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NO WARRANTY
Information and materials provided in this Articulating Crane Reference Manual are provided as is without warranty of any kind, either express or implied, including without limitation warranties of merchantability, fitness for a particular purpose, and non-infringement. NCCCO specifically does not make any warranties or representations as to the accuracy or completeness of any such information and materials. Under no circumstances shall NCCCO be liable for any loss, damage, liability, or expense incurred or suffered which is claimed to have resulted from use of this publication, including without limitation, any fault, error, omission, interruption, or delay with respect thereto. Use of this publication is at users sole risk. Under no circumstances, including, but not limited to, negligence, shall NCCCO be liable for any direct, indirect, incidental, special, or consequential damages, even if NCCCO has been advised of the possibility of such damages. Copyright 2010 by National Commission for the Certification of Crane Operators. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without prior written permission from the publisher. For information, contact the publisher, the National Commission for the Certification of Crane Operators, at info@nccco.org.
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Preface
rticulating crane operators are unique among crane operators in that they are often responsible for, among other things, pre-operation inspection of the crane and truck; securing the load to the truck; driving the crane truck to the job site; identifying any hazards; properly setting up the truck and crane to make the lift; planning the lift; selecting, inspecting, and utilizing the proper rigging; attaching the rigging to the load and hook; and, finally, making the lift safely. This Articulating Crane Reference Manual provides technical information, specifications, load charts, and general information regarding articulating cranes. This manual is to be used in conjunction with the exam content outline and the exam reference list found in the Articulating Crane Operator Candidate Handbook to prepare for the Written Examination for the National Commission for the Certification of Crane Operators (NCCCO) Articulating Crane Operator certification.
The information contained herein is not specific to any single manufacturer. Further, none of the information is to be used for the actual use, operation, or maintenance of any articulating crane. That information must be obtained from the operators manual specific to the crane involved. This reference guide is not intended to supersede or replace manufacturers operators manuals, nor the current ASME B30.22 standard for articulating boom cranes. The material contained herein is not to be used for any other purpose than as reference material in association with preparing for the NCCCO certification exams. No part of this manual is to be copied or used in any other manner.
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CREDITS
NCCCO deeply appreciates the work and contributions of the following individuals and organizations, all of whom have assisted in developing this reference manual:
NCCCO also appreciates contributions from the various organizations that provided material and resources including the members of the Articulating Crane Council of North America (ACCNA)and thanks them for their continued support of crane operator safety.
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Table of Contents
2010 National Commission for the Certification of Crane Operators. All rights reserved. ACO RM REV 3/10
Appendix A: ACCNA Crane Inspection Checklist ........................................................ 51 Appendix B: Standard Hand Signals for Articulating Crane Operations ...................... 55 Appendix C: NCCCO Load Charts ................................................................................ 57
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CHAPTER 1:
1.1 Terminology
ancillary attachments: Devices attached to the crane that perform functions other than lifting a load with a hook, such as forks, augers, grapples, or a digging bucket; see chapter 4 antitwo block device: A device that prevents two blocking from occurring if crane is used with load hoist mechanism articulating boom crane (ABC): A crane with two or more boom sections that pivot (articulate) via hydraulic cylinder(s); also known as a knuckle-boom crane; see Figure 1.1 (page 4) articulating boom crane with winch (ABW): A crane with two or more boom sections that pivot (articulate) via hydraulic cylinder(s) and used with a load hoist mechanism; see Figure 1.3 (page 6) articulating boom loader (ABL): A non-folding articulating crane with a permanently attached hydraulic fork restricted to loading and unloading materials from a truck; also known as a drywall or material-handling crane; see Figure 1.2 (page 5) base: The main supporting structure of the crane that supports the stabilizer system and column (mast) to the vehicle boom extensions: A telescopic (hydraulic or manual) boom section that extends the reach of the crane certified articulating crane operator: A person possessing a currently valid articulating crane operators certification issued by a nationally accredited certifying agency (such as NCCCO)
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load handling deductions: The reduction of a cranes gross lifting capacity based on the sum of the additional weight of devices or attachments not already accounted for by the manufacturer (other than the weight of the load to be lifted) load hoist mechanism: A hoist drum or rope reeving system used for lifting and lowering loads load-holding valve: A valve that will hold a function in position and prevent movement in the event of hydraulic system failure load hook: A device attached to the end of the cranes last extension (or hoisting line) and used for attaching loads to the crane load radius (ABC): The horizontal distance from the center line of the cranes rotation to the center of gravity of the load load radius (ABL): The horizontal distance from the center of the cranes rotation to the center of the rotator lower load block: The assembly suspended by the hoisting rope, including the hook, swivel, sheaves, pins, and frame (if crane is used with load hoist mechanism) manual boom extension(s): Manually extended and pinned boom section(s) that extend the cranes reach and are housed inside the last hydraulic boom extension net capacity: The total weight a crane may lift after the load handling deductions have been subtracted from the gross capacity net load: The weight of the load being hoisted, not including the weight of rigging or attachments operators station (manual controls): The position where the manual controls are located for operating the crane operators station (top seat): The elevated seat attached to the column where the operator can control the crane
