Mobile Crane Inspector Training Program Guide

INTRODUCTION
Mobile Crane
Inspector Training
_______________________________________
Student Name
_______________________________________
Program Instructor
_______________________________________
Program Date(s)

MOBILE CRANE INSPECTOR TRAINING
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© 2001 - NorAm Productions, Inc.
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INTRODUCTION
Table of Contents
©Copyright 2001 - NorAm Productions, Inc. All rights reserved. Page iii
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 XI
29 CFR 1910.180 with 1926.550 Inserts .......................................................XI - 1
Section XII
Sample Forms ............................................................................................... XII - 1

SECTION I
The Need For Inspection
Mobile Crane Inspector Training

THE NEED FOR INSPECTION
©Copyright 2001 - NorAm Productions, Inc. All rights reserved. Section I - Page 1
The effort put forth in properly inspecting your equipment is greatly rewarded.
Thorough inspections by trained and qualified inspectors will do the following for
your company:
• Save your company money and time due to unscheduled downtime and
maintenance costs
• Ensure product warranty standards by meeting manufacturer maintenance
and inspection requirements
• Ensure the equipment meets customer requirements (contracts)
• Limit liability issues, including civil, criminal, and workers compensation
Cranes lift very large weights over large areas. Consequently, it is the “largest risk”
piece of equipment at a site. Equipment safety and reliability cannot be ensured
unless it receives regular inspections. They provide the only means of detecting
potential hazards that could contribute to accidents, forewarn of any necessary
maintenance, and ensure compliance with OSHA Standards. Lack of maintenance
can mean serious deterioration of the equipment and expensive replacement or
repair charges.
The equipment owner or supplier has the responsibility to ensure that all cranes
are given thorough inspections according to manufacturer’s recommendations. These
inspections should only be performed by QUALIFIED PERSONS who are able to
detect and assess defects and potential hazards that could limit the safe performance
of the crane’s functions.
Due to the wide variations of conditions under which identical machines 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 operating intervals for average conditions.
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.

Section I - Page 2 ©Copyright 2001 - NorAm Productions, Inc. All rights reserved.
What Inspection Intervals Must Be Maintained?
Frequent Inspections
Components that have a direct bearing on the safety of the crane, and whose status
can change from day-to-day with use, must be inspected on a daily basis, and when
possible, observed during operation for any defects which could affect the safe
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 and manufactured with a given safety factor, every machine
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 will occur unless all parts subject to wear or failure are regularly inspected
and repaired or replaced.
Periodic Inspections
The periodic inspection procedure is intended to determine the need for repair or
replacement of parts as required to keep the machine in approximately new condition.
It includes those items listed in 29 CFR 1910.180 and 1926.550 for frequent inspections
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 at frequent
intervals, both the load block and boom must be given a more detailed inspection
on an annual basis (We recommend this inspection be performed by an 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 operation 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 visual inspection should be made of the boom, jib, load line, and all other
structural items that could have been damaged, after every instance of severe
snapping, whipping or jerking of the boom. Inspect the boom bottom plate for any
signs of buckling. Also inspect the corner and the boom head welds for cracks.

©Copyright 2001 - NorAm Productions, Inc. All rights reserved. Section I - Page 3
NOTES:
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Section I - Page 4 ©Copyright 2001 - NorAm Productions, Inc. All rights reserved.
Section I - Survey and Review
1. T F The investment made inspecting a mobile crane may reduce a
companies liability.
2. T F Regular inspections can help forewarn of necessary maintenance.
3. Mobile crane inspections should be performed only by ____________ persons.
4. When the cranes' boom has been struck by or against an object, a
_______________ inspection should be performed.
5. Periodic inspections include those items inspected in a _________ inspection.

SECTION II
How to Read & Apply OSHA & ASME Standards

HOW TO READ & APPLY OSHA & ASME STANDARDS
©Copyright 2001 - NorAm Productions, Inc. All rights reserved. Section II - Page 1
Before we can begin to perform inspections, we must first know where to find the
requirements for inspections and we must be able to properly apply those
requirements.
The requirements for inspections may be derived from many sources, including but
not limited to Federal or “Compliance” standards, Consensus or “Industry”
standards, as well as maintenance and operator manuals supplied by the crane
manufacturer.
Since inspection requirements found in maintenance and operator 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 legislative branch) does not have the authority to
create law. They have, however, been given the authority to “promulgate standards”.
For purposes of this section, we will 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 place of
employment that are free from recognized hazards to their employees. This
requirement, is commonly referred to as the employer’s “Section 5-(a) (1)” or “General
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 addition to the employer’s general duty clause responsibility, they are also
required to comply with those specific standards promulgated under the Act. It is
extremely important to remember when applying the OSHA standards, they
establish only the MINIMUM requirements that are acceptable to OSHA for
workplace 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:

Section II - Page 2 ©Copyright 2001 - NorAm Productions, Inc. All rights reserved.
Table 1

Table 1 (Cont.)

Table 2 shows the items that need to be examined for the Grove Rough Terrain 45 Ton
Hydraulic Crane and their corresponding applicable OSHA1926 andANSI B30.5 Standards.
Table 2
STANDARD INSPECTION ITEMS ANSI
(1926.550) B30.5
O utriggers
1. Lubrication
2. Structural Condition 5-2.1.3
3. Pressure hoses/connections 5-2.1.2
Turntable/Crane Body
1. Ensure Level/Stability
2. W ear/G ear/Teeth/Rollers
3. Cracks
4. Bolts/Ensure Securely Attached
Counter W eight
1. Proper Size
2. Attachm ent Connection/Bolts 5-3.4.2
Engine Housing
1. Cleanliness/No Rags/Trash
2. G ear/M achinery G uards 5-1.9.6
550(a)(13)(ii)&(iii) 3. Clear Access/W alkways 5-1.8.2 & 3
5. Hand Signal Illustration 5-3.3.2 (Fig.16)
6. Swing Break 5-1.4.2
Cab
1. G lass/Visibility
2. Instrum ents and Controls 5-1.6.2
3. Functioning Horn (warning signal)
4. Fire Extinguisher
550(a)(2) 5. Appropriate Load Charts and Warning Signs 5-1.1.3
& 5-1.9.9
550(a)(13)(ii)& 5-1.8.2 & 3
550(a)(13)(iii)
Drum
1. Proper Size and Spoiling of Hoistlines 5-1.3.1 & 2
2. Drum Sides/Shields for cracks
3. Dogs/Pawls/Locking Devices
4. Drum Rotation vs. Control M otion
Boom Sections
(Boom sections correspond with crane m odel)
1. 5-2.1.3
5-2.1.3
550(a)(8)
550(a)(8)
4. Brakes/Clutch Adjustments 5-1.9.7
550(a)12 5-1.8.1
550(a)(14)(i)(5BC) 5-3.4.9 (10BC)
6. Proper and Adequate Access (steps/walkway)
2.
3. Boom Stops
4.
5. Hoist Line Guides/Sheaves
6.
7.
ROUGH TERRAIN 45 TON HYDRAULIC CRANE

