Periodic Inspection SOP

Title Periodic Inspection FOR INTERNAL USE ONLY
SOP Document # Rev#:

Created by: Dave Dolph Date: 9/10/2018
Technical Review by: Rob Page Date: 2/6/2019
Safety Review by: Tim Puyleart Date: 2/7/2019
Operations Manager Approval: Date:
Applicable Models All
Description of Task
This procedure dictates the process to complete a Periodic Inspection. All steps marked with an “*” indicate a step
included in a Frequent Inspection.
Personal Protective Equipment Required (Minimum)
Hard Hat Eye Safety Konecranes Balaclava Ear Arc Flash Hard Hat Fall
Protection Boots Protective Protection Glove Set with Face Protection
Uniform and Light Shield
Duty
Hazards (More Could be present)
Required Tools/Equipment
Mobile Basic Hand Sheave Feeler Gauge Rags Broad face

Elevated Work Tools Gauge calipers
Platform or
Ladder
Pre-Task Check List
 Agree work area with site contact  Barricade work area

 Inform operator of task being carried out  Carry out POWRA/JHA
 Isolation of adjacent cranes/as required  Carry out Elevated Work Platform prestart/as
required
STEPS
1 Stage the Work Area
a Complete SOP 1.1.8.1 Pre-Task Check and Work Area Preparation

2 *Prepare Work Package in SLIM
a Sync Slim Device

• Synchronization is required to download the latest information in
the system, including but not limited to, information regarding a
Service Request, Work Package, and Asset. One must
synchronize to receive assigned Work Packages, to upload data
after a Work Package is completed, and to receive desired
customer reports.
b Verify Asset
• Determine if the asset is correct. If not, reject the work
package and contact the office and have them create the correct
asset.
• Determine if components need to be added. If so, reject
the work package and contact the office and have them add the
appropriate components.
• Determine if components need to be uninstalled from the
structure in the SLIM device.
• Re-Reported:
• Field Operative Finds a Previously Documented Fault Is
Still Active
▪ The Next Step of "Re-Reported" is not to be
used when creating any action on the current
SR.
▪ As part of a visit, Field Operatives are
responsible for reviewing active faults and
reporting to the customer which of those faults
are still present during their visit.
▪ Field Operative navigates to Active Faults.
▪ Field Operative copies existing fault to create a
new Action.
▪ New Action is updated with additional details of
the current visit.
▪ The appropriate Next step is selected/verified
during the Safety Review and/or Visit Review.
• Action is saved.
▪ Upon saving the action, the active fault which
was copied to create the new fault will be
updated with a Next Step of "Re-Reported."
▪ Additionally – Siebel will check for all similar
active faults with the same Fault Code, Risk and
Recommendation on that specific component
and update those actions' Next Step to "Re-
Reported."
▪ If the Fault Code, Risk or Recommendation is at
all changed on the new Action, the Field
Operative will have to manually change the
previously existing active fault's Next Step to

"Re-Reported."
• Actions with a Next Step of "Re-Reported" will be
cleared from the active faults tab and will be visible in
the Service History.
• Unable to Inspect Components

• Hoisting gear - internal
• Hoisting coupling – internal
• Micro motion coupling
• Mechanical load brake
• Hook nut and locking parts
• Hook forging – internal
• Overload protector (slip clutch)
• Drive sprocket
▪ Date Reported
▪ Technician
▪ Task Type Unable to Inspect
▪ Fault Code Not in Scope
▪ Risk Undetermined Condition
▪ Recommendation Disassemble
▪ Comment: Disassembly is required to inspect
this component. Inspection frequency is as
required by the OEM and/or governing
regulations.
c Fill out the fields of the asset header.

3 *Operational Test Checklist
*a Runway Mainline Disconnect

• Visually check that the disconnect is clearly identifiable as to its
intended purpose and should not power any other equipment
other than the crane runway.
• Verify that it is clearly and freely accessible to the operator.
The path between the disconnect and the operator should be
free of obstruction in the event of an emergency.
• Ensure 36 inches of clearance in front of the disconnect.
• Verify it is able to be locked in the “off” position.
• Visually verify the condition, type, matching voltage and current
ratings of the fuses.
• If a circuit breaker is used as the runway disconnect, verify a
circuit breaker lockout device is capable of being installed.
*b Markings & Main Girder Beam and Markings

• Ensure capacity markings are found on both sides of the crane
and are legible from the ground or floor.
• If more than one hoist, ensure capacity markings are found on
each hook block.
*c Pendant/Radio Controller
• Visually check the condition of the enclosure, the buttons and
boots, and grommets. Check for missing screws. Check the
condition and presence of the ANSI warning tag.
• Operate all buttons and/or levers manually to ensure that they
are not sticking or binding.
• Ensure that the emergency stop button or off button shuts off
the crane when it is depressed.
• Ensure the motions on the pendant/Radio controller match the
directional signs attached to the crane and that the labels are
legible.
• Test all speeds and directions.
• Ensure the pendant strain relief (cable or chain) effectively
keeps the strain off the electrical conductors.
• Ensure proper grounding if it has a metal enclosure.
• Ensure the radio controller battery, holster, belt/strap is in good
condition.
*d Pendant Cable
• Ensure the cable insulation is in good condition with no nicks,
cracks, cuts, tears or deterioration.
• Ensure cable conductors are protected against strain and that a
strain relief cable or chain is present and correctly installed
• Ensure the pendant cable length is such that the operator does
not need to strain or stretch to operate the crane.
*e Pendant Balancer – If Applicable

• Ensure the balancer cable is not damaged.
• Ensure proper operation including the ratchet positioning
device, if equipped.
• Ensure the balancer is mounted properly including hooks for
wear or signs of damage, if installed.
*f Hoisting Limit Switches

