LEEA ACADEMY Course Study Materials - MCE - V1.0 Mar 2020

Developing Professionals for the Lifting Equipment Industry
©LEEA Academy
Mobile Crane Examination – Course Study Materials – v1.0 Mar 2020
Mobile Crane Examination
Advanced Programme
Course Study Materials
©LEEA Academy
INSTRUCTOR LED TRAINING ONLY
LEEA Learning and Development Agreement

In the interests of all parties and to ensure the successful achievement of the LEEA Mobile Crane
Examination Advanced Programme, the following arrangements are to be confirmed:
Student:
I agree to:
• Always follow instructions from my LEEA trainer

• Follow all rules and procedures regarding health and safety matters whilst on site
• Respect the tidiness and cleanliness of training areas and rest area facilities
• Notify my LEEA trainer immediately if I have any concerns
• Inform my LEEA trainer of any learning difficulties at the soonest opportunity (this may be done
privately between you and your LEEA training facilitator)
• Keep to agreed session times and return quickly from rest breaks and lunchtime periods
• Keep my mobile phone on ‘silent’ for the duration of all training sessions and to leave the class if I
have to make or receive an urgent call, for the benefit of my fellow students
• Provide feedback to the LEEA trainer regarding the training I have received
• Respect the opinions of my fellow students and to actively engage in group discussion
• Follow the rules regarding LEEA Assessments
4
Signed _____________________________________ Date ________________________
LEEA Trainer:
Your LEEA Trainer agrees 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
• Always maintain confidentiality for all students
• 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 can discuss any issues or concerns which arise during the training course
©LEEA Academy
Disclaimer
These Course Study Materials are a useful and authoritative source of information for the LEEA
Mobile Crane Examination Advanced Programme student.
Whilst every effort has been made to achieve the highest degree of accuracy in the generation of
the data and information supplied, ultimate responsibility remains with the student and their employer
to ensure that current legal requirements are followed.
First Edition.........................November 2019
© LEEA 2019. 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 Equipment Engineers Association.
Operative training for all the equipment covered in these course study materials should always take
the manufacturer’s information and instructions for use into account.
©LEEA Academy
CONTENTS
Contents ...............................................................................................................................6
1. Legislation .........................................................................................................................7
2. Standards and Code of Practice ........................................................................................ 20
3. On Site Safety .................................................................................................................. 24
4. Personal Protective Equipment ........................................................................................ 30
5. Origins of Mobile Cranes.................................................................................................. 32
6. The Thorough Examination .............................................................................................. 34
7. Types of Crane ................................................................................................................. 43
8. Rated Capacity Charts ...................................................................................................... 48
9. Load Indicators ................................................................................................................ 66
10. Crane Signals ................................................................................................................. 80
11. Mobile Crane Hydraulic Systems Basics .......................................................................... 87
12. Thorough Examination of Mobile Crane CARRIER/CHASSIS ............................................. 94
13. Thorough Examination of Mobile Telescoping Crane Superstructure ............................ 107
14. Wire Rope Examination ............................................................................................... 127
15. Testing as Part of the Thorough Examination ............................................................... 138 6
16. Reporting .................................................................................................................... 144
References and Resources ................................................................................................. 150
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1. LEGISLATION
Moral, Legal and Financial Reasons for Health and Safety Legislation
• Employers have a moral responsibility to ensure appropriate working conditions are provided
o This is known as a common law duty of care
• Unsafe working conditions are likely to have an impact on production

o Loss of output leading to lowering of morale and motivation
o Loss of sales turnover and profitability
• Society and customer expectations of a company’s approach to managing safety - health and safety
culture
o Negative public relations would have a damaging effect on any business
• Financial cost from loss of output

o Fines, damages, legal costs, insurance etc.
The Legislative Framework
Health and Safety at Work etc. Act 1974 (UK)

• The Act is general in nature
• There is no reference to specific articles or substances
• The Act applies to all sectors
Specific duties of care for:

• Manufacturers/suppliers of articles or substances
• Employers
• Employees
The Health and Safety at Work Act (HSWA) is an enabling Act for specific regulations.
Status in UK: legal requirement.
Status internationally: adopted as best practise and requested by customers and authorities.
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Mobile Crane Examination – Course Study Materials – Nov 2019 v1.0
The Main Purpose of the HSWA
The Health and Safety at Work Act covers nearly all occupations. It is designed to protect people at work
including staff, visitors, contractors and members of the public. The HSWA supersedes nearly all previous
health and safety laws in the UK.
The main purposes of the Act are set out in section 1 as follows:
• To secure the health, safety and welfare of persons at work

• To protect other people from hazards arising from work
• To control the keeping and use of dangerous substances and materials, including
explosives and highly flammable materials
• To control the emission of noxious substances from certain premises
It sets out a framework of general duties, primarily on employers, but also on employees and the controllers
of premises, and on designers, manufacturers, importers and suppliers in relation to articles and substances
used at work.
Regulations from the HSWA

Regulations are one form of delegated legislation made possible by Section 15 of HSWA
which gives powers to the Secretary of State (UK) to make regulations for matters concerned with health
and safety at work.
8
Regulations are not Acts of Parliament but do have the support of the law and therefore must be complied
with.
Regulations are increasingly drafted by reference to European Directives (these will be discussed at a later
stage in this module).
There are many sets of regulations applying to health and safety. Some apply to all places of work and others
are specific to particular industries, operations, substances, materials or premises.
Here are some examples of Regulations:

• The Manual Handling Operations Regulations
• The Control of Substances Hazardous to Health Regulations
Notes:
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Health and Safety at Work Act Section 2
Duties of the Employer
“Duty to ensure so far as is reasonably practicable, the health, safety and welfare at work of all his/her
employees”
• Safe plant and systems of work
• Safe use, handling, storage and transportation of articles and substances
• Information, instruction, training and adequate supervision
• Safe place of work and a safe means of access and egress
• Safe working environment and adequate welfare facilities

Duties of Designers, Manufacturers, Importers and Suppliers
• To ensure, so far as is reasonably practicable, that articles they design, construct, make, import,
supply etc. are safe and without risk to health at all times e.g. when it is being set up, cleaned, used
9 or maintained by someone at work
• To carry out or arrange such testing and examination necessary to perform the duties above
• To ensure that those supplying the item have adequate information about its designed and tested
use. This includes essential conditions for dismantling and disposal
• Take steps to ensure, so far as is reasonably practicable, that those supplied are given updated
information where it becomes known that the item gives rise to serious risk to health and safety

Duty of Employees
• States that employees must not endanger themselves, or others, by their acts or omissions
• Also, they must co-operate with their employers; as long as this does not lead to an increased risk
to health and safety, or is an illegal act; so that employers can comply with their statutory duties
This makes responsibility for safety a joint employer/employee effort
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Misuse and interference of any provisions:
No person shall intentionally or recklessly or interfere or misuse anything provided in the interests of health,
safety and welfare in pursuance of any of the relevant statutory provisions.
Management of Health and Safety at Work Regulations 1992 (Revised 1999)

In addition to Section 2 (2) c of the HSWA, The Management of Health and Safety at Work Regulations 1999
require employers to ensure the effective planning, organisation, control, monitoring and review of
preventive and protective measures. All these arrangements must be recorded and made known to
employees. This is usually accomplished by the design of a company health and safety policy.
• MHSWR underlines the requirements for employers to provide instruction and training
• Employers must ensure that their personnel are properly trained to use any equipment necessary
in the course of their work, but the regulations also place an obligation on employees to undergo
such training and follow the instructions given by their employer
• Operatives are required to only use equipment for which they are trained and to use it in the
manner and for the purpose for which they have been trained
10
LEEA Definition of a Competent Person
The term ‘Competent Person’ has long been used in legislation. Current legislation uses it for a variety of
duties to describe a person with the necessary knowledge, experience, training, skill and ability to perform
the specific duty to which the requirement refers. There can therefore be several ‘Competent Persons’,
each with their own duties and responsibilities, i.e. competent for the purpose.
The term has never been fully defined in law but, for the purpose of thoroughly examining lifting
equipment, the LEEA definition of a Competent Person is a person having such practical and theoretical
knowledge and experience of the equipment which is to be thoroughly examined that will enable him/her
to detect defects or weaknesses which it is the purpose of the examination to discover and assess their
importance to the safety of the equipment.
The Competent Person should have the maturity to seek such specialist advice and assistance as may be
required to enable him/her to make necessary judgements and be a sound judge of the extent to which
he/she can accept the supporting opinions of other specialists. He/she must be able to certify with
confidence whether it is free from patent defect and suitable in every way for the duty for which the
equipment is required. It is the view of LEEA that competency can be a corporate responsibility.
Notes:
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Primary Elements of Competency
Information Instruction
Training Supervision
Note: LEEA training course certificates and Advanced Programme qualifications are not evidence,
declaration or proof of competency.
Employers must ensure that their personnel are properly trained to use any equipment necessary in the
course of their work. To ensure the personnel are correctly trained, Risk Assessment processes will be
carried out to decide on the level of training to be provided to the employees based on their duties.
What are the Required Elements of Competency?
11
Experience
Professional –
Appropriate
morals and
qualifications
ethics
What are the

Continual main
Subject matter
professional requirements
expert
development expected for
competency?
Knowledge and Know your

understanding limits and when
of applicable to seek further
laws Access to advice
standards and
other related
product
information
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The European Machinery Directive
European Directives
• A need for common requirements throughout Europe
• European Directives implemented
• Main Directives are already regulations in the UK
• Most countries in the European Free Trade Area have similar laws
2 types of Directives:
• Those that remove barriers to trade
• Those that concern health and safety
Lifting equipment legislation addresses:

• Requirements for design
• Condition of the equipment
• The manner in which it is used
Machinery Directive 2006/42/EC

Provides the harmonisation of the Essential Health and Safety Requirements (EHSRs) for machinery.
It applies only to products that are intended to be placed on or put into service in the market for the first
time.
Machinery is "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". 12
The manufacturer is responsible for verifying whether a product falls within the scope of the Machinery
Directive.
Supply of Machinery (Safety) Regulations 2008 – SM(S)R

Machinery Directive is implemented in the United Kingdom under the Supply of Machinery (Safety)
Regulations 2008:
• Manufacturers to issue information for care and safe use of lifting equipment
• Coefficients of Utilisation (Factor of Safety)
• Static and dynamic loads that the equipment must withstand
• No requirement for a test certificate to be issued
• Certain safety information must be placed on the equipment
• Compliance can be achieved through working to Harmonised European Standards
• Implements the European Machinery Directive within the UK
• Mandatory on member states of the European Union
• Designed to prevent barriers to trade
Under the Supply of Machinery (Safety) Regulations 2008, machinery needs:
• A Declaration of Conformity (DOC)

• To be “CE” marked
• A “technical file”
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An EC Declaration of Incorporation (DOI) is a device to legally market machinery which can function but is
not complete and may not be safe. Such machinery is not to be used until incorporated into an assembly
for which a DOC has been issued – in doing so you assume the obligations of the manufacturer of the finished
assembly.
Definitions
WLL – Working Load Limit
The maximum load or mass that an item of lifting equipment is designed to sustain, i.e. raise, lower or
suspend. This is the load required to be marked on an item by the product standards.
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 marked on the
item by LOLER and which appears on any report of thorough examination.
MBL – Minimum Breaking Load

The minimum breaking load is the calculated load at below which the item will not break or fail due to
distortion.
Coefficient of Utilisation/Factor of Safety/Working Coefficient

It is a factor which is applied to the MBL to determine the WLL. It varies with the product to take account of
the susceptibility to damage and considers the type of stresses the item will meet in normal use.
13 Mode Factor
A factor applied by the user (slinger or rigger) that takes into account the geometry of a sling assembly to
obtain the maximum load it may lift for a particular mode of use.
Lifting Accessory
Any device such as a sling, shackle, eyebolt, clamp, spreader beam etc used to connect the load to a lifting
appliance but which is not itself part of the load or the appliance.
Lifting Appliance
A device or mechanism, such as a crane, winch, pulley block, gin wheel, chain block, which does the work in
lifting the load or provides the means of movement, or the supporting structure and anchoring devices for
such a mechanism, e.g. runway, gantry etc., which may also permit a suspended load to be moved in the
horizontal plane.
Static Test
Lifting machinery or a lifting accessory is first inspected and subjected to a force corresponding to the
maximum working load multiplied by the appropriate static test coefficient. The load is released and the
machinery/accessory is inspected again to ensure that no damage has occurred.
Dynamic Test
Lifting machinery is operated in all its possible configurations at the maximum working load multiplied by
the appropriate dynamic test coefficient, taking into account the dynamic behaviour of the lifting
machinery, in order to check that it functions properly.
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Supply of Machinery (Safety) Regulations 2008
Lifting equipment must be designed and built to sustain a static overload of:
Manually operated machines 1.5 x WLL

Other machines 1.25 x WLL
Lifting accessories 1.5 x WLL
Machinery must be capable of sustaining a dynamic overload of:
1.1 x WLL
PUWER and LOLER

PUWER: Provision and Use of Work Equipment Regulations 1998
Applies to all work equipment
LOLER: Lifting Operations and Lifting Equipment Regulations 1998

Applies to lifting equipment in addition to PUWER
Both LOLER and PUWER apply to all sectors of industry
Status of PUWER and LOLER

These are legal requirements in the UK. 14
Internationally, these are good practice demanded by customers and local authorities. They are integral to
the LEEA Code of Practice.
The Essentials of PUWER

PUWER places duties on the employer to ensure that:
• Work equipment coming into their undertaking meets with any EHSRs and in the case of lifting
equipment, this would be according to directive 2006/42/EC.
• Work equipment is suitable for the purpose for which it is to be used
• The working conditions and risk to health and safety of personnel in which the work equipment is
used is to be considered
• Equipment is suitably maintained and a log kept up to date
• Equipment is inspected on a regular basis (ref. LOLER)
• All inspection and maintenance records are kept and recorded
• All persons using work equipment have sufficient information pertaining to its use, e.g. operating
manuals and guides to safe use
PUWER requires employer to address risks or hazards of equipment from all dates of manufacture and
supply.
Equipment first provided for use after 31st December 1992 must comply with any ‘essential requirements’.
©LEEA Academy
Equipment may still present a hazard or risk if:
• Application is different from that originally envisaged

• Safety depends upon the way it is installed
• Technical mismatch between the supply side and user side legislation
Employers can ensure compliance by checking:

• CE Marking
• EC Declaration of Conformity
When providing equipment for use at work PUWER requires that the purchaser obtains equipment
complying with the relevant European Directives.
Provision and Use of Work Equipment Regulations (PUWER)
Regulation 4 Suitability of Work Equipment

Regulation 5 Maintenance
Regulation 6 Inspection
Regulation 7 Specific Risks
Regulation 8 Information and Instructions
Regulation 9 Training
15
Lifting Operations and Lifting Equipment (LOLER)
Regulation 4 Strength and Stability

Regulation 5 Lifting Equipment for Lifting Persons
Regulation 6 Positioning and Installation
Regulation 7 Marking of Lifting Equipment
Regulation 8 Organisation of Lifting Operations
Regulation 9 Thorough Examination and Inspection
Regulation 10 Reports and Defects
Regulation 11 Keeping of Information
Notes:
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Regulation 4: Strength and Stability
Employers must ensure that 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.
Regulation 5: Lifting Equipment for Lifting Persons

Every employer shall ensure that lifting equipment for lifting persons –
(a) is such as to prevent a person using it being crushed, trapped or struck or falling from the carrier; 16
(b) is such as to prevent so far as is reasonably practicable a person using it, while carrying out activities
from the carrier, being crushed trapped or struck or falling from the carrier;
(c) has suitable devices to prevent the risk of a carrier falling;
(d) is such that a person trapped in any carrier is not thereby exposed to danger and can be freed.
A mobile crane used for lifting people should

• be adequate and suitable for the task
• have a freefall capability lock-out
• be equipped with appropriate devices such as a hoisting limiter, 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 lift, etc.). If it is not regularly used, then inspect it before it is first used each time it
is put into service and every day it is used.
The crane and associated equipment should be suitably de-rated (by 50%) and the crane should be operated
in accordance with the recommendations in the BS 7121 series of standards.
Regulation 7: Marking of Lifting Equipment

All lifting equipment to be marked with its SWL and information that gives the items characteristics, e.g.
boom length, radius, capacity (load charts) etc.
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Regulation 8: Organisation of Lifting Operations
Each lifting operation must be
• planned by a competent person
• supervised
• carried out in a safe manner
Regulation 9: Thorough Examination and Inspection

Every employer shall ensure that before lifting equipment is put into service for the first time by them, it is
thoroughly examined for any defect unless:
• The lifting equipment has not been used before
• An EC Declaration of Conformity should have been drawn up, the employer has received such
declaration and;
• The equipment is no older than 12 months before the lifting equipment is put into service.
Maximum fixed periods for thorough examinations and inspection of lifting equipment as stated in
regulation 9 of LOLER are:
Lifting Accessories 6 months
Lifting Equipment 12 months
Lifting equipment for lifting persons 6 months
The information to be contained in the report of thorough examination is given in schedule 1 of LOLER.
LEEA also makes it available in LEEA Members templates for ROTE.
17 Examination Scheme
An examination scheme may specify periods of time between in-service thorough examinations different
(longer or shorter) to the periodic examination intervals stated in the Regulations. But a longer period must
be based on a rigorous assessment of the risks based on how and where the equipment will be used.
This should be included in the information provided to the competent person where the thorough
examination is conducted by someone other than the competent person who agreed the longer/shorter
examination periods. The examination scheme should be regularly reviewed, especially where
circumstances change.
The examination scheme can be drawn up by the user, owner, manufacturer or some other independent
party provided they have the necessary competence.
The examination scheme drawn up by the competent person should identify and specify those parts of the
lifting equipment that should be thoroughly examined. It should specify the intervals at which the lifting
equipment (or individual parts thereof) should be thoroughly examined and, where appropriate, those parts
that should be tested.
Any examination scheme for lifting equipment should take account of:
(a) its condition;
(b) the environment in which it is to be used; and
(c) the number of lifting operations and the loads lifted.
Different items or parts of the lifting equipment may be thoroughly examined at different intervals, taking
into account the degree of risk associated with each item or part.
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Regulation 10: Reports and Defects
A person making a thorough examination for an employer under regulation 9 shall:
• Notify the employer immediately of any defect in the lifting equipment which in his opinion is or
could become a danger to persons
• As soon as 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 Schedule 1 to the
employer
• 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 relevant
enforcing authority
Every employer who has been notified shall ensure that the lifting equipment is not used before the defect
is rectified.
Regulation 11: Keeping of Information

An employer obtaining lifting equipment shall:
• Keep the EC Declaration of Conformity for so long as they operate the lifting equipment
• Ensure that the information contained in every report is kept available for inspection
18
Notes:
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Notes:
19
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2. STANDARDS AND CODE OF PRACTICE
What are Standards?
Standards are a published specification that sets a common language and contains a technical specification
or other precise criteria. They are designed to be used consistently, as a rule, a guideline, or a definition.
Standards are applied to many materials, products, methods and services helping to make life simpler and
increase the reliability and effectiveness of goods and services.
Standards are designed for voluntary use and do not impose any regulations, but laws may refer to a specific
standard, making compliance with them compulsory.
Reference is made in legislation to Standards and Codes of Practice and we must refer to these for further
information and guidance.
Manufacturing standards detail dimensions, materials and safe working loads.

• E.g. BS EN 14492 (Winches and Hoists)
Performance standards offer a range of criteria that the final product must meet.
• E.g. BS EN 13001 – Cranes (General Design)
Creating Standards 20
Standards are usually created by a collective of appropriately experienced and qualified people who
function together as a committee. Details of proposed standards are agreed and a draft of the standard is
released for anyone who has an interest in the standard to make comments about the contents. When the
reviews have finished, the standard may be published.
Notes:
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British Standards
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.
Harmonised European Standards (Transposed)

For lifting equipment, these standards are made through the European Standards body CEN. The standards
bodies of the member states (BSI in the UK) are then required to withdraw any conflicting standards and
publish the Harmonised Standard as their national standard. A manufacturer can demonstrate compliance
with the requirements of a Directive by working to Harmonised Standards since the standards address the
requirements.
CEN standards carry the prefix EN. In practice the standards bodies of the member states publish the
standards with the additional prefix used for their national standards, e.g. in the UK they are published
with the prefix BS EN and in Germany as DIN EN. The number of the standard and its content is then
identical throughout Europe. However, not all EN standards are Harmonised and it is necessary to refer to
the standard to establish its relationship with Directives.
21 Transposed Harmonised European Standards are intended to remove technical barriers to trade and to be
recognised throughout Europe and beyond. They have a quasi-legal status under the European Directives
and working to them is the easiest way for a manufacturer to demonstrate compliance with the ‘essential
safety requirements’ addressed by the standard.
ISO Standards
ISO (or International Standards) are generally performance standards which are agreed internationally by a
majority vote.
Their use is optional, but they are often used as the basis for writing national standards.
Where the UK accepts these as written, they are published as British Standards.
A new practice has been adopted in recent years of using the ISO number and adding the prefix BS, for
example ISO 4301- Cranes Classification -General-2016 is published as BS ISO 4301-1-2016
Approved Codes of Practice

The Regulations which provide the detailed requirements of the general duties set out in HSWA do not
specify how employers and others should meet those requirements. This is the role of the Approved Codes
of Practice (ACoPs). They detail how to comply with the legal requirements.
©LEEA Academy
ACoPs are issued by the Health and Safety Executive with the consent of the relevant government minister
and following consultation with government departments, employers’ and employees’ organisations, and
expert opinion in the subject area.
There are ACoPs accompanying some of the health and safety regulations which have particular significance
beyond providing guidance on how to comply with the requirements of the regulations. This is because
contravention of the advice in a code of practice is admissible in evidence to prove a breach of the statutory
provisions as set out in HSWA itself and the associated regulations.
The introduction to ACoPs contains the following statement:
“Although failure to comply with any provision of the code is not actually an offence,
such a failure may be used in criminal proceedings as evidence that a person has
contravened a regulation to which the provision relates. In such a case, however, it will
be open to that person to satisfy the court that he has complied with the regulation in
some other way.”
It is important not to confuse Regulations with Approved Codes of Practice (ACoPs). ACoPs do not state legal
requirements and, therefore, you cannot be prosecuted for failing to comply with any guidance contained
in them. However, if you do not comply with them, this may be used as evidence of non-compliance with
the Regulations, unless you can prove otherwise.
Examples of Approved Codes of Practice are:

• ACoP L113 - LOLER ACoP (Lifting Operations and Lifting Equipment Regulations)
• ACoP L22 - PUWER ACoP (Provision and Use of Work Equipment Regulations)
22
Codes of Practice and Guidance
• Approved Codes of Practice (e.g. L113 LOLER ACoP 2014)
• Recommended CoP (e.g. LEEA COPSULE)
• Trade or Professional Code of Practice (e.g. LEEA Technical requirements)
• Technical publications (e.g. Manufacturer’s specifications)
• Safety information sheets
Status of the Approved Code of Practice (ACOP) is quasi-legal

• An ACOP is a step down from the regulations
• The requirements are not absolute
• Normally be expected to follow them
• Provide a benchmark against which a court may judge alternatives
Status of Guidance
• Guidance is another step down in status
• Does not have a special status in law
• The guidance is not compulsory
• If you follow the guidance you will normally do enough to comply with the law
Health and safety inspectors seek to secure compliance with the law and may refer to this guidance as
illustrating good practice. (Section 20, 21 and 22 of HSWA)
©LEEA Academy
Notes:
23
©LEEA Academy
3. ON SITE SAFETY
A Few Essential Rules
• Do not take shortcuts in the planning of safety for the work to be done
• Do not take risks
• If your job cannot be done safely, your employer will not want you to do it
o Always talk to your line manager if you have concerns
• Report unsafe conditions or unsafe working behaviour immediately
Working at Height
Thorough examination activities carried out on mobile cranes outside of edge protected areas are required
to comply with the Work at Height Regulations 2005, which prioritise the fall protection measures which
should be used.
Duty holders must:
24
Notes:
©LEEA Academy
25
Working Above Ground Level

Hierarchy of Control Measures
1. Working Platforms (crane walkways etc.)

2. Scaffolding
3. MEWPs
4. Controlled Zones
5. Safety Nets and Air bags
6. Work Positioning
7. Horizontal and Vertical Lifelines
8. Fall Arrest Equipment
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Rescue Plan
A Rescue Plan must be developed whenever fall-arrest systems are in use and when personnel may not be
able to perform a self-rescue should a fall occur.
Before requesting a Rescue Kit (which is the last resort), you must first consider whether ladders,
stepladders, MEWPs, controlled decent devices or other equipment can be used to perform a rescue.
If all else fails, then a Rescue Kit should be used.
Other Things to Consider for a Rescue Plan
• You must never rely on the emergency services as a primary rescue plan
• What obstructions may be in the way of reaching a suspended worker?
• How will the rescue be assured within 10 minutes of the fall to minimise the risk of further injury or
suspension trauma?
• How will the safety of the rescuers be assured as well as the suspended worker?
• What communications will be used between the suspended worker and the rescue team?
Risk Assessment
When identifying sensible measures to control risks, concentrate on real risks - those most likely and those
which will cause most harm.
Consider particular control measures as part of overall assessment. 26
•An object or situation that has the

Hazard
potential to cause harm
•A liability or exposure to harm;

Danger
something that causes peril
•How likely is it that someone could be

Likelihood
harmed by the hazard?
•If the potential for harm occurs, how

Severity
severe would the incident be?
•The likelihood that the harm from the

Risk
hazard is realised
Notes:
©LEEA Academy
5 Steps to Risk Assessment
Step One Identify the hazards
Step Two Decide who might be harmed and how
Evaluate the risks and decide on control

Step Three
measures
Step Four Record your findings and implement them
Review your assessment and update if

Step Five
necessary
Example of Risk Assessment
27
Hierarchy of Control Measures
©LEEA Academy
Monitor and Review
“Ensure control, measure compliance”
Note any changes during operations such as:

• additional hazards presented
• traffic, pedestrians etc.
• changes in production activity
Record your findings and change the risk assessment as necessary. This may result in the requirement for
additional control measures.
Safe System of Work

So far. you have reviewed how to implement a safe system of work.
A safe system of work is a best practice that will allow you to minimise the risks.
When you follow a safe system of work:
✓ You have identified the hazards

✓ You have decided who may be harmed
✓ You have evaluated risks and implemented the control measures required (ERIC PD)
✓ You have recorded your findings
✓ You have reviewed and monitored the situation when required 28
Method Statements and Work Instructions

• Generic risk assessments will normally suffice
• Unusual or potentially hazardous tasks may require specific risk assessment
• Always follow a ‘Safe system of work’
• Toolbox talk
o All team members are fully briefed
o Focussed
o Discuss the ‘job specific’ method statement
o Briefings should be recorded
o Unusual features of the job to be highlighted
©LEEA Academy
Notes:
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©LEEA Academy
4. PERSONAL PROTECTIVE EQUIPMENT
Making the workplace safe includes providing instructions, procedures, training and supervision to
encourage people to work safely and responsibly.
Before starting a thorough examination or test, the competent person will have completed a site risk
assessment and so 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.
For example,
PPE is required to protect from these hazards as a control measure.
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What do the PPE Regulations Require?
PPE as a control measure is one of the least preferred methods. 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 PPE to be supplied.
The Regulations also require that PPE is:

• Properly assessed before use to make sure it is fit for purpose
• Maintained and stored properly
• Provided with instructions on how to use it safely
• Used correctly by employees
Key Points
Are there other ways to adequately control the risk? e.g. by using engineering controls.
If not, check that:

• Suitable PPE is provided
• It offers adequate protection for its intended use
• Those using it are adequately trained in its safe use
• It is properly maintained, and any defects are reported
• It is returned to its proper storage after use.
Ensure all site safety procedures are followed always!

©LEEA Academy
31 Notes:
©LEEA Academy
5. ORIGINS OF MOBILE CRANES
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.
Meet the crane: at first a simple winch and pulley system and then later
a compound pulley system credited to Aristotle.
Today, you can see the difference in the ways buildings were
constructed in different time periods.
Pre-cranes, building blocks tended to be much larger, because so much effort was required to push each
one up a ramp, it was less labour-intensive to use bigger and fewer blocks.
Origins of Mobile Cranes

Post-cranes, blocks were smaller but stacked higher, in more complicated and advanced structures, and
quicker.
In the end, the Greeks proved just how much more ambitious projects could be, with the help of a crane.
Rome wasn’t built in a day, but without the introduction and improvement of the Greek cranes, construction
would have taken much, much longer than it did. 32
In fact, the Romans were the first to use multiple cranes for cooperative lifting tasks, as is evident by the
massive cornerstone blocks used in some of the famous structures.
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. The Roman Empire stretched further and further away from Rome and
conquering armies became more and more ambitious, so mobility and versatility in their cranes became
key.
©LEEA Academy
The Roman army needed cranes that could move quickly, be assembled and torn down quickly, and perform
a variety of tasks—all without losing their powerful lifting capabilities.
Today, you can see that influence in how mobile cranes are used all over the world. You find them on boats,
docks, trains, and trucks, often able to be quickly adapted for difficult and unusual tasks.
The lifting capacity in mobile cranes has skyrocketed, up to 1,500 tonnes. In the end, the Romans proved
just how much mobility and versatility has increased construction capabilities.
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Notes:
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Notes:
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©LEEA Academy
6. THE THOROUGH EXAMINATION
In accordance with LOLER and PUWER 1998, a thorough examination must be:
• A systematic and detailed examination of the equipment and safety-critical parts

• Carried out at specified intervals
• Undertaken by a competent person
• Used to determine whether the equipment under examination is safe to take into use or safe to
continue in use
• Documented in a written report.
When planning the examination, also consider the operating environment – is it hazardous and/or
populated?
The owners/users may use report information to plan maintenance based on trends of breakdowns and
repairs – reducing incidents – and to determine the effectiveness of maintenance schedules.
Thorough Examinations of Mobile Telescoping Cranes and Intervals

Periodic Thorough Examination - LOLER Reg. 9(3)(a)(i) and (ii) and BS 7121-2-1 (8.7)
LOLER specifies intervals of:

• 6 months maximum for mobile cranes used to lift personnel
35 • 12 months for mobile cranes that only lift goods
The maximum intervals may be reduced by a competent person, the mobile crane user or the mobile crane
owner if they decide that environmental factors, the age or the condition of the mobile crane warrant it or
if the frequency and likely load schedule justify it.
Thorough Examination after Exceptional Circumstances

LOLER 1998 requires that if the crane is subjected to exceptional circumstances, it must be removed from
service and subjected to a thorough examination to determine whether it is safe to be returned to service.
Exceptional circumstances include:

• overload
• jib clash
• collision
• use for particularly arduous duties
• failure of a structural component or
• being subjected to weather in excess of design parameters
The scope of the thorough examination should be proportional to the nature of the exceptional
circumstances and the extent of any repairs, It should consider the reports of previous thorough
examinations, where applicable.
©LEEA Academy
Scope of Periodic Thorough Examination
The competent person carrying out a periodic thorough examination should work to a defined scope of
thorough examination that has been drawn up specifically for the crane they are required to examine.
Different scopes might be required for individual cranes of the same type and model to reflect different
thorough examination requirements resulting from differing service histories, past use and intended future
use.
It is recommended that a defined scope of thorough examination approach should be used for all cranes. It
is likely that generic scopes of thorough examination, supported by crane specific information, can be
written for specific makes and models of crane.
The defined scope of thorough examination should be drawn up in advance of the examination and should
identify those parts of the crane that should be thoroughly examined, together with required
supplementary supporting reports and tests and the extent to which they should be witnessed.
E.g. ISO 4309 for wire rope discard criteria.
The defined scope of thorough examination should specify the intervals at which the crane (or its individual
parts) should be thoroughly examined and, where appropriate, intervals for specific supplementary
supporting reports and tests. These intervals should reflect the anticipated rate of deterioration and the
likelihood and potential consequences of failure.
The defined scope of thorough examination should be drawn up by a formally appointed competent person.
The competent person may be employed by the user, owner or manufacturer of the crane or by some other
independent party, provided they have the necessary competence. This competent person could also carry 36
out the thorough examinations, supplementary reports and tests of the crane. However, in practice, it is
likely that these will be undertaken by other competent persons who are suitably knowledgeable and
trained.
Supplementary Testing in Support of Thorough Examination

Supplementary testing in support of thorough examination can include:
• Anemometer functional test and calibration check
• Spark arrestor test
• Electrical system inspection and tests
• Electrical/electronic control system test program run
• Function testing
• Hoist brake operational test
• Hoist/luffing winch assessment
• Hook blocks inspection
• Hydraulic system tests
• Overload testing
• Maintenance log/reports check
• Non-destructive testing of individual components
• Performance testing of the crane
• RCI/RCL calibration checks and functional tests
• Sheaves check
• Slew brake, test of operational efficiency
• Slew ring bearing clearance measurement and condition assessment
• Stowage of the crane’s superstructure for transport, functional test
Note: This list is not exhaustive.

©LEEA Academy
Scope of Periodic Thorough Examination
The defined scope of thorough examination should take account of…
• the crane manufacturer’s information (which may include a scope of thorough examination)
• the maintenance history of the crane
• previous thorough examination history
• the environment in which it is to be used
• the number of lifting operations to be carried out
• the magnitude of the loads to be lifted
• recurring defects
The competent person carrying out the thorough examination may add to the defined scope but is not
permitted to reduce it. The competent person should highlight any concerns about the scope to the
competent person who prepared the defined scope.
The defined scope of thorough examination should be documented and kept in a way so that it cannot be
lost or modified without authorization and can be reproduced as a paper copy if required. The competent
person who prepared the defined scope of thorough examination should periodically review it to take
account of changes in usage of the equipment, findings of previous thorough examinations, supporting
supplementary reports and tests together with any information from maintenance activities, manufacturers
or other sources.
It is essential that the defined scope of thorough examination includes all components that may be used
with the crane in different configurations, together with dedicated ancillary equipment. Pay attention to
wire ropes.
37 Components that are regularly used with the crane should be included in every thorough examination of
the crane. Other components should be thoroughly examined prior to use. Take precautions like
quarantining to ensure that such components are not used unless there is a current through examination
report for the component.
Examination Schemes
As an alternative to the maximum intervals of 6 months or 12 months for periodic thorough examination,
LOLER 1998 allows a competent person to draw up an “examination scheme” for an item of lifting
equipment such as a crane.
These intervals may be shorter or longer than the 6 month or 12 month intervals and should reflect the
anticipated rate of deterioration and likelihood and consequences of failure. This is to ensure that the
examination scheme will identify defects of a serious nature in good time and before they become a danger
to persons.
The benefit of an examination scheme is that, by focusing on the most safety critical areas, the examinations
can be carried out the most cost effective way. This may provide a means of reducing examination costs,
however, it may also provide a means of enhancing safety without increasing costs.
Notes:
©LEEA Academy
Information for Examination Schemes
The examination scheme should contain at least the following information:
a) name and address of the crane owner
b) name, qualifications and address of the person drawing up the scheme and certifying that it is
suitable and sufficient. If the competent person is not working on their own account, the name of
their employing organization and their position in that organization
c) make, model and unique identification number of the crane
d) references of any information used in drawing up the scheme. This might include the
manufacturer’s instructions and/or specific information from the designer on the design life of the
structure and mechanisms
e) details of any data logging system fitted, including a listing of the parameters monitored and the
means by which data retrieval, monitoring and storage is achieved
f) details of the environment in which the crane is to be used during the period covered by the scheme
g) identification of those parts of the crane requiring thorough examination and the probable modes
of deterioration, for example wear and corrosion
h) frequency of thorough examination for those parts of the crane identified. This frequency might be
time based, or based on loading or duty cycle limits and might vary for different parts of the crane
i) method of thorough examination of those parts of the crane identified as requiring thorough 38
examination, which might include the degree of dismantling required, any preparation to be carried
out by the user prior to the examination, NDT techniques and timed component renewal
j) an indication of the resources required to carry out the thorough examination. This might include
qualified personnel, workshop facilities, specialist NDT and metallurgical facilities
k) any changes to crane condition, operational or environmental parameters that would require a
review of the scheme by the competent person. These might include damage to the structure,
change of use from general use to heavy duty work, or moving from an inland location to a marine
environment
l) the date of drawing up the scheme and the date on which the next routine review of the scheme is
required
The examination scheme should determine whether all mechanisms function correctly and are free
from defects and whether the crane is safe for further use.
Notes:
©LEEA Academy
Overload Testing
Under LOLER there is no requirement for 4 yearly overload testing
Disadvantages of overload testing include:

• Damage over time to the crane structure
• Structural failures are usually a consequence of fatigue, defects of this type will not be shown by an
overload test
• The result of cranes that fail during testing can be both hazardous and costly
• Inspection organisations and most manufacturers do not advocate overloading as there are no
mechanical or structural benefits
• Some insurance contracts will not insure a crane that has been overloaded even if the overload was
only carried out for testing purposes
• It gives a false sense of security to both owners and users
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 if load testing is necessary.
Verification Tools and Inspection Aids

When carrying out thorough examination and/or testing of a mobile telescoping crane it will be necessary
to verify calculations, dimensions, measurements, radii, weights or angles.
To do this requires using some of or all the following instruments:

39
• Vernier gauges • Calculator and notebook
• Rope and sheave gauges +5% • Tyre pressure gauge
• Tape measures • DTI gauge
• Load cells • Torch / supplementary lighting
• Angle indicator / inclinometer • Inspection mirrors
• Spirit level • Engineers chalk / liquid chalk or paint
This list is not exhaustive.
©LEEA Academy
40
©LEEA Academy
Test Weights
Use test weights which have been proven to be accurate within ±1.0% of their nominal value by a weighing
device which has been calibrated within the previous 12 months.
The accuracy of the weighing device should be such that the sum of the possible calibration error and the
indicated load error do not exceed ±1.0% of the required test load.
Concrete Test Weights
• Cheap to make
• Easy to use
• Easily damaged
• Verified annually because of damage or erosion
Steel Test Weights
• Initially weighed for verification

• Expensive - require heavy transport
• Easy to use, compact
• More secure lifting points
41
Water bags
• Easy to transport
• Awkward to handle
• Requires disposal of water after use
• No requirement for verification but…….
The LEEA recommendation is in LEEA Guidance Document 051 – Guidance on Design, Inspection, and Use
of Water Bags as Test Weight in the Offshore Industry. To meet PUWER and LOLER, all bags and associated
lifting accessories should be inspected by a competent person at least at 6 monthly periods, as the beam or
shackle that comes with it, for example, are accessories and fall under LOLER’s inspection regime. An
examination before each use is also recommended.
Notes:
©LEEA Academy
Notes:
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©LEEA Academy
7. TYPES OF CRANE
There are many types of mobile crane. In this module, you will find some common types that you are likely
to encounter during examinations.
Rough Terrain Crane
43
This crane is ideal for rough terrain and is capable of “free on rubber” duties.
When function testing “free on rubber” duties, as safety precautions in the event of the tyres failing, it is
advisable to have the outriggers extended and the jacks sufficiently clear of the ground to allow loading.
©LEEA Academy
Truck Mounted Crane
If not fitted with a 5th or front jack, this type of crane may have restricted or no duties in the front quadrant.
Always refer to the rated capacity chart.
All Terrain Crane
44
This crane is designed to be used under different ground conditions. Outrigger controls allow the operator
from the upper cab to raise and stow the jacks and outriggers. A steering wheel and brake pedal are also
fitted in the upper cab to allow 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.
©LEEA Academy
City Crane
The city 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.
Yard Crane
45
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 rated loads (e.g. pumps, motors, valves) as per the rated capacity chart may be
transported.
©LEEA Academy
Crawler Mounted Telescopic Crane
Telescoping cranes mounted on tracks are usually used for on-site work and can be examined in the same 46
manner as wheeled cranes with the exception, obviously, of the undercarriage. It is easier nowadays to
inspect the tracks as the drive system is hydraulic rather than mechanical so you do not have to worry about
drive chains, gears etc.
Notes:
©LEEA Academy
Notes:
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©LEEA Academy
8. RATED CAPACITY CHARTS
Rated Capacity Charts provide critical information to enable Rated Capacity Limiters (RCLs) to be calibrated
correctly and lifting operations to be planned and carried out safely.
Rated Capacity Charts are essential to the crane operator to enable them to input the correct information
into his RCL so they can operate safely and within the design parameters of the crane.
The technical information contained in Rated Capacity Charts is important to the competent person(s) when
carrying out their examinations.
In this module are examples of Rated Capacity Charts which shows the type of the information that the
competent person may use to carry out a complete thorough examination and functional test of a mobile
crane.
Crane Dimension
Knowing the dimensions of the mobile crane allows a lift planner and the examiner to determine whether
the crane can access the required area for the lift or test.
48
Knowing the weight of the crane ensures it can safely

travel to its location without exceeding weight
restrictions for roads, bridges, crossings or recent
excavations.
With rough terrain cranes, the weight is required to

ensure appropriate heavy transport is available to
relocate the crane from site to site.
©LEEA Academy
Crane Weights
The transport weight determines the trailer to be used, how to load the crane on the trailer, the route to
take, and what permits are required to get the crane to the jobsite.
Along the top axis is the gross vehicle weight. In the other two columns, the arrows indicate the weight load
for each axel, depending on what additional accessories are loaded.
49
Counterweights, Installation and Tail Swing
Knowing the height of the counterweight configuration allows the crane to be set up in a location that does
not interfere with overhead or protruding obstructions such as scaffolding.
©LEEA Academy
Outrigger Configuration
Because different cranes have different configuration of outriggers, it is important to know the outrigger
50
setup, whether X pattern as shown or H pattern where the outriggers extend straight out from the chassis,
and also the length of the outriggers. This allows the crane to be set up so the outrigger pads do not sit on
underground utilities or recent excavations.
Knowing the turning circle confirms that the crane can actually access the site at the required location. There
have been cases of cranes arriving at a site and being unable to enter because of the width of road restricts
the turning circle of the crane and prevents it entering the gates.
Notes:
©LEEA Academy
Hoists and Wire Rope
The information shown here assists the examiner for a number of reasons.
51
The left hand boxes highlighted show the number of hoists.
The middle box shows the line pull for a single line.
The boxes on the right show firstly the diameter of the hoist wire rope and secondly the length of the wire
rope. You may notice there are 2 different wire rope lengths. The shorter length is for the auxiliary hoist and
is usually a single fall configuration. The longer length is required for the main hoist - as it will require
multiple reeving to achieve the maximum capacity.
The box in the bottom right is the maximum and minimum boom elevation and is also shown in degrees,
which allows boom limit switches to be verified.
Notes:
©LEEA Academy
Hook Block
The above shows types of hook blocks for specific maximum loads, their actual weight, number of sheaves
and the reeving required to achieve maximum load lift.
The ‘D’ circled refers to the minimum distance where the hook block activates the anti two block. This
ensures that the hook block does not contact the boom at its maximum elevation.
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©LEEA Academy
Rated Capacity Chart (Load Chart – Over Rear)
This chart shows the area of operation over the rear only. Over the rear means that the crane is only rated
for these capacities between the arc formed by the rear outriggers when they are extended.
5th Jack being deployed-
53
Notes:
©LEEA Academy
Rated Capacity Chart (Load Chart – 360°)
This chart shows 360° capacity. By deploying the front jack, the crane rated capacities shown are applicable
through the full 360° rotation.
Rated Capacity Chart (Load Chart)

This rated Capacity Chart clearly outlines the areas of operation with and without the 5th jack being
deployed. 54
©LEEA Academy
Load Chart
Simple load chart showing required counterweight, range of swing, radius and boom length.
55
On this chart, the box in the top left corner shows the counterweight required- in this case, 140 tonnes.
The highlighted box underneath shows the boom length ranges – in this case, 15.5 metres to 60 metres.
The box in the bottom left corner shows the maximum radius – in this case, 54 metres.
In this example, the counterweight required is 140 tonnes. With 40.5m boom length set out at 20m radius,
it would give a rated capacity of 64 tonnes according to the chart.
Notes:
©LEEA Academy
The next charts show the effect of different configurations of counterweights.
The first chart shows 160 tonnes of counterweight.
The second chart shows 100 tonnes of counterweight.
Initially with short boom and minimum radius there is no appreciable difference.
However, with the increase in boom length and radius - the difference in Rated Capacity is almost halved.
This underlines the importance of the crane being configured according to the Rated Capacity Charts.
56
Notes:
©LEEA Academy
Load Chart (Iron Fairy)
57
Note the differences in performance between “on stabilisers” and “free on wheels” duties.
This is a good illustration of the difference in capacities when using free on wheels duties. A quick
explanation of “free on wheels” means the ability to lift loads with a stationable crane without the use of
outriggers or stabilisers.
Notes:
©LEEA Academy
Rated Capacity Chart
This chart illustrates the lift capacity for a pick and carry task.
The first column indicates the radius of the lift.
The second column shows the rated capacity allowed to be lifted with 360-degree rotation, but no
movement.
The ratings in Column 3 are for a pick and carry with the crane locked over the front, which is indicated by 58
the padlock symbol and allows movement at a “creep” which is a slow roll.
These capacities are further reduced if the crane will roll at 2.5 miles per hour as shown in Column 4.
Column 5 on the right states the maximum boom length.
For example, with a radius of 40ft and a boom length of 57ft and allowing movement at “creep” speed, the
rated capacity would be 8700lbs.
Notes:
©LEEA Academy
Key to Symbols
Example of the symbols used within Rated Capacity Charts:
59
Basic symbols shown above are:
1 - Available boom length

2 - Counterweight
3 - Outrigger extension
4 - Area of operation or working area
5 - Radius
6 - Actual boom length
©LEEA Academy
Range Diagram
Range diagrams are useful to lift planners and rigging supervisors as they set out the boom lengths and
angles required to reach specific heights and radii, allowing correct positioning of the crane.
60
Configuration Acronyms
Here is an example of configuration acronyms for a specific crane. (These are not in general use).
Main Boom
Main Boom with SSL
Main boom extension

Main boom extension with SSL
Fixed fly jib

Fixed fly job with SSL
Luffing fly jib

Luffing fly jib with SSL
©LEEA Academy
Boom Configurations
The above illustrates various boom configuration that should be recognised. Examiners should be familiar
with all configurations of the equipment under examination.
61 HA shows crane main boom without the side supported lift and HASSL with the side supported superlift.
This configuration shows a main boom fitted without a fixed jib and then with a side supported Superlift.
©LEEA Academy
Fly Jib
Additional jib fitted to the main boom tip to extend or offset the reach. In the illustration below, there is an
example of without and with Superlift attachment.
Luffing Jib
In the illustration below, there are examples of luffing jibs without and with Superlift attachment.
62
©LEEA Academy
Range Diagram
This range diagram illustrates the main boom length with a fixed jib extension and then sets out the duties
for the jib length at different jib angles.
63
Lift Angle for Fixed Jib
©LEEA Academy
This chart illustrates the various angles of lift if a fixed jib is used.
The highlighted areas in the centre of the chart show jib lengths of 32 feet and 49 feet.
The highlighted box in the top left shows with a boom extension of 105 feet.
With higher angles of lift (15° and 30°), the maximum load capacity decreases.
With a fixed jib, the angle remains fixed.
Summary
Each crane has a load chart that specifies the crane's capabilities—detailing its features and how its lift
capacity varies when considering distance and angle.
These values are critical for the crane examiner/inspector as initially, they are the values they have to verify
the Rated Capacity Limiter (RCL) against. Comparing the values shown on the Rated Capacity Chart against
the RCL allows the examiner to confirm that they match. The examiner can then use the chart to select
different configurations to verify the structural integrity and stability of the crane.
It is vital that the examiner uses the specific manufacturer’s charts for the specific crane being examined.
You can identify rated capacity charts easily by the crane serial number. Otherwise, use the model
designation and number to find the correct rated capacity chart.
64
Notes:
©LEEA Academy
Notes:
65
©LEEA Academy
9. LOAD INDICATORS
Some of the indicators and limiters that the competent person may come across are: 66
RCL Rated Capacity Limiter
RCI Rated Capacity Indicator
SLI Safe Load Indicator
ASLI Automatic Safe Load Indicator
All these indicators/limiters aid the equipment operator by sensing (directly or indirectly) the overturning
moment on the equipment, i.e. load multiplied by radius. They compare the lifting condition to the
equipment's rated capacity, and when the rated capacity is reached, warn the operator that an increase in
the load or radius will result in the rated capacity being exceeded. This, of course, could result in serious
consequences.
Rated Capacity Limiters

A Rated Capacity Limiter is a device designed to lock out various functions if it considers the equipment is
exceeding the manufacturers rated capacities.
It can 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.
©LEEA Academy
Functions which decrease the severity of the loading on the equipment usually remain operational, e.g.
lowering, telescoping in, or luffing in.
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.
A Rated Capacity Indicator will inform the operator with an audible or visual warning only, e.g. a horn or
flashing beacon.
Rated Capacity Limiter systems are usually composed of a microprocessor connected to various sensors on
the crane itself. The RCL measures the angle and extension of the boom along with the load weight and
compares this with the manufacturer's specifications to determine if the lift is safe.
The RCL has the capability of detecting the angle, weight of load lifted, and ground radius of any lifting
device. It controls the lifting equipment to keep the machinery functioning as per the manufacturer's
suggested safety charts.
The crane is fitted with sensors for each of the measured parameters, which are displayed in the operator's
cabin.
RCI - Schematic Representations
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Notes:
©LEEA Academy
Anti-Two Block Assembly
Part of the Rated Capacity Limiter system is the anti-two block assembly or cut out. This normally consists
of a weight wrapped round the dead line of the crane hoist wire and suspended from a micro switch by a
chain or small wire.
If a hook block travels past the limit of the chain or wire, the weight is lifted and the micro switch is activated.
This sends a signal to the rated capacity limiter and cuts out any further hoisting movement but may allow
lowering.
68
Reel Off Cable Drum
The extension reel is designed to provide accurate measurement of boom extension when the reel off cable
forms a single flat layer across the surface of the extension reel as the boom is telescoped in and out. Any
stacking of the cable will cause extension errors as the boom retracts.
To check the reel-off cable, telescope the boom fully out and then fully in. Check that the reel-off cable
forms a flat single layer across the surface of the extension reel, with each successive turn of cable lying
next to the last.
©LEEA Academy
If any stacking or build-up of the cable occurs, make sure that the first cable guide at the top of the boom
root section is correctly aligned with the outside edge of the extension reel, as shown in the illustration
below.
Clean the reel-off cable; then lubricate it with a silicone oil.
69
Notes:
©LEEA Academy
Load Indicator Display
Example of a load indicator display -
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©LEEA Academy
Remote Bar Graph Overview
The Remote Bar Graph, shown below, displays the percentage of rated capacity of the crane. The 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.
Notes:
71
©LEEA Academy
Example of RCL System
Liebherr cranes have their own crane computer called Liccon – stands for Liebherr Computer Controlling.
Liccon allows the crane operator to enter information depending on the crane’s configuration so the
computer can calculate 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
• The 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.
Warning: Always refer to the particular manufacturer for the operating instructions and readings of rated
capacity limiters as they change from manufacturer to manufacturer.
Information that is typically entered into the system computer are:
• Type of boom and boom extension

• Amount of counterweight on crane
• Lengths of outriggers used
• Working area or area of operation
• Reeving of main hook block
All data is entered via corresponding “F” keys directly located under each data value. 72
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Example of RCL System – Data Input
The example of rated capacity limiter below displays:

• Configuration code
• Radius
• SWL
• Boom lengths
• Number of falls
• Percentage of each boom section to be used for chosen crane configuration
• Type of boom and boom extension
• Amount of counterweight on crane
• Length of outriggers
• Working area or area of operation
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Example of RCL System – Working Screen
The Rated Capacity Limiter working screen may display:
• Utilization chart
• Winches and their movements
• Warnings
• Wind speed (if anemometer is installed)
• SWL
• Tare weight
• Radius and boom angle
• Boom length with current percentages of each section used,
• Possible head height and options
To the right of the screen there is a keypad for entering more adjustments.
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Example of RCL System – Function screen for boom telescoping configurations and percentages
Via the keypad, the crane operator can access more functions of the RCL System. These can include:
• Go to the setup/load chart screen
• Retrieve information about outrigger pressures or adjust outriggers
• Go directly into telescoping mode
• Enter the configuration code
• Adjust speed of movements
• and more
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Example of RCL System – Function screen for outriggers
From the key pad, the crane operator can display the outriggers screen.
Here the crane operator can see all outrigger pressures, adjust outrigger lengths and height, see current
crane level and main lifting data.
Example of RCL System – Maximum Speed

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Maximum speed can also be altered via joystick directly by pressing the high speed (rabbit) button. After
pressing the high speed button, this change is displayed on the main working screen with a rabbit symbol.
©LEEA Academy
Important Note on RCL
Although all the systems shown display the same basic information, for example;
• Boom Length
• Boom Angle
• Radius
• Capacity
• Actual Load
They do require some input from the operator.
Unforeseen and tragic consequences can result from inputting

the wrong code, number of falls or amount of counterweight
RCL - A Tale of Two Misfortunes
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After successful completion of a full main boom and fly jib test, it was decided that a crane should undergo
a maximum boom test.
The owner of the crane did not have the facility to carry out this test, however there was a testing area
which did have this facility.
To allow the crane to access the testing area, the fixed jib was removed and the 112 tonnes of counterweight
was transferred with trucks for relocation.
Because of a delay in accessing the testing area, the crane owner, who had recently purchased the crane
second-hand from another company, decided to have the name of the previous owner removed from the
boom and to replace it with his name.
To facilitate this task, the operator extended the boom sufficiently to allow the name change and started
booming down.
Unfortunately, he had forgotten to change the configuration of the crane on the RCL. Therefore, the crane
“thought” that there was still 112t of counterweight attached.
As a result, the RCL allowed the downward motion of the boom, the crane lost stability and tipped over. The
RCL performed as if there were still 112t of counterweight attached.
©LEEA Academy
Two misfortunes happened here:
1. The crane had zero counterweight duties- this had to be inputted but wasn’t!
2. The owner had just finalised the payment transaction of the crane when he got the incident call!
Notes:
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Notes:
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10. CRANE SIGNALS
Confusion can be caused by riggers, banksmen or labourers working with cranes who have evolved their
own method of signaling in unconventional ways with various body parts including feet or heads.
To counter this potentially dangerous trend, an internationally recognised set of signals as per those
illustrated in BS 7121-1 has been developed to allow communication between riggers, banksman, signallers
and crane operators. These should be used by all competent persons when performing a thorough
examination or test on a mobile crane.
This module gives examples of these signals.
Crane Signals as per BS 7121-1
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Regarding crane signals, the competent person should always remember the following points:
• Always have a clear view of the crane operator and the load
• Beware of people working around the area of lifting; the load should never go above people
• There should be only one designated signaller at any one time
• The emergency stop signal can be given by any person on site
• Discuss signals with the crane operator and all personnel prior to the lift
• If you use handheld radios, they must be reliable, secured and must have a hands-free option for
the crane operator.
Always ensure that everyone is informed of the particular signals that are being used before
commencement of a lift!
Notes:
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Notes:
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11. MOBILE CRANE HYDRAULIC SYSTEMS BASICS
The operating system for mobile telescoping cranes is a hydraulic pump powered by a power take off (PTO)
shaft or a dedicated engine to drive the pump. It is therefore essential that the competent person
performing the examination has a basic knowledge of this type of system.
A hydraulic crane works on the same principle as the human body as far as fluid, circulation and pressure
are concerned.
The heart is a pump that pumps blood round the system. The hydraulic oil in the system is like the human
blood and if we don’t get enough blood circulating through the system, the system will get weak and
ultimately break down (flow).
If our blood pressure is not correct, we will also be weak and tired (pressure).
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.
If we want to run or exercise vigorously our heart pumps faster to allow us to do this (accelerator).
Hydraulic Systems Basic Components

Mobile Crane systems have the following same basic components of any hydraulic system:
87
• A power source
• A hydraulic oil reservoir
• A pump
• Directional control valves and actuators
©LEEA Academy
Most hydraulic truck cranes use two-gear pumps that have a pair of inter-meshing gears to pressurize the
hydraulic oil.
When speed needs to increase, the operator pushes the foot throttle to run the pump to give the maximum
flow rate (approx. 1600 rpm).
In a gear pump, the only way to get full flow is to run the engine at recommended rpm as per the pump
specification.
Example
A typical 70-ton hydraulic truck crane uses a 12.7-L diesel engine that generates up to 365 horsepower. The
engine is connected to three two-gear pumps, including:
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 because it is responsible for
moving much more weight.
Pilot pressure counterweight pump - A hydraulic truck crane uses counterweights on the back of the 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.
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.
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Mobile Crane Operator Cab

A mobile crane has two basic types of controls for manoeuvering a load:
Joysticks - There are a minimum of two joysticks in the cab. Most mobile crane joysticks are configured so
that one will control hoist and boom motions and the other will control boom telescoping and swing
motions.
Foot pedals - One pedal controls the amount of pressure being generated by the pump, but ancillary pedals
can be responsible for retracting and extending the telescoping sections of the boom or as a swing brake, a
change over from main winch to auxiliary or as a means of booming up and down.
Joy sticks and foot pedals are connected to hydraulic hoses that connect various hydraulic rams to spool
valves.
The spool valve is connected to the hydraulic pump via a third hose that is placed between the two hoses
that run from the spool valve to the hydraulic ram. When a joystick is pushed in one direction, it causes the
valve to direct the oil through the spool valves to operate the function as required.
©LEEA Academy
Some older style cranes may still be equipped with mechanical levers that use direct linkages to spool banks
rather than electronic signals.
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Hydraulic Circuit
The crane’s engine powers a hydraulic pump via a rotating shaft, (PTO – Power Take Off) or a dedicated
engine that drives the hydraulic pump. This then applies pressure to the oil, which is then directed through
spool valves to either a cylinder or a motor. This is converted back to mechanical power, which then
activates the relevant motion of the crane such as hoist, boom, swing, telescoping.
The system is protected by pressure relief valves which are set to protect the main components of the crane
and to prevent overloading.
©LEEA Academy
Here is an example of a typical hydraulic circuit.
Boom Circuit
Typical boom hydraulic circuit
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Outriggers
Typical outrigger hydraulic circuit
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Hydraulic System Performance
Hydraulic system performance can be affected by:
• Insufficient oil/no oil/contaminated oil in the system

• Dirty or clogged filter
• Excess loads
• Presence of air in the system
• Engine speed
©LEEA Academy
Safety Warning
Anything under pressure is a potential hazard
Hydraulic fluid injection injury is a very serious hazard for anyone who works with hydraulic equipment.
Other dangers with hydraulic fluid may include-fire, explosion, slips, trips, environmental effect, whipping 92
hoses, mechanical failure and burns.
Notes:
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Notes:
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12. THOROUGH EXAMINATION OF MOBILE CRANE
CARRIER/CHASSIS
Modern mobile telescopic cranes are complex pieces of equipment which are constantly developing and a
competent person should take every opportunity to keep up to date with advancements.
Manufacturer’s public relation releases often provide updated product information.
To ensure that a thorough examination is carried out methodically the following steps should be observed:
1. Carry out examination of the mobile crane chassis/carrier as per BS 7121-2-1 and BS 7121-2-3
2. Carry out examination of the mobile crane upper works as per BS 7121-2- 1 and BS 7121-2-3
3. Perform wire rope examination as per BS ISO 4309
4. Generate a Report of Thorough Examination (ROTE) as per Schedule 1 of LOLER
5. Ensure that all details in the Report of Thorough Examination (ROTE) are correct
Thorough Examination of Crane Carrier/Chassis

Mobile cranes are currently exempt from the Goods Vehicles (Licensing and Operators) Regulations 1995
and the Goods Vehicles (Plating and Testing) Regulations 1988.
However, the Road Vehicles (Construction and Use) Regulations 1986 Regulation 100 requires that mobile
cranes should: 94
“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”
©LEEA Academy
Steering and Brakes
Check the steering to ensure all wheels turn in the correct direction. This is essential with all-wheel or multi-
wheel steering. This check can be done when the crane is manoeuvring into position.
To check brakes, ask the operator to:
• Ensure gear is in neutral and apply the handbrake. Engage first gear and check to see if crane moves
• Press the footbrake and release handbrake. Check to see if crane moves
• Engage neutral and apply handbrake.
The competent person should then position themselves with a rear view of the crane to one side. Instruct
95 the operator to apply the footbrake and check for brake lights operation.
Next, ask the operator to select reverse gear and check the reverse alarm and light(s).
Manufacturer’s Information Plate/Label & CE mark

The manufacturer’s information plate will contain Type/Model, Works or Serial number, Year of
Manufacture, and where applicable, manufacturers name & CE mark.
Make sure all required markings are clear and legible.
©LEEA Academy
Lights, Windscreen & Registration Plate
Examine…
• Headlights
• Sidelights
• Warning lights
• Indicators
• Hazards
• Windscreen wipers/washers
• Registration plate
Check that all lights function correctly.
Check the condition, function and security of windscreen wipers/washers.
Check that the registration plate is clear, secure and legible.
Reverse Alarm/Lights
Not all cranes will be fitted with both. What is fitted, however, must work properly.
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Hook Attachment Points

Carefully check the hook attachment points, especially bolts or welds that are not normally visible - like
behind the bumper.
Use a torch & mirror to inspect these if necessary.
Ensure that all accessories used to attach the hook block are examined and reported on as required to
comply with local legislations.
©LEEA Academy
Operator Cab on Carrier
Check…
• Housekeeping
• control identification
• Seat
• Safety belt
• Condition of pedals
• External condition of cab including bodywork, door & window
mechanisms & mirrors
Tyres and Wheels

Check…
• Tyre condition
• Size
• Type
• Tyre pressures
• Valve caps
• Fixing studs/nuts for correct torque values
Tyre pressure is important for any crane, but it is essential that it is correct for cranes that have free on
rubber (free on wheels) duties.
97 Manufacturers load calculations and speed of travel are based on the tyre pressures being correct to avoid
tipping.
If testing on rubber duties, check to see if axle or suspension locks are fitted or required.
Most mobile cranes nowadays are fitted with radial tyres. Although cross ply tyres are rare, the examiner
must ensure that the tyres fitted to a mobile crane are either all radial or all cross ply. A mix between the
two types of tyres is not acceptable.
©LEEA Academy
Automatic carrier levelling/ suspension system
Observe suspension lowering when setting up and suspension raising when preparing to finish. Investigate
if any problems are observed.
Leaf/leaves springs suspension

Check…
• Security
• Condition
• Corrosion
• That they are correct for the model of crane 98
Notes:
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Hydraulic Systems
Hydraulic tank fitted to crane

Hydraulic tanks may be round, square or rectangular, but all should have a visual means of checking the
hydraulic oil level. Check the tank cap is the correct type and is fitted.
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• Check the hydraulic tank oil level is correct before setting up the crane
• Ensure the cap is fitted to the tank
• Check the filter if accessible
• With the PTO engaged, listen for adverse sounds coming from the pump during operation
• Check all pipes, flexible hoses and connections for leaks and condition
WARNING: Be aware of hot pressurised hydraulic oil whilst carrying out these checks
• Check all telescoping ram seals for signs of leakage
Notes:
©LEEA Academy
Outriggers, Jacks & Pads
Outrigger Beams
Visually examine the outrigger beams to ensure they are level. Beams that are offset could indicate cracked
or damaged welds or wear and that shims may need adding or replacing.
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Examine all visible hoses, connections & pipes for cracks, deformation or leaks.
If access holes are available on the side of the beam, remove the covers and check the interior of the beam
for hydraulic oil presence - this can indicate a leak in the system.
While the operator is setting up the crane and outriggers, observe them for smooth operation.
Ensure that the locking holes line up and that the locking pins are available and can be inserted.
Check the condition of operating controls and that they are clearly labelled.
Notes:
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Safety Warning
When checking the outriggers, take all adequate precautions.
Working within the radius of the crane carries serious risk that the competent person must take into
consideration.
Serious injury and fatalities have occurred because operators and workers have approached a working
crane.
Notes:
©LEEA Academy
Outrigger Jacks & Pads
Check that the jack ram is dry. A film of oil can indicate a seal is leaking and it will get progressively worse.
Use a torch if necessary and check the outer seal cover.
Ensure pads are undamaged and locking pins are available and can be easily fitted.
Further images of outrigger jacks, pads, hoses & pins…
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Notes:
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Outrigger controls & level gauges
Different crane levels gauges
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Drive Shaft
Visually examine to ensure the shaft is secure, the condition of the shaft and, if visible, the PTO shaft is
engaged.
©LEEA Academy
Access Ladders
Check access ladders for damage, missing steps, attachment fixtures, broken welds and missing bolts etc.
Summary
✓ Drivers Cab ✓ Drive shaft
✓ Lights ✓ Power take off (PTO) is engaged
✓ Brakes ✓ Outrigger jacks, pads & beams
✓ Gears ✓ All pipework & connections including
✓ Reverse Alarm flexible & rigid hoses and holding valves
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✓ Hydraulic tank oil level (checked before ✓ Hydraulic cylinders
operating any hydraulic functions) ✓ Access ladders
✓ Fuel Tank ✓ All bolts pins & fastenings
✓ Tyres & Pressures ✓ Superstructure for cracks or damage
✓ Suspension
This list is not exhaustive.
Notes:
©LEEA Academy
Typical Checklist for Thorough Examination
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Notes:
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13. THOROUGH EXAMINATION OF MOBILE
TELESCOPING CRANE SUPERSTRUCTURE
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Although important in its own right, the function of the crane carrier is to transport the crane superstructure
to its operational site.
When there, the crane superstructure becomes the star of the show, and it is crucial that it performs as per
the manufacturers specifications and works safely and efficiently.
The examiner is required to check the following key examination areas as a minimum:
• Manufacturers plate, serial number, • Boom telescoping hose recoil drum

model, year of manufacture • Boom length/angle sensor, recoil drum
• Counterweight and counterweight and cable
attachment system • Boom wear pads
• Operator cab • Winches
• RCIs • Wire rope
• Boom cylinder • Wire rope anchors/terminations
• Boom • Hook block including sheaves
• Boom telescoping sections • Anti two block mechanism
Notes:
©LEEA Academy
Manufacturer Plate
The information on the manufacturer’s plate is required not just to confirm the identity of the crane, but
also to ensure that the correct load charts are available to correctly verify the RCL. So, these markings are
required to be clear and legible.
Counterweights and Attachments

Counterweights are essential to enable the crane to perform its duties. Fitting the counterweights as
detailed in the load charts will ensure that the crane is working to its maximum boom lengths and radius.
Check that…
• the counterweight attachment rams fully extend when deployed and that they engage and lock
• both rams deploy correctly when the counterweights are fitted and both activate (rotate) to lock
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• the operator’s system display shows the correct sequence of operation
Examine the hydraulic rams and attachments for leaks, loose connections or damage.
Notes:
©LEEA Academy
Operators Cab
As the competent person, you are checking the following:
• The cab housekeeping is good

• The operator’s seat is in good condition
• There are no loose wires or panels anywhere in the cab
• The RCL is fully functional
• The crane-specific load charts are present in the operator cab
• There are no obstructions to the operators view
• The glass in the cab is all safety glass and has not been modified with anything other than the
manufacturers specific glass
• That all the control functions and switches are clearly marked and that they perform as marked
• The swing brake engages and holds
• The tilt cab mechanism if applicable operates correctly
• Lights and windscreen wipers/washers function correctly
• Air conditioning/heater controls operate correctly
Speak to the operator or technician - they can tell you if there have been problems with the crane.
Sometimes they will tell you more than they will report to their manager or maintenance colleague.
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Crane Controls
Check that all the control functions and switches are clearly marked and that they perform as marked.
©LEEA Academy
Rated Capacity Limiter
To verify that the RCL is operating correctly, take the following steps:
• Check rated capacity (load) charts are correct for model and type of crane
• Verify closed boom length on RCL against figures on rated capacity chart
• Pick a configuration and request operator to set boom length accordingly
• Boom out to a selected radius/angle
• Verify that capacity shown on RCL is same as shown in rated capacity chart
• Physically measure radius to verify it matches RCL
• Attach a known load, or lift a load using calibrated load cell and verify RCL
• Repeat for at least two different radii
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Load Monitoring Indicator

Check that the Load Monitoring Indicator (remote bar graph) is
functioning and secure.
Cab Mounted Load Chart

Ensure that the load chart is correct and legible.
©LEEA Academy
Swing Gear Mechanism
If internal gearing is used for the swing mechanism the only way to examine this, short of dismantling the
assembly, is by using your visual and audible senses.
If the swing drive is external, it is relatively easy to examine. The points to consider are:
• Worn gear teeth

• Noisy drive motor
• Loose bolts
111 Observe 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.
If excessive movement is noted when the crane is under load, then take measurements using a dial test
indicator (DTI) and compare with manufacturers readings if available. Dial test indicator measurements are
a last resort that are rarely used and are non-conclusive unless previous data is available. However, it is
another potential tool we can use.
Positive Swing Lock

All mobile telescoping cranes must be fitted with a positive swing lock to ensure that the boom cannot swing
when in the locked position. This is essential if the crane is to be moved with the boom in the upright position
(pick and carry duties).
While moving/being transported with the boom on the rest,

the positive swing lock ensures the boom cannot rotate
unexpectedly. There have been cases of booms swinging whilst
travelling and causing accidents to other road users.
The example shown is just one type; there are many more
different types.
©LEEA Academy
Central Rotary Distributor
All mobile telescoping cranes are fitted with a central rotary distributor to
allow the crane to rotate through a 360° arc.
The rotational coupling for hydraulics and electrical connections allows all
crane actions to be performed normally even when the cab is rotated.
The examiner should ensure that all fastenings are secure, all hydraulic
hoses and connections are not leaking and there is no damage to visible
wires.
On older cranes, a safety chain was attached to ensure the coupling rotated
with the crane in case securing bolts sheared.
Telescoping Booms
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The telescopic boom on a mobile telescoping crane is attached to the swivel structure by boom pins and
raised by a one or two hydraulic ram system.
• Check upper and lower boom pins, particularly the boom derrick ram attachment pins
• Failure to ensure locking pins are in place can cause the pin to work loose, resulting in boom collapse
• Check all hydraulic connections for loose fittings and leaks
• Observe derrick piston(s) while boom is being lifted. If oil is detected on the piston, it can indicate
that the seal is leaking
• Operate boom up and down to clarify if there is actually a leak, as a leak would be more visible
whilst the system is under pressure.
• Verify allowable deflection by measuring radius
Examples of single cylinder boom derrick ram -
©LEEA Academy
Telescoping Boom Flexing
When fully extended and under load, modern booms can flex
quite extensively. This is normal and allowable. However, if there
is a downward bend whilst not under load, it may indicate that
the bottom and top wear pads may need adjustment or
replacement.
Wear pad adjustment or replacement is a commonly reported

action. Crane owners and mechanics often don’t like to hear this
as it sometimes means pulling the boom to replace the inner set
of wear pads.
Looking at a boom like the one on the right indicates that the side
wear pads on the outer section of the boom require adjustment
or replacement.
A simple method of checking to see if boom wear pads require

replacing or adjustment is to fully extend the boom and get the
operator to swing a short distance then stop suddenly, any
movement in the boom can then be observed.
If the whole boom moves, this is expected and acceptable. If

individual sections of the boom move sideways, adjustment or
replacement of the wear pads in these sections are indicated.
Some examples of wear pad locations are shown below.

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Notes:
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Boom Pressure Transducer
Pressure transducers are installed in the hydraulic circuit that raises and lowers the boom cylinder(s). They
monitor the pressure within that circuit.
The difference in pressure between an unloaded boom and a loaded boom allows the rated capacity limiter 114
to calculate the actual load being lifted.
Another method is to install a tensionmeter on the load line. With this, the differences in tension allow the
rated capacity limiter to calculate the actual load being lifted.
Telescoping Systems
Older cranes may use a multi ram system for telescoping the boom and in these cases, all or most of the
boom sections will move at the same time.
The modern tendency is to use a single ram telescoping system which will telescope the boom section a
specific percentage of movement and then lock it in place before returning to its start point and repeating
with the next section.
Because the telescoping rams are internal, it is not always possible to examine them. However, some cranes
have viewports at the base of the boom that allow you to observe the rams closing.
©LEEA Academy
If there is no option for seeing the ram, examine the boom base for signs of oil to determine whether there
are any hydraulic leaks.
The condition of the hydraulic hoses on the recoil drum is also a clue as to whether there are any leaks.
Single stage ram systems have to be checked on the RCL display to ascertain whether they are operating to
their correct configuration and whether the boom pin locking system is functioning.
Boom Furniture
Boom furniture may include:
• Boom length/angle sensor

• Cable Reeling Drum
• Limit switches
115 • Dynamometer
• Anti two block switch
Attachments on booms are critical for the correct working of the Rated Capacity Indicator/Limiter.
©LEEA Academy
Cable Reeling Drum (Power feed to angle sensor and other boom furniture)
Ensure that cable is laid flat on the drum, otherwise false length readings may
be obtained.
The length of cable is mounted to the tip of the boom and transmits the anti-
two block signal.
The number of turns and the diameter of the cable drum controls the length
of the uncoiled cable. This determines the telescopic length.
Angle Sensor
The angle measurement is determined by an angle sensor mounted inside the cable reel housing shown
below.
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Fly Jibs and Mounting Structures

The difference between a fly jib and a luffing jib is that a fly jib is normally fixed in position during a lift and
the main boom moves up and down.
A luffing jib, however, is the main mover in luffing configuration and the main boom is normally set at a
fixed length and angle.
When fly jibs are stowed on the side of the crane boom it is critical to ensure that the jib attachment pins
are also stowed on the boom to ensure that the correct pins are available to pin the jib to the boom.
The jib attachment lugs should also be examined to ensure they have not been damaged or distorted.
©LEEA Academy
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.
Because most fly jib extensions are of lattice boom construction, pay attention
to the main cord and lacings.
Check for damage such as distortion and cracked welds. Also check the
attachment lugs and holes.
Fly Jib Angles

The angle of the fly jib may be variable from 0°- 60° and may be manually set or have a powered adjustable
system in place.
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Luffing Jibs
Luffing Jibs are used in conditions where it is impractical to boom the
main boom up or down, e.g. close to a building(s) and to offer a
greater radius as well as height for the crane.
The luffing jib is attached for extra height and extended to clear all
obstructions. Then it can be ‘luffed’ up and down to cover a larger
horizontal area than a fixed boom.
Luffing Jib Examinations

Performing an examination of a luffing jib involves more individual parts than a simple fly jib.
The jib itself is also a lattice boom construction and all cords and lacings require examination for distortion,
damage and weld cracks.
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.
This examination is performed at ground level during assembly.
©LEEA Academy
Side Supported Lift
Old style superlifts 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.
Some cranes have the side mounted superlift assembly permanently mounted. On others, it comes as a
separate attachment for road weight restrictions. Shown here is a detachable version.
Boom Tip Sheaves

Examine boom tip sheave assemblies:
• Check for damage to sheaves
• Check sheaves are free running with no play in the bearings 118
• Ensure rope guides are in place and secured
• Check for wear caused by wire rope rubbing on guide
Severe damage can indicate that the wire rope may have damage as well.
Sheaves must all be checked for wear. To do this apply a correctly sized sheave gauge and check.
©LEEA Academy
Wire Rope Anchor
The hoist wire operates a hook block. To do this, the wire is either attached to the hook block or reeved and
attached to the boom tip by a wire rope anchor.
It is essential that the correct wire rope anchor is attached and that the wire hoist rope has been inserted
correctly and locked in place. Shown here are two methods currently in use to anchor the wire hoist rope.
The one on the left is known as a button type anchor and the one on the right is a wedge and socket anchor.
It is essential the manufacturers guidelines are followed as the efficiency on the termination is only 80% for
a wedge and socket within the manufacturers calculation with the rope fitted.
119
If the wire rope fitted with the manufactured end (button) 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 manufacturer recognised company for re-
terminating, as the efficiency is not affected and will hold 100% in the calculation with the wire rope. e.g. 1t
rope, the button termination will hold 1t. This can be as expensive as buying a new wire rope and often
crane owners will just buy new.
With the wedge and socket, the socket must be the correct size for the diameter of the rope being used and
that the wedge and socket are part of the same assembly and not mixed. 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. Shown below is the wrong way and the
correct way. 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. This causes the wire rope to sit at an angle and under load
the pressure of the load will be concentrated on that small area at the anchor instead of being distributed
over the whole diameter of the wire rope.
©LEEA Academy
There are also several options for securing the tail. An example of one manufacturer’s method is shown
below.
120
Notes:
©LEEA Academy
Piggyback wedge socket clip
The piggyback wedge socket clip, is designed to secure the dead end of the hoist rope on a wedge socket.
Using a piggyback wedge socket clip prevents crimping and damage to the live end of the wire rope.
The dead end is positioned between the first saddle and the “U” bolt. The hoisting end is positioned between
the first and second saddle.
The nuts can then be installed and tightened. This allows the hoisting end to float within the space between
the first and second saddle.
121
Anti Two Block System

The anti two block actuator consists of a weight suspended a measured distance from the boom tip by a
chain or wire rope attached to the anti-two block switch.
When the weight is suspended from the microswitch, a continuous signal is transmitted to the RCL. When
the weight is raised by the hook-block, it interrupts the signal causing a warning light and audible alarm to
be activated at the operators console and prevents any further upward movement of the hook-block.
©LEEA Academy
Ensure that all the assembly and safety pins are present and correctly in place.
To test the anti-two block alarm, ask the operator to raise the hook block until it is just below the suspended
weight then slowly raise the hook block until the alarms activates or the weight is raised so that the alarms
should activate.
Care must be taken to ensure a block to block incident does not occur during this test.
Hook Block
This hook block demonstrates the correct information that should be
available on all mobile crane hook blocks.
• Capacity or SWL - 25T 122

• Weight of Hook Block - 360kgs
• Manufacturer’s plate
If the manufacturer’s plate is not on side of the hook block, it can often
be found on top of the block.
Examination of the hook block

Examination of the Hook Block should include but not be confined to the following:
• Check for any visible damage to the hook block

• Check that the hook swivels in all directions and there is no excessive play in
the bearings
• Check hook safety latch and throat opening for security and function
• Check manufacturers plate to find capacity, hook weight, wire rope diameter
• Confirm wire rope is of the correct diameter
Notes:
©LEEA Academy
On hook blocks that have a cross swivel, it must be checked to ensure it is free and operating correctly.
• Check block for overall damage

• Check sheaves for damage and free rotation with no excessive side to side movement
• Using a Sheave Gauge, check for wear on sheaves
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Notes:
©LEEA Academy
During the thorough examination, as the crane operator booms up, check to see that the hook block is
reeved correctly.
If in doubt consult the load chart or the manufacturer’s recommendations.
Hoist Drum Examination

Hoist drums must be thoroughly examined to ensure that:
• They are securely fastened to the superstructure

• There is no visible damage to the drum
• The hydraulic hoses and connections are secure and not leaking
124
• The wire hoist rope is layered on the drum correctly
• The drum rotates correctly
• The hoist brake operates
• There are no detrimental sounds coming from the drum during
operation
Rope Block and Rope

A common fault is called cabling or putting a twist into the rope.
This fault occurs when reinstalling anchors after reeving up or down,

putting a twist in to the rope or cabling as pictured.
Other reasons for the fault may be fitting the wrong lay of rope onto
the drum or incorrectly installing the rope.
This fault means that the hoist cannot be used as all the parts will
become stuck, potentially causing damage to various parts on the
mobile crane.
One method to remedy this is to fully close the boom and lower down.
Remove the anchor socket and reeve down to a single line. Use the
hook block as weight and boom up, extend fully and lower off. The hook
will spin. When the hook stops spinning, fold up and re-reeve, taking
care not to introduce a twist.
©LEEA Academy
125
©LEEA Academy
Notes:
126
©LEEA Academy
14. WIRE ROPE EXAMINATION
Wire ropes are generally regarded as an expendable component.
The load rope requires replacement when examination shows that its condition has deteriorated and
further use would not be suitable for safety reasons.
These criteria should never be exceeded if you follow well-established principles, such as those detailed in
• various standards
• LEEA COPSULE
• additional specific instructions from the ‘original equipment manufacturer’ (OEM) of the crane or
hoist and/or by the manufacturer of the rope
When correctly applied, the discard criteria given in full in BS ISO 4309 are aimed at retaining an adequate
safety margin. Failure to recognize them can be extremely harmful, dangerous and damaging.
Wire Rope Examination

The wire rope should always be clean. If this is not possible, consider using the electromagnetic wire rope
method of examination.
In the absence of OEM criteria, BS ISO 4309 criteria may be used to determine the serviceability of the load
rope fitted to a mobile crane.
127 BS ISO 4309:2017 - Modes of Deterioration and Assessment Methods

Mode of Deterioration Assessment Method
Number of visible broken wires (randomly distributed, localized By counting

groups, valley breaks and those that are in the vicinity of a
termination point)
Decrease in rope diameter (resulting from external By measurement

wear/abrasion, internal wear and core deterioration)
Fracture of strand(s) Visual
Corrosion (external, internal and fretting) Visual

Deformation Visual and by measurement (wave
only)
Mechanical damage Visual

Heat damage (including electric arcing) Visual
©LEEA Academy
BS ISO 4309 – Wire Rope Discard
Discard Criteria (General)
The safe use of wire rope is qualified by the following criteria:
• The nature and number of broken wires

• Broken wires at the termination
• Localised grouping of wire breaks
• The rate of increase of wire breaks
• The fracture of strands
• Reduction of rope diameter, including that resulting from core deterioration
• Decreased elasticity
• External and internal wear
• External and internal corrosion
• Deformation
• Damage due to heat or electric arcing
• Rate of increase of permanent elongation
Wire Rope Examination

The examination of wire ropes should be systematic and follow a logical order so that no part of the rope,
or the accessories and attachments to which it connects are missed. On cranes, pay particular attention at
the following locations:
• Rope drum anchorage 128

• Rope within the area of a termination point
• Sections of rope travelling through sheaves
• Sections of rope travelling through the hook block
• Sections of rope that spool onto the rope drum, especially in areas where the rope crosses over
itself in multi-layer drums
• Any section of the rope that can be damaged by abrasion in contact with an external fixture
• Any part of the rope that is exposed to heat
Broken Wires
It is usually the number of broken wires developing in a wire rope which causes its removal from service.
It is essential that the entire length of a wire rope is inspected frequently for broken wires, excessive wear,
and lack of lubrication, especially areas adjacent to terminal fittings and where an accelerated rate of wear
or corrosion is expected, e.g. where a rope passes around sheaves or pulleys, or is particularly exposed to
the elements.
All examinations shall take into account these individual factors, recognising the particular criteria. BS ISO
4309 details the discard criteria for the allowable amount of broken wires, depending on the rope category
number of the rope (RCN).
©LEEA Academy
Example of BS ISO 4309 Rope Category Number
Before determining the discard criteria for load ropes under BS ISO 4309, it is necessary to identify the RCN
of the rope.
As an example, we are going to look at a RCN 02 which is known from the manufacturers documentation:
The example from BS ISO 4309 below shows that an ordinary-lay rope, categorised as an RCN 02 (single-
layer or parallel-closed rope) fitted to a multi-layer drum may have a maximum of 6 broken wires over a
length of 6 x its diameter, or 12 broken wires over a length of 30 x its diameter, in a machine such as a
mobile crane.
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Notes:
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What if you do not know the RCN number?
If the RCN number of the load rope cannot be found in annex G of BS ISO 4309, the following method should
be used for calculating the number of allowable broken wires:
• Determine the total number of load-bearing wires in the rope;

o Simply add together all of the wires in the outer layer of strands except for any filler wires
and read off the discard values for broken wires over a length of 6d and 30d for the
appropriate conditions, in the tables provided.
Deterioration
With 6 and 8-strand ropes, broken wires usually occur at the external surface.
With rotation-resistant ropes, there is a probability that the majority of broken wires will occur internally 130
and are “non-visible” fractures.
Access to relevant standards, such as BS ISO 4309, is necessary in order to carry out thorough examinations
correctly.
Notes:
©LEEA Academy
Examples of Rate of Increase for Broken Wires in 2 Different Ropes
Generally, ropes develop broken wires at a greater rate later on in the life of a rope than in the early stages.
Have a look at the following graph which shows two examples of this.
Key:
X = time, in cycles
Y = number of randomly distributed broken wires per unit length
• Check the entire length of the rope!

• Crane wire ropes do not have an indefinite life
• In 6 or 8 strand wire ropes, the wires tend to break at the surface
• In rotation resistant ropes, it is likely that the majority of broken wires will be internal
• One broken wire in a valley may be deterioration, but two or more should be considered grounds
for discard
• Termination broken wires indicate high stress and therefore discard, although rope can be
shortened if practicable.
131
Decrease in Rope Diameter

Uniform Decrease Along the Rope
Table 5 in the standard BS ISO 4309:2017 refers to decrease in wire rope. However, it does not apply to
those sections of rope which are comparable to ropes in cross over zones or other sections of rope which
are similarly deformed as a rope on a multi-layer rope.
Mobile cranes fall into this category so the table would be irrelevant in the wire rope inspection for the
mobile crane competent person.
Reduction of Rope Diameter Resulting from Core Deterioration

Reduction of rope diameter resulting from deterioration of the core can be caused by:
a) Internal wear and wire indentation

b) Internal wear caused by friction between individual strands and wires in the rope, particularly when
it is subject to bending
c) Deterioration of a fibre core
d) Fracture of a steel core
e) Fracture of internal layers in a rotation-resistant rope
If these factors cause the actual rope diameter to decrease by 3% of the nominal rope diameter for rotation-
resistant ropes, or by 10% for other ropes, discard the rope even if no broken wires are visible.
Note: New ropes will normally have an actual diameter greater than the nominal diameter.
©LEEA Academy
Heating and Arcing Damage
Ropes that are not normally operated at temperature, but have been subjected to exceptionally high
thermal effects, are externally recognizable by the associated heat colors 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 the current enters
or leaves the rope.
Check for:
132
External Wear
Abrasion of the crown wires of outer strands in the rope results from rubbing contact, under pressure, with
the grooves in the sheaves and drums. The condition is particularly evident on moving ropes at points of
sheave contact when the load is being accelerated or decelerated, and is revealed by flat surfaces on the
outer wires.
Wear reduces the strength of ropes by reducing the cross-sectional area of the steel strands. If the actual
rope diameter has decreased by 7% or more of the nominal rope diameter due to external wear, discard
the rope even if no wire breaks are visible.
©LEEA Academy
External and Internal Corrosion
General
Corrosion occurs particularly in marine and polluted industrial atmospheres. It will diminish the breaking
strength of the rope by reducing the metallic cross-sectional area, and it will accelerate fatigue by causing
surface irregularities which lead to stress cracking. Severe corrosion can cause decreased elasticity of the
rope.
External Corrosion
Corrosion of the outer wires can often be detected visually. Wire slackness due to corrosion attack/steel
loss is justification for immediate rope discard.
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 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
b) Loss of clearance between the strands in the outer layer of the rope, frequently combined with wire
breaks between or within the strands
Confirmation of severe internal corrosion is justification for immediate rope discard.
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Notes:
©LEEA Academy
Level of Corrosion
134
Deformation
General
Visible distortion of the rope from its normal shape is termed “deformation” and can create a change at the
deformation position which results in an uneven stress distribution in the rope.
Waviness
Waviness is a deformation in which the longitudinal axis of the wire rope takes the shape of a helix under
either a loaded or unloaded condition. While not necessarily resulting in any loss of strength, a severe
deformation can transmit a pulsation, resulting in irregular rope drive. After prolonged working, this will
give rise to wear and wire breaks.
©LEEA Academy
Discard the rope if either of the following conditions exists (see Figure 10 below):
a) On a straight portion of rope, which never runs through or around a sheave or spools on to the
drum, the gap between a straight edge and the underside of the helix is 1/3 x d or greater
b) On a portion of rope, which runs through a sheave or spools on to the drum, the gap between a
straight edge and the underside of the helix is 1/10 × d or greater
Local Increase in Rope Diameter

If the rope diameter increases by 5% or more for a rope with a steel core or 10% or more for a rope with a
fibre core during service, investigate the reason for this and consider discarding the rope.
135 NOTE: An increase in rope diameter that might affect a relatively long length of the rope. For example, the
swelling of a natural fibre core can occur due to excessive absorption of moisture. This creates imbalance in
the outer strands, which become incorrectly oriented.
Other conditions which affect the safe use of wire can include:
• Basket or lantern deformation
• Core or strand protrusion/distortion
• Wire protrusion
• Flattened portions
• Kinks or tightened loops
• Bends
Lubrication
Correct lubrication of wire ropes is essential if the ropes are to give satisfactory service. Good lubrication
not only prolongs the life of the rope but also helps to reduce friction and preserves the internal parts.
All ropes are lubricated internally, and nearly all externally, during manufacture. During use, an approved
neutral lubricant should be externally applied at frequent intervals and, if practicable, whilst not in use.
Thinner types of lubricant have the best lubricant qualities but the heavy, thicker lubricants are more
suitable if the rope is constantly exposed to the elements or to water. For certain applications, dry lubricants
may be preferable. In all cases, the lubricant must be acid free in nature.
Wire ropes should be clean and dry before lubricants are applied.
©LEEA Academy
Combined Effect Assessment
Although broken wires are a common reason for discard, deterioration often results from a combination of
factors. In such cases, the competent person needs to:
• Take account of the different modes of deterioration, particularly when they occur at the same
location in the rope
• Make an overall assessment of the “combined effect” of the different modes of deterioration
• Decide whether the rope is safe to remain in service and, if so, whether it needs to be subjected to
any revised inspection/discard provisions.
Method
One method of determining the combined effect is:
• Inspect the rope and record the type and amount of each individual mode of deterioration, e.g.
number of broken wires in 6d, decrease in diameter in millimetres and extent of corrosion
• For each of these individual modes of deterioration, rate the severity and express it either as a
percentage of the respective individual discard criteria, e.g. if 40 % of the allowable number of
broken wires according to the individual discard criteria are found to exist, this represents a rating
of 40 % towards discard, or in words, e.g. slight, medium, high, very high or discard
• Either add together the individual ratings at selected locations, only when they occur at the same
location, and express the severity as a combined per cent value or make a judgement as to the 136
combined degree of severity and express the rating in words, e.g. slight, medium, high, very high or
discard.
Rope Examination Record

• For each periodic or special examination, the examiner shall provide a record containing
information relating to the examination
• (Form 1 – ISO 4309) can be viewed for typical examples of examination records.
Serial Crane Sub-assembly Safe Unsafe Observations

3.0 Hoist ropes
©LEEA Academy
Notes:
137
©LEEA Academy
15. TESTING AS PART OF THE THOROUGH
EXAMINATION
Personnel carrying out thorough examinations – BS 7121-2 Extract
Competent persons should have the necessary attributes, competencies, knowledge and experience to
enable them to carry out effective thorough examinations of cranes. The nature and extent of these will
depend on the purpose of the examination to be undertaken, the complexity of the cranes to be examined
and the consequences of failure of those cranes. It is essential that such persons have adequate training,
information and independence to carry out the work required
Attributes of the Competent Person

Competent Persons should:
• Be physically fit for the tasks they are to undertake

• Have adequate eyesight (with correction if needed)
• Be comfortable working at height, over water or in a confined space (if required)
• Have a responsible attitude
• Be able to communicate clearly with other personnel in the location where thorough examination
is taking place, including the need to take the crane out of service if it is unsafe to use
• Be able to demonstrate adequate literacy and numeracy
• Be aware of their own limitations in knowledge and experience
138
Source: BS 7121-2-1:2012 5.3.2
Competencies of the Competent Person

Competent Persons should be:
• Fully conversant with the machinery they are required to examine and its hazards, including
operation necessary for thorough examination activities
• Properly instructed and trained
• Familiar with the procedures and precautions required for safe work at height, over water or in a
confined space (where required)
• Have a responsible attitude
• Fully conversant with the appropriate sections of the manufacturer’s instruction manual
• Familiar with the use of permit to work systems where they are required by the safe system of work,
and able to operate them correctly
• Familiar with site specific safety requirements (e.g. manufacturing, construction, process plant,
nuclear, docks, airports, railways)
• Trained and competent in the selection, pre-use inspection and correct use of their personal
protective equipment
Source: BS 7121-2-1:2012 5.3.3
©LEEA Academy
Knowledge Base
Competent Persons should have:
• An understanding of the applicable crane design standards and codes of practice for the selection
and use of the relevant cranes, together with the applicable examination criteria
• An understanding of the safety rules and associated codes of practice that are applicable to the
relevant cranes
• An understanding of the inspection and maintenance requirements of cranes
• Knowledge of appropriate test procedures which may be employed and the interpretation and
limitations of those techniques
• An understanding of drawings and manufacturing literature relevant to the cranes to be examined
• Knowledge of the materials and techniques used in the manufacture and assembly of the type of
cranes to be examined
Source: BS 7121-2-1:2012 5.3.4
Practical Skills
Competent Persons should:
• Be capable of detecting defects or weaknesses in cranes which could compromise the safety of the
crane
• Have sufficient knowledge and experience to assess the importance of defects or weaknesses in the
139 crane and identify what actions need to be taken in order to rectify them. In particular, they should
be able to:
o Determine whether the crane is operating as intended
o Specify the appropriate time-scales within which identified defects or weaknesses need to
be rectified
o Determine whether defects identified in the previous report of thorough examination have
received attention
o Determine whether all safety devices are functioning correctly
o Check whether warning notices are correctly fixed and legible, and where necessary specify
any limitations on the use of the crane
o Witness any testing required as part of the thorough examination and evaluate the results
o Report on the findings of the thorough examination
Source: BS 7121-2-1:2012 5.3.5
Assessment of Competence
Employers should determine through a formally documented assessment process the competence of each
individual person, both existing employees and new entrants, based on the attributes, competencies,
knowledge and skills listed in 5.3.2 to 5.3.5. A shortfall in attainment level does not necessarily preclude
employment in this role but it is essential that such shortfalls are addressed before the person is allowed to
carry out unsupervised thorough examinations of cranes.
©LEEA Academy
All Competent Persons should be assessed on appointment, again within their first 12 months, and at regular
intervals (not exceeding 4 years) thereafter. Assessment should form part of any training.
Source: BS 7121-2-1:2012 5.3.6
Training Records
A comprehensive individual training record should be established for all personnel carrying out thorough
examinations. This should be updated as training is undertaken and as a minimum should include:
• When the training, refresher training, assessment or re-assessment took place

• Where the training took place
• The scope of the training, including types and models of crane
• The duration of the training
• The outcome of the training
• Who delivered the training
• When refresher training is required
Source: BS 7121-2-1:2012 5.3.10
Continual Professional Development

Continuing professional development (CPD) is a joint responsibility between the Competent Person and
their employer. 140
The employer should maintain a CPD record for each Competent Person. The record should include details
of how CPD is being achieved and should include for example:
• Specific training towards enhancements/additions to competency

• Familiarization/re-familiarization, ongoing training and mentoring
• Any alterations and/or withdrawals of competency
• Enhancements to qualifications
• Membership of professional bodies/institutions
• Attendance at seminars and refresher training courses
• Visits to manufacturers and trade shows
Source: BS 7121-2-1:2012 5.3.11
Notes:
©LEEA Academy
Thorough Examination
Technical product information
Before carrying out the thorough examination of a specific make and model of crane, the competent person
should be provided with access to all relevant product specific technical information. This may be
supplemented by information provided at briefing or training sessions delivered by the crane manufacturer
or the employer.
It is recommended that in-house training is carried out by a trainer who has received model-specific
technical training directly from the manufacturer.
Maintenance and Thorough Examination
Selection of the Competent Person
It is essential that the Competent Person undertaking the thorough examination of a crane has not been
involved in the maintenance of the crane.
Testing as a Part of the Thorough Examination

Supplementary tests in support of thorough examination and for other purposes
The purpose of any supplementary testing is to support the thorough examination. These supplementary
tests may be specified by the competent person and can cover a wide range of techniques, not just overload
testing.
Tests directly supporting a thorough examination should be undertaken, completed by the date specified
141 by the competent person and the results documented, in order to enable the subsequent thorough
examination to be completed. The exception to this is overload testing, where a thorough examination
should be undertaken before the overload test as well as afterwards.
Failure to complete these supplementary tests could prevent the completion of the subsequent thorough
examination. In all circumstances the competent person should witness the supplementary tests.
The results of any tests not witnessed by the competent person should be forwarded to the competent
person for review without delay.
Supplementary testing can be carried out to verify the accuracy of the Rated Capacity Limiter and its
conformance to the Rated Load Capacity Charts.
• Check the calibration of the RCL by raising a known test weight or by verifying using a calibrated
load cell
To function test the RCL, configure the boom as per the Rated Load Charts for a selected load.
• Raise the selected load and boom load out to the maximum radius as allowed by the RCL
• Verify by measuring the radius and comparing it against the Rated Load Chart. Operate crane
through all functions and return load to original start point
©LEEA Academy
Configurations and Weights Generally Used
• To test the structural integrity of the crane, the crane would be configured with minimum boom
length, minimum radius and maximum weight.
• To test the crane’s stability, the crane would be configured with maximum boom length, maximum
radius and minimum weight.
• The test should also include one intermediate test to confirm the rated capacity arc.
Hoist Brake Test

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 and correct adjustments
made.
As a minimum, the operational testing should conform to the following:
• Dynamic testing to verify that a moving load can be halted at normal lifting and lowering speeds as
per the manufacturer’s instructions for dynamic testing
• Dynamic testing to verify that a moving load can be halted at normal lifting and lowering speeds
after the emergency stop has been operated, as per the manufacturer’s instructions for dynamic
testing
• A static test to verify that the brake can hold a load without slippage.
142
Load Testing after Repair

Overload testing of cranes which have been altered or repaired
In addition to overload testing in support of a thorough examination, overload testing should be carried out
in the event of any alteration or repair which could affect the strength of the crane.
Ensure that all parts affected by the repair are subjected to the test loads in accordance with the original
crane specification.
It is essential that the competent person consults the crane manufacturer (or if they no longer exist, another
design authority) to ensure that the selected test programme is adequate.
A load test should be completed shortly after any repair 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
instructions. In this case, the report should also contain the following information: -
• Date of test and subsequent examination completion

• The crane configuration at time of test
• The unique serial number or identifying mark of the crane
• What test weights and what radii was used during the test
• Details of any defect and deformations
©LEEA Academy
Notes:
143
©LEEA Academy
16. REPORTING
LOLER requires that the competent person carrying out the thorough examination makes a written report
of that examination to the client for whom the examination has been carried out and also to the owner/hirer
of the mobile crane. Often this may be the same person.
The competent person must sign their report, or have it authenticated on their behalf, and it must contain
at least the information requested in LOLER Schedule 1.
A written report should be given at the time of thorough examination, especially if a defect has been
discovered that is or could become a danger to persons.
Report Example
This is an example of a Thorough Examination Report that meets the requirements of Schedule 1 of LOLER.
144
©LEEA Academy
The first part of the form needs to be filled in with the details of the equipment being examined.
The second part describes the type of examination being carried out and the examination periods.
In the third part, the examiner will report the defects identified, if any.
The fourth will display the details of the examiner.
With this example of a completed examination report, the examiner has just finished examining a mobile
crane before it was put into service for the first time.
The examiner will complete the following in the first section:

145 • The date when the examination took place
• The date when the report was completed
• The report number
• The name and address of the owner/ hirer of the crane
• The address where the examination took place
• The description of the equipment that has been examined and all the information needed to identify
the equipment.
With this example, you will notice that the crane is new and it has never been examined before, therefore,
the date of the last thorough examination is not available.
Notes:
©LEEA Academy
In the second section, the examiner will choose the options which are relevant to the TYPE of examination
carried out.
In our example, since it is the first examination of the crane before being put into service, we have chosen
yes. We will assume for this example that the crane has been installed correctly.
Because it is the first examination, we’re going to choose “No” for all the options regarding previous
examinations.
If this was not the first examination, then the appropriate box would be marked with Yes.
146
In the third section, the examiner will insert all the details of the defects they have been able to identify.
Because it is a new crane, no defects have been found in our example. But if the examiner did find any
defects, they would need to specify what repairs are needed to remedy it.
Since no defects have been found, the examiner writes “none” here.
The examiner was able to access all the parts that needed to be inspected.
The examiner performed a static test of the hoist brake and a function test of the RCL. These details need
to be clearly specified and the results included.
Finally, the examiners judgement is that the equipment is safe to operate, so the examiner circled yes.
©LEEA Academy
This last section is where the examiner will insert their details, starting with their name, position and
signature.
The person authenticating the report has the responsibility of verifying the identity of the inspector and
their qualification. Their name and signature is also included.
The examiner will insert the address of the company they work for.
Finally, the examiner states the date when the next examination must be completed by. Considering the
conditions of use, the examiner set the date of the next examination to be completed within a period of 12-
months.
Regulation 10 LOLER
A person making a thorough examination for an employer under regulation 9 of LOLER shall:
a) notify the employer forthwith of any defect in the lifting equipment which in their opinion is or
147
could become a danger to persons;
b) as soon as is practicable make a report of the thorough examination in writing authenticated by
them or on their behalf by signature or equally secure means and containing the information
specified in Schedule 1 to:
i. the employer; and
ii. any person from whom the lifting equipment has been hired or leased;
c) 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 practicable to the relevant
enforcing authority
A person making an inspection for an employer under regulation 9 shall:
a) notify the employer forthwith of any defect in the lifting equipment which in their opinion is or
could become a danger to persons;
b) as soon as is practicable make a record of the inspection in writing
Every employer who has been notified under paragraph (1) shall ensure that the lifting equipment is not
used:
a) before the defect is rectified; or
b) after a time specified and before the defect is rectified
In this regulation “relevant enforcing authority” means –

a. where the defective equipment has been hired or leased by the employer, the Executive;
and
b. otherwise, the enforcing authority for the premises in which the defective equipment was
thoroughly examined
©LEEA Academy
All defects need to be reported on. This includes where something has been repaired before, during or
after the thorough examination.
Failure to report all defects is contrary to LOLER and potentially hides underlying problems with the crane.
It also will not reflect the true history of the crane if not reported.
ACoP to Regulation 10 LOLER

Where the competent person identifies defects which must be made good within a specified timescale, they
should submit the report promptly to allow the employer to take the necessary action within the required
period.
In normal circumstances the competent person should complete the report and forward it within a
maximum of 28 days of the thorough examination.
Notes:
148
©LEEA Academy
Notes:
149
©LEEA Academy
REFERENCES AND RESOURCES
Standard Title
BS 7121-2-1:2012 Code of practice for the safe use of cranes. Inspection, maintenance
and thorough examination. General
BS ISO 4309:2017 Cranes. Wire ropes. Care and maintenance, inspection and discard
LEEA Guidance Ref. Title

LEEA-015 BSI Reference Library List
LEEA-051 Guidance on Design, Inspection, and Use of Water Bags as Test Weight
in the Offshore Industry
Resource Link
Lifting Operations and Lifting Equipment http://www.hse.gov.uk/pubns/priced/l113.pdf
Regulations - Approved Code of Practice and
Guidance
150
Provision and Use of Work Equipment Regulations – http://www.hse.gov.uk/pubns/priced/l22.pdf
Approved Code of Practice and Guidance
©LEEA Academy
TRAINING
Operative training for all the equipment covered in this course study material should always take
the manufacturer’s information and instructions for use into account.
FEEDBACK
We would be grateful for your feedback regarding this course study material – you can use the note box
below to list anything you would like to bring to our attention.
We value your views and will use your comments to help our continual improvement of our learning and
development materials.
Thank you for your participation.
Andrew Wright
LEEA Deputy Chief Executive Officer
Course Study Materials - feedback to LEEA:
151
©LEEA Academy

LEEA ACADEMY Course Study Materials - MCE - V1.0 Mar 2020

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Developing Professionals for the Lifting Equipment Industry

Course Study Materials

LEEA Learning and Development Agreement

• Always follow instructions from my LEEA trainer

Signed _____________________________________ Date ________________________

Your LEEA Trainer agrees to:

First Edition.........................November 2019

To return to the Contents, click the at top of each page

• Unsafe working conditions are likely to have an impact on production

• Financial cost from loss of output

The Legislative Framework

Health and Safety at Work etc. Act 1974 (UK)

Specific duties of care for:

Status in UK: legal requirement.

• To secure the health, safety and welfare of persons at work

Regulations from the HSWA

Here are some examples of Regulations:

• Safe plant and systems of work

• Safe use, handling, storage and transportation of articles and substances

• Information, instruction, training and adequate supervision

• Safe place of work and a safe means of access and egress

• Safe working environment and adequate welfare facilities

Health and Safety at Work Act Section 6

Health and Safety at Work Act Section 7

This makes responsibility for safety a joint employer/employee effort

Management of Health and Safety at Work Regulations 1992 (Revised 1999)

What are the Required Elements of Competency?

What are the

Knowledge and Know your

Lifting equipment legislation addresses:

Machinery Directive 2006/42/EC

Supply of Machinery (Safety) Regulations 2008 – SM(S)R

Under the Supply of Machinery (Safety) Regulations 2008, machinery needs:

• A Declaration of Conformity (DOC)

SWL – Safe Working Load

MBL – Minimum Breaking Load

Coefficient of Utilisation/Factor of Safety/Working Coefficient

Manually operated machines 1.5 x WLL

Machinery must be capable of sustaining a dynamic overload of:

PUWER and LOLER

LOLER: Lifting Operations and Lifting Equipment Regulations 1998

Both LOLER and PUWER apply to all sectors of industry

Status of PUWER and LOLER

The Essentials of PUWER

• Application is different from that originally envisaged

Employers can ensure compliance by checking:

Provision and Use of Work Equipment Regulations (PUWER)

Regulation 4 Suitability of Work Equipment

Lifting Operations and Lifting Equipment (LOLER)

Regulation 4 Strength and Stability

Regulation 5: Lifting Equipment for Lifting Persons

A mobile crane used for lifting people should

Regulation 7: Marking of Lifting Equipment

Regulation 9: Thorough Examination and Inspection

Regulation 11: Keeping of Information

Manufacturing standards detail dimensions, materials and safe working loads.

Harmonised European Standards (Transposed)

Approved Codes of Practice

The introduction to ACoPs contains the following statement:

Examples of Approved Codes of Practice are:

Status of the Approved Code of Practice (ACOP) is quasi-legal

Duty holders must:

Signed _____________ Date