outer boom: The boom section that connects to the inner (main) boom and houses extension section(s) outer boom cylinder: The hydraulic cylinder that raises and lowers the outer boom overload protection (OLP): A system that prevents lifting a load or increasing a load radius that exceeds the cranes capacity qualified person: A person who, by possession of a recognized degree in an applicable field or a certificate of professional standing or by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work reeving: A manner of running additional parts of line from the boom tip to the lower load block with the purpose of increasing the lifting capacity of the hoist line relief valve: A valve that governs hydraulic pressure remote crane controls: Portable crane controls that allow the operator to operate a crane from remote locations in the general vicinity of the crane rope lay: The axial distance along the rope in which one strand makes one complete turn around the rope rotation-resistant wire rope: A wire consisting of an inner layer of strands laid in one direction covered by a layer of strands laid in the opposite direction; this has the effect of counteracting torque by reducing the tendency of the finished rope to rotate rotator: A hydraulically controlled device that is pinned to the last boom extension and is used to control rotation of the load with respect to the longitudinal centerline of the boom sheave: A grooved wheel or pulley over which the rope travels shock loading: A condition that occurs when a moving load and/or crane component decelerates very rapidly, causing excessive inertial forces to be borne by the cranes structure
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side loading: A force applied horizontally on the boom slew: The rotation of the boom about the axis of the column (mast), normal to the base slewing system: The mechanism that rotates the boom stability: A condition where the forces to remain upright are greater than the forces to overturn stabilizer: A component attached to the mounting base to increase the stability of the crane stabilizer beam: The telescoping beam that holds the stabilizer leg stabilizer beam housing: The portion of the base that holds the stabilizer beam stabilizer leg: The hydraulic cylinder attached to the stabilizer beam used to stabilize the unit stabilizer pad: A fixed or removable structural component of the stabilizer that distributes the applied force over a greater area stowed: The position in which the crane is to be secured for transit tag line: A line attached to the load to help control it during lifting three-point bridge: The structural component of the cranes base that pivots, reducing stress on the mounting to the chassis transit: The moving or transporting of a crane from one job site to another two blockdamage prevention feature: A system that prevents damage to the hoist rope or crane machinery components caused by two blocking two blocking: A condition where the lower load block or hook assembly comes in contact with the upper load block or boom point sheave assembly
upper load block: The assembly of sheaves, pins, and frame attached to the boom tip (if crane is used with load hoist mechanism) winch: Power-driven drum(s) capable of lifting and lowering rated loads with a hoist cable work zone: An area designated by means of recognized safety identifiers (such as cones, tape, or barriers) for the purpose of preventing non-authorized persons from entering
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1. Base 2. Three-point bridge 3. Stabilizer beam 4. Slewing cylinder 5. Column 6. Inner (main) boom 7. Inner (main) boom cylinder 8. Stabilizer leg
9. Manual control station 10. Outer boom 11. Outer boom cylinder 12. Extensions 13. Extension cylinders 14. Link(s) 15. Load hook 16. Hydraulic oil cooler
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Figure 1.2: Articulating boom loader (ABL) and components 1. Base 2. Ladder 3. Stabilizer beam 4. Platform 5. Column 6. Inner (main) boom 7. Inner (main) boom cylinder 8. Stabilizer leg 9. Operators station (top seat) 10. Outer boom 11. Outer boom cylinder 12. Extension booms 13. Fork tine 14. Rotator 15. Fork assembly 16. Hydraulic oil cooler 17. Fork cylinder 18. Fork tine lock
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CHAPTER 2:
2.2 Articulating Crane Council of North America warning decals and locations
The table below shows standardized ACCNA decals and where they must be placed. Replace any missing or damaged decals.
Function: To inform the operator of the hazard associated with contact or proximity to electrical lines, the possible consequences should the hazard occur, and how to avoid the hazard. Used on: Articulating cranes Placement: At or near the operators control station(s) Quantity: 2
Figure 2.1: Operators Control Station(s) Electrocution Hazard decal (Label #1)
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Function: To inform the operator and other personnel in the work area of the hazard associated with contact or proximity to electrical lines, the possible consequences should the hazard occur, and how to avoid the hazard. Used on: Articulating cranes Figure 2.2: Carrier Vehicle decal (Label #2) Placement: Place on all four sides of the carrier vehicle. Quantity: 4 Function: To inform the operator and other personnel in the work area of the lack of protection from electrocution afforded by the remote control handle, the possible consequences of the crane becoming electrically charged, and how to avoid the hazard. Used on: Remote controls on articulating cranes Figure 2.3: Remote Control Electrocution Hazard decal (Label #3) Placement: If crane is equipped with manual control(s) in addition to remote controls, place at or near the operators manual control station(s). If crane is equipped with remote controls only, place at remote control handle storage point. Quantity: 2 (or 1 if crane only equipped with remote control) Function: To inform the operator and other personnel in the work area of the hazard associated with the operation of outriggers or stabilizers, the possible consequences should the hazard occur, and how to avoid the hazard. Used on: Articulating and service bodymounted telescoping cranes Placement: On each outrigger or stabilizer Quantity: 2
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Function: To inform the operator of the hazard associated with outrigger or stabilizer operation, the possible consequences should the hazard occur, and how to avoid the hazard. Used on: Articulating and service bodymounted telescoping cranes Placement: At or near the outrigger or stabilizer control station(s) Quantity: 2
Figure 2.5: Outrigger Control decal (Label #5) Function: To inform the operator and other personnel in the work area of the hazard associated with a moving boom especially while stowing and unfolding the crane, the possible consequences should the hazard occur, and how to avoid the hazard. Used on: Articulating cranes Placement: At or near the operators control station(s) and/or the boom stow area(s) Quantity: 2
