| Works: Erection and maintenance manual for | CRANEX electric overhead cranes CRANEX LIMITED Fogs. fF Toi-676 ane S571 Indus Site 4, Sahibabad (U. Area, Site 4. Te-eenss OJ20— 4167624, SAUNTINDEX 4. Introduction 2. General Description 3. Erection Instructions 4, Operating Instructions 5. Maintenance Instructions 6. Common Sources of Trouble 7. Permissible Deviations Page 10 12 16INTRODUCTION Congratulations. You have just joined a select band of organisations using Cranex ‘equipment. In order to ensure long and trouble free service, this manual should be kept handy and maintenance undertaken as indicated. CCranex Lid. s one ofthe leading crane manufacturers having supplied equipments to all pars of he country. Whether a Turbine Is tobe ited in Imphal, Defence Installations to be maintained in Ladakh, Locomotives tobe lifted in Vishakapatnam, 747 Jumbo jets to be ‘serviced in Bombay or Rockets to be checked before launching from Trivandrum, all are handled by Cranex Equipments. The range covers EOT, HOT, Goliath, Jib cranes, Winches ang ElocticHosts, Talor made or hood, thaso unis eicirity and timelessy work to make your job of material handling totaly caretree,b GENERAL DESCRIPTION 1. Bridge Girders a) Double Girder Crane: Two bridge girders consisting of weldod,rivetted or machine bolled stuetures. The glider towards the long travel machinery is known as dive side irder and the second girder as idle side girder. 'b) Single Girder Crane: Only one girder consisting of a welded, riveted or machine bolted slructure. In this case the hoist machinery is suspended and runs on the bottom of the arder. 2. End Carriages ‘These house the long travel who's, driving as well as idle, and the girders are supported on them, 3. Crab ‘This consists of the holst and the cross traverse machineries. (Aux. hoistf required) 1a) Hoist machinery consists of the following, 4) Motor 2) Brake 3) Gear Box 4) Rope Drum 5) Wire Rope 6) Snatch Blocks b)_ Cross traverse machinery consists ofthe following: 7) Motor 8) Brake 9) Gear Box 10) Wheels Platform ‘This ig a walkway along the length ofthe crane for maintenance purpose. I also. provides suppor for the lang travel machinery. . Long Travel Machinery Tris machinery moves the crane along the length of the building and consists othe folowing: 11) One motor at centre of span or hwo motors connected directly to two wheels, 42) Brake, 13) Gear Box 14) Wheels 16) Shaft along the full length 6. Cabin ‘Tre cabin, it provided is suspended from one end, so positioned to give the operator an. structed view of the load to be handled. All the contro's are housed inside theELEVATIONERECTION INSTRUCTIONS General Erecting cranes may be either a simple or complicated and expensive process, depending ‘upon the preparations made prior to the receipt othe crane and to the amount of importance altached to the instructions given below. We provide for easy erection by dismantling the Crane in the shop after ithas been completed and matct-marking each dismantled part to facilitate erection The instructions ven here for assembly, wting, esting and commissioning of the Crane should be carefully folowed as good installation wil engure years of satisfactory and Carefree operation Enaure hat al parts are idntiied and thoroughly cleaned prior undertaking erection All paris have been matct-marked atthe works for easy assembly at sie 1. Gantry Rails A.correctly made runway is an important factor to ascertain tha the crane will work for ‘years with a minimum cost of maintenance. The span should be equal o the crane ‘span and deviations, i any, must be within permissible limits, Flefer chant enclosed for Permissible deviations, Fist straighten the runway along one side and use a stee! tape and spring scale for checking the span and alignment of rail on the other side. While checking span, a force of 10 kgs. should be maintained. Regardless of span the ape must only be held at both ends with no supports. End siops must be provided al the end of the gantry rails and the rails should be electrically earthed. 