FR-43.B - Crane Test Specification

Doc No : FR-43B CTS
CRANE TEST SPECIFICATION Pages :1

(F.E.M.1.001 3rd EDITION REVISED 1998.10.01) Rev No :0
Mühendislik Ltd. Issue Date : 10.06.2015
CONTENTS
1. SUMMARY
1.1. APPLICATION
1.2. INITIAL CONDITION PRIOR TO TEST
1.3. TEST PROCEDURE
2. CRANE PRINCIPAL DIMENSIONS
2.1. PRINCIPAL DIMENSIONS
2.2. LOAD-WORKING RADIUS DIAGRAM
3. MOTOR, BRAKE, REDUCER LIST
3.1. MOTOR LIST
3.2. BRAKE LIST
3.3. REDUCER LIST
4. TEST
4.1. INSULATION RESISTANCE TEST AND RESULT
4.1.1. AC MOTOR LIST
4.1.2. MAIN POWER SUPPLY LIST
4.2. MOTION TEST OF AUXILIARY EQUIPMENT
4.2.1. MOTION TEST OF FLOODLIGHT
4.2.2. MOTION TEST OF EMERGENCY LIGT
4.2.3. MOTION TEST OF AUTO LUBRICATION
5. TEST AND RESULT
5.1. MAIN HOIST TEST AND RESULT
5.1.1. MAIN HOIST MOTOR SPECIFICATION
5.1.2. MOTION TEST OF MAIN HOIST OPERATION
5.1.3. SAFETY EQUIPMENT TEST OF MAIN HOIST OPERATION
5.2. BOOM HOIST TEST AND RESULT
5.2.1. BOOM HOIST MOTOR SPECIFICATION
5.2.2. MOTION TEST OF BOOM HOIST OPERATION
5.2.3. SAFETY EQUIPMENT TEST OF BOOM HOIST OPERATION
5.3. SLEWING TEST AND RESULT
5.3.1. SLEWING MOTOR SPECIFICATION
5.3.2. MOTION TEST OF SLEWING OPERATION
5.3.3. SAFETY EQUIPMENT TEST OF SLEWING OPERATION
5.4. TRAVELLING TEST AND RESULT
5.4.1. TRAVELLING MOTOR SPECIFICATION
5.4.2. MOTION TEST OF TRAVELLING OPERATION
5.4.3. SAFETY EQUIPMENT TEST OF TRAVEL OPERATION
5.4.4. TEST OF TRAVELLING AUXILIARY EQUIPMENT
KREYN KONTROL FORMU Page 1

Doc No : FR-43B CTS
1. SUMMARY
1.1. APPLICATION
This test is carried out so as to confirm operating performance relating control system and also, strength of
reinforcement under deck where crane is installed.
1.2. INITIAL CONDITION PRIOR TO TEST

- Check all cable and mechanical fitting installation before operation.
- Check supply the of rated voltage and check lubricant levels
- No access in thest area for unauthorized personnel
1.3. TEST PROCEDURE
CHECK OF ERECTION WORK COMPLETION

↓↓
MEASUREMENT OF INSULATION RESISTANCE
↓↓
SUPPLY OF ELECTRICAL POWER
↓↓
CHECK ELECTRICAL SEQUENCE
↓↓
CHECK OF SAFETY DEVICES
↓↓
ADJUSTMENT OF AUXILIARY AND MISCELLANEOUS EQUIPMENTS
↓↓
ADJUSTMENT OF BRAKES
↓↓
NO LOAD TEST FOR INDIVIDUAL APPARATUS
↓↓
NO LOAD FUNCTIONAL TEST FOR THIS SYSTEM
↓↓
LOAD TEST FOR INDIVIDUAL APPARATUS & SYSTEM
2. CRANE PRINCIPAL DIMENSIONS
2.1. PRINCIPAL DIMENSIONS
CAPACITY MAIN HOISTING

