bahrain overhead crane training
DESCRIPTION
cranes05TRANSCRIPT
3
Course Introduction 1
Your tutor(s)
Experienced safety professionals
Experienced surveyors
Experienced trainers
Introduction
4
1
Bureau Veritas Group
Established in 1828
More than 18,000 people
More than 600 offices
Introduction Course Introduction
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Course Introduction 1 Introduction
WELCOME TO BUREAU VERITAS
OVERHEAD CRANE OPERATOR
TRAINING COURSE
6
DAY ONE
RIGGING / SLINGING
1. COURSE INTRODUCTION
2. GENERAL
3. SWL & WLL
4. LOAD WEIGHT CALCULATIONS
5. CENTRE OF GRAVITY
6. LIFTING TACKLE TYPES & INSPECTION AREAS
7. KINDS OF HITCHES
8. ANGLES OF LIFTING
9. MULTI-LEG SLING METHOD OF RATING
10. RIGGING EQUIPMENT “GOOD & BAD PRACTICES”
11. HAND SIGNALS
SUMMARY
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DAY TWO
OVERHEAD CRANE
1. CRANE CLASSIFICATION
2. CRANE TYPES
3. ELECTRIFICATION
4. TROLLEY TYPES
5. CAB CONTROLLERS
6. CRANE TERMINOLOGY
7. HOIST ASSEMBLY
8. LIMIT SWITCHES
9. TROLLEY CONTROLLERS
10. BRIDGE CONTROLLERS
11. THREE MOVEMENT COORDINATION
12. MAGNET HOISTING
13. PRE OPERATION CHECKS
SUMMARY
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DAY THREE
1. PRACTICAL TRAINING (RIGGING)
2. PRACTICAL TRAINING (OPERATORS)
3. PRACTICAL EXAM (RIGGING)
4. PRACTICAL EXAM (OPERATORS)
5. WRITTEN EXAM (RIGGING)
6. WRITTEN EXAM (OPERATORS)
7. COURSE CLOSING
SUMMARY
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Course Introduction 1 Introduction
Document prepared by BUREAU VERITAS ABU DHABI
This course has been produced to BRITISH STANDARDS and
Lifting Equipment Engineers Association (LEEA – UK)
BS 7121, BS 302, BS 1290, BS 6210
ISO 4309& ANSI B30
French National Institute for Search and Safety.
BUREAU VERITAS TECHNICAL GUIDE AL4
BUREAU VERITAS TECHNICAL GUIDE AL10
BUREAU VERITAS TECHNICAL SHEET AL-PR-T-005
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Course Introduction 1 Introduction
Course structure:
» Tutorials
» Discussions
» Video Illustration
» Practical Assessment
» Examination
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1
Successful delegates will be able to understand:
· Lifting Appliances & Lifting Tackle types;
· Colour Coding system;
· SWL & WLL;
· Kinds of Hitches;
· Centre of Gravity;
· Load Weight calculations;
· Different types of Cranes;
· Crane Operator Manual and Log Book;
· Limit Switches;
· Safe Load Indicator;
. Vertical Angle (sling angle);
. Cranes Signals & Communication Systems;
· Good & Bad Rigging Practices;
· Crane identification;
Introduction Course Benefits
· Crane Equipment Records;
· Overhead Crane Types;
· Crane Brakes;
· Crane Safety Features;
· Crane Operator Controls;
· Crane Operator Precautions;
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1 Introduction
PHYSICAL FITNESS (EYESIGHT,
HEARING AND GENERAL HEALTH).
CONVERSANT WITH ENGLISH LANGUAGE.
FAMILIARITY WITH CRANES AND LIFTING OPERATIONS IN CONSTRUCTION SITE / INDUSTRIAL YARDS ACTIVITIES.
Course Pre-Requisites
ALL PARTICIPANTS SHALL WEAR P.P.E.
BEFORE COURSE STARTING.
OVERHEAD CRANE & NECESSARY
LIFTING ACCESSORIES SHALL BE
AVAILABLE FOR PRACTICAL TRAINING
ON SITE.
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1
THIS IS A TWO – DAY COURSE
DAY ONE
Timing : 07:00 - 15:00
Coffee/Tea breaks : 9:00 – 9:15
Coffee/Tea breaks : 11:15 – 11:30
Pray Time : 12:30 – 13:00
Lunch : 15:00
Tutorials & Discussions : 3 1/2 HOURS
Video Illustration : 1/2 HOUR
Practical Training : 2 1/2 HOURS
Written Examination : 1/2 HOUR
Introduction Course Timing & Structure
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1 Introduction Course Timing & Structure
THIS IS A TWO – DAY COURSE
DAY TWO
Timing : 07:00 - 15:00
Coffee/Tea breaks : 9:00 – 9:15
Coffee/Tea breaks : 10:45 – 11:00
Pray Time : 12:30 – 13:00
Lunch : 15:00
Tutorials & Discussions : 3 1/2 HOURS
Practical Training : 3 HOURS
Written Examination : 1/2 HOUR
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1
Facilities
Safety rules & evacuation routes
Courtesy (mobile phones, pagers)
Local arrangements
Course House Rules Introduction
17
GENERAL 2 P. P. E.
PERSONAL PROTECTIVE EQUIPMENT
THE BANKSMEN, RIGGERS & CRANE OPERATORS
SHOULD WEAR THE REQUIRED P. P. E. AND AS
FOLLOWS:
- HELMET
- SAFETY SHOES
- COVERALL
- WORK VEST
- GLOVES
- AND SPECIAL REQUIREMENTS AS APPLICABLE
(SUCH AS EAR PLUGS, GAS MASK, GLASSES
ETC.)
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GENERAL 2
A) LIFTING TACKLE TYPES:
- WIRE ROPE SLINGS
- CHAIN SLINGS
- SHACKLES
- EYEBOLTS
- SYNTHETIC WEBBING SLINGS
- TURN BUCKLES
- HOOKS
- RINGS AND LINKS
LIFTING EQUIPMENT COMPRISES OF:-
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GENERAL 2
B) LIFTING APPLIANCES TYPES:
- CRANES
- FORKLIFTS
- PULLEY BLOCKS
- CHAIN HOISTS
- TIRFORS
- CHAIN BLOCKS
- CONTAINERS
- BASKETS
LIFTING EQUIPMENT COMPRISES OF:-
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GENERAL 2 COLOUR CODING
- EACH COMPANY HAS ITS OWN COLOUR CODING SYSTEM FOR ALL LIFTING EQUIPMENT.
- ALL LIFTING EQUIPMENT IS SUBJECT TO A SIX MONTHLY INSPECTION AS PER ARTICLE 20 OF
UAE MINISTERIAL ORDER NO. 32 OF 1982.
