RASHTRIYA ISPAT NIGAM LTD

VISAKHAPATNAM STEEL PLANT

VISAKHAPATNAM

STORAGE, PRESERVATION, ERECTION,

OPERATION AND MAINTENANCE MANUAL

OF DG EOT CRANE- CN-03

90/20 TONNES x 31.55 M SPAN EOT CRANE

FOR CASTING / TUNDISH PREPARATION/ MOULD PREPARATION AISLE (H-J)
OF SMS-2

7.3 MTPA EXPANSION PROJECT

SUPPLY & ERECTION

BY

FURNACE & FOUNDRY EQUIPMENT CO.

Plot No.4, Sub-Survey No.1, Off Saki Vihar Road,
Chandivli farm, Andheri (E), MUMBAI 400 072
 OPERATION & MAINTENANCE MANUAL

INDEX

SR NO. DESCRIPTION PAGE NOS

1.0 GENERAL DESCRIPTION 1

2.0 INSTRUCTIONS FOR STORAGE OF CRANES. 3

3.0 INSTRUCTIONS FOR ERECTION OF CRANES. 3

4.0 COMMISSIONING INSTRUCTIONS 5

5.0 OPERATING INSTRUCTIONS 7

6.0 MAINTENANCE INSTRUCTIONS 13

ANNEXURES

I LUBRICATION CHART 21

II OIL CAPACITIES OF VARIOUS

GEAR BOXES 23

III TROUBLE SHOOTING POINTS 25

IV PERMISSIBLE BACKLASH FOR 29

GEARS & PINIONS
 -1-
1.0 GENERAL DESCRIPTION

1.1 E.O.T Crane:

The Crane moves on the gantry rails fixed on Gantry Girders. The crane has
4 motions namely Main & Aux Hoist, Cross Traverse and Long Travel. Creep
Speed arrangement is provided on all the motions. Hoist and C.T.machineries
are fitted on a common frame called crab / trolley, which moves on rails fixed on
the Bridge Girders.

1.2 Crane consists of the following main parts:

a. Bridge Girders.
b. Bogies.
c. Platforms.
d. Crane Traveling Mechanisms.
e. Trolley & Pulley blocks.
f. Electrical Equipments & Cabin.

1.2.1 a) Bridge Girders:

Bridge girders consists of a welded structure which is composed of double
box girders. These form the main supporting members for all dead and live
loads.

1.2.2 b) End Carriages

These house driving L.T. wheels, and support the Bridge Girders, which in turn
supports the Trolley assembly

1.2.3 c) Platforms:
These provide support for Electrical panels. They provide walking space along
the span of the Crane to attend to maintenance of Crab, L.T.Mechanism &
Electrical Equipment.

1.2.4 d) Crane Traveling Mechanism:

Crane traveling machinery moves the Crane along the track. It consists of:

i. Motors provided at each end of drive girder.

ii DCEM Brakes which apply brake to the motion.
iii Gear Boxes which provide exact speed ratio as required between
motor and L.T.Wheel
 -2-
iv Flexible couplings which transmits the torque from motor to gear
box input and gear box output to wheels.

v Double Flanged Flat Treaded Wheels which move on the gantry rail along
the bay length.

1.2.5 e) TROLLEY / Crab:

Crab consists of following:

1. Hoist Machinery for Main Hoist and Aux Hoist.

2. Cross Travel Machinery.

1. Hoist Machinery for Main & Aux.Hoist

Hoist Machinery consists of the following:-

i) Motors, one for main hoist, One for Aux.Hoist.
ii) DCEM Brakes.
iii) Gear Boxes for Main & Aux. Hoists.
iv)Rope Drums, Couplings etc. for Main & Aux.Hoists.
v) Wire Ropes for Main & Aux.Hoists.
vi) Snatch Blocks for Main and Aux. Hoists.

ii Cross Travel Machinery:

Cross Travel Machinery consists of the following:

i) Motors for CT motion.
ii) DCEM Brakes.
iii) Gear Boxes for CT motion.
iv) Shaft & Couplings.

1.2.6 Cabin

Cabin is provided with Master Controllers for operating various motions of

E.O.T Crane.

