CRANE MANUFACTURERSASSOCIATION OF AMERICA, INC. Standards and Guidelines for Professional Services DetformedOn Overhead and Traveling Cranes and Lscn~iatodHnicting Equipment Preparsd by The Cmne Manufacturers Senrice mrnrnittea of CMAA 78 &+;: ;,--. * ,. -8,L - l , tyq*y, ; . , # .. . CMAA Specification #78, Released 2002 , , . .&. vg~..:, ,'~~$>:&:g,~w&%~:,;".2+;;~i$@2; M a 1 ) s r n CMSC is a Standing Committee of the 1 1 1 1 Crane Manufacturers Association of America CRANEMANUFACTURERS SERVICE COMMITTEE OF CMAA CMAA Specification No. 78-2002 Standards and Guidelines for Professional Services Performed On Overhead Traveling Cranes and Associated Hoisting Equipment INTRODUCTION These Standards and Guidelines designated CMAA Specification No. 78-2002 (Specification) have been developed by the Crane Manufacturers Service Committee (CMSC) under the oversight of the Crane Manufacturers Association of America, Inc. (CMAA), an organization of leading electric overhead traveling crane manufacturers in the United States. The purpose is to recognize overhead traveling crane service and service for associated hoisting equipment as an "industry" worthy of having guidelines and standards for providing high quality, professional services performed by safety-minded, manufacturer-trainedand certified technicians. The Specification also contains information that should be helpful to the purchasers and users of cranes and to plant engineering and maintenance professionals. While much of this information must be of a general nature, the items listed may be checked with individual manufacturers, and comparisons may be made, leading to optimum selection of a service provider. The words "shall" and "should" are used throughout this Specification in accordance with the definitions in the ASME 830 standards as follows: Shall: this word indicates that a rule is mandatory and must be followed. Should: this word indicates that a rule is a recommendation, the advisability of which depends on the facts in each situation. This Specification consists of eight sections, as follows: General Information Technical Qualifications Jobsite Safety Crane Inspection, Maintenance and Load Testing OEM (Factory) Parts Crane Service Classifications Glossary Appendix Index No part of this Specification may be reproduced in any form without the prior written permission of the publisher. Copyright a 0 0 2 by Crane Manufacturers Association of America, Inc. All rights reserved. DISCLAIMERS The Crane Manufacturers Association of America, Inc. (CMAA) is an independent incorporated trade association affiliated with Material Handing lndustry and its Division, Material Handling Industry of America (MHI). MHI provides CMAA with certain services and arranges for the development, production and distribution of these Standards and Guidelines. Neither MHI, its officers, directors, nor employees participate in any way in the preparation of the information contained in these Standards and Guidelines, and MHI does not approve, rate, or endorse these Standards and Guidelines. These Standards and Guidelines represent suggested technical qualifications for service and inspection personnel and guidelines for jobsite safety and inspection procedures. It was developed with the sole intent of offering information to parties engaged in the manufacture, marketing, purchasing, servicing or use of such cranes. These Standards and Guidelines are advisory only and should be regarded as a guide that the Specification user may or may not choose to adopt, modify, or reject. The information does not constitute a comprehensive safety program and should not be relied upon as such. Such program should be developed and an independent safety adviser consulted to do so. The acceptance or use of these Standards and Guidelines are completely voluntary. Their existence does not in any respect preclude any company, whether it has approved the Specification or not, from manufacturing, marketing, purchasing, servicing, or using products, processes, or procedures not conforming to these Standards and Guidelines. Disclaimer of Liability CMAA and its members assume no responsibility and disclaim all liability of any kind, however arising, as a result of acceptance or use or alleged use of the Standards and Guidelines. User specifically understands and agrees that CMAA, its officers, agents, and employees shall not be liable under any legal theory of any kind for any action or failure to act with respect to the design, manufacture, preparation for sale, erection, installation, inspection, service, or characteristics, features, or delivery of anything covered by these Standards and Guidelines. Any use of this information must be determined by the User to be in accordance with applicable federal, state, and local laws and regulations. Disclaimer of Warranty CMAA makes no warranties of any kind, express, implied, or statutory, in connection with the information in these Standards and Guidelines. CMAA specifically disclaims all implied warranties of merchantability or of fitness for particular purpose. Indemnity By referring to or otherwise employing these Standards and Guidelines, the User agrees to defend, protect, indemnify, and hold CMAA and its officers, agents, and employees harmless from and against all claims, losses, expenses, damages, and liabilities, direct, incidental, or consequentlal, arislng from acceptance or use or alleged use of these Standards and Guidellnes, including loss of profits and reasonable attorney's fees which may arise out of the acceptance or use or alleged use of these Standards and Guidelines. The intent of this provision and of the User is t o absolve and protect CMAA and its officers, agents, and employees from any and all loss relating in any way to these Standards and Guidelines, including those resulting from the user's own negligence. NOTICE It is the responsibility of the OwnerlUser to install, inspect, test, maintain, and operate a crane or associated lifting equipment in accordance with the applicable volume of the ANSUASME 830 Safety Standard, OSHA Regulations, and ANSUNFPA 70, National Electric Code and local regulations and laws. If the crane or associated lifting equipment is installed as part of a total llfting system, it is also the responsibility of the ownerluser to comply with the applicable ANSllASME B30 volumes that address other types of equipment used in the system. Further, It is a responsibility of the OwnerIUser to require all personnel who install, inspect, test, maintain, and operate a crane or associated lifting equipment to read and to comply with the contents of the instruction manuals furnished by the manufacturer of the crane or associated lifting equipment, and the applicable portions of the volume of the ANSUASME 830 Safety Standard, OSHA Regulations, and ANSUNFPA 70, National Electric Code. If the crane or associated lifting equipment is installed as part of a total lifting system, the applicable ANSVASME 830 volumes that address other types of equipment used in the system must also be read and followed by all personnel. 1 Scope General Purpose 1.3 Frequent lnspection Appendix A 4.7 Load Testing .2 Crane Inspector Recommendationfor Complete Parts Requirements 78-3 Jobsite Safety Guidelines Counterfeit Parts Technical Information Commitment to Safety Statement Packaging Employee Responsibility Regulation Compliance Safety Orientation and Documentation Regulations 78-6 Crane Classlfications Equipment Operator Certification Safety and First Aid General Drug-Free Workforce Class A Personal Protective Equipment Class B Equipment. TABLE OF CONTENTS 78-1 General Information 78-5 Genuine OEM (Factory) Parts 1.2 Reference Documents Assurance Application and Design Familiarity 78-2 Technical Qualifications Component Updating and Modernization 2.4 Periodic lnspection Appendix B 4.2 Pre-Shift lnspection 4.6 Maintenance 78-8 Index 4.1 Initial lnspection 78-7 Glossary 4. Tools Class C Fire Prevention Class D Ergonomics Class E Class F 78-4 Crane Inspection.1 Crane Technician Root Cause Analysis and Solutlons 2. Maintenance and Crane Service Class In Terms Of Load Testing Load Class and Load Cycles 4.5 Reporting 4. Rigging. 78-1 GENERAL INFORMATION 1.2 The information contained in this publication applies to top runnina and underrunnina bridge and gantry type single or double girder overhead traveling cranes and associatei hoisting eauipment. 1. 1. Mentioned in the text are the latest revisions of publications of the following organizations: ANSI American National Standards Institute 11 West 42nd Street New York. Where interpretations differ.1. These factors must be given careful consideration to assure maximum equipment operating life and minimum breakdowns. In many cases there are no clear categories of service in which a particular crane operation may fall. 1 . New York 10036 ANSI-ASME 830 specifications that are applicable to overhead & gantry cranes. 