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ARTICULATING CRANE REFERENCE MANUAL

1. Hoist line winch Figure 3 1 Typical operator s station control function labels Control Systems Check for the following 3 2 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 The equipment must have a horn that is either built into the equipment or is on the equipment and immediately available to the operator If a built in horn is not working properly it must be tagged out or removed If a removable horn is not working properly it must be removed OSHA 1926 1415 Manual control station Check for the following Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 The manual control station should be located where it can be operated from the ground from an elevated stand up platform or the top mounted 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
2. 29 S T General FC G ller uuu uuu aan 29 8 2 Operator responsibilities l I n nn a 31 8 3 Controlling load SWING 31 8 4 Attaching or engaging the load esie eremi eye tias tu E 31 8 5 Handling THE load l I L L caaesasatanqiaiaiandiateiendianetaadiasetabauaneaes 31 8 6 Safety and performance systems nnne nnn nnns 32 8 7 Load movement rated eoe ba ran nro 32 8 8 Load placement I I e Drac bin ve rre n 32 8 9 Leaving the crane unattended when leaving the work zone 33 eT 33 8 11 Ending Operation ULLA 33 8 12 In transit unloaded or loaded 33 8 13 Tag lines or guide ropes I I I ccn ccn ccn 33 8 14 Maintenance and service U I n n nn nn 34 Chapter 9 Crane Inspection 1 u 35 9 1 General precautions J n n 00 35 9 2 Monthly inspections eeeeeeeeeee eene enne 35 9 3 Annual tarea aad rego abr atado 35 9 4 Cranes not In regular seu uuu u t GAIN REV AV UT 35 9 5 Articulating crane inspection checklist sess 35 Chapter
3. 55 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 CHAPTER 1 Types This chapter defines and illustrates various terms used to describe an articulating crane s components and func tions These terms often differ greatly from other types of cranes so specific knowledge of these terms is invaluable when discussing various parts of the crane with manufac turers parts and service personnel See also OSHA 1926 1401 Terminology and OSHA Small Entity Compliance Guide for Final Rule for Cranes and Derricks in Construction for additional terms that are applicable to articulating cranes 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 anti two 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 knuckleboom 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 mecha nism see Figure 1 3 page 6 articulating boom loader ABL A non folding articulat ing crane with a
4. Before engaging the power take off PTO ensure that all controls are in the off or neutral position and that all personnel are in the clear Engage the PTO and set the truck RPM per the manufacturer s recommendations Establish a minimum 10 ft safe distance around the work zone Figure 8 1 The work zone should be 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 Figure 8 2 BY STANDERS 10 0 3 05m MINIMUM Figure 8 1 Establish a work zone with at least a 10 ft safety perimeter e Ensure there are no unauthorized persons inside the work zone before you begin working Crane Operation This chapter presents criteria rules and standards for safe crane operation LAL N SM 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 operator s 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 operator s position or another person Figure 8 3 Figure 8 3 Never pass load over operator or any other person When the c
5. Fassi e Iowa Mold Tooling e Manitowoc e Palfinger North America e PM North America For further information about the NCCCO Articulating Crane Operator Written Examination please consult the NCCCO website at or email info nccco org to request an Articulating Crane Operator Candidate Handbook Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 55 This page intentionally left blank Crane A ARTICULATING BOOM CRANE FT 180 OVER THE FRONT le 180 OVER THE BED s 204 263 326 391 4811 532 608 9500 6800 5200 4100 3300 2800 2400 151 204 283 326 391 4511 532 BUG 5500 3800 2700 2100 1600 1300 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 57 Crane B ARTICULATING BOOM CRANE GS See 20 4 2611 8900 100 LBS 20 4 76 11 7 f 49 3 858 ft 3600 2600 2000 1600 1300 1000 58 Copyright 2009 2014 National Commission for the Certification of Crane Operators Alll rights reserved ACO RM REV 06 14 Crane C ARTICULATING BOOM LOADER gb IL sola L NENNEN kk ee mom E EE Li ERA LLL I TI o E mum i em VI NS N N 331
6. Figure 1 3 Articulating boom crane with winch ABW Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 CHAPTER 2 Nothing is more important than operating the crane in a safe manner This chapter presents general rules warn ings and standards regarding safety including warning decals that were developed by the Articulating Crane Council of North America ACCNA to provide standard ized graphic illustrations of various safety concerns Additional safety information is also provided in other chapters throughout this reference manual 2 1 General safety precautions e Never tamper with the safety devices e A fire extinguisher of type and rating specified by DOT or jurisdiction must be maintained on the crane or vehicle at all times Crane operators shall be trained in the correct use of fire extinguishers Do not refuel the vehicle while the engine is running e Smoking or open flames are prohibited while refueling Do not use this equipment to transport people unless approved by the manufacturer e Do not wear jewelry or loose fitting garments that might become caught in moving parts e Use personal protective equipment when necessary or required e Respect all lockouts tag outs or red tags Electrocution Hazard Crane is not insulated NEVER approach or contact power lines with any part of this equipment or load
7. 4174 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 Crane D ARTICULATING BOOM CRANE _ o o I NLI tao eA iL LR EES _ im _ _ T vil LLL LI OO oi og I EM di Jua 0 CENTERLINE SURFACE 1 E d E a i Loch ARTICULATING BOOM CRANE Crane E lt D Crane F ARTICULATING BOOM LOADER N i OM Le Ll T 000 Ibs ground MAX 4 100 lbs 6 000 Ibs Tt O ft 1231 20 ft oU Tt 40 ft 20 Tt 60 ft 70 TL 10 ft 62 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 Crane G ARTICULATING BOOM LOADER 4000 io lx g 5000 Ib LLL LLLI 30 fetta 0 vowwe 0 10 20 30 40 50 60 70 CENTERLINE This page intentionally left blank IMPORTANT CONTACT INFORMATION Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 NATIONAL COMMISSION FOR THE CERTIFICATION OF CRANE OPERATORS 2750 Prosperity Avenue Su
8. Keep 50 feet away from any power line if voltage is not known Keep 20 feet away from any power line 350 kilovolts or less Account for swaying motion of power lines equipment and load line Follow OSHA 29CFR 1926 1400 Death or serious injury will result from approaching or contacting a power line Figure 2 1 Electrocution Alert to Crane Operator decal A01 Safety Precautions and Warnings When operating in an enclosed area e g inside a building ensure proper ventilation A high voltage minimum clearance sign must be visible to the operator while at the operator s station Figure 2 1 this decal indicates the minimum 10 ft clearance for lines under 50 kV as well as the minimum for higher voltages as specified in OSHA 1926 1407 through 1926 1411 Electrocution hazard warning labels must be visible from all four sides of the carrier vehicle e Decals must be legible they must be replaced if they become illegible due to repainting fading or scratches e Operators must be familiar with the location and purpose of required decals as detailed below in section 2 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 sho
9. All rights reserved ACO RM REV 06 14 CHAPTER 12 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 hard ware shackles eye bolts etc and slings wire rope chain synthetics a d Figure 12 1 Typical rigging components 12 1 General precautions When employees are engaged in hooking unhooking or guiding the load or in the initial connection of a load to a component or structure and are within the fall zone all of the following criteria must be met e The materials must be rigged by a qualified rigger e Never exceed the Working Load Limit WLL for each piece of rigging WLLs are rated for a straight vertical lift e Visually inspect rigging before each use Removed from service any items meeting rejection criteria e Avoid shock loading e Slings shall be hitched so as to provide the best load control Do not allow any body parts to get in between the sling and the load e Personnel shall not ride the sling e When multiple slings are used they should be attached to the bow of the shackle and the hook to the shackle pin Do not pull sling s from under a load when the load is resting on the sling s e Synthetic slings can be used in temperatures up to 200 F e Slings that come in cont
10. including without limitation warranties of merchantability fitness for a particular purpose and non infringement NCCCO specifically does not make any warranties or representa tions 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 user s 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 2009 2014 by the 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 ii Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 Preface x crane operators are unique a
11. All rights reserved ACO RM REV 06 14 Figure 5 2 Never pass load over operator or any other person Test the fork control functions prior to use improper rotation or accidental opening of fork tines may cause loss of the load To maintain stability keep the load as close to the ground and as short a radius as practical Do not allow the load or attachments to swing or contact any part of the crane During transport the fork assembly must be stowed and secured on the vehicle in such a manner that it cannot swing out Overloading the fork assembly could cause the fork assembly to open uncontrollably Starting and stopping rotating the crane and fork assembly and opening and closing of the forks shall be done under controlled speed to prevent loss of control or load Use the proper fork assembly to match the application to provide proper load support When handling drywall close the fork as soon as the load clears the truck bed or ground surface The transport of persons is prohibited using a fork assembly attachment under any conditions no riders on forks or load 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 sh
12. RM REV 06 14 1 2 Types of articulating cranes 1 2 1 Articulating boom crane ABC and components 2 NN LAW Ww 5 N AWA gt X NN 5559 1 Base 9 Manual control station Figure 1 1 Articulating boom crane ABC 2 Three point bridge 10 Guter booi and components 3 Stabilizer beam 11 Outer boom cylinder 4 Slewing cylinder 12 Extensions 5 Column 13 Extension cylinders 6 Inner main boom 14 Link s 7 Inner main boom cylinder 15 Load hook 8 Stabilizer leg 16 Hydraulic oil cooler 4 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 1 2 2 Articulating boom loader ABL and components Figure 1 2 Articulating boom loader ABL and components OO Ot Q Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 Base Ladder Stabilizer beam Platform Column Inner main boom Inner main boom cylinder Stabilizer leg Operator s station top seat 10 12 13 14 15 16 17 18 Outer boom Outer boom cylinder Extension booms Fork tine Rotator Fork assembly Hydraulic oil cooler Fork cylinder Fork tine lock 1 2 3 Articulating boom crane with winch ABW Winch Sheave Wire rope hoist line Hook block Hook UN
