ELECTRO - FAB

ELECTRO - FAB

ELECTRO FAB - CRANE INDUSTRIES

Add: Sr. No. 58, Plot No. 49B, Sai Industrial Associate,
Near Maharashtra Wear House, Nasik Road, ELECTRO FAB - CRANE INDUSTRIES
Chovisawadi, Charoli (Bk),
Tal - Haveli, Dist. Pune - 412105
Ph. No.: 09822593201 / 09822593202
Email: nilesh@electrofabcrane.com, sales@electrofabcrane.com
Website: www.electrofabcrane.com

User Guide

Impulse Vision : 9822871710 www.electrofabcrane.com

ELECTRO - FAB ELECTRO - FAB

INDEX

1. About Us

2. History of Crane Design

3. Types of Crane

4. Parts of Crane

5. Operation Instructions

6. Maintenance Instructions

7. Do’s and Don't’s

8. Before Making Service Call

9. Test Certificates
 ELECTRO - FAB
About Us
We envisage Electrofab becoming a world - wide brand
leader in its field of operations by consistently delivering
world class quality products in the lowest possible lead
times.
True to this vision, Electrofab over its history of operations,
has shown a consistent improvement in performance by
delivering top class products and by catering to a wide range
of client requirement’s. Electrofab has made its own
ELECTRO - FAB
History Of Crane Design
Traveling cranes of the hand operated type were in use in the
1880's. About this time complicated designs of powered
motion were offered by English & American builders,
involving a driving shaft along the runway and multiple
clutches for transferring the power of the driven shaft to the
hoist, trolley or bridge motions.
The first three-motor electric crane was placed in operation
in 1890. J.H. Whiting Founder of Whiting Corporation, built
the first three motor Whiting crane in 1898. Early speeds
were slow and load ratings limited, with 40 tons maximum.
Crane design has changed about every 20 years. 1880 saw
the hand powered crane; 1900 the electrically driven crane
 ELECTRO - FAB ELECTRO - FAB

Types Of Cranes Types Of Cranes

This section shows the many types of cranes which are in

use today to fulfill the demands of material handling
Part A- Overhead Cranes:
problems. A line drawing, title and brief description of use
for each type of crane is given.
Magnet Crane Latticed Girder
Rugged design for severe service in foundry make-up, Recommended for any of the foregoing types of overhead
scrap and steel storage yards cranes in outdoor service where spans exceed 160 ft.

3-Motion Single Trolley General Service 4-Motion Single Trolley

Slow speed main hook for heavy loads; fast speed
auxiliary hook for light loads

7-Motion Triple Trolley 2-Motor Double-Hook Trolley

Three equal or unequal hoists for handling of long Two hooks on same trolley at right angles to bridge girders
rolls in paper mills for special beams and grapples. Hook may be between
girders as shown or outside of girders as indicated by
broken lines

5-Motion Double Trolley 7-Motion Double Trolley

Two equal hoists for handling of long loads Two main hooks for heavy loads at slow speeds, & close
at any desired centers approach for fast auxiliary hooks at both sides of building

Trailer Cab Cab-On-Trolley

The cab is supported from wheels, which run along The cab is supported from the trolley frame and is
the bridge rail, and moves with the trolley cantilevered beyond the bridge idler girder, opposite the
main footwalk

5-Motion Double Trolley Bucket Crane

One heavy and one light capacity trolley for heavy single Handling coal, refuse, cement, fertilizer & similar materials
load or light, long loads
 ELECTRO - FAB ELECTRO - FAB

Types Of Cranes Types Of Cranes

Part B- Gantry Cranes: Part C- Nuclear Plant Cranes:

Deck-Leg Gantry Through-Leg Gantry Polar Overhead Operates on a circular runway located Polar Gantry Same as Polar Overhead Crane, expect
Both tracks at ground level. Trolley travels between legs only Both tracks at ground level. Trolley travels through legs near thespring line of the containment that the runway rail is located at or above the operating floor
on to overhangs which may be at one end or both ends / reactor building level. This crane usually has a through leg on one end to
of bridge. Load may or may not be carried through the leg service the area between the runway rail & the inner wall

