YQ2000-10t-22m Hydraulic Crane

Service Manual

Drw. No.：1YQ2000-001-00SM
FILE: mcm\..\1YQ2000-001-00SM
英.doc
DESIGN SCALE m2
No. Q'ty Revision No. By Date
Service Manual
Designed by Verified by
Checked by Appr. by PAGE 1 OF 24
Signed by Traced by
Std. checker Checked by SCMMP, CHINA
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 SCMMP Service Manual 1YQ2000-001-00SM Page 2 of 24

Content

Main Technical Data···············································································3

Ordering Spare Parts ··············································································4
Usage, Construction and Performance Features···································5
Safety System ·························································································6
Mounting Guidance ······················································································7
Initial Start·······························································································8
Adjustment for Working Pressure ·························································9
Adjustment for Load Holding Valve of Jib Cylinder ···························10
Adjustment for Winch Counter Valve ···················································11
Adjustment of the Slew Movement-Stop Length ·································12
Slew Gear Brake Setting ········································································13
Securing Wire to Winch ··················································· 14
Filtration - General ·················································································15
Lubricating Positions and Time ·····························································16
Hydraulic Oil List···················································································17
Maintenance····························································································18
Re-tightening of Bolts in Slew Bearing ···································································19
Wear Measurement for Slew Bearing ·······················································20
Slew Bearing Wear Measurement Table ·········································································21
Hydraulic System failures and Trouble Shooting·································22
Surface Treatment···················································································24

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 SCMMP Service Manual 1YQ2000-001-00SM Page 3 of 24

Main Technical Data

General:

Model YQ2000-10t-22m hydraulic crane is one kind of our YQ series

cylinder-luffing, box-type jib electric-hydraulic crane, which incorporates
our more than ten-year experience of introducing foreign crane and absorbs
foreign advanced technology. It is of a new generation marine lifting
appliance Chinese-designed and developed with high starting points. This
crane is suitable for various vessels, dock or platform to lift hose, cargo,
provision, spare parts and other goods. The crane has a novel construction,
beautiful appearance and reliable quality. Its main technical data are as
follows:

Crane model: YQ2000-10t-22m

Rated safety working load: SWL 10t
Max. working radius: Rmax = 22 m
Min. working radius: Rmin = 4.5m
Lifting speed at SWL : 0~18 m/min
Slewing speed at noload: 0~0.7 r/min
Luffing time at noload: ~110 s
Hoisting height: 30m
Slewing sector: 360°(without limit)
Max. allowable list/trim: 5°/2°

El. motor model: Y225M-4-H

Power/voltage: 65kW/380V/50Hz/3ph
Insulation class: B
Enclosure: IP44
Rated current: 121.4A
Duty : S6-40%

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 SCMMP Service Manual 1YQ2000-001-00SM Page 4 of 24

Ordering Spare Parts

When ordering spare parts, quote crane type and machine number. Order
parts from:

South China Marine Machinery Plant

Add: 73 Qian Jian Road, Wuzhou, Guangxi, China

Telephone: (0774) 5845600
Telefax: 0774 - 5827016
Cable: 4767
Post code: 543004

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 SCMMP Service Manual 1YQ2000-001-00SM Page 5 of 24

Usage, Construction and Performance Features

YQ1400-4t-14m hydraulic crane is of a lifting appliance absorbed foreign

advanced technology as well as Chinese-designed and developed with high
starting points. It can be selected by various of ships for lifting goods.

There are four parts for crane's integral construction including base, king, jib
and control console.

Base is of a circular column. It is necessary to mount this part to the deck

counter foundation when using the crane.

The inside of king is equipped with oil tank, oil pump and electric motor
unit, slewing reduction unit and hydraulic system.

Jib adopts a box-type construction welded with steel plates. No maintenance

is needed inside the box.

Control console is securely mounted to the side of the king. The operation of
crane can be controlled on control cabin.

This crane's actions are performed by the three power systems of lifting,
slewing and luffing. Three power systems are full hydraulic type which the
power is supplied by one set of electric motor drives one set of oil pump.

The central slip ring is mounted in the middle between base and king to
provide the power supply for crane.

Lifting winch is mounted on the jib and is driven by axial piston motor with
good quality. The winch lifts goods through the planetary gear reduction-box
with high strength drives the drum to wind wire rope.

Slewing unit is mounted on the king and is driven by axial piston motor with
good quality. King's slewing motion is realized through the planetary gear
reduction-box with high strength meshes directly with the inner-tooth ring of
slew bearing.