1.2.7 Power Feeding

M.S.Angle type Down Shop Leads along with C.I.Current Collectors are
provided for the supply of power to E.O.T Crane.

Power supply to E.O.T Crane is through the main MCCB switch fuse unit
rated for 160 amps. The incoming power supply to the switch is 415 V,
50 Hz, 3 Phase .AC.
 -3-

2.0 INSTRUCTIONS FOR STORAGE OF CRANES.

Crane is to be stored preferably indoor near the site where the crane is to be
erected. However, if sufficient cover space is not available near the erection site,
all Structures like Girder, End Carriages, Platforms and its supports, Gantry
Rails, Brackets, DSL and Hand Railing may be stored out door, but as far as
Possible near to the erection site.

All Electrical Equipments like Panels, Driver’s Cabin, Resistance Boxes etc should
preferably be stored in side the shed, where the Crane is to be erected. However,
if covered space is not available then Electrical Equipment is to be thoroughly
covered with plastic / tarpaulin sheets properly so that no water seeps through.
It is also important to see that these components are stored in a place where there
is no possibility of damage due to site activities.

All main mechanical assemblies like Trolley, L.T. Machinery, Shafts etc., to be
stored in such a way that there is no possibility of damage due to site activities.

These assemblies should preferably be covered in case of areas having heavy rain
fall.

It is imperative to protect the expensive equipment like Electricals and lighter parts
from theft.

3.0 INSTRUCTIONS FOR ERECTION OF CRANES

General:
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 of
construction job should take place on this site while the Crane erection is in
progress. The site dimensions should allow easy handling 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.
 -4-
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 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: 3 ph 50 C/s. A.C. supply

b) 350 A - Welding Transformer.
c) 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. Ref. Annexure-“A”.

iv) The position, spacing and alignment of the main supply conductors
i.e.Downshop 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 carriages 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 carriages 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.
 -5-
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 reeving through the snatch block and the top
block assembly. Wire rope reeving 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. Assemble 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 fully tightening them. This will prevent them
From working loose and falling out since they are not likely to be seen during
Routine maintenance. Ref.Annexure-“B”.

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.

4.0 COMMISSIONING INSTRUCTIONS:

4.1 Pre Commissioning checks:

Check the following point by point, to ensure that the crane is finally ready for

i) The gear boxes are filled with recommended lubricants upto the maximum
level marked on the respective level indicator.

ii) The group lubrication system is functioning properly and that all the
connected points are getting lubricated.

iii) For all other points where individual greasing is required the proper amount
of lubricant is filled manually by a grease gun.

iv) The wire rope is lubricated with the recommended grease.

v) The rotary hoist limit switch contacts are set and operate at the upper and
lower limits of the hook travel. The upper limit contact must operate slightly
ahead of the over-hoist limit switch operation.
 -6-

The over-hoist limit switch provided should be assembled and wired properly. For
gravity limit switch the position of the hanging weight should be such that the hook
assembly, as it raises to the top limit, lifts the hanging weight upwards to operate
the limit switch. Ensure that this hanging weight is properly guided by the idle
ropes from the top sheaves and does not get displaced sideways or sway out.

vi) The lever type limit switches provided for long travel and cross traverse are
properly positioned, wired and are operating smoothly.

vii) Buffers and end stops wherever required are properly assembled.

viii) Rope clamps are properly positioned and tightened.

4.2 Commissioning checks.

The crane is operated by manipulating the control governing each motion.

Before beginning to operate the crane, complete the following preparatory
routine checks.

i) Check all cable interconnections are as per schematic wiring diagrams.

ii) Ensure that no connection is loose.

iii) Carry out insulation resistance test on both power and control circuits.
Insulation resistance shall not be less than 0.5 M ohms and the voltage used
shall be of DC voltage of not less than twice the rated voltage of system
concerned.

iv) Remove power circuit fuses in the Main Panel and switch on the Main
isolator. Test only the control circuit by energizing the various circuits.

v) Switch off the Main Isolator, replace the Power Circuit Fuses in the
Main Panel.

vi) Check, over Load Relay settings for LT Drive and ensure that the same have
been set at 24A.

vii) Switch on power.

viii) Test Power Circuit.