Semi-Gantry Deck-Leg Semi-Gantry Through-Leg Dual-Load-Path Trolley Used for handling critical loads, such as nuclear fuel casks to and from the spent
One end of bridge on high runway. Trolley travels between One end of bridge on high runway. Trolley travels from fuel pool. This trolley has two independent full load-rated load paths from the fuel cask to the hoist brakes
upper runway truck and gantry leg only upper runway truck through leg on overhang. Load may (dual load path hoisting system)
or may not be carried through the leg

Part D- Special Electric Cranes:

Outdoor Storage Gantry

Long span (usually over 150 ft.) and high lift (over 50 ft.)
used for storage of bulk material
Wall Bracket Crane (fixed) Single-beam boom with under Traveling Wall-Bracket Crane Covers the area near the
hung trolley and hoist. Used to serve localized area building columns without obstructions at floor level. Typically
used to 10 ton rated load in foundry molding & cleaning bays
and structural fabrication shops. Requires special design of columns
 ELECTRO - FAB ELECTRO - FAB

Types Of Cranes Types Of Cranes

Under Hung Crane. A traveling bridge running on the Under-hung Stacker Crane Bridge may be top-running or Single Girder Under-Hung Bridge
lower flange or T-rail of two or more runway tracks, usually under-hung, with under-hung trolley on which is mounted a with under-hung trolley. Hoist of the chain or
supported from the building roof trusses vertically-traveling fork or platform for handling the load. wire rope type. Ratings to 10 tons
Mast or fork (or both) may also rotate

Part F- Jib and Pillar Cranes:

Controlled Mechanical Storage Crane A specialized lifting

machine, traveling on a floor-mounted rail(s), usually
in aisles between storage racks or bins. Used in
automated, warehousing to transfer loads into
and out of storage Top-Braced Single beam boom with under-
Under Braced with top-running trolley, double-
channel boom; trolley travel and load size limited running trolley. Hoist may be of the chain or wire rope type
by bracing. General purpose use in localized area operated by electric or hand power. Used to serve
localized area

Part E- Manually-Operated Cranes:

Floor-Mounted: Single beam boom with under-running Ground-Mounted

Double Girder Top-Running Bridge Single Girder Top-Running Bridge trolley. Hoist may be of the chain or wire rope type Same construction and use as previous
with top-running trolley. Ratings to 10 tons with under-hung trolley. Hoist of the chain or wire operated by electric or hand power. Used to crane, expect for base mounting
rope type. Ratings to 10 tons serve machine shops and assembly floors
 ELECTRO - FAB ELECTRO - FAB

Parts Of Cranes Operation Instruction

Various Terms / Parts used in cranes are as follow : Inspection before Operation :
Hoisting Motion : Up or Down motion i.e. Lifting or lowering the load. Check the following point, to ensure that the Crane is ready for trial operation.

Cross Travel (CT) Motion : Right/Left motion i.e. Moving load Right or Left across the span. The gear boxes are filled with recommended lubricants
Long Travel (LT) Motion : FRD/REV motion i.e. Moving the load Forward or Reverse along the bay length.
up-to the maximum level marked on the respective
Span : Centre-to-centre distance between two LT wheels across the crane width.

Bay Length : Maximum length of crane traverse (LT Motion).

dipsticks.
Litt: Maximum height at which load can be lifted (Hoisting Motion). lubricant.
Trolley : In single girder cranes-for moving load across the span (CT Motion). The centralized / grouped lubrication system, if provided,
The rotary limit switch operates at the upper and lower limits of the hook travel.

Crab : In double girder cranes- for moving load across the span (CT Motion).
is functioning properly and that all the connected points
End Carriage: For moving the load along the bay length.

Girder : It is a main part of crane to which end carriage/crab are attached.

getting lubricated.
> In general, trolley/crab/end carriage have total 4 wheels-gearbox is coupled to two wheels while other two wheels are idle.

