5Ton Cap SG EOT Crane

GLOBAL ELECTRIC OPERATED CRANE
INSTRUCTION MANUAL
FOR
OPERATION
AND
MAINTENANCE
GLOBAL TECHNOLOGIES
Sy.no 303, Rami Reddy Nagar, Jeedimetla.
Hyderabad-500055
Phone: - +91 9848031866
Email:- info@globalenviro.in
Index
Page No.
1. INTRODUCTION 1
2. GENERAL INFORMATION OF CRANE 2
3. SYSTEM OPERATION 4
4. FUNCTIONAL OPERATION
A. REDUCTION GEAR BOX 6
B. CREEP GEAR BOX 7
C. EHT/DCEM BRAKE 8
D. MOTOR 10
E. WIRE ROPE 25
F. LIMIT SWITCHES 26
G. FLEXIBLE GEAR COUPLING 28
5. OPERATING INSTRUCTIONS 30
A. INSPECTION&PREPARATION
B. PROCEDURE FOR OPERATING CRANE
C. SAFE HOISTING PRACTICES
6. MAINTENANCE INSTRUCTIONS 36
A. GENERAL INSPECTIONS
B. MAINTENACE-ELECTRICAL PARTS
C. MAINTENACE-MECHNICAL PARTS
7. TROUBLE SHOOTING CHART 45
8. SAFETY RULES 50
9. PERIODIC INSPECTION CHART 55
10. DRAWINGS 56
11. SPARES,TOOLS AND TACKLES 74
MANUAL SIGNALS FOR CRANE OPERATION
Global Technology
INTRODUCTION
CRANES
The Cranes manufactured by us are in compliance to IS 3177 to meet Class II

Duty applications. Type of cranes ranging from Single Girder EOT Cranes, Single Girder
Under slung Cranes, Double Girder EOT Cranes, Gantry cranes and jib Cranes etc.
All these Cranes are custom built to the specifications of clients and are fully
manufactured, inspected and tested at our works only. Stringent quality controls at all
levels of manufacturing results in quality cranes to suit the customer’s requirements.
HOISTS
The Hoists manufactured by us are in compliance to IS 3938/1967 to meet Class

II Duty applications. The Hoists are robust, Reliable and ideal for Heavy Duty
applications. Hoist with motorized trolley is recommended for continuous production
units, where travelling of load is essential. Hoist units are driven through squirrel cage
crane duty motor of 'F' Class insulation and are provided with D.C. Electromagnetic
brake for instant stoppage of the unit.
The Hoists are custom built to suit the customer’s requirement like lift, speeds,
end projections, headroom and hook approaches. Controlling of these wide ranging
parameters is the essence for complete satisfaction of customer’s requirements.
Operation & maintenance manual Page 1

Global Technology
GENERAL INFORMATION OF THE CRANES

These are various type of cranes used in industrial application, Some of them Are
defined as below.
1. OVER HEAD TRAVELLING CRANE:-The crane comprising a bridge,

supported by end carriages capable of travelling along elevated tracks. Depending
upon the number of girder the over head travelling cranes can be named as
Double Girder crane, Single Girder Crane.
2. UNDER SLUNG CRANE:-An overhead travelling crane supported for its long
travel motion, from the bottom flanges of the tracks on which it travels.
3. JIB CRANE:-A Crane comprising cross traveling, Hoisting and third motion is
rotation of arm on which hoisting arrangement has been done. The arm of jib
Crane is fixed on column / pillar as a cantilever. It can be rotated about its axis
through any required angle.
4. GOLIATH CRANE:-A crane comprising bridge supporter by leg(s) and capable

of travelling on tracks at ground or deck level. A pillar / Column type structure is
used to move bridge / Box girder at elevated Level.
5. SEMIGOLIATH CRANE:-A Crane comprising a bridge supported by leg and at

the other end carriage(s) capable to travelling along tracks, one at ground or deck
level and other at elevated level.

Global Technology
SYSTEM OPERATION:-
Generally the crane girder is of box type construction with necessary vertical diaphragm.
The ends of girder are noticed to receive the end carriages. The end carriages are
connected to the girders either by welding or through bolts in tow plans. The end carriage
is to welded construction with plates / rolled sections.
The crane platform is laid with anti skid plates / chequered –plates protective hand rails
and toe guards.
In case of single girder Crane the girders can be made from fabrication / rolled sections.
The end of girder has end carriage welded / bolted. The girder flanges have cross
travelling wheels of the hoist. The whole girder with end carriage move on elevated
gantry tracks. The hoist performs the lifting / lowering of load.
The main hoist drive is through motor & reduction gear box. The motor is coupled to
input shaft of gear box through flexible geared coupling. The drum is connected with
output shaft through geared coupling .The geared coupling .The other end is supported on
anti friction bearings. A creep gear box is introduced to attain micro speed while hoisting
.A creep gear box assembly consists of creep box, creep motor , brake drum etc. the
similar functions of hoisting would be incorporated in auxiliary hoist.
For both the hoist the wire rope is fastened on to the drum by wire rope clamps and the
other end is wound round pulley and bottom blocks sheaves.
The cross travel motion has four wheels, two of them being driven on one axle. One of
the wheels is directly connected to output shaft gear box through coupling. The input
shaft of gear box is connected to the motor through coupling. Similarly for long travel
motion four wheels are there, two of them being driven.
Bottom block Assembly houses the lifting hook and rope sheaves. The hook swivels
freely in the bottom block assembly. Depending upon the capacity of crane hook
capacity, Thrust bearing, Sheaves diameter will be selected.

Global Technology
Limit switches are emergency stopping devices. Its functional performances should be
checked to ensure the perfectness of limit switches drive motion slowly through limits
and check the motion to be stopped. Limit switches can be set at required distances to
stop at limiting position.
Power feeding arrangement required to give the supply on various operating parts of
cranes like hoisting motor , long travelling motor , Supply to control panel Etc.There are
many type of power feeding arrangement, Out of these some can be classified as :-
- Taut Wire Type
- Angle Iron type
In taut wire type power feeding arrangement a wire has been taught between tow ends on
which power is to be transmitted. The freely moving trolleys provided on taut wire
carriers the power supplying cable, hence, power is feeded to required Destination.
In Angle iron type power feeding arrangement required length of angle irons have been
fixed between tow ends. The quantity of angle iron depends on the input supply, and
length of travel in our case input is three phase supply, Hence number of angle iron is
four. On these angles one current collector assembly is provided which takes current from
angle iron and supplies the power through cables to required destination.

