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E ER RE EC CT TI IO ON N & & M MA AI IN NT TE EN NA AN NC CE E M MA AN NU UA AL L F FO OR R
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Office & Works: GAT No.-316. Plot No. A1 & B1, Industrial Area, Kasar Amboli Taluka Mulshi,
Pirangut, District Pune - 412 111 (India), Tele Fax: 91-020-66542222.
E-mail: cranes@emech.in
Web: www.emech.in




Document No.: CS/DO/01
Release Date: 01/12/07
Rev-01



ERECTION & MAINTENANCE MANUAL
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Foreword from the CEO

We envisage Electromech becoming a world-wide 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 a consistent
improvement in performance by delivering top-class products and by catering to a wide range of
client requirements. Be it a case of supplying mass-customized hoisting applications for a multi-
million dollar, multinational power project, or be it the case of supplying specialized material
handling equipment for 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 innovations 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 exercises, 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.

Apart from being a major player in the customized material handling equipment field, we are also
proud to present our large range of standardized EL Series wire rope hoists to suit a diverse
range of applications. Be it a garage or be it a fully integrated automobile manufacturing plant, our
hoists are used for handling a multitude of jobs.

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

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Introduction

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

EOT Cranes - Single / Double Girder
These cranes move on the gantry rails fixed on the top of the gantry girders. In this type,
3 common motions are incorporated; namely Hoisting, Cross Traverse and Long Travel.
Sometimes according to the customers' 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 the part and parcel of
the Electric Hoist itself in case of a single girder crane.

Goliath / Gantry Cranes
Goliath or Gantry Cranes differ from the above described cranes since they move on the
rails fixed at ground level as compared to rails fixed at a height as in the case of above.
These are invariably used for outdoor duty, as in stock yard and dam sites.

Component Parts of Crane
A crane consists of the following main parts ~
1. Bridge Girders
2. End Carriages
3. Platforms
4. Crane Travelling Mechanism
5. Hoisting & Cross Traverse Mechanism
6. Cabin (if equipped)
7. Electrical panel

1. Bridge Girders
A crane bridge consists of a welded or machine bolted structure which is
composed of a single girder or double girders. These form the main supporting
members for all dead and live loads.

2. End Carriages
These house the LT wheels (driven as well as idle wheels) and support the
girders at the ends.

3. Platforms
They provide support for the LT machinery and for electrical panels also. They
provide walking space along the crane in case of a double girder crane and
provide maintenance space in case of a single girder crane.

4. Crane Travelling Mechanism
Crane travelling machinery moves the crane along the bay length. It consists of ~
a. One motor at the centre of the span or 2 motors provided at ends of the
span.
b. Electromechanical or Electromagnetic or Thruster Brakes which apply to
the LT motion.
c. Gear box which provides exact speed ratio as required between motor
and LT wheel.

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d. LT shaft which transmits the torque from gear box output to the wheel.
e. Wheels which move on the gantry rail along the bay length.

5. Hoisting Mechanism
a. Motor
b. Electromechanical / Electromagnetic / Thruster Brake
c. Gear Box
d. Rope Drum
e. Rope
f. Snatch Block

6. Cross Traverse Machinery
a. Motor
b. Electromechanical / Electromagnetic / Thruster Brake
c. Gear Box
d. Shafting
e. Wheels

7. Cabin (if equipped)
The cabin, if provided, is suspended from one end of the girder. All cam / master
controllers and main panel are mounted in the drivers cabin.

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.

Storage Instructions

The crane and its components are dispatched to the site by road / rail in suitable packing and
protection against damage during transit in 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.

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

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 the girder
should be stored flat, 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

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there is a marked evidence of rusting. This is in addition to the normally
applied coat before erection.

2. Mechanical Items
a. Crab Assembly / Electric Wire Rope Hoist (despatched 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 covered, 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.
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.

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 these items should be
stored in vertical position and the cases containing the panels and resistances should
also be stored in vertical position.

4. General
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 -
a. No load running trial of all mechanisms.
b. Insulation test of all electrical components like motors, brakes, limit switches,
panels, resistances, controllers, etc.
c. To check the condition of grease in wheel assemblies for crane and trolley
and to ensure that these move freely.
d. To check the lubrication in pulleys, couplings, etc.,
e. To check the gear boxes through inspection covers.
f. In case the storage area is easily susceptible to pilferage, then 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.