AUXU. HOIST (IF
ANY)
DRIVING MOTION SPEED MOTOR CONTROL
SYSTEM MAIN 55Kw x 2 VFD
AUX …. VFD
LUFFING 30 kW x 1 VFD
SLEWING 11 kW x 2 VFD
TRAVELLING 5,5 kW x 4 VFD
SPAN 6000 RAIL SIZE ……
LIFTING HEIGHT +24 M ABOVE RAIL | -12 M BELOW RAIL
TRAVELLING DISTANCE +/- 50 M
WIRE ROPE MAIN HOISTING MAKER STANDARD
AUX HOISTING MAKER STANDARD
LUFFING MAKER STANDARD
DEAD WEIGHT
MAX. WHEEL LOAD IN SERVICE …. T/WHEEL
OUT OF SERVICE …. T/WHEEL
ELECTRIN CONTROL SYSTEM ABB / SIEMENS
(VFD, PLC)
MAIN POWER AC 400V, 50Hz, 3PH
DESIGN WIND SPEED IN SERVICE …. T/WHEEL
OUT OF SERVICE …. T/WHEEL
TIE DOWN …. T/WHEEL
SAFETY SYSTEM MOMENT LIITER
OVER WINDING LIMITER
LUFFING LIMITER
TRAVELLING END LIMITER

Doc No : FR-43B CTS
2.2. LOAD-WORKING RADIUS DIAGRAM
….
3. MOTOR, BRAKE, REDUCER LIST
3.1. MOTOR LIST
ITEM REF. RATING MAKER

NO. kW VOLT (V) CURRENT (A) RPM
MAIN HOIST
AUX HOIST
LUFFING
SLEWING #1
SLEWING #1
TRAVELLING #1
TRAVELLING #2
TRAVELLING #3
TRAVELLING #4
3.2. BRAKE LIST
ITEM REF. RATING MAKER

NO. TYPE VOLT (V) CURRENT (A) TORQUE
MAIN HOIST
AUX HOIST
LUFFING
SLEWING #1
SLEWING #1
TRAVELLING #1
TRAVELLING #2
TRAVELLING #3
TRAVELLING #4
3.3. REDUCER LIST
ITEM OIL REDUCER RATING MAKER

CAPACITY RATIO
MAIN HOIST
AUX HOIST
LUFFING
SLEWING #1
SLEWING #1
TRAVELLING #1

Doc No : FR-43B CTS
TRAVELLING #2
TRAVELLING #3
TRAVELLING #4
4. TEST
4.1. INSULATION RESISTANCE TEST AND RESULT
- Measuring apparatus:
- Insulation resistance case is tested in condition to connect with each device,
but electronic circuit case is tested in condition to divide for circuit protection
4.1.1. AC MOTOR LIST
NO. MEASURING POINTS RESISTANCE MOHM RESULT

TB. NO. LOCATION R-E S-E T-E
1 CABLE REEL MOTOR
2 TRAVELLING MOTOR #1
10
11
12
13
14
4.1.2. MAIN POWER SUPPLY LIST
NO. MEASURING POINTS RESISTANCE MOHM RESULT

TB. NO. LOCATION R-E S-E T-E
1 INCOMING POWER LINE
2 MAIN POWER SUPPLY LINE
3 MAIN UTILITY POWER LINE
4 230 VAC LINE
5 …
6 …
7 …

Doc No : FR-43B CTS
4.2. MOTION TEST OF AUXILIARY EQUIPMENT
4.2.1. MOTION TEST OF FLOODLIGHT
ITEM LOCATION TEST POSITION RESULT REMARK

FLOOD LIGTHS LOWER PART CONSOLE
UPPER PART
4.2.2. MOTION TEST OF EMERGENCY LIGT
ITEM LOCATION RESULT REMARK

EMERGENCY BOGIE #1
SWITCH BOGIE #2
…
…
4.2.3. MOTION TEST OF AUTO LUBRICATION

ITEM LOCATION RESULT REMARK
AUTO LUBRICATION SLEWING PART
PORTAL (if any)
5. TEST AND RESULT
5.1. MAIN HOIST TEST AND RESULT
5.1.1. MAIN HOIST MOTOR SPECIFICATION
ITEM MAKER REMARKS

