Attach 5 PM Task List.xlsx
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- Solicitation number
- SP330023Q0156
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Defense Logistics Agency Distribution
About this file
This document contains a preventative maintenance task list and inspection checklist for an American-Clyde rail guided portal crane. The task list details 53 lubrication tasks of varying frequencies, along with inspection criteria for items such as the engine, electrical systems, brakes and hoist components. The related federal contract opportunity is for preventative and corrective maintenance, as well as crane rental support, for the specified American-Clyde crane located at the Defense Logistics Agency Distribution facility in Anniston, Alabama. Services include load testing, inspections, lubrication, repairs and certification in accordance with applicable OSHA, ASME and manufacturer standards.
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Lubrication Preventive Maintenance Lubrication Task List
| AM-Clyde portal crane rail guided 80 ton capacity, EJON 0a3999, Registration Key 4456-85372 | ||||||||||||||
| PM Task Description | FREQUENCY | Notes | ||||||||||||
| Item No | LUBRICATION | 4hrs of operation | 8hrs of operation | 40hrs of operation | 100hrs of operation | 250hrs of operation | 500hrs of operation | 2000hrs of operation | 4000hrs of operation | as required | (M) Month | (A) Annual | 3 years | IAW manufacturer specifications & industry standards |
| 1 | Boom Hinge (2 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 2 | Truck Axle (32 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 3 | Truck Equalizer (24 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 4 | Swivel Trunnion (8 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 5 | Center Pin (1 grease fitting) | x | * | IAW man spec & industry stds | ||||||||||
| 6 | Equalizer Carriage (16 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 7 | Rail Lubricator: Check oil level. Add as required. | x | * | IAW man spec & industry stds | ||||||||||
| 8 | Swinger Pinion (1 grease fitting) | x | * | IAW man spec & industry stds | ||||||||||
| 9 | Boom Hoist Drum Shaft(2 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 10 | Boom Hoist Intermediate Shaft (2 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 11 | Boom Hoist Brake Band Pivot Bearings (2 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 12 | Boom Hoist Pinion and drum gear: Hand lubricate. | x | * | IAW man spec & industry stds | ||||||||||
| 13 | Boom Hoist Speed and Limit Switch Drive Chain: Hand Lubricate. | x | * | IAW man spec & industry stds | ||||||||||
| 14 | Main Hoist Drum Shaft (2 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 15 | Whip Hoist Drum Shaft (2 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 16 | Main Hoist Intermediate Shaft (2 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 17 | Main Hoist Brake Band Pivot bearings (4 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 18 | Whip Hoist Brake Band Pivot bearings (4 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 19 | Main Hoist Pinion and Drum gears: Hand lubricate. | x | * | IAW man spec & industry stds | ||||||||||
| 20 | Main Hoist Speed Switch Drive chain: Hand Lubricate. | x | * | IAW man spec & industry stds | ||||||||||
| 21 | Whip Hoist Speed Switch Drive chain: Hand Lubricate. | x | * | IAW man spec & industry stds | ||||||||||
| 22 | Main Hoist Limit Switch Drive Chain: Hand Lubricate | x | * | IAW man spec & industry stds | ||||||||||
| 23 | Whip Hoist Limit Switch Drive Chain: Hand Lubricate. | x | * | IAW man spec & industry stds | ||||||||||
| 24 | Air line Lubricator: Check oil level. Add as required. | x | * | IAW man spec & industry stds | ||||||||||
| 25 | Air Compressor- Check crankcase oil level. Add as required. | x | * | IAW man spec & industry stds | ||||||||||
| 26 | Fleeting Sheave (2 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 27 | Inner Hanger (7 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 28 | Top Sheave (1 grease fitting) | x | * | IAW man spec & industry stds | ||||||||||
| 29 | Hanger Tackle (7 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 30 | Main and Whip Guide Sheave (2 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 31 | Main Tackle Upper Sheave (5 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 32 | Whip Dead End (1 grease fitting) | x | * | IAW man spec & industry stds | ||||||||||
| 33 | Whip Point Sheave (1 grease fitting) | x | * | IAW man spec & industry stds | ||||||||||
| 34 | Whip Block Sheave (1 grease fitting) | x | * | IAW man spec & industry stds | ||||||||||
| 35 | Whip Block Hook Bearing (1 grease fitting) | x | * | IAW man spec & industry stds | ||||||||||
| 36 | Main Block Sheaves (4 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 37 | Main Block Hook Bearings (1 grease fitting) | x | * | IAW man spec & industry stds | ||||||||||
| 38 | Truck Gearboxes: Check oil level. Add as required. | x | * | IAW man spec & industry stds | ||||||||||
| 39 | Truck Gear Reducer: Check oil level. Add as required. | x | * | IAW man spec & industry stds | ||||||||||
| 40 | Swinger Gearbox: Check oil level. Add as required. | x | * | IAW man spec & industry stds | ||||||||||
| 41 | Boom Hoist Chain Case: Check oil level. Add as required. | x | * | IAW man spec & industry stds | ||||||||||