Global Technology
FUNCTIONAL DESCRIPTION:-
REDUCTION GEAR BOX:-
The gear box is provided to attain specified speed. The reduction in speed from motor to
output shaft through reduction gear box is done in various stages. Depending upon the
reduction ratio, power transmitted, and the reduction gear boxes have been designed.
Number of stages of reduction shall be decided as per reduction ratio.
Reduction gearboxes have all helical gears. The helical gears are very well hardened and
profile grounded. Hence it will give smooth and vibration less operation. These gear
boxes are filled with lubricant up to one third of the total capacity of gear box.
The lubricant used in reduction in reduction gear box is Castrol Alpha SP-220 Gear oil or
any other equipment. Besides this an inspection cover is provided on the top of gear box
to visualize the condition of gear and gearing, an oil level indicator is also provided to
change the lubricant after certain interval. In reduction gear box a breather is provided to
escape all entrapped gasses / air from box when it is in motion.

Global Technology
CREEP GEAR BOX:-
To attain the specified speed reduction gear box is designed. While for attaining micro
speeds a creep gear box is designed. Creep gear box have sun planet type gear
arrangement. As in sun planet gear type arrangements have more reduction ratio hence it
is used to attain micro speed. Generally for creep gear box a separate motor is used to
give input. Creep gear box is grease packed type hence it requires less attention for
lubrication, Creep gear is arranged inside the brake drum box.

Global Technology
EHT BRAKE DCEM BRAKE
Brakes are very important equipment used in material handling equipment it holds the
motion when it is required. In material handling equipments brakes are various types
some of them are classified according to the type of supply, shape of lining, operating
mechanism and are listed below:-
01. ELECTRO MAGNETIC SHOE BRAKE.

02. ELECTRO MAGNETIC DISC BRAKE.
03. ELECTRO HYDRAULIC THRUSTER BRAKES.
This Electromagnetic brake may work on AC or DC supply these brake works on

solenoid principal. When the solenoid is energized an armature which is linked with the
shoe layer apart from brake drum to release the brake .When the supply is cut off the
mechanism comes to its original position under spring action and brake is applied.
Hence the brake is spring applied and it is released by electromagnetic these solenoid
brakes electrically released and spring braking is fail safe device. Depending upon the
shape of lining used the brake may be names as Electromagnetic shoe brake (EM-SHOE)
Electromagnetic disc Brake (EM-DISC). In Electromagnetic brakes the braking is usually
applied to the extended shaft motor. The braking torque of this type brake is easily
adjustable.

Global Technology
In Electro hydraulic thruster (EHT) braking movement given to the brake shoe by
hydraulic mechanism. In EHT a brake braking is done by lifting the Thruster upward and
thereby releasing shoe / brakes against spring force. When thruster is switches off braking
is done through spring force. Thus hydraulic thruster brakes hydraulically released and
spring from applied, hence braking is fail safe type. Thruster of EHT brakes are designed
for the load required in braking, at required torque.
The braking pressure on the shoe is transmitted from the springs by means of an
extremely rigid and simple lever tie rod mechanism. Braking is smooth and positive.
Release of the brake shoes is affected by energizing the 3 Phase thruster which
overcomes the spring force and the shoes are moved clear of the drum by the lever / arm
linkage system.
Owing to the extremely rigid leverage / linkage system there is no dead zone and the
shoes open as soon as the thruster operates the lever. This type of linkage / lever makes
adjustment very simple and assembly of these brakes also much faster.
BRAKE MAINTENANCE / SETTING:-
I) The improved design of the leverage system and the linkage makes it possible
to utilize only a portion (70-75%) of the thruster stroke initially i.e. the time of
commissioning of the brake when the brake lining is new.
II) The angle of the brake shoe being 70 degrees makes the replacement and
maintenance of the brake shoes at site easy
III) The springs are vertically mounted and the setting has been so adjusted that
even an appreciable wear of the lining does not have a marked effect on the
braking torque. If the lining wear is excessive the braking torque under goes a
slight reduction and it can be compensated by resetting the spring to original
value, by means of the adjustment nut which is readily accessible.
The thruster motor is totally o closed B Class insulated suitable for 3 Phase
440V C.50 cycles supply system. The top bearing of the motor is grease
lubricated and the bottom bearing splash lubricated from oil in the tank.

Global Technology
MAINTENANCE INSTRUCTIONS FOR MOTORS

Global Technology

Global Technology

Global Technology

Global Technology

Global Technology

Global Technology

Global Technology

Global Technology

Global Technology

Global Technology
Fig. Description of Motor parts

Global Technology

Global Technology
Fig. Terminal Box

Global Technology

Global Technology
Fig. Terminal Box Dimension Chart

Global Technology

Global Technology
MAINTENANCE OF WIRE ROPE
A steel wire rope is lubricated by rope grease at the time of winding on

drum and not less than twice a month when it is in use.
Uncoiling & Unreeling wire rope
When uncoiling wire rope, it is important that no kinks are allowed to

form, because once a kink is made, no amount of strain can take it out and rope is
unsafe for use. The best method of removing rope from a reel is to mount the reel
on jacks or stands by inserting a shaft through the centre hole. So that the rope is
pulled off in the same manner it was installed on the reel. A turntable may also be
employed (a cart wheel mounted on a spindle for instance) to mount a reel or coil.
This allows the rope to lead with perfect safety.
If a turntable is not available, the coil or rope may be rolled along the
ground. In no case must the coil or reel be laid on the ground on its face and the
rope taken over the end or from the centre of the coil, as kinks will result and the
rope will be completely spoiled. See illustration given bellow
Fig. Uncoiling & Unreeling Wire rope

Global Technology
LIMIT SWITCHES:-
Limit switches are emergency stopping devices or these devices are used generally to
stop the cranes / hoist at its extreme ends. For example .When hoisting limit switches
comes into action hoisting will stop at ground level which will stop further hoisting
downwards and vice versa. Similarly is cross traversing & long travelling.
Contact & all mechanisms of limit switches should be free from dust and dirt one should
inspect the limit switches for its clearances. If required, limit switches can be set for
intermittent positions also.
ROTARY GEAR TYPE LIMIT SWITCH:-
Rotary Geared type limit switches shown in the sketch are used on control and power
circuits of reversing drives so as to limit their rotation / movement within predetermined
operating range.
It basically consists of heavy duty worm gear drive with a ration of 48:1.This worm gear
unit is built in a sturdy cast housing, which is bolted to the main body of limit switch
which is also cast iron. The operating shafts of limit switch, the contacts are shield etc.
Are housed in a duct light, gasket sheet steel enclosure. The body of the contact is made
of high grade material which is suitable for heavy duty.
In all cranes this type of limit switch is normally used to limit motion, if properly
installed, this unit doesn’t require special attention afterwards.

