GENERAL INSTRUCTION MANUAL

BRIDGE CRANE GANTRY CRANE

VINCA EQUIPOS INDUSTRIALES, S.A.
Pol. Ind. Torre Bovera C/ Tcnica 39
08740 SANT ANDREU DE LA BARCA (BARCELONA) SPAIN
Telf.: +34 936 356 120 / Fax.: +34 936 356 130
www.vinca.es

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INDEX
PRELIMINARY .................................................................................................................2
0.1 Symbols and abbreviations ...........................................................................................2
1
DESCRIPTION OF THE CRANE ......................................................................................3
1.1. Identification VINCA Cranes components.......................................................................3
1.2. Identification VINCA Gantry Cranes components ...........................................................4
2
GENERAL SAFETY INSTRUCTIONS ..............................................................................5
2.1. Crane classification according its service conditions ......................................................5
2.1.1
Load spectrum ...................................................................................................5
2.1.2
Average daily operating time..............................................................................5
2.1.3
Determining the operating group........................................................................6
2.1.4
Duty factor .........................................................................................................6
2.2. Safety operating instruction VINCA lifting equipments....................................................7
2.3. Warnings........................................................................................................................7
2.4. Labelling and Inscriptions ...............................................................................................9
3
CRANE INSTALLATION ................................................................................................11
3.1. Prior the installation......................................................................................................11
3.2. Lifting equipment positioning ........................................................................................11
3.3. Electrical connection of VINCAs equipments ...............................................................15
3.3.1.
Prior the installation .........................................................................................15
3.3.2.
VINCAs lifting equipment connection. .............................................................15
3.3.3.
Overload protection..........................................................................................16
After lifting equipment connection .......................................................................................17
3.5. Storage ........................................................................................................................17
3.6. Equipment dismantling .................................................................................................18
3.7. Demolition ....................................................................................................................18
4
OPERATING MODE .......................................................................................................19
4.1. Prior the start up...........................................................................................................19
4.2. Start up and operation..................................................................................................19
4.3. Using the pushbutton controller. ...................................................................................20
4.4 Stopping the equipment. ...............................................................................................20
5. MAINTENANCE..............................................................................................................21
5.1. Safety instructions ........................................................................................................21
5.2. Preventive Maintenance Program ................................................................................21
5.2.1. Bridge Crane / Gantry Crane Maintenance ............................................................21
5.2.2.
Hoist Maintenance ...........................................................................................23
5.3. Travelling reducers......................................................................................................25
5.4. Travelling brakes regulation ........................................................................................25
5.5.1 Servicing frequency ................................................................................................26
5.5.2 Points to be checked during examinations..............................................................26
5.5.3 Replacement criteria...............................................................................................26
5.6. Inspection calendar ......................................................................................................26
5.7. Troubleshooting ...........................................................................................................27
6. APPENDIX......................................................................................................................28
MAINTENANCE AND BREAKDOWNS HISTORICAL RECORD.........................................29
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0 PRELIMINARY
The necessary instructions for the installation, use and maintenance of the crane are included
with the crane delivery. Make sure all the necessary documentation is available, specially the
HOIST MANUAL.
ATENTION: Read carefully all the instructions before using the equipment. A
misunderstanding can cause several damages to other people and to the crane.
For an easier later request, sep the manuals in a safe place to all the staff who uses the crane
and do the maintenance.

0.1 Symbols and abbreviations

In the present manual the following symbols are used:

Attention!

Warning

Danger!

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1 DESCRIPTION OF THE CRANE

VINCA cranes are machinery for the hoisting and transport of loads. There are 2 basic models:
SINGLE GIRDER and DOUBLE GIRDER. The cranes are calculated and manufactured
according to their use: load, span, speeds, etc.
All movements are controlled by a pendant suspended from one of the beams or radio
controlled, except in special cranes.

1.1. Identification VINCA Cranes components

NMBER
1
2
3
4
5
6
7
8
9

DESCRIPTIN
GIRDER
END CARRIAGE
END CARRIAGE TRANSLATION MOTORS
HOIST
HOOK
TROLLEY
TROLLEY GEAR MOTORS
PENDANT
CONTROL BOX

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1.2. Identification VINCA Gantry Cranes components

NMBER
1
2
3
4
5
6
7
8
9
10
11
12
13

DESCRIPTIN
GIRDER
END CARRIAGE
END CARRIAGE GEAR MOTORS
HOIST
HOOK
TROLLEY
TROLLEY GEAR MOTORS
PENDANT
CONTROL BOX
GANTRY POWERING CABLE REEL (OPTIONAL)
COUNTERWEIGHT (OPTIONAL)
STAIRS (OPTIONAL)
MAINTENANCE FOOTWALK (OPTIONAL)

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2 GENERAL SAFETY INSTRUCTIONS

2.1. Crane classification according its service conditions
For a correct, an effective and safe operation of the lifting and transport equipment the correct
classification adapted for each type of application must be chosen. According to FEM 9511
standard the classification depends on the following factors:



