3_112_254_en_20110330.pdf

Safety Manual

3 112 254 en 30.03.2011

Importante note Any type of duplication or excerpt from this document, also in electronic form, is not subject to the revision service of Manitowoc Crane Group Germany GmbH.

© Copyright reserved by

Industriegelände West D-26389 Wilhelmshaven, Germany Tel: [+49] (0)44 21 294-0 Fax: +[49] (0) 44 21 294-301 The passing on or duplication of this document as well as the utilisation and disclosure of its contnets are prohibited unless expressly permitted. Infringement will incur liability for compensation. All rights pertaining to registration of patente or utility model are reserved. The original language of this document is German.

3 112 254 en

Safety Manual

30.03.2011

Manitowoc Crane Group Germany GmbH

1

About this safety manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

1

2

Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

3

3

General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

5

The truck crane as a vehicle and a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 You as the crane operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Helpers (banksmen, slingers, guides for holding ropes). . . . . . . . . . . . . . . . . . . 1 Signals and hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Horn signals by the crane operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Whistling signals by the banksman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Hand signs by the banksman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

6 8 10 11 11 11 12

3.1 3.2 3.3 3.4

4

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 23

4.1 4.2

Before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 On-road driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Driving on the site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Off-road driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Driving with a rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Driving with a load on the hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Driving from the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Driving with all-wheel steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Driving with a trailer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 After driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

4.3 5

Crane work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 33

5.1 5.2 5.3

Before crane work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Rigging lattice extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 During crane work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Crane operation with a lattice extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Two-hook operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Working with a free-standing truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Working with attached solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Working with two cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 After crane work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Work break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Unrigging the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

5.4

6

23 25 26 27 28 29 30 31 31 32 32

33 39 43 49 51 51 52 52 53 53 53

Crane operation under special operating conditions. . . . . . . . . . . . . . . . . . . . . . . 1 - 55

6.1 6.2 6.3

30.03.2011

6.4

During the winter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Working near electric cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Working near strong high-frequency transmitters or in potentially stormy weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Working near supply lines (e.g. oil or gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

55 56 57 58

s Safety Manual

3 112 254 en

1-1

7 7.1

7.2

7.3 7.4 7.5 8

Fuse change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Breakdown in road traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tyre change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tilting the driver's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Towing away. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tow starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Crane operation malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -

59 59 60 60 61 61 61 62 62 62

Transporting the truck crane on a separate vehicle. . . . . . . . . . . . . . . . . . . . . . . 1 - 63 Loading the truck crane yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 63 Loading the truck crane with another crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 64

30.03.2011

8.1 8.2

Proper conduct in the event of malfunctions, accidents and fires . . . . . . . . . . . 1 - 59

1-2

3 112 254 en

Safety Manual

1 About this safety manual

1

About this safety manual This safety manual only applies to truck cranes constructed by Manitowoc Crane Group Germany GmbH. The safety manual is part of the documentation supplied with your truck crane. As a truck crane operator you are responsible for the safe operation of your truck crane. This safety manual is intended to warn you of the hazards that may occur during the daily operation of your truck crane and show you how to avoid these hazards from the onset or react appropriately should they occur. The safety manual contains: – Information about the proper use of your truck crane. – General safety instructions. – Safety instructions that apply to truck crane driving. – Safety instructions for rigging and working with truck cranes. – Safety instructions for crane operation under specific operating conditions. – Instructions concerning proper conduct in the event of malfunctions, accidents and fires. – Safety instructions concerning truck crane transport with another vehicle. The crane operator is obliged to read the safety manual carefully, as this is essential for the safe operation of the truck crane. Keep the manual in a place that is handy so that it is easily accessible whenever you need to reread certain sections. The instructions and measures contained in this safety manual will not protect you from all hazards that may occur when working with the truck crane.

