CRANE MANUFACTURERS ASSOCIATION OF AMERICA, INC.

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-trained and 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:

78-1. General Information

78-2. Technical Qualifications

78-3. Jobsite Safety

78-4. Crane Inspection, Maintenance and Load Testing

78-5. OEM (Factory) Parts

78-6. Crane Service Classifications

78-7. Glossary

Appendix

78-8. Index

No part of this Specification may be reproduced in any form

without the prior written permission of the publisher.

Copyright 02002 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 lndustry 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 MHl 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. CMAAspecifically 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

less from and against all claims, losses, expenses, damages, and liabilities, direct, ntal, or consequential, arising from acceptance or use or alleged use of these

Standards and Guidelines, 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 to absolve and protect CMAA and its officers,

Is, 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.

sibility of the OwnerNser to install, inspect, test, maintain, and operate a ated lifting equipment in accordance with the applicable volume of the Safety Standard, OSHA Regulations, and ANSllNFPA 70, National Electric

Code and local regulations and laws. If the crane or associated lifting equipment is installed as part of a total lifting system, it is also the responsibility of the ownerluser to

the applicable ANSIIASME B30 volumes that address other types of equipment used in the system.

Further, it is a responsibility of the OwnerlUser to require all personnel who install, inspect, test, maintain, and operate a crane or associated lifting equipment to read and to

the contents of the instruction manuals furnished by the manufacturer of the ciated lifting equipment, and the applicable portions of the volume of the 30 Safety Standard, OSHA Regulations, and ANSIINFPA 70, National Electric

e crane or associated lifting equipment is installed as part of a total lifting m, the applicable ANSUASME 830 volumes that address other types of equipment in the system must also be read and followed by all personnel.

78-1 General lnformation

1.1 Scope 1.2 Reference Documents

78-2 Technical Qualifications

2.1 Crane Technician 2.2 Crane Inspector

78-3 Jobsite Safety Guidelines

Commitment to Safety Statement Employee Responsibility Safety Orientation and Documentation Regulations Equipment Operator Certification Safety and First Aid Drug-Free WorMorce Personal Protective Equipment Equipment, Rigging, Tools Fire Prevention Ergonomics

78-4 Crane inspection, Maintenance and

4.1 Initial lnspection 4.2 Pre-Shift lnspection 4.3 Frequent lnspection 4.4 Periodic lnspection 4.5 Reporting 4.6 Maintenance 4.7 Load Testing

78-5 Genuine OEM (Factory) Parts

General Purpose Assurance Application and Design Familiarity Component Updating and Modernization Root Cause Analysis and Solutions Recommendation for Complete Parts Requirements Counterfeit Parts Technical lnformation Packaging Regulation Compliance

78-6 Crane Classifications

General Class A Class B Class C Class D Class E Class F Crane Service Class In Terms Of Load Class and Load Cycles

78-7 Glossary

Appendix A Appendix B

78-8 Index

78-1 GENERAL INFORMATION

1 SCOPE

1.1.1 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.

1.1.2 The information contained in this publication applies to top running and underrunning bridge and gantry type single or double girder overhead traveling cranes and associated hoisting equipment. It should be understood that the Specification is general in nature and other specifications may be agreed upon between the Purchaser and the service provider (Seller) to suit each specific case.

1.1.3 Section 78-6 outlines six different classes of crane service as a guide for determining the service requirements of the individual application. In many cases there are no clear categories of service in which a particular crane operation may fall, 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.

1.1.4 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. These factors must be given careful consideration to assure maximum equipment operating life and minimum breakdowns.

1 . I .5 Serious property damage, personal injury or death can occur if cranes are not operated properly or not regularly inspected, serviced and maintained.

1.2 Reference Documents

Parts of this Specification refer to certain portions of other applicable specifications, codes or standards. Where interpretations differ, CMAA recommends that this Specification be used as the guideline. 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, New York 10036

ANSI-ASME B30 specifications that are applicable to overhead & gantry cranes, chain and wire rope hoists, below-the-hook devices and associated equipment.

ASME The American Society of Mechanical Engineers Three Park Avenue New York, New York 10016-5990

CMAA Crane Manufacturers Associat~on of America, Inc. ~ ~

8720 Red Oak Blvd., Suite 201 Charlotte, North Carolina 28217-3992

Specification No. 70 - Top Running Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes

Specification No. 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., Suite 201 Charlotte, North Carolina 28217-3992

Specification No. MH27.1 - Standard for Patented Track Underhung Cranes and Monorail Systems

Specification No. MH27.2 - Standard for Enclosed Track Underhung Cranes and Monorail Systems

NECINFPA National Electric Code National Fire Protection Association 1 Batterymarch Park, P.O. Box 9101 Quincy, Massachusetts 02269-91 01

OSHA U.S. Department of Labor Directorate of Safety Standards Programs 200 Constitution Avenue, N.W. Washington, D.C. 20210

29 CFR Part 1910 - Occupational Safety & Health Standards for General Industry

78-2 TECHNICAL QUALIFICATIONS

Crane Technician

Any person engaging in repairing, troubleshooting, maintaining, servicing and functional testing 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 technician should have relevant work experience in maintaining, servicing, repairing and modifying cranes. This experience should provide a working knowledge of how to identify deficiencies and make repairs in mechanical, structural, electrical systems and components of cranes. 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, regulations and the product being repaired.

Physical qualifications - A crane technician should possess the following minimum qualifications:

Have vision of at least 20130 Snellen in one eye, and 20150 Snellen in the other, with or without corrective lenses and have normal depth perception, field of vision, hand-eye coordination, and no tendencies to dizziness or similar conditions.

Be able to hear, with or without hearing aid, adequately for a specific task.

Have sufficient strength, endurance, agility, coordination, manual dexterity a speed of reaction to meet the demands of the job.

Not have evidence of physical restrictions; not be subject to seizures or loss physical control, or emotional instability that could render a hazard to t technician or others. Evidence of such conditions may be cause f disqualification. In such cases, specialized clinical or medical judgments and tests may be required.

Be capable of working at extended heights in a safe manner under varying environmental and adverse physical conditions.

Other Qualifications:

Should demonstrate proficiency to read and write in English.

Should demonstrate proficient oral and written communication skills.

