MAINTENANCE MANAGEMENT

LECTURE – 30

MAINTENANCE MANAGEMENT

AUTOMOBILE ENGINEERING SUBJECT COORDINATOR

8th Semester VAIBHAV GUPTA

Topic Covered

 Maintenance of Crane
 Maintenance of Crane Hoist

Source: Maintenance Engineering HandBook by R. Keith Mobley Page 1

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CRANE

CRANE INSTALLATION

Good maintenance begins with a good installation. Prior to, during, and following erection of the
crane, the following precautions should be observed:

1. Crane runway rails should be straight and accurately aligned to the correct span the entire length
of the runway.

2. Be sure the crane is assembled in accordance with the match marks and instructions provided by
the manufacturer.

3. It is of utmost importance that girders be square with the end trucks, that the trucks be parallel to
each other, and that the bolts furnished with the crane be used for making the connection between
the girders and end trucks. These bolts are usually of the ground-body type fitted into reamed
holes.

4. Check all connecting bolts for tightness, and be sure lock washers or other locking means have
been used as furnished.

5. Check for and remove any loose articles, such as bolts, hammers, or wrenches, which may have
been left on top of the trolley or girders or on the platform.

6. Grease bearings on the crane as required. Check and add oil to gear housings as required.

7. Grease the hoisting cables.

8. Be sure the hoisting cable is reeved properly.

9. Check for any oil or grease spillage that may have occurred during erection, and wipe all oil spot
dry.

Source: Maintenance Engineering HandBook by R. Keith Mobley Page 2

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CRANE INSPECTION

Daily to monthly inspections are recommended to include

1. Operation of all limit switches, without load on hook (the crane motion should be inched or run
into the limit position at slow speed for these checks)

2. All functional operating mechanisms for misadjustment, damage, or wear

3. Air and hydraulic systems components for deterioration or leakage

4. Hooks for deformations, cracks, and wear

5. Hoisting ropes for broken wires, abrasions, kinks, or evidence of not spooling properly on drum

Monthly to yearly inspections should include checks on

1. Loose connections, bolts, nuts, rivets, keys, etc.

2. Cracked, worn, deformed, or corroded members, including rails or beam flanges on which the
crane operates

3. Cracked, worn, or distorted mechanical parts such as shafts, bearings, pins, wheels, rollers, gears,
pinions, and locking or clamping devices

4. Excessive wear on brake parts, pawls, pins, levers, ratchets, linings, etc.

5. Rope drums and sheaves for excessive wear or cracks

6. Electric or other types of motor for performance and wear of commutator, slip rings, brushes, etc.

7. Chain and sprockets for excessive wear or stretch

8. Crane hooks for cracks, by magnetic particle, dye penetrant, or other reliable crack-detection
method; and hook-attaching means including hook nut, locking pin, etc., for security of hook
attachment to lower block

9. Load-limiting or other safety devices installed on the crane

10. Electrical devices, controls, and wiring for signs of deterioration or wear; electrical contactor
points for excessive pitting.

Source: Maintenance Engineering HandBook by R. Keith Mobley Page 3

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CRANE MAINTENANCE

 A preventive-maintenance program should be established based on the manufacturer’s or a

qualified person’s recommendations.

 Service schedules and dated detailed records should be maintained.

 Since the original equipment manufacturer is usually in the better position to provide replacement
parts and ensure their safety, interchangeability, and suitability for the application, it is
recommended that such parts be obtained from the original equipment manufacturer.

Typical recommended spare-parts lists are apt to include

 Brake solenoids, coils, disks, linings

 Hoist-limit switches

 Contactors

 Contact kits

 Timing relays

 Push-button stations or parts

 Crane wheels and guide rollers

 Motor couplings and brushes

 Current collectors or collector shoes

 Bearings

 Load hooks, nuts, and thrust bearings

 Hoisting ropes

 Load brake parts

Source: Maintenance Engineering HandBook by R. Keith Mobley Page 4

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When ordering parts for a crane, observation of the following points can save time and expense:

1. Identify the crane by manufacturer’s serial number.

2. Refer to the parts manual furnished by the manufacturer, and identify parts by the numbers given.

3. For cranes with auxiliary hoists, specify whether parts are for main or auxiliary hoist; if for a
bucket crane, if parts are for the holding-line or closing-line mechanism.

4. If the crane carries more than one trolley or hoist, specify which trolley or hoist the parts relate to.

5. When ordering brake parts, specify which brake, whether hoist (main or auxiliary), trolley, or
bridge.

6. If parts are for electrical equipment or other equipment not shown on the parts lists, describe the
part and identify the serial number of the unit for which it is required.

