INSTALLATION, DESIGN AND MAINTENANCE OF OVERHEAD CRANE

INSTALLATION OF CRANE

The following are the list of items to be installed at site:

1. Crane Rail Installation.
   • Fixing for Crane Rail, End stoppers – Please refer site fixing drawing
2. Complete crane.
3. Crane power line, main isolator, terminal box, rising cable & towing arm.
4. Crane limit switch & actuators.
5. Complete Hoist (Please refer Hoist O&M).

FIXING CRANE RAIL & END STOPPERS

General Instruction

Check the dimensions and clearance of the runway with reference to General arrangement drawing. Crane track tolerances shall be as per DIN 4132. Refer next page for the details of crane track tolerances as per DIN 4132.
Correctly positioned crane tracks are a prerequisite for the smooth running of the crane. The life of the travel units and their wearing parts is thereby considerably increased. Non compliance with our specification for the crane track could lead to rapid wear on wheel flanges, damage to antifriction bearings through over heating, torsional deformation of the steel structure, fracture of welds and derailment.

Crane End Stops Fixing:

Fit stable end stops to the end of crane runway. The front edges of the end stops must be flush with each other and be at right angles to the crane runway.

Max F = 10mm

CRANE TRACK TOLERANCES AS PER DIN 4132:

GENERAL CLIP INSTALLATION RECOMMENDATIONS

INSTRUCTIONS FOR CORRECT POSITIONING AND WELDING

Installation Recommendations

• The centerline of the rail must be used as the reference. Using gages is recommended.
• Clips should be installed in opposing pairs. They should never be staggered.
• Welding should be completed prior to pad installation, as excessive heat could damage the pad.
• Do not paint between clip components unless accepted by GANTEX.
• Clip spacing, distance of weld to the edge of the steel plate. as well as corrosion protection will depend on the application Please consult GANTREX.

Recommendations for Welding

The lower component of the GANTREX clips is welded to the support structure. The actual weld size is dictated by design thrust and should be specified by the designer, who must also give comprehensive welding procedure Weld Y on the back and sides of the clip may be as large as required to accommodate the imposed side thrust and to meet governing welding code requirements.

Welds X an Z” on the side facing the rail may not exceed the indicated values. This will avoid any interference with the locating lug on the upper component or the rail Weld Z on the side along the rail is not applicable if no pad is used: the toot of the rail may touch the weld. If the weld size or length are reduced, the full capacity of the chip might be jeopardized, please consult GANTEX.

CLIP INSTALLATION INSTRUCTIONS

New features

The Double Wedge Design ensures upper component remains in contact with rail toot during installation process. Hitting the clip upper part with a hammer is not required anymore.

Due to the special Square Shank Base screw head. electrical and pneumatic torque wrench is allowed and will rot damage the screw.
To be sure the right torque is achieved; regular control during installation with a calibrated torque wrench is recommended. Patent pending.

Torques

CLIP SPARE PARTS

Detail for Rail Clip

CUP SPECIFICATION

The RailL o” patent pending clips are specifically designed to facilitate correct mounting of crane rails
• The Double Wedge Design” ensures tight contact with the rail foot.
• Bolts with “Square Shank Base” allow the use of impact-wrenches.
• Easier installation because of the wider adjustment range.

• Compact design . fits narrow girders and soleplates, avoid interference with guide rollers. Once installed, the clips are self-locking and self-tightening.

COMPONENTS MATERIALS

Tre Rail ok”” W1C is standard with a weldable forge steel lower component a ductile cast iron upper component and vulcanize-bonded rubber nose. As standard, the bolts and nuts are hot dip galvanized. The upper component can also be hot dip galvanized on request. Contact GANTEX for other options.

