You are on page 1of 68

For Evaluation Only.

Copyright (c) by VeryPD


F.com Inc
Edited by VeryPDF PDF
Editor Version 2.2

Overhead EOT Cranes


Operation,
Maintenance and
Safety Manual
1 Manual Contents

Sr.No. Particulars Page No

A General
1 Foreword from CEO 2
2 About ElectroMech & Cranedge 3
3 Introduction to Manual 5
4 General description of cranes 6

B Crane erection & commissioning


5 Instructions for gantry rail alignment 15
6 Instructions for alignment of Down Shop Lead
(power angles) 18
7 Instructions for storage of crane components at site 19
8 Standard procedure for erection of EOT Cranes 22
9 Standard procedure for commissioning of EOT cranes 24

C Safe operation of crane


10 Instructions for safe operation of EOT cranes 27

D Crane Maintenance Guidelines


11 Guidelines for maintenance of wire ropes,
electrical equipments, brakes, etc 32
12 Activities to be done on EOT cranes during
preventive maintenance 37

E Standard Drawings 40

F Annexure A : Lubrication chart 51


Annexure B : List of critical spares 55
Annexure C : Precautions for crane operation 57
Annexure D : Wire rope information, storage & handling 59
Annexure E : Safety related to load lifting accessories 65

G ElectroMech - sales & service network 67


General 1. Foreword from CEO 2

We envisage ElectroMech becoming a worldwide brand leader in its field of operations by consistently
delivering world-class quality products in the lowest possible lead times at the most competitive rates.

True to this vision, ElectroMech, over its history of operations, has shown consistent improvement in
performance by delivering top-class products and by catering to a wide range of client requirements. Be
it the case of supplying mass-customized hoisting applications for a multi-million dollar, multinational
power project, or of supplying specialized material handling equipment to various infrastructure
projects funded by the World Bank, ElectroMech has made its own contribution towards the
successful commissioning of such projects.

In the Indian industry today, ElectroMech has become a name to be reckoned with when it comes to
engineering of customized material handling solutions to suit complex customer requirements.

We, at ElectroMech, have a strong tradition of innovation and we are constantly engaged in upgrading
our products to match the current world-class standards. Unique business processes that have evolved
in-house through continuous improvement exercise ensure the high quality of products and timeliness
of deliveries. We are proud of the fact that we have set quite a few benchmarks for our competitors to
emulate.

Today, ElectroMech ranks among one of the premier manufacturers of Cranes and Hoists in India and
the vision of the management is to extend this reputation to the global stage. We thank you for
considering ElectroMech for your material handling requirements.

A V R Murty
CEO
Electromech
3 General 2. About ElectroMech & Cranedge

2.1 ElectroMech

As an ambitious company that is bent on attaining the leadership position in the material handling
industry globally, we, at ElectroMech, are always doing something newer and more exciting. Thus, it
gives me pleasure to introduce one more issue of our newsletter, EMPOWER that chronicles the latest at
ElectroMech.
Considering the long-term growth plans of ElectroMech and to ensure proper funding for this growth,
ElectroMech took on an exciting move of inducing Private Equity investment in the company. This paves
our way to pursue exciting growth opportunities involving strategic investments, consolidations and
new product introductions. India is all set to reach the figure of USD 5 Trillion in GDP by 2020 from the
level of approximately USD 1.5 Trillion currently. This massive growth, expected to happen in the
compressed time frame spread over the next decade, throws up a lot of exciting challenges. We, at
ElectroMech, believe that this is a once-in-several-centuries opportunity that needs to be tapped
properly as this opportunity is never going to come up again. Hence, having the right financial partner
with us helps us in making our foundations stronger and fuels our growth plans.
This issue also talks about the two latest tie-ups we have entered into - Sibcranex of Russia and
Shuttlelift of USA. This could have been considered to be a political coup in the eighties as getting
Russian and American collaborations for the same company was quite unlikely. However, the world has
changed for the better and India is the place where the action is.
Through Sibcranex, we aim at participating in the growth set to unfold in the Indian steel industry
where more than 100 Mn MT of annual steel producing capacity is estimated to be set up in the next
decade.
Through Shuttlelift, we are introducing an exciting new product - Rubber Tyred Gantry cranes for
industrial applications. We believe that this product can revolutionize the way bulky items are handled
at sites and improve productivity and enhance safety of men and material
We are proud to be associated with several prestigious infrastructure projects like coal power plants,
water supply, sewage, nuclear power plants and renewable energy. This issue shares with you some
details of the projects that we have been associated with.
Technical leadership is something that is not developed overnight. The Stahl Ex range of products is a
perfect example of this. Being in existence since 1920s, the Ex range of products from Stahl continues
to dominate the global market technologically. We have an interesting write-up in this issue showcasing
Stahl Ex's technical prowess.
Our services subsidiary, Cranedge continues to cover newer ground every passing day. In this issue, we
are proud to share with you the way Cranedge helped one of our esteemed customers derive maximum
ROI by refurbishing old equipment and enhancing productivity and safety.
General 2. About ElectroMech & Cranedge 4

2.2 Cranedge

Cranedge India Pvt. Ltd. is a company initiated by ElectroMech. At Cranedge, we have access to the rich
knowledge of ElectroMech built painstakingly over more than 30 years and spread over a few thousand
installations. Also, we have quick access to ElectroMech databank, spares inventory and manufacturing
facilities. This makes Cranedge a knowledgeable and resourceful organization which will always benefit
our customers. This company is exclusively engaged in providing after-sales-service to users of
overhead cranes. These services are made available through a team of well-trained and skilled
engineers and technicians.

To ensure maximum up-time of your material


handling equipment (irrespective of the make of
the equipment), Cranedge Service offerings
include -
• Spares Sales
• Repairs, Services and Overhauling
• Annual Maintenance Contracts
• Crane Health Checks
• Modifications and Retrofits
• Relocation of Cranes
• Remote Conditioning Monitoring
• Crane Safety Certification

The manufacturing industry employs several advanced material handling systems, where EOT cranes
play a pivotal role in efficient material handling. Plant productivity is greatly dependent on 24x7
availability of such cranes. Hence, periodic crane maintenance is a key to productivity. In some plants,
several cranes are used. They vary not only in type and capacity, but are installed at different times. In
some cases, even the makes of these cranes are different.
This poses a challenge for the maintenance department of the user company. The option could be,
either to train their own manpower for different makes and different types of crane maintenance and
also maintain spares inventory for each of the cranes, or alternatively hire maintenance services of the
individual supplier companies which may not be available or reliable in all cases.
Some companies also tend to opt for the services from local maintenance companies.

Cranedge services are available for all brands of


cranes and anywhere in India.
Various service packages are available to suit your
requirement.
Toll Free Number: 1800-209-0010.
E-mail: enquiry@cranedge.com,
Web Site: www.cranedge.com
5 General 3. Introduction to Manual

This manual is prepared for providing our clients with comprehensive directions for erection, operation
and maintenance of the cranes supplied. Do take care to place this manual in the hands of the right
individual, the mechanic and the operator who actually attend to the maintenance work and operation
of the crane.

Definitions of signal words used in this manual.

This safety alert sign indicates important safety


information where your safety is involved.
Carefully read the information that follows and use
clear channels of communication to inform other
operators and maintenance personnel to avoid
serious bodily injury, death and damage to
equipment.

This safety alert sign indicates important safety


information when operating conditions are
involved. Carefully read the information that
follows, and use clear channels of communication
to inform other operators and maintenance
personnel to avoid serious bodily injury and
damage to equipment.

Read all the detailed information available in the manual before putting the crane into
operation

Important Note:
It is the responsibility of the owner / factory in-charge to ensure that all personnel operating and
maintaining this equipment are properly trained. No one should be permitted to operate or maintain
this equipment until they have received such training and become fully acquainted with the relevant
operating and maintenance instructions in this manual.
General 4. General description of cranes 6

4.1 Basics of Electric Overhead Travelling (EOT) cranes

EOT cranes travel on a pair of gantry rails mounted on gantry girders, which in turn, are supported on
columns on two sides of the bay. The crane consists of bridge girders, end carriages, platform, trolley
assembly and long travel drive machinery. Machineries for the hoisting motion and trolley travel
(traverse motion) are mounted on the trolley, which moves on rails fixed on the top of bridge girders.
These cranes find their applications in a wide range of industries. Depending upon the needs specified
by the customer in enquiry, the cranes are supplied with special features such as -

Ø All motions, with in-built DC disc brakes Ø Top and bottom limit switches
(rotary / gravity)
Ø Hardened and ground helical gears that provide
high efficiency, quiet and long lasting operation Ø Hoist motors with minimum 40 CDF and
150 starts / hour
Ø All electrical connections of plug socket type Ø Soft start / soft stop through inventors
Ø All wheels with direct drives Ø Twin cross travel drives
Ø No open gears on any travel motions Ø Low crane headroom
Ø Maintenance platform Ø Anti collision device
Ø Load display indicator,

In EOT cranes, 3 common motions are incorporated; namely Hoisting, Cross Traverse and Long Travel.
Sometimes, according to the customer's requirements, Auxiliary Hoisting and Micro Motions are also
incorporated. Hoist and CT machineries are fitted on a common frame known as a crab in case of a
double girder crane, whereas they are a part and parcel of the Electric Hoist itself in case of a single
girder crane.

4.2 Main types of cranes


4.2.1 Single Girder EOT Cranes
A single girder crane utilizes a single bridge beam attached to the two runway/end trucks. This bridge
beam or single girder supports a lifting mechanism or hoist that "runs" on the bottom flange of the
bridge beam.

4.2.2 Double Girder EOT Cranes


A double girder crane is an overhead travelling bridge crane
that utilizes two bridge beams set atop the runway (end)
trucks. Generally, this type of crane utilizes a top running
trolley hoist, which moves along the top of the two bridge
beams on its own set of trucks/trolley wheels. The hook from
the hoist "falls" between the two bridge beams. The
headroom under the crane is increased by utilizing this
hoist/crane configuration.

4.2.3 Underslung Cranes


These cranes are used in places where adequate space is not available between the top of the gantry
girder and the bottom of the roof truss. These cranes run suspended on the bottom flanges of the
runway beam.
7 General 4. General description of cranes

4.2.4 Gantry / Semi Gantry Cranes


Unlike EOT cranes, Gantry cranes run on rails
mounted on the floor level. The bridge
girders are supported on a pair of legs which
are supported on end carriages.
Semi Gantry cranes operate on the rails
mounted on the gantry girders on one side
and on the floor on the other side. Goliath cranes can be supplied with bridges extending beyond the
center line of the rail mounted on the ground to facilitate loading and unloading of material beyond the
crane span.

4.2.5 Wall Travelling Cranes


A wall travelling crane is a travelling jib crane consisting of a fixed or
moveable hoisting mechanism and operating on a runway attached to
the side walls or columns of a building.

4.2.6 Stacker Cranes


The stacker crane is basically a 'fork truck on a crane.' In appearance, it
looks like a conventional bridge crane except that in place of a hoist, a
rotating ridged or telescoping mast is suspended from the bridge trolley
with the mast equipped with single or double forks or a grab. Stacker
cranes are used for storing and retrieving loads in storage racks, typically
where the rack is taller than 15.24 meter. They can be controlled remotely
or by an operator in the cab.

4.2.7 Jib Cranes


Jib cranes are useful especially for loading or unloading of work
pieces on machine tools. These are also useful for loading or
unloading of trucks. They can also become an inseparable part of a
standalone workstation and machine assembly area.

4.2.8 Other applications


A tunnel mucking system is a unique and cost-effective bulk material
handling system for extraction and disposal of overburden generated
during construction of tunnels. These systems can very efficiently remove
overburden generated during construction of deep shafts with access
tunnels as well as the overburden generated during the tunneling
operations
General 4. General description of cranes 8

4.3 Major parts of EOT cranes

4.3.1 Trolley Assembly


The trolley assembly consists of the hoist drive
mechanism, trolley travel mechanism and the
trolley frame. Typically the trolley frame is
supported by 4 wheels which runs on rails
mounted on the bridge girder.
For the safety of maintenance personnel, the
following is provided on the trolley -
Ø The top of the trolley frame is covered with a checkered plate
Ø Toe guards around opening and
Ø Hand railing
Ø Spring / rubber buffers
Ø Depending upon the customer requirement, the trolley frame also houses rail sweep plates,
derailment guard, jacking pads, etc.

4.3.2 Bridge Girder


The bridge girders are
fabricated using tested
weldable quality steel plates.
The bridge girders are
stiffened internally with the
help of vertical / longitudinal
stiffeners according to the design requirement. The girders are cambered upwards. The bridge girder
transmits the lifted load and the loads arising out of weight of trolley, LT drive mechanism, platforms,
electrical panels, operator’s cabin and its self weight to the gantry girder through end carriages and
long travel wheels.

4.3.3 End Carriages


The end carriages are fabricated from tested weldable quality steel
channels or plates. The end carriages are rigidly connected to the
girders through high tensile bolts. The end carriages along with bridge
girders form a rigid frame which resists skewing forces. The end
carriages are housed with cross travel with long travel wheels, rubber /
spring buffers, etc.

4.3.4 Long Travel Drive Mechanism


Depending on the crane span, duty classification and long
travel speed, either single or twin units of long travel drives
are provided on each crane. Long travel drive consists of a
squirrel cage / slip ring motor, gearbox, brakes, couplings,
floating shafts and long travel wheels. The selection of the
type of motors, gearboxes and brakes is governed by design
requirements and the specifications of the customer.
9 General 4. General description of cranes

4.3.5 Platforms
Access platforms are provided for easy access to the operator’s cabin,
electrical panels and for maintenance of long travel machinery. Toe
guards and hand rails are provided on the platform for the safety of
operating personnel. The platform may also support fixtures for under
bridge lights. Generally, separate platforms are provided for supporting
foot mounted long travel drive mechanism. Access ladders may be
provided from girder/end carriage to the platform depending upon
geometry.

