Mobile Crane Inspector Training - Student Manual

8/13/2019 Mobile Crane Inspector Training - Student Manual

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INTRODUCTION

Mobile CraneInspector Training

_______________________________________Student Name

_______________________________________

Program Instructor

_______________________________________Program Date(s)


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MOBILE CRANE INSPECTOR TRAINING

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© 2001 - NorAm Productions, Inc.

Pursuant to Section 17 of the United States Code, regulations of agencies, boards,commissions, and departments of states become matters of public domain whenapproved and filed with the Secretary of State. The compilation, styling, pagination,page layout, indexing, and editorial additions by the publisher’s staff are copyrightedby NorAm Productions, Inc. All rights reserved.

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INTRODUCTION

Table of Contents

© Copyright 2001 - NorAm P roductions, I nc. All rights r eserved. P age i ii

Section I

The Need for Inspection .................................................................................... I - 1

Section II

How to Read & Apply OSHA & ASME Standards ......................................... I I- 1

Section III

The Mobile Crane Inspector ..........................................................................III - 1

Section IV

Lockout/Blockout ........................................................................................... IV - 1

Section V

Basic Operating Practices .............................................................................. V - 1

Section VI

Tools of the Trade ............................................................................................ VI - 1

Section VII

Inspection of Carriers & Mounts .................................................................VII - 1

Section VIII

Inspection of Superstructures & Booms .................................................... VIII - 1

Section IX

Basic Rigging Inspection ...............................................................................IX - 1

Section X

Nondestructive Testing Procedures ............................................................... X - 1

Section XI29 CFR 1910.180 with 1926.550 Inserts .......................................................XI - 1

Section XII

Sample Forms ............................................................................................... XII - 1


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SECTION IThe Need For Inspection

Mobile Crane Inspector Training


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THE NEED FOR INSPECTION

© Copyright 2001 - NorAm P roductions, I nc. All rights r eserved. Section I - P a ge 1


The effort put forth in properly inspecting your equipment is great ly rewarded.

Thorough inspections by trained and qualified inspectors will do the following for

your company:

S a v e y ou r com pa n y m on ey a n d t i m e du e t o u n sch ed u led d ow n t i m e a n d

maintenance costs

• Ensure product warran ty s t andards by meet ing manufac turer ma in tenance

and inspection requirements

• Ensure the equ ipment meet s cus tomer requi rements (con t ract s)

• Limit l iabi li ty issues, including civi l, cr iminal , and w orkers compensa t ion

Cranes lift very large weights over large areas. Consequently, it is the “largest risk”

piece of equipment at a site. Equipment safety and reliabili ty cannot be ensured

unless it receives regular inspections. They provide the only means of detect ing

potent ia l hazards tha t could contr ibute to acc idents , forewarn of any necessary

maintenance, and ensure compliance with OSHA Standards. Lack of maintenance

can mean serious deteriorat ion of the equipment and expensive replacement or

repair charges.

The equipment owner or supplier has the responsibility to ensure that all cranes

a re given th orough inspections a ccording to ma nufa cturer’s recommenda tions. These

inspections should only be performed by QUALIFIED PERSONS who are able to

detect a nd a ssess defects a nd potential ha zar ds tha t could limit t he safe performa nceof the crane’s functions.

Due to the wide va r ia t ions o f cond i t ions under wh ich iden t ic a l mach ines may

operate, it is impossible for the manufacturer to state exact time intervals for which

inspections should be performed. All inspection publications represent minimum

safe operat ing intervals for average condit ions.

If the equipment is found to be dangerous or unsafe, management must prohibit all

persons from using the equipment, under any circumstances, until the danger is

removed or the unsafe condition is repaired.


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Section I - P a ge 2 ©C opyright 2001 - NorAm P roductions, I nc. All rights reserved.

What Inspection Intervals Must Be Maintained?

Frequent Inspections

Components tha t ha ve a direct bearing on the sa fety of the crane, and w hose sta tus

can change from day-to-day with use, must be inspected on a daily basis, and when

possible , observed during opera t ion for any defec ts which could a f fec t the sa fe

operation of the crane. Frequent inspections shall be carried out as outlined in 29

CFR 1910.180 and 1926.550.

While a crane is designed a nd ma nufactured with a given sa fety factor, every m achine

begins to wear and depreciate once it is used. This process will inevitably continue

until, at some future date, the machine will no longer be capable of its original work

load. This w ill occur unless a ll pa rt s subject to wea r or failure a re regula rly inspected

and repaired or replaced.

Periodic Inspections

The periodic inspection procedure is intended to determine the need for repair or

replacement of par ts a s required to keep the ma chine in a pproximat ely new condition.

It includes th ose items list ed in 29 CFR 1910.180 an d 1926.550 for frequ ent in spections

as well as those listed in 29 CFR 1910.180 and 1926.550 for periodic inspections.

Annual Inspections

These inspections include all the aforementioned criteria combined with the load

block and boom. Even though these two components are inspected a t f requent

intervals, both the load block and boom must be given a more detailed inspection

on a n a nnua l ba sis (We recommend this inspection be performed by a n independent

third party inspection firm).

Incident Inspections

These inspections are necessary whenever incidents occur which apply sudden and

unusual shock loads, unusual stress or possible damage due to any cause. All such

incidents which affect the safe operat ion of the crane should be followed by an

immediate and thorough inspection. All damage found must be repaired before the

machine is returned to service (We recommend this inspection be performed by an

independent third party inspection firm).

A thorough visua l inspection should be ma de of the boom, jib, loa d line, a nd a ll other

st ruc tura l i tems tha t could have been damaged, a f ter every instance of severe

snapping, whipping or jerking of the boom. Inspect the boom bottom plate for any

signs of buckling. Also inspect th e corner a nd t he boom h ead w elds for cracks.


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© Copyright 2001 - NorAm P roductions, I nc. All rights r eserved. Section I - P a ge 3

NOTES:

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Section I - P a ge 4 ©C opyright 2001 - NorAm P roductions, I nc. All rights reserved.

Section I - Survey and Review

1. T F Th e in vest men t ma de in spect in g a m obile cr a ne m a y r ed uce a

companies liability.

2. T F R eg ula r in spect ion s ca n h elp for ew a r n of neces sa r y ma in ten a nce.

3. Mobile cra ne ins pect ions should b e performed only by ____________ persons .

4. When the cra nes' boom has been struck by or aga inst an object , a

_______________ inspection should be performed.

5. P eriodic inspections include th ose items inspected in a _________ inspection.


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SECTION IIHow to Read & Apply OSHA & ASME Standards



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HOW TO READ & APPLY OSHA & ASME STANDARDS

© Copyright 2001 - NorAm P roductions, I nc. All rights r eserved. Section II - Page 1


Before we can begin to perform inspections, we must first know where to find ther e q u i r e m e n t s f o r i n s p e c t i o n s a n d w e m u s t b e a b l e t o p r o p e r l y a p p l y t h o s e

requirements .

The requirement s for inspections ma y be derived from m a ny sources, including but

n o t l i m i t e d t o F e d e r a l o r “ C o m p l i a n c e ” s t a n d a r d s , C o n s e n s u s o r “ I n d u s t r y ”

standards, as wel l as maintenance and opera tor manuals supplied by the crane

manufac turer .

Since inspect ion requirements found in maintenance and opera tor manuals are

different from crane to crane, each must be treated individually. This is far beyond

the scope of this section. In this section we will discuss how to use the OSHA and

ASME standards in inspections.

OSHA Standards

OSHA is the acronym used for the Occupational Safety and Health Administration.

It is an agency within the U.S. Department of Labor, created in 1970. The authority

to “create law” is reserved for the legislative branch of our government. Therefore,

OSHA (not being a part of the legislat ive branch) does not have the authority to

crea te law. They ha ve, how ever, been given the au thority t o “promulgate st a nda rds”.

For purposes of th is sec t ion , we wil l consider these terms as having the same

meaning. The standards promulgated by OSHA are published under Title 29 of the

Code of Federal Regulations, hereafter referred to as 29 CFR, or the Act.

