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一、克令吊操作模式 根据说明书操作规范，MHI 克令吊装卸货操作有2 种模式，分别是钩头和抓斗模式，说明书里是这样定义的： 1. 钩头模式 Hook operation [Intended purpose]The hook operation is performed for a mass cargo such as containers or blocks.The hook hung from the tip of the deck crane jib is used to hang a cargo with a wire rope in order to load/unload[Maximum load] Same as the rated load of the deck crane.30.5 ton 钩头模式用于装卸集装箱或块状之类大件货物，钩头下方吊挂钢丝用于装卸货物。该模式最大负荷可达克令吊的标定负载，本轮是 30.5 吨。 2. 抓斗模式
Grab operation[Intended purpose] The grab operation is performed for a bulk cargo suchas, coals, iron stones and nickels. The grab bucket (opening type cargo handling equipment) is hung from the hook at the tip of the deck crane in order to load/unload.[Maximum load] 24t。 抓斗模式用于装卸煤，铁矿，镍矿等散装货物，铲斗（开放式的装卸货设备）悬挂于钩头下直接装卸货。该模式下本轮最大负载是 24 吨。 Precautions for grab operationThe grab operation is apt to apply more load to the deck crane than the hook operation due to followingr easons: 使用抓斗模式的注意事项：由于下列原因使得抓斗模式的负载较钩头模式负载大，原因如下： ● Unlike the hook operation, there is no hooking work required, operation cycle is apt to shorten. 与钩头模式不同，抓斗模式不需要脱钩，挂钩，操作周期短。 Key Points for MHI Deck Crane Operating & Safety Device ● Because the grab bucket is equipped, the load is always applied. 因为加装了抓斗，所以整个过程克令吊始终受载。 ● It is hard to adjust loaded volume with the grab bucket method, which is apt to cause overload. 由于每个循环抓斗装卸量不好控制，所以有可能导致装货量超载。 ● The operation by the controller is apt to have a great impact on the deck crane.Since the grab operation is apt to have a great impact on the components of the deck crane, itcould increase the risk of a serious accident. 抓斗模式较钩头模式冲击负荷大。因其各个部件冲击较大，所以克令吊损坏的风险加大。 Do not operate the crane in the hook mode when carrying out the grab operation. (Turn the HOOK GRAB selector switch to“GRAB.”) * Otherwise, the deck crane could be overloaded, resulting in equipment damage or serious accidents. 当使用抓斗模式装卸货时，请将“HOOK-GRAB”选择开关摆至 “GRAB”位置。 3. Warm-up operation 暖机操作 When the deck crane is used in low-temperature environment or when the deck crane is used on condition that the hydraulic oil temperature is 20ºC or less, rapid start of the hydraulic pump or crane will cause decrease in the service life of the hydraulic equipment (pumps, motors, etc.) because the viscosity of the hydraulic oil increases with the temperature of the machine room dropped. In the worst case, the hydraulic equipment could be damaged. 当低温环境或液压油温度低于 20ºC，因油温低油粘度大，快速启动主油泵或直接操吊将缩短液压装置（主油泵，油马达等）的使用寿命，严重时将导致设备损坏。 The following is the procedure of the warm-up operation. 下列是克令吊暖机程序 1. Starting the hydraulic pump 点动启动液压泵。 Press the start button for inching operation. (4 to 5 times) (Refer to the figure below.) 参考下图点动操作 4-5 次。
● Oil pump starting in cold condition is not to be done rapidly, to be done gradually by inching operation of electric motor start/stop button. 低温下通过点动启停电机，慢慢启动主油泵 2．After oil pump starting, when the oil thermometer indicates below 20°, control handles are to be positioned on neutral and oil pump is to be idly run until the oil thermometer indicates over 20°. 电机启动运转后，如果温度还低于 20°，不要操作操纵杆，保持中位怠机运行，直到油温上升至 20°以上。（温度计位于操纵室外油冷却器出口管路上） Key Points for MHI Deck Crane Operating & Safety Device。 二．安全保护装置
1. Hydraulic equipment 液压部件保护 (1) Thermostat for upper limit of oil temp. high。
