TRAINING MANUAL

FOR OVERHEAD CRANES AND JIB

CRANES

01

00 18/06/21

Rev. Date Prepared Reviewed

10T/3T Overhead Crane & Jib Cranes
Training Manual

Effective Date: 28 July 2022

Revision: R01

REVISION STATUS SHEET

Revision No. Effective Date Summary of Revision

R01 28/07/2022 Updated based on CMX comments.

 TRAINING MANUAL Revision: 1
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FOR OVERHEAD CRANES AND JIB CRANES Page 1 of 5

Contract: P-JLPH255-04
LRT Line 1 – South (Cavite) Extension Project
Project Description:
Document Title:
Document No: Revision No: 1
Issue Status: Project Phase: Training

TECHNICAL SUBMITTAL ACTION – CMX CONSORTIUM

CODE 1: “NO OBJECTION”

CODE 2: “NO OBJECTION SUBJECT TO RECTIFICATION OF COMMENTS NOTED”
CODE 3: “RETURNED DUE TO OBJECTION”
CODE 4: “INFORMATION NOTED”

ACCEPTANCE OF TECHNICAL SUBMITTALS DOES NOT RELIEVE THE CONTRACTOR OF ITS RESPONSIBILITY FOR
ACCURACY OF SUCH TECHNICAL SUBMITTALS, NOR FOR FURNISHING OF MATERIAL OR WORK REQUIRED BY THE
CONTRACTOR NOT INDICATED IN TECHNICAL SUBMITTALS NOR SHALL IT RELIEVE HIM FROM RESPONSIBILITY FOR
ERRORS OF ANY SORT IN TECHNICAL SUBMITTALS.

RECOMMENDING APPROVAL: ____________________ DATE: _____________________

Project Manager CMX – Line 1

APPROVED BY: _______ __ DATE: _____________________

OIC – Project Manager, L1 SEP

1 28 Jul 22 2nd Submission

- 18 Jun 21 1st Submission
Revision Date Details Remarks

ISSUED
REVIEWED BY: REVIEWED BY: REVIEWED BY CM APPROVED BY PM
DATE

28 Jul 22
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FOR OVERHEAD CRANES AND JIB CRANES Page 2 of 5

Contents
1. Overview .................................................................................................................................... 3
2. Training Objectives .................................................................................................................... 3
3. Training Participants .................................................................................................................. 4
4. Training Course .......................................................................................................................... 4
5. Training Agenda ........................................................................................................................ 4
6. Appendices ............................................................................................................................... 5
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1. Overview

Name of the Course Overhead cranes and Jib Canes overview/training

Course Code 002, 017, 027

Training Type Theoretical and Practical

Overview about operation and maintenance of Overhead

Course Description
Cranes and Jib Cranes

Providing trainees with proper knowledge on how to operate

Objectives
and maintain the Overhead Cranes and Jib Cranes

Main Topics Operation and Maintenance

Training location LRTA Expansion Depot (Training room and Workshop area)

Duration (hours) 1 day

Number of trainees 12 (maximum)

1. Technical background

Training Pre-requisites 2. English speaking

3. Read O&M manual

1. Training room

Means and Training 2. Operation and Maintenance Manual

Materials 3. Video projector

4. Overhead and Jib cranes at the site for practical training.

1. Theoretical assessment
Qualification
2. Practical assessment

2. Training Objectives

After this training, key men are able to:

• Understand the architecture of the equipment

• Know the different components, their functions and their interfaces

• Give an introduction to the use of the equipment

• Give an introduction to the maintenance of the equipment

• Operate and maintain the equipment

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3. Training Participants

• O&M Staff (i.e. Depot and RS Technicians)

• Employer’s / Concessionaire’s training instructors

4. Training Course

Duration: 1 day

Training type: Theoretical & Practical training

Number of participants: 12 (maximum)

Location: LRTA Expansion Depot (Training room and Workshop area)

