SINGLE GIRDER & DOUBLE GIRDER E.O. T CRANE.

INSTRUCTIONS

FOR THE CARE AND OPERATION

OF

CARRYMORE CRANES

MAUFACTURED BY:-

CARRY MORE CRANES,

3/3 MILE STONE, SOHNA ROAD,
NAGLA GUJRAN, P.O. PALI,
FARIDABAD–121 004. (HARYANA)
PH.: (0129) 2470022, 2480358,
2481092, 3290697
TELEFAX : (0129) 2232975

E-mail : [email protected]
[email protected]
 I N D E X

Page No.

Introduction 01

General Description 02

Characteristics of EOT Crane 05

Erection Instructions 06

Operation Instructions 07

Maintenance Instructions 12

Permissible Wear 18

Lubrication Chart 19
 1. I N T R O D U C T I O N

“CARRY MORE CRANES” is today’s leading name in cranes. Carry

More Cranes will be found working in all parts of the country.
Cranes of wide capacity/ span ranges are regularly manufactured.
The range covers E.O.T. Cranes, Goliath cranes, Grabbing cranes,
and special purpose cranes. Carry More Cranes are built in
accordance with Indians/International Standards and engineered to
meet the exact specification and requirements of the user. Tailor
made for the job; these cranes handle loads with at most ease,
efficiency and economy.

This manual is prepared for providing our clients with

comprehensiv e Instructions for erections, operation and maintenance
of the crane supplies.

However our partnership with our clients does not end with the
installation & commissioning. We go on to provide maintenance,
repair, & modernization services with the goal of reducing client’s
costs.
 GENERAL DESCRIPTION

2. 1 E. O. T Cranes :

The crane moves on the rails, fixed on top of the gantry girders. In this type
generally three motions are incorporated, namely hoist, cross travel and long travel.
At times according to the customer’s requirement Auxiliary Hoist and micro motions
are also incorporated. The Hoist and C. T. machinery are fitted on a common frame
called the “Crab or Trolley” which moves on rails fixed on the Crane Girders.

2. 2 Goliath Cran es :

Goliath or gantry cranes is the one, which travels on rails fixed at ground
level instead of rails fixed at a height as for E.O.T. cranes. These cranes are
mainly used for outdoor duty as in stockyard and Dam sites.

2. 3 Grabbing Cranes :

These cranes are used for handling bulk materials, Fertilizers, Coal, Sand,
Limestone, Gypsum, Clinker, Ore, Grains etc.

2. 4 Component Parts of a Crane :

The crane consists of the following main parts :

A) Bridge girders.
B) End carriages.
C) Platforms.
D) Travel mechanism.
E) Trolley.
F) Cabin.
G) Electrical Equipment.

A. Bridge Girders :

A crane bridge consists of welded Box or composite beam structure, which is

Composed of either a single girder or two girders. These form the main
supporting members for all dead and live loads. The girders carry rails on
which the trolley runs.

B. End Carriages :

These are the two supporting members on which the girders rest. The end
carriages carry the crane wheels.
C. Platforms :

These provide support for the LT machinery, electrical panels, secondary resistors
for the motors etc. They provide walking space along the span of the crane.

D. Travel mech an ism

This consists of :
1. Electric motor.
2. Electro Magnetic or Electro-Hydraulic Thruster Brake.
3. Gear box to give the necessary output speed.
4. LT shafting transmitting the torque from the gear box output shaft to LT
drive wheels.
5. LT wheels held in the End carriages and running on the gantry rails along
the by length.

E. Trolley

The trolley consists of :

a) Hoisting machinery.
b) Traverse mechanism.

a) Hoisting machinery consists of :

I) Motor.(Sq. Cage )
II) EM DC Shoe Type Brake.
III) Gear box.
III) Rope drum & Coupling .
IV) Wire rope.
V) Snatch block.
VI) Rope Pulleys
VII) Rotary Limit Switch
VIII) Brake drum & coupling
b) Traverse mechanism consists of :

I) Motor
II) Electro Hydraulic Thruster Brake
III) Gear box.
IV) Shaft with couplings
V) Wheels
VI) Two way lever type Limit switch
F. Cabin :

The operator’s cabin if provided is suspended either from one end of the
girder, center of the girder or from the trolley. Drum/cam/Master
controllers for each motor are located that he has maximum view of the
working space.

G. Electrical Equipme nt :

In case of a Drum controller operated crane there is only panel called

protective Panel located in the operator cabin. When the crane is “Floor
operated” or “Cabin operated” through master controllers, the contactor
panels for the individual motors are generally located on the Bridge.

