LESSON

2
LECTURE
CRANES
SUB-OBJECTIVE
At the end of the Lesson the Trainees will be able to desribe witho!t error the
!se of ranes"
#"$ %EC&ANICAL LI'TIN(
Mechanical lifting means that material and machinery lift or moves by cranes
or fork lifters or by other power lifting equipment.
Many different kinds of cranes are used for lifting and moving loads in
industry. They vary in size, function, and design. In general, however,
cranes can be divided into two groups: bridge cranes and boom
cranes.
2"$ BRI)(E CRANES
ridge cranes are lifting devices with overhead girders or trusses that
travel on rails. Their hoist motors travel on trolleys that roll back and
forth along the bridge. This arrangement allows bridge cranes to move
loads in two horizontal dimensions: for e!ample, the bridge may travel
north and south while the trolley rolls east and west. ridge cranes can
be divided into two general categories: overhead traveling cranes and
gantry cranes.
2"# OVER&EA) TRAVELLIN( CRANES
" typical overhead traveling crane is illustrated in #ig. $%&'&$. The
bridge of an overhead traveling cranes moves along elevated rails that
are at the same height as the bridge. (perating controls are usually
located in a cage that hangs below the bridge and travels along with it.
(verhead traveling cranes are usually indoor machines. Their rails
e!tend from one end of a building to the other, along the building)s long
a!is. *hen loads are moved along the building)s length, bridge travel
is used. *hen loads are moved across the floor, trolley motion is used.
"n overhead crane)s controls include bridge travel, trolley travel, and
hoist action. Many overhead cranes have two hoists on a single trolley.
If this is the case, a second hoist control is added. The second, or
au!iliary hoist is usually less powerful and has a smaller hook than the
main hoist.
MECHANICAL MAINTENANCE COURSE MODULE 16
LESSON 2 PAGE 1 CRANES AND LIFTING MATERIALS
There are several possible arrangements for the controls. +ome
cranes are operated by push buttons, while others have levers that can
be pushed either forward and back or left and right. Many cranes have
variable speed controls: the farther a button or lever is pushed, the
faster than bridge, trolley, or hoist movement. (ne typical control
station is shown in #ig. $%&'&'.
'i*" #+-2-#" O,erhead tra,elin* rane"
'i*" #+-2-2" O,erhead rane ontrols"
MODULE 16 MECHANICAL MAINTENANCE COURSE
CRANES AND LIFTING MATERIALS LESSON 2 PAGE 2
-"$ (ANTR. CRANES
" typical gantry crane is illustrated in #ig. $%&'&,. -antry cranes differ
from overhead traveling cranes in that their bridges are supported on
legs that travel on ground&level rails.
'i*" #+-2--" (antr/ Crane"
-antry cranes are usually outdoor machines. +ince they travel on
rails, their working area is limited only by the length of the rails. #ig.
$%&'&. shows a similar type of crane that travels on one ground&level
rail and one elevated rail. This crane, called a semi&gantry, is actually a
cross between a gantry crane and an overhead traveling crane.
'i*" #+-2-0" Se1i-(antr/ rane"
MECHANICAL MAINTENANCE COURSE MODULE 16
LESSON 2 PAGE 3 CRANES AND LIFTING MATERIALS
/ontrols for gantry and semi&gantry cranes can be found either in a cab
attached to the bridge, or, more commonly, on a pendant that hangs
down from the bridge.
The pendant is a control bo! suspended from a cable that is attached
to the electrical system of the bridge. The operator walks along with
the bridge as it travels. " typical pendant control bo! is illustrated in
#ig. $%&'&0. The arrangement of controls may vary from crane to
crane.
'i*" #+-2-2" T/3ial 4endant ontrol arran*e1ent
1ike all mechanical equipment, cranes must be inspected for safety at
regular intervals, and daily by the operator.
(verhead cranes are inspected periodically on a yearly basis.
MODULE 16 MECHANICAL MAINTENANCE COURSE
CRANES AND LIFTING MATERIALS LESSON 2 PAGE 4
The inspection must be carried by an authorized trained person. This
inspection may involve the disassembly of the control panel.s, brake
mechanisms, or other parts that shown signs of internal wear or
damage.
The inspection includes checks of the following conditions.
$. Misad2ustment or ineffective operating controls.
'. ent or cracked parts.
,. 1oose fasteners.
.. /racked or worn sheaves and hoist drums.
0. *orn, cracked, or distorted bearings, shafts, gears, and
rollers.
%. Improper performance of motors and electrical system.
3. 1oose or worn, damaged hoist ropes.
4. 5eformed or cracked hooks 6dye penetrant or magnetic
particle tests for hidden cracks7.
'i*" #+-2-+"
MECHANICAL MAINTENANCE COURSE MODULE 16
LESSON 2 PAGE 5 CRANES AND LIFTING MATERIALS
0"$ 'RE5UENT INS4ECTIONS
The crane operator will carry out frequent inspections at intervals
specified by the manufacture of the crane. Ideally, an operator should
inspect his crane at the start of every shift.
The inspection will include checks on each operating control, limit
switch and brake. The operating control switch will be tested for
operation in both directions.
Moving and stopping each of the mechanisms tests the bridge and
trolley brakes. 1oad brakes must be tested before lifting any heavy
load: the load is hitched a few inches off the ground.
*hen the hoist control is returned tot he neutral position, the load
brakes should automatically hold the load in place without slipping.
8oist limit switches are tested by slowly raising the hoist as far as it will
go.
*hen the hook reaches the limit of its upward travel, the switch should
cut power to the hoist.
The hoist controls should not be able to raise the any further, but they
should be able to lower the hook.
ridge and trolley travel limit switches are tested similarly.
MODULE 16 MECHANICAL MAINTENANCE COURSE
CRANES AND LIFTING MATERIALS LESSON 2 PAGE 6
5UESTIONS
$. 1ist the three basic controls found on all overhead traveling cranes.
a. 9999999999999999999999999999999999
b. 9999999999999999999999999999999999
c. 9999999999999999999999999999999999
'. (verhead cranes travel on 9999999999999999rails.
,. (verhead cranes are usually99999999999999999999machines.
6indoor, outdoor7
.. "ll overhead cranes have99999999999999999999999brakes.
0. -antry cranes travel on999999999999999999999rails.
%. /ontrols for gantry cranes are found either in a cage attached to the
bridge or on a 999999999999999999999suspended from the bridge.
3. -antry cranes are usually 99999999999999999999999machines.
6Indoor, outdoor7
4. :eriodic inspections of overhead cranes must take place at least once
a 99999999999999999999999999999999999.
;. 9999999999999999999999are dye penetrant or magnetic particle
tested for hidden cracks.
$<. Ideally, how often should an operator inspect his crane=
99999999999999999999999999999999999999999999999999999999
999
$$. 999999999999999999999999are safety devices that automatically cut
power to part of the crane when it has reached its travel limit.
$'. #requent inspections include checks of all
a 999999999999999999999999.
b. 999999999999999999999999.4. :eriodic inspections of
overhead cranes must take place at least once a
99999999999999999999999999999999999.
;. 9999999999999999999999are dye penetrant or magnetic particle
tested for hidden cracks.
$<. Ideally, how often should an operator inspect his crane=
99999999999999999999999999999999999999999999999999999999
999
MECHANICAL MAINTENANCE COURSE MODULE 16
LESSON 2 PAGE 7 CRANES AND LIFTING MATERIALS
$$. 999999999999999999999999are safety devices that automatically cut
power to part of the crane when it has reached its travel limit.
$'. #requent inspections include checks of all
a 999999999999999999999999.
b. 999999999999999999999999.
c. 999999999999999999999999.
MODULE 16 MECHANICAL MAINTENANCE COURSE
CRANES AND LIFTING MATERIALS LESSON 2 PAGE 8