Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

1
 About Crane Institute of America

Crane Institute of America is the nation’s leading provider of

training services to the lifting industry. We offer a wide
variety of safety programs for operators, supervisors, and
inspectors of mobile cranes, overhead cranes, and offshore
cranes, as well as rigging and other lifting equipment
including forklifts and aerial lifts. Train-the-trainer programs
for those wishing to set up or enhance their own training
programs are also available.

Our team of instructors is among the most qualified in the

industry and our presentations are consistently acclaimed
both for the quality and breadth of their content and their
motivational style.

Crane Institute of America seminars are offered at cities

across the country. Alternately, we can tailor a program to
your specific needs and equipment and present it at your
company’s facility.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 2

 PROGRAM CONTENT

Day One:
Lesson 1 Overview and objectives
Lesson 2 Workshop: Why inspect mobile cranes
Lesson 3 Standards and regulations
Lesson 4 Levels of Inspection
Lesson 5 Inspector qualification and competency
Lesson 6 Frequency of inspections, record-keeping and
rules
Lesson 7 Crane types and components
Lesson 8 Aspects of inspection and senses used in
inspection

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 3

 PROGRAM CONTENT

Day Two:
Lesson 9 Workshop: Latest ASME B30.5 standard

Day Three:
Lesson 10 Workshop: ANSI B30.5(1968), PCSA #2, OSHA
1926.550 and OSHA 1910.180 and wire rope
Lesson 11 Periodic (annual) inspection

Day Four:
Lesson 12 Load Test
Lesson 13 Workshop: Load chart instructions
Lesson 14 Load Test exercises
Lesson 15 Rigging
Lesson 16 Certification exam

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 4

 Seminar Objectives

 Enable companies to perform their own

in-house OSHA and ANSI/ASME crane
inspections.

 Equip inspectors to properly identify

immediate and potential hazards and
prescribe corrective actions.

 Reduce employers liability exposure

through training and certification.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 5

 Course Objectives

SAFETY
The act or process designed to eliminate risk
or danger from an environment.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 6

 Course Objectives

Remember,
learning has not
taken place
until behavior
has changed.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 7

 Training Focus

UNDERSTANDING,
INTERPRETING
and
APPLYING
STANDARDS & REGULATIONS.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 8

 Why Inspect Mobile Cranes?

 Accident Prevention
 Limit Liability Exposure
 OSHA Citation

 Civil Penalties
 Criminal Charges

 Crane’s Ratings are based more

on Structural Strength

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 9

  Accident Prevention
? ? ? MENTAL
? ?
? Wrong Attitude
Way crane is perceived.

Wrong Assumptions
Takes little skill to operate.

PHYSICAL

Wrong Actions
Allows unqualified personnel
to operate cranes.

ACCIDENTS

Accident Prevention takes place first in

the mind. Thinking has to change!

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 10

  Accident Prevention
Main Causes of
Mobile Crane Fatalities

Rigging
Load
15%
Handling Electrocution
14%
44%
Operator Error 7%

Overload 7%

Dismantling Boom 5%

Wire Rope Failure 3%

Miscellaneous 3%
Struck by Crane 3%

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 11

  Accident Prevention

One out of every five deaths

is crane related!

CRANE
RELATED
20%

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 12

  Accident Prevention
Main Causes of Mobile Crane Accidents
High Wind
1.6%

Support Failure
Machinery &
Structural Failure 31.5%
11.2%

Failure to Use
Outriggers Operator Error
22.6% 33.1%

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 13

  OSHA Citation

$7,000 for serious violations

$70,000 for willful violations

Can use egregious multiplier

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 14

  Civil Penalties

Final Lampson Accident

or other law suit cost

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 15

  Criminal Charges

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 16

  Crane’s Ratings are based more
on Structural Strength
Basis for
Rated Capacities

STRUCTURAL
(Breaking)

STABILITY
(Tipping)

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 17

  Crane’s Ratings are based more on
Structural Strength
Division of Load Charts

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 18

  Crane’s Ratings are based more on
Structural Strength
Load Limits Determined by Calculations and Testing

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 19

  Crane’s Ratings are based more on
Structural Strength

Yield Point Before Tipping Occurs

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 20

  Crane’s Ratings are based more on
Structural Strength

Components That
Can Fail

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 21

 Standards
Without a standard for
straightness, this flag pole
could be called straight.

