岸边集装箱起重机构造及维护手册 英文PDF电子书下载

Chapter 1 The Quayside Crane 1

1.1 Outline and main parameters for quayside container cranes 1

1.2 Crane steel structure 2

1.3 Crane drive mechanisms 3

1.3.1 Main hoist drive 3

1.3.2 Boom hoist system 10

1.3.3 Trolley travel system 14

1.3.4 Gantry 20

1.4 Crane safety facilities 23

1.4.1 Crane stowage devices and tie-downs 23

1.4.2 Boom stowage device 23

1.4.3 Ship collision protection 24

1.4.4 Obstruction lights 24

1.5 Crane auxiliary equipment 24

1.5.1 Continuous catenary roller support system 24

1.5.2 Power cable reel 25

1.5.3 Trolley festoon system 25

1.6 Maintenance equipment 25

1.6.1 Machinery house service crane 25

1.6.2 Outdoor service crane 26

1.6.3 Wire rope re-reeving device 26

1.6.4 Service platform 26

1.6.5 Tool kit and workbench 27

1.7 Walkways， access and elevator 27

1.7.1 Walkways and platforms 27

1.7.2 Elevator 28

1.8 Handling system 29

1.8.1 Spreader 29

1.8.2 Headblock 29

1.8.3 Over-height adapter 29

1.8.4 Hook beam 30

Chapter 2 Crane Maintenance 31

2.1 General 31

2.2 Cautions and safety notes 31

2.2.1 Safety rules of operation 32

2.2.2 Safety rules during repair or maintenance 32

2.2.3 Safety rules after maintenance／ repair 33

2.3 Cleanliness 33

2.3.1 Major methods of cleanliness 33

2.3.2 Main cleaning 34

2.4 Fastenings 36

2.4.1 Grades of fasteners 36

2.4.2 Inspection of bolts 37

2.4.3 Bolt replacement and tightening 39

2.4.4 Anti-loosening for bolts 41

2.4.5 Pin connections 41

2.5 Inspection of alignment 42

2.5.1 Redress methods for alignment of motor and gear reducer 42

2.5.2 Inspecting alignment with a dial indicator 43

2.5.3 Adjustment of alignment for drum couplings 44

2.5.4 Alignment of brake-disc 44

2.6 Lubrication 45

2.6.1 Summary 45

2.6.2 Lubricants 45

2.6.3 Lubricant replacement standards 46

2.6.4 Lubrication Procedures 47

2.6.5 Lubrication analysis and monitoring 47

2.6.6 Lubrication points 48

2.6.7 Lubrication frequency 49

2.7 Prevention and inspection 54

2.7.1 Summary 54

2.7.2 Inspection of temperature rise 55

2.7.3 Inspection of abnormal noise 56

2.7.4 Inspection of abnormal vibrations 56

2.7.5 Inspection of cracks 57

2.7.6 Inspection of rails and rail clips 57

2.7.7 Inspection of gantry and trolley travel wheels 61

2.7.8 Inspection of rope sheaves， drums， idlers and slap blocks 62

2.7.9 Inspection of the spreader 63

2.7.10 Inspection of hook and twist lock pin 63

2.7.11 Inspection of the hydraulic handspike brake 64

2.7.12 Inspection of the brake disc 64

2.7.13 Inspection of shaft and axle sleeve 65

2.7.14 Inspection of oil seals 66

2.7.15 Bearing unit inspection 66

2.7.16 Inspection procedure for key and keyway 66

2.7.17 Inspection of consumable parts 67

2.7.18 Inspection of steel structural members 67

2.7.19 Inspection of all safety protections 68

2.8 nspection task list 68

Chapter 3 Parts Replacement 95

3.1 General 95

3.1.1 Note 95

3.1.2 List of common tools 95

3.2 Bearing block replacement 99

3.2.1 Preparation 99

3.2.2 Replacement procedure 99

3.3 Motor coupling replacement 101

3.3.1 Preparation 101

3.3.2 Replacement procedure 101

3.4 Drum coupling replacement 103

3.4.1 Preparation 103

3.4.2 Replacement procedure 104

3.5 Motor brake replacement 107

3.5.1 Preparation 107

3.5.2 Replacement procedure 108

3.6 Drum brake replacement 113

3.6.1 Preparation 113

3.6.2 Replacement procedure 113

3.7 Wheel brake replacement 115

3.7.1 Preparation 115

3.7.2 Replacement procedures 115

3.8 Gantry wheel replacement 118

3.8.1 Preparation 118

3.8.2 Replacement procedure 119

3.9 Trolley wheel replacement 121

3.9.1 Preparation 121

3.9.2 Replacement procedure 122

3.10 Main hoist pulley replacement 128

3.10 .1 Preparation 128

3.10 .2 Replacement procedure 129

3.11 Fixed idler roller replacement 130

3.11 .1 Preparation 130

3.11 .2 Replacement procedure 131

Chapter 4 Wire Ropes 133

4.1 Wire rope basics 133

4.1.1 Construction 133

4.1.2 Core 133

4.1.3 Types of laying 133

4.2 Handling wire rope 134

4.2.1 Transportation and storage 134

4.2.2 Installation of wire ropes 135

4.3 Termination and treatment of wire rope ends 136

4.3.1 The termination of wire rope ends 136

4.3.2 Wire rope cutting and the treatment of rope ends 138

4.4 Inspection of wire rope 139

4.4.1 Factors influencing rope life 139

4.4.2 Inspection method 140

4.4.3 Wire rope inspection schedules 141

4.4.4 Inspection targets 141

4.4.5 Discard criteria 142

4.4.6 Procedures for wire rope inspection 149

4.5 Wire rope lubrication 152

4.5.1 Importance of lubrication 152

4.5.2 Selection of lubricant 152

4.5.3 Method of lubrication 153

