Mobile Crane Inspection Guidelines

for OSHA Compliance Officers

This information booklet is intended to provided a generic, nonexhaustive overview of
a particular standards-related topic. This publication does not itself alter or determine
compliance responsibilities, which are set forth in OSHA standards themselves and the
Occupational Safet and Health Act. !oreover, because interpretations and
enforcement polic ma change over time, for additional guidance on OSHA
compliance re"uirements, the reader should consult current administrative
interpretations and decisions b the Occupational Safet and Health #eview
$ommission and the courts.
!aterial contained in this publication is in the public domain and ma be reproduced,
full or partiall, without permission of the %ederal &overnment. Source credit is
re"uested b not re"uired.
This information will be made available to sensor impaired individuals upon re"uest.
'oice phone( )*+*, *-.-/*0.1 Telecommunications 2evice for the 2eaf )T22,
message referral phone( --/++-3*4-*055

This report was written b Anthon 2. 6rown
Mobile Crane Inspection Guidelines for OSHA Compliance Officers
7S 2epartment of 8abor
#obert 6. #eich, Secretar
Occupational Safet and Health Administration
9oseph 2ear, Assistant Secretar
Office of $onstruction and :ngineering
$harles &. $ulver, 2irector
9une -..;
TABLE OF CONTENTS
A$<=O>8:2&:!:=TS
A6ST#A$T
:?:$7T@': S7!!A#A
-.+ @=T#O27$T@O=
*.+ !O6@8: $#A=:S
*.- 8ifting Brinciples
*.* Operational $onsiderations
3.+ #:C7@#:!:=TS %O# !O6@8: $#A=:S
3.- OSHA $onstruction #e"uirements
3.* AS!:DA=S@ and B$SA #e"uirements
;.+ @=SB:$T@=& A !O6@8: $#A=:
;.- Breinspection
;.* $rane Setup
;.3 :lectrical HaEards
;.; 8oad $harts
;.0 Safe Operating Brecautions
;.4 @nspection Tpes
;.5 Starting the @nspection
;./ Specific @nspection @tems and #eferences
ABB:=2@? A - &:=:#A8 T:#!S A=2 2:%@=@T@O=S
ABB:=2@? 6 - &:=:#A8 8OA2 $HA#TS A=2 OB:#AT@O=A8 $O=S@2:#AT@O=S
ABB:=2@? $ - 6AS@$ $#A=: $O!BO=:=TS
ACNO!LE"GEMENTS
Staff from the OSHA =ational Office provided assistance in preparing this report. !ike
!arshall and $huck Hardest, Office of $onstruction and :ngineering1 Ted
Twardowski, Office of $onstruction and $ivil :ngineering Safet Standards provided
initial information and reviewed comments1 9ames $alvert, :ngineer in Training,
tped and edited the report, and developed charts, tables, and graphics for the
report.
>illiam Smith, 2irector of Safet and Health, @nternational 7nion of Operating
:ngineers1 #ichard &iacin, Administrator, 8ocal ;5/, @nternational 7nion of Operating
:ngineers, !eridan, $T.1 and Scott 6uck, Safet 2irector, 8ocal -0+, @nternational
7nion of Operating :ngineers, Blainfield, @8, contributed technical assistance,
photographs and review comments throughout the proFect.
@ndividual members of the AS!:DA=S@ 63+ $ommittee, provided technical
information, materials, pictures and continual review comments. Those members
include(
Baul Gorich, 7.S. 2epartment of the =av and $hair of the 63+ $ommittee1 Theodore
A. $hristensen, 8ibert !utual @nsurance $o1 6radle 2. $losson, Bresident, =orth
American $rane 6ureau, >est1 9ames 9. Headle, Bresident, $rane @nstitute of
America, @nc.1 $arson 8. Hunecutt, :"uipment Operations !anager, 9.A. 9ones, @nc.1
:dward :. #ud, 7.S. 2epartment of the Arm1 and #obert $. >ild, 7.S. Arm $orps
of :ngineers.
A special thanks to 8eon )Skip, S. 9ohnson, American :"uipment $ompan for his
technical assistance and review comments and in ac"uiring photographs and video
footage of a simulated crane inspection on a %lour 2aniels, @nc., construction proFect
in 8A.
Steve Beterson, Training !anager, American $rane $orporation, 2ennis :ckstine,
2irector, Broduct Safet, &rove $orp., and 2an >olff, !anager for :ngineering,
=ational $rane $orp. for review comments and technical assistance.
Tom <ollins, 'ice Bresident, SpecialiEed $arriers and #iggers Association, S$H#A,
through the membership, provided assistance and initial evaluation of contents and
format.
ABST#ACT
This document provides background information about lifting principles and serves as
a guideline for inspecting mobile construction cranes. The relationship of man
components of cranes and their inter-dependence in lifting operations, OSHA
re"uirements for proper maintenance schedules, and safe crane operations will be
discussed in this document.
This document contains a listing and description of maFor components or operations to
be considered or examined when inspecting lifting e"uipment. Two tpes of commonl
used cranes, a crawler lattice boom crane and a hdraulic rough terrain crane, were
selected as examples in developing these guidelines. 2escriptive text and
photographs illustrate -/ inspection items critical to most crane inspections.
E$EC%TI&E S%MMA#'
2
OSHA compliance officers, proFect safet and health managers, and insurance
inspectors are often re"uired to inspect construction cranes. @nspections normall
include length checklists that identif mechanical components and maintenance
schedules without ade"uate descriptions or explanations, pertinent to the relationship
between these components and the craneIs overall function. Although some crane
inspection checklist items are self-explanator, it must be recogniEed that due to
increasing applications of developing technolog in the design and manufacture of
cranes, OSHA compliance officers need a better understanding of crane operations
and their basic lifting principles, and to keep abreast of related developments in
todaIs construction industr.
Since cranes affect a large segment of work at an construction site, crane
inspections b the compliance officer and proFect safet manager must include a
surve of the entire operation "uestions on how the crane will be operating and how
other crafts will be affected b working with and around the crane.
Observing crane operations prior to an inspection, or asking "uestions about how it
will or has been operating, can indicate possible problem areas that ma need a closer
review during the inspection process.
This document provides an overview and background information on lifting principles
of mobile cranes for OSHA inspectors. Also discussed is the relationship between
various components of mobile cranes to their lifting capacit and the manufacturersI
re"uirements for conducting proper maintenance schedules are also discussed.
Tpical $onstruction Site
8oad 6lock 8owered for @nspection
3
()* Introduction
Over the past few decades, there has been a
significant increase in the cost of cranes due in
part to improved engineering design and specific
Fob site re"uirements.
Toda, manufacturers design and build stronger
and lighter cranes in response to specific
industr needs. Speed, utilit, capacit, and
reach )radius, have been improved to the point
that the crane has become an indispensable
workhorse for construction. Therefore, a more
thorough understanding of cranes, their
capabilities and limitations is criticall important
for everone involved in construction toda. The
crane can perform safel and economicall when
operated within the design parameters set b
the manufacturer.
!odern #inger $rane
0++-Ton $apacit
2ue to significant advances in lifting technolog, crane operators, site supervisors,
safet professionals, and OSHA compliance officers need to keep abreast of modern
crane technolog and changes in operating procedures to help them recogniEe
problems before potentiall unsafe conditions lead to accidents that result in inFuries
andDor fatalities, as well as e"uipment damages.
>ith these factors in mind, the need for a better understanding of crane operations
and the implementation of appropriate maintenance schedules is evident in
preventing accidents.
A recent stud b 2on 2ickie, a recogniEed crane authorit with the $onstruction
Safet Association of Ontario, indicates that although mechanical failures represent
onl --J of the causes of crane accidents, the usuall result in the maFor accidents
involving inFuries, fatalities, substantial material costs, and usuall spectacular media
coverage. Studies and analses of crane accidents involving mechanical failure show
the are fre"uentl due to a lack of preventive maintenance or ade"uate training
andDor experience on the part of the personnel involved. @t is important that not onl
crane operators but also other personnel working with cranes receive training in crane
operations. $ranes and associated rigging e"uipment must be inspected regularl to
identif an existing or potentiall unsafe conditions. @n addition, preventive
maintenance must be performed as re"uired b the crane manufacturer andDor the
supplier to ensure safe crane operation. The inspections performed b OSHA
compliance officers andDor other safet professionals also can pla an important role
b identifing haEards as well as safe crane operations.
This report addresses maFor issues related to the crane itself and provide some basic
information on crane capacities and inspection criteria for OSHA compliance officers.
Since it would be difficult for a single report to full address all tpes of cranes
available in todaIs market, two tpes of cranes tpicall found on construction sites
