Overhead Crane Operator's Manual

PROFESSIONAL CRANE INSPECTIONS

Overhead Crane Operating Manual
Introduction

Crane Guidelines

The safe and efficient use of cranes requires a basic knowledge of crane operations, extreme caution, good common sense, alertness, concentration, and awareness of and adherence to ANSI and OSHA safety standards.
The following people should not be permitted to operate a crane:

(a) Persons who are unable to speak the appropriate language or read and understand printed instructions or warning labels;
(b) Persons under the legal age required to operate crane equipment;
(c) Persons with uncorrected hearing or eyesight impairment;
(d) Persons with poor heart condition or any other ailments which might be detrimental to safe crane operation;
(e) Persons who have not carefully read the crane manufacturer’s operation manual;
(f) Persons who have not been instructed on the proper use of the crane;
(g) Any individual that has not demonstrated his ability to operate the crane to a qualified
person;
(h) Any individual unfamiliar with proper rigging and load lifting practices.

Crane Use
Before initial use of the crane, the crane operator should carefully read the Crane Manufacturers’ operating manual to note any special instructions or safety procedures not previously given by the instructor or supervisor.
With the mainline power off, the crane operator should operate the master switch and push button controls in every direction to familiarize himself with the controls and to make sure that none of the buttons bind or stick in any position. If the controls do not operate freely, the operator should immediately report the condition to the pertinent supervisor.

Crane Controls
Once the crane operator has read the crane manufacturer’s manual and become familiar with the controls, he is ready to turn the power on and operate the crane.

First, check the crane and runway to be sure that no one is on the crane or in the path of the crane. Then, turn on the main power and press the “On” or “Reset” button.

Start with the hoisting motion first. Move the master or push button slowly in the “up” or “down” direction. The resulting movement should correspond with the master switch or push button controls for all motions. Observe any discrepancies in motion, speed controls or hoist braking. Position the hook several feet from the bottom of the hoist. Very slowly move the hook up to its upper travel limit. The limit switch should engage causing the hoist to stop at its upper limit. If any malfunctions are detected in the controls, hoisting brake, or limit switch, report these conditions immediately to the supervisor.

After thoroughly testing the hoist, test the trolley in the same manner. If the trolley is not equipped with a brake, stop the trolley by momentarily operating the control in the first point of the reverse direction. This is known as “plugging” and should only be used when absolutely necessary. Use of plugging causes added wear to trolley. Next test the bridge motions to make sure that the bridge is operating smoothly in every direction. Be sure to test the brakes and check the stopping speed.

Keep in mind these four simple rules:
1. Always start the crane motions in the slowest speed and “step up” the controls to a safe speed.
2. Stop the crane in the same manner. Stopping slowly will not only help keep the load from swaying, but it will minimize the wear on the braking system.
3. Notice the drift of each function. Learn the time it takes each motion to stop once the power is removed.
4. Always remain alert and cautious when lifting a load. Make sure that the crane, runway, and lifting area is free of personnel and any unsafe obstructions.

The Bridge
The operator should always be sure that the hook and load is positioned high enough to clear everything in its path. Prior to lifting a load, the bridge should be positioned directly over the load to be lifted. This will help in positioning the hoist and trolley over the load and help prevent “side pulling.”

The brake on a bridge is usually activated by a foot pedal in a cab operated crane or a push button on a pendant station. The brake is used on a bridge to perpetuate exact lifting. Once the operator learns the distance the crane bridge will travel when the brake is applied, and the distance the bridge will coast when no brake is applied, the operator should be able to position the bridge where desired without using the braking mechanism. On cranes with pendant station controls, the electric brake sets automatically when the push button is released.
If the crane does not have “Variable Speed Control” or a creep function, the practice of “inching” can be applied. Inching is achieved by toggling the control button on and off to produce a minimal motion. This practice should be used only as necessary because it causes extra wear on control contacts as well as the brake itself. Avoid rough braking actions. Locking the brake and skidding the wheels can cause flat spots on the bridge wheels and can damage the runway system. Always start and stop the bridge slowly and gradually.

