1. Casting Crane Use and operation

1.1 Cab operation

1.1.1 Cab arrangement

 

1.1.2 Combination Control Console

Kingda casting crane (ladle crane) combination control console is used to control the starting, speed control, reversing and braking of the motor, and generally consists of left & right control boxes, chair, foot switch, etc. Control box is the core part of combination control console and consists of operating transmission mechanism, zero position self-lock device, contact system, cam, locating ratchet wheel, box, etc. The box panel is configured with indicator light and various function buttons.

According to different demands, the combination control console is divided into two types:

•  --QT5 series common combination control console

it consists of left & right control boxes, mobile-type chair and foot switch, and employs split-type installation. The enclosure protection grade is IP30 and operating handle is spherical structure.  

1. 1)  Operating transmission mechanism

Operating transmission mechanism can be divided into 4 types according to different control objects: single-handle linkage operating mechanism, double-handle operating mechanism, double-handle independent operating mechanism and single-handle vertical operating mechanism.

[Single-handle linkage operating mechanism]
The mechanism employs gear transmission. When the handle is operated vertically (forth and back) driven by the front group of bevel gear. the front camshaft will rotate to complete contact opening & closing procedures of the 1st group of the mechanism. When the handle is operated horizontally (leftward and rightward) driven by the rear group of bevel gear, the rear camshaft will rotate to complete contact opening & closing procedures of the 2^nd group of the mechanism. When the handle is operated in oblique line, the front and rear camshafts will rotate simultaneously and two groups of the controlled mechanisms will work simultaneously. The mechanism can be operated conveniently and move freely, and is the operating mechanism used most widely in Combination control console.
Operating handle of the mechanism is 280mm angle in any vertical or horizontal operating direction is 36° from the zero position.

[Double-handle independent operating mechanism]
Except that the shape of operating rod is changed and horizontal rod is cancelled, other structure of the mechanism is the same with grab double handle. Lt is commonly used to control the crane's main and auxiliary hoisting mechanism that do not work simultaneously. Therefore, it’ s also called main and auxiliary hook double handle. The handle next to the driver side is generally used to operate the main hook.

[Single-handle vertical operating mechanism]
The handle of the operating mechanism can only move vertically and the camshaft will rotate by virtue of a group of bevel gar, it’s generally used for hook control of three-mechanism crane. The Kingda ladle crane (casting crane) and trolley employ linkage handle for related operation.
 

2. 2)  Zero position self-lock device.

To prevent malfunction of combination control console arising from the vibration and accidental collision of the casting crane (ladle crane) and other devices, the operating handle is configured with zero position self-lock device. The handle comprised of upper and lower hemispheres. Only when the lower hemisphere is lifted and held can the handle leave zero position to carry out corresponding operation. Once the handle leaves zero position, release the lower hemisphere and carryout operation continuously in case plug braking is employed for parking frequently, when it’s inconvenient in corresponding operation, it’s able to lift the lower hemisphere of the handle and rotate it clockwise to fix the lower hemisphere in the lifting position, and then zero position self-lock will not work.
 

3. 3) Contact system

Contact group has 4 specifications in total, including DC 10A.AC 10A, AC 32(25) A and AC 63 (60) A. It generally adopts double breaking point structure. After AC 10A contact is embedded with permanent magnet, it will become DC 10A contact increase its silver contact and it will become AC 32(25) A contact, increase it again and it will become AC 63 (60) contact.
Contact installation can be carried out in two forms, namely, single-row arrangement and double-row arrangement single-row arrangement means to mount all contacts on one side, namely, the side next to the driver. Which is convenient for repair. Double-row arrangement means to mount the contacts internally and externally, which can reduce the height of control box and is convenient for operation.
 

4.   4) Cam.

The cam is made by black phenolic injection molding compound by injection molding and employs plug-in structure. Such structure not only can guarantee accurate assembling position of the cam with strong universality, but also is convenient for disassembling any cam when it’s necessary to change contact opening and closing procedure.
 

5. 5）Locating ratchet

Locating ratchet wheel is made by 3mm-thick steel plate by punching and has high abrasive resistance through thermal treatment. Multiple location holes are punched on the ratchet wheel and locating screws are mounted in different holes. In this way, it’s able to confirm the number of gears of operating handle and the number of gears can be selected arbitrarily within the range of 6 gears on the left and right respectively. Spring force on ratchet wheel is adjustable and it’ s able to adjust the spring force to make the operating force of the handle within the allowable range according to specific condition in the premise that there is clear gear division.
 

6. 6）Box body

The box is made by 2mm steel plate and can be opened in four directions for the convenience of wiring and repair. Cover panel of the box is configured with indicator light, button, electric lock, emergency switch and other control elements. In case there are too many elements which can’ t be arranged on the panel, it’ s able to mount an accessory box additionally in front of the control box. The control boxes in different types can be comprised according to different operating transmission mechanism, contacts and contact arrangement forms
 

• -- QTA-C series Combination control console

QTA-C series combination control console is mainly used in the control circuit with AC 50Hz (60Hz), rated voltage of 380V (440V) and rated current of AC2/ 6A, DCO/3A or lower to control the starling, speed control, braking, reversing and other functions of the motor of the Kingda ladle crane (casting crane). Aiming at different service condition requirements, it can realize double-mechanism linkage/ single action. It employs integral installation and button-type operating handle, which complies with the philosophy of ergonomics. Besides it’s configured with WLK master controller with distinct hand feeling and clear gears, and zero position reset and locking device. In addition, PLC module and HMl touch screen can also be mounted additionally according to different demands.

