丰汇 40t龙门吊 (MDG40&10-42) 中英文说明书

MDG40/10-42 Type Gantry Crane
Operation&
maintenance manual
Shandong Fenghui Equipment Technology Co,.Ltd
http:∥www.chinacrane.cc
MDG40 型龙门式起重机使用维护说明书
Owner’s manual for MDG40 gantry crane
Notification
敬告
Any kind of the crane has its fatalness. To insure user body and
treasure free of death or ruin, the specification of this manual must be
followed while operation, maintenance, disassembly proceeding!
任何类型的起重机都具有危险性。为保证您的人身及财产安全，
请务必按说明书的要求进行操作、维护、安装、拆卸！
Letters boldfaced in this specification must be comprehended,
understood by user.
请用户务必对本使用维护说明书中的黑体字内容进行重点的理
解、掌握。
Cope ， explanation right of the manual belongs to Shandong
Fenghui Equipment Technology Co., Ltd.(Finehope)
本使用维护说明书的版权、解释权归山东丰汇设备技术有限公
司。
Inquire will be welcome by Fax, Tel, letter, Internet to gain
information relating relevant products, services, technical support.
欢迎垂询产品信息，您可以通过传真、电话、信函、Internet 网
络获得有关产品、服务、技术支持信息。
www.chinacrane.cc - i -
Notification 敬告
Postal Address：No. 18 Zhushun Road Jinan Hi-tech. industrial

zone Shandong P. R. China
Shandong Fenghui Equipment Technology Co.,Ltd
通讯地址：山东·济南市高新开发区祝舜路 18 号
山东丰汇设备技术有限公司
Zip code 邮编：250100
Domestic inquire free call 垂询电话：800 8606173
Sale hot line 营销热线：+0086-531-82379898
Fax 传真：0531-82379888
Web site 网址：www.fhjs.net
www.chinacrane.cc
我们新的工业园地址：
济南市章丘明水经济开发区唐王山路
山东丰汇集团
Our new address:
Tangwangshan road Mingshui economic development zone
Zhangqiu Jinan city P. R. China
Shandong Fenghui Group Co., Ltd.
联系电话 Tel：0086-531-81793106
传真 Fax： 0086-531-81793188
邮政编码 Post code：250200
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Forward
前言
The manual is to describe elemental schematic structure of
MDG series gantry crane, information on operation and
maintenance. The excellent performance function of the crane
would be only achieved by operator fully read and comprehended
of the manual.
本说明书为操作、维修、安拆人员提供了 MDG 系列龙门式
起重机的结构原理、操作和维修保养方面的知识，希望操作人员
在操作前能够仔细地阅读和理解，并在使用中，最充分地发挥起
重机的性能和作用。
Sincerely we are waiting for operator ’s comments on aspects
of operation and maintenance, crane performance improvement,
please feel free to inform your comments and experience on aspect
of crane using to our service personal or salesman, deeply
appreciated.
诚恳地希望操作人员在改进产品性能、操作和维修保养方面
提出宝贵意见，请随时将使用方面的意见和经验告知我公司服务
人员或营销人员，至为感谢。
Heartily thank you for chosen of our MDG series of gantry
crane.
衷心地感谢您选用我公司的 MDG 系列龙门式起重机。
Model of MDG40/10-42A3 gantry crane (40t gantry crane in
short), is our newly developed product.
www.chinacrane.cc - iii -
Forward 前言
MDG40/10-42A3 型龙门式起重机（简称 40t 龙门式起重机），
是我公司最新研制产品。
The integrated structure of the crane consists of Seamless of
truss frame, is provided with advantages of light weight,
compacted structure, easy erection and disassembly, beautiful
neatly externality etc. cabin and operation mechanism is designed
and manufactured according to ergonomics principle with
comfortable convenience control, wide visual field. Enable its
characteristic advantages of balance operation, stable safe, high
efficiency execution etc.
该机整体结构采用无缝钢管桁架结构，具有重量轻、结构紧
凑、迎风面积小、安拆方便、外形简洁美观等特点。操作室及操
作机构按照人机工程学原理设计制造，操作方便舒适，视野开阔。
具有运行平稳、安全可靠、作业效率高等特点。
The bridge frame is designed specially; two type of span can
be achieved by simple compounding of the bridge truss. Either
type of span is random used as optional for user.
专门设计的桥架，通过简单的桥架组合，即可实现两种跨度
的互换。用户可自由选择使用任一种跨度。
To make sure the crane operated, maintained and
disassembled correctly, please read the manual carefully before
using it!
为保证起重机的正确操作、维护及安拆，使用前请认真阅
读本使用说明书！
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目录 Table of content
敬告 ........................................................................................................................ i
前言 ......................................................................................................................iii
目录 Table of content ............................................................................................ v
第一章主要技术参数......................................................................................... 1
第二章整体结构性能......................................................................................... 5
第三章 Erection of the crane 起重机的安装 .................................................... 13
第一节 Erection 安装.............................................................................................. 13
第二节 Electric technical explanation 电气技术说明................................................ 19
第三节安装螺栓一览表 Erection bolt listwise ..........................................................33
第四节主要部件清单 Major component list.............................................................. 37
第四章 safety operation of the crane ................................................................. 41
第五章起重机零件总成................................................................................... 47
第一节主要外购件 Major outsourcing component .................................................... 47
第二节外购件供货商信息 outsourcing supplier information....................................49
第三节减速器技术说明 ............................................................................................. 51
第四节电动葫芦技术说明 ......................................................................................... 59
第五节制动器技术说明 technical specification for brake ......................................... 65
第六节电缆卷线器技术说明 ..................................................................................... 71
第六章维护保养规程....................................................................................... 77
第七章起重机的润滑 Lubrication of crane ..................................................... 85
1、润滑的基本原则 Basic principle of lubrication： ................................................... 85
2、润滑注意事项 Lubrication precaution： ................................................................. 85
3、40t 起重机推荐用油 Recommended crane lubricant...............................................85
4、润滑表 Lubrication table： ...................................................................................... 87
5、润滑图 Lubrication chart： ...................................................................................... 91
第八章常见故障与排除方法 common trouble and troubleshooting method . 93
第九章附录 annexure ................................................................................. 103
附录一 annexure one：电气备件清单 electric spare list ................................. 105
附录二 annexure two：主要部件运输外形尺寸图 major component transportation
figuration dimension diagram ....................................................................................... 107
附录三 annexure three：电气系统图 electric system drawing ................................... 113
附录四 annexure four：卓轮减速机安装检修图 Zollern speed reducer erection and
maintenance drawing..................................................................................................... 133
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第一章主要技术参数
Major Technical parameter
1、Crane group working grade 整机工作级别：A3

2、Main hook (MH) hoisting capacity 主钩起重量：40t
3、Aux. hook (AH) hoisting capacity 副钩起重量：10t（Electric hoist 电动
葫芦）
4、Span 跨距：42m
5、Cantilever beam length 悬臂长度：11m
6、Trolley rail distance 小车轨距：2.8m、wheel distance 基距 3.2m、
7、MH hoisting height 主钩起升高度：15.5m
8、AH hoisting height 副钩起升高度：15m
9、MH hoisting speed 主钩起升速度：0~5m/min
11、AH hoisting speed 副钩起升速度：7m/min
12、Truck travel speed 大车运行速度：0~21.4m/min
13、Trolley travel speed 小车运行速度：22m/min
14、Electric hoist travel 电动葫芦行走：20m/min
15、Truck max. wheel load 大车最大轮压：215kN
16、Trolley max. wheel load 小车最大轮压：55kN
17、Truck rail model 大车轨道型号：P43
18、Total power 总功率：76.8kW
19、Power supply 电源：AC 415V 50Hz three phase four wires 三相四线
制
20、Crane group self weight 整机自重：85.64t
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第一章主要技术参数
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MDG40/10-42A3龙门式起重机总图b
第二章整体结构性能
Crane group structure performance
The model of MDG40/10-42A3 gantry crane is our new designed piping type
brace girder, light weight, easy dismantling. Hoisting and travel mechanism adopts
rotor resistance cutting speed regulating method, rotation and operation more easy
and stable. Special designed bridge structure can interchange the two types of span
by simply truss frame compound.
MDG40/10-42A3 型龙门式起重机为我公司新型设计的管桁结构，重量轻、
易装拆。起升及行走机构采用转子切电阻调速，运转、操作简便可靠。专门
设计的桥架，通过简单的桥架组合，即可实现两种跨度的互换。
Crane span is 42000mm (32000mm), single cantilever beam length of
10945mm, main hook (MH) max. hoisting height is 15500mm, aux. hook max.
hoisting height is 15000mm.
起重机跨距 42000mm（32000mm）
，单端悬臂长 10945mm，大钩最大起
升高度为 15500mm，小钩最大起升高度为 15000mm。
The crane gross weight is 85.64t.
起重机总重为 85.64t。
The segment of the crane consist of bridge frame, bridge bracket, travel
mechanism, hoisting and variation pulling mechanism, trolley, electric control and
safety device etc.
起重机主要组成部分有：桥架、支腿、行走机构、起升及变幅牵引机构、
小跑车、电气控制及安全装置等。
There are 5 portions of the bridge truss, four portions of main bridge, one
portion of cantilever beam portion, total of 55720mm in length, total of 32.8t in
weight, section of the frame is an isosceles triangle figure, the width and height
both are 2800mm, bridge truss rigid bracket portion length of 12000mm, weight of
第二章 Entire structural function 整体结构性能
10320kg, bridge middle portion Ⅰ 10975mm by length, 6021kg by weight,

bridge truss middle portion Ⅱ 10000mm by length, 5787kg by weight, bridge
truss flexible bracket portion length of 11800mm (upper string), weight of 8051kg,
bridge truss cantilever beam portion length of 10945mm (lower string), weigth of
2610kg.
桥架共五节，主桥架四节，悬臂段一节，全长 55720mm，总重 32.8t，断
面为等腰倒三角形，宽、高均为 2800mm，桥架刚性腿段长 12000mm，重
10320kg，桥架中间节Ⅰ，长 10975mm，重 6021kg，桥架中间节Ⅱ，长 10000mm，
重 5787kg，桥架挠性腿段长 11800mm（上弦），重 8051kg，桥架悬臂段长
10945mm（下弦），重 2610kg。
Main bridge truss portion all to be connected by flange apiece, it is connected

by circular flange for the main string between main bridge truss and bridge
cantilever beam portion, bridge web member is connected by circular flange, all of
the connecting plate of the vertical flange can be interchanged. The bridge frame
main string and bridge truss another side of the web member is connected by M24
reamer bolt, the horizontal web rod of the upper string of the bridge truss is
connected by M20 reamer bolt.
主桥架各节主弦均采用竖法兰连接，主桥架与桥架悬臂段主弦采用圆法
兰连接，桥架腹杆采用圆法兰连接，所有竖法兰连接板均能互换。桥架主弦
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及桥架两侧腹杆连接螺栓均采用 M24 铰制孔用螺栓，桥架上弦水平腹杆连接

螺栓采用 M20 铰制孔用螺栓。
The special designed bridge truss, can interchange two type of span by simple
compound of the bridge truss. The integrated bridge combination of the bridge
truss is 42m span, by deducting the middle portion Ⅱ (10m portion), can be
combined as 32m span.
专门设计的桥架，通过简单的桥架组合，即可实现两种跨度的互换。完
整的桥架组合为 42 米跨度，去掉桥架中间节Ⅱ（10 米段）
，即可组合为 32 米
跨度。
Either kind of span usage can be freely selected by user according to site
condition.
用户可根据现场条件自由选择使用任一种跨度。
Whether the cantilever beam erected or not decided by user according to site
using requirement.
用户可根据现场使用要求确定是否安装悬臂。
The truss bracket is distinguished by ridge leg and flexible leg. The upper is
connected to bridge truss with flange; lower of it is connected to the end carriage.
The connection of the bracket and bridge truss is all by M24 reamer bolt. The four
right angles of the connection flange between the bracket and the end carriage by 4
Nos. of reamer bolt, the balance to fix up by high tensile bolt for easy erection and
dismantling. The cabin and the electric panel is furnished on middle floor of the
rigid bracket.
支腿分为刚性腿和挠性腿。上部与桥架通过法兰连接，下部与行走梁相
连接。支腿与桥架连接均采用 M24 铰制孔用螺栓。支腿与行走梁连接法兰四
角采用 4 支铰制孔螺栓，其余均为高强螺栓固定，以方便安装和拆除。刚性
支腿中间平台上布置有操作室和电气柜。
The rigid leg weight of 8.848t, consist of symmetry of left and right piece,
each piece is divided by upper and lower parts, it is connected by M20 reamer bolt
between left and right piece, it is connected by M24 reamer bolt between upper and
lower parts.
刚性腿重 8.848t，由左右对称两片组成，每片分上下两段，左右两片间以
方法兰用 M20 铰制孔用螺栓连接，上下两段间以圆法兰用 M24 铰制孔用螺栓
连接。
The flexible leg weight of 5.580t total, consist of symmetry of left and right
piece, each single piece is made by H section steel, channel steel and seamless
pipe.
挠性腿总重 5.580t，由左右对称两片组成，每单片由 H 型钢、槽钢和无
缝钢管焊接而成。
-8-
The movement mechanism is divided by rigid bracket mechanism and flexible

bracket mechanism (note: travel mechanism not interchangeable). Consist of
one travel beam and two travel carriages respectively.
行走机构分为刚性腿行走机构和挠性腿行走机构（注意：行走机构不可
互换）
。分别由一行走梁和两行走台车组成。
The travel beam is box type structure beam, center span of 9000mm, the
travel beam and travel carriage is hinged by pinned shaft. Each travel carriage is
furnished with one drive wheel unit and one driven wheel unit. The drive wheel
unit is consist of three in one mechanism i.e. speed reducer, electric motor and
brake, provided with advantages of economy operation, simply structure etc. There
are 4 drive and 4 driven for whole crane group.
行走梁为箱型结构梁，中心跨距 9000mm，行走梁与行走台车以销轴铰接。
每行走台车设一主动车轮组和一从动车轮组。主动车轮组采用减速机、电动
机和制动器组成的三合一机构，具有运行经济，结构简单等优点。整车为 4
主 4 从。
Both of the main hoisting and variation pulling mechanism is erected on front
end of the bridge truss ridge bracket floor, main hoisting mechanism on down floor,
variation pulling mechanism on up floor. The imported inside concealed planetary

speed reducer for the main hoisting and variation pulling hoist is provided with
advantages of light weight, less volume, maintenance not required and high
stability etc.
主起升及变幅牵引机构均安装在桥架刚性腿段端部平台，主起升机构在
下层平台，变幅牵引机构在上层平台。主起升及变幅牵引卷扬机均采用进口
内藏行星减速机，卷扬机具有重量轻、体积小、无需维护及高可靠性等优点。
The main hoister is a double rope feeding aligned drum, the rope fastening at
one end though an attachment plate on the drum, the other end of the rope is fixed
on end of the bridge truss flexible bracket portion.
主起升卷扬机为双出绳卷筒，钢丝绳一端通过压板固定在卷筒上，另一
端固定在桥架挠性腿段端部。
The trolley double direction variation is controlled by variation pulling hoister
though steel wire.
变幅牵引卷扬机通过钢丝绳控制小跑车双向变幅。
Electric system: The electric control of the MH, pulling trolley, truck travel is
achieved by resistance cutting method, is combined with master controller station
centralized way of control, easy operation and maintenance.
电气系统：采用联合操作台集中控制方式，主钩、牵引小车、大车运行
电器控制采用转子切电阻调速方式，便于操作和维护。
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Safety device: The main hoisting mechanism load limiter, hoisting height
limiter, hook descended limiter, truck & trolley travel limiter, buffer, electric hoist
hoisting height limiter, gate limiter, new type rail fastener (rail sweeper) on the
truck etc. is furnish with the crane.
安全装置：起重机配置有主起升机构重量限制器、起升高度限位、落钩
限位，大、小车运行限位、缓冲器，电动葫芦起升高度限位，仓门限位，大
车设有新型的夹轨（扫轨）器等。
第三章 Erection of the crane 起重机的安装
第一节 Erection 安装
The foundation treated and laid of the rail should be confirmed with national
specification, the required wheel load should not lower than 215kN. The erection
site should have ground require for component assembly, sling etc. The erection
strategy and compiling of the “execution instruction manual” and “safety
construction precaution” should be decided by capability of the crane to be used
and site condition. Commonly erection of the 40t gantry crane follows as
sequences listed under.
起重机的轨道基础处理、轨道敷设应符合国标规范，轮压要求不小于
215kN。安装现场应具备部件组合、起吊等的场地条件。安装前应根据安装用
起重机械能力和场地条件，确定施工方案，编制起重机安装“作业指导书”
和“安全施工措施”
。40t 龙门式起重机的安装，一般按以下顺序进行。
1、Put temporary alignment taper or liner 行走台车定位垫支；
（Note: speed
reducer should be located inside of the crane span 注意：减速机在起重机跨内）
2、Assembly for 4 portions of the bridge truss and electric hoist rail 组合主桥
架 4 节及电动葫芦轨道（Hoisting and pulling hoister included 包括起升、牵引
卷扬机）；
3、Cable winch erection 安装电缆卷线器；
4、Assembly and sling of the rigid bracket, stair case erection and rigid
bracket steel rope pulled tensioning; 4 right angle of the lower edge of the rigid
bracket flange are reamer bolt, the rest of the bolts are high tensile bolts.组合起吊
安装刚性腿，安装爬梯拉设缆风绳；刚性腿下部法兰四角为铰制孔螺栓，其
余为高强螺栓。
5、Cabin, rigid bracket upper portion and rheostat, distribution panel erection
第三章起重机的安装
安装操作室、刚性腿上部及电阻箱、配电柜；
6、Sling of the flexible bracket，alignment steel rope pulled 起吊安装挠性腿，
拉设缆风绳；
7、Sling and erection of the main bridge truss; sling and erection of the
cantilever beam portion of the bridge truss 起吊安装主桥架；起吊安装桥架悬臂
段（Complete with electric hoist 带电动葫芦）；
8、Electric cable arrangement, cable connection; electrical installation 电气布
线，接线；安装电气设备；
9、Sling and trolley putting 吊放小跑车；
10、Hoisting（2×145m）and pulling（90+55m）steel rope putting though and circling;

(See steel rope circling drawing)穿绕起升（2×145m）和牵引钢丝绳（90+55m）；
（见绕
绳图）
11、Proceeding overall inspection and outstanding completion to the crane 对
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起重机进行全面检查完善；
12、Commissioning, load test 调试、负荷试验。
Safety precaution 安装注意事项：