Should be subject to other safety, drug, or other specific Seller and/or Purchaser's requirements. Should adhere to Seller andlor Purchaser's health and safety guidelines.

Should be able to distinguish colors, regardless of position of colors, if color differentiation is required for the task.

8

REQUIRED TRAINING

The technicians should have received formal training in the areas of their trade or discipline and area(s) of expertise. Additional training should include, but not be limited to:

Trade skills - examples such as, basic electricity and wiring practices, basic mechanical principles, machinery alignment, rigging, etc.

Safe operating practices of cranes - receive classroom and practical training on basic operating principles and methods such as rigging, hand signals, starting, stopping and controlling loads, do's and don'ts for safe operation, etc.

Products - training on how to maintain, troubleshoot and repair the common components of cranes and specific product lines or models produced by the manufacturer.

Safety - training on all aspects of job-site safety, safe work practices and additional on-site training as required by the Purchaser. Refer to section 78-3.

Tools and Equipment - training on proper and safe operation of work tools and equipment such as ladders, man-lifts, jacks, hand tools, meters, etc.

Job-site Conduct - training on customer communication, proper check-in and checkout, site preparation and cleanup, etc.

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. Technicians should be able to present documentation of successful completion of training for topics that require examination.

Crane Inspector

Any person engaging in the testing, 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

Acrane inspector shall have a minimum of 2,000 field hours of experience related to the maintaining, servicing, repairing, modifying and functional testing of cranes and associated hoisting equipment. This experience should provide a working knowledge of how to identify deficiencies in mechanical, structural, electrical systems and components of cranes. 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.

Physical qualifications -A crane inspector should possess the following minimum aualifications:

Have vision of at least 20130 Snellen in one eye, and 20150 Snellen in the other, with or without corrective lenses and have normal depth perception, field of vision, hand-eye coordination, and no tendencies to dizziness or similar conditions.

Be able to hear, with or without hearing aid, adequately for a specific task.

Have sufficient strength, endurance, agility, coordination, manual dexterity and speed of reaction to meet the demands of the job.

Not have evidence of physical restrictions; not be subject to seizures or loss of physical control, or emotional instability that could render a hazard to the technician or others. Evidence of such conditions may be cause for disqualification. In such cases, specialized clinical or medical judgments and tests may be required.

Be capable of working at extended heights in a safe manner under varying environmental and adverse physical conditions. Other Qualifications:

Should demonstrate proficiency to read and write in English

Should demonstrate proficient oral and written communication skills.

Should be subject to other safety, drug, or other specific Seller andlor Purchaser's requirements.

Should adhere to Seller andlor Purchaser's health and safety guidelines.

Should be able to distinguish colors, regardless of position of colors, if color differentiation is required for the task.

REQUIRED TRAINING

The inspector should have received formal training in the areas of: safety and design codes related to cranes; Federal, State and local codes and regulations; safe operating practices of cranes; report writing and documentation; and communication skills.

Due to continuing changes and updates to standards and codes, an inspector should receive additional formal training every two years as a minimum and be able to provide documentation of such training.

The words "should and "shall" are used extensively throughout the codes and specifications including ASME 830, OSHA 1910.179 and CMAA. 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, but recommended ("should).

Additional training should include, but not be limited to the following areas. These areas are a prerequisite to training as an inspector in addition to training in the safe interpretation of the Federal, State and local codes and regulations:

Trade skills - examples such as basic electricity and wiring practices, mechanical principles, machinery alignment, rigging, etc.

Products - training on how to interpret wear patterns and recommendations for repair or replacement utilizing sound judgemen manufacturers' guidelines.

Safety - training on all aspects of job-site safety and safe work practices, proper crane operation and the understanding of crane controls, and additional on-site trainingas required by the Purchaser. Refer to section 78-3.

Tools and Equipment - training on proper and safe operation of work tools and equipment such as ladders, man-lifts, jacks, hand tools, meters, etc.

Job-site Conduct - training on customer communication, proper check-in and check-out, site preparation and cleanup, etc.

Testing

The inspector shall be required to demonstrate proficiency by passing both a written and practical examination. Inspector should be able to present documentation of successful completion of above qualifications.

If local code bodies or governments mandate, additional testing and registration for inspector certification or licensing may be required.

78-3 JOBSITE SAFETY GUIDELINES

Commitment to Safety Statement

There must be a commitment to providing a safe workplace for employees and customers. Their goal is to ensure a working environment free from recognized hazards. This section has been prepared as a general guideline and cannot cover all specific work situations that may occur. it is the responsibility of the employees at each specific work site to ensure all precautions are taken and safe work practices are followed.

Employee Responsibility (Employee of a service provider)

Each employee of a service provider (Employee) has the responsibility to become familiar with all safety practices and be knowledgeable regarding all safety issues, policies, procedures and equipment. If Employees are NOT familiar with these practices, procedures and equipment, it is their responsibility to obtain the proper information to become familiar with them.

Safety Orientation and Documentation

All Employees should receive appropriate safety training and orientation before beginning any work. Additional training may be required if it is found that there is a lack of understanding of safety programs, policies and procedures.

Regulations

Purchaser Site Regulations

Employees shall comply with all purchaser site regulations and safety policies. It is the responsibility of these Employees to review all site-specific requirements with the purchaser. Any required training at the purchaser's site shall be completed prior to starting any work.

Federal, State and Local Regulations

All work shall be performed in compliance with Federal, State and Local regulations, codes and requirements.

Equipment Operator Certification

Motor Vehicle Use

All motor vehicles shall be operated in accordance with all Federal, State, and Local requirements. In the event of a motor vehicle accident refer to Accident Reporting, section 3.6.4.3.

3.5.2 Mobile crane, forklift, scissors lift, boom lift and other machinery

Mobile cranes, forklifts and other machinery are often required to complete the work. Each Employee has the responsibilityfor the safe operation and use of any such equipment prior to operation. Mobile cranes, forklifts, scissors lifts, boom lifts and other machinery shall only be operated by trained, licensed (where required) individuals. Refer to manufacturer's requirements for specific operating procedures and requirements. All equipment shall be in good operating condition with all required inspection and maintenance documentation available.

3.5.3 Ladders

All ladders shall be used in compliance with the manufacturer's recommendations. Care shall be taken to secure the ladder to prevent falling or slipping.