Load spectrum
Average operation time for a working day

2.1.1 Load spectrum

The

load

spectrum

evaluation

is

based

on

of

service

conditions:

% max. lifting load

2. Moderate

% max. lifting load

1. Ligth

types

% Operating time

% Operating time

Occasional full load

Usually light load
Average fixed load

3. Heavy

4. Very heavy
% max. lifting load

% max. lifting load

Occasionally full load

Usually light load
Small fixed load

% Operating time

% Operating time

Repetitive full load

Usually average load
Heavy fixed load

Usually almost full load

Very heavy fixed load

2.1.2 Average daily operating time.

The average daily operating time (t) can be calculated as follows:

t=

2 H N T
V 60

H = Average hoisting height [m]

N = Number work cycles per hour [cycles/h].
A cycle consists of a lifting movement and a descent one.
T = Daily working time [h]
V = Hoisting speed [m/min]

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2.1.3 Determining the operating group.

When the load spectrum and the average daily operating time are identified, the hoistss
operating group is obtained from the table below:
Average daily operation time
UNE/ISO/FEM
(hours per day)

Load
Spectrum

0.5

16

M3
1Bm
M4
1Am
M5
2m

M3
1Bm
M4
1Am
M5
2m
M6
3m

M4
1Am
M5
2m
M6
3m
M7
4m

M5
2m
M6
3m
M7
4m

M6
3m
M7
4m

Ligth
Moderate
M3
1Bm
M4
1Am

Heavy
Very heavy

A classification example:
Lifting speed:
Average lifting heigt:
Cycles/hour:
Daily working time:

10 mpm
3m
20
8h

Average operation time:

Load class to expect:

1.6 h
Medium

We will obtain:

Classification 1 Am / M4

2.1.4 Duty factor

The Duty Factor (%ED) is the percentage of maximum possible operation time in a time
interval of maximum 10 minutes.
%ED= (working time x 100) / (working time + resting time)
The FEM 1.001 clasification of a lifting equipment demands a minimum duty factor according
the the attached table.
Lifting
Grupo
M3 (1Bm)
M4 (1Am)
M5 (2m)
M6 (3m)
M7 (4m)

a/h
150
180
240
300
360

Traversing
%ED
25
30
40
50
60

a/h
120
150
180
240
300

%ED
20
25
30
40
50

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2.2. Safety operating instruction VINCA lifting equipments

The owner of this VINCA Bridge Crane or Gantry Crane is the responsible to fulfil with all the
requirements described in these instructions, excluding those for which it has been accorded
that the manufacturer will carry out the necessary procedures.
The owner should train and instruct operators in the safe use of VINCA lifting equipment. This
manual should be in an accessible place to the personal in charge of operation and
maintenance. The operator, serviceman and work manager for the lifting equipment should be
familiar with the safe working principles for the hoist. The user will have to consider the
following norms and prescriptions regarding the construction, manufacture and use of VINCA
lifting equipment:





Low tension installation Regulations (400 V or less).

Environmental Health and Safety Regulations.
FEM Regulations.
CE Machinery Safety Regulations.
It is essential for the safety of people and property that the crane operator, the
crane serviceman and the personnel in charge of crane operation and servicing
are familiar with and comply with the safe working principles described in the
instructions

The protective equipment must always be at users and maintenance personnel reach.
The owner must also ensure that personnel are adequately trained, that they follow safe
working methods and that they use foresight in all stages of the work.

2.3. Warnings
 The use of this lifting equipment for any work different from the described is strictly
forbidden.
 Only specifically authorized personnel by the company management will use this lifting
equipment and after having received the corresponding training according to UNE 58-14094 regulations and precise instructions.
 Read all the instructions supplied with the equipment. The hoist operator must be
familiarized with all the instructions and must follow them. At the same time, the hoist
operator must be competent for this task, must know all the equipment controls and be
able to use them correctly and safety.
 The hoist operator must know also the lifting equipment operation and be aware of any risk
of accident in the work location.
 Learn how to operate the hoist in safe conditions before starting to work. Learn also how to
control the movements of the hook and load. Use the Hoist Owners Manual to familiarize
yourself with the hoist and hoist controls.
 Learn the hand signals for hoisting motion, trolley traversing and crane travel. The hoist
operator should only accept hand signals from an authorized person.
 Be sure that there is adequate lighting as well as proper tools and equipment for the
working site, and that appropriate working procedures are established.
 The lifting equipment operator is the person in charge of it, for this reason he will have to
daily review the elements subjected to an stress, as well as the brakes and safety limit
switches correct operation, mainly the lifting mechanism ones.
 Do not lift people on the hook or load.
 Do no lift a load that is heavier than the maximum permissible load for the hoist or lifting
accessories.

