LH TYPE OVERHEAD TRAVELLING

CRANE WITH ELECTRIC HOIST

Installation Manual

Shanghai Zhenhua Heavy Industry (Group)

Shenyang Elevator Co., Ltd.

1

The Table Of Contents

1 Preparations before installation.................................................................................................... 2

2 Machinery Assembly.................................................................................................................... 2

3 Trolley positioning ....................................................................................................................... 4

4 Electrical Assembly...................................................................................................................... 5

5 Checking all the Procedure .......................................................................................................... 5

6 Transporting ................................................................................................................................. 6

7 Placing the gantry and trolley ...................................................................................................... 6

8 Make sure the suspension position of cable rail and than welding.............................................. 6

9 Installation of slippery line of gantry assembly ........................................................................... 6

10 Finish wiring distribution of control box of gantry.................................................................... 6

11 Adjust ......................................................................................................................................... 6

12 Testing ........................................................................................................................................ 7

13 Access Power Debugging .......................................................................................................... 7

14 Type Test .................................................................................................................................... 7

15 Final Handing Over.................................................................................................................... 8

2

1 Preparations before installation

1.1 Preparations

a. trolley assembly;

b. parts of gantry driving wheel unit;

c. parts of gantry driven wheel unit

d. gantry carriage

e. cable, limit switch, fixed tackle, rail, connector and other components.

1.2 Necessary tools and measures.

1.3 Recheck

1.3.1 Recheck all the related dimensions (general calipers)

1.3.2 Visual measurement of the quality of all the parts to be installed

Note:

Failed components, appearance damaged parts do not allowed to enter

the assembly procedures.

2 Machinery Assembly

Fig.1 driving wheel assembly 1. bearing cover 2. shield bearing 3. bearing 4. axle sleeve 5. wheel 6. key 7. driving axle 8. cover 9. trinity decelerator 10. shield bearing 11. connecting pipe of oil nozzle 12. oil nozzle 13. rings 14. M16105 bolts 5. washer 16. rubbery cushion 17. baffle 18.M16 nuts 19.M16 fasten nuts

3

Fig.2 driven wheel assembly 1. oil nozzle 2. driven axle 3. shield bearing 4. shield bearing 5. bearing 6. wheel 7. spacer 8. baffle

2.1 Assembly of driving wheel (see fig.1),

driven wheel (see fig.2)

Requirements: Detection on 4 sets of wheel treads flatness,

tolerance 2mm,

Flange parallel, tolerance 1 / 1000

Means: laser detection

2.2 Installation for 2 sets of Trinity Decelerator (see fig.1)

Requirements: lug with two rubbery cushions, baffles, M16 105 bolts, washers, nuts

(tightening torque of 42Nm) and fasten nuts are fixed on the Trinity

decelerator with lug, and adjust correctly, weld the lug on the end of

bridge beam. Check the appearance on polishing, paint and other

treatment.

Measure: Visual measurement.

2.3 Installation for Gantry Nameplate

4

Requirements: Check the content of nameplate whether clear and correct or not, and

then rivet beams installed in the large car owners around the middle of

the inside of position, after the riveting smooth vertical and horizontal

installation.

Measure: ruler, visual

3 Trolley positioning (weighs about 3150Kg) (see fig.4)

Fig4

3.1 Lift and install the trolley motor and towing cable on the same side of the

gantry track, and then adjusting and checking.

Requirement: 4 wheels of trolley should be connect well with track, tolerance1.3mm

Means: feeler gauge

3.2 Adjusting & Checking the Anti-drop Plate of Trolley

Requirements: Tighten the 4 sets of 4-M12X45 bolts (tightening torque is 50Nm) so

as to reach the anti-jump function.

Means: Visual, ruler

5

4 Electrical Assembly

4.1 Install the electrical control box of gantry on the side brackets of the gantry

main beam.

4.2 Install the gantry cable lead, fixed tackle, cable tackle and cable. (see fig.5)

Fig.5 cable towing 1. end cap 2. connector 3. Model C guide 4. hanger 5. guy rod unit

6. cable tackle 7. steel rope 8. fixed tackle 9. cable

Requirements: Adjust the height of tackle regularly moving flexible.

