ELECTRO - FAB

ELECTRO - FAB

ELECTRO FAB - CRANE INDUSTRIES

Add: Sr. No. 58, Plot No. 49B, Sai Industrial Associate, Near Maharashtra Wear House, Nasik Road, Chovisawadi, Charoli (Bk), Tal - Haveli, Dist. Pune - 412105 Ph. No.: 09822593201 / 09822593202 Email: nilesh@electrofabcrane.com, sales@electrofabcrane.com Website: www.electrofabcrane.com

ELECTRO FAB - CRANE INDUSTRIES

User Guide
www.electrofabcrane.com

Impulse Vision : 9822871710

ELECTRO - FAB

ELECTRO - FAB

INDEX

1. About Us

2. History of Crane Design

3. Types of Crane

4. Parts of Crane

5. Operation Instructions

6. Maintenance Instructions

7. Dos and Don'ts

8. Before Making Service Call

9. Test Certificates

ELECTRO - FAB

ELECTRO - FAB

About Us

History Of Crane Design

We envisage Electrofab becoming a world - wide brand leader in its field of operations by consistently delivering world class quality products in the lowest possible lead times. True to this vision, Electrofab 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. Electrofab has made its own

Traveling cranes of the hand operated type were in use in the 1880's. About this time complicated designs of powered motion were offered by English & American builders, involving a driving shaft along the runway and multiple clutches for transferring the power of the driven shaft to the hoist, trolley or bridge motions. The first three-motor electric crane was placed in operation in 1890. J.H. Whiting Founder of Whiting Corporation, built the first three motor Whiting crane in 1898. Early speeds were slow and load ratings limited, with 40 tons maximum. Crane design has changed about every 20 years. 1880 saw the hand powered crane; 1900 the electrically driven crane

ELECTRO - FAB

ELECTRO - FAB

Types Of Cranes

Types Of Cranes

Part A- Overhead Cranes:

This section shows the many types of cranes which are in use today to fulfill the demands of material handling problems. A line drawing, title and brief description of use for each type of crane is given.
Magnet Crane Rugged design for severe service in foundry make-up, scrap and steel storage yards Latticed Girder Recommended for any of the foregoing types of overhead cranes in outdoor service where spans exceed 160 ft.

3-Motion Single Trolley General Service

4-Motion Single Trolley Slow speed main hook for heavy loads; fast speed auxiliary hook for light loads

7-Motion Triple Trolley Three equal or unequal hoists for handling of long rolls in paper mills

2-Motor Double-Hook Trolley Two hooks on same trolley at right angles to bridge girders for special beams and grapples. Hook may be between girders as shown or outside of girders as indicated by broken lines

5-Motion Double Trolley Two equal hoists for handling of long loads at any desired centers

7-Motion Double Trolley Two main hooks for heavy loads at slow speeds, & close approach for fast auxiliary hooks at both sides of building

Trailer Cab The cab is supported from wheels, which run along the bridge rail, and moves with the trolley

Cab-On-Trolley The cab is supported from the trolley frame and is cantilevered beyond the bridge idler girder, opposite the main footwalk

5-Motion Double Trolley One heavy and one light capacity trolley for heavy single load or light, long loads

Bucket Crane Handling coal, refuse, cement, fertilizer & similar materials

ELECTRO - FAB

ELECTRO - FAB

Types Of Cranes
Part B- Gantry Cranes: Part C- Nuclear Plant Cranes:

Types Of Cranes

Deck-Leg Gantry Both tracks at ground level. Trolley travels between legs only

Through-Leg Gantry Both tracks at ground level. Trolley travels through legs on to overhangs which may be at one end or both ends of bridge. Load may or may not be carried through the leg

Polar Overhead Operates on a circular runway located near thespring line of the containment / reactor building

Polar Gantry Same as Polar Overhead Crane, expect that the runway rail is located at or above the operating floor level. This crane usually has a through leg on one end to service the area between the runway rail & the inner wall

Semi-Gantry Deck-Leg One end of bridge on high runway. Trolley travels between upper runway truck and gantry leg only