The Trolley
The trolley should be positioned directly over the load before making a lift. Failure to center the hoist and trolley above the intended load could cause sway when the load is lifted and may result in damage to the hoist and hoist rope.
If the trolley is equipped with a brake, the same instruction given for controlling the bridge can be followed. If the trolley is not equipped with a brake, the operator must gain a familiarity with the motion of the trolley. The distance the trolley travels after the control motion is released is called “drift.” By learning the amount of drift a trolley has, the operator will be able to gauge its distance eliminating the need of reversing power to the trolley motor to bring the trolley to a stop.

Always start and stop the trolley slowly and gradually. Inching, the procedure explained in “The Bridge” section of this manual can be used for slight trolley motions.

The Hoist
With the hoist in position over the load, lower the hook until the load can be attached to it with a safe and proper rigging technique.
With the load attached, raise the load slightly off the ground and stop the hook. The hoist brake should engage immediately stopping the load at the point that the control button was released. Repeat this step in the down direction. If any drift is detected in either motion notify the proper supervisor or manager.

If slings are used to handle the load, the slings should be fully seated in the saddle of the hook to avoid stretching the hook (tip loading) or damaging the sling. Raise the hook until all of the slack is taken out of the sling. Lift the load slowly and make sure that the load is secure and properly balanced before increasing hoisting speed. Raise the load until it is clear of all obstructions. Use caution in lowering loads. Slowly decrease lowering speed until the load is near its stopping point. If a hitcher is used to help direct the load, the operator should pay close attention to the instructions of the hitcher. When the operator is signaled to continue lowering, it should be done at the slowest possible speed. If creeping function is not available, final positioning can be achieved by using the inching procedure. Reminder: using inching to position the load adds extra wear and tear on the hoist.

Cleanliness
The crane cab and its surroundings should be kept clean and free of clutter and debris at all times. Loose items such as tools, nuts, bolts, coffee cups, shoes etc... should not be left in the cab as they perpetuate a safety hazard. Such items could get lodged underneath the brake pedal (or other controls) making it impossible to decelerate the crane.

Maintenance
The crane or cranes must have a preventative maintenance program. A program involving maintenance and inspections will help keep the crane functioning properly and operating safely. Routine maintenance is critical to the life and productivity of a crane.

Inspection
Crane controls must be checked at the beginning of each shift. Be sure that all brakes, limit switches, ropes, hooks, safety devices and crane controls are functioning properly. Inspect crane for any loose items or damaged parts. Any problems should be immediately reported to the supervisor.

Signals
Standard crane signals should be accepted from only one qualified and authorized person unless the situation requires more than one person for reasons of safety.

Always obey Stop signals no matter who is signaling.

Loads should not be lifted if the crane signals are not clearly given, seen and understood.

Awareness
The operator should always remain alert with hands kept on the handles of the master controls so that motion changes and stops can be made quickly and easily in the event of an emergency. The operator should stand up when necessary to improve sight of the load or signals. Stay focused on your surroundings-be aware of any unusual sounds or warnings.

Operating Tips
Smooth operation of a crane is a sign of a careful and safe crane operator. Quick starts, slamming reversals, jumpy and jerky motions, and sudden stops are signs of unsafe and inefficient crane handling. Here are some tips for better crane operation:

1. Operate crane controls in a smooth and gradual motion. Avoid moving the crane or the load in sudden or jerking movements. Remove all the slack from slings and hoist rope before lifting the load.
2. Avoid load sway by centering the crane directly above the load and then positioning the hoist and trolley directly above the load.
3. Keep hoist ropes vertical. Do not use crane for side pulling and do not position a load by swinging it into an area that the crane cannot reach.
4. Be aware of the hoists upper and lower limits. The traveling limit switch is an emergency safety device. Do not use the limit switch as a means to stop hoist travel. Never lower the block so far that less than 2 wraps of hoist rope remain on the drum. If hoist rope is completely unwound from the drum, rewind the wire rope in the correct direction and seat it properly in the drum grooves. Failure to do so could result in damage to the hoist rope and drum as well as causing the upper limit device to malfunction.
5. Before moving a load, be sure that everyone in the area is clear of the load and aware that the load is being moved. A warning device if provided should be sounded before raising, lowering or moving a load in an area where people are working.
6. Do not make lifts beyond the working load limit of any crane, sling, or lifting device.
7. Do not operate the crane if the upper limit switch is not functioning, or if the hoist rope shows defects or extensive wear.
8. Before moving a load, be certain that all chain slings, wire rope slings, synthetic slings or lifting devices are fully seated in the saddle of the hoist hook with hoist and sling hook latches closed. The hoist hook must be equipped with a latch but a sling may not have one.
9. When a duplex or double saddle hook is used, a double sling or two single slings should be used to assure that the load is equally divided over both saddles of the hook.
10. When lifting loads on or near full capacity of the crane, test the hoist brakes by picking up the load just a few inches off the floor and then stopping. Make sure that the hoist is holding the load and that there is no drift. If there is no drift lower the load down a few inches and stop it. Again check for drift. Report any problems to the supervisor.
11. When moving the bridge, or trolley, make sure that the bottom block is raised enough to clear any obstructions in its path.
12. When using a rigger, it is the joint responsibility of the crane operator and the rigger to ensure that the load and all its attachments are secure and that all loose material has been removed from the load.
13. Never leave any unused sling hooks hanging from the load. All legs of the sling should be used. Refer to ASME B30.9 for proper sling selection.
14. Remove sling cables, and chain slings from the hook when the crane is not being used for lifting. Dangling sling hooks can inadvertently snag other objects when the crane is moving without a load.
15. Limit switches should not be used to stop hoist travel under normal operating conditions. (Limit switches are emergency safety devices and shall not be used as a control function.)
16. Do not adjust, or disconnect limit switches in order to exceed the hoists allowable limits.
17. Limit switches should be tested at the beginning of each shift or in as frequent as deemed necessary by the supervisor or qualified personnel.
18. Crane operators shall not carry loads or empty loads over any people or personnel. Extra caution should be used when lifting a load with devices such as magnets or vacuum lifters. Failure of power to these types of lifting devices could result in loss of load. Also, hazardous materials such as molten metals, and harmful chemicals should be handled with extreme caution and should be kept away from the proximity of personnel.
19. During a power failure, the crane operator should switch all controls to the “off” position until the power is restored.
20. Before disconnecting the main or emergency power to the crane for maintenance or other purposes, be sure that all controls are in the “off” position.
21. If plugging protection is not provided (ie... automatic delay, interlocking switches etc..) always stop the controls momentarily in the “off” position before reversing. (This time is necessary to give the braking mechanism time to function properly.)
22. Upon leaving a crane, the operator should adhere to the following procedure:

(a) Raise all hooks to an intermediate position.
(b) Place the crane at an approved designated location.
(c) Switch all control to the “off” position.
(d) Turn the main switch to the “off” position.
(e) Make a visual check before leaving the crane.

Note: Crane operators should always set the brake and anchor securely on outdoor cranes to keep the wind from moving the crane.
23. When two or more cranes are used in making a single lift, the crane operators should take signals from one designated person.
24. Never attempt to operate a switch that has an “Out of Order” or “Do Not Operate” card on it. Even when a crane operator himself has placed the card, it is necessary to make a careful check to determine that no one else is working on the crane, before removing the card.
25. In the event of an emergency, or during inspection or maintenance, a warning sign should be displayed at the crane and the main power switch should be locked in the “Off” position no matter who is working on the crane. A cab-crane operator should remain in the cab when others are doing work unless otherwise instructed by the supervisor.
26. Never move or bump another crane that has a warning sign or signal displayed. Extreme caution should be used when making contact with runway stops or another crane. If contact must be made, the operator should do so with maximum care for the safety of persons on or below the crane, and only after making sure these persons are aware of what is taking place.
27. Do not change fuse sizes. Do not attempt to make repairs to the electrical system or other major repairs on the crane unless specific authorization has been granted.
28. Never bypass any emergency device, electrical limit switch, or warning device.
29. Load limiters or overload devices shall not be used as a means to test the weight of a load. A load limiter is an emergency device and shall not be used as an operating control.