1.1 This specification shall be known as the Standards and Guidelines for Professional Services Performed on Overhead Traveling Cranes and Associated Hoisting Equipment - CMAA Specification #78. serviced and maintained.I . The American Society of Mechanical Engineers Three Park Avenue New York. 1. personal injury or death can occur if cranes are not operated properly or not regularly inspected.1. It should be understoodthat the Specification is aeneral in nature and other Gec'ifications may be agreed upon between the 'Purchaser andthe service provider (Seller) to suit each specific case. CMAA recommends that this Specification be used as the guideline.4 Proper operator training and regular maintenance and inspections by qualified individuals have an important influence on the operating life of the wearing parts of a crane. codes or standards.2 Reference Documents Parts of this Specification refer to certain portions of other applicable specifications.5 Serious property damage.3 Section 78-6 outlines six different classes of crane service as a guide for determining the senrice requirements of the individual application. below-the-hook devices and associated equipment. and the proper selection of a crane can be made only through a discussion of service requirements and crane details with the crane manufacturer or other qualified persons. New York 10016-5990 .1 SCOPE 1. chain and wire rope hoists.1.1. . 70 -Top Running Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes Specification No.W. Department of Labor Directorate of Safety Standards Programs 200 ConstitutionAvenue.C. Inc. P.Standard for Enclosed Track Underhung Cranes and Monorail Systems NECINFPA National Electric Code National Fire Protection Association 1 Batterymarch Park. D.Occupational Safety & Health Standards for General Industry .CMAA Crane Manufacturers Association of America. North Carolina 28217-3992 Specification No. Suite 201 Charlotte. Box 9101 Quincy. MH27. Suite 201 Charlotte. 20210 29 CFR Part 1910 .Standard for Patented Track Underhung Cranes and Monorail Systems Specification No. North Carolina 28217-3992 Specification No..O. Massachusetts 02269-9101 OSHA U. N. Washington.2 .S. 74 -Top Running & Under Running Single Girder Electric Traveling Cranes Utilizing Under Running Trolley Hoist CMAA Crane Operators Manual Overhead Crane Inspection and Maintenance Checklist MMA Monorail Manufacturers Association 8720 Red Oak Blvd. 8720 Red Oak Blvd.1 . MH27. Under no circumstances should an individual be permitted to perform repairs who has not received appropriate training and cannot demonstrate a working knowledge of the codes. manual dexterity and speed of reaction to meet the demands of the job. Should demonstrate proficient oral and written communication skills. servicing and functional testing of cranes. . In such cases. regardless of position of colors. adequately for a specific task. Be able to hear. Should be subject to other safety. specialized clinical or medical judgments and tests may be required. agility. This experience should provide a working knowledge of how to identify deficiencies and make repairs in mechanical. not be subject to seizures or loss of physical control. repairing and modifying cranes. Be capable of working at extended heights in a safe manner under varying environmental and adverse physical conditions. servicing. Work Experience A crane technician should have relevant work experience in maintaining. or emotional instability that could render a hazard to the technician or others. and no tendencies to dizziness or similar conditions. or other specific Seller and/or Purchaser's requirements. electrical systems and components of cranes. A crane technician should possess the following minimum qualifications: Have vision of at least 20130 Snellen in one eye. Physical qualifications . with or without corrective lenses and have normal depth perception. and 20150 Snellen in the other. hand-eye coordination. including but not limited to top running and under- running bridge and gantry type single or double girder overhead traveling cranes and associated hoisting equipment. troubleshooting. with or without hearing aid. Other Qualifications: Should demonstrate proficiency to read and write in English. maintaining. Have sufficient strength. Evidence of such conditions may be cause for disqualification. drug. structural. if color differentiation is required for the task. Should adhere to Seller and/or Purchaser's health and safety guidelines. coordination. field of vision. regulations and the product being repaired. 78-2 TECHNICAL QUALIFICATIONS Crane Technician Any person engaging in repairing. Should be able to distinguish colors. Not have evidence of physical restrictions. endurance. Refer to section 78-3.receive classroom and practical training on basic operating principles and methods such as rigging. hand signals. but not be limited to: 2.4.4. This experience should provide a working knowledge of how to identify deficiencies in mechanical.1 Trade skills .1. Technicians should be able to present documentation of successful completion of training for topics that require examination. servicing. etc. 2.3 Products .000 field hours of experience related to the maintaining.6 Job-site Conduct . REQUIRED TRAINING The technicians should have received formal training in the areas of their trade or discipline and area@) of expertise. structural. 2. repairing. machinery alignment. Crane lnspeotor Any person engaging in the testing. safe work practices and additional on-site training as required by the Purchaser.2 Safe operating practices of cranes .1.4. starting. Additional training should include.1.training on how to maintain. 2. modifying and functional testing of cranes and associated hoisting equipment.1 -4. jacks.4.5 - Tools and Equipment training on proper and safe operation of work tools and equipment such as ladders. etc. rigging. examination and/or certification of cranes. including but not limited to top running and under-running bridge and gantry type single or double girder overhead traveling cranes and associated hoisting equipment Work Experience A crane inspector shall have a minimum of 2.training on customer communication.1. etc. 2. do's and don'ts for safe operation.1. Testing Technicians should be able to successfully demonstrate retained knowledge and proficiency by passing a written and/or practical examination on topics determined by the Seller or Purchaser.4 - Safety training on all aspects of job-site safety.4. stopping and controlling loads. troubleshoot and repair the common components of cranes and specific product lines or models produced by the manufacturer. 2. hand tools. proper check-in and checkout. Under no circumstances should an individual be permitted to perform inspections who has not received appropriate training and cannot demonstrate a working knowledge of applicable codes and regulations and of the product being inspected. meters. basic electricity and wiring practices. Physical qualifications -A crane inspector should possess the following minimum qualifications: . basic mechanical principles. electrical systems and components of cranes. site preparation and cleanup. man-lifts.examples such as. etc. and no tendencies to dizziness or similar conditions. Should demonstrate proficient oral and written communication skills. State and local codes and regulations. Be able to hear. and 20150 Snellen in the other. Federal. In such cases. Should be subject to other safety. with or without corrective lenses and have normal depth perception. OSHA 1910. not be subject to seizures or loss of physical control. Have sufficient strength. manual dexterity and speed of reaction to meet the demands of the job. agility. and communication skills. Due to continuing changes and updates to standards and codes. Other Qualifications: Should demonstrate proficiency to read and write in English. These areas are a prerequisite to training as an inspector in addition to training in the safe interpretation of the Federal. endurance. Should adhere to Seller andlor Purchaser's health and safety guidelines. The words "should" and "shall" are used extensively throughout the codes and specifications including ASME 830. field of vision.1 79 and CMAA. Additional training should include. Not have evidence of physical restrictions. regardless of position of colors. but recommended ("should"). or emotional instability that could render a hazard to the technician or others. Evidence of such conditions may be cause for disqualification.Have vision of at least 20130 Snellen in one eye. drug. Be capable of working at extended heights in a safe manner under varying environmental and adverse physical conditions. adequately for a specific task. specialized clinical or medical judgments and tests may be required. an inspector should receive additional formal training every two years as a minimum and be able to provide documentation of such training. Should be able to distinguish colors. with or without hearing aid. coordination. safe operating practices of cranes. but not be limited to the following areas. REQUIRED TRAINING The inspector should have received formal training in the areas of: safety and design codes related to cranes. State and local codes and regulations: . if color differentiation is required for the task. or other specific Seller andlor Purchaser's requirements. hand-eye coordination. The inspector shall receive training to understand the meaning of these words so helshe can accurately explain if corrective action is mandatory ("shall") or is voluntary. report writing and documentation. 