Safety Instructions

Chapter 4
for Operation
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4.1 Use Conditions

1) All components of crane are in the running-in condition in beginning of using. So, in the
first 100 hours of using, working load and speed should not be too heavy and high. The
maximum load should be less than 80% of the rated load. And the maximum working
speed is forbidden.
2) The workplace for crane should be rigid and flat, and its bearing capacity should not be
less than 3.5MPa. During crane working, it must be horizontal and the ground for
supporting can not sink. If the ground is soft, get hard wood under outrigger floats.
3) All tires must be off ground during working.
4) Ambient temperature between -20℃ and +40℃ is suitable for crane working.
5) If wind is over Grade Six (13.8m/s) or it thunders during working, stop working right now
and retract boom to let crane in traveling condition.

Please consult the following table to estimate wind force correctly:

Wind force Wind speed
Effect
Grade Description m/s km/h
0 Windless 0～0.2 0～0.7 Smoke rises straight up.
1 Light air 0.4～1.4 1～5 Vane does not move while smoke
does.
2 Light breeze 1.6～3 6～11 Wind can be felt and leaves move.
3 Gentle breeze 3.4～5.3 12～19 Branch and leaves move lightly.
4 Moderate breeze 5.5～7.8 20～28 Branch moves.
5 Fresh breeze 8～10.6 29～38 Small trees begin to move.
6 Strong breeze 10.8～13.7 39～49 Wind roars and to maintain
umbrella is difficult.
7 Moderate gale 13.9～17 50～61 All trees move and to walk against
wind is difficult.
8 Fresh gale 17.2～20.6 62～74 Branch fractures and walking is
more difficult.

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9 Strong gale 20.8～24.5 75～88 House fracture lightly and tiles are
swept away.
10 Whole gale 24.7～28.3 89～102 Trees pulled out, buildings
fracture.
6) Only crane without fault is allowed to work.

4.2 Instructions for Safety Operation

1) No person is allowed to stand under boom during crane working.
2) No person is allowed to stand on slewing table.
3) Keep safe in turning radius.
4) Forbid lifting load over people.

5) Forbid lifting load on which people stand.

6) Forbid overloading. Forbid lifting load slantingly. Forbid lifting staggered load.

7) Forbid lifting load buried in ground or frozen on the ground.

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8) Forbid working without outriggers.

9) Forbid traveling with load.

10) Inclination angle of entirety crane must be less than 1% during working.

11) Forbid boom extending or retracting with load.

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12) In any condition, wire rope around winch is not allowed to be less than 3 circles.

13) Brake is not allowed to be adjusted in the condition with load.

14) When load is suspending in the air, operator is not allowed to leave the cab.

15) If there is high voltage cable nearby, the distance between boom/jib and cable must meet
relative rules.

16) Operating should be gently. Violent operation is forbidden.

17) Examining crane should be done frequently. If abnormity is found, fix it as soon as
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possible.
18) When actual load reaches 90% of rated one and load moment limiter alarms, to which
should pay high attention.
19) Forbid any reworking towards crane without permission. Otherwise take responsibility by
yourself.

WARNING: Stop working in one of the following conditions:

a. Over load or load is uncertain.
b. Load’s binding or hanging is not good. Or load may fall due to imbalance.
c. There is no mat between load edge and wire rope.
d. In case of poor visibility and /or darkness, it is difficult to identify load or conducting
signal.
e. There is something wrong with structures or parts, which may cause accident,
for example, brake and safety device are out of control or wire rope is damaged.

4.3 Operator and Conductor

4.3.1 Operator
1) With position certificate
2) The people who have learned at least half a year under master’s supervision
3) The maintenance or examining people who do their work.
4) Supervisor appointed by authority institution.
4.3.2 Qualifications of operator:
1) Healthy and agility.
2) Eyesight (cured one included) is above 0.7，no color blindness.
3) Hearing is suitable for work.
4) The ability to estimate and monitor load effectively.
4.3.3 Selection and qualifications of personnel
4.3.3.1 Crane operator
Qualifications of crane operator:
1) Crane operator must be familiar with the operation manual for crane, knowing crane’s
work principle, its structure performance and safety device’s function, and master
operation essentials and maintenance skills.
2) Crane operator and conductor should be familiar with safety rules, signals and
symbols.

