Double Girder Gantry Crane Installation Guide

General Overview

This guide specifies the standard installation procedures, persyaratan keselamatan, and commissioning steps for double girder gantry cranes. It applies to industrial outdoor and indoor double girder gantry cranes used for material handling in factories, Ports, dan lokasi konstruksi. All installation work must be performed by certified professional technicians in strict accordance with manufacturer specifications and national crane safety standards. Unauthorized modification of installation procedures is prohibited to avoid equipment failure, kerusakan struktural, or safety accidents.

Double girder gantry crane installation guide

Persiapan Pra-Instalasi

1. Inspeksi Lokasi & Foundation Verification

Pertama, inspect the installation site to ensure the ground foundation meets the load-bearing requirements of the double girder gantry crane. Check the flatness, kekerasan, and levelness of the foundation, and confirm there is no subsidence, retakan, or uneven settlement. Verify the installation spacing, track center distance, and overall dimension of the site match the crane’s design parameters. Clean up obstacles on the installation route and working area to ensure sufficient space for hoisting, perakitan, and subsequent operation.

2. Instalasi Rel & Inspeksi

Install the crane running rails strictly according to the design drawings. Fix the rails on the foundation embedded parts, adjust the rail levelness, kelurusan, and gauge deviation to meet standard requirements. Setelah instalasi, conduct a comprehensive inspection: check rail connection firmness, weld quality, and end clearance; ensure no deformation or dislocation of the rails. Record all inspection data for subsequent acceptance reference.

3. Component Checking & Tool Preparation

Unpack all crane components including double main girders, kaki pendukung, gerbong akhir, traveling wheels, hoist trolley, sistem kendali kelistrikan, pengencang, and safety accessories. Carefully check each part for manufacturing defects, deformasi, karat, atau kerusakan, and verify the quantity and model of components are consistent with the delivery list. Prepare professional installation tools, hoisting equipment (auxiliary cranes, gendongan, belenggu), measuring instruments (laser level, Kunci pas torsi, pita pengukur), and safety protection supplies.

4. Persiapan Keamanan

Set up warning zones and safety barriers around the installation site, and post safety warning signs. All construction personnel must wear safety helmets, safety belts, and other protective equipment. Conduct pre-installation safety technical disclosure to clarify operation specifications, risk points, and emergency disposal measures. Confirm the power supply of the site is stable and grounded reliably to ensure safe electrical operation.

Double girder gantry crane installation guide

Main Mechanical Structure Installation

1. Ground Pre-Assembly

Complete partial pre-assembly of components on the flat ground to reduce high-altitude operation risks. Assemble the two main girders as a whole structure according to the assembly marks, fasten all connecting bolts with a torque wrench to reach the specified torque value. Install the walking platform, pegangan tangan, and trolley running track on the main girders, and check the flatness and firmness of the track surface. Then assemble the supporting legs and end carriages into integrated parts respectively.

2. Supporting Leg & End Carriage Installation

Use qualified auxiliary hoisting equipment to lift the assembled supporting leg and end carriage assemblies vertically, and place them accurately on the reserved installation position of the running rails. Adjust the verticality, kerataan, and spacing of the supporting legs strictly, fix the traveling wheel boxes on the rails, and ensure the wheels are completely attached to the rail surface without deviation or suspension. Temporarily fix all connecting parts to prevent displacement during subsequent girder installation.

3. Double Main Girder Hoisting & Fixing

Adopt integral hoisting method for the assembled double main girders. Hang the slings at the designated lifting points of the girders to ensure uniform stress and balance during hoisting, and avoid tilting or structural deformation. Slowly lift the main girder assembly to the design height, align the connecting holes with the top of the supporting legs accurately, and carry out butt joint installation. After precise alignment, install and tighten all high-strength bolts in sequence, and use a laser level to recheck the levelness and span deviation of the main girders to ensure compliance with design standards.

