1. Overhead Crane Operators
OPERATION SAFETY
FOR
Overhead Crane Operators
WELCOME

2. Mechanical
Electrical

3. Selection Of Over Head Crane
Note:- 1) Crane weight and wheel loads are approx. Values given to evaluate size of supporting structure. 2) Pendent push button is suspended from Hoist / crab. 3) Hook approach: a) Hook position is assumed at center of rope drum b) Dimensions given are without consideration of DSL and its location 4) A. C. Disc brakes are provided for all motors 5) For SG - EOT Hoist with Electric Trolley will be supplied. For DG - EOT Hoist with crab assembly will be supplied. 6) Dimensions E & F will change for higher lifts. 7) For every fraction of spans above the specified span Dimensions of nearest higher span shall be applicable. 8) Cranes can be offered to suit higher size of runway rails on request. 9) Data tolerance + 10% 10) For SG - EOT Diameter of long travel wheel is 150 and 250 for cranes upto 3Tx12 mtrs. and 5Tx3 mtrs to 10T x 12 mtrs. respectively. 11) (L) Lift on crane = Height of Rail (R) + C - K  

4. @ An overhead crane operator’s job is very important
@ Employers and employees need to be aware that all cranes are different and may have specific operating, safety, inspection and maintenance requirements.
@ It is essential that you have the manufacturers operating manuals

5. OVERHEAD CRANE SAFETY

6. OVERHEAD AND GANTRY CRANE OPERATION
Hoist operators must inspect equipment daily before use.
Do not operate a crane or hoist if limit switches, steel ropes, chains or other components are worn or in disrepair.
Replace nylon or web slings immediately if excessively worn.

7. OVERHEAD AND GANTRY CRANE OPERATION
Associates in the direction of travel should be warned to move and remain clear of a lifted load at all times.
Loads should not be suspended over personnel below.
Under no circumstances may anyone ride the hook or load.
Directional movement should be made smoothly and deliberately. Avoid rapid movements in any direction.

8. OVERHEAD AND GANTRY CRANE OPERATION
Do not exceed the rated load capacity of the crane, hoist, chain, cable, slings, or other component.
Slings, load chains and other lifting devices must be fully and securely seated in the hook before moving a load. Remove slack from the sling, chain, or cable before lifting a load.

9. OVERHEAD AND GANTRY CRANE OPERATION
Use the following practices to avoid swinging loads:
 Locate the hoist directly above the lifting point of the load before lifting.
 Lower loads directly below the hoist.
 Keep hoisting ropes vertical. Do not pull or push the load.
 Maintain two full wraps of cable on the hoisting drum.

10. OVERHEAD AND GANTRY CRANE OPERATION
When lifting loads at or near capacity, test the hoist brakes by returning the master switch or push button to the “OFF” position after raising the load a few inches off the floor. If the brakes do not hold, lower the load to the floor slowly and do not operate the crane. Report the situation immediately and DO NOT USE until repaired.

11. OVERHEAD AND GANTRY CRANE OPERATION
Ensure that all loads are lifted high enough to clear obstructions before moving the bridge or trolley. Whenever possible, maintain a minimum clearance of one foot above loads and to the sides. Raise the load only to the height necessary to clear lower objects.
Never pull a hoist by the pendant cable.

12. OVERHEAD AND GANTRY CRANE OPERATION
Never leave the controls unattended while a load is suspended. If it becomes necessary to leave the controls, lower the load to the floor.
Familiarize yourself with the location of the disconnect switch.
If loss of electrical power occurs, place controls in the “OFF” position to prevent unexpected startup upon restoration of power.

13. OVERHEAD AND GANTRY CRANE OPERATION
Disconnect power to a hoist that is unsafe or in need of repair. Arrange to have the disconnect switch locked and the control panel tagged with an “Out of Order” or “Do Not Operate” tag. Never operate a hoist that has been tagged with an “Out of Order” or “Do Not Operate” tag, or is your opinion, UNSAFE TO OPERATE…

14. HOISTS / CRANES Daily Inspection Checklist
Check for any loose or missing parts.
Check end stops. End stops prevent the trolley from running off the beam.
Know the location of disconnect switch that will cut the power off only to the hoist or crane. Be sure it is readily accessible and not blocked.