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 Do not pull a load from the side. Lower the load with the ropes perpendicular.
 Do not lift a load that is fastened to its base.
 Do not go under the hook or load. Do not move the hook or load over a person. A load
must never be lifted in a way that can injure a person if the load drops.
 Do not leave a suspended load unattended.
 Avoid short, jerky motions. Unnecessary short starts cause the hoisting motor to overheat
quickly.
 Start and stop the traveling motion at low speed to prevent the load from swinging
excessively.
 Avoid swinging the hook or load during travel motion.
 Do not operate the hoists if you know that medication, an illness, injury or other such
handicap impairs you alertness or working ability.
 Avoid any manipulation that may question the working area safety.
 Stop operating the hoist if it operates abnormally.
 If the hoist is not in use, stop it by pressing the emergency stop button.

NEVER POSITION YOURSELF UNDER THE LOAD.

DANGER! !

BEFORE USING THE LIFTING EQUIPEMENT READ AND UNDERSTAND

THE ENTIRE SUPPLIED MANUAL. IN CASE OF DOUBT CONSULT TO
THE OWNER OR GO TO THE MANUFACTURER TECHNICAL SERVICE.
IF THESE INSTRUCTIONS ARE IGNORED, THE POSSIBILITY OF
PERSONAL INJURY AND IMPORTANT MACHINE DAMAGES
MAY EXIST.

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2.4. Labelling and Inscriptions

VINCAs lifting equipments have the following labels and inscriptions:
 Sign with nominal load indication and manufacturer EC plaque.
The value indicated in this sign corresponds to the maximum load that can be lifted by the
equipment. There are to different models:

In this plaque appears the equipment model and code as well as the nominal load, the power
and VINCAs brand.
Each VINCAs lifting equipment has the following plaque, placed in an accessible place,
usually inside the control box.

DANGER! !

BEFORE USING THE LIFTING EQUIPEMENT READ AND UNDERSTAND

THE ENTIRE SUPPLIED MANUAL. IN CASE OF DOUBT CONSULT TO
THE OWNER OR GO TO THE MANUFACTURER TECHNICAL SERVICE.
IF THESE INSTRUCTIONS ARE IGNORED, THE POSSIBILITY OF
PERSONAL INJURY AND IMPORTANT MACHINE DAMAGES
MAY EXIST.

It warns about the importance of reading and understanding the instructions manual as well as
the safety measures before using the equipment.

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 Inspection calendar disk.

The inspection calendar intends to maintain at sight the dates of the next inspection to carry
out in the crane. This calendar is constituted by a disk where the month and year of the
following inspection is marked using red stickers.

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3 CRANE INSTALLATION
3.1. Prior the installation

Before starting any lifting equipment installation post warnings and barricades
at this working area. It is important to warn that exceptional works are carrying out and
they can cause injuries to unauthorized people.

The Bridge Cranes installation can only be carried out by specifically trained and
qualified personnel.

3.2. Lifting equipment positioning

The first sep is the assembly of the girders with the end carriages. Being the crane in the
ground, assembly the end carriages tightening the joint screws between girder and end
carriage. There is a centering pivot in the union plate to facilitate the assembly dismantling.
Detail centering pivot and union plates of end carriages-girder :

Anchoring plate

Anchoring plate

Cranes end carriage

Centering pivot

Cranes girder

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The recommended torques for the end carriages screws are the following:

Size
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30

Torque [Nm]
Quality 8,8
Quality 10,9
45
66
77
115
125
180
190
280
275
390
385
550
530
750
660
950
980
1400
1350
1900

Before lifting the crane to its position, make sure it does not interfere with the building or any
other machinery.
The lifting of the equipment will be done using a self-supporting crane or any other lifting
system able to develop this work with enough security.

The crane lifting and positioning will be only done by staff specifically authorized
by VINCA.
Before lifting it and positioning the equipment over the rails, it must be tied up using its own
structure. The used slings must fulfill the norm IN 1492.
Usually the crane has special points to fix the slings. The following drawings show the
procedure for each type of cranes:


Single girder cranes: the following drawing shows how to prepare the slinging:

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Double girder cranes: the following drawing shows the slings correct positioning:

NOTE: In case of a boggie type crane (double end carriage with 4 independent wheels by
band and beams), the elevation must be done in 3 steps:
Step 1+2

Step 3

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Gantry Cranes: in this case two self-supporting cranes are necessary to complete
the lifting and installation with total security.
Crane 1

Step 1

Crane 2

Step 2
Crane 2

Step 3

Crane 1

Step 4

Step 1: Join the legs with the end carriages and both girders (for double girder model).
Step 2: Lift the legs with the first crane. Lift the girders assembly with the second crane.
Proceed with the assembly of both groups.
Step 3: While keeping the structure suspended with the second crane, the first crane must take
the second leg (or pair of legs) and lift it. Then join the second leg to the structure.
Step 4: Finish the installation with the rest of safety devices, etc.

BEFORE ATTEMPTING TO LIFT ANY LOAD MAKE SURE THE SLINGS ARE WELL
FIXED TO THE HOOK AND TO THE CRANE.