Table 2 (Cont.)
(1926.550) B30.5
Sheave System
1. Ensure hoist line and sheave size match 5-1.7.4
2. Worn
3. Lubrication/M ove freely
Load/Auxilary Hook and Block System
1. Sheaves Function Sm oothly 5-1.7.6
2. Hook Rotates Freely/Lubricated
3. Proper Becket
4. Properly R eeved
W ire Rope/H oist Line
1. Overall Condition
550 (a)(7)(v) 2. End Connections 5-1.7.3
-------- 3. Lubrication
------- 4. Clips
Safety Devices
550(a)(7)
--------- 1. Anti-Tw o Block Devices
--------- 2. Boom Backstop D evices 5-1.9.1
550(a)(9) 3. Sw ing R adius Warning Devices
550(a)(15) 4. Job or Site Specific Devices/system (Fig. 17)
(near electric power/personnel hoisting
platforms)
Additional references:
550(a)(1) ---- Crane used in accordance with manufactures specification.
550(a)(5) ---- Inspection: Com petent Person.
550(a)(6) ---- Annual Inspection Record.
550(a)(16)--- No m odifications without written approval of manufacturer

Table 3 shows the items that need to be examined for the Manitowoc 4100 150 Ton
Lattice Boom Crawler Crane and their corresponding applicable OSHA 1926 and
ANSI B30.5 Standards.
Table 3
(1926.550) B30.5
Track Craw ler S ystem
1. Lubrication
2. C onnection Bolts 5-2.1.3
3. D rive C hain (slack & w ear) 5-2.1.2
Turntable/C rane Body (U pper W orks)
1. Assure level/Stability 5-2.1.3
2. W ear/G ear/Teeth/Rollers
3. C racks
4. Bolts/Pins A ssure Securely Attached
C ounterw eight
1. Proper S ize 5-3.4.2
2. Attachm ent C onnection/B olts
E ngine H ousing
550 (a) (8) 1. C leanliness/No R ags/Trash
550 (a) (8) 2. G ear/M achinery G uards 5-1.9.6
550 (a) (13) (ii) & (iii) 3. C lear Access/W alkw ays 5-1.8.2 & 3
4. B rakes/C lutch Adjustm ents 5-1.9.7
5. H and S ignal Illustration 5-3.3.2 (Fig.16)
6. Sw ing Break 5-1.4.2
C ab
550(a) (12) 1. Glass/Visibility 5-1.8.1
2. Instrum ents and C ontrols 5-1.6.2
3. Functioning H orn (w arning signal)
550 (a) (14) (I)(5BC ) 4. Fire Extinguisher 5-3.4.9(10BC )
550 (a) (2) 5. Appropriate Load C harts and W arning D evices 5-1.1.3&5-1.9.9
6. Proper and Adequate Access (steps/w alkw ay) 5-1.8.2 & 3
H oist Drum S ystem 5-1.3.1&82
1. Proper S ize and Spoiling of H oistlines 5-1.3.1 & 2
2. D rum Sides/S hields for Cracks
3. D ogs/Paw ls/Locking D evices
4. D rum Rotation vs. C ontrol M otion
5. C lutch and Brakes
B oom Sections
(Boom sections correspond w ith crane m odel)
-------- 1. B ase Section P roperly Attached 5-2.1.3
-------- 2. P in C learance
-------- 3. B oom Lacing/C ord D am age
-------- 4. B oom Stops
-------- 5. G antry System A -Fram e
-------- 6. H oist Line G uides/Sheaves
-------- 7. Boom Section C onnection Pins/Keys
8. Boom and Gantry S upport System
9. Jib A ttachm ent/B ackstops/B elly Slings
550 (a) (13) (ii)&
550 (a) (13) (iii)
550 (b)(1)
150 TON LATTICE BOOM CRAWLER CRANE

Table 3 (Cont.)
(1926.550) B30.5
Additional references:
550(a)(1) ---- Crane used in accordance with m anufactures specification.
550(a)(5) ---- Inspection: Com petent Person.
550(a)(6) ---- Annual Inspection Record.
550(a)(16)--- No modifications without w ritten approval from m anufacturers.
Sheave System
1. Ensure Hoistline and Sheave Size M atch 5-1.7.4
2. Worn
3. Lubrication/Move freely
Load/Auxiliary Hook and Block System
1. Sheaves Function Sm oothly 5-1.7.6
2. Hook Rotates Freely/Lubricated
3. Proper Becket
4. Properly Reeved
W ire Rope/Hoist Line
550 (a) (7) 1. Overall Condition
550 (a) (7) (v) 2. End Connections 5-1.7.3
3. Lubrication
4. Clips
Safety Devices
1. Anti-Two Block Devices
2. Boom Backstop Devices 5-1.9.1
550 (a) (9) 3. Swing Radius Warning Devices
550 (a) (15) 4. Job or Site Specific Devices/System s/ (Fig. 17)
Program for work near electric
power and use of personnel hoisting platforms)
150 TON LATTICE BOOM CRAWLER CRANE

The best way to illustrate how the OSHA standards are cited is for us to look at an
example of how a typical violation, which might be discovered during an 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 “Title” and is a designation for the U.S. Department of
Labor. Since OSHA is an agency within the U.S. Department of Labor, their standards
are promulgated under “Title 29”. Although other Titles exist, such as “Title 30” for
“Mineral Resources,” we will concern ourselves here only with “Title 29”.
“CFR” refers to the “Code of Federal Regulations”. This is a compilation 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 parts exist, such as “Part 1917” for “Marine Terminals”, 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 number for the subject. The title of section number .180 is “Crawler
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, italics and parenthesis ( ) in outline format, to
lead us to the topic, subtopic and requirement for the item. In our example, (d)
leads us to the topic “Inspection classification”, (3) leads us to the subtopic “Frequent
inspection”, and (i) leads us to the requirement which states “All control mechanisms
for maladjustment interfering with proper operation: Daily.”

