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NAME OF TRAINING PROGRAM

April 2009 BCMEA Training Department

Mobile Crane TrainingProgram

PRINTED VERSIONS OF THIS DOCUMENT ARE CONSIDERED UNCONTROLLED. FOR MOST RECENT VERSION, CONTACT THE BCMEA TRAINING DEPARTMENT.

Confi dential information

© British Columbia Maritime Employers Association

This material contains confi dential information of the British Columbia Maritime Employers Association and is protected by copyright owned by the British Columbia Maritime Employers Association, and is issued to the recipient by the British Columbia Maritime Employers Association solely for the purposes of training and evaluation.

This material must be kept confi dential and reasonable precautions taken to ensure that it is not discovered, used, or copied by third parties. The original and all copies of all or any part of this material remains the property of the British Columbia Maritime Employers Association, and must be returned to the British Columbia Maritime Employers Association promptly on request by the British Columbia Maritime Employers Association.

No part of this material may be reproduced, transmitted, used, stored in a retrieval system, or lent to others in any form or by any means.

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MOBILE CRANE TRAINING PROGRAM

April 2009 PRINTED VERSIONS OF THIS DOCUMENT ARE CONSIDERED UNCONTROLLED. FOR MOST RECENT VERSION, CONTACT THE BCMEA TRAINING DEPARTMENT.

Table of Contents

1 Introduction1 Introduction

1.1 Job Overview 3

1.2 Roles and Responsibilities 4

2 Safety1 Safety and Security Review

1.1 Safety and Security Review Document 11

2 Mobile Crane Safety2.1 Web Sling Safety 12

2.2 Wire Rope Sling Safety 14

2.3 Crane Safety 15

2.4 Hoisting Hand signals 16

2.5 Common Hazards 17

2.6 Factors that Reduce Hoisting Capacity 20

2.7 Electrical Hazards 21

2.8 Other Hazards in Crane Operating Areas 24

2.9 Outrigger Safety 27

2.10 Pre-Operation Site Inspection 32

3 Rigging1 Introduction

1.1 Overview 35

2 Equipment2.1 Wire Rope Slings 36

2.2 Inspecting Wire Rope Slings 36

2.3 Inspecting Web Slings 42

2.4 Rigging Hardware 43

2.5 Inspecting Rigging Hardware 46

2.6 Rigging Operations 46


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April 2009PRINTED VERSIONS OF THIS DOCUMENT ARE CONSIDERED UNCONTROLLED. FOR MOST RECENT VERSION, CONTACT THE BCMEA TRAINING DEPARTMENT.

Table of Contents

4 Hoisting1 Equipment

1.1 Hoisting Equipment 51

2 Inspections2.1 Pre-operation Inspection 52

3 Operations3.1 Preparing load for a lift 54

3.2 Loading/Discharge 55

5 Grove Cranes1 Introduction

1.1 Controls 59

1.2 Procedures 60

6 Terex Cranes1 Introduction

1.1 Controls 63

1.2 Procedures 64

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1 Introduction



Modules

1 Introduction

2 Safety

3 Rigging

4 Hoisting

5 Grove Cranes

6 Terex Cranes


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Notes

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1 Introduction1.1 Job OverviewMobile crane work involves two tasks: hoisting and rigging. Hoisting is lifting, holding and lowering cargo with a crane. Rigging is the attachment of wire slings, web slings, chains or other holding devices to cargo to prepare it for hoisting.


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1 Introduction1.2 Roles and ResponsibilitiesAll personnel involved in crane operations must understand their jobs, their responsibilities, and their part in the overall safety of each lift.

Preparation begins with a clear defi nition of responsibilities. No single set of guidelines can cover every detail of the many different types of crane operation spells out primary responsibilities for the major parties involved – owners, operators, site supervision, and workers.

Riggers must be trained, experienced and understand the following:

How to establish weights How to judge distances, heights, and clearances How to select tackle and hardware suitable to the load How to rig the load safely.

Signallers must be competent and capable of directing the crane and load to ensure safe, effi cient operation. Knowledge of the hand signals for hoisting is a must for Signallers and Operators.

The Crane Operator is generally responsible for the safety of the operation as soon as the load is lifted clear of the ground. Whenever there is reasonable cause to believe that the lift may be dangerous or unsafe, the Operator must refuse to proceed until the concern has been reported to the supervisor, any hazard has been corrected, and safe conditions have been confi rmed.

This section includes information of use to riggers, operators, and others involved either directly or indirectly in crane operations. The information covers major responsibilities, hazards and safeguards in crane operating areas, factors that affect crane capacity, pinch points and other hazards around equipment, considerations for safe setup, requirements for providing signallers, and the international hand signals for hoisting.

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1 Introduction



1 Introduction1.2 Roles and Responsibilities (continued)Crane Owner (Terminal Operator)

The Crane Owner is responsible for providing safe, suitable equipment that meets the requirements of the job. The Owner is also responsible for maintaining that equipment and ensuring that no unsafe equipment is used by Operators. This includes providing:

A thorough equipment maintenance and inspection program, including inspecting logbooks and other required documentation

Equipment maintenance and inspection in accordance with manufacturer’s requirements and applicable regulations.

The Owner is also responsible for ensuring that Operators are capable and aware of their responsibilities. This includes ensuring that:

Maintenance, repair, transport, assembly, and other personnel are trained and experienced to handle their specifi c jobs

Training and upgrading are provided for all personnel Responsibilities and authority are clearly designated for each crew.


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1 Introduction1.2 Roles and Responsibilities (continued)Operator

The Operator is generally responsible for the safety of the crane operation as soon as the load is lifted. Operators must know:

The particular model of crane they operate, its characteristics, functions, and limitations The information in the crane’s operating manual The crane’s load chart, including all notes and warnings, and how to calculate or determine

the crane’s actual net capacity in every possible confi guration Proper inspection and maintenance procedures to be followed in accordance with the

guidelines of manufacturer and owner Any site conditions that may affect crane operation, including the presence of overhead

power lines Basic load rigging procedures.

In addition, the Operator must:

Report any problems with the machine, preferably in the machine’s logbook Record in the logbook all inspection, maintenance, and work done on the crane in the fi eld Check that the site is properly prepared for crane operation Review plans and requirements with site supervision Find out the load and rigging weight and where the load is to be placed Check the load chart to ensure that the crane has enough net capacity for each planned lift Select the best boom and crane confi guration to suit load, site, and lift conditions Assume responsibility for setting up the crane properly Follow the manufacturer’s operating instructions in accordance with the load chart Consider all factors that may reduce crane capacity and adjust the load weight accordingly Maintain communication with signallers Operate in a smooth, controlled, and safe manner Shut down and secure the machine properly when leaving it unattended.

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1 Introduction



1 Introduction1.2 Roles and Responsibilities (continued)Site Supervisor

The Site Supervisor has overall responsibility for the lift and must therefore plan all phases of the operation. Specifi cally, Site Supervisors must:

Supervise all work involving the crane Determine the correct load weight and radius and inform the operator Ensure that the rigging crew is experienced and capable of establishing weights; judging

distances, heights, and clearances; selecting tackle and lifting gear suitable to the loads; rigging the load safely and securely

Supervise the rigging crew Ensure that the load is properly rigged Ensure that signallers are capable of directing the crane and load, including use of the

international hand signals where other forms of communication are not possible Designate signallers and identify them to the operator Ensure the safety of the rigging crew and other personnel affected by crane operations Keep the public and all non-essential personnel clear of the crane during operation Control the movements of all personnel in the area affected by the lift Ensure all required precautions when the lift is near power lines Ensure that all personnel involved in the operation understand their jobs, responsibilities, and

their role in the overall safety of each lift.


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Notes

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2 Safety



Modules

1 Introduction

2 Safety

3 Rigging

4 Hoisting

5 Grove Cranes

6 Terex Cranes


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Notes

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2 Safety



1 Safety and Security Review1.1 Safety and Security Review DocumentThe following section of this training program deals with general waterfront safety and security theory. The information pertaining to this section can be found in the Safety & Security Review supplement supplied to every trainee at the beginning of the training program.

At the end of the Safety & Security Review all trainees are required to complete and submit to the following to the designated trainer:

The 21 short answer Self-Directed Review A signed and dated Summary Checklist

The above submissions are located in the assessment package handed out by the trainer. The trainer will identify to the trainee when the appropriate time to complete the above deliverables is.

NAME OF TRAINING PROGRAM

Oct. 2010 BCMEA Training Department

Safety & Security Review


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2 Mobile Crane SafetyThe following section covers important safety information for hoisting and rigging loads. This includes safe procedures designed to prevent injury due to bights, pinch points and being struck by machinery. It also includes safe handling of equipment designed to minimize unexpected equipment failure.

2.1 Web Sling SafetyWeb slings that appear to be damaged shall not be used unless inspected and accepted as usable. Web slings must always be hitched in a manner providing maximum control of the load. Web slings are for hoisting cargo loads only, and must never be used as bridles on suspended personnel platforms.

Multi-leg slings

A multi-leg bridle sling will not always safely lift a load equal to the safe load on one leg multiplied by the number of legs. There is no way of knowing that each leg is carrying its fair share of the load. With slings having more than two legs and a rigid load, it is possible for some of the legs to take practically the full load while the others merely balance it

When lifting rigid objects with three- or four-leg bridle slings, Riggers must ensure that at least two of the legs alone can support the total load. In other words, multi-leg slings used on a rigid load should be treated as having only two legs. Where the load is fl exible and can adjust itself to the sling legs, Riggers may assume that each leg can take its own share of the load.

When using multi-leg slings to lift loads in which one end is much heavier than the other, the tension on the most heavily loaded leg is much more important than the total weight. The sling must be selected to suit the most heavily loaded leg rather than the total weight.

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2 Mobile Crane Safety2.1 Web Sling Safety (continued)Reducing Wear and Tear

To prevent wear and tear of slings and give them a longer operating life, Riggers should:

Store all web slings in a cool, dry and dark place when not in use to prevent loss of strength through exposure to ultra-violet light

Avoid storing Web slings in chemically active environments Avoid shock loading Avoid twisting and kinking the legs Avoid dropping web slings equipped with metal fi ttings Avoid pulling web sling from under loads when the load is resting on the web sling Place blocks under load prior to setting down the load to allow removal of the web sling.

Loading Precautions

When the choker hitches, Rigger must not force the eye down towards the load once tension is applied

Whenever two or more rope eyes must be placed over a hook, Rigger must install a shackle on the hook with the shackle pin resting in the hook and attach the rope eyes to the shackle

The web sling’s legs should contain or support the load from the sides above the center of gravity when using a basket hitch

Tags and labels should be kept away from the load, hook and point of choke Web slings shall not be constricted or bunched between the ears of a clevis or shackle.


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2 Mobile Crane Safety2.2 Wire Rope Sling SafetyWire rope slings that appear to be damaged shall not be used unless inspected and accepted as usable. Wire rope slings must always be hitched in a manner providing maximum control of the load. Wire rope slings are for hoisting cargo loads only, and must never be used as bridles on suspended personnel platforms.

Loading Wire Rope Slings

Riggers must never overload the rope Riggers should avoid shock loading when possible To ensure there is no slack in the rope, Riggers should start the load carefully, applying power

smoothly and steadily.

Selecting Safe Wire Ropes

Riggers must never use frozen ropes Riggers must never use wire rope that has been cut, kinked, or crushed Riggers must ensure that rope ends are properly seized.

Avoiding Damage to Wire Ropes

Riggers must use thimbles in eye fi ttings at all times Riggers should avoid reverse bends in the rope Riggers must keep wire rope slings away from fl ame cutting and electric welding Riggers should avoid bending the eye section of wire rope slings around corners. The bend

will weaken the splice or swaging. There must be no bending near any attached fi tting Riggers should never pull loops in slack lines tight, as this kinks them If a loop forms, Riggers should unfold it Riggers must avoid dragging rope out from under loads or over obstacles Riggers must not drop rope from heights All unused rope should be stored in a clean, dry place.

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2 Mobile Crane Safety2.3 Crane Safety Major rigging operations must be planned and supervised by competent personnel to guarantee that the best methods and most suitable equipment are employed.

Most crane and rigging accidents can be prevented by fi eld personnel following basic safe hoisting and rigging practices. The single most important precaution in rigging and hoisting is to determine load weight before attempting any lift.

Riggers must always follow these three rules:

When in doubt, check the load chart. If unsure, take a test run empty. Have someone watch (spot) your outriggers

Maintain control and smoothness of levers – do not rush When slewing over back of mobile crane, be aware of the blind spot – lift load high enough

to be completely visible.

At the same time, Riggers must:

Determine the available capacity of the equipment being used Rig the load so that it is stable (unless the centre of gravity of the load is directly below the

hook, the load will shift) Identify and Make allowances for potential hazards, such as wind.

Accessing the Cab

Falling is a major cause of injury. Operators minimize the risk by doing the following:

Operator must never hold anything in their hands when getting on or off the machine Operator always faces the machine Operator maintains 3-point contact with the steps and handholds when mounting and

dismounting the machine Operator uses only the proper handholds when mounting or dismounting Operator never jumps on or off the mobile crane Operator never attempts to mount or dismount a moving mobile crane.

In addition, Riggers and Operators must be aware of common hazards, factors that reduce hoisting capacity, the inspection and use of slings, and safe practices in rigging, lifting, and landing loads.

It is imperative that all workers who prepare, use, and work with or around hoisting and rigging equipment are well trained in both safety and operating procedures. All hoisting equipment should be operated only by trained personnel.


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2 Mobile Crane Safety2.4 Hoisting Hand signals

STOPOpen hand,

raised, palm forward.

HOISTForefinger pointing up,

move hand in small circles.

SLEWArm extended, finger pointing in direction hook is to swing.

BOOM UPArm extended, closed fist,

thumb pointing UP.

BOOM DOWNArm extended, closed fist,

thumb pointing DOWN.

LOWERForefinger pointing down, move hand in small circles.

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2 Mobile Crane Safety2.5 Common HazardsThis section identifi es common hazards and causes of hoisting and rigging accidents.

Working Load Limit (WLL) not known

Riggers must always know the working load limits of the equipment and tackle being used. Riggers must never exceed these limits

Defective Components

Riggers must examine all hardware, equipment, tackle, and slings before use and destroy any defective components. Equipment merely discarded may be picked up and used by someone unaware of its defects.

Hazardous Wind Conditions

Riggers must never carry out any hoisting or rigging operation when winds create hazards for workers, the general public, or property. Riggers must assess load size and shape to determine whether high winds may cause problems. In particular, Riggers must avoid handling loads that present large wind-catching surfaces. Even though the weight of the load is within the normal capacity of the equipment, high or gusting winds may prevent proper control during the lift. Wind-loading can be critical to how the load is rigged, lifted, and landed, with consequences for the safety of everyone involved. When winds reach 25-30 mph, the Supervisor should consider limiting hoisting operations.

Hazardous Weather Conditions

When the visibility of Riggers or hoist crew is impaired by snow, fog, rain, darkness, or dust, strict supervision must be exercised and, if necessary, the lift should be suspended. At sub-freezing temperatures, supervision must ensure that no part of the hoisting device or tackle is shock-loaded or impacted, since brittle fracture of the steel may result.


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2 Mobile Crane Safety2.5 Common Hazards (continued)Electrical Contact

One of the most frequent killers of Riggers and Operators is electrocution caused by an electrical arc or contact between the hoist, load line, or load and a live overhead power line. When a crane is operating near a live power line no encroachment into the limits of approach (see table below) is permitted.

Normal phase-to-phase voltage rating Minimum Distance

750 to 150,000 volts 3 meters or 10 ft.

150,000 to 250,000 volts 4.5 meters or 15 ft.

More than 250,000 volts 6 meters or 20 ft.

DANGER: The wind can blow power lines, hoist lines, or the load. This can cause them to cross the minimum distance.

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2 Mobile Crane Safety2.5 Common Hazards (continued)Hoist line not plumb

The working load limits of hoisting equipment apply only to freely-suspended loads on plumb hoist lines. If the hoist line is not plumb during load handling, side loads are created which can destabilize the equipment and cause structural failure with no warning.


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2 Mobile Crane Safety2.6 Factors that Reduce Hoisting CapacityThe working load limits of all hoisting and rigging equipment are based on almost ideal conditions seldom achieved in the fi eld. It is important the factors that can reduce the lifting capacity of equipment be recognized. Equipment that has its capacity reduced may not be able to lift loads that it otherwise would be able to, and could fail.

Swing

The rapid swinging of suspended load subjects equipment to additional stresses that can cause collapse. The force of the swinging action makes the load drift away from the machine, increasing the radius and side-loading the equipment. The load must always be kept directly below the boom point or upper load block.

Condition of equipment

The rated working load limits apply only to equipment and hardware in good condition. Any equipment damaged in service should be taken out of service and repaired or destroyed.

Dynamic Forces

The working load limits of most rigging and hoisting equipment are determined from static loads and the appropriate design factor is applied to account for dynamic motions of the load and equipment. To ensure that the working load limit is not exceeded during the operation, Employees allow for wind loading and other dynamic forces created by the normal operational movements of the machine and its load. Operators must always avoid the sudden snatching, swinging, and stopping of suspended loads. Rapid acceleration and deceleration can only increase the stresses on both the machine and the tackle.

Weight of tackle

The rated loads of most hoisting equipment do not generally account for the weight of hook blocks, hooks, slings, equalizer beams, and other parts of the lifting tackle. Their combined weight must be subtracted from the load capacity of the equipment to determine the maximum allowable load to be lifted

High Wind Speeds

Almost all crane manufacturers specify in the load chart that chart ratings must be reduced under windy conditions, and they may also recommend a shut-down wind velocity. In almost all cases, when the wind speed exceeds 30 mph (50 kph) it is advisable to stop operations.

Wind affects both the crane and the load, reducing the rated capacity of the crane. Never make a full capacity lift if it is windy. Operators must use a great deal of discretion even when lifting under moderate wind conditions of 20 mph (30 kph).

Operators should be cautious when handling loads that present large wind-catching surfaces. The result could be loss of control of the load and crane even though the weight of the load is within the normal capacity of the crane.

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2 Mobile Crane Safety2.7 Electrical Hazards High voltage electrocution is the largest single cause of fatalities associated with cranes. All can be prevented. The power company or utility may consider (if given advance notifi cation) shutting down the line temporarily or moving the line. If it is not possible to have the line moved or the power shut off the following procedures should be enforced by the Supervisor and strictly followed by all Operators.

Maintain distance. Surrounding every live power line is an area where an electric arc is capable of jumping from the power line to a conductor of electricity. Operators must keep all of their equipment and its load at least the minimum permitted distance away from the power line (see below). If there is a chance for any part of the hoisting operation to encroach on that distance, protective measures must be taken to prevent this encroachment. Operators must take these measures unless they have controlled the hazard by de-energizing or moving the lines, or by rerouting the electricity around the work.

Operators must treat all power lines as live until reliable information assures you that the lines are de-energized.

Identify the voltage of the service by checking markings on the utility pole and calling the utility. When equipment or its load can encroach on the minimum permitted distance from a power line, written procedures must be in place to prevent the equipment or its load from encroaching on the minimum distance.

Power lines should be moved, insulated or de-energized following appropriate precautions. Insulating or “rubberizing” power lines offers some protection in case of brush contact in some circumstances.

Employees must place enough warning devices (such as signs) near the hazard so that the equipment Operator can always see at least one of them. The Operator must be able to see them under all possible environmental conditions (e.g., night, rain, fob). Signs must be specifi c about the hazard.

The Operator’s station (e.g., driver’s cab) must have a sign (such as a sticker) warning of the hazard. The machine may come with a warning sticker in the cab. The sticker must be legible.

A qualifi ed employee must be designated as a signaller to warn the Operator when any part of the equipment, load, or hoist line approaches the minimum permitted distance to a power line. The Signaller must be in full view of the Operator and have a clear view of both the equipment and the electrical conductor.

Employees should avoid using tag lines. Unless it is necessary to prevent the load from spinning into the minimum distance to a power line, the tag line itself can be a hazard because it can swing into the minimum distance.

DANGER: All ropes are capable of conducting electricity.


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2 Mobile Crane Safety2.7 Electrical Hazards (continued)

To reduce electrical hazards, the Operator should slow down the operating cycle of the machine by reducing hoisting, booming, swinging and travel speeds.

The Operator must exercise caution when working near overhead lines that have long spans as they tend to swing laterally in the wind and accidental contact could occur.

The Operator must exercise caution when travelling the crane as uneven ground can cause the boom to weave or bob into the lines.

Employees must ensure that whenever cranes must repeatedly travel beneath power lines a route is plainly marked and “rider poles” are erected on each side of the crossing approach to ensure that the crane structure is lowered to a safe height.

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2 Mobile Crane Safety2.7 Electrical Hazards (continued)In Case of Power Line Contact

If the Operator makes electrical contact with a power line:

Operator must stay on the equipment. Operator must not touch the equipment and the ground at the same time. Touching anything in contact with the ground can be fatal. If a new hazard develops that could be life-threatening, such as a fi re, the Operator should jump clear of the vehicle. He or she must never step down, allowing part of his or her body to be in contact with the ground while any other part is touching the machine.

No others may approach. No one else should touch the equipment or its load – including buckets, outriggers, load lines, or any other part of the machine. Employees should beware of time-delayed relays: Even after electrical contact trips the breakers, relays may still try to restore power. They may come on automatically two or three times.

Operator should attempt to break contact. If possible – while remaining inside the machine – the Operator should try to break contact by moving the equipment clear of the wires. This may be impossible if contact has welded conductors to the equipment.

Supervisor or other employee must call the local utility. Operator must get someone to call the local utility for help. Operator must stay on the equipment until the utility shuts down the line and confi rms that the power is off.

Supervisor must report the contact. Supervisor or other employee must report every incident of electrical contact to the local electrical utility – they’ll check for damage that could cause the line to fail later.

When the power line is rated at 750 volts or more:

1. Supervisor or other employees must report the contact to the inspection department of the Electrical Safety Authority within 48 hours.

2. Provide notice in writing to the Ministry of Labour and to the joint health and safety committee, health and safety representative, and the trade union. Employees must inspect the crane. The crane must undergo a complete inspection for

possible damage caused by electrical contact. The electric current could take several paths through the crane, damaging bearings, electronic controls, valves, and the crane’s cable. Wire rope must be replaced. Damage to the wire rope – such as welding, melting, or pitting – may not be visible.


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2 Mobile Crane Safety2.8 Other Hazards in Crane Operating AreasThe majority of all mobile crane accidents are the result of mistakes made when the crane was being set up. These accidents can be prevented by following the manufacturer’s recommendations for assembly and dismantling, by using the correct components, and by observing the precautions outlined in this section. Improvising or taking shortcuts during setup can be fatal.

To stay safe while a load is hoisted, Riggers must:

1. Stay alert during the lift2. Watch the load3. Not turn their back on a load4. Not place any body parts between the sling and the load5. Not stand under suspended loads6. Stand clear of suspended loads7. Not ride the load or the hoist line.

Boom Angle

The capacities listed in the load chart are also based on and vary with the boom angle of the machine.

On telescopic boom cranes, the boom angle is the angle between the base (bottom) of the heel section of the main boom and the horizontal while the boom is under load.

Because of boom and machine defl ection, the boom angle will lower somewhat from its un-loaded condition once a load is applied. Boom angle reductions will be even larger when the crane is “on rubber” because of tire defl ection.

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2 Mobile Crane Safety2.8 Other Hazards in Crane Operating Areas (continued)Load Radius

The capacities listed in the load chart also depend on and vary with the crane’s load radius. The load radius is the horizontal distance measured from the center of rotation of the crane (center pin) to the load hook (center of gravity of the load) while the boom is loaded.

Because of boom and machine defl ection and pendant stretch, the load radius will increase when the load is lifted off the ground. When the crane is “on rubber” because of tire defl ection, the increases in radius will be even larger.

Boom Angle Indicators and Critical Lifts

Boom angle indicators are required on all mobile cranes but they must not be relied on for accuracy during critical lifts because:

They can give as much as a 2° reading error in boom angle which can substantially affect the gross capacity reading on the load chart.

The indicators are mounted on the base section of the boom and may not register the defl ection of the extended sections under heavy load particularly if the wear pads are worn excessively. Consequently, the boom angle may actually be lower than the indicator reads.

For these reasons, using boom angle indicator readings during critical lifts can be misleading. Operators should rely on load radius (where possible) or if the boom angle must be used (for example when lifting from a jib), they should assume the correct reading to be lower than what the indicator usually says.


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2 Mobile Crane Safety2.8 Other Hazards in Crane Operating Areas (continued)Importance of Quadrants

The leverage and capacity of a crane change during rotation of the upperworks. Leverage and capacity are also affected by the location of the tipping axis. For these reasons the crane’s stability can change during operation.

To provide uniform stability, regardless of the position of the upperworks relative to the carrier, the crane’s capacity is adjusted by the manufacturer according to the quadrant of operation.

These capacity changes are identifi ed in the load chart by the quadrant of operation.

Sweep Area

The sweep area is the total area that the crane boom can swing over.

The sweep area is divided into operating areas called quadrants of operation. The crane’s capacity is then based on the quadrants.

Division of Sweep Area into Quadrants

The crane is said to be in a particular quadrant of operation when the load hook is located over that portion of the sweep area.

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2 Mobile Crane Safety2.9 Outrigger SafetyThe load chart ratings of carrier-mounted and rough terrain mobile cranes apply to three base confi gurations:

On outriggers On tires Partially extended outriggers.

On Outriggers

Full chart ratings apply only when:

All outrigger beams are fully extended, and All tires are clear of the ground.

Partially Extended Outriggers

In special circumstances, a crane may be operated on outriggers that are not fully extended. In this situation the crane must be equipped with load charts coinciding with this partial extension of the outriggers and there must be a method of measuring the outrigger extension.


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2 Mobile Crane Safety2.9 Outrigger Safety (continued)Soft Footing

Load chart ratings apply only when the ground conditions are fi rm enough to support the crane and keep it level during the lift. If the ground is soft or unstable, the tires, crawlers, or outriggers will sink or subside, causing loss of capacity. In almost all cases, heavy duty blocking having large bearing areas will be necessary to prevent sinking and provide a solid base for the crane.

Level Crane

All load chart ratings are based on the machine being perfectly level in all directions. This applies to cranes “on crawlers”, “on tires”, “on outriggers” and when travelling with load.

One of the most severe effects of being out-of-level is that side loads develop in the boom. Because of side loads all mobile cranes lose capacity rapidly as the degree of out-of-level increases.

When a crane is set up off level, swinging from the high side to the low side increases the operating radius. It also increases the load on the turntable, on outriggers ad on the supporting frame structure.

CAUTION: If the crane is not level, the load chart does not apply. The Operator must either level the crane by using its outriggers or level the ground the machine is resting on. Even though the crane might have been properly levelled during set-up, ground subsidence during operation can cause an out-of-level condition. Operators should check level frequently.

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2 Mobile Crane Safety2.9 Outrigger Safety (continued)Sideloading

Load chart ratings apply only when the load is picked up directly under the boom tip. If the load is to either side of the boom tip, side-loading occurs and decreases capacity. This applies to both lattice and telescopic booms and is one of the most common causes of boom failure. It usually causes structural failure and always occurs without warning.


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2 Mobile Crane Safety2.9 Outrigger Safety (continued)Increase of Load Radius

Load chart ratings apply only when the hoist line is vertical at all times and the load is freely suspended during the lift. If the line is not vertical, regardless of the reasons, capacity is lost. In addition to the examples relating to side loading, the following conditions produce non-vertical hoist lines which result in increased load radius.

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2 Mobile Crane Safety2.9 Outrigger Safety (continued)Rapid Swing Rate

Load chart ratings apply only when the load is vertically in line with the boom tip at all times. Rapid swing rates bring the load out of vertical and decrease the stability of the crane. Therefore, load chart capacities do not allow for fast swings.

The swing rate must be adjusted to keep the load directly below the boom tip at all times.

DANGER: On long boom mobile cranes, rapid swing rates, rapid swing acceleration, or rapid application of the swing brake can overturn the crane or collapse the boom with or without load on the hook.

Moving the dead weight of the boom at the start of a swing or trying to stop it at the end of a swing causes the boom to sideload itself.

The centrifugal force of the boom during a high speed swing causes a high forward tipping load.

At high boom angles, the boom can collapse over the back of the machine if the boom is accelerated or decelerated rapidly.

Impact Loading and Rapid Acceleration or Deceleration of Load

Load chart capacities do not allow for sudden starting or stopping of the load, impact loading or sudden machine movements.


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2 Mobile Crane Safety2.10 Pre-Operation Site InspectionIf a working area has not been adequately prepared for the crane, the operation will be unsafe, regardless of machine capacity or operator skill. Employees must consider the following factors.

Appropriate equipment

Wire and web slings in good condition and of suffi cient capacity are available A mobile crane (Grove or Terex) in good condition and of suffi cient capacity is available Mats or other equipment that may be necessary for the use of outriggers is available, if

needed.

Clear work area

No objects are in the path of the crane or the crane’s cargo as the operator performs hoisting tasks

Other employees or cargo are prevented from entering the path of the crane or the crane’s cargo as the operator performs hoisting tasks.

Correct signage

Necessary signage and marking tape has been placed to indicate the unsafe zone around the crane

Potential hazards that cannot be removed or controlled have been indicated with signs and/or marking tape, if necessary.

Unobstructed visibility

No objects obstruct the crane operator’s view of the crane, the cargo or the destination. No objects obstruct the crane operator’s view of any safety signage or marking tape No objects obstruct the view of signallers or other employees who observe crane operations

and signal to the crane operator.

Roles and responsibilities

If necessary, an employee has been assigned to observe the crane’s boom and signal to the crane

The Signaller is familiar with all of the necessary hand signals The Signaller is wearing appropriate PPE, including hi-visibility vest.

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3 R

iggingMOBILE CRANE TRAINING PROGRAM


Modules

1 Introduction

2 Safety

3 Rigging

4 Hoisting

5 Grove Cranes

6 Terex Cranes


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1 Introduction1.1 OverviewA variety of slings, chains, wire ropes, and hardware are used in the operation of mobile cranes. The rigger must be able to rig the load to ensure its stability when lifted. This requires knowledge of safe sling confi gurations and the use of the related hardware used on hoisting operations on the waterfront.

This section describes the common equipment used for rigging with mobile cranes. This is not exhaustive list. Riggers should be familiar with the equipment and its limitations before rigging loads.


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2 Equipment2.1 Wire Rope SlingsMany factors infl uence the selection of wire rope. Rope strength, although of major importance, is only one factor. Pay attention to other factors such as size grade, type and construction. These factors will infl uence their suitability for specifi c lifts. Wire rope slings should not be used around fl ame cutting or welding operations.

All wire rope slings must have an identifi cation tag. This tag must be legible and indicate the safe working load of the sling.

Employees should only handle wire rope when wearing gloves. Employees must never insert tools or body parts into coils of wire rope or between wire rope and the load.

2.2 Inspecting Wire Rope SlingsRiggers must inspect all equipment prior to use. Conditions such as the following should be looked for during inspection:

Broken Wires

Occasional wire breaks are normal for most ropes and are not critical provided they are at well-spaced intervals. Note the area and watch carefully for any further wire breaks. Broken wire ends should be removed as soon as possible by bending the broken ends back and forth with a pair of pliers. This way, broken ends will be left tucked between the strands.

Regulations under The Occupational Health and Safety Act establish criteria for retiring a rope based on the number of wire breaks.

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2 Equipment2.2 Inspecting Wire Rope Slings (continued)Worn and Abraded Wires

Abrasive wear causes the outer wires to become “D” shaped. These worn areas are often shiny in appearance. The rope must be replaced if wear exceeds 1/3 of the diameter of the wires.


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2 Equipment2.2 Inspecting Wire Rope Slings (continued)Reduction in Rope Diameter

Reduction in rope diameter can be caused by abrasion of outside wires, crushing of the core, inner wire failure, or a loosening of the rope lay. All new ropes stretch slightly and decrease in diameter after being used.

Rope Stretch

All steel ropes will stretch during initial periods of use. Called “constructional stretch”, this condition is permanent. It results when wires in the strands and strands in the rope seat themselves under load. Rope stretch can be recognized by increased lay length. Six-strand ropes will stretch about six inches per 100 feet of rope while eight-strand ropes stretch approximately 10 inches per 100 feet. Rope stretched by more than this amount must be replaced.

Corrosion

Corrosion is a very dangerous condition because it can develop inside the rope without being seen. Internal rusting will accelerate wear due to increased abrasion as wires rub against one another. When pitting is observed, consider replacing the rope. Noticeable rusting and broken wires near attachments are also causes for replacement. Corrosion can be minimized by keeping the rope well lubricated.

Crushed, Flattened or Jammed Strands

These dangerous conditions require that the rope be replaced. They are often the result of crushing on the drum.

High Stranding and Unlaying

These conditions will cause the other strands to become overloaded. Replace the rope or renew the end connection to reset the rope lay.

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2 Equipment2.2 Inspecting Wire Rope Slings (continued)Bird Caging

Bird caging is caused by the rope being twisted or by a sudden release of an overload. The rope, or the affected section, must be replaced.


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2 Equipment2.2 Inspecting Wire Rope Slings (continued)Kinks

Kinking is caused by loops that have been drawn too tightly as a result of improper handling. Kinks are permanent and will require that the rope, or damaged section, be taken out of service.

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2 Equipment2.2 Inspecting Wire Rope Slings (continued)Core Protrusion

Core protrusion can be caused by shock loads and/or torsional imbalance. This condition requires that the rope be taken out of service.

Electrical Contact

Rope subjected to electrical contact will have wires that are fused, discoloured or annealed and must be removed from service.

DANGER: Even if a rope does not look damaged, if it has had electrical content, internal strands may be fused or annealed. The rope must always be removed from service following electrical contact.

Worn or Damaged Sheaves

Sheaves with deeply worn or scored grooves, cracked or broken rims, and worn or damaged bearings must be replaced.


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2 Equipment2.3 Inspecting Web SlingsWeb slings are very common on the waterfront. These slings are very strong and durable. They are also relatively easy to work with. Web slings offer a number of advantages for rigging purposes.

Their relative softness and width create much less tendency to mar or scratch the surface of the object and they have less of a tendency to crush fragile objects.

They tend to mould themselves to the shape of the load. They do not rust. They minimize twisting and spinning during the lift. Their light weight make them easier to work with.

If any of the identifi cation items are missing or any of the listed damage criteria are met the sling must be destroyed.

Identifi cation: Web slings must be permanently identifi ed with the manufacturer’s name or mark, manufacturer’s code or stock number, working load limits for the types of hitches permitted, and type of synthetic web material.

Damage: A web sling must be removed from service when any of the following circumstances occurs:

The length of an edge cut exceeds the web thickness The penetration of abrasion exceeds 15% of the webbing thickness taken as a proportion of

all plies Abrasion occurs on both sides of the webbing and the sum of the abrasion on both sides

exceeds 15% of the webbing thickness taken as a proportion of all plies Warp thread damage up to 50% of the sling thickness extends to within 1/4 of the sling width

of the edge or exceeds 1/4 the width of the sling Warp thread damage to the full depth of the sling thickness extends to within 1/4 of the sling

width of the edge or the width of damage exceeds 1/8 the width of the sling Weft thread damage allows warp thread separation exceeding 1/4 the width of the sling and

extends in length more than twice the sling width Any part of the sling is melted or charred, or is damaged by acid or caustic Stitches in load bearing splices are broken or worn End fi ttings are excessively pitted or corroded, cracked, distorted or broken A combination of the above types of damage of approximately equal total effect is present.

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2 Equipment2.4 Rigging HardwareIt is important to know the working load limit of the hardware in comparison to the rope, chain or web sling used in conjunction with it.

All fi ttings must be of adequate strength for the application. Only forged alloy steel load-rated hardware shall be used for hoisting operations. Load-rated hardware will have the working load limit stamped on the equipment. Common equipment includes:

Hooks

Hooks should be equipped with safety catches (except sorting or grab hooks) and must be forged steel with WLL markings clearly visible. It is important that hooks should be loaded at the middle of the hook. Applying the load to the tip of the hook could drastically reduce the safe working load.


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2 Equipment2.4 Rigging Hardware (continued)Shackles and Swivels

Whenever multiple lines (2 or more) are placed over a hook, a shackle or a swivel should be used. This reduces the stress on the lines and prevents the lines from slipping off the hook. Shackle and swivels must be forged alloy steel and have the WLL clearly marked. Swivels should be used when the load may twist. This will allow the load to orient itself freely. A bolt is not an acceptable replacement for a shackle pin. This is incompatible equipment and may result in an equipment failure.

Lifting Cages

Lifting cages are used to lift cargo. Typically pallets are loaded into the lifting cage and the cage is lift to the ship. It is important to know the WLL of the lifting cage and the approximate weight of the load. The WLL should be clearly marked on the lifting cage.

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2 Equipment2.4 Rigging Hardware (continued)Spreader and Equalizer Beams

Spread beams are usually used to support long loads during lifts. They eliminate the hazard of the load tipping, sliding, or bending as well as the possibility of low sling angle and the tendency of the slings to crush the load.

Equalizer beams are used to equalize the load in sling legs and to keep equal loads on dual hoist lines when making tandem lifts.

Spreader and equalizer beams are both normally fabricated to suit a specifi c application. If a beam is to be used which has not been designed for the application, make sure that it has adequate width, depth, length and material.

The capacity of beams with multiple attachment points depends on the distance between the points. For example, if the distance between attachment points is doubled, the capacity of the beam is cut in half.

Snatch Blocks

A snatch block is a single or multi-sheave block that opens on one side so a rope can be slipped over the sheave rather than threaded through the block. They are available with hook, shackle, eye and swivel end fi ttings.

Snatch blocks are normally used when it is necessary to change the direction of pull on a line. Stress on the snatch block varies tremendously with the angle between the lead and load lines. With both lines parallel, 1000 pounds on the head line results in 2000 pounds on the block, hook, and anchorage. As the angle between the lines increases, the stress is reduced.

Chains

Chains should be inspected on a link by link basis on a regular basis and whenever the chain has been exposed to shock or load impacts. Chains should carry a small metal identifi cation tag showing the safe working load and the serial number. When chains are inspected, Riggers should check for:

Cuts Chips Gouges Worn links at the bearing surfaces Twists or knots in the chain.


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2 Equipment2.5 Inspecting Rigging HardwareA thorough inspection of all hardware should be conducted prior to beginning lifting operations. It is also recommended that equipment be quickly inspected before each lift. This is especially important for critical lifts.

Riggers look for the following when inspecting hooks:

Wear – no greater the 10% wear is permissible Cracks Severe corrosion Deformation/bending Mismatched parts Obvious damage Missing or illegible WLL markings Incompatible equipment.

2.6 Rigging Operations

Sling Angles

The rated capacity of any sling depends on its size, its confi guration, and the angles formed by its legs with the horizontal.

For instance, a two-leg sling used to lift 1000 pounds will have a 500-pound load on each leg at a sling angle of 90º. The load on each leg will go up as the angle goes down. At 30º the load will be 1000 pounds on each leg.

Sling angles must be greater than 45º whenever possible. The use of any sling at an angle lower than 30º is ex-tremely hazardous. This is especially true when an error of only 5º in estimating the sling angle can be so danger-ous.

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2 Equipment2.6 Rigging Operations (continued)Pre-operation setup

Before rigging, Riggers must inspect slings to ensure their safety and ensure that slings are long enough so that their rated capacity (WLL) is adequate when the sling to load angle is taken into consideration. Riggers may use only slings and rigging hardware with legible identifi cation tags or WLL markings..

Rigging Precautions

Riggers must rig loads to prevent any parts from shifting or dislodging during the lift Suspended loads should be securely slung and properly balanced before they are set in

motion Riggers must never wrap the hoisting line around the load Riggers must attach the load to the hook by slings or other rigging devices adequate and

suitable to the load being lifted Riggers must ensure that the sling angle is always greater than 45°.

Operating Practices

When rigging a load in preparation for hoisting, Riggers must:

Determine the weight of the load Verify that the weight of the load is within the rated capacity of the rigging equipment Select a sling that has suitable characteristics for the type of load, hitch and environment. Do

not load rigging equipment or slings in excess of the rated capacity. Consideration shall be given to the sling to load angle.

If the sling has fi ttings, which are used in a choker hitch, verify that they are of suffi cient length to assure that the choking action is on the webbing, and is not on the fi tting, the base of the eye or fi tting, the load carrying splice or the sling tag.

Verify that the openings in the fi ttings are the proper shape and size to ensure that the fi tting will seat properly in the hook or other attachments.

Ensure suffi cient protection to protect the slings from being cut or damaged by corners, edges, protrusions or abrasive surfaces. Protection should also be provided to ensure the load is not damaged.

NOTE: Web slings should not be dragged on the fl oor or over abrasive surfaces.

Ensure the load is centered on the base of the hook to prevent point loading on the hook.


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49

4 H

oistingMOBILE CRANE TRAINING PROGRAM


Modules

1 Introduction

2 Safety

3 Rigging

4 Hoisting

5 Grove Cranes

6 Terex Cranes


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1 Equipment1.1 Hoisting EquipmentRough Terrain Cranes

Rough Terrain Cranes are short wheel-base hydraulic cranes, usually on oversized tires, which enable them to move across uneven sites. Because of the tire size, they also have excellent pick and carry capacities. Rough Terrain Cranes are preferred in refi neries, pulp mills and in the coastwise operations because of their compact size and crab steering ability, enabling them to manoeuvre in tight areas.

Coastwise operations are typically performed using Terex and Grove Rough Terrain Mobile Cranes. The following general information applies to all rough terrain cranes:

Boom length: Each section of boom decreases the lifting capacity of the crane – check the load charts to ensure capacity is not exceeded.

Boom angle: Boom angle is also used to determine the capacity of the crane. Operators often use the boom angles on the load as the true determinant in assessing radius.

Load radius: The centre of the load to the centre of rotation of the crane. Deductions from gross capacity: All weights below the boom tip on the load line including

rigging and hooks, must be added to the weight of the load to determine the gross weight of the load. The allowable weight in the chart for each confi guration of boom and radius must be greater than this gross weight of the load.

Crane Charts

Crane Charts are an invaluable tool for the Operator and Rigger. Operators and Riggers must follow crane charts to the letter. Failure to do so can result in damaged cranes, damaged slings, serious injury and death.


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2 Inspections2.1 Pre-operation InspectionPre-operation inspections are mandatory and must be done before using any piece of equipment. Faults must be reported to the Trainer or Foreman. When approaching the machine, Operator must visually inspect all equipment. Operator should take note of any strange noises (such as air leaks), or smells (such as propane leaks or hot brakes) coming from the machine.

Pre-operation Inspection Checklist

1. Operator fi rst ensures there are no personnel working on, in, under or around the machine.

2. Operator checks for damage, cracks, excessive wear, abnormal movement or leaks on hydraulic cylinders

3. Operator checks hydraulic system: a. Crushed lines or hoses b. Spilled oils and grease c. Bulging or chafed hoses d. Loose or broken lines, hoses or fi ttings.

4. Operator checks for fl uid leaks: a. Hydraulic oil b. Engine oil c. Engine coolant.

5. Operator checks the following components and areas for leaks, material build-up, bent, broken, damaged or missing parts:

a. Mirrors b. Lights c. Wipers d. Side access doors e. Steps f. Hand holds g. Windows h. Refl ectors i. Operator’s cab.

6. Operator reports any damage (especially recent damage) or problems to Foreman before operating the mobile crane.

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2 Inspections2.2 Interior Cab Check Checklist

1. Operator checks the condition of the cab and cleans up if required2. Operator ensures there are no warning lights on

NOTE: If there is a warning light on, Operator must not operate the machine until the problem has been corrected by a mechanic

3. Operator ensures the fi re extinguisher is secure in its designated location4. Operator ensures all windows and mirrors are clear5. Operator adjusts the operator’s chair so that all controls are within comfortable range6. Operator reports any concerns or damage to Foreman before operating the mobile crane.


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3 Operations3.1 Preparing load for a liftBefore making a lift, loads must be safely landed and properly blocked before being unhooked and unslung. All lifting beams must be plainly marked with their weight and designed working loads and should only be used for their intended purpose. The load line should be brought over the load’s center of gravity before the lift is started.

Before making a lift, the Rigger must:

Check to see that the sling is properly attached to the load Never point-load a hook unless it is designed and rated for such use Make sure that the load is free before lifting and that all sling legs are taking the load When using two or more slings on a load, ensure that they are all made from the same

material Prepare adequate blocking before loads are lowered. Blocking can help prevent damage to

slings

Estimating Crane Capacity

The net capacity is determined as follows:

1. Employee determines weight of load to be lifted.2. Employee determines weight of slings and rigging hardware to be used.3. Employee determines parts of line required and hook / block weight.4. Employee determines load radius, boom length and boom angle.5. Employee selects correct main boom load chart based on the crane’s actual confi guration and

quadrant(s) of operation.6. Employee reads the gross capacity from the main boom load chart, based on the load radius,

boom length and boom angle.7. Employee determines capacity deductions.8. Employee calculates net capacity: Net Capacity = Gross Capacity – Capacity Deductions.9. Employee compares net capacity to the weight of the load to be lifted.

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3 Operations3.2 Loading/DischargeSetting up start of loading / discharge operations

Once mobile crane is in position and as directed by Foreman, Employees secure save-all to the side of the vessel and secure the platform to the side door of the vessel.

Hook Up Cage

1. Forklift Driver positions cage for mobile crane hook up.2. Employees hook up cage as directed by Foreman.3. Employees then position pallet jacks in the cage.4. Crane Operator lifts cage and places it on platform.5. Employees from the ship remove pallet jacks for ship unloading and loading.

End of Shift

1. Crane Operator positions cage on dock.2. Employees unhook cage for Forklift Driver to remove.3. Crane Operator removes platform from side of vessel.4. Forklift Driver then removes the platform.5. Crane Operator removes the save-all and places it on dock. 6. Employees will roll up the save-all and stow along side of bullrail.


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rove Cranes



Modules

1 Introduction

2 Safety

3 Rigging

4 Hoisting

5 Grove Cranes

6 Terex Cranes


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Notes

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1 Introduction1.1 ControlsStart-up

1. Operator confi rms that the “ON”/”OFF” battery switch, located at driver’s side, is “ON”.

2. Once inside operator’s cab, Operator places the transmission in neutral.

3. Operator turns the key to start the crane.

4. System Test will be displayed on touch screen.


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1 Introduction1.1 Controls (continued)Touch screen controls:

1. Push #1 for English. Press E to confi rm.2. Press INFO 5 times. Press E to confi rm.3. Press INFO to display the screen that prompts you for the code.4. On the Numeric Keypad enter Code #1. Press E to confi rm.5. Code 0001 will be displayed. 6. Press symbol “PLACEHOLDER, see original Mobile Crane manual p. 28” next to Keypad

for Winch.7. Press INFO, then #2 for two part line. Press E to confi rm.8. Outriggers positioned correctly? Press E to confi rm.9. Crane on fi rm supporting surface? Press E to confi rm.10. Crane is now ready to operate.

1.2 ProceduresUsing the Steering System

Steering wheel controls the front steering Rear Wheel Lever controls the rear steering Operator uses both in combination to obtain crabbing and 4 wheel operations.

Adjustable Throttle for Setting RPM

1. Operator pulls lever out and twist right to lock RPM.2. Operator twists left to release (unlock).

Positioning Outriggers (out and in)

To raise outriggers, Operator holds down the buttons on right side of console, then pulls down on right lever.

To lower outriggers, Operator holds button down and pushes lever forward.

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6 Terex C

ranesMOBILE CRANE TRAINING PROGRAM


Modules

1 Introduction

2 Safety

3 Rigging

4 Hoisting

5 Grove Cranes

6 Terex Cranes


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Notes

63

6 Terex C

ranesMOBILE CRANE TRAINING PROGRAM


1 Introduction1.1 ControlsStart-up

1. Operator confi rms that the “ON”/”OFF” battery switch, located at driver’s side, is “ON”.2. Once inside operator’s cab, Operator places the transmission in neutral.3. Operator turns the key to start the crane.4. Operator waits for the computer light to go out.5. Operator presses the bottom red light on the computer.6. Operator pushes the Start button.7. Operator lets the crane warm up.


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1 Introduction1.2 ProceduresUsing the Steering System

When switching steering modes the Axle Centering Indicator Light (red) must be OFF, indicating wheels are properly aligned

Crane must be stopped when changing steering modes Steering mode switch is located next to the seat on the left side

o Set switch to middle position for 2 wheel drive

o Set switch to left position for 4 wheel drive

o Set switch to right position for crabbing.

Adjustable Throttle for Setting RPM

Operator pulls the lever out and pushes button to lock RPM Operator pushes button in to release RPM.

Positioning Outriggers (out and in)

To raise outriggers, operator holds down the buttons on right side of console, then pulls down on right lever.

To lower outriggers, operator holds button down and pushes lever forward.

NOTE: If boomed up past the limit, the Operator turns the key on the Computer Control Panel to the right and holds it until the boom is down to the limit.

In Case of Hydraulic Line Burst

DANGER: If a hydraulic line bursts, Operator must turn the mobile crane “OFF”

Bypass lever is located at back (rear) of swing circle (crane turret), Operator pulls lever to bypass the hydraulic system.

Power steering is unaffected and it is safe for Operator to move the crane.

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