25 tons of general-purpose gantry crane, as a modern industrial field of indispensable large-scale equipment, the scientific and rational design of its mechanism is directly related to the operational efficiency and safety. The purpose of this manual is to comprehensively explain the design details of the crane, from outlining its basic concepts, design intent and scope of application, to an in-depth analysis of the core components of the mechanical structure, power transmission, control system, etc., every aspect of the cohesion of the unremitting pursuit of high efficiency, stability and safe operation. Through the detailed interpretation of the main beam, end beam, lifting mechanism, running mechanism and other key components of the design ideas, as well as motor configuration, reducer selection, transmission layout and other power transmission system of the subtle arrangement, the reader will be able to deeply understand the essence of the construction of this heavy equipment. In addition, this manual also covers practical guidelines for installation and commissioning, maintenance and safe operation, providing a solid guarantee for the smooth operation and long-term service of the equipment.
PLC control system design
As the intelligent control core of the crane, the design of the PLC control system is crucial. We use high-performance PLC controllers and programming software to program and debug according to the operating requirements and operating procedures of the crane. By adopting this high-performance PLC controller and programming software, the PLC control system can realize the functions of automatic control, fault diagnosis and alarm of the crane.

Through this design, not only the operating efficiency and safety of the crane are improved, but also the labor intensity of the operator is reduced. The entire control system is made more intelligent and automated, providing a strong guarantee for the stable operation of the crane.

Safety monitoring and alarm system
In order to ensure the safe operation of the crane, we have equipped it with a complete safety monitoring and alarm system. This system can monitor the various parameters and status of the crane in real time, such as lifting weight, lifting height, running speed, etc. When the crane is abnormal or fails, the system can promptly send out an alarm signal and take corresponding protective measures to avoid accidents. The design and implementation of this system provides a more comprehensive and reliable safety guarantee for the entire control system. It enables operators to use the crane for operations more confidently.

Installation and commissioning guide
Preparation before installation
Before installing the crane, we need to make adequate preparations. Including but not limited to: carefully check each component of the crane to ensure that it is intact and has the corresponding strength and stability; conduct a comprehensive assessment of the installation site to ensure that the environmental conditions meet the installation requirements of the crane, such as flat site, no debris, no water accumulation, etc.; prepare necessary installation tools and materials, such as cranes, wrenches, screwdrivers, cables, etc.; provide professional training and guidance to the installers so that they can master the installation methods and precautions.

Installation steps and precautions
The installation process of the crane needs to be carried out strictly in accordance with the installation steps. First, install and debug the main beam and end beam to ensure that their horizontality and verticality meet the requirements; then install and debug the lifting mechanism and operating mechanism to ensure that their movements are smooth and accurate; finally install and debug the operating system and control system to ensure that their functions are normal and reliable. During the installation process, it is necessary to pay attention to the connection and coordination between the various components to ensure that the installation quality meets the requirements. At the same time, it is necessary to operate in accordance with the corresponding operating procedures to avoid safety accidents caused by improper operation.

Debugging and trial operation process
After the installation of the crane is completed, debugging and trial operation are required. First, no-load debugging is carried out to check whether the various movements of the crane are smooth and accurate; then load debugging is carried out to check whether the load-bearing capacity of the crane meets the requirements; finally, the whole machine is tested to check the overall performance and safety of the crane. During the debugging and trial operation process, the data needs to be recorded in detail and analyzed and processed in order to further optimize and improve the crane. At the same time, it is necessary to pay close attention to the operating status of the crane and promptly discover and solve potential problems.

Safety inspection during installation and debugging
During the installation and debugging process, it is necessary to always pay attention to the safety of the crane. Regularly inspect and maintain the various parts of the crane to ensure that they are in good working condition. At the same time, safety education and training are required for operators to improve their safety awareness and operating skills. After installation and commissioning, a comprehensive safety inspection is required to ensure that the safety and reliability of the crane meet the requirements. In addition, a complete safety management system and operating procedures need to be established to ensure the safe use of the crane.

Maintenance and Care Manual
Daily Maintenance
Daily maintenance and care is the key link to ensure the long-term and stable operation of the crane. First of all, we need to regularly clean the various components of the crane to remove dust, debris and other factors that may affect the operation. At the same time, according to the requirements of each component, necessary lubrication work is carried out to reduce wear and extend the service life. While cleaning and lubricating, we also need to carefully inspect the various components of the crane, including structural parts, electrical systems, hydraulic systems, etc., to promptly discover and deal with potential faults to prevent the expansion of faults or cause greater losses. In addition, we also need to regularly inspect and test the electrical control system of the crane to ensure that it functions normally and reliably.

Regular inspection and maintenance
In addition to daily maintenance and care, we also need to regularly inspect and maintain the crane. According to the use of the crane and the working environment, formulate a reasonable inspection and maintenance plan, including the inspection cycle, content, methods, etc. During the inspection and maintenance process, we need to conduct a comprehensive inspection and repair of various components of the crane, including structural parts, electrical systems, hydraulic systems, etc. Replace or repair severely worn parts to ensure that the overall performance and safety of the crane meet the requirements. At the same time, we also need to regularly clean the hydraulic system of the crane and replace the hydraulic oil to prevent the oil circuit from being blocked or the hydraulic system from failing.

Fault diagnosis and troubleshooting
When a crane fails, we need to promptly diagnose and troubleshoot the fault. By inspecting and analyzing each component of the crane, we can find out the cause of the fault and take corresponding repair measures. During the troubleshooting process, we must strictly abide by the safety operating procedures and maintenance procedures to ensure that the fault is handled in a timely and effective manner. At the same time, we must also analyze and summarize the fault, find out the problem and make improvements to prevent similar faults from happening again.

