Marine - Engine Room Crane

JIANGSU BOLIN MACHINERY MANUFACTURING CO;LTD Tel: 086-0523-84819600 Mail: bl@jsbolin.
com

1

Documentation
FINAL Drawing

Shipyard: Taizhou SanFu
Designation: Engine room crane
Type: Steel wire Hoist
Hull No.: SF060137
SWL 4t
Span: 5.6m
Language of Documentation: English
Classification: ABS
Supplier: BOLIN MACHINERY
MANUFACTURING
CO;LTD
E-mail: bl@jsbolin.com
Edition: A
Date: June 23

JIANGSU BOLIN MACHINERY MANUFACTURING CO;LTD Tel: 086-0523-84819600 Mail: bl@jsbolin.com

2
TABLE OF CONTENTS

Table of Contents.. 2
Description.. 4
Scope of Supply. 5
Paint System6
General Assembly Drawing...7
Tolerance of Runway.8
Details of the I beam by yard..10
Limit Switch CraneTrolley Travelling..11
Limit switch striker by yard...12
Rubber bumper..13
Hook Details...14
Drawing Hand Control Pendant..15
Blank Form for Spare Part Orders..16
Safety instructions.17
General...17
Safety..19
General Guidance on Hazards23
General Maintenance Procedure/wearing parts...26
General Instruction for Welding Work on the Crane/Trolley...27
Principle of Travelling...28
Assembling instruction for Welding Toothed Rack..29
General Lubrication Oil Chart..30
Initiation of Engine room Cranes 31
Testing of Cranes and Hoists with Testload.32
Hoisting motor manual.33
Travelling Motors & Gear box
Motor..55
Gearbox.59


3

BCQ Crane Overload Limiter..64
General description...65
Main parameter.65
Working principle..66
Operation instructions..66
Usage of Load Limiter..67

ELECTRICAL DIAGRAM.68
MANUAL RELEASE.72


4
DESCRIPTION

Hull: .SF060137
Type:Steel wire hoist
Capacity..4t
Test load..5t
Steel wire type6X37-14
Length of steel wireapprox. 41m

Hoisting speed8/0.8 m/min
Span.5.6m
Lifting height16m
Control cable length18m
Travelling speed..6m/min

Runway(by yard):
Weight:.4000Kg(without runway)
Dimensions(LXWXH)6000mmX1520mmX1308mm

Protection mode of motor..IP56
Insulation class of motorF
Supply voltage440V/60Hz
Control voltage24V
Limit switch..LXK3-20S/T

Operation.The operation of the double girder system
will be controlled pendant(approx.10m
cable),which is hanging down from the
crane.


5
SCOPE OF SUPPLY

Quantity Unit Description
1 pc Engine room crane SWL 4.0t
16 pc Toothed rack(LXHXW):1100mmX22mmX40mm welding on runway by yard)
1 pc Toothed rack mounting piece 22mmX40mmX300mm
Spare parts
1 pc Bearing: 6208
3 pc Fuse element 6A
1 pc Break ring
1 pc Push botton


