Course Overview

Working On and Around

Heavy Equipment
Course Overview

Overview
This course covers the safety procedures for working on and around
Caterpillar heavy equipment.
The following course curriculum has been developed using the
reference materials and tooling listed on the following pages.

©2006 Caterpillar Inc.

Property of Caterpillar Inc.
NOTES
 Table of Contents
Working On and Around
Heavy Equipment
Table of Contents
UNIT 1: Working On and Around Heavy Equipment
Lesson 1: Working On and Around Heavy Equipment
NOTES
Working On and Around

Course Syllabus
Heavy Equipment
Course Syllabus

Description
1. Caterpillar Communications Course
2. Course Number ___________
3. Prerequisite: None
4. 2 lecture hours
Methods of Presentation
1. Lecture and discussion
2. Demonstrations
3. Supporting laboratory exercises and lab worksheets
Suggested Evaluation of Student Achievement
1. Unit quizzes ______%
2. Laboratory worksheets ______%
3. Class and laboratory participation--_______%
NOTES
Working On and Around

Objectives
Heavy Equipment
Objectives

At the completion of this course, the student will be able to safely

work on and around Caterpillar products.
NOTES
 Reference Materials
Working On and Around
Heavy Equipment
Reference Materials

None
NOTES
 Tooling Requirements
Working On and Around
Heavy Equipment
Tooling Requirements

None
NOTES
 Unit 1: Working On and Around Heavy Equipment
Unit 1
Working On and Around Heavy Equipment

Unit Objectives:
At the completion of this unit each student will be able to safely work
on and around Caterpillar heavy equipment.
Unit References:
None

Tooling:
None
NOTES
 Lesson 1: Working On and Around Heavy Equipment
Lesson 1: Working On and Around Heavy
Equipment
Introduction:
This lesson will discuss the safety aspects when working on and
around heavy equipment.

Objectives:
After completion of this lesson the student will be able to:
1. Identify safety labels and safety information on Caterpillar
equipment.
2. Identify appropriate personal protective safety equipment.
3. Use the equipment lockouts when performing service work.
4. Identify hazardous items on equipment.
5. Safely lift and block equipment.
6. Perform a hoist and sling inspection.
7. Safely move equipment using a hoist and sling.

References:
None

Tooling:
None
Unit 1 2 Working On and Around Heavy Equipment
Lesson 1

Introduction

A piece of heavy equipment can weigh well over 200,000 lbs and individual parts
on this equipment can weigh over 10,000 lbs. When servicing heavy equipment a
technician must know:
• The basic safety rules and the use of personal protective equipment
• Lockout procedures to put the equipment in zero mechanical status
• Correct method of lifting and blocking equipment
• The limits of the tools and lifting devices
• Correct methods of using tools and lifting devices
Unit 1 3 Working On and Around Heavy Equipment
Lesson 1

Safety Information

Prior to performing work on heavy equipment, the technician must read and
understand all safety information before servicing the equipment.

Safety information can be found in the following documents:

• Operation and Maintenance Manual
• Testing and Adjusting Manual
• Disassembly and Assembly Manual
• Warning labels that are located on the machine and engine

NOTE: If these hazard warnings are not heeded, bodily injury or death could
occur.
Unit 1 4 Working On and Around Heavy Equipment
Lesson 1

Safety Labels

There are specific safety labels on equipment. The technician must become familiar
with all equipment safety labels.

Make sure that all of the safety labels are legible. Clean the safety labels or replace
the labels if you cannot read the words. When you clean the safety messages, use a
cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to
clean the safety messages. Solvents, gasoline, or harsh chemicals could loosen the
adhesive that secures the safety messages.

Replace any safety label that is damaged or missing. If a safety label is attached to
a part that is replaced, install a safety label on the replacement part.
Unit 1 5 Working On and Around Heavy Equipment
Lesson 1

Personal Protective Equipment

When you work around the machine, always wear protective equipment that is
required by the job conditions. Protective equipment includes the items that follow:
• Hard hat
• Protective glasses or face shield
• Protective shoes.

Do not wear loose clothing, neckties, or jewelry (finger rings, necklace, long
earrings or ribbons) that can catch on parts of the machine.
Unit 1 6 Working On and Around Heavy Equipment
Lesson 1

Mounting and Dismounting

Use steps and handholds whenever you mount or dismount a machine. Before you
mount the machine, clean the step and the handholds. Inspect the step and
handholds and make all necessary repairs.

Face the machine when mounting and dismounting. Always maintain a three-point
contact with the step and with handholds.

NOTE: Three-point contact can be two feet and one hand or one foot and two
hands.

Do not mount or dismount a moving machine. Never jump off the machine. Do not
try to mount or dismount the machine when you carry tools or supplies. Use a hand
line to pull equipment onto the platform. Do not use any controls as handholds
when you enter the machine or when you exit the machine.
Unit 1 7 Working On and Around Heavy Equipment
Lesson 1

Hot Fluids and Parts

To avoid burns, be alert for hot parts on machines which have just been stopped and
hot fluids in lines, tubes, and compartments.

Be careful when you remove filler caps, breathers, and plugs on the machine. Hold
a rag over the cap or plug in to prevent being sprayed by pressurized liquids. When
the machine has just been stopped, the possibility of hot fluids is greater.
Unit 1 8 Working On and Around Heavy Equipment
Lesson 1

Batteries

Do not smoke when an inspection of the battery electrolyte level is made. Never
disconnect any charging unit circuit or battery circuit cable from the battery when
the charging unit is operating. A spark can cause an explosion from the flammable
vapor mixture of hydrogen and oxygen that is released from the electrolyte through
the battery outlets.

Do not allow battery electrolyte to make contact with the skin or with the eyes.
Battery electrolyte is an acid. In case of contact with battery electrolyte,
immediately wash the skin with soap and water. For contact with the eyes, flush the
eyes with large amounts of water for at least 15 minutes and seek medical attention.
Unit 1 9 Working On and Around Heavy Equipment
Lesson 1

Pressurized Components

Pressure can be trapped in a hydraulic system. Releasing trapped pressure can

cause sudden machine movement or attachment movement. Use caution if you
disconnect hydraulic lines or fittings. High pressure oil that is released can cause a
hose to whip. High pressure oil that is released can cause oil to spray. Fluid
penetration can cause serious injury and possible death.

Pressure can be trapped in the hydraulic circuit long after the engine has been
stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or parts until pressure has been relieved
or personal injury may occur. Do not disassemble any hydraulic components or
parts until pressure has been relieved or personal injury may occur. Refer to the
Service Manual for any procedures that are required to relieve the hydraulic
pressure.

Fuel and hydraulic lines that are damaged or loose may leak. This could result in a
fire if the fluid comes in contact with a source of ignition. Do not bend or strike
high pressure lines. Do not install lines which have been bent or damaged. Check
lines, tubes, and hoses carefully. Do not use your bare hand to check for leaks.
Unit 1 10 Working On and Around Heavy Equipment
Lesson 1

Air and Water Pressure

Pressurized air or pressurized water can cause personal injury. When pressurized
air or pressurized water is used for cleaning, wear a protective face shield,
protective clothing, and protective shoes. The maximum air pressure for cleaning
purposes must be below 205 kPa (30 psi). When you use a pressure washer, keep in
mind that the nozzle pressures are very high. The nozzle pressures are frequently
above 13790 kPa (2000 psi). Follow all of the recommended practices that are
provided by the manufacturer of the pressure washer.
Unit 1 11 Working On and Around Heavy Equipment
Lesson 1

Fueling

Use caution when you are refueling a machine. Do not smoke while you are
refueling a machine. Do not refuel a machine near open flames or sparks. Always
stop the engine before refueling. Fill the fuel tank outdoors.
Unit 1 12 Working On and Around Heavy Equipment
Lesson 1

Tire Precautions

Explosions of air inflated tires have resulted from heat-induced gas combustion
inside the tires. Explosions can be caused by heat that is generated by welding, by
heating rim components, by external fire, or by excessive use of the brakes.

A tire explosion is much more violent than a blowout. The explosion can propel the
tire, the rim components, and the axle components as far as 500 m (1500 ft) or more
from the machine. Both the force of the explosion and the flying debris can cause
property damage, personal injury, or death.

Do not approach a warm tire. Maintain a minimum distance, as shown. Stay

outside the shaded as shown above.

Do not use water or calcium as a ballast for the tires. Dry nitrogen gas is
recommended for tire inflation. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the pressure. Nitrogen mixes properly with
air.

Nitrogen inflated tires reduce the potential of a tire explosion because nitrogen does
not aid combustion. Nitrogen also helps to prevent oxidation of the rubber,
deterioration of the rubber, and corrosion of the rim components.
Unit 1 13 Working On and Around Heavy Equipment
Lesson 1

Tire Inflation

To avoid over inflation, proper nitrogen inflation equipment and training in the
usage of the equipment are necessary. A tire blowout or a rim failure can result
from improper equipment or from misused equipment.

When you inflate a tire, stand behind the tread and use a self-attaching chuck.

Servicing tires and rims can be dangerous. Only trained personnel that use proper
tools and proper procedures should perform this maintenance. If correct procedures
are not used for servicing tires and rims, the assemblies could burst with explosive
force. This explosive force can cause serious personal injury or death. Carefully
obey the specific instructions from the tire dealer.
Unit 1 14 Working On and Around Heavy Equipment
Lesson 1

General Service Precautions

Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch
or to the controls before you service equipment.

When possible, make all repairs with the machine parked on a level, hard surface.
The machine should be blocked in order to prevent the machine from rolling.

Know the width of your equipment to maintain proper clearance when you operate
the equipment near fences or near boundary obstacles.

Be aware of high voltage power lines and power cables that are buried. If the
machine comes in contact with these hazards, serious injury or death may occur
from electrocution.

Make sure that all protective guards and all covers are secured in place on the
equipment. If a guard, a cover, or a shield must be removed to perform the repair
work, use extra caution.

Keep the equipment free from foreign material. Remove debris, oil, tools, and other
items from the deck, from the walkways, and from the steps.

Secure all loose items such as lunch boxes, tools, and other items that are not a part
of the equipment.
Unit 1 15 Working On and Around Heavy Equipment
Lesson 1

General Service Precautions

Use all cleaning solutions with care. Report all necessary repairs.

Do not allow unauthorized personnel on the equipment.

Disconnect the battery and discharge any capacitors before starting work on the
machine.

Do not work on any machine that is supported only by lift jacks or a hoist. Always
use blocks or jack stands in order to support the machine before performing any
service or disassembly.

Make sure that the work area around the machine is safe and be aware of any
hazardous conditions that may exist. If an engine is started inside an enclosure,
make sure that the engine's exhaust is properly vented.

Always use tools that are in good working condition. Ensure that you understand
the proper use of the tools before performing any service work.
Unit 1 16 Working On and Around Heavy Equipment
Lesson 1

Hazardous Energy Sources

• Electrical Circuits
• Mechanical devices
- Transitional
- Rotational
- Accumulators
• Airlines
• Pressures
- Hydraulic
- Pneumatic
- Vacuum
• Springs
• Gravity

The technician should lockout any of the following energy sources to avoid injury
or death:
• Electrical Circuits
• Mechanical devices
- Transitional
- Rotational
- Accumulators
• Airlines
• Pressures
- Hydraulic
- Pneumatic
- Vacuum
• Springs
• Gravity
Unit 1 17 Working On and Around Heavy Equipment
Lesson 1

Lockout Safety

It is imperative that equipment is "Locked Out" before use. The five fatal causes of
injuries while working on heavy equipment are:
• Failure to stop equipment
• Failure to disconnect power source
• Failure to dissipate (bleed, neutralize) residual energy
• Accidental restarting of equipment
• Failure to clear work area before restarting equipment

Lockout is the placement of a lock and tag on an energy isolating device ensuring
control over the device and equipment to make sure the device cannot be re-
energized until the the lock is removed.

The goal of equipment lockout is to protect the safety and health of employees and
protect the equipment from damage.

Lockout is required when an employee is:

• Involved in repairs
• Cleaning equipment
• Performing maintenance
• Required to place any body part in a point of operation
• Required to move a guard or safety device to perform work
Unit 1 18 Working On and Around Heavy Equipment
Lesson 1

Lockout Procedure

1) Shut down equipment

2) Battery disconnect switch OFF
3) Install master switch lockout device
4) Attach a Do Not Operate tag to the
lockout device
5) Attach a Do Not Operate tag in the
Operator’s Compartment.
6) Relieve all pressure

Before locking out equipment notify all affected employees.

1. Turn the master battery disconnect switch to the OFF position and remove the
key.
2. Shut down equipment at controls.
3. Install the master switch lockout device over the master switch. If the machine
is not equipped with a master disconnect, install a lockout device on the ignition
switch.
4. Close the lockout device and attach a Do Not Operate tag to the lockout device
with a plastic tie.
5. After the master disconnect has been locked out, turn the ignition switch to the
on position to verify that electrical power is off. Then, attach a Do Not Operate
tag in the Operator’s Compartment.
6. Relieve all pressure in air, oil, or water systems before any lines, fittings, or
related parts are disconnected or removed.
Unit 1 19 Working On and Around Heavy Equipment
Lesson 1

Lift Arm Supports

Lift arm supports (arrow) allow the technician to safely service the machine with
the lift arms raised. Install the lift arm supports if performing service work with the
lift arms raised.

Keep all work tools tilted downward when repair work is being formed with the lift
arms in the raised position. Prior to performing any maintenance or repairs, ensure
that all hydraulic pressure has been relieved.
Unit 1 20 Working On and Around Heavy Equipment
Lesson 1

Bucket Safety Pins

Lock Pin Stored

Lock Pin Installed

Bucket control group safety pins also allow the technician to safely service the
machine with the loaders arms raised. Install the bucket safety pins if performing
service work near the loader arms.
Unit 1 21 Working On and Around Heavy Equipment
Lesson 1

Steering Frame Lock

Lock Pin Stored

Lock Pin Installed

The steering frame lock pin is located at the articulating hitch in the center of the
machine. Install the steering frame lock if performing service work near the
articulating hitch. The steering frame lock pin allows the technician to safely
service the machine while the engine is running.
Unit 1 22 Working On and Around Heavy Equipment
Lesson 1

Dump Body Pins

Lock Pin Stored

Lock Pin Installed

The body retaining pins are located below the rear of the truck dump body to allow
technicians to safely service the truck when the body is raised. Install the body
retaining pins when performing service work near the dump body when the dump
body is raised.
Unit 1 23 Working On and Around Heavy Equipment
Lesson 1

Lifting Machine

Support the equipment properly before you perform any work or maintenance below
the equipment. Do not depend on the hydraulic cylinders to support the equipment.
Equipment can fall if a control is moved, or if a hydraulic line breaks.

Do not work below the machine component unless the component is properly
supported.

Hydraulic jacks can be used to lift and hold heavy equipment while jack stands or
wood blocking is installed. The jack is put into position so that one end will be on a
solid support and the other will push against the load. The jack handle is operated
to move the large plunger and the load. To release pressure caused by the jack, a
valve must be opened. This valve will release the oil in the jack and the large
plunger will retract to the normal position.

Each hydraulic jack has a maximum rated capacity. Do not use a hydraulic jack to
lift more than the maximum capacity for that specific jack.
Unit 1 24 Working On and Around Heavy Equipment
Lesson 1

Tractor Lift

Tractor lifts can be used to lift a track-type tractor while jack stands or wood
blocking is installed.

Each tractor lift has three sides with a steel plate brace in the middle. The tractor
lift uses the track movement to provide the force to lift the tractor. The inside curve
side of the tractor lift is put against the track at the rear of the tractor. The edge
where the inside curve and straight sides come together must be held below a
grouser bar. The operator causes the track to move slowly in a reverse direction,
which will lift the rear of the tractor. The track must be stopped before the tractor
lift is in a position below the roller frame. The rear jack stands are then put into
position. Two technicians can lift and hold with jack stands, any track-type vehicle
in three to five minutes with tractor lifts.

Inspect the tractor lifts before each use to make sure that they are in good condition.
Use two people when tractor lifts are used to lift a tractor. One person must put the
tractor lifts into position while the other operates the tractor. Keep personnel away
from the ends of the tractor while the lifts are used.
Unit 1 25 Working On and Around Heavy Equipment
Lesson 1

Supporting Machine

When equipment is lifted by a hydraulic jack, jack stands should be placed into
position under the equipment. Lower the equipment until it is held by the jack
stands.

Jack stands are strong vertical supports which can be adjusted to different heights.
There are two primary components of a jack stand. The first is the bottom assembly
(base). The base is used as a solid support against the ground or shop floor. The
second component is a straight vertical support (tube). The tube is held vertical and
at a specific height by the base. To the top of the tube can be added a fixture
(saddle) to give better contact between the tube and the vehicle. The maximum
capacity for a specific jack stand can be found on the jack stand base.

Never work under a load that is held only by jacks. Put jack stands under the load
and lower the load until all of the weight is held by the jack stands. Make sure that
the load is held solidly on the jack stand tube or saddle. All lock fixtures must be in
position on the jack stand before a load is put on it.
Unit 1 26 Working On and Around Heavy Equipment
Lesson 1

Supporting Equipment

Another method to support heavy equipment is wood blocking. Wood blocking

generally has equal sides opposite each other. Wood blocking can be cut to any size
to fit special applications. Use caution with wood blocking since maximum load
factors are not known.

Wood blocking is best used as a spacer. A load held on wood blocking has the
space needed to install or remove lifting equipment or to move with a lift
truck. Wood blocking must be inspected before it is used. Do not use wood
blocking that has cracks or deep cuts. Wood blocking must be put into a position so
that the long sides of the blocks are parallel to the contact between the wood
blocking and the load.
Unit 1 27 Working On and Around Heavy Equipment
Lesson 1

Lifting Devices - Hoist

If any component that weighs more than 23 kg (50 lb) is lifted, a hoist should be
used. If any component is difficult to move due to the size, the grip, or any other
difficulties, a hoist should be used.

Use approved cables, chains, and lifting devices to lift components. Refer to the
manufacturer's weight's to determine the application when selecting cables, chains,
and lifting devices. When you lift a component, the lift angle is critical.

Ensure sure that all chains, hooks, slings, and any other lifting devices are in good
condition.

Ensure that the hooks are equipped with a safety latch. Do not place a side load on
the lifting eyes during a lifting operation.
Unit 1 28 Working On and Around Heavy Equipment
Lesson 1

Lifting Devices - Slings

These illustrations show examples of different types of lifting slings used to move
heavy equipment. The most common types of slings are chain, wire rope, and
synthetic web.
Unit 1 29 Working On and Around Heavy Equipment
Lesson 1

Lift Angles

The capacity of a sling decreases as the angle at which it is used to lift increases.

Lift angles for lifting slings:

(A) The load capacity is 100% of the working load limit for the sling.
(B) The load capacity is 86% of the working load limit for the sling.
(C) The load capacity is 70% of the working load limit for the sling.
(D) The load capacity is 50% of the working load limit for the sling.
Unit 1 30 Working On and Around Heavy Equipment
Lesson 1

Lifting Devices - Eyebolts

Eyebolts have a ring at the head of the bolt. The bottom part of the eyebolt has
threads that are made to fit a bolt hole. The ring must be large enough to hold the
end fixture on a sling leg or hoist. The eyebolt connects lifting equipment
to a load. The eyebolt must be turned into the bolt hole until only one or two
threads can be seen.

Lifting equipment is fastened to the eyebolt so that it will pull axially when the load
is lifted.

NOTE: Eyebolts are designed for a straight vertical pull. Do not pull eyebolts
at an angle or damage to the eyebolt could occur and the load could drop.

Do not use an eyebolt that has damaged threads. Remove from service any eyebolt
that has cracks, damaged threads, or is badly worn.
Unit 1 31 Working On and Around Heavy Equipment
Lesson 1

Lifting Devices – Link Brackets

Link brackets have a ring that is attached directly to the link bracket or they may
have an intermediate link. The link bracket is used to connect lifting equipment to a
load. The link bracket must be connected to the load with a bolt. Lifting equipment
is fastened to the outer link to lift the load. Link brackets can be pulled at an angle.

Do not use bolts with damaged threads to connect the link bracket. Remove from
service any link bracket that has cracks or is badly worn.
Unit 1 32 Working On and Around Heavy Equipment
Lesson 1

Lifting Devices – Spreader Bar

The spreader bar holds the legs of a sling apart. When used with a chain, the
spreader bar is held in position by a lock junction. The lock junction is made by the
chain links and the notch in the end of the spreader bar.

Without a spreader bar, the legs of a sling generally pull lifting eyes at an angle
toward the center fixture of the sling. The direction of this pull can damage
eyebolts and lifting plates. When a spreader bar is used, the sling will pull straight
on the lifting eyes. The spreader bar prevents damage to the lifting eyes.

Angles of the chain sling legs must be kept as small as possible. For
this reason, the spreader bar must be kept near the load. The angle between the two
legs of the sling causes a reduction in the maximum capacity of the sling.

Know the weight of the load before it is moved. There is more reduction in the
maximum capacity of a sling when a spreader bar is used. The tension on the legs
of the sling is more between the spreader bar and the center fixture of the sling than
between the spreader bar and the load.
Unit 1 33 Working On and Around Heavy Equipment
Lesson 1

Lifting Devices – Lifting Beam

The lifting beam is used to connect heavy loads to lift equipment. The
lifting beam is used as a lifting sling and a spreader bar. The hooks on the lifting
beam can be put into position directly above the lifting eyes on a load to prevent
damage to lifting eyes.

The ring at the top of the lifting beam is fastened to the lift equipment. Lifting
slings can be used between the hooks on the lifting beam and the load. The hooks
must be put into position on the lifting beam to give the load stability when it is
lifted. A lifting beam can be used where there is only a small clearance between the
load and other components of a machine.

Know the weight of the load before it is moved. Do not lift more than the
maximum rated capacity of a specific lifting beam.
Unit 1 34 Working On and Around Heavy Equipment
Lesson 1

Lifting Devices – Load Positioning Sling

The load positioning sling allows heavy loads to be turned to different positions
while being held by the lift equipment. The position of the load is changed when an
adjustment screw is turned. As the wheel in the center fixture is turned, one sling
leg is made longer while the other leg is made shorter. Because the legs of the sling
are made of different lengths, the load is turned.

The load positioning sling is a good selection if heavy components must be put into
position where side clearances are small.

Know the weight of a load before it is moved. Check the decrease in the maximum
capacity caused by the angle of the legs. Check a lift chart to find the amount of
decrease. Make sure that the hook openings are away from the load. The load must
have good stability before it is moved. Follow chain safety procedures.
Unit 1 35 Working On and Around Heavy Equipment
Lesson 1

Hoist Inspection

Hoists and lifting devices (chains, slings etc.) require inspection and maintenance as
well as the effective training of employees in their use.

Inspections are required to prevent injuries by insuring the hoists and lifting devices
are safe to use and function properly before attempting to lift heavy equipment.

Inspection procedures for hoists in regular service is divided into two general
classifications based upon the intervals at which the inspection should be
performed. The intervals in turn are dependent upon the nature of the critical
components of the hoist and the degree of their exposure to wear, deterioration, or
malfunction. The two general classifications are "frequent" and "periodic."

Frequent inspections are normally daily to monthly inspections. Periodic

inspections are normally done in 1-12 month intervals.

Frequent and periodic inspection intervals should be determined by hoist usage as

defined in local regulations.

It's good practice to perform daily inspections (if not required by regulations),
which includes a visual and operational inspection.
Unit 1 36 Working On and Around Heavy Equipment
Lesson 1

Hook Gauge

Hook size is measured between the tip and the back of the hook. This measurement
is made with a hook gauge. The hook gauge is made from a flat piece of metal.
Two opposite sides of the hook gauge are cut at intervals to make different widths.
These different widths are made to fit the different sizes of the openings on hooks.
There is a mark at each interval to give an indication of the correct size for a
specific hook.

For example, how is a size 29 hook checked for size? Hold the hook gauge in the
opening of the size 29 hook. The width of the hook gauge at the 29 mark must just
fit between the tip and the back of the opening on the lifting hook. If the hook
opening is larger than the width at the 29 mark, the hook must be removed from
service.
Unit 1 37 Working On and Around Heavy Equipment
Lesson 1

Sling Inspection

The operator should perform a daily visual inspection of all lifting devices that will be used.

Any lifting devices found to be defective must be taken out of service. A chain sling could
be considered defective for one of the following reasons:

• the sling is missing a tag,

• the sling is tagged incorrectly,
• the sling has been modified by unauthorized personnel,
• the sling is stretched due to improper usage,
• the sling has a defective attachment (i.e. bent plate hook or damaged alligator), or
• the chain is gouged.

Chain slings, wire ropes and web slings are identified with an ID tag. The ID tag for chain
slings is usually located just below the top ring of the sling and contains the following
information:

1. size of the chain,

2. grade of chain,
3. rated capacity of the sling,
4. reach of the chain,
5. manufacturer and
6. serial number.

The ID tag for wire ropes and web slings contains the manufacturer name, serial number
and rated capacity.
Unit 1 38 Working On and Around Heavy Equipment
Lesson 1

Wire Rope Sling Inspection

Wire rope slings should be inspected daily and removed from service if any of the
following conditions are found:
1. Three randomly distributed broken wires in one strand, in one rope layer.
2. Wear or scraping of 1/3 the original diameter of outside individual wires.
3. Kinking, crushing, or any damage resulting in distortion of the wire rope.
4. End attachments that are cracked, worn, or deformed.
5. Corrosion of the rope or end attachments
Unit 1 39 Working On and Around Heavy Equipment
Lesson 1

Chain Sling Inspection

Chain slings should be inspected and removed from service if any of the following
conditions apply:
1. Hooks have been opened more than 25% of the normal throat opening
measured at the narrowest point or twisted more than 10 degrees from
the plane of the unbent hook.
2. Chain slings with cracked or deformed master links, coupling links, or
other components shall be removed.
3. Chain size at any point of any link is less than required, the sling shall
be removed.

Chain slings should never be modified or repaired by operators. Only qualified

personnel may do so.
Unit 1 40 Working On and Around Heavy Equipment
Lesson 1

Synthetic Web Sling Inspection

Synthetic web slings should be inspected and removed from service if any of the
following conditions apply:
1. Acid or caustic burns on the sling.
2. Melting or charring of any part of the slings surface.
3. Snags, punctures, tears, or cuts are present.
4. Stitching is broken or worn.
Unit 1 41 Working On and Around Heavy Equipment
Lesson 1

Lifting and Moving Operation

Before Attaching Lifting Device

The following information will provide a general procedure for lifting and moving a
load.

NOTE: All local regulations and safety rules must be followed before moving a
load.

Before attaching the lifting device:

• Know the weight of the load and the balance point

• Determine the correct lifting device

• Don’t exceed the capacity of the lifting device

• Familiarize yourself with the hoist controls and response time

Unit 1 42 Working On and Around Heavy Equipment
Lesson 1

Lifting and Moving Operation

Attaching Lifting Device

Attaching the lifting device:

• Closed hook facing out

• Sling seated in bowl of hook

• Load secured and balanced

• Device not kinked

Unit 1 43 Working On and Around Heavy Equipment
Lesson 1

Lifting and Moving Operation

Moving Load

Moving the load:

• Lift load straight up

• Stay as close to floor as possible

• No sudden acceleration or deceleration of load

• Clear path and escape route

• Stay behind load and push only

• Never move load over an employee or work station

• Raise hook when finished

• Never anyone under load (except to attach and detach load or place
blocking equipment under load)
 DAILY HOIST INSPECTION
HOIST #: ______________ BLDG: _____________ START DATE: ____________________________
INSPECTOR'S NAME (PRINT): _______________________________DEPT. & SHIFT:_____________
NOTIFY YOUR SUPERVISOR IMMEDIATELY OF ANY ITEMS MARKED "RA"
AND DO NOT USE THE CRANE UNTIL MAINTENANCE HAS INSPECTED OR REPAIRED IT.

Please mark one of the following: (9 or RA) 9 = ITEM MEETS REQUIREMENTS

RA = ITEM NEEDS REPAIR OR
ADJUSTMENT

VISUAL INSPECTION ITEMS Mon. Tues. Wed. Thurs. Fri. Sat. Sun.

MOUNTING BRACKETS
NO STRUCTURAL DAMAGE, NO CRACKED OR BROKEN
WELDS, AND NO MISSING PARTS. ____ ____ ____ ____ ____ ____ ____
RAILS OR BOOM ARM
NO SIGNS OF STRUCTURAL DAMAGE;
NO MISSING OR LOOSE BOLTS. ____ ____ ____ ____ ____ ____ ____
TROLLEY OR CARRIER STOPS
CARRIER STOPS ARE PRESENT, ARE IN THE RIGHT PLACE, AND
DO NOT APPEAR TO HAVE ANY LOOSE OR MISSING BOLTS. ____ ____ ____ ____ ____ ____ ____
HOIST CABLE OR CHAIN
NO FRAYS, ARC STRIKES, KINKS, WELD SPLATTER;
NO OBVIOUS SIGNS OF STRETCHING ____ ____ ____ ____ ____ ____ ____
HOOK
NO SIDE TWIST, EXCESSIVE WEAR, OR STRUCTURAL
DEFORMITY; SAFETY LATCH WORKS PROPERLY ____ ____ ____ ____ ____ ____ ____

OPERATIONAL INSPECTION ITEMS

CONTROLS
EACH WORKS PROPERLY AND IS PROPERLY LABELED. ____ ____ ____ ____ ____ ____ ____
UPPER LIMIT SWITCH
THE SAFETY SWITCH PREVENTS THE BLOCK FROM TRAVELING
UP--THIS PROCEDURE IS FOR INSPECTION PURPOSES ONLY!!! ____ ____ ____ ____ ____ ____ ____
BRAKES
WORK EFFECTIVELY FOR TRAVEL IN ALL DIRECTIONS, BOTH
WITH AND WITHOUT A LOAD ON THE CRANE. ____ ____ ____ ____ ____ ____ ____

ADDITIONAL
COMMENTS:___________________________________________________

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INSPECTOR'S SIGNATURE_____________________________