HU1.03.0004en E

MAINTENANCE INSTRUCTION PAGE FILE
MAINTENANCE
HU 1.03.0004 En 1 ( 11 ) INSTRUCTION 1
KCI Konecranes DEPT./HANDLED BY: APPROVED BY: DATE: SOFTW./VERS. LANG. ISSUE
International Plc NVA/ CHD/
J. Kalmi R. Räikkönen 13.01.2001 Word 97/Vertex En E
ERECTION, INSTALLATION AND TESTING OF OVERHEAD

ELECTRIC TRAVELLING CRANES
1. GENERAL
Prior to erection, the building dimensions must be verified. The measurements must correspond
with those shown on the drawings. The clearances must be in accordance with the applied safety
standards. Verify that the crane tracks are within the allowable tolerances.
2. TRANSPORTATION TO THE SITE

2.1 Transportation routes and equipment
Transportation routes, door openings etc. must be checked prior to erection.
Verify the dimensions of the crane parts, the vehicle and the load fixing device.
Take the following precautions in positioning the ropes to avoid damaging the crane parts:
− Protect the edges of box girders so that the flanges will not bounce or deform.
− Use lifting tubes if they are provided with the main girders.
− Balance all parts prior to lifting to avoid uneven loading of lifting devices and hazardous
gliding of ropes.
− If the center of gravity deviates from the centerline of the girder, see figures 1 and 2 (example
on the right) which show alternate methods that may be used to secure the ropes.
2.2 Transportation damages
If the equipment is damaged during shipment or unloading, the consortium is obligated to report
the damages to the seller and shipping company promptly. A written report describing the
location and extent of damages should be prepared with photos.
MAINTENANCE
Figure 1: The lifting of the main girder (with lifting tubes)
Figure 2: The lifting of main girder (without lifting tubes)

A = by one hook
B = by two hooks
MAINTENANCE
Figure 3: Protection of box girder flanges

A = with wood while using lifting tubes
B = with flange protectors
C = with wood when the rope is hung around the girder
MAINTENANCE
3. ERECTION AREA
Reserve an area large enough for the crane parts, transportation vehicles and mobile cranes. This
area is to be fenced in to ensure the safety of personnel not involved with the erection of the
crane. Refer to figure 5 for the space above the crane rails required. Verify that the clearance
between the crane and the ceiling is sufficient. If the clearance is insufficient, the crane must be
erected before the ceiling is laid, or an opening for the mobile crane jib must be left in the ceiling.
3.1 Loads on the erection area
The erection area must be inspected prior to the erection of the crane to verify that the loads
caused by the crane parts, transportation vehicles and mobile cranes are acceptable. Note that
there is a considerable peak load caused by the support legs of the mobile crane.
Figure 4: The erection area required in a typical erection situation

MAINTENANCE
Figure 5: The space required above the crane track level for a mobile crane jib, hook
and lifting ropes
4. ERECTION OF CRANE PARTS BY MOBILE CRANES

4.1 Main girders
4.1.1 Erection with one mobile crane
When operating with one mobile crane, the lifting ropes are to be adjusted to balance the girder.
Position the girder so that it may be lifted straight up to the level of the rail. Attach a guide rope
to the girder. Lift the girder to the proper height. Rotate the girder to the proper position and
lower it onto the rails (Figure 6).
MAINTENANCE
Figure 6: Use one mobile crane to lift the main girder and rotate it to
the proper position
4.1.2 Erection with two mobile cranes

When operating with two mobile cranes, follow the procedure in figure 7. Verify the capacity of
the mobile cranes. If possible, use one crane to lift the girder and the other to guide the operation.
When using only one crane to lift and the other to guide, precautions must be taken so that the
lifting ropes do not slide. If lifting tubes are not available, weld supports onto the lower flange.
Figure 7: Erection with two mobile cranes

1. Raise one end first
2. Move one end above the rail
3. Align the girder
4. Move the girder horizontally to the final position
5. Lower the girder onto the rails
MAINTENANCE
4.2 The cabin, platforms, stairs etc.

