TCL005 - SGD - V4 (Jacking)

Jacking,
Blocking
and Lifting
TCL005
Student Guide
Caterpillar Service Technician Module
TCL005
Jacking, Blocking and Lifting
Published by Caterpillar of Australia Pty Ltd.

1 Caterpillar Drive
Tullamarine Victoria Australia 3043
Version 4.0, 2005
Copyright © 2005 Caterpillar of Australia Pty Ltd. Melbourne, Australia.
All rights reserved. Reproduction of any part of this work without the permission of the
copyright owner is unlawful. Requests for permission or further information must be
addressed to the Caterpillar Learning Manager, Australia.
This subject materials is issued by Caterpillar of Australia Pty Ltd. on the understanding that:
Caterpillar of Australia Pty Ltd., its officials, author(s), or any other persons involved in the
preparation of this publication expressly disclaim all or any contractual, tortious, or other form
of liability to any person (purchaser of this publication or not) in respect of the publication and
any consequence arising from its use, including any omission made by any person in reliance
upon the whole or any part of the contents of this publication.
Caterpillar of Australia Pty Ltd. expressly disclaims all and any liability to any person in
respect of anything and of the consequences of anything done or omitted to be done by any
such person in reliance, whether whole or partial, upon the whole or any part of the contents
of this subject material.
Acknowledgements
A special thanks to the Caterpillar Family for their contribution in reviewing the curricula for
this program, in particular:
 Caterpillar engineers and instructors

 Dealer engineers and instructors
 Caterpillar Institutes.
Table of Contents
Included in this Module:

1
Topic Safety...........................................................................15
Important Safety Information........................................................ 16
Preparation of a Machine for Jacking and Blocking..................... 17
Parking The Machine In Preparation For Jacking And Blocking 18
Jacking (Lifting) And Blocking (Supporting) The Machine........... 19
2
Topic Jacks and Lift Stands................................................23
Hydraulic Jack.............................................................................. 24
Guard Jack...................................................................................26
Jack Stands/Lift Stands...............................................................27
Stands (General)..........................................................................30
Caterpillar Tube Stands................................................................30
Wood Blocking.............................................................................35
Tractor Lift.....................................................................................36
Wheel Stand.................................................................................37
3
Topic Jacking and Blocking Caterpillar Machines............39
Wheel Loader...............................................................................40
Track Type Tractor........................................................................50
Motor Grader................................................................................52
Off Highway Truck........................................................................62
Wheel Tractor Scrapers................................................................68
Jacking, Blocking and Lifting – TCL005

© Caterpillar of Australia Pty Ltd
Table of Contents Continued . . .
Topic 4 Lifting Methods and Equipment...............................73

Synthetic Fibre Slings...................................................................83
Slinging Theory............................................................................89
Hook Gauge............................................................................... 109
Single Sling................................................................................. 109
Shackles..................................................................................... 110
Lift and Block.............................................................................. 121
Fibre and Nylon Rope................................................................ 123
Load Positioning Sling................................................................ 124
Barrel Grip.................................................................................. 125
Chain Hoist................................................................................. 126
Electric Hoist............................................................................... 127
Ratchet Hoist.............................................................................. 128
Dual Hook Hoist......................................................................... 129
Block and Tackle........................................................................ 131
Jacking, Blocking and Lifting– TCL005

Module Outline Document
Included in this Section:

Learning Outcome Details and Module Information
Jacking Blocking and Lifting – TCL005

Module Number: TCL005
Module Name: Jacking, Blocking and Lifting
Objective:
This unit identifies the competence required to carry out jacking and blocking
heavy vehicles and the requirements of safely using lifting equipment
Prerequisites:
The following module(s) must be completed prior to delivery of this module:
n BUS006 Workplace Occupational Health and Safety Procedures
Date: 4 October 2005
Version: 4.0
Recommended Delivery
1. As a minimum, personnel delivering this module must have the status of a
Caterpillar Trainer and Assessor Program (CTAP) Level 1 Facilitator, or equivalent.
2. Media delivery plus exhibit and explain facilitation, given:

− Notebook Computer
− PowerPoint Presentation
− Video Projector
− Various training aids/models and machines
3. Estimated time of delivery – 30 hours
4. Classroom and Workshop Environment
5. Resources:
− Nil.
6. Reference/s
− TCL005 – Facilitator Guide
7. Recommended Student Teacher Ratio

− Classroom – 15:1
− Workshop – 8:1

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8. Resources for Students:

− TCL005 Student Guide (one for each student)
− TCL005 Student Activity Workbook (one for each student)
Revision
Nil
Assessment
This is an underpinning knowledge and practical module. Learning Outcomes should
be assessed using formative and summative assessments. Evidence of achieving
this modules learning outcomes, at a knowledge level, is attained by oral and written
assessment. The written assessment is closed book and a minimum standard of 80% is
required. Attainment of the student performance at a hands-on level is achieved by the
use of practical activities aligned with marking guides.
The practical activities may be used as a learning activity or as a practical assessment.
If the practical activity is used as a practical assessment, the student must work alone
and be deemed competent in all aspects. The assessment method must confirm
consistency and accuracy of performance together with application of underpinning
knowledge. The assessment must be by direct observation of tasks, with questioning on
underpinning knowledge. Personnel conducting the assessment must be qualified as a
workplace assessor.

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Learning Outcome 1: Identify safety requirements for jacking, blocking

and lifting heavy vehicle equipment.
_______________________________
At the completion of this learning outcome, students should be able to:

1.1 Identify safety requirements for jacking, blocking and lifting heavy vehicle
equipment.
Attainment of the performance is confirmed if the student can:
1.1 Identify safety requirements for jacking, blocking and lifting heavy
vehicle equipment:
1.1.1 Safety information
1.1.2 Preparation of a machine for jacking and blocking
1.1.3 Parking a machine in preparation for jacking and blocking
1.1.4 Jacking (lifting) and blocking (supporting) the machine.

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Learning Outcome 2: Identify jacks and lift stands used in the repair
and maintenance of heavy vehicles.
_______________________________

2.1 Identify jacks and lift stands used in the repair and maintenance of heavy
vehicles.
2.1 Identify jacks and lift stands used in the repair and maintenance of
heavy vehicles:
2.1.1 Hydraulic jack
2.1.1.1 Use
2.1.1.2 Maintenance
2.1.1.3 Rated capacity
2.1.2 Guard jack
2.1.2.1 Use
2.1.2.2 Maintenance
2.1.3 Jack stands/Lift stands
2.1.3.1 Use
2.1.3.2 Maintenance
2.1.4 General stands
2.1.5 Caterpillar tube stands
2.1.5.1 Small stand base
2.1.5.2 Large stand base (old type)
2.1.5.3 Large stand base (new type)
2.1.5.4 Stand capacities
2.1.5.5 Tube thickness
2.1.6 Wood blocking
2.1.7 Tractor lift
2.1.7.1 Maintenance
2.1.8 Wheel stand
2.1.8.1 Maintenance.

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Learning Outcome 3: Identify jacking and blocking methods used for

heavy mobile equipment.
_______________________________

3.1 Identify jacking and blocking methods used for heavy mobile equipment.
3.1 Identify jacking and blocking methods used for heavy mobile equipment:
3.1.1 Wheel Loader
3.1.1.1 Steering frame locking link
3.1.1.2 Chocking wheels
3.1.1.3 Chocking the oscillating rear axle
3.1.1.4 Supporting implement loader frame
3.1.1.5 Placing front frame on stands
− Raising method
− Supporting method
3.1.1.6 Placing the rear frame on stands
− Raising method
3.1.2 Track-type Tractor
3.1.2.1 Placing tractor on stands
− Raising method
3.1.2.2 Supporting the blade
3.1.2.3 Supporting the ripper
3.1.3 Motor Grader
3.1.3.1 Frame lock pin
3.1.3.2 Wheel lean pin
3.1.3.3 Chocking the wheels
3.1.3.4 Placing front frame on stands
− Raising method
3.1.3.5 Placing rear frame on stands
− Raising method
3.1.3.6 Supporting draw bar and mouldboard
3.1.3.7 Supporting the ripper
3.1.4 Off-highway Truck

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3.1.4.2 Supporting the tray

3.1.4.3 Placing the front on stands
− Raising and supporting method – front cross member
− Raising and supporting method – front towing hooks
3.1.5 Placing the rear on stands
− Raising method
− Raising method (777 or smaller)
− Supporting method (777 or smaller)
3.1.6 Wheel Tractor Scraper
3.1.6.2 Placing the front on stands
− Raising method
3.1.6.3 Placing the rear on stands
− Raising method
3.1.6.4 Supporting the bowl.

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Learning Outcome 4: Explain the correct inspection procedures,

identify the correct lifting slings and describe the
correct lifting methods.
_______________________________

4.1 Explain the correct inspection procedures for chains
4.2 Explain the correct inspection procedures for slings
4.3 Identify the correct method of slinging a load.
4.1 Explain the correct inspection procedures for chains:

4.1.1 Introduction
4.1.2 Manufacture and identification
4.1.2.1 Manufacture
4.1.2.2 Energy absorption factor
4.1.3 Care of chains
4.1.3.1 Heat treatment
4.1.3.2 Storage
4.1.3.3 Cutting a chain
4.1.4 Inspection of chains
4.1.4.1 Register
4.1.5 Damage
4.1.5.1 Elongation
4.1.5.2 Wear
− External wear
− Wear caused by use
4.1.5.3 Deformed links
4.1.5.4 Cracks and cuts
4.1.5.5 General
4.1.6 Safe use of chains
4.1.7 General
4.1.7.1 Don’ts
4.1.7.2 Do’s
4.2 Explain the correct inspection procedures for slings:
4.2.1 Synthetic fibre slings
4.2.1.1 Flat webbing slings
4.2.1.2 General usage
4.2.1.3 Types of damage
4.2.1.4 Cleaning slings

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4.2.1.5 Sling chart

4.2.1.6 Sling inspection
− Recommendations for use
− Permanent loss of strength
− Causes of loss of strength
− When to inspect
− Recording inspections
− Inspection procedures
4.3 Identify the correct method of slinging and lifting a load
4.3.1 Methods of applying slings to loads
4.3.1.1 Direct hitch
4.3.1.2 Chock or reeved hitch
4.3.1.3 Basket hitch
4.3.1.4 Double wrap
4.3.2 Slinging terminology
4.3.2.1 Working load limit
4.3.2.2 Safe working load
4.3.2.3 Breaking load
4.3.2.4 Proof loading
4.3.2.5 Safety factor
4.3.2.6 Common safety factors
4.3.3 Temporary change to sling strength
4.3.3.1 When choke hitched
4.3.3.2 Square corners and sharp edges
4.3.3.3 Shackles and lifting lugs
4.3.3.4 Basket hitches
4.3.4 Included angles
4.3.5 Use of three and four leg slings
4.3.6 Steps for safely lifting a load with a crane
4.3.6.1 Check the load
− The weight
− The size
− The shape
− Moving parts
− Fragile or valuable loads
− Lifting points
− Fixed machinery
4.3.6.2 Establish the capacity of the crane
4.3.6.3 Where is the load to be placed
4.3.6.4 Establish the centre of gravity of the load
− Uniform shape
− Non uniform shape
− Centre of gravity outside the object

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4.3.6.5 How the load is slung

− Single sling
− Two slings or two leg assemblies
− Slinging accessories
4.3.6.6 Selecting appropriate slings and gear
− Safe Working Load
− Sling condition
− Sling type
− Length
− Beams, shackles, protective packaging, tail ropes
4.3.6.7 Directing crane hook over load
4.3.6.8 Applying slings
4.3.6.9 Taking the tension
4.3.6.10 Hoisting and checking load
4.3.7 Sling hooks
4.3.7.1 Standard hook
4.3.7.2 Safety hook
4.3.7.3 Latchlock hook
4.3.7.4 Grab hook
4.3.8 Hook gauge
4.3.9 Single sling
4.3.9.1 Maintenance
4.3.10 Shackles
4.3.10.1 ‘D’ shackle
4.3.10.2 Bow shackle
4.3.11 Lifting beams
4.3.11.1 Spreader beam
4.3.11.2 Equaliser beam
4.3.12 Eyebolts
4.3.12.1 Collared
4.3.12.2 Uncollared
4.3.12.3 Eyebolt usage
4.3.12.4 Eyebolt dimensions
4.3.12.5 Safe Working Loads
4.3.13 Steel plate clamps
4.3.13.1 Vertical type
4.3.13.2 Single clamp use
4.3.13.3 Two sling support
4.3.14 Lift and block
4.3.14.1 Use
4.3.14.2 Maintenance
4.3.15 Fibre and nylon rope
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4.3.15.1 Use
4.3.16 Load positioning sling
4.3.16.1 Use
4.3.17 Barrel grip
4.3.17.1 Use
4.3.18 Chain hoist
4.3.18.1 Use
4.3.19 Electric hoist
4.3.19.1 Use
4.3.20 Ratchet hoist
4.3.20.1 Use
4.3.21 Dual hook hoist
4.3.21.1 Use
4.3.22 Block and tackle
4.3.22.1 Use
4.3.23 Crane signals.
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Learning Outcome 5: Demonstrate the correct method of jacking and

blocking heavy earthmoving and heavy-road
transport vehicles.
PREREQUISTE: The student must have completed the knowledge assessment

prior to attempting this learning outcome.
At the end of this learning outcome, students should be able to:

5.1 Demonstrate the correct methods of jacking heavy vehicles
5.2 Demonstrate the correct method of supporting heavy vehicles
5.3 Demonstrate the correct method of chocking heavy vehicles
5.4 Demonstrate the correct method of returning the jacked, supported and
chocked heavy vehicles to ground
Students must:
− State and follow the safety precautions that must be observed to prevent
personal injury or damage to equipment
− Tasks are identified according to manufacturer’s specification
 Tasks should be completed:
− Without causing damage to components or equipment
− Using appropriate tooling, techniques and materials
− According to industry/enterprise guidelines, procedures and policies
− Using and interpreting correct information from the manufacturer’s
specifications
Attainment of the performance is confirmed if the trainee can:
5.1 Demonstrate the correct method of jacking heavy vehicles:

5.1.1 Inspection prior to jacking
5.1.2 Correct tooling selected
5.1.3 Correct jacking location selected
5.1.4 Jacking procedures are conducted according to manufacturer’s
specifications
5.2 Demonstrate the correct method of supporting heavy vehicles:
5.2.1 Correct supports selected
5.2.2 Inspection of supports prior to use
5.2.3 Correct support locations selected
5.2.4 Support procedures are conducted according to manufacturer’s
specifications
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5.3 Demonstrate the correct method of chocking heavy vehicles:

5.3.1 Correct chocking material selected
5.3.2 Inspection of chocking materials prior to use
5.3.3 Correct chocking locations selected
5.3.4 Chocking procedures are conducted according to manufacturer’s
specifications
5.4 Demonstrate the correct method of returning the jacked, supported and
chocked heavy vehicles to ground:
5.4.1 Correct method selected
5.4.2 Support procedures are conducted according to manufacturer’s
specifications
5.5 When conducting jacking, blocking, chocking and returning vehicle to
ground, the facilitator must ensure that the student is conducting the
activity:
5.5.1 Using and interpreting correct information from the manufacturer’s
specifications
5.5.2 Without causing damage to components or equipment
5.5.3 Using appropriate tooling, techniques and materials
5.5.4 According to industry/enterprise guidelines, procedures and policies.
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Learning Outcome 6: Conduct a lifting exercise using the correct slings,

slinging method and procedures.
PREREQUISITES: The student must have completed the knowledge assessment

prior to attempting this learning outcome.
At the end of this learning outcome, students should be able to:

