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ENGINE ROOM OVERHEAD CRANE OPERATING

PROCEDURE

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3CL MARTE, JAZFER

3CL PATIAK, LEONARD FUMIYA
3CL SALIGBON, JEFF LLOYD
3CL RIZALDO, MERVIN JON

ELECTRO 3

3/E ANACLETO REYES

TOMOKOMAI
NOVEMBER 2019

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I. Introduction

A. Description of the motor/equipment

Merchant vessels are fitted with engine room cranes mainly as per the main engine
specification. This is done so that the crane can lift all the individual parts of the engine
during routine maintenance. Engine room overhead crane is a machine that allows you
to lift and move heavy materials from one location to another in a precise manner.
Normally, the capacity range for engine room cranes is from 0.5 to 15 tonnes.
The engine room crane consists of a motor coupled with wire drum so that the
motor can lift or lower the crane hoist by winding of unwinding the wire over the drum.
The whole system is fitted in a trolley.
Two pathways are built with a rack and pinion arrangement, both in transverse and
longitudinal direction so that the whole unit can move forward, aft and port starboard.
A remote is provided so that the crane can be operated from any position, thus
allowing the user to keep a safe distance from the lifted load. It is the duty of the
responsible engineer onboard to operate the crane and to have regular checks on the
safety and working of the crane. Second engineer is responsible for operation,
maintenance, and safety checks of the engine room crane.

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There are various types of engine room overhead cranes
1. Single Girder Crane

Suitable for engine rooms with good headroom height, and provide a good working
area on the x and axis movement.

2. Double Girder Crane

Suitable for engine rooms with very limited height, and can provide a good
working area on the x and z axis movement, Great crane to adapt customized
solutions.

3. Single Jib Crane

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 Suitable for engine room with very limited height and only one hoist is required
for the service jobs

4. Monorail Crane

-Suitable for simple jobs where the crane only works on one crane beam instead f
two. A great way to adapt to customized solutions

B. Purpose

o
Whether it’s overhauling of main engine/ machinery or shifting of heavy parts, the
engine room crane is regularly used for “heavy-duty” lifting jobsyff5, which are
usually beyond the physical capabilities of the engine room crew.

A ship is a huge floating structure which is propelled with the help of a main engine,
along with several other machinery and systems inside the engine room which require
proper operation and continuous maintenance. Maintenance and repair of engine room
machinery requires moving of heavy parts from one place to another. As individual
parts of main engine and machinery of ship weighs in tones. Engine room crane
operation and safety plays a major contribution for the continuous operation of the ship.
Engine room overhead cranes are more efficient than using a group of workers or low
motors to lift and move materials and can work 2-3 times faster. Cranes are more
efficient and can help in speeding up processes and procedures by lifting, maneuvering
and unloading heavy material with ease and precision.
R Another advantage for engine room overhead cranes is for its safety. Cranes are a

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 safer way to move and transfer heavy equipment that may danger the life and health
of an individual. Cranes help do hard and tedious jobs with ease ergonomically. Cranes
can also be used to lift and move in extreme and dangerous environments, handling
different dangerous and corrosive materials like hot metals. chemicals and heavy loads;
reducing muscle strains and motor injuries in the workplace overall.
Engine room cranes improve the work flow, lower time and work cost, reduce of
product and material damage and reduce workplace accidents overall, making it an
essential equipment not just for the ship business but also its crew.

II. Safety Procedure

Important Reminder: The Engine Room Overhead Crane must not be put to use unless final
load-and-function test carried out by the classification society.

