Attach 4 Load Test and Check List.xls

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Overhead Cranes Maint & Repair, Area I & II
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W90VN822R0003
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Attach 3 DA Form 2404 Equipment Inspection and Maintenance Worksheet.pdf PDF
W90VN822R0003 Overhead Cranes Maint and Repair for ROK Area I and II.pdf PDF
Attach 1 List of Overhead Cranes in USAG Yongsan Casey.xls XLS spreadsheet
TE 1 Unit Price for Annual Inspection Load Testing and On Call CLINs X001 X002 X003.xls XLS spreadsheet
TE 2 Unit Price for Identified Task Items CLIN X004.XLS XLS spreadsheet
Attach 2 Checklist for Inspection and Preventative Maintenance Service.docx DOCX document

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Lo.Test_CheckList

Attachment 4 - Load Test and Check List
Load Test (OH Crane) & Check List
Table I-2 (Page I-6, EM-385-1-1. 3 Nov 08)
Bldg No:Date:
OH Capa.: (ton) Test Load: (ton)
[Bridge/Overhead traveling, wall and gantry]
Requirement & SpecificationInitialsRemark
L2(2) = Load and boom hoist static test .
For variable-rated crane, perform the applicable variable-rated crane teats in addition to any other required tests.
L2m(2) = Load and boom hoist static test, main hoist
L2a(2) = Load Hoist static test, auxiliary hoist.
L3(2) = Load hoist dynamic test.
For variable-rated crane, perform the applicable variable-rated crane teats in addition to any other required tests.
L3m(2) = Load hoist dynamic test, main hoist.
L3a(2) = Load hoist dynamic test, auxiliary hoist
L4(2) = Wire rope test.
For variable-rated crane, perform the applicable variable-rated crane teats in addition to any required tests. During either the static or dynamic test, where possible, test the entire working length of the wire rope.
L6(2) = Hoist load brake test (hydraulic or Mechanical brake)
L6b(2) = Hoist load brake.
L9(2) = Load hoist lose of power (panic test)
L9b(2) = Load hoist lose of power (panic test)
L15 = Trolley motion test. Page I-14
L16 = Bridge Motion Test. Page I-14
L19 = Primary and Secondary holding brakes. Page I-15
L20 = Hoist dynamic load brake (Eddy Current) Page I-16
Checking lowering speed against specifications to ensure correct brake operation.
Note: Eddy current brakes will not stop motion.
Contractor Signature: Date:
COR/ACOR Signature: Date:

Lo.Test_Requirement

Load Test Requirement (OH Crane) & Check List
Table I-2 (Page I-6, EM-385-1-1. 3 Nov 08)
Bldg No:Date:
OH Capa.:(ton)Test Load:(ton)
[Bridge/Overhead traveling, wall and gantry]InitialsRemark
L2(2) = Load and boom hoist static test .
For variable-rated crane, perform the applicable variable-rated crane teats in addition
to any other required tests.
L2m(2) = Load and boom hoist static test, main hoist
1) Raise test load to clear ground and hold for 10 minutes with boom at maximum radius;
2) Rotate load to check bearing operation;
3) Do not engage boom or load hoist pawl;
4) Observe lowing that may occur which indicates malfunction of boom or hoisting
components or holding brakes or outriggers;
5) For all cranes, repeat test (except for step(2)) at minimum radius, maximum load, and boom
fully extended, minimum radius, and maximum load for the radius.
L2a(2) = Load Hoist static test, auxiliary hoist.
1) Raise test load to clear ground and hold for 10 minutes with boom at maximum radius;
2) Rotate load to check bearing operation – observe lowing that may occur which will indicate
malfunction of hoisting components or holding brakes.
L3(2) = Load hoist dynamic test.
For variable-rated crane, perform the applicable variable-rated crane teats in addition
to any other required tests.
L3m(2) = Load hoist dynamic test, main hoist.
1) Raise and lower test load on each hoist controller point and visually observe smooth
control between point;
2) Lower the test load to unload the hoist components, wait 5 minutes, and continue testing.
L3a(2) = Load hoist dynamic test, auxiliary hoist
Raise and lower test load on each controller point and visually observe smooth control
between points.
L4(2)=Wire rope test.
For variable-rated crane, perform the applicable variable-rated crane teats in addition
to any other required tests.
During either the static or dynamic test, where possible, test the entire working length
of the wire rope.
L6(2)=Hoist load brake test (hydraulic or Mechanical brake)
For variable-rated crane, perform the applicable variable-rated crane teats in addition
to any other required tests.
Lower test load, using first control point, then apply the foot brake: this should stop
the lowering motion of the test load.
Caution: Not applicable to load-sensitive reactor type hoist controls.
L6b(2) = Hoist load brake.
1) Raise test load approximately 5 ft (1.5 m)
2) With hoist controller in the neutral position, release (by hand) the holding brake-the load
brake should hold the test load;
3) Again, with holding brake in the released position, start the test load down (first point) and
returned the controller to off position as the test load lower-the load brake should prevent
the test load from accelerating.
Note: It is not necessary for the load brake to halt the downward motion of
the test load.
L9(2)= Load hoist lose of power (panic test)
For variable-rated crane, perform the applicable variable-rated crane teats in addition
to any other required tests.
This test is designed to test the reaction of a hoisting unit in the event of power failure
during a lift;
1) Hoist the test load approximately 3m (10 ft) above the ground at maximum allowable
radius.
2) Lower test load at slow speed and with the controller in the slow lowering position,
disconnect the main power source by pushing the main power stop button(s);
3) Return the controller to the neutral position- the test load should stop lowering when the
controller is placed in the neutral position.
Caution: This test is not to be performed on cranes that do not have
powered-down boom and load hoists.
L9b(2)= Load hoist lose of power (panic test)
For variable-rated crane, perform the applicable variable-rated crane teats in addition
to any other required tests.
This test is designed to test the reaction of a hoisting unit in the event of power failure
during a lift;
1) Hoist the test load to convenient distance above the surface;1) Hoist the test load to convenient distance above the surface;
2) Lower test load at slow speed and with the controller in the slow lowering position,
disconnect the main power source and return the controller to the neutral
position - the test load should stop lowering when the controller is placed in the
neutral position.
Note: Air operated hoist should be vented during this test.
L15 = Trolley motion test. Page I-14
1) Raised test load to clear ground and move trolley to the maximum allowable
radius - do not move trolley beyond the trolley limit switch;
2) Hold test load for 10 minutes;
3) Lower test load to ground until hoist lines are slack;
4) Wait 5 minutes, raise test load and trolley the allowable length of the trolley
runway.
L16 = Bridge Motion Test. Page I-14
Operate bridge with test load(if space is available) the full distance of runway using
extreme causion and observe for any binding of bridge trucks and for proper brake
operation.
L19 = Primary and Secondary holding brakes. Page I-15
For cranes with primary and secondary holding brakes (configuration of crane
where a primary brake actuates when controller is returned to the neutral position
and secondary brake actuates a few seconds later) and/or eddy current hoist
dynamic load brakes):
1) During either the static or dynamic test, raise the test load and observe the
proper timing sequence in the application of primary and secondary brake when
controller is returned to neutral (Virtually observe both hoist holding brakes to
ensure correct position);
2) Raise test load approximately 1 ft (0.3 m), hold for 10 minutes, and inactivate
the secondary holding brake while testing the primary holding brake-
observe for noticeable lowing of test load that may occur which will indicate
malfunction of hoisting components of brakes;
3) Re-engage secondary holding brake and release the primary holding brake
and hold for 10 minutes- observe for noticeable lowering of test load that may
occur which will indicate malfunction of hoisting components or brakes;
4) Re-engage the primary holding brake - recheck proper operation of time
delay and ensure smooth positive stopping.
L20 =Hoist dynamic load brake (Eddy Current) Page I-16
Checking lowering speed against specifications to ensure correct brake operation.
Note: Eddy current brakes will not stop motion.
1. Requirement for boom stop test. Page I-16
Boom stop tests shall follow these steps.
Step 1: Check for availability of appropriate operator manual.
Step 2: Make sure crane is level with outriggers(if so equipped)
Step 3: Check boom and boom stops for misalignment, bent parts, and other
physical damage.
Step 4: Check boom stop pins (at connection) for lubrication,
Step 5: Check boom angle indicator with inclinometer for connectness.
Step 6: Check boom hoist disengaging device for proper adjustment and proper angle
in accordance with operator’s manual.
Step 7: Check for proper operational setup of the boom stops and boom hoist
disengaging device. Physically boom up the boom just to the points listed
below as long as the boom does not go beyond the point of operation of the
boom hoist disengaging device.
a. For cantilever or scissors types, this is the point just before the boom and boom
stops touch.
b. For telescoping types, this is the point just prior to compression.

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