Under the Act , employers are required to provide employment and a p lace of

employment tha t a re f ree f rom recogn ized haza rds to the i r employees . Th is

requ irement , is commonly referr ed to a s th e employer ’s “S ection 5-(a ) (1)” or “G enera l

Duty Clause” responsibility. The importance of this section is the authority it gives

OSHA to issue a citation when a hazardous condition exists in the workplace not

addressed by a specific OSHA standard.

In addi t ion to the employer ’s genera l duty c lause responsibi l i ty , they are a lso

required to comply with those specific standards promulgated under the Act. It is

e x t r e m e l y i m p o r t a n t t o r e m e m b e r w h e n a p p l y i n g t h e O S H A s t a n d a r d s , t h e y

es t ab l i sh on ly the MINIMUM requ irements tha t a re accep tab le to OSHA forworkplace safety, and it is not unusual for more stringent requirements to exist .

Violation of either section 5-(a) (1) or a specific OSHA standard could result in a

citation, which in turn could result in fines levied against the company.

OSHA has prepared for its’ compliance officers guidance documents to assist them

in determining what items must be inspected on mobile cranes. Included in these

documents are the following items:


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Section II - P a ge 2 ©C opyright 2001 - NorAm P roductions, I nc. All rights reserved.

Ta ble 1


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Ta ble 1 (C ont .)


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Ta ble 1 (C ont .)


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Table 2 show s the items th a t need to be examined for the Gr ove Rough Terra in 45 Ton

Hydraulic Cra ne a nd t heir corresponding a pplicable OSHA 1926 and ANSI B 30.5 Sta ndards.

Ta ble 2

STA ND A RD IN SP ECTIO N ITEM S ANS I

(1926.550) B30.5

Out r iggers1. Lubricat ion2 . S truc tu ra l C o nd ition 5 -2 .1 .33 . P ressu re h oses /co nn ec tions 5 -2 .1 .2

Turn tab le /Crane Bo dy1. Ensure Level /Stabi l i ty2 . Wea r /Gear /Teeth /Ro l le rs3 . Cracks4. Bo l t s /Ensure Secure ly A t tached

Counter Weight1 . P roper S ize2 . A ttac hm en t C on ne ction /B o lts 5 -3 .4 .2

Eng ine Hous ing1. C lean l iness /No Rags /Trash2 . G ea r/M ac h in ery G ua rds 5 -1 .9 .6

550 (a)(13 )(i i)& ( iii) 3 . C lea r A ccess/W a lkw ays 5-1 .8 .2 & 3

5 . H and S igna l Illu s tra tion 5-3 .3 .2 (F ig .16 )6 . S w ing B reak 5 -1 .4 .2

C ab1. Glass/Vis ibi l i ty

2 . Ins trum en ts a nd C on tro ls 5 -1 .6 .23. Func t ion ing H orn (warn ing s igna l )4. Fi re Ext inguisher

550 (a)(2) 5 . Ap prop ria te L oa d C ha rts and W arn ing S ign s 5-1 .1 .3& 5-1 .9 .9

550 (a)(13 )(ii)& 5 -1 .8 .2 & 3550(a)(13)( i i i )

D rum1 . P rop er S iz e a nd S po il ing o f H ois tlin es 5 -1 .3 .1 & 22. Drum S ides /Sh ie lds fo r c racks3. Dogs /Paw ls /Lock ing Dev ices4. Drum Rota t ion vs . Cont ro l Mot ion

Boom Sec t ions(Boom sec t ions cor respond w i th c rane mod el )

1 . 5 -2 .1 .3

5-2.1.3

550(a) (8)550(a) (8)

4 . B rakes/C lu tch A dju stm en ts 5 -1 .9 .7

550 (a)12 5 -1 .8 .1

550 (a)(14 )(i)(5B C ) 5 -3 .4 .9 (1 0B C )

6. P roper and Adeq uate Access (s teps /wa lkway )

2 .3 . B oom S t ops4 .5 . Ho is t L ine Gu ides /Sheaves6 .7 .

ROUGH TERR AIN 45 TON HYDRAULIC CRANE


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Ta ble 3 shows t he item s t ha t n eed to be exam ined for t he Ma nit owoc 4100 150 Ton

Latt ice Boom Crawler Crane and their corresponding applicable OSHA 1926 and

ANSI B 30.5 St anda rds.

Ta ble 3

STAND ARD IN SPECTION ITEM S ANSI(1926.550) B30.5

Tr ac k Cr aw le r Sy s tem1. Lubr icat ion2 . C o nn e ct io n B o lts 5 -2 .1 .33 . D rive C ha in (s la ck & w e ar ) 5 -2 .1 .2

Tur n tab le /Cr ane Body ( Up per Wor k s )1 . A s su re le v e l/S ta b ili ty 5 -2 .1 .32. Wear /Gear /Teeth/Rol lers3 . Cr ac k s

4 . Bo l ts /P ins As s ur e Sec ur e l y A t tac hed

Counter we igh t1 . P r oper S i z e 5 - 3 .4 .22 . A t t ac hment Con nec t ion /Bo l t s

E n g i n e H o u s in g5 50 (a ) (8 ) 1 . C le a n lin e s s/N o R a g s /Tras h5 50 (a ) (8 ) 2 . G e a r/M a c h in ery G u a rd s 5 -1 .9 .6

5 5 0 (a ) (1 3) ( ii) & (i ii) 3. C le ar A c ce s s /W a lk w a ys 5 -1 .8 .2 & 3 4 . B ra kes /C lu tch A d jus tm e nts 5 -1 .9 .7

5 . H a nd S ig n a l I llus tra tio n 5 -3 .3 .2 (F ig .16 )6 . S w in g B re a k 5 -1 .4 .2

C a b5 50 (a ) (1 2 ) 1 . G la ss /V is ib il ity 5 -1 .8 .1

2 . Ins tru m en ts a n d C on tro ls 5 -1 .6 .23 . Func t i on ing Ho r n ( war n ing s i gna l )5 5 0 (a ) (1 4) ( I) (5 B C ) 4. F ire E x t in gu is he r 5 -3 .4 .9 (1 0B C )

5 50 (a ) (2 ) 5 . A p p ro p r ia te L o a d C h a rts a n d W a rn in g D e v ic es 5 -1 .1 .3& 5-1 .9 .96 . Pr oper and Adequ ate Ac c es s ( s teps /wa l k way ) 5 - 1 .8 .2 & 3

H o is t D rum S ys te m 5 -1 .3 .1& 8 21 . P ro p e r S iz e a n d S p o il ing o f H o is t lin e s 5 -1 .3 .1 & 22 . Dr um S ides /Sh ie lds f o r Cr ac k s3 . Dogs /Paw ls /Loc k ing De v i ces4 . Dr um Rota t ion v s . Con t ro l Mot i on5 . C lu t ch and Br ak es

B o o m S e c t io n s( Boom s ec t ions c or r es pond w i t h c rane m ode l )

-- --- - -- 1 . B as e S e ctio n P ro p e rly A tta ch e d 5 -2 .1 .3----- - -- 2 . P in C le a ra nc e----- - -- 3 . B oo m La c in g /C ord D a m ag e----- - -- 4 . B oo m S to p s----- - -- 5 . G a ntry S y s te m A -F ra m e

-- ---- -- 6 . H o is t L ine G uid e s/S h e a v e s-- ---- -- 7 . B o om S e c tio n C o nn ec t io n P in s /K e y s

8 . Boom an d Gan t ry Suppo r t Sy s tem9. J ib At tachment /Backs tops /Bel ly Sl ings

550 (a) (13) ( i i )&550 (a) (13) ( i i i)

550 ( b ) ( 1 )

150 TON LATTICE BOOM CRAWLER C RANE


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Ta ble 3 (C ont .)

STA ND A RD IN SPE CTION ITEM S ANS I(1926.550) B30.5

Additional references:

550(a)(1) - - -- Crane used in accordance with manufactures speci fication.550(a) (5) - - -- Inspec tion: Competent Person.550(a) (6) - - -- Annual Inspec tion Record.550(a)(16)--- No mo dif icat ions without wr it ten approval f rom manufacturers.