INSTALLATION AND SUGGESTED WELD INSTRUCTION

The lower component is welded on the support parallel to the axis of the rail and the upper component is fastened to it by means of one bolt and nut. The recommended torque is 75 Nm. Electrical and pneumatic torque wrenches are allowed as long as the minimum torque of 60 Nm is met and the torque does not exceed 100 Nm. It is recommended the torque is regularly controlled with a calibrated torque wrench.

For most applications, the recommended weld throat size is X4 mm; the weld leg size is then 6 mm. If the pad is not used, the weld along the toot of the rail must be removed. Use any low hydrogen rod suitable for use with structural steel. ISO2560 type E 425 B 32 H5, E7018 or equivalent. For full instructions on weld size and electrodes, refer to the data sheet ‘Installation and suggested weld instructions”.

Do not apply protective coating on the contact surface between upper and lower components unless accepted by GANTEX. Do not use solvents as they may seriously damage the rubber nose.

INSTALLATION OF CRANE

TYPICAL LAYOUT OF SINGLE GIRDER TOP RUNNING CRANE:

1) Crane bridge girder.
2) End carriage.
3) Girder-End carriage connection.
4) Crane drives.
5) Hoist+ Trolley.
6) Power supply festoon line.
7) Control pendent.
8) Bridge panel.
9) Buffer stop for trolley.
10) Equipotential bonding (for Ex-proof cranes).

TYPICAL LAYOUT OF DOUBLE GIRDER EOT CRANE:

1) Crane bridge girder.
2) End carriage.
3) Girder-End carriage connection.
4) Crane drives.
5) Hoist+ Trolley.
6) Power supply festoon line.
7) Control pendent.
8) Bridge panel.
9) Buffer stop for trolley.
10) Equipotential bonding (for Ex-proof cranes).

If the end carriages are dismantled before dispatch due to transport constraints, the same have to be assembled at site as per the following procedure:

The end carriages shall be assembled with the girder(s) on the ground before raising it up. Arrange the crane so that the side for electrical connection is on the side of the power line.

Assembling end carriages:

• Free the connecting surfaces of the girder & end carriage from rust, dust, paint, oil and impurities. Soiling of the contact surface between end carriage & connection plate can lead to unintentional loosening of the bolt connection and thus a fatal accident. Align end carriage connection and span at right angles and parallel and check.
• Screw down bolt connection. The tightening torque shall be applied by the nut (refer table). Only calibrated/certified torque wrench should be used. Use only original parts supplied by Stahl. Original nuts are factory coated with MoS2.
• Close the hand holes with cover after tightening the bolts.

Top running end carriages:

2) Bolt
3) Nut
4) Washer
6) Flanged bush
8) Adjustable washer

Assembly of power supply to trolley & electrical equipment.

The trolley and pendent festoon systems are fixed to the suspension bracket which are clamped or plugged to the crane gider as shown below. If the suspension brackets were removed or loose, they must be properly refixed to the girder.

Hoist unit

• Hoist unit of single girder cranes will always be dispatched duly assembled with girder.
• For double girder cranes dispatched in dis assembled condition, after assembling the end carriages and festoon system, place the Hoist unit over the trolley rails welded to the girder.
• Fix the towing arm to trolley.

Electrical installation

• Refer Electrical drawings. Connect the Trolley festoon cable to Hoist panel & Bridge panel.
• Connect the cables between crane travel motors and Bridge panel.
• Connect the Pendant festoon cable to Bridge panel.
• Fix the control pendent to the control unit trolley of the pendent festoon.