6
PAINT SYSTEM

Trolley RAL 9003
Travelling Motor RAL 5012
Hoisting Motor RAL 6027
Note: 1x Epoxy primer , 2x Epoxy finish paint, total approx.160m
J/AAGCU ECL/A LACH/AER1 LAAUFACTUR/AG CC,LTD TeI: U-Uo2-4(9UU LaI: oI_/soIn.cm
8
According to CB-T 3012-92 standard
1. Distance between both ends of girder L12mm
2. Distance between girder at other position L23mm
3. As below drawings : bB/200, hH/300
9
4. Distance between bottom of girder h3mm at one section.
5. Distance between rack work of two girder should 5mm
6. Height error of girder joint f1mm
Side error of girder joint e1mm
Distance of joint g2mm
10
'HWDLOVRI ,EHDPE\\DUG
According to GB/T706 -1988 standard
11
/LPLW6ZLWFK&UDQH7UROOH\7UDYHOOLQJ
Type: LXK3-20S/T
12
/LPLWVZLWFKVWULNHUE\\DUG
Material: Q235B
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16
Blank Form for Spare Part Orders
This data is required to process your spare order!
Shipyard:
Hull No.:
Year of manufacture:
Serial No.:
Type of product:
ltem Pos Qty Description Pert No.
1
2
3
4
5
6
7
8
9
10
17
SAFETY NSTRUCTONS
*HQHUDO
Important informationThe crane|ifting gear must not be put to use before the fina|
|oad-and function test carried out by the c|assification society
How to Use These Instructions
These assemblyoperating and service instructions must be read thoroughly and
understood before the %2/,1 lifting appliance(cranechain hoistwire rope hoist
or trolley) is commissioned,and must be accessible by operators at all times during
use
By its nature a lifting appliance represents a potential hazard as a result of the lifting
and handling of loadsand so this chapter should be read with particular care and
attention
These instructions also contain dangerwarning and safety advice and instructions
Failure to comply with these instructions can expose persons to direct risk or to risk
from premature damage to the product
This hazard information must be complied withSubject to technical modification
without notice
Proper Use
%2/,1 lifting appliances are designed solely for lifting and also for the horizontal
off-floor handling of loads when used ln Conjunction with travel trolleysThe Safety
Working Load(SWL)as stated in the lnspection Schedule and on nameplatesthe
FEM classification and the operating time and number of switching operations must
be observed
The lifting gear can be operated as hoists mounted on static supporting structures or
as traveling hoists suspended from suitable running rails by means of manual or
electric travel trolleysln all cases the supporting structure must be adequately
designed having regard to the SWL and dead weight of the hoists and the relevant
regulations
18
The lifting appliances are designed essentially for operation indoors within
nonaggressive environments and at temperatures between,1 0,C and+45,C,
Higher ambient temperatures will require a reduction in the maximum operating
times
Non-standard operating conditions and configurations must be specially inspected
and agreedand the manufacture's approval may be necessary
lmproper use includes
* Exceeding the SWL
* Dragging loads at an angle
* Using the hoists in explosive area
* Pulling jammed loads free, dragging or towing loads
* Catching falling loads
* Carrying persons with the load or load carrying devices
* "Jogging('inching')operations
* Persons standing under suspended loads
* Slack chaining
* Straight reversingi.e. reversing the hoist while it is running
* lntentionally running up against emergency limit switches and end stops
Regu|ations'
%2/,1 lifting appliances are designedmanufacturedtested and must be operated in
accordance with China standards and regulations
Warranty
%2/,1 can accept no Liability for damage to the crane or hoist caused by
improper use or by work which has not been properly carried out or carried out by
unskilled personneland can accept no Liability for claims made by third parties
The terms of the warranty for the Lifting appliance are voided if the user alters parts
arbitrarilyassembles the item other than as directed in these instructions or uses
parts that are not %2/,1 original partslt is essential for the safe operation for the
product that only %2/,1 original parts are used
Safe operation within the stated service life can only be guaranteed when the lifting
appliance is operated according to its product classification and when these
assemblyoperating and service instructions are followed,Please refer to the
inspection Schedule or product data sheet for the drive group of your lifting appliance
19
lnformation on the theoretical service life of the lifting appliance will be found in the
appropriate assemblyoperating and service instructions
Other Information
The year of manufacture is shown on the product nameplate
To ensure that the product performs its tasks reliably and satisfactorily it may only be
operated, serviced and maintained by personnel who are duly appointed by the user
and who are familiar with these assemblyoperating and service instructions and the
relevant safety regulationse.g.
Accident Prevention Regu|ations
The assembly, operating and service instructions must be made available to the
appointed personnel at all times%2/,1 products are essentially maintenance-free
The limited amount of service work that is necessary must be carried out carefully and
according to the assemblyoperating and service instructions and the service
schedule
6DIHW\
0rganizationa| Information
The operatingservice and maintenance personnel must have read and understood
the operating instructions before they start work
The user has a duty to ensure that operation is safe and hazard-freeThis can be
assisted by a number of measures including
* Providing and publishing the operating instructions
* Testing the product prior to commissioning and after major modifications
* Performing the routine tests and inspections
* Logging test results in the lnspection Schedule and keeping the lnspection Schedule
in a safe place
* Keeping a recording of elapsed service life
Only reliabletrained and properly appointed personnel may carry out work on or with
the lifting appliance
The user has a duty to supervise the safety conscious handling of the lifting appliance
by his personnel
20
Safety Information for the User
A thorough knowledge of these assemblyoperating and service instructions by
operating and maintenance personnel is an essential of safe working practice
Any and all arresting devices must be released before the start of operation
The rotaryEmergency Stopswitch must be turned off in case of danger
At the end of work load carrying devices such as grippes and magnets must be
detachedThe empty hook pulled up and the lifting appliance moved to its park
position
Any arresting device must be engaged and the red rotaryEmergency Stopswitch
turned off
The relevant safety regulationse.g. Accident Prevention Regulations(UVV)and
official requirementsspecifically the operating regulations for hoistsmust be followed
when operating and servicing the lifting appliance
Users of Lifting appliances must follow the safety instructions given below
1. The user must ensure that lifting appliances and their supporting structures are