Sheave System1. Ensure Hoistline and Sheave S ize M atch 5-1.7.42. Worn3. Lubrication/Move freely

Load/Auxi liary Hook and B lock System1. Sheaves Function Sm oothly 5-1.7.62. Hook Rotates Freely/Lubricated3. Proper Becket4. Proper ly Reeved

Wire Rope /Hoist Line

550 (a) (7) 1. O verall Condition550 (a) (7) (v) 2. End Connections 5-1.7.3

3. Lubrication4. Clips

Safety Devices1. Anti-Two Block Devices2 . Boom Backstop Devices 5-1.9.1

550 (a) (9) 3. Swing Radius Warning Devices550 (a) (15) 4. Job or S ite Specific Devices/System s/ (F ig. 17)

Prog ram for work near electricpower an d use of personnel hoist ing plat forms)

1 5 0 TON LATT ICE BOOM CRAWLE R C RANE


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The best way to illustrate how the OSHA standards are cited is for us to look at an

example of how a typical viola tion, wh ich might be discovered during a n inspection,

might be cited. The sample we will use is as follows:

“A requirement to inspect all control mechanisms for maladjustment is not being

conducted on a daily basis.” The crane is used for “General Industry” type work.

This violation of the OSHA standards may be cited as follows:29 CFR 1910.180 (d) (3) (i)

“29” is referred to as the “Tit le” and is a designation for the U.S. Department of

La bor. Since OSH A is an a gency w ithin the U .S. Depart ment of Labor, their sta nda rds

a re promulga ted un der “Title 29”. Alth ough other Titles exist , such a s “Title 30” for

“Mineral Resources,” we will concern ourselves here only with “Title 29”.

“CFR” refers to the “Code of Federal Regulat ions” . This is a compilat ion of the

standards into a code for publication. Since the regulations are federal, as opposed

to state or local, they are found in the “Code of Federal Regulations”. Some states,

such as California , have state administered workplace safety and health programs,

also known as State OSHA’s. The crane inspector should check with each state in

which their cranes operate to determine if more stringent state requirements exist.

“1910” is referred to as the “Part”. This designation indicates the types of industry

that are covered. “Part 1910”, for instance, designates “General Industry”. Although

other par ts exist, such a s “P a rt 1917” for “Mar ine Termina ls”, for purposes of this

inspector course, we will concentrate on the more common parts “1910” for “General

Industry” and “1926” for “Construction Industry”.

“.180” is the section num ber for th e subject. The tit le of section number .180 is “Cr a w ler

locomotive and truck cranes.”

“(d) (3) (i)” OSHA uses any combination of upper case (D) and lower case (d) letters,

roman (i) and cardinal (3) numbers, i talics and parenthesis ( ) in outline format, to

lead us to the topic , subtopic and requirement for the item. In our example, (d)

leads us to th e topic “I nspecti on cl assi fi cati on” , (3) lead s us to t he subt opic “Frequent

inspection ”, an d (i) leads us t o the requirement w hich sta tes “All control mecha nisms

for maladjustment interfering with proper operat ion: Daily.”


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ASME Standards (sometimes referred to as ANSI Standards)

ASME is the acronym used for the “American Society of Mechanical Engineers” .

ASME commit tees develop stan da rds in meetings by r eaching consensus (agreement).

Hence , the name “Consensus” s t andard i s o f t en used to desc r ibe the va r ioussta nda rds developed by ASME . The procedures ASME operat es under a re a ccredited

by ANSI, w hich is t he a cronym used for t he “American Nat ional Sta ndards Inst itut e”.

ANSI pub l i shes these s t andards to serve a s a gu ide to government and o ther

regu la tory bod ies and munic ipa l au thor i t ies respons ib le for the guard ing and

inspection of the equ ipment fa lling w ith in it s’ scope. The int ent of the ANSI /ASME

Standards is to enhance safety. Neither OSHA, ANSI or ASME “approve”, “rate”, or

“endorse” any item, construction, proprietary device, or activity.

ASME standards may affect our mobile crane inspections in different ways. Let ’s

look briefly at some of these ways.

The first w a y w e will consider is in the ar ea of compliance with t he OSHA Sta nda rds.

As we discussed earlier, employers are required to comply with both “Section 5 (a)

(1)” of the Act, as w ell as a ny “specific sta nda rds” promulgat ed under th e act. OSH A

has the authority to incorporate into its’ standards documents generated by outside

sources. This process is referred to as “incorporation by reference” and is actually

quite common. The specific OSHA Standards that regulate mobile cranes are found

in 29 CF R 1910.180 a s w ell as 29 CF R 1926.550. The ASM E St a nda rd B 30.5 – 1968, is

incorporated into both of these OSHA standards, either in whole or in part , and

a ffects cranes constructed a nd ut ilized on or a fter August 31, 1971. This mea ns t ha t

a failure to comply with the mandatory (shall) language found in any portion of the

B30.5 incorporated by reference, is a fa ilure to comply with the specific OSHA

standard in which the mandatory (shall) language was incorporated.

An exam ple of this violat ion on a mobile cra ne built in sa y 1995, an d used in G eneral

Industry, which might be discovered during an inspection is as follows:

“A jib that is used on a particular mobile crane has had its’ identification number

obliterated so that it is no longer legible.”

This violation of the OSHA standards may be cited as follows:29 CFR 1910.180 (b) (2)

29 CFR 1910.180 (b) (2) incorporates by reference the desi gn specifi cati ons of B30.5– 1968. No specific requirement for a jib to have identification on it is found in 29

CF R 1910.180. How ever, Section 5-1.9.1 (d) of ANS I/AS ME B 30.5 – 1968 sta tes : “B ooms,

boom sections, and jibs shall be clearly identif ied and shall be used only for the

purposes recommended by the manufac turer . ” The word “ sha l l ” i s manda tory .

Therefore a failure to maintain an identifier on the jib is a violation, though most

likely De Minimis, of this standard.


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Next, let’s consider how ASME B 30.22, for Articulat ing B oom C ra nes, might be used

in an example of a section 5 (a) (1) citation.

“The engine exhaust stack installed on an Articulat ing Boom Crane built in , say,1995 and used in General Industry is not guarded properly.”

This violation of the OSHA standards may be cited as follows:

5 (a) (1) The employer shall provide employment and a place of employment that is

free from recognized hazards.

Since the specific OSHA standards applicable to mobile cranes, 29 CFR 1910.180

and 29 CFR 1926.550, are totally silent on Articulating Boom Cranes, a violation of

these standards does not exist. However, an unguarded exhaust stack would present

a recognizable, hazard to those working around the crane and would violate the

employer’s “G eneral Dut y” r esponsibility. To provide evidence tha t the ha zar d exists

a nd is recogniza ble, ma king it a violat ion, OSH A ma y ma ke use of the ASME B 30.22

consensus standard. Under section 22-1.7.3 of ASME B30.22a – 1994 we find the

following requirement: “Engine exhaust gases shall be piped and discharged in a

direction away from the operator. All exhaust pipes shall be guarded or insulated to

prevent contact by personnel when performing normal duties.”

Remembering that OSHA only establishes minimum requirements, and realizing that

complying only with minimums may not provide the level of safety we desire for our

employees, we must look beyond the compliance issues. We stated in the first paragraph

of discussion a bout ANSI/ASME sta nda rds, th at their intent w as to enhan ce sa fety.

Neither ANSI or ASME have the authority to conduct workplace inspections, issue

citations, or levy fines against an employer. The committees that develop the ASMEstandards such as B30.5 or B30.22, are made up of experts in the industry, recognizing

haza rds w ithin the industry, and providing wa ys to mitigate t hose haza rds.

Fina lly, beyond t he compliance and sa fety issues, liability issues must be considered.

Keep in mind that we are not attempting to render a legal opinion. If a legal opinion

is needed a competent a tt orney should be consulted. If, however, a person is injured

or killed becau se a s t he owner/operat or of the crane, I did not t a ke every reas onable

step to ensure their safety, the potential for increased liability would certainly exist.

Often, ASME Standards are used in personal injury cases to seek damages.


