• Feb 21, 2025
• News

Overhead Crane Installation Procedure

The installation of overhead cranes involves a number of steps and requires some preparation in advance to ensure that the installation goes smoothly.

Overhead crane installations, especially large overhead crane installations, usually require the personal presence of engineers and installers to scrutinize the conditions at the installation site to ensure that the installation goes smoothly. Secondly, as a large piece of equipment, the installation process for crane installations can be complex as it involves the connection of various wiring. Proper crane installation isn't just about bolting things together. In the event of an installation error, you will face downtime in the future and even serious installation all-hazards. So, whether you're overseeing a new facility build, upgrading your material handling, or just curious about what goes into putting these industrial giants in place, let's walk through the key steps of overhead crane installation. We'll break down the crane installation sequence, talk about the crane installation checklist essentials, and give you a good sense of what's involved in getting an overhead crane up and running safely and efficiently.

Pre-Installation Prep Work

Before your overhead crane arrives, there are a few things you need to make sure of that affect whether or not you'll be able to install the crane without any problems.

Checking Your Building

First up, you gotta make sure your building can actually handle the crane. This isn't just about whether the roof will hold it up (though that's important too!). It's about the nitty-gritty details of dimensions and clearances. You'll want to check actual building dimensions against the general installation drawing provided by your crane manufacturer. This means double-checking things like:

• Building Span and Length: Does your building's width and length match what the crane is designed for? You need to be sure the crane bridge will fit comfortably within your building's span.
• Runway Clearances: Are the crane runways (the tracks the crane travels on) clear of any obstructions? You need to ensure there's enough space for the crane to move freely along its entire path, without bumping into walls, lights, pipes, or anything else.
• Headroom: Do you have enough vertical space, or headroom, for the crane to operate safely? You need to account for the crane structure itself, the hoist, the trolley, and the maximum lifting height required for your operations. Not enough headroom and you'll be bumping into the ceiling!

Basically, you're confirming that the crane and your building are a good match – like making sure the puzzle pieces actually fit together before you try to force them.

Component Inspection: Checking for Shipping Damage

Once the crane components arrive, resist the urge to just start bolting things together! First, you need to play detective and inspect the crane carefully for possible damage in transit. These are heavy, sometimes delicate components, and shipping mishaps can happen.

• Dents, Scratches, or Bent Parts: Especially on critical structural components like girders and end trucks.
• Damaged Wiring or Electrical Components: Check for any signs of crushed or cut wires, cracked enclosures, or broken connectors.
• Missing Parts: Carefully check each item on the packing list provided by the manufacturer. Make sure everything that's supposed to be there, is there. It's way easier to catch missing parts now than halfway through the installation.

If you find any damage or shortages, obtain proper notation of damage on the freight bill. This is crucial if you need to file a claim with the carrier. And notify the crane manufacturer (EMH in the PDF example) immediately about any issues. Don't just assume you can fix it yourself – get their guidance, especially before returning any parts. Yuantai's cranes are carefully packaged before they are sent out, and plastic wrapping is used to protect them from rain before they are boxed.

Storage Savvy

Sometimes, unforeseen circumstances may arise and your installation does not begin immediately. Maybe the building isn't quite ready, or your installation crew is booked up. If you need to store the crane prior to installation, do it right! These components are built to last, but they need to be protected from the elements while they're waiting.

• Indoor Storage is Best: Ideally, store the crane components inside under cover. This protects them from rain, snow, sun, and temperature swings.
• Outdoor Storage – If Necessary: If indoor storage isn't possible, store the crane outside, covered and blocked off the ground. Use tarps or heavy plastic sheeting to protect from rain and snow, and use timbers or blocks to keep the components elevated off the ground. This prevents moisture damage and promotes adequate ventilation to prevent condensation, which can lead to rust and corrosion.

Before you finally start the crane assembly process after storage, inspect the crane for rust, corrosion, and moisture. If you find any, again, contact the manufacturer for instructions on how to correct it before you proceed with installation. Prevention is always better (and cheaper) than dealing with rust later!

The Crane Installation Sequence

Alright, the prep work is done, the components are checked, and you're ready to get building! The overhead crane installation sequence is a logical progression, building the crane from the ground (or runway rails) up. While the exact steps can vary slightly depending on the crane type and manufacturer.

