Situation 4

1
Situation 4

• Port Machinery Maitenance

2
Content

• Task1 Engine Maintenance
• Lesson36 Engine Maintenance I
• Lesson37 Engine Maintenance II
• Lesson38 Engine Maintenance III
• Task2 Chasis Maintenance
• Lesson 39 Chasis Maintenance I
• Lesson 40 Chasis Maintenance II
• Task3 Crane Maintenance
• Lesson 41 Crane Maintenance I
• Lesson 42 Crane Maintenance II
• Lesson 43 Crane Maintenance III

3
Task1 Engine Maitenance

• I Why to learn?
• Engine is an important part of the machine, if it
  cant work the whole machine has to stop, to
  avoid the inconvenience students need to know how
  to communicate with foreign engineers in
  maintaining and repairing the machine .

4
Task1 Engine Maitenance

• II How to learn?
• Seminar (??????????)
• Organize the students in groups and ask them to
  do some role-play based on the information of the
  lesson.
• Lecture(?????)
• III Content
• Lesson36 Engine Maintenance I
• Lesson37 Engine Maintenance II
• Lesson38 Engine Maintenance III

5
Lesson36 Engine Maintenance I

• New words
• Text
• Tasks
• 1) Discuss with your group members to understand
  the text thoroughly.
• 2) Make a dialogue and act it out

6
New Words

• engine maintenance ?????
• deformation n. ??
• crack n. ??,??
• roundness error ????
• cylindricality error ?????
• coaxiality error ?????
• water pressure method ???
• bonding method ???
• repairing welding method ???
• piston ring end gap ???????
• piston ring side clearance ?????
• piston back clearance ?????

7
Text

• The following passages (lesson 1, 2 and 3) are
  all about engine maintenance. They mainly deals
  with the following aspects about engine
  maintenance, maintenance for cylinder block,
  cylinder head, cylinder, piston and
  connecting-rod unit and crankshaft and flywheel
  unit, maintenance for valve mechanism,
  maintenance for fuel system, maintenance for
  ignition system and maintenance for lubricating
  system and cooling system.
• Engine Maintenance I tells us something about
  maintenance for cylinder block, cylinder head,
  cylinder, piston and connecting-rod unit and
  crankshaft and flywheel unit.

8

• The common defects of cylinder block and cylinder
  head are deformation, crack, roundness error,
  cylindricality error and coaxiality error.
• We can find obvious crank only through our own
  eyes. But sometimes we need some outside means to
  find hidden crack. For example, we can use water
  pressure method (see fig 1-1).
• 1-cylinder head 2-cylinder block 3-water pipe 4-
  pressure gauge 5-hand-pressure pump 6-
  accumulator tank
• Fig1-1water pressure test for cylinder block and
  head

9

• Once we find crack, we can use bonding method and
  repairing welding method for repair. Make sure
  that water pressure test should be carried after
  repair.
• At present, there are two methods for cylinder
  repair. One method is to bore the over-wear
  cylinder to enlarge the cylinder diameter and
  then fit it with proper piston and piston rings
  the other one is to replace the cylinder liner if
  wet cylinder liner is used.
• Piston and connecting-rod unit is the important
  unit in the engine. During operation, it always
  bears high temperature, high pressure and travels
  with high speed. So wear and deformation is
  easily produced.
• The main damage for piston is wear, which is in
  piston ring groove and pin boss hole, as
  illustrated in fig1-2.

10
1- original pin hole 2-pin hole after wear Fig1-2
main worn position of piston
11

• Piston rings are the easiest worn part in piston
  and connecting-rod unit. A tester shown in fig1-3
  often tests elastic of piston rings.

Fig1-3 check for the elastic of piston ring
12

• It is well known that piston rings have 3 gaps or
  clearances, piston ring end gap, piston ring side
  clearance and piston back clearance. We often use
  methods shown in fig 1-4 and fig 1-5 to check
  piston ring end gap and piston ring side
  clearance separately.
• Fig1-4 check and correction of piston ring end gap

13
Fig1-5 check for piston ring side clearance The
main defect of connecting-rod is bending
deformation and twist deformation.
Usually we correct the deformation as explained
in fig1-6.
14

• For deformation of crankshaft, we usually use the
  test shown in fig1-7 to test. At last for
  flywheel repair, we always do these things,
• i) Repair for working face of flywheel,
• ii) Repair for flywheel gear ring.
• Make sure that the flywheel needs static balance
  test after repair.