inspected and tested by an expert before first-time commissioning and before
re-commissioning following major modifications
2. The user must ensure that lifting appliances and their supporting structures are
inspected and tested at least once a year by an expertHe must also have them
inspected by an expert at other times as the need arises depending on the
conditions of use and internal company circumstances
3. The inspection and test before first-time commissioning referred to in Point 1
includes examining for proper assembly and operational readiness
4. During the inspection referred to in Point 2 the user must determine the elapsed
proportion of the theoretical service life of lifting appliances,He should appoint an
expert to do this if necessary.
5. The user must ensure that records are kept of the results of the tests on lifting
appliances carried out in accordance with Points 1 to 4
6. The results of tests on the lifting appliance must be logged in an lnspection
Schedule
7. The user may only entrust the assembly. servicing and unsupervised operation of
the lifting appliance to insured persons who are suitable and familiar with it
8. lnsured persons may not assemble. service or operate lifting appliances
unsupervised unless they have been appointed by the user for this purpose
21
9. The User must ensure that the operating instructions supplied by the manufacturer
is available and accessible to those insured persons to whom the assembly
servicing or unsupervised operation of the Lifting appliance has been entrusted
10. lf internal company circumstances so requirethe user must produce readily
understandable operating procedures in the language of the insured persons and
based on the operating instructions supplied by the manufacturer, setting out
measures for safe operation in accordance with company circumstances
11The insured persons must observe these operating instructions and procedures
12When assembling the lifting appliance the user must ensure that its control stand
is positioned or protected such that the lifting appliance operator is not put at risk
by the lifting applianceload carrying devices or the load itself
13The user must ensure that the lifting appliance is only mounted on structures and
suspensions which are capable of safely accepting the anticipated forces
14. The user must ensure that the lifting appliance is assembledpositioned or
attached such that its position cannot be accidentally changed by the forces
which occur during operation
15The user must ensure that the lifting appliance is assembled or positioned such
that load carrying devices is not drawn across edges and the chain is not
deflected to the side when it enters the lifting appliance
16The lifting appliance operator must ensure that load carrying devices is not drawn
across edges
17The user and lifting appliance operator must ensure that the safe working load of
the lifting appliance is not exceeded
18Where loads are lifted by several lifting appliances togetherthen the user must
ensure that the lifting appliances are selected and positioned such that individual
lifting appliances are not overloaded even when the load is unevenly distributed
19. The lifting appliance operator must test emergency stop equipment-except
slipping clutches-at the beginning of each working shift
20lf the lifting appliance operator finds obvious defects with the lifting appliance
including the load carrying devicesrollersequipment and supporting structure
he must rectify these immediatelylf this is not his responsibility or if he does not
possess the necessary skills he must take the lifting appliance out of service if
necessary and report the defect to the user
21. The user must ensure that loads are not slung by being wrapped around with the
22
lifting wire
22. lnsured persons must not sling loads by wrapping the lifting chain around them
23. The lifting appliance operator must not initiate any load movement until he is
satisfied that the load is safely slung and that personnel have cleared the danger
areaor after he has received a sign from the slinger
24. The lifting appliance operator must keep all movements by the loads and load
carrying devices under observation
25. lf the lifting appliance operator cannot observe all movements by the load or load
carrying devices from the control standthen the user must take precautions to
ensure that persons are not at risk from the load or load carrying devices
26. Where work is to be carried out on or beneath loads lifted with lifting
appliancesthe user must ensure that the loads are additionally secured against
dropping on stable supports before work commences
27. Where work is to be carried out on or beneath loads lifted with the lifting
appliancethe lifting appliance operator must additionally secure the loads
against dropping on stable supports before work commences
28. The lifting appliance operator must not leave the control stand of the lifting
appliance when the load is suspended
29. lf contrary to Point 28 the lifting appliance operator has to leave the control stand
when the load is suspendedthen the user must create the conditions whereby
the danger area beneath the load can be protected,
30. lf contrary to Point 28 the lifting appliance operator has to leave the control stand
when the load is suspendedthen he must protect the danger area beneath the
load
31. The lifting appliance operator must not carry persons with the load or load carrying
devices
32. The user must ensure that the lifting appliance is not used to handle molten
substances
33. The lifting appliance must not be used to handle loads which are jammed or which
can become caughtsnagged or obstructed as they move
34. The lifting appliance operator must not drive the lifting appliance against
emergency limits as part of normal operating practice
35. The user must take the lifting appliance out of service at the end of its theoretical
service life
36. Contrary to Point 35 the lifting appliance may continue in operation provided an
23
expert
a)confirms that there are no objections to continued operationand
b)the conditions for continued operation have been established These
conditions must be recorded in the lnspection Schedule
37. The user must ensure that continued operation complies with the conditions
according to Point 36 b)
38. lnsured persons may not carry out service and inspection work unless they are
satisfied that the lifting appliance has been switched o7"and locked outThey
may only carry out service work that cannot be done from the ground from work
stands or staging
39. The user must direct and supervise the following safety precautions for all repairs
and modifications to the lifting appliance and for work in areas where persons may
be at risk from the lifting appliance
a)The lifting appliance must be switched off and a locked out
b)lf there is a risk from falling objectsthen the danger area beneath the lifting
appliance must be protected with barriers or by posting safety assistants
c)lf the safety precautions described in a)and b)are not appropriate or not relevant
or adequate for company reasonsthen the user must direct and supervise other
or additional safety precautions.
