overhead cranes

Hydraulik & MaschinenbauBuxtehude GmbH

Instruction ManualTechn. Description ofOverhead Travelling Crane2,5 to-7,36m

HMB-order: 2126 Aker Finnyards Order: 120294/ 1352

NB 1352

Contents

Important informations for the operator 1

Technical data / rope specification 2L.4.0307.0600.02 (1)

Maintenance hints 3How to order spares

Electrical System, acc. to Drg. No. 4L.4.0307.5700.01 (4)L.4.0307.5700.10 (4)

Hydraulical System, acc. to Drg. No. 5L.4.0307.4900.00 (2)

Drawings and details of components 6L.4.0307.1100.01 (0) Overhead travelling crane0.0.0300.2500.08 (1) Hoisting Winch0.0.0300.2600.07 (2) Preload RollerL.4.0307.1112.00 (4) Führungsrolle Ø 113L.4.0307.1117.00 (4) Laufrolle Ø 1130.0.0300.3100.00 (3) Lower Block0.0.0100.2000.02 (4) Rope Sheave0.0.0020.4000.00 (3) Plunger CylinderL.4.0307.7100.00(2) Limit switch for travelling

-2-

The crane motions can be operated simultaneously with reduced

speeds.

The crane only be used within the specified LOAD RANGE only.

Whilst the ship is at sea the crane has to be stowed and locked in sea -

locking device. The runner has to be tightened with its hooks to the

highest position.

For ventilation and expansion of the oil level the oil tank has to be

continuously open by the air pipe on the upper side of the tank.

After running of appr. 3 min. without any control motion, the E-motor is

switching off, to safe the hydrl. circuit against overheating.

.

.

CL

D e c k 5

- L

D e c k 4

P u m p u n i t w i t he l e c t r . s w i t c h b o x

Remote con t ro l

L 6

( 1 ) ( 2 )

123

2 2L

1

2L

CL

6A

A

Z

2 6 1 7

1 2

2 2- L - L

- L

- L

Hyd rau l i k & Masch inenbauB u x t e h u d e G m b H

L.4.0307.0600.02(1)

Overhead-Traveling Crane SWL 2,5T - 7,36MI n s t a l l a t i o n o f

2127 K

88

a = 1 0

8

8 8

88 1044

B B

B

C r o s s - S e c t i o n B - BM 1 : 5

8 8"H"

9

c a b l e d r u m

D e c k 5

C r o s s - S e c t i o n A - As c a l e c a . 1 : 1 0

F 3 0 8RF 3 0 9R CL F 3 0 7RF 3 1 0R

C a b l e i n l e t

H1

low

est

poin

t pu

mp

unit

W

H E M 1 4 0

"H"

8 8

44

" T "

C o n n e c t i o n p o i n t o fr u n - w a y g i r d e r s

9

1 7- L / 1 7L6- L / 6L1 7- L / 1 7L6- L / 6L

D e t a i l Y M 1 : 5

Y

" T "

S t bB b

B b

10

9

N B 1 3 5 2

AB

D imens ion o f "H " t o be measu red by Ya rd

2 - L

C LP S

150 150 150150 150150 250250 250 250

A

B

P S

" T "

S b

B b S t b

Sb

CL

2127 / 2,5 T - Overhead Deck CraneDistances to the Runway - Girder

M %

2 2 L 1 7 L 1 2 L 6 L 2 L 6- L 1 2- L 1 7- L 2 2- L

L L L L L - L - L - L - L - L

2 2 L

- L /2 2 L 2 2

- L /1 2- L / L 1 2

2- L / 2L

D e t a i l Z M 1 : 5

5

a = 1 0

f l a t g r i n d e d

B

w e l d e d a r o u n d

23:08:04


TECHNICAL DATA SHEETorder 2127 Overhead Travelling Crane

drawing L.4.0307.0600.02 (1)

working load (to) 2,5

outreach (m) 7,36 (3,2m over board)

hoisting speed (m/min) 0 – 25

travelling speed (m/min) 0 – 15

hoisting height (m) 18

Install. E-motor (kW) 16 S1

max. power consumption (kW) 20 S6 15%

heel (°) 5

trim (°) 2

total weight (kg) appr.9.000incl. runway girder

main supply (V/Hz) 440 / 60

operating temperature (°C) -20° - 45°

humidity (%) 95


Section 3Maintenance Hints

12 weeks lubricate the following:bearings of jib rollerscylinder and bearings of hook lockingsload swivel with rope sheave,winch-preload axles and bearingsrope sheaves

After lubricating, it is important to move the crane-parts and thanrepeat the lubrication process.