• Inspect the general condition and mounting for any damage or
defects.
• Test that the upper limit activates and stops the hook block.
Test first in slow speed followed by high speed, under no load.
The block shall stop before touching any structure on the
trolley/hoist. For low headroom or other specific hoists, consult
the manufacturer’s manual for correct “C” dimension. Adjust
the upper limit if the customer has purchased Routine
Maintenance, otherwise, do not adjust.
• Check the operation of the back-up upper limit if possible and
practical. Manually activate the back-up limit and try to operate
the hoist up direction. No movement should occur. Some
back-up limits may require a manual reset.
• Test the operation of the lower and slowdown switch(es), if
installed)
• Ensure no less than 2 wraps of rope (not including rope
installed under the drum clamps) shall remain on the drum
when the hook is in its extreme low position. Adjust the lower
limit, if the customer has purchased Routine Maintenance,
otherwise, do not adjust.
g Runway Power Supply

Conductor
• Operate the crane along the available portion of the runway
paying particular attention to dead spots on the conductors.
• Verify a dedicated grounding bar (fourth bar) is installed and
easily distinguishable from power conductor bars. Grounding
bar should be furthest from the runway structure.
• Inspect the bar insulation, splice covers and end covers that
may be broken cracked or missing.
• Inspect for heat damage at the splices.
• Inspect for overall mounting, straightness.
• Inspect the condition of insulators supporting bare copper wire

or conductors.
• Ensure bare copper wire or conductor is sufficiently supported
throughout its entire length.
OR
Festoon Cable
• Inspect the condition of the cable for nicks, cracks or any other
deterioration of the insulation.
• Inspect the condition and mounting of the C-track, C-track
couplings and track joint assembly.
• Verify the festoon cable is not sagging on any objects and is
not placed in situation where excessive stress is imposed on
the conductors.
• Ensure the stack up distance is appropriate.
• Verify electrical connections, If applicable.
Cable Trolley
• Ensure free movement of the cable trolleys as the crane travels
on the available portion of the runway and crane.
• Inspect the condition of the fixed trolley and ensure that its
fasteners are tight.
• Randomly check the cable saddle fasteners for tightness on a
few trolleys. Tighten loose fasteners if the customer purchased
Routine Maintenance.
• If tow chains are present, ensure they are correctly installed
and of the correct length.
*h Crane Travelling Limit Switches

defects.
• Operate the bridge in both directions to activate the limit
switches, if installed.
• Activate the limit switch at slow speed and then at higher
speeds to verify they slowdown and/or stop, without a load.
*i Trolley Traversing Limit Switches

defects.
• Operate the trolley in both directions to activate the limit
switches, if installed.
• Activate the limit switch at slow speed and then at higher
speeds to verify they slowdown and/or stop, without a load.
*j Warning Devices
Warning devices can be audible or visual.
• Activate all warning devices to ensure they are operational.
• Ensure the warning device is an audible type if the asset is
radio controlled. It is Konecranes stance a visual warning
device alone is not sufficient to ensure safety on radio operated
cranes.
*k Interlocks and Switches

This component refers to interlock devices that allow transfer of
trolley/hoist from the bridge of one crane to the bridge of another or one
monorail system to another.
• Operate the interlock mechanism several times.
• Ensure the interlock mechanism operates correctly and
activates when the beams are properly aligned.
• Run the trolley through the switch mechanism to check for
clearances and observe transitions.
• Verify the trolley is making proper contact with the interlocks
preventing it from falling when the crane is not aligned with the
switch.
*l Indicating Devices
This component refers to a wind indicator or a process indicating light.
This component does not refer to a general warning light.
• Ensure indicating devices are in good working order and are
functioning for their intended purpose and under correct
condition.
• Ensure proper mounting and that fasteners are tight.
*m Lighting
• Ensure the lighting is protected against vibration and is
securely mounted.
• Ensure lights are operational and illuminate the working area.
• It is best practice that lights remain on, even when the mainline
contactor is off.
*n Runway
• Drive the crane down the entire length of the runway, as much
as practical, listen for any unusual noise and look for any
skewing of the crane.
*o Beam
Do not record any information under this component as this
component is out of scope for a Periodic or Frequent inspection.
4 Hook Block – Wire Rope

*a Hook Block
• Visually inspect for loose or missing fasteners, damaged or
missing sheave guards, grease fittings or any other
components.
*b Hook Block Structure and Markings

• Ensure the capacity markings are on the hook block and are
legible.
missing sheave guards, grease fittings, broken welds or any
other damaged components.
*c Crosshead
This component is also referred to as the trunnion. Not all hook blocks
have a crosshead.
• Ensure free movement of the crosshead in the hook block
assembly.
• Visually inspect for any damage or deformation.
• Lubricate the crosshead, if the customer has purchased Routine
Maintenance, otherwise, do not lubricate.
Rope Sheave and Bearings

*d
• Ensure the wire rope is making at least 120 degrees of contact
with the rope groove.
• Ensure the bottom of the rope sheaves are circular in

shape and have not begun to show wear. Use a sheave gauge
to verify.
• Check the flange thickness for sharp edges.
• Inspect rope sheave for imprinting (memory) that would

damage the rope (shall not exceed 1mm or .040 inches).
• Check for axial and radial play of the sheave to determine

possible bearing or sheave pin damage.
• Ensure sheave(s) rotates freely and are properly secured.
• Lubricate the bearings, if the customer has purchased Routine

e Hook Nut and Locking Parts

• An internal inspection of the hook nut and locking parts is not
included in the scope of a MAINMAN Assessment, OSHA
Periodic or OSHA Frequent inspection.
• SLIM automatically creates an action showing the Fault as Not
In Scope with a Recommendation of Disassemble.
• The system generated comment should be edited with the
OEM's specific recommendation for hook nut and locking parts
inspection if known. This is edited in the Workpackage Review.
*f Thrust ball bearing