13. 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 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 iii CREDITS NCCCO deeply appreciates the work and contributions of the following individuals and organizations all of whom have assisted in developing this reference manual Articulating Crane Task Force Members Tim Arkilander Cargotec USA Inc HIAB Task Force Chairman Eric Andrews Gypsum Management amp Supply Udo Beyersdorff North American Lifting Equipment Effer USA Bo Collier Crane Tech James Darr Iowa Mold Tooling Co Tony Dotto Crane Tech Bernie Faloney Fascan International John Field Iowa Mold Tooling Co Robert Fischer Fischer Crane Co Stefano Ghesini PM North America LLC Ted Gill L amp W Supply Corp Ed Hatcher Cargotec USA Inc HIAB Pinchas Leitner Lifting Solutions Thomas Lyon Trench Plate Rental Co Harry Newmann V amp H Trucks Inc Ron Overton Overton Safety Training Peter Sharkey Bradco Supply Co Kenneth Shinn KJ Shinn Sid Shreiner Manitowoc Crane Group Dave Taff Ruco Equipment Co Walter Timm Palfinger North America This subgroup of Articulating Crane Task Force members deserves special recognition for providing the foundation for this reference manual NCCCO also apprec
14. grounding point 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 dur ing lifting three point bridge The structural component of the crane s base that pivots reducing stress on the mounting to the chassis touch potential The voltage between the energized object and the feet of a person in contact with the object e g a crane that contacted an energized line would expose any person in contact with the crane or its uninsulated load line to a touch potential nearly equal to the full fault voltage transit Ihe moving or transporting of a crane from one job site to another two block damage 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 Ihe 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 lower ing 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 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO
15. hazard occur and how to avoid the hazard Used on Articulating cranes Placement Visible to person s standing near each stabilizer Quantity 1 per stabilizer Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 Crush Hazard Before operating crane Look around vehicle Clear area of all people Stand on side opposite boom Moving boom may injure or kill A06 2011 Do not paint over this label Replace if damaged or lost Figure 2 6 Crane Strike decal A06 DANGER Rotating Shaft Hazard Keep body hands hair clothes away Do not work around shafts with engine on Rotating parts will injure or kill A07 2011 Do not paint over this label Replace if damaged or lost Figure 2 7 Rotating Shaft Hazard decal A07 Falling Load Hazard Always stop operation before block contacts sheave Two Blocking Do not rely on limit switch to stop block If block contacts sheave lower load by letting out cable and inspect for damage Falling loads may injure or kill Fall Hazard Never use crane to hoist personnel Never ride on boom hook load or any other device attached to crane boom or load line Riding on boom hook or loadline may injure or kill A09 2011 Do not paint over this label Replace if damaged or lost Figure 2 9 Riding on Crane decal A09 Copyright 2009 2014 National Commission for the Certification of Cran
16. 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 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 19 6 3 Reading load charts rating charts are specific to every make and model of crane Some cranes are equipped with multiple load charts for various operating conditions If your chart does not match the specific crane you are using and or the current conditions notify your supervisor immediately and DO NOT USE THE CRANE e Onsome load charts the angle of the inner boom is also stated to indicate what position the boom must be at for the capacities to be valid e Interpolation is a technique of estimating what the crane s gross Capacity is between two stated values on the load chart Never interpolate when reading and interpreting load charts always use the next lower capacity 6 4 Charts reflecting stabilizer deployment e Charts may reflect Stabilizers Fully Extended best position for maximum stability and rating or Stabilizers Mid Span position reflects reduced stability and reduced ratings e Rated capacities indicate the radius and rated lifting capacity for the crane in the position shown STABILIZERS FULLY EXTENDED iliiin Figures 6 3a amp 6 3b Sample
17. of Crane Operators All rights reserved ACO RM REV 06 14 39 11 3 Latches 11 4 Load hook inspection e Usea hook equipped with a latch at all times except e Inspections and record keeping requirements for when a latch proves impractical or poses a danger in hooks are determined by the kind of equipment a particular application the hooks are used on When the inspection requirements for hooks are specified in regulations applicable to your equipment those regulations will take precedence over the information presented Hook latches for loose sling retention are not here 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 The latch is used to retain such items as slings and chains under slack conditions e Prior to initial use inspect all new and repaired hooks to ensure compliance with the items listed in the hook inspection checklist below Figure 11 4 Hook latches should never be crowded by oversized rope or stiff riggings e Make certain the load is properly seated on the bowl saddle before a lift is attempted HOOK INSPECTION CHECKLIST Remove hook from service if you see the following Check for conditions DISTORTION Bending or twisting Any visible bend or twist from the plane of the unbent hook DISTORTION Increased throat openi
18. the manufacturer s load chart specification there may be multiple load charts based on different stabilizer spans CAUTION Shorter Distance Reduces Stability EN mz 174 a i ii A B Figure 7 9 Setting up stabilizers on uneven ground e 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 9 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 25 Figure 7 10 Keep limbs away when deploying or retracting stabilizers e Stabilizers are not to be used for purposes other than stabilizing the crane e g do not use stabilizers as a parking brake 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 11 Figure 7 11 Stay away from stabilizer beams when they are moving e To avoid instability all steering and drive tires must remain firmly on the ground when setting up stabilizers Figure 7 12 Figure 7 12 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 13 Max
19. to the load When using a basket hitch balance the load to prevent slippage e Cracked distorted or broken fittings 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 42 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 CHAPTER 13 Winch 13 1 General information e Every wire rope has three basic components Figure 13 1 The wires form the strands and collectively provide rope strength The strands which are CORE wound around the core STRAND The core that forms a foundation for the strands the core of WIRE IWRC independentwire Figure 13 1 Components rope core wire rope is a smaller independent wire rope of wire 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 ov
20. 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 crane s 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 crane s rotation to the center of gravity of the load load radius ABL The horizontal distance from the center of the crane s 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 crane s 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 includ ing the weight of rigging or attachments operator s station manual controls The position where the manual controls are located for operating the crane operator s station top seat The elevated seat attached
21. 10 Crane Communication and Signals 37 10 1 General requirements I I nnne nnne nnn nnn nnn nnn nnn nnn nnn nnn nnns 37 10 7 Standard voice signals 37 Chapter 11 Load 39 11 1 General pecu LULU lli a a 39 45 39 TAL cmm 40 11 4 Load hook inspection 1 rennen nnn nnn nnne nnn nnn nnn nnn nnns 40 Chapter 12 Rigging U SEU UR REX 41 12 1 General precautions I nnne L nnne nnn nnn nnn 41 12 2 Sling WIS erret fitr ttftt ttt or 41 PERE NEN T TT TT 42 Chapter 13 Winch u 43 13 1 General information n nrnna 43 43 13 3 Safety precautions for wire ropes I nennen nnne nnn nnn nnne nnns 44 13 4 Calculating working load limit permissible line pull esses 44 19 5 Thimble attachinenti 45 13 6 Wedge socket 45 Appendix A ACCNA Crane Inspection Checklist 49 Appendix B Standard Hand Signals 54 Appendix C NCCCO Load Charts a u u
22. 3 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 3 3 Cable and radio remote controls Check for the following e Ensure the cable on a cable remote does not become entangled or a tripping hazard e To prevent damage to the remote control only put it down in a safe dry location e To prevent unauthorized operation switch the remote OFF and remove the key when not in use e Ifany of the controls are not working properly do not use the remote use manual controls instead e Use extreme caution while walking with an active remote e Ensure your path is clear of any slipping or tripping hazards before walking e Never walk backwards when using a remote control QQ 4 i tion Figure 3 4 Cable remote control e Operator must maintain three points of contact with the crane when accessing and exiting the control station Figures 3 5a and 3 5b e Use caution when entering and exiting the control station to avoid unintentional movement of controls e Only one person may occupy the operator s station area except during training 14 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 CHAPTER 4 Ancillary Attachments Figure 4 1 Typical articulating crane attachments This chapter presents some of the various attachments that can be used
23. 5 Figure 7 13 Avoid underground hazards when setting up stabilizers Do not operate stabilizer controls while the boom is elevated e Articulating cranes shall be leveled to the manufactures specifications prior to unstowing the boom e Stabilizer legs should not be set on uneven or slippery surfaces Figure 7 14 A amp B Figure 7 14 Incorrect and correct use of stabilizer support pads plates e Most stabilizers require additional support pads and or plates refer to the manufacturer s operator s manual Figure 7 14 C amp D 7 Leveling e Means must be provided to determine levelness such as a spirit level or bull s eye level Figure 7 15 Figure 7 15 Sample bull s eye level e Cranes and boom trucks must be level to within the manufacturer s specifications prior to deploying the boom e Ifa built in crane level indicator is not working properly it must be tagged out or removed If a removable crane level indicator is not working properly it must be removed 26 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 7 8 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 16 Figure 7 16 Sample cribbing Cribbing shallbe of sufficient size and stre