2. rigging.1 Trade skills .2. basic mechanical principles. 2. If local code bodies or governments mandate. jacks.4.4. hand tools.4. machinery alignment. proper crane operation and the understanding of crane controls.4. Refer to section 78-3.5 - Job-site Conduct training on customer communication.4. site preparation and cleanup.4.4.2.2. etc.2. 2.training on how to interpret wear patterns and to make recommendations for repair or replacement utilizing sound judgement and the manufacturers' guidelines.examples such as basic electricity and wiring practices. 2. 2. additional testing and registration for inspector certification or licensing may be required.4. man-lifts.3 Safety -training on all aspects of job-site safety and safe work practices. Testing The inspector shall be required to demonstrate proficiency by passing both a written and practical examination.2. Inspector should be able to present documentation of successful completion of above qualifications.4. etc.4.2 Products . and additional on-site training as required by the Purchaser. proper check-in and check-out. . meters. etc.4 Tools and Equipment -training on proper and safe operation of work tools and equipment such as ladders. procedures and equipment. It is the responsibility of the employees at each specific work site to ensure all precautions are taken and safe work practices are followed. procedures and equipment. If Employees are NOT familiar with these practices. Their goal is to ensure a working environment free from recognized hazards. it is their responsibility to obtain the proper information to become familiar with them. Federal. . Equipment Operator Certification Motor Vehicle Use All motor vehicles shall be operated in accordance with all Federal. and Local requirements.3. policies and procedures. Regulations Purchaser Site Regulations Employees shall comply with all purchaser site regulations and safety policies.4. Safety Orientation and Documentation All Employees should receive appropriate safety training and orientation before beginning any work. 78-3 JOBSITE SAFETY GUIDELINES Commitment to Safety Statement There must be a commitment to providing a safe workplace for employees and customers. 3. State and Local Regulations All work shall be performed in compliance with Federal. This section has been prepared as a general guideline and cannot cover all specific work situations that may occur.2 Employee Responsibllity (Employee of a service provider) Each employee of a senrice provider (Employee) has the responsibility to become familiar with all safety practices and be knowledgeable regarding all safety issues. In the event of a motor vehicle accident refer to Accident Reporting. State. Any required training at the purchaser's site shall be completed prior to starting any work. Additional training may be required if it is found that there is a lack of understanding of safety programs. It is the responsibility of these Employees to review all site-specific requirements with the purchaser.6. policies. State and Local regulations. codes and requirements. section 3. scissors lift. boom lift and other machinery Mobile cranes. forklifts. This policy should cover general safe working practices and accident prevention. pneumatic. Site specific conditions shall be evaluated to determine the required method of fall protection to be used. Care shall be taken to secure the ladder to prevent falling or slipping.2.6.2 All Employees shall be trained on the Lockout / Tagout policy.2. It is the responsibility of all Employees to actively provide a safe work environment for themselves and all other site personnel. barriers or other appropriate means to alert others that overhead work is being performed. and corrected prior to commencement of work. All equipment shall be in good operating condition with all required inspection and maintenance documentation available. hydraulic. Each Employee has the responsibilityfor the safe operation and use of any such equipment prior to operation. Electrical Safety 3. .2 Safety meetings are an important part of any Accident Prevention Plan. be identified by highly visible signs. These meetings should be conducted on a routine basis as necessary by site conditions or purchaser requirements. Mobile cranes. reported. Refer to manufacturer's requirements for specific operating proceduresand requirements. boom lifts and other machinery shall only be operated by trained.6.6. 3. 3. chemical and other potential energy sources. It is the responsibility of the Employee to assess site specific conditions and determine the best method to provide maximum safety.1 All service providers shall adopt an Accident Prevention Policy. The purpose of this policy is to protect Employees against unexpected release of energy including electrical. wherever practical. Ladders All ladders shall be used in compliance with the manufacturer's recommendations. Mobile crane. Fall protection applies to all Employees who are working at heights above 6 feet from the ground. scissors lifts. Safety and First Aid Fall Protection Service providers should have a Fall Protection Policy. All fall protection equipment shall be regularly inspected and in good working condition. forklifts and other machinery are often required to complete the work. Employees shall be competent in the use of fall protection equipment. licensed (where required) individuals. Site specific issues shall be reviewed prior to the start of any work. Job Site Work Area and Signage Work areas should. Accident Prevention and Awareness 3.4. forkli. Any unsafe conditions should be addressed.6.1 Service providers should have a Lockout / Tagout policy.4. gases. sprays or vapors which may cause serious injury or illness. Hazardous Materials All service providers shall have a Hazardous Material Policy. Coordination and exchange of MSDS sheets with the Purchaser and other contractors shall be incorporated in this policy and every effort shall be made to define hazardous materials. All Employees shall be trained. mists. All Employees shall be trained on the requirements of this policy. appropriate respiratory pmtection shall be used. on this policy. (See Appendix Afor sample of an accident report. Respiratory Protection Program All service providers shall have a Respiratory Protection Policy. This policy should identify procedures to be followed for entry into a permit- required confined space. The purpose of this policy is to protect Employees from breathing air contaminated with harmful dusts. fumes. The policy should consider methods to eliminate or minimize exposure to hazardous air contaminants. Identity of medical treatment facilities on site or near work area. shall be reported to the appropriate designated person for both the Seller and Purchaser. Confined Space Regulations All service providers should have a confined space program. Basic First Aid training and supplies. All Employees should be aware of the location of Material Specification and Data Sheets (MSDS) and be knowledgeable of their contents and safe means of handling and disposing of Hazardous Materials. All Employees shall be trained on the requirements of this policy. as applicable and as dictated by specific work conditions. Access to the following information should be made available prior to commencement of work: Emergency contact personnel and phone numbers. regardless of severity. When contmls are not feasible or while they are being instituted. Employees should be capable of identifying and understanding the difference between a penit-required situation and other confined space conditions. .All accidents. An accident report should be used to investigate the incident.) First Aid and Emergency Response All service providers shall have a First Aid and Emergency Response Policy. to identify the root cause and to initiate corrective action to prevent future occurrences. fire extinguisher and other appropriate equipment. goggles or face shields must conform to the latest published standards for protective eyewear (Reference USA-ANSI 287). and hearing protection. Fire Prevention Policy should include hot work permit procedure. Personal Protective Equipment All service providers shall have a Personal Protective Equipment Policy. They shall properly take care of the equipment and maintain it in a clean and sanitary manner. Employees shall be required to wear personal protective equipment that has been selected for the job.Drug-Free Workforce All service providers should be committed to providing a Drug and Alcohol Free Workplace. Extreme caution shall be used when working with tools that may ignite