| 42 | Main Hoist Chain Case: Check oil level. Add as required. | x | * | IAW man spec & industry stds | ||||||||||
| 43 | Engine Alternator (oil cup) (Caterpillar - Engine/Generator Unit) | x | * | IAW man spec & industry stds | ||||||||||
| 44 | Engine Fan Drive Bearing (1 grease fitting) (Caterpillar - Engine/Generator Unit) | x | * | IAW man spec & industry stds | ||||||||||
| 45 | Boom Hoist Motor (2 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 46 | Main hoist Motor (2 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 47 | Swinger Motor (2 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 48 | Truck Motor (2 grease fittings) | x | * | IAW man spec & industry stds | ||||||||||
| 49 | Generator Bearing (1 grease fitting) (Caterpillar - Engine/Generator Unit) | x | * | IAW man spec & industry stds | ||||||||||
| 50 | Wire Rope: Hand Lubricate as required. | x | * | IAW man spec & industry stds | ||||||||||
| 51 | Check Engine Oil level (Caterpillar Engines- Qty 2 total) | x | * | IAW man spec & industry stds | ||||||||||
| 52 | Replace Engine Crankcase Oil And Oil Filter on Caterpillar - Diesel Engine. Model# 3412 serial # 81Z04553 | * | IAW man spec & industry stds | |||||||||||
| 53 | Replace Engine Crankcase Oil And Oil Filter on Caterpillar Diesel Engine. Model# 3412 serial# 81Z04563 | * | IAW man spec & industry stds | |||||||||||
| 54 | Replace Air Compressor Oil: Quincy Model QT 7.5 serial# QU1001080003 | * | IAW man spec & industry stds | |||||||||||
| * hours of operation or calendar frequency, whichever comes first. |
&"Arial,Bold"Attachment 2
Maintenance Inspection Preventive Maintenance Task List
| Type Equipment: AM-Clyde portal crane rail guided 80 ton capacity, EJON 0a3999, Registration Key 4456-85372 | ||||
| Item No | PM Task Description | Notes | ||
| Inspect and Adjust | (A) Annual | 3 years | ||
| 1 | Cooling System (Hoses, Thermostat, Pump, Radiator): Inspect hoses for cracks, clamps for evidence of looseness, and entire system for leaks. Inspect for proper coolant level, color, and clarity. During operation, inspect for leaks and verify proper shutter operation. Inspect for proper engine coolant temperature. Listen for abnormal noise originating from the water pump and inspect for leaking seals. Inspect for proper coolant freeze protection. Inspect radiator fan for damage. | X | IAW manufacturers specifications and industry standards. | |
| 2 | Lube Oil Lines and Lube Pressure: Inspect for evidence of loose connections, leakage, or damage. During operation, inspect for leaks. Inspect gauge for proper lube oil pressure. | X | IAW manufacturers specifications and industry standards. | |
| 3 | Fuel Lines and Fuel Pressure: Inspect for evidence of loose connections, leakage, or damage. During operation, inspect for leaks. Verify proper operation of the fuel pump and fuel pressure gauge and inspect fuel pressure. | X | IAW manufacturers specifications and industry standards. | |
| 4 | Starter: Inspect for damaged or deteriorated wiring, evidence of loose connections, and proper lubrication. Operate starter and listen for abnormal noise and verify proper operation. | X | IAW manufacturers specifications and industry standards. | |
| 5 | Drive Belts: Inspect drive belts on fan, water pump, oil pumps, alternator, and external fuel transfer pumps for tension and wear. | X | IAW manufacturers specifications and industry standards. | |
| 6 | Engine Alternator/ Generator (Battery Charging System): Inspect for cleanliness and proper lubrication Inspect external wiring for damage, deterioration, or oil or grease contamination, and for evidence of loose connections. During operation, inspect for rubbing, vibration, and sparking. Listen for abnormal noise. Verify that alternator/generator is properly charging batteries. | X | IAW manufacturers specifications and industry standards. | |
| 7 | Battery and Cables: Inspect battery for proper electrolyte level, cleanliness, structural distortion, damaged racks/holders, and evidence of loose terminals. Inspect battery cables for damage or deterioration, and for evidence of loose connections. | X | IAW manufacturers specifications and industry standards. | |
| 8 | Voltage Regulator (Battery Charging System): Inspect for evidence of loose or damaged wires and connections. During operation, verify regulator cycles and does not overcharge batteries. | X | IAW manufacturers specifications and industry standards. | |
| 9 | Engine Wiring: Inspect wiring to lights, warning devices, and meter connections for damage or deterioration, and for evidence of loose connections. | X | IAW manufacturers specifications and industry standards. | |
| 10 | Gauges (Oil, Fuel, Temperature, Ammeter, Tachometer, Etc.): Inspect for identification, legibility, and condition. Inspect for evidence of loose electrical or mechanical connections. Verify operation (calibration not required). | X | IAW manufacturers specifications and industry standards. | |
| 11 | Turbocharger: Inspect for evidence of loose or missing mounting bolts and parts. During operation, inspect for vibration and oil leaks. Listen for abnormal noise. | X | IAW manufacturers specifications and industry standards. | |
| 12 | Governor: Inspect linkage for evidence of binding, looseness, and damaged parts. Inspect for proper oil level. Verify proper operation. | X | IAW manufacturers specifications and industry standards. | |