Definition of a standard:

...set up and established by

authority as the rule for the
measure of quantity,
weight, extent, value or
quality.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 22

 Government Regulations

1. OSHA (Occupational Safety and Health Administration)

a. Construction Industry, Code of Federal
Regulations (CFR) 1926.550
b. General Industry (CFR) 1910.180
c. Shipbuilding, Longshoring and Marine Terminals
CFR 1917, 18 and 19

2. MSHA (Mine Safety and Health Administration)

3. DOE (Department of Energy)

4. NRC (Nuclear Regulatory Commission)

5. USAC (US Army Corps of Engineering)

6. California OSHA

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 23

 OSHA Regulation Divisions

 Construction: New construction,

repair & demolition.
 General Industry: Everything not
construction or specifically handling
raw material or finished product.
 Applications: Most mobile cranes are
used in construction.
 Note: Rule of predominant use. If a crane is
used in construction most of the time but
sometime in general industry, it would still be
inspected to construction requirements.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 24

 OSHA Regulations

History:

• OSHA created by the Occupational Safety and

Health Act of 1970

Purpose:

• To assure safe and healthful working conditions for

working men and women

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 25

 Voluntary Industry Standards

History:

• ASME created Safety Standard for Cranes in 1916.

• USAS B30.5 Crawler, Locomotive & Truck Cranes
was produced in 1943.
• Currently ASME B30.5 is revised annually.

Purpose:

• Guard against & minimize injury to workers by

prescribing safety requirements.
• Provide direction to equipment owners, employers
& supervisors.
• Guide regulatory bodies.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 26

 Incorporation by Reference
Construction

Industry Standards, Manufacturer’s Specifications

Incorporated by Reference,
have the same force as law.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 27

 Incorporation by Reference
General Industry

Industry Standards, Design Specifications

Incorporated by Reference

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 28

 Levels of Inspection

GOAL = Provide the SAFEST crane that is

reasonably and practically possible.

• Inspect to OSHA regulations

• Inspect to ANSI B30.5 1968
& PCSA 2
• Inspect to crane manufacturer's
inspection requirements.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 29

 Inspector Qualification and
Credentials

 ANSI: Qualified person - A person who,

by extensive knowledge, training, and
experience, has successfully
demonstrated his ability to solve and
resolve problems related to the subject
matter and work.
 OSHA: Competent person - One who is
capable of identifying existing and
predictable hazards, and has
authorization to take prompt corrective
measures to eliminate them.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 30

 CIA Requirements for Inspector
Qualification and Certification

 Complete a four day MCI Training

Program
 Document three years
telescoping/lattice boom mobile crane
experience
 Be physically capable of performing all
aspects of crane inspection
 Make a passing grade of at least 80% on
CIA examination

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 31

 CIA Requirements for Recertification

 Remain physically capable to perform

all aspects of crane inspection
 Complete a one day Recertification
Program every two years
 Be not found to be responsible for a
crane accident resulting from
inadequate inspection
 Not cited by OSHA or other authority for
failure to properly inspect or keep
proper records

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 32

 Benefits of Certification

 Satisfy OSHA and ANSI’s requirement

for demonstration of competency and
qualification
 Documentation and verification in case
of litigation
 Ensures that cranes are safe for the job
 Mandatory certification may be required
in the future by OSHA and Industry

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 33

 Inspection Requirements
 Initial
 New, altered, repaired
 Baseline measurements
 Pre-operational by competent person
 Functions
 Safety devices
 Visual
 Monthly on critical items by qualified person
 Hooks, Ropes, Hydraulic system, brakes
 Annual - periodic - by competent person or
accredited by US-DOL
 Frequent - pre-op
 Periodic - monthly

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 34

 Recordkeeping Requirements

 Initial: not specified

 Pre-op: not specified
 Monthly: certification record
 Annual: record of results

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 35

 Mandatory and Advisory Rules

Shall — this word indicates that the rule

is mandatory and must be
followed.