Semi-Gantry Through-Leg One end of bridge on high runway. Trolley travels from upper runway truck through leg on overhang. Load may or may not be carried through the leg

Dual-Load-Path Trolley Used for handling critical loads, such as nuclear fuel casks to and from the spent fuel pool. This trolley has two independent full load-rated load paths from the fuel cask to the hoist brakes (dual load path hoisting system)

Part D- Special Electric Cranes:

Outdoor Storage Gantry Long span (usually over 150 ft.) and high lift (over 50 ft.) used for storage of bulk material Wall Bracket Crane (fixed) Single-beam boom with under hung trolley and hoist. Used to serve localized area Traveling Wall-Bracket Crane Covers the area near the building columns without obstructions at floor level. Typically used to 10 ton rated load in foundry molding & cleaning bays and structural fabrication shops. Requires special design of columns

ELECTRO - FAB

ELECTRO - FAB

Types Of Cranes

Types Of Cranes

Under Hung Crane. A traveling bridge running on the lower flange or T-rail of two or more runway tracks, usually supported from the building roof trusses

Under-hung Stacker Crane Bridge may be top-running or under-hung, with under-hung trolley on which is mounted a vertically-traveling fork or platform for handling the load. Mast or fork (or both) may also rotate

Single Girder Under-Hung Bridge with under-hung trolley. Hoist of the chain or wire rope type. Ratings to 10 tons

Part F- Jib and Pillar Cranes:

Controlled Mechanical Storage Crane A specialized lifting machine, traveling on a floor-mounted rail(s), usually in aisles between storage racks or bins. Used in automated, warehousing to transfer loads into and out of storage

Under Braced with top-running trolley, doublechannel boom; trolley travel and load size limited by bracing. General purpose use in localized area

Top-Braced Single beam boom with underrunning trolley. Hoist may be of the chain or wire rope type operated by electric or hand power. Used to serve localized area

Part E- Manually-Operated Cranes:

Double Girder Top-Running Bridge with top-running trolley. Ratings to 10 tons

Single Girder Top-Running Bridge with under-hung trolley. Hoist of the chain or wire rope type. Ratings to 10 tons

Floor-Mounted: Single beam boom with under-running trolley. Hoist may be of the chain or wire rope type operated by electric or hand power. Used to serve machine shops and assembly floors

Ground-Mounted Same construction and use as previous crane, expect for base mounting

ELECTRO - FAB

ELECTRO - FAB

Parts Of Cranes
Various Terms / Parts used in cranes are as follow :
Hoisting Motion : Up or Down motion i.e. Lifting or lowering the load. Cross Travel (CT) Motion : Right/Left motion i.e. Moving load Right or Left across the span. Long Travel (LT) Motion : FRD/REV motion i.e. Moving the load Forward or Reverse along the bay length. Span : Centre-to-centre distance between two LT wheels across the crane width. Bay Length : Maximum length of crane traverse (LT Motion). Litt: Maximum height at which load can be lifted (Hoisting Motion). Trolley : In single girder cranes-for moving load across the span (CT Motion). Crab : In double girder cranes- for moving load across the span (CT Motion). End Carriage: For moving the load along the bay length. Girder : It is a main part of crane to which end carriage/crab are attached. > In general, trolley/crab/end carriage have total 4 wheels-gearbox is coupled to two wheels while other two wheels are idle.

Operation Instruction
Inspection before Operation :
Check the following point, to ensure that the Crane is ready for trial operation.

The gear boxes are filled with recommended lubricants up-to the maximum level marked on the respective dipsticks.
lubricant. The rotary limit switch operates at the upper and lower limits of the hook travel.