The personnel who are screwing the legs must be placed on auxiliary lifting
platforms or scaffolds (depending on the height) but NEVER using means that are
resting on the same crane or gantry crane that are assembling!

Once the crane is lifted and placed, it must be positioned over the crane runaways. This
operation is very delicate by the risk that it involves. Check that the crane lenght corresponds
to the existing runaways with a maximum difference of 1 mm.
Before resting the equipment over the guides, check that the wheels flange are perfectly
placed over the runaways solid square rail.

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END CARRIAGE

WHEEL

SOLID SQUARE RAIL

CRANE RUNWAY

3.3. Electrical connection of VINCAs equipments

3.3.1. Prior the installation

It is recommended that qualified service personnel authorized by the manufacturer of

the crane do the installation work. They must be familiarized with the installation instructions
delivered with the crane before commencing and they must pay special attention to the
instructions on safe operation of the crane.

Before proceeding with the crane connection, be sure that the existing tension is
the specified by the manufacturer.
Only a 5% of variation of nominal tension is accepted (220 V 380 V).

The customer must provide an electrical line with all the protections according to
the local legislation.
Perform the electrical line connections to the VINCAs equipment junction box (three phase
and ground).
The ground connection is made up of a yellow / green cable that goes until the junction box
terminal.
Connect the ground connection to the power system with the yellow / green cable.

The ground connection must not have any signal of tension.

3.3.2. VINCAs lifting equipment connection.

The electrical supply of VINCAs lifting equipments could be done using the following systems:
 Festoon systems:
This system consists of an end clamp which secures the cable at the non-moving end, a tow
trolley or a control unit trolley which is moved back and forth by the crane translation, and a

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series of intermediate trolleys supporting the cable. The trolleys roll smoothly in a specially
formed C shaped track.

 Compact lines:
This system consists on a channelling electrical conductor introduced in PVC dielectric
housing of four poles with marked ground pole and different amperages.

The adaptation of one of these systems will depend on the costumer needs, geometry or
lenght of the warehouse, security requirements, etc...
 Cable reels:
This system is the most used for Gantry Cranes supply. A motor or an spring coils the
electrical cable up in a coil.

3.3.3. Overload protection

Overload protection on VINCAs equipement prevents hoisting motion when there is an
excessive load.

All load limiters supplied by VINCA are tared in our warehouse, before delivery.

It could happen that, by the steel cable adaptation or other different causes, the tare loses
precision.
The supply and assembly of this equipment do not include its final calibration in the costumer
facilities, except written order specifying this task. The disposition of the loading test must be
facilitated by the client, at his charge and excluding the auxiliary means.

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Although a limiter tare is realized in factory, is recommendable to order to VINCA the limiter
tare to be carried out immediately after the assembly. For it, the client will have to indicate
this order in writing and to agree the cost with VINCA. In addition, the costumer must have the
loading test, with the ropes, before the tare. New displacements of VINCAs personnel to
realize the tare will suppose, logically, an additional cost that the client will have to take care
of.
VINCA has different load limiter models, as follows:
 Load limiter with tensiometer:
Formed by a resistant steel body, its installed on an end of the hoist fixed rope. The electrical
connection is realized so that it interrupts the lifting maneuver at the moment that is tried to
elevate a load superior to the prefixed in the limiter. This is the model that VINCA installs
habitually.
 Electronic load limiter with tensiometer load cell:
Its operation is identical at the previos one but in this case it has an electronic regulation.
 Electronic load limiter with amperimeter:
This limiter controls the circuit of the motor electrical supply, based on the power absorbed by
this one. The regulation of the limiter is realized by means of a potentiometer of warning level.
When the limit exceeds, the relay of the detector changes its state and sends a signal to the
the lifting group stop system.
There is an specific users manual of this component. We only install this model exceptionally.

DO NOT MANIPULATE THE LOAD LIMITERS. ANY UNAUTHORIZED

MANIPULATION MAY COMMIT SERIOUS RESPONSIBILITIES. ONLY A SERVICE AGENT
AUTHORISED BY THE MANUFACTURER MAY ADJUST THE OVERLOAD PROTECTION

NOTE: IF NECESSARY, THE USERS CAN ASK FOR ADDITIONAL TECHNICAL

INFORMATION ABOUT LOAD LIMITER SYSTEMS.

After lifting equipment connection

Get ready for a possible error in the sense of the movement of the equipment during the tests.

OBSERVE THAT THE CRANE HOOK LIFTS CORRECTLY WHEN ACTIVATING THE
LIFTING PUSH BUTTON. IF NOT THE CRANE POWER SUPPLY PHASES WILL NEED TO
BE REVERSED, OTHERWISE THE LIMIT SWITCH DEVICES WOUDNT ACTIVATE AND
THE ROPE AND THE GUIDE WOUD BRAKE.

