116253 Learner Guide Operate a Truck Mounted Loader Crane

OPERATE A TRUCK MOUNTED LOADER CRANE: SAQA ID: 116253
Operate a truck mounted loader

crane: 116253
Credits:
Notional Hours:
Learner Guide
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February 2013 Version 1 ©Prodigy Business Services
PURPOSE OF THE UNIT STANDARD
The qualifying learner is capable of:
 Demonstrating an integrated practical and theoretical grounding in Crane Operations

according to safe handling and maintenance practices in compliance with crane
manufacturer's and legislated standards.
 The contribution to The National Skills Development Strategy is the key developmental
interface between learners and new competencies to be achieved.
 Learners who master the applied competence described in this unit standard will
contribute to the development of a professional community of Civil Engineering
Construction Crane Operators who are able to competently use science and technology
when applying operation techniques
 The contribution to socio-economic transformation is that learners will be able to
undergo RPL-assessment and thereby receive recognition for previous learning and
experience. This in turn will enhance the employability and career prospects of learners
employed in this sector.
LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING
The following knowledge, skills attitude and/or equivalent:
 NQF Level 1 Numeracy and NQF Level 1 Literacy

 The driver should be declared physically fit and have completed an eyesight test (such
as the Orthorator test, the Purdue University Test No. 3, etc.) and an industry recognised
depth perception and hand-eye co-ordination test.
It is assumed that people starting to learn towards this unit standard have already undergone
company induction, have an appropriate licence to operate in the work area, and are competent
in unit standards which address:
 Relevant Code of practice

 Occupational Health, Safety and General Housekeeping
 Mechanical Awareness and Plant Appreciation
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UNIT STANDARD RANGE
Limited to work carried out on a standard crane, or with standardised fittings
Major components include:
 Chassis
 Counter weight, hoist
 Hoist & slew systems
 Brakes & Transmission
Factors influencing safety and suitability of a crane:
 Proximity of other machines and workers, vehicles, equipment, ground condition,

underground services, overhead power lines, overhead service lines, trees, buildings,
structures, unauthorised people, stability, suitability, state of repair
Statutory requirements include but are not limited to:
 Relevant Code of practice

 Safety, Health & Environmental legislation
 Local Provincial authority requirements
Appropriate checklist is any one or a combination of the following:
 Manufacturer's checklist
 Pre-operational checklist
 Site-specific checklist
 Daily checklist
 Weekly checklist
 Site-specific checklist
Inspecting and recording the operational fitness of all components of the crane should cover:
 Structural Components
 Mechanical & Electrical Systems
 Cab, controls & levers
 Chassis
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 Worksite procedures include manufacturer's procedures, operators manuals and site

operational requirements, or similar procedures
 Corrective action includes inspections and/or reporting
 Controls include levers, switches forwards, reverse, left, right, gear selection, braking
 All implement and attachment movements
 Corrective action includes repairing and/or reporting
UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE
Truck Mounted Loader crane operating procedures and main functions of all major components
and systems
The maximum operating capacities of the designed working capabilities.
Statutory requirements including the Relevant Code of practice and Safety, Health &
Environmental legislation
Recognized hand signals (and other methods of communication) to direct the crane
movements.
Selection of crane against environmental restraints
Critical Cross-field Outcomes (CCFO)
UNIT STANDARD CCFO IDENTIFYING
Identify and solve problems
Evident in the following speicific outcome and assessment creteria:
Demonstrate knowledge of the functions of a truck mounted loader crane
Corrective actions are described or demonstrated in terms of neutralising warnings received.
UNIT STANDARD CCFO WORKING
Work effectively with others
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Apply the recognised methods for inspecting and recording the operational fitness of all
components of the crane
Checklist is completed according to worksite procedures and corrective action taken if required,
ensuring compliance with manufacturer's specifications.
UNIT STANDARD CCFO ORGANISING
Employ self management
components of the crane > Daily and weekly operator maintenance is performed according to
the appropriate post-operational checklist and record keeping using a logbook.
UNIT STANDARD CCFO COLLECTING
Manage information
Demonstrate knowledge of the functions of a truck mounted loader crane
Warnings from crane indicators and gauges are explained according to manufacturer's
specifications.
UNIT STANDARD CCFO COMMUNICATING
Communicate effectively
components of the crane > Appropriate measures used to rectify and/or prevent basic faults and
defects in the mechanical function of the crane are identified.
UNIT STANDARD CCFO SCIENCE
Demonstrate scientific and technological competence
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Identify the safety and suitability of the crane.
Demonstrate ability to assess operational capability of lifting equipment (e.g. Correct swl of
slings etc).
Demonstrate an understanding of what constitutes safety in the broader working environment,

and when operating a truck mounted loader crane in compliance with statutory regulations.
UNIT STANDARD CCFO DEMONSTRATING
Understand contextual world-systems
Identify the safety and suitability of the crane
Demonstrate an understanding of what constitutes safety in the broader working environment,

and when operating a truck mounted loader crane in compliance with statutory regulations.
Operate a truck mounted loader crane
Hazards specific to operating truck mounted loader crane's and ways to minimise these are
explained in terms of potential damage to machine and property, and injury to people.
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Contents
Topics Page Number
Functions of truck mounted cranes
Operation of truck mounted crane
Crane inspections and safety
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Module 1
Functions of truck mounted cranes
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A 'crane' is a type of machine, generally equipped with a hoist, wire ropes or chains, and
sheaves, that can be used both to lift and lower materials and to move them horizontally. It is
mainly used for lifting heavy things and transporting them to other places. It uses one or more
simple machines to create mechanical advantage and thus move loads beyond the normal
capability of a man. Cranes are commonly employed in the transport industry for the loading
and unloading of freight, in the construction industry for the movement of materials and in the
manufacturing industry for the assembling of heavy equipment.
Cranes exist in an enormous variety of forms – each tailored to a specific use. Sometimes sizes
range from the smallest jib cranes, used inside workshops, to the tallest tower cranes, used for
constructing high buildings. For a while, mini - cranes are also used for constructing high
buildings, in order to facilitate constructions by reaching tight spaces. Finally, we can find larger
floating cranes, generally used to build oil rigs and salvage sunken ships.
Truck mounted crane
A crane mounted on a truck carrier provides the mobility for this type of crane. This crane has
two parts: the carrier, often referred to as the Lower, and the lifting component which includes
the boom, referred to as the Upper. These are mated together through a turntable, allowing the
upper to swing from side to side. These modern hydraulic truck cranes are usually single-engine
machines, with the same engine powering the undercarriage and the crane. The upper is
usually powered via hydraulics run through the turntable from the pump mounted on the lower.
In older model designs of hydraulic truck cranes, there were two engines. One in the lower
pulled the crane down the road and ran a hydraulic pump for the outriggers and jacks. The one
in the upper ran the upper through a hydraulic pump of its own. Many older operators favor the
two-engine system due to leaking seals in the turntable of aging newer design cranes.
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Generally, these cranes are able to travel on highways, eliminating the need for special
equipment to transport the crane unless weight or other size constrictions are in place such as
local laws. If this is the case, most larger cranes are equipped with either special trailers to help
spread the load over more axles or are able to disassemble to meet requirements. An example
is counterweights. Often a crane will be followed by another truck hauling the counterweights
that are removed for travel. In addition some cranes are able to remove the entire upper.
However, this is usually only an issue in a large crane and mostly done with a conventional
crane.
When working on the job site, outriggers are extended horizontally from the chassis then
vertically to level and stabilize the crane while stationary and hoisting. Many truck cranes have
slow-travelling capability (a few km per hour) while suspending a load. Great care must be taken
not to swing the load sideways from the direction of travel, as most anti-tipping stability then lies
in the stiffness of the chassis suspension. Most cranes of this type also have moving
counterweights for stabilization beyond that provided by the outriggers.
Loads suspended directly aft are the most stable, since most of the weight of the crane acts as
a counterweight. Factory-calculated charts (or electronic safeguards) are used by crane
operators to determine the maximum safe loads for stationary (outriggered) work as well as (on-
rubber) loads and travelling speeds.
Truck cranes range in lifting capacity from about 14.5 short tons (12.9 long tons; 13.2 t) to about
1,300 short tons (1,161 long tons; 1,179 t).
A crane truck is much like a track crane without the tracks. A crane truck places the crane boom
onto a truck chassis with rubber tires. This allows the truck crane to operate on public streets
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and to be driven to a work site on its own without needing to be trailered. A crane truck has
outriggers which are deployed when working with the boom that keep the crane level and
stable. Without the outriggers, the crane would be limited on the amount of weight it could lift—it
would only be able to accommodate the amount of weight the tires could support without
blowing out.
The function of a crane on a work site is not easily replaceable. Lifting very heavy objects high
into the air and setting them into position can be difficult. The track crane can work well for this
purpose; however, it is very slow-moving and limited to its location since it cannot be driven on a
public road. The crane truck responds to these issues by placing the boom works onto a tire-
driven truck chassis. This allows the truck crane to be given a quick lift to a work site and then
driven to another site in a matter of minutes.
The hindrance in a truck crane is found in its lifting capacity. As with any rubber-tired vehicle,
the tire is the determining factor in the amount of weight the chassis can support. The truck
crane addresses this problem by mounting a hydraulic jack at each corner of the chassis. When
the jacks are deployed, the crane truck is actually lifted into the air, and the rubber tires do not
make contact with the ground. The crane now functions as a non-mobile crane and is capable of
lifting and supporting great amounts of weight.
Major components
Although everything on the truck begins and ends with the hydraulic system, there's more to a
hydraulic truck crane than the hydraulics. There are many components involved in lifting a load.
Here are the basic parts of every hydraulic truck crane:
 Boom
 Rotex gear
 Outriggers
 Counterweights
 Reinforced-steel cable
 Hook
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Operator’s cab
Cab attached to the chassis from which the operator manipulates the crane.
Elevating cylinder
Hydraulic device that consists of a telescopic arm for raising and lowering the boom.
Outrigger
Hydraulic truck cranes are used to lift heavy loads to tall heights, and it's important that the truck
be completely stable during the lifting operation. The tires don't offer the stability needed, so the
truck employs outriggers that act as balances to keep the crane from leaning too much to one
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side or the other. The outriggers use hydraulics to lift the entire truck, tires and all, off the
ground. The outriggers are comprised of the beam, which is the leg of the outrigger, and the
pad, which is the foot. Sometimes, "floats" are placed under the pad to dissipate the force of the
crane and the load over concrete or pavement. Floats are usually wood planks that are lined up
to create a base that is larger than the pad itself. The outriggers keep the crane balanced during
a lift. The outriggers are only one mechanism used to balance the crane during lifting
operations.
Telescopic boom
Boom whose parts slide one inside the other so that its height can be adjusted and it can be
stored compactly for transportation.
The Boom: The boom is the most recognizable part of the crane — the long, strong “arm” that
does the heavy lifting and makes challenging projects doable. Some cranes feature long fixed
booms, while others use telescopic booms that add a greater degree of operational flexibility to
the equipment.
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The Counterweights:
There are also detachable counterweights that can be placed on the back of the crane on the
underside of the cab. These counterweights prevent the crane from tipping forward during
operation. The amount of counterweight needed for a particular lift is determined by the weight
of the load, the radius of the boom and the boom's angle during operation. The 70-ton Link-Belt
truck crane has counterweights that come in 4,000-pound (1,814-kilogram) sections.
Counterweights are only used during lifts; they have to be removed before the truck can be
driven.
The Rotex Gear
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This set of equipment allows the crane to rotate its apparatus — a critical function that enables
the crane to move heavy objects to awkward or difficult-to-reach positions. Hook rollers can also
be used to achieve this rotational function.
Reinforced-steel cable lines run from a winch just behind the operator's cab, extending up and
over the boom and jib. Each line is capable of holding a certain amount load. The lines run up
the boom and jib and attach to a metal ball that keeps the lines pulled taut when no load is
attached to the hook.
A hook block is an assembly to which the hook of a hoist or crane is attached; it typically
consists of a steel enclosure housing a number of sheaves or pulleys that carry the ropes or
chains that facilitate the lifting of a load. Although this sounds unnecessarily complex, it would
be impossible for a crane or hoist to operate efficiently and safely if the crane hook was simply
attached directly to a rope and then raised or lowered by the cranes boom and winch system. A
hook block allows for a considerable amount of flexibility and safety in lifting operations as
opposed to a direct connection.
One of the most important functions of any hook block is facilitating of a free turning or rotating
hook arrangement. When loads are lifted, it is often necessary to turn the load to position it in a
new location or to avoid striking obstructions. A crane hook attached directly to the hoist ropes
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would cause the ropes to twist if the load was turned from its original orientation. This would
have a number of undesirable effects such as over-stressing the ropes and boom pulleys,
creating an unbalanced load, and causing the load to swing back in an uncontrolled fashion
when released. A hook block allows loads to be freely rotated without changing the orientation
of the hoist ropes.
A crane hook is a point of attachment on a crane designed to connect with chains and ropes
attached to loads like crates, construction beams, and machinery. Hooks come in a variety of
styles to meet various needs and like other parts of the crane, they are rated for loads of a
specific size and type. It is important to avoid using an underrated crane hook, as this could
result in damage to the crane or loss of the load.
Hooks are a preferred method of load connection, as they are easy to use and they can be
secured with locks if necessary. The crane hook can also interface with a wide variety of
connectors, allowing people to move different kinds of loads without changing the hook
attachment.
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There are several safety concerns with crane hooks. A lowering hook can pose a safety threat,
as crane hooks are large and can cause significant head injuries if someone is struck. It is
important to confirm that loads are securely mounted on the hook and that people are clear of a
load during raising and lowering. People must also be careful while securing loads to the crane
hook, as there is a risk of trapping fingers or limbs in the load's rigging.
In addition to being used for attaching loads, a crane hook can also serve as a point of
attachment for a crane fitting like a wrecking ball. A ball and crane fitting can be used to quickly
break down a structure as part of a demolition project. Crane manufacturers often produce an
array of accessories designed to work with their products, including hooks of different sizes and
various attachments.
Warning devices
Controls on vehicle-loading cranes must be of the constant pressure (deadman) type, and
permanently marked with clearly visible symbols.
The position and layout of controls on vehicle-loading cranes should be designed so that the
risk of the operator being crushed against the vehicle or controls by inadvertent operation of the
crane is eliminated.
An emergency stopping device should be provided at every control station on the vehicle-
loading crane. The emergency stopping device should:
 remove the energy supply to the crane, and bring the crane to a complete stop when
activated
 be readily visible and coloured red
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 be arranged for easy access, and located so that the operator will not be exposed to
other hazards when activating the device
 lock in the ‘stop’ position when activated and require manual reset.
Limiting and indicating devices
The purpose of limiting devices is to stop a specific crane motion before the crane moves out of
its load-radius limits into an unsafe situation. Indicating devices are used to visually or audibly
warn the crane operator that the crane may be approaching its set limits or an unsafe situation.
These devices may be used individually, or together, for specific crane motions.
Reliability of devices
Limiting and indicating devices are intended as an aid to crane operators. The devices should
not be relied upon to replace the use of the crane’s load chart and operating instructions under
any circumstances. Sole reliance on these devices, especially indicating devices, in place of
good operating practices may cause an accident.
Rated capacity limiters
When an overload is detected a rated capacity limiter prevents further overloading of the crane
by stopping all relevant crane functions that will increase the overload. Rated capacity means
the maximum load that may be attached and handled by the crane in its current configuration,
and may not include the weight of the hook block, falls of rope, slings and rigging hardware. The
load to be raised must include the weight of all lifting appliances that are not permanently
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attached to the crane. The crane’s load chart will provide guidance on any deductions that may
need to be made.
Motion limiting devices
Motion limiting devices are used to prevent physical damage to the crane or part of the crane
due to movement of the crane or part of the crane past its designed range of motion.
Motion limiter
Unless the geometry of the crane ensures that the boom system remains stable in all working
positions (e.g. booms approaching or passing the vertical), the crane shall be equipped with
motion limiters for that purpose.
This requirement does not apply to movements for coming in to or out of transport position.
Integrated Stability Control
Monitoring of the outrigger position in combination with the overload protection in maximum
version.
Stabilizer Leg
Stabilizer feet is designed to adjust to a ground unevenness.
Working radius indicator

