Basic Performancetest

APPENDIXK

BASIC PERFORMANCETEST

FORWEIGHTHANDLINGEQUIPMENTOPERATORLICENSECATEGORY2ANDCABOPERATEDCATEGORY3CRANES

Notes:(1)Prerequisiteforthisexamination is complete familiarity with StandardHandSignalsforControllingOverheadandGantryCranesshowninfigure10-2.

(2)Performancetestrequirementsshallbesupplementedandmodifiedbytheactivityfor theparticular operating characteristics and featuresofthecranesas well as the unique mission ofthe activity.

(3)Theperformancetestingincludesevaluationoftheoperator'sabilitytofollowhandsignals.Unacceptableactionsincludemovingwithoutasignalandincorrectresponsetosignals.Iftheoperatorwillberequiredtooperatewithoutseeingtheload,thetestshallbemodifiedaccordingly.AdditionalcriteriafortestingtheabilitytofollowhandsignalsandblindoperationareincludedinappendixJ basicperformancetestproblem #3.

(4)NotationonTestForms:Ashortlineisprovidedbeforeeachtestitem.Theexaminershallmakeacheckmarktoindicatethattheapplicanthascorrectlyperformedoransweredthequestion.Theexaminershallindicatebyzeroorcirclewheretheapplicantfailstoperformoranswercorrectly.Theexaminershallprovideashortwrittenexplanationofallfailures.Itemsthatarenotapplicableshall bemarked"NA."

GENERALINFORMATION:

TESTINGACTIVITY:TEST DATE:

APPLICANT'SNAME:TOBE COMPLETEDBYEXAMINER

MAKEANDMODEL OFTESTCRANE:

TYPEOF CONTROLS:

CAPACITY:

RESULTS:SATISFACTORY

UNSATISFACTORY

REMARKS:

SIGNATURE:

GROUPA- PRE-OPERATIONINSPECTION

1.PRE-USECHECK.

a. Ensurethe crane iscurrentlycertified before proceeding.

b. Checkthecrane for tags orotheroperationalrestrictions or warnings.

c. Ensurenorepairsare inprogress.

d. Performthewalk-around,machinery,andoperator’scabcheckslistedontheOperatorDailyChecklist(ODCL)anddocumentontheODCL(figure9-1).

e. Ifaccessible,checktracksforobstructions,misalignment,damage,looseconnections,andconditionsthatmayimpactproperoperation.

f.Checktheworkareaforhazardsandobstacles. Requestcorrectionbeforeproceeding whennecessary.

2.FAMILIARITYWITHLUBRICATIONREQUIREMENTS.

a.Check lubricant levels where accessible and identify points that mayrequirelubrication during periodsofoperation.

GROUPB-TESTINGOPERATINGCONTROLS

1.Checktoassurethatallcontrollersareinthe"Off" position.

2.Energizethecrane.

3.Ifequipped, checkthe action ofdeadman switches.

4. Testtheactionofhoistcontrollersbyraising,lowering,andstoppingthehook.

5. Testtheactionoftravelcontrollersandbrakesbymovingthecranebackand forth afewfeet. Checkfor proper brakeaction.

6. Testthetrolleycontrollersandbrakesbymovingthetrolleybackandforthafewfeet. Checkforproperbrake action.

7. Testthe limit switchesandothersafetydevices.

8. Checktheemergencystop,operationalsafetydevices,warningdevicesandgauges.Notifytheexaminerofdiscrepancies.

9. DocumenttheoperatingtestportionontheODCL. Theapplicantandtheperformanceexaminershallsign theODCL.

GROUPC - OPERATING

Notes:(1)Theaccuracystandardsindicatedareconsideredminimum. Theactivitymayimposemorestringentstandardsbaseduponlocalormissionrequirements.

(2)Atnostageofthetestingshalltheoperatorallow the wire rope tobecomeslackenough toloosenonthedrum.This is anunacceptablepracticeandthe examiner shallmark thisaction accordingly.

PROBLEM1-TESTFORACCURACY

Placeanopencontainerorothersuitabletargetwithintheoperatingrangeofthecraneandnearonecorner ofthetest area.Thetargetshouldbeatleasthalftheheightofthehook blockandapproximately12inchesindiameter larger thanthe largestdimension ofthehookblock.Thecraneshallbepositionedsothatthehookisoverthediagonallyoppositecorneroftheworkarea.Theoperatorshallpositionthehookover thecontainerortarget.Simultaneouscontrolleroperation,i.e.,bothbridgeandtrolleytravel,shallbetestedasappropriate.Theoperatorshalldemonstrateproficiencyinplacing the hookinthe container orat the targetlocation.