24. Chapter 5 Articulating Boom Loader and Fork Assembly 17 5 1 General DrecaltloriS uuu uu u u u uuu dtd edid n det 17 5 2 SENET PRECAUTIONS uu 17 Chapter 6 Load Charts TO 19 6 1 General precautions U QR cae env n waste niin 19 6 2 Types 19 Reading load 20 6 4 Charts reflecting stabilizer 2 J U I S snn 20 6 5 Work area charts lifting quadrants J J I n nn 20 6 6 Charts reflecting manual boom extensions J I U nnne 20 6 7 Capacity rigging and attachments prt bidon rr orario ror 21 Vs Net Capaci an uu yu y ua na 21 Chapter 7 Preparation for Crane Setup 23 FECIT Ne Iw MI EET T OO TS 23 Peace ee u uu ee 23 23 TA easi 24 7 5 Operator s control area s 1 n nana 25 7 6 Stabilizers n nn nn nrnna 25 Uca 26 9 CONDOM IG 26 79 Wind eode hd eene eus 27 ne OE UEM 28 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 vi Chapter 8 Crane Operation U u u
25. Load charts for stabilizers fully extended top vs mid span bottom 12790 100 LBS STABILIZERS MID SPAN 418 493 569 ft 6 5 Work area charts lifting quadrants e Rating charts may also identify work areas or lifting quadrants for rated capacities Articulating boom cranes may use a back 180 over the rear a front 180 over the cab and or a 360 chart Figure 6 4 Figure 6 4 180 over the bed vs 180 over the front work areas 180 OVER THE BED 151 204 283 13660 9470 15830 aaas 391 4911 532 608 ft 3300 2770 Figures 6 5a amp 6 5b Sample work area load charts top chart for lifting over the truck bed bottom chart for lifting over the truck front 180 OVER THE FRONT 326 391 4811 532 608 ft 1571 204 5470 3790 2740 2000 1600 1320 19980 hs 6 6 Charts reflecting manual boom extensions e Articulating cranes may be equipped with manual boom extensions that are optional and or removable When using manual boom extension s do not exceed the rating of the manual extension s regardless of the working radius or amount of boom extension same rating for all radii e When the crane is equipped with manual boom extension s that are not being used deduct the weight of the extension s from the crane s gross capacity to calculate net capacity Do not deduct this weight when
26. M REV 06 14 47 This page intentionally left blank Appendix A ACCNA Crane Inspection Checklist REV JUNE 2012 USE OF THIS CHECKLIST IS SUBJECT TO TERMS CONDITIONS NOTICES AND DISCLAIMERS OF WARRANTY ATTACHED HERETO ADDITIONAL COPIES Inspection Checklist ARTICULATING BOOM CRANES MAY BE OBTAINED BY CALLING 1 800 441 NTEA OR AT WWW NTEA COM OWNER COMPANY TYPE OF INSPECTION check one DAILY if deficiency found QUARTERLY TYPE OF INSPECTION NOTES Daily and monthly inspections are to be performed by a competent person who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary hazardous or dangerous to employees and who has authorization to take prompt corrective measures to eliminate them Quarterly and annual inspections are to be performed by a qualified person who by possession of a recognized degree certificate or professional standing or who by extensive knowledge training and experience successfully demonstrated the ability to solve resolve problems relating to the subject matter the work or the project 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
27. NATIONAL COMMISSION FOR THE CERTIFICATION OF CRANE OPERATORS NCCCO ARTICULATING CRANE REFERENCE MANUAL ACO RM REV 06 14 HOLD HARMLESS RELEASE AGREEMENT The user of this publication for and in consideration of the assistance cooperation and information provided by the National Commission for the Certification of Crane Operators NCCCO in this publication Articulating Crane Reference Manual the receipt of which is acknowledged does hereby and for all future time release and hold harm less from any liability and forever discharge for itself its administrators and assigns the said NCCCO from all and any manner of action or demands whatsoever in law in admiralty or in equity which against NCCCO anyone ever had now have or which shall later be claimed This Agree ment relates specifically to any cause of action arising out of the publication information provided subsequent conduct and any use of the information provided in this publication and related uses or demonstrations of skills methods and techniques cited in the publication This mutually beneficial release and hold harmless agreement may not be changed orally and exists in perpetuity This publication is issued solely as a public service to improve the lifting industry and promote public safety 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
28. Operators All rights reserved ACO RM REV 06 14 General precautions Articulating cranes shall be inspected by a competent person at the start of each shift following the manufacturer s inspection recommendations ASME B30 22 and or OSHA 1926 1412 The crane and attachments should be observed while in use for signs of defects or operating problems Review operator s manual for additional items to check Never use your hand to check for fluid leaks use a piece of cardboard If high pressure fluid comes in contact with your skin consult a doctor immediately Do not allow unauthorized personnel to approach the hoses or cables while the machine is in use Monthly inspections Monthly inspections are to be carried out in accordance with the manufacturer s recommendations ASME B30 22 and or OSHA 1926 1412 Records of monthly inspections are required and are to be maintained for 90 days Conditions examined during the frequent inspection shall be determined if they are a hazard or not Hazardous deficiencies shall be corrected before the crane use continues Annual inspections Annual inspections are to be carried out in accordance with the manufacturer s recommendations ASME B30 22 and or OSHA 1926 1412 Records of annual inspections shall be maintained for 12 months Noted deficiencies shall be repaired and or defective parts replaced before use continues Crane Inspection 9 4 9 5 A cran
29. Y INSPECTION DESCRIPTION All daily inspection items 99 Monthly All monthly inspection items All quarterly inspection items Hydraulic fluid change per maintenance schedule 1102 Controls Control valve calibration for correct pressures amp relief valve settings Safety valve calibration for correct pressures amp relief valve settings Valves for failure to maintain correct settings Sys Rotation drive system for proper backlash clearance amp abnormal wear deformation amp cracks FA 106 Lubrication Gear oil change in rotation drive system per maintenance schedule Sd A 30r Hardware Check tghinessofallfsteners SSS A 108 Wear Pads Wearpadsforewesswewea SSS LA W9 lode Loadine fr proper gt gt gt gt gt Deficiency Recommendation Corrective Action Report GUIDELINES A deficiency X may constitute a hazard X must be corrected and or faulty parts replaced before resuming operation Recommendations R should be considered for corrective actions Corrective action for a particular recommendation depends on the facts in each situation Corrective actions CA repairs adjustments parts replacement etc are to be performed by a qualified person in accordance with all manufacturer s recommendations specifications and requirements NOTE e 2 5 corrective ac
30. a dedicated channel articulating crane hand signals depicted in Appendix 10 2 Standard voice signals B page 53 Each voice signal must contain the following three ele Hand signal charts must be either posted on the ments given in the following order equipment or conspicuously posted in the vicinity of the hoisting operations e Operators shall take hand signals from only one person at a time other than emergency stop or halt signals e Emergency stop or halt signals shall be taken from any individual at any time Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 Function and direction Distance and or speed Function stop 37 38 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 CHAPTER 11 Load Hooks 11 1 General precautions e 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 hook s ability to handle these loads e Hook materials are designed to permanently deform before a failure occurs e Load hooks or hook block assemblies shall be labeled with rated capacity and weight e Load hooks shall be included in the daily shift inspec
31. act with abrasive surfaces and edges shall be protected with material of sufficient strength and thickness 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 122 Figure 12 2 Center of gravity or balance point e Determine load s 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 12 2 Sling inspections 12 2 1 Wire rope slings causes for removal Remove wire rope slings from service if any of the follow ing conditions are found e Broken wires 5 broken wires in one strand or 10 broken wires among all strands in one rope lay Metal loss one third 1 4 of wire s original diameter e Distortion wire is crushed or kinked e Heat damage wire shows weld marks or is burned Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 41 e Bad deformed or broken end attachments 12 3 Basic hitches Bent hooks see Chapter 11 Load Hooks The type of hitch affects the load capacity rating Following are some basic types of hitches e Identification tag ID missing or illegible Vertical or straight at
32. ad handling deductions including weight of forks rotators hook s and rigging Be aware that any of the following items can create a limiting factor beyond the crane s calculated net capacity Wire rope limit Hoisting hook Lifting attachments Rigging Winch capacity 27 BEAUFORT WIND SCALE Force WMO Appearance of Wind Effects 3 Sea surface smooth amp mirror like Calm smoke rises vertically Light Air Scaly ripples no foam crests Smoke ud indicates wind BEN Light Breeze Small wavelets crests glassy not breaking Wind felt on D leaves rustle i lil 7 10 Gentle Breeze Large wavelets crests begin to break Leaves and small twigs constantly scattered whitecaps moving light flags extended 11 16 Moderate Breeze Small waves 1 4 ft becoming longer Dust leaves and loose paper lifted 17 21 Fresh Breeze Moderate waves 4 8 ft taking longer form Small trees in leaf begin to sway many whitecaps some spray 22 27 Strong Breeze Larger waves 8 13 ft whitecaps common Larger tree branches moving Wiki d 28 33 Near Gale Sea heaps up waves 13 20 ft white foam Whole trees moving resistance felt streaks off breakers walking against wind 34 40 Gale Moderately high 13 20 ft waves of greater Whole trees in motion resistance length edges of crests begin to break into felt walking against wind spindrift foam blown in streaks 41 47 Strong Gale High waves 20 ft sea begi