Common faults and troubleshooting methods (crane)

Fault phenomenon   Possible reasons   Methods of elimination
The crane cannot start   Power supply failure, electrical control system failure   Check the power supply line to confirm that the power supply is normal; check the electrical control system to repair or replace the faulty parts
The crane is unstable in operation   Loose structural parts, electrical system failure, hydraulic system failure   Fasten structural parts, check electrical systems and repair faults; clean hydraulic systems, replace hydraulic oil
Crane noise is too loud   Bearing damage, gear wear, insufficient hydraulic oil   Replace damaged bearings and gears; replenish hydraulic oil to the specified level
Crane brake failure   Brake failure, electrical control system failure   Inspect and repair the brakes; inspect the electrical control system, repair or replace faulty parts
Crane load drop   Hydraulic system leakage, electrical control system failure   Inspect the hydraulic system and repair leaks; inspect the electrical control system and repair or replace faulty parts
Preventive maintenance measures for cranes

Maintenance projects   Maintenance cycle   Maintenance content
Cleaning work   Daily   Remove dust, debris, etc. from various parts of the crane
Lubrication work   Weekly/monthly   Perform necessary lubrication according to component requirements
Structural parts inspection   Monthly/Quarterly   Check whether the structural parts are intact, whether there are cracks, deformation, etc.
Electrical system inspection   Monthly/Quarterly   Check whether the electrical circuits, switches, motors, etc. are normal
Hydraulic system inspection   Quarterly/half-year   Check the hydraulic system pressure, oil temperature, oil level, etc., clean the hydraulic system, and replace the hydraulic oil
Brake system inspection   Monthly/Quarterly   Check whether the brake is working properly and whether the wear and tear is serious
Safety device inspection   Monthly/Quarterly   Check whether the safety devices such as limiters, buffers, overload protectors are intact and effective
Safety operating procedures
Operator qualification requirements
In order to ensure the safe, efficient and standardized operation of the crane, the qualification and training requirements for the operators are extremely strict. First of all, every crane operator must have the corresponding professional knowledge and skills, which means that they must undergo formal training and obtain a valid operating certificate after passing the assessment. This certificate is not only a recognition of personal professional ability, but also the first line of defense to ensure the safety of crane operation.

In addition to the initial qualification certification, we also implement a regular safety education and training system. Through continuous learning, operators can keep abreast of the latest safety operating procedures, technical standards and equipment update information in a timely manner, so as to continuously improve their safety awareness and operating skills, and better cope with various complex working environments.

Pre-operation inspection and preparation
Before each crane operation, a series of detailed and meticulous inspections and preparations are required to ensure the safe operation of the crane and the compliance of the working environment. The inspection covers a wide range of key components of the crane, such as structural parts, hydraulic systems, electrical control systems, etc., to ensure that they are in an intact state. Special attention is paid to whether the structural parts are deformed or damaged, whether the hydraulic system leaks, and whether the electrical control system works properly. It is also necessary to check the environmental conditions of the work site, including the flatness of the ground, whether there is enough working space, whether there are obstacles, etc., to ensure that the working environment meets safety requirements. Comprehensive safety briefing and risk warnings for operators are also essential links. By explaining the work content, operation steps and possible risk points in detail, ensure that operators can fully understand and master the operation methods and precautions.

Key points for safety in the operation process
In the process of operating the crane, it is crucial to strictly abide by the safe operating procedures and standardized operating procedures. Operators must ensure that the crane moves smoothly and accurately, and avoid any form of dangerous behaviors such as overloading and overspeeding. Smooth operation can reduce mechanical wear and extend the service life of the equipment, and can also effectively prevent safety hazards caused by excessive loads. It is the responsibility and obligation of every operator to always pay attention to the safety conditions of the work site. They need to maintain a high degree of vigilance to promptly discover and deal with potential safety hazards. This includes observation of the working environment, monitoring of equipment status, and evaluation of the operation process. Through close cooperation with on-site managers, colleagues and other types of work, operators can effectively prevent accidents and create a safe and efficient working environment. During the operation, staying focused and calm is essential to ensure safety. Concentration is the cornerstone of safety, which means that operators need to devote themselves to the operation without distraction; calmness is the key to dealing with emergencies. It helps operators to rationally analyze, judge and take correct actions to avoid wrong operations or negligence caused by panic.

Emergency response measures
When a crane encounters an emergency or malfunctions, effective emergency response measures are essential. First of all, it is a vital first step to immediately cut off the power supply and activate the emergency stop device. This can quickly stop the operation of the crane to prevent the accident from further expanding or causing greater losses. Secondly, it is also necessary to organize professionals to carry out troubleshooting and repair work. By systematically checking and evaluating the status of the equipment, determining the cause of the fault and repairing it in time, the normal operation of the crane can be restored as soon as possible. It is essential to stay calm and rational in an emergency. When faced with an emergency, relevant personnel must make judgments quickly and take correct actions. In order to ensure the orderly progress of emergency handling, we have developed a detailed emergency plan. The plan covers various emergencies that may be encountered and their response measures. By learning and familiarizing yourself with the content and procedural requirements of the emergency plan in advance, operators can quickly make correct judgments and actions at critical moments, effectively respond to emergencies and reduce potential risks and losses.

25 ton general purpose gantry crane mechanical mechanism design instructions