40Following repairs or modificationsor work carried out within its danger areathe
lifting appliance may only be put into service when the user has approved the
resumption of operationBefore giving his approval, the user or his representative
must satisfy themselves that
a)the work has definitely been completed
b)the complete lifting appliance is in a safe condition
c)all personnel involved in the work have cleared the danger area
Caution!
Where the lifting appliance is suspended from a traveling trolley or cranethen the
Accident Prevention Regulations BGV D 6(VBG 9)Cranes which are not
reproduced here in full must be observed and complied with in addition to the
safety instructions listed
Genera| Guidance on Hazards
The product is designed to be operated on industrial power systemsThere are
24
hazardous live bare parts and movingrotating parts in the interior of the product
while it is in operation
Serious injury to persons and damage to property may result from
* the prohibited removal of covers
* improper use
* incorrect operation
* inadequate servicing and maintenance
Failure to observe the safety information given in these instructions may cause injury
or even deathThe product may constitute a danger to life and limb if it is operated or
used by untrained or inadequately trained persons or if it is not operated for its
intended purpose The user must ensure that his operator and maintenance
personnel receive training in good time before they work with or
on the productOwing to the risk of injuryegfrom becoming caught pulled into the
productthis personnel must wear no loose clothingloose long hair or jewelry
including rings(!)No work of any kind with or on the product may be carried out by
persons who are under the influence of narcoticsalcohol or medication which affects
their ability to reactContact with concentrated acids or alkalis can attack plastic
housings and cause dangerous corrosion of metal partsany parts affected in this way
must be promptly replacedThe product must not be used in areas subject to
explosion hazards unless specifically prepared for this purpose
During operation
All actions specified in the instructions both before during and after commissioning.
and guidance on general safetyespecially those affecting operational safety and
accident preventionmust be strictly followedfailure to do so may cause accidents
with fatal consequences
The use of prohibited or unsuitable tools or equipment can cause injuryThe
movement or rotation of parts can cause pinch andor shear hazards both on the
product and between the product and parts of lts surrounding areaadequate safety
distances from moving or rotating parts should be maintained at all times to prevent
persons from reaching into them and clothing, parts of the body or hair from being
caught
Extreme heat (e.g. from welding)sparks produced when using cleaning agents and
naked flame in the vicinity of materials that are flammable or which can distort in
heat(egwoodplasticsoilsgreaseselectrical plant or cables)must be avoided
25
otherwise there is a risk of fire with the release of hazardous gases or damage to
insulation etc
Measures for Ensuring Safe Working Periods
The EC Machine Directive stipulates safety measures for avoiding hazards with hoists
as a result of material fatigue and agingThe following measures have therefore been
taken to ensure safe working periods(SWP.)
Record of Operating Performance
The user has a responsibility to ensure that the actual operating performance of the
lifting The actual operating performance is not inspected or if this is not possible or if it
is only estimatedthen the general overhaul(GO)according to Point 244 must be
carded out after 10 operating years at the latest
Assessment of the Safe Working Period (S.W.P.)
The expert responsible for inspecting the production hoist must check at every routine
inspection whether the production hoist is still being used within the S.W.P.
Further Safety Instructions
Please also pay attention to the relevant information given within the operating
instructions of the individual components
26
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A Visual inspection and trial braking without load before use are required to ensure
safety
The following maintenance jobs and periodic tests must be carried out at given
intervals in order to maintain operational reliability and prolong service life
Oil changelubrication and inspection of components subject to wear as shown in
below table
This table is a general guide
Please also refer in any case to the safety and maintenance instructions in the
manuals of the individual components
lt goes without saying that any component which shows signs of damage must be
inspectedexchanged at once
27
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ATTENTION:
Before we|ding the crane / tro||ey must be grounded!
28
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P|ease take care that toothed rack and pinion are a|ways we|| greased!
29
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Assemb|ing procedure
1. Align and fixate the toothed rack sections using the mounting piece for correct
spacing.
2. Fixation with screw clamps
3. Before welding, all toothed rack sections have to be assembled and fixed.
4. Pre-heat toothed rack to approx. 100 degrees Celsius and keep this temp.
5. Beginning in the middle, weld toothed rack using back-step method.
30
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After assembling the engine room crane it is necessary to check every bolt
connectionwhich was unscrewed for assembling Please note the required torque of
the screws
1 Before first-time commissioning the user must ensure that there are no obstructions
such as cablesladderspipes etc in the line of travel.
2 The equipment must be operated from a three-phase power supply with a clockwise
phase sequence to ensure the correct functioning of the limit switches Please
compare the direction of symbols on the control pendant with the motions of the
cranetrolley
3 The stopping cams of the limit switches on the cranetrolley have to be installed
and adjusted The cranetrolley has to break with a distance of 100 mm to the end
of the track or an obstruction The stopping cams must be made available by yard
and must be modified in accord with the given circumstances
4 lmportantBefore initial operation the cranepinion and toothed rack must be
greased
ATTENTION
During we|ding on crane or tro||eyyou have to take care that the we|ding has an
abso|ute|y separate we|ding ground. If notany guarantee wi|| expire
32
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Testing of craneshoists with overload was carried out during the Work's Test and
the lnspection Test .The tests were carried out by crane experts or a surveyor of a
classification society resp.
The overload protection of cranes and hoists is adjusted at delivery so that working
load can be lifted safely The cranes and hoist are herewith protected against overload
An adjustment for higher load is not allowed
33
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35
Sanma-Brand electric hoistsMD model are uniformly designed light hoisting
