Thorough Examination

of Crawler Cranes in
Accordance with
ASME/ANSI B30.5
 Introduction to Crawler Cranes
A Crawler Crane is basically a tracked vehicle
that has a crane mechanism attached to it

This crane has the capability to work on every

type of ground surface, even on the softest
grounds, thanks to its specially designed track
properties. The metal tracks make the crawler
crane very stable on the ground and also
provide increased maneuverability on the
ground.

The lifting capacity of the crawler crane ranges

from 30 to 3000 tons depending on the model.
Introduction to Crawler Cranes

Crane – Consists of a rotating structure for

lifting and lowering horizontally on crawler
treads
Hoist - Used to lift and lower load.
Boom – An inclined spar, strut, or other
long member supporting the hoisting tackle
Jib – Extension attached to the boom point
to provide added boom length for lifting
specified loads.
Counter weight – Weights used for
balancing loads and the weight of the
crane in providing stability
Introduction to Crawler Cranes
All crawler cranes consist of several parts. The propulsion system
and the tracks are the main parts of the crane. The engine and the
control cabin are placed on top of the tracks.

A long boom is attached to the cabin and can be raised high above
the control cabin. Cables move through the boom and a hook is
attached at the end of the boom for catching, lifting and moving
various kinds of items and loads from one place to another.

Some crawler crane models come with additional part known as a

jib which is attached at the end of the boom. The jib allows the
crawler crane to move items even further from its position on the
ground. The crawler crane moves like a crawler tractor, but
because of its weight it moves very slowly on the ground.
Pros and Cons of Crawler Cranes
The main advantage of the crawler crane is the
ability to move and lift items and other heavy loads
around the construction site very easily. In addition,
the tracks of the crawler crane provide support and
increased stability.

The biggest disadvantage of the crawler crane is the

big size and weight. The crawler crane is not
transported fully assembled. They are just too big
for the roads. That’s why they are delivered in
manageable pieces and assemble on site. This can
be a project on its own and will involve a team of
professional heavy lift technicians such as riggers &
operators. The configuration of the crane is
predetermined in advance by the lift engineer based
on the customer’s project requirement.
 Major Causes of Accidents according to OSHA
OSHA identified the major causes of crane accidents to
include:

Crane buckling or collapsing -

All cranes have weight limits to ensure that the crane will
not tip over. To counterbalance the weight, cranes use
counterweight and out-rigging systems. If the maximum
weight is exceeded the crane will be in danger of either
buckling or the boom may collapse.

Improper Crane Assembly -

One of the biggest reasons that a boom collapses is
improper assembly. Specifically, if the crane does not
have the proper blocking (wood or metal supports) to
stabilize the load, the unbalanced load will move and may
lead to the crane collapsing.
 Major Causes of Accidents according to OSHA

OSHA identified the major causes of crane

accidents to include:

Improper Employee Training

Operators who have insufficient training in
crane operation and safety procedures are
prone to causing Accidents involving cranes.

Mechanical Failures -
Routine crane maintenance should be followed
to prevent accidents due to mechanical failure.
Crane components should be oiled on a
regular basis and components with excessive
wear should be repaired and replaced right
away.
.
 Major Causes of Accidents according to OSHA

OSHA identified the major causes of crane accidents to include:

Contact with overhead power lines -

Electrocution from contact with overhead power lines is a leading cause of crane
related accidents. Both the crane operator and workers in the crane basket should be
aware of the placement of power lines surrounding the worksite. Before work
commences the current to active power lines should be shut off to prevent
electrocution from accidental contact with live wires.

Flawed or Infrequent Inspections -

Timely, consistent inspections by experienced and well-trained inspectors can wholly
prevent tragic accidents. It is an inspectors Responsibility to protect others!
.
Main Reasons for Accidents Summarised

Instability – unsecured load, load

capacity exceeded
Ground not level or too soft
Lack of communication
Lack of training
Inadequate maintenance or
inspection
Unguarded swing radius
Excessive speeds
Working too close to power lines
Mobile Crane With Lattice Boom Sections

Boom Tip Main Hoist Sheaves

Floating Sheaves Boom hoist Boom Pennants

Boom Hoist Wire

Boom Hoist ‘A’ Frame Sheaves

‘A’ Frame Structure

Main Hoist Wire

Main hook Block

Main Hoist Winch

Boom Hoist Winch

Boom Cathead Section

Boom Root Section

MOBILE CRANE
WITH LATTICE
BOOM SECTIONS.

Crane Outriggers
EXAMPLE OF A TRACKED
CRAWLER CRANE FITTED
WITH A LATTICE BOOM.
Pre Inspection Criteria

Before the actual inspection, some general information about the crane
operator's qualifications and the crane's certifications should be gathered,
such as:

Operator Qualifications Observe the operator in action and when the

opportunity permits ask a few question concerning the cranes capacity and
restrictions imposed, either due to activity involved in or functional
limitations.

Crane Records Ask for inspection and maintenance records and verify
that the appropriate operator's manual and load charts are available for
that particular crane in use.
Introductions – Inspecting a Crawler Crane

Since cranes impact such a large segment of

work going on at any job site, crane
inspections (to the Compliance Officer and
Project Safety Managers) must include a
survey, or walk around, of the entire operation
that questions how the crane will be operating
and how other crafts will be effected by
working with and around the crane?
Observation of crane operations prior to an
inspection, or simply asking how cranes have
or will be used, can indicate possible problem
areas that may need a closer review during
the inspection process.
Crane Setup – Prior to Inspection

In your initial survey of crane operations, look

for crane stability, physical obstructions to
movement or operation, and proximity of
electrical power lines, as well as the following:

Leveling Has the crane operator set the crane

up level and in a position for safe rotation and
operation?

Outriggers Are the outriggers, where

applicable, extended and being used in
accordance with manufacturer's
recommendations?
Crane Setup – Prior to Inspection

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
ofgravity 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.

Structural Integrity The crane's main frame, crawler, track and outrigger
supports, boom sections, and attachments are all considered part of structural
components of lifting. In addition, all wire ropes, including stationary supports,
help determine lifting capacity and are part of the structural elements of crane
operations.
Electrical Hazards – Prior to Inspection

Working around or near electrical power lines is one of the most dangerous
practices for crane operations. The OSHA requirements limit crane
operations to a minimum clearance of 10 feet. Cranes should not be used to
handle materials or loads stored under electric power lines. In addition,
operation of mobile cranes near de-energized electric power lines is not
recommended until the following steps have been taken:

The power company or owner of the power line has deenergized the lines.
The lines are visibly grounded and appropriately marked at jobsite.
Durable warning signs are installed at the operator's station and on the outside of the crane
identifying the clearance requirements between the crane/load and electrical power lines.
A qualified representative of the power company or owner of the electrical powerline are on the
job site to verify that the power lines have been de-energized orproperly grounded.
Load Charts – Prior to Inspection

Load Charts are the principle set of

instructions and requirements for boom
configurations and parts of line which
establish crane capacity for safe crane
operations.
Availability The crane operator must have in
his/her possession the appropriate load
charts related to the crane in use and for the
loads being lifted.

Correct Use The crane operator must show

adequate understanding and proficient use of
the load charts as related to the equipment in
use and the loads being lifted.
Inspection Types – Frequent Inspections

Frequent Inspections (daily to monthly

intervals) - Frequent inspections are
usually performed at the start of each shift
by the operator who walks around the
crane looking for defects or problem areas.
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 daily, and when possible,
observed during operation for any defects
that could affect safe operation. To help
determine when the crane is safe to
operate, daily inspections should be made
at the start of each shift.
 Inspection Types – Periodic Inspections
Periodic Inspections (1 to 12 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. It includes those items listed for daily inspections
as well as, but not limited to, structural defects, excessive wear, and hydraulic or air
leaks.

Inspection records of the inspected crane shall be maintained monthly on critical items
inuse, 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 readily available
for review. The manufacturer's maintenance and inspection records, forms/checklist, or
equivalent should be used.
Starting the Inspection….

