Mobile Crane 80t

VERSION 2.
0
British Columbia CraneSafe Certification
HYDRAULIC MOBILE CRANE
80 TONNES AND UNDER
Based on BC Crane Operator Common Standards of Competence
Core Workplace Competencies
Practical Experience Requirements
Industry Skills & Knowledge Standards
To order additional copies please contact:
Fulford Harbour Group Ltd
www.fulford.ca
SAFETY ADVISORY
Be advised that references to the WorkSafe BC safety regulations contained within
these materials do not/may not reflect the most recent Occupational Health and Safety
Regulation (the current Standards and Regulation in BC can be obtained on the following
website: http://www.worksafebc.com.
Please note that it is always the responsibility of any person using these materials to
inform him/herself about the Occupational Health and Safety Regulation pertaining to his/
her work.
Core Workplace Competencies - HYDRAULIC MOBILE CRANE 80 Tonnes & Under 3
Table of Contents
Forward................................................................................................................................. 4
Competency Profiles ............................................................................................................. 5
Crane Operator Core Knowledge & Workplace Competency Profile Chart ............................................. 6
CraneSafe Certification Competencies:
Knowledge, Skills & Abilities Identified by Industry ............................................................... 8
Introduction to CraneSafe Certification Assessments .......................................................................... 9
Section 1 Safety .............................................................................................................. 10
Unit Standard CS 1.5 W .................................................................................................................. 11
Unit Standard CS 1.6 W ................................................................................................................... 13
Section 2 Communications ............................................................................................. 14
Unit Standard CCOM 2.5 W .............................................................................................................. 15
Section 4 Rigging ............................................................................................................ 26
Unit Standard CR 4.6 W ................................................................................................................... 27
Section 5 Load Charts..................................................................................................... 37
Unit Standard CLC 5.3 W .................................................................................................................. 38
Section 8 Crane Operations ............................................................................................. 43
Unit Standard CCO 8.4 W ................................................................................................................. 44
Section 9 Maintenance and Service ................................................................................. 49
Unit Standard CMS 9.7 W ................................................................................................................ 50
Glossary ............................................................................................................................. 53
Metric Conversion Help ....................................................................................................... 58
Recommended Reference Textbooks, Video/DVD Resources ................................................. 60
Reference Authority ......................................................................................................................... 62
4 Core Workplace Competencies - HYDRAULIC MOBILE CRANE 80 Tonnes & Under
Forward
These core skills and abilities are the common foundation for all types of cranes.
1. Mobile Crane - 80 tonnes and under
2. Mobile Crane - Unlimited tonnage
3. Mobile Lattice Boom Friction Crane
4. Mobile Lattice Boom Hydraulic Crane
5. Folding Boom Truck Crane - 22 tonnes and under
6. Folding Boom Truck Crane - Unlimited tonnage
7. Stiff Boom Truck Crane - 40 tonnes and under
8. Stiff Boom Truck Crane - Unlimited tonnage
This is a guide to the skills, knowledge and ability identified by the crane industry in BC
that you need to be a competent operator. This manual is designed to give you a brief
overview of the crane standards and assessment process.
Competency Profiles
Crane Operator Core Knowledge & Workplace Competency
Profile Chart
CORE UNITS - Prerequisite for Mobile Crane 80 tonnes & under
1. Safety (CS)
1.1 Demonstrate knowledge of safe working practices for crane operators (K)
1.2 Demonstrate knowledge of Workplace Hazardous Materials Information
System (WHMIS) (K)
1.3 Manage first aid in emergency situations (K)
1.4 Demonstrate knowledge of power line hazards and high voltage equipment
(K)
1.5 Comply with WorkSafe BC and OH&S regulations (W)
1.6 Respond to fire emergencies (W)
2. Communications (CCOM)
2.1 Demonstrate knowledge of personnel involved in crane operations (K)
2.2 Demonstrate knowledge of hand signals (K)
2.3 Demonstrate knowledge of radio communications (K)
2.4 Demonstrate knowledge of workplace communications (K)
2.5 Use hand signals in the workplace (W)
2.6 Use radio communications in the workplace (W)
2.7 Communicate information clearly and check for understanding in the
workplace (W)
3. Cranes (CC)
3.1 Demonstrate knowledge of types of cranes and classifications (K)
3.3 Demonstrate knowledge of terminology related to craning and craning
concepts (K)
3.6 Demonstrate knowledge of hoisting terminology, functions and systems (K)
3.7 Demonstrate knowledge of regulatory requirements pertaining to cranes
(K)
4. Rigging (CR)
4.1 Demonstrate knowledge of lifting theory and forces (K)
4.2 Demonstrate knowledge of rigging hardware, materials, tools and manuals (K)
4.3 Demonstrate knowledge of types and function of wire rope and chains (K)
4.4 Demonstrate knowledge of installation, inspection and storage of wire rope (K)
4.5 Demonstrate knowledge of rigging techniques (K)
4.6 Use rigging hardware and tools in the workplace (W)
5. Lead Charts (CLC)
5.1 Demonstrate knowledge of determining weight loads using fundamental
math functions and calculations (K)
5.2 Demonstrate knowledge of loading and lifting (K)
5.3 Interpret load charts and load study drawings to configure crane for
workplace operation (W)
6. Transportation & Delivery (ATD)
7. Site Planning & Crane Positioning (ASPCP)
8. Crane Operations (CO)
8.1 Demonstrate knowledge of pre-operational requirements in crane
operations (K)
8.4 Demonstrate crane set-up per manufacturers instructions (except Task 4 in
Mobile) (W)
9. Maintenance & Service (CMS)
9.7 Maintain an equipment logbook to retain a permanent written record of
maintenance and repairs (W)
PROFILE CHART:
Mobile Crane Operator Knowledge Units & Workplace Competency
Hydraulic Boom 80 tonnes and under
ADVANCED UNITS
3. Cranes (AC)
3.2 Demonstrate knowledge of crane components and attachments (K)
3.4 Demonstrate knowledge of engines and ancillary systems (K)
3.5 Demonstrate knowledge of power transfer for cranes (K)
6. Transportation & Delivery (ATD)
6.1 Demonstrate knowledge of BC Ministry of Transportation - Commercial
Transport rules and regulations as they pertain to transportation of cranes
(K)
6.2 Demonstrate knowledge to prepare and to transport a mobile crane (K)
6.3 Demonstrate knowledge of to assemble and disassemble a crane at a
worksite (K)
6.4 Prepare and transport a mobile crane to a worksite following all highway
and traffic rules and regulations (W)
6.5 Assemble and disassemble a crane at a worksite (W)
7. Site Planning & Crane Positioning (ASPCP)
7.1 Demonstrate knowledge of accurate site assessment tools (K)
7.2 Demonstrate knowledge to locate and safely position crane (K)
7.3 Conduct an accurate site assessment and safely position a crane in the
workplace (W)
8. Crane Operations (ACO)
8.2 Demonstrate knowledge of crane operations (K)
8.3 Demonstrate knowledge to leave a crane unattended (K)
8.4 Demonstrate crane set-up per manufacturers instructions Task 4 only
(others core) (W)
8.5 Use a mobile crane to safely pick and carry loads in a workplace (W)
8.6 Leave a crane unattended (W)
9. Maintenance & Service (AMS)
9.1 Demonstrate knowledge of inspecting engines, monitoring devices and
hydraulic systems (K)
9.2 Demonstrate knowledge of servicing and maintenance procedures on
mobile cranes (K)
9.3 Complete maintenance checklists (engine on / engine off) and maintain
engines to manufacturers specifications (W)
9.4 Perform routine inspections and maintenance of hydraulic systems (W)
9.5 Inspect monitoring devices and control mechanisms (W)
9.6 Perform service on engine cooling systems on mobile cranes (W)
CraneSafe Certification Competencies:
Knowledge, Skills & Abilities Identified by Industry
Trainees demonstrate the skills they
have learned in class and on the job in
a practical assessment conducted by a
CraneSafe Assessor.
Introduction to CraneSafe Certification Assessments
Section 6 Transportation & Delivery
Unit Standard ATD 6.4 W
WORKPLACE ASSESSMENT
PREPARE & TRANSPORT A MOBILE CRANE TO A WORKSITE FOLLOWING ALL HIGHWAY
& TRAFFIC RULES & REGULATIONS - MOBILE
PURPOSE
This unit allows a trainee to demonstrate his or her skills to prepare and transport a
mobile crane to a worksite.
TASK 1
You must take responsibility to prepare a crawler crane and rubber-tired crane and
components for highway travel. In doing this task you must follow the manufacturers
recommendations and the BC Ministry of Transportation Commercial Transport
Regulations.
It is important you record the activities in date order in your trainee logbook showing
where and when you performed the tasks. These logbook entries are checked by the
Mentor to see you have had sufficient practice in the task prior to assessment
This assessment should naturally occur as you demonstrate the skills in the workplace.
Signoff from your Mentor can be done after successfully completing preparation of
crawler cranes and rubber tired cranes a minimum of three times. It is through repeated
demonstration of skills that competency is achieved.
You must be able to show you can safely load
and secure the cranes and components for
transporter travel. This includes displaying the
correct signs and ensuring the signage and
signals are serviceable.
In preparing the cranes and their components for travel you must clearly show you have:
followed the manufacturers recommendations
adhered to and followed the BC Ministry of Transportation Commercial Transport
Regulations
considered and addressed the transporters structural integrity and capacity
used flags correctly
installed flashers for correct use
used all warning signals appropriately
verified the transportation permit
Refer to Task #1
Point 1.1
Unit Standard ATD 6.5 W
ASSEMBLE & DISASSEMBLE A CRANE AT A WORKSITE - MOBILE
PURPOSE
This unit allows a trainee to demonstrate his or her skills to assemble and disassemble a
crane at a worksite.
The emphasis of this unit assessment is getting the crane adjusted as outlined in Task 1
and checking the location on the worksite prior to set up.
Note:
This assessment may be able to be completed simultaneously with the assessment for Site
Planning and Crane Position MC7.3 W it will depend entirely on the workplace and the
opportunities you have to demonstrate the skills. Please ensure you read the assessment
requirements for unit MC7.3 W to see if you can combine the activities and be assessed
for both at the same time.
TASK 1
You must take responsibility to assemble
a mobile crane for usage on a worksite.
There are adjustments that may be
required to be made to:
Attachments
Counterweights
Booms
Undercarriage
Boom dollies
When the crane is assembled it is
critical that the area in which the crane
will operate is checked to ensure that
it is secure and free from obstructions.
Typical things to check for include:
Any overhead wires
Any other overhead obstructions like trees
Any underground services sometimes not well known and without any visible
signs of existence, e.g.: buried piping and parking garages
A level site
Refer to Task #1
Point 1.1
Once the area is checked to make sure there
are no obstacles the crane can be positioned
according to the site assembly plan. The site
assembly plan takes into consideration the room the crane requires to be assembled and
then safely and successfully operate. The area must be:
Large enough for the crane assembly
Large enough to allow the proper radius for loading and unloading the load
Level so the crane can operate safely
TASK 2
After successful assembly of a crane, you must
be able to show you can safely disassemble the
crane making the necessary adjustments for the
crane to travel again.
Note:
Task 1 and Task 2 may be done on different cranes at different worksites or on the same
crane at the same location. It is possible to complete Task 2 at one worksite and then a
few weeks later complete Task 1 in a different location with a different crane.
The emphasis of the assessment is that it takes into account the naturally occurring
practices in the workplace. Signoff from your Mentor can be done after successfully
completing assembly and disassembly a minimum of three times. It is through repeated
demonstration of skills that competency is achieved
Refer to Task #1
Point 1.3
Refer to Task #2
Points 2.1, 2.2
Section 7 Site Planning & Crane Positioning
Unit Standard ASPCP 7.3 W
CONDUCT AN ACCURATE SITE ASSESSMENT & SAFELY POSITION A CRANE IN THE
WORKPLACE - MOBILE
Purpose
This unit allows a trainee to demonstrate his or her skills to conduct a site assessment and
position a crane safely in the right location.
The emphasis of this unit assessment is site planning and crane positioning as outlined
in Tasks 1 and 2. This assessment may be able to be completed simultaneously with the
assessment for Transportation and Delivery /Assembly of Crane MC6.5 W and the Crane
Operation units in section 8 (MC 8.4, 8.5, 8.6) it will depend entirely on the workplace
and the opportunities you have to demonstrate the skills. Please ensure you read the
assessment requirements for all the units to see if you can combine the activities and be
assessed for several at the same time.
Mentor to see you have had sufficient practice in the task prior to assessment.
TASK 1
You must inspect a site and develop an accurate
lift plan. In order to develop the lift plan correctly
your must refer to blue prints and, if applicable,
engineers drawings.
When conducting a site plan there are a number of things that must be taken into
consideration including:
Assessment of area and soil condition
The ground the crane will be on must be able to support a loaded crane. It needs to be
reasonably level and reasonably compacted. As a rule of thumb side slopes, shoring
locations, excavations and trenches should be avoided. Often the ground near to a
building is made up of backfill and not as compacted as the rest of the site. This needs to
be considered.
Refer to Task #1
Point 1.1
Assessment of hazards and obstacles
Typical obstacles and hazards are overhead wires, trees, other structures or equipment.
These are obvious and must be avoided. Less obvious are underground utilities or
structures for which there may be no visible sign on the top surface. These may include
cables, wires, pipes, sewers, tanks, parking garages, etc. As critical as it is to avoid above
ground obstacles it is also necessary to check for underground utilities and structures
to ensure safe crane operation. While the weight of the crane may not cause immediate
damage the combination of the crane weight and vibration from hoisting, swinging,
lowering etc., during operation can cause collapse and/or other damage.
Ground pressure points should be considered as they vary depending on the type of lift
movement. For example, lifting a load over the corner of the crane produces the maximum
ground bearing pressure and consideration must be made for this increased pressure.
Underground utilities or structures can usually be checked by the site supervisor or your
supervisor who will have been in contact with local authorities. Task 2 addresses some of
the actions to take to more safely and evenly distribute the weight of the crane and allow
for ground bearing pressure points.
TASK 2
Once the ground surface has been checked for obstacles and hazards the crane must be
positioned in the correct location. This often requires the use of additional equipment to
distribute the load more evenly and ensure crane stability.
In this part of the assessment you must
demonstrate the use of blocking and blocking
mats prior to positioning. Then once positioned
you must use the correct signalling and barrier signage. The crane will also need to have
the correct grounding and bonding. This must all be in place and checked prior to the
crane being used.
Blocking and blocking mats
To be safe, blocking under the outrigger
float should be three times larger in area
than the float itself. The blocking must
be firm and be capable of supporting the
total weight of the crane and load. A pile
of blocking may not create a firm and
stable surface for support as it may move
or topple under the weight or action of
the crane. Blocking should not be placed
under the outrigger beams.
Blocking mats, which are made of steel
or wood, provide a much more stable
platform over a larger surface of ground
than blocks. If there is ever any doubt
about the grounds stability on the worksite you should consult the site supervisor who
may contact a soil professional. The risk of setting a crane up on an unstable or unknown
surface is too great to take a chance!
When a crawler crane is positioned on blocking mats timber blocking must be placed at
the ends of the tracks so the crawler does not move.
Signalling and Barrier Signage
While the crane is being positioned the crane operator and signaller must communicate
effectively by using the correct hand and/or radio signals. Once the crane is in position the
appropriate signage must be displayed to identify and hazard.
Signage is put in place to make sure that those working on the site or those new to the site
know what areas should be avoided or where dangerous areas are located.
Grounding and Bonding
Before the crane is used it must be properly grounded to make sure that in the event of
an electrical contact (lightning strike, contact with power cables) the current will travel
through the crane into the ground and not cause injury to the operator or others. Of equal
importance is the bonding of the crane and its components as there must be continuity
between all parts so that the current passes from one part to the next and then into the
ground. Without this the purpose of grounding the equipment is futile.
Refer to Task #2
Points 2.1, 2.2
A correctly bonded crane that has been properly grounded should avoid injuries to the
crane operator or others.
Note:
Your Mentor must verify he has seen you complete these tasks. After demonstrating these
skills at work a minimum of three times you can be assessed. Your Mentor will advise
if you are to do this as part of routine operations in the workplace or as a separate
assessment task.
Section 8 Crane Operations
Unit Standard ACO 8.4 W
WORKPLACE ASSESSMENT (Core except Task 4)
DEMONSTRATE SAFE CRANE SET UP ACCORDING TO MANUFACTURERS
INSTRUCTIONS
Purpose
This unit allows a trainee to demonstrate his or her skills to conduct a pre-operation
inspection of a crane prior to use.
The emphasis of this unit assessment is an accurate pre-operation inspection and the
need to do this according to the manufacturers recommendations.
Mentor to see you have had sufficient practice in the task prior to assessment.
Note:
This assessment may be able to be completed at the same worksite, on the same day as
assessments in sections 6 and 7 on Transportation and Assembly, then Site Planning,
Positioning and Location (MC 6.4, 6.5, 7.3). This will depend entirely on the workplace
assessment requirements for units MC 6.4, 6.5, and 7.3 W to see if you can combine the
activities and be assessed for several of them at the same time.
TASK 1 - SAFE CRANE SET UP
You must conduct a pre-operational inspection for the following types of cranes:
Mobile crane
Boom truck
Rubber tire crane
Crawler crane
Typically the inspection involves a walk around with visual checking of a number of key
parts and their components. Companies require the crane operator to complete daily
safety inspections and use the inspection charts from an inspection repair book for this
purpose.
In addition to the daily crane inspections a crane may be inspected at other times as
well. These include after a period of no use, during annual inspections, and/or whenever
sudden and unusual shock loads are applied to the crane.
The inspection requirements for assessment
purposes must include checking for the
following:
Refer to Task #1
Points 1.1, 1.2,1.3
Operators aids for the crane are in place and verified
The LMI Load Moment Indicator
Boom length indicator
Boom angle indicator
Inspection and erection reports are completed and accurately filed
including the
Crane logbook
Lift plan
OH&S requirements are followed
Control systems and system gauges are located
TASKS 2 & 3
After the initial inspection you will be required to perform routine tests, and possible
repairs and maintenance as warranted by the inspection. For assessment purposes you
must complete the requirements of the task even though the repairs and maintenance
opportunities will be varied. It may take several inspections in different worksites to be
able to complete some maintenance and repairs and this will be totally dependent on
whatever is found with the equipment that day.
After repairs and maintenance are done
perform these tests for the following functions:
Boom up and down
Hoist up and down
Swing left and right
Scope in and out
Brakes
Any defects and deficiencies found during the tests, and any repairs or maintenance
performed to correct them, need to be reported to the supervisor and recorded accurately
in the crane log book.
When entries are made in the crane log book
they must include:
Date
Description of issue
Signature of person doing repairs
Signature of operator
Refer to Task #2
Points 2.1, 2.2
Refer to Task #3
Points 3.1, 3.2
TASK 4 (MOBILE)
This task has two parts:
1. setup a rubber tire
2. setup a hydraulic crawler crane.
In setting up either crane you must ensure
the area of operation is correctly scoped, that
site plans are followed and the manufacturers
specifications are addressed. (4.1)
As is the case with any setup you must check for overhead obstructions and underground
hazards.(4.2)
Also, blocking and/or mats used must be sufficient considering the load requirements and
conditions to level the crane. (4.3)
Prior to the lifts you must programme and adjust the safety devices. This is required to
ensure accuracy and safety when lifting. These include: (4.4)
LMI load moment indicator
Anti two block systems
Boom angle indicators
Level crane
The assessment should take place in the workplace during normal operations and your
Mentor must verify he has seen you complete these tasks. After demonstrating these skills
at work a minimum of three times you can be assessed. Your Mentor will advise if you are
to do this as part of routine operations in the workplace or as a separate assessment task.
Refer to Task #4
Points 4.1, 4.2, 4.3, 4.4
USE A MOBILE CRANE TO SAFELY PICK UP & CARRY LOADS IN A WORKPLACE -
MOBILE
Purpose
This unit allows a trainee to demonstrate his or her skills to pick and carry a load with a
mobile crane.
The unit assessment encompasses a variety of actions including operating a crane,
adjusting procedures as required for weather and conditions, performing hoists,
monitoring the equipment, placing the load and then performing post operation
procedures. A key requirement for the success of this assessment is for you to work
through the tasks in the routine manner of a competent crane operator with a smooth
transition between the responsibilities and an ability to be monitoring and sensing what is
occurring during the process.
Note:
This assessment may be able to be completed at the same worksite, on the same day
as assessments in section 6 and 7 on Transportation and Assembly, then Site Planning,
Positioning and Location (MC 6.4, 6.5, 7.3). This will depend entirely on the workplace
assessment requirements for previous units to see if you can combine the activities and be
assessed for several of them at the same time.
TASK 1
You must operate a crane first without a load
and then with a load. The operations you must
include in both scenarios are:
Booming up and booming down
Slewing clockwise and counter clockwise
Hoisting up and down
Travelling on the site
Refer to Task #1
Points 1.1, 1.2
TASK 2
In this portion of the assessment you must
show that you are able to safely control the
hook block during the lifts by making the
necessary adjustments. In the assessment
process you may not have, on that particular day, any of the weather conditions outline in
the assessment. In this case you must simulate how you would make adjustments to suit
weather conditions that include:
Ice
Frozen to the ground
High winds
Lightning storm
The types of adjustments you must demonstrate are:
Maintaining even control
Using slower swing speeds
TASKS 3, 4 & 5
When you perform hoisting procedures you
must also be monitoring the equipments
performance and trouble shooting any
problems that arise. At the same time all
safety regulations must be adhered to and
the manufacturers recommendations for safe
operation must be followed.
When you demonstrate pick and carry procedures you must include: (3.1)
Travelling at low speed
Using the shortest boom length possible
Having the load as low as possible
Simulating a lift near high voltage equipment
Conducting a blind lift
For the purposes of the assessment, you must show you are able to operate in the
vicinity of high voltage equipment and for safety reasons, until you are a qualified crane
operator, this must be simulated. As a trainee you must demonstrate that you know how to
competently avoid touching high voltage equipment and it is not safe practice to have you
learn and demonstrate this around live high voltage equipment instead, to protect you
and others, this is done through a mock situation. (3.2)
Refer to Task #2
Points 2.1, 2.2
Refer to Task #3, 4, 5
Points 3.1, 3.2, 3.3,
4.1, 4.2, 5.1, 5.2
The blind lift you perform is a way to measure your ability to complete a lift while not
having the benefit of seeing the cranes operation. It is important you attempt this task
only when you feel confident of your ability. (3.3)
During any lift the crane operator has a variety of responsibilities. As well as ensuring
the lift is safely carried out and completed he or she must monitor the equipment
performance and trouble shoot any problems that arise as they occur. The essential parts
of this include monitoring: (4.1, 4.2)
Water levels
Oil fluid levels
Hydraulic levels
Instrument gauges
Some things to watch for might include:
A drop in pressure may indicate the levels may be low or there is a problem with
the pump
An increase in temperature may indicate that coolant or hydraulic fluid may be low,
a fan belt may be broken, or the apparatus might be overloaded or overworked.
In these instances operation must be stopped and the levels, belts and equipment must be
checked. Adjustments must be made prior to continuing with the lift.
A successful lift will include the load being safely placed at its intended destination,
avoiding all obstacles and obeying the signal person. This must be demonstrated during
the assessment process. (5.1)
Multi Crane Lift
Another part of this assessment includes the completion of a multi-crane lift. This type
of operation is not as common as single lifts and you may have to wait for a time in which
this one part of the task can be assessed. The use of two or more cranes demands extra
precautions and planning. Any multi crane lift must be analysed to determine whether
it is a relatively basic simple lift or whether it will be a complex lift that may require
engineering planning and procedures.
The assessment page allows for this particular skill to be demonstrated and witnessed at
a completely different time and, if necessary, at a different location. Just make sure the
place and date are recorded and obtain the sign off from the Mentor as required in the
assessment. (5.2)
TASK 6
On completion of the lifts you must perform the regular post operational procedures that
include the following:
You will notice you have to also demonstrate these same skills in the assessment for Unit
Standard 8.6 W so it may be possible to have both tasks signed off at one time.
Wheels/ tracks, deck, and cab are cleaned and all garbage or obstacles are
removed from the cab
Equipment is safely parked in the correct location
Equipment is properly shut down and safely secured with the battery, and night
switch if applicable, disconnected and the machine locked up.
Post operation checks are made to verify:
Fluid levels
Safe shut down
Correct lockup
Appropriate location
The assessment should take place in the workplace during normal operations and will
take a number of days to complete. Your Mentor must verify he has seen you complete
these tasks. After demonstrating these skills at work a minimum of three times you can be
assessed. Your Mentor will advise if you are to do this as part of routine operations in the
workplace or as a separate assessment task.
LEAVE CRANE UNATTENDED - MOBILE
Purpose
This unit allows a trainee to demonstrate his or her skills to leave a crane unattended for
short and long periods of time. Short periods of time are usually lunch breaks or brief
stoppages whereas long periods or time are overnight, weekends or holidays.
A special note:
An operator must never, except in extreme emergencies, leave the controls of the
machine while any load is suspended.
The emphasis of this unit assessment is for the trainee to demonstrate how to leave a
crane unattended in a variety of situations.
As this is a requirement after any lift this assessment may be able to be completed at
the same worksite, on the same day as assessments in section 6, 7 and other tasks in
Section 8. This will depend entirely on the workplace and the opportunities you have to
demonstrate the skills. Please ensure you read the assessment requirements for units in
the pervious sections to see if you can combine the activities and be assessed for several
of them at the same time.
TASK 1
You must leave a crane unattended for long and short periods of time. The difference
between the two scenarios is that when a crane is to be used again within a short period
of time, on the same day, it is acceptable to leave the crane in a working position. All other
requirements are the same and include:
Key is turned off and removed
Swing brake is applied
Swing dogs are applied
Attachment is on the ground
Boom down on blocking or cradle (for overnight, weekends or vacations only
otherwise it is left in the working conditions)
TASK 2
Another part of this assessment includes performing the shut down procedures:
Note:
You will notice you have to also demonstrate
these same skills in the assessment for Unit
Standard 8.5 W, so it may be possible to have
both tasks signed off at one time.
Wheels/ tracks, deck, and cab are cleaned and all garbage or obstacles are
removed from the cab
Equipment is safely parked in the correct location
Equipment is properly shut down and safely secured with the battery and night
switch disconnected and the machine locked up.
Post operation checks are made to verify:
Fluid levels
Safe shut down
Correct lockup
Appropriate location
these tasks. After demonstrating these skills at work a minimum of three times you can be
assessed. Your Mentor will advise if you are to do this as part of routine operations in the
workplace or as a separate assessment task.
Refer to Task #2
Points 2.1, 2.2, 2.3, 2.4, 2.5, 2.6
Section 9 Maintenance and Service
Unit Standard AMS 9.3 W
COMPLETE MAINTENANCE CHECKLISTS (ENGINE ON / ENGINE OFF) & MAINTAIN
ENGINES TO MANUFACTURERS SPECIFICATIONS - MOBILE
Purpose
This unit allows a trainee to demonstrate his or her skills to perform engine maintenance.
The unit assessment covers routine engine inspections as well as basic maintenance and
cleaning procedures. This assessment has many different components so it is unlikely
that you would be able to complete all the tasks at the same worksite on the same day. By
reading through the assessment you will see the different requirements. It may end up that
you replace oil filters on a crane one day, clean the crane battery another day at another
site, and maintain hydraulic tank breathers on another day on another crane. You should
be aware of all the assessment components and where possible, demonstrate your ability
to perform the requirements as they would naturally occur during the work processed.
Note:
When conducting this assessment you must complete the work and make necessary
entries in the crane maintenance logbook and other documents as required. This forms
part of the assessment for Unit MC 9.7W Maintaining an equipment logbook. Unit MC
9.7 W is achieved naturally while completing the other units in section 9 on Maintenance
and Service.
TASKS 1 & 2
You must complete maintenance checklists
while the engine is off and then when the
engine is on. Engine off checks are done
to find any obvious problems and correct
them before starting the engine and possibly
endangering others. When conducting the maintenance checklists the following process
must be followed:
Properly check all things as outlined on the checklist and check it off accordingly
Follow the company requirements as well as the manufacturers manuals
Accurately identify any problems and record them clearly in the maintenance
logbook
Report any problems to the crane superintendent/supervisor
Refer to Task #1 & 2
Points 1.1, 1.2, 1.3, 1.4,
2.1, 2.2, 2.3, 2.4
TASK 3
The requirements for Task 3 include
using a variety of tools to perform a
number of maintenance and service
activities. It is unlikely you will be able to
perform the range of jobs in one day so
you may have to gradually work towards
having each part signed off separately, or
in segments.
It is important you record the activities
in date order in your trainee logbook
showing where and when you performed
the tasks. These logbook entries are
checked by the Mentor to see you have
had sufficient practice in the task prior to
assessment.
Basic Service and Maintenance
The basic service you are required
to demonstrate must be performed
according to the manufacturers manuals
and you should refer to those while
completing the tasks which include:
addition of required fluids
adjustment of belts
replacement of belts
replacement or cleaning of air
cleaners
replacement of oil filters
replacement of hoses
Tools
As a crane operator you are required to use a number of different tools and part of the
assessment looks at your ability to use the following tools while performing the service and
maintenance requirements:
grease gun
wrenches
screwdrivers
hammers
vice grips
Refer to Task #3
Point 3.1
Refer to Task #3
Point 3.2
shovels (track)
pinch bar
step ladder
cloth or fibre glass tape measure
Structural maintenance
During your course of time as a trainee you must be able to show that you are able to
perform structural maintenance as required. The maintenance you perform may vary
as different requirements will arise in different situations. For assessment purposes the
structural maintenance should include maintenance to the following:
bolts
wedges
cotter keys
pins
guard rails
Maintenance to crane accessories
The crane and accessory systems require maintenance from time to time. You must, over a
period of time, demonstrate your ability to service and perform required maintenance on
the following:
gearbox
hydraulic tank breathers
outriggers and stabilizers
booms
steering systems
Refer to Task #3
Point 3.3
Refer to Task #3
Point 3.5
air tanks
filters
Cleaning
Finally, the last step in any maintenance and service process is to clean the equipment.
You may have demonstrated some of these skills in earlier assessments and you are able
to cross reference those experiences to this task if you wish.
You must clean the following crane components:
batteries
cab and windows
wheels and tracks
deck and carbody
these tasks. After demonstrating these skills at work a minimum of three times you can
be assessed. Your Mentor will advise if you are to do this as part of routine operations in
the workplace or as a separate assessment task. Remember to record all of the experience
doing these tasks in your trainee logbook.
PERFORM ROUTINE INSPECTIONS & MAINTENANCE ON HYDRAULIC SYSTEMS -
MOBILE
Purpose
This unit allows a trainee to demonstrate his or her skills to perform routine inspections
and maintenance on hydraulic systems on mobile cranes.
The unit assessment covers routine inspections as well as basic maintenance procedures.
It will be easy to complete the inspections in a given day or time frame; however,
performing the variety of maintenance specified in the assessment may have to occur over
a period of time as the situations arise.
Note:
9.7 W is achieved naturally while completing the other units in Section 9 on Maintenance
and Service.
TASK 1
You must inspect the hydraulic systems and perform any necessary maintenance to ensure
their safe and effective operation. The inspection and the maintenance must include each
of the following:
pumps
fluid levels
hoses
motors
doing these tasks in your trainee logbook as this will be referred to by the Mentor.
Refer to Task #1
Point 1.2
INSPECT MONITORING DEVICES & CONTROL MECHANISM ON MOBILE CRANES -
MOBILE
Purpose
This unit allows a trainee to demonstrate his or her skills to perform routine inspections
of two important features of mobile cranes: the monitoring devices and the control
mechanisms. After inspection, maintenance is to be performed on monitoring devices, as
required, and adjustments are to be made to control mechanisms.
Note:
It may be possible to include the work for this unit in conjunction with other assessment
tasks in another unit or combination of units. Make sure you are familiar with the other
units assessment requirements so you can obtain sign off on relevant tasks on the same
day if practical.
and Service.
TASK 1 - MONITORING DEVICES
You must inspect the following
monitoring devices to ensure they
operate properly. Maintenance must be
performed on the devices according to
the manufacturers manual.
Right: Load Moment Indicator
Right above: Boom angle indicator
Right below: Boom length indicator
Below: Anti two block system
TASK 2 CONTROL MECHANISMS
You need to demonstrate an ability to inspect control mechanisms and perform the
necessary adjustments. If the control mechanisms are not correctly adjusted accidents
can occur. The variety of control mechanisms you must inspect and maintain may require
you to complete different adjustments to different mechanisms on different days as it will
depend on which mechanism needs adjustment. If this is the case, record all the work by
date order in your trainee logbook and also seek sign off at different times if necessary.
Inspections and adjustments must be demonstrated for the following control mechanisms:
slack adjusters
rollers
cables
brakes
clutches
levers
This assessment should take place in the workplace during normal operations and will
Refer to Task #2
Points 2.1, 2.2
PERFORM SERVICE ON ENGINE COOLING SYSTEMS ON MOBILE CRANES - MOBILE
Purpose
This unit allows a trainee to demonstrate his or her skills to perform routine service on
engine air cooling systems and water cooling systems.
The unit assessment covers routine maintenance of cooling systems. It may be possible to
complete these tasks at the same time as being assessed for other tasks in other sections.
Make sure you read through all the assessment requirements to see if you can cover
several assessment tasks in one assessment.
It is important that manufacturers manuals are referred to and interpreted properly so
you are able to correctly perform the required service. (1.1)
Note:
and Service.
TASK 1
You must service air cooling systems on
mobile cranes.
Engine Air Cooling System
Perform service on the system which may include cleaning of fans and grills and changing
belts. This is done to ensure proper cooling.
Water Cooling System
Perform service on the system which may include changing fluids, hoses or belts. This is
done to ensure proper operating temperatures.
Refer to Task #1
Points 1.2, 1.3
MAINTAIN AN EQUIPMENT LOGBOOK TO RETAIN A PERMANENT WRITTEN RECORD OF
MAINTENANCE & REPAIRS
Purpose
This unit allows a trainee to demonstrate his or her skills to complete the maintenance and
service documentation that is required.
Note:
This assessment should occur while you are completing the other assessments in Section
9 on Maintenance and Service. As you work through each of those units you must make
the necessary entries in the maintenance logbooks. This should not be something that is
done later, but a key step in completing the maintenance process.
It is important that company policy is followed
and that all documents are easy to read and
accurate. Legible writing is critical.
TASKS 1 & 2
All inspections, defects, deficiencies and
maintenance must be recorded and reported:
1. You must record the inspection when it occurs. If you do not record the inspection
it could cause confusion as another worker may not realize the inspection has
occurred
2. All requests for maintenance that will be performed by external suppliers must be
recorded. This provides any easy trail for anyone to see what has been requested
from which service provider.
3. When maintenance is completed it must be accurately recorded. This includes the
date, details of the repair, and the name and signature of the person doing the
maintenance.
4. When advising the crane supervisor and site supervisor of inspections, defects,
deficiencies and maintenance use clear, easy to understand English. Make sure
the person to whom you give the message has a solid understanding of the issues.
Often times our accents or the speed at which we speak, combined with the noises
on a busy worksite may stop the person hearing the information correctly. It is up
to you to ensure you have been clearly understood. If your site supervisor mishears
you he may approve continued work with the crane instead of putting the crane out
of commission until the repair is completed
Refer to Task #1
Point 1.1
Refer to Tasks #1 & 2
Points 1.3, 1.4, 1.5, 2.1, 2.2
5. Complete reports and documents as required. Most companies will have the same
basic requirements but on top of that may be specific reports or documents that
company uses as well. All documents must be completed properly and copies are
required to be submitted as part of the assessment to demonstrate the entries you
have made.
The assessment should take place during the other assessments in this section and your
assessment stipulates the documents for which you must keep copies to go with your
assessment for the Mentor.
This completes the Core Workplace Competencies:
Hydraulic Mobile Crane 80 Tonnes & Under
The Assessment Tools against which you will be assessed as an Operator throughout, and
at the end of your training period are included in the publication:
Crane Operators Practical Assessment
This manual is available to guide you in reaching your goal as a competent Crane Operator
and is also the Manual your Mentor will use to guide his or her assessment of your
developing competence.
You record your evidence of workplace activity in a third book:
The Work Record
This is the place where you get your daily work experience down. The mentor will use this
book to cross reference with the Assessment Manual.
Best wishes and Safe Craning!
Glossary
Assessor The Assessor is the BCACS Assessor who is responsible
for the final assessment of the Trainee (student) against a
knowledge or workplace unit standard
Assessor Third Party Third Party Assessor means a person recognized by the
BCACS to perform practical assessments. This person must
be dedicated to assessing only and not be a trainer of crane
operators or otherwise be in any other potential conflict of
interest.
BCACS BC Association for Crane Safety
Common Core of
Competence Standards
The Common Core of Competence Standards are the
Knowledge and Workplace unit standards that must be
completed by all students before they can undertake further
specialised training for certification on either the four Mobile
Cranes types or the four Boom Truck crane types.
Certification Upon successful completion of the Mobile Crane Common
Core and successful completion of one further advanced
module, either: Mobile Cranes 80 tonnes and under, Mobile
Cranes Unlimited Tonnage, Mobile Lattice Friction Cranes,
Mobile Lattice Hydraulic Cranes, Boom Truck with Folding
Boom 22 tonnes and under, Boom Truck with Folding Boom
(unlimited tonnage), Boom Truck with Stiff Boom 40 tonnes
and under, Boom Truck with Stiff Boom (unlimited tonnage),
Tower Crane or Self Erect Tower Crane, the Trainee will receive
a Certificate of Qualification Mobile Crane (Crane Type) or
Certificate of Qualification Boom Truck Crane (Crane Type)
or Certificate of Qualification Tower Crane (Crane Type)
Imperial Ton
short ton & long ton
The standard ton in the U.S. measurement system is the
short ton, equal to 2000 pounds (exactly 907.18474 kg).
Both long and short tons are defined as 20 hundredweights,
but a hundredweight is 112 pounds in the Imperial system
(long or gross hundredweight) and 100 pounds in the US
system (short or net hundredweight).
The spelling tonne denotes the metric tonne of 1000
kilograms (approximately 2204.623 pounds).
Long Ton (L/T sometimes known as a Gross Ton, Weight Ton,
or Imperial Ton) is the name for the unit called the Ton
in the Avoirdupois or Imperial system of measurements,
as formerly used in the United Kingdom and several other
Commonwealth countries. It has been replaced by the metric
tonne. It is equal to 2240 pounds (exactly 1016.0469088
kilograms). A long ton-force is 2,240 pounds-force (9,964
newtons
1
).
1 http://www.wikipedia.org
Incumbent/Existing
Operator
Incumbent / Existing Operator means an operator who is
registered with the BCACS as of July 1, 2007 or an operator
coming from outside of British Columbia after July 1,2007
and who is in possession of an acceptable certificate. (Please
contact the BCACS in writing or by email for more information
regarding acceptable certificates.) Incumbent operator status
will end on July 1, 2008. As of July 1, 2008 all operators
will be required to possess their documented proof of
competency as issued by BCACS.
ITA Industry Training Authority
Knowledge Unit
Standards of
Competence
The theoretical component of Mobile Crane Certification is
made up of the Knowledge Units, which:
can be taught in a classroom setting by a qualified
instructor, or
delivered on line, or
learned through self study on line or through printed
materials
Level One Operator Level One Operator means a person new to crane operations
who has not successfully challenged the core theory. This
operator can operate only under direct hands-on supervision.
A level one operator may only operate up to six months
without successfully challenging the theory assessment. The
Level One Certificate will be issued jointly to the employer and
the operator and the Certificate may apply to any crane type.
Level Two Operator Level Two Operator means a person who has passed the
theory assessment and is certified to make routine lifts but
will require hands-on supervision for all first time significant
lifts and all high risk lifts. These routine lifts will be clearly
documented by both the operator and the employer. Theory
assessments for existing operators who choose to obtain
Level 2 will be conducted by the employer. New operators
will be required to pass a formal written assessment. A level
two operator may choose to remain at this level for their
working career or eventually they could challenge both the
theory and the practical assessment to obtain a Level Three
Certificate. A Level Two Certificate will specify what type of
crane the operator may operate and their employer. The Level
Two Certificate is only valid while working for the identified
employer on the certificate.
Level Three Operator
and Interim Level Three
Operator
Level Three Operator means a person who has passed
both the theory and practical assessments conducted by a
third party assessor for a specific crane type. A Level Three
Certificate will specify what type of crane the operator may
operate. This certificate means that the operator is competent
to safely perform all crane lifts within the scope of the
identified crane type and size. The employer is not identified
on this certificate.
Interim Level Three Operator means an incumbent operator
who has registered before July 1, 2007 and has also signed
a statement declaring that he or she is qualified to provide
hands on supervision for Level One operators and to provide
hands on supervision and has the ability to sign off for
Level Two operators. This interim provision is necessary to
phase in OHSR 14.34.1 (the new certification process) and
will allow the Interim Level Three operator to sign off Level
Two operators who have successfully performed first time
significant lifts. This interim provision will expire on July 1,
2008 and only certified Level Three operators may provide
hands on supervision or sign off after July 1, 2008.
Mentor A mentor is a journeyperson who is the student/trainees on-
the-job coach, and is responsible for day-to-day assessment of
the Trainees work and for coaching, training and supervision
on-the-job.
Metric tonne A tonne (t) or metric ton (M/T), sometimes referred to as
a metric tonne, is a measurement of mass equal to 1,000
kilograms. A tonne (t) or metric ton (M/T), sometimes
referred to as a metric tonne, is a measurement of mass
equal to 1,000 kilograms
2
.
2 http://www.wikipedia.org
Practical Assessment Practical Assessment means an assessment conducted by
a third party assessor, and supervised by the BCACS. The
assessment involves spoken questions, as well as the operator
using the crane to show that they have the basic knowledge,
skills and ability to safely operate the crane. The operator
is then considered to be competent (having the right skills
and knowledge of the crane) and will receive written proof.
If the operator is found not yet competent after performing
the practical assessment they would be allowed to continue
operating with a Level One or Two Certificate as decided by
the third party assessor. An action plan and a follow-up date
will be set following the completion of the assessment. The
operator will be informed of this date both verbally and in
writing.
Theory Assessment Theory Assessment means an assessment administered by
the BCACS, conducted on either paper, computer, verbal or
other means. These assessments will be delivered through
the ITA (Industry Training Authority) and administered by the
BCACS.
Work Experience Diary The Work Experience Diary is a Work Record book (a journal)
with pages in which the Trainee documents the dates and
details of the practice tasks he has performed leading up
to the assessment. The amount of time a Trainee must
demonstrate the tasks prior to being assessed is stipulated in
the Workplace Assessment Documents.
It also contains an Evidence section in which the Trainee
inserts the pieces of evidence that are requested in the
Workplace Assessment Document.
Workplace Units
Standards of
Competence
The practical component of Mobile Crane Certification is
made up of the Workplace Units, which:
require hands on experience
are assessed on the job by a Registered Workplace
Assessor
may be begun in a simulated setting such as a training
yard, but are assessed for credit in the workplace
Metric Conversion Help
For an online Metric Converters try:
http://www.worldwidemetric.com/metcal.htm
http://www.sciencemadesimple.com/weight_conversion.php
Conversion Factors
IMPERIAL TO METRIC
1 ounce =
1 pound =
1 short ton (2K) =
1 metric tonne (2.2K) =
1 inch =
1 foot =
1 yard =
1 cubic foot =
1 Imperial gallon =
1 Imperial gallon =
1 Imperial pint =
28.375 grams
454 grams
907 kilograms
1,000 kilograms
2.54 centimetres
30.48 centimetres
91.44 centimetres
28,316.846 cubic centimetres
1.201 US gallons
4.546 litres
0.568 litres
METRIC TO IMPERIAL
1 gram =
1 kilogram =
1 metric tonne =
1 centimetre =
1 metre =
1 cubic metre =
1 litre =
1 litre =
1 litre =
1 litre =
0.0352 ounces
2.204 pounds (= 1000 grams)
2,204 pounds
0.394 inches
39.37 inches
1.308 cubic yards
61.024 cubic inches
0.220 Imperial gallons
0.264 US gallons
1.760 Imperial pints
Recommended Reference Textbooks, Video/DVD Resources
From the Construction Safety Association of Ontario http://www.csao.org/
Mobile Crane Manual
by Donald E. Dickie, P. Eng., D. H. Campbell, P. Eng.
Construction Safety Association of Ontario ISBN 0-8273-6527-6
Rigging Manual
by Donald E. Dickie, P. Eng.
Hoisting and Rigging Safety Manual
Slings
Safety in Rigging Video/DVD Series
The complete set of 10 Safety in Rigging DVDs (FD001-FD010), complete with instructors
notes. Includes:
Cranes: Types, Components and Case Histories (FD001)
Hazard Awareness in Crane Operating Areas (FD002)
International Hand Signals (FD003)
Wire Rope (FD004)
Hardware (FD005)
Chain (FD006)
Slings (FD007)
Reeving (FD008)
Hoists, Winches and Related Devices (FD009)
Jacks, Rollers and Related Devices (FD010)
Cranes: Types, Components and Case Histories Video/DVD (set of 10)
From the Operating Engineers Training Institute of Ontario http://www.oetio.com
Mobile Craning Today
Operating Engineers Training Institute of Ontario ISBN 0-8273-5460-6
Additional Resources
IPTs Crane and Rigging Handbook
by Ronald G. Garby ISBN 0-920855-14-8
IPTs Crane and Rigging Training Manual
By Ronald G. Garby ISBN 0-920855-16-4
Reference Authority
(to be developed when revised OSH regulations released in Summer 07)
1. WorkSafeBC Occupational Health and Safety (OHS) regulations
2. WorkSafe BC Occupational First Aid Requirements
3. CSA Standard Z150-1998 Safety Code for Mobile Cranes,
4. ANSI Standard ANSI/ASME B30.5-2004, Mobile and Locomotive Crane or ANSI/
ASME B30.22-2005, Articulating Boom Crane,

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