3.6 Safety and First Aid

3.6.1 Fall Protection

Service providers should have a Fall Protection Policy. Fall protection applies to all Employees who are working at heights above 6 feet from the ground. Site specific conditions shall be evaluated to determine the required method of fall protection to be used. Employees shall be competent in the use of fall protection equipment. All fall protection equipment shall be regularly inspected and in good working condition.

3.6.2 Electrical Safety

3.6.2.1 Service providers should have a Lockout / Tagout policy. The purpose of this policy is to protect Employees agalnst unexpected release of energy including electrical, pneumatic, hydraulic, chemical and other potential energy sources.

3.6.2.2 All Employees shall be trained on the Lockout / Tagout policy.

3.6.3 Job Site Work Area and Signage

Work areas should, wherever practical, be identified by highly visible signs, barriers or other appropriate means to alert others that overhead work is being performed. It is the responsibility of the Employee to assess site specific conditions and determine the best method to provide maximum safety.

3.6.4 Accident Prevention and Awareness

3.6.4.1 All service providers shall adopt an Accident Prevention Policy. This policy should cover general safe working practices and accident prevention. Site specific issues shall be reviewed prior to the start of any work. Any unsafe conditions should be addressed, reported, and corrected prior to commencement of work. It is the responsibility of all Employees to actively provide a safe work environment for themselves and all other site personnel.

3.6.4.2 Safety meetings are an important part of any Accident Prevention Plan. These meetings should be conducted on a routine basis as necessary by site conditions or purchaser requirements.

All accidents, regardless of severity, shall be reported to the appropriate designated person for both the Seller and Purchaser. An accident report should be used to investigate the incident, to identify the root cause and to initiate corrective action to prevent future occurrences. (See Appendix A for sample of an accident report.)

First Aid and Emergency Response

All service providers shall have a First Aid and Emergency Response Policy. Access to the following information should be made available prior to commencement of work:

Emergency contact personnel and phone numbers.

Identity of medical treatment facilities on site or near work area

Basic First Aid training and supplies.

Confined Space Regulations

All service providers should have a confined space program. All Employees shall be trained, as applicable and as dictated by specific work conditions, on this policy.

This policy should identify procedures to be followed for entry into a permit- required confined space. Employees should be capable of identifying and understanding the difference between a permit-required situation and other confined space conditions.

Respiratory Protection Program

All service providers shall have a Respiratory Protection Policy. All Employees shall be trained on the requirements of this policy. The purpose of this policy is to protect Employees from breathing air contaminated with harmful dusts, fumes, mists, gases, sprays or vapors which may cause serious injury or illness.

The policy should consider methods to eliminate or minimize exposure to hazardous air contaminants. When controls are not feasible or while they are being instituted, appropriate respiratory protection shall be used.

Hazardous Materials

All service providers shall have a Hazardous Material Policy. All Employees shall be trained on the requirements of this policy.

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.

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.

Drug-Free Workforce

All service providers should be committed to providing a Drug and Alcohol Free Workplace.

All service providers shall have a Substance Abuse Policy. All Employees shall agree to participate in any seller or purchaser mandated drug screening.

Personal Protective Equipment

All service providers shall have a Personal Protective Equipment Policy. Personal protective equipment is intended to protect Employees from specific hazards. Employees shall be required to wear personal protective equipment that has been selected for the job. They shall properly take care of the equipment and maintain it in a clean and sanitary manner.

Other Personal Protective Equipment includes but is not limited to hard hats, face shields, goggles, gloves, steel toe shoes/boots, aprons, sleeve protectors, and hearing protection.

All Personal Protective Equipment shall conform to existing standards and be in proper operating condition. Safety glasses, goggles or face shields must conform to the latest published standards for protective eyewear (Reference USA-ANSI 287). This includes both prescription and non-prescription eye wear.

Equipment, Rigging, Tools

Slings and other rigging shall be visually inspected and in proper condition prior to use and must conform to all applicable specifications. Each Employee shall have knowledge of proper use of all hand and power tools applicable to the work being performed by that Employee.

Fire Prevention

All service providers shall have a Fire Prevention Policy. All Employees shall be knowledgeable and trained on fire prevention. Extreme caution shall be used when working with tools that may ignite in and around combustible materials. Fire Prevention Policy should include hot work permit procedure, fire watch training, fire blankets, fire extinguisher and other appropriate equipment.

3.11 Ergonomics

All service providers should have a policy to help prevent back and other injuries and to provide training on proper methods of lifting.

78-4 CRANE INSPECTION, MAINTENANCE AND LOAD TESTING

Initial lnspection

New, reinstalled, altered, repaired, and modified cranes shall be inspected prior to initial use. lnspection of all altered, repaired, and modified cranes may be limited to the provisions affected by the alteration, repair, or modification, as determined by a qualified person.

Performance of lnspection

A new crane's initial inspection shall be performed by a qualified manufacturer's representative. Refer to section 2.1 and 2.2.

An altered, repaired, modified or re-installed crane's initial inspection shall be performed by a qualified person.

Scope of lnspection

New or reinstalled equipment shall be inspected in accordance with original manufacturer's recommendations. Examples of typical inspection items may include but are not limited to clearances, operating speeds, lubrication levels, proper control settings, and properly operating safety devices, etc.

Altered, repaired, or modified cranes shall be inspected to assure that the altered, repaired, modified component(s) have been properly installed and functionally tested.

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. The report should also contain specific start-up settings necessary to achieve optimum equipment performance. This document should be maintained for the life of the equipment.

Altered, repaired, or modified cranes should have an initial inspection report on file documenting the areas affected by the alteration, repair 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.

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.

Scope of lnspection

Refer to the CMAA Crane Operator's Manual

4.3 Frequent Inspection

4.3.1 Hooks, wire ropes and load chains shall be inspected at minimum monthly intervals and documented with a certification record which includes date of inspection, the signature of the person who performed the inspection and the serial number or identifier of the hook, chain or wire rope inspected.