Thrust bearings may also be a needle or roller style.
• Ensure the hook rotates freely.
• Listen and feel for any evidence of damaged bearings while
rotating the hook.
*g Hook Forging
• Visually inspect the forging for stretch, twist, bend at the shank,
welds on the hook, saddle wear and cracks.
• Refer to OEM or ASME for removal criteria and rejection limits.
h Hook Forging – Internal

• An internal inspection of the hook forging - internal is not
OEM's specific recommendation for hook forging - internal
*I Latch
The majority of hooks are equipped and will require a hook latch.
However, hook latches are not required in cases where they are
impractical or unnecessary. Examples include: Dip tank applications,
Aux hoist hook on a ladle and/or scrap crane.
If equipped:
• Ensure the latch is in good condition and closes fully.
• Ensure that the latch can keep loose lifting devices in the hook
saddle.
• Ensure the self-locking latch works properly, If equipped.
• Ensure the installed latch operates in the manner as designed
by the OEM.
5 *Hook Block - Chain
*a Hook Block
missing sheave guards, grease fittings or any other
components.
*b Hook Block Structure and Markings

• Ensure the capacity markings are on the hook block and are
legible.
• Verify hook block guards are guiding the chain properly (if there
are 2 or more falls of chain).
missing hook block guards, grease fittings, broken welds or any
other damaged components.
*c Chain Wheel (also called Pocket Wheel)

This component refers to the chain wheel located in the hook block.
• Inspect any visible portion of the chain wheel.
• Verify the condition of the bearing(s) by running the hoist up and
down, observing any signs of bearing damage.
• Lubricate the chain wheel bearings (if applicable) if the customer
has purchased Routine Maintenance, otherwise, do not
lubricate.
*d Crosshead
This component is also referred to as the trunnion. Not all hook blocks
have a crosshead.
• Ensure free movement of the crosshead in the hook block
assembly.
• Visually inspect for any damage or deformation.
• Lubricate the crosshead, if the customer has purchased Routine
e Hook Nut and Locking Parts

• An internal inspection of the hook nut and locking parts is not
OEM's specific recommendation for hook nut and locking parts
*f Thrust ball bearing

Thrust bearings may also be a needle or roller style.
• Ensure the hook rotates freely.
• Listen and feel for any evidence of damaged bearings while
rotating the hook.
*g Hook forging
• Visually inspect the forging for stretch, twist, bend at the shank,
welds on the hook, saddle wear and cracks.
• Refer to OEM or ASME for removal criteria and rejection limits.
h Hook Forging – Internal

• An internal inspection of the hook forging - internal is not
OEM's specific recommendation for hook forging - internal
*i Latch
The majority of hooks are equipped and will require a hook latch.
However, hook latches are not required in cases where they are
impractical or unnecessary. Examples include: Dip tank
applications, Aux hoist hook on a ladle and/or scrap crane.
If equipped:
• Ensure that the latch can keep loose lifting devices in the hook
saddle.
• Ensure the self-locking latch works properly, If equipped.
• Ensure the installed latch operates in the manner as designed
by the OEM.
6 Wire Rope – For a more detailed SOP, see Wire Rope Inspection
*a Hoisting Wire Rope

• Set the hook block in a proper support or on the floor in order to
remove tension from the wire rope. (may need a ladder or lift to
inspect the wire rope).
• Turn off crane and maintain control of pendant/radio controller
• Using broad face calipers, take a measurement on each fall of
wire rope within 1 ft. from the bottom block.
• Tie rag around wire rope fall (as a guide).
• Rag the wire rope up to the guide, while wearing leather palmed
gloves & mark defects with paint marker or chalk.
• Using the man-lift/ladder continue to rag the wire rope.
• Measure each fall of wire rope at approx. the mid-point and
another measurement within 1 ft. of the upper sheave nest on
each fall line.
• Record each of the measurements
• Visually inspect the entire length of rope for deficiencies and
lubrication.
• Verify proper wire rope diameter is installed on the hoist per
OEM Specifications.
• Use the wire rope removal criteria provided in ASME B30.2-4.3.
• Lubricate the wire rope, if the customer has purchased Routine
*b Rope Anchorage
• Inspect the condition of the rope anchorage assembly including
the load and safety pin (safety pin should only be used once).
• Inspect the rope clips for tightness.
• Rope anchorage may be of various types such as: wedge and
socket assembly, button and various swaged end connection,
verify proper installation per OEM Specifications.
• Verify free movement of the anchorage point.
• Lubricate the rope anchorage point (if equipped and accessible),
if the customer has purchased Routine Maintenance, otherwise,
do not lubricate.
*c Rope Clamps
• Ensure proper installation and that none are missing.
• Manually check the tightness of the rope clamps attaching the
rope to the drum.
• Consult OEM requirements for rope clamps reutilization and
torque specification.
*d Rope Drum
• Observe the wire rope is properly seated into the drum grooves
and does not cross over a land into an adjacent drum groove.
• Ensure the bottom of the drum grooves are circular in shape and
have not begun to show wear. Use a sheave gauge to verify.
• Inspect the rope drum for lands that are sharp or worn.
• Inspect drum grooves for imprinting (rope memory) that would
damage the rope (shall not exceed 1 mm or .040 inches).
• Inspect drum gearings for damage or wear, if accessible and
equipped
*e Upper Block Structure

