PART 2 Tower Cranes178 CRANE HANDBOOK aMACHINE SELECTION AND EQUIPMENT REQUIREMENTS 179 CHAPTER 5 MACHINE SELECTION AND EQUIPMENT REQUIREMENTS MACHINE SELECTION Like mobile cranes, tower cranes must be selected to suit the requirements of the job. If the crane’s basic characteristics do not match the job’s requirements then unsafe conditions will be created before any work is done. Job personnel will be forced to “make do” and im- provise in a rushed atmosphere, a combination that leads to accidents. The decision to use a tower crane rather than ‘a mobile crane is a relatively easy one since the determining conditions are simple. — Whenever the need for a crane is long term ina given location. —Whenever the site is constricted or con- gested. — Whenever the lift heights are extreme and the reach may be deep. — Whenever there is little need for mobility but lift frequency is high. — Whenever long term rentals of tower cranes ate less than for mobile cranes. —Whenever load placement in the working areas is more easily done by a crane working from within that area rather than one outside. The use of any type of crane requires plan- ning but tower cranes require more than usual because their structures, foundations, and pre- sence on the site are generally permanent for as long as the heavy construction phases are on- going In selecting the most suitable type, size and number of tower cranes for a particular applica- tion, the characteristics of the various machines available must be considered against the re- quiroments imposed by the loads to be handled and the surroundings in which the crane will operate. In addition to considering such factors as the weights, dimensions and lift radii of the heaviest and largest loads, those selecting the crane for a specific project must also consider the charac- teristics of the available cranes against — The type and size of the base for the crane. —The maximum free standing height of the crane. (Fig. 5.1) —The maximum braced height. (Fig. 5.2) —The climbing arrangement. —The weight of the crane that will have to be supported by the building, —The jib lengths available. — The possible necessity of auxiliary guys. —The available head room between the maxi- mum height position of the hook and the upper most work level. (Fig. 5.3) —The area that has to be covered. —The hoist and lower speeds. —The length of cable the hoist drum carries. (Fig. 5.4) —The number of parts of line the machine needs to do the required hoisting, —The service availability and cost. —The rental charges.180 CRANE HANDBOOK eee —The cost of operations such as erection, dis- maniling, off site transport and charges for climbing the machine. —The capacity of the crane must be such that there is a least a 5% working margin on every lift Both static and mobile tower cranes are avail- able in a wide variety of types and configurations according to the particular combination of tower, jib and type of base which they employ. Tower Configurations Tower cranes are available with either fixed (Fig. 5.5) or slewing (Fig. 5.6) towers. On the fixed tower type the slewing ring is situated at or near the top of the tower and the jib slews about the vertical axis of the stationary tower. The slewing ring on the slewing tower type is situated at the bottom of the tower and the whole of the tower and jib assembly slews rela- tive to the base of the crane. In addition to being elther fixed or slewing, the towers can be further classified as being mono towers, inner and outer towers and tele- scopic towers. On the mono tower the jib is carried by a single tower structure which may be either fixed or slewing (Fig. 5.7). The inner and outer tower types are characterized by the jib being carried by a slewing inner tower which is supported at the top of the fixed outer tower (Fig. 5.8). The telescopic tower structure con- sists of 2 or more main sections which nest into each other to enable the height of the crane to be altered without the need for partial dis- mantling and re-erection (Fig. 5.9). Telescopi towers are usually of the slewing type and are more common on rail mounted and mobile tower cranes. Jib Configurations The main types of jibs used on tower cranes are ‘saddle jibs, lufing jibs, fixed-lutf jlbs and fear pivoted luffing jlbs. Saddle jibs are supported by pendants in a horizontal or near horizontal position and the load hook is suspended trom a trolley which moves along the jib to alter the hook radius (Fig. 5:10). Luffing jbs are pivoted at the jib foot and are Supported by luffing cables much like the boom on mobile cranes (Fig. 5.11). The hoist rope which supports the load usually passes over a sheave at the jib head, and the hook Fadius is altered by changing the angle of in- Glination of the jb. Fixed-luffjibs are also mounted on pivots at the jib foot but unlike the lung jibs these are