in and around combustible materials. Each Employee shall have knowledge of proper use of all hand and power tools applicable to the work being performed by that Employee. gloves. Equipment. sleeve protectors. Safety glasses. Tools Slings and other rigging shall be visually inspected and in proper condition prior to use and must conform to all applicable specifications. Other Personal Protective Equipment includes but is not limited to hard hats. Rigging. All service providers shall have a Substance Abuse Policy. fire watch training. aprons. Personal protective equipment is intended to protect Employees from specific hazards. Ergonomics All service providers should have a policy to help prevent back and other injuries and to provide training on proper methods of lifting. Fire Prevention All service providers shall have a Fire Prevention Policy. steel toe shoes/boots. This includes both prescription and non-prescription eye wear. All Personal Protective Equipment shall conform to existing standards and be in proper operating condition. . face shields. All Employees shall agree to participate in any seller or purchaser mandated drug screening. All Employees shall be knowledgeable and trained on fire prevention. goggles. fire blankets. repair. lnspection of all altered.2. Performance of lnspection The Pre-shift inspection should be performed by the crane operator unless the employer or supervisor has assigned this responsibility to another designated person. and properly operating safety devices. etc. The report should also contain specific start-up settings necessary to achieve optimum equipment performance. Refer to section 2. and modified cranes shall be inspected prior to initial use. or modified cranes shall be inspected to assure that the altered. Examples of typical inspection items may include but are not limited to clearances. repaired.78-4 CRANE INSPECTION. Scope of lnspection New or reinstalled equipment shall be inspected in accordance with original manufacturer's recommendations. as determined by a qualified person. proper control settings. and modified cranes may be limited to the provisions affected by the alteration. This document should be maintained for the life of the equipment. or modified cranes should have an initial inspection report on file documenting the areas affected by the alteration. reinstalled. modified component(s) have been properly installed and functionally tested. Altered. MAINTENANCE AND LOAD TESTING Initial lnspection New. modified or re-installed crane's initial inspection shall be performed by a qualified person. repaired. repaired. Documentation of lnspection New or re-installed equipment shall have an initial inspection report on file documenting the items inspected as recommended by the manufacturer. operating speeds. Performance of lnspection A new crane's initial inspection shall be performed by a qualified manufacturer's representative. repair or modification. repaired. lubrication levels. or modification. Pre-shift lnspection A visual and operational inspection of the crane shall be performed at the start of each shift or when it is first used during each shift.1 and 2. An altered. Altered. repaired. Scope of lnspection Refer to the CMAA Crane Operator's Manual. repaired. . altered. 4 All wire rope that has been idle for a period of a month or more due to shutdown or storage of a crane on which it is installed shall be given a thorough inspection before it is used. Table 4.3.3 A crane that has been idle for a period of one month or more.3. 4.2 The Frequent Inspection is a visual and operational inspection performed as often as daily.2 SERVICE CUSS ISERVICE CUSS 1 STAND-BY 1 SHIFT 2 SHIFTS 3 SHIFTS IAI FREQUENCY OF INSPECTION SEMI-ANNUALLY SEMI-ANNUALLY SEMI-ANNUALLY SEMI-ANNUALLY MONTHLY MONTHLY MONTHLY MONTHLY MONTHLY SEMI-MONTHLY TO MONTHLY MONTHLY SEMI-MONTHLY WEEKLY TO TO MONTHLY SEMI.3-1 Freauent lns~ectionChart NUMBER OF SHIFTS OPERATED PER DAY I I CMAA I ASME 630.1 Crane Inspector. but less than six months.MONTHLY WEEKLY 3-5 DAYS DAILY DAILY DAILY DAILY 4. Refer to section 2.5 Performance of the Inspection The Frequent lnspection shall be performed by a qualified Inspector. as determined by a qualified person or as outlined in Table 4. Frequent lnspection 4. The qualified Inspector shall determine whether conditions found during the inspection constitute a hazard and whether a more detailed inspection is required. This inspection shall be for all types of deterioration and shall be performed by a qualified person in accordance with section 2.3. 4.3.1 Hooks.3-1.3. wire ropes and load chains shall be inspected at minimum monthly intervals and documented with a certification record which includes date of inspection. chain or wire rope inspected. 4. and an identifier for the rope that was inspected. environmental and application factors. based on service. the signature of the person who performed the inspection and the serial number or identifier of the hook. . A certification record shall be kept on file and shall include the signature of the person who performed the inspection. shall be given a frequent inspection in accordance with 4.3.2. 3-2 marked with (*) shall be inspected monthly and documented with a certification record which includes date of inspection. chain or wire rope inspected.Scope of Frequent lnspection shall include. . the signature of the person who performed the inspection and the serial number or identifier of the hook. but not be limited to the items in Table 4.3-2 Llst of Frequent Inspection ltems ith the hoist load that audible and visual Documentation of lnspection Items in table 4.3-2. Table 4. 2 All wire rope that has been idle for a period of a month or more due to shutdown or storage of a crane on which it is installed shall be given a thorough inspection before it is used. Periodic lnspection A Periodic lnspection is a detailed visual and operational inspection whereby individual components are examined to determine their condition.3. 4. and an identifier for the rope that was inspected.2 SERVICE SERVICE 1 SHIFT 2 SHIFTS 3 SHIFTS CLASS CLASS FREQUENCY OF INSPECTION A ANNUALLY ANNUALLY ANNUALLY B NORMAL ANNUALLY ANNUALLY ANNUALLY C ANNUALLY ANNUALLY ANNUALLY D HEAVY ANNUALLY SEMI-ANNUAL TO SEMI -ANNUAL ANNUAL E QUARTERLY QUARTERLY QUARTERLY SEVERE F QUARTERLY QUARTERLY QUARTERLY 4. Safety hazards shall be reported to the responsible person immediately upon discovery.7.4. .4.3.4-2.2. Performance of the lnspection The Periodic lnspection shall be performed by a qualified inspector.4. which may be used to document the inspection. Table 4. The qualified Inspector shall determine whether conditions found during the inspection constitute a hazard and whether a more detailed inspection is required.3 Refer to the Overhead Crane lnspection and Maintenance Checklist in Appendix B.4-1. environmental and application factors as determined by a qualified person or as outlined in Table 4.2 Crane Inspector. 4. Refer to section 2. The Periodic lnspection is performed as often as quarterly based on service.1 A crane that has been idle for a period of six months or more shall be given a periodic inspection in accordance with Table 4.4-1 Periodic Inspection Chart NUMBER OF SHIFTS OPERATED PER DAY CMAA ASME 830. lnspection reports should identify the specific hazard or maintenance problem and kept on file for 3 years. This inspection shall be for all types of deterioration and shall be performed by a qualified person in accordance with section 2. A certification record shall be kept on file and shall include the signature of the person who performed the inspection.3-2 should be documented.2.7.2 All other items of table 4. wiring. but not be limited to. misalignment. Check for any loose wire connections or damaged wiring. Check for I cracked or insufficient welds. wear. Bumpers and end stops Check all bumpers and end stops for damage. motor slip rings. Conductor system Check the conductor system for alignment. lands. axles. Sheaves and drums I Check for worn grooves. Check mechanical components for wear. I Check for excessive wear of chain drive sprockets I I and excessive chain stretch. brushes. I Electrical components Check all electrical apparatus. and missinglloose hardware. cracked or deformed members. and undamaged. Table 4. pushbutton stations. resistors.4-2 Llst of Periodic lnspection Items trucks. Brakes (holding . Check for proper functioning of electric control brake. gaaes or other devices I Check for load. footwalks. Are they legible from floor? Are warning signs in place and legible? Connection points Check for looselbroken bolts or rivets. - Self-containedelectric. Check for looselmissing hardware. alignment. splices. Trollev and runway rail Check rails and fastening devices for looseness. - Covers and guards 1 Check that all covers or guards are in place. hvdraulic or aasoline 1 Check for im~roperperformance or noncompliance I powered generating units Transmissions with applicable safety requirements. Scope of Periodic lnspection should include. trap doors. Shafts. gaps. bent or broken parts. Check for proper restraints and obvious undersizing or improper energy absorption capabilities. power feeds. handrails. worn groove . Check for I evidence of overheating. etc? Does cab have a fire extinguisher. cab. etc. and cracks.4-2. secure. Check all motors. Check that all guards are in place and .'iadders. re-calibrate as required. conductor shoes for wear. Runway structure Check runway structure for proper anchors. couplings Check for wom. controls. cracked. -- Indicators. wheels. limit switches. the items in Table 4. linings. fastening. sharp edges. Are footwalks free of debris. corrosion. unsecured members. grease. Open gearbox inspection covers and check for gear teeth wear and proper lubrication. pawls and ratchets. wind. proper type? Signs and labels Check for proper capacity labels. trolley frame. and other indicators over their full range. Below the hook devices Check for cracks or structural damage. loose bolted connections.and control) Check for excessive wear and proper adjustment on brake system parts. for signs of pitting or any deterioration of controller contactors. Reports should be specific with regard to the violation. or the standard reference. if applicable. 