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Additional Regulations and StandardsIn addition to the requirements found in 29 CFR 1910.180 and 29 CFR 1926.550,

inspection personnel must consult requirements in 29 CFR 1910.184 and 29 CFR

1926.251, i f they wil l be responsible for the inspect ion of s l ings and r igging

equipment. Inspectors should also be knowledgeable of the ASME standards that

may be applicable to their mobile crane operat ions. These ASME standards will

often contain addit ional inspection, safety and design guidelines that inspectors

should follow. Some of these ASME standards include:

ASME B30.5 – Mobile and Locomotive Cranes

• ASME B 30.9 – Slings

• ASME B30.10 – Hooks

• ASME B30.20 – Below-the-Hook Lifting Devices

• ASME B30.22 – Articulating Boom Cranes

• ASME B 56.7 – Industr ial C ra ne Trucks

OSHA § 1903.1 - PURPOSE AND SCOPEThe Williams-Steiger Occupational Safety and Health Act of 1970 (84 Stat. 1590 et

seq., 29 U .S.C. 651 et seq.) requires, in pa rt, t ha t every employer covered under th e

Act furnish to his employees employment a nd a place of employment w hich ar e free

from recognized hazards that are causing or are likely to cause death or serious

physical harm to his employees. The Act also requires that employers comply with

occupa t iona l sa fe t y and hea l th s t andards promulga ted under the Ac t , and tha t

employees comply with standards, rules, regulat ions and orders issued under the

Act which are applicable to their own actions and conduct. The Act authorizes theDepartment of Labor to conduct inspections, and to issue citat ions and proposed

penalties for alleged violations. The Act, under section 20(b), also authorizes the

Secretary of Health, Education, and Welfare to conduct inspections and to question

employers and employees in connection with research and other related activities.

The Act contains provisions for adjudication of violations, periods prescribed for

the abatement of violations, and proposed penalties by the Occupational Safety and

Heal th Review Commission , i f contested by an employer or by an employee or

authorized representat ive of employees, and for judicial review. The purpose of

this P ar t 1903 is t o prescribe rules a nd t o set forth genera l policies for enforcement

of the inspection, citation, and proposed penalty provisions of the Act. In situations

where this Part 1903 sets forth general enforcement policies rather than substantive

or procedural rules, such policies may be modified in specific circumstances wherethe Secretary or his designee determines that an alternative course of action would

better serve the objectives of the Act.


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OSHA § 1910.6 - INCORPORATION BY REFERENCE(a) The stan dards of agencies of the U .S. G overnment, a nd organizat ions which are

not agencies of the U.S. Government which are incorporated by reference in thispart , ha ve the same force and effect a s other sta ndar ds in this par t . Only the

mandatory provisions ( i .e . , provisions conta in ing the word “sha l l ” or other

mandatory language) of s tandards incorpora ted by reference are adopted as

standards under the Occupational Safety and Health Act .

(b) Copies of the sta nda rds w hich are incorpora ted by reference ma y be examined

at the na t iona l of f ice of the Occupat iona l Sa fety and Heal th Administ ra t ion ,

U .S. D epa rt ment of La bor, Wa shington, D C 20210, or at a ny of its r egiona l offices.

Copies of such privat e stan da rds ma y be obta ined from the issuing organiza tions.

Their names and addresses are listed in the pertinent subparts of this part.

(c) Any changes in the st anda rds incorporated by reference in this part and an official

historic file of such changes are available for inspection at the national office of

the Occupational Sa fety and Health Administra t ion, U .S. Departm ent of La bor,

Washington, DC 20210.


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Material Approved for Incorporation by Reference(Revised as of July 1, 1991)

The Director of the Federal Register has approved under 5 U.S.C.552(a) and 1 CFR Part 51, the incorporation by reference of the following publications.

Part 1910 (General Industry)

American National Standards Institute

ANSI A14.3-56 Sa fety Code for Fixed La dders 1910.179

ANSI A90.1-69 Sa fety Sta nda rd for Ma nlift s 1910.68

ANSI A92.2-69 Standard for Vehicle-Mounted Eleva t ing and Rota t ing 1910.67

Work Platforms

ANSI B 30.2-67 Sa fety Code for Overhea d a nd G antry Cra nes 1910.179

ANSI B30.5-68 Safety Code for Craw ler, Locomotive and Truck Cranes 1910.180

American Society for Testing and Materials

AS TM A391-65 Alloy S teel Cha in (ANSI G 61.1-1968) 1910.184

American Welding Society

AWS A3.0 (1969) Terms a nd Definit ions 1910.251

Crane Manufacturer's Association of America, Inc.

CMAA Spec. #61 Specificat ion for Electric Overhead Traveling Cra nes 1910.179

Society of Automotive Engineers

SAE 765 (1961) SAE Recommended Prac t ice: Crane Loading Stabil ity 1910.180

Test Code

Part 1926 (Construction Standards)

American National Standards Institute

ANSI A10.5-69 Sa fety Requirements for Workma n's Hoists 1926.552

ANS I B 30.2.0-67 S afety C ode for Overhea d a nd G a nt ry C ra nes 1926.550

(P a rt ia l Rev. of B 30.2-43)

ANSI B30.5-68 Safety Code for Craw ler, Locomotive and Truck Cranes 1926.550

ANS I B 30.6-69 S a fet y Cod e for D er ricks (P a r t ia l Rev. of B 30.2-43) 1926.550

ANS I B 56.1-69 S a fet y S ta n da r ds for P ow er ed I ndus. (I SO R 1074) 1926.602

Power Crane and Shovel AssociationS td. No. 1 - 1968 1968 Mobile Cra ne a nd E xca va tor Sta nda rds 1926.602

St d. No. 2 - 1968 1968 Mobile Hydr aulic Cra ne St a nda rds 1926.550,

1926.602

Society of Automotive Engineers

SAE J 959 - 1966 Lift ing Cra ne Wire Rope S trength Fa ctors 1926.550


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OSHA § 1903.13 - IMMINENT DANGERWhenever and as soon as a Compliance Safety and Health Officer concludes on the

basis of an inspection that conditions or practices exist in any place of employmentwhich cou ld reasonab ly be expec ted to c ause dea th or ser ious phys ica l ha rm

immediately or before the imminence of such danger can be eliminated through the

enforcement procedures otherwise provided by the Act, he shall inform the affected

employees and employers of the danger and that he is recommending a civil action

to restr a in such conditions or pra ctices a nd for other a ppropriat e relief in a ccordance

with the provisions of section 13(a) of the Act. Appropriate citations and notices of

proposed penalties may be issued with respect to an imminent danger even though,

after being informed of such danger by the Compliance Safety and Health Officer,

the employer immediately eliminates the imminence of the danger and init ia tes

steps to abate such danger.


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Section II - Survey and Review

1. T F Th e Willia m s-S t eiger Occupa t ion a l S a fet y a nd H ea lt h Act w a s

enacted in 1973.

2. T F G en er a l I ndu st ry St a nda r ds a r e fou nd in pa r t 1926 of t he Act .

3. Mobile cra ne r egula tions can be found in section ____________ of par t 1910.

4. ASME s t andards a re somet imes refer red to a s " indus t ry " or

" _______________" s t a n da r ds .

5. ASME B 30 _________ covers th e inspection a nd design criteria of ca b gla ss.


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SECTION IIIThe Mobile Crane Inspector



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h


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THE MOBILE CRANE INSPECTOR

© Copyright 2001 - NorAm P roductions, I nc. All rights r eserved. Section I II - P a ge 1


According to Webster’s Dictionary, inspection is defined as the act of inspecting or

viewin g. To inspect somet hing is t o view closely a nd critica lly or to view or exam ine

formally or officially. Inspection is the action of determining whether a process or

product is in compliance with establ ished regula tory s tandards and procedures.

When a person is inspecting a crane, they are viewing every part carefully and

critically. That person is examining the crane to ascertain its quality or condition.

The effort put forth in properly training inspectors is great ly rewarded. A well-

trained, qualified inspector will assure your company of continued production and

safety through machine condition.

What are an inspector’s qualifications? The terms appointed, designated, qualified

and competent raise many questions. According to 29 CFR 1910.180(a):• Appointed means “assigned speci f ic responsibi l i t ies by the employer or

employer’s representat ive” .