held by lib pendants at a fixed angle of inclina- tion (Fig. 8.42). On some types the hook is sus- pended irom the jib head and the hook radius Gannot be altered while on others the hook is MAXIMUM FREE ‘STANDING HEIGHT.MACHINE SELECTION AND EQUIPMENT REQUIREMENTS 181 suspended from a trolley which travels on the jib. On rear pivoted luffing jibs the jib pivot is situated towards the rear of the top of the tower and the hook is supported by the hoist rope which passes over a sheave at the jib head. (Fig. 5.13) The saddle jib usually has a smaller minimum operating radius than the equivalent luffing jib and is thus able to handle loads closer to the tower of the crane. For a given height of tower, however, a greater height of lift is available with a luffing jib, and the jib can be raised or low- ered to clear obstacles. One advantage of a fixed luff jib is that its extra height at the jib head enables it to clear objects that would ob- struct a saddle jib. The advantage of a rear- pivoted luffing jib is that it has a smaller mini- mum hook radius than an ordinary luffing jib, Mounting Configurations In addition to being classified according to tower and jib configurations, tower cranes are also characterized according to their mounting configuration. They are available as rail mounted units, stationary units, climbing units and mobile units (either truck or crawler mounted). The rail mounted units can be equipped with fixed or slewing towers and any of the jib con- figurations (Fig. 5.14), Because of their mobility they generally have a larger area of coverage than do climbing and stationary tower cranes. They are also better adapted to travelling with load than are mobile (truck or crawler mounted) tower cranes. Their primary advantage is maxi mum coverage with minimal site space. Disad- vantages of the units include the expense of Maximum BRACED HEIGHT. ‘TOWER BRACES. Fig. 52182 CRANE HANDBOOK installing the track and the inconvenience of disrupting the crane service whenever work must be done on or neat the track, The stationary tower configuration can be used to good advantage because they occupy such a limited area (Fig. 5.15). They can be set at varying heights up to their maximum free standing height and can be extended beyond this limit by tying the crane back to the struc- ture. A tower crane on a static base must be able to cover from its fixed position all points at which the loads are to be handled. The crane’s capacity decreases as the operating radius in- creases, therefore, caution must be exercised in selecting the crane to ensure that the maxi- ‘mum lift weights can be handled at the desired radius. If the crane is used at a height which is to be later extended, it is advantageous if the tower has the facility for adding its own extra sections without dismantling any of the jib/ counterjib assembly. (Fig. 5.16) The climbing tower crane is generally used to good advantage when the building structure is high, the side area is limited and the structure itself is capable of supporting the crane (Fig. 5.17). This configuration of crane is supported by the structure which it is being used to con- struct, and to which it is attached by support frames and wedges. The height of the crane can be extended as the height of the structure in- creases by means of climbing ladders attached to the frames. The cranes are usually initially mounted on fixed bases and are later trans- ferred to climbing frames and ladders. The mobile mounting configuration consists of either crawler or truck mounted units much like the mobile crane class. The crawler units are equipped with special booms that are set ver- tically and carry either horizontal or luffing jibs (Fig. 5.18). Their advantage lies in great inward each without the long boom which would normally be required to reach over the top of the structure if a mobile crane were to be used. The crawler mounted tower crane must be set firm and level when handling its rated loads. They are able to travel over firm and level ground in their erected state, but have limited ability to handle loads while doing so. They are also able to travel in a partially erected state over unprepared ground providing it is within certain limits of level and compaction. The truck mounted mobile tower crane must also have its outriggers extended and be set up secure and level on its jacks when handling loads (Fig. 5.19). The majority of these machines have slewing towers and folding luting jibs which facilitate transportation and erection. Some units are completely self-contained and self-powered and can be driven on the public highways. These machines are usually capable of comparatively rapid erection and dismantling but are generally unable to travel in their fully erected state and cannot handle loads while travelling. The selection of a crane of cranes for any job