TYPES OF DOCK MOUNTED PEDESTAL CRANES

There are basically two types of hydraulic pedestal cranes used on docks.

The first is the telescopic straight boom

crane. Other than the normal features
of a crane, the boom can be extended
in and out. This feature allows the
crane to reach out further and higher
when the need arises.

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HYDRAULIC

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The second type of crane is
STRAIGHT BOOM
the knuckle boom crane. This
CRANE

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crane has two boom sections.
The second boom section
hinges at the tip of the first

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section. Each boom section
can be operated independently
of the other and this feature

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allows the operator to position
the load more accurately. The

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HYDRAULIC KNUCKLE second boom section may also
BOOM CRANE be fitted with a telescopic
section.

The swinging boom type of

crane is the simplest crane
found on most docks. It
consists of a fixed length
boom that is mounted on a
vertical mast. The boom
cannot be raised or lowered.
Crane rotation is typically
manual, by means of bar or
pipe which is pushed or
pulled to rotate the crane.
SWINGING FIXED The winch used to hoist the
BOOM CRANE load is often electrically
powered, with the up / down
control mounted on the end
of an electrical cord 1
 CRANE COMPONENTS

CRANE COMPONENTS

Boom
Boom
Winch
Winch

Boom
Boom Tip
Tip

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Turret
Turret Wire
Wire
Rope
Rope

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Lift
Lift Cylinder
Cylinder

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Hook
Hook

Pedestal
Pedestal

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6

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SWINGING BOOM CRANE COMPONENTS

Mast
Mast
Sheave
Sheave

Boom
Boom
Boom
Boom Tip
Sheave
Sheave
Tip

Mast
Mast
Boom
Boom Hook
Hook
Support
Support
Winch
Winch

Rotation
Rotation
Dock
Dock Mounting
Mounting
Bearing
Bearing

2
 CRANE INSPECTION

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CRANE INSPECTION CHECK LIST

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INSPECTION AREA INSPECTION RESULTS
Sat. Unsat. N/A Comments
Supporting Structure
Welds
Bolts

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Rotating System
Bull & PinionGear
Swing Brakes

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Hydraulic Drive Motor
Boom
Welds

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Stress & Distortion
Hinge Pin
Boom Cylinder & Pins
Wear Pads
Telescopic Operation
Tip Section & Sheaves
Angle/Radius Indicator
Anti-Two Blocking Sys.
Winch System
Wire Rope Condition
Rope Reeving
Mounting Bolts
Brakes
Functional Operation
Hydraulic System
Pump Performance
Control Functions
Control Markings
Hydraulic Leaks
Hose Condition
Fluid Level
Load Block
Sheaves
Pins
Swivel
Hook

The operator is responsible for inspecting the crane prior to using it.
3
 TURRET INSPECTION

BOOM HINGE PIN

PINS & BOSSES

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ROTATION BEARING

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The four areas in the slide can be checked by performing the

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following test:

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• Retract the boom fully and raise it to its most vertical position
and extend the hoist wire about 10 feet.

• Abruptly lower the boom momentarily which will result in the

turret and boom component rocking. Observe the movements in
the rotation bearing, boom hinge pin and bushing, and the lift
cylinder pins and bushings. CAUTION: WHEN SHAKING THE
CRANE, OBSERVE THE HOOK AND STOP ANY BOOM
MOVEMENT IF IT CAN SWING INTO THE BOOM.

• Any excessive movement must be noted and evaluated per the

manufacturer’s specifications.

• Check the turret area for cracked welds and any deformed components.

4
 ROTATION INSPECTION

ROTATION BEARING & DRIVE

ROTATION BEARING
Rotation gear
Rotation ring
Rotation
Bearing Mounting holes

Seal

Holes spaced for uniform load

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Grease fitting

Bearing spacer

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Ball bearing

Bearing raceway

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Swing Drive Motor

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and Assemble

• S A
The only thing that keeps the boom from detaching from the
pedestal is the rotation bearing. If it fails, the boom comes down.

The rotation bearing should be greased on a regular basis per

the manufacturer maintenance manual.

• The rotation bearing is attached to the pedestal by bolts. These

need to be checked for tightness. The turret is also attached to
the bearing with bolts and they also need to be checked.

• The rotation drive motor is typically mounted up in the pedestal

and the mounting bolts need to be checked.

• Check the ring and pinion gears for grease.