• Designated means “selected or assigned by the employer or the employer’srepresentative as being qualified to perform specific duties”.

According to 29 CFR 1926.550(a)(5), “the employer shall designate a competent person

who shall inspect all machinery and equipment.” 29 CFR 1926.550(a)(6) states that “a

thorough, annual inspection of the hoisting machinery shall be made by a competent

person, or by a government or private agency recognized by the U.S. Department of

Labor.” Competent , according to Webster’s Dict ionary, means “having suitable or

sufficient skill, knowledge, experience, etc., for some purpose; properly qualified”.

According to ASME B 30.5-2.1.1(a ), “… a ll new a nd a ltered cran es sha ll be inspected

by a q ua lif ied person… ”. For frequent inspections, ASME uses “designa ted”. For

periodic inspections, it uses “qualified”.

ASME B 30.5 defines a qua lified person “a s a person w ho, by possession of a recognized

degree of cer t i f ica te of professional s tanding, or who, by extensive knowledge,

tra ining, a nd experience, has successfully demonstr a ted t he a bility to solve or resolve

problems relating to the subject matter and work.”

The personnel involved in the inspection process include mobile crane inspectors,m a i n t e n a n c e p e r s o n n e l , a n d t h o s e w i t h e x p e r i e n c e i n s p e c i a l i z e d t e c h n i c a l

backgrounds or trades. There are many different types of inspectors. They include:

• mechanics

• elec t r ic ians

• electr onics technicia ns

• engineers


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Section III - P a ge 2 ©C opyright 2001 - NorAm P roductions, I nc. All rights reserved.

• opera tors

• outside machinists

• r iggers

The minimum requirements stated in ASME B30.5 for inspectors and maintenance

personnel are those established for operator trainees. The qualif icat ions include,

but are not limited to, the following:

• Successfully pass a physical examination

• Sat isfactorily complete a writ ten examination covering safety, operat ional

characteristics, limitations and controls of the type of crane for which they

are being qualified

• Operator trainees shall demonstrate their ability to read, write, comprehend,

a nd exhibit a rithm etic skills a nd loa d/capacity chart usa ge, in the la ngua ge

of the crane ma nufacturers’ operat ions a nd ma intenance instruction m at erial

• Sa t is fac tory complet ion of a combinat ion wri t ten and verba l test of load/

capacity chart usage covering various crane configurations

Inspectors are required to have general knowledge of the following:

• opera t ing r equirements

• operat ing skills

• types of mobile cranes

• crane components

• inspection techniques

• test ing techniques

• inspection report ing issues

Inspectors should have very good vision and exercise good judgement. They must

understand that they are a l ink in a good preventive maintenance program.


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© Copyright 2001 - NorAm P roductions, I nc. All rights r eserved. Section I II - P a ge 3

NOTES:

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________


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Section III - P a ge 4 ©C opyright 2001 - NorAm P roductions, I nc. All rights reserved.

Section III - Survey and Review

1. T F Mech an ics m ay som et im es be cr a ne in spect or s.

2. T F An in spect or mu st h a ve g ood vision a nd soun d jud gem en t.

3. 29 CF R 1926.550 (a )(5) st a tes " th e employer sha ll designa te a ____________

person who shall inspect all machinery and equipment.

4. ASME _______________ requires th a t a ll new a nd a ltered cra nes be

inspected by a qualified person.

5. ASME B30.5 requires inspectors to meet the minimum requirements

es t a bl is hed for _______________.


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LOCKOUT/BLOCKOUT

© Copyright 2001 - NorAm P roductions, I nc. All rights r eserved. Section IV - P a ge 1

LOCKOUT/BLOCKOUT

Introduction

Fa ilure to lock out a nd block out ma chinery before working on it is a ma jor caus e ofserious injury and death. Workers are electrocuted, lose fingers, hands, arms, and

suffer severe crushing injuries all because machinery is inadvertently turned on

while they are maintaining, repairing or adjusting components. These injuries can

be prevented by est a blishing , an d using , a lockout /blockout progra m.

Lockout/blockout mea ns t ha t a ny energy source, wh ether elect r ica l , hydra ul ic,

mecha nical, compressed air, or a ny other energy source tha t m ight cause movement,

is disengaged or blocked. There is a difference between turning off a machine and

actually disengaging or de-energizing a piece of equipment. When you turn off a

contr ol switch, you ar e opening a circuit. There is still electrical energy a t the sw itch,

and a short in t he switch or someone inadvertently turning on th e switch will start

the machine running again.

Even a locked-out machine may n ot be sa fe if there are par ts of the machine tha t a re

not blocked to prevent movement. This potential energy can come from suspended

parts that are subject to gravity, energy stored in compression or stretched springs,

and electricity stored in capacitors.

A U.S. Bureau of Labor Statistics study

on in jur ies re la ted to serv ic ing

equipment found that 80 percent of the

workers surveyed failed to even turn off

equipment before performing service

work. Additional statistics show that of

the 20 percent of the workers who did

turn off the machinery, about half of

them were injured when someone else,

generally a co-worker who was unaware

that the machine was being serviced,

react ivated the machinery. A fif th of

those workers who turned off the control

switch were injured by the energy still

c o n t a i n e d i n t h e e q u i p m e n t w h i c h

should have been blocked.

Always Observe the Lockout ProceduresApproved by your Safety Department.WARNING


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Section IV - P a ge 2 ©C opyright 2001 - NorAm P roductions, I nc. All rights reserved.

Section IV - Survey and Review

1. T F Th e in spect or s hou ld lock ou t a n d b lock ou t cr a n es bef or e con du ct in g

a walk around inspection.

2. T F B r a ke s pr in gs un der t en sion w ould not be con sid er ed a h a za r dou s

energy source.

3. When you open a circuit y ou a re t urn ing th e power _______________.

4. A _______________ in a cont rol sw itch w ill sta rt ma chinery r unn ing a ga in.

5. You should alw ay s observe the lockout procedures approved by your

_________ depa r t m en t .


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BASIC OPERATING PRACTICES

© Copyright 2001 - NorAm P roductions, I nc. All rights r eserved. Section V - P a ge 1


Cranes are carefully designed, tested, and manufactured. When used properly by

qualified operators, they will give safe, reliable service.

29 CFR 1910.180 (c) (i) (ii) (iii) and (iv) stipulate stability conditions for

operating a mobile crane.

According to 29 CFR 1926.550(a), “ the employer shall comply with the

manufacturer’s specifications and limitations applicable to the operation of

any and all cranes. Where manufacturer’s specificat ions are not available,

t h e l i m i t a t i o n s a s s i g n e d t o t h e e q u i p m e n t s h a l l b e b a s e d o n t h e

determinat ions of a qua l i f ied engineer competent in th is f ie ld and such

determinations will be appropriately documented and recorded. Attachments

used w ith cra nes sha ll not exceed the capa city, ra ting, or scope recommended

by the manufacturer.”

Cra nes have the ability to li f t heavy loads to great h eights. They also ha ve a potential

for accidents if safe operating practices are not followed. This section will help you

prevent accidents that could result in injury, death, or property damage.

General safe pract ices for working on machinery must be followed as well as the

safe operat ing pract ices recommended here.

NOTE: An inspector may be required to operate the crane during the course of theinspection. I t is important that the inspector be qualif ied at least to the level of

“opera tor t ra inee” and tha t the inspector fol low sa fe opera t ing procedures. The

qualif icat ions for an “operator trainee” are covered

u n d e r A S M E B 3 0 . 5 a – 1 9 9 5 S e c t i o n 5 - 3 . 1 . 2

Qualif icat ions for Operators.

During Operation

• Start the engine only in a well-ventilated area.

• Always warm up the engine and hydrau l icsyst em before a tt empting to operat e the cra ne.

• Wa t c h a l l i n s t r u m e n t r e a d i n g s . S t o p t h ee n g i n e a n d f i n d c a u s e s i f r e a d i n g s a r e

incorrect .

• Avoid sudden applications of all controls, particularly at the start and endof each operation.

• P r o p e l w i t h t h e e n g i n e R P M ’ s ( r e v o l u t i o n s p e r m i n u t e ) a c c o r d i n g t oma nufac turer recommendat ions.