For all other points where individual greasing is required,

Motors : Two types of motors are used in cranes-slipring & Preparation for Operation :
squirrel cage. Now a days slipring motors are not used
compared to conventional motors.
The crane is operated by manipulating the controllers governing each motion. Before beginning the operation, complete the following
preparatory routine.
frequently.
wheels or rope drum incaseExcept
of hoist. for their maintenance, they are very Check all cable interconnections as per wiring diagram.

smooth in operation. Due to availability squirrel cage Ensure that no connection is LOOSE.

operation but operates gradually.

motors are used now a days. To limit jerks during starting, If VFD is provided, check parameter setting as per the list. If required set desired parameters.

a)
because of high starting torque of squirrel cage motors,
diameter decides final speed of hoisting motion. If VFD’s provided- switch on MCB in power ckt of one
VFD’s are used frequently. Crane duty motors are of special
b)
motion at a time. Press Respective PB of the motion.
d e
pulleys which are mounted above hook.
s i g n
Trial Operation :

One by one, operate all the mechanism of the Crane by NO

Gearbox : These are used to reduce motor speed to LOAD, Check performance of the mechanism and safety
desired level. Motor is coupled to input side of gearbox & device and ensure that there is no malfunctioning of any
o u t p u t s i d e i s c o n n e c t e d t o components
Record current drawn by motors or assembly.
during each one of the above tests. Closely observed for any
abnormal noise, vibrations, etc.
> Report any abnormalities observed to Works for rectification.
 Operation Instruction Operation Instruction
ctices : Tender no circumstances shall the crane driver attempt to tra
ypes are designed with the safety of the operating personal has been hoisted clear of an obstructions.
our own safety and that of your fellow workers will be
When handling loads approaching maximum rated capacity
driver shall test the hoist brakes after the first load has been
competent and property authorized crane drivers are
cms clear of the floor by placing the controller in the OFF po
operate overhead traveling cranes. A crane driver shall
brakes do not hold, the load shall be lowered at once and th
dge of English. Floormen’s Standarad Hand Signals :
be adjusted.
The determination of a system of operating signals side by sid
s must be physically, and have good hearing and eye-sight. adherence there to, is strongly
r shall not operate his crane if not physically fit; but shall For Hoisting : Hold forearmrecommended from up
horizontally, palm theand
poinm
sability to the medical officer or other appropriate person. upward.
For Lowering : Hold forerarm horizontally, palm down, and
shall be alert at all times. Sleeping on the job, throwing pipe downward.
arette butts or spitting from the control cabin or budget For Traveling : Hold upperarm horizontally, at the side of t
e not permitted under any circumstances. forearm vertically with palm facing the direction of the movem
forearm in the direction of movement.
eep their hands free when going up or down saddler. When a whistle is used, with the signals, the following note are sounded before the hand sign
a)
b)Short movement
lothing and other personal belongings shall not be kept in c)
Continuous movement
the control position. It is essential that only one man be assigned to the work
Operation
Crane Parkingaccording
: to signals received from two or more me
miliarize with all crane safety operating instructions, the Before leaving his control position, the crane driver shall at all times ensure that :
a)
nism and its proper care. b) Crane is parked at designed location.
c)
d)
There is no load suspended from the hook.
e shall at all times be exercised by the crane drivers and e)
f)
The hook is raised clear of all obstructions.
and all other personnel working or present on premises where Crane Attendants or Slingers :
cated, to avoid contact with the crane collector wires and/or The crane attendant shall have an adequate knowledge of s
power cables, whether covered or bare. methods.
He shall have sound knowledge of knotting, slinging and han
r cars or other transport vehicles, shall not be towed by the a)
Any lifting equipment is not overloaded. If there is any doubt t
load.
b)
c)
of
Thethe equipment
crane or the
attendant is allweight of the load,for
time responsible this
theshould be i
safe slingi
d) ascertained.
 ELECTRO - FAB ELECTRO - FAB

Maintenance Instruction Maintenance Instruction

Needless to say, daily maintenance and inspection are not only important for safe operation but also govern the efficiency and service life
of the Crane. plunger of the solenoid sticks during the movement when a
General Precautions :
There are many points requiring attention for maintenance of the overhead Crane, but the most important items may be roughly classified lot of dust enters the solenoid opening: With the right
as follows :
maintenance. If the dust is kept down, the movement of the
Lubrication
Inspection and repair of wearing parts and deforming parts
The above items will be explained in details later but the following, points should be especially be kept in mind to ensure through
maintenance.
Lubrication :

Lubrication, which is an important to a Crane as breathing is

Worn or Deformed Parts and Broken Parts :
for a man, must never be forgotten. Apply the proper
If the wear or deformation is within a certain limit, the part
A.C.Electromagnetic Solenoid Oprated Electro Hydraulic Thrust
can still be used. Every wear limit mentioned in the wear Single Phase Brake or
Oprated Brake
table isofthe
Loosening usable
Fastened Parts: wear limit.

