Manual for operation and maintenance of 15ton Pneumatic winch AW150 series

Keyword:Pneumatic winch AW150   Time:2021-12-18 9:55:13

PNEUMATIC WINCHES MODEL AW150 SERIES

MANUAL FOR OPERATION AND MAINTENANCE

 Operation and maintenance of Pneumatic winch AW100 series-1.jpg

CONTENTS

CHAPTER 1   BRIEF INTRODUCTION  ……………………………………………………………2

CHAPTER 2   MAIN STRUCTURE AND PRINCIPLE OF WORK  ……………………………………4

CHAPTER 3   MAIN MECHANICAL DATA  …………………………………………………………5

CHAPTER 4   CONVEYING AND INSTALLMENT……………………………………………………5

CHAPTER 5   OPERATION AND ADJUSTMENT  ……………………………………………………6

CHAPTER 6   TROUBLES AND THEIR REMEDIES …………………………………………………7

CHAPTER 7   FITTING CLEARANCE AND WEAR LINITS OF THE MAIN PARTS …………………8

CHAPTER 8   MAINTENANCE ………………………………………………………………………9

CHAPTER 9   PRESERVATION AND STORAGE OF PNEUMATIC WINCHES …………………………9

 

CHAPTER 1: BRIEF INTRODUCTION

Adopting pneumatic motor as power, Pneumatic winch model AW series can tow and lift heavy goods through speed-reducing gearbox to drive roll. It has the advantages of compact structure, convenient operation, safety and reliable operating, simple maintenance, smoothly running and stepless speed–changing etc. It is suitably used in oil field, well-drilling in oil field, mine-exploiting and other place with inflammable or easy exploding air.

To ensure the pneumatic winch works normally, make best use of it and prolong its working life, it is very important for users to install, operate and maintain it correctly and carefully. It is advisable that the consumers should read the manual book carefully before using it.AW150 Pneumatic Winches Outline Drawing.png

图1 AW150 系列气动绞车(高底座)外形图

(Fig 1: The Series Of AW150 Pneumatic Winches Outline Drawing For High Seat)

Technical parameter of AW150 Pneumatic Winches.png

Air intake pressure (MPa)0.8
Rated. lifting force (kg)15000
Rated. lifting speed (m/min)4
Rated air consumption (m3/min)20
MotorRated power (KW)32
Cylinder (unit)5
Dia. of Cylinder (mm)160
Piston stroke (mm)76
No (unit)1
RollerDia. (mm)425
Width (mm)705
Rim dia. (mm)740
Wire capacity (m)200
Diameter of wire Φ28mm
Outline dimension1650*800*870
Net weight1700

CHAPTER 2: MAIN STRUCTURE AND PRINCIPLE OF WORK

1. Main structure (Fig 2)

2. Principle of Work

        When move handle lever(3) to staring position, the distributing valve(2) opens and the compressed air enters distributing valve filter(1) and makes it turn. With the turning of filter, the compressed air will be sent into the five cylinders(6) in proper order. The air in cylinders will expand, it can drive piston (4),connecting rod(5) and crankshaft(7) turn. When the piston(4) turn to “B.T.D” position, the filter(1) turns to the exhaust position at the same time. The expanded air will discharge through exhaust hole directly, the other air in cylinder also discharge through the exhaust hole of filter(1) and distributing valve(2).Circulating like this, the crankshaft(7) turns continuously which drives reel(8) turn through transmission shaft and gears.

 The pneumatic motor has self-lock function. When the handle lever is in neutral position, All the inlets and outlets close. At this time, if the winch is lifting goods, the goods will not fall or fall very slowly. In addition, to ensure that users work safely, the winch also adopts brake system. According to the quantity of brake, the system is classified into single-brake, double-brake, according to brake types, it is classified into hand-brake, foot-brake, hydraulic-brake and pneumatic brake. 

       Disc brake is composed of a transmission shaft, a friction plate, a pressing disc, spring, a piston, an automatic brake mechanism is normally closed brake mechanism, winch parking or air breath, under the action of the spring two pressing disc friction clamping plate, so that the winch can not rotate; to the winch supply begins to work, the handle is pulled to make the winch is rotating forward and reverse, but also automatically to the brake mechanism of piston air supply, the piston moves to overcome the spring compression force plate loosen, make the friction disk can be rotated, the reel begins to rotate. Manual brake as the auxiliary brake and lock function.

Operation and maintenance of Pneumatic winch AW100 series-4.png

图2 AW150 系列气动绞车主要结构及工作原理图

(Fig 2: Pneumatic Winches Main Structure And Working Principle)

1. 配气总成(Air blended assembly)               2. 缸体总成(Cylinder assembly)                 3. 护罩及底座总成(Frame assembly)

4. 卷筒总成(Roll assembly)                          5. 制动总成(Brake assembly )                    6. 离合器总成(Gear drive assembly)

(1) 配气阀芯(Distributing valve core)        (2) 分配阀(Assigning valve)       (3) 操纵手柄(Lever)        (4) 活塞(Piston)

(5)连杆(Connect rod )          (6)气缸(Cylinder )         (7)曲轴( Crankshaft)         (8)卷筒(Reel)        (9)离合器(Clutch)

(10)齿轮副(Gear cluster)                        (11)油雾器(Oil injector)                 (12)分水滤气器(Bifurcation air filter)

CHAPTER 3: MAIN TECHNICAL DATA 

Item

Specification

Model

AW150

Max. lifting force

150KN

Max. lifting speed

6m/min

Rated power

30Kw

Air intake pressure

0.8Mpa

Rated air consumption

25m3/min

Wire capacity

200m

Diameter of wire

Φ26mm

Net weight

1700Kg

 

CHAPTER 4: CONVEYING AND INSTALLMENT

1.Carrying

To avoid damaging spare parts, be sure not to knock air-distributing assembly when carry the pneumatic winch.

