Please read this User Manual before installation and operation of this product

General Series Overhead Crane

User Manual

Product Code: A133900066MS(HSM01)

DALIAN HUARUI HEAVY INDUSTRY GROUP CO.,LTD.

July. 2017
 Special Equipment Manufacture License No.: TS2410E60-2013

Please read this User Manual before installation and operation of this product

General Series Overhead Crane

User Manual

Product Code: A133900066MS(HSM01)

DALIAN HUARUI HEAVY INDUSTRY GROUP CO.,LTD.

DALIAN HUARUI HEAVY INDUSTRY CRANE CO.,LTD.

July. 2017
 Foreword

Distinguished clients:

Thanks for choosing our products!

To ensure correct assembly, safe and fault-free operation of the overhead crane, please
read carefully this User Manual and pay special attention to safety rules and warnings
herein.

Please put this “User Manual” at place of easy access for timely checkup in case of
any doubt.
This User Manual is delivered to the equipment user and the copyright belongs to
DHHI Co., Ltd. Without our authorization or approval, technical specification,
drawings or sketches can’t be duplicated, distributed, used for competition or
provided to the third party completely or partially.
Please keep carefully the User Manual within the equipment’s lifespan.
This “User Manual” is suitable for overhead cranes in general series.

If you can’t find answers about your query in this manual, please contact us and we
are pleased to offer any help.
Our Company’s Correspondence
Address: No.29, Shunda Road, Lushunkou Economic and Technological
Development Zone, Dalian, Liaoning
PC: 116052
Website: http://www.dhidcw.com
Hotline: 0411-86852642 E-mail:fanyl@dhidcw.com
Client Service Center: 0411-86202423 Fax: 0411-86202424
E-mail:qzjgs@dhidcw.com
 Installation and adjustment(Mechanical Part)

Table of Content

3.1 Transport and storage

3.2 Unpack and inspect

3.3Equipment foundation, installation condition and technical

requirements of installation

3.4 Preparation before installation

3.5 Specific installation and adjustment procedure

 Installation and Adjustment
3.1 Transport and storage
3.1.1 Attentions during lifting and transport
3.1.1.1 Attentions during lifting
 A Lifting Leader Team shall be established before lifting to work out a
consummate and efficient operation commanding procedure for the lifting
process, including “drawing the Site Lifting Position Plan View”, “fixing the
machine, fixing the person, fixing the position, fixing the responsibility” to make
sure that the entire lifting process is carried out orderly.
 The user and installation unit shall provide safety training about lifting operation
to workers in accordance with applicable national rules of production safety and
ask staff to pay attention to safety rules and safety responsibilities.
 Before lifting, check carefully the site, load, lifting tool and locking devices for
any hidden danger. If there is any hidden danger, it must be corrected properly
before any lifting work is carried out.
 The lifting working area shall be enclosed by warning lines and doesn’t allow the
entrance of unauthorized staff. During lifting, persons are prohibited to enter into
the working area.
 Observe strictly the rule of “Ten No-Lifting Situations” when operating the crane
at the worksite, i.e. “no lifting if the weight isn’t clear, no lifting if ground sinking
depth isn’t clear, no lifting if the signal isn’t clear, no lifting if it allows only
upward movement but no downward movement, no lifting if the load isn’t clear,
no lifting during nighttime if there is no lighting, no lifting if the sling doesn’t
conform to applicable requirements, no lifting if the load isn’t bound firmly, no
lifting if there is people standing below the load, no lifting when the wind is
Level 6 or higher.
 No lifting when there is people standing on the load, no lifting if there is people
standing below the crane’s cantilever.
 The crane operator can’t drive or give commands when they haven’t license or
after drinking.
 The operator must be concentrated, shall not talk, smoke or do things irrelevant to
work.
 When lifting big or exceptionally heavy parts, the operator must pay attention to
the contour, dimension and position of centroid and work out an effective lifting
plan.
 Shall pay attention to warning signs of the load, like “easy to break, don’t use
hand hook, upward, kept away from direct sunshine, anti-radiation, rainproof,
centroid, no rolling, don’t use handcart at this side, don’t use the fork lift, clamp
tightly at this place, don’t fasten or clamp at this place, limit of stacking weight,
limit of stacking tiers, no stacking, lift from here, temperature limit and etc. Carry
out the lifting work in strict accordance to such signs to avoid unnecessary
damage to the equipment due to any negligence.
 If the box is damaged during lifting, the box shall be repaired immediately and
 adopted with rainproof, moisture-proof and dustproof measures to ensure
consistent with the original state and avoid elements in the box from being
damaged.
3.1.1.2 Transport attentions
 A Transport Team shall be established before transport and work out a complete
set of transport plan and safety rules.
 Before transport, the transport department needs to check carefully the weight
and exterior dimension of cargoes and choose the suitable vehicle. Before
transport, the route, road junction, road condition and loading/unloading site shall
be checked carefully and problems identified shall be corrected timely. The team
shall work out a feasible transport plan to ensure no deformation, no damage or
wetting of the cargos.
 Check carefully whether cargoes are bound and padded firmly during transport,
whether it is firmly fixed onto the vehicle, whether the ultra-wide and ultra-long
parts have warning signs and warning lamps during night transport.
 During transport, don’t drive when being tired, don’t violate traffic rules, observe
national rules about safety of road transport.
 As to poor road segments (sharp slope, bending, winding road, narrow road and
etc), a dedicated commander shall give instructions and prevent occurrence of
any accident.
 During transport of packages, pay attention to signs on the package, such as “easy
to break, don’t use hand hook, upward, kept away from direct sunshine,
anti-radiation, rainproof, centroid, no rolling, don’t use handcart at this side, don’t
use the fork lift, clamp tightly at this place, don’t fasten or clamp at this place,
limit of stacking weight, limit of stacking tiers, no stacking, lift from here,
temperature limit and etc. Carry out the lifting work in strict accordance to such
signs to avoid unnecessary damage to the equipment due to any negligence.
 Bundles, like pipes, round steel, profile steel and simple structure could be
stacked during transport. During transport, protective measure shall be adopted
(like adding shock-absorptive material, rubber products, tightening bots and etc
for fixation and anti-slide) to prevent bundles from becoming loose, which might
make it inconvenient for lifting, or case crushing or bending of thin-wall pipe
materials.
 When being loaded to trucks, the equipment shall be uniformly configured, not
placing too much weight on one side or one end. Adopt counterweight measures
when necessary.
 After the equipment is loaded into truck, the center of gravity can’t be higher than
that specified by road or railway transport rules.
 The maximum exterior dimension and weight of product parts being transported
shall conform to rules about not exceeding the size and weight limit for cargo
transport. Observe national rules for transport of ultra-long, ultra-wide and
ultra-heavy cargos.
 As to ultra-large and ultra-heavy parts that need special vehicles for railway
transport, the loading reinforcement structural diagram shall be drawn, marking
 the largest exterior dimension and position of gravity center. It shall meet
applicable rules of railway transport and ensure that equipment is safely delivered
to clients.
 Anti-theft measures shall be adopted for transport of valuable cargoes. The carrier
shall be responsible for any damage caused during the transport.
 Other technical requirements of the transport shall conform to rules in
GB/T18923-2002 (Transport).
 The transport company shall provide a complete record on damage of cargoes
before and after the transport. Regarding damage caused by transport, the user
shall communicate immediately with the manufacturer, work out a repair plan and
repair it immediately to prevent further loss.
3.1.2 Storage conditions, storage period and attentions
When the equipment is delivered to site, it shall be stored in strict accordance with
storage conditions as specified on the package. If such conditions are not given on the
package, the following requirements shall be met rigorously.
 Bundles of steel structures could be placed outdoors at high places and without
accumulated water. The body of equipment shall be cushioned with wood.
Ultra-high objects that are easy to fall shall be fixed firmly and set up with
waning signs of “Danger of Falling Object, Keep far away”. As to rotating shaft
and planes bound by high-strength bolts, check whether the waterproof and
rustproof measures are damaged or not. Repair damaged parts timely to prevent
entry of water, dust or appearance of rust.
 Packages shall be placed under rainproof sheds, without water accumulation. It
shall prevent rainwater from entering into the box and damaging internal
elements.
 Packages of electrical and hydraulic elements shall be placed in dry rooms to
prevent moisture. As to boxes that have strict damp-proof requirements, check
regularly the state of desiccant, and change it immediately if the service life is
expired.
 When the equipment is delivered to the worksite, it shall be installed and receive
normal maintenance within six months. If the user chooses not to install the
equipment for a long period due to other reasons, the user shall work out a proper
storage and maintenance plan. The user shall check and maintain the equipment
every two months after it is delivered to the site (including removing rust and
conduct repair painting on damaged surface, adopting rustproof measures on
surfaces bound by high-strength bolts, fill grease into bearing box, adopt
dustproof and waterproof measures on bearing box, adopt waterproof and
damp-proof measures on electric and hydraulic elements), keep a complete record
on damages and maintenance for future reference. The supplier gives an
18-month warranty (since the cargo is delivered to the site) on equipment
performance provided that it is stored and maintained by the user in accordance
with above requirements. When the cargo has been in the store for more than 18
months, the supplier will not provide any warranty on the equipment performance
even it has been stored and maintained by the user in accordance with above
 requirements. The user shall be responsible for any problem arising hereof.
3.2 Unpack and inspect
3.2.1 Unpacking attentions
 When the equipment is delivered to the worksite or the user’s warehouse, the user
shall unpack and inspect the equipment delivered according to the contract and
the supplier shall send its representative to attend the unpacking and inspection.
The user shall notify the supplier to send its staff to attend the joint unpacking
and inspection 15 days before the unpacking and inspection. The inspection result
shall be regarded as the inspection result jointly recognized by both parties. If the
client unpacks and inspects by itself without the attendance of the supplier’s
representative, the unpacking and inspection result shall be regarded as that “the
user shoulders voluntarily the unpacking responsibilities and the supplier isn’t
responsible for the unpacking result. If the supplier notifies the user that it will
not send any representative to attend the unpacking and inspection, the user shall
work out a new unpacking and inspection plan together with the supplier. The
new unpacking and inspection result shall be regarded as the inspection result
jointly recognized by both parties.
 The user shall prepare suitable unpacking tools before unpacking, unpack
carefully and don’t damage any object inside the box, don’t work brutally. Lifting
or transport, if necessary for unpacking and inspection, shall be carried out in
accordance with 3.1. As to any damage caused by unpacking and inspection
(during lifting, unpacking), the user shall shoulder the responsibility and the
supplier doesn’t shoulder any responsibility.
 If it is found that cargoes are damaged during packing, transport or manufacture,
but are not timely repaired, the user shall communicate with the supplier
immediately and work out a solution. Don’t assemble cargoes that are damaged
or have hidden danger into the equipment to prevent occurrence of any
subsequent accidents.
 After unpacking and inspection, the box shall be restored to the original state.
Store it in accordance with the storage requirements as specified in 3.1.2.
3.2.2 Inspection items
 It shall be inspected, verified and recorded in accordance with the contract or
packing list. Inspection items are as below:
 Appearance inspection on damages of bundles and cargo boxes
 Check the quantity of cargoes
 Inspect damage of cargoes inside the box (becoming damp, rusted or not)
 Inspect the working state of cargoes, check whether they are qualified products
(whether rotating normally, whether there is transformation due to transport)
3.3 Equipment foundation, installation condition and technical requirements of
installation
3.4 Preparation before installation
The crane must be installed and adjusted by the unit with proper qualifications
based on drawings provided by the manufacturer and this User Manual. Before
installation:
 Unpack the package, count the quantity of parts and documents in accordance
with the packing list and check the appearance
 Read installation drawings and user manual provided by the manufacturer, and
work out a installation plan and procedure based on the actual situation
 Eliminate errors or defects caused by improper transport or storage based on
technical requirements in drawings
 If it is stored for a long period (generally more than half a year), it shall check the
corrosion and apply painting again when necessary.
 The installation staff must have received safety training regarding specific
procedures and passed the examination.
 The installation unit shall check the lifting devices from all aspects and ensure the
safety of installation process.
 The installation unit shall hang or adhere warning signs at the installation site.
3.5 Specific installation and adjustment procedure
3.5.1 Installation and adjustment of major lifting mechanism
The lifting mechanism is already assembled at the manufacture’s workshop and
has completed idle running test. Drum, crown block, motor and other parts and
accessory devices on the platform that are disassembled due to exceeding size limit
during transport shall be installed onto the frame in accordance with positions and
technical requirements on drawings after the main trolley frame is assembled and
adjusted.
 One end of the drum rests on the output shaft of the reducer through the drum
coupler and the other end rests on the drum seat. Before installation, check
whether bolts of the drum coupler are loose or not, whether there are gaps at two
ends of the bearing, check whether bolts at the output shaft end of the speed
reducer are fastened.
 As to motors that have been stored for a long period, check the insulation
resistance between the stator and rotor’s winding and shell or shaft with 500V
megameter before installation. If it is lower than 0.5M, the motor must be dried
and the winding’s temperature shall not exceed 145℃ during drying. Interior
space of the motor shall be blown clean with dry compressed air and conducted
with mechanical inspection: check whether fasteners are loose, the rotor shall
rotate flexibly when being turned by hand, whether nuts at axle head of coupler
installed on the extension of taper shaft is tightened. Let the motor run for
30~40min without load. After power-on, judge the direction of rotation and
confirm it as correct before installation, not to damage parts due to wrong
connection. During installation, calibrate relevant position between centerlines of
the motor and reducer’s high speed spindle (Refer to 3.5.2 for permissible
deviation). Tighten ground bolts after adjustment.
 When the crown block is installed with a sensor, check whether the sensor is
firmly fixed to the crown block, whether wirings are intact.
 Check the assembly position of the brake:
--Coaxiality of the brake’s centerline and braking wheel’s axial line: When the
braking wheel’s diameter D<315mm, the coaxiality is 2mm, When D≥ 315mm, the
coaxiality is 3mm.
--Adjust the gap between the brake wheel and brake washer (Refer to 3.5.2) and
their contact area≮70%
--Adjust the compensating stroke of brake pusher to reach rated value（adjustment
methods refer to brake user manual）
--Turn the brake wheel by hands, the drum shall not have sticking during one turn.
Joints and hinges of the brake shall rotate flexibly, without sticking.
--Adjust the spring at each brake to ensure the same braking torque.
--Other requirements of installation and adjustment refer to brake User Manual.
 When the trolley is lifted above the bridge, install the steel wire rope.
The left-handed drum uses right-handed steel wire rope and right-handed drum uses
left-handed drum rope. The end of steel wire rope is fixed onto the drum by a
clamping plate by not less than two turns. The other end of each steel wire rope
(meanwhile, attach the counterweight sleeve of the counterweight switch onto the
balance pulley rope), pass through the pulley on the hook and crown block on the
frame, and then fix the end with rope clamp (wedge sleeve) (when the wedge sleeve is
used, clamp the rope’s end with a rope clamp). Steel wire ropes shall be installed in
accordance with the installation drawings.
 Install and adjust the limit switch to conform to limit position requirements.
 After each mechanism is installed, the installation precision of axial lines of parts
and brake wheel shall conform to rules in 3.5.2. Double-teeth coupler shall be
paid with special attention and inspected rigorously.
 Install and check the lubrication system of the main lifting mechanism: each
coupler shall be filled with grease; thin oil shall be filled into the speed reducer in
accordance with requirements on drawings, two oil pumps shall be installed to
proper position on the speed reducer; the oil inlet pipeline of the crown block and
drum shall be intact, without deformation; the lubricator of steel wire rope shall
be firmly installed and filled with grease.
The installation and adjustment of each part shall also observe
rules in latest User Manual provided by part manufacturers.