The centralized / grouped lubrication system, if provided, is functioning properly and that all the connected points getting lubricated. For all other points where individual greasing is required,

Motors : Two types of motors are used in cranes-slipring & compared to conventional motors. squirrel cage. Now a days slipring motors are not used wheels or rope drum incase of hoist. frequently. Except for their maintenance, they are very smooth in operation. Due to availability squirrel cage operation but operates gradually. motors are used now a days. To limit jerks during starting, diameter decides final speed of hoisting motion. because of high starting torque of squirrel cage motors, VFDs are used frequently. Crane duty motors are of special d e s i g n pulleys which are mounted above hook. Gearbox : These are used to reduce motor speed to desired level. Motor is coupled to input side of gearbox & o u t p u t s i d e i s c o n n e c t e d t o

Preparation for Operation :

The crane is operated by manipulating the controllers governing each motion. Before beginning the operation, complete the following preparatory routine. Check all cable interconnections as per wiring diagram. Ensure that no connection is LOOSE. If VFD is provided, check parameter setting as per the list. If required set desired parameters. a) b)

If VFDs provided- switch on MCB in power ckt of one motion at a time. Press Respective PB of the motion.

Trial Operation :

One by one, operate all the mechanism of the Crane by NO LOAD, Check performance of the mechanism and safety device and ensure that there is no malfunctioning of any components assembly. observed for any Record current drawn by motors or during each one of the above tests. Closely abnormal noise, vibrations, etc.
> Report any abnormalities observed to Works for rectification.

Operation Instruction

Operation Instruction

ctices :

ypes are designed with the safety of the operating personal our own safety and that of your fellow workers will be

Tender no circumstances shall the crane driver attempt to tra has been hoisted clear of an obstructions.

competent and property authorized crane drivers are operate overhead traveling cranes. A crane driver shall dge of English.

s must be physically, and have good hearing and eye-sight. r shall not operate his crane if not physically fit; but shall sability to the medical officer or other appropriate person.

When handling loads approaching maximum rated capacity driver shall test the hoist brakes after the first load has been cms clear of the floor by placing the controller in the OFF po brakes do not hold, the load shall be lowered at once and th Floormens Standarad Hand Signals : be adjusted. The determination of a system of operating signals side by sid adherence there to, is strongly recommended from up theand poin For Hoisting : Hold forearm horizontally, palm m upward. downward.

For Lowering : Hold forerarm horizontally, palm down, and

shall be alert at all times. Sleeping on the job, throwing pipe arette butts or spitting from the control cabin or budget e not permitted under any circumstances.
a) b) c)

For Traveling : Hold upperarm horizontally, at the side of t forearm vertically with palm facing the direction of the movem forearm in the direction of movement.

eep their hands free when going up or down saddler.

When a whistle is used, with the signals, the following note are sounded before the hand sign

lothing and other personal belongings shall not be kept in the control position.

Short movement Continuous movement It is essential that only one man be assigned to the work Operation according to signals received from two or more me Crane Parking : Crane is parked at designed location. There is no load suspended from the hook. The hook is raised clear of all obstructions.

miliarize with all crane safety operating instructions, the nism and its proper care.

e shall at all times be exercised by the crane drivers and and all other personnel working or present on premises where cated, to avoid contact with the crane collector wires and/or power cables, whether covered or bare.

Before leaving his control position, the crane driver shall at all times ensure that : a) b) c) d) e) f)

Crane Attendants or Slingers :

r cars or other transport vehicles, shall not be towed by the

The crane attendant shall have an adequate knowledge of s methods. He shall have sound knowledge of knotting, slinging and han a) Any lifting equipment is not overloaded. If there is any doubt t load. b) of the equipment or the weight of the load, this should be i The crane attendant is all time responsible for the safe slingi c) d) ascertained.

ELECTRO - FAB

ELECTRO - FAB

Maintenance Instruction
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.

Maintenance Instruction

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

The above items will be explained in details later but the following, points should be especially be kept in mind to ensure through maintenance.