equipment based on national standardThe MD model electric hoist has an auxiliary
hoist motor and a set of slow driving unitwhich enable the hoist to have two hoisting
speed(normal 9.6 m/min and slow 0.96 m/min)
1. Mode|
Model.................MD
Hoisting Capacity............0.2510(tons)
Hoisting Height.............3-30(m)
lnstallation or Working mode........D-electric wagon mode
A1A2A3A4- fixed mode
ExampleMD2-6D represents a wagon type electric hoist with a hoisting weight
of 2 metric tons and a hoisting height of 6 meters
2. Usage
MD model electric hoists are light hoisting equipment commonly used in
factoriesminesportswarehousesdepots and marketplacesetcThe hoists have
a working class of 3 with their bodies fixed to or suspended through a wagon to a
"H-type'' steel beam and travel along either direct or profiled tracksThey can be
integrated in various hoist equipment to hoist heavy cargossuch as single beam
cranes or suspended hoisting systems. Thereforethey are indispensable mechanical
equipment in improving working conditions and enhancing productivity and also are
preferred equipment for manipulating cargosParticularly, they are ideal for the
following applications
1. Used in public facilities and construction fields for easy installation and
removal
2. Used in machinery factoriesequipment installationmounting or dismounting
of parts in machinesas well as transportation of finished products
3. Used in production lines
4. Used as simple elevation equipment and used for food transportation and
cargo lifting
3. App|icab|e Environment
MD model electric hoists are general-purpose steel rope hoists with a rated 10
minutes working cycle period a lasting energizing benchmark of40%and an
equivalent hour starting number less than 120 times
The rated power supply to the main circuits of the electric hoistsAC 440 voltage,
60 Hz
36
The work environment of electric hoists-25+40
The electric hoists are not designed for use in circumstances with relative
humidity above 85%or circumstances full of corrosive gasesThey cannot be used in
substitution for anti-explosive hoists and cannot be used in hoisting melted metals or
flammable or explosive substances
The electric hoists shall have shield hood for rains and snows if used outdoors
37
IIMajor Technical Parameters of MD1 Electric Hoist
Table lists the major technical parameters of MD electric hoist
3DFNDJLQJ/LVWRI(OHFWULF+RLVW3URGXFWV
Note: No oil added to hoist decelerator. Oil application by customer according to table 4 needed
MD Model 5 ton
NO. Name
Unit Amt. Remark
1 Main body pc 1
2 Soft cablein-feeder set 1
3 Electrical control unit set 1
4 Screw bolt M5X14 pc 4 For limiter
5 Screw bolt M8X16 pc 2 For flexible inlet
6 Spring5 pc 4 For fixing wire box
7 Spring 8 pc 2 For flexible inlet
8 Washer5 pc 4 For limiter
9 Hooking unit set 1
10 Rope clip pc 1
11 Packaging list pc 1
12 Hoist quality certificate pc 1
13 Hoist operation manual pc 1
38
Main parameter of capability
Hoisting capacity 5 t
Hoisting height 18 m
Hoisting speed 8/0.8 m/min
Rope diameter 14 mm
Specification(GB918) 6X37 Steel rope
Length 41 m
Specification(GB918) 25a~63c
Track
Min. curvature 2.5 m
Rated voltage 380/440 V
Power supply
Rated frequency 50/60 Hz
Number of switch-on 120 Nos./hour
Model ZD41-4
Power 7.5 KW
Rotation speed 1400 Tums/min
Main hoisting
motor
Current 18 A
Model ZDM21-4
Power 0.8 KW
Rotation speed 1380 Tums/min
Minor hoisting
motor
Current 2.4 A
44
IIIStructure and Operation
The main structure of a MD model electric hoist consists of three major parts
hoisting mechanism and electrical unit . See figure 1-4 for its schematic drawing
Electric hoists with hoisting capacity of 0.55 tons and hoisting height of 39
meters consist of decelerator 1winding drum 2steel rope guide 3dual-motor
group(MD model)4hooking unit 5 etc
1Hoisting Mechanism
The operation of hoisting mechanism of MD model electric hoist is to drive the
winding drum clockwise or counterclockwise by the heisting motor through a
couplerThen the steel rope on the rotating drum will bring the hooking unit up and
down through the rope guide.
The hoisting motor is a conical rotator motor with braking unitlf the motor is in
idleThe conical brake will clutch in the back cover of the motor and force the motor in
constant braking state During operationafter the motor is switched onthe conical
rotator will generate axial magnetic forceThe magnetic force will overcome the spring
force andby driving the fan brake wheelmake the brake ring to declutch the back
coverThen the motor will work normallyWhen the motor is switched off, in the
absence of axial magnetic forceThe fan brake wheel will restore the clutched state
under the spring force and keep the motor in braking state
The dual hoisting speeds of MD model electric hoist are achieved by the
combination 0f main hoisting motor, slow hoisting motor and slow driving unit When
the main hoisting motor worksthe slow driving unit will not work due to the braked
slow hoisting motor in switched-off stateAt this timethe back cover of the hoisting
motor serves as the brake When the slow hoisting motor worksit will drive the conical
rotator of the main hoisting motorThis timethe main hoisting motor does not work
and the fan brake wheel will serve as a clutch the whole system relies on the slow
heisting motor for braking and thus generates two hoisting speeds.
2E|ectrica| Unit
The unit consists of fin electrical control boxControl push buttons and hoisting
limiters. Except for controlling the hoist systemthere is still a pair of redundant push
buttons for the control of other mechanism The push button themselves have interlock
mechanismsWhich prevent the error operation.
45
The hoisting limiters are used to prevent accidents caused by heavy cargo's
traveling out of up or down limitation from happeningWhen a heavy cargo reaches its
travel endsit will drive the stopping block on the limiting rocker shaft of steel rope
guide The rocker shaft will trig the limitersswitch off the main circuit or electrical
control box and stop the heavy cargo moving upwards or downwards
IVElectrical Control
ln ltem "ELECTRlCAL DlAGRAM
IVElectrical Control
1. The package of an electric hoist should not be open until its installation to
avoid any problem due to poor storage condition if opened early,After the
package is opened, please check the product and technical documents
according to the Package List for any missing or damageAny damage
occurred during shipment shall be repaired prior to the installation
2. Customer should choose a standard structure or self-design the structure of
"l steel track or any construction with such track for travelling of electric
hoistSee table l for the specification of the"lsteel
3. Elastic buffer or wooden(or rubber)blockade shall be mounted at the both ends
of the "l type steel track with the same height as the wagon wheel to prevent
the electric hoist from derailing
4. The "l type" steel track shall have a reliable grounding linewhich is
normally a naked copper line of 4-5 mm diameter or a flat steel band with a
cross section area above 25mm
5. Lubricant shall be filled up according to table 3