 -7-

5.0 OPERATING INSTRUCTIONS:

5.1 Trail operation

i) One by one operate all the mechanisms of the crane through controllers at NO
LOAD. The operation of all drives are through controllers. Check performance
of the mechanisms, safety services and also ensure that there is no malfunction-
ing of any component or assembly. Closely observe for any abnormal noise,
vibrations, etc.

ii) Repeat the trial with about 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. Check deflection
at 100% rated load.

iii) Hoist 125% rated load and check whether the structure is able to sustain
the load without any permanent deformation.

iv) Record current drawn by motors during each one of the above tests.

Report any abnormalities observed.

Safe Hoisting Practices:

Electric Hoists, Trolleys and Cranes of all types are designed with the safety of the
operating personnel first in mind. Your own safety and that of your fellow
workers will be assured when the overhead material handling equipment is
used as recommended. Disregarding such recommendations endangers life and
property. The following are basic rules worthy of your careful consideration and
attention.

i) DO NOT LOAD BEYOND THE RATED CAPACITY.

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

ii) DO NOT USE ANY OVERHEAD MATERIAL HANDLING EQUIPMENT

FOR HANDLING PERSONNEL.

iii) CONDUCT A PERIODIC VISUAL INSPECTION FOR SIGNS OF

DAMAGEOR 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 destroyed or opened out,
call it to the attention of the safety engineers before loading the hoist.
 -8-

iv) DO NOT USE HOISTING ROPES OR CHAINS AS A SUBTITUTE FOR

SLINGS. Use the slings only. Slings should be of the proper size and type for
load handling. Never use slings showing physical damage of any extent.

v) WHENEVER THE HOIST IS LOWERED IN SUCH A MANNER AS TO

TAKE THE LOAD OFF THE WIRE ROPE. The operator should determine
before making a lift that the wire rope is properly reeved on the drums.

vi) STAND CLEAR OF ALL LOADS. If you travel a load over the heads of
other personnel, give ample warning of your intention before you move.

vii) 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 the operation.
A phase reversal with the block in this position will probably result in damage
to the hoist if the down motion is operated.

viii) BE SURE THAT THE HOIST RAISES AND LOWERS PROPERLY WHEN
THE CORRESPONDING CONTROLLER IS OPERATED. A reversal of
direction indicates a phase reversal in the current conductor, or an interchange
of wires on the controller and 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.

ix) CENTRE THE HOIST OVER THE LOAD BEFORE LIFTING, Do not
sidepull or end pull. When the centre 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.

x) USE PADDING ON THE EDGE OF LOAD IF IT IS SHARP AND

ANGULAR
to prevent damage to the rope. Contact of the wire rope with a sharp
angular edge of the load is unsafe. The wire rope can cut very easily when it
is twisted.

xi) When the straddle angle of the rope slings is large, a larger load than
commonly supposed works on the wire ropes. The limit for this angle
should be kept within 90 o.
 -9-
xii) 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 rope do not become loose. When the ropes become loose,
the next thing to expect is a sudden reversal of the object position which will
cause a very heavy strain on the ropes and possibly make them snap.

xiii) DO NOT DRAG THE LOAD. It is dangerous to assume that a load which
has been safely tied can be dragged. Dragging the load creates higher stress in the
wire to open than when suspending it.

xiv) KNOW THE HAND SIGNALS FOR HOISTING, CROSS TRAVEL AND
LONG TRAVEL. Operators should accept the signals of only those persons
authorized to give them. Do not operate when signals are not clear.

xv) DO NOT LEAVE THE LOAD SUSPENDED IN THE AIR AND

UNATTENDED.

xvi) DO NO JOG CONTROLS UNNECESSARILY. Motors are generally of

high torque. Each start causes an in rush of current much greater than the running
current and leads to overheating and heat failure, or burnout, if continued in
excess.

xvii) When the Crane is to be operated after a long idle period, be sure that it
operates all the motions & try it first without load.