4.4. if applicable.5. Documentation of lnspection 4.2 Proof of lnspection (tags. in written format. lnspection reports shall be kept on file by the owner/Purchaser and.4. Unsafe conditions disclosed by the inspection should be corrected before operation of the crane is resumed.5. immediately upon discovery. etc. Reporting Safety Hazards Safety hazards shall be reported to the responsible person. the service provider. the applicable code. name of the inspecting company. within a reasonable time from discovery. if applicable.5. and the individual that performed the inspection.) shall be affixed to the inspected equipment by the inspector. 4. Reports should include specific identification of the item and a recommendation(s) for remediation of the item. The reports should be maintainedfor at least 3 years.5.2 Refer to the Overhead Crane lnspection and Maintenance Checklist in Appendix 8. Standards for Reporting lnspection reports shall be given to the Purchaser's responsible person in a specific and legible format. manufacturer's serial number and owner's equipment number. Maintenance Issues Maintenance issues shall be reported to the appropriate supervisor or responsible person.5. . Code or Standard Violations Code or standard violations shall be reported as part of the inspection process. including its location. which may be used to document the inspection. Damage. safety related issues andlor imminent equipment failure must be reported immediately.5. Reports should include specific identification of the hazard. in written format.1 Reports for Periodic Inspections documenting the above items shall be kept on file by the owner1Purchaser and. Equipment Identification 4. and a recommendation(s) for remediation of the hazard.1 lnspection reports shall specifically identify the equipment inspected. the service provider for a period of three (3) years from the date of the actual inspection. Proof of inspection shall be in plain sight and shall contain the date of the last inspection. After adjustments. the following precautions: The crane to be maintained shall be moved to a location where it will cause the least interference with other cranes and operations in the area. Warning or "out of order" signs shall be placed on the crane and shall also be placed on the floor beneath or on the hook so as to be visible from the floor. maintenance. maintenance. All controllers shall be at the off position. other crane operators on the same runway and in adjacent runways shall be notified of the out-of-service crane. . which may be used to document the repairs. maintenance. safety devices reactivated and maintenance equipment removed. as a minimum. or repairs to correct any unsafe conditions shall be disclosed by the inspection reports or by operating personnel before operation of the crane is resumed.Maintenance Preventive maintenance shall be performed based. Adjustments. Maintenance records should be retained for the life of the equipment. The main electrical disconnect switch shall be open and locked in the open position. Follow appropriate lockout/tagout procedures. rail stops or other suitable means shall be provided to prevent interference with the idle crane. Refer to the Overhead Crane Inspection and Maintenance Checklist in Appendix B. maintenance. Maintenance records should document routine and preventive maintenance activities as well as adjustments. Adjustments. Maintenance Records Records shall be kept on file evidencing adjustments. the crane shall not be operated until all guards have been reinstalled. maintenance and repairs that result from inspections. on the crane manufacturer's recommendations. Additionally. Where other cranes are in operation on the same runway. or repairs shall be done only by qualified personnel in accordance with section 78-2. as a minimum. or repairs have been made. and repairs that have been performed. Maintenance procedures shall include. 7. 4. extensively repaired and altered cranes shall be tested in accordance with OSHA Part 1910. .4 The load test should be performed at a minimum of once evety four years.4.7. 4.7.7. The test load should be equal to and not exceed the rated load lifting capacity of the crane.2 All cranes should be periodically load tested by or under the direction of a designated or authorized person and a written report be furnished by such person confirming the load rating of the crane.7 Load Testing 4.1 All new.3 Reports for documenting the load test should be maintained by the OwnerIPurchaser for the life of the crane.179(k). 4. problems may occur that do not have obvious or readily apparent causes. or changes of application. and should be consulted to help determine the root cause of the problem and recommend potential solutions. Component Updating and Modernization The OEM is in the best position to determine a cross-reference between the original part and a suitable replacement. Root Cause Analysis and Solutions During a crane's operating life. the Purchaser is better assured of proper mating of parts and the interaction of components necessary to maintain the integrity of the repair. . The OEM shall assure the part is without defects in material and workmanship at the time it is shipped. the OEM is most capable of developing or recommending design improvements. Assurance The OEM shall assure that the replacement part is a proper fit for the part to be replaced. The OEM is a reliable. By purchasing replacement parts from the OEM. Application and Design Familiarity The OEM is responsible for the total design of the crane and the selection of its components. The Purchaser and the OEM should carefully review the application or how the crane is being used so that operating life of-the part appropriate to the service class is achieved. The OEM should also be considered for engineered solutions pertaining to equipment upgrades. 78-5 GENUINE OEM (FACTORY) PARTS General Purpose The original equipment manufacturer (OEM) should be considered a primary source for obtaining repair parts. . Use of other than OEM-recommended or approved parts can affect the performance and structural integrity of the crane and can expose workers and bystanders to serious injury or death. may be considered if its operating life is not acceptable to the purchaser. expert resource. The OEM should be the primary source for recommending the substitution of a replacement part for the original part. performance enhancements. A part or component upgrade . As the sole source of the original design drawings and calculations. The OEM shall assure that the replacement part is made of a material that is Properly selected and suited for the application. add structural reinforcements. .the Purchaser may wish to increase the working life to enhance performance. other diaanostic methods would be used to determine if OEM-established operating conditions are being met. Based on its knowledge of the repair. the mating gear should also be replaced. Problem Solutions Type A Problem: may take the form of recommendations to increase operating component size. the OEM is able to recommend all parts that may be required to efficiently complete the repair. etc: Recommendatson for Complete Parts Requirements Parts required for common repairs are often supplied in kits by the OEM to better ensure availability and to reduce individual part cost. mechanical and electrical connections. etc. bearings. etc. Problem Analysis Type A Problem: would typically include studies of crane duty cycle.Every part has a working life. lifting capacity uprate. Type B Problem: in addition to the studies performed for Type A Problems. component part stress analysis. Type B Problem. upgrading material specifications. For example. if a pinion is being replaced. quality of power supply. or conducting'operator training classes. The OEM