Contacting Parts:
You will therefore see that in the event of sticking, it results
This may concern electrical parts. Always perform Hoisting, in some air gap, after the coil has ben energized. It will
Details of Maintenance : therefore continue to draw a heavy current, lasting a few
Brake setting-electro magnetic brakes :

Motors : Check if the magnet stroke is 20mm.

Electrical motors should be protected against drops of If not, manipulate adjuster nuts to obtain 20mm stroke.
water, oil, etc. Terminal boxes should be carefully closed. Make the head release lever ‘NO’
The electric motor should be periodically inspected and Check uniformity of gap between brake drum and shoes.
Installation & Maintenance of Electro Hydraulic.
cleaned. Before inspection, the motor and slipring box Thruster :

Brakes : The thruster incorporates a motor-driven centrifugal oil

Installation :

Wipe away any dirt accumulated around the oil filler plug in
the tank cover. There is also an oil level plug. Remove both
Brake setting - Thruster Brake :

Please refer diagram of EHT brake. In normal case, brake

shoe “A” opens, but to open brake shoe “B” with “A” adjust
 ELECTRO - FAB ELECTRO - FAB

Maintenance Instruction Maintenance Instruction

Bearings :

All sizes have as integral stator/rotor unit; top bearing is Permissible

grease lubricated
Maintenance : and the bottom bearing splash lubricated First pair of 10% of tooth
Normally the operating oil will not require changing more 20% of tooth
frequently
ster, take than
greatonce
careinthat
twono
years.
dust Itdrops
is advisable
into thetotank
check
or
Master Controller / Cam Controller - Maintenance : 50% of full size.
Flang
(If provided)
Isolate the main supply before opening the controller
50% of full size.
Bearings : When the
A thin film of cid-free grease is to be provided at the pivot 50% of wire rope diameter
Contacts :

The Contact surface will become dark and rough due to

Gears :
Brake Lining 50% of full size

Gears are to be inspected at least once every six months. Wire Rope 10% pf total
During a check-up, care should be paid to the condition of
working
Bearings : surface, degree of teeth wear and correctness of
When checking roller bearings care should be paid to their
fastening
Wire Rope : in the bodies, tightness of covers, condition of
The reliability and soundness of wire rope for further use
Traveling Wheels :

Traveling
Control Panel : wheels should not have cracks or worn collar

Control panel should always be closed & locked in order to

protect it from dust, water, oil, foreign particles etc. Do not
remove drawings pasted on inside of doors. Do not play /
Permissible Wear :
Do not use the parts of the Crane over the following limits of
 ELECTRO - FAB ELECTRO - FAB

Maintenance Instruction Maintenance Instruction

Sr.
Part to be lubricated
Method of
INTERVAL RECOMMENDED LUBRICANTS Gantry Rail Alignment Allowance:
No. application
Indoor Outdoor I.O.C. HP CALTEX
1. Enclosed Gearing:
a) Less than 12HP Splash A B Servomesh Enklo 85 Catlex
ambient temperature 50 or 120 Meropa No.4
Less than 50°c
Ambient temperature Splash C D “ “
greater than 50°c

b) 12 to 40 HP ambient temperature Splash A B “ “

Less than 50°c

Ambient temperature Splash C D “ “

greater than 50°c

c) above 40 HP ambient temperature Splash A B “ “

Less than 50°c

Ambient temperature Splash C D “ “

greater than 50°c

2. Open Gearing : Manual E E Servocoat Hytak F30 Catlex

120 or 300 Crater No.1

3. Ball Bearing : Used for Motor, Grease A B Servocoat Lithon Catlex

Limit Switch, Controller & other Nipple 2 Ep2 Multifax No.2
Mechanical Equipment.