Erection Instructions

The instructions given here for assembly, wiring, testing and commissioning of the crane should
be carefully followed, as good installation will ensure years of satisfactory and carefree operation.
Before erection, the person in charge of erection is requested to go through all instructions and
drawings enclosed.

Checking of the consignments
Packing lists containing details of consignment in each crate are sent prior to the dispatch
of the crane. The contents of each crate are to be checked carefully against packing lists.
Any damage that may have occurred in transit, despite the care taken during packing and
dispatch, must be first looked into. Report to us immediately on any breakage or shortage
so that proper corrective measures can be undertaken by us. This will also help you in
making proper claims to the insurance company if the consignment has been insured by
you. This claim should be raised by you directly with intimation to us. If the damages are
very minor, then the parts may be repaired and kept ready for assembly.

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Preparatory work for erection
1. Select a space in the bay where the crane is to be erected and which is free from all
obstructions and also other construction work. The dimensions should allow for easy
manipulation of the girders, etc., at a preparatory stage as well as during the erection.
The most suitable location is in the span between the columns that have no
horizontal ties in between and between the roof trusses above.
2. Keep all erection equipment such as derricks, pulley blocks, sling tools, etc., ready
before commencing erection work. The following services should be available at the
erection site -
a. 415 V, 3 Phase, 50 Hz, AC supply
b. 7 kg/cm
2
compressed air supply
c. 400 A welding transformer
d. Oxy-Acetylene gas cutting set
3. Ensure that all parts are identified thoroughly cleaned and kept in orderly manner.
Look for match marks at every stage of the erection work so that the assembly
proceeds in the right manner.
4. Check the gantry rails and make sure that they are in proper alignment. The proper
running of the crane depends very much upon the rail alignment. Check the span
which should be equal to the crane span and make sure that deviations if any are
within the permissible limits. Any abnormal variations must be rectified prior to the
erection of the crane. End stops must be provided at the end of the gantry rails and
the rails electrically earthed.
5. The position, spacing and alignment of the mains supply conductors have to be
examined with respect to the general assembly drawing. If down shop leads are of
bare copper wire, see that there is no excessive sag. If they are of angle or rails, see
that they are reasonable straight and their joints are smooth.
6. Assemble the end carriage and girders on the ground if the size of the crane is small
and the lifting capacity as well as space available is adequate for lifting the entire
girder saddle frame as a unit and placing it on the gantry rails. Alternatively, place the
end carriage along with the wheels assembled one on each gantry rail and clamp
them in position.
7. Check the hands as required by general assembly drawing. Check the wheel
verticality and straightness individually and relatively between the two end carriages.
Check the diagonals of wheel positions. Make necessary adjustments to position the
end carriages as required. Place the girders one after the other over the end
carriages and locate them corresponding to the match marks by means of taper pins.
Use taper dowel pins at least 20% in number to locate the girders. Check the
alignment and fix the reamer bolts. Remove dowel pins and put reamer bolts to
complete the joint. If the girders are sent in pieces, they must be pre-assembled on
the ground. In no case should gas cutting of holes be done if they do not match.
Ream them to a larger size and use larger diameter tight fit bolts.
8. Now fix the platform and its supports. Assemble the LT machinery. Check the
alignment of the motors, gear boxes and brakes. Weld locating pads to prevent
shifting of thee units from the aligned position.
9. Place the crab assembly on top of the girders. Fix the rope as per the revving shown
in the crab assembly drawings. Fix the platform and hand railings, weld all loose or
tack welded angle supports and cleats fully. Weld the nuts to the bolts that hold the
platform angles and supports after fully tightening them. This will prevent their
working loose and falling out since they are not likely to be seen during routine
inspection. Weld locating flats in the slots to prevent shifting of the platform gratings
wherever platforms are of MS grating.
10. Fix the cabin ladder, guards, main collector platform and CT conductor arrangement.
Any site work and welding to be done as per the drawings is to be completed now.
11. Next, complete the wiring as per the wiring diagram. Inspect all parts to ensure that
everything is in order.