(Safety First! Before starting any physical work, ensure main power supply is turned off and locked out. Follow proper lockout/tagout procedures to prevent accidental energization during installation. And always use appropriate lifting equipment and rigging techniques – these are heavy components!)

1. End Truck Installation: Raise end trucks into position on the runway rails and lash in place. End trucks are the wheel assemblies that allow the crane bridge to travel along the runway. Carefully lift and position them onto the runway rails, ensuring they are properly seated and aligned. Use appropriate rigging and lifting equipment, and temporarily secure them to the runway to prevent movement. Lash in place means to temporarily secure them, often with chains or straps.

2. Drive Girder Installation: Raise drive girder into position on end trucks and bolt into place. Do Not Torque at this time. The drive girder is one of the main horizontal beams of the crane bridge, usually the one with the drive motors and mechanisms. Carefully lift the drive girder and align it with the pre-positioned end trucks. Insert bolts to connect the girder to the end trucks, but do not fully tighten (torque) the bolts yet. This allows for adjustments later in the process.

3. Idler Girder Installation: Raise idler girder into position on end trucks and bolt into place. Do Not Torque at this time. The idler girder is the other main horizontal beam of the crane bridge. Repeat the process from step 2, lifting and aligning the idler girder with the end trucks and loosely bolting it in place. Again, do not torque the bolts fully at this stage. It is worth mentioning that the idler girder exists only on double girder cranes, a girder that is not fitted with a drive.

4. Runway Conductor Guard Installation (if equipped): The runway conductor guard (if equipped) may bolt to the bridge -girder/end truck connection. If your crane uses a conductor bar system for power, there might be a guard to protect the conductor bars. Install this guard according to the manufacturer's instructions. It often bolts to the crane bridge and/or end trucks.

5. Cab Installation (if equipped): Raise cab (if equipped) into position, bolt in place, and locate and bolt or weld brace, if provided. If your crane has an operator cab, now's the time to install it. Carefully lift the cab into position on the crane bridge, aligning it with the mounting points. Bolt the cab securely in place, and if there are any braces provided for extra support, install and bolt or weld them as well.

6. Hoist Trolley Installation: Raise hoist trolley into position on the Crane Bridge. Ensure correct orientation of trolley. The hoist trolley is the assembly that carries the hoist unit and travels along the crane bridge. Lift the trolley and carefully place it onto the crane bridge girders. Ensure correct orientation of trolley – make sure it's facing the right way and positioned correctly on the bridge.

7. Torque End Truck Bolts: Torque end truck bolts to 410 Foot lbs (or as specified by manufacturer). Now that the main crane structure is assembled (but still without wiring or hoist reeving), it's time to fully tighten the bolts connecting the girders to the end trucks. Torque end truck bolts to the specified torque value using a calibrated torque wrench. This ensures a strong and rigid connection. The PDF example specifies 410 Foot lbs, but always refer to your crane's specific installation manual for the correct torque specification.

8. Festooning and Main Collector Wiring: Connect festooning and main collector wiring to bridge and trolley panels. Now comes the electrical work! Connect festooning (the cable management system for power and control cables to the trolley) and main collector wiring (wiring from the runway conductor system or cable reel) to the appropriate bridge and trolley panels. Refer to the crane wiring diagram for correct connections.

9. Install Remaining Wiring: Install remaining wiring to proper locations as marked. Continue installing all other electrical wiring according to the crane wiring diagram. This includes wiring for motors, controls, sensors, and safety devices. Install remaining wiring to proper locations as marked - carefully follow the wire markings and connection points indicated in the wiring diagrams and on the components themselves.

10. Connect Cab Wiring (if equipped): Connect cab wiring (if equipped) as marked. If your crane has an operator cab, connect all the necessary wiring to the cab controls, lights, and other electrical components within the cab, again following the crane wiring diagram.

11. Install Main Collector Supports and Collectors: Install main collector supports and collectors. If using a conductor bar system, install the main power collectors, collector support, and conductor guards (if furnished) to their proper supports on the crane and runway. Ensure the collectors are properly aligned to make good contact with the conductor bars.

12. Complete Start-up Procedures: This is a crucial step to verify everything is installed correctly and functioning safely. We'll detail the crane start-up procedures in the next section.