ASME Standards (sometimes referred to as ANSI Standards)
ASME is the acronym used for the “American Society of Mechanical Engineers”.
ASME committees develop standards in meetings by reaching consensus (agreement).
Hence, the name “Consensus” standard is often used to describe the various
standards developed by ASME. The procedures ASME operates under are accredited
by ANSI, which is the acronym used for the “American National Standards Institute”.
ANSI publishes these standards to serve as a guide to government and other
regulatory bodies and municipal authorities responsible for the guarding and
inspection of the equipment falling within its’ scope. The intent 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 way we will consider is in the area of compliance with the OSHA Standards.
As we discussed earlier, employers are required to comply with both “Section 5 (a)
(1)” of the Act, as well as any “specific standards” promulgated under the act. OSHA
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 CFR 1910.180 as well as 29 CFR 1926.550. The ASME Standard B30.5 – 1968, is
incorporated into both of these OSHA standards, either in whole or in part, and
affects cranes constructed and utilized on or after August 31, 1971. This means that
a failure to comply with the mandatory (shall) language found in any portion of the
B30.5 incorporated by reference, is a failure to comply with the specific OSHA
standard in which the mandatory (shall) language was incorporated.
An example of this violation on a mobile crane built in say 1995, and used in General
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.”
29 CFR 1910.180 (b) (2)
29 CFR 1910.180 (b) (2) incorporates by reference the design specifications of B30.5
– 1968. No specific requirement for a jib to have identification on it is found in 29
CFR 1910.180. However, Section 5-1.9.1 (d) of ANSI/ASME B30.5 – 1968 states: “Booms,
boom sections, and jibs shall be clearly identified and shall be used only for the
purposes recommended by the manufacturer.” The word “shall” is mandatory.
Therefore a failure to maintain an identifier on the jib is a violation, though most
likely De Minimis, of this standard.

Next, let’s consider how ASME B30.22, for Articulating Boom Cranes, might be used
in an example of a section 5 (a) (1) citation.
“The engine exhaust stack installed on an Articulating Boom Crane built in, say,
1995 and used in General Industry is not guarded properly.”
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 “General Duty” responsibility. To provide evidence that the hazard exists
and is recognizable, making it a violation, OSHA may make use of the ASME B30.22
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 about ANSI/ASME standards, that their intent was to enhance safety.
Neither ANSI or ASME have the authority to conduct workplace inspections, issue
citations, or levy fines against an employer. The committees that develop the ASME
standards such as B30.5 or B30.22, are made up of experts in the industry, recognizing
hazards within the industry, and providing ways to mitigate those hazards.
Finally, beyond the compliance and safety 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 attorney should be consulted. If, however, a person is injured
or killed because as the owner/operator of the crane, I did not take every reasonable
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.

Additional Regulations and Standards
In 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, if they will be responsible for the inspection of slings and rigging
equipment. Inspectors should also be knowledgeable of the ASME standards that
may be applicable to their mobile crane operations. These ASME standards will
often contain additional inspection, safety and design guidelines that inspectors
should follow. Some of these ASME standards include:
• ASME B30.5 – Mobile and Locomotive Cranes
• ASME B30.9 – Slings
• ASME B30.10 – Hooks
• ASME B30.20 – Below-the-Hook Lifting Devices
• ASME B30.22 – Articulating Boom Cranes
• ASME B56.7 – Industrial Crane Trucks
OSHA § 1903.1 - PURPOSE AND SCOPE
The Williams-Steiger Occupational Safety and Health Act of 1970 (84 Stat. 1590 et
seq., 29 U.S.C. 651 et seq.) requires, in part, that every employer covered under the
Act furnish to his employees employment and a place of employment which are 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
occupational safety and health standards promulgated under the Act, and that
employees comply with standards, rules, regulations and orders issued under the
Act which are applicable to their own actions and conduct. The Act authorizes the
Department of Labor to conduct inspections, and to issue citations 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
Health Review Commission, if contested by an employer or by an employee or
authorized representative of employees, and for judicial review. The purpose of
this Part 1903 is to prescribe rules and to set forth general 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 where
the Secretary or his designee determines that an alternative course of action would
better serve the objectives of the Act.

OSHA § 1910.6 - INCORPORATION BY REFERENCE
(a) The standards of agencies of the U.S. Government, and organizations which are
not agencies of the U.S. Government which are incorporated by reference in this
part, have the same force and effect as other standards in this part. Only the
mandatory provisions (i.e., provisions containing the word “shall” or other
mandatory language) of standards incorporated by reference are adopted as
standards under the Occupational Safety and Health Act.
(b) Copies of the standards which are incorporated by reference may be examined
at the national office of the Occupational Safety and Health Administration,
U.S. Department of Labor, Washington, DC 20210, or at any of its regional offices.
Copies of such private standards may be obtained from the issuing organizations.
Their names and addresses are listed in the pertinent subparts of this part.
(c) Any changes in the standards 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 Safety and Health Administration, U.S. Department of Labor,
Washington, DC 20210.

Material Approved for Incorporation by Reference
(Revised as of July 1, 1991)
TheDirectoroftheFederalRegisterhasapprovedunder5U.S.C.552(a)and1CFRPart51,theincorporationbyreferenceofthefollowingpublications.
Part 1910 (General Industry)
American National Standards Institute
ANSI A14.3-56 Safety Code for Fixed Ladders 1910.179
ANSI A90.1-69 Safety Standard for Manlifts 1910.68
ANSI A92.2-69 Standard for Vehicle-Mounted Elevating and Rotating 1910.67
Work Platforms
ANSI B30.2-67 Safety Code for Overhead and Gantry Cranes 1910.179
ANSI B30.5-68 Safety Code for Crawler, Locomotive and Truck Cranes 1910.180
American Society for Testing and Materials
ASTM A391-65 Alloy Steel Chain (ANSI G61.1-1968) 1910.184
American Welding Society
AWS A3.0 (1969) Terms and Definitions 1910.251
Crane Manufacturer's Association of America, Inc.
CMAA Spec. #61 Specification for Electric Overhead Traveling Cranes 1910.179
Society of Automotive Engineers
SAE 765 (1961) SAE Recommended Practice: Crane Loading Stability 1910.180
Test Code
Part 1926 (Construction Standards)
American National Standards Institute
ANSI A10.5-69 Safety Requirements for Workman's Hoists 1926.552
ANSI B30.2.0-67 Safety Code for Overhead and Gantry Cranes 1926.550
(Partial Rev. of B30.2-43)
ANSI B30.5-68 Safety Code for Crawler, Locomotive and Truck Cranes 1926.550
ANSI B30.6-69 Safety Code for Derricks (Partial Rev. of B30.2-43) 1926.550
ANSI B56.1-69 Safety Standards for Powered Indus. (ISO R1074) 1926.602
Power Crane and Shovel Association
Std. No. 1 - 1968 1968 Mobile Crane and Excavator Standards 1926.602
Std. No. 2 - 1968 1968 Mobile Hydraulic Crane Standards 1926.550,
1926.602
Society of Automotive Engineers
SAE J959 - 1966 Lifting Crane Wire Rope Strength Factors 1926.550

OSHA § 1903.13 - IMMINENT DANGER
Whenever 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 employment
which could reasonably be expected to cause death or serious physical harm
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 restrain such conditions or practices and for other appropriate relief in accordance
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 initiates
steps to abate such danger.

Section II - Survey and Review
1. T F The Williams-Steiger Occupational Safety and Health Act was
enacted in 1973.
2. T F General Industry Standards are found in part 1926 of the Act.
3. Mobile crane regulations can be found in section ____________ of part 1910.
4. ASME standards are sometimes referred to as "industry" or
"_______________" standards.
5. ASME B30 _________ covers the inspection and design criteria of cab glass.