are discussed in this report. Some of the issues encountered during inspections cover
the following three areas(
Basic Crane Operations + 8ifting principlesDmechanics and some operational
criteria.
T,pical Crane inspection C-ec.list + 8isting of critical items and
components recommended for periodic inspection.
#e/ulations + %ederal OSHA regulations and applicable AS!:DA=S@ and B$SA
standards.
4
This report also contains general guidelines for crane inspections, as well as some
suggested operational considerations and inspection items recogniEed b a number of
construction companies.
$ranes are designed for both general use and for specific purposes. Similar to the
vast automobile industr, crane manufacturers produce similar models or tpes of
cranes for the same purpose, often with different siEes of the same model of crane.
:ach tpe, model, or siEe of crane manufactured, ma have different operating
controls and re"uire specialiEed operator training, individualiEed inspection criteria,
and different preventive maintenance schedules.
Two commonl used cranes, a hdraulic rough terrain crane and a crawler lattice
boom friction crane, are shown as examples for developing this document. There are
several significant differences between these two cranes, primaril in boom hoist and
load line controls. The somewhat smooth operation of the boom control adFustments
on the hdraulic cranes ma suggest falsel to the novice operator or inspector that it
is a simple crane to operate. On the other hand, the lattice boom friction cranesI
movement in its boom, or its adFustment in load position tend to be a little Ferk
re"uiring more skill and experience to operate smoothl. Another clear difference
between the two tpes of cranes is their load charts. 2ue to the fixed boom length,
the lattice boom friction crane has a somewhat simplified load chart. This re"uires
extensive motion control and an anticipation of boom movement to accuratel lift or
place loads. $onversel, the hdraulic craneIs load charts are more extensive or
complicated due to the variations in boom length thus re"uiring more training in the
multiple charts available. The differences between these two tpes of cranes are
significant enough to re"uire specific training on each tpe of crane. $rane operators
cannot be expected to be totall knowledgeable and proficient in the operation of the
man diverse tpes of cranes available toda. The cannot be expected to move from
one tpe of crane to another without ade"uate education and training on the specifics
of each piece of e"uipment.
'ariet of $rawler #ough Terrain )#DT, $rane
5
!obile $rawler $rane OperatorIs 'iew 8attice 6oom
0)* Mobile Cranes
0)( Liftin/ 1rinciples
There are four basic lifting principles that govern a craneIs mobilit and safet during
lifting operations(
-. Center of Gravity The center of gravit of an obFect is the point in the obFect
where its weight can be assumed to be concentrated or, stated in another
wa, it is the point in the obFect around which its weight is evenl distributed.
The location of the center of gravit of a mobile crane depends primaril on
the weight and location of its heaviest components )boom, carrier, upperworks
and counterweight,.
*. Leverage $ranes use the principle of leverage to lift loads. #otation of the
upperworks )cab, boom, counterweight, load, changes the location of the
craneIs center of gravit, its leverage point or fulcrum.
As the upperworks rotates, the leverage of a mobile crane fluctuates. This rotation
causes the craneIs center of gravit to change and causes the distance between the
craneIs center of gravit and its tipping axis to also change. Stabilit can be effected
b the fluctuating leverage the crane exerts on the load as it swings. The craneIs
rated capacit is therefore altered in the load chart to compensate for those changes
in leverage.
Brovided the ground is capable of supporting the load, a crane can be made more
stable b moving the tipping axis further awa from its center of gravit. The extra
stabilit gained b moving the tipping axis can then be used to carr largerDheavier
loads.
@=$#:AS:2 STA6@8@TA K !O#: 8OA2
3. Stability @s the relationship of the load weight, angle of the boom and its
radius )distance from the cranes center of rotation to the center of load, to the
center of gravit of the load. The stabilit of a crane could also be effected b
the support on which the crane is resting. A craneIs load rating is generall
developed for operations under ideal conditions, i.e., a level firm surface.
7nlevel surfaces or soft ground therefore must be avoided. @n areas where soft
ground poses a support problem for stabilit, mats and or blocking should be
used to distribute a craneIs load and maintain a level stable condition.
@n addition to overturning )stabilit failure,, cranes can fail structurall if overloaded
enough. Structural failure ma occur before a stabilit failure. @n other words, a
mobile craneIs structure ma fail long before it tips. As loads are added beond its
rated capacit, a crane ma fail structurall before there is an sign of tipping.
Structural failure is not limited to total fracture1 it includes all permanent damage
such as overstressing, bending and twisting of an of the components. >hen a crane
is overstressed, the damage ma not be apparent. =evertheless, a structural failure
has occurred and overstressed components are then subFect to catastrophic failure at
some future time.
;. Structural Integrity The craneIs main frame, crawler track andDor outrigger
supports, boom sections, and attachments are all considered part of the
structural integrit of lifting. in addition, all wire ropes, including stationar
supports or attachment points, help determine lifting capacit and are part of
the overall structural integrit of a craneIs lifting capacit. The following
elements ma also affect structural integrit(
The load chart capacit in relationship to stabilit1
The boom angle limitations which affect stabilit and capacit1 and
The knowledge of the length of boom and radius in determining
capacit.
6
Stabilit failures are foreseeable, but in structural failure it is almost impossible to
predict what component will fail at an given time. =o matter what the cause, if the
crane is overloaded, structural failure can occur.
0)0 Operational Considerations
$ranes are carefull designed, tested, and manufactured for safe operation. >hen
used properl the can provide safe reliable service to lift or move loads. 6ecause
cranes have the abilit to lift heav loads to great heights, the also have an
increased potential for catastrophic accidents if safe operating practices are not
followed.
$rane operators and personnel working with cranes need to be knowledgeable of
basic crane capacities, limitations, and specific Fob site restrictions, such as location of
overhead electric power lines, unstable soil, or high wind conditions. Bersonnel
working around crane operations also need to be aware of hoisting activities or an
Fob restrictions imposed b crane operations, and ensure Fob site coordination of
cranes. $rane inspectors therefore should become aware of these issues and, prior to
starting an inspection, take time to observe the overall crane operations with respect
to load capacit, site coordination, and an Fob site restrictions in effect.
#ough Terrain )#DT, ;0-Ton $rane -0+-Ton $rawler 8attice 6oom
)Hdraulic $rane, %riction $rane
7
2)* #e3uirements For Mobile Cranes
2)( OSHA Construction #e3uirements
A review of the OSHA crane standards provide a basis for a crane inspection.
$onstruction crane standards re"uirements are found in Subpart =, *. $%# -.*4.00+.
Some ke re"uirements state that(
)-, The emploer shall compl with the manufacturerIs specifications and limitations
applicable to the operation of an and all cranes and derricks. >here manufacturerIs
specifications are not available, the limitations assigned to the e"uipment shall be
based on the determinations of a "ualified engineer competent in this field and such
determinations will be appropriatel documented and recorded. Attachments used
with cranes shall not exceed the capacit, rating, or scope recommended b the
manufacturer.
)*, #ated load capacities, and recommended operating speeds, special haEard
warnings, or instruction, shall be conspicuousl posted on all e"uipment. @nstructions
or warnings shall be visible to the operator while he is at his control station.
)0, The emploer shall designate a competent person who shall inspect all machiner
and e"uipment prior to each use, and during use, to make sure it is in safe operating
condition. An deficiencies shall be repaired, or defective parts replaced, before
continued use.
)4, A thorough, annual inspection of the hoisting machiner shall be made b a
competent person, or b a government or private agenc recogniEed b the 7.S.
2epartment of 8abor. The emploer shall maintain a record of the dates and results of
inspections for each hoisting machine and piece of e"uipment.
)-0, :xcept where electrical distribution and transmission lines have been de-
