General description
This course provides maintenance personnel with the knowledge and practical guidance needed to inspect, evaluate, adjust, and maintain electromagnetic brakes used on overhead cranes. Participants examine Warner and Binder brake construction, operating principles, technical specifications, inspection requirements, wear limits, and maintenance procedures. The course also covers air-gap measurement and adjustment, brake-disc inspection, coil-resistance testing, limit-switch adjustment, brake disassembly and reassembly, and second-brake maintenance.
Emphasis is placed on safe work practices, manufacturer specifications, and recognizing conditions that could affect braking performance or require component replacement. This course is intended for qualified crane maintenance technicians and other personnel responsible for inspecting and servicing crane braking systems. Upon successful completion of the course and testing, all participants will receive a certificate of course completion. Participants are also asked to complete an evaluation critique of the course content and instruction.
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DO YOUR OPERATORS KNOW?
- Emergency stop signals?
- How much weight they can safely lift with each crane in your plant?
- Emergency shutdown procedures for your cranes?
- How to perform OSHA required pre-operational inspections?
- Can you provide documentation showing the training program you
provided to your operators? - Do you have a refresher training program for your operators?
- Poorly trained operators could cause serious injury to your plant personnel,
substantial damage to your equipment or the loads they carry. - Your operators
are required by OSHA to be qualified and trained to operate this equipment.
Course outline
- Crane Brake Fundamentals
- Brake functions, operating principles, and regulatory requirements.
- Brake Construction and Components
- Identification of Warner and Binder brake types and major components.
- Technical Specifications
- Brake torque, air-gap requirements, wear limits, duty cycles, and electrical data.
- Brake Inspection
Course objectives
- Explain the function and operating principles of holding and control brakes used on overhead cranes.
- Identify the major components and technical characteristics of Warner and Binder brake assemblies.
- Inspect brake components and compare air gaps, brake-disc thicknesses, and wear conditions with manufacturer specifications.
- Perform common brake maintenance procedures, including air-gap adjustment, limit-switch adjustment, coil-resistance testing, and brake-disc replacement.
- Safely disassemble, inspect, reassemble, and operationally check main and secondary hoist brakes using the appropriate procedures and technical data.
