Crane Model: Crane Serial Number: Date Of Report: Date Of Rework: Hoist Serial Number: Synthetic Rope Certificate of Compliance No.

Transcription

1 Crane Model: Crane Serial Number: Date Of Report: Date Of Rework: Hoist Serial Number: Synthetic Rope Certificate of Compliance No.: Crane Hours: Rev-1 1 of 28

2 1.0 PURPOSE 1.1 To establish the procedure for hoisting rope system reconditioning for synthetic hoist rope application. 2.0 SCOPE 2.1 This procedure covers the reconditioning / rework requirements for the hoisting rope system used on in-service telescopic mobile hydraulic cranes, boom trucks and industrial cranes. 3.0 DEFINITIONS: 3.1 Hoisting Rope System: Crane components such as hoist, wedge, boom contact points, anti two block, boom nose/ hook block sheaves and pins, etc. that may contact the rope during operation. NOTE: This Usage Guide is intended as reference material only and the engineering drawing shall be referred too for the tolerance and other detail requirements. ROPE SCHEMATIC WITH END TERMINATION: Direct bury splice: outboard end termination (diameter tapers in splice area) Constant diameter splice: inboard end termination (required 8 wrap minimum on the drum) Rev-1 2 of 28

3 NOTE: Before any work is begun the entire work instruction must be read and understood. Failure to understand and follow this procedure may cause property damage, severe bodily harm, and death. 1. Care should be taken when removing the Hook Block. The Sheave Wheels on the Hook Block must be examined and evaluated for proper condition to receive the KZ100 Synthetic Rope. No sharp edges are permissible. Geometries with radius lower than 2 mm are considered as sharp edges. 2. Disconnect cable from the Hook Block and unspool from the Hoist. 3. CAUTION: If the Sheave Wheels are steel and are rusty the wheels will need to be cleaned, deburred, and prepped as well. 1. Carefully set the hook block in a receptacle or area that can be set aside for reassembly after the rework process is completed. Rev-1 3 of 28 PRE-INSTALLATION CRANE INSPECTION 1) Any surfaces which may contact the Rope during operation must be inspected prior to installation. 2) Surface roughness must be equivalent to a finish of 300 micro-inches RMS or smoother. 2. Carefully unspool all of the wire Rope from the hoist. Dispose of the wire cable or salvage properly. 3) Surfaces rougher than 300 micro inches RMS should be ground down and (if necessary) repainted to reduce rusting. 4) Any sharp corners which may cause cutting should be rounded off. 5) Special attention should be taken when inspecting the following areas: a. Hoist flanges, drum, wedge, cable packer b. Sheaves (boom nose & hook block) groove condition, sharp edges, freely rotating c. Boom contact points wear pads, sharp edges d. Boom nose & hook block pins, Anti-Two-Block Weight(s) 3. After the wire cable is removed, the hoist must be prepared to receive an acceptable paint. Minimum requirements to be met are commercial finish preparation. Proper preparation of the hoist surface is essential.