Oil level of the hydrl. system has to be checkedby the level gauge glass. To fill or let out oil thetank is equipped with a stop-valve (pos.4 of thehydrl. diagram)

The filling capacity is correct when oil is shown in the lower glass.Never fill more than the upper glass shows oil.

hydraulic oil The oil charge should be changed every 12months.

The oil charge f the travelling and hoisting gearis filled for life-time in acc. to the crane group.

oil quantities hydraulical system appr. 250 lhoist gear box appr. 4 ltravelling gear box appr. 1,5 l

For recommended lubricants see next page.


Schmierstoffempfehlung: Standard für alle Antriebe bei allen auftretenden Umgebungstemperaturen

Recommended Lubricants: standard for all drives during all possible ambient temperatures

OELFÜLLUNG / OIL FILLINGStockpunktPour point

min.

ViskositätKin. viscosity

cSt/40°C

Visk. IndexVisc. index

min.

OelqualitätenOil qualities

Shell ESSO Mobil Texaco BPhydrl. Kreisläufehydrl. circuits

-40°C 46 150 Tellus T 46 Univis N 46 DTE 15M Rando HDZ 46 Barton HV46

Stirnrad- und PlanetengetriebeSpur gear boxes and planetary gears

-30°C 220 140 Omala HD 220 --- Mobilgear SHC 220 Pinnacle EP 220 Enersyn HTX 220

SchneckengetriebeWorm gear boxes

-30°C 460 160 Omala HD 460 --- Mobil SHC 634 Pinnacle EP 460 ---

FETTSCHMIERUNG / GREASINGTropfpunktdropping pt.

Penetrationpenetration

wasserresistentwaterresistant grease qualities

Gleitlager und offene AntriebeBearings and open drives 185°C ca. 250 yes Molylube 126 EP

Seiltrieberope drives Ceplattyn 300

19.07.04


Ordering spare parts

It is essential that, when ordering spares, the following informationis supplied with each order:

Type of crane

Contract number

Drawing number

Part number of drawing

if possible special hints of defect


Section 4 Principal of electrical control drawing L.4.0307.5700.01(4)

The electrical equipment for crane operation mainly exists of pump-

motor, switch box and portable control desk.

The electrical wiring consists of the following sections:

- Power circuit for pump motor

- Heating

- Control circuit for electronic current-regulator

For starting the unit it is necessary to swtich on the main power supply

in separate compartment. The crane is equipped with a sea locking

device controlled with a safety switch. Before the pump can start, the

sea locking device must be released.

After having released the EMERGENCY OFF button (SO) you can start

the pump unit by START-button (S1) and indication lamp (H1) will

signalize running motor by permanent green light.

Normally now the crane is ready for operation. By means of the defined

control levers you can operate crane movements into either direction.

R1 starts travelling

R2 starts hoisting/lowering

S3 direction of operating side (PS, Stb)

The travelling drive is protected by limit switches for left and right

position (B1, B2).

The hoisting winch is protected by limit switch for highest and lowest

hook position (S4, S5).

However, inherent ramp-functions of the electronic integrator (A2) will

allow smooth response of movements.

Description of the integrator for control see next pages.

-2-

-2-

During crane operation power supply for anti-condensation heating of

motor (E2) and switch box (E1) is interrupted. To safeguard the electric

motor and the hydraulic circuit against overheating the system is

protected by time relay (K4); the running time will be interrupted by

center switches of (R1.1/R1.2) , unloaded running time 3 min. appr.

The oil level (NV) and oil temperature (°C) is checked by switch and

relay (K2), this gives fault-alarm by signal lamp (H2) only.

To set off the crane press STOP/EMERGENCY-OFF push button (SO)

until it snaps into locked position.