2. Crane The Crane has been fist fully assembled inthe workshop and then dismantled for despatch, The two main bridge girders and end carriages have been match-marked for {238y assembly The connocting pots nine end carnages and bidge gdershave oon marked A1, A2.B1, and8) The End Carriages should be first placed on the gantry rails and clamped in postion The bridge girders should then be ifted and placed on the end camages ensuring that fend At rests on point At and so on. It the girders are sent in pieces, they must be preassembled on the ground taking extra care to ensure straightness before welding, ») Alter the Crane girders have been fixed in position the trolley shouldbe ited and placed ‘correctly on the bridge rails and inthe correct direction. n case headroom prevents tre assembled trolley to be erected, it should be totally dismantled and erectod place by Piece and finally assembied on the top itself ©) Now the platform and its supports should be fied using proper bolts at each support ‘The LT machinery should be fixed next, checking the alignment of motors, gear boxes {and brakes. Allocating pads should be welding to prevent shifting of any urittrom ie aligned position. ‘) The bottom block should now be suspended from the trolley with rope wire clamping the {ds of he rope drum with the clamps provided. Tie reeving shouldbe as per the assembly drawing. 3. Down Shop Leads 4) The support brackets should frst be welded tothe gantry as per the drawing. The Insulators etc. should now be fixed in position. The copper wire should then be lifted and {ightened in postion using the strain insulators at each end. The copper wire should be Clear of each intermediate insulator by atleast 50 mm. Before the crane Is finally put into Commission it should be run very slowly over each bracket to ensure thal he current collector does net foul Alternatively he Down Shop Leads (DSL) can be of Angle ton type in which the ‘Conductor is of Angle ron instead of copper wir. In this caso also the brackets should first be welded tothe gantry girder and then the busbar insulators fixed on them, ‘Subsequently the Angle ron conductors should be straigthened, aligned and welded as Perthe assembly drawings ©) In some cases, specially for flameproof and spark resistant cranes, flexible cable down ‘shop leads are provided. In this case the conductor isa flexible cable of suitable sao ‘suspended on suitable runners running on a support along the length of the shed 4,Electrical Wiring During transportation, a number of electric cables have to be disconnected and hence the electrician should reconnect all wires consulting the wiring dlagram. Care should be taken to ensure that all the connections are made with properlugs, glands and ferrules to event loose contacts ata later date due to normal crane vibralvons, ») ‘The crane structure, motor frames and metal cases of electrical equipment are all earthed. The gantry ailis also earthed as Itis generally accepted that for normal ‘conditions the crane wheels can be considered to make an effective earth with the rail; OPERATING INSTRUCTIONS Inspection before operation ‘Check the following point by point to ensure that the Crane is finally ready for trial operation. 1) Make sure that phasing of Crane power supply is correct. 2) The gear boxes should be filed with recommended lubricants upto the maximum level marked on the respective Dip sticks. 3) Al points of lubrication should be greased manually by a grease gun. Refor the enclosed lubrication chart for selecting the proper kind of lubricant 4) Test and adjust the hoist limi switches. The actuating nuts are easly adjustable to sult the limits of hook its required oy disengaging the driving chain. The lever limit switches. forlong travel and cross traverse should be properly positioned and wired. '5) Butters and end stops must be property fixed. Trial Operation 1) One by one, operate all the mechanisms of the Crane on NO LOAD. Check performance ofthe mechanisms and salety devices and ensure tha heres no malunctoning of ary componentor assem. Closely observe for any abnormal noise, vibration ete. 2) Drive the crane carellly along the whole length ofthe runway or checking clearances, 8) Test the Crane first with 100% load and then 25% overload. Safe Hoisting Practices Cranes are designed withthe safety of the operating personnel first in mind. Your own satety and that of your fellow workers will Be assured only when the equipment is used in a proper ‘manner and as recommended by the manufacturer. Disregarding such recommendations will endanger ite and property. 