- COLOUR CODING IS IMPORTANT TO IDENTIFY THAT THE SLINGING MATERIALS HAVE BEEN
TESTED AND CERTIFIED BY A COMPETENT PERSON.
- REMEMBER DO NOT USE LIFTING APPLIANCES IF THERE IS:
“NO SWL (SAFE WORKING LOAD), ID/NO. AND COLOUR CODE”
ADNOC GROUP OF COMPANIES HAVE THE FOLLOWING COLOUR CODING SYSTEM:
JANUARY 2004 – JUNE 2004 PASTEL ORANGE
JULY 2004 – DECEMBER 2004 GRASS GREEN
JANUARY 2005 – JUNE 2005 TRAFFIC WHITE
JULY 2005 – DECEMBER 2005 SIGNAL BLUE
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3 SWL & WLL WHAT IS SWL & WLL ?
SWL (SAFE WORKING LOAD)
IS THE MAXIMUM LOAD THAT CAN SAFELY BE LIFTED OR LOWERED UNDER
PARTICULAR SERVICE CONDITIONS AS CONFIRMED IN TESTS AND EXAMINATION
RECORDS AND SHOULD NOT BE EXCEEDED.
WLL (WORKING LOAD LIMIT)
IS THE MAXIMUM LOAD THAT AN ITEM OF LIFTING EQUIPMENT IS DESIGNED TO
LIFT OR LOWER AS DETERMINED BY THE MANUFACTURER.
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4 LOAD WEIGHT
CALCULATIONS
IF YOU DO NOT KNOW THE LOAD
WEIGHT, WHAT U WILL DO?
LOAD WEIGHT:
• KNOW THE LOAD WEIGHT BEFORE RIGGING IT.
• MAY BE MARKED ON THE LOAD.
NEVER RIG A LOAD IF YOU DO NOT KNOW HOW MUCH IT WEIGHS.
CALCULATING LOAD WEIGHT:
IF YOU CANNOT FIND THE WEIGHT LISTED, YOU CAN ESTIMATE THE WEIGHT BY:
- CALCULATING THE VOLUME IN CUBIC METER.
- MULTIPLYING THE VOLUME BY THE DENSITY OF THE MATERIAL .
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4 LOAD WEIGHT
CALCULATIONS
STANDARD SHAPES
LOAD SHAPE FORMULA FOR CALCULATION OF VOLUME SHAPES
RECTANGULAR SOLID LENGTH X WIDTH X HEIGHT
SOLID CYLINDER 3.14 X LENGTH X (RADIUS)2
THICK WALLED PIPE 3.14 X (R12 – R2
2) X LENGTH
THIN WALLED PIPE 3.14 X DIAMETER X LENGTH X THICKNESS
SPHERE 4.19 X (RADIUS)3
PYRAMID 0.25 X LENGTH X BASE X HEIGHT
STANDARD SHAPED LOADS
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4 LOAD WEIGHT
CALCULATIONS
COMPLEX SHAPES
COMPLEX SHAPED LOADS
In some cases as shown in the picture on
right side, it is best to imagine the whole
shape enclosed by a rectangle and calculate
the volume of the rectangle.
Assumed total volume = l x b x h
FOR IRREGULAR SHAPED LOADS SEVERAL CALCULATIONS MAY BE REQUIRED TO
DETERMINE THE TOTAL WEIGHT.
For the load shown on left side, add the
calculated volumes of each of the two
rectangular solids to determine the
weight of the load.
Total volume = (l1 x b x h1)+ (l2 x b x h2)
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4 LOAD WEIGHT
CALCULATIONS
MATERIAL TABLE
MATERIAL POUNDS / CUBIC FOOT KILOGRAMS / CUBIC METER
Aluminium 170 2700
Brass 530 8500
Brick 130 2100
Coal 90 1450
Copper 550 8800
Concrete 150 2400
Earth 100 1600
Iron - Steel 480 7700
Lead 700 11200
Magnesium 110 1750
Oil 50 800
APPROXIMATE WEIGHTS OF COMMON MATERIALS
Paper 70 1120
Water 62 1000
Wood 50 800
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4 LOAD WEIGHT
CALCULATIONS
LOAD CELL (DYNAMOMETER)
WHEN YOU HAVE TO CALCULATE THE LOAD WEIGHT, IT IS SAFER TO OVER- ESTIMATE.
BETTER TO CHECK THE LOAD WEIGHT BY LOAD CELL (WEIGHING SCALE)
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CENTRE OF GRAVITY WHAT IS COG ?
REGULAR SHAPES
COG IN THE MIDDLE
5
IS THE CENTRE OF LOAD BY WEIGHT AND THE POINT THAT LOAD WILL BE BALANCED
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CENTRE OF GRAVITY
EFFECT OF CENTRE OF GRAVITY MISALIGNMENT ALIGNMENT OF CENTRE OF GRAVITY
5
IF LOAD SHIFTS OR TIPS OVER MORE THAN 5º IT SHOULD BE SET DOWN
EACH SLING LEG SHOULD BE STRONG ENOUGH TO SUPPORT THE
ENTIRE LOAD IN CASE OF LOAD UNBALANCED
IRREGULAR SHAPES
COG NOT IN THE MIDDLE
IRREGULAR SHAPES
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CENTRE OF GRAVITY LOAD STABILITY
FIG (A) FIG (B)
5
LOAD WILL BE BALANCED IF THE CENTRE OF GRAVITY IS DIRECTLY BENEATH CRANE HOOK
AND IF POSSIBLE; BELOW OR LEVEL WITH ATTACHMENT POINTS. FIG (A)
WHEN THE LOAD CENTRE OF GRAVITY IS ABOVE OR LEVEL POINT WITH SLING ATTACHMENT, A
GREATER STABILITY OF THE LOAD CAN BE ACHIEVED WHEN ANGLE BETWEEN THE
HORIZONTAL AND SLING LEG, IS SUBSTANTIALLY GREATER THAN THE ANGLE FORMED
BETWEEN THE HORIZONTAL AND CENTRE OF GRAVITY. FIG (B)
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LIFTING TACKLE TYPES
6 WIRE ROPES
STEEL WIRE ROPES
Description
FLEXIBLE ELEMENT.
PERMITS THE TRANSFER OF
STRAIN TO PULL, LIFT OR HANG.
COMPOSED OF STRANDS SPUN
HELICALLY AROUND A METALLIC
OR TEXTILE CORE.
STRAND STEEL WIRES ARE
SPUN HELICALLY AROUND A
METALLIC CORE.
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LIFTING TACKLE TYPES
WIRE ROPES
THE PITCH
THE PITCH IS THE NECESSARY ROPE LENGTH FOR THE STRAND
TO COMPLETE ONE ROTATION AROUND THE CORE. IT IS ALSO
CALL LAY LENGTH.
