Changing Trolley Wheels & Grinding Rails “Noell Cranes”

Eng. M. Eng. M. ElnagdyElnagdyJunior Mechanical EngineerJunior Mechanical Engineer

Cranes TeamCranes Team

Contents:Contents:

* * --Problem & Solution.Problem & Solution.

****--Project Planning.Project Planning.

******--Tools.Tools.

II--Wheels assembly procedures.Wheels assembly procedures.

IIII--Changing wheels procedures.Changing wheels procedures.

IIIIII--Grinding the railsGrinding the rails..

********--General Considerations.General Considerations.Safety for Life

SCCT

Goal of the projectGoal of the project

11--Eliminate vibration of the operator cabins.Eliminate vibration of the operator cabins.22--Eliminate noise.Eliminate noise.33--Healthy working to the operator.Healthy working to the operator.

44--No BDN during operationNo BDN during operation..

* Problem* ProblemIn operation and during loading and discharging containers from In operation and during loading and discharging containers from and to vessels, and after and to vessels, and after

many crane working hours, the shape of trolley wheel and trolleymany crane working hours, the shape of trolley wheel and trolley rail will change.rail will change.

During many times of trolley movements, the trolley wheel During many times of trolley movements, the trolley wheel waerwaer from middle, and the rail from middle, and the rail have a crown at the middle and appendages at ends which results have a crown at the middle and appendages at ends which results to heavy vibration to heavy vibration and big noiseand big noise..

RailsRailsoriginal shapeoriginal shape

shape after time shape after time

SolutionSolutionGrinding the rails by a special machinesGrinding the rails by a special machines

Rail MaterialRail MaterialSt70 E360St70 E360hardness hardness brinellbrinell 205205--250250

Wheels

The shape of the wheels changed and become with groove at middle from contact point with the rails. Which lead to damaged the bearings.

SolutionChange trolley wheels

Wheel MaterialForging 1.6582+QT

Damaged bearing

Changing of wheel shape

** Planning of the projects** Planning of the projects

For each crane it take from 10 to 11 days,For each crane it take from 10 to 11 days,-- one day preparation.one day preparation.-- four days changing trolley wheels and adjustment.four days changing trolley wheels and adjustment.-- five or six days grinding railsfive or six days grinding rails

*** Tools*** ToolsToolTool QtyQty ApplicationApplication

Hydraulic jack 100 t 2 Lifting trolley

Hydraulic jack 50t 2 Adjusting bearing housing center, remove gearbox support pin, and remove gear box from wheel shaft

Hydraulic pump 2 Operating jacks

Thread rod M24, length 50cm 2 Lifting up and down wheels

Thread rod M24, length 20cm 4 Insert gearbox into wheel shaft.

Nuts M24 6 For thread rods M24 (for install gearbox)

Thread rod M16, length 1m 4 Extracting gearbox from wheel shaft

Chain block 3 t 1 Between service crane and gearbox

Small wire rope 1m length 2 Lift gearboxes and wheels

shackles 2 Lifting gearboxes and wheels

Lashing rope, 3m long 2 Lifting guide rollers

Various lining plates 100x150mm, with various thickness (2,5,8,10,20,30mm)

20 To put under the trolley

Metal plates, thickness 40mm, 50x100mm

4 To put between jack and trolley

Grease type TEXCLAD2 For gearbox shaft and shrink disc

Grease type EP2 For bearings

CirclipCirclip lock plierslock pliers 22 For shrink disc For shrink disc

II-- Wheel Assembly ProceduresWheel Assembly ProceduresAA--Gearbox Side AssemblyGearbox Side Assembly

11-- Cleaning the shaft surfaceCleaning the shaft surface

22-- Insert first cover (No. 6 in drawing) cover 360/172x25Insert first cover (No. 6 in drawing) cover 360/172x25--See the seal direction (No. 11 in drawing)See the seal direction (No. 11 in drawing)--Seal No. 170x200x15Seal No. 170x200x15

33--Heating the bearing (No. 10 in drawing),Heating the bearing (No. 10 in drawing),--bearing type: spherical roller bearingbearing type: spherical roller bearing--bearing No. 23230bearing No. 23230--using SKF induction heater (type TIH 100m).using SKF induction heater (type TIH 100m).--heating temperature 160 C.heating temperature 160 C.

44--Insert the bearing in its position.Insert the bearing in its position.--insert bearing must be fast. insert bearing must be fast. --must wear heater gloves.must wear heater gloves.

55--Insert bearing housing (No. 4 in drawing).Insert bearing housing (No. 4 in drawing).--housing must be cleaned by soft grinding machine.housing must be cleaned by soft grinding machine.

66--Insert distance bush 170/136x57 (No. 3 in drawing)Insert distance bush 170/136x57 (No. 3 in drawing)

77--Insert second cover (No. 5 in drawing).Insert second cover (No. 5 in drawing).--cover 360/172x25cover 360/172x25

--see seal directionsee seal direction

BB-- Another SideAnother Side11--Insert first cover (No. 7 in drawing)Insert first cover (No. 7 in drawing)

--cover 360/172x25.cover 360/172x25.

--see seal directionsee seal direction

22--Heating the bearingHeating the bearing

33--Insert the bearing.Insert the bearing.--wearing a special gloveswearing a special gloves

44--Insert washer plate (No. 9 in drawing).Insert washer plate (No. 9 in drawing).--PL 15x180x180PL 15x180x180

55--Insert bearing housing.Insert bearing housing.--housing must be cleaned by soft grinding machine.housing must be cleaned by soft grinding machine.