Since most crane inspections begin

with a general walk around and
observation of the overall crane set
up and operation, followed by 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 any
type of crane, followed by the
specific
inspection items for Crawler
Cranes.
 Starting the Inspection….
In General, the following factors ought to be considered when inspecting any crane ;

• Request for and review all inspection and maintenance documents for the crane being inspected, including the
crane manufacturer's inspection and maintenance requirements.

• Conduct a walkaround inspection, paying particular attention to mechanical systems leaks or damage (oil,
hydraulic, air) and structural deficiencies.

• Look at crane cab for properly marked controls, damaged instruments and for properly displayed and legible
load charts..

• Ask the operator, ground crew (riggers), and/or supervisors appropriate questions on load charts, rigging and
load weight. determinations, and capacities.
 Starting the Inspection….
In General, the following factors ought to be
considered when inspecting any crane ;

• Request the operator to raise and lower the boom/load

line, where practical, and inspect, from the cab position,
the running line or rope of the main hoist drum and
secondary line or jib line. Check brake action and. its
ability to stop.

• If practical, request the operator to lower boom to look at

the condition of boom’s sections, lacing, lifting
components, anti-two-block devices, jib back stops, and
the condition of the hook.

• Check crane set up and stability of outriggers on

hydraulics and/or theeffectiveness of cribbing on crawlers.
If possible, request that the crane be rotated to check all
clearances and overall stability.
Inspection Items – Description and Purposes

Manufacturer's Operating and Maintenance Manuals -

Manufacturer's operating and maintenance manuals shall
accompany all mobile hoisting equipment. These manuals
set forth specific inspection, operation and maintenance
criteria for each mobile crane and lifting capacity.

Guarding - All exposed moving parts such as gears,

chains, reciprocating or rotating parts are guarded or
isolated.

Swing Clearance Protection – Materials used for guarding

rear swing area

Boom Stops - Shock absorbing or hydraulic type boom

stops are installed in a manner to
resist boom overturning
Inspection Items – Description and Purposes

Jib Boom Stops - Jib stops are restraints to resist

overturning.

Boom Angle Indicator - A boom angle indicator readable

from the operator station is installed accurately to indicate
boom angle.

Boom Hoist Disconnect, Automatic Boom Hoist

Shutoff– A boom hoist disconnect safety shutoff or
hydraulic relief to automatically stop the boom hoist when
the boom reaches a predetermined high angle.

Power Controlled Lowering - Cranes for use to hoist

personnel must be equipped for power controlled
lowering operation on all hoist lines. Check clutch, chains,
and sprockets
for wear.
Inspection Items – Description and Purposes

Levelling Indicating Device - A device or procedure for

leveling the crane must be provided.

Sheaves- Sheave grooves shall be smooth and free from

surface defects, cracks, or worn places that could cause
rope damage. Flanges must not be broken, cracked, or
chipped. The bottom of the sheave groove must form a
close-fitting saddle for the rope being used. Lower load
blocks must be equipped with close fitting guards. Almost
every wire rope installation has one or more sheaves --
ranging from traveling blocks with complicated reeving
patterns to equalizing sheaves where only minimum rope
movement is noticed.
Inspection Items – Description and Purposes

Main Hoist and Auxiliary Drums System- Drum 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 by the care and skill with which the first
larger of wraps is applied on the drum. Manufacturer's
criteria during inspection usually specify:

• Minimum number of wraps to remain on the drum.

• Condition of drum grooves.
• Condition of flanges at the end of drum.
• Rope end attachment.
• Spooling characteristics of rope.
• Rope condition.
Inspection Items – Description and Purposes

Main Boom, Jib Boom, Boom Extension

Boom jibs, or extensions, must not be cracked or corroded. Bolts and rivets must be tight. Certification that
repaired boom members meet manufacturers original design standard shall be documented. Non-certified
repaired members shall not be used until recertified.
Inspection Items – Description and Purposes

Load Hooks and Hook Blocks - Hooks and

blocks must be permanently labelled with rated
capacity. 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 5% of
normal or twisted off centre more than 10%
from the longitudinal axis. All hooks used to
hoist personnel must be equipped with effective
positive safety catches -especially on hydraulic
cranes.
Inspection Items – Description and Purposes

Hydraulic Hoses Fittings and Tubing -

Flexible hoses must be sound and show no
signs of leaking at the surface or its junction
with the metal and couplings. Hoses must not
show blistering or abnormal deformation to the
outer covering and no leaks at threaded or
clamped joints that cannot be eliminated by
normal tightening or recommended procedures.
There should be no evidence of excessive
abrasion or scrubbing on the outer surfaces of
hoses, rigid tubing, or hydraulic fittings.
Inspection Items – Description and Purposes

Outriggers - Outrigger number, locations, types

and type of control are in accordance with
manufacturer's specifications. Outriggers are
designed and operated to relieve all weight
from wheels or tracks within the boundaries of
the outriggers. If not, the manufacturer's
specifications and operating procedures must
be clearly defined. Outriggers must be visible to
the operator or a signal person during extension
or setting.
Inspection Items – Description and Purposes

Load Rating Chart –

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 manufacturer's crane loading ratings
at all stated operating radii.
• Optional equipment 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.
• Weights of auxiliary equipment, i.e. load block, jibs, boom
extensions.
• A clearly distinguishable list of ratings based on structural,
hydraulic or other factors rather than stability.
• A list of no-load work areas.
• A description of hoist line reeving requirements on the chart or in
operator's manual.
Inspection Items – Description and Purposes

Wire Rope- Main hoist and auxiliary wire

rope inspection should include examining
for:
• Broken wires,
• Excess wear.
• External damage from
crushing, kinking, cutting or
corrosion.

Cab - Contains all crane function controls

in addition to mechanical boom angle
indicators, electric wipers, dash lights,
warning lights and buzzers, fire
extinguishers, seat belts, horn, and clear
unbroken glass.
Inspection Items – Description and Purposes

Breaking Systems - Crawler cranes are

provided with brakes or other locking devices
that effectively hold the machine stationary on
level grade during the working cycle. The
braking system 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
Inspection Items – Description and Purposes

Turntable/Crane Body - Make sure that the

rotation point of a crane gears and rollers are
free of damage, wear and properly adjusted and
the components are securely locked and free of
cracks or damage. The swing locking
mechanism must be functional (pawl, pin) and
operated in the cab.

Counterweight - The counterweight must be

approved and installed according to
manufacturer’s specifications with attachment
points secured.
 Inspection - Lattice Boom
Crawler Crane in accordance
applicable OSHA 1926 and
ANSI B30.5 Standards.
Track Crawler System

Criteria of Inspection

1. Lubrication
2. Connection Bolts
3. Drive Chain (slack & wear)

Applicable Standards :

ASNI B30.5
5-1.9.9
5-2.1.3
5-2.1.2
Turntable/Crane Body (Upper Works)

Criteria of Inspection

1. Assure level/Stability
2. Wear/Gear/Teeth/Rollers
3. Cracks
4. Bolts/Pins - Assure Securely
Attached
5. Outriggers

Applicable Standards :

ASNI B30.5
5-1.1 & 5-1.2
Outrigger Beam Inspection

Outrigger Beams and

housings should be checked
for cracks and distortions.
Outrigger floats, or pads
should be checked for
damage. The floats/Pads
must have the capacity to
securely attached to the
outriggers. Outrigger beams
should be marked to indicate
when they are fully extended.

Mobile crane Outriggers & Pads.

Outrigger Beam Inspection

• The outrigger beams are to be clearly and durably marked to show

when they are fully extended. If the manufacturer allows an
intermediate extension position, then it is to be clearly and durably
marked.

• Check all the outrigger beam components for distortion, denting, and
corrosion, bolting soundness and cracked welds. This is to include the
hydraulic rams and the supply piping.