6
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LIFTING TACKLE TYPES
6 WIRE ROPES
TYPE OF CORES TEXTILE METALLIC
DESCRIPTION THE TEXTILE CORE IS GENERALLY MADE
WITH SOME KIND OF SYNTHETIC FIBRES
MORE RESISTANT IN THE TIME THAN THE
NATURAL FIBRES.
THE METALLIC CORE IS
GENERALLY MADE WITH 7X7
STEEL WIRE ROPE.
ADVANTAGE GIVE A GOOD FLEXIBILITY TO THE ROPE.
ACT AS INTERNAL LUBRICATOR.
GIVE A HIGHER BREAKING
LOAD TO THE ROPE.
GIVE A BETTER
RESISTANCE TO CRUSHING
DISADVANTAGE POOR RESISTANCE TO CRUSHING POOR FLEXIBILITY
THE CORE :
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LIFTING TACKLE TYPES
6 WIRE ROPES
PREFORMING
FORMING THE FINISHED STRAND INTO THE HELICAL SHAPE .
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6
REDUCTION IN WIRE ROPE DIAMETER WIRE BREAKS NEAR FITTINGS & INSIDE A ROPE
WIRE ROPES INSPECTION LIFTING TACKLE TYPES
NORMAL UNDAMAGED ROPE
ONE ROPE LAY
STRETCHED ROPE SHOWS INCREASED LAY LENGTH
UNDAMAGED ROPE SECTION
DAMAGED ROPE SECTION
STRANDS TAKE AN OVAL SHAPE IF
THE CORE HAS FAILED
TYPICAL VALLEY
BREAKS ARE SERIOUS
SOCKET MUST BE REPLACED
IF THERE IS ONE BROKEN
WIRE NEAR FITTING
WATCH FOR BROKEN WIRES IN THIS AREA
DUE TO CORE DETERIORATION DISCARD ROPE IF THERE IS
DECREASE BY 3% OF THE NOMINAL ROPE DIAMETER FOR
ROTATION-RESISTANT ROPES OR 10% FOR OTHER ROPES.
DUE TO EXTERNAL WEAR DISCARD ROPE IF THERE IS
DECREASE BY 7% OR MORE OF THE NOMINAL ROPE DIAMETER.
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6
THE EASIEST WAY TO
DETECT INSIDE WIRE
BREAKS IS “LISTENING”
HOLD A LENGTH OF ROPE
UP TO YOUR EAR AND BEND
IT BACK AND FORTH, IF YOU
HEAR POPPING VOICE,
THERE ARE LIKELY BROKEN
WIRES INSIDE THE ROPE
TO ENSURE THAT
YOUR NON-ROTATING
ROPE IS FREE FROM
INTERNAL WIRE
BREAKS
REPLACE THE ROPE IF THERE ARE
- 6 OR MORE RANDOM BROKEN WIRES IN ONE LAY
- 3 OR MORE BROKEN WIRES IN ONE STRAND OF A ROPE LAY
- 1 BROKEN WIRE AT THE FITTING
WIRE ROPES INSPECTION LIFTING TACKLE TYPES
TO CHECK IF YOUR ROPE
HAS BROKEN WIRES
THE EASIEST WAY IS
“LOOKING”
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6 LIFTING TACKLE TYPES
Due to heavy corrosion
the wires breaks when
you bend the rope
Extrusion of steel core (discard immediately)
Basket (bird cage) deformation of multi-strand construction
(discard immediately)
DEFECTS
WIRE ROPES DEFECTS
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6 LIFTING TACKLE TYPES
Local increase in diameter of langs lay wire rope caused by distortion
of the steel core resulting from shock loading (discard immediately)
Severe kink with extrusion of fibre core (discard immediately)
DEFECTS
WIRE ROPES DEFECTS
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6 LIFTING TACKLE TYPES
A wire rope which has been kinked during installation (discard immediately)
Outer strands take the place of the fibre core which has disintegrated (discard immediately)
Flattened portion of multi-strand rope caused by mis-coiling on a drum (discard immediately)
DEFECTS
WIRE ROPES DEFECTS
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6 LIFTING TACKLE TYPES
flattened portion due to local crushing (discard immediately)
Example of severe bend (discard immediately)
DEFECTS
WIRE ROPES DEFECTS
47
CHAINS ASSEMBLIES 6
PIPE SLING CASE GRAB SLING WITH
SHORTENING CLUTCH
DRUM SLING
DIFFERENT CHAIN SLING
CONFIGURATIONS
LIFTING TACKLE TYPES
48
CHAIN LINK’S INSPECTION AREAS 6 LIFTING TACKLE TYPES
MEASURE THE REMAINING MATERIAL
AND DISCARD IF IT IS LESS THAN
ALLOWED BY MANUFACTURER.
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WEBBING SLINGS 6 LIFTING TACKLE TYPES
SYNTHETIC FIBRES
(WEBBING SLINGS / BELTS):
THREE BASIC MAN-MADE
MATERIALS, PROCESSED AS
SYNTHETIC FIBRES, ARE USED TO
MANUFACTURE ROPES, AND FLAT
WOVEN WEBBING FOR MAKING
SLINGS AND FOR THE
MANUFACTURE OF ROUND
SLINGS, THESE ARE:
POLYAMIDE (NYLON)
POLYESTER
POLYPROPYLENE
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6
ACID DAMAGE
HEAT DAMAGE
CUTS
CUTS & TENSILE DAMAGE
ABRASION DAMAGE
FACE CUTS
PUNCTURES & SNAGS
TENSILE BREAK
ILLIGIBLE OR MISSING TAG
WEBBING SLINGS DEFECTS LIFTING TACKLE TYPES
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SHACKLES & THE INSPECTION AREAS 6
BOW SHACKLES DEE SHACKLES
SAFETY ANCHOR SAFETY PIN SAFETY ANCHOR SAFETY PIN
LIFTING TACKLE TYPES
CHECK FOR WEAR
CHECK FOR WEAR AND STRAIGHTNESS
CHECK THAT PIN IS ALWAYS SEATED
CHECK THAT SHACKLE IS NOT OPENING UP
SHACKLE
INSPECTION
AREAS
52
EYEBOLTS 6
EYEBOLTS TYPES
LIFTING TACKLE TYPES
SWL IN AXIAL LOADING IS LOWER
BUT AT INCLINED LOADS ARE
ABOUT DOUBLE THOSE OF
COLLAR EYEBOLTS
SWL IN AXIAL LOADING IS HIGHER
BUT AT INCLINED LOADS ARE
ABOUT HALF OF EYEBOLT WITH
LINK
IS EXTREMELY LIMITED IN ITS
USE FOR LIFTING PURPOSES
(ONLY FOR ELECTRICAL
INDUSTRY)
EYEBOLT WITH LINK
SHANK
THREAD RUNOUT
COLLAR
LINK
COLLAR EYEBOLT
SHANK
THREAD RUNOUT
COLLAR
EYE
RAISED FLAT
AREAS FOR
MARKING
UNDERCUT
SHANK
COLLAR
EYE
DYNAMO EYEBOLT
53
EYEBOLT’S INSPECTION AREAS 6
EYEBOLTS INSPECTION AREAS
LIFTING TACKLE TYPES
CHECK FOR
CRACKS AND
WEAR
CHECK FOR
STRAIGHTNESS
FROM SIDE VIEW
CHECK FOR
SHANK
STRAIGHTNESS AND
THREAD
SOUNDNESS
54
HOOK’S INSPECTION AREAS 6 LIFTING TACKLE TYPES