6. Sometimesthe motorafter switch-onwill not start due to adhesion of brake
ring caused by its susceptibility to temperature or humidity influenceTo
correct thisfollow the below proceduresremove the wind hood of the motor
insert a screw driver or other similar shaft into the interface between fan
braking wheel and the back coverpry the fan braking wheel axially for
separationThe motor will be now ready for workThenre-install the wind
hoodSee the figure below
46
iRemove the motor wind cover and check the axial free space 0fthe
fan-braking wheel with a lever 3 Normally the free space should be
about 2 mm.
ii. lf the brake slippage increases after a period of operationplease do the
following procedures for correctionloose the screw 1, Turn the
adjustable lock nut 2 counter clockwise for 1-2 scales and retighten the
screw 1
7. Check the normal functioning and agility of the hoisting limiter 1(the limiting
shaft 4 shall be inserted into the switching shall 2 of the limiterAt user's will
the stopping block 3 Call be set to a specific position according to actual
hoisting height and tightened on the limiting shaft as illustrated below)
47
8. A thorough inspection shall be performed upon the final assembly of an electric
hoist
(a) Check the accordance between field power supply and electric hoist
requirement The tolerated voltage fluctuation shall be+5%10%
(b) Check the wire connection for error
(c) Check all lubricating points for proper lubrication
(d) Check the tightness of steel rope 1 and the inserting block 2as well as the
clamp 3 (as below)
(e) After installing the electrical equipmentcheck the insulation resistance
between the live parts in all power circuits and control circuits and ground
to be above 0.38 MD
9. Power supplying
Rubber insulated soft cable shall be used as required in ease the cable
supply method is to be adopted
i. The cable shall be of suitable length and out of any connector and be
connected directly fnc0 the terminals of the electrical control box
iiThe cable shall be fixed properly to avoid a direction application of cable
tension on the wiring portion of the terminalProper wire gauge shall be
selected based on power supply distance to avoid over drop of power
voltage
iiiThe tension steel wire attached along the cable of push button box shall
be adjusted before the operation so that the steel wire undertakes the
tension to relax the cable when the pushbutton box is in suspension
48
10. Normally, when the hook is put to its lowest point, the newly installed steel
rope will twist together to a certain extent At this timeloose the rope-fixing
insert iron at the back of outer drum case, remove the steel rope end
completely release its internal stress(turn the rope end) until the two ropes
do not twist again
11The procedures of test running
(a)Test running with no load-operate the motors in each mechanism without
load to run positively or reverselyCheck the control circuit for proper
functioningcheck the direction of hoisting and the indication on control push
button for proper correlationcheck the function reliability of electrical
equipmentsuch as hoisting limitersetc
(b)Test running with static loadkeep the travel system still and hoist a 125
times rated load above the ground 100 mm for 10 minutesAll mechanism
shall be in their normal state.
(c)Test running with dynamic load-Based on the good static load test resultthe
test running with rated load shall be performed, repeatedly hoist the load up
and down and travel left end right for at least 15 minutesAll mechanism
shall be in their normal state. The load slippage after braking shall be less
than 80mmOtherwise, the brake system shall be adjusted accordingly
See the following figure for adjustment methodLoose the screw 1 at the end of
motor spindleTighten the lock nut 2 to reduce the gap between the braking
ring4 of fan-braking wheel 3 and the back cover 5This will increase the
pressure of brake spring 6 and acquire bigger brake momentThe axial free
space should be 1.5-3 mm (may be measured through repeated start)
49
VIMaintenance
1. The electric hoist shall be operated by dedicated operator, who is familiar
with the safety operation regulation
2. Each time prior to the normal operationthe operator shall test electric hoist
with empty load and check the following items
(a) Check the push button for proper control of the hoist's up and down
(b) Check the proper functioning of hoisting limiters
(c) Check for abnormal sound or odd smell during operation
(d)Check for the proper winding of steel rope
The electric hoist cannot be set into use until the abnormal occurrence is
eliminated if any
3. Hoisting overload cargo is strictly prohibitedwhen hoisting a cargo with
weight approaching the rated 10adthe operator shall have the proof of
weight or estimation
4Hoisting cargos aslant is prohibitedAnd alsodragging cargo along the
ground by hoist or hoisting cargo with tip of the hook is prohibited
5Each time when hoisting a cargothe operator should first jog the pushbutton
to tighten the steel rope and then continue the hoisting to see if the steel
rope is clamped tightly
6. The hoisting limiter is all insurance gadget used to prevent the hook from up
or down traveling out side the limiting position during hoistingwhich can
neither be frequently used as a travel switch nor be removed
7. Jogging the hoist excessively should be avoided
8. During installation end maintenance, the hoisting 1imiter shall be strictly
checked fur its proper functioning When the hook rises to its upper
limitationthe distance between the out case of the hook and the out case
of the winding drum shall be greater than 50mm When the hook reaches to
its lower limitationThe number of safety turns of steel rope on the drum
shall be adjusted to an effective number of above 3 turns
9. The elastic buffers or blockades on both ends of the"Hsteel track is only
used as a curb in case of any event and shall not be collided frequently
during normal operation
10lf the brake system fails to function during operation and the cargo falls
rapidly, the operator shall press the UP push button instantly and let the
cargo rise a distance and then press the DOWN pushbutton to enable the
50
normal falling of the cargo Once the load is removedcheck the cause
immediatelyNormally, the hoist slipping Call be eliminated after propel
adjustmentlf the adjustment does not workthen careful check shall be
performed on braking spring for crackson surface of braking ring for
grease contamination and on the braking ring itself for any damage.
11. lt is not preferable to suspend a cargo on the air for along period of time to
avoid a permanent transformation of parts
12. lf the push button fails to work during operation or the contacts welds
together, the general power supply shall be switched off immediatelylf the
system adopts XLDl5 control boxThe general power supply can be cut 0fr
by gearing the switch to Power-off position
13. After operationthe empty hook shall be suspended at least 2meters above
the ground and the general power supply shall be switched off.
14. Check and ensure all lubricating points are applied with enough lubricant
/greaseAs below table:
15. lf the steel rope looses and twists together, the proper solution is to remove
the rope guide and reinstall it after clearing up the twistLoosing steel rope
by rotating winding drum shall be avoided to prevent damage of the rope
guide or rope's jamming into side of drum from happening
16. Periodic complete maintenance shall be performed according to the
operation duty of the electric hoistNormally, such maintenance shall be
performed annually
17. Replacement of steel rope
lf a surface prefect steel rope is proved to have up to 22 strands of internally
broke steel wires in a single segment between two twist nodesthe steel
rope shall be replaced with new ropeThe following table is the standard for
replacement of surface worn or corroded steel rope.
51
18. After long term's operationif the braking ring is no longer serviceableis
shall be replacedThe replacement procedures are as following
Remove the fan brake wheeland then remove the old brake ring Note to
remove any bur caused by the old ring Put a new break ring on the fan
brake wheel and knock the ring evenly and roundly into the trough. Then
the process the braking surface of the brake ring with a lathe machine to the
required taper (203')