33. al Do not drag loads sideways or from the front Figure 8 11 Figure 8 11 Never drag a load sideways Check the hydraulics each time a maximum rated load is handled by raising it a few inches and checking for boom drift unintended slow lowering Do not move the load or attachments in such a way that they can make contact with any portion of the crane Figure 8 12 Figure 8 12 Never allow the load or attachments to come in contact with the crane Load placement Do not rest loads on structures of unknown load bearing capacity No one shall stand or pass under an elevated load Figure 8 13 Overhead hazard warning Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 8 9 Leaving the crane unattended when leaving the work zone Land the load do 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 8 10 Power failure 8 11 In case of power failure set all brakes and locking devices Move all power controls to the off or neutral position If load can be controlled land the suspended load Ending operations Booms requiring a boom support may need to be reset on level ground prior to transport e g ABL booms Secure the boom system and or attachments sufficiently so as to restrict movement as recommended
34. amaged or lost Figure 2 4 Electrocution Alert to Crane Operator with Remote decal A04 Crush Hazard Before extending Stabilizers Look around vehicle Clear area of all people Extending stabilizers on people may injure or kill A05 2011 Do not paint over this label Replace if damaged or lost Figure 2 5 Stabilizer Crush decal A05 Function To inform 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 Placement Visible to people approaching the crane Quantity 4 Function To inform the operator of the lack of protection from electrocution afforded by the remote control the possible consequences of the crane becoming electrically charged and how to avoid the hazard Used on Articulating cranes Placement Visible to crane operator Quantity 1 if crane only equipped with remote control Function To inform the operator of the lack of protection from electrocution afforded by the remote control the possible consequences of the crane becoming electrically charged and how to avoid the hazard Used on Remote controls on articulating cranes Placement On the remote control unit Quantity 1 Function To inform the operator and other personnel in the work area of the hazard associated with the operation of stabilizers the possible consequences should the
35. ane Figure 8 7 TII b NL di L r Figure 8 7 Avoid quick or jerky movements at full extension e 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 e Never disconnect or tamper with the safety systems e To minimize load swing position the boom tip directly over the load s center of gravity prior to lifting When releasing manual extension boom pins position the boom as flat as possible To avoid injury do not stand directly in line with the extension travel path e Donotuse any ofthe crane s booms to push downward onto anything e Donotoperate the crane when there are any loose objects on the load or boom Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 8 2 Do not allow personnel to ride the hook boom or load Figure 8 8 Figure 8 8 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 materia
36. ards over 0 75 to 50 6 walk the planned lift route prior to traveling it to over 50 to 345 10 check for proximity and voltage of any overhead over 345 to 50 16 power lines over 750 to 1 000 20 over 1 000 as established by the utility owner operator or regis e Determine the radius requirements of the lift tered professional engineer who is a qualified person with respect to electrical power and distribution e Determine the gross and or net weight of the load Note Table T is used in conjunction with the travel Calculate the lifting solution Section 7 11 requirements in 1926 1411 7 3 Electrical hazards e When entering the job site be sure to maintain minimum transport clearance away from electrical e Under OSHA 1926 1407 1409 during assembly power lines as specified in Table T disassembly and operations the employer must determine whether the crane s movements could e Select a work zone so proper minimum clearances take it closer than 20 feet to energized power lines If can be maintained while operating the crane so the employer must takes steps to prevent contact These include de energizing and grounding the lines maintaining at least a 20 ft clearance between any part of the crane and the lines or maintaining a minimum distance as specified by Table A e Besure to take into consideration any potential sway or whipping of energized electrical lines caused by wind when determining the safe working proximit
37. as to whether the deficiency constitutes a safety hazard and must be corrected prior to operation NOT APPLICABLE FREQUENCY ITEM KEY INSPECTION DESCRIPTION Labels ible Presence amp proper operation of hook safety latches 6 Wire Rope Inspect for apparent deficiencies per applicable requirements and manufacturer s specifications 1 Labels All load charts safety amp warning labels amp control labels are present and legible D 2 D D 771 Proper engagement of all connecting pins amp pin retaining devices D issi D D Control and operator s station for dirt contamination by lubricants amp foreign materials Hyd System Hydraulic system hoses tubes amp fittings for leakage amp proper oil level 2 Control mechanisms for proper operation of all functions leaks amp cracks 8 General Overall observation of crane for damaged or missing parts cracked welds amp presence of safety covers Operation During operation observe crane for abnormal performance unusual wear loose pins wire rope damage etc If observed discontinue use amp determine cause amp severity of hazard Remote Ctrls Operate remote control devices to check for proper operation Electrical Operate all lights alarms etc to check for proper operation 12 Anti Two Operate anti Two blocking device or Two Block Damage Prevention to check for proper operation Blocking or Two Bl
38. by the manufacturer Prior to transit always fold or stow the crane boom as directed in the operator s manual Raise the stabilizer legs completely prior to retracting the stabilizer beams completely Ensure the stabilizer beam locks are engaged and working properly Disengage PTO stow chocks and secure all loads on truck bed for travel Perform final walk around visual check to ensure the crane is ready for transit Do not use the crane boom for towing Check exit path from job site to ensure there are no obstructions such as low tree limbs or other overhanging obstacles 8 12 In transit unloaded or loaded The vehicle driver must know the total height axle loads and gross vehicle weight including crane ancillary equipment and load and proceed accordingly Ensure bridge ratings are sufficient to handle the weight of the truck crane and load traveling across it Travel only with the boom fully retracted and in a traveling stowed position Figure 8 14 Figure 8 14 Always travel with the crane properly stowed Never travel with a load suspended from the crane When in transit maintain proper clearance from electrical power lines Figure 8 15 note that when stowed and in transit the distance to power lines is not the same as when operating the crane per Figure 7 2 X X NX Figure 8 15 Maintain required clearances from tunnels and power lines when in transit 8 13 Ta
39. ce manuals supplied with this equipment Crane load and work area charts Safety signs and instructions Employer work rules and applicable government and OSHA regulations Manuals can be obtained from manufacturer s website or by contacting customer service Operating this equipment without knowledge or training may lead to injury or death for you or others A10 2011 Do not paint over this label Replace if damaged or lost Figure 2 10 Untrained Operators decal A10 Safe Operating Procedures Must be Followed Keep guards safety signs and safety features in good condition Read and follow the crane load and work area charts Do not exceed crane or winch ratings Never operate with personnel under boom or load Keep three wraps of load line on winch Use crane with truck level on solid surface and with stabilizers properly deployed Operate crane controls slowly and smoothly Do NOT operate in high winds Stow boom and stabilizers before traveling Failure to follow these safe practices may injure or kill 11 2011 Do not paint over this label Replace if damaged or lost Figure 2 11 Operational Procedures decal A11 Inspection Required Follow the instructions in the operator s manual for daily frequent and annual inspections Operation of a poorly inspected crane may injure or kill A12 2011 Do not paint over this label Replace if damaged or lost Figure 2 12 Inspection decal A12 Copyrig
40. charts One dimensional load charts show the crane in a hori zontal position with various lifting capacities at their associated radii Figure 6 1 STABILIZERS FULLY EXTENDED 204 341 418 493 569 ft 3970 3350 2670 Figure 6 1 Sample one dimensional load chart 6 2 2 Two dimensional load charts Two dimensional load charts show both the vertical and the horizontal ranges of a boom s lifting capabilities This type of chart gives the operator a reference as to the crane s capabilities when the crane s hook point moves in the vertical direction as well as horizontally As shown in Figure 6 2 two dimensional load charts spec ify the boom lifting capacity for each two dimensional range on the chart 40 mM Capacity Jet curve line l T 2 lot Vertical ain reach iBit Capacities P ML 2000 1053 12 601 a Note On this load Ht chart vertical distance TOES 8 is measured from the a ground level ifi 124 169 200 24h 28ff T 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 e Capacity lines or curves show what loads can be lifted by the crane at different
41. crane must be set up away from power lines and leveled with stabilizers deployed according to the crane manufacturer s directions DAILY D Before each shift of operation those items designated with a D must be inspected 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 and retained for a minimum of 3 months 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 documented maintained and retained for a minimum of 12 months by the employer that conducts the inspection 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 documented maintained and retained for a minimum of 12 months by the employer that conducts the inspection Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 49 Appendix A ACCNA Crane Inspection Checklist Inspection Checklist ARTICULATING BOOM CRANES V SATISFACTORY R RECOMMENDATION EX X DEFICIENCY should be considered for corrective action R P an immediate determination must be made
42. e Operators All rights reserved ACO RM REV 06 14 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 Visible to people standing near the crane Quantity 1 Function To inform personnel of the hazard associated with rotating shaft the possible consequences should the hazard occur and how to avoid the hazard Used on Articulating cranes that are powered by a rotating shaft driven pump Placement One sign each side of vehicle on the frame rail and any other place where rotating shaft hazard is apparent Quantity 2 or more 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 cranes Placement Visible to crane operator Quantity 1 Function To inform the operator 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 cranes Placement Visible to crane operator Quantity 1 Only trained personnel should operate this equipment Do not operate or service until you have read and understood Operation and servi