• The hydraulic rams are to be checked for correct operation and that no
obvious leaks are present. The outrigger beams and rams are to be
fully extended and the wheels checked to see that they are clear of the
ground. Check for any unusual rubbing marks on the beams caused by
distortion.
Levelling Device

The leveling of the mobile crane is

extremely important. If a crane is
out of level more than 1 degree it
exerts a side load on the crane,
and can effect structural capacity. It
can also increase the load radius
when the crane is rotated to
another quadrant of operation.
Note: Modern mobile cranes are
fitted with leveling devices.
Slew ring Machinery

• Check for bearing wear in the slew ring which is carried out by doing
rocking motions and the results should be available in the
maintenance log for review & reference.

• There should also be a history / records of rocking motions & grease

samples analysis which have previously been carried out.

• Slew ring is to be checked for general condition of lubrication.

• During function checks crane is to be rotated and brake applied to

check for excessive backlash. (Refer to manufacturer for tolerances).
Slew ring Machinery

Picture showing three

different types of Slew ring.
Note: Taking rocking motions &
grease samples detects wear
on these bearings, and give you
an idea about there condition.
Slewring Machinery

Picture showing slew

Automatic brake assembly.
Slew ring Machinery

Other bolts have

caps, known as
Rota bolts. If this
cap turns it is an
indication that the
bolt is slack.
Only use a divers
wheel to determine
slackness.

Picture showing
Slew parking
brake.
Slew ring Machinery

Diagram showing slew

ring bolts (Rotabolt type)

 Slew ring bolts should be checked

for security and looseness.
If this cap turns it is an indication that
the bolt is slack.
Check external & internal slew ring
Rotabolt Cap. bolts.
(For divers tool)
Only use a divers wheel to
determine slackness.

Grease samples are normally

collected by the crane mechanic
to verify internal condition of the
Divers Wheel tool, slew ring, which are sent away for
(acts as a ratchet)
checks, looking for metal particles etc..
Slew ring Machinery

Diagram showing Slew

ring teeth and pinion.

 Visual examination is to
be conducted on the slew
bearing and pinion teeth,
to check for scoring,
pitting, mechanical
damage, gouging etc..
Rock crane side to side
and check for excessive
backlash.
Slew ring Machinery

• Crane is to be rotated 360 deg at various speeds in both directions

and any irregular vibrations, jerks or bumps investigated further.

• If Any limits are fitted internally or externally on the slew ring, these
should be verified during function of the crane.

• Gears and guard covers should be secure and intact, with no

missing bolts etc.. (As these are potential dropped objects).
Slew ring Machinery

CRAWLER CRANES
ARE FITTED WITH
A ROLLER AND
HOOK ASSEMBLY,
AROUND 4 OFF
ROLLERS.
Slew ring Machinery

NOTE: DURING
INSPECTION OR
TESTING ADJUSTMENTS
TO THE CLEARANCE OF
THE LOWER ROLLER TO
THE UNDERSIDE OF THE
ROTATION FLANGE CAN
BE MADE, IF REQUIRED.
Inspection of Counterweight – Crawler Crane

Counterweight Inspection
Criteria:

1. Proper size
2. Attachment
Connection/Bolts all in good
order and secure.
3. Calibrated Weight

Applicable Standards
ASNI B30.5
5-3.4.2
Inspection of Counterweight – Crawler Crane

• Ballast weights are to be checked for security and suitability for

operation being performed.

• Counterbalance weights are to be adequately secured to prevent

accidental release or removal.

• Counterbalance blocks should be marked with their correct

weight.

• All attachment bolts and fittings are to be checked for security.

Engine Housing/Guard Inspection – Crawler Crane
Guards and Engine Housing Inspection Criteria

1. Cleanliness/No Rags/Trash
2. Gear/Machinery Guards
3. Clear Access/Walkways
4. Brakes/Clutch Adjustments
5. Hand Signal Illustration
6. Swing Break

All exposed moving parts such as gears, chains

reciprocating or rotating parts are to be guarded
or isolated.

Applicable Standard : ASNI B 30.5

5-1.9.6
5-1.8.2 & 3
---------
5-2 (Fig.16)
5-1.4
POWER UNIT/ENGINE COMPARTMENT.

• Check that all the machinery compartment is in a clean and tidy

condition. If any tins of oil, rags, tools or other materials are present
then they are to be stored in an appropriate place.

• Fire extinguisher (s) are to be available or in close vicinity of the

machinery housing. (Generally stored in the drivers cab, or mounted
on the machinery house external wall).

• Check that no electrical equipment is exposed to contaminants such

as oil, grease, water or dirt.
POWER UNIT/ENGINE COMPARTMENT.

Picture showing
underside of
engine
compartment
drainage.
POWER UNIT/ENGINE COMPARTMENT.

Picture showing Engine

and Clutch Linkages.
 Check all pins for security,
condition and freeness of
operation.
POWER UNIT/ENGINE COMPARTMENT.

Engine compartment,
showing Torque
converter, Air
receiver, water jacket
heater & Radiator.
POWER UNIT/ENGINE COMPARTMENT.

(Prove Rig saver).

Diagram of
typical Crane
Engine
Layout.
POWER UNIT/ENGINE COMPARTMENT.

Picture showing
hydraulic starter
system located in
engine
compartment.
POWER UNIT/ENGINE COMPARTMENT.

Picture showing
Engine exhaust
silencer,
(Located on top of
Machinery house.
 POWER UNIT/ENGINE COMPARTMENT.

• Listen for any undue noise from the pumps and motors during operation,
(Ear protection to be worn).

• Check for oil leakage from the prime mover gear boxes, accumulators, and
tanks etc.

• Check the operation of the rig saver (Gas sensor, which shuts the engine
down, when gas is detected), to check operation, put crane on low revs and
manually trip to shut down engine.

• All Hoses to be checked for condition and wear, looking for damage and
abrasions.

• All controls and gauges to be checked for operation and damage, broken
glass etc. Operation of the start/stop controls should be verified.
The machinery house ventilation ducts are to operate when the engine is
running.
Crawler Crane Cab Inspection

Inspection Criteria for Cab Inspection

1. Glass/Visibility
2. Instruments and Controls
3. Functioning Horn (warning signal)
4. Fire Extinguisher
5. Appropriate Load Charts and Warning
Signs
6. Proper and Adequate Access and Egress
(steps/walkway)

Applicable Standard – ASNI B30.5

5-5.1.6.1.1 , 5-3.4.9 , 5-5.1.1.3, 5-1.8.2 & 3
 CABIN AND CONTROLS.

Mobile crane drivers cab unit.

The drivers cab should be clean and free
from clutter. All controls should be
labeled as to there function and free to
return to the neutral position when
released, unless designed to do
otherwise. All gauges and warning lights
should be operational and a fire
extinguisher should be mounted in the
drivers cab. The seat should be securely
attached and the cab door should open
outward and operate smoothly. Electrical
and other warning signs should be
posted in the cab. All glass must be
safety glass with no cracks or distortions.
 CABIN AND CONTROLS.

• Control levers are to return to the neutral position on release and

their function/operation clearly marked from the operator position.

• Crane duty load charts specifying the duties of the crane for the
Permitted operating condition are to be maintained and located
conspicuously.

• All windscreen glass to be complete and undamaged.

• Windscreen wipers and water dispensers are to be operational.

• Drivers crane cab heating and ventilation unit to be operational

• Crane lights are to be operational.

 Diagram showing
one type of layout of
a Crane cab &
controls.
 Diagram showing
one type of layout of
a Crane cab &
controls.
 Diagram showing
one type of layout of
a Crane cab &
operating controls.
 Diagram showing
one type of layout of
a Crane cab &
controls on rear of
cab wall.
 Picture
showing
drivers Crane
cab layout.
 Picture showing
Brake linkages
located underside
of Drivers crane
cab.
CABIN AND CONTROLS.

• All limits, over hoists and overload warning devices including

audible warnings are to be operational. This to include the
Gross overload protection system or G.O.P. (If fitted) for
correct settings for the crane.

• The rated capacity indicator is to be checked for operation.

It may be necessary to pick-up a known load with the crane in
order to verify the accuracy of the rated load indicator.
(The allowable acceptable inaccuracy is to be within +/- 5%) as per the
previous mentioned standards.
 CABIN AND CONTROLS.