5. Training Agenda

Duration Training Training

Start End Trainer Actions Training Aids
(min) Location Material

Day 1

O&M
Manual video
08.00 09.00 60 Introduction Training room
projector
ppt

O&M
Theoretical Manual video
09.00 11.00 120 Training room
training projector
ppt

11.00 12.00 60 Questions Training room

12.00 13.00 60 Lunch

Overhead
Cranes and Load and
On site Jib Cranes / lifting /
13.00 16.00 180 Practical training
(Workshop) personal rigging
protective gears
equipment

16.00 16.30 30 Assessment Training room

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Evaluation of the
16.30 17.00 30 training & Training room
questions

End of the
17.00
training

Note:

Whenever practical training takes place at the site, the trainees shall bring along their
own personal protective equipment (PPE) and they shall adhere to all Safety practices as
necessary and as required by applicable Safety Rules and Regulations.

6. Appendices

Appendix A: Power Point Presentation

Appendix B: Theoretical Assessment

Appendix C: Practical Assessment

Appendix D: Training Evaluation Form

Appendix A
 Training and Safety Practice
Manual for Jib Cranes, 10T/3T
Overhead Crane, and 1.5T
Overhead Crane

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Table of Contents:

1. Overview
2. About this Training manual
3. Scope of Training
4. Course outline
5. Introduction to Overhead cranes and Jib cranes
6. Cranes and hoist terminologies
7. Overhead crane operations
8. Overhead crane safe operating sequence
9. Overhead crane and Jib crane inspection and maintenance
10. Rigging signals
11. Question and answer

2
1. Overview
Overhead cranes and Jib cranes are installed in Baclaran Expansion
depot and commissioned by Hitachi Plant Construction Ltd. Phil. Branch.
▪ Two units of 10T/3T overhead cranes in Baclaran expansion depot Heavy
maintenance area

3
1. Overview

▪ One (1) unit of 1.5T OH crane single girder in Air brake compressor area.

4
1. Overview

▪ Three (3) units of Slewing Jib cranes in Baclaran expansion depot Heavy
maintenance area.
Aircon Space area, 1T Jib crane

Wheel & axle box area, 2T Jib crane Panta work space area, 1T Jib crane
5
1. Overview

6
2. About this Training Manual

This Training Manual aims to provide trainees with the basic knowledge of
the electric overhead travelling crane (EOTC) and Jib cranes in terms of
safety, operation, and maintenance.

For more in-depth knowledge and understanding about the EOTC and Jib
Cranes, it must be read together with the Operation and Maintenance
Manual.

7
3. Scope of Training

This training shall provide trainees with the basic knowledge in safety, operation
and maintenance, of the electric overhead travelling cranes (EOTC) and Jib
cranes installed and commissioned in the Baclaran Expansion Depot.

Persons (not limiting to) to attend the training:

▪ Supervisor : a person who has been authorized and tasked to oversee the
operation that involves using the electric overhead travelling crane

▪ Operator : a person who has been authorized and tasked to operate the
electric overhead travelling crane

▪ Maintenance Personnel : a person who has been authorized and tasked to

perform the maintenance duty of the electric overhead travelling crane

8
3. Scope of Training

Training Objectives:
Upon completion of the training, the trainees shall be able to:

▪ Understand the purpose of the EOTC

▪ Be familiar with the layout of EOTC in Baclaran Depot

▪ Understand and follow the General Safety Guidelines regarding the operation
of the EOTC

▪ Understand the key components of the EOTC

▪ Operate the EOTC in a safe manner

▪ Carry out inspection and maintenance duty on the EOTC

▪ Understand the faults and cause of breakdown

▪ Relate to the EOTC Operation & Maintenance Manual

9
4. Course Outline

❑ Introduction to Overhead Crane

▪ Common Types of Demag Cranes
❑ Crane and Hoist Terminologies
▪ Crane duty
▪ Definition of terms
▪ Parts of a Standard Crane

10
4. Course Outline

❑ Overhead Crane Operation

▪ Principles of Operation
▪ Operators Qualification & Requirement
▪ Do’s and Don'ts
❑ Crane safe operating sequence
❑ Crane Inspection and Maintenance
❑ Rigging Signals

11
5. Introduction to Overhead cranes

Overhead Travelling Cranes and hoists - are specialized

equipment designed to perform lifting and moving of loads.
Their function and methods of operation are not like any
other equipment. They require specific instructions and
training for safe operation and proper maintenance.