43. e line pull Divide the manufacturer s rated breaking strength BS by an industry design factor DF to determine the working load limit WLL for one part of the hoisting line Parts of Line POL are defined as the number of lengths of hoisting line between the boom tip and the hoisting hook On articulating cranes there are usually one or two POLs Wire rope design factors DF Standard wire rope is 3 5 to one 3 5 1 Rotation resistant wire rope is 5 0 to one 5 1 BS divided by DF equals WLL per POL for example 9 16 wire rope 6x19 IPS with nominal 35 000 Ib BS 3 5 DF 10 000 Ib WLL For one POL 10 000 Ib wire rope capacity Fortwo POL 20 000 Ib wire rope capacity There must be no less than two full wraps of wire rope on the drum at all times Verify that the wire rope is seated tightly on the drum prior to operation slack in the hoisting wire rope can cause the wire rope on the drum to unspool The drum flange must extend 1 2 or more above the top layer of the wire rope Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 13 5 Thimble attachment 13 6 Wedge socket attachment When attaching a thimble to a winch wire rope Figure e Caution The efficiency rating of a wedge socket is 70 13 9 proceed as follows percent of the breaking strength of the wire rope 1 Note that the base of the clip is applied to the
44. e that has been idle not in use for more than three months shall receive a monthly inspection as designated by the manufacturer or ASME B20 22 Cranes not in regular use A crane idle for more than three months shall be given an inspection equal to the monthly inspection requirements indicated in section 9 2 before placing it in service Inactive cranes should be started up every 30 days and the hydraulics run through a complete use cycle This keeps the seals moist and may reduce the possibility of a hydraulic failure once regular use has begun again Articulating crane inspection checklist An example of an inspection checklist the Articulating Crane Council of North America ACCNA Inspection Checklist is provided in Appendix A pages 51 54 35 This page intentionally left blank CHAPTER 10 This chapter presents effective crane communication methods and standards for both the operator and the authorized person providing signals Allarticulating crane operators must able to identify the signals understand their meanings and be able to apply them in the field 10 1 General requirements e Articulating crane operators must know the standard Crane Communication and Signals Agree on any special signals in advance Blind load placement requires visual hand signals or an effective coordinated radio system Signals shall be discernible or audible at all times Signal transmission must be through
45. eficiency constitutes a safety hazard and must be corrected prior to operation NA NOT APPLICABLE FREQUENCY INSPECTION DESCRIPTION o fa ww All daily inspection items Monthly All monthly inspection items Fa Rasen bearing for proper toque of a mounting Boke E Structure All structural members for deformation cracks amp corrosion G G TTE OOOO as ner bom ji Odebom x x _ x O j the Q 58 Hardware Pins bearings shafts gears rollers amp locking devices for wear cracks corrosion amp distortion EN G imerbompiotpi s amp reame s 7 7 27 fet Oweoompiotpi s amp reemers x 7 L e Outer boom cylinder pin s amp retainer s tension cider fe Jib cylinder pin s amp retainer s 13e pnis rine Le Other 70 HydLines Hoses fittings amp tubing for proper routing leakage blistering deformation amp excessive abrasion mA resins fom pap o raene E Return line s from control valve to reservoir nets fom resent te pan Pressure inet rom conoi valve to Load holding valve pipe s and hose s 77 Pumps amp Pumps amp Motors for loose bolts
46. eir stowed position shall maintain the required clearances as specified in Table T above see OSHA 1926 1411 for full explanation 7 4 Work site inspection e Check access and egress to work zone to ensure the crane can safely enter and exit e Check for overhead clearances and obstacles e When setting up take into consideration wind weather proximity to electrically charged lines underground hazards and other safety factors e Prior to set up carefully examine ground conditions to verify the ground s ability to support the weight of the forces being applied to it e 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 3a amp 7 3b FOR SOLID OR COMPACTED SOIL USE THE ONE TO ONE RULE FOR EVERY 1 FOOT OF VERTICAL STAY BACK FROM THE BASE EDGE 1 DISTANCE B MUST BE EQUA OR GREATER THAN DISTANCE A DISTANCE DISTANCE A Figures 7 3a amp 7 3b Guidelines for setting up stabilizers near a vertical drop e Position and orient the crane truck to lift over the proper lifting quadrants e Set up truck level within allowable range specified by manufacturer Figure 7 4 ano Figure 7 4 Level truck within manufacturer s specifications e Determine maximum height and radi
47. enhancing features Some cranes are designed with a mechanical leverage linkage device link attached to the column and inner boom this device improves the crane s ability to lift tall loads near a crane s base and at high boom angles Figure 8 10 Figure 8 10 Mechanical leverage linking device link Some cranes have links only between the inner and outer booms these links provide a straight line lifting curve at longer reaches Some cranes have both inner and outer link systems and provide the benefits of both 8 6 2 Overload protection OLP systems 8 7 32 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 but all cranes manufactured after November 8 2011 must have an OLP system OSHA 1926 1416 Articulating crane operators must know how to read and understand the crane s load chart s and shall not exceed the crane manufacturer s lifting capacity ratings Load movement Do not lift in any quadrant unless rated by manufacturer All loads shall be well secured and balanced before they are lifted more than a few inches Be sure the lift and swing path are clear of obstructions Be sure that all persons are clear of the swing radius of the load Lift and move the load smoothly always keeping the load as close to the ground as practic
48. erloaded misused damaged or improperly maintained 13 2 Wire rope inspection Shift Inspection Inspect for kinking sharp bends crushing unstranding birdcaging core protrusion rope diameter loss rope strand uneveness general corrosion broken or cut strands heat damage and integrity of end attachments e Monthly Inspection Each month inspect the entire length of the rope the wire rope eye and the sheaves drums and other apparatus with which the rope makes contact 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 For rotation resistant wire ropes Two randomly distributed broken wires in six rope diameters Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 CENTER WIRE This chapter presents criteria rules and standards for using a winch with articulating cranes or four randomly distributed broken wires in 30 rope diameters For standard wire rope 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 Figure 13 2 Example of six broken wires in one rope lay When flat spots on the outer wires appear and those ou
49. fasteners leaks noise vibration loss of performance T ka amp excess pressure Winchmotors motor s a Vanes Hyeraulc valves for cracks spool return to neutral sticking spools relief wawealue eT Manos x 8 SOS Stabilizer or auxiliary 22 qia Rods for nicks scores amp dents Case for damage Case amp rod ends for damage amp abnormal wear 88 Stabilizer Stabilizer cylinder s ee Outer boom cylinder s 8I e Rotation oyindetsy E L o JE Winch Winch sheaves amp drums for damage abnormal wear abrasions amp other irregularities a Hyd Filters Hydraulic filters for replacement per maintenance schedule Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 51 Appendix A ACCNA Crane Inspection Checklist Inspection Checklist ARTICULATING BOOM CRANES V SATISFACTORY R RECOMMENDATION es X DEFICIENCY should be considered for corrective action R an an immediate determination must be made as to whether the deficiency constitutes a safety hazard and must be corrected prior to operation NA NOT APPLICABLE FREQUENCY ITEM KE
50. g lines or guide ropes Non conductive tag lines are required when working in the proximity of energized electrical lines Tag lines shall be used on all loads that swing or rotate freely Tag lines shall be held only by experienced persons Never wrap the tag line around yourself behind yourself or around your elbow for leverage Avoid carrying or guiding loads over people Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 Figure 8 16 Never pass load over operator or any other person 33 8 14 Maintenance and service e Only authorized personnel shall perform maintenance functions on the crane then only at the direction of a supervisor e Maintenance inspection and repair personnel are permitted to operate the equipment only where all of the following requirements are met The operation is limited to those functions necessary to perform maintenance inspect the equipment or verify its performance he personnel either Operate the equipment under the direct supervision of an operator who meets the requirements of 1926 1427 Operator qualification and certification or ii Are familiar with the operation limitations characteristics and hazards associated with the type of equipment e Maintenance and repair personnel must meet OSHA s definition of a qualified person with respect to the equipment and maintenance re
51. horizontally RAISE THE BOOM TIP AND LOWER THE LOAD With arm extended thumb pointing up flex fingers in and out and long as load movement is desired Appendix B Standard Hand Signals FOR ARTICULATING CRANE OPERATIONS DECREASE RADIUS OF BOOM TIP Both fists in front of body with thumbs pointing toward each other EMERGENCY STOP Both arms extended palms down move arms back and forth LOWER THE BOOM TIP AND RAISE THE LOAD With arm extended thumb pointing down flex fingers in and out and long as load movement is desired SIYBU s101e1ed JO UOILL au 101 uorssiuuo euoneN Z 0Z Appendix C NCCCO Load Charts FOR ARTICULATING CRANES AND LOADERS The following NCCCO load charts have been included in cooperation with crane manufacturers to help candidates prepare for the NCCCO Articulating Crane Operator Written Examination THE LOAD CHARTS CONTAINED HEREIN ARE NOT TO BE USED FOR ACTUAL CRANE OPERA TION 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 e Cargotec USA Inc Hiab Effer