Global Technology
TWO WAY LEVER TYPE LIMIT SWITCH:-
Two / one way limit switch, as shown in the

sketch, Prevents over travel and over traverse
.This type of limit switch normally remains
closed and cuts off power supply to stop the
motor of the crane. This limit switch operates
when it reaches predetermined position, when the
lever is moved over a projecting member fixed on
girder. The limit switch contacts automatically
reset when it return to zero position due to spring
action.
The housing is of strong reinforced sheet steel of heavy gauge, the cam shaft mounted on
moulded bushes of synthetic material. These bush bearing do not require any lubrication.
The cams are also moulded from synthetic material and are accurately out to have an
exceptionally long life.
PENDENT
The pendant push button station is a suspended frame

which moves along with the hoist. Pendant contains push
buttons, indicating light or some other optional items like
emergency switch, key switch etc.The No. of functions
used in pendant can be defined as no. of ways of that
pendant. The push buttons have different functions
depending upon the type of use, For example push buttons
may be used for hoisting up and hoist down, cross
traversing right &left, long travelling forward and
backward, rotation clockwise and anti clockwise ( in case of jib Cranes).the push button
pendant may be of suspended type or may be of fixed type. Depending upon the site
condition pendant would be used. An emergency Stop push button is provided to stop the
crane / hoist in emergency.

Global Technology
FLEXIBLE GEAR COUPLING:-
The fundamental characteristic of

flexible full gear coupling is to provide
smooth and efficient transmissions of
mechanical power, thus offering a
compact assembly capable for higher
torques, higher Speed and
accommodates sufficient flexibility to
overcome misalignment of various
angularity within allowable rating and
permit float.
Fig. Flexible Geared Coupling
CONSTRUCTION FLEXIBLE GEAR COUPLING:
Flexible gear coupling is forged from EN-9/C-55 steel and heat treated to 35-40
RC consist of two identical external teeth hubs, two flanged sleeves with internal teeth
are identical and interchangeable and are connected with each other by forged tempered
alloy steel bolts and nuts in a jig drilled and jig reamed flange hole with provision of ‘O’
ring for sealing of oil/grease, eliminates the necessity of dismantling the hubs from shafts
for changing the oil.
APPLICATION FLEXIBLE GEAR COUPLING:
It can be used effectively and economically for transmission of mechanical power

in industries like- cement, brewing and distilling, food, rolling mills, oil and petroleum,
chemical, fertilizers, paper, rubber, sugar, textile, thermal power and others etc.

Global Technology
BUFFERS:-
Buffers are the device to absorb shocks while impact. Buffers are of various
constructions, but in our case buffers are of rubber type or spring action type. Generally
in long travelling arrangement spring type buffers are used and I cross travelling
arrangement rubber type buffers are used. To attain good efficiency of buffers end
stoppers are provided.
RESISTANCE BOX:-
It consists of corrosion resistant stainless steel in the form of grids. Suitable sizes of wires
are used to give wide range of current ratings. The resistor consist of a continues
resistance wire of uniform section formed into required number of loops and bent so as to
from typical grids. These are than mounted on mica insulated steel rods with mica
washers between steel spares acting as grid separators.
MAINTENANCE OF RESISTANCE BOX:-
i) The resistors should be cleaned monthly at the insulators inserted between
grids and earth.
ii) The terminal bolts and insulated spindles should be checked monthly.
iii) The resistor racks should be checked monthly.

Global Technology
OPERATING INSTRUCTION
INSPECTION&PREPARATION BEFORE OPERATION (DURING

COMMISSIONING):-
GLOBAL Material handling equipments are tested under specified load and adjusted
for proper operation before leaving the factory, it is supplied in assembled / semi
assembled condition and should be unpacked at the place where it is going to be used.
Before the unit is placed in service, there are several items that must be checked to ensure
correct application and avoid service trouble.
1. Check the power supply from specification / G.A drawing of the equipment.
Check the voltage, frequency and phase. The voltage supplied to the equipment
must be same as indicated from specification, otherwise over heating of the motor
will reduce the lifting capacity and result in improper functioning of all electrical
components. Although all individual motors are protected by HRC fuses, Solid-
state / thermal overload relay, single phasing and sequence preventers.
2. Check the tightness of all nuts 7 bolts and screws.
3. Check condition of the wire rope marketing sure it is neither kinked nor thirsted
out to shape, since damage of this kind rendered the rope unserviceable. Also
check the rope fasteners.
4. Check that hook block is undamaged and that all screws & nuts are secure. Check
that hook forging rotate freely.
5. Check that the rope sheaves rotate freely ad are undamaged.
6. Check that the push button station is not mechanically damaged. Check the fixing
of the cable and supporting wires. Test the operation of emerging stop.
7. It is vitally important when applying power to the hoisting motor or the first time
after installation, that correct direction of rotation is obtained from the motor.
8. LIFITING END SWITCHES
Check that the end switch selector stops the hook course on the high and low
extreme positions. If this does not occur, then regulation of the end switch must

Global Technology
take place, following the instructions in the installation, operation and

maintenance manual.
9. CROSS TRAVEL END SWITCHES
Manually check the correct operation of the end switch. The end switch buffer
will be subsequently placed in order to limit the cross travel to the desired length.
10. BRAKES
Check that the brakes are operating correctly on with load and without load.
11. OIL LEVEL
Check the oil level.
12. INSULATION RESISTANCE
This simplest method of checking the condition of motor insulation is to measure
its resistance. That of a dry and clean motor is high .A low resistance is normally
caused by dampness or dirt. If the insulation resistance is not in accordance with
the following instructions, the motor unit must be dried out.Inlow voltage motors,
the resistance should normally be at least 5 M ohm when cold and 1 M ohm when
warm.
13. END STOPS
Check the end and runway stops.
14. BUILDING
Check that there no strange noises or vibrations in the different movements of the
hoist mechanisms.
15. The overload device is normally adjusted to ensure that the hoisting motor is
switched off when the rated load is exceeded by 10%.Check the cut out load by
using a 10% overload, otherwise it will have to be regulated following the
instructions indicated in the point of the installation, operation and maintenance
Manual.

Global Technology
TRIAL OPERATION:-
1. Before operating the equipment, the operator should thoroughly accustom

himself to the working of the various motions. The breaks, limit switches &
performances of controls should be invariably checked up and perfectness
ensured, in case that examination and trails reveal some defect that should be
rectified by the servicing personal. It is not advisable to use the faulty hoist.
2. The above tests should be carried out with no load on the equipment.
Operations must never use the limit switches as a normal means of stopping
the motion, limit switched are emergency devices only. The operator should
check the working and setting of hoist limit switches after all hoist rope
changes and repairs likely to alter their correct position.
3. Before hoisting a load, the operator should ensure that the load has been
reliably latched and secured on the hook. Before commencing the operation,
he should give a warning signal for all workers to withdraw themselves from
the load to safe distances. The hoisting operation should be stopped when the
load is clear of the floor by a reasonable distance say 200 to 250 mm for the
riggers to ensure that latching of the load is perfect. Do not lift the load unless
you are sure that it is properly suspended from the hook or has been cleared
by the slinger.
4. The load should be hoisted and conveyed in exact conformity with the signals
given by authorized rigger, Signaler or supervisors, only one person should
render the signals to avoid confusion to the operator.
5. Locate the emergency stop push button. The operator should obey the signal
STOP Signal, irrespective of by whom it has been given. In the event of
accident or if the hoist should get out of your control, immediately trip the
circuit breaker / main contractor by means of this emergency stop push button.
6. It is desired to AVOID following practices wherever possible:
a) Leaving a load suspended from the hoist.
b) Hoisting and dragging a long on the cross travel at the same time.
c) Carrying loads over heads of men working on the shop floor.

Global Technology
7. A load whose weight is near about the rated load should be hoisted in two
stages. First lift is to about 2000-3000 mm clear of the floor, check the rigging
and reliability of the brake. Then after ensuring the correctness of rigging ad
efficient performance of the brake the hoisting operation is continued.
8. While the load is being hoisted, conveyed and lowered no one should pull off
the load by hand for turning it, level out the load suing his own weight or
release the holding ropes or slings entrapped in the load falling zone.
9. The hoist should be positioned in such manner that load is lifted perfectly
vertical from the start. It should not be positioned to drag the load with the
hoisting rope inclined.
10. While the load is being hoisted ,conveyed and lowered no one should pull off
the load by hand for turning it level out the load using his own weight or
release the holding ropes or slings entrapped in the load. No one should move
in front of the moving load or in the load falling zone.
11. Never exceed the safe working load and also never run the hoist more than the
safe working period as indicated by class of duty, hoist, which is intended
while ordering the hoist.
12. Further the operator should be alert for:
a. Change in sound, which may indicate a developing, mechanical or
electrical fault.
b. Mechanical faults, such as loose key, coupling, bolts and the like.
These faults may be noticed whilst checking and carrying out the
lubrication of hoist.
c. Excessive side play during runway of hoist on the I-beam.
REPORT ANY IRREGULARITIES TO THE APPROPRIATE DEPARTMENT

WITHOUT DELAY.
13. Do the GO (general overhauling) of hoist as per the schedule GO contains

periodic inspection. Lubrication and minor repairing.
14. When leaving the hoist make sure that all the contractors are in the OFF
position.

Global Technology
PROCEDURE FOR OPERATING CRANE:-
GENERAL: When an operator resumes the duty the very first thing he has to do is to
carry out the daily inspection procedure. Never use the hoist if it is not in perfect
condition, but report the matter to the concerned supervisory staff member or executive.
DURING OPERATION:-
01. Ensure that the load is vertically below the hoist in case of fixed hoist. If the hoist
is provided with the trolley bring the trolley just above the load. If the load is
much away from the centre line of the monorail push it manually towards the
centre line until it is placed exactly below the hoist. Dragging of the load on floor
by hoist is to be avoided.
02. Ensure that the load is securely slung on the hook and it should be free i.e., it is
not anchored on the ground or stayed to any other object or to building structure.
03. Lift the load just above the floor to ensure that it is well balanced. If it is not well
balanced, lower it and adjust it for the balance. RAISE it again about a few
centimeters above the floor and cheek the hoist brake to ensure its perfectness.
04. If the brake is provided with trolley, then traverse the load both ways and test the
performance of the trolley brake. If this brake has ensured its perfectness then the
hoist is ready for use. While rising further, check up the spoiling of the rope on
the drum and its smoothness.
05. Avoid impact loading caused by sudden lifting or lowering ,Raise the load slowly
to tension the rope gradually and avoid swinging of the load .This can be done by
inching the control before subjecting the hoist normal / maximum speed. Sudden
hoisting or lowering may cause breakage of wire rope.
06. Do protect wire rope, hook from weld spatter.
07. AVOID running of hoist more than safe working period.
08. DO NOT lift the load with excess sling rope hanging loose.
09. DO NOT allow anyone to ride on a load being handled.
10. ABIDE all signals given signalman.(Refer handle signal chart)

Global Technology
AFTER COMPLETING THE HANGLING OF LOAD:-
When the hoist id idle or when the operator leaves the hoist he has to do:-
(a) Lower off all loads.

(b) Raise the hook to its highest position.
(c) Place all controls in off position.
(d) Place main switch off, if any and lock the switches box.
SAFE HOISTING PRATICES:-
Being familiar with the equipment and our safe operating practices, is an extremely
important factor in minimizing the possibility of personal injury to the operator, those
working in the same area, and preventing damage to property, the equipment and other
materials.
Hoists and trolleys are designed for lifting and transporting material only. Under no
circumstances, either during initial installation, or in regular use, are hoists to be used for
lifting or transporting personnel.
No operator should be permitted to operate the equipment that is not familiar with its
operations or has not been trained in the safe operating practices. The misuse of hoists
can lead to certain hazards which cannot be protected against by mechanical means
hazards can only be avoided by the exercise intelligence, care and common sense.
Safe operating practices also involves and programme of periodic inspection and
preventative maintenance (covered in a separate section).part of the operators training
should be an awareness of potential malfunction / hazards requires, and bringing these to
the attention of the supervisor for corrective action.
Supervision and management also have an important role to play in any safety program,
by ensuring that maintenance schedules are suitable for the job intended, without
violation of any of the rules covering safe operating practices or good common sense.

Global Technology
MAINTENANCE INSTRUCTIONS:-
GENERAL PRECATIONS:-
Maintenance and inspection are not only important for safe operation but also govern the
efficiency and services life of the crane.
In general precautions there are many points requiring attention for maintenance of the
cranes but the most important points are classified as following.
i) Lubrication
ii) Inspection & replacement of wearing parts.
iii) Inspection for loosened fastening parts.
iv) Inspection of electrical parts.
LUBRICATION:-
Is the most important maintenance tool. Apply proper amount of oil or grease as
specified in the next chapter.
Worn or deformed and broken parts should have very much attention in maintenance.
If the wear or deformation found more than the specified limit as specified below, the
part should be changed.
PERMISSBLE WEAR:-
Do not use the parts of the crane of the crane / hoist over the following limits of worn.
The parts are worn out over these limit should be replaced immediately.
PART DESCRIPTION PERMISSIBLE WEAR LIMIT

Gears Backlash is first pair of gearing 0.5mm
backlash is pair of gearing

Global Technology
Wheels Flanges 0.65mm

Sheaves Groove dia 5 mm
Brake lining Thickness 3 mm
Wire rope No of breakages 8 % in dia total no of visible broken
wires not to exceed 10% of total no
of wires at any place in length
equivalent to 8% dia of rope.
LOOSEN OF FASTENED PARTS:-
May result in serious trouble. Inspect all the fastened parts (nuts, bolts etc.) with
special care. The maximum tightening torque valves for bolts are
M08 50 Kg Cm
M10 100 Kg Cm
M12 180 Kg Cm
M20 800 Kg Cm

Global Technology
MAINTENANCE:-Electrical Parts
Motors:
The feet of the motor 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. Check free
running of the motor by rotating the shaft.
Electric motors should be protected against water, oil etc.Terminal hooks should be
carefully inspected and cleaned. Before inspection the motor terminal box should be
cleared or all dirt and dust.
Bearing of motors should be checked and washed with petrol and lubricants should be
added every three months. It should be noted that the lubricant fill is not more than
the level indicated.
CONTROL PANEL:
(i) The entire power and control terminal should be inspected at least in a month.
Every terminal and connection at switch gears must be fully tight.
(ii) Panel must be cleaned with compressed air to avoid accumulation of
conductive dust and type of dirt.
(iii) Insulation resistance between terminals and earth point should be checked on
monthly basis and any reading less than 0.5mega Ohms shall be disregarded.
(iv) All fixing bolts of switch gears and mounting plate should be checked for
their tightness.
MAINTENANCE INSTRUCTIONS OF CONTRACTORS:-

Bhartia cutler hammer freedom series contractors are suitable for AC 1 to AC 4 duties
(for CR AC 15& DC13 duties as per IEC947-4-1.These contractors can be coupled to
bhartia cutler –Hammer TORI F & TOR –Z series overload relays.
Contractors CE 15 AN to CE15CN have either 3or4 main poles. These contractors

can have built in auxiliary contracts with 3 main poles. The contractors CE15FN have

Global Technology
3 Main poles.By attaching top & side mounted contract Blocks upto 8 additional
Auxiliary contracts circuits may be added to the above contractors.
Add on blocks can be selected to provide configurations of upto 8 normally open or 4

normally closed contact circuit.
INSTALLATION:
The contractors can be mounted on 35mm din rail or directly.Fordirect mounting as
below.
i) Drill 2 M4 Holes for mounting.

ii) Check the current rating & operating coil voltage.
iii) Check operation of moving mechanism manually.
iv) Mount the contractor on the panel by using two M4 screws.
PROCEDURE FOR CHANGING COILS

i) Disconnect cables /wires.
ii) Open side clamps.
iii) Separate top housing and base.
iv) Remove defective coil and replace new coil.
v) Assemble base and housing.
vi) Close side clamps.
vii) Connect cables / wires.
PROCEDURE FOR CHANGING CONTACTS :( Sizes D to F only)

i) Disconnect all cables / wire.
ii) Remove contractor from its mounting.
iii) Open side clamps.
iv) Separate top housing & base.
v) Pull out the fixed contacts.
vi) Separate contact carried easy.
vii) Take out contact springs by compressing.
viii) Till & remove contracts.
ix) Insert new contracts carrier & springs.
x) Assemble contact carrier & housing.
xi) Push in new fixed contracts.
xii) Assemble top housing & base and close the clamps.

Global Technology
MAINTENANCE:-Mechanical Parts
GEAR BOXES MAINTENANCE:
We have developed gear boxes of welded constructions of our hoists. This enables
steel to be used, making a lighter stronger job, compares with cast-iron or cast steel
boxes.
After welding, the boxes annealed and descalled.The gear box is then machined at
one setting for accuracy and finally painted to prevent corrosion.
LUBRICATION OF THE GEARS:
01. It is of great importance to maintain the required level of the lubricant constant,
not only to prevent the wear but also to maintain, silence in operation. The level
of lubricant should therefore, be periodically examined.
02. There is filter plug in every gear box. There is also an oil level indicator in the
form of tapered screw plug or dipstick indication situated within 1/3 to ½ the
casting height from its bottom. The lubricant is to be poured through the filter
plug hole (After removing the plug) until it over –flows through the tapered
indicator plug hole (While removing indication plug). A drop stick may in some
case, be provided on the side of the gear box, for ascertaining the level of
lubrication in the case. The oil should be upto the mark indicated on the dip stick.
03. Every time, before opening the gear box, it should be wiped off thoroughly with a
clean or brush in order to prevent any foreign matter such as dirt or girt, getting
into the getting into the gear box when the lid is being opened for examination.
Even the fillure plug is to be treated accordingly while open in for adding
lubricant.

Global Technology
04. Replacing the gear oil should be done with specified lubricant, however in cold
seasons the fluid might be slightly thicker. It is best to use a funnel for the
purpose.
05. When replacing the use lubricant, drain out the gear case completely wash the
gear teeth and shafts with clean fresh brush,replace the drain plug, pour some
paraffin in the hoist .This will thoroughly clean the gear and at the same time
dislodge any small particle of metal or dirt causing them to sink to the bottom
and to flow out with paraffin when drained off. The gears and shafts are to be re-
examined for cleanliness. If required, repeat the cleaning process with fresh
paraffin .it is better now to repack the ball / roller bearing with fairly thick acid
proof grease to protect the bearings from abrasive action of the particles of metal
which often come of the gears.
06. Never fill the gear box with excess of oil .Too much oil will result in definite loss
of power due to churning action and increase in frictional resistance. Too thick oil
should also not to beused.the golden rule is to use the recommended gear oil to
use as thin oil as possible under the circumstances and replace after maintaining
the required level always.
EXAMINATIONS AND REPLACING OF GEARS:-
01. When the gear box is emptied and thoroughly cleaned with paraffin for replacing
the lubricant oil, examine the gears thoroughly.
02. The sides of the gears tooth should be inspected for wear or burring. Any
appreciable wear is evident if two faces of any tooth are not symmetrical.
03. If the teeth have not been meshing properly there will be lack of parallelism on
the crowns of the teeth. The worn portions of the teeth surfaces will be indicated
by a high polish while on the unworn parts the original grinding or machining
marks will be visible.

Global Technology
WIRE ROPE MAINTENANCE:-
(i) The proper inspection and maintenance of wire ropes is most essential subject
in crane maintenance programme from the view point of SAFETY. The wire
ropes their related components should be thoroughly inspected and maintained
regularly, on schedule.
(ii) As major inspection points special care should be taken of securing rope
anchors and clips, finding out any defect on ropes at socket outlets and
equalizers sheaves if used and performance of rope equalizers, besides
inspecting the normally running parts of ropes to measure were and damages
of wires, deformation of ropes and their strands.
(iii) The wire ropes should be lubricated throughout periodically, taking care not to
miss at socket outlets and equalizer sheaves if used.
(iv) When replacing wire ropes the unwinding of new ropes from reels should be
carried out very carefully to avoid harmful kinks.
WHEN TO DISCARD THE WIRE ROPE:-
Steel wire rope determine during storage as well as in service. The deterioration and
the life of the wire rope depends on factors such as storage handling operation service
conditions maintenance etc.A busy rope will deteriorate faster. Generally accepted
criteria for discarding wire rope in electric wire rope hoists / cranes are appended
below:
01. When the outer wire have become difference in diameter of the portion of the
rope subjected to abrasion e.g. drum lead anchor lead etc.is to be determined by
measurement. The reduction in the two diameters should be exceeding six percent
of the original wire rope diameter.
02. When the rope has been subjected to sever over load or shock load at any stage.
03. When total number of visible broken wires exceed 10% of the total number of
wires in the rope at any portion in a length equal to eight times the diameter of the
rope.

Global Technology
04. When there is evidence of severe corrosion like pitting. Fatigue in conjunction
with corrosion, may affect the safety of the rope even at relatively early stages or
corrosion.
05. When the rope has been subjected to localized distortion damage or kink which
disturbs the balance between the various strands of the rope and various wires in
any strand.
06. When the diameter of the rope has suddenly decreased at any portion, of when the
length of the lay has suddenly increased or decreased.
07. When the core of the rope is collapsed. When the core has collapsed the strands
will tend to flatten out and deformation may the localized.
08. When one / more strands are found broken.
09. When a bird cage is formed anywhere in the length of the rope.
Wire rope must always be kept lubricated to protect them from rust and abrasion. Before
applying a fresh lubricant, the strands must be cleaned by a brush without opening. The
rope should not be cleaned by any grease solvent. When the rope is clean and dry apply
the recommended lubricant by an ordinary paint brush or a soft wire brush.
ROPE INSPECTION:-
For machines in service all running rope should visually inspected each working day for
distortion, kinking crushing unstringing bird caging main strand displacement, core
protection, loss of rope dia in a short length narrowing of rope at any portion of its length
of unevenness of stands general corrosion broken wire or strands core failure etc.On the
rope only surface layers are needed to be examined. No attempt is to be making to open
the rope. End connections of the rope should be examined for damage of corrosion. The
inspections are for evaluating whether more detailed inspection of the rope or discarding
of the rope is needed.

Global Technology
SHEAVES AND DRUMS:-
The sound profile of grooves in sheaves and drum is essential for reasonable rope life the
grooves should be inspected periodically and the necessary counter-measure should be
taken if they show unusual signs e.g. excessive wear, scoring by wire rope etc.
The correct and orderly winding of rope on the drum is also essential to prevent the early
failure of wire ropes, therefore any of disordered winding of rope should be eliminated.
WHEEL AND WHEEL ASSEMBLY:-
Generally all wheels are closed die forged from medium carbon steels. The wheel
dimensions have designed according to the type of loading, rail size etc.
As normally wheel treads and flanges wear of by very slow degrees, if excessive wear is
detected in a short period, check the alignment of the wheel and set the distance from
wheel and I beam to ensure proper clearance between wheels & beam.
The wheels treads and should be free from oil, which may cause the wheel to slips.the
wheels are shrink fit to the axles and the driving wheel is coupled to output shaft of gear
box or to motor pinion directly as required.

Global Technology
TROUBLE SHOOTING CHART:-
S.No. DEFECTS POSSIBLE REMEDY

CONSEQUENCE
01.HOOK
1.1 Crack in the hook. Hook failure Replace hook.
1.2 Excessive wear and Hook failure. Replace hook crane operation
damage to working until procurement of hook.
area of hook. (wear
over 5%on height)
02.PULLEYS
2.1 Uneven wear of Rapid wear of rope. If non-uniformity of wear is
sheaves. over 2mm, wise correct surface
by remachining.
2.2 Rope & sheaves do Damage to rope and Check bearing.
not rotate uniformly. axle.
03.DRUM
3.1 Damage on working Eventual failure of the Replace drum.
surface of drum. drum.
3.2 Wear out of the May lead to damage of Replace drum.
drum surface over drum.
10% of wall
thickness.
04.WIRE ROPE
4.1 Breakage of wire is Failure of rope. Replace rope if the breakage is
strands. beyond the 10% of total wire.
4.2 Twisting of rope. Eventual damage to Eliminate reason for twist.
rope.

Global Technology
05.BRAKES
5.1 Wear out of brake Inefficient breaking Replace lining if rivet of part of
lining. and damage to drum. shoe touches the drum.
5.2 Excessive wear of Improper operation. Enlarge holes and put over size
hing pins. pins.
5.3 Heating of drum. Damage to lining. Check brake release and set
proper.
5.4 Inefficient braking. Excessive load slip. Correct spring tension.
5.5 Frequent burning of Brake failure to open. Check for excessive spring
brake coil. tension and correct magnet gap.
06.GEAR BOX
6.1 Breaking of tooth. Jerky operation and Replace gear or repair if
further damages to breakage is small.
gear.
6.2 Wear of tooth. Excessive backlash and Replace if wear is more than
jerky start and stop. 0.5mm.
6.3 Crack in body. Final failure. Replace gear.
6.4 Gear box getting Gear deterioration. Replace oil.
over heated.
6.5 Oil leakage. Gears running dry. Apply shellac to joints. Replace
damaged oil seals tighten bolts
&fill oil.
6.6 Vibration in gear Breaking of shaft or Tighten bolts. Check alignment.
box. couplings.

Global Technology
07.COUPLING
7.1 Loosing of bolts. Damage of bolts and Tighten bolt. Use lock washer.
couplings.
7.2 Hole wear out. Jerky start and frequent Enlarge holes &use oversize
loosening of bolts. bolts.
7.3 Surface cracks. Ultimate failure. Replace coupling.
7.4 Key damage Shearing of key and Replace key and repair keyway
damage to shaft. if damage.
08.BEARING
8.1 Heating of bearing. Premature failure. Replace bearing.
8.2 Jerky running. Failure of bearing Replace bearing.
8.3 Holding bolts going Damage of bearing. Tighten bolts.
loose.
09.WHEEL
9.1 Non uniform wear Jerky running and Turn wheel to uniform size and
to treads. further damage to surface.
wheel.
9.2 Excessive flange Damage of bearing. Check wheel and rail alignment.
wear.
10. ELECTRICAL
10.1 Main Line discontinuity Check voltage in all three lines.
switch(contractor) in Main fuse burnt Check main switch is on or not.
operation Check the entire fuses and
replace burnt fuse.

Global Technology
DEFECTS
1.1 Wear out. Control switch Check the control switches &
defective. replace if defective.
1.2 Mechanism operates One of the limit switch Check and repair limit switch.
in one direction. contacts not closing.
1.3 Motor fails to start. Single phasing. Check fuses and replace if one
fuse is burnt out. Check voltage in
all phases. Check protective
devices.
Defective stator Check whether there is
winding. discontinuity. Rectify if it exists.
1.4 Motor runs in wrong Supply phase Reverse phase and recheck limit
direction. interchanged. switch operation.
1.5 Motor does not Brake not opening Check brake setting.Adjust brake
supply sufficient properly. clearance and spring tension.
torque.
1.6 Motor heating up. Short circuit in Check phases and correct short
winding. circuit.
Overloading. Check line current and if excessive
find out reason and rectify. Avoid
excessive jogging.
Low voltage. Check voltage and do not operate
it below 360V.
Improper lubrication Clean bearing and relubricate.
1.7 Brake lifting noisy. Low voltage. Check voltage.

Global Technology
SAFETY RULES:-
As we know that a check for faults which can be seen or heard is called inspection and a
more thorough inspection which may or may not involve dismounting or use of testing
equipment follow the safety rules one should follow regular inspection.
Regular inspection and periodical inspection are particularly important as they are the
only means of detecting potential hazards which could lead to accidents. The following
are the routine inspections / examinations to be carried over the crane.
1. Weakly inspections : By the operator when he resumes daily duty
Every day / shift.
2. Monthly inspections : By service mechanic or supervisor.

3. Yearly / annual inspection : By senior authorized executive within the
Organization or from outside for testing.
WEEKLY INSPECTION:-
1. CHECK UP that the equipment is quite clean otherwise getting it cleaned. The tackles
and attachments to be used are also likewise to be treated.
2. CHECK UP that the wire rope is not damaged lubricate if dry.
3. CHECK UP the lubrication oil level in the gear box fill up to indicated level, if
required.
4. CHECK UP freedom of operation or the hook swivel, Sheaves, etc.
5. CHECK UP all functions operation mechanism without load such as brakes, limit
switches, sheaves, drums, wire rope spooling, hooks, etc.
6. CHECK UP that all guards like rope guard are in position.
7. ENSURE that grease and oil are removed from all walking surface.
8. When load is first lifted, check up the hoisting and trolley brakes, load is raised only
by a few centimeters above floor.
9. Never operate the hoist if any mechanism does not function. Report to concerned
executive for getting the effect removed.

Global Technology
MOUNTHLY INSPECTION:-
(MAY BE THREE MONTHS A WHILE THE INSPECTION IS DONE IF THE UNIT
USES IT VERY LESS)
1. Carry out all daily inspection specified above.
2. INSPECTION the entire units for structural damage such as distortion crack dents
bend corrosion etc.Carefully inspect all welded connections for cracks paints
flaking and cracking may indicate potential damage.
3. INSPECT sheaves drum etc.for any crack or damage.
4. INSPECT pins bearings shafts gears looking devices hook blocks etc.for any
damage.
5. CHECK UP the wear of brake disks or shoe linings. Change the part if the wear is
excessive.
6. CHECK UP for loose bolts or studs. DO NOT TIGHTEN loose bolt but renew the
parts with fresh one.
7. CHECK all control mechanism for excessive wear of components for

contamination by lubricants of other foreign matters.
8. CHECK UP that all exposed moving parts are well guarded.

Global Technology
YEARLY EXAMINATION:-
(This load can carried out also to hoists subject sudden or unusual shook loads or to
major repairs)
1. The load hook should be thoroughly examined for swivel and also for any
distortion elongation cracks etc.if in the opinion of the examiner the hook is to be
discarded if it should scrapped or replaced. Even if fresh hook is not readily
available the hook should be discarded and the hoist idled until replacement of
hook.
2. The entire structure mechanism attachments chain ropes sheaves drum etc, should
be thoroughly examined for any cracks or damage. If some defect found have it
replaced with a new one.
3. SUCH examination should be carried out for slings and tackles customarily used
with the hoist under inspection.
4. The gear box should be opened oil drained out, all gears pinions shafts etc,
thoroughly cleaned and then FULL UP the gear box case with fresh oil as per
instructions given under the heading GEAR BOX MAINTENANCE broken or
distorted parts if any should be replaced bearings should be thoroughly examined.
In case of play between shafts and bearing replace the appropriate part or bearing
or both.
5. Brakes should be examined to wear and slackness. Any lining or part required to
be renewed should be replaced.

Global Technology
6. CHECK UP all rectifications / replacement records for such rectification or

replacement done after the pervious annual inspection to ensure that such
rectification / replacement need not be carried out again.
7. IN CASE if any rope of hook etc.Had been replaced after the pervious annual
inspection the certificates pertaining to those parts should be verified.
8. CHECK UP the proper function of all oil holes oil ways grease nipples / cups, oil
level indication etc.
9. CHECK UP grease packed housing of ball / roller bearings.
10. CHECK UP if wire rope is fairly lubricated, if it is dry get it lubricated.
11. CHECK the equipment for operational test with rated load or with maximum load
generally handled. Test the function of brakes limit switches control panel etc,
thoroughly.

Global Technology
INDEPENDENT ANNUAL TEST:-
IN ADDITION TO THE ANNUAL examination / test by the service staff it is necessary

to get the hoist tested by an authorized representative of the organization or an external
authority.
The following tests / procedure are required to be carried out:-
1. Operational test with rated load during which the speeds if operation any also be
conducted and recorded.
2. Momentary overload test of 25% overload above the rated capacity.
3. All the customary slings and tackles being used with the equipment should also be
tested for overload.
4. A certificate indication all test carried out and authorizing the safe working load
to which the unit should be used obtained from the testing authority indicating the
date of test and affixing his signature. The certificate should be connected with
unit file for ready reference.
5. In case the testing authority recommends any essential alterations of additions to
the unit before continuing the use or the unit for hoisting they should be carried
out and got the testing done by the some authority (preferably) and certificates
obtained before commencing again the utility of the unit.
6. For the case in inspecting safe operation following chart would show the stage
and interval of inspection.

Global Technology

Global Technology
periodic inspection chart:-
DESCRIPTION WEEKLY MONTHLY QUARTERLY ANNUALLY

Fastening bolts of * * * *
motors, brakes ,gear
box, Rope drums,
sheaves etc.
Bridge girders & end * * * *
carriage joints
(bolted / welded).
Brakes lining. * * * *
Brake solenoid gap. * * * *
Braking performance * * *
Gear box noise level, * * *
leakages.
Lubrication of * * *
various parts.
Motor terminal * *
connections.
Hook free rotation / * *
swiveling.
Alignment of motor. * *
Contractors tip. * *
Limit switch * *
operation.
End buffers for CT & *
LT.
All structural joints & *
welds wear off.
Wear of wheel *
flanges.
Replacement. *
Gear / pinion wear. *
Pitting & wearing of *
hook.
Hook nut & its *
locking.
Rope grooves on *
drum.
Condition of pendent *
push button, circuit
breaker, cable etc.

Global Technology
GENERAL ARRANGEMENT DRAWINGS

Drg. - GA for 5Ton Cap x 18.78 Mtrs Span 14.724 mtrs

Global Technology

Global Technology

Global Technology

Global Technology

5Ton Cap SG EOT Crane

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

5Ton Cap SG EOT Crane

Uploaded by

Copyright:

Available Formats

GLOBAL ELECTRIC OPERATED CRANE

The Cranes manufactured by us are in compliance to IS 3177 to meet Class II

The Hoists manufactured by us are in compliance to IS 3938/1967 to meet Class

Operation & maintenance manual Page 1

GENERAL INFORMATION OF THE CRANES

1. OVER HEAD TRAVELLING CRANE:-The crane comprising a bridge,

4. GOLIATH CRANE:-A crane comprising bridge supporter by leg(s) and capable

5. SEMIGOLIATH CRANE:-A Crane comprising a bridge supported by leg and at

Operation & maintenance manual Page 2

Operation & maintenance manual Page 3

Operation & maintenance manual Page 4

Operation & maintenance manual Page 5

CREEP GEAR BOX:-

Operation & maintenance manual Page 6

EHT BRAKE DCEM BRAKE

01. ELECTRO MAGNETIC SHOE BRAKE.

This Electromagnetic brake may work on AC or DC supply these brake works on

Operation & maintenance manual Page 7

BRAKE MAINTENANCE / SETTING:-

Operation & maintenance manual Page 8

MAINTENANCE INSTRUCTIONS FOR MOTORS

Operation & maintenance manual Page 9

Operation & maintenance manual Page 10

Operation & maintenance manual Page 11

Operation & maintenance manual Page 12

Operation & maintenance manual Page 13

Operation & maintenance manual Page 14

Operation & maintenance manual Page 15

Operation & maintenance manual Page 16

Operation & maintenance manual Page 17

Operation & maintenance manual Page 18

Fig. Description of Motor parts

Operation & maintenance manual Page 19

Operation & maintenance manual Page 20

Fig. Terminal Box

Operation & maintenance manual Page 21

Operation & maintenance manual Page 22

Fig. Terminal Box Dimension Chart

Operation & maintenance manual Page 23

Operation & maintenance manual Page 24

MAINTENANCE OF WIRE ROPE

A steel wire rope is lubricated by rope grease at the time of winding on

Uncoiling & Unreeling wire rope

When uncoiling wire rope, it is important that no kinks are allowed to

Fig. Uncoiling & Unreeling Wire rope

Operation & maintenance manual Page 25

ROTARY GEAR TYPE LIMIT SWITCH:-

Operation & maintenance manual Page 26

TWO WAY LEVER TYPE LIMIT SWITCH:-

Two / one way limit switch, as shown in the

The pendant push button station is a suspended frame

Operation & maintenance manual Page 27

FLEXIBLE GEAR COUPLING:-

The fundamental characteristic of

Fig. Flexible Geared Coupling

CONSTRUCTION FLEXIBLE GEAR COUPLING:

APPLICATION FLEXIBLE GEAR COUPLING:

It can be used effectively and economically for transmission of mechanical power

Operation & maintenance manual Page 28

Operation & maintenance manual Page 29

INSPECTION&PREPARATION BEFORE OPERATION (DURING

Operation & maintenance manual Page 30

take place, following the instructions in the installation, operation and

Operation & maintenance manual Page 31