Fig. 1. Indicated the nomenclature of crane parts as generally applied

to the cranes. The actual configuration of the crane would be as per the
general arrangement drawing of the unit.

The characteristics of the crane are indicated in this Manual for ready reference.
 CHARACTERISTICS OF E.O.T. CRANE

HOISTING MECHANISMS TRAVERSING AND TRAVELLING MECHANISMS

MA I N A U X. CRA B CRA N E
H OI ST H OI ST
Hoist Cap. Tonnes 15 5 Weight(Tonnes) 8 33 (approx.)
Speeds Speed (m/min)
Main/micro (m/min) 10/1 15/1. Main 40 18
Lift Mtrs 9.25 8.6 Wheel Base ------------ 4200mm
Duty (IS 807/IS 4137) III III Span 21 0 00 m m
Power Supply 415V,3 415V,3 Duty(IS 807/IS 4137) III III
Ph,.50Hz Ph,.50Hz Power Supply 415V 3PH 415V 3PH.
50 C/S 50 C/S
Falls/Dia(mm) 4 / 20mm FMC 4/12mm Buffer Type Spring Spring
6x37 Const. RH FMC Rail Size 60 Lbs /yd CR80
Ungalvanised Wheel Load(T) 16.9 Ton
WIRE ROPE

(IS 2266 ) 180Kg/m

Wheel Dia & Nos. 320mmx4 500 mm x 4
Tensile Strength m2
Tread Width mm. 75mm 100 mm
Breaking Strength.
Total Length 80 Mtrs.
75 Mtrs.
Make. BBL BBL Make ALSTOM ALSTOM
Insulation F F Rating/Insulation. F F
MOTOR

H.P. /RPM. 60 / 980 30 / 975 H.P./RPM. 6 / 950

Motor

2x18 / 970
Sq. Cage Sq Cage SR SR

Make & Type Speedage & Speedage/EHT

Make / Type BCH / DC BCH / DC EHT
BRAKE

Size (mm) & 300 dia 250 dia 150mm dia 200 dia
Size (mm)
Specn. Nos. - . Specn Nos
GEARBOX

Make / Type Carrymore Carrymore Make & Type Carrymore Carrymore

Redn. Ratio. Cranes Cranes Redn. Ratio. Cranes Cranes

Drum dia & Length 580/1600 353/1400 C. T. Conductors Flex. Cable

(mm) D.S.L. Conductors Angle Iron
Input Coupling Platforms Provided.
Output Coupling DSL Insp Cage

Hook Type ---------------- -------------- Limit Switch --------------- ------------------

Sheave Dia(mm)&Nos. ---------------- -------------- SPECIAL FEATURES --------------- ------------------
 3. INSTRUCTIONS OF ERECTION OF CRANES

3. 1 G en eral :

The Instructions given here for the assembly, wiring, testing and
commissioning of the Crane should be carefully followed as good installation will
ensure years of satisfactory and trouble free operation.

Check up the cases, crates etc. forming the consignment. Open each case carefully and check
up the contents as per the packing list. Any shortage or breakage should be reported
immediately so that proper claims could be lodged with the Insurance Co. In case the
consignment has been insured by you, this claim should be lodged by you directly with
intimation to us.

For erecting the crane a clear site should be allotted. No other operation or construction job
should take place on this site while the crane erection is in progress. The site dimensions
should allow easy manipulation of the crane as preparatory stage as well as during the erection.

The person in-charge of erection is requested to go through all the instructions given
here, and should also study the drawings sent along with this manual.

3. 2 Preparatory Work for Erection :

i). Select a space in the bay where the Crane is to be erected. The most suitable
location of erection site is in the span in between Columns. It is advisable to choose
a span which has no horizontal ties between trusses.
ii). Keep all the erection equipment such as derricks, winches, pulley blocks,
slings, tools etc. ready before commencing erection.

The following facilities should be available at the erection site.

a) 415 V - 3ph 50 C/S. A. C. supply.

b) 350 A – Welding Transformer.
c) Oxy – acetylene gas cutting set.

