bundle of rope is broken;
——The diameter of rope is reduced by 7% due to abrasion;
——The outer wires of rope is reduced to 40% of their diameter due to abrasion;
——The wire rope has basket-shaped distortion
——The wire rope is severely flattened, knotted
——When replacing the wire rope, do not damage the screws of the fixing bolts, otherwise
the bolts are difficult to tighten and cannot reach the torque;
——When changing the wire rope, the position of the steel wire rope where need to be fixed
74
by high strength bolt must be fixed with the new high strength bolt.
——After changing the wire rope, the wire rope will be elongated, causing the positioning of
the limit switch to be inaccurate, so it is important to check frequently in the early stages.
5.4.12 Hook assembly
Damage form of hook assembly：
——The wear of the hook mouth is normal, if the auxiliary spreader used properly, it will
wear more slowly, or even little wear and tear. The practice proves that the method of
lifting heavy weights with single wire rope is the main factor causing the wear of the
hook. When the weight is hoisted, it is necessary to adjust the center of gravity on its
own, forcing the wire rope to slide at the hook, causing the hook to wear out quickly.
The hoisting hook should be scrapped or reduce the load using when the wear depth of
the hook risk section is more than 10% of its height. The hidden trouble in the lifting
hook group is usually the bottom diameter of the tail thread of the hook and the empty
knife slot between the thread and the rod part, which produce the cracks due to the stress
concentration. During the inspection, the hook nut should be unloaded, cleaned up the
dirt and carefully checked. It is also necessary to check whether the bolts of the hook nut
and the hook, or other parts of the connection are loose or cut off, to prevent the hook
from falling off.
Table 16Inspection table of hook assembly
Items Inspection time and methods
Rotatory state of the hook Regular hand rotation, should be light and flexible
Anti-hook device Hand test, confirm the reliability
Pulley There should be a protective cover. There should be no abnormal sound when turning
bolt , pin Regular inspection, no loose, no falling off
Regular inspection according to national standards, no more than 10% of the original size
Wear of dangerous section
(once a 3 months)
Cracks A magnetic particle inspection was conducted in half a year
Hook opening degree Check if necessary. No more than 15% of the original size
Thread Remove the nut and check for cracks
Bearing and bearing bush Cracks and severe wear and tear should not be allowed
75
Hook’s scrapping standards：

——There are cracks and crevasse on the surface；
——The wear of the hook dangerous section reaches 10% of the height of the original
section;
——The opening degree adds 15% of the original size;
——There are plastic deformation on the hook dangerous section or after section;
——There are tensile cracks around the tool withdrawal groove or transitional section;
——There are any cracks or deformation on the nuts, hook, or beam.

5.4.13 Maintenance of main structural parts
The failure of the crane metal structure mainly include the crack, local or overall deformation, broken,
rust, bolt connection loose and other forms, in which the crack is the main form of crane failure; in order to
avoid the occurrence of malignant accidents, it is a very important work to inspect the important parts of the
metal structure and timely find the hidden trouble in the structure. The following wear conditions must be
repaired:
——Corrosion is 10% of the plate thickness；
——10% of the painting appears coating stripping, cracks and fracturing etc.
5.4.13.1Fracture component members

Table 17 is the fracture component members in metal structure. Special attention should be paid to daily
maintenance.
Table 17Fracture component member（FCM）
No. Component Recommended key inspection area
Head and auxiliary boom joint, boom root, the area to install the
1 Boom
pulley
2 A-bracket Weld seams in all parts of the head, all hinge points
3 Turntable Each hinge point, joint with the rotary track.
4 cylindrical structure joint with the rotary track, Root flange joint
5.4.13.2Reinforcement and repair of structure