can usually determine if mating parts should also be replaced. improve reliability and productivity. preventive maintenance practices and operator performance. original factory settings. change component type. abding line reactors or filters to the power supply.the original part may fail before it reaches its working life due to an undetermined cause. enhancing a preventive maintenance program. Two types of problems may occur: Type A Problem. etc. such as runway tolerances. impose a formal preventive maintenance program or conduct operator training classes. such as seal kits. T v ~ eB Problem: mav take the form of correction of the root cause such as aibning the runway. The crane application and the service class impact the working life. etc. . Regulation Compliance The OEM can assist the Purchaser by recommending modifications or upgrades to bring the crane into compliance with Federal. including replacement parts. personal injury or death. Use of other than recommended or approved parts may void the OEM crane manufacturer's warranty. Technical Information The OEM shall furnish parts manuals that clearly identify replacement parts to better assure that the correct part is ordered. Use of replacement parts not recommended or approved by the OEM crane manufacturer can result in a potentially unsafe workplace situation resulting in serious property damage. Packaging The OEM shall provide adequate packaging to prevent damage during shipment. The OEM shall provide written guidelines to assist the Purchaser in the proper operation and maintenance of the equipment. 5. distribution and sale of counterfeit trademarked products.3 Certain non-proprietary drawings may be available from the OEM to aid in the maintenance or upgrade of the crane. in the United States.8. Counterfeit Parts The Federal Trademark Counterfeiting Act is aimed at curbing the manufacture. State and Local regulations and codes. The crane service classification is based on the load spectrum reflecting the actual service conditions as closely as possible. Operation with no lifted load and the weight of any attachment must be included. Where W = Load magnitude. The selection of the properly sized crane component to perform a given function is determined by the varying load magnitudes and given load cycles which can be expressed in terms of the mean effective load factor. The individual parts which are clearly separate from the rest. or forming a self contained structural unit. Load spectrum is a mean effective load. Loads may vary from no load to occasional full rated loads with two to five lifts per hour. therefore for the purpose of the classifications.80 to 40°C) and normal atmospheric conditions (free from excessive dust. CLASS A (STANDBY OR INFREQUENT SERVICE) This service class covers cranes which may be used in installations such as power houses. expressed as a ratio of cycles under each load magnitude condition to the total cycles. service buildings. k = Mean effective load factor. The cranes can be classified into loading groups according to the service conditions of the most severely loaded part of the crane. light warehousing. moisture and corrosive fumes). (Used to establish crane service class only) All classes of cranes are affected by the operating conditions. motor rooms and transformer stations where precise handling of equipment at slow speeds with long. which is uniformly distributed over a probability scale and applied to the equipment at a specified frequency. it is assumed that the crane will be operating in normal ambient temperature 00 to 104O F (-17. The sum total of the load probabilities P must equal 1. expressed as a ratio of each lifted load to the rated capacity. averaging ten feet per lift. Capacity loads may be handled for initial installation of equipment and for infrequent maintenance. public utilities. . 78-6 CRANE CLASSIFICATIONS GENERAL Service classes have been established so that the most economical crane for the installation may be specified in accordance with CMAA Specifications #70 and #74. P = Load probability. CLASS B (LIGHT SERVICE) This service covers cranes which may be used in repair shops.O. where service requirements are light and the speed is slow. light assembly operations. can be classified into different loading groups if the service conditions are fully known. etc. turbine rooms. idle periods between lifts are required. fabricating plants. magnetibucket combination cranes for scrap yards. lumber mills. foundries. etc. container handling. fertilizer plants. etc. not over 65 percent of the lifts at rated capacity. with twenty or more lifts per hour at or near the rated capacity.. loads approaching 50 percent of the rated capacity will be handled constantly during the working period. where service requirements are moderate. CLASS D (HEAVY SERVICE) This service covers cranes which may be used in heavy machine shops. bucket. .. averaging 15 feet. etc. cement mills. Applications may include custom designed specialty cranes essential to performing the critical work tasks affecting the total production facility. lumber mills. and standard duty bucket and magnet operations where heavy duty production is required. Applications may include magnet. CLASS F (CONTINUOUS SEVERE SERVICE) This type of service requires a crane capable of handling loads approaching rated capacity continuously under severe service conditions throughout its life. container yards. In this type of service the crane will handle loads which average 50 percent of the rated capacity with 5 to 10 lifts per hour. These cranes must provide the highest reliability with special attention to ease of maintenance features. CLASS E (SEVERE SERVICE) This type of service requires a crane capable of handling loads approaching a rated capacity throughout its life. steel warehouses.CLASS C (MODERATE SERVICE) This service covers cranes that may be used in machine shops or paper mill machine rooms.. In this type of service. High speeds are desirable for this type of service with 10 to 20 lifts per hour averaging 15 feet. not over 50 percent of the lift at rated capacity. LOAD CYCLESRIFE OF CRANE 20.000.531 .000 cycles 100. very light loads.OO Irregular Regular use Regular use Regular use occasional in in in severe use followed intermittent continuous continuous by long idle operation operation. L3 = Cranes which hoist the rated load fairly frequently and normally. L2 = Cranes which rarely hoist the rated load.85 L4 D E F F 0.000 to 2.53 '-2 6 C D E 0. CRANE SERVICE CLASS IN TERMS OF LOAD CLASS AND LOAD CYCLES The definition of CMAA crane service class in terms of load class and load cycles is shown in Table 6.8-1.8-1 DEFINITION OF CMAA CRANE SERVICE CLASS IN TERMS OF LOAD CLASS AND LOAD CYCLES LOAD CYCLES k = MEAN LOAD EFFECTIVE LOAD CLASS N1 N2 N3 '"4 FACTOR L1 A 6 C D - 0.67 L3 C D E F 0.0. TABLE 6. L4 = Cranes which are regularly loaded close to the rated load.000.671 .000 cycles 500.000 cycles . and normal loads of about 113 of the rated load.35 0.000 cycles Over 2.000 to 100. loads between 113 and 213 of the rated load.851 . operation periods LOAD CLASSES: L1 = Cranes which hoist the rated load exceptionally and. normally.1.000 to 500.0. . and the trolley for retarding or stopping motion by friction or collectors are mounted on the trolley to power means. usually designed to handle lighter loads at a higher speed than the main CMAA: Crane ManufacturersAssociation of hoist. etc. etc. hoisting unit. MAGNETIC: An conductors located along the bridge electromagnetic device for opening and structure of a crane to provide power to the closing an electric power circuit. 78-7 GLOSSARY ABNORMAL OPERATING CONDITIONS: CAB-OPERATED CRANE: A crane Environmental conditions that are controlled by an operator in a cab located on unfavorable. 