   

1.1.3 Function description

During the use, insert the key of electric lock and rotate the key switch clockwise. Press the button “start”, green power light will be ON and the starting process will be finished. Press the button “stop”, green power light will be OFF, rotate the key switch anticlockwise to initial position, and then pull out the key of electric lock. When leaving the Combination control console, the driver must stop operation, push the handle back to zero position and pull out the key of electric lock. Descriptions of each handle and function button are as follows: main and auxiliary hook operating handle: control the lifting and lowering of main and auxiliary hooks; crane and trolley operating handle: control the crane and trolley to run left ward and rightward with 4 gears successively; power light: after it’s connected with external power supply, the light will be ON: start indicator light: press the button “start” and the indicator light will be ON

1. 1) Electric lock: it can be started only after the key is inserted.
2. 2) Start: press the button, control power supply will be provided and the contactor of each mechanism will be powered on.
3. 3) Stop: press the button, control power supply will be cut off and the contactor of each mechanism will be powered off;
4. 4) Trip: after the button is pressed, the main power supply will be cut off;
5. 5) Standby: it’s used to extend other functions: plummet reset: after the main circuit is powered off, press the button and the main circuit will provide power supply to operate the hook to lower, After the plummet is reset, release the button; fault reset: after the fault is removed, press the button to recover to the normal state; emergency button: red mushroom-shape button device. It has rotary unlocking mechanism. Upon the button is pressed, it’ s able to cut off the power supply of main circuit of the crane quickly in emergencies to protect equipment and personal safety.
6. 6) Light switch: control the floodlight of bridge frame
7. 7) : control mode changeover switch
8. 8) : foot switch, tread down the switch and the alarm outside the cab will give audible and visual alarm

1.1.4 Hoisting operation

 

1. 1) Lift and hold the lower hemisphere (OT5) or press the operating handle (OTA-C) and pull it backwards from zero position, the object will be lifted and lifting speed will be increased successively. After the handle is pulled back to zero position, the lifting will be stopped.
2. 2)  Lift and hold the lower hemisphere (QT5) or press the operating handle (QTA-C) and push it forwards from zero position, the object will be lowered and lowering speed will be increased successively. After the handle is pulled back to zero position, the lowering will be stopped.
3. 3) When the object lifted exceeds the rated load, overload limiter will give an alarm and send out a signal to limit the lifting. In such case, the hoisting mechanism can only carry out lowering operation.
4. 4) The hoisting mechanism is configured with lifting and lowering limits. After the stop limit acts, it will prohibit the hoistingmechanism to run in the direction, but it can run in reverse direction.

1.1.5 Travelling operations of casting crane (ladle crane) and trolley

1. 1) Lift and hold the lower hemisphere (QT5) or press the operating handle (QTA-C) and push it forwards from zero position, trolley mechanism will move forwards and traveling speed will be increased successively. After the handle is pulled back to zero position, the forward movement will be stopped
2. 2) Lift and hold the lower hemisphere (QT5) or press the operating handle (QTA-C) and pull it backwards from zero position, trolley mechanism will move backwards and traveling speed wil be increased successively. After the handle is pulled back to zero position, the backward movement will be stopped.
3. 3） Lift and hold the lower hemisphere (OT5) or press the operating handle (OTA-C) and push it leftwards from zero position, crane mechanism will move leftwards and traveling speed will be increased successively. After the handle is pulled back to zero position, crane will stop moving.
4. 4）Lift and hold the lower hemisphere (QT5) or press the operating handle (OTA-C) and push it rightwards from zero position, crane mechanism will move rightwards and traveling speed will be increased successively. After the handle is pulled back to zero position, crane will stop moving.
5. 5） Crane and trolley operating mechanisms are configured with forward moving and backward moving terminal limits. After the stop limit acts, it will prohibit the hoisting mechanism to run in the direction, but it can run in reverse direction.

 

Precautions

- - In case of sudden power failure during the work，before the work is recovered, it’s required to place all controller handles to “zero position” and only in this way can master contactor be started. - -When moving direction of the crane and trolley is changed, it is required to place the handle in “zero position”and the operation in reverse direction can be carried out only after the mechanism stops operation completely. -- lt is forbidden to realize parking by operating the crane or trolley in a reverse direction. -- When pushing the handle, it will realize acceleration or deceleration gradually. Before the crane moves, operation personnel shall consider the distance of start and stop.

1.2 Wireless remote control operation

In case casting crane (ladle crane) employs remote control unit for control, corresponding operation manual will be provided with the equipment.
 

1.3 Multipoint operation

in case cab + remote control is employed, its required to carry out the switching of Combination control console and remote control unit. During the use, it’s required to insert the key of remote control unit into the unit at first, press the green start button to activate the remote control receiver, then rotate the “changeover switch "on Combination control console to “start position, and it’s able to carry out related operations of remote control unit. When it is required to switch back to the operation of Combination control console. Rotate the“changeover switch” on Combination control console to close position, and then pull out the key of remote control unit.

2. Casting Crane Inspection and Maintenance

2.1 Safety precautions

1. 1）Observe the locations and adjacent areas to be inspected and maintained, and set up warning signs and safety operation areas;
2. 2）Park the crane in an area free of disturbance;
3. 3）Cut off the power supplies of the slide wire or the master switchgear circuit-breaker before crane maintenance;
4. 4）Put up an “in inspection” or “in maintenance" warning sign, or lock the controller switch into the “Off” position: only the designated personnel are allowed to perform such operation;
5. 5）Remove the load from the crane if it has;
6. 6）Set up warning signs or a warning area underneath in case the maintenance overhead may cause danger to the underneath;
7. 7）Use safe and reliable tools;
8. 8）Inspection or maintenance personnel should wear personal protection devices (e.g., protective footwear, safety helmets, safety belts or goggles);
9. 9）Take measures against electric shocks;
10. 10）Do not turn on or off the power switch in inspection unless the designated personnel give instructions;
11. 11）Be sure to turn off the power switch, put up an “in inspection” warning sign and lock it and/or designate a person to watch it if getting into a position subject to electric shocks; put up an “in inspection” warning sign for the control room;
12. 12）Do not operate the crane in inspection unless the designated personnel give instructions;
13. 13）Inspect slings and the test load for defects before a load test;
14. 14）Other personnel are not allowed to enter dangerous areas unless authorized;
15. 15）Inspection should be jointly carried out by 2 or more inspectors;
16. 16）Inspection or maintenance requires adequate lighting;
17. 17）Welding needs to take appropriate measures of protection;
18. 18）After maintenance and before the crane’s resuming to normal work, reinstall protective facilities; restore the safety devices and calibrate them;
19. 19）Maintenance requires to take necessary fire-fighting measures:
20. 20）After maintenance, remove the temporary facilities used and clean the site;

2.2 Routine inspection

The items and requirements of routine inspection should be determined according to the specific features of every set of equipment and should be not lower than the requirements given in Table 8-1.