should be made only after a thorough examina- tion of all the factors involved. When renting a EE = Available head mI a EEEEERE EERE WHEN SELECTING A CRANE CONSIDER THE HEAD ROOM IT WILL,MACHINE SELECTION AND EQUIPMENT REQUIREMENTS 183 crane be certain to let the rental agent know your requirements as their selection must be based on the data provided. When making equipment selections, those re- sponsible must ensure that the unit is going to be safe and reliable for as long as it will be used and under all anticipated conditions to which it will be exposed and operated. Nothing ‘can take the place of experience in making these decisions, however, the guidelines set out in this section are intended to simplify the process by stressing those critical considerations that must not be overlooked. The responsibility of equipment selection in- volves getting units that will not only get the job done as quickly and economically as possible, but also units that eliminate all possibility of hazard to personnel on the site, the public and the property. Machines should be rented only from repu- table firms or contractors and every effort must be made to ensure that they are in good working condition. EQUIPMENT REQUIREMENTS One of the prime requirements of any crane safety program is ensuring that all necessary equipment is on the machine and that it is in good working order. If the machine has been designed, manufactured, inspected, tested and maintained in accordance with Canadian Stand- ards Association Code 2248 — Tower Cranes then that is adequate assurance that all these tecommendations and all Provincial and Federal Safety Regulations are met. If any of this equipment or information is ing then it is the equipment owner's re- sponsibility to see that it is made available and put on the crane and its accessories. Identification Every major structural, electrical and mech- anical component of a tower crane should have a permanent durable plate bearing the manu- facturer's name, machine model number, serial number, year of original sale by the manufac- turer and weight of the unit. (Fig. 5.20) In addition, identification numbers should be clearly marked on all basic removable compo- nents and attachments of the machine (such as counterweights etc.) to show that they belong with that machine. It is extremely important that these components be used only on that ma- chine or identical models or on equipment for which they were specifically intended by the manufacturer, Any components or structural sections de- signed and manufactured or altered by anyone other than the original equipment manufacturer or his agent must have the certificate of a qua- lied Professional Engineer attesting to their structural integrity to accommodate all the loads which the structure or components of the ori- ginal equipment manufacturer can sustain and must be permanently identified in the same manner as the structural sections from the ori- ginal equipment manufacturer WHEN SELECTING A CRANE, CONSIDERATION MUST BE GIVEN TO THE ROPE CAPACITY. Fig. 5.4184 CRANE HANDBOOK Fixed (non-slewing) tower FIXED TOWER j CONFIGURATION. SLEWING TOWER } ‘CONFIGURATION. Slewing ringMACHINE SELECTION AND EQUIPMENT REQUIREMENTS. 185 Mono tower Fig. 5.7 INNER AND OUTER ‘TOWER CONFIGURATION. Fixed section of tower —| Fig. 5.8186 CRANE HANDBOOK Telescopic action Fig. 5.9 ‘TELESCOPIC TOWER CONFIGURATION. ‘SADDLE JIB CONFIGURATION. Fig. 5.10 Load Rating Information Every tower crane must be equipped with a substantial and durable load chart with clearly legible letters and figures. It must be securely attached to the cab in a location easily visible to the operator while seated at his control station When the crane is operated from the remote control console the load chart must be attached to a substantial plate that is secured to the console. (Fig. 5.21) The following information must be available to the operator on the load chart so that he can quickly and accurately determine the crane's capacity — Crane model number, ser of manufacture. —A full and complete range of the manutac- number and dateMACHINE SELECTION AND EQUIPMENT REQUIREMENTS 187 turer's approved crane load ratings at all stated operating radii (or boom angles) for each recommended counterweight, boom length, tower height or other installation condition. — Gear change instructions. —Allternate load ratings when using permis- sible, optional and variable geometry equip- ment on the crane, such as guy wires, bracing, additional ballast, movable counter- weights, etc. which affect the ratings. — Work areas, for which capacities are listed in the chart. The manufacturer may, at his op- tion, list capacities for one or more of these working areas or may list capacities for any combination of working areas so long as such areas or combinations of areas are identified on the capacity