4 4. PRE-INSTALLATION CRANE INSPECTION. 5. SURFACE PREPARATION STANDARDS. NOTE: One or two coats of the high-solids Urethanes or Epoxies coating may be used at the customers discretion. Other paint alternatives are acceptable as well, as long as they are not thick and brittle, and capable of causing damage to the rope. Acceptable paints available from Grove Crane Care are: A Black Enamel Gray Enamel Yellow Enamel Gray Enamel, National Black Enamel, National Initial Steel Surface Brush Off SSPC-SP7/NACE 4 4. After the wire cable is removed the hoist must be inspected and prepared to receive An Acceptable Coating of Paint. Minimum requirements to be met are Commercial finish preparation. Good surface preparation is essential. SSPC-SP7 / NACE 4 Brush-Off Blast Cleaning When viewed without magnification, the surface shall be free of all visible oil, grease, dirt, dust, loose mill scale, loose rust, and loose coating. Tightly adherent mill scale, rust, and coating may remain on the surface. Mill scale, rust, and coating are considered tightly adherent if they cannot be removed by lifting with a dull putty knife. SSPC-SP6 / NACE 3 Commercial Blast Cleaning When viewed without magnification, the surface shall be free of all visible oil, grease, dust, dirt, mill scale, rust, coating, oxides, corrosion products and other foreign matter of at least 66-2/3% of unit area, which shall be a square 3 in. x 3 in. (9 sq. in.). Light shadows, slight streaks, or minor discolorations caused by stains of rust, stains of mill scale, or stains of previously applied coating in less than 33-1/3% of the unit area is acceptable. SSPC-SP10 / NACE 2 Near-White Blast Cleaning When viewed without magnification, the surface shall be free of all visible oil, grease, dust, dirt, mill scale, rust, coating, oxides, corrosion products and other foreign matter of at least 95% of each unit area. Staining shall be limited to no more than 5 percent of each unit area, and may consist of light shadows, slight streaks, or minor discolorations caused by stains of rust, stains of mill scale, or stains of previously applied coatings. Unit area shall be approximately 3 in. x 3 in. (9 sq. in.). SSPC-SP5 / NACE 1 White Metal Blast Cleaning When viewed without magnification, the surface shall be free of all visible oil, grease, dust, dirt, mill scale, rust, coating, oxides, corrosion products and other foreign matter. 5. Listed above are the standards for surface preparation. Good surface preparation is essential for proper performance and longevity of the KZ100 Synthetic Rope. Rev-1 4 of 28 Commercial SSPC-SP6/NACE 3 Near White SSPC-SP10/NACE 2 White Metal SSPC-SP5/NACE 1

5 Hoist Drum Preparation Hoist Drum Pockets Photos NOTE: Before any work is begun the entire work instruction must be read and understood. Failure to understand and follow this procedure may cause property damage, severe bodily harm, and death. 6. Any sharp or abrasive areas MUST be prepared to make them suitable to accept the Synthetic Rope. Areas that MUST be thoroughly inspected are the Hoist, Hoist Rollers, Boom, all Sheave Wheels, Retainer Pins, and Anti- Two-Block weight. Any other areas that will contact the new Synthetic Rope should be thoroughly inspected as well. 6. All components that come in contact with the new Synthetic Rope will need to be evaluated for sharp edges or abrasive areas. Hoist Drum Flanges 6. All components that come in contact with the new Synthetic Rope will need to be evaluated for sharp edges or abrasive areas. Incomplete preparation 7. All sharp edges, loose paint, and abrasive areas MUST be removed or rounded and smooth before applying an acceptable paint alternative. 6. All components that come in contact with the new Synthetic Rope will need to be evaluated for sharp edges or abrasive areas. Rev-1 5 of All sharp and abrasive areas should be prepared with Scotch-brite pads and Merit wheels to remove sharp edges.

6 Preparation Photos 8. The hoist areas must be prepared to receive the new Finish Paint coating. An acceptable Oil based Enamel paint, Urethane paint, Epoxy Paint, or Powder Coating may be used as well. Coatings may peel off due to the high forces exerted by the Rope on the hoist drum. Thick coatings that may result in sharp debris when delaminated are not acceptable since these may damage the Rope. 9. No loose or peeling paint is permissible. Any mill scale should be removed. The smoothness and the roundness of the hoist drum pocket is critical. 10. All paint should be removed and a good clean surface with no sharp edges or gouges should be present for painting. 8. Carefully remove any dust, grindings, or debris from the drum and flange areas in preparation for the new paint coating. 9. The cleaned surfaces should closely resemble the picture above. 11. A good solvent such as acetone or alcohol should be used to thoroughly clean the hoist for good paint adhesion. 10. Examine the entire hoist drum and flanges to assure all paint and debris has been removed. Rev-1 6 of Thoroughly clean the prepared hoist with acetone or alcohol. Assure proper surface preparation.

