MOBilE CRANE OPERATION
MODULE NUMBER 6OFINSTRUCTION GUIDE NUMBER 43ON-THE-JOB TRAINING MODULESFORSURFACE METAL AND NONMETAL MINESMOBilE CRANE OPERATION
This module describes the basic job steps, potential hazards or accidents, andrecommended safe job procedures for mobile crane operation. Much of the material inModule 3, "Hauler Operation," may also be used in the "truck driving" portion of trainingfor operators of truck mounted cranes.Mobile cranes (both truck cranes and crawler cranes) are used at surface metal andnonmetal mines for various types of applications. Mobile cranes are most frequently usedfor hoisting and placing parts during the assembly and maintenance of large miningmachines, mine/mil facilities, and buildings. Cranes are used with a breaker ball at somelocations for breaking oversize boulders before loading. They are also used to hoist andmove stone blocks at dimension stone operations. Mobile crane operators have a heavyresponsibility for the safety of persons and equipment. A ground person (rigger) or groundcrew is usually present, and can be injured if the operator makes mistakes. The loads thatare handled may be expensive and fragile. Cranes often operate close to buildings orother machines. The job demands top skils, good judgement, and thorough training.The safe operation of a crane requires careful selection and training of operators andmaintenance personneL. Only trained and qualified persons should be permitted tooperate cranes. Training should include a thorough review ofthe operating characteristicsof the equipment, its limitations, and the hazards of improper usage. Operators must bethoroughly trained in safe procedures for operating the crane and handling loads.Most accidents related to crane operations involve fallng, dropped, or swinging loads.Slings and other fastenings sometimes break or slip off. Overturning the crane is, ofcourse, extremely dangerous and damaging, as is boom collapse. Crane operators mustbe alert for power lines and other overhead obstructions. Operators are also subject toslipping and fallng while mounting and dismounting, cleaning windows, inspecting themachine, and refueling. Ground personnel can be caught in rigging if the crane operatorbegins hoisting while they are stil making adjustments.Standardized signaling between the ground person and crane operator is very importantto safe operation. Taglines must be attached to loads that may require steadying orguidance while suspended. Hitches and slings must be suitable for the particular materialhandled. Everyone, including the ground crew, must stay clear of suspended loads.Serious hazards include overloading, dropping or slipping of the load caused by improperhitching or slinging, obstruction to free passage of the load, and using the machine for apurpose for which it was not intended or designed.No one is permitted to ride on loads or hoisting hooks except in certain unusual situationswhere this method eliminates a greater hazard. If persons must be lifted, safetyprecautions specified in ANSI/ASME Standard 830.5 must be taken. Standard 830.5,"Mobile and Locomotive Cranes", is published by the American Society of MechanicalEngineers.2
Chains, slings, ropes, or tongs are used to fasten the load for lifting. The lifting ability ofa crane depends primarily on balance, rather than engine power. Cranes are moreeffcient than other machines for most hoisting work because: (1) they do not carry theslower and smoother lifting can be .dead weight of a bucket and other digging parts, (2)achieved by increasing the number of lines, and (3) the operator has a better view of thehook and the load.A crane can lift maximum loads only if the boom is held high enough to keep the load closeto the crane. A crane can handle lesser loads with greater safety and convenience if theloads are close enough so that there is no question about stability. It is thereforecustomary to operate cranes with their booms held high. This practice does, however,involve two dangers - the boom fallng over backwards; and overturning the crane byabrupt swinging.The basic job steps included in this module are:1. Conduct walk-around check of crane.2. Mount crane and check cab.3. Start crane and complete pre-shift examination.4. General operation.5. Lift, transport, and lower materiaL.5. Load and move crane.7. Use of breaker balL.8. Use of magnet.9. Shutdown procedures.10. Perform maintenance and repairs.The operator's manual provided with the machine, and the mine's operating procedures,should also be used in training machine operators.3
The following safe job procedures wil help minimize incidents which may cause injuries andadversely affect production:Required and/or recommended personal protective equipment:Hard hat, safety shoes, safety glasses with side shields, gloves,clothing appropriate for weather conditions, hearing protectionwhere neededSEQUENCE OFJOBSTEPSBASIC1. Conduct walk-around checkof crane.RECOMMENDED SAFE JOBPOTENTIALACCIDENTS OR, PROCEDURESHAZRDS1. A) Frostbite,1. A) Dress to suit weatherconditions.hypothermia,sunburn, heatstroke, heatcramps, heatexhaustion.B) Be aware of slick spots andB) Slips or trips,struck by flyingobjects such asdirt or splashedfluids, mechanical hazards.4debris while making safetychecks. Be especially careful ofruts, uneven ground, and frozenground. Use suitable access ifnecessary to mount anddismount crane to check engineor other area of machine.
