The installation of emulsion lifting cranes needs to follow four core processes: foundation preparation, main body installation, hydraulic system debugging, and safety acceptance. Combined with the explosion-proof and anti-corrosion requirements of special scenarios such as coal mines underground, the specific steps and key points are as follows:

1、 Preparation before installation: Environmental and equipment inspection

Confirmation of basic conditions

The basic maintenance period should be ≥ 7 days, and no drainage ditch should be excavated within 5 meters to ensure that the foundation bearing capacity meets the design requirements (such as C30 concrete strength).

When installing underground, it is necessary to complete the roof support in advance to ensure that there is no risk of debris or roof collapse on the working surface.

Equipment and tool preparation

Lifting plan: Select a suitable winch and guide pulley according to the weight of the equipment (such as a 5-ton emulsion crane), and the lifting points should be reinforced parts such as lifting holes and base frames to prevent deformation.

Cleaning tools: diesel, kerosene, cleaning gauze, used for cleaning components (such as spindle, sprocket) to prevent impurities from entering the hydraulic system.

Testing instruments: pressure gauge, level gauge, plug gauge, used for precision adjustment.

2、 Main installation: assembly of core components

Base alignment and leveling

Use shims to adjust the levelness of the base, with an error of ≤ 0.2mm/m. It is forbidden to force leveling by tightening the anchor bolts.

Recheck the deviation of the spindle centerline and lifting centerline to ensure they coincide with the centerline of the tunnel, with an error of ≤± 3mm.

Assembly of key components

Spindle device: Clean the taper hole and spindle taper surface before installation, apply lithium based grease to prevent metal burr damage.

Chain and sprocket: Adjust the tension of the chain to ensure that the sagging of the loose edge is ≤ 2% of the chain distance, avoiding over tightening and accelerating wear.

Brake: After the disc brake cylinder is connected to the oil pipe, the air (oil pressure ≤ 1MPa) needs to be drained to prevent brake failure.

Hydraulic system connection

Pump station layout: The bottom of the emulsion tank is higher than the pump body, and the length of the inlet hose is ≤ 10m to reduce pressure loss.

Pipeline laying: The high-pressure pipeline is connected to the accumulator with dual inlet valves, and a high-pressure filter (filtration accuracy ≤ 10 μ m) is added to prevent impurities from blocking.

Electrical wiring: Connect the control cabinet and sensors according to the drawings to ensure the sealing of the explosion-proof junction box, with an IP rating of ≥ IP55.

3、 Hydraulic system debugging: pressure and flow calibration

Pump station startup

Run for 5-10 minutes without load, discharge the air in the pipeline, and observe that the emulsion is free of foam and leakage.

Adjust the unloading valve pressure to the design value (such as 31.5MPa), and set the safety valve pressure to 1.1 times the rated pressure.

Residual voltage adjustment

Manually lift the control lever and observe the stable value of the pressure gauge (residual pressure should be ≤ 0.5MPa).

If the residual pressure is too high, reduce the diameter of the throttle plug or check the sealing of the threaded connection.

Braking performance test

No load braking test: braking distance ≤ 0.5m, braking time ≤ 2s.

Heavy load braking test: The load is 80% of the rated value, and the braking is smooth without slip.

4、 Safety acceptance and trial operation

No load trial operation

Run forward and reverse for 30 minutes each, check the stability of the chain operation and the sensitivity of the brake.

Monitor the temperature (≤ 60 ℃) and noise (≤ 85dB) of the hydraulic system, and adjust the cooling fan or check the wear of the pump body when exceeding the standard.

Load trial operation

Gradually load to the rated load (such as 5 tons) and observe the deformation of the structural components (≤ L/1000, where L is the span).

Test the reliability of limit switches and overload protection devices to ensure accurate operation.

Documents and Identification

Record installation parameters (such as centerline deviation, pressure values), maintenance cycles, and establish equipment files.

Hang operating procedures and safety warning signs, clearly prohibiting violations such as overloading and diagonal pulling.

5、 Special scenario adaptation: Key installation points for underground coal mines

Explosion proof treatment

The electrical components are selected with ExdI explosion-proof structure, and the cable entry device is sealed with a pressure plate.

The hydraulic pipeline joints are sealed with O-rings to prevent gas explosions caused by emulsion leakage.

Anti-corrosion measures

The surface of the structural components is coated with epoxy zinc rich primer (dry film thickness ≥ 80 μ m), and the topcoat is made of weather resistant polyurethane coating.

Regularly inspect the rusting of chains and sprockets, and replace severely corroded components in a timely manner.

space optimization

Adopting the backward installation method, first install the end support of the tunnel and gradually advance towards the working face to reduce the risk of debris.

The pipeline is laid along the side wall of the roadway, with a reserved maintenance space of 0.5m to avoid interference with the conveyor.

The main equipment produced by Hebei Makita: stage electric hoist, electric chian hoist, wire rope electric hoist，Hand chain hoist, lever hoist, pneumatic hoist and other lifting equipment