Professional Documents
Culture Documents
1
About Crane Institute of America
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
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
SAFETY
The act or process designed to eliminate risk
or danger from an environment.
Remember,
learning has not
taken place
until behavior
has changed.
UNDERSTANDING,
INTERPRETING
and
APPLYING
STANDARDS & REGULATIONS.
Accident Prevention
Limit Liability Exposure
OSHA Citation
Civil Penalties
Criminal Charges
Wrong Assumptions
Takes little skill to operate.
PHYSICAL
Wrong Actions
Allows unqualified personnel
to operate cranes.
ACCIDENTS
Rigging
Load
15%
Handling Electrocution
14%
44%
Operator Error 7%
Overload 7%
Dismantling Boom 5%
CRANE
RELATED
20%
Support Failure
Machinery &
Structural Failure 31.5%
11.2%
Failure to Use
Outriggers Operator Error
22.6% 33.1%
STRUCTURAL
(Breaking)
STABILITY
(Tipping)
Components That
Can Fail
Definition of a standard:
6. California OSHA
History:
Purpose:
History:
Purpose:
Carrydeck Crane
(Rotating Boom)
Carrydeck Crane
(Fixed Boom)
Swing Cab
Fixed Cab
All-Terrain Crane
Carrier
Mounted Crawler
Mounted
Rear-Mounted Turret
Extension Erected
Telescoping Boom
Crane With Luffing Jib
__
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
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
__
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
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
Visual Audible
(Seeing) (Hearing)
Olfactory
(Smelling) Test
Tactile
(Touching)
Measurement
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.
Swivel
Hook Latch
Hook
TRUNNION PIN
HOOK LATCH
HOOK
Groove Damage
Flange Taper
Cracks, Deformation, Defects
wire
core
wire rope
strand
center wire
Regular Lay
Lang Lay
Alternate Lay
Right Left
Lay Lay
Lay Length
Right Wrong
Across Crowns Across Flat Areas
Preformed Ropes
Always reel from top to top Never reel from top to bottom
or from bottom to bottom. or from bottom to top.
dead end
Right way: saddle on live end
Core
Slippage
Body spread
Non-
shouldered eye
bolts are only
designed for
vertical loads.
It is recommended that
shouldered type eye
bolts not be used at 30°
and below
cylinder
weight
+ = estimated
weight
block
weight
Rigid Beam
Fixed lift
points
Spreader Beam
Basic Hitches
Vertical Vertical Choker
Basket
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)
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)
Steps:
1. Divide length by height to get Load Angle Factor.
( 6 ft ÷ 4 ft = 1.5)
Floating Sheave
1/2°Min 1/2°Min
11/2°Max 11/2°Max
Left Right
Fleet Fleet
Angle Angle
Structural Integrity
Stability
Control Functions
2. Proof test
3. Static test
Hoisting only
4. Dynamic test
1. Inspect crane
Gross Load =
Load weight
plus attachments,
lifting devices,
hooks, wire rope,
and rigging.
Net Load:
Actual weight of
item being lifted.
Boom Deflection
Boom Angle
Tire deflection
Boom deflection
will result in a
larger radius.
+ Weight of Rigging
(Slings, Hardware and Lifting Devices)
+ Load Weight
= Suspended Weight
Suspended Weight
Safe Working Load of Hoist Rope
GENERAL
SETUP
5. Side Load: Horizontal force applied to the lifted load either on the
ground or in the air.
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
37,300
41,030
1,063
1,900
100
37,967
3
37,455
15
3,584
300
1,900
90
31,566
3
14,500
15,950
580
75
15,295
2
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
54,000
59,400
1,498
4,740
400
52,762
2
108,000
118,800
3,600
94
900
1,685
4,740
400
107,381
4
26,100
28,710
375
1,217
4,740
900
275
21,203
1
40,000
44,000
796
188
4,470
1,200
150
36,926
2
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
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 146
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 147
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 148
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 149
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 150
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 151
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 152
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 153
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 154
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 155
Rev. 07-31-02 © 2002 Crane Institute of America, Inc. 156