6.1 Conduct a lifting exercise using the correct slings, slinging method
and procedures
Attainment of the performance is confirmed if the trainee can:
6.1 Conduct a lifting exercise using the correct slings, slinging method
and procedures
6.1.1 State and follow the safety precatutions that must be observed to
prevent personal injury or damage to equipment
6.1.2 Tasks to include:
6.1.2.1 Checking the load (including weight of load)
6.1.2.2 Establishing the capacity of the lifting equipment
6.1.2.3 Where is the load to be placed
6.1.2.4 Establish centre of gravity
6.1.2.5 How the load is to be slung
6.1.2.6 Select appropriate slings and gear
6.1.2.7 Direct crane over the load
6.1.2.8 Apply slings to load
6.1.2.9 Take up tension in the slings, stop and check
6.1.2.10 Hoist and check the load is balanced
6.1.2.11 Move the load
6.1.2.12 Place load in a designated area
6.1.3 Tasks are to be completed:
6.1.3.1 Without causing damage to components or equipment
6.1.3.2 Using appropriate tooling, techniques and materials
6.1.3.3 According to industry/enterprise guidelines, procedures and
policies
6.1.3.4 Using and interpreting correct information from the
manufacturer’s specifications
6.1.4 The facilitator must ensure that the student is conducting the
activity:
6.1.4.1 Using and interpreting correct information from the
manufacturer’s specifications
6.1.4.2 Without causing damage to components or equipment
6.1.4.3 Using appropriate tooling, techniques and materials
6.1.4.4 According to industry/enterprise guidelines, procedures and
policies.
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1 Safety
Topic
Included in this Topic:

Important Safety Information........................................................................................................................16
Preparation of a Machine for Jacking and Blocking.....................................................17
Parking The Machine In Preparation For Jacking And Blocking..................18
Jacking (Lifting) And Blocking (Supporting) The Machine....................................19
J acking , B locking and L ifting – TCL005

Student Guide – Topic 1
It is a responsibility of all employees to take reasonable care to protect their own

health and safety and the health and safety of any other person. Employees also
have an obligation to follow company procedures, rules, policies and any safety
instructions in regard to lifting and slinging equipment.
Under no circumstances are service technicians to rely solely on the overhead

crane, a post crane or other lifting devices to support a load that they must climb
onto, under or into to carry out work. Where it is necessary to work on jobs while
they are suspended in a particular position, additional supports must be used.
Bracing and temporary supports must be capable of holding the workload

without the lifting device being attached, even if it is to remain in place for the
duration of the work.
This procedure applies to all suspended workloads, without exception. The size
of the job or time constraints are not reasons for failure to comply.
Important Safety Information
WARNING:
Read and understand all safety precautions and warnings before performing
repairs to equipment.
Basic safety precautions, skills and knowledge are listed in the SAFETY section
of the machine’s manuals and there are descriptions of operations where
hazards exist. Warning labels have also been put on the machine to provide
instructions and identify specific hazards which, if not heeded, could cause
bodily injury or death to you or other persons. These labels identify hazards
which may not be apparent to a trained mechanic. There are many potential
hazards during the repair for the untrained mechanic and there is no way to label
the machine against all such hazards. These warnings in the Service Manuals
and on the machine are identified by a Safety Alert Symbol and followed by the
Signal Word such as WARNING as shown below.
WARNING:
Attention! Be Alert – Your Safety is Involved.
Operations that may result only in machine damage are identified by the labels
on the machine and in the Service Manual by the word NOTICE.
Replace any damaged, illegible or missing warning plates, signs or decals

(stickers).
16
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¨ Caterpillar cannot anticipate every possible circumstance that might involve

a potential hazard. The warnings in Caterpillar’s service publications and
on machines are therefore not all inclusive. If a procedure, tool, device or
work method not specifically recommended by Caterpillar is used, you must
satisfy yourself that it is safe for you and others. You should also ensure
the machine will not be damaged or made unsafe by the procedures you
choose.
¨ Obtain the complete and most current information available before starting
any job.
¨ Support equipment and attachments properly when working beneath them.
Do not depend on hydraulic cylinders to hold them up. A machine and or
attachment can fall if a control is moved, or if a hydraulic line breaks.
¨ Where there are areas of the machine which articulate or oscillate, the
clearance in these areas will decrease and increase with the movement of
the machine. Be aware of these areas for your own safety and the safety of
other personnel.
¨ Where there are attachment linkages, the clearance in the linkage area will
increase or decrease with the movement of the attachment.
¨ Retainer pins, when struck with force, can fly out and injure nearby
persons. Make sure the area is clear of people when driving retaining pins.
Additionally chips or other debris can fly off objects when struck. Make sure
no flying debris can injure other persons before striking any object.
NOTE:
Explanation for Notice and Warning in service publications.
The word NOTICE is currently being used in new service publications to bring
to your attention the possibility of machine or component damage. Formerly, the
word CAUTION was used. This change has been made in agreement with the
latest industry standards. When there is a possibility of personal injury or death
Caterpillar will continue to use the word WARNING.
Preparation of a Machine for Jacking and

Blocking
¨ The machine must be empty of any material it has been used to transport,
dig or carry.
¨ Select and prepare a suitable work area, with consideration for jacking/
blocking and dismantling requirements. Special considerations must be
taken into account for the condition of the ground on which the machine is
being lifted.
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WARNING:
Personal injury can result if the surface below the machine cannot support the
machine. Perform the following procedures only on a hard level surface. Make
sure the surface under the machine is able to support the full weight when it is
concentrated at the jacking/lift points.
¨ Select the correct service manual and locate the relevant section
concerning the service repair and or maintenance to be performed.
¨ Check the machine’s weight and select and check the appropriate tooling.
NOTE:
Always use tooling that is in good condition and be sure you understand how to
use them before performing any service work.
¨ Identify appropriate jacking or blocking points to be used in lifting the

machine.
¨ Check the jacking or blocking points for security and or surface condition.
¨ Develop a suitable jacking and blocking plan. Refer to the relevant section
of the machines service manual on the procedure to be implemented.
Parking The Machine In Preparation For Jacking

And Blocking
¨ Relocate the machine to the area selected by you, suitable for the jacking or
lifting operation to take place.
¨ Place the machine in neutral.
¨ Engage the parking brake or any other locking device for gear, directional or
hydraulic controls.
¨ Lower the bucket, blade, ripper or other implements to the ground before
performing any work on the machine. If this cannot be done, make sure
the bucket blade, ripper or other implement is blocked to prevent it from
dropping unexpectedly.
¨ Shut off the engine.
¨ Turn the engine start switch key to OFF.
¨ Turn the battery disconnect key to OFF.
¨ Tag out the machine using the appropriate safety tags. Tag as per site
specific tagging procedures.
¨ Chock the wheels.
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Jacking (Lifting) And Blocking (Supporting) The

Machine
¨ Position and lock any articulation locking devices. Refer to the relevant
section of the machine’s service manual on the procedure to be
implemented.
NOTE:
If the wheels are already chocked, move the chocks slightly away to allow the
machine to articulate without riding up on the chocks.
¨ Chock the wheels to prevent forward and backward movement of the

machine during the jacking procedure/s.
¨ Chock any oscillation type components. Refer to the relevant section of the
machine’s service manual on the procedure to be implemented.
¨ Position and lock any ancillary locking devices, e.g. wheel lean. Refer to the
relevant section of the machine's service manual on the procedure to be
implemented.
¨ Clean the machine's jacking/supporting contact surfaces of any material
that might reduce the maximum friction ability of the surfaces. Such as oil,
grease, dirt, flaking rust, loose paint, etc.
¨ Clean the contact areas of the jacking/supporting devices for the same
reasons outlined above.
¨ Select the correct size jacking unit for the work.
¨ Check the jacking unit/s for operational serviceability.
− Check the hydraulic fluids of all pumping unit/s whether self contained
in the jacking unit/s or remote.
− Inspect all gauges, hoses, couplings and fittings for operational
condition and/or tightness.
− Inspect that all locking devices, if fitted to the unit/s, will operate
correctly before the unit/s is put into operation.
− Test the unit/s lifting stroke free from the load. This is to check for
possible operational problem that may be encountered during the
jacking procedure, e.g. leaks, binding etc.
¨ Position the jacking devices and recheck the contact surfaces. Ensure the
surface below where the jacking is to take place will be able to support the
weight of the machine when it is concentrated at these points.
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NOTE:
Use the jacking device/s only on a hard flat level surface and only to lift vertically.
Examples of hard surfaces are concrete or steel but NOT asphalt.
Do not overload or exceed the maximum allowable height.
Do not exceed the working pressure of the connected cylinders or other

connected devices.
¨ Position the supporting devices in readiness and as close to the support

contact area as practical. If the support device is adjustable, adjust to the
approximate height or a height that will require minimum adjustment once
the machine is lifted high enough to be supported.
NOTE:
Use the supporting device/s only on a hard flat level surface. Example of hard
surfaces are concrete or steel but NOT asphalt.
Never exceed the safe working limit of the support device.
If the device is adjustable use only the locking mechanism designed for the unit/s
Do not exceed the maximum allowable height for unit/s.
¨ Ensure the immediate area is clear of all personnel.

¨ Allow for machine pivot points during raising, e.g. rippers, blades, buckets
and other implements to be neutralised or raised for clearance.
¨ Locate jack controls to maximise vision and safety.
¨ Steadily raise the machine to the required height while continually checking
the machine stability.
NOTE:
If the jacking contact surface begins to distort while jacking, stop jacking
immediately, lower the machine and reposition the jacking device/s to a more
appropriate position.
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¨ When the machine is at the required height, lock the jacking device/s if
equipped with a locking mechanism. For jacking device/s which do not have
a lock mechanism, ensure the jack will not retract unexpectedly, e.g. return
valves closed or control valves in the hold position if equipped.
¨ If any personnel is required to work under the machine, which is supported
by the jacking device only, to position or adjust the support device/s, the
following precautions should be followed:
− Only one person should be working beneath the machine at any
time and that person should plan beforehand an exit path – or the
person should have enough clearance under the machine in case of
emergency, e.g. the machine shifts its weight or the jacking device/s
start to collapse.
− An observer must be present at all times at or near the controls of the
jacking device/s. The observer’s responsibility is to:
• observe the stability of the machine at all times.
• warn the person venturing under the machine of any impending
danger.
• assist in any emergency which may arise that may trap and/or injure
the person underneath the machine.
¨ If more than one lift is required, ensure the supporting devices are properly
supporting the machine during the intermediate steps.
¨ Once the supporting devices are in position, ensure the immediate area is
then cleared of all personnel. Lower the machine slowly onto the support
device/s. If you are using jack/lift stand and are leaving them in place to
support the machine while it is being serviced, ensure the locking devices
are engaged.
¨ Retract the jacks to ensure they are not hydraulically supporting any weight.
Remove the lifting devices.
¨ Lower support implements and or attachments.
¨ Store the lifting devices.
WARNING:
Always remember: If a procedure, tool, device or work method not specifically
recommended by Caterpillar is used, you must satisfy yourself that it is safe for
you and others.
NOTE:
You should also ensure the machine will not be damaged or made unsafe by the
procedures you choose.
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2 Jacks and Lift Stands
Topic

Hydraulic Jack................................................................................................................................................................. 24
Guard Jack............................................................................................................................................................................ 26
Jack Stands/Lift Stands...................................................................................................................................... 27
Stands (General)............................................................................................................................................................. 30
Caterpillar Tube Stands........................................................................................................................................ 30
Wood Blocking. ............................................................................................................................................................... 35
Tractor Lift.............................................................................................................................................................................. 36
Wheel Stand........................................................................................................................................................................ 37

Hydraulic Jack
Figure 1 – Hydraulic Jack
A jack (Figure 1) is a lifting device which is placed under a machine or

component for this specific purpose. Whatever jack is chosen to make the lift,
you should make sure that it has been designed for this purpose and that the
load which is used to lift does not exceed the rated capacity of the jack. One
commonly used device for a jack is the hydraulic cylinder/ram.
Hydraulic jacks are made in many different forms and arrangements. On the
other hand, the principal components of hydraulic jacks are very similar.
A large plunger will push directly on the load or will engage a second mechanical
component of the jack, which will push the load. There is a long handle, which is
operated in an up and down movement. This handle causes a small plunger to
move. The small plunger moves oil to the bottom of the large plunger.
This movement of oil causes movement of the large plunger. For releasing oil
and consequently lowering the jack, a valve is located in a position to allow the
oil to drain out the bottom of the large plunger. This equipment is used to lift
heavy loads. Hydraulic jacks can be used to lift and hold a heavy vehicle while
jack stands or wood blocking is installed. A hydraulic jack can be used to push
any two items away from each other.
For this application there first must be enough room to install the jack between
the two items. The jack is put into position so that one end will be on a solid
support and the other will push against the load. The jack handle is operated to
move the large plunger and the load. To release pressure caused by the jack,
a valve must be opened. This valve will release the oil in the jack and the large
plunger will retract to the normal position.
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Maintenance
Keep clean. Remove outside dirt and oil. Inspect all of the components regularly
to make sure they are in good condition. Follow the maintenance instructions for
the specific jack used. Maintenance must include checks for correct oil levels
and the release of air from the hydraulic system.
Rated Capacity
The rated capacity of the hydraulic cylinder/rams may be found by manufacturers
markings or a decal on the unit itself. Capacity of Caterpillar hydraulic cylinder/
ram may also be found via the:
¨ Tool Operating Manual
¨ Special Instructions
¨ Listing in the Caterpillar Tools & Shop Product Guide
¨ Ordering the proper pressure-force conversion decal for that particular
hydraulic cylinder/ram.
Figure 2 – Jack Example. The 8S7650 hydraulic cylinder set up in a base assembly.
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Guard Jack
Figure 3 – Guard Jack
The guard jack (Figure 3) is a type of hydraulic jack. An example of the guard
jack is the 5P3050 Jack Group. There are upper supports that form the jack
table. The forward end of the jack table has two vertical supports. These
supports hold the forward end of the crankcase guard.
There is a hook and bolt at the top of both of these supports to fasten the
crankcase guard to the jack table. The rear of the jack table has one screw
support for the crankcase guard. Two hydraulic cylinders move the jack table up
and down. The forward end of the guard jack has a lever type handle to operate
the hydraulic cylinders.
The bottom assembly is fitted with wheels so that the guard jack can be moved
easily. This equipment is used to hold crankcase and transmission guards during
removal and installation. To remove a crankcase guard, one bolt is removed from
the same position on each side. These bolts will be in the second position from
the higher end.
Turn the remainder of the bolts until the crankcase guard is lowered about 38mm
from the normal position. Put the guard jack into position under the crankcase
guard. Raise the jack table and adjust the vertical supports. Put the vertical
support hooks between the crankcase guard and the frame of the vehicle.
Engage the empty bolt holes with the bolts on the vertical supports. Hold the
vertical supports in position with lock pins. Adjust the rear support screw.
Remove the remainder of bolts. Lower the jack table and the crankcase guard.
Check the length of the crankcase guard bolts one at a time before removal of
the crankcase guard. If the bolts are not a minimum of 100mm, install longer
replacement bolts.
Make sure the bolts are long enough so that they will hold the crankcase guard
until the guard jack solidly holds it. After the guard is removed from the vehicle,
keep the guard in the lowered position.
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Maintenance
Keep clean. Remove outside dirt and oil. Inspect all of the components regularly
to make sure they are in good condition. The hydraulics of the guard jack must
be correctly adjusted.
Jack Stands/Lift Stands
Figure 4 – Example of Lift Stands
Figure 5 – Example of Jack Stands