4.3.6 Trolley power supply arrangement


The power supply to the trolley is through festoon cable arrangement.
The arrangement typically consists of fabrication brackets supported
from girder / platform brackets, I beam and cable supporting trolleys. A
fabricated cable collector arm is provided on the crane trolley for
bringing cables from the cable trolley to the crane trolley. A steel chain
is provided between cable trolleys to eliminate pull (tension) on the
cable during movement of the crane trolley along the span.

4.3.7 Operator’s Cabin


Open / close / air-conditioned cabin is provided for the operation of the crane as
per requirement of the customer. If so specified by the customer, a pendant push
button station / remote control is provided for controlling the crane operation
with or without cabin control.
The cabin is of fabricated construction. It houses crane controllers, chair for the
operator, ventilation, fan and bell. The front portion of the cabins is made
compact to improve visibility of the operator.
Toughened glasses and door for entry are provided for closed and air-conditioned cabin.
Air-conditioned cabins are of double walled construction and are insulated to minimize heat transfer
and to enhance comfort of the operator.
Depending upon the availability of space on the crane, a staircase or ladder is provided for access to the
crane platform from the cabin.

4.3.8 Electrical Panel


All the operating, control and safety electrical circuits are located in the
electrical panel. Components such as contactors, fuses, relays, timers,
etc. are to be found here. The panel is generally mounted on the platforms
or on the crab / electric hoist.

4.3.9 Pendant
The operation of the crane is generally through a pendant push
button section. The pendant gives the crane operator precise control
over the motions of the crane. There are many configurations of the
pendant depending on the functions of the equipment being
controlled. Each push button on the pendant controls an operating
function of the crane.
General 4. General description of cranes 10

There are 8 push buttons on the pendant. They are Hoisting Up, Hoisting Down, CT Right, CT Left, LT
Forward, LT, Reverse, Start and Emergency Stop. The pendant may be suspended from the Trolley
Hoist, requiring the operator to walk with and beside the load, or on a separate sliding track system
allowing the operator to move independently of the load.

The function of each push button on the pendant is as follows


For start & stop operations of the crane, Start & Emergency Stop push buttons are used respectively.
When Start push button is pressed, Main contactor is operated. Similarly, in case of emergency stop of
the crane, Emergency Stop push button is pressed and all motions are stopped.
For hoisting operations, Up & Down push buttons (twin step push button) are used. As Up push button
is pressed, the hoist moves in upward direction & by Down push button, the hoist moves in downward
direction. To get second hoisting speed, twin step push buttons are pressed twice.
The same operation is done for CT (Cross Travelling) motion & LT (Long Travelling) motion. For CT
motion, Right & Left push buttons (twin step push button) are used and for LT motion Forward &
Reverse push buttons (twin step push button) are used.

4.3.10 RRC Pendent


The operation of the crane can also be done through RRC (i.e. Radio
Remote Control). The radio control performs exactly like the pendant, but
operates using a radio frequency. The radio control incorporates
numerous safety features and allows the operator a greater range of
operator motion than a pendant. Power Supply - the electrical service
available in the building for which the crane is being designed (i.e 415
Volt, 3 phase, 50 Hertz). Enclosures - the enclosures house all the
electrical components on the crane and are rated to meet the conditions in the surrounding
environment.
There are 9 Relay contacts of RRC. Those are Start, Stop, Up, Down, East, West, North South, & Fast.
The function of each Relay contacts of RRC is as follows
1. For start & stop operation of the crane, Start & Stop push buttons are used respectively. When
Start push button is pressed, Main contactor C1 will be operated. Similarly, in case of stop of the
crane, Stop push button is pressed, as a result, all motions are stopped.
2. For hoisting operations Up & Down push buttons are used. As Up push button is pressed, the
hoist moves in upward direction & by Down push button, the hoist moves in downward
direction. To get second hoisting speed, Fast push button is to be kept pressed with Up or Down
push, the buttons.
3. The same operation is done for CT (Cross Travelling) motion & LT (Long Travelling) motion. For
CT motion, East & West push buttons are used & for LT motion, North & South push buttons are
used. To get second speed in respective motion, Fast push button is to be pressed continuously
with respective push buttons.

4.3.11 Master Controller


The operation of the crane is through Cabin By Master Controller &
Pendant. In Cabin 4, way push button pendant is used for Start,
Emergency stop, Light, Spare. With 3 master controllers are used for
Hoisting, CT & LT motions to get 4 speeds in every motion.
11 General 4. General description of cranes

The functions of the master controller are as follows


For hoisting operations MH Master Controller is used. Four speeds are achieved by moving the lever of
Master Controller step by step (1-2-3-4). The contacts are closed respectively. The same functions in
the opposite direction result in down motion with 4 speeds.

For CT (Cross Travelling) motion & LT (Long Travelling) motion CT & LT master controllers are used.
Four speeds are achieved by moving the lever of Master Controller step by step (1-2-3-4). The contacts
are closed respectively. The same functions in the opposite direction result in opposite motion with 4
speeds & vice versa.

4.3.12 Rotary Limit Switch


The lift is limited in the highest & lowest hook position by means of a rotary limit switch. The limit switch
comes with two set points which have the following functions.
1. Upper limit safety switch-lifting
2. Emergency limit switch-lowering

4.3.13 Gravity Limit Switch


The gravity limit switch is situated in series with MH UP motion & this is operated after failure of rotary
limit switch & also as fail-safe of rotary limit switch. The operational principle of this limit switch is based
on gravity, when weight lifted by the lower block limit switch is operated.

4.3.14 VFD (Variable Frequency Drive)


VFD is fitted in the control panel and it is used to achieve variable speed of
induction motor. VFD has inbuilt functions as follows
1. Overload protection
2. Phase failure
3. Torque settings
4. Soft start or stop
5. Over-voltage & under-voltage protection
6. Single phasing protection
7. Brake control
8. Reduce starting current
It gives Fault massage on display after trip of VFD.
The buttons on the pendant operate a VFD unit in much the same way as two speed control. The first
step is held to maintain the current speed, while the second step is used for acceleration. Deceleration is
achieved by releasing the button entirely. Pressing the button back to the first step will maintain the
new slower speed. It should be noted that the deceleration is not achieved through uncontrolled
coasting, but through a programmable dynamic braking system. The control provided by a VFD allows
for a high level of customization.

4.3.15 Slip Ring Motors


Slip ring motors usually have 'Phase-Wound' rotor. This type of rotor is provided with a 3 - phase,
double-layer, distributed winding consisting of coils used in alternators. The rotor core is made of steel
laminations which have slots to accommodate formed 3 - single phase windings. The main advantage
General 4. General description of cranes 12

of slip ring induction motors is it has high starting torque when compared to squirrel cage induction
motors. Approximately 200 - 250% of its full-load torque. However, speeds cannot be adjusted. Slip
ring motors come with external resistance.

4.3.16 Squirrel Cage Motors


A squirrel cage rotor is the rotating part used in the most common form of
AC induction motor. An electric motor with a squirrel cage rotor is termed a
squirrel cage motor.
Main advantage of this type of motor are speed can be varied through
VFD. It is easy for maintenance and its has a low cost.

4.3.17 Down Shop Leads (DSL)


It is electrical supply feeds to the crane. The main types of DSL
used in cranes are:
1. Angle Iron DSL
2. Bare copper wire system
3. Trailing cables flexible type DSL
4. Shrouded conductors
5. Cable reeling drum
6. Through drag chain
Most commonly used are shrouded conductors, as they are very safe, economical and maintenance free.

4.3.18 MCB (Miniature circuit breakers)


A circuit breaker is an automatically-operated electrical switch designed to protect
an electrical circuit from damage caused by overload or short circuit. Its basic
function is to detect a fault condition and, by interrupting continuity, to immediately
discontinue electrical flow. Unlike a fuse, which operates once and then has to be
replaced, a circuit breaker can be reset (either manually or automatically) to resume
normal operation. MCB is thermally operated and used for short circuit protection in
small current rating circuit

4.3.19 MCCB (Moulded case circuit breakers)


MCCB is a moulded case circuit breaker capable of switching on and off a large amount
of power. It is designed to carry large amount of making current and breaking current.
It comes with accessories like hunt trip, UV release, adjustable short circuit and
overload protection releases, earth fault release, etc. Normally, it is used where normal
current is more than 100A.

4.3.20 Contactors
A contactor is an electrically controlled switch used for switching a power circuit. Contactors typically
have multiple contacts, and those contacts are usually (but not always) normally open, so that power to
the load is shut off when the coil is de-energized. Perhaps the most common industrial use for
contactors is the control of electric motors.
13 General 4. General description of cranes

relay
A
3-phase motor
B
AC power
C

120 VAC
coil

4.4 Important terminologies used in cranes


• Capacity /SWL - Maximum weight which the crane is designed to lift.
• Span - Horizontal distance between the rails of the runway or the crane is to travel.
• Height of Lift - Required distance from the floor to the crane hook. This dimension is critical in
most applications as it determines the height of the gantry from the floor and is dependent on
the clear inside height of the building
• Bridge, Trolley and Lift Speeds - Rate at which the bridge or trolley travels, or at which the hoist
lifts, usually in meters per minute or mpm. It can be either single speed or two speed travel/lift
or a specific rate of speed. Another option is a variable frequency drive.
• Deflection - Displacement due to bending or twisting in a vertical or lateral plane, caused by the
imposed live and dead loads.
• Camber - Slight upward vertical curve given to girders to compensate partially for deflection due
to the hook load and weight of the Crane.
• End Approach - Minimum horizontal distance, parallel to the runway, between the outermost
extremities of the crane and the centerline of the hook
• Hook Approach - Minimum horizontal distance between the center of the runway rail and the
hook.
• Overload Protection (Over current) - Device operative on excessive current to cause and
maintain the interruption or reduction of current flow to the equipment governed.
• Reeving - Term describes the path of the hoist wire rope as it pays off the hoist drum and wraps
around the various upper and lower sheaves.
• Wheel Load - Load without vertical inertia force on any wheel with the trolley and lifted load
(rated capacity) positioned on the bridge to give maximum loading.
• Wheel Base - Distance from center-to-center of outermost wheels
• Voltage Drop - Loss of voltage in an electric conductor between the supply tap and load tap.
• Under Voltage Protection - Device operative on the reduction or failure of voltage to cause and
maintain the interruption of power in the main circuit.
• Variable Frequency - Method of control by which the motor supply voltage and frequency can be
adjusted.
General 4. General description of cranes 14

Hoisting Options for ElectroMech Cranes

Double Girder Single Girder

Conventional Crab Conventional Hoist

Empact Crab Empact Hoist


Crane erection &
15
commissioning 5. Instructions for gantry rail alignment

5.1

A proper alignment of gantry rails plays a very significant role in long and trouble the free service and
safety of crane. Poorly maintained tracks reduce the service life of rails and wheels. They also have a
detrimental effect of poor conditions of rail tracks on hoisting appliances. It is so great, both for the
structures and machineries, that no shock loading co-efficient can compensate the damage caused by
poor alignment / maintenance of rail joints specially in case of high speed cranes.

5.2 Dimensional and geometric tolerances of tracks for overhead and under
slung cranes.
5.2.1 General
Tracks should be within the tolerances given in clause no.s 5.2.2 to 5.2.6. The measurement should be
done when the tracks are not supporting the crane.

5.2.2 Tolerance on span


The span is checked at every 5 m intervals on the centre of the rails. Use suitable measuring steel tape
with a pull of 14/16 Kg for this purpose. Diagonal is measured between two points diagonally opposite
to each other marked on the centre line of rails at 5 m each (see fig 5.1)
5M

5M
10 M

10 M
5M

5M

Tolerance on diagonal of gantry rails permissible difference in diagonal - 5mm


Fig. 5.1

The tolerance on span should be as follows (see fig F 5.2).


Ø S<
_ 5 mm where S <
_ 15 m
Ø S<
_ 5 + 0.25 (S-15) mm where S <
_ 15 m
Ø S max = 10 mm

SPAN
-+ S
H

Overhead travelling crane


H

W-
-+
+
W S = =
SPAN

Underslung cranes

Tolerance on span level differences and track width for gantry rails
Fig. 5.2
Crane erection &
commissioning 5. Instructions for gantry rail alignment 16

5.2.3 Misalignment of track running surfaces in the vertical plane.


This is checked by using either a dumpy level or a water tube with reference to pre-decided bench mark.
The tolerance on track misalignment should be as follows (see
Ø H 0.0001 x span in mm
Ø Max = 10 mm

5.2.4 Tolerance on track width (underslung only)


The tolerance on track width (underslung only) should be as follows (see fig 5.2)
Ø W Max = 0.025 W

5.2.5 Track straightness tolerances


This is checked by trying piano wire on both the rails centers at the two ends. The other method is to
check by theodolite. This should be checked prior to taking span & diagonal readings

5.2.5.1 Permissible deviation in the lateral plane


For the total length of the track, the maximum lateral deviation from the straight line mean datum
should not exceed 10 mm (see fig F 5.3)

Straight line
Mean datum
10

2000
1

L
L/2000

10

Permissible deviation of track straightness in lateral (horizontal) plane.


Fig. 5.3

The straight line mean datum is the line about which deviations of track on each side will be equal, when
summated over the whole length of the track.