SECTION III
The Mobile Crane Inspector

THE MOBILE CRANE INSPECTOR
©Copyright 2001 - NorAm Productions, Inc. All rights reserved. Section III - Page 1
According to Webster’s Dictionary, inspection is defined as the act of inspecting or
viewing. To inspect something is to view closely and critically or to view or examine
formally or officially. Inspection is the action of determining whether a process or
product is in compliance with established regulatory standards 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 greatly 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 specific responsibilities by the employer or
employer’s representative”.
• Designated means “selected or assigned by the employer or the employer’s
representative 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 Dictionary, means “having suitable or
sufficient skill, knowledge, experience, etc., for some purpose; properly qualified”.
According to ASME B30.5-2.1.1(a), “…all new and altered cranes shall be inspected
by a qualified person…”. For frequent inspections, ASME uses “designated”. For
periodic inspections, it uses “qualified”.
ASME B30.5 defines a qualified person “as a person who, by possession of a recognized
degree of certificate of professional standing, or who, by extensive knowledge,
training, and experience, has successfully demonstrated the ability to solve or resolve
problems relating to the subject matter and work.”
The personnel involved in the inspection process include mobile crane inspectors,
maintenance personnel, and those with experience in specialized technical
backgrounds or trades. There are many different types of inspectors. They include:
• mechanics
• electricians
• electronics technicians
• engineers

Section III - Page 2 ©Copyright 2001 - NorAm Productions, Inc. All rights reserved.
• operators
• outside machinists
• riggers
The minimum requirements stated in ASME B30.5 for inspectors and maintenance
personnel are those established for operator trainees. The qualifications include,
but are not limited to, the following:
• Successfully pass a physical examination
• Satisfactorily complete a written examination covering safety, operational
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,
and exhibit arithmetic skills and load/capacity chart usage, in the language
of the crane manufacturers’ operations and maintenance instruction material
• Satisfactory completion of a combination written and verbal test of load/
capacity chart usage covering various crane configurations
Inspectors are required to have general knowledge of the following:
• operating requirements
• operating skills
• types of mobile cranes
• crane components
• inspection techniques
• testing techniques
• inspection reporting issues
Inspectors should have very good vision and exercise good judgement. They must
understand that they are a link in a good preventive maintenance program.

©Copyright 2001 - NorAm Productions, Inc. All rights reserved. Section III - Page 3
NOTES:
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Section III - Page 4 ©Copyright 2001 - NorAm Productions, Inc. All rights reserved.
Section III - Survey and Review
1. T F Mechanics may sometimes be crane inspectors.
2. T F An inspector must have good vision and sound judgement.
3. 29 CFR 1926.550 (a)(5) states "the employer shall designate a ____________
person who shall inspect all machinery and equipment.
4. ASME _______________ requires that all new and altered cranes be
inspected by a qualified person.
5. ASME B30.5 requires inspectors to meet the minimum requirements
established for _______________.

SECTION IV
Lockout/Blockout

LOCKOUT/BLOCKOUT
©Copyright 2001 - NorAm Productions, Inc. All rights reserved. Section IV - Page 1
LOCKOUT/BLOCKOUT
Introduction
Failure to lock out and block out machinery before working on it is a major cause of
serious 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 establishing, and using, a lockout/blockout program.
Lockout/blockout means that any energy source, whether electrical, hydraulic,
mechanical, compressed air, or any other energy source that might 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
control switch, you are opening a circuit. There is still electrical energy at the switch,
and a short in the switch or someone inadvertently turning on the switch will start
the machine running again.
Even a locked-out machine may not be safe if there are parts of the machine that are
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 injuries related to servicing
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,
reactivated the machinery. A fifth of
those workers who turned off the control
switch were injured by the energy still
contained in the equipment which
should have been blocked.
CAUTION
DON'T CLEAN, OIL, OR
REPAIR MACHINERY
WHILE IN MOTION
Always Observe the Lockout Procedures
Approved by your Safety Department.WARNING

Section IV - Page 2 ©Copyright 2001 - NorAm Productions, Inc. All rights reserved.
Section IV - Survey and Review
1. T F The inspector should lock out and block out cranes before conducting
a walk around inspection.
2. T F Brake springs under tension would not be considered a hazardous
energy source.
3. When you open a circuit you are turning the power _______________.
4. A _______________ in a control switch will start machinery running again.
5. You should always observe the lockout procedures approved by your
_________ department.

SECTION V
Basic Operating Practices

BASIC OPERATING PRACTICES
©Copyright 2001 - NorAm Productions, Inc. All rights reserved. Section V - Page 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 specifications are not available,
the limitations assigned to the equipment shall be based on the
determinations of a qualified engineer competent in this field and such
determinations will be appropriately documented and recorded. Attachments
used with cranes shall not exceed the capacity, rating, or scope recommended
by the manufacturer.”
Cranes have the ability to lift heavy loads to great heights. They also have 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 practices for working on machinery must be followed as well as the
safe operating practices recommended here.
NOTE: An inspector may be required to operate the crane during the course of the
inspection. It is important that the inspector be qualified at least to the level of
“operator trainee” and that the inspector follow safe operating procedures. The
qualifications for an “operator trainee” are covered
under ASME B30.5a – 1995 Section 5-3.1.2
Qualifications for Operators.
During Operation
• Start the engine only in a well-ventilated area.
• Always warm up the engine and hydraulic
system before attempting to operate the crane.
• Watch all instrument readings. Stop the
engine and find causes if readings are
incorrect.
• Avoid sudden applications of all controls, particularly at the start and end
of each operation.
• Propel with the engine RPM’s (revolutions per minute) according to
manufacturer recommendations.
CAUTION
READ INSTRUCTION MANUAL
THOROUGHLY BEFORE OPERATING
WARNINGIMPROPER USE OF THIS PRODUCT
MAY RESULT IN PERSONAL INJURY
OR DAMAGE TO PRODUCT

Section V - Page 2 ©Copyright 2001 - NorAm Productions, Inc. 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 operator
to rest his legs when suspending the load for short periods of time. 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 applicable
ANSI standard for the type of crane in use. An illustration of the signals
shall be posted at the job site.
• Trying to repair or adjust equipment with a suspended hook or load, or with
the boom raised, could release machinery and let it move unexpectedly.
Always lower the load to the ground and the boom onto proper cribbing
before doing maintenance or repair work.
Park Safely
Before you leave the cab:
• Lower the load to the ground and apply the
brakes.
• Put the control levers in the neutral position.
• Shut off the engine.
• Never park on an incline without carefully
blocking the crane to prevent movement.
• Don’t leave the crane where there is a chance
of a bank caving in, or a low spot where rains
may wash out the footing.
• Take the engine key and the cab door key
with you.
• Always dismount facing the crane using the
handholds and steps provided by your
employer or crane manufacturer.