• Hook load and load radius indicators to be functional and accurate,

the deck should be marked from the centre of the pedestal in either
feet/meters and the hook block lowered to the mark, checking load
charts fitted on the crane cab wall against the Safe load indicator.

• The Anemometer

• All communications and deck horn to be functional.

• A fire extinguisher to be available in the cabin or in close vicinity of

the crane cabin.
 ALL ACCESS & EGRESS POINTS.

All access and egress points are to be safe and maintained in a

good condition.

Walkways should not be used for the storage of any drummed

substances etc.. When checking the walkways look for loose
clips and missing retainers on walkway gratings, and damage to
walkway structure.

Check handrails for damage, and wire security and

condition/Tension (if fitted).
ALL ACCESS & EGRESS POINTS.

. ALL ACCESS & EGRESS POINTS.

ACCESS TO MACHINERY
HOUSE & TOP OF MACHINERY
HOUSE / MAST. ACCESS TO TOP OF
MACHINERY HOUSE / MAST.
ALL ACCESS & EGRESS POINTS.

ALL ACCESS & EGRESS POINTS.

ACCESS TO DRIVERS CRANE CAB LEVEL.

Electrics in the Cab

• All electrics, switchgear and panels to be checked for integrity and

damage.

• All electrical connections and wiring to be checked for any loss of

integrity or damage.

• Operation of all electrical equipment to be verified, including all

internal and external lights etc..
Hoist Drum Inspection – Crawler Crane

Inspection Criteria for Hoist Drum Inspection –

1. Proper Size and Spoiling of Hoistlines

2. Drum Sides/Shields for Cracks
3. Dogs/Pawls/Locking Devices
4. Drum Rotation vs. Control Motion
5. Clutch and Brakes

Drum lagging and flanges should be inspected for cracks or other deficiencies an winch
mounting bolts should be checked. Any 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 “overspooled.” In other words, with the rope fully spooled on the drum, the drum
flanges must extend above the top wrap of the rope. Any spoiling devices, such as rollers, or
drum rotation indicators, must be functioning properly.

Applicable to ASNI B30.5 : 5-1.3.1 & 2

Boom Hoist winch assembly

 Check all base bolts or welds

for corrosion, wear, damage
and security.
Any loose or missing bolts
should be replaced, not
re-tightened as there is a good
chance that they have been
stretched.

 Check spooling of wire rope

during operation, and condition.

 Check for any hydraulic leaks

Inspection areas. from the pipe work and hose
connections.
MAIN HOIST ROPE.

 Check main hoist wire rope in

accordance with ISO4309, ASNI or Whip hoist limit
switch box.
Main hoist limit switch
A.P.I. Specifications etc. box, (Ensure freedom
of movement of arm)

 Inspect the other end of the wire

rope terminated on either the main
hook block or terminated on the
underside of the boom cathead
section.
Picture showing Main hoist and Aux. hoist winches.

 Inspect the drum

anchor point of the
rope for security
and correct fitment.

 Inspect base mounting

bolts or weldments,
and check crane
fittings.
Main hoist upper limit assembly

 Check the upper and lower

limits (if lower limit is fitted),
ensure that there is plenty
of wire rope left on the
drum if reeved to its full fall
capacity, if not inspect as
much as possible underlying
wire rope on drum for
crushing etc..
HOIST MACHINERY (Main & Whip).

• Check all bolts and rivets for corrosion, wear, damage and security.

NOTE: Any loose or missing bolts should be replaced, not re-tightened

as there is a good chance that they have been stretched.

• Inspect for excessive wear on brake and clutch system, parts, linings,
pawls and ratchets.

• Ensure that all safety pawls operate correctly and are in good
condition, free to move and sufficiently lubricated.

• Check hoist rope on drum termination for security and correct fitting.

Hydraulic and Pneumatic systems should be inspected for deterioration.

If any of the following faults are noted then the faulty part should be
replaced.
HOIST MACHINERY (Main & Whip).

Illustration showing
Aux. winch & Main
hoist winch drums.
HOIST MACHINERY (Main & Whip).

Picture showing Main

Hoist winch
assembly.
Ensure freedom of
movement of rollers &
tensioning device.
HOIST MACHINERY (Main & Whip).

• Check for Oil or oil leaks on the surface of flexible hoses or at

the points at which the hose joins the metal end couplings.

• Abnormal deformation of the outer covering of the hydraulic

hose, including any enlargement, local or otherwise.

• Any leakage at connections which cannot be remedied by

normal tightening.

• Signs of abrasion on the wall of any hose or tube which could

reduce their pressure retaining capabilities. It is also important
to eliminate the cause of abrasion.
HOIST MACHINERY (Main & Whip).

Main hoist Winch drum.

Picture showing Main

Hoist & Aux. hoist
winches.

Aux. hoist Winch drum.

HOIST MACHINERY (Main & Whip).

• Check all rope drum assemblies for wear and or damage in score,
damaged or worn bearings and journals.

• Listen for any signs of undue noise during winch operation.

• Ensure that at least five full wraps of wire rope remain on the drum
in all service conditions.

• Ensure that the drum end of the rope is securely anchored to the
drum by a means approved by either the crane or rope manufacture,
and also that it is clear of the rope windings.

• Inspect during function operation and spooling of the wire rope, and
operation of the Pawl.
HOIST MACHINERY (Main & Whip).

• Inspect all indicators, including those for load and jib angle, and
automatic safe load indicators, for any significant inaccuracies.

Note: Always work to the safe condition of the crane.

• Verify function/operation of all limit switches during function.

Boom Section Inspection – Crawler Crane

Inspection Criteria for Boom Inspection is as follows:

1. Base Section Properly Attached
2. Pin Clearance
3. Boom Lacing/Cord Damage
4. Boom Stops
5. Gantry System A-Frame
6. Hoist Line Guides/Sheaves
7. Boom Section Connection Pins/Keys
8. Boom and Gantry Support System
9. Jib Attachment/Backstops/Belly Slings
(Jib Security Device)

Applicable ASNI B30.5 Standard - 5-2.1.3

Boom Section Inspection – Crawler Crane

Comprising of: Main Chords & Intermediate Bracings.

(Located on Boom Root, Intermediate and Cathead sections).

Inspect the entire boom for straightness and for any evidence of physical damage,
such as cracking or flaking paint as this may indicate yielding of the material, which
may precede failure.
Check all chords and struts for damage, cracking, bending or excessive corrosion. No
damage to the main chords is permissible, although a small amount of damage to the
latticework is allowed (Max three struts in any one section) as long as the damage to
the strut and strut roots is not in the “Picture frame area” which is regarded as critical.
Check along the top of the boom for any signs of damage caused by the main block
wire, and underside of cathead for main block damage to lattice sections.
Check all connecting pins for wear, damage and distortions, also ensure that all
cotter pins/nuts are fitted/installed.
Crane Lattice boom sections.
Crane Lattice boom sections. BOOM ROOT SECTION.
Crane Lattice boom sections BOOM INTERMEDIATE
SECTION.
Crane Lattice boom sections BOOM CATHEAD SECTION.
Crane Lattice boom sections. BOOM FLYJIB SECTION (IF
FITTED).
Crane Lattice boom sections.
Crane Lattice boom sections.

Crane Lattice boom sections.

Crane Telescopic boom section.

Extra Information on Boom Inspections

All components of the boom assembly

should be checked for cracks, bends, or
other deformities. On hydraulic 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. Wear pads should
be properly adjusted or replaced if
necessary.
BOOM FOOT BEARINGS/BUSHES

• Check boom foot pins for wear, this can be done by

putting the boom in the rest and slewing back and fore,
if excess movement is observed then the pins or
bushings may be worn, (Further investigation would be
required to ascertain problem) also boom foot and
housing should be checked for signs of cracking and
flaking paint on the structure and all welds. Carry out
N.D.T. to verify integrity if any signs are noted.
NOTE: There will be limited access to inspect these
parts fully.
BOOM FOOT BEARINGS/BUSHES

Boom Foot Pin

Assemble, Note:
Locking plate.

Boom foot housing

Weldments to
crane structure.
BOOM FOOT BEARINGS/BUSHES

NOTE: ON TELESCOPIC BOOMS, NOTE: ON LATTICE BOOMS THERE

THERE IS A BOOM PIVOT PIN ARE BOOM FOOT PINS. NOTE: PIN
WITH LOCKING DEVICE FITTED. LOCKING /RETAINING PLATE.
Boom Foot pins, location.
A Frame / Mast Inspection

• Check all ‘A’ Frame components for distortion, corrosion, bolting

soundness and cracked weldments. This would include anchor
points, sheaves, fixed axle pins, guard-rails, backscratchers etc..

• Bottom pins to be checked for detrimental wear, distortion and

cracking with all securing/locking pins to be in place.

• Foundation bolts to be examined for signs of corrosion.

• Boom backstop points to be checked for deformation, correct

operation and security, also check for any hydraulic leakage
(If applicable).

• Check all handrails for security, Damage, excessive corrosion &

holes
A Frame / Mast Inspection

Inspect ‘A’ Frame sheaves and

boom hoist rope.

Inspect Boom hoist Anchor points.

‘A’ Frame Boom Back stops.

Inspect
Access/Egress
ladders &
Backscratchers,
for security,
corrosion.

‘A’ Frame Connecting pins.

‘A’ Frame / Mast Assembly.
 A Frame / Mast Inspection

• Confirm upper boom limit switch is operational during function

test, check radius reading on Safe Load Indicator and compare
with Load chart in Drivers Cab.
Boom limits can be operated by hand to check the operation
(If possible) so as to prevent boom approaching a dangerous
condition, especially if the limit fails.

• Check Paint for integrity, and for sports/signs of corrosion.

• Inspect access/egress ladders and backscratchers for corrosion

and security.
LUFFING HOIST MACHINERY.

 Check all rope drum assemblies for wear and or damage in score,
damaged or worn bearings and journals.

 Ensure that at least five full wraps of rope remain on the drum in all
service conditions. Ensure that the drum end of the rope is securely
anchored to the drum by a means approved by either the rope
manufacture, and that it is clear of the rope windings.

 Inspect all indicators, including those for load and jib angle, and
automatic safe load indicators, for any significant inaccuracies.

 Check spooling of rope during operation, and check upper and lower
boom limit switches correspond with manufacturers load chart fitted in
Drivers crane cab.
LUFFING HOIST MACHINERY.

Picture showing
typical band brake
assembly fitted to
winches.

 Inspect for excessive wear

on brake and clutch system,
parts, linings, pawls and
ratchets.
Ensure the operation &
movement of the piston
mechanism.
LUFFING HOIST MACHINERY.

 Ensure that all safety

pawls (If fitted) operate
correctly and are in good
condition, free to move and
sufficiently lubricated.
 Check the timing of the
pawl and ensure it
re-engages within seconds
of crane movement ceasing.

Picture showing
Boom Pawl
arrangement on
winch.
LUFFING HOIST MACHINERY.

Picture showing
Automatic brake
assembly hydraulic
cylinder etc..
LUFFING HOIST MACHINERY.

Ram luffing crane.

Rams fitted for

lifting boom, some
cranes fitted with
one or more Rams.

 Hydraulic and pneumatic systems

should be inspected for deterioration.
If any of the following faults are noted
then the faulty part should be replaced.
(See next slide).
LUFFING HOIST MACHINERY.

 Check for Oil or air leaks on the surface of flexible hoses or at the
points at which the hose joins the metal end couplings.

 Abnormal deformation of the outer covering of hydraulic hose,

including any enlargement, local or over wise.

• Any leakage at connections which cannot be remedied by normal

tightening.

• Signs of abrasion on the wall of any hose or tube which could reduce
their pressure retaining capabilities. It is also important to eliminate the
cause of abrasion.
LUFFING HOIST MACHINERY.

Ram luffing crane picture.

Inspection areas.
LUFFING HOIST MACHINERY.

 Inspect connection points of

hydraulic Rams, Ensure
keepers / locking plates are
intact.
 Check during operation of
boom for any hydraulic leakage.
 Ensure that the pad eye
clevises are not cracked.

Ram luffing crane.

Sheave System Inspection – Crawler Crane

Inspection Criteria for Sheave System Inspection

1. Ensure Hoistline and Sheave Size Match

2. Worn
3. Lubrication/Move freely

Applicable Standard

ASNI B30.5 : 5-1.7.4

SHEAVES/BRACKETS AND PINS.

 Sheaves to be checked with a

rope groove profile gauge for
wear, and the contour is to be
smooth and free from defects
injurious to the wire rope.

Almost every rope installation has one

or more sheaves with complicated
reeving patterns to equalizing sheaves
where only minimal rope movement is
noticeable. Each sheave should receive
an individual examination at periodic
inspections.
SHEAVES/BRACKETS AND PINS.

 Sheaves to be checked for rope tracking or

imprint on the groove, this may be more evident
on the fast spooling sheaves (Fast line sheaves).

 Sheaves are to be checked for broken or

chipped flanges and cracks in the main body, if
possible, check that the sheaves rotate freely
without drag and that there is no wear on the
bearing.
Picture showing a sheave
To check with the rope relaxed, the sheave should corrugated by the rope’s “print”, a
be rotated by hand to determine the fit of the condition which could seriously
damage the wire rope.
bearing and effectiveness of its lubrication,
whether the sheave runs true without wobbling on (Sheave requires to be replaced).
its shaft, whether the bottom of the groove is still
concentric or round in relation to the shaft and
whether the sheave and its shaft are in proper
alignment with other sheaves or components of
the system.
SHEAVES/BRACKETS AND PINS.

Note: Correctly gauging sheave grooves to

check compatibility with wire rope fitted.
SHEAVES/BRACKETS AND PINS.

Boom hoist termination.

‘A’ Frame sheaves to be

checked.
‘A’ FRAME / MAST SHEAVE ASSEMBLY.

Boom hoist sheave cluster assy.

Note: Safety harness to be worn for
access to inspect. Check boom
hoist rope termination at same time.
SHEAVES/BRACKETS AND PINS.

Crane Boom
Cathead and
boom tip sheaves
to be inspected.

Safety catch Must be lockable

SHEAVES/BRACKETS AND PINS.

• Keeper plates and locking tabs are to

be checked for soundness.
• Grease points to be in place and
functional, this is to include the hose
for carrying the grease to the point of
use.
• Sheaves should also be checked for
rope path alignment.
• Sheave guards are to be checked for
damage, crack and distortion.
• Sheave retaining pins to be secure,
and fitted with locking device to
prevent displacement.
SHEAVES/BRACKETS AND PINS.

 Check that there is a means to prevent the rope from displacing

itself from the sheave, if not, one should be fitted.
Assessing the general physical condition of a sheave, such
as groove smoothness, freedom from cracks & nicks,
existence of wear on guards, etc.. Is a matter of careful &
Knowledgeable observation.

Properly gauging and evaluating the width, depth and contour of

grooves with a groove gauge, requires keen observation as well as
knowledge of gauge design and use.
SHEAVES/BRACKETS AND PINS.

NOTE: There are two types of wire rope groove gauges:

 Those used by the manufacturers of sheaves and drums, which make

allowance for the maximum allowable oversize for wire rope and are used to
determine the proper contour for new sheaves.
 Those ones used in the field, which are made to the nominal diameter of
the rope plus one-half the allowable rope oversize. These are used to
determine the minimum condition for worn grooves.
 In the field inspection, when the gauge for worn grooves fits perfectly, the
groove is at the minimum permissible contour. Anything narrower is
unsuitable for use.
SHEAVES/BRACKETS AND PINS.

It is a good rule to keep in

mind that under normal
operating conditions, as a
groove wears it tends to
become deeper and
Narrower.

Excessive wear in an
over-width manner
frequently indicates
some operating
abnormality such as A Proper fitting groove should support
alignment problems. the rope over 135-150 degrees of the
rope circumference.
Load/Auxiliary Hook and Block System

Inspection Criteria for Load/Auxiliary Hook and Block System Is as Follows :

1. Sheaves Function Smoothly
2. Hook Rotates Freely/Lubricated
3. Proper Becket
4. Properly Reeved

Applicable Standard :

ASNI B30.5 : 5-1.7.1-6

Main Hook Block

All sheaves should be checked for

cracks, grooving, or damage from
two-blocking. Undue looseness in
the bearing or bushing should be
noted. The sheaves groove surface
should be smooth and slightly larger
than the wire rope being used. It
should be checked with a sheave
gauge to be sure it is the proper size
for the wire rope being used. On
most hydraulic cranes, sheave
guards which prevent the wire rope
from coming off the sheave, are
removable pins. Be sure that all of Picture showing main hook block.
these pins are in place. NOTE: NON POSITIVE LOCKING LATCH.
Section 6-1. MAIN HOOK BLOCK.

MAIN HOIST CRANE HOOK BLOCK,

CHECKING OF WIRE ROPE SHEAVES WITH
SHEAVE GAUGE.
Main Hook Block

Hooks should be examined to see if

they are cracked or distorted beyond
allowable tolerances. No welding or
heating should be done on hooks.
Hooks and blocks should be labeled as
to there capacity and weight.
Note: On some SLI systems the hook
block weight is included as part of the
safe working load and the crane SLI
load is set accordingly.
Connecting bolts on blocks cheek
plates should be checked. Hook
swivels and sheave guards should also
be checked.
 Main Hook Block

The blocks and all the sheaves shall be checked for the following
defects:

• The ‘Safe working load’ and identification marking is legible and

corresponds with the test certificate.

• Wear or any fracture in the eye of the hook.

• Ensure that there is a positive locking safety catch fitted and is

serviceable, if not advise and recommend fitment of new catch to
prevent loss of load during operations.

• Remove any hook shank nuts (where possible) and examine the
condition of the threads.
Main Hook Block

• Check for wear or any fracture in the shank of the head fitting
(There will be limited access to inspect). Where the shank of
the head fitting has been welded to the collar or nut, then the
wear on the shank shall be determined by rotating the head
fitting, the wear shall not exceed a maximum of 1.5mm to
25mm shank diameter, or the shank bent.

• Check block side plates for any distortion, or damage,

Ensure all nuts and bolt fittings are tight and intact if fitted
with weights on the hook block.
Main Hook Block

• Check to see if any visible fractures are noticeable leading

from centre pin holes. (Carry out N.D.T. on any parts suspected
to verify).

• Check side straps for distortion or fracture.

• Check for wear in bushes, wobble, distortion or for any signs

of fractures.

• Check all sheaves for chipped fractures, wear & damage at

sheave edge, ensure wire rope groove of sheave is compatible
with the size of the wire rope being used.
Main Hook Block

• Check that all oil and grease

ways in the pin and bush,
sheave and shell are clear.

• Inspect the crane hook block Becket

(If fitted), for distortion, or fracture,
also ensure that it is the correct
size for the load applied to it).
Main Hook Block

Exploded diagram
showing Main hook
block assembly.

Note: The safety catch is to be a positive

locking type, to prevent the crane pennant
from falling out during operation.
Main Hook Block

Note: The safety catch is to be a positive

locking type, to prevent the crane pennant
from falling out during operation.
AUX. (WHIPLINE) HOOK BLOCK. (IF FITTED).

Check as per wire rope inspection, previously shown (ISO4309 Spec).

• Check the upper and lower limits (if lower limit is fitted), ensure that
there is plenty of wire rope left on the drum,
(Five wraps as a minimum).

• Inspect the drum anchor point of the rope for security and correct
fitment.

• Inspect the other end of the wire rope terminated onto the Aux hook
block.
AUX. (WHIPLINE) HOOK BLOCK. (IF FITTED).

Examine wire rope

for wear & corrosion, Exploded diagram of
a typical Aux. Hook
(If accessible)

block, (Headache ball

/ Whip hoist,
(Although there are
many variations).
AUX. (WHIPLINE) HOOK BLOCK. (IF FITTED).

The block shall be checked for the following defects:

• The ‘Safe working load’ and identification marking is legible and
corresponds with the test certificate.
Note: The SWL of the block must be at least equal to the crane WLL.

• Wear or any fracture in the eye of the hook.

• Ensure that there is a positive locking safety catch fitted and is

serviceable, if not advise and recommend fitment of new catch to
prevent loss of load during operations.

• Check for wear or any fracture in the shank of the head fitting
(There will be limited access to inspect).
AUX. (WHIPLINE) HOOK BLOCK. (IF FITTED).

• Check block for distortion, and damage, ensure all nuts and
bolt fittings are tight and intact.

• Check to see if any visible fractures are noticeable leading from

centre pin holes. (Carry out N.D.T. on any parts suspected
to verify).

• Check for wear in bushes, wobble, distortion or for any signs of

fractures.

• Check that all oil and grease ways in the pin and bushes /
bearings are clear, (Limited Access to Inspect).

• Check wire rope which is inside the ball assembly if this type is fitted,
and check for freedom of swivel rotation.
 Wire Ropes and Hoist Lines

Inspection Criteria for Wire Ropes and Hoist lines is as follows :

1. Overall Condition
2. End Connections
3. Lubrication
4. Clips

Applicable Standards :

ASNI B 30.5 : 5-1.7.6

Rope Anchors and Pins

• Rope anchors and pins are to be checked for security, loose

fittings, missing retaining clips etc..

• Check for damage and correct fitment as per manufacturer’s

procedures.

• Check anchor points for distortion and internal hole wear due to
free movement during crane operations, or excessive oversize
hole and incompatible shackle pin size fitted, etc..
Rope Anchors and Pins

MAIN HOIST WIRE ROPE TERMINATION,

USING A TERMINATOR CROSBY WEDGE
SOCKET.
Rope Anchors and Pins

Picture showing the underside of

the boom cathead section, Main
hoist wedge socket termination.
Whip hoist cut
out assembly
These limits operate when there is no
Main hoist cut pressure/tension on the chains, in turn then
out assembly trips the air or electric supply, thus stopping
the hook blocks continuing any higher.

Three preferred methods

for wedge socket
termination.
LUFF AND SUSPENSION ROPES.-

All wire ropes used on the crane shall be inspected in accordance

with ISO4309 over their entire length for the following defects
paying particular attention to the sections that pass through the
block or over the pulleys/sheaves, and also that form part of the
rope that lies on a compensating pulley, is continually exposed to
the elements or may be subject to regular abrasion.

• Check all terminations, whether wedge socket, hard eye or spelter

sockets For correct fitment, and damage etc..

• Check for corrosion, Kinks, Broken wires, Changes in rope

diameter, wear, heat damage, and lack of lubrication.

• Check terminal fittings for wear, damage and distortion.

Also for signs of overloading (i.e. Collapsed thimbles).
Wedge Sockets

• Ensure all wedge and socket terminations are as per BS7166:1989

Spec or relevant specifications, A.P.I. etc, and the wedge is fitted the
correct way! (if Applicable), Some wedges can be fitted either way,
and others only one way!

NOTE: This
diagram shows a
wedge that can
be fitted either
way into the
wedge socket
body!
Wedge Sockets

NOTE: This Diagram

shows two acceptable
methods of terminating
wedge sockets.
Wedge Sockets

NOTE: This Picture shows a

terminator type wedge socket,
that is fitted incorrectly on a
crane at the ‘A’ Frame, Boom
hoist dead end termination.
This type of wedge can only
be fitted one way, as it has
one side with a straight edge
which needs to go into the
straight side of the wedge
socket body, (Live wire side).
Wedge Sockets

Picture showing in-correct fitment of standard wedge

socket termination to mobile crane, main hoist.

Note: Live wire from main

hoist hook block is entering
the wrong side of the
wedge socket, and dead
end of rope terminated
correctly but on wrong side
of wedge.
Note: Live wire should
always enter the flat side on
wedge sockets, ensure
correct during inspections.
LUFF AND SUSPENSION ROPES.

Picture showing incorrect termination of standard

wedge socket on wire.

Note: Only one bulldog

grip fitted, terminated
incorrectly.

Note: That the load split

pin is missing from
location not preventing
the pin from being
removed.
Wedge Sockets

Crosby Terminator Wedge socket Diagrams,

NOTE: Wedge can only be fitted one way!
LUFF AND SUSPENSION ROPES.

• Examine wire rope test certificate to ensure rope is of correct size,

capacity and construction for the crane.

Deterioration normally results from a combination of several defects

occurring simultaneously giving a cumulative effect.
The overall effect should be taken into consideration when deciding
if a wire should continue In service.
However the following defects would result in the rejection of the
rope.

• Total number of broken wires in any one lay length must not exceed
six.
LUFF AND SUSPENSION ROPES.

• Total number of broken wires in one strand in one lay length must
not exceed three.

• Total number of broken wires in a measured length of ten rope

diameters must not exceed 5% of the number of wires in the rope.

• No broken wires are permitted where the rope enters the termination.

• Wear must not exceed 10% of the original diameter for a six-strand
rope and 3% for a multi-strand rope.
LUFF AND SUSPENSION ROPES.

NOTE:
Any broken wire found in the course of the examination which does
not constitute rejection shall be broken off in the lay of the rope and
their location noted for future reference.

• The reeving configuration of the crane must be checked against

the manufacturers schematic which shall be provided by the
operator prior to the inspection.
Particular attention should be paid to any area where the rope
could come into contact with the crane structure during travel of
the jib, (See Examples of crane reeving on next slides).
LUFF AND SUSPENSION ROPES.

Example of Boom
hoist Reeving
Diagram.

NOTE: Five full wraps of wire rope must

remain on the boom hoist drum when the
boom is in its lowest working position, or
when in its boom rest position, whichever is
the lowest!
LUFF AND SUSPENSION ROPES.

Example of Main &

Example of Main Hoist Aux. (Whip) hoist
Reeving diagram. Reeving Diagram.

NOTE: Five full wraps (as a minimum)

of wire rope must remain on the hoist
drums when the hook blocks are at its
lowest working position, and the crane
Example of Auxiliary / Whip boom at its highest working position.
hoist Reeving diagram.
 Boom Pennant Ropes

Boom pennant ropes (If fitted),

•Should be inspected for security, condition and end terminations

inspected as per type fitted, i.e. Spelter sockets or crimped fork eyes,
and steel ferrules.

It should be noted that Boom pennants require to be replaced at

intervals when in use of 5 years pending specification or various
company implemented procedures. Check the dates they were fitted.
MAIN HOIST ROPE.

 Check main hoist wire rope in

accordance with ISO4309 or A.P.I. Whip hoist limit
switch box.
Main hoist limit switch
Specifications etc. box, (Ensure freedom
of movement of arm)

 Inspect the other end of the wire

rope terminated on either the main
hook block or terminated on the
underside of the boom cathead
section.
Boom Pennant Ropes
Floating Bridle Assembly

The bridle assembly is to be inspected for loose fittings and damage.

• Sheaves are to be checked for damage, rope groove, freedom of

movement. (Limited access to rotate sheaves freely), but observe
during operation for freedom of rotation.

• Ensure that all bolts and fittings are secure and fitted with locking
devices.

NOTE: Access to inspect these items will either require the use of a
personnel basket or use of a safety harness fitted with twin lanyards.
And if classed as over side work will require the use of a life vest etc..
Floating Bridle Assembly

Picture showing
location of Bridle
assembly / Floating
sheave block.

NOTE: For access to

inspect the this assembly
the boom hoist wire must
be lowered down to the
top of the crane boom,
with access using either a
basket or safety harness
etc..
RECAP ON WIRE
ROPE
EXAMINATION
Crane wire rope damage.

Introduction:
Wire ropes of a properly designed and
maintained crane will deteriorate
throughout their entire service life by two
principal degradation mechanisms:
1. External and Internal Fatigue, caused
by bending over sheaves and/or winding
on drums, and
2. Crushing, caused by spooling on
multilayer drums.
While the above types of rope
deterioration can be minimized by proper
crane design and rope maintenance
procedures, they are deemed
unavoidable and part of normal rope life.
Crane wire rope damage.

Wire rope deterioration modes:

Fatigue – A wire rope subjected to
repetitive bending over a sheave will
develop cracks in individual wires.
Broken wires develop primary in
sections that move over sheaves.
Further, if a rope travels on and off a
grooved single layer drum, it will also This picture shows a rope with
surface wire fatigue breaks. Note the
go through a bending cycle. Tests
square ends of wires that are typical
and practical experience have shown for fatigue breaks. It also shows
that winding on a single layer drum is abrasion-plus-fatigue patterns
equivalent to bending over a sheave characterized by chisel shaped wire
and will cause similar fatigue ends. This is considered a long term
damage. condition normal to the operating
process.
Crane wire rope damage.

Usually, fatigue breaks develop in

segments of the rope surface that come
into direct contact with a sheave or drum.
Breaks in these areas are external and
usually visible. Once broken wires appear,
a good many more are likely to develop
within a relatively short period.
Internal breaks can develop depending on
the loading and, especially, the rope
construction. For example, many ropes are This diagram shows a cutaway
of the torque-balanced multi strand type section of Multi strand type
comprising two or more layers of strands. rope. Torque balance is
achieved in these types of
ropes by laying outer and inner
strands in opposite directions.
Crane wire rope damage.

In single fall operations the use of non-

rotating ropes is mandatory. This type of
rope construction limits axial rotation of the
freely suspended rope under load. In
addition, multi strand ropes offer flexibility
and a wear resistant profile. However, the
wires and strands in different layers of
these ropes touch locally and at an angle.
Therefore when multi strand ropes bend
over sheaves or on a drum, they are
subjected to the combined effect of radial
loading, relative motion between wires and
bending stresses. This causes inter strand
nicking (Figure 3) and, eventually, fretting
wear or fatigue across the interface
between layers as seen in Figure 4.
Crane wire rope damage.

Therefore, multi strand ropes are prone to

develop internal broken wires. As
Indicated in Figure 5, this breakup
occurs primarily on the interface between
the outer and second layer of strands,
usually with no externally visible signs.
Wires in the second layer of strands
typically show inter strand nicking and
breaks caused by a combination of
fluctuating axial wire stresses, inter-wire
motions and fluctuating radial loads. The
broken wires usually have squared-off
and z-shaped ends that are typical of
fatigue breaks.
Crane wire rope damage.

Similar nicking and fatigue patterns occur in

IWRC (Independent wire rope core) ropes.
Figure 6 shows a typical cross-sectional
diagram of such a rope. For IWRC ropes, the
outer wires of the outer strands have a larger
diameter than the outer core strand wires. To
minimize inter strand nicking between the outer
strands and the IWRC, these ropes are
designed such that the wires of the outer
strands and the IWRC are approximately
parallel. (This is usually achieved by choosing a
Lang lay construction for the IWRC and an
ordinary lay construction for the outer strands.
Typically, the wires of the outer strands are well
supported by their neighbors while the outer
wires of the IWRC are relatively unsupported.
 Crane wire rope damage.
What this means, is that under fluctuating tensile loads, the outer IWRC
wires are continuously forced into the valleys between the outer strand
wires and then released. This action results in secondary bending stresses
leading to large numbers of core wires with fatigue breaks. These breaks
can be very close together and can form groups of breaks. Eventually, the
IWRC can break, or it can even completely disintegrate into short pieces of
wire about half a lay length long. This condition is commonly called
complete rope failure.
 Crane wire rope damage.
As the IWRC fails, the outer strands lose their radial support. This
allows the wires of the outer strands to bear against each other .
The resulting inter strand nicking restricts the movement of the
strands within the rope. Without this freedom of movement,
secondary fatigue breaks in the wires of the outer strands will
develop at the strand tangent points. Because these fatigue
breaks develop in the valleys between the outer strands, they are
also called Valley breaks. (Figure 7).
 Crane wire rope damage.

Spooling on Multi layer drums. If a rope section travels on and off a grooved multi
layer drum, it goes through a bending cycle. Rope sections spooling in the first layer
are bent around the drum surface. When the second layer comes in, rope sections in
the first layer will be spooled over, compressed and damaged on the upper side by the
second rope layer. Rope sections spooling in the second and higher layers will be
damaged on all sides during contact with the neighboring wraps. In addition, they will
bend around the very rough surface created by the previous rope layer, leading to
additional wire damage. It is obvious that by these conditions the rope will be damaged
far more than by just one bend on a single layer drum.
 Spooling on Multi layer drums.

The point where the rope is squeezed between the drum flange and the previous wrap, as it rises
to form the next layer, is an area of accelerated wear. Typically, the slap of the rope at the
crossover points can cause peening, embrittlement and/or wire plucking with the associated rope
damage as the rope crosses over from layer to layer on a drum. Further, if the lower layers were
not spooled under sufficiently high tension, the lower wraps can be displaced by the incoming rope
section, allowing it to slide down between them. This can lead to severe rope damage. Various
types of rope damage caused by drum winding are shown in Figure 8.(Next Slide).
Crane wire rope damage.
 Visual Examination of Wire Rope

The rag-and-visual method is a simple yet useful method for detecting a wide variety of
external rope deteriorations. Using this approach, the inspector lightly grasps the rope –
which moves at inspection speed from the drum – with a rag or cotton waste. External broken
wires will often porcupine and, as the rope moves, snag the rag or cotton waste. The rope is
then stopped at that point and the inspector assesses the rope condition by a visual
examination.
Frequently, broken wires do not porcupine. Then a different test procedure must be used. The
rope is moved two or three feet at a time and visually examined at each stop. This method is
tedious and, because the rope is often covered in grease, many external and internal defects
elude detection.
 Visual Examination of Wire Rope

Another visual inspection tool is measurement of the rope diameter. Rope diameter
measurements compare the original diameter – when new and subjected to a known load –
with the current reading under like circumstances. A change in rope diameter indicates
external and/or internal rope damage. Inevitably, many sorts of damage do not cause a
change of rope diameter. Several visible signs can indicate distributed losses of metallic
cross-sectional area, due to corrosion, abrasion and wear.
Visual inspections are inherently not well suited for the detection of internal rope
deterioration. Therefore, they have limited value as a sole means of wire rope inspection.
However, visual inspections are simple and do not require special instrumentation. When
combined with the knowledge of an experienced rope examiner, visual inspection can
provide a valuable supplementary tool for evaluating many forms of rope degradation.
Final Section – Safety Devices

Inspection Criteria for Safety Devices on Crawler Cranes is as Follows :

1. Anti-Two Block Devices

2. Boom Backstop Devices
3. Swing Radius Warning Devices
4. Job or Site Specific Devices/System/Program for work near electric power
and use of personnel hoisting platforms

Applicable Standard for Inspection :

ASNI B30.5 : 5-1.1.9 / 5-2

Load Sensor / Indicator

• Load sensors should be checked for security of

fittings, with no damage to electrical cables etc..

• Ensure terminations are fitted with locking pins or

tab washes.

• If load sensor type has sheave fitted, check for rope

groove wear and damage to sheave body, and
freeness of movement.
Load Sensor / Indicator

Sheaves to be inspected.

Load sensor type, with

sheaves, to be checked for
wear, mountings &
freeness of movement.
This would be located
mounted on top of the
boom section.
Other types would include the Wylie
weighload ones which operate
using fluid in a type of bladder, The
pressure is then sent back to the
drivers cab, to let him know what
the load is. These bladders would
require to be re pressurized at
regular frequencies.
Load Sensor / Indicator

LOAD SENSOR SHEAVE ASSEMBLY.

BOOM ANGLE INDICATORS.

Boom angle indicators are required to indicate the angle of the boom
tip from the base section on a horizontal plane. They may be either
mechanical (Activated by gravity) or electronic, with a display readout
in the drivers cab. Accurate readout of the boom angle determines load
capacity and working radius.

 Check operation of Angle

indicator, freeness of movement,
and check for damage.

 Verify operation during boom

movement and measure against a
check line at a set radius on the
deck area, and compare with SLI
reading.
BOOM ANGLE INDICATORS.

Picture showing
Radius indicator
mounted on side
of crane boom.
Load Sensor / Indicator Continued

SLI
• Check the safe load indicator for position and Visibility in the drivers cab.

• Check crane load rating charts with the readings noted on the safe load
indicator with the current and other configurations.
Boom in & out to ensure that both readings are the same.

The settings and satisfactory operation of the Automatic safe load indicator,
radius and or jib angle indicator, if fitted shall be confirmed.
This can be achieved by measuring the radius with the known load
suspended. Note: The allowable figure for the hoist load readings is +/- 5%,
and for the radius check is +/- one foot discrepancy either way.

Note: Always ensure that the crane is operating to the safe side with any
errors, i.e. Safe load indicator reading on the high side, allows less load to be
picked up, reading on the low side would allow possible overloading of the
crane, as it could pick up more load than its is suppose to.
Load Sensor / Indicator Continued

NOTE: The Radius is the Horizontal distance measured between the

vertical centre line of the hook and the perpendicular projected through
the centre line rotation,

• Audible / visual function tests are to be carried out to verify operation,

check all cables for security and damage.
Note: To carry out overload alarm checks, switch the SLI to the
maximum sea state available, pick up a load greater than what is
allowed and boom out until the alarm sounds.
Note: This tests the alarm but does not overload the crane structure.

Many different types of S.L.I.’s are fitted to cranes some utilizing

wires/pulleys and various cables for operation, theses should be
checked for freeness of movement, damage and security.
Overload Proctection

• The overload protection device is to be checked for equipment

condition, looking for loose fittings, leaks and any signs of damage.
 Navigation and Floodlights

• All Boom floodlights (If fitted) are to be operational.

• Check security of fittings and safety slings on lights to prevent

dropped objects.

• Check glass and lights for breakages/distortion damage and

electrical cable for any obstruction or damage to wire.
Navigation and Floodlights

Picture showing boom

tip floodlight and lights
underside of boom
cathead section.
Note: There may also be
lights on the boom Root
& Intermediate sections
as well as the ‘A’ Frame
assembly.
BOOM ROPE ROLLERS & ROPE SUPPORTS.

 Check buffer supports

along top of boom for
security on fasteners, if
rollers fitted ensure
freedom of movement.
Check paintwork and
support weldments.
BOOM ROPE ROLLERS & ROPE SUPPORTS.

FLY JIB.

 Check underside of
cathead for main block
protector frame
(If fitted), Sometimes
there is just rope
wrapped around the
underside of the lattice
sections, (Which may
hide bent lattices from
view).
Crane Boom Stops/Buffers.

Boom stops are telescoping, shock

absorbing, or hydraulic-type safety
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 centre
of gravity is shifted to the rear of the
crane causing the boom to fall
backwards from lack of resistance
and/or control of boom movement.
Boom limits will operate prior to the
boom making contact with the Boom
stops. Check the function by raising the
boom very slowly until the limits operate Boom Stops.
and the boom movement has stopped.
Boom Hoist Disconnects / Limits.

Boom Hoist disconnects /

Limits are designed to
automatically stop the
Crane boom from hoisting
when the boom reaches a
predetermined high angle.
Anti-Two Block devices.

Anti-two block devices

are designed to prevent a
hoist block from being
hoisted into contact with
the boom tip to prevent
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. NOTE: WHEN THE
HOOKBLOCK LIFTS THE LIMIT SWITCH
All hydraulic cranes are to WEIGHT THE LIMIT SWITCH (MOUNTED TO SIDE
be equipped with anti-two SHOULD OPERATE, AND OF BOOM CATHEAD
block devices. STOP OPERATION OF THE SECTION).
HOIST.
Thanks for Attending
the Thorough
Examination of
Crawler Cranes
Course