15. HOISTS / CRANES Daily Inspection Checklist
Make sure all control buttons are labeled to indicate their function. Operate each button to make sure it functions properly, releases immediately, and does not stick. N W S E
Check upper hoist limit switch by slowly raising the block to trip the switch.
Lower the hoist block to activate the lower limit switch if the hoist is so equipped, leaving at least one turn of rope on the take-up drum.

16. HOISTS / CRANES Daily Inspection Checklist
Make sure wire rope is properly seated in its drum and sheave grooves without any slack or overlapping.
Operate the crane or hoist several feet in each direction that it travels. Listen for any unusual noises. Look for any jerky movements.
When moving an A frame hoist, take care to ensure that the wheels on each side stay on the track.

17. HOISTS / CRANES Daily Inspection Checklist
Check all hooks. Hooks should not be cracked, stretched, bent, or twisted. Each hook must have a safety latch that automatically closes the throat of the hook. If the latch is bent, spring is broken, or is otherwise damaged the latch must be repaired before use. Hooks should rotate freely in block assembly without any “grinding” felt or heard.

18. HOISTS / CRANES Daily Inspection Checklist
Check the block assembly for structural damage or cracks in any components. Sheaves should rotate freely without any grinding felt or heard coming from the bearings. The sheave guard must be unbroken and intact. No part of the sheave guard should be in contact with the wire rope or sheave.

19. HOISTS / CRANES Daily Inspection Checklist
Check the wire rope by lowering the block to the lowest level and looking for the following conditions. If any of these conditions are observed, they should be reported immediately.
 Reduced diameter of the rope. This may indicate the rope has been stretched, has lost its inner core support, or has worn outside wires.
 Any number of broken strands of wires.
 Kinked, crushed, cut, or “bird caged” wiring, or wiring with heat damage.

20. HOISTS / CRANES Daily Inspection Checklist
Check load chain for damage, wear at contact points, cracks, or distorted (bent, twisted, or stretched) links. Inspect all mechanical coupling links to insure linking pins are secure and in good condition. Report unsafe conditions immediately.

21. HOISTS / CRANES Daily Inspection Checklist
Check the condition and capacity of nylon or synthetic web slings. Capacity ratings must be legible on the manufacturer’s label. The capacity of the sling being used must be adequate for the load and attachment method. Replace slings immediately if excessive wear occurs.

22. * coordination between eyes, hands, and feet.
@ The minimum qualifications for an employee selected to operate a crane are as follows:
* Corrected vision
* Effective use of all 4 limbs
* Sufficient height to operate the controls & in
to the working area.
* coordination between eyes, hands, and feet.
* Be free of known convulsive disorders and episodes of unconsciousness.
* Every 3 Year medical Fitness Check up is necessary

23. By Issuing Authority: _______________________________________________
Sample Permit
CRANE OPERATOR PERMIT
(Firm Name)
Operator’s Name:
Operator’s Number:
Is Authorized To Operate: (Insert Type of crane/Crane(s) Authorized)
Restrictions: (Explanation of Restrictions)
Date Issued: (Month-Day-Year
Date Expiring (Month-Day-Year)
By Issuing Authority: _______________________________________________
Title

24. Personal Protective Equipment
Head Protection
Hearing Protection
Hand Protection
PROPER CLOTHING & DRESS
Face Protection
Special Clothing
Respirators
Safety Foot Wear
Fall Protection