• Fig1-7

15
Make a Dialogue and Act It out

• Sentence Patterns
• Whats wrong with the machine?
• the trouble with the machine?
• the matter?
• Do you need any help?
• ________doesnt work.
• Let me see.
• Lets check _____
• Dont worry,I will fix it.
• How to fix / repair it?

16
Lesson37 Engine Maintenance II

• New words
• Text
• Tasks
• 1) Discuss with your group members to understand
  the text thoroughly.
• 2) Make a dialogue and act it out

17
New Words

• wear n. ??
• ablation ??
• valve grinder ?????
• reaming ??
• clearance check ????
• scuffing ??
• fatigue flaking ????
• camshaft deformation check
  ????????
• valve clearance ????
• cylinder by cylinder adjusting ?????
• two-step adjusting ?????

18
Text

• This passage mainly deals with maintenance for
  valve mechanism. Valve mechanism consists of two
  parts, valve group and valve transmission group.
• Firstly, lets see how to do the valve group
  repair. We all know that the working condition of
  valve is very bad. So wear, crack or ablations
  often occur on the valve head. These wears can be
  found by eyes. But for deformation of valve stem,
  we often judge it by means of equipment (see fig
  2-1). When grinding method cant solve the
  problem of the working face of valve, a valve
  grinder is often needed.

19
Fig 2-1
20

• During operation of engine, over-wear and
  ablation often occur on the working face of valve
  seat. So we often do reaming (see fig 2-2) and
  repair grinding for valve seat.
• Fig 2-2 reaming for valve seat

21

• Valve guide acts guiding role when valve travels
  repeatedly. It always bears side force of valve
  transmission group. So the inside hole of valve
  guide often wears. Practically we use the method
  shown in fig2-3 to check the clearance between
  valve stem and the inside hole of valve guide.

Fig 2-3 clearance check
22

• Secondly, lets look at the repair method of
  valve transmission group. Wear, scuffing and
  fatigue flaking of camshaft journal and the
  working face of cam is the common defect during
  operation of camshaft. We can use a check method
  explained in fig2-4 to check the deformation of
  camshaft.

23
1-plate 2-V iron 3-percent meter 4-camshaft Fig
2-4 camshaft deformation check
24

• At last, lets learn how to adjust valve
  clearance. There are 2 means used to adjust valve
  clearance, cylinder by cylinder adjusting and
  two-step adjusting. We can use an example to
  explain the two-step adjusting. For instance,
  6135 diesel engine, its firing order is
  1-5-3-6-2-4, we can adjust the clearance as table
  2-1 illustrated. Table 2-1 tells us which valves
  are the adjustable valves when No. 1 cylinder is
  in its TDC in compression stroke. After the first
  step, we should rotate the crankshaft 360,then
  we can adjust the valves which are not adjusted
  in the first step, as shown in table 2-2. Note, I
  means intake valve, E means exhaust valve.

25

• Table 2-1
• Table 2-2

26
Make a Dialogue and Act It out

• Sentence Patterns
• Whats wrong with the machine?
• the trouble with the machine?
• the matter?
• Do you need any help?
• ________doesnt work.
• Let me see.
• Lets check _____
• Dont worry,I will fix it.
• How to fix / repair it?

27
Lesson38 Engine Maintenance III

• New words
• Text
• Tasks
• 1) Discuss with your group members to understand
  the text thoroughly.
• 2) Make a dialogue and act it out

28
New Words

• fuel injector ???
• needle valve assembly ????
• fuel injector tester ??????
• fuel injection pump ???
• seal surface ???
• decompression zone ????
• outlet valve ???
• carbon deposition ??

29

• electrode gap ????
• short-circuit ??
• open circuit ??
• ground v. ??
• additional resistance ????
• disassemble v. ??
• reassemble v. ??
• thermostat n. ???