Means: Visual, general tools

4.3 Welding the limit bumper of trolley on the gantry main beam

Requirements: Operate the trolley first, adjust the position between limit switch and

bumper and ensure the action sensitively after welding.

Means: Visual, adjusting.

4.4 Cable Assembly

Requirements: Towing cables should be regulated and fixed with no loosing and

shedding, Cable connector terminals should be pressed firmly in strict

accordance with the wiring drawings.

Means: visual, instrument.

5 Checking all the Procedure (2.1 to 4.4) Requirements: In accordance with the drawings and technical requirements.

6

6 Transporting

Moving to the machinery house (due to the customers responsibility )

Requirements: Do not damage any part.

7 Placing the gantry and trolley

Supporting rail beam should be provided by customer, and the maintenance crane

may in palace after adjusting and getting the test qualification.

Requirements: Make sure the ocean/land direction in accordance with final assembly

drawings.

Means: Refer to the drawings.

8 Make sure the suspension position of cable rail and than welding. 9 Installation of slippery line of gantry assembly. Requirements: All the fasteners should be regulated and fixed with no loosing.

Slippery line is flat.

Fig.6 Powerail enclosed conductor system 1.power supply device 2. collecting electric apparatus 3. fixed clip 4. hang 5. connecting clip 6. slippery line 7.end cap 8. tractor

10 Finish wiring distribution of control box of gantry

11 Adjust

The multi-function travel limit device of hoisting mechanism, limit switches of

7

heavy hammer and other limit switches.

Requirements: Running sensitively and accurately

12 Testing

Inspect the whole assembly procedures for the entire test.

Requirements: moving parts runs smoothly without interference block; fasteners are

fixed and reliable; wiring distribution is regularly and well-done; all

the electrical components should be sensitive and reliable.

Means: visual, instrument, common tools.

13 Access Power Debugging

Requirements: Lifting, gantry/trolley running smoothly without noise 80 dB (6m

radius) ;lifting cam limit, heavy hummer limit, overspeed switch and

gantry/trolley limit switch should be sensitive, accurate and reliable.

14 Type Test

Test should be carried out in accordance with JB/T3695-1994 OVERHEAD TRAVELLING CRANE WITH ELECTRIC HOIST

Requirements: follow the prescribed testing methods strictly, and fill in test results

carefully in the table.

14.1 Visual measurement

Visual inspection should include all the specification and the

state of important parts which must meet the requirements, such

as: all systems, electrical facilities, safety devices, metal

structures, platform railings and protective facilities.

14.2 Approval inspection

8

Accumulate the load gradually by 2 or 3 times up to the rated load (test load

tolerance 1%), and you may do movement trials and testing for each direction

with the voltage fluctuation 5% 10% and nominal speed of motor. 14.3 Load Capacity Test for Lifting

14.3.1 Static Test

125% overload weight accumulated gradually at mid-span position. Run the

machine upward until 100 200mm for 3 cycles. After unloading, the bridge

may not have permanent deformation and the main beam bridge camber should

be 0.7/1000 span, as well as the appearance of paint can not fall off.

14.3.2 Dynamic Load Test

110% overload running follow the operating instruction and the manual. Moving

for lifting, gantry/trolley should be carried out respectively, and the linkage test

following. Testing, for repeated starting and braking with various actions, should

be continued at least 1 hour in accordance with working cycle.

Requirements: Technical performance parameters should meet the requirements for

drawings and relevant standards.

14.3.3 Fill in the test results and product qualification certificate carefully.

15 Final Handing Over

After the approval of quality inspection, supervision or customers on-siteprepare all the random necessary documents and formalities for delivery.

9

Shanghai Zhenhua Heavy Industry (Group) Shenyang Elevator Co.,Ltd.

Address: ADD:No.23 Xinyang Road,Huishan Economic Development Zone, Shenbei New District,Shenyang,P.R.China

Postal code:110164 Tel:024-88085258 Fax: 024-88041495 Email:zpmcsy@163.net Web sitewww.zpmc-lift.com