Crane Overload Test Procedures

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Questions and Answers

What should be confirmed before testing the anti-two block alarm?

The alarm system is functioning properly

All assembly and safety pins are present and correctly in place (correct)

The weight is not suspended

Only the hook block is present

What is the correct procedure for activating the anti-two block alarm?

Test the alarm without any weight attached to the hook block

Lower the hook block until the weight is on the ground before testing the alarm

Raise the hook block until it is just below the suspended weight and then proceed slowly (correct)

Raise the hook block quickly until the alarm sounds

Which information is NOT typically displayed on a mobile crane hook block?

The operator's name (correct)

Manufacturer's plate

Weight of Hook Block

Capacity or SWL

What risk must be avoided during the testing of the anti-two block alarm?

Block-to-block incidents Signup and view all the answers

What is the weight of the hook block mentioned in the information provided?

360kgs Signup and view all the answers

Which of the following must be confirmed during the examination of hoist drums?

There should be no visible damage to the drum. Signup and view all the answers

What is a necessary condition concerning hydraulic hoses in hoist drums?

They should be securely fastened and not leaking. Signup and view all the answers

What indicates a problem with the operation of a hoist drum?

The drum emits detrimental sounds during operation. Signup and view all the answers

Who is primarily responsible for conducting a detailed examination of wire rope?

A Competent Person as part of periodic inspections. Signup and view all the answers

What should be followed along with manufacturer instructions during the examination of wire ropes?

Local or application-specific regulations. Signup and view all the answers

What must the examiner record in the examination report format?

A '% severity rating' for various factors Signup and view all the answers

In what form can the degree of severity be presented according to the guidelines?

In a descriptive format or as a percentage Signup and view all the answers

What action might the examiner take if the rope is deemed safe?

Reduce the time until the next examination Signup and view all the answers

How does the examiner determine the total combined severity for the rope?

By summing individual severity ratings to form a percentage Signup and view all the answers

What specific factors are evaluated to determine the '% severity rating'?

Number of broken wires, diameter decrease, corrosion, and damage Signup and view all the answers

What factor is NOT considered when determining the frequency of inspections for hoists?

The physical color of the hoist Signup and view all the answers

Which of the following is a way to express the percentage rating of severity from an inspection?

Slight, medium, high, very high, discard Signup and view all the answers

What is the primary purpose of keeping an inspection record for wire ropes?

To maintain a running record of condition and performance Signup and view all the answers

Which method is NOT mentioned as a way to assess deterioration during inspections?

Ultrasonic testing Signup and view all the answers

In what scenario might a competent person require more frequent inspections beyond original recommendations?

Due to previous inspection results indicating issues Signup and view all the answers

Which classification could lead to a determination of more frequent inspections?

Classification group of the machine Signup and view all the answers

What does the combined effect assessment refer to?

An overall assessment of wire rope condition Signup and view all the answers

Which of the following is NOT a consideration for the frequency of inspecting hoists?

The manufacturer’s marketing strategy Signup and view all the answers

What is the minimum height at which the load should be held during the test?

200 mm Signup and view all the answers

During the test, how should the load be slewed to assess structural integrity?

At the lowest speed through a small arc Signup and view all the answers

What should be examined after the completion of the overload test?

The crane's structural integrity Signup and view all the answers

Which of the following information is NOT typically found on the manufacturer's information plate?

Manufacturer's address Signup and view all the answers

What should be checked regarding the windscreen wipers and washers?

They should be functioning, secure, and in good condition Signup and view all the answers

How should lights, including headlights and indicators, be assessed during a thorough examination?

All lights must function correctly, and their condition must be inspected Signup and view all the answers

Which statement about reversing alarms/lights in cranes is accurate?

They are optional and may not be fitted on some cranes Signup and view all the answers

What must be ensured about the markings on the manufacturer's information plate?

They are clear, legible, and comply with legislation Signup and view all the answers

What action must be taken if equipment is to be removed from service?

Ensure it is quarantined and marked, 'DO NOT USE'. Signup and view all the answers

What priority issues should be reported when completing reports?

Safety critical issues that require immediate notification. Signup and view all the answers

During the debrief meeting, what should primarily be presented?