30.03.2011

s

Safety Manual

3 112 254 en

1-1

1 About this safety manual

The safety manual contains only general safety instructions and basic safety measures. They supplement the safety instructions and precautionary measures that are contained in the operating manual and other documentation supplied with your truck crane (lifting capacity and outrigger pressure tables, maintenance manual) and displayed on warning and information signs on and in your truck crane. You must observe these safety instructions and precautionary measures as well as those contained in this safety manual. Special operating conditions may also require additional safety measures. Always observe the laws and regulations of the country in which you are working. Additional safety instructions may be specified in the terms and conditions of insurance policies, company policy, etc. These instructions must also be observed. The truck crane manufacturer is not liable for accidents caused during the operation of the truck crane if the user has not complied with the laws, regulations and requirements that apply to mobile boom cranes. The manufacturer has no direct influence on the way you use, operate or maintain your truck crane. You are therefore responsible for ensuring the safe operation of the crane and the fulfilment of all laws and regulations.

30.03.2011

If you have questions on the operation or safety of your truck crane, contact Manitowoc Crane Care.

1-2

3 112 254 en

Safety Manual

2 Proper use

2

Proper use Your truck crane was built in accordance with the state of the art and the recognized safety regulations valid at the time of commissioning. Nevertheless, personal injury to the operator or a third party as well as damage to the crane and other property may occur during use. Your truck crane may only be modified with the consent of the manufacturer. Your truck crane must be in proper working order and may only be used for its intended purpose, while taking into account the safe operation of the unit and any related hazards. Malfunctions that may affect the safe operation of the unit are to be corrected immediately. Your truck crane may only be operated at temperatures of between –25 and +40 °C if it is not equipped with the proper special equipment. Your truck crane may only be used as an erection crane to vertically lift loads in the authorized rigging modes using a hook block that is reeved to the hoist rope. The weight and centre of distribution of the loads must be known. Any other use of the crane is considered improper. The manufacturer is not liable for damage resulting from the improper or unauthorized use of the truck crane. The user shall take on full responsibility for any such use. Proper use also includes: – Observation of the complete crane documentation, consisting of the operating instructions, the lifting capacity table, the outrigger pressure table and the safety manual. – Following of the inspection and maintenance requirements according to the maintenance manual.

30.03.2011

s

Safety Manual

3 112 254 en

1-3

2 Proper use

Improper use includes: – Transporting loads on the carrier. – Pushing, pulling or lifting loads with the level adjustment system, the beams or the outrigger cylinders. – Pushing, pulling or lifting loads off of the ground using the slewing gear, the derricking gear or the telescoping gear. – Pulling off fixed objects using the crane. – Two-hook operation. – Free-standing operation outside the authorized slewing range. – Defining RCL codes that do not correspond to the actual rigging mode. – Working with an overridden RCL. – On-road driving in an unauthorized driving mode (axle load, dimension). – Moving the rigged crane in an unauthorized driving mode. – Use of equipment that is not authorized for use with the crane. – Transportation of people with unauthorized means of passenger transportation. – Carrying passengers outside of the driver's cab.

30.03.2011

– Loading and unloading work, i.e. continuous operation without a corresponding break.

1-4

3 112 254 en

Safety Manual

3 General Safety Instructions

3

General Safety Instructions Always use extreme caution when operating the truck crane. Keep in mind that accidents could cause injury or death or significant damage to property. Safety-conscious operation protects not only you but also those around you. You are personally responsible for safety. It is your job to read the documentation of your truck crane (operating manual, lifting capacity table, outrigger pressure table, maintenance manual) completely and carefully and ensure that you understand its contents. Read the warning and information signs on and in the truck crane with the same care and follow their instructions. Ensure that the signs remain legible and replace any missing or damaged signs immediately.

30.03.2011

Always keep the operating manual and the lifting capacity table in the truck crane. This documentation is to accompany you through every working day. The manufacturer is not liable for malfunctions and damage arising from the non-observance of the commissioning, operating and maintenance instructions contained in this documentation.