MAIN HOIST MOTOR
RATING:
RPM:
DUTY RATING:
ENCLOSURE:
SPACE HEATER:
TEMPERATURE DETECTOR:
ENCODER:
O.S:
5.1.2. MOTION TEST OF MAIN HOIST OPERATION
LOAD MOTION STEP FREQ VOLT CURR. RPM SPEED REMARKS

(HZ) (V) (A) (M/MIN)
NO LOAD HOISTING FULL
LOWERING
…. HOISTING FULL
LOWERING
…. HOISTING FULL
LOWERING
(100%) RATED HOISTING FULL
LOAD LOWERING
(115%) HOISTING N/A
OVERLOAD LOWERING
The voltage, current and frequency of motor measure from VFD.

Overload test case only confirms operation.
Acceptable velocity limit of deviation +10% ~-5% of rated speed.

Doc No : FR-43B CTS
DEVICE TEST ITEM TEST METHOD SETTING RANGE (m) RESULT

DESIGN / WR ACTUAL / WR
GEARED EMERGENCY 1
CAM L/S UPPER STOP
GEARED NORMAL UPPER 2
CAM L/S STOP
GEARED UPPER SLOW 3
CAM L/S DOWN
GEARED EMERGENCY 4
CAM L/S LOWER STOP
GEARED NORMAL 5
CAM L/S LOWER STOP
GEARED LOWER 6
CAM L/S SLOW DOWN
LOAD HOIST TRIP 7
LIMITER OVERLOAD TRIP
SLACK HOIST TRIP 8
ROPE
5.2. BOOM HOIST TEST AND RESULT
5.2.1. BOOM HOIST MOTOR SPECIFICATION
ITEM MAKER REMARKS

BOOM HOIST MOTOR
RATING:
RPM:
DUTY RATING:
ENCLOSURE:
SPACE HEATER:
ENCODER:
O.S:
5.2.2. MOTION TEST OF BOOM HOIST OPERATION

LOWERING
…. HOISTING FULL
LOWERING
…. HOISTING FULL
LOWERING
LOAD LOWERING
(115%) HOISTING N/A
OVERLOAD LOWERING


GEARED EMERGENCY 1
CAM L/S UPPER STOP
CAM L/S STOP
GEARED UPPER SLOW 3
CAM L/S DOWN
Doc No : FR-43B CTS
GEARED EMERGENCY 4
CAM L/S LOWER STOP
GEARED NORMAL 5
CAM L/S LOWER STOP
GEARED LOWER 6
CAM L/S SLOW DOWN
LOAD HOIST TRIP 7
SLACK HOIST TRIP 8
ROPE
5.3. SLEWING TEST AND RESULT
5.3.1. SLEWING MOTOR SPECIFICATION
ITEM MAKER REMARKS

SLEWING MOTOR
RATING:
RPM:
DUTY RATING:
ENCLOSURE:
SPACE HEATER:
ENCODER:
O.S:
5.3.2. MOTION TEST OF SLEWING OPERATION

LOWERING
…. HOISTING FULL
LOWERING
…. HOISTING FULL
LOWERING
LOAD LOWERING
(115%) HOISTING N/A
OVERLOAD LOWERING

5.3.3. SAFETY EQUIPMENT TEST OF SLEWING OPERATION

GEARED EMERGENCY 1
CAM L/S UPPER STOP
CAM L/S STOP
GEARED UPPER SLOW 3
CAM L/S DOWN
GEARED EMERGENCY 4
CAM L/S LOWER STOP
GEARED NORMAL 5
CAM L/S LOWER STOP
GEARED LOWER 6
CAM L/S SLOW DOWN
LOAD HOIST TRIP 7
SLACK HOIST TRIP 8
Doc No : FR-43B CTS
ROPE
5.4. TRAVELLING TEST AND RESULT
5.4.1. TRAVELLING MOTOR SPECIFICATION
ITEM MAKER REMARKS