A summary of the report findings. Signup and view all the answers

Which behavior is essential for all equipment users in a professional context?

To maintain personal behaviors that are exemplary. Signup and view all the answers

What is a key component to identify when detailing repairs needed?

The expected timescale for completion of repairs. Signup and view all the answers

Before leaving a site, what is a critical action to ensure customer satisfaction?

To verify customer satisfaction with their service experience. Signup and view all the answers

What types of tools may a Mobile Crane examiner require?

A selection of hand tools tailored to the job. Signup and view all the answers

What is the primary focus of continuous professional development (CPD)?

Honing skills and maintaining competencies. Signup and view all the answers

What does the examiner determine after summing up the individual severity ratings?

The total combined severity as a percentage Signup and view all the answers

Which of the following factors does NOT contribute to the '% severity rating' during the examination?

The length of the wire rope Signup and view all the answers

When might an examiner choose to reduce the time before the next examination?

If the rope is deemed safe but deteriorated Signup and view all the answers

In what format can the degree of severity be recorded aside from a percentage?

As a descriptive word indicating condition Signup and view all the answers

What is the significance of ensuring that assembly and safety pins are correctly in place before testing the anti-two block alarm?

They ensure that no block-to-block incidents occur. Signup and view all the answers

What should the examiner primarily focus on to assess if a rope is safe to continue in service?

The current level of deterioration identified Signup and view all the answers

Which of the following pieces of information is NOT essential to be clearly legible on a hook block?

Date of Manufacture Signup and view all the answers

During the testing of the hook block, what is the primary purpose of slowly raising the hook block until the alarm activates?

To confirm the proper functioning of the anti-two block alarm. Signup and view all the answers

If the manufacturer’s plate is not located on the side of the hook block, where is it most likely to be found?

On top of the hook block. Signup and view all the answers

What potential hazard should be particularly monitored while raising the hook block during the alarm test?

A block-to-block incident occurring. Signup and view all the answers

What essential feature must be ensured about the wire rope anchor used in cranes?

It should have a locking mechanism to secure the wire. Signup and view all the answers

What should be checked regarding the boom tip sheave assemblies during an examination?

Freedom from damage and adequate bearing play. Signup and view all the answers

What happens if the wire rope fitted with a button type anchor gets damaged near its fitting?

It requires replacement from the manufacturer. Signup and view all the answers

Which component is crucial in ensuring the functionality of the wire rope during operation?

The correct installation and locking of the wire rope anchor. Signup and view all the answers

What is a common issue that might arise from severe damage to a boom tip sheave?

Frequent wear of the wire rope due to friction. Signup and view all the answers

What does the presence of wear on the rope guides indicate during an examination?

Accumulated damage likely affecting the sheaves. Signup and view all the answers

Which statement correctly describes the two methods for anchoring wire hoist ropes?

Wedge and socket anchors are generally more secure. Signup and view all the answers

What should be done to ensure the sheaves are functioning correctly?

Ensure they are free running without bearing play. Signup and view all the answers

What is the primary purpose of the LEEA Mobile Cranes Diploma qualification?

To validate the testing, inspection, and examination of Mobile Cranes Signup and view all the answers

Which aspect of mobile cranes is included in the scope of the MOB course?

Rated Capacity Indicators and Rated Capacity Limiters Signup and view all the answers

What knowledge area is emphasized in the learning outcomes of the MOB course?

Analysis of lifting equipment suitability for continued service Signup and view all the answers

Which type of examination is specifically part of the curriculum in the Mobile Cranes Diploma?

Thorough Examination - Mobile Telescoping Crane Structure Signup and view all the answers

Which of the following is a critical factor that students learn to assess during their training?

Effectiveness of load testing for Mobile Cranes Signup and view all the answers

What competency is required for students completing the Mobile Cranes Diploma?

Ability to prepare inspection reports Signup and view all the answers

What kind of tools and equipment are covered in the MOB course?

Specific tools used for Mobile Crane examinations Signup and view all the answers

Which aspect constitutes an important part of the Mobile Cranes Diploma's objectives?

Learning to extrapolate information from various sources for assessments Signup and view all the answers

What is the primary advantage of yard cranes compared to rough terrain cranes?

Ability to operate without outriggers Signup and view all the answers

Which characteristic distinguishes crawler mounted telescopic cranes from wheeled cranes?

Use of hydraulic drive systems Signup and view all the answers

What is an essential focus of BS7121-2-1 and BS7121-2-3 standards?

Inspection criteria for cranes Signup and view all the answers

In what situations might a yard crane need to be equipped with outriggers?

On uneven ground Signup and view all the answers

Why is it noted that the undercarriage inspection for crawler mounted telescopic cranes differs from wheeled cranes?

Undercarriages of wheeled cranes are generally more complex. Signup and view all the answers

What primary feature do telescoping cranes provide for on-site work?

Versatility in maneuverability Signup and view all the answers

What is a common misconception regarding yard cranes?

They offer no advantages over rough terrain cranes. Signup and view all the answers

What significant determination can be made from the criteria provided by ISO9927-1 and ISO9927-5?

Inspection standards for specific types of cranes Signup and view all the answers

What action must be taken if a crane frequently works near personnel?

Reduce the thorough examination interval Signup and view all the answers

Which factor might warrant changing the interval of thorough examinations?

The crane's age, condition, or environmental factors Signup and view all the answers

Under what circumstance could a mobile crane be used for lifting people?

In exceptional circumstances, including unplanned rescue Signup and view all the answers

What should be done following an inspection and assessment of a crane?

Completion of repairs and establishment of a maintenance regime Signup and view all the answers

Who is responsible for deciding whether to change the interval of thorough examinations?

The crane users, owner, and competent person Signup and view all the answers

What must in-house examiners have to ensure proper examinations?

Genuine authority and independence Signup and view all the answers

What could necessitate a competent person to review an in-service lift plan?

Assessing the expected load spectrum and frequency of use Signup and view all the answers

What might be a factor in determining the thorough examination frequency due to environmental conditions?

Extreme temperatures or dusty atmospheres Signup and view all the answers

What should be checked regarding the hydraulic system before setting up the crane?

The hydraulic tank oil level Signup and view all the answers

What is the primary reason for closely observing hydraulic rams when fitting counterweights?

To verify that each ram extends fully and locks in position. Signup and view all the answers

What is a critical action to perform after engaging the Power Take Off connection?

Listen for any adverse sounds from the pump Signup and view all the answers

Which of the following is a critical check that must be performed before operating the crane with fitted counterweights?

Examine attachments for leaks, loose connections, or damage. Signup and view all the answers

Which of the following is NOT part of the examination checks for the hydraulic system?

Verify the type of hydraulic fluid used Signup and view all the answers

When checking leaf spring suspension, which aspect is NOT necessary?

Identifying specific spring colors Signup and view all the answers

What aspect of counterweight deployment can indicated a malfunction if not observed?

The locking mechanism of the rams. Signup and view all the answers

What should be done if the operator's system display shows an incorrect sequence during counterweight fitting?

Immediately halt operations and investigate the display. Signup and view all the answers

What must be systematically checked during the examination of hydraulic system components?

The potential for hydraulic leaks and burst pipes Signup and view all the answers

Which action should be taken if issues are identified during the suspension checks?

Conduct further investigation Signup and view all the answers

Which condition is NOT essential when observing counterweight attachment rams?

Rams should remain stationary during deployment. Signup and view all the answers

Which component should be inspected for condition during the thorough examination of the hydraulic system?

Pipes, flexible hoses, and connections Signup and view all the answers

What should be observed regarding suspension during crane operation setup?

Suspension lowering should be observed Signup and view all the answers

What should be checked regarding the boom tip sheave assemblies during inspection?

Damage to sheaves and free running condition Signup and view all the answers

Which method of anchoring wire hoist rope is mentioned as a type that requires the rope to be correctly inserted and locked in place?

Button type anchor Signup and view all the answers

What is a consequence of damage to a wire rope fitted with a manufactured button fitting close to the fitting?

It must be sent back to the manufacturer for a replacement Signup and view all the answers

What is critical to ensure regarding the wire guides of boom tip sheaves?

They are in place and secured Signup and view all the answers

Why is it important to check for severe damage in boom tip sheave assemblies?

It may suggest potential damage to the wire rope Signup and view all the answers

What must the wire hoist rope be prepared for after selecting the correct anchor method?

Insertion and locking in place Signup and view all the answers

What action should be taken if a button fitting on the wire rope gets damaged?

Return it to the manufacturer for replacement Signup and view all the answers

Which of the following statements accurately represents a component of the detachable version of the super lift assembly?

It can be attached based on road weight restrictions Signup and view all the answers

In what scenario would a truck-mounted crane be rated for 360° operation?

If it has a 5th jack at the front end. Signup and view all the answers

What is a key characteristic of all-terrain cranes?

They are designed to operate under various ground conditions. Signup and view all the answers

How do city cranes enhance maneuverability in urban areas?

Their boom is kept low to avoid overhead obstructions. Signup and view all the answers

Which of the following features is not typically associated with all-terrain cranes?

Having a crane boom length exceeding 50 meters. Signup and view all the answers

What operational limitation do truck-mounted cranes experience concerning their duties?

They may have reduced duties in the front quadrant. Signup and view all the answers

What is the purpose of having steering and braking functions in the upper cab of an all-terrain crane?

To enable ease of maneuvering around the site. Signup and view all the answers

Which feature contributes to the high maneuverability of city cranes?

Shorter boom lengths and more sections. Signup and view all the answers

What aspect is critical when examining an all-terrain crane?

Verifying that both steering and braking systems operate correctly. Signup and view all the answers

What is the primary advantage of a luffing jib compared to a fixed boom?

Ability to cover a larger horizontal area Signup and view all the answers

What is a critical component to examine for damage during a boom inspection?

The primary cord and lacings of the fly jib extension Signup and view all the answers

What range of angles can the fly jib be set to maximize its effectiveness?

0° to 60° Signup and view all the answers

How has modern crane technology evolved in terms of side-supported lifts?

By eliminating the need for additional weights on the platforms Signup and view all the answers

What is a key consideration regarding the area where the crane is positioned for a thorough examination?

The area should be safe and suitable for the examination. Signup and view all the answers

What kind of construction is primarily associated with most fly jib extensions?

Lattice boom Signup and view all the answers

Which of the following equipment is considered necessary for ensuring safe access during the examination?

Fixed access structures like walkways and scaffolding Signup and view all the answers

What should be particularly monitored for damage in the attachment lugs of a fly jib?

Cracked welds and structural distortion Signup and view all the answers

In what scenario is the use of luffing jibs particularly beneficial?

In obstructed work environments near buildings Signup and view all the answers

What is the responsibility of the examiner concerning the cleanliness of the crane?

The examiner must ensure the crane is clean enough to identify defects. Signup and view all the answers

What type of identification should be verified before conducting the examination?

The I.D. and rated capacity markings of the crane Signup and view all the answers

What characteristic is unique to the powered adjustable system of a fly jib?

It allows for effortless angle adjustments without manual labor Signup and view all the answers

Which records should be viewed to assess the crane's operational history?

The previous thorough examination report and maintenance log Signup and view all the answers

What must be agreed upon beforehand regarding the personnel involved in the examination?

The PPE requirements between the owner and the competent person Signup and view all the answers

What is critical to ensure about the crane before the examination regarding its prior issues?

That any recorded defects or malfunctions are addressed Signup and view all the answers

Which aspect of the crane examination does NOT involve the verification of external features?

Performance under load Signup and view all the answers

What is a common indication of decreased rope elasticity?

Fine powder emerging from the valleys of the rope Signup and view all the answers

What is a consequence of insufficient clearance between strands and wires in a rope?

Decreased rope elasticity Signup and view all the answers

In rotation-resistant ropes, where are the majority of broken wires typically found?

Internally as non-visible fractures Signup and view all the answers

What usually leads to the removal of a wire rope from service?

The number of broken wires developing Signup and view all the answers

What type of break is indicated by flat ends on broken wires?

Fatigue breaks Signup and view all the answers

What inspection area typically shows an accelerated rate of rope wear?

Adjacent to terminal fittings Signup and view all the answers

Why is the standard for the allowable number of visible broken wires lower in rotation-resistant ropes?

Most breaks occur internally and are not visible Signup and view all the answers

What effect does prolonged service have on wire ropes?

Increased rate of broken wires Signup and view all the answers

What is a key characteristic of yard cranes?

They can transport light loads on a strong platform. Signup and view all the answers

Which system is now commonly used in the tracks of crawler mounted telescopic cranes for easier inspection?

Hydraulic system Signup and view all the answers

What does the examination of cranes refer to in relation to established standards?

It adopts a combination of BS and ISO standards. Signup and view all the answers

What is an important aspect of yard cranes regarding their operational capabilities?

They are designed for use in confined spaces without necessary outriggers. Signup and view all the answers

In which way should the inspection of crawler mounted telescopic cranes differ from wheeled cranes?

The undercarriage needs a different inspection approach. Signup and view all the answers

What is the primary benefit of using rubber on yard cranes?

It provides mobility without the need for outriggers. Signup and view all the answers

Which set of standards provides criteria for crane inspections?

BS and ISO standards Signup and view all the answers

What type of loads are yard cranes typically intended to transport?

Light loads like pumps, motors, and valves. Signup and view all the answers

Study Notes

Load Testing and Examination Procedures

Test load should be raised between 100 mm and 200 mm above the ground for 10 minutes.
No over-run or creep is permitted during tests.
Slewing of the load must occur at the lowest possible speed in both directions to assess lateral load resilience.
The load should then be slewed to the maximum angle allowed by crane design.

Post-Test Examination

A comprehensive examination is required after completing the overload test to ensure crane safety and functionality.

Thorough Examination Components

Mobile Crane Carrier/Chassis:
- Check the manufacturer's information plate for type, model, serial number, manufacturing year, and manufacturer’s name.
- Ensure all markings comply with legislation and are clear.
Lighting Systems:
- Inspect all lights (headlights, sidelights, warning lights) for functionality and condition.
- Verify the security and clarity of windscreen wipers and registration plate.
- Conduct anti-two block alarm tests ensuring safety pins are in place during tests.

Hook Block Specifications

The hook block must display clear legible information including:
- Safe Working Load (SWL): e.g., 25T.
- Weight of Hook Block: e.g., 360 kg.
- Manufacturer's plate should be accessible for verification.

Hoist Drum Inspection

Hoist drums should be examined for:
- Secure fastening to the superstructure.
- Absence of visible damage.
- Integrity of hydraulic hoses and connections.
- Proper layering of wire hoist rope.
- Correct rotation and functioning of the hoist brake.
- No unusual sounds during operation.

Wire Rope Examination

Operators must perform detailed checks regularly, supported by thorough inspections from a Competent Person.
Various factors for inspection frequency include environmental conditions, type of hoist, and operational history.

Inspection Record Keeping

Maintain records of all inspections as per ISO 4309, including a running record of crane rope inspections.
Each inspection will evaluate different aspects of wire rope condition, noting any faults beyond just broken wires.

Assessment and Severity Rating

Inspectors should assess the severity of deterioration and rate it as a percentage (e.g., 20%, 40%, 60%), or descriptively ('slight', 'medium', 'high', 'very high', 'discard').
Use visual inspections, measurements, and Magnetic Rope Testing (MRT) for assessments.

Final Evaluations

The examiner must determine the suitability of the wire rope for continued service, considering its degradation.
If deterioration is evident, recommend decreasing the duration before the next inspection based on current safety and reliability concerns.

Introduction to Mobile Cranes Diploma

Essential for professionals involved in mobile crane testing, inspection, and examination.
Recognized as the industry standard qualification by Lifting Equipment Engineers Association (LEEA).
Ensures qualified individuals assess cranes’ suitability for continued service post-examination.

Learning Outcomes

Acquire knowledge to perform thorough examinations of mobile cranes.
Ability to evaluate cranes' fitness for further service and maintain compliance with necessary conditions.
Skills to extract and utilize information from various sources for equipment analysis.

Scope of MOB Course

Covers practical aspects such as working on-site and utilizing examiners' tools.
Details various types of mobile cranes and examination methods.
Discusses assessment criteria, preparation methods, competency standards, and load testing protocols.
Emphasizes thorough examinations of crane carriers, structures, and safety mechanisms, such as Rated Capacity Indicators.

Inspection Protocol

Complete assessment reports highlighting issues and recommendations, prioritizing safety-critical concerns.
Immediate notification to equipment owners for severe issues and proper quarantining of out-of-service equipment.
Establish repair timelines for identified issues and ensure clear communication of findings.

Importance of Professional Standards

LEEA members are ambassadors for industry standards; maintaining exemplary professional conduct is crucial.
Continuous Professional Development (CPD) is emphasized for maintaining competencies.

Examiners’ Tools and Equipment

Essential tools include spirit level, tyre pressure gauge, inclinometer, and load cell.
Choice of tools varies based on inspection needs.

Boom Tip Sheaves Examination

Inspect for damage and ensure sheaves operate without bearing play.
Verify proper installation and securing of rope guides.
Check for wire rope wear caused by friction with guides.

Wire Rope Anchor Examination

Ensure correct wire rope anchoring at hook blocks and boom tips.
Test the anti-two block alarm by raising hook blocks cautiously to activate alarms.
Confirm the presence and correct placement of all safety pins during inspections.

Hook Block Information

Each hook block should display clear information, including capacity (e.g., 25T) and weight (e.g., 360kgs).
Manufacturer’s plate should be inspected for compliance and recorded in examination reports.

Severity Rating and Assessment

Record findings on broken wires, diameter decrease, corrosion, and other damages.
Calculate total severity ratings as a percentage to gauge equipment safety for continued service.
Assess the potential need for more frequent future examinations based on current conditions.

Yard Cranes

Designed for use in yards where deploying outriggers is inconvenient or impractical.
May have outriggers and can operate in tight spaces where rough terrain cranes are too large.
Capable of transporting light loads such as pumps, motors, and valves on a stable rubber platform.

Crawler Mounted Telescopic Cranes

Mounted on tracks for on-site operations similar to wheeled cranes.
Easier inspection due to hydraulic drive systems replacing mechanical ones.
Under-carriage examination requires different methods compared to wheeled cranes.

Types of Examination

Adheres to LEEA’s COPSULE and global best practices, referencing standards like BS7121 and ISO9927.
Inspections may require removal of access covers or dismantling parts for complete assessment.
Post-inspection repairs and documentation of maintenance regimes are essential.

Amending the Intervals of Periodic Thorough Examination

Maximum intervals for thorough examinations typically range from 6 to 12 months.
Increased inspection frequency may be warranted due to various conditions:
- Operations near personnel or the public.
- Lifting people in exceptional circumstances.
- Working in extreme environmental conditions (e.g., temperature extremes, sandy or dusty atmospheres).
- Changes in the crane's duty cycle determined by risk assessments.

Automatic Carrier Levelling and Suspension System

Observe suspension adjustments during setup and conclusion of operations.
Investigate any anomalies in suspension behavior to ensure safety.

Hydraulics

Check hydraulic tank oil levels before crane setup and ensure caps are secure.
Verify filters are accessible and in good condition; listen for irregular sounds from the pump during operation.
Inspect all hydraulic pipes, hoses, and connections for leaks and wear.

Counterweights

Fit counterweights according to load charts to maximize boom lengths and radius.
Monitor counterweight attachment rams to ensure proper deployment and locking.
Inspect hydraulic rams for full extension, locking capability, and any hydraulic leaks or damages.

Boom Tip Sheaves

Check for damage and ensure sheaves are functioning smoothly without excessive play.
Confirm that rope guides are secured and wear from wire rope friction is minimized.
Significant damage could indicate potential issues with the wire rope itself.

Wire Rope Anchor

Wire hoist operates via hook block, with the wire attached to the boom tip through a wire rope anchor.
Correct anchoring technique is crucial, using either button type or wedge and socket type anchors.
Damaged wire ropes near fittings necessitate returning to the manufacturer for repair rather than simply cutting and reusing the fitting.

Truck Mounted Cranes

May have reduced operational duties in the front quadrant unless equipped with a 5th jack, which can enable full 360° operation.

All-Terrain Cranes

Designed for diverse ground conditions, with upper cab functions to steer and stow jacks.
Equipped with steering wheel and brake pedal for mobility on-site.
Both steering and braking systems must be inspected for functionality.

City Cranes

Feature a shorter, multi-section boom, enhancing maneuverability in urban settings.
Designed with all-wheel steering and a low boom to navigate overhead obstacles.