52. ht 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 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 cranes Placement Visible to crane operator Quantity 1 Function To inform the operator of safe operating procedures for the crane and the possible consequences of operation without taking those precautions Used on Articulating cranes Placement Visible to crane operator Quantity 1 Function To inform the operator of the hazard associated with operation of poorly inspected crane the possible consequences should the hazard occur and how to avoid the hazard Used on Articulating cranes Placement Visible to crane operator Quantity 1 Overload Hazard Read understand and follow the crane load and work area charts Do not exceed winch or crane ratings Weights of accessories attached to the boom or loadline must be deducted from the load chart ratings or be added to the load weight Do not exceed manual boom extension or jib load ratings at reduced boom lengths Overloading the crane may injure or kill Falling Boom Extension Hazard Unsecured boom extensions may fall without warning Do not stand in front of extension s when removing retention pins s Do not let extensions s free fall I
53. iates 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 ACCNA AN INDUSTRY DIVISION OF THE National Truck Equipment Association Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 Table of Contents Chapter 1 Articulating Crane Terminology and Types 1 Terminology 1 1 2 Types of articulating 4 Chapter 2 Safety Precautions and Warnings 7 2 1 General safety precautions I I I U U nnne nnne nnne nnn nnn nnns nnns nnns 2 2 Articulating Crane Council of North America warning decals and locations 7 Chapter 3 Control Systems 13 3 1 General precautions I nennen n n nn nn nn 13 3 2 Manual control station J L n n nn n 13 3 3 Cable and radio remote controls sss 14 244 Seal Stallone oes uuu anasikika WE VA cV 14 Chapter 4 Ancillary Attachments 15 AT General 15
54. ift 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 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 CHAPTER 6 Load Charts This chapter presents various types of load charts and direction on how to read and interpret chart informa tion to verify the load does not exceed the crane s rated capacity 6 1 General precautions e Load charts must be posted on the crane so that they are visible when the operator is at the control station e Ifacrane is equipped with a remote control the load charts must be at a level visible to the operator from the ground Load charts must be maintained so they remain legible never operate a crane without a legible load chart e Crane operators must know how to read and understand the crane s load chart s and shall not exceed the capacity ratings 6 2 Types of load charts Articulating cranes typically come with one of two types of load charts The first and simplest is a one dimensional load chart the second less common variety is a two dimensional load chart Samples of each are presented in the following sections The details and presentation of the load charts from dif ferent crane manufacturers vary but the concepts apply similarly across all brands 6 2 1 One dimensional load
55. including but not limited to the area directly beneath the load in which it is reasonably foreseeable that partially or completely suspended materi als could fall in the event of an accident fork assembly A device attached to the last extension of either an articulating boom crane or an articulating boom loader commonly used to engage loads of consistent characteristics e g palletized loads or bundles of drywall or lumber fork tines The component of a fork assembly that actually engages the load gross capacity Ihe capacity listed on the crane s load chart hoist cable The wire rope used to lift loads via the winch and load hook hydraulic oil cooler A heat exchanging device used during crane operation to reduce the temperature of the crane s hydraulic oil hydraulic tank Ihe reservoir that holds the crane s hydraulic fluid inner main boom The boom section that connects the column to the outer boom inner main boom cylinder The hydraulic cylinder that raises and lowers the inner main boom Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 1 jib A hydraulic boom section that articulates extends and attaches to the end of the outer boom s last extension link mechanical device that changes the lifting curve of the crane load handling deductions The reduction of a crane s gross lifting capacity based on the sum of the additional
56. ing to a crane s hook The load shall be attached to the hook by means of slings or other devices of sufficient capacity The hook shall be brought into place so as to minimize swinging Handling the load Take care to avoid lowering the boom and increasing the working radius in such a manner that the boom and or stability become overloaded and unsafe Do not handle loads with the outer boom or fly jib in a negative position Figure 8 9 Figure 8 9 Never handle loads with the outer boom or Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 fly jib in a negative position Never load the crane beyond the specifications of the load chart 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 31 8 6 Safety and performance systems 8 6 1 General precautions Never disconnect or tamper with the safety systems The simplest boom system is a standard folding articulating crane with no performance
57. ite 505 Fairfax VA 22031 4312 Phone 703 560 2391 Fax 703 560 2392 E mail info nccco org INTERNATIONAL ASSESSMENT INSTITUTE Attention NCCCO Testing 600 Cleveland Street Suite 900 Clearwater Florida 33755 Phone 727 449 8525 Fax 727 461 2746 65 NATIONAL COMMISSION FOR THE CERTIFICATION OF CRANE OPERATORS 2750 Prosperity Avenue Suite 505 Fairfax VA 22031 4312 Phone 703 560 2391 Fax 703 560 2392 info nccco org nccco org
58. l 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 Operator responsibilities Only one operator shall operate the crane at a time Only one person is allowed on a top seat control station or catwalk at a time except during training Do not use the top seat control station or catwalk as an access to the roof or other elevated areas Do not engage in any distracting activities while operating the crane Figure 8 10 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 After receiving a local weather storm warning secure the crane according to the manufacturer s recommendations 8 3 8 4 8 5 Controlling load swing Start the boom rotation very slowly keep the boom tip above the load accelerate slowly To stop the load movement begin slowing well in advance of target area always keep the boom tip above the load Attaching or engaging the load Only qualified persons e g crane operators certified riggers shall attach rigg
59. l Bent broken or significantly rusted corroded parts 29 Electrical Electrical apparatus for malfunctioning signs of apparent excessive deterioration dirt or moisture accumulation Electrical systems for presence of dirt moisture amp frayed wires 21 2 23 26 7 Structure welds Pins Hardware WM foa Wer PadsCond onofwearpads OOOO OOOO O o Oo o 35 Pump amp Hydraulic pumps amp motors for leakage at fittings seals amp between sections Check tightness of Motor mounting bolts 36 Transmission PTO for leakage abnormal vibration amp noise alignment amp mounting bolt torque EN M 37 HydFluid Quality of hydraulic fluid and for presence of water ae Hoses amp tubes for leakage abrasion damage blistering cracking deterioration fitting leakage amp secured properly 39 Hook Load hook for abnormal throat distance twist wear amp cracks M 40 Wire Rope Condiion ofloadine L Li Manual Presence of operators as eee 50 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 lt lt lt Fs lt lt Appendix A ACCNA Crane Inspection Checklist Inspection Checklist ARTICULATING BOOM CRANES V SATISFACTORY R RECOMMENDATION X DEFICIENCY should be considered for corrective action R m an immediate determination must be made as to whether the d
60. l rights reserved ACO RM REV 06 14 This page intentionally left blank CHAPTER 7 Preparation for Crane Setup This chapter presents criteria rules and standards for Table A Minimum Clearance Distances reparing the crane for setup at a job site including how to p as it d i Voltage nominal kV Minimum clearance distance feet account for various site specific external hazards that may alternating current be encountered E I 15 7 1 General precautions 20 Do not use equipment for purposes other than what idis z it d si df over 500 to 750 35 over 750 to 1 000 45 Carefully plan each lift before hoisting the load Lift over 1 000 as established by the utility owner operator or regis tered professional engineer who is a qualified person planning must be done prior to each lift with respect to electrical power and distribution Determine load weight and verify that it does not Note The value that follows to is up to and includes overload the crane that value For example over 50 to 200 means up to and including 200kV e When operating in extreme temperatures always consult the manufacturer s operator s manual for Table T Minimum Clearance Distances While applicable recommendations Traveling With No Load 7 2 Lift planning Voltage nominal kV Minimum clearance distance feet e Visually inspect the work site i cue up to 0 75 4 e Identify any above and or below ground haz
61. live Crimping effect of wedge sockets can reduce the end of the rope and the U bolt is applied to the dead working load limit of a line by as much as 30 percent end e When attaching a wedge socket use one of the 2 Attach the first clip so the U bolt is no less than the approved methods shown in Figure 13 11 clip base width from the dead end of the rope 3 Attach the second clip as near the loop as possible 4 Use specifications in Figure 13 10 when fabricating a thimble LOOP BACK METHOD EXTRA PIECE OF SAME SECURING DEAD END SIZE ROPE CLIPPED TO OF WIRE ROPE Figure 13 8 Thimble attachment to winch wire rope MAIN ROPE TO WEDGE Figure 13 10 Approved methods for attaching a wedge socket WIRE ROPE THIMBLE SPECIFICATIONS AMOUNT OF ROPE TO SPACE BETWEEN WIRE ROPE DIAMETER in MINIMUM OF CLIPS TURN BACK in CLIPS in TORQUE ft Ibs 5 Figure 13 9 Specifications for two sizes of thimble Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 45 This page intentionally left blank NCCCO ARTICULATING CRANE REFERENCE MANUAL APPENDICES Appendix A ACCNA Crane Inspection Checklist Appendix B Standard Hand Signals for Articulating Crane Operations Appendix C Sample Articulating Crane Load Charts Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO R
62. mong 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 set ting 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 techni cal 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 Certi fication 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 operator s manual specific to the crane involved This reference guide is not intended to supersede or replace manufacturers operator s manuals OSHA 29 CFR 1926 Subpart CC nor the current ASME B30 22 standard for articulating boom cranes The material contained herein is not to be used for