1) While the bridge truss being assembled, the upper string of the
bridge truss where connecting plate bolt near the rail should
be go trough from inside to the outside (i.e. the tail o the
bolt towards to the trolley rail), as drawing showed. Otherwise,
trolley might be blocked at the location bridge truss jointed.
桥架组合时，桥架上弦靠近轨道的连接板连接螺栓应由里向外穿（即：
螺栓尾部朝向小跑车轨道），如图示。否则，小跑车在桥架接头位置
可能受阻。
2) The travel carriage should be correctly fastened on its securing

mounting position, notice that rigid bracket mechanism and
flexible bracket mechanism are not interchangeable, moreover
the speed reducer should be at inside of the crane span 行走
台车应正确牢固定位安放，注意刚性腿行走机构和挠性腿行走机构不
可互换，且减速机应在起重机跨内。
3) For assembly of the rigid bracket, should first erect lower part
of the rigid leg, then cabin erection, further more erection

for bridge leg upper part and distribution panel and rheostat,
finally sing for bridge truss put it on position; Otherwise
distribution panel, rheostat and cabin can not be erected 刚
性腿组合安装，应先安装刚性腿下半部分，然后安装操作室，再安装
刚性腿上半部分和配电柜和电阻箱，最后起吊桥架就位；否则，配电
柜、电阻箱和操作室将无法安装。
4) There should be rigidity connection between electric hoist and
initial end of the cable tackle, the preferable length of
connection should ensure not squeezing the rear cable tackles
while the hoist backward to the end stop 电动葫芦和首端滑车之
间应做硬连接，连接长度应能保证葫芦退到挡板位置时不挤着后部的
滑车为宜。
5) The trail cable conductor sagging portion should not collision
with the rigid leg, otherwise the cable would be damaged 电缆
滑线下垂部分不应与刚性腿相碰，否则易损坏电缆。
6) For easy of dismantling, the connection joint between rigid leg
and bridge truss flange should take in care, mounting cap should
be added on special location; For the places where applicable
the bolt should be putting though from up to downward 为便于
拆除，刚性腿与桥架法兰连接处的螺栓应注意安装方法，特殊位置加
装备帽；有条件的位置应由上向下穿螺栓。
7) All of the reamer bolt lubrication grease coated for anti-rust
所有铰制孔用螺栓涂润滑脂防止锈蚀。
8) All of the reamer bolts must be tighten to meet stander torque
required 所有铰制孔用螺栓必须按标准力矩紧固：
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9) M24 reamer bolt –660NM; M24 铰制孔用螺栓--660 牛米；

10) M20 reamer bolt -385NM; M20 铰制孔用螺栓--385 牛米。
11) Sing of the crane, should proper sing position and sling
equipment be selected 起重机吊装，应合理选择起吊位置和起重设
备。
第二节 Electric technical explanation 电气技术说明
1、Power supply system 供电系统

The crane is AC 415V 50Hz three phase four wires system power supply,
main circuit is ～415 V supply power, the control circuit is ～220V supply power,
the residual current protection device is provided with the socket inside of the
cabin, the insulated transformer is mounted in the electric panel to supply power to
crane illumination. The DC 24V electromagnetism brake is used for truck travel
mechanism, its required voltage variation should not more than ＋5％～－15％.
The power of the electromagnetism brake is supplied by 1500W switch DC source,
the potentiometer is furnished on the switch DC source to inching adjust the output
voltage, ensuring operational voltage scope required by the electromagnetism
brake.
本机采用交流 415V 50Hz 三相四线制电源供电，主回路采用～415 V 电
源，控制回路为～220V 供电，操作室插座配有漏电保护装置，在电源柜装有
415V/240V/220V 隔离变压器，为起重机照明提供电源。大车行走机构采用直
流 24V 电磁制动器，要求电压波动范围不超过＋5％～－15％。该电磁制动器
由 1500W 开关电源供电，开关电源上设有电位器可以对输出电压进行微调，
保证电磁制动器的工作电压在要求范围内。
The power supply of the crane via cable winch, directly connect to
distribution panel is distributed to each mechanism and control circuit by
1Q1breaker. The emergency stop is mounted both on the master controller and the
end carriage, can cut off main power 1K1 contactor when required.
本机电源通过安装在刚性腿侧行走梁上的电缆卷线器，直接引至配电柜。
经过断路器 1Q1 分配到各机构及控制回路。联动台及行走梁上均设有急停开
关，紧急时可切断总电源接触器 1K1，使系统全部断电。
The total load of the crane is 76.8kW (see column follows), complete crane
operational current 115A, max. operational current 184A. The voltage drop of
crane internal should not more than 4%, if requirement could not met the power
supply cable section should be enlarged, connection point to be changed or
special-purpose power transformer to be added. Simultaneity, the out connected
power voltage should not beyond ±10% of rated voltage.
本机总负荷 76.8ｋW（见下表）
，整机工作电流 115A，最大工作电流 184A。
机构运行时要求机内压降不大于 4%，若不满足要求则应增加电源电缆截面、
改变引入点位置或设置专用电源变压器。同时，外接电源电压不能超过额定
电压的±10%。
Table for power supplied equipment 供电设备表
机构名称 mechanism description 电机型号 motor model 功率 power（ｋW）
主起升机构电动机 main hoisting
YZR250M1-6 37
mechanism motor
电动葫芦起升电动机 electric 锥形转子电动机
13
hoist hoisting motor cone-shaped rotor motor
电动葫芦运行 electric hoist 锥形转子电动机
2×0.8
travel cone-shaped rotor motor
小车牵引电动机 trolley pulling
YZR160L-6 11
motor
大车运行机构电动机 truck
YZR132M2-6 4×3.7
travel mechanism motor
整机用电设备总容量 overall
power capacity of the crane 77．4
complete
2．配电线路 distribution line

机内动力电缆一律采用 YC 系列橡套电缆，最小截面不小于 1.5mm2，其
截面与电气设备相适应。控制电缆为 KVVR 型控制电缆，最小截面不小于
1.5mm2。电缆必须保持完好，当发现电缆绝缘或芯线受损或绝缘老化时，必
须进行更换。Internal connection for the crane power cables is YC series rubber
insulated cable all and singular. The minimum section of the cable is not less than
1.5mm2，which suitable with the electric equipment connected. The control cable is
KVVR type with section area of 5mm2. The cable shall be protected well, if there
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are any damages or aging on the cable insulation or wire core, the cable should be
changed.
3．接地 Earthing
本机通过大车轨道接地，所有电气设备的金属外壳，电缆保护管、操作
室等均需与起重机金属结构有可靠的电气连接。本机任一点的接地电阻均不
大于 4Ω。当接地电阻不满足要求时，应对起重机轨道接地进行改进，直到满
足要求。All the metal enclosure of electric equipment, the cable conduit and the
operation cabin is all required to firmly connect to the truss crane structure via the
truck rail grounded. Any parts of the earthing resistance of the crane are not be
more than 4Ω. If the earthing resistance could not be satisfied, the crane rail
earthing shall be improved until it reaches the suitable requirements.
4．控配方案 control & distribution scheme
操作室位于刚性腿中间平台，电气柜布置于操作室上部平台右侧（面向
揉型腿为前方），电阻箱布置于电气柜的对面。The operation cabin is located on
middle platform of the right leg. The electric control panel (the front facing
flexible leg) is erected on the right of the platform above the cabin. The resistance
box is erected on the opposite side of the panel.
电缆卷线器安装于刚性腿侧行走梁上。总电源断路器安装于总电源柜，
通过操作室内联合操作台上的表计可以实施对电源的监视和控制。操作室内
的配电箱可实现空调、照明等电源控制。电气柜可实现主副起升、大车运行、
小车运行各机构的控制和保护。主要配控设备见下表： The cable winch is
erected on the end carriage of the rigid leg side. The main power breaker is
mounted on the electric control panel, and the power supply can be controlled and
monitored by the master controller inside the operator cabin. The AC, illumination
lighting power switch etc. can be controlled by the electric cabinet inside the cabin.
The main and aux. hoisting & truck travel, trolley various mechanism control &
protection can be achieved by the electric control panel. The major facilities
relating to distribution & control are as shown below:
主要控配设备明细表 Detailed list for major distribution & control facility

序号
安装地点 Mounting
Sl. 名称 Description 备注 remark
location
No.
电缆卷线器 cable
1 行走梁 end carriage
winch
2 操作室 cabin 刚性腿平台 rigid leg platform
配电柜 electric 刚性腿中间平台 rigid leg
3
control panel middle platform
联合操作台
4 combined control 操作室内 inside the cabin
station
传感器安装于钢丝绳
重量限制器 weight 固定端 sensor is
5 操作室 cabin
limiter erected the fixing end
of the rope
电阻箱 resistance 刚性腿中间平台 rigid leg
7
box middle platform
主钩限位 main hook
8 主钩卷扬机 main hook winch
limiter
小车运行限位 trolley 小车牵引卷扬机 trolley
9
travel limit pulling winch
大车运行限位 truck
10 行走梁 end carriage
travel limit
11 门限位 gate limit1 登机爬梯门 landing stair gate
操作室平台入口 entrance of
12 门限位 gate limit2
the cabin platform
5．电气设备安装 Erection of electric equipment

5.1 所有电气接线必须按线标正确连接，接线应牢固、接触良好。All the wiring
shall be connected correctly as per the wire Id. marks. The wiring shall be firm and
be in good contact.
5.2 所有电缆应按敷设管穿管敷设，无管子的地方应进行可靠绑扎，以防止电
缆磨损，电缆敷设应整齐美观。All the cables shall be laid through the conduits. If
no tubes are applied, the cables shall be firmly bounded to prevent from cable
abrasion. The cable shall be laid in good order.
5.3 电动葫芦滑车应与电缆固定牢固，滑线电缆长度必须一致，安装后的小滑
车应滑动灵活，无卡阻，滑线电缆的长度应保证电动葫芦在最大行程时，电
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缆不拉紧，小滑车牵引钢丝绳的长度应略小于滑线电缆长度，以保证在电动
葫芦向远端运行时，电缆不受力。The electric hoist trailing pulley shall be fixed
firmly with the cable. The sliding cable shall be in the same length. The tackle
shall slide well without any blockages after the erection. The length shall be
enough to ensure that the sliding cable will not tightened when the electric hoist at
its maximum travel. The length of the tackle pulling wire rope shall be a little bit
shorter than those of the sliding cable, so that the cable could not be pulled while
the electric hoist travels to the far end.
5.4 附电气系统原理图共 10 页 The electric system schematic drawings total 10
pages attached.（见附录 see annexure 3）
。
6．调试 commissioning
6.1 通电前检查 inspection before energizing
在配线安装完毕，准备通电前，要对所有电路、器件进行检查。检查电
气设备及电缆安装是否符合图纸，电器元件安装是否牢固，接线是否松动，
检查锡焊点是否虚焊，同时检查与电气有关的机构固定是否可靠，制动器等
传动机构及限位器等保护装置是否安装正确。检查回路绝缘是否可靠。并检
查各机构系统是否正常。Once the wiring arrangement is finished, all the electric
circuit, instrument and component should be inspected before energizing. The
inspections shall include the followings: whether the electric equipment and cables
are erected as per the drawings; whether the instrument components are fixed well;
whether the wire connections are loosen; whether the tin welding points are fake
welded; whether all the mechanism electric involved is stable fixed; whether the
safety device like brake, transmission mechanism and limit etc. is erected correctly;
whether the circuit insulation are reliable; whether either mechanism systems are in
good operation.
注意：系统检查前各机构必须先进行机构方面检查，并在电气分机构动
作中做好监护工作。Note: every mechanism shall be inspected prior to the
system inspection. And the surveillance shall be done during the electric
sub-mechanism trial operation.

双大车运行机构必须先测转向，使 4 电动机驱动方向一致。The rotation
direction of the double truck travel mechanism must be checked to ensure
that the driving direction of the 4 motors keep compliance.
6.2 通电调试电气回路 Energizing for various mechanism electric circuit
commissioning
在接线工作完成后，应对二次回路及动力主回路进行调试，确保系统正
常后方可投入运行。Once the wiring is completed, the secondary circuit and the
main power circuit shall be commissioned to ensure the system run properly before
putting into normal operation.
6.2.1 先断开主起升机构断路器 2Q1、副起升机构断路器 3Q1、大车运行机构
断路器 Q401 及小车牵引机构断路器 5Q1，接通总电源断路器 1Q1。First switch
off the hoisting mechanism breaker 2Q1, aux. hoisting mechanism brake 3Q1,
truck travel mechanism Q401 and trolley pulling mechanism breaker 5Q1, then
switch on the power supply breaker 1Q1.
6.2.2 通过联合操作台上的控制按钮进行停、送电操作，以确认电源回路
的正确性。当无法实现电源操作时，可按图纸检查电源回路，并检查各限位
开关是否闭合。The correctness of the power supply circuit could be confirmed by
switching on or switching off the control buttons on the master controller to stop
and start the power supply. If the power switch can not be operated properly, the
power circuit should be checked again according to the drawing; should also the
limit switch whether being closed be checked.
6.2.3 主起升系统：根据调速方式不同选择进行。Main hoisting system: to
proceed selectively according to different speed variation method.
6.2.3.1 自励磁调速方式 Self-excitation speed variation method：
操纵主起升主令 S40，做上升动作，K1、K3、K108、K7 接通，上升 2
挡接触器 K43 接通，上升第三挡接触器 K42、K01 接通，上升第四挡接触器
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K41、K02、K07、K40 接通。Navigate main lifting main command S40 to achieve

up action, K1、K3、K108、K7 actuated on, rising second speed step contact K43
actuated on, rising third speed step contact K42、K01 actuated on.
下降时：下降 1 挡 K8-F9-K7-K04-K42-K01-K41-K02-K07-K40 先后接通；
下降 2 挡 K8 保持，K41、K40 先后失电；下降 3 档 K42 失电；下降 4 挡 K8
失电，K2 接通，F9 断电，K7、K3 接通 K04、K08 继续接通 K43、K42 接通，
经延时，K41、K40 接通。K2、K02 接通，使 K03、K07 也接通，当 S40 快速
由下降 4 挡打回到下降 2－1 挡时，K03 使 K42 延时接通，以免切换力矩过大。
When lowering: lowering first speed step
K8-F9-K7-K04-K42-K01-K41-K02-K07-K40 actuated on early or late; lowering
second speed step K8 retained, the K41, K40 lost power successively; lowering
third speed step K42 lost its power; lowering speed step fourth K8 lost power, K2
switched on, F9 power cut off, K7, K3 switched on K04, K08 continually switch
on K43, K42 switched on, via relay, K41, K40 switched on, to enable K03, K07
switched on also, while S40 speediness form lowing speed fourth step back to
lowering 2－1 speed step, K03 enable K42 delayed switched on to avoid excessive
transfer torque.
时间继电器的整定值 Set value of the time relay：for K01 为 0.6s，for K02
为 0.3s，for K03 为 0.8s，for K04 为 0.7s。
注意 Notice：电压继电器在电动或再生制动时处于接通状态 The voltage
relay while at electric operation or regeneration braking is situated at on condition；
F9 为失磁保护继电器，K04 为初始磁场建立状态保护继电器。F9 is
an field-loss relay, K04 is an initial field formed condition protection relay.
6.2.3.2 串级调速方式 Cascade speed variable method：
合上控制开关 QF202，主令 2S 自锁在零位，继电器 K211 常开触点闭合并
自保，控制系统带电。合主电路开关 Q201，主电路带电，可控硅 2U1、2U2、
2U3 正常工作。搬起主令 2S，K1 触点闭合→中间继电器 K212 及时间继电器
K222、K223 带电，接触器 K201 吸合，同时 K205 延时吸合，制动器打开（防

止溜钩），电动机起动。将主令 2S 拉到底，KA 触点闭合，时间继电器 K221 延
时闭合，接触器 K204 吸合，电动机到满速。将主令退回到零位，电动机可由
满速到停止。推动主令 2S 到重降区，K2 闭合，中间继电器 K214 吸合，时间
继电器 K224 接点吸合，继电器 K203A→K203B 带电，电动机通入直流励磁电
压，同时，接触器 K205 吸合，制动器打开。电动机在重物拖动下可以实现下
降（注意：在重降区能够下降时，严禁将主令打到轻降区）
。当起吊物太轻时，
钩子无法下降。继续推动主令，进入轻降区，K3 闭合，中间继电器 K213 吸合，
接触器 K202 吸合，电动机实现动力下降。主令 2S 缓慢推到底，电动机逐渐
加速，KA 闭合，时间继电器 K221 带电，接触器 K204 延时吸合，电动机进入
额定转速。反向将主令回到零位，电动机由满速到停止。Switch on control
switch QF202, main command 2S is self-locked zero, the normal open contact
K211 of the relay is closed and maintaining in closed condition, the control system
is energized now. Switch the main circuit switch Q201 on, the main circuit is
energized, thyristor 2U1、2U2、2U3 working in normal. Lift the main command 2S,
K1 contactor closed →interposing relay K212 and time relay 222、K223 energized,
contactor K201 contacted, simultaneously K205 contact delayed, allows the brake
open up (prevented hook slides), the electric motor starts.
主钩控制柜在起升动作时检查脉冲信号和给定板参数与大车运行机构检
查方法基本一致，只是在重降区时，电机转速由低到高，脉冲信号（β 角）
由 90°渐渐移至 30°，轻降区则从 30°渐渐移至 90°。此外，还要检查霍
而元件的供电及输入、输出，放大板 I+与 I- 间的输出。The main hook control
cabinet when at lifting travel inspects the pulse signal and given circuit board
parameter basically according to the truck movement mechanism inspection
method, only is at the heaving lowering zone, the electrical motor rotation speed
from low to high, the pulse signal (βangle) from 90° moves gradually to 30°, for
light lowering zone in the other hand from 30° gradually to move lightly to 90°. In
- 26 -
addition, relating Hall component electric power supply and input, output,
amplification circuit board the output between I+ and I-.
6.2.3.3 双向对称电阻调速方式（以起升过程为例）The bidirectional symmetrical
resistance speed variable method (take lifting process as example)
断主回路开关 2Q1，合控制开关 2Q2。主令于零位，中继 2K0 得电，常
开触点闭合并自锁。Cut main circuit switch 2Q1, switch on control switch 2Q2.
Main command in the zero position, relays 2K0 result in electricity on, the normal
opened contact closed and the self-locking.
起升一档：接触器 K201 线圈得电，辅助常开触点闭合，接触器 K203 线圈得
电，制动器打开，电机运行于一档速度。Lifting speed step one: The recombiner
K201 coil results in electricity on, auxiliary normally opened contact closed, the
recombiner K203 coil results in electricity on, the brake opens, electrical
machinery movement in first step speed.
起升二档：接触器 K204 线圈得电并动作，切除第一段电阻。电机运行于二档
速度。Lifting speed step two: The recombiner K204 coil results in the electricity on
and its action actuated, the first section of resistance has been cut off. Electrical
motor runs in second speed.
起升三档：接触器 K205 线圈得电并动作，切除第二段电阻。电机运行于三档
速度。Lifting speed third: the recombiner K205 coil results in the electricity
energizing, the second section of resistance has been cut. Electrical motor runs at
speed third.
起升四档：接触器 K206 线圈得电，辅助常开触点闭合，时间继电器 K20S
得电并延时闭合，切除最后一段电阻。电机电机获得第四档速度。Lifting
speed forth: the recombiner K206 coil results in the electricity energizing,
auxiliary normally opened contact being closed, time relay K20S results in the
electricity energizing and at the same time delayed closed, the last section of
resistance has been cut. The electrical motor gained speed fourth.
6.2.4 小车牵引机构：本机构共设四个档位，采用不对称的电阻起动控制方式，
系统比较简单。Trolley pulling mechanism: the crane is set with four speed steps,
asymmetrical resistance start up control method is used, the system quite is simple.
主令打到小车单方向运行时，5K3、5K4、5K5、5K6、5K7 及负责方向的
接触器 5K1 或 5K2 能否正常吸合即可。When the main command is handle to
trolley single direction travel, 5K3, 5K4, 5K5, 5K6, 5K7 and direction functional
contacts 5K1 or 5K2 whether normally attract gather then.
6.2.5 大车运行机构：根据调速方式不同选择进行 Truck travel mechanism: to
proceed according to the different speed variable method.
6.2.5.1 串级调速控制方式：主令 4s 在零位时，4K0 吸合，双向操作主令，
以检查各接触器是否正常动作。Cascade speed variation control mode: main
command 4s when at zero position, 4K0 attracts gathers, by bidirectional operate
the main command to check whether various contacts actuated with normal
movement.
用双踪示波器来检查脉冲（Q401 必须在断开位置）
。一组探头的正极，接
A 相可控硅的控制极，负极接可控硅的阴极；另一组探头的正极，接 T2 同步
变压器-a 端，负极接 D- 端。主令在零位时，在示波器上观察脉冲信号（β 角
应在 30°）；如位置不准，微调触发板上相应电位器。当主令离开零位升至满速
时，方波渐渐左移至 90°位置。同样可检查 B、C 相脉冲。Inspects the pulse with
the double trace oscillograph (Q401 must in the position open). A group of probe is
connected to positive pole, connecting with -2 terminal of T2 synchronization
transformer, the negative pole connecting with the D- terminal. When main
command at zero position, observes the pulse signal (β angle should be at 30°); If
the location displayed not appropriate, slightly adjust relevant potentiometer on the
trigging circuit plate. When the main command leaves the zero position rises to the
full speed, the square-wave gradually move leftward to 90° position. Similarly may
inspect B, C phase pulse.
检查给定板参数：先将触发板用专用引线插件引出，再合主电路开关
QS401，操纵主令开关 4S，使其刚刚离开零位，电机得电，但可控硅不工作，
- 28 -
，这时，用万用表（置于直流 50V 档）测量给定