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A radius indicator displays the radius of the suspended load generally measured from the centre
of the slew ring. A radius indicator should be fitted on all mobile cranes that were originally
designed with this feature. The indicator should be displayed in metres and be accurate to
+10% and -3% of the actual radius.
Load indicators
Load indicators should be fitted to all mobile cranes with a maximum rated capacity of more
than three tonnes. Load indicators measure and display the mass of the load being lifted. This
indicator assists the crane operator to stay within the load chart and safe working limit of the
crane. The load indicator should be capable of displaying the mass of the suspended load at all
times.
All vehicle-loading cranes manufactured after 2003 are fitted with a load indicator. The load
indicator must warn the crane operator when the load exceeds 90% of the rated capacity. The
load indicator must give a separate warning to the operator and persons in the vicinity of the
crane if the rated capacity is being exceeded.
The warning for approach to rated capacity must be clearly distinguishable from the warning for
exceeding the rated capacity by all persons while the crane is being operated. Both warnings
must be continuous.
Free fall lock-out
When a crane is fitted with a free fall facility, the free fall function is to be activated with a keyed
system that incorporated a non-adjustable timed reset function.
Securing for transport

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When the boom system of a vehicle mounted loader crane is to be parked on the load platform
or on top of the load during transport, an indicator (e.g. angle sensor) shall be provided.
A warning visible and audible from the transport driving position shall indicate when the crane
height exceeds a predetermined maximum.
The audible warning may be silenced by an acknowledgement button or by a signal that the
parking brake of the vehicle is engaged.
Cranes, with manually operated stabilizers extensions, shall have a warning visible and audible
from the transport driving position that indicates when the stabilizers are not locked in the
transport position.
Cranes, with hydraulically operated stabilizer extensions, shall have a warning visible and
audible from the transport driving position that indicates when the stabilizer extensions are not
in the transport position
Operational Warning
Cranes with a remote control system shall have a device to warn persons in the vicinity that the
crane is in operation.
The warning device shall be either acoustic or by flashing lights that are visible from all
directions. The warning shall be continuously given when the crane is in operation.
Control Stations
The control station for stabilizer extension deployment shall only operate movements in full view
of the operator.
These requirements also apply to stabilizer extensions that are remote controlled, in which case
a device shall be provided that detects that the operator can have a clear view of a stabilizer
extension before it may start to extend.
Crane Safety Systems
Due to the height of cranes and the size of the loads that they carry, mistakes can be potentially
deadly. As a result all operators must be trained and certified to reduce the risk of injury on
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construction sites. Additionally, there are safety systems that can be installed to ensure that the
crane operates as it should and that the operator is given warning if there are any faults.
Examples of crane safety systems are load monitors, load moment indicators, wind speed
indicators, overhead voltage indicators, boom angle indicator systems, and anti-2-block
systems. Other instruments that could be used include tension load cells, load measuring
shackles, handheld indicators, linear displacement transducers, pressure transmitters and load
measuring pins.
Crane markings
Each lifting equipment and its component parts should be identified with a visible marking
including the safe working load (SWL). The markings serve the following purposes.
• Communicate clearly the maximum SWL of the equipment.

• Communicate clearly the maximum number of persons it can carry if it is used for lifting
people.
• Facilitate the identification of the equipment and its component including whether it is
genuine and compatible with the equipment.
If practicable, the SWL should be marked on the equipment prominently. However where this is
not possible (i.e., a small lifting gear), a coding system can be used to provide the user with the
required information. Examples of such systems include colour coding or attaching some form
of label.
If a number of lifting accessories are assembled to form a single lifting equipment which is not
dismantled after use, the assembly should be marked to indicate its safety characteristics to
users.
If there are other characteristics which may cause a lifting accessory to become unsuitable for
use in a particular application, this information should be marked or otherwise made available to
the user.
Lifting equipment with variable Safe Working Load
Some lifting equipment is designed to operate with variable SWL. Examples of such lifting
equipment include mobile crane equipped with a telescopic jib that can be raised or lowered.
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Tower cranes are also designed to have variable SWL. In principle, the closer the load is to the
body of the crane, the higher will be the SWL of the equipment.
For such lifting equipment, besides the mandatory load capacity chart, they must be equipped
with a load radius indicator to indicate to the operator the SWL of the crane at that configuration
(load radius). It should also provide a visual and audible warning to the operator if the load lifted
is close to the SWL.
Consequently, due to the variable SWL, the crane operator must exercise extreme care
whenever he lowers the jib or telescope the boom outwards with a load. This will lead to a
reduction of the SWL and will result in crane overloading.
For lorry cranes, if the load radius indicator is not feasible, it must be equipped with fully
hydraulic protection valves and pressure relief system to prevent crane overloading.
Some modern cranes are designed such that a different load capacity chart will apply
depending on whether the outriggers are fully or partially extended. Under such circumstances,
the operator must be fully aware of the configurations and make the necessary adjustment to
the parameter settings of the indicator. Information on how changes to the configuration can
affect the SWL must be provided in the operator’s cabin. The information should be placed in
the operator's cabin and not in the office as it needs to be easily retrieved by the operator while
carrying out a lifting operation.
Answer the following questions
1. List the main functions of Truck Mounted Loader Cranes.
2. List the major components of Truck Mounted Loader cranes and explain their functions.
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3. List the safety features and warning devices on the crane. What are the functions of
these devices?
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4. What do we mean by ‘the maximum operating capacity’ of a crane?
5. What are the dangers of exceeding the operating capacity of a crane?
6. What warnings can we get from crane indicators and gauges?
7. How should you respond to these warnings?
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Module 2
Operation of truck mounted crane
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Cranes are built for safe and economical operation, but are only as safe as the operator. While
the crane operator is primarily responsible for crane stability to ensure a crane will not overturn,
other persons who are also responsible for the stability of a crane include:
 the crane manufacturer and supplier

 the principal contractor or relevant person
 the crane owner, and
 doggers.
The crane operator
Crane operators must have a comprehensive knowledge of the operating capabilities of the
crane and be competent to carry out the lifting operation to ensure the crane does not overturn.
Pre-operational inspections are the responsibility of the operator and are required to be
performed at the commencement of each shift or at the first use of the crane or mobile crane in
the shift. Information is to be recorded in the equipment daily pre-start check sheet.
All faults that may affect the safe operation of the equipment must be reported immediately to
supervision, and the equipment removed from service until the risk has been assessed by a
competent person and rectified as appropriate.
The operator should have the final say about whether a lift should proceed and must be
satisfied that:
 the crane is adequately supported on the ground and the crane is level to within the
tolerance specified by the crane manufacturer
 materials placed under the outriggers or crawler tracks, to help ensure the crane does
not overturn, are set up to comply with the crane manufacturer’s specifications, or the
crane owner’s specifications if the former do not exist the suspended load will remain
within the rated capacity of the load chart
 the functions of the crane are operating properly, including all crane motions, brakes,
load moment systems and indicators
 the wind is not excessive for the load being lifted, particularly for loads with a large
surface area, and when the load is high above the ground.
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Crane operators and doggers should also regularly inspect the ground to ensure that continuous
operation of the crane has not compressed the ground to the extent that further operation of the
crane will be unsafe.
An operator should not operate a pick-and-carry crane on gradients exceeding those specified
by the manufacturer. Operators should not be expected to calculate how much to de-rate the
capacity of the crane where the crane manufacturer does not provide written guidance on this
issue.
Each crane operator should be held directly responsible for the safe operation of the crane or
hoist. Whenever there is any doubt as to safety, the operator should stop the crane and refuse
to handle loads until safe conditions have been restored. Persons must also have good hearing
and peripheral vision. These attributes are necessary for safe operation of the crane. All crane
operators must have received training including: written materials; hands on experience; and
testing of knowledge, both written and practical. Persons must also have had some training in
the important fundamentals of rigging loads. Crane operators using a new lifting device must be
familiar with the manufacturer's directions, noting any special instructions.
The crane manufacturer and supplier
The crane manufacturer must ensure that the crane complies with the strength and stability
requirements of the design standard to which the crane has been manufactured. The crane
manufacturer should be able to demonstrate that the stability of the crane with the stability factor
marked on the load chart.
The crane supplier must ensure that the information about the crane’s stability factor is provided
to the crane user.
A principal contractor or relevant person
A principal contractor or relevant person should supply the crane crew with all relevant
information on the location of trenches, underground pipes, backfilled excavations and covered
penetrations at a construction workplace. In some situations, it will not be obvious that the
ground will support the crane by simply looking at the ground surface. Where documentation is
available to the principal contractor or the relevant person on ground bearing capacity, this
information must be made available to the crane operator.
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The principal contractor or relevant person should obtain documented information about the
ground bearing pressure from a geo-technical engineer when a mobile crane is required to
perform heavy lifts including bridge beams and tilt-up or precast concrete elements.
A principal contractor or relevant person must provide this information to the crane owner to
ensure the crane owner can verify that the mobile crane will have adequate support to carry out
the heavy lift.
A principal contractor or relevant person must not attempt to unduly influence a crane crew to
perform a lift that the crane operator considers to be unsafe.
The crane owner
Information on the loads imposed by each of the outriggers should be available from the
manufacturer. The crane owner should ensure that the timbers or pads supplied with the crane
will adequately support the crane. The crane owner may need to seek the advice of a
competent person when selecting appropriate materials to support the outriggers.
Where the timbers or pads supplied by the crane owner will not ensure adequate crane support
on soft ground with a bearing capacity of less than 10 tonnes per m2 the crane owner should
clearly state the minimum ground bearing capacity. This information should be placed in the
operator’s cabin.
The crane owner must be given information about the ground bearing capacity from the
principal contractor or relevant person before a mobile crane can be supplied to heavy lifts
including bridge beams and tilt-up or precast concrete elements.
Once this information is obtained, the crane owner can ensure that adequate control measures
are available to ensure the crane has adequate support to carry out the heavy lift.
The dogger
The dogger is responsible for the safe slinging and movement of the load and providing
accurate directions to the crane operator on load movement to ensure crane stability. This
includes:
 communicating the weight of the load to the crane operator, where this is known, to help
ensure the rated capacity of the crane and lifting attachments is not exceeded
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 calculating the safe working load of the ropes, slings, chains and other lifting accessories
to be used in the lift
 providing the crane operator with clear and accurate directions
 communicating with other persons in the crane working area
 taking adequate precautions when directing a pick-and-carry crane across rough
surfaces and checking the area for other hazards.
Operational issues
The vehicle-loading crane must be operated in accordance with the operator’s instruction
manual provided by the crane manufacturer and:
 operators must be trained in the operation of the particular vehicle-loading crane

 if the load is out of the operator’s view at any stage during the lifting process, the
movement of the load must be directed by a licensed dogger or rigger
 the vehicle-loading crane may only be used with all stabilisers extended in accordance
with the crane manufacturer’s instructions - where multiple positions can be used on
stabiliser legs, the legs must be set up in compliance with the manufacturer’s load chart
 timbers or other pads specified by the crane manufacturer are to be provided under the
stabiliser feet
 crane hooks must be provided with spring-loaded safety latches and must be adequately
maintained
 vehicle-loading cranes are not to be used for lifting persons where provided, spring lock-
outs on the vehicle are to be activated during crane operation
 the vehicle-loading crane must only be used with a load suspended vertically from the
hook - the crane is not to be used to drag a load across a supporting surface.
Selecting a crane
It is important to select the type and number of cranes to suit the particular needs of a
workplace and the work to be undertaken. Hazards can be experienced if crane characteristics
do not match the work requirements and work environment.
When selecting a crane, the size and characteristics of the crane should be assessed including:
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 the workplace conditions, including the ground on which the crane is to be set up, wind
conditions, access roads and ramps it must travel on, space for erection, and any
obstacles that may impede access or operation
 the weights and dimensions of loads to be lifted and the locations of the loads relative to
the crane
 the range of lift heights and radii from the crane and the weight of the loads to be
handled at these points
 the number and frequency of lifts to be made
 the length of time that the crane will be required at the workplace
 the type of lifting to be done (for example, precise placement of loads)
 the type of carrier required—this depends on ground conditions and machine capacity in
its various operating quadrants
 whether loads are to be walked or carried
 whether loads may need to be suspended for lengthy periods of time.
Using cranes in the workplace
Crane documentation and markings
Load charts
Each crane has a specific load chart that sets out how its lift capacity varies when considering
how the crane is set up, the weight of the load, boom extension and boom angle. Using the load
chart correctly is critical to ensure safe crane operation.
Where the crane has one main load chart, this should be fixed in the operator’s cabin in a
clearly visible location. Where the crane has numerous load charts (for example, for different
boom and fly jib configurations) the charts must be easily accessible for the operator to verify
that the crane is not overloaded and may be kept electronically or in hard copy.
The lifting capacity of a crane is limited by:
 structural strength when the working radius is small

 stability when the working radius is greater.
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If a crane is overloaded in the structural area of the load chart a structural or mechanical
component of the crane may fail. However, if the crane is overloaded in the stability area of the
load chart the crane may overturn.
The lifting capacities specified on a load chart must never be exceeded except during testing of
the crane by a competent person under controlled conditions.
On some mobile cranes there may be numerous load charts for differing boom and
counterweight configurations. The load charts may be complex and include numerous
conditions that must be complied with to ensure the crane can safely lift a load. Two important
factors that are often overlooked when reading load charts are:
 The need to subtract the mass of the hook block and lifting slings from the capacity of
the crane at the particular radius, unless otherwise noted on the load chart. For example,
if the load chart states that the crane can lift 20 tonnes at a given radius but the hook
and lifting gear have a combined mass of one tonne the load to be lifted cannot be
greater than 19 tonnes. This issue becomes critical for heavier hook blocks and lifting
gear (for example, spreader beams).
 The need to subtract the mass of the fly jib from the capacity of the main hook when
lifting from the main hook on the main boom with a fly jib attached to the boom head
(unless this is allowed for and noted on the load chart). Capacities of the main boom are
generally based on the fly jib being removed. If this issue is ignored, the likelihood of the
crane overturning can be very high.
A mobile crane and its lifting components should be marked permanently and legibly. All
operator controls must be suitably marked to indicate their function and operation. The crane’s
computer should be compatible with these requirements and indicate the control function,
options and settings.
Siting the crane
The siting of cranes should be considered in the planning phase and occur after careful
consideration of the relevant factors, including:
 the crane overturning or collapsing due to:

the failure of the foundations or structure (crane standing) supporting the crane
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failure of the crane to withstand the forces likely to be imposed on it

 collision between the crane with other plant and structures at the workplace.
A crane can be set up in a range of locations and environmental conditions. Some cranes (pick
and carry) can also carry a load while moving (mobiling). Crane design, ground conditions and
loads need to be considered when siting and setting up a mobile crane
The siting of a crane should consider hazards such as:
 overhead electric lines and other services

 nearby structures
 other cranes or high obstructions, including those on adjacent workplaces (for example,
concrete placement booms)
 other mobile equipment moving within the crane working area
 the vicinity of airports and aircraft flight paths for ‘high’ cranes.
Cranes should be positioned to maintain sufficient clearance between the crane and its load and
other plan, structures and workers. A collision between the crane or its load and other plant or
structures may:
 damage crane components, such as the boom, may seriously weaken the component
leading to structural collapse of the crane and/or loss of load
 result in overturning cranes or other plant
 result in dropped loads
 damage the structure or other plant making it unsafe
 result in injury to persons in the vicinity of the crane, including workers and members of
the public.
A risk of injury from collision may exist for example where:
 a concrete placement boom is working within the crane’s operating radius, or

 cranes located on adjacent sites are operating in the same air space.
When cranes operate in adjacent areas, they may share the same airspace. The persons in
control of each work area should consult and develop safe systems of work to ensure sufficient
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clearances are maintained between the cranes. Each work area should nominate a person who
has a responsibility to implement the safe system of work to minimise the risk of collision.
This issue is particularly important where mobile cranes are set up on public roads. In this
situation, the traffic control procedures of the road controlling authority must be complied with.
Overhead electric lines
Siting of the crane must prevent contact with overhead electric lines. Contact with electric lines
while operating a crane can pose a risk of electrocution and crane failure. It can be extremely
difficult for crane operators to see electric lines and to judge distances from them.
Careful planning and preparation is essential to ensure that work is done safely when operating
a crane in the vicinity of overhead electric lines. Consideration should be given to:
 identifying the nature of the work, the height and voltage of electric lines and the
proximity of the crane to overhead electric lines
 consulting the electricity supply authority about the work and complying with any
conditions imposed by them
 eliminating the risk by arranging for the electricity supply authority to isolate the
electricity supply for the duration of the work
 establishing and implementing approach distances to energised electrical conductors
and no-go zones in the work area
 providing an effective communication system between workers at the site
 ensuring a safety observer is used whenever mobile plant is in motion and is likely to
come closer than the approach distances
 ensuring the operator has the appropriate training and competency to undertake the
work
 emergency rescue procedures.
Crane stability
Failure to maintain stability is one of the key factors associated with serious crane incidents.
Things to consider are:
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 crane operation parameters that result in an overturning moment greater than the
stabilising moment of the crane - the crane counterweight generally provides the primary
stabilising moment
 the ground conditions and means of supporting the outrigger pads or the crane tyres
 the slope of the ground - both side slope and slope in direction of crane travel
 wind conditions - this will vary depending on the size and shape of the suspended load
and crane boom
 the manner in which loads are to be lifted or moved (for example, when mobiling a load
a sudden stop may cause the load to swing, destabilising the crane).
Minimising risk when lifting loads
Lifting loads may present a risk to the health and safety of persons in the vicinity of a crane due
to:
 damaged or inadequate lifting gear

 unexpected crane movement while mobiling and/or or slewing
 crane overload or instability, and
 poorly secured and dropped loads (falling objects).
Limiting and indicating devices
Limiting devices prevent a specific crane motion before the crane moves out of its limits into an
unsafe situation.
Indicating devices rely on a person’s intervention. Indicating devices visually or audibly warn
the crane operator that the crane may be approaching its set limits or an unsafe situation.
These devices may be used individually, or together, for specific crane motions and are
intended as an aid to crane operators. The devices should not be relied upon to replace the use
of the crane’s load chart and operating instructions under any circumstances. Sole reliance on
these devices in place of good operating practices may cause an accident.
There are a number of devices that can be used including rated capacity limiters.
Lifting gear
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Lifting gear should be checked before and after use, as well as being regularly inspected for
suitability of ongoing use. Checks should include that:
 the lifting gear is tagged and all relevant information listed

 lifting hooks are provided with operable safety latches
 shackles used as terminal fittings are prevented from unscrewing (for example, mousing
or similar)
 lifting eyes and inserts are compatible
 lifting slings are not damaged (for example, excessive wear, damaged strands, cracks,
deformation or severe corrosion)
 the sling is appropriate for loads being lifted, including adequate capacity and protection
from sharp edges.
All lifting gear, including slings, hooks and material boxes, should be periodically inspected for
damage and wear by a competent person and inspection records kept. The period between
inspections will depend on the severity of use, but should generally not exceed 12 months. The
period between inspections of synthetic slings and fibre rope slings should not exceed 3
months.
Where synthetic slings are used, protective sleeves and corner pieces should be used for all
loads. Although the edges of the load may not appear to be sharp, the sling may become
damaged when it is placed under tension.
All lifting gear should be tagged to identify the date of the lifting gear’s last inspection.
Documented maintenance records for the lifting gear should be available at the workplace.
Unexpected crane movement
Unexpected crane movement while mobiling and/or slewing can cause the load to swing
unexpectedly. Cranes should only be sited and operated on stable surfaces, with adequate
bearing pressure and without significant holes or indentations that may cause unexpected
movement of the crane and the load due to instability.
Crane overload
Before starting to hoist a load, the crane operator or dogger should make sure that the hoist
rope hangs vertically over the load. Care should be taken to ensure that swinging of the load is
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avoided when the lift is taken. The crane operator should always have the load under control
when lowering loads, or when the load is suspended.
Except in an emergency, the crane operator should not leave the crane cabin or controls while a
load is suspended from the crane.
Falling objects
Where possible, handling loads over public access areas, such as footpaths, roads, highways,
railways, waterways and buildings, should be avoided. If lifting over these areas cannot be
avoided, appropriate control measures (for example, exclusion zones or suitably designed
gantries) must be in place to control the risk of being hit by falling objects during the lifting
operation.
Exclusion zones
Exclusion zones should be established around cranes and adjoining areas to prevent persons
from entering the area and being injured by falling materials. The size of the exclusion zone
should be based on a written risk assessment.
Where the exclusion zone requires closure of a public footpath or roadway, approval must be
obtained from the relevant authority, and persons should be safely directed to an alternative
footpath. Lane closures and other operations that require the erection of barricades and signs
should comply with the requirements of the local road traffic authority, local government
authorities and any relevant building or local acts.
Lifting materials
Crane-lifted loads should be slung and secured so that the load (or any part of it) cannot fall.
Loads must not be lifted over a person unless the crane is equipped with secondary back-up
systems that prevent the load from falling if the primary lifting device fails. Loads must be
controlled during while being lifted/suspended by, for example, using tag lines or similar control
devices.
Material boxes
 The tare mass and safe working load should be clearly marked on all material boxes.
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 Material boxes should be appropriate for the material being lifted and be engineer-
designed and certified.
 Four chains (one in each corner) should be attached to material boxes during lifting.
 Specifically designed material boxes should be used to lift smaller components. Boxes
should have enclosed sides or robust mesh, with openings less than the minimum size
of materials being lifted.
 Material boxes should be inspected and maintained and inspection records kept.
 Loads within material boxes should be secured against movement.
 Materials should not be stacked higher than the side of the material box unless they are
adequately secured, but at no time should the material box become top heavy.
General lifting
 Formwork frames should be either tied together or lifting slings should be wrapped
around the load.
 Loads of joists or bearers should be strapped together before lifting.
 Timber sheeting should be strapped together and lifted in a flat position.
 Sheets of plasterboard may be lifted in a specifically designed material box. If a material
box is not used, then the lifting system should:
be certified by an engineer
specify the minimum and maximum number of sheets
specify the number and locations of lifting slings
specify the capacity of lifting slings.
 Tag lines should be used as required to control loads.
 All loads should be supported where possible with dunnage, with the load uniformly
distributed over the supporting surface.
 Basket hitches should not be used wherever persons may be located near a lifted load,
unless the sling is positively restrained from sliding along the load.
Communication
A reliable method of signalling between the crane operator and dogger (or rigger) is essential for
safe crane operation. Failure to implement a reliable method of communication may lead to
unsafe crane operations and contribute to injury to persons from:
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 dropped loads
 collision with other plant and structures.
Only one dogger should give visual and audible signals at any time. When more than one
dogger is involved in a lift, each dogger should understand when responsibility for their part of
the lifting operation should be handed over to another dogger.
An effective means of communication is particularly important where:
 the crane operator cannot see the load

 the crane operator cannot see the load’s landing area
 the crane operator cannot see the path of travel of the load or the crane
 the crane operator is not in a position to make an accurate judgement of distance, and
 it is possible for the crane to come into contact with overhead electric lines.
Persons using radio equipment should be familiar with the manufacturer’s operating
instructions. A dedicated radio frequency should be selected for the duration of the crane
operations to prevent interference with other radio equipment being used in the vicinity of the
crane. Work should stop immediately if there is a loss of radio communication.
The safe use of radio communication usually involves:
 the crane operator and dogger performing an operating safety check to ensure the
radios are operational, dry, performing satisfactorily and a fully charged battery and
spare are available
 ensuring operators are familiar with the specific procedures for using radio
communication for that workplace
 adopting a constant talk method between radio users so that all involved persons are
aware of the progress of the lifting operations at all times
 ensuring the crane operator takes radio instructions from one person only, unless
special circumstances exist that require specific arrangements to be in place for the use
of more than two radios.
Where radio communication cannot be used, other forms of communication, such as hand
signals and bell, buzzer and whistle signals should be used. Mobile phones should not be used
for directing mobile crane operations.
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Operator position
Protective devices
Suitable operator protective devices must be provided for powered mobile plant, including
cranes. Typically these could include falling object protective structures (FOPS) and operator
restraints. For example, if a person travels in a mobile crane operator’s cabin while the crane is
driven by another person, a seat belt is required.
Safe means of access
Cranes should be fitted with safe means of access that allow the crane operator to safely
access the crane cabin and other frequently accessed areas of the crane. Safe access includes
the provision of ladders, footholds, steps and grabs rails.
Access provisions provided by the crane manufacturer should not be removed or modified
unless a competent person specifies otherwise.
Seating
The design of crane seating should take account of the extensive periods of time the crane
operator may spend in the seat. The seating should be comfortable, have adequate back
support and be adjustable so that the crane controls can be easily accessed by the operator.
Windows and windscreens
Clear vision must be provided in the operator's cabin at all times. Windows and windscreens
need to be easily accessible for regular cleaning.
Working in heat
Heat stress may occur in hot work environments when heat is absorbed faster than the body
can release it. One way to reduce heat stress on crane operators is to minimise the heat in the
crane cabin. Temperature control units supplied with the crane should be maintained and kept
in a serviceable condition according to the crane manufacturer’s instructions.
Noise
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Activities, such as the erection or dismantling of cranes, and in particular, the use of an impact
wrench, create noise which can damage hearing immediately. This type of noise is particularly
damaging to hearing because of its high impulsive noise levels. Other loud noise, for example
that is created by the operation of a crane’s diesel engine without sound proofing, will gradually
damage a person’s hearing after repeated exposures.
Engineering controls, such as enclosing the engine in a sound proof cabinet, should be applied
to manage exposure to the noise created by the operation of a tower crane’s diesel engine.
Routine inspection and maintenance
Routine inspection and maintenance should be carried out in accordance with the crane
manufacturer’s instructions. These inspections may include a program of weekly, monthly and
quarterly inspections, and should include:
 all functions and their controls for speed, smoothness of operation and limits of motion
 all emergency and safety switches and interlocks, including limiting and indicating
devices
 lubrication of all moving parts
 inspection of filter elements and fluid levels
 visual inspection and measurements as necessary of structural members and other
critical components such as brakes, gears, fasteners, pins, shafts, wire ropes, sheaves,
locking devices and electrical contactors
 signage, including warning signs and control markings
 wear on wheels
 additional items nominated in the crane manufacturer’s instructions.
All replacement parts should be identical or equivalent to the original parts or components. A
written report should be prepared on completion of the inspection.
Pre-operational inspection
The crane operator should carry out a visual inspection and functional tests before the
commencement of each work shift, including inspecting and testing the following:
 all relevant items indicated in the operations manual

 operating and emergency controls
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 brakes
 safety switches and interlocks, including limiting and indicating devices
 visual inspection of the structure
 wire ropes to ensure they are on the drum and correctly reeved on the sheave.
The results of the inspection should be entered into a logbook and kept with the crane.
All personal protective equipment should also be inspected to ensure it is functioning correctly.
Where issues are identified these should be recorded, reported and rectified before the crane is
used.
Maintenance, repair and cleaning of plant
Cranes should be maintained, serviced and cleaned according to the manufacturer’s

instructions, competent person specifications or, in the absence of such specifications, in
accordance with relevant technical standards and engineering principles
All worn or damaged parts of a crane that constitute a hazard or impair the operation of the
crane should be repaired or replaced. In particular:
 repairs are carried out in accordance with manufacturer’s or a competent persons

instructions so as to retain the crane within its original design limits
 replacement parts and components should be identical or equivalent to the original
equipment parts and components
When a crane has been damaged to the extent that its function or condition is impaired,
resulting in increased risk to health or safety, it should be immediately taken out of service. A
competent person should assess:
 the nature of the damage

 whether the crane is able to be repaired, and if so, what repairs must be carried out.
The regulations require that the operator controls either prevent the person undertaking
maintenance or cleaning to operate the plant or if the plant must be operated during
maintenance or cleaning that there are appropriate risk controls in place to enable this to occur
without risk to health and safety.
Unattended cranes, parking and storage

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Leaving a crane parked and unattended may encourage unauthorised use of the crane by
person who are not competent crane operators. Cranes may also present a risk to health and
safety if measures are not taken to prevent them moving of their own accord (for example,
rolling down a sloping surface).
A crane should not be left unattended unless:
 all loads are removed from the hook or lifting device

 the hook has been secured or raised to a position where is clear of other operations
 all powered motions have been disabled
 the keys removed or the starting device locked out.
When leaving a mobile crane unattended for a longer period of time, ensure the crane’s boom is
folded up and retracted as far as possible.
If a crane is to be stored it should be prepared as above and:
 the manufacturer storage instructions followed

 any remote control equipment isolated
 the power supply and controls isolated and locked off
 storm anchors applied (if fitted)
 doors and windows locked to prevent unauthorised access.
Road travel
Failure to follow proper precautions before and during road travel may increase the risk of injury
to the crane operator and other persons, such as pedestrians and other drivers. The crane
manufacturer’s instructions must be followed when preparing a mobile crane for road travel.
Precautions for road travel include:
 securing outriggers (both hydraulic and manual) with a locking device specified by the
crane manufacturer, and stowing them in a travelling position to ensure that there is no
lateral movement
 storing loose components in appropriate storage areas in accordance with the crane
manufacturer’s instructions or any other relevant published guidelines for the safe
carriage of loads on road vehicles.
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 disengaging all drives to hydraulic pumps, booms and outriggers, and putting the
controls in the OFF position
 restraining the boom in accordance with the crane manufacturer’s instructions to ensure
there is no unintended movement of the boom.
Ground conditions and crane support
Ground conditions can vary dramatically from one workplace to another, and even within the
one workplace. Failure to address poor ground conditions to ensure crane stability may cause
the crane to overturn resulting in serious injury to the crane operator and other persons in the
vicinity of the crane.
Ground factors
Factors that will affect the ability of the ground to provide adequate support include the
following:
 the presence of water, including when it is mixed with the soil as mud, and where it is
present under the surface (for example, underground springs or streams)
 the type of ground (for example, clay, sand, rock or a mixture of these)
 backfilled ground that was previously an excavation or trench
 cavities or penetrations in the ground that have been covered but still exist
 continued operation of the crane in one location.
Generally, rock provides the most stable supporting surface for a crane. However, although rock
may be present on the surface, it may not extend far below the surface. One way to establish
how far rock may extend below the surface is to examine nearby excavations or trenches at the
workplace if any. Rock that extends far below the surface provides a good indication of the
ground’s integrity. However, this will only provide a reasonable indication of the ground’s
strength when the excavation is not too far from the crane. Additional risks must be managed
when outriggers are positioned close to an excavation.
Care must also be taken with ground that has a ‘crust’ on its surface. The surface of this type of
ground is usually firmer than the ground underneath. The firm surface may give the perception
that the ground is more stable than it actually is. If the ground is punctured by an outrigger, or
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the end of a crawler track, the softer ground will be exposed, which may cause the crane to
overturn.
Where a mobile crane is continuously operated in one location, the ground underneath the
outriggers will compact. Additional care must be taken to ensure that the crane has not
compacted the ground to the extent that the minimum overturning moment of the crane is
reduced (that is, the crane is more likely to overturn).
Performing heavy lifts
The likelihood of a crane overturning is greater when the crane is operated near its maximum
rated capacity or with loads at long radius and maximum load chart capacity.
The crane owner should compare the ground bearing capacity with the maximum pressure the
crane will apply to the ground for the lift. The maximum pressure applied by a crane is a function
of the crane mass, crane configuration (that is, boom length and centre of gravity) and the mass
of load on the hook. The ground bearing capacity must be greater than the maximum pressure
applied by the crane to the ground to ensure adequate crane support. If not, then appropriate
control measures, such as the use of appropriate outrigger pads, must be in place to increase
the ground bearing capacity before the lift is performed.
Cranes on outriggers (or stabilisers)
The use of outriggers helps to provide greater stability to the crane when lifting loads.
Irrespective of the ground conditions, timbers or other means of distributing the load should
always be placed under the outriggers.
Outriggers should be set according to the manufacturer’s operating instructions for the specific
type of cranes. The outriggers are also used to level the crane.
Safe crane operation
All these built-in protections are just the start of crane safety. A skilled, safety-conscious
operator has to be able to lift and handle loads without creating a risk to the materials or the
safety of other workers. Without covering every detail, let's look at this job. You'll see why we
can't let just anyone operate a crane.
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To prevent overload, the operator has to check equipment load capacity and the weight and
shape of the load. Even this isn't simple, as limits on some cranes are affected by boom length
and radius.
The actual operations require a lot of precision. Before lifting, the operator brings the hook over
the load, making sure that it's not swinging. Slings or other approved devices attach the load to
the load-block hook. Then, the operator checks that the hoist chain or rope has no kinks or
twists and isn't wrapped around the load. If the load has sharp edges, it has to be padded to
prevent cutting the slings.
If the load is close to the rated capacity, the operator has to test the brakes by raising the load a
few inches and then braking. Even organizing the inside of the cab takes thought. To give the
operator as much working space as possible and protect those below, OHSA requires operators
to store clothing and other belongings out of the way. Tools, oil cans, waste, etc., must be kept
in the tool box. Once all the checks are complete and there's no one on the load or hook, the
operator's skills get a real workout. OHSA specifically requires operators to stay at the controls
while the load is suspended and to "avoid carrying loads over people." The operation must be
very smooth and careful, avoiding sudden starts and stops as well as any contact with other
equipment, materials or people.
Safety Instructions
 Do not lift people and never ride the hoisting load.

 Do not lift load over people. No one shall be under the hoisting load.
 Make sure the sling is well balanced. Avoid tip loading, and loading on hook latch.
 Never lift the load over the rated capacity.
 Do not operate with kinked, twisted or damaged chain.
 Avoid side pull or end pull, and quick reversal operations.
 Never leave the suspended load unattended.
 Make sure you take up slack slowly.
A crane is a vertical lifting device. It should never be used to drag or pull a load. Always position
the crane directly perpendicular to the load to be lifted. Non-vertical lifts can damage both the
crane and the rigging materials and may result in improper wrapping around the drum. If the
drum wraps are not seated in the proper position, immediately cease crane operation and
inform facility maintenance.
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An operator who leaves a load suspended and unattended is subject to disciplinary action,
which may include revocation of his or her license to operate the crane.
Checking limit switch
 Move crane to open area.

 No load should be on hoist lines.
 Slowly run (#2 position) block up to 3’ from limit switch and stop.
 Continue to raise hook slowly (#1 position).
 If limit switch does not operate at point where it should, do not use crane.
The first procedure in any crane lift is to assess the valid performance of the limit switches of the
crane. To accomplish this task, run the length of the crane rope to the lower limit. Once the
lower limit switch has been tested, raise the crane hook to the upper limit switch, all the while
making sure the rope wraps correctly. There should be no cross wrapping or ill sitting of the
rope on the grooves of the drum. Ensure the top limit switch stops before hitting the drum. As
you approach the top limit switch slow the crane from the fastest position to the slowest position
to prevent hitting the upper limit. If either limit fails the crane should be locked out.
Safety procedures
OHSA divides inspection requirements for cranes in regular use into two categories: frequent
(daily to monthly) and periodic (one to 12 months). You might have to step up inspections for
equipment that's near the end of its useful life. You must inspect cranes for any defects that
might be a safety hazard. Here are OHSA's time frames and some things to look for:
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Daily: operating mechanism maladjustments; deterioration of air or hydraulic line, tank, etc.;
deformed or cracked hooks; worn, twisted, or stretched hoist chain.
Monthly: rope condition; deformed or cracked hooks and hoist chains. These inspections must
be certified, dated and signed.
Frequently: excessive component wear on functional operating mechanisms; rope reeving.
Periodically: deformed, cracked or corroded members; loose bolts or rivets; cracked or worn
sheaves or drums; worn, cracked or distorted pins, gears, and other parts; excessive brake
system wear; indicator inaccuracies; power plant performance; chain drive sprocket wear and
chain stretch; pitted or deteriorated electrical apparatus.
There are similar inspection requirements for cranes not in regular use. In addition, new or
altered cranes must be tested before use, and ongoing maintenance must follow the
manufacturer's recommendations. Crane repair or maintenance has to be performed in a
location out of harm's way. Before starting, you turn it off, lock the main or emergency switch
open, and put up warning or "out of order" signs. You can't always fix crane parts. OHSA says
to discard crane hooks that show defects; defective load attachment chains and rope slings;
cracked, broken, bent or excessively worn critical parts.
You also cannot use a rope if damage could reduce its strength and cause a safety hazard. Be
alert for these danger signs: wire wear or corrosion that reduces its diameter; broken or worn
outside wires; broken or corroded end connections or wires; severe kinking, crushing, cutting or
unstranding.
Summary
Below is a summary of the guidelines or safety measures you need to follow;
 Bystanders should be 3m or more away from the load at all times.

 Outriggers must be deployed at all times during crane operation (also, all personnel
should be clear of the outrigger before it is deployed to avoid a serious crushing injury).
 Never ride on the boom, boom hook or load line.
 Never operate the crane unless you've had the appropriate training, and never operate
the crane if you're under the influence of alcohol, drugs or medications that could impair
your abilities.
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 The crane should be inspected daily.

 Only operate the crane on a solid, level surface.
 Never operate the crane with anyone standing under the boom or the load at any time.
 Keep at least three wraps of load line on the winch drum.
 The boom and the outriggers must be stowed at all times while the truck is in motion.
 Reduce loads to allow for factors such as wind, ground conditions, operating speeds,
and the effect of freely suspended loads.
 Only operate the crane within its load and work-area limitations (never exceed winch or
crane ratings).
 When the crane is in operation, pay attention to it at all times and do not engage in any
distracting activities.
 Respond to any "stop" signal from anyone immediately.
 If you have to leave the crane unattended, you must first land the load, disengage the
main power source, set any locking devices, put all controls in the off or neutral position,
secure the crane against accidental travel (i.e., use chock blocks), and stop the engine.
 Plan your lifts carefully, taking into account the presence of power lines, bystanders,
overhead obstructions, and solid surface support; position the crane so that it is
impossible for it to come into contact with electricity in its fully extended position (if this is
impossible, then the electrical source needs to be shut off).
 Set the parking break and disengage the drive axle before attempting a lift.
 Do not operate the crane controls when your hands are oily or greasy (it's preferable to
wear gloves).
 Wear a hard hat and safety glasses during crane operation.
 Eliminate load swing by positioning the boom tip directly over the center of the load
before lifting.
 First check the safety of the load by barely lifting if off the ground.
 When lifting a load, keep it as close to the ground as possible.
 Never use the boom or the winch to drag a load.
 Never lift a load you cannot see.
 Do not operate the crane during electrical storms or high winds or when suitable lighting
is not available.
 Never leave a suspended load unattended.
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 Never extend or retract booms out of sequence (they must be retracted and extended
from largest to smallest).
 The wire rope should be inspected frequently because it is often the weak link in crane
safety; wire rope will fail if it is worn, misused, overloaded, damaged, or improperly
maintained.
 Crane hooks should be tested periodically to ensure that they are in sound condition
(crane hooks are designed to lift a specific rated load, and this rated load only applies to
new and unused hooks; age, environmental conditions and other factors alter a hook's
ability to handle a load).
Answer the following questions
1. List 4 controls of truck mounted cranes and explain their functions.
2. List the safe working procedures to be followed when operating truck mounted cranes.
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3. How is crane performance monitored in your organisation?
4. List the activities that can cause damage to machine or injury to people.
5. List the hazards specific to operating Truck Mounted Loader Cranes.
6. How can these hazards be minimised or reduced?
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7. How do you start-up and shutdown a truck mounted loader crane?
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8. How do you park a Truck Mounted Loader Crane?
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Module 3
Crane inspections and safety
54
Inspections
The crane should operate with a smooth, regular motion without any hesitation, abnormal
vibration, binding, gross shimmy, or irregularity. There should be no apparent damage,
excessive wear, or deformation of any load-bearing part of the equipment. All safety devices,
load indicators, boom angle and radius indicators, controls, and other operating parts of the
equipment should be checked during each inspection and should be in good working order.
Daily preoperational check
Operators or other designated personnel should visually inspect items such as the following
each day or prior to use if the crane has not been in regular service (records are not required):
1. All control mechanisms for maladjustment interfering with proper operation.
2. Crane hooks and latches for deformation, cracks, and wear.
3. Hydraulic systems for proper oil level.
4. Lines, tanks, valves, pumps, and other parts of air or hydraulic systems for leakage.
5. Hoist ropes for kinking, crushing, birdcaging, and corrosion.
6. Anti-two-block, two-block warning, and two-block damage prevention systems for proper
operation.
7. Booms for damage or deformation of structural components.
b. Operators or other designated personnel should examine deficiencies and determine whether
they constitute a safety hazard.
Monthly inspection
a. The operator or other designated person should visually inspect the following items for
damage, wear, or other deficiency that might reduce capacity or adversely affect the safety of
the crane:
1. Critical items such as brakes and crane hooks.
2. Hoist ropes.
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b. Lower the hook block to its lowest position and examine for any condition that could result in
an appreciable loss of strength.
c. Hooks for cracks, deformation, damage from chemicals, latch engagement (if provided), and
evidence of heat damage.
e. Signed and dated inspection records should be kept on file and should be readily available.
F. Before the crane is returned to service, correct deficiencies that could reduce its capacity or
adversely affect its safety.
Frequent inspection
a. Operators or other designated personnel should visually inspect the crane at daily to monthly
intervals (records are not required).
b. These inspections should, in addition to the requirements of “Preoperational Check,” include

the following:
What to inspect
1. All control mechanisms for maladjustment, excessive wear, and contamination by lubricants
or other foreign matter that could interfere with proper operation.
2. All safety devices for malfunction.
4. Electrical apparatus for malfunctioning, signs of excessive deterioration, and accumulation of

dirt or moisture.
5. Tires for recommended inflation pressure.
6. Boom sections for damaged, deformed, or missing structural members or parts.
c. Operators or other designated personnel should examine deficiencies and determine whether
a more detailed inspection is required.
Periodic inspection
a. Complete inspections of the crane should be performed by a qualified inspector at 1- to 12-

month intervals, depending on the crane’s activity, severity of service, and environment.
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b. The qualified inspector should examine deficiencies and determine whether they constitute a
hazard.
c. Dated and signed inspection records should be kept on file and should be readily available.
Cranes
Inspect for:
a. Deformed, cracked, or corroded members in the crane structure and entire boom.
b. Bolts, rivets, nuts, and pins for being loose or absent.
c. Check for suspect/counterfeit parts.
d. Cracked or worn sheaves and drums.
e. Hooks damaged from chemicals, deformation, or cracks, any visibly apparent bend or twist
from the plane of the unbent hook, or any distortion causing an increase in throat opening of 5%
not to exceed 1⁄4 in.
f. Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers, and locking
devices.
g. Excessive wear on brake and clutch system parts, linings, pawls, and ratchets.
h. Load, boom angle, and other operating aids over their full ranges for any significant
inaccuracies (if calibration is required, it should be done by a qualified person).
i. Gasoline, diesel, electrical, or other power plants for improper performance or noncompliance
with safety requirements.
j. Radiators and oil coolers, for leakage, improper performance, or blockage of air passages.
k. Excessive wear of chain drive sprockets and excessive chain stretch.
l. Steering, braking, and locking devices, for malfunctioning.
m. Excessively worn or damaged tires.
n. Rust on piston rods and control valves when crane has been idle.
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Hydraulic and Pneumatic Hose, Fittings, and Tubing
Inspect for:
a. Evidence of leakage at the surface of the flexible hose or its junction with the metal couplings.
b. Blistering or abnormal deformation of the outer covering of the hydraulic or pneumatic hose.
c. Leakage at threaded or clamped joints that cannot be eliminated by normal tightening or

recommended procedures.
d. Evidence of excessive abrasion or scrubbing on the outer surface of a hose, rigid tube, or
fitting (means should be taken to eliminate the interface of elements in contact or to otherwise
protect the components).
Hydraulic and Pneumatic Pumps and Motors
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Inspect for:
a. Loose bolts or fasteners.
b. Leaks at joints between sections.
c. Shaft seal leaks.
d. Unusual noises or vibration.
e. Loss of operating speed.
f. Excessive heating of the fluid.
g. Loss of pressure.
Hydraulic and Pneumatic Valves
Inspect for:
a. Cracks in valve housing.
b. Improper return of spool to neutral position.
c. Leaks at spools or joints.
d. Sticking spools.
e. Failure of relief valves to attain correct pressure setting (relief valve pressures should be
checked as specified by the manufacturer).
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Hydraulic and Pneumatic Cylinders
Inspect for:
a. Drifting caused by fluid leaking across the piston.
b. Rod seal leakage.
c. Leaks at welded joints.
d. Scored, nicked, or dented cylinder rods.
e. Dented case (barrel).
f. Loose or deformed rod eyes or connecting joints.
Hydraulic Filters
Evidence of rubber particles on the filter element may indicate deterioration of the hose, “O”
ring, or other rubber components. Metal chips or pieces on the filter may denote failure in
pumps, motors, or cylinders. Further checking will be necessary to determine the origin of the
problem before corrective action can be taken.
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Wire Rope
a. A qualified inspector should inspect wire ropes at least annually.
1. Reduction of rope size below nominal diameter, whether due to loss of core support, internal
or external corrosion, or wear of outside wires
2. The number and distribution or concentration of broken outside wires.
3. Worn outside wires.
4. Corroded or broken wires at end connections.
5. Corroded, cracked, bent, worn, or improperly applied end connections.
6. Kinking, crushing, cutting, or unstranding.
b. The qualified inspector should take care when inspecting running rope where rapid
deterioration could occur, such as in the following:
1. Sections in contact with saddles, equalizer sheaves, or other sheaves where rope travel is
limited.
2. Sections of the rope at or near terminal ends where corroded or broken wires may protrude.
5. Wear of one-third the original diameter of outside individual wires.
6. Kinking, crushing, birdcaging, or any other damage resulting in distortion of the rope
structure.
7. Evidence of heat damage from any cause.
f. All rope that has been idle for a month or more due to shutdown or storage of a crane on
which it is installed should be inspected before it is placed in service. This inspection should be
for all types of deterioration and should be performed by an appointed person whose approval
should be required before further use of the rope. A written and dated report of the rope
condition should be filed.
g. In order to establish data as a basis for judging the proper time for replacement, a continuing
inspection record should be maintained.
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h. Replacement rope should be the same size, grade, and construction as recommended by the
crane manufacturer, unless otherwise recommended by a rope or crane manufacturer due to
actual working condition requirements.
i. Never use discarded wire rope for slings.
Load hooks/load blocks
Load hooks/load blocks that have been changed out should be inspected by a qualified
inspector before returning the crane to service. Inspection records should be retained
throughout the service life of the hook or load block and should be readily available.
Cranes not in regular use
a. A crane that has been idle for 1 month or more but less than 6 months should be given a
thorough inspection before being placed in service.
b. A crane that has been idle for more than 6 months should be given a complete inspection
before being placed in service.
c. Standby cranes should be inspected at least semiannually. Cranes exposed to adverse

environments should be inspected more frequently
d. The determination supporting these alternate inspection frequencies and procedures should
be made by a qualified person for each affected crane. Documentation supporting this
determination should be kept readily available.
Operational tests
The following should be tested during an initial test:
a. Load lifting and lowering mechanisms.
b. Boom lifting and lowering mechanisms.
c. Boom extension and retraction mechanism.
d. Swinging mechanism.
e. Travel mechanism.
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f. Safety devices.
Rated load test
a. Prior to initial use, all cranes in which load sustaining parts have been modified, replaced, or
repaired should be load-tested by a qualified inspector or under the direction of that inspector.
All rated load tests should be performed in accordance with manufacturer’s recommendations.
A designated or authorized person should determine if repairs made to a crane are extensive
and require a rated load test, or if repairs are routine maintenance and require only operational
testing. The replacement of rope is excluded from this requirement. However, a functional test
of the crane under a normal operating load should be made prior to putting it back in service.
b. Test weights should not exceed 110 percent of the rated capacity and should be accurate to
within –5 percent, +10 percent of stipulated values.
NOTE: Load tests should not be conducted in locations where the lift meets the definition of a
critical lift.
c. A written report should be furnished by the inspector showing test procedures and confirming
the adequacy of repairs or alterations. Test reports should be kept on file and should be readily
available to appointed personnel.
Maintenance
Preventive maintenance
a. A preventive maintenance program should be established and based on the recommendation

of the crane manufacturer. Dated maintenance records should be kept where readily available
to appointed personnel.
b. Replacement parts should be at least equal to the original manufacturer’s specifications.
c. All moving parts of the crane for which lubrication is specified should be regularly lubricated.
Lubricating systems should be checked for proper delivery of lubricant. Operators and
maintenance personnel should follow the manufacturer’s recommendations as to the points and
frequency of lubrication, maintenance of lubricant levels, and types of lubricant to be used.
Maintenance procedures
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a. Before starting adjustments or repairs on a crane, maintenance personnel should take the
following precautions as applicable:
1. Place the crane where it will cause the least interference with other equipment or operations
in the area.
2. Lower the lower load block to the ground or otherwise secure it against dropping.
3. Lower the boom to the ground, if possible, or otherwise secure it against dropping.
4. Place all controls in the OFF position and secure all operating features from inadvertent
motion by brakes, pawls, or other means.
5. Ensure starting means are rendered inoperative.
6. Stop the power plant or disconnect it at the power takeoff.
7. Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing
hydraulic components.
b. Warning or out-of-order signs should be placed on the crane controls. Signs or flags should
be removed only by authorized personnel.
c. After adjustments and repairs have been made, the crane should not be returned to service
until all guards have been reinstalled, trapped air has been removed from the hydraulic system,
safety devices are reactivated, and maintenance equipment is removed.
Wire-rope maintenance
Personnel using wire rope should ensure proper care by doing the following:
a. Store rope to prevent damage or deterioration.
b. Unreel or uncoil rope as recommended by the rope manufacturer and with care to avoid
kinking or inducing a twist.
c. Before cutting a rope, use some method to prevent unlaying the strands. Heat-affected zones
of flame cut wire rope should not be allowed to bear load.
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d. During installation, avoid dragging the rope in the dirt or around objects which will scrape,
nick, crush, or induce sharp bends in it.
e. Maintain rope in a well-lubricated condition to reduce internal friction and to prevent

corrosion. Ensure that lubricant applied as part of a maintenance program is compatible with the
original lubricant. Consult the rope manufacturer when in doubt. Lubricant applied should be of
the type that does not hinder visual inspection. Those sections or rope that operate over
sheaves or are otherwise hidden during inspection and maintenance procedures require special
attention when the rope is lubricated.
f. When an operating rope shows greater wear at its ends than on the remainder, its life can be
extended (in cases where a reduced rope length is adequate) by cutting off the worn end, thus
shifting the wear to different areas of the rope.
Conduct of operator
a. Cranes should only be operated by personnel qualified for the type of crane being operated..
b. Do not engage in any practice that will divert your attention while operating the crane.
c. Keep the operating area free of water, snow, ice, oil, and debris that could cause your hands
or feet to slip from the controls.
d. Keep the operating cab windshields clean and free of anything that obstructs vision. Replace
broken windows.
e. Ensure proper functioning of tires, horn, lights, battery, controller, lift system (including load-
engaging means, chains, hoist rope, and limit switches), brakes, and steering mechanisms. If at
any time a lifting device is found to be in need of repair, is defective, or is in any way unsafe,
report it immediately to the designated authority and take the unit out of service until it has been
restored to safe-operating condition or a determination has been made by the responsible
manager that the deficiency will not adversely affect the safe operation of the unit.
f. When two or more cranes are used to lift one load, one designated person should be
responsible for the operation. That person should analyze the operation and instruct all
personnel involved in the proper positioning, rigging of the load, and the movements to be
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made. That person should also determine the necessity to reduce crane ratings, position of
load, boom location, ground support, and speed of movement.
g. Determine that no one is working on the crane or is close to it before starting the engine or
beginning to operate the crane.
h. Barricade accessible areas within the swing radius of the rear of the rotating superstructure of
the crane to prevent anyone from being struck or crushed by the crane.
i. Do not hoist two or more separately rigged loads in one lift, even though the combined load is
within the crane’s rated capacity.
j. When fueling the crane, stop the engine(s) and ensure that smoking or open flames are not
permitted within 8metres of the fueling area.
k. Ensure that a 10BC or larger fire extinguisher is installed at all operator stations. Fire
extinguishers should be maintained in a serviceable condition.
l. Do not store gasoline, acids, caustics, or cleaning solvents that emit toxic fumes in operating
cabs. Store fuel in safety cans in safe locations.
m. Ensure that alternate egress routes are not locked on mobile units with operating enclosures.
n. Position the crane on a solid and level footing. It may be necessary in certain situations to
use heavy timber mats to build a good working foundation.
o. When swinging the crane, watch out for centrifugal force. Swing the crane slowly to avoid an
outward swing of the load. Attach a tag-line to the load if necessary to control the swing.
p. Watch for boom kickback. Never operate with the boom at a higher angle than shown on the
capacity charts.
q. Use extreme caution when operating the crane near workers in elevated areas.
r. Use power lowering when lowering loads.
When lowering heavy loads, keep the hoist brake as reserve. Use a safety pawl on the boom-
hoist drum when not lowering.
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s. Avoid two-blocking, caused when the hook block makes contact with boom-point sheaves. A
continuing pull on the hoist lines can break the rope or pull the boom back over the cab on some
types of booms. On hydraulically telescoping booms, be sure to play out the hoist line when
extending and spool in the hoist line when retracting.
t. Lock carrier air brakes ON when operating, and check the pressure of the air brakes
frequently.
u. Watch out for the carrier-cab on truck mounted units when swinging the boom. Keep boom
high enough to swing clear of cab.
v. In the absence of crane manufacturer’s instructions regarding maximum wind speeds for
operation, operations undertaken at wind speeds in excess of 25 mph should be evaluated by a
qualified person to determine if the size, shape and weight of the load can be safely lifted.
w. When a crane is to be operated at a fixed radius, the boom-hoist pawl or other positive
locking device should be engaged.
x. On truck-mounted cranes, no loads should be lifted over the front area, except as approved
by the crane manufacturer.
y. Crane cabs, necessary clothing and personal belongings should not interfere with access or
operations.
z. Tools, oil cans, waste, extra fuses, and other necessary articles should be stored in the tool
box, and should not be permitted to lie loose in or about the cab.
Travelling the Machine
When travelling the machine:
a. Secure the boom and book block.
b. Check bridges before crossing; make sure they will support the weight of the machine.
d. Check clearances under overpasses, overhead lines, or any overhead obstruction; when side
clearances are tight, install a barrier or post a lookout, and make certain there is sufficient
clearance for tail swing.
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Making Adjustments or Repairs
a. When making adjustments or repairs:
1. Stop the machine.
2. Lower the boom or secure it against dropping.
3. Neutralize all controls.
4. Lock starter and remove ignition key to make the machine inoperative.
5. Display proper warning signs on controls of machine.
6. Keep hands, feet, and clothing away from gears, ropes, drums, and sheaves.
7. Never put hands on wire rope when climbing to the top of the cab.
8. Use a bar or stick to guide wire rope onto drums.
9. Keep hands well away from the fan drive while engine is running.
10. Safeguard the crane oiler; do not resume operation until a positive ALL CLEAR signal has
been given.
11. Replace all guards and shields before resuming operation.
b. Place blocking or other adequate supports under the boom before beginning boom
disassembly operations. Never stand under or on the boom during this work.
c. Before disconnecting oil lines, if machine has hydraulic controls, be sure to place boom on
the ground or in the boom rest; then move the pedals and control levers to equalize pressures
within the cylinders.
Always release any air supercharge on the hydraulic reservoir and shut off the engine (or
declutch pumps) before disconnecting oil lines.
d. Do not reach into hydraulic-boom holes unless the sections are securely anchored together.
Ensuring Stability
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a. Know the rated capacity of the crane and the weight of the load. A safe lift depends on many
factors including boom length, boom angle, and load radius. Follow these requirements to avoid
buckling the boom or tipping:
1. Know the radius of the load; the radius is measured from center of rotation, not from the
boom foot pin.
2. Always operate within the rated capacity of the machine.
3. The gross capacity includes weight of hook, block, and any material-handling devices, (i.e.,
slings, concrete bucket, magnet lifter, etc.); subtract the weight of all these to find the true
weight (net capacity) the crane can handle safely.
4. Ratings are based on operating the machine on firm, level ground; outriggers should be
properly extended and lowered before operation.
5. Avoid fast swings, hoists, or sudden braking; these can cause overloads.
6. Do not handle large, heavy loads in strong winds; the wind can catch the load and create an
unstable condition.
b. Test stability before lifting heavy loads.
Check outrigger footing. Lift load slightly off the ground and stop. Check the machine for
movement ad check to be sure the brakes hold with the load elevated.
c. Never use machine stability to determine capacity.
d. If there are any indications of tipping, the machine is already overloaded for that working
radius.
e. Do not back crane away from the load while carrying a maximum load; this may cause the
crane to tip.
f. Always use outriggers when making lifts (with pick-and-carry units), and never lift a load
forward of the front outriggers, unless allowed on manufacturer’s load chart.
g. Lower outrigger jacks until the tires clear the ground, and level the unit to reach the machine’s
full capacity. Recheck and, if necessary, reset outriggers between heavy lifts.
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h. Always fully extend outrigger beams unless otherwise specified on the manufacturer’s load
charts for the crane.
Further Safety Considerations
a Make only vertical lifts; never pull the load sideways.
b Keep speed slow in lifting and lowering loads.
c Swing carefully and slowly, and avoid boom or jib “whipping”; check counterbalance
clearance.
d Do not let the load strike the boom or outriggers.
e Allow maximum clearance between the hook block and boom-point sheaves.
f Keep near-capacity loads as close to the ground as possible.
g Avoid hitting anything with the boom; an engineering analysis should be made before putting
the crane back in service if this occurs.
Operating near power lines and transmitter towers
It is recognized that operating mobile cranes where they can become electrified from electric
power lines is an extremely hazardous practice.
It is advisable to perform the work so there is no possibility of the crane, load line, or load
becoming a conductive path.
The following steps should be taken to minimize the hazard of electrocution or serious injury as
a result of contact between the energized power lines and the crane, load line, or load:
b. Any overhead wire should be considered to be an energized line unless and until the person
owning the line or the electrical utility authorities indicate that it is not an energized line.
c. Durable signs should be installed at the operator’s station and on the outside of the crane,
warning that electrocution or serious bodily injury may occur unless a minimum clearance of 10
ft (3.1m) is maintained between the crane or the load being handled and energized power lines.
Greater clearances are required because of higher voltage.
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d. Exercise caution when working near overhead lines having long spans as they tend to move
laterally or vertically due to the wind, which could cause them to breach the safety zone.
e. Cranes should not be used to handle materials stored under electric power lines unless any
combination of the boom, load, load line, or machine component cannot enter the prohibited
zone.
f. Crane operators should not rely on the coverings of wires for their protection.
Crane Operation near de-energized and grounded electric
Power Lines
This is the preferred condition under which the operation can be performed safely. The hazard
of injury or death due to electrocution has been removed. The following steps should be taken
to assure de-energization of the power lines has occurred:
a. The power company or owner of the power lines should de-energize the lines.
b. The lines should be visibly grounded to avoid electrical feedback and appropriately marked at
the job-site location.
c. A qualified representative of the owner of the lines or a designated representative of the

electrical utility should be on site to verify that steps (a) and (b) have been completed and that
the lines are not energized.
Crane Operation near transmitter towers
a. Prior to work near transmitter towers where an electrical charge can be induced in the
equipment or materials being handled, the transmitter should be de-energized or tests should
be made to determine if electrical charge is induced on the crane. The following precautions
should be taken when necessary to dissipate induced voltages:
1. The equipment should be provided with an electrical ground directly to the upper rotating
structure supporting the boom.
2. Ground jumper cables should be attached to materials being handled by boom equipment
when electrical charge is induced while working near energized transmitters; crews should be
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provided with nonconductive poles having large alligator clips or other similar protection to
attach the ground cable to the load.
3. Combustible and Flammable materials should be removed from the immediate area prior to
operations.
Hoist-limit switch
Check all limit switches, if supplied, without a load on the hook at the beginning of each work
shift or the first time the crane is used that shift.
Inch each motion into its limit switch to ensure that two-blocking does not occur during the test.
If a lift is in progress during a shift change, this testing requirement is considered to have been
satisfied for the completion of that lift. However, test the limit switch again before the next lift.
Identification of signalers
a. All personnel acting as signalers during crane operations should be clearly identified to the
crane operator. Options for improving signaler visibility include using an orange hardhat, orange
gloves or an orange vest.
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b. In those cases where the crane operator cannot see the signaler, a second person (relay
signaler) should be stationed where he or she can see both the signaler and the crane operator,
and can relay the signals to the operator. The relay signaler should also be clearly identified to
the crane operator.
c. The operator should obey signals only from the designated signaler. Obey a STOP signal no
matter who gives it.
Standard voice signals
a. Prior to beginning lift operations using voice signals, the signals should be discussed and
agreed upon between the person-in-charge, the crane operator, the appointed signal person
and the riggers.
b. Radios or equivalent should be tested before lifting operations begin.
c. Prior to commencing a lift, the crane operator and the signal person should contact and
identify each other.
d. All directions given to the crane operator by the signal person should be given from the crane
operator’s direction perspective (e.g., right swing).
e. Each series of voice signals should contain three elements stated in the following order:
1. Function and direction
2. Distance and/or speed
3. Function stop
Special signals
For operations or crane attachments not covered by standard hand, voice or audible signals,
additions to or modifications of the standard signal procedures may be required. In all such
cases, the required special signals should be agreed upon in advance by the manager, person-
in-charge, crane operator, signal person and riggers.
These special signals should not be in conflict with the standard signals.
Size of load
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The crane should not be loaded beyond its rated capacity.
Attaching the load
a. Ensure that the hoist rope is free from kinks or twists. Do not wrap the hoist rope around the
load.
b. Ensure that the load is attached to the load block hook by means of slings or other approved
devices.
c. Ensure the load is well secured and properly balanced in the sling or lifting device before it is
lifted more than a few inches.
d. Take care to make certain that the sling clears all obstacles.
Moving the load
a. The appointed person directing the lift should make certain that the load is well secured and
properly balanced in the sling or lifting device before it is lifted more than a few inches.
b. Before starting to hoist, note the following conditions:
1. Hoist rope should not be kinked.
2. Multiple-part lines should not be twisted around each other.
3. The hook should be positioned above the center of gravity of the load in such a manner as to
minimize swinging when the load is lifted.
4. Following any slack-rope condition, it should be determined that the rope is properly seated
on the drum and in the sheaves.
5. All personnel including the qualified rigger should be clear of the load.
c. During hoisting, take care to ensure that:
1. There is no sudden acceleration or deceleration of the moving load.
2. Load does not contact any obstructions. A “dry run” should be conducted in areas where
clearance is limited.
74
d. Cranes should not be used for side pulls, except when specifically authorized by a designated
person who has determined that the stability of the crane is not endangered and that various
parts of the crane will not be over stressed.
e. Avoid carrying loads over people.
f. No hoisting, lowering, swinging, or traveling should be done while anyone is on the load hook.
g. Test the brakes each time a load approaching the rated capacity is handled by raising the
load a few inches and applying the brakes.
h. Do not lower the load below the point where less than two full wraps of rope remain on the
hoist drum.
i. Do not leave your position at the controls while the load is suspended, unless required to do
so by an approved emergency procedure.
j. If the load must remain suspended for any considerable length of time, the operator should
hold the drum from rotating in the lowering direction by activating the positive controllable
means of the operator’s station.
k. Work on suspended loads is prohibited under normal conditions. When the responsible
manager decides that it is necessary to work on a suspended load, guidelines for ensuring
safety of the work should be established through consultation with the appropriate safety
organization. Suspended loads that must be worked on should be secured against unwanted
movement.
l. Tag lines should be used as required to guide, snub, or otherwise control the load.
Practical Activity: The learner will be observed operating a crane from start to finish. The
assessor will complete the checklist below.
The learner was able to: Yes No
 identify the suitability of the crane prior to utilisation
 assess operational capability of lifting equipment (e.g. correct SWL

of slings etc).
75
 load the crane in accordance to the manufacturer’s requirements
 observe safety rules while using the crane
 use correct protective clothing and equipment
 do pre-operational checks according to appropriate checklist
 complete a checklist according to worksite procedures
 use various controls in accordance with the manufacturer's

specifications
 effectively manoeuvre the crane within manufacturer's specifications
 follow start-up and shutdown procedures according to manufacturer's

specifications
 operate crane without risk of damage or loss to machine or property,

or injury to people
 take corrective action if required to ensure compliance with

manufacturer's specifications
 identify appropriate measures to rectify and/or prevent basic faults

and defects in the mechanical function of the crane
 read and follow instructions on warning devices
 Park crane according to manufacturer's and company requirements
Assessor Name……………………………………………Surname:…………………………………
Assessor Signature………………………………………. Date……………………………………….
Learner Signature………………………………………… Date………………………………………
76
Unit Standard, Specific Outcomes and Assessment Criteria
Elective: Operate a truck mounted loader crane: SAQA ID 116253

Specific Outcomes Assessment Criteria
Demonstrate knowledge of  The main functions of Truck Mounted Loader Crane's
the functions of a truck are explained in terms of manufacturer's specifications.
mounted loader crane  The operation of all major components is explained in
terms of their functions.
 All safety features and warning devices on the crane
are identified, and their purposes explained in
accordance with manufacturer's specifications.
 The maximum operating capacities are explained in
terms of the designed crane capabilities.
 Warnings from crane indicators and gauges are
explained according to manufacturer's specifications.
 Corrective actions are described or demonstrated in
terms of neutralising warnings received.
Identify the safety and  Demonstrate the ability to identify the suitability of the
suitability of the crane crane prior to utilisation
 Demonstrate ability to assess operational capability of
lifting equipment (e.g. correct SWL of slings etc).
 Demonstrate an understanding of the influence of
load/range characteristics, manufacturers'
requirements and environmental conditions.
 Demonstrate an understanding of what constitutes
safety in the broader working environment, and when
operating a Truck Mounted Loader Crane in
compliance with statutory regulations.
Apply the recognised  Pre-operational checks are carried out according to
methods for inspecting and appropriate checklist.
recording the operational  Daily and weekly operator maintenance is performed
77
fitness of all components of according to the appropriate post-operational checklist

the crane and recordkeeping using a logbook.
 Checklist is completed according to worksite
procedures and corrective action taken if required,
ensuring compliance with manufacturer's
specifications.
 Appropriate measures used to rectify and/or prevent
basic faults and defects in the mechanical function of
the crane are identified.
Operate truck mounted  The purpose of the various controls is explained in
loader crane accordance with their designed use.
 Functions of the various controls are demonstrated in
accordance with the manufacturer's specifications.
 Controls are used to effectively manoeuvre the crane
within manufacturer's specifications.
 Safe working procedures are followed according to
manufacturer's specifications, site specific and
statutory requirements.
 Crane performance is monitored and corrective action
is taken when necessary, in accordance with
manufacturer's specifications.
 Crane is operated without risk of damage or loss to
machine or property, or injury to people.
 Hazards specific to operating Truck Mounted Loader
Crane's and ways to minimise these are explained in
terms of potential damage to machine and property,
and injury to people.
 Start-up and shutdown procedures are followed
according to manufacturer's specifications.
 Truck Mounted Loader Crane is parked according to
manufacturer's and company requirements.
78
References
Pictures: Microsoft ClipArt, www.gettyimages.com

Google images
Other References: Wikipedia

Google
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116253 Learner Guide Operate a Truck Mounted Loader Crane

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OPERATE A TRUCK MOUNTED LOADER CRANE: SAQA ID: 116253

Operate a truck mounted loader

PURPOSE OF THE UNIT STANDARD

The qualifying learner is capable of:

 Demonstrating an integrated practical and theoretical grounding in Crane Operations

LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING

The following knowledge, skills attitude and/or equivalent:

 NQF Level 1 Numeracy and NQF Level 1 Literacy

 Relevant Code of practice

UNIT STANDARD RANGE

Limited to work carried out on a standard crane, or with standardised fittings

Major components include:

Factors influencing safety and suitability of a crane:

 Proximity of other machines and workers, vehicles, equipment, ground condition,

Statutory requirements include but are not limited to:

 Relevant Code of practice

Appropriate checklist is any one or a combination of the following:

 Worksite procedures include manufacturer's procedures, operators manuals and site

UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE

The maximum operating capacities of the designed working capabilities.

Selection of crane against environmental restraints

Critical Cross-field Outcomes (CCFO)

UNIT STANDARD CCFO IDENTIFYING

Identify and solve problems

Evident in the following speicific outcome and assessment creteria:

Demonstrate knowledge of the functions of a truck mounted loader crane

Corrective actions are described or demonstrated in terms of neutralising warnings received.

UNIT STANDARD CCFO WORKING

Work effectively with others

Evident in the following speicific outcome and assessment creteria:

UNIT STANDARD CCFO ORGANISING

Employ self management

Evident in the following speicific outcome and assessment creteria:

UNIT STANDARD CCFO COLLECTING

Evident in the following speicific outcome and assessment creteria:

Demonstrate knowledge of the functions of a truck mounted loader crane

UNIT STANDARD CCFO COMMUNICATING

Evident in the following speicific outcome and assessment creteria:

UNIT STANDARD CCFO SCIENCE

Demonstrate scientific and technological competence

Evident in the following speicific outcome and assessment creteria:

Identify the safety and suitability of the crane.

Demonstrate an understanding of what constitutes safety in the broader working environment,

UNIT STANDARD CCFO DEMONSTRATING

Understand contextual world-systems

Evident in the following speicific outcome and assessment creteria:

Identify the safety and suitability of the crane

Demonstrate an understanding of what constitutes safety in the broader working environment,

Operate a truck mounted loader crane

Topics Page Number

Functions of truck mounted cranes

Operation of truck mounted crane

Crane inspections and safety

Functions of truck mounted cranes

Truck mounted crane

The Rotex Gear

Limiting and indicating devices

Rated capacity limiters

Motion limiting devices

Integrated Stability Control

Stabilizer feet is designed to adjust to a ground unevenness.

Working radius indicator

Free fall lock-out

Securing for transport