Ensure that all the parts are identified, thoroughly cleaned and kept in
an orderly manner. Look for match marks at every stage of the erection work, so that
the assembly proceeds in the right manner.

iii). Check the gantry rails and ensure that they are in proper alignment. The smooth 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 should be within the permissible
limits. Any abnormal variations must be rectified prior to the erection of the Crane. End
stoppers must be provided at the end of the gantry rails and the rails electrically earthed.

iv) The position, spacing and alignment of the main supply conductors i.e. Down
Shop Leads (D.S.L.) have to be checked with respect to the General Arrangement
drawing. See that the position of the end Carriage carrying the current collector is on
the same side where shop D.S.L are provided.
V) In case the size of the Crane is small and the space and the lifting equipment
permits, then the end carriage and girders may be assembled together on the ground
and the complete assembled structure lifted together and placed on the gantry rails.

If this is not possible, the individual end carriage should be taken up and placed on
either side, gantry rails. They should be properly secured to the gantry girder. Next
the girders are to be taken up one at a time. In case the girder is having joint, it
should be first assembled and joined together on the ground, before lifting.

The girders are then placed on the end carriages and fixed by means of machined bolts.

Place the Crab assembly on top of the girders, In case it is not possible to lift the fully
assembled Crab, the hoisting machinery- Motor, gear box and rope drum, should be
dismantled and the Crab frame with the C. T. mechanism should be lifted in one
piece. Now the hoisting machinery should be reassembled, and wire rope wound on
the rope drum, after riving through the snatch block and the top block assembly wire
rope riving between snatch Block and Top Pulley block should be done in such a way
that reverse fall. If any should be on Equalising Pulley (pulley which does not rotate).

Now fix the platform and Hand railing. Assembling the L.T. Machinery, check the
alignment of the motors, gear boxes and brakes. Weld all loose or tack welded angle
supports and cleats fully. Weld the nuts to the bolts which hold the Platform angles and
supports after tightening them. This will prevent them from working loose and falling
out since they are not likely to be seen during routine maintenance. Where platforms are
of I.S. grating weld locating flats in the slots to prevent them from shifting.

Fix the cabin, panels and Resistance Boxes, ladder, guards, main D.S.L.
Collector bracket and C. T. conductor arrangement. Any site work and welding to be
done as per the drawing, is to be completed now.

Now complete the wiring as per the wiring diagram. Inspect all parts to ensure that
everything is in order.

4. O PE R A T I ON I N S T R U C T I O NS

4. 1 Inspection before Operation :

Check the following, thoroughly, to ensure that the Crane is finally for trial runs.

4.1. 1 The gear Boxes are filled with recommended lubricants, up to the maximum
level marked on the respective dip sticks.
4.1. 2 All points requiring lubrication are well lubricated.
4.1. 3 Open reduction gears wherever used are properly greased with the
recommended lubricant
4.1. 4 The wire rope is properly greased.
4.1. 5 Check buffers, and end stoppers are properly assembled.
4.1. 6 Check all nuts and bolts, especially the girder-end carriage and joint bolts, machinery
foundation bolts, wire rope-clamp bolts, to ensure that they are fully tightened.
4.1. 7 Release the Brakes of each motion manually and ensure that all motion are
free. Set the breaks.
4. 2 Preparation for Operation :

The Crane is operated by manipulating the controllers for each motion. Before
charging the D.S.L. complete the following routine checks.

4.2. 1Check cable interconnections as per wiring diagrams.

4.2. 2Check for loose connections.
4.2. 3Carry out insulation resistance test.
4.2. 4Remove Power Circuit Fuses in the Main Panel, and switch on the main Isolator.
Check the control circuit for proper operation. Operate the controller step by step,
and check the sequence of operation.
4.2. 5 Switch off the main isolator. Replace the Power fuses. Ensure that all the over load relays
are set for the full load currents of the respective Motors, as mentioned on the name plates
4.2. 6 Switch on due Power.
4.2. 7 In case any mechanism is provided with more than one drive, de-couple the Motors and
check their direction of rotation. Ensuring all motors are rotating in the same direction,
couple the motors to the gear boxes.
4.2. 8 Check the direction of each motion, with respect to the movement of the controller handle
4.2. 9 Try all the motion on no load.
4.2. 10 Set all the limit switches and check their functioning.
4.2. 11 Check the brakes and set them.
1.3 Trial Operation :

The Crane is now ready for Load-Testing. Load Test should be conducted as follows :

4.3.1 Check the gantry girder joints and the rail clamping.
4.3.2 Operate individual motions on No-Load. Record the Motor currents.
4.3.3 Take 25% of the rated Load. Operate the motions, record the currents. Follow the
same Procedure by taking 50% load, 75% load and 100% load.
4.3.4 On 100% load record the speeds of each motion.
4.3.5 Position the load at the center. Remove the hook from slings. Take the trolley to one
extreme end. Note down the height from fixed points on the floor at the center of the
span. Now bring the trolley to the center of the span. Sling the load and lift the load to
clear the floor. Once again note the height from the center of the span, to the fixed
point on the floor. The difference in these two readings will give the deflection of the
girder on full load. If this is within the permissible limits, load the Crane to 125% of the
rated load. 4.3. 6 Check all the motions for over load. It is not necessary to record any
readings. only ensure that the individual motions perform under overload conditions.
4.3. 7 From the records, see the currents drawn by each motor and set the overload relay
at this point.
4.3 8 The Crane is now commissioned and ready for Regular Service.