L.4.0307.5700.01(4)

E-Schal tp lan E-Diagram

H y d r a u l i k & M a s c h i n e n b a uB u x t e h u d e G m b H

01

04

R5

R6

°C



02

04L.4.0307.5700.01(4)



03

04L.4.0307.5700.01(4)



04

04L.4.0307.5700.01(4)

Zeichnungs- Nr. /Drawing No Benennung / Description Bl./PageKlassifizierung Classification

Auftrags- Nr. Commission- No.

2127Baugruppe/Section Stck /BG /Pc./Section von Bl.

of pageAusgabe / Edition

00

Pos.

Stc

k

pcs Abmessungen / Dimensiones Werkstoff DIN; Material

(Abn.n.DIN50049)Gewicht

Weight (kg)

Bemerkungen Remarks

housing

AE 1050

switch box heating

SK 3115

main switch

VCF3

main contactor + auxiliary contactor

LC1D40M7 + LA D22

lamp

ZB2 - BV 6

lamp

ZB2 - BV 6

Auxiliary relay + relay socket

R.T 1.3.024

Electronic card

Typ 092836

emergency stop push button

XB2 - B4885

thermistor

LT3-SA00MW

push Button

XB2-BA31

control transformer

ST 160 / 4 / 2x115

control transformer

green

14 T2 1 Block

Block

Telemecanique

14 T1 1

11 A1 1

12 S1 1

K2 - 108

Telemecanique

I E N

8

red

Telemecanique

Telemecanique

Telemecanique

7

K1

H2

1

1

7 H1 1

2 R6 1

5

1 Telemecanique

Tele

10 S0 1

Zeichnungs- Nr./Drawing No.

1

9 A2 1

4 Q1

Telemecanique

TB

Rittal

AV/K Werkst.

L.4.0307.5700.01 (4)

57KundeVerteilung/ Distribution

Rittal1

E - Diagram

RAL 7032

Auftrags- Menge Commission- Quantity


Seite/ page 1 of 2 2127-L-0-1-0106-5700-01(4)-E-Schaltplan-Englisch / 17.05.2005





00

Pos.

Stc

k



Weight (kg)

Bemerkungen Remarks


TB AV/K Werkst.

L.4.0307.5700.01 (4)

57KundeVerteilung/ Distribution

E - Diagram



ST 160 / 4 / 24

protection switch

GB 2 CD12

motor protection switch

GV2 ME04

Rectifier

30V 10A / 183-4242

motor protection switch

GV3 ME63

protection switch

GB2 CD07

protection switch

GB2 CD09

19 F3 1 Telemecanique

16 Telemecanique

Block

Telemecanique20 F5 1

14 T1 1

1

1F4

Telemecanique

F2

V1

F1

R + S

1 Telemecanique16

17

18

1

Seite/ page 2 of 2 2127-L-0-1-0106-5700-01(4)-E-Schaltplan-Englisch / 17.05.2005


Section 5Description of hydraulic-circuitin acc. to drawingno. L.4.0307.4900.00(2)

The system is powered by a load sensing pump (2).

The functions are as follows:

- hoisting winch

- travelling gear

All systems operate on the open circulation method.

The manual/electr-hydrl. operated directional control valve (1), two

sections, distributes the oil-flow in dependence of the control-valve into

the chosen circuit. In 0-position of the control valve the oil charge is

reduced to a minimum. The back flow goes to the preload-valve (8).

The preload arise up to appr. 5 bar.

The hoisting winch circuit consists beside the pump (2) and the

directional valve section (1.2) by overcenter valve (12), motor (15) with

brake (14) as way-change valve (13).

The open circulation circuit works with the overcenter valve (12). This

valve is coupled directly to the motor . The overcenter valve is

controlled by the lowering oil pressure and provides controlled lowering

of the load. In case of power failure valve (12) closes due to loss of

operating pressure and the winch is brought to a halt. The spring loaded

-2-

-2-

brake acts directly as a purely mechanical device to stop the winch

drum.

The spring loaded multi-plate brake, integrated in the gearbox, is

automatically operated by the way-change valve (13).

In the way of hoisting the oil flow goes directly through the non-return

valve inside of the overcenter valve (12) to the motor.