66--Insert second (No, 8 in drawing).Insert second (No, 8 in drawing).--cover 360x22cover 360x22

IIII-- Changing Wheels ProceduresChanging Wheels Procedures

11--Bring the Trolley under the MBring the Trolley under the M-- house, so that the WShouse, so that the WS-- wheels standing under the wheels standing under the covers and we can using the Mcovers and we can using the M-- house crane.house crane.

22--Under the trolley, between the rail and the trolley traveling giUnder the trolley, between the rail and the trolley traveling girder one hydraulic rder one hydraulic jack 100t under the jacking pointjack 100t under the jacking point-- only make strong not lifting.only make strong not lifting.

33--Check everywhere, also underneath the girder is free. Check everywhere, also underneath the girder is free.

44--Loose all screw of the guide roller support, and remove them.Loose all screw of the guide roller support, and remove them.

55--Dismantle the Dismantle the cardancardan shaft on the gear box and the torque supportshaft on the gear box and the torque support-- the gearbox is the gearbox is secured on the hook of the Msecured on the hook of the M--house crane.house crane.

Torque supportTorque support jack 50tjack 50t CardanCardan shaftshaft

66--Dissolve the shrink disc.Dissolve the shrink disc.

*shrink disc components.*shrink disc components.

77--Pull off the gearbox.Pull off the gearbox.

Jack 50tJack 50tthread rod M16thread rod M16

88--Dismantle on both sides of the bearing platesDismantle on both sides of the bearing plates-- in and outside.in and outside.

99--Lift up the trolley, so high that we can rolling out the wheel. Lift up the trolley, so high that we can rolling out the wheel. Before secure the Before secure the wheel by sling at the hook of the Mwheel by sling at the hook of the M--house crane.house crane.

1010--Bring the dismantled wheel on the ground and lift a new oneBring the dismantled wheel on the ground and lift a new one-- mount itmount it-- put the put the trolley again on the rail.trolley again on the rail.

1111--Amount again bearing plates, torque support, Amount again bearing plates, torque support, cardancardan shaft, gearbox, and shrink shaft, gearbox, and shrink disc.disc.

*before amount *before amount shrink disc, shaftshrink disc, shaftmust be cleanedmust be cleanedand put black and put black grease as see grease as see

*amount the gearbox using thread rod M24, length 20cm, and nut 2*amount the gearbox using thread rod M24, length 20cm, and nut 244

IIIIII-- Grinding the railGrinding the rail

--Grinding the rail is carried out by two special grinding machineGrinding the rail is carried out by two special grinding machine mounted and mounted and driven by trolley.driven by trolley.--The electrical supply from machinery house.The electrical supply from machinery house.--The trolley moves by maintenance speed (from maintenance panel oThe trolley moves by maintenance speed (from maintenance panel on the n the trolley).trolley).--Thickness of erased layer of the Thickness of erased layer of the rail by grinding rail by grinding Max. 2mmMax. 2mm

--Grinding the rails take from 5 to 6 days, depend on rail status.Grinding the rails take from 5 to 6 days, depend on rail status.

Grinding the rails from side.Grinding the rails from side.

Grinding the rails from top.Grinding the rails from top.

--Grinding the rails at beginning (grinding part is thin).Grinding the rails at beginning (grinding part is thin).

--Grinding the rail at finish (grinding part from Grinding the rail at finish (grinding part from 87:90 %87:90 % of rail face)of rail face)

--Grinding the rail at hinge point at Grinding the rail at hinge point at startstart of grinding.of grinding.

--Grinding the rail at hinge point at Grinding the rail at hinge point at finishingfinishing of grindingof grinding

--Difference between Difference between startstart of grinding and of grinding and finishingfinishing

General considerationGeneral consideration*Before Start trolley wheels changing:*Before Start trolley wheels changing:

11--Secure the area under the crane by safety cones.Secure the area under the crane by safety cones.22--Check maintenance crane of the crane.Check maintenance crane of the crane.33--Check bolts of machinery house for maintenance crane.Check bolts of machinery house for maintenance crane.

*Adjustment of wheel*Adjustment of wheel11--Lift the trolley by hydraulic jack (100t).Lift the trolley by hydraulic jack (100t).22--Put the hydraulic jack (50t) under point (2) to rotate the housiPut the hydraulic jack (50t) under point (2) to rotate the housing to be the ng to be the point (1) at same level with point (3).point (1) at same level with point (3).

33--After finishing the adjustment of four wheels, move the trolley After finishing the adjustment of four wheels, move the trolley forward forward and backward, and see the contact of the wheels with the raiand backward, and see the contact of the wheels with the raill

44--If there is any deviation of the wheel, lift the trolley up and If there is any deviation of the wheel, lift the trolley up and move the point move the point (2) up little pit and repeat again until the wheel adjusted.(2) up little pit and repeat again until the wheel adjusted.

*When assembly the gear box, you must not put any grease on the *When assembly the gear box, you must not put any grease on the shaft (at shrink disc area).shaft (at shrink disc area).

(3)(3) (1) (2)(1) (2)

*Before Grinding the rail:*Before Grinding the rail:--Adjustment of rail level at hinge point by butting chimes betweeAdjustment of rail level at hinge point by butting chimes between boomn boomand girder (thickness between 0.5 to 1 mm).and girder (thickness between 0.5 to 1 mm).

girdergirder boomboom

*After grinding the rail:*After grinding the rail:--Cleaning the rail ,girder, and boom.Cleaning the rail ,girder, and boom.

& operation test.& operation test.