2.3 Regular inspection

The items, requirements, and cycles of regular inspection should be determined according to the working class, work environment and working condition of every piece of equipment and should be not lower than the requirements given in Table8-1. For the equipment handling dangerous articles like molten metal, the inspection cycle should be shortened accordingly.
 

No.	Items		Methods, Contents, and Requirement	Recommended Treatments	Cycle
					Day	Week	Month	Quarter	Year
1	Technical Documents	Attached documents	Check that the attached drawings, the operation manual and the certificate are complete.	Correct and improve					○
2		Inspection records	Check that the past inspection records are complete and there are no untreated defects.	Correct and improve					○
3		Maintenance records	Check that the past maintenance records are complete and there is no non-validated maintenance	Correct and improve					○
4		Other documents	Check that the past maintenance records are complete and there is no non-validated maintenance.	Correct and improve					○
5	whole crane	Operating environment	Visually check that the operating environment has no factors influencing operation safety.	Treat according to the enterprise management system and the operation specifications	○	○	○	○	○
6		Appearance	Visually check that the crane has no trash, sundries, left tools in it.	Clean	○	○	○	○	○
7			Visually check that the crane has no trapped oil and water in it.	Clean		○	○	○	○
8			Visually check that there are no defects on its surface like serious corrosion, paint peeling. damage, etc.	Prevent corrosion/ repair				○	○
9		Wheel loading	Visually check that every wheel has no suspension.	Adjust/repair			○	○	○
10		Span	The span deviation should meet the requirements of relevant crane standards.	Adjust/repair					○
11	Metal structure	Main beam, end beam, trolley frame, balance beam, track roller frame, etc.	Visually check the crane for the corrosion, cracks and plastic deformation of metal structures like the main beam, end beam, trolley frame, track roller frame, balance beam, etc. and they should meet the requirements set forth in Section 3.9 ofGB6067.1-2010.	Prevent/corrosion/repair/change				○	○
12			Visually check that the welds of main stressed structures have no visible cracks	Repair				○	○
13	Fastenings	Stressed structure safety device fastenings	Visually check that there are no damage and looseness in the hinge shafts and bolts of main stressed structures and safe by devices.	Change/adjust				○	○
14		Fastenings of mechanisms and electrical components	Visually check thar there are no damage and looseness in the connecting bolts of the motor, speed reducer gearbox, brake, coupling, electric cabinet, and other components	Change/festen			○	○	○
15	Mechanism	Hoisting mechanism	Check that the hoisting mechanism has no abnormal noise and vibration by a no-load test.	Maintain		○	○	○	○
16		Long travelling mechanism	Check that the operating mechanism has no abnormal noise and vibration by a no-load test.	Maintain		○	○	○	○
17			Visually check that there is no deflection, track biting, etc. influencing the cranes operation.	Adjust/change			○	○	○
18		Trolley travelling mechanism	Check that the trolley operating mechanism has no abnormal noise and vibration by a no-load test.	Maintain		○	○	○	○
19			Visually check that there is no deflection, track biting, etc. influencing the trolleys operation.	Adjust/replace			○	○	○
20		Slewing mechanism	Check that the slewing mechanism has no abnormal noise and vibration by a no-load test.	Maintain		○	○	○	○
21		Telescoping mechanism	Check that the slewing mechanism has no abnormal noise and vibration by a no-load test.	Maintain		○	○	○	○
22		Crane power supply unit	Check that the crane power supply unit has no abnormal noise and vibration by a no-load test.	Maintain			○	○	○
23		Trolley power supply unit	Check that the crane power supply unit has no abnormal noise and vibration by a no-load test	Maintain			○	○	○
24		Lifting spreader mechanism	Check that the trolley power supply unit has no abnormal noise and vibration by a no-load test.	Maintain			○	○	○
25		Lubricating system	Visually check that the lubricating system should work normally with no clogging and leakage.	Maintain			○	○	○
26		Electric hoist	Check that the block has no abnormal noise and vibration by a no-load test.	Maintain			○	○	○
27	key component	Lifting spreader	Check that the lifting appliance welds and structures have no wear-out and deformation and abnormal noise influencing safety	Repair/change			○	○	○
28			Visually check that the lifting appliance pins do not get loose or pull out, and the pin-end retainers safe and effective.	Fasten/repair/change			○	○	○
29			Visually check that the hook locking device and the hook nut locking device are effective.	Adjust/repair/change			○	○	○
30			Check the surface crack, deformation, abrasion and corrosion of the forged hook according to the method specified in GB/T10051.2 and GB/T10051.3, and relevant items shall comply with corresponding requirements.	Repair/change				○	○
31			Check the suspension fork structure, lifting beam structure and weld joint by visual inspection, and there shall not be any crack or plastic deformation	Repair/change		○	○	○	○
32			Check the surface of laminated plate hook according to the method specified in GB/T10051.13 and GB/T 10051.14, and there shall not be any crack or serious deformation. In addition, the rivet shall not be loose, the clearance of hook pieces shall be normal, and the lining at the mouth of hook shall not have any obvious abrasion, crack or plastic deformation.	Fasten/adjust/repair/change				○	○
33		Pulley	Visually check that the trolley should meet the requirements set forth in Section 4.2.5 ofGB6067.1-2010.	Repair/change				○	○
34			Visually check that the pulley can turn flexibly.	Lubricate/adjust				○	○
35			Visually check that the pulley stopper is safe and effective.	Repair/change				○	○
36		Reel/Drum	Visually check that the reel should meet the regulations set forth in Section 4.2.4.5 inGB6067.1-2010	Change			○	○	○
37		Steel wire rope	Check the steel rope according to the methods specified in GB/T5972 and make sure it meet the requirements.	Change			○	○	○
38			Visually check that the steel rope should have no obvious mechanical damage.	Repair/change		○	○	○	○
39			Visually check that the steel ropes of the reel and the pulleys have no disengagement from the	Fasten/adjust	○	○	○	○	○
40			groove.	Fasten/adjust			○	○	○
41		Brake	Visually check that the fixation at the end of the steel rope can meet requirements; be sure the press plate is in good operation condition; the end length of the steel rope should be greater than 5 times the diameter.	Lubricate/adjust		○	○	○	○
42			Visually check that the lubrication of turning points and slewing points meet requirements.	Maintain	○	○	○	○	○
43			Check through a no-load test that the hoisting mechanism can work properly	Change			○	○	○
44		Wheel	Visually check that the brake should meet the requirements set forth in Section 4.2.6.7 of GB6067.1-2010.	Fasten/adjust/repair/change				○	○
45		Coupling	Visually check that the wear and deformation of wheel flanges and treads meet the specifications set forth in Section 4.2.7 fGB6067.1-2010	Fasten/repair		○	○	○	○
46		Reducer	Visually check that the coupling has no defects looseness, oil leakage, and abnormal vibration and noise in operation.	Fasten/repair			○	○	○
47			check that the running reducer has no abnormal noise, vibration, oil leakage and overheat	oil			○	○	○