Luffing motion is realized by one hydraulic cylinder.

Hand emergency oil pump is arranged outside the control cabin for
emergency releasing under the condition of power is cut off.

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 SCMMP Service Manual 1YQ2000-001-00SM Page 6 of 24

Safety System

All lifting, luffing and slewing are equipped with automatic protection which
has nothing to do with the control oil line of main power system. All motions
can be automatically stopped at the event of cutting-off power or pressure for
making sure the crane is safe.

There is a safety valve mounted inside the main control valve .

Winch and slewing unit are equipped with automatic brakes.

Luffing cylinder is arranged with automatic load protective valve.

Overload protection on all motions.

Automatic stop is arranged in upper/lower hook position.

Luffing limitation is determined by cylinder's own stroke.

Hand emergency releasing gear is arranged on control table..

Electric motor is equipped with short circuit protection and overheat

protection.

Note: The crane has been adjusted and tested before delivering. Each
hydraulic component, safety valve, limit valve has been adjusted already.
Please don't turn them at will for avoiding the safe accident.

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 SCMMP Service Manual 1YQ2000-001-00SM Page 7 of 24

Mounting Guidance
This crane is normally designed to be welded directly to the deck or some
other type of support. If the User had a special requirement, the crane can be
designed to be bolted to the flange of deck foundation by using bolts.

As the minimum requirement of the various classifications, the deck must be

designed to withstand the cranes max. bending moment with a 25 ％
overload.

Due to the reason of transportation, the crane can be delivered by

dismounting several parts, i.e. jib (including winch, wire rope and hook),
base and king (including electric motor, oil pump, slew gear box, control
valve, slew bearing etc.), control console, luffing cylinder, starter cabinet and
other accessories.

The following procedures should be complied with when mounting the crane
components onboard ship:

1. Weld the crane base (including king) to the deck, check butt welding
grooves to obtain an even gap through the circumference. Also an evenly
distributed heat input is required to avoid distortion. In case the flange bolt is
adopted to connect, it should check if the dimensions and strength of bolt,
nut and washer are in compliance with the requirements shown on the
drawings. The tension /torque of holding bolt should be in compliance with
the values stated on the drawings.

2. Mount the jib and luffing cylinder on the king according to General
Arrangement. It should be very careful when lifting cylinder for preventing
the important parts from being damaged. Please note that don't mistake the
direction of cylinder. The pin shaft for jib and cylinder should be locked with
bolts and press cover and be greased.

3. Connect the hoses between king, jib and cylinder according to the
hydraulic flow diagram. Before delivery the dismantled hoses and
connections should be marked. Please note that connect the hose to the
connection which mark is matchable and then tighten up.

4. Connect the cables between electric motor, starter cabinet against the
electric principle drawing and wiring drawing, then check the wiring for
correction again and again.

After finishing the above mentioned installation, then carry out the check
prior to start-up.

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 SCMMP Service Manual 1YQ2000-001-00SM Page 8 of 24

Initial Start

Fill the hydraulic system oil tank with the correct amount of an approved oil
(see lubrication chart). The oil level is to be in the middle of level glass.

It is of the upmost important that only pure clean oil be used. Under no
conditions must water, dirt and other foreign matters enter the tank.
Impurities and moisture will drastically reduce the efficiency and life span of
the hydraulic system. As a result, oil tank cavity can not be connected with
air directly.

The crane has been operated and tested at our works prior to delivery.
However, improper storage and handling during transport may result in oil
leakage.

Therefore, check the oil level in the slew gear box and winch and top up if
necessary, making sure to use only those oils recommended in this manual.

All pressure control valves have been adjusted by the maker and must not be
altered.

As a final check before starting, check the rotation of the el. motor. The
motor must rotate in a clockwise direction (subject to the rotation of oil
pump) as seen from the fan end. If the motor is rotating in the wrong
direction interchange 2 phases and check again for clockwise rotation.

The pump must not be allowed to run in the wrong direction for an exceeded
period of time, as this will adversely affect the life span of the pump.

Upon completion of initial test run, check the oil level in the system oil tank
top up if necessary.

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 SCMMP Service Manual 1YQ2000-001-00SM Page 9 of 24

Adjustment for Working Pressure

Connect a manometer to the pressure-measuring point on the main control

valve then start el. motor.

Raise the jib to its uppermost position and hold the control valve handle in
the jib up position, take the pressure indicated on the manometer. This
pressure should be the same as the pressure shown on the hydraulic flow
diagram. If the pressure differs more than 10％ the following adjustment
should be made.