Lubrication Inspection and repair of wearing parts and deforming parts

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

Lubrication :

Lubrication, which is an important to a Crane as breathing is for a man, must never be forgotten. Apply the proper If the wear or deformation is within a certain limit, the part can still be used. Every wear limit mentioned in the wear Loosening ofthe Fastened Parts: wear limit. table is usable
Worn or Deformed Parts and Broken Parts :

A.C.Electromagnetic Solenoid Oprated Single Phase Brake

Electro Hydraulic Thrust or Oprated Brake

Contacting Parts:

This may concern electrical parts. Always perform Hoisting,

Details of Maintenance :
Motors :

Electrical motors should be protected against drops of water, oil, etc. Terminal boxes should be carefully closed. The electric motor should be periodically inspected and cleaned. Before inspection, the motor and slipring box
Brakes :

You will therefore see that in the event of sticking, it results in some air gap, after the coil has ben energized. It will Brake setting-electro magnetic brakes : therefore continue to draw a heavy current, lasting a few Check if the magnet stroke is 20mm. If not, manipulate adjuster nuts to obtain 20mm stroke. Make the head release lever NO Check uniformity of gap between brake drum and shoes. Installation & Maintenance of Electro Hydraulic.
Thruster :

The thruster incorporates a motor-driven centrifugal oil Installation : Wipe away any dirt accumulated around the oil filler plug in the tank cover. There is also an oil level plug. Remove both
Brake setting - Thruster Brake :

Please refer diagram of EHT brake. In normal case, brake shoe A opens, but to open brake shoe B with A adjust

ELECTRO - FAB

ELECTRO - FAB

Maintenance Instruction
Bearings :

Maintenance Instruction

All sizes have as integral stator/rotor unit; top bearing is Maintenance : grease lubricated and the bottom bearing splash lubricated Normally the operating oil will not require changing more frequently once twono years. is advisable check ster, take than great carein that dust It drops into theto tank or
Master Controller / Cam Controller - Maintenance :
(If provided)
Isolate the main supply before opening the controller

Permissible
First pair of Flang 10% of tooth 20% of tooth
50% of full size.

Bearings :

50% of full size. When the

50% of wire rope diameter

A thin film of cid-free grease is to be provided at the pivot

Contacts :

The Contact surface will become dark and rough due to

Gears :

Brake Lining Wire Rope

50% of full size

Gears are to be inspected at least once every six months. During a check-up, care should be paid to the condition of Bearings : working surface, degree of teeth wear and correctness of When checking roller bearings care should be paid to their fastening in the bodies, tightness of covers, condition of Wire Rope : The reliability and soundness of wire rope for further use
Traveling Wheels :

10% pf total

Traveling Control Panel : wheels should not have cracks or worn collar Control panel should always be closed & locked in order to protect it from dust, water, oil, foreign particles etc. Do not Permissible Wear : remove drawings pasted on inside of doors. Do not play / Do not use the parts of the Crane over the following limits of

ELECTRO - FAB

ELECTRO - FAB

Maintenance Instruction
Sr. No. Part to be lubricated Method of application INTERVAL Indoor
1. Enclosed Gearing: a) Less than 12HP ambient temperature Less than 50c Ambient temperature greater than 50c b) 12 to 40 HP ambient temperature Less than 50c Ambient temperature greater than 50c c) above 40 HP ambient temperature Less than 50c Ambient temperature greater than 50c 2. 3. Open Gearing : Ball Bearing : Used for Motor, Limit Switch, Controller & other Mechanical Equipment. Plan Sleeve Bearing Splash A

Maintenance Instruction
RECOMMENDED LUBRICANTS I.O.C.
Servomesh 50

Gantry Rail Alignment Allowance:

Outdoor
B

HP
Enklo 85 or 120

CALTEX
Catlex Meropa No.4

Splash

Splash Splash

A C

B D

Splash

Splash

C E

Manual Grease Nipple

E B

Servocoat 120 Servocoat 2

Hytak F30 or 300 Lithon Ep2

Catlex Crater No.1 Catlex Multifax No.2

4.

Grease Pump

Servocoat 2

Lithon Ep2

5.

Track Whell : a) Plain Sleeve Bearing

Felt Lubricated or Grease Pump

G F

G F

Servomesh 50 Servogem 2 Servogem 2

Enklo 85 or 120 Lithon Ep2 HYTAK F300

Catlex Cetus Oil

Multi park No.2

b) Antifriction 6. Sheave & Hook Block : a) Plain Sleeve Brg. b) Antifriction Brg.