12
5. Introduction to Overhead cranes
Common types of Overhead cranes

Single Girder crane

Model : ELKE

▪ Overhead Travelling crane

with rolled steel I-beam
▪ Favorable solution for light
loads and small crane spans
▪ SWL : up to 5 tonnes
▪ Spans : up to 15 meters

13
5. Introduction to Overhead cranes
Common types of Overhead cranes

Double Girder crane

Model : ZKKE

▪ For high load capacities and

large spans
▪ SWL : up to 63 tonnes
▪ Spans : up to 35 meters

14
5. Introduction to Overhead cranes
Common types of Overhead cranes

Slewing Jib Crane

▪ Slewing Jib cranes for heavy

and light applications.
▪ Column-mounted slewing jib
cranes
▪ SWL: 80 kgs up to 2,000 kgs
▪ Spans: 2 m up

15
6. Cranes and Hoist Terminologies
Parts and components

▪ Single girder Overhead crane

▪ Double girder Overhead crane

▪ Slewing jib crane

16
6. Cranes and Hoist Terminologies
Parts and components
LONG TRAVEL END
Single Girder DRIVE CARRIAGE

FESTOON
SYSTEM
LONG TRAVEL CROSS-TRAVEL
DRIVE TROLLEY

GIRDER
MAIN
ELECTRICAL
PANEL
HOIST

BOTTOM PENDANT
END BLOCK
CARRIAGE

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6. Cranes and Hoist Terminologies
Parts and components
END
HOIST CARRIAGE
Double Girder FESTOON
SYSTEM

MAIN
ELECTRICAL
PANEL

LONG
TRAVEL
WIRE ROPE DRIVE

BOTTOM
RUBBER BLOCK
BUFFER

END GIRDER
CARRIAGE PENDANT

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6. Cranes and Hoist Terminologies
Parts and components

Jib Crane
JIB ARM

CHAIN HOIST
FESTOON

SLEWING
BOTTOM BLOCK DRIVE
(OPTIONAL)
PENDANT

STEEL PIPE

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6. Cranes and Hoist Terminologies
Parts and components

Chain Hoist parts SUSPENSION

BRACKET
ELECTRICAL
ENCLOSURE HOIST MOTOR

CHAIN COLLECTOR GEAR BOX

BOTTOM BLOCK

CONTROL PENDANT EMERGENCY BUTTON

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6. Cranes and Hoist Terminologies
Parts and components
Rope Hoist parts
ROPE DRUM ELECTRICAL
ENCLOSURE

GEARBOX CROSS
TRAVEL
MOTOR
HOIST MOTOR
RETURN SHEAVE

WIRE ROPE

BOTTOM BLOCK 4/2

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6. Cranes and Hoist Terminologies
Parts and components
PARTS of a ROPE HOIST

HOIST CONTROL
MOTOR BOX

HOIST
GEARBOX WIRE
ROPE

RETURN
SHEAVE BOTTOM
BLOCK

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7. Overhead Crane Operation
Principles of Operation

EOT CRANES - MOTION

▪ 3 basic motion; Bridge (N-S), Trolley (E-W) and Hoist (U-D)

▪ A typical overhead crane travels on a runway structure or pair of tracks

above the work floor.

▪ The crane includes a bridge that spans between the tracks; and with a
fixed or trolley-mounted hoisting system.

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7. Overhead Crane Operation
Principles of Operation

Emergency stop
UP button
Start Button
DOWN button Reset Button
RIGHT button Main Aux. Switch
Flood Light Switch
LEFT button
FORWARD button Fault Indicator Light

BACKWARD button

10T/3T OH Crane Pendant

Control the three (3) Basic motion of the crane using a pendant
pushbutton.