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12. Then connect the main collectors and power supply to the crane.

Operating Instructions

Inspection before operation

Check the following point by point to ensure that crane is finally ready for trial operation -

The gear boxes are filled with recommended lubricants upto the maximum level
marked on the respective dipsticks.
The centralized / group lubrication system, if provided, is functioning properly and
that all the connected points are getting lubricated.
For all other points where individual greasing is required, the proper amount of
lubricant is filled manually by a grease gun.
Open reduction gears wherever used, are properly greased with the
recommended lubricant.
The wire rope is lubricated with the recommended grease.
For the rotary limit switch set the contacts so that it operates at the upper and
lower limits of the hook travel. The upper limit contact must operate slightly
ahead of the over-hoist limit switch, of provided.
The over-hoist limit switch if provided, should be assembled and wired properly.
For counterweight actuated limit switch, the position of the hanging weight should
be such that the hook assembly as it raises to the top limit, lifts this weight
upwards to operate the limit switch. Ensure that the hanging weight is properly
guided by the idle ropes from the top sheath and does not get displaced
sideways or sway out.
The lever type limit switches provided for long travel and cross traverse are
properly positioned and wired and are operating smoothly.
Buffers and end stops wherever required are properly assembled.
Rope clamps are properly positioned and tightened.

Preparation for operation

The crane is operated by manipulating the controllers governing each motion. Before
beginning the operation of the crane, complete the following preparatory routine -

1. Check all cable interconnections as per wiring diagram.
2. Ensure that no connection is loose.
3. Carry out insulation test on both, Power as well as Control circuits.
4. Remove Power Circuit Fuses in the main panel and switch on the Main isolator.
Test only the Control Circuit by energizing the various circuits.
5. Switch off the Main Isolator, replace the Power Circuit Fuses in the main panel.
6. Check Over Load Relay settings and ensure that the same have been set for the
full load current of the motor as per the name plate details.
7. Decouple all the motors.
8. Switch on the power.
9. Check the direction of rotation with respect to controller handle movement
against all motions.
10. Couple all motors.
11. Test Power Circuit.


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Trial Operation

1. One by one operate all 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. Closely observe for any abnormal
noise, vibrations, etc.
2. Repeat the trial with 10%, 25% and 50% of the rated load and then with 100%
rated load. Check the simultaneous operation of the various mechanisms and
ensure proper functioning of the same.
3. Hoist 125% rated load by the crane and check whether the structure is able to
sustain the load without any permanent deformation.
4. Record current drawn by motors during each one of the above tests.
5. Set Thermal Overload Relays to 125% of the recorded full load current and
Magnetic Overload Relays to 10% of the recorded full load current.
6. Report any abnormalities observed to us for the purpose of rectification.

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.

Do not load beyond the rated capacity. The immediate danger is possible
failure of some load carrying part. Overloading might also start a defect which
could lead to some future failure, even at less than rated capacity.
Do not use any overhead material handling equipment for the purpose of
transportation of personnel.
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 the
safety engineers before loading.
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 of any extent.
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.
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.
Limit switches are for emergency uses 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.

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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.
Centre 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.
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.
The limit of the straddle angle of the sling should be kept within 90
o
. Else a
larger load than commonly supposed works on the wire ropes.
Wire ropes for load handling should not be placed on the portion of the
load that may cause them to move or slip off.
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.
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.
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.
Do not leave the load suspended in the air unattended.
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.
When the crane is operated after a long period of disuse, be sure to operate
all the motions without load first.

Crane Drivers (For Cabin Operated Cranes)

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.
Crane drivers must be physically fit, and have good hearing and eye sight. A
crane river shall not operate his crane if not physically fit, but shall report any
disability to the medical officer or other appropriate person at once.

