2. The Advantages of Electric Open Winch Trolley:

• ►  Without the need for any additional design or development work: Fast, safe and reliable.
• ►  Without any problems caused by additional interface. 
• ►  Those component are extremely reliable elements for double girder crane, not only hoist trolley, but also open winch trolley.

 

3. Electric Open winch Trolley Cross Traveling Mechanism

No.	component	Technical features	Picture demonstration
1	Motor	3 in 1 compact structure; Motor insulation class: F, Protection class：IP55, Duty-cycle:40%;
2	Brake	Electromagnetic disc braking
3	Gear box	Gear-hardened; Gear grinding or shaving; No need oil change in gearbox’s service life
4	Wheel	Forging; Wheel flange and tread hardness：HB330~380
5	Inverter	All speed controlled by inverter; Fast speed in light loading; Slow speed in heavy loading; Speed scope: 1:10; Smooth running and no impact
6	Cross travel limit switch	Cross hair motion limit switch; Make crab reducing the speed to 0 before buffer impact on stopper weld on the end of the crab rail

 

4. Electric Open Winch Trolley Lifting Mechanism

No.	component	Technical features	Picture demonstration
1	Welding drum	Short-shaft type steel plate coiled, fitted with bearing support at the two ends; one of ends is stretched for shaft installation; simple structure; easy installation and maintenance;
2	Hoisting motor	Frequency converter motor; optimum cooling fan; Insulation class: F; Protection level: IP55; Duty-cycle:40%;
3	Hoisting gearbox	Tooth surface carbon case hardening; treatment, Hardness: HRC60; Gear grinding or shaving; Light deadweight, good seal, no oil leak;
4	Hoisting brake	Normally closed type; With wear automatic compensation; Can manually release in emergency condition; Can equipped with double brake(option);
5	Hook block	Organized by hook and pulley; Material: DG34CrMo; Pulley material: Q245, hot rolling; Wear-resistance rolling bearing, 360°rotation; Spring safe lock All pulleys employ maintenance-free bearing Reduce wear and tear between rope and pulley;
6	Lifting limit	Cam rotating type, 4 levels: Up 2 levels, down 2 levels; self-recovery, safe and reliable;
7	Crab control box	Protection level: IP55; Aviation plug Quick installation

 

5. Electric Open Winch Trolley Pictures Demonstrations in Kingda Crane Workshop 

 

6. Electric Open Winch Trolley Inspection and Maintenance

6.1 Safety precaution

• ►  1)  Observe the inspection and maintenance site and adjacent areas, set up warning signs and safe working areas;
• ►  2)  If encountering adverse weather, such as strong winds, thunderstorms, severe ice and snow, or heavy fog, outdoor inspections and maintenance should be postponed;
• ►  3)  The crane should be parked in an undisturbed area;
• ►  4)  Disconnect the power supply of the sliding wire or the main circuit breaker of distribution cabinet before conducting maintenance on the crane;
• ►  5)  There should be warning signs indicating "inspection in progress" or "maintenance in progress", or the controller switch should be locked in the "off" position, only designated personnel can able to identify and/or lock it;
• ►   6)  If there is a load on the electric open winch trolley, the load should be removed;
• ►  7)  If the maintenance work poses a danger to the area under crane, warning signs and warning areas should be set up below;
• ►  8)  Safe and reliable tools should be used;
• ►   9)  Inspection or maintenance personnel should be equipped with personal protective devices (such as protective shoes, safety helmets, seat belts, or protective glasses);
• ► 10) Measures should be taken to prevent electric shock;
• ► 11) During inspection, it is strictly prohibited to close or disconnect the power switch except for instructions given by designated personnel;
• ► 12) When entering a location with a risk of electric shock during inspection, it should be ensured to disconnect the power switch, give a warning sign of "inspection in progress", lock it and/or send personnel to guard it; There should be a warning sign indicating 'under inspection' in the control room;
• ► 13)  During the inspection, it is strictly prohibited to operate the electric open winch trolley except for instructions given by designated personnel;
• ► 14)  Before the load test, the lifting attachments and the testing load should be checked for defects;
• ► 15)  Prohibit other personnel from entering hazardous areas unless authorized;
• ► 16)  The inspection should be carried out by two or more inspectors together;
• ► 17)  Adequate lighting should be provided during inspection or maintenance;
• ► 18)  When welding, appropriate protection should be taken;
• ► 19)  After maintenance operations and before the electric open winch trolley resumes normal operation, protective facilities should be reinstalled; Restore safety protection devices and proceed;
• ► 20)  Necessary firefighting measures should be taken during maintenance;
• After the maintenance work is completed, the temporary facilities taken during maintenance should be removed and the site cleaned up.