7 Hoist Roller Preparation Boom Photos NOTE: Before any work is begun the entire rework instruction must be read and understood. Failure to understand and follow this procedure may cause property damage, severe bodily harm, and death Any sharp or abrasive areas MUST be smoothed to make them suitable to accept the Synthetic Rope. Areas that MUST be thoroughly inspected are the Hoist, Hoist Rollers, Boom, all Sheave Wheels either on the Boom Nose or the Hook Block, the Anti-Two-Block Weight(s), and all Retainer Pins. Any other areas that will contact the new Synthetic Rope should be thoroughly inspected as well. Photos shown are examples of, but not limited to, areas and components that must be inspected and prepared to accept the Synthetic Rope. 12. All components that come in contact with the new Synthetic Rope will need to be evaluated for sharp edges or abrasive areas. Sheave Wheels & Retainer Pins 14. All components that come in contact with the new Synthetic Rope will need to be evaluated for sharp edges or abrasive areas. Rev-1 7 of All components that come in contact with the new Synthetic Rope will need to be evaluated for sharp edges or abrasive areas. Anti-Two-Block Weights 15. All components that come in contact with the new Synthetic Rope will need to be evaluated for sharp edges or abrasive areas.

8 1 Surface as received 2 Surface after cleaning Surface Preparation NOTE: Use a Technical Data Sheet for drying time for the product being used on the Hoist before installing the Synthetic Rope. Apply all coatings according to the manufacturer s recommended TDS (Technical Data Sheet). 16. Hoist preparation. Acceptable paints available from Grove Crane Care are: 3 Acceptable Finish Paint 4 A Black Enamel Gray Enamel Yellow Enamel Gray Enamel, National Black Enamel, National 16. Hoist preparation showing an acceptable finish paint alternative. Acceptable Finish Paint Rev-1 8 of 28

9 First Coat Preparation Photos First Coat 17. & 18. When installing a new paint coating, carefully apply the paint with even brush strokes. When using a paint brush to apply the paint, assure no paint brush bristles are left in the new paint coating. 19. All areas of the coated surfaces should be completely coated. Acceptable paints available from Grove Crane Care are: A Black Enamel Gray Enamel Yellow Enamel Gray Enamel, National Black Enamel, National 17. First coat of the new paint coating applied on the boom surface. First Coat 18. First coat of the new paint coating being applied on the hoist drum. Second Coat Apply all coatings according to the manufacturer s recommended TDS (Technical Data Sheet). 19. Careful attention must be paid to applying the paint to the hoist drum, hoist flanges, and the hoist pockets. Rev-1 9 of Second coat of the new paint coating being applied on boom surface.

10 Second Coat Preparation Second Coat Photos 21. & 22. When using the new Finish Paint, carefully apply the paint with even brush strokes when using a brush. Assure no paint brush bristles are left in the paint. All areas of the coated surfaces should be completely coated. Allow sufficient drying time for the second coat. 23. Assure there is good coverage in the pocket areas and the edges are rounded. 24. The second coat of paint must be allowed to completely cure. Careful inspection of the coated surfaces must be done at this time. If there are open pockets or pitted areas they must be touched up. Failure to do this will cause the coating to peel in these areas and come off. Good adhesion of the new Finish Paint is critical. 21. Second coat of Finish Paint being applied on the hoist drum. Second Coat 22. Second coat of Finish Paint being applied to the hoist drum and hoist drum flange. 23. Second coat of Finish Paint on the hoist drum flange, hoist drum, and the hoist drum pocket. Rev-1 10 of Check the surfaces that have been coated and assure there are no pitted or open areas where the coating or paint is broken.