OFSEQUENCEBASICJOBSTEPS1. (Continued)RECOMMENDED SAFE JOBPOTENTIALACCIDENTS ORPROCEDURESHAZRDSCheck:B) (Continued)1) tires and wheels on truckmounted cranes for lug nuts,cracked rims, cuts, tire pressure, embedded stones, orabnormal wear.2) tracks on crawler cranes fortightness and rollers, idlers, andsprockets for damage.3) area around, under, and oncrane for people or obstructions.4) bolts, guards, covers, safetydevices, and mechanicalcomponents of crane to makesure they are in place.5) visually for oil leaks.6) engine compartment for dirt,debris, oily rags, tools. Graspengine covers firmly whenremoving. Get help if needed.7) fluid levels. Wear safetyglasses with side shields andgloves.8) hydraulic oil and coolant linesand hoses for breaks, leaks,rubbing lines or loose fittings.Pay particular attention tohydraulic hoses which flex innormal operation of crane.9) fire extinguisher (if on outside ofmachine) to make sure it's fullycharged.10) bolts and pins for looseness orexcessive wear.11) wire ropes for obvious frays,kinks, or broken strands.5
RECOMMENDED SAFE JOBPOTENTIALACCIDENTS OROFBASIC JOBSTEPSSEQUENCEPROCEDURESHAZRDS12) wire rope terminations andsheaves, drums and rollers forimproper installation, wear andB) (Continued)1. (Continued)damage.13) load hooks for damage, cracks,spreading, or twisting.14) surrounding area where crane isparked by checking;(a) clearances under bridges,overhead lines, or any overhead obstruction,(b) side clearance, when tight,to be sure there isclearance for tail swing.15) ladders, steps, handholds, andhandrails for loose bolts,breaks, cracks, missing parts, orbent and twisted steps.C) Sludge depositsor ice whichmight preventvalve operation tank rupturefrom excessiveC) If your truck mounted crane hasair brakes, bleed the air lines torelease any condensation thatmight have accumulated andtrip the pressure relief to besure it's operable.pressure.D) Report and, if possible, repairany defects found. Do not useD) Potentialhazards goingmachine with uncorrected safetyuncorrected.defects.,6
BASIC JOBPOTENTIALACCIDENTS ORSTEPSHAZRDSSEQUENCEOF2. Mount craneand check cab.2. A)RECOMMENDED SAFE JOBPROCEDURESSlips and falls,clothing caught2. A)on control leversNOTE: Checkor othertruck cab prior todriving truckmounted cranes.Check crane cabprior to operatingprojections.Wear snug fitting clothing.Keep ladders and boots free ofmud, ice, snow, grease, and oiL.crane.B)F ailng fromladder.B)Use belt hooks, pockets, etc.,for carrying materials up to caband keep both hands free forclimbing. Ropes can be used tohoist bulkier items. Face ladderand use three points of contactwhen climbing (two hands andone foot, or two feet and onehand, in contact with ladder atall times). Take only one stepat a time. Use grab rails orhandholds and select firmfooting.C) Being thrownC)Notify operator when mountingmachine that is already inoperation. Do not get on or offa moving crane.D)Keep the cab, deck, footholdsand handholds free of mud, ice,snow, grease, and oiL.E)Check fire extinguisher.from ladder,struck bymachine.D) Tripping,slipping andstumblinghazards.E)Missing orinoperative fireextinguisher.7
OFSEQUENCEBASICJOBPROCEDURESHAZRDSSTEPS2. (Continued)RECOMMENDED SAFE JOBPOTENTIALACCIDENTS ORF)F)Struck by flyingobjects, jammedcontrols,projectingcontrol levers.G) Accident causedby poor visibility.Remove or secure any looseobjects in cab. Avoidprojections.G) Inspect and clean windows.(Clean and adjust mirrors ifapplicable.)H) MachineH)gauges before start-up to besure they aren't stuck. Makesure all controls are in theproper shutdown position.malfunction.3. Start crane3. A)and completepre-shiftexamination.Hitting orrunning overpersons or3. A)Check machine for warningtags. Check controls to be surethey are properly positioned.Warn any members of nearbywork crews that you are startingobjects in area,striking interiorof cab if cranemoves suddenly.B)Check all instruments andEngine orauxiliaryyour machine by sounding startup signaL. Check backup alarm(if applicable) after start-up.B)equipmentmalfunction.Let engine run until it reachesnormal operating temperature.Check all gauges, indicators,and warning lights again fornormal readings.C) Loss of control,improperoperation.D)C) Test all controls to be sure theyare properly adjusted accordingto manufacturer'srecommendations.Electrocution.D)Be cautious of overhead powerlines at all times. Pay particularattention to clearance.8
OFBASIC JOBSTEPSSEQUENCE3. (Continued)RECOMMENDED SAFE JOBPOTENTIALACCIDENTS ORPROCEDURESHAZRDSE) Thrown againstcab interior orthrown out of theE) When driving truck mountedcranes, wear seat belts (ifprovided).machine.4. General4. A)operation.Overloading,4. A)tipping thecrane.Know the rated capacity of yourcrane for various boom angles,and be sure to check boomangle indicator. When figuringthe weight of the load be sure toinclude the weight of the hook,block, or any material handlingdevice such as a concreteblock, magnet, etc. Safe ratingsare based on operating themachine on firm, level ground.B)Overloading.B)C) Tipping theC) Check stability before liftingloads. Ensure the outriggersare firmly positioned on solidsurfaces, crane is level, brakesare set, and load is properlyrigged. Lift load slightly off theground and confirm stabilitybefore hoisting further.crane.D)Tipping theD)crane,overloading.E)Determine (if possible) theweight of the load, or estimateit, before lifting.Dropping load,E)Do not operate crane too fast.Avoid fast swings, hoists orsudden breaking.Lift only the proper types oftipping thematerials. Do not handle largecrane.heavy loads in strong winds, asthe wind could create anunstable condition.9
SEQUENCEOFJOBSTEPSBASIC4. (Continued)RECOMMENDED SAFE JOBPOTENTIALACCIDENTS ORPROCEDURESHAZRDSF) Do not allow anyone to ride theF) Fall to ground.Crushed againstload or load hook.a stationaryobject.G) Striking nearbyG) Make a "dry run" in tight areasto help determine the safest wayto operate under existingconditions.personnel orequipment.H) Keep boom away from overheadH) Electrocution,electric shock,lines. NEVER ALLOW ANYPORTION OF THE MACHINEOR LOAD TO PASS WITHIN 10FEET OF AN ENERGIZEDHIGH VOLTAGE POWER LINE.Consider every overhead lineenergized until the powercompany states otherwise. Ifyou do hit a power line,fires.remember:1) Stay inside cab, if possible,until line is cleared or poweris shut off.2) Warn all persons in thearea to keep clear of thecrane and the suspendedload.3) If you must leave the cab,such as in the event of afire, be sure to jump clear ofthe machine. Do notcontact any part of themachine or the load.10
BASIC JOBPOTENTIALACCIDENTS ORSTEPSHAZRDSSEQUENCEOF5. Lifting,5. A)RECOMMENDED SAFE JOBPROCEDURESCatching groundtransporting,personnel inand loweringmateriaL.pinch points,dropping load,striking5. A)between ground personnel(hookman) and crane operator.Crane operator shouldcommunicate with only onesignal person; however, craneoperator should observe anystop or emergency signaL.personnel orobstructions.B)Caught in pinchpoint, struck bydropped orBe certain that proper signalprocedures are establishedB)swinging load.Ground personnel must ensureproper rigging, stay out of pinchpoints, and stay clear of hoistedloads. Tag lines permit steadying or guiding a load from a safedistance.C) Dropping load,setting load onpersons orobstructions.D)Boom failure orC) Ensure the area beneath theload is clear of all obstructionsand personneL. Make sure theload is well secured and thatlines are not kinked.D)damage.E) Overloading,overturning,losing control ofMake sure the hoist line isverticaL. Do not make side loadings.E) Avoid sudden starts and stops.Keep speeds low when liftingand lowering loads.load, machinedamage.F) Additional strainon rigging,rigging comingoff hook,hazards inhooking andunhookingloads.11F)Do not hoist two or moreseparately rigged loads in onelift, even though the combinedload is within the crane'scapacity.