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3) Be qualified with the work in hearing, eyesight and reaction ability. Be strong enough to
operate safely, and has ability to estimate distance, height and clearance correctly.
4) Be familiar with the usage of fire extinguishing equipment and be well trained. Know how
to survive under emergence conditions.
Only person meeting above items and authorized is permitted to operate crane.

Caution:
a. Operator should examine brake, hook, wire rope and safety equipment before
operating. If there is something wrong, fix it as soon as possible.
b. Operator must fix his attention on his work during operating and is forbidden
chatting with others. Generally speaking, operator must follow signal only sent out by
appointed persons. For stopping signal, follow it no matter who or when it issued.
Operator should refuse to accept signal which violates operation regulations. Stop the
crane immediately if somebody is found climbing crane.
c. Operator who is in bad condition is not allowed to operate crane. Forbid operating
after drinking.

4.3.3.2 Hanging worker

Hanging worker’s work is to hang or detach load from hook and to decide which hook or
component to be used in accordance with work plan. Hanging worker also has responsibility to
guide operator’s safe operating.
Qualifications of hanging worker:
1) With crane operation certificate.
2) Be qualified with the work in hearing, eyesight and reaction.
3) Have labor force to carry hook or component.
4) Have the ability to estimate load and balance, distance, height and clearance correctly
5) Be trained in hanging skill.
6) Have the ability to choose hook and component correctly according to load.
7) Be trained in lifting signals and familiar to use signal.
8) Be able to use audio equipment and sent oral order truly and clearly.
9) Have the ability to conduct crane to move the load safely
10) Make sure that only authorized personnel are allowed to carry out work.
4.3.3.3 Signal worker
Signal worker’s work is to transfer signal from hanging worker to operator. Sometimes signal
worker can substitute for hanging worker to do conducting and hanging work, but the work should
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be done only by one person at any time.

Qualifications of signal worker:
1) Be suitable for the work in hearing, eyesight and reaction.
2) Have ability to estimate distance, height and clearance correctly.
3) Be trained with lifting signal and familiar to use signal.
4) Be able to use audio equipment and sent oral order truly and clearly.
5) Have ability to control and conduct crane and load to move safely
6) Be authorized to take responsibility.
4.4 Before Crane Operation
Operator should examine following items before operating:
1) Estimate load condition before lifting.
2) Crane position, ground condition and horizontal support.
3) Examine all wire rope condition (including tail, roller and pulley).
4) Examine crane oil level, power and so on.
Instruction:
a. Fuel should be more than 25% full of fuel tank (examined by fuel meter).
b. lever of oil in oil tank should be between the maximum level and the minimum
level..
5) There is no barrier in the view of load and working area. Examine communication system
of operator and supervisor to make sure safety.
6) Safety equipment works normal.
7) Keep communication between operator and hanging worker.

4.5 Examine before Traveling

4.5.1 Crane’s ready work
1) Retract all booms and place jib and hooks in the prescribed position. Connect main hook to
small hook in vehicle frame with ring, and fix with pin. The keeping steps of main hook are
listed as follows:
(1)Adjust crane status as below shows.

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●
● Extend outriggers.
●
● Move main hook above the
place where it keeps.

(2)Connect main hook to small hook in vehicle with ring.

(3)Lower main boom and place it on its support. At the same time, wind wire rope.
Remember! Not disarrange wire rope.

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(4)Fix main hook.

If traveling short distance, it is feasible to hang main hook in front of cab.

CAUTION: Main hook can hang in front of cab only in following condition:
a. The falls is less than 4.
b. Wire rope has already tied with front clevis joint and auxiliary wire rope has
already tied with connect of clevis joint.

