LX Type Electric Single Beam Suspension Crane

I. Introduction of LX Type Electric Single Beam Suspension Crane
This crane is applicable in factories, warehouses for goods handling where the height from the rail surface to the lower edge of the truss is equal to or shorter than 500mm. The trolley is equipped with a specific electric hoist that features flexible structure and reliable and safe operation. With the supporting of Model CD1 or MD1 Electric Hoist, the Electric Single Beam Suspension Crane is designed and manufactured as one small-sized rail lifting machine according to the latest national standard. The lifting weight is 0.5t to 5t, and the span is 3m to 16m. The classification group is A3 – A5, and the operating ambient temperature is-25℃ to 40℃. It has three operation modes: ground handle, wireless remote control and cab.

II.Products Parameter of Electric Single Beam Suspension Crane

It has six standard lifting weights (namely 0.5t, 1t, 2t, 3t, 5t, 10t ) , four hoisting heights ( 6m, 9m, 12m, 18m); the span ranges from 3m to 6m.

III.Instructions of LX Type Electric Single Beam Suspension Crane
1. Drivers of the crane must meet the demands of the files “GB6067-85” Safety Rules of Lifting Appliances.
2. It’s not allowed to lift loads beyond the specified lifting weight.
3. Be sure that no one is under the crane when you are working.
4. Lifting appliance should above one person’s height when the crane travels in the air.
5. The lifting appliance must keep vertical when lifting, and it cannot be used in moving or burying things under the ground.
6. It’s not allowed to reversely rotate the motor to braking unless an emergency happens.
7. The limit switch works only under incorrect manipulation or negligence. Do not use the switch to cut off the power.

IV. Installation instructions of the Single Beam Suspension Crane

1. Construction preparation
(1)The construction managers and safety supervisors should survey the environment, roads, power and lighting facilities, and estimate the net space and limiting dimension (by the reference of rules JB/T1306-2008) of the construction site according to the installation contract.
(2)Check and measure the crane beam as required in the files of GBJ301-88 & G328. Take actions when the crane below the demand.
(3)Mangers should determine a scheme to unload the equipments, and choose a right place to store them by the practical construction site.
(4)The construction managers should make the construction scheme, confirm the date of construction, arrange the staffs, exchange the skills, and prepare construction equipments, tools, and safety products. Prepare the identifying paper if necessary.

2、Staff criterion
(1) The installers should be in good health with license and strictly install the crane in accord with installation rules.
(2) Put on uniform, footware, safety gloves and helmet before you enter the construction site. Tighten the safety belt when you climbing high.
(3) No drinking and smoking at the work site. Stay away from the other equipments of the project part.
(4) Fasten the safety belt on a stable object when you are working high above the ground. No littering includes the tools.

3. Site preparation of LX Type Electric Single Beam Suspension Crane
(1) Let the workers unload the products and construction tools, then store them in a designated place.
(2) The construction managers show the working site, explain the requests and security matters to the workers.
(3) Specially-assigned worker check whether the contents is complete, proper, intact or not.
(4) Check out the boundary dimension, appearance quality and the major components. Contact the department in charge timely if there are any problems with the goods
(5) Examine the steel rail by the rules of Chapter Three in GB50278-98. Flame straightening or other methods could be used for non-compliance.
(6) Get all the assembly components ready for installation.
(7) Piece the end girder and the main beam together according to the working drawing, so does the actuating drive. Reexamine the dimension of the crane in accordance with the Chapter Six GB50378-98.
(8) Install the electric hoist and electric cabinet on the crane; Cable and wire it as shown in the Figure. The installation of the electric hoist should be conforming to the rules of Chapter Four GB50278-98.
(9) Fix the electric hoist in the middle of the beam temporarily with hemp rope.

4. Rail-laying of LX Type Electric Single Beam Suspension Crane
(1) Affirm the datum line of the railways in accordance with Chapter Three GB50278-98, and use the lorry-mounted crane to lay the rails preliminarily.
(2) Connect, straighten and fix the rails in advance, then interlace the joints of the two tracks by the reference of the Chapter Three GB50278-98.
(3) Use the rubber plates or steel plates to adjust errors of the span, the height, and the standard height of the same section of the rails by the reference of the Chapter Three GB50278-98.
(4) The track gauge is ±8mm; The longitudinal gradient should within the limits of 1/1500. The difference of the peak and the nadir of the rails should be less than 10mm; the joint gap of the rails should be limit up to 1mm; any of the longitudinal gradient of the rail should keep in the limits of 1/1500. The maximum of the track topmark should under the limits of 20mm in the whole course; the nonstraightness of the track should be no more than 3mm.
(5) Fix the flat fishplates, pressing plates and the hooked bolts tightly.
(6) Weld the car stop on the ends of the rails so that the bumper can contact them according to the rules of GB-325.
(7) Install the grounding devices in accordance with GB50256-96, and the ground resistance should conform to the standard code.