3.5.2 Installation precision of parts

The installation precision of parts shall be decided based on couplers being
connected:
 The angle of skew α between axial lines of two parts (Fig.3-1) can’t exceed
1.5°for gear coupler and not 10°～15°for universal coupler.
y
α

Fig.3-1 Angle of skew and radial displacement of coupler

 When there is skew between axial lines of two parts, refer to Table 3.1 for
permissible radial displacement of the gear coupler (Fig.3-1).
Table 3.1 Permissible deviation for installation of couplers (mm)
Type Type Type Type Type Type Type Type
3 4 5 6 7 8 9 10
Modulus (m) 3 3 3 4 4 4 6 6
Number of teeth
40 48 56 48 56 62 46 56
(Z)
Gear’s external
126 150 174 200 232 256 288 348
diameter (D)
Displacement
1.6 1.2 1.4 1.4 1.5 1.7 1.8 2.0
(△y)
 Refer to Table 3.2 for installation accuracy of the gear coupler
Table 3.2 Installation accuracy of couplers
Diameter of permissible deviation of permissible deviation of angle
coupling hole Coaxiality between two axial between two axial lines (°)
lines(Circular run-out),(mm)
≤100
0.05
＞100~180 0.05
＞180~250
0.1
＞250~315
0.1
＞315~450 0.15
＞450~560
0.15 0.2
＞560~630
＞630~710 0.25
0.2
＞710~800 0.3
 The swing (or run-out) after the brake wheel is installed shall not exceed values
in Table 3.3
Table 3.3 Permissible run-out deviation for installation of the brake wheel (mm)
Diameter of brake wheel ≤250 ＞250～500 ＞500～800
Radial run-out 0.1 0.12 0.15
Axial swing 0.15 0.20 0.25
 Refer to Table 3.4 for initial gap between the brake and brake wheel.
Table 3.4 Initial gap between the brake and brake wheel (mm)
Diameter of brake wheel D 250 315 400 500 630 710 800
Initial gap between brake 1.25 1.25 1.25 1.25 1.6 1.6 1.6
washer and wheel
3.5.3 Installation and adjustment of the truck and trolley’s traveling mechanism
Truck and trolley’s traveling mechanism are already assembled in the
manufacturer’s workshop and have passed the idle running test. If they need to be
assembled after being disassembled for transport or repair, it shall ensure that:
 The permissible tolerance of the truck’s span is ±5～±8mm (±5mm when the
span S≤28m, ±8mm when the span S＞28m). The relative difference between
 spans measured on each pair of wheels shall not exceed 5mm; the trolley track
gauge measured at wheels of the trolley is±3mm and the relative difference of
trolley track gauge measured at each pair of wheels shall not exceed 3mm.
 When there are four wheels, the horizontal skew at end face of each wheel is
△P=│P1-P2│≤m/1200 and the skew of two wheels on the same axis has opposite
directions. When there are more than four wheels, two wheels under each balance
bogie (balance beam) △P=│P1-P2│≤m/1200, the skew between all wheels under
the same end beam isn’t bigger than m/800 and it is permissible not to control the
direction of wheel skew. Unparallel direction of two corresponding drive (driven)
wheels should be opposite, as shown in Fig.3-2.
 Vertical skew at the end face of wheel isn’t bigger than D/400 and must deviate to
outer side of the steel track at the top.
 As to two wheels installed on the same balance beam, the position deviation shall
not exceed 1mm. Maximum position deviation of wheels under the same beam: <
2mm when there are two wheels, <3mm when there are more than two wheels, as
shown in Fig.3-3.
 Idle running, suspend the wheel in air, turn manually the wheel by one turn, no
sticking
 During idle running, all wheels should touch the steel track.
P1
m

φ
基距W（Wc）

P2

φ
D

跨度S（轨距K）

≤D/400

Span S(track gauge K)

Fig.3-2 Horizontal skew
≤3mm

≤1mm

Fig.3-3 Position deviation

 Adjust the spring compression of two brakes (four brakes) and make the brake
torque consistent
 Adjust the limit switch so that it could stop precisely at the limit position
 Cushion plates and bottom seats of parts are allowed to add adjusting pads onto
 non-machining planes during alignment, but not more than two layers (three
layers are allowed at the wheel). After installation, they must be welded onto the
bottom rack; the welding seam at the pad shall be increased to ensure that it is
firmly welded and doesn’t come loose when working.
3.5.4 Install and adjust the bridge, and connect high-strength bolts
The crane’s bridge is already pre-assembled in the manufacturer’s workshop and
has passed quality inspection. The bridge is then disassembled, lifted, loaded and
stored due to transport. Hence, what is delivered to the user isn’t the integral bridge.
They must be assembled and adjusted at the worksite.
During lifting, use the lifting lug on the main beam (trolley frame)’s cover, the
angle between the lifting rope and horizontal line shouldn’t be greater than
70°(otherwise, it will damage the lifting lug and cause serious consequences). Keep
the center of gravity at the central position, as shown in Fig.3-4.
When lifting the main beam (trolley frame), other loads can’t be added to it to
avoid accident.

Fig.3-4 Lifting the Main Beam

3.5.4.1 Install connectors of end beam
Put bridge segments onto the horizontal and parallel steel rails
Connect the main beam and end beam with bolts of main beam and end beam
according to the labeled part diagram and rules in 3.5.4.2.
3.5.4.2 Connect through high-strength bolts
The crane’s steel structure is connected by high-strength bolts, transferring load by
friction. Connection by high-strength bolts has the advantage of small stress
concentration, good rigidity, uniform transfer of force and large bearing capacity. To
ensure the load transfer, the friction plane being connected has already undergone
steps of sandblasting and painting to reach high roughness and slip factor. During site
installation, use torque wrench provided together with the crane in accordance with
the following steps:
 Torque wrench used must be calibrated before use.
Torque= the arm of force × gravity
 The connector’s friction face shall be cleaned. Uneven plates could be assembled
only after having reached the straightness requirements. Friction plane can’t have
fins, burrs, welding splashing, welding scar, oxide skin, dirt or unnecessary paint,
 mud; no burrs around the hole; the friction plane being installed must be cleaned
by steel wire, and the direction of brushing shall be vertical to the direction of
friction force.
 Front plates connected by high-strength bolts must have close contact. The gap
between friction surfaces resulting from tolerance of plate thickness, deviation of
manufacture or installation shall be handled in accordance with rules in Table 3.5.
Table 3.5 Addressing the gap between connecting plates
No. Scheme Remarks