LOAD CHART INTERPRETATIONS
An Overview for Lifting Service Cranes
The crane manufacturer designs a load
chart for each model crane that is sold. The
load chart may go one step further. It could
be serial number or other identifier specific,
i.e., a different load chart is required for
each machine even if a manufacturer only
makes one model crane. This is done
because there could be some slight
differences between each crane due to
design changes, manufacturing techniques,
materials used or a host of other reasons.
The load chart in this situation will bear not
only the model number but also the serial
number or other identifier of the crane into
which it is installed. This chart cannot be interchanged with another crane.
Should the load chart become lost or illegible, it can only be replaced by the manufacturer.
No crane may be operated without the correct load chart in place.
Load charts indicate the GROSS LIFTING CAPACITY of the crane. Those capacities
are limited by either the STRUCTURAL STRENGTH of the crane or STABILITY
(the cranes ability to resist tipping). It is critical to remember that tipping cannot
be relied upon as an indication that the crane has reached capacity.
The GROSS CAPACITIES listed on the load chart are based on the configuration of
the crane. Changing the configuration will change the chart that you are using.
Configuration can include the following:
1. On outriggers or on rubber;
2. Lifting from a boom attachment ie: jib, extension, auxiliary point sheave;
3. Mast installed;
4. Gantry position (lowered, intermediate or fully erected);
5. Boom type, lattice (tubular or angle, heavy or light) or hydraulic;
6. Type of boom point installed;
7. Counterweights used, and
8. Levelness of the crane, (list charts).
The operator must have read and understood the
Operator’s Manual. He or she must also be able to read
and understand the load chart, even if the crane is equipped
with an LMI or electronic load chart system.WARNING

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
ABoom On Outriggers 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* 23,000
19,900* 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* 23,100
20,100* 19,000
15,000* 13,700
58,000* 56,000*
54,700* 54,700*
43,200* 42,800*
34,600* 34,100*
28,500* 28,200*
23,700* 23,200
20,100* 19,100
15,000* 13,800
11,700* 10,500
49,900* 49,900*
43,100* 42,700*
34,400* 34,000*
28,500* 28,000*
23,700* 23,200
20,000* 19,100
15,000* 13,800
11,700* 10,500
9,400* 8,300
40,800* 40,800*
34,300* 33,900*
28,400* 27,900*
23,600* 23,200
19,900* 19,000
14,900* 13,700
11,600* 10,500
9,300* 8,300
7,800* 6,600
37,100* 37,100*
33,300* 33,300*
28,200* 27,800*
23,500* 23,100
19,800* 19,000
14,800* 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 13,800
14,100 10,700
11,500 8,600
9,500 7,000
47,800 31,400*
42,800 28,200*
38,700 27,300*
35,200 25,600*
24,100 18,800
18,000 13,900
14,200 10,800
11,600 8,600
9,600 7,100
6,900 4,900
38,700 27,200*
35,300 25,200*
24,100 18,800
18,000 13,900
14,200 10,800
11,500 8,600
9,600 7,100
6,900 4,900
5,200 3,500
35,200 25,300*
24,100 18,800
18,000 13,900
14,100 10,700
11,500 8,600
9,500 7,000
6,900 4,900
5,200 3,500
3,900 2,500
24,000 18,700
17,900 13,700
14,100 10,600
11,400 8,500
9,500 6,900
6,800 4,800
5,100 3,400
3,900 2,400
2,900 1,700
23,900 18,700
17,800 13,700
14,000 10,500
11,300 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 with
machine travel at creeping speeds only.
Point
Length Radius Angle Height
(Feet) (Degrees) "w"
A

Typical Lattice Boom Configurations

Typical Hydraulic 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.
Outriggers Fully 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)
LOADED LOADED
LOAD BOOM OVER BOOM OVER
RADIUS ANGLE 360 FRONT ANGLE 360 FRONT
(ft./m) (deg) (lbs./kg) (lbs./Kg) (deg) (lbs./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 3,100
Capacity 1179 1678 998 1406
LOADED
BOOM OVER LOAD
ANGLE 360 FRONT RADIUS
(deg.) (lbs./kg) (lbs./kg) (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°

Typical Hydraulic Boom Configurations

Section V - Survey and Review
1. T F Hand signals for mobile cranes must be posted at the job site.
2. T F Load charts can be interchanged between cranes of different serial
numbers as long as they are the same model.
3. Load charts can only be replaced by the _______________.
4. Load charts indicate _______________ capacities.
5. In addition to the OSHA and ASME standards, anyone who operates the
crane must also have read __________________ .

SECTION VI
Tools of the Trade

TOOLS OF THE TRADE
©Copyright 2001 - NorAm Productions, Inc. All rights reserved. Section VI - Page 1
TOOLS OF THE TRADE
Tools are designed to make a job easier and enable you to work more efficiently. If
the 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 time,
reduce efficiency, and may even injure themselves.
A knowledge of the tools and their fundamental uses is the primary step in mastering
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 find it.
Improperly storing tools will result in damage to the tools.
• Keep tools in good condition. Protect them from rust, nicks, burrs, and
breakage. Cutting tools should be kept sharp.
• Use each tool to do only the job for which it was designed. Using a tool outside
of its design parameters can result 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, damage other parts or cause a painful injury. A gauge 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, mallets and sledges are used for striking. The
type of hammer you select will depend on your intended use. Hammers
may be further divided into soft-faced and hard-faced, as well as by
different styles such as a carpenter’s (claw) hammer and a ball peen
(machinist’s) hammer. For inspection purposes a 12 ounce hard-faced claw
hammer, 6 ounce hard-faced ball peen hammer and a 10 ounce soft-faced
mallet would make good choices.
2. Turning tools – They include open-end wrenches, box-end wrenches,
combination wrenches, socket wrenches, adjustable wrenches, torque
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 in
one or both ends. Their jaws may be parallel to the handle or at angles up
to 90°. The average angle is 15°. Handles may be either straight or curved.
• Box-end wrenches – This type of wrench is a safer alternative to an
open-end wrench, since there is less likelihood they will slip off the

Section VI - Page 2 ©Copyright 2001 - NorAm Productions, Inc. 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 with 16 points should only be used for light duty
work. The wrenches with 12 points should not be used for greater than
medium 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 be
turned much faster with an open-end wrench than with 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. Usually a set of combination wrenches in the smaller
sizes will be sufficient for most inspection kits.
• Socket wrenches – A good set of socket wrenches is a must for any
inspector’s tool kit. A socket set basically consists of socket type wrenches
which can be attached to various types of handles. Most inspection kits
will contain a ¼” drive socket set, as well as a ½” drive socket set.
Sockets are normally of the shallow well type and in the smaller sizes.
Handles should include a ratchet type handle and a hinged type
(breaker bar) handle. A couple of different length extensions should be
included for those hard-to-reach places.
• Adjustable wrenches – A handy all-round wrench generally included
in every tool box is the adjustable wrench. The adjustable wrench is not
intended for use on extremely hard to turn items. When used
improperly, adjustable wrenches are known to slip, earning them the
nickname “knuckle busters”. Although available in a number of sizes,
most inspection tool kits will contain one 6” and one 10” length
adjustable wrench.
• Torque wrenches – There are times when, for engineering reasons, a
definite 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 are the deflecting beam, dial indicating and the
micrometer setting. Accuracy of the torque wrench depends on its
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
Bristol head and the Allen head. Allen head screws are the more common
type and are hexagonal (six-sided) in shape. A good set of Allen wrenches
are a must for any inspector’s tool kit.