• Inspect for any damage or wear including cracked welds, bent
structure and evidence of two blocking.
• Ensure close fitting guards are present and are not damaged.
*f Rope Sheave and Bearings

• Ensure the wire rope is making at least 120 degrees of contact
with the roper groove.
• Ensure the bottom of the rope sheaves are circular in shape and
have not begun to show wear. Use a sheave gauge to verify.
• Check the flange thickness for sharp edges.
• Inspect rope sheave for imprinting (memory) that would damage
the rope (shall not exceed 1mm or .040 inches).
• Check for axial and radial play of the sheave to determine
possible bearing or sheave pin damage.
• Ensure sheave rotates freely and are secured properly
g Re-Energize the Crane

• Remove the rag and position the lift at least 4 ft. from the hoist
or bottom block and lower than the bottom of the bridge girders.
*h Rope Guide
• Verify rope guide is present, moves smoothly and has no
obstructions across the entire drum, if the hoist was originally
designed with a rope guide.
• Inspect the general condition of the rope guide and associated
components for damage and for signs of side pulling.
• Ensure the guide bar or rail is free of damage.
• Lubricate the rope guide, if the customer has purchased Routine
*i Rope Drum Bearings

• Operate the hoist in all speeds paying particular attention to
abnormal noises coming from the drum rotation.
*j Overload Protector
This component refers to any sort of load measuring and overweight
protection device.
• Visually inspect for damage. If possible, manually activate the
switch and try to run the hoist in the up direction, no movement
should occur.
• Ensure the overload protector is not disabled.
• Looks for signs of shock load or overload.
• If equipped with a load sensor, consult condition monitoring unit.
k Stage the Bottom Block

• After inspection, position hook block in an intermediate position,
out of the way.
7 Chain Inspection
*a Chain
• Clean the chain, if needed.
• Inspect individual links of the chain including the chain in the
chain container for and its end connection for wear, twist,
distortion, nicks, gouges, stretch (1.5% per ASME or OEM
Specifications), corrosion and proper lubrication.
• Ensure the link welds orientation is per OEM specification.
• Lubricate the chain, if the customer has purchased Routine
8 Bridge/Trolley/Hoist Cubicles – For a more detailed SOP, see How to Inspect Loose Wiring in
Control Panels
a Condition Monitoring Unit

Arc Flash PPE, required when working near live equipment
• Inspect the physical condition and wiring.
• Verify the condition monitoring unit shows “0” load with an empty
hook.
• *Condition monitoring unit may vary by manufacturer. At
minimum, record the following values if provided:
o SWP %
o Number of starts
o Run Time
o Brake SWP%
o Number of Overload
o E-Stops.
(control pro – Press ENT 5201 ENT – then scr0ll up and down to find
values).
b Traveling/Traversing/Hoisting Inverters
Arc Flash PPE, required when working near live equipment
• Ensure the inverter is securely mounted inside the enclosure.
• Ensure the inverter has ample means of cooling. Consult the
OEM Specifications.
• Ensure the cooling fan is working and the heat sink is clean.
• Ensure electrical connections are properly landed and tight.
(power, control and signal).
• Ensure encoder and/or communication bus cables are grounded
with 360-degree clamps.
• Verify double collector shoe assemblies are installed on the
crane.
• *Check fault history/counters and record relevant faults.
c LOTOTO at Runway Disconnect/Inspect Disconnect

• Properly perform Lock out/Tagout/Tryout at the runway
disconnect.
• Ensure line and load wires are wired properly.
• Go up on lift, and while wearing arc flash PPE, ensure zero
energy at the conductor bars and in each of the control panels
(bridge, trolley hoist), (then remove arc flash PPE).
*d Crane Main Switch

Also referred to as the bridge disconnect or safety switch.
• Ensure it opens all three phases and is lockable in the “Off”
position.
• Ensure the crane main switch is installed on the side of the
runway as the conductor bars.
• On cranes with a cab, must be within reach of the cab operator.
e Bridge/Trolley/Hoist Cubicle
LOTOTO will not eliminate the risk of arc flash if the disconnect is of
the through panel door type.
• Inspect the cubicle mounting and ensure the fasteners are tight.
• Ensure the cubicle is capable of protecting the controls from all
environmental conditions. Inspect the condition of the seal.
• Ensure that the door is secured by hinges, safety chain or cable.
• Ensure cubicle can be closed, latched.
f General Wiring and Conduits

• Ensure all components in the cubicle are mounted properly.
• Visually verify that wiring is neat.
• Ensure all conduits and cable entries are mounted properly and
free of damage.
• Terminals should be tight. Randomly check a few for tightness.
You may tighten the ones you find loose. Check the rest of the
terminals in the enclosure if you found loose screws and if the
customer purchased Routine Maintenance, otherwise, only
check for tightness of random terminals.
• Ensure all low voltage signal cabling is routed at least 8 inches
(20 cm) away from all power cabling and 4 inches (10 cm) from
control voltage cabling, to prevent unwanted interference.
g Resistor Cubicle
• Ensure the resistor cubicle enclosure fully protects the resistors
and prevents accidental contact.
• Ensure the enclosure will contain any falling debris or molten
metal in case of a resistor failure.
• Ensure the resistors and cubicle are free from dust and debris
that could pose a fire hazard and/or inhibit the resistors cooling
ability
• Ensure resistors are properly mounted.
• Ensure connections are tight.
9 Crane Access
a Crane access (I/A)