ERECTING CRANE:

1. For full outdoor cranes Sealant is supplied along with the shipment. Using this sealant, seal the gap between connection plate & End carriage as shown below:
2. 
3. For lifting the crane, the use of a mobile crane is recommended. If it is impractical to use mobile crane, suitable chain pulley block can be used. In this case provision for fixing the chain pulley block at centre of the span is to be made.
4. Attach lifting slings. We recommend using webbing ropes as lifting sling & protecting endangered sections with wooden blocks. For Double girder cranes, provide suitable support between the Girders at the slinging points to avoid the Girders getting pulled inside during lifting.
5. Balance crane and trolley/crab so that the crane hangs horizontal during lifting.
6. Secure trolley/crab against shifting sideways by wedging and lashing it.
7. Caution: If the trolley/crab shifts while the crane is being lifted or is suspended in the air, the crane may fall and cause a fatal accident.
8. Lift the crane. Guide with ropes while lifting. Each rope must be guided by one person.
9. Attach the guide ropes in such a way that the persons holding them are not standing underneath the load. (Refer sketch below)
10. When lifting the crane, position it diagonally and lift it over the crane runway.
11. Swivel the crane and set down on crane runway.

Double girder Cranes having 8 wheels with bogie design.

For this type of crane, lifting the fully assembled crane from floor is difficult due to the bogie connection of end carriages. Hence the following steps is recommended:
Lift the first girder duly assembled with end carriage bogies and place over the runway.

Lift and place the second girder assembly over the runway.
Connect the end carriage bogie of both girders with end carriage tie using tie pin, lock flat & screws as shown below:

Lift the Hoist unit and place the trolley wheels over the trolley rail. Ensure the orientation. Carryout the electrical installation.

Fixing of Crane power line

Fixing of Crane power line

2C) FIXING OF CRANE POWER LINE:

01) Refer Crane power line fixing drawing and mounting instructions given below.
02) According to the safety regulations, crane power supply systems must be arranged or protected in such a way that they cannot be touched by the load-bearing parts even if the load swings.
03) The power supply must be able to be switched off on all poles by a main isolator.
04) The main isolator must be lockable to prevent unauthorized use.
05) The main isolator must be easily accessible in the area of the crane. The followings are the type of Crane power line system:

01) Festoon Power line (Mainly used for Hazardous area – Explosion proof cranes)

OVERHEAD CRANE INSTALLATION PROCEDURE

For Festoon Power line:

01) Typical layout of festoon power line:

No Description:

1 C-rail.
2 Support arm.
3 Track coupler.
4 Track support bracket.
5 Earth connection clamp.
6 Protective conductor.
7 Earth connection piece.
8 End cap.

9 End stop.
10 Towing trolley.
11 Cable trolley.
12 End clamp.
13 Trolley rope + thimbles.
14 Rope eye.
15 Cable.

NOTE: The items marked (*) are applicable for Hazardous area application only.

02) Part details:

03) Tools Standard metric tools are sufficient (not included in Stahl supply)
04) Fixing of support arm on runway for Monorail hoists:
The support arms shall be fitted to the top of runway using “Girder clips” or fitted to the bottom of runway top flange using “Weldable bracket”. For Both girder clip & Weldable bracket, the bolt size : M8 & Tightening torque 25 Nm.

05) Fixing of support arm on runway for Cranes:

The support arms shall be fitted to the bottom of runway using “Girder clips” or fitted to the runway web using “Weldable bracket”. For Both girder clip & Weldable bracket, the bolt size :

MB & Tightening torque • 25 Nm

06) The track support brackets shall be mounted to the support arm. The C-rail shall be inserted into the track support bracket.

07) The track coupler is slipped halfway onto the first joint of the C rail and then clamped. The correct position can be verified at the sight hole of the coupler. The second C-rail piece is inserted and clamped gap-free. Be sure that the locking screws are tightened equally to avoid any displacement of the rails in the coupler area. In case if the C-rail is required to be cut at site to suit the travel length, it shall be cut in a right angle and deburred.

08) After all the track couplers are fixed, in the first and last track support bracket the C-rail has to be secured against sliding in the horizontal direction. Therefore, 6.2 mm diameter holes are drilled into the side of the rail for the locking screws. It is important to note that the locking screws do not dent or bend the inner wall of the C-rail as the rollers of the trolleys may be damaged.