TOOLS OF THE TRADE
3. Punches – Although there are a number of types of punches, including pin
punches, prick punches, drift punches and others, the only type normally
found in an inspector’s tool kit is the center punch. Their use in inspections
is usually limited to marking measuring points, or Tram points, on hooks.
When using any type of punch, be sure to strike it squarely and that it is
positioned properly so that it will not slip on the work.
4. Screwdrivers – One of the most basic of hand tools, it is also the most
abused of the hand tools. Here we will look at three different types of
screwdrivers-the Standard head, the Phillips 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 - Standard screwdrivers are classified by size according
to the combined length of the shank and blade. The most common sizes
range from 2 ½” to 12”. The diameter of the shank and the width and
thickness of the blade are normally proportionate to the length, but
not always. When selecting a Standard screwdriver, it 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 Phillips-type screw has a four-way,
beveled wall slot into which the screwdriver fits. The screwdriver head
has about 30° flukes and a blunt end. Never attempt to use Standard or
Reed and Prince type screwdrivers on a Phillips-type screw.
• Reed and Prince head – Although Reed and Prince head screws look
a lot like a Phillips head screw, the screwdrivers are not
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° flukes and a blunt end, a Reed and Prince type screw has 45° flukes
and a sharper pointed end. Reed and Prince type screws are less common
on cranes than the Phillips type.
5. Pliers – Like screwdrivers, pliers come in many different styles and sizes and
are 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, they
are 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.

• Slip-joint pliers – These pliers have straight, serrated (grooved) jaws,
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 water
pump pliers. They have extra long handles to provide extra leverage, a
slip joint to allow multiple positioning of the jaws, and coarse teeth
inside the jaws to assist in holding round stock.
• Vice-grip pliers – These pliers can be used for holding objects
regardless of their shape. The pliers may be adjusted for use on a wide
variety of objects, and the pliers may be clamped to the object by turning
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 scientific fact that as we age we require more light in
order to see properly. In every inspector’s tool box should be a variety of
light sources. Beyond the common hand held flashlight that everyone is
familiar with, there are others that will greatly assist the inspector in
performing their job. These other types of lights include bendable flashlights
with lights at the end of a small diameter stem made for getting into tight
places, flashlights that clip to hard hats or caps, allowing the inspector’s
hands to be free, and magnifying glass and light combinations.
7. Inspection mirrors – There are several types of inspection mirrors available
for 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 in
light source.
8. Measuring tools – There are a number of different types of measuring tools
used in inspections. Any measurement is only accurate if it is performed
correctly. Here we will look at rules and tapes, calipers, depth gauges, levels,
sheave gauges, protractors and pressure gauges.
• Rules and Tapes – Every inspector’s tool kit should contain a tape
measure at least 25’ in length. This allows the inspector to verify boom
lengths and load radii. A steel rule is also very helpful in measuring the
distance between Tram points on a hook and for use as a straight 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 pocket
slide calipers, vernier calipers, and micrometers. A good choice for an
inspector’s tool box might be a vernier caliper with a built in depth
gauge. Today these calipers are normally “Dial” type calipers or
“Digital” calipers and read in thousands of an inch. However, calipers
that read in fractions of an inch are also available, as well as those that

TOOLS OF THE TRADE
automatically convert from fractions to decimals or vice-versa. Calipers
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 of
damaged spots on the chords of tubular type booms.
• Depth gauges – If the style of caliper you choose has a built in depth
gauge, it may not be necessary to purchase a separate one. However, if
there is no depth gauge on your calipers, depth gauges may be purchased
separately.
• Levels – Levels are tools designed to prove whether a plane or surface is
true 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 are read, an inspector should have at least one small target
level available that will fit on the rotating structure next to the boom foot
pins, or hinge pins. The inspector will then be able to determine if the
leveling device provided on the crane is accurate.
• Sheave gauges – Sheave is a term used to describe the pulleys used in
the 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 protractor is a circular or semicircular instrument for
measuring or constructing angles. A magnetic protractor has a magnetic
base which allows the protractor to be temporarily mounted to a crane’s
boom. By raising and lowering the boom, a comparison can be made
between the angle shown on the magnetic protractor and the crane’s
boom angle indicator.
• Pressure gauges – For the mobile crane inspector, a tire pressure
gauge is very important. A cranes “on-rubber” capacities are based on
the tires being properly inflated. The crane manufacturer specifies in
the load chart for the crane what the proper inflation pressure is for
the various sizes of tires that the crane may be equipped with.
9. Brushes – An inspection tool kit should be equipped with two wire brushes,
one small and one large. It is impossible to inspect what you cannot see. It
will sometimes be necessary for the inspector to brush the dirt or grease
from a part before it can be inspected. Also, inspectors who perform non-
destructive testing on the crane hooks will need to remove any paint, coatings
or contamination from the hook prior to the NDT.

10. Marking instruments – Once damage is found during an inspection, it is
important that the damage be marked so it can be located later by those
responsible for repairs. Some common marking instruments found in
inspection tool kits include a center punch, chalk, paint stick or grease pen,
and a steel marking pen.
11. Personal protective equipment – Although not normally found in the tool
kit, it is important for mobile crane inspectors to use the proper personal
protective equipment. Your employer dictates what personal protective
equipment is appropriate for your job in the company safety policy. A common
list might include the following items: hard-hat, safety glasses, gloves and
safety shoes.
12. Miscellaneous items – In addition to those items we have discussed, other
items that are useful to stock in your inspector’s tool kit are: (1) a stick
magnet, which is used to move up and down next to boom lacings to determine
if body putty is concealed beneath a fresh paint job, (2) hand cleaner, if hand
washing facilities are not available a waterless hand cleaner should be
stocked, (3) shop rags, and (4) disposable latex gloves.
In closing, you may think of items other than those listed above that may make your
job easier and help you to be a more effective inspector.