SLEWING MOTOR
RATING:
RPM:
DUTY RATING:
ENCLOSURE:
SPACE HEATER:
ENCODER:
O.S:
5.4.2. MOTION TEST OF TRAVELLING OPERATION

LOWERING
…. HOISTING FULL
LOWERING
…. HOISTING FULL
LOWERING
LOAD LOWERING
(115%) HOISTING N/A
OVERLOAD LOWERING
5.4.3. SAFETY EQUIPMENT TEST OF TRAVEL OPERATION

GEARED EMERGENCY 1
CAM L/S UPPER STOP
CAM L/S STOP
GEARED UPPER SLOW 3
CAM L/S DOWN
GEARED EMERGENCY 4
CAM L/S LOWER STOP
GEARED NORMAL 5
CAM L/S LOWER STOP
GEARED LOWER 6
CAM L/S SLOW DOWN
LOAD HOIST TRIP 7
SLACK HOIST TRIP 8
ROPE
5.4.4. TEST OF TRAVELLING AUXILIARY EQUIPMENT
DEVICE TEST ITEM TEST METHOD RESULT

STORM ANCHOR L/S Travelling Permission…
RAIL CLAMP
CABLE REEL
WARNING HORN
ANTI-COLLUSION

Doc No : FR-43B CTS
ITREM PASS REMARK

Simple checks
Emergency limit switches
Brake functions
Emergency stop
Comprehensive checks
the settings and conditions of the electrical safety devices,
integrity of protective earth systems,
integrity of equipotential circuits,
insulation of all the electrical equipment,
tightness of all connections,
predetermined resistance values, if any,
physical condition of cables and cable inlets,
physical condition of safety devices,
presence and condition of devices protecting against direct contact,
the technical performance of replaced parts is
compatible with the proper functioning of the hoisting appliance
checking that all the hoisting appliance’s electrical equipment is in
conformity with regulations and standards,
checking that the electrical equipment agrees with the circuit diagrams,
checking the switching sequence of the safety and control circuits,
checking the proper functioning of the electrical components
checking that the control system does not permit any uncontrolled excess
speeds in normal operation,
checking the correct settings for all the electrical equipment and its proper
functioning
LIGHTING
A fixed non-dazzling service lighting should be provided,

When the general area lighting equipment is not sufficient to permit access
and exit out of the cabin in safety, supplementary portable lighting should
be provided ; this equipment must be able to work, even if the principal
electrical circuits of the crane are isolated.
When the working area lighting is provided by the appliance, projectors

should be suitably placed on the crane, so that a minimum illumination of
30 lux at ground level is guaranteed.
This lighting circuit should be independent of the principal circuits of the

hoisting appliance.
Precautions must be taken to avoid voltage drops produced by starting the

motors cutting out the gas discharge lamps.
When the lighting of the area does not permit exit out of the appliance in
safety, a portable lamp, equipped with batteries should be provided. A
battery charger must be provided in the cabin.
Doc No : FR-43B CTS
CRANE TEST SPECIFICATION Pages : 10
MARKING AND PLATES