5.2 Crane Driver’s Conduct:

i) Only trained, competent and properly authorized crane drivers are

permitted to operate crane. A Crane driver shall have written knowledge
of English.
ii) Crane drivers must be physically fit, and have good hearing and eye-
sight. A crane driver shall not operate his crane if not physically fit,
but shall report to the medical officer, or other appropriate person
at once.

iii) Crane drivers shall be alert at all times. Sleeping on the job, throwing
pipe, ashes or cigarette butts or spitting, are not permitted under any
circumstances.

iv) They shall familiarize themselves fully with all crane safety operating
instructions, crane mechanisms and its proper care.

v) Extreme care shall at all times be exercised by crane drivers, attendants

and all other personnel working or present on premises where cranes
are located, to avoid contact with any power cables, whether covered
or bare.
 -10-
vi) Rail trucks, cars or other transport vehicles should not be towed by any
crane.

vii) The communication between the crane driver and crane attendant
(slinger) shall be through mutually agreed code of hand signals.

viii) The crane driver is at all times responsible for the safe operation of
his crane.

ix) He shall not leave the controls while the load is suspended from the
crane.

x) He shall not permit anyone to be in any position of the crane while

the crane is performing normal working operation.

xi) Where and when any crane fails to correctly respond to control, the crane
driver shall immediately stop operation and open the power switch and notify
the supervisor. No attempt shall be made to get out of difficulty by repeated
operations of the controls.

xii) In case of power failure, the crane driver shall move all controllers to OFF
position. Report the matter, and await instructions.

xiii) He shall not rely on LIMIT SWITCHES in ordinary working, they are for
emergency only.

xiv) The crane driver shall not tamper with circuit breakers, limit switches,
and/ or other safety devices.

xv) Before closing main switches, make sure that all push buttons are in
“OFF” position.

xvi) All crane movements whilst loads are being handled, maintenance or
repair work done, shall be governed absolutely by the standard operating
signals as given to the crane driver by the person authorized.

xvii) The crane driver shall obey a STOP signal, regard less to who gives it.

xviii) Under no conditions shall any crane driver move a load unless he had
clearly seen and understood the given signals.

xiv) Bumping into run-way stoppers shall be avoided.

xx) All load movements shall be done smoothly without jerking or sudden
stops.
 -11-

xxi) Under no circumstances shall the crane driver attempt to travel any load
until that local area has been hoisted clear of all construction.

xxii) When handling loads approaching maximum rated capacity, the crane
driver shall test the hoist brakes after the first load has been lifted a few Cms
clears of the floor, by placing the push button on OFF position. If the brakes do
not hold, the brakes should be adjusted immediately.

xxiii) While the crane is in motion, crane drivers shall keep their hands on the
controls at all times.

5.3 Floorman’s Standard 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.

i) For Hoisting : Hold upper arm horizontally, palm up and move

forearm upward.

ii) For Lowering: Hold upper arm horizontally, palm down, and move
forearm downward.

iii) For Traveling: 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.

iv) Degree: When degree of extent is 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 is desired.

v) Stop Lowering and hoisting: The previous position of the forearm is

maintained, but the palm is turned over with the forearm in the same
position and motion of forearms stopped.

vi) Stop Traveling: The previous position of the forearm is the same as
that for traveling, but the palm is turned over as in the case of Stop
Lowering and motion of both forearm stopped.

vii) Stop quickly Hold both upper arms horizontally and raise both fore
arms vertically up.
 -12-
viii) Close: The completion of work is shown by putting both arms on
waist.

If the traveling distance or lift is such the 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, the following notes are
sounded before the hand signals are made:

a) Short movement.

b) Continuous movement.

c) Stop.

It is essential that only one man be assigned to the work of signalling. 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.

5.4 Crane Parking.

Before leaving his control position of the crane driver shall at all times ensure
that:-

a) The crane is stopped at the location designated for leaving the crane.

b) There is no load suspended from the hook.

c) All Master Controllers and push buttons are placed in the OFF position.

d) Subject to more specific local instructions, the main power switch in

the crane is locked in the OFF position.

e) Parking brakes are used to lock the crane.