• Verify ease of access from the building structure to the crane
and its structural integrity.
• Ensure the gap between the access point and crane service
platform does not exceed 12 inches.
b Service Platform
This component refers to the service platform attached to the building
structure. This does not refer to the catwalk of the crane.
• Inspect for loose fasteners, deterioration of metal or damage
such as bent supports.
• Ensure there is a minimum of 48” headroom clearance and
designed to sustain a distributed load of 50 pounds per square
foot and of anti-slip material.
• Ensure the service platform is equipped with railing and toe
boards.
c Handrails
• Ensure fasteners are tight and inspect for deterioration of
structural supports, damaged rails and a smooth top rail that will
not snag or cut your hand.
• Measure the guard railing, they shall be at least 42 (+/- 3 inches)
in height and determine if the railing is provided with an
intermediate rail.
• The footwalk shall be protected on all exposed edges by a
suitable toe guard and be minimum of 3.5 inches.
d Ladders
This component refers to the ladder attached to the building structure.
This component does not refer to any ladders installed on the crane.
• Check fasteners for tightness, deterioration of ladder rungs,

damage at the bottom and sides where it attaches.
10 End Trucks and Power Supply
a End Truck Structure

• Visually check for damaged, corroded or cracked components
near main girder connections and loosed or missing fasteners.
*b Bridge Structure
• Visually check for loss of camber on box girders of span 50 feet
or greater.
• Visually check for negative camber on crane of span less than
50 feet.
• Visually check for damage to the girder
• Ensure there is a minimum clearance of 3 inches overhead and
2 inches laterally.
*c Main Girder
Edit component description in SLIM
• For a double girder crane, edit the component description in
SLIM to G1 and G2 based on the OEM drawings. In the event
that information is not available, G1 girder is typically the one
containing the bridge controls.
*d Main Girder Connection

• Visually check for damaged, corroded, cracked components or
welds of the main girder connections and loose or missing
fasteners.
*e Crane Driving Wheel and Bearings

• Inspect the wheel gearing for wear and proper lubrication, if
equipped.
• Inspect for damaged or worn parts such as pins, bearings and
shafts.
• Look for metal shavings.
• Inspect and assess overall condition of the wheel.
• Measure the wheel flanges with a caliper for wear greater than
25% of the original thickness.
• Inspect the wheel tread for any type of wear.
*f Crane Idle Wheel and Bearings

shafts.
*g Crane Bumpers
• Ensure bumpers are not missing or damaged.
• If the bridge is power-operated, ensure bumpers are provided.
• If equipped, verify an effective tether cable or chain is installed
to prevent falling to the ground. Tethers are not required for
small rubber bumpers that are not equipped with means for
attaching the tether. Tethers are required for hydraulic
bumpers and mechanical bumper extensions.
h Rail Sweep
• Inspect for any damaged or missing rail sweep.
• Ensure all fasteners are tight.
• Ensure the rail sweep extends below the top of the rail at least
½ of the thickness of the rail head and projects in front of the
leading wheels on both ends of the end truck.
• Ensure the gap between the rail sweep and the top of the rail
does not exceed 3/16 inches.
i Guide Roller (I/A)

• Ensure the guide rollers can rotate freely.
• Inspect for wear on the guide roller contact surface.
• Inspect for proper clearance between the guide roller and the
rail. Proper clearance must allow for float but not be so
excessive as to allow the bridge to bind.
*j Open Gear Transmission

• Inspect for damage, wear and verify lubrication of gearing.
• Inspect physical condition of all guards and covers of the open
gear transmission if equipped. If it has a guard, ensure all
guards can support the weight of a 200 lb. Person without
distortion.
• Lubricate the open gear transmission, if the customer has
purchased Routine Maintenance, otherwise, do not lubricate.
*k Traveling Gear
• Run the crane and listen for any unusual noise coming from the
gears or bearings.
• Inspect the mounting of the gearcase. Ensure all fasteners and
mounting hardware are tight.
• Check the condition and level of lubricant in the gearcase.
• Ensure the breather plug is not clogged.
• Look for leakage and dirt accumulation.
• If equipped, open the inspection cover and inspect for damage
or wear on gears.
• Lubricate the traveling gear, if the customer has purchased
Routine Maintenance, otherwise, do not lubricate.
*l Traveling Coupling
• Manually attempt to rotate the coupling to feel for play, if
possible.
• Visually inspect for external wear and signs of damage.
• Inspect condition of set screws and keyways, if equipped.
• On bigger cranes, operate the machinery in both directions to
observe the play in the coupling components.
• Check for sufficient lubrication, if possible.
• Lubricate the coupling, if the customer has purchased Routine
*m Traveling Power Transmission Shaft and Bearings

• Run the machinery and listen for any unusual noise.
• Verify straightness of the line shaft and condition of the
couplings.
• Inspect the bearings condition, lubrication and cleanliness.
• Inspect the bearing supports for cracks or loose fasteners.
*n Traveling Motor
• Inspect the motor mounting and tightness of the fasteners.
• Run the motor and listen for any unusual noise.
• Ensure the motor case is free of dirt and debris that would
cause the motor to overheat.
• Check the condition of the fan, if equipped. Ensure its
operating properly.
• Verify motor leads are connected properly and are secure.
*o Traveling Brake
• Test brake operation and ensure no drift is observed after the
brake has set.
• Remove brake cover and without disassembling the brake
perform visual inspection of all brake components.
• Measure the air gap, compare to OEM specifications.
• If necessary, based on brake design and/or if initial assessment
warrant, disassemble and examine all brake components.
• Adjust the air gap if the customer has purchased routine
maintenance, otherwise, do not make any adjustments.
p Traveling Encoder
This component refers to encoders, pulse sensors, pulse generators or
any component that provides signals related to motor speed.
• Inspect mounting, coupling and cleanliness, if equipped.
• Observe if encoder vibrates during operation.
• Verify encoder cabling is neat and secured.
q Protection Guards and Covers