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Crane drivers are expected to be extremely alert at all times. Sleeping on the job,
throwing pipe ashes or cigarette butts or spitting from the control cabin or bridge
structure are not to be permitted under any circumstances.
They must keep their hands free when going up or down the access ladders.
Their spare clothing or any personal belongings should not be kept in the vicinity
of the controls.
The operators must be fully aware of the crane safety, operating instructions, the
crane mechanism and its proper care.
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.
Rail trucks, cars, or any other transport vehicles should not be towed by any
crane.
The crane driver must ensure that the fire extinguisher is kept in an accessible
position and fully ready for use.
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.
The crane driver should maintain a log book and make the appropriate entries in
it on a daily basis.
The crane driver is at all times responsible for the safe operation of the crane.
He should at all times ensure that the crane is properly lubricated in accordance
with the instructions issued.
He should not leave the controls while a load is suspended from the crane.
He should not permit anyone to be in any position on the crane, during normal
operation of the crane.
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.
In case of power failure, the crane driver shall move all controllers to OFF
position, report the matter to the supervisor and await instructions.
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.
Before closing the main switches, all controllers must be in the OFF position.
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.
The crane driver should obey a STOP signal, regardless of who gives it.
Under no conditions should any crane driver move a load unless he has clearly
seen and understood the given signal.
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.
Bumping into runway stops should be avoided.
All load movements should be done smoothly without jerking or sudden stops.
Under no circumstances shall the crane driver attempt to travel any load until that
load has been hoisted clear of all obstructions.
When handling loads approaching maximum rated capacity, the crane driver
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clear of 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.
While the crane is in motion, crane drivers should keep their hands on the
controls at all the times.
All loads should be carried or suspended at a maximum height of 2.5 metres,
except above machineries where it may be further increased.
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.

Floor mans standard hand signals

The determination of a system of operating signals side by side with a strict adherence
there to is strongly recommended from the standpoint of operating efficiency and
accident elimination. Suitable examples are given below for operators information

1. For HOISTING, hold forearm horizontally, palm up and move forearm upwards.
2. For LOWERING, hold forearm horizontally, palm down, and move forearm
downwards.
3. For TRAVELLING, hold arm horizontally at the side of the body, raise forearm
vertically with palm facing the direction of movement, and move the forearm in
the direction of movement.
4. For DEGREE OF EXTENT to be indicated, the motion of the forearm is reduced
(or repeated in small movements) for a slight movement, or increased when a
greater movement in desired.
5. To STOP LOWERING, the previous position of the forearm is maintained, but the
palm is turned over with the forearm in the same position.
6. To STOP TRAVELLING, the position of the forearm is same as that for
travelling, but the palm is turned over as in the case of stopping lowering.
7. For EMERGENCY STOP, hold forearm horizontally in front of the body and
swing rapidly to left and right.
8. COMPLETION OF OPERATION is shown by raising both arms horizontally and
lowering both at the same time.

If the travelling distance or lift is so much, that above signals are difficult to distinguish,
the entire arm may be moved, instead of the forearm. The use of a whistle together with
the above signals will help in making them clearly understood.

When a whistle is used with the signals, following notes are sounded before the hand
signals are made

Short Movement :

Continuous Movement :

Stop :

It is essential that only one man be assigned to the work of signalling as operations as
per the signals received from two or more men are extremely dangerous. The operations
of the crane should also be performed by one man for this purpose.

Crane parking

Before leaving his control position, the crane driver should at all times ensure that

1. The crane is stopped at the location designated for leaving the crane.

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2. There is no load suspended from the hook.
3. The hook is raised clear of all the obstructions.
4. All controllers are placed in the OFF position.
5. Subject to more specific local instructions, the main power switch in the crane is
locked in the OFF position.
6. Where the crane is exposed to wind, travel brakes are locked ON and the hook
secured to avoid damage by free swinging.

Crane attendants or slingers

1. The crane attendants shall have an adequate knowledge of safe handling
methods.
2. He must have a sound knowledge of knotting, slinging, strength of ropes, chains,
cables and slings.
3. The crane attendant s at all times responsible for the safe slinging and handling
of the load.
4. He should notify his supervisor whenever, and prior to, any unusual or special
lifts are to be made.
5. The crane attendant is responsible for ensuring that
a. Any lifting equipment is not overloaded. If there is any doubt about the
capacity of the equipment, or the weight of the load, it should be
immediately clarified.
b. All loads are moved in such a manner as to clear all obstructions and are
not carried over the personnel.
c. All loads are securely slung, and that all slings, cables, etc., used, are of
the correct size and quality.
d. Slings are so arranged that they cannot slip, catch on, or strike any
object.
e. All piling and stacking is done in a safe and orderly manner.
f. The slack is carefully removed from all the slings prior to the load being
lifted and during such process, special care taken when it is necessary to
steady the slings by hand.
g. Chains, cables and ropes should be kept free from knots, twists and
kinks.