52
VIICommon Problems and Troubleshooting
53
VIIISafety Issues
The following issues shall be noted upon understanding the above content
1. The electric hoist shall be operated by a dedicated operator, who is familiar with
the safety operation regulation
2. The operator shall not operate the hoist until heshe read the operation manual
and the content of name plate
3. The upper and lower mopping blocks shall be adjusted prior to the operation
4. The brake system shall be checked for functioning reliability prior to the operation
5. The electric hoist cannot be operated if the steel rope is found to have following
condition
(1) Curving, transforming and corrosion, etc
(2) The broken condition of the steel rope exceeds the requirement or
excessive worn occurs
(3) Random winding of steel rope on winding drum
6. Prior to the installation of an electric hoist, please use a 500V insulation meter to
check the insulation resistance of motor and electrical control boxthe electric
hoist can be operated on condition that the resistance at the ambient temperature
and in cool state exceeds 5MD
7. Hoisting overloading cargo or unclear cargo with a weight potentially exceeding
the rated weight is strictly prohibitedThe rated hoisting weight is declared on the
nameplate of the hook
8. Riding on the hoisted cargo is prohibitedFurthermoreit is forbidden to use the
electric hoist as the hoisting mechanism for a man-carrying lift
9. lt is forbidden for any person to stand under the hoisted cargo
10. Hoisting can not be performed if the cargo or the hook is swaying
11. The electric hoist shall be driven right above the cargo to hoistAslant hoisting is
not allowed
12. The hoisting limiters can not be used as travel switch for a repeat abuse.
13. Hoisting all object rooted in the ground is not allowed
14. Suspending a cargo in the air using the electric hoist for a long time is not
allowed
15. Pulling an object by push button control box cable is not allowed
16. The power supply shall be cut off prior to a maintenance work
17. The maintenance work shall be performed under empty load situation.
54
18. Check the inserting iron for its tightness before operations
Cautions
To ensure the safety and re|iabi|ity of an e|ectric hoistcustomer sha|| check a||
connections comp|ete|y based on the maintenance and |ubrication period of the hoist
and tighten each screw and nut as requiredAny |oose screw or nut during operation
sha|| be time|y e|iminatedOtherwise, the user sha|| assume a|| the damage and |ose
caused according|y
.
IXQuality Warranty
Company Commitmentlf any quality problem arises on our electric hoistswe
will take action within 24 hours upon notice
1Quality insurance and reparation of electric hoists
We will lawfully assume liability (see the insurance policy of the product) and
provide indemnity for user's casualty or direct economic damage due to the
quality defects of our products
We will provide refundfree replacement and free reparation services on our
product in case that any quality problem due to material or workmanship defects
occurs within one year's normal usage
2The following conditions are not within the quality warranty coverage
The user fails to maintain the hoist according to the requirement or exceeds its
technical limitation during operation
The quality problem is due to that the user self-replaces any parts and fails to
install the standard parts supplied by our company
Any indirect damages caused by quality problem of our products
Any damages due to user's improper storage and operation
Normal degradation caused by long-term operation
3Reparation of Electric Hoist
Our company will provide lifetime reparation service on our sold electric hoist
products
The parameters specified in this manua| are sub[ect to new deve|opment of our
productsIn case of any unconformity between physica| products and this manua|
the parameters specified in the manua| attached to the product app|ies
55
7UDYHOOLQJ0RWRUV*HDUER[
Gear box Type: NMRV090 i=60
56
BCQ Crane Overload Limiter
OPERATON MANUAL
57
58
59
Ele. Motor Type: Y90L-6-H