4. Troli & Hoisting Mechanism Installation

Place the assembled hoist trolley stably on the trolley track of the double main girders, adjust the trolley wheel gap and running parallelism to ensure flexible and jitter-free movement. Install the lifting mechanism, steel wire rope, blok katrol, and hook group in strict accordance with the mechanical assembly drawings. Check the winding direction and tightness of the steel wire rope to ensure no strand disorder, extrusion, atau memakai. Install buffer devices, limit stoppers, and anti-derailment devices at both ends of the trolley track.

Double girder gantry crane installation guide

Electrical System Installation

1. Electrical Component Installation

Install the main electrical control cabinet, trolley control box, resistance box, and operating device (pendant control or cab control) at the designated positions. Fix all electrical boxes firmly with shock absorption measures to prevent vibration damage during crane operation. Install travel limit switches, lifting height limit switches, pembatas beban berlebih, and other safety electrical accessories, and ensure all sensor components are installed accurately and fixed reliably.

2. Pengkabelan & Grounding

Lay cables strictly in accordance with the electrical wiring diagram, arrange cables neatly, and fix them with cable clamps to avoid dragging, extrusion, and friction damage. Connect L1, L2, L3 power lines, neutral line N, and protection grounding line PE correctly, and tighten all copper wire terminals firmly to ensure good electrical contact. Complete the grounding connection of the crane metal structure, and test the grounding resistance to ensure it meets safety standards, preventing electric leakage accidents.

3. Circuit Inspection

After wiring completion, conduct a comprehensive circuit inspection. Check for wrong wiring, missing connection, virtual connection, and short circuit risks. Verify the phase sequence of the power supply to ensure the walking and lifting directions of the crane are consistent with the control operation. Inspect the insulation performance of all circuits to ensure no insulation damage or electric leakage hidden dangers.

Double girder gantry crane installation guide

Debugging & Komisioning

1. No-Load Debugging

Switch on the power after confirming all mechanical and electrical installations are qualified. Conduct no-load operation debugging: operate the crane’s longitudinal traveling, trolley transverse traveling, and lifting mechanism respectively. Check whether each mechanism runs smoothly without abnormal noise, jitter, or stuck phenomenon. Test the sensitivity and reliability of all limit switches, perangkat penyangga, and safety protection functions, and adjust the limit stroke to the standard range.

2. Uji Beban & Kalibrasi

After qualified no-load debugging, carry out graded load tests according to standard procedures, termasuk 25%, 50%, 75%, 100%, Dan 125% rated load tests. During the test, check the structural deformation of the main girders and supporting legs, the operating stability of each transmission mechanism, the braking performance of the brake system, and the accuracy of the overload protection device. Record all test data, and adjust and calibrate unqualified items until they meet the standard requirements.

3. Overall Performance Inspection

Inspect the overall operation coordination of the crane, confirm the synchronous operation of each mechanism, accurate control response, and reliable braking. Check the tightness of all connecting bolts, the lubrication state of transmission parts, and the integrity of safety accessories. Eliminate all installation defects and hidden troubles to ensure the crane’s overall performance meets design and safety operation standards.

Final Acceptance & Safety Notes

1. Completion Acceptance

Sort out all installation records, inspection data, laporan pengujian, and component qualification certificates to form a complete acceptance document. Conduct final acceptance jointly by the construction team, supervision party, and user party. The crane can only be put into formal operation after passing the overall acceptance and obtaining the crane use qualification certificate.

2. Daily Safety Operation Notes

Operators must receive professional training and hold valid certificates before taking up their posts. Strictly abide by the crane operating specifications, prohibit overload operation, oblique pulling, and random limit operation. Conduct daily inspection and regular maintenance of the crane’s mechanical structure, sistem kelistrikan, and safety devices to ensure long-term stable and safe operation of the equipment.

3. Post-Installation Maintenance

After installation and commissioning, lubricate all rotating and transmission parts comprehensively. Check and fasten all loose fasteners again. Clean the equipment surface, sort out installation tools and residual materials on site, and complete site cleaning and finishing work.

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