5. Installation of the trolley lines/ the reel flexible cable
Install the safety trolley lines or the reel flexible cable to reach the rules of 2.0.11 GB50256-96.

6. Complete machine hoisting
(1) The driver take a seat in place, then let the hydraulic leg down.
(2) Thread the steel cable into the lifting hole of the beam, bolster the steel cable and the beam and fasten the traction hemp ropes.
(3) Lift the crane lever in the air (10-20cm) to check out the balance, and you can transfer the hoist to keep the balance of the crane.
(4) The construction managers conduct the all the worker in their position to raise the crane in a proper height evenly above the rails, then pull the hemp ropes to get the wheels on the track.
(5) Loose the steel cable, ropes and drive the lorry-mounted crane away.
(6) The distance of the bridge cranes is 16.5±5mm; the difference of the diagonal is ±5mm; the tga of trolley wheels is equal to 0.005-0.0030; the tg0 of the wheel’s horizontal curve is equal to -0.0015; connect and tighten the screw and gas cushion.
(7) Hoist installation
You can adjust the gasket of the bolt to debug the driving distances (range from 3 to 5mm) of the hoist.
(8) Cab installation
The ladder of the cab should be weld tightly, and cab must be installed uprightly.

7. Electrical mounting
(1) Connect the safety trolley line collectors/ reel flexible cables according to the Product Figure.
(2) Install the limit switches in accordance with the Product Figure.
(3) Install the three-phase power lamp in the end of the track.
(4) Install the air switches of the power, then connect them to the safety trolley lines/ reel flexible cables.
(5) Survey the resistance of the major electrical loop and the control loop by the reference of GB50256-96.
(6) Check out the resistance to ground of any location of the track and crane according to the rules of GB50256-96.
(7) Electrical installation must be conform to the standards of GB50256-96 and GB6067-58.

8. Inspection after installation
(1) Check out term by term and record them according to the Self-inspection Record of Single, Double Beam Crane and the Report of the Completion Acceptance.
(2) Reexamine whether the joints have been fastened or not. If the joints become loose, you should fix them.
(3) Check out all the components whether they are complete and valid.
(4) Add lubricating oil to the hoists and actuating devices, etc by the reference of Product manual.
(5) Reexamine the insulation resistance before in an energized state. You can have a electrical test and commissioning after confirming all the things are ready.

9. Machine debugging
The debugging of the complete machine should be cohering with the standards of JB/T1306-96, GB6067-85, GB50278-98 and GB50256-96.

V. Trial operation of the LX Type Crane


Before the operation of the crane, the workers should check out the machinery and all the parts of electrical equipment seriously. The joints of the parts, the lubrication of the components, the positive/negative inversion of the electric motors, and especially the direction of rotation of the two electric motors should be examined earnestly.
Trial operation could be carried out under proper functioning of the crane. Here are the three steps:

1. Test runs with no-load of the LX Type Electric Single Beam Suspension Crane
(1)Turn the head blocks of all the parts manually to make sure that the last axle (for example the axletree) won’t be get stuck per rotation.
(2)Hoist travelling: Under normal circumstances, no slipping when the hoists without any load travel three times back and forth on the track. The main wheel should come into connect with the tracks along. Start and stop device should be in good condition. The limit switch acts precisely. The buffer of the hoist should fit the collision domain of the crane bridge.
(3)Empty hook lifting: Press the button box on the ground to go up and down for three times. The operational motions should be accurate and reliable.
(4)Drive the hoist to the midspan. Let the crane move twice along the workshop to verify the house racks and tracks. Then drive it three times back and forth in its rated speed to test the quality of the work about the travelling mechanism. Under the circumstance, the wheels should move placidly without slipping, and the buffer works well when you start or stop it.