3.5. Storage
In case the bridge crane needs to be stored it its own location or in any alternative location
during periods of time more or less long (interior or exterior storage), or in case its necessary
to make interventions over the bridge that could damage the equipment, will be necessary to
cover the motors, control box and limit switches with suitable materials that protect from the fall
of objects, dust and direct water. In long periods of storage, or in case of defective storage, or

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if damages in the equipment are appreciated, it will be necessary to contract a new starting
up or a preventive maintenance before his new use.

Warning

The protection is especially necessary in construction sites in which the bridge has mounted
previously to works that will be realized in superior levels! The installation of protections is not
included in the crane delivery and is responsibility of the client to carry it out. We remember
that the guarantee does not cover failures and damages caused by a inadequate maintenance

3.6. Equipment dismantling

It is recommended that qualified service personnel authorized by the

manufacturer of the hoist do the installation work.
In order to dismantle the crane, act as follows:
1. Disconnect the crane from the electrical supply. Be sure that the power source has been
locked out before starting with the dismantling.
2. Dismantle and lower the translation trolley at floor level. Use a self-supporting crane or any
other auxiliary system able to develop this work with enough security.
3. Sling properly the crane girders and lower them at floor level. The correct equipment
slinging is explained in section 3.2.
4. Once the crane is on the floor, dismantle the end carriages, loosing the union bolts
between girder crane and end carriage. There is a centering pivot in the union plate to
facilitate the assembly dismantling (explained in section 3.2). Regarding the gantry
cranes, follow the procedure explained in section 3.2 but on a reverse order.

3.7. Demolition
In the construction phase, VINCA certifies its contribution to the environment with the iron,
plastic, paper and oil recycling.
For the construction of lifting equipments VINCA has used preferably ferrous materials. There
are also aluminum and plastic components.
The materials are easily disposable and they dont represent any environmental pollution risk
or against personal security.
In the phase of demolition, its advisable to separate correctly the different materials in case
they will be reused, based on current legislation.

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4 OPERATING MODE
4.1. Prior the start up

Before starting up the Crane, a visual inspection of all the installation should be
done observing that does not exist any defect in the assembly nor obstacles in the
course of equipment.

 Do not activate the equipment without following the safety instructions detailed in this
manual.
 Verify that maintenance personnel or unauthorized people isnt near the equipment location
and that the crane runaway and electrical cables do not present objects that could obstruct
them.
 If the equipment has movement locking devices, they must be released before using it.
 Before connecting the main supply, be sure that all the controls are in position 0.
 Check that all the safety switches are working correctly.
 Check that all the brakes are working correctly.
 Avoid any manipulation that may put the security at risk.

4.2. Start up and operation

This manual should be thoroughly read and understood before beginning the
operation or servicing of this crane. Pay special attention to the instructions on safe
operation of the crane.
 Activate the main switch. (This switch is placed at the general supply line).
 Before carrying out any task of elevation, be sure that the hoist accessories are safely
located in the lifting surface of the hook and that the safety catch of this one is closed.
 Before activating the lifting and transport equipment, be sure that you know a safe and
effective route to move the load.
 Lift the load enough to avoid collisions with objects during its displacement. However, dont
lift the load to a height superior to the necessary one in each occasion. Dont lift the hook
until the safety limit superior.
 Start and stop the traveling motion at low speed to prevent the load from swinging
excessively. Avoid swinging the hook or load during travel motion.
 Move the load to the desired point.
 Lower the load until position it on a safe level of support.
 Do not leave a suspended load unattended.
 In a potentially dangerous situation, all the hoist movements could be stop pressing the
emergency pushbutton. Dont use this button if is not necessary.
 If some dysfunction in the Crane is detected, stop the work immediately, position the Crane
in safe place and warn immediately to the person or department responsible.
 Once the work has finalized, be sure to protect the Crane against any unauthorized use.
Push the button of cancellation of maneuvers, so that a mistaken later pulsation does not
generate an erroneous maneuver.

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4.3. Using the pushbutton controller.

1.
2.
3.
4.
5.

Movement pushbuttons.
Hoist selection pushbutton (only if the pushbutton controls several hoists)
ON pushbutton and warning signal.
Emergency stop pushbutton.
Screen.

4.4 Stopping the equipment.

 To avoid obstructing the traffic lift enough the empty hook or the loading mechanism. Do
not lift it until the security upper limit.
 Place all the controls in situation 0.
 Push the emergency stop pushbutton before opening the main contact.
 Disconnect the security switch of main electric current.
 Close the mechanical brakes (optional, for ex in case of winds that may move the crane
sliding it on the rails).
 Report about any detected fault to the person in charge.

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5. MAINTENANCE
5.1. Safety instructions
 Execute the habitual tasks of inspection and preventive maintenance according to these
instructions. Maintain a record of the inspection and maintenance tasks. Regular
procedures of maintenance and inspection for the safe and effective operation of the
equipment are necessary.
 Pay special attention to the brake operation, the limit switches, the hook condition, the
cable and the pushbutton controller. It is fundamental that the safety devices (protective
devices against overload, limit switches, etc) work correctly and that they are in perfect
state of operation, since they protect against any human error.
 The equipment maintenance must be executed only by qualified personnel authorized by
the manufacturer of the equipment. The maintenance personnel must be familiarized with
the instructions of maintenance and inspection.
 Use only original spare parts approved by the manufacturer of lifting equipment.
 Any modification or addition realized in the structure or output values of the equipment
must be dealt first with the manufacturer.
 Any task of inspection or repair carried out in the equipment after an overload or collision
must be dealt with the manufacturer.