Maintenance Instructions

Needless to say, daily maintenance and inspection are not only important for safe operation, but
also govern the efficiency and service life of the crane.

General precautions

There are many points requiring attention for maintenance of the overhead crane, but
most important items may be roughly classified as follows

1. Lubrication

a. Lubrication is as important to a crane as breathing is to man and hence
must never be forgotten. Apply proper amount of oil or grease at proper
intervals. The lubrication chart for overhead cranes is enclosed for
reference.


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FOR ELECTRIC OVERHEAD CRANES
www. e me c h . i n 13
2. Worn or deformed parts and broken parts

a. If the wear or deformation is within a certain limit, the part can still be
used. Every wear limit mentioned in the wear table is the usable wear
limit.
b. At each periodic inspection, consider the amount of expected wear
before the next inspection and repair or replace the part if necessary.
Since this wear limit is specified as a percentage of the initial dimensions
in some cases, you are advised to make a table indicating the initial
dimensions and the wear conditions to facilitate inspection.

3. Loosening of fasteners

a. Loose nuts, screws, etc., may result in serious trouble. Hence all
fasteners must be inspected with special care.

4. Contacting parts

a. This mainly concerns electrical parts. Always perform hoisting, travelling
and traversing operations with no load to check the operating condition
before starting actual operation with load. At the same time, check the
contacts of the electrical equipment.

Details of maintenance

1. Motors

Electric motors should be protected against drops of oil, water, etc. Terminal boxes
should be carefully closed. The electric motor should be periodically inspected and
cleaned. Before inspection, the motor and slip ring box should be cleaned of all dirt and
dust.
When checking slip rings and brush holders, it is necessary to remove metal and coat
dust from the box. The rings are to be wiped with cotton cloth. If there is no dust or oil on
the ring, the cloth should be soaked in petrol. Scorched rings can be polished with fine
emery paper. When inspecting the brush holder, it is necessary to check the brush
pressure on the rings and smoothness of arm motions. Worn out bushes should be
replaced by spare ones.
Bearings of motors should be checked and washed with petrol and the lubricant should
be changed after about 8 months. Lubricant should be added every 3-6 months. It should
be noted that the lubricant fills no more than two thirds of the bearing housing.

2. Brakes

The braking torque of the electro magnetic or thruster brake is produced by the action of
a strong compression spring. When the current is switched on, the brake is released by
the solenoid / thruster, closing against the pressure of operation spring. The normal
position of the brake is therefore ON and the brake will return to this position if the current
fails.
The heavy duty cast iron brake shoes have treated fabric lining secured with brass or
aluminium rivets. They have large cooling surfaces and are self aligning.
If spare shoes complete with brass lining are kept in stock, they can be fitted in a few
minutes when the lining in use becomes worn. The worn shoes should be then relined
and kept in readiness for future replacement.
The length of the brake operating spring is set during assembly to give the required
torque and no subsequent alteration is required.

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FOR ELECTRIC OVERHEAD CRANES
www. e me c h . i n 14
Complaints regarding the electro-magnetic type of brakes have been frequent only where
maintenance has not been properly done. Generally, the plunger of the solenoid sticks
during the movement when a lot of dust enters the solenoid opening. With the right
maintenance, if the dust is kept down, the movement of the plunger will be smooth and
therefore there will be less trouble.
In an AC magnet, a heavy starting current is produced when the supply is switched on,
but this current comes down considerably as the gap between the plunger and the
magnet reduces. The current becomes very low after the plunger has been fully drawn in
and the air gap in the magnet circuit reduces to zero.
It will therefore be seen that in the event if sticking, it results in some air gap after the coil
has been energized. It will therefore continue to draw in a heavy current, lasting for a few
minutes every time and there is a likelihood of a burnout of the coil. Hence the magnet
must be periodically so adjusted so that there is no sticking and the magnet is able to pull
the plunger throughout the entire length of the stroke. In other words, after the magnet is
energized, there should be no air gap between the plunger and the inner core of the
magnet. If this precaution is followed, there will be no coil burnout.