78. trucks or other members collecting current from the runway or bridge enclosed on four sides. a BRIDGE: That part of an overhead crane gearbox. motor base. corrosive fumes. other than a motor. A method of control by which the motor supply voltage can be adjusted. trucks. consisting of girders. performance. AUXILIARY GIRDER (OUTRIGGER): A girder arranged parallel to the main girder for CMAA MEMBER SERVICE COMPANY: A supporting the platform. safety features. or to the runway. Inc. the motor or other equipment. crane. a brake. the bridge.Electric Overhead Crane Institute). The mainline collectors are mounted on the bridge to transmit current BRAKE: A device. reduce the torsional forces such load would and in compliance with CMAA Specification otherwise impose on the main girder. America. a wheel assembly. CAPACITY: The maximum rated load (in ADJUSTABLE OR VARIABLE VOLTAGE: tons) which a crane is designed to handle.e.. BRIDGE CONDUCTORS: The electrical CONTACTOR. BUMPER (BUFFER): An energy absorbing COVER PLATE: The top or bottom plate of device for reducing impact when a moving a box girder. transmit current from the bridge conductors. and hazardous locations. control panels. the operation of a hoist. end ties. No. used from the runway conductors. to inspections as part of its normal business. CONTROLLER: A device for regulating in a BRIDGE RAIL: The rail supported by the predetermined way the power delivered to bridge girders on which the trolley travels. harmful or detrimental to or for the bridge or trolley. BRANCH CIRCUIT: The circuit conductors COMPONENT: Either a single part or a between the final overcurrent device group of parts assembled into a working protecting the circuit and the outlet@). deflection due to hook load and weight of the dust laden or moisture laden atmospheres. used to transmit torque . crane or trolley reaches the end of its permitted travel. unit. trolley. or when two moving cranes CROSS SHAFT: The shaft extending across or trolleys come into contact. conductors. i. given to girders to compensate partially for F) ambient temperatures. member company that performs service and operator's cab. BOX SECTION: The rectangular cross COLLECTORS: Contacting devices for section of girders. such as excessively CAMBER: The slight upward vertical curve high (over 104 deg. CLEARANCE: Minimum distance from the extremity of a crane to the nearest AUXILIARY HOIST: A supplemental obstruction. COMPONENT UPGRADE: To modify or walkway and drive mechanism which carries replace a component so as to improve or the trolley and travels in a direction parallel increase its operating life. F) or low (below 0 deg. (formerly EOCl . which LIFT: Maximum safe vertical distance supports the bridge girders. it acts as a body that serves in place of the earth. EDDY-CURRENT BRAKING: A method of HOLDING BRAKE: A brake that control by which the motor drives through an automatically prevents motion when power electrical induction load brake. LIFT CYCLE: Single lifting and lowering FLOOR-OPERATED CRANE: A crane that motion (with or without load). to petform specific duties. usually specified by a DRIVE): A method of control by which the NEMA classification number. 74 "Specifications for ENCLOSED CONDUCTOR(S): A conductor Top Running & Under Running Single Girder or group of conductors substantially Electric Traveling Cranes Utilizing Under enclosed to prevent accidental contact. Running Bridge and Gantry Type Multiple "Employee" means a person employed Girder Electric Overhead Traveling Cranes" directly by the service provider. wheels. it is not termed a ELECTRICAL BRAKING SYSTEM: A running sheave. consisting of a movable bridge carrying a fixed or movable hoisting mechanism and IDLER SHEAVE: A sheave used to equalize traveling on an overhead runway structure. . magnet. axles. is pendant controlled by an operator on the floor or an independent platform. etc. frame. Running Trolley Hoist". means. method of controlling crane motor speed when in an overhauling condition. classification covered by CMAA Specification No. 70 "Specifications for Top EMPLOYEE: For this specification. or bucket FIXED AXLE: An axle that is fixed in the can move. and is supported by the end trucks. member joining the building column and roof END TRUCK: The unit consisting of truck truss. lowering and transporting loads. that when it is equipment and the earth or some conducting overhauled by the load. is off. through which the hook. Because of its slight movement. without INDUSTRIAL DUTY CRANE: Service the use of friction braking. ELECTRIC OVERHEAD TRAVELING HYDRAULIC BRAKE: A brake that provides CRANE: An electrically operated machine retarding or stopping motion by hydraulic for lifting. bearings. DYNAMIC LOWERING: A method of control GROUND FAULT: An accidental conducting by which the hoist motor is so connected in connection between the electrical circuit or the lowering direction. in which an operator may of the crane bridge that supports the trolley ride while controlling the crane. having no permanently mounted GIRDERS: The principal horizontal beams electrical controls. truck and on which the wheel revolves. generator and forces current either through HOIST: A machinery unit that is used for the resistors or back into the line. GANTRY CRANE: A crane similar to an DRIVE GIRDER: The girder on which the overhead crane except that the bridge for bridge drive machinery is mounted. ENCLOSURE: A housing to contain INVERTER (VARIABLE FREQUENCY electrical components. fixed line voltage and frequency is changed END TIE: A structural member other than the to a three-phase system with infinitely end truck that connects the ends of the variable voltage and frequency.DESIGNATED PERSON: A person selected FOOTWALK: The walkway with handrail or assigned by the employer or the and toeboards attached to the bridge or employer's representative as being qualified trolley for access purposes. or platform on a pendant or radio controlled crane. tension in opposite parts of a rope. carrying the trolley or trolleys is rigidly DUMMY CAB: An operator's compartment supported on two or more legs running on fixed rails or other runway. girders to maintain the squareness of the KNEE BRACE: The diagonal structural bridge. lifting and lowering a load.. and Specification No. " OEM. This unidirectional device requires torque PURCHASER: An entity that buys cranes. compartment from which movements of the LOAD BLOCK: The assembly of hook. LONGITUDINAL STIFFENERS: Horizontal members attached to the web of the bridge OVERLOAD LIMIT DEVICE: A device that is intended to permit the hoist to lift a freely girder to prevent web buckling. MECHANICAL LOAD BRAKE: An PROTECTIVE PANEL: An assembly automatic type of friction brake used for containing overload and undervoltage controlling loads in the lowering direction. To be specified by the swivel. used for ease in handling NON-COASTING MECHANICAL DRIVE: A certain types of loads. crane are controlled. trolley or crane. complete with roof. consisting of a magnetic contactor that can PITCH DIAMETER (ROPE): Distance be operated by remote pushbutton and can through the center of a drum or sheave from be manually operated by a handle on the center to center of a rope passed about the switch. magnets. per minute when traveling at rated speed LlNE CONTACTOR: A contactor to with rated load. the has two or more girders for supporting the weight of which is to be considered part of live load. the rated load. MULTIPLE GIRDER CRANE: A crane that grabs and other supplemental devices. sheaves. etc. drive with coasting characteristics such that LIMIT SWITCH: A device designed to cut off it will stop the motion within a distance in feet the power automatically at or near the limit of equal to 10 percent of the rated speed in feet travel for the crane motion. windows. disconnect power from the supply lines.LIFTING DEVICES: Buckets. REPRESENTATIVE: A "Qualified Person" "Specification for Electric Overhead who is employed by or is representing the Traveling Cranes for Steel Mill Service. MASTER SWITCH: A manually operated PLUGGING: A control function that device that is used to control the operation of accomplishes braking by reversing the contactors and auxiliary devices of an motor line voltage polarity or phase electric control. protection for all crane motions. 6. maintained hoist. or enclosed. LIVE LOAD: A load that moves relative to OPERATOR'S CAB: The operator's the structure under consideration. sequence. bearing. having only sides or suspended by the hoisting ropes. . OEM: Original Equipment Manufacturer. from the motor to lower a load but does not impose additional load on the motor when associated hoisting equipment andlor lifting a load. manual switch which breaks the power lines PENDANT PUSHBUTTON STATION: leading from the main line collectors. a railing around the operator. Means suspended from the crane for MANUAL-MAGNETIC DISCONNECT operating the controllers from the floor or SWITCH: A power disconnecting means other level beneath the crane. periphery. LOAD CYCLE: One lift cycle with load plus one lift cycle without load. services for these cranes and equipment MILL DUTY CRANE: Service classification QUALIFIED MANUFACTURERS covered by AlSE Standard No. and interrupts energy flow in the MAIN LlNE DISCONNECT SWITCH: A event of a current overload condition. but MAGNETIC CONTROL: A means of prevents lifting of an overload that would controlling direction and speed by using cause permanent damage to a properly magnetic contactors and relays. current. OVERLOAD: Any load greater than the rated load. pins and frame manufacturer as open. suspended load within its rated capacity. MAIN LlNE CONTACTOR: A magnetic OVERLOAD PROTECTION contactor used in the incoming power circuit (OVERCURRENT): A device that senses from the main line collectors. each situation. #74. This device normally is attached to a fixed structure and normally RUNNING SHEAVE: A sheave that rotates does not have energy absorbing ability. NEMA that classifies resistors according to percent of full load current on first point and STEPPED CONTROL: A type of control duty cycle. beams. electric conductor between supply tap and load tap. RUNWAY: The rails. TWO BLOCKING: Condition under which SEMI-GANTRY CRANE: A crane similar to the load block or