13. Limit Switch Checks: Operate the hoist in low speed only when checking the upper and lower limit switches. All LOAD limit switches (if installed) must be set in the field. Carefully test the upper and lower limit switches for the hoist. Operate the hoist at low speed only during these checks. All lower limit switches (geared limit) must be set in the field according to the manufacturer's instructions. All LOAD limit switches (if installed) must be set in the field as well. Limit switches are critical safety devices, so ensure they are properly adjusted and functioning correctly.

Crane Start-Up Procedures

Once the physical installation is complete, you're not quite ready to lift heavy loads. You need to go through a rigorous crane start-up procedures checklist to verify everything is wired correctly, moving smoothly, and, most importantly, safe.

(Safety Reminder: Before starting any electrical checks, ensure main power to the bus bar is off and the disconnect is LOCKED OUT! Only qualified personnel should perform these checks.)

1. Mechanical System Check:

A complete check of the mechanical system to ensure proper installation. This is a thorough visual and hands-on inspection of the mechanical components:

• Wheel Alignment: End truck wheels (both bridge and trolley) on rail and centered, wheel flanges not rubbing. Check that all wheels are properly seated on the rails, centered, and that wheel flanges are not rubbing against the rails, which could indicate misalignment.
• Trolley Stops: If under running hoist, trolley stops in proper location and secure. For under-running hoists, ensure the trolley stops are correctly positioned and securely fastened to prevent the trolley from running off the end of the bridge.
• Festooning Check: Festooning installed properly and free of binding, hangers and track secure, track splices tight. Trolley festoon tow bar installed and travel area free of obstructions. Visually inspect the festoon system – ensure it's installed correctly, cables move freely without binding, hangers and track are secure, and that the trolley tow bar moves smoothly without obstructions.
• Pendant Installation: Pendant installed with strain relief cable attached, Operator warning card secured and legible. If using a pendant control, check that it's properly installed, the strain relief cable is attached to prevent stress on the wiring, and the operator warning card is in place and readable.
• Bumpers Installed: End truck bumpers installed and secure. Ensure end truck bumpers are installed at the ends of the bridge and are securely fastened to cushion any accidental impacts with runway stops.
• Wire Rope Check: Wire rope tight on drum, feeding properly through the rope guide if installed. (If shipped installed) Verify that the hoist wire rope is properly wound on the drum, tight, and feeding smoothly through the rope guide (if equipped) without kinking or overlapping.

2. Electrical Connections Check:

• Collector Shoe Seating: Collector shoes seated in bus bar. Ensure the current collector shoes are properly seated and making good contact with the conductor bars along the runway.
• Power Feed Wiring: Power feed from collectors to bridge panel installed and free of obstructions. Connections at shoe leads tight and insulated (tape) connection in bridge panel correct (no bare leads touching). ensure no cross phasing of collector shoes (both wires from same shoe connected to same power lead to bridge panel.) Check the main power wiring from the collectors to the bridge control panel. Ensure wires are free of obstructions, connections at the collector shoes are tight and properly insulated (taped), and connections within the bridge panel are correct with no bare wires touching. Crucially, ensure no cross phasing of collector shoes – that wires from the same collector shoe are connected to the same power lead in the bridge panel to prevent short circuits.
• Motor Power Cables: Power cables for bridge drive motors plugged into bridge panel and secure. Verify that the power cables for the bridge drive motors are securely plugged into the bridge panel and properly connected.
• Festoon Cable Plugs (Bridge): Festoon cable plugs connected to bridge panel as marked, and secure. Check that the festoon cable plugs are correctly connected to the bridge panel, matching any markings or labels, and are securely plugged in.
• Festoon Cable Plugs (Trolley): Trolley festoon plugs connected to hoist panel as marked and power feeds installed in hoist panel (if hard wire, ensure no bare wires touching panel). Similarly, verify that the trolley festoon cable plugs are correctly connected to the hoist panel as marked and secure. If there are any hardwired power feeds in the hoist panel, ensure they are properly connected with no bare wires exposed.

3. Initial Power-On Checks:

Now for the moment of truth – powering up the crane for the first time! Prior to turning on main power, check to ensure all personnel are CLEAR of crane and conductor bar – safety first!

• Turn Main Power On: Turn main power on. Carefully switch on the main power disconnect for the crane.
• E-Stop Check: Turn E-STOP button to the on position, mainline contactor in bridge panel should be engaged at this time and the system is ready for test. Turn the Emergency Stop button to the "on" or "released" position. Listen and check if the mainline contactor in the bridge panel should be engaged at this time (it should close, indicating power is now flowing to the crane). This confirms the basic power circuit is complete and the system is ready for initial testing.
• Hoist Phasing Check: First push the hoist up button, if the hook goes down this will indicate that the phasing is incorrect. Change positions of 2 of the 3 main power feeds in the bridge panel to correct direction of this function. (DO NOT change control wires at this time to correct the hoist directions). This is a crucial phasing check. Carefully and briefly press the hoist up button. If the hook goes down, it indicates incorrect motor phasing. Change positions of 2 of the 3 main power feeds in the bridge panel to correct direction of this function. Important: DO NOT change control wires at this time to correct the hoist directions – only swap the main power leads.
• Dual Hoist Phasing (if applicable): If the bridge has two hoists on it and only one has the wrong direction (up/down) initially, change the phasing in the hoist panel of the incorrect hoist. If you have a dual-hoist crane and only one hoist is phased incorrectly, correct the phasing only in the hoist panel of the incorrect hoist, not in the main bridge panel.
• Directional Control Check: Check bridge and trolley directional control, if change is required it can be accomplished in the respective panels via the control wires (red), for that particular function. Test the directional controls for the bridge and trolley. Verify that the crane moves in the correct direction when you press the corresponding buttons on the pendant or remote. If change is required it can be accomplished in the respective panels via the control wires (red), for that particular function – if the directions are reversed, you can usually correct this by swapping specific control wires in the bridge or trolley control panels.

4. No Load Operational Check:

• Lower Limit Switch Setting: Run the hoist down to the lowest desired hook height above the floor and set the lower limit switch. (Refer to limit switch instructions enclosed). Carefully lower the hoist to the lowest safe hook height above the floor and then set the lower limit switch according to the manufacturer's enclosed instructions. This prevents the hoist from accidentally lowering too far.
• Lower Limit Operation Check: After limit switch is set run the hook up 2 to 3 feet and down to check for proper operation of lower limit. Run hook up to upper limit to check for proper operation. Last 1 to 2 feet operate hoist in low speed. Test the lower limit switch. Raise the hook a few feet, then lower it again until the limit switch activates and stops the hoist. Verify that it stops correctly. Then, run hook up to upper limit to check for proper operation – raise the hoist to the upper limit and verify that the upper limit switch also stops the hoist correctly.
• Trolley Travel Check: Operate trolley travel full length of bridge in slow speed. Observe festoon and tow arm for binding and obstructions. Operate the trolley to travel the full length of the crane bridge at slow speed. Observe festoon and tow arm for binding and obstructions.
• Bridge Travel Check: Operate bridge travel full length of runway in slow speed, watch for any obstructions above, below and to the sides. Collector shoes should be free of binding and no vibration should be noted in the collector pole. Operate the crane bridge to travel the full length of the runway at slow speed. Watch for any obstructions above, below and to the sides. Collector shoes should be free of binding and no vibration should be noted in the collector pole.
• High-Speed Checks (Optional): Repeat steps c. and d. in high speed (not necessary to run full length of bridge or runway during this test.) Optionally, repeat the trolley and bridge travel checks at high speed, but not necessary to run full length of bridge or runway during this test - for high-speed checks, shorter movements are sufficient to verify performance and stability.
• Completion of Start-up: This completes the start up and check out of the crane. After completing all these no-load checks, the basic start-up and checkout of the crane is complete.

5. Load Test:

All overhead cranes require load testing to verify the crane's ability to work safely. Please refer to the appropriate OSHA (1910.179) and ANSI (B30.2.0) for explanation of test procedures. These standards outline the specific load test procedures, load increments, deflection limits, and inspection criteria that must be followed.

Conclusion

As you can see from the above introduction, there are many steps involved in the installation of an overhead crane, all of which require proper installation and careful inspection. If you have purchased a crane from Yuantai, we can send an installer to install the crane for you, or if you want to install it yourself, we can assist you remotely with the installation.