48		Bearing	Visually check that the oil level should be within the required range.	Change				○	○
49		Trolley rail	Visually check that the bearing has no abnormal noise and temperature rise.	Adjust					○
50			joint gap and height difference to make sure they meet relevant standards.	Change			○	○	○
51			Visually check that the track has no cracks and serious wear-out.	Fasten/change			○	○	○
52		Cab	Visually check that the track press plates have no damage and looseness.	Fasten/repair			○	○	○
53			Visually check that the cab connecting parts have no sealing-off, looseness and cracks.	Repair/change		○	○	○	○
54			Visually check that the cab has no electrified parts inside and the indoor floor is well insulated.	Clean/change		○	○	○	○
55	Electrical control system	Power supply	Visually check that the door, windows, glass and lock of the cab are not damaged and they should be clean and present a clear sight	Maintain	○	○	○	○	○
56		Control device	Visually check that the power supply works properly.	Repair/change		○	○	○	○
57			Visually check that all buttons are flexible and effective and the lower insulation protection of the control lever is not damaged.	Adjust/change	○	○	○	○	○
58			Visually check that the control levers of all mechanisms are flexible and free of jamming and the gears can feel clearly and the zero lock is effective.	Repair/change		○	○	○	○
59		Power feeding device	check that the shells of remote control device and have no damage and the control buttons are marked clearly and correctly and functions normally.	Adjust/repair/change				○	○
60		Motor	Visually check that the live indicating devices are complete and effective; the soft cable protective coating has no serious aging, damage, bulging; the cable reeling device are complete and effective; and the current collector is contacted reliably.	Repair				○	○
61			Measurement of motor insulation resistance should meet the requirements of various product standards	Adjust/change				○	○
62		Main power switch	Visually check that the motor slip-ring has no burns and carbon brush wear, and the pressure should be proper.	Adjust/change			○	○	○
63		Control cabinet/console and electric facilities	Visually check that the main power supply switch functions properly.	Adjust/change			○	○	○
64			Visually check that the door switch of the control cabinet is flexible and the lock is secure.	Change			○	○	○
65			Visually check that the electrical wires and components in the control cabinet have no overheat, scorch, and melting; and the components have no damage in the surfaces and the shell does not shed.	Adjust/change			○	○	○
66			Visually check that electrical connection and earthing are reliable and cables have no serious cracking and damage.	Clean/fasten					○
67			Visually check that the mark of every section of lines is clear and the connection is not loose.	Repair/change					○
68			Check through a function test that the lines have no overheat, the insulation and earthing resistance are satisfactory	Adjust/change				○	○
69		Communication	Check through a function test that the wiring terminals, contactors and relays are in good contact; visually check that the arc-control device is complete.	Maintain	○	○	○	○	○
70		Lighting	Check through a function test that the communication between the host computer and the central control room is good.	Repair/change	○	○	○	○	○
71		Air conditioning system	check that the lighting equipment has no damage.	Maintain		○	○	○	○
72	Hydraulic system		Visually check that the air conditioners in the electrical room and the cab work normally.	Fasten/repair	○	○	○	○	○
73			check that the hydraulic system has no oil leakage.	Maintain			○	○	○
74	Pneumatic system		Visually check that the hydraulic system works normally and has no abnormal noise and overheat.	Fasten/repair	○	○	○	○	○
75			check that the pneumatic system has no oil leakage	Maintain					○
76	Safety protection device	Lifting height limiter	Visually check that the pneumatic system works normally and has no abnormal noise.	Fasten/repair	○	○	○	○	○
77		Secondary lifting height limiter	Check through function testing that the lifting height limiter is fixed securely and functions effectively.	Fasten/repair			○	○	○
78		Travel limiter	Check through function testing that the secondary lifting height limiter is fixed securely and functions effectively.	Fasten/repair	○	○	○	○	○
79		Slewing limiter	Check through function testing that the travel limiter is fixed securely and functions effectively	Fasten/repair			○	○	○
80		Slewing locking device	Check through function testing that the slewing limiter is fixed securely and functions effectively	Fasten/repair				○	○
81		anti-crash device	Visually check that the slewing locking device has no deformation, damage and looseness	Fasten/repair			○	○	○
82		Buffer and end stopper	Visually check that the anti-crash device has no deformation and damage and functions effectively	Fasten/repair/change				○	○
83		Load lifting limiter	Visually check that the buffer has no deformation and damage and the end stopper has no deformation and open welds.	Fasten/repair					○
84		Overspeed protection device	Check through function testing that the load lifting limiter is fixed securely and functions effectively.	Change					○
85		Interlock protection	Visually check that the overspeed protection device is not absent.	Adjust/change		○	○	○	○
86			Visually check that the interlock device has no damage and short-circuit.	Repair/change			○	○	○
87		Earthing protection	Check through function testing that the electrical interlock device is normal and reliable.	Repair/change			○	○	○
88		Electrical protection	Visually check that the earthing device is intact and functionally effective.	Change					○
89		Safety monitoring and management system	Visually check that the electrical protection has no damage, including short-circuit, voltage loss, zero and overcurrent.	Adjust/repair	○	○	○	○	○
90		Emergency stop switch	Visually check that the control units of the safety monitoring and management system work normally.	Repair/change				○	○
91		Sound and light alarming	Once activating the emergency stop switch, the crane should stop immediate; the emergency stop switch should not reset automatically; after being manually reset, it should enable the crane to recover normal operation when restarted.	Repair/change			○	○	○
92		Marks and warning signs	Check through function testing that the sound and light alarm can work properly.	Repair/change	○	○	○	○	○
93		Stair, step platform, walkway, railing	Visually check that the nameplate, tonnage mark and safety warning sign are clear and has no damage.	Fasten/repair					○
94		Protective cover	Visually check that the stair, step, land form walkway, and railing are intake and secure.	Fasten/repair					○
95		Maintenance cage	Visually check that the protective covers of the rotating parts are secure, complete and intact.	Fasten/repair					○
96		Conductive trolley line protective device	Visually check that the maintenance cage has no damage, the connection is not loose, and the protection is effective.	Fasten/repair					○
97		Rail sweeper	Visually check that the conductive trolley line protective device is complete and intact.	Adjust/change				○	○
98		Radiant heat protection device	Visually check that the clearance between the track sweeper and the track is 5mm~10m	Fasten/repair				○	○
99		Fire-fighting equipment	Visually check that the radiant heat protection device is intact and connected firmly.	Adjust/change	○	○	○	○	○

