1. Purpose and scope
This practical manual is devoted to the maintenance of an electric crane, in particular the inspection of the hydraulic gearbox, the measurement of the brake disc and the inspection of the tension of the link. This process is performed once every 500-1000 hours of operation or when unusual sounds, vibrations, low efficiency or an increase in temperature are detected in the system.
2. Security
Warning: Before starting work, perform a lockout and tagout (LOTO) procedure to eliminate hazardous energy sources. Use protective clothing, including work gloves, goggles, a face mask, and printed socks.
Warning: Before opening the hydraulic gearbox housing, ensure that the power supply is disconnected and the pneumatic or hydraulic systems are disconnected. Use insulated tools and keep away from spilled liquids.
3. Necessary tools and materials
| Name of the tool | Specification | Quantity |
|---|---|---|
| Torque screwdriver | The range is 10–100 Nm | 1 |
| Multimeter | MicroVolt, microAmp, Ohm | 1 |
| A ruler with a scale of 0–500 mm | Millimeter divisions | 1 |
| Clearance indicator | 0–2 mm | 1 |
| Laser aluminum level | Accuracy ±0.02 mm/m | 1 |
| Screwdriver with opening | The range is 5–100 Nm | 1 |
| Thermometer | Temperature range -50 to +300°C | 1 |
| Key to open | The minimum size is 4–12 mm | 1 |
4. Pre-support inspection checklist
| Item | Verification | Acceptance/rejection criteria | Notes |
|---|---|---|---|
| 1 | Power is off | Shutdown indication | LOTO documentation |
| 2 | The pneumatic system is disabled | No connection | Pressure 0 bar |
| 3 | Absence of backfilling | Lack of liquid | Hydraulic gearbox housing |
| 4 | On-site cooling | The temperature is no more than 60°C | Thermometer |
| 5 | Protective clothing | Complete set | Gloves, glasses |
5. Step-by-step procedure
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Opening the hydraulic gearbox case
Use an opening wrench (4-12 mm) and open the case. Check for seals and gaps. Error: Using the wrong key can cause corruption.
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Gear gap measurement
Use a gap indicator (0-2 mm). The gap should not exceed 0.15 mm. Error: wrong measurement can lead to wrong conclusion.
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Gear wear check
Use a ruler with a scale of 0-500 mm. Wear should not exceed 1.5 mm. Bug: Incorrect interpretation of wear and tear can lead to the wrong option being selected.
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Checking the brake disc
Measure the thickness of the disc. The minimum thickness is 18 mm. Use a ruler with a scale of 0-500 mm. Error: wrong measurement can lead to wrong solution.
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Chain recovery check
Use a laser aluminum level (accuracy ±0.02 mm/m). The tightening of the link should not exceed 3 mm. Error: Incorrect installation may lead to incorrect result.
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Installing a hydraulic gearbox
Use a torque wrench (range 10-100Nm) to install. Nuts are installed taking into account 10 Nm. Error: Incorrect installation may result in refund.
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Work check
Use a multimeter to check the power supply for short circuits. Error: An incorrect check can lead to an incorrect conclusion.
6. Post-support checklist
| Test | Expected result | Actual | Pass/Fail | |
|---|---|---|---|---|
| 1 | The gap between the gears | No more than 0.15 mm | Checked | Pas |
| 2 | Brake disc thickness | Not less than 18 mm | Checked | Pas |
| 3 | Foreclosure chain | No more than 3 mm | Checked | Pas |
| 4 | Electricity supply | No short circuit | Checked | Pas |
| 5 | Hydraulic system pressure | 0 bar | Checked | Pas |
7. Issue tracking
| Symptom | The problem | Recovery |
|---|---|---|
| Unusual noise | Gear wear | Replace gears |
| Vibration | Foreclosure chain | Replace the chain |
| Low efficiency | Brake disc wear | Replace the disc |
| Increased temperature | Wear of the hydraulic gearbox | Replace the gearbox |
| Wrong job | Incorrect installation | Install according to the scheme |
8. Recommended support schedule
| Task | Frequency | Estimated duration | Skill level |
|---|---|---|---|
| Overview of the hydraulic gearbox | 500–1000 hours | 2 hours | Average |
| Measuring the brake disc | 500–1000 hours | 1 hour | Average |
| Checking the collection chain | 500–1000 hours | 1 hour | Average |
| Replacement of gears | 1000–1500 hours | 3 hours | Tall |
| Brake disc replacement | 1000–1500 hours | 3 hours | Tall |
9. Special parts
| Part description | Normal specification | UNITEC-D category |
|---|---|---|
| Hydraulic gearbox gear | Material: steel, diameter: 20–100 mm | Gear boxes |
| Brake disc | Material: steel, thickness: 18–25 mm | Brake components |
| Chain | Material: steel, length: 1–10 m | Chains |
| Nut with brake washers | Material: steel, size: M10–M24 | Nuts |
| Sealing | Material: Nickel, size: 4–12 mm | Sealing |
For details, please visit our e-catalog: https://www.unitecd.com/e-catalog/
10. Links
The documentation complies with DSTU 2331:2010, EN 81-1:2010, ISO 14116:2013, CE, UkrSEPRO standards. Use the appropriate manufacturing instructions from the manufacturer.
Note: All procedures are performed in accordance with technical standards and supported by CE and UkrSEPRO certifications.
