Reva EOT series Maintenance Manual

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MAINTENANACE MANUAL

FOR

EOT CRANE

REVA INDUSTRIES LIMITED

Regd. Off. & Unit I : Plot No. 28, Sector 25, Faridabad – 121004 (Haryana)

Phn : +91-129-4185400

Fax : +91-129-4185414

E-mail :

reva@revacranes.com

Web :

www.revacranes.com

Unit II : Plot No. 164, Sector 24, Faridabad – 121005 (Haryana)

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Page 1 MAINTENANACE MANUAL EOT CRANE REVA INDUSTRIES LIMITED Regd. Off. & Unit I : Plot No. 28, Sector 25, Faridabad – 121004 (Haryana) Phn : +91-129-4185400 Fax : +91-129-4185414 E-mail : reva@revacranes.com Web : www.revacranes.com Unit II : Plot No. 164, Sector 24, Faridabad – 121005 (Haryana)
Page 2: Table Of Contents
MAINTENANACE MANUAL INDEX REVA EOT CRANES - DESCRIPTION. OPERATIONS OPERATION OF CRANES & T PERATORS UALIFICATION RAINING PERATING ROCEDURE PERATING ULES & H IGNALS FOR VERHEAD RANES OISTS MECHNICAL MAINTENANCE OF WIRE ROPES XAMINATION OF OPES :- W ALIENT AINTENANCE...
Page 3 ERIODICITY OF AINTENANCE MONTHS 11 MAINTENANCE OF BRAKES 11.1 DC D RAKES 11.2 E LECTRO YDRAULIC HRUSTOR RAKE 12 MAINTENANCE OF CONTROL PANEL 13 POWER FEEDING ARRANGEMENT TESTING OF CRANES. TROUBLE SHOOTING 16 ANNEXURE A REVA INDUSTRIES LTD. Page 2...
Page 4: Reva Eot Cranes - Description
MAINTENANACE MANUAL REVA EOT CRANES - DESCRIPTION. The EOT Cranes are manufactured to carry out the following functions: Hoisting, i.e, lifting and lowering of all loads upto the maximum specified working load at different specified speeds. Travelling at specified speeds in both loaded and unloaded conditions;...
Page 5 CT DSL Arrangement LT Wheel UNDERSLUNG EOT CRANE ( Fig. 3 ) The items shown here may not necessarily be the part of the crane offered. Please refer detailed General arrangement drawing for the same. REVA INDUSTRIES LTD. Page 4...
Page 6: Operation Of Cranes
 Traverse the trolley with load both ways and check the functioning of cross travel brakes. Similarly, check the brakes for long travel.   Avoid impact loading by sudden lifting or lowering of the load. Sudden hoisting or lowering may cause breakage of the wire rope. REVA INDUSTRIES LTD. Page 5...
Page 7  Be careful while moving molten metal. Even slight swing can cause spurting of the molten metal.  Approach to the runway stop or to any other crane in the vicinity should be with extreme caution. REVA INDUSTRIES LTD. Page 6...
Page 8: Hand
It is recommended that the signal chart/diagram should be framed and displayed at suitable locations at the place of work so that the operators and the signalmen are fully familiar with the signals to be used during crane operation. REVA INDUSTRIES LTD. Page 7...
Page 9: Maintenance Of Wire Ropes
& wire manufacturer’s recommendations, if any, and local rejection criteria based on the experience gained. It is not possible to prescribe or lay down an exact code for decision-making. There are, however, certain generally accepted criteria for discarding wire ropes:- REVA INDUSTRIES LTD. Page 8...
Page 10: R Eplacement Of
Two more clamps should be fixed adjacent to cutting marks. distance between these two clamps at the cutting point should be kept minimum. These measures ensure that the outer layers containing shapes wires do not become slack on REVA INDUSTRIES LTD. Page 9...
Page 11: Maintenance Of Pulleys & Sheaves