Should — this word indicates that the rule

is a recommendation, the
advisability of which depends
on the facts in each situation.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 36

 Crane Types

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 37

 Telescoping Boom Crane Types
Industrial Cranes

Carrydeck Crane
(Rotating Boom)

Carrydeck Crane
(Fixed Boom)

Pick and Carry Crane

(Fixed Boom)

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 38

 Telescoping Boom Crane Types
Rough Terrain Cranes

Swing Cab

Fixed Cab

All-Terrain Crane

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 39

 Telescoping Boom Crane Types
Carrier and Crawler Mounted

Carrier
Mounted Crawler
Mounted

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 40

 Telescoping Boom Crane Types
Commercial Truck-Mounted Cranes

Rear-Mounted Turret

Articulating or Knuckle Boom

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 41

 Telescoping Boom Crane Types
Boom Attachments

Telescoping Boom Crane

with Extension Stowed

Extension Erected

Extension and Jib Extension & Telescoping Jib Jib on Boom

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 42
 Telescoping Boom Crane Types
Boom Attachments

Telescoping Boom
Crane With Luffing Jib

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 43

 Telescoping Boom Crane Types
Rough Terrain Cranes

__
2 Jib Forestay Pendant 10
__ Main Boom Tip Sheave
__
5 Boom Extension Tip Sheave 20
__ Engine
19
__ Outrigger Pads 23
__ Main Hoist Winch
__
8 Headache Ball __
7 Auxiliary Hoist Line
22
__ Auxiliary Winch 24
__ Boom Extension, Stowed
13
__ Main Boom Head 11
__ Main Hoist Line
__
3 Jib Mast 21
__ Counterweight
17
__ Ring Gear 18
__ Center of Rotation
__
1 "A" Frame Jib 12
__ Main Hook Block
__
6 Anti-Two-Blocking Device __
4 Jib Backstay Pendant
__
9 Boom Extension, Erected 15
__ Boom Hoist Cylinder
16
__ Operator's Cab 14
__ Auxiliary Boom Head

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 44

 Telescoping Boom Crane Types
Carrier-Mounted Cranes

11
__ Main Boom Head __
8 Jib Hook & Headache Ball
13
__ #2 Power Telescoping Section 12
__ #3 Power Telescoping Section
21
__ Main Hook or Block or Manual Section
15
__ Base Boom Section 25
__ Center of Rotation
19
__ Boom Hinge Pin 18
__ Counterweight
22
__ Boom Hoist Cylinder __
3 Jib Mast
__
2 Jib Forestay Pendant __
4 Jib Backstay Pendant
17
__ Auxiliary Hoist 16
__ Main Hoist
__
5 Boom Extension Tip Sheave 20
__ Main Hoist Line
__
9 Boom Extension, Erected __
1 "A" Frame Jib
__
7 Auxiliary Hoist Line 24
__ Carrier
14
__ #1 Power Telescoping Section 10
__ Main Boom Tip Sheave
__
6 Anti-Two-Blocking Device 23
__ Upperworks

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 45

 Telescoping Boom Crane Types
Boom Truck Cranes

__
6 Center of Rotation
__ Hoist
12
__
2 Telescoping Boom Section
__
9 Turret or Pedestal
__
4 Lift Cylinder
__ Boom Point Sheave
10
__
3 Boom Base Section
__
8 Truck Chassis
__
1 Anti-Two-Blocking Device
__
11 Boom Head
__
5 Front Stabilizers
__ Overhaul Ball
13
__
7 Rear Stabilizers
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 46
 Lattice Boom Crane Types
Crawler & Carrier Mounted Cranes