5.2. Preventive Maintenance Program

5.2.1. Bridge Crane / Gantry Crane Maintenance
The interval of a crane inspection in continuous operation is one week. The cranes that are
intermittently used must be inspected before using them.
The measures that are executed in the inspection points are necessary if other methods do not
produce a suitable result. If some type of defect or anomaly is observed, it must be
investigated and execute corrective actions according to the specific instructions for this
device.

If the works of maintenance present some difficulty, contact with VINCA Service
Department.

The table of the following page enumerates some general points of inspection of the crane as
well as the methods to follow.

Attached is the document Maintenance Card and Operating record of

maintenance, to facilitate the inspection and monitoring workings.

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Inspection method
Structure/
Component

Inspection Point

Consult the specific instructions of Hoist

Components in the Hoist Manual.
Bridge Crane Fastening of units from movable
movable
equipment
equipment
Motors operation
Brakes operation
Gearing operation
Lubricant level on gearbox
Travelling rollers condition
Operation of limit witches
Trolley
Fastening of units from movable
movable
equipment
equipment
Motors operation
Brakes operation
Gearing operation
Lubricant level on gearbox
Travelling rollers condition
Operation of limit switches
Trolley
Ropes condition
electrical
Trolley ropes condition
supply
Condition and cleanliness electrical
wiring rails
Cleanliness of equipment and
mechanisms
Condition of cables from electrical
cubicles
Cable clamps condition
Temporized relays operation
Electrical
Contactors operation
cubicles
Adjustment overcurrent protectors
Fuses condition
Starting rheostats cleaning
Cables fastening of starting rheostats
Main switch operation and condition
Steel
Cleaning and strange substances
structure
elimination
Conductor rails condition
Bumpers condition
Handrails condition and fastening
Bridge Crane Bridge crane platform condition
platform
Ground connection condition
Condition of bridge crane electrical
feeding equipment

Visual

Auditory

Manual
Test/
measuring

Hoist

X
X
X
X

X
X
X

X
X
X
X
X
X

X
X
X
X
X

X
X
X

X
X
X
X
X

X
X
X
X
X
X

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

X
X
X
X

X
X

22

Ref.: 18 - Cranes
Edition 01/10

5.2.2. Hoist Maintenance

The lifetime of the hoist is divided into Safe Working Periods (SWPs). At the beginning of the
Safe Working Period, a new hoist has an SWP% of 100. A Safe Working Period ends when
the SWP% of the hoist is zero. When a Safe Working Period ends, a General Overhaul (GO)
must be conducted, after which the hoist is assigned a new Safe Working Period, refer to the
section General Overhaul, GO.
During the SWP, the safe and efficient operation of the hoist is contingent on regular servicing.

For the safety carry out the inspection and servicing procedures for the hoist in
accordance with the table below
The servicing intervals for the hoist are defined as SWP% periods. The actual operation of the
hoist is taken into account in SWP%. If the hoist is provided with a condition monitoring unit,
the SWP value can be read from the SWP-data counter display of the unit. Refer to the more
detailed instructions given in the separate operating instructions for the condition monitoring
unit.
The SWP% corresponding to the SWP value can be found from the table below. Check the
rating plate fixed to the hoist for classification of the hoists operating group.
In case the hoist does not have a condition monitoring unit, the Safe Working Period (SWP)
will have to be calculated according to the FEM standard 9775. There is an appendix to this
manual where the necessary information to calculate the Safe Working Period is detailed.

Operating group of the hoist ISO (FEM)

M4
M5
M6
M7
2m
3m
4m
1 Am
SWP value shown in the condition
monitoring unit
800
1600
3200
6300
720
1440
2880
5670
640
1280
2560
5040
560
1120
2240
4410
480
960
1920
3780
400
800
1600
3150
320
640
1280
2520
240
480
960
1890
160
320
640
1260
80
160
320
630
40
80
160
320
8
16
32
63
0
0
0
0

SWP (%)

100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
5%
1%
0%

23

Ref.: 18 - Cranes
Edition 01/10

The table below shows the service intervals for the hoist in SWP% periods and in calendar
months. Items for inspection and servicing refer to the servicing procedures described earlier
in these operating instructions. The servicing procedure must be carried out latest at the end of
a SWP% period, or by the end of the stated number of calendar months. Hoists without a
condition-monitoring device must follow a servicing procedure guide by calendar months. For
ensuring the usability of the hoist the servicing intervals can be shortened.

In order to guarantee the hoist availability, reduce the maintenance intervals.