转子不转（相当于转子开路）
板上 WD1 应为 11.5~12.5 伏，若不在此范围，需调整 R2 或 R5 的电阻值，也
可以调整测速变压器电压，使 R2 上的直流电压为 11.5~12.5 伏。Inspect given
circuit board parameter: first draw out the triggering circuit board by special lead
mould, then switch on main circuit switch QS401, operate the main command
switch 4S, enable it just to leave the zero position, the electrical motor results
electricity energizing, but the thyristor is not working, the rotor is not rotating
(equal to rotor circuit open), by now, use avometer (put with DC 50V) to check and
make sure that WD1 on the given circuit board should be 11.5~12.5 V, if value out
of the scope, adjust R2 or the R5 resistance value required, also might adjust the
voltage of the speed measurement transformer to enable DC voltage on R2 in
scope 11.5~12.5 V.
注意：出厂前系统参数已经设定，现场未经厂家许可不得随意调整。
Attention: Before the ex-work the system parameter already set, site
adjustment could not be done without the factory permitted.
6.2.5.2 转子切电阻调速：此种调速方式共设五个档位，采用不对称的电阻起
动控制方式。The rotor resistance variation speed control: This speed variation way
is set with five speed steps, the asymmetry resistance start up control method is
used.
操纵大车机构主令 4S，先检查主令在零位时，4K0 是否吸合，再检查主
令打到大车单方向运行时，4K3、4K4、4K5、4K6、4K7、4K8 及负责方向的
接触器 4K1 或 4K2 能否正常吸合即可。Navigate the truck mechanism main
command 4S, firstly inspects when main command at zero position, 4K0 whether
attracts together, then inspects while main command moves at truck single
direction travel, 4K3, 4K4, 4K5, 4K6, 4K7, 4K8 and the recombiner which
services for direction 4K1 or 4K2 whether normally attract together is just ok.
6.2.6 副起升机构：本机构由电动葫芦实现。操纵电动葫芦主令 3S，检查控制
回路是否正常。Aux. hoisting mechanism: the crane is achieved by the electric
rope hoist. Operates the electric hoist main command 3S to inspect whether control
loop being normal.
6.2.7 在控制回路调试前，除特别说明，不可将机构的主回路开关合上，否则
可能造成事故。Before control loop commisioning, oter than specified,
the main isolator should not be switch on, otherwise possibly creates
the accident.
6.2.8 当确定控制回路正确后，分别对各机构进行空载试车，以验证机构运转
是否正常，运行方向与标识是否一致。After determination control loop correct,
separately carries out the idle test run to various mechanism, to confirm whether
operation of the variable mechanism rotating in normal, whether movement
direction corresponds with the direction marked.
6.2.9 当确定各机构运转正确后，对主钩限位、小车牵引机构限位、电动葫芦
高度限位及大车运行限位进行调整，必须确保各机构在距离极限位置 200mm
以上，机构能可靠停车（当用户有特殊要求时，用户可根据使用要求，自行
。After determined various mechanism
进行设定，但必须确保系统运行的安全性）
runs correctly, adjustment should be carried to main hook limit, trolley pulling
mechanism limit, electric hoist height limit and truck travel limit, the distance of
200mm above limiting position must be guaranteed to various mechanism, reliably
stop can to the mechanism (when user has special request, user may self set
according to operation requirements, but must guarantee system movement
security).
7．运行注意事项 Caution to be taken while operation
7.1 进行正常的停送电操作，必须使用总电源停送电钮，严禁正常情况下使用
“紧急停止”开关进行停电。For normal switch on and off operation, the main
isolator switch must be used, the “emergency stop” switch to cut the power off
should be avoided while at normal operation.
7.2 在停车 10 分钟以上不工作时，应按下“电源停止”按钮，断开总电源接
- 30 -
触器，操作人员完成工作离车时，应断开底部总电源。The “power off” button

shall be pushed to stop the main power contactors if the crane is stopped over 10
minutes. Isolator switch for power supply at floor should be cut when the operator
leaves the crane.
7.3 在操纵各动作手柄时，为防溜钩，应避免手柄在低速档长时间停留，尽快
使电机置于高速，在动作完成后，应确定手柄位置停在“零”位。While
navigating various action though the handle, for avoid hook slipped should not
keep in low-speed for a long time. The motor shall be changed to the
high-speed as soon as possible. The handle navigator shall be confirmed to put in
“zero” position after completing all the travel action.
7.4 在机械运行中，如地面监护人员发现异常情况，可按下刚性腿行走梁内侧
“紧急停止”按钮进行及时制止。（正常运行中，不得碰触此按钮）During the
mechanical operation, if the surveillance person on the ground finds any unusual,
the “emergency stop” button where located inside the rigid leg end carriage, shall
be pushed to stop the crane. (Normal operation, touch avoided with the said
button)
8．电气设备拆除注意事项：Caution for dissembling electric equipment
8.1 电气设备拆除前必须首先切断总电源。The main power switch isolator shall
be switched off before dissembling the electric equipment.
8.2 各连接导线在拆除时，必须从接线端拆卸，严禁钳断，线标不清晰或丢失，
应及时重写。When the connecting wires are disassembled, they should be
disconnected from the connecting ends. Pliers cutting to the wires are prohibited. If
the wire marks are not clear or worn, it is required to label again.
8.3 配电柜与操作室之间的控制电源连线，只拆卸配电柜端，拆除后收入操作
室地板下面。There is a connection cable between the electric distribution cabinet
and the cabin, only disassembly the cabinet terminal, put these under the cabin
floor after removal.
8.4 拆除后的导线和各部件应妥善保管，防止损坏和丢失。All the dissembled
wires and the components should be properly preserved to kept form damaging and
missing.
- 32 -
第三节安装螺栓一览表 Erection bolt listwise
国标代号 National
序号名称规格型号 standard 数量
备注 remark
SN Description Specification specification comply Qty
to
桥架主弦杆连接 bridge
1 铰制孔用螺栓 M24×90 Lo=50 GB/T 27-88 480 main truss girder
Reamer bolt
connection
桥架两侧腹杆连接
2 铰制孔用螺栓 M24×80 Lo=40 GB/T 27-88 60 bridge truss two sides web
Reamer bolt
rod connection
桥架上弦水平腹杆
3 铰制孔用螺栓 M20×70 Lo=40 GB/T 27-88 18 bridge truss upper truss
Reamer bolt
girder horizontal web rod
桥架悬臂段连接 bridge
4 铰制孔用螺栓 M24×90 Lo=50 GB/T 27-88 28 truss cantilever section
Reamer bolt
connection
铰制孔用螺栓 M24×75 电动葫芦轨道梁 electric
5 Lo=36 GB/T 27-88 12
Reamer bolt hoist rail beam
铰制孔用螺栓 M24×65 电动葫芦轨道梁 electric
6 Lo=24 GB/T 27-88 48
Reamer bolt hoist rail beam
支腿与行走梁法兰四角
铰制孔用螺栓 M24×100 four flange corners
7 Lo=60 GB/T 27-88 16*
Reamer bolt between leg and end
carriage
刚性腿上下连接 rigid leg
8 铰制孔用螺栓 M24×80 Lo=40 GB/T 27-88 64 upper and lower
Reamer bolt
connection
铰制孔用螺栓 M20×70 刚性腿左右连接 rigid leg
9 Lo=40 GB/T 27-88 24
Reamer bolt left and right connection
挠性腿 H 型钢连接
10 铰制孔用螺栓 M24×90 Lo=48 GB/T 27-88 40 flexible leg H section
Reamer bolt
steel connection
挠性腿斜杆连接 flexible
11 铰制孔用螺栓 M24×80 Lo=40 GB/T 27-88 44 leg diagonal rod
Reamer bolt
connection
挠性腿水平杆连接
12 铰制孔用螺栓 M24×75 Lo=32 GB/T 27-88 44 flexible leg horizontal rod
Reamer bolt
connection
挠性腿角钢连接 flexible
13 铰制孔用螺栓 M24×60 Lo=18 GB/T 27-88 16
Reamer bolt leg angle steel connection
操作室平台连接杆 cabin
14 铰制孔用螺栓 M20×70 Lo=40 GB/T 27-88 32
Reamer bolt platform connection rod
操作室平台连接法兰
15 铰制孔用螺栓 M20×65 GB/T 27-88 16 cabin platform connection
Reamer bolt
flange
备注 remark
to
支腿与行走梁 leg and
16 螺栓 bolt M24×100 8.8S GB/T 1228-1991 76*
end carriage
导向梁结构连接 guide
17 螺栓 bolt M24×75 8.8S GB/T 5783-2000 16
beam structure connection
导向梁底座连接 guide
18 螺栓 bolt M20×45 GB/T 5781-2000 12 beam structure pedestal
connection
刚性腿与桥架连接 rigid
19 螺栓 bolt M24×80 8.8S GB/T 5783-2000 32 leg and bridge truss
connection
起升卷扬机架固定 lifting
20 螺栓 bolt M24×55 GB/T 5781-2000 12
winch frame fixing
牵引卷扬机架固定
21 螺栓 bolt M24×65 GB/T 5781-2000 4 pulling winch frame
fixing
桥架导向滑轮座 bridge
22 螺栓 bolt M20×65 GB/T5781-2000 16
truss guide pulley base
葫芦轨道阻挡板 electric
23 螺栓 bolt M16×60 GB/T5781-2000 2
hoist rail end stop
起升钢丝绳托辊座
24 螺栓 bolt M16×40 GB/T5781-2000 8
hoisting rope roller base
牵引钢丝绳托辊座
25 螺栓 bolt M16×45 GB/T5781-2000 36
pulling rope roller base
直梯连接 ladder
26 螺栓 bolt M20×50 GB/T5781-2000 8
connection
爬梯 1 连接 stair 1
27 螺栓 bolt M20×60 GB/T5781-2000 2
connection
28 螺栓 bolt M20×30 GB/T5781-2000 2
connection
29 螺栓 bolt M20×45 GB/T5781-2000 4
connection
操作室与平台连接
30 螺栓 bolt M20×50 GB/T5781-2000 4 connection between cabin
and platform
操作室平台连接 cabin
31 螺栓 bolt M10×50 GB/T5781-2000 8
platform connection
十字槽机器螺钉
栏杆连接 handrail
32 cross groove M5×15 GB/T818-2000 36
machined screw connection
螺栓 bolt(镀锌桥架内通道连接 bridge
33 M8×30 GB/T5781-2000 100
galvanized) internal access connection
斜垫圈 slant
卷扬机架固定 winch
34 washer (方形 d24 GB/T853-1988 20
frame fixing
square)
- 34 -
备注 remark
to
小跑车止挡连接 trolley
35 销轴 pin shaft Φ32×65 GB/T882-1986 8
end stop connection
小跑车止挡连接 trolley
36 开口销 split pin Φ6.3×50 GB/T91-2000 8
end stop connection
挠性腿临时支撑连接
37 螺栓 bolt M20×50 GB/T5781-2000 16 flexible temporary
support connection
第四节主要部件清单 Major component list
部件重量
序部件名称外形尺寸 figuration 数
weight of the
号 component dimension（mm）量备注 remark
component
SN description (L×B×H） quantity
（kg）
一刚性腿 rigid leg
刚性腿上段 rigid
1 4764×3238×2268 2 1020 2040
leg upper
刚性腿下段 rigid
2 12272×3900×2240 2 3400 6800
leg lower
操作室平台 cabin
3 2860×2648×310 1 368
platform
电器站至桥架
4 直梯二 ladder two 4370×540×124 1 49 electric station
to bridge truss
操作室至电器站
直梯三 ladder
5 5135×540×124 1 52 cabin to electric
three
station
行走梁至操作室
6 爬梯一 stair one 9655×716×990 1 540 end carriage to
cabin
地面至行走梁
7 爬梯二 stair two 1780×2368×706 1 140 ground to end
carriage
操作室平台二
8 cabin platform 870×1850×133 1 70
two
含操作系统
operation system
9 操作室 cabin 1800×1540×2200 1500
included\电铃
bell
10 夹轨器 rail clamp 756×410×220 2 70 140
11 缓冲器 buffer 2
含三合一机构
行走台车 travel
12 1860×750×1065 2 2200 4400 three in one
end carriage
mechanism
刚性腿行走梁
13 rigid leg end 9540×650×902 1 2610
carriage
行走台车连接销轴
travel end
14 carriage φ150×540 2 34 68
connection pin
shaft
大车行走限位
15 truck travel 2
limit
部件重量
weight of the
component
（kg）
紧急停车按钮开关
16 emergency stop 1
button switch
恒力矩电缆卷筒
17 constant torque 1 500
cable winch
上车门开关
18 landing gate 2
switch
电阻箱
19 3
resistance box
20 电控 panel 1 1300×475×1800 1 440
电控柜 electric
21 distribution 800×475×1800 1 245
cabinet 2
揉性腿 flexible
二
leg
揉性腿 flexible
1 15758×2172×400 2 2842 5684
leg
揉性腿连接杆
2 flexible leg L140×12—3398 2 86.6 173
connection rod
揉性腿连接杆
3 flexible leg 2946×500×159 2 143 286
connection rod
揉性腿连接杆
4 flexible leg 1666×500×133 2 51 102
connection rod
揉性腿行走梁
5 flexible leg end 9540×650×902 1 2622 2622
carriage
含三合一机构
行走台车 travel
6 1860×750×1065 2 2200 4400 three in one
end carriage
mechanism
行走台车连接销轴
travel end
7 carriage φ150×540 2 34 68
connection pin
shaft
8 夹轨器 rail clamp 756×410×220 2 70 140
揉性腿临时支撑
flexible leg
10 4000×110×110 2 61 122
temporary
support
三桥架 bridge truss
- 38 -
部件重量
weight of the
component
（kg）
桥架刚性腿段
1 bridge truss 12000×3330×3313 1 10320
rigid leg section
2 直梯一 ladder one 2915×540×124 1 36
导向梁连接座
3 guide beam 520×370×295 2 67 134
connection base
含托辊 roller\滑
4 导向梁 guide beam 3500×280×1010 1 390
轮 pulley included
小车阻挡板
5 220×192×210 4 10 40
trolley end stop
桥架中间节
6 bridge truss 10975×3330×3313 1 6021
middle sectionⅠ
桥架中间节
7 bridge truss 10000×3330×3313 1 5787
middle sectionⅡ
桥架揉性腿段
bridge truss
8 11800×3330×3313 1 8051
flexible leg
section
桥架悬臂段
bridge truss
9 10945×3280×3200 1 2610
cantilever
section
葫芦轨道
10 electric hoist 11200×467×310 1 1050
rail 1
葫芦轨道
11 electric hoist 12450×467×310 1 1168
rail2
葫芦轨道
12 electric hoist 10000×467×310 1 938
rail 3
葫芦轨道
13 electric hoist 10800×467×310 1 1012
rail 4
葫芦轨道
14 electric hoist 11915×467×310 1 1117
rail 5
桥架竖法兰连接板
bridge truss
15 630×110×14 120 7.6 912
vertical flange
connection plate
起升钢丝绳托辊
16 hoisting rope 600×140×140 2 24 48
roller
部件重量
weight of the
component
（kg）
牵引钢丝绳托辊
17 pulling steel 300×200×412 3 31 93
rope roller 1
牵引钢丝绳托辊
18 pulling steel 600×200×412 2 50 100
rope roller 2
起升导向滑轮
19 lifting guide 590×225×535 2 103 206
pulley
牵引导向滑轮
20 lifting guide 500×215×433 2 75 150
pulley
钢丝绳固定架附销轴 pin shaft
21 rope fixing 645×98×150 2 40 80 enclosed、开口销
bracket split pin 10 个 pics.
DCQ 板式传感器
22 1 10t
plate sensor
楔形接头 beveled
23 2 22#
joint
钢丝绳夹 rope
24 8 16KTH
clamp
含车轮 wheel\滑轮
25 小跑车 trolley 3660×3070×815 1 2343
pulley included
牵引卷扬机
26 2725×907×830 1 1142
pulling winch
牵引钢丝绳
27 6×31SW+FC-16-1870 1 135 90+55m
pulling winch
起升卷扬机
28 3756×1030×1225 1 2942
lifting winch
起升钢丝绳
29 6×31SW+FC-21-1870 1 700 145m×2
lifting winch
30 吊钩组 hook group 3840×630×1614 1 1620
电动葫芦
31 1 1183 10t/18m
electric hoist
32 滑线 DSL 2
33 滑车 pulley 14
- 40 -
第四章 safety operation of the crane
起重机的安全操作
起重机的操作应遵守国家及有关的安全规程，下列事项提请有关人员注
意。The operation of the crane shall obey the national and relevant safety
regulations. The followings attentions shall be paid:
1．起重机应配备下列物品：Following articles shall be provided complete with
the crane:
1.1 保养起重机的必备工具。The necessities special tools for crane maintenance
1.2 橡胶手套和橡胶鞋。Rubber gloves and rubber shoes
1.3 安全绳、安全带。Safety rope and safety belt
1.4 干式灭火器。Dry fire extinguisher.
2．起重机使用前应检查下列设施是否符合要求 The followings shall be
checked before the crane started operation:
2.1 操作室地板应铺设橡胶地毯或其它绝缘材料。The rubber carpet or other
insulation materials shall be laid on the floor of operator cabin.
2.2 起重机必须装有音响清晰的喇叭或电铃等信号装置。The horn with clear
sound or the other alarms, e.g. electric bell, shall be provided on the crane.
2.3 起重机电气设备必须有良好的防雨设施。The good weather proof facilities
shall be provided to the crane electric equipment.
2.4 起重机的梯子、平台和走道应符合标准。The ladders, platform & walkway
accessing to the crane shall comply with specification.
2.5 起重机所有带电部分的外壳，均应可靠接地，以免发生意外的触电事故。
All the enclosure with the electric component of the crane shall be grounded to
prevent from electric shock.
3．作业前的安全检查 Safety inspection before operation (Shift wise system 交
第四章起重机的安全操作
接班制度）
交接班时，交班操作工应将当班中发现的情况详细地向接班操作工详细
说明，然后共同检查起重机各工作机构。When one shift hands over to the next,
the shift operator shall report the details found in his shift to the next operator,
then together should they check all the crane working mechanisms.
3.1 首先断开刀闸开关，不允许带电检查。First, switch off the power supply.
Energized inspection is strictly prohibited.
3.2 起重机钢结构部分不应有异常，连接螺栓无松动、脱落现象。
The crane steel
structure part should not have exceptionally phenomenon, the connecting bolt not
loose, falls off.
3.3 起重机各机构、部件无异常，固定螺栓无松动、脱落现象。There should not
be unusual on every mechanism & every component of the crane. The bolts free
from loosen or fallen.
3.4 钢丝绳不得有断股，断丝数或磨损不应超过标准。Should there not be a wire
broken on the wire rope. The wire broken or worn should not beyond the
specification regulated.
3.5 制动器的工作弹簧、销轴、杠杆和锁紧螺母、开口销应完好，推动器无漏
油和渗油现象，制动器无卡塞现象。The working spring, pin shaft, lever and lock
nuts, split pin of the brake should be in good condition. There is no oil leakage or
seepage on the thruster, free of deprived of movement or action though.
3.6 电气部件和电缆外观无异常。There should be no unusual by visual
inspection on the electric components and cable.
3.7 试验各安全装置应灵敏可靠，否则应进行修复或制定安全措施。Testing all
kinds of safety device to ensure its sensitivity and reliability, otherwise should be
repaired or safety precaution to be made.
3.8 电动葫芦滑线来去自如。电缆卷线器的运行与大车运行相协调。The
flexible trailing cable of the electric hoist should be moved freely. The operation
of the cable winder should coordinate with the movement of the truck travel.
- 42 -
3.9 经过以上检查各工作机构和各部转动件无异常，并进行必要的调整、检修，
试验符合要求以后，填写交接班日志，交接班操作工无异议签字后即认为交
接班完毕。All the working mechanisms and the rotating components should be
checked via above specified, and after proceeding necessary adjustment,
maintenance and testing to meet desired requirements, the turn-over-shift diary
shall be filled up, once shifted operator agreed by signature signed only it is
regarded that the shift turning over is completed.
特别提醒：操作人员上车前必须检查夹轨器是否已经打开。Precaution:
the operator shall check whether the rail clamp has been released before
climb up the crane.
4．起重机操作注意事项 Crane operation notice
4.1 起重机操作人员应经过专门培训，了解起重机的结构性能，熟悉安全操作
规程，持证上岗。The crane operator shall be specially trained. The operator shall
know the structure performance of the crane and the safety operating regulation.
And holding the operator qualified certificate while operating.
4.2 操作人员上车前应首先打开夹轨器。The rail clamp shall be released before
the operator starts the work and climb up.
4.3 每班第一次起吊重物时，应首先将重物吊离地面 0.5m，然后放下，试验
制动器是否可靠，然后再进行正常作业。As the time every initial shift begins the
first lift of the heavy objects, the objects shall be lifted 0.5m, then lowered down
the object to check whether the brake in good condition. If so, the normal
operation can be done.
4.4 起车要平稳，逐档加速。Smoothly start the operation, and speed up by
increasing speed steps gradually.
4.5 不允许将负荷长时间悬吊在空中，以防造成起重机构件永久变形或其它事
故。It is prohibited that hanging the heavy objects with a long time, to prevent
from permanent deformation of the lifting components or resulting the other
accidents.
4.6 电动葫芦严禁倾斜起吊和超负荷使用，以防事故发生。To prevent form the