1) DO NOT OVERLOAD. The safe working loads very clearly marked on the Crane and under no condition should the crane be overloaded. Overloading may permanently ‘damage some load carrying part and this could lead to a future failure even at less than rated capacity. USE SLINGS ONLY. Cable or chain slings should be of proper size and type for handing the load. Never use slings showing any type of damage. Use padding on the ‘edge of te load if itis sharp, to prevent damage 10 the sling. ‘STAND CLEAR OF ALL LOADS. Ifa load must be travelled over the heads of other Personnel, ample warning must be given before the Crane is put into motion 4) INCH THE HOIST INTO THE LOAD. Running into the load at fll hoisting speed imposes an excessive overioad on the hoisting mechanism and could result inthe failure ‘of vital parts andior he supporting structure, Ths is particularly ue with high hoisting Speeds. To voi theload swinging he same prince shouldbe applied othe vaveing ‘motion also 2) 35) LIMITS SWITCHES ARE FOR EMERGENCY ONLY. Care shou'd betaxeact‘oti9 limit switches during normal operation. iitis necessary to travel lo Meexvers 1. use Caution and approach the limit in siow speed, 6) CENTRE THE LOAD BEFORE LIFTING. Do not pull the load. The load shou'd ne -a'sed lite at atime to see that each par clears the ground at the same time. Care sh also be taken to ensure that ali slings are supported evenly to avoid excess load on any ‘one sling. Do not drag the load as dragging creates higher stress in the wire rope than ‘when the load is suspended, USE HAND SIGNALS. Hand signals must always be used for cabin operated Cranes ‘and only one person should signal to the operator. The floorman's standard hand, signals areilustrated below for reference. 8) AFTER DISUSE. When the Crane is to be operated after a long period of disuse always ‘un all motions without load fist. FLOORMAN'S STANDARD HAND SIGNALS. Itis essential that only one man be assigned the work of signalling as operating the Crane ‘on signals from two or more men can spell disaster. The operation of the erane should also be performed by one trained man oniy, 1. HOIST. The floorman makes small circles with his hand with his index finger extended and his forearm in a vertical position. 2. LOWER. ‘The floorman, with his hand open and forearm extending downward below the hip, waves to indicate downward movement 3, STOP. The floorman, with his hand level with his hip, extends and holds his arm rigid 4, TROLLEY TRAVEL. ‘The floorman extonds his arm just above his hip with fingers closed and thumb extended and indicates direction with his thumb, in the same way he would "thumb aide,” 5. BRIDGE TRAVEL. ‘The floorman, with his hand open and with his palm facing the direction of travel and forearm vertical, indicates direction of travel by waving his arm. 6 EMERGENCY STOP. ‘The floorman extends his arm with hand level with his hip and palm downward and ‘moves his hand quickly to right and let. 7 co owen a eTo> } ii Kt, ( \u \ N\ ‘ ‘ BN | Sf i f 25coroO MAINTENANCE INSTRUCTIONS GENERAL ‘An overhead crane represents a sizeable investment which has been made to obtain the service thal an overhead crane can give. This investment can and should be protected. as By doing 80 the life ofthe crane is prolonged anc the cost to maintain it kept to a minimum. Due to their complex nature, electric overhead cranes present special problems in that they ‘are a combination of three branches of engineering, electrical, mechanical and structural Each can immobilize the equipment due to poor maintenance. The economic upkeep of ‘cranes can only be attained through a rigidly enforced preventive maintenance programme. Reepairs can then be caried oul without having to pay for overtime. Loss of production can be kept 0.4 minimum, Additionally, the if span ofthe crane will be extended and the Sequence of a defective part contributing to major breakdown can be prevented, [Needless to say, dally maintenance and inspection are nat only important fo safe operation bbutalso govern the efficiency and ultimately life of the Crane. ‘The following points should especially be kept in mind to assure thorough maintenance. CRANE RUNWAY {A good runway is essential for proper performance of a crane. Columns and runway members must be braced and strengthened to take the longitudinal and braking action of the crane, Runway rail alignment and span should be carefully checked al least onco a year 0 thal corrections may de made for normal settling of building or runway structures that ‘occur through changes of seasons. Rails should be both level and paraiel. Joints should be free from wide gaps and worn edges causing wear to the wheel surfaces and bearings. In aligning runway rails, a definite procedure should be jaid down. The rail adjacent to the main ine conductors should be lined up first. A check ofthe dimension between the centre Of the collectors contacting the runway wires and the adjacent track wheels should then be made witha ranstalhough reasonably sastactory resus can be obained witha chalk line on shorter runways, The second ral can be set Up using a steel tape. Fails should be checked for span in increments of not more than 3 metres of runway length. Runway rail alignment should never be allowed to deviate more than 6 mm as the danger of ‘wheel flanges scruobing the rail head can do irrepairable damage on the wheels and place Undue strain on mechanical and structural components. ‘After runway rails have been aligned the conductors can be checked by using an indicator ‘set up on the erane bridge. Rugged crane bumpers are provided at each end ofthe runway. These are of steel and should engage with the buffers on the crane. Itis essential that the bumpers are set square with the runway, otherwise the crane may be thrown askew when it comes into contact with them, “The main eunway conductors form the basis of good electrical performance. The bare copper wire type should be supported on insulators at frequent intervals to prevent saggizSerious problems with runway conductors frequently occur due to the power sure: @ long runway being at a great distance trom the operating area of the crane. The ‘ce voltage drops due tothe distance involved. When making checks, capacity loads shox: handled in the areas farthest away trom the conductor feeder taps. At no time should voltage fluctuations be allowed, efforts should be made to maintain the vollage within 52 below and 10% above. 1. Lubrication Lubrication is most important and hence must be regularly checked. The lubrication charts enclosed for reference, 2. Loosening of fastened parts Loose nuts ete. may result in serious trouble and should therefore be fastened with ‘special care 3. Loose contact Electrical contacts must be periodically checked and cleaned as required, DETAILS OF MAINTENANCE 1. Motors Electne motors should be protected against drops of water, oil etc. Terminal boxes should be carefully closed. The electric motor should be periodically inspected and leaned. Belore inspection, tne motor and slpring box should be cleaned of al dit and just When checking slip rings and brush holders, itis necessary to remove metal and coal dust trom the box. The rings are to be wiped with cotton cloth. If there Is no dust or oll on the rng, the cloth could be soaked in petrol.‘Scorched' rings can be polished with fine ‘emery paper. When inspecting the brush holder itis necessary to check the brush Pressure on the rings and smoothness of arm motion. Worn out brushes should be Feplaced by spare ones. Bearings of motors should be checked and washed with petrol, and the lubricant changed every 8 to 12 months. Lubricant should be added every 3 to & months, It should be noted that the lubricant fils no more than 2rards of the bearing housing. 2. Brakes General ‘The pressure applied by the main compression spring determines the braking torque ‘capacity of the brake. The brake comes from the manufacturer preset to give the required {orque and the main spring should not normally need adjustment. When the currents. ‘switched on the brake is released by the solenoidithruster closing against the pressure ‘of the operating spring. The normal positon ofthe brake is therefore ‘ON’ and the brake willretum to this positon in he event of a power failure. The brake shoe clearance must be equal and is adjusted by the shoe clearance adjuster boit In case the shoe is to be replaced, the stroke adjuster hut should be slackenec and the brake released by operating the hand lever. The shoe pivot pin should then be removed and tne shoe replaced. Always keep spare shoes with new linings ready for mmeciate replacements, Electromagnetic With the brake deenergised and with the shoes gripping the brake drum, adjust the solen='= stroke by turning the adjuster nut unl stroke gap is adjusted between 16-19 mm, Don ‘exceed the rated stroke as this will rnder the brake ineffective, ‘Complaints about electromagnetic brakes have been frequent only when maintener: notbeen proper lot of dust nlersthe solenod opening then te lunge tics. fi movement. cust is kept down then the movement ofthe plunger wil be sm trouble free, Inthe magnet a heavy starting current is produced when the supply is swito™: ‘current drops considerably as the gap between the plunger and the magne: current drawn is at its lowest when the plunger has boon fully drawn in = ‘magnet circult reduces to 2er9, In the event of sticking, some air gap results after the coll has beer therefore continue to draw heavy current and tvs can resultin ‘that there is no air gap between plunger and the inner core of then there wil ben coil Burnout, Brake setting 4. Magnet stroke should be 16-19 mm, 2. Hand release lever should be ON. 3. Shoe ciearance should be around 1.5 mm ands 4. Handretease lever shou be OF 6 Press the solenoid lever by. Solenoid stroke should be’ELECTROMAGNETIC BRAKE SeAtNG PRESSURE AQLUSTING NUTS oxgguones a FB) sista BP : i 4 DA HOLES for FONG BAS ELECTRO HYDRAULIC THRUSTOR BRAKE TER AN) AMY \L \ rN o- tHruston__| 4Electro Hydraulic Thrustor The thrustor consists ofa cylinder filled with oll containing the centrtugal pump located at the bottom and the electric motor assembled on the top cover. The rotor shalt of ie motor is, ‘extended vertically downwards into the cylindor and carries an impoller a ts lower end, The {fp bearing of ho motor is grease lubricated and the bottom bearing Is splash lubricated ‘rom ollinthe tank. Remove oiler plug and slowly fi oil tovertiows. Normally ol wil not require changing more frequently than onco in wo years. However, the level mst be checked percicaly in order to drain the ol the Grain plug should be removed without alsmarting the una 3, Master Controllers Theale uppy mustbe std before he aster conor is opened The contact surtace wilbecome dark and ough due o arcing but this does no affect ne mconing and the contacts are not to be cleaned. I the siver contact faci is burt down the contac must be replaced. To remove, unscrew the contact stud and replace with ann saves tipped contact stud 4. Gears Gears should be inspected atleast every six months, During a check up care should be paid fo the condition of werking surtaces, degree of teeth, wear and corocinces of meshing (specially during the frst wook of gear working), Normal gosr shout rot make asharp or cyec sound. Axial shiting of gaars ic ol pormss Se Geer case flanges should not leak. Tho oll level should stay Between he markings on te cp sick “heist change of on the gear case shouldbe aie’ 180 hours of oration Bearings \When checking roler bearings care shouldbe pai ther fastening inthe bodies, tightness of covers, condlion of packing and lubrication, When morally operated, bearings shouid noi heat much, hor squeak asa resul of art. nsuffaett Moreton, damage of some elements or ticion ot rolsing pars againet the bode 6. Wire Rope The reliability and soundness of wire rope for further use should be determined by the ‘number of broken wires per strand per Gay. Dur foutne chisck-up.fs mperarve 10 thoroughiy inspect ane tgrten fastening of rope ods on dur. Tprevent untimely wea of op0s, thoy should be lubricated wih the recommended lubreant 7, Travelling Wheels Travelling wheels should not have cracks or worn collar rims. The roling surtace of the wheels should be clear of hollows and dents. 6E COMMON SOURCES OF TROUBLE GENERAL Nis very important that any rouble with electrical contol is rectilied as soon asitis detected, o avoid high maintenance or replacement costs later. Most control devices have moving paris. Thus maintaining electrical contol devices mostly means watching oul for ‘mechanical problems, not electrical ones, Low voltage is a common source af trouble, especially on smaller systems. tcan show up ‘either in starting or running. Hfrunning, the motor will draw a higher Gurrent, causing frequent {ripping ofthe overload relay. It may aiso drop tothe point where the contactor may ride, ‘back on the springs and treeze the trips, ‘Another source of trouble is when the inrush of the motor in starting drawe such a high ‘current that the voltage is proportionately lowered. This could result in the welding and freezing ofthe contacts. Ovorheated parts are always a sign of trouble, Since various parts operate at diferent {emporatures it may be dificult to identity this symptom. For example Diow-out cols and cother parts ofthe contactor may operate at or exceeding the temperature of boling water, hence these parts cannot be touched by the naked hand. Any evidence of baking or ‘smoking, however, should be checked immediately. ‘Loose connections, always a source of trouble, may develop at any time. Therefore, contre’ ‘connections should be checked periodically along with the main line connections, ‘The best way to find grounds which may develop isto check the cables and conduits Periocicaly wih an ohm meter. Ths s 6specially necessary it water could colt in the conduit Only personne! familar with electrical equipment and the hazards involved should be Permitted to service these control units. CONTACTORS AND SPRINGS. ‘The contactors are designed with adequate margin for crane operation. After some time c ‘operation however, small craters will appear on the contact surlaces which vil cause. increased resistance and accelerate the process of wear on the contacts. The contactor Contacts should therefore be inspected at regular intervals and worked plane with afi Fr all yes of contactors new contacts can be bought anditis not necessary to buy new contactors. Contactors need the most care. Deposits on contacts should be removed with ether ‘Sandpaper or afine fle. Emery paper should never be used because the emery dust embeds itset inthe contact face and continuas to wear.CRANI In fling care sould be laen to mainline orginal shape fhe contact, bu dona overdo "While copper oxde shouldbe removed because isan noulaor, trying to Keep contact Suaces shoot only wastes the mallee contac suracs Silver contacts should never be filed unless they become severely roughened. Silver oxide |s.agood conductor and does not need to be removed. When contacts are deeply pitted, Dum or wor thin, they should be replaced by new ones. Screws holding the contacts in ‘lace should be kept tight at all times. Springs should maintain the proper contact prossure contacts are pried to woar too thin, spring pressure decreases and. oveheting ea results, Ths overheating generaly causes ‘the Spring to lose its temper, further decreasing the contact pressure. ‘New methods of impregnation have greatly reduced coil burn outs. However, in the event ofa coil failure, the contactor should be checked for mechanical binding or blocking. For, example, a contactor coll may have a 47 amp. inrush value with the magnet closed in the sealed position. Ifthe magnet is accidentally blocked open, or the voltage is so slow that the magnet cannot seal against the contact springs, the AC current willbe high, causing a burn out. CONTROL FAULT DIAGNOSIS CHART ‘Symptom Possible Cause Cure MANUALLY OPERATED CONTROLLERS. Excessive __Lowcontact Pressure, contacts Adjustment inspection. On drum Contact not propery aligned controllers adust star whee! ever Siming Spring lo centre the finger sot afr he contact squarely Burning Out Starting sequence stopped at instruct operator Restor, mispont ° ae Failure to Low votage on coll Check system Pick Up Faiuroto Coilbumtoutorwiong coil ——_—~Replace, Check gap din Faire to Mechanica binding Clean and adjust Drop Out Contact welded ‘See contacts ‘THERMAL OVERLOAD RELAYS Failure to ‘Wrong size heater. Relay (Check instruction sheets. Clean Tap damaged by short circuits, and adjust. Replace relay. Trips at Wrong healer. Heater assembled Check instruction sheets. Check Lowcurrent incorrectly. Heater inhigh ambient instructions. Install relay and Controller noar motor orin cooler place. Tripson Starting cycle of motor toolong Refer to factory Starting Failure to Broken mechanism Replace relay or broker 22° Reset Burning ot Short circuit ‘Check wiring of ps Relay Contacts High coil curent Vibration Dirt and corrosion \Misapplication18 y ‘Symptom Possible Cause ‘CONTACTS: Short Contact Interrupting too high a current tite Using oibimmersed device when air should be used (Note: Contacts bam mach faster ino than in air) Bounce on opening or closing ‘Abrasive dust Low Contact Pressure Frequent jogging (inching) Contactor Chatter Poor contact in Control Circuit ‘or Pumping Fluttering control relay, such as Pressure or temp switch Broken Shading Coil Bad interlock Overheating Copper oxide Heavy load for more than eight hours continuous operation. Overioaded Weak contact Pressure Poor connection Weak Pressure Womtips Poor adjustment Cure {nn Use special tips or next larger siz contactor. Use air break device if olis not necessary oF it oli imperative tr heavier duty oilimmersed device Readjust contactor for ‘Bounce’ Dust tight enclosure Now contacts andor Springs Larger size contactor ‘Check connections in control cir Repair pilot device Replace Increase wipe and pressure seal interlock Use silver alloy ts Reduce load or use larger Contr Clean