Repair of metal material cracks in shaft hole weld and its thermal influence zone：
——This type of crack may appear in the turntable on the hinge point, etc., there are two
kinds of repair methods：one is welding and replenishing under the stressing condition of
the axle hole，the second is to remove the component member to repair, which is called
unload repair welding;
76
——During the repair under the stressing condition, the repeated cracking - welding -
cracking phenomenon is prone to appear in the same part. At the same time, the metal
structure is subjected to repeated heat treatment (welding); the material mechanical
properties of the part, especially the impact toughness decrease significantly, the metal
around the heat affected zone is repeatedly cracked. Uninstall and repair welding can
prevent this kind of repair phenomenon.
The repair methods of the variable cross-section of the box structure, Noncircular transition and
crack at the corner are : directly repair welding the cracks, add the web and repair welding, repair
welding by excavating holes alongside the wreck and mend the crack by replacing a damaged part,
etc.
——Directly repair welding the cracks and add the web and repair welding. Metal materials
are easier to crack again, and sometimes even crack continue to expand through the web；
——Repair welding by excavating holes alongside the wreck. Drill aφ8~φ12 hole (called
stop- crack hole) at the start point and end point of the crack, and directly repair welding
the cracks and holes. The principle of drilling is to release part of the local stress to
prevent the metal material from continue cracking；
——Mend by replacing a damaged part, it is to dig the crack and a piece of its nearby metal
material, then uses the butt weld to weld a new steel plate. The fatigue limit of butt weld
is more than 1 times higher than that of corner welding seam, when the structural parts
are subjected to the alternating load cutting and the dynamic load conditions, the butt
weld can transmit the internal force evenly throughout the section, and the local stress is
minimal. The following points should be noted during the application of this method;
——The joint between the plate and the original metal should be in a four-angle transition,
without the presence of a sharp Angle, requiring arc radius r = 10δ (δ for the thickness)；
——Apply welding in strict welding sequence. Firstly weld the middle part of the steel plate
in the Length and width direction, and then weld the welds of the four corners of the arc;
——Post-weld inspection. After the complete welding, the weld quality shall be inspected
according to the standard. The method generally has a hammering method and a
non-destructive testing method. The former is to use the small hammer to hit the weld, to
77
judge whether there are weld defects according to the sound type.
——The metallic ringing sound is generally fine welds, on the contrary, when the sound is
hoarse; it is proved to be defective.

Metal structure crack of crane only can be found with careful inspection. Once the crack is found, it must
be repaired in time to prevent crack expansion. In the crack repair welding, try to uninstall repair or weld the
repair part under the pressure state. It is not allowed to weld and cut at will on the flange girth in tension of the
box structure to reduce its fatigue strength. The mending method by replacing a damaged part is used in
preference.
5.5Crane lubrication
5.5.1 Methods of lubrication
Lubrication condition is directly related to the normal working life of the crane and the service life of
each mechanism. Therefore, careful inspection and maintenance of the lubrication system must be taken
seriously to ensure that the lubrication system performs its functions properly and finally ensure that the crane
works properly
Because the machine is not used very often, it is not suitable to use electric centralized lubrication, all of
which adopt manual lubrication, the lubricating system consists of the following parts：
——All the pulley bearing lubrication points of the boom are concentrated in the pipe, and a
manual lubrication pump is set on the turntable of the boomroot to supply oil for all
lubricating points；
——The lubrication points of all the pulley bearings on A- bracket are concentrated in the
pipe, and a manual lubrication pump is installed on the roof of the machine to supply oil
for all lubricating points；
——Reaction wheel, boom hinge points, bearing seat, the open gear and pin gear
transmission, roller track and reaction wheel track and hook slide shaft adopt manually
decentralized lubrication with the manual lubrication oil gun, lubricating points are
equipped with a nozzle PT1/4；
—— Reducer uses oil bath lubrication；
—— The wire rope is lubricated with the lubricator.

5.5.2The model and lubrication cycle of lubricating oil (grease)
Table 18 Manual lubrication
Lubrication Cleaning
No. Lubricating points Lubricant
mode cycle
1 Boom , A-bracket, hook bearing 3＃calcium base grease once a week per year
Roller track, reaction wheel track, Molybdenum Disulfide every 2
2 per year
central pivot Lithium Grease month
3 reaction wheel, boom hinge point, General lithium base grease once a week per year
78
bearing seat of the mechanism