11 NOTE: Before any work is begun the entire work instruction must be read and understood. Failure to understand and follow this procedure may cause property damage, severe bodily harm, and death. REMOVING ROPE FROM A REEL OR COIL Synthetic-fiber Ropes are normally shipped on reels for maximum protection while in transit. The Rope should be removed from the reel by pulling it off the top while the reel is free to rotate. This can be accomplished by passing a pipe through the center of the reel and jacking it up until the reel is free from the deck. Rope should never be taken from a reel lying on its side. MINIMUM WRAP COUNT NOTE: A minimum number of 8 wraps shall be maintained on the drum at all times during operation to ensure load is not applied to drum termination. PRE-INSTALLATION CRANE INSPECTION 1) Any surfaces which may contact the Rope during operation must be inspected prior to installation. 2) Surface roughness must be equivalent to a finish of 300 micro-inches RMS or smoother. 3) Surfaces rougher than 300 microinches RMS should be ground down and (if necessary) repainted to reduce rusting. 4) Any sharp corners which may cause cutting should be rounded off. 5) Special attention should be taken when inspecting the following areas: a. Hoist flanges, drum, wedge, cable packer b. Sheaves (boom nose & hook block) groove condition, sharp edges, freely rotating c. Boom contact points wear pads, sharp edges d. Boom nose & hook block pins, Anti-Two-Block Weights 25. Before installing the Synthetic Rope all areas and components that will come into contact with the Rope must be thoroughly inspected to assure proper preparation for receiving the Rope. ATTACHING ROPE TO HOIST DRUM 1) The Rope soft eye is to be attached at the hoist termination point. a. Insert Rope eye through the slot in the hoist drum. b. Position of the eye/wedge is critical to insure that the wedge does not cut the Rope and to prevent diving on the first layer of wraps on the drum. Push the eye through the slot and insert the wedge. Pull the eye/wedge into position such that the Rope body lays in contact with the flange. c. Pull Rope eye into the hoist drum slot using a rubber mallet to secure wedge completely within the drum. Rev-1 11 of 28 Contact Samson/Manitowoc personnel for a microfinish comparator. Insert the Rope eye through the slot in the hoist drum 26. Careful attention must be given to the installation of the Synthetic Rope on the hoist drum by following the instructions above. The allowable surface roughness for maximum life is 300 micro inches. Correct placement eye/wedge should be aligned with the flange.

12 NOTE: Before any work is begun the entire work instruction must be read and understood. Failure to understand and follow this procedure may cause property damage, severe bodily harm, and death. REMOVING ROPE FROM A REEL OR COIL Synthetic-fiber Ropes are normally shipped on reels for maximum protection while in transit. The Rope should be removed from the reel by pulling it off the top while the reel is free to rotate. This can be accomplished by passing a pipe through the center of the reel and jacking it up until the reel is free from the deck. Rope should never be taken from a reel lying on its side. MINIMUM WRAP COUNT NOTE: A minimum number of 8 wraps shall be maintained on the drum at all times during operation to ensure load is not applied to drum termination. LOADING ROPE ONTO HOIST DRUM 1) Spooling shall be performed during initial installation and following all periodic inspections. a. It is permissible to install the Rope without tension. However to minimize the Rope diving on the drum, it is highly recommended to use a rope tensioning device with the Rope loaded to 5% of rope break strength. b. Care must be taken to ensure tight packing of the first layer. c. Remove all twist from the Rope during installation. 2) Before operation of the machine under normal service, the Rope shall be cycled with increased load and increasing speeds. a. Reeving and boom orientation must be chosen to remove hoist Rope to minimum wrap limit. b. Load should be chosen to maximize line pull but not to exceed max permissible line pull. c. At least 3 cycles should be performed at low speed followed by another 3 cycles at increased hoist speed. 27. Loading KZ100 Synthetic Rope onto the hoist is a critical operation and care must be taken when loading the Rope. Rope Removal Minimum Wrap Count 28. Improper and proper spooling of the KZ100 Synthetic Rope is critical and proper spooling procedure must be followed. Pay particular attention to the minimum number of wraps to be maintained on the hoist drum at all times. Rev-1 12 of 28

13 Preparation Photos NOTE: Before any work is begun the entire work instruction must be read and understood. Failure to understand and follow this procedure may cause property damage, severe bodily harm, and death. 29. Any area of pitting or loosening and peeling of the Finish Paint that has been applied is unacceptable. The area will need to be recoated or repainted. 30. Never unspool Synthetic Rope from a spool laying on its side. 31. The Synthetic Rope must not be drug across the ground or any abrasive surface. 32. After rounding any sharp edges on the wedge, test fit the wedge into the wedge pocket and assure the wedge will not drop completely through the wedge pocket. 29. Any area of pitting is unacceptable and must be repaired to prevent damage to the Synthetic Rope. 31. Carefully pass and route the Rope to the hoist area not allowing the Rope to drag on the ground. Rev-1 13 of Place the spool of Rope on a device where a shaft is passed through the spool. The Rope must be unreeled from a spool as shown. 32. Carefully prepare and round any sharp edges on the wedge to receive the Rope. Test fit the wedge.