BASIC JOBPOTENTIALACCIDENTS ORSTEPSHAZRDSSEQUENCEOF5. (Continued)RECOMMENDED SAFE JOBPROCEDURESG) Overheatinghoist brake,losing control ofload.G) When lowering load always use"power-controlled lowering", ifpossible. When lowering heavyloads, keep hoist brake as areserve.H)I)Boom or jibdamage orfailure.H) Avoid boom or jib "whipping".Wire rope ori)Do not let load strike boom oroutriggers. Avoid hitting nearbystructures with boom.J)Overturning fromAllow maximum clearancebetween hook and headsheaves.load attachmentfailure.J)Use the shortest boom possible.Keep near-capacity loads as .close to the ground as possible.K)Test stability before fully liftingunbalancedload, loss ofbrakes.K)Overturning fromload by:excessive loadfor boom angle,loss of brakes.1 )2)lifing load slightly off thegroundchecking the machine formovement, and checking tobe sure the brakes hold withthe load elevated.L)Overturning fromL)Be aware of centrifugal forceunbalancedwhen swinging. Swing craneload.slowly to avoid outward swingsof load. If necessary, attachline to the load to control theswing.tag12
OFBASIC JOBSEQUENCESTEPS5. (Continued)POTENTIALACCIDENTS ORRECOMMENDED SAFE JOBPROCEDURESHAZRDSM) Damaging orover-stressingboom, boomfailure.M) Watch for boom "kickback".Never operate with boom at ahigher angle than shown on thecapacity plate. Know whatcontrols give you emergencystopping.N) StrikingN) Always controlequipment orpeople withboom.load. To preventexcess motion dunng travel, usetaglines to guide or snub theload. Never carry suspendedloads over personnel.0) Hoist line failure,boom failure ordamage.0) Watch for "two-blocking". "Twoblocking" happens when hookblock colldes with boom pointsheaves. Continuing pull onhoist lines can break the cables,or pull boom over cab on sometypes of machines. Withhydraulically telescopingbooms, be sure to payout hoistline when extending and reel inhoist line when retracting. Ifyour crane has a two-blockingwarning device check itoccasionally by a safe means.P) Tipping of crane.P) Always use outriggers to makeany lifts, except light loads withpick-and-carry units. Loweroutrigger jacks to completelyremove all machine weight fromtires and level unit to safelyreach the full capacity of themachine. Recheck and, ifnecessary, reset outriggersbetween heavy lifts.13
OFBASIC JOBSEQUENCEPROCEDURESHAZRDSSTEPS5. (Continued)RECOMMENDED SAFE JOBPOTENTIALACCIDENTS ORQ) Striking truckcab with boom.Q) Watch out for the truck cab ontruck-mounted units. Keepboom high enough, whenswinging the boom, to be sure itclears the truck cab.R) Carrier shiftingor rollng.R) Lock carrier air brakes "on"when operating crane andcheck air pressure frequently.6. Loading and6. A)Personal injury6. A)from improperprocedure.moving crane.Always use ramp when loadingmachine on trailer. If ramp isnot available, use blocking tobuild one.B)Wrecking orB)strikingobstructionswhile transporting,Lock turntable before travelingon highway. Use house lock orswing brake, and lower boominto rack to prevent swing.machinedamage.C)Striking objects,C) Carefully observe the areawhen traveling your machine.tipping of crane.D)Collsion onhighway, bridgecollapse underweight of crane.D)Obey all traffc rules whentraveling on highway. Useproper warning flags and signs.Check bridges before crossingto make sure they wil supportthe weight of the machine.E)Machine stalledor damaged inriver, drowning.E) Check river depths by loweringline and hook to gauge depth.Swing side-to-side and checkdepth before proceeding.14
GENERAL INFORMATIONThis module is part of an Instruction Guide that was developed to assist the surface metal andnonmetal mining industry in conducting effective on-the-jcfc, training (OJT) of new employees,or employees reassigned to diferent jobs. The use of training materials, such as this module,is an important part of an effective, systematic, OJT program.This Instruction Guide uses a generic Job Safety Analysis (JSA) of jobs common to the industry.The JSA format facilitates uniform basic training in safe job procedures, while requiring only aminimum of time and effort on the part of the trainer. This material is generic to the industry;therefore, each company using this guide wil need to tailor the material somewhat to fit theirparticular requirements. In some cases, the material must be general in nature, and wil notinclude specific details of procedures or equipment that must be taught by the trainer.Recommendations for an overall OJT program are contained in the Mine Safety and HealthAdministration (MSHA) guide: "Structuring Effective On.The-Job Training Programs," June,1983.TRAINING RECOMMENDATIONSOn-the-job training is usually best done by the employee's immediate supervisor. If thesupervisor relies on another employee to do certain parts of the training, the supervisor shouldbe present to monitor the training. OJT is conducted at the actual job site where the work wilbe done.The supervisorltrainer should use the training materials (this module, or other materials) whilethe training is being done, to help ensure that all job steps are covered, and that no importantsafety precautions are omitted. Effective OJTshould begin with an explanation (lecture and/ordiscussion) of the safe job procedure. The explanation should be followed by a hands-ondemonstration of the proper job procedure. A good demonstration is, perhaps, the mostimportant part of OJT. The demonstration is followed by supervised practice. during which thesupervisor/trainer coaches (corrects and encourages) the employee, and evaluates when theemployee is ready to do the job without direct supervision.The first step - explaining the job to the employee - can be done in different ways. Thesupervisor/trainer and the employee can sit down and go through the training materialstogether. It may be advantageous to provide the employee with a copy of the training modulesthat are applicable to his/her job. The fact that most of the training is conducted at the job sitedoes not preclude the use of a classroom or a quiet offce for the first part of the training. Anygeneral theory or knowledge training, as well as the initial explanation ofthe job procedure, maybe best done in an offce/classroom setting; especially when noise levels, or other conditionsat the job site, make communication difficult. A complete series of job steps could be presentedthrough the use of slides developed at the mining operation.15
The basic job steps included in this module are: 1. Conduct walk-around check of crane. 2. Mount crane and check cab. 3. Start crane and complete pre-shift examination. 4. General operation. 5. Lift, transport, and lower materiaL. 5. Load and move crane. 7. Use of breaker balL. 8. Use of magnet. 9. Shutdown procedures. 10. Perform maintenance .
Double Girder Overhead Traveling Crane Double Beam EOT Crane P r o d u c t s & S e r v i c e s. MATERIAL HANDLING CRANES Material Lifting Crane Heavy Duty Crane Electric Overhead Travel Crane Single Beam Crane P r o d u c t s & S e r v i c e s. GANTRY CRANE Portable Gantry Crane Heavy Duty Gantry Crane Semi
o 3.3.9 Bulk-handling crane o 3.3.10 Loader crane Overhead crane: An overhead crane, also known as a bridge crane, is a type of crane where the hook-and-line mechanism runs along a horizontal beam that it self runs along two widely separated rails. Often it is in a long factory building and runs along rails along the building's two long walls .
“Mobile Crane Operator” means a person who operates a mobile crane to perform lifts, assembles and disassembles cranes and plans lifts and crane procedures. SAFETY A Comply with regulations, policies, and manufacturers’ manuals . A1
Mobile crane: a self-powered crane with a boom, which may be fitted on a mast (tower). It is capable of travelling laden or unladen, without the need for fixed runways. It relies on gravity for stability, with the chassis of the crane not having any capability to carry goods. Crawler crane: an off-road mobile crane which travels on site.
Mobile Crane Operator Tower Crane Operator Overhead Crane Operator Crane Inspector / Cer . Mobile Crane Training Programs Dates: Mar. 12-14, 2013 Nashville, TN Mar. 19-21, 2013 St. Louis, MO Apr. 23-25, 2013 Newark, NJ Apr. 30-May 2, 2013 Tulsa, OK May 22-24, 2013 Honolulu, HI
Overhead Crane Safety and Prevention Basic Crane Safety 1. No one but a regularly authorized operator is allowed to use any crane. 2. Do not carry a load over people on the floor. Sound warning devices to alert persons nearby. 3. Do not allow anyone to ride on a load carried by the crane or on the crane hook.
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be directed to various components of the thermal system. The coolant-based heat distribution is adaptable and saves signifi - cant amounts of refrigerant per vehicle. Also, a coolant-based system reduces refrigerant emissions by requiring fewer refrig - erant pipe joints. The authors present bench-level test data and simulation analysis and describe a preliminary control scheme for this system .
