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:
01) 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:
02) 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.
03) 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.
04) Balance crane and trolley/crab so that the crane hangs horizontal during lifting.
05) Secure trolley/crab against shifting sideways by wedging and lashing it.
06) 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.
07) Lift the crane. Guide with ropes while lifting. Each rope must be guided by one person.
08) Attach the guide ropes in such a way that the persons holding them are not standing
underneath the load. (Refer sketch below)
09) When lifting the crane, position it diagonally and lift it over the crane runway.
10) Swival 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.