TOOLS OF THE TRADE
NOTES:
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Section VI - Survey and Review
1. T F Sheave gauges are most commonly "No-Go" gauges.
2. T F Socket wrenches may be purchased with different size drives.
3. Standard, Phillips, and Reed and Prince are types of ____________ .
4. ____________ wrenches have a box end and an open end.
5. A Magnetic _________ can be used to help verify the accuracy of boom angle
indicators.

SECTION VII
Inspection of Carriers & Mounts

INSPECTION OF CARRIERS & MOUNTS
©Copyright 2001 - NorAm Productions, Inc. All rights reserved. Section VII - Page 1
REAR TANDEM FRONT TANDEM
CARRIER CAB
POW ER
PLANT
FRONT
JACK
FRONT
OUTRIGGER
SWING BEARING
OUTRIGGER JACK
REAR OUTRIGGER
OUTRIGGER FLOAT
TRUCK MOUNT
RUBBER TIRED CARRIERS APPLICABLE TERMINOLOGY
W A G O N M O U N T
E N G IN E
C O M PA R TM E N T
R E A R O U TR IG G E R
B E A M S
FR O N T O U TR IG G E R
B E A M S
ROUGH TERRAIN MOUNT
RING GEAR ROLLER PATH
OUTRIGGER
JACK
WAGON MOUNT

Section VII - Page 2 ©Copyright 2001 - NorAm Productions, Inc. All rights reserved.
Tires/Wheels/Chocks
Inspect the tires for uneven wear, flat spots, chips, flange wear, cracks, and looseness
of axle pins. If damage is found, qualified personnel should be allowed to repair
damage. Always check pressure. Use only approved methods when adding air to
tires. Check that the wheel chocks (where applicable) are stored on the unit for use.
Wear or Damaged Tires

Outriggers
Lets examine outrigger structures and see how they get their strength. The
undersides of all outrigger boxes are reinforced in critical areas. It is very important
that outrigger beams be fully extended when lifting on outriggers. If the beams are
not fully extended, excessive loads on the rear of the beams can cause the plates of
the outrigger boxes to fail. This is due to the rear of the beams not being located
over the specially reinforced areas.
The side plates of outrigger beams are also reinforced in structurally critical areas.
The outrigger beams and boxes are reinforced only in areas that are considered high
stress points with the outrigger beams fully extended. Therefore, it is crucial when
using outriggers, they must be fully extended to assure safe operation of the machine.
Outrigger/Stabilizer Condition
Check the following for cracks, distortion, wear, or leaks:
• Pad
• Pad welds
• Beams/housings
• Outrigger attachment welds
• Outrigger attachment bolts/pins
• Cylinder hoses/fittings
• Outrigger cylinders/check valves
- LH Front
- RH Front Outrigger Jack
Outrigger
Box
Telescopic
Outrigger Beam

- LH Rear
- RH Rear
• Outrigger pin retainers
- LH Front
- RH Front
- LH Rear
- RH Rear
• Controls Broken Outrigger Float

Typical Cylinder Assembly
SLIDER
PADS
EXTERNAL
RETAINING RING
OUTER BOX
PIN
EXTERNAL
RETAINING RING
INNER
BOX
PIN
EXTERNAL
RETAINING RING
OUTRIGGER
LINK
PIN
PEDESTAL (REF.)

Typical Stabilizer Assembly
Outrigger Damage
TOP PLATE
TORQUE
(200 FT. LBS. TYP.)
SUB FRAME (REF.)
TRUCK FRAME (REF.)
CROSS
BAR
U-BOLT
FRAME
STIFFENER
CYLINDER
ASSEMBLY
HITCH
BALL
FLOAT

Crawlers
Crawlers need to be inspected for the following conditions:
• Brake and clutch system parts, linings, pawls, and ratchets for excessive wear
• Chain drive sprockets for excessive wear
• Drive chain for excessive stretch
• Rollers for wear, cracks and distortion
• Travel steering and brakes for proper operation
• Gears and open roller chains for proper lubrication
• Drive shafts, couplings and gears – Internal: Check gear case lubrication oil
for proper level, evidence of leaking gaskets, and vents. Inspect all drive
shaft couplings for loose bolts, worn keyways, loose keys, misalignment and
loose shaft. Inspect for excessively chipped or warn gears.
• Drive shafts, couplings and gears – External: Inspect the external drive shafts
for damage, alignment, worn keyways, loose keys and covers. Inspect for
excessively chipped or worn gears.
• Bearings – roller, ball sleeve – Inspect for discoloration due to excessive
heat. Check for noise, vibration and lubrication.
• Chains and sprockets – Inspect for loose or worn links and pins. Inspect for
worn or damaged teeth, loose shaft and keys and lubrication.
• Pawls and ratchets – Inspect for loose, damaged or worn pawls and ratchets,
worn keys, loose securing bolts, linkage problems, and broken springs.
• On crawler cranes, brakes or other locking means shall be provided to hold
the machine stationary during working cycles on a level grade or while the
machine is standing on the maximum grade recommended for travel. Such
brakes or locks shall be arranged to remain in engagement in the event of
loss of operating pressure or power.
Track Rollers
• Location: Located at bottom and top of the track frame.
• Things to Check: Check for missing rollers, broken shafts, and broken u-bolts.

Drive Chain Adjustments
• Location: Centrally located at rear, inner or outer part of track frame.
• Things to Check: Check sprockets for broken teeth or excessive wear. Check
chain adjustment, broken pins, and for excessive dirt build up.
Fixed Vertical Pin
Carbody
Hydraulically Powered
Horizontal Pin
Crawler
CRAWLER TO CARBODY
CONNECTING PINS

Track Adjustment Chart
Shim Retainer
Drive End Idler End
Shims
1“
Shoes
Shims
1“
Track Pad Condition
• Location: Outer part of tracking system.
• Things to check: Check for cracks in pads, make sure the track pad pins are in
place and in good condition, and also check the pin holes for excessive wear.

Sprocket
Top Idler
Front Idler
Track Rollers
Forward
Reverse
CAUTION
Before operating the travel levers, check the
position of the lower. It is recommended that
the lower faces forward.
Track Behavior
Track Adjustments
• Location: Located at main tracking structure
• Things to Check: Make sure the tracks are adjusted properly. Proper and
improper adjustments are illustrated in pictures.

Forward
Reverse
Track Torque
Tracks
• Top Idlers
— Flat Rollers: Flatted rollers is a
condition resulting from packing or
idler seizure due to lack of lubricant,
restricting rolling and causing the track
chain to slide.
— Flat Rollers: In packing conditions or
when lubricant escapes, top idler rolling
can become restricted, creating a sliding
of the chain over the top idlers,
resulting in flat spots or square rollers.
— Flat Rollers: Proper track tension will
reduce the rolling friction of the chain
moving over the top idlers. Cleaning
material will help prevent “flatted”
rollers; checking for lubricant leaks
will help prevent seized rollers.