| 13 | Fuel Filters: Inspect for leaks prior to and during operation. | X | IAW manufacturers specifications and industry standards. | |
| 14 | Air Cleaner: Inspect mounting brackets for evidence of loose or missing fasteners. Inspect for proper oil level and condition of filter element or vacuum indicator. | X | IAW manufacturers specifications and industry standards. | |
| 15 | Throttle Linkage: Inspect for evidence of loose and damaged components. Verify proper operation. | X | IAW manufacturers specifications and industry standards. | |
| 16 | Clutch-Main Drive: Inspect linkage for damage, for evidence of binding, loose and worn components, and for proper lubrication and adjustment. During operation, inspect for slippage and evidence of binding. Listen for abnormal noise. | X | IAW manufacturers specifications and industry standards. | |
| 16a | Clutch-Main Drive: Disassemble and inspect all internal components. | X | IAW manufacturers specifications and industry standards. | |
| 17 | Exhaust System: Inspect for holes, for damaged gaskets, for evidence of loose or missing fasteners, and for proper insulation. During operation, inspect for leaks and sparks. Listen for abnormal noise. | X | IAW manufacturers specifications and industry standards. | |
| 18 | Engine Condition: During operation, inspect for excessive smoking and vibration. Listen for abnormal noise. Follow main and or auxiliary engine OEM guidelines for specific additional inspection items. | X | IAW manufacturers specifications and industry standards. | |
| 19 | Engine Alarm Safety Devices: Inspect wiring for damage or deterioration, and for evidence of loose connections. | X | IAW manufacturers specifications and industry standards. | |
| 19a | Engine Alarm Safety Devices (not applicable to auxiliary or mobile crane engines): Verify proper operation of engine overspeed, oil system, and water system shutdown and/or alarm systems by testing with sensors installed where practical. If sensor removal is necessary for shop testing or calibration, reinstallation and inspection shall be per controlled procedures approved by the activity engineering organization. | X | IAW manufacturers specifications and industry standards. | |
| 20 | Heat Exchanger: Inspect for oil and water leaks, and for evidence of loose or missing fasteners. During operation, verify operation of temperature gauges. | X | IAW manufacturers specifications and industry standards. | |
| 21 | Fuel Tank: Inspect fuel tank for leaks, for condition of gauge, and for evidence of loose or missing fasteners. Inspect fuel strainers and filters. Inspect for proper venting. | X | IAW manufacturers specifications and industry standards. | |
| 22 | Clutches (Boom, Hoist, Swing, and Travel): Inspect clutch linkage for damage, for evidence of binding and loose or worn components, and for proper lubrication and adjustment. Inspect clutch linings for wear, debonding, and glazing, and drums for smoothness and for evidence of overheating. During operation, inspect for slippage and evidence of binding. Listen for abnormal noise. | X | IAW manufacturers specifications and industry standards. | |
| 23 | Mechanical Brakes: Inspect system for damage, for evidence of binding, loose, and worn components, and for proper lubrication. Inspect brake linings for wear, and drums for smoothness and for evidence of overheating. Inspect brakes for proper settings and for alignment of brake shoes. During operation, verify proper release, engagement, and stopping action in both directions of motion. Inspect for evidence of overheating. | X | IAW manufacturers specifications and industry standards. | |
| 23a | Mechanical Brake Linings: Disassemble as required to inspect brake linings for wear, debonding, and glazing. For hoist brakes that stop the movement of the load under normal operation conditions. | X | IAW manufacturers specifications and industry standards. | |
| 23b | Mechanical Brake Linings: For other hoist brakes (i.e., holding brakes) and for rotate and travel brakes, disassemble as required to inspect brake linings for wear, debonding, and glazing. | X | IAW manufacturers specifications and industry standards. | |
| 24 | Air Brake System: Inspect system for damage, for evidence of binding, loose, and worn components, and for proper lubrication. Inspect brake linings and discs for wear, and drums or rotors for smoothness and for evidence of overheating. Inspect brakes for proper settings, and for alignment of shoes, calipers, and bands. Inspect air lines for damage and evidence of loose connections. During operation, verify proper release, engagement, and stopping action in both directions of motion. Verify proper operation of the air application valves and inspect air application valves and air lines for leaks. | X | IAW manufacturers specifications and industry standards. | |
| 24a | Air Brake Linings: Disassemble as required to inspect brake linings for wear, debonding, and glazing. For hoist brakes that stop the movement of the load under normal operation conditions. | X | IAW manufacturers specifications and industry standards. | |
| 24b | Air Brake Linings: For other hoist brakes (i.e., holding brakes) and for rotate and travel brakes, disassemble as required to inspect brake linings for wear, debonding, and glazing. | X | IAW manufacturers specifications and industry standards. | |