CHECK FOR WEAR AND
DEFORMATION
CHECK FOR CRACKS AND
TWISTING
DISCARD IF TWISTED 10º OUT
OF PLACE
CHECK FOR WEAR AND
CRACKS
CHECK FOR SIGNS OF
“OPENING UP”
DISCARD IF THROAT IS
OPENED BEYOND THE
MANUFACTURER’S
SPECIFICATIONS BY 15%
LOOSE GEAR HOOK
55
TURNBUCKLES & THE INSPECTION
AREAS 6
TURNBUCKLES AND FITTINGS
LIFTING TACKLE TYPES
TURNBUCKLES
INSPECTION AREAS
CHECK FOR CRACKS AND BENTS
CHECK FOR THREAD DAMAGE
AND BENT RODS
CHECK FOR CRACKS AND BENTS
CHECK FOR THREAD DAMAGE
AND BENT RODS
CHECK FOR CRACKS AND BENTS
CHECK FOR THREAD DAMAGE
AND BENT RODS
CHECK FOR CRACKS AND DEFORMATION
EYE JAW STUB HOOK (HAS REDUCED
CAPACITY)
JAW AND EYE COMBINATION
JAW AND JAW COMBINATION
HOOK AND HOOK COMBINATION
HOOK AND EYE COMBINATION
58
HITCHES TYPES
BRIDLE HITCH (2-3-4-LEG)
BASKET HITCH CHOKER HITCH
BASKET ANGLE FACTOR = 1.4 CHOKER ANGLE FACTOR = 0.8
7
SINGLE VERTICAL HITCH
60
ANGLES OF LIFTING SLING (VERTICAL) ANGLE
RELATIONSHIP
OF SLING
(VERTICAL)
ANGLE AND
SWL
THE SLING ANGLE
(VERTICAL ANGLE)
BETWEEN 2 SLINGS
MUST PREFERABLY
NOT BE LARGER
THAN 120º
RECOMMENDED
SLING
(VERTICAL)
ANGLES ARE
BETWEEN 0-90 º
THIS ALSO
APPLIES TO
CHAINS, ROPES
AND HOISTING
UNITS
8
62
2 – LEG SLING 9
DETERMINATION OF CAPACITY – 2-LEG SLING
AS PER THE UNIFORM LOAD RATING MATHOD OF MULTI LEG SLINGS
SWL OF THE 2-LEG SLING IS DETERMINED BY THE FOLLOWING:
SWL OF THE 2-LEG = 1.4 x WLL (OF SINGLE VERTICAL LEG)
MULTI-LEG SLING METHOD
OF RATING
63
3 – LEG SLING 9
DETERMINATION OF CAPACITY – 3-LEG SLING
AS PER THE UNIFORM LOAD RATING MATHOD OF MULTI LEG SLINGS
LOAD MAY BE SUPPORTED BY ONLY 2 LEGS WHILE THE 3RD ONE BALANCES IT ONLY.
THEREFORE SWL OF THE 3-LEG SLING IS DETERMINED BY THE FOLLOWING:
SWL OF THE 3-LEG = 2.1 x WLL (OF SINGLE VERTICAL LEG)
MULTI-LEG SLING METHOD
OF RATING
64
4 – LEG SLING 9
DETERMINATION OF CAPACITY – 4-LEG SLING
AS PER THE UNIFORM LOAD RATING MATHOD OF MULTI LEG SLINGS
LOAD MAY BE SUPPORTED BY ONLY 3 LEGS WHILE THE 4TH ONE BALANCES IT ONLY.
THEREFORE SWL OF THE 4-LEG SLING IS DETERMINED BY THE FOLLOWING:
SWL OF THE 4-LEG = 2.1 x WLL (OF SINGLE VERTICAL LEG)
MULTI-LEG SLING METHOD
OF RATING
66
NEVER USE A LIFTING GEAR THAT IS NOT STAMPED WITH SWL
GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT 10
67
GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT 10
USE OF CHOKERS
GOOD – NO CUTTING ACTION ON RUNNING LINES
BAD – BOLT
ON RUNNING
LINE CAN
WORK
LOOSE
BAD – CUTTING
ACTION OF EYE
SPLICE ON
RUNNING LINE
68
GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT 10
HOOKS’ DIRECTION
GOOD – HOOKS
ARE TURNED OUT
BAD – HOOKS
OPENING ARE TURNED IN
YES
NO
69
GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT 10
DOUBLE SLINGS SHALL BE USED WHEN HOISTING TWO OR MORE PIECES OF MATERIAL
OVER 12 FT LONG
RIGHT – LOAD OVER 12 FT LONG
WRONG – LOAD OVER 12 FT LONG
LIFTING OF BUNDLES
70
GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT
ENSURE THAT SLINGS ARE PROTECTED FROM SHARP CORNERS ON
HEAVY ITEMS
10
CONTACT RADIUS
SHOULD BE EQUAL TO 1
ROPE LAY OR 7 TIMES
ROPE DIAMETER
71
GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT
WIRE ROPE CLIPS – WRONG WAY WIRE ROPE CLIPS – RIGHT WAY
10
72
GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT 10
GOOD PRACTICE
PACK THE PIN WITH
WASHERS TO CENTRALIZE
THE SHACKLE
HOOK PACKAGE
POOR PRACTICE
NEVER ALLOW SHACKLE TO
BE PULLED AT AN ANGLE –
THE JAW WILL OPEN UP
THEORETICAL
IF THE LOAD SHIFTED, THE ROPE
WILL UNSCREW THE SHACKLE PIN
DO NOT USE SCREW PIN SHACKLES IF THE PIN
CAN ROLL UNDER LOAD AND UNSCREW
THE LOAD WILL BEND THE BOLT
NEVER
REPLACE
SHACKLE PIN
WITH BOLT
73
GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT 10
WHEN YOU LIFT
HEAVY BULK LOADS,
KEEP IT CLOSE TO
GROUND AS MUCH
AS POSSIBLE
CHECK YOUR CRANE
CHECK YOUR SLING
CHECK YOUR LOAD
BALANCE
USE TAGLINE TO CONTROL BULKY LOADS
74
GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT 10
HOOK SHOULD BE
SWIVELED (ROTATE)
FREELY
TO PREVENT WIRE
ROPES TWISTING &
CRUSHING
75
GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT 10
LAND YOUR LOAD ON
WOODEN BLOCKS
TO
REMOVE YOUR SLINGS
EASIER
PROTECT YOUR SLINGS
SECURE ALL LOOSE
SLINGS BEFORE YOU LIFT
76
GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT 10
USE YOUR 4-LEG
OR 5-LEG SLING
WITH MAX. SLING
ANGLE OF 90º
REMEMBER
SWL MARKED ON
YOUR SLING
BETWEEN 0-90º
USE SHACKLE IF YOU
PUT 2 SLINGS OR
MORE ON CRANE
HOOK
PUT THE SHACKLE PIN
ON CRANE HOOK
79
GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT 10
WATCH YOUR HAND WHILE
HANDLING CASING BE CAREFUL WHILE OPENING
CASING BUNDLE
80
GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT 10
WATCH
YOUR
HANDS
BE SURE THE LOAD
PROPERLY OVERLAPPED USE PALLET FORKS
81
GOOD AND BAD RIGGING PRACTICES RIGGING EQUIPMENT 10
LIFTING
PLATE WITH
HORIZONTAL
CLAMPS
GOOD HANDLING
DANGEROUS HANDLING
HANDLING PLATES
LIFTING PALLET WITH
VERTICAL CLAMPS
94
CRANE SERVICE CLASSIFICATIONS OVERHEAD CRANE 1
THERE ARE SIX SERVICE CLASSIFICATIONS OF E.O.T. CRANES:
CLASS A1 (STAND-BY SERVICE):
IT OPERATES AT SLOW SPEED AND ALWAYS SITS IDLE FOR LONG PERIODS; (POWER
HOUSE, NUCLEAR REACTOR AND TURBINE ROOM).
