Gantry crane inspection is a key step in ensuring safe operation and extending the service life of gantry crane equipment. Here are 10 examples of faults and inspection that will be encountered in the safety inspection process, so you can quickly understand these faults and correct the possible safety risks in time.
● Check whether there is any settlement, fracture, or crack in the track foundation of the gantry crane.
● Check the rail for cracks, severe wear, and other defects.
● Check the contact between the rail and the rail foundation, and shall not hang on the foundation.
● Check whether the rail joints meet the requirements, generally 1-2MM and 4-6MM in cold areas.
● Check the transverse dislocation and height difference of the rail for the gantry crane, the requirement is not greater than 1 MM.
● Check the fixing of the guide rail, the plate and bolts should not be missing, and the plate and bolts should be tightened and meet the requirements.
● Check the connection condition of the guide rail connecting board.
● Check whether the longitudinal slope of the rail meets the design requirements, generally at 1‰. The overall length is not greater than 10 MM.
● The height difference of the same section track is not greater than 10 MM.
● Check whether the gauge is over the deviation, the truck gauge deviation is not greater than ± 15 MM, or according to the parameters in the operation manual of the gantry crane.
Most of the track and foundation faults appear in the installation process of gantry cranes, so special attention should be paid to this aspect when installation, so as to avoid greater problems in the later stage.
●Check the tightening of the leg flange connection bolts of the gantry crane.
●Check the bonding of the leg flange joints.
●Inspect the weld connecting the leg flange to the leg string.
●Check whether the connecting rod pin shaft is normal, whether the connecting bolts are fastened, and whether the connecting rod ear plate and the leg are welded.
●Check the tightness of the connection bolts between the lower beam and the leg and the connection bolts between the lower beam.
●Check the welding of the lower leg beam.
●Check the tightness of the bolt connecting the upper beam and the main beam.
●Check the welds on the upper leg beam and the welding part.
●Check the connection position of the main beam, including the fastening of the pin or connection bolts, the deformation and the weld condition at the connecting joints.
●Check the welds at each weld of the girder, and pay attention to the tear joints between the upper and lower strings and the belly rod of the girder.
●Check whether the whole main beam is deformed, and whether the deformation is within the specification range.
●Check whether the height difference between the left and right main beams is large and whether it is within the specification range.
●Check the transverse connection between the left and right main beams and check the weld of the transverse connecting ear plate.
●Check whether the walking wheel is worn, cracked, whether it has serious deformation, whether the rim is seriously worn or has no rim, etc.
●Check the adequacy and the quality of lubricating oil.
●Check the reducer box for cracks and oil leakage.
●Check the fixing condition of the speed reducer.
●Check the brake for properly.
●Check the brake clearance, wear of brake pads, and wear of brake wheel.
●Check the connection of coupling, tightness of connecting bolts, and wear of elastic connector.
●Check the motor for its sealing and protection.
●Check whether the walking wheel is worn and cracked, seriously deformed, and severely worn or has no rim.
●Check the condition of the running track, including track joints, wear and damage.
●Check the condition of the lubricating oil of the reducer.
●Check the braking condition of the walking part.
●Check the fixation of each part of the walking section.
●Check the fixing of the lifting wire rope end on the lifting winch.
●Check the lubrication of the winch gear box, including the lubricating oil capacity and quality.
●Check whether the hoisting truck reducer has oil leakage phenomenon and whether the reducer is damaged.
●Check the fixation of the gearbox.
●Check that the winch brake is working properly.
●Check the brake clearance, wear of brake pads, and wear of brake wheel.
●Check the connection of coupling, tightness of connecting bolts, and wear of elastic connector.
●Check the motor for its sealing and protection.
For the hydraulic brake system, check whether the hydraulic pump station works normally, whether the oil leakage, and whether the brake pressure meets the requirements.
●Check the wear and protection of the pulley.
●Check the tightening of each component.
●Check the connection between the electric hyacinth running rail and the main beam and the wear of the rail.
●Check the connection condition of the running track, including whether the connecting plates and connecting bolts are fastened, and whether the track connecting joints meet the operation requirements.
●Check whether the wear of the electric hoist wheel and the clearance between the wheel and the rail belly meet the safety requirements.
●Check the winding of the lifting wire rope on the electric hoist.
●Check whether the electric wire ist is working properly or damaged.
●Check the working condition of the electric hoist brake and the wear condition of the brake pads, whether the brake clearance and braking force meet the requirements.
●Check the fixing of the wire rope end on the electric hoist.
●Check the tightness of the connecting bolts at each connection.
●Check the hook for wear.
●Check the configuration of the hook sealing machine and its damage.
●Check the operation and wear of the hook pulley and whether there is any device to prevent the wire rope from jumping out of the groove.
●Check the lubrication of the moving parts.
●Check the use of wire rope, whether there is a deformation, such as knot, extrusion deformation, cutting, broken stock, corrosion, high temperature black, rope diameter thinning, etc.
●Check the fixing of the wire rope end.
●Check whether each part of the cable line is damaged, hung, and whether the bracket is firmly connected.
●Check whether the motor shield is complete and intact.
●Check whether the appearance of each motor is complete and without damage, whether the junction box and cover are intact, whether the wiring terminals are fastened, and whether the wires are broken or broken.
●Check whether each limit switch is complete and intact.
●Check that the lighting is intact.
●Check the protection of the control cabinet.
●Check the components and electrical wiring in the control cabinet.
●Check whether the electrical components in the operating room are intact.
●Check that the main cable drum is working properly.
●Check whether the cable slide rail of the bridge crane is normal, and whether the cable moves on the slide rail normally when the crane is running.
●Check whether the electric hoist wire slide works normally and whether the wire rope moves on the slide normally when the electric hoist runs.
●Check the brake cable joints and cable.
●Check the fixation of the gantry crane up and down the stairs.
●Check the fixation condition of each platform.
●Check the fixation of the handrails on the stairs and on the platform.
●Check the fixation in the operating room.
●Check the safety device of the truck operation, including whether the driving limit switch is installed and works normally, whether the driving limit block is installed and firm, whether the electric or hydraulic iron boots are installed and works normally as required, and whether the rail clamp is installed and works normally as required.
●Check whether the trolley operation deviation correction device is installed and works normally.
●Check whether the wind protection cable is installed.
●Check whether the ground anchor is installed correctly and works properly.
●Check whether the trolley running buffer device is installed.
●Check whether the trolley running sound and light alarm device is installed and works normally.
●Check whether the safety device of the hoisting mechanism is complete and working normally. It includes trolley operation limit device, limit block, lifting height limiter, and lifting weight limiter.
●Check that the monitoring system is working properly.
●Check whether the anemometer is working properly.
●Check whether there are obstacles affecting the operation of the gantry crane near the gantry crane track.
●Check for scattered objects on each platform and truss.
●Check whether there are obstacles affecting the operation of the gantry crane.
The frequency of inspection depends on a variety of factors, including equipment type, workload, operating environment, and regulatory requirements. Usually, routine examinations should be performed daily or before each use. Regular inspection can be carried out regularly according to the use of the conditions, usually every three months to a year.
Electrical system: Check the electrical wiring, control boxes, buttons and switches to make sure everything is normal and there are no loose wires or connections.
Mechanical parts: Check various mechanical parts, including gears, bearings, wire rope, pulleys, brakes, etc., to ensure that there are no abnormal wear or damage.
Hook: check the hook without crack, deformation, damage, safe and reliable.
Lubrication: Check the lubrication point to ensure that the equipment is fully lubricated to minimize wear and friction.
Protective device: check the limit switch, safety rope, emergency stop device and other safety devices to ensure their normal operation.
Cable and harnesses: Check the cables and harnesses to ensure they are not broken or worn to avoid electrical failure.
External: Check the exterior of the crane including welded joints, coatings and markings to ensure no corrosion or damage.
periodic inspection
Regular structural inspection of beams, columns and other major components for cracks, wear or deformation.
Lift rope: Check the lift rope regularly for any wear, deformation, or damage. Crane ropes are important safety components and must be kept in good condition.
Electrical system: regularly check the electrical system, including cables, switches, contactors, control system, to ensure its normal operation.
Brake system: Check the brake system to ensure it stops the movement of the crane.
Hydraulic system (if applicable): If the gantry crane is equipped with a hydraulic system, the hydraulic oil, lines and seals shall be checked regularly to prevent leakage or damage.
But be careful to ensure compliance with local regulations and manufacturer recommendations, as certain equipment may require more frequent inspections. In addition, if a fault is found during a routine or regular inspection, a repair or a more detailed inspection should be performed immediately. Safety is always the primary consideration and should not be ignored.
Whether it is gantry crane or bridge crane, safety is the most important issue, so the safety inspection should pay attention to every manager, make a reasonable day, month, quarter, or year inspection plan, hope that your lifting equipment factory does not exist the above faults, always safe production.
