Overhead

Lifting Equipment Inspection
overhead and gantry crane inspection
Prepared By :yousef Akbari

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Tel: 09169382465
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Type
TYPES OF OVERHEAD CRANES
Bridge Crane
Floor Mounted Jib
Monorail Crane Wall Mounted Jib

Type
Crane, wall: a crane having a cantilever frame with or without trolley, and
supported from a side wall or line of columns of a building. It is a traveling type
and operates on a runway attached to the side wall or columns

Type
Jib cranes can also be post (mast) mounted to create a free standing crane

Type
crane, gantry: a crane similar to an overhead crane except that the bridge for carrying the
trolley or trolleys is rigidly supported on two or more legs running on fixed rails or other
runway

Type
Crane, overhead: a crane with a single or multiple girder movable bridge carrying a
movable or fixed hoisting mechanism and traveling on an overhead fixed runway
Structure•This overhead bridge crane is specifically – an Double Girder Overhead
Under hung Bridge Crane Under hung means the trolley rides below the top of the
bridge

basic components

Definition overhead and gantry crane inspection
Normal Service: Involves operations of the crane with randomly
distributed load within the rated load limit or uniform loads of
less than 65% or rated load limit for no more than 25% of the time
.for a normal work shift
Heavy Service: Involves operation of the crane within the rated load
limit that exceeds normal service
Severe Service: Involves operation of the crane in normal or heavy

.service with abnormal operating conditions
Definition of condition
.Some cranes are used more than others .1
The frequency of service is a key factor in determining how often the crane .2
.should be inspected and serviced
.Even cranes that are not used need to be inspected, lubricated and maintained .3
Especially cranes that are out in the weather all year or in corrosive
environments

bridge: that part of a crane consisting of one or more girders, trucks, end ties, foot walks,
and drive mechanism, which carries the trolley or trolleys
span: the horizontal distance, center to center, between runway rails

runway: an assembly of rails, beams, girders, brackets, and framework on
which the crane travels

trolley: the unit that travels on the bridge rails and supports the load block
trolley travel: the trolley movement•

truck: a unit consisting of a frame, wheels, bearings, and axles that supports the bridge
girders, the end ties of an overhead crane, or the sill of a gantry crane
end tie: a structural member that connects the ends of the bridge girders to maintain
squareness of the bridge

runway: an assembly of rails, beams, girders, brackets, and framework on which the
crane travels

Inspection
Personnel responsible for the supervision, installation, operation, inspection,
or maintenance of the crane shall be familiar with the applicable contents of
the manual furnished with the crane. Inspection of crane is important for Our
department. Inspection Include Visual Examination, Functional test and
.Load test
INSPECTION CHECK LIST
This is a sample of the inspection booklet found on your CD. You can print .1
one out for every crane. There are two versions, this one, and one that has
check boxes at the bottom of the page for the operator to initial that he has
.performed a pre-shift inspection
This is a good time to go out to one of the cranes in your facility and do an .2
.inspection of it
Pre-shift inspections do not have to be lengthy. You are basically looking for .3
.obvious things that might be wrong with the crane
Monthly or yearly inspections, of course, should be thorough and performed .4
by a competent individual
Bridge Hoist
Supporting Trolley Wire Rope Condition
Rails & Alignment Wheels
Structure Trucks & Wheels Rope Reeving
Welds Motor & Drive Train Chain Condition
Motor & Drive Train Brakes
Bolts Brakes Brakes & Ratchets
Stops & Limit Controls Equalizer Sheaves
Stops & Limit Controls Rails & Alignment
Electrical Hoist Limit Control
Control Markings Load Block Functional Operation
Control Functions Sheaves
Warning Alarms Pins
Power Disconnect Swivel
Control Pendants Hook Prepared By :yousef Akbari
Festoons
SUPPORTIING STRUCTURE
.Check all fasteners for loose, stretched, missing, or broken fasteners .1

A good clue is checking for cracked paint around the fastener that shows there .2
.has been movement
.Sometimes a build up of dirt or grease can do the same thing .3
.Using a torque wrench to check for tightness does not always work .4
.Corrosion could give you a false reading
Replace a loose or stretched bolt rather than tighten it. It probably has been .5
.damaged
.Be sure to replace the bolt with a grade 8 or better .6
.If there are other bolts near by that show signs of looseness, then replace them all .7