If the upper limit of the hydraulic oiltemperature of the deck crane becomes 75ºC,the thermostat for upper limit of oil temp. highwill automatically be actuated. 当油温高>75ºC，电机停止运行，油冷却器继续运行，直到油温<65ºC，高温复位。 (2) Thermostat of electric motor for oil cooler 油冷却器温控器 The thermostat of electric motor for oil cooler detects the oil temperature in the hydraulic circuit to automatically start/stop the electric motor for the oil cooler. Start Hydraulic oil temperature: 50ºC Stop Hydraulic oil temperature: 35ºC。 当油温在 35ºC-50ºC 时，冷却风机自动启停 (3) Thermostat for oil temp. low 油温低保护 The thermostat for oil temp. low is a device to protect the hydraulic pump at starting operation under low temperature. If the hydraulic oil temperature becomes below 10ºC, it will automatically be actuated. 当油温低于 10ºC 时，低温开关动作，MVLR 电磁阀动作，吊臂和回转无法操作。 <Resetting method> 复位方法 Once the oil temperature drops below 10 ºC, luffing and slewing operation cannot be performed until the temperature reaches 20ºC. Perform warm-up operation until the oil temperature becomes 20ºC or more while checking the oil temperature gauge. (Refer to “3.3.3 Warm-up operation”.) 当油温低于 10 ºC，吊臂和回转无法操作，执行暖机程序，直到油温高于 20ºC 以上。 Key Points for MHI Deck Crane Operating & Safety Device
出厂设定：20℃，幅差 10℃，复位：30℃ (4) Relief valve (for hoisting, luffing and slewing) 泄压阀（用于升降，变幅，回转） If the pressure in the hydraulic circuit becomes over the specified value, the relief valve will beopened and the hydraulic oil will be relieved.当系统中压力超过泄压阀设定值，泄压阀动作泄压。 For hoisting: Overload hoisting prevention and hydraulic circuit protection （20.6Mpa）For luffing and slewing: Hydraulic circuit protection （20.6Mpa）。 (5) Pressure switch
If the pressure switch detects the pressurecorresponding to the overload, the relief valve will unload the circuit pressure to return the oil to the return line. （控制 MVHR）Also, the overload alarm lamp and buzzer on thecontrol panel will work to call operator's attention. 当压力开关（共 2 个,其触点为常闭，动作时断开，根据操作模式不同，分别设定 20/16Mpa）动作，触点断开，MVHR 电磁阀获电动作，将起升回路压力卸放至回油管路，Hoisting 无法动作，同时过载指示灯亮，蜂鸣报警。 2. 电器设备保护 (6) Off notch interlock (断槽联锁) 操纵杆上的微动开关 If each controller is not in the neutral position, the micro-switch installed in the controller detects that it is not in the neutral position, and the main electric motor will not start even if the start button is pressed. 如果操纵杆上的微动开关检测到操纵杆不在中位，主电机则无法启动，或者当按下启动钮后，电机处于星三角转换时（设置 4 秒）操作操纵杆，电机也会停止。 (7) “LUFF. LOWER LIMIT” switch 变幅下降限位开关 When the “LUFF. LOWER LIMIT” switch is switched to “BYPASS”, the following limit switches (4pcs.) will be inactive. 当“变幅下降限位开关”摆至“BYPASS”, 下列 4 个限位将失去保护。 Key Points for MHI Deck Crane Operating & Safety Device ● Limit switch of slack detector for hoisting wire rope 起升钢丝松弛限位 ● Limit switch of slack detector for luffing wire rope 变幅钢丝松弛限位 ● Luffing lower limit switch 变幅下降限位 ● Collision prevention limit switch 钩头吊臂间距防撞限位 因此当此开关摆至“BYPASS”时，要格外注意操吊安全。 (8) Overload test mode selector switch （货物超载测试模式：即旁通压力开关） The over load test mode selector switch disables the pressure switch for over load test. When “OVERLOAD TEST MODE” is selected, the pressure switch is disabled and the load limit will not work. (Select the “NORMAL OPERATION” after using the overload test mode.) Also the buzzer sounds at intervals of 1 second when the “OVERLOAD TEST MODE” is selected. 当选择开关摆至“OVERLOAD TEST MODE”时，2 个过载压力开关失去作用，实际过载时将无过载保护，但启动箱面板蜂鸣器会发出嘀嘀声。 (9) Pressure switch test mode selector switch。 压力开关测试模式选择开关