25. Shift/Operator Inspection Checks
Inspection Item
Description of Inspection Check Points
Tagged Crane or Hoist
Check that crane or hoist is not tagged with an out-of-order sign.
Control Devices
Test run that all motions agree with control device markings.
Brakes
Check that all motions do not have excessive drift and that stopping distances are normal
Hook
Check for damage, cracks, nicks, gouges, deformations of the throat opening, wear on saddle or load bearing point, and twist. Refer to the manual furnished by the original manufacturer of the crane.
Hook Latch
If a hook latch is required, check for proper operation.
Wire Rope
Check for broken wires, broken strands, kinks, and any deformation or damage to the rope structure.
Revving
Check that the wire rope is properly revved and that rope parts are not twisted about each other.
Limit Switches
Check that the upper limit device stops lifting motion of the hoist load block before striking any part of the hoist or crane.
Oil Leakage
Check for any sign of oil leakage on the crane and on the floor area beneath the crane.
Unusual Sounds
Check for any unusual sounds from the crane or hoist mechanism while operating the crane or hoist
Warning and Safety Labels
Check that warning and other safety labels are not missing and that they are legible.
Housekeeping and Lighting
Check area for accumulation of material, trip or slip hazards, and poor lighting

26. Operating Points
@ A hoisting limit switch on a crane or hoisting device must not be used as an operating control unless the crane is also equipped with a backup limit switch.
@ A load must not be lowered below a point where less than 2 full wraps of wire rope remain on the hoisting drum.
@ If there is doubt, safety of a crane or hoisting, the operator must immediately stop the crane and report the condition creating the doubt to the supervisor.
@ Compressed gases can only be lifted by a cradle or enclosed platform.
@ An operator must only respond to signals from the employee directing the lift

27. Standard Hand Signals For Controlling Overhead
And Gantry Cranes
HOIST. With forearm vertical, forefinger pointing up, move hand in small horizontal circle
LOWER. With arm extended downward, forefinger pointing down, move hand in small horizontal circle.

28. Standard Hand Signals For Controlling Overhead
And Gantry Cranes
BRIDGE TRAVEL. Arm extended forward, hand open and slightly raised, make pushing motion in direction of travel.
TROLLEY TRAVEL. Palm up, fingers closed, thumb pointing in direction of motion, jerk hand horizontally.

29. Standard Hand Signals For Controlling Overhead
And Gantry Cranes
STOP. Arm extended, palm down, hold position rigidly.
EMERGENCY STOP. Arm extended, palm down, move hand rapidly right and left.

30. Standard Hand Signals For Controlling Overhead
And Gantry Cranes
MULTIPLE TROLLEYS. Hold up one finger for block marked “1” and two fingers for block marked “2”. Regular signals follow.
MOVE SLOWLY. Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal. (Hoist Slowly shown as an example.)

31. Standard Hand Signals For Controlling Overhead
And Gantry Cranes
MAGNET IS DISCONNECTED. Crane operator spreads both hands apart – palms up.

32. @ Annually or at intervals of 500 hours of use, whichever comes first.
Inspection
The inspection procedure for cranes in regular service is divided into 2 general classifications:
@ Monthly to quarterly or at intervals of 100 hours of use, whichever comes first.
@ Annually or at intervals of 500 hours of use, whichever comes first.
The inspections cover topics outlined in the standard or manufacturers guidelines.

33. Maintenance
# A preventative maintenance program will be established and the program will be based on the manufacturer’s recommendations
# Application is reviewed by a qualified person.
Before adjustments or repairs are made on a crane, all of the following precautions must be taken:
1. The crane will be moved to a location where it will cause the least interference with other moving equipment on the track or rails and operations in the area.

34. 2. Controllers will be placed in the “off” position.
3. The main switch will be placed in the “off” position or “open” position and LOCKED OUT, except where power is necessary to adjust or service the crane
4. A warning sign or “out of order” sign will be placed at the operator control station.
5. A Caution Board will be provided while maintenance is performed on the crane.

35. In the event of power failure
@ The operator must place all controllers in the “off” position.
@ When an operator leaves a crane unattended he must land any attached load.
@ Place the controllers in the “off” position, and open the main switch.
@ Before closing a main switch the operator must make sure all controllers are in the “off” position.
@ The main switch does not need to be opened on a pendant-controlled crane if the crane is left unattended for short periods.

36. Follow the Safe Practices All Time
VIJAY VYAS