.Check cracks in the structure and in all welds .1

A crack in a weld will always start on the end and work itself along the entire .2
.weld until it fails completely
.Many times a crack in the paint will be a clue to a weld that is failing .3
.If caught early, the crack many times can be ground out and re-weld .4
Before welding on any part of the crane, make sure you have a certified .5
welder and if it is on a structural part of the crane you should get the
.manufactures procedure
Also, try to determine why it cracked in the first place. Is the crane being .6
overloaded or used improperly
All ladders incorporate a cage to eliminate the need

for fall protection
Fire extinguishers are located at the base of ladders

Runway stops overhead and gantry crane inspection
Stops shall be provided at the limits)1(

of travel of the bridge
Stops shall engage the bumpers or )2(
bumper pads mounted on the bridge
Stops shall be designed to )3(
withstand the forces applied to the
bumpers
Bridge bumpers have the capability of

stopping the bridge when traveling
with power off in either direction at
20% of rated load speed

Runway stops overhead and gantry crane inspection
Near the ends of all runways is a dog that trips a switch on the end truck-
The switch reduces the maximum speed that the crane can travel near the ends of the -
runways
Operators must be aware of where they are relative to the switch and not be -
surprised by a change in speed

BRIDGE SYSTEM
Stops shall be provided at the limits of travel of the trolley )a(

Stops shall engage the bumpers or bumper pads mounted on the )b(
trolley
Stops shall be designed to withstand the forces applied by the )c(
bumpers

Brake overhead and gantry crane inspection
There are 4 Trolley brakes, one at each drive wheel

Brake overhead and gantry crane inspection
Each drive wheel has a motor with an

.integrated brake
Power must be applied to the brake to
“disengage” the brake and allow drive to
rotate. In the event of a power failure or
fault the brake is automatically engaged
mechanically. This feature makes the drive
fail safe

BRAKE overhead and gantry crane inspection

DRIIVE COUPLIINGS

BRIDGE TRUCK DRIIVE

WHEEL ALIIGNMENT FOR BRIIDGE CRANE
overhead and gantry crane inspections
Climbing up a and checking the bridge system is normally not part of the daily .1
inspection. Use these slides to familiarize the student with the components of
.the bridge crane and how they work together to make a successful lift
Many of these components can be inspected from the ground as the crane is .2
being operated. If something seems wrong, then a closer look would be
.warranted

TROLLEY SYSTEM

MONORAIIL CRANE TROLLEY

Hoisting equipment
Hoist: a machinery unit that is used for lifting or lowering a freely suspended
(unguided) load

Hoisting equipment

WIIRE ROPE overhead and gantry crane inspections
Point out the trade-offs between abrasion and .1

.fatigue resistance
Show how sheave size and wire rope diameter .2
relate to each other and the
.effects they have on wire rope life
.Review how sheaves are dimensioned .3
Evolution of usual defect of Wire Rope -4
DRUM IINSPECTIION overhead and gantry crane inspections
.Check to make sure the wire rope is spooled properly on the drum .1
On lagged drums, make sure the rope hasn’t jumped a groove which could .2
.damage the rope
.Check to make sure the dead end is secured properly .3
.Never hoist down to the point that there would be less than 2 wraps left on the drum .4
Check oil often .5

HOIIST MACHIINERY overhead and gantry crane inspections
.Check to make sure the wire rope is spooled properly on the drum .1
On lagged drums, make sure the rope hasn’t jumped a groove which could damage the .2
.rope
.Check to make sure the dead end is secured properly .3
.Never hoist down to the point that there would be less than 2 wraps left on the drum .4
Check oil often .5

HOIIST MACHIINERY overhead and gantry crane inspections
.Check running and equalizing sheaves for wear and free movement .1
.Check the limit switch to make sure it stops the hook or load if two-blocked .2
Check the oil often, especially if you detect any leakage .3

IINSPECTIING SHEAVES overhead and gantry crane inspections
.Check for bearing wear and lubrication .1

.Check the flanges and treads .2
.Show how to use a sheave gauge .3
Sheaves can only be repaired per manufacture’s procedures .4
CHAIIN HOIIST overhead and gantry crane inspections
Bent links (Usually a sign that it has been used to wrap around a load and bent .1
)on sharp corners
,Stretched links. The links will be sucked in slightly on the sides. Also .2
.measure 5 links and check that measurement during your annual inspection
,Chain should not be rusted or brown. If the crane is in a corrosive atmosphere .3