The cabin, separate platforms, stairs and similar parts should be assembled prior to lifting the
main girders. Lift the girder to a height which will allow a forklift to be used to fasten the cabin.
Fasten the lifting ropes so that the girder is balanced after the loose parts have been fastened.
Figure 8: Pull the main girders together into the docking position to fasten the end
carriage joints
1. Roller block or roll
2. Ratchet lever
3. Jack or suitable support
4.3 Erection of the end carriages

Follow the appropriate erection method based on the type of crane:
4.3.1 Single end carriage, light crane
Align the end carriages on the floor and fasten them to main girders. Use the torque values given
on the drawing when tightening the bolts. Then lift the crane to the rails.
4.3.2 End carriages with bolted joints
If the entire crane is to be raised with one lift, follow the procedure from section 4.3.1 to
assemble the end carriages.
If the girders will be lifted separately, use the following procedure :
A) Lift both of the carriages onto the rails. The main girders are then lifted separately, and the bolt
joints are fastened.
B) The end carriages may be mounted to the main girders on the ground. The girders are to be
lifted separately (Figure 8).
MAINTENANCE
4.3.3 End carriages provided with joint beam

The main girders are to be lifted onto the tracks separately. Use ratchet levers to pull the girders
together, then lift and mount the beams. It is also possible to join the beams to one of the girders
on the ground and lift them with the main girder.
4.4 Erection of trolley(s)
The trolleys may be mounted on the bridge while it is on the ground if the crane is light. The
trolley(s) must be fastened (i.e. to the buffer stops) while they are being lifted to the proper
position.
If clearances are acceptable, the trolley(s) may be lifted through the bridge girders and rotated to
the proper position.
If clearances do not allow the trolley(s) to be lifted through the girders, the trolley(s) must be
lifted over one girder. Verify that the clearance above the girder is sufficient. Check the outreach
of the crane.
If only one trolley is to be mounted, it may be lifted between the girders before they are
connected. The girders may then be connected and the trolley may be lowered onto the girders.
5. ELECTRICAL CONNECTIONS
The cranes are delivered from the factory completely wired. To prepare the crane for shipping,
remove the conduits at the terminals. The cables and the conduits are marked according to the
wiring diagrams. Follow the wiring diagrams to rewire the controls. Cut the cables to the proper
length when needed and relabel them.
6. INSTALLATION TESTING
6.1 Inspection prior to electrical connection
6.1.1 Mechanical parts
− Inspect the mechanical structures for damage or cracks which may have occurred during
shipping or erection.
− Pay special attention to the flanges of the gears, brakes and motors.
− Check the ropes for damage.
− Check the bolted joints and tighten all loose bolts.
− Check the fastening of all rope clamps.
− Check the adjustment of the brakes.
− Check the adjustment of the hoisting limit switches and travelling/traversing limit switches.
− Remove the temporary corrosion protection from surfaces such as the brake, clutch and trolley
rails.
MAINTENANCE
6.1.2 Lubrication
− Verify the fluid levels in all gear boxes. If necessary, fill to the proper level with the fluid
recommended in the maintenance manual.
− Check grease lubrication of rail wheels, rope pulleys and other moving parts.
− Lubricate all open gears, gliding surfaces, ropes etc.
6.1.3 Inspection of electrical equipment
Inspect the mounting of electrical equipment. Tighten all loose screws. Open all junction boxes,
limit switches etc. to check for damage from corrosion or moisture. If necessary, clean and dry
the equipment. Check all wire connections. Tighten all loose connections. Place all switches in
the OPEN position.
6.1.4 Insulation resistance test
Open the motor terminal strips. Measure the insulation resistance of all motors, brakes and
electrical circuits between each phase and ground using a voltage of 1000 V. All resistance
readings must be at least 5 MΩ. If the reading is less, the wiring equipment etc. must be checked
and corrected to obtain a reading of 5 MΩ.
6.2 Temporary power supply
If the permanent power supply line to the crane is not ready for testing, a temporary power supply
cable may be used. The permanent power supply cable is normally connected to the incoming
terminal of the crane's main switch. The grounding conduit is then connected to the grounding
strip in the same cubicle.
The temporary power supply cable must be protected with fuses with the same rating as the main
fuses on the crane. The temporary cable must have the same current rating as the fuses. If the
cable supplied is long, adjust it such that the initial voltage drop does not exceed 5 % of the
nominal voltage when measured at the main switch terminals.
6.3 Powering up
Verify that all switches are in the OPEN position before turning the power on. Verify that the
main line disconnect switch is protected by the proper fuses. Verify that the proper supply voltage
is used. Verify that the system has been properly grounded. Check that the power comes to the
main switch.
6.4 Testing the electrical circuits
6.4.1 Lighting and heating circuits
Turn on the power for the lighting and heating. Verify that all devices in the circuits are func-
tioning properly.
6.4.2 Control circuits
If a test switch is provided with the crane, switch it on. If a main current safety switch is supplied
with the crane, switch it to the OPEN position. If neither of these safety switches have been
provided, press the STOP button. Switch all controls to the zero position. Turn the power on.
MAINTENANCE
Check the relay functions in the cubicles when adjusting the controls. Test the limit switches by
adjusting them by hand and verifying that the correct relays are functioning in the cubicles.
6.5 No-load test
Release the stop push-button and press the start push-button. The main contact should activate. If
it does not activate, verify that all of the limit switches are off and check the wiring.
Test drive each speed. Begin driving at the slowest speed and check that there are no mechanical
obstacles in the path.
When testing the hoist, make sure that the hook block does not touch the steel construction of the
trolley. If the hook block is already reeved, set the hoist limit switches.
Prior to testing travelling, remove any mechanical obstacles (i.e. steel bars on the rails, air
conditioning tubes or devices, low hanging lamps etc.). When driving to the end limits for the
first time, drive slowly to check the function. Gradually raise the speed.
6.6 Reeving the bottom block
If the bottom block is not reeved, it is to be done after the no-load testing. First, reeve the hoist
rope with a suitable fiber rope as shown in the diagram. Connect the rope to the hoist rope and
then pull it by using the hoisting machinery. After connecting the hoist rope, check and reset the
hoist limit switches if necessary.
6.7 Load test
The crane must be load tested prior to operation. Prepare a report to indicate the test results. After
adjusting the test load, make sure that the load is secure and properly balanced. Raise the load
gradually to specific intervals (such as 1, 2, 4 and 8 feet). Drive downwards and press the stop to
test the stopping and the holding of the hoist brakes.
6.7.1 Overload tests
Test the hoist brakes prior to performing the overload tests. To perform the overload tests, drive
all motions by overload. If static loading is required, lift the test load only a few inches. Maintain
the load at that height for 10 minutes. Lower the test load. If the hoist brakes glide, reset the brake
torque according to maintenance instructions.
Test loads according to various standards
Country Finland Sweden UK Germany Europe

Standard SFS-4261 IKH 8.00.03 BS 466 DIN 15030 FEM
SWL/tons
0 <? 5 1.25 x SWL 1.25 x SWL 1.25 x SWL 1.25 x SWL + 1.20 x SWL
0.25 x load dyn.
5 < ? 20 1.25 x SWL 1.20 x SWL 1.25 x SWL handling device,
if its weight
exceeds 5 % of 1.40 x SWL
SWL
MAINTENANCE
20 < ? 50 SWL + 5 ton 1.15 x SWL 1.25 x SWL static
50 < 1.10 x SWL 1.10 x SWL 1.25 x SWL
SWL = safe working load

6.7.2 Tests by rated load
When testing the crane by rated load, measure the speeds and adjust the steps for use according to
instructions. Adjust the brakes and time relays for travel and traverse so that braking is
comfortable.
6.7.3 Reset of the overload switch
The overload switch is to be reset so that the rated load can be lifted normally. An overload of 3-
5 % should break. Follow the instructions given to reset the overload switch. If the crane is
furnished with a load indicator, adjust it according to the test load which is equal to the rated
load.
7. COMPLETING THE SURFACE TREATMENT

Repair damage to the paint coat as a result of shipping or erection as soon as possible to prevent
further corrosion. Use the appropriate solvent to clean the area to be repaired. Make sure that all
dust, grease, salts etc. are removed from the area. Remove the paint and rust in the damaged area
by using a steel brush or shot blasting for the grade stated according to the paint type. Use the
same method to remove paint in the surrounding area. Use paint which matches the original paint
combination. Apply the paint to the area. Apply multiple coats to match the thickness of the
original paint. Use of a roller is not recommended.

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MAINTENANCE INSTRUCTION PAGE FILE

ERECTION, INSTALLATION AND TESTING OF OVERHEAD

2. TRANSPORTATION TO THE SITE

Figure 1: The lifting of the main girder (with lifting tubes)

Figure 2: The lifting of main girder (without lifting tubes)

Figure 3: Protection of box girder flanges

Figure 4: The erection area required in a typical erection situation

4. ERECTION OF CRANE PARTS BY MOBILE CRANES

4.1.2 Erection with two mobile cranes

Figure 7: Erection with two mobile cranes

4.2 The cabin, platforms, stairs etc.

4.3 Erection of the end carriages

4.3.3 End carriages provided with joint beam

Test loads according to various standards

Country Finland Sweden UK Germany Europe

20 < ? 50 SWL + 5 ton 1.15 x SWL 1.25 x SWL static

50 < 1.10 x SWL 1.10 x SWL 1.25 x SWL

SWL = safe working load

7. COMPLETING THE SURFACE TREATMENT

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