Brake Settings For Electro Magnetic Brakes ~
a. Check if the magnet stroke is 20 mm.
b. If not, manipulate adjuster nuts to obtain 20 mm stroke.
c. Make the hand lever release lever ON.
d. Check uniformity of gap between brake drum and shoes. This gap should be 1.5
mm. If not uniform, adjust the shoe clearance adjuster bolts.
e. Make the hand release lever OFF.
f. Press the solenoid lever by hand and confirm that both the shoes clear the brake
drum.
g. Energize coil. In case the magnet hesitates to close, adjust the spring pressure
by adjusting nuts.
h. Solenoid stroke should be reset periodically to the figure given in the instruction
plate to compensate for the wear. The shoe clearance bolt should also be
adjusted simultaneously.

Brake Setting for Electromechanical Brake ~
Please refer to the attached leaflet for operation of this brake. This type of brake is
employed in electric wire rope hoists, CT motion, LT motion, etc. depending on the
design.

Installation and Maintenance of Electro Hydraulic Thruster Brakes ~
The thruster incorporates a motor driven centrifugal oil pump which exerts an upward
thrust on the top cross bar or pin point. Thrusters sent are ready to work after filling
carefully with oil.
Wipe away any dirt accumulated around the oil filter plug in the tank cover. There is also
an oil level plug. Remove both these and fill oil slowly through the filter plug hole until it
overflows through the level plug hole. Replace both plugs and operate the thruster
several times. It will operate in a jerky and irregular manner due to fall of oil level. Repeat
this procedure until smooth operation of the thruster is obtained at repeated operations.
The operations of the thruster having no side overflow plug should have oil poured in until
it overflows from the filler plug hole. Use oil to British Standard 148 Grade B-30. It is
completely satisfactory for operation in ambient temperatures down to 10
0
C.

Bearings ~
All sizes have an internal stator / rotor unit. The top bearing in grease lubricated and the
bottom bearing is splash lubricated from the oil in the sump. The grease lubricated
bearing should run satisfactorily without attention for several years under severe
conditions. Shell Alvania 3 is the suitable grease for lubrication of these bearings in
future.

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FOR ELECTRIC OVERHEAD CRANES
www. e me c h . i n 15

Maintenance ~
Normally the operating oil will not require changing more frequently than once in two
years. It is advisable to check periodically that the oil level is correct, as some
evaporation may take place with a hard worked thruster. When the occasion arises to
drain the oil from the tank, it is only necessary to remove the drain plug at the bottom of
the tank without dismantling the unit. If at any time, dismantling of the thruster is required,
care should be taken that no dirt drops in the tank or remains on the piston or other parts
when the unit is reassembled. Try movement of assembled units by raising the piston in
the cylinder by means of the top cross bar to see that it moves freely.

3. Maintenance of master controller

Isolate the main supply before opening the controller.

Bearings ~
A thin film of acid free grease is to be provided at the pivot points of the roller every
twelve months by means of a thin brush. The cam shaft ends must be provided with the
same lubrication at the same interval. In Joystick master controllers, the grease should
be provided every six months.

Contacts ~
The contact surface will become dark and rough due to arcing but this does not affect the
functioning and contacts are not required to be cleaned. Only if the silver contact facing is
burnt down, should the contact be replaced. TO remove, unscrew the contact stud and
replace with new silver tipped contact stud.

4. Gears

Gears are to be inspected at least once every six months. During a check up, attention
should be paid to the condition of the working surfaces, degree of teeth wear and
correctness of meshing (especially during the first week of gear working). Normally, gears
should not make a sharp noise or knock. It is also necessary to check gear fit on the
shafts. Axial shifting of the gears is not permissible. Gear case flanges should not leak.
The oil level in the case should stay between the notches on the dip stick. The first
change of oil in the gear case is to take place after 150 hrs of operation.

5. Bearings

When checking roller bearings, attention should be paid to their fastening in the bodies,
tightness of covers, condition of packing and lubrication, etc. When normally operated,
bearings should not heat much nor squeak as a result of dirt, insufficient lubrication,
damage of some elements or friction of rotating parts against the body.