Note:

• ►Kingda casting crane (ladle crane) inspection should keep an inspection record, with the contents including the items above, and the record should conform to Section 5.5 of GB/T31052.1-2014.
• ►An inspection report should be produced for the unsatisfactory items found in regular inspection, the content at least including the regulations set forth in Appendix B of GB/T31052.1-2014.

2.4 Inspection and maintenance of main parts

2.4.1 Inspection of steel rope

As a key part having a direct impact on the safe use of a casting crane (ladle crane), the steel rope is usually scrapped because of wear-out and breakage. Therefore, the steel rope must be subject to regular inspection and maintenance according to GB/T 5972 Care. Maintenance, Installation, Inspection and Discard of Wire Ropes for Cranes so as to ensure safe and effective operation of casting crane (ladle crane).
The following inspection and maintenance procedures should be carried out regularly:

1. 1. The steel rope should be inspected according to GB/T 5972 Care, Maintenance, Installation, Inspection and Discard of Wire Ropes for Cranes and changed if necessary.
2. 2. The steel rope is lubricated.

2.4.1.1 Steel rope change

1. 1）Change the worn or damaged steel rope. Refer to the attached documents for the type and the main properties of the steel rope.
2. 2）Descend the hook to the ground o make the stee rope remain slack;
3. 3）Remove the press plate from the reel;
4. 4）Coil up the old steel rope before putting it in storage.
5. 5）Take a new steel rope and keep it lubricating;
6. 6）inspect to make sure the new steel rope matches the reel; see the steel rope certificate to ensure the type and properties are satisfactory to the steel rope.
7. 7）At the end of the reel, there are press plates used to fix the steel rope, whose specifications and quantity varies with the type. When the hook is in the lowest position, be sure there are at least two circles of steel rope winding round the reel at the end.
8. 8）Fix the starting end of the steel onto the reel with no looseness;

9. 9）Wind the steel rope onto the reel with a motor;
10. 10）Wind the steel rope according to the winding diagram, the end of the steel rope fixed tightly on the reel with the press plate;
11. 11）Test the winding of the steel rope. If the steel rope knot to rotate the lifting appliance, remove it to eliminate its twisting

2.4.1.2 Requirements for installation of steel rope clamps

The minimum quantity of steel rope clamps needed for a connection is recommended as Table 7-2. In installing a steel rope clamp, the pedestal should be fastened to the stressed section, and the U-shaped bolt to the end: the spacing between two clamps equals 6-7 times of the steel rope diameter; the last clamp should be at least 150mm distant from the rope end.
 

Table 8-2 Quantity of Steel Rope Clamps
Nominal diameter of steel rope/mm	≤19	19~32	32~38	38~44	44~60
Minimum quantity/set of steel rope clamps	3	4	5	6	7

2.4.2 Reel inspection

The reel should be discarded in case that:

1. 1）There are defects on the surface that influence the performance (e.g., cracks, etc.)
2. 2）The wall wear takes up 20% of the original thickness of the wall.

2.4.3 Hook inspection

The hook should be discarded in case that:

1. 1）There are cracks in the surface;
2. 2）There are dangerous sections or the hook neck shows plastic deformation;3) The torsional deflection of the hook exceeds 10°;
3. 3）The wear of the hook’ s dangerous section reaches 5% of its original size5) The opening deformation of the hook reaches 10% of its original size;
4. 4）The hook neck shows plastic deformation;
5. 5）The others should conform to GB10051.3 Lifting Hooks-Part 3: Inspection of Forged Hooks in Service.

2.4.4 Trolley inspection

The pulley should be discarded in case that:

1. 1）There are defects on the surface that influence the performance (e.g., cracks, etc.):
2. 2）The uneven wear of the pulley groove reaches 3mm:
3. 3）The wear of the groove wall reaches 20% of its original thickness;
4. 4）The reduction in the groove bottom diameter due to wear reaches 50% of the steel rope diameter.

2.4.5 Brake inspection

The parts should be changed or the brake should be discarded in case that one of the following occurs:

1. 1）Drive unit
   1. a. The magnet coils or motor windings burn;
   2. b. The engine thrust fails to meet the requirement of brake release or there is no thrust.
2. 2）Brake spring
   1. a. The spring has plastic deformation to an extent that takes up more than 10% of its normal extent;
   2. b. The spring has obvious damage on its surface, of which 20% suffers corrosion and cracks.
3. 3）Driving member
   1. a. The member presents serious deformation influencing its performance)
   2. b. The main slewing hinge points suffer serious wear, which cause the driving travel of the brake to lose more than 20%
4. 4）Brake lining
   1. a. The wear of the riveted or assembled brake lining reaches 50% of its original thickness:
   2. b. The wear of the clamped brake lining with steel backing reaches 2/3 of its original thickness:
   3. c. There shows charring on the surface of the brake lining or the peeling area reached 30%:
   4. d. There are cracks or serious chaps in the surface of the brake lining.
5. 5）Brake wheel
   1. a. There are defects on the surface that influence the performance:
   2. b. For the brake wheel of the hoisting mechanism, the wear of the brake surface reaches 40% of its original thickness:
   3. c. For the brake wheels of other mechanisms, the ear of the brake surface reaches 50% of its original thickness;
   4. d. If the roughness of the wheel is 1.5mm, the thickness of the brake surface should, after being repaired, meet the requirements above.

2.4.6 Wheel inspection

Wheel parts shall be subject to an overall check at regular intervals and shall be discarded in case that:

1. 1）There are defects on the surface that influence the performance;
2. 2）The wheel edge wear reaches 50% of its original thickness or the wheel edge disintegrates partially;
3. 3）The tread wear reached 15% of its original thickness;
4. 4）The bending deflection of the wheel edge reaches 20% of its original thickness;
5. 5）When the speed is less than 50m/min, the roundness is 1mm; and when more than 50m/min, 0.1mm.

2.5 Lubrication

To ensure the reliability and life of a casting crane (ladle crane), the crane must be subject to regular lubrication and maintenance. lf a crane works long in an extremely freezing cold condition (below -20'C) and a high temperature condition (above +55'C), synthetic lubricating oil is recommended. The casting crane (ladle crane) usually adopts decentralized lubrication, that is, oil guns are used to manually fill lubricating oil at different lubricating points. Centralized lubrication may be also employed as needed, that is, manual or electric gasoline pumps are used to pump grease into a distributor, which distribute grease into bearing lubricating points of reels, wheels and fixed pulleys along the pipelines.  

2.5.1 Distribution of manual lubrication points of casting crane (ladle crane)

♦ Pulley spindle 
♦ Gear coupling 
♦ Steel rope
♦ Reducer Brake hinge shaft
♦ Reel coupling 
♦Reeling gear
♦Motor bearing
♦ Wheel bearing box  
♦ Cable trolley bearing 
♦ Reel bearing housing

2.5.2 Notes for lubrication

1. 1）Casting crane (ladle crane) must use appropriate lubricating grease for regular lubrication and timely change;
2. 2）The lubricating equipment and lubrication points must keep clean;
3. 3）The greases of different makes are not allowed to be mixed;
4. 4）A regular inspection should be given to the sealing of the lubricating system;
5. 5）For the lubrication points having a higher temperature, the frequency of lubrication should be increased accordingly and an insulating or cooling device should be provided;
6. 6）In a humid environment, sodium base grease is not suitable, because it will be not effective due to strong water absorption;
7. 7）For the rotating parts having no oiling points, the rotating gaps should be filled drop by drop with an oil pot to reduce mechanical wear and corrosion;
8. 8）Lubricating requires an overall power cut (except the electric lubricating system).

Table 8-3 Crane Component Lubrication List
Lubricating component	Oil (grease) injection cycle	Oil (grease) injection measure	Recommended oil (grease)
Steel rope of main hoisting mechanism	Weekly	Heat the lubricating grease to 80-100C and coat to saturation	Special lubricating grease for exclusive use of steel rope
Steel rope of auxiliary hoisting mechanism	Every half month	Coating	Special lubricating grease for exclusive use of steel rope
Reducer	Initial using period change the oil within300 hours since the operation, then every 6months later	Injection oil quantity shall comply with the scale pointed by oil needle	L-CKD320 industrial heavy load gear oil
Electro hydraulic brake	Quarterly	Oil injection quantity shall comply with the height of oil hole	DB-25 hydraulic oil
Gear coupling	Monthly	Press-in by oil gun till overflow	No.2 common lithium-based grease
Universal coupling	Monthly	Press-in by oil gun till overflow	No.3 composite calcium-based grease
Reel coupling	Monthly	Inject oil into each oil hole successively. Where the oil hole is in lower part, press the oil in the hole by oil gun till overflow from spherical surface	No.3 extreme pressure lithium-based grease
Reel ring gear	Monthly	Coating until it is full	No.2 common lithium-based grease
Bearing	Weekly	Press-in by oil gun (oil injection pump) till overflow	common lithium-based grease
Motor	Yearly	Coating until it is full	No.2 common lithium-based grease
Hinged shaft	Monthly	Press-in by oil gun till overflow	No.3 composite calcium-based grease
Hinged point of brake, limit switch, etc.	Every 3 months	Coating until it is fill	No.2 common lithium-based grease

Note:
if the casting crane (ladle crane) is operated in hostile environment, the maintenance interval should be shortened.
- High humidity
- Dusty, acid and other corrosive environments:
- Environment with large temperature difference
 

2.5.4 Oil injectionquantity of the reducer

 

Table 8-4 Table of Reducer Fuel Charge
A1960	115L	L-CKC320 industrial heavy load gear oil
A1650	95L
A1570	80L
ZQ1000	60L
ZQ850	40L	L-CKC220 industrial medium load gear oil
ZQ650	19L
ZQ500	12L
ZQ400	5L
ZSC600	5L
ZSC400	3L
Note: be sure the reducer inner case keeps absolute clean before changing lubricating oil

2.6 Recommended tightening torque

 

Table 8-5 Bolt Torque Table
Specification	Tightening Torque
	Strength magnitude 8.8(Nm)	Strength magnitude 10.9(Nm)
M4	2.7	4
M5	5.4	7.9
M6	9.3	14
M8	23	33
M10	45	66
M12	77	115
M14	125	180
M16	190	280
M18	275	390
M20	385	550
M22	530	750
M24	660	950
M30	1350	1900

3. Casting Crane Fault analysis and removal

When a casting crane (ladle crane) is under operating, the mechanical parts and the components and parts of the control system will be worn to an extent to cause auls. Therefore, the faults should be analyzed carefully to find out the causes and take corresponding pointed measures so as to restore the
technical performance of the parts suffering faults. The faults of a crane should be removed by experienced technicians. The common faults and treatments are shown as the table below.

  

Table 9-1 Mechanical Failure
Failure		Causes and Consequences	Treatments
Reducer	shell heating	Bearing failure; lack of lubricating oil in  gears and bearings. (It is normal when the temperatuC7:C28re is not more than 40℃ above the medium temperature and the absolute value is not more than 80℃)	Check the lubrication and bearings; Change oil and bearings
	Oil seeping of clipping plane and bearing cap	Loose connection, and sealant damage	Tighten, clean, and apply sealant
	Vibration	Loose connection, misaligned axle center of connecting pieces	Readjust, tighten, and reinforce the pedestal
	Vertical reducer runout	Deformation of connecting hinge shafts, and key damage	change the shaft, adjust and reinforce the hinge support, and change the key
Gear pair	Tooth fracture	Overload or fatigue failure, tooth root cracks	Change
	Gear pitting	Peeling off	Change it when the surface is more than 30% of the working surface, and the pit depth is more than 10% of the tooth thickness.
	Tooth wear	Starting or braking runouts	Change when the wear limit of the hoisting mechanism is 10% of the original tooth thickness and of the operating mechanism 15~25%.
	Gear	Improper lubrication	Change
	Spoke and rim cracks	Gear damage results in gearing chain damage	Change the hoisting mechanism, and repair the operating mechanism.
	Noise and clash	Improper machining and assembly: in adequate contact surfaces, tooth scars, tooth tip-root biting, skew assembly	Ensure accuracy, and no-load running-in
Coupling	Cracks in coupling half	Coupling damage	change
	Wear of connecting bolt holes	Impacts and vibration, bolt shear-off and load falling of hoisting mechanism at braking	change
	Tooth wear or fracture	Lack of lubrication, overload, overturn, coupling damage	Grease regularly; change when the tooth wear reaches 15% of the original thickness for the hoisting mechanism and 30% for the operating mechanism.
	Key groove wear or deformation	Key slippage leads to failure to transmit torque.	Change the hoisting mechanism, and repair the wear by welding for the operating mechanism
pulley	No rotation of pulleys	Bearing damage	change
	Uneven wear of pully groove	Uneven material, unacceptable installation and poor contact of rope and pulley	change
	pulley spindle wear reaches 3-5%ofits nominal diameter	Spindle damage	change
	Pulley tipping and loosening	On-shaft locating element loosening	fasten
	Pulley cracks or rim fracture	Pulley damage	change
Rolling bearing	High temperature	Lack of lubricating oil and dirt; cracks	Remove dirt and grease or change
	Tooth fling and clash	Damage of holders and rolling elements	Change bearing
Brake	Failure to stop the falling of load and weight	A. Lever hinge is jammed; B. There is greasy dirt on the brake wheel or friction disc; C. The brake wheel or friction disc is serious worn; D. The main spring gets loose or damaged; E. The locknut and tie rod get loose; F. Engine impeller fails to turn agilely; G. The clearance of the brake shoe is too large.	A. Remove the jamming and apply lubricant; B. Clean off the dirt; C. Change the friction disc; D. Change the main spring or locknut; E. Tighten up the locknut; F. Repair the engine; G. Adjust the clearance
	Failure to open	A. The fiction disc sticks to the brake wheel; B. The moving hinge is jammed; C. The main spring has too large force; D. The brake push rod is bent; E. Inappropriate oil is used; F. The impeller is jammed;	A. Cleaning; B. Remove the jamming and apply lubricant; C. Adjust the main spring force: D. Change the push rod; E. Change the oil according to the ambient temperature; F. Adjust the push-rod mechanism and check the electrical devices
	Heating and friction disc coking	A. After releasing the brake, it fails to separate from the brake wheel unevenly, causing friction. B. The clearance between the brake shoes and the brake wheel is uneven or too small; C. The working surface of the brake wheel is rough.	A. Adjust the clearance;  B Adjust the clearance; C. Machine the brake wheel surface as required
	Brake leaving its setting position; unsteady braking torque	A. The adjusting nut and the back nut are not tightened up; B. Threads are damaged.	A. Tighten up the nuts B. Change
Wheel	Noise or vibration	The rim is terribly worn.	change
	Track biting in one direction	The lateral deviation of the wheel is excessive and the direction of deflection at both ends is not reverse.	readjust
	Different track biting back and forth	The operating motor or the brake is asynchronous.	Inspect and adjust
	Track biting in a section	The rail is installed incorrectly	Inspect and adjust the section of track
	Outer edge biting or inner edge	The span is wrong	Inspect and adjust
	Trolley track biting	The main beam sinks to bend inwards.	Repair the main beam
	Unsteady and inclined traveling	Rim wear is excessive; and the track is not level.	Change the wheel and adjust the track
	Wheel slip	There is grease dirt on the track.	Remove the dirt

 

Table 9-2 Structural Failure and Treatments
Failure		Causes and Consequences	Treatments
Main beam, end beam	Weld cracks	Centralized stress, overload and enlarging cracks involving rupture risks.	Disperse the stress, and repair the welds to stop them enlarging; overload prohibited
Main beam	Camber disappeared	Overload; trolley climbing	Flame straightening, stiffness and strength reinforcing and increasing
	Oversized sidewise bending	Inadequate horizontal stiffness	Flame straightening
End beam	Oversized sidewise bending	Inadequate horizontal stiffness and joint strength	Restored by professional technicians
Rail	Deformation	Loose connection, oversized tracks, and noise	Readjust and fasten bolts
Balance beam	Weld crack and deformation	Too large lateral force, track biting	Adjust and repair
Plate hook	Rivet loosening	Increased plate clearance; difficult for hanging hook	Rivet again
Trolley frame	Partial deformation	Weak structure excessively stressed; parts damaged	Rivet again

 