Crawler-Mounted
Lattice Boom Crane

Carrier-Mounted
Lattice Boom Crane

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 47

 Lattice Boom Crane Types
Heavy Lift Attachments

Crawler Crane With

Heavy Lift Ring
Attachment

Crawler Crane With

Guy Derrick

Crawler Crane With

Additional
Counterweight
Attachment
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 48
 Lattice Boom Crane Types
Boom Attachments

Crawler and Carrier-Mounted

Lattice Boom Cranes With
Jibs

Crawler Crane With

Luffing Boom And Jib Carrier-Mounted
Lattice Boom
Crane With Tower
Attachment

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 49

 Lattice Boom Crane Types
Carrier-Mounted Cranes

13
__Counterweight 8 Lattice Boom Section
__
7
__Main Hook Block 17
__ Boom Stops
21
__Jib Forestay Pendant 6 Main Hoist Line
__
15
__Boom Hoist Reeving 9 Boom Heel Section
__
11
__Center of Rotation 18
__ Boom Pendants
10
__Turntable 20
__ Jib Mast or Gantry
19
__Deflector (idler) Sheaves 3 Headache Ball
__
14
__Live Mast 16
__ Bridle
1 Anti-Two-Blocking Device
__ 2 Auxiliary Hoist Line
__
12
__Carrier 5 Boom Tip Sheave
__
4
__Jib Inserts
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 50
 Lattice Boom Crane Types
Crawler-Mounted Cranes

12
__ Counterweight 19
__ Jib Heel Section
23
__ Main Hook Block __
5 Boom Pendants
1 Jib Forestay Pendant
__ __
9 Backhitch
7 Boom Hoist Reeving
__ 15
__ Auxiliary Hoist Line
14
__ Jib Tip Sheave __
6 Outer Bail
26
__ Turntable, Swing Circle 17
__ Jib Tip Section
18
__ Jib Mid Section __
8 Inner Bail
10
__ Gantry 16
__ Headache or Overhaul Ball
2 Jib Mast (Gantry)
__ 13
__ Machine Deck
11
__ Boom Hoist Line __
4 Deflector (Idler) Sheaves
22
__ Main Hoist Line 20
__ Boom Tip Sheaves
3 Backstay Pendant
__ 21
__ Anti-Two-Blocking Device
24
__ Boom Heel Section 25
__ Boom Stop
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 51
 Areas of Inspection

Operational
Electrical

Structural

Mechanical

Power Systems
Safety Devices

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 52

 Method of Inspection

Visual Audible
(Seeing) (Hearing)

Olfactory
(Smelling) Test

Tactile
(Touching)

Measurement

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 53

 Lattice Boom Loading

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 54

 Positive Stops

5°Max.
All jibs shall have positive stops to
prevent their movement of more than
5 degrees above the centerline of the CL
jib and boom.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 55

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 56
 Hook Inspection







Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 57

 Overhaul Ball Inspection

Wedge & Socket

Capacity & Weight
Markings
Connections & Pins

Swivel

Hook Latch

Hook

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 58

 Load Block Inspection
SIDE PLATES

CENTER PLATES DEAD END

CONNECTION

UPPER TIE BOLTS

CENTER PIN
CHEEK WEIGHT
WIRE ROPE CAPACITY & WEIGHT
SHEAVES MARKINGS

HOOK NUT LOWER TIE BOLTS

THRUST BEARING
CHEEK WEIGHT BOLT
HOOK HOUSING

TRUNNION PIN
HOOK LATCH

HOOK

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 59

 Sheave Inspection
Groove Conditions

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 60

 Sheave Inspection
Sheave Guard
Properly Matched Rope

Groove Damage

Flange Taper
Cracks, Deformation, Defects

Alignment Bearing / Bushing Play

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 61

 WIRE ROPE • Basic Components

wire

core
wire rope
strand
center wire

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 1 62
 Reduction in Diameter

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 1 63
 WIRE ROPE
Lays

Regular Lay

In regular lay ropes, wires appear to run parallel

to the axis of the rope. It has good resistance to
kinging, crushing and distortion.