4.3.2 The Frequent Inspection is a visual and operational inspection performed as often as daily, based on service, environmental and application factors, as determined by a q;alified person or as outlined in Table 4.3:1'

NORMAL MONTHLY MONTHLY MONTHLY

Table 4.3-1 Frequent lnspection Chart NUMBER OF SHIFTS OPERATED PER DAY

MONTHLY MONTHLY SEMI-MONTHLY TO MONTHLY

CMAA ERVICE 2LASS

A

HEAVY

SEVERE F

MONTHLY SEMI-MONTHLY WEEKLY TO TO MONTHLY SEMI- MONTHLY

ASME 830.2 SERVICE

CLASS

WEEKLY 3-5 DAYS DAILY

STAND-BY 1 SHIFT 2 SHIFTS 3 SHIFTS

FREQUENCY OF INSPECTION SEMI-ANNUALLY SEMI-ANNUALLY SEMI-ANNUALLY SEMI-ANNUALLY

DAILY DAILY DAILY

4.3.3 A crane that has been idle for a period of one month or more, but less than six months, shall be given a frequent inspection in accordance with 4.3.2.

4.3.4 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. 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, and an identifier for the rope that was inspected.

4.3.5 Performance of the Inspection

The Frequent lnspection shall be performed by a qualified Inspector. The qualified lnspector shall determine whether conditions found during the inspection constitute a hazard and whether a more detailed inspection is required. Refer to section 2.1 Crane Inspector.

4.3.6 Scope of Frequent lnspection shall include, but not be limited to the items in Table 4.3-2.

Table 4.3-2 List of Frequent lnspection Items

. . , grooves.

Limit Switches Check that the upper limit device stops lifting motion of the hoist load block before striking any part of the hoist or crane. Caution: exercise extreme care during this test to avoid striking any part of the hoist or trolley with the hoist load block in the event of a faulty limitswitch.

3il Leakage Check for any sign of oil leakage on the crane and on the floor area beneath the crane.

Jnusual Sounds Check for any unusual sounds from the crane or hoist mechanism while operating the crane and hoist.

Varning and Safety Check that warning and other safety labels are not missing .abels and Warning and that they are legible. Check that audible and visual levices warning devices are operational.

4.3.7 Documentation of Inspection

All other items of table 4.3-2 should be documented. lnspection reports should identify the specific hazard or maintenance problem and kept on file for 3 years. Safety hazards shall be reported to the responsible person immediately upon discovery.

Refer to the Overhead Crane lnspection and Maintenance Checklist in Appendix B, which may be used to document the inspection.

Periodic lnspection

A Periodic lnspection is a detailed visual and operational inspection whereby individual components are examined to determine their condition. The Periodic lnspection is performed as often as quarterly based on service, environmental and application factors as determined by a qualified person or as outlined in Table 4.4-1.

CMAA ;ERVICE CLASS

A

B

C

D

E

F

ASME 830.2 SERVICE CLASS

NORMAL

HEAVY

SEVERE

Table 4.4-1 Periodic Inspection Chart

NUMBER OF ShlFTS OPERATED PER DAY

1 SHIFT 2 SHIFTS 3 SHIFTS

FREQUENCY OF INSPECTION ANNUALLY ANNUALLY ANNUALLY

ANNUALLY ANNUALLY ANNUALLY

ANNUALLY ANNUALLY ANNUALLY

ANNUALLY SEMI-ANNUAL TO SEMI-ANNUAL ANNUAL

XJARTERLY QUARTERLY QUARTERLY

WARTERLY QUARTERLY QUARTERLY

A crane that has been idle for a period of six months or more shall be given a periodic inspection in accordance with Table 4.4-2.

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. 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, and an identifier for the rope that was inspected.

Performance of the lnspection

The Periodic lnspection shall be performed by a qualified inspector. The qualified Inspector shall determine whether conditions found during the inspection constitute a hazard and whether a more detailed inspection is required. Refer to section 2.2 Crane Inspector.

4.4.4 Scope of Periodic Inspection should include, but not be limited to, the items in Table 4.4-2.

Table 4.4-2 List of Periodic lnspection Items ,

I powered generating unts I with app1icab.e safe4 reqL.rements. ( Transmiss~ons I Chec~ for excessave wear of chain o w e sprockets

and excessive chain stretch. Open gearbox inspection covers and check for gear teeth wear and proper lubrication.

Electrical components Check all electrical apparatus, for signs of pitting or any deterioration of controller contactors, limit switches, pushbutton stations, motor slip rings, brushes, resistors. Check for any loose wire connections or damaged wiring. Check for evidence of overheating.

Covers and guards Check that all covers or guards are in place, secure, and undamaged.

Bumpers and end stops Check all bumpers and end stops for damage. Check for proper restraints and obvious undersizing

I or Improper energy absorpt~on capabilities. Trolley and runway rad ( Check ralls and fastening deuces for looseness, I

Documentation of lnspection

Reports for Periodic Inspections documenting the above items shall be kept on file by the owner1Purchaser and, if applicable, the service provider. The reports should be maintained for at least 3 years.

Refer to the Overhead Crane lnspection and Maintenance Checklist in Appendix B, which may be used to document the inspection.

Reporting

Safety Hazards

Safety hazards shall be reported to the responsible person, in written format, immediately upon discovery. Reports should include specific identification of the hazard, and a recommendation(s) for remediation of the hazard.

Maintenance Issues

Maintenance issues shall be reported to the appropriate supervisor or responsible person, in written format, within a reasonable time from discovery. Damage, safety related issues andlor imminent equipment failure must be reported immediately. Reports should include spec~fic identification of the item and a recommendation(s) for remediation of the item. Unsafe conditions disclosed by the inspection should be corrected before operation of the crane is resumed.

Code or Standard Violations

Code or standard violations shall be reported as part of the inspection process. Reports should be specific with regard to the violation, the applicable code, or the standard reference.

Standards for Reporting

lnspection reports shall be given to the Purchaser's responsible person in a specific and legible format. lnspection reports shall be -kept on file by the ownerIPurchaser and, if applicable, the service provider for a period of three (3) years from the date of the actual inspection.

Equipment Identification

lnspection reports shall specifically identify the equipment inspected, including its location, manufacturer's serial number and owner's equipment number.

Proof of lnspection (tags, etc.) shall be affixed to the inspected equipment by the inspector. Proof of inspection shall be in plain sight and shall contain the date of the last inspection, name of the inspecting company, if applicable, and the individual that performed the inspection.

Maintenance

Preventive maintenance shall be performed based, as a minimum, on the crane manufacturer's recommendations.