accidents, inclined lifting and overload operation of the electric hoist is strictly
prohibited.
4.7 电动葫芦与大钩抬吊重物时，起重物重量不得大于 40t，并且电动葫芦承
载不超过 8t，以防二者不同速或其它原因造成对电动葫芦的冲击。While
lifting with electric hoist and the main hook lifts, the objects lifted should not
more than 40t, and the electric hoist load bearing does not surpass 8t, to against
the two of the above not synchronize or other reasons created collision to the
electric hoist.
4.8 大钩或电动葫芦刹车失灵时，不能断电停车应操纵下降动作，使重物按正
常下降速度降至地面，再进行检修。When impossible to switch off the crane due
to failure occurs on the main hook or the electric hoist brake, should operate the
lowering movement, have the heavy object down to the ground at the normal
speed, the maintenance can be done then.
4.9 起重机在正常运行过程中，禁止使用紧急开关，限位开关，打反车等手段
来停车。No emergency switch, limit switch or counterclockwise crane operated
etc. should be used to stop the crane during the normal operation.
4.10 操作人员对任何人发出的危险信号均必须听从。The operator should obey
that the danger signals given by any persons.
4.11 按规定保养润滑起重机各部位，以保证起重机正常工作，延长使用寿命。
Various parts of the crane lubricate and maintain according to specification
regulated to ensure normal crane operation and extend its service life.
4.12 每班工作完毕，把起重机开到指定地点，把电动葫芦开到刚性腿雨罩下，
吊钩升起高出地面或物件 2 米以上，控制手柄放到零位，切断主电源，紧固
夹轨器。After daily shift finishing stops the crane at appointed location, have the
electric hoist moved under weather proof cover near rigid leg. The hook should be
lifted 2m above the ground or the object. The navigate handle is put in zero
position. The main power supply is switched off. The rail clamp is fastened well.
- 44 -
4.13 操作人员发现起重机有异常情况时，应及时向主管人员报告。Once crane

unusual found should report to the person in charge.
特别提醒 Special warning：
z 夹轨器为起重机主要防风装置，操作人员每班工作完毕，必须锁紧夹
轨器后方可离开。The rail clamp is the important wind anti-proof
device for the crane. After locking and fastening the rail
clamp, should only the operator can leave the site when the
shift is over.
z 操作人员上车前必须切记打开夹轨器。The rail clamp should be
opened before the operator begins to work.
5．安全操作“十”不吊“Ten” hoisting prohibited for operation safety:
①超负荷、偏拉斜挂不吊 Lifted object overloaded or hanged in inclination
hoisting prohibited.
②重量不明、埋在地下或冻结在地面上的物件不吊 The weight of the
object is uncertain, or the object is embedded under the ground or frozen on the
ground prohibiting from hoisting.
③起吊物捆绑不牢或吊物上有浮动物件不吊 The lifted object is not
bounded well or there are unsteady object on the lifted object prohibiting from
hoisting.
④吊物上站人或吊物越过人头不吊 The person is standing on the lifted
object or when the lifted object is above the person prohibiting from hoisting.
⑤安全装置失灵没有防范措施不吊 The failure occurs on safety device
and without any precautions is taken also preventing form hoisting.
⑥机械、电气部分发生故障或结构部分有异常情况未排除不吊 Some
unusual occurred in the mechanical or electrical parts or in the structures
preventing from hoisting until outstanding defects is removed.
⑦指挥信号不明或乱指挥不吊 The commanding order is not clear or the
commanding is in disorder prohibiting from hoisting.
⑧大雪、大雾、雷雨天气或夜间视线不清不吊 It is not permitted lifting

under the weather of heavy snow, dense fog, thunderstorm or under the vague
night-visibility.
⑨爆炸品、危险品、边缘锋利物件没有防范措施不吊 The explosive, the
hazards and the object with hard edges should not be lifted if no precautions has
taken.
⑩风力大于六级不吊 The wind speed level is over 6 prohibiting from
hoisting.
- 46 -
第五章起重机零件总成
crane component assembly
第一节主要外购件 Major outsourcing component

部件名称数量
序号设备名称 Equipment 规格型号单位
component quant 备注 remark
SN description specification model Unit
description ity
电气系统 electric 电缆卷线器 cable 多排
1 JDO-300model 型 100A 台 set 1
system winch Multi-layers
2 操作室 cabin 台 set 1
联合操纵台
3 combined control 套 set 1
station
主钩 main
行程限位开关 travel 只
4 DXZ-4/3 2 hook、牵引
limit switch Nos.
pulling
行程限位开关 travel 只大车运行 truck
5 LX10-11s 2
limit switch Nos. travel
行程限位开关 travel 只门限位 gate
6 YBLX-WL/CA2 2
limit switch Nos. limit
葫芦高度限位器
只
7 electric hoist height SL1-H 1
Nos.
limit
防水按钮 water proof 只
8 LA10-1S 1
button Nos.
电缆滑车 cable 台
9 14 1＋12＋1
trailing pulley Nos.
小车 trolley、吊只
10 直柄单钩 plain hook LYD25-P（DG20Mn） 1
钩组 hook group Nos.
吊钩横梁 hook cross 只
11 45 1
beam Nos.
只
12 吊钩螺母 hook nut 45 1
Nos.
单向推力球轴承
只
13 single direction 8322 1
Nos.
anti-thrust bearing
只
14 滑轮 pulley WJ3202 16 Φ450
Nos.
只
15 轴承 bearing 220 32
Nos.
只
16 滑轮 pulley WJ2203 3 Φ355
Nos.
部件名称数量
序号设备名称 Equipment 规格型号单位
component quant 备注 remark
SN description specification model Unit
description ity
只
17 轴承 bearing 218 6
Nos.
只
18 小车轮 trolley wheel φ300 8
Nos.
只
19 轴承 bearing 42512E 16
Nos.
起重量限制器 DCQ 板式传感器 plate 台
20 1
hoisting load limit sensor(10t) Nos.
行走台车 travel 台
21 电动机 motor YZRE132M1-6 3.7Kw 4
end carriage Nos.
TCS16 传动比 transmission 台
22 减速机 speed reducer 4
ratio i＝80 Nos.
只
23 轴承 bearing 22322 TNI/W33 16
Nos.
只
24 车轮 wheel φ600 8
Nos.
只
Nos.
主起升卷扬机
YZR250M1-6 台
main hoisting 26 电动机 motor 1
JC%=40% 37kw Nos.
winch
台
27 联轴器 coupling MLL10-Ⅰ-500 1
Nos.
台
28 制动器 brake YW500-800 1
Nos.
台
29 减速器 brake 卓轮 4.26 i=126 1
Nos.
30 钢丝绳 steel rope 6×31SW -22 -1770 m 290 2×145m
牵引卷扬机 YZR160L-6
31 电动机 motor 台 set 1
pulling winch JC%=40% 11 kw
32 联轴器 coupling MLL6-Ⅰ-250 台 set 1
33 制动器 brake YW250-500 台 set 1
34 减速器 speed reducer 卓轮 Zollen 4.19 i=71 台 set 1
35 钢丝绳 steel rope 6×31SW –16-1770 m 145 90+55 m
- 48 -
第二节外购件供货商信息 outsourcing supplier information
1、行走减速器 Travel speed reducer

1.1 生产厂家 Manufacturer：江苏省泰兴减速机厂。Taixing speed reducer plant,
Jiangsu
1.2 厂址 address：江苏省泰兴市姚王镇泰姚北路 10 号 No. 10 North-taiyao road,
Yaowang town, Taixing city, Jiangsu Province
1.3 邮编 Zip code：225402 传真 fax：0523-7541045
1.4 服务热线 service tel：0523-7541045 7541354
1.5 网址 web site：http://www.txreducer.com
1.6E-mail：jsjtx@pub.tz.jsinfo.net
2、卓轮减速器 Zollen speed reducer

2.1 生产厂家 Manufacturer：卓轮 Zollen（天津 Tianjin）减速机有限公司 speed
reducer Co., Ltd.（德国独资 Germany sole ownership）
2.2 厂址 Add：天津经济技术开发区第七大街睦宁路 67 号 No.67 Muning road
Seventh avenue Tianjing ecomemy development zone
2.3 邮编 Zip：300457 电话 Tel：022-25323811 传真 fax：022-25323810
2.4 电子信箱 Mail：Zollern@public.tpt.tj.cn.
2.5 网址 web：http：//www.zollern.de
3、YW 系列电力液压块式制动器 series electric hydraulic block brake

3.1 生产厂家 Manufacturer：焦作制动器股份有限公司 Jiaozuo brake stock Co.,
Ltd.
3.2 厂址 add：
河南省焦作市环城北路 1 号 No.1 North circle city road Jiaozuo city
Henan province
3.3 电话 tel：86-0391-2931307 邮编 zip：454000 传真 fax：86-0391-2924446
4、联轴器 coupling
4.1 生产厂家 Manufacturer：镇江蓝星联轴器制造有限公司 Zhenjiang Bluestar
coupling fabrication Co., Ltd.
4.2 厂址 add：江苏省镇江市跑马山路 4 号 No.4 Paoma mountain road Zhenjiang
city Jiansu province
4.3 电话 tel：0511—8795822 传真 fax：0511—5616244
5、限位器 limiter
5.1 生产厂家 Manufacturer：德力西集团有限公司 Delixi group Co., Ltd.
5.2 电话 tel：800 857 7788 0577-62720738
6、JDO 长期堵转力矩电机式电缆卷线器 JDO permanent rotating block up
torque cable winch
6.1 生产厂家 Manufacturer：沈阳市兴港电缆卷线器厂 Shenyang city Xinggang
Cable Winch Factory
6.2 联系电话 contact tel.：024—88121611
6.3 服务电话 service tel：024—88442149
7、钢丝绳 rope
7.1 生产厂家 manufacturer:贵州钢绳股份有限公司 Guizhou steel rope Co., Ltd.
7.2 厂址 add.:贵州省遵义市桃溪路 47 号 No.47 Taoxi road Zunyi City Guizhou
province
- 50 -
第三节减速器技术说明
Technical specification of speed reducer
1．主起升机构减速器 main hoisting speed reducer

1.1 名称 Description：内藏式行星减速器 Inside hided planet gear（卓轮 Zollen）
1.2 型号 Model：ZHP4.26EG
1.3 润滑 Lubrication：
1.3.1 卓轮减速器采用浸油润滑。Submerged lubrication is used for Zollen gear
原厂润滑油牌号 Original manufacturer lubricant No.：BP 优质合成齿轮油
excellent compound gear oil（BP ENERSYN SG-XP 220）
执行标准 standard execution：DIN 51502
符合规格 specification comply：润滑油 Lubricant PG 220
润滑油注入量为 6 升 fill column for lubricant is 6L（参见设备铭牌 see
equipment nameplate）
。
如出厂时因特殊原因未注满润滑油，则有特殊明显标记。When ex-work
because the special reason has not poured in full lubricating oil, then has the
special obvious tag marked.
1.3.2 减速器输出轴大轴承为油脂润滑。Reduction gear output shaft big bearing
for grease lubrication.
原厂润滑脂牌号 Original factory lubricant trademark：BP ENERGREASE
LS-EP 2
执行标准 standard execution：DIN 51502
符合规格 specification comply：润滑脂 lubrication grease DIN 51825-KP2
G-50
在工作前注入润滑脂直至密封外轮廓有润滑脂溢出。Pours into the
lubricant grease until outside figuration have the lubricant grease overflow.
1.4 建议润滑周期 Recommended lubrication cycle

润滑油检查 Lubricant check：每周 weekly
润滑油更换周期首次为 200 个工作小时，以后每 1000 个工作小时，至少
每年一次。The lubricating oil replacement cycle is 200 working hours for the first
time, later every 1000 work hours, at least every year one time.
注意 Caution：
检查油位应在减速器静止状态时为准。The oil level should be checked
only when the reduction gear at static condition.
换油排油应在减速器热机状态下进行，并应将注油口同时打开。The oil
replacing or oil draining should be done under the reduction gear heat engine
condition, and should also open the oil filling cover.
在环境温度过低时，应加入适量热油进行冲洗，以便使停留在输出端的
及残留的废油排出。When the ambient temperature excessively low, should
pour suitable amount of hot oil to carry out the flushing, in order to
discharges remaining or impurity oil form the input end.
润滑脂检查 Lubricant inspection：每周或工作前 weekly or before each
work start.
1.5 检修 Overhaul
1.5.1 检查周期 Overhaul duration：
每工作 1000 小时，或至少每年一次应对放出的减速器润滑油进行检测，在保
留运转余温时放出的润滑油中提取样品，最能检测出油的使用情况。Works
every time for 1000 hours, or every year a time at least should be check to the
reduction gear lubricating oil, spot sample inspection taken from draining
maintained residual heated lubricating oil, mostly can examine the oil the service
condition.
1.5.2 检查油量是否达到标准时，将放出的油量与减速器标示油量相比较，即
可确认油量是否充足。Inspection oil level whether comply with the required
- 52 -
standard, will compare oil drained amount vs. reduction gear indication, then oil
level can be confirmed whether sufficient.
1.5.3 当减速器油呈现深黑色的时候，表示油温在减速器运转时曾超过 100 摄
氏度，油质已老化，润滑能力已达不到要求，必须及时进行油的更换。While
the reduction gear oil appears in dark black, indicated the oil temperature has been
surpassed 100 degrees Celsius when speed reducer revolves, the oil material got
older, lubricity could not meet the requirements, had to carry on the oil promptly
the replacement.
当润滑油呈现混浊现象，说明油中有水渗入，此时应用新油对减速器进行
彻底冲洗并立即换入新油。同时，我们建议用户拆开减速器，以检查各零件
受腐蚀状况。When the lubricating oil presents the muddy phenomenon, said has
water permeating, this time carries on the thorough flushing using the fresh oil to
the reduction gear and replace into the fresh oil immediately. At the same time, we
suggested the user disassembles the reduction gear, inspects corrosion condition to
various components.
1.5.4 重视固体杂质对减速器的损害，建议对放出的润滑油进行固体杂质检测。
Pay attention to solid impurity harm on the reduction gear, we suggested proceed
examination on to the lubrication oil drained.
当有固体杂质颗粒不大于 25μm，含量少于减速器油总重量的 0.15%，减
速器可以在换油后立即重新投入使用。When the grain solid remained is not
more than 25μm, the content is short in the reduction gear oil gross weight 0.15%,
the reduction gear may be use immediately after replacing the oil.
当有固体杂质颗粒大于 25μm 或确认是减速器齿面剥落的颗粒，则无论
固体杂质含量多少，必须拆检减速器。对所有齿轮的齿面，特别是输出级太
阳轮进行检查。When has the solid grain impurity more than 25μm or the flake
form the gear tooth surface is confirmed, regardless of how much impurity
contained, the reduction gear must be opened and examined to all gear tooth face,
to the output stage sun gear wheel especially.
减速器经过运转和磨合后，正常磨损的齿面呈平滑明亮状。如齿轮出现
其它情况，如磨损程度大、咬根、根切、齿面粗糙、凹坑、点蚀、表层脱落、
塑性变形等，必须对该齿轮进行更换，必要时对整个减速器修理。Reduction
gear after revolution and wearing, normal wear tooth appears in smooth bright
shape. If the gear has other situations, like the attrition degree big, nips the root,
undercuts, the tooth face roughly, the pit, the pitting, the surface layer falls off, the
plastic deformation and so on, must carries on the replacement to this gear, when
the necessity to entire reduction gear repair.
1.6．螺栓拧紧力矩 The bolt screws tighten moment：
（见下表 Sees the next table）
螺栓在摩擦系数为 0.125 时的拧紧力矩表
The bolt at friction coefficient 0.125 screws tighten moment table
螺栓型号
螺栓强度等级 bolt 螺栓强度等级 bolt 螺栓强度等级 bolt
bolt
hardness grade 8.8 hardness grade 10.9 hardness grade 12.9
model
M12 80.0 Nm 110.0 Nm 135.0 Nm
M14 125.0 Nm 180.0 Nm 215.0 Nm
M16 195.0 Nm 275.0 Nm 330.0 Nm
M18 270.0 Nm 390.0 Nm 455.0 Nm
M20 385.0 Nm 540.0 Nm 650.0 Nm
M22 510.0 Nm 720.0 Nm 870.0 Nm
M24 660.0 Nm 930.0 Nm 1100.0 Nm
M26 980.0 Nm 1400.0 Nm 1650.0 Nm
1.7 推荐的润滑剂表 Recommendation lubricant table

润滑油标准按润滑油标准按润滑油标准按
生产厂家 lubrication standard lubrication standard lubrication standard
manufacturer accords to accords to accords to
/牌号 API GL 5 DIN 51502 DIN 51502
trademark 润滑油 lubricant 润滑油 lubricant 润滑脂 lubricant
SAE 90 DIN 51517-CLP 220 DIN 51825-KP2K
ARAL 润滑脂 lubrication
齿轮油 gear oil
BG 220 graese
亚拉 HYP 90
HLP 2
齿轮油 gear oil
AVIA RSX 220 Avialith 2 EP
Hypoid 90 EP
BP BP Hypogear EP 90 GR-XP 220 BP Energr. LS EP 2
- 54 -
CASTROL EPX 90 Alpha SP 220 Spheerol EPL 2