Lang Lay

Wires in lang lay ropes are laid in the same

direction as the strands. Outside wires
provide good resistance to abrasion.

Alternate Lay

Regular lay and lang lay strands are alternately

laid around the core.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 8 64
 WIRE ROPE • Classification
6 X 19 Classification

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 2 65
 WIRE ROPE • Grades

• Extra Extra Improved Plow Steel (EEIPS)

10% Strength Increase over (EIPS)

• Extra Improved Plow Steel (EIPS)

15 % Strength Increase over (IPS)

• Improved Plow Steel (IPS)

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 5 66
 WIRE ROPE • Cores
Basic Cores

Fiber Core (FC)

Independent Wire Rope

Core (IWRC)

Wire Strand Core (WSC)

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 6 67
 WIRE ROPE • Lays

Right Left
Lay Lay

Lay Length

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. RB p. 7 68

 WIRE ROPE • Lay

Rotation Resistant Ropes

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 10 69
 WIRE ROPE • Special Ropes

Compacted Strand Wire Rope

Flattened Strand Wire Rope

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p.10 70
 WIRE ROPE • Measurement

Right Wrong
Across Crowns Across Flat Areas

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 16 71
 WIRE ROPE • Seizing and Cutting

Preformed Ropes

Non-Preformed or Rotation Resistant

Ropes

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 11 72
 WIRE ROPE • Anchorage Point

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 12 73
 WIRE ROPE • Winding onto Drum

Always reel from top to top Never reel from top to bottom
or from bottom to bottom. or from bottom to top.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 12 74
 WIRE ROPE • Clips
live line

dead end
Right way: saddle on live end

Wrong way: clips staggered

Wrong way: clips reversed

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 20 75
 WIRE ROPE • Wedge Sockets
Right Wrong Tail Length
Minimum 6 rope
diameters not less
dead than 6 inches
end
live
end

Core
Slippage

Rotation Resistant Ropes

Minimum 20 rope diameters

not less than 6 inches
Rev. 07-31-02 © 2002 Crane Institute of America, Inc.
RB p. 25 & 26 76
 WIRE ROPE • End Attachments
Wedge Sockets
Wrong Right
extra piece loop back extended
of rope method wedge
method method

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p 27 77
 HARDWARE • Hooks • Application

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 95 78
 HARDWARE • Hooks • Inspection
Hooks must be inspected by a competent person and removed
from service when any of the following conditions exist:

• Cracks, nicks or gouges.

• Twist exceeding 10° from plane of unbent hook.
• Latch engagement, damage or malfunction.
• Throat opening exceeding 15%.
• Wear exceeding 10% of original dimension.
• Damage from heat.
• Unauthorized repairs.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 97 79
 HARDWARE • Shackles

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 98 80
 Hardware - Shackles - Application

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. RB p. 99 81

 Hardware - Shackles - Application

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. RB p.100 82

 Hardware - Shackles - Application

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p 102 83
 Hardware • Shackles • Inspection
 Absence of capacity
or identifying marks

 Bent or distorted pin

and/or body
wear

 Nicks, gouges or cracks pin

distortion

 Heat or chemical damage

 Body spread

 Reduction in diameter spread

of pin and/or body
shoulder
flush

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. RB p 103 84

 HARDWARE • Eyebolts • Types
Shouldered Shouldered Non-Shouldered
with Nut Machinery with Nut

Non-
shouldered eye
bolts are only
designed for
vertical loads.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p 105 85
 HARDWARE • Eyebolts • Installation

For angular loading, shouldered eye bolts must

always be positioned to take the load in the plane
of the eye.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p 106 86
 HARDWARE • Eyebolts • Application