2.Installment

(1)   Installment of well-drilling platform in oil field: the pneumatic winch has two types bases: high base and low one. Its connecting dimension and technical are in technical form.

(2)   Permanent installment

The pneumatic winch should be installed on a concrete foundation made by mixing cement with sand and gravel etc. The mixing ratio of material: 1cement, 2.5sands and 4gravel. The dimension of foundation should be wider 200mm than the connecting dimension at least.

(3) The end of air intake has two connecting ways: scale-joint and screw-joint. User can choose one of them.

 

CHAPTER 5: OPERATION AND ADJUSTING

1. Preparation before operating:

 (1) Lubricating

(1.1)         Add two liter oil to pneumatic motor. Use L-DAG 46 oil in summer and L-DAG32 in winter.

(1.2)         Gear transmission parts and grease gap should be added lithium base grease.

(1.3)         The capacity of Lub. Oil in pneumatic winch Model AW150 is 2 liters.

(2) Remove the nut of oil injection, add 0.5 liter lubricating oil. Adjust nozzle valve to let it supply oil at the speed of 10 to 15 drop/min at the rated condition.

(3) Move the clutch lever to “engagement” position.

2. Operation

(1)   Operate the lever of distributing valve as the indication of arrow mark: pulling in is lifting and pushing out is descending.

(2)   After starting, let the machine run 1-2mintues without any load. Check if the brake system is reliable and find if there is abnormal sound.

3. Stopping

(1)   When stopping, move the lever of distributing valve to middle position, then operate brake system to stop the engine.

(2)   In urgent situation, move the levers of distributing valve and brake system at one time if necessary.

4.Precausions when operating

(1)   If hear any abnormal sound when the pneumatic winch is working, should stop it and check immediately.

(2)   If find obvious air leak between the surfaces of cylinder cover and distributing valve when the pneumatic is working, should stop it and check.

  

CHAPTER 6: TROUBLES AND THEIR REMEDIES

Troubles

Cause

Remarks

Inadequate lifting traction

1. The clearance of piston ring of pneumatic motor is too large because of wear and tear, the compressed air leak.

2. The pressure of intake air is not up to the standard requirement.

3. The supplying pipeline wasn’t installed as the standard requirement. It’s too small to supply enough air and it wastes too much pressure..

1. Replace piston ring.

2. Increase the intake air pressure.

3. Reinstall the air pipeline according to requirement.

Difficult to start and operate

1. After being repaired, piston connecting rod and base body was assembled without being cleaned.

2. Clutch isn’t hitched..

1. Dismantle the pneumatic motor and clean it again.

2. Move the lever of clutch to “open”.

There is abnormal sound while air motor is working

1. The clearance between the little end and big end of connecting rod is too large because of wear and tear

2. The clearance of main bearing on crankshaft is too large.

1. Replace piston pin and copper sleeve of   crankshaft and ring.

2. Replace main bearing of crankshaft.

The brake is ineffective

The brake belt is loosen.

Adjust the adjusting blot.

Serious leakage of lub. oil from inner gear ring

The oil seal ring of spline shaft is   seriously damaged.

Replace the oil seal ring.

Air motor is over hot

1. Running for a long time with overloading.

2. Lubricating oil is not enough or deteriorated.

1. Decrease loading.

 

2. Replenish or replace lub. oil.

The cover of clutch is abnormally hot

Inadequate grease or worse.

Replenish or replace grease.

  

CHAPTER 7: FITTING CLEARANCE AND WEAR LINITS OF THE MAIN PARTS

Serial No.

Fitting Parts

Type of Filter

Limit of wearing (mm )

1

Distributing valve filter and valve cover

Running

0.2

2

Piston pin and small end of connecting rod

Running

0.13

3

Big end of piston and copper bush

Running

0.2

4

Big end of connecting rod and ring

Running

0.28

5

Open gap of air ring


1.2

6

Open gap of oil ring


2

7

Roller bearing and hollow shaft

Running

0.15


CHAPTER 8: MAINTENANCE

Item

Contents of maintenance

Period

Lub. oil

Replenish Lub. oil to pneumatic motor timely, and frequently remove the oil-discharging plug to check if the oil is worse, if necessary, replace it at once

Seven days

Check oil injector, if necessary replenish it at once

Every day

Evaporating water

Check the assigning water filter, if the evaporating water is full, drain it out at once

Every day

Grease

Replenish grease to gear drive parts and all nozzles timely

500 hours

  

CHAPTER 9: PRESERVATION AND STORAGE OF PNEUMATIC WINCHES

1.      Preservation and storage for short time

If the period of preservation and storage is not over 3 months, it’s enough to wrap up the intake, exhaust gap and respirator with paraffin paper and plastic film.

2.       Preservation and storage for long time

a)       Remove the oil-discharging plug under the pneumatic motor and drain out Lub. oil.

b)       Dehydrate about two liter of compressed lub. oil of L-DAG 32 (Heat it to 110-150°C when all the bubbles on its surface disappear). Pour 1.5 liter of this oil into the pneumatic motor, and crank it unit it is full of this oil.

c)       Dismount air-mixing assembly, smear the surface of the air-mixing valve and inside of air-distributing valve with remaining dehydrated lub. oil.

d)       Replenish grease to parts of gear drive and all spray nozzle.

e)       Wrap up the intake, exhaust gap and respirator in paraffin paper or plastic film to keep dust out.

f)        Pneumatic winch should be stored in a clean and dry place with good ventilation and no corrosive gas.

It is advisable to repeat the procedure when the preservation is over one year.