6. Wire rope

The reliability and soundness of wire rope for further use should be determined by the
number of broken wires per strand per day. During routine check up, it is imperative to
thoroughly inspect and tighten fastening of rope ends on drum, grab and other places. To
prevent untimely wear of ropes, they should be lubricated with the recommended
lubricant.

7. Travelling wheels

Travelling wheels should not have cracks or worn collar rims. The rolling surface of the
wheels should be clear of hollows and dents.

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FOR ELECTRIC OVERHEAD CRANES
www. e me c h . i n 16
Weekly Crane Inspection Table
Equipment No. Department Crane No. Inspection


Inspection of items ~
1. Check bolts & nuts
a. Fastening bolts of hoist motor
b. Fastening bolts of hoist brake
c. Fastening bolts of hoist gear box
d. Fastening bolts of hoist drum bearing housing
e. Fastening bolts of hoist drum gear
f. Fastening bolts of hoist brake drum lock plate (if on an extended shaft)
g. Fastening bolts of traverse motor
h. Fastening bolts of traverse brake
i. Fastening bolts of traverse wheels
j. Fastening bolts of traverse gear box
k. Fastening bolts of traverse shaft bearings and couplings
l. Fastening bolts of LT motor
m. Fastening bolts of LT brake
n. Fastening bolts of LT gear box
o. Fastening bolts of LT shaft couplings and bearing housing.
2. Condition of girder and end carriage joint bolts
3. Check motor slip rings and brush
4. Switchboard
5. Contact condition of controller tip finger
6. Wire rope
7. Pilot lamp and flood lights
8. Foot brake
9. Current collectors and LT
10. Lubrication

Note
Inscribe O for items found satisfactory
Inscribe R for items requiring repair
Inscribe H for items required by hand

Permissible Wear
Do not use the parts of the cane over the following limits of wear. The parts which are worn out
over these limits should be replaced immediately.

Part Description
Permissible Wear Limits
(Decrease in size)
First pair of gearing 10% of tooth thickness on the PCD
Gears
Other gears 20% of tooth thickness on the PCD
Flanges 50% of full size
Wheels
Tread
30% of full size. When the difference in diameter
between right side and left side wheels exceeds
1.5%, re-machine to rectify.
Sheaves Groove Diameter 50% of wire rope diameter
Brake Lining Thickness 50% of full size
Wire Rope No. of breakages of steel wire
10% of total strands every 300 mm length over
the entire length.

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www. e me c h . i n 17
Annexure A
Details of lubricants and method of application for
Electromech make Electric Overhead Travelling Crane

Interval Recommended Lubricants
Parts to be lubricated
Method of
application Indoor Outdoor IOC HP BPCL

Enclosed Gearing
a) Less than 12 HP
Ambient Temp less
than 50
0
C
Splash A B Servomesh 68 Gervil EP68
Amocan OIL
100

Ambient Temp
greater than 50
0
C
Splash C D Servomesh 68 Gervil EP68
Amocan OIL
100
b) 12 40 HP
Ambient Temp less
than 50
0
C
Splash A B Servomesh 68 Gervil EP68
Amocan OIL
100

Ambient Temp
greater than 50
0
C
Splash C D Servomesh 68 Gervil EP68
Amocan OIL
100
c) Above 40 HP
Ambient Temp less
than 50
0
C
Splash A B Servomesh 68 Gervil EP68
Amocan OIL
100

Ambient Temp
greater than 50
0
C
Splash C D Servomesh 68 Gervil EP68
Amocan OIL
100

Open Gearing Manual E E
Servocoat
120
Hytak
1/N2
Camex
Comp.D

Ball Bearings
Used for motor, limit
switch, controller and other
mechanical equipments
Grease Nipple A B Servogem 2 Lithon 2 MP Grease 2

Plain Sleeve Grease Pump F F Servogem 2 Lithon 2 MP Grease 2

Track Wheel

a) Plain Sleeve
Bearings
Felt
Lubricated
G G Servomesh 68 Gervil EP68
Amocan OIL
100
Grease Pump F F Servogem 2 Lithon 2 MP Grease 2
b) Anti Friction Grease Nipple A B Servogem 2 Lithon 2 MP Grease 2