42/194


Section V - P a ge 2 ©C opyright 2001 - NorAm P roductions, I nc. All rights reserved.

Always use the 3-point rule – 2 hands and 1 foot or 2

feet and 1 hand.CAUTION

• Foot pedal brake locks are furnished on some cranes to allow the operatorto rest his legs when suspending the load for short periods of t ime. Keep

your feet on the pedals while foot pedal brake locks are in use. Brakes may

cool, allowing the load to fall.

• When you operate the crane, do not let another person on the crane.

• Hand signals to crane operators shall be those prescribed by the applicableANSI standard for the type of crane in use. An illustrat ion of the signals

shall be posted at the job site.

• Trying t o repa ir or adjust equipment w ith a suspended hook or loa d, or withthe boom ra ised , could release machinery and let i t move unexpectedly .

Always lower the load to the ground and the boom onto proper cribbing

before doing maintenance or repair work.

Park SafelyBefore you leave the cab:

• Lower the load to the ground and a pply thebrakes.

• Put the control levers in the neutral position.

• Shut off the engine.

• Never park on an incline without carefullyblocking the crane to prevent movement.

• Don’t leave the cran e where there is a chan ce

of a ban k caving in, or a low spot w here rainsmay wash out the footing.

• Ta ke the engine key a nd t he cab door keywith you.

• Alwa ys dismount facing the cra ne using theh a n d h o l d s a n d s t e p s p r o v i d e d b y y o u r

employer or crane manufacturer.


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LOAD CHART INTERPRETATIONS

An Overview for Lifting Service Cranes

The crane manufac turer designs a loadchart for ea ch model crane t ha t is sold. The

load chart may go one step further. It could

be serial number or other ident ifier specific,

i.e., a different load chart is required for

each machine even if a manufacturer only

makes one model c rane . This i s done

because there cou ld be some s l igh t

d i f ferences be tween each c rane due to

design changes, manufacturing techniques,

materials used or a host of other reasons.

The loa d chart in this situa tion will bear not

only the model number but also the serial

number or other identifier of the crane into

w hich it is inst alled. This chart cannot be interchanged with another crane.

Sh ould the loa d char t become lost or illegible, it can only be replaced by the ma nufa cturer.

No crane may be operated without the correct load chart in place.

Load charts indicate the GROSS LIFTING CAPACITY of th e cran e. Those capa citiesare limited by either the STRUCTURAL STRENGTH of the crane or STABILITY (the cranes ability to resist tipping). It is critical to remember that tipping cannotbe relied upon as an indication that the crane has reached capacity.

The GROSS CAPACITIES listed on th e loa d chart a re based on the configura tion ofthe crane. Changing the conf igura t ion wil l change the chart tha t you are using.

Configura tion can include the follow ing:

1. On ou t r iggers or on rubber ;

2. Lift ing from a boom at ta chment ie: jib, extension, auxiliary point sheave;

3. Ma s t in st a lled ;

4. G ant ry posi t ion (lowered, in termedia t e or fu l ly erected);

5. B oom type, la t t ice (tubular or angle, heavy or light) or hydra ulic;

6. Type of boom point insta l led ;

7. C ou nt er w eig ht s u sed , a nd

8. Levelness of the crane, (l is t charts).

The operator must have read and understood theOperator’s Manual. He or she must also be able to readand understand the load chart, even if the crane is equippedwith an LMI or electronic load chart system.WARNING


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Typical Lattice Boom Capacity Chart

These load charts are intended for instructional purposes only. They were derived

from manufacturer sales information which may not be complete or machine specific.

Not responsible for typographical errors.

81.5 45' 0"11 80.1 45' 11"12 78.6 44' 9"13 77.2 44' 6"14 75.7 44' 3"

40' 15 74.2 44' 0"20 66.6 42' 3"25 58.5 39' 8"30 49.7 36' 0"35 39.5 30' 11"40 26.2 23' 3"

12 80.9 54' 11"13 79.8 54' 9"

14 78.6 54' 6"15 77.4 54' 4"20 71.5 52' 11"

50' 25 65.3 50' 11"30 58.8 48' 4"35 51.9 44' 10"40 44.1 40' 4"50 23.4 25' 5'

14 80.5 64' 9"15 79.6 64' 6"20 74.7 63' 4"25 69.6 61' 9"

60' 30 64.4 59' 8"35 59.0 56' 11"40 53.3 53' 8"50 40.1 44' 2"60 21.4 27' 4"

15 81.1 74' 8"20 76.9 73' 9"25 72.6 72' 4"

30 68.3 70' 6"70' 35 63.8 68' 4"40 59.2 65' 8"50 49.0 58' 4"60 37.0 47' 8"70 19.8 29' 2"

20 78.6 83' 11"25 74.9 82' 9"30 71.1 81' 3"35 67.3 79' 4"

80' 40 63.4 77' 0"50 55.0 71' 0"60 45.7 62' 9"70 34.6 50' 11"80 18.5 30' 10"

20 79.8 94' 2"25 76.6 93' 0"30 73.3 91' 9"35 69.9 90' 0"40 66.5 88' 0"

90' 50 59.4 82' 11"60 51.6 76' 0"70 42.9 66' 10"80 32.5 53' 11"90 17.4 32' 5"

10

ABo o m On Outr iggers Tires (Static )

Rear SideRear Side

70,000* 70,000*70,000* 70,000*70,000* 70,000*65,200* 65,200*60,900* 60,800*57,100* 58,900*43,300* 42,900*34,600* 34,200*28,500* 28,200*23,700* 23,00019,900* 18,900

65,600* 65,600*63,800* 63,800*60,900* 60,800*57,100* 56,900*43,300* 42,900*34,600* 34,200*28,600* 28,200*23,700* 23,10020,100* 19,00015,000* 13,700

58,000* 56,000*54,700* 54,700*43,200* 42,800*34,600* 34,100*28,500* 28,200*23,700* 23,20020,100* 19,10015,000* 13,80011,700* 10,500

49,900* 49,900*43,100* 42,700*34,400* 34,000*28,500* 28,000*23,700* 23,20020,000* 19,10015,000* 13,80011,700* 10,500 9 ,400* 8,300

40,800* 40,800*34,300* 33,900*28,400* 27,900*23,600* 23,20019,900* 19,00014,900* 13,70011,600* 10,500 9 ,300* 8,300 7 ,800* 6,600

37,100* 37,100*33,300* 33,300*28,200* 27,800*23,500* 23,10019,800* 19,00014,800* 13,700

11,500* 10,400 9 ,200* 8,200 7 ,500* 6,600

8,200* 4,400

62,000 36,800*53,900 33,900*47,700 31,400*42,600 29,200*38,500 27,300*35,100 25,600*24,000 18,700*18,000 13,80014,100 10,70011,500 8,600 9,500 7,000

47,800 31,400*42,800 28,200*38,700 27,300*35,200 25,600*24,100 18,80018,000 13,90014,200 10,80011,600 8,600

9,600 7,100 6,900 4,900

38,700 27,200*35,300 25,200*24,100 18,80018,000 13,90014,200 10,80011,500 8,600 9,600 7,100 6,900 4,900 5,200 3,500

35,200 25,300*24,100 18,80018,000 13,90014,100 10,70011,500 8,600 9,500 7,000 6,900 4,900 5,200 3,500 3,900 2,500

24,000 18,70017,900 13,70014,100 10,60011,400 8,500 9,500 6,900 6,800 4,800 5,100 3,400 3,900 2,400 2,900 1,700

23,900 18,70017,800 13,70014,000 10,50011,300 8,400 9,400 6,800 6,700 4,700

5,000 3,300 3,800 2,400 2,900 1,600 2,100 1,000

A Static capacities are defined as loads without machine travel or withmachine travel at creeping speeds only.

PointLength Radius Angle Height

(Feet) (Degrees) "w"

A


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46/194



Typical Hydraulic Boom Capacity Chart

These load charts are intended for instructional purposes only. They were derived

from ma nufa cturer sa les informa tion w hich ma y not be complete or ma chine specific.

Not responsible for typographical errors.