5
 CRANE INSPECTION
Head

Winch

Slide Pads

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Welds
Pins & Bosses

M P BOOM & TURRET INSPECTION

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• The boom needs to be extended and checked for smoothness of
operation. Any binding or difficulty in extending could be the
result of damaged boom sections.

• All welds need to be checked for cracks.

• Any hydraulic leaks need to be investigated and repaired. Check

the hoses for chaffing and wear.

• The slide pads can be checked for proper alignment by extending the
boom completely and lowering the tip toward the ground. Move the
boom tip back and forth by pushing on it and observe how much the
boom sections move inside each other. Excessive movement will
require the slide pads to be adjusted or replaced.

• The boom tip needs to be checked for deformation and twisting.

• The winch should be checked for proper reeving. The most common
cause of damage to wire rope is crushing due to crossed wraps
on the winch drum.
6
 CRANE INSPECTION

• Check sheaves for bearing wear and INSPECTING SHEAVES

lubrication.
• Check the flanges and treads. Use a CHECK FLANGES FOR
CHIPS, CRACKS, WEAR CHECK
GROOVE

sheave gauge. WEAR

• Sheaves can only be repaired per

manufacturer’s procedures. CHECK BEARINGS FOR
WOBBLE, GREASE, EASE
OF ROTATION

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150º
CONTACT

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MEASURE GROOVE

WORN GROOVES PROPER SIZE GROOVE

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• The sheaves and bearings need to be
checked on crane blocks.
• Check the side plates and any additional
CRANE BLOCK

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weights attached to the sides need to be
checked for loose or missing bolts or SIDE PLATE
BOLTS TIGHT

fasteners.

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SHEAVE GROOVE

• The hook and shank nut should be SIDE PLATES

STRAIGHT
NOT WORN, SHEAVES
TURN FREELY

separated periodically and the threads SHEAVE PIN

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& BEARING HOOK NUT TIGHT
TIGHT & THEADS INSPECTED
inspected for corrosion and other damage. SAFETY
PERIODICALLY

LATCH
• The safety latch must be in place and SHEAVE PIN
KEEPER IN PLACE
FUNCTIONING

AND TIGHT
functioning properly. HOOK ROTATION &
SWIVEL SMOOTH &

• The hook should rotate freely on the CHECK FOR DISTORTIONS

OR WEAR
TIGHT

swivel bearing. Check for excessive

movement.

• Wear in excess of 5% in the neck of the HOOK INSPECTION

hook and 10% in other areas is cause for [
CHECK FOR:
Wear
removal. [
[
Deformation
Cracks & Sharp Nicks
Wear & Deformation
[ Modifications
• An increase in the hook throat opening of [
[
Safety Latches
Swivel Wear & Lubrication

more than 15% is cause for removal [ Hook Shackle Housing

Cracks &
“Opening Up”
Twisting
• Any twist in the hook of more than 10% is
cause for removal.
• Hooks can only be repaired per
manufacturer’s procedures. Wear & Cracks

7
 WIRE ROPE INSPECTION

Kinks are a permanent distortion. After a wire rope KINKED WIRE ROPE
is kinked it is impossible to straighten the rope enough
to return it to its original strength. The rope must be
replaced. Causes: crossed lines on drum, improper
handling and installation, and uncoiling.

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Strand Nicking is due to continued operation under a STRAND NICKING
high load which results in core failure.

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Metal Fatigue is usually caused by bending stress FATIGUE FAILURE

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from repeated passes over sheaves, or from vibration
such as crane pendants.

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Fatigue Breaks can be either external or internal.
They also can be caused by wobbly sheaves, tight
grooves, poor end terminations. In the absence of all
these causes, remember that all wire rope will
eventually fail from fatigue.
FATIGUE BREAKS

BIRDCAGE
Bird Caging is a result of mistreatment such as
sudden stops, wound on too tight of drum, or pulling
through tight sheaves. The strands will not return to
their original position

High Stranding is a condition caused when HIGH STRAND

overloading and crushing take place and the other
strands become overloaded.

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 DYNAMIC LOADING
IMPACT OF DYNAMIC
LOADING STATIC LOAD DYNAMIC LOAD

DIRECTION OF MOVEMENT
When a load is moved, additional
stresses are imposed on the crane’s
structure. To start a load moving either
by hoisting, booming or swinging, the
crane will have to exert an additional
force. How much additional force is STATIONARY
dependent on the weight of the load

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LOAD
and how fast it has started moving. STOPPED

Loads started slowly and stopped

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TOTAL LOAD = STATIC LOAD +
slowly will not exert as much stress
DYANAMIC LOAD
on the crane as those which are move

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rapidly.

The below chart shows how the dynamic load increases as the rate of

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starting and stopping the load increases.
40
1 ft

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35

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Increase in Load %

30

25
Distances in which
2 ft load is stopped.
20

15
4 ft

10 6 ft
8 ft
5 10 ft

0 30 60 90 120 150 180 210 240 270 300

0
Load Velocity F.P.M. 9
 SIDE LOADING

AVOID SIDE
The boom is very susceptible to LOADING
side loading damage and needs to FROM TILTING
be above the load at all times.
Tilting up panels are a common
cause of side loading. When
tilting up a panel, the hoist line

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must remain vertical at all times.
Although it is not very apparent,

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wind can cause excessive
stresses on the crane. The
operator must stop operations AVOID SIDE

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when the wind becomes a LOADING
significant factor. The wind FROM SWING
pressure on the load can also add AND/OR

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side loading to the boom as well WIND
as losing control of the load. Tag

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lines may be necessary to help
control the load, but should never

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be used to pull the load around.

Never intentionally side load

the crane by yarding or
dragging a load on the ground.
This could seriously damage
the boom or swing
mechanisms on the crane.
Knuckle booms are particularly
suseptable to damage from
this practice. This puts
tremendous strain on the
pinion gear of the swing motor
which over time could fail.

10
 LOAD CHART
RANGE DIAGRAM

HEIGHT IN FEET
80
The range diagram
shows the various boom
60
tip heights based on
boom length and
radius. This chart will 40
help to determine if this

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crane is able to make a
20
certain lift.

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RATED LOAD CAPACITY CHART

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The load capacity section of the load chart states the lifting capacity of the
pedestal crane for a given radius and boom length. A typical chart will show the
radius in the left hand column and the corresponding boom angle and length on
top. If the desired radius falls between two figures on the chart, the longer of the
two must be used with their corresponding angles and capacities. Never try to
“split the difference.” The boom angles on the chart are for loaded booms. When
pre-determining where the boom angle is to be used as a means for establishing
the radius, 2 degrees should be added to the load chart number. As the boom is
loaded, it will tend to drop a few degrees, so the 2 degrees should compensate for
that.

11
 CRANE SAFETY

• Do not leave the crane with a suspended load

• Rig the crane with sufficient parts of line for the load
• Avoid two-blocking the crane
• Always have a minimum of three wraps of cable on the drum
• Monitor the winch to make sure that it is spooling correcting
• Do not lift loads over personnel
• Lift one load at a time

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MAKING THE LIFT

PL
Review the lift scenario with the operator, riggers and signal person
Attach taglines when necessary

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Position signal person within visibility of the load and operator
Begin by lifting the load slowly

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Re-check the boom angle indicator to assess radius increase

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Keep load as low as possible when moving it
Swing slowly to avoid swing out.
Avoid erratic booming
Follow signal and stop operation when uncertain
Lower load slowly

SIGNALS

• Only one person should be designated as the signal person.

• The emergency stop signal can be given by anyone on the site.
• The signals must be clear and precise.
• The crane operator should never respond to a signal that is not
clearly understood.

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 HAND SIGNALS

DOG EVERYTHING EXTEND BOOM EMERGENCY STOP

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LOWER THE LOAD

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RETRACT BOOM
RAISE THE LOAD

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RAISE THE BOOM LOWER THE BOOM

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RAISE THE LOAD RAISE THE BOOM SWING

STOP
LOWER THE LOWER THE BOOM
LOAD
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 SHACKLE INSPECTION

The working load limit (WLL) must

be printed on the shackle or it must
be taken out of service. This WLL
is for vertical lifts only.

Only two types of shackles are to be used in rigging for lifts. The screw pin
type and the bolt type shackle.

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Shackles that are deformed or damaged must be removed from service.

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IN-LINE
45 DEGREES

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90 DEGREES

Side Loading Reduction Chart

For Screw Pin & Bolt Type Shackles Only†
Angle of Side Load Adjusted Working Load Limit
0° In-Line 100% of Rated Working Load Limit
45° from In-Line 70% of Rated Working Load Limit
90° from In-Line 50% of Rated Working Load Limit

† DO NOT SIDE LOAD ROUND PIN SHACKLES

14
 EYE BOLTS

Eye bolts should always be inspected before use. Look for signs of wear and
damage. Look to see if shank is bent or elongated. Make sure the threads on
the shank and the receiving hole are clean.

DIRECTION OF PULL ADJUSTED WORKING LOAD

In-Line Full Rated Working Load

45 Degrees 30% of Rated Working Load

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60 Degrees 60% of Rated Working Load

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• Always use Shouldered Eye Bolts
for angular lifts.

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• For angular lifts, reduce working load
according to chart.

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• Never exceed load limits. WRONG!
• Always screw eye bolt down completely
for proper seating.
• Always tighten nuts securely against the
load.
• Always stand clear of load when lifting.
• Always lift load with steady, even pull-
do not jerk.
• Do not reeve slings from one eye bolt to
another.
• Never machine, grind or cut the eye bolt.
CAUTION

STRUCTURE MAY BUCKLE FROM

Shoulder Nut
COMPRESSION FORCES
Eye Bolt

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 WIRE ROPE SLING INSPECTION

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Wire rope slings need to be inspected in the same way wire rope is and

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a record kept of those inspections. All slings must have a tag on them
indicating the capacity or they must be taken out of service.

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Chain slings are to be inspected
regularly and a record kept of

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these inspections also. Again, if
there is no capacity tag, it must be
taken out of service.
Chain slings are often used to hold
steel while it is being welded. Always
check to make sure heat damage
has not occurred. Heat damage can be
detected by discolored metal.

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 SYNTHETIC SLING INSPECTION

Far too many web slings have to be

discarded prematurely simply because
abusive or careless work habits caused
irreparable damage.

To the right are some examples of

damaged
slings.

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Regardless of whether a sling shows

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damage from abuse or regular wear, the
overriding rule in all cases is that the sling

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eyes should be cut, and the sling
discarded immediately whenever damage
is detected.

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When using synthetic slings, remember:

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• Slings without a capacity tag should be

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discarded. That tag should have the
following information:
-Name and trademark of manufacturer.
-Manufacturer’s code or stock number.
-Rated loads (rated capacities) for the
type of hitches used.
-Type of synthetic material.

• Use wear pads on corners to protect the

sling from cuts, or abrasions.

• Do not pull the sling out from under the

load if caught under it.

• Take into consideration the sling angles

when calculating the capacity of the
sling to handle the load.

17
 SLING ANGLES

When slings are brought together and form a hitch, as shown Tension in slings
at right, the stresses in the slings increase and a compression
force on the load is created. As the sling angle decreases, Sling angle
the stresses in the sling and on the load increase.

Compression in load

bs
500 lbs

500 lbs
1000 lbs

57
5l
70

5l

s
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57
lbs 1000

lb
5

bs
lb 000

5
lbs

70
s 1

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60° 45° 30°

1000 lbs 1000 lbs 1000 lbs 1000 lbs 1000 lbs

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Sling angles of 60 degrees are the best to use because of the minimal

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increase of stress in the slings. When required to use smaller sling
angles, slings need to be selected based on the increased stress and bs 5735 lb
not on the weight of the load. The compression in the load also has 5735 l s

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5°
to be considered. When the sling angle is 30 degrees for a 1000 lb
load, the compression which is crushing the load will be 866 lbs.
Depending on the structural strength of the load, it may be damaged.
1000 lbs

Sling Angle Degree (A) Load Angle Factor = L/H

All that is needed to calculate the 90 1.000
stress in a sling is the weight of the 60 1.155
object and a measuring tape. 50 1.305
45 1.414
Load in each sling = 30 2.000
500 x Load Angle Factor Load On Each Leg Of Sling = (Load/2 x Load Angle Factor

Example:
If the sling was 8’ long and the
500 lbs

500 lbs

height (H) was 4’, then 8 divided

by 4 equals 2 which equals the L
H A
Load Angle Factor. So, if the load
is 1000lbs, each sling is required to
support 500lbs. The stress in the
sling is equal to 500lbs x the load 1000 lbs 1000 lbs 1000 lbs
angle factor of 2 or 1000lbs.
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Student Manual
Dock
& Vessel

E
Mounted

PL
A M
S Pedestal Crane
Operator Safety
Training