chart. — Adequate warning must be indicated that no allowance is made for such factors as effects of swinging loads, tackle weight, wind and operating speeds. —Recommended parts of hoist reeving, size, and type of rope for various crane loads. — Essential precautionary or warning notes rela- tive to limitations on equipment and operating - procedures. Fig. 5.11 —Drum data, available line pull, permissible line pull, line speeds and rope spooling capacity. — Wind vetocity operating limits. — Low temperature operating limits. — If special materials such as high tensile stee! or aluminum alloys have been used in the structure, the load chart must bear notice to this effect, LUFFING JIB CONFIGURATION. Trolley moves along ‘boom to alter load radius Crane Cabin (Fig. 5.22) Every operating cab that is intended to be attached to the structure of the crane or placed at a remote location should meet the following \ requirements. When the machine is operated ib angle does not change from the remote console or from a temporary work level (Fig. 5.23) attached to the tower and | the operator is not enclosed by a cab, these recommendations do not apply. The cabin should: — Be constructed of fire proof materials. —Be designed and constructed to protect the operator and the controls from the weather. —Be of sufficient size to allow operation with- out inconvenience particularly with regard to roof height and floor space. (Fig. 5.24) FIXED JIB CONFIGURATION. — Be provided with a roof of adequate strength to protect the operator from falling objects, Fig, 6.12188 CRANE HANDBOOK Rear pivot REAR PIVOTED LUFFING JIB CONFIGURATION. Fig. 5.13 {> SLEWING TOWER CONFIGURATION. INNER AND OUTER ‘TOWER CONFIGURATION. Fixed section of tower tH RAIL MOUNT CONFIGURATIONS. Fig. 5.14MACHINE SELECTION AND EQUIPMENT REQUIREMENTS: 189 —Be securely attached to whatever structure itis located on, —Be designed and constructed to provide the > operator a clear and unrestricted view of the load and boom point in all normal working positions, visibility to either side and as clear 2 view of the job site as possible, (Fig. 5.25) —Have windows constructed of safety glass or @ equivalent and designed to provide ventila- tion as needed. The front window should have a section which can be removed or held open if desired. If the section is of the type held in the open position it must be well secured to prevent accidental closure. The frames of the windows should be designed so that the panes can be cleaned without danger to personnel. — Be fitted with a lock to prevent unauthorized entry when the unit is left unattended, unless the control unit can be separately locked, The cab doors must be restrained from open- ing and closing accidentally whenever the machine is in use. ‘The fixed or stationary tower configuration ‘can be used to good advantage because the base occupies such a small and the tower can be ‘extended up to te maximum free standing or braced height. ae ® HT MAY BE ADVANTAGEOUS, WHEN USING A “FIXED BASE” CRANE, TO SELECT ONE THAT HAS ‘THE ABILITY TO INCREASE ITS OWN HEIGHT BY ADDING SECTIONS. Fig. 5.15 Fig. 5.18,CRANE HANDBOOK ‘CLIMBING CRANE CONFIGURATION. Fig. 8.17MACHINE SELECTION AND EQUIPMENT REQUIREMENTS 1 FSA > Se BIAAAIASS KAWAI i > Por (CRAWLER MOUNTED TOWER CRANE. Fig. 5.18192 CRANE HANDBOOK DI rs bi SOWA ZAZA 7 Lk BLOT CS L ‘TRUCK MOUNTED AND TRAILER MOUNTED TOWER CRANES. Fig. 5.19 — Have a safe access route to and from the cab (Fig. 5.26). The means of access to the cabin should ensure that there is no danger of the operator being trapped in the cabin. Where access is through the floor, there must be sufficient room in the cabin for the driver to stand beside the trap and raise it without dif- ficulty, and the trap door must be of adequate size, —If the vertical position of the control cabin is adjustable, the means of access and exit must be effective at all levels. Means should be provided for supporting the cabin without, imposing a load on the cabin hoisting rope and if the hoisting mechanism for the cabin is hand operated, an effective holding ar- rangement such as a ratchet and pawl should —Have lighting in the cab adequate to enable the operator to see clearly enough to perform his work. —Be provided with an operator's seat that is fully adjustable (fore-aft, up-down, and tilt) — Have all walking surfaces to and from the cab of the anti-skid type. The most common ac- cidents that happen to crane operators are slips and falls while walking, climbing or working on the structure. A spray-on anti-MACHINE SELECTION AND EQUIPMENT REQUIREMENTS 193 skid paint would prevent most of them if it were applied to all surfaces to which they have access. —Have guardrails provided on all outside and access platforms (Fig. 5.27). If they are too narrow for guardrails, hand holds, steps or safety lines should be provided at