4. Plan Sleeve Bearing Grease F F Servocoat Lithon

“
Pump 2 Ep2

5. Track Whell : Felt G G Servomesh Enklo 85 Catlex

a) Plain Sleeve Bearing Lubricated 50 or Cetus Oil
or F F Servogem 120 Multi park
Grease Pump 2 Lithon Ep2 No.2

b) Antifriction Grease Nipple A B Servogem 2 HYTAK F300

6. Sheave & Hook Block :

a) Plain Sleeve Brg. Grease Nipple F F Soverex L 1 HYTAK Multi park
F300 No.2

b) Antifriction Brg. Grease Nipple A B “ “ “

c) Antifriction Brg. Manual G E Mobile “ “

Grease SPL

7. Wire Rope : Manual E E Servocoat Hytak F30 Catlex

120 Crater No.1

8. Electrical Part (PINS) : Manual E E Servomesh Enklo 85 Catlex

50 Cetus Oil

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

Maintenance Instruction Maintenance Instruction

Permissible Deviation in Crane Alignment : Maintenance Schedule:

No. Description Frequency Of Check

A) Mechanical:

Bolts & Nuts

a Bolts of Hoist/CT/LT motors 3 Months
b Bolts of Hoist/CT/LT brakes 3 Months
c Bolts of Hoist/CT/LT gearboxes 12 Months
d Bolts of Hoist Drum bearing housing 6 Months
e Bolts of hoist drum gear 6 Months
f Bolts of CT wheels 6 Months
g Bolts of LT wheels 3 Months
h Bolts of CT shaft & coupling 6 Months
i Bolts of LT shaft coupling & bearing housing 6 Months
j Bolts ofgirder & end carriage joints 12 Months
Greasing of all CT/LT wheels 6 Months
Lubrication/top-up of oio-Gearbox/brakes 12 Months
LT wheel assembly & its movement 6 Months
CT wheel assembly & its movement 12 Months
Condition of brake shoes 1 Month
Brake adjustment 3 Months
Machinery alignment 6 Months
Movement of wire rope pulleys 12 Months
Wire rope for breakage of strands etc 12 Months
B) Electrical:
Operation of hoist limit switch 3 Months
Operation of CT/LT limit switch 6 Months
Direction of motion with respect to pendent Daily
pushbutton
No load current check of all motors 12 Months
Functionally of control logic 12 Months
Brake operation Daily
Current collector functionality 6 Month
C) Visual inspection of wearing out / damage Weekly
to mechanical parts
D) Noise in all motions Weekly
E) Complete No-load test of crane 6 Months
 ELECTRO - FAB ELECTRO - FAB

DO’S And DON’T’S DO’S And DON’T’S

AFTER DISUSE. When the crane is to be operated after a long period of the disuse be sure to operate all the motion without load first.

Always lift load with slow speed and then with fast speed. While lowering, fast speed is to be used up to certain level, then go to slow
DO NOT “LOAD BEYOND THE RATED CAPACITY” i.e.
some load carrying parts. Overloading might also start a defect even at less rated capacity in future. speed & then release button. This will avoid falling or slipping of load. This because of delayed operation of thrustor brake.

safe working load (SWL). The immediate danger is the

DO NOT USE ANY OVERHEAD MATERIAL HANDLING EQUIPMENT FOR HANDLING PERSONNEL. While operating CT or LT motion, always change to slow speed once you approach extreme ends & then release button. This will stop
motion exactly where you want otherwise crane will cross the desired position.

p o s s i b l e
engineers before loading the hoist
f a i l u r e o f When VFD’s are provided, excessive inching is not allowed. This cause tripping of VFD frequently. Instead use slow speed.

you move.

CONDUCT A PERIODIC VISUAL INSPECTION FOR

SIGNS OF DAMAGE OR WEAR. Particular attention Look My Capacity Rest The Load Before You Go Look A Twist

should be paid to the wire rope and hook. If there are signs
operated
of wear of damage or if the hook is distorted or opened out,
call it to the attention of the safety
.been found and corrected.