30
Text

• This passage is concerned about maintenance for
  fuel system, ignition system, lubricating system
  and cooling system.
• Maintenance for fuel system
• Firstly, lets pay our attention to the repair
  for fuel injector. Needle valve assembly often
  wears during operation. For with slight wear,
  milling by hand is always used. But for excessive
  wear and serious leak, just replace a new one.
  Check and adjustment for the fuel injector is
  shown in fig3-1.
• 1-fuel injector tester 2- adjusting screw 3-fuel
  injector 4- for three-way union 5-pump
• Fig3-1

31

• Secondly, lets turn to repair for fuel injection
  pump. It is necessary to mention the repair for
  outlet valve couple parts. The wear of outlet
  valve couple parts mainly occurs on seal surface
  between valve and valve seat or decompression
  zone of the outlet valve.
• Tests are often made to test the outlet valve
  couple parts (see fig3-2).Or sometimes we may use
  easy method (see fig3-3).
• 1- outlet valve holder 2-outlet valve 3- testing
  fixture 4-head screw
• Fig3-2 Fig3-3

32

• Maintenance for ignition system
• In this part, we will mainly deals with the
  repair for spark plug, ignition coil and
  distributor.
• The main defect of spark plug is carbon
  deposition, crack on the insulator and excessive
  gap of electrode. The usual electrode gap is
  about 0.6 0.7mm.We can use the method displayed
  in fig3-4 to check and adjust the gap.

• Fig3-4

33

• The main defect of ignition coil is
  short-circuit, open circuit or ground of the
  primary coil and secondary coil, or
  short-circuit, ground or burn-out of additional
  resistance. The check for ignition coil consists
  of, checking for additional resistance and low
  voltage coil and checking for high voltage coil
  and inside insulating property.
• The overhaul of distributor includes,
• i) Checking for spring leaf elastic of moving
  contact arm of breaker (see g3-5),
• i) Checking for moving contact,
• iii) Checking and adjustment for contact
  clearance (see fig3-6),
• iv) Checking and repair for distributor cap and
  distributor rotor,
• v) Checking for the capacitor.
• Fig 3-5
  Fig 3-6

34

• Maintenance for lubricating system
• The oil pumps used on most engines are volume
  type oil pump. The main failure of this kind of
  pump is the poor sealing performance after some
  parts wear. The poor sealing performance always
  leads to low supply pressure.
• Generally speaking, we can refer to the
  followings to do the oil pump maintenance.
• i) Disassemble the oil pump,
• ii) Repair the oil pump (see fig3-7),
• iii) Reassemble the oil pump,
• iv) Test the oil pump.
• Fig3-7 check for clearance

35

• For the oil filter maintenance, we mainly deals
  with the maintenance for rough filter and fine
  filter.
• The filter element used on rough filter consists
  of metal filter element and paper filter element.
  The paper filter element neednt repairing. We
  can just change a new one if the old one doesnt
  work well. But the metal filter element needs
  repairing.
• For fine filter with paper filter element, only
  the housing and central tube needs cleaning. Its
  filter element can be changed easily.
• Maintenance for cooling system
• This part is mainly about maintenance for water
  pump, radiator and thermostat.
• The common injury of the water pump is of leakage
  or rupture of the pump housing, bending or wear
  of the pump shaft, damage or corrosion of the
  impeller vane and damage or aging of washer.
  Before we repair the water pump, please do check
  its technical state with the engine running.
• The main defects of the radiator are internal
  incrustation, leakage, injury of fin and
  water-pipe blockage. Steam pressure method is
  always used to checking for leakage of the
  radiator.
• If failure occurs in the thermostat, replace a
  new one directly.

36
Make a Dialogue and Act It out

• Sentence Patterns
• Whats wrong with the machine?
• the trouble with the machine?
• the matter?
• Do you need any help?
• ________doesnt work.
• Let me see.
• Lets check _____
• Dont worry,I will fix it.
• How to fix / repair it?

37
Task2 Chasis Maitenance

• I Why to learn?
• Chasis is an important part of the machine, if it
  cant work the whole machine has to stop, to
  avoid the inconvenience students need to know how
  to communicate with foreign engineers in
  maintaining and repairing the machine .

38
Task2 Chasis Maitenance

• II How to learn?
• Seminar (??????????)
• Organize the students in groups and ask them to
  do some role-play based on the information of the
  lesson.
• Lecture(?????)
• III Content
• Lesson 39 Chasis Maintenance I
• Lesson 40 Chasis Maintenance II

39
Lesson39 Chasis Maintenance I

• New words
• Text
• Tasks
• 1) Discuss with your group members to understand
  the text thoroughly.
• 2) Make a dialogue and act it out

40
New Words

• chassis maintenance ????
• universal gearing ??????
• differential n. ???
• rupture n. ??
• driven disk ???
• hub n. ??
• internal spline tooth ????
• friction disk ???
• riveting n. ??
• repair grinding ??
• discharge n. ??
• disconnect v. ????

41
Text

• The following passages (lesson4 and lesson5) are
  all about chassis maintenance. Lesson 4 is all
  about the maintenance for transmission system
  which includes clutch, gearbox (or transmission),
  universal gearing and differential.
• A clutch is a mechanism for transmitting
  rotation, which can be engaged and disengaged.
  The driven disk is the quick wear part of the
  clutch. The common defects of the driven disk are
  as follows,
• i) Wears, rupture of friction disk and fall-out
  of rivet,
• ii) The warping of steel sheet of the driven
  disk,
• iii) Wear of key seat of the driven disk hub,
• iv) Fracture or of failure of the damping spring.
• We can repair the driven disk as follows,
• i) Remove the old lining,
• ii) Check the wear degree of internal spline
  tooth,
• iii) Check whether the driven steel plate is
  warped (see as fig4-1),
• iv) Match new friction disks and rivets,
• v) Drilling or riveting,
• vi) Repair grinding for the lining.

42

• Fig4-1
• The common injury of the pressure plate is
  warping or crack. And for clutch spring, its main
  defects are fatigue, distortion, break and weaken
  elastic. We usually repair the spring by simple
  replace.
• After the brief introduction of clutch, lets
  turn to the maintenance about the transmission.
  In fact, the transmission structure varies from
  one type to another. So their maintenance
  differs. But basically, the procedures are
  similar.
• i) Discharge the lubricant,
• ii) Disconnect the rear axle or the front end of
  the propeller shaft or the universal joint,
  according to different type of transmissions,
• iii) Dismount shifting linkages from
  transmission, hand-brake linkage or spring, and
  speedometer cable,
• iv) Set engine support,
• v) Remove attaching bolts or stud nuts.
• vi) Reassemble.

43

• The common injury of the pressure plate is
  warping or crack. And for clutch spring, its main
  defects are fatigue, distortion, break and weaken
  elastic. We usually repair the spring by simple
  replace.
• After the brief introduction of clutch, lets
  turn to the maintenance about the transmission.
  In fact, the transmission structure varies from
  one type to another. So their maintenance
  differs. But basically, the procedures are
  similar.
• i) Discharge the lubricant,
• ii) Disconnect the rear axle or the front end of
  the propeller shaft or the universal joint,
  according to different type of transmissions,
• iii) Dismount shifting linkages from
  transmission, hand-brake linkage or spring, and
  speedometer cable,
• iv) Set engine support,
• v) Remove attaching bolts or stud nuts.
• vi) Reassemble.

44

• Now lets see something about maintenance for
  universal gearing and differential. We may use
  the method shown in fig4-2 to check the radial
  clearance of universal joint bearing.
• Fig4-2
• 
  Fig4-3
• At last, for the maintenance for differential
  (see fig4-3), the author just wants to mention
  the importance of oil change. Although periodic
  replacement of the gear oil is specified by
  manufacturers to maintain the performance and
  longevity of the differential, this is probably
  the most commonly overlooked service in personal
  transportation. It is important that differential
  fluid service gets the attention it deserves.
  Doing that can help to prolong differential
  component life, provide superior protection
  especially under extreme conditions and protect
  against friction, wear and corrosion.

45

• At last, for the maintenance for differential
  (see fig4-3), the author just wants to mention
  the importance of oil change. Although periodic
  replacement of the gear oil is specified by
  manufacturers to maintain the performance and
  longevity of the differential, this is probably
  the most commonly overlooked service in personal
  transportation. It is important that differential
  fluid service gets the attention it deserves.
  Doing that can help to prolong differential
  component life, provide superior protection
  especially under extreme conditions and protect
  against friction, wear and corrosion.

46
Make a Dialogue and Act It out

• Sentence Patterns
• Whats wrong with the machine?
• the trouble with the machine?
• the matter?
• Do you need any help?
• ________doesnt work.
• Let me see.
• Lets check _____
• Dont worry,I will fix it.
• How to fix / repair it?

47
Lesson40 Chasis Maintenance II

• New words
• Text
• Tasks
• 1) Discuss with your group members to understand
  the text thoroughly.
• 2) Make a dialogue and act it out

48
New Words

• suspension component ????
• tire n. ??
• steering n. ??
• running deviation ??
• shimmy n. ??
• cleanliness n. ??
• inspect v. ??
• preventive maintenance ?????

49
Text

• Lesson 40 mainly deals with maintenance for the
  steering system, suspension components and brake
  system.
• Firstly, lets see where the failure often
  occurs for steering system. Generally speaking,
  the common failures are as follows,
• i) Uncommon wear for front tire,
• ii) Over great steering wheel free displacement,
• iii) Hard steering,
• iv) Running deviation automatically,
• v) Front wheel shimmy in driving.
• Cleanliness of the suspension components is an
  area in which most vehicles are completely
  ignored throughout their operating life. It is
  recommended as good practice that all components
  of the suspension be cleaned by hand with shop
  towels on an every 5000 mile basis. This allows
  the owner to inspect all bolts and various
  components both visually and by feeling for any
  damage that may have occurred in use and for any
  loosening or increase in clearances due to wear.
• Your car's brake system is a complex grouping of
  parts which serve a critical role in keeping you
  safe.  No other system in the car is more
  important than it for your safety.

50

• Common problems about the brake systems are as
  follows.
•  Wear, the braking system does a lot of work and
  the brake pads take the brunt of the punishment. 
  It is a good idea to have your brake pads checked
  every 6 months or when you suspect a problem. 
  Symptoms include squeaking, grinding, or
  increased stopping distance.  Most pads have a
  thin metal tab which vibrates against the rotor
  when the pads wear down to a dangerous level. 
  Some pads do not have this and if not checked
  periodically, they can wear down far enough to
  ruin the rotors.  A modern trend is to make the
  brake pads very hard, thus extending life.  This
  harder material can squeak and sounds like the
  wear indicators.  Brake dust can also cause
  squealing but can be fixed by spraying brake
  cleaner on the brake system to remove the dust.
• Warped Rotors,  More common in newer cars, but
  possible on all disc brake systems, rotors warp
  due to being overheated or incorrect tightening
  of the wheel . A warped rotor will give a pulsing
  feeling when applying the brakes. This pulsing
  can be annoying and dangerous.  Most new cars
  have rotors which are very thin and warp very
  easy. 

51

• Preventive Maintenance
• Avoid "riding" your brakes.  It's better to slow
  down with moderate pressure and then releasing
  the brake to cool, than riding the brakes and
  overheating them.
• On steep grades, consider downshifting to save
  your brakes. Only do this when traction
  conditions are good.  On icy, snowy, or even
  rainy days, downshifting into too low of a gear
  may cause a skid.  Downshifting lets your engine
  do some of the braking instead of your brakes.
• Keep your wheels and braking system clean.  Clean
  brakes work better and keep temperatures down. 
  Use a good wheel cleaner which you know if safe
  for your wheel finish.

52
Make a Dialogue and Act It out

• Sentence Patterns
• Whats wrong with the machine?
• the trouble with the machine?
• the matter?
• Do you need any help?
• ________doesnt work.
• Let me see.
• Lets check _____
• Dont worry,I will fix it.
• How to fix / repair it?

53
Task3 Crane Maitenance

• I Why to learn?
• Crane is an important part of the machine, if it
  cant work the whole machine has to stop, to
  avoid the inconvenience students need to know how
  to communicate with foreign engineers in
  maintaining and repairing the machine .

54
Task3 Crane Maitenance

• II How to learn?
• Seminar (??????????)
• Organize the students in groups and ask them to
  do some role-play based on the information of the
  lesson.
• Lecture(?????)
• III Content
• Lesson 41 Crane Maintenance I
• Lesson 42 Crane Maintenance II
• Lesson 43 Crane Maintenance III

55
Lesson41 Crane Maintenance I

• New words
• Text
• Tasks
• 1) Discuss with your group members to understand
  the text thoroughly.
• 2) Make a dialogue and act it out

56
New Words

• crane maintenance ?????
• unwind v. ??
• reverse direction ?????
• sheave n. ??
• thimble joint ????
• provision n. ??
• loose adj. ???
• ladder n. ??

57
Text

• These passages (lesson 6, lesson 7 and lesson 8)
  are mainly concerned about crane maintenance.
  Lesson 6 answers the 2 questions which are what
  to check for when inspecting a crane before
  maintenance, and what things are to remember when
  repairing a crane.
• What should you check when inspecting a crane
  before maintenance? Whats the answer to this
  question? We may answer it like followings.
• Unwind all wire rope from the hoist drum to
  expose all parts of a rope, making sure that the
  rope does not rewind in the reverse direction.
• Inspect sheaves, sockets, dead-ends, thimble
  joints, and all wire rope hardware.
• During rope changes, check the sheaves for worn
  bearings, broken flanges, proper groove size,
  smoothness, and contour.
• Inspect all parts of the cable, cleaning wire
  rope only as required to complete an inspection.
  Excessive removal of lubrication will lead to
  damage.
• Re-lubricate rope to prevent corrosion, wear,
  friction, and drying out of the core.
• Then for another question -What are the things to
  remember when repairing a crane?
• Take a crane to a location where repairs will
  least interfere with other cranes.
• Ensure that all controllers are placed in the
  "off" position, and the main switches are open
  and locked.

58

• Place on the switch a standard warning tag
  stating "DO NOT START." The tag must be filled
  out and signed
• Place rail stops or make other safety provisions
  when another crane operates on the same runway.
• Do not carry anything in your hands when going up
  and down ladders. Items that are too large to go
  into pockets or belts should be lifted to or
  lowered from the crane by a rope.
• Prevent loose parts or tools from falling to the
  floor.
• The area below the crane must be cleared and a
  barrier erected to prevent injury from a falling
  object.
• Replace all guards and other safety devices
  before leaving a crane.
• Remove all stops, tools, loose parts and other
  material and dispose of them before completing
  the repair job.
• Enter all service inspections and repairs in a
  crane log book or file.

59
Make a Dialogue and Act It out

• Sentence Patterns
• Whats wrong with the machine?
• the trouble with the machine?
• the matter?
• Do you need any help?
• ________doesnt work.
• Let me see.
• Lets check _____
• Dont worry,I will fix it.
• How to fix / repair it?

60
Lesson42 Crane Maintenance II

• New words
• Text
• Tasks
• 1) Discuss with your group members to understand
  the text thoroughly.
• 2) Make a dialogue and act it out

61
New Words

• wire rope ???
• trained personnel ???????
• discard v. ??
• sling n. ??,??
• drag v. ??
• hook n. ??
• twist v. ??

62
Text

• Lesson 7 tells something about hoisting wire rope
  and slinging on overhead crane hooks.
• Firstly, lets pay our attention to hoisting wire
  rope? We may grasp something important by
  answering some questions as follows. Who
  should inspect wire ropes and when?
• Only trained personnel should carry out an
  inspection of wire ropes.
• Inspect a wire rope when installing it.
• Inspect wire ropes every working day.
• Keep records of daily inspections.
• Check for abrasions, corrosion, pitting, and
  lubrication inside rope. Insert a marlin spike
  beneath two strands and rotate to lift strands
  and open rope.
• When should you eliminate the rope from its use?
  
• Assess the condition of the rope at the section
  showing the most wear. Discard a wire rope if you
  find any of the following conditions.
• In running ropes (wound on drums or passed over
  sheaves), 6 or more broken wires in one lay
  length 3 or more broken wires in one strand in
  one lay.
• In pendant standing ropes, there are 3 or more
  broken wires in one lay length.
• Wear of 1/3 of the original diameter of
  individual outside wires.
• Heat damage (check for burn marks, discoloration
  of the metal).
• Excessive stretch or sharp reduction in the rope
  diameter,
• Knots or splices (except eye splices) in a wire
  rope.

63

• Secondly, lets notice slinging on overhead crane
  hooks, also by finding answers for certain
  questions.
• How should you sling a load onto a crane hook?
• Make clear signals according to standard signals.
  Refer to "Materials Handling - Crane and Hoist
  Hand Signals" for examples.
• Give a signal to the crane operator from only the
  one slinger who is in charge of lift. The only
  exception is a stop signal. (A slinger or rigger
  is the person who hooks loads onto cranes using
  various types of slings.)
• Determine the weight of the load to be lifted.
• Select the right sling for each job, using the
  manufacturers' tables. A slinger must be familiar
  with these tables showing the safe capacities of
  slings.
• Inspect each item of lifting equipment before and
  after lifts.
• Protect slings from damage by sharp edges with
  corner saddles, padding, or wooden blocks.
• Warn all people out of the load area before
  starting the lift.
• Protect your hands and fingers, when slack is
  being taken out of a sling, keep them from
  between the sling and load so they will not be
  trapped and crushed. Step away before the lift is
  made.
• Make sure a load is high enough to clear all
  objects before signaling for the crane to move.
• Walk ahead of the moving load and warn people to
  keep clear. Use guide ropes

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• to prevent rotation or other uncontrolled motion.
  
• Hook unused sling legs to the sling ring.
• What should you avoid when slinging a load?
• Do not exceed the capacities of slings, fixtures
  and cranes.
• Do not twist or tie knots in slings or use bolts,
  nails or pieces of wire to shorten slings.
• Do not splice together broken slings.
• Do not ride on hooks or loads.
• Do not allow workers to walk or work under a
  load.
• Do not attempt to pull or push loads to a spot
  that is not under the hoist.
• Do not drag slings. Avoid pulling slings out from
  under loads by crane. Set down loads on blocking,
  never directly on a sling.
• Do not leave unused slings, accessories, or
  blocking lying on the floor. Hang on racks or
  store in a proper place.
• Do not carry a load by inserting the point of the
  hook into a link of the chain.
• Do not hammer a sling into place.
• Do not leave loose materials on a load.
• Do not use slings that are stretched, broken, or
  defective. Tag them as defective and dispose of
  any damaged slings.
• Do not leave suspended loads unattended.

65
Make a Dialogue and Act It out

• Sentence Patterns
• Whats wrong with the machine?
• the trouble with the machine?
• the matter?
• Do you need any help?
• ________doesnt work.
• Let me see.
• Lets check _____
• Dont worry,I will fix it.
• How to fix / repair it?

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Lesson43 Crane Maintenance III

• New words
• Text
• Tasks
• 1) Discuss with your group members to understand
  the text thoroughly.
• 2) Make a dialogue and act it out

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New Words

• pre-operation ???
• rope drum ??
• chipped adj. ????
• switch n.
  ??
• load n
  ??

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Text

• This passage is all about pre-operation
  inspection of cranes.
• What should you check for before operating a
  crane?
• Rope appearance - lubrication, kinks, breaks,
  corrosion, reduced diameter, or other signs of
  wear or damage.
• A rope drum - position of cable in groove
  tracking, means of anchoring and drum wear or
  damage.
• Sheaves - alignment of ropes, guides, dead ends,
  wear in sheave groove.
• Hooks - cracks, twisting, straightening, hook
  throat opening or other signs of wear or damage.
• Lights - burned out, broken.
• Mechanical parts and guards - loose, bent,
  broken, and missing.
• Rails - broken, chipped, cracked.
• Wheels - worn (showed by bumpy riding).
• Bearings - loose, worn.

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• Brakes - shoe wear.
• Bridge bumpers and a trolley end stop - loose,
  missing, improper placement.
• Controllers and collector shoes or bars - worn,
  pitted, loose, broken, or faulty operation.
• A foot walk - condition of the boards, railings,
  and ladders.
• Gears - lack of lubrication or foreign material
  in gear teeth (indicated by grinding or
  squealing).
• A fire extinguisher must be in the crane cab.
• Make sure that no one is on or around a crane
  before closing the main or emergency switch, even
  when starting on regular duty.
• Before closing the main switch, make sure that
  all controllers are in the "off" position.
• Inspect oil only after opening and locking out
  the main switch.
• What should you inspect a moving crane for?
• Before lifting any load you should start the
  crane and inspect it when it is moving.
• Smooth play out of wire rope to and from a drum.
• Sheaves turning without binding or jerking as a
  rope passes over them.
• Proper alignment where ropes enter sheaves.
• Rubbing, scraping, or clattering noises during
  operation.
• Proper operation of controls and brakes.
• Test the limit switch. Slowly raise the hook
  block with no load attached to the hook. If the
  switch is defective, make sure the block does not
  strike the cable drum.

70
Make a Dialogue and Act It out

• Sentence Patterns
• Whats wrong with the machine?
• the trouble with the machine?
• the matter?
• Do you need any help?
• ________doesnt work.
• Let me see.
• Lets check _____
• Dont worry,I will fix it.
• How to fix / repair it?