| 25 | Electric Magnetic Brake System (Shoe Type Brakes): Inspect system for damage, for evidence of binding, loose, and worn components, and for proper lubrication. Inspect brake linings for wear, and drums for smoothness and for evidence of overheating. Inspect brakes for proper settings and for alignment of brake shoes. Inspect wiring for damage or deterioration, and for evidence of loose connections. During operation, inspect for proper release, engagement, and stopping action in both directions of motion and timing of release and engagement. Inspect for evidence of overheating or other evidence of incomplete brake release. | X | IAW manufacturers specifications and industry standards. | |
| 25a | Electric Magnetic Brake Linings (Shoe Type Brakes): Disassemble as required to inspect brake linings for wear, debonding, and glazing. For hoist brakes that stop the movement of the load under normal operation conditions. | X | IAW manufacturers specifications and industry standards. | |
| 25b | Electric Magnetic Brake Linings (Shoe Type Brakes): For other hoist brakes (i.e., holding brakes) and for rotate and travel brakes, disassemble as required to inspect brake linings for wear, debonding, and glazing. | X | IAW manufacturers specifications and industry standards. | |
| 26 | Electric Magnetic Brake System (Disc Type Brakes): Inspect brake housings for damage or evidence of loose hardware. Inspect brakes for proper settings. During operation, verify proper release, engagement, alignment of components, and stopping action in both directions of motion and timing of release and engagement. Inspect for vibration and overheating. Listen for abnormal noise. | X | IAW manufacturers specifications and industry standards. | |
| 26a | Electric Magnetic Brake System (Disc Type Brakes) Internal Brake Components: Disassemble as required to inspect brake linings for wear, debonding, alignment of components, or glazing or for damaged brake discs, splines, or other internal components. For hoist brakes that stop the movement of the load under normal operation conditions. | X | IAW manufacturers specifications and industry standards. | |
| 26b | Electric Magnetic Brake System (Disc Type Brakes) Internal Brake Components: For other hoist brakes (i.e., holding brakes) and for rotate and travel brakes, disassemble as required to inspect brake linings for wear, debonding, and glazing. | X | IAW manufacturers specifications and industry standards. | |
| 27 | Shafts and Couplings, including couplings integral to motor/speed reducer assemblies: Inspect for damage, for leaking seals, and for evidence of loose keys, coupling bolts, and covers. During operation, inspect for vibration and other evidence of misalignment or damaged components. Listen for abnormal noise. Inspect for evidence of bearing damage, overheating, and abnormal wear. Inspect pillow blocks for damage, paying special attention to possible cracks in cast iron pillow blocks loaded in shear and tension, loose or missing fasteners, and cracks caused by overtensioned fasteners. | X | IAW manufacturers specifications and industry standards. | |
| 28 | Gearing (Boom, Hoist, Rotate, Travel) External Gears: Inspect for damaged or worn gears, for evidence of misalignment or loose keys, and for proper lubrication. During operation, listen for abnormal noise, and inspect for other evidence of possible damage. Inspect pillow blocks for damage, paying special attention to possible cracks in cast iron pillow blocks loaded in shear and tension, loose or missing fasteners, and cracks caused by overtensioned fasteners. | X | IAW manufacturers specifications and industry standards. | |
| 28a | Gearing (Boom, Hoist, Rotate, Travel) Internal Gears: Inspect for proper gear case lubricant level, leaks, and evidence of loose or missing mounting fasteners. Inspect breathers for restrictions. During operation, inspect for vibration, overheating, and other evidence of damaged internal components or misalignment. Listen for abnormal noise. Inspect for evidence of bearing damage, overheating, and abnormal wear. | X | IAW manufacturers specifications and industry standards. | |
| 28b | Internal Gears, Boom, Hoist, and Single Rotate Drives: Internal gears shall be visually inspected for wear or damage and for evidence of misalignment. If all gears cannot be visually inspected through inspection ports or by video probe or similar inspection devices, the gear cases shall be disassembled for visual inspection. Document the results in equipment history file. |
| X | IAW manufacturers specifications and industry standards. | |||
| 29 | Chains and Sprockets: Inspect chains for proper tension and lubrication, and for evidence of loose or worn links and pins. Inspect sprockets for worn or damaged teeth, for evidence of loose shafts and keys, and for proper lubrication. During operation, listen for abnormal noise. | X | IAW manufacturers specifications and industry standards. | |
| 30 | Pawls, Ratchets, and Rotate Locks: Inspect for evidence of loose, damaged, or worn components. Inspect operating system for evidence of worn keys, loose fasteners, and broken springs. Operate pawls and rotate locks and inspect for proper setting. Verify limit switch and indicator light operation. | X | IAW manufacturers specifications and industry standards. | |