Figure 2.6: Operator Control/Boom Stow Area decal (Label #6) Function: To inform the operator of the hazard associated with servicing an operating driveline or power take-off (PTO), the possible consequences should the hazard occur, and how to avoid the hazard. Used on: Articulating and service bodymounted telescoping cranes that are driven by a PTO/ pump system Placement: At or near the driveline/PTO Quantity: 2
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Function: To inform the operator of the hazard associated with bringing the sheave(s) into contact with the hook, snatch block, or load; the possible consequences should the hazard occur; and how to avoid the hazard. Used on: Articulating and service bodymounted telescoping cranes Placement: At or near the operators control station(s) Quantity: 2
Figure 2.8: Two Blocking Warning decal (Label #8) Function: To inform personnel in the work area of the possible consequences of riding on the boom, boom hook, the load, or winch loadline and how to avoid the hazard. Used on: Articulating and service bodymounted telescoping cranes Placement: On all four sides of the vehicle Quantity: 4 Figure 2.9: No Riding Warning decal (Label #9) Function: To warn operator against the possibility of death or serious injury caused from hoisting workers or other personnel on the crane boom, hook, or loadline. Used on: Articulating and service bodymounted telescoping cranes Placement: Near the operators control station(s) Quantity: 2
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Function: To inform the operator of the need for proper training, familiarity with safe operating procedures, and the possible consequences of operation without training. Used on: Articulating and service bodymounted telescoping cranes Placement: At or near the operators control station(s) Quantity: 2
Figure 2.11: Untrained Operator decal (Label #11) Function: To inform the operator of precautions necessary in the safe operation of the crane and the possible consequences of operation without taking those precautions. Used on: Articulating and service bodymounted telescoping cranes Placement: At or near the operators control station(s) Quantity: 2
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Function: To inform personnel of the hazard associated with improper and unauthorized modifications, the possible consequences should the hazard occur, and how to avoid the hazard. Used on: Articulating and service bodymounted telescoping cranes Placement: At or near the operators control station(s) Quantity: 2
Figure 2.13: Maintenance Danger decal (Label #13) Function: To inform the operator of precautions necessary in the safe deployment of manually operated extension booms and the possible consequences of not taking those precautions. Used on: Articulating and service bodymounted telescoping cranes Placement: At or near the manual boom extension(s) retention mechanism(s) Quantity: 1
Figure 2.14: Failure to Obey Danger decal (Label #14) Function: To inform personnel in the work area of precautions necessary in the safe deployment of manually operated extension booms and the possible consequences of not taking those precautions. Used on: Articulating and service bodymounted telescoping cranes Placement: At or near the manual boom extension(s) retention mechanism(s) Quantity: 1 Figure 2.15: Free Falling Danger decal (Label #15)
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CHAPTER 3:
Control Systems
This chapter presents the criteria, rules, and standards for the inspection and safe use of the articulating crane control systems. This includes the manual control station, remote control station, and top seat control station. Check for the following: Control function labels must be legible. Ensure that controls return freely to their neutral position before engaging power source. Ensure that overload protection (OLP) systems have not been compromised. Remote control unit carrying aids (belt or neck strap) should be used when supplied.
Stabilizer beam
Stabilizer cylinder
Slewing
Outer boom
Extension boom
Check for the following: The manual control station should be located where it can be operated from the ground, from an elevated stand-up platform, or the topmounted seat.
Flooring of elevated stand-up platforms must be made of slip-resistant material. Elevated stand-up platforms must have designated handholds to access and egress the platform. Do not use controls or hoses as handholds. Use three-point contact (both feet and one hand, or both hands and one foot) for access and egress of elevated platforms (Figure 3.3).
Rotator
Grab
Hoist cable winch Figure 3.1: Typical operators station control function labels
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Figure 3.3: Use three-point contact (both feet and one hand, or one foot and both hands) when climbing to and from control station
Figures 3.5a & 3.5b: Top Seat Control Station Operator must maintain three points of contact with the crane when accessing and exiting the control station (Figures 3.5a and 3.5b). Use caution when entering and exiting the control station to avoid unintentional movement of controls. Only one person may occupy the operators station area (except during training).
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CHAPTER 4:
Ancillary Attachments
Figure 4.1: Typical articulating crane attachments This chapter presents some of the various attachments that can be used with an articulating crane. As depicted in Figure 4.1, these attachments include (from left to right): Brush grapple Stone grapple Brick grab Clam bucket Log grapple Barrier clamp Only use attachments for their designed purpose. Refer to the accessory manufacturers operating instructions for the attachment before using it. Before operating equipment, understand the descriptions, operations, and maintenance requirements for the attachments, components, and base machine (crane). When using pallet forks, make sure the fork tines are centered under the load to balance the load and lift level. Do not push down on the lifting attachment with the boom. Do not allow lifting attachments to push upward on the boom. Never lift personnel with any attachment unless its a personnel lifting device that is approved by the crane manufacturer and is attached or pinned to the last boom extension.
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CHAPTER 5:
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When practical, the load should be clamped between the tines and backrest of the fork assembly. Adjust the width of the fork tines as necessary to safely lift different-sized loads. The tine locking devices shall be in the locked position for all lifts to prevent load shift or load loss.
Figure 5.3: Always lock fork tines to prevent load shift The fork assembly should not be moved manually to engage the load. The operator shall always present the load in a manner that ensures a safe unloading environment.