Not handled when t<1.0mm

1

t=1.0～3.0mm, grind the thick plate side

2 into a gentle slope of 1∶10 and make the
gap smaller than 1.0mm
Add cushion plate when t＞3.0mm, the
thickness of cushion plate isn’t bigger
than 3mm, and doesn’t exceed three
3 tiers at most, the material of cushion
plate and treatment method of friction
plane shall be same with the structural
members
Control the gap as specified in above table, ensure uniform transfer of force on
structural parts after connection.
 If the installation hole has some problem, the hole can’t be reamed by
oxyacetylene. You can’t put high-strength bolt into the hole while correcting the
hole position with a punch. When the displacement is big, use reamer to ream to
hole. When some holes have large displacement,, drill again after repair-welding.
After reaming, clean again burrs around the hole.
 During assembly of structural parts, temporary bolts shall be installed at first (or
punching). Bolts for temporary installation can’t replace high-strength bolts. The
quantity of temporary bolts is generally 1/3 of holes in connecting plates and
can’t be less than 2.
If few holes don’t have right positions and displacement is small, it could be fixed
by punching in nails at first and then installing bolts.
When 30% bolts are installed, bolts could be tightened and fixed.
 Install high-strength bolts:
--High-strength bolts shall pass through the hole freely. Never drive high-strength
bolts into the hole with hammer.
--High-strength bolts shall have same entry direction, except for some areas with
structural hindrance. Don’t install high-strength bolts in rainy days.
--High-strength bolts shall have consistent washer positions. Pay attention to the
direction of front and back side of the washer upon installation.
--High-strength bolts shall not be subject to shearing force inside inspection holes,
and shall be timely tightened.
 Fastening of high-strength bolts
--After all hexagon high-strength bolts are installed to proper place, they could be
tightened. The tightening method is generally divided to two steps, i.e. initial
tightening and final tightening. Apply initial tightening on all high-strength bolts. The
initial tightening torque is 60%~80% of the standard value, which shall be decided
based on the thickness of steel plates and distance of bolts. If the steel plate is too
thick and bolt distance is too big, the initial tightening force should be bigger. The
initial tightening sequence is decided based on the tightening sequence of hexagon
high-strength bolts, generally from joints with big rigidity to free end not being
constrained, or from center of bolt group to surrounding areas. The reason is that
when connecting steel plates warp and are not fixed firmly and if it is tightened from
two ends to the center, it might cause swelling at middle of the spliced plates and they
don’t contact closely, and transfer of friction force is partially lost.
--mark the initial tightening of hexagon high-strength bolts and prevent missed
tightening. It is generally marked by one color after initial tightening, and another
color after final tightening, for purpose of distinction, as shown in Fig.3-5.

Label

After initial tightening After final tightening

Fig.3-5 Tightening of high-strength bolts
--To prevent the high-strength bolts from being affected by external environment
and change of torque coefficient, the initial tightening and final tightening are
generally finished in the same day.
--If some hexagon high-strength bolts don’t have the same entry direction due to
structural reasons, apply torque on nuts when tightening the bolt. Don’t apply torque
on screws to prevent change of torque coefficient.
 Acceptance inspection:
--Knock with 0.3kg hammer, conduct general inspection on high-strength bolts,
and prevent no missed tightening
--Inspect the torque, make random inspection of 12% of bolts at each node, but
not less than one. Draw firstly a straight line on end face of bolts and nuts before
inspection, loosen the nut by about 60o, tighten again with torque wrench so that two
lines meet, the torque measured at this moment shall be within the permissible range
as listed in Table 3.6
 Table 3.6 Reference of Permissible Torque
Reference of
Bolt Torque Torque
Bolt Performance Pre-tension Torque Torque permissible torque
diameter wrench wrench
size level coefficient coefficient wrench
mm kN Nm Nm Nm
16 8.8 80 0.11 154.88 0.15 211.2 ＞154.88－211.20
M16
16 10.9 100 0.11 193.6 0.15 264 ＞193.60－264
20 8.8 125 0.11 302.5 0.15 412.5 ＞302.50－412.50
M20
20 10.9 155 0.11 375.1 0.15 511.5 ＞375.10－511.50
22 8.8 155 0.11 412.61 0.15 562.65 ＞412.61－562.65
M22
22 10.9 190 0.11 505.78 0.15 689.7 ＞505.78－689.70
24 8.8 180 0.11 522.72 0.15 712.8 ＞522.72－712.80
M24
24 10.9 225 0.11 653.4 0.15 891 ＞653.40－891.00
＞751.41－
27 8.8 230 0.11 751.41 0.15 1024.65
1024.65
M27
＞947.43－
27 10.9 290 0.11 947.43 0.15 1291.95
1291.95
＞1034.55－
30 8.8 285 0.11 1034.55 0.15 1410.75
1410.75
M30
＞1288.65－
30 10.9 355 0.11 1288.65 0.15 1757.25
1757.25
--Based on the actual measurement of torque coefficient (torque coefficient in the
inspection report) of high-strength bolts, adjust and measure the torque coefficient to
obtain the torque of final tightening. The torque applied on hexagon high-strength
bolts for the steel structure is obtained through calculation based on actual
measurement of torque coefficient. Calculation formula （GB 50017-2003）：
N ＝ 1.1×f×Py×M
In the formula:
N-final tightening torque (m)
F-Torque coefficient
Py-Pre-tension of bolts(kN)
M- Nominal diameter of bolts(mm)
Each batch of high-strength bolts shall be carried out with torque
coefficient test before delivery and the torque coefficient is given. Find
the tightening torque from the table below based on the torque coefficient.
The guarantee period of torque coefficient (effective period) is six months.
If it exceeds six months, it shall be tested again.
--If it is found not to conform to applicable rules, expand the scope of inspection
by 10%. If it still doesn’t conform to applicable rules, tighten again high-strength
bolts of the entire node
--Torque inspection shall be carried out 1h after final tightening of bolts, and
completed within 24h.
--Check the gap between connecting plats with a feeler gauge. When the gap
exceeds 1mm, it shall be treated again.
--Check whether hexagon high-strength bolts have the same entry direction, check
whether the washer has correct direction
--Slip factor of connecting plane of high-strength bolts. It must conform to design
requirements, check the slip factor test report provided by the manufacturer of
structural members, check the re-verification report of slip factor at the construction
site, check the re-verification report of torque coefficient, bolts for re-verification
shall be bolts randomly chosen from the batch of bolts installed on the construction
site. Eight bolts shall be randomly chosen from each batch for re-verification.
--Quality record
 Quality certificate of high-strength hexagon bolts
 Re-verification certificate of high-strength hexagon bolts
 Initial tightening and final tightening torque of high-strength bolts
 Inspection record of torque wrench for construction
 Construction quality inspection and acceptance record
3.5.4.3 Install other accessory parts in accordance with requirements specified on
drawings
3.5.4.4 Quality requirements on welding seam
Welders shall have qualification certificates.
The quality of welding seam of major bearing structures and other important
welding seams made during installation shall be guaranteed and conform to
requirements of welding quality in drawings or Level II in GB/T3323-2005, Level I in
JB/T1152-1981 or Level B-I in GB/T11345-2013.
3.5.4.5 Requirements on installation deviation
After installation (or repair or change of steel track), check the installation quality
based on following technological requirements:
 The limit deviation △S of the crane’s span S (Fig.3-6) shall conform to following
rules:
When it adopts the structure of detached end beam and boring for direct
installation of wheel, when ≤10m，△S=±2mm；when S＞10m，△S=±[2+0.1
（S-10）]mm, the unit of S is m. Refer to Table 3.7 for deviation of above formula
after rounding or simplification.
Table 3.7 Limit deviation of the crane’s span

S（m） 10 ＞10～15 ＞15～20 ＞20～25 ＞25～30 ＞30～35

△S（mm） ±2 ±2.5 ±3 ±3.5 ±4 ±4.5

Fig.3-6 Span Deviation

 The main beam shall have a camber and the span’s camber shall be（1.0～1.4）S
/1000. The maximum camber shall be controlled to midspan S/10.
 The beam’s bending along the horizontal direction shall not be greater than
S/2000 for middle-rail box beam and half bias-rail box beam (could only bulge
towards the walkway). When bias-rail box beam S≤16.5m, ±5mm; when S＞
16.5m, ±S/3000 (horizontal bending refers to the value from measurement of top
cover plate).
 K deviation of track gauge, limit deviation △K can’t be greater than the following
value:
K+ K

Fig.3-7 Bias-rail beam trolley track gauge deviation

As to bias-rail beam (Fig.3-7), it shall not exceed ±3mm.
As to symmetrical middle-rail box beam and half bias-rail box beam (Fig.3-8):
±2mm at end of the span; when at mid span, +5+1mm if the span ≤19.5m, +7+1mm
when the span S>19.5m.
K+ K
h

Fig.3-8 Symmetrical Middle-Rail or Half-bias-trail Beam Trolley Track Gauge

Deviation
 The displacement deviation from the steel rail’s centerline to centerline of the
webplate of rail-bearing beam(Fig.3-9): As to bias-rail box beam, the
displacement deviation from the trolley rail’s centerline to centerline of the web
plate of rail-bearing beam shall not be bigger than the following value: when
δ≥12mm，g≤δ/2；whenδ＜12mm，g≤6mm。
 Fig.3-9 Rail Installation Deviation
 The height difference △h of steel rail on the same cross section(Fig.3-7, 3-8):
when K≤2m,△h≤3mm；when 2m＜K＜6.6m, △h≤0.0015K；when K≥6.6m,
△h≤10mm.
 Local flatness of the main beam web plate (measured by 1m level ruler shall not
be bigger than 0.7δwithin the area about 1/3 from the upper wing flange plate or
1.2δin other areas.
 The end beam’s camber is h=W（±0.3W/1000）/1000
 The end beam’s horizontal bending q＜W/2000
 Height difference at connections of trolley’s steel track d≤1mm(Fig.3-10, right)
 Lateral displacement at connections of the trolley steel track f≤1mm(Fig.3-10,
left)