4.4 Safe Hoisting Practices :

E.O.T Cranes are designed with the safety of the operating personnel first in mind. Your
own safety and that of your follow workers will be assured when the overhead material
handling equipment is used as recommended by the manufacturer. Disregarding such
recommendations, endangers life and property. The following are basic rules worthy of
your careful consideration and attention.
4. 4. 1 Do not Load Beyond the Rated Capacity :

The immediate danger is the possible failure of some load carrying parts.
Overloading might also start a defect which could lead to some future failure
even at less than rated capacity.

4. 4. 2 DO NOT USE ANY OVERHEAD MATERIAL HANDLING EQUIPMENTS FOR

HANDLING PERSONNEL.

4. 4. 3 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 of wear or damage or if the hook is distorted or opened out, bring it
to the notice of the safety engineers before loading the hoist.

4. 4. 4 DO NOT USE HOISTING ROPES OR CHAINS AS A SUBSTITUTE FOR

SLINGS. Cable or chain slings should be of the proper size and type for the
load being handled. Never use slings showing damage of any extent.

4. 4. 5 Whenever the hook is lowered in such a manner as to take the load off the wire
rope, the operator should determine, before making a lift again, if the wire
rope is properly wound on the rope drum.

4. 4. 6 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.

4. 4. 7 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.

4. 4. 8 LIMIT SWITCHES ARE FOR EMERGENCY USE ONLY, and should not be
tripped during normal operation. 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 operation. A
phase reversal with the block in this position will probably result in damage to
the hoist if the “down” button or control lever is operated.

4. 4. 9 BE SURE THAT THE HOIST RAISES OR 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 the wires on the push button or controller any of which would cause
the limit switches to be inoperative. DO NOT, UNDER ANY CIRCUMTANCES,
operate the Crane until the fault has been located and corrected.
4. 4. 10 CENTRE THE HOIST OVER THE LOAD BEFORE LIFTING. Do not side pull
or end pull. When the center of gravity is difficult to ascertain, 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.

4. 4. 11 USE PADDING ON THE EDGE OF LOAD IF IT IS SHARP AND ANGULAR

to prevent damage to the rope (sling). Contact of the wire 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.

4. 4. 12 When the straddle angle of the sling is large, a larger load than commonly
supposed, works on slings. The limit for this angle should be kept within 90 o .

4. 4. 13 WIRE ROPES FOR LOAD HANDLING should not be placed on the portion
of the load which may cause them to move or slip off.

4. 4. 14 REVERSING THE POSITION OF AN OBJECT OR LOAD is among the most

dangerous types of operations. 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 several of the object position, which will
cause very heavy strain on the ropes and possibly cause them to snap.

4. 4. 15 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 STRESSES in the wire rope, than when suspending it.

4. 4. 16 KNOW THE HAND SIGNALS, if working with cabin operated Cranes.

Operators should accept the signals of only those persons authorized to
give them. Do not operate when signals are not clear.

4. 4. 17 DO NOT LEAVE THE LOAD SUSPENDED IN THE AIR AND

UNATTTENDED.

4. 4. 18 DO NOT JOG CONTROLS UNNECESSARILY. Hoist Motors are generally

with a high starting torque, and high slip. Each start causes an inrush of
current and leads to overheating and heat failure or burn out, if continued
to excess.

4. 4. 19 AFTER DISUSE: When the Crane is be used after a long period of disuse, be
sure to operate all the motions without load first.
4. 5 Floor man ’s Stan dard Hand Signals

The determination of a system of operating signals side by side with a strict

adherence thereto is strongly recommended from the standpoint of operating
efficiency and accident elimination. Suitable examples are given below for the
Operator’s information.

4. 5. 1 For Hoisting : Hold forearm horizontally, palm up and move forearm upward.

4. 5. 2 For Lowering : Hold forearm horizontally, palm down, and move forearm downward.

4. 5. 3 For Travelling : Hold upper arm horizontally at the side of the body, raise
forearm vertically with palm facing the direction of movement and move
forearm in the direction of movement.