| 31 | Air Compressor: Inspect for cleanliness, for evidence of loose or missing mounting fasteners, for proper belt tension and wear, and for condition of filters. During operation, verify proper operation of unloader valve and pressure switch. Listen for abnormal noise and inspect for vibration. | X | IAW manufacturers specifications and industry standards. | |
| 32 | Air Control System: Inspect valves, cylinders, lines, regulators, and gauges for damage or deterioration, and for evidence of loose or missing fasteners. During operation, inspect system for leaks, and verify proper operation of valves, regulators, and gauges. | X | IAW manufacturers specifications and industry standards. | |
| 33 | Wheels and Axles: Inspect wheels for uneven wear, flat spots, chips, flange wear, and cracks, for evidence of loose or missing fasteners and bearing caps, and for proper lubrication. During operation, inspect for excessive movement between components, improper tracking, overheating, and other evidence of component wear or bearing damage. Listen for abnormal noise. | X | IAW manufacturers specifications and industry standards. | |
| 34 | Travel Trucks, Equalizers, Gudgeons, Gudgeon Pins, and Retainers: Inspect for damage or deterioration, for evidence of loose or missing fasteners and cracked welds, and for proper lubrication. Verify proper operation. | X | IAW manufacturers specifications and industry standards. | |
| 35 | Structure (Portal Base, Boom, A-Frame, Tower, Stiff legs, Sills, Support Pins, Retainers, Etc): Inspect structural components for damaged, distorted, or deteriorated members (remove wire rope buffer blocks to ensure they are not hiding boom corrosion), and for evidence of loose or missing fasteners and cracked welds. Inspect support pins for proper lubrication. Ensure drain holes are clear. | X | IAW manufacturers specifications and industry standards. | |
| 36 | Crane Boom: Inspect boom structure for damaged, distorted, or deteriorated members (remove wire rope buffer blocks to ensure they are not hiding boom corrosion), and for evidence of loose or missing fasteners and cracked welds. Inspect support pins for proper lubrication. Ensure drain holes are clear. | X | IAW manufacturers specifications and industry standards. | |
| 37 | Handrails, Walkways, Ladders, and Personnel Safety Guards: Inspect for damage or deterioration, and for evidence of loose or missing fasteners and cracked welds. | X | IAW manufacturers specifications and industry standards. | |
| 38 | Counterweight: Inspect counterweight and counterweight support structure for damage or deterioration, and for evidence of loose or missing fasteners. |
| X | IAW manufacturers specifications and industry standards. | |
| 39 | Rotate Path Assembly: Inspect spider assembly and roller path for damage or deterioration, and for evidence of loose or missing fasteners and cracked welds. Inspect rollers for uneven wear, flat spots, chips, flange wear, cracks, or deterioration, for evidence of loose or missing fasteners, and for proper lubrication. During operation, verify free rotation of rollers and inspect for evidence of misalignment. |
| X | IAW manufacturers specifications and industry standards. | |||
| 40 | Center Pin Steadiment and Support Assembly: Inspect for damaged or deteriorated components, and for evidence of loose or missing fasteners and cracked welds. Inspect for proper lubrication. | X | IAW manufacturers specifications and industry standards. | |
| 41 | Center Collector Assembly (Electrical or Hydraulic): Inspect for loose or bent supports. Inspect wiring for damage or deterioration, and for evidence of loose connections. Inspect for worn brushes and proper spring tension. Inspect slip rings for damage, deterioration, indications of excessive wear, streaking, arcing/overheating, and proper contact. During operation, verify brush to collector ring alignment. Inspect for loose hydraulic connections, defective tubing, and leaks. |
| X | IAW manufacturers specifications and industry standards. | |
| 42 | Slewing Ring Bearings: Inspect expelled lubricant for evidence of metal flakes or metal or plastic particles. Inspect fasteners for proper tightness. For portal and floating cranes, measure and record internal axial clearance (thrust direction) between bearing rollers (balls) and races. Refer to OEM's literature for method and acceptance/rejection criteria. (If tightness verifications or clearance/wear checks are performed by maintenance personnel, the inspector shall perform an in-process review on a sample basis.) During operation, listen for abnormal noise and inspect for vibration. |
| X | IAW manufacturers specifications and industry standards. | |||
| 43 | Wire Rope Drums, Followers, and Machinery Foundations: Inspect drums for distortion, cracks, worn grooves, and for evidence of loose or missing fasteners and cracked welds. Inspect wire rope followers for proper adjustment and alignment. Inspect bearings for evidence of damage, overheating, or abnormal wear. Inspect machinery foundations for damaged or deteriorated components, and for evidence of loose or missing fasteners and cracked welds. During operation, verify that at least two complete wraps of wire rope remain on grooved drums (at least three complete wraps on ungrooved drums) in all operating conditions, including extremes of hook or boom positions. Listen for abnormal noise. Inspect for vibration, overheating, and other evidence of component wear, bearing damage, or misalignment. Inspect pillow blocks for damage, paying special attention to possible cracks in cast iron pillow blocks loaded in shear and tension, loose or missing fasteners, and cracks caused by overtensioned fasteners. | X | IAW manufacturers specifications and industry standards. | |