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 7. Overhead Crane Operation
Principles of Operation

Emergency stop
Emergency stop
UP button
UP button
DOWN button DOWN button
RIGHT button RIGHT button
LEFT button LEFT button
FORWARD button
FORWARD button
BACKWARD button
BACKWARD button
RESET button

1.5T OH Crane Pendant Jib Crane Pendant

Pendant pushbutton has two pressure on the switch, to shift from

slow speed to fast speed.

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7. Overhead Crane Operation
Principles of Operation

HOISTING/LOWERING

CROSS TRAVEL

LONG TRAVEL

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7. Overhead Crane Operation
Operator’s Qualification and requirements

▪ Vision test 20/30 in one eye & 20/50 in the other (corrected &
uncorrected), normal depth perception, field of vision 7 color vision.
▪ Sufficient strength, endurance, agility, coordination &
responsiveness to meet the demands of the equipment operation.
▪ Adequate Hearing
▪ No physical defects or emotional disorders.
▪ No evidence of seizures or loss of physical control

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7. Overhead Crane Operation
Operator’s Qualification and requirements

“Crane shall be operated only by the following qualified personnel:

a) designated person;
b) Trainees under the direct supervision of a designated person;
c) Maintenance and test personnel, when it is necessary in the
performance of their duties;
d) Inspectors (crane)”

section 2-3.1.5 ASME B30.2b

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

Reporting Unsafe Equipment

Do NOT proceed to operate an unsafe piece of equipment

You should:
▪ LOCK OUT any unsafe equipment
▪ Notify your supervisor of the unsafe equipment and contact the
equipment owner to have it fixed immediately.

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

▪ 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.

▪ Under no circumstances may

anyone ride the hook or load.

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

▪ 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.

▪ Directional movement should be made smoothly and

deliberately. Avoid rapid movements in any direction.

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

▪ 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.

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

▪ 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.

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

▪ 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.

▪ 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. .

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

▪ 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.
▪ 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 and “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 if your opinion, UNSAFE TO
OPERATE…

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts
Proper slinging of load
CHECK the compliance and
integrity of provided slings
More in detail check that there is
- no tear
- flattening
- broken strands
- elements which are not
lubricated

Use longer slings to prevent sling

snap (lifting angle
small due to short sling)

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

CORRECTLY check the load

slings on the hoisting hook, after
balancing the load itself before
hoisting it

slowly but reliably stretch

the slings until there is enough
tension to stabilize the load.

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

Check that the load is reliably

placed in a sling and that it is
correctly balanced before
hoisting

UNSAFE – the load might slip

SAFE – the sling is secured

against the shaft.

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

Follow these
instructions when
using shackles.

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

Always remember the

pinch point hazard

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

Warn the personnel working

within the crane operating
area when any load handling
operation starts

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

Work outside the hoisted

load moving range

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

Avoid rapid quick Use slow speeds in the

reversals and case of load approaching
excessive inching and positioning

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

NEVER walk, stop, work NEVER use the crane for

or do operating under an operations ,such as
overhanging load ceiling painting, lights
replacement

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

NEVER hoist loads NEVER swing the load

which are not balanced or the hook during
travelling

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

NEVER - use the crane to

try to hoist elements NEVER - hoist sliding
which are fixed on the loads
ground which could get stuck

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

NEVER diagonally pull

the wire rope. Avoid side
pulling

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

NEVER use the hook

end as a loading support

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

NEVER- slack wire

rope by resting bottom
block on the floor or
on the lifting object or
any other object

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts
AVOID any impact between
the block and the crane structure ,factory
walls or other machinery or installation

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

NEVER - operate two cranes at the same

time to hoist the same load ,without enforcing
the specific safety measures

CRANE 1 CRANE 2
STOP! STOP
unbalance

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

NEVER- constantly switch the automatic

over-travel switches : they are
only emergency switches

Over-travel
Limit switch

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts
NEVER constantly switch the upper limit/lower limit
switches for bottom block: they are only emergency
switches. Any abnormal behavior
hit the red button on the pendant immediately.

upper
Limit switch

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts
NEVER exceed the safe working capacity of your
crane, hoist, chain, web slings, and other load
attachments.