load suspended from the an overhead traveling crane except that the hook becomes jammed against the crane bridge for carrying the trolley or trolleys is structure preventingfurther winding up of the supported on one end by an end truck with hoist drum. crane is designed to handle safely as SPAN: The horizontal distance center-to- designated by the manufacturer. by SHALL: This word indicates that adherence possession of a recognized degree. SHOULD: This word indicates that the RAIL SWEEP: A device attached to the truck requirement is a recommendation. ROTATING AXLE: An axle that rotates with STOP: A device to limit travel of a trolley or the wheel. STEPLESS CONTROL: A type of control system with infinite speed control between RESISTOR RATING: Rating established by minimum speed and full speed. RUNWAY CONDUCTORS: The main TORSIONAL BOX GIRDER: Girder in which conductors mounted on or parallel to the the bridge rail is located over one web. relating to the subject matter and work. inspections. other end on a leg or legs extending down to an end truck with wheels riding on a lower I VOLTAGE DROP: The loss of voltage in an eve1 railirunway.QUALIFIED PERSON: A person who. repairs. TROLLEY FRAME: The basic structure of SELLER: An entity that sells cranes. center of runway rails. training. and SHEAVE: A grooved wheel or pulley used experience. as the hook is raised or lowered. TROLLEY: The unit carrying the hoisting RUNWAY RAIL: The rail supported by the mechanism that travels on the bridge rails. by any method other than pendant or rope control. has successfully demonstrated with a rope or chain to change direction and the ability to solve or resolve problems point of application of a pulling force. TEFC: Totally enclosed fan cooled. wheels riding on a fixed raiVrunway and the VARIABLE FREQUENCY: See Inverter. Also see section 78-6. TENV: Total enclosed non-ventilated. brackets and framework on which the crane operates. to the particular requirement is necessary in certificate of professional standing or who by order to conform to the specification. REMOTE OPERATED CRANE: A crane STATIC CONTROL: A method of switching controlled by an operator not in a pulpit or in electrical circuits without the use of contacts. SERVICE CLASS: The type of service that a crane is subjected to during its operating life WHEELBASE: Distance from center-to- as defined by CMAA Specifications #70 and center of outermost wheels. crane bridge. . extensive knowledge. system with fixed speed points. runway beams on which the bridge travels. the cab attached to the crane. testing on overhead traveling cranes and associated hoisting equipment. the trolley on which are mounted the hoisting associated hoisting equipment and/or and traversing mechanisms. runway that supply current to the crane. services for these cranes and equipment. alterations and the bridge to give maximum loading. WHEEL LOAD: The load without vertical SERVICE PROVIDER: An entity that inertia force on any wheel with the trolley performs maintenance. RATED LOAD: The maximum load that the SKELETON CAB: Same as dummy cab. the and located in front of the truck's leading advisability of which depends on the facts in wheels to remove obstructions. and lifted load (rated capacity) positioned on troubleshooting. P. OFcupaUan 8 How Long? INJURY 8 PART EQUIPMENT WHAT COULD BE DONE TO FUTURE RE- OCCURENCES? ROWING (SIGNATURES ) I Employee Date 2. Clodc No. Safety Team Member Date THESE SECTIONSTO BE FILLED O W BY SUPERVISOR . APPENDIX A Accident Investigation I COMPLETE WITHIN 24 HOURS OF INCIDENT TYPE OF INCIDENT Employee Incident Report Form THESE SECTMNSTO BE FILLED OUT BY EMPLOYEEAND SARTYTUM MEMBER BE SPECIFIC AND INCLUDEALL DETAILS 81 Injury or llliness 61 NearMiss B Property Damage Date of Injury 1 Time a AM.M ( Reported I I Name Home Phone CmpartmenlNo. (3 Close deamnca and amgestkm hazards (3 Taking an unsah poritbn or po9ture. 8 Unsab Pincement. (3 Falkwe to waar pmmnal pmledw equipment 0 Unsafe kmdlng. S a f a t y l H m Rerouraa6 Date . (3 Inadequate Hlumination. 0 Failura to -re against umpactad tmvment 0 Lack of or inadequate warnlng systems. etc. equipment. (3 Falkrre to warn wslgnal 86 rrrguliud. di6bahg. (3 Fire and axploslon hazard. etc. C3 Lsdc of or Inadequate guards or deviap. (3 Using Dds a equipnent unsafe&. wnlrKwle to the cause of thb incident? ) HOW W L D THIS MVE BEEN PREVENTED? WHAT COULD BE DONE TO PRNENT FUTURE RE- OCcuRWCES7 WHO Is R~SPONSWU FOR CORRECT~VCACTION? BY WEN? ROUTING (SIGNATURES) 3. (3 Homlsy. (3 krnovhg or maklng safay dsvices in-th.nsa activiiy being pcwlormcld) INCIDENT RIPT TI ON . a Other than a b m ( Old anything el. teasing. (3 Unetpscted movement hazard.pp. Be SPECWIG AND INCLUDEA U DETAILS ACCIDENT! (L-aabn. (3 Hazardous anangsment. what h. placmmnt a storage. CONTREUTING FAC. 81 Paor housekesplng hazards. 6Uskgdssdivebisorequ!+nnant 0 Pmbuding o bw hazard. 0 Ormaling a waking at an unsafe speed. 0 Hazardousdetects of tools. (3 Fa#weto kdr out equipmsnt befas mrvldng. (3 Riding ~~ZMIOIISm m g equipment. (What was ths underlying c a m of this lnddmt?) (3 OpastingEquipnent wiMout authcnity. Separate inspectionfiles should be maintained for each crane. NC 28217-3992 7041676-1190 OVERHEAD CRANE INSPECTION AND MAINTENANCE CHECKLIST The following checklist is furnished by the Crane ManufacturersAssociation of America. place all controllers inthe "off" position. severity of service.. 8720 Red Oak Blvd. Inspectors or maintenance personnel should never go on a crane without first notifying the crane operator of exactly what they are doing and what they expect the operatorto do. Depending e r a n e activity. APPENDIX B Crane Manufacturers Association of America. Suite 201 Charlotte.0-1983 Saf service personnel also must be maintenanceand repair manualassupplied by th to read and understandthese instructions can r This checklist includes instructionsfor information does not apply to all e r important items requiring frequent inspectionwhich are not ne manufacturerregarding any special information about spec1 lished with the designated inspector completing. The responsibilHy for the interpretation of current OSHA standards and the adherence to any such interpretation rest with the owner andlor user of the equipment. Before repairs areconducted. Special e given to the inspection and maintenance of hoisting equipment and safety devices. CMAA and its member companies assume no liability for general or special damage which may arise in connectionwith this checklist. and maintenance of cranes are a continuin user.2. and add a warning sign to the switch. . This inspectionin no way representsthat the requirementsof OSHA have been met. and environment. more frequent inspectionand maintenance may be required. in accordance with ANSI 830. Inc. testing. signing. based on a40 hour work week. (CMAA) as an aid to owners of overhead cranes when conducting periodic maintenan installation. and dating the . operation. are for an average industrial operation. indicating that a man is on the crane. Inc. lockthemainswitch open. No. Idnt. CRANF INSPECTION SCHFnlli F AND MAINTFNANCE RFPQBI Cust.: Master Switches Mainline Disconnect 8 Warning Device Fire Extinguisher . No.INSPECTIONSCHEDULE AND MAINTENANCE REPORT Cust Idnt.: When Corrected . When Corrected . 3 First aid 3.8.4 Drug free workforce 3.2.2 - Inspection initial 4.6.1.crane technician 2.5 Reference Document 1.1 - Maintenance procedures 4.2 - Maintenance records 4.2 Rigging 3.4 Crane classification 6.1 - Inspection periodic 4.replacement 5. 5.1.3 - Certification operator 3.1.1.8 Problem-ClassA 5.3.2.1 .3.5.1 Parts .7.1 Hazardous materials 3.1.5 Safety and first aid 3.8.8 Load Testing 4.6.7.5.9 - Parts repair 5.3.6.6.4.5.packaging 5.counterfeit 5.2.1 Reporting 4.8 Appendix B .2 Personal protective equipment 3.5.5.3.5 Crane Inspector 2.3 Ergonomics 3.6. 5. 5.4.1 Fire prevention 3.7 Electrical safety 3.6.4 - Work experience crane technician 2. 5.2.1.6.9 Emergency response 3.7.8.5.1 - Problem Class B 5.2.7 - Maintenance preventative 4.6. 2.6.2 Appendix A -Accident Investigation Report Load class 6.1. 4.Maintenance Checklist Load cycle 6.1 - Parts O.2.5.1 Fall protection 3.1.2.4.5 Trademark Counterfeiting Act 5.1 0 Signage 3.1 Required training .4 Crane technician 2.2 Parts .2 Safety orientation 3.2 Parts . 5.1 PUpgrade parts 5. 5.1 Performance enhancements 5.1 - Inspection pre-shift 4.3 .kits 5.1 Scope 1.6.M.1.2.2 Confined space 3.1 - Work experience crane inspector 22.2.E.4 Manuals 5.5.7.7.1.8 Upgrade .component 5.7 Respiratory protection 3.4.1 - Parts manuals 5.6.6 Employee responsibility (CMAA employee) 3. 5.2 - Required training crane inspector 2. 78-8 INDEX Accident prevention 3.2 - Inspection frequent 4.3. 5.2 - Problem root cause 5. - Upgrade equipment 5.6.5.6 Regulations 3.2.6.11 Safety statement 3.4 - Qualifications crane technician 2.3.6.1 Parts .5. NC 28217-3992 Telephone: (704) 676-1190 Fax: (704) 676-1199 Website: www..CMAA is an Affiliate of Material Handling Industry 8720 Red Oad Blvd.org/cmaa .mhia. Suite 201 Charlotte.