| 44 | Sheaves: Inspect for abnormally worn or corrugated grooves, flat spots, abnormal play, and broken or cracked flanges. Inspect for evidence of loose or missing fasteners, keepers, and lubrication fittings. Gauge the wire rope grooves of all sheaves. Pay particular attention to sections of equalizer sheaves and saddles in contact with wire rope and where corrosion may develop because of poor drainage. During operation, verify free movement of all sheaves. Listen for abnormal noise. Inspect for abnormal play, overheating, and other evidence of component wear or bearing damage. |
| X | IAW manufacturers specifications and industry standards. | ||
| 45 | Wire Rope, Fastenings, and Terminal Hardware. See attached page for wire rope rejection criteria.: Thoroughly inspect the entire length of running ropes and standing ropes. The depth and detail of the inspection shall be that necessary to ensure that the entire rope is acceptable with special attention paid to areas of expected wear or damage, and to areas not normally visible to the operator during operation or pre-use check. During the inspection, pay the wire rope out as far as possible. For sections that can not be spooled off the drum, visual inspection of the wire rope on the drum is sufficient. Where it is not possible to pay out to the lowest layer, the crane shall not be used for applications where the uninspected rope (i.e., covered layers) would be spooled off the drum under load. The first layer of wire rope shall be properly reinstalled on the drum to provide adequate support for the upper layers. Remove wire rope dressing from selected areas exposed to significant wear, exposure, and abuse. Dimensional (diameter) measurements shall be taken at several places over the length of the rope. Record minimum dimension measured. Pay particular attention to sections in contact with equalizer sheaves and saddles or where corrosion may develop because of poor drainage. Lubricate areas after inspection. Inspect for defects noted below and proper lubrication. Inspect poured sockets, wedge sockets, swage fittings, eyes, swivels, trunnions, and fasteners for undue looseness, wear, cracks, corrosion, and other damage. Undue looseness in poured sockets is defined as looseness or evidence of slippage of wires in the securing material, evidence of deterioration of the securing material, looseness of wire rope strands or wires adjacent to the socket or any looseness resulting from cracks or other defects in the basket. Evidence of looseness between the securing material and the basket resulting solely from seating of the material in the basket is acceptable. Drum end fittings need only be disconnected or disassembled when experience or visible indications deem it necessary. The Federal Specification for wire rope is RR-W-410. | ||
| X | IAW manufacturers specifications and industry standards. | ||
| 46 | Hoist Blocks and Hooks: Inspect hoist blocks, cheek plates, swivels, trunnions, and lubrication fittings for damage or deterioration, cleanliness, freedom of movement, and for evidence of loose or missing fasteners. Inspect for loose, damaged, missing, or improperly sized retaining rings. Inspect hooks and mousing devices for damage. Inspect drip pans and gaskets for damage, proper clearance, and for evidence of loose or missing fasteners. Inspect for evidence of bearing damage, overheating, and abnormal wear. | X | IAW manufacturers specifications and industry standards. |
| 47 | Machinery House and Operator's Cab: Inspect for leaks, broken glass, deterioration, and cleanliness. Verify proper operation of louvers, doors, windows, windshield wipers, heaters (particularly combustion heaters), air conditioners, operator's chair, and communication equipment. | X | IAW manufacturers specifications and industry standards. |
| 48 | Load Indicators, Load Warning Devices, Load Shutdown Devices: Inspect wiring for damage or deterioration, and for evidence of loose connections. These devices shall be tested for proper operation at this inspection. Use SAE J-159 as a guide for calibration checks for (testing and tolerance) of category 1 cranes. For other cranes, if not specified by device OEM, the preferred accuracy requirement for all devices is plus 10 percent minus 0 percent of the actual weight. Do not test beyond 131.25 percent of rated capacity. If SAE guidelines or preferred accuracy requirement cannot be met, the minimum accuracy requirement is plus 10 percent minus 5 percent of the actual weight. | X | IAW manufacturers specifications and industry standards. |
| 49 | Radius/Boom Angle Indicator: Verify radius indications by comparing against measured radii at the minimum and maximum boom operating positions. Verify boom angle indications by comparing the indicated boom angle to the boom angle on the load chart corresponding to the boom length and measured radius. This test shall be accomplished at the minimum and maximum boom operating positions. Use SAE J-159 as a guide for calibration checks (testing and tolerance) of applicable systems. | X | IAW manufacturers specifications and industry standards. |