Remove the cover and the seal ring from the main relief valve C. Loosen the
locking nut with the jib in its uppermost position continue holding the
control valve handle in the jib up position.

The operating pressure may now be adjusted using a screw driver on the
adjusting screw. Turning the screw clockwise will increase the pressure.
When the desired pressure is reached hold the adjusting screw in place with
the screwdriver while tightening the locking nut. Take a final pressure
reading before replacing the seal ring and cover.

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 SCMMP Service Manual 1YQ2000-001-00SM Page 10 of 24

Adjustment of Jib Cylinder Load Holding Valve

Lift full load with jib to a position of approximately 15°over horizontal.

Stop the electric motor leaving the load hanging on the hook. Move the
operating handle for jib down to its maximum position and hold it there.

Screw off the locking nut on the load holding valve, located near the bottom
of the cylinder, loosen the adjusting screw just enough to allow the load to
sink slightly. Then tighten the locking nut and return the operating handle to
its neutral position.

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 SCMMP Service Manual 1YQ2000-001-00SM Page 11 of 24

Adjustment For Winch Counter Balance Valve

The winch counter balance valve insures a smooth and safe winch down
movement. In the event the winch operates in a jerky manner, the following
adjustments are to be made:

Loosen the locking nut and adjust the adjusting screw until a smooth winch
down movement is achieved.

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 SCMMP Service Manual 1YQ2000-001-00SM Page 12 of 24

Adjustment of The Slew Movement - Stop Length

Operate the crane with no load. Lower the jib to its horizontal position.
Operate the slewing movement at max. speed. Release the operating handle.
The crane should now stop via relatively smooth movement. If adjustments
are necessary procedures as follows:

Remove plug H. To increase stop length turn adjusting screw J in. To

decrease stop length turn screw out.

In the event the restriction valve is completely out of adjustment, turn the
adjusting screw in until it stops, then turn out 1.5 turns. Replace plug H and
check for proper operation.

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 SCMMP Service Manual 1YQ2000-001-00SM Page 13 of 24

Slew Gear Brake Setting

Brake friction piece in the slew gear will be worn as a result of use. When
adjustments become necessary proceed as follows.

Loosen plug H2. Measure dimension X.

Using a 10mm square wrench in a clockwise direction will increase

dimension X, turning in anticlockwise will decrease dimension X.

Fig. 3 Local Sectional View of Slew Unit Adjustment

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 SCMMP Service Manual 1YQ2000-001-00SM Page 14 of 24

Securing Wire To Winch

Thread end of wire through slotted hole in wire drum and then under the
square clamps.

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 SCMMP Service Manual 1YQ2000-001-00SM Page 15 of 24

Filtration - General

The operation and lifespan of hydraulic system is greatly dependent upon the
quality of the hydraulic oil.

The lubrication schedule in the service manual indicates the type of oil to be
used and frequency of oil change.

A hydraulic system when in use will always produce particles. The amount
and hardness of the particles varies dependent upon how well the system
functions and where in the system the particles are produced.

Each type of pollutant entering the oil will reduce the quality. In order to
avoid reducing the oil quality or in the worst case damaging important and
costly components it is of the utmost importance that the oil quality be
maintained as close to that of new oil for the systems entire lifespan.

Therefore are the built-in filters which function continuously while the
system is in use an important part of the hydraulic system.

The filter element must be changed during each oil change. Cleaning and
reusing the filter element is not acceptable.

In many cases the filters are equipped with indicators that reveal the
condition of the filter. As soon as the indicator signals a dirty or
contaminated filter, the filter element is to be replaced immediately.

Under no circumstances shall a filter operates more than one year without
changing the filter element. A clogged filter element causes a “BY-PASS”
through the filter which results in the system operating with unfiltered oil.

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 SCMMP Service Manual 1YQ2000-001-00SM Page 16 of 24

Lubricating Positions and Time

Hour 1 2 3 4 5 6 7
50 C A
100 C C A A C
150 C A
200 C C B A C First 200 hours running
200 C C A C
250 C A
300 C C A A C
350 C A
400 C C A A C
450 C A
500 C C A A D C
550 C A
600 C C A A C
650 C A
700 C C A A C
750 C A
800 C C A A C
850 C A
900 C C A A C
950 C A
1000 C C B B D C C

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 SCMMP Service Manual 1YQ2000-001-00SM Page 17 of 24

Hydraulic Oil List

Hydraulic system: 1000 liter wear-proof hydraulic oil (Trade mark YB-N68)

Lifting winch: 15 liter Middle load gear oil 220

Slew gearbox: 30 liter Middle load gear oil 220

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 SCMMP Service Manual 1YQ2000-001-00SM Page 18 of 24

Maintenance
The use check and regular maintenance check for the crane should be carried
out in compliance with the rules of marine lifting appliances.