It is recommended that
shouldered type eye
bolts not be used at 30°
and below

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. RB p110 87

 HARDWARE • Hoist Rings
Application

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. RB p 115 88

 Procedures - Determining Load Weight

cylinder
weight

+ = estimated
weight

block
weight

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p 131 89
 PROCEDURES • Center of Gravity

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p 137 90
 PROCEDURES • Handling Loads
Softeners

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p 138 91
 PROCEDURES • Handling of Loads
• Lifting Beams

Rigid Beam
Fixed lift
points

Spreader Beam

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. RB p 145 92

 PROCEDURES • Handling of Loads
Tag Lines

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p 147 93
 Slings • Hitches
The method in which a sling is rigged or
attached to a load is referred to as a hitch.

Basic Hitches
Vertical Vertical Choker
Basket

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 39 94
 SLINGS • Hitches
Double Wrap Basket Hitch

A double wrap hitch compresses

the load which makes it excellent
for lifting loose materials.

When wrapping the

sling around the load, make sure
that the sling is not wrapped over itself.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 44 95
 SLINGS • Sling Angles

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 49 96
 SLINGS • Calculating Sling Loading

Steps:
1. Determine sling angles. (45°)
2. Go to 2-leg bridle capacity column at 45°
3. Select 2-leg bridle with capacity equal to or greater
than load to be lifted. (½ inch rope diameter at 3.6 tons)

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 50 97
 SLINGS • Calculating Sling Loading

Steps:
1. Determine sling angles. (45°)
2. Select corresponding
Load Angle Factor. (1.414)
3. Multiply load weight by
Load Angle Factor to get
total load on sling legs.
(2000 lbs x 1.414 = 2828)

4. Divide total load by the

number of sling legs.
(2828 lbs ÷ 2 = 1414 lbs per sling leg)

5. Select slings from the single vertical leg column

within the sling capacity table.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 51 98
 SLINGS • Calculating Sling Loading

Steps:
1. Divide length by height to get Load Angle Factor.
( 6 ft ÷ 4 ft = 1.5)

2. Multiply Load Angle Factor by load weight to get

total load on sling legs.
( 1.5 x 2000 lbs = 3000 lbs)

3. Divide total load by number of sling legs to get

load on each sling leg.
( 3000 lbs ÷ 2 = 1500 lbs per sling leg)

4. Select slings from the single vertical leg column

within the sling capacity table.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc.

RB p. 52 99
 Fleet Angle
Fixed Sheave

Floating Sheave

1/2°Min 1/2°Min

11/2°Max 11/2°Max

Left Right
Fleet Fleet
Angle Angle

Smooth Face Drum

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 100
 Load Test Verify

 Structural Integrity

 Stability

 Line Pull Capacity

 Boom Lift Capacity

 Control Functions

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 101

 Load Test

1. Rated load test

100% of gross capacity

2. Proof test

100% of gross capacity

3. Static test

Hoisting only

4. Dynamic test

Full range of motion

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 102

 Load Test Director Responsibility

1. Inspect crane

2. Correct all deficiencies

3. Select test site

4. Develop rigging & lift plan

5. Select test weights

6. Rig test weights

7. Mark maximum radius

8. Direct operator in load test

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 103

 Capacity Limited by Strength or Stability

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 104

 Net Load vs Gross Load

Gross Load =
Load weight
plus attachments,
lifting devices,
hooks, wire rope,
and rigging.

Net Load:
Actual weight of
item being lifted.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 105

 Boom Angle

Boom Deflection

Boom Angle

The boom angle will lower

when the load is lifted
because of boom deflection.

Tire deflection

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 106

 Load Radius

Boom deflection
will result in a
larger radius.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 107

 Finding Net Capacity

The greater dollar

amount on a
pay check is
gross pay.