energiEed and visibl grounded at point of work or where insulating barriers, not a
part of or an attachment to the e"uipment or machiner, have been erected to
prevent phsical contact with the lines, e"uipment or machines shall be operated
approximate to power lines onl in accordance with the following(
)i, %or lines rated 0+ k' or below, minimum clearance between the lines and an part
of the crane or load shall be -+ feet1
)ii, %or lines rated over 0+ k', minimum clearance between the lines and an part of
the crane or load shall be -+ feet plus +.; inch for each - k' over 0+ k', or twice the
length of the line insulator, but never less than -+ feet1
)iv, A person shall be designated to observe clearance of the e"uipment and give
timel warning for all operations, where it is difficult for the operator to maintain the
desired clearance b visual means1
)vi, An overhead wire shall be considered to be an energiEed line unless and until the
person owning such line or the electrical utilit authorities indicate that it is not an
energiEed line and it has been visibl grounded.
)-4, =o modifications or additions which effect the capacit or safe operation of the
e"uipment shall be made b the emploer without the manufacturerIs written
approval. @n no case shall the original safet factor of the e"uipment be reduced.
To supplement the OSHA standards for $ranes and 2erricks, references are made to
applicable AS!:DA=S@ and B$SA standards. The AS!:DA=S@ L63+L series of standards
address( L$ranesL, L$ablewasL, L2erricksL, LHoistsL, LHooksL, L9acksL and LSlingsL.
%or the purpose of this document AS!:DA=S@ 63+.0, L!obile and 8ocomotive $ranesL
will be the reference document for the crane inspection criteria.
#eferences also are made to the Bower $rane Shovel Association )B$SA,, Standard
=o. *, L!obile it Hdraulic $rane Standards.L
2)0 ASME4ANSI and 1CSA #e3uirements
8
AS!:DA=S@ 63+.0 BS$A Standard =o. *
5)* Inspectin/ A Mobile Crane
Since cranes impact such a large segment of work going on at an Fob site, crane
inspections )to the OSHA $ompliance Officer and BroFect Safet !anagers, must
include a surve, or walk around, of the entire operation that "uestions how the crane
will be operating and how other crafts will be effected b working with and around the
craneM Observation of crane operations prior to an inspection, or simpl asking how
cranes have or will be used, can indicate possible problem areas that ma need a
closer review during the inspection process.
5)( 1reinspection
6efore the actual inspection, some general information about the crane operatorIs
"ualifications and the craneIs certifications should be gathered, such as(
Operator Qualifications Observe the operator in action and when the opportunit
permits ask a few "uestion concerning the cranes capacit and restrictions imposed,
either due to activit involved in or functional limitations.
Crane Records Ask for inspection and maintenance records and verif that the
appropriate operatorIs manual and load charts are available for that particular crane
in use.
5)0 Crane Setup
@n our initial surve of crane operations, look for crane stabilit, phsical
obstructions to movement or operation, and proximit of electrical power lines, as
well as the following(
A. Leveling Has the crane operator set the crane up level and in a position for
safe rotation and operationM
6. Outriggers Are the outriggers, where applicable, extended and being used in
accordance with manufacturerIs recommendationsM
$. Stability The relationship of the load weight, angle of boom, and its radius )the
distance from the cranes center of rotation to the center of load, to the center
of gravit of the load. Also, the condition of crane loading where the load
moment acting to overturn the crane is less than the moment of the crane
available to resist overturning.
2. Structural Integrity The craneIs main frame, crawler, track and outrigger
supports, boom sections, and attachments are all considered part of structural
9
components of lifting. @n addition, all wire ropes, including stationar supports,
help determine lifting capacit and are part of the structural elements of crane
operations.
5)2 Electrical Ha6ards
>orking around or near electrical power lines is one of the most dangerous practices
for crane operations. The OSHA re"uirements limit crane operations to a minimum
clearance of -+ feet.
$ranes should not be used to handle materials or loads stored under electric power
lines. @n addition, operation of mobile cranes near de-energiEed electric power lines is
not recommended until the following steps have been taken(
The power compan or owner of the power line has deenergiEed the lines.
The lines are visibl grounded and appropriatel marked at Fobsite.
2urable warning signs are installed at the operatorIs station and on the
outside of the crane identifing the clearance re"uirements between the
craneDload and electrical power lines.
A "ualified representative of the power compan or owner of the electrical
power line are on the Fob site to verif that the power lines have been de-
energiEed or properl grounded.
5)5 Load C-arts
8oad $harts are the principle set of instructions and re"uirements for boom
configurations and parts of line which establish crane capacit for safe crane
operations
N
.
Availability The crane operator must have in hisDher possession the
appropriate load charts related to the crane in use and for the loads being
lifted.
Correct Use The crane operator must show ade"uate understanding and
proficient use of the load charts as related to the e"uipment in use and the
loads being lifted.
5)7 Safe Operatin/ 1recautions
As stated above, cranes are carefull designed, tested, and manufactured for safe
operations. >hen used properl the can provide safe reliable service to lift or move
loads. 6ecause cranes have the abilit to lift heav loads to great heights, the also
have an increased potential for catastrophic accidents if safe. operating practices are
not followed.
Accidents can be avoided b careful Fob planning. The person in charge must have a
clear understanding of the work to be performed and consider all potential dangers at
the Fob site. A safet plan must be developed for the Fob and must be explained to all
personnel involved in the lift.
6efore operations begin for the da, a walkaround inspection needs to be conducted
to ensure that the machine is in proper working condition. Onl "ualified and properl
designated people shall operate the crane. #egular inspections are important, the
provide a means of detecting potential haEards or conditions that could contribute to a
se"uence of events leading to an accident. Safe, reliable, and the economic operation
of lifting e"uipment, cannot be ensured without regular safet inspections and
thorough preventive maintenance programs. A thorough inspection program can
forecast maintenance needs or potential e"uipment failures or malfunctions. The lack
of such a program could result in serious deterioration of the e"uipment which might
lead to excessive replacement, or repair charges, as well as an increased potential for
accidents.
10
N
See &eneral 8oad $harts and Operational $onsiderations, Appendix 6.
2ue to the wide variation of conditions under
which a crane ma operate, it is impossible for the
manufacturer to determine inspection intervals
appropriate for ever situation. @nspection
intervals recommended in manufacturerIs
publications represent minimum intervals for
average operating conditions. !ore fre"uent
inspection intervals should be re"uired if use and
site conditions are severe and warrant it.
@nspections are also designed as maintenance
checks andDor as a verification that proper repairs
or modifications of e"uipment have been
completed which, if not checked could affect
capacities as well as personnel safet. Since the
initial load rating for cranes was determined and
set under ideal conditions, inspections are
re"uired b manufacturers to guarantee optimal
operating efficienc and capacit as determined
b the load charts.
Tower $rane $ollapse
)$leaning 7p 2ebris,
The American =ational Standards @nstitute, A=S@
63+.0, )-.4/,, and OSHA both re"uire inspections
be divided into two categories( fre"uent and
periodic. @n addition to the performance of these
regular inspections, e"uipment is re"uired to be
inspected and tested to ensure that it is capable
of safe and reliable operation when initiall set or
placed in service and after an maFor repairs or
an design modification.
$rawler $rane
Brepared for @nspection
5)8 Inspection T,pes
A. Frequent Inspections )dail to monthl intervals,. %re"uent inspections are
usuall performed at the start of each shift b the operator who walks around
the crane looking for defects or problem areas. $omponents that have a direct
bearing on the safet of the crane and whose status can change from da to
da with use must be inspected dail, and when possible, observed during
operation for an defects that could affect safe operation. To help determine
when the crane is safe to operate, dail inspections should be made at the
start of each shift. %re"uent inspections should include, but are not limited to
the following(