Crane Attendants or Slingers:

1) The crane attendants shall have an adequate knowledge of safe handling

methods.

2) The crane attendants at all times is responsible for the safe slinging and
handling of the load.
 -13-

3) He shall notify his supervisor whenever, and prior to any unusual or

special lifts are to be made.

4) The crane attendant is responsible for ensuring that:

a) Any lifting equipment is not overloaded.

b) All loads are securely slung, and that all sling etc., used are of the
correct size and quality.

c) All loads are moved in such a manner as to clear all obstructions

and are not carried over personnel on shop floor.

d) All piling and stacking is done in a safe and orderly manner.

e) The slack is carefully removed from all slings prior to the load
being lifted and during such process special care taken (when it is
necessary) to steady the slings by hand.

f) Chains, cables and ropes shall be kept free from knots, twists and
kinks.

6.0 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 Crane, but
the most important items may be roughly classified as following:

i) Lubrication.

ii) Inspection and replacement of wearing parts, deforming parts and

deletion of broken parts.

iii) Inspection for loosened fastening parts.

iv) Inspection of contacting parts.

 -14-
6.1.1 Lubrication:

Lubrication, which is as important to a crane as breathing is for a man, must

never be forgotten. Apply the proper amount of oil or grease at proper
intervals. The lubrication chart for cranes is given in Annexure II.

6.1.2 Worn or Deformed and broken parts:

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, refer
clause 6.4 on Page No.19.

At each periodic inspection, consider the amount of expected wear before

the next inspection and repair or replace the part if necessary. Make a table
indicating the initial dimensions and the wear condition to facilitate inspection.

6.1.3 Loosening of Fastened parts:

Loose nuts, etc. may result in serious trouble; inspect all fastened parts (nuts
etc) with special care.

Maximum tightening torque values for bolts are:

M8 165 kg.cm.
M10 330 kg.cm.
M12 580 kg.cm.
M16 1510 kg.cm.
M20 2950 kg.cm
M22 4100 kg.cm.
M24 6000 kg.cm

6.1.4 Contacting parts:

This mainly concerns electrical parts. Always perform hoist, traveling and
traversing operation with no load to check the operating conditions before
starting actual operation with load. At the same time, check the contact
of the electrical equipment.

6.2 DETAILS OF MAINTENANCE:

6.2.1 Motors:
Before mounting the motor maintain the gap properly, check free running of
motor by rotating the shaft. The feet of the motors should be free from dirt and
surface on which motor is to be mounted should be properly cleaned and
leveled. Motor and driven machinery must be aligned for avoiding stresses on
motor bearing and noisy operation. Installation bolts of motor should be secured
properly to the foundation i.e. motor support.
 -15-

Electric 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 terminal box should be
cleared of all dirt and dust.

Bearings of motors should be checked and Washed with petrol and lubricants
should be added every month. It should be noted that the lubricant fills no more
than 2/3 rds of the bearing housing.

6.2.2 Brakes:
Electromagnetic brakes are electrically released and spring set. When coil is
Energized the armatures are attracted together to compress the torque spring
and move the shoes away from the brake wheel. De-energizing the coil allows
the torque spring to separate the armatures and press the shoes against the
wheel, setting the brake thus making it fail safe in the event of power failure.

The heavy duty cast iron brake shoes have treated fabric lining secured with
brass or aluminum bolts. They have large cooling surface and each shoe can be
adjusted independently to compensate for lining wear.

Spare Shoes complete with brake lining can be fitted in few minutes when the
lining in use becomes worn. The worn shoes should be then relined and kept
in readiness for future replacement. Please refer permissible wear chart as per
clause 6.4.

REPLACEMENT OF BRAKE LINERS.

By removing the bolts of the liners, the liners can be replaced after dismantling
the brake shoe. New brake liners shall be fitted by bolts with shoe.

6.2.2.1 INSTALLATION & MAINTENANCE OF DCEM BRAKE:

SETTING OF DCEM BRAKE

a) Magnet Stroke Setting.