CLASS A2 (INFREQUENT USE):
IT OPERATES AT SLOW SPEED AND LIGHT LOADS TO FULL CAPACITY WITH SEVERAL
LIFTS PER DAY; (PUMP ROOMS AND LABORATORIES).
CLASS B (LIGHT SERVICE):
IT OPERATES AT SLOW SPEED WITH AN AVERAGE 50% LOAD CAPACITY AND 2-5 LIFTS
PER HOUR; (WAREHOUSES, LIGHT FABRICATION AND REPAIR SHOP).
CLASS C (MODERATE SERVICE):
IT OPERATES AT 50% LOAD CAPACITY AND 5-10 LIFTS PER HOUR; (TYPICAL MACHINE
SHOP).
CLASS D (HEAVY DUTY):
IT OPERATES AT HIGH SPEED WITH 65% LOAD CAPACITY AND 10-20 LIFTS PER HOUR;
(STEEL FABRICATION SHOP, FOUNDRIES).
CLASS E (SEVERE SERVICE):
IT OPERATES AT HIGH SPEED WITH FULL LOAD AND 20 OR MORE LIFTS PER HOUR;
(SCRAP YARD, FERTILIZER AND CEMENT PLANTS).
95
CRANE SERVICE CLASSIFICATIONS OVERHEAD CRANE 1
THERE ARE ANOTHER THREE SERVICE CLASSIFICATIONS OF E.O.T. CRANES:
NORMAL SERVICE:
IT OPERATES AT LESS THAN 85% LOAD CAPACITY WITH NO MORE THAN 10 LIFTS PER
HOUR.
HEAVY SERVICE:
IT OPERATES AT 85 – 100% LOAD CAPACITY WITH 10 LIFTS PER HOUR.
SEVERE SERVICE:
EITHER NORMAL OR HEAVY SERVICE UNDER ABNORMAL OPERATING CONDITIONS.
97
CRANE TYPES OVERHEAD CRANE 2
TYPICAL E.O.T. CRANE – TOP RUNNING
3 – MOVEMENTS
Hoisting
Cross Travel
Long Travel
BRIDGE STRUCTURE
THE RUNWAY ON WHICH THE CRANE RUNS UP AND DOWN THE PLANTARE CALLED RAILS
THESE RAILS ARE ATTACHED TO THE BUILDING COLUMNS ON EITHER SIDE OF THE BAY
100
CRANE TYPES OVERHEAD CRANE 2
OVERHEAD TRAVELING CRANE
3 – MOVEMENTS
Hoisting
Cross Travel
Long Travel
HOISTING
CROSS TRAVEL
BRIDGE OR LONG TRAVEL
104
CRANE TYPES OVERHEAD CRANE 2
PENDANT CONTROL CRANES
CANTILEVER GANTRY CRANE
GANTRY CRANE
OVERHEAD FLOOR OPERATED CRANE
SEMI GANTRY CRANE
105
CRANE TYPES OVERHEAD CRANE 2
CAB OPERATED CARRIER
CAB OPERATED CRANE
CAB OPERATED CRANE
PENDANT CONTROL CRANE
106
CRANE TYPES OVERHEAD CRANE 2
WALL MOUNTED PUSH BUTTON
SEMI GANTRY CRANE
DROP SECTION
INTERLOCKING SYSTEM
107
CRANE TYPES OVERHEAD CRANE 2
UNDERHUNG STACKER CRANE
FLOOR OPERATED STACKER CAB OPERATED STACKER
111
TROLLEY TYPES OVERHEAD CRANE 4
TROLLEY TYPES
BUCKET CRANE
5-MOTION DOUBLE TROLLEY MAGNET CRANE
7-MOTION TRIPLE TROLLEY
114
TYPICAL CAB CONTROLS OVERHEAD CRANE 5
TYPICAL CAB CONTROL
1) FAN SWITCH
2) HEATER SWITCH
3) ELEVATOR
4) STATUS LIGHT / PUSH-PULL SWITCH
5) MGNET CONTROLLER
6) AUXILIARY TROLLEY CONTROLLER
7) AUXILIARY HOIST CONTROLLER
8) MAIN TROLLEY CONTROLLER
9) BRIDGE CONTROLLER
10) MAIN HOIST CONTROLLER
11) BRIDGE DYNAMIC BRAKE PEDAL
12) BELL PEDAL
13) LIGHT SWITCH
14) CRANE LIGHT SWITCH
15) MAIN SWITCH
16) MEATER SWITCH
115
TYPICAL CAB CONTROLS OVERHEAD CRANE 5
CRANE CONTROL PEDALS AND BUTTONS
THESE CONTROLS AND SWITCHES ARE THOSE
COMMONLY FOUND IN EOT CRANES,
ALTHOUGH THE ACTUAL CONTROLS AND
SWITCHES AND THEIR POSITIONS WILL VARY
FROM CRANE TO CRANE.