-. $heck that all exposed moving parts are guarded. A removed guard
ma indicate that a mechanic is still working on part of the crane.
11
*. 'isuall inspect each component of the crane used in lifting, swinging,
or lowering the load or boom for an defects that might result in
unsafe operation.
3. @nspect all wire rope )including standing ropes,, sheaves, drums
rigging, hardware, and attachments. #emember, an hook that is
deformed or cracked must be removed from service. Hooks with
cracks, excessive throat openings of -0J, or hook twists of -+ degrees
or more, must be removed from service.
;. $heck for freedom of rotation of all swivels.
0. 'isuall inspect the boom and Fib for straightness and an evidence of
phsical damage, such as cracking, bending, or an other deformation
of the welds. 8ook for corrosion under an attachments that are
connected to the chords and lacing. >atch carefull for cracking or
flaking of paint. This ma indicate fatigue of the metal which often
precedes a failure. On lattice booms, look for bent lacing. @f the are
kinked or bent, the main chord can lose substantial support in that
area. >hen lacing is bent, the ends also tend to draw together which
pulls the main chords out of shape. This precaution is especiall
important on tubular booms where ever component must be straight
and free from an dents. 2o not attempt to straighten these members
b hammering or heating them and drawing them out. The must be
cut out and replaced with lacing to the manufacturerIs specifications,
procedures, and approval.
4. @nspect tires for cuts, tears, breaks, and proper inflation.
5. 'isuall inspect the crane for fluid leaks, both air and hdraulic.
/. 'isuall check that the crane is properl lubricated. The fuel,
lubricating oil, coolant and hdraulic oil reservoirs should be filled to
proper levels.
.. $heck that the crane is e"uipped with a full charged fire extinguisher
and that the operator knows how to use it.
-+. $heck all functional operating mechanisms such as( sheaves, drums,
brakes, locking mechanisms, hooks, the boom, Fib, hook rollers
brackets, outrigger components, limit switches, safet devices,
hdraulic clinders, instruments, and lights.
--. $heck the turntable connections for weld cracks and loose or missing
bolts. @f the are loose, there is a good chance that the have been
stretched.
-*. >hen checking the outriggers be sure that neither the beams nor the
clinders are distorted. $heck that the welds are not cracked and that
both the beams and clinders extend and retract smoothl and hold
the load. $heck the condition of the floats, and check that the are
securel attached.
-3. @nspect and test all brakes and clutches for proper adFustment and
operation.
-;. Alwas inspect boom hoist lockout and other operator aids, such as
anti-two-block devices )AT6, and load moment indicators )8!@,, for
proper operation and calibration.
-0. >hile the engine is running, check all gauges and warning lights for
proper readings and operate all controls to see that the are
functioning properl.
-4. $heck for an broken or cracked glass that ma affect the view of the
operator.
6. eriodic Inspections )- to -* month intervals,. The periodic inspection
procedure is intended to determine the need for repair or replacement of
components to keep the machine in proper operating condition. @t includes
those items listed for dail inspections as well as, but not limited to, structural
defects, excessive wear, and hdraulic or air leaks.
@nspection records of the inspected crane shall be maintained monthl on critical
12
items in use, such as brakes, crane hooks, and ropes. These inspection records should
include, the date of inspection, the signature of the person who performed the
inspection, and the serial number, or other identifier. This inspection record should be
kept readil available for review. The manufacturerIs maintenance and inspection
records, formsDchecklist, or e"uivalent should be used.
-. @nspect the entire crane for structural damage. 6e careful to check for
distortion or cracks in main frame, outrigger assemblies, and structural
attachments of the upperworks to the carrier.
*. @nspect all welded connections for cracks. @nspect the main chords and lacings
and other structural items for paint flaking and cracking which ma indicate
potential failure, as well as for dents, bends, abrasions, and corrosion. $heck
hdraulic booms for bending, side swa, or droop.
3. $heck for deformed, cracked, or corroded members in the loadDstress bearing
structure. !agnetic particle or other suitable crack detecting inspection should
be performed at least once each ear b an inspection agenc retained b the
owner. @nspection reports should be re"uested and retained in the crane file.
;. @nspect cracked or worn sheaves and drums.
0. @nspect for worn, cracked, or distorted parts such as( pins, bearings, shafts,
gears, rollers, locking devices, hook roller brackets, removable outrigger
attachments lugs, and welds.
4. @nspect for excessive wear on brake and clutch sstem parts, linings, pawls,
and ratchets.
5. @nspect all indicators, including load and boom angle indicators, for proper
operation and calibration.
/. @nspect all power plants for proper operation.
.. @nspect for excessive wear on drive sprockets andDor chain stretch.
-+. @nspect for correct action of steering, braking, and locking devices.
--. $heck that the counterweight is secure.
-*. $heck that the identification number is permanentl and legibl marked on
Fibs, blocks, e"ualiEer beams, and all other accessories.
-3. @nspect all hdraulic and pneumatic hoses, fittings, and tubing. An
deterioration of an sstem component should cause the inspector to "uestion
whether further use would constitute a safet haEard. $onditions, such as the
following, re"uire replacement of the part in "uestion(
a. An evidence of oil or air leaks on the surfaces of flexible hoses or at
the point at which the hose in "uestion Foins the metal end couplings.
b. An abnormal deformation of the outer covering of hdraulic hose,
including an enlargement, local or otherwise.
c. An leakage at connections which cannot be eliminated b normal
tightening.
d. An evidence of abrasive wear that could have reduced the pressure
retaining capabilities of the hose or tube effected. The cause of the
rubbing or abrasion must be immediatel eliminated.
5)9 Startin/ t-e Inspection
Since most crane inspections begin with a general walkaround and observation of the
overall crane set up and operation, followed b a specific inspection of items or
components, the following guidelines are presented in that order. The first section
addresses the general items and operational considerations when inspecting an tpe
of crane, followed b the specific inspection items for two specific tpes of cranes1
&rove #ough Terrain ;0 Ton )hdraulic, and !anitowoc ;-++ -0+ Ton $rawler )lattice
boom friction, cranes.
@n general, the following should be considered when inspecting an crane(
-. #e"uest for and review all inspection and maintenance documents for the
crane being inspected, including the crane manufacturerIs inspection and
maintenance re"uirements.
13
*. $onduct a walkaround inspection, paing particular attention to mechanical
sstems leaks or damage )oil, hdraulic, air, and structural deficiencies.
3. 8ook at crane cab for properl marked controls, damaged instruments and for
properl displaed and legible load charts.
;. Ask the operator, ground crew )riggers,, andDor supervisors appropriate
"uestions on load charts, rigging and load weight determinations, and
capacities.
0. #e"uest the operator to raise and lower the boomDload line, where practical,
and inspect, from the cab position, the running line or rope of the main hoist
drum and secondar line or Fib line. $heck brake action and its abilit to stop.
4. @f practical, re"uest the operator to lower boom to look at the condition of
booms sections, lacing, lifting components, anti-two-block devices, Fib back
stops, and the condition of the hook.