convenient Points above the platform. —Have hand holds and steps to facilitate en- trance to and exit from the cab. — Have the following accessories: (a) Windshield wipers to cover the operator's normal viewing area. (b) A cab heater capable of maintaining the temperature in the cab at 50°F minimum when the outside temperature is 20°F. (c) Awindshield defroster. (d) A CO, dry chemical or equivalent fire extinguisher. It is recommended that it be a 5:B:C type, Wind Balance When tower cranes are left overnight they must be able to weathervane, i.e., their main jib turns freely in the wind and aligns itself with the direction the wind is blowing, much like a flag (Fig. 5.28). They are able to do this be- cause the surface area of the main jib is greater than the counter jib (Fig. §.29). If, however, someone hangs a large name board on the counter jib, this wind balance is upset. This Practice may have serious consequences, It may mean that the crane will not be able to Swing into the wind when working or the result may be crane failure during high winds because of the extra sail area of the crane. (Fig. 5.30) ‘The wind balance can be checked as follows: When the wind speed is around 6 - 12 mph slew the jib side on to the wind and release the coupling of the slewing gear units. If the wind balance is correct the jib should slew in the direction of the wind. If the jib remains in posi- sition reduce the sail area of the counter jib by Temoving the advertising signs, If the crane still does not slew into the wind, put the signs on the main jib at its tip, (Fig. 5.31) Operating Controls — Alll controls used during the normal operating cycle must be located within easy reach of the operator and allow him ample room for operation. —All controls should be of the dead man type in that they return to neutral automatically when released. (Fig. 5.32) —The controls should be arranged so that acci- dental displacement is prevented and inad- vertent pressure on them does not cause the crane to be set into motion. NUATAYATANTAVATPAAPATAVTAVAVTATN EVERY MAJOR STRUCTURAL, ELECTRICAL AND MECHANICAL COMPONENT MUST BE PERMANENTLY IDENTIFIED. Fig. 5.20CRANE HANDBOOK @_ ever conraoL un ‘THE LOAD CHART MUST BE VISIBLE TO THE OPERATOR AT ALL TIMES. Fig. 5.21MACHINE SELECTION AND EQUIPMENT REQUIREMENTS 195 OPERATING CAB. Fig. 5.22 NOTE THAT AS THE CRANE GETS OLDER (YEAR 1-2, 2.3, 3-4 45) THE RATE OF FATIGUE CRACKING. INCREASES (A vs B vs Cvs D. Fig. 6.13,226 CRANE HANDBOOK Note: The results of all inspections should be carefully recorded in the log book, in full detail, and should be dated and signed by the inspector. It must be recognized that, while a crane is designed and manufactured ‘with a factor of safely, every machine begins to wear on the day it starts working. This process will inevitably continue until, at some future date, the machine will no longer be capable of its original work load, unless all parts subject to wear or failure are regularly inspected and repaired or replaced. TESTING Testing is necessary to prove that any work carried out on the machine has been done correctly and that the machine is capable of performing safely and reliably within its in- tended scope. Immediately after the crane has been erected it must be run through a series of tests in order that the limit switches can be correctly set. — The adjustment of the trolley “in” and trolley “out” limit switches should be done at no load and with the hook at its highest working height. The limit switches must be set to stop the trolley well before it strikes the end stops ‘on the main boom. (Fig. 6.14) — Hook height limit switch: To prevent the hook assembly from fouling the trolley or head block, the distance between the hoist limit switch and trolley should be adjusted as follows: (Fig. 6.15) (a) Use the minimum part reeve of the hoist service. (b) Hoist the unloaded hook at maximum speed. (c) Stop—and check the approximate amount of over-run. (d) Add to this measured over-run distance an extra 1 foot. (©) Adjust the distance between the stop frame and the trolley to give this sepa- ration. No fixed distance can be given because the over-run can vary according to winch drum diameter, motor speed, brake wear, etc. The check should always be carried out when cranes are erected or any changes or maintenance is made on the hoist winch or motor brake. —High boom and low boom limit switches: On luffing boom cranes the boom hoist cut-outs Limit switch activated with no load irolley positions ADJUSTMENT OF TROLLEY LIMIT SWITCHES. ‘Over-run at max.speed Innermost and outermost __ Fig.6.INSPECTION, TESTING AND MAINTENANCE 227 operate to shut the hoist down whenever the boom reaches a predetermined high angle and a predetermined low angle. These switches must be adjusted by booming up and down slowly (without load) and allowing the boom to come in