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts
NEVER pull the hoist by the pendant cable

NEVER leave the controls unattended. If is

necessary to leave the controls, lower the load to
the floor.

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7. Overhead Crane Operation
Safe Practices - Do’s and Don’ts

Safety

Safety is everyone’s responsibility.

This means you must:

▪ Take the effort to do your job safely

▪ Take control by minimizing the risk of injury

▪ Use your knowledge and skill to perform the job

safely and efficiently

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8. Overhead Crane Safe Operating Sequence

Shackle Loading

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8. Overhead Crane Safe Operating Sequence

Rigging Protection from Cutting or Slipping

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8. Overhead Crane Safe Operating Sequence

Safe lifting

Know the capacity of the Overhead crane by:

▪ capacity plate of the bottom block
▪ capacity plate of the bridge

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8. Overhead Crane Safe Operating Sequence

Safe Lifting

▪ Clear the Area

▪ Test Lift
▪ Use Hand Signals (if necessary)
▪ Controlled Movement
▪ Avoid Obstruction

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9. Overhead Crane Inspection and Maintenance

Kinds of Inspections:

▪ Initial Inspection – Prior to initial use, all new and

altered cranes shall be inspected to ensure compliance
with regulations.

▪ A preventive maintenance program based on the

crane manufacturer’s recommendations must be
available.

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9. Overhead Crane Inspection and Maintenance

Kinds of Inspections:
The following inspections are required for each piece of lifting
equipment:
Pre-Operational:
▪ Completed by each individual operator prior to the use of any
lifting device.
▪ No documentation requirements
Monthly:
▪ Completed by a designated person or third party
▪ documentation required
Annual:
▪ Completed by a designated person or third party
▪ documentation required
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9. Overhead Crane Inspection and Maintenance

Kinds of Inspections:

▪ Internal Inspection
▪ Before using on site
▪ Monthly

▪ Third Party Inspection

▪ Accredited agency by DOLE-BWC . . . MHE Demag
▪ Yearly or after modification, alteration, repairs, transfer or
re-installation
▪ Load Testing = 125% above the maximum load

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9. Overhead Crane Inspection and Maintenance

What part should be inspected ?

I. Overhead crane bridge VIII. Wheel inspection (Overhead

crane)
II. Overhead crane control system
IX. Travel drive inspection
III. Overhead crane power supply
(Overhead crane)
system
X. Hoist gearbox inspection
IV. Overhead crane runway
(Overhead crane and Jib crane)
V. Chain inspection (Overhead
XI. Jib Crane maintenance
crane and Jib crane)
inspection schedule
VI. Hook inspection (Overhead
XII. Pre-operational inspection
crane and Jib crane)
(Overhead crane and Jib crane)
VII. Wire rope inspection (Overhead
crane and Jib crane)

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9. Overhead Crane Inspection and Maintenance
I. Overhead crane bridge

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9. Overhead Crane Inspection and Maintenance
I. Overhead crane bridge (Cont.’)

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9. Overhead Crane Inspection and Maintenance
II. Overhead crane control System

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9. Overhead Crane Inspection and Maintenance
II. Overhead crane control System (Cont.’)

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9. Overhead Crane Inspection and Maintenance
II. Overhead crane control System (Cont.’)