Grease Nipple

Grease Nipple Grease Nipple Manual

F A G

F B

Soverex L 1 E Mobile Grease SPL Servocoat 120 Servomesh 50

HYTAK F300

Multi park No.2

c) Antifriction Brg.

7.

Wire Rope :

Manual

Hytak F30

Catlex Crater No.1 Catlex Cetus Oil

8.

Electrical Part (PINS) :

Manual

Enklo 85

Legennd : A - Check and lubricate weekly B - Check and lubricate weekly C - Check and lubricate weekly D - Check and lubricate weekly E - Apply weekly or every 50 hours. F - Apply daily or every 8 hours. G - Apply monthly or every 50 hours.

Change after 2000 hrs. of operation or every six months. Change after 1500 hrs. of operation or every three months. Change after 1000 hrs. of operation every three months. Change after 750 hrs. or two months.

ELECTRO - FAB

ELECTRO - FAB

Maintenance Instruction
Permissible Deviation in Crane Alignment : Maintenance Schedule: No.
A) Mechanical: Bolts & Nuts
a b c d e f g h i j Bolts of Hoist/CT/LT motors Bolts of Hoist/CT/LT brakes Bolts of Hoist/CT/LT gearboxes

Maintenance Instruction

Description

Frequency Of Check

3 Months 3 Months 12 Months 6 Months 6 Months 6 Months 3 Months 6 Months 6 Months 12 Months

Bolts of Hoist Drum bearing housing Bolts of hoist drum gear Bolts of CT wheels Bolts of LT wheels Bolts of CT shaft & coupling Bolts of LT shaft coupling & bearing housing Bolts ofgirder & end carriage joints

Greasing of all CT/LT wheels Lubrication/top-up of oio-Gearbox/brakes LT wheel assembly & its movement CT wheel assembly & its movement Condition of brake shoes Brake adjustment Machinery alignment Movement of wire rope pulleys Wire rope for breakage of strands etc B) Electrical: Operation of hoist limit switch Operation of CT/LT limit switch Direction of motion with respect to pendent pushbutton No load current check of all motors Functionally of control logic Brake operation Current collector functionality Visual inspection of wearing out / damage to mechanical parts Noise in all motions Complete No-load test of crane

6 Months 12 Months 6 Months 12 Months 1 Month 3 Months 6 Months 12 Months 12 Months

3 Months 6 Months Daily 12 Months 12 Months Daily 6 Month Weekly Weekly 6 Months

C) D) E)

ELECTRO - FAB

ELECTRO - FAB

DOS And DONTS

DOS And DONTS

AFTER DISUSE. When the crane is to be operated after a long period of the disuse be sure to operate all the motion without load first. Always lift load with slow speed and then with fast speed. While lowering, fast speed is to be used up to certain level, then go to slow speed & then release button. This will avoid falling or slipping of load. This because of delayed operation of thrustor brake. While operating CT or LT motion, always change to slow speed once you approach extreme ends & then release button. This will stop motion exactly where you want otherwise crane will cross the desired position. When VFDs are provided, excessive inching is not allowed. This cause tripping of VFD frequently. Instead use slow speed.

some load carrying parts. Overloading might also start a defect even at less rated capacity in future.

DO NOT LOAD BEYOND THE RATED CAPACITY i.e. DO NOT USE ANY OVERHEAD MATERIAL HANDLING EQUIPMENT FOR HANDLING PERSONNEL. safe working load (SWL). The immediate danger is the p o s s i b l e f a i l u r e o f engineers before loading the hoist

you move.