Sheave & Hook Block

a) Plain Sleeve
bearings
Grease Nipple F F Servorex L1 Plutex 1 Lotex A
b) Anti Friction bearings Grease Nipple A B Servorex L1 Plutex 1 Lotex A
c) Hook swivel Manual G E Servorex L1 Plutex 1 Lotex A

Wire Rope Manual E E Servocoat 120 Hytak 1/N2
Camex
Comp.D

Electrical Parts Manual E E Servomesh 68 Gervil EP68
Amocan OIL
100

Legend :

A Check and lubricate monthly Change after 2000 hrs of operation or every 6 months, whichever is earlier.
B Check and lubricate monthly Change after 1500 hrs of operation or every 3 months, whichever is earlier.
C Check and lubricate monthly Change after 1000 hrs of operation or every 3 months, whichever is earlier.
D Check and lubricate monthly Change after 750 hrs of operation or every 2 months, whichever is earlier.
E Apply monthly or every 200 hrs
F Apply monthly or every 50 hrs
G Apply monthly or every 20 hrs


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www. e me c h . i n 18
Annexure B
What Not To Do

Never move or lift the equipment by the electric cables.
Do not let the equipment drop.
Never modify the equipment until Electromech has studied
and authorized the modifications.
Never modify the values and adjustments of the safety
components, outside the limits provided for in the manual, or
without the approval of Electromech.
Never try to repair or intervene on the equipment (by
welding, etc.) without the authorization of Electromech.
Never shunt the disconnect switches, electric switches,
prevention or limitation equipment.
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.
Never remove the hook safety latch.

Never block, adjust or remove the limit switches or stops to go further to the left or right than
these allow.
Never use the equipment to extract, loosen, or pull sideways.
Never use the equipment to transport people.
Do not touch the moving components.
Do not operate the equipment if your physical condition does
not allow it.
Never use the equipment when in bad repair (wear,
deformation, etc.)
Never use suspect spare parts, or parts whose origin is not
unknown.
Do not subject the equipment to brutal shocks.
Never distract the operator when the equipment is being
operated.
Never leave a suspended load hanging, if it is not necessary.
Never use the equipment as an earth reference for welding.
Do not use the equipment for a purpose or in an area for which is not intended.
Do not expose the machine to an aggressive atmosphere
(temperature, acidity, etc.)
Do not use safety components as operation components.
Do not use the controls needlessly (avoid inching stop
start operation of the buttons). This can cause overheating
and damage the machine.
Never pull the load slantwise.
Make sure that the hook is vertical to the load before lifting it.
Do not use the equipment with a power supply that is
different to the one recommended (under voltage , over
voltage, absence of phase, etc.)
Never transport a load with people nearby.
Do not pass the equipment, with a load, above a person.




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FOR ELECTRIC OVERHEAD CRANES
www. e me c h . i n 19
What To Do

Handle the equipment by its structure, or by the devices
provided for this purpose, or in its original packing.
Store the equipment away from aggressive atmospheres (dust,
humidity, etc.)
Make sure that the machine is always clean and protected
from corrosion (lubricated....).
The equipment should be installed by a technician with the
necessary competence.
Make sure the machine attaching structure is rigid.
Make sure that the safety rules are followed (harness,
clearance of work areas, posting up of instructions to be
followed in the area...)
Neutralize the power sources.
Comply with the distance between the trolley and the runway.
Replace any worn or defective element.
The equipment should be maintained regularly, following the
instructions in the manual.

Regularly check the equipment.
Check that the assembly elements are correctly tightened.
The components should only be replaced by original pars that are compatible with the type of
machine.
Before operation, check that the load is correctly
fastened and slinged.
Make sure that the load is correctly balanced before
moving it.
Pay attention to the centre of the load to be moved.
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.
If manually moving the equipment, push the load.

The prevention instructions to be carried out during the
operations should be well known.

Use the equipment under normal
working conditions (ambient
temperature, atmosphere, etc.).
Equipment used outdoors should be
protected as well as possible against
bad weather conditions.
Notify the authorized persons after a
dangerous operation or if the
equipment seems problematic
(abnormal noise, abnormal behaviour,
etc.)

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