 Check the pulleys and sheaves frequently for wear and alignment and take corrective action.  The pulleys and sheaves are made of hard metal to minimize the wear during service.  Check the pulley & sheave bearings for wear and see that these are lubricated. REVA INDUSTRIES LTD. Page 10...
Page 12: Maintenance Of Reduction Gear Box
Wear can be recognized from outside by checking the position of the points in relation to the two notches in the boss. If the pointer is exactly between both notches, no wear has taken place. REVA INDUSTRIES LTD. Page 11...
Page 13: Maintenance Schedule
Check and ensure the single phase preventor is free of dust. Test the operation of the same.  Check & clean timers. Adjust the timing of the timers.  Check the fuses and replace blown ones  Thoroughly check motors at six months intervals, i.e., second quarterly schedule. REVA INDUSTRIES LTD. Page 12...
Page 14: Yearly
Note:- It may be noted that the maintenance schedule hitherto given is only for guidance. The user may suitably modify the schedule based on the site and working conditions and keeping in mind the safety aspects. REVA INDUSTRIES LTD. Page 13...
Page 15: Maintenance Chart
Gear Box Check and top oil Motor Bearings Routine Check in monthly/quarterly. Thorough check six monthly Brake Routine Check in functioning monthly/quarterly. Thorough check six monthly Limit Switch Check functioning. Wheel Check for wear. Condition REVA INDUSTRIES LTD. Page 14...
Page 16 The yearly schedule is primarily for carraying out repairs where welding on structure is involved or replacement of a major part is required. During this schedule, more time is available and a thorough attention is possible as compared to monthly schedule when limited time is available for maintenance. REVA INDUSTRIES LTD. Page 15...
Page 17: Recommended Lubricants
Once in quarter Hook bearing Greasing - do - Thrustor Oil change Once a year HYSPIN EP-100/ Transformer Oil Plummer Blocks Greasing Once a month. Asatma AP 3 Grease Pulleys/Sheaves Greasing Once a month. - do - REVA INDUSTRIES LTD. Page 16...
Page 18: Maintenance Of Electric Motors
5 megaohms and in warm winding (greater than 40 C), at least 1 megaohm. If resistance is lower, the winding needs to be dried. This could be accomplished by putting the motor into a warm and well-ventilated oven (temperature about 80 REVA INDUSTRIES LTD. Page 17...
Page 19 If the stator frame feels burning hot (temperature over 50 measure the accurate temperature with the thermometer. The maximum allowed temperature of hottest spot on the widening is 130 C for B class and 150 C for class insulation. REVA INDUSTRIES LTD. Page 18...
Page 20 Stator A/B Mounting Bolt and Washers Armature Plate Friction Plate Torque Adjusting Ring Rubber Seal Compression Ring Mounting Flange Compression Parts A-E Hand Release Assembly Rotor Adjustment Tube REVA INDUSTRIES LTD. Page 19...
Page 21 Carry out load test to check the operation of assembled units.  Note: - For detailed maintenance, it is advisable to go through the maintenance instructions of brake suppliers. Some extracts are given as Annexures at the end of this chapter. REVA INDUSTRIES LTD. Page 20...
Page 22 10.2.1 Adjustment of Hoist Brakes The brakes are suitably adjusted before dispatch from Reva factory with a gap of 0.3 or 0.4 mm on the drum and no additional adjustment is normally required at the site.
Page 23 0.5 mega ohm. Power Feeding Arrangement Reva has provided the following types depending on the customers requirements:- Taut wire type has a wire held tight between two ends on which the power is to be ...