Magnet stroke is set by adjusting the tie rod nut. Initially stroke is set 70 to 75%
of maximum stroke. The stroke 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
stroke length required to be maintained. Periodically the stroke length should be
measured, to ensure the same has not been disturbed.
 -16-

b) Shoe Clearance Setting.

Shoe clearance shall be adjusted by rotating shoe adjusting bolt. Recommen-

ded Clearance 0.5 to 1.0 mm.

c) Torque Adjustment

Torque is get by turning the torque adjusting nut clockwise to positive stop and
then backing off to present number of turns to obtain rated torque.

6.2.3 Gear Boxes.

Noise level, leakage and level of oil should be checked once a month.

Gears are to be thoroughly inspected at least once in a Year. During the

checkup care should be paid to the conditions of working surfaces, degree
of teeth wear and correctness of meshing. (per-missible back lash shall be
as per Annexure V). Normally gears should not make a sharp noise or knock.
It is also necessary to check gearfit on the shafts. Axial shifting of gears is not
permissible. The oil level in the case should stay between the notches on the
level indicator.

6.2.4 Bearings:

When checking bearings, care should be paid to their fastening in the bodies,
tightness of covers, conditions of packing and lubrication. 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.

6.2.5 Wire Rope

The reliability and soundness of wire rope for further use should be determined
by the number of broken wires per strand. Refer Cl 6.4 for allowable maximum
number of breakages. During routine checkup it is imperative to thoroughly
inspect and tighten fastening of rope ends on drum and other places.

To prevent untimely wear on ropes, it should be lubricated.

6.2.6 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. Jacks shall be
used at jacking pads in any end carriage to lift it when removing of wheel
is required.
 -17-

6.3 MAINTENANCE SCHEDULE

6.3.1 Proforma as given below should be followed by user:

------------------------------------------------------------------------------------------------
Equipment No. Dept. Crane No. Inspection
------------------------------------------------------------------------------------------------

6.3.2 Weekly Inspection of Items:

i) Check fastening bolts of hoist motors, brakes, gear box, drum pedestal,
hoist drum gear and hoist brake drum, lock plate, if any. Check fastening bolts
of traverse motor, brake, gear box, wheels, shafts, bearing covers and couplings.

ii) Check fastening of LT Motor, brake, gearbox, shaft, coupling, bearing and
its housing.

iii) Conditions of girder and end carriage joint bolts.

iv) Brakes:

DC EM Brakes - Condition of hinged pins, condition of liners, solenoid

gap, fixing bolts, lubrication of pins and whether operation is free from
chatter.

v) Junction Box - Connections for looseness.

Note:
Inscribe ‘O’ for items found satisfactory.

Inscribe ‘R’ for items requiring repair.

Inscribe ‘H’ for items repaired by hand.

6.3.3 Monthly inspection:

i) Gearboxes - Noise level. Leakage of oil, topping up if necessary.

ii ) Lubrication of various parts.

6.3.4 Quarterly inspection.

i) Motor terminal connections.

ii ) Hook - Free rotation of hook, lubrication of moving parts.

iii ) Alignment of motors, couplings, floating shaft, if any.

 -18-

iv ) Electrical Contactor tips, limit switch operating mechanism including

connections.

6.3.5 Annual Inspection:

i) End buffers for CT & LT.

ii) All structural connections, joints and welds condition.

iii) Wheel flanges for wear.

iv) Replacement of lubricants.

v) Wear of brake drums.

vi) 1st stage Gear /Pinion wear.

vii) Check for pitting and wearing of hook.

viii) Hook nut for proper locking.

ix) Rope groove.

x) Contactor tips.

xi) Condition of motors, contactors, isolators, circuit breakers controllers.

xii) Condition of cable.