Local lateral deviation at any point of the track should not be greater than L/2000, measured over a
length of not less than 2 meters on a line parallel to the straight line mean datum.

5.2.5.2 Permissible deviation in the vertical plane


For the total length of the track, the maximum vertical deviation from the theoretical datum line should
not exceed 10 mm (see fig 5.4). The theoretical datum line may be the true horizontal line or a
theoretical camber line.
Crane erection &
17
commissioning 5. Instructions for gantry rail alignment

Theoretical datum
2000

10
1

10
L/2000
L

Permissible deviation of track straightness in vertical plane.


Fig. 5.4

Local vertical deviation at any point of the track should not be greater than L/2000. Measured over a
length of not less than 2 meters on a line parallel to the theoretical datum.

5.2.6 Running surface permissible traverse inclination from the horizontal datum position.
The maximum permissible traverse inclination from the horizontal datum position should be as shown
in figure 5.5
0
_ 1 IN 30

_< 1
<

IN
300

DATUM POSITION

TOP RUNNING UNDERSLUNG

FIG. 5.4

5.3 Measurement of crane tracks


When measuring crane tracks, calibrated steel measuring tapes should be used. It is important that
readings obtained are corrected to allow for sag in the tape and for temperature variation. All track
measurements for a particular crane should be made with the same measuring tape and the same
applied tension force.

5.4
It is assembled that the gantry girders, columns & foundations are designed in such a fashion that with trolley
positioned in the centre of the span, the deflection of both gantry rails tracks is approximately equal.
Crane erection &
commissioning 6. Instructions for alignment of Down Shop Leads (power angles) 18

6.1

Proper alignment of Down Shop Leads (DSL) play an important role in trouble-free operation of the
crane. Poorly maintained DSL leads to short circuiting / single phasing due to falling of current
collectors.

6.2 Dimensional and geometrical tolerances for DSL


6.2.1 General
DSL alignment should be within tolerances given in clause no 6.2.2 to 6.2.4

6.2.2 Tolerance on distance between center line of gantry rail to datum line of DSL.
The tolerance on the above should be as follows.
S 5 mm

6.2.3 Misalignment of top gantry rail to top of DSL


The tolerance on the above should be as follows (see fig 6.1)
H max = ± 5 mm

6.2.4 Track straightness tolerances


6.2.4.1 Permissible deviation in the lateral
plane
For the total length of DSL, the Straight line
Mean datum
maximum lateral deviation from the
10
2000
straight line mean datum should not
2

exceed 100 mm (see figure 6.2)


L
L/1000

The straight line mean datum is the line


10

about which deviations of DSL on each


side will be equal, when summated
over the whole length of DSL Permissible deviation of track straightness
Local lateral deviation at any point of In lateral (horizontal) plane.
DSL should not be greater than L/1000 Fig. 6.2
measured over a length of not less than 2 meters on a line parallel to the straight line mean datum.

6.2.4.2 Permissible deviation in the vertical plane


For the total length of the DSL, the
maximum vertical deviation from the
Theoretical datum theoretical datum line should not
10

2000
exceed 10 mm (see fig 6.3). The
4

theoretical datum line may be the true


10

L
horizontal line.
L/500

Local vertical deviation at any point of


the track should not be greater than L /
500 measured over a length of not less
Permissible deviation of track straightness than 2 meters on a line parallel to the
In vertical plane. theoretical datum.
Fig. 6.3
Crane erection &
19
commissioning 7. Instructions for storage of crane components at site

The crane and its components are dispatched to the site by road / rail / sea route in suitable packing and
protection against damage during transit is ensured to the maximum extent. However, during storage
at site for long periods, special precautions are to be taken to eliminate the possible deterioration and
exposure to elements of nature.
ElectroMech method of crane dispatch

Girder Transportation Crab Transportation

Loose Material Packing Packing List Shipping Marks

The following precautions should be taken for storage of material at site ~

7.1 Structural Items


a. The main girders should be stored with their web plates in vertical plane and rail on the top side.
While storing, the girder should be supported only on the bottom flange, preferably at every
three meters interval. In no case should the girder be stored on its side, resting on the web.
b. The end carriages should also be stored vertically similar to main girders with a minimum of two
supports equi-spaced in case the length is less than 3 m. They should be stored vertically with
wheels on the lower side. The ends of end carriage where wheels are mounted should be
covered with tarpaulin to prevent water from entering inside and damaging the bearings and
other mechanical parts. Wheel tread and flanges should be painted periodically with rust
preventive paint.
c. All other structural members like platform, ladders, hand railings, etc. may be stored in open
area but should be covered with tarpaulin for protection against rain
d. All structural members, if required to be stored in the open for a very long period, should be
repainted wherever the paint has peeled off and where there is a marked evidence of rusting.

7.2 Mechanical Items


a. Crab Assembly / Electric Wire Rope Hoist (dispatched in a wooden case): As far as possible the
crab should be stored in a covered area. However, if this is not possible, the crab may be stored
in open yard but should be fully covered with tarpaulin. In addition to the tarpaulin cover, the
electrical components like motors, brakes, limit switches, etc. should be covered with thick
polythene sheet to avoid entry of moisture into these components. All exposed machined
surfaces should be coated with anti-rust compound.
Crane erection &
commissioning 7. Instructions for storage of crane components at site 20

b. Miscellaneous Items - Other mechanical items like Lower Block, Wire Ropes, Shafts, Couplings,
etc. which are dispatched in closed cases should be stored in covered storage area. All fasteners
including machined bolts should be kept properly oiled.

7.3 Electricals
All electrical items like operator's cabin, panel boxes, resistance boxes, pendants, cables, etc., should
be stored only in closed area. In no case should these items be stored in vertical position and the cases
containing the panels and resistances should also be stored in vertical position.

7.4 General
a. If the materials have been lying for a long time at the site, it is necessary to do the following
before the commencement of erections.
b. No load running trial of all mechanisms.
c. Insulation test of all electrical components like motors, brakes, limit switches, panels,
resistances, controllers, etc.
d. To check the condition of grease in wheel assemblies for crane and trolley and to ensure that
these move freely.
e. To check the lubrication in pulleys, couplings, etc.
f. To check the gear boxes through inspection covers.
g. In case the storage area is easily susceptible to pilferage, all electrical components like motors,
brakes, limit switches, etc. may be dismantled from assembly and stored separately in a safe
location or inside the store. Also, in case of indoor storage, the area may be cordoned off and
should be located away from the main handling area.

7.5 List of standard equipment tools and tackles required at the time of
Erection and commissioning of crane.
a. Multi-meter h. Line tester n. Hammer
b. Piano wire i. Screw driver set o. Safety belt
c. Measuring tape j. Cutting pliers p. Safety shoes
d. Deflection meter k. Combination pliers q. Safety helmet
e. Spanner set l. Wire stripper r. Fire extinguisher
f. Arc welding machine m. Torque wrench s. First aid box
g. Arc welding rod

Customer Scope during Crane Erection & Commissioning:


1. Power Supply
2. Loads for Load & Overload Testing in the form of steel plates, concrete blocks, etc.

Statutory Requirement: "As per Factories Act 1948 (Section 29), it is mandatory to test the crane in presence of
a competent person after the crane installation & subsequently at least once in twelve months and records of
testing must be maintained"
Hence, the customer is to arrange for a competent person to witness the Load Testing during crane erection to
avoid re-arranging for load testing separately.
Crane erection &
21
commissioning 8. Standard procedure for erection of EOT cranes

The instructions given below for site assembly and erection of


crane should be carefully read and followed. Proper erection of
crane is important for long and trouble-free service.
Material sent to site is packed according to the requirement and is
based on the experience gained in transporting such material. The
material received at site should be verified against the packing list.
Any loss or damage to the material during transit
should be checked immediately on receipt of
material at site. Please intimate us regarding any
shortages / damages for lodging claims with
insurance company. In case the consignment is
covered under customer’s insurance policy, such
claims should be lodged directly by the customer
with a copy to us. Minor damages to structural parts can be repaired at site.

8.1 Preparation for Erection


Before start of actual erection activity, please ensure that –
8.1.1 The space where the crane is to be erected is free from any obstruction. Ensure that covered platform
with safety hand rails are available at gantry girder top for safe movement of the erection crew.
8.1.2 The columns and gantry girders are properly grouted / anchored and are stable to receive the crane.
8.1.3 Safe access is available to the gantry girder top at the place of erection. Also ensure that covered
platform with safety hand rails are available at gantry girder top for safe movement of the erection crew.
8.1.4 Erection equipment such as mobile crane, derrick, pulley block, and winch slings, tools, etc are
available at site
8.1.5 The following services are available at site:
Ø Electrical Power: 415V, 3 Ph A.C
Ø Welding transformer
Ø Oxyacetylene gas and cutter set
Ø Dry compressed air at 5 kg/cm2
8.1.6 The gantry rails and DSL are erected and aligned. For instructions on alignment of gantry rail, refer to
Chapter 5 and for alignment of DSL, please refer to Chapter 6 of this manual.
8.1.7 The power supply to Down Shop Leads (power angle) is effectively cut off and is not started
inadvertently/accidentl when the erection crew is at work.

8.2 Steps for Erection


8.2.1 Single Girder EOT Crane
1. Assemble both the end carriages with the main girder, which has to be held with nylon belt or
suitable slings using suitable hydraulic mobile crane.
2. Assemble the hoist to the main girder, holding the girder with nylon belt or suitable slings using
suitable hydraulic mobile crane.
3. In case of ABUS single girder crane, install the guide rails, control carrier, energy chain for
pendent control and main hoist power supply.
4. Install the LT panel as per GA drawing and complete the wiring for LT panel and hoist power
supply.
Crane erection &
commissioning 8. Standard procedure for erection of EOT cranes 22

5. Lift the girder with suitable slings with the help of suitable mobile crane in balanced condition
and place it on the crane track.
6. Remove the mobile crane after placing the girder on the crane track.
7. Proceed with the crane free running on the entire bay length area to ensure trouble free
movement of the crane on the tracks.
8. Install the LT motors and other accessories after the crane free running.
9. Proceed with crane wiring and commissioning.

8.2.2 Double Girder EOT Crane


1. Assemble both the end carriages with one girder, which has to be held with nylon belt or suitable
slings using suitable hydraulic mobile crane.
2. Lift the girder with suitable slings with the help of suitable mobile cranes and place it on the
crane track.
3. Remove the mobile crane after placing the girder on the crane track.
4. Lift the second girder with suitable slings with the help of the mobile cranes.
5. Bolt the second girder to both the end carriages with the correct torque.
6. Remove the mobile cranes after second girder is properly bolted.
7. Lift the main trolley as per position with respect to girders in balanced condition with suitable
nylon slings & mobile crane as per weight given in GA drawing
8. Put the CT trolley on top of both girders.
9. Lock the CT trolley from all four points.
10. Remaining work such as mechanical assemblies for platform has to be done according to site
situation & condition
11. Proceed with crane wiring and commissioning

8.2.3 Double Girder Goliath Crane


1. Assemble the end carriage with rigid leg in horizontal position, which has to be held with nylon
belt or suitable slings. Balancing of leg to be ensured during assembly with end carriage.
2. The same procedure has to be followed for flexible leg, in horizontal position, which has to be
held with nylon belt or suitable slings. Balancing of the leg is to be ensured during assembly with
the end carriage.
3. Join both the rigid legs with both the tie members in horizontal position, which have to be held
with nylon belt or suitable slings. Balancing of the leg is to be ensured during assembly with the
bend carriage.
4. The above mentioned same procedure has to be followed for flexible leg, which has to be held
with nylon belt or suitable slings. Balancing of the leg is to be ensured during assembly with end
carriage.
5. The assembly of all four legs with end carriages must be done in horizontal condition with tie
members
6. Punch the two points on one side of rails considering long travel wheel base & two points on
opposite side of rail considering long travel wheel base with proper diagonal between four
points.
7. Put the nylon sling to the top tie member in centre with proper weight balancing & make the rigid
leg vertical with suitable mobile crane
8. Put the rigid leg assembly on one side of rail between the punched points on rail with suitable
Crane erection &
23
commissioning 8. Standard procedure for erection of EOT cranes

mobile crane
9. Hold the rigid leg with the mobile crane; put the stopper on both sides of rigid leg end carriage
10. Repeat the process from points 7 to 9 for flexible leg with suitable crane
11. Lift one main girder with suitable nylon slings with the help of suitable mobile crane in balanced
condition
12. Put that main girder as per match marking given on girder joining (which has to be decided on
site as per site situation) between rigid leg & flexible leg
13. Bolt the girder between flexible & rigid leg with given fasteners with torque mentioned in GA
Drawing

ROPE - REEVING DAIGRAM

Two falls Four falls

Six falls Eight falls


(ARRGT - 1)

Eight falls Ten falls


(ARRGT - 2)
Crane erection &
commissioning 9. Standard procedure for commissioning of EOT cranes 24

9.1 Checks to be made before commissioning

Before commissioning the crane, carry out the following checks to ensure that the crane is ready for
peration.
9.1.1 Check physical dimensions / tolerances such as span, diagonal, skew, etc. of the crane & ensure that
they are within acceptable limits as given in chapter 16 of this manual.
9.1.2 Carry out insulation test of motors with 1000 V megger. The megger value should be minimum 50 mega
ohms (during monsoon a lower merger value of 2 mega ohms should be ensured). Improve merger
value if necessary.
9.1.3 Check DSL insulation value. Ensure that the supply voltage is within ± 6% of rated voltage at DSL.
9.1.4 Fill up oil in gearboxes as per the marking on the dipstick.
9.1.5 Check functioning of Group / Centralized lubrication systems. Grease various points using lubricating
system / grease gun. Grease the thrust bearing provided in the hook block.
9.1.6 Apply lubricant to the wire rope.
9.1.7 Fill up brake oil in the thruster brakes.
9.1.8 Give supply to control transformer, check all sequences of control panel.
9.1.9 Give power to the crane & carry out power test on panels. At this time, de-couple the motors from
gearboxes & direction of rotation.
9.1.10 Set all limit switches & brakes.
9.1.11 Install buffer, buffer stoppers & actuators for limit switches.
9.1.12 Check setting of timers for smooth operation.

