Don't Gamble With Your Lifting Equipment: LMM LMP RCS
Don't Gamble With Your Lifting Equipment: LMM LMP RCS
When it comes to overhead lifting, nothing should be left to chance. Stay safe in the
knowledge that TEAM cards are only issued to employees of LEEA member companies who
have passed LEEA's rigorous Diploma examination.
2 3
Signed __
First Edition .July 2015
Date
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or
transmitted in any form or by any means, without the prior written permission of the Lifting
LEEATraining Facilitator Equipment Engineers Association.
I agree to:
• Safeguard the health, safety and welfare of my students throughout the training programme
• Provide my students with quality training, maintaining the highest of professional standards
throughout
• Maintain confidentiality for all students at all times
• Provide regular feedback to students on their progress, identifying areas which may need
additional study
• Keep appropriate records of any assessments conducted
• Ensure that all students are able to discuss any issues or concerns which may arise during
the training course
Signed __
Date
©LEEA Academy - MCE - Step Notes - July 2015 - v1.4 ©LEEA Academy - MCE - Step Notes - July 2015 - vl.4
Introd uction Legislation
• Because of the propensity to build towering structures, mobile telescoping cranes are
playing an essential role in the construction, maintenance and freight industries globally
• Their ever increasing capacity (1,200 tonnes at present) mobility, versatility and speed of
erection allow them to be quickly adapted for difficult, unusual tasks giving all industries
greater capabilities to achieve the incredible . n
g\s\at\O
Le rnent.,
g Overn r.o
• Internationally, legislation, regulations or standards concerning mobile cranes are not always u\ote,
clear or being adhered to to reg o , r.o
• As a result, incidents involving mobile cranes appear to be on the increase and damage to
property, injuries to persons or even fatalities are a result
Moral, legal and Financial reasons for Health and Safety legislation
• Economically, the outcome of this is loss of business, increased insurance costs and a loss of • Employers have a moral responsibility to ensure appropriate working conditions are
confidence in crane operations provided
• By increasing the level of knowledge and understanding in this field it is hoped to achieve a • Financial cost from loss of output
significant decrease in adverse occurrences
legislation
• Most countries in the European Free Trade Area have similar laws
• 2 types of Directives:
o Those that remove barriers to trade
o Those that concern health and safety
©LEEA Academy - MCE - Step Notes - July 2015 - v1.4 ©LEEA Academy - MCE - Step Notes - July 2015 - vl.4
Duty of Care
• Lifting equipment legislation calls for:
o Requirements for desig
Employer and employee have a common law duty of care to each other and to other
o Condition of the equipment
o The manner in which it is used) employees.
• General in nature
• Ensure that articles they design, construct, make, import, supply etc. are safe and without
• Employers
essential conditions for dismantling and disposalf
• Employees
• Ensure that customers are given updated information where it becomes known that the
Machinery: "an assembly, fitted with or intended to be fitted with a drive system other than directly
applied human or animal effort, consisting of linked parts or components, at least one of which
moves, and which are joined together for a specific application".
Manufacturer responsible for verifying whether a particular product falls within the scope of the
Machinery Directive.
• No person (i.e. not just employees) shall knowingly, intentionally or recklessly misuse, or
Implemented in the United Kingdom under the Supply of Machinery (Safety) Regulations 2008
interfere with anything provided in the interests of health, safety and welfare
• Manufacturers to issue information for care and safe use of lifting equipment
"0ne who has the requisite knowledge and experience, both theoretical and practical, of the type ofl Supply of Machinery (Safety) Regulations 2008 (Originally 1992)
material under examination to certify with confidence whether it is free from patent defects and}
suitable in every way for the duty for which the article is required. "I • Implements the European Machinery Directive within the U.K
©LEEA Academy - MCE - Step Notes - July 2015 - v1.4 ©LEEA Academy - MCE - Step Notes - July 2015 - v1.4
]
Under the Supply of Machinery (Safety) Regulations 2008, machinery needs: SWL - Safe Working Load
The maximum load or mass (as certified by a competent person) that an item of lifting equipment
may raise, lower or suspend under particular service conditions. It is the SWL which is required to be
• A Declaration of Conformity (DOC) I
marked on the item by LOLERand which appears on any report of thorough examination.
• To be "CE" marked
MBl- Minimum Breaking Load FO?
The minimum breaking load is the calculated load at below which the item will not break or fail due
• A "technical file" t
to distortion.
An EC Declaration of Incorporation (001) is a device to legally market machinery which can function,
Coefficient of Utilisation/Factor of Safety/Working Coefficient
but is not complete and may not be safe] Such machinery is not to be used until incorporated into an
It is a factor which is applied to the MBL to determine the WLL. It varies with the product to take
assembly for which a DOC has been issued - in doing so you assume the obligations of the
account of the susceptibility to damage and considers the type of stresses the item will meet in
manufacturer of the finished assembly.
normal use.
Dynamic Test
1.1 x W.L.L
Lifting machinery is operated in all its possible configurations at the maximum working load
multiplied by the appropriate dynamic test coefficient with account being taken of the dynamic
behaviour of the lifting machinery in order to check that it functions properly.
Key Definitions from the Machinery Directive
©LEEA Academy - MCE - Step Notes - July 2015 - v1.4 ©LEEA Academy - MCE - Step Notes - July 2015 - v1.4
Equipment first provided for use after 31st December 1992 must comply with any 'essential
PUWER and LOLER
requirements'
These are legal requirements in the UK. • Technical mismatch between the supply side and user side legislation
Internationally these are good practice demanded by customers and local authorities and are Employers can ensure compliance by checking:
PUWER places duties on the employer to ensure that: PUWER requires that, when providing equipment for use at work:
• Work equipment is suitable for the purpose for which it is to be used The purchaser obtains equipment complying with the relevant European Directives.
• The working conditions and risk to health and safety of personnel in which the work E.g. In the case of grade 8 mechanically assembled chain slings, specifying BS EN 818-4 and
requesting the EC Declaration of Conformity will ensure that the slings meet this requirement.
• Equipment is suitably maintained and a log kept up to date PUWER Key Regulations I
• Equipment is inspected on a regular basis (ref. LOLER) • Regulation 4: Suitability of work equipment
• All inspection and maintenance records are kept and recorded • Regulation 5: Maintenance
• All persons using work equipment have sufficient information pertaining to its use, e.g. • Regulation 6: Inspection
PUWER requires employer to address risks or hazards of equipment from all {lites) of manufacture • Regulation 8: Information and instructions
and supply.l
• Regulation 9: Training
NOTES
Applicable to all areas of industry within GB including offshore installations. A mobile crane used for lifting people should be adequate and suitable for the task, have a freefall
'I -rr £' u \ II capability lock-out and should be equipped with appropriate devices such as a hoisting limiter,
Ib..O¥()"'1'" (. ~\ ......n.,.... "r' "'-4p«-.I,b...,
Covers existing used leased and new equipment. lowering limiter, rated capacity indicator and rated capacity limiter. The carrier should be adequately
attached to the crane (e.g. by a shackle or a hook with a latch). The crane and carrier should be
inspected every day by someone competent to do so (e.g. trained operator, person in charge of the
lifting Operation:
An operation that includes lifting and lowering of a load. The "load" includes people. lift, etc.) and if it is not regularly used then before it is first used each time it is put into service and
ever.y day it is used. The crane and associated equipment should be suitably de-rated (by 50%) and
lifting Equipment: the crane should be operated in accordance with the recommendations in the BS 7121 series of
Any work equipment used for lifting or lowering loads and includes attachments used for anchoring, standards.
• Lifting equipment is of adequate strength and stability for each load, particularly when stress
may be induced at mounting or fixing points
• Every part of a load and anything attached to it and used in lifting is of adequate strength
©LEEA Academy - MCE - Step Notes - July 2015 - vl.4 ©LEEA Academy - MCE - Step Notes - July 2015 - v1.4
J
Written Scheme of Examination
Regulation 7: Marking of lifting equipment
Should be produced by a Competent Person, taking account of conditions of use, frequency of use
All lifting equipment to be marked with its SWL and information that gives the items characteristics, and type of load being handled.
e.g. boom length, radius, capacity (load charts) etc.
Example: a crane which is used infrequently in a clean environment
• Must be planned by a competent person • Written scheme could be used to specify which parts of the crane are inspected, paying
attention to the wire rope or chain and all safety devices
• Must be supervised
The written scheme is to be fully detailed to reflect the risk associated with the various component
parts.
• Must be carried out in a safe manner
Exceptional circumstances - such as a sudden and unexpected shock loading or a major repair to a
load-bearing component - require a Thorough Examination before placing the equipment back into
Regulation 9: Thorough examination and inspection
service, irrespective of whether or not it is due for its regular periodic examination.
Before lifting equipment is put into service for the first time it is thoroughly examined for any defect
unless the lifting equipment: Dependant on the associated risks, additional (non-routine) detailed inspections may be necessary
at regular intervals between the thorough examinations to ensure that no damage or deterioration
has occurred.
• Has not been used before
Regulation 10: Reports and defects
16 17
• Is less than 12 months old
A person making a thorough examination for an employer under regulation 9 shall:
• Owner holds the original DOC
• Notify the employer immediately of any defect in the lifting equipment which in his opinion
Maximum fixed periods for thorough examinations and inspection of lifting equipment are: - is or could become a danger to persons
• Lifting accessories 6 months • As soon as is possible, make an examination report in writing authenticated by him or on his
behalf by signature or equally secure means and containing the information specified in
• Lifting equipment.. 12 months Schedule 1 to the employer
• Man-Riding Equipment 6 months • Where there is in his opinion a defect in the lifting equipment involving an existing or
imminent risk of serious personal injury, send a copy of the report as soon as is possible to
The information to be contained in the report of thorough examination is given in schedule 1 of the relevant enforcing authority
LOLER.
Every employer who has been notified shall ensure that the lifting equipment is not used before the
defect is rectified.
NOTES
• Keep the EC declaration of Conformity for so long as they operate the lifting equipment
Lifting
Standards
• Ensure that the information contained in every report is kept available for inspection.
Worldwide
-----_._---
In the case of a thorough examination for lifting equipment:
Code of Practice
• Until he ceases to use the lifting equipment for the Safe Use
of Lifting
Equipment
In the case of a thorough examination for lifting accessories:
• For two years after the report is made
lOlER refers to 'Thorough Examination and Inspection' - of which a test may be part
• Technical publications
Health and safety inspectors seek to secure compliance with the law and may refer to this guidance BS 7121·2·3:2012
as illustrating good practice. (Section 20,21 and 22 of HSWA) I
Maintenance, Inspection
and
Thorough Examination Code of practice for the safe
of use of cranes
Mobile Cranes Part 2-3: Inspection, maintenance
and thorough examination -
Mobile cranes
20 21
Standards
The law places duties on manufacturers, suppliers, repairers and hirers of equipment who must
Best Practice Guide meet certain minimum requirements.!
Legal duties are also imposed on the owners and users of lifting equipment and on those who make
4';.-" HSE the tests and examinations to verify the equipment. t
The purpose is to ensure that lifting equipment is designed and manufactured to be safe and that it
is regularly maintained and examined whilst in service to ensure that it remains safe)
Some reference is made in legislation to Standards and Codes of Practice and it is to these that we
must refer for further information and guidance.
Performance standards offer a range of criteria that the final product must meet.
E.g. BS EN 13001- Cranes (General Design)
NOTES
©LEEA Academy - MCE - Step Notes - July 2015 - v1.4 ©LEEA Academy - MCE - Step Notes - July 2015 - v1.4
I
I
Harmonised Standards
ISO (or International Standards) generally take the form of performance standards, which are
agreed internationally by a majority vote:
• Where the UK accepts these as written, they are published in this country as British
Fulfils a large part of the manufacturers 'technical file'
Standards
• Saves time and work in putting the file together
• A new practice has been adopted in recent years of using the ISO number and adding the
Compliance = no deviation from the standard, no matter how small
prefix BS, for example ISO 2330 - Fork lift trucks - Fork arms - Technical characteristics and
testing is published as BS ISO 2330
EC Declaration of Conformity to be issued before placing equipment into service
• No requirement for a test certificate
British Standards
Records oftest and lor examinations made will be held in the technical file
• Some manufacturers may issue both test certificate and DOC
Modern standards are written as safety standards for new products.
Older standards are more detailed covering, materials, workmanship, design, test and examination
requirements.
Some standards take the form of recommended Codes of Practice, covering the use, maintenance or
application of specific products or the conduct of certain processes.
23
22
CEN/CENELEC
British, European and International Standards. This lists most of the relevant standards, including
some which have been withdrawn or declared obsolescent.
Standards lay down the verification methods, including proof loads or other tests to be applied, for
new items and give the examination rejection and acceptance criteria for them. In the case of load
tests, it is often left to the tester and examiner to decide how to apply the load and what the
examination procedure should be.
NOTES
• Prevent falls
o have measures in place to arrest a fall i.e. air bags, nets, fall arrest equipment
Risk Assessment
On-Site Safety
Identifying sensible measures to control risks.
Mobile crane thorough examination is a legal requirement.
Concentrating on real risks, those most likely and those which will cause most harm. 25
24
Site managers must schedule downtime for the cranes requiring thorough examination.
Looking at particular control measures as part of overall assessment.
A thorough examination requires that the crane is operated through all its motions and to this end, a
competent, trained operator must be made available by the user.
HSE publication INDG 163 Risk Assessment Guide refers
An area to perform the thorough examination in should be large enough to allow all necessary 0-
HSE ;:::-
motions of the crane to be performed and should be secured such as to restrict access to the area by
personnel not involved in performing the thorough examination.
Risk assessment
Work at Height
Thorough Examination activities carried out on the mobile crane outside of edge protected areas
should comply with The Work at Height Regulations 2005 which prioritise the fall protection
measures which should be used.
NOTES
A rescue plan must be developed whenever fall-arrest systems are in use and when personnel may
Hazard:
not be able to perform a self-rescue should a fall occur.
• A hazard is something (object or situation) that has the potential to cause harrru
Risk: (a combination of likelihood and severity) ! Note: Use of a rescue kit should be considered a last resort - other methods should be evaluated
first.
• Risk is that likelihood that the harm from the hazard is realised I
Rescue plan considerations include: 1
Danger:
• A liability or exposure to harm; something that causes peril
• Never rely upon the emergency services as a primary rescue plan
Likelihood:
• What obstructions may be in the way of reaching a suspended worker?
• How likely it is that someone could be harmed by the hazard
• How will the rescue be assured within 15 minutes of the fall to minimise the risk of further
Severity:
injury or suspension trauma?
• If the potential for harm was to occur, how severe would the accident be?
• How will the safety of the rescuers be assured as well as the suspended worker?
Do you need to
• changes in production activity
What are you do anything Action Action by
What are the Who might be
already doing else to control by who when Record your findings and change the risk assessment as necessary. This may result in the
Hazards harmed & how
this risk _I requirement for additional control measures.
It I.
Site cleared of
unnecessary
All personnel Monitor During
equipment & Site
present personnel Thorough NOTES
personnel. safety
Slips trips & falls Broken arms, accessing this examination
Correct PPE officer
broken legs, area Testing
worn.
broken neck Barrier tape
strung
II
PPE
Making the workplace safe includes providing instructions, procedures, training and supervision to
encourage people to work safely and responsibly. 29
Before initiating a Thorough Examination or test the competent person, having carried out his site
risk assessment will be able to select the appropriate safety equipment to wear.
Even where engineering controls and safe systems of work have been applied, some hazards might
remain. These include injuries to:
NOTES PPE should be used as a last resort. Wherever there are risks to health and safety that cannot be
adequately controlled in other ways, the Personal Protective Equipment at Work Regulations 1992
require PPEto be supplied.
I.
Origins of Mobile Cranes
The Regulations also require that PPE is:
Are there ways other than using PPEto adequately control the risk, e.g. by using engineering
controls?
30 31
Democracy and Devotion: Greeks Invent the Crane
Traditional methods like ramps for moving and lifting the enormous building stones of massive
monuments like the Parthenon just weren't going to get the jobs done.
SAFETY FIRST
WEAR PERSONAL
PROTECTIVE
EQUIPMENT
NOTES
Pre-cranes, building blocks actually tended to be much larger, beca~se so much effort was required
In fact, the Romans were the first to use multiple cranes for cooperative liftingtasks. as is evident by
to push each one up a ramp that it was less labour-intensive to use bigger and fewer blocks.
the massive cornerstone blocks used in some of the famous structures.
Post-cranes, blocks were smaller, but stacked higher, in more complicated and advanced structures,
In the end, the Greeks proved just how much more ambitious projects could be with the help of a
crane. But beyond the beautiful, historic, crane-built city still very visible today, perhaps the most
impressive aspect of Roman crane use was the way they were used far from their home.
Again-necessity drives innovation. And as the Roman Empire stretched further and further away
from Rome, and as conquering armies became more and more ambitious, mobility and versatility in
their cranes became key.
The Roman army needed cranes that could move quickly, be assembled and torn down quickly, and
Lifting capacity has skyrocketed, up to 1,000 tons. In the end, the Romans proved just how much
mobility and versatility multiply capability.
• Used to determine whether the equipment under examination is safe to take into use o~
continue in use
Owners/users may use report information to plan maintenance based on trends of breakdowns and
repairs - reducing incidents - and to determine effectiveness of maintenance schedules.
NOTES
NOTES
Periodic Thorough Examination - LOLERReg. 9(3)(a)(i) and (ii) • The standards and regulations applied during the course of examination
• The tools required to carry out such examination
LOLj:R specifies intervals of: • The requirements priorrto carrying out that examination
• A list of all parts to be examined
Thorough Examination after Exceptional Circumstances • Damage over time to crane structure
A mobile telescoping crane that has undergone: • Structural failures are usually a consequence of fatigue; 'defects of this type will not be
• The result of cranes that fail during testing can be both hazardous and costly I
• Shock loading
31
37
• Overloading
• Inspection organisations do not advocate it as there are no mechanical or structural
benefits
• Jib collislon
• Exposure to extreme weather conditions outside its design limits' • Some insurance contracts will not insure a crane th'at has been overloaded even if only
Should be taken out of service and thoroughly examined to determine its capacity to continue to for testing purposes
carry out its duties safely.
Defined Scope for Periodic Thorough Examination The requirement for any testing and the types of test are at the discretion of the competent person
and the crane manufacturer should be contacted for guidance should load testing be deemed to be
A competent person carrying out thorough examination of mobile telescoping cranes should work to necessary.
a defined scope of examination.
The defined scope should stipulate at what intervals within the specified maximum intervals of 6 and
NOTES
12 months a mobile crane should undergo thorough examination and should specify what and when
any accompanying tests or additional reports are required.
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necessary at some stage to verify calculations, dimensions, measurements, radii, weights or angles.
•
•
Easy to use
Easily damaged
».
To do so will require the use of some of or all of the following instruments: • Calibrated annually because of damage or erosion
• Easy to transport
• Awkward to handle
• Requires disposal of water after use
• No requirement for verification but .......
LEEA recommendation is as per LEEA051 - that, to meet LOLERand PUWER, bag and lifting gear
should be inspected by a competent person at least 6 monthly. An examination before each use
This crane is ideal for rough terrain and is capable of "free on rubber" duties When functio t t'
"f bb "d . .. . . n es Ing
ree on ru er ut.les It IS advisable to have outriggers extended and jacks sufficiently clear of the
4' ground to allow loading, as a safety precaution in the event of tyres failing. 41
NOTES
This type of crane may have front jacks which must be deployed to allow 360 slew.
This crane is designed to be used under different ground conditions and one option is that the
outrigger controls can be operated from the upper cab and a steering wheel and brake pedal are
fitted that allows the operator to raise and stow the jacks and outriggers and travel around the site
to a new position. When examining this type of crane it is essential that both sets of steering and
braking systems are shown to operate.
41 43
- Wh ftted with a front jack the
Unless fitted with a fifth jack, this crane cannot lift ~ver the front. en I -
0 City Crane)
crane will have 360 not 240 area of slewing operation.
0
So called because the crane has a very short boom with more sections than a normal mobile crane
to allow greater manoeuvrability while still retaining boom length, it is all-wheel steering and the
boom is kept low to avoid overhead obstructions prevalent in an urban area.
This type of crane is designed for use in yards where it is not always convenient or possible to deploy
outriggers and where a rough terrain crane is too large. The yard crane has free on rubber
capabilities and a strong platform where light loads (e.g. pumps, motors, and valves) can be
transported.
Telescoping cranes mounted on tracks are usually used for onsite work and can be examined in the
4~ 45
same manner as wheeled cranes with the exception obviously of the undercarriage. It is however Load Charts (Rated Capacity Chart)
easier nowadays to inspect the tracks as the drive system is hydraulic rather than mechanical so you
Load Charts provide critical information to enable RCI R d ' ,
don't have to worry about drive chains, gears etc, correctly and lifting operations to be I d d ,5 ( ate Capacity Indicators) to be calibrated
p anne an carned out safely.
NOTES
Crane Dimensions
00
+ 4·
41 47
+5860'
Hook Blocks
+.5380·
+4900· Types of hook blocks for specific maximum loads, their actual weight, number of sheaves and the
reeving required to achieve maximum load lift.
+2630·
Type Possible load Number of sheaves Weight Number of lines Heavy-lilt attachment
Typ Mogliche Traglast Anzahl der Rollen Gewlht Srrangzahl Schwerlasteinrichtung
Type Charge possible Nombre de poulies Poids .0' Nombre de brins Equipement levage lourd
Tipo Portata possibile N° di pulegge Peso N()max awolgim. Equipaggiamento pesante
Tipo Carga permitida No de poleas Peso Reenvlos max. Equipo de carga pesada
Configuration Acronyms
Key to Symbols
CONTENTS· INHALT . CONTENU . INDICE . CONTENIDO
Porlate soustabilinatori
Lilting capacities<O!Ioutrlggcrs' Tragfahigkeiten, abgestOtll· Capatites de Icvage sur stabilisateurs
Capacidad de eleyacion sobre los apoyos . 360· HA MaIn boom IfauptDuslegor FIQChe prineipalOt. Bnlcdo Das.o Plumo principall ~ ..
HA-SSL Moln boom wlIh SSL . 'HauptDuslegcr mit SSL . Floci'>o prlnclpalo evec SSL Braccio bas" 000 SSL
Plums principal con SSL •••.•••.. , .•••..•••••.•.••••.••••..••••..••••..••....••.•..••....•••
Radius. AlIsladung . Portee· Sbraccio Radio
Fixed lIy jib. Starrer Hilfsausleger . Flechette frxe . Falcone Iissa . Plumln lijo
LF Fixed fly Jib Starrer Hiltsausleger . FI~cheue fixe Falcone fissa Plumtn fijo •••.•..••• _ ..••••..•• __ ..••.
Adapter. Adapter Adaptateur· Adattatore· Aadaptador LF-SSL Fixed fly Jib \Vfth SSL Starrer Hiltsauslege-r mit SSL . Flechette fixe avec SSL Falooof1efissa oon SSL
Ph.lfTlln '!Jo co-n SSL ••• _•••.•••• _ .• _ •. _ .. __ • _ • _ • __ ••• _ • _ ••••••••.••••••• _ ..•••.•••.. .••••
nech Angolazione bracero . Elevacion de pluma
Boom elevation. Ausleger-WinkelsteJlung - ReteY3gede e
T~'
o •
_L
Boom Combinations
NOTES
':A.
~~'.
i\, \
positions of the boom rather than a load capacity.
...... . It shows how to position the crane to pick at a specific radius and what boom configuration is
-, \ required to lift to the specific height.
...... \
........ \
......
"
"
eo.o m
55,5 m
50,S m
45,5m
35,S m
30,5m
51
~.
, 15,5m'
NOTES
Simple load chart showing required counterweight, range of swing, radius and boom length.
=
HA 140 t J-) 360· ISO
fa
I~ <>
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60.0 m + e-
-~.-'-2-m-2-0' 18 m
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20.5 25.5' 25.5 30,5 35.5 40.5 45,5 50.5 55.5 60,0
m
o·
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20' ~ t.--.-c0,-·' ___:2:.:0~·
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20.5' I
.~:! ~~:~
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m I
700.0') .- 19 53.5
43.1 35.0 14 53.0
S77.0l! 312.0 312.0 312.0 __ 51._2__ 41.6 ' 33.9
312.0 312.0 16--- 51.2
H3.011 312.0 32.1
.35.011 311.0 312.0 310.0 300.0 300.0
292,0
~: 49.6
48.0
40.~5
38.6 31.2 31.,~6_~_ 18 :~:g
403.011 293.0
375.01' 276.0
312.0
312.0
291.0
275.0
300.0
300.0 275,0 230.0
218,0
197.0
187.0 158.0
20
22
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2640
236.0
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219.0
203.0
186.0
220.0
200,0
204.0
187.0 m:g 166.0
lf16.0
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201.0 172,0 183,0 173.0 172.0 86.0 74,5 65.0
2120 114.0 149.0 150.0 128.0 101.0 92.5 ~~ 38.3 29.9 29.5 24,4 21.9 32 38.3
171.0 150.0 172.0 149.0 156,0 76.5 67.5 59.0
131,0 131.0 115.0 89.5 82.5 :;.;- ...;3!.f1~.0'-_ 28.9 286 23.S 213 34 35.1
146.0 130.0 137.0 19.5 74.0 69.0 61,5 54.5
116.0 121,0 116.0 115.0 1040 [ ~~ 35.8 28.0 21.1 22.8 20.9 ~ 31.1
126.0 96.0 71.0 66.5 62.0 56.5 SO.O 34.6 21~1 26 9 22,0 20~
93.5 93.5 109.0 104.0 1(&(1 56.5 52.5 46.5
L
40 28.8
92.0 92.0 88.0 64.0 60.0 40 33.5 26.4 26.2 2l.4 20.0 42 26.3
98.5 54.5 51.5 48.5 43.0
81,0 81.0 83.5 80,5 58.0 42 32d 25,9 25 4 2Q,8 196 24,0
]4,0 52.5 49.5 47.5 45,0 40.0 44 31.3 25.0 24.8 20,3 19.2 44 21.9
15.0 44,0 42,0 37.5
6BJO 68.0 48,0 45.5 :6 30 3 24,.3 24.1 19~B __ 18~8 46 19~9
U.S .41.5 40.5 39.0 35.0 29.3 23.8 23.5 19,4 18.5 48 18.2
62.5 37.5 36.5 32.6 ~ 8
56.0 41.0 39.5 ;~ 28 4 23,2 23.0 182
50.0 38.5 36.0 35.0 34.0 30.5 26.1 22.3 22.0
35.5 33.5 32.5 31.5 28.8
30.0 29.8 27.0 ~~ 21.4 21.1
33.5 31.0 66 20.3 20.3
.29.4 29,3 28,0 25.3
27.6 26.5 26.3 23.8
_' __ 25.9 24.8~.8 22.5
23.4 23,4 21.2
22,1 22Ll 20,0
20,9 19.0 Range diagram for luffing jib where main boom remains static and luffing jib moves.
191 18.0
16.2
53
Chart showing different counterweight and side mounted superlift attachment with a subsequent -- ~ - ._.
difference in load lifting capability.
m t
5 195.0
195.0 164,0
6 139.0
7
8
-m:g-- ~~:g--- 154.0
135,0
132,0
---'14.0
113.0 94.0 12.5
9 184.0 112,0 92,5 11.
170.0 150,0 130,0
10 109,0 89.5 69.5
147.0 142.0 125.0 61.0
12 121.0 105.0 86.0
128.0 130.0 64.0 16
14 116,0 102.0 _82.0 61.0---- --,8
113.0 115.0 78.0
16 103.0- 104.0 98,0 20
18--- 10l,O 74.0 58.0
92.5 93.5 92.0 22
r~!
20 91.5 86,0 70,S 55.5
84.0 85,0 24
83.0 79,0 67.0 53.0
75.5 76.5 77.5 50.5 26
69.5 70,S 72,0 63.S
28
26 68.0 65.5 60.0 48.5
61.5 63.0 64.0 46.5 30
28 60.0 51.0
30 54.0 51.5 58.5
55.0 54.0 44.5 32 - .-. I-
_ _!?5 52.5 53.5 34
32
47.5 49.0- 50.5 51.0 43.0
36 - _.
34-- 47.0 48.0 41.0
39.0 45.5 39.5 38
36 42.0 43,5 44.5 40
38 40.5 41.5 38.0
35.5
36.5 42 1-
40 37.5 38.5 44 ._+....
14244 -- 33.0
21.0
36,0
33,5
30.5
35.5
34.0
31.5
46 ,. ,/;;;- -
46
48 25.9 29.8
50 23.1
54
83°
45° 5°
\-Md
19.0 To illustrate how to read a crane chart, we've chosen the chart for the Terex RT345XL, a rough
1.9 2.2
20.0
21.0 1.7 1.95 Mddle MIddle Minimum I 'I _ terrain crane with a maximum lift capacity of 45 Tons.
22.0
24.0
26.0
1.75
1.4
1.15
Extended
WIdth
AnG ... •
Extended
.J.Mmj
15
Extended
(3.6m1
15
E~ended
5 ---x7
!"or .. _~
Dimensions and Weight
0.95
28.0
The following chart shows the crane dimensions. It includes data for operation with the outriggers
extended, transport weight, and steering dimensions.
Knowledge of this information is especially critical if the crane will be working in a confined space, as
the lifting capacity varies depending on whether the outriggers are extended.
NOTES
II
~,
Lift Capacity
TerexRT345
t
- 6.51on l~ 22 n x 22.3 n (!J 300' AMERICAN STANDARD ASME 830.5
·B~O:lll ~lIte-I~O f,~fllJlir·e(l
~'
~ ~».15'11 4S,0 II 51,!) fl 69,0 ft 81,0 It 93.0 u 1I)S.(j (I
It It
9 ~ 9
10 04400 016500 10
i2 ssooa 46S00 <6500 12
15 00700 016500 44500 41600 15
2i
20
25
30
ss
~~OO
l'J600 III
20300
~ ..oo
31000
15600
20900
34800
29400
25600
21100
30000
26000
22500
1~600
23'00
20300
11100
i~oo
16200
20:
25'
30
35
kl ~o 16100
""00 moo 11400 15600 woo 40
&11 ~5 14100 15100 15300 14100 moo 45'
se WOO 12900 13100 12600 11600 50
56 11100 11300 moo "0400 5S
be ~ 9800 tXI00 qSOO 60
b5 8400 8500 8600 65
70 7200 7300 1400 70
75 0100 0300 0400 J5
eo 5500 5600 sc
, d h t load the crane on the trailer,
'lght (below) determines the trailer to be use , ow 0 In the legend at the top of the chart, you can see these ratings apply when using 6,5 Tons of
The transpor t we , he i b 't
the route to take, and what permits are required to get It to t e JO Sl e, , counterweight, with the outriggers extended to 22 X 22.3 feet. Here, you'd graph out the specific lift
the crane is needed for. The 'ft.' indicator on the left axis represents the radius, the distance from
the centre pin to the centre of the load,
Example Lift
You need to lift a load of 15 Tons (30,000 pounds) a distance of 25 feet, The distance is measured
from the centre pin of the crane to the centre of the load. Once you determine the distance, look on
that line for the largest capacity; that will indicate how many feet of boom must be extended, In this
case, it is 45 feet.
Aidl Subtrad nrmeln opHooahqOJlpl1'lent
.:mltl It's important to note that the maximum capacity is always measured by the shortest lift, usually
• qb9l::l .W In
12tl over the rear of the crane, and with the outriggers fully extended. While the Terex RT345 has a
S1o.\~U~ l"l~l'O:)".']
maximum capacity of 45 Tons, lifts at any distance or height drops the maximum capacity
.. ~4b~C dramatically .
:2·4911 • 25TS 10 .ialil
S!I)\\'!jas Ll! I'j! OC(:,..
, ' mber is the gross vehicle weight. In the other two columns, the arrows
Along the top aXIS,the first nu I d d' on what additional accessories are loaded.
indicate the weight load for each ax e epen Ing
--
11015.00 ft
¥'ij jA e-
3~ It
15' 1!)'· o-
~9 ~I
1~' .lOt /LJ
': (I
._ ss
50
5f>
co
8693
SOOft
1563,
1114
?~1
1420 b25~
so
55
t>O
~08 3Ul 2514 05
10 0134 7070 bi01 4176 3027 2460 70
15 6343 6112 5896 3859 2916 2409 15
eo 5716 (>493 S03S 3636 2812 2360 eo
85 5101 5840 ~2a 3"148
... 90
os
"'99'
;W10
505.4
4328
.967
4193
3n?
JOn
271b
~628
25'1
23H
2269
2220
85
90
95
100
lOS
3n. 3661 3745 297. 2451 »es 100
2710 3052 l'33 28 .. 3- 2.'8 2U5 lOS
110 2219' 2.99 1551 2694 2404 lOa? 110
115 1680 2003 2016 2"91 2320 21-1.0 115
1]0 1153 1563 '$10 nS2 .219$ 2102 10
125 b3~ I 79 20.11 203'- 1972 125
130 1773- 1828 . 1752 13()
135 1418 1586 1444 l1S
140 115' 130~ )4(1
59
Crane in Motion r
- This illustrates the lift capacity for a pick and carry. It shows the total weight able to be picked up at
360-degrees while stationary on wheels, the total weight being able to be supported both while
._ slowly rolling with the load at a zero degree angle (creep), and the total weight able to be supported
while moving at 2.Smph. The column to the left indicates the radius of the lift, the one to the far
right, the maximum boom length each weight can be carried at.
.La 0
e--'
tHCI
oceE'~
.. ",
\(T'Jtt!lf
15
~ 0!YJ
'-'"
3.60' s!ra,ghl C'.er 1'001 ~'I'ax
rl n
10 3-4200 48600 4ObOO 338
12 3-4300 42100 l3lOO 338
15 21300 3-4SOO 2'8100 450
2'0 13100 26400 21500 450
2'5 8300 20300 16500 450
:;0 5100 14600 '2900 450
35 4100 .,200 10700 570
~O 3000 6700 8700 570
45 2200 7000 1000 570
51) 1500 5100 5100
NOTES 55
MO
4600 4600 oqO
bO 3800 3800 810
b5 29()0 2CI'l}0 810
11) 2100 21CO 810
15 1300 llOO 9'30
II
RCI, SLI or ASLI
Load Indicators This is a device which is installed on mobile cranes to alert the 0 . ., .
safe operating range of the rnachlnervi In some cas~s the de' pe.~~tor If. the lift IS exceedln~ the
in circumstances it determines to be unsafe. ' vice WI physically lock the machinery
Pressure
Anti-two block Transducer SLI systems are usually composed of a microprocessor connected to vario
Switch itself. The hi
SLI measures
. the angle and extension of th e b oom aIong with
.us sensors
the loadonweight
the crane
a d
compares t ISwith the manufacturer's specifications to determine if the lift is safe. ! n
I Anti-twoSwitch
block Pressure
Transducer
I Load Indicators
61
consequences.
Only a device known as a Rated Capacity Limiter will actually shut off elements of the crane's
systems to prevent an increase in the severity of the loading on the equipment,' e.g. hoisting,
telescoping out, or luffing out. Typically, those functions which decrease the severity of loading on
the equipment remain operational, e.g., lowering, telescoping in, or luffing in.
NOTES
In some crane models the device informs the operator of the configuration of the boom, confirms
that all the locking devices are in place and aids the operator in installing the counterweights.
1 BOOM ; If a hook block travels past the limit of the chain or wire the weight is lifted and the micro switch is
activated to send a signal to the operator cab and cut out any further hoist movement.
\ \
; ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::1::
::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: \ f···················
: BARGRAPH UNIT (OPTIONAl.) 1 ! :
0000000000000000
EXTENSION REEL
SIGNAl CABLE
CAB
(INTERNALI..----""'oillilsiPiPLALAv:;-"1
CONSOLE
...... -_ - . ....................
~===='-'=9
REAR OF
cRANE
WIRING
HARNESS
\
CRANE UPPER
COMPUTER UNIT
/ :
11- ~
Fi~'C.b,eL \
~-:::----
TIlT
•
•
ORs Full 9.7Klb Ctwt
ERECTED 60' TELEJIB 170
PICK FROM MAIN BOOM
3600
AUXHD ON
FRONT WINCH • o
tEl
Reel-Off Cable
Outside Edge of
Reel
Readings are:- 44.8ft boom length; 26.4ft radius; 62.r boom angle; 6 falls of rope; max capacity
23,5001bs; actual load 12,3001bs;
65
The Remote Bar Graph, shown below, displays the percentage of rated capacity of the crane. The
II remote bar graph is mounted at the top of the cab front window, in the operator's line of sight. User
selectable levels of brightness are available on the device, which is designed for reading under all
lighting conditions. Defective remote bar graphs cannot be serviced. The remote bar graph is
optional and is not used on all cranes.
(
~ " ~•• ' ••• ' ,- , •• " .' 1''' .' ~"e.,~,-..,• 0 .~" , ~ t'
-
I' ~ • • • • • t, •• j
All data is entered via corresponding "F" keys ditree tl y un d er each data value.
67
NOTE: this equipment is only an operator aid and should not be expected to replace the training and
experience of the operator. It will only perform correctly if given the correct information.
Liebherr cranes have their own crane computer called Liccon - stands for Liebherr Computer
Controlling.
Liccon allows crane operator to enter information depending on crane's configuration, so the
computer can work out what the crane can safely lift at all possible distances and heights with
different boom angles and lengths, basically:
• Every crane configuration entered into the computer is given a unique code
• That code is displayed at the top of the screen NOTES
• Crane operator can enter the code directly into the computer for a given crane configuration
without going through the steps of adjusting all the data separately
~ 46 I 92 I 92 I
Via the key pad, crane operator can access al! functions of Liccon - go back to the setup/load chart
69
screen, retrieve information about outrigger pressures or adjust outriggers, go directly into ~rom the same key pad, crane operator can go straight to the outriggers screen
ere the crane operator can see all outrigger pressure di . .
telescoping mode, enter the configuration code, adjust speed of movements and more. current crane level and main lifting data. s, a Just outrigger lengths and height, see
::(: (4)
o / 8 / 92 / 92
With the telescope button the crane operator can access the telescoping adjustments screen
directly.
crane motions. Although all the systems shown display the same basic information i.e.
Besides entering the maximum speed, in this screen winches can also be completely blocked to
• Boom Length
prevent undesired movements made by mistake.
• Boom Angle
• Radius
• Capacity
• Actual Load
*Unforeseen and eve~ tragic results can result from inputting the wrong code number of falls or
amount of counterweight" I
71
Maximum speed can also be altered via joystick directly - by pressing "rabbit" button. After pressing
the high speed button, change is displayed on main working screen with rabbit symbol:
NOTES
Crane Signals
Confusion can be caused by riggers, banksmen, or labourers working with cranes who have evolved
their own method of signalling - often in unconventional ways with various body parts including feet 73
or heads!
To counter this an internationally recognised set of signals, as per these illustrated in BS 7121-1,
should be used by all competent persons when performing a thorough examination or test on a
mobile crane.
HOIST UP
NOTES
©LEEA Academy - MCE - Step Notes - July 2015 - viA ©LEEA Academy - MCE - Step Notes - July 2015 - viA
Extend Boom
Retract Boom
75
I 1
Cease Operations
Use Whipline Mobile Crane Hydraulic Systems Basics
id-o
Slew drive
molar
77
Because the operating system for mobile telescoping cranes is a hydraulic pump powered by a
power take off (PrO) shaft, it is essential that the competent person performing the examination has
a basic knowledge of this type of system.
The crane also has a brain, (spool valves) the same as the human
body, which gives it instructions on what part of the body to
move.
NOTES
If we want to run or exercise vigorously our heart pumps faster to
allow us to do this (accelerator).
Rest of
body
• A power source J
• A hydraulic oil reservoid
• A pump
• Directional control valves and actuators
Mechanical
Tank Control
Pump
i Pull ~
~hJ'l~ C'M_'"'-(.
Most hydraulic truck cranes use two-gear pumps that have a pair of inter-meshing gears to A mobile crane has two basic types of controls for manoeuvring a load:
pressurize the hydraulic oil.
Joysticks - There are two joysticks in the cab.
When pressure needs to increase, the operator pushes the foot throttle to run the pump faster.
79
Most Mobile crane joysticks are configured so that one '11 .
P>t)o ""' 1-rv.t (c
other will control boom telescoping and swing motions. WI control HOist and Boom motions and the
In a gear pump, the only way to get high pressure is to run the engine at full power.
EXAMPLE: Foot pedals T One pedal controls the amount of pressure bein
pedals can be responsible for retracting and t di h g gen.erated ?y the pump, but ancillary
A 70-ton hydraulic truck crane uses a 12.7-L diesel engine that generates up to 365 horsepower. The ex en mg t e telescoping sections ofthe boom.
engine is connected to three two-gear pumps, including:
Joy sticks and foot pedals are connected t h d r
spool valves. 0 y rau IC hoses that connect various hydraulic rams to
Main pump - This pump operates the piston rod that raises and lowers the boom, as well as the
hydraulic telescoping sections that extend the boom. The main pump is able to generate 3,500
pounds per square inch (psi) of pressure. It generates more pressure than the other two pumps The spool valve is connected to the hydraulic um via' .
a
because it is responsible for moving much more weight. hoses that run from the spool valve to the hYd~aUIi~ ram. third hose that IS placed between the two
Pilot pressure counterweight pump - A hydraulic truck crane uses counterweights on the back of the When a joystick is pushed in one direction it causes th I
II leading to the ram and open the other.' e va ve to shut off one of the hydraulic hoses
cab to keep it from tipping over. These may be added and removed by a hydraulic lift that has its
own pump. The counterweight gear pump can generate 1,400 psi.
NOTES
Steering/outrigger pump - One pump controls the steering and the outriggers! The outriggers are
used to stabilize the truck during lifting operations. Because steering and outrigger operation are not
performed simultaneously, they can run off of the same pump. This pump generates 1,600 psi.
Outriggers 81
A Hydraulic circuit:
• Receives mechanical power in the form of a rotating shaft. (PTO - Power Take Off)
NOTES
Maintenance Issues
Thorough Examination of Mobile Cranes
..... ............... ''' ..
. .
Modern Mobile Telescopic Cranes are complex pieces of equipment which are constantly developing 83
r-D-u-st---") . and a competent person should take every opportunity to keep up to date with advancements .
.
Manufacturer's publicity releases can be quite helpful in providing updated product information
To ensure that a Thorough Examination is carried out methodically the following steps should be
observed:
• Carry out examination of the mobile crane chassis/carrier as per BS 7121-2-1:2012 and BS
7121-2-3:2012 ,
• Carry out examination of the mobile crane upper works as per BS 7121-2- I 1:2012 and
Condensation BS 7121-2-3:2012
causes Rust
• Perform wire rope examination as per BS.ISO 4309: 2010 C\11~ Lv;-;"_' -upc
• Ensure that all details in the Report of Thorough Examination are correct,
However:
The Road Vehicles (Construction and Use) Regulations 1986 (as amended) [8] Regulation 100
requires that mobile cranes should:
"At all times be in such condition ... that no danger is caused or is likely to be caused to any person
in or on the vehicle or on a road"
• Lights!
0 Headlights
0 Sidelights
0 warning lights I
0 Indicators
0 Hazards'
• Windscreen wipers/washers
85
• Registration plate
• Steering
o Steering should be checked to ensure all wheels are turning in correct direction; this
is essential with all or multi-wheel steering. This can be done when crane is
manoeuvring into position.
• Brakes
o To check brakes, ask the operator to:-
Ensure gear is in neutral and apply handbrake put in first gear and check to
see if crane moves.
Press footbrake and release hand brake, check to see if crane moves.
Put gear in neutral and apply handbrake.
o The competent person should position himself with a rear view of crane and get
operator to apply footbrake;
Check brake lights.
NOTES
© LEEAAcademy - MCE - Step Notes - July 2015 - v1.4 ©LEEA Academy - MCE - Step Notes - July 2015 - vlA
• Drive Shaft
• Reverse alarm/lights
o ViS~~IIY exam to ensure shaft is attached correctly
o Ask operator to select reverse gear
o If visible check P.T.O. shaft is engaged
check reverse alarm and light(s)
• Access Ladders
• Operator Cab on Carrier
o Check housekeeping
o Control identification
o Seat
o Safety belt
o Condition of pedals
o Tyre Pressure is important for any crane, but it is essential that it be correct for
cranes that have free on rubber (free on wheels) duties
©LEEA Academy - MCE - Step Notes - July 2015 - v1.4 ©LEEA Academy - MCE - Step Notes - July 2015 - v1.4
-- -
- ~
• Drivers Cab
• Lights
• Brakes
• Gears
• Reverse Alarm
• Hydraulic tank oil level (should be checked before any hydraulic functions are operated)
• Fuel Tank
• Suspension
• Drive shaft
• All pipework and connections including flexible and rigid hoses and holding valves
• Hydraulic cylinders
• Access ladders
NOTES
©LEEA Academy - MCE - Step Notes - July 2015 - vl.4 ©LEEA Academy - MCE - Step Notes - July 2015 - vl.4
Thorough Examination of
Mobile Telescoping Crane Superstructure
Hoist Mechanism
- Jib
Superstructure Boom
- Sheaves
Load Blocks
Hook
Chassis or Base Rope
Counterweights
Winch
Cab
Travel Mechanism
93
Information for the written report can be found on the manufacturer's plate.
Mobile Telescoping Crane Superstructure
Although important in its own right, the function of the crane carrier is to transport the crane
superstructure to its operational
I I
Baunummer
Crane t'fPO SorlllNo.
Type de groe No de construction
To this end it is required to perform the following checks as a minimum:
CJ
8aUjahr
CJ
Elste Inbotll.~
Year oC manu(aclure Year of fil1it ocmmlsslonlr,g
Annee de consltucllon Annes de 1. rTAO on IItC'I\CO
Boom length/angle sensor recoil
• Manufacturers plate: serial number; •
I
Matorlelatung
model; year of manufacture drum and cable Englno pC7ll'or
Plrl8Mnce du mtteur
IkW
• Counterweight and counterweight • Boom wear pads
95
Counterweights must be observed when being fitted to ensure that both rams deploy correctly and
By closely observing the hydraulic rams for the counterweight we can ensure that each ram is
extending fully and is locking in position before lifting the counterweight.
NOTES
Check the operator's system display to ensure it is showing the sequence of moves.
Check the hydraulic rams and attachments for leaks, loose connections or damage.
• Verify that capacity shown on RCI is same as shown in Rated Capacity Chart
• Attach a known load, or lift a load using calibrated load cell and verify RCI
97
NOTES
NOTES
If internal gearing is used for the swing mechanism the only way, short of dismantling the assembly,
to exam is by visual and audible observation.
• Loose bolts
If excessive movement is noted when the crane is under load, then measurements can be taken
using a DTI and compared with manufacturers readings if available.
Watch the crane whilst slewing and note if there is any discernible rocking movement that would
indicate loose bolts or worn gearing, listen for any grinding of the drive motor.
Dial test indicator measurements are a last resort that is seldom utilised, and, unless previous data is
available, are non-conclusive. However - it is another tool we can use.
Cab Mounted load Chart
~ (
9.5m
25.0
16.5m 23.5m 3O.5m
19.0 12.5
X
83° 3.0
5° 25°
2.1
45°
1.6
5°
2.0
25°
1.2
45°
0.8
2.5 2.0 1.2 0.8
25.0 19.0 12.5 7.0 76° 3.0 2.1 1.6
3.0 1.1 0.8
19.0 12.5 7.0 72" 3.0 2.1 1.6 1.75
3.5 25.0 0.8
12.5 7.0 70° 2.8 2.1 1.6 1.65 1.05
4.0 23.0 19.0
7.0 65° 2.35 1.8 1.5 1.4 0.95 0.78
4.5 21.2 18.0 12.5
7.0 60· 2.0 1.55 1.35 1.2 0.9 0.75
5.0 19.4 16.7 12.5
7.0 55· 1.45 1.35 1.2 1.05 0.85 0.74
5.5 17.8 15.6 11.75
0.85 0.75 0.7
6.0 16.3 14.6 11.1 7.0 so· 1.05 1.0 0.95
10.5 7.0 45· 0.75 0.7 0.7 0.6 0.55 0.55
6.5 15.1 13.8
10.0 7.0 40· 0.55 0.5 0.4 0.4
7.0 13.7 13.0
8.0 10.55 9.0 7.0 35· 0.38 0.35
9.0 8.65 8.2 6.3 A • Boom Length
10.0 7.05 7.3 5.8 B .. Working Radlu.
5.3 C • Jlb Length
11.0 5.85 U
4.9
o "JlbOff .. t
12.0 4,95 5.5 E. Boom Angl.
13.0 4.2 4.75 4.5
14.0 3.6 4.1 4.15
15.0 3.6 3.8
3.15 3.45 NOTES
16.0
17.0 2.8 3.05
I 2.7
18.0 2.45
2.15 2.45
i 19.0
1.9 2.2
20.0
I
I
21.0
22.0
24.0
1.7 1.95
1.75
1.4
Ir ~ ~:
ndtd \ MddM
15
~
Mlddlt
15
llllnlonum \
Ex!Indtd
5 .l
- --
1.15 Mal .. '
26.0
28.0 0.95
I
Also while travelling with the boom on the rest it ensures the boom cannot rotate unexpectedly,
(there have been cases of booms rotating whilst travelling and causing accidents to other road
users).
The example shown is just one type there are many more different types.
101
• ~~:~~::n~p~~d lower boom pins paying particular attention to boom derrick ram
Mobile cranes are fitted with a central rotary distributor to allow the
• Check all hydraulic connections for loose fittings and leaks
0
The rotational coupling for hydraulics and electrical connections allows all
• Observe derrick piston(s) while boom is bein lifted If . .
that the seal is beginning to leak g
..
I oil is detected on piston It can indicate
crane actions to be performed normally even when the cab is rotated.
Ensure that all fastenings are secure all hydraulic hose and connections are
• Operate boom up and down to clarify1fthere is actually a leak
On older cranes a safety chain was attached to ensure the coupling rotated
with the crane in case securing bolts sheared.
Looking at a boom like this indicates that the .~d~ wear pads
on the outer section of the boom require serious
Single cylinder boom derrick ram adjustment or replacement.
In M",t·~ ~.
The condition of the hydraulic hoses on the recoil drum is also
a clue as to whether there are any leaks.
Telescoping Systems
Single stage ram systems have to be checked on the R.C!. display to ascertain whether they are
operating to their correct configuration and whether the boom pin locking system is functioning.
• Limit switches
• Dynamometer
• Anti two block switch
"'17,.Ji~1') ~
SKM300
Running Line
Tensiometer ~--w
Length and Angle
-------0
Sensor
109
NOTES
NOTES
Boom stowed Fly Jib extensions, sometimes known as swing-aways, can be examined even when not
erected.
With the main boom in a horizontal position over the side, the length of the boom can be examined.
The 'A' frame, Support frame and all pendants and attachments require thorough examination to
detect any distortion, damage weld cracks or missing/unsuitable attachment pins.
Old style superlift normally consisted of additional weights on a platform or wheeled trolley, which
then had to be attached to the crane.
Modern technology has evolved a method of supporting the boom by rigging extendable boom side-
mounted wings which can increase the crane capacity significantly .
•t
NOTES
It is essential that the correct wire rope anchor is attached and that the wire hoist rope has been
Check sheaves are free running with no play in the bearings
• inserted correctly and locked in place.
Efficiency 80%
Both have drawbacks as detailed below: There are also a number of options for securing the tail:
If the wire rope fitted with the manufactured end fitting for the easy assembly anchor gets damaged
close to the fitting, it cannot be cut and reused in that fitting.
The wire rope has to be returned to the manufacturer for a replacement fitting or sent to a 'WRONG Ilrnstall,aUolt'li Crosby "'te-rmil1lali()r'I'M-IP(iljc;iple:
manufacturer recognised company for re-terminating. U$o ., \S4IIIIc;l9Id ~sby
cIoIllO o;l<Jmp bIlo toil1lfld
dlnoolly 10 tJlo _dlJll
This can be as expensive as buying a new wire rope and often crane owners will just buy new.
With the wedge and socket it is imperative that the socket is of the correct size for the diameter
Extended wedl)ll prolrud'es
rope being used and that the wedge and socket are a part of the same assembly and not mixed. out of tile iSOd(ill
Non-Rotating Ropes
Note: Damaged end fittings are sometimes cut off and a suitable wedge and socket assembly fitted
to allow the rope to continue in use. This is acceptable if correct assembly is used for the diameter ,
wire and the mounting fittings.
There are a number of ways the wedge and socket can be fitted and shown is the wrong way and the
correct way.
..
ill '~ 115
Also shown is a wedge with rope checker holes in it that can be used as a guide to check if the wedge
and socket are suitable for the wire rope size.
A common method of wrongly fitting a wedge and socket anchor is to reeve the live end down the
slanting side of the wedge and back up the straight side.
The anti two block actuator consists of a weight suspended a measured distance from the boom tip This hook block demonstrates the correct information that should be available on all mob' I
hook blocks. I e crane
by a chain or wire rope attached to the anti-two block switch.
When the hook block moves the weight up, the switch is activated and sends a signal to the console • Capacity or SWL: 25T
in the crane cab alerting the operator by a flashing light and an audible alarm.
• Weight of Hook Block: 360kgs
lit
117
To test the anti-two block alarm request the operator to raise the hook block until it is just below the
suspended weight then slowly raise the hook block until the alarm activates or the weight is raised
so that the alarm should activate.
Examination of the Hook Block should include but not be
confined to the following:-
Care must be taken to ensure a block to block incident does not occur.
Ensure that all the assembly and safety pins are present and correctly in place. • Check for any visible damage to the hook block
©LEEA Academy - MCE - Step Notes - July 2015 - vi.4 ©LEEA Academy - MCE - Step Notes - July 2015 - vl.4
/
Sheaves should be checked for:
1, Correct grOOJe diameter
2, Roundness or contour to give proper support to the rope
3. Small holes, cracks, uneven surlaces, or other defects that
might be detnmentalto the rope
4. Extreme deep wear
GrOOt'c 100 Groovo \'10m New ropewil
small, rope 001 gel damaged A sheave should also be chocked to rnako sure it turns freely,
gels damaged is properly aligned, has no broken or cracked Manges, and has
bearings thai wor1c properly.
Hook block sheaves must be checked for wear with a sheave gauge, as previously covered in this
course.
During the thorough examination, as the crane operator booms up, check to see that hook block is
reeved correctly.
Check Block for overall damage
•
Check sheaves for damage and free rotation with no excessive side to side movement If in doubt consult the load chart or the manufacturer's recommendations.
•
Using Sheave Gauge, check for wear on sheaves
•
.( (0'
~
Again. in this scenario it is
nssurnad that ltIe shoova
t" this scooario is OSSLanOO gauge diameter is equal or ,
that ihe sheave gauge slightly lARGER t.h.on lIlo WlI9
rope diametGr UltendGd to bG
d.:ameter .s equal OJ t'ltly used, If you $GO UGHT under
lARGER than the ,~'rorope tho g:lugG tho sh9QVG is wom ~
d1ameter '"tended 0 bo used rutd rneQds to be raplaced o~ ~
I you see NO UGHT under thG sal90lad ropG diamot9r JS
oBSISO 4309:2010
,.g.,w
1
ro ...........
._.. . . • Those provided by the manufacturer of the rope
There are no detrimental sounds coming from the drum during operation
•
Failure to recognize stated discard criteria for crane wire ropes can be extremely harmful, dangerous
.}~c.h&.",'\·( .
and damaging:
NOTES When carrying out examination of wire ropes as part of the thorough examination of a mobile crane,
the competent person should examine the rope in accordance with B5 ISO 4309:2010. (Cranes. Wire
ropes. Care and maintenance, inspection and discard)
BS ISO 4309:2010 stresses the importance of examining critical areas of the rope such as:
• that part of the rope which passes through the block or over sheaves
• in the case of cranes performing a repetitive operation, any part of the rope which lies over
• any part of the rope which might be subject to abrasion by external features
Beginning of surface .oxidation. Can be wiped cIean, superficial
..
Rating: 0% towards discard
Rope should always be clean - if this is not possible, consider electromagnetic wire rope inspection
method.
• Kinks
• Fatigue
122
123
• Wear
Wires rough ~o touch, general surface oxidation
• Corrosion Rating: 20% towards discard
NOTES
Reduction of rope diameter resulting from deterioration of the core can be caused by:
Surface heavily pitted and wires quite slack, gaps between wires If th f 1Y!.f~ I "".f,.,."" \
ese actors cause the actual rope diameter to d b 110"" ~.-y()'
Rating: Discard immediately rotation
. . t
-resls ant ropes, or by 10% for other ro ecrease y 3% of the . I
. nomina rope diameter for
wires are visible. pes, the rope shall be discarded even if no broken I
Broken Wires NOTE'. New ropes WI'11normally have an actual diamet er greater than the nominal diameter.
w
• Check entire length of the rope Calculating percentage reduction in diameter: ~tt.~~ ",lIo C\v-t.<; I"c'IQ"'; ·h $ '<
• Crane wire ropes do not have an indefinite life Nominal Diameter - Measured Diameter = ?
grounds for discard E.g. A wire rope having a nominal diameter of 26mm is
percentage reduction in diameter. measured at 24.35mm what is the
• Termination broken wires indicate high stress and therefore discard, although rope can be
1.65
X 100 6.34%
Heating and Arcing Damage 26
Ropes that are not normally operated at temperature, but have been subjected to exceptionally
high thermal effects, externally recognizable by the associated heat colours produced in the steel
wires and/or a distinct loss of grease from the rope, shall be immediately discarded.
If two or more wires have been affected locally, due to electric arcing, such as that resulting from
incorrectly grounded welding leads, the rope shall be discarded. This can occur at the point where
Abrasion of the crown wires of outer strands in the rope results from rubbing contact, under Visible distortion of the rope from its normal sh .
change at the deformation position which result . ape IS termed "deformation" and can create a
pressure, with the grooves in the sheaves and drums. The condition is particularly evident on moving s In an uneven stress distribution in the rope'
ropes at points of sheave contact when the load is being accelerated or decelerated, and is revealed
Waviness
by flat surfaces on the outer wires.
Wear reduces the strength of ropes by reducing the cross-sectional area of the steel strands. Waviness is a deformation in which the longitudinal axis .
under either a loaded or unloaded condition Wh'l of the ~Ire rope takes the shape of a helix
not
such a deformation if severe can transmit I e I . necessanly resulting in any loss of strength
If, due to external wear, the actual rope diameter has decreased by 7% or more of the nominal rope , , ml a pu sation resu It' . . '
prolonged working, this will give rise to wear and wire breaks. mg In Irregular rope drive. After
diameter, the rope shall be discarded even if no wire breaks are visible.
Corrosion occurs particularly in marine and polluted industrial atmospheres. a) on a straight portion of rope, which never runs thr r
the drum, the gap between a straight edge a d t~ugh °d ar~und a sheave or spools on to,
greater n e un erside of the helix is 1/3 x d or
• Diminishes the breaking strength of the rope by reducing the metallic cross-sectional area
• Accelerates fatigue by causing surface irregularities which lead to stress cracking b) on a portion of rope, which runs through a sheave or s ools on
between a straight edge and the underside of the heli:'ls 1/10 todthe drum, the gap
• Severe corrosion can cause decreased elasticity of the rope x or greater
External corrosion
Corrosion of the outer wires can often be detected visually. Wire slackness due to corrosion 126
d = rope
attack/steel loss is justification for immediate rope discard. diameter 127
Internal corrosion
This condition is more difficult to detect than the external corrosion which frequently accompanies
it, but the following indications can be recognized:
a) Variation in rope diameter; in locations where the rope bends around sheaves, a reduction
g = gap
in diameter usually occurs. However, in stationary ropes it is not uncommon for an increase
in diameter to occur due to the build-up of rust under the outer layer of strands Wire Rope Waviness - Example:
b) Loss of clearance between the strands in the outer layer of the rope, frequently combined
with wire breaks between or within the strands
©LEEA Academy - MCE - Step Notes - July 2015 - vlA ©LEEA Academy - MCE - Step Notes - July 2015 - vl.4
r
Combined Effect Assessment
Local Increase in Rope Diameter
Although broken wires are a common r f'
If the rope diameter increases by 5 % or more for a rope with a steel core or 10 % or more for a' combination of factors. In such cases th eason or discard, deterioration often results from a
, e competent person needs to:
rope with a fibre core during service, the reason for this shall be investigated and consideration
Other Conditions which affect the safe use of wire can include but not be restricted to:
• Dec.ide whether the rope is safe to remain in service and
subjected to any revised inspection/discard provisions ' if so, whether it needs to be
Basket or lantern deformation.
•
One method of determining the combined effect is as follows:
• Core or strand protrusion/distortion
• Flattened portions
• For each of these individual modes of deterioration
a percentage of the respective individu I di d'
rate t .
he seventy and express it either as
• Kinks or tightened loops j
number of broken wires according to t:e i~~~~~du~it~ria:, e.g. ~f4? % of the allowable
represents a rating of 40 % towards di d . discard cntena are found to exist, this
• Bends or discard scar, or In words, e.g. slight, medium, high, very high 129
internal parts. I
All ropes are lubricated internally, and nearly all externally, during manufacture but care should be
taken to see that an approved neutral lubricant is externally applied at frequent interval.s during use
Thinner types of lubricant have the best lubricant qualities but if the rope is constantly exposed fo
the elements or to water, the heavy, thicker lubricants are more suitable. For certain applications
dry lubricants may be preferable but in all cases the lubricant must be acid free in nature. NOTES
Wire ropes should be clean and dry before lubricants are applied.
130 131
NOTES
131
133
Broken Wires
NOTES
NOTES
Measured 19.36mm
12% Loss
External Wear
Swaging Effect
135
Shock Loading
NOTES
©LEEA Academy - MCE - Step Notes - July 2015 - v1A ©LEEA Academy - MCE - Step Notes - July 2015 - vIA
Trapped Rope
Internal Corrosion
136 137
Mechanical Damage
Birdcaging
NOTES
©LEEA Academy - MCE - Step Notes - July 2015 - v1.4 ©LEEA Academy - MCE - Step Notes - July 2015 - vl.4
Spooling Damage Electric Arcing
140
141
Mechanical Damage and Heat
Fused Strand
© LEEAAcademy - MCE - Step Notes - July 2015 - vl.4 © LEEAAcademy - MCE - Step Notes - July 2015 - vl.4
I
J
Heat Effect
Testing as Part of the Thorough Examination
I()(J(JO rss
2()fJfJ() L')!;
142
Brazed Repair?
143
A competent person, under LOLER has no requirement to carry out a 4 yearly overload test on a
mobile crane, this was a requirement of the old Construction (Lifting Operations) which LOLER
replaced in 1998.
The ACOP to LOLERasserts that any testing is carried out at the competent person's discretion when
I carrying out a thorough examination, the nature and method to be decided by him and if necessary
in consultation with the manufacturer:)
I
Supplementary testing can be carried out to verify the accuracy of the Rated Capacity Indicator and
its conformance to the Rated Load Capacity Charts.
Raise the selected load and boom load out to the maximum radius as allowed by the RCI • Date of test and subsequent examination completion
•
Verify by measuring the radius and comparing it against the Rated Load Chart. Operate • The crane configuration at time of test
•
crane through all functions and return load to original start point
• The unique serial number or identifying mark of the crane;
A Hoist Brake test and examination may be carried out to determine if a major overhaul of the
braking system or the replacement of brake pads or shoes has been carried out successfully.
• Dynamic testing to verify that a moving load can be halted at normal lifting and lowering
speeds,
• 'Dynamic testing to verify that a moving load can be halted at normal lifting and lowering
144 145
speeds after the emergency stop has been operated
• 'A static test to verify that the brake can hold a load without slippage
After any major repair a Load Test should be completed shortly after to verify the structural integrity
of the crane and to reveal any weaknesses.
The type, scope and method of the test should be as per the crane manufacturer's specifications.
NOTES
NOTES
6) In relation to the first thorough examination of lifting equipment after installation or after
n. •. _._.f._..._ ....._ ...........o.-_1.tJIiIIIII~,..,._,
(. •• t.fic ",. uf 1 hOI oH,1I L ~UIUlll"lh)1I of 1_111111& l (IUII.UI(I'III ...,.
.... ~ __
assembly at a new site or in a new location
.-~ (a) that it is such a thorough examination
(b) (if such be the case) that it has been installed correctly and would be safe to use
t--"~--..,._--~-
-===:.:='.:,.:~. ['\7.\1.
r~-':::.=::.~ .......
It!}.I_:l ~:;,_~'-.-
_.,l: __·
[liCL j SJQ I I
examination to which paragraph 6 relates:-
(a) whether
(~?
it is a thorough examination-
w~th~n an ~nterval of 6 months under regulation 9(3)(a)(i);
::-.::=-~..,-........ ['@ol I~ ] (~~?~"thm an Interval of 12 months under regulation (9)(3)(a)(ii);
(III) In accordance with an examination scheme under regulation
(9)(3)(iii); or
(iv) after the occurrence of exceptional circumstances under
II
regulation(9)(3)( a)(iv)
b) (if such be the case) that the lifting equipment would be safe to operate ,
LOLER Schedule 1 9) The name, a~dress and qualifications of the person making the report; that if he is self-
employed or, If employed, the name and address of his employer
Minimum Information to be contained in a Report of a Thorough Examination:
•
10) The name and address of a person signing or authenticating the report on behalf of its
1) The name and address of the employer for whom the thorough examination was made author
2) The address of the premises where the thorough examination was made 11) The date ofthe report
3) Particulars sufficient to identify the equipment, including where known its date of
manufacture
:11
©LEEA Academy - MCE - Step Notes - July 2015 - viA ©LEEA Academy - MCE - Step Notes - July 2015 - v1.4
LOLER Report Report Example
Namll and addross 01omplo~ lor whom tllll thOrough lIX3n~natlon was made Addross of PIIlIlllSOSat vdllCh thll oll8m1nallOn was madll.
_----
OesCliplkln and IdllntlOcatltll of lhe equipment: Salll \\()rklngload(S). Dalll 01 manulacture II Dale 01 last Ihorough
knO'Ml: exanunauon:
..
4I'SOII;I __ '" 15:11D~1ft
li~1 NO
.,.. .. ~41(. .. lYE .. I x INO I
hit..I I !'IO I
-
• ..... ...,...fltt; ..... •
":I NQ
.u. __ flt .. ,1 UI
In1t[ I t.lO I J
t ~• (\'1.., NO I
"' ....... ..._ ...... .. ... wq- ...
148
If 149
IS this tile llrst examinatlon after Installation Was the examlnallon carriQd au I.
or afler assembly at a new sHe or Iocanon? I YES I I NO I wallin an Interval of 6 nlonU1S? YES NO
Il the answer to (hf;! above question Is YES. wIlllln an Interval 01 12 months? YES NO
has tho squtpmant been tnstauad cormctly? I YES I I NO I In accorcanca wllh an exammatlon scheme? YES NO /1
after the occorrcnce of exccpuonat circumstances? YES NO
Identification of nny part found 10 have a defect which Is or could become a danger 10 porsoos and a descrtpuou of the defect: (If none state NONE)
.. c-.:. I
15 the above a defect which Is of Irtuneclate danger 10 persons? YES NO
Is lhQ above
Particulars
a defect
of any repair.
which Is nOI yot but
renewal or altaratlcn
cOlJcl become
requfrert
a danger 10 parsons?
klenllhed above:
by wtlel1) I YES by: NO
II
Partlculara 01 tiny tests carried out as part 01 the exarulnafton: (If none state NONE)
NanlO 011110 parson making this (aport. Name of tho parson aulhonucallng IhlS report: tatos: caro by which next thorougll
oxamination mus! flo canted out:
Signature:
XYZ Lifting Equipment Co Ltd, Any Street, Any Town, Any County
nnel Cllllhenilcatlng IhlS (open.
------------_._---_. _,--
©LEEA Academy - MCE - Step Notes - July 2015 -v1A ©LEEA Academy - MCE - Step Notes - July 2015 - vl.4
Report Distribution and Time Scale
DESCRJPTIO:" O.iFTEST
It is usual for the crane owner to request a thorough examination be carried out on a mobile crane
~LWHO~Tl ~L~ iI'IO~&1' ~. .\\:XIl.l!.\lRY H,o!SlJ: fI.\'JJJ3. s n.l::"'c:."I.'1: U and the person carrying out this examination on behalf of the owner should send him a copy of the
examination report.
UfiE lffl,'ORKI::':C..lOU' JO,JIi® 1I'r.."'G l,J(!i(l· ~ l,'1Ml KC
The crane owner should send a copy of the report to the crane user as ultimately it is his duty to
+!t 'Il)YE!IillJOi!j.1Jl) !,IItO(I m ill(! KG ::,7'JD iOC.C I ensure the crane is safe.
!;:.WllI;.."$ iI :u .l! M ll..t= M The owner and the user must be apprised right away of any defects found that constitute an
immediate or forthcoming danger to persons (this is essential if crane is on site). This can be
!.RO,E. C-O·:'-"RC'l"R...1j,."]'[lO~ 15XlSl l!ll\l 1;\':)9 ;:;'.n~u ! x lSI t\l\[
achieved by verbal or/and handwritten notification of the owner and user. (An in house competent
person may have the authority to remove the crane from service immediately).
The crane can then be removed from service or prevented from entering service until such time as
Report Categorisation and level of Detail the defects have been remedied.
Should defects be found during the course of the thorough examination they must be categorised by Where the competent person has ascertained that there are defects which if not remedied within a
the severity of the defect and how it could affect the safety of persons. stipulated time period could become a danger to persons, a report should be submitted as soon as
practical, to enable the owner to remedy the defects within the specified time limit.
Defects can be classified in one of three categories:- _
Note: It is the personal responsibility of the competent person to ensure that a copy of the report 151
1) Defects that are an immediate danger to persons or could become so
has been sent not his company, or secretary, or manager. He should follow up on it. Should a case
2) Defects affecting the safety of persons that have to be remedied within a stipulated time
end up in court and the report had not been sent then the competent person could be held
period
responsible.
3) Observations or recommendations which may require planning to resolve and which may
fall outside the strict scope of the thorough examination
(e.g. you may have noticed a working practice or location that the crane is in that is
detrimental in the long term to the continued safety and integrity of the crane but which
could be altered). This could be, for example, continuous lifting at the maximum radius or
working near chemical/acid areas
The report should be such that it can be clearly comprehended by crane users.
The report should include such details of any defects that the crane owner can ascertain the exact
nature and site of the defect thus allowing him instigate an appropriate course of remedial action.
NOTES
Abbreviations should not be used when making this type of report to avoid confusion.
At times maintenance personnel from the mobile crane owners company could attend the thorough Examination of: Acceptable Defective
examination and defects revealed by the thorough examination may be corrected immediately. Chassis
Operator cab exterior
The defects must still be reported even if they have been cleared otherwise the report will not
Hook block attachment point
reflect the true condition of the crane at the time and will be undocumented in the history of the
Operator cab interior
mobile crane. Cab Glass
Windscreen wipers
A failure to document defects is contrary to LOLER.
Lights
If, according to the competent person, a serious defect has been revealed by the thorough Indicators
examination that poses an existing or impending risk of personal injury when the crane is reused or Brake lights
shortly after, the competent person must send a copy of the report to the relevant enforcing
Reverse lights and alarm
authority. Warning horn
Brakes
In the UK this is the Health and Safety Executive (H.S.E)
Gears
P.T.O
Switches/Electrics
Tyres/pressures
Suspension
Outrigger controls
152 153
Outrigger level gauges
Outrigger Beams
Outrigger Jacks
Outrigger pads
Hydraulic Tank
Fuel tank
Air reservoirs
Counterweights
Counterweight attachments
Auxiliary Hook blocks
Superstructure
Swing Ring
Access ladders
Operator cab external
Safety glass
NOTES Operator cab internal
Rated capacity charts
Rated Capacity Indicator
Controls
Hoist
Swing
Boom up/down
Boom telescoping
Throttle
lEEA 051 (01 Oct. 2012): Guidance on the design, Inspection and Use of Water Bags as Test Weights
in the Offshore and Marine Industries
BS. 150.4309:2010. Cranes -Wire Ropes: Care, Maintenance, Inspection and Discard
The Road Vehicles (Construction and Use) Regulations 1986 (As Amended)
©lEEA Academy - MCE - Step Notes - July 2015 - v1.4 ©lEEA Academy - MCE - Step Notes - July 2015 - vl.4