63. ng An increase in throat opening exceeding five percent or as recommended by the manufacturer WEAR If wear exceeds 10 percent of the original section dimension or as recom mended by the manufacturer CRACKS NICKS GOUGES Cracks nicks and gouges must be repaired by a designated repair person by grinding longitudinally following the contour of the hook provided that no dimension is reduced by more than 10 percent of its original value or as rec ommended by the manufacturer A qualified person may authorize continued use if the reduced area is not critical LATCH Engagement damage malfunction If a latch becomes inoperative because of wear or deformation it must be replaced or repaired before being put back into service If the latch fails to fully close the throat opening remove the hook from service or wire it shut until repaired HOOK ATTACHMENTS amp OTHER MEANS OF If any indication of distortion wear cracks nicks or gouges is present remove SECURING LOADS from service unless a qualified person authorizes their use Or as recom mended by the manufacturer 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 40 Copyright 2009 2014 National Commission for the Certification of Crane Operators
64. ngth 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 Wind and weather Operators should have a means of determining the speed of the wind such as a handheld anemometer or Beaufort wind scale chart Figures 7 17 right and 7 18 next page Figure 7 17 Handheld anemometer Winds can affect the load of all articulating cranes regardless of the crane s capacity Do not operate the crane in wind speeds exceeding limits established by the manufacturer Wind can cause side loading of a boom so take appropriate precautions in windy conditions use a tag line and shrink wrap or belly lash the load to make sure part of it can t break off Potential wind effects should be considered during lift planning as well as during operation particularly if conditions change The effect of the wind can differ greatly based upon factors such as how high the load is the length at which the boom is extended the weight of the load and or the shape of the load If lightning is present stow the boom immediately Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 7 10 Lifting solution Calculate and determine a lifting solution prior to every pick no matter how simple in some cases this can be done in your head Account for all lo
65. ns to roll dense Slight structural damage occurs streaks of foam spray may reduce visibility slate blows off roofs 48 55 Storm Very high waves 20 30 ft with Seldom experienced on land trees overhanging crests sea white with densely broken or uprooted considerable blown foam heavy rolling lowered visibility structural damage 55 63 Violent Storm Exceptionally high 30 45 ft foam patches cover sea visibility more reduced 644 Hurricane Air filled with foams waves over 45 ft sea completely white with driving spray visibility greatly reduced Figure 7 18 Beaufort Wind Scale 28 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 CHAPTER 8 General precautions The operator s manual shall be with the crane at all times Read the operator s manual prior to operating the crane Operation of cranes varies by make model and manufacturer Become familiar with the crane controls and load charts before attempting to operate it Pay particular attention to the folding and unfolding process as severe damage or injury can occur with the wrong movement or sequence Do not operate the crane unless there is sufficient light to see the boom tip and your load in all configurations Lighting can be either natural or supplied
66. nstall retention pin s prior to operation Falling boom extenstion may injure or kill A14 2011 Do not paint over this label Replace if damaged or lost Figure 2 14 Boom Extension decal A14 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 Function To inform the operator of precautions necessary to prevent overloading the crane and the possible consequences of not taking those precautions Used on Articulating cranes Placement Visible to crane operator Quantity 1 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 cranes Placement Visible to crane operator Quantity 1 11 This page intentionally left blank CHAPTER 3 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 3 1 General precautions Operator s station controls must be labeled with their designated functions and directions as recommended by the manufacturer 99 p Stabilizer beam Stabilizer cylinder rd Inner boom Extension boom
67. ock Damage Prevention D 113 j Ties Check tires when in use for proper inflation and condition 14 Ground Ground conditions around the equipment for proper support including ground settling under and around ee stabilizers and supporting foundations ground water accumulation or similar conditions 15 Level The equipment for level position within the tolerances specified by the equipment manufacturer s ee ee recommendations both before each shift and after each move and setup D a sl windows wass asss s a ss p ss 5 7 17 Rails rail Rails rail stops rail clamps and supporting surfaces when the equipment has rail traveling stops rail supporting surfaces NN devices w NEN NEN Was EN NEN HEN 19 Safety Stabilizer positioning indicators are present clear and visible devices 20 Electrical Electrical apparatus for malfunctioning signs of apparent excessive deterioration dirt or moisture accumulation 2 21 22 EE All daily inspection items M Visual inspection of cylinders for leakage at rod fittings amp welds Damage to rod amp case M Daily Cylinders V Valves 25 Holding valves for proper operation 26 Valves Control valve for leaks at fittings amp between sections 2 Valves Control valve linkages for wear smoothness of operation amp tightness of fasteners Relief valve for proper pressure settings Genera
68. pair tasks performed e Carry out periodic maintenance according to the crane s maintenance manual Use only original equipment manufacturer OEM equipment and parts for repairs e Disengage the PTO before any service repairs are performed Do not disconnect any hydraulic hoses components while there is still pressure in the lines e Stand clear of high pressure hydraulic fluid leaks ingested or injected hydraulic fluid can cause serious illness or even death e Keep the crane free of oil and dirt buildup to assist in the visual inspection of the crane e Never tamper with hydraulic valve pressure settings e Immediately repair or have repaired any components found to be inadequate e Welding or drilling of the crane must be carried out by the manufacturer or a manufacturer s representative e Before welding anything on the carrier truck always Consult manufacturer or representative for authorization Ground the welder as near the welding site as possible Disconnect all connections to the crane s remote control power box Disconnect the truck batteries 34 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 CHAPTER 9 This chapter presents both what is recommended and what is required to inspect a crane for service 9 1 9 2 9 3 Copyright 2009 2014 National Commission for the Certification of Crane
69. 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 center of gravity The center of gravity of any object is the point in the object around which its weight is evenly distributed if you could put a support under that point you could balance the object on the support certified articulating crane operator A person possessing a currently valid articulating crane operator s certification Articulating Crane Terminology and issued by a nationally accredited certifying agency such as NCCCO column mast The vertical structure of the crane between the inner main boom and base crane rating A crane s gross lifting capacity established by the manufacturer designated person A person selected or assigned by the employer or employer s representative as being competent to perform specific duties electrical contact occurs when a person object or equip ment makes contact or comes in close proximity with an energized conductor or equipment that allows the passage of current extension cylinders The hydraulic cylinders used to extend and retract boom extensions fall zone means the area
70. rane has multiple operator s positions use the operator s position that ensures maximum visibility Do not move the vehicle with the boom unstowed Figure 8 4 29 30 40 Z Mec Lr Figure 8 4 Do not travel with boom unstowed e Do not push or drag loads from the side e 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 5 Lift the load clear of the ground before other movement e When working with elevated loads always ensure there is adequate clearance above and below the load e Removing part of the load may affect boom deflection so adjustments may be required e 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 e 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 6 Use gentle lever movements to avoid shock loading e 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 e Avoid quick or jerky movements at full extension as they can cause undue stress and wear to the cr
71. s 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 crane s structure side loading A force applied horizontally on the boom slew The rotation of the boom about the axis of the col umn 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 2 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 stabilizer pad A fixed or removable structural component of the stabilizer that distributes the applied force over a greater area step potential The voltage between the feet of a person standing near an energized grounded object a person could be at risk of injury during a fault simply by standing near the
72. tachment is simply connecting a sling from a lift ing hook to the load Full rated load Remove chain slings from service if any of the following of the sling may be used but never conditions are found exceeded A tag line should be used on such a lift to prevent rotation which can damage the sling 12 2 2 Chain slings causes for removal e Wear nicks cracks breaks gouges stretch bends weld splatter and or discoloration from excessive temperature e Links and attachments do not hinge freely Hook latches have evidence of permanent distortion or do not hinge freely e Sling identification tag missing or illegible 12 2 3 Synthetic slings causes for removal Choker S hu tine Remove synthetic slings from service if any of the follow capability of a vertical sling because ing conditions are found this method of rigging affects the ability of the sling components to adjust during the lift places angular e Melting or charring loading on the body of the sling and creates a small diameter bend in the sling body at the choke point e Holes tears cuts or snags Provides excellent grip and load control e Acid caustic burns e Powder is detected e Broken or worn stitching e Excessive abrasive wear e Knots in any part of the sling Basket hitches distribute a load equally between the two legs of a sling and capacity is based on e Missing or illegible sling identification tag the angles at which legs are rigged