The lesser dollar

amount on a pay
check is
net pay.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 108

 When to Calculate Weight
of Crane’s Hoist Rope
 When manufacturer specifies in the load chart that hoist rope be
deducted.
 When crane is reeved with more than the minimum parts of line
required to lift the load.
 When crane is reeved with hoist line not being used to make the lift.
 When there are parts of line below ground level.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 109

 Total Load

Total Load equals

Static load plus
dynamic load.

Due to the forces that can

be caused by movement,
always operate in a smooth
and controlled manner.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 110

 Determining Parts of Line, Weight of Line
and Sizing the Hook Block
Count the number of lines between the
boom point and the block.

Weight of Hook Block (or Ball)

+ Weight of Rigging
(Slings, Hardware and Lifting Devices)

+ Load Weight

= Suspended Weight

Suspended Weight
Safe Working Load of Hoist Rope

Minimum Parts of Line Required

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 111
 Load Charts
Notes for Lifting Capacities

GENERAL

1. Rated loads as shown on lift chart pertain to this machine as

originally manufactured and equipped. Modifications to the
machine or use of optional equipment other than that specified
can result in a reduction of capacity.
2. Construction equipment can be hazardous if improperly
operated or maintained. Operation and maintenance of this
machine shall be in compliance with the information in the
operator’s, parts, and safety manuals supplied with this
machine. If these manuals are missing, order replacements from
the manufacturer through the distributor.
3. The operator and other personnel associated with this
machine shall fully acquaint themselves with the latest
applicable American National Standards Institute (ANSI) Safety
Standards for cranes.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 112

 Load Charts
Notes for Lifting Capacities

SETUP

1. The machine shall be leveled on a firm supporting surface.

Depending on the nature of the supporting surface, it may be
necessary to have structural supports under the outrigger floats
or tires to spread the load to a larger bearing surface.
2. For outrigger operation, outriggers shall be fully extended with
tires raised free of crane weight before operating the boom or
lifting loads.
3. If the machine is equipped with front jack cylinder, the front
jack cylinder shall be set in accordance with written procedure.
4. If the machine is equipped with extendable counterweight, the
counterweight shall be fully extended before operation.
5. Tires shall be inflated to the recommended pressure before
lifting on rubber.
6. With certain boom and hoist tackle combinations, maximum
capacities may not be obtainable with standard cable lengths.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 113

 Load Charts
Notes for Lifting Capacities
DEFINITIONS

1. Operating Radius: The horizontal distance from a projection of the

axis of rotation to the supporting surface before loading to the center of
the vertical hoist line or tackle with load applied.

2. Loaded Boom Angle (shown in parentheses on Main Boom

Capacity chart): The angle between the boom base section and the
horizontal, after lifting the rated load at the rated radius.

3. Working Area: Areas measured in a circular arc about the center

line of rotation, as shown on the working area diagram.

4. Freely Suspended Load: Load hanging free with no direct external

force applied except by the lift cable.

5. Side Load: Horizontal force applied to the lifted load either on the
ground or in the air.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 114

 On Outriggers Fully Extended - 360°

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 115

 Grove RT865 65 Ton Capacity
36 ft. - 146 ft. Boom (Power Pinned Fly) PCSA Class 10-312 85% of Tipping
ON OUTRIGGERS FULLY EXTENDED — OVER THE FRONT