4. 5. 4 Degree : When degree or extent is to be indicated, the motion of the

forearm is reduce (or repeated in small movements) for a slight movement ,
or increased when a greater movement is desired.

4. 5. 5 Stop Lowering : The previous position of the forearm is maintained, but the
palm is turned over with the forearm in the same position.

4. 5. 6 Stop Travelling : The position of the forearm is the same as that for
travelling, but the palm is turned over as in the case of Stop Lowering.

4. 5. 7 Emergency Stop : Hold forearm horizontally in front of the body and swing
rapidly to left and right.

4. 5. 8 Operation : The completion of work is shown by raising both arms horizontally

and lowering both at the same time.

If the travelling distance of lift is so much that the above signals are difficult to
distinguish the entire are 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, the following notes are sounded before the
hand signals are made :
a) Short movement
b) Continuos movement
c) Stop

It is essential only one man be assigned to the work of signaling. Operation according
to signals received from two or more men is extremely dangerous. The operation of
the Crane should also be performed by one man chosen for this purpose.
4. 6 H o w t o S ta r t t h e C ra n e

4. 6. 1 Check Crane and Crane track way for any obstructions.

4. 6. 2 Release all locking devices.
4. 6. 3 Check all lubricating points for required quantity of lubricants.
4. 6. 4 Ensure that no item are lying loose on the Crane and trolley.
4. 6. 5 See that all controllers are in the neutral position.
4. 6. 6 Switch “on” Crane protective gear.
4. 6. 7 Check signal and warning devices.
4. 6. 8 Check brake and limit switches for their proper functioning.

NOW THE CRANE IS READY FOR OPERATION.

4. 7 How to Stop the Crane

4. 7. 1 Run the empty hook and trolley into the specified resting position.
4. 7. 2 Bring the Crane to access point.
4. 7. 3 Set all control gears neutral position.
4. 7. 4 Trip working lights.
4. 7. 5 Trip protective gear.
4. 7. 6 Trip and Itch isolating switch.
4. 7. 7 Lock operators cabin.
4. 7. 8 Actuate locking devices, if any.

N OW T H E CR A N E I S OU T OF O P ER A T I O N .

5. MAINTENANCE :

Service life and operational safety of the crane depend to a large extent on proper
maintenance and lubrication. 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.
All driving parts should be regularly examined for faultless operation. In the event of
unusual sounds or undue heating, the cause is to be investigated and the fault eliminated.

5. 1 General Precautions :

There are many points requiring attention for maintenance of the Crane, but
the most important item may be broadly classified as follow :

5. 1. 1 Lubrication :

Lubrication, which is as important to a Crane as breathing for a human, must

never be forgotten. Fill the proper amount of oil or grease at proper intervals. The
lubrication chart for overhead Cranes is given for reference. The charts are only for
guidance and small variations are permitted to suit local conditions and plant
practices. Lubricants must be clean and stored in dust tight containers.
5. 1. 2 Worn or D eformed Parts and Brok en Parts :

If the wear of 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.

At each periodic inspection, consider the amount of expected wear before the next
inspection and repair or replace the part if necessary. Since the wear limit is specified
as a percentage of the initial dimension is some cases, it is advisable to make a table
indicating the initial dimensions and the wear condition to facilitate inspection.

5. 1. 3 Fasten ers :

Loose nuts etc. may result in serious trouble. Inspect all fasteners like nuts, lock, pins
etc. with special care.

5. 1. 4 Contactin g P arts :

This mainly concerns electrical parts. Every operator while commencing his
days work, should first go round the Crane once for a casual inspection. He should
then operate all the motions without load. Check for unusual sounds. Operate the
controller stepwise, and ensure the Crane is responding normally. If everything is
satisfactory, put the Crane into operation. In case if any unusual thing is noticed,
immediately switch off the Crane and report to the “Maintenance Staff”.

5. 2. D etails of Maintenance :

1) Lu brication :
a) Antifriction Bearing :

These should be completely freed of old grease, the bearing housing rinsed and
filled with clean antifriction bearing grease.

The grease filling should be according to the instructions of the manufactures of

antifriction bearing and should not exceed two thirds of the free inner space.

During lubrication care should be taken, that no dirt gets into the bearing. Antifriction
bearing enclosed in gear boxes do not normally require grease lubrication, since the oil mist
formed inside the gear box provides sufficient lubricating film in the antifriction bearings.

b) Plain Bearings :

Plain bearings are re-lubricated in such a way that the old grease is pressed of the
bearing by the new grease. Re-lubrication should be continued until clean grease
comes out at the face sides of the bearing.