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9. Overhead Crane Inspection and Maintenance
III. Overhead crane power supply system

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9. Overhead Crane Inspection and Maintenance
IV. Overhead crane runway

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9. Overhead Crane Inspection and Maintenance

V. Chain Inspection (Overhead crane and Jib crane)

▪ Chains must be inspected daily before use as often as necessary

during use to assure safety
▪ Inspect Chains for:
▪ Damage Link
▪ Stretch & bend
▪ Corrosion

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9. Overhead Crane Inspection and Maintenance
Pre-operational Inspection
VI. Hook Inspection (Overhead crane and Jib crane)
Inspect Hooks for:
▪ Throat spread (not exceeding 10%)
▪ Grading (nicks, gouges, bowl wear)
▪ 10 degrees from vertical (twist)
▪ Functioning safety latches
▪ Chemical damage
“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.”
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▪ Inappropriate Use

▪ * Do not allow loads to drop when

the chain is in slack condition.
▪ * Do not subject the control pendant
to inappropriate mechanical loads.
▪ * Do not allow the control cable to be
wound around the chain when lifting
motion are performed.

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9. Overhead Crane Inspection and Maintenance
Pre-operational Inspection

VII. Wire Rope inspection (Overhead crane and Jib crane)

▪ Wire Rope – consists of many individual wires laid into a number of

strands which in turn, laid around a center core

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9. Overhead Crane Inspection and Maintenance
Pre-operational Inspection

VIII. Wire Rope inspection (cont’)

Inspect Wire Rope for:

▪ Reduced diameter of the rope (>=15%)
▪ Any number of broken strands of wires
▪ Abrasion (>10%)
▪ Core Failure
▪ General Corrosion
▪ Kinked, crushed, cut, or Bird Caged”
wiring, or wiring with heat damage

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9. Overhead Crane Inspection and Maintenance
Pre-operational Inspection
VIII. Wire Rope inspection (cont’)
Criteria For Wire Rope Replacement

Wire rope measurement

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9. Overhead Crane Inspection and Maintenance

IX. Wheel Inspection (Overhead crane)

The wear indicator in the flange facilitates the

preventive inspections of the installation.

The travel wheel must already be replaced

even if only one segment of the wear indicator
is open.

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9. Overhead Crane Inspection and Maintenance

IX. Wheel Inspection (cont.’)

Travel wheels must be replaced when the following

values are reached:

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9. Overhead Crane Inspection and Maintenance

X. Travel Drive Inspection (Overhead crane)

Under normal operating condition, the oil must be changed after 10,000
hours of service. The oil should, however, be changed at least every 4 years.
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9. Overhead Crane Inspection and Maintenance

XI. Hoist Gearbox Inspection (Overhead crane and Jib crane)

Under normal operating condition, the oil does not have to be changed until the
general overhaul is carried out.

Upon expiration of 90% of the theoretical duration of service – if the hoist unit is
correctly classified after 8 – 10 years – the owner must arrange for a general
overhaul to be carried out.

Planetary Type
Helical Type

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9. Overhead Crane Inspection and Maintenance

XI. Jib Crane Maintenance Inspection schedule

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9. Overhead Crane Inspection and Maintenance

XI. Jib Crane Maintenance Inspection schedule (Cont.’)

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9. Overhead Crane Inspection and Maintenance

XII. Pre-operational Inspection (Overhead crane and Jib crane)

Operator to ensure:
▪ Rated load capacity and recommended operating speeds are
posted on the equipment
▪ Controls and operating mechanisms for proper operation
(hoist, motor and brakes)
▪ Hoist upper limit switch is functional
N

W E

S
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10. Rigging Signals
Hoist UP

With forearm vertical, fore finger

pointing up, move hand in small
horizontal circle

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10. Rigging Signals
Hoist DOWN

With arm extended downward,

forefinger pointing down, move
hand in small horizontal circles.

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10. Rigging Signals
Move slowly

Use one hand to give any motion

signal and place other hand
motionless in front of hand giving the
signal (hoist slowly as shown in
example)

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10. Rigging Signals
Long travel

Arm extended forward, hand

opened and slightly raised, make
pushing motion in direction of
travel.

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10. Rigging Signals
Traverse / cross travel

Palm up, fingers closed, thumb

pointing in direction of motion,
jerk hand horizontally.

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10. Rigging Signals
All stop

Both arms outstretch at the side,

palm down, hold position rigidly.

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10. Rigging Signals
Emergency stop

Arms extended, palm down, move

hand rapidly right and left.

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11. Question and Answer

Any Questions?