The loose parts (hook, shackle, shrink ring, sheave) should be external
checked regularly (not more than 3 months) by the responsible person
working onboard ship. The annual inspection should be carried out at least
every 12 months.

Wire rope should be external checked regularly (not more than 3 months).
Any wire ropes which are found to be over worn and be seriously corroded
or be broken by more than 5％ within the length of 10 times diameter
should be replaced.

The crane should be annually checked every year and the lifting test should
be carried out according to the Rules' requirements every 4 years.

The methods for removing the hydraulic cylinder from crane are that lay the
jib on the rigid support surface of about 5°over horizontal and fix it, then
remove the hoses, the cylinder is now ready for removing. For the detailed
maintenance methods, please refer to 《Service Manual For REXROYH CD
Series Hydraulic Cylinder》.

Check or adjust the mounting dimensions for lifting winch and the brake
piston of slew gearbox every 1000 hours. We recommend to change brake
piece every 3000 hours.

Check bolt and nut tightening torque for lifting winch and slew gearbox
every 500 hours.

For the thread tightening torque, the following data should be used (Lightly
grease the thread and support surface):

Tightening Torque (N·m)

Thread Spec.
8.8 10.9 12.9
M10 50 80
M12 80 120
M14 120 170
M16 190 265 320
M18 260 365 435
M20 370 560 620
M24 640 950 1080
M27 950 1350 1620
M30 1300 1800 2200

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 SCMMP Service Manual 1YQ2000-001-00SM Page 19 of 24

Re - Tightening of Bolts in Slew Bearing

The safe operation of slew bearing is dependent upon proper tightening of

the bolts. It is very important that the bolts be regularly checked and
re-tightened if necessary.

The necessary bolt tension/torque indicated is based upon lightly oil bolt
threads and nut/bolt head bearing surfaces.

For re-tightening of bolts (type 10.9) use the following bolt tension/torque
moment:

Bolt Size Torque Moment

M16 265 N·m
M20 560 N·m
M24 950 N·m
M27 1350 N·m
M30 1800 N·m

The first bolt check is to be made after 100 running hours. The second bolt
check is to be made after 400 running hours. The interval between following
bolt checks is about every 300 running hours, depending upon how much
and at what loads the crane is being used.

In the event that the bolts are loosing up between checking intervals,
increase the frequency of bolt check.

It is very important that mounting bolts have the correct pre-tightening

torque.

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 SCMMP Service Manual 1YQ2000-001-00SM Page 20 of 24

Wear Measurement For Slew Bearing

Wear on the slew bearing will result in a height difference between the
crane's base and the rotating part of the slew ring.

In order to perform an exact check on the possibility of this condition

existing a measuring plate (ca. 25mm×25mm) is welded to the upper flange
of the crane base. All measurements are made from the upper surface of this
plate to the lower edge of the outer slew ring.

Measurements are taken with no load on the hook and the boom in
horizontal position.

The first measurement is taken at position 1 with the boom on center directly
over the measuring plate at position 1. The next measurement is made by
rotating the boom 45°in a clockwise direction, and so on until all 8
measurements have been made. The measuring positions are numbered in a
clockwise sequence as shown in the sketch.

In order to obtain accurate measuring data, it is very important that all future
measurements are made with the boom in the same positions each time. The
enclosed table is to be filled out as each measurement is taken, also sort out
and store these measurements carefully. Measuring instruments with an
exactness of at least 1/10mm are to be used. The first set of measurement are
to be taken after installation onboard and are to be recorded in the table as
the basic measurements.

The maximum allowable deviation between the basic measurement and all
future measurements is indicated on the table. If the difference is noticed to
deviate more than expected, the intervals between making sets of
measurements must be increased. The safe functioning of the slew ring is
dangerously reduced if the maximum allowable deviation is exceeded.

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 SCMMP Service Manual 1YQ2000-001-00SM Page 21 of 24

Slew Bearing Wear Measurement Table

(Max. Allowable Deviation = 1.9 mm)

Measurements to be made every Boom Position

6 months from the date of basic
measurements 1 2 3 4 5 6 7 8
Basic Measurement
Measure-ment
Date Deviation 0 0 0 0 0 0 0 0
Measurement
Date
Deviation

Measurement
Date
Deviation

Measurement
Date
Deviation

Measurement
Date
Deviation

Measurement
Date
Deviation

Measurement
Date
Deviation

Measurement
Date
Deviation

Measurement
Date
Deviation

Measurement
Date
Deviation

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 SCMMP Service Manual 1YQ2000-001-00SM Page 22 of 24

Hydraulic System Failures And Trouble Shooting

Failures Reason Analysis Trouble Shooting

No action 1. Electric connection failure. 1. Check electric circuit if
there is connection mistake
or joint is bad.
2. There isn't enough oil in oil 2. Check oil level height, add
tank. oil up to the specified value.

3. There isn't enough oil 3. Adjust main control valve

pre-ssure to raise oil pressure.
4. Oil filter is stopped up. 4. Check, clean or replace.
Operating 1. Valve core of main control 1. Check, clean, repair or
main control valve produces hydraulic replace valve core, remove
valve, blockage or dirty. the blocked dirty.
perfor-ming 2. Main control valve pressure 2. Adjust main control valve
unit have no is too low. pressure.
action
3. Oil filter is blocked or 3. Clean or replace.
damaged.
4. Breaking or loosening of 4. Check, tighten or replace.
hose.
Control lever 1. Control valve spring is damaged. 1. Check, clean or replace spring.
can't return
2. Sliding valve of control valve 2. Repair or replace valve core.
produces blockage.
3. Control connecting valve has 3. Check, adjust or replace.
failure.
Breaking and 1. Adjusting pressure is too 1. Readjust and lower
oil leakage of high. pro-perly.
hose 2. Hose mounting isn't correct. 2. Remove then remount,
re-place.
3. Hose is loose 3. Tighten hose connection.
Oil 1. Operating oil capacity, heat 1. Replenish proper operating
temper-atur exchange aren't enough. oil.
e rise, oil 2. Continuous working time is 2. Stop operating to lower
motor is too long. te-mperature.
over heated 3. Wear inside the oil motor. 3. Check, repair.
Lifting is 1. Safety valve adjusting 1. Check and raise pressure
powerless pre-ssure in main control valve properly, but the specified
or can't up. isn't enough value can't be exceeded.
2. Failure inside the oil motor. 2. Repair or replace.

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 SCMMP Service Manual 1YQ2000-001-00SM Page 23 of 24

Continuation:

Failures Reason Analysis Trouble Shooting

Hook doesn't 1. The action of counter balance 1. Check, clean, repair.
get down valve isn't normal.
2. Failure inside the oil motor. 2. Repair or replace.
Jib can't up 1. Pressure isn't enough. 1. Check and adjust, but the
specified value can't be
ex-ceeded.
2. Cylinder seal is damaged. 2. Repair cylinder.
Jib can not 1. Counter balance valve is 1. Check, clean, repair blocked
lower blocked (hydraulic blockage). position or replace the related
elements.
2. Leakage of pressure relief 2. Raise the pressure suitably.
valve is too much.
3. Restriction valve opening is 3. Close restriction opening a
too big. little.
Slew doesn't 1. Oil motor has failure. 1. Check, replace the related
move or is element or motor.
powerless
2. Slewing unit has failure. 2. Check, clean or replace.
3. The adjustment of check 3. Readjust restriction
re-striction valve isn't proper. open-ing.
Emergency 1. Emergency valve doesn't 1. Remove emergency valve
lower has change. handle to emergency lower
no action position.
2. Counter balance valve is 2. Repair or replace.
blocked.
3. There is no pressure through 3. Repair hand pump.
hand pump.

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 SCMMP Service Manual 1YQ2000-001-00SM Page 24 of 24

Surface Treatment

Surface treatment: sandblasted to Sa2.5.

Primer/workshop primer:
Epoxy zinc-phosphate primer or zinc-rich epoxy primer, 30~50μm;

Intermediate paint::
Epoxy zinc-phosphate paint or epoxy thick-liquid paint, 100~125μm;

Top coat:
Epoxy thick-liquid paint, epoxy enamel or epoxy polyester paint.Top coat
colour will be grey, yellow or orange 100~150μm;

※ The painting can be done as per-customer’s requirement, but should be defined

in approved document. Should customer has no confirmation in writing, we would consider the
customer agrees our standards, i.e. the painting colour would be grey. ※

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