 -19-

6.4 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.

i) Gears First pair of gearing 2mm

Other gears 3 mm

ii) Wheels Flanges 5 mm

Tread 5 mm

iii) Sheaves Groove dia. 5 mm

iv) Brake lining Thickness 3 mm

v) Wire Rope- No. of breakages of strands a) 8% in dia. rope

b) Total Number of visible broken wires not to exceed 10% of total number of
wires in ropes at any place in length equivalent to 8 dia of rope.
--------X-------
ANNEXURE- 1
LUBRICATION CHART:

Sl.No Part to be lubricated Method of Interval RECOMMENDED LUBRICANT

application
IOC HP BP
01 ENCLOSED
GEARING
A Less than 12HP
i) Ambient Tempr. Less Splash A Servomesh Gear Oil Amocam
than 50 o C SP 320 EP 320 Oil 320
ii) Ambient Tempr. Splash C Servomesh Gear Oil Amocam
More than 50 o C SP 320 EP 320 Oil 320
B 12 to 40 HP
i) Ambient Tempr. Less Splash A Servomesh Gear Oil Amocam
than 50 o C SP 320 EP 320 Oil 320
ii) Ambient Tempr. Splash C Servomesh Gear Oil Amocam
More than 50 o C SP 320 EP 320 Oil 320
C Above 40HP
i) Ambient Tempr. Less Splash A Servomesh Gear Oil Amocam
than 50 o C SP 320 EP 320 Oil 320
ii) Ambient Tempr. Splash C Servomesh Gear Oil
More than 50 o C SP 320 EP 320
02 OPEN GEARING Manual E Servogem Lithon MP
2 EP2 Grease 2
03 BALL BEARING A Servogem Lithon MP
2 EP2 Grease 2
04 PLAIN SLEEVE F Servogem Lithon MP
BEARING 2 EP2 Grease 2
05 TRACK WHEEL
i) Anti- Friction Grease A Servogem Lithon MP
Bearing Pump 2 EP2 Grease 2
ii) Wheel Flange Graphite B
06 SHEAVE & HOOK
BLOCK
i) Plain sleeve bearing Grease A Servogem Lithon MP
Pump 2 EP2 Grease 2
ii) Anti- Friction Grease A Servogem Lithon MP
Bearing Pump 2 EP2 Grease 2
iii) Hook Swivel Grease A Servogem Lithon MP
Pump 2 EP2 Grease 2
 -

07 WIRE ROPES Brush & A Servocoat Hytak-1 Camex

Box 120 Compound
D
08 ELECTRICAL Oil Can G Servomesh Gear oil Amocam
PARTS (PINS) Manual 150 150 oil 150

LEGEND:
A. Check and lubricate weekly. Change after 2000 hrs.of operation or every six months.
B. Check and lubricate weekly. Change after 1500 hrs of operation or every three months
C. Check and lubricate weekly Change after 1000 hrs of operation or every three months
D. Check and lubricate weekly Change after 750 hrs or two months.
E. Apply weekly or every 50 hours.
F. Apply daily or every 8 hours.
G. Apply monthly or every 50 hours.
ANNEXURE -2

OIL CAPACITIES OF VARIOUS GEAR BOXES:

Sl.No. GEAR BOX MIN LEVEL MAX LEVEL ANNUAL

CONSUMPTION
01 MAIN HOIST 140 150 600
02 AUX. HOIST 50 60 240
03 CROSS TRAVERSE 12 14 56
04 LONG TRAVEL 15 17 68
ANNEXURE -3
TROUBLE SHOOTING POINTS