? ?

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Appendix B
 Theoretical Assessment

Course Title Course Code

Date Company

Name Department

Put your answer in the space provided below the question or tick the box you think is
correct in answer to the question.

Equipment Overview

1. What is the main function of Pendant?

____________________________________________________________________

2. What is the function of the HOIST?

____________________________________________________________________

3. What is the function of the emergency stop?

____________________________________________________________________

4. What is the function of the Sling?

____________________________________________________________________

5. At what angle position required for sling attachment?

____________________________________________________________________

Page 1 of 3
Safety

6. What is the meaning of the following symbols?

7. What is the function of Limit Switch

Operation

8. First thing to Familiarize before the start of using Crane.

___________________________________________________________________

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 9. The Function of two pressure on the switch of the pendant

____________________________________________________________________

10. Speed of hoisting during the positioning of the load

____________________________________________________________________

11. How many speed of the traversing motor?

-----------------------------------------------------------------------------------------------------------------

12. First thing to do when there is trouble on crane

____________________________________________________________________

Maintenance

13. Percent of Load required by Third Party Inspection

14. Re-tightening of bolts connection of main girder/end carriage

Yearly
Every 2 years
Every 3 years

15. Reduced diameter of the rope for replacement

____________________________________________________________________

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Appendix C
 Practical Assessment

Course Title Course Code

Date Company

Name Department

Assessment by

Trainee Practical Assessment – Overhead and Jib Cranes

ALL TOPICS MUST BE PASSED

Name:

Trainee ID:

Organization

Result (Pass/Fail):

Assessor Name:

Signature:

Date:

Page 1 of 3
 Operation Assessment

Assessment Date:

Attitude Ability
Topic Instructor’s Comments
(Pass/ Fail) (Pass/ Fail)

Safety precautions during operation.

Check the trainee can
start up and function test
the Cranes

Assembling the equipment

Check the trainee can
set-up the load for lifting

Lifting of load
Check the trainee can
do the lifting and
positioning of the load

Maintenance Assessment

Assessment Date:

Check trainee can

demonstrate safe
practices when working
on the equipment.
Check trainees can
demonstrate knowledge
of maintenance.
Note: When trainees are conducting maintenance activities safe working practices must be assessed
at all times.
Check trainee on
checking the wear and
tear of the crane
components
Note: When trainees are conducting the physical checking of the crane components must observe
safe working practices

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 Additional Instructor’s Comments (to be used if necessary)

Topic Instructor’s Comments

Page 3 of 3
Appendix D
TRAINING EVALUATION FORM
Class title
Instructor
Date
Time

INSTRUCTOR RATING
In your opinion, please tell us if the trainer:

Strongly Disagree Neither Agree Strongly

Disagree agree
1. Demonstrated knowledge of subject matter. 1 2 3 4 5
2. Provided appropriate feedback and answers. 1 2 3 4 5
3. Acted professionally and was prepared and organized. 1 2 3 4 5
4. Projected an enthusiastic and positive image. 1 2 3 4 5

ADMINISTRATIVE CONCERNS
Strongly Disagree Neither Agree Strongly
Disagree agree
1. The facilities and equipment were favorable to learning. 1 2 3 4 5
2. This course was made available to me when I needed it. 1 2 3 4 5
3. I clearly understood the course objectives. 1 2 3 4 5
4. The course met all of its stated objectives. 1 2 3 4 5

TECHNICAL TRAINING
Strongly Disagree Neither Agree Strongly
Disagree agree
1. The technical training was well prepared. 1 2 3 4 5
2. The explanation of the safety usage of crane 1 2 3 4 5
3. I do understand after this training the functionality and
1 2 3 4 5
technical contents of the crane operation
4. The course content was organized and easy to follow. 1 2 3 4 5

PERCEIVED IMPACT
Strongly Disagree Neither Agree Strongly
Disagree agree
1. My knowledge and skills increased as a result of this
1 2 3 4 5
course.
2. Overall, I was satisfied with this course. 1 2 3 4 5