Jack stands are strong vertical supports, which can be adjusted to different
heights. There are two primary components of a jack stand. The first is the
bottom assembly (base). The base is used as a solid support against the ground
or shop floor. The second component is a straight vertical support (tube). The
tube is held vertical and at a specific height by the base. To the top of the tube
can be added a fixture (saddle) to give better contact between the tube and
the vehicle. Jack stands are available in a range of heights from approximately
300mm to 2130mm.
The maximum capacity will range up to 18 tons. The maximum capacity for a
specific jack stand can be found on the jack stand base. Each hydraulic jack
has a maximum rated capacity. Do not use a hydraulic jack to lift more than the
maximum capacity for that specific jack.
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Never work under a load that is held by a hydraulic jack. Use jack stands or
wood blocking to hold a load while work is done. This equipment is used as a
support for heavy loads. A common application is to hold a vehicle after a jack is
used to lift it. A vehicle held up on jack stands has undercarriage components,
tyres and many other items available for removal and installation. In normal
applications, a jack is used to lift a vehicle. Jack stands are then put into position
under the vehicle body.
The serviceman will lift the jack stand tubes to a position as near as possible to
the bottom of the vehicle body. A lock pin assembly then holds the tubes in that
position in the jack stand base. The jack is then lowered until the vehicle is held
by the jack stands. The vehicle is now ready to be worked on. The Stand, Collar
and Hydraulic Cylinder can be used to both lift and hold a vehicle.
Never work under a load that is held only by jacks. Put jack stands under the
load and lower the load until all of the weight is held by the jack stands. Make
sure the load is held solidly on the jack stand tube or saddle. All lock fixtures
must be in position on the jack stand before a load is put on it.
Maintenance
Keep clean. Remove all dirt and oil. Inspect all of the components of the jack
stand regularly to make sure they are in good condition. Do not use jack stands
that have cracks or components that are broken.
Jack Stands and Lift Stands are designed to combine the function of a jack
(lifting device) and a stand (supporting device).
Caterpillar now uses the term Lift Stand to describe their current range of jack
stands instead of the former term Jack Stand.
Lifting is accomplished by pressurising a single acting, spring return hydraulic

cylinder.
A locking device, consisting of a threaded ring on a threaded cylindrical tube, in

the case of the current Caterpillar Lift Stands or single or double pins through
the tube or column extension of the Jack Stands, is used to support the load
(e.g. a machine) when it has been raised to the desired position.
NOTE:
Ensure the pressure of the hydraulic cylinder is released after the locking device
is in place.
Special piloted extension tubes, in the case of the Lift Stands, or different
extension tubes/assemblies for the Jack Stands can be used to extend the
height of these lift stands.
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Always refer to tool operating manual or special instructions for how these Lift
Stands and Jack Stands are to be used correctly and the type of hydraulic pump
to be used.
Lift Stands and Jack Stands are to be used in pairs unless otherwise specified in
the Service Manual. If you need to use only one lift stand, remember safety.
NOTE:
If a procedure, tool, device or work method not specifically recommended by
Caterpillar is used, you must satisfy yourself that it is safe for you and others.
You should also ensure the machine will not be damaged or made unsafe by the
procedures you choose.
WARNING:
Use lift stands and jack stands on flat, level and hard surfaces only to lift
vertically. Examples of hard surfaces are concrete or steel plate but NOT asphalt.
Do not overload or exceed the maximum allowable height. Do not exceed working
pressure of the connected cylinders or other connected devices.
Failure to heed to these warnings can result in damage to the stands, or possible
personal injury or death.
SPECIAL NOTE:
Caterpillar does not recommend the use of jack stands/lift stands unless they are
specifically approved by the Caterpillar Service Technology Group.
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Stands (General)
Always refer to the machine’s service publications for the selection of
appropriate stands to be used to support the machine or its implements.
IMPORTANT NOTES:
Use only certified or approved stands in which:
– The maximum load or capacity is specified by the manufacturer of the stand

or
– The stand has a maximum load or capacity which has been approved by the
State Mining Engineer.
WARNING:
Never exceed the safe working load of the support device.
¨ Use the supporting device/s only on a hard flat level surface. Example of
hard surfaces are concrete or steel but NOT asphalt.
¨ If the device is adjustable use only the locking mechanism designed for the
unit/s.
¨ Do not exceed the maximum allowable height for unit/s.
Caterpillar Tube Stands
Figure 6 – Typical stand, tube and pin combination
The most common type of stand (support device) which will be available for your
use is Caterpillar’s range of manufactured tube stands.
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A full list of the range of the tubes, stands, accessories and associated jacking
devices for these tube stands, can be found in the Caterpillar Tools and Shops
Product Guide or in the Caterpillar and Shops Product Guide.
SPECIAL NOTE:
All stands are rated in US tons. 1 US ton = 2000 pounds.
Unfortunately at present there is no Tool Operating Manual or Special

Instructions for these Caterpillar Tube Stands.
Even though assembly and use of these stands seems straight forward and
obvious, there are several important points you must be aware of before
selecting the stands to use.
¨ Never exceed the stand capacity or Safe Working Load (SWL) of the stand.
(Refer to the warning decal on the stand).
¨ Always use the correct pin (Refer to the warning decal on the stand).
¨ Do not drop the load on the stand (Refer to the warning decal on the stand).
¨ Do not extend the bottom hole in tube above the top hole of stand
(refer to the warning decal on the stand).
¨ Keep fingers out of the holes (refer to the warning decal on the stand and
the warning stamp on the top of every tube).
¨ Stand clear of load when raising and lowering (refer to the warning decal on
the stand and in the general procedures section of this handbook).
¨ Always use thick walled tubes in preference to thin walled tubes unless the
weight being supported is well below the capacity of the stand (refer to the
information presented in this section of the hand book).
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Types of Caterpillar Tube Stands
Figure 7 – Small Stand Base 8S7630
Figure 8 – Large Stand Base (Old Style) 8S7640
Figure 9 – Large Stand Base (New Style) 4C6486
There are three types of tube stand bases in the Caterpillar range: one small
and two different large stand bases. The older style of large stand base being
currently used is no longer available and is now replaced by the newer style
of large stand base which has a larger capacity and uses a different style of
locking pin.
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Stand Capacities
¨ The stand capacity or Safe Working Load (SWL) of the stand is indicated on
the warning decal.
¨ The stand capacity for the small stand base 8S7630 and the large stand
base (old style) 8S7640 is:
− 10 Tons SWL (Painted Blue)
− New Warning Decal Fitted.
NOTE:
Use only the 8S7615 pin as indicated on the warning decal.
¨ The stand capacity for the large stand base (new style) 4C6486 is:
− 25 tons to 48 inch height
− 18 tons above 48 inch height.
Figure 10 – Different Stand Pins:

(4C6562) New Style Large Stand Base
(8S7615) Small and Old Style Large Stand Base
NOTE:
Use only the dual 4C6562 pin as indicated on the warning decal.
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Tube Thickness
Figure 11 – Thin and Thick Walled Tubes

There are four different lengths of tubes available for use in conjunction with the
stand bases.
Thickness of the tubes for each of these range from 0.5 inch (12.7mm) (Figure
11)
Thick Walled Tube to 0.25 inch (6.35mm)
Thin Walled Tube for the first three tubes in the range –8S7611, 8S7621, 8S7631.
For the tallest tube in the range the thickness varies from 0.375 inch (9.5 mm)
Thick Walled Tube to 0.25 inch (6.35 mm)
Thin Walled Tube –8S7641.
NOTE:
There is no service information on why the wall thickness has changed and when
this had occurred.
The part number for the different thickness of each length of tube has not
changed.
SPECIAL NOTES:
The rated capacity for the different thicknesses of the tube is the same.
This rating is the same as the rating of stand base in which it is to be used.
Always use thick walled tubes in preference to thin walled tubes unless the weight
being supported is well below the capacity of the stand.
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The warning decal on the stand must be legible. (Replace any warning decal
that cannot be easily read).
Wood Blocking
Figure 12 – Wood Blocking
Wood blocking (Figure 12) is made of short wood blocks. A cross section of
wood blocking generally has equal sides opposite each other. Typical sides
measure between 100mm and 200mm. A common length for wood blocking is
in the range from 460mm to 910mm. Wood blocking can be cut to any size to fit
special applications.
Use caution with wood blocking since maximum load factors are not known.
This equipment is used as a support for heavy loads. Wood blocking is best
used as a spacer. When a load is held on wood blocking, space to remove
lifting equipment or to move with a lift truck is provided. Wood blocking must be
inspected before it is used.
Do not use wood blocking that has cracks or deep cuts. Wood blocking must be
put into a position so that the long sides of the blocks are parallel to the contact
between the wood blocking and the load.
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Tractor Lift
Figure 13 – Tractor Lift
An example of the tractor lift is shown in Figure 13. Each tractor lift has three
sides with a steel plate brace in the middle. Of the three sides, one is straight,
one has an inside curve, and one has an outside curve. The capacity of each lift
is 27 tonnes. The lift height is 460mm.
This equipment is used to lift track-type vehicles. The tractor lift uses the track
movement to give the force to lift the tractor. The inside curve side of the tractor
lift is put against the track at the rear of the vehicle. The edge where the inside
curve and straight sides come together must be held below a grouser bar
(extension on the outside of the track). The operator causes the track to move
slowly in a reverse direction. This will lift the rear of the vehicle.
The track must be stopped before the tractor lift is in a position below the roller
frame. The rear jack stands are then put into position. Now the same procedure
can be done at the forward end of the vehicle. Two men can lift, and hold with
jack stands, any track-type vehicle in three to five minutes with tractor lifts.
Inspect the tractor lifts before each use to make sure they are in good condition.
Use two people when tractor lifts are used to lift a vehicle. One person must put
the tractor lifts into position while the other operates the vehicle. Keep personnel
away from the ends of the vehicle while tractor lifts are used. The 9S27 Lift
Assembly is made of special steel and heat treated.
Maintenance
Keep clean. Remove dirt and oil. Remove rust, inspect and give an application of
paint at regular intervals.
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Wheel Stand
Figure 14 – Wheel Stand (Lift Truck)
Lift one end of a lift truck with a hydraulic jack. Put the lift truck wheel stands
into position under the two high wheels. Lower the jack until the wheels are held
solidly on the wheel stands. These stands are made of steel plate. The sides
and bottom of this wheel stand are flat. The top has a curve, which makes the
ends higher than the middle. This shape will not let the lift truck wheels turn
(roll).
The maximum capacity of these stands is 4500kg. This equipment is used as

a support for lift trucks. When a lift truck is put on wheel stands, the underside
becomes available for work. To put a lift truck on wheel stands, lift one end of
the lift truck with a hydraulic jack. Put two wheel stands below the high wheels.
Lower the lift truck on to the wheel stands.
This same procedure can now be used on the other end of the lift truck. Make
sure that the lift truck wheels are held solidly on the centre of the wheel stands.
Do not hold a lift truck with a jack while it is on wheel stands.
Maintenance
Keep clean. Remove all dirt and oil, inspect wheel stands before each use. Do
not use a wheel stand that has cracks or is badly bent.
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3 Jacking and Blocking
Topic
Caterpillar Machines

Wheel Loader. ................................................................................................................................................................... 40
Track Type Tractor....................................................................................................................................................... 50
Motor Grader...................................................................................................................................................................... 52
Off Highway Truck....................................................................................................................................................... 62
Wheel Tractor Scrapers...................................................................................................................................... 68

Wheel Loader
Steering Frame Lock Link
Figure 15 – Steering Frame Lock Link in the locked position (980F Wheel Loader)
WARNING:
There is no clearance for a person in the area between the front and rear frames
when any articulated machine is turned to either side.
When a machine is to be lifted, transported on another vehicle, or service work

is to be performed near the centre of the machine, connect the steering frame
lock link between the front and rear frames. This will keep the machine in a
straight ahead position. Before operating the machine, be sure the steering
frame lock link is disconnected, and put into the storage position.
Retainer pins, when struck with force, can fly out and injure nearby persons.
Make sure the area is clear of people when driving retainer pins.
Wear protective glasses when striking a retainer pin to avoid injury to your eyes.
Use only the steering frame lock link, pins and retainer pins designed for the
wheel loader you are working on.
The Steering Frame Lock Link is located in the articulation area of the wheel
loader.
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Chocking the Wheels of the Wheel Loader
Figure 16 – Chocking the Rear Wheels (938F Wheel Loader)
When the Wheel Loader is parked and personnel are on or around it place
chocks to prevent any forward or backwards movement.
Chocks can be placed at any of the following positions:

¨ At the front of the front tyres and at the rear of the rear tyres.
¨ At the front of the front tyres and at the rear of the front tyres.
¨ At the front of the rear tyres and at the rear of the rear tyres.
Place chocks only on one side of the Wheel Loader if only using one set of
chocks.
The bottom of the chocks must have full contact with the ground and the ramp of
the chock full contact with the tyre.
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Chocking the Oscillating Rear Axle
Figure 17 – Wedge Blocks in position (980G Wheel Loader)
WARNING:
The rear axle housing group is designed to oscillate. When raised off the ground
it can oscillate easily and may cause possible personal injury.
When service work is to be carried out which requires the rear or front of the
wheel loader to be raised off the ground, blocks must be inserted between the
rear axle housing and the rear frame on both sides.
This prevents any sudden unexpected movement of the machine when being
raised.
The wooden blocks must be a tight fit.
Do not raise the rear or front of the machine off the ground before inserting the
steering frame lock and chocking the tyres.
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Supporting the Implement Loader Frame
Figure 18 – Tube Stands Supporting the Implement
If the Implement Loader Frame is raised in the air while personnel are working
under or on it, it must be supported.
The Implement Loader Frame can be supported by placing tube stands fitted
with saddles under the main lift arms and lowering the weight of the lift arms and
bucket onto the tube stands.
Ensure the lift arms have complete contact with the saddles.
WARNING:
Do not support the implement loader frame by placing the tube stands only under
the bucket. Supports must be under the loader frame.
Ensure the bucket is tilted all the way forward after the implement loader frame
is placed on stands.
If the wheel loader is inoperable refer to Service Tip: Use caution when
hydraulically operated implements must be lifted with a hoist while the engine is
stopped.
Placing the Front Frame on Stands

The following procedures must be carried out before you attempt to raise the
front of the Wheel Loader off the ground.
Insert the steering frame lock link refer to Steering Frame Lock Link.
Chocking of the rear wheels refer to Chocking the wheels of the Wheel Loader.
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To chock the oscillating rear axle refer to: Chocking of the rear axle housing to
the rear frame.
Remember: After the Wheel Loader has been placed on stands to support the
implement loader frame refer to Supporting the Implement Loader Frame.
If the engine is inoperable refer to Service Tip: Use caution when hydraulically
operated implements must be lifted with a hoist while the engine is stopped.
Raising the front of the Wheel Loader off the ground and supporting it can be
done by one of the following methods:
Raising Method
Figure 19 – Raising the front by using hydraulic jacks (980F Wheel Loader)
¨ Placing jacks under the front frame on the flat surfaces in front of the
articulation area.
Figure 20 – Raising the front by jacking on the differential

housing (990D Wheel Loader)
¨ Placing jacks under the front frame on the flat surfaces just behind the front
axle housing.
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Supporting Method
Figure 21 – Stands supporting the front (980G Wheel Loader)
¨ Placing stands under the front frame on the flat surfaces in front of the
articulation area.
Figure 22 – Stands supporting the front (938F Wheel Loader)
¨ Placing stands under the front frame on the flat surfaces just behind the
front axle housing.
IMPORTANT NOTES:
Ensure the Wheel Loader weight doesn’t exceed the Safe Working Limit of the
lifting device or stand.
When placing jacks or stands under the front frame ensure that it is not hollow
and if possible position jack or stand where the frame members intersect at right
angles.
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Placing the Rear Frame on Stands