14 33. & 34. Care must be taken when removing sharp edges or points so that the paint coating is not broken or otherwise damaged. 35. When the Cable Wedge is properly installed in the Synthetic Rope, the Rope eye should be rotated slightly toward the hoist flange. The bottom of the eye should not be in the center of the bottom of the wedge. Do not insert the Rope through the wedge pocket at this time. 36. Assure the prepared wedge will fit correctly into the soft eye. Notice the yoke of the soft eye is rotated slightly toward the hoist flange and is not positioned in the center of the flat bottom on the wedge. This is for proper fit in the wedge pocket and allows for proper spooling of the Rope. 33. Slowly rotate the hoist before attaching the Synthetic Rope and evaluate the final coating for any sharp or abrasive areas. 34. Using a small file, carefully smooth the sharp points or abrasive edges that are found. 35. Route the Synthetic Rope over the hoist and to the rear of the hoist. Rev-1 14 of Carefully insert the wedge into the soft eye to assure proper fit.

15 NOTE: Before any work is begun the entire work instruction must be read and understood. Failure to understand and follow this procedure may cause property damage, severe bodily harm, and death. 37. Insert a small piece of nylon Rope through the soft eye to allow proper installation of the Synthetic Rope in the hoist pocket. The Synthetic Rope should not be pushed through the pocket. Damage may occur. 39. Care must be exercised when inserting the eye that no damage is done to the Rope. Pushing the Rope through with a rod or other object is NOT acceptable. 37. Remove the wedge and insert a piece of nylon Rope through the soft eye. 38. Insert the small nylon Rope through the hoist pocket. 39. Using the small Rope attached to the soft eye, carefully pull the Synthetic Rope eye through the pocket. Rev-1 15 of Pull the Synthetic Rope completely through the hoist pocket and out into the open to install the wedge..

16 41. Do not remove the short piece of nylon Rope used to pull the Synthetic Rope through the hoist pocket. Be sure to insert the cable wedge into the soft eye as instructed in Step Carefully pull the soft eye and wedge into the pocket. A small rubber hammer may be used to lightly tap the wedge soft eye combination into the hoist pocket. Excessive force must not be used. This may damage the Synthetic Rope. An alternative method may be used to properly seat the Rope/Wedge combination in the hoist pocket and is shown in 43. & Carefully reinsert the wedge into the soft eye of the Synthetic Rope. 42. Pull the soft eye and the wedge back into the hoist drum pocket. 43. & 44. Proper nesting of the Rope/Wedge combination is essential. Insert the two by four or acceptable substitute into the loop as shown. 43. Using a short two by four with rounded edges, wrap the Rope around the Cable Follower as shown. Rev-1 16 of Use the two by four as a lever to pull the wedge into the pocket. Care must be exercised to prevent damage to the Rope.

17 45. After assuring that the Wedge/Rope combination is properly seated, remove the short piece of nylon cord used to pull the Rope and Wedge into place. It is not permissible to leave the nylon cord in place. 46. All areas where the Rope will make contact with any part of the boom must be evaluated for proper preparation to accept the Rope. 47. & 48. Evaluate any area where the Rope will come into contact with the Boom, Wear Pads, Boom Ears, or any other such contact point. All areas must be smooth and must not snag or cut the Synthetic Rope. 45. Assure the soft eye and wedge combination are properly seated in the wedge pocket. Remove the short piece of nylon rope. 46. Evaluate the placement of the Rope on the boom and assure the Rope is not twisted. 47. Re-assess all areas on top of the boom for sharp edges or corners that the Rope may come in contact with. Rev-1 17 of This includes boom wear pads and any ears or areas where the Rope touches

18 NOTE: Before any work is begun the entire work instruction must be read and understood. Failure to understand and follow this procedure may cause property damage, severe bodily harm, and death. 49. It is permissible to install the Rope without tension. However to minimize the Rope diving on the drum, it is highly recommended to use a rope tensioning device with the Rope loaded to 5% of Rope break strength. 49. Carefully begin reeving the Synthetic Rope onto the hoist drum. 50. Continue reeving the Rope on to the hoist being careful to keep the lay tight and flat with no twisting. 50. Care must be taken to ensure tight packing of the first layer. 51. Remove all twist from the Rope during installation. 52. There should be no evidence of twist in the Rope after reeving the Synthetic Rope. 51. Continue reeving the second layer while keeping the Rope tight. Rev-1 18 of Evaluate the placement of the Rope on the hoist drum and continue until all layers are wrapped.