With centralized lubrication. Care should be taken to see that the grease reservoir is never allowed
to remain empty. Further the grease pipes should be checked for clogging or mechanical damage.
5. 2. 1 c) Gear Boxes :

The first oil change for all gear boxes should be carried our after 150 operating
hours. For further oil changes the information given in the lubrication charts, are applicable.
For oil change, the old oil is to be entirely removed and the gear box thoroughly
rinsed, with rinsing oil, which is also to be removed completely, before filling fresh oil.

From time to time the oil level should be checked with the oil level indicator. Oil
level should be maintained at the maximum mark by topping. Under no
circumstances the level should be allowed to fall below the minimum mark.

d). Wire Ropes :

Wire Ropes should always be kept well lubricated to protect them from rust
and abrade. Before applying a fresh lubricant, the strands should be cleaned with
a wire brush. The wire rope should not be cleaned by any grease solvent. When
the rope is clean and dry apply the recommended lubricant by an ordinary paints
brush.

5. 2. 2 Motors :

Electric Motors should be kept clean, and protected against drops of water, oil
etc. terminal covers should be carefully closed. It should be periodically inspected,
for loose connections inside the terminals box, slip ring assembly, carbon
brushes, and in the Resistor Bank while the Motor is running check the bearings
for sound.

When checking the slip ring and brush holders, it is necessary to remove metal
and coal dust from inside the terminal box and end casing. Portable blower should be
used to drive away dust and other foreign particles from inside the casing. The slip
rings should be wiped with cotton cloth. Pitted slip rings may be polished with fine
emery paper, or a light cut can be taken on the lathe machine. When inspecting
the brush solder, it is necessary to check the brush pressure on the rings and
smoothness of arm motions. Worn out and broken brushes should be replaced.

Bearings of motors should be checked and washed with petrol, and the lubricant
changed every 8 to 12 months. Lubricant should be added every 3 to 6 months. It
should be noted that the lubricant fills no more than two-thirds of the bearing housing.

5. 2. 3 Brakes :

The braking torque of the electromagnetic/thrustor brake is produced by the

action of a strong compression spring. When the power is switched on, the brake is
released by the solenoid/thrustor, working against the pressure of the operating
spring. The normal position of the brake is therefore “ON” and the brake will
return to this position if the power fails, or is switched off.
 If spare shoes with brake lining are kept in stock they can be fitted in a
few minutes, when the lining in use worn out. The worn shoes should then be
relined and kept in readiness for future replacement.

The length of the operating spring is set during assembly to give the required torque,
and no subsequent alteration is required. In case this spring requires to be replaced
the brake name plate will indicate the length required to be maintained. Periodically
the spring length should be measured, to ensure the same has not been disturbed.

The A. C . electro magnetic brakes need more attention than either thrustor
operated brakes or D.C. E. M. Brakes. The most common complaint is regarding,
burning of the magnet coils. If this brake is properly maintained and regularly
checked, trouble free service can be achieved.

Burning of coil occurs when the magnet stroke is not maintained up to 20 mm.
When the stroke is more than 20 mm, the magnet coil may not develop sufficient power to
pull the plunger instantaneously. The plunger operation become sluggish and the plunger
may stick in some intermediate position being an A. C. coil, under these circumstances the
air gap gives rise to a heavy current. A few operations in these conditions is sufficient
to burn the coil. For trouble free service, proper maintenance of the brake is essential.

5. 2. 3 (A). Brake setting A. C. Electromagnetic Brakes :

1) Ensure magnet stroke is 20 mm. If not manipulate the adjuster nuts to

obtain 20 mm stroke.
2) Make the hand release lever “ ON”.
3) Check uniformity of gap between brake drum and shoes. This gap should
be 1.5 mm on both sides. If the gap is not uniform, adjust the shoe
clearance adjuster bolts.
4) Make the hand release lever “ OFF ”. Press the solenoid lever manually and
Confirm that both shoe clear the brake drum.
5) Energize the coil. In case the magnet hesitates to close, adjust the spring
pressure by loosening the adjusting nuts.
6) The stroke of the solenoid should be reset periodically to the figure given
in the instruction plate to compensate for wear. The shoe clearance bolt
should be adjusted simultaneously.