contact with the striker switches. (Fig. 6.16) —Travel limit switches on rail mounted cranes must be adjusted to stop the travel motors and apply the brakes at least 8 feet from the rail stops. (Fig. 6.17) —Overload limit switches (Fig. 6.18): Every tower crane has at least one overload limit, most have two and some have more. Different makes of cranes require different test procedures, however, in general they require that a test weight equal to the rated safe working load be lifted several feet off the ground and the switch adjusted to just permit the load to be lifted, A second weight is chained to the first and the crane’s limit switch should cut out when the attempt is made to lift them both. This second weight should impose no more than a 5% overload on the crane. It may be necessary to have two sets of weights on hand; one set to check the hoist cable overload cut-out (to be tested with the weights at minimum radius) and the other set to check the moment overload cut-out (to be tested with the weights at maximum radius). Too many test procedures specify up to 25% overload. This is a gross overload and is con- sidered highly dangerous, in fact more damage could be done to the crane at this time than it will receive during service. Never deliberately overload any tower crane by more than 5% no matter how carefully con- trolled the test conditions are. The manufacturer has achieved a vety fine balance when the load chart is produced. To exceed any of these loads may damage structural components and the undetected damage may cause an accident sometime in the future. The safety factor on a tower crane is extremely low, they are not de- signed to be grossly overloaded. The setting of all limi checked periodically and th be tested on a weekly basi In addition to testing after erection, 100% rated load tests should be carried out on all cranes that have been extensively repaired, altered or climbed to prove: —The structural integrity of the unit. —The adequacy of the supporting structures and method of holding the crane. switches must be operation should —The adequacy of all functions under rated loads. —Confirm the adequacy of all repairs and alterations. If for any reason the crane fails any portion of the functional tests or rated load test, then it, must be removed from service until the problem is corrected. It the person carrying out these tests con- siders that the maximum load that may be safely lifted is less than the normal working load of the unit, a loading diagram appropriate to the con- ditions should be posted in place of the load chart. All cranes should be functionally tested at no Hoist mit switen pont brake ADJUSTMENT OF HOOK HEIGHT LIMIT SWITCH. Fig. 6.15228 CRANE HANDBOOK load at the start of every shift to ensure that those items mentioned under Frequent Inspec- tion ate operating correctly and to ensure that no one tampered with the crane while it was unattended. No units should be re-rated in excess of th original load ratings unless the rating changes are approved by the manufacturer or an Engi- eer who is capable of assessing the strength of the structure. MAINTENANCE In order to keep the crane operating safely, reliably and efficiently, it is essential that main- tenance be carried out before it is needed, not after. This necessitates the establishment of a Preventive maintenance program based on the ‘equipment manufacturer's recommendations. Keep track of all past, present and future maintenance by using the equipment log book and recording the details of hours worked, adjustments, checks, repairs, renewed parts, inspections and tests. The preparation and im- plementation of a planned program of mainte- nance and repair, based on the log book, not only ensures trouble free and safe operation, but also is economically attractive. ADJUST HIGH BOOM ANGLE ‘AND LOW BOOM ANGLE LIMIT SWITCHES $0 THAT ‘THE BOOM HOIST CUTS OUT AT THE PREDETERMINED HIGH AND LOW ANGLES. Due to the wide variation in job applications, severity of service, machine activity and envi- ronment, it may be impossible for the manufac- turer to develop a single, complete maintenance program which will fit all applications. The maintenance personnel should adjust, extend or otherwise modify the manufacturer's recom- mendations to suit the specific needs of the equipment. The frequency of use particularly affects the service life of expendable components such as wire ropes, the failure of which usually results in serious consequences, All maintenance staff must be made fully aware of the hazards involved in working on tower cranes, and the maintenance foreman should be responsible for instructing his staff in all aspects of work safety on and around this equipment. The maintenance staff must also have a good working knowledge of the ma- chinery and have access to the manufacturer's literature. Most of