Tranself Typ B
ELF Reductelf SP 220 ELF Epexa 2
SAE90
ESSO 齿轮油 gear oil
Spartan EP 220 ESSO Beacon 2 EP
埃索 ESSO GX-D90
FUCHS 齿轮油 gear oil Compound 106
Renolit FEP 2
福斯 Renogear Hypoid 90 VG 220
Gulf Multi-Purpose EP Lubricant
GULF Gulf Crown Grease 2
Gear Lubricant SAE90 HD 220
MOBIL
Mobilube HD-A 90 Mobilgear 630 Mobilux 2 EP
美孚
SHELL 壳牌施倍力 MB 90 壳牌可耐压 220 壳牌爱万利 EP 2
壳牌 Shell Spirax MB 90 Shell Omala 220 Shell Alvania EP 2
注：用户可根据需要自行选用符合以上标准的国产润滑油（脂）
Note: Above the user may according to need to select voluntarily conforms to
the standard domestically produced lubricating oil (grease)
2．牵引机构减速器 pulling mechanism speed reducer

2.1 名称 Description：内藏式行星减速器 Inside hided planet gear（卓轮 Zollen）
2.2 型号 Model：ZHP4.19EG
2.3 润滑 Lubrication：
2.3.1 卓轮减速器采用浸油润滑。Submerged lubrication is used for Zollen gear.
原厂润滑油牌号 Original manufacturer lubrication oil trademark ：壳牌齿轮
油 Shell gear oil Spirax 施倍力 A90
（Shell SPIRAX A90）
执行标准 execution standard：DIN 51502 resp. API GL5
符合规格 specification comply：润滑油 lubrication oil DIN 51517-CLP 220
润滑油注入量为２升 the amount poured is 2L（参见设备铭牌 see equipment
nameplate）
。
如出厂时因特殊原因未注满润滑油，则有特殊明显标记。When ex-work
because the special reason has not poured in full lubricating oil, then has the
special obvious tag marked.
2.3.2 减速器输出轴大轴承为油脂润滑 Reduction gear output shaft big bearing
for grease（免维护 free of maintenance）。

原厂润滑脂牌号 Original manufacturer lubrication oil trademark：
壳牌爱万力 EP LF2
（Shell ALVANIA EP LF2）
执行标准 Standard execution：DIN 51502
符合规格 Specification comply：润滑脂 Lubrication grease DIN 51825-KP
2K
在工作前注入润滑脂直至密封外轮廓有润滑脂溢出。Pours into the
lubricant grease until outside figuration have the lubricant grease overflow.
2.4 建议润滑周期 recommended lubrication period
同本节 1.4 条款。Same as article 1.4 this section
2.5 检修 maintenance
同本节 1.5 条款。Same as article 1.5 this section.
2.6．螺栓在摩擦系数为 0.125 时的拧紧力矩 The bolt at friction coefficient 0.125
screws tighten moment：
同本节 1.6 条款。Same as article 1.6 this section.
2.7 推荐的润滑剂表 recommended lubrication cable
同本节 1.7 条款。Same as article 1.7 of this section.
3．大车行走机构减速器 truck travel mechanism speed reducer

3.1 名称 Description：硬齿面轴装式减速器 Hardness face bearing mounted speed
reducer
3.2 型号 Model：TCS-16
3.3 安装、使用及维护 erection, operation and maintenance：
3.3.1 减速器输入（输出）轴轴线，与其联接部分的轴线，应保证同轴，其误
差不得大于所用联轴器的允许值。安装联轴器时不许锤击。The axial line of
- 56 -
input (output) shaft of the speed reducer should be coaxial with portion of its
coupled. Its deviation shall not exceed the permissive value of the coupling used.
No hammering is permitted for erecting the coupling.
3.3.2 安装好后，必须注入所需润滑油，油面达到规定的高度。The lubrication
shall be filled after the erection. The oil surface level filled shall reach the required
height.
3.3 油的选用 lubrication selection:
环境温度-10℃~0℃时用 L-CKC46~68 润滑油；ambient temperature within
-10℃~0℃: L-CKC46~68 lubricant is selected;
环境温度 0℃~30℃时用 L-CKC100~150 润滑油；ambient temperature
within 0℃~30℃: L-CKC100~150 lubricant is selected;
环境温度 30℃以上时用 L-CKC220 润滑油。ambient temperature over 30
℃: L-CKC220 lubricant is selected;
3.3.4 新减速器第一次使用一个月后必须更换新的润滑油，在以后的使用中应
定期检查油的质量，发现老化变质应及时更换，同时经常检查油面高度，低
于规定高度时，及时补足。对长期连续工作的减速器必须三个月换油一次，
对每天工作不超过八个小时的减速器，须六个月换油一次。The new lubrication
shall be replaced after the new speed reducer is operated for one month. The
lubrication shall be checked periodically in future and it should be replaced if the
lubrication is aged or deteriorated. Also the lubrication level shall be checked
periodically, if the level is below the specified, the lubrication shall be added
immediately. The lubrication shall be replaced every three months for those speed
reducer in continuous operation. For the reducer operated daily not exceed 8 hours,
the lubricant shall be replaced every six months.
3.3.5 在使用中若发现油温显著升高，温升超过 60℃或油温超过 85℃时，以及
产生不正常的噪音现象时，应停止使用，检查原因及时排除故障，更换新油
后使用。If the temperature of the lubricant is risen rapidly during the usage, when
the temperature rose above 60℃ or when the lubricant temperature exceeds 85℃,
resulting in the abnormal noise, the speed reducer shall be stopped for inspection
and solving the problems. And then the speed reducer can be operated after
replacing the new lubricant.
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第四节电动葫芦技术说明
Technical specification of electric hoist
1．名称 Description：CD1 型钢丝绳电动葫芦 Model electric rope hoist

型号 Model： CD1--10t/18m
2．构造特征 Structure feature：
电动葫芦主要由减速器、运行机构、卷筒装置、吊钩装置、联轴器、软
缆电流引入器、限位器、电动机及钢丝绳等组成。The electric hoist is consisted
of speed reducer, travel mechanism, drum device, hook device, coupling, cable
lead-in device, limiter, motor and wire rope, etc.
电动葫芦的运行机构为电动小车式，运行机构适用的工字钢轨道应按
GB/T 706-1988 标准选择。The traveling mechanism of the electric hoist is consist
of the motor driven trolley, its H steel rail used for the traveling mechanism shall
be selected as per GB/T706-1988.
起升电动机采用较大起动力矩的锥形制动电动机，以适应产品断续工作
最大转矩为额定力矩的 2.4~3 倍。
中频繁的直接起动， The cone type brake motor
had been selected for the hoisting motor to satisfy the frequent direct startup during
the intermittent running. The max. torque is 2.4~3 times than rated torque.
电动葫芦使用钢丝绳结构型式为：6×37+NF，直径 14mm，强度等级
1770MPa。The format of the wire rope of the electric hoist is 6×37+NF, 14mm
diameter, 1770MPa strength grade.
3．安装 erection：
3.1 电动葫芦的安装一定要由专业人员进行，非专业人员不得从事安装工作。
安装前应检查有无损坏情况，若发现有损坏情况，应及时修复使用。The
erection of the electric hoist shall be done by the experienced professional person.
The unprofessional person is not allowed to erect rope hoist. The hoist shall be
inspected before the erection, if there exists any damage, it is required to repair
immediately.
3.2 电动小车行走轮组件在安装时应根据工字钢轨道的宽度，用垫圈进行调整，
使轮缘与轨道间保持每边 4mm 间隙。The motorized driven trolley wheel
assemblies shall be erected based on the width of H steel rail. There shall be a
4mm gap on each side between the wheel flange edge and the rail by adjusting the
washers.
3.3 所有润滑部位应分别加足润滑油/脂 All the lubricated parts shall be
lubricated/ greased fully.
3.4 电动葫芦供电电缆必须使用规定的橡胶绝缘电缆线，电缆线中间不得有接
头，长度合适，并直接插入控制箱端子上。The power cable of the electric hoist
shall be the specified rubber insulated cable without any interval joints. The cable
shall be long enough to directly connect to the control cabinet terminal.
4．使用维护 Operation Maintenance：
4.1 新安装或经拆检后安装的电动葫芦，首先应进行空车试运转数次。但在未
安装完毕前， The newly erected or those reassembled electric hoist
切忌通电试转。
shall be run several times without any loads to count running rotation. The
energized trial run is only carried out until the erection is finished.
4.2 在正常使用前，应进行以额定负荷的 125%，起升离地面约 100mm，悬停
10 分钟的静负荷试验，并检查是否正常。The dead load test shall be done before
the normal running. The dead load test refers the test with 125% rated load for
suspending the object 100mm above the ground for 10 minutes and check whether
everything in normal.
4.3 动负荷试验是以额定负荷重量，作重复升降与左右移动试验，试验后检查
其机械传动部分、电器部分和连接部分是否正常可靠。The live load test refers
the test of hoist traveling upward/downward and leftward/rightward for more than
15 minutes with the rated load. The mechanical rotating parts, electric parts and the
connecting parts shall be inspected whether normal stable after the test.
4.4 在使用中，绝对禁止在不允许的环境下，及超过额定负荷和每小时额定合
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闸次数（120 次）的情况下使用。It is prohibited running the hoist if the working

circumstance is not satisfied or the rated load is exceeded or the numbers of rated
switching on & off (240 nos.) per hour is exceeded.
4.5 安装调试和维护时，必须严格检查限位装置是否灵活可靠，当吊钩升至上
极限位置时，吊钩外壳到卷筒外壳之距离必须大于 120mm；当吊钩降至下极
限位置时应保证卷筒上钢丝绳的安全圈数，有效安全圈数必须在 2 圈以上。
The limiter shall be inspected during the commissioning and maintenance. If the
hood is lifted to the upper limited position, remaining 120mm distance shall be
maintained between the hook sheave and drum enclosure. If the hook is lowered to
the lower limited position, the drum shall have the safe 2 remaining circles on the
rope drum.
4.6 电动葫芦操作人员应充分掌握安全操作规程，严禁歪拉斜吊。电动葫芦不
工作时，不允许把重物悬于空中，防止零件产生永久变形。The electric hoist
operator shall fully master the safety operation regulations. Not permitted hanging
the object in inclination. The lifted objects shall not be suspended in the middle to
prevent from permanent deformation of the parts.
4.7 在使用中必须由专业人员定期对电动葫芦进行检查，应特别注意易损件情
况，发现故障及时采取措施，并仔细加以记录。The electric hoist shall be
inspected periodically by the professional person during the operation duration.
Special attention shall be paid to those easily damaged parts. The troubles shall be
shoot immediately once the troubles are found. The records shall be made for those
trouble shooting.
4.8 电动葫芦在额定载荷下下降时制动的下滑距离应小于 70mm，如超出此规
定数值应进行调整，锁紧大螺母逆时针转动为紧刹车。The gliding distance of
the electric hoist while brake at lowering operation at rated load should be smaller
than 70mm. For numeral value exceeding the above limit should be adjusted, big
lock nut anti-clockwise rotate is to tighten the brake.
4.9 电动葫芦使用中必须保持足够的润滑油，并保持润滑油的干净，不应含有
杂质和污垢。The electric hoist shall be lubricated enough during its operation. The
lubrication oil shall be clean without any dirties and impurities.
4.10 电动葫芦在长时间连续运转后，可能出现自动断电现象，这属于电机的
过热保护功能，此时可以下降，过一段时间，待电机冷却下来即可继续工作。
The electric hoist could be switched off automatically after a long continuous
operation, due to motor over heat protection. If the switching off is occurred, the
hoist can be lower down and could be startup again after some time while the
motor cooling down.
4.11 电动葫芦钢丝绳的检验和报废应按 GB/T 5972-1986《起重机械用钢丝绳
检验和报废实用规范》执行。The inspection and discarding of the electric hoist
wire rope shall be as per the GB/T 5972-1986 《Practical specification for
inspecting & discarding of crane mechanic wire rope》.
5．安全注意事项 Safety precaution：
5.1 请对说明书和铭牌上的内容熟记后再操作。Before operation start the
operator should be familiar with the specifications shown in the manual and
nameplate.
5.2 请将上、下限位的停止块调整后再起吊物体。The objected can be hoisted
only the down & up end stop has been adjusted.
5.3 在使用之前请确认制动器状况是否可靠。The braking condition should be
verified before the operation.
5.4 使用前若发现钢丝绳出现弯曲、变形、腐蚀等异常情况，或者钢丝绳断裂
程度超过规定要求，磨损量大时，绝对不要继续操作。 If the bending,
deformation, corrosion etc. are found in the steel rope, or the breakage of the wire
rope exceed the requirements, or the wearing capacity is higher, the hoist is
prohibited from operating.
5.5 请绝对不要起吊超过额定负荷的物件，额定负荷在吊钩铭牌上已标明。The
overloaded objects are not allowed to be hanged. The rated load is specified in the
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hook nameplate.
5.6 起吊物上禁止乘人，绝对不要将电动葫芦作为电梯的起升机构用来载人。
The person on the lifted object is prohibited. It is prohibited that the electric hoist
is used as the elevating device for passenger.
5.7 起吊物体、吊钩在摇摆状态下不能起吊。不得起吊与地面相连的物体。The
object shall not be hanged if the hook is swinging. It is prohibited hanging the
object connected with the ground.
5.8 限位器不允许当作行程开关反复使用。请不要过度点动操作。The limiter
shall not be used repeatedly as travel switch. Please do not operate the inch
movement excessively.
5.9 在维修检查前一定要切断电源。维修检查工作应在空载状态下进行。The
power should be switched off before the maintenance. The maintenance should be
done at the condition load idle.
6．润滑油量 lubrication volume
起升减速器 Lifting speed reducer：4 升 L
运行减速器 Traveling speed reducer：1 升 L
第五节制动器技术说明 technical specification for brake
1．名称 description：YW 系列电力液压块式制动器 series electric hydraulic

block brake
2．型号 model：主起升卷扬机 main hoisting winchYW500-D800
牵引卷扬机 Pulling winchYW250-D500
3．结构及工作原理 structure and principle：（如图 as shown on drawing）
1.溢流螺塞 overflow plug 2.注油螺塞 oil pouring plug 3.杠杆 lever

4.弹簧下座 spring lower seat 5.制动弹簧 brake spring 6.弹簧拉杆 spring lever 7.
调整螺钉 adjust screw 8.调整板 adjust plate 9.拨杆 pull rod 10.拉杆 tie rod
11.制动臂 brake beam 12.制动瓦 brake tile 13.制动瓦随位调整装置 Brake tile
along with position adjuster 14.固定销 set pin 15.销轴 pin shaft
16.退距均等装置 Draws back equal device 17.底座 Foundation
18.手动装置 Manual device 19.推动器接线孔 thruster unit wiring hole

制动器由制动架和相匹配的 ED2 型电力液压推动器两大部分组成。The
brake is consisted of brake frame and its matching ED2 electric operated hydraulic
pressure thruster two major parts.
制动架主要摆动铰点采用自润滑轴承，传动效率高，动作灵敏可靠；压
铸型制动摩擦片更换方便、迅速、寿命长、利用率高；联锁式等退距装置，
自动均等，效果极佳。The main swing hinged joint of the brake frame uses the
self-lubricating bearing, the transmission efficiency is high, movement keen
reliable; The compression casting brake lining plate replacement convenient, rapid,
the life long, the utility factor is high; The interconnection type draw back equal
distance device, automatic equal, the effect is extremely good.
推动器动作性能优良，密封性能好，外壳防护等级高。The thruster
movement performance is fine, the sealing property is good, the shell protection
grade is high.
当通电时，推动器动作，其推杆迅速顶出，并通过杠杆作用把制动瓦打
开（松闸）
；当断电时，推动器动作，其推杆在制动弹簧力的作用下，迅速回
缩，并通过杠杆作用把制动瓦闭合（抱闸）。When the power is on, the thruster
unit actuated, its thrust lever jack out rapidly, and the brake tile opens (damper
loose) through the leverage; When power failure, thruster unit acted, its thrust lever
rapid retracted under spring functional pressure, and through leverage brake tile
closed (band brake).
4．安装与调整 Erection and adjustment：
4.1 安装前应检查制动器是否有损坏或缺件。检查制动轮及制动摩擦片表面是
否清洁，若有油污或其他脏物，应彻底清除干净。Before the installment should
inspect the brake whether has the damage or the missing item. Inspects the brake
pulley and the brake lining plate surface is whether clean, if has the greasy dirt or
other dirty, should eliminate thoroughly cleanly.
4.2 制动器的安装 Brake installment:
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4.2.1 根据制动器在主机的安装位置，确定出制动器的维修、调整空间较大或
较方便的一侧。如果制动瓦随位调整装置或退距均等装置不在维修空间一侧
时，可将其卸下装在同侧。According to the brake in the main engine installment
position, determined one side as maintenance side, the brake the service, the
adjustment space at that side should be big or convenient. If the brake tile or draws
back along with the position adjuster is or the equal draw back device is not
located in the maintenance space side, may it disassemble and install again at the
same side required.
4.2.2 制动器安放在主机底座上后，松松地拧上固定螺栓，旋转制动臂调整拉
杆，此时制动瓦随位调整装置的调整螺栓应与制动瓦脱离，使制动摩擦片与
制动轮贴合，当制动摩擦片与制动轮表面贴合达到最佳状态时，拧紧固定螺
栓。After the brake is put on the main frame foundation, screw the bolt loosely,
revolves the brake adjust the tie rod, when the brake lining plate and the brake
pulley surface fitting with optimum condition, screws tight the set bolt.
4.2.3 推动器在出厂前已加好液压油，用户可直接使用。在维修时，用户可加
注 DB-25 号（SY2536-1990）油液至溢流螺塞处。The thruster unit has been filled
with hydraulic oil before ex-work, the user may use directly. When maintenance,
the user may refill DB-25 number (SY2536-1990) oil liquor to the overflow thread
plug place.
4.3 制动器的调整 Adjustment of the brake：
4.3.1 推动器工作行程的调整 Adjustment of movement journey of the brake：首
先将弹簧力释放到最小值，然后旋转制动臂调整拉杆，使制动器处于闭合状
态；继续旋转制动臂调整拉杆，使推动器推杆慢慢顶出，当顶出的推杆长度
H1（即工作行程）达到规定值（主起升卷扬机制动器为 15mm，牵引卷扬机
制动器为 15mm）时，即完成调整。First releases the spring strength to minimum
value, then the rotate brake arm adjust for tie rod, causes the brake to be at the
closed position; Continues to rotate the brake arm adjust tie rod, causes the thruster
lever to jack out slowly, when the thrust rod jacked length H1 (i.e. working travel
distance) achieved the rated valve (main hoisting winch brake at 15mm, pulling
winch brake at 15mm), namely completes the adjustment.
4.3.2 制动瓦随位装置的调整：当制动器处于抱闸状态时，旋转制动瓦随位装
置调整螺栓，使其顶端与制动瓦筋板轻轻接触，产锁紧锁定螺母 Adjustment for
Brake tile along with position adjustment device: When the brake is at the band
brake condition, the rotate the bolt of brake tile along with the position adjustable
device, causes its top and the brake tile stiffener muscle contacts gently, screw the
locking nut securely.
4.3.3 制动力矩的调整：旋转弹簧拉杆使弹簧压缩，并使弹簧下座上边沿对准
所需要的制动力矩（主起升卷扬机额定制动力矩 800~1600Nm，牵引卷扬机额
定制动力矩为 300~550Nm）。Braking moment adjustment: The rotate the spring
tension bar causes the spring to compress, and causes the spring base upper edge to
the alignment required braking moment (main hoisting rated braking 800~1600Nm,
pulling winch rated braking moment is 300~550Nm).
4.6 补偿机构的调整：推动器通电后，推杆动作顶出达到规定的工作行程位置，
同时拨杆在相应杠杆孔边带动下，向上转动一定角度；推动器断电后调整侧
部圆弧面与拔杆接触，并旋紧螺钉，可使制动器补偿机构有效。Compensation
mechanism adjustment: After the thruster unit energizing, the thrust lever action to
required working travel position, simultaneously pull rod corresponding driven by
lever hole side, upward rotats certain angle; After the driver unit power failure
adjusts the lateral circular arc surface and the pull rod slightly contacts, and the
screw fasten, may cause the brake compensation mechanism to be effective.
4.7 该系列制动器配备有无需调整等退距装置，当制动器打开时两边退距自动
均等。This series brake equipment has equipped with free adjustment equal
backward device, when the brake opens nearby two backward automatically
withdraw equally apart from each sides.
4.8 当推动器不工作时，可通过扳动手柄使制动器打开，以便停电检修。When
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the thruster does not work, may through manual handle to cause the brake to open,
in order to power cut overhaul.
5．使用与维修 operation and maintenance：
5.1 制动器运行前应全面检查，检查各项调整是否正确无误，各部分的锁紧螺
母是否锁紧，推动器接线是否正确。Before the brake movement should inspect
comprehensively, inspects each item to adjust whether correct unmistakable,
whether various part of locking nut does lock, the thruster unit wiring is whether
correct.
5.2 检查确认正常无误后，制动器应在主机上无载试运行数次，让制动摩擦片
进行一定的磨合，从面使之与制动轮的贴合良好。The inspection after confirmed
normal unmistakable, the brake should no-load try on the main engine to move
several times, let the brake lining plate carry on certain wearing in, caused it from
the surface and the brake pulley fitting is good.
5.3 使用中，应定期检查制动器的工作状况，着重于以下各项 In the use, should
the periodic inspection brake working condition, emphatically in below each item：
z 制动器的构件运动是否正常，各螺母是否坚固。The brake component
movement is whether normal, various nuts are whether firm.
z 推动器的工作是否正常，液压油是否足量，有无漏油和渗油现象，引
入电缆的绝缘是否良好。The thruster unit work is whether normal, the hydraulic
fluid whether full quantity, whether there is does the oil leak and infiltrate the oil
phenomenon, the cable entrance insulation is whether good.
z 各铰接处是否磨损，当销轴及心轴磨损量超过原直径的 5%或椭圆度超
过 0.5mm 应更新。Whether various hinged place worn, when pin shaft and the
arbor wearing capacity surpasses the original diameter 5% or the ellipticity
surpasses 0.5mm to be supposed to renew.
z 杠杆和弹簧发现裂纹应更新 The lever and the spring discovered the crack
should renew。
z 制动轮温度不应超过 200℃。制动轮上发现有 0.5mm 深裂纹时应重新

