20t Single Rope Timber Grab

OPERATION MANUAL

SHANGHAI JANUS GRAB CO., LTD

OCT, 2014
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目录

1. Main Technical Data .................................................................................................................... 3

2. Operation Rule.............................................................................................................................. 4

3. Grab Structure: ............................................................................................................................. 6

4. Working Principle（DRAWING 5） .......................................................................................... 8

5. Operation Instruction ................................................................................................................... 9

6. Transportation ............................................................................................................................. 10

7. Maintenance and Repair ........................................................................................................... 10

8. Fault and Diagnose .................................................................................................................... 12

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1. Main Technical Data

Crane SWL (t) 20

Maximum cross section (m2) Φ 1.9

Minimum cross section (m2) Φ 0.5

Width of teeth (mm) 2000

Grab lifting capacity (t) 14

Grab dead weight (t) 6

Sheave out-diameter (mm) Φ 560

Steel rope diameter (mm) Φ 32

Rope folds 3

Rope withdraw distance (mm) 2243 x 3

Grab close state dimension (mm) 4884 × 1540 × 2000

Working height (mm) 12000

Crane type Crane with single hook

Timber
Cargo type

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2. Operation Rule
a. This grab is suitable for crane with single hook to loading/unloading timber.

b. Running into any material, hoist equipment, the side of the ship, floor and other objects is

forbidden.

c. For the slider moving down smoothly, and make sure the open/close cycle normally, grab shall

be vertical during working. The inclining angel shall be smaller than 15°(DRAWING 1), and

grab shall be vertical on timber piles.

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d. For maximum loading/unloading volume, grab shall be operated from horizontal position.

e. During grab working time, if some small stone particles or similar granules inserts into the slider,

guide rail groove etc, which might make grab cannot work normally, the particles or granules

shall be cleaned out immediately.

f. Timber inside grab teeth shall be in following states before be lifted:

a) all timbers shall be clipped by grab teeth;

b) timbers are paralleling with each other;

c) Timber two ends diameter difference smaller than 1 meter;

d) The lifted timbers gravity center shall be in the grab center line or nearby.

g. Timbers shall be lifted again if found one of following situations:

a) The being held timber is withheld heavily by other timber;

b) Grab teeth is not closed completely;

c) Timber two ends diameter difference bigger than 1 meter;

d) Timber diameter is over than grab maximum diameter;

e) The incline angel is over than 5°when timber is lifted.

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3. Grab Structure:
Grab is mainly made up by eight parts: （DRAWING 2）

Balancer-1: Holding two steel ropes, and make two ropes hold same stress.

Rope guide-2: Be made of by rollers, shafts, bearings and support base.

Grab head-3: Welded by steel plates, connecting with press rod, guide rail, and buffering cylinder by

joint shafts, two sheaves locate in a symmetrical position.

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Press rod-4: Grab press rod is a tank structure with the good bending resistance and compression

resistance ability. The two ends of press rod connect with grab head and scoops by corresponding

shafts.

Slider-5: Made by bracket, star wheel, steel ball, mechanical spring, set screw, bolt, and sheaves.

（DRAWING 3）

Teeth-6: Shell structure, connecting with down beam and press rod by shafts, it is mainly made by

bended plate, side plate and teeth. For making the teeth lip more abrasive resistance, teeth lip is

abrasive resistant alloy cast steel and surface with harden treatment.

Grab lock, slider, star wheel, and stop dog together are timber open/closing mechanism. Lock upper end

is guide rail, which is seamless tube, slider can move up and down along guide rail. Lock is located on

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down beam, when slider moves down and make star wheel hooked with lock, slider will be a whole body

with down beam.

Down beam-8 is variable cross section beam, two shafts connect with two scoops by joint shafts.

To make grab have enough rigidity and strength with limited weight, grabs raw plates are mainly light

alloy steel plate of Q345B.

4. Working Principle（DRAWING 5）
Grab close cycle: When grab is in state of (图 A), crane rope falls down, slider moves down along guide

rail, star wheel on slider will touch with stop dog on down beam (图 B and 图 F), stop dog make star

wheel rotate some angel (图 G), then crane ropes are lifted, which make slider move up, star wheel in

slider will hook with the lock in down beam (图 H), and by sheaves working, down beam moves up and

grab will close.