Note: The following actionsareconsidered unacceptable:

a.Striking. Theoperatorshallnotcausethe hook tostrikeanything.

b.Operatingabruptly.The operator shall not cause the hook to swingexcessivelywhileoperating.

c.Contactinglimitswitches.

PROBLEM2- LIFTINGANDHANDLINGHEAVYLOADS

Theloadtobeliftedinthistestshouldweighbetween25percentand50percentofthecrane'sratedcapacity.The operator shall be toldtotreattheload as aheavyload. Useofatestweightisrecommended.After theloadisstaged, properly rigged, andattachedtothehook, alineshallbedrawnonthefloor4inchesbeyondtheperimeter oftheload.Uponreceivingthepropersignal,theoperatorshalllifttheloadjustabovethefloorandtesttheoperationofautomaticbrakesandfootbrakesasappropriate.Theoperatorshallbedirectedtomovetheloadthroughapredeterminedcoursethatteststheoperatorsabilitytomovetheload.Thecourseshallrequirediagonalmovementormultiplecontroller movements as appropriate.Theoperator shallthenreturntheloadtothemarkedarea.Ariggermayassistbyrotatingtheload,butshallnotguidetheloador directload movement.

Note: The following actionsareconsidered unacceptable:

a.Failingtokeepsafedistances. Theoperatorshallnotcauseanypartofthecrane or load to pass toocloselytoobstructions.

b.Striking.Theoperatorshallnotcausetheloadorhooktostrikethegroundor anyobjector person.

c.Abruptmovement. Theoperatorshallnotcausetheloadtojerk,seesaw,or wobbleduetomovementsofthecrane.

d. Hoistingtheloadprematurely.Theoperatorshallnothoistuntiltheloadhasbeenproperlysecured,theriggerisclearoftheload,andthehoistsignalisgiven.

e. Failingtoobserveimproperrigging.Theoperatorshallinformtheexaminerwhenever,intheopinionoftheoperator,theriggingappearstobeimproper or unsafe.

f.Snappingtheload. Theoperatorshallremoveanyslackinthehoistlineusing alowspeed controller position or otherappropriate method.

g.Failingtotestbrakes. Brakesshallbetestedimmediatelyaftertheloadislifted.

h. Endangeringpersonnel.Theoperatorshallnotpositiontheloadoverpersonnelandshallsoundawarninggongorsirenandwaitforpersonneltoclear the area.

i.Improperlylandingtheload. Theoperatorshalldemonstrateproficiencyinsafelyandsmoothlylanding the loadwithinthemarked perimeter.

PROBLEM3- LIFTINGANDHANDLINGODD-SHAPED OR SHIFTING LOADS

Theoperatorshallliftandcarryalighttomoderatelyheavyloadapproximately20feetlongoverapredeterminedcourse.Pipe,logs,beams,orlooselumberareacceptable.Ariggershallgivetheoperatordirectionsusinghandsignalsandcontroltheloadusingtaglines.

Note: The following actionsareconsidered unacceptable:

a.Placingthehookincorrectly. Theoperatorshalldemonstrateproficiencyinlocating thehookasrequired for thelift.

b. Hoistingprematurely.Theoperatorshallnothoistuntiltheloadhasbeenproperlysecured,theriggerisclearoftheload,andthehoistsignalisgiven.

c.Improper rigging. Failuretoidentifyunsaferigging.

d.Snappingtheload. Theoperatorshallremoveanyslackinthehoistlineusing alowspeed controller position or otherappropriate method.

e. Endangeringpersonnel.Theoperatorshallnotpositiontheloadoverpersonnelandshallsoundawarninggongorsirenandwaitforpersonneltoclear the area.

f.Failingtokeepsafedistances. Theoperatorshallnotcauseanypartofthecrane or load to pass toocloselytoobstructions.

g. Striking.Theoperatorshallnotcausetheloadorhooktostrikethegroundoranyobjectorperson.Theloadshallbesafelyandsmoothlylandedasdirected.

h.Swingingabruptly. Theoperatorshallnotcausethehookorloadtojerk,seesaw, or wobbledue to movementsofthecrane.

GROUPD - SECURINGTHE CRANE

1.Travel the crane tothe proper storagelocation.

2. Placethehookintheappropriatestoragelocation,normallyinitsuppermostposition,belowanyupperlimitswitch,butwithsufficientclearancebelowtheuppersheaveassemblyortrolley/hoistframesothatthesubsequentoperatorperforminganODCLorpre-usecheckwillbeabletostopthehoistmotionbeforeatwo-blockeventoccursincasethehoistdoesnotoperateinthe correctdirection uponinitiation.

3.Placeallcontrollersin neutral.

4.Secure the power supplyandlock asappropriate.