graphite calcium base grease every 2
4 pin tooth transmission per year
month
5 open gear 2＃calcium base grease once a week
Mobil Universal Brake Fluid once a During the
weekadd oil inspection
6 Rotary hydraulic brake pump
as required and
maintenance
machine oil HJ20 once a week During the
inspection
7 Brake hinge points
and
maintenance
R5319Special anti-rust oil for every 2
8 Wire rope per year
wire rope month
Table 19 Reducer lubrication
No. Lubricating points Lubricant Lubrication Cleaning cycle
mode
Main hoisting add oil as required per year
1 ISO VG460/equivalent
mechanismreducer
Auxiliaryhoisting add oil as required per year
2 ISO VG460/equivalent
mechanismreducer
3 luffing mechanismreducer ISO VG460/equivalent add oil as required per year
4 slewing mechanismreducer ISO VG460/equivalent add oil as required per year
Table 20Brake hydraulic push rod oil recommendation table
Ambient temperature Oil for push rod
+45℃~+20℃ 20#machine oil
+20℃~0℃ 10＃transformer oil
0℃~-15℃ 25＃transformer oil
The specific relative use and maintenance requirements and the matters needing attention for specific
lubrication system, the components in each lubrication system and the lubricated parts, please refer to the
respective maintenance manuals.
79

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Before the Erection

and Operation of the

Operation and Maintenance Manual

Dalian Huarui Heavy Industry Group Co., Ltd.

Our respected clients:

Thank you for selection of our product!

Part one Product Overview ............................................................... 4

1.1 Product Features ...................................................................... 5

1.2 Main purpose and scope of application .................................................... 5

1.3 Technical Features .................................................................... 5

1.3.2 Main technical parameters............................................................. 6

1.3.3Load - amplitude curve ............................................................... 8

1.4 SITE CONDITION ................................................................... 8

1.5 Operation condition ................................................................... 9

1.6 Impact on the environment and energy .................................................... 9

1.7 Structural features and working principle ................................................. 10

Part 2 Safety ........................................................................... 39

2.1 Items to be observed and forbidden ...................................................... 40

2.1.1Genaral Precautions ................................................................. 40

2.1.2Crane Foundation ................................................................... 42

2.2Warning signs and definition and location of signs .......................................... 42

2.5 Faults handling methods............................................................... 43

2.7Disposal of deleterious material ......................................................... 43

2.8 Other safety notes and methods ......................................................... 43

Erection and Adjustment (or Commissioning) ................................................. 45

3.1 transportation and storage ............................................................. 45

3.1.1Items to be observed and forbidden ..................................................... 45

3.1.2Storage conditions, storage period and precautions ......................................... 45

3.1.2.1Mechanical parts .................................................................. 45

3.1.2.2Electrical parts .................................................................... 45

3.2 Unpack and check ................................................................... 45

3.2.1 Unpack matters need attention ........................................................ 45

3.2.1Checking items ..................................................................... 45

3.3Equipment foundation, erecting condition and technical requirement of erection ................... 45

3.4 Erection procedure, methods and matters need attention ...................................... 46

3.5Commissioning procedure, methods and matters need to be observed ............................ 46

3.7 Preparation before the commissioning, start of commissioning, commissioning. ................... 46

4.1 Prepare and check before operation ...................................................... 48

4.3Operational methods and precautions ..................................................... 48

4.4 Operations and records in operation ...................................................... 48

4.5Procedures and precautions for operating procedures for shutdown .............................. 48

4.6Malfunction analysis and problem shooting ................................................ 49

4.6.1Classification of common faults of lifting machinery ....................................... 49

4.6.2Failure cause and trouble shooting ...................................................... 52

4.7Faults handling procedures and methods .................................................. 56

Part V Service and Maintenance ........................................................... 57

Service and Maintenance ................................................................. 58

5.1Routine Service and Maintenance ........................................................ 58

5.2Maintenance and inspection ............................................................ 60

5.2.1Maintenance, inspection and repair requirements .......................................... 60

5.2.2Maintenance and inspection record ..................................................... 61

5.3Preparation of the crane operation........................................................ 68

5.4Maintenance of the main parts .......................................................... 69

5.4.2 High speed shaft plum coupling ....................................................... 69

5.4.3Low speed shaft gear coupling ......................................................... 69

5.4.4 Reducer .......................................................................... 69

5.4.5High speed shaft brake ............................................................... 70

5.4.5safety brake ....................................................................... 72

5.4.6 Drum ............................................................................ 72

5.4.7 Roller ............................................................................ 73

5.4.8 Open gear ........................................................................ 73

5.4.10 Wire rope ........................................................................ 73

5.4.11Hook assembly .................................................................... 75