For complete oil supply on the low pressure side of the motor (15) the

system is provided with preload-valve (8) to secure appr. 5 bar circuit

pressure in way to the filter (9).

The hoisting winch is equipped with limit switches for the lower hook

position.

The travelling system consists of a hydraulic drive motor (20) with its

multi plate brake and planetary gearbox. As the system is to operate in

both directions (right and left) the circuits are secured by throttel valve

(17). The control of the multi plate brake is controlled by the way-

change valve (18).

To operate the winch on PS resp. Stb-side the sheave blocks are

locked by locking devices, hydrl. operated by cylinder (10), controlled by

valve (11).


A BA B

X

A

L

Ls

P

LsPR

H L

R H D20S

*

*

* A n s c h l u ß N o t h a n d p u m p e

3 0

3 1

3 2

3 3

3 43 5

3 6

3 7

3 83 9

4 0

4 14 2

4 3

4 4

L





01

Pos.

Stc

k



Weight (kg)

Bemerkungen Remarks

2-fold Proportinal-Valve

1.1 - 1.2

L - S Pump PV 15

Oil tank, included in subgroup 16

1/2" Ball valve 16bar

Thermo switch 70°

Niveau switch

Air plug 1/2"

Non - return valve 1" 0,5 bar

Filter

UC MX 1518 - 101

Plunger cylinder

4/2 - Control valve NG 6, 24=

with base plate

Overcentre valve

1 CE 30

Change valve WV8l Feil13 1

Bolz

12 1 Integrated Hydraulik

11 1

UCC

10 2 HMB

9 1

HMB

8 3 Feil

7 1

1

6 1

Feil4 1


TB AV/K Werkst. KundeHydraulik - Diagram

Brevini

Denison

Verteilung/ Distribution


1 1

1

5

L.4.0307.4900.00(2)

49

2 1

3


Seite/ page 1 of 4 2102-L-4-0307-4900-00(2)--Hydraulik-Diagramm-Englisch / 17.05.2005





01

Pos.

Stc

k



Weight (kg)

Bemerkungen Remarks





L.4.0307.4900.00(2)

49


Feil13 1






01

Pos.

Stc

k



Weight (kg)

Bemerkungen Remarks





L.4.0307.4900.00(2)

49


Brake, integraded on gear box

Motor

SAM HPR 50cm³

Throttel non - return valve 1/4"

F 400 SF

Throttel non - return valve 3/8"

F 600 SF

Change valve WV8l

Brake, integraded on gear box

Change motor

SAM AR 50

Female - Quick connection

3/8" for hand - pump

Male - Quick connection

3/8" for hand - pump

Σ Gewicht/Weight

2% Zuschlag

ges. Gewicht / Weight

22 1

20 Brevini

19 1 Brevini

18 1 Feil

17

Brevini1

Parker2

16 1 Parker

15

14 1 Brevini

1

121






01

Pos.

Stc

k



Weight (kg)

Bemerkungen Remarks





L.4.0307.4900.00(2)

49



Hy drau l i k & M asc h inenbauBux tehude Gm bH

L.4.0307.1100.01(0)

Overhead - Travel ing crane SWL 2,5T - 7,36M

CL

42,4514,4025 2

5

28

48

18

17

12 339 35

35

13

16

39

3839

50

38

27 43 ,49

7

6

13 3835 39

S c h n i t t D - DM 1 : 2 , 5

S c h n i t t E - EM 1 : 2 , 5

15

19 ,46 ,47

35

38

S c h n i t t F - FM 1 : 2 , 5

I n n e n k a n t e H E M 1 4 0

A c h t u n g : A u f t r a g s a b h ä n g i g e S t ü c k l i s t e n b e a c h t e n

A t t e n t i o n : P a y a t t e n t i o n t o t h e m a t e r i a l l i s t d e p e n d i n g o n t h e o d e r n o .

