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LEEA ACADEMY Course Study Materials - MCE - V1.0 Mar 2020
LEEA ACADEMY Course Study Materials - MCE - V1.0 Mar 2020
©LEEA Academy
Mobile Crane Examination – Course Study Materials – v1.0 Mar 2020
Mobile Crane Examination
Advanced Programme
©LEEA Academy
Mobile Crane Examination – Course Study Materials – v1.0 Mar 2020
INSTRUCTOR LED TRAINING ONLY
Student:
I agree to:
LEEA Trainer:
• 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
Mobile Crane Examination – Course Study Materials – v1.0 Mar 2020
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.
© 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
Mobile Crane Examination – Course Study Materials – v1.0 Mar 2020
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
Digital Navigation
If you are viewing this document electronically, you can navigate using the Contents table above. Click
the heading to jump to that module.
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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
• 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
The Health and Safety at Work Act (HSWA) is an enabling Act for specific regulations.
Status internationally: adopted as best practise and requested by customers and authorities.
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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:
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 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.
Notes:
©LEEA Academy
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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”
• 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
• 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
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Health and Safety at Work Act Section 8
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.
• 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:
©LEEA Academy
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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.
11
Experience
Professional –
Appropriate
morals and
qualifications
ethics
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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
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.
• 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
©LEEA Academy
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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.
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.
©LEEA Academy
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Supply of Machinery (Safety) Regulations 2008
Lifting equipment must be designed and built to sustain a static overload of:
1.1 x WLL
Internationally, these are good practice demanded by customers and local authorities. They are integral to
the LEEA Code of Practice.
• 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
Mobile Crane Examination – Course Study Materials – v1.0 Mar 2020
Equipment may still present a hazard or risk if:
When providing equipment for use at work PUWER requires that the purchaser obtains equipment
complying with the relevant European Directives.
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.
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.
©LEEA Academy
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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
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.
©LEEA Academy
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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.
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Notes:
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Notes:
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©LEEA Academy
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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.
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.
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
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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.
“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.
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 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
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Notes:
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©LEEA Academy
Mobile Crane Examination – Course Study Materials – Nov 2019 v1.0
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.
24
Notes:
©LEEA Academy
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©LEEA Academy
Mobile Crane Examination – Course Study Materials – Nov 2019 v1.0
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.
• 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.
Notes:
©LEEA Academy
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5 Steps to Risk Assessment
27
©LEEA Academy
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Monitor and Review
“Ensure control, measure compliance”
Record your findings and change the risk assessment as necessary. This may result in the requirement for
additional control measures.
A safe system of work is a best practice that will allow you to minimise the risks.
• 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
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Notes:
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©LEEA Academy
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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,
30
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.
Key Points
Are there other ways to adequately control the risk? e.g. by using engineering controls.
©LEEA Academy
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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.
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
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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.
33
Notes:
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Notes:
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©LEEA Academy
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6. THE THOROUGH EXAMINATION
In accordance with LOLER and PUWER 1998, a thorough examination must be:
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.
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.
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
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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.
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.
• 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
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Information for Examination Schemes
The examination scheme should contain at least the following information:
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
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:
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Overload Testing
Under LOLER there is no requirement for 4 yearly overload testing
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.
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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.
• Cheap to make
• Easy to use
• Easily damaged
• Verified annually because of damage or erosion
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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:
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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.
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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.
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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.
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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.
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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
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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.
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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:
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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.
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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.
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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.
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Outrigger Configuration
Because different cranes have different configuration of outriggers, it is important to know the outrigger
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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:
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Hoists and Wire Rope
The information shown here assists the examiner for a number of reasons.
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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:
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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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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.
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Notes:
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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.
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Load Chart
Simple load chart showing required counterweight, range of swing, radius and boom length.
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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:
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The next charts show the effect of different configurations of counterweights.
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.
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Notes:
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Load Chart (Iron Fairy)
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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:
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Rated Capacity Chart
This chart illustrates the lift capacity for a pick and carry task.
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.
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:
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Key to Symbols
Example of the symbols used within Rated Capacity Charts:
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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.
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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
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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.
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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.
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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.
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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.
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.
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Notes:
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Notes:
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9. LOAD INDICATORS
Some of the indicators and limiters that the competent person may come across are: 66
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.
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.
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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.
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Notes:
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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.
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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.
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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.
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Notes:
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Load Indicator Display
Example of a load indicator display -
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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:
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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.
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
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Example of RCL System – Working Screen
• 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.
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Important Note on RCL
Although all the systems shown display the same basic information, for example;
• Boom Length
• Boom Angle
• Radius
• Capacity
• Actual Load
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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.