Safety Manual

3 112 254 en

1-5

3 General Safety Instructions

3.1

The truck crane as a vehicle and a crane A new truck crane must be run in during the first few hours of operation. The run-in regulations for your truck crane may be found in the maintenance manual. Your Manitowoc Crane Group Germany GmbH truck crane is an erection crane. The truck crane was designed and manufactured as an erection crane in accordance with the state of the art and the applicable technological standards. The laws, regulations, requirements and guidelines that apply to mobile boom cranes have been observed. The truck crane is not designed for loading and unloading work (continuous operation without corresponding breaks). Monitor the temperature of the hydraulic oil and note the shorter maintenance intervals (refer to Maintenance Manual) for loading and unloading work. Only operate the truck crane at permissible outdoor temperatures. Without special equipment, the truck crane may only be operated in outside temperatures of –25 °C to +40 °C. The truck crane may only be operated at temperatures outside of this range if it is equipped with this special equipment. You must know the lifting capacity of your crane under the respective operating conditions. You may not begin crane work unless your truck crane disposes of the required lifting capacity. Further information may be found in the lifting capacity table.

30.03.2011

Your truck crane must be roadworthy and in good working order. If you are unsure of the operational safety and roadworthiness of your truck crane, you must stop driving or discontinue crane work immediately.

1-6

3 112 254 en

Safety Manual

3 General Safety Instructions

All maintenance and repair work must be completed before starting up the truck crane. Carry out the prescribed inspections daily before starting up the truck crane. Further information may be found in the operating instructions. Observe the prescribed maintenance intervals. All maintenance work must be carried out professionally. Further information may be found in the maintenance manual.

Never put off necessary repair work. All repair work must be carried out immediately by trained, qualified personnel. Only original manufacturer replacement parts may be used if any parts need replacing. Further information may be found in the spare parts list. Always keep your truck crane clean. This applies in particular to the warning and information signs, operating and control instruments, mirrors, windows and other glass surfaces. Keep all accessible surfaces free of dirt, oil and grease. Clean your shoes and wash your hands before climbing onto or getting into your truck crane. Always use the mounting brackets on your truck crane that are provided for the specific piece of equipment (e.g. wheel chocks, ladders). Keep all tools in the tool-box. Secure all loose articles. The truck crane may only be modified with the manufacturer's express consent. The manufacturer is not liable for malfunctions and damage if the truck crane is modified or re-equipped without our consent, especially if the effectiveness of built-in safety devices is deliberately reduced or eliminated.

30.03.2011

Any welding work on load carrying members of the truck crane may only be carried out with the manufacturer's express consent. Observe all applicable regulations of the country in which you are working (e. g. rules for the prevention of accidents or rules for fire prevention).

Safety Manual

3 112 254 en

1-7

3 General Safety Instructions

3.2

You as the crane operator If you drive or work with a truck crane, you must fulfil the following fundamental requirements:

• You must possess the prescribed authorization certificate and carry it with you at all times.

• You must have read and understood the documentation of your truck crane and all warning and information signs in and on your truck crane.

• You must know and understand the signals and hand signals used to communicate with banksmen, slingers and others.

• You must be in good mental and physical condition, have excellent vision and hearing and good coordination. Have regular physical examinations.

• You must be physically able to operate all operating element on the truck crane.

• You must have mastered all operating procedures and be able to operate all safety devices. Furthermore, profound knowledge of the truck crane's behaviour is essential. Familiarize yourself with the truck crane, its operation and special features before initial use. Take a training course for crane operators if you have no previous experience with truck cranes.

• You must be able to foresee possible safety risks and act accordingly. In particular, you must strive to observe all rules and regulations and follow all instructions.

• You must keep calm and act in a responsible manner even if you are under stress or incidents occur. If a malfunction occurs, you must try to prevent consequential damage.

• If an accident occurs, you must be able to give first aid and know where

30.03.2011

to find additional help.

1-8

3 112 254 en

Safety Manual

3 General Safety Instructions

• In the event of a fire, you must know how to use the appropriate aids and a fire extinguisher and know where to find additional help. Always wear appropriate working clothes. Wear close-fitting clothes. Avoid open jackets and shirt sleeves, loose scarves, rings, chains and other objects that may catch on the operating elements and movable parts of your truck crane. Wear the prescribed articles of protective clothing (e.g. hard hat, reflective clothing and safety boots) when working with the crane. When working with ropes and chains, always wear safety gloves made of thick leather. Also wear safety gloves when working outside the crane cab.

Stay alert. Never work with your truck crane when under the influence of drugs, alcohol or medication. Keep your eyes on the load or the banksman. Concentrate on your work and do not let anything distract you. Do not read, drink, eat or smoke during crane work. Stop working when you feel tired and can no longer guarantee the safe operation of your truck crane.

30.03.2011

Notify your relief operator. You must inform your relief of the condition of the crane and any agreements that have been made when handing over the crane to the new operator.

Safety Manual

3 112 254 en

1-9

3 General Safety Instructions

3.3

Helpers (banksmen, slingers, guides for holding ropes) You are responsible for the safety of your helpers. Employ trained, qualified and experienced helpers, e.g. as banksmen, slingers and holding rope guides. Give your helpers careful instruction.

Use a banksman. The banksman monitors the movements of the truck crane and the load and helps you when you: – Cannot see the entire working area. – Cannot see the load at all times or cannot see it well enough. Agree on the signals that you and your banksman will use. Do not begin crane work until you and your banksman understand all of the signs and signals that you intend to use. The banksman may guide you using whistling signals, hand signs or a walkie-talkie. Watch only the hand signs and signals used by your banksman, but always heed stop signals, even those used by others. Stop work immediately if you can no longer see your banksman or have lost contact to him.

30.03.2011

When operating the crane at night, ensure that your banksman is standing in a well-illuminated area so that you can see him clearly at all times.

1 - 10

3 112 254 en

Safety Manual

3 General Safety Instructions

3.4

Signals and hand signals Signal systems that are not based on hand signs (e.g. walkie-talkies) must be sufficiently protected against unauthorized use, damage, weathering and all other conditions that may impair operational safety.

Horn signals by the crane operator

30.03.2011

Whistling signals by the banksman

You may use the horn of your truck crane to communicate with your banksman. The following horn signals are recommended in order to prevent misunderstandings: I understood your signal: (also: I will follow your signal)

1 short blast

Repeat your signal: (also: give me signals)

2 short blasts

I cannot follow your signal: (also: I have a malfunction)

Continuous blast

Be careful, you are in danger:

Long blasts with short pauses

The banksman may communicate with the crane operator by blowing a signal whistle. The following whistle signals are recommended in order to prevent misunderstandings: To get attention:

1 very long blow

Stop movement:

1 long blow

Raise a load:

2 short blows – pause – 2 short blows

Lower a load:

3 short blows – pause – 3 short blows

s Safety Manual

3 112 254 en

1 - 11

3 General Safety Instructions

Hand signs by the banksman

The banksman and crane operator may also communicate using hand signals. The banksman uses an appropriate hand signal to indicate the movement that is to be performed with the truck crane. The crane operator performs the respective movement until the banksman uses the hand sign Stop to indicate the end of the movement. All hand signs must be clear and recognizable, even if the banksman is standing far away. The banksman must therefore keep his arms beside his body for some hand signals. If he holds his arms in front of his body, the signs will not be distinguishable at greater distances. The following hand signs are recommended in order to prevent misunderstandings: Hand signals for driving with the truck crane The banksman stands in front of the truck crane. Drive to the right Movement to the side with the bent arm.

Drive to the left

30.03.2011

Movement to the side with the bent arm.

1 - 12

3 112 254 en

Safety Manual

3 General Safety Instructions

Drive backwards Hand movements with the bent arm.

Drive forward and show distance Hand movements with the bent arm. If necessary, show distance with both hands.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 13

3 General Safety Instructions

Hand signals for driving with the truck crane The banksman stands behind the truck crane. As the driver, make sure that you see the banksman laterally reversed in the rear vision mirror. Drive to the right Movement to the side with the bent arm.

Drive to the left Movement to the side with the bent arm.

Drive forward

30.03.2011

Hand movements with the bent arm.

1 - 14

3 112 254 en

Safety Manual

3 General Safety Instructions

Drive backwards and show distance Hand movements with the bent arm. If necessary, show distance with both hands.

Hand signals for crane operation The banksman is within the crane operator's field of vision.

Stop movement Stretch both arms out to the side.