O utr iggers Ful ly Extended

64' - 70.25' (19.51-21.41M) Main Boom

64' 70.25(19.51m) (21.4m)

25' Fixed Fly+ 70.25' Main Boom

(7.62m) (21.41m)

LOA D ED LOAD EDLOA D B O O M O VER BOO M O VERR A DIUS ANG LE 360 FRO NT AN GLE 360 FRO NT(ft./m ) (deg) (lbs./kg) (lbs./K g) (deg) (lb s./kg) (lbs./kg )

° °

15 76 .5 37 ,500 37,500 78.5 34,900 34 ,900

20 72 .0 30 ,100 30,100 74.0 28,200 28 ,200

25 67 .0 23 ,500 23,500 70.0 23,500 23 ,500

30 62 .0 19 ,200 19,200 65.0 19,200 19 ,200

35 56 .5 15 ,100 15,900 60.5 15,100 15 ,900

40 51 .0 12 ,000 13,400 55.5 12,000 13 ,400

45 44 .5 9 ,800 11,400 50.0 9,800 11 ,400

50 37 .5 81 ,000 9,900 44.5 8,100 9 ,900

55 28 .5 6 ,800 8,600 37.5 6,800 8 ,600

60 16 .0 5 ,700 7,500 30.0 5,700 7 ,500

65 19.5 4,900 6 ,600

70

75

80

85

90

4 .57 17010 17010 15831 15831

6 .10 13653 13653 12792 12792

7 .62 10660 10660 10660 10660

9 .14 8709 8709 8709 8709

10.67 6849 7212 6849 7212

12.19 5443 6078 5443 6078

1372 4445 5171 4445 5171

15.24 3674 4491 3674 4491

16.76 3084 3901 3084 3901

18.29 2586 3402 2586 3402

19.81 2223 2994

21.34

22.86

24.38

25.91

27.43m

0 Angle 2,600 3,700 2,200 3,10 0

Capacity 1179 1678 998 1406

LOADEDB OO M O VE R LO A DANG LE 360 FRONT RADIUS(deg .) (lb s./kg ) (lbs./k g) (ft./m )

°

15

78.5 16 ,200 16 ,200 20

75.5 13 ,900 13 ,900 25

72.5 12 ,200 12 ,200 30

69.5 10 ,900 10 ,900 35

66.0 9 ,800 9 ,800 40

62.5 8 ,800 8 ,800 45

59.0 8 ,100 8 ,100 50

55.5 7 ,500 7 ,500 55

52.0 6 ,600 6 ,900 60

47.5 5 ,700 6 ,300 65

43.0 4 ,900 5 ,800 70

38.5 4 ,300 5 ,400 75

33.0 3 ,700 5 ,000 80

26.5 3 ,300 4 ,600 85

17.0 2 ,800 4 ,200 90

4.57

7348 7348 6 .10

6305 6305 7 .62

5534 5534 9 .14

4944 4944 10.67

4445 4445 12.19

3992 3992 13.72

3674 3674 15.24

3402 3402 16.76

2994 3130 18.29

2586 2858 19.81

2223 2631 21.34

1950 2449 22.86

1678 2268 24.38

1497 2087 25.91

1270 1905 27.43 Minimum Boom Angle for No Load 0 °


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Typical Hydraulic Boom Configurations


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Section V - Survey and Review

1. T F H a nd sign a ls for mobile cr a nes mu st be pos ted a t th e job sit e.

2. T F L oa d ch a r ts ca n be in ter ch a ng ed bet w een cr a nes of d iffer en t s er ia l

numbers as long as they a re the sam e model.

3. Loa d cha rt s ca n only be repla ced by t he _______________.

4. Loa d cha rt s indica te _______________ capa cities.

5. In addi t ion to the OSHA and ASME standa rds, anyone who opera tes the

cra ne m us t a ls o ha ve rea d __________________ .


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SECTION VITools of the Trade



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h


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TOOLS OF THE TRADE

© Copyright 2001 - NorAm P roductions, I nc. All rights r eserved. Section VI - Pa ge 1

TOOLS OF THE TRADE

Tools a re designed t o make a job easier a nd ena ble you to work more efficiently. Ifthe tools are not used properly or cared for, their advantages will be lost. Without

the proper tools and the knowledge of how to use them, inspectors waste t ime,

reduce efficiency, and may even injure themselves.

A knowledge of the tools an d their funda menta l uses is the prima ry st ep in ma stering

the basic hand tool skills.

Let’s take a look at a few good tool habits.

• Store tools in their proper place. A tool is useless if you cannot f ind it .

Improperly storing tools will result in damage to the tools.

• Keep tools in good condit ion . Protec t them from rust , n icks, burrs , andbreakage. Cutting tools should be kept sharp.

• U se each tool to do only th e job for which it w a s designed. Using a tool outside

of i t s design parameters can resul t in damage to the tool , damage to the

work and personal injury.

• NEVER use damaged tools. A damaged screwdriver may slip and damage

the screw slot, da ma ge other pa rts or ca use a painful injury. A ga uge or other

measuring device which has been damaged will render useless information.

Now that we have looked at some basic good hand tool habits, let’s take a look at

some tools commonly found in a mobile crane inspector’s tool box.

1. Hammers – Hammers , ma l le t s and s ledges a re used for s t r ik ing . Thetype of hammer you selec t wi l l depend on your in tended use. Hammers

m a y b e f u r t h e r d i v i d e d i n t o s o f t - f a c e d a n d h a r d - f a c e d , a s w e l l a s b y

d i f f e r e n t s t y l e s s u c h a s a c a r p e n t e r ’ s ( c l a w ) h a m m e r a n d a b a l l p e e n

(ma chinist ’s) ha mm er. For inspection purposes a 12 ounce ha rd-fa ced claw

hammer, 6 ounce hard-faced ball peen hammer and a 10 ounce soft-faced

mallet would make good choices .

2. Turning tools – They inc lude open-end wrenches, box-end wrenches,c o m b i n a t i o n w r e n c h e s , s o c k e t w r e n c h e s , a d j u s t a b l e w r e n c h e s , t o r q u e

wrenches, and Allen wrenches. Let’s look at each different type of wrench.Screwdrivers will be addressed later.

• Open-end wrenches – Solid, non-adjustable wrenches with openings inone or both ends. Their ja ws ma y be para llel to the ha ndle or a t a ngles up

to 90°. The average angle is 15°. Ha ndles may be either str a ight or curved.

• Box-end wrenches – This type of wrench is a safer alternative to anopen-end wrench, since there is less likelihood they will slip off the


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Section VI - P a ge 2 ©C opyright 2001 - NorAm P roductions, I nc. All rights reserved.

work. The heads on these wrenches have either 6, 8, 12, or 16 points or

notches arranged in a circle that completely surrounds a nut or bolt

head. Those wrenches w ith 16 points should only be used for light duty

w ork. The w renches with 12 points s hould not be used for grea ter t ha nmedium duty work. Box-end wrenches are more time consuming to use

than open-end wrenches.

• Combination wrenches – After a tight nut is broken loose, it can beturned much f a s ter wi th an open-end wrench than wi th a box-end

wrench. A combination wrench has a box-end on one end of the handle

and an open-end wrench on the other end of the handle. Always make

sure the wrench is seated squarely on the flats and is the proper size

for the bolt or nut. U sua lly a set of combinat ion w renches in the sma ller

sizes will be sufficient for most inspection kits.

• Socket wrenches – A good set of socket wrenches is a must for any

inspector’s t ool kit. A socket set ba sically consist s of socket t ype w rencheswhich can be attached to various types of handles. Most inspection kits

wi l l con t a in a ¼ ” d r ive socket se t , a s w ell a s a ½ ” d r ive socket se t .

Sockets are normally of the shallow well type and in the smaller sizes.

H a n d l e s s h o u l d i n c l u d e a r a t c h e t t y p e h a n d l e a n d a h i n g e d t y p e

(breaker bar) handle. A couple of different length extensions should be

included for those hard-to-reach places.