A. Maintenance tasks must be only carried out by maintenance personnel authorized
by the hoist manufacturer.
B. Periodical inspecting and servicing procedure may only be carried out by a

serviceman authorized by the hoist manufacturer or service personnel adequately

trained by the hoist manufacturer
C. Daily inspection tasks that must be carried out by the user.

Items for inspection and servicing

Inspection of hoisting gear
Inspection of hoisting motor and brake
Inspection of rope drum
Inspection of rope guide
Inspection of rope clamps
Inspection of wedge frame
Inspection of wire rope
Inspection of hook block
Inspection of rope sheave beam1)
Inspection of hoisting limit switch
Inspection of overload protector
Inspection of travelling machinery1)
Inspection of frequency controller1)
Inspection of trolley wheels1)
Inspection of buffers1)
Inspection of pushbutton controller
Inspection of condition monitoring unit1)
Annual inspection according to local
requirements2)

Daily
inspection

C
C
C

SWP Period(%)
Mes
1%
5%
10%
1
6
12
B
A
A
B
A
B
A
B
A
B
A
B
A
B
A
B
A
A
B
A
A
B
A
B
A
B
A
B
A
B
A
A

1) Not all hoist types include this equipment.

2) Germany: Inspection according to VBG 8,9 (VBG, Vorschrift der Berufsgenossenschaft)

24

Ref.: 18 - Cranes
Edition 01/10

5.2.3 General Overhaul (GO)

Once the SWP% of the hoist reaches zero, the hoist has exhausted its theoretical lifetime. The
probability of a defect in the hoist is therefore higher and operating safety is jeopardized.
When the theoretical lifetime is exhausted, a General Overhaul (GO) of the hoist must be
conducted. Only the hoist manufacturer or a service organization authorized by the hoist
manufacturer may conduct a GO.
The components in the hoist that have an impact on hoist lifetime are inspected in a GO and
critical components are replaced. A new theoretical SWP is given to the hoist after completion
of a GO.

When the Safe Working Period (SWP) of the hoist is exhausted, the hoist may
only be used after a GO has been conducted.

5.3. Travelling reducers

Replacement or dismantling instructions:
First loosen the fixing bolts and remove the reducer.
Before the assembly, is important to check the following points:
 The base of support and fixation of the reducer must be rigid, flat and to be mechanized, in
order to secure a good support and to avoid vibrations.
 Carefully align the motor and machine axes with the reducer ones, avoiding any angular or
radial displacement between them.
 The transmission parts such as connections, pinions, motors, etc, will be correctly
assembled, using the threaded holes placed in the reducer axes, avoiding any blow or
leverage on them.

5.4. Travelling brakes regulation

Due to the existence of different types of motors and to the difficulty that the correct
accomplishment of this task presents, it is advised that only specialized technical personnel
should carry it out.
Attached to this manual, some technical information referring to the motors installed in the
lifting and traveling equipment is provided.
5.5. Criteria about wire rope examination and replacement

In order to ensure safe and efficient operation of the hoist, it is essential to

monitor the ropes and, if necessary, remove and replace them at the adequated
moment. Regular inspection of the rope is a vital safety procedure requirement.

The rope shall be changed before the limits have been reached. Change the rope if
there is a risk that limits are reached before the next examination.
25

Ref.: 18 - Cranes
Edition 01/10

5.5.1 Servicing frequency

 Daily examinations:
Visual deformations and damages in the rope shall be inspected daily by the user. Pay special
attention to the anchorage points to the machine.
 Periodical examinations:
The periodical examinations should be determined based on the following :





The prescribed exigencies that are applied to equipment in which the cable is used.
The type of material and the rope working conditions.
The equipment duty class group.
Previous examinations results.

In any case, an inspection must be always realized after an incident, an startup and any
disassembly followed by a new assembly.

5.5.2 Points to be checked during examinations

Although the ropes must be examined in all their length, is necessary to watch particularly:






The fixing points at the rope ends both the active and the inactive ropes (A description
of the areas to be inspected exists, for each fixation type, with its corresponding
regulation).
The rope parts that pass through the blocks and pulleys and for equipment that carry
out a repeated work.
The rope parts that pass through compensating pulleys.
The rope parts that may be usually worn by external causes.

The examination results must be raccorded in doc. annexed Equipment verification registry.

5.5.3 Replacement criteria

These replacement criteria are very well detailed at UNE 58-111: 1881 (ISO/DIS 4309)
regulation. In order to increase information about replacement criteria contact with VINCA
Equipos Industriales.

An appendix regarding the criteria of rope replacement exists at disposal of our

clients.

5.6. Inspection calendar

The inspection calendar intends to maintain at sight the dates of the next inspection to carry
out in the crane. This calendar is constituted by a disk where the month and year of the
following inspection is marked using red stickers. In section 2.4 there is an image of this
calendar.

26

Ref.: 18 - Cranes
Edition 01/10

5.7. Troubleshooting
The table below lists some of the faults and malfunctions that may occur in the equipment,
their causes and the corrective actions needed to eliminate them.