HOOK IINSPECTIION overhead and gantry crane inspections
.Hooks with threads and nuts need to have threads inspected periodically .1
.Hooks can only be repaired per manufacturer’s procedures .2
Wear in excess of 5% in the neck of the hook and 10% in other areas including .3
.the bow of the hook is cause for removal
.An increase in the hook throat opening of more than 15% is cause for removal .4
.Any twist in the hook of more than 10% is cause for removal .5
The hook safety latch should be present and function properly .6
CRANE BLOCK
The sheaves and bearings need to be .1

.inspected as discussed earlier
The side plates and any additional .2
weights attached to the their sides need to
be
inspected for loose or missing bolts or
.other fasteners
The hook should rotate freely on the .3
swivel bearing. Check for excessive
.movement
The hook shank and nut should be .4
separated periodically and the threads
inspected for corrosion and other
damage. The lose of more than 20% of
the
treaded area due to corrosion is cause for
.removal
The safety latch must be in place and .5
functioning properly

Accident 014504732 - Employee Killed When Struck By Loose Crane Hook
At approximately 8:15 am on January 29, 1990, employee #1 was working on a
large steel panel weighing approximately 2,608 pounds and measuring 22 feet
long and 6 feet wide. The panel was supported by an overhead crane chain and
hook and was set on metal horses at an angle. The hook slipped off of the
steel panel and struck employee #1 on the head, resulting in his death

ELECTRIICAL
ELECTRIICAL CONDUCTORS CURRENT COLLECTORS
:Check Conductors for :Check Collectors for

Loose fasteners • Good spring tension •
Burned surfaces • Collector surfaces are •
Dirt and corrosion • not corroded or burned
Electrical connections • Electrical connections •
Ease of movement •
ELECTRIICAL
The power supply to the runway )a(

conductors shall be controlled by a
switch or circuit breaker located on a
fixed structure, accessible from the
floor, and arranged to be locked in the
.open position
The electrical disconnects for all LLE bridge
.cranes are clearly labeled on the cover

FESTOON SYSTEMS
Festoons need to .1
be checked for
proper cable
tension, free trolley
movement
and wire
.connections
Also, make sure .2
there are no pinch
points during
bridge or trolley
movement

PENDANT AND CONTROLS
Many times the pendant controls get .1
.dropped or banged up during operation
Never use the pendant to pull the .2
.crane around
Use a strain relief chain or cable to .3
.protect the wires from pulling out
Make sure all controls are marked .4
.and legible
Check for buttons that are broken or .5
.stick
Always check the emergency stop .6
button on the pendant

SAFE CRANE OPERATIONS overhead and gantry crane inspections

SAFE CRANE OPERATIONS
.The safe-working-load of the crane should be easily visible to the operator .1
The safe working load would be the maximum load of the “weakest link” on the .2
crane. For example: If the maximum SWL of the hoist was 5 tons, then the
SWL, but the beam that it was hung under was good for 7 ½ tons, the SWL of
the crane could not exceed 5 tons and if stenciled on the beam, it should reflect
.the 5 ton rating
All warning labels on the crane including crane operation instructions must be .3
on the crane and legible


At the beginning of each operator's shift, the upper limit switch of each hoist shall
be tried out under no load. Extreme care shall be exercised; the block shall be
inched" into the limit or run in at slow speed. If the switch does not operate"
.properly, the appointed person shall be immediately notified
The upper limit switch will keep the load or hook from being pulled into to .1
.hoist, possibly parting the line
Never use the limit switch to operate lower your load .2
.Marking overhead and gantry crane inspection
Rated Load Markings - Crane

Rated Load Markings - Hoists
Manufacturer's Identification Markings
Multiple Hoist Identification Markings
Warnings

TESTING overhead and gantry crane inspection
Inspection, Testing, and Maintenance
.Lifting and lowering .1
.Trolley travel .2
.Bridge travel .3
Locking, limiting, and indicating devices, if .4
.provided
Limit switches/devices .5