1. User and instruction manual must be read thoroughly and understood before
operating the engine room overhead crane. Instruction contain danger, warning and
safety advice and instructions, failure to comply with instructions can expose
person to direct risk and can also risk damage to the product.
2. It is the duty of the user to ensure that operation is safe and hazard-free. User should
check the following: operating instructions. Product testing after commissioning or
major modifications, routine tests and inspections, keep record on service life and
running hours, and ensure that only trained and properly appointed personnel can
handle the engine room overhead crane.
3. Engine room crane are designed solely for handling loads under a specified capacity.
The SWL or Safety Working Load should be inspected before using crane to lift
load. SWL can found in the inspection schedule and the equipment nameplate, load
should adhere to SWL as for safety regulation.
4. Users must ensure that engine room overhead crane is tested and inspected by an
expert before first-time commissioning or re-commissioning after major
modifications.
5. User determine the elapsed proportion of the service life and working hours of the
engine crane, ensuring to keep a constant record of these inspections and continuous
logging and monitoring,
6. Monitor all connection based on maintenance and lubrication period, all nuts and
screws of the crane should be tightened as required since lose nut and screw during
operation may damage and cause accident and failure.
7. Users are not permitted to assemble and disassemble engine room crane without the
proper credentials, unless supervised or appointed to do so. Only persons who are
capable can conduct these types of maintenance with the manufacturer operating
manual and instructions as the primary basis.
8. When assembling the engine room crane it must be positioned such that engine
crane does not risk falling on by the crane or the load itself.
9. Users must ensure that safe working load of the engine room overhead crane is
strictly followed.
10. Emergency stop button must be tested prior the use of the crane.

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 11. If any fault or defect is detected with the engine room crane, all must be rectified
immediately. User must be responsible and capable enough to tell and assess the
condition of the engine room crane, taking it out from service if needed.
12. Engine room overhead crane must not be used to handle loads that are molten, loads
that have a tendency to be jammed or get caught, snagged or obstructed. Also loads
that are alive or with persons.
13. During inspection, repair or maintenance, the engine room crane must be switched
off and locked out, all load must be removed from the crane for it may be at risk as
a falling hazard.
14. Following the repairs or maintenance, the engine room crane can be put into service
after approved to be completely functional and working, and prior to testing a newly
repaired engine room overhead crane, all personnel must be cleared out of any
danger area to prevent from accident due to sudden failure.

Other Safety Features of Engine Room Crane

The most important safety feature of the crane is the electromagnetic fail safe brakes
which do not allow the crane to fall with the load even when there is failure of power.
For this:

1. Normally centrifugal brakes are used which are fitted inside the rotating drum.

a) The brake pads are always in applied state and pushed by magnetic springs
when not in operation or when there is a power failure.
b) As the crane is operated or the power is supplied, the spring gets pulled inward
or compressed due to the electromagnetic effect of the current. This allows
the crane to be operated normally.

 Emergency stop is provided in the remote so that the operator can stop the crane
at any time.

 The motor is fitted with distance limit switch in both transverse and longitudinal
direction so that the travel of the trolley and hence crane should not overshoot the
rack’s end.

 Mechanical stoppers are provided for both directions in case the electrical distance
limit trips fail.

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  The up and down travel of
the hook is also attaches with
automatic stopper to avoid
overloading of the motor.

 The motor is fitted with

thermal protection trip.
When the motor windings
get overheated, trip will
activate saving the winding
from burning.
 Load limit switch is also
fitted which will trip the
motor if the load to be lifted
is above the crane capacity.

 The controls switches of the

crane arepush button type,
while pressing only the
power is supplied, this is also
one of the safety for crane
operation.

 Additional tools like i-bolts,

shackle, wire sling, belts etc.
used for lifting must be
checked for fatigue,
deformation and SWL (if it
suits the load to be picked)
before use.

 It should be noted that no one

walks or stand below the
crane when it is in the loaded
condition.

III. Operation

The main structure of the engine room overhead crane consists of two major parts: the
hoisting mechanism and electrical unit.

1. Hoisting Mechanism
The operation of the hoisting mechanism of the engine room crane is to drive the winding

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drum clockwise or counterclockwise by the heisting motor through a coupler

PRIOR STARTING

Precautions
Operator training should include:

 Workplace induction
 Safe operating procedures
 Manufacturer’s instructions (read and understand)
 Nature of hazards
 Fitting of personal protective equipment
 Manual handling
 Housekeeping
 First Aid

Pre-operational Inspection
Engine crane inspection
 Pre-operation inspection should be done each day
 Pre-operation inspection should be done each day
 Operational and maintenance instructions to be displayed on crane
 Safe Work Load (SWL) to be prominently displayed on crane
 Checks pins and bolts are in place
 Check controls for proper response
 No signs of hydraulic fluid leaks
 No signs of cracks or damage to crane parts
 All safety devices checked to be operational.
Ensure area:
 There are no obstructions above or around the vehicle that could interfere with or
obstruct the lifting
 ProcedureExclusion zone in position
 Clear of overhead wires and obstructions
 Access and egress is clear
 Lighting is appropriate.