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CHAPTER 6:
Load Charts
This chapter presents various types of load charts and direction on how to read and interpret chart information to verify the load does not exceed the cranes rated capacity. 6.2.2 Two-dimensional load charts Two-dimensional load charts show both the vertical and the horizontal ranges of a booms lifting capabilities. This type of chart gives the operator a reference as to the cranes capabilities when the cranes hook point moves in the vertical direction as well as horizontally. As shown in Figure 6.2, two-dimensional load charts specify the boom-lifting capacity for each twodimensional range on the chart. Capacity curve/line Vertical reach
Capacities
Note: On this load chart vertical distance is measured from the ground level
Horizontal reach Figure 6.2: Sample two-dimensional load chart The crane capacity is shown in two dimensions, horizontal (measured from crane centerline of rotation) and vertical (measured from crane mounting surface or from ground level). Capacity lines or curves show what loads can be lifted by the crane at different horizontal and vertical reaches. The load shown on the curve can be lifted anywhere on the curve or anywhere closer to the crane. As with one-dimensional charts, capacities must never be interpolated.
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CHAPTER 7:
Figure 7.2: Minimum required clearance for various power lines (ASME B30.22) No portion of the boom, hoisting line, hook, rigging, load, or machine component shall enter the Danger Zone, as shaded in Figure 7.3.
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Electrical hazard warning signs should be posted on all four sides of the vehicle (Figure 7.5).
Figure 7.3: Overhead power line Danger Zone (indicated by shaded area) All overhead wires shall be considered energized unless the owner of those lines or an electrical utility authority verifies that the lines are de-energized. Be sure to take into consideration any potential sway or whipping of energized electrical lines caused by wind when determining the safe working proximity to those lines. Do not rely on electrical wire coverings for protection from energized lines.
Figure 7.5: Electrocution Hazard decal A spotter is required to help maintain the required clearances whenever the booms length (in the crane work zone) can reach the prohibited or danger zone with the electrical lines energized. Cranes in transit and in their stowed position shall maintain the required clearances, as specified in ASME B30.22.
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Per OSHA Trenching and Excavation guidelines, stabilizers or tires should not be set up closer than 1.5 times the depth of an excavation in sandy or gravel soil; 1.0 times the depth in solid or compacted soils or next to cellar or basement walls (Figures 7.6a & 7.6b).
Figure 7.8: Establishing and marking work zone Set the parking brake and place wheel chocks (Figure 7.9). Figures 7.6a & 7.6b: Guidelines for setting up stabilizers near a vertical drop
Figure 7.9: Setting wheel chocks Position and orient the crane truck to lift over the proper lifting quadrants. Set up truck level, within allowable range specified by manufacturer (Figure 7.7).
Figure 7.7: Level truck within manufacturers specifications Determine maximum height and radius within the work zone for where the load is to be placed. Establish and clearly mark the work zone to prevent unauthorized entry (Figure 7.8).
Figure 7.10: Use three-point contact (both feet and one hand, or one foot and both hands) when climbing to and from control station Do not use the controls or hoses as a handhold. Do not jump into or out of the machine.
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7.7 Stabilizers
Stabilizers shall be locked in the retracted position during transit. Prior to taking the boom out of the cradle stowed position, stabilizers shall be properly deployed and locked, if so equipped by the manufacturer (Figure 7.11).
Do not operate the stabilizer beam controls while the stabilizer legs are contacting the ground. Do not stand in the path of the stabilizer beams when deploying them (Figure 7.13).
Figure 7.13: Stay away from stabilizer beams when they are moving To avoid instability, all steering and drive tires must remain firmly on the ground when setting up stabilizers (Figure 7.14). Figure 7.11: Deploying and locking stabilizers. Stabilizers shall be fully deployed per the manufacturers load chart specification; there may be multiple load charts based on different stabilizer spans. Stabilizers shall be visible to the operator when extending and setting unless assisted by another person. Ensure all limbs are kept well away from the danger areas to prevent crushing or pinching when deploying or retracting stabilizers (Figure 7.12). Figure 7.14: Keep all steering and drive tires on ground when setting up stabilizers Do not set stabilizers over underground hazards, cavities, or drain covers (Figure 7.15) Max 5
Figure 7.15: Avoid underground hazards when setting up stabilizers Do not operate stabilizer controls while the boom is elevated. Figure 7.12: Keep limbs away when deploying or retracting stabilizers Stabilizers are not to be used for purposes other than stabilizing the crane (e.g., do not use stabilizers as a parking brake).
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Articulating cranes shall be leveled to the manufactures specifications prior to un-stowing the boom. Stabilizer legs should not be set on uneven or slippery surfaces (Figure 7.16, A & B).
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Cribbing shall be of sufficient size and strength to prevent crushing, bending, or shear failure. Use appropriate cribbing to protect the surface of concrete or asphalt against imprinting or damage caused by the stabilizer pad.
7.8 Leveling
Means must be provided to determine levelness, such as a spirit level or bulls eye level (Figure 7.17).
Figure 7.17: Sample bulls eye level Cranes and boom trucks must be level to within the manufacturers specifications prior to deploying the boom.
7.9 Cribbing
Cribbing is solid material placed under the stabilizer pads to disperse the downward pressure over a larger area of the ground and eliminating sinking (Figure 7.18).
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9 10
4147 4855
11 12
5563 64+
Be aware that any of the following items can create a limiting factor beyond the cranes calculated net capacity: Wire rope limit Hoisting hook Lifting attachments Rigging Winch capacity
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CHAPTER 8:
Crane Operation
This chapter presents criteria, rules, and standards for safe crane operation.
Figure 8.2: Establish a well-marked work zone and ensure no unauthorized persons are inside the designated area before operating crane. If load or placement area is not visible from operators position, establish proper crane communication with a qualified signalperson. Always ensure the person giving signals is a safe distance from the load. Never perform a maneuver that causes the load to pass over the operators position or another person (Figure 8.3).
Figure 8.1: Establish a work zone with at least a 10 ft. safety perimeter Ensure there are no unauthorized persons inside the work zone before you begin working.
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Figure 8.4: Do not travel with boom unstowed Do not push or drag loads from the side. Always lift the load clear of the ground (resting surface) with boom lift or hoist before rotating the boom, extending or retracting the boom, or moving the load in any manner (Figure 8.5).
Figure 8.6: Use gentle lever movements to avoid shock loading When the cylinder is approaching the end of its stroke, slowly move the lever to its neutral position gradually; sudden movements can cause damage to the crane. Avoid quick or jerky movements at full extension as they can cause undue stress and wear to the crane (Figure 8.7).
Figure 8.5: Lift the load clear of the ground before other movement. When working with elevated loads, always ensure there is adequate clearance above and below the load. Removing part of the load may affect boom deflection, so adjustments may be required. When operating at high boom angles, do not lower the extended boom because this can cause an overload situation; instead, retract the boom extensions first. Always operate the crane with smooth and gentle lever movements. Do not jerk the controls to full speed or from one direction to the other; doing so is a major cause of shock loading (Figure 8.6).
Figure 8.7: Avoid quick or jerky movements at full extension. Remove or secure all attachments (extensions, grapple, forks, etc.) when they are not being used. Always adhere to the load chart(s); failure to do so can cause damage or injury. Never disconnect or tamper with the safety systems. To minimize load swing, position the boom tip directly over the loads center of gravity prior to lifting. When releasing manual extension boom (pins), position the boom as flat as possible. To avoid
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injury, do not stand directly in line with the extension travel path. Do not use any of the cranes booms to push downward onto anything (Figure 8.8).
Use tag lines where required or necessary (see section 8.13). If the overload protection (OLP) safety system activates, operate any function that reduces the boom radius to continue.
Figure 8.9: Do not allow anyone to ride on hook, boom, or load Use only appropriate personnel baskets, as directed by the crane manufacturer. Ensure no part of the boom, ancillary equipment (attachment), or load can come in contact with any obstructions. Do not permit ancillary equipment to push upward on the boom. Closing open clam buckets or grapples can do damage this way, particularly if they are placed open on a very hard material.
Figure 8.10: o not engage in distracting activities D while operating crane Do not operate the crane when physically or mentally unfit or under the influence of alcohol or controlled substances. Operators are responsible for all operations under their direct control, including setting up the crane, knowing the accurate weight of the load, and determining the lifting solution. If any doubt exists about the safety of a lift, consult with your supervisor before handling the load.
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After receiving a local weather storm warning, secure the crane according to the manufacturers recommendations.
Prior to the lift, calculate the load weight and range capacity, accounting for the full range of potential configurations during the entire lift. Ensure that all lifting devices below the hook (rigging) are of appropriate lifting capacity to handle the load being lifted. Only lift freely suspended loads. Booms shall not be side loaded because doing so can cause boom damage, collapse, or failure; side loading can be caused by lifting out of level, dragging the load, or operating in strong or gusty winds.
Figure 8.12: Mechanical leverage linking device (link) Some cranes have links only between the inner and outer booms; these links provide a straightline lifting curve at longer reaches. Some cranes have both inner and outer link systems and provide the benefits of both. Never load the crane beyond the specifications of the load chart.
Figure 8.11: Never handle loads with the outer boom or fly jib in a negative position
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8.6.2 Overload protection (OLP) systems Many articulating cranes come equipped with rated-capacity limiting devices (overload protection systems) that prevent the crane from exceeding its gross capacity. Not all cranes are equipped with OLP systems. Articulating crane operators must know how to read and understand the cranes load chart(s) and shall not exceed the crane manufacturers lifting capacity ratings.
Do not move the load or attachments in such a way that they can make contact with any portion of the crane (Figure 8.14).
Figure 8.14: Never allow the load or attachments to come in contact with the crane
8.9 Leaving the crane unattended (when leaving the work zone)
Land the loaddo not leave suspended. Lower the boom. Disengage the main power source/power takeoff (PTO) to prevent unauthorized use. Stop the engine and secure the key. Figure 8.13: Never drag a load sideways Check the hydraulics each time a maximumrated load is handled by raising it a few inches and checking for boom drift (unintended slow lowering).
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Welding or drilling of the crane must be carried out by the manufacturer or a manufacturers representative. Before welding anything on the carrier truck, always: Consult manufacturer or representative for authorization Ground the welder as near the welding site as possible Figure 8.19: ever pass load over operator or any other N person Disconnect all connections to the cranes remote control power box Disconnect the truck batteries
2010 National Commission for the Certification of Crane Operators. All rights reserved. ACO RM REV 3/10
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CHAPTER 9:
Crane Inspection
This chapter presents both what is recommended and what is required to inspect a crane for service. Records of annual inspections shall be maintained. Noted deficiencies shall be repaired and/or defective parts replaced before use continues. A crane that has been idle (not in use) for more than six months shall receive an annual inspection as designated by the manufacturer or ASME B20.22.
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CHAPTER 10:
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2010 National Commission for the Certification of Crane Operators. All rights reserved. ACO RM REV 3/10
CHAPTER 11:
Load Hooks
11.1 General precautions
Crane hooks are designed and manufactured to lift specific loads. The specified rated load of a hook applies to loads held uniformly in direct tension. The rated load applies to new and unused hooks; age, type of service and environmental conditions can alter a hooks ability to handle these loads. Hook materials are designed to permanently deform before a failure occurs. Load hooks or hook block assemblies shall be labeled with rated capacity and weight. Load hooks shall be included in the daily/shift inspection. Dont use a hook if it meets rejection criteria. Hooks shall be equipped with functioning safety latches (Figure 11.1). Figure 11.2: Improper hook loading Do not place hands, fingers, or body between a hook and the load. Do not apply side loads, back loads, or tip loads on a hook (Figure 11.2).
Figure 11.1: Types of load hooks Latches shall close the entire throat opening. If in doubt about a hooks serviceability, contact the hook manufacturer. Never weld attachments to a finished hook; the heat from the welding process will alter and destroy the design properties of the hook material. Center the load in the base (bowl-saddle) of the hook to prevent applying load to the hook point. Avoid shock loading. Do not apply loads of any nature on a latch device.
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11.3 Latches
Use a hook equipped with a latch at all times, except when a latch proves impractical or poses a danger in a particular application. The latch is used to retain such items as slings and chains under slack conditions. Hook latches, for loose sling retention, are not anti-fouling devices. They must never be allowed to support any portion of the load. Hook latches must be inspected for damage just as the hook must be inspected. Ensure the latch is in place and properly centered on the hook. Hook latches should never be crowded by oversized rope or stiff riggings. Make certain the load is properly seated on the bowl-saddle before a lift is attempted.
*Hooks having any of the deficiencies listed shall be removed from service unless a qualified person approves their continued use and initiates corrective action. Hooks approved for continued use shall be subjected to periodic inspection. Figure 11.4: Hook inspection checklist
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2010 National Commission for the Certification of Crane Operators. All rights reserved. ACO RM REV 3/10
CHAPTER 12:
Rigging
This chapter presents the general criteria for the selection, inspection, and use of slings and other rigging hardware used to attach the load to the crane hook properly and ensure load stability. Rigging components include hardware (shackles, eye-bolts, etc.) and slings (wire rope, chain, synthetics). The center of gravity is the central point at which the load weight would be evenly distributed to any side; this is also referred to as the balance point (Figure 12.2).
Figure 12.2: Center of gravity or balance point Determine a loads approximate location of the center of gravity before hoisting. The load must be rigged over the center of gravity (placing it directly below the load hook) or the load will shift when hoisted (Figure 12.3).
Figure 12.3: Rig load over center of gravity or load will shift when hoisted
2010 National Commission for the Certification of Crane Operators. All rights reserved. ACO RM REV 3/10
Bad, deformed, or broken end attachments Bent hooks: see Chapter 11, Load Hooks Metal corroded Identification tag ID missing or illegible 12.2.2 Chain slingscauses for removal Remove chain slings from service if any of the following conditions are found: Wear, nicks, cracks, breaks, gouges, stretch, bends, weld splatter, and/or discoloration from excessive temperature Links and attachments do not hinge freely Hook latches have evidence of permanent distortion or do not hinge freely Sling identification tag missing or illegible 12.2.3 Synthetic slingscauses for removal Remove synthetic slings from service if any of the following conditions are found: Acid/caustic burns Melting or charring Powder is detected Holes, tears, cuts or snags Broken or worn stitching (particularly loadbearing stitching) Excessive abrasive wear Knots in any part of the sling Cracked, distorted, or broken fittings Missing or illegible sling identification tag
Choker hitches reduce lifting capability of a vertical sling because this method of rigging affects the ability of the sling components to adjust during the lift, places angular loading on the body of the sling, and creates a small diameter bend in the sling body at the choke point. Provides excellent grip and load control. Basket hitches distribute a load equally between the two legs of a sling and capacity is based on the angles at which legs are rigged to the load. When using a basket hitch, balance the load to prevent slippage. Bridle hitches are defined as two or more slings working together and attached to the same collection point. They can be attached to the hoisting hook by means of a master link or a shackle.
Figure 12.4: Types of hitches (in order, from top) vertical, choker, basket, and bridle
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2010 National Commission for the Certification of Crane Operators. All rights reserved. ACO RM REV 3/10
CHAPTER 13:
Winch
This chapter presents criteria, rules, and standards for using a winch with articulating cranes. Corrosion can be cause for replacement. Note any corrosion developing and monitor it closely. Immediately remove and replace wire rope showing any of the following deficiencies: When there are either three broken wires in one strand or a total of six broken wires in all strands in any one rope lay. A rope lay is the axial distance along the rope in which one strand makes one complete turn around the rope.
The core that forms a foundation for the strands; the core of IWRC (independent wire rope core) wire rope is a smaller wire rope which is similar to an outer strand of the rope
Hoisting steel wire rope comes in various grades. The term grade is used to designate the nominal strength of the rope. The three hoisting rope grades are: Improved Plow Steel (IPS) Extra Improved Plow Steel (EIPS) Extra Extra Improved Plow Steel (EEIPS) The grade of wire rope cannot be determined by feel or appearance. To properly evaluate a rope system, you must obtain the grade from the manufacturer or supplier. Wire rope will fail if worn out, overloaded, misused, damaged, or improperly maintained.
Figure 13.2: Example of six broken wires in one rope lay When flat spots on the outer wires appear and those outside wires are less than two-thirds the thickness of the unworn outer wire (1/3 loss).
Figure 13.3: Example of flat spots on outer wires When there is a decrease of diameter indicating a core failure
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Do not expose the rope to corrosive chemicals, heat, or electrical contact. Lubricate the rope frequently to reduce friction and help prevent corrosion.
Figure 13.5: Example of kinked or crushed wire rope When there is noticeable heat damage (discoloration) of the rope by any means
Figure 13.6: Example of heat damage (discoloration) When the diameter is reduced from nominal size by 1/32 (0.8 mm) or more
Figure 13.7: Example of wire rope reduced >1/32 from original size If a broken wire protrudes or loops out from the core of the rope.
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2010 National Commission for the Certification of Crane Operators. All rights reserved. ACO RM REV 3/10
Figure 13.11: Approved methods for attaching a wedge socket Figure 13.9: Cable thimble attachment to winch wire rope
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APPENDICES
Appendix A: ACCNA Crane Inspection Checklist Appendix B: Standard Hand Signals for Articulating Crane Operations Appendix C: Sample Articulating Crane Load Charts
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CONTACT PERSON CRANE MAKE & MODEL CRANE SERIAL NUMBER UNIT I.D. NUMBER LOCATION OF UNIT
TYPE OF INSPECTION NOTES: Daily and monthly inspections are to be performed by a designated person, who has been selected or assigned by the employer or the employers representative as being competent to perform specific duties. Quarterly and annual inspections are to be performed by a qualified person who, by possession of a recognized degree in an applicable field or certificate of professional standing, or who, by extensive knowledge, training and experience has successfully demonstrated the ability to solve or resolve problems related to the subject matter and work. One hour of normal crane operation assumes 20 complete cycles per hour. If operation exceeds 20 cycles per hour, inspection frequency should be increased accordingly. Consult Operator / Service Manual for additional inspection items, service bulletins and other information. Before inspecting and operating crane, crane must be set up away from power lines and leveled with outriggers fully extended. DAILY (D): Before each day of operation, those items designated with a (D) must be inspected. This inspection need not be recorded unless a deficiency ( ) is found. MONTHLY (M): Monthly inspections or 100 hours of normal operation (which ever comes first) includes all daily inspections plus items designated with an (M). This inspection must be recorded. QUARTERLY (Q): Every three months or 300 hours of normal operation (which ever comes first) includes all daily and monthly inspection items plus items designated with a (Q). This inspection must be recorded. ANNUAL (A): Each year or 1200 hours of normal operation (which ever comes first) includes all items on this form which encompasses daily, monthly and quarterly inspections plus those items designated by (A). This inspection must be recorded.
= SATISFACTORY = DEFICIENCY (must be corrected prior to operation)
FREQUENCY ITEM KEY INSPECTION DESCRIPTION
STATUS
, R, NA
D D D D D D D D D D
1 2 3 4 5 6 7 8 9 10
Labels Controls Station Hyd System Hook Rope Pins General Operation
D D D D D
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All load charts, safety & warning labels, & control labels are present and legible. Check all safety devices for proper operation. Control mechanisms for proper operation of all functions, leaks & cracks. Control and operators station for dirt, contamination by lubricants, & foreign materials. Hydraulic system (hoses, tubes & fittings) for leakage & proper oil level. Presence & proper operation of hook safety latches. Proper reeving of wire rope on sheaves & winch drum. Proper engagement of all connecting pins & pin retaining devices. Overall observation of crane for damaged or missing parts, cracked welds & presence of safety covers. During operation, observe crane for abnormal performance, unusual wear (loose pins, wire rope damage, etc.). If observed, discontinue use & determine cause & severity of hazard. Operate remote control devices to check for proper operation. Operate all lights, alarms, etc. to check for proper operation. Operate anti 2-blocking device to check for proper operation. Other Other
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REV: 5-14-98
Inspection Checklist
Inspection Checklist
FREQUENCY ITEM KEY INSPECTION DESCRIPTION
2
STATUS
= SATISFACTORY = DEFICIENCY (must be corrected prior to operation) M M M M M M M M M M M M M M M M M M M M M Q Q Q Q Q 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 Daily Cylinders Valves Valves Valves General Electrical Structure Welds Pins Hardware Wear Pads Pump & Motor PTO Hyd Fluid Hyd Lines Hook Rope Manual
, R, NA
Hardware
Hyd Lines
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All daily inspection items. Visual inspection of cylinders for leakage at rod, fittings & welds. Damage to rod & case. Holding valves for proper operation. Control valve for leaks at fittings & between sections. Control valve linkages for wear, smoothness of operation & tightness of fasteners. Relief valve for proper pressure settings. Bent, broken or significantly rusted/corroded parts. Electrical systems for presence of dirt, moisture & frayed wires. All structural members for damage. All welds for breaks & cracks. All pins for proper installation & condition. All bolts, fasteners & retaining rings for tightness, wear & corrosion Condition of wear pads. Hydraulic pumps & motors for leakage at fittings, seals & between sections. Check tightness of mounting bolts. Transmission/PTO for leakage, abnormal vibration & noise, alignment & mounting bolt torque. Quality of hydraulic fluid and for presence of water. Hoses & tubes for leakage, abrasion damage, blistering, cracking, deterioration, fitting leakage & secured properly. Load hook for abnormal throat distance, twist, wear & cracks. Condition of load line. Presence of operators manuals with unit. Other Other All daily inspection items. All monthly inspection items. Rotation bearing for proper torque of all mounting bolts. Base mounting bolts for proper torque. All structural members for deformation, cracks & corrosion. G Base G Outrigger beams & legs G Mast G Inner boom G Outer boom G Extension(s) G Jib boom G Jib extension(s) G Other Pins, bearings, shafts, gears, rollers, & locking devices for wear, cracks, corrosion & distortion. G Rotation bearing(s) G Inner boom pivot pin(s) & retainer(s) G Outer boom pivot pin(s) & retainer(s) G Inner boom cylinder pin(s) & retainer(s) G Outer boom cylinder pin(s) & retainer(s) G Extension cylinder pin(s) & retainer(s) G Jib boom pin(s) & retainer(s) G Jib cylinder pin(s) & retainer(s) G Jib extension cylinder pin(s) & retainer(s) G Boom tip attachments G Other Hoses, fittings & tubing for proper routing, leakage, blistering, deformation & excessive abrasion. G Pressure line(s) from pump to control valve G Return line(s) from control valve to reservoir G Suction line(s) from reservoir to pump G Pressure line(s) from control valve to each function G Load holding valve pipe(s) and hose(s) G Other
2010 National Commission for the Certification of Crane Operators. All rights reserved. ACO RM REV 3/10
Inspection Checklist
FREQUENCY ITEM KEY INSPECTION DESCRIPTION
3
STATUS
= SATISFACTORY = DEFICIENCY (must be corrected prior to operation) Q 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 Pumps & Motors
, R, NA
Valves
Cylinders
Q Q A A A A A A A A A A A A
DATE
Winch Hyd Filters Daily Monthly Quarterly Hyd Sys Controls Valves Valves Rotation Sys Lubrication Hardware Wear Pads Loadline
Pumps & motors for loose bolts/fasteners, leaks, noise, vibration, loss of performance, heating & excess pressure. G Winch motor(s) G Rotation motor(s) G Other Hydraulic valves for cracks, spool return to neutral, sticking spools, relief valve failure. G Main control valve G Load holding valve(s) G Outrigger or auxiliary control valve(s) G Other G Other Hydraulic cylinders for drifting, rod seal leakage & leakage at welds. Rods for nicks, scores & dents. Case for damage. Case & rod ends for damage & abnormal wear. G Outrigger cylinder(s) G Inner boom cylinder(s) G Outer boom cylinder(s) G Extension cylinder(s) G Rotation cylinder(s) G Jib lift cylinder(s) G Jib extension cylinder(s) G Other Winch, sheaves & drums for damage, abnormal wear, abrasions & other irregularities. Hydraulic filters for replacement per maintenance schedule. All daily inspection items. All monthly inspection items. All quarterly inspection items. Hydraulic fluid change per maintenance schedule. Control valve calibration for correct pressures & relief valve settings Safety valve calibration for correct pressures & relief valve settings. Valves for failure to maintain correct settings. Rotation drive system for proper backlash clearance & abnormal wear, deformation & cracks. Gear oil change in rotation drive system per maintenance schedule. Check tightness of all fasteners and bolts. Wear pads for excessive wear. Loadline for proper attachment to drum.
GUIDELINES A. A deficiency () may constitute a hazard. must be corrected and/or faulty parts replaced before resuming operation. B. Recommendations (R) should be considered for corrective actions. Corrective action for a particular recommendation depends on the facts in each situation. C. Corrective actions (CA), repairs, adjustments, parts replacement, etc. are to be performed by a qualified person in accordance with all manufacturers recommendations, specifications and requirements. NOTE: Deficiencies () listed must be followed by the corresponding corrective action taken (CA).
CA = CORRECTIVE ACTION TAKEN
DATE CORRECTED
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DATE CORRECTED
If additional space is required, reproduce this page and attach to this report. 54
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SWING
Arm extended, point with finger in direction of swing of boom.
MOVE SLOWLY
Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal. (Hoist slowly shown as example.)
STOP
Arm extended, palm down, move arm back and forth horizontally.
EMERGENCY STOP
Both arms extended, palms down, move arms back and forth.
HOIST LOADLINE
With forearm vertical, forefinger pointing up, move hand in small horizontal circle.
LOWER LOADLINE
With arm extended downward, forefinger pointing down, move hand in small horizontal circle.
2010 National Commission for the Certification of Crane Operators. All rights reserved. ACO RM REV 3/10
The following NCCCO load charts have been includedin cooperation with crane manufacturersto help candidates prepare for the NCCCO Articulating Crane Operator Written Examination. THE LOAD CHARTS CONTAINED HEREIN ARE NOT TO BE USED FOR ACTUAL CRANE OPERATION AND ARE FOR TESTING PURPOSES ONLY. If you need a crane load chart for a specific crane, you should contact the relevant manufacturer or an authorized dealer/ distributor. In some cases only excerpts of the load charts have been included. The National Commission for the Certification of Crane Operators would like to thank the following crane manufacturers, who have provided the time and resources necessary to create this manual: Cargotec USA Inc., Hiab Effer Fassi Iowa Mold Tooling Manitowoc Palfinger North America PM North America For further information about the NCCCO Articulating Crane Operator Written Examination, please consult the NCCCO website at www.nccco.org or email info@nccco.org to request an Articulating Crane Operator Candidate Handbook.
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Crane A
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Crane B
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Crane C
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Crane D
70' 60'
50' 16900
40'
22500
30'
MOUNTING SURFACE
CENTERLINE
10'
20'
30'
40'
50'
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2010 National Commission for the Certification of Crane Operators. All rights reserved. ACO RM REV 3/10
Crane E
CRANE E
85 70 50 40
10500 4400 2600 19'11" 30'11" 42'5" lb ft 6400 25'5" 3300 36'8"
4400
13 0
lb ft
4300 3100 56' 67'3" 4800 3800 2500 50'7" 61'6" 73'
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Crane F
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2010 National Commission for the Certification of Crane Operators. All rights reserved. ACO RM REV 3/10
Crane G
90' 4000 lb 80' 70' 60' 50' 4400 lb 3200 lb 40' 30' 2200 lb 20' 10' 0
5000 lb 2500 lb
MOUNTING SURFACE
CENTERLINE
10'
20'
30'
40'
50'
60'
70'
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