Maintenance procedures shall include, as a minimum, 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.

All controllers shall be at the off position.

The main electrical disconnect switch shall be open and locked in the open position. Follow appropriate lockout/tagout procedures.

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.

Where other cranes are in operation on the same runway, rail stops or other suitable means shall be provided to prevent interference with the idle crane. Additionally, other crane operators on the same runway and in adjacent runways shall be notified of the out-of-service crane.

After adjustments, maintenance, or repairs have been made, the crane shall not be operated until all guards have been reinstalled, safety devices reactivated and maintenance equipment removed.

Adjustments, maintenance, 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. Adjustments, maintenance, or repairs shall be done only by qualified personnel in accordance with section 78-2.

Maintenance Records

Records shall be kept on file evidencing adjustments, maintenance, and repairs that have been performed. Maintenance records should be retained for the life of the equipment.

Maintenance records should document routine and preventive maintenance activities as well as adjustments, maintenance and repairs that result from inspections.

Refer to the Overhead Crane Inspection and Maintenance Checklist in Appendix €3, which may be used to document the repairs.

4.7 Load Testing

4.7.1 All new, extensively repaired and altered cranes shall be tested in accordance with OSHA Part 1910.179(k).

4.7.2 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. The test load should be equal to and not exceed the rated load lifting capacity of the crane.

4.7.3 Reports for documenting the load test should be maintained by the OwnerIPurchaser for the life of the crane.

4.7.4 The load test should be performed at a minimum of once every four years.

78-5 GENUINE OEM (FACTORY) PARTS

General Purpose

The original equipment manufacturer (OEM) should be considered a primary source for obtaining repair parts. The OEM should also be considered for engineered solutions pertaining to equipment upgrades, performance enhancements, or changes of application.

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.

Assurance

The OEM shall assure that the replacement part is a proper fit for the part to be replaced.

The OEM shall assure that the replacement part is made of a material that is Properly selected and suited for the application.

The OEM shall assure the part is without defects in material and workmanship at the time it is shipped.

Application and Design Familiarity

The OEM is responsible for the total design of the crane and the selection of its components. By purchasing replacement parts from the OEM, the Purchaser is better assured of proper mating of parts and the interaction of components necessary to maintain the integrity of the repair.

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. A part or component upgrade may be considered if its operating life is not acceptable to the Purchaser.

Component Updating and Modernization

The OEM is in the best position to determine a cross-reference between the original part and a suitable replacement.

The OEM should be the primary source for recommending the substitution of a replacement part for the original part.

As the sole source of the original design drawings and calculations, the OEM is most capable of developing or recommending design improvements.

Root Cause Analysis and Solutions

During a crane's operating life, problems may occur that do not have obvious or readily apparent causes. The OEM is a reliable, expert resource, and should be consulted to help determine the root cause of the problem and recommend potential solutions.

Every part has a working life. The crane application and the service class impact the working life. Two types of problems may occur:

Type A Problem- the Purchaser may wish to increase the working life to enhance performance, improve reliability and productivity, etc.

Type B Problem- the original part may fail before it reaches its working life due to an undetermined cause,

Problem Analysis

Type A Problem: would typically include studies of crane duty cycle, component part stress analysis, lifting capacity uprate, preventive maintenance practices and operator performance.

Type B Problem: in addition to the studies performed for Type A Problems, other diagnostic methods would be used to determine if OEM-established operating conditions are being met, such as runway tolerances, quality of power supply, mechanical and electrical connections, original factory settings, etc.

Problem Solutions

Type A Problem: may take the form of recommendations to increase operating component size, change component type, add structural reinforcements, impose a formal preventive maintenance program or conduct operator training classes, etc.

Type B Problem: may take the form of correction of the root cause such as aligning the runway, adding line reactors or filters to the power supply, upgrading material specif~cations, enhancing a preventive maintenance program, or conducting operator training classes, etc.

Recommendation 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.

Based on its knowledge of the repair, the OEM is able to recommend all parts that may be required to efficiently complete the repair, such as seal kits, bearings, etc.

The OEM can usually determine if mating parts should also be replaced. For example, if a pinion is being replaced, the mating gear should also be replaced.

Counterfeit Parts

The Federal Trademark Counterfeiting Act is aimed at curbing the manufacture, distribution and sale of counterfeit trademarked products, including replacement parts, in the United States.

Use of other than recommended or approved parts may void the OEM crane manufacturer's warranty.

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, personal injury or death.

Technical Information

The OEM shall furnish parts manuals that clearly identify replacement parts to better assure that the correct part is ordered.

The OEM shall provide written guidelines to assist the Purchaser in the proper operation and maintenance of the equipment.

Certain non-proprietary drawings may be available from the OEM to aid in the maintenance or upgrade of the crane.

Packaging

The OEM shall provide adequate packaging to prevent damage during shipment.

Regulation Compliance

The OEM can assist the Purchaser by recommending modifications or upgrades to bring the crane into compliance with Federal, State and Local regulations and codes.

78-6 CRANE CLASSIFICATIONS

GENERAL

Service classes have been established so that the most economical crane forth installation may be specified in accordance with CMAA Specifications #70 an #74.

The crane service classification is based on the load spectrum reflecting t actual service conditions as closely as possible.

Load spectrum is a mean effective load, which is uniformly distributed over a probability scale and applied to the equipment at a specified frequency. 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.

Where W = Load magnitude; expressed as a ratio of each lifted load to the rated capacity. Operation with no lifted load and the weight of any attachment must be included.

P = Load probability; expressed as a ratio of cycles under each load magnitude condition to the total cycles. The sum total of the load probabilities P must equal 1.0.

k = Mean effective load factor. (Used to establish crane service class only)

All classes of cranes are affected by the operating conditions, therefore for the purpose of the classifications, it is assumed that the crane will be operating in normal ambient temperature O0 to 1040 F (-17.80 to 40°C) and normal atmospheric conditions (free from excessive dust, moisture and corrosive fumes).

The cranes can be classified into loading groups according to the service conditions of the most severely loaded part of the crane. The individual parts which are clearly separate from the rest, or forming a self contained structural unit, can be classified into different loading groups if the service conditions are fully known.