the tower crane’s maintenance will be dictated by what is found during the inspec- tions, however, regardless of what is required the following safety precautions should be taken as applicable. —Everyone working on the crane structure must wear a safety belt and lanyard and tie himself off to the structure whenever there is a possibility of falling, — Lock the master power switch “off” and place a sign on it indicating that it is not to be switched on. —Under no circumstances should the mainte- nance personnel be on or under any part of the machine when the power is on or when the operator is at the controls without the full knowledge and consent of the operator. —Be a good housekeeper . . . keep tho hoist deck clean, free of concrete, oll, grease, rags, cables and other hazards. Keep loose parts in 2 tool box. Use only non-flammable solutions for cleaning. Be sure your shoes are clean and dry before climbing on the structure, —Keep hands, feet, clothing away from gears, ropes, drums and sheaves. — Never wear loose clothing which may become entangled in moving machinery. Be sure that safety equipment (such as fire extinguishers) is available, and in good condition. Never tamper with safety devices. —Before returning a crane to operational service, all components which have been affected by the maintenance or repair should be subjected to a visual inspection, followed by an operational check by the operator toINSPECTION, TESTING AND MAINTENANCE 229 ensure that the components are functional. — Always replace protective guards and panels before operating the machine. —Never restart operations until all_ personnel are well clear of the crane. Never re-engage the master switch until everyone knows what is going to happen and when. Damaged equipment requiring significant or extensive structural repairs should be com- pletely re-tested before being put back into service by a licenced, qualified inspection and testing agency or by a manufacturer's repre- sentative. Each tower, jib or mast section of any crane which has been involved in a mishap causing structural failure or which is suspected of hav- ing been overstressed must be removed from service until a certificate of a qualified regis- tered Professional Engineer or other acceptable authority has been issued testifying that its structural integrity has not been impaired. Note: Structural repairs or alterations of any kind are a skilled operation requiring special training and experience. Do not attempt to make any structural repair with out first contacting the manufacturer, his agent or an authorized repair and main- tenance agency. This is particularly impor- tant when welding must be done. Improper weld repairs can cause much greater problems conducive to fast cracking in the weld or parent metal. This condition would be worse than the condition before the repair and could be hidden. All weld- ing must be carried out by a licenced welder and the method and choice of electrode is to be governed by the parent material and the manufacturer's instruc- ions. Any structural tubes or other thin-walled structural sections which have been buckled, dented or deformed are not to be repaired. They ‘Over run ADJUSTMENT OF TRAVEL LIGHT SWITCHES. a7230 CRANE HANDBOOK ADJUST HOIST OVERLOAD CUT OUT. een 2 RATED LOAD. [Hl oventonn. SET LIMIT SwitcH. =p> [ws] RATED LOAD. CHECK OPERATION OF LIMIT SWITCH, (om ‘ADJUST MOMENT ‘OVERLOAD CUT OUT. oad endive Y RATED LOAD. [wn] overtoao. [i SET LIMIT RATED switch. > CHECK OPERATION OF LIMIT SWITCH. CHECK OPERATION OF MOMENT OVERLOAD CUT OUT ON ‘TROLLEY DRIVE, ———> TROLLEY our. (CHECK THAT TROLLEY =p DRIVE CUTS ‘OUT AT PROPER [m=] RATED RADIUS. Loap. fon] RATED LOAD. Fig. 6.18INSPECTION, TESTING AND MAINTENANCE must be cut out and replaced ponent. (Fig. 6.19) No reinforcements, alterations or similar structural repairs may be made without the manufacturer's permission. Detects such as the following must be cor rected immediately to ensure safe operation: All enitical parte of functional operating mechanisms which are cracked, broken, cor- roded, bent or excessively worn. —Any critical part of the structure which is cracked, bent, broken, dented or excessively worn. anew com- —Defective load hooks must be discarded, Repairs by welding or reshaping are not acceptable. —Any corroded structural members must be cleaned to bare metal and then repainted. Do not paint over rust or old paint as you succeed only in hiding defects and creating pockets for water to accumulate, (Fig. 6.20) All replacement parts and repairs must have at least the same safety factor and reliability as the original part and be in accordance with the specifications of the original equipment manu- facturer. It is also recommended that the re- placement parts be purchased from the original equipment manufacturer to ensure that the machine's original