RATING PLATE
The lifting capacity (and radius where applicable) shall be
permanently marked in a visible position and shall be easily legible
from the ground.
The lifting capacity shall be the heaviest mass which may be hoisted
by the crane; (in the case of grabbing cranes, the lifting capacity shall
be the permissible total weight of the grab and contents.)
In the case of luffing cranes, the lifting capacity corresponding to each
radius shall be indicated in durable form showing appropriate
graduations, and shall be clearly legible from the ground.
More detailed indications of permissible loads at different radii shall
be obtainable from the manufacturer's operating manual.
In the case of cranes with more than one hoist, the lifting capacity of
each hoist shall be indicated on the relevant hook block. It should
furthermore be indicated if all the hoists can be used at the same
time.
MANUFACTURER'S PLATE
Each lifting appliance, independent crab or winch shall be fitted at a
convenient point with the
maker's plate, detailing the following :
- name of manufacturer,
- year of manufacture,
- manufacturer's serial number,
- lifting capacity in kgs and/or tonnes,
- type.
WARNING NOTICES
A notice reading : "Do not stand under the load" shall be suitably
located so as to be clearly visible.
Crane access points shall be marked with a notice reading : "No access
for unauthorized personnel".
Particularly dangerous areas shall be marked with a notice reading :
"Danger - Crane" and, where necessary, by means of warning colour
stripes
CLEARANCES
Safety distances
All moving parts of lifting appliances shall be at least 0,05 m from any
fixed part of a building, at least 0,1 m from any guard rail or handrail
and a minimum of 0.5 m from access areas
DRIVER'S CABS IN GENERAL
Driver's cabs shall be designed so that the driver has a clear view of all
work areas or so that he may adequately follow all operations with
the aid of suitable equipment.
Driver 's cabs shall have a minimum headroom of 1,9 m and shall be
fitted with a guard rail of at least 1,0 m high.
A protective shield shall be installed above the driver 's cab when
there is any danger of falling objects.
The floor of the driver's cab shall be covered with non-metallic, heat-
insulating material.
In cabs with windows less than 1,0 m from the floor and glazed areas
in the floor, the glazing
Doc No : FR-43B CTS
shall be constructed or protected to a height of 1,0 m so that

personnel cannot fall through them ; walkover windows shall be tread
proof.
It must be possible to clean the windows of the driver's cab without
risk. Glazed openings let into the floor of the driver's cab and those
which are exposed to an increased risk of breakage or subjected to
heat radiation when the crane is in operation shall be made of
suitable safety glass.
Anti-glare lighting and heating
Driver's cabs shall be provided with adequate anti-glare lighting to
allow handling of the controls and, if necessary, can be ventilated.
Driver's cabs exposed to conditions presenting a health hazard, such
as dust, vapours or gases, shall be protected against their entry and
provided with a clean air supply.
GANGWAYS AND PLATFORMS
Pulleys and moving parts placed at the end of jibs shall be designed so
that no lubrication is necessary between erecting and dismantling the
crane. If this is not the case, the jib must be provided with access.
The above-mentioned access to the jib may be omitted when the
latter can be lowered for the purpose of a complete visual check or
when other constructions permit a visual check.
Stairways, gangways and platforms shall have a headroom of not less
than 1,8 m.
A clear passageway not less than 0,5 m wide must be provided in the
vicinity of driven parts which move relative to gangways and
platforms ; this dimension may be reduced to 0,4 m up to a height of
0,6 m by providing a handrail. The clear width of passage way etween
stationary parts shall be not less than 0,4 m
The clear headroom of little used access ways inside crane structures
may be reduced to a minimum of 1,3 m, whilst at the same time the
width shall be increased to 0,7 m, varying linearly with the reduction
in height. The headroom above platforms used only for maintenance
purposes may be reduced to 1,3 m.
Guard rails
Parts of crane installations with access shall be provided with
continuous guard rails on those sides where there is a danger of
falling from a height of over 1 m.
Toe guards shall be not less than 0,1 m high.
Guard rails shall, as a rule, be not less than 1 m high and shall be
provided with toe guards and intermediate rails
Stairways and ladders shall be provided wherever the difference in
level exceeds 0,5 m.
Footholds provided with hand grips may be installed on vertical
surfaces where the height does not exceed 2 m
Ladders shall be interrupted by intermediate landings if they exceed a
height of 8 m
STAIRWAYS
The slope of stairways shall not exceed 65°
the height of individual steps shall not exceed 0,25
m (0,2 m for tower cranes) and their depth shall not be less than 0,15
m.
2 . step height + 1 tread width = 0,63
Doc No : FR-43B CTS
The height interval between steps shall be constant. In the case of