(B) Electro Hydraulic Thrustor Brakes :

The Thrustor incorporates a Motor driven centrifugal oil pump which exerts an
upward thrust to the top cross bar or pen point. Thrustor sent out are ready to
work after filling with hydraulic oil to B. S. 148 Grade B –
Wipe away any dirt accumulated around the oil filter plug in the casing. There is
also an oil level plug. Remove both these and slowly start pouring oil through
the filter plug hole until it overflows through the level plug hole. Replace both
plugs and operate the thrustor manually, several times, it will operate in a jerky
and irregular manner due to fall in oil level. Repeat this process until the
thrustor operates smoothly. The thrustor having no side over flow plug should
have oil poured in until it overflows from the filter plug hole.

All sizes of thrustors have an integral stator/rotor unit, the top bearing is grease
lubricated and the bottom bearing splash lubricated from oil in the pump. These
bearing should run satisfactorily without attention for several years under
severe conditions.

Normally the operating oil will not require changing more than once in two
years time. It is advisable check periodically that the oil level is correct. In case
level has gone down top it.

5. 2. 4 Cou pling :

Maximum service life of the flexible couplings can be effected through exact
alignment of the motor gear box, shafting, wheels, rope drum etc. In the event of excessive
wear and tear occurring, the alignment should be checked, and if necessary, realigned
also ensure that in case of gear coupling the same are filled with grease properly.

The normal flexible geared coupling is examined by trying to twist one shaft,
while holding the other shaft. If excessive free play is noticed, it indicates the gear
teeth are worn out and the coupling opened and checked. It is likely that only the teeth
on the bush or the outer casing, or both are worn out. The same should be replaced.

5. 2. 5 Electrical Equipment :

In general the break downs on Cranes are more often on the Electrical side
then the mechanical. Hence your Electrical Equipment need special attention.
The Electrical break downs are more often and are, of a very minor nature, like
loose connection, but they are likely to put off the Carne.

Regular maintenance carried out by trained personnel ensures

unhampered operation.

A. Control Gear :

The control gear, i.e. either, drum controller, cam – controller, master
controllers pendent push button station, should be regularly checked for free
functioning. Also the contacts be in good condition, pitted contacts are likely to
cause single phasing. Keep the contracts clean with CTC and cotton cloth. Avoid
using emery paper. Check the contact springs for proper tension. The rotor of
the controller should be kept well lubricated at the pivot point.
Keep all terminal screws tight to avoid loose connections. Contacts should be
kept covered with a thin film of petroleum jelly (white grease)

B. Con trol Panels :

Panels should be kept clean of dust etc. by regularly cleaning them with
a portable bl ower. Do no t use pa nel s as a locker to kee p to ols etc. Attend the
panels once i n fifte en days. After attending the panels, it is most i mporta nt
to operate the c ontr ol circuit and c heck the co ntractor sequence. Next try all
the moti ons on load, if any found satisfactory hand over for “operati on”.

C. Resistor Bank s :

Check for loose connections. Due to vibrations, it is quite likely that the
grid s may work l oose. This will ca use sp arking, which i n tur n wil l puncture
the mica tub es, o n w hich the grids are stacked. Grids should be ke pt rigid ly
fixed on the racks.
 6. PERMISSIBLE WEAR

Do not use the parts of the Crane 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)

Gears First pair of gearing 10% of tooth thickness on the p. c. d.

Other gears 20% of tooth thickness on the p. c. d

Wheels Flanges 50 % of full size

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 dia. 50 % of wire rope diameter

Brake lining Thickness 50 % of full size

Wire rope No. of breakages of 10 % of total stand per every 300 mm

Steel wires length over the entire length
 7. LUBRICATION CHART

S. No. Part to be lubricated Method of INTERVAL RECOMMENDED LUBRICANTS

application Indoor Outdoor I. O. C. HP CALTEX

1. CLOSED GEARING
a) Less than 12 HP Splash A B Servomesh 140 Enklo 120 Alpha Znn
ambient temperature . 140
Less than 50oc

Ambient temperature
greater than 50oc Splash C D Servomesh 140 Enklo 120 Alpha Znn
140
b) 12 to 40 HP ambient
temperature less than Splash A B Servomesh140 Enklo 120 Alpha Znn
50oc 140

Ambient temperature
Greater than 50oc Splash C D Servomesh140 Enklo 120 Alpha Znn
140
c) Above 40Hp ambient
temperature less than Splash A B Servomesh 140 Enklo 120 Alpha Znn
50oc 140

Ambient temperature
Greater than 50oc Splash C D Servomesh 140 Enklo 120 Alpha Znn
140

