| Item | Contents | Standard | |
| Gantry | Main girder distortion | Check the deflection of the main girder with rated load located in the mid-span |
deflection < S/700（on the basis of level line） |
| Check the level sideway bending and other distortion of the main girder when hoisting rating load | Sideway bending and other distortion value should be in accordance with standard | ||
| structure | Check if there is any crack,rust, abnormal distortion,twist as a whole for the structure and local instability | All these trouble cannot exist | |
| Check if there is any looseness, break off, crack, erosion in connection parts | All these trouble cannot exist. | ||
| Others | Check the surface protection of the metal structure | No bubble, peeled off paint or obvious rust | |
| Trolley frame | structure | Check if there is any crack，distortion or crack | No crack,distortion or craze |
| Check surface protection of steel structure. | No bubble,peeled off about paint or clear rust | ||
| Check if there is any looseness and fall off in connection parts | No looseness or fall off | ||
| Connection of Cab and main girder | Check if there is any crack in main material and welding area | No crack | |
| Check if the bolts are tight and reliable | Each one should be tight and reliable | ||
| Item | contents | standard | |
| Drum assembly | Drum group | Check if there is crack distortion or abrasion,any abnormality | No crack,obvious distortion or abrasion |
| Check if there is any abnormality for the fastening of steel rope | No looseness | ||
| Check if there is any trace of steel rope missing from the grooves fastening of the drum fixed. | No trace of steel rope missing from the grooves，drum is fixed well. | ||
| Shaft and bearing | Check if there is crack,distortion or abrasion | No crack, obvious distortion or abrasion. | |
| Check if there is any distortion or looseness on baffle in the shaft end | No distortion or looseness | ||
| Check if there is any abnormal noise,heat or vibrations from bearing | No abnormal noise vibration or heat | ||
| Pulley group | Pulley | Check if there is any crack flaw,damage or abrasion | No crack,flaw,damage or abrasion |
| Check if there is any abnormality of rope groove | No abnormality of rope groove | ||
| Check if there is any trace of steel rope missing from the grooves | No trace of steel rope missing from the grooves | ||
| Check if there is any looseness of clamp or orientation pin | No looseness | ||
| Rope baffle for shaft and bearing balance pulleys, etc. | Check if there is any crack or abrasion | No crack，obvious abrasion | |
| check the lubrication | Lubrication is good | ||
| Check if there is any abnormal noise or eccentricity for turning pulley | No abnormal noise or eccentricity. | ||
| Check if there is any rope missing from grooves,any break off distortion or crack. | No rope missing from grooves,break off,distortion or crack | ||
| Wire rope | Structure of the rope | Check if the structure and diameter of the wire rope conform to design when wire rope is changed. | Completely in accordance with drawing attached； |
| Check the safe circles of wire rope on drum when the spreader is at the lower limit position. | There must be at least 2 circles of wire rope on the drum for the sake of safety | ||
| Structure of the rope | Check the safe circles of wire rope on drum when the spreader is at the lower limit position. | There must be at least 2 circles of wire rope on the drum for the sake of safety | |
| Check if there is any broken thread, broken strand,exposed core,twist,erosion， looseness,abrasion | There must not be 10％broken thread in 1 length of lay. Diameter of the rope is not allowed to be less than 93％ of that rated；no obvious defect； | ||
| Rope condition | Check if there is any broken thread,broken strand,exposed core,twist,erosion， looseness,abrasion | There must not be 10％broken thread in 1 length of lay. Diameter of the rope is not allowed to be less than 93％ of that rated；no obvious defect； | |
| Check if the structure of the wire rope applied in high temperature environment is correct； | The structure should accord with the purpose of application | ||
| Check if the processing of the end and the fastening is correct | There should not be any defects fastening should be reliable | ||
| Check if there is any rope missing from grooves | No rope missing from grooves； | ||
| Check if there is any dust sand,impurity or moisture attached on the rope | No dust，sand,impurity or moisture attached to the rope | ||
| Installation and application of the wire rope | Check if the wire rope crash against structure parts； | There should not be any collision | |
| Check the contacting condition with each pulley. | No obvious abrasion. There should not be any pressed deflection or loose | ||
| spreader | Hook | Check the hook and see if there is crack distortion or abrasion | No crack,obvious distortion or abrasion |
| Rotate Hook and see if there is any abnormal noise for bearing and thread part. | Rotate smoothly and no abnormal noise；no abnormal distortion | ||