While the switch is turned to "TEST MODE", the release pilot pressure of the hoisting motor brake doesn't rise. Therefore, the disk brake continues to work even if the operation handle is operated, and the hydraulic circuit pressure will rise. 当此开关摆至"TEST MODE"时，操纵起升时油马达剎车将不会松开，测试系统压力是否上升，待升到压力开关设定值后，MVHR 动作，指示灯亮。可根据操作模式分别选择测试“Hook 或 Grab”压力开.“Hook”压力开关设置 20Mpa,对应负载 30.5T; 开关指针指示高度约为 7mm, “Grab”压力开关设置 16 Mpa, 对应负载 24T 开关指针指示高度约为 9mm(10) Overload protection device （主电机过热过载保护）。 The main electric motor is equipped with thermostat (TH1) and thermal relay (51M) as the overload protection devices. For the electric motor for oil cooler, the thermal relay (51F) is equipped. 主电机配有 TH1 过热保护和 51M 热继电器保护，冷却器风扇电机也配有 51F 热继电器保护。 When these protection devices are actuated, the main electric motor will stop, and“Motor overload lamp” (RL2) will light or blink. 当这 3 个保护动作，主电机停止，电机过载灯闪亮。 The overload protection device of the electric motor is actuated if the temperature increased due to overcurrent or unbalance of the 3-phase current occurred. Therefore, missing phase (one of three phases is faulty) operation can also be protected. So, it is necessary to check whether the overload is the real cause of the actuation of the protection device. Because poor contact betweenthe ring and brush in the slip ring could also be the cause, take extreme care when deciding the cause. 当主电机由于过流或 3 相电流不平衡引起绕组温度升高，电机过热保护动作，因此该保护也具有缺相保护功能，特别是当滑环和碳刷接触不良引起的过热保护。 Key Points for MHI Deck Crane Operating & Safety Device。 (11)其它保护： 主油泵电机过载：热继电器保护，电机过载灯亮，蜂鸣常向； 冷却器电机过载：主泵电机停止，冷却器电机停止，冷却器电机过载灯每 0.5s 闪动，蜂鸣报警常向； 主油泵电机温控开关过热保护，电机绕组过热，温控保护动作，主电机停，油温高及主电机过载灯均 1s 闪亮, 待两报警灯消掉后自动复位。 Braking mechanism 剎车装置 Dual braking mechanism is provided to the deck crane. 克令吊配置双剎车装置：机械碟剎和液压回路平衡阀制动 (1) Mechanical disc brake 碟剎动作 1)当电机运转，换向阀处于中位时，起升，变幅剎住，回转松开； 2)当电机停止时，所有（3 个）剎车均抱死； 3)当限位开关动作，电机停止时，3 个剎车均抱死（不管操纵杆在什么位置） (2) Braking with a counterbalance valve in the hydraulic circuit. 平衡阀制动 防止吊臂因油路意外故障突然掉落或回转，也可防止油泵马达自转（卷筒自转）。 操作故障现象案例 (1). 操纵杆行程开关引起的故障
由于操纵杆上的微动开关控制剎车电磁阀，微动开关上的滚轮为塑料材质，年限久了可能磨损，导致操纵杆微动时接触不良，剎车打不开，但控制阀（换向阀）此时已动作向油马达供油，待操纵杆进一步操作时，微动开关动作，剎车突然打开，导致油压波动，使油马达转速突变，导致货物摆动厉害，增加危险。 因此，平时操吊作业时应注意剎车指示灯动作情况，正常剎车灯亮应优先于卷筒动作时间，也可以同步，但无论如何剎车指示灯亮的时间不能晚于卷筒动作时间，避免货物晃动厉害。 (2). 平衡阀节流孔
平衡阀充当液压系统的液压制动锁，防止吊臂因油路意外故障突然掉落或回转，也可防止油泵马达自转（卷筒自转）常見故障为吊貨下降速度较慢，可能是平衡閥流量控制阻尼孔脏堵导致，尝試調节該阻尼孔旋塞看看，是否變化。本輪起升变幅回转一共有 5 个平衡閥，5 个阻尼孔。 Key Points for MHI Deck Crane Operating & Safety Device (3). 主油泵磨损 主油泵 P1（Hoisting）,P2(Luffing & Slewing) ,油泵磨损图片：常见的磨损面：(1)定子内曲面；(2)配油盘内面；(3)转子上下两侧。
本轮克令吊主油泵为 DENISON （丹尼逊）三联叶片泵，型号：T7EEC -052-052-025-2L 34-A1 M070, 其中三排数字分别是 3 个泵的容积排量代码，泵 P1 和 P2 排量虽然一样，但因为转子和配油盘结构不同，所以不能通用，但叶片一样，可以互换。 上图为主油泵内 P1 叶片泵芯解体图。 其中泵上下配油盘磨损严重，导致内漏，无法达到工作压力。 克令吊操作中可通过实测泵出口压力来判断故障原因，平时也可通过泵出口压力的测取来检查泵的性能，以便提前了解，有备无患。泵的压力测试步骤见后面描述。 Key Points for MHI Deck Crane Operating & Safety Device。 （4）. 如下图，在船有出现过由于该开关锁紧螺母松动，上紧后由于位置没对好，结果开关实际位置是在 Grab，导致吊货无法达到预定 SWL。
四．使用建议 根据船上现场操作观察，在克令吊启动及操作的过程中能按说明书的操作规范做到位的较少，故常常导致设备实际使用寿命大大缩短，特别是在气温较低的环境下操作，暖机做不到位，就快速操作，因此建议：
1. 将低温保护开关动作温度适当调高，延长暖机时间。 2. 低温启动主油泵时，虽然有低温保护，但该保护只限制变幅和回转动作，起升仍然可以动作，因此有见过操吊人员采用操纵钩头升降使油温快速上升，这种操作使油泵或油马达潜在损坏的风险加大，因此需严禁这种操作（低温时禁止用操纵钩头升温）。 3. 根 据 装 卸 货 性 质 ， 选 择 相 应 操 作 模 式（Hook/Grab），而不是每次都摆在 Hook 模式。 4. 定期测试压力保护开关，确保功能良好。 5. 根据其滑油颜色适时更换减速齿轮箱滑油（变幅，起升，回转）。 6. 注意滑环碳刷，及启动箱内主接触器触点清洁保养。 Key Points for MHI Deck Crane Operating & Safety Device 五．三联叶片泵压力测试及调节方法：（如图中⑥3个压力表接口，分别测试Hoisting P1,L&slewingP2,BrakeP3。
准备工具：设备随船压力表及高压快速接头（2HS socket）, 小活动扳手，4mm 内六角扳手。
Key Points for MHI Deck Crane Operating & Safety Device。
本文作者：郑老轨，感谢他的分享！ |
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油温高保护