• Adjustable wrenches – A ha ndy a ll-round w rench generally includedin every tool box is th e adjusta ble wrench. The a djusta ble wrench is not

i n t e n d e d f o r u s e o n e x t r e m e l y h a r d t o t u r n i t e m s . W h e n u s e d

improperly, adjustable wrenches are known to slip, earning them the

nickname “knuckle busters”. Although available in a number of sizes,most inspec t ion too l k i t s wi l l con t a in one 6” and one 10” leng th

adjustable wrench.

• Torque wrenches – There a re times w hen, for engineering rea sons, adefinite force must be applied to a nut or bolt. In such cases a torque

wrench must be used. There are three commonly used types of torque

wrenches . These a re the de f lec t ing beam, d ia l ind ica t ing and the

micrometer set t ing. Accuracy of the torque wrench depends on i t s

proper use, the cut and cleanliness of the threads on the fastener and

the condition and calibration of the torque wrench. When selecting a

torque wrench for your inspection kit, choose one that will read about

mid-range for the torque to be applied.• Allen wrenches – Sometimes referred to as set screw wrenches, they

are actually made up of a couple of types of head shapes, including the

B ristol head a nd t he Allen hea d. Allen hea d screws a re the more common

ty pe an d a re hexa gona l (six-sided) in sh a pe. A good set of Allen w renches

are a must for any inspector’s tool kit .


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TOOLS OF THE TRADE


3. Punches – Although there are a number of types of punches, including pinpunches, prick punches, drif t punches and others, the only type normally

found in an inspector’s tool kit is the center punch. Their use in inspections

is usua lly limited to ma rking mea suring points, or Tra m points, on hooks.When using any type of punch, be sure to strike it squarely and that i t is

positioned properly so that it will not slip on the work.

4. Screwdrivers – One of the most basic of hand tools, i t is a lso the mostabused o f the hand too ls . Here we wi l l look a t th ree d i f feren t t ypes o f

screwdrivers-the Standard head, the Phill ips head and the Reed and Prince

head. A variety of sizes in each type and size of head should be kept in the

inspector’s tool box to ensure the most appropriate size is available for use.

• Standard head - S ta nda rd screw drivers ar e classified by size a ccordingto th e combined length of the sha nk a nd bla de. The most common sizes

ra nge from 2 ½ ” to 12”. The diameter of the shank a nd the w idth a nd

thickness of the blade are normally proport ionate to the length, but

not always. When select ing a Standard screwdriver, i t is important to

select a screwdriver with the thickest blade that will fit properly into

the slot of the screw. When using a screwdriver, be sure to keep the

shank perpendicular to the screw head.

• Phillips head – The head of a Phill ips-type screw has a four-way,beveled wall slot into which the screwdriver fits. The screwdriver head

has about 30° f lukes and a blunt end. Never at tempt to use Standa rd orReed and Prince type screwdrivers on a Phillips-type screw.

• Reed and Prince head – Although Reed a nd P rince head screws looka l o t l i k e a P h i l l i p s h e a d s c r e w , t h e s c r e w d r i v e r s a r e n o t

interchangeable. The way to recognize a Reed and Prince type screw is

by the shape of its slot. Where a Phillips type screwdriver has about

30° f lukes a nd a blunt end, a Reed and P rince type screw ha s 45° flukesa nd a sha rper pointed end. Reed and P rince type screws a re less common

on cranes than the Phillips type.

5. Pliers – Like screwdrivers, pliers come in many different styles and sizes andare used to perform many different functions. For our inspector’s tool box, we

are only going to look at four types. These are the long-nose (needle-nose) pliers,

slip-joint pliers, channel-lock pliers and the vise-grip pliers. Regardless of the

type, pliers should never be used as a substitute for a wrench.

• Long-nose pliers – Commonly referred to as needle-nose pliers, theyare not as rugged as the other types of pliers. However, due to their

long slender nose they are especially useful for holding small objects in

tight places and for making more delicate adjustments.


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Section VI - P a ge 4 ©C opyright 2001 - NorAm P roductions, I nc. All rights reserved.

• Slip-joint pliers – These pliers ha ve stra ight, serra ted (grooved) jaw s,and the screw or pivot with which the jaws are fastened together may

be moved to either of two positions, depending on the size of the object

to be held.

• Channel-lock pliers – This type of pliers is a variation on the waterpump pliers. They have extra long handles to provide extra leverage, a

slip joint to allow mult iple posit ioning of the jaws, and coarse teeth

inside the jaws to assist in holding round stock.

• Vice-grip pliers – These pl iers can be used for holding objec tsregardless of their shape. The pliers may be adjusted for use on a wide

va riety of objects, an d t he pliers m a y be cla mped to the object by tur ning

the knurled screw in the end of the handle. Vice-grip pliers should be

used with care since the teeth in the jaws tend to damage the object on

which they are clamped.

6. Flashlights – It is a scientif ic fact that as we age we require more light inorder to see properly. In every inspector’s tool box should be a variety of

l ight sources. Beyond the common hand held f lashl ight tha t everyone is

f ami l i a r wi th , there a re o thers tha t wi l l g rea t ly a ss i s t the inspec tor in

performing their job. These other types of lights include bendable flashlights

with lights at the end of a small diameter stem made for gett ing into t ight

places, f lashlights that clip to hard hats or caps, a llowing the inspector’s

ha nds to be free, a nd ma gnifying glass and light combinations.

7. Inspection mirrors – There a re several t ypes of inspection mirrors a vaila blefor use. The mirrors may be round or rectangular, and may either be a fixed

length or adjustable length. Some inspection mirrors come with a built inlight source.

8. Measuring tools – There a re a number of different types of measur ing t oolsused in inspections. Any measurement is only accurate if i t is performed

correctly. Here w e will look a t r ules an d t a pes, calipers, depth ga uges, levels,

sheave gauges, protractors and pressure gauges.

• Rules and Tapes – Every inspector’s tool kit should contain a tapemea sure a t least 25’ in length . This a llow s t he inspector t o verify boom

lengths a nd load ra dii. A steel rule is a lso very helpful in measuring the

dista nce betw een Tra m points on a h ook an d for use as a str a ight edge

across “dings” in boom chords to allow the inspector to determine the

depth of the damage.

• Calipers – Calipers come in many different types, including pocketslide calipers, vernier calipers, and micrometers. A good choice for an

inspector’s tool box might be a vernier caliper with a built in depth

ga uge . Today t hese ca l ipers a re norma l ly “Dia l ” t ype ca l ipers or

“Digital” calipers and read in thousands of an inch. However, calipers

tha t read in fract ions of an inch a re also available, as w ell as t hose that


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TOOLS OF THE TRADE


a utoma tically convert from fra ctions t o decima ls or vice-versa. Ca lipers

are commonly used on mobile cranes to measure the diameter of the

rope for compliance with applicable standards. When equipped with a

built in depth gauge, they are also useful in determining the depth ofdamaged spots on the chords of tubular type booms.

• Depth gauges – If the style of caliper you choose has a built in depthgauge, it may not be necessary to purchase a separate one. However, if

there is no depth ga uge on your calipers, depth ga uges ma y be purcha sed

separa tely .

• Levels – Levels are tools designed to prove whether a plane or surface istrue either horizontally or vertically. They may display this information

in a number of ways depending on the type of level chosen. Probably one

of the more popular types of levels today is the laser level. Regardless of

how the results a re read, an inspector should ha ve at least one sma ll target

level available that will fit on the rotating structure next to the boom footpins, or hinge pins. The inspector will then be able to determine if the

leveling device provided on the crane is accurate.

• Sheave gauges – Shea ve is a t erm used to describe the pulleys used inthe boom points and hook blocks on a mobile crane. These sheaves are

required to provide adequate support for the rope which runs on them.

When these sheaves are inspected, they must be checked to see if they

are worn excessively, requiring replacement. A sheave gauge is similar

to a radius gauge in appearance, but is designed to fit into the track of

these sheaves. Sheave gauges are most commonly “No-Go” type gauges.

However, “Go” gauges may also be used.

• Protractors – A protra ctor is a circular or semicircula r inst rument formeas uring or constructing a ngles. A ma gnetic protra ctor ha s a m ag netic

base w hich a llow s the protra ctor to be tempora rily mounted to a cra ne’s

boom. By raising an

Mobile Crane Inspector Training - Student Manual

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