Sl.No. Inspection / Mechanical Possible Consequence Remedy

1 HOOK
a Crack in hook Hook failure Replace Hook
b Crack in surface of hook Development of deep crack Replace hook
and hook failure
c Excessive wear & Hook Failure Replace hook, crane
damage to working area can be used with
(wear over 5% in height) hook in this
condition, subject to
procurement of new
hook immediately
2 PULLEYS
a Uneven wear of pulleys Rapid wear of ropes In case of non-
uniformity of wear is
over 2 mm, replace
pulley. Otherwise
correct the same
pulley surface by re-
machining
b Rope sheaves do not Damage to rope and axle Check bearing
rotate
3 DRUM
a Crack on working Eventual failure of the Replace drum
surfaces of the drum drum
b Wear out of drum surface May lead to breakage of Replace drum
over 10% of drum drum
thickness
c Wear or damage to drum Fall of load Replace drum
coupling
4 WIRE ROPE
a Wire breakage in strands Failure of rope Replace wire rope
b Twisting of rope Eventual damage to rope Eliminate twist on
the rope. Replace
rope if excessive or
correct it
4 BRAKES
a Wear out of brake lining Inefficient braking and Replace lining if rivet
damage to drum is touching the brake
drum
b Breakage or damage to
part of lining
c Excessive wear of hinge
pins
d Heating of drum
e In-efficient braking
f Crack or damage to lever
GEAR BOX
a Breakage of tooth
b Wear of teeth
c Crack in body of gear
d Gear box getting over
heated
e Oil leakage
f Vibration in gear box
COUPLINGS
a Loosening of bolts
b Hole wear out
c Surface cracks
d Key damage
BEARINGS
a Heating of bearing
b Jerky running
c Holding bolts going loose Damage to bearings
WHEELS
Inefficient braking and Replace lining
damage to drum
Improper operation Enlarge holes and
use over size pins
Damage to lining Ensure brake
release is proper
Excessive load slip Correct spring
tension
Brake failure Weld or replace
lever
Jerky operation and further Replace gear or
gear damage repair if damage is
small
Excessive back lash and Replace if wear is
jerky start / stop more than
recommended
Final failure Replace gear
Gear deterioration Replace oil
Gears running dry Apply shellac to
joints. Replace
damaged oil seals.
Tighten bolts
Breaking of shaft or Tighten bolts.
coupling Check alignment
Damage to bolts and Tighten bolts. Use
coupling lock washer
Jerky starts and loosening of Replace coupling
bolts
Ultimate failure Replace coupling
Shearing of key and damage Replace key and
to shaft repair damaged key
way if possible.
Premature failure Ensure lubrication,
check alignment
Failure of bearings Replace bearing
Tighten bolts
a Non uniform wear out of Jerky running and further Turn wheel to
tread damage to wheel uniform size and
surface
b Excessive flange wear Damage to wheel Check wheel & rail
alignment.
STRUCTURE
a Crack in weld Damage to structure Grind out crack and
re-weld. Take DP
test.

ELECTRICAL

1 Main switch (Contactor) Line discontinuity Check voltage in all

in operative three lines / phases.
Main fuse burnt out Replace
Main current collector not Repair or replace
making contact collector
Control Switch defective Check and replace
‘O’ position interlock Bring all
operated controllers to ‘O’
position. If any
contact found
defective replace.
2 Travelling motion is in Discontinuity Check all three
operative phases
Protective device operated Check overload
relay and limit
switches
Defective contact in Check all contacts
controller and replace
defective contact.
3 Hoist or Trolley control Same as point 2 Same as point 2
not operative
4 Mechanism operates in One of the limit switch Check and replace
one direction contact not closing contacts
Controller is connected in Check and rectify
one direction connection

5 Motor fails to start Single Phasing Check fuses and

replace one if burnt.

6 Motor runs in wrong
direction
7 Motor does not develop
sufficient torque
8 Motor heating up
9 Heating of motor bearing
10 Frequent burn out of
controller contact
11 Brake Opening Noisy &
sluggish
Check voltage in all
phases. Check
protective devices.
Defective stator winding Check and correct
as required
Rotor circuit defective Check whether
rotor resistance is
defective. Correct as
required
Supply phase interchanged Correct sequence.
Check limit
switches
Brake not opening properly. Check brake setting.
Adjust brake
clearance and
spring tension
Under voltage Check line voltage
Short circuit in rotor / stator Check phases &
winding correct short circuit.
Dry motor winding
if insulation is low.
Overloading Check line current if
found excessive
correct and rectify
Excessive jogging Avoid excessive
jogging
Low voltage Check voltage and
do not operate it
below permitted
value.
Improper lubrication Clean bearing and
re-lubricate with
proper grease
Low contact pressure Adjust spring
tension
Low voltage Check and rectify
ANNEXURE- IV

PERMISSIBLE BACK LASH FOR GEARS & PINIONS AS PER IS 4460- 1967

MODULE MIN MAX

1.5 0.0 0.10
2 0.08 0.13
3 0.10 0.15
3.5 0.12 0.18
4 0.13 0.20
5 0.15 0.25
6 0.20 0.33
8 0.22 0.40