19 NOTE: Before any work is begun the entire work instruction must be read and understood. Failure to understand and follow this procedure may cause property damage, severe bodily harm, and death. 53. Similar to wire rope, induced twist is not desirable and care should be taken when reeving the hook block to keep from adding twist to the line. If the twist level in the line exceeds 2 turns per meter (3.28 Feet), action must be taken to remove the twist prior to maximum load lifting operations. 53. Care must be exercised to assure the proper lay of the Synthetic Rope when it is reeved onto the hoist. 55. Steps for removing or preventing twist in the braided Synthetic Rope. NO TWIST Picks in a straight line MODERATE TWIST Picks not in a straight line HEAVY TWIST Picks spiral around the Rope tightly Evidence of twist in a twelve strand Rope. Twist has a negative impact on any braided structure. Careful attention must be paid to prevent twist from being imparted during handling/installation. Shown above are examples of a Rope without twist. Notice the alignment of the braid cross-over points in the Rope. The sample on bottom shows a Rope with twist, evidenced by the angling of the alignment of the braid cross-over points and longitudinal line. Note: Rope strength can be reduced by 10% when the Rope makes three turns within a 1 meter span (length). 54. Evaluate the rope for twist as the Rope is reeved and after the Rope is in place on the hoist. Twist in a Rope is identified by the alignment of the picks. Removing Twist If a twisted line has been identified, take the following steps to remove the twist: 1. Pay out as much of the twisted section of Rope as possible onto a flat surface. 2. Manually untwist the line by flipping the Rope Eye repeatedly in the opposite direction of the twist until the twist is removed. 3. It may be necessary to milk the twist to the end of the line for the best results. 4. Wind the line back onto the winch or spool under reasonable tension taking care to prevent re-twisting of the line. 5. If the strands appear damaged or the twist is impossible to remove, contact a Samson representative for advice. Rev-1 19 of 28

20 NOTE: Before any work is begun the entire work instruction must be read and understood. Failure to understand and follow this procedure may cause property damage, severe bodily harm, and death. 56. Care should be used so that the Rope does not contact any sharp areas. 57. & 58. As the Rope is being routed through the various areas, the Rope should not come in contact with any abrasive areas. Remove all twist from the Rope during installation. Assure all areas that will come in contact with the Rope are smooth and all pins are in place. 56. Route the Synthetic Rope over the boom and onto the sheave wheel. Assure all retaining pins are smooth and in place. 57. Route the Synthetic Rope over the lower sheave wheels. Assure all retaining pins are smooth and in place. 59. Continue reeving the Synthetic Rope through the boom nose and onto the sheave wheels being careful not to pull the Rope 58. Continue reeving the Synthetic Rope through the hook block. over the ground. Rev-1 20 of Evaluate the placement of the Rope on the hoist drum and continue until all remaining layers are wrapped.

21 60. Care should be used so that the Rope does not contact any sharp or abrasive areas. Assure all pins and clips are secure. 61. As the Rope is being routed through the various areas of the hook block, the Rope should not come in contact with any sharp or abrasive areas. Remove all twist from the Rope during installation. 62. Before operation of the machine under normal service, the Rope shall be cycled with increased load and increasing speeds. a. Reeving and boom orientation must be chosen to remove hoist Rope to minimum wrap limit. b. Load should be chosen to maximize line pull but not to exceed max permissible line pull. c. At least 3 cycles should be performed at low speed followed by another 3 cycles at increased hoist speed. 63. Samson recommends a daily visual inspection of the section of line in use. Like any other Rope, inspection frequency and criteria are based on application-specific considerations (i.e. duty cycle, environmental conditions, etc.) and should be determined by a qualified person on-site. All inspection should be conducted by a Samson representative or otherwise qualified person. 60. After the Synthetic Rope is in place, attach the Rope Thimble to the Shackle, and hook the Shackle to the Dead End on the Boom Nose. 62. Before normal operation and returning of the crane to service the Rope will need to be cycled several times. Rev-1 21 of Slowly take up the slack in the Synthetic Rope being careful not to jerk the Rope or drag it across the ground Perform daily and periodic inspections as suggested by the Manufacturer.