Table 9-3 Common Motor Failure and Treatments
Failure		Causes and Consequences	Treatments
Even overheat of motor		A. The actual type of work exceeds the rating; B. The supply voltage is too low; C. The specified values are exceeded in the operating environment.	A. Reduce the motor’s working frequency; B. Reduce the motor load at low voltage; C. Reduce the ambient temperature
Partial overheat of stator iron		Partial short-circuit of the silicon steel sheet of the iron	Remove the burrs and other faults causing short circuit and apply insulating paint
Rotor overheat; great current surge of stator; failure to reach the full speed under the rated load		A. Poor contact between or open weld of coil ends neutral points or shunt winding; B. Poor connection between windings and slip rings; C. Poor contact in brush assembly; D. Interruption or short circuit of rotor circuit	A. Inspect all the welds and remove external defects; B. Inspect windings and slip rings; C. Inspect and treat the brush assembly; D. Inspect and treat the rotor contactor or control the contact point
High vibration in working hours		A. Misalignment of motor shaft and reducer shaft; B. Bearing wear Rotor deformation	A. Measure and align the shaft concentricity; B. Inspect and change the bearing; C. Inspect and machine the rotor
High noise in working hours		A. Phase loss of stator; B. Mal-compression of stator iron; C. Rolling bear wear; D. Slot wedge expansion; E. Low stator voltage F. Stator voltage imbalance; G. Phase loss of rotor; H. Rotor voltage imbalance	A. Inspect and remove motor phase loss; B. Press or change; C. Inspect or change; D. Saw off the expanded part or change; E. Find out the cause of low voltage; F. Eliminate the imbalance; G. Inspect and eliminate rotor phase loss; H. Eliminate imbalance
Overtemperature		Motor oversize, ventilating passage blockage, coil earthing, stator and rotor scuffing, bearing wear	Stop use it and eliminate the failure

 

Table 9-4 Common Failure and Treatments of Electrohydraulic Thruster
Failure		Causes and Consequences	Treatments
Failure to actuate		A. Power failure B. Mechanical hinge points are inflexible C. No oil in the oil cylinder D. The brake spring force is too large.	A. Inspect the power circuit B. Remove the failure at hinge points and add lubricant C. Add oil according to the specified oil level D. Adjust or change the thruster
Inadequate travel		A. Oil shortage in the cylinder B. The mechanical part is jammed	A. Add oil according to the specified oil level B. Eliminate the failure of the mechanical part
Slow and weak movement		A. Oil shortage in the cylinder B. High oil viscosity C. Air exists in the oil cylinder D. Too large braking force E. Low motor voltage	A. Add oil according to the specified oil level B. Change suitable oil as required C. Eliminate the air in the oil cylinder D. Adjust the spring force E. Inspect the power supply line
Motor overheat		A. Thruster overload B. Low motor voltage	A. Adjust the braking force B. Inspect the power supply line

 

Table 9-5 Common Failure and Treatments of Circuits and Components
Failure		Causes and Consequences	Treatments
Crane failing to actuate		A. No power supply B. Button failure of the portable controller	A. Inspect the power supply source and emergency button B. Inspect the button and wiring
Only one-way action of hoisting and operation		A. Wiring failure B. Limiter actuated	A. Inspect the wiring B. Leave the limiting position
Main air switch trip		Short-circuit or earthing failure of the main circuit	Inspect the main circuit
Control circuit air switch tripping		Earthing failure of the control circuit	Inspect the circuit
Overcurrent relay actuating at operating the controller		A. Lower ratings B. Mechanical part jammed C. Brake not opened D. Excessive load	A. Adjust the operating value to 2.25 times of the rated motor current B. Inspect the mechanical part C. Inspect and adjust the brake D. Inspect whether the load is too large
Limit switch fails to function		A. Contact welded B. Earthing or short-circuit failure in circuits C. Sneak circuits in the circuit D. Inaccurate adjusting point	A. Repair the switch contact B. Inspect the circuit C. Inspect the circuit D. Readjust the cam position
Relay contact fails to release after power failure		A. Contact welded B. Earthing or short-circuit failure in circuits C. Sneak circuits in the circuit D. Actual wiring and drawing inconsistence	A. Repair the contact B. Inspect the circuit C. Inspect the circuit D. Correct the wiring according the circuit diagram
The controller is out of order		A. Disconnection or wrong wiring in circuits B. Poor contact of the contact C. Malfunction of the locating mechanism D. Cam disc loosening E. Wrong contact action	A. Inspect the circuit B. Repair the contact C. Restore the locating mechanism D. Adjust and fasten the cam disc E. Repair the contact
The controller contact is burnt.		A. Poor contact B. Controller overload C. Arc control device damaged D. Controller closing procedure errors E. Line errors	A. Repair the contact B. Change the load or the controller C. Change the arc control device D. Inspect and correct E. Inspect the line
The temperature of the relay and contract coils is too high.		A Higher coil voltage B. Larger coil suction. C. Clearance existing between moving or fixed irons in suction	A. Adjust the coil voltage to the rating B. Adjust the contact spring pressure C. Remove the clearance
The pull-in noise of the relay and contact is too loud.		A. Larger coil suction B. Oil dirt on the bonding surface of moving or fixed irons C. Misaligned magnetic circuit D. Moving part jammed	A. Adjust the contact spring pressure B. Remove oil dirt C.  Adjust the magnetic circuit to align it D. Eliminate the additional resistance
The pull-in action of the relay and contact is slow.		A. Longer distance between moving or fixed irons B. Larger friction of movable parts C. Lower coil voltage	A. Adjust the initial position of the moving and fixed irons B. Add lubricant to reduce friction C. Adjust coil voltage
The relay and contact release slowly.		A. Inadequate contact pressure B. Magnetic remanence or oil dirt on the iron C. Moving part jammed	A. Adjust the contact spring B. Eliminate magnetic remanence or oil dirt C. Eliminate additional resistance
The contact of the relay and contactor is burnt because of overheating.		A. Inadequate contact pressure B. Oil dirt on the contact C. Inadequate contact capacity	A. Adjust the contact spring B. Remove