4.5.4 Lubricating main hoist and trolley towing wire ropes 154

4.5.5 Lubricating boom hoist wire ropes 155

4.6 Rope re-reeving 156

4.6.1 Disassembling or assembling the rope reel 157

4.6.2 Procedure for main hoist rope re-reeving 159

4.6.3 Re-reeving the trolley towing rope 163

4.6.4 Re-reeving of boom hoist ropes 167

4.7 Re-adjusting rope lengths 169

4.7.1 Re-adjusting the main hoist rope lengths 170

4.7.2 Re-adjusting trolley towing rope lengths 170

4.7.3 Measuring waterside trolley rope length 171

Chapter 5 Hydraulic System Maintenance 173

5.1 General 173

5.1.1 Overview 173

5.1.2 Common tools for hydraulic maintenance 173

5.2 Common parts of the hydraulic system 174

5.2.1 Hydraulic pumps 174

5.2.2 Hydraulic cylinders 176

5.2.3 Hydraulic valves 177

5.2.4 Other concerns 182

5.3 THE GANTRY WHEEL BRAKE SYSTEM 184

5.3.1 Schematic and main parameters 184

5.3.2 instruction 186

5.4 Machine house disc brake system 187

5.4.1 Schematic and main parameters 187

5.4.2 Instructions 189

5.5 Multifunctional hydraulic systems 189

5.5.1 Schematic and main parameters 189

5.5.2 Instruction 193

Chapter 6 Electrical Maintenance 197

6.1 Maintenance stations 197

6.1.1 Over-travel bypass operation 197

6.1.2 Snag load reset operation 197

6.1.3 T／L／S local station 198

6.1.4 Emergency operator station／ Rope-reeving station 199

6.1.5 Spreader cable reel operation 200

6.2 Medium Voltage （MV） switchgear 200

6.2.1 Daily inspection 201

6.2.2 Periodic inspection 201

6.2.3 Periodic inspection items 201

6.2.4 Items to be tested 201

6.2.5 MV switchgear cleaning 201

6.2.6 Out of service items 201

6.2.7 Safety checklist for MV switchgear service 201

6.3 Transformer 202

6.3.1 Maintenance period 202

6.3.2 Periodic inspection items 202

6.3.3 Transformer cleaning 203

6.3.4 Preventive testing 203

6.3.5 Bolt torque verification 203

6.3.6 Normal faults and solutions 203

6.4 Three-phase AC motor 204

6.4.1 Motor inspection period and items 204

6.4.2 Motor lubrication and lubrication grease 205

6.4.3 Motor filter cleaning 205

6.4.4 Normal faults and solutions 205

6.5 Special cables 207

6.6 Air conditioners 208

6.6.1 Monthly maintenance items 208

6.6.2 Yearly maintenance items 208

6.6.3 Common problems and solutions 209

6.7 Low Voltage cabinet 210

6.7.1 Low-voltage cabinet maintenance 210

6.7.2 Low-voltage cabinet inspection 211

6.8 Slip ring Box 211

6.8.1 Slip ring box inspection items 212

6.9 Gear limit switch 212

6.9.1 Hoist Gear Limit Switch adjustment： 212

6.9.2 Boom cam limit switch adjustment 213

6.10 Load cell sensor 213

Chapter 7 Emergency Operation 214

7.1 General 214

7.1.1 Standard emergency tools 214

7.2 Personnel emergency escape 215

7.2.1 Escape to boom and girder walkway 215

7.2.2 Escape from the machinery house 216

7.2.3 Emergency operation of the elevator 217

7.3 Trolley shaft breakage during vessel loading／unloading 218

7.4 Main crane power failure with spreader inside vessel cell 220

7.5 Gantry drive axle failure during gantrying 220

7.6 Loss of hydraulic function 221

7.6.1 Manual release of wheel brakes 221

7.6.2 Manual release of emergency brakes 222

7.6.3 Releasing pressure on trolley tension cylinders during maintenance 222

7.6.4 Loss of multi-function power unit hydraulic function 223

7.6.5 Operating a crane after a snag 223

7.7 RESETTING SNAG／TRIM／LIST／SKEW DEVICES？ 223

7.8 Boom hoist emergency operation 224

7.8.1 Using the boom hoist emergency drive 224

7.8.2 Preparing the boom hoist emergency drive 224

7.8.3 Procedure for boom hoist emergency operation 225

7.8.4 Restoring the boom hoist emergency 226

7.9 Trolley emergency operation 226

7.9.1 Trolley emergency drives 226

7.9.2 Using a trolley emergency drive 227

7.9.3 Procedures for trolley emergency operation 227

7.9.4 Restoring trolley emergency 227

7.10 Main hoist emergency operation 228

7.10 .1 Using the main hoist emergency drive 228

7.10 .2 Using the main hoist emergency device 228

7.10 .3 Procedures for main hoist emergency drives 228

7.10 .4 Restoring the main hoist emergency drive 229

Chapter 8 Paint Repair 230

8.1 GENERAL 230

8.1.1 Scope 230

8.1.2 Criteria and code 230

8.1.3 Surface preparation 230

8.1.4 Paint application 231

8.1.5 Paint criteria 231

8.1.6 Inspection 231

8.1.7 Color scheme 231

8.2 Paint application and repair technics 231

8.2.1 Introduction 231

8.2.2 Surface preparation 232

8.2.3 Shop primers 233

8.2.4 Paint application 233

8.2.5 Inspection 235

8.2.6 Others 235

8.2.7 Repair／touch-up 236

8.3 Paint inspection 236

8.3.1 Repair of aging or deteriorated coatings 236

8.4 Paint Requirements 237

8.5 European rust scale 238