Stop movement when danger is present Up-and-down movements with both arms stretched out to the side.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 15

3 General Safety Instructions

Move the main hoist Place fist on helmet, then normal signals.

Move auxiliary hoist Place hand under the bent arm, then normal signals.

Raise a load

30.03.2011

Circular movements with hand pointing upwards.

1 - 16

3 112 254 en

Safety Manual

3 General Safety Instructions

Raise load slowly Circular movements with hand pointing upwards, holding the other hand stretched out above it.

Lower a load Circular movements with hand pointing downwards.

Lower load slowly Circular movements with hand pointing downwards, holding the other hand stretched out below it.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 17

3 General Safety Instructions

Raise the main boom Upward movements with arm stretched out.

Raise the main boom slowly Circular movements with arm pointing upwards, holding the other hand stretched out above it.

Lower the main boom

30.03.2011

Downward movements with arm stretched out.

1 - 18

3 112 254 en

Safety Manual

3 General Safety Instructions

Slowly lower the main boom Downward movements with arm pointing upwards, holding the other hand stretched out below it.

Raise main boom and lower load Upwards movements with arm stretched out, at the same time circular movements with the other hand stretched out downwards.

Lower the boom and raise the load Downwards movements with arm stretched out, at the same time circular movements with the other hand stretched out upwards.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 19

3 General Safety Instructions

Raise main boom and hold load Upward movements with stretched out arm, put other hand together with fist.

Lower main boom and hold load Downward movements with stretched out arm, put other hand together with fist.

Extend main boom telescoping

30.03.2011

Movement to the side with both bent arms.

1 - 20

3 112 254 en

Safety Manual

3 General Safety Instructions

Retract main boom Movement to the side with both bent arms.

Raise the luffing jib Upward movements with stretched out arm, stretch out other arm upwards.

Lower the luffing jib Downward movements with stretched out arm, stretch out other arm upwards.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 21

3 General Safety Instructions

Turn the superstructure to the left Stretch out arm to side.

Turn the superstructure to the right Stretch out arm to side.

End work

30.03.2011

Put both hands together above head.

1 - 22

3 112 254 en

Safety Manual

4 Driving

4

Driving The following safety instructions and precautionary measures for driving supplement the safety instructions and precautionary measures contained in the operating manual.

4.1

Before driving Ensure that none of the vent grilles in the driver's cab are covered (e.g. by pieces of clothing or bags). Use only the steps and ladders when getting on and off your truck crane. Use only the handles provided to keep a firm hold. Never hold onto control levers, hoses or cables. Always make sure you have a solid foot-hold and firm grip, particularly in wet conditions. Never jump from your truck crane unless it is an emergency. Never reach into movable components unless these are securely locked against each other and the engines of both the vehicle and the crane are shut off. Inspect your truck crane. Walk around the truck crane before beginning to drive. Do not assume that everything is in working order simply because it was in working order when work was last completed. Check that all necessary safety devices (e.g. guards, covers and lighting) are properly secured and in good working order. Ensure that no fluids (e.g. oil, fuel or water) have leaked or are leaking. Seal the leak and dispose of the leaked material accordingly. If nuts or bolts have loosened, tighten the screw connection again and replace missing parts. Use only the original spare parts provided by the manufacturer.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 23

4 Driving

Check the level of the fuel, engine oil, coolant, hydraulic oil and all other consumables and lubricants. Only authorized consumables and lubricants may be used for refilling. Ensure that the seals, e.g. filler-necks and outlet sleeves, on all systems are in place and secured properly. Check the condition of all tyres and wheel rims. Check the air pressure in all tyres. Details concerning the tyre pressure may be found in the operating manual and the maintenance manual. Keep in mind that the air pressure in warm tyres is higher. Exhaust fumes are deadly! Ensure that you have sufficient ventilation if you must start the engine in a closed-in area.

Warning tags may be located in or on the truck crane. Never start the engine if you find one of these tags anywhere. Wait until the warning sign is removed by either the person who put it there or someone who knows why it was put there.