6.2 Daily inspection

Daily inspection items and requirements should be determined based on the specific characteristics of electric open winch trolley, should not be lower than the provisions in Table 7-1.

6.3 Periodical inspection

 

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	Mechanism	Hoisting  mechanism	Check that the hoisting mechanism has no abnormal noise and vibration by a no-load test.	Maintain		○	○	○	○
6		Trolley travelling mechanism	Check that the trolley operating mechanism has no abnormal noise and vibration by a no-load test.	Maintain		○	○	○	○
7			Visually check that there is no deflection, track biting, etc. influencing the trolleys operation.	Adjust/replace			○	○	○
8		Trolley power supply unit	Check that the crane power supply unit has no abnormal noise and vibration by a no-load test	Maintain			○	○	○
9	Key component	Pulley	Visually check that the trolley should meet the requirements set forth in Section 4.2.5 ofGB6067.1-2010.	Repair/change				○	○
10			Visually check that the pulley can turn flexibly.	Lubricate/adjust				○	○
11			Visually check that the pulley stopper is safe and effective.	Repair/change				○	○
12		Reel/Drum	Visually check that the reel should meet the regulations set forth in Section 4.2.4.5 inGB6067.1-2010	Change			○	○	○
13		Wire rope	Check the steel rope according to the methods specified in GB/T5972 and make sure it meet the requirements.	Change			○	○	○
14			Visually check that the steel rope should have no obvious mechanical damage.	Repair/change		○	○	○	○
15			Visually check that the steel ropes of the reel and the pulleys have no disengagement from the	Fasten/adjust	○	○	○	○	○
16			groove.	Fasten/adjust			○	○	○
17		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		○	○	○	○
18			Visually check that the lubrication of turning points and slewing points meet requirements.	Maintain	○	○	○	○	○
19			Check through a no-load test that the hoisting mechanism can work properly	Change			○	○	○
20		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				○	○
21		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		○	○	○	○
22		Reducer	Visually check that the coupling has no defects looseness, oil leakage, and abnormal vibration and noise in operation.	Fasten/repair			○	○	○
23			check that the running reducer has no abnormal noise, vibration, oil leakage and overheat	oil			○	○	○
24		Bearing	Visually check that the oil level should be within the required range.	Change				○	○
25		Trolley rail	Visually check that the bearing has no abnormal noise and temperature rise.	Adjust					○
26			joint gap and height difference to make sure they meet relevant standards.	Change			○	○	○
27			Visually check that the track has no cracks and serious wear-out.	Fasten/change			○	○	○
28	Safety protection device	Lifting height limiter	Visually check that the pneumatic system works normally and has no abnormal noise.	Fasten/repair	○	○	○	○	○
29		Secondary lifting height limiter	Check through function testing that the lifting height limiter is fixed securely and functions effectively.	Fasten/repair			○	○	○
30		anti-crash device	Visually check that the slewing locking device has no deformation, damage and looseness	Fasten/repair			○	○	○
31		Buffer and end stopper	Visually check that the anti-crash device has no deformation and damage and functions effectively	Fasten/repair/change				○	○
32		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					○
33		Overspeed protection device	Check through function testing that the load lifting limiter is fixed securely and functions effectively.	Change					○
34		Emergency stop switch	Visually check that the control units of the safety monitoring and management system work normally.	Repair/change				○	○
35		Radiant heat protection device	Visually check that the clearance between the track sweeper and the track is 5mm~10m	Fasten/repair				○	○