WARNING: When traveling in highway, forbid hanging hook in front of cab.

(5)Wind wire rope in slight tension. Do not wind it too much.
2) Set switches and operating equipment to ‘OFF’ position. Set brake in hoist mechanism to
braking mode.
3) When operator leaves cab, remember locking the door.
4) Retract outriggers fully.
4.5.2 Chassis
Examine following items before operating. If abnormities are found, fix it as soon as
possible:
1) Examine if chassis appearance is good, whether oil and water is sufficient, whether there is
leakage in fitting of oil, air and water pipes.
2) Examine whether air pressure of tire meets requirements, whether tire is damaged.
3) Examine whether accumulator’s terminals are good.
4) Examine whether meters, lamps, signals, wiper and others is good.
5) Examine whether steering and braking system works safely.
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6) Examine whether steering shaft’s universal joint bolts, leaf spring bolts and hub bolts fix
tightly, whether leaf spring is broken.
7) Examine whether there is water in air-reservoir.
8) Examine whether PTO is off.
4.6 Instruction for Chassis Running-in
Chassis is in the running-in condition when it leaves factory. So follow this instruction during
working.
1) Keep observing oil pressure gauges and thermometers during working.

CAUTION: If any meter’s value is abnormal, stop working at once.

2) After first 50 and 100 kilometer (30 or 60 mile), do following examines:
(1) Examine whether wheel nuts are tight. (Permitted maximum torque of wheel nuts is
600N.m, 445ft-1b) .
(2) Examine levels of cooling liquid and oil in engine.
(3) Examine oil level in equipments of drive shafting and automatic transmission.
(4) Examine whether the installation of engine, transmission and axis is tight, where
there is leakage (Estimate it with eyes.).
(5) Examine whether the connection of driving shaft is good.
(6) Examine whether other parts in chassis are fixed well.
(7) Examine pressure in air-reservoir and tire.
3) Running-in of braking pad:
In order to gain best braking effect, new braking pad needs running-in. New braking pad
should run-in from low speed to high, but no compulsory running-in is needed. According to
vehicle condition, the nominal mileage for running-in is 500Km (310mile) at least. In this
phase, the temperature of braking hub and plate can not be over 200°C (392°F). Temperature
increasing which is caused only by single braking can not be over 15% of the maximum.

WARNING: DON’T run-in with one or several continuous braking for a long time.
DON’T brake violently at high speed, it may cause serious accident.
4.7 Examine after Lifting
1) Crane and auxiliary equipment is in idle status. (e.g. park the crane in the prescribed
position.)
2) Stop engine, and switch off power.
3) Examine whether there is leakage in someplace and fit it if necessary.
4) Do some necessary cleaning，such as kinetic parts and exposure part of the piston rod of

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cylinder.
5) Examine whether bolts and nuts are tight. Fix it as soon as possible if there is something
abnormal. Forbid working with fault.
6) Record working condition and any thing abnormal.
7) Examine whether the number of tool and accessory meet requirement
8) Lock operator’s cab and safety control devices.
9) Do measures to keep away from storm or thunder.

WARNING: As temperature declines in winter, for crane without anti-freezer in

cooling water, drain all cooling water out to avoid engine freezing.
4.8 Traffic Rule
1) Obey local traffic rule when the crane travels on road.
2) Before traveling on road or highway, maintain crane in good condition to meet traffic rule.
3) Make sure that weight, axle load and size is in the permitted range.
4) In the country which adopts rule EEC, axle load must be less than 12 ton when the crane
travels on road or highway. If any of axle loads is more than 12 ton, operator must take
responsibility himself.

DANGER:
a. If axle load or total weight exceeds permitted values, the brake force will
decrease in proportion to the redundant weight.
b. Brake pad’s wear and brake’s overheat will increase possibility of danger.
c. Steering system, brake, parking brake and retard device will not meet
requirements any longer.
d. Service life of brake, axle, wheel hub, suspending oil cylinder and bearing will
shorten.

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