22 DAILY INSPECTION NOTE: Before any work is begun the entire work instruction must be read and understood. Failure to understand and follow this procedure may cause property damage, severe bodily harm, and death. 64. Synthetic Rope daily Inspection requirements. All inspection should be performed by a Samson representative or sufficiently trained and qualified person. 1. All running Ropes in service shall be visually inspected once each working day. The visual inspection shall consist of observation of all Rope that can reasonably be expected to be in use during the day s operations. These visual observations should be concerned with discovering gross damage that may be an immediate hazard. The inspector s focus shall be on sections susceptible to rapid deterioration or Rope types or applications requiring special attention. When damage is discovered, a qualified person shall inspect the effected section(s) prior to operation as detailed in the Periodic Inspection to determine if the Rope needs to be retired from service. 2. Care shall be taken when inspecting sections of rapid deterioration such as flange contact points, crossover points, and repetitive pickup points on drums. 3. Document findings on the Daily Inspection Log. 4. Specific types of damage requiring removal from service for inspection by a qualified person include the following: 64. Rope daily inspection requirements. All inspection should be conducted by a Samson representative or sufficiently trained and qualified person. Rev-1 22 of 28

23 NOTE: Before any work is begun the entire work instruction must be read and understood. Failure to understand and follow this procedure may cause property damage, severe bodily harm, and death. 5. Specific types of damage requiring removal from service for inspection by a qualified person include the following: 64 Continued. Synthetic Rope daily Inspection requirements. All inspection should be performed by a Samson representative or sufficiently trained and qualified person. 64 Continued. Rope daily inspection requirements. All inspection should be conducted by a Samson representative or sufficiently trained and qualified person. Synthetic Rope showing correct lay. Rev-1 23 of 28

24 65. Synthetic Rope periodic Inspection requirements. All inspection should be performed by a Samson representative or sufficiently trained and qualified person. For more in formation consult the Rope Handling, Installation, Inspection and Retirement Guidelines booklet. Information for this document was taken from Manitowoc and Samson documentation. Contact Manitowoc or Samson with any further questions. PERIODIC INSPECTIONS 1. The inspection frequency during field trials shall be once a week or 80 hours of operation, whichever comes first. 2. The entire length of Rope will be removed from the hoist drum during this inspection by the following procedure. a. Crane boom will be retracted and angle dropped to zero. b. Hoist Rope will be removed by hand at boom tip and stored in an open container. c. During removal, hand-over-hand inspection will be conducted by a qualified person. d. Check for abrasion at termination and layer transitions per Periodic Inspection Log. e. Termination at the hoist will be inspected without removing the eye and wedge from the hoist drum. Care shall be taken when observing the following: (i) Base of eye where Rope exits hoist drum. (ii) Back of eye within hoist drum. (iii) Other damage should be noted and referenced by distance from outboard termination. f. Following inspection, the Rope will be re-installed following Rope Installation guidelines defined in this manual. 3. Prior to re-installation of the Rope on the hoist, the crane must be visually inspected for potential wear concerns at all points where Rope comes in contact with the crane. Special attention should be paid to the following areas: a. Hoist flanges, drum, wedge, cable packer b. Sheaves (boom nose & hook block) groove condition, sharp edges, freely rotating c. Boom contact points wear pads, sharp edges d. Boom nose & hook block pins, Anti-Two-Block Weight(s) 4. Any issues or damage should be repaired prior to reinstallation. 5. No precise rules can be given for determination of the exact time for Rope replacement since many variable factors are involved. Once a Rope reaches any one of the specified removal criteria, it may be allowed to operate to the end of the work shift based on the judgment of a qualified person. The Rope shall be removed after that work shift, at the end of the day, or prior to the equipment being used by the next work shift. Refer to Samson s Inspection and Retirement Pocket Guide or Samson s mobile app for inspection guidelines. Specific inspection attributes and removal criteria are to follow what is documented in the Samson Manuel, Rope Handling, Installation, Inspection and Retirement Guidelines booklet or Samson s mobile app. Rev-1 24 of 28