and adjust. Replace conte Spring and contact if wear allowance is used up. Tighton New tips Readjust gap and wear allowan: Overheating Contact pressure Excessive Burning Rapid lever Operation Itregular Surface Lack of maintenance Abrasion Lack of Lubrication SLIDING CONTACTS USED ON RHEOSTATS, KNIFE AND ORUM SWITCHES Dress capper contac or uso special alloy contacts. Lubricate ‘contacts periodically as recommended. Operate more siow/y to eiminat starting across the line which ‘Causes burning of contact surtac ‘and flashover, ‘Smooth over contact surface a lubricate (Donotuse emery cloth) Apply light coat of vaselineTROUBLE SHOOTING CHART would be a good idea to keep a record of all breakdowns and tere~ates - form. Atypical example would be the formation ofa trouble shooting =a 25 fraucrs POSSIBLE REASON FOR FAULT REMARKS, eGV1r§ =r __REMARKS No motions of crane operate and ensure they are @ 8) Runway coliectors not making conductor wires ‘contact with eonductors 4) Broken wire or connection Hoist motion 41) Control panel fusos out fails to 2) Thermal relay out Press re-set bution operate 3) Undervottage relay out 4) Limit switch in open position ‘Open up limit switch and free only; allowing hoist to contact be lowered 8) Trolley collector off wire or dirty collectors Trolley motion 1) Control panel tuses out fails to 2) Thermal ralay out Press re-set button operate 3) Fuses or trolley blown 4) Undervoltage relay out 5) Trolley collector off wire or dirty collectors 6) Wheel axle broken ‘Seized bearing or broken gear Bridge motion 4) Control panel fuses out fallsio 2) Thermal relay aut Press re-set bution operate 3) Undervoltage relay out 4) Wheel axle broken ‘Seized bearing or broken gear Hoist motion too 1) Non-release of magnetic brake Coil bumt out or broken wire slowortoofast’ 2) Drum controller linger contacts ‘not connecting '3) Magnetic controllers aceelrating contacts not ‘operating 4) Loose resistor leads Braking action 1) Magnetic brake needs Brake linings wom or loose too slow for adjustment linkages. motion Bridge Skows 1) Low Voltage 2) Grane overioaded '3) Poor mechanical condition of bearings, gears wheals etc. Flashing of 1) Dirty main connectors, main conductor systems but no ‘motion 2; Preventive Maintenance Check List. | maintenance is done in accordance withthe folowing checklist, crane tie ups and ‘operating expenses may be kept to a minimum. In order to ensure thorough eran inspection the below mentioned check list should be relerred to. FIRST DISCONNECT MAIN SWITCHBEFORE WORKING ONCONTROLS.. ‘cHEcK TEN ‘OPERATION > rerarion Dust Clean Rustand Corrosion Clean— Report excessive. Connections Tighten electrical connections. { {or discoloration of any copper current carrying parts. Nuts & Botts Tighten Fuse Clips ‘Check for spring clip pressure, Contact Tips Look for copper oxide seale and dress only itnecessary. Check whether contact pressure is same on all tip, Bearings Donotoil; Check whether they are free moving. Coils ‘Check for any signs of over heat ‘or mechanical injury. Overload relays Trip by hand, mechanically free, Push button Giean, check contacts. Resistors ‘Check for signs of overheating, Gear Boxes Drain small quantity of oll from dr plug to remove sludge, iftoo mu sludge, drain oll and clean. Chec\ level and add ifrequired. Replace ollif black and diny. Drum Contacts, ‘Tighten and check for contact we ‘and overheating, put small amour ‘f vaseline of sliding surfaces. Pe ‘list should be maintained of all parts which may need replacement in the near future Regular periodic checks should be carried out as detailed above.IMPORTANT POINTS FOR CRANE OPERATORS Te foundation of ago preventwe maintenance san educational programme fr both ‘operative and maintenance personnel. A few simple ideas applied in this respect can repay the offor involved many times over. tis suggested that a card be installed in the cab of ‘each crane stipulating the folowing regulations: Do: Clean walkway, control cabinets, etc. regulary. ‘Take up slackin slings and cables gradually. Provide good access to crane from the floor. ‘Secure all covers after maintenance. ‘Tum off main switch when operator leaves cab, Remove main uses when maintonanco has tobe carried out on crane. Report immediately any adjustments that should be made on the crane to the Foreman. Regularly test he brakes, limit switch and controis before you start your “shit on the crane. DONT: ‘Move any load except on signal rom one