LEFT/RIGHT/CENTRE CAB LAYOUT
117
OVERHEAD CRANE TERMINOLOGY OVERHEAD CRANE 6
BRIDGE:
THE BRIDGE IS MADE UP OF GIRDERS
THAT ARE CONNECTED ON EACH END
TO WHEEL TRUCKS.
BRIDGE TRAVEL IS THE CRANE
MOVEMENT FROM ONE END OF A
BUILDING RUNWAY TO THE OTHER.
BUMPERS:
ARE LOCATED ON BOTH SIDES OF
THE BRIDGE AND TROLLEY TO
PREVENT OVERTRAVEL.
CAB:
IS USUALLY HUNG UNDER THE
BRIDGE AND CONTAINS THE CRANE
CONTROLS.
CAB OPERATED CRANE
TYPICAL E.O.T. CRANE – TOP RUNNING
118
OVERHEAD CRANE TERMINOLOGY OVERHEAD CRANE 6
CENTERING:
LOADING AND UNLOADING IS ACCOMPLISHED IN 3
MOTIONS:
• CENTER BRIDGE OVER LOADING AREA
• CENTER THE TROLLEY OVER LOADING AREA.
• LOWERING AND RAISING OF HOIST OVER THE LOAD.
CONTROLS:
CONTROLLERS IN THE CAB GIVE MOTION TO THE
BRIDGE, TROLLEY AND HOIST. CONTROL CABINETS
ARE LOCATED ON THE WALKWAY OF THE BRIDGE.
CONTROLS ALSO CAN BE PENDANT OR REMOTE.
CRANE BRAKING (MECHANICAL):
IS APPLIED BY FOOT PRESSURE ON A BRAKE PEDAL.
CRANE BRAKING (ELECTRICAL):
IS APPLIED MECHANICALLY WHEN THE HOIST IS NOT
POWERED.
GANTRY CRANE
PENDANT CONTROL CRANE
119
OVERHEAD CRANE TERMINOLOGY OVERHEAD CRANE 6
CRANE BRAKING (DYNAMIC):
EDDY CURRENT BRAKING OCCURS WHEN THE HOIST
IS BEING LOWERED WITH A LOAD.
DRIVE MOTORS:
THE BRIDGE MOTOR DRIVES THE BRIDGE AND A
TROLLEY MOTOR DRIVES THE TROLLEY. THE HOIST
MOTOR POWERS THE LOAD BLOCK.
FESTOON:
POWER CABLES ARE HUNG IN DRAPED CURVES ON
THE CRANE.
HOIST:
THE HOIST MECHANISM RAISES AND LOWERS THE
LOAD. IT IS A DRUM MOUNTED ON THE TROLLEY
WHICH IS SPOOLED WITH WIRE ROPE AND IS DRIVEN
BY A MOTOR AND A GEARING SYSTEM.
120
OVERHEAD CRANE TERMINOLOGY OVERHEAD CRANE 6
HOIST (AUXILIARY):
THIS HOIST IS SIMILAR TO THE MAIN HOIST BUT HAS
LESS LIFTING CAPACITY.
HOIST BLOCK:
IT CONSISTS OF SHEAVES, SHEAVE PINS, BEARINGS,
SWIVEL AND HOOK SUSPENDED BY THE HOIST WIRE
ROPE.
HOIST MOVEMENT:
THE LOAD BLOCK IS RAISED AND LOWERED BY THE
OPERATOR CONTROLS.
HOOK:
IS CONNECTED TO THE HOIST BLOCK AND IS USED
FOR LIFTING LOADS. A HOOK SAFETY LATCH
PREVENTS THE SLINGS OR CHAINS FROM SLIPPING OFF
THE HOOK.
HOOK BLOCK ASSEMBLY
121
OVERHEAD CRANE TERMINOLOGY OVERHEAD CRANE 6
INCHING:
IT IS VERY SHORT MOVEMENTS ACCOMPLISHED BY APPLYING MOTOR POWER
FOR A FRICTION OF A SECOND THEN QUICKLY REMOVING THE POWER TO STOP
THE BRIDGE, TROLLEY OR LOAD MOVEMENT AFTER IT HAS MOVED A SLIGHT
DISTANCE .
IDLER:
IS AN END TRUCK OR BOGIE WHEEL THAT DOES NOT DRIVE.
LOAD SWING:
IS MOVEMENT OF THE BLOCK AND LOAD CAUSED BY ACCELERATION OR
DECELERATION OF THE CRANE.
MAIN LINE SHAFT:
IT IS THE MOTOR POWERED SHAFT DRIVING THE BRIDGE.
MECHANICAL LOAD-BRAKE:
THIS IS A DRAG BRAKE WHICH IS ENGAGED ONLY WHILE LOWERING. WHEN
HOISTING, THE BRAKE RELEASES, THEREBY ELIMINATING THE DRAG ON MOTOR.
122
OVERHEAD CRANE TERMINOLOGY OVERHEAD CRANE 6
MONORAIL:
THIS IS A SINGLE RAIL WITH A HOIST.
PENDANT CONTROL:
THIS IS THE OPERATORS CRANE CONTROLLER BOX HANGING FROM THE
BRIDGE OR TROLLEY BY A CABLE. THE PENDANT BOX MUST BE SUPPORTED SO AS
TO ELIMINATE ANY STRAIN ON THE ELECTRICAL CONNECTIONS.
PLUGGING:
IS THE USE OF THE REVERSE MOTOR POWER TO STOP A FORWARD-MOVING
LOAD.
RAIL RUNWAYS:
ARE FLOOR TRACKS OR TRACKS SUPPORTED BY BEAMS ON THE SIDE OF THE
BUILDING ON WHICH THE CRANE CAN TRAVEL OVER THE WORK AREA.
SKEWING:
WHEN THE CRANE GIRDERS ARE NOT PERPENDICULAR TO THE RUNWAY RAILS
AND ONE END OF THE CRANE IS AHEAD OF THE OTHER. THIS CONDITION SHOULD
BE IMMEDIATELY CORRECTED.
123
OVERHEAD CRANE TERMINOLOGY OVERHEAD CRANE 6
SLACK OUT:
THIS OCCURS WHEN THE INITIAL LIFTING TENSION IS APPLIED TO THE HOIST
WIRE ROPE AND THE LOAD CHAINS OR SLINGS.
REEVING:
THIS IS THE SYSTEM OF WIRE ROPE CONNECTING THE UPPER AND LOWER
SHEAVES ON THE HOISTING BLOCKS.
TROLLEY:
THIS IS A FRAME WHICH CONSISTS OF END TRUCKS, A DRIVE MOTOR, A HOIST
MOTOR, A DRUM WITH WIRE ROPE AND A HOIST BLOCK. IT IS OPERATED
THROUGH CONTROLLERS AND IT TRAVELS ON RAILS ACROSS THE BRIDGE
STRUCTURE, WHILE SUPPORTING THE LOAD.