quality and strength are maintained. It is good practice to stop the machinery while lubricating it, except in cases where the 231 DAMAGED SECTIONS OR ELEMENTS MUST BE CUT ‘OUT AND REPLACED. Fig. 6.19 lubrication system is designed for safe applica- tion while the machinery is in motion. Any guards or panels which must be removed for access should always be replaced before re- suming operations. All wire rope and rigging equipment must be inspected and maintained as per the manufac- turer’s instructions and in accordance with the information provided in the Construction Safety Association of Ontario “Rigging Manual” hy hy a Ae) : ST NEVER PAINT OVER RUST — CLEAN TO BARE METAL FIRST. Fig. 6.20232 It is very important that all repairs and adjust- ments be made only by properly designated and authorized personnel. When a crane is being repaired, the maintenance man assigned is in charge of all phases of crane movement and operation, and his instruction should or- dinarily be obeyed without question. Only if his instructions are contrary to safe operating prac- tices should the operator question them. Under these circumstances, the maintenance super- visor should be contacted at once for a decision Note: Under no circumstances should any per- sor attempt any repair for which he is not fully qualified, Storage of Tower Crane Components When a tower crane has been dismantied, all sub-assemblies should be properly cleaned, repaired if necessary, repainted and stacked in asuitable area. Structural Parts — Tower sections, mast and jib sections should be cleaned to remove oil, grease and con- crete. —A detailed magnetic particle non-destructive inspection should be carried out to detect structural cracks and damage on all sections. — Rust spots should be scraped or wire brushed and then painted with one coat of primer and one coat of enamel paint, —All sections should be laid horizontally on the ground with timber blocking beneath them. (Fig. 6.21) —All sheaves should be inspected for bearing wear, groove wear and cracks. All bearings CRANE HANDBOOK should be packed with grease and a light film of rustproofing compound sprayed over the entire sheave assembly. — Oil all pins and bolt threads and screw on all washers and nuts. Put in a container and place inside a dry storeroom. Wire Ropes and Pendants —Wire ropes and pendants must be thoroughly inspected for wear, broken strands, kinks or other damage. Damaged or worn ropes must NOT be re-used. Destroy them by cutting them with a torch, —Relubricate all ropes with wire rope lubricant. —Coil up ropes and pendants into large loops and store on skids in a dry storeroom. Ensure they are well covered Turntable Assembly —The turntable assembly should be cleaned to remove grease, then sent to the repair shop for a thorough inspection and re-fitting, —All gears and shafts should be coated with a coat of rustproofing compound. —All gear boxes must be filled with the proper lubricant and the assembly should be put on timber blocking in a dry storeroom. Trolley Drive Assembly —This unit should be inspected, cleaned and ‘checked for worn out belts or sheaves. — The sheave bearings should be packed with grease. —The electrical connections should be tight- ened and the cables rolled up and tied. ENSURE THAT ALL STRUCTURAL SECTIONS ARE STORED ON TIMBER BLOCKING. Fig. 6.21INSPECTION, TESTING AND MAINTENANCE. 233 Climbing Assembly —Alll climbing components must be cleaned and sprayed with a rustproofing compound —The hydraulic cylinders must be inspected for damage or leakage. —The hydraulic pipes should be cleaned and checked for damage. —The power pack must be checked for loose bolts, and the hydraulic reservoir filled up with the proper fluid. — All electrical connections should be checked and the electric cables rolled up, tied and the plugs wrapped in a waterproof cover. Limit Switches — All limit switches should be checked for torn gaskets and replaced if necessary. — All worn gears and cams should be lubricated —Check all electrical connections for positive hook-up. —Limit switches when disconnected should be kept indoors in a dry heated storeroom whenever possible. Hoist Machinery Assembly —The hoist machinery should be cleaned and the drum bearings checked for wear and then greased. —The reduction gear reservoir should be checked and the oil topped up or changed if found contaminated, —The brake shoes should be checked and replaced if worn out. —All V-belts and sheaves must be checked for wear and replaced if necessary. — Sheave bearings must be packed with grease —All electrical cables should be coiled up and tied and the plugs wrapped in waterproof covers. Electrical Panels and Controls —All electrical connections and switches should be inspected and repaired if neces sary. —The electrical cables should be rolled up and placed in a storeroom with the controls.