2. Procedures for test run with static load (it’s necessary to regulate the brake of the hoisting mechanism to test with overload):
(1)Drive the electric hoist to the extreme position, then mark the zero position of the midpoint in the girder after the machine becomes smoothly.
(2)Move the electric hoist to the mid part of the girder, then elevate placidly and load it to the rated lifting capacity (suspend ten minutes with 100mm liftoff distance). Measure the deflection of the mid part of the girder, and the deflection must be less than 1/800 of the span length. Test three times as the above steps with intervals (≧10minutes), and assure there is no residual deformation after unloading of the third experiment.
(3)After finishing the experiments above, you can test the machine with a 25% load over the rated one (namely lift 1.25 times of the elevating capacity), and it is the same method as described before.
(4)Verify the crane after all the trials, and it is not allowed to generate any cracks, loose joints or damages on the crane.
To minimize the impacts caused by elastic deformation of the crane on the Trials Record, you should drive the crane near the pillars of the factory during the test run with static load.

3. Procedures for test run with dynamic load
(1)Let the crane lift the rated weight, then start, stop, corotate, contrarotate the machine no less than 10minutes repeatedly. Meanwhile, the limit switch and electric control should be accurately. The wheels wouldn’t slip, girder vibrates in normal, joints connect tightly, every parts and components have no cracks and damages after unloading.
(2)If the experiments go on well, you can test the crane with a 10% load over the rated dynamic load with the same way as shown as above.


VI. Maintenance Instructions of LX Type Suspension Crane

1. Maintenance about major parts
To a great extent, use quality and working life of the components of the crane are depending on the usage of the lubrication frequently and accurately. Inspect all the lubrication condition every three month to add lubricant oil or replace the oil. To guarantee a favorable lubrication condition, it’s necessary to shorten the lubricating period for frequency used or poor environment.

(2)Wire rope
In case of reducing the intensity caused by the loose of the wire rope, it should be avoided that the lifting appliance revolves when the hoisting mechanism works. Proper lubrication of the wire rope is using a rag which is saturated with kerosene to clean the used oil. It is prohibited to use metal brushes, sharp metal tools, acid or other highly corrosive lubrication to clean the wire ropes.

Examine the gear lubrication, the gear meshing and bearing temperature, etc. on a regular basis. Lockout and fix the machine if there were abnormal situation.
●Replace the lubricating oil every three month in the initial stage (half a year) of the Reducer. In line with the oil resolving, oxidation, degree of cleanliness, you can replace the lubricating oil half a year afterwards. Remember to swash the inner walls of the case with kerosene.
●Check out the reducer in detail half a year to affirm whether there are pitting, scratch, agglutination, and cracks on the gears. Fix or change the parts if the bearings or the obturators have abrasions as required.
●Corotate or contrarotate the reducer sharply will reduce the service life and influence the safety use, so handle it properly as a tip.

(4). Inspect the wheel assemblies regularly. Scrap them when the following situations happened:
● Cracks
●The flange thickness abrasion reaches the 50% of the original.
●The deformation of the flange thickness is up to the 20% of the original.
●The tread thickness abrasion goes to the15% of the original.
●The deviation caused by unbalanced abrasion of the working diameter of the active wheels which must be less than 1/600 of the diameter. It should be reinstalled if it exceeds the limits. The reconditioning wheels should apply to the Regulation Four.

2. Maintenance about metal structure
(1) Girder is the main stress component in the metal structure of the crane. Its maintenance plays an important role in the safety and performance. So you should pay attention to the following tips:
●It must be avoided to start, stop or run into the other cranes, because the sharp motions generate much additional dynamic load to the bridge.
●We should measure the deflection of the girder regularly to find out if it exceeds the limits.
●Check out the welding lines of the girder and the trolley, and it should stop at once if there were cracks on them. Re-weld the flawed welding lines with high-class welding rods (E4303). Check out the connecting bolts of the girder and trolley are fixing tightly so that the re-welding would work well.
●It must stop promptly if there are residual deformations of the girder (or the plates can’t keep balance). Then find out a method to fix it after a survey.
●After fixing or reinforce, the machine could be used after being qualified by the trial run which is on the basis of the steps mentioned above.

(2) Tracks
Observe the straightness of the rail and fastness of the pressing plate. Regulate the tracks or wheels if the electric hoist get stuck when it travelling.

3. Maintenance about electrical equipment
To ensure the cranes could work stably and securely, the users should formulate the overhaul system of electrical equipments which conforms to the rules of GB6067-85, as well as get familiar with the reasons and methods of the breakdowns.
Maintenances of the major electric equipments are as follows:
(1) To prolong the service life of the electric equipment of the crane, the users should keep the contact lines of the control cabinet tidy and clean in case of the electric leakage, broken-down or short circuit, etc.
(2) The rust or dirt on the guide rail of the trolley must be clean up to keep the motor tractor in its good condition when adapting the festoon cable for the electric conduction.