floorman. Fun bridge or trolley up against the stops, ease it gently. Use limit switches as regular stops. Pick up a load at an angle or drag sings, hooks, or loads along the floor with the crane, Let the block swing excessively. Brake too hard and siop crane Suddenly Overload the crane. ‘Jerk load off the floor. Leave tools etc. loose on crane or runway after maintenance. Leave nook blocks hanging at head height over gangway or aisles. “Try lodo maintenance on the crane with power on. ‘Step on cross shaft or couplings when crane is in motion. LLethook block tie on the ground so that hoist cables become loose as this wll cause cables to jump the sheaves and may resulin broken cables.E PERMISSIBLE DEVIATIONS Permissible Wear Do not use the parts of he Crane over the following limits of weer. The parts which are w: out over these imits should be replaced immediately, Part Description Permissible wear limits (decrease in size) Gears First part of gearing 10% of tooth thickness on the p.cd. Other gears 20% of tooth thickness on the ped. $$ Wheels Flanges 80% of ull size ‘Thread 30% of fullsiz0. When the Uifference in diameter between + side and eft side wheels exceed 1.5% remachine to rectly. ONO ‘Shoaves Groove dia 50% of wire rope diameter Oren Brake lining Thickness 50% of fullsize uci orem Wire rope No.of breakages ofsteel wires 10% of total strands per every 300 mm length aver he entire length elGANTRY RAIL ALIGNMENT ALLOWANCES HEIGHT DIFFERENCE & SLOPE 5. SVENTINTENA\SSETIESFONEXAURE 7 A A A agar Ce J mo Aas a — “gg rorace (OF LH. RAM HEIGHT MEASUREMENT MEASURED VALUE OF RAIL SURFACE OVER DATUM LINE ZA SORE SERALSURFACE TOLERANCE... 8M v800 0M BETWEEN INTERVALS. FORSMINTERVALS RELATIVE SLOPE Dit TOLERANCE... 5M x 1500 1014m ERENCEBETWEENRH. S500 FoRBMINTERVALS BUR RAIS RELATIVE HEIGHT + 16MM FOR SPAN M~ 16M. SUVERENCE SETWEEN CHeRN RAILS ++ 20MM FOR SPAN 16M~ 20 TOLERANCE: < + 25MMFORSPAN20M~ 250. £315 MM FOR SPAN25 M~32M, | 40 MM FOR SPAN 2M ~ 40M. SPAN & RAIL UNDULATION [MEASUREMENT INTERVALS 5 METRES FOR EXAMPLE BAA AA AA sHOULONOT Exceeo 25MM EVENAT MAX POINT OF UNDULATION gorse | Typpwate ne Lune waicr connects, STANDARD UNE TOorrional Poms SEUNDULATION TOM APART “£ 10MM FORSPANEM ~ 20m. ‘SPAN (+ 12MM FOR SPAN 20M ~ 25M. O Berson rare. { stirnarSt +2 20MM FOR SPANS2M ~ 40M.PERMISSIBLE DEVIATION IN CRANE ALIGNMENT 1. INCLINATION OF GIRDER | GIRDER DEPTH mm ALLOWANCE | wot 800 25 | { 500 to 630, 3.15, 5 630 to 800, 40 * 18001 1000 50 700019 1250 63 1250 to 1600 8.0 ” 1600 > 2000 700 : 2.DISPLACEMENT OF VERTICAL 4. DEVIATION OF THE SQUARENESS OF THE PLANE OF SYMMETRY OF TWO WHEELS Ginoen w sADDLE + A-BE2 a] FoR TROLLEY wHeeL | |_| |u| fe B| Zl == t A-B<3 i Ton FS FoR crane wee. | * | ~ 3 eee 7 q Y < F000 T AB = ec =a S. DEVIATION OF THE VeRTiCALITY OF THE WHEELS WHEEL BASE mm [ALLOWANCE mam (Aes ore) 2500 Under | 10 2500) 3150 125 3150 4000) 18 . 4000 5000, 20 5000 6300 25 6300 3000) 36 2 3000 T0000 20 mK A-8 < 7000 10000 12500 Under 50LUBRICATION CHART No. | Partobe brcated Mothod ot INTERVAL RECOMMENDED LUBRICANTS appbeatien Indoor Outdoor | 10.6, HP 3. | exeroseo cane 4) Less tran 12HP Splash A 8 | Pathansz0 nko 220/320 Ambient Temperature iessinan °C “Ambion temperature Splash c ° . ‘reaterthan 80°C ) 121040 HP ambient Splash A 8 ‘ ’ tomporature age than 50°C Splash c > : . ©) Above 4OHP ambiont Spach a 8 . temperature lous than 50°C | ‘Ambient temperature Splash c > : ‘reatortnan 60°C 2. | OPEN GEARING Manual E | tana Hytak 4/0 3. | BALL BEARING Grease Nipple A 8 | ten Litton EP 2 4. | PLAINSLEEVEBEARING Grease Pump F F | uton2 Lihen EP 2 5. | TRACK WHEEL 4) Plan sloove beerngs Fet lubricated 6 6 | Patnanse0 nko 220/320 or grease pump Luthon 2 Lihon EP 2 ®) Anttiton Grease Nipple A 8 | Lion Hifako 6. | sHeavesHooK sock 8) Plan sleeve Brg, Grease Nipple F | panos Hytek 4 ») Aninigion Bg. Grease Nepple a 8 " ) Hook Swivel Manval @ E | Mobie . Grease Spt 7. | wiRE ROPES Manual E | Fyaet Hytak Fa 8 | ELECTRICAL PARTS (PINS) Manual e | Patnansz0 Eno 220 LEGEN |A- Check and iubricato wookly ‘8 — Check and ubricate weekly (—Check and lubricate weekly 1D —Check and ubrcate wookly E— Apply weekly orevery 50 hours F — Apply daly or every 8 hours (G— Apply monthly or ovary 50 hows ‘Change afer 2000 hr. f operation or every sicmonths ‘Change after 1500 hrs. of operation or every three months (Change after 1000 hrs. of operation or every three months ‘Change ater. 750 hrs. of operation or every wo months