WALKWAY:
THIS IS AN ISLEWAY ACROSS THE SPAN OF THE BRIDGE GIRDERS. IT ALLOWS
ACCESS TO THE TROLLEY, AND TO THE BRIDGE DRIVE MECHANISM.
126
HOIST ASSEMBLY OVERHEAD CRANE 7
HOIST ASSEMBLY:
IT CONSISTS OF HOIST MOTOR, SPEED
REDUCER, HOIST BRAKE, DRUM, WIRE ROPE,
HOIST BLOCK AND HOOK.
IT MAY BE FOUND AS FOLLOWS:
• SINGLE TROLLEY – SINGLE HOIST
• SINGLE TROLLEY – DOUBLE HOIST
• DOUBLE TROLLEY – SINGLE HOIST SINGLE TROLLEY – SINGLE HOIST
SINGLE TROLLEY – DOUBLE HOIST DOUBLE TROLLEY – SINGLE HOIST (EACH)
127
HOIST ASSEMBLY OVERHEAD CRANE 7
WIRE ROPE ANCHORAGE:
THE BASIC MINIMUM REQUIREMENTS IS
THAT THERE BE NOT LESS THAN 2 WRAPS OF
WIRE ROPE ON THE HOIST DRUM WHEN THE
LOAD BLOCK IS AT ITS LOWEST POSITION.
IT MAY BE 5 WRAPS AS PER:
• LOCAL RULES; AND / OR
• MANUFACTURER RECOMMENDATION
THE MOST COMMON TYPE OF WIRE ROPE
USED IN EOT CRANES IS 6 x 37 CLASSIFICATION.
SHEAVES IN THE BLOCK MUST BE EQUIPPED
WITH CLOSE FITTING GUARDS TO PREVENT
THE WIRE ROPE FROM FOULING IF THE BLOCK
IS LYING ON THE FLOOR WITH SLACK LINES.
ALL HOOKS SHOULD HAVE SAFETY LATCH TO
RETAIN SLINGS AND LIFTING ATTCHMENTS
WIRE ROPE TO DRUM ATTACHMENTS
SHORT AND LONG BLOCK TYPES
128
HOIST BRAKES OVERHEAD CRANE 7
HOIST BRAKES:
TO HOLD THE LOAD STATIONARY WHEN THE
HOIST CONTROLLER HANDLE IS IN THE “OFF”
POSITION, THE BRAKE IS AUTOMATIC, AND IS
APPLIED BY A SPRING WHEN THE POWER IS
OFF.
THE BRAKE IS RELEASED ELECTRICALLY
WHEN THE CONTROLLER HANDLE IS MOVED
TO RAISE OR LOWER THE LOAD.
DE-ENERGIZED BRAKE
ENERGIZED BRAKE
129
HOIST CONTROLLERS OVERHEAD CRANE 7
LIFTING:
HEAVY LOAD SHOULD BE LIFTED MORE SLOWLY
THAN LIGHT ONE.
P1: START THE EMPTY HOOK
P2: START EMPTY HOOK AND MEDIUM SIZE LOAD
P3: START EMPTY HOOK, MEDIUM AND HEAVY LOAD
P4: FURTHER MOVEMENT FOR ALL
LOWERING:
USE P2, P3 & P4 WHEN LOWERING HEAVY LOAD
P1: INCH THE LOAD DOWN
P2: LOWER ALL LOADS
P3: FURTHER INCREASE IN SPEED
P4: FURTHER LOWERING TO HIGHEST SPEED. POINT BY POINT LOWERING
POINT BY POINT LIFTING
130
HOIST CONTROLLERS OVERHEAD CRANE 7
DYNAMIC LOWERING:
IT IS AN AUTOMATIC FEATURE OF THE CONTROLLER WHICH DRIVES THE EMPTY
HOOK OR LIGHT LOAD DOWN AND HOLDS A HEAVY LOAD.
TO PREVENT HEAVY LOADS FROM LOWERING TOO QUICKLY, TWO SYSTEMS ARE
USED:
1) MECHANICAL
2) ELECTRICAL
CRANE OPERATOR SHOULD REPORT ANY FAULT TO THE SUPERVISOR SUCH AS
OVERSPEEDING DURING LOWERING AT ANY POINT.
LOAD RAISING:
WHEN RAISING A HEAVY LOAD; USE THE FIRST POINT OF CONTROLLER TO TAKE
THE SLACK OUT OF THE ROPE.
TEST HOIST BRAKE AND IF YOU HAVE ANY PROBLEM, LOWER THE LOAD AND
CALL YOUR SUPERVISOR.
131
HOIST CONTROLLERS OVERHEAD CRANE 7
INCHING THE LOAD:
START AND STOP THE HEAVY LOAD IN SLOW SPEED.
WHEN REACHING THE LANDING POINT; USE THE FIRST (SLOW) SPEED.
133
LIMIT SWITCHES OVERHEAD CRANE 8
HOIST LIMIT SWITCH TYPES:
TO PREVENT OVER-HOISTING; CRANES
ARE REGULARLY EQUIPPED WITH SOME
TYPE OF HOISTING LIMIT SWITCH.
THREE BASIC TYPES ARE USED:
PADDLE OR LEVER TYPE (FIG. B)
WEIGHTED SWITCH TYPE (FIG. C)
ROTATING OR GEARED TYPE (FIG. D)
LIMIT SWITCHES DISCONNECT POWER
FROM THE MOTOR AND
AUTOMATICALLY SET THE ELECTRIC
HOLDING BRAKE.
PADDLE OR LEVER TYPE
WEIGHTED SWITCH TYPE
134
LIMIT SWITCHES OVERHEAD CRANE 8
LOWER LIMIT SWITCH TYPES:
IF LOWER LIMIT SWITCH IS FITTED TO
THE HOIST; IT WILL BE USUALLY BE
THE ROTATING TYPE WHICH WILL STOP
THE LOWERING MOVEMENT AFTER A
SET NUMBER OF REVOLUTIONS
IF NOT FITTED; THE MOTOR MAY RUN
AFTER THE HOOK TOUCHES THE
FLOOR, THE WIRE ROPE WILL RUN OFF
THE HOISTING DRUM AND THEN WIND
UP IN THE OPPOSITE DIRECTION.
IF THIS OCCURS STOP THE WORK
IMMEDIATELY, YOU MAY DAMAGE THE
WIRE ROPE, DROP THE LOAD AND
DAMAGE THE CRANE.
AT LEAST 2 FULL WRAPS SHOULD
REMAIN ON THE DRUM WHEN THE
HOOK IS AT ITS LOWEST POSITION.