Before adjustments or repairs are started, several precautions should be taken:

1. The crane to be repaired should be located where it will cause least interference with other
operations in the area.

2. All controllers should be placed in the off position.

3. Main and emergency switches should be locked in the open position.

4. Warning signs should be placed on the crane and on the floor beneath the crane or on the crane
hook if near the floor.

5. If other cranes are operating on the same runway, rail stops or other means should be provided to
prevent collision with the idle crane, or a signal man may be employed to warn off approaching
cranes.

 Any load-bearing parts which are cracked, bent, or excessively worn must be repaired or replaced.
Pitted or burned electrical contacts should be corrected only by replacement and only in sets.

 All control stations should be kept clean with function labels intact. Missing or illegible warning
labels must be replaced promptly.

 Lubrication should be applied regularly to all moving parts for which lubrication is specified
and/or indicated by lubrication fittings. Follow the manufacturer’s recommendations as to

Source: Maintenance Engineering HandBook by R. Keith Mobley Page 5

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frequency and types of lubricants to be used. Avoid over greasing of bearings and overfilling of
gear cases.

 Unless the crane is equipped with automatic lubricators, the same preliminary precautions should
be taken for lubricating the crane as for making repairs.

 Hoisting ropes require special attention. On cranes in continuous service, ropes should be
inspected visually daily, and a thorough inspection should be made at least once a month, with
written record made as to rope condition and possible need for replacement. All inspections
should be made by an appointed or authorized person. Any form of rope deterioration which
could result in appreciable loss of original rope strength should be carefully noted. Conditions
such as the following require a determination as to whether continued use constitutes a safety
hazard.

1. Kinked, crushed, cut, or unstranded sections

2. Broken, worn, or corroded outside wires

3. Reduction of rope diameter due to loss of core support, corrosion, or wear

4. Damaged end connections or damaged rope wires at the connections

Source: Maintenance Engineering HandBook by R. Keith Mobley Page 6

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CHAIN HOIST

 Performing regular maintenance is an essential safety practice in any workplace. This is especially
true in a place that deals with industrial equipment, like cranes.

 Cranes are both extremely useful, and extremely dangerous. According to OSHA, crane-related
injuries kill approximately 71 workers each year.

 Maintaining your crane’s chain hoist is essential to keeping your employees safe. Additionally,
regular maintenance will also keep your crane operating efficiently.

1. Understand Common Chain Hoist Problems

 The first step to maintaining your chain hoist on your crane is understanding how it works. This
way, you’ll be better able to identify when wear and tear are impacting its effectiveness.
 There are three kinds of hoists that your crane might use: differential, lever ratchet, and hand
chain. All three of these hoists use some combination of a chain and hook to both lift and move
heavy objects.
 Since these hoists work by rotating a chain, the most common problem associated with them are
related to wear and tear on the chain. That said, regular maintenance can greatly extend the
lifespan of a chain.

2. Keep the Chain Clean and Lubricated

 The most common causes of wear on a chain are rust and debris. Chains can become stiff and
difficult to move due to the buildup of rust and grit.
 Most hoists will require dismantling in order to be properly cleaned and oiled. You should do this
at least once or twice a year, depending on what you primarily use the hoist for.

3. Watch out for Signs of Damage

 Over time, the chain in a hoist will become worn. Make sure to look for signs of deterioration, and
replace the chain before it is overused.
 Common signs of a chain that needs to be replaced include kinking and stretching. Additionally, if
chains “pop” when they are in use, that is likely because they are becoming too stiff.
 Remember, it’s always better to replace a chain than it is to have an accident.

Source: Maintenance Engineering HandBook by R. Keith Mobley Page 7

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4. Perform Regular Inspections

 Testing and inspecting your industrial equipment is not just a good idea. OSHA requires that
certain tests and inspections take place on a regular basis.
 The hoist operator should perform a brief, visual inspection every day to make sure the equipment
is operating properly.
 Monthly, a more in-depth inspection should be done to document an existing wear, tear, and
damage to the equipment.

5. Conduct Necessary Testing

 In addition to inspecting your crane’s chain hoist, you should also test it regularly to ensure it is
functioning properly.
 You should perform a service load test at least quarterly. These tests are designed to observe how
well the equipment functions while lifting objects of various weights.
 Finally, at least every six months, make sure to test the chain hoist’s ability to lift heavy loads.

Performing these tests will help demonstrate how the hoist operates under various conditions and will
reveal any problems with performance.

Fortunately, when it comes to belt drives, downtime can often be prevented, and there are
straightforward steps you can take to improve workplace safety. In addition to proper selection and
storage of belts, a preventive maintenance (PM) plan includes proper inspection, maintenance and
replacement. Making a PM plan part of routine maintenance frees up plant managers and maintenance
engineers to focus on other important tasks—like boosting productivity and improving the bottom line.

Source: Maintenance Engineering HandBook by R. Keith Mobley Page 8