60
61
62
63
64
7DEOHRI&RQWHQWV
1. General description
2. Main parameter
3. Working principle
4. Operation instructions
5. Usage of Load Limiter
6. User notice
:X[L+H$Q/LIWLQJ0DFKLQHU\)LWWLQJ(TXLSPHQWV)DFWRU\
65
General description
As a kind of mechanical safety protection device, BCQ Crane Overload Limiter can
be used in lifting equipments such as bridge crane, door crane. This device consists
of sensor. Display screen and pressure block.
The load limiter is designed with the single-chip micro-processing technology and
has capacity of automatic checking and inspection. The advantages are strong
function , compact structure easily operation and installation , working stability.
Main parameter
1. Scope of applications
Force on single wire < 10t
2. Deviation of Load Limited
< 5%
3. Alarm way
a) Pre-alarming: When lifting weight is of 90% rated weight, successive
pre-alarming is generated, the weight is shown on the screen.
b) Delay alarm: Delay 3s at 105% of the rated lifting weights, and right now if
it is still 105% of the rated lifting weights, successive alarm is generated,
contactor source of crane for lifting will be cut off automatically, the weight
is shown in the screen
c) lnstant alarm: When lifting weights is of 130% rated weight, contactor
source of crane for lifting will be cut off immediately and successive alarm
is generated, the screen flickers to display weight.
4. Working temperature: -10~+60
5. Supply Voltage: 380V/440V
6. Display way: 4 figures of LED digital displayed.
7. Grade protection of sensor: lP56
66
Working principle
lt is used a sensor to monitor force in single wire, then compare setting SWL with
lifting goods, if weight of goods reached 90% of SWL, Alarm will make intermittent
warning sounds to remind operator , lifting normally at the same time
Delay 3s at 105% of the rated lifting weights, and right now if it is still 105% of the
rated lifting weights, successive alarm is generated, contactor source of crane for
lifting will be cut off automatically, the weight is shown in the screen
When lifting weights is of 130% rated weight, contactor source of crane for lifting will
be cut off immediately and successive alarm is generated, the screen flickers to
display weight.
After cutting off the contactor source of crane for lifting, the crane will stop working at
the position of unsafe, but it has no affect on other movements.
Above performance for load limiter can make a protection of load limited.
Operation instructions
Connection type as below:
Cable of sensor joint as color shown on above
Cable of alarm joint with 6 7
67
8 & 10 used for power supply
11 & 12 used for control
1) The electrical control box is hang mounted inside operator cabin for the
convenience of observing, but it can't impede the operation sight for driver.
The installation should be stability
2) Electrical control box shall not be installed in places where are rained or water
sprayed.
3) 440V source for electrical control box should be connected with control source of
crane, if only crane is under working condition. The electrical control box must
powers on automatically and won't be controlled by other electric equipments
4) PVC insulating sheath shielded cables are used for the connection of sensor and
electrical control box, and hang on cable bracket with other control cable,
moving with other control cable, moving with trolley of crane
5) The shell of electrical control box should earth reliable
6) lnstallation and wiring of electrical control box should comply with relative
requirements clause 3 in GB6067-85 Safety Specification for lifting
Machinery).
Usage of Load Limiter
Check all cables and supply voltage prior to the load limiter is being used Only no
error, can source be got through
After getting through the source, microcomputer in controller begins to check and
adjust the system:
1. Lifting empty hook off ground, zero clearing
2. Lifting counter weight, adjust figure shown on screen same with it
3. Overload Limiter can used immediately because it is setting already in
workshop
4. lf want to try 1.25XSWL testing, control cable should remove , but can still
show weight of testing weight and alarm.
User notice
This device should check every 6 months , include displaying accuracy , alarming
function.
68
(/(&75,&$/',$*5$0
0DQXDO5HOHDVH
lf power supply is break and goods lifting in the air, connect Nut A with screw at the
end of fan ,turn haulm in this direction, then goods will down.

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JIANGSU BOLIN MACHINERY MANUFACTURING CO;LTD Tel: 086-0523-84819600 Mail: bl@jsbolin.

5. Lubricant shall be filled up according to table 3

J/AAGCU ECL/A LACH/AER1 LAAUFACTUR/AG CC,LTD TeI: U-Uo2-4(9UU LaI: oI_/soIn.cm

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