DO NOT USE HOISTING ROPES OR CHAINS AS A

meaning less if the load is not supported evenly.
Never Stand Under The Load Not Meant For Joy Ride Avoid Jerks
SUBSTITUTE FOR SLINGS. Use the slings only. Cable or
method employed when it is necessary to cut the wire rope.
cWIREhROPES a FORi LOADn HANDLING should notsbe kept l oni thenloadgwhichsmay move or slip off. s h o u l d
be of the proper size and type for load handling. Never use
slings showing physical damage of any extent.
reversal of the object position which will cause a very heavy strain on the ropes and possibly make them snap

creates higher stress in the wire rope then when suspending it.

WHENEVER THE
signals of only those persons authorized to giveHOIST ISwhenLOWERED
them. Do not operate signals are not clear. IN SUCH A
MANNER
DO NOT LEAVE THE LOAD ASSUSPENDED
TO TAKE THE
IN THE AIR AND LOAD OFF THE CENTER,
UNATTENDED. Balance The Load Properly Please Do Not Swing The Load

tcurrent
h greater
e then the running currentoandpleadseto overr heating,
a tor burno outr if continue to excess. s h o u l d
determine, before making a lift again, if the wire rope is
 ELECTRO - FAB
Before Making Service Call
No supply in control panel
Supply present in Control Panel, but does
not start any Motion
All above points OK, still does not start any
motion
VFD display & pushbutton operation OK,
but motion does start
Still motion does not start
Humming noise in motor
Slow speed not functioning
(If VFD’s provided)
Only one direction working
(If VFD’s provided)
Crane not stopping at extreme ends
Brakes not operating properly
Oil leakage in gearbox/brakes
Noise in LT motion
While lowering, load falls
down suddenly
Hoist Up & Dn limit switch not
operating
Direction of motion not as per
push button
ELECTRO - FAB
Test Certificates
i) Check main switch in ON position.
ii) Check fuses in main switches are OK.
iii) Check incoming supply to main switch.
iv) Check supply in busbars.
v) Check availability of supply in the switch feeding busbars.
vi) Check current collectors.
i) Check position of EM OFF pushbutton. It should be in release or out position.
ii) Check control MCB’s are in ON position. (Normally MCB 1& MCB2)
iii) Check operation of main contactor MC by pressing STA.RT pushbutton.
iv) Check individual motion power MCB’s are in On position (Normally MCB3,
MCB4 & MCB5 For Hoist /CT & LT respectively).
v) Check for RED lamp on SPP, if provided. If RED it has tripped due to phase
reversal or phase failure.
vi) Check contactors A1 & A2 lare ON. If provided, they checks resence of all 3
phases.
i) Check all VFD display shows “0”. If not, supply at incoming terminals of VFD.
ii) By pressing pushbuttons of all motions, check that VFD display shows
frequency,either Slow (eg.15) or Fast (eg.50)
i) Check cables between VFD & motors are properly connected. If required, check
continuity not start.
ii) Check that brake is releasing properly after pressing any push button of any
motion.
i) Check for VFD showing any trip signal. If so, please refer attach sheet for
various trip signal & try to rectify problem.
ii) Still problem persists, remove coupling between motor & gearbox and also keep
brake in loose position. Now check that mo tor is rotating freely by turning the
shaft manually. If shaft is jam, call us or send motor for repairing.
iii) If VFD indicating trip signal & you are not able to rectify problem, please call VFD
service person.
It is quite if VFD’s are provided & is acceptable.
Check contactors, normally D3, D6 & D9 are operating for Hoist/CT/LT respectively.
Check contactors, normally D1-D2,D4-D6& D7-D8 are operating for Hoist/CT/LT
respectively.
Check that limit switches operate properly by actuator in case of CT & LT motion.
For hoisting check geared limit switch.
i) Check oil in brake.
ii) Check cable connections
iii) Check wearing out of brake shoes/liners.
iv) Check thruster for any damage.
i) Check exact location of oil leakage.
ii) If required change oil seals.
iii) Check any damage for housing.
i) Check LT wheels for any wearing out.
ii) Check rail joints & rail alignment.
i) Always follow load lowering instructions mentioned in DO’S AND DON’T’S.
ii) Check condition of brake shoes.
iii) Adjust brake if required.
Check incoming phase sequence.
Check incoming phase sequence.