This component refers to guards covering couplings, line shafts, open
gear transmissions and other rotating parts.
• Inspect the general condition for deformities or damage
• Verify the guard can support the weight of a 200 lb person

without distortion and that they are properly mounted, if
equipped.
*r Trolley Rail End Stops

• Inspect the condition, alignment and mounting of the end stops.
• Ensure the end stops make full contact with the bumpers.
s Trolley Rail
This component refers to the rail installed on the bridge girder that the
trolley rides on.
• Inspect for straightness and wear on the running surfaces and
edges of the beam flanges.
• Inspect for missing rail fasteners and tightness of rail fasteners.
• Inspect for cracked welds that attached rail sections and attach
rail to the girder.
t Runway, Trolley & Pendant Power Supply

• Visually inspect the condition of the power bar or festoon
system including the grounding conductor (for straightness,
dead spots or broken/missing insulation casing). (See below).
u Connection Box
• Inspect the condition and mounting of the pendant carrier and if
equipped, the connection box.
• Ensure the pendant carrier and connection box trolleys move
freely.
• Inspect the cable entries and connections including the ground
connection.
v Festoon Cable (Runway, Trolley & Pendant)
• Inspect the condition of the cable for nicks, cracks or any other
deterioration of the insulation.
• Inspect the condition and mounting of the C-track.
• Verify the festoon cable is not sagging on any objects and is
not placed in situation where excessive stress is imposed on
the conductors.
• Ensure the stack up distance is appropriate.
• Verify electrical connections, If applicable.
w Cable Trolley (Runway, Trolley & Pendant)

• Ensure free movement of the cable trolleys as the crane travels
on the available portion of the runway and crane.
• Inspect the condition of the fixed trolley and ensure that its
fasteners are tight.
• Randomly check the cable saddle fasteners for tightness on a
few trolleys. Tighten loose fasteners if the customer purchased
Routine Maintenance.
• If tow chains are present, ensure they are correctly installed
and of the correct length.
x Conductor (Runway, Trolley & Pendant)

• Operate the crane along the available portion of the runway
paying particular attention to dead spots on the conductors.
• Verify a dedicated grounding bar (fourth bar) is installed and
easily distinguishable from power conductor bars. Grounding
bar should be furthest from the runway structure.
• Inspect the bar insulation, splice covers, and end covers that
may be broken cracked or missing.
• Inspect for heat damage at the splices.
• Inspect for overall mounting, straightness.
• Inspect the condition of insulators supporting bare copper wire
conductors.
• Ensure bare copper wire or conductor is sufficiently supported
throughout its entire length. (as indicated by the red arrow in
the adjacent photo)
y Tow Arm (Runway, Trolley & Pendant)
This component refers to both a collector mast on which collector
shoes are mounted or a tow arm type assembly used with a festoon
power track.
• Inspect the condition and mounting of the tow arm or collector
staff.
• For festoon system, ensure tow arm is engaged or tied properly
to the lead trolley.
• For conductor bars, ensure the collector staff is adjusted
properly. Consult OEM for mounting specifications.
z Collector Assembly (Runway & Trolley)
• Inspect the condition, mounting and alignment of the collector
assembly.
• Ensure collector arms have enough upward pressure to
maintain continuous contact with the conductor bar.
• Inspect contact shoes for wear.
• Verify double collector shoe assemblies are installed if the
crane has inverters.
• Ensure free movement and smooth transition of the collector
shoes over each of the conductor bar joints while the crane
travels down the available portion of the runway/crane.
aa Service Platform
This component refers to the service platform attached to the bridge
structure, commonly referred to as a catwalk.
• Inspect for loose fasteners, deterioration of metal or damage
such as bent supports.
• Ensure there is a minimum of 48” headroom clearance and
designed to sustain a distributed load of 50 pounds per square
foot and of anti-slip material.
• Check for debris or loose parts that could fall from the service
platform or could be a trip hazard when walking on the platform.
bb Handrails
This component refers to the handrail attached to the bridge structure.
• Ensure fasteners are tight and inspect for deterioration of
structural supports, damaged rails and a smooth top rail that
will not snag or cut your hand.
• Measure the guard railing, they shall be at least 42 (+/- 3
inches) in height and determine if the railing is provided with an
intermediate rail.
• The footwalk shall be protected on all exposed edges by a
suitable toe guard and be minimum of 3.5 inches
cc Ladders
This component refers to the ladder attached to the bridge
structure.
• Check fasteners for tightness, deterioration of ladder rungs,
damage at the bottom and sides where it attaches.
*dd Storm Lock Device

• Inspect the condition and operation of the storm locking device
and/or automatic rail clamp.
• Storm locking devices can be manually operated.
• Rail clamps must be automatically set when power is removed
from the crane.
ee Runway beam
• Inspect the alignment, straightness and level of the runway
beams and their connections to the supporting structure.
• This inspection is done from the lift or the catwalk at the point
where the crane is staged. This is not a full inspection of the
runway. A full runway inspection falls outside of the scope of
the MAINMAN Assessment and OSHA Periodic products.
ff Crane rail
• Inspect the alignment, straightness and level of the crane rail
and its connections to the runway beam.
• Inspect the rail head for wear.
gg Rail fasteners
• Inspect for evidence of loose rail clips, J bolts or broken welds.
*hh End stops

• Inspect the general condition including all welds and fasteners
for structural integrity.
• Ensure parallel alignment of the end stops from one runway
beam to the other so the crane evenly contacts the end stops.
• Ensure that the end stops make full contact with the bumpers.
11 Trolley
a Trolley Driving Side Structure