Fig.3-10 Rail connector’s deviation

Refer to the Electric Part for installation and adjustment of electrical parts.
3.5.5 Testing and inspection procedure
Due to constraints of conditions at the manufacturer’s workshop, the entire crane’s
test shall be carried out at the user’s premises after assembly. The user shall carry out
the running test after the crane is installed. As to super-large products ≥300t, the user
shall notify the manufacturer to send staff to attend the experiment and make joint
verification and summary.
Check whether fasteners (especially fixation of steel wire rope on the lifting
mechanism) after each test run. Once it is found loose, it must be tightened
immediately.
3.5.5.1 Inspection and preparation before test run
 Inspect the installation quality carefully, adjust any improper installation timely,
check whether it is firmly or reliably connected or fastened.
 Check whether limit switch and other safety devices are complete
 Check whether each lubrication point has been filled with a suitable amount of
lubricant as specified, whether a suitable amount of gear oil is added as specified.
 Suspend the wheel in air, power on and check whether the rotating direction of
wheels is consistent.
 Check the accuracy of wiring of other circuit systems, check the insulating
resistance of circuit system and all electric devices with megameter.
 Prepare accurate poise (load) corresponding to the rated load of crane, and
additional load equivalent to 0.1 and 0.25 times of rated load.
3.5.5.2 No-load testing
Turn the brake wheel of each mechanism. When the last stage of axle (like wheel
axle, drum axle and etc) rotates by one turn, all transmission mechanisms could rotate
smoothly, without any sticking, and then start the motor of each mechanism and carry
out no-load continuous running test. It shall last for not less than 10min for each
lifting mechanism and traveling mechanism. All transmission mechanisms shall be
able to work steadily, without vibration, noise, sticking on rail, excessive friction of
the rail, discomfort, oil leakage and etc. Check the reliability of limit switch and other
safety devices, adjust the tension of cable and etc.
3.5.5.3 Static load test (cut off the measuring apparatus’ circuit).
The main aim of static load test is to check the main beam of the crane’s bridge,
important metal structures and sling systems, as below:
 Lift small loads at first and make several trial runs
 The lift the rated load and travel on the full length of the bridge back and forth for
several times
 Remove the load, move the trolley to the end, measure the camber of the main
beam, or decide the beam’s zero line on the beam column based on the beam’s
actual height
 Move the trolley to mid-span, lift gradually a load, i.e. 1.25times of the rated load
(increase the load gradually) to about 100mm above the ground, let it suspend for
10min and then remove the load, check whether the main beam has any
permanent deformation. Repeat it for three times, the bridge shall not have any
permanent deformation. Special reminder: When it lifts 1.25times of the rated
load, it shall be lifted to about 100mm above the ground and then suspended for
10min. After each suspension and trial run, check whether relevant fasteners are
loose (especially fixation of steel wire ropes on the lifting mechanism). If they
become loose, tighten them immediately.
 Then move the trolley to the end, measure the actual camber of the main beam,
the measurement (mid-span camber) shall be within（1.0～1.4）S/1000.
 Finally, lift the rated load and check that the down warping of the main beam
shall be smaller than S/1000 (calculated from the actual camber).
3.5.5.4 Dynamic load testing (cut off the measuring device’s circuit)
The lifting mechanism lifts a load which is 1.1times of the rated load, start each
mechanism to travel positively and reversely, the accumulated working time shall not
be less than 10min (shall have pauses according to the working system) or have
specified actions for not less than ten times, to ensure that the performance and action
reach the working and design requirements; parts are firmly and reliably connected
and fastened; the mechanism works normally without vibration; the brake works
flexibly and reliably; speed reducer and gear pair engage correctly without noise and
well-lubricated; the rise of temperature shall not exceed the specified value; limit
switch, safety device and interlocking device have no fault.
3.5.5.5 Check whether relevant fasteners (especially at fixation of steel wires of
the lifting mechanism) are loose after each trial run. Tighten loose ones (if any)
immediately.

Installation and adjustment(Electric Part)

Table of Content
3.1 Transport and storage

3.2 Unpack and inspect

3.3Technical requirements of equipment foundation, installation

conditions and installation

3.4 Installation procedure, method and attentions

3.5 Adjustment or commissioning procedure, method and attentions

3.6 Acceptance inspection items, method and judgment basis after

installation, adjustment (or commissioning).

Installation and Adjustment

The installation of electrical equipment for general overhead crane shall conform
to applicable rules in national standards. When the product has special requirements,
such requirements shall be abided by. This User Manual is suitable for installation and
adjustment of electrical equipment for general overhead crane.
The safety measures during construction shall conform to rules in GB
GB50256-9, applicable safety technical standards and product technical documents.
The installation of electrical equipment for general overhead crane (including
receipt and lifting of electric control devices) shall conform to electrical drawings
provided, documents and relevant instructions.

3.1 Transport and storage

3.1.1 Attentions during lifting and transport

When lifting heavy and large electrical equipment like motor and control cabinet
with lifting rings, they shall be lifted by the lifting ring. Don’t lift by other parts.
When lifting control panel, it shall be lifted by the main framework of the control
panel. Don’t lift by parts that can’t stand heavy parts or elements inside the panel.
When handling and lifting electrical equipment, avoid collision, falling, tumbling,
stacking too many articles and other working methods that may affect the quality and
performance of electrical equipment. Pay attention not to lose or damage parts in
electrical equipment.
During transport, the electrical equipment shall be secured firmly and vibration
be avoided. The electrical equipment or parts shall be properly packaged to avoid
entry of rain, snow or other sundries into the electrical equipment that might damage
the electrical equipment or parts, and avoid also the loss of electrical equipment and
parts during the transport.

3.1.2 Storage conditions, storage period and attention

3.1.2.1 General rule
When the crane’s equipment is delivered, the user shall keep it properly.
Electrical equipment not installed yet shall be put into the store away from
moisture to avoid corrosion of parts in the motor, control cabinet (panel) and other
electrical equipment.
As to electrical equipment that have been installed but will not be used for a long
period, they shall be put into the store if conditions allow. When they can’t be put into
store, they shall be put in shady, ventilated and dry place and the user shall adopt
measures to prevent the entry of rain, snow, condensate and moisture into the
equipment and prevent long-period exposure of the electrical equipment to direct
sunshine.
The equipment that has been idle for a long period must be powered on to
remove moisture or its heater is started, specially in rain season.
The storage temperature of electrical equipment shall conform to applicable
requirements regarding equipment storage.
3.1.2.2 Storage of controllers
 Besides storage instructions in this section, the user shall still read the Storage
Instructions provided by the equipment’s manufacturer.
When the equipment isn’t installed immediately after delivery, it must be stored
in dry and dustless indoor space or buildings. The ambient temperature during storage
is in the range of -25℃~+60℃ , but the temperature difference during storage must
be kept as small as possible to prevent formation of condensate.
3.1.2.3 Storage of motor
Pay special attention to motor that has been stored for a long period before use.
These motors shall be stored in indoor space or buildings with temperature difference
as small as possible. If above conditions are not available, a heating device must be
provided to keep constant temperature, or temporary power supply is provided to the
motor’s heater (single-phase 230V 50Hz).

3.2 Unpack and inspect

3.2.1 Unpacking attentions

After the crane is delivered to the user, the user itself or both parties (the user and
manufacturer) shall verify and check the electric equipment and documents provided
by the manufacturer based on the list of hardware and software specified by the
Packing List.
The user shall prepare the equipment’s archive card by itself. Equipment and
device adopted by general overhead crane shall conform to rules in national technical
standards and be provided together with the Qualification Certificates and
Nameplates.
After the equipment and device are delivered to the worksite, they shall be
inspected as below:
The package shall be complete, and sealed parts shall have good sealing effect.
Pay attention to following matter:
 Notify immediately the project’s supervisor when any damage of the equipment is
identified.
 Damaged device shall be taken with a photo for recording purpose.
 Notify the project’s supervisor about any damage of the equipment for convenient
maintenance or change of damaged parts.
 In case of any loss of parts during transport, notify the project’s supervisor
immediately

3.2.2 Inspection items

Check and verify the model, specification and quantity of electrical equipment
and parts in accordance with the packing list of electrical equipment and design
requirements, and keep the inspection and verification record
Products shall have complete technical documents.
Appearance inspection shall show no damage, deformation or corrosion.
 All outsourced electrical equipment of the crane shall have complete
qualification certificates, user manuals, accessory parts and standby parts.

3.3 Technical requirements of equipment foundation, installation conditions

and installation
This section describes only general requirements regarding the installation of
electrical equipment of general overhead crane. As to electrical equipment with some
special requirements, please read carefully additional drawings provided and User
Manual of electrical system.

3.3.1 Check and clean all electrical equipment and parts before installation
 Clean and remove dirt and defects of the electrical equipment parts, change
defective parts
 All moveable parts and components shall work flexibly, without sticking, stiction
or loose phenomenon.
 All wire fasteners shall be complete, and bolts already wired shall be tightened.
 Fasteners, framework, steel pipe, connectors, joints, conductor, racks and etc for
installation of electrical equipment inside the crane and other non-charged metal
parts shall be galvanized or applied with anti-corrosive painting or use galvanized
products.

3.3.2 Power conductor

 The arrangement, installation and connection of slide wire assembly shall
conform to rules in GB50256-96.
 The insulation resistance of the crane’s power slide wire shall conform to
applicable rules and be generally not lower than 0.5MΩ.
 The insulation resistance of power conductor measured by 500V megameter shall
not be lower than 1MΩ.
 The net distance between conductive parts of adjacent slide wires and that
between conductive parts and grounding shall not be smaller than 30mm (the
distance attainable when crane swings while traveling).
 The installation position and dimension of the power conductor shall be
consistent with that of the power slide wire and conform to rules in general
drawing of the crane. The installation position and dimension of the power
conductor wire shall be indicated clearly in the Order.

3.3.3 Trolley’s cable power supply

The trolley’s power supply described in this User Manual is suspended cable
mobile method.
 Measure the cable’s insulation resistance with a 500V megameter, the insulation
resistance shall not be lower than 5MΩ/km under normal temperature (+20℃)
dry conditions. The permissible working temperature of the conductor’s core is
 generally not lower than 0.15MΩ/km.
 Before being fastened, pulley cables shall be neatly arranged according to the
diameter to remove torsion and each cable shall be clamped tightly.
 A length of cable with suitable allowance shall be left on the cable pulley. When
the trolley is at the limit position and the cable pulley is pulled to the full length,
the cable between two adjacent pulleys shall keep an angle of 120°. When it is
towed, the traction steel rope is stressed and the cable isn’t subject to additional
pull.
 When the cable moves, it shall not have collision, friction or sticking with other
metal structures or parts. The profile steel rail for the cable power supply shall be
straightened and joints shall be smooth. The vertical and horizontal curvature
along the full length shall conform to requirements in mechanical design
drawings.

3.3.4 Installation requirements for electric control cabinet, junction box and
etc.
 The installation of control cabinet (panel) shall conform to rules in GB50256-96.
 The control cabinet (panel) shall be installed on the electric room’s dedicated
undercarriage, which shall span across the walkway’s large tiepiece.
 The control cabinet (panel) shall be installed firmly and reliably to reduce its
vibration when the crane is working. Bracing shall be added when necessary. The
verticality error of the control cabinet (panel) shall not exceed 12‰.
 The passage before the control cabinet (panel) shall not be smaller than 600mm
for single-row arrangement or 800mm for double-row arrangement. Its distance
from the wall could be reduced by 250mm if it is unnecessary to maintain from
the back. If such as distance can’t be achieved due to structural constraints, the
minimum distance shall not be smaller than 100mm.
 The insulation resistance between phases of the control cabinet (panel)’s main
circuit and control circuit and that between phase and grounding when being
measured by 500V megameter (working voltage ≥48V) shall not be lower than
0.8MΩ in general environment or 0.4MΩ in wet environment. During dielectric
test, the insulation resistance shall not be lower than 1MΩ. As to electric parts
(like semiconductor parts, capacitors and etc) that can’t stand high-voltage impact
of the megameter, it shall be disassembled or shorted before testing.