Grab opening cycle: When grab is in state of (图 C), crane rope falls down make slider go down along

with the guide rail, star wheel in slider will touch with stop dog in down beam (图 D), stop dog make star

wheel change some angel (图 I), then crane rope lifted, make slider move up, star wheel in slider will

separate from lock in the down beam (图 F), and by slider pushing with crane head, grab will open (图 A).

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5. Operation Instruction

5.1 Must obey crane use rules when using grab.

5.2 First time use and daily use

Check crane safety working loading

Check installation of steel rope, wedge socket, steel rope clip and shackle, if any loose state, fasten

them. If shackle and rope chip transformed , fragment, over-abrasion, please replace new one.

Check grab all fasten parts, whether it is fastened. All joint shafts whether become loose.

The balancer is hooked on crane hook.

Test without any load, all joints parts rotate smoothly. Grab opening / closing mechanism runs normally,

the buffering cylinder without apparent oil leakage, buffering is good.

All joint points with full grease, and guide rail also be with full grease.

5.3 Operation

If found any block during grab opening / closing, stop working, check the problem and solve the problem,

then use it again.

5.4 Stop using

When stop using, grab shall be blushed clean by water, take out anything inserted in guide rail groove,

sheave groove and all rotate joint parts, clear out anything inside grab teeth. All joints shall be greased

enough, slider opening / closing mechanism and guide rail shall be greased enough, grab shall be in

complete open and vertical state, and fixed it.

5.5 Reuse

Obey all said in 5.2

Check grab in case of any accident.

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6. Transportation
Grab shall be in close state when transported.

7. Maintenance and Repair

7.1 Maintenance

7.1.1 For anti-rust, grab joint points should be greased after 8 working hours, opening/closing

mechanism and guide rail also should be greased.

7.1.2 Lubrication (DRAWING 5)

Point “a”: Greased every 8 working hours.

Point “b”: Greased every 100 working hours.

Point “c”: Greased every 8 working hours.

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If grab stop using, every week, guide rail, inner side of slider and star wheel shaft points should be

greased.

If grab stop using, every month, point “a”, “b”, “c” should be greased, steel rope should be greased.

Please clear out waste, dust before greasing.

1.1.3 If grab part-rusted, please clean it and spray-paint. Paint type is following:

Epoxy zinc rich primer;

Chlorinated rubber paint middle and finish paint.

7.2 Daily check

7.2.1 Open / Close mechanism check

After every time finishing using, open/close mechanism should be checked, cleaned and greased. If star

wheel has any break or damage, please replace it.

7.2.2 Repair of open / close mechanism

Firstly open grab, make slider falls down.

If slider cannot move up or fall down, it might because star wheels are not in right positions, please

make slider up a little, and make star wheel inside down beam groove can rotate normally. So you can

make star wheels rotate to symmetrical position. (图 I)

If slider cannot move up or fall down when grab close, the grab head should be lifted to make grab open,

then check and repair by above method.

7.2.3 Rope guide check and repair

All guide roller rotate flexible, it should be repair if found block, guide roller should be replaced if

abrasion heavily.

7.2.4 Guide rail check and repair

If guide rail become bent and affect grab normal work, it should be repaired to use. If connection

between guide rail and down beam become loose much, and affect slider moving up and down, it should

be repaired to use.

7.2.5 Joint shaft check and repair.

All joint shafts greasing channel should be unblocked, if greasing channel is blocked, it should be

cleared out for smooth greasing. If bush and bearing broken, inner hole abrasion is more than 20% of

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original dimension, they should be replaced.

7.2.6 Bush check

Bush should be replaced if abrasion more than 20% of original dimension.

7.2.7 Steel rope check

Steel rope should be checked, greased in time, it should be replaced if it is up to scrapping standard.

7.2.8 Shackle

Shackle should be replaced if following situations happen:

a. Any break on shackle;

b. Shackle transformation is over than 5%;

c. Shackle shaft cannot rotate;

d. Abrasion over 5% of shackle or transverse shaft.

Shackle cannot be reheated, re-welded and repaired

8. Fault and Diagnose

Fault Reason

8.1 Grab cannot open / close ------star wheel damage, break

------Guide rail bent or transformed heavily

------steel ball, mechanical spring not in right position

8.2 Grab difficult to close ------Teeth transformed heavily

------Press rod transformed heavily

------Joint shaft abrasion heavily.

------Guide rail bent, transformed heavily.

------Joints blocked by something

8.3 Grab cannot open ------Grab transformed heavily

------Two star wheels in slider rotate not in same step

------star wheel broken

------height of stop dog is not high enough

------guide rail twisted and transformed

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