| 50 | Capacity Signs and Load Ratings: Inspect capacity signs and brackets for damage or deterioration, and for evidence of loose or missing fasteners. Verify that load ratings are correct, are noted in pounds, and are visible or otherwise available to the operator and riggers. | X | IAW manufacturers specifications and industry standards. |
| 51 | Fire Extinguishers: Verify inspection is current. | X | IAW manufacturers specifications and industry standards. |
| 52 | Controllers: Inspect for broken or loose springs, cracked or loose operating levers and pitted or burned contact points and segments. Inspect for broken segment dividers and insulators, for excessive arcing, for evidence of worn or loose cams, pins, rollers, or chains, and for evidence of loose connections. Inspect for proper contact pressure. Inspect wiring for damage or deterioration, and for evidence of loose connections. Inspect for identifying label plates and indicators, and that crane and controller horizontal direction indicators match. Inspect such parts as bearings, star wheels, and pawls for proper lubrication. Inspect for proper spring return and neutral latching. During operation, verify proper sequencing of speed points and operation of controller indicating lights and deadman devices. | X | IAW manufacturers specifications and industry standards. |
| 53 | Control Panels, Relays, Coils, Transfer and Disconnect Switches, Conductors and Electronic (Solid State) Drive Control Systems: Inspect (without removing) contacts for proper alignment, pitting, and evidence of excess heating and arcing. Inspect transfer and disconnect switches, conductors, coils and contact leads, and shunts for insulation breakdown, missing hardware, and evidence of overheating. Inspect wiring for damage, deterioration, and evidence of loose connections. Inspect fuses for proper ratings and type, for evidence of loose connections and overheating. Inspect overload devices for evidence of loose connections and overheating. Inspect circuit breakers and switches for cleanliness and proper operation. Inspect panel boards and arc shields for cracks, evidence of loose or missing fasteners, cleanliness, and moisture. Manually operate relays, switches, contactors, and interlocks and verify that all moving parts operate freely without binding or excessive play. Inspect enclosures for cleanliness or damage, and for evidence of loose or missing fasteners and gaskets. During operation, verify proper operation of panel indicating lights and contactor sequence. Verify proper operation of environmental controls (e.g., strip heaters, cooling fans). |
Inspect the electronic (solid state) drive control systems wiring for damage or deterioration, and for evidence of loose connections. Visually inspect (without removing) components for evidence of damage or overheating. Verify that the drive is dry and free of dust, dirt, and debris
| X | IAW manufacturers specifications and industry standards. | |||
| 53a | Control Panels, Relays, Coils, Transfer and Disconnect Switches, Conductors and Electronic (Solid State) Drive Control Systems: Verify that the switch mechanism and/or handle on disconnects and safety switches cannot be moved to the energized or on position when locked in the de-energized or off position and that the handle properly indicates whether the switch is energized or de-energized. | X | IAW manufacturers specifications and industry standards. | |
| 54 | Resistors: Inspect resistors, insulators, and brackets for damage, distortion, deterioration, and for evidence of loose or missing fasteners or overheating. Inspect wiring for damage or deterioration, and for evidence of loose connections. | X | IAW manufacturers specifications and industry standards. | |
| 55 | Limit and Bypass Switches: Remove covers and inspect electrical and mechanical components and wiring for damage or deterioration, and for evidence of loose connections. Inspect enclosures for evidence of moisture and arcing. Inspect drive and actuating components for damage or deterioration, for proper lubrication, and for evidence of loose or missing fasteners. | X | IAW manufacturers specifications and industry standards. | |
| 56 | Warning Devices, Operational Aides, General Safety Devices (Horns, Bells, Lights, Reflectors, etc.): Inspect components and associated wiring for damage or deterioration, and for evidence of loose connections. During operation, verify proper functioning of devices. | X | IAW manufacturers specifications and industry standards. | |
| 57 | Electrical Hardware and General Lighting: Inspect conduits, raceways, junction boxes, light fixtures, and associated wiring for damage or deterioration, and for evidence of loose connections. Verify operation of lights. | X | IAW manufacturers specifications and industry standards. | |
| 58 | Electrical Cable Reels: Inspect wiring for damage or deterioration, and for evidence of loose connections. Inspect reel assembly for damage, deterioration, and evidence of loose or missing fasteners. Inspect slip rings for damage, deterioration, indications of excessive wear, streaking, arcing/overheating, and proper contact. Verify proper operation. | X | IAW manufacturers specifications and industry standards. | |
| 59 | Main and Auxiliary Generators: Inspect generators and associated wiring for cleanliness, damage, deterioration, and evidence of loose connections. Inspect for proper lubrication. Inspect slip rings for damage, deterioration, indications of excessive wear, streaking, arcing/overheating, and proper contact. Inspect commutators for evidence of destructive commutation. Inspect brushes for proper brush tension and length, and for damage and deterioration. Inspect insulation for deterioration and evidence of overheating. Inspect drive belts or coupling for damage deterioration and evidence of misalignment and loose or missing fasteners. During operation, inspect for vibration, overheating, or other evidence of misaligned, worn, or damaged internal components or bearings. Listen for abnormal noise. Verify proper voltage output. Verify proper operation of environmental devices (e.g., strip heaters, cooling fans). | X | IAW manufacturers specifications and industry standards. | |
| 60 | Electric Motors (Boom, Hoist, Rotate, Travel): Inspect motors and associated wiring for cleanliness, damage, deterioration, and evidence of loose connections. Inspect for proper lubrication. Inspect slip rings for damage, deterioration, indications of excessive wear, streaking, arcing/overheating, and proper contact. Inspect commutators for evidence of destructive commutation. Inspect brushes for proper brush tension and length, and for damage and deterioration. Inspect insulation, for deterioration and evidence of overheating. During operation, inspect for vibration, overheating, other evidence of misaligned, worn, or damaged internal components or bearings. Listen for abnormal noise. Verify proper operation of environmental devices, (e.g., strip hearers, cooling fans). | X | IAW manufacturers specifications and industry standards. | |
| 61 | Operation of Crane Controls: Verify proper operation of all hoist, rotate, and travel functions, primary and secondary limit switches, bypass switches, indicator lights, level indicators, and settings. | X | IAW manufacturers specifications and industry standards. | |
| 62 | Lubrication and Servicing Records: Perform a review of lubrication and servicing records since the last Maintenance Iuspection Specification Record to ensure the lubrication and servicing was performed as specified. | X | IAW manufacturers specifications and industry standards. | |
| 63 | Crane Runway: Inspect rails, rail joints, rail bolts, rail clips, fasteners, rail alignment, and rail stops for damaged or deteriorated components, loose or missing fasteners, and cracked welds. | X | IAW manufacturers specifications and industry standards. |
&P
Wire Rope Rejection Criteria
| Preventive Maintenance Task List - Attached page for wire rope rejection criteria. |
| Wire Rope Rejection Criteria. Remove damaged portions (or replace entire length, if necessary) if any of the following are found: |
1. Kinked, Birdcaged, Doglegged, or Crushed Sections. Kinked, birdcaged, doglegged, or crushed rope in straight runs where the core is missing or protrudes through or between strands, or where the rope does not fit properly in sheave or drum grooves. (This does not apply to runs around eyes, thimbles, or shackles.)
2. Flattened Sections. Flattened sections where the diameter across the flat is less than 5/6 of nominal diameter. (This does not apply to runs around eyes, thimbles, and shackles.)
3. Broken Wires
a. Running Ropes. Six randomly distributed broken wires in one lay or three broken wires in one strand in one lay. For rotation resistant wire rope, two in a length equal to six times the rope diameter or four in a length equal to 30 times the rope diameter. One outer wire broken at the point of contact with the core of the rope that has worked its way out of the rope structure and protrudes or loops out from the rope structure ("valley break"). For end connections, two broken wires within one lay length of the end connection.
b. Standing, Guy, and Boom Pendant Ropes. Three broken wires in one lay length in sections beyond end connection or two broken wires within one lay length of the end connection.
| 4. Loss in Diameter. Reduction from nominal diameter of more than five percent. |
| 5. High Strand. High strand where the height exceeds 10 percent of the nominal diameter. |
6. Corrosion. Corrosion such that significant pitting occurs on the surfaces of outside wires. Minor surface roughness on outside wires is acceptable provided no significant pitting occurs and the rope is not corroded internally. Significant pitting is defined as pitting that can not be removed by abrasive removal of less than 1/3 of the original diameter of individual outside wires.
7. Heat Damage. Evidence of heat damage from any cause.
8. Wavy Rope. Wavy rope (where the longitudinal axis of the wire rope takes the shape of a helix instead of a line) when the diameter of the envelope of the wave is greater than 133 percent of the diameter of the nominal diameter of the wire rope. Use ISO 4309 as a guide.
9. Accumulation of Defects. An accumulation of defects that in the judgment of the inspector creates an unsafe condition.
10. Splices. Wire rope shall not contain splices.
Certification Preventive Maintenance Certification Task List
| Type Equipment: AM-Clyde portal crane rail guided 80 ton capacity, EJON 0a3999, Registration Key 4456-85372 | ||
| PM Task Description | Notes | |
| Certification | (A) Annual | |
| 1. Load Test and certification | X | IAW CFR29,1910,and ASME B30.5 standards. |
File details come from the government source that posted it. Updated .