| Check if there is any abnormal distortion at the hook mouth; check lubrication of the bearing | Lubrication is good and oil mass is right | ||
| Connecting Plate，connecting piece | Check the fastening of connecting plate and connecting pieces，it shall has no falling | Reliable fastening，safe，no loose | |
| Pin,shaft ,side plate have no deformation | No distortion | ||
| Check if anti-off device of wire rope function well | Normal function and no distortion | ||
| Check the lubrication of bearing | No crack,abrasion and distortion | ||
| Check the lubrication of bearing | No crack,abrasion and distortion | ||
| Item | Contents | Standard | |
| Motor | Base | Checks if there is crack on the base，loose connection or fall off. | No crack，loose or fall off. |
| coupling | key and key slot | Check if there is key loose out of the slot or deformation. | No loose，out of slot or evident deformation |
| Check if there is crack or deformation of key slot. | No crack and evident deformaion | ||
| Transmission shaft | Rotate coupling to check if there is run-out and end face run-out | No evident radial run- out and end face swing | |
| Rubber elastic ring | Check the condition of deformation and wear | Don’t exceed scrap limit | |
| Gear coupling | Check the lubrication and see if there is leakage. | Proper lubrication and no leakage | |
| Bolts and nuts | Check if there is abnormal noise | No abnormal noise | |
| Brake | Brake | Check the working condition of brake | Normal,effective,no eccentric wear |
| foot-pedal-op erated brake | Check if they’re normal for pedal gap and clearance between pedal and bottom plate when treading. | Gap and clearance should be appropriate | |
| Check if there is loose or mis alignment for lever system. | No loose or mis-alignment | ||
| Hydraulic brake | Check the fluid level and if there is an oil leak | Oil proper,no leakage | |
| Check the function of cylinde， damage and leak | Work well,no damage and leaks | ||
| Check if there are bending，deformation，oil and leakage for push rod | No obvious bending,appropriate oil and no leakage | ||
| Electrical magnetic disk brake | Check the work condition of electromagnet | Stable movement，no abnormal noise and disgusting smell | |
| Brake wheel and brake shoe | Check if there is any loose for brake installation，and if it is any peel off，damage and eccentric wear for friction shim. | No loose,no peel off,damage and eccentric wear. | |
| Check if it is ageing for spring | No aging | ||
| Check if there is any crack， wear down and damage for brake wheel | No crack and damage,normal wear. | ||
| Check if it is appropriate for brake clearance. | Brake clearance meets requirements. | ||
| Regulating mechanism for stroke and brake torque | Check if there are any abnormal for regulating mechanism such as stroke, brake torque | Suitable regulator, stable movement | |
| Check if they are any crack， bend and wear for pull rods，axis pins，levers and bolts. | No crack, distortion and obvious wear. | ||
| Installation of bolts and pin shaft | Check if bolts and nut shave any loose from axis pin | No loose. | |
| Reducer | Gearbox casing | Check if there is any crack deformation and damage. | No crack,obvious deformation and damage |
| Check if there is any loose or fall off for installation connection | No loose and fall off. | ||
| Check oil mass，oil product and oil quality. | Appropriate oil mass, no pollution | ||
| Check if there is leakage | No leakage | ||
| Gear wheel | Check if there is any abnormal noise，fever and shaking | No abnormal noise, fever and shaking. | |
| Check if there are any abrasion and damage on tooth surface | No obvious abrasion or damage | ||
| Check if there is any crack， deformation or damage for wheel hub，wheel disc and gearwheel | No crack,deformation and damage | ||
| Check if there is any loose，drop from groove or deformation of key | No loose,drop from groove and obvious deformation | ||
| Check if there is any crack or deformation on key groove | No crack and deformation | ||
| Check if they are abnormal for gear tooth contact and engagement | Good contact,suitable contact depth | ||
| Check the lubricate condition | Good lubrication | ||
| Gear box cover | Check if there are any crack， deformation or damage. | No crack,obvious deformation and damage | |
| Check if there is any loose for connection and installation | No loose | ||
| Shaft | Rotation shaft. Arbor transmission shaft | Check any deformation and abrasion. | No deformation,damage,good lubrication. |
| Check if there is vibration for drive shaft | No abnormal vibration,noise or obvious heating. | ||
| Check if there are any loose deformation or crack for key and key groove | No loose and crack | ||
| Bearing | Rolling bearing | Check if there is any crack and damage. | No crack and damage. |
| Check the lubrication conditions | Good lubrication | ||
| Check if there is any abnormal vibration，lever and noise in idling and load situation | No abnormal vibration,noise or obvious heating | ||
| Sliding bearing | Check if there is wear for bearing. | No obvious wear | |
| Check if there is burning loss or heating in no load and loaded condition | No burned or obviously rise in temperature. | ||
| wheels | flange | Check if there is any crack loss，deformation，wear | No obvious deformation and abrasion |
| Wheel tread | Check if there is any abrasion for tread； | No obvious abrasion | |
| Check the diameter deviation of driving wheel and driven wheel | Error value of wheel diameter should conform to the related standards. | ||
| Check the crack,deformation and peeling off of tread surface | No crack,deformation and peeling off. | ||
| Bearing in the wheel hub | Check the lubrication condition of the sliding bearings | Normal | |
| Check if there is abnormal vibration, noise,rising in temperature in no load and loaded condition. | Normal | ||
| Check the lubrication condition shaking,noise, and rising in temperature of rolling bearing. | Normal | ||
| Gap between hub for vehicle wheel and end carriage side plate | Check if there is any friction and wear | No friction and wear | |
| Check the installation accuracy | Good installation | ||
| Item | Contents | Standard | |
| Rail | Rail | Check if there is crack,head of rail sag,distortion，or any damaged on side face | No crack，evidence cave in，distortion or seriously wear |
| Rail fastening bolts | Check if connecting bolts have any loose or fall off | No loose or fall off | |
| Connecting plate and pads | Check if Check if bolits have any loose or fall off | No loose or fall off | |
| Connecting plate and pads | Check if there is displacement,fault or fall off for connecting plate and pads | No displacement，faults or fall off | |
| Buffers, end stoppers | Check if there is any damage or dislocation；any loose or fall off for installation. | No damage or dislocation，No loose or fall off. | |
| Rail joint | Check if rail joint have any dislocation and gap change | No obvious dislocation and gap change | |
| rail welding and install | Check if there is crack and gap for welding line | No crack or craze | |
| Geometry dimension error | Check deviation of gauge，center line and top elevation of rail | Don’t exceed the specified value | |
| Item | Contents | Standard | |
| Motor | Resistor | Check if insulated resistance has any heating | No abnormal heating within the prescribed scope |
| Bearing | Check the lubrication condition，any abnormal noise | Good lubrication and no abnormal noise | |
| Sliding ring | Check whether there’s any change in color any crack，any loose connection | No obvious change in color，crack or loose connection | |
| Brush and conductor | Check whether there’s any wear and loose | No obvious wear or loose | |
| Brush and conductor | Pressure | Proper pressure | |
| Toner adhesion check if there is carbon powder | No carbon powder absorbed | ||
| Check whether there’s loose for rotating the motor shaft | No loose | ||
| Current Collecting device | Sliding wire，current collecting rail | Check if there is any deformation，abrasion or damage | No obvious deformation， abrasion or damage |
| Check whether it is normal for tension device | tensile force is normal | ||
| Check the contact condition of sliding wire and sliding block | Good contact | ||
| Check if there is any loose for insulator supports | No loose | ||
| enclosure，cover | Check whether there’s enough damage or deformation | No damage or obvious deformation | |
| Insulated collector | Check if it is normal for anti-electric shock device | There’s enough distance from sliding wire | |
| Insulator | Check if the wiring of for insulated collector has any abormality | Reliable connection among cable core，joint and enclosure. | |
| Mechanical part | Check if there is any fall off, loose,crack,or dirty | No fall off,loose,crack,dirty | |
| Check whether there’s any damage or wear | No obvious damage or wear | ||
| Spring | check whether lubrication is good | Good lubrication | |
| Wiring and insulation | Check if there’s any deformation， erosion， and fatigue damage | No deformation,obvious erosion, and fatigue damage | |
| joint bolt | Check any break of wire，any dirt or damage of isolator | No broken line or damage，dirty | |
| insulating layer | Check if there’s any loose or fall off for fastening parts | No loose or fall off | |
| joint | Check if there’s any damage | No damage | |
| Cable and direction guider | Check if there’s any loose or fall off for fastening parts | No loose or fall off | |
| Electric parts and the control system | Switch， contact part and protector | Check if stretching part of cable has any bending，distortion，or damage | No bending,distortion or damage |
| Movement condition of cable and guiding device | Smooth movement | ||
| Check whether the switch motion is abnormal，and there is any appearance damage. | normal motion and no damage | ||
| contactor | Check whether pressure of the hinge and clip of contact part is appropriate | contacting pressure is appropriate | |
| spring | Check whether installation and capacity of protector is appropriate | Installed correctly and capacity is appropriate | |
| movable iron core | Check the contacting pressure of contactor and the damage of contact surface. | No gap between contacting surfaces and disconnect completely when disconnecting | |
| Check if there’s any deformation，damage，erosion and fatigue aging. | No deformation，and fatigue aging. | ||
| Check whether there is any adhesive material on the suction surface of iron core | No attachments | ||
| check whether there’s abnormal sound or any broken line for shielded coil | no abnormal sound or broken line | ||
| arc-suppression coil | check if there’s any damage or wear on limited block | no damage or wear | |
| arc chute | check whether there is any gap when open circuit | no gap | |
| Check if there’s any loose for fastening parts | no loose | ||
| fastening parts | Check whether it’s in the original position | should be in the original position | |
| spring | check whetherit’s over-burning | no obvious over-burning | |
| time relay | check if there’s any loose | no loose | |
| damp delayer | check whether there’s fatigue damage | no buckling，deformation，erosion，fatigue damage | |
| check the time-limited | time limit is correct | ||
| operation of contact pieces | Check whether the oil drum falls off，leak oil | No oil leakage or falls off | |
| oil quantity and quality | oil quantity and quality are normal | ||
| Check whether contact surface has any damage and wear | No obvious damage and wear | ||
| Mechanism and operation test | Hand operated,check movement conditions | movement should be normal | |
| Mechanism and operation test | Check the connection of connect terminal | No loose or fall off | |
| Internal wiring | check whether wiring and insulation have damage ，degradation | no damage,pollution and degradation | |
| check whether conduit inlet have any abnormality | no damage or obvious degradation | ||
| check if there’s any loose | no loose | ||
| connection of fastening parts | Check if there’s any abnormal for electric shock protection device | no damage,fall off,deformation or degradation | |
| electric shock protection device | check if movement is normal | smooth movement | |
| movement condition | check whether movement of zero limiter and pendant are normal. | position of limiter and pendant is reliable | |
| check contact pressure； Fastener with no looseness |
contact completely， or disconnect completely when separated. | ||
| Clutch disc and clutch roller | ubricating condition of clutch roller | no loose，oil feed is normal | |
| Check if there is any breakage，deformation，corrosion and fatigue damage | No breakage，deformation，corrosion and fatigue damage | ||
| return spring | check lubricating condition | oil feed is appropriate，lubrication | |
| bearing and gear | check whether contact surface has damage or wear | no obvious damage or wear | |
| contact chip and terminal | contact depth of contact chip | contact completely | |
| check whether there’s crack，defacement | no crack，or obvious defacement | ||
| insulating rod | check whether there’s damage or pollution | Display clearly，no obvious defacement | |
| Lines and communication | display board of movement direction | check whether conduit inlet have any abnormality | no damage or obvious change |
| wire inlet | check movement condition | normal movement | |
| Switch | if there’s any damage，pollution | no damage or pollution | |
| check if any abnormality for enclosure， cover， gravity protection device | no damage | ||
| Check if fastners have any looseness | no loose | ||
| terminal | whether there is any crack， damage | no crack or damage | |
| resistor disc | check whether there is any contact between resistor discs | no contact | |
| check whether there’s any loose | no loose | ||
| check whether wiring and insulation near terminal is overheating or burning | no over-burning | ||
| check whether there is any dust on the insulator | no dust accumulation is allowed | ||
| check if there’s any loose for tightening part | no loose | ||
| connection of fastening parts | check if there’s any damage on protection layer，and there is too tight twisted，and loose wire clamp | no damage，shall not be too tight，twisted or loose | |
| open wire | check whether illuminating is appropriate brightness | Ensure sufficient brightness for operation and instrument | |
| lighting and signal light | any loose joint | no loose | |
| check whether fastners have any looseness. | no loose | ||
| check whether there is any damage for bulk and protection device | no damage | ||
| check whether insulation resistance of each branch circuit of distribution circuit is abnormal. | Insulation resistance value should be within the prescribed scope | ||
| Name of parts | Lubricating cycle | Lubricating condition | Lubricating material |
| Wire Rope | Commonly once every 15-30day,or according to actual conditions | 1.Heat the lubricating to 50-100℃ then apply.2.Apply without heating | core wire rope (SH/T0388 19992);Calcium-based graphite grease(SH/T0369-1992) |
| reducer | At change beginning oil once a season, later change oil once half or one year according to actual condition | Industrial closed gear oil L-CKC（GB5903-1995） | |
| open gear | Clean once every half month, season or half year | Extreme pressure lithium base grease (GB/T7323-1994) | |
| gear coupling | once a month | 1.temperature ranges from -20℃ to 50℃ 2.working temperature higher than 50℃ 3.working temperature lower than -20℃ |
1.calcium lubricating grease(GB/T491-1987) 2.General Purpose Lithium Lubricating Grease(GB/T5671-1995) 3.use no.1 and no.2 special lubricating grease(Q/SY1110-70) |
| rolling bearing | once every 3～6 months | ||
| sliding bearing | according to actual situation | ||
| gear disk inside drum | add oil when over haul | ||
| motor | annual repair or overhaul | 1. normal motor 2.with H insulating grad,and used |
1. General Purpose Lithium(GB/T5671-1995) 2.complex aluminium base grease（SH/T0378-2003） |
| hinge point of brake | once every month | industrial lithium lubricating grease |
| Faults | Causes | Eliminating Method |
| Fatigue crack on main web plate or cover plate | Overload for long time | When crack is less than 0.1mm,use grinding wheel to grind it. For bigger crack，drill Ф8 holes at each side of the crack and open 60° on both sides of the groove,and weld. |
| Wave-like distortion on web plate of main girder | Overload makes local part of web plate lose balance | Rectify with flame,remove distortion,eliminate internal stress with Hammer,strictly prohibit overload operation. |
| side bending of main girder | caused by overlaying of working stress,wrong transportation and storage | Rectify with fire，heating the protrude parts of main girder and use some tools. |
| Main girder sinking distortion. | Main girder structure stress web plate wave-likes distortion effect wrong storage,transportation. | Adopt pre-stressing force to rectify， After flame-treatment,use channel steel to strengthen along lower cover plate of main girder. |
| Name | Failure and damage condition | Reason and Result | Trouble-shooting |
| Forged Hook | fatigue crack on hook surface | Overload，overtime use,flaw of material | replace it if any crack found |
| wear of opening and dangerous section | Lessen the rigidity, or it is easy to cause hook break and accident | replace hook when the abrasion over 10％ of dangerous section | |
| Crack and wending parts have plastic deformation | Long time overload and fatigue. | Replace immediately | |
| Laminated hook | distortion of hook | Long time overload,and it is easy to cause hook break | replace |
| surface has fatigue crack | overtime， overload and hook damage | replace | |
| the abrasion of pinshaft is more than 3％ -5％ of nominal diameter | Hook fall off | replace | |
| earring has crack or burr | earring breakage | replace | |
| the abrasion of earring’s lining reaches 50％ of original thickness | bad forced condition | replace | |
| wire rope | Breakage,knotting,abrasion | Cause to breakage of rope | Stop to use it when wire rope break and knot; replace according to standard when thread break,and replace the wire according to standard rope-when it have abrasion |
| pulley | Uneven abrasion of block’s groove | material asymmetry, bad installation and bad connection of rope and wheel | replace it when abrasion of groove’s wall reaches 1/10 of previous thickness,and gauge ware reaches 1/5 of wire rope diameter |
| pulley can not rotate | shaft and bearing damage | replace the shaft and bearing and then lubricate and maintain them | |
| pulley incline or loose | keeper of shaft loose or wire rope hop out of groove | Fasten the keeper and repair the wire rope’s hopping | |
| crack of pulley or break of wheel flange | pulley damage | replace | |
| drum | Drum fatigue crack | break of drum | replace drum |
| abrasion of drum’s shaft and key | break of shaft and cause the load fall off | stop using and inspect the shaft key immediately | |
| Groove abrasion and rope hopping.The abrasion reaches 15％～20％ of the original thickness |
The rigidity of drum becomes weaker and easy to break. And wire rope is twisted | replace the drum | |
| gear | Gear teeth break | abnormal noise during operation,if continue to use, it will damage the transmission mechanism | replace the new gear |
| Abrasion of gear reaches the 15％ ~20％ of the original teeth thickness | impact and vibration occured during working and then damage the transmission mechanism | replace the new gear | |
| Gearc rack，gear key groove damaged by rolling of key | Vibration and noise caused by overtime use and improper installation, which make load fall off | replace lifting mechanism,for traveling mechanism,repair or renew the key | |
| Flack section reaches 30％ of the working area. And the depth reaches 10％of the teeth thickness；Carburized layer abrasion reaches 80％ of teeth the thickness. | Overtime use,Bad material, improper heat treatment cause the damage of shaft. | replace:for the reducer with peripheral speed>8m/s, when there is some abrasion,replace pairs of high speed gear of reducer. | |
| shaft | crack | Bad material， improper heat treatment cause the damage of shaft. | replace |
| Bending of shaft is more than 0.5mm/m | cause damage of shaft and influence the transmission and cause vibration | Replace or rectity | |
| damage of key groove | unable to transmit torsion | for lifting mechanism,replace them,or traveling mechanism,repair them | |
| wheel | wheel tread and wheel flange have fatigue crack | damage of whee | replace |
| Uneven abrasion of drive wheel surface | leads to rail gnawing,tilt of crane | replace in pairs | |
| Abrasion of tread reaches 15％ of wheel flange thickness | vibration when traveling;damage of wheel | replace | |
| Wheel flange abrasion reaches 50％ of the previous thickness | Due to the crane tilt and rail gnawing,and cause derailment | replace | |
| brake part | Fatigue crack on lever | brake fails to work | replace |
| Fatigue crack on spring | brake fails to work | replace | |
| The abrasion of mi⁃ nor shaft and mandrel reaches 3％ ～5％ of nominal diameter | Fails to brake | replace | |
| the abrasion of brake wheel 40% ～50％ of the original wheel flange thickness | load fall off or crane slide | replace | |
| Brake shoe friction shim wear 2mm，or to 50％ of primary thickness | failure break | replace friction shim | |
| Coupling | crack on coupling | damage of coupling | replace |
| loose in connection bolts | Impact and vibration during braking starting will cause bolts breakage and falling of loads | Tightened | |
| Abrasion or breakage of coupling gear | Lack of lubrication, heavy workload,start oppositely will lead to damage of coupling | For the lifting mecha nism,when the abrasion of gear teeth reaches 15％ the original thickness, replace it,and for the traveling mechanism,when the abrasion of gear teeth reaches 30％ the original thickness,replace it. |
|
| Press and deformation of key groove | cannot transmit the moment of torsion, key falls off | for lifting mechanism, replace them,for other mechanisms,repair them | |
| Abrasion in shaft, pin and rubber ring etc | Heavy impact and vibration when starting or braking | Replace worn parts | |
| rolling bearing | Temperature is too high | lubricating oil dirt | clean dirt,replace bearing |
| Completely lack of oil | add lubrication oil as per regulation | ||
| Too much oil | check the quantity of lubrication oil | ||
| abnormal noise（Continue to dead sound） | dirty bearing | clean dirty | |
| metal grinding noise | lack of oil | add oil | |
| topping or impact sound | Pamage of coupling support, rolling body | Replace bearing | |
| sliding bearing | over heating | incline of bearing and press too tight | Eliminate deflection,tighten reasonablely |
| improper clearance | adjust clearance | ||
| lubrication shortage | add lubrication | ||
| bad lubricants | use good and qualified lubrication |
| Name | cause | Solutions | |
| brake | Fail to lock brake wheel (load fall down) |
Hinges of leverage is stuck | Remove stuck and give lubrication |
| oil on the brake wheel and friction shim | Clern oil dirt | ||
| lack of travel distance of magnet iron core | adjust brake | ||
| brake wheel and friction shim have heavy abrasive wear | replace friction shim | ||
| main spring loose or damage | replace main spring and nut | ||
| Lock nut and lever loose | Fasten lock nut | ||
| Hydraulic thruster impeller not work | Check electrical part of thruster | ||
| Brake fails to release | Magnetic wire burned | Replace | |
| Disconnection of wire to magnetic conductor | Connect the wire | ||
| Shoe block on on braking wheel | Clean with kerosene | ||
| Gemel stuck | Eliminate the lock and lubricate it. | ||
| Main spring force is too large or configuration is too heavy | Adjust the main spring force | ||
| Push bar inflected，can not move the magneticiron(hydraulic push bar break) | Straighten the mandril or change he mandril | ||
| Improper oil application | Chang oil according to working condition | ||
| Impeller is locked | Adjust push rod and check electrical part | ||
| 85％ lower than the rated load,magnetic force is not enough. | Find out the reason of voltage reduction,eliminate the trouble. | ||
| Break heating, friction shim realease scorched smell and get worn soon. | Shoe can’t fully disengage braking wheel friction when break loose，so cause friction | Adjust clearance | |
| Asymmetrical distance from two brake shoes to braking wheel | Adjust clearance | ||
| Supporting spring damage or bending | Replace or repair the spring | ||
| Rough surface of break wheel | Turning the surface of brake according to requirements | ||
| The brake is easy to deviate from the adjusted po sition. And the breaking torque is not steady | Fasten nut is loose. Screw thread damage | Fasten nut；Replace it | |
| Magnetic overheat or abnormal noise | Main spring is over pressed | Adjust to proper extent | |
| Push bar is blocked | Eliminate the block and make lubrication | ||
| Wrong position of iron core and mandrel | leveling fitting surfaces | ||
| reducer | phenomenon of periodic cyclical gear vibration, especially for the driven wheel | Section distance error,gear side clearance beyond tolerance | Repair,re-install |
| Severe metal friction sound, reducer shake, shell tinkers. | Gear backlash is too small,gear axes are not parallel,gear has sharp edges |
adjust,re-install | |
| gear meshing,irregular rattle, shell shake. |
teeth surface is not flat，teeth with flaws, gear contact surface are not completely clench,but contacton on one angle | replace gear | |
| shell heating,especially the place where bearing installed | bearing damage | replace bearing | |
| bearing neck is stunk | replace bearing | ||
| bearing wear | replace gear | ||
| lack of lubrication oil | Replace lubrication oil | ||
| oil lealcage of subdivision surfaces | seal failure | replace sealing parts | |
| shell deformation | check Subdivision surfaces, replace it when heavy damaged | ||
| Subdivision surfaces are not flat | Subdivision surface levelled | ||
| Connection bolt is loose | Clear the return chute,and fasten the nuts | ||
| reducer shake on base | anchor bolt is loose | adjust anchor bolt | |
| shaft center lines are not match | Diagonal line adjustment | ||
| base rigidity is not enough | reinforce base and increase rigidity | ||
| Heating of reducer | Too much oil | Adjust oil level | |
| Rope and pulley | Wire rope abrasion and damage | Diameter of pulley and drum are too small | change wire rope with better flexibility,increase the diameter of pulley and drum |
| The wire rope diemension does notmatch with the groove of drum,it is too small | Use thinner wire rope of same capacity,or change sheaves and drum | ||
| dirty and lack of oil | Clean and lubricate | ||
| False installation of lifting baffte and cause rope abrasion frequently | Adjust | ||
| Pulley groove and wheel edge are not smooth and have defects | Adjust | ||
| some pulleys cannot rotate | Bearing lacks of oil；dirt and corrosion in bearing | lubricate,clean | |
| Name | Reason | Method | |
| crane travel mechanism | bridge travel tilt, rail gnawing | two driving wheel diameter difference excessive | measure, machin and replace wheel |
| driving wheels are not fully contact with rail | balance rails and adjust wheel | ||
| wheel horizontal difference is too much | Check and eliminate wheel lateral deviation exceeds to lerance pnenomenon | ||
| Deformation of metal structure | rectify | ||
| Gauge,side direction and 2 rail height differences deviation too much | Adjust rail and make rail in⁃ stallation satisfy technical requirements | ||
| oil or ice on rail head | remove oil dirt and ice | ||
| trolley travel mechanism | Rail skid | oil on rail head | clean |
| wheel load is not even | adjust wheel load | ||
| rail top height difference is too much at the same cross section | adjust rail till it meets technical requirements | ||
| start or brake too violently | change method of motor start，choose winding motor | ||
| trolley twists when starting | 1.trolley wheel load not even or on Wheel suspend in air 2.Rail gnawing |
1. Adjust the problems that only 3 wheels touch the rail 2. Solve rail gnaw |
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| AC motor | Evenly overheat of the whole motor | JC％ too big cause over load | lower down working duty or change high JC％ motor |
| working at low voltage | stop working when working voltage is 10％ lower than rated voltage | ||
| motor selection is not right | select right motor | ||
| Crane Parometers specs changed after checking | Check and adjust to ensure specification | ||
| local overheat of stater | silicon-steel plate is short circuited | use insulation paint to the places where short circuit happened | |
| local overheat of stator winding | Uiring fault | Check and eliminate the wrongly wiring | |
| 2 points on winding have short circuit with shell | repair winding of phase | ||
| temperature of raise rotor，heavy current impalt stator，motor cannot get full speed at rated current | End winding terminals，neutrality points and parallel winding get poor contact. | check welds and eliminate defects | |
| winding group and sliding loops have loose connection | check connection condition | ||
| Electrical brushes have loose connection | check and adjust brushes | ||
| Poor contact in rotator circuit | Check loose and poor contact condition and rectify Check the resistance and change the brolken one. | ||
| motor vibration when working | Motor and reducer axes are not at the same line | Re-install | |
| Bearing damage and wear | replace bearing | ||
| Deformation of rotor | check | ||
| abnormal noise when working | phase of stator error | check wiring and modify | |
| stator iron core is not pressed | check stator and repair | ||
| bearing wear | replace bearing | ||
| wedge expands | cut expanded part or replac wedge | ||
| After motor is loaded, its rotation specd slow down | ends of rotat or short circuit or 2 locations of rotor winding earthing | eliminate short circuit check each loop, repair the damaged and eliminate short circuit. | |
| friction of stator and rotator when motor working | end of bearing connection is short circuited | replace damaged bearing and check the cover position,eliminate rag on stator and rotor | |
| loop connection is not right, flux is not balanced | make connection right and check if each phase is equalin stator | ||
| spark on brush or sliding ning is burned | brush bad grinding | nice grinding | |
| brush is too loose when working | just properly brush or grinding | ||
| brush or loop are dirty | clean with alcohol | ||
| loop is not flat，cause brush jumping | machining and grinding loop | ||
| low pressure of brush | (18~20KPa) adjust brush pressure | ||
| brush grade can not match | replace | ||
| current distribution of brush is not even | check power-feeding wire and brush，corret | ||
| sliding ning open circuit | loop and brush dirty | clean dirt | |
| AC electri cmagnet | overheat of loop | Overload of Magnetic iron force | Adjust the spring pulling force |
| Fixed part and stationary part of close circuit have gap | eliminate clearance | ||
| Loop voltage and power voltage are not match | replace loop or change connection method | ||
| too noisy when working | Magnetic iron overload | Adjust the spring | |
| Dirt on magnetic flow circuit surface | Clean dirty | ||
| Deflection of magnetic system | Adjust mechanical part of brake and eliminate deflection | ||
| Unable to over-come the spring force | Magnetic iron overload | Adjust the main spring of break | |
| spring force is too big | Adjust the main spring of break | ||
| low voltage | stop working | ||
| AC contactor and relay | overheat of loop | loop overload | reduce the pressure that the movable termincal acts on the fixed terminal. |
| Movable part of magnetic flow can⁃not contact with fixed part | Eliminate deflection jamming,dirt or change loop | ||
| contact is too noisy | loop overload，dirt on magnetic flow surface | reducer contact pressure, clean dirty | |
| Magnetic flow self adjust system jamming | eliminate jam | ||
| contact overheat or burned | contact lacks of pressure | adjust pressure | |
| contact is dirty | clean or replace | ||
| main contact cannot get through | Switch not close，EM switch not close | close switch | |
| upper door switch not close | close switch | ||
| control stick is not at 0 position | put stock to 0 position | ||
| control circuit fuse burned | check or replace fuse | ||
| no power in circuit | check if voltage is on | ||
| Break-off happens frequenly when crane is working | contact pressure is not enough | adjust contact pressure | |
| contact is burned | replace or grinde contact | ||
| contact is dirty | clean | ||
| working overload, over current | reduce current load | ||
| slide wire is not parallel, loose contact between current collector and slide wire | adjust the rail or wire | ||
| contact too slow | clearance of magnet pole surface is too large | Shorten pole surface clearance | |
| upper part of base plate is more protruding than lower part | install parts vertically |
| Name | Reason | Method |
| fuse in control circuit burned after knife switch closed | This circuit phase earthing in control circuit | check earthing part by ohmmeter and eliminate malfunction |
| after mechanism transmission over current relay still work | setting value of over current relay cannot meet requirements | adjust relay as following formula Irated=（2.25～2.5）I rated |
| mechanical transmission part jammed led to motor overload | check transmission part and eliminate jam | |
| Motor cannot rotate after controller is closed | first phase power cut and motor has noise | find damage and re-wiring |
| wire breakage in rotor circuit | find damage and re-wiring | |
| loop has no voltage | find damage and re-wiring | |
| Contacts in controller cannot contact | repair controller | |
| current collector brush failure | repair brush of collector | |
| brake malfunction and cannot release | repair brake | |
| motor can only rotate to one direction after controller is closed | reverse contact loose connection or malfunction with steering mechanism | check controller and adjust contact terminal |
| distribution wire failure | find malfunction by short method | |
| working mechanism travel to limit and press limit switch | Eliminate malfunction | |
| limit switch malfunction | check switch and eliminate malfunction | |
| terminal limit switch is on,main contact not release | short circuit of lerminal suitch circuit | Check，eliminate short circuit |
| connect with controller cause disorder | correct wrong wire distrimltion | |
| controller jam and impact when working |
malfunction when positioning | eliminate error |
| contact jam in curve chamber | adjust contact position | |
| controller cannot pull when working | Positioning mechanism failure | just pressure |
| contactors kurning and bonding | clean contactor | |
| generator cannot excitant | Excitation loop wiring cut | check excitation loop |
| reverse rotation of generator | replace 2 phase wiring of driving motor | |
| After disconnecting power (control circuitbreak)the contactor of protection box won't break off | short circuit or earthing in control circuit | find those places and solve problems |
| Weld contact terminal, give power supply to main circuit | Cut burued contact terminal, to malce it function again. |