The following procedures must be carried out before you attempt to place the
rear frame of the wheel loader on stands.
Insert the steering frame lock link refer to: Steering Frame Lock Link.
Chocking of the front wheels refer to: Chocking the Wheels of the Wheel Loader.
Chock the oscillating rear axle refer to: Chocking the Oscillating Rear Axle.
NOTE:
During the process of lifting the rear frame of the wheel loader, the bucket or
implement loader frame must not come into contact with the ground or any other
body.
If this occurs the wheel loader will pivot from the bucket and not the front tyres
and you will be lifting the weight of the whole machine. If the engine is inoperable
refer to Service Tip: Use caution when hydraulically operated implements must be
lifted with a hoist while the engine is stopped.
Raising the rear of the Wheel Loader off the ground can be done by using the
following methods:
Raising Method
Figure 23 – Raising the rear by jacking under the rear axle housing
(980F Wheel Loader)
¨ Placing jacks under the axle housing (Figure 23).
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Figure 24 – Using Jack Stands:

Raising the rear by jacking under the machine in line with the
chassis frame rails (980F Wheel Loader)
Figure 25 – Using Lift Stands:

chassis frame rails (980G Wheel Loader)
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Figure 26 – Using Hydraulic Jacks:

chassis frame rails (916E Wheel Loader)
¨ Placing jacks under the machine in line with the rear chassis frame rails, see
Figure 24, Figure 25 and Figure 26.
Supporting Method
Figure 27 – Stands in position under the rear axle housing (980G Wheel Loader)
¨ Placing stands under the rear axle housing (Figure 27).
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Figure 28 – Stands in position under the rear

chassis rails (938F Wheel Loader)
Figure 29 – Stands in position under the rear

chassis rails (916E Wheel Loader)
¨ Placing stands under the rear chassis rails (Figure 28 and Figure 29).
IMPORTANT NOTES:
Ensure the Wheel Loader weight doesn’t exceed the Safe Working Limit of the
jacks and the stands used.
Do not jack directly under the counter weight.
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Track Type Tractor

Placing the Tractor on Stands
Figure 30 – Stands supporting the tractor (D9R Track Type Tractor)
The following methods can be used to raise both the front and the rear of the
Tractor off the ground.
Raising Methods
¨ Refer to the method which is recommend in the machine's service manual.
¨ Using the machine's hydraulics implements (blade and ripper).
Supporting Method
¨ Place tube stands evenly apart, under the front and the rear of the Tractor.
IMPORTANT NOTES:
Ensure the weight of the Tractor does not exceed the Safe Working Limit of the
stands or the jacks in use.
Ensure that where the jacks and stands are placed under the tractor it is not
hollow casing or an unsupported plate, and will not cause damage to the tractor.
If the tractor is inoperable refer to Service Tip: Use caution when hydraulically
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Supporting the Blade
Figure 31 – Stands Supporting the Blade (D9R Track Type Tractor)
If the blade is to be left in the raised position while personnel are around, under
or on it, it must be supported.
Supporting the blade is done by placing stands under the draft arms.
IMPORTANT NOTES:
Ensure the weight of the blade does not exceed the Safe Working Limit of the
stands.
If the tractor is inoperable and the bulldozer assembly cannot be hydraulically

lifted, refer to Service Tip: Use caution when hydraulically operated implements
must be lifted with a hoist while the engine is stopped.
Supporting the Ripper

If the ripper assembly is left in the raised position while personnel are around,
under or on it, it must be supported.
Supporting the ripper assembly is done by:

¨ Placing tube stands under the tool bar and under the ripper frame assembly
if equipped with both ripper lift and ripper tilt cylinders.
¨ Placing tube stands under the tool bar if only equipped with ripper lift
cylinders.
Ensure the tool bar is level and the stands are evenly spaced.
IMPORTANT NOTES:
Ensure the weight of the ripper assembly does not exceed the Safe Working Limit
of the stands or the jacks in use.
If the tractor is inoperable refer to Service Tip: Use caution when hydraulically
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Motor Grader
Frame Lock Pin
Figure 32 – Stored Position
Figure 33 – Locking the Articulation
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Figure 34 – Locked Position
WARNING:
There is no clearance for a person in the area between the front and rear frames
when the machine is being articulated to either side.
Secure the frame lock pin in the locked position before lifting, transporting on
another vehicle, or service work is to be preformed near the pivot area. This will
keep the machine in the straight ahead position. Before operating the machine,
be sure the frame lock pin is removed and put into the storage position.
Retainer pins, when struck with force, can fly out and injure nearby persons.
Use only the frame lock pin designed for the grader you are working on.
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Wheel Lean Pin
Figure 35 – Wheel Lean Pin in the Locked Position (140H Grader)
NOTE:
When the front tyres are not in the vertical position (wheel lean activated) the
stability of the Motor Grader has decreased.
Install the wheel lean pin in the lock position before lifting, transporting on
another vehicle, or service work is to be performed near the front axle assembly.
Retainer pins when struck with force, can fly out and injure nearby persons.
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Chocking the Wheels of the Motor Grader
Figure 36 – Chocking of the front wheels
Figure 37 – Chocking of the rear wheels

(140H Grader)
When the Motor Grader is parked and personnel are on or around the Motor
Grader place chocks to prevent any forward or backwards movement.

¨ At the front of the front tyres and at the rear of the rear tandem tyres.
¨ At the front of the front tyre and at the rear of the front tandem tyres.
¨ At the front of the front tandem tyres and at the rear of the front tandem
tyres.
¨ At the front of the front tandem tyres and at the rear of the rear tandem
tyres.
¨ At the front of the rear tandem tyres and at the rear of the rear tandem tyres.
Place chocks only on one side of the Motor Grader if only using one set of
chocks.
The chocks must have full contact with the ground surface and with the tyre
surface.
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Placing The Front Frame On Stands

The following procedures must be carried out before any attempt is made to
raise the Motor Grader off the ground.
Insert the frame lock pin, refer to Frame Lock Pin.
Insert the wheel lean pin, refer to Wheel Lean Pin.
Insert wedge blocks between the front axle and the front frame to prevent the
front axle from oscillating when the front of the Motor Grader is raised off the
ground. This prevents any sudden unexpected movement of the machine.
Remember:
If the front is being raised, ensure the ripper assembly does not come in contact
with the ground or any other object. If this occurs the Motor Grader will not pivot
from the rear tyres and you will have the weight of the machine pivoting on the
ripper.
Ensure the ripper and blade are placed back on the ground or supported by a
stand after the lift is made.
If the Motor Grader is inoperable, refer to Service Tip: Use caution when
stopped.
Raising and supporting the front of the Motor Grader off the ground can be done
by one of the following methods:
Raising Methods
Figure 38 – Raising the Front (140H Grader)
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¨ Placing a jack under the front axle mount but not on the front counter
weight.
Figure 39 – Raising the front by jacking under

the front of the draw bar (140H Grader)
¨ Placing a jack under the front of the draw bar.
Supporting Methods
Figure 40 – Stands supporting the front (140H Grader)
¨ Placing tube stands under the front axle.

¨ If using Caterpillar lift stands wind the lock ring down and release the
pressure on the jack.
IMPORTANT NOTE:
Ensure the Motor Grader weight doesn’t exceed the Safe Working Limit of the
stands and jack/s being used.
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Placing the Rear Frame on Stands

The following procedures must be carried out before making any attempt to raise
the rear of the Motor Grader off the ground.
1. Insert the frame lock pin, refer to: Frame Lock Pin.
2. Insert the wheel lean pin, refer to: Wheel Lean Pin.
3. Insert wedge blocks between the front axle and the front frame to prevent the
Motor Grader from oscillating on the front axle mount.
This prevents any sudden movement of the machine.
Raising the rear of the Motor Grader off the ground can be done by the following
methods:
Raising Method
Figure 41 – Jacking the rear (140H Grader)
¨ Jacks placed under the ripper support, in line with the rear frame rails.
¨ Using the machine hydraulic implements, e.g. ripper.
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Supporting Method
Figure 42 – Stands supporting the rear (140H Grader)
¨ Placing tube stands under the main frame.
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Figure 43 – Stands supporting the rear (140G Grader)
¨ Placing tube stands under the rear frame rails.

¨ Placing tube stands under the tandem housing (4 stands required).
IMPORTANT NOTES:
When the rear of the Motor Grader is raised off the ground the tandem housing
can oscillate.
Ensure the weight of the motor grader does not exceed the Safe Working Limit of
the stands and the lifting devices.
If using Caterpillar lift stands and they are left in place to support the machine,
wind the lock ring down and release the pressure on the hydraulic cylinder.
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Supporting the Draw Bar and Mouldboard
Figure 44 – Stands supporting the draw bar and mouldboard (140H Grader)
If the draw bar and mouldboard are to be left in the raised position while
personnel are around, under or on it, it must be supported.
Supporting the draw bar and mouldboard could be done by placing tube stands
under the front of the circle, or the draw bar, and a tube stand with a saddle
under the tilt cylinder at the rear.
Ensure the circle or the draw bar has complete contact with the stands.
If the Motor Grader is inoperable refer to Service Tip: Use caution when
stopped.
Supporting the Ripper
Figure 45 – Stands supporting the ripper (16H Grader)
If the ripper assembly is to be left in the raised position while personnel are
around, under or on it, it must be supported.
Supporting the ripper is done by placing stands under the tool bar of the ripper
assembly.
Ensure the tool bar is level and the stands are evenly spaced apart.
If the Motor Grader is inoperable refer to Service Tip: Use caution when
stopped.
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Off Highway Truck

Chocking the Wheels of the Off Highway Truck
Figure 46 – Chocking the rear tyres (777D OHT)
When the Off Highway Truck is parked and personnel are on or around it place
chocks to prevent any forward or backwards movement.

¨ At the front of the front tyres and at the rear of the rear tyres.
Chocks must be on one side of the Off Highway Truck.
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Supporting the Tray

If the tray is to be placed in the raised position while personnel work around or
under the tray, it must be supported.
Supporting the tray can be done by:
Figure 47
Pull rod (1) and

remove body
safety pin (2) from
storage
Move the body to

an up position
Put body safety pin

(2) in position as
shown
Figure 47 – Supporting the tray (777C Off Highway Truck)
1. Installing the body safety pins in the holes of the rear frame and into the
brackets of the tray body.
Figure 48 – Supporting the tray (785B Off Highway Truck)
2. Attaching the wire tray cable from the tray to the rear frame of the truck.
IMPORTANT NOTES:
Use only the pins and cables designed for the truck you are working on.
Ensure all the components are in good condition and that they are stored in the
correct position during and after the procedure of supporting the tray.
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Placing the Front on Stands

The following procedures must be carried out before the rear of the truck can be
placed on stands.
¨ Chock the rear wheels.
¨ Ensure the tray is completely down.
¨ If the front is to be lifted with the body up, ensure the body retaining pins or
the wire cable is in place. Refer to Supporting the Tray.
Raising Method:
Figure 49 – Raising the front by jacking under

the main front cross member (777D OHT)
Raising the front of the truck can be done by:

¨ Place a pair of Caterpillar jack/lift stands evenly apart under the main front
cross-member on the flats.
Supporting Method
¨ If using Caterpillar jack/lift stands under the main front cross-member wind
the lock ring down and release the pressure on the jacks.
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Raising Method
Figure 50 – Raising the front by jacking under the

front towing hooks (777D OHT)
¨ Place a pair of Caterpillar lift stands under the front towing hooks.
Supporting Method
Figure 51 – Stands supporting the front (777D OHT)
¨ Place a pair of stands evenly apart under the main front cross-member on
the flats.
IMPORTANT NOTES:
Ensure the Off Highway Truck’s weight doesn’t exceed the Safe Working Limit of
the stands and jacks being used.
WARNING:
Before commencement of any work around the front of the truck ensure that both
of the front suspension cylinders are not hung up. There should be approximately
345mm of visible chrome showing between the seal and the top of the stub axle
forging.
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Figure 52 – Front suspension strut
Placing the Rear on Stands

The following procedures must be carried out before the rear of the truck can be
placed on stands.
¨ Chock the front wheels.
¨ Ensure the tray is completely down.
¨ If the rear is to be lifted with the body up, ensure the body retaining pins or
the wire cable is in place (refer to Supporting the Tray).
Raising the rear of the Truck can be done by:
Raising Method
¨ Place a pair of Caterpillar jack/lift stands evenly apart under the rear axle
housing in a suitable position where the stands will have a maximum contact
area with the housing.
Supporting Method
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Raising Method (777 OHT or smaller)
Figure 53 – Raising the rear by jacking under the rear axle

housing (777D OHT)
¨ Placing a single jack under the centre of the rear axle housing at a suitable
position where the jack has maximum contact area with the housing.
Supporting Method
Figure 54 – Stands supporting the rear (777D OHT)
¨ Place two stands evenly apart under the rear axle housing in a suitable
position where the stands will have maximum contact area with the housing.
IMPORTANT NOTE:
Ensure the Off Highway Truck’s weight doesn’t exceed the Safe Working Limit of
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Wheel Tractor Scrapers

Chocking the Wheels of the Tractor Scraper
Figure 55 – Chocking the front tyres (621B Tractor Scraper)
When the Tractor Scraper is parked and personnel are on or around the Tractor
Scraper place chocks to prevent any forward or backwards movement.

¨ At the front of the front tyres and at the rear of the rear tyres
¨ At the front of the front tyres and at the rear of the front tyres
Chocks must be on one side of the Tractor Scraper.
Placing the Front on Stands
WARNING:
Actuation of the cushion-hitch or steering control can cause movement in the
hitch area, reducing clearances suddenly. Personal injury or death can result from
hitch movement if a person is in the hitch area.
The following procedures must be carried out before the front of the tractor
scraper can be placed on stands.
¨ Chock the rear wheels
¨ Ensure the bowl is completely down
¨ Ensure the cushion-hitch is lowered completely
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¨ Ensure that two jacks are always used to lift the front.
Raising Method
Figure 56 – Raising the front (621B Tractor Scraper)
Raising the front of the Tractor Scraper can be done by:

¨ Placing two jacks evenly apart under the front bumper or push block in line
with the chassis rails.
Supporting Method
Figure 57 – Supporting the front (621B Tractor Scraper)
¨ Using two tube stands under the front chassis rails.

pressure on the jacks.
IMPORTANT NOTE:
Ensure that the Tractor Scraper’s weight doesn’t exceed the Safe Working Limit of
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Placing the Rear on Stands

The following procedures must be carried out before the rear of the tractor
scraper can be placed on stands.
¨ Chock the front wheels
¨ Ensure the bowl is completely down
¨ Ensure the cushion-hitch is lowered completely.
Raising Method
Figure 58 – Raising and supporting the rear (621B Tractor Scraper)
Raising the rear of the Tractor Scraper can be done by:

¨ Placing a single jack under the centre of the push block at a suitable
position where the jack has maximum contact area with the block.
¨ Placing two jacks evenly apart under the push block or under the rear
chassis rails at suitable positions where the jacks have maximum contact
area.
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Supporting Method
Figure 59 – Supporting the rear (627E Tractor Scraper)
¨ Using two tube stands under the rear chassis rails.

¨ If using Caterpillar jack stand/s wind the lock ring down and release the
IMPORTANT NOTE:
Ensure the Tractor Scraper’s weight doesn’t exceed the Safe Working Limit of the
stands and jacks being used.
Supporting the Bowl

1. Raise the bowl and place suitable stands under it.
2. Lower the bowl carefully onto the stands.
Do not support the bowl any higher than necessary to remove the cutting
edge or router bits.
WARNING:
Personal injury or death can result if the bowl is not supported before changing
the cutting edge or router bits.
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4 Lifting Methods and Equipment
Topic

Synthetic Fibre Slings. ........................................................................................................................................... 83
Slinging Theory............................................................................................................................................................... 89
Hook Gauge.......................................................................................................................................................................109
Single Sling........................................................................................................................................................................109
Shackles................................................................................................................................................................................ 110
Lift and Block..................................................................................................................................................................121
Fibre and Nylon Rope...........................................................................................................................................123
Load Positioning Sling........................................................................................................................................124
Barrel Grip. .........................................................................................................................................................................125
Chain Hoist.........................................................................................................................................................................126
Electric Hoist...................................................................................................................................................................127
Ratchet Hoist...................................................................................................................................................................128
Dual Hook Hoist...........................................................................................................................................................129
Block and Tackle........................................................................................................................................................131

Chains
Introduction
Throughout recorded history, chains have been fashioned for many purposes
– gold and silver chains for ornamental reasons, bronze, iron and later steel
chains for lifting and hauling operations. The earliest example of a chain found is
thought to be approximately 3,000 years old.
Chain still serves in many ways and is used for such diverse purposes as ship
anchors, load binders, land clearing, animal hobbling and for decorative and
display purposes. The chains we are interested in are primarily for lifting and
haulage purposes.
To efficiently cope with this range of everyday use, chain makers have provided
us with a suitable variety of sizes, lengths and types. In an industry in which
materials are lifted or moved, modern chains will be encountered and the
following information is provided to ensure their safe and economical use.
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Manufacture and Identification
Manufacture
At the turn of the century, most chains in use for lifting or haulage work were
made of wrought iron. Today, these have almost entirely disappeared and have
been replaced by steel chains – Herc Alloy or Type ‘T’, which are made of the
same material.
Figure 60
The modern type is manufactured from steel, which are initially hot rolled into
rods. The rods are then cleaned, the links cold formed in automatic machines
and the link ends are electrically welded under close control. As such, these
chains have load bearing, fatigue and wear restraint characteristics far superior
to the earlier wrought iron chains.
Energy Absorption Factor

This factor is defined as the ultimate breaking load multiplied by the elongation
of the chain at the time of fracture, measured under certain test conditions.
This is a measure of the chain’s ability to withstand impact loads by stretching

rather than by ‘snapping like a carrot’. In the past, experience has shown
that wrought iron chains snap on a cold morning, due not only to the low
temperature, but also to the fact that the chain has work hardened over its period
of use.
To offset the resultant shortening of life from these effects, wrought iron chains
require periodic annealing, a process of heating and slow cooling in order to
toughen and reduce brittleness. This returns the energy absorption factor to a
reasonable level. More modern chains maintain their ability to stretch throughout
their life without the need for such periodic annealing treatment.
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Care of Chains
Heat Treatment
No type of chain may be heat treated by the user after delivery from the chain
manufacturer’s premises. Heat treatment of chains is a specialised process, only
to be undertaken with full knowledge of the material specifications for the chain
and only in very closely controlled furnace conditions. The manufacturers of
chains are usually the only agencies with the knowledge and equipment to carry
out this work properly.
Storage
Like any other product, chain can wear or be damaged during storage and in
handling prior to use. Chains should be carefully stored by hanging in a clean,
dry area. If carelessly thrown on the floor or into a box, chains will collect dust
and grit, which can cause damaging wear.
If chains are to be stored for lengthy periods, they should be oiled and allowed to
hang. In hanging these oiled chains, no part of the chain should touch the floor
and it is a good idea to provide a drip tray under the chains to collect any run off
oil. This method also provides convenient inspection facilities.
Cutting a Chain
It is strongly recommended when cutting chains that an abrasive wheel be
used. Should chain be cut with a flame, it is possible to adversely affect the heat
treatment of adjoining links, thus reducing chain performance and impairing safe
use of the chain. It is also possible that any spatter from the flame cut may stick
to the other links thus providing projections to further wear areas of the chain
away from the cut.
Inspection of Chains
All chains should be thoroughly inspected and tagged at least once every 12
months. All stored chains should be inspected immediately prior to use. Every
chain, whether attached to a piece of equipment as a hoisting chain, or used as
a sling, should be given a serial number, which can be stamped on a metal tag
attached to the end link or ring.
Register
¨ A register should be kept of each chain. This register should identify each
chain by its serial number and test certificate number, and recorded against
each chain should be such information as:
¨ Date of purchase (and for future reference – original order number)
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¨ Make of chain (and grade of steel)

¨ Safe Working Load
¨ Length of 5 links (when new, measured to inside of end links – within 1mm
accuracy)
¨ Any distinguishing marks on the chain which might be picked up at later
inspection (for reference).
Damage
The following are some types of damage commonly sustained by chains:
Figure 61
Elongation
Links that are stretched (Figure 61) indicate that the chain has been overloaded.
Unless this is of a very minor degree it is good reason to condemn the chain. No
more than 10% stretch is permitted.
If the chain register has recorded the length of 5 links when the chain was new,
an easy comparison is offered to the inspector.
Wear
Can be exhibited in two ways:
Figure 62
¨ External Wear (Figure 62) – caused by dragging chains along the ground
instead of carrying them to the job, or by dragging them out from under a
load.
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Figure 63
¨ Wear caused by use (Figure 63) – if the diameter of the chain material has
been reduced in any position by 10% or more, due to either external wear or
wear caused by use, condemn the chain immediately.
Figure 64
Deformed Links
A free hanging chain that is not perfectly straight is indicative of binding links
(Figure 64). Links will bind for several reasons (wear, stretching etc) but one of
the most common causes is deformed links. This can be caused by picking up
a load with chains pulled tight around sharp corners. If links bind, condemn the
chain immediately.
Chains that are badly overloaded may suffer permanent stretching or

deformation. A chain will become elongated or drawn in at the sides
(peanutting). If this occurs, the chain is to be condemned.
Cracks, Cuts
Use of a chain on unprotected sharp edges may cause a link to crack. Any
link that shows evidence of a crack should be removed from service for further
inspection. A suspect link may be soaked in thin oil and then wiped dry. A
coating of powered chalk is applied to the surface and allowed to remain there
for several hours. If a crack exists, the oil contained in the crack will be drawn
out and will noticeably discolour the white coating. Commercial crack detection
methods are better, if available.
The presence of a crack, however fine, is sufficient cause for removing the
chain from service. Gouges and cuts make the chain equally unsafe if the
material diameter has been reduced by 10% at any point. Take particular care in
examining sharp nicks and cuts, as it is in these spots that cracks usually start.
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General
If unsure about the condition of a chain, take it out of service and have the chain
inspected. Most reputable makers of chains provide this service and based on
their inspection can repair the chain and test the repaired article.
Safe Use of Chains

The following chart gives the maximum Safe Working Load (SWL) for Herc-Alloy
Chains (Grade ‘T’) in tonnes (1 tonne = 1000kg).
Figure 65
The loads listed are suitable for normal use. For rough use, or where impact
loads may be encountered, the SWL for any given size of chain should be
reduced by one-fifth (20%).
The principle features that require consideration in the selection of a chain are:
1. The load (mass) to be lifted.

2. The nature of duty i.e. light to moderate or heavy duty.
3. The manner of attaching the load i.e. by direct means (hooking on), by encircling
the load and back hooking etc.
4 The effects of any divergent angle which may exist between the legs of a multi-
legged sling.
The load chart above sets out the SWL of various sizes of Herc-Alloy chains
where duties are light to moderate. Where the duty can be considered to be
arduous to heavy, the next larger size of chain is to be used.
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Compensation for the manner of attachment of a sling to its load (item 3 above)
is often overlooked in the every day use of a chain. The local increase in stress
induced in the chain by passing it over a hook or reeving it around itself or
around corners of a load can be considerable, as shown by the chart above.
In the case of item 4 above, it must be recognised that the SWL of multi-leg
slings decreases as the angle between the legs increases.
For example, if we use a 10mm (⅜”) Herc-Alloy chain with a SWL of 3.2 tonnes
for each leg and try to lift a load using 2 legs at 600 included angle, the SWL is
not as we might expect (6.4 tonne), but is only 5.5 tonne.
If the angle between legs increases to 120°, then the SWL decreases to 3.2
tonnes – the same SWL as one leg when the load is being directly lifted.
Figure 65 also lists the SWL at 60°, 90° and 120°. The SWL at angles between
600 and 900 should be read as the SWL for 90°. The SWL at angles between
900 and 1200 should be read as the SWL at 120°.
The SWL listed at 600 is not to be exceeded, regardless of how small the angle
between the legs. That is, the SWL at 45° or 30° is the same as the SWL at 60°.
Angles greater than 90° should be avoided where possible.
WARNING:
Angles in excess of 120° MUST NOT BE USED.
WARNING:
No matter how many legs are on a sling, the SWL of the whole unit is based on
two legs only. That is, in practice, a two leg, three leg or four leg sling all have the
same SWL.
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General
A chain, properly selected for a particular job, is a dependable piece of
equipment, manufactured strictly in accordance with the appropriate standard
and fully tested to ensure high quality. Misused – it can be lethal.
Listed below are some Dos and Don’ts of everyday chain usage.
Don’t:
1. Overload a chain.
2. Use a chain in which the links are not free in their movement.
3. Use a chain that is pitted, corroded, unduly worn, chipped, nipped, cracked or
otherwise damaged.
4. a. cross, twist, knot or kink any chain
b. drag a chain from under a load
c. drop a chain from any height
d. roll a load over a chain.
5. Use a chain reeved around sharp corners of a load without protective

padding.
6. Use a chain in temperatures above 250°C.
7. Use load chains of a chain block or other hoisting chain as a sling.
8. Hammer a chain to straighten a link or to force a link into position.
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Do:
1. Always use only one grade of chain in a workshop environment to avoid
confusing the SWL of different grades in the same size range.
2. Ensure that any screw threads used in connection with chains are securely
locked.
Figure 66
3. Ensure all four legged chains are fitted with two intermediate links on the main
ring as illustrated in Figure 66 to ensure an even distribution of load.
4. Always inspect chains regularly and keep the register up to date.
5. Always ensure that when selecting a chain to lift a particular load that all
allowances are made, e.g:
a. The effect of angle between legs.
b. The allowance for back hooking or reeving around a load.
c. The allowance for any nipping that may take place on sharp corners.
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Synthetic Fibre Slings

Lifting Slings manufactured from synthetic fibre are available in three common
forms: rope slings, flat webbing and round slings.
Flat Webbing Slings

Flat Webbing Slings are made from synthetic fibres woven to form a flat strap or
belt. They can be purchased as an endless sling, constructed to form an eye at
each end or be built-in with metal fittings.
Figure 67 – With Folded Eyes
This type of sling has the advantage of high strength combined with lightness
and ease of handling. These types of slings have the ability to stretch but still
absorb shock loads well.
One major disadvantage of woven webbing slings is that grit can penetrate the
sling causing internal fibre damage, which is not always obvious. Because of
this weakness, the Safety Factor for these slings is 8.
Figure 68
If there is an outer sleeve on webbing slings, it is a requirement that the outer

sleeve be made from the same synthetic material as the inner fibres so that any
contact with a chemical, which may damage the fibres, will also damage the
sleeve and be readily seen.
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General Usage
Some manufacturers of Synthetic slings use different colours and sometimes
stripes woven into the sling to give an indication of the sling’s capacity. These
methods do not eliminate the requirement for a Working Load Limit (WLL) tag to
be attached to the sling.
When any dangerous condition is suspected in a sling, it is not to be used until

inspected and approved by a person competent in sling inspection.
WARNING:
Synthetic slings are easily damaged. Packing must be used when lifting loads
that have sharp edges.
WARNING:
Different synthetic fibres react differently to chemicals such as acids, solvents,
alkalis etc. For example, some may not be affected by battery acid but can be
severely damaged by contact with caustic soda, because of this, care must be
taken to keep fibres away from contact with chemicals.
Remember that chemical damage may not become apparent for some time after
contact.
Where a sling has been in contact with any chemical, and the possibility of
damage is not known, the sling is to be removed from service immediately and
advice from the manufacturer sought as to the action to be taken.
Polyester slings are not damaged or weakened by exposure to oil or grease. If it is

required, slings may be washed in warm, soapy water – but any type of cleaning
solvent is not to be used.
WARNING:
Extreme care is to be taken when using Polyester Slings near heat sources such
as hot loads or welding equipment. The maximum working temperature allowed
is 90°C.
Store in a clean, dry, well ventilated place, away from ultraviolet light, extremes
of heat, chemicals and fumes. Wet slings should be hung up and dried under
atmospheric conditions only.
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Types of Damage
¨ External wear from prolonged use or caused by dragging slings over rough
surfaces. Sling surface will have a furry appearance.
¨ Local abrasion and cuts mostly caused by movement of the sling while
under load over rough or sharp edges.
¨ Internal wear caused by repeated flexing, particularly where particles of
grit have penetrated into the fibres. Any thickening of the sling may indicate
internal wear or the presence of dirt particles.
¨ Damage to a fixed protective coating or sleeve can allow abrasive grit easy
access to the sling fibres and the sling must not be used.
¨ Melting or shrinkage of fibres due to exposure to high temperatures.
Remember the high temperatures can result from friction as well as from
other heat sources.
¨ Prolonged exposure to ultraviolet light, generally from sunlight, will weaken
synthetic fibres. This may be indicated by powdering on the outer layers.
¨ Chemical attack may also cause fibres to break down and soften. Surface
fibres may be plucked or rubbed off. There may be local stiffening of the
sling stitching on Webbing Slings coming apart.
Cleaning Slings
If oil or grease is present, slings may be washed in warm, soapy water, but any
type of cleaning solvent is not to be used.
Slings caked with mud and dirt should be hung up and hosed down. The aim of
this is to get the grit to flow off the sling rather than forcing it into the fibres by
scrubbing.
Slings must be dried under atmospheric conditions only and not hung up near a
heat source.
WARNING:
There is no rule of thumb for Webbing Slings.
WLL tags must be attached to all slings.
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FLAT WEBBING SLINGS
Bas Choke
Colour Web Direct Choke

0° 30° 60° 90° 120° 60° 90°
Code Width Load Hitch
SINGLE PLY
Violet 50 1.0 0.8 2.0 1.9 1.7 1.4 1.0 1.4 1.1
White 75 1.5 1.2 3.0 2.8 2.5 2.1 1.5 2.1 1.6
Green 100 2.0 1.6 4.0 3.8 3.4 2.8 2.0 2.8 2.2
Yellow 150 3.0 2.4 6.0 5.7 5.1 4.2 3.0 4.2 3.3
Orange 200 4.0 3.2 8.0 7.6 6.8 5.6 4.0 5.6 4.4
Brown 300 6.0 4.8 12.0 11.4 10.2 8.4 6.0 8.4 6.6
DOUBLE PLY
Green 50 2.0 1.6 4.0 3.8 3.4 2.8 2.0 2.8 2.2
Yellow 75 3.0 2.4 6.0 5.7 5.1 4.2 3.0 4.2 3.3
Orange 100 4.0 3.2 8.0 7.6 6.8 5.6 4.0 5.6 4.4
Brown 150 6.0 4.8 12.0 11.4 10.2 8.4 8.0 8.4 6.6
Blue 200 8.0 6.4 16.0 15.2 13.6 11.2 10.2 11.2 8.8
Grey 300 12.0 9.6 24.0 22.8 20.4 16.8 12.0 16.8 13.2
Table 1 – Synthetic Fibre Sling Chart
Sling Inspection
What is the inspection for?
Not Recommended For Use

¨ Slings with no SWL/WLL tags or marks or tags that cannot be read. This
category will also include home made slings.
Permanent Loss of Strength

¨ Slings considered to have lost 10% or more of its strength (for whatever
reason) should not be used.
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Causes of Strength Loss

Cause of Strength Loss Affected Material
Sling Material Breakdown

Chemical attack Webbing slings
Rotting Webbing slings
Corrosion and rust Chain
Ultraviolet light Webbing slings
Stretch
Overloading, exceeding SWL All slings

Shock loads All slings
Wear
Internal All slings

External All slings
Gouges Chain
Heat
Flame All slings

Friction All slings
Welding All slings
Distortion
Crushing All slings

Bends/twists Chain
Knots All slings
Breaks
Cuts All slings

Cracks Chain
Table 2
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General
When inspecting slings, there is a need to look for any permanent loss of
strength, whether from normal wear or from abuse.
In many cases, when a sling has been damaged, the user of the sling will be
aware that the damage has occurred. It would be irresponsible to leave such a
sling where others may use it, unaware that it has been damaged.
Immediately after any damaged equipment has been detected, it must be

removed from service, clearly marked and reported. If the equipment is not
repairable it must be cut up before being discarded.
When in doubt about the condition of a sling, the manufacturer is the agent most
qualified to judge whether it is safe to use or if repair action is necessary.
When to Inspect
It is the responsibility of the user of any lifting equipment to satisfy themselves
that the equipment has not suffered any significant damage before any lift. This
requirement demands that slings be given some reasonable inspection before
every use. All lifting slings and equipment must have a thorough inspection at
least once every 12 months by a qualified person to inspect such equipment.
Recording Inspections
A sling register is established to record inspections, repairs and any relevant
information concerning slings.
Inspection Procedure
Sling inspection requires experience in assessing damage, patience and plenty
of time. A well lit work bench and possibly a magnifying glass may be necessary.
Thoroughness is vital. Damage can be difficult to see, particularly with chain and
if one weakened link is missed, the inspection has been a waste of time. Slings
must be examined over their entire length and from every side.
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Slinging Theory
Methods of Applying Slings to Loads
Direct Hitch
Figure 69
The sling remains straight and without any bends between the lifting hooks and
the attachment point on the load. When using a two legged sling, the legs will be
pulling at an angle but they are still not bent in any way.
Single slings are rated according to their lifting capacity in a Direct Hitch. For
example, a chain sling marked with a SWL if 3.2 tonne can lift that weight when
used in a Direct Hitch.
Choke or Reeved Hitch
Figure 70
The sling is passed around the load and may be back-hooked onto itself or in the
case of a sling with eyes at each end, one end is threaded through the eye at the
opposite end. When the load is lifted, the weight pulls the sling tight and grips
the load firmly.
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Basket Hitch
Figure 71
The sling is passed around the load and both ends of the sling are connected to
the lifting device, a crane hook or perhaps a lifting beam.
Double Wrap
Figure 72
The sling, having been passed once around the load, is taken around an
additional time. This method may be used to reduce the possibility of slings
slipping on the load or to pull a loose load, such as a bundle of steel or pipes,
together. A Double Wrap may also be used to shorten the sling.
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Slinging Terminology
The two terms used to describe the strength of lifting equipment are:
Working Load Limit (WLL) – is the stated capacity of a piece of lifting

equipment when new and being used under perfect conditions.
Safe Working Load (SWL) – is the load the equipment can safely lift in the
workplace, where it is the responsibility of the user to make allowances for the
loss of strength resulting from wear, damage or the way in which it is used.
For equipment in good condition, under most normal working conditions, the
SWL will be the same as the WLL.
Breaking Load (BL) – the load in which a manufacturer guarantees that the
sling or equipment will support without breaking.
Proof Loading – slings may be proof loaded by a testing authority. A controlled

strain is applied to detect any weakness or manufacturing fault.
Safety Factor (SF) – these are used to calculate the WLL & SWL of different
types of lifting equipment
Common Safety Factors

All slings when used to support people –10
Fibre slings, Webbing and Round Types –8
Fibre Rope Slings –6
Wire Rope Slings –5
Herc-Alloy or Type ‘T’ chains –4
The formula used to calculate the WLL of a sling is:
Breaking Load
WLL
Safety Factor
¨ e.g. A type 'T' chain used to make a particular sling has a minimum
Breaking Load (BL) of 10 t. The Safety Factor for the chain is 4.
10
2.5t SWL
4
The use of the Safety Factor ensures there is a very big margin between the
weight that will cause a sling to fail and the WLL, or maximum weight, which the
user is allowed to pick up. This safety margin allows for the loss of strength that
occurs with normal wear on the sling and for unexpected shock loads etc.
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WARNING:
The safety margin is built into the SWL to protect the user.
It must not be abused.
Temporary Changes to Sling Strength

The way a sling is used can affect its strength.
Loss of Strength in Slings When Choke Hitched

When any sling is choke hitched onto a load, it loses strength. The choke hitch is
similar to tying a knot in the sling, as a sharp bend is created, known as the Nip
Point.
When a square load is lifted by a choke hitch, slings are additionally stressed
by the corners of the load, and a loss of 25% occurs to Herc-Alloy or Grade ‘T’
chains and a loss of 20% occurs to Synthetic Webbing Slings.
Square Corners and Sharp Edges

When basket hitches are used, sharp edges and square corners on loads will
weaken the sling. The use of packing will protect slings and reduce the losses.
Packing on corners and sharp edges must be used with webbing slings if the
20% minimum loss of strength is to be achieved.
Shackles and Lifting Lugs
Figure 73
When slings are passed through shackles or lifting lugs, care must be taken
that severe nip points are not created. Small lugs and shackles concentrate
the load at one point on the sling, reducing strength and with heavy loads, very
often damage the sling. Shackles should have a diameter of at least twice the
diameter of the sling they are used with.
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Basket Hitches
In some situations, when a basket hitch is used, a sling may be able to support
double its rated capacity. To achieve the doubling effect, the following
requirements are essential:
¨ The load must be round.
¨ The diameter of the load must be at least five times the diameter of the sling
in use.
¨ If there is an included angle it can be no greater than 30°.
Figure 74
Load A could be lifted with one tonne slings. The load is round and has large
diameters compared with the slings.
Load B could not be lifted with a one tonne sling – the included angle is
incorrect.
Load C is slung in a basket hitch but does not achieve a doubling effect as the
load is square and the included angle is greater than 30°.
Sling Charts are the safest way of assessing Basket Hitch capacities.
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Included Angles
When using multi-leg slings, the angle created between the sling legs is called
the Included Angle.
Sling charts generally deal with three angles: 60°, 90° and 120°. Assistance in
estimating angles are indicated below:
Figure 75
At 60° an equilateral triangle is formed. The distance between the attachment

points A is the same as the sling length S.
Figure 76
At 90° the distance between the attachment points A equals twice the height of
the triangle H.
Figure 77
At 120° the height of the triangle H equals half of the sling length.
Included angles do not weaken slings as choke hitches do, however there is
more tension developed in the sling legs. As the included angle increases, the
tension also increases, consequently the sling’s lifting capacity decreases.
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Figure 78
In diagram (A) above, two slings are direct hitched from a lifting beam. There is
no included angle and the slings will share the load. Two 500kg slings would be
OK for this job.
If the slings are both hung from a crane hook, as in (B) above, the slings still
have to support 500kg each, but because of the angle, there will be additional
tension in each leg. Two 500kg slings would not be sufficient to lift the load
safely.
The following chart shows the tension developed in each sling leg at different
included angles. Though the load being lifted remains the same, the tension in
the sling legs increases as the angles increase.
In the extreme situation, at 171°, two 6 tonne slings would be required to lift a
one tonne load.
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Figure 79
WARNING:
The recommended maximum angle between the two legs of a sling for general
work is 90°.
It must be remembered that an increase in tension, because of larger included

angles, increases the chance of sling legs slipping into the centre of the load.
Large included angles mean that the sling attachment points are well spread,
thus giving good stability for the load, but larger capacity slings are needed and
the possibility of the slippage increases.
The maximum included angle allowed (120°) would only be used if the slings
were to be hooked to sound lifting lugs. A choke hitch at such a wide angle
would not be secure or safe.
When using multi leg slings, the majority of loads can be safely lifted using sling
angles between 30° and 60°, giving good stability without excessive tension.
Use of Three and Four Leg Slings

These slings provide better support for loads and make the balancing of the load
a simple task.
When lifting a rigid load with a three or four leg sling, the load will not be equally
shared between all the legs. Two legs will generally be taking most of the weight
while the remaining leg, or legs, will only be balancing the load.
For this reason, three and four leg slings have the same lifting capacity as two
leg slings of the same size.
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Ten Basic Steps
To Safely Lift a Load With a Crane

1. Check the load.
2. Establish the capacity of the crane.
3. Where is the load to be placed?
4. Establish centre of gravity of the load.
5. How is the load to be slung?
6. Select appropriate slings and gear.
7. Direct crane over the load.
8. Apply slings to load.
9. Take up tension in slings, stop and check.
10. Hoist and check load is balanced.
Note:
The ten steps suggested above are more appropriate for lifting a load with an
Overhead Travelling Crane. Additional steps would be required if a Mobile Crane
were to be used. Nevertheless, leaving the crane type aside, the procedure would
be relevant to the safe slinging and hoisting of most loads.
Step 1: Check the Load
The Weight
Figure 80
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What is important?
Before any lift can be carried out, every effort must be made to ascertain the
weight of the load. Without this information, the selection of both crane and
slings becomes pure guess work and the safety of the lift is at risk.
WARNING:
Remember, all slings and lifting gear, such as beams, becomes part of the load
and their weight must be added to the load weight.
The Size
Figure 81
If the slings are to be passed around the load, its dimensions will govern the
length of the slings needed. Long loads may need additional support to prevent
sagging and so a lifting beam may be necessary.
The Shape
Figure 82
A load with sharp edges will need to be lifted using slings that will not be
damaged, or else packing must be used.
Loads that are heavier at one end or not uniform in shape could require slings of
different lengths or perhaps chain slings with shortening hooks fitted.
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Are There Moving Parts?
Figure 83
Machinery with components that are free to move can become unstable if the
moving parts are not restrained or tied up before the lift is made. For the same
reason, tanks containing liquids can be hazardous if the liquid runs to one end of
the tank.
Care must be taken that the whole of the load is supported by the slings and that
parts such as the base of a machine do not separate after the load is lifted.
Is the Load Fragile or Valuable?

¨ If the load belongs to either of these categories, a great deal more attention
will need to be paid to sling selection and the slinging method.
¨ Will the load be scratched or marked by slinging?
¨ Does it need extra support because of its length or inability to withstand the
crushing effect of the slings?
Are Lifting Points Fitted?

Lifting points simplify the slinging of any load. They may consist of lugs welded
to the load or holes provided to take sling hooks. They should only be used if in
good condition.
Fixed Machinery
If the load was formerly bolted to the floor, it should be raised with jacks and
wedges before attempting to lift with a crane. This ensures that the crane is only
lifting the load and is not being asked to break the adhesion which might exist
between the load and the floor.
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Step 2: Establish the Capacity of the Crane

Every crane should have the SWL clearly marked on it. The operator should
understand the abilities and limitations of the crane.
Step 3: Where is the Load to be Placed?

¨ Is there a clear path to follow to the destination?
¨ Is there space at the destination to land the load?
¨ Will there be packing at the destination to place the load on?
¨ If the load is to be lifted high, greater care will be needed with slinging
methods.
¨ Are there people in the area who should be considered?
Step 4: Establish the Centre of Gravity of the Load
Figure 84
Figure 85
Figure 86
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The Centre of Gravity (COG) of a load or any object might be described as the
point that is at the centre of the weight or balance point of that object.
With a uniform shaped load, such as a length of steel, the COG will be at the
centre of the load and its position can be determined by measurement.
With objects that do not have uniform shape, the COG will not be at the centre
of the load and its position will have to be estimated. Some objects, because of
their shape, will have a COG outside the body of the object.
Figure 87
A freely suspended load will hang with its COG directly below the crane hook.
Therefore, correctly estimating the COG is important if the load is to be balanced
and stable when lifted.
In the examples in Figure 87, the load is slung with the hook not over the COG
(A). When the load is raised, it moves to compensate (B).
For a uniform load to remain level:

¨ The hook must be over the COG.
¨ The sling legs must be equal lengths.
¨ The attachment points must be equal distances from the COG.
Figure 88
When slinging a load that is not uniform in shape, it may be necessary to

use slings of different lengths. Care must be taken that one sling leg is not
overloaded.
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Figure 89
When slinging top-heavy loads that have a high COG, the slings must be
attached above the COG as indicated in A.
Figure 90
The load in B will be unstable when lifted and will tip if not restrained.
Step 5: How is the Load to be Slung?

Some common choices are:
A Single Sling – direct, choke or basket hitched.

A single sling may be used on a compact load but a long load would be unstable
and difficult to balance.
Two Slings Attached to a Lifting Beam – this method supports a load well and
stability is good.
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If the load is level, the chance of the slings slipping is minimal. A beam
with short slings is a very compact assembly if headroom is limited. The
disadvantage is the time taken to set up the assembly and the extra weight of
the beam. The capacity of the slings will vary depending on whether a direct,
basket or choke hitch is used.
Two Slings or Two Legs Assemblies.

Included angles must be estimated and kept to a minimum to reduce sling
tension and the possibility of sling slippage.
A direct hitch is quick to apply if the load has suitable lifting lugs. Slip is not a
problem and smaller capacity slings may be used.
The most commonly used slinging method is two legs, choke hitched. The choke
reduces the sling capacity but grips the load securely. The possibility of crushing
fragile loads is a disadvantage.
A two leg basket hitch gives good sling capacity and does not crush loads as
much. The load is not securely gripped by the slings, so there is a possibility of
a load slipping out of the slings. Basket hitches would not be recommended for
any high lifts.
Slinging Accessories
See Section on Steel Plate Clamps on page 118.
Step 6: Select Appropriate Slings and Gear

The following should be taken into consideration when selecting the appropriate
slings and gear:
¨ Legal slings – SWL/WLL clearly marked.
¨ SWL/WLL of slings adequate for weight of load and hitch method chosen.
¨ Condition of sling – inspect for damage.
¨ Sling type – select slings which will not be damaged by the load or slings
which might damage the load.
¨ Length – slings long enough to go around the load if required.
¨ Other gear – beams, shackles, protective packing, tail ropes etc.
Step 7: Direct Crane Hook Over Load

If working with someone else, clear signals must be given to direct the crane.
Recommended hand signals are shown on page 132.
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Step 8: Apply Slings to Loads
Figure 91 – 60° angle maximum
The main considerations when applying slings are:

¨ Type of hitch to be used (see step 5).
¨ Included angle to be used. Remember to use a sling angle that provides
enough stability to the load without developing excessive tension in the sling
legs. When choke hitches are used, for most lifts, the minimum angle would
be 30° and the maximum is 60°. If increased spread is needed, longer slings
will be required to maintain the same angle.
Figure 92 – 30° angle maximum
¨ Control of sling slippage is achieved by:

− reducing sling angles
− double wrapping slings
− using packing.
¨ Protection of slings and loads
− using correct type of sling
− using packing.
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Figure 93
¨ No nip points on sling splices or ferrules.

¨ Slings are not twisted or kinked.
¨ Sling and shortening hooks are correctly applied.
¨ When a number of sling eyes are to be attached to the crane hook, a bow
shackle should be used to avoid crowding the sling eyes in the hook and to
prevent the possibility of a sling coming off the hook.
Step 9: Take Up Tension in Slings

At this point the hook is slowly raised until the slings take some weight but the
load is not lifted. It is an opportunity to give a final check to the way the load is
slung. Some items to check are:
¨ Slings secure and not twisted
¨ Shortening hooks correct
¨ Packing in place
¨ Crane hoist rope vertical
¨ Hook over the Centre of Gravity
¨ Tail rope attached if necessary
¨ Any hazards such as power lines
¨ People clear of the load
¨ Are you standing in a safe position?
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Figure 94
WARNING:
Never hit chocked slings down at the nip point. This damages the slings and
creates excessive tension. They must be allowed to find their own angle.
Step 10: Hoist and Check Load is Balanced

Lift the load off the ground slightly and check the load is balanced. If not, lower
to the ground and re-adjust the slings.
Packing
Packing has three main uses:
¨ To protect loads from damage by slings.
¨ To protect slings from damage.
¨ To prevent slings slipping on loads.
Materials suitable for packing include pieces of rubber, carpet, soft wood or pipe
cut to suit the load.
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WARNING:
Where there is any danger of slings being damaged or weakened by sharp edges,
or the possibility of slippage, packing must be used.
Care must be taken that packing is secured and cannot fall from loads that are to
be hoisted high.
Tail Ropes
Tail ropes, when attached to loads, have a number of uses:
¨ They enable the person using the crane to control the load and also keep at
a safe distance.
¨ If there are two people moving the load, the person using the tail can stay
within sight of the person operating the crane.
¨ A dry fibre rope will insulate the person using the tail from the load in the
event of contact with power lines etc.
¨ Tail ropes can be used to tie the load back to the crane if the load is to be
transported.
Sling Hooks
Sling hooks are made in a variety of styles. They may be of the open type or
be fitted with a latch mechanism designed to prevent slings from accidentally
coming off the hook.
They are usually not marked with a SWL/WLL capacity but good quality hooks
will have markings that identify the maker and a reputable supplier of slinging
gear can give advice on appropriate usage.
Currently most sling hooks are manufactured from alloy steel and have the
same strength as the size Alloy chain they are matched with. Poor quality hooks
are sold through hardware outlets and must not be used for slinging in the
workplace.
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Some common sling hook styles are:
Figure 95
Figure 96
Of these hooks, the Latchlock is the best and the safest for general use.
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Hook Gauge
Figure 97 – Hook Gauge
The hook gauge is made from a flat piece of metal. Two opposite sides of the
hook gauge are cut at intervals to make different widths. These different widths
are made to fit the different sizes of the openings on hooks. There is a mark at
each interval to give an indication of the correct size for a specific hook. This
equipment is used to measure the opening of a lifting hook.
For example, how is a size 29 hook checked for size? Hold the hook gauge in
the opening of the size 29 hook. The width of the hook gauge at the 29 mark
must just fit between the tip and the back of the opening on the lifting hook.
If the hook opening is larger than the width at the 29 mark, the hook must be
removed from service.
Single Sling
Figure 98 – Single Sling
The single sling (Figure 98) has only two ends where a load can be connected.
The material for the sling can be rope (wire, nylon or fibre), nylon web, or chain.
On each end of the sling will be a hook or other fastener, which can be fastened
to a load. The steel hook is the most common fastener. The centre of the sling
generally has a steel ring that can be fastened to hoist equipment.
The maximum rated capacity can be found on the centre fixture or on a small
sign fastened to the sling. A leg is the name of the section of the sling between
the centre fixture and the end fastened to the load. This equipment is used to
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connect lift equipment to a load. The load to be moved must have some type
of lifting eyes. The hooks, or end fixtures, of the sling are fastened to the lifting
eyes on the load.
Be careful to have the hook openings away from the load. The centre of the sling
is fastened to the lifting equipment. The sling will hold the load when the lifting
equipment is operated. The distance between the lifting eyes and the length of
the legs of the sling has an effect on the amount of weight a specific sling will
hold. This information can be found on lift charts.
If one or more legs must be made shorter on a chain sling, grab hooks
(Figure 96) can be used. Remember that a grab hook causes a 50% reduction
from the maximum rated capacity.
Slings must be inspected regularly. Maximum rated capacity signs must be on

all slings. If these signs are absent, a replacement sign must be fastened to the
sling immediately. The weight of the load must be known before it is lifted. The
selection of a sling is made respective to the weight of the load and the angle of
the sling legs. Steel hooks can bend apart.
A sling with a bent hook must not be used. A sling has to be in good condition
before it is used. Never lift a load higher than necessary for a specific job. Keep
the load as low as possible at all times. Fasten the sling in a position where the
load will be in balance. When a sling made of wire rope is used, the operator
needs to wear protection for his hands.
Maintenance
Keep clean. Remove dirt and oil. Slings must be inspected regularly. Oil must be
put on chain and wire rope slings before they are put into storage. Other types
of slings must be kept clean at all times. When not in use, hang slings in a clean,
dry space.
Shackles
The two main types of lifting shackles are the Dee and Bow. Both types can
support a load in a straight pull but only the bow shackle is designed to support
a load from two or slings with an included angle.
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WARNING:
Since shackles are made of a variety of qualities and strengths, there are two
important points to remember:
The capacity of the shackle must never be guessed. The SWL/WLL must be
clearly stamped and be checked before use.
Do not mix pins and shackles of different strengths. Replace pins immediately
after use. A pin may screw into another shackle but be of a lower strength.
Figure 100
The capacity of a shackle, as stated by the manufacturer, only applies if the

shackle is not being distorted or pulled unevenly by the sling (Figure 100). For
heavy loads, packing may be required as shown above.
Lifting Beams
As with other items of lifting gear that might be made up on site, beams should
be approved by OHSA before use. The approval number issued should be
stamped on the beam. The load capacity of the beam must be clearly marked
and the Tare weight of the beam itself is necessary when working out the total
load to be lifted. Lifting beams may be used in a variety of ways, depending on
the requirements of the lift.
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Figure 101
The lifting beam shown in Figure 101 above is being used as a Spreader Beam.
The slings are being spread or held apart so that the fragile load will not be
crushed.
Figure 102
In the lift above, this beam is being used with the crane hook directly attached to
the beam. A beam used in this way is known as an Equalising Beam. The weight
of the load is equally shared between the two slings.
This is not always the case when a spreader beam is being used. In this
situation the beam is used to provide support for a long load, but this method
may also be used to prevent crushing of a load.
When a beam is being used as an equaliser, the load is applied to each end and
the crane is lifting between those two points. The forces being applied are trying
to bend the beam. With a spreader beam, the slings are only compressing the
beam.
Beams are weakest when used in an equalising situation.
Equaliser beams are obviously better where headroom is limited.
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Eyebolts
Eyebolts used for lifting are either Collared or the Uncollared type.
Figure 103
Collared Eyebolts are made to Australian Standards. They do not generally have
a SWL stamped on them. A chart must be used to identify an eyebolt and also
how much it can lift. The chart for Collared Eyebolts is on page 116.
Uncollared Eyebolts are not made to any standard. There are no charts for them
and so their lifting capacity cannot be determined. They are often supplied by
manufacturers as lifting points for small items of equipment.
Because their lifting capacity is not known, do not lift with uncollared eyebolts if
there is an alternative lifting method.
If they must be used, the guidelines are:

¨ Use with extreme caution
¨ Never use to lift a load other than the item they were supplied with
¨ Use for low lifts only
¨ Lift with a steady vertical pull
¨ Never put any side load on an uncollared eyebolt.
With collared type eyebolts, the collar supports the eye and some side loading
is allowable. This means that two or more collared eyebolts may be used to lift a
load when hitched with a multi-leg sling.
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Figure 104
When using two or more collared eyebolts (Figure 104):

¨ The maximum included sling angle allowed is 90°.
¨ The eyebolts must be aligned as shown above. In this position, the sling is
pulling the eye in the direction of its greatest strength.
Shims or washers between the collar and the load may be required to ensure the
eyebolt is correctly aligned when nipped up.
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Figure 105
Causes of loss of strength when using collared eyebolts:

¨ Eyebolt not tightened, leaving a gap between collar and load.
¨ Thread damaged caused by over tightening or mismatched threads.
¨ Threads damaged through corrosion.
¨ Eyebolt fatigue through being bent or overloaded.
¨ Eyebolt altered e.g. thread shortened.
¨ Eyebolts not correctly aligned. Shims or washers not used.
¨ Excessive side pull developed if the included angle is over 90°.
¨ Sling hooks binding in eyes. Use shackles to attach slings.
How much can be lifted with eyebolts?
To determine the lifting capacity of one or more eyebolts, it is necessary to

consult a chart. (See Table 3)
Using the dimensions given on the top of the chart enables the user to identify
an eyebolt that has been made to Australian Standards.
The bottom of the chart gives the lifting capacity of eyebolts when used
singularly or in multiples.
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Figure 106
EYEBOLT DIMENSIONS (millimetres)

1 2 3 4 5 6 7 8 9
Nominal
A B C D min E F G H min
Size
M12 12 28 18 9 19 11 25 21
M16 16 35 24 12 24 14 32 28
M20 20 42 30 15 29 16 38 35
M24 24 57 36 18 38 22 51 42
M30 30 71 45 22 48 27 64 52
M36 36 85 54 26 57 34 75 63
M42 42 100 63 30 66 39 89 74
M48 48 114 72 35 75 44 102 84
M56 56 128 84 40 85 50 114 98
M64 64 142 96 45 95 55 127 112
M72 72 171 108 50 114 60 152 126
Table 3
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SWL for Class 3 Applications as Specified by AS1418, Part 1
Single Eyebolt Pair of Eyebolts (see note)
Trunnion–
type Included Included Included
Axial Mounting Perpendicular Angle 30º Angle 60º Angle 90º
M12 0.32 0.08 0.16 0.40 0.26 0.16
M16 0.63 0.16 0.32 0.79 0.50 0.32
M20 1.25 0.31 0.63 1.6 1.0 0.63
M24 2.0 0.50 1.0 2.5 1.6 1.0
M30 3.2 0.80 1.6 4.0 2.6 1.6
M36 5.0 1.3 2.5 6.3 4.0 2.5
M42 6.3 1.6 3.2 7.9 5.0 3.2
M48 8.0 2.0 4.0 10.0 6.4 4.0
M56 12.0 3.0 6.0 15.0 9.6 6.0
M64 16.0 4.0 8.0 20.0 13.0 8.0
M72 20.0 5.0 10.0 25.0 16.0 10.0
Reduction Factor for Single Eyebolt
1 0.25 0.25 0.63 0.40 0.25
Table 4
NOTE:
The included angle, between the legs of every two leg sling connected to a load
by a pair of eyebolts, should not exceed 90°.
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Steel Plate Clamps
Vertical Type
Figure 107
This type of clamp is designed primarily to lift steel plates that are in a vertical
position. Steel sheets can be stored on edge in racks, thus saving space and yet
still be easily removed.
WARNING:
All plate clamps must have their Safe Working Load and the thickness of the steel
plate they are designed to lift, clearly marked.
With these clamps, it is also possible to lie a plate down or to stand it up from
a horizontal position. Plates may be lifted using one clamp only or using two or
more clamps.
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Methods of Using Vertical Plate Clamps
Figure 108
Here, a single clamp is being used. Care must be taken to place the clamp so
that the load is balanced
Figure 109 – A way of supporting a long plate and it

also keeps the clamps themselves vertical.
In this lift, a beam is being used with a pair of clamps. This arrangement is a
preferred way of supporting a long plate and also keeps the clamps themselves
vertical, as there is no included angle between the slings.
More than one clamp may be required to share the load if the plate is too heavy
for a single clamp.
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Figure 110
Here the two slings supporting the clamps are attached to a crane hook and the
included angle must be considered.
WARNING:
Not all manufacturers allow this method to be used with their clamps. They should
be consulted, or the operator’s manual consulted, if there is any doubt.
IF THE INCLUDED ANGLE IS ALLOWABLE, IT MUST NOT EXCEED 20°.
Vertical plate clamps depend on friction to work successfully. The condition of

the teeth is most important, as is the condition of the plate. Blunt teeth, or a plate
heavily coated with rust, scale or paint may mean that the clamp will not have a
sound grip, resulting in the load being dropped.
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Take Time To Follow These Safety Guidelines

¨ Inspect clamps and loads before use and consult if there are any doubts
about their condition.
¨ Know the weight of the load.
¨ Refer to SWL and thickness markings on clamp. Fully engage clamp on to
the plate.
¨ Use a short sling between the clamp and the crane hook
¨ Never lift more than one plate at a time.
¨ Keep plates as low as possible. Clamps are not meant for high lifts.
Make sure, at all times, that you or other people are not in a position where
they would be struck if the plate fell.
WARNING:
Plate clamps are very quick and convenient for lifting plates, but the user must
remember that many serious accidents have occurred as a result of their misuse.
Lift and Block
Figure 111 – Lift and Block
Wire rope (Figure 111) is made when a number of single steel wires are turned
together. A number of wires twisted around a single wire makes a strand of
wire rope. A number of strands twisted around a core material are a finished
wire rope. The core material can be a fibre rope or a smaller wire rope. Size
description is given by the diameter of the wire rope. The true diameter of a wire
rope is the diameter of a circle, which will just go around it.
The number of strands and the number of wires in a strand are the classification
of a wire rope. For example, a wire rope with 6 strands and 19 wires per strand
has a 6 x 19 classification. Wire rope is variable according to the conditions of
use for the wire rope. This equipment is used to hold and lift heavy loads. It can
be used in any application where high tensile (stretched) strength is needed.
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TCL005
Wire rope can be used in connection with many types of hooks and other
fixtures to fasten it to a load. Wire rope is commonly used for lifting slings and
on drums of winches. When wire rope is used, the operator must be careful not
to cause permanent bends. These are caused when the wire rope is bent over a
small diameter. When a wire rope is fastened to a load, remove the extra length
of wire rope slowly. Do not start to move the load until all wire ropes are tight.
Sudden, fast movements of loads must not be made because of the increased
stress it will cause.
A safety inspection of wire ropes must be made regularly to check for:

¨ Burned areas
¨ Cut or broken wires
¨ Wires that are bent out of shape
¨ Permanent bends
¨ Corrosion
¨ Distortion of wire rope.
The wire rope must be clean when it is inspected. Wire rope can be cleaned with
the shop air system or with kerosene and a wire brush. Hand protection must be
worn when working with wire rope.
Maintenance
Keep clean. Remove dirt and dirty oil. Check wire ropes regularly for correct
amounts of lubrication. The wire rope must be clean for this inspection. This
check can be done at the same time as the safety inspection. Put the correct
lubricant on the wire rope when needed. The lubricant selection will be
according to the application of the wire rope. When not in use, put wire ropes in
a clean, dry space. For wire rope on winch drums, put a cover over the drums
when not in use.
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TCL005
Fibre and Nylon Rope
Figure 112 – Fibre and Nylon Rope
Fibre (Figure 112, left) and nylon ropes (Figure 112, right) are made from either
natural or man-made fibre materials. To make fibre rope, separate fibre threads
are twisted together. The material made by this action is a strand of fibre
material. A number of strands are twisted together to make a natural fibre or
nylon rope.
The serviceman can find the maximum rated capacity for a specific type and
size of rope in the specification sheet that comes with rope when it is new. This
equipment is used to hold and lift light loads. Because these ropes are made of
fibre materials, they can be used to move light loads that can be damaged by
wire rope or chains.
Ropes made of fibre materials will change in length when put under tension.
This effect will cause less shock when a load is put on a rope too fast. A nylon
rope will generally change in length more than other fibre ropes. A fibre rope
that is in good condition and has not been under too much stress will go back
to the original length when a load is removed. Ends of a fibre rope can be made
into eyes or fastened to special fixtures. The size of a fibre rope is measured by
the circumference.
Make sure that a fibre rope is not used where the stress is more than the
maximum rated capacity of that rope. All fibre ropes must be inspected regularly.
Remember that all of the strands of a fibre rope must be free from defects for
the rope to have the full rated strength. Service technicians must wear hand
protection when working with fibre ropes that will move through their hands.
Protection material must be used between rope and any sharp corners, which
could cut the rope.
Maintenance
Keep clean. A natural fibre or nylon rope must be kept dry and free from oil and
grease. All fibre ropes must be inspected regularly. A fibre rope that is cut or
badly worn must be removed from service. Fibre ropes must be put into a clean,
dry space for storage.
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TCL005
Load Positioning Sling
Figure 113 – Load Positioning Sling
The load positioning sling (Figure 113) is a type of chain sling. This sling has
two legs. The two legs are made from the two ends of a single chain. There is
a hook on the end of each leg. The centre fixture can be moved to any position
between the ends of the sling legs. The centre fixture is made of steel and has
a wheel to hold the chain. The wheel has pockets to hold the links of the chain.
This shape will not let the chain slide over the wheel. The name of a wheel made
for this purpose is a load sheave.
An adjustment screw on the centre fixture is designed so that it can be turned