修磨。The brake pulley temperature should not surpass 200℃. On the brake pulley
the discovery has when the 0.5mm depth of torn crack should resharpen.
z 制动摩擦片是否正常的贴合在制动轮上，摩擦表面的状态是否完好，
有无油腻、赃污痕迹。当制动摩擦片的厚度达到允许最小值（主起升卷扬机
制动器为 6mm，牵引卷扬机制动器为 4mm，插入式制动瓦摩擦片不包括凸台
厚度）时，应更换新的制动摩擦片。Brake lining plate whether normal fitting on
brake pulley, friction surface condition is whether complete, whether there is
greasy, dirty trace. When brake lining plate thickness achieved the permission
minimum value (main lifting hoist brake is 6mm, pulling hoist brake is 4mm,
jack-in brake tile friction disk not including lug boss thickness), should replace the
new brake lining plate.
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第六节电缆卷线器技术说明
Technical specification for cable winch
1．名称 Description：长期转力矩电机式电缆卷线器 Long term stop rotating

torque motorized cable winch
型号 Model：JDO300 型 type
2．结构及工作原理 structure feature
电缆卷线器主要由长期堵转力矩电机、减速机、集电器总成、电缆卷盘
等组成。The cable winding device includes: long term rotating block up torque
motor, speed reducer, current collector compound, cable drum etc.
长期堵转力矩电机具有独特的电气和机械特性，电机调速范围宽，具有
较软的机械特性，当负载变化时，电机的转速相应地变化（负载增加，转速
下降），使电缆卷线器可近似地保持电缆的恒张力。The long term rotating block
up torque motor has the peculiar electric and mechanical features: the speed
governing scope of the motor is wide and with the softer mechanical characteristic.
If the load is changed, the rotating speed will be changed respectively (the rotating
speed will be decreased if the load is increased), so that the constant tension of the
cable could be maintained for the cable winch.
该电机可在其转矩-转速曲线上任意一点都能长期稳定的运行，可以保证
电缆在电缆卷盘的相应卷绕半径上获得卷绕速度和拉力。The motor can be
operated long & stably at any points at its torque-rotating speed curve, to ensure
that the cable can achieving the winding speed and tension at the respective drum
winding radius.
电机带有强力通风装置，在电机堵转时，风机仍独立运转，为电机提供
冷却。The motor is completed with the strong ventilation device. The fan could
still be run independently for motor cooling even if under motor long term rotating
blocked condition.
电机装有盘式常闭制动器，可以保证电机断电时，电缆不会因重力作用
从卷盘上滑落。The disc type normally closed brake is equipped with the motor.
The brake will ensure that the cable will not slip from the drum by self-gravity in
case of motor de-energizing.
分装式电缆卷盘，运输、安装方便。Assemble type cable winch, for easy
transportation and erection.
3．安装与调整 Erection and adjustment：
3.1 将电缆卷线器机体安放到机座上，并临时固定。The cable winding device
shall be erected on the machine seat and make a temporally fixing.
3.2 把电缆卷盘安装固定到机体上。The cable drum shall be fixed to the machine.
3.3 调整电缆卷线轴：Adjusting the cable drum shaft:
z 卷线轴应水平；The cable drum shaft shall be aligned horizontally.
z 卷线轴应与轨道正交（垂直）；The cable drum shaft shall be perpendicular
(vertical) to the rail.
z 电缆锚固装置应处于电缆卷盘中心。The cable anchoring device shall be
in the middle of the cable drum.
3.4 调整完毕后紧固电缆卷线器机体。The cable winding device shall be fixed
after the adjustment.
3.5 接线调试 Commissioning after wiring：
z 电机后端的制动间隙一般为 0.8mm；The braking clearance of the motor
rear end commonly shall be 0.8mm.
z 冷却风机旋转方向应与箭头指向相同；The rotating direction of the
cooling fan shall be the same with that shown by mark.
调试结束即可投入使用。It could be operated after the commissioning.
4．电缆锚固装置 Cable anchoring device：
电缆卷线器在收放电缆的过程中，始终受到一定的拉力作用，同时，电
缆卷盘与电缆锚固点的相对位置直接影响卷线的效果，所以对电缆锚固点的
- 72 -
设置情况有一定的要求 If the cable is released or retracted, there shall be a

tension force for the cable winding machine. And also the relative position of cable
drum and cable anchoring points shall affect the cable winding. The following
requirements shall be obeyed for cable anchoring points：
z 电缆锚固装置与电缆卷盘中心线的运行轨迹重合为最佳 Best result
can achieved by the cable anchoring and cable winch center ling
movement trail superposition；
z 电缆锚固装置与地面或其他物体固定联接时要能抵抗一定的拉力。If
the cable anchoring device is fixed with the ground or fixed with the
object on the ground, there should be some tensile force counteracted.
5．使用及维护注意事项 notice for operation and maintenance
5.1 长期堵转力矩电机绝缘等级为 F 级，防护等级为 IP44，使用条件等同于普
通电机。The motor is equipped with the strong ventilation device. The fan shall be
run independently for motor cooling even if the motor at long term blocked
condition. The protection grade is IP55. The operation condition will be the same
with the common motor.
5.2 长期堵转力矩电机连续的、长期在过热条件下工作，将会对电机的寿命有
较大影响，应确保冷却风机的正常工作，一旦发现冷却风机不能正常工作，
应及时维修。 If the long-term rotating block up torque motor is operated
continuously, permanently in an overheated condition, the motor life would be
affected severely, so that should ensure the cooling fan to operate normally. Once
the cooling fan is out of work, it should be maintained immediately.
5.3 应每周一次对减速器齿轮、齿面涂抹润滑脂。The lubrication grease shall be
applied on the speed reducer gear and gear teeth face once a week.
注意：不能注机油 Note: The engine oil could not be applied.

5.4 对拖动电机的前后轴承每年清洗一次，重新充填润滑脂。The front and rear
bearing for dragging motor shall be cleaning once a year. And the lubrication
grease shall be refilled.
推荐采用 7017-1 高低温润滑脂（-60~250℃）
。The 7017-1 H-L temperature
grease (-60~250℃) is recommended.
5.5 当集电环与电刷发生打火或过热现象时，应对烧伤的电环表面进行磨光处
理，当需要更换电刷块时，应采用同一型号的电刷块，不同型号的电刷块不
准在一组同时使用。If the fire strike and overheating occurred on current ring and
current brush, the burned ring surface shall be polished. The same type brush block
shall be used if it is required to be replaced. The brushes with different types shall
not be used together.
5.6 高压集电器的绝缘件应保持清洁，每两个月检查一次。The insulate piece of
high voltage current collector shall be maintained clean and shall be inspected once
per two months.
5.7 制动器采用两只整流管串连使用以保证其工作的可靠性。二极管型号为
ZP、5A、1600V。Two Nos. of rectifying tubes is used for the brake to ensure its
working reliability. The diode type is ZP, 5A, 1600V.
5.8 制动器具有手释放机构，以便于设备的调整。顺时针旋动手动调整螺栓使
制动器压盘（衔铁）与制动片脱离接触，释放制动器。不需要释放时，必须
将手动调整螺栓旋回到原位置，以保证制动器的有效制动。The brake is
equipped with manual releasing mechanism for equipment adjustment. The bolts
shall be manually adjusted clockwise to make the brake disc (armature)
disconnecting with the braking bar and brake would have been released. The bolts
shall be screwed to the original position if no releasing is required to ensure the
effective braking.
5.9 制动片的使用磨损将引起电磁铁与衔铁之间气隙增大，
导致制动力矩减小。
气隙的增大也造成衔铁吸合电压上升，严重时衔铁将不能吸合。应定期检查
气隙大小，及时进行调整。The air gap between electromagnetic metal and
- 74 -
armature will be increased caused by the wearing of the braking bar. So the braking
torque will be decreased. Also, the increasing of the air gap will result in increasing
the adsorption voltage of the armature, and the armature could not be adsorbed for
worst. The air gap shall be check periodically and adjust the gap as needed
气隙值也不可过小，不影响电机工作的气隙最小值为 0.8mm。The air gap
value shall not be too small. The min. air gap, which will not affect the motor
operation, is 0.8mm.
5.10 制动片为易损件，当双边磨损 3mm 以上时，应更新。The braking bar is
easily damaged pieces. If both edges are worn above 3mm, a new braking piece
shall be replaced.
第六章维护保养规程
Inspection and maintenance specification
一、日检基本作业项目和技术要求 Daily inspection items & technical

requirement
部序
维护部件作业项目
位号 item 技术要求 technical requirement
par Sl. Activity
maintenance
t No
目测轨道平直度无明显变化，轨道基础无塌陷，
检查、清理
大车轨道轨道上及两侧各 1.5 米范围内无障碍物。The rail
调整
1 longitude shall be straight without obvious changes by visual
inspection,
travel rail inspection. There shall be no sunk on the rail foundation.
cleaning &
No obstacles on the rails and within 1.5m at both sides of
adjustment
rails.
金各部螺栓连接牢靠，无松动无锈蚀。目测支腿和
属支腿和桥架检查、紧固桥架无明显变形。The connecting bolts of every parts
结 2 support leg & inspection, shall be fastened well, and no loosen or rusts. The leg and
构 bridge truss fastening bridge truss shall have no obvious deformation by visual
me inspection.
tal 梯子、平台、
str 检查、清洁安全可靠，防滑，无污垢和积水。They shall be safe
3 栏杆 stairs, inspection,
uct and anti- slippery. There shall be no dirt, water on them.
platform, cleaning
ure
handrail
安全可靠、防滑、密封，无污垢和积水，窗户洁
检查、清洁净明亮，室内无易燃、易爆物品。There shall be safe
4 操作室
inspection, and anti-slippery, sealing, no dirt and water. The window
operator cabin
cleaning shall be clean. No inflammable and explosive articles in the
cabin.
传防脱钩保险装置安全可靠。吊钩转动灵活，无裂
动检查纹等缺陷。 The hook safety latch shall be safe and
5 吊钩 hook
机 inspection reliable. The hook shall be rotated flexible. There shall be
no cracks on the hook.
构
绳端固定牢靠。钢丝绳无压扁，弯折、断股等现
象，断丝不超标，在卷筒上排列整齐，正确地穿
过滑轮。The rope end shall be fixed & fastened. There
钢丝绳 steel 检查
6 shall be no flattens, bending, breaking for the fiber core.
rope inspection The breakage of wire core shall not exceed the
specification limitation. The wire rope shall be aligned in
good order on the drum and pulled through the rope sheave
correctly.
部序
par Sl. Activity
maintenance
t No
大车行走减
速器和起升
7 牵引减速器检查无卡阻，无异响。齿轮油无泄漏。There shall be no
truck travel inspection blockage, unusual noise. No gear oil leakage is occurred.
mechanism
speed reducer
各部销轴无脱落，刹车泵油量，油质合格，刹车
8 检查灵敏可靠。The pin shaft for every parts shall not be
制动器 brake
inspection dropped. The oil quantity and oil quality of the brake pump
shall be satisfied. The brake shall be in good condition.
操作手柄灵敏可靠，操作台无灰尘、指示灯和仪
检查、清洁表显示正常。The operation handle shall be operated
9 操作台 cabin inspection, well. There shall be no dirt on the control station. The
cleaning indicator lights and the instruments shall be displayed in
normal.
紧固螺栓无松动现象，电缆滑线无摩擦、牵拉损
伤，起升钢丝绳排列整齐，吊钩无裂纹损伤，齿
轮油无渗漏。The bolts shall be tightened and no loosen.
电动葫芦检查 There shall be no friction, pulling damages for the trailing
10
electric hoist inspection cable. The rope fastening at the swinging end shall
be self aligned and rope should not come off its
reeving. There shall be no cracks on the hook. There shall
be no leakage of gear oil.
空负荷试动
检查大小车不啃轨，运转机构无异常音响，电机和轴
11 转 trial run inspection 承无振动、过热现象。电气操控件灵敏可靠。
without load
紧急开关检查
12 emergency 反应灵敏，安全可靠。Sensitive reaction, safe reliable.
switch
inspection
大车行走限
检查
13 位 longitude 反应灵敏，安全可靠。Sensitive reaction, safe reliable.
inspection
travel limit
大钩高度限
检查
14 位 truck 反应灵敏，安全可靠。Sensitive reaction, safe reliable.
安 inspection
height limit
全
小跑车行走
装检查
15 限位 trolley 反应灵敏，安全可靠。Sensitive reaction, safe reliable.
置 inspection
travel limit
电动葫芦高
度限位 height 检查
16 反应灵敏，安全可靠。Sensitive reaction, safe reliable.
limit of electric inspection
hoist
检查、清洁
电动机绝缘良好、无异响，无灰尘。 Good insulation, no
17 inspection,
motor unusual noise, no dust.
cleaning
- 78 -
部序
par Sl. Activity
maintenance
t No
①保持箱内的清洁、干燥，所有电气元件无灰尘。
The panel cabinet shall be clean and dry. There shall be no
dust on the all electric components.
控制箱、配 ②箱内的电线，电缆固定牢靠，无松动、脱落现
电电柜、电阻检查、清洁象。The wire & cable in the panel shall be fixed well and
18 箱 Electric inspection,
路 not loosen or dropped.
panel, cleaning
及 ③各保护开关和保险安全可靠。 Every protection
resistance box
电 switches and fuses shall be safe and reliable.
④箱体密封良好。The sealing of the panel body shall be
气
well.
保
检查所有电线、电缆无磨损、破裂、漏电老化等现象。
护 19 电线、电缆
There shall be no abrasion, breakage, electric leakage on all
wire, cable inspection the wires and cables.
接地保护检查接地线无脱落、断开现象，接地安全可靠。The earth
20 earthing bar shall not be dropped or broken. The earthing shall be
protection
inspection safe and reliable.
电铃 alarm 检查
21 声音清晰明亮 The bell sounds clear and loud.
bell inspection
无损坏、卷线速度与大车行走协调一致。There shall
电缆卷线器检查 be no damages on the cable drum. The cable rolling speed
22
cable winch inspection shall be cordinate with the moving speed of the longitude
travel.
①做好班前班后的清洁工作 Every shift shall be
其 responsible for cleaning the crane when they hand over to
the next shift.
它 ②下班后收起吊钩离地 2 米以上，电动葫芦停在
检查、清洁雨罩下。The electric hoist shall be stopped under the
23 整机 crane
inspection, weather cover when the shift finish their work. The hook
complete
cleaning shall be lifted 2m above the ground.
③关好操作室门窗以及配电柜。 The window and
door of the operator cabin shall be closed.
④做好防风、防汛工作。Anti-wind anti-flood measure
shall be secure.
二、月检基本作业项目和技术要求 monthly inspection basic items & technical