CONDUCT A PERIODIC VISUAL INSPECTION FOR SIGNS OF DAMAGE OR WEAR. Particular attention should be paid to the wire rope and hook. If there are signs operated of wear of damage or if the hook is distorted or opened out, call it to the attention of the safety been found and corrected. .
meaning less if the load is not supported evenly. DO NOT USE HOISTING ROPES OR CHAINS AS A SUBSTITUTE FOR SLINGS. Use the slings only. Cable or method employed when it is necessary to cut the wire rope. c a FOR i LOAD n HANDLING should nots l on i the nloadg smay move or slip off. s h o u l d WIREh ROPES be kept which be of the proper size and type for load handling. Never use reversal of the object position which will cause a very heavy strain on the ropes and possibly make them snap slings showing physical damage of any extent. creates higher stress in the wire rope then when suspending it.

Look My Capacity

Rest The Load Before You Go

Look A Twist

Never Stand Under The Load

Not Meant For Joy Ride

Avoid Jerks

WHENEVER THE HOIST ISwhen LOWERED IN SUCH A signals of only those persons authorized to give them. Do not operate signals are not clear. DO NOT LEAVE THE LOAD SUSPENDED IN THE AIR AND UNATTENDED. MANNER AS TO TAKE THE LOAD OFF THE CENTER, t h greater e then the running current oandp e r heating, a tor burn o out r if continue to excess. s h o u l d current leads to over determine, before making a lift again, if the wire rope is

Balance The Load Properly

Please Do Not Swing The Load

ELECTRO - FAB

ELECTRO - FAB

Before Making Service Call

No supply in control panel i) Check main switch in ON position. ii) Check fuses in main switches are OK. iii) Check incoming supply to main switch. iv) Check supply in busbars. v) Check availability of supply in the switch feeding busbars. vi) Check current collectors. i) Check position of EM OFF pushbutton. It should be in release or out position. ii) Check control MCBs are in ON position. (Normally MCB 1& MCB2) iii) Check operation of main contactor MC by pressing STA.RT pushbutton. iv) Check individual motion power MCBs are in On position (Normally MCB3, MCB4 & MCB5 For Hoist /CT & LT respectively). v) Check for RED lamp on SPP, if provided. If RED it has tripped due to phase reversal or phase failure. vi) Check contactors A1 & A2 lare ON. If provided, they checks resence of all 3 phases. i) Check all VFD display shows 0. If not, supply at incoming terminals of VFD. ii) By pressing pushbuttons of all motions, check that VFD display shows frequency,either Slow (eg.15) or Fast (eg.50) i) Check cables between VFD & motors are properly connected. If required, check continuity not start. ii) Check that brake is releasing properly after pressing any push button of any motion. i) Check for VFD showing any trip signal. If so, please refer attach sheet for various trip signal & try to rectify problem. ii) Still problem persists, remove coupling between motor & gearbox and also keep brake in loose position. Now check that mo tor is rotating freely by turning the shaft manually. If shaft is jam, call us or send motor for repairing. iii) If VFD indicating trip signal & you are not able to rectify problem, please call VFD service person. It is quite if VFDs are provided & is acceptable. Check contactors, normally D3, D6 & D9 are operating for Hoist/CT/LT respectively.

Test Certificates

Supply present in Control Panel, but does not start any Motion

All above points OK, still does not start any motion VFD display & pushbutton operation OK, but motion does start

Still motion does not start

Humming noise in motor Slow speed not functioning (If VFDs provided) Only one direction working (If VFDs provided) Crane not stopping at extreme ends Brakes not operating properly

Check contactors, normally D1-D2,D4-D6& D7-D8 are operating for Hoist/CT/LT respectively. Check that limit switches operate properly by actuator in case of CT & LT motion. For hoisting check geared limit switch. i) Check oil in brake. ii) Check cable connections iii) Check wearing out of brake shoes/liners. iv) Check thruster for any damage. i) Check exact location of oil leakage. ii) If required change oil seals. iii) Check any damage for housing. i) Check LT wheels for any wearing out. ii) Check rail joints & rail alignment. i) Always follow load lowering instructions mentioned in DOS AND DONTS. ii) Check condition of brake shoes. iii) Adjust brake if required. Check incoming phase sequence. Check incoming phase sequence.

Oil leakage in gearbox/brakes

Noise in LT motion While lowering, load falls down suddenly Hoist Up & Dn limit switch not operating Direction of motion not as per push button