• Inspect the condition of the trolley drive side structure (frame)
for any damage.
• Inspect that all fasteners are tight, and welds are not cracked
2 inches laterally.
• Ensure the trolley gauge is of proper width.
*b Traversing Gear
• Run the crane and listen for any unusual noise coming from the
gears or bearings.
• Inspect the mounting of the gearcase. Ensure all fasteners and
mounting hardware are tight.
• Check the condition and level of lubricant in the gearcase.
• If equipped, open the inspection cover and inspect for damage
or wear on gears.
• Lubricate the traversing gear, if the customer has purchased
*c Traversing Brake
• Test brake operation and ensure no drift is observed after the
brake has set.
• Remove brake cover and without disassembling the brake
perform visual inspection of all brake components.
• If necessary, based on brake design and/or if initial assessment
warrant, disassemble and examine all brake components.
*d Traversing Motor
• Inspect the motor mounting and tightness of the fasteners.
• Ensure the motor case is free of dirt and debris that would
cause the motor to overheat.
• Check the condition of the fan, if equipped. Ensure it is
operating properly.
• Verify motor leads are connected properly and are secure.
*e Trolley Driving Wheel and Bearings

• Inspect the wheel gearing for wear and proper lubrication, if
equipped.
shafts.
*f Open Gear Transmission

• Inspect for damage, wear and verify lubrication of gearing.
• Inspect physical condition of all guards and covers of the open
gear transmission if equipped. If it has a guard, ensure all
guards can support the weight of a 200 lb. Person without
distortion.
• Lubricate the open gear transmission, if the customer has
purchased Routine Maintenance, otherwise, do not lubricate.
*g Trolley Bumpers
• If the trolley is power-operated, ensure bumpers are provided.
attaching the tether. Tethers are required for hydraulic bumpers
and mechanical bumper extensions.
h Rail Sweep
i Trolley Idle Side Structure

• Inspect the condition of the trolley idle side structure (frame) for
any damage.
• Inspect that all fasteners are tight, and welds are not cracked
2 inches laterally.
• Ensure the trolley gauge is of proper width.
*j Trolley Idle Wheel and Bearings

shafts.
*k Trolley Bumpers
• If the trolley is power-operated, ensure bumpers are provided.
attaching the tether. Tethers are required for hydraulic bumpers
and mechanical bumper extensions.
l Rail Sweep
*m Traversing Coupling
possible.
• Inspect condition of set screws and keyways, if equipped.
• On bigger trolleys, operate the machinery in both directions to
observe the play in the coupling components.
• Lubricate the coupling, if the customer has purchased Routine
n Guide Roller (I/A)

• Ensure the guide rollers rotate freely.
• Inspect for wear on the guide roller contact surface.
• Inspect for proper clearance between the guide roller and the
rail. Proper clearance must allow for float but not be so
excessive as to allow the trolley to bind.
o Traversing Encoder
This component refers to encoders, pulse sensors, pulse generators
or any component that provides signals related to motor speed.
p Protection Guards and Covers

This component refers to guards covering couplings, line shafts,
open gear transmissions and other rotating parts.
• Inspect the general condition for deformities or damage
• Verify the guard can support the weight of a 200 lb person
without distortion and that they are properly mounted, if
equipped.
12 Hoisting Machinery
a Hoisting Machinery
• Visual inspection, obtain and record in the SLIM device
the hoist information.
*b Hoisting Brake - Holding

• Test brake operation and ensure no drift is observed
after the brake has set.
• Remove brake cover and without disassembling the
brake perform visual inspection of all brake components.
• If necessary, based on brake design and/or if initial
assessment warrant, disassemble and examine all brake
components.
*c Hoisting Brake – Control

This component refers to an Eddy Current Brake.
• Inspect for proper mounting and tightness of fasteners.
• Run the hoist and listen for any unusual noise coming
from the eddy current brake.
• Ensure the eddy current brake is free of dirt and debris
that would cause it to overheat.
operating correctly.
• Verify electrical leads are connected properly and are
secure.
• Lubricate the bearings, if the customer has purchased
routine maintenance, otherwise, do not lubricate.
*d Hoisting Gear
• Run the gearcase and listen for any unusual gear or
bearing noise.
• Inspect the mounting of the gearcase. Ensure all
fasteners and mounting hardware are tight.
• Check the condition and level of lubricant in the
gearcase.
• If equipped, open the inspection cover and inspect for
damage or wear on gears.
• Lubricate the Gearcase, if the customer has purchased
routine maintenance, otherwise, do not lubricate.
e Hoisting Gear – Internal

**Unable to Inspect**
• An internal inspection of the Hoisting Gear – Internal is
not included in the scope of a MAINMAN Assessment,
OSHA Periodic or OSHA Frequent Inspection.
• SLIM automatically creates an action showing the Fault
as Not In Scope with a Recommendation of
Disassemble.
• The system generated comment should be edited with
the OEM’s specific recommendation for Hoisting Gear –
Internal inspection if known. This is edited at the
Workpackage Review.
f Mechanical Load Brake
• An internal inspection of the mechanical load brake is not
included in the scope of a MAINMAN Assessment,
as Not in Scope with a Recommendation of
Disassemble.
the OEM’s specific recommendation for mechanical load
brake inspection if known. This is edited at the
Workpackage Review.
*g Hoisting Coupling
possible.
• Inspect condition of set screws and keyways, if
equipped.
• On bigger hoists, operate the machinery in both
directions to observe the play in the coupling
components.
• Lubricate the coupling, if the customer has purchased

h Hoisting Coupling – Internal
• An internal inspection of the Hoisting Coupling – Internal
is not included in the scope of a MAINMAN Assessment,
Disassemble.
the OEM’s specific recommendation for Hoisting
Coupling – Internal inspection if known. This is edited at
the Workpackage Review.
*i Hoisting Motor
• Inspect the motor mounting and tightness of the
fasteners.
• Ensure the motor case is free of dirt and debris that
would cause the motor to overheat.
operating correctly.
• Verify motor leads are connected properly and are
secure.
*j Micro Motion Motor