S c h n i t t A - A M 1 : 2 , 5

A u f t r a g 2 1 2 7 a b A u s g a b e 0 5

37

23

20

31

32

36

S c h n i t t B - BM 1 : 2 , 5

4

4051

2624

S c h n i t t C - CM 1 : 2 , 5

34

44

S c h n i t t G - GM 1 : 2 , 511

8

9

10

9

10

B

CD

DC

22

F

F

B

A

T a n k + H y d r . U n i t1

E

E

G

G

A

8

30

Assembly list of mechanical partsaccording to drawing L.4.0307.1100.01(0)

Pos. Description Supplyer Type o. Drawing o. following

Tank und Hydraulik-Einheíteigene StücklisteAuslegereigene StücklisteLaufradbrückeeigene StücklisteSeilscheibe kompl. ø170 / ø195eigene StücklisteGetriebe - Halterungeigene StücklisteWinde 3,0 Teigene StücklisteAndruckrolleeigene StücklisteUnterflasche SWL 3,0 Teigene StücklisteHydr. - Zylinder, Plunger ø 20 - 20 Hubeigene StücklisteVerriegelung für Ladehaken , komp.eigene Stückliste

Laufrolle ø 113 für Laufradbrücke

Rd. Ø 130 - Lg. 70 FMLaufrolle ø 113 Rd. Ø 115 - Lg. 54 FMBolzen für LaufradbrückeRd. Ø 90h6 FM - Lg. 279 FM Achse für FührungsrolleRd. Ø 70 FM - Lg. 169 FMAchshalter für FührungsrolleFl. 30 x 8 - Lg. 100 FMFührungsrolle ø 113Rd. Ø 115 - Lg. 95 FMDeckel für FührungsrolleRd. ø 110 - Lg. 6 FMScheibe für GetriebehalterungRd. Ø 40 - Lg. 8 FMScheibeRd. Ø 70 - Lg. 37 FM

See - Zurrungeigene StücklisteBolzen mit SplintlöcherRd. Ø 30h11 - Lg. 147 FMBolzen für Seilscheibeeigene Stückliste

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

HMB

L.4.0307.1400.01(1)

L.4.0307.1400.10(3)

0.0.0100.2000.02(4)

L.4.0307.2201.00(3)

0.0.0300.2500.08(1)

0.0.0300.2600.07(2)

0.0.0300.3100.00(3)

0.0.0020.4000.00(3)

L.4.0304.8500.00(3)

L.4.0307.1112.00(4)

L.4.0307.1113.00(4)

L.4.0307.1114.00(4)

L.4.0307.1115.00(3)

L.4.0307.1116.00(4)

L.4.0307.1117.00(4)

L.4.0307.1118.00(4)

L.4.0307.1119.00(4)

L.4.0307.1120.00(4)

L.4.0307.8500.10(2)

N 3300 - 109

N 3600 - 21

Bundbuchse mit SchmiernuteRd. Ø 110 / ø90 FM - Lg. 83 FMDistanzhülseRd. Ø 60 - Lg. 27,4 FMKoaxialgetriebe EM 1010 - Mr - 7, 1-FL 620 / 010Hydraulikmotor 448 / S08H / 05CCTyp: SAM AR50, AR50 NC25

Drahrseil Python 505 znk 1960 sZø 10mm - Länge 64mLadehaken - WirbelNenngröße 2 toSchäkel Form BNenngröße 2 to

Rillenkugellager6009 - 2RS1

Splint8 x 45Sicherungsring45 x 1,75Sicherungsring75 x 2,5FlachschmierkopfR 1/4"

Achshalter40 x10Scheibe ø 8,4

6kt. SchraubeM 16 x 206kt. SchraubeM 16 x 606kt. MutterM 166kt. SchraubeM 8 x 166kt. SchraubeM 8 x 306kt. SchraubeM 12 x 206kt. MutterM 30

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

49

50

51

45

46

47

48

HMB

HMB

Brevini

Brevini

standard

standard

standard

standard

standard

standard

standard

standard

standard

standard

standard

standard

standard

standard

standard

standard

standard

N 2600 - 77

N 1600 - 66

82018

82101

94 / MS

471 / F St

472 / F St

3404 / Ms

15058 / St 37-1

125 / St gal. Zn

933 / 8.8 gal. Zn

933 / 8.8 gal. Zn

934 / 8 gal. Zn

933 / 8.8 gal. Zn

931 / 8.8 gal. Zn

934 / 8 gal. Zn

933 / 8.8 gal. Zn

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