CLASS A (STANDBY OR INFREQUENT SERVICE)

This service class covers cranes which may be used in installations such as power houses, public utilities, turbine rooms, motor rooms and transformer stations where precise handling of equipment at slow speeds with long, idle periods between lifts are required. Capacity loads may be handled for initial installation of equipment and for infrequent maintenance.

CLASS B (LIGHT SERVICE)

This service covers cranes which may be used in repair shops, light assembly operations, service buildings, light warehousing, etc. where service requirements are light and the speed is slow. Loads may vary from no load to occasional full rated loads with two to five lifts per hour, averaging ten feet per lift.

CLASS C (MODERATE SERVICE)

This service covers cranes that may be used in machine shops or paper mill machine rooms, etc., where service requirements are moderate. 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, averaging 15 feet, not over 50 percent of the lift at rated capacity.

CLASS D (HEAVY SERVICE)

This service covers cranes which may be used in heavy machine shops, foundries, fabricating plants, steel warehouses, container yards, lumber mills, etc., and standard duty bucket and magnet operations where heavy duty production is required. In this type of service, loads approaching 50 percent of the rated capacity will be handled constantly during the working period. High speeds are desirable for this type of service with 10 to 20 lifts per hour averaging 15 feet, not over 65 percent of the lifts at rated capacity.

CLASS E (SEVERE SERVICE)

This type of service requires a crane capable of handling loads approaching a rated capacity throughout its life. Applications may include magnet, bucket, magnetlbucket combination cranes for scrap yards, cement mills, lumber mills, fertilizer plants, container handling, etc., with twenty or more lifts per hour at or near the rated capacity.

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. ~p~ l i ca t i ons may include custom designed specialty crane; essential to performing the critical work tasks affecting the total production facility. These cranes must provide the highest reliability with special attention to ease of maintenance features.

6.8 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 cvcles is shown in Table 6.8-1.

TABLE 6.8-1 DEFINITION OF CMAA CRANE SERVICE CLASS IN TERMS OF LOAD CLASS AND LOAD CYCLES

LOAD LOAD CYCLES k = MEAN

CLASS EFFECTIVE LOAD N1 N2 N3 N4 FACTOR

L1 A B C D 0.35 - 0.53

'-2 B C D E 0.531 - 0.67

L3 C D E F 0.671 - 0.85

L4 D E F F 0.851 - 1 .OO

Irregular Regular use Regular use Regular use occasional in in in severe

use followed intermittent continuous continuous by long idle operation operation. operation

LOAD CLASSES:

L1 = Cranes which hoist the rated load exceptionally and, normally, very light loads.

L2 = Cranes which rarely hoist the rated load, and normal loads of about 113 of the rated load.

L3 = Cranes which hoist the rated load fairly frequently and normally, loads between 113 and 213 of the rated load.

L4 = Cranes which are regularly loaded close to the rated load.

LOAD CYCLESILIFE OF CRANE

N.1 = 20,000 to 100,000 cycles N2 = 100,000 to 500,000 cycles N3 = 500,000 to 2,000,000 cycles N4 = Over 2,000,000 cycles

NORMAL OPERATING CONDITIONS: Environmental conditions that are unfavorable, harmful or detrimental to or for the operation of a hoist, such as excessively high (over 104 deg. F) or low (below 0 deg. F) ambient temperatures, corrosive fumes, dust laden or moisture laden atmospheres, and hazardous locations.

ADJUSTABLE OR VARIABLE VOLTAGE: A method of control by which the motor supply voltage can be adjusted.

XlLlARY HOIST: A supplemental hoisting unit, usually designed to handle lighter loads at a higher speed than the main hoist.

UXILIARY GIRDER (OUTRIGGER): A rder arranged parallel to the main girder for

supporting the platform, motor base, operator's cab, control panels, etc., to reduce the torsional forces such load would otherwise impose on the main girder.

OX SECTION: The rectangular cross section of girders, trucks or other members enclosed on four sides.

AKE: A device, other than a motor, used for retarding or stopping motion by friction or power means.

RANCH CIRCUIT: The circuit conductors between the final overcurrent device protecting the circuit and the outlet(s).

RIDGE: That part of an overhead crane consisting of girders, trucks, end ties, walkway and drive mechanism which carries the trolley and travels in a direction parallel to the runway.

RIDGE CONDUCTORS: The electrical conductors located along the bridge structure of a crane to provide power to the trolley.

lDGE RAIL: The rail supported by the bridge girders on which the trolley travels.

MPER (BUFFER): An energy absorbing device for reducing impact when a moving crane or trolley reaches the end of its permitted travel, or when two moving cranes or trolleys come into contact.

CAB-OPERATED CRANE: A crane controlled by an operator in a cab located on the bridge or trolley.

CAMBER: The slight upward vertical curve given to girders to compensate partially for deflection due to hook load and weight of the crane.

CAPACITY The maximum rated load (in tons) which a crane is designed to handle.

CLEARANCE: Minimum distance from the extremity of a crane to the nearest obstruction.

CMAA: Crane Manufacturers Association of America, Inc. (formerly EOCl - Electric Overhead Crane Institute).

CMAA MEMBER SERVICE COMPANY: A member company that performs service and inspections as part of its normal business, and in compliance with CMAA Specification No. 78.

COLLECTORS: Contacting devices for collecting current from the runway or bridge conductors. The mainline collectors are mounted on the bridge to transmit current from the runway conductors, and the trolley collectors are mounted on the trolley to transmit current from the bridge conductors.

COMPONENT: Either a single part or a group of parts assembled into a working unit, i.e., a brake, a wheel assembly, a gearbox, etc.

COMPONENT UPGRADE: To modify or replace a component so as to improve o increase its operating life, performance, o safety features.

CONTACTOR, MAGNETIC: electromagnetic device for opening closing an electric power circuit.

CONTROLLER: A device for regulating i predetermined way the power delivered the motor or other equipment.

COVER PLATE: The top or bottom plat a box girder.

CROSS SHAFT: The shaft extending acr the bridge, used to transmit torque

ESIGNATED PERSON: A person selected or assigned by the employer or the employer's representative as being qualified to perform specific duties.

RIVE GIRDER: The girder on which the bridge drive machinery is mounted.

DUMMY CAB: An operator's compartment or platform on a pendant or radio controlled crane, having no permanently mounted electrical controls, in which an operator may ride while controlling the crane.