3.3.5 Installation requirements for low-voltage electric appliance outside the

control cabinet (panel) or box.
---The installation height of the low-voltage electric appliance shall conform to design
rules. When there isn’t
specific design requirements, it shall conform to following requirements:
 Low-voltage electric appliance installed on ground shall have its bottom
 50~100mm above the ground.
 The distance from the handle’s spindle center to the ground is better to be 1200～
1500mm, the distance from the side-operated handle to the building or equipment
is better not to smaller than 200mm.
----Fastening
 The low-voltage electric appliance could be fastened to the wall, column or other
structural members of the building by framework, metal plate and insulation plate
based on different structures. When it is fastened by expansion bolt, the bolt
specification shall be chosen based on the product’s technical requirements. The
diameter and depth of drilled hole shall conform to the bolt’s specification.
 Fasteners shall use galvanized products, bolts shall be of proper specification, the
electrical appliance shall be fastened firmly and steadily. If it has anti-shock
requirements, fastening bolts shall adopt anti-loosening measures.
----External wiring
 Connectors shall be labeled as terminals, and arranged neatly, clearly and
elegantly, and wires shall have proper insulation, without damages.
 The wire with side entry shall be connected at the incoming terminal, i.e.
terminals with fixed contacts; the wire with side exit for load shall be connected
at the outgoing terminal, i.e. terminals with moveable contacts.
 The wiring of electric appliance shall use bolts and screws made of copper or
with galvanized anti-corrosive coat. They shall tightened in the wiring circuit and
have anti-loosening device.
 When the bus-bar is connected with the electrical appliance, the contact plane
shall conform to applicable rules in existing national standard “Implementation
and Acceptance Inspection Procedure for Installation of Engineering Bus-bar
Device in Electrical Equipment”. The minimum distance between bus-bars of
different phases at the connection shall conform to rules in Table 3.1
Table 3.1 Minimum Distance between Bus-bars of Different Phases
Rated Minimum electric gap Minimum electric
Rated voltage (V)
voltage (V) (mm) gap (mm)
U≤500 10 500＜U≤1200 14

 The neutral line or grounding of the metal shell and framework of electric
appliance shall conform to applicable rules in existing national standard
“Implementation and Acceptance Inspection Procedure for Installation of
Engineering Bus-bar Device in Electrical Equipment”.
 The measurement of insulation resistance between conductive parts including
main circuit, control circuit and auxiliary circuit and metal framework shall
conform to applicable rules in existing national standard “Implementation and
Acceptance Inspection Procedure for Installation of Engineering Bus-bar Device
 in Electrical Equipment”.

3.3.6 Technical requirements for installation of resistor

The resistance element of the resistor shall be on the vertical plane. The vertical
stacking of resistors shall not have more than four cases. When it exceeds four cases,
it shall be fastened by a rack and a proper distance is kept. When it exceeds six cases,
it shall be arranged in another group. As to resistors with special requirements, the
installation method shall conform to design rules. A gap between the resistor’s bottom
and the ground shall not be smaller than 150mm.
----When the resistor and other electrical appliances are vertically arranged, it shall be
above other electrical
appliances. Two of them shall not have any clearance.
----The wiring of electrical appliance shall conform to following requirements.
 It shall be wired in accordance with the terminal number specified in the
Electrical Wiring Diagram and Wiring Diagram (Table). Clamping plates or bolts
of the resistor shall have signs corresponding to the equipment wiring diagram.
When it is connected with the insulation conductor, measures that prevent the
drop of insulation intensity of conductors due to too high temperature at the joint
shall be adopted.
 The outgoing wire of the resistor boxes that are stacked by several layers shall be
fixed by brackets and can’t hinder the change of resistor elements.
 The resistor shall not have broken wire or short circuits. The error of DC
resistance shall conform to applicable rules in the product’s technical
specification.
 The cover plate or protective cover of the resistor shall be installed correctly,
firmly and reliably.
 As to wires or cables connecting resistors, the vertical part shall be arranged at
two sides (left and right) to the resistor and shall not affect the resistor’s
assembly/disassembly. The horizontal part could be wrapped by mineral wool
rope and other heat-resistant materials to avoid the insulation from being aged
due to being adjacent to hot resistor elements.
 The actual working temperature of the resistor when working shall not exceed
350℃.

3.3.7 Wire, cable and laying requirements

---Except for weak current system, the crane’s wiring shall be copper-core
multi-strand wire or cable with the
rated voltage not lower than 500V. The cross section of multi-strand wire shall not
be smaller than 1.5mm2. The cross section of multi-strand cable shall not be smaller
than 1.0mm2.
---At places subject to mechanical injury, heat radiation or droplets of lubricant, the
wire or cable shall be
installed in steel tubes, wire casing, protective cover or be adopted with heat-proof
protective measures.
---At holes where the wire or cable passes through the steel structure, burrs shall be
removed and protective
measures be adopted.
----Laying of cables on the crane shall conform to following requirements:
 Cables shall be arranged neatly based on the outgoing sequence, without crossing.
Strong current and weak current cables shall be laid separately, and two ends of
the cable shall be labeled.
 Cables that shall be fixed shall be fixed firmly, and the distance between bracing
points shall not exceed 1m.
 When fixing and laying cables, the curvature radius shall be larger than five times
of the cable’s external diameter. When cables adopt mobile laying, the curvature
radius shall be larger than eight times of the cable’s external diameter.
 When wires and cables are laid in or protected by water and gas steel pipes, the
total cross-section of wires (except for two wires) in the steel pipe shall not
exceed 40% of the cross section of the inner diameter of the steel pipe. The pipe’s
inner diameter isn’t smaller than 1.5times of the cable’s external diameter. When
the steel pipe is short and bending radius is large and they don’t affect the passing
of cables, it could be widened properly.
 Wires and cables laid on the crane can’t have joints in the middle. Two ends of all
wires and cables shall use copper cold-pressed connectors for connection with
wiring terminals. It shall adopt dedicated pressing plier for pressing connection of
cold-pressed connectors. Don’t use common steel wire pincers to make pressing
indention with the jaw.
 Cores of cables transferring low-voltage and low-power signals shall not use the
same cable with cores of power cables or cores with different levels of voltage. It
shall use a separate cable or cable with shield measures if necessary to prevent
interference.

3.3.8 Laying wire tube and cable groove

--- Steel tube and cable grooves shall be fixed firmly.
---All steel tube openings of the crane shall be added with a protective sleeve.
---The installation of groove shall conform to laying requirements of wire or cable.
Protective measures shall
be adopted at the entry and exit of wires or cables.
---As to AC wires passing through metal tubes or metal grooves, all phase lines and
N-line shall be contained
in the same shell. Lines of different circuits shall not be contained in the same pipe.
Under following
 conditions, they could be contained in the same pipe.
 Circuit with the nominal voltage below 50V.
 The power circuit of the same equipment and control circuit without
anti-interference requirements
 Several circuits of the same lighting device
 Several circuits of the same category of lighting, but total number of insulation
conductors inside the pipe shall not be more than eight.
 When there are several circuits in the same pipe, all insulation conductors shall
adopt the same insulation as that of the circuit with maximum nominal voltage.
---When laying, the motor shall adopt uniform wirings for stator and rotor.
Three-phase AC conductor or DC polar lines exceeding 25A are better to be contained
in the same tube. Wires of different mechanisms, AC or DC wires and wires with
different voltage levels shall be bundled respectively. They shall be separated as much
as possible while passing through the pipe. Single-core conductors with AC
current-carrying capacity above 25A are not allowed to pass through the metal pipe
separately. Lighting lines shall be laid separately.

3.3.9 Requirements of protective grounding

---Crane grounding
 The user is responsible for grounding of the crane truck’s rail, which shall
conform to requirements in relevant procedures.
 When AC power supply adopts slide wire or suspended cable trolley, it shall be
provided with slide wire, collector ring or grounding wire for protective
grounding.
 When the crane adopts cable with grounding core for power supply, the
grounding core shall be connected firmly and reliably with the grounding slide
ring and carbon brush.
----The crane electric equipment’s grounding
 Among all electric equipment in the crane, electric equipment that might be alive
due to damage of insulation shall have protective grounding for its metal parts.
Metal shells that are not alive under normal situations, metal wire tube, cable
metal skin, cabinet (panel, box)’s frame, box, door and the low-voltage side of the
lighting transformer shall be reliably grounded.
 The connection between the grounding wire and metal structure or electrical
equipment could be welded or bolted for connection. When it uses bolted
connection, it shall adopt anti-loosening measures to ensure reliable connection.
It is not allowed to connect by twisting, soldering or other unreliable method.
 The grounding part of each electric equipment shall be connected with separate
grounding wire and grounding trunk (or metal structure of crane). Never use the
grounding wire as the current-carrying neutral line.
 The fasteners of grounding device shall use galvanized parts.
---Cross section and resistance of grounding body
 The connection of steel grounding wire (body) shall use lap welding. The welding
length must be twice of the flat steel’s width and use three-side welding; or six
times of the round steel’s diameter and use two-side welding).
 The cross section of the line’s grounding conductor shall meet requirements in
Table 3.2.
Table 3.2 Cross Section of Grounding Body
Cross section of Cross section of
Cross section of Cross section
grounding wire grounding body
line (mm2 ) of line (mm2 )
(mm2 ) (mm2 )
S≤16 S S ＞35 S/2，but grounding
trunk
The steel isn’t
；copper isn’t
216＜S≤35 16 greater than
greater than 50
800 mm2
mm2

 The connecting resistance between metal shells of all electrical equipment on the
crane and possibly alive metal parts and grounding screws shall not be greater
than 0.1Ω.
 The grounding resistance on any point of the crane shall not be greater than 4Ω.

3.3.10 Over-speed switch

 The model and specification of over-speed switch shall conform to requirements
in design drawings.
 The contact’s triggering speed of the manual over-speed switch shall be able to be
adjusted within 1.2~1.7 times of the rated speed.
 The contact’s triggering speed of the automatic resetting over-speed switch shall
be able to be adjusted within 1.1~1.6 times of the rated speed.
 The contact’s acting period of the over-speed switch shall not be greater than
0.15S, and the repetitive error of the contact’s acting speed shall not be greater
than +8%.
 The setting value of the over-speed switch is generally 1.1~1.3 times of the
highest working speed.

3.3.11 Limit switch

----When the crane’s travel limit switch acts, it shall be able to cut off the power
supply automatically and
make each mechanism to stop at the following position:
 The hook rises to not less than 100mm from the limit position
 As to the crane bridge’s trolley and etc, the distance to the traveling end shall not
be smaller than 200mm.
 When one crane approaches another crane, the distance shall not be smaller than
400mm.
----Installation of the sinker bar and determination of the dimension shall ensure that
the travel limit switch acts reliably, the sinker bar and sinker bar’s carriage shall
not wobble when the crane works. The width of sinker bar shall meet the
requirements about mechanical (bridge and trolley) transverse play. The length of
sinker bar shall meet the requirements of maximum mechanical (bridge and
trolley) braking distance and shall not affect the movement of mechanical parts.
----The collision block or sinker bar shall be installed on the action axis of the switch
roller or push bar. As to
electronic travel switch, the distance between moving parts shall be adjusted based
on product technical specifications.
----The acting force of the collision block or sinker bar on the switch and the acting
distance of the switch shall
not exceed the permissible value.

3.3.12 Lighting equipment

 Lighting fixtures shall be complete, hung firmly and have no violent sway when
the crane travels.
 The lighting circuit shall have a dedicated neutral line or isolation transformer
and shall not use the wire tube or the crane’s own grounding wire as the neutral
wire.

3.3.13 Other electrical equipment

 Model and specification of unmentioned equipment shall be same with the design
drawings.
 The installation shall conform to applicable regulations and standards.
 Refer to the User Manual provided for requirements on installation, adjustment
and experiment of frequency converter, voltage regulator, PLC, alarm,
telecommunication device, transformer, wireless remote controller, laser
protective device on the crane.

3.4 Installation procedure, method and attentions

The product’s installation shall conform to “3.3 Technical Requirements on
Equipment Foundation, Installation Conditions and Installation”.
Before installation, read carefully the installation instructions, detailed
specification of specific equipment and specification provided by manufacturers; shall
read carefully drawings and documents; understand the working principle of electric
equipment and installation attentions, list specifically the installation and
commissioning steps and procedures and safety measures
The installation of electrical equipment on general overhead crane shall be
carried out by the unit with installation license and business license. The work shall
be completed by proficient electricians and other specialties of workers.
During installation of electrical equipment, keep original records carefully. After
the installation work is completed, keep a complete set of installation records and
record the revisions of original design.
This User Manual puts forward advice on the installation of general bridge
cranes with the rated voltage below 0.5Kv.

3.4.1 Assembly of electrical equipment

The installation of electrical equipment shall be carried out as per the Installation
Agenda. The installation shall be conducted together with the mechanical assembly
work.
The assembly of electrical equipment refers to “fixing and installing the
installation fittings of electrical equipment and cables onto the crane structure”.
Before assembly, read carefully the Electrical Equipment Layout Diagram and
drawings of installation fittings and determine the position of electric equipment,
including a suitable fixing plan. The fixing plan of cable groove and limit switch shall
be indicated on corresponding mechanical drawings.
Fixing by welding must be carried out before surface coating of the crane.
Note: To avoid that the welding current passes through the hinged point, the steel
structure must be grounded before welding.
----Install the base or bracket of the control cabinet (panel) and junction box
 The electric cabinet (panel) shall be installed in accordance with rules in existing
national standard “Installation Project of Electric Equipment—Panel, Cabinet and
Secondary Circuit’s Wiring Work and Acceptance Inspection Rules” and meet
relevant requirements in 3.3.4.
 Conduct general inspection on control cabinet (panel) and junction box
 Check whether the model, specification and quantity of electric cabinet (panel)
conform to requirements in design drawings, and the protective type and level
shall conform to applicable standards and workplace requirements
 Assemble the control cabinet (panel), junction box’s base or support.
 After the control cabinet (panel) is placed at suitable position of the base, the base
shall be drilled. The base of control panel and support of junction box shall be
firmly welded or bolted to suitable position on the structure.
----Assemble resistor
 Before installation, the resistor shall be carried out with general inspection to
meet “Technical Requirements for Installation of Resistor” in 3..3.6.
 The layout of resistor rack shall help the heat dissipation and also service and
change of resistor elements.
 A maintenance passage not less than 500mm shall be kept in front of the resistor.
 The resistor shall be arranged along the direction parallel with the main beam.
 The resistor bracket shall be firmly welded to two large tie-pieces of the walkway.
When necessary, a pull plate or pull bar could be added at top end of the bracket.
The resistor inside the electric room shall have also similar treatment.
----Assembly of lighting and auxiliary parts
 Please read carefully the Layout Diagram, Lighting Circuit Diagram and
Drawings of installation fittings before installation
 Check whether the model, specification and quantity of lighting and auxiliary
equipment conform to requirements in design drawings, and the protective type
and level shall conform to applicable standards and workplace requirements.
 Fix the bracket to corresponding position by welding or bolt connection based on
the Installation and Layout drawings and conform to technical requirements in the
drawing.
----Assemble wire tube and cable bridge
 Before installation, read the cable pipeline diagram and general drawing of
electrical equipment, determine the cable’s laying route and specification of cable
bridge, cable tube and guide tube.
 Assembly of wire tube and cable bridge shall conform to rules in GB50256-96
and conform to 3.3.8 “Technical Requirements for Laying Wire Tube and Cable
Groove”.
 The wire tube and cable groove could be fixed by mechanical or welding fixation
method. When it is fixed by electric welding method, the welding point shall be
firm to prevent cracking and damage at the welding point due to vibration or
deformation when the crane travels.
----Bending of wire tube
The wire tube shall be bent based on the actual situation. The bending radius
shall not be smaller than five times of the external diameter of the wire tube. The
bending angle shall not be smaller than 90. After bending, the wire tube shall not have
apparent flatting defects (the flatting defect shall not be greater than 10% of the pipe’s
external diameter).
When the pipe has a 90o bend, the distance between two bracing wire points shall
not exceed 20mm. When there are two 90o bends, the distance between two bracing
wire points shall not exceed 1.5m. When there are three 90o bends, the distance
between two bracing wire points shall not exceed 8m. Otherwise, it shall use a pipe
with a tube of a higher level of diameter.

3.4.2 Fix the electrical equipment

----Control cabinet, junction box, lighting, limit switch and other electrical equipment
 The electrical equipment must use hot-dip galvanized or stainless steel screw and
nut, reliably fixed by double nuts or locking nuts. The length of screws must be
long enough to expose from another side of the nut or thread.
 The electrical equipment shall be arranged and fixed based on the Equipment
 Layout Diagram.
----Nameplate of the electrical equipment
The nameplate of the electrical equipment must be fixed onto the equipment’s
nearby structure.
----Cable entrance of the electrical equipment
The equipment cable must be laid into the cabinet and electrical equipment from
the bottom. Protective measures shall be adopted at the cable entrance.

3.4.3 Lay the cable inside the metal tube and wire groove
----Laying and installation of cable inside the metal tube shall conform to relevant
requirements in 3.3.7.
----Cable cutting and fixation
 A correct length of cable shall be cut at the site. Before cutting, a correct length
must be measured on the crane’s structure.
 Fasten the cable bundle inside the cable bridge based on the binding type of cable
as specified in the contract. Put the cable into the groove based on the wiring
table and requirements that high voltage, low voltage power, control and lighting
cables are separated.
 As to vertical laying, use two cable ribbons in parallel and fix it with ribbons
every 1.5m~2m at the top three fixing points of the vertical cable groove. When it
is laid horizontally, it shall be fixed with ribbons every 5m except for positions at
head, tail and middle parts of the cable.
 Regarding 400V~500V cable (cable for motor, brake and other main circuit), the
diameter of each bundle must be smaller than 60mm, and the minimum distance
between two bundles is 10mm.
24V~240V cable (control cable): the diameter of each bundle of cable must be
smaller than 60mm, 24V cable must be separately bundled from 240V cable.
The shield cable must be separately arranged from other cables at the other side,
and at least 10cm away from the cable with a voltage above 24V.
Avoid cross-arrangement of cables and bundles of cables.
The port of cable groove must be laid with rubber board to protect cable. Two
ends of the metal tube must be added with plastic sleeve.
----Installation at the hinged joints
 The hinged joint where the cable passes through the structure must adopt flexible
cable.
 The cable ring at the hinged joint must have enough length to guarantee flexible
movement.
----Install shield cable
The shield cable (shied layer) shall be connected based on the wiring diagram.
Except for special remarks, the principle is that the cable shield layer at the current
source is grounded.
----Laying temperature
Never install at a temperature below -10℃. If the cable is stored below 0℃, the
cable must be preheated in at least 15℃ store for 24hr before laying. Otherwise the
cable is too hard and can’t be moved, it might damage the insulation while bending.
Temperature fluctuation might cause the cable’s length to change. Hence, long
cable must be laid with a slight bending.
----Cable connectors
 The cable’s wire is connected to the equipment with clamping-type cable
connector. A pair of special pliers must be used for clamping. The correct jaw size
shall be chosen based on the size of cable connector.
 The size of cable connector must be chosen based on the wire’s cross section.
----Labeling of cable and core:
 The cable is labeled by plastic labels and numbered based on the Cable Table
(Note: PE line (yellow green)) isn’t labeled with Terminal No.).
 The core is labeled with the plastic wire marking tube. The marking sign is color
fast.
 Each core of the cable must be labeled with the number of connecting terminal.
 The starting point of the wire marking starts from the wire end.
 The wire’s stripping length shall be suitable.

3.4.4 Grounding
The grounding of general bridge crane shall conform to technical requirements in
3.3.9.
All metal parts (i.e. non-conductive parts) of electrical equipment must be
grounded. Fixed electrical equipment must use external grounding wire or
green/yellow wire for grounding. As to cable without yellow/green wires, the
grounding conductor shall be marked by green/yellow adhesive tape.
 The hinged joint must use grounding bolts or jumper for grounding.
 Refer to the Electric System’s Grounding Diagram or grounding requirements for
grounding of electric cabinet, metal structure or electrical equipment.
 The grounding nut and screws must be hot-dip galvanized, acid-proof or stainless
steel.

3.4.5 Connection of wire and cable

The wire and cable shall be wired between parts based on the wiring diagram.

3.4.6 Wiring inspection and insulation test

 After cables are connected, wiring shall be inspected based on the schematic
diagram. The schematic diagram shall be marked and put into the worksite
archive.
 Test the insulation of power source bus-bar and keep record.
 Test the motor’s insulation
 Use 500V megameter to measure the insulation resistance between windings of
the motor and windings against the ground. The stator’s winding could be measured
together with connecting cable. The rotor’s winding shall be measured together with
the connecting startup device. When winding terminals are drawn out from each
phase, the insulation resistance between winding phases shall be measured.
The motor is installed with an embedded temperature switch or thermometer, the
winding’s insulation resistance shall be measured by a 250V megameter.
The testing test shall be filled into the Table, marking the date of completion and
be put into the worksite archive.
Note: As to motor driven by thyristor and frequency-converting controller, the
cable must be loosened from the device before testing the insulation. Don’t switch on
the power before wiring is inspected.

3.4.7 Drawings and documents necessary for installation

 Electrical equipment (General electrical drawing)
 Install equipment in the driver’s cab
 Layout diagram of electrical equipment
 Layout diagram of cable pipeline
 Table of electric equipment and elements
 Wiring diagram
 Cable Table
 User Manual of Electrical Equipment
 User Manual of General Overhead Crane

3.4.8 Installation and acceptance inspection conditions

Upon inspection and hand-over of electrical installation of the general overhead
crane, electric appliances must meet following conditions:
 Electrical installation work is all completed.
 Electrical wiring is correct, with fixed terminals, good contact and clear labels.
 The insulation resistance of electrical equipment and lines conform to applicable
rules in existing national standard “Handover and Experiment Standard of
Electrical Equipment in Installation Project of Electric Facilities”.
 The capacity, voltage and frequency of power supply shall meet the design and
requirements of electricity-consuming equipment.
 Good protective grounding
 Electrical equipment including motor, controller, contact, brake, voltage relay and
current relay have been inspected and adjusted.
 The safety protective device has been inspected as qualified after the simulation
testing and adjustment.
 The installer has provided six additional files about electric installation inspection
and adjustment of general overhead crane. The document provides a clear,
 accurate and complete record, with dates and responsible individual as requested.
Annex 1: Cable Bridge and Cable Pipeline Installation and Inspection Table
Annex 2: Electrical Equipment Installation and Inspection Record
Annex 3: Cable Laying and Inspection Record
Annex 4: Cable Connection and Inspection Record
Annex 5: Electric Equipment’s Insulation Inspection Record
Annex 6: Grounding System Inspection Record

3.5 Adjustment or commissioning procedure, method and attentions

3.5.1 Conditions for adjustment

 Has provided power supply that meets the crane’s working requirements
 Has completed installation and adjustment of all mechanical devices, and has the
condition for putting into mechanical operation.
 Has completed the installation and adjustment of all electrical equipment, passed
the product’s installation acceptance inspection; the manufacturer and
commissioning party have accepted and fixed the signature.
 The installer has provided six additional files about installation inspection and
adjustment of general overhead crane. The document provides a clear, accurate
and complete record with dates and responsible individual as requested.

3.5.2 Inspection and adjustment of electromechanical equipment before

power-on
Before the general overhead crane is powered on and adjusted, the electrical
equipment shall be inspected and adjusted before power-on based on “Electrical
Device Installation Project Implementation and Acceptance Inspection Rules”. Please
read Section 3.3 in this User Manual.
----Low voltage power distribution cabinet, control cabinet and junction box
 Check whether low-voltage components in the cabinet conform to drawings or
technical requirements of the low-voltage electric appliance
 Check the grounding of control cabinet (panel))
 The capacity of the junction box’s terminal shall adapt to the current-carrying
capacity of the wire connected.
 Shall set properly elements that need adjustment and setting (setting of relay is
generally arithmetic average of three actions).
 The clearing time of the winding motor’s startup resistance is set based on
requirements in design drawings.
 The setting action value of delay relay shall be the average of three actions, and
the action error shall not be greater than +10%. The repetitive error shall not
exceed +6%.
 Inspection result, and confirm whether it is at the “Able to Power On” state.
----Drive system
 Check whether all cables connecting with the drive unit are properly connected
 Check whether all cables connecting with the motor and accessories are properly
connected, and whether the insulation testing has been completed.
 Check the brake’s electrical and mechanical connection.
 Check the electrical and mechanical connection of pulse encoder, over-speed
switch, rotary limit switch, travel limit switch, brake’s limit switch, anti-lap
winding limit switch and load sensor.
 Adjust the brake
 Check the motor’s position
 Fill oil into the speed reducer
 Record the inspection result and determine whether each mechanism could enter
into the power-on adjustment state
----Inspection and adjustment before the motor’s power-on
General inspection and adjustment
The motor’s insulation inspection
Under cold state, the winding’s insulation resistance isn’t lower than 1MΩ/KV if
calculated based on the winding’s rated voltage. Under hot state, the winding’s
insulation resistance isn’t lower than 1MΩ, and the rotor winding’s resistance isn’t
lower than 0.5 MΩ.
----Inspection and adjustment before the brake is powered on (the mechanical staff
inspects and adjusts)
---Inspection and adjustment before the resistor is powered on (winding motor)
 Measure the insulation resistance: use 500V megameter to measure the insulation
resistance between resistance elements of each phase in the resistor and that
between resistance element of each phase and the ground, which shall not be
lower than 1MΩ
 As to the mechanism driven by several AC winding motors, suitable choice shall
be made for installation of resistors. When resistors with big resistance (the
resistance has positive deviation) is used for motors with short rotor conductor,
high rated speed (the permissible slip differential is negative) and hard features, it
could adjust suitably the normally-connected section of the rotor resistor when
the condition allows so that multiple motors have the same feature.
----Inspection and adjustment before the power supply conductor is powered on.
 The installation, inspection and adjustment of power supply’s slide wire and slide
connector shall conform to “Crane’s Electrical Device Implementation and
Acceptance Inspection Procedure”. Please read 3.2.2 in this User Manual before
inspection and adjustment.
 Conduct general inspection on the performance of power supply conductor.
 The measurement of insulation resistance of power supply conductor and
experiment of dielectric strength shall conform to requirements in 3.3.2.
 ---Inspection and adjustment before the master controller and limit switch are
powered on.
 The current type (AC and DC), quantity, capacity and opening/closing procedure
of master controller and cam controller’s contact shall conform to requirements in
design drawings.
 The handle shall act flexibly, with a clear gear and accurate positioning. The
automatic resetting switch shall act flexibly and reliably. The controller has
zero-position self-locking function. The handle’s acting force conforms to
requirements in the product’s User Manual.
 Check the relative position of the travel limit switch and sinker bar. When the
crane’s travel limit switch acts, it could cut off the power supply automatically at
the preset position.
 The travel limit switch shall be adjusted together with the mechanical facilities.
After the action is confirmed as reliable, it could be connected into the circuit.
 Measure the insulation resistance. The insulation resistance of the master
controller and limit switch shall conform to requirements in 3.3.4.
 Electric gap between each electric element and naked conductive parts on the
linkage console, electric gap and creepage distance in the cam and master
controller shall conform to requirements in 3.3.4 and 3.3.5.
----Lubrication system
 Check whether all cables connecting with the lubrication system are properly
connected, whether the insulation testing has been completed.
 Check the electrical and mechanical connections of all electromagnetic valves
 Check whether internal wiring of the system has been completed.
 Fill oil
Record the inspection result, confirm whether the lubrication system could enter
into the power-on adjustment state
----Air conditioning and cooling system
 Check whether all cables connecting with the air conditioner and air cooler are
properly connected, whether the insulation testing has been completed
 Check whether all cables connecting with the air cooler’s temperature controller
and buttons are properly connected.
Record the inspection result, confirm whether the air conditioning and cool air
system has entered into the power-on adjustment state
 Check the connection and voltage level of all power supplies
 Check all DI/DO connections and AI/AO connections
 Check the connection of power supply and telecommunication circuits of all
remote control modules.
 Check DI/DO and AI/AO connections of all remote control modules.
 Check the connection of monitors (optional)
----Other parts
 Check whether all cables connected with the emergency stop button are properly
connected
 Check whether the feeding and cut-off circuits of the crane are properly
connected
 Check whether all cables connected with the junction box are properly connected
 All whether all lighting, lighting switch and sockets could be powered on and put
into operation.
----Check the insulation of electrical equipment and record it into “Insulation
Inspection Record”.

3.5.3 Product adjustment

3.5.3.1 General rules on power-on adjustment of electrical equipment
The power-on adjustment must be carried out after the crane’s electrical
equipment are installed and properly adjusted.
The power supply’s quality shall be guaranteed during power-on adjustment. As
to AC power supply, the voltage loss from the low-voltage bus-bar of self-powered
transformer to the terminal of any motor on the crane shall not exceed 15% of the
rated voltage.
The voltage loss inside the crane is 5% for the crane with the rated lifting
capacity below 32t, and 4% for the crane with the rated lifting capacity in the range of
32t to 250t.
3.5.3.2 Attentions for power-on experiment
----Remove temporary wirings and obstacles for alive parts and restore all terminals
that have been temporarily
removed before power-on experiment
----The power-on experiment shall be carried out under the principle of “First partially
and then completely,
first control circuit and then the main circuit”
----The measured voltage of main circuit and control circuit shall conform to
requirements. The main circuit’s
voltage shall not be lower than 95% of the rated value, and the control circuit’s
voltage shall not be lower
than 85% of the rated value.
----Power on the control circuit at first, repeat the operation, check the correction of
opening/closing procedure, interlocking, protection and other actions of the
electrical components. The main circuit could be powered on after when being
confirmed as correct, check the correctness of the motor, brake, resistor and
conversion of main circuit.
 When the main circuit is powered on, it shall make inching operation at first,
check the motor’s rotation direction, make sequential adjustment of “idle load at
 first and with load later on”.
 The master controller’s operating direction must be consistent with the
mechanism’s working direction.
 When the master controller works, it shall be operated from the low-speed gear to
high-speed gear gradually and check the accuracy and reliability of action of
electrical equipment at each gear. The master controller’s gear shall correspond to
the mechanism’s traveling speed and conform basically to requirements in design
drawings. The speed at each gear of the speed regulating system shall be adjusted
necessarily. Each gear in the non-speed-regulating system serves as reference
values and doesn’t need to be adjusted.
 The brake shall be roughly adjusted in advance, and then adjusted accurately
upon power-on experiment.
 Simulate manually the action at the contact of each interlocking step (for safety
purpose) to check the action’s correctness and reliability.
 When the main circuit has power-on adjustment, check and adjust again the
setting value of thermal relay, over-current protective device and delay relay.
 Turn the mechanism manually before power-on experiment, confirm that it
rotates flexibly, without abnormal situation before power-on experiment.
When it needs to remove interlocking with other parts during the mechanism’s
experiment, notify relevant staff before the experiment and restore it to the original
state after experiment.
Ventilation, lubrication and other devices for the mechanism’s normal operation
shall work normally before each mechanism has power-on adjustment.
The positive and reverse period of each mechanism’s power-on experiment shall
not be less than 10min.
Record the inspection record into the Adjustment Report.
3.5.3.3 The crane’s common par for power supply and operation
Before power feeding, the equipment and mechanism shall have non-powered
testing and adjustment. The power-on experiment could be carried out only when it
conforms to applicable requirements.
Before power-on, all switches are at cut-off position. After it is powered on,
measure and record the voltage of all circuits.
----Engage low-voltage main power supply, close the isolation switch=00-Q1
Measure the slide wire’s A phase/AB voltage; slide wire’s B phase/BC voltage;
slide wire’s C phase/CA voltage, record the measurement result,
Measure again grounding resistance of each phase at lower end of power
supply’s isolation switch=00-Q1, and insulation resistance between phases. When it
meets requirements, close the isolation switch=00-Q1
----Power supply to lighting equipment
Measure grounding resistance of each phase at lower end of lighting and
auxiliary switch and insulation resistance between phases. When it meets
requirements, close the power switch and check the voltage,
Close the lighting power switch
 Power on the lighting devices, including
 Lighting of the driver’s cab
 Lighting below the bridge
 Lighting of the main beam at non-conductive side
 Lighting of the main beam at conductive side
 Other
----Close the control power switch, and measure the control switch
 Check the connection of emergency stop chain, prepare to close the main breaker
 Check whether PLC input module works normally, whether peripheral equipment
is connected correctly, whether the contact nature is correct.
 Check whether PLC input module works normally, whether peripheral equipment
is connected correctly,
 Check whether PLC output module works normally, whether the peripheral
device is connected correctly.
 Check whether PLC main station and remote controllers work normally
 Check PLC’s program section of “On/Off Control”, switch on the control circuit,
confirm whether CPU works normally
----Adjust the operating circuit of each mechanism
Operate each gear repeatedly, check the accuracy and reliability of
opening/closing program, interlocking and protective action of electrical equipment
corresponding to the operating circuit based on the circuit diagram (could short
relevant contacts in the circuit), record the result
----Close the switch to main circuit of the air conditioner, air cooler and lubricator,
measure the circuit’s
voltage and record it.
After the auxiliary and control circuits are powered on, engage auxiliary
equipment necessary for operation and cut off other breakers.
3.5.3.4 Adjustment of power distribution protective system
 Check the closing and opening situation of the main power breaker’s contact,
whether the opening/closing action is accurate and reliable
 Open/close the power circuit’s contact, check the action’s reliability
 Check whether each interlocking step of the main contact coil circuit of the
protective cabinet (door’s safety switch, zero interlocking, limit protection,
over-current protection, limit of lifting capacity and etc) is correct or not.
 Upon power-on adjustment of the power distribution’s protective part, cut off the
breaker or knife switch in the main circuit of each mechanism
 Record the adjustment result
3.5.3.5 Lifting mechanism (=05, =06 )
Upon power-on for the first time, the mechanism shall work under idle load.
When idle-load adjustment succeeds, the lifting mechanism could wind the steel wire
rope under low speed.
3.5.3.5.1 Adjustment of lifting non-speed-regulating system
The master controller controls the single phase and plug braking’s descending
control circuit
Two gears of plug-braking descending controlled by the master controller could
be directly changed to the ascending control circuit.
Adjustment steps:
 Close the lifting mechanism’s power and control power breaker, check the
three-phase power and control voltage, which shall conform to design
requirements.
 Check and adjust the setting value of protective element related with the circuit;
the setting value of time relay; whether the setting value of over-current relay and
thermal relay meet the circuit requirements
 Check each control circuit of the master controller
Inspect the operation by gears
Check that the positive and negative contact connected with the controller, and
closing/opening program of the rotor’s contact shall conform to requirements in
drawings
 Check the function of lifting limit’s protective circuit at two poles
The rotary limit switch is used for the first level of lifting limit protection and
cuts off the positive contact of the lifting control cabinet; the hammer-type limit
switch is used for second and lifting protection and cuts off main contact inside the
protective cabinet; the limit of lifting capacity is used for protection at ascending
direction; the over-speed switch is generally used for protection at descending
direction.
3.5.3.5.2 Startup and adjustment of the lifting mechanism’s speed regulator
(speed-regulating system)
To meet technological requirements, the main lifting mechanism of the general
overhead crane adopts generally a speed-regulating drive plan. For adjustment of the
speed-regulating mechanism, start and adjust the drive mechanism firstly. Choose one
of following devices to start based on the speed-regulating device chosen by the
mechanism:
Start and adjust SIEMENS stator voltage/speed-regulating device (SIMOTRAS
HD)
Start and adjust ABB stator voltage/speed regulating device （ASTAT 10_5）
Start and adjust MH stator voltage/speed regulating device
（THYROMAT-BDH）
 Start and adjust Wenjiujiu stator voltage/speed regulating device （Jiujiu Electric
Appliance QY2_S/T）
Start and adjust ABB frequency-changing speed-regulating device
Start and adjust SIEMENS frequency-changing speed-regulating device
Start and adjust other speed-regulating devices
Power on and adjust the speed-regulating device based on the User Manual.
Before power-on adjustment, read carefully documents provided and instructions on
adjustment of speed-regulating device, particularly safety warning.
3.5.3.5.3 Adjustment of lifting mechanism
After the device is adjusted, adjust the function of all devices in the lifting
mechanism with load or no load, record the data
----Main lifting mechanism winds steel ropes, adjust the protective switch, record the
testing result into Table
3.4 (Idle Load)
Table 3.4 Lifting Mechanism’s Adjustment Result Record
Inspecte
No. Item Result
d by
First and second lifting mechanism uses the low-speed
1
gear to wind the steel rope
Set the lifting mechanism’s ascending emergency stop
2 m
limit, check its function
Set the lifting mechanism’s descending emergency stop
3 m
limit, check its function
Set the lifting mechanism’s ascending stop limit, check
4 m
its function
Set the lifting mechanism’s descending stop limit, check
5 m
its function
Set the lifting mechanism’s ascending acceleration limit,
6 m
check its function
Set the lifting mechanism’s descending deceleration
7 m
limit, check its function
8 Simulate the lifting drive unit’s failure
9 Simulate the lifting mechanism’s emergency stop
10 Other
Note: As to multi-stage limit protective device, the first stage of limit protection is
generally used for the mechanism’s deceleration operation; the second stage of
limit protection is used for normal stop after the mechanism’s deceleration; the
third stage is used for emergency stop of the mechanism. The first and second
stages of limit protection act on the mechanism’s control system. The third stage
of action cuts off the power supply.
----The lifting drive cabinet is put into operation with idle load (if two motors work,
they shall be put into
operation at the same time). Record the testing result into Table 3.5.
Table 3.5 Lifting Drive Cabinet Adjustment Result Record
No. Item Inspected by Result
1 Adjust the switch and protective element
Close the main breaker=05-Q10, test the main
2
circuit’s voltage
Close the braking breaker=05-Q70, test the braking
3
circuit’s voltage
4 Inspect the startup and stop procedure
5 Check and adjust the motor’s rotation direction
Check and adjust the motor blower’s rotation
6
direction and current (if yes)
7 Check the brake’s voltage and operation
8 Check the motor brake’s braking torque
9 Check the drive unit’s blocking function
Check the rotor contact’s change of
10
direction/interlocking (winding motor)
Check the rotor contact’s closing sequence
11
(winding motor)
12 Inspect the emergency stop
Check the correctness and reliability of protective
13
interlocking action
14 Other

----Adjust the lifting drive cabinet with load (if two motors work, they shall be put
into operation at the same
time), and record the adjustment record.
Adjust all main (auxiliary) lifting mechanisms of the crane based on above
project requirements, and record it by above form.
3.5.3.6 Translation mechanism (=10, =12)
3.5.3.6.1 Non-speed regulating circuit of the translation mechanism
Control circuit of the rotor symmetric resistor startup as controlled by the master
controller
The master controller controls first gear sliding, control circuit capable of direct
reversing
The master controller controls the first gear sliding, reset, automatic reverse
connection of control circuit.
 Adjustment steps:
 Close the mechanism’s power and control power breaker, check whether the
three-phase power source and control voltage shall conform to design
requirements
 Check and adjust the setting of protective elements related with the circuit; the
setting of time relay, whether the setting of over-current relay and thermal relay
conform to circuit requirements.
 Check each operating and control circuit of the master controller
Check by gears
Check that positive/negative contact connected with the controller and
opening/closing program of the rotor contact shall conform to requirements in
drawings.
As to the truck’s traveling mechanism driven by two or more motors, check
carefully whether motors have consistent rotation direction.
As to the truck’s traveling mechanism braked by multiple brakes, adjust carefully
the brake’s action and braking tightness, without apparent deviation, to avoid torsion
of crane bridge when traveling.
 Check the function of limit protective circuit
Simulate manually the action of contact at each protective interlocking step,
check the correctness of safety protective device and interlocking step action.
3.5.3.6.2 Start and adjust the speed-regulating device (speed-regulating system)
of the translation mechanism.
To meet technological requirements, some trucks or trolleys of overhead and
gantry cranes have adopted the speed-regulating drive plan. As to adjustment of
speed-regulating mechanism, start and adjust the drive unit firstly. Refer to
instructions on adjustment of lifting mechanism.
3.5.3.6.3 Adjustment of translation mechanism
Adjust the trolley’s limit switch
Record the result into Table 3.6

Table 3.6 Trolley Limit Switch’ Adjustment Result Record

No. Item Inspected by Result
Set the trolley’s leftward
1 stop limit, check its m
function
Set the trolley’s rightward
2 stop limit, check its m
function
3 Set the trolley’s leftward m
 deceleration limit (if any),
check its function
Set the trolley’s rightward
4 deceleration limit (if any), m
check its function
Simulate the trolley’s
5
drive unit failure
Simulate the trolley’s
6
emergency stop
7 Other

----Trolley’s drive control cabinet, record the result into Table 3.7

Table 3.7 Trolley Drive Control Cabinet Adjustment Result Record

Inspected
No. Item Result
by
1 Set the switch and protective element
Close the main breaker=10-Q10, test the
2
main circuit’s voltage
Close the braking breaker=10-Q70, test the
3
braking circuit’s voltage
4 Inspect the startup and stop procedure
Check and adjust the motor’s rotation
5
direction
Check and adjust the motor blower’s rotation
6
direction and current (if yes)
7 Check the brake’s voltage and operation
8 Check the drive unit’s blocking function
Check the rotor contact’s change of
9
direction/interlocking (winding motor)
Check the rotor contact’s closing sequence
10
(winding motor)
11 Inspect the emergency stop(if any)
Check the correctness and reliability of
12
protective interlocking action

Adjust all truck and trolley’s translation mechanism based on above project
requirements and record it by above form.
3.5.3.6.4 Adjust CMS (optional)
 Functional test of all windows and graphics
Checked by:
 Check fault and status
Checked by:

3.6 Acceptance inspection items, method and judgment basis after installation,
adjustment (or commissioning).

3.6.1 Trial run with idle load

Switch on the power under idle load. Operate each mechanism and check the
actions of some systems. Make the truck and trolley to travel to the limit, check
whether the truck and trolley’s limit switch acts sensitively. When the lifting
mechanism travels to the preset limit, the mechanism shall work at low speed to the
limit and then stop. Check whether each protective device and interlocking device act
flexibly. Measure the voltage, current and speed during trial run and keep record.
Table 3.8 is the form of trial run record.

Table 3.8 Trial Run Record

Mechanis Rotation Curr Volta Inspecte
No. Item Result
m speed ent ge d by
1. Up/down 1st gear
2. Main Up/down 2nd gear
3. lifting Up/down 3rd gear
4. Up/down 4th gear
5. Up/down 1st gear
6. Auxiliary Up/down 2nd gear
7. lifting Up/down 3rd gear
8. Up/down 4th gear
9. Left/right 1st gear
10. Left/right 2nd gear
Trolley
11. Left/right 3rd gear
12. Left/right 4th gear
13. Left/right 1st gear
14. Left/right 2nd gear
Truck
15. Left/right 3rd gear
16. Left/right 4th gear

3.6.2 Trial run with load

Lift respectively 0.25, 0.5 and 0.75 of the rated load until the rated load. Make
each mechanism to travel along full length of the bridge, measure the voltage, current
and speed of the motor when each mechanism works under different load, and record
them into the table.

3.6.3 Trial run with dynamic load

Lift 1.1times of the rated load, drive each mechanism respectively and operate
them repeatedly, the accumulation period is not smaller than 10min. Each mechanism
shall act sensitively and work reliably. Measure voltage, current and speed during the
trial run and record them into the table.
Note: The crane shall operate in accordance with the operation procedure during the
experiment. Pay attention to limit the acceleration, deceleration and speed into the
crane’s normal working range.

3.6.4 Functional trial run

Start and operate relevant mechanisms, check the function of following
mechanisms and record the trial run result
 Overload
Not greater than 5% when the error of lifting weight limit Gn≤50t, and not
greater than 8% if Gn＞50t. When the lifting weight limit is 0.9Gn, it will send the
acoustic and light warning signals. When it is at Gn, it will send the alarm signals and
cut off the power supply at the descending direction.
When it travels at the ascending direction, simulate manually the over-load
signal (delete this item for translation mechanism), check the system’s response and
record the result.

Checked by:

 Over-travel
Excite manually the over-travel limit at A/B direction, check the response of the
mechanism’s power distribution system, record the over-travel trial run record of the
lifting mechanism.

Checked by:

 Over-speed protective system

Descend the hook, simulate firstly an over-speed, check the system’s response
and record the result
Actual over-speed measurement: discuss with the user whether it is necessary to
conduct an actual over-speed test, the over-speed monitoring needs to be protected by
the safety system.

Checked by:
 Torque equilibrium (large speed reducer or three speed reducers, the lifting
mechanism with two motors)
As to the speed-regulating system, record the trial run record, inspect the current
or torque equilibrium of two motors

Checked by:

 Speed synchronization (planetary speed reducer, double-motor system, large-span

traveling mechanism driven by double transmission chain)

Checked by:

 Functional test of emergency stop chain and boarding switch

Checked by:

 Simulate and inspect the function of limit switch

Excite manually the speed-reducing limit at A direction, the mechanism will
travel with the deceleration at A direction, finally, it will be stopped by the stop limit
at A direction. Check the function of limit switch at B direction with the same method.

Checked by: