Appendixc- Maintenanceinspection Specificationand Record Forcategory 1And 4 Cranes

Appendixc- Maintenanceinspection Specificationand Record Forcategory 1And 4 Cranes

APPENDIXC- MAINTENANCEINSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4 CRANES

Notes:

1.Thefollowingaretheminimuminspection requirements.DuetothevariousmakesandmodelsofcranesintheNavyinventorywithuniqueorspecialcomponents,thesespecificationsmay requireadditional instructions.Componentsneednot bedisassembledforinspection,except:(a)wherenotedspecificallytodisassemble;(b)whereactivityexperiencewarrantsdisassemblyofspecificcomponents;or (c)whereproblemsindicatedbytheseinspectionsrequiredisassemblyforfurtherinspection.Wheredisassemblyandreassemblyarerequired,orforotherdetailedinspectionguidelines,TWDs,SROs,orother workdocumentsshall be utilized(exceptforinspection covers) toproperlydocumentthenecessarystepsrequiredfordisassembly,reassembly,and/orotherinspectionguidelines.DeletingorreducingthefrequencyoftheseinspectionsrequiresNavyCraneCenterapproval(seeparagraph3.6fordeferralofmaintenanceinspections).Justificationshallbeprovidedwiththeactivity'srequest.Additionalormorefrequent inspectionsbaseduponactivityexperienceorOEMrecommendationsmaybeperformedatthediscretionoftheactivity.AdditionalinspectionrequirementsandrecommendationsforspecificOEMsarecontainedinCSAsandEDMslocatedontheNavyCraneCenterwebsite(

2.Thesespecificationsincludebothnon-operationalandoperationalinspectioncriteria.Wherenecessarytoensurethesafetyofinspectionandmaintenancepersonnel,thecraneshall be de-energizedinaccordance withapprovedlockoutprocedures.

3.Forinspectionsthatinvolvefluids(lubricants,coolants,brakefluid,hydraulicfluid,etc.)orgrease,inspectthefluidorgreaseforvisualappearance,smell,andfeel,andinspectfor indicationsofdamagedormalfunctioning components.

4.Whereanunsatisfactoryconditionisfound,theitemshallbeidentifiedonthe"UnsatisfactoryItems"sheettogetherwithastatementoftheconditionobserved.Correctiveactionintermsofadjustments,repairs,orreplacementsofitemsshallbedetailedonaTWD,SRO,orotherappropriatedocument.(SeeNAVFACP-300forasampleSRO.)

5.Brakedatameasurementsshallberecordedonthe"BrakeData"sheet.Measurementattributesandcriteriashallbebasedonbrakeand/orcraneOEMrecommendationsand/orrecommendationsoftheactivityengineeringorganization.Inadditiontominimumandmaximumsettings,apreferredsettingmaybespecifiedwhereappropriate.Wheremeasurementsareinaccessiblewithoutdisassembly,thosemeasurementsneed onlybetakenwhenthebrakeisdisassembled.

6.Wheremeasurementsarespecifiedbytheactivityengineeringorganization,thosemeasurementsshallberecorded.Wireropedimensionalmeasurementsshallberecorded.

7.Asanalternativetotheabovedimensionalmeasurements,gagesmaybeusedifsuppliedbytheOEMorasapprovedbytheactivityengineeringorganization.Ifgagesareused,thegage partnumber or drawing number shall berecordedon theMISR.

8.Whereaninspectionitemappliestomultiplecomponents(e.g.,mainhoist,auxiliaryhoist,whiphoist),each componentshallbeidentifiedinthe"systeminspected" column.

9.Theseinspectioncriteriaaddressmostofthefeaturesandcomponentsontypicalcranes.Ifacraneisequippedwithfeaturesorcomponentsnotspecificallycoveredbytheserequirements,thosefeaturesandcomponentsshallbeinspected(whereinspectionispractical,asdeterminedbytheactivityengineeringorganizationandapprovedbythecertifyingofficial)forproperconditionandoperation,e.g.,emergencydynamicbraking,motoroverspeedandovertemperaturesensors,travelandrotate limitswitches,andmicrodrives.

10.Where“NA” isusedtonotethataninspectioncriteriondoesnotapplyduetoareasonother thanthecomponentorfeature is notonthe crane,orother thantheinspectionisnotrequiredduetothetypeofinspection(e.g.,a “B” inspectionitemduringan“A” inspection),the reasonfor the“NA” shall beenteredonthe“Remarks” sheet.

For example, ifan“NA” isenteredin theelectricmagneticbrakesystembrakelininginspectioncriterion(item27abelowthedashedline)duetothe cranehaving holdingbrakesandthisnotbeing thesecond“C” inspection,thesefactsshall benotedonthe“Remarks” sheet.

11.Itemsmarkedwithalowercasesigma(cr)aftertheitemnumbermaybeinspectedbyamechanicor electricianinlieuofaninspector.

MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET1__OF
Crane / Type / OEM / Capacity
PriorInspection / CurrentInspection / Legend:Checkundercondition
S=SatisfactoryC = Corrected(Ifdeferred, leaveblank
andidentifyonUnsatisfactoryItems sheet.)
U = Unsatisfactory NA = Not Applicable
DATE/HOURS / TYPE / DATE/HOURS / TYPE
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
1 / X / X / X / CoolingSystem(Hoses,Thermostat,Pump,Radiator) / Inspecthosesforcracks,clampsforevidenceoflooseness,andentiresystemforleaks.Inspectforpropercoolantlevel,color,abnormal particles,andclarity.Duringoperation,inspectforleaksandverifypropershutteroperation.Inspectforproperenginecoolanttemperature.Listenforabnormalnoiseoriginatingfromthewaterpumpandinspectforleakingseals.
X / X / Inspectforpropercoolantfreezeprotection.Inspectradiatorfanfordamage.
2 / X / X / X / LubeOilLinesandLubePressure / Inspectforevidenceoflooseconnections,leakage,ordamage.Duringoperation,inspectforleaks.Inspectgaugeforproperlubeoilpressure.
3cr / X / X / X / FuelLinesandFuelPressure / Inspectforevidenceoflooseconnections, leakage,ordamage.Duringoperation,inspectforleaks.Verifyproperoperationofthefuelpump andfuelpressuregaugeandinspectfuelpressure.
cr
4 / X / Starter / Inspectfordamagedordeterioratedwiring,evidenceoflooseconnections,andproperlubrication.Operatestarterandlistenforabnormalnoiseandverifyproperoperation.
5cr / X / X / AirStartingLines / Inspectforevidenceoflooseconnectionsanddamage.Whenlinesarecharged,inspectforleaks.Inspectlubricatorsforlubricationlevelandleakage.
6cr / X / X / DriveBelts / Inspectdrivebeltsonfan,waterpump,oilpumps,alternator,andexternalfueltransferpumpsfortensionandwear.
7cr / X / X / EngineAlternator/Generator(BatteryChargingSystem) / InspectforcleanlinessandproperlubricationInspectexternalwiringfordamage,deterioration,oroilorgreasecontamination,andforevidenceoflooseconnections.Duringoperation,inspectforrubbing,vibration,andsparking.Listenforabnormalnoise.Verifythatalternator/generatorisproperlychargingbatteries.
8cr / X / X / BatteryandCables / Inspectbatteryforproperelectrolytelevel,cleanliness,structuraldistortion,damagedracks/holders,andevidenceoflooseterminals.Inspectbatterycablesfordamageor deterioration,andforevidenceoflooseconnections.
9cr / X / X / VoltageRegulator(BatteryChargingSystem) / Inspectforevidenceoflooseordamagedwiresandconnections.Duringoperation,verifyregulatorcyclesanddoesnotoverchargebatteries.
10cr / X / X / EngineWiring / Inspectwiringtolights,warningdevices,andmeterconnectionsfordamageordeterioration,andforevidenceoflooseconnections.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET2__OF
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
11cr / X / X / Gauges(Oil,Fuel,Temp,Ammeter,Tachometer,etc.) / Inspectforidentification,legibility,andcondition.Inspectforevidenceoflooseelectrical ormechanicalconnections.Verifyoperation(calibrationnotrequired).
12 / X / X / Turbocharger / Inspectforevidenceoflooseormissingmountingboltsandparts.Duringoperation,inspectforvibrationandoilleaks.Listenforabnormalnoise.
13 / X / X / Governor / Inspectlinkageforevidenceofbinding, looseness,anddamagedparts.Inspectforproperoillevel.Verifyproper operation.
14cr / X / X / X / FuelFilters / Inspectforleakspriortoandduringoperation.
15cr / X / X / X / AirCleaner / Inspectmountingbracketsforevidenceoflooseormissingfasteners.Inspectforproperoillevelandconditionoffilterelementorvacuumindicator.
16cr / X / X / ThrottleLinkage / Inspectforevidenceoflooseanddamagedcomponents.Verifyproperoperation.
17 / X / X / Clutch-MainDrive / Inspectlinkagefordamage,forevidenceofbinding,looseandworncomponents,andforproperlubricationandadjustment.Duringoperation,inspectforslippageandevidenceofbinding.Listenforabnormalnoise.
X / At everysecond"C"inspection,disassembleandinspectallinternalcomponents.Note:Thisitemappliestofriction-typecranes;itdoesnotapplytochassisdriveclutches.
18cr / X / X / ExhaustSystem / Inspectforholes,fordamagedgaskets,forevidenceoflooseormissingfasteners,andforproperinsulation.Duringoperation,inspectforleaksandsparks.Listenforabnormalnoise.
19 / X / X / X / EngineCondition / Duringoperation,inspectforexcessivesmokingandvibration.Listenforabnormalnoise.FollowmainandorauxiliaryengineOEMguidelinesforspecificadditionalinspectionitems.
20 / X / X / EngineAlarmSafetyDevices / Inspectwiringfordamageordeterioration,andforevidenceoflooseconnections.
20a / X / EngineAlarmSafetyDevices(notapplicabletoauxiliaryormobilecraneengines) / Verifyproperoperationofengineoverspeed, oilsystem,andwatersystemshutdownand/oralarmsystemsbytestingwithsensorsinstalledwherepractical.Ifsensorremovalisnecessaryforshoptestingorcalibration,reinstallationandinspectionshallbepercontrolledproceduresapprovedbytheactivityengineeringorganization.
21 / X / HeatExchanger / Inspectforoilandwaterleaks,andforevidenceoflooseormissingfasteners.Duringoperation,verifyoperationoftemperaturegauges.
22cr / X / FuelTank / Inspectfueltankforleaks,forconditionofgauge,andforevidenceoflooseormissingfasteners.Inspectfuelstrainersandfilters.Inspectforproperventing.Inspectforvisiblecorrosionandevidenceofcorrosionbelowfuellevel anddebrisinfuel.
23 / X / X / X / Clutches(Boom,Hoist,Swing,andTravel) / Inspectclutchlinkagefordamage,forevidenceofbindingandlooseorworncomponents,andforproperlubricationandadjustment.Inspectclutchliningsforwear, de-bonding, andglazing,anddrumsforsmoothnessandforevidenceofoverheating.Duringoperation,inspectforslippageandevidenceofbinding.Listenforabnormalnoise.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET3__OF
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
24 / X / X / X / MechanicalBrakes / Inspectsystemfordamage,forevidenceofbinding,loose,andworncomponents,andforproperlubrication.Inspectbrakeliningsforwear,anddrumsforsmoothnessandforevidenceofoverheating.Inspectbrakesforpropersettingsandforalignmentofbrakeshoes.Duringoperation,verifyproperrelease,engagement,andstoppingactioninbothdirectionsofmotion.
Inspectforevidenceofoverheating.
X / X / BrakeLinings / Disassembleasrequiredtoinspectbrakeliningsforwear,de-bonding,andglazing.Forhoistbrakesthatstopthemovementoftheloadundernormaloperationconditions,thisshallbedoneannually.Forotherhoistbrakes(i.e.,holdingbrakes)andforrotateandtravelbrakes (includingchassistravelbrakes),disassembleasrequiredateverysecond“C”inspection.
25 a / X / X / X / HydraulicBrakeSystem(Shoe,Caliper/Disc,andBandTypeBrakes) / Inspectsystemfordamage,forevidenceofbinding,loose,andworncomponents,andforproperlubrication.Inspectbrakeliningsforwear,anddrumsorrotorsforsmoothness,andforevidenceofoverheating.Inspectbrakesforpropersettingsandforalignmentofbrakeshoes, calipers,andbands.Inspectmastercylindersforproperhydraulicbrakefluidlevel.Inspectlinesfordamageorleakage,andforevidenceoflooseconnections.Duringoperation,verifyproperrelease,engagement,andstoppingactioninbothdirectionsofmotion.Inspectforevidenceofoverheating.(Notapplicabletointernaldiscbrakesonmobileandfloatingcranehoistandrotateassemblies.)
X / X / BrakeLinings / Disassembleasrequiredtoinspectbrakeliningsforwear,de-bonding,andglazing.Forhoistbrakesthatstopthemovementoftheloadundernormaloperationconditions,thisshallbedoneannually.Forotherhoistbrakes(i.e.,holdingbrakes)andforrotateandtravelbrakes(includingchassistravelbrakes),disassembleasrequiredateverysecond“C”inspection. (Notapplicabletointernaldiscbrakes onmobileandfloatingcranehoistandrotateassemblies.)
25 b / X / X / X / HydraulicBrakeSystem(CaliperBrakesonWireRopeDrums) / Inspectsystemfordamage,forevidenceofbinding,loose,andworncomponents,andforproperlubrication.Inspectbrakeliningsforwear,andbrakingsurfacesforsmoothnessandforevidenceofoverheating.Inspectbrakesforpropersettingsandforalignmentofcalipers.Inspectforproperhydraulicbrakefluidlevel.Inspectsystem(pumps,accumulator,gauges,andlines)fordamageorleakage,andforevidenceoflooseconnections.Duringoperation,verifyproperreleaseandengagementandstoppingactioninbothdirectionsofmotionandtimingof releaseandengagement.ForbrakeswithBellevilletorquesprings,recordthenumberofcyclesasshownonthebrakecyclecounter.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET4__OF
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
25 bcont / X / X / HydraulicBrakeSystem(CaliperBrakesonWireRopeDrums) / Comparethetotalnumberofcyclesappliedtoeachbrakeactuator'sBellevillespringstotheallowablemaximumnumberofcyclesspecifiedforthatactuatorandensurethatnoneofthespringshaveexceededthemaximum value.RecordBellevillespringcyclelimitandnumberofcyclesintheequipmenthistoryfile.(Forbrakeswithoutcyclecounters,theactivityshallconservativelyestimatethebrakeusageandensurethatthespringsarereplacedbeforetheirfatiguelifeisreached.)
25bcont / X / X / BrakeLinings / Disassembleasrequiredtoinspectbrakeliningsforwear,de-bonding,andglazing.Forbrakesthatstopthemovementoftheloadundernormaloperatingconditions,disassembly,asrequired,shallbedoneannually.Forotherbrakes(e.g.,holdingbrakes),disassembleasrequiredateverysecond“C”inspection.
26 / X / X / X / AirBrakeSystem / Inspectsystemfordamage,forevidenceof binding,loose,andworncomponents,andforproperlubrication.Inspectbrakeliningsanddiscsforwear,anddrumsorrotorsforsmoothnessandforevidenceofoverheating.Inspectbrakesforpropersettings,andforalignmentofshoes,calipers,andbands.Inspectairlinesfordamageandevidenceoflooseconnections.Duringoperation,verifyproperrelease,engagement,andstoppingactioninbothdirectionsofmotion.Verifyproperoperationoftheairapplicationvalvesandinspectairapplicationvalvesandairlinesforleaks.
X / X / BrakeLinings / Disassembleasrequiredtoinspectbrakeliningsforwear,de-bonding,andglazing.Forhoistbrakesthatstopthemovementoftheloadundernormaloperationconditions,thisshallbedoneannually.Forotherhoistbrakes(i.e.,holdingbrakes)andforrotateandtravelbrakes (includingchassistravelbrakes),disassembleasrequiredateverysecond“C”inspection.
27a / X / X / X / ElectricMagneticBrakeSystem(ShoeTypeBrakesincludingThrusterBrakes) / Inspectsystemfordamage,evidenceofbinding,loose,worncomponents,andproper lubrication.Inspectbrakeliningsforwear,anddrumsforsmoothnessandforevidenceofoverheating.
Inspectbrakesforpropersettingsandforalignmentofbrakeshoes.Inspectwiringfordamageordeterioration,andforevidenceoflooseconnections.Duringoperation,inspectforproperrelease,engagement,andstoppingactioninbothdirectionsofmotionandtimingofreleaseandengagement.Inspectforevidenceofoverheatingorotherevidenceofincompletebrakerelease.
Forthrusterbrakes,checkhydraulicthrusteractuatorreservoirforfluidlevelandleakage.
X / X / BrakeLinings / Disassembleasrequiredtoinspectbrakeliningsforwear,de-bonding,andglazing.Forhoistbrakesthatstopthemovementoftheloadundernormaloperationconditions,thisshallbedoneannually.Forotherhoistbrakes(i.e.,holdingbrakes)andforrotateandtravelbrakes,disassembleasrequiredateverysecond“C”inspection.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET5__OF
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
27 b / X / X / X / ElectricMagneticBrakeSystem (DiscTypeBrakes) / Inspectbrakehousingsfordamageorevidenceofloosehardware. Inspectbrakesforpropersettings. Duringoperation,verifyproperrelease,engagement,alignmentofcomponents, andstoppingaction inbothdirectionsof motionandtimingofreleaseandengagement. Inspectforvibrationandoverheating. Listenforabnormalnoise.
X / X / InternalBrakeComponents / Disassembleasrequiredtoinspectbrakeliningsforwear,debonding,alignmentofcomponents,orglazingorfordamagedbrakediscs,splines,orotherinternalcomponents.Forhoistbrakesthatstopthemovementoftheloadundernormaloperationconditions,thisshallbedoneannually.Forotherhoistbrakes(i.e.,holdingbrakes)andforrotateandtravelbrakes,disassembleasrequiredateverysecond“C”inspection.
28 / X / X / Shafts andCouplings,includingcouplingsintegraltomotor/speedreducerassemblies. / Inspectfordamage,forleakingseals,andforevidenceofloosekeys,couplingbolts,andcovers.Duringoperation,inspectforvibrationandotherevidenceofmisalignmentordamagedcomponents.Listenforabnormalnoise.Inspectforevidenceofbearingdamage,overheating,andabnormalwear.Inspectpillowblocksfordamage,payingspecialattentiontopossiblecracksincastironpillowblocksloadedinshearandtension,looseormissingfasteners,andcrackscausedbyovertensionedfasteners.
X / Boom,Hoist,andSingleRotateDrives / VerifycouplingalignmentsarewithinOEMtolerancesat everysecond"C"inspection (notapplicabletoNEMAc,d,andp-facemotors).Couplingalignmentverificationdatashallbefiledintheequipmenthistoryfile.
29 a / X / X / Gearing(Boom,Hoist,Rotate,Travel)ExternalGears / Inspectfordamagedorworngears,forevidenceofmisalignmentorloosekeysorfasteners,andforproperlubrication.Duringoperation,listenforabnormalnoise,andinspectforotherevidenceofpossibledamage.Inspectpillowblocksfordamage,payingspecialattentiontopossible cracksincastironpillowblocksloadedinshear andtension,looseormissingfasteners,and crackscausedbyover-tensionedfasteners.
29 b / X / X / Gearing(Boom,Hoist,Rotate,Travel)InternalGears / Inspectforpropergearcaselubricantlevel,leaks,andevidenceoflooseormissingmountingfasteners.Inspectbreathersforrestrictions. Duringoperation,inspect forvibration,overheating,andotherevidenceofdamagedinternal componentsormisalignment.Listenforabnormal noise. Inspectforevidenceofbearingdamage,overheating,andabnormalwear.
29 c / X / X / InternalGears,Boom,Hoist,andSingleRotateDrives.(Notapplicabletohydraulicmobilecranes.) / Monitorusinganoilorvibrationanalysisprogram.Theoilorvibrationanalysisshallbeperformedatleastonceeachcertificationperiodwithresultsanalyzedbyaqualifiedsource.Theresultsoftheanalysisshallbedocumentedandretainedintheequipmenthistoryfileforthelifeofthecomponent.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET6__OF
Crane:
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
29 ccont / X / InternalGears,Boom,Hoist,andSingleRotateDrives-Alternate.(Notapplicabletohydraulicmobilecranes.) / Asanalternativetooilorvibrationanalysis, internalgearsshallbevisuallyinspectedfor wearordamageandforevidenceofmisalignment.Ifallgearscannot bevisuallyinspectedthroughinspectionportsorbyvideoprobeorsimilarinspectiondevices,thegearcasesshallbedisassembledforvisualinspection.Ifthisalternativeisselected,performinspectionsat everythird"C"inspection.Documenttheresultsinequipmenthistoryfile.
29 d / X / X / HydraulicMobileCraneHoistandRotateDrives(AlsoseeItem#35a) / FollowOEMserviceguidelinesfordisassembly,inspection,andreplacementand/orrepairofinternalcomponentssuchasgears,clutches,internalbrakecomponents,splinecouplings, etc.DocumentOEMinspection/replacementintervalandcraneageinhistoryfiles.Note:UsethisitemforWestmontfloatingcrane(YD)hydraulicrotatedrivesandbrakes.
30 / X / ChainsandSprockets / Inspectchainsforpropertension,lubrication,andforevidenceoflooseorwornlinksandpins.
Inspectsprocketsforwornordamagedteeth,forevidenceoflooseshaftsandkeys,andforproperlubrication.Duringoperation,listenforabnormalnoise.
31 / X / X / X / Pawls,Ratchets,andRotateLocks / Inspectforevidenceofloose,damaged,orworncomponents.Inspectoperatingsystemforevidenceof wornkeys,loosefasteners,andbrokensprings.Operatepawlsandrotatelocksandinspectforpropersetting.Verifylimitswitchandindicatorlightoperation.
32cr / X / X / AirCompressor / Inspectforcleanliness,forevidenceoflooseormissingmountingfasteners,forproperbelttensionandwear,andforconditionoffilters.Duringoperation,verifyproperoperationofunloadervalveandpressureswitch.Listenforabnormal noiseandinspectforvibration.
33 / X / X / X / PressureVesselInspectionCertificate / Verifythat pressurevesselinspectioncertificateisproperlypostedandcurrent.(SeeUFC3-430-07orappropriatedocumentfortestprocedure).
34 / X / X / AirControlSystem / Inspectvalves,cylinders,lines,regulators,andgaugesfordamageordeterioration,andforevidenceoflooseormissingfasteners.Duringoperation,inspectsystemforleaks,andverifyproperoperationofvalves,regulators,andgauges.Inspectcontrollersfordamagedorworn seals,bootsandguards.
35 / X / X / HydraulicSystem / Inspecthydraulicsystemcomponents,includingbutnotlimitedtomotors,pumps,valves,cylinders,swivels,axlelockoutdevices,coolers,lines,regulators,andgaugesfordamageordeterioration,andforevidenceoflooseormissingfasteners.Inspectreservoirforproperfluidlevel.Duringoperation,inspectsystemforleaks,andverifyproperoperationofmotors,brakes,pumps,valves,cylinders,areadefinitiondevices,axlelockouts,regulators,andgauges.Ensuremanualvalvesareproperlypositioned.Inspectcontrollersfordamagedorwornseals,bootsandguards.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET7__OF
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
35a / X / X / HoistHydraulicSystems(includingboom liftandtelescopingfunctions) / Monitorusinganoilanalysisprogram.Theoilanalysisshallbeperformedatleastonceeachcertificationperiodwithresultsanalyzedbyaqualifiedsource.Theresultsoftheanalysisshallbedocumentedandretainedintheequipmenthistoryfileforthelifeofthecomponent.EnsurehydraulicsystemfiltersarechangedinaccordancewithOEMrequirements.
36 / X / WheelsandAxles / Inspectwheelsforunevenwear,flatspots,chips,flangewear,andcracks,forevidenceoflooseormissingfastenersandbearingcaps,andforproperlubrication.Formobilecranewheels,performinspectionsinaccordancewithOEMrecommendations.Duringoperation,inspectforexcessivemovementbetweencomponents,impropertracking,overheating,andotherevidenceofcomponentwearorbearingdamage.Listenforabnormalnoise.
37 / X / X / X / MobileCraneChassis(Steering,andSuspension) / Inspectcomponentsfordamageordeterioration,andforevidenceoflooseormissingfastenersandcrackedwelds.Duringoperation,inspectforabnormalplayandotherevidenceofcomponentwear.Listenforabnormalnoise.
38 / X / X / X / Tires / Inspectforproperairpressure.Inspectfordamage,deterioration,orworntreads,andforevidenceoflooseormissingwheellugs.
39 / X / CrawlerSystem / Inspectcrawlertracksfordamagedorbrokentreads,missingorbrokenpins,forpropertrackadjustment,andforevidenceoflooseormissingfasteners.Inspectdrivesprocketsforbrokenteeth,wornidlersorrollers,damagedtrackadjustingscrews,damagedormissinglubricationfittings,andforproperlubrication.Duringoperation,inspectforabnormalplay,overheating,andotherevidenceofbearingdamageorcomponentwear.Listenforabnormalnoise.
40 / X / TravelTrucks,Equalizers,Gudgeons,GudgeonPins,andRetainers / Inspectfordamageordeterioration,forevidenceoflooseormissingfastenersandcrackedwelds,andforproperlubrication.Verifyproperoperation.
41 / X / X / X / OutriggerAssemblies / Inspectfordamageordeterioration,andforevidenceoflooseormissingfasteners.Duringoperation,inspectsystemforleaks,andverifyproperoperationofcylinders.Ensuredrainholesareclear.
42 / X / Structure(PortalBase,Boom(exceptmobilecraneboom),A-Frame,Tower,Stifflegs,Sills,SupportPins,Retainers,etc.) / Visuallyinspectstructuralcomponentsfordamaged,distorted,ordeterioratedmembersandforevidenceoflooseormissingfasteners andcrackedwelds.Inspectsupportpinsfor properlubrication.Fordamagedbooms,seesection6.Ensuredrainholesareclear.Thisinspectiondoesnotincludeinaccessibleareassuchasvoidsandcrawlspaces.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET8__OF
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
42
cont / X / Structure(PortalBase,Boom(exceptmobilecraneboom),A-Frame,Tower,Stifflegs,Sills,SupportPins,Retainers,etc.) / Inspectstructuralcomponentsfordamaged,distorted,ordeterioratedmembers(removewireropebufferblocksevery“C”inspectiontoensuretheyarenothidingboomcorrosion),andforevidenceof looseormissingfastenersandcrackedwelds. Inspectsupportpins forproperlubrication. Fordamagedbooms,seesection6.Ensuredrainholesareclear. Thisinspection isinmore detailandincludesusuallyinaccessibleareassuchasvoidsandcrawlspaces.
43 / X / X / MobileCraneBoom / Inspectboomstructurefordamaged,distorted,ordeterioratedmembers(removewireropebufferblockstoensuretheyarenothidingboomcorrosion),andforevidenceoflooseormissingfastenersandcrackedwelds.Inspectsupportpinsforproperlubrication.Fordamagedbooms,seesection6.Ensuredrainholesareclear.
43a / X / X / X / TelescopingBoom / Verifysmoothoperation,andinspectforproperlubricationandevidenceof abnormallywornorimproperlyadjustedwearpads.Ensuredrainholesareclear.
44 / X / X / Handrails,Walkways,Ladders,andPersonnelSafetyGuards / Inspectfordamageordeterioration,andforevidenceoflooseormissingfastenersandcrackedwelds.
45 / X / Counterweight / Inspectcounterweightandcounterweightsupportstructurefordamageordeterioration,andforevidenceoflooseormissingfasteners.Forconcretecounterweights,inspectforlooseormissingconcrete.
46 / X / RotatePathAssembly / Inspectspiderassemblyandrollerpathfor damageordeterioration,andforevidenceoflooseormissingfastenersandcrackedwelds.Inspectrollersforunevenwear,flatspots,chips,flangewear,cracks,ordeterioration,forevidenceoflooseormissingfasteners,andforproperlubrication.
Duringoperation,verifyfreerotationof rollersandinspectforevidenceofmisalignment.
47 / X / CenterPinSteadimentandSupportAssembly. / Inspectfordamagedordeterioratedcomponents,andforevidenceoflooseormissingfastenersandcrackedwelds.Inspectforproperlubrication.
48 / X / X / CenterCollectorAssembly(ElectricalorHydraulic) / Inspectforlooseorbentsupports.Inspectwiringfordamageordeterioration,andforevidenceoflooseconnections.Inspectforwornbrushesandproperspringtension.Inspectslipringsfordamage,deterioration,indicationsofexcessivewear,streaking,arcing/overheating,andpropercontact.Duringoperation,verifybrushtocollectorringalignment.Inspectforloosehydraulicconnections,defectivetubing,andleaks.Inspectforsignsofdamagedorwornbearingsandsmooth/properrotation.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET9__OF
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
49 / X / X / X / SlewingRingBearings / Lubricatebearingatevery“A”,“B”,and“C”inspectionunlessOEMrequiresmorefrequentlubrication.Bearingshouldberotatedwhileitislubricatedandrotated720degreesasaminimum.Inspectexpelledlubricantforevidenceofmetalflakesormetalorplasticparticles.
49a / X / X / SlewingRingBearings / Inspectfastenersforpropertightness.Forportalandfloatingcranes,measureandrecordinternalaxialclearance(thrustdirection)between bearingrollers(balls)andraces.RefertoOEM'sliteratureformethodandacceptance/rejectioncriteria.Formobilecranes,followOEMrecommendationsforbearingwearinspection.RCDRsonperiodicity,method,oracceptance/rejectioncriteriawillbeevaluatediftherequestingactivityobtainsinputandconcurrencefromthecraneandbearingOEM.(Iftightnessverifications orclearance/wearchecksareperformedbymaintenancepersonnel,theinspectorshall perform anin-processreviewonasamplebasis.)Duringoperation,listenforabnormalnoiseandinspectfor vibration.
49b / X / SlewingRingBearings / Inspectfastenersforpropertightness.Forcranesthathavehadaminimumofthreeconsecutivesatisfactoryfastenertightnessinspectionswithatorquewrench,tensioner,ultrasonictensionmeasuringdevice,orothermeasuringdevicethatmeasurestension,thefastenertightnessinspectionwithatorquewrench,tensioner,orultrasonictensionmeasuringdevicemaybeperformedatevery“C”inspectioninlieuof every“B”inspection.Avisualinspectionoftightnessshallstillbeperformedat every“B”inspection.Asatisfactorytightnessinspectionisdefinedasnomorethanoneloosefastenerinanyringoffastenersformobilecranes,ornomorethanfiveloosefastenersinanyringoffastenersforportalandfloatingcranes.AllloosefastenersdetectedusingthisoptionshallbereportedtotheNavyCraneCenter,Code03.Loosefastenersshallbeidentifiedbypermanentfastenernumber/locationoninnerorouterring.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET__10OF_
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
50 / X / WireRopeDrums,Followers,andMachineryFoundations / Inspectdrumsfordistortion,cracks,worngrooves,andforevidenceoflooseormissingfastenersandcrackedwelds.Inspectwireropefollowersforproperadjustmentandalignment.Inspectbearingsforevidenceofdamage,
overheating,orabnormal wear.Inspectmachineryfoundationsfordamagedordeterioratedcomponents,andforevidenceoflooseormissingfastenersandcrackedwelds.Duringoperation,verifythatatleasttwocompletewrapsof wireroperemainongrooveddrums(atleastthreecompletewrapsonungrooveddrums)inalloperatingconditions,includingextremesofhookorboompositions.Listenforabnormalnoise.Inspectforvibration,overheating,andotherevidenceofcomponentwear,bearingdamage,ormisalignment.Inspectpillowblocksfordamage,payingspecialattentiontopossiblecracksincastironpillowblocksloadedinshearandtension,looseormissingfasteners,andcrackscausedbyovertensionedfasteners.
51 / X / X / Sheaves,EqualizerBar / Inspectforabnormallywornorcorrugatedgrooves,flatspots,abnormalplay,andbrokenorcrackedflangesinsheaves.Inspectforevidenceoflooseormissingfasteners,keepers,andlubricationfittings.Gagethewireropegroovesof all sheaves.Payparticularattentiontosectionsofequalizersheavesandsaddlesincontactwithwireropeandwherecorrosionmaydevelopbecauseofpoor drainage;thesesections ofequalizer sheavesandsaddlesshallbeexposedandexaminedduring“C”inspectionsforboomhoistsand“B”inspectionsforallotherhoists.Duringoperation,verifyfreemovementofallsheaves.
Listenforabnormalnoise.Inspectfor abnormalplay,overheating,andotherevidenceofcomponentwearorbearingdamage.Forpolymer(plastic)sheaves,inspectforproperadjustmentofsheavebearings(usingOEMbearingspecifications),inspectsheavesforanysignsofabnormalplayorwobble,cracks,deformationofthesheavehub,web,orflange,orbearingworkingloosefromthesheavehub.Inspectequalizerbarfordamageordeterioratedcomponents.Ensurefreemovementandthatbardoesnotbottom outovertherangeofhoist/boom operation.
Note:Inspectionof extend/retractsheavesinternaltotelescopingboomsmaybelimitedtoinspectionthroughboominspectionportsunlessthereisevidenceofdeteriorationordamagerequiringdisassemblyof boomforcompleteinspectionorreplacement.Forcraneswithoutinspectionports,thisNotemaybeutilizedifthe extend/retractcables,sheaves,andcableendconnectionscanbevisuallyinspectedfrom eitherendoftheboom.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET11OF_
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
52 / X / X / WireRope,Fastenings,andTerminalHardware.Seenextpageforwireroperejectioncriteria. / Thoroughlyinspecttheentirelengthof runningropesandstandingropes.Thedepthanddetailoftheinspectionshallbethatnecessarytoensurethattheentireropeisacceptablewithspecialattentionpaidtoareasofexpectedwearordamage,areasnotnormallyvisibletotheoperatorduringoperationorpre-usecheck,androtation-resistantrope.During theinspection,paythewireropeoutasfaraspossible.Forsectionsthatcannotbespooledoffthedrum,visualinspectionofthewireropeonthedrum issufficient.Whereitisnotpossibletopayouttothelowestlayer,thecraneshall notbeusedforapplicationswheretheuninspectedrope (i.e., coveredlayers)wouldbespooledoffthedrumunderload.Thefirstlayerof wireropeshallbeproperlyreinstalledonthedrumtoprovideadequatesupportfortheupperlayers.Removewireropedressing fromselectedareasexposedtosignificantwear,exposure,andabuse.Diametermeasurementsshallbetakenatseveralplacesoverthelengthoftherope.Recordminimumdimensionmeasuredinthe“remarks”block.Payparticularattentiontosections incontactwithequalizersheavesandsaddlesorwherecorrosionmaydevelopbecauseofpoordrainage;thesesectionsshallbeexposedandexaminedduring“C”inspectionsforboomhoistsand“B”inspectionsforallotherhoists.Inspectwearblockstoensureropeisnotcontactingstructure.
Lubricateareasafterinspection.
Inspectfordefectsnotedbelowandforproperlubrication.Inspectpouredsockets,wedgesockets,swagefittings,eyes,swivels,trunnions,andfastenersforunduelooseness,wear,cracks,corrosion,andotherdamage.Aspecialareatoinspectisthebase(lugorbail)toshanktransitionareaforswagedsockets.Undueloosenessinpouredsocketsisdefinedaslooseness orevidenceofslippageofwiresinthesecuringmaterial,evidenceofdeteriorationofthesecuringmaterial,loosenessofwireropestrandsorwiresadjacenttothesocketorany loosenessresultingfromcracksorotherdefectsinthebasket.Evidenceofloosenessbetweenthesecuringmaterialandthebasketresultingsolelyfromseatingofthematerialinthebasketisacceptable.Drum end fittingsneedonlybedisconnectedordisassembledwhenexperienceorvisibleindicationsdeemitnecessary.
Note:Inspectionof extend/retractcablesinternaltotelescopingboomsmaybelimitedtoinspectionthroughboominspectionportsinlieuofOEMrequiredboom disassembly,unlessthereisevidenceofdeteriorationordamagerequiringdisassemblyofboomforcompleteinspectionorreplacement.Forcraneswithoutinspectionports,thisNotemaybeutilizediftheextend/retractcables,sheaves,andcableendconnectionscanbevisuallyinspectedfromeitherendoftheboom.Additionally,performmeasurement/adjustmenttoextend/retractcabletension/slackinaccordancewithOEMinstructions.

WireRope RejectionCriteria.Removedamagedportions(orreplaceentirelength,ifnecessary)if anyof thefollowingarefound:

1.Kinked,Birdcaged,Doglegged,orCrushedSections.Kinked,birdcaged,doglegged,orcrushedropeinstraight runswhere thecoreismissingorprotrudesthroughor between strands, orwhere therope doesnotfitproperlyinsheaveordrumgrooves.(Thisdoesnotapplytorunsaroundeyes,thimbles,orshackles.).

2.FlattenedSections.Flattenedsectionswherethediameteracrosstheflatislessthan5/6ofnominaldiameter.(Thisdoesnotapplytorunsaroundeyes,thimbles,andshackles.)

3.BrokenWires

a.Running Ropes.Sixrandomlydistributedbrokenwiresinonelayorthreebrokenwiresinonestrandinonelay.Forrotation-resistantwirerope,twoinalengthequaltosixtimestheropediameterorfourinalengthequalto30timestheropediameter.Oneouterwirebrokenatthepointofcontactwiththecoreoftheropethathasworkeditswayoutoftheropestructureandprotrudesorloops outfromtheropestructure("valleybreak").Forendconnections,two brokenwireswithinonelaylengthoftheendconnection.

b.Standing,Guy,andBoomPendantRopes.Threebrokenwiresinonelaylengthinsectionsbeyondendconnectionortwobrokenwireswithinonelaylengthoftheendconnection.

4.LossinDiameter.Reductionfromnominaldiameterofmorethanfivepercent.

5.HighorLowStrand.Highorlowstrandwheretheheightordepthexceedsone-halfthestranddiameter.

6.Corrosion.Corrosionsuchthatsignificantpittingoccursonthesurfacesofoutsidewiresandobvioussignsofinternalcorrosion,suchasmagneticdebriscomingfromthevalleys.Minorsurfaceroughnessonoutsidewiresisacceptableprovidednosignificantpittingoccursandtheropeisnotcorrodedinternally.Significantpittingisdefinedaspittingthatcannotberemovedbyabrasiveremovaloflessthan1/3oftheoriginaldiameterofindividualoutsidewires.

7.HeatDamage.Evidenceofheatdamagefromanycause.

8.WavyRope.Wavyrope(wherethelongitudinalaxisofthewireropetakestheshapeofahelixinsteadofaline)whenthediameteroftheenvelopeofthewaveisgreaterthan110percentofthediameterofthenominaldiameterofthewirerope(133percentinstraightsectionswheretheropedoesnotpassoversheavesorthedrum).UseISO4309asaguide.

9.AccumulationofDefects.Anaccumulationofdefectsthatinthejudgmentoftheinspectorcreatesanunsafecondition.

10.Splices.Wireropeshallnotcontainsplices.

Note:Forthosesectionsofwireropewithhighstrands,wavy,orflattenedrope,considerationshouldbegiventoincreasingtheinspectionperiodicityduetothepossibilityofincreasedwearandreeving/spoolingissues.

MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET__12OF_
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
53 / X / X / X / HoistBlocksandHooks / Inspecthoistblocks,cheekplates,swivels,trunnions,andlubricationfittingsfordamageordeterioration,cleanliness,freedomofmovement,andforevidenceoflooseormissingfasteners.Inspectforloose,damaged,missing,orimproperlysizedretainingrings.Inspecthooksandmousingdevicesfordamage.Inspectdrippansandgasketsfordamage,properclearance,andforevidenceoflooseormissingfasteners.Inspectforevidenceofbearingdamage,overheating,andabnormalwear.SeeappendixEforfurtherinspectionsandtests.
54 / X / X / X / InsulatedLink / Inspectlinksurfaceforconductivecontaminantssuchasgraphite,grease,metallicparticles,orruststreaks.Inspectfordamage.SeeappendixEforfurtherinspectionsandtests.
55cr / X / X / MachineryHouse andOperator'sCab / Inspectforleaks,brokenglass,deterioration,andcleanliness.Verifyproperoperationoflouvers,doors,windows,windshieldwipers,heaters(particularlycombustionheaters),airconditioners,operator'schair,andcommunication equipment.
56 / X / X / LoadWarningDevices,LoadShutdownDevices / Inspectwiringfordamageordeterioration,andforevidenceoflooseconnections.ThesedevicesshallbetestedforproperoperationatthisinspectionortheCCIR/loadtest (markN/AandexplaininRemarksifperformedattheCCIR/loadtest).UseSAEJ-159asaguideforcalibrationchecksfor(testingandtolerance)ofcategory1 and4mobilecranes.Forothercranes,ifnotspecifiedbydeviceOEM,thepreferredaccuracyrequirementforalldevicesistowarnorshutdownatthesetpointminus10percentoftheactualweightatthesetpoint.Donottestbeyond125percentofratedcapacity(105percentformobilecranes,mobileboathoists,andrubber-tiredgantrycranes).IfSAEguidelinesorpreferredaccuracyrequirementcannotbemet,theminimumaccuracyrequirementistowarnorshutdownatthesetpointplus5percentminus10percentoftheactualweightatthesetpoint. Testingshall ensuretheoverloadwarningorshutdownworksproperlytowarnorprevent anoverloadanddoesnotengageatanuisancelowlevel.Testingvalueswilldependontest weightavailabilityandis notrequiredtoproveexacttolerancesspecified above.
56a / X / X / LoadIndicators / Inspectwiringfordamageordeterioration,andforevidenceoflooseconnections.ThesedevicesshallbetestedforproperoperationatthisinspectionortheCCIR/loadtest (markN/AandexplaininRemarksifperformedattheCCIR/loadtest).UseSAEJ-159asaguideforcalibrationchecksfor(testingandtolerance)ofcategory1 and4mobilecranes.Forothercranes,ifnotspecifiedbydeviceOEM,thepreferredaccuracyrequirementforalldevicesisplus10percent minus0percentoftheactualweight.Donottestbeyond125percentof ratedcapacity(100percentformobilecranes,mobileboathoists,andrubber-tiredgantrycranes).IfSAEguidelinesorpreferredaccuracyrequirementcannotbemet,theminimumaccuracyrequirementisplus10percentminus5percentoftheactualweight.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET13OF_
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
57cr / X / X / DrumRotationIndicators / Inspectwiringfordamageordeterioration,andforevidenceoflooseconnections.Verifyproperoperation.
58 / X / X / Radius/BoomAngleIndicator / Verifyradiusindicationsbycomparingagainstmeasuredradii attheminimumandmaximumboom operatingpositions.Verifyboom angleindicationsbycomparingtheindicatedboom angletotheboomangleontheloadchartcorrespondingtotheboomlengthandmeasuredradius.Thistestshallbeaccomplishedattheminimum andmaximumboomoperatingpositions.ThismaybeperformedduringtheCCIR/loadtestinlieuofthisinspection(markN/AandexplaininRemarksifperformedattheCCIR/loadtest). UseSAEJ-159asaguideforcalibrationchecks(testingandtolerance)ofapplicablesystems. Forothercranes,ifnotspecifiedbythecraneofradiusindicator/boomangleindicatorOEM,the preferredaccuracyrequirementsareplus10percentminus 0percentoftheactualradius(orequivalentboomangle).Forallindicators,iftheSAEguidelinesorpreferredaccuracyrequirementscannotbemet,theminimumaccuracyrequirementsareplus10percentminus3percentoftheactual radius(orequivalentboom angle).
59 / X / X / X / CapacitySignsandLoadRatings / Inspectcapacitysignsandbracketsfordamageordeterioration,andforevidenceoflooseormissingfasteners.Verifythatloadratingsarecorrect,arenotedinpounds,andarevisibleorotherwiseavailabletotheoperatorandriggers.
60cr / X / X / X / FireExtinguishers / Verifyinspectioniscurrent.
61 / X / X / Controllers / Inspectforbrokenorloosesprings,crackedorlooseoperatinglevers,andpittedorburnedcontactpointsandsegments.Inspectforbrokensegmentdividersandinsulators,forexcessivearcing,forevidenceof wornorloosecams,pins,rollers,orchains,andforevidenceoflooseconnections.Inspectforpropercontactpressure.Inspectwiringfordamageordeterioration,andforevidenceoflooseconnections.Inspectforidentifyinglabelplatesandindicators,andthatcraneandcontrollerhorizontaldirectionindicatorsmatch.Inspectsuchpartsasbearings,starwheels,andpawlsforproperlubrication.Inspectforproperspringreturnandneutrallatching.
Inspectfordamagedorwornseals,bootsandguards.Duringoperation,verify propersequencingofspeedpointsandoperationofcontrollerindicatinglightsanddeadmanswitches.Forcranesthatutilizesecondaryorbackupcontrollers,all controllersshallbeoperationallytestedduringeitherthis inspectionortheCCIR/test. If performedat the CCIR/test, notethis in Remarks.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET14_OF
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
62 / X / X / ControlPanels,Relays, Coils,TransferandDisconnectSwitches,ConductorsandElectronic(SolidState)Drive ControlSystems / Inspect(withoutremoving)contacts forproperalignment,pitting,andevidenceofexcessheatingandarcing.Inspecttransferanddisconnectswitches,conductors,coilsandcontactleads,andshuntsforinsulationbreakdown,missing hardware,andevidenceof overheating.Inspectwiringfordamage,deterioration,andevidenceoflooseconnections.Inspectfusesforproperratingsandtype(seenote1regardingdisassembly),andforevidenceoflooseconnectionsandoverheating.Inspectoverloaddevicesforevidenceoflooseconnectionsandoverheating.Inspectcircuitbreakersandswitchesforcleanliness,loosebrokenwornormissingparts,andproperoperation.Inspectpanelboardsandarcshields forcracks,evidenceoflooseormissingfasteners,cleanliness,andmoisture.Manuallyoperaterelays,switches,contactors,andinterlocksandverifythatallmovingpartsoperatefreelywithoutbindingorexcessiveplay.Inspectenclosuresforcleanlinessordamage,andforevidenceoflooseormissingfastenersandgaskets.Duringoperation,verifyproperoperationofpanelindicatinglightsandcontactorsequence.Verifyproperoperationofenvironmentalcontrols(e.g.,stripheaters,coolingfans).
Inspecttheelectronic(solidstate)drivecontrolsystemswiringfordamageordeterioration,andforevidenceoflooseconnections.Visuallyinspect(withoutremoving)componentsforevidenceofdamageoroverheating.Verifythatthedriveis dryandfreeofdust,dirt,anddebris.Ifapplicable/possible,inspectconditionoforreplacedrivebackupbatteries.
X / Verifythattheswitchmechanism and/orhandleondisconnectsandsafetyswitchescannotbemovedtotheenergizedoronpositionwhenlockedinthede-energizedoroffpositionandthatthehandleproperlyindicateswhethertheswitchis energizedor de-energized.
63 / X / X / Resistors / Inspectresistors,insulators,andbracketsfordamage,distortion,deterioration,andforevidenceoflooseormissingfastenersor overheating.
Inspectwiringfordamageordeterioration,andforevidenceoflooseconnections.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET15_OF
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
64 / X / X / Limit andBypassSwitches / Removecoversandinspectelectricalandmechanicalcomponentsandwiringfordamageordeterioration,andforevidenceoflooseconnections.Inspectenclosuresforevidenceofmoistureandarcing.Inspectdriveandactuatingcomponentsfordamageordeterioration,forproperlubrication,andforevidenceoflooseormissingfasteners.Duringoperation,verifyproperfunctioningofprimaryandsecondarylimitswitches,indicatorlights,settings,andbypassswitches.Ensureproperfunctioningandsettingof secondaryhoist limit switchesbyusingblock(orboom)to engagelimit switchandensureblockorboomdoesnot two-block. This shall beperformedanddocumentedatleastonceduringthelifeofthecrane(orlimit switch)andre-performedif thesettingis affectedorchanged.Beforeperforming,ensureswitchisfunctioningproperlyelectricallyandstationwatch-stander topreventdamage.Checkelectrical functionannuallybyusinghandorothermeanstoactivatetheswitch. Checkelectricalfunctionannuallyatthisinspection,CCIR,orAppendixEno-loadtest byusinghandorothermeanstoactivatetheswitch.Ifproperoperationofsecondaryupperlimitswitchand/orlowerlimitswitchisperformedattheCCIRorAppendixEno-loadtest,notethisinRemarks.
65 / X / X / X / WarningDevices,OperationalAids,GeneralSafetyDevices(Horns,Bells,Lights,Reflectors,etc.),WindSeedIndicators / Inspectcomponentsandassociatedwiringfordamageordeterioration,andforevidenceoflooseconnections.Theactivityengineering organizationmayreducethefrequencyofopeningenclosuresbasedontheirexposuretoweatherand pastfindings.Thereducedfrequencyshallbenolessfrequentthaneverysixthannualinspection.
Duringoperation,verifyproperfunctioningofdevices.Verifyproperfunctioningof windspeedindicator.
66cr / X / X / ElectricalHardwareandGeneralLighting / Inspectconduits,raceways,junctionboxes,lightfixtures,andassociatedwiringfordamageordeterioration,andforevidenceoflooseconnections.Verifyoperationoflights.Theactivityengineeringorganizationmayreducethefrequencyofopeningenclosuresbasedontheirexposuretoweatherorbasedonpastfindings.Thereducedfrequencyshallbenoless frequentthana“C”frequency.
67 / X / X / ElectricalCableReels / Inspectwiringfordamageordeterioration,andforevidenceoflooseconnections.Inspectreelassemblyfordamage,deterioration,andevidenceoflooseormissingfasteners.Inspectslipringsfordamage,deterioration,indicationsofexcessivewear,streaking,arcing/overheating,andpropercontact.Verifyproper operation.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET__16_OF
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
68 / X / X / Main andAuxiliaryGenerators. / Inspectgeneratorsandassociatedwiringforcleanliness,damage,deterioration,andevidenceoflooseconnections.Inspectforproperlubrication.Inspectslipringsfor damage,deterioration,indicationsofexcessive wear,streaking,arcing/overheating,andpropercontact.Inspectcommutatorsforevidenceofdestructivecommutation.Inspectbrushesforproperbrushtensionandlength,andfordamageanddeterioration.Inspectinsulationfordeteriorationandevidenceofoverheating.
Inspectdrivebeltsorcouplingfordamagedeteriorationandevidenceofmisalignmentandlooseormissingfasteners.Duringoperation,inspectforvibration,overheating,orotherevidenceofmisaligned,worn,ordamagedinternalcomponentsorbearings.Listenforabnormalnoise.Verifypropervoltageoutput.Verifyproperoperationofenvironmentaldevices(e.g.,stripheaters,coolingfans).
69 / X / X / ElectricMotors(Boom, Hoist,Rotate, Travel) / Inspectmotors(includingaccessibleinternalareassuchas commutatorsandbrushes)andassociatedwiringforcleanliness,damage,deterioration,andevidenceoflooseconnections. Inspect forproperlubrication.
Inspectslipringsfordamage,deterioration,indicationsofexcessivewear,streaking,arcing/overheating,andpropercontact.Inspectcommutators forevidenceofdestructivecommutation. Inspectbrushesforproperbrushtensionandlength,andfordamageanddeterioration. Inspect insulation,fordeteriorationandevidenceofoverheating.
Duringoperation,inspect forvibration,overheating,otherevidenceof misaligned,worn,ordamagedinternal componentsorbearings.Listenforabnormalnoise. Verifyproperoperationofenvironmentaldevices,(e.g., striphearers,coolingfans).
Portal cranetravel motorsmaybeinspectedatthefollowingintervals:25percentateach“B”inspection,withtheremaining50percentatthe“C”inspection,unlessissuesarefoundatthe“B”inspectionthatindicatethatallmotorsshouldbeinspectedduringthe“B”inspection.
70 / X / X / X / OperationofCraneControls / Verifyproperoperationofall hoist,rotate,andtravelfunctions, primaryandsecondarylimitswitches,bypassswitches,indicatorlights,levelindicators,andsettings. SeeItem64foradditionalinstructionsduring“B”and“C”maintenanceinspections.
71 / X / X / BargeCompartments / Inspectcompartments(voids)forstandingwater.
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANES
SHEET__17_OF
Crane
ItemNo / InspectionType / Items to beInspected / MaintenanceInspectionSpecification / SystemInspected / Condition
A / B / C / S / U / C / NA
72 / X / X / Crane Davits / Inspectdavitstructureforproperoperationandanysigns ofdamage.Checkdavitropeforcuts,abnormalwear,heatdamage,ordiscoloration.Checktackleforfreemovementandoperation.Checkhookandtackleattachmentsforsignsofdamageandcorrosion.
73 / X / X / LubricationandServicingRecords / Performareviewoflubricationandservicingrecordssincethelastmaintenanceinspectiontoensurethelubricationandservicing wereperformedasspecified.
74 / X / X / OEMprovidedwarninglabels / EnsureOEM-suppliedwarninglabelsanddecalsarepresentandlegible.
REMARKS:
MAINTENANCE INSPECTION SPECIFICATIONAND RECORD FORCATEGORY 1AND 4CRANESUNSATISFACTORYITEMSSHEET OF
Crane
NOTE: DESCRIBE ITEMSFOUNDUNSATISFACTORY ANDLISTSRONUMBERISSUEDFORCORRECTIVE ACTION.SIGNANDDATE TOVERIFY THATTHEDEFICIENCYHASBEENCORRECTEDORACCEPTEDAS IS.IDENTIFY DEFERREDITEMSBY ANNOTATING A“D”INTHE SROBLOCK. (SEE SECTION 3 FORREQUIREMENTS FORDEFERRALOFWORK.)
ItemNo. / Deficiency / SRONo. / VerificationofCorrection(SignatureandDate)
Mechanical Inspector(Signature): / Date: / ElectricalInspector(Signature): / Date:
Mechanical Inspector(Signature): / Date: / ElectricalInspector(Signature): / Date:
Mechanic(Signature): / Date: / Electrician(Signature): / Date:

MAINTENANCEINSPECTIONSPECIFICATIONANDRECORDFORCATEGORY 1 AND 4CRANES
BRAKEDATASHEETOF
REMARKS: