Truck cranes are special equipment with specific safety requirements for operation. The following aspects are detailed:
- General safety requirements for crane operation
- Crane setup requirements for the work site
- Setup requirements for operating on slopes and ditches
- Requirements for the support vehicle before operation
- Obstacles around the crane
- safe loading and unloading of the crane
- Instructions for non-operating conditions
General Requirements for Crane Safety Operation
- Only trained professionals may operate cranes;
- Operators are not permitted to engage in other distracting operations while operating a crane;
- Operators are not permitted to operate a crane if they are unwell;
- The operator’s view of the load and operating area must be clear and unobstructed. If visibility is limited, the operator must operate under the direction of the hoisting operator and signalman, who must be within the operator’s line of sight. The operator and signalman must ensure that the load and lifting wire rope are completely free from obstacles.
- Operators must operate according to crane operation command signals. The operator must immediately execute any stop signal given by anyone;
- Operators are responsible for the operations they directly control. Whenever an unsafe situation is suspected, the operator must consult with the authorized person (supervisor) before lifting the load;
- Before leaving an unattended crane, the operator must meet the following requirements:
- The load to be hoisted should be lowered to the ground; it must not be suspended.
- Ensure the brakes of the operating mechanism are locked or other safety devices are in place.
- Raise the hook to its highest position.
- Disconnect the power supply or disengage the main clutch, if necessary.
- Place all controllers in the “zero” or neutral position.
- Secure the crane to prevent accidental movement.
- Lower the crane/super-lift’s suspension counterweight to the ground.
- Turn off the engine;
- Do not place large heavy objects on the crane hook. The hook and wire rope must not touch other parts of the crane (such as the boom) or other obstacles (such as buildings). When the hook is empty, it must be several meters below the height limit switch or secured in a designated position;
- Turn off all secondary systems (e.g., heating system, air conditioning system). Except when maintaining a certain temperature/dryness for restarting the crane;
- The power supply and functionality of any safety equipment (e.g., aircraft warning lights) must be guaranteed.
- Keep all keys in a safe place and do not use them without authorization;
- All doors and windows of the crane must be closed (both for loading and unloading) to prevent unauthorized use;
- Depending on the type of crane, mobile control panels connected to the crane by cable need to be removed and/or placed in a safe place and not used without authorization;
- If equipped with a wireless remote control, place it in a safe place and do not use it without authorization. Ensure the power supply is recharged.
- If the boom is extended and the site conditions do not allow the main boom and/or jib to be fully lowered to the ground, the unattended crane shall be configured as follows:
- The crane setup shall be determined by qualified personnel familiar with the crane, based on the site configuration, operating conditions, limitations, safety regulations, and anticipated weather forecasts.
- In addition, the following provisions shall apply: An emergency plan shall be ensured for unattended operation of the crane. The crane shall be placed in a safe location in emergency situations, such as unforeseen weather changes or other potential accidents listed above. This emergency plan shall include sufficient space to move the equipment to a safe location.
- The crane’s location and configuration shall not pose a hazard to the surrounding environment (e.g., the risk of road traffic or collision with surrounding obstacles). This may require a specific operational risk assessment before leaving the unattended crane.
- Safe Use of Machinery
- Inspect the crane for unintentional slow movement (e.g., due to internal or external leaks in all load-bearing hydraulic cylinders and winches):
- Outrigger vertical cylinders, boom luffing cylinders, jib luffing cylinders, if applicable, hoisting winches, luffing winches, if applicable
- Other
- Weather forecasts shall be obtained in advance during crane erection.
- Before determining the location and configuration of an unattended crane, changes in weather conditions, including but not limited to: wind, icing, rainfall, flooding, lightning, etc., should be considered.
- If, due to unforeseen weather conditions, wind speeds exceed permissible levels and the crane boom is in an upward position, the crane should be secured and personnel evacuated from the area.
- Before connecting the power supply or starting the equipment, the operator should check all controllers and ensure they are in the “zero” or neutral position. All personnel on site must be within a safe area.
- In the event of a power failure during operation, the operator should:
1) Lock the brakes or install other safety devices where appropriate;
2) Disconnect all power supply or place the clutch in neutral;
3) If feasible, lower the suspended load to the ground using control of the brakes.
- Operators should be familiar with the equipment and its routine maintenance. If the crane requires adjustment or repair, the operator should promptly report the situation to management and notify the incoming shift.
- At the start of each shift, the operator should test all control devices. If any control device malfunctions, it should be adjusted and repaired before the crane is operated.
- Operation is prohibited when the wind speed exceeds the specified maximum operating wind speed.
- When operating a crane in weather conditions where the crane structure is icy or visibility is reduced, the crane speed should be slowed down or effective communication methods (such as walkie-talkies) should be provided to ensure safe operation.
- When operating a crane at night, the work site should have sufficient lighting.
- It is prohibited to make any alterations or modifications to the crane that may affect safety. This includes:
1) Altering electrical wiring;
2) Unauthorized installation or modification of safety devices, etc.
- Welding work on lifting components must be performed by qualified personnel according to the manufacturer’s specifications. To prevent injury, all welding work must be carried out according to the prescribed procedures, especially the welding of electronic components. Please contact XCMG after-sales service department before performing any welding work to understand the relevant precautions.
- When using a crane for the first time or after a long period of non-use, each operation should be repeated five times under no-load conditions to purge air from the hydraulic system.
- Incorrect calculation and judgment of the vehicle’s lifting capacity will lead to accidents. The lifting capacity listed in the lifting performance table includes the weight of the load, the hook, and the rigging.
Crane Operation Management
Crane Installation Requirements for the Work Site:
- 1.Ensure the outriggers can extend to the positions specified in the rated lifting capacity table;
- All movements (e.g., slewing, hoisting, luffing, etc.) should not be obstructed by any obstacles;
- The crane should be supported on a solid, level surface. All tires should be off the ground. The work site should not sink during operation, otherwise the crane may tip over;
- The overall tilt angle should be ≤0.5% (angle value 0.29). If necessary, steel plates or wooden blocks can be placed under the outriggers; otherwise, there is a risk of tipping over.
Installation Requirements for Operation on Slopes and Ditches:
The crane should not be installed very close to slopes or ditches. If operation in such locations is unavoidable, a safe distance should be maintained based on the geological conditions. The safe distance depends on the soil type.
The safe distance D can be determined by measuring the depth T of the ditch. For reference only:
For soft or filled soil: Minimum safe distance D = 2 x T
For hard soil: Minimum safe distance D = T
Pre-operation Support Requirements
When operating a crane, all tires must be completely off the ground.
Obstacles Around the Crane
When operating a crane, consider surrounding obstacles such as nearby buildings, other cranes, vehicles or vessels undergoing loading/unloading operations, stacked goods, and public transportation areas including highways, railways, and rivers.
Safe Access to and from the Crane
Due to the special structure and generally large size of crane machinery, caution should be exercised when accessing or alighting from cranes to avoid accidental injury.
Before climbing onto the crane, ensure it is completely stopped. Jumping onto or off the machine is prohibited.
Use existing access facilities such as ladders and handrails to enter and exit the operator’s cab or work platform.
Operators should maintain three-point contact with ladders, handrails, and footboards to ensure body balance.
Do not walk on platforms without anti-slip devices or where the anti-slip devices are severely worn. Keep all access routes and work platforms of the crane clean, dry, and slip-resistant.
It is recommended that operators or maintenance personnel wear non-slip shoes when entering the operator’s cab or work platform.
Do not use the boom as a walkway.
Do not step on the outrigger beams or footplates when getting on or off the crane.
Never use the steering wheel or control levers as handrails.
Do not alter the crane’s inherent access control without permission.
Non-Working State Instructions:
The crane’s non-working state refers to the state in which the crane is not performing lifting operations. In the non-working state, the outriggers and boom are fully retracted.
The crane must be parked on a flat, firm surface in a safe location.
After stopping lifting operations, retract the jib and other attachments as required, turn off the power in the upper operator’s cab, and close and lock the operator’s cab doors and windows.
Stop the engine, turn off the lower operator’s power, engage the parking brake (handbrake), and close and lock the operator’s cab doors and windows.
Safe operation of cranes is important. If you buy truck crane and are unfamiliar with its operation, please contact us. SUNRISE will arrange professional technical engineers from the factory to provide training. We are a crane supplier and can also provide original spare parts for Chinese construction machinery.