5. $heck crane set up and stabilit of outriggers on hdraulics andDor the
effectiveness of cribbing on crawlers. if possible, re"uest that the crane be
rotated to check all clearances and overall stabilit.
5): Specific Inspection Items and #eferences
The following table identifies the specific inspection items for cranes as well as a brief
description and purpose to help the inspector to have a better understanding of what
and wh the item is being inspected.
Table 5):A +Inspection Items and "escription
ITEM "ESC#I1TION 4 1%#1OSE
;(< Manufacturer=s operatin/ and
Maintenance Manuals
!anufacturerIs operating and maintenance
manuals shall accompan all mobile hoisting
e"uipment. These manuals set forth specific
inspection, operation and maintenance
criteria for each mobile crane and lifting
capacit.
;0< Guardin/ All exposed moving parts such as gears,
chains, reciprocating or rotating parts are
guarded or isolated.
;2< S>in/ Clearance 1rotection !aterials for guarding rear swing area.
;5< Hi/-?&olta/e !arnin/ Si/n High-voltage warning signs displaing
restrictions and re"uirements should be
installed at the operatorIs station and at
strategic locations on the crane.
;7< Boom Stops Shock absorbing or hdraulic tpe boom
stops are installed in a manner to resist boom
overturning.
;8< @ib Boom Stops 9ib stops are restraints to resist overturning.
;9< Boom An/le Indicator A boom angle indicator readable for the
operator station is installed accuratel to
indicate boom angle.
;:< Boom Hoist "isconnectA Automatic
Boom Hoist S-utoff
A boom hoist disconnect safet shutoff or
hdraulic relief automaticall stops the boom
hoist when the boom reaches a
predetermined high angle.
;B< T>o?Bloc.in/ "eCice $ranes with telescoping booms should be
e"uipped with a two-blocking damage
prevention feature that has been tested on-
site in accordance with manufacturers
14
re"uirements. All cranes hdraulic and fixed
boom used to hoist personnel must be
e"uipped with two-blocking devices on all
hoistlines intended to be used in the
operation. The anti-two blocking device has
automatic capabilities for controlling functions
that ma cause a two-blocking condition.
;(*< 1o>er Controlled Lo>erin/ $ranes for use to hoist personnel must be
e"uipped for power controlled lowering
operation on all hoistlines. $heck clutch,
chains, and sprockets for wear.
;((< LeCelin/ Indicatin/ "eCice A device or procedure for leveling the crane
must be provided.
;(0< S-eaCes Sheave grooves shall be smooth and free
from surface defects, cracks, or worn places
that could cause rope damage. %langes must
not be broken, cracked, or chipped. The
bottom of the sheave groove must form a
close fitting saddle for the rope being used.
8ower load blocks must be e"uipped with
close fitting guards. Almost ever wire rope
installation has one or more sheaves
O ranging from traveling blocks with
complicated reeving patterns to e"ualiEing
sheaves where onl minimum rope
movement is noticed.
;(2< Main Hoist and AuDiliar, "rums
S,stem
2rum crushing is a rope condition sometimes
observed which indicates deterioration of the
rope. Spooling is that characteristic of a rope
which affects how it wraps onto and off a
drum. Spoiling is affected b the care and
skill with which the first larger of wraps is
applied on the drum. !anufacturerIs criteria
during inspection usuall specif(
!inimum number of wraps to remain
on the drum.
$ondition of drum grooves
$ondition of flanges at the end of
drum.
#ope end attachment.
Spooling characteristics of rope.
#ope condition.
;(5< Main BoomA @ib BoomA Boom
EDtension
6oom Fibs, or extensions, must not be
cracked or corroded. 6olts and rivets must be
tight. $ertification that repaired boom
members meet manufacturers original design
standard shall be documented. =on-certified
repaired members shall not be used until
recertified.
;(7< Load Hoo.s and Hoo. Bloc.s Hooks and blocks must be permanentl
labeled with rated capacit. Hooks and blocks
are counterweighted to the weight of the
overhaul line from highest hook position.
Hooks must not have cracks or throat
openings more than -0J of normal or
15
twisted off center more than -+
o
from the
longitudinal axis. All hooks used to hoist
personnel must be e"uipped with effective
positive safet catches especiall on hdraulic
cranes.
;(8< H,draulic Hoses Fittin/s and Tubin/%lexible hoses must be sound and show no
signs of leaking at the surface or its Function
with the metal and couplings. Hoses must not
show blistering or abnormal deformation to
the outer covering and no leaks at threaded
or clamped Foints that cannot be eliminated
b normal tightening or recommended
procedures. There should be no evidence of
excessive abrasion or scrubbing on the outer
surfaces of hoses, rigid tubing, or hdraulic
fittings.
;(9< Outri//ers Outrigger number, locations, tpes and tpe
of control are in accordance with
manufacturerIs specifications. Outriggers are
designed and operated to relieve all weight
from wheels or tracks within the boundaries
of the outriggers. @f not, the manufacturerIs
specifications and operating procedures must
be clearl defined. Outriggers must be visible
to the operator or a signal person during
extension or setting.
;(:< Load #atin/ C-art A durable rating chart)s, with legible letters
and figures must be attached to the crane in
a location accessible to the operator while at
the controls. The rating charts shall contain
the following(
A full and complete range of
manufacturerIs crane loading ratings
at all stated operating radii.
Optional e"uipment on the crane such
as outriggers and extra counterweight
which effect ratings.
A work area chart for which capacities
are listed in the load rating chart, i.e.
over side, over rear, over front.
>eights of auxiliar e"uipment, i.e.
load block, Fibs, boom extensions.
A clearl distinguishable list of ratings
based on structural, hdraulic or other
factors rather than stabilit.
A list of no-load work areas.
A description of hoistline reeving
re"uirements on the chart or in
operatorIs manual.
;(B< !ire #ope !ain hoist and auxiliar wire rope inspection
should include examining for
6roken wires.
:xcess wear.
:xternal damage from crushing,
kinking, cutting or corrosion.
16
;0*< Cab $ontains all crane function controls in
addition to mechanical boom angle indicators,
electric wipers, dash lights, warning lights
and buEEers, fire extinguishers, seat belts,
horn, and clear unbroken glass.
;0(< Bra.in/ S,stems Truck cranes and self-propelled cranes
mounted on rubber-tired chassis or frames
must be e"uipped with a service brake
sstem, secondar stopping emergenc brake
sstem and a parking brake sstem. 7nless
the ownerDoperator can show written
evidence that such sstems were not
re"uired b the standards or regulations in
force at the date of manufacture and are not
available from the manufacturer. The braking
sstems must have been inspected and
tested and found to be in conformance with
applicable re"uirements.
$rawler cranes are provided with brakes or
other locking devices that effectivel hold the
machine stationar on level grade during the
working ccle. The braking sstem must be
capable of stopping and holding the machine
on the maximum grade recommended for
travel. The brakes or locks are arranged to
engage or remain engaged in the event of
loss of operating pressure or power.
;00< Turntable4Crane Bod, !ake sure that the rotation point of a crane
gears and rollers are free of damage, wear
and properl adFusted and the components
are securel locked and free of cracks or
damage. The swing locking mechanism must
be functional )pawl, pin, and operated in the
cab.
;02< Counter>ei/-t The counterweight must be approved and
installed according to manufacturerIs
specifications with attachment points
secured.
Table ;./6 shows the items that need to be examined for the &rove #ough Terrain ;0
Ton Hdraulic $rane and their corresponding applicable OSHA *. $%# -.*4 and A=S@
63+.0 Standards.
Table 5):B
+ #ou/- Terrain 57 Ton H,draulic Crane
STAN"A#"
;0B CF# (B08)77*<
INS1ECTION ITEMS ANSI
B 2*)7