with a wrench. Movement of the adjustment screw will turn a large gear. The
large gear is fastened to the load sheave. The chain is caused to move from
one side of the centre fixture to the other when the adjustment screw is turned.
The centre fixture has a steel ring at the top. This ring can be fastened to lifting
equipment. The maximum rated capacity can generally be found on the side of
the centre fixture.
This equipment is used to connect heavy loads to lift equipment. The advantage
of the load positioning sling is that a heavy load can be turned to different
positions while it is held by lift equipment. The position of the load is changed
when the adjustment screw is turned. As the wheel in the centre fixture is turned,
one sling leg is made longer while the other leg is made shorter. As the legs of
the sling are made different lengths, the load is turned.
The load positioning sling is a good selection if heavy components must be put
into position where side clearances are small. An example of this application is
the removal or installation of the transmission in a 631 Wheel-Tractor Scraper.
Know the weight of a load before it is moved. Check the decrease in the
maximum capacity caused by the angle of the legs. Check a lift chart to find the
amount of decrease.
Make sure that the hook openings are away from the load. The load must have
good stability before it is moved. Follow safety procedures for the use of chain.
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TCL005
Maintenance
Keep clean. Remove dirt and oil. Load positioning slings must be inspected
regularly. Put oil on the load positioning sling before it is put into storage. When
in storage, hang the load positioning sling in a clean, dry space.
Barrel Grip
Figure 114 – Barrel Grip
The barrel grip (Figure 114) has two large metal arms. These arms cross and are
fastened together with a hinge pin. When the arms are moved toward each other
on one end of the set, the arms on the other end also move toward each other.
The arms on one end of the barrel grip are fastened to a steel ring with links of
chain. The other ends of the arms are fastened to metal bars. The metal bars
have a shape that will fit the curve of the sides of a barrel.
The maximum rated capacity can be found on the centre ring or on the side of
the arms. This equipment is used to fasten lift equipment to a 208 litre barrel.
The steel ring on the end of the barrel grip is put on the load hook of a hoist.
The bars on the other end of the barrel grip are put just below the top edge of a
barrel. When the hoist moves in an up direction, the top ends of the barrel grip
are pulled toward each other. This will cause the other ends of the barrel grip
arms to put pressure against the sides of the barrel.
The barrel grip can be used when barrels must be moved from one location to
a second location. Inspect the barrel grip before it is used. Make sure that the
hoist equipment has the capacity for both the barrel grip and the load. Never
work under a load that is held by a barrel grip.
Maintenance
The chain components of a barrel grip must have lubrication at regular intervals.
Inspect all of the components regularly to make sure that they are in a safe
condition. Keep the barrel grip clean. Remove dirt and oil. Make sure that the
maximum rated capacity can be easily found on the barrel grip.
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TCL005
Chain Hoist
Figure 115 – Chain Hoist
The body of the chain hoist (Figure 115) has a series of load sheaves. One load
sheave holds a closed circle of chain. When one side of this circle of chain is
pulled, the other load sheaves are caused to turn. These other load sheaves
hold a hook and chain arrangement. As the load sheaves turn, the chain is
moved and the hook moves vertically. The hook and chain arrangement can
be fastened to a load. There is a steel hook on the top of the body of the chain
hoist. This hook is used to fasten the chain hoist to a strong support.
Using gears or pulleys of different sizes creates a mechanical advantage. There

is also a mechanical brake in the body. This brake will not let the load move
while it is held in a specific position.
This equipment is used to lift and hold heavy loads. The load hook on the chain
hoist is moved vertically when the closed circle of chain is moved. The body of
the chain hoist can be fastened above a load. The load hook is then fastened to
the load. The serviceman pulls on one side of the circle of chain and the hoist
will lift the load. When the serviceman is ready to lower the load, he will pull on
the other side of the circle of chain.
The arrangement of the load chain and hook can be made in many forms. These
arrangements can change the mechanical advantage and the maximum rated
capacity of a chain hoist. The maximum rated capacity can generally be found
on the side of the body of the chain hoist.
Inspect the chain hoist before it is used. Make sure that all of the components
are in good condition. Make sure that the body of the hoist is held solidly by a
strong support. Know the weight of a load before it is moved. Do not lift more
than the maximum rated capacity of the chain hoist. Make sure that the load is in
balance before it is moved. Never work under a load that is held by a hoist.
Maintenance
Chains must have lubrication at regular intervals. Inspect all of the components
regularly to make sure that they are in safe condition. Keep the chain hoist clean.
Follow the maintenance instructions for the specific chain hoist used.
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TCL005
Electric Hoist
Figure 116 – Electric Hoist
The electric hoist (Figure 116) is generally fastened to a high horizontal beam.
The beam can generally be moved to different positions. The electric hoist can
be moved axially to different positions on the beam. There is a hook on the
electric hoist that hangs on a vertical arrangement of chain or wire rope. The
main components of the body of an electric hoist are:
¨ An electric motor
¨ Load drums for wire rope or load sheaves for chain
¨ A series of drive gears
¨ A mechanical brake.
The electric motor is operated by controls that hang down from the hoist body
to the level of the serviceman. The arrangement of wire rope or chain between
the hook and the body of an electric hoist can be made in many forms. This
arrangement can change the mechanical advantage and the maximum rated
capacity of an electric hoist. The maximum rated capacity can generally be
found on the side of the electric hoist body.
This equipment is used to lift and move heavy loads. The hook on the electric
hoist is moved vertically when the electric motor is operated. The control switch
hangs by a cable from the hoist body and is held by the serviceman. The control
switch on some electric hoists can also control movement of the body of the
hoist.
This movement can have two directions. The first is movement of the hoist body
on the support beam. The second is horizontal movement of the support beam
with the hoist body. If these movements cannot be made electrically, then they
are made manually. The hook can be fastened to a load by a fixture such as a
lifting eye or a sling. When the hoist is operated, the hook must be moved in the
up direction slowly until all the weight of the load is held by the hoist.
Lift the load only high enough so that it will not hit items on the way to the final
location for the load. If the hoist body and beam do not move electrically, the
serviceman must push the load to the new location. When the load is put down,
127
TCL005
it must be lowered slowly until there is no weight on the hook of the electric
hoist. Keep the passage between the lift area and the final location of the load
as clear as possible. Make the final location ready to take the load. Inspect the
electric hoist before it is used. Know the weight of the load before it is moved. Do
not lift more than the maximum rated capacity of the electric hoist used.
Make sure that the load is in balance before it is moved. If it is not in balance
when the lift is started, lower the load and put the hoist hook in a better position.
Lift the load only as high as necessary. Push the load to the new position.
Never pull on a load. Never stand under a load on an electric hoist. When the
hoist is not in use, the hook must be put at a vertical height that will not let it hit
people in the shop.
Maintenance
Chains and wire rope must have lubrication at regular intervals. Inspect all
components regularly to make sure they are safe and in good condition. Follow
the maintenance instructions for the specific electric hoist used.
Ratchet Hoist
Figure 117 – Ratchet Hoist
The ratchet hoist (Figure 117) has a single length of chain or wire rope with a
load hook on one end. The body of the hoist has a load sheave to hold and
move the chain or wire rope. A large lever is fastened to one side of the body.
When the lever is moved, the load sheave will turn and change the length of
chain or wire rope between the body and the load hook. There is a second hook
fastened to the top of the ratchet hoist body. This hook is used to fasten the
ratchet hoist to a strong support.
This equipment is used to lift or pull heavy loads. The ratchet hoist can be used
to pull a load in any direction. This is a light hoist and can be moved easily.
Extra chain or wire rope can be moved through the ratchet hoist rapidly. When
the chain or wire rope is tight, the load is moved as the large lever is operated.
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TCL005
There is also a small lever that will cause the load hook to move up or down
according to its position.
Generally, operating instructions are found on the side of the hoist body. Read
these instructions before the hoist is operated. Do not use a pipe extension on
the ratchet hoist lever. This can result in an overload stress on the ratchet hoist.
Keep the load chain or wire rope straight when tension is present.
Do not put more load on the ratchet hoist than the maximum rated capacity. The
maximum rated capacity can generally be found on the side of the ratchet hoist
body. Inspect all of the components of the ratchet hoist regularly.
Make sure the body of the ratchet hoist is held solidly by a strong support. Never
work under a load that is held by a ratchet hoist. Do not drop or throw a ratchet
hoist.
Maintenance
The hoist chain or wire rope must have lubrication at regular intervals. Inspect all
of the components regularly to make sure they are in a safe condition. Be careful
with lubrication around mechanical brakes. Keep the ratchet hoist clean. Follow
the maintenance instructions for the specific ratchet hoist used.
Dual Hook Hoist
Figure 118 – Dual Hook Hoist
The dual hook hoist (Figure 118) is a type of electric hoist. It has a single length
of chain with a hook on each end. The chain is held in the body of the hoist by a
load sheave. The load sheave is turned through a series of gears by an electric
motor. There is a steel hook on the top of the hoist body.
The electric cable for the motor extends from the hoist body. This electric cable
can be connected to either a 220 or 440 volt, three phase power supply. The
dual hook hoist is operated by controls that hang down from the hoist body to
the level of the serviceman. The maximum rated capacity can generally be found
on the side of the hoist body. The Dual Hook Hoist has a maximum capacity.
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TCL005
This equipment is used to change the position of a heavy load for example, to tilt
or turn over an engine block on an engine stand. The dual hook hoist must hang
from a main electric or air hoist. The main hoist must have a height of at least
3m.
To connect the dual hook hoist to an engine block, two 9S9090 Lifting Eyes are
used. The lifting eyes are fastened with bolts to the top of the engine block. A
Sling Assembly is fastened to the side eyes. The centre of the sling assembly
is put under the engine block. A chain sling is fastened to the top eyes on the
engine block. The centre fixture of the chain sling is fastened to one hook of the
dual hook hoist. The other hook is fastened to the centre of the Sling Assembly.
Lift the engine block with the main hoist. The engine block will turn over when
the Sling Assembly is pulled up while the chain sling is lowered. Inspect all of the
components of the dual hook hoist regularly. Make sure that the main hoist has
a maximum capacity that will hold the full load. Never work under a load that is
held by a hoist. Fasten sling hooks to eyes so that the hooks have their openings
away from the centre of the load. The Sling Assembly is made of three layers of
nylon web. The middle layer is for strength. The two outside layers are to protect
the middle layer from wear. Do not use a sling assembly, which has a damaged
middle layer.
Maintenance
The hoist chain must have lubrication at regular intervals. Inspect all of the
components regularly to make sure they are in a safe condition. Keep the dual
hook hoist clean. Follow the maintenance instructions for the specific dual hook
hoist used.
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TCL005
Block and Tackle
Figure 119 – Block and Tackle
The block and tackle (Figure 119) has three primary components. Two of
these components are the blocks. The blocks are made of one or more rollers
(sheaves) that are held in a body. Each block body has a hook fastened to one
end. A rope fastens the two blocks to each other. The rope can be natural fibre,
nylon or wire rope.
The edges of the sheaves have a rounded groove that will fit the diameter of the
rope used. The rope will go from one block to the other and will be held on the
sheaves. One end of the rope is fastened to a fixture on one of the blocks. Each
sheave will hold one part of the rope. A free end of rope will come off of the last
sheave.
This equipment is used to lift or move heavy loads. The force of the serviceman
is multiplied by the use of a block and tackle. The block that holds the free end
of the rope is generally fastened to the support above the load. The other block
is fastened to the load.
The serviceman pulls on the free end of the rope to lift the load. The sheaves will
turn as the rope is pulled through the blocks. Generally, the more sheaves used,
the more the force of the serviceman is multiplied. This multiplication is limited
because the efficiency will decrease as the number of sheaves increases.
The mechanical advantage of a block and tackle is approximately equal to the
number of rope parts that go to the sheaves on the lower block.
Inspect all of the components of the block and tackle regularly. Make sure that
the sheaves turn freely in the block body. Also make sure that the sheaves are
held solidly in the block body. Know the weight of the load before it is moved.
Make sure that the maximum capacity of the roe is enough for the stress on the
block and tackle. Service technicians must wear safety protection on their hands
when they use a block and tackle.
Maintenance
Keep clean. Remove dirt and oil. Follow the maintenance instructions for the
specific block and tackle used. Some types of sheaves will need lubrication
according to the types of bearings used. Follow the maintenance instructions for
natural fibre, nylon and wire rope.
131
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Crane Signals
Motion Hand Signal Motion Hand Signal
Raise Lower
Slew
Slew Left
Right
Travel STOP!
Figure 120
132
TCL005

TCL005 - SGD - V4 (Jacking)

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Jacking,

Published by Caterpillar of Australia Pty Ltd.

Version 4.0, 2005

Copyright © 2005 Caterpillar of Australia Pty Ltd. Melbourne, Australia.

 Caterpillar engineers and instructors

Included in this Module:

Jacking, Blocking and Lifting – TCL005

Topic 4 Lifting Methods and Equipment...............................73

Jacking, Blocking and Lifting– TCL005

Included in this Section:

Jacking Blocking and Lifting – TCL005

Module Number: TCL005

Module Name: Jacking, Blocking and Lifting

Date: 4 October 2005

2. Media delivery plus exhibit and explain facilitation, given:

3. Estimated time of delivery – 30 hours

4. Classroom and Workshop Environment

7. Recommended Student Teacher Ratio

8. Resources for Students:

Learning Outcome 1: Identify safety requirements for jacking, blocking

At the completion of this learning outcome, students should be able to:

Attainment of the performance is confirmed if the student can:

At the completion of this learning outcome, students should be able to:

Attainment of the performance is confirmed if the student can:

Learning Outcome 3: Identify jacking and blocking methods used for

At the completion of this learning outcome, students should be able to:

Attainment of the performance is confirmed if the student can:

3.1.4.2 Supporting the tray

Learning Outcome 4: Explain the correct inspection procedures,

At the completion of this learning outcome, students should be able to:

Attainment of the performance is confirmed if the student can:

4.1 Explain the correct inspection procedures for chains:

4.2.1.5 Sling chart

4.3.6.5 How the load is slung

Learning Outcome 5: Demonstrate the correct method of jacking and

PREREQUISTE: The student must have completed the knowledge assessment

At the end of this learning outcome, students should be able to:

Attainment of the performance is confirmed if the trainee can:

5.1 Demonstrate the correct method of jacking heavy vehicles:

5.3 Demonstrate the correct method of chocking heavy vehicles:

Learning Outcome 6: Conduct a lifting exercise using the correct slings,

PREREQUISITES: The student must have completed the knowledge assessment

At the end of this learning outcome, students should be able to:

Included in this Topic:

J acking , B locking and L ifting – TCL005

It is a responsibility of all employees to take reasonable care to protect their own

Under no circumstances are service technicians to rely solely on the overhead

Bracing and temporary supports must be capable of holding the workload

Important Safety Information

Replace any damaged, illegible or missing warning plates, signs or decals

¨ Caterpillar cannot anticipate every possible circumstance that might involve

Preparation of a Machine for Jacking and

¨ Identify appropriate jacking or blocking points to be used in lifting the

Parking The Machine In Preparation For Jacking

Jacking (Lifting) And Blocking (Supporting) The

¨ Chock the wheels to prevent forward and backward movement of the

Do not overload or exceed the maximum allowable height.

Do not exceed the working pressure of the connected cylinders or other

¨ Position the supporting devices in readiness and as close to the support

Never exceed the safe working limit of the support device.

Do not exceed the maximum allowable height for unit/s.

¨ Ensure the immediate area is clear of all personnel.

procedures you choose.