DYNAMIC LOWERING: A method of control by which the hoist motor is so connected in the lowering direction, that when it is overhauled by the load, it acts as a generator and forces current either through the resistors or back into the line.

EDDY-CURRENT BRAKING: A method of control by which the motor drives through an electrical induction load brake.

ELECTRIC OVERHEAD TRAVELING CRANE: An electrically operated machine for lifting, lowering and transporting loads, consisting of a movable bridge carrying a fixed or movable hoisting mechanism and traveling on an overhead runway structure.

ELECTRICAL BRAKING SYSTEM: A method of controlling crane motor speed when in an overhauling condition, without the use of friction braking.

EMPLOYEE: For this specification, "Employee" means a person employed directly by the service provider.

ENCLOSED CONDUCTOR(S): Aconductor or group of conductors substantially enclosed to prevent accidental contact.

ENCLOSURE: A housing to contain electrical components, usually specified by a NEMA classification number.

END TIE: Astructural member other than the end truck that connects the ends of the girders to maintain the squareness of the bridge.

END TRUCK: The unit consisting of truck frame, wheels, bearings, axles, etc., which supports the bridge girders.

FIXED AXLE: An axle that is fixed in the truck and on which the wheel revolves.

FLOOR-OPERATED CRANE: A crane that is pendant controlled by an operator on the floor or an independent platform.

FOOTWALK: The walkway with handrail and toeboards attached to the bridge or trolley for access purposes.

GANTRY CRANE: A crane similar to an overhead crane except that the bridge for carrying the trolley or trolleys is rigidly supported on two or more legs running on fixed rails or other runway.

GIRDERS: The principal horizontal beams of the crane bridge that supports the trolley and is supported by the end trucks.

GROUND FAULT: An accidental conducting connection between the electrical circuit or equipment and the earth or some conducting body that serves in place of the earth.

HOIST: A machinery unit that is used for lifting and lowering a load.

HOLDING BRAKE: A brake that automatically prevents motion when power is off.

HYDRAULIC BRAKE: A brake that provides retarding or stopping motion by hydraulic means.

IDLER SHEAVE: A sheave used to equalize tension in opposite parts of a rope. Because of its slight movement, it is not termed a running sheave.

INDUSTRIAL DUTY CRANE: Service classification covered by CMAA Specification No. 70 "Specifications for Top Running Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes" and Specification No. 74 "Specifications for Top Running 8 Under Running Single Girder Electric Traveling Cranes Utilizing Under Running Trolley Hoist".

INVERTER (VARIABLE FREQUENCY DRIVE): A method of control by which the fixed line voltage and frequency is changed to a three-phase system with infinitely variable voltage and frequency.

KNEE BRACE: The diagonal structural member joining the building column and roof truss.

LIFT: Maximum safe vertical distance through which the hook, magnet, or bucket can move.

LIFT CYCLE: Single lifting and lowering motion (with or without load).

G DEVICES: Buckets, magnets, grabs and other supplemental devices, the weight of which is to be considered part of the rated load, used for ease in handling certain types of loads.

LIMIT SWITCH: A device designed to cut off the power automatically at or near the limit of travel for the crane motion.

LlNE CONTACTOR: A contactor to disconnect power from the supply lines.

E LOAD: A load that moves relative to the structure under consideration.

BLOCK: The assembly of hook, swivel, bearing, sheaves, pins and frame suspended by the hoisting ropes.

CYCLE: One lift cycle with load plus one lift cycle without load.

GlTUDlNAL STIFFENERS: Horizontal members attached to the web of the bridge girder to prevent web buckling.

€TIC CONTROL: A means of ing direction and speed by using

magnetic contactors and relays.

LlNE CONTACTOR: A magnetic contactor used in the incoming power circuit from the main line collectors.

LINE DISCONNECT SWITCH: A al switch which breaks the power lines

leading from the main line collectors.

UAL-MAGNETIC DISCONNECT SWITCH: A power disconnecting means consisting of a magnetic contactor that can be operated by remote pushbutton and can be manually operated by a handle on the switch.

MASTER SWITCH: A manually operated device that is used to control the operation of contactors and auxiliary devices of an electric control.

MECHANICAL LOAD BRAKE: An automatic type of friction brake used for controlling loads in the lowering direction. This unidirectional device requires torque from the motor to lower a load but does not impose additional load on the motor when lifting a load.

MULTIPLE GIRDER CRANE: A crane that has two or more girders for supporting the live load.

NON-COASTING MECHANICAL DRIVE: A drive with coasting characteristics such that it will stop the motion within a distance in feet equal to 10 percent of the rated speed in feet per minute when traveling at rated speed with rated load.

OEM: Original Equipment Manufacturer.

OPERATOR'S CAB: The operator's compartment from which movements of the crane are controlled. To be specified by the manufacturer as open, having only sides or a railing around the operator, or enclosed, complete with roof, windows, etc.

OVERLOAD: Any load greater than the rated load.

OVERLOAD LIMIT DEVICE: A device that is intended to permit the hoist to lift a freely suspended load within its rated capacity, but prevents lifting of an overload that would cause permanent damage to a properly maintained hoist, trolley or crane.

OVERLOAD PROTECTION (OVERCURRENT): A device that senses current, and interrupts energy flow in the event of a current overload condition.

PENDANT PUSHBUTTON STATION: Means suspended from the crane for operating the controllers from the floor or other level beneath the crane.

PITCH DIAMETER (ROPE): Distance through the center of a drum or sheave from center to center of a rope passed about the periphery.

PLUGGING: A control function that accomplishes braking by reversing the motor line voltage polarity or phase sequence.

PROTECTIVE PANEL: An assembly containing overload and undervoltage protection for all crane motions.

PURCHASER: An entity that buys cranes, associated hoisting equipment andlor services for these cranes and equipment

MILL DUTY CRANE: Service classification covered by AlSE Standard No. 6, "Specification for Electric Overhead Traveling Cranes for Steel Mill Service."

QUALIFIED MANUFACTURERS REPRESENTATIVE: A "Qualified Pers who is employed by or is representing OEM.

Name Home Phone

Depaitment No. Clock No. Occupation 8 How ~ong?

PREVENTED? WHAT COULD BE DONETO PREVENT FUTURE RE- OCCURENCES?

ROUTING (SIGNATURES)

1. Employee --- Date_--

2. SafetyTeam Member D a l e -

BE SPECIFIC AND INCLUDE ALL DETAILS

DESCRlPTiON

TRlBUTlNG FACTORS (What was the underlying cause of this inddent?)

61 Operating Equipment without authority. 61 Lack of or inadequate guards or devices. 61 Failure to sewre against unexpected mwement. 61 Lack of w inadequate warning systems. 61 Operating or working at an unsafe sped. 61 Fir. and explosion hazard. 61 Failure to warn or signal as required. 61 Unexpected mwement hazard. 81 Remwing or making safety devices inoperative. 61 Poor housekwping hazards.

61 Using defective t w b or equipment. 61 Protruding objed hazard. 61 Using tools or equipment unsafely. 61 Close dearance and wngestion hazards 61 Taking an unsafe positan or posture. 61 Unsafe ventilation. 61 Failure to lock out equipment before servicing. 61 Hazardous arrangement, placement or storage. 61 Riding hazardous moving equipment. 61 Hazardous defects of tools, equipment, etc. 61 Horseplay, distracting, teasing, etc. 61 Inadequate illumination. 61 Failure to wear personal pmtective equipment 61 Intense noise.

Unsafe loading. 61 Hazardous personal attin 61 Unsafe Placement.

61 Other than above (Did anyihing else mntribute to the cause of this incident'? )

ROOT CAUSE

THIS HAVE BEEN PREMWED? WHAT COULD BE DONE TO PREVENT FUTURE RE- OCCURENCES?

O IS WSPONSIBLE FOR CORRECTNE ACTION? BY WHEN?

1. Supervisor Date

2. Department Manager Date

3. Safety 1 Human Resources Date

HS, €-MAILS, MEMOS (attach all other related information )

Crane Manufacturers Association of America, Inc. 8720 Red Oak Blvd., Suite 201

Charlotte, NC 28217-3992 7041676-1 190

The following checklist is furnished by the Crane Manufacturers Association of America, Inc. (CMAA) as an aid to owners of overhead cranes when conducting periodic mainte installation, operation, testing, and maintenance of cranes are a continui user, in accordance with ANSI 830.2.0-1983 Safety Standards for "Ove Section 1910.179 of OSHA. In addition to these two doc service personnel also must be thoroughly familiar with maintenanceand repair manu to read and understand these ins

This checklist includes in information does notapply to all frequent inspection which are n any special information about

signing, and dating the each crane. Special e and safety devices. In work week. Depend inspection and maintenance may be required. 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 operatortodo. Before repairs are conducted, placeallcontrollers intheaoff" position, lockthe mainswitch open, and add a warning sign to the switch, indicating that a man is on the crane.

CMAA and its member companies assume no liability for general or special damage which may arise inconnection with this checklist. Thisinspectionin no way represents thatthe requirements of OSHA have been met. The responsibility for the interpretation of current OSHA standards and the adherence to any such interpretation rest with the owner andlor user of the equipment

CRANE MANUFACTURERS ASSOCIATION OF AMERICA, INC. CRANE INSPECTION SCHEDULE AND MAINTENANCE REPORT

Customer Date:

Capacity: Span: Type:

Mfr. Ser. No.: Cust. idnt. No.:

Component & Location

I I Motor

Brake & H draulics Control Panels Control Operation Resistors L Wheels Wheel Gearing Wheel Bearings Girder Connections

Inspection Condition Corrective Notes Interval

- Describe, Initial, m and Date

n When Corrected

SPECTION SCHEDULE AND MAINTENANCE REPORT Cust Idnt. No.:

Component & Location

Inspection Condition I Interval I I Corrective Notes

- 5 %

C - - $ s Describe, Initial, U1 -

Component 9 5 x = g g . - z and Date z J 2 2 ~ 1 6 0 ' 5 0 < a s 3 b When Corrected

I l l

Hook & Latch

I l l

SPECTION SCHEDULE AND MAINTENANCE REPORT Cust Idnt. No.:

Component Inspection Condaion I Corrective Notes &Location I interval I

Describe, Initial, and Date

Remarks: O CMAA

Crane Inspector

Maintenance Foreman

Accident prevention 3, .6.4 certification - operator 3.5 Confined space 3.6.6 Crane classification 6.1 Crane inspector 2.2 Crane technician 2.1 Drug free workforce 3.7 Electrical safety 3.6.2 Emergency response 3.6.5 Employee responsibility (CMAA employee) 3.2 Ergonomics 3.11 Fail protection 3.6.1 Fire prevention 3.10 First aid 3.6.5 Hazardous materials 3.6.8 lnspection - frequent 4.3 Inspection - initial 4.1 lnspection - periodic 4.4 Inspection - pre-shift 4.2 Load class 6.8 Load cycle 6.8 Load Testing 4.7 Maintenance - preventative 4.6.1 Maintenance - procedures 4.6.2 Maintenance - records 4.6.3, 4.6.4 Manuals 5.8.1 Parts - counterfeit 5.7, 5.7.1 Parts - kits 5.6.1, 5.7.1 Parts - manuals 5.8.1 Parts - O.E.M. 5.1.2 Paris - packaging 5.9 Parts - repair 5.1.2 Parts - replacement 5.3.1, 5.4.2, 5.7.1, 5.8.1 Performance enhancements 5.1.2 Personal protective equipment 3.8 Problem-ClassA 5.5.2.1,5.5.3.1,5.5.4.1 Problem - Class B 5.5.2.2, 5.5.3.2, 5.5.4.2 Problem - root cause 5.5.1

Qualifications - crane technician 2.2.2, 2.2.: Reference Document 1.2 Regulations 3.4 Reporting 4.5 Required training - crane inspector 2.2.4 Required training - crane technician 2.1.4 Respiratory protection 3.6.7 Rigging 3.9 Safety and first aid 3.6 Safety orientation 3.3 Safety statement 3.1 Scope 1.1 Signage 3.6.3 Trademark Counterfeiting Act 5.7.1 Upgrade - component 5.3.2 Upgrade - equipment 5.1.2Upgrade - parts Work experience - crane inspector 2.2.1 Work experience - crane technician 2.1.1 Appendix A - Accident investigation Report Appendix B - Maintenance Checklist

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CMAA is an Affiliate of