9.2 Trial operation & commissioning


Before taking the load trial, the client is requested to arrange for the load to SWL of the crane & 25%
extra load for taking static over-load trial.
The load should be of any type i.e. it may be concrete block, coils, any solid block, but it should have
proper lifting arrangement by sling to carry the load on the crane hook. These slings must be having test
certificate before taking load trial.
No Load Test
1. Perform no load test of the crane. Test all the motions i.e. long travel motion, cross travel motion
& hoisting motion without load.
2. One by one, operate all the mechanisms of the crane at No load. Check the performance of the
mechanisms and safety devices and ensure that there is no malfunctioning of any component or
assembly. Check all limit switches for operation. Ensure rope clamps are properly positioned and
tightened. Closely observe for any abnormal noise, vibrations, etc.
3. Check the speed of all motions i.e. long travel motion, cross travel motion & hoisting motion
without load.
4. Check the current by tong tester of all motions i.e long travel motion, cross travel motion &
hoisting motion without load.

Load Test
a) Raise a load equal to about 100 % of the rated load not higher than required to clear its
supports/ stop and adjust the brake, if necessary, raise load about 1 m above its supports and
stop. Lower the load about 300mm and stop. Check drift of load during stopping. If load slips, it
indicates that brakes are not properly adjusted and should be corrected. Repeat this operation
until proper adjustment of brakes is obtained. Lower load carefully back to its supports.
Crane erection &
25
commissioning 9. Standard procedure for commissioning of EOT cranes

b) Then hoist the load high enough to clear all obstructions but not higher than necessary. Move
trolley across the entire span of bridge. Transport the test load by means of the bridge for full
length of the runway in one direction with the trolley at the extreme right hand end of the crane
and then move in the other direction with the trolley at the extreme left hand end of the crane.
c) Measure the deflection when the trolley with 100% of SWL is at the middle of the girder and at
extreme end of the girder. Check whether the deflection is within the allowable limit.
d) Measure the full load current of the motor and verify whether it is as per the recommendations
of motor manufacturers.

The permissible value / tolerances are as follows

No. Parameter Tolerance


1 For speeds
- For all motions except lowering ± 10%
motion of hoist + 25% / - 10%
- For lowering motion of hoist drive
For girder deflection with safe
2 Span in mm / 900
working load
3 For hook approach + 50 mm
4 For height of lift '- 100 mm
5 For head room + 2% of specified value
6 For end clearance + 20 mm
7 For end approach + 100 mm

9.3 Overload test


9.3.1 After successful completion of load test, the crane should be subject to overload test with 125% of the
rated load to ascertain.
Ø That the crane mechanism and the structure are capable of withstanding overload
Ø There is no permanent set in the girder when the crane is subjected to the overload.
9.3.2 During overload test, performance parameters such as speeds and girder deflection are not to be
recorded.
9.3.3 Before taking reading for 'Permanent set' of the girder, hoist and lower load equivalent to 125% of SWL
several times. Then place the trolley at one end of the Girder and measure the girder level under NO
LOAD condition. Bring the trolley at centre and sling the load (125% o SWL) to crane hook and hoist the
load very slowly by about one meter. Hold the load for about 2 minutes to confirm that there is no
permanent set in the girder.
9.3.4 Similarly, operate all the motions of the carne with 125% SWL to confirm that the crane mechanisms
are capable of withstanding the overload.
9.3.5 Only after completion of above mentioned tests and attending to the punch points, the crane should be
handed over for regular operation.

9.4 Girder Deflection Test


Before taking girder deflection test, the client must first arrange the load of SWL capacity of the crane
for taking the above test.
Note that this test will be carried out after successful Load / Overload test trials.
The load should be of any type i.e. it may be concrete blocks, coils, any solid blocks but it should have
Crane erection &
commissioning 9. Standard procedure for commissioning of EOT cranes 26

proper slinging locations and arrangements to carry the test by crane hook, & the slings must have test
certificates before taking test.
Deflection Test:
9.4.1 Crane to be moved to the location, so that it can be just above shop columns. This will avoid the
deflection of gantry girders (if any)
9.4.2 Crab hoist will be moved in CT motion to its extreme end of the crane span with smaller hook approach
to achieve the datum line of the reading.
9.4.3 First reading 'H' is to be taken at the girder bottom. This will be measured with the help of deflect meter
(laser type).
9.4.4 Move crab/hoist to the central position of crane span. Lower the hook to extreme bottom position &
connect the load with the help of slings to crane hook.
9.4.5 Now load this particular load which is exactly that of SWL capacity with 'UP' motion of the crane hook.
9.4.6 Allow the load to come to its stable condition (girder shall be allowed to come to its stable position after
oscillations due to lifting of the load)
9.4.7 Measure the second reading 'h' on the girder bottom with the help of deflect meter.
9.4.8 Deflection (∂) of the girder is nothing but subtraction of reading above mentioned readings.
i.e. ∂ = 'H'- 'h'
9.4.9 As per clause 7.4.1 of IS 807, vertical deflection caused by SWL & crab/hoist in the central position
(without taking into consideration of impact factor) is SPAN/900.

NOTE : Please note that measurements shall not be taken on the first application of the load.
27 10
Safe Operation
10. Instructions for Safe Operations of EOT Cranes
Of Crane

Suggested hand signals

1.Emergency Stop 2. Stop 3. Ready to move 4. Move away 5. Move towards


from signalman the signalman

6. Move slowly 7. Move towards 8. Move towards 9. Swing towards the 10. Swing towards
by indicating the hand stretched the hand stretched hand stretched the hand stretched
distance direction direction direction direction

11. Raise the boom 12. Raise the boom 13. Lower the boom 14. Lower the boom 15. Raise the boom
slowly slowly & lower the load

16. Lower the boom 17. Extent the boom 18. Retract the boom 19. Use the main 20. Use whip line
& raise the load hoist

21. Lower the hoist 22. Lower the hoist 23. Raise the hoist 24. Raise the hoist 25. Stop every thing
slowly slowly

Contd…..
Safe Operation
Of Crane 10. Instructions for safe operations of EOT sranes 28

10.1 Procedure to start the crane

10.1.1 Check the crane and crane way for any obstructions.
10.1.2 Release all locking devices.
10.1.3 Check that parts needing lubrication have required quantity of lubricants.
10.1.4 Ensure that no item is lying loose on the crane and the trolley.
10.1.5 Check for neutral position of all the control gears.
10.1.6 Switch on the crane protective gear.
10.1.7 Check signal and wiring devices.
10.1.8 Check brakes and limit switches for their proper functioning.

10.2 Procedure to Stop the Crane


The following procedure should be observed while leaving the operator’s cabin & the crane.
10.2.1 Run the empty hook and trolley to the specified resting position.
10.2.2 Ensure the hook is raised clear of all obstructions
10.2.3 Put all controllers in off position.
10.2.4 Set the master controller in neutral position.
10.2.5 Actuate locking devices if any.
10.2.6 Switch off lights.
10.2.7 Press the off push button provided in the cabin / pendent.
10.2.8 Lock the operator cabin.
10.2.9 Subject to more specific local instructions, the main power switch in the crane is locked in the OFF
position.
10.2.10 Where the crane is exposed to wind, travel brakes are locked ON and the hook secured to avoidn
damage by free swinging.

10.3 Safe Hoisting Practices


Electric hoists, trolleys and cranes of all types are designed by keeping the safety of the operating
personnel foremost in mind. Your own safety and that of your fellow workers will be assured when the
overhead material handling equipment is used as recommended by us. Disregarding such
recommendations will endanger life and property. The following are basic rules worthy of your careful
consideration and attention.

Ø Do not load beyond the rated capacity. The immediate danger is possible failure of some load
carrying part. Overloading might also develop a defect which could lead to some future failure,
even at less than rated capacity.
Ø Do not use any overhead material handling equipment for the purpose of transportation of
personnel.
Ø Conduct a periodic visual inspection for signs of damage or wear. Particular attention should be
paid to the wire rope and the hook. If there are signs of wear or damage, or if the hook is
distorted or opened out, immediately intimate safety engineers before loading.
Ø Do not use hoisting ropes or chains as a substitute for slings. Always use slings. Cable / chain /
belt / rope slings should be of proper size and type for load handling. Never use slings showing
physical damage to any extent.
Ø Stand clear of all loads. If you must travel a load over the heads of other personnel, give ample
warning of your intention before you move.
29 10
Safe Operation
10. Instructions for Safe Operations of EOT Cranes
Of Crane

Ø Always 'inch' the hoist into the load. Running into the load at full hoisting speed imposes an
excessive overload on the hoisting mechanism and could result in the failure of parts and / or the
supporting structure. This is particularly true with high hoisting speeds. The same principle
applies to the travelling motion also, which would otherwise cause a swinging of the load leading
to unforeseen damages.
Ø Limit switches are for emergency use only. They should not be tripped during normal
operations. If it is necessary to travel to the limit, use extreme caution and approach the limit in
slow speed or by inching. Do not leave the hook block in contact with the limit switch at the end
of the operation. A phase reversal with the block in this position will probably result in damage to
the hoist of the Down button or control lever is operated.
Ø Be sure that the hoist raises and lowers properly when the corresponding push button or control
lever is operated. A reversal of direction indicates a phase reversal in the current conductor, or
an interchange of wires on the push button, any of which would cause the limit switch to be
inoperative. Do not, under any circumstances, operate the equipment until the fault has been
found and corrected.
Ø Center the hoist over the load before lifting. Do not side pull or end pull. When the centre of
gravity is difficult to determine, the load must be raised a little at a time to see that each part
leaves the ground at the same time. The use of many ropes would be meaningless if the load is
not supported evenly.
Ø Use padding on the edge of load if it is sharp and angular. This prevents the damage of the rope.
Contact of the wire rope with a sharp angular edge of the load is unsafe. The wire rope can be
cut very easily when it is twisted. Remember that twisting and pulling is the method employed
when it is necessary to cut the wire rope.
Ø The limit of the straddle angle of the sling should be kept within 90o. Else a larger load than
commonly supposed works on the wire ropes.
Ø Wire ropes for load handling should not be placed on the portion of the load that may cause
them to move or slip off.
Ø Reversing the positions of an object or load is very dangerous. This operation should be done
very slowly taking care that the ropes do not become loose. When the ropes become loose, the
next thing to expect is a sudden reversal of the object. This will cause a very heavy strain on the
ropes and possibly make them snap.
Ø Do not drag the load. It is dangerous to assume that a load which has been safely tied can be
dragged, because dragging the load creates higher stress in the wire rope than when
suspending it.
Ø Proper knowledge of hand signals for hoisting, cross travel and long travel is imperative, if
working with a cabin operated crane. Operators should accept the signals of only those persons
authorized to give them. Do not, repeat, do not operate when the signals are not clear.
Ø Do not leave the load suspended in the air unattended.
Ø Do not jog controls unnecessarily. Hoist motors are generally of high torque, high slip type. Each
start causes an inrush of current greater than the running current and leads to overheating and
subsequent failure due to heat or burnout, if continued to an excess.
Ø When the crane is operated after a long period of disuse, be sure to operate all the motions
without load first.
Safe Operation
Of Crane 10. Instructions for Safe Operations of EOT Cranes 30

10.4 Crane Drivers (For Cabin Operated Cranes)

Ø Only trained, competent and properly authorized crane drivers are permitted to operate
overhead travelling cranes. A crane driver must have a written knowledge of English.
Ø Crane drivers must be physically fit, and have good hearing and eye sight. A crane driver shall
not operate his crane if not physically fit, but shall report any disability to the medical officer or
other appropriate person at once.
Ø Crane drivers are expected to be extremely alert at all times. Sleeping on the job, throwing
ashes or cigarette butts or spitting from the control cabin or bridge structure are not to be
permitted under any circumstances.
Ø They must keep their hands free when going up or down the access ladders.
Ø Their spare clothing or any personal belongings should not be kept in the vicinity of the controls.
Ø The operators must be fully aware of the crane safety, operating instructions, crane mechanism
and its proper care.
Ø Extreme care shall be exercised at all times by the crane drivers and attendants, and all other
personnel working or present on the premises where cranes are located, to avoid contact with
the crane collector wires and / or any other power cables, whether covered or bare.
Ø Rail trucks, cars, or any other transport vehicles should not be towed by any crane.
Ø The crane driver must ensure that the fire extinguisher is kept in an accessible position and fully
ready for use.
Ø The communication between the crane driver and crane attendant (slingers), shall be through
mutually agreed code of hand signals / radio device. Verbal instructions can be given only if they
are rendered audible.
Ø The crane driver should maintain a log book and make the appropriate entries in it on a daily
basis.
Ø The crane driver is at all times responsible for the safe operation of the crane.
Ø He should at all times ensure that the crane is properly lubricated in accordance with the
instructions issued.
Ø He should not leave the controls while a load is suspended from the crane.
Ø He should not permit anyone to be in any position on the crane, during normal operation of the
crane.
Ø If and when any crane operation fails to respond correctly to the control, the crane driver must
immediately stop operation and open the power switch and notify the supervisor. No attempt
should be made to get out of difficulty by repeated operations of the controls.
Ø In case of power failure, the crane driver shall move all controllers to OFF position, report the
matter to the supervisor and await instructions.
Ø The crane driver should not rely on the limit switches in ordinary working, as they are for
emergency purposes only. The crane driver should not tamper with circuit breakers, limit
switches and / or any other safety devices.
Ø Before closing the main switches, all controllers must be in the OFF position.
Ø All crane movements, whilst loads are being handled, or maintenance or repair work done, shall
be governed absolutely by the standard operating signals, as given above, transmitted to the
crane driver by the person authorized to direct these movements.
Ø The crane driver should obey a STOP signal, regardless of who gives it.
Ø Under no conditions should any crane driver move a load unless he has clearly seen and
understood the given signal.
31 10
Safe Operation
10. Instructions for Safe Operations of EOT Cranes
Of Crane

Ø Where two cranes are operating in tandem, the driver of each crane shall take movement signals
only from the same person. Before such tandem operations, however, special instructions will
have to be issued by the engineer.
Ø Bumping into runway stops should be avoided.
Ø All load movements should be done smoothly without jerking or sudden stops.
Ø Under no circumstances shall the crane driver attempt to travel any load until that load has been
hoisted clear of all obstructions.
Ø While handling loads approaching maximum rated capacity, the crane driver should test the
hoist brakes after the first load has been lifted a few centimeters clear off the floor by placing the
controller in the off position. If the brakes do not hold, the load should be lowered at once and
the brakes must be adjusted.
Ø While the crane is in motion, crane drivers should keep their hands on the controls at all the
time.
Ø All loads should be carried or suspended at a maximum height of 2.5 meters, except above
machineries where it may be further increased.
Ø After the load has been landed, crane drivers should not move the crane until the hook has been
lowered and the crane attendant has either hooked up or removed the lifting equipment used.
Safe Operation
Of Crane 11. Crane Maintenance Guidelines 32

11.1 Wire Ropes

11.1.1 Replacement of wire ropes


Observe the condition of the wire rope periodically for the following defects and change the rope if
necessary.
a. Replace the wire rope if the outer wires of the rope have become loose
b. Observe the wear of the wire rope. Replace the wire rope if the reduction in rope diameter is
more than 5%
c. Replace the wire rope if it is subjected to serve overload or shock load.
d. Replace the wire rope when the total number of visible broken wires exceeds 10% of total
number of wires in the rope at any place, in a length of eight times
e. Replace the wire rope when there is evidence of severe corrosion or if the core of the wire rope
has collapsed
f. Replace the wire rope when it has been subjected to localised distortion, damage or kinks

11.1.2 Handling & storage of wire ropes


Refer to Annexure D

11.2 Instructions for tightening of high tensile bolts


11.2.1 Surface preparation
At the time of assembly, surface in contact must be free of paint or any other applied finish, oil dirt, loose
scale, burrs and other deposits which would prevent solid seating of the parts or would interfere with
the development of the friction between them.

No. Bolt Size Grade 8.8 (Nm) Grade 10.9 (Nm)


1 M6 10.3 15.1
2 M8 25.0 37.0
3 M 10 50.0 74.0
4 M 12 87.0 128.0
5 M 14 139.0 205.0
6 M 16 214.0 315.0
7 M 18 304.0 435.0
8 M 20 431.0 615.0
9 M 22 586.0 835.0
10 M 24 745.0 1060.0

11.3 Hooks
Criteria for hook replacement
A worn or damaged hook must be permanently removed from service if
(a) The throat opening, measured at the narrowest point, has increased by more than 15% of the
original opening
(b) The hook has twisted more than 10° from the original plane of the hook
(c) The hook has lost 10% or more of its cross-sectional area
(d) The hook is cracked or otherwise defective
(e) Wear or damage exceeds any criteria specified by the manufacturer
33 10
Safe Operation
11. Crane Maintenance Guidelines
Of Crane

11.4 Instruction for Maintenance of Electrical Machinery

11.4.1 General
In order to maintain electrical machinery in good condition, prevent accidents and make their life long,
it is essential to carry out routine and periodical inspection and maintenance.
Depending upon the environmental and operating conditions the rate of deterioration of electrical
machinery varies. Thus, it is difficult to establish uniform standards for inspection of electrical
machinery.

11.4.2 General Consideration on Maintenance & Inspection:


With any crane in use for a long time, the crane and its electrical machinery gradually deteriorates which
should be distinguished from that of the trouble caused by the constructional or functional defect. The
essential purpose of inspection and maintenance is to prevent such trouble from occurring.
Different electrical machineries have different rates of deterioration. In making the maintenance plan, it
is important to understand which part has the high rate of wear and the degree of functional importance
of the part.

11.4.3 The following parts have high rate of wear and hence should be considered as expendable.
• Contact piece of reversible master controller
• Contact piece of magnetic contactor for main circuit
• Auxiliary contact piece
• Carbon brush
• Brake lining

11.4.4 The following parts have moderate rate of wear.


1. Bearing of motors
2. Mechanical movable parts of magnetic contactor (pin. lever spring, etc).

11.4.5 The following parts should be serviced when damaged to some extent
1. Slipring face of AC motor
2. Contact face of contactors

11.4.6 The following items are detrimental to the proper functioning of electrical machinery and require proper
attention.
1. Abnormal decrease in insulation resistance
2. Entry of water into the machinery
3. Accumulation of carbon powder, dust or dirt in the machinery having a possibility to cause
moisture absorption, deterioration of insulation or interference with ventilation
4. Badly imbalanced air gap of AC motor or collision of rotor with stator.
5. Loosening of lead or terminals
6. Abnormal drop of supply voltage / frequency

11.4.7 The following parts may cause trouble due to carelessness in use or due to poor maintenance; hence
these parts should be repaired or replaced.
1. Fused contact piece
2. Burnt out magnetic coil
Safe Operation
Of Crane 11. Crane Maintenance Guidelines 34

3. Slip-ring face damaged by flash over


4. Winding burnt out by overloading
5. Winding short circuit between layers due to deteriorated insulation or burnt out by grounding
The scope and frequency of inspection depends on the conditions applicable to each machine, but the
minimum recommended requirements are as follows

11.4.8 Power Source


As the characteristics of the motor and its performance depend on the voltage variation, care should be
taken to prevent voltage variation beyond 10%

11.4.9 Main Collector


Check weekly that collectors line-up correctly with main conductors. Wear on the collector shoes should
be examined monthly. Collector shoes should be replaced when their thickness is reduced by 50% of
original thickness.

11.4.10 Motors
a) Insulation resistance
Insulation resistance of motors shows reasonably high value when the motor is new. With the time of
use it gradually decreases due to deterioration of insulating material, moisture absorption or
accumulation of dust or dirt. The rate and degree of such decrease in insulation resistance depend upon
environmental conditions.
Insulation resistance of the windings both between phases and to earth should be taken by means of a
1000V megger before the motor is put into service. The insulating resistance should not be lower than 2
mega ohms when the motor is cold. If it is lower due to moisture, it should be dried before full voltage is
applied to the motor terminals.

b) Slip-ring and Brush Gear


Slip-ring and brush gear of slip-ring motor require careful inspection and attention. Slip-rings should be
checked with specific attention to the following points-
Ø Check slip-ring for pin holes on contact surface. If excessive pinholes are observed then remove
them by machining or replace the slip-ring.
Ø Sparking the slip-ring is harmful. Due to distortion of slip-ring of shaft, slip-ring rotates
eccentrically, which leads to sparking. In such an event the slip-ring surface should be
machined.
The reduction in slip-ring motors should be checked periodically for wear and smoothness. Brushes
should not be allowed to wear 12 mm. Brushes should press evenly and radially on to the slip-ring.
Recommended brush pressure is 0.13 to 0.20 kg/cm2. The slip-rings and brushes should be free from
oil and dust. The slip-ring covers should be opened every month and any carbon dust accumulated
should be blown out to avoid flashover.

c) Terminal Box and Lead Terminal


Screwed / bolted part of terminal box and lead terminal is liable to get loosened due to mechanical
vibration. Check it periodically and tighten if necessary. At the time of periodical inspection also clean
the inside of terminal box to remove dust or dirt.
35 10
Safe Operation
11. Crane Maintenance Guidelines
Of Crane

d) Bearing
All motors are fitted with antifriction bearings in bearing housings and are charged with grease. Grease
the bearings periodically. Also disassemble the bearings annually and after washing, refill it with high
quality grease.

11.4.11 Electro-mechanical Brakes


Maintenance of Electro-mechanical brakes is vital for safe operation of the crane, hence utmost
attention must be paid to ensure that brakes are in proper working condition at all the times.
Fail-safe brakes are used on cranes to ensure application of brake in the event of power failure. When
the power is supplied to the fail-safe brakes, spring is compressed due to the actuation of electro
hydraulic thrusters / magnet and the brake is opened. When power supply to thrusters / magnet is
stopped, the brake closes under the force of spring.
Heavy-duty, self-aligning cast iron shoes are provided on brakes for gripping the brake drums when the
brakes are applied. Brake shoes are provided with treated fabric lining.
To minimize down time in replacement of shoe lining, complete brake shoes with shoe lining should be
kept in stock. To adjust the brake torque, the length of the brake spring should be adjusted suitably.

11.4.12 Electro-hydraulic Thruster Brakes


The thruster consists of motor-driven centrifugal oil pump. Before installing the brake, wipe out dirt
around oil filter plug. To charge oil in thruster, remove oil filter plug and fill oil slowly. Operate thrusters
several times till they operate smoothly.
Change thruster oil periodically after 2 years. Top up the oil if the level is below the requirement. When
thruster is dismantled, take precautions to ensure that dirt does not enter inside the thrusters.

11.4.13 Electro-magnetic DC Brakes


In case of electro-magnetic DC brake, the release of brake takes place through actuation of magnet.
The torque of the brake can be adjusted by turning torque adjuster nut. To increase the torque, rotate
the nut clockwise and to reduce, rotate in anticlockwise.
When the brake is properly adjusted for stroke, the torque adjuster washer face stands clear of
armature surface. As the lining wears, this clearance decreases. If the adjustment is neglected, the
brake operation becomes sluggish and when the torque adjuster washer touches armature surface, the
torque drops rapidly reaching zero when clearance is used up.
The clearance dimension is not a measurable, value but depends upon proper adjustment of individual
brake.
After replacement of shoe lining, readjust the brake. The brake should also be readjusted to
compensate for lining wear when pressed in de-energised condition.

11.4.14 Master Controller


Master Controller is housed in sheet steel enclosure and is provided with easily removable cover for
ease of maintenance. Before opening the master controller, isolate the main power supply. Contacts
should be checked periodically for the wear and should be replaced where the wear is found than 30%
Apply a thin film of grease at pivot points of roller and on shaft cam ends every six months.

11.4.15 Control Panels


Maintenance of equipment in the control panels has the greatest effect on the efficient operation of the
crane
Safe Operation
Of Crane 11. Crane Maintenance Guidelines 36

Contactors and relays should be protected from dust and heat. Inspect and clean them frequently to
prevent leakage.
Contact pressure, stroke and gap contacts should be maintained properly.
Examine wear of contacts periodically and replace the contacts when excessive wear is observed.

11.4.16 Limit Switches


Limit Switches though not normally used in regular operation of crane, are important for safety of the
crane.
Functioning of limit switch should be checked periodically to ensure that they remain operational all the
time.

11.4.17 Contactors
Before inspection, switch off the contactor and upstream fuse switch. Inspect the contactor terminal
first after two months of installation and then after every six months.
Alteration of contact arrangement (NO to NC and vice versa) adversely affects the contactor
performance. Also removal of unitized contacts from contactor affect performance of remaining
contacts. Hence, this should be avoided.
Do not get perturbed over tarnished, blackened or slightly pitted contactors. These are normal
phenomena.
Contactors can be cleaned by carbon tetra-chloride Do not use abrasives to clean the contacts. Hard
deposits on contact tips can be removed by blunt knife, however, deposits on contact bridges need not
to be removed.
Do not apply grease or petroleum jelly on contacts. If contacts are slightly welded, they can be
separated by a screw driver, if they are not easily separable by the above procedure, replace them.
Replace contacts when only 30% of original contact tip remains balance. Contacts should be replaced in
pairs of moving and fixed contacts. After replacement, operate the contactor a few times before putting
it back in operation.
Tighten arc chambers screws periodically. Do not use broken / damaged / cracked arc chambers and
coil. Replace it. Do not clean magnet with sharp / pointed object / file or sand paper as it upsets mating
of magnet faces. Clean magnet with lubricant / chamois lather.
The only parts that can be replaced in a contactor are contacts, arc chambers and coils. Other parts of
the contactor are designed for life. Finally, use only genuine spare parts to ensure safety.
37 10
Safe Operation
12. Activities to be done on EOT Crane During Preventive Maintenance
Of Crane

List of activities to be done on eot crane during preventive maintenance

Customer Name- Address-

Crane No.- Capacity- Ton- Type- SG/DG/Goliath/Monorail/Under slug


Manufacturer- Span- Mtr. Height of lift- Mtr.

Rail- DSL- Bay Length- Mtr. Hoist Model-

Location- P. M Dtd.- P. M. Done By-

Report Certified By-

FREQUENCY- MONTHLY / QUARTERLY

MECHANICAL

Sl. Actual Actual Condition


No. Points to be Checked Range OK/Not OK Action Taken Remark
Value

1 Brake setting MH N.A.

2 Brake liner thickness MH


Coupling condition and bolts
3 checking MH N.A.

4 Oil level in gearbox MH

5 Oil level in thrustor MH


Checking of Wire rope
6 N.A.
condition & Lubrication MH
7 Checking of rope Clamp MH N.A.
Lower block & Equalizer
8 pulley checking MH N.A.

9 Brake setting AH N.A.

10 Brake liner thickness AH


Coupling condition and bolts
11 checking AH N.A.

12 Oil level in gearbox AH

13 Oil level in thrustor AH


Checking of Wire rope
14 N.A.
condition & Lubrication AH
15 Checking of rope Clamp AH N.A.
Lower block & Equiliser
16 pulley checking AH N.A.

17 Brake setting LT N.A.

18 Brake liner thickness LT


Coupling condition and bolts
19 checking LT N.A.

20 Oil level in gearbox LT

21 Oil level in thrustor LT

22 Wheel mounting bolt LT N.A.


Safe Operation
Of Crane 12. Activities to be done on EOT Crane During Preventive Maintenance 38

List of activities to be done on eot crane during preventive maintenance

Sl. Actual Actual Condition


Points to be Checked Action Taken Remark
No. Range Value OK/Not OK
Wheel condition &
23 N.A.
Lubrication LT
24 Motor-Gearbox-Wheel Bolt LT

25 Brake setting CT N.A.

26 Brake liner thickness CT


Coupling condition and bolts
27 N.A.
checking CT
28 Oil level in gearbox CT

29 Oil level in thrustor CT

30 Wheel mounting bolt CT N.A.

Wheel condition &


31 N.A.
Lubrication CT
32 Motor-Gearbox-Wheel Bolt CT

ELECTRICAL
1 Gravity limit Switch checking N.A.
MH
2 Motor connection checking MH N.A.
Brake / Thrustor operation
3 N.A.
checking MH
Rotory / up-down limit switch
4 N.A.
checking MH
5 Motor Current during AMC MH No Load / Part Load /
Full Load
6 Motor Winding Resistance MH

7 Overall condition in Running N.A.


MH
VFD Parameter / Relay
8
setting MH
9 Gravity limit Switch checking N.A.
AH
10 Motor connection checking AH N.A.
Brake / Thrustor operation
11 N.A.
checking AH
Rotary /up-down limit switch
12 N.A.
checking AH
13 Motor Current during AMC AH No Load /Part Load /
Full Load
14 Motor Winding Resistance AH

15 Overall condition in Running N.A.


AH
VFD Parameter / Relay
16
setting AH
17 Motor connection checking LT N.A.
Brake / Thrustor operation
18 N.A.
checking LT
39 10
Safe Operation
12. Activities to be done on EOT Crane During Preventive Maintenance
Of Crane

List of activities to be done on eot crane during preventive maintenance

Sl. Actual Actual Condition


Points to be Checked Action Taken Remark
No. Range Value OK/Not OK
Rev-forward limit switch
19 N.A.
checking LT
20 Motor current during AMC LT No Load / Part Load /
Full Load
21 Motor winding resistance LT

22 Overall condition in running LT N.A.


VFD parameter /relay
23
Setting LT
24 Motor connection checking CT N.A.
Brake / thrustor operation
25 N.A.
Checking CT
26 Both limit switch checking CT N.A.

27 Motor current during AMC CT No Load / Part Load /


Full Load
28 Motor winding resistance CT

29 Overall condition in running


CT
VFD Parameter / relay
30 N.A.
setting CT
31 Motor connection checking LT

ELECTRICAL- General / Common Points


1 Anti collision Device Checking N.A.

2 LIS Connection Checking N.A.


Incoming power supply
3
voltage
4 Control transformer checking N.A.
Electrical Panels checking &
5 N.A.
servicing
6 Incoming power supply N.A.
Connection at DSL end
Bus bar checking &
7 N.A.
Alignment checking
Pendant cable & trolley
8 N.A.
Checking
Cross travel cable & trolley
9 N.A.
Checking
Current collector & carbon
10 N.A.
Brush checking
11 M H Contactor checking N.A.

12 A H Contactor checking N.A.


Cross travel contactor
13 N.A.
Checking
Long travel contactor
14 N.A.
Checking
15 Main contactor checking N.A.

Customer Remark :- Customer Name & Sign :-


Standard
G. A. for spares list 40
drawings

No. PART NO. DESCRIPTION


01 100 GEAR BOX
MAIN HOIST MACHINERY

02 200 MOTOR
03 300 THRUSTOR BRAKE
04 400 LOWER BLOCK ASSEMBLY
05 500 UPPER BLOCK ASSEMBLY
06 600 EQUILISER PULLEY ASSEMBLY
07 700 PEDESTAL ASSEMBLY
08 800 M.H. LIMIT SWITCH (ROEARY GEARED TYPE)
09 900 COUNTER WT.LIMIT SWITCH FOR M.H.
10 1900 GEAR BOX
CT MACHINERY

11 2000 MOTOR
12 2100 THRUSTOR BRAKE
13 2200 CROSS TRAVEL LIMIT SWITCH R R TYPE
14 2300 CROSS TRAVEL WHEEL
15 2400 GEAR BOX
LT MACHINERY

16 2500 MOTOR
17 2600 THRUSTOR BRAKE
18 2700 LONG TRAVEL LIMIT SWITCH R R TYPE
19 2800 LONG TRAVEL WHEEL
20 2900 TROLLEY FRAME
CRANE MAJOR COMPONENT

21 3000 GIRDER
22 3100 END CARRIAGE/BOGIE
Note - TITLE
''To order any spares kindly mention the serial 23 3200 PENDANT PUSH BUTTON
G. A. FOR SPARES LIST 24 3300 CABLE TROLLEY
number and assembly part no. with sub part no.''
Example - For ordering hook bearing crane sr. 25 3400 RRC
no.-Assly part no.-Sub part no. DRG. NO. REVISION 26 3500 MAIN HOISTING WIRE ROPE
e.g. - Order no. - 2095 - 400 - 402 SHEET NO.
001 0 27 3700 ‘IGUS’ DRAG CHAIN

(Note: While ordering for any Spare Parts mention Crane Sr. No., Drawing No. & Part/s No.)
41 10
Standard
G. A. for spares list
drawings

No. PART NO. DESCRIPTION


01 100 GEAR BOX
MAIN HOIST MACHINERY

02 200 MOTOR
03 300 THRUSTOR BRAKE
04 400 LOWER BLOCK ASSEMBLY
05 500 UPPER BLOCK ASSEMBLY
06 600 EQUILISER PULLEY ASSEMBLY
07 700 PEDESTAL ASSEMBLY
08 800 M.H. LIMIT SWITCH (ROEARY GEARED TYPE)
09 900 COUNTER WT.LIMIT SWITCH FOR M.H.
10 1000 GEAR BOX
11 1100 MOTOR
AUX. HOIST MACHINERY

12 1200 THRUSTOR BRAKE


13 1300 LOWER BLOCK ASSEMBLY
14
15 1500 EQUILISER PULLEY ASSEMBLY
16 1600 PEDESTAL ASSEMBLY
17 1700 A.H. LIMIT SWITCH (ROEARY GEARED TYPE)
18 1800 COUNTER WT.LIMIT SWITCH FOR A.H.
19 1900 GEAR BOX
CT MACHINERY

20 2000 MOTOR
21 2100 THRUSTOR BRAKE
22 2200 CROSS TRAVEL LIMIT SWITCH R R TYPE
23 2300 CROSS TRAVEL WHEEL
24 2400 GEAR BOX
LT MACHINERY

25 2500 MOTOR
26 2600 THRUSTOR BRAKE
27 2700 LONG TRAVEL LIMIT SWITCH R R TYPE
28 2800 LONG TRAVEL WHEEL
29 2900 TROLLEY FRAME
CRANE MAJOR COMPONENT

30 3000 GIRDER
31 3100 END CARRIAGE/BOGIE
32 3200 PENDANT PUSH BUTTON
Note - TITLE
''To order any spares kindly mention the serial 33 3300 CABLE TROLLEY
G. A. FOR SPARES LIST 34 3400 RRC
number and assembly part no. with sub part no.''
Example - For ordering hook bearing crane sr. 35 3500 MAIN HOISTING WIRE ROPE
no.-Assly part no.-Sub part no. DRG. NO. REVISION 36 3600 AUX. HOISTING WIRE ROPE
e.g. - Order no. - 2095 - 400 - 402 SHEET NO.
001 0 37 3700 ‘IGUS’ DRAG CHAIN

(Note: While ordering for any Spare Parts mention Crane Sr. No., Drawing No. & Part/s No.)
Standard
M. H. Lower block assembly 42
drawings

WIRE ROPE
14 15
18
13

12

11
16
10

9
CL PIN
8

4
17

3
19
7

6 2

5
CL TRAVERSE

CL HOOK

NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.

19 HEX. HD. SCREW+PL/SP. WASHER 418

HEX. HD. SCREW+PL/SP.


18 IS : 1364 / 6735
WASHER - M6 X 20 LG.
17 GUARD MOUNTING CLEAT 417
16 PULLEY BEARING 416
15 SPACER - TYPE 'B' 415
14 PULLEY GUARD (MIDDLE) 414
13 PULLEY GUARD (OUTSIDE) 413
12 PULLEY 412
11 INTERNALL CIRCLIP 411
10 SPACER - TYPE 'A' 410
09 PULLEY PIN 409
08 EXTERNAL CIRCLIP 408
07 SUSPENSION PLATE 407
06 EXTERNAL CIRCLIP 406
05 TRAVERSE 405
WELDING TABLE GENERAL TOLERANCES: ISO 2768 TITLE 04 LOOKING PLATE ( HOOK NUT ) 404
THK OF PLATE WELDING SIZE FOR 'X' PERMISSIBLE DEVIATIONS
OVER INCLUDING FOR BASIC SIZE RANGE M.H. LOWER BLOCK ASSEMBLY 03 HOOK NUT 403
< 5.0 10.0 3.0 <3 +_ 0.2 < 400 +_ 1.2
' x'

02 HOOK BEARING 402


10.0 20.0 5.0 <6 +_ 0.3 < 1000 +_ 2.0
DRG. NO. REVISION 01 HOOK 401
20.0 32.0 6.0 < 30 +_ 0.5 < 2000 +_ 3.0
400 0
32.0 50.0 8.0 WELDING < 120 +_ 0.8 < 4000 +_ 4.0 SHEET NO. No. DESCRIPTION PART NO.
43 10
Standard
Upper block assembly
drawings

6
5
7 3
4
CL
2
9
CL
PULLEY
1

CL

10

CL

NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.

10 HEX. HD. SCREW+STD NUT+PL./SP. WASHER M12x35 LG. 510


09 HEX. HD. SCREW+PL./SP. WASHER M12x35 LG. 509
08 HEX. HD. BOLT+STD NUT+PL./SP. WASHER 508
07 MOUNTING BLOCK SUPPORT 507
06 UPPER BLOCK GUARD 506
05 PULLEY 505
WELDING TABLE GENERAL TOLERANCES: ISO 2768
TITLE 04 PULLEY BEARING 504
THK OF PLATE WELDING SIZE FOR 'X' PERMISSIBLE DEVIATIONS
OVER INCLUDING FOR BASIC SIZE RANGE
UPPER BLOCK ASSEMBLY 03 INTERNAL CIRCLIP 503
< 5.0 10.0 3.0 <3 +_ 0.2 < 400 +_ 1.2
'x'

02 SPACER 502
10.0 20.0 5.0 <6 +_ 0.3 < 1000 +_ 2.0
DRG. NO. 01 MOUNTING BLOCK 501
20.0 32.0 6.0 < 30 +_ 0.5 < 2000 +_ 3.0 REVISION
500
32.0 50.0 8.0 WELDING < 120 +_ 0.8 < 4000 +_ 4.0 SHEET NO. 1 0 NO. DESCRIPTION PART NO.
Standard
AUX. H. Lower block assembly 44
drawings

18 WIRE ROPE
13

12

11

14 15
10

9
CL PIN
8
16

17

7 3
CL TRAVERSE
6
2
5

CL HOOK

NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.

19 HEX. HD. SCREW+PL/SP. WASHER 1318

HEX. HD. SCREW+PL/SP.


18 IS : 1364 / 6735
WASHER - M6 X 20 LG.
17 GUARD MOUNTING CLEAT 1317
16 PULLEY BEARING 1316
15 SPACER - TYPE 'B' 1315
14 PULLEY GUARD (MIDDLE) 1314
13 PULLEY GUARD (OUTSIDE) 1313
12 PULLEY 1312
11 INTERNALL CIRCLIP 1311
10 SPACER - TYPE 'A' 1310
09 PULLEY PIN 1309
08 EXTERNAL CIRCLIP 1308
07 SUSPENSION PLATE 1307
06 EXTERNAL CIRCLIP 1306
05 TRAVERSE 1305
WELDING TABLE GENERAL TOLERANCES: ISO 2768 TITLE 04 LOOKING PLATE ( HOOK NUT ) 1304
THK OF PLATE WELDING SIZE FOR 'X' PERMISSIBLE DEVIATIONS
OVER INCLUDING FOR BASIC SIZE RANGE AUX. H. LOWER BLOCK ASSEMBLY 03 HOOK NUT 1303
< 5.0 10.0 3.0 <3 +_ 0.2 < 400 +_ 1.2
'x'

02 HOOK BEARING 1302


10.0 20.0 5.0 <6 +_ 0.3 < 1000 +_ 2.0
+_ 0.5 DRG. NO. REVISION 01 HOOK 1301
20.0 32.0 6.0 < 30 < 2000 +_ 3.0
1300 0
32.0 50.0 8.0 WELDING < 120 +_ 0.8 < 4000 +_ 4.0 SHEET NO. No. DESCRIPTION PART NO.
45 10
Standard
'L' Type driving wheel assly cross trave wheel
drawings

‘A’

3 1
2
9 3
13
12 4
8 5
10 11
6

14

‘A’

SECTION “A-A”

NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.

14 HEX. HD. SCREW+STD NUT+SP. WASHER


IS: 1364/6735
13 HEX. HD. SCREW+STD NUT+SP. WASHER
12 BEARING AXLE SIDE COVER 2312
11 DRIVING AXLE 2311
10 AXLE KEY 2310
09 BEARING INNER COVER 2309
08 SPACER 2308
07 WHEEL KEY 2307
06 GREASE NIPPLE M8 SIZE 2306
05 WHEEL BEARING 2305
WELDING TABLE GENERAL TOLERANCES: ISO 2768 TITLE 04 BEARING OUTER COVER 2304
THK OF PLATE WELDING SIZE FOR 'X' PERMISSIBLE DEVIATIONS
OVER INCLUDING FOR BASIC SIZE RANGE 'L' TYPE DRIVING WHEEL ASSLY 03 ‘L’ TYPE BEARING HOUSING 2303
< 5.0 10.0 3.0 <3 +_ 0.2 < 400 +_ 1.2 CROSS TRAVE WHEEL 02 GUIDE PLATE 2302
' x'

10.0 20.0 5.0 <6 +_ 0.3 < 1000 +_ 2.0


DRG. NO. REVISION 01 WHEEL 2301
20.0 32.0 6.0 +_ 0.5
< 30 < 2000 +_ 3.0
2300 0 NO. DESCRIPTION PART. NO.
32.0 50.0 8.0 WELDING < 120 +_ 0.8 < 4000 +_ 4.0 SHEET NO. 1
Standard
'L' Type driving wheel assly long trave wheel 46
drawings

‘A’

3 1
2
9 3
13
12 4
8 5
10 11
6

14

‘A’

SECTION “A-A”

NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.

14 HEX. HD. SCREW+STD NUT+SP. WASHER


IS: 1364/6735
13 HEX. HD. SCREW+STD NUT+SP. WASHER
12 BEARING AXLE SIDE COVER 2812
11 DRIVING AXLE 2811
10 AXLE KEY 2810
09 BEARING INNER COVER 2809
08 SPACER 2808
07 WHEEL KEY 2807
06 GREASE NIPPLE M8 SIZE 2806
05 WHEEL BEARING 2805
WELDING TABLE GENERAL TOLERANCES: ISO 2768 TITLE 04 BEARING OUTER COVER 2804
THK OF PLATE WELDING SIZE FOR 'X' PERMISSIBLE DEVIATIONS
OVER INCLUDING FOR BASIC SIZE RANGE 'L' TYPE DRIVING WHEEL ASSLY 03 ‘L’ TYPE BEARING HOUSING 2803
< 5.0 10.0 3.0 <3 +_ 0.2 < 400 +_ 1.2 LONG TRAVE WHEEL 02 GUIDE PLATE 2802
'x '

10.0 20.0 5.0 <6 +_ 0.3 < 1000 +_ 2.0


DRG. NO. REVISION 01 WHEEL 2801
20.0 32.0 6.0 +_ 0.5
< 30 < 2000 +_ 3.0
2800 0 NO. DESCRIPTION PART. NO.
32.0 50.0 8.0 WELDING < 120 +_ 0.8 < 4000 +_ 4.0 SHEET NO. 1
47 10
Standard
M. H. Equalizer pulley assembly
drawings

C
L
1

C PIN
L

4
2

NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.

06 EXTERNAL CIRCLIP 606


05 PIN 605

WELDING TABLE GENERAL TOLERANCES: ISO 2768 04 SPACER 604


TITLE
THK OF PLATE WELDING SIZE FOR 'X' PERMISSIBLE DEVIATIONS
OVER INCLUDING FOR BASIC SIZE RANGE 03 INTERNAL CIRCLIP 603
+_ 0.2
M. H. EQUALIZER PULLEY ASSEMBLY
< 5.0 10.0 3.0 <3 < 400 +_ 1.2 02 PULLEY BEARING 602
'x'

10.0 20.0 5.0 <6 +_ 0.3 < 1000 +_ 2.0


01 EQUILISER PULLEY 601
20.0 32.0 6.0 < 30 +_ 0.5 < 2000 +_ 3.0 DRG. NO. REVISION
600 0 NO. DESCRIPTION PART NO.
32.0 50.0 8.0 WELDING < 120 +_ 0.8 < 4000 +_ 4.0 SHEET NO. 1
Standard
AUX. H. Equalizer pulley assembly 48
drawings

C
L
1

C PIN
L

4
2

NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.

06 EXTERNAL CIRCLIP 1506


05 PIN 1505

WELDING TABLE GENERAL TOLERANCES: ISO 2768 04 SPACER 1504


TITLE
THK OF PLATE WELDING SIZE FOR 'X' PERMISSIBLE DEVIATIONS
OVER INCLUDING FOR BASIC SIZE RANGE 03 INTERNAL CIRCLIP 1503
+_ 0.2
AUX. H. EQUALIZER PULLEY ASSEMBLY
< 5.0 10.0 3.0 <3 < 400 +_ 1.2 02 PULLEY BEARING 1502
'x'

10.0 20.0 5.0 <6 +_ 0.3 < 1000 +_ 2.0


01 EQUILISER PULLEY 1501
20.0 32.0 6.0 < 30 +_ 0.5 < 2000 +_ 3.0 DRG. NO. REVISION
1500 0 NO. DESCRIPTION PART NO.
32.0 50.0 8.0 WELDING < 120 +_ 0.8 < 4000 +_ 4.0 SHEET NO. 1
49 10
Standard
M. H. Pedestal assembly
drawings

1
2
4
3

6
7
5

NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.

HEX. HD. SCREW+STD NUT+SP./PL. IS-1364


08
WASHER M8x30 LG. IS-6735

ROUND HD. SCREW+PL. & SP.


07 706
WASHER WITH NUT

HEX. HD. SCREW+STD NUT+SP./PL. IS-1364


06
WASHER M6 X 25 LG. IS-6735

05 LIMIT SWITCH MOUNTING STAND 705

TITLE 04 GEARED ROTARY LIMIT SWITCH 704

M. H. PEDESTAL ASSEMBLY 03 INTERNAL CIRCLIP 703


02 PEDESTAL BEARING 702

DRG. NO. 01 DRUM PEDESTAL 701


REVISION
SHEET NO. 1
700 0 NO. DESCRIPTION PART NO.
Standard
AUX. H. Pedestal assembly 50
drawings

1
2
4
3

6
7
5

NOTE
1. QTY. GIVEN IN PARTLIST FOR ONE ASSEMBLY.

HEX. HD. SCREW+STD NUT+SP./PL. IS-1364


08
WASHER M8x30 LG. IS-6735

ROUND HD. SCREW+PL. & SP.


07 1606
WASHER WITH NUT

HEX. HD. SCREW+STD NUT+SP./PL. IS-1364


06
WASHER M6 X 25 LG. IS-6735

05 LIMIT SWITCH MOUNTING STAND 1605

TITLE 04 GEARED ROTARY LIMIT SWITCH 1604

AUX. H. PEDESTAL ASSEMBLY 03 INTERNAL CIRCLIP 1603


02 PEDESTAL BEARING 1602

DRG. NO. 01 DRUM PEDESTAL 1601


REVISION
SHEET NO. 1
1600 0 NO. DESCRIPTION PART NO.
51 10A :
Annexure Lubrication Chart 53

Details of lubricants points in ElectroMech make Electric Overhead Travelling Crane

Lubrication Points (As applicable)

Component Type of Recommended


Description Lubrication Point
Lubricant Grade

Double Girder Crane

Gearbox Oil Mobil VG 320

Thruster Brake Oil Servo.3

DCM Brake Oil Servo.3

Coupling Grease Mobil XHP 222

Upper Block
Grease Mobil XHP 222
Equalizer Pulley

Lower Block
Grease Mobil XHP 222
Equalizer Pulley
Annexure A : Lubrication Chart 53 52

Lubrication Points (As applicable)

Component Type of Recommended


Description Lubrication Point
Lubricant Grade

Double Girder Crane

Wire Rope Servo Coat120 /


Grease
CamexCom D

Sew / Nord Geared Refer SEW / Nord Geared Motor


Motors Maintenance Manual

CT Wheel Bearing Grease Mobil XHP 222

LT Wheel Bearing Grease Mobil XHP 222

Spring Buffer Grease Mobil XHP 222

Bearing Block Grease Mobil XHP 222


53 10A :
Annexure Lubrication Chart 53

Lubrication Points (As applicable)

Component Type of Recommended


Description Lubrication Point
Lubricant Grade
Single Girder Crane

Hoist Grease Mobil XHP 222

Hoist Upper
Grease Mobil XHP 222
Block Pulley

Hoist Upper
Grease Mobil XHP 222
Block Pulley Hinge

Geared Motor Mobil VG


Oil
(LHP) 460/600

Gear Pinion
Grease Mobil XHP 222
Bearing

LT Wheel Inside
Grease Mobil XHP 222
Bearing
Annexure A : Lubrication Chart 53 54

Lubrication Points (As applicable)

Component Type of Recommended


Description Lubrication Point
Lubricant Grade

Golliath Crane

Boggie Connector Pin Grease Mobil XHP 222

Balancer Hinge Block Grease Mobil XHP 222

Flexible Hinge Pin Grease Mobil XHP 222


55 10B :
Annexure List of Critical Spares

Brief List of Critical Spare Parts for ElectroMech make Electric Overhead Travelling Crane

Conventional DGEOT Crane:

Item No. Item Description Qty.


1 Main Hoist Brake Shoes 1 Set
2 Auxiliary Hoist Brake Shoes 1 Set
3 Cross Travel Brake Shoes 1 Set
4 Long Travel Brake Shoes 1 Set
5 Thruster Brake Assembly for main hoist 1 Set
6 Thruster Brake Assembly for auxiliary hoist 1 Set
7 Long Travel Limit Switch RR Type 1 No.
8 Cross Travel Limit Switch RR Type 1 No.
9 Wire Rope for Main Hoist Length as per Drawing
10 Wire Rope for auxiliary Hoist Length as per Drawing
11 Bearing Set for Long Travel wheels 1 Set for 1 wheel
12 Bearing Set for Cross Travel wheels 1 Set for 1 wheel
13 Long Travel wheel drive axle 1 No.
14 Long travel wheel idler axle 1 No.
15 Pendent Push Buttons with elements 12 No.s
16 Cable Trolley 6 No.s
17 Mains MCB 1 No.
18 Control Transformer 1 No.
19 Overload relay for Hoist, CT & LT 1 Each

Conventional SGEOT Crane:

Item No. Item Description Qty.


Hoist

1 Rope Guide 1 No.

2 Rope Tightner 1 No.

3 Roller Bearing with Sleeve 2 No.s.

4 Thrust Bearing 1

5 Brake Disc with Liner 1

6 Rotor Pinion 1

7 Brake Shims 24

8 Rotor Shims 5

9 Wire Rope 1 Length


Annexure B : List of Critical Spares 56

Conventional SGEOT Crane:

Item No. Item Description Qty.


10 CT Motor – 1 No.s

11 Roller Bearing with Sleeve 2

12 Thrust Bearing 1

13 Brake disc with Liner 1

14 Rotor Pinion 1

15 Brake Shims 24

16 Rotor Shims 5

17 Long Travel Motor – 2 No.s

18 Brake unit LHP 2

19 Rectifier 2

Electrical

Item No. Item Description Qty.


1 Pendant Push button with elements 12 No.s
2 Cable trolley 6 No.s
3 Mains MCB 1 No.
4 Control Transformer 1 No.
5 Overload relay for Hoist, CT & LT 3 No.s
57 10C :
Annexure Precautions for Crane Operation

What Not To Do

Do not let an unqualified Never swing the load


Never pull slantwise.
person use the machine internally

ý Never move or lift the equipment by electric cables.


ý Do not let the equipment drop.
ý Never modify the equipment until ElectroMech has studied and authorized the modifications.
ý Never modify the values and adjustments of the safety components outside the limits provided for in
the manual, or without approval of ElectroMech.
ý Never try to repair or intervene the equipment (by welding, etc.) without authorization of ElectroMech.
ý Never shunt the disconnect switches, electric switches, prevention or limitation equipment.
ý Never lift more than the maximum working load indicated on the equipment. Shocks or accidental
collision of the load with objects can cause excess loads.
ý Never remove the hook safety latch.
ý Never block, adjust or remove the limit switches or stops to go further to the left or right than these
allow.
ý Never use the equipment to extract, loosen, or pull sideways.
ý Never use the equipment to transport people.
ý Do not touch the moving components.
ý Do not operate the equipment if your physical condition does not allow it.
ý Never use the equipment when in bad repair (wear, deformation, etc.)
ý Never use suspicious spare parts, or parts whose origin is not unknown.
ý Do not subject the equipment to brutal shocks.
ý Never distract the operator when the equipment is being operated.
ý Never leave a suspended load hanging, if it is not necessary.
ý Never use the equipment as an earth reference for welding.
ý Do not use the equipment for a purpose or in an area for which is not intended.
ý Do not expose the machine to an aggressive atmosphere (temperature, acidity, etc.)
ý Do not use safety components as operation components.
ý Do not use the controls needlessly (avoid inching – stop – start operation of the buttons). This can
cause overheating and damage the machine.
ý Never pull the load slantwise.
ý Make sure that the hook is vertical to the load before lifting it.
ý Do not use the equipment with a power supply that is different to the one recommended
(under voltage , over voltage, absence of phase, etc.)
ý Never transport a load with people nearby.
ý Do not pass the equipment, with a load, above a person.
Annexure C : Precautions for Crane Operation 58

What To Do

Material used outdoors should


If manually moving the be protected as well as possible
Neutralize power sources
machine, push the load against bad weather conditions

þ Handle the equipment by its structure, or by the devices provided for this purpose, or in its original
packing.
þ Store the equipment away from aggressive atmosphere (dust, humidity, etc.)
þ Make sure that the machine is always clean and protected from corrosion (lubricated....).
þ The equipment should be installed by a technician with the necessary competence.
þ Make sure the machine attaching structure is rigid.
þ Make sure that the safety rules are followed (harness, clearance of work areas, posting up of
instructions to be followed in the area...)
þ Neutralize power sources.
þ Comply with the distance between the trolley and the runway.
þ Replace any worn or defective element.
þ The equipment should be maintained regularly, following the instructions in the manual.
þ Regularly check the equipment.
þ Check that the assembly elements are correctly tightened.
þ The components should only be replaced by original parts that are compatible with the type of machine.
þ Before operation, check that the load is correctly fastened and slinged.
þ Make sure that the load is correctly balanced before moving it.
þ Pay attention to the centre of the load to be moved.
þ When moving the load, make sure that it is sufficiently raised and distant from the surrounding
machines and other objects so as to avoid all obstacles during operation.
þ If manually moving the equipment, push the load.
þ The prevention instructions to be carried out during the operations should be well known.
þ Use the equipment under normal working conditions (ambient temperature, atmosphere, etc.).
þ Equipment used outdoors should be protected as well as possible against bad weather conditions.
þ Notify the authorized persons after a dangerous operation or if the equipment seems problematic
(abnormal noise, abnormal behaviour, etc.)
59 10D :
Annexure Wire Rope : Basic Information, Storage & Handling

Component part

Contd….
Annexure D : Wire Rope : Basic Information, Storage & Handling 60

— While transferring the rope from reel to reel or


which drum, the rope should be wound from
top tp top or from bottom to bottom so as so
avoid any reverse bend to the rope.

— Heavy coils should be uncoiled by placing the


coil on a turn-table and ensuring that the rope
is kept tight and straight. A smaller length of
coil can be rolled along the ground so that the
rope lies straight.

— Care should be taken to avoid dragging wire rope through sand, gravel and dirt since it may pick
up abrasive particles, which can cause deterioration of the rope during its use.
— wherever necessary, a wire rope, whether preformed or non-preformed, should not be cut
unless seizings are provided on either side of the cut. for multi-strand non-rotating rope at least
three seizings are suggested on either side of the cut. Ropes should never be cut with a chisel
and hammer. It should be cut either using an abrasive cutter or by gas-cutter.

seizing of wire rope

Installation
— The free end of the rope must remain
tightly served / fused or welded during the
entire installation procedure. When
attaching a rope end in a wedge socket /
clamp, it is important that the entire rope
cross-section, including steel core if
applicable, be firmly secured or anchored.

— While winding the rope on to the


equipment winch drum, it is necessary that ample tension is maintained out through the
winding of the rope so as to keep all the turns of the rope on the drum tight and true.

— The position of the anchorage point of the drum should be located in relation to the direction of
lay of the rope. As a thumb rule, a right hand lay rope should start winding from the left hand
flange of the drum, the rope over winding and the observer standing behind the drum. The
opposite is true for a left hand lay rope, that is, the anchorage should be at he left hand flange of
the winch drum, with the observer standing behind the drum.
61 10D :
Annexure Wire Rope : Basic Information, Storage & Handling

— For the multi-layer coiling on the drum, any cross winding should be avoided by ensuring that
the rope winds uniformly in the grooves formed between the successive turns of the preceding
layer of the rope.

Maintenance :
— After installing a new rope, it is advisable to run through its normal operating cycle for a number
of trips under light load and at reduced speed. This allows the new rope to adjust itself gradually
to operating conditions and enable the strands to settle down and some stretch to occur, the
rope then becomes less liable to damage when the full load is applied.

— While hoisting or lowering, never lift or stop a load with a jerk. This shock load may equal several
times the static working load and may be suffering to break a rope. Even if the jerks do not snap
the rope, they can cause rapid deterioration resulting in reduced rope life.

Guidelines on discard criteria for steel wire ropes


Steel wire rope, like any machine, deteriorates during storage as well as service. The deterioration and
thus the life of the rope depends on various factors, in addition to the manufacturing quality of the rope,
like storage, handling, maintenance and operating conditions. Obviously, a busy and heavily stressed
rope will deteriorate faster during use. It is, therefore, difficult to predict the life of a wire rope.
However, generally accepted criteria for removal of General engineering rope from service are as
follows.
1. When the all over diameter of the rope is reduced by 8% or the outer wires have lost its diameter
by 33% through wear. This reduction in diameter of the rope is measured on a portion of the
rope which is subjected to abrasion and stresses with respect to the portion of the rope which is
subjected to stresses, but not abrasion e.g. portion near drum or anchorage.
2. When the total number of visible broken wire exceeds 10% of the total number of wires in the
rope in a length equivalent to eight times the diameter of the rope. This condition is applicable
where the breakages of wires are more or less evenly distributed in all the strands and not when
the breakages are concentrated in only one or two strands of the rope.
3. When there is evidence of considerable plastic wear or surface embrittlement.
4. When the diameter of the rope has suddenly reduced or the lay length has suddenly increased
or decreased. The decrease in lay length is usually associated with waviness in the rope.
5. When there is evidence of severe corrosion like chain pitting. The condition may be alarming if in
addition to corrosion, fatigue is also present.
6. When there is any evidence of internal corrosion in the rope. This can be recognized by
slackness of outer wires due to the internal wires corroding away or under wet condition, a rusty
emulsified liquid / substance exudes between the strands under load.
7. When the rope has been subjected to localized distortions as a result of mechanical damage,
crushing, kink, bird cage, etc.
8. When the core of the rope has collapsed.
9. When the rope has been subjected to a high temperature or heat due to fire.
10. When the rope has been subjected to sever shock load or over load due to some accident with
the equipment.
11. When the rope has been subjected to severe shock load or over-load due to some accident with
the equipment.
Annexure D : Wire Rope : Basic Information, Storage & Handling 62

The above-mentioned conditions guide general lines for discard of wire rope during use. However, the
discretion of the user or an inspecting officer, associated with the equipment or installation have be final
for judging and ascertaining the safe condition of the rope, based on his earlier observations and
experience on the particular installation. Hence, if the inspection of the rope leaves any doubt about its
safety in the mind of the user / inspecting officer, the rope should be changed.

Types of failures
Survey of removal criteria
a wire rope must be removed if one or more of the following criteria can be satisfied.

1. Broken wires
A wire rope must be discarded if the permissible number of wire breaks has reached or
exceeded. It must also be replaced when local concentrations of wire breaks occur ( discard
number of wire breaks.)

2. Reduction in diameter
Reduction in diameter can be caused by abrasion, corrosion or a local failure of the rope core.
According to B.S. 6570 a wire rope should be discarded '' when the rope diameter anywhere is
reduced to 90% of the nominal diameter in the case of six and eight strand ropes''.
Considering the fact that a rope is allowed to have an oversize of 4% when new, this figure
would allow for a diameter reduction of 14% which seems to be excessive.
For multi-strand ropes, B.S. 6570 recommends a detailed examination '' if the rope diameter
falls to 97% of the normal'', because '' discard may be necessary''.

3. Corrosion
Corrosion may be external or internal, general or localized.
According to B.S. 6570, a wire rope should be discarded '' when the surface of the wires is
severely roughened or pitted, or if the wires are slack within the strands due to wastage''.

4. Deformation of rope

waviness

This deformation, while it may not necessarily affect the strength of the rope, transmits
pulsation and produces uneven rope wire. When the rope is laid on a level surface under no load,
the maximum height of the ''wave'' should not be greater than the normal rope diameter +
1/3.Otherwise the rope should be removed from service.
63 10D :
Annexure Wire Rope : Basic Information, Storage & Handling

Loop Formations

Wire or groups of wires may form a line of loops parallel to the axis of the rope. The deformation
is often caused by shockloading. Loop formations are a justification for discard.

Loose Wires

Where loose outer wires are found without any adjacent mechanical damage, the most likely
cause will be corrosion and the rope should be removed from service. Where loose wires have
been caused by mechanical damage, a full examination will decide if the rope can remain in use.

Nodes
A node is a local increase in rope diameter with the core easily visible between several covering
strands. It can be caused by shock loading or, in the case of fibre main core ropes, by the
absorption of moisture. A node is a justification for discard.

Misplaced Outer Wires


Misplaced outer wires are wires forced out position along the line of the rope to form small
flattened loops. This can be caused by bad drum spooling or by the rope being drawn across a
sharp edge. Langs lay ropes are often worst affected. Misplaced outer wires are a justification
for discard.
Annexure D : Wire Rope : Basic Information, Storage & Handling 64

Thinning of the rope

Thinning is a reduction in the diameter of the rope over a short length. It is often associated with
older fibre cored ropes usually in areas of sustained heavy loads over sheaves. The
disintegration and loss of the core can allow one of the covering strands to take the place of the
core. When this condition occurs in ropes with IWRC the distortion will most often be in the
vicinity of the termination away from drum. The most likely cause is rope rotation which has
allowed the rope to unlay, resulting in the overload and reduction in diameter or failure of the
IWRC.

Kinks

Deformation caused by a loop in a rope being tightened when the rope cannot rotate about its
axis to release the torque. The tight bend or kink thus formed, can result in a serious loss of
strength due to unbalance in the lay lengths. Ropes with kinks must be discarded.

Flat areas

A flattening can be caused by bending the rope severely over the rim of a sheave or any sharp
object with the wires on the inside of the bend being forced out of position. Ropes with flat areas
should be discarded.
65 10E :
Annexure Safety related to load lifting accessories

Wire Rope Slings

— Wire rope consists of individual wires laid into a number of strands,


which are then wrapped around a central core.

— Different number of wires in the strands and various methods of


arrangement may affect the characteristics of the wire rope sling.
The wire rope shall be equipped with a thimble with a Safe Working
Load (SWL).

Inspection points
— The wire rope sling shall not be used and shall be disposed if they are -
Points for attention
— Use only suitable wire rope slings.
— Never use damaged wire rope slings.
— During lifting, the safe working load must not be
exceeded.
— Regular inspections shall be conducted
— Sudden elevation is not allowed
— If more than one wire rope slings is used in lifting,
pay attention to the angle between the slings.

Wire Rope Slings - Cable Clip

ü
The cable clip shall be properly installed according to
the following points
— The wire rope sling is equipped with thimble.
— There is a minimum of 3 cable clips.
— The direction of installation shall be correct.
— The distance between the cable clips shall be the same.
O
O
Method of connection of wire rope slings

O
ü
Annexure E : Wire Rope : Basic Information, Storage & Handling 66

Hook
Hooks are a vital part of the lifting gear. A variety of them cater to different lifting purposes.

Check for wear


Check for signs of and deformation
“opening up”

Check for cracks


and twisting

Check for wear


and cracks

— All hooks shall be installed with safety latched (other than specially designed hooks.)
— Hooks can be installed with swivels to allow the load to revolve.

Points for attention


— Select hooks of the right size.
— Do not tie or remove the safety latches.
— Maintain the hook in a vertical position. If the hook is eccentrically loaded, the safe working load
will be reduced.

Safety points
— The hook shall not be directly fixed to on the eye bolt.
— Plain eye bolts only apply to the vertical lifting.
— The angle of lifting of shoulder eye bolts shall not be
less than 45O.
— Washers may be used to ensure that the shoulder is
firmly in contact with the surface.
— Never use a sling through a pair of eye bolts.

— Move the loads as near to the ground level as possible.


— Stop people from standing in the lifting area.
— Do not ride on a load that is beind lifted.
How to reach us

Corporate Office
Branch Office

ElectroMech - sales & service network


Vadodara

ElectroMech Material Handling Systems (India) Pvt. Ltd.


L

Corporate Office & Plant


Gat No. 316, At Post Kasar Amboli, Pune-Paud Road, Tal. Mulshi,
Dist. Pune 412 111, INDIA
Telefax : +91-20-6654 2222 E-mail : cranes@emech.in

Bangalore : No 22, 3rd Floor, Above Bombay Dyeing Showroom, 5th Cross, 5th Block,
Koramangala, Bangalore 500 095 Cell : 099008 15071
E-mail : shashank@emech.in

towards Lavasa
Chennai : No. 6, 5th Floor, B Wing, Gemini Parsn Manere, No. 602 Anna Salai,
Chennai 600 006 Cell : 099406 57525
E-mail : palani@emech.in

Delhi : ElectroMech House - Flat No. 2900/3, 9th Floor, Golflink Apartments,
Nagina Co-operative Housing Society Ltd., Sector 54, Gurgaon, Haryana
Cell : 099719 43232 E-mail : yuvan@emech.in

Kolkata : 716, Jogendra Gardens, Ground Floor, Bosepukar, Kolkata 700 078
Cell : 098740 64646 E-mail : sena.biswas@emech.in

Mumbai : Technocity, B-503, Plot No. X-1/2 & X-1/4, Mahape, Navi Mumbai 400 710
Cell : 099701 73366 E-mail : runal@emech.in

Vadodara C / 46, Shripad nagar Society,Vip Road,Opp.Bright School,Karelibaug,


Vadodara - 390018 Gujarat Cell : 9998747475
E-mail : bankim@emech.in

www.emech.in

Ex-02 / 0711 / 1k / kaleidoscope@vsnl.com

You might also like