LOWER LIMIT SWITCH
ROTATING OR GEARED TYPE
135
LIMIT SWITCHES OVERHEAD CRANE 8
LIMIT SWITCH TEST:
THE OPERATOR SHOULD CHECK THE LIMIT SWITCHES WITHOUT LOAD AT THE
BEGINNING OF EACH SHIFT.
LIMIT SWITCHES ARE FOR EMERGENCY SITUATION ONLY.
NEVER CHANGE THE LIMIT SWITCH SET UP (ONLY QUALIFIED PERSONS).
MOVE THE CRANE TO A CLEAR PLACE.
RAISE THE BLOCK UP JUST BELOW THE LIMIT SWITCH AND OFF CONTROLLER.
USE THE FIRST POINT HOISTING (PROCEED CAREFULLY).
IF THE BLOCK DOES NOT OPERATES; REPORT TO YOUR SUPERVISOR (SHOULD BE
REPAIRED AND RESETED BY A QUALIFIED PERSON).
IF OPERATES PROPERLY; LOWER THE HOOK HALF WAY TO THE FLOOR.
MOVE THE HOIST UP TO THE LIMIT SWITCH AT FULL SPEED.
IF NOT FUNCTIONING; CHECK BRAKE OR LIMIT SWITCH.
137
TROLLEY CONTROLLERS OVERHEAD CRANE 9
TROLLEY BRAKE:
THE ELECTRIC BRAKE OPERATES AUTOMATICALLY SIMILAR TO THE HOIST
MOTOR BRAKE. POWER THROUGH THE MOTOR RELEASES IT. WHEN POWER IS
CUT OFF THE BRAKE WILL BE APPLIED BY A SPRING TO STOP THE TROLLEY.
THE TROLLEY BRAKE IS MANDATORY ON CAB OPERATED CRANES WHEN THE CAB
IS ATTACHED TO THE TROLLEY, EITHER AS A TRAILER TYPE OR OVERHANGING
TYPE. (ON OTHER TYPES THE TROLLEY BRAKE IS OPTIONAL.
TROLLEY CONTROLLER PLUGGING:
IF NO TROLLEY BRAKE FITTED, THEN APPLY REVERSE POWER TO THE MOTOR.
138
TROLLEY CONTROLLERS OVERHEAD CRANE 9
TROLLEY STOPPING:
THERE IS NO LIMIT SWITCHES AT THE TROLLEY ENDS ON MOST CRANES,
BUMPERS USUALLY USED (FIG. A). A SELDOM USED WHEEL STOP (FIG B).
WHEN STOPS ARE USED, AVOID STRIKING AT HIGH SPEED (TROLLEY MAY BE DE-
RAILED).
DO NOT OPERATE THE TROLLEY OVER LONG DISTANCES USING INTERMEDIATE
POINTS AS THIS HEATS UP THE MOTOR.
140
BRIDGE CONTROLLERS OVERHEAD CRANE 10
HYDRAULIC BRAKE SYSTEM
BRIDGE BRAKING SYSTEM:
CAB OPERATED BRIDGE BRAKE USUALLY IS HYDRAULIC TYPE.
WHEN STOPPING, PUT CONTROLLER TO OFF POSITION FOR SOME DISTANCE THEN
APPLY BRAKE GRADUALLY.
141
BRIDGE CONTROLLERS OVERHEAD CRANE 10
BRIDGE BRAKING SYSTEM:
WHERE THE BRIDGE IS OPERATED BY MAGNETIC HOLDING BRAKES, THE BRIDGE
MAY BE STOPPED BY THE USE OF PLUGGING.
BUMPERS USUALLY FITTED TO THE CORNERS OF THE CRANE AND SHOULD NOT BE
USED TO STOP THE CRANE (ONLY FOR SAFETY MEASURE).
142
BRIDGE CONTROLLERS OVERHEAD CRANE 10
MANUAL CONTROLLER:
DO NOT OPERATE THE BRIDGE OVER LONG DISTANCES UP AND DOWN THE
RUNWAY WITH THE CONTROL HANDLE PART WAY BETWEEN THE OFF AND FULL
ON POSITIONS. THIS HEATS UP THE CONTROLLER EXCESSIVELY. IF THE BRIDGE
TRAVELING TOO FAST, RETURN THE CONTROLLER TO OFF AND COAST. RE=APPLY
POWER AS NEEDED.
143
THREE MOVEMENT COORDINATION OVERHEAD CRANE 10
HOIST / TROLLEY / BRIDGE MOVEMENTS:
ALWAYS KEEP THE ONE HAND ON THE HOIST CONTROLLER TO STOP THE HOOK.
TROLLEY AND BRIDGE MOTIONS MUST NOT BE STARTED UNTIL THE LOAD IS OFF
THE GROUND AND WILL SAFELY PASS BY, OR OVER FLOOR EQUIPMENT OR
OBSTACLES.
3 MOVEMENTS REQUIRE SUFFICIENT EXPERIENCE FOR CRANE OPERATOR.
FOR NEW OR INEXPERIENCED OPERATOR, 3 MOVEMENTS MAY BE PRACTICED
ONLY WITHOUT A LOAD AND WHEN THERE ARE NO CRANES IN THE RUNWAY.
146
MAGNET HOISTING OVERHEAD CRANE 11
MAGNET SAFETY GUIDELINES:
DO NOT USE THE MAGNET AS A HAMMER TO BREAK UP PACKED MATERIAL.
KEEP THE MAGNET AS DRY AS POSSIBLE.
DO NOT COOL IT OFF WITH WATER.
STORE IT UNDER COVER AND OFF THE GROUND.
KEEP THE TERMINAL BOX CLOSED AND DO NOT ALLOW IT TO GET WET.
KEEP THE CHAIN LINKS GREASED TO PREVENT FRICTION AND WEAR.
WATCH TEMPERATURE WHEN HANDLING HOT MATERIALS, CHANGE THE MAGNET
IF ONE OVERHEATS (HEAT WILL DAMAGE THE MAGNET).
LOWER THE MAGNET CAREFULLY (MAGNET IS COSTLY).
CHECK MAGNET BOLTS FOR TIGHTNESS.
NEVER USE THE MAGNET TO TRANSPORT OXYGEN OR HIGH PRESSURE CYLINDER
NEVER SLING ANOTHER LOAD TO THE HOOK WITH ATTACHED MAGNET,
NEVER TRANSPORT ANYTHING ON THE TOP OF THE MAGNET.
PREVENT UN-NECESSARY SWINGING OF THE MAGNET WITH LOAD,
147
MAGNET HOISTING OVERHEAD CRANE 11
THE OPERATOR SHOULD ENSURE THAT THE POWER HAS BEEN DISCONNECTED
BEFORE HOOKING / UNHOOKING MAGNET PLUGS.
LIFT, MOVE AND LOWER AS SOON AS POSSIBLE (THE MAGNET WILL GET HOT).