main stairways the guard rail posts shall be spaced not less than 0,6 m
apart, but in the case of other stairways 0,5 m shall suffice.
LADDERS
The length of rungs between side frames shall be no less than 0,3 m ;
their pitch shall be constant and not exceeding 0,3 m. The rungs shall
be at least 0,15 m away from fixed structural members. A rung shall
be able to withstand a force of 1200 N at the centre without suffering
permanent deformation.
Climb-through openings shall not be smaller than 0,63 m x 0,63 m or
less than 0,8 m in diameter.
Ladders over 5 m in height shall be provided with safety hoops
starting at a height of 2,5 m.
The distance between safety hoops shall be not greater than 0,9 m.
They must be interconnected by at least three equally spaced
longitudinal stringers. In all cases, one longitudinal stringer must be
placed at a point which is exactly opposite the vertical centre line of
the ladder.
The strength of safety hoops, reinforced by the longitudinal stringers,
must be adequate to withstand a force of 1000 N distributed over 0,1
m acting on any point of the hoop, without any visible deformation.
The sides of ladders shall extend at least 1 m above the top rung,
unless some other appropriate handhold is provided. Where space is
limited, 0,8 m shall be acceptable.

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Doc No : FR-43B CTS

CRANE TEST SPECIFICATION Pages :1

KREYN KONTROL FORMU Page 1

1.2. INITIAL CONDITION PRIOR TO TEST

1.3. TEST PROCEDURE

CHECK OF ERECTION WORK COMPLETION

2. CRANE PRINCIPAL DIMENSIONS

2.1. PRINCIPAL DIMENSIONS

CAPACITY MAIN HOISTING

KREYN KONTROL FORMU Page 2

2.2. LOAD-WORKING RADIUS DIAGRAM

3. MOTOR, BRAKE, REDUCER LIST

3.1. MOTOR LIST

ITEM REF. RATING MAKER

3.2. BRAKE LIST

ITEM REF. RATING MAKER

3.3. REDUCER LIST

ITEM OIL REDUCER RATING MAKER

KREYN KONTROL FORMU Page 3

4.1. INSULATION RESISTANCE TEST AND RESULT

4.1.1. AC MOTOR LIST

NO. MEASURING POINTS RESISTANCE MOHM RESULT

4.1.2. MAIN POWER SUPPLY LIST

NO. MEASURING POINTS RESISTANCE MOHM RESULT

2 MAIN POWER SUPPLY LINE

3 MAIN UTILITY POWER LINE

4 230 VAC LINE

KREYN KONTROL FORMU Page 4

4.2. MOTION TEST OF AUXILIARY EQUIPMENT

4.2.1. MOTION TEST OF FLOODLIGHT

ITEM LOCATION TEST POSITION RESULT REMARK

4.2.2. MOTION TEST OF EMERGENCY LIGT

ITEM LOCATION RESULT REMARK

4.2.3. MOTION TEST OF AUTO LUBRICATION

5. TEST AND RESULT

5.1. MAIN HOIST TEST AND RESULT

5.1.1. MAIN HOIST MOTOR SPECIFICATION

ITEM MAKER REMARKS

5.1.2. MOTION TEST OF MAIN HOIST OPERATION

LOAD MOTION STEP FREQ VOLT CURR. RPM SPEED REMARKS

The voltage, current and frequency of motor measure from VFD.

KREYN KONTROL FORMU Page 5

5.1.3. SAFETY EQUIPMENT TEST OF MAIN HOIST OPERATION

DEVICE TEST ITEM TEST METHOD SETTING RANGE (m) RESULT

5.2. BOOM HOIST TEST AND RESULT

5.2.1. BOOM HOIST MOTOR SPECIFICATION

ITEM MAKER REMARKS

5.2.2. MOTION TEST OF BOOM HOIST OPERATION

LOAD MOTION STEP FREQ VOLT CURR. RPM SPEED REMARKS

The voltage, current and frequency of motor measure from VFD.

5.2.3. SAFETY EQUIPMENT TEST OF MAIN HOIST OPERATION

DEVICE TEST ITEM TEST METHOD SETTING RANGE (m) RESULT

5.3. SLEWING TEST AND RESULT

5.3.1. SLEWING MOTOR SPECIFICATION

ITEM MAKER REMARKS

5.3.2. MOTION TEST OF SLEWING OPERATION

LOAD MOTION STEP FREQ VOLT CURR. RPM SPEED REMARKS

The voltage, current and frequency of motor measure from VFD.