requirement
部序
位号 item Activity 技术要求 technical requirement
par Sl. maintained content
t No
金轨道轨距、平直度符合要求，基础无塌陷。The rail
大车轨道检查、调整
属 1 distance and the rail straightness shall be as per the
longitude inspection,
requirements. There shall be no sunk on rail foundation
结 travel rail alignment
base.
部序
t No
构 ①各部连接螺栓、轴、销无松动、缺损现象。The
me bolts, pins, shafts used for connecting the parts shall not be
tal loosen, damaged or missed.
str 支腿和桥架检查、维护 ②结构无裂纹、扭曲、变形、腐蚀、焊缝开裂等
uct 2 support legs & inspection,
bridge truss maintenance
现象。 There shall be no cracks, twists, deformation,
ure
corrosion, weld crack on the structure.
③有锈蚀部分，应除锈补漆。If the rust is found, it is
required to paint up.
梯子、平台、
检查、清洁
3 栏杆 Stair, inspection, 安全可靠 safe & reliable
platform, cleaning
handrail
传检查、润滑
无磨损、损坏，注 ZG-3 钙基润滑脂适量。Free of
动所有滑轮 all inspection
4 worn, damage, pour popper amount of ZG-3 Ca
机 pulley and
based lubrication grease.
构 lubrication
driv ①防脱钩保险装置安全可靠。The hook safety latch
ing shall be safe and reliable.
mec
hani 检查、润滑 ②吊钩转动灵活，无裂纹，剥裂等现象。The hook
sm 5 吊钩 hook inspection, shall be rotated flexible. There shall be no cracking or
lubrication peeled crack on the hook.
③注 40 号机械油适量。Apply right amount of #40
mechanical oil .
①钢丝绳绳端固定牢靠。The wire rope ends shall be
fixed & fastened well.
②钢丝绳无压扁、弯折断股现象，磨损、断丝数
不超标。There shall be no flattens, bending, breaking for
the wire rope. The breakage of fiber core shall not exceed
钢丝绳 steel 检查、润滑 the specification limitation.
6 inspection, ③钢丝绳在卷筒上排列整齐，正确穿过滑轮。The
rope lubrication wire rope shall be aligned good order and pulled through
the pulley sheave correctly.
④牵引绳松紧度适当。The tightness of the pulling wire
shall be suitable.
⑤适量涂抹钙基润滑脂。The right amount Calcium
base lubricant applied.
滚动轴承
检查、润滑无卡塞、损坏，加注 ZG-3 钙基润滑脂适量。There
7 inspection, shall be no blocking, damage on the bearing. The Lithium
rolling bearing
lubrication base lubricant right amount fill up.
大车行走减
速器和起升减速器固定牢靠，转动无卡阻、无异响，油位油
牵引减速器检查、加油
8 inspection, oil
质合格。The speed reducer shall be fixed well. There shall
speed reducer be no blockage, unusual noise on the reducer. The oil level
of truck travel filling
and the oil quality shall be satisfied.
and lift pulling
speed reducer
- 80 -
部序
t No
缓冲件无损伤，磨损不超标。两轴对中无明显偏
联轴器检查、调整
9 inspect,
差 There shall be no damages, abrasion of the buffering
coupling component shall not exceed the specification. There shall be
adjustment
no obvious deviation for centering of the two shafts.
①调整摩擦片与制动轮间隙保证灵活可靠。Adjust
the clearance between the friction piece and the braking
检查、清洁、 wheel to ensure the brake can be operated well.
调整 ②在刹车状态下接触良好，制动牢。（接触面积不
10 制动器 brake inspection,
cleaning,
小于 70%）The contacting area of the brake shall be in
adjustment good condition during the braking, and the braking result is
well. (The contacting area of the brake shall be not less than
70%)
紧固螺栓无松动现象，齿轮油无渗漏。电缆滑线
无摩擦、牵拉损伤，起升钢丝绳排列整齐，吊钩
检查、紧固、无裂纹损伤。按润滑表润滑，补充齿轮油。The bolts
电动葫芦润滑 shall be tightened and no loosen. There shall be no leakage
11 inspection, for gear oil. There shall be no friction, pulling damages for
electric hoist
fastening, the trailing cable slide. The lifting wire rope shall be
lubrication aligned not falling from its reeving. There shall be no
cracks on the hook. The oil shall be filled up as per the
lubrication list, to renew gear oil.
电 ①绝缘良好，无异响和过热，电机轴承润滑良好。
路电动机检查、清洁 Good insulation, no unusual noise & overheat. The
及 12 electric inspection, lubrication of the motor bearing is good.
motor cleaning ②清洁机体及通风道内的杂物、灰尘。Cleaning the
电
dust, dirt inside the motor body and the air dust.
气每年春秋季摇测接地电阻，保证起重机上任一点
保接地电阻不大于 4Ω。主回路和控制回路的对地
护接地与绝缘绝缘电阻不小于 0.5MΩ。The earthing resistance shall
Ele 13 检测 testing be checked in every spring and autumn to ensure that any
earthing &
ctri
c insulation point on the crane its resistance less than 4 Ω . The
circ insulation resistance of the main circuit and control circuit
uit to the ground shall not be less than 0.5MΩ.
and
elec ①所有电线、电缆无磨损、破裂、漏电、老化等
tric
prot
现象。 There shall be no abrasion, breakage; electric
ecti 电线、电缆检查 leakage aging etc. appeared on all the wires and cables.
14
on wire & cable inspection ②无短路、断路。No short cut or tripping occurred.
③无接头松动、绝缘破损等情况。No joint loosen, no
insulation damages occurred.
部序
t No
①保持箱内的清洁、干燥，所有电气元件无灰尘。
配电柜、电 The panel and the box shall be clean & dry. There shall be
no dust on all electric component.
阻箱、控制
②箱内的电线、电缆固定牢靠。The wire & cables in
箱 the panels shall be fixed well.
检查清洁
15 distribution inspection, ③各电气元件的触点开闭可靠，触点弧坑应及时
panel, cleaning 磨光。The contacts (off & on) of the electric components
resistance should be in good condition. The contact burned pit shall be
box, control polished.
box ④操作台应灵敏、可靠。The controlling station shall be
sensitive and reliable.
紧急开关检查
16 emergency 反应灵敏，安全可靠。Sensitive reaction, safe reliable.
stop button
inspection
大车行走限
位 travel limit 检查
安 of longitude inspection
全 travel
装大钩高度限
检查
置 18 位 main hook 反应灵敏，安全可靠。Sensitive reaction, safe reliable.
inspection
safe height limit
ty 小跑车行走
devi 检查
ce 19 限位 trolley 反应灵敏，安全可靠。Sensitive reaction, safe reliable.
inspection
travel limit
电动葫芦高
度限位 height 检查
limit of electric inspection
hoist
整空负荷运转各机构能正常工作，无振动、过热、啃道等异常
检查
机 21 running 现象。Every mechanism shall be operated normally. There
cran without load
inspection
shall be no vibration, overheating, gnawing occurred.
e
com 执行日检所检查
plet 22
e
有作业项目 inspection
检查、清洁、
其各部运转正常，必要时拆开卷线器罩壳清洁、润
电缆卷线器润滑
它 23 滑。 Every component shall be operated normally. The
cable winch inspection,
oth winch cover could be dissembled for cleaning & lubricating
cleaning,
er as necessary.
lubrication
注意：起重机每使用一年至少进行一次有专业人员参加的全面技术检查。
Note: the crane shall be inspected by the professional person at least once per
year for the overall technical inspection.
- 82 -
三、新装、拆迁和大修后，在使用前应进行负荷试验；可按下表进行 If the items

are newly erected, dissembled and overhauled, the load test shall be done
prior to operation. The tests are shown as below:
部序维护部件作业项目
位号 maintenance Activity 技术要求 technical requirements
par part content
no
t
执行所有月
检作业项目
1 executing all
the monthly
inspection item
各工作机构能正常工作，无振动、过热、啃轨等现
空负荷运转象，各种电气动作应灵敏、可靠、准确。Every working
2 running 检测 testing mechanism shall be operated normally. No vibration,
without load overheating, rail gnawing shall be occurred. Each electrical
motion shall be sensitive, reliable and accurate.
大、小车行走，大钩起降，起动和制动平稳，各部
额定载荷试分无异响，不过热。The traveling of the longitude travel,
3 验 rated load 检测 testing the traveling & lifting of the electric hoist and the startup &
整 test braking of the crane shall be smooth. There shall be no
unusual noise, overheating for all the components.
超载 125%，离地 100mm，试验后钢结构无永久变
形，焊缝无开裂，结构铰制螺栓无损坏，起升机构
静载试验制动可靠。Surcharge 125%, 100m above the ground, after
4 检测 testing testing, the steel structure shall have no permanent
dead load test
deformation. There shall be no cracks on the welds. There
机
shall be no damages on the structure reamer bolts. The
Cra lifting device shall be braked well.
ne
co 超载 110%，各机构起动制动应平稳，无过大冲击
mp 和振动，各部连接无松动，制动器工作可靠。电气
lete 设备和控制器能正常工作。Surcharge 110%, the startup
5 动载试验
检测 testing & braking of all the mechanical shall be operated normally.
live load test There shall be no big impacts and vibration on the crane.
There shall be no loosen for all the connecting parts. The
brake shall be operated normally. The electric devices and
controller shall be operated normally.
电动葫芦静
载 125%和葫芦轨道无开裂变形，悬挂可靠。行走轮固定可靠，
动载 110% 行走轮与轨道平面的接触尺寸合格，起降制动可
6 试验 electric 检测 testing 靠。The electric hoist free of torn crack, rail hung
hoist static reliable. Travel wheel fixed reliable, travel wheel and
125% and rail plane contact dimension is qualified, the lifting
dynamic and lowering brake is reliable.
110% testing
第七章起重机的润滑 Lubrication of crane
1、润滑的基本原则 Basic principle of lubrication：

凡是有轴和孔动配合的部位以及摩擦面的机械部分，都要进行润滑。All
the parts with axles and holes and all the mechanical parts with frication surfaces
shall be lubricated.
2、润滑注意事项 Lubrication precaution：

2.1 润滑时必须全车停电。The crane power shall be switched off during the
lubrication.
2.2 润滑材料必须保持清洁。All the lubrication materials shall be kept clean.
2.3 不同牌号的润滑脂不可混用。Different trademark lubricant could not be mix
used.
2.4 根据机械运转情况和日常检查情况，对需润滑部位进行不定期保养。The
lubricated parts shall be maintained irregularly as required according to the
mechanism running and the daily inspections.
2.5 没有注油点的转动部位，用稀油壶加入各转动缝隙中，以使转动灵活，减
少磨损和锈蚀。For those the rotating parts without oil pouring holes, the
lubrication shall be poured to the rotating gaps by dilution oil can to reduce the
abrasion and rusts.
2.5 对电动机轴承的润滑一般在大修时进行。The lubrication of the motor
bearing commonly would be done during the major overhaul.
3、40t 起重机推荐用油 Recommended crane lubricant

3.1 行走减速器 travel speed reducer
原厂润滑油牌号 Original manufacturer default lubricant trade mark:
第七章起重机的润滑
环境温度-10℃~0℃时用 L-CKC46~68 润滑油；ambient temperature within

-10℃~0℃ the L-CKC46~68 lubricant is selected
环境温度 0℃~30℃时用 L-CKC100~150 润滑油；ambient temperature
within 0℃~30℃ the L-CKC100~150 lubricant is selected
环境温度 30℃以上时用 L-CKC220 润滑油。ambient temperature above 30
℃the L-CKC220 lubricant is selected
3.2 主起升减速器 Main hoisting speed reducer（卓轮 Zollen）
、牵引减速器 Pulling
speed reducer（卓轮 Zollen）
详见第五章第三节 Detailed information see chapter three section five
3.3 电动葫芦减速箱 electric hoist speed reducer
原厂推荐 L-AN46，GB443 全损耗系统用油。The manufacturer recommends
L-AN46, GB443 entire loss system oil used.
3.4 制动器推动器油泵 brake thruster oil pump
原厂推荐 DB-25 号（SY1351-77）液压油。夏季可用 25#变压器油，冬季
可用 10#变压器油。The manufacturer recommends DB-25 numbered (sy1351-77)
hydraulic oil. The #25 transformer oil can be used in the summer and the #10
transformer oil for the winter.
3.5 滚动轴承 rolling bearing
可用钙基或通用锂基润滑脂。The calcium grease or the general lithium
based grease could be applied.
3.6 电机轴承 motor bearing
可用钠基或通用锂基润滑脂。The natrium based grease or the general
lithium based grease shall be applied.
3.7 电缆卷线器电机轴承 cable winch motor bearing
推荐采用 7017—1 高低温润滑脂（-60~250℃）The 7017-1 H-L temperature
lubricant grease (-60~250℃) is recommended.
- 86 -
4、润滑表 Lubrication table：

润滑点数
润滑部位名称 lubrication 润滑材料润滑方法润滑周期
序号
lubricated part drop lubrication lubrication lubrication
SN
description counted material method period
quantity
大车行走机构
1 longitude travel
mechanism
锂基润滑脂
油枪注入
行走轮轴承 travel Lithium base 每月 per
1.1 8 poured by
wheel bearing lubrication month
oil gun
grease
齿轮油 gear 换油 oil 每半年 per
1.2 减速箱 speed reducer 2
oil replace half year
制动器油泵 oil pump 液压油换油 oil 每半年 per
1.3 2
for brake hydraulic oil replace half year
制动器各铰接点
机械油注油 oil 每月
1.4 every hinged points of
mechanic oil pouring monthly
brake
起升卷扬机 hoisting
2
winch
卓轮减速机 Zollen 齿轮油 gear 换油 oil 每年
2.1 1
speed reducer oil replace annually
锂基润滑脂
油枪注入
卷筒轴承 drum Lithium base 每月
2.2 1 oil gun
bearing lubrication monthly
pouring
grease
制动器油泵 brake oil 液压油换油 oil 每半年 per
2.3 1
pump hydraulic oil replace half year
制动器各铰点 various 机械油注油 oil 每月
2.4
hinged joint of brake hydraulic oil pouring monthly
钢丝绳脂涂抹 spread 每年
2.5 钢丝绳 rope
rope grease wipe annually
牵引卷扬机 pulling
3
hoist
卓轮减速机 Zollen 齿轮油 gear 换油 oil
3.1 1 每年
speed reducer oil replace
锂基润滑脂
卷筒轴承 drum Lithium base 每月
3.2 1 油枪注入
bearing lubrication monthly
grease
制动器油泵 oil pump 液压油换油 oil 每半年 per
3.3 1
for brake hydraulic oil replace half year
制动器各铰点 various 机械油注油 oil 每月
3.4
hinged joint of brake mechanic oil pouring monthly
润滑点数
序号
SN
quantity
钢丝绳脂涂抹 spread 每年
3.5 钢丝绳 rope
rope grease wipe annually
锂基润滑脂
桥架端部导向滑轮油枪注入
Lithium base 每月
4 bridge truss end 8 oil gun
lubrication monthly
guide pulley pouring
grease
5 小跑车 trolley
锂基润滑脂
油枪注入
小车轮轴承 trolley Lithium base 每月
5.1 8 oil gun
wheel bearing lubrication monthly
pouring
grease
小车轮支承销轴
5.2 trolley wheel support 4
pin shaft
锂基润滑脂
油枪注入
起升定滑轮 hoisting Lithium base 每月
5.3 6 oil gun
fixed pulley lubrication monthly
pouring
grease
6 大钩 main hook
锂基润滑脂
油枪注入
起升动滑轮 hoisting Lithium base 每月
6.1 2 oil gun
follow-up pulley lubrication monthly
pouring
grease
滑轮架及钩体转动轴
6.2 pulley sheave and 3
hook rotation shaft
电动葫芦 electric
7
hoist
起升机构减速器
齿轮油 gear 换油 oil 每年
7.1 speed reducer for 1
oil replace annually
lifting mechanism
运行减速器 travel 齿轮油 gear 换油 oil 每年
7.2 1
speed reducer oil replace annually
锂基润滑脂
钢丝绳及卷筒 steel Lithium base 涂抹 spread
7.3 3 个月
rope and drum lubrication wipe
grease
锂基润滑脂
吊钩推力轴承 hook Lithium base 涂抹 spread 每年
7.4 1
thrust bearing lubrication wipe annually
grease
- 88 -
润滑点数
序号
SN
quantity
锂基润滑脂
滑轮轴承 pulley Lithium base 涂抹 spread 每半年 per
7.5 2
bearing lubrication wipe half year
grease
锂基润滑脂
走轮轴承 run wheel Lithium base 涂抹 spread 每年
7.6 8
bearing lubrication wipe annually
grease
锂基润滑脂
卷筒轴承 drum Lithium base 涂抹 spread 每年
7.7 2
bearing lubrication wipe annually
grease
锂基润滑脂
电动机轴承 motor Lithium base 每年
7.8 3 挤入
bearing lubrication annually
grease
滑线小车 trailing 机械油注油 oil
7.9 56 3 个月
cable pulley block mechanic oil pouring
电缆卷线器 cable
8
winch
锂基润滑脂
减速机齿轮 speed Lithium base 涂抹 spread 每月
8.1
reducer gear teeth lubrication wipe monthly
grease
电机轴承 motor 7017—1 脂每年
8.2 2 填充 stuffed
bearing grease annually
5、润滑图 Lubrication chart：
- 92 -
第八章常见故障与排除方法 common trouble

and troubleshooting method
序部件名称
Part 故障情况 trouble 排除方法 trouble shooting
号原因 reason
descriptio existing method
SN n
1．尾部螺纹及其退 1．材质或制造缺陷。 1．出现裂纹更换。Crack
刀槽、钩头表面出 Material or manufacture appear replacement.
现裂纹。Tail thread defect. 2．当磨损量超过危险断面
and its cut groove, 2．超载使用。Overload 高度 10%，应更换新件。在
top hook surface usage. 此标准内，可根据试验降低
锻制吊钩
crack existing. 3．超期使用。Overdue 负荷使用。 When the
1 forged
2．钩口危险断面的 usage. wearing amount surpasses
hook
磨损超标。 Hook the dangerous section 10%
mouth dangerous of height, should replace
sectional worn new. Within the scope, may
beyond standard. reduce the load according to
the experiment tested.
断丝、断股、打结使用方法不当或超期、 1．断股、打结者更换新绳。
或磨损超标。Fiber 超载使用 Application For fiber break, knotted
breaks, core breaks, method improper or replace for a new.
ties a knot or overdue, overload usage 2．断丝数在一捻距内超过
attrition exceeding 10%，应更换新绳。When
the allowed wire breaks quantity
钢丝绳 limitation.
2 surpasses 10% in one drum
steel rope
circle, should replace the
new rope.
3．钢丝径向磨损 40%，应
更换新绳。The steel rope
radial worn to 40%, should
replace the new rope.
1．滑轮槽磨损不均 1．材质不均。material 1．重新安装、修补或更换。
匀。 The pulley qualities are uneven. reinstall, repair up or
groove wears 2．安装不符合要求，绳、replacement.
non-uniform. 轮接触不均匀。 2 ．加强润滑。 lubrication
2．滑轮心轴磨损。 installments does not enhancement.
滑轮
3 Pulley arbor worn. conform to the 3 ．检修心轴和轴承。
pulley
3 ．滑轮转不动。 requirement, the rope, Overhaul the arbor and the
Pulley the rotation the wheel contacts bearing.
to be motionless. non-uniform.
3．心轴或轴承损坏
Arbor or bearing
第八章常见故障与排除方法
序部件名称
号原因 reason
SN
n
damages
1．卷筒上有裂纹。 1．材质或制造缺陷。 1．修补或更换。