Special Precaution:

During the assembly of the rail track it is recommended to check that there is trouble-free movement of the trolleys within the rail with the help of one of the supplied cable trolleys.

09) Mounting the Components in the C-Rail

After the C-rail has been installed the towing trolley and cable trolleys are to be inserted into the C-rail from the power feed end of the festoon system. The end stop is inserted into the C-rail and clamped at the power feed end, leaving space for end clamp and rope eye. Second end stop installed at the other end of the system to prevent the trolleys from rolling off of the rail. According to German work safety regulations it is recommended to additionally secure the end stop with a screw M6x40 crosswise to the rail.

• Fix the rope eye next to the end stop and then the end clamp is fixed.
* Finally the open rail ends are closed with end caps.

19) Mount the terminal box A2 to the building nearest to the end clamp.

11) Mounting the Cable

* All the cable trolleys and towing trolley shall be pushed towards the end clamp
* The length of cable supplied consists of a certain length for hookup at the movable end, a length required for the system itself, and the length required for hookup at the fixed end.
– Cable length for hook up at the fixed end is decided based on the distance between the end clamp and the terminal box. This length is marked on the cable from the free end.
– Cable length for each loop shall be 2 times the loop depth + 10% extra. For the required cable loop depth, refer power line fixing drawing e.g. For loop depth= 1000mm.
Cable length for each loop = 2 x 1000 x 1.1 = 2200mm.

Mark the cable length for each loop.

The remaining cable length is for hookup at the movable end. After the cable is marked, feed it through the end clamp support saddles making sure the fixed and mobile ends are in the proper direction. Locate the termination length (marked), position it on the center line of the end clamp support saddle. Place all intermediate cable saddle marks on the center line of the appropriate intermediate cable trolley support saddle. After the cable is positioned properly. It shall be secured by tightening the saddle into place making sure that the marks remain at the center line.

Note:

Alternatively it is possible to pre- assemble the cable with the trolleys at floor and to insert the complete system into the C-rail afterwards.

12) For higher travel speed, bigger cable loop, and curved rail tracks Tension relief towing rope may be required for each cable loop to avoid tension on the cable. Refer Power line fixing drawing for the requirement. If it is required, the cable trolleys and towing trolley are provided with holes for fastening the rope. Rope eye is used to fix the rope near the end clamp.

13) Grounding of C-Rail

In an explosion-proof application C-rail system should be properly grounded. The earth connection clamp is fitted to the C-rail at any convenient location. The earth connection piece is welded to the building structure (crane runway beam). The protective conductor shall be connected between earth connection clamp & piece.

14) Terminate the free cable end at the end clamp to terminal box A2.
15) Fix the main isolator (A 1) to the building structure at floor level.
16) Fix the rising cable & connect terminal box A2 & main isolator A1.
17) Towing arm is fixed to the crane end carriage as shown in below. To achieve best end approach of the crane. the towing arm to be fixed on the end carriage towards opposite side of main isolator so that the festoon trolley accumulation will be accommodated within the end carriage width.

Fixing of Crane Limit Switch & Actuators

For Hazardous area- Explosion proof cranes :

1. Crane limit switch is fixed to the Power line pick-up arm & the Power line pick-up arm is fixed to the End carriage.
2. Limit switch actuators are supplied loose and to be fixed to the Crane runway on both ends as shown below :

NOTE

1. Limit switch actuator has to be fixed at a position so that the distance from the Crane stopper to the End carriage Buffer is -400mm.
2. The above picture shows 2 limit switches, one for each direction to stop the crane. For 2 step limiting (fast speed – slow speed & slow speed – Stop), 3 limit switch and 4 actuators will be supplied. This is an optional feature. 2 nos to be fixed on each side, the 1st to be fixed so that the distance of the crane stopper to the end carriage buffer is ∼1400mm and the 2nd to be fixed as per note-1.

Read More:

Crane Lifting Procedure

Safe Use of Overhead Cranes