Vehicle:
 Set parking or emergency brake and put gear shift in park
 Manual transmissions should be in lowest gear
 Vehicle ignition off with steering wheel lock on
 Chock all wheels
 Ensure engine anchor points are in good condition.

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STARTING OPERATION

2. Check for Lockout or Tagout. If a tag or lock is present, do not operate the
equipment. Electrical Disconnect and switch to the off position if possible
3. Check the floor for any leaks, particularly in the area under which the crane has
been parked
4. Visually inspect bridge bumpers and end stops
5. Check crane and block capacity
6. Check Pendant Control and ensure that all buttons move freely. Be sure to return
to OFF position
7. Make sure that the pendant is properly labeled and all functions are easily
identified
8. Before conducting operational checks, make sure that the fall zone is clear
9. Operation of all pendant control buttons function as labeled
10. Pendant control restraint is in safe condition. Check for bare wires and loose
connections
11. Check block and hook for free movement while in lowered position
12. Test Crane Traveling Brakes. Crane should stop smoothly and should not bind
or grab.
13. Listen for unusual sounds or vibrations while crane is traveling or braking.
14. Visually inspect bridge for anything out of the ordinary.
15. Make sure that all safety guards are in place

16. Lifting arm lowered to clear the engine bay, wheel crane into position at the
front of the vehicle
17. Close bleed valve on ram and pump handle to set ram to required height for
positioning hook over the engine
18. Connect hook to engine sling
19. Ensure load is balanced
20. Undo engine from vehicle
21. Pump ram so engine clears vehicle body
22. Lower engine crane slowly
23. Wheel crane away and mount on an engine stand as soon as practicable.

STOPPING/ STORAGE

1. Make sure that the load was transported on the spot

2. The lifter should be positioned at height which does not interrupt the work of
other employees or vehicles in the employing institution
3. The device must be placed in the parking place
4. After the device was situated in the parking place the operator must block it
by pushing an appropriate button
5. Control systems must be blocked and the device must be switched off
6. If the device is equipped with anti-wind brakes, they must be secured
7. The operator should carry out the visual inspection of the crane

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 8. The device must be protected against the use of unauthorized persons
9. In case of spotting failures or other problems connected with the working of
the crane the persons responsible must be informed
10. The entry in the device service log book must be made after finishing the work
11. Leaving the workplace is possible only when another operator comes or when
the supervisor agreed on it
12. Before storage, twist release valve 1-1/2 turns counter clockwise to release pressure
in hydraulic cylinder
13. In a clean, dry area to protect engine crane from moisture.

IV. Troubleshooting Procedure

1. A visual inspection and trial braking without load are required first before the
operation of the engine room crane. The following maintenance jobs and tests are required
to be done in intervals to maintain operational reliability and prolong service life. Follow
the general scheduled maintenance of the engine room overhead crane as a guide for
maintenance and observe it.

2. . “Not To Forget” Daily Checks : Prior carrying out any operation using engine room
crane, a brief check on the following should be done:
 Check the lubrication
 Check the noise level by operating the crane without load
 Check the heat generation
 Check all the limits and trips are working properly

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  Check the contact areas of electrical equipment
 Check the brake operation
 Check condition of clamp in the hook
2. Follow Proper Planned Maintenance: The planned maintenance of crane should
be followed properly and the following inspections should be done as per the
working hours prescribed by the makers:

 Overhauling of motor
 Greasing of wires
 Renewal of wire ropes
 Annual survey
 Load test

3. Ensure Adequate Lubrication: In an engine room crane system, two lubricants are
used:

 Grease: Wire ropes, rollers, plain bearings are applied with grease for smooth
working. Reduction gear for hoisting and sewing are not applied with grease.
Check the greasing of these parts and replenish the grease every 2000 working hrs.
or as prescribed by the makers. Ensure not to excessively apply the grease on
moving parts as it may cause overheating at the time of rotation, which can have
adverse affects.
 Oil: Lube oil is used for lubrication of ball bearing and roller bearing of hoisting
and slewing gears. Check the oil level regularly and replenish once the level is
below the mark. The condition of oil needs to observed for stain, foam and dust.
Renew the oil if the condition is not up to the requirement
4. Check Minimum Requirements Of Wire Ropes: The wire rope of a crane is the
main operational part of the system, which is responsible to lift and move the load
from one part of the engine room to another part. Following maintenance to be
performed on wire rope:

 Wind the wire rope in correct way to prevent kink of the rope
 Lubricate the wire rope at regular interval to reduce internal friction and to prevent
corrosion
 Before greasing the rope, clean it with a cloth to remove duct and foreign matter

Requirements for the renewal of wire rope:

 When diameter of rope is reduced by 7%

 When the number of visible wire fracture is 15 over length of 6 times the wire
rope diameter
 When the number of visible wire fracture is 30 over length of 60 times the wire
rope diameter
 When a kink caused at some part of the rope does not restore to its original shape
 When the rope is reduced in length
 When the rope is twisted out of shape

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  When the rope is deemed unusable because of rust or corrosion
5. Inspect The Gears: Gears are used to hoist or slewing the crane to manoeuvre the
load at the desired location. Following inspection and maintenance are carried on
the gear assembly:

 Drain the gear case oil if the condition is not good and after cleaning the case,
replenish it with fresh lube oil
 Keep a check on the gear case noise while the crane is in operation
 Measure the thickness of the gear teeth and if has decreased by 20-25% , renew it
with new one
 Inspect the gear for damage of teeths and renew it with new one if the damage is
more
6. Check Condition Of Sheave: Sheaves are used to carry the wire ropes from gearing
chamber to the hook of the crane. Numbers of sheaves are installed in the assembly
for the wire to move smoothly for operation. Following inspection must be carried
out:
 Inspect the groove which is in contact with the wire for wear down
 Check all the sheaves for freedom of rotation
 Check the trueness of sheaves. It may bend if the load is lifted obliquely
 Check for cracks and broken circumference on the face of the sheave
 Check the bearings provided in the sheave assembly
 Check the bolt and the pin holding the sheave in place are in good condition
 Check each sheave to insure rope groove is smooth and free from burrs, or other
surface defects
7. Carry Out Hook Maintenance: The hook assembly is such made that while the
load is ON, it can rotate 360 degree to adjust the position of the load and it
comprises of bearings and drums. Following maintenance and checks needs to
carried out:

 Lubrication of bearing to be done regularly

 If the partial wear of the part to be suspended with rope is not much worn, use
grinder to make it an even surface
 Never repair any crack by welding
 Make sure the dowel pin holding the hook is in position. Measure the pin diameter
and replace if its worn out
 Ensure safety latch spring is in working condition to avoid jumping of load
 If rotation lock is provided, check its operation
 Check the material for brittleness, cracking and hardness during annual survey
 If the part used for rigging the rope has worn out, check its shape (concave) and
repair or replace as per the condition
 Check throat opening of the hook and if the throat opening exceeds 15% of the
original opening, or if the hook is twisted more than 10 degrees, replace the same
8.Check The Brake: The engine room crane is equipped with electromagnetic brake
with fail-safe arrangement. This is the most important safety arrangement provided
in the crane. Following maintenance and inspection needs to be carried out:

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  Measure the distance between magnet and armature. It should be approx. 0.5mm
around the circumference(refer manual for exact value)
 If the gap is more or less than the recommended value, adjust the braking power
nut to reach the required gap
 If any overhauling is carried out, supply the current tot the magnetic coil only to
confirm that running shaft is operating without any resistance
 The electromagnetic brake is operated by the brake lining. Check for the moisture
on the surface of the lining to avoid slippage
 Check for signs of overheating and mechanical damages
 Check the tension of spring which carries the brake during overhauling of the
brake assembly
The engine room crane is an assembly of various important parts, which need
equal attention as any other machinery in the engine room. While the engineers and
engine crew are responsible for operating the crane, it is the core responsibility of
engineer officers to ensure no breakdown of crane occurs by following correct
operating procedures and maintenance schedule.

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 Common Engine Room Overhead Crane Troubleshooting Problems

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