25 Acceptable and Unacceptable Practices: Synthetic rope crossover is acceptable but NOT recommended. When two Synthetic Ropes cross, additional inspection may be required. 68. If the headache ball comes in contact with the Synthetic Rope at any time, immediate inspection of the Rope is required. Rope Options 69. It is acceptable to use both Wire Rope and Synthetic Rope together. It is unacceptable for the Wire Rope and the Synthetic Rope to contact each other at any point. Wire Rope and Synthetic Rope may NOT come into contact at any time. If the Wire Rope comes in contact with the Synthetic Rope at any time, immediate inspection of the Synthetic Rope is required. 66. It is acceptable to use Synthetic Rope on both the Main Hoist and the Auxiliary Hoist. 67. The Main Hoist Synthetic Rope and the Auxiliary Hoist Synthetic Rope may cross but is NOT recommended. Acceptable 68. It is NOT acceptable for the Headache Ball to come in contact with the Synthetic Rope at any time. 69. While it is acceptable to use Wire Rope and Synthetic Rope together, it is not acceptable for the them to cross or come into contact. Rev-1 25 of 28

26 Unacceptable Unacceptable 70. At no time is it acceptable for Wire Rope and Synthetic Rope to come into contact. If this condition occurs the synthetic Rope must be thoroughly inspected for possible damage. 71. It is unacceptable for the Synthetic Rope and the Wire Rope to come into contact with each other at any point or in any combination. Synthetic rope over Steel Rope, or Steel Rope over Synthetic Rope, coming into contact is not acceptable. Wire Rope and Synthetic Rope may NOT come into contact at any time. If the Wire Rope comes in contact with the Synthetic Rope at any time, immediate inspection of the Synthetic Rope is required. 72. & 73. WARNING: When using Wire Rope and Synthetic Rope together, during regular inspections, the operator shall ensure that all crane surfaces such as Hoist, Hoist Rollers, Boom surfaces, Wear Pads, all Sheave Wheels, Retainer Pins, and Anti- Two-Block Weights or any areas that have come into contact with the Wire Rope and will contact the Synthetic Rope have not been damaged by the wire in a manner that can then damage the Synthetic Rope. Wire over Synthetic 70. It is unacceptable for the Wire Rope and the Synthetic Rope to come into contact with each other at any point. Unacceptable 72. Cutting and damage to any surfaces that will come into contact with the Synthetic Rope is unacceptable. Rev-1 26 of 28 Synthetic over Wire 71. It is unacceptable for the Synthetic Rope and the Wire Rope to come into contact with each other at any point. Unacceptable 73. When any unacceptable surface is found, the area must be smoothed and the rope inspected immediately.

27 74. During installation and setup such as changing hook block, stowing or erecting the boom extension, re-revving, etc. care shall be taken to avoid overlap and crossing of wire and synthetic ropes. 75. When re-revving from Wire Rope to Synthetic Rope, thoroughly inspect all surfaces that will contact the Synthetic Rope. When such a condition exists, rework any nicks, gouges, or areas that may be abrasive to the Synthetic Rope before reinstalling the Synthetic Rope. 74. It is never permissible for Wire Rope and Synthetic Rope to come into contact for any reason. Immediate inspection is required. 75. When re-revving from Wire Rope to Synthetic Rope, thoroughly inspect all surfaces that will contact the Synthetic Rope. Wire Rope and Synthetic Rope may NOT come into contact at any time. If the Wire Rope comes in contact with the Synthetic Rope at any time, immediate inspection of the Synthetic Rope is required. Rev-1 27 of 28

28 REVISION RECORD REV Crane Care Reference DESCRIPTION BY DATE APPR D BY A PI New Release J.Shelly 25SEP14 S.Munuswamy B C Rev-1 28 of 28