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 116

 On Rubber Capacities

NOTES FOR RUBBER CAPACITIES

1. Capacities are in pounds and do not exceed 85% of tipping loads as determined by test in accordance with SAE J -765.
2. Capacities are applicable to machines with Cold Inflation 2.5 MPH 29.5 x 25 (28 ply) 75 PSI 65 PSI 33.25 x 29 (26ply) 65
PSI 50 PSI
3. Defined Arc - Over front includes +/-6° on either side of longitudinal centerline of machine. (Ref. drawing C6 -829-003529.)
4. Capacities are applicable only with machine on firm level surface.
5. Axle lockouts must be functioning before lifting on rubber. (Check automatic lockout system for proper functioning: refer to
"Operation and Maintenance Manual" for description of a proper functioning axle lockout system.)
6. All rubber lifting depends on proper tire inflation, capacity and condition. Capacities must be reduced for lower tire inf lation
pressures. See lifting capacity chart for tire used. Damaged tires are hazardous to safe operation of crane.
7. For pick and carry operation, boom must be centered over front of machine, mechanical swing lock engaged, and load
restrained from swinging. When handling loads in the structural range with capacities close to maximum ratings, travel should
be reduced to creep speeds.
8. On rubber lifting with power pinned fly extended, boom extension or jib is not permitted.
9. Creep - not over 200 feet (61 meters) of
Rev. 07-31-02 ©movement
2002 Crane in any 30 - minute
Institute period, and
of America, not exceeding 1 mph (1.6kph).
Inc. 117
 Jib Capacities In Pounds
28ft. “A” Frame Jib On Outriggers - 360°

NOTES FOR JIB CAPACITIES

1. All capacities are in pounds. Capacities are based on structural strength of 28 ft. and 32 ft. boom extension
combination at given main boom angle regardless of main boom length. Note: Two part lifting service is required
with Krueger LMI; at any other time, single or two part line may be used.
2. WARNING: Operation of machine with heavier loads than the capacities listed is strictly prohibited. Machine
tipping with jib occurs rapidly and without advance warning.
3. 28 FT. JIB WARNING: For main boom length with power pinned fly extended greater than 82 ft. with 32 ft. boom
extension and 28 ft. jib in working position, the boom angle must not be less than 40° since loss of stability will
occur causing a tipping condition. The boom angle is not restricted for main boom length with power pinned fly
extended equal to or less than 82 ft. This warning applies for jib erection purposes also.
4. WARNING: Lifting on rubber with 32 ft. boom extension or 28 ft. jib and 32 ft. boom extension combination is
prohibited.
5. Reference radii listed are for fully extended main boom only.
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 118
 Weight Reductions For Load Handling Devices

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 119

 Lifting Area Diagrams
Example Only: Not to be used as an actual load chart.

Rear axle oscillation lockouts Note: Bold lines determine the

must be set to maintain 360
capacities.
Note: Bold lines determine the
limiting position of any load for
operation within any working
areas indicated.
limiting position of any load for
operation within working areas
indicated.
Note: Over the side capacities
can be lifted in the over the rear
area.

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 120

 Range Diagram

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 121

 Grove Load Test Exercises

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 122

 Hoisting From Main Boom

37,300

41,030

1,063

1,900
100

37,967
3

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 123

 Hoisting From Main Boom
34,050

37,455

15
3,584
300

1,900
90

31,566
3

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 124

 Hoisting From Main Boom

14,500

15,950

580
75

15,295
2

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 125

 Hoisting From Jib

6,520

7,172
300
60

6,812
1
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 126
 Manitowoc Load Test Exercises
Crawler Crane

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 127

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 Hoisting From Main Boom

54,000

59,400

1,498

4,740

400

52,762
2

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 136

 Hoisting From Main Boom

108,000

118,800

3,600
94
900
1,685

4,740
400
107,381
4

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 137

 Hoisting From Jib

26,100

28,710

375

1,217

4,740

900
275

21,203
1

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 138

 Hoisting From Jib

40,000

44,000

796

188

4,470

1,200
150

36,926
2

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 139

 National _________ Load Test Exercises

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 140

 National 562C
with 24 ft. Jib

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 141

 National 562C
with 24 ft. Jib

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 142

 National Capacity Chart
Old Style Example

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 143

 National Capacity Chart
Old Style Example

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 144

 Hoisting From Main Boom

Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 145

 Inspection Process

 Condition Inspection -
inspect and report

 Certification Inspection -
inspect, report and verify

 Follow Checklist -
management summary report

 Form of Report -
What - State Problem
Why - Reference to problem
How - Corrective action
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