If you are unable to identify and eliminate the fault using this
table, contact a service agent authorized by the manufacturer!

Fault

Probable cause

Corrective action

The equipment is not

operative.

Main supply power is not

connected.

Switch the main power supply

on.
Release the Emergency Stop
button.
Press the Start button.
Replace the fuses.
Drive away from the limit.

A fuse has blown.

A motion has reached its
limit.
One phase is dead (no
voltage).
Pushbutton controller fault.

Equipment motions are in

the wrong direction.

The phases of the power

supply are connected
wrongly.

The crane doesnt stop

correctly when the crane or
trolley travelling pushbutton
is released.
Travel motion is not
operative. The rest of
equipment is working
correctly.

The motor brakes doesnt

work correctly.
Travelling temporisation
wrongly regulated.
Fault on motors electrical
supply.
Limit switches are activated.
The motor brake coil is
burned.
The activation limit switches
are not working/ deactivation
of rapid speed.
One of the rods of limit
switches activation is
missing.
The electrical winding is
partially burned.

The equipment has only a

travelling speed working.

The hoist is operative

but does not hoist the
load.
The load slips
downwards

The hook is holding an

overload.
The hoisting brake is worn.

Repair the power supply.

Check the multi-connector and
the pushbutton controller
cable.
Interchange the sequence of 2
phases of the power supply.
Check the directions of
motion.
Contact immediately the
VINCA service department.

Check all the motors electrical

connections.
Check all limit switches.
Contact immediately the
VINCA service department.
Check the limit switches
position and condition.
Replace rods

Damaged motors must be

replaced. Contact
immediately the VINCA
service department.
Check that the load on the
hook does not exceed the
maximum permitted load.
Contact immediately the
VINCA service department.

27

VINCA EQUIPOS INDUSTRIALES, S.A.

Pol. Ind. Torre Bovera C/. Tcnica 39
08740 ST. ANDREU DE LA BARCA (Barcelona)
Telfono: (93) 635 61 20 Fax: (93) 635 61 30

www.vinca.net

6. APPENDIX
The following Appendix are at disposal of VINCA lifting and travelling equipment users:
 Hoist manual.
 Motors technical information.
 Instructions how to calculate Safe Working Periods (SWP).
 Criteria about wire rope examination and replacement.
 Spare parts list.
 Inspection points and maintenance records.
 Certificates (CE, rope or chain, hook and loading factory tests).

VINCA EQUIPOS INDUSTRIALES, S.A.

Pol. Ind. Torre Bovera C/. Tcnica 39
08740 ST. ANDREU DE LA BARCA (Barcelona)
Telfono: (93) 635 61 20 Fax: (93) 635 61 30

www.vinca.net

APPENDIX

MAINTENANCE AND BREAKDOWNS HISTORICAL RECORD

WORKSHEET

CLIENT:
ADDRESS:
CITY:
Phone:

WORKER Mr.:

Date
/

Equipment: _______________________
/
Section:
CORRECT
NOTES

YES/ NO

MONTHLY INSPECTION
a.b.c.d.e.f.g.h.i.-

Check the reducers oil level, adding with the recommended type if necessary. Grease
all movable parts.
Check the metallic ropes condition:
- Exempt from deformations, bends or rust
Check the hoisting brake operation. Regulate the brake if necessary and check the
wearing in this case.(See "Service Manual for hoist")
Check the travelling brake. Regulate if necessary.
Check hoisting limit switches (Up / Down).
Check the hook rotation, the safety latch condition and the apparent pulleys motion.
Check the pushbutton controller condition, the electrical wire and the suspension
cable.
Check the counters operation and the of control box general condition.
Check the electrical outlet trolley condition.
SIX-MONTHLY INSPECTION

j.k.-

Clean and check the hoisting limit switches.

Check the pushbutton controller cable tension.

l.-

Lubricate travelling gears and hook axial bearing.

ANNUAL INSPECTION

m.-

Clean all the electrical components of control box.

n.-

Clean and check coals, graphites, etc.. from the outlet trolley (only compact lines).

o.-

Check wearings on travelling and traversing wheel flanges.

p.-

Check wearings and junctions along the bridge travel (beams and rails).

q.r.-

Check the hook to detect wear, deformation or fissures from overloads.

Empty the reducers used oil, clean with gasoline and refill with the recommended
lubricant.
Final report and worker signature
Verified and accepted (Client)

Doc.: Cranes Manual VINCA Ed.: 08/09

Ver 01-10 EN.DOC

Rev.: 0

Autor: SM

30
32

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MAINTENANCE AND BREAKDOWNS HISTORICAL RECORD

Maintenance register sheet

Date

Preventive and extraordinary Maintenance operations register

Kind of operation
Remarks and signature

Doc.: Cranes Manual VINCA Ed.: 08/09

Ver 01-10 EN.DOC

Rev.: 0

Autor: SM

31
32

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