Professional Documents
Culture Documents
Ref.: 18 - Cranes
Edition 01/10
Ref.: 18 - Cranes
Edition 01/10
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
0
Ref.: 18 - Cranes
Edition 01/10
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.
Attention!
Warning
Danger!
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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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Edition 01/10
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)
Ref.: 18 - Cranes
Edition 01/10
Load spectrum
Average operation time for a working day
load
spectrum
evaluation
is
based
on
of
service
conditions:
2. Moderate
1. Ligth
types
% Operating time
% Operating time
3. Heavy
4. Very heavy
% max. lifting load
% Operating time
% Operating time
t=
2 H N T
V 60
Ref.: 18 - Cranes
Edition 01/10
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
1.6 h
Medium
We will obtain:
Classification 1 Am / M4
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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Edition 01/10
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.
DANGER! !
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Edition 01/10
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! !
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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Edition 01/10
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.
Anchoring plate
Anchoring plate
Centering pivot
Cranes girder
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Edition 01/10
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
CRANE RUNWAY
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.
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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.
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.
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
3.7. 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.
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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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.
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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.
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.
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Inspection method
Structure/
Component
Inspection Point
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
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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.
SWP (%)
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
5%
1%
0%
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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.
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
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When the Safe Working Period (SWP) of the hoist is exhausted, the hoist may
only be used after a GO has been conducted.
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
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.
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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.
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.
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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
27
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).
www.vinca.net
APPENDIX
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.-
l.-
m.-
n.-
Clean and check coals, graphites, etc.. from the outlet trolley (only compact lines).
o.-
p.-
Check wearings and junctions along the bridge travel (beams and rails).
q.r.-
Rev.: 0
Autor: SM
30
32
de
Date
Rev.: 0
Autor: SM
31
32
de