• Front Idler
— Idler Wear: Most wear on the idler
tread is caused by abrasive packing
conditions of materials that come
between the idler tread and link rails.
— Tight Track: A track that is too tight
creates excess friction between the
idler tread and link rails, causing tread
wear.
— Loose Track: Reducing track tension will decrease the rolling friction
between link and treads, thus slowing the rate of wear. If track tension
is too loose, tightening will eliminate any buckling of the chain into the
idler, causing chipping or other damage.
Track Frame
• Location: Center, main structure of tracking system.
• Things to Check: Check drives and idlers, and also check for loose mounting
bolts.

Section VII - Survey and Review
1. T F A track that is too tight creates excess friction between the idler
tread and link rails.
2. T F Outrigger attachment welds must be checked for cracks, distortion
and wear.
3. The outrigger ____________ are reinforced only in those areas that are
considered high stress points.
4. The inspector should check the _______________ for missing rollers.
5. Bearings should be inspected for _________ which is an indication of
excessive heat.

SECTION VIII
Inspection of Superstructures & Booms

INSPECTION OF SUPERSTRUCTURES & BOOMS
©Copyright 2001 - NorAm Productions, Inc. All rights reserved. Section VIII - Page 1
Machinery House and Operator’s Cab
Insofar as practical, all cabs and enclosures shall be constructed to protect the
superstructure machinery, brakes, clutches, and operator’s station from the weather.
All cab glass shall be of safety glazing
material as defined in ANSI Z26.1. Windows
shall be provided in the front and on both
sides of the cab or operator’s compartment
with visibility forward and to either side.
Visibility forward shall include a vertical
range adequate to cover the boom point at
all times. The front window may have a
section that can be readily removed or held
open. If the section is held open it shall be
secured to prevent inadvertent closure. A
windshield wiper should be provided on the
front window. The glass must be free from
any defects that would obstruct the
operator’s view.
All cab doors, whether of the sliding or
swinging type, shall be restrained from
inadvertent opening or closing while
traveling or operating the machine. The door
adjacent to the operator, if of the swinging
type, should open outward, and, if of the
sliding type, should slide rearward to open.
A clear passageway shall be provided from
the operator’s station to an exit door on the
operator’s side.
A seat belt shall be provided in all single
control station wheel mounted cranes for use
during transit and travel.
Inspection should include the following areas:
• Leaks
• Broken glass
• Corrosion
• Cable louvers
• Proper operation of doors and windows
Dirty
Clean
Cab Glass

Section VIII - Page 2 ©Copyright 2001 - NorAm Productions, Inc. All rights reserved.
• Proper operation of windshield wipers
• Proper operation of seat belt
• Proper operation of defroster where applicable
Control Functions
Check all control functions for maladjustment interfering with proper operation
ona daily basis, excessive wear of components by lubricants or other matter, and
electrical apparatus for malfunctioning, signs of excessive deterioration, dirt, and
moisture accumulation. Operate all controls through the full range of their individual
functions while observing the crane’s movements. Check that all brakes, boom hoist
(where applicable), load hoist (where applicable) and swing are operating correctly.
Any control problems shall be repaired prior to operation.
Basic controls used during the crane operating cycle shall be located within reach
of the operator while at the operator’s station. Controls for load hoist, boom hoist,
swing, and boom telescope (when applicable) shall be provided with means for holding
in the neutral position, without the use of positive latches.
Remote-operated cranes shall function so that if the control signal for any crane
motion becomes ineffective, the crane motion shall stop. Provisions shall be made
for emergency stop in the event of a device malfunction for remote-operated cranes.
Forces shall not be greater than 35 lbs. on hand levers and not greater than 50 lbs.
on foot pedals. Travel distance on hand levers shall not be greater than 14 inches
from the neutral position on two-way levers and not greater than 24 inches on one-
way levers. Travel distance on foot pedals shall not be greater than 10 inches.
Corrosion Cracked Glass

The PTO cable (when applicable) and throttle linkage and cable must have freedom
of movement, proper securing, no sharp bends or excessive cable, and clearance
from exhaust system and moving parts.
Hand Levers Foot Pedals
Rotating Cab Fixed Cab
GASKET
PTO SHIFTER
CABLE
PTO
HYDRAULIC PUMP
PTO Cable

Section VIII - Page 4 ©Copyright 2001 - NorAm Productions, Inc. All rights reserved.
Load Rating Charts
Federal and state regulations require that the load chart be legible and mounted
within the operator’s view. Load charts are normally divided into two different
categories: structural competence and stability.
Structural competency: normally shown on the load chart as those capacities above
the bold line, but may also be denoted with an asterisk (*) or through the use of a
shaded area. Structural competence means the crane is rated on certain structural
components that may not have sufficient strength to derive enough leverage to allow
the machine to tip.
Stability: the crane’s resistance to overturning. Rough-terrain and truck-mounted
cranes when lifting on tires (rubber) are based on 75% of their tipping capacity and
85% of their tipping capacity when lifting on outriggers.
DO NOT OPERATE ANY CRANE WITHOUT THE PROPER LOAD CHART.
A durable rating chart(s) shall be provided with each crane and attached in a location
accessible to the operator while at the controls. The data and information to be
provided on these charts shall include, but not be limited to, the following:
• A full and complete range of manufacturer’s crane load ratings at all stated
operating radii, boom angles, work areas, and all stated boom lengths and
configurations, jib lengths and angles (or offset), as well as alternate ratings
for use and nonuse of optional equipment on the crane, such as outriggers
and extra counterweights, which affect ratings.
• A work area chart for which capacities are listed in the load rating chart.
• Where ratings are limited by structural, hydraulic, or other factors rather
than stability, the limitations shall be shown and emphasized on the rating
charts.
• In areas where no load is to be handled, the work area figure and load rating
chart shall so state.
• Recommended reeving for the hoist lines shall be shown.
In addition to the data required on the load rating chart, the following information
shall be shown either on the rating chart or in the operating manual:
• Recommended parts of hoisting reeving, size, and type of rope for various
crane loads
• Recommended boom hoist reeving diagram, where applicable; size, type and
length of rope;
• Tire pressure, where applicable;
• Cautionary or warning notes relative to limitations on equipment and
operating procedures, including indication of the least stable direction;

• Position of the gantry and requirements for intermediate boom suspension,
where applicable;
• Instructions for boom erection and conditions under which the boom, or boom
and jib combinations, may be raised or lowered;
• Whether the hoist holding mechanism is automatically controlled, manually
controlled, whether free-fall is available, or any combination thereof;
• The maximum telescopic travel length of each boom telescopic section;
• Whether sections are telescoped with power or manually;
• The sequence and procedure for extending and retracting the telescopic
boom section;
• Maximum loads permitted during the actual boom extending operation, and
any limiting conditions or cautions;
• Hydraulic relief valve settings specified by the manufacturer.
Load Chart

Mobile Crane Inspector Training Program Guide

Mobile Crane Inspector Training Program Guide

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