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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.
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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).
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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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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.
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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.
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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:
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Safety Warning
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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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.
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
However, the Road Vehicles (Construction and Use) Regulations 1986 Regulation 100 requires that mobile
cranes should: 94
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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.
• 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).
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Lights, Windscreen & Registration Plate
Examine…
• Headlights
• Sidelights
• Warning lights
• Indicators
• Hazards
• Windscreen wipers/washers
• Registration plate
Reverse Alarm/Lights
Not all cranes will be fitted with both. What is fitted, however, must work properly.
96
Ensure that all accessories used to attach the hook block are examined and reported on as required to
comply with local legislations.
©LEEA Academy
Mobile Crane Examination – Course Study Materials – v1.0 Mar 2020
Operator Cab on Carrier
Check…
• Housekeeping
• control identification
• Seat
• Safety belt
• Condition of pedals
• External condition of cab including bodywork, door & window
mechanisms & mirrors
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.
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Automatic carrier levelling/ suspension system
Observe suspension lowering when setting up and suspension raising when preparing to finish. Investigate
if any problems are observed.
Notes:
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Mobile Crane Examination – Course Study Materials – v1.0 Mar 2020
Hydraulic Systems
99
• 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
Notes:
©LEEA Academy
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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.
100
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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101
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
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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.
102
Notes:
©LEEA Academy
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Outrigger controls & level gauges
103
Drive Shaft
Visually examine to ensure the shaft is secure, the condition of the shaft and, if visible, the PTO shaft is
engaged.
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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
104
✓ 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
Notes:
©LEEA Academy
Mobile Crane Examination – Course Study Materials – v1.0 Mar 2020
Typical Checklist for Thorough Examination
105
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Notes:
106
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13. THOROUGH EXAMINATION OF MOBILE
TELESCOPING CRANE SUPERSTRUCTURE
107
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:
Notes:
©LEEA Academy
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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.
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
108
• the operator’s system display shows the correct sequence of operation
Examine the hydraulic rams and attachments for leaks, loose connections or damage.
Notes:
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Operators Cab
As the competent person, you are checking the following:
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.
109
Crane Controls
Check that all the control functions and switches are clearly marked and that they perform as marked.
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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
110
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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:
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.
The example shown is just one type; there are many more
different types.
©LEEA Academy
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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
112
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
©LEEA Academy
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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.
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.
Notes:
©LEEA Academy
Mobile Crane Examination – Course Study Materials – Nov 2019 v1.0
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
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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:
Attachments on booms are critical for the correct working of the Rated Capacity Indicator/Limiter.
©LEEA Academy
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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.
116
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
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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.
117
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.
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.
©LEEA Academy
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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.
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
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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.
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There are also several options for securing the tail. An example of one manufacturer’s method is shown
below.
120
Notes:
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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
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
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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.
If the manufacturer’s plate is not on side of the hook block, it can often
be found on top of the block.
Notes:
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On hook blocks that have a cross swivel, it must be checked to ensure it is free and operating correctly.
123
Notes:
©LEEA Academy
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During the thorough examination, as the crane operator booms up, check to see that the hook block is
reeved correctly.
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.
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Typical Checklist for Thorough Examination
125
©LEEA Academy
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Notes:
126
©LEEA Academy
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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.
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.
©LEEA Academy
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BS ISO 4309 – Wire Rope Discard
Discard Criteria (General)
The safe use of wire rope is qualified by the following criteria:
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).
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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.
129
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:
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:
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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
Mobile cranes fall into this category so the table would be irrelevant in the wire rope inspection for the
mobile crane competent person.
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.
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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
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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
133
Notes:
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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.
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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
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
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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.
• (Form 1 – ISO 4309) can be viewed for typical examples of examination records.
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Notes:
137
©LEEA Academy
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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
• 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
©LEEA Academy
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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
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
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.
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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.
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:
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:
Notes:
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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.
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
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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.
• 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.
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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: -
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Notes:
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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.
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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.
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.
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:
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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.
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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.
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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
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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) 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
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.
In normal circumstances the competent person should complete the report and forward it within a
maximum of 28 days of the thorough examination.
Notes:
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Notes:
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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
Resource Link
Lifting Operations and Lifting Equipment http://www.hse.gov.uk/pubns/priced/l113.pdf
Regulations - Approved Code of Practice and
Guidance
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Provision and Use of Work Equipment Regulations – http://www.hse.gov.uk/pubns/priced/l22.pdf
Approved Code of Practice and Guidance
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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.
Andrew Wright
LEEA Deputy Chief Executive Officer
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