Outri//ers
-. 8ubrication
*. Structural $ondition
3. Bressure HosesD$onnections

0--....
0-*.-.3
0-*.-.*
17

Turntable4Crane Bod,
-. :nsure 8evelDStabilit
*. >earD&earDTeethD#ollers
3. $racks
;. 6oltsD:nsure Securel Attached

0--.- H 0--.*

Counter !ei/-t
-. Broper SiEe
*. Attachment $onnectionD6olts


0-3.;.*

-.*4.00+)a,)/,
-.*4.00+)a,)-3,)ii, H )iii,
??????????
-.*4.00+)a,);,
----------
----------
En/ine Housin/
-. $leanlinessD=o #agsDTrash
*. &earD!achiner &uards
3. $lear AccessD>alkwas
;. 6rakesD$lutch AdFustments
0. Hand Signal @llustration
4. Swing 6reak

0--...4
0--./.* H 3
----------
0-* )%ig.-4,
0--.;


-.*4.00+)a,)-*,
----------
??????????
-.*4.00+)a,)-;,)i,
-.*4.00+)a,)*,
-.*4.00+)a,)-3, H
-.*4.00+)a,)-3,)iii,
Cab
-. &lassD'isibilit
*. @nstruments and $ontrols
3. %unctioning Horn )>arning
signal,
;. %ire :xtinguisher
0. Appropriate 8oad $harts and
>arning Signs
4. Broper and Ade"uate Access
)StepsD>alkwa,


----------
0-0.-.4.-.-
----------
0-3.;..
0-0.-.-.3
0--./.* H 3

"rum
-. Broper SiEe and Spoiling of
Hoistlines
*. 2rum SidesDShields for cracks
3. 2ogsDBawlsD8ocking 2evices
;. 2rum #otation vs. $ontrol
!otion

0--.3.- H *

----------
----------
----------
----------
----------
----------
----------
-.*4.00+)b,
Boom Sections
;Boom sections correspond >it-
crane model<
-.
*.
3. 6oom Stops
;.
0. Hoist 8ine &uidesDSheaves
4.
5.
/. 9ib AttachmentD
6ackstopsD6ell Slings


0-*.-.3
S-eaCe S,stem
-. :nsure Hoist 8ine and Sheave

18
SiEe !atch
*. >orn
3. 8ubricationD!ove %reel
0--.5.;

Load4AuDiliar, Hoo. and Bloc.
S,stem
-. Sheaves %unction Smoothl
*. Hook #otates %reelD8ubricated
3. Broper 6ecket
;. Broperl #eeved

0---5.--4
-.*4.00+)a,)5,
-.*4.00+)a,)5,)v,
-----------
-----------
!ire #ope4Hoist Line
-. Overall $ondition
*. :nd $onnections
3. 8ubrication
;. $lips

0--.5.4
----------
----------

----------
----------
-.*4.00+)a,).,
-.*4.00+)a,)-0,
Safet, "eCices
-. Anti-Two 6lock 2evices
*. 6oom 6ackstop 2evices
3. Swing #adius >arning 2evices
;. 9ob or Site Specific
2evicesDsstem
)near electric powerDpersonnel
hoisting platforms,


0--.-..
0-* )%ig. -5,
Additional #eferences(
-.*4.00+)a,)-, ---- $rane used in accordance with manufactures specification.
-.*4.00+)a,)0, ---- @nspection( $ompetent Berson.
-.*4.00+)a,)4, ---- Annual @nspection #ecord.
-.*4.00+)a,)-4, ---- =o modifications without written approval of manufacturer.
Table ;./$ shows the items that need to be examined for the !anitowoc ;-++ -0+
Ton 8attice 6oom $rawler $rane and their corresponding applicable OSHA -.*4 and
A=S@ 63+.0 Standards.
Table 5):C + (7* Ton Lattice Boom Cra>ler Crane
STAN"A#"
;0B CF# (B08)77*<
INS1ECTION ITEMS ANSI
B 2*)7


Trac. Cra>ler S,stem
-. 8ubrication
*. $onnection 6olts
3. 2rive $hain )slack H wear,

0--....
0-*.-.3
0-*.-.*

Turntable4Crane Bod, ;%pper
!or.s<
-. Assure 8evelDStabilit
*. >earD&earDTeethD#ollers
3. $racks
;. 6oltsDBins - Assure Securel
Attached

0--.- H 0--.*
19

Counter !ei/-t
-. Broper SiEe
*. Attachment $onnectionD6olts

0-3.;.*

-.*4.00+)a,)/,
-.*4.00+)a,)-3,)ii, H
)iii,
---------
-.*4.00+)a,);,
----------
----------

En/ine Housin/
-. $leanlinessD=o #agsDTrash
*. &earD!achiner &uards
3. $lear AccessD>alkwas
;. 6rakesD$lutch AdFustments
0. Hand Signal @llustration
4. Swing 6reak

0--...4
0--./.* H 3
----------
0-* )%ig.-4,
0--.;


-.*4.00+)a,)-*,
-----------
----------
-.*4.00+)a,)-;,)i,
-.*4.00+)a,)*,
-.*4.00+)a,)-3, H
-.*4.00+)a,)-3,)iii,
Cab
-. &lassD'isibilit
*. @nstruments and $ontrols
3. %unctioning Horn )warning
signal,
;. %ire :xtinguisher
0. Appropriate 8oad $harts and
>arning Signs
4. Broper and Ade"uate Access
)stepsDwalkwa,

----------
0-0.-.4.-.-
----------
0-3.;..
0-0.-.-.3
0--./.* H 3

Hoist "rum S,stem
-. Broper SiEe and Spoiling of
Hoistlines
*. 2rum SidesDShields for $racks
3. 2ogsDBawlsD8ocking 2evices
;. 2rum #otation vs. $ontrol !otion
0. $lutch and 6rakes

0--.3.- H *


----------
----------
----------
----------
----------
----------
----------
-.*4.00+)b,
Boom Sections
;Boom sections correspond >it-
crane model<
-. 6ase Section Broperl Attached
*. Bin $learance
3. 6oom 8acingD$ord 2amage
;. 6oom Stops
0. &antr Sstem A-%rame
4. Hoist 8ine &uidesDSheaves
5. 6oom Section $onnection
BinsD<es
/. 6oom and &antr Support
Sstem
.. 9ib AttachmentD6ackstopsD6ell
Slings
)9ib Securit 2evice,


0-*.-.3

S-eaCe S,stem
-. :nsure Hoistline and Sheave SiEe
!atch

0--.5.;
20
*. >orn
3. 8ubricationD!ove freel

Load4AuDiliar, Hoo. and Bloc.
S,stem
-. Sheaves %unction Smoothl
*. Hook #otates %reelD8ubricated
3. Broper 6ecket
;. Broperl #eeved

0---5.--4
-.*4.00+)a,)5,
-.*4.00+)a,)5,)v,
-----------
-----------
!ire #ope4Hoist Line
-. Overall $ondition
*. :nd $onnections
3. 8ubrication
;. $lips

0--.5.4
----------
----------

----------
----------
-.*4.00+)a,).,
-.*4.00+)a,)-0,
Safet, "eCices
-. Anti-Two 6lock 2evices
*. 6oom 6ackstop 2evices
3. Swing #adius >arning 2evices
;. 9ob or Site Specific
2evicesDSstemDBrogram for
work near electric power and use
of personnel hoisting platforms,

0--.-..
0-* )%ig. -5,
Additional references(
-.*4.00+)a,)-, ---- $rane used in accordance with manufactures specification.
-.*4.00+)a,)0, ---- @nspection( $ompetent Berson.
-.*4.00+)a,)4, ---- Annual @nspection #ecord.
-.*4.00+)a,)-4, ---- =o modifications without written approval from manufacturers.
21
AppendiD A ? General Terms and "efinitions
Auxiliar Hoist
A supplemental hoisting unit, usuall of lower
load rating and higher speed than the main
hoist.
Axis of #otation
The vertical axis around which the craneIs
superstructure rotates.
6oom
@n cranes and derricks usage, an inclined spar,
strut, or other long member supporting the
hoisting tackle. Also defined as a structural
member attached to the revolving
superstructure used for guiding and acting as a
support for the load.
6oom Angle @ndicator
An accessor device that measures the angle
of the boom base section centerline to
horiEontal.
6oom Stops
A devise used to limit the angle of the boom at
its highest position.
6rake
A device used for retarding or stopping motion
b friction or power means.
6lock
Sheaves or grooved pulles in a frame
provided with hook, ee, and strap.
$rane
A machine consisting of a rotating
superstructure for lifting and lowering a load
and moving it horiEontall on either rubber
tires or crawler treads.
$ounterweight
>eights used for balancing loads and the
weight of the crane in providing stabilit for
lifting.
2eck
The revolving superstructure or turntable bed.

2rum
The spool or clindrical member around which
cables are wound for raising and lowering
loads.
&antr
A structural frame work )also known as an A
%rame, mounted on the revolving
superstructure of the crane to which the boom
supporting cables are reeved.
Headache 6all
A heav weight attached above the hook on a
single line or whip line to provide sufficient
weight to lower the hook when unloaded.
Holding 6rake
A brake that automaticall sets to prevent
motion when power is off.
22
9ib
An extension attached to the boom point to
provide added boom length for lifting specified
loads.
8oad
The weight of the obFect being lifted or
lowered, including load block, ropes, slings,
shackles, and an other ancillar attachment.
8oad 6lock
The assembl of the hook or shackles, swivel,
sheaves, pins, and frame suspended from the
boom point.
!ain Hoist
Hoist sstem or boom used for raising and
lowering loads up to maximum rated capacit.
!echanical 8oad 6rake
An automatic tpe of friction brake used for
controlling loads in the lowering direction. This
device re"uires tor"ue from the motor to lower
a load but does not impose additional loads on
the motor when lifting a load.
Outriggers
Support members attached to the craneIs
carrier frame which are used to the crane and
ma be blocked up to increase stabilit.
Bawl
Also known as LdogL. @t is a gear locking device
for positivel holding the gears against
movement.
Bendants Stationar cables used to support the boom.
#adius
The horiEontal distance from the axis of
rotation of the craneIs superstructure to the
center of the suspended load.
#eeving
The path that a rope takes in adapting itself to
all sheaves and drums of a piece of e"uipment.
#unning Sheave
Sheaves that rotate as the hook is raised or
lowered
Superstructure
The rotating frame, gantr and boom or other
operating e"uipment.
Test 8oad
An load or force, expressed in pounds, used
for testing or certifing the limitations within
acceptable tolerances of the anticipated load.
Two-6lock
The condition in which the lower load lock or
hook assembl comes in contact with the
upper load block or boom point sheave
assembl.
Cuadrant of Operation
The area of operation that the lift is being
made in. 7suall divided into four "uadrants,
i.e. front, rear and side)s, - left side and right
side.
23
AppendiD B ? General Load C-arts and Operational
Considerations
General Load C!arts( !anufacturerIs operating notes supplied with the machine
contain important information concerning proper set-up, operation and additional
points that need to be considered when calculating load handling capacities of cranes.
!istakes in calculating capacit can cause accidents. Several factors to be considered
when calculating a cranes load capacit, including the following(
A. Load Radius( the horiEontal distance between the center of the crane rotation
to center of the load.
6. "oo# lengt!( including the Fib, swing awa extension or an other
attachments that ma increase length of the boom.
$. arts of line(
2. Quadrant of operation( the area of operation that the lift is being made in1
note different "uadrants usuall have lower lifting capacities.
:. "oo# angle( the angle formed between the horiEontal plane of rotation and
center line of the boom.
%. $eig!t of any attac!#ents( Fib, lattice extension or auxiliar boom point.
&. $eig!t of !andling devices( ball, block, andDor an necessar rigging.
Operational Considerations:
A. >hen working at boom lengths or radii between the figures shown on the load
capacit chart, the next lower capacit rating should be used. @t is dangerous
to guess the capacit for boom lengths or radii between those listed on the
rating plate.
6. @t is ver dangerous to lift a load without knowing whether it is within the
rated capacit while expecting the crane to start to tip to warn of an overload.
$ranes ma suddenl tip over or the boom ma collapse if the load is too
heav.
$. Alwas sta within the rated capacit. Operators must reduce the load
capacit under adverse field conditions until, it is determined, the machine can
safel handle the lift.
2. 8oads shall not be allowed to exceed rated load capacit and working radius.
:. 2o not use counterweights heavier than the manufacturerIs recommended
weight.
%. :ven a light wind can blow the load out of control, collapse booms, or tip
machines.
>inds aloft can be much stronger than at ground level.
&. Broper precautions shall be taken when the velocit of wind exceeds *+-mph.
H. $rane capacit can be adversel effected when the machine set is not level.
@. 2o not lift loads when winds create an unsafe or haEardous condition. 6ooms
should be lowered, if possible, under high wind conditions.
9. %oot pedal brake locks are furnished on some cranes to allow the operator to
rest his legs when suspending the load for short periods of time. Operators
should keep their feet on the pedals while foot pedal brake locks are in use.
6rakes ma cool allowing the load to fall.
<. =o one, except the oiler, instructor or designated person should be allowed on
a crane with the operator when the crane is in operation.
24
AppendiD C ? Basic Crane Components
@n addition to reviewing the OSHA and American =ational Standards @nstitute )A=S@,
standardsDre"uirements for mobile construction cranes, it is important that each
inspector have a basic knowledge of crane components and their general purpose.
The following is a list of basic crane components which should be included in an
inspection. @n addition to a description or purpose statement photographs are
provided to help the inspector recogniEe each item. The list ma not be inclusive, but
is intended to be an aid for an inspector who ma not be a crane expert.
-. !anufacturerIs Operating !anual
*. !achine &uarding
@=SB:$T@O= @T:!S
25
-. !anufacturerIs operating and
maintenance manuals shall accompan
all mobile hoisting e"uipment. These
manuals set forth inspection, operation,
and maintenance criteria for each mobile
crane and not generall available from
an other source.
-. !anufacturerIs Operating !anual
*. All exposed moving parts such as
gears, chains reciprocating or rotating
parts are to be guarded or isolated.
*. !achine &uarding
3. Swing $learance Brotection
;. High 'oltage >arning Signs
@=SB:$T@O= @T:!S
3. The swing radius of the counterweight
shall be established and guarded to
prevent personnel or other e"uipment
from being struck b the counterweight.
Special attention shall be given to
guarding of the swing radius when near
buildings or other structures. The swing
radius guarding is intended to simpl be a
warning device and not necessaril a
barricade guard rail. There are no strength
re"uirements associated with swing radius
protection.
26
3. Swing $learance Brotection
;. High voltage warning signs shall be
displaed on the exterior of the
e"uipment on each side and on the
counterweight of the crane.
;. High 'oltage >arning Signs
0. 6oom Stops
4. 9ib 6oom Stops
@=SB:$T@O= @T:!S
0. 6oom stops are telescoping, shock
absorbing, or hdraulic-tpe safet
devices designed and installed in a
manner to stop or shut off power to the
boom controls. The purpose of the boom
stops is to prevent the boom from being
raised to a point where the center of
gravit is shifted to the rear of the crane
causing the boom to fall backwards from
to lack of resistance andDor control of
boom movement.
6oom stops can be inspected and
checked for proper function b raising
the boom ver slowl until contact is
made and power for boom movement is
stopped.
0. 6oom Stops
4. 9ib stops are restraints designed to
prevent the Fib from being raised to the
point that it overturns onto the boom
sections. 9ib stops, like boom stops, are
telescoping, shock absorbing, hdraulic
devices, designed to warn the operator
that the Fib load block has approached
the point at which
overtippingDoverturning is possible if
raising the load line continues.
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4. 9ib 6oom Stops
5. 6oom Angle @ndicator
/. 6oom Hoist 2isconnects
@=SB:$T@O= @T:!S
5. 6oom Angle @ndicators are re"uired to
indicate the angle of the boom tip from the
base section on a horiEontal plane. The
ma be either mechanical )activated b
gravit, or electronic, with a displa
readout in the cab. Accurate readout of
boom angle determines load capacit and
working radius.
5. 6oom Angle @ndicators
/. 6oom Hoist 2isconnects are designed to
automaticall stop the boom from hoisting
when the boom reaches a predetermined
high angle
/. 6oom Hoist 2isconnects
.. Anti-Two 6lock 2evices
-+. Bower $ontrolled 8owering
@=SB:$T@O= @T:!S
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.. Anti-Two 6lock 2evices are designed to
prevent a hoist block andDor load from being
hoisted into contact with the boom tip b
putting sufficient stress on the wire rope
that it is either cut or stressed to the point
that the line separates and the load falls
onto someone or something. A=S@ re"uires
that all hdraulic cranes be e"uipped with
anti-two block devices.
.. Anti-Two 6lock 2evices
-+. All functions of hdraulic cranes
feature Lpower controlled loweringL.
Safet devices known as Lholding valvesL
or Lcounter balanceL valves, which
prevent uncontrolled decent in the event
of hdraulic pressure loss. To test the
effectiveness of these safet devices,
retract the clinders or lower the hoist
drum with the engine not running. This
would appl to the boom lift and
extension clinder as well as the
outrigger clinders and hoist drums. =o
movement should take place without
hdraulic pressure.
-+. Bower $ontrolled 8owering

--. 8eveling @ndicator 2evices
-*. Sheaves
@=SB:$T@O= @T:!S
29
--. 8eveling of the crane is extremel
important. @f a crane is out of level more
than -
o
it exerts a side load on the crane,
and can effect structural capacit. @t also
can increase the load radius when the
crane is rotated to another "uadrant of
operation.
--. 8eveling @ndicator 2evices
-*. All sheaves should be checked for
cracks, grooving, or damage from two-
blocking. 7ndue looseness in the bearing
or bushing should be noted. The sheaveIs
groove surface should be smooth and
slightl larger than the wire rope being
used. @t should be checked with a sheave
gauge to be sure it is the proper siEe for
the wire rope being used. On most
hdraulic cranes, sheave guards which
prevent the wire rope from coming off
the sheave, are removable pins. 6e sure
that all of these pins are in place.
-*. Sheaves
-3. !ain Hoist and Auxiliar 2rums
-;. !ain 6oom, 9ib and 6oom :xtensions
@=SB:$T@O= @T:!S
30

-3. 2rum lagging and flanges should be
inspected for cracks or other deficiencies
and winch mounting bolts should be
checked. An undue movement of the
drum on its bearings should be noted.
The wire rope anchoring to the drum
should meet the manufacturers
specifications and must not be
LoverspooledL. @n other words, with the
rope full spooled on the drum, the
drum flanges must extend above the top
wrap of the rope. An spoiling devices,
such as rollers, or drum rotation
indicators, must be functioning properl.
-3. !ain Hoist and Auxiliar 2rums
-;. All components of the boom
assembl should be checked for cracks,
bends, or other deformities. On
hdraulic cranes, special attention
should be given to the topside of the
boom where the extension sections
exert an upward force. All connecting
pins and bolts should be checked. >ear
pads should be adFusted properl or
replace if necessar.
-;. !ain 6oom, 9ib and 6oom :xtensions

-0. 8oad Hooks and Hook 6lock
-4. Hdraulic Hoses, %ittings and Tubing
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31

-0. Hooks should be examined to see if
the are cracked or distorted beond
allowable tolerances. =o welding or
heating should be done on hooks. Hooks
and blocks should be labeled as to their
capacit and weight.
$onnecting bolts on block cheek plates
should be checked. Hook swivels and
sheave guards should also be checked.

-0. 8oad Hooks and Hook 6lock
-4. All hdraulic hoses, fittings, swivels,
and tubings should be checked for
leaking. On flexible hoses, be sure that
the working pressure stamped on the
hose is more than the working pressure
it will be exposed to.
-4. Hdraulic Hoses, %ittings and Tubing
-5. Outriggers
-/. 8oad #ating $hart
@=SB:$T@O= @T:!S
32
-5. Outrigger beams and housings should
be checked for cracks or distortions.
Outrigger floats, or pads, should be
checked for damage. The floats must
have the capacit to be securel attached
to the outriggers. Outrigger beams should
be marked to indicate when the are full
extended.
-5. Outriggers
-/. A durable load rating chart for the
specific model and serial number of the
crane shall be accessible to the operator
at his operating or work station. All
limitations, warnings, specifications and
safet data should be displaed
-/. 8oad #ating $hart
-.. >ire rope
*+. $ab
@=SB:$T@O= @T:!S
33
-.. >ire rope should be removed from
service when the conditions listed in *.
$%# -.*4.00+)a,)5, are found. The
include outside wire wear, reduction in
diameter, broken wires, distortion,
corrosion, or heat damage. Special
attention should be given to standing
rope, such as pendants, at the end
fittings. @t should be determined that the
wire rope is the proper diameter, length,
and tpe of construction for that
particular crane and it should be spooled
evenl on the hoist drum.
-.. >ire rope
*+. The cab should be clean and free
from clutter. All controls should be
labeled as to their function and free to
return to the neutral position when
released, unless designed to do
otherwise. All gauges and warning lights
should be operable and a fire
extinguisher )at least 0-6$, should be
mounted in the cab. The seat should be
securel attached and the cab door
should open outward and operate
smoothl. :lectrical and other warning
signs should be posted in the cab. All
glass must be safet glass with no cracks
or distortions.
*+. $ab
34