Page 24 The maintenance requirement is to check that there is no physical damage to taut wires or angle irons or the insulators connected to those. Sometimes bird dropping creates problems of contact with current collectors. All that is required is cleaning of wires or angle irons. REVA INDUSTRIES LTD. Page 23...
Page 25 START Hoist Motion Not working Check fuses F10-F12 Check Contactor 2C1 Working & 2C2 operation Working Next Page by presing pendent push button /VVVFD Measure DC V switching on 2C1 or 2C2 Voltage = 190 V (DC) Check Voltage at 225 of 226 Check brake Voltage Replace...
Page 26 Continue Working Fuse Check Blown Control fuse Replace Fuse Fuse Check Fauh Replace O/L O/L Relay 2OL1 Replace O/L Check O/L Relay 2OL Fault Limit Switch Replace Limit Switch Check Limit Switch Contactor Coil Check Contactor Coil Replace coil Check for Loose Connection...
Page 27 MH SPEED INCR. BRAKE RELEASE /4.1:D /4.1:E /4.1:E /4.5:C /4.5:C MH MOTOR 3 PHASE INPUT AC VVVFD - 2D1 SUPPLY HOIST REVA INDUSTRIES LTD /4.5:D FARIDABAD-121004 RELAY IN BUILT IN DRIVE /4.5:D REVISION NO. SIGN SCALE:NTS SIGN DATE DATE /4.8:B DRAWN...
Page 28 /4.0:A AC EHT AC EHT AC EHT BRAKE 2S1 BRAKE 2S3 BRAKE 2S2 MH MOTOR 11 KW 2M2CREEP MOTOR 1.5KW 2C42 /4.5:D 2C41 REVA INDUSTRIES LTD /4.4:D FARIDABAD-121004 DATE REVISION NO. SIGN SCALE:NTS DATE SIGN TITLE:- DRAWN 2C40 CHKD /4.3:D...
Page 29 6 /3.1:B 6 /3.5:B /4.3:C /4.2:C /4.2:D /4.2:D /4.7:D /4.7:D /4.7:C /4.6:C /4.3:C /4.4:C /4.8:B /4.9:B /4.7:B /4.8:B REVA INDUSTRIES LTD FARIDABAD-121004 DATE REVISION NO. SIGN SCALE:NTS DATE SIGN TITLE:- DRAWN CHKD CONSIGNEE :- APPD PROJECTION CLIENT:- M/s - COFMOW...
Page 30 If hoist contactor and rotation is not correct, switch off power and reverse leads on the main supply collectors or on the hoist (whichever is incorrect) to obtain correct phasing. Restore power and recheck. REVA INDUSTRIES LTD. Page 24...
Page 31  Adjust end limit switches.  Reset bridge timers, if needed.  Check the functioning of accessories. 13.3.2 Hoist Block Reeving The hoist blocks and rope may now be installed. The various reeving arrangements are as below. REVA INDUSTRIES LTD. Page 25...
Page 32 MAINTENANACE MANUAL 2/8 FALL 2/4 FA LL 2/8 FALL 2/12 FALL PA RA LLEL TY PE PARRALLEL TYPE REVA INDUSTRIES LTD. Page 26...
Page 33 The overload test takes care of any deviation in performance of relays and is more a design safety factor. The satisfactory commissioning of the crane shall be demonstrated to the purchaser and commissioning certificate attained. REVA INDUSTRIES LTD. Page 27...
Page 34 Ream the hole and use oversize bolts bolts / Replace Coupling. Keyway damage damage to key & shaft Repair keyway and replace key. Surface crack ultimate failure Replace. Bearings Heating of bearings failure Replace Jerking running failure Replace. REVA INDUSTRIES LTD. Page 28...
Page 35 Main Switch a) Contact burnt/ Replace defaced b) No power Check & replace burnt fuses c) Line discontinuity Check voltage in all three lines. Check whether main switch is ON. REVA INDUSTRIES LTD. Page 29...
Page 36 Screw the adjustment tubes out of the stator if the gap is too small  The width of air gap changes by approx. 0.15 mm when turning the sleeve  1/6 revolution. c) Tighten the screws on stator Check the air gap and repeat the adjustment, if necessary. REVA INDUSTRIES LTD. Page 30...