Load Test
a)New, reinstalled, altered, repaired, and modified cranes should be load tested
.prior to initial use, as determined by a qualified person
Load testing of altered, repaired, and modified cranes may be limited to the )b(
functions affected by the alteration, repair, or modification, as determined by
.a qualified person
The replacement of load chain and rope is specificallyexcluded from this load )c(
test; however, an operational test of the hoist shall be made in accordance
with
para. 2-2.2.1(b) prior to putting the crane back in service
If a load test is conducted, the load shall be not )d(
,less than 100% of the rated load of the crane or hoist(s)
whichever governs; or more than 125% of the rated load
of the crane or hoist(s), whichever governs; unless otherwise
recommended by the manufacturer or a qualified
person

Load Test
If a load test is conducted, the person conducting the load test shall prepare a written )e(
report of the load
if) If a load test is conducted, operations shall be performed as outlined below or as

.modified by a qualified person
Hoist the test load a distance to assure that the load is supported by the crane and held )1(
.by the hoist brake(s)
.Transport the test load by means of the trolley for the full length of the bridge )2(
Transport the test load by means of the bridge for the full length of the runway in one )3(
direction with the trolley as close to the extreme right-hand end of the
crane as practical, and in the other direction with the trolley as close to the left-hand end
.of the crane as practical
.Lower the test load, and stop and hold the test load with the brake(s) )4(

Summery
Inspection, Testing, and Maintenance
Frequent Inspection. Visual examinations by the operator or other designated personnel with
records not required, as follows
normal service - monthly )a(
heavy service - weekly to monthly )b(
severe service - daily to weekly )c(
Periodic Inspection. Visual inspection of the

equipment in place by a designated person making records of apparent external conditions to
:provide the basis for a continuing evaluation, as follows
normal service - yearly )a(
heavy service - yearly )b(
severe service - quarterly )c(

Summery
Our information that we need includes provisions that apply to the construction,
installation, operation, inspection, and maintenance of hand-operated and
power-driven overhead and gantry cranes that have a top-running single girder or
multiple-girder bridge, with one or more top running trolley hoists used for vertical
lifting and lowering of freely suspended, unguided loads consisting of
equipment and materials

Summery
Scope, Definitions, and References
,Definitions
bridge: that part of a crane consisting of one or more girders, trucks, end ties, foot
.walks, and drive mechanism, which carries the trolley or trolleys
.bridge travel: the crane movement in a direction parallel to the crane runway
bumper (buffer): a device for reducing impact when moving crane or trolley reaches
the end of its permitted travel, or when two moving cranes or trolleys come into
contact. This device may be attached to the bridge, trolley, or runway stop
crane, cantilever gantry: a gantry or semi gantry crane in which the bridge girders or
trusses extend transversely beyond the crane runway on one or both sides (see

Summery

these eight hand signals
Hoist Bridge Career Travel

Lower
Travel
Stop Emergency Stop Multiple Trolleys Move slowly

End of Presentation 2
?Any Question
http://www.bgcrane.com/crane-load-charts.php
Thanks' For Your Attention

Yousef Akbari Prepared By :yousef Akbari
End of Presentation 2
?Any Question
http://www.bgcrane.com/crane-load-charts.php
Thanks' For Your Attention

Yousef Akbari Prepared By :yousef Akbari

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Lifting Equipment Inspection

overhead and gantry crane inspection

Prepared By :yousef Akbari

TYPES OF OVERHEAD CRANES

Monorail Crane Wall Mounted Jib

Monorail Crane Wall Mounted Jib

Monorail Crane Wall Mounted Jib

Monorail Crane Wall Mounted Jib

Monorail Crane Wall Mounted Jib

Monorail Crane Wall Mounted Jib

Severe Service: Involves operation of the crane in normal or heavy

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span: the horizontal distance, center to center, between runway rails

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.Check all fasteners for loose, stretched, missing, or broken fasteners .1

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.Check cracks in the structure and in all welds .1

All ladders incorporate a cage to eliminate the need

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Stops shall be provided at the limits)1(

Bridge bumpers have the capability of

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Stops shall be provided at the limits of travel of the trolley )a(

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Each drive wheel has a motor with an

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overhead and gantry crane inspections

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Point out the trade-offs between abrasion and .1

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.Check for bearing wear and lubrication .1

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The sheaves and bearings need to be .1

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ELECTRIICAL CONDUCTORS CURRENT COLLECTORS

:Check Conductors for :Check Collectors for

The power supply to the runway )a(

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Rated Load Markings - Crane

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if) If a load test is conducted, operations shall be performed as outlined below or as

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