2. OPEN GEARING Manual E E Servocoat 120 Hytak F 30 AP-3

3. BALL BEARING Grease Nipple A B Servogem 3 Lithon EP 2 AP-3

2. PLAIN SLEEVE Grease Pump F F Servogem 3 Lithon EP 2 AP -3

BEARIG

7. WIRE ROPE MANUAL E E Servocoat-120 Cardium Compound

LEGED:-

A- Check & Lubricate weekly. Change after 2000 Hours of operation or every 6 Months.
B- Check & Lubricate weekly. Change after 1500 Hours of operation or every 3 Months.
C- Check & Lubricate weekly. Change after 1000 Hours of operation or every 3 Months.
D- Check & Lubricate weekly. Change after 750 Hours of operation or every 2 Months.
E- Apply Weekly or every 50 Hours.
F- Apply Daily or every 8 hours

Caution: - Be careful to keep oil away from the brake linings, electric cables, wires etc.
 TROUBLE SHOOTIG FOR ELECTRIC HOISTS
SL. ATURE OF POSSIBLE CAUSE REMEDY
O. DEFECT
1. Hoist Motor does not A. One of the supply fuse is blown A. check the fuse for all the 3 phases after
start at all. off. the main fuse.

B. Limit switch not making contact B. Move the snatch block in opposite
due to over travel of the snatch block direction to reset the limit switch. If it
in either direction or faulty internal does not reset open the limit switch and
contact assembly /cam. check the contacts. Replace the damaged
contact or cam. Also verify the settings of
the limit switch.

C. O/L relay tripped. C. Check cause of over loading and reset

the relay.

D. Pendent push buttons are not D. Open pendent & click for proper
working. connection & function.

E. Supply voltage too low. E. Take action to correct the voltage.

2. Main Hoist contactors A. Brake does not operate A. Check for brake setting & proper
operate but motor does electrically. function of brake.
not work.
B. Motor defective. B. Check the motor.

C. Loose connections in the control C. Check all connections & tighten.

panel or motor terminals.

D. Jamming in the mechanical D. Check Mechanical parts and rectify the

system. Cause for mechanical jamming.
Relubricate the parts if required.
3. Over heating / A. Bearing worn out. A. Check bearings and change if required.
interruption of motor
B. Overloading B. Check bearings & change if required.

C. Supply voltage too low or too C. Check the load.

high.

D. Wrong star or delta connection of D. Check & correct the connections.

Motor.

E. Loose connections of Power or E. Check the Loose connections.

control circuit.

F. Rotor of motor rubbing with F. Check the Motor and rectify

starter. accordingly.
4. Limit switch does not A. Improper contact of Limit switch. A. Replace the defective contacts.
function.
B. Wrong connection of limit switch. B. Verify the connections with circuit
diagram and correct it.

C. Incorrect of supply. C. Correct the sequence of supply.

5. Motor is noisy. A. Single phasing. A. Check all the three phases for proper
voltage.

B. Bearing worn out. B. Check bearings & replace them.

C. Brake is defective. C. Check the brake for proper operation &

gap.

D. Fan of the motor ribbing with the

fan cover.
6. Brake does not operate. A. Supply voltage to coil is improper. A. Check for proper voltage on coil
(AC/DC).

B. Open circuit in brake coil. B. Change the coil.

C. Brake circuit is improper. C. Re-set brake properly.

7. Brake slips on load. A. Improper setting of brake. A. Change or adjust the gaps of liners as
per instructions.

B. Worn out lining or springs. B. Check brake holding springs, change

them if required. Inspect the condition of
lining if springs are OK.
8. Brake magnet burns. A. Brake magnet coil and armature A. Clean the E section of magnet.
dusty or sticky.

B. Mounting of magnet loose. B. Check all mounting screws of magnet

and tighten them up.

C. Air gap of the armature or disc is C. Set the brake properly.

more non uniform.

D. Armature of the solenoid

misaligned.
9. Brake coil burning out. A. Jamming of brake. A. Check for working of brake manually,
adjust the gap.

B. Supply voltage too low or too B. Check for proper voltage.

high.

C. Frequent inching. C. Avoid unnecessary inching

D. More or non uniform gap of the D. Set the brake properly.

armature.
10. Improper winding of A. Rope guide is not working. A. Check rope guide for proper function.
rope.
B. Rope is over lapping because of B. Avoid pulling load at an angle.
angular load pulling.

C. Hook touching on ground. C. Adjust limit switch accordingly.

11. Motor runs but hoist A. Rigid coupling key sheared off. A. Replace the key.
does not operate.
B. Shaft broken.

C. Coupling has given away.