6.4 Inspection and maintenance of main components

6.4.1 Wire rope inspection

6.4.1.1 Replacement of wire rope

• ► 1)  Replace worn or damaged wire ropes. The model and main performance of the wire rope can be found in the random file:
• ► 2)  Lower the hook to the ground to keep the rope loose;
• ►  3)  Dismantle the fixed parts of the wire rope (hoist crane);
• ► 4)  Remove the rope guide (hoist crane);
• ► 5)  Remove the pressure rope plate from the drum;
• ► 6)  Put down the old wire rope, coil it neatly and put it into storage;
• ► 7)  Take out a new wire rope and keep it lubricated;
• ►   8)   Check and ensure that the new wire rope and drum are compatible. Check the certificate of the wire rope to ensure that the model and performance of the wire rope meet the requirements:
• ► 9)  There is a pressure plate at the end of the roll for fixing wire rope, the specifications and quantities vary depending on the model. When the hook is in the lowest position, it must be ensured that there are at least two complete coils of wire rope wrapped around the drum at the end of the drum;
• ► 10)  Fix the starting end of the wire rope to the drum with a pressure plate, which must be firm and not loose;

• ► 11)  Wrap the wire rope onto the drum through lifting motor;
• ► 12)  According to the rope winding diagram, correctly thread the wire rope through the pulley;

• ► 13)  Fix the end of the wire rope on the drum with a pressure plate, which must be firm and free from looseness (open winch trolley crane);
• ► 14)  Fix wire rope in the wedge sleeve, tighten wire rope and clamp rope clamp (hoist trolley crane) on the free end of wire rope;
• ► 15)  Place the wire rope wedge sleeve on the suspension point, install the pin shaft and lock it firmly (hoist trolley crane);
• ►  16)  Clean and install the rope guide (hoist trolley crane);
• ► 17)  After replacing the wire rope, adjust and check the lifting limit switch;
• ► 18)  Test the condition of wire rope winding. If the wire rope is knotted and causes the hook to rotate, the wire rope must be removed to eliminate the twisting of the wire rope;

Matters needing attention

►   Only wire ropes specified by the crane manufacturer can be installed.

►   When uncoiling the wire rope, it should be prevented from tying or twisting.

►   When cutting the wire rope, measures should be taken to prevent the rope strands from spreading.

►   Place the wire rope in the wedge sleeve in the correct way, andsuspension hole of the wedge sleeve should be in line with the load-bearing rope.                               As shown in the above figure

6.4.1.2 Installation requirements for wire rope clamps  

Table 6-2 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

6.4.2 Drum inspection

If one of the following situations occurs, the drum should be scrapped:

• ► 1)  Surface defects that affect performance (such as cracks);
• ► 2)  Wear of the simple wall reaches 20% of the original wall thickness.

6.4.3 Hook inspection

If one of the following situations occurs, the hook should be scrapped:

• ►  1)  Surface cracks appear;
• ► 2)  Plastic deformation of the dangerous section or neck of the hook;
• ► 3)  Torsion deformation of the hook exceeds 10 °;
• ► 4)  Dangerous section wear of the hook reaches 5% of the original size;
• ► 5)  Deformation of the hook opening reaches 10% of the original size;
• ► 6)  Plastic deformation of the hook shank;
• ► 7)  Other requirements shall be in accordance with GB10051.3 "Lifting Cranes - Part 3: Inspection of Forged Cranes for Use"

Defects on the hook shall not be repaired by welding
 

6.4.4 Pulley inspection

If one of the following situations occurs, the pulley should be scrapped:

• ►  1)  Surface defects that affect performance (such as cracks);
• ► 2)  Uneven wear of the wheel groove reaches 3mm;
• ► 3)  The wear of the groove wall thickness reaches 20% of the original thickness;

4) Due to wear and tear, the diameter at the bottom of the wheel groove has decreased by up to 50% of wire rope’s diameter.
 

6.4.5 Brake inspection

If one of the following situations occurs to brake parts, the parts should be replaced or the brake should be scrapped
► 1)  Driving device
a)  Burn out of magnet coil or motor winding;
b) The thruster’s thrust cannot meet the brake release requirement or there is no thrust;
► 2)  Brake spring
a) The spring occurs plastic deformation and the deformation reaches more than 10% of the spring’s working deformation;
b) Spring surface occurs more than 20% rust; Or obvious damage such as cracks.
► 3) Transmission component
a) Severe deformation affects performance
b) When severe wear occurs at the main swing point, and the wear leads to a loss of over 20% of the original brake drive stroke;
► 4)  Brake pad
a) Riveted or assembled brake pads’ wear amount reaches 50% of the original thickness of the liner;
b) Wear amount and mounted brake pad of steel backer reaches 2/3 of the original thickness of the gasket;
c)Carbonization on the surface of the brake pad; Or the peeling area reaches 30% of the pad area;
d)Cracks or severe cracking on the surface of the brake pad.
► 5)  Brake wheel
a) Surface cracks and other defects that affect performance;
b) The brake wheel of the lifting mechanism has a thickness wear of 40% of the original thickness on the brake surface;
c) The brake wheels of other institutions have a thickness wear of 50% of the original thickness on the brake surface;
d) When the unevenness of the wheel surface reaches 1.5mm, if it can be repaired, the thickness of the brake surface after repair should meet the above requirements
 

6.4.6 Frequency converter inspection

 

Daily Inspection Items

►  Does the sound of the motor change abnormally during operation

►  Is there any vibration generated during motor operation

►  Whether the converter fan works normally

►  Is the frequency converter overheated

►  Effectively remove surface dust on the frequency converter and prevent dust from entering the interior of the frequency converter.

►  Especially metal dust. Effectively remove the oil stain of the converter fan.

 

6.5 lubrication

Table 6-3 Brand and filling quantity of lubricating oil
Electric open winch trolley lifting mechanism  reducer	Reducer Mode	Oil Mode	Adding Quantity(Litre)	Every 3 months	Every 6 months	Every 3 years	Every 5 years
	P3HM5	L-CKC220	16		check lubricating oil condition	replace lubricating oil(if mineral oil)	replace lubricating oil (if it is synthetic)
	P3HM6		18
	P3HM7		29
	P4HM9		48
	P4HM10		50
	P4HM12		87
	P4HM13		120
	P4HM15		170
Hoist trolley lifting mechanism  reducer	GH3201	L-CKC680	1.4
	GHX63	L-CKC220	4
	GH12500	L-CKC680	5
	GH20000	L-CKC680	9
	GH25000	L-CKC220	13
	GH40000	L-CKC220	15
Travelling reducer	G…27	L-CKC220	0.6
	G…37		1
	G…47		1.5
	G…57		2.8
	G…67		2.9
	G…77		6
	G…87		10.8
	G…97		18.5
	G…107		27
Wire rope	No galvanized	Lubricating grease for wire rope	Proper amount	Smear
Bearing		Calcium-based grease ZG-3	Proper amount	Smear

 

6.6 Recommended tightening torque

Table 6-4 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

 

7. Electric Open Winch Trolley Fault analysis and troubleshooting

When electric open winch trolley has malfunctioned, timely analysis and handling should be carried out. Do not use a crane until the cause of the malfunction has been identified and eliminated.
 

Malfunction phenomenon	Malfunction cause	Solving method
Crane does not move	No power supply	Inspect power source and emergency stop button
	Malfunction of hand-held controller	Insepct button and wire
Excessive brake distance	Large brake disc clearance	Adjust clearance
Lifting motor does not move, there is noise when press button	Wiring fault	Check the main power supply incoming line
	Contactor issues	Replace the contactor
	Brake not open	Check the brake
Lifting motor and long travelling motor only can move in single firection	Button failure of handheld controller	Check button
	Wiring fault	Check wiring
	Lifting limiter triggered	Leave the limiter position
Brake does not act	Brake coil power supply fault	Check the wiring or repair and replace the worn brake coil
Wire rope wear out	Poor working environment, fixed attachments on the wire rope	Regularly clean the steel wire rope
	Abnormal use, resulting in pulley wear	Restore normal use and replace the pulley
Lifting motor moves in wrong direction	Power phase connection error	Change the two phase sequences of the power supply voltage and check the direction of operation
Active wheels slip	Oil stains on the rail	Remove oil stains
	Excessive braking force	Adjusting the braking torque
Rail gnawing	Travelling motor out of sync	Check the motor speed and maintain consistency
	Inconsistent braking torque during travelling	Adjusting the braking torque
	Span deviation	Check rail span