• Inspect the motor mounting and tightness of the
fasteners.
• Ensure the motor case is free of dirt and debris that
would cause the motor to overheat.
operating properly.
• Verify motor leads are connected properly and are
secure.
*k Micro Motion Coupling

• An internal inspection of the Micro Motion Coupling
is not included in the scope of a MAINMAN Assessment,
Disassemble.
the OEM’s specific recommendation for Micro Motion
Coupling inspection if known. This is edited at the
Workpackage Review.
*l Hoisting Encoder
This component refers to encoders, pulse sensors, pulse
generators or any component that provides signals related to
motor speed.
m Drive Sprocket (also known as Pocket or Chain wheel)

• An internal inspection of the drive sprocket is not
included in the scope of a MAINMAN Assessment,
Disassemble.
the OEM’s specific recommendation for drive sprocket
inspection if known. This is edited at the Workpackage
Review.
*n Chain Anchorage
• Inspect the condition of the chain anchorage assembly
including the load and safety pin.
• Verify free movement of the anchorage point.
• Lubricate the anchorage point, if the customer has
purchased Routine Maintenance, otherwise, do not
lubricate.
*o Chain Guide
• Inspect the chain guide condition at the point where the
chain enters the hoist body, for excessive wear and
evidence of side pulling.
• Ensure all mounting hardware is tight.
• Ensure the chain guide provides proper alignment of the
chain into the drive sprocket.
p Chain Container
• Inspect the chain container for cracks, tears, proper and
secure mounting, if applicable.
• Verify a chain container is installed for a hoist that was
designed with one.
• Ensure chain container is large enough to contain all the
load chain when the hook is at the upper limit.
q Overload Protector
• An operation test of the overload protector (slip clutch)

with weights is not included in the scope of a MAINMAN
Assessment, OSHA Periodic or OSHA Frequent
Inspection.
In Region AME, this component shall be coded as:

Fault Code: Not In Scope
Risk: Undetermined Condition
Recommendation: Unable To Inspect
Comments should include the OEM recommended test
interval.
*r Hanging Hook
This component refers to the top hook of the chain hoist that
attaches to the structure.
• Visually inspect the forging for stretch, twist, bend at the
shank, welds on the hook, saddle wear and cracks.
• Refer to OEM or ASME for removal criteria and rejection
limits.
*s Latch
• Ensure the installed latch operates in the manner as
designed by the OEM.
*t Frame
This component refers to the chain hoist body
• Inspect for cracks, damage, missing bolts, fasteners, or
any other deficiencies in the chain hoist frame (body).
Post-Task Checklist
 All tools and rubbish removed from the crane  Work area is clear including barricades and signs
 All tags and locks removed  Notify operator(s) of crane status
 Perform Crane Operational test  Safety/Visit Review conducted

Periodic Inspection SOP

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Periodic Inspection SOP

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Title Periodic Inspection FOR INTERNAL USE ONLY

SOP Document # Rev#:

Personal Protective Equipment Required (Minimum)

Hazards (More Could be present)

Mobile Basic Hand Sheave Feeler Gauge Rags Broad face

Pre-Task Check List

 Agree work area with site contact  Barricade work area

a Complete SOP 1.1.8.1 Pre-Task Check and Work Area Preparation

2 *Prepare Work Package in SLIM

a Sync Slim Device

previously existing active fault's Next Step to

• Unable to Inspect Components

c Fill out the fields of the asset header.

3 *Operational Test Checklist

*a Runway Mainline Disconnect

*b Markings & Main Girder Beam and Markings

*e Pendant Balancer – If Applicable

*f Hoisting Limit Switches

g Runway Power Supply

• Inspect the condition of insulators supporting bare copper wire

*h Crane Travelling Limit Switches

*i Trolley Traversing Limit Switches

*k Interlocks and Switches

4 Hook Block – Wire Rope

*b Hook Block Structure and Markings

Rope Sheave and Bearings

• Ensure the bottom of the rope sheaves are circular in

• Check the flange thickness for sharp edges.

• Inspect rope sheave for imprinting (memory) that would

• Check for axial and radial play of the sheave to determine

• Ensure sheave(s) rotates freely and are properly secured.

• Lubricate the bearings, if the customer has purchased Routine

e Hook Nut and Locking Parts

*f Thrust ball bearing

h Hook Forging – Internal

5 *Hook Block - Chain

*b Hook Block Structure and Markings

*c Chain Wheel (also called Pocket Wheel)

e Hook Nut and Locking Parts

*f Thrust ball bearing

h Hook Forging – Internal

*a Hoisting Wire Rope

*e Upper Block Structure

*f Rope Sheave and Bearings

g Re-Energize the Crane

*i Rope Drum Bearings

k Stage the Bottom Block

a Condition Monitoring Unit

c LOTOTO at Runway Disconnect/Inspect Disconnect

*d Crane Main Switch

f General Wiring and Conduits

a Crane access (I/A)

• Check fasteners for tightness, deterioration of ladder rungs,

10 End Trucks and Power Supply

a End Truck Structure

*d Main Girder Connection

*e Crane Driving Wheel and Bearings

*f Crane Idle Wheel and Bearings

i Guide Roller (I/A)

*j Open Gear Transmission

*m Traveling Power Transmission Shaft and Bearings

q Protection Guards and Covers

• Verify the guard can support the weight of a 200 lb person

*r Trolley Rail End Stops