2．卷筒轴、键磨损。2．超载使用。 2．调整钢丝绳偏斜角。
3．卷筒绳槽磨损或 3．安装不符合要求，钢 1. Repairing or replacement.
跳槽。丝绳偏斜角偏差。 2. Adjustment on steel rope
1. Crack on the 1. Material quality or angle of declination.
卷筒
4 drum. manufacture defects.
drum
2. drum shaft, key 2. Overload uses.
attrition. 3. Installments do not
3. Rope groove conform to the
worn or groove requirement, the steel
jump. rope diagonal deviation.
1．裂纹。Crack. 1．材质或制造缺陷。 1．更换新轴。
2．轴的弯曲。Shaft 2．事故损坏。 2．超过每米 0.5mm 应校直。
5 轴 shaft bends. 1. Material quality or 1. Replaces a new shaft.
manufacture defect. 2. surpasses each meter
2. Accident damages. 0.5mm to be supposed
alignment.
1．在半联轴器体内 1．材质或制造缺陷。 1．更换新件。
有裂纹。 2．缓冲件损坏。 2．修复。
2．起动时有跳动现 3．超期使用。 1. Replaces new.
1. Material quality or 2. Repairs.
联轴器象。
6 manufacture defect.
coupling 1. Crack inside
coupling body. 2. Flexible part damages.
2. when starting 3. Goes over the time
has the beat limit used.
phenomenon.
1．周期性的颤振的 1．周节误差过大或齿侧 1．修整，重新安装。
声响。间隙超过标准，可能引 2．检修齿轮啮合状态和轴
2．发生剧烈的金属起机构震动甚至断齿。承的工作状态，更换润滑
锉擦声，引起减速 2．轮对中心未对正。轮油。
器的震动。齿工作面磨损后不平 3．更换垫料，将原垫料剥
减速器
3．壳体，特别是安坦，齿顶有尖锐的边缘。离用醋酸乙脂和汽油各
7 speed
reducer 装轴承处发热。 3．轴承有故障。轴颈卡 50%溶液洗刷，除净后涂液
4．润滑油沿剖分面住，齿轮磨损，缺少润体密封胶。检修壳体结合
流出。滑油。面，拧紧螺栓。
5．减速器在架上振 4．密封损坏，减速器壳 4．拧紧紧固螺栓。
动。体变形，螺钉松动。 1. Repairing, reinstall.
1. Periodic flutter 1. Circular pitch 2. Overhaul gear meshed
- 94 -
序部件名称
号原因 reason
SN
n
sounds. deviation oversized or condition and bearing
2. Has the fierce the tooth side clearance working status, lubricating
metal rubbed, surpasses the standard, oil replacement.
causes the reduction possibly causes the 3. Replacement for fillers,
gear vibration. mechanism vibration the original filler peeling
3. Heat found on even to the tooth break. with the acetic acid second
shell, specially 2. Center alignment not grade grease ie. C4H8O2 and
bearing mounted matched. Gear teeth gasoline each liquer 50%
place. working surface is not washing and scrubbing, after
4. Lubricating oil smooth after worn, the clean spread the liquid
flow out along tooth top has the sharpen sealant. The overhaul shell
section interface. edge. junction plane surface,
5. Reduction gears 3. Bearing broke down. screws tight the bolts.
vibrate on the The trunnion blocked, 4. Screws tight the bolt.
frame. lubricating oil lacks.
4. Seal damages, the
reduction gear shell
deformation, the bolt
becomes loosed.
序部件名称
号原因 reason
SN
n
1．不能刹住货物 1．制动器杠杆系统中有 1．用油润滑活动关节。
（对运行机构来说的活动关节（铰链）被 2．用煤油清洗制动轮及制
断电后溜车）。卡住。 The movable 动带。
2．制动器不能打 elbow (hinge) in the 3．更换新制动带。
开。 brake lever system has 4．检修推动机构和电器部
3．在制动带上发生 been blocked. 分。
焦味制动带迅速磨 2．油滴入制动轮的工作 5．消除卡住现象。
损。面上。Oil dripping on the 6．调整弹簧压力。
brake pulley working
4．制动器易于脱开 7．按不同温度更换制动器
surface.
调整的位置。液压油。
3．制动带磨损严重。
1. Cannot stop the 8．调整制动器。按要求重
Brake band attrition is
cargo (after 新加工制动轮。
serious.
movement 9．拧紧主弹簧调整螺母。
4．液压推杆制动器动作
mechanism power
不灵活。Hydraulic thrust 10．修复或更换新的螺母或
failure
accelerating-sliding) lever brake movement is 螺杆。
. not flexible. 1. Lubrication oil used on
2. Brake cannot 5．制动带胶粘在有污垢 joint.
open. 的制动轮。Brake band 2. Uses the coal oil to clean
3. Attrition rapidly sticks on dirt brake the brake pulley and the
happens on the pulley. brake band.
制动器 brake band. Has the 3. Replaces the new brake
8 6．弹簧张力过大。
brake burnt taste on brake band.
Spring tensions
band. 4. Overhaul thrust
oversized.
4. Brake easy to mechanism and electric part.
7．液压推杆制动器液压
withdraw the 5. Eliminates caught
油使用不当。Hydraulic phenomenon.
adjustment position. pressure thruster lever 6. Regulating spring
brake hydraulic fluid pressure.
uses improper. 7. According to different
8．制动带与制动轮间隙 temperature replace brake
不均匀而磨擦生热。 hydraulic fluid.
Brake bands and the 8. Brake adjusting. Brake
brake pulley gaps pulley re-fabricate according
non-uniform rub the heat to the request.
generation. 9. Screws tight the main
9．调整主弹簧 the nut of spring adjusting nut.
adjustment main spring 10. Either repair or replace
（制动弹簧） brake the new nut or the screw rod.
spring 的螺母松动
loosen.。
10．螺母或螺杆丝扣被
破坏。Nut or the screw
thread damaged.
- 96 -
序部件名称
号原因 reason
SN
n
1．轴承产生高热。 1．缺少润滑油。 1．检查轴承中的润滑油使
2．工作时滚动轴承 2．轴承中有污垢。其达到规定的标准。
响声大。 3．装配不良而使轴承卡 2．用汽油清洗轴承并注入
1. Bearings have the 滞。新润滑油。
high fever. 4．轴承部件损坏或磨 3．检查轴承的装配。
2. when work the 损。 4．更换新轴承。
rolling bearing 1. Lacks the lubricating 1. inspects in the bearing the
滚动轴承
sound is big. oil. lubricating oil to enable it to
9 rolling
bearing 2. bearings has the dirt. achieve the stipulated
3. Assembly not good standard.
causes the bearing 2. uses the gasoline clean
freezing. bearing and pours into the
4. bearing part damage new oil.
or wears. 3. inspects the bearing
assembly.
4. replaces the new bearing.
行走轮啃轨。Travel 1．车轮偏差过大。 1．检修车轮，重新安装。
wheel to gnaw the 2．传动系统偏差过大。 2．使电动机，制动器合理
rail. 3．金属结构变形。匹配，检修传动轴、键、齿
4．轨道偏差或有油污与轮传动情况。
冰霜。 3．检修矫正。
大车运行 1. wheel deviations 4．检修轨道，去掉油污或
机构 oversized. 冰霜。
10 truck 2. Transmission system 1. overhaul the wheel,
travel deviation oversized. reinstall.
mechanis 3. metal structure 2. causes the electric motor,
m distortion. the brake reasonable match,
4. run way rail errors or overhauls drive shaft, key,
have the greasy dirt and the gear drive situation.
icy water. 3. overhaul correction.
4. overhaul the rail, removes
the greasy dirt or icy water.
1．轮辐、踏面（滚 1．材质或制造缺陷。 1．更换新车轮或修补。
动面）有裂纹。 2．车轮走斜啃轨。 2．重新车制或成对更换。
2．车轮滚动面磨损 3．安装不符合要求。 3．补焊或更新。
不均匀。 1. material quality or 1. replace the new wheel or
3．轮缘磨损。 manufacture defects. repairing.
车轮 1. wheel rib, tread 2. wheel run slanting 2. Machined again or pair
11
wheel face (roller face) has gnaw the rail. replace.
the crack. 3. installment does not 3. welds repair or renewal.
2. wheel roller face conform to the
wear non-uniform. requirement.
3. wheel rim
attrition.
序部件名称
号原因 reason
SN
n
起动后，电机不转，1．过度超载。Overloaded 1．禁止超载使用。
不能提起重物。The operation 2．等电压恢复正常。
motor is not run 2．电压比额定电压低 3．检修电器与线路。
after startup. The 10%以上。The voltage is 4．卸下制动轮，清洁锈蚀
object can not be lower more than 10% of 表面。
lifted. the rated voltage. 5．按序号 20（扫膛）。
3．导线断开或接触不 6．更换符合要求的导线。
良。The conductor is cut 1 ． Overload lifting is
off or improper prohibited.
contacting.
2． Wait until the voltage
电动葫芦 4．制动轮与后端盖锈蚀
12 electric recovered.
咬死，制动轮脱不开。 3 ． Checking the electric
hoist The braking wheel and apparatus and the wiring.
the rear cover are rusted
4． Dissembling the braking
and bit tighter, so that
wheel and getting rid of the
the braking wheel could
rust.
not be split.
5． As per the Sl. No.20
5．电机扫膛。The motor
(Fouled).
is fouled.
6 ． Replacing a qualified
6．导线过长或截面小。
conductor.
The conductor is too
long or the section of the
conductor is small.
- 98 -
序部件名称
号原因 reason
SN
n
制动不可靠、下滑 1．制动环磨损大或其它 1．调整、增大弹簧力。
距离超过规定要原因使弹簧压力减小。 Adjusting and increasing the
求。The effective of The braking ring is worn spring pressure.
braking is not heavily or others etc. like 2．拆下修磨。Dissembling
satisfied and the the spring pressure is and polishing.
sliding distance reduced. 3．拆下清洗。Dissembling
exceeds the 2．制动环与后端盖锥面 and cleaning.
requirements. 接触不良。 The 4．更换制动环。Replacing
contacting between the the braking ring.
braking ring and the rear 5．更换弹簧。Replacing the
end cover taper surface spring.
电动葫芦
is not good. 6．检查其联结部分。
13 electric
hoist 3．制动面有油污。There Checking the connected
are some oil dirt on the portion.
braking surface.
4 ．制动环松动。 The
braking ring is loosened.
5．压力弹簧疲劳。The
pressure spring is
fatigued.
6．联轴器窜动不灵或卡
死。The movement of the
coupling is inflexible or
blocked.
电动机温升过高。 1．超载使用。Overloaded 1．禁止超载使用。
The temperature operation. Overloaded operation is
risen of the motor is 2．作业过于频繁。The prohibited.
too high. operation is too 2．按 25%和 120 次/h 要求
frequently. 操作。Operating as per the
14 3．制动器间隙小，运转 requirement of 25% and
时制动环未完全脱开。 120no./h.
The brake’s clearance is 3．重新调整间隙。
too small to split the Readjusting the clearance.
braking ring during the
operation.
减速器响声过大。 1 ．润滑不良。 The 拆卸检修。Dismantling and
The noise of the lubrication is not good. checking.
speed reducer is 2．齿轮过度磨损，齿间
louder. 间隙过大。The gears are
15 worn badly, the teeth gap
is too large.
3．齿轮或轴承损坏。The
gear or the bearing is
damaged.
序部件名称
号原因 reason
SN
n
起动时电机发出嗡 1．电源及电机缺相。The 1．检查输入电源、电机。
嗡声。 The motor phase is lacked for Checking the input power
sounds “bee-bee” power supply and motor. and the motor.
16
during the startup. 2．接触器接触不良。The 2．更换接触器。Replacing
contacting of the the contactors.
contacts are not proper.
重物升至半空，停电压过低或波动大。The 等电压恢复正常后再起动。
车后不能再起动。 voltage is too low or Starting up again once the
When the object is fluctuated much. voltage is normal.
17 lifted in the air, the
hoist cannot startup
again after the hoist
is stopped.
起动后，不能停车，1．接触器触头熔焊。迅速切断总电源。 Switch
或者到极限位置 Fusion happened on to off the main power
时，仍不停车。The the contactor end. immediately:
hoist could not 2 ．限位器失灵。 The ①检修或更换交流接触器。
18 stopped after the limit is out of work. Maintaining or replacing the
startup; or the hoist AC contactor.
could not stopped ②检修或更换限位器。
when it is at the Maintaining or replacing the
maximum limit limit.
position.
减速器漏油。 1、箱体与箱盖之间，密 1、拆下检修或更换密封。
oil leakage of speed 封装配不良或损坏。The Dismantling for inspection
reducer sealing ring between the or replacing the seal.
box body and the box 2、拧紧螺钉。Tightening the
19 cover is dis-matched or bolts.
damaged.
2、联接螺钉未拧紧。The
connecting bolts are not
tightened well.
- 100 -
序部件名称
号原因 reason
SN
n
电机锥形转子与定出厂产品是不允许“扫拆下更换支承圈，使定子转
子间间隙太小发生膛”的，发生“扫膛” 子锥面之间有均匀的间隙，
碰擦（俗称扫膛）。的主要原因是：电机轴每边为 0.35~0.55mm（小电
The clearance 上支承圈磨损严重，转机间隙小）或送回制造厂修
between the conical 子铁芯轴向位移，或者理。Dismantling & replacing
motor rotor and the 定子铁芯位移。 The the bearing support ring;
stator is too small “fouling” is not make a even clearance
resulting the wiping permitted for ex-work between the stator rotor
(as fouling called) products, if occurs, the conical surfaces. There shall
20
main reasons shall be: be a 0.35~0.55mm clearance
the bearing support ring each side (small clearance
of the motor shaft is for small motor). Or the
worn badly; axial machine shall be send back
displacement happened to the manufacturer for
on the iron core of the repairing.
rotor; or the axial
displacement happened
on iron core of the stator.
第九章附录 annexure
一．电气备件清单 Electric spare list

二．主要部件运输外形尺寸图 major component
transportation figuration dimension diagram
三．电气系统图 electric system drawing
四．卓轮减速机安装检修图 Zollern speed reducer erection
maintenance drawing
附录一 annexure one：电气备件清单 electric spare list

配件名称数量
序号规格型号 specified
replacement quanti 备注 remark
SN model
description ty
急停按钮
1 LA10-1S 4
emergency button
急停按纽
2 ZB2－BS54C 4
emergency button
3 按纽 push button XB2－EA145 6
信号灯 signal
4 XB2-BVM4C 4
lamp
5 电压表 voltmeter 85L1-600V 1
电流表
6 85L1-200A 1
amperemeter
7 电铃 bell UN4-125 2
相序继电器 phase
8 XJ2 2
sequence relay
交流接触器 AC
9 CJX4-d-150 2
contactor
交流接触器 AC
10 CJX4-d-50 2
contactor
交流接触器 AC
11 CJX4-d-170 2
contactor
交流接触器 AC
12 CJX4-d-8011C 2
contactor
交流接触器 AC
13 CJX4-d-4004 2
contactor
交流接触器 AC
14 CJX4-d-9511C 2
contactor
中间继电器
15 JZC3－22dc 2
interposing relay
时间继电器 time
16 JZC-22d+SK4-222d 2
relay
热继电器 thermal LR2－D3357C＋
17 2
relay LA7-D3064
18 2
relay LA7-D1064
19 1
relay LA7-D2064
20 1
relay LA7-D1064
小型断路器 mini
21 DZX4-40L 40A 2P 2
breaker
22 小型断路器 mini DZX4-40L 20A 2P 4
第九章附录
breaker
GSM1－225L／3300
23 断路器 breaker 2
180A
GSM1－100L／3300
24 断路器 breaker 2
50A
限位开关 limit
25 LX10－11S 4个大车行走 truck travel
switch
电动葫芦高度限位
限位开关 limit
26 SL1-H 2个 electric hoist height
switch limit
Common for 40t
27 滑环 1套
and 和 20t 共用
- 106 -
附录二 annexure two：主要部件运输外形尺寸图 major component

transportation figuration dimension diagram
第九章附录
- 108 -
第九章附录
- 110 -
第九章附录
- 112 -
附录三 annexure three：电气系统图 electric system drawing
目录 table of content
序号备注
名称 Description 图号 drawing No.
SN remark
总电源电路图 General
1 MDG40/10-d-020701
electric circuit drawing
主起升机构电气电路图
2 main hoisting mechanism MDG40/10-d-020702
electric circuit drawing
电动葫芦原理图 electric
3 MDG40/10-d-020703
hoist principle drawing
大车运行原理图 truck travel
4 MDG40/10-d-020704
principle drawing
小车牵引机构原理图 trolley
5 pulling mechanism principle MDG40/10-d-020705
drawing
联合操作台元件布置示意图
6 combined station component MDG40/10-d-020706
arrangement sketch diagram
操作室配电箱原理图 cabin
7 distribution box principle MDG40/10-d-020707
drawing
联合操作台对外接线图
8 combined station outgoing MDG40/10-d-020708
wiring diagram
电控柜对外接线图 electric
9 panel outgoing wiring MDG40/10-d-020709
diagram
第九章附录
- 116 -
第九章附录
- 118 -
第九章附录
- 120 -
第九章附录
- 122 -
第九章附录
- 124 -
第九章附录
- 126 -
第九章附录
- 128 -
第九章附录
- 130 -
第九章附录
- 132 -
附录四 annexure four：卓轮减速机安装检修图 Zollern speed reducer

erection and maintenance drawing
1．主起升减速机 Main hoisting speed reducer（Total 7 pages）

2．牵引减速机 Pulling speed reducer（Total 6 pages）

丰汇 40t龙门吊 (MDG40&10-42) 中英文说明书

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丰汇 40t龙门吊 (MDG40&10-42) 中英文说明书

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MDG40/10-42 Type Gantry Crane

Shandong Fenghui Equipment Technology Co,.Ltd

Postal Address：No. 18 Zhushun Road Jinan Hi-tech. industrial

1、Crane group working grade 整机工作级别：A3

10320kg, bridge middle portion Ⅰ 10975mm by length, 6021kg by weight,

Main bridge truss portion all to be connected by flange apiece, it is connected

及桥架两侧腹杆连接螺栓均采用 M24 铰制孔用螺栓，桥架上弦水平腹杆连接

The movement mechanism is divided by rigid bracket mechanism and flexible

variation pulling mechanism on up floor. The imported inside concealed planetary

第三章 Erection of the crane 起重机的安装

10、Hoisting（2×145m）and pulling（90+55m）steel rope putting though and circling;

Safety precaution 安装注意事项：

2) The travel carriage should be correctly fastened on its securing

of the rigid leg, then cabin erection, further more erection

9) M24 reamer bolt –660NM; M24 铰制孔用螺栓--660 牛米；

第二节 Electric technical explanation 电气技术说明

1、Power supply system 供电系统

2．配电线路 distribution line

主要控配设备明细表 Detailed list for major distribution & control facility

5．电气设备安装 Erection of electric equipment

sub-mechanism trial operation.

K41、K02、K07、K40 接通。Navigate main lifting main command S40 to achieve

K222、K223 带电，接触器 K201 吸合，同时 K205 延时吸合，制动器打开（防

，这时，用万用表（置于直流 50V 档）测量给定

触器，操作人员完成工作离车时，应断开底部总电源。The “power off” button

第三节 安装螺栓一览表 Erection bolt listwise

第四节 主要部件清单 Major component list

第四章 safety operation of the crane

4.6 电动葫芦严禁倾斜起吊和超负荷使用，以防事故发生。To prevent form the

4.13 操作人员发现起重机有异常情况时，应及时向主管人员报告。Once crane

⑧大雪、大雾、雷雨天气或夜间视线不清不吊 It is not permitted lifting

第一节 主要外购件 Major outsourcing component

2 操作室 cabin 台 set 1

30 钢丝绳 steel rope 6×31SW -22 -1770 m 290 2×145m

32 联轴器 coupling MLL6-Ⅰ-250 台 set 1

33 制动器 brake YW250-500 台 set 1

34 减速器 speed reducer 卓轮 Zollen 4.19 i=71 台 set 1

35 钢丝绳 steel rope 6×31SW –16-1770 m 145 90+55 m

第二节 外购件供货商信息 outsourcing supplier information

1、行走减速器 Travel speed reducer

2、卓轮减速器 Zollen speed reducer

3、YW 系列电力液压块式制动器 series electric hydraulic block brake

Technical specification of speed reducer

1．主起升机构减速器 main hoisting speed reducer

1.4 建议润滑周期 Recommended lubrication cycle

1.7 推荐的润滑剂表 Recommendation lubricant table

CASTROL EPX 90 Alpha SP 220 Spheerol EPL 2

2．牵引机构减速器 pulling mechanism speed reducer

for grease（免维护 free of maintenance）。

3．大车行走机构减速器 truck travel mechanism speed reducer

Technical specification of electric hoist

1．名称 Description：CD1 型钢丝绳电动葫芦 Model electric rope hoist

闸次数（120 次）的情况下使用。It is prohibited running the hoist if the working

第五节 制动器技术说明 technical specification for brake

1．名称 description：YW 系列电力液压块式制动器 series electric hydraulic

1.溢流螺塞 overflow plug 2.注油螺塞 oil pouring plug 3.杠杆 lever

18.手动装置 Manual device 19.推动器接线孔 thruster unit wiring hole

z 制动轮温度不应超过 200℃。制动轮上发现有 0.5mm 深裂纹时应重新

Technical specification for cable winch

1．名称 Description：长期转力矩电机式电缆卷线器 Long term stop rotating

设置情况有一定的要求 If the cable is released or retracted, there shall be a

注意：不能注机油 Note: The engine oil could not be applied.

一 、 日 检 基 本 作 业 项 目 和 技 术 要 求 Daily inspection items & technical

第三节安装螺栓一览表 Erection bolt listwise

第四节主要部件清单 Major component list

第一节主要外购件 Major outsourcing component

第二节外购件供货商信息 outsourcing supplier information

第五节制动器技术说明 technical specification for brake

一、日检基本作业项目和技术要求 Daily inspection items & technical

第七章起重机的润滑 Lubrication of crane

第八章常见故障与排除方法 common trouble

一．电气备件清单 Electric spare list

1．主起升减速机 Main hoisting speed reducer（Total 7 pages）