73. ting e Account for any load handling deductions e g weight of attachments e Ensure that the attachment is designed for use on articulating cranes e Only use attachments for their designed purpose e Refer to the accessory manufacturer s operating instructions for the attachment before using it Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 15 This page intentionally left blank CHAPTER 5 Fork Assembly 5 2 This chapter presents the criteria rules and standards for the inspection and safe use of the articulating boom loader hydraulic fork assembly Articulating Boom Loader and Safety precautions The load should not pass over the operator or any other person Figure 5 2 5 1 e Use the right attachment for materials to be lifted General precautions e The plastic supports on the back of the fork must closely fit the load to prevent shifting and damage to the load The load shall rest on the load handling forks evenly and be engaged in a manner that places the load center of gravity directly on or between the forks The swivel fork must always be able to float freely and never allow the fork or load to rest against the crane boom Figure 5 1 Figure 5 1 Fork or load should never rest against crane boom as shown by arrow Copyright 2009 2014 National Commission for the Certification of Crane Operators
74. tion Don t use a hook if it meets rejection criteria e Hooks shall be equipped with functioning hook latches Figure 11 1 SWIVEL SHANK EYE HOOK HOOK HOOK NOTE All hooks shown with Latch Figure 11 1 Types of load hooks e Latches shall close the entire throat opening e Ifin doubt about a hook s serviceability contact the hook manufacturer e Never weld attachments to a finished hook the heat from the welding process will alter and destroy the design properties of the hook material e Centerthe load in the base bowl saddle of the hook to prevent applying load to the hook point e Avoid shock loading Do not apply loads of any nature on a latch device e 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 Side Load Figure 11 2 Improper hook loading 11 2 Hook swivels e Swivels prevent a load from twisting caused by the natural tendency for wire rope to unwind under load These swivels usually a part of the hook are fitted with bearings to provide for rotation e Regular lubrication of the swivel bearings is extremely important and is normally applied by way of a grease zerk located on the swivel Figure 11 3 EYE SWIVEL LATCH GREASE ZERK HEEL Figure 11 3 Components of a hook swivel Copyright 2009 2014 National Commission for the Certification
75. tion id CA D COMMENDATION CORRECTIVE ACTION TAKE DATE ITEM EXPLANATION CORRECTED m N Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 Appendix A ACCNA Crane Inspection Checklist Deficiency Recommendation Corrective Action Report cont X DATE If additional space is required reproduce this page and attach to this report Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 53 RAISE BOOM TIP VERTICALLY Arm extended fingers closed thumb pointed SWING Arm extended point with finger in direction of swing of boom HOIST LOADLINE With forearm vertical forefinger pointing up move hand in small horizontal circle 54 LOWER BOOM TIP VERTICALLY Arm extended fingers closed thumb pointed downward MOVE SLOWLY Use one hand to give any motion signal and place other hand motionless in front of hand giv ing the motion signal Hoist slowly shown as example LOWER LOADLINE With arm extended downward forefinger pointing down move hand in small horizontal circle Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 INCREASE RADIUS OF BOOM TIP Both fists in front of body with thumbs pointing outward STOP Arm extended palm down move arm back and forth
76. 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 crane s capacity qualified person A person who by possession of a rec ognized 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 i
77. tside wires are less than two thirds the thickness of the unworn outer wire 1 3 loss Section Through Worn Rope View of Single Strand Figure 13 3 Example of flat spots on outer wires When there is a decrease of diameter indicating a core failure Figure 13 4 Example of decrease in diameter indicating a core failure 43 When kinking crushing bird caging or other distortion occurs 3 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 5 or more Ifa broken wire protrudes or loops out from the core of the rope Figure 13 7 Example of protruding wire core 13 3 Safety precautions for wire ropes 44 Never overload a wire rope Never shock load a wire rope Avoid the formation of kinks Do not intentionally knot wire rope Do not drag wire rope over a non rotating support such as a non functioning sheave Do not use worn flat grooved nicked or otherwise broken sheaves Wrap wire rope onto the drum evenly Select replacement wire rope to match the original Capacity and use of the crane Do not expose the rope to corrosive chemicals heat or electrical contact Lubricate the rope frequently to reduce friction and help prevent corrosion 13 4 Calculating working load limit permissibl
78. uld the hazard occur and how to avoid the hazard Used on Articulating cranes Placement Visible to crane operator Quantity 1 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 DANGER Electrocution Hazard Never approach this vehicle or the load if it is near power lines Death or serious injury will result from touching or being near this vehicle if it becomes charged Figure 2 2 Electrocution Alert to Pedestrians decal A02 Electrocution Hazard Crane is not insulated Remote is not Insulated NEVER approach or contact power lines with any part of this equipment or load Keep 50 feet away from any power line if voltage is not known Keep 20 feet away from any power line 350 kilovolts or less Account for swaying motion of power lines equipment and load line Follow OSHA 29CFR 1926 1400 Death or serious injury will result from approaching or contacting a power line A03 2011 not paint over this label Replace if damaged or lost Figure 2 3 Electrocution Alert to Crane Operator with Remote decal A03 DANGER Electrocution Hazard Tethered remote control is not insulated Never allow this vehicle equipment or load to become charged while you are holding this control Death or serious injury will result from touching this control if this vehicle becomes charged A04 2011 Do not paint over this label Replace if d
79. us within the work zone for where the load is to be placed 24 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 e Establish and clearly mark the work zone to prevent unauthorized entry Figure 7 5 S of G wa s Nem N 2 T Figure 7 5 Establishing and marking work zone e Set the parking brake and place wheel chocks Figure 7 6 P albi Figure 7 6 Setting wheel chocks 7 5 Operator s control area s Keep the controls clean and free of oil mud ice and snow e Make sure the steps and handrails are clean and not slippery e Use three point contact at all times when entering or exiting Figure 7 7 Figure 7 7 Use three point contact both feet and one hand or one foot and both hands when climbing to and from control station e Donotuse the controls or hoses as a handhold Do not jump into or out of the machine 7 6 Stabilizers e Stabilizers shall be locked in the retracted position during transit e 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 8 Figure 7 8 Deploying and locking stabilizers e Stabilizers shall be fully deployed per
80. using the manual extension s 20 Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 6 7 Capacity of rigging and attachments e The capacity or rating of the rigging or attachment being used may be a limiting factor for the lift e Never exceed the rated capacity of the rigging or attachment being used regardless of what the crane Capacity rating shows 6 8 Gross capacity vs net capacity e Capacities shown on load charts are gross capacities Net capacity is the gross capacity minus the weight of any attachments or other lifting deductions e When determining what the crane can actually lift deduct the weight of all devices below the boom tip these lifting deductions can include attachments such as pallet forks hydraulic clamps rotators drywall forks and clam buckets e Also deduct from the gross capacity the weight of rigging materials such as lifting slings shackles and spreader bars e The gross capacity minus the lifting deductions equals the net capacity or what the crane can actually lift load weight e Alternatively determine the gross load by adding the weight of the rigging and or attachments to the weight of the actual load then compare this gross load to the crane rating chart to determine the maximum lifting radius without overloading the crane Copyright 2009 2014 National Commission for the Certification of Crane Operators Al
81. with an articulating crane As depicted in Figure 4 1 these attachments include from left to right e Before operating equipment understand the descriptions operations and maintenance requirements for the attachments components and e Brush grapple base machine crane e Stone grapple e When using pallet forks make sure the fork tines are centered under the load to balance the load and lift e Brick grab level e Clam bucket Do not push down on the lifting attachment with the e Log grapple boom e Barrier clamp Do not allow lifting attachments to push upward the boom 4 1 General precautions Never lift personnel with any attachment unless it s a personnel lifting device that is approved by the crane manufacturer and is attached or pinned to the last forks auger etc that are approved by the crane boom extension See OSHA 1926 1431 for complete manufacturer guidance and restrictions on hoisting personnel e Use only lifting attachments basket grapple e When connecting and disconnecting the hydraulic connections often called quick disconnections or QDs to the accessory always clean the connections and be careful not to pinch your fingers or hands e When using add on aftermarket lifting accessories always follow the instructions supplied by the lifting accessory manufacturer Do not exceed the load rating of the attachment note that the attachment s load rating may be less than the crane s ra
82. y to those lines e Minimum clearance warning signs for electrical hazards during both operation and transport shall be posted on the crane e Tables A and T may only be utilized when the exact voltages of the lines are known Please consult OSHA 1926 Subpart CC sections 1926 1407 1411 for full details on power line safety requirements Copyright 2009 2014 National Commission for the Certification of Crane Operators All rights reserved ACO RM REV 06 14 23 Do not rely on electrical wire coverings for protection from energized lines step potential and touch potential may still exist Figure 7 1 The greatest danger is faced by a person who simultaneously touches both the crane and the ground but a person who is near but not touching the crane can also suffer electric shock Figure 7 1 Be aware of all potential electrical hazards e Electrical hazard warning signs should be posted on all four sides of the vehicle Figure 7 2 DANGER Electrocution Hazard Never approach this vehicle or the load if it is near power lines Death or serious injury will result from touching or being near this vehicle if it becomes charged lace if damaged or lost Figure 7 2 Electrocution Hazard decal e Aspotter is required to help maintain the required clearances whenever the boom s length in the crane work zone can reach the prohibited or danger zone with the electrical lines energized e Cranes in transit and in th

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