All operating elements that may cause the inadvertent movement of the truck crane when the engine is started must be in zero position. All pedals must be clean and dry. Keep the cab floor free of dirt and moisture to prevent your feet from slipping off the pedals.

1 - 24

3 112 254 en

Safety Manual

30.03.2011

Check all operating elements before starting the engine. Ensure that all operating elements are clean, dry, accessible and operable. Remove any loose objects from the cab floor.

4 Driving

Adjust the driver's seat and the rear vision mirror accordingly. Do not start the engine until you are sure that all preparatory work inside, outside and in particular under the truck crane has been completed. You may only start the engine when sitting on the driver's seat. This is the only position from which you have control of all operating elements and can quickly and properly react to potential danger. Monitor all warning and indicator lamps as well as the control instruments when the engine is started. Further information may be found in the operating instructions.

4.2

While driving Drive carefully and do not endanger the lives of others or cause damage to property. Only start the engine when sitting on the driver's seat. This is the only position from which you have control of all operating elements and can quickly and properly react to potential danger. You may only take the permitted number of passengers on the seats provided in the driver's cab. No one is permitted to ride in the crane cab or anywhere else on your truck crane. Activate the warning devices required by the regulations of the country in which you are working (e.g. headlights, rotating beacons). Begin driving slowly. Ensure that all driving functions (e.g. braking and steering) are in good working order and note any unusual noises. Stop immediately if you detect a malfunction. Monitor the indicating instruments in the driver's cab continuously while driving. In order to prevent accidents and damage, you must know what to do if a warning light illuminates or an indicating instrument displays a critical value.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 25

4 Driving

Always take the dimensions and driving characteristics of your truck crane into account. You must know the total weight and the axle loads of your truck crane in order to avoid exceeding the weight restrictions on roads and bridges as well as the load bearing capacity of the ground. You must know the width and height of your truck crane in order to pass through narrow and low places safely. Always keep a sufficient distance away from overhead cables and trolley-wire cables.

When driving, keep in mind that the boom of your truck crane protrudes over the front of the driver's cab and the rear section of the crane swings out around corners. Keep a safe distance from buildings, poles or trees that are close to the edge of the road. Have someone guide you in confined or blind areas. The banksman determines the driving speed and monitors the movements of your truck crane. Use the agreed signals and hand signs.

On-road driving Use the operating manual to determine whether your truck crane is in the prescribed condition for on-road driving (e.g. counterweight, hook block or lattice extension) before setting off. Maintain this condition at all times while driving.

30.03.2011

Observe the applicable traffic regulations of the country in which you are working. Keep in mind that your truck crane is a large, heavy vehicle that is to be driven with particular care and prudence in heavy road traffic.

1 - 26

3 112 254 en

Safety Manual

4 Driving

Do not drive with all-wheel steering or activated differential locks. Decrease your driving speed in good time when approaching sharp corners, narrow places, places with low headroom, undulations and in particular railroad crossings with trolley-wire cables. Always keep away from soft shoulders, as these could prove to be treacherous traps for your truck crane. Use extreme caution when driving on wet, slippery roads.

Driving on the site

The site will often have soft, narrow driving paths. Refer to the sections Offroad driving and Driving with a rigged crane depending on the specific operating conditions. Have someone guide you whenever possible. If you must drive without the help of a banksman, use the following horn signals to make your intentions known: I am driving forwards:

2 short blasts

I am driving backwards:

3 short blasts

I am stopping:

1 short blast

Do not drive on the site until you are certain that your path is clear. Drive slowly.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 27

4 Driving

Off-road driving

You may not start off-road driving until: – The boom is placed on the boom rest. – The superstructure is locked into place and secured against turning. – The hook block is secured and cannot swing.

You must know the load-bearing capacity of the terrain and the axle loads of your truck crane for off-road driving. You must know when your truck crane is no longer stable on inclines. You may only drive over an obstacle (e.g. a large bump or a step in the ground) if you are certain that the truck crane will not run aground. If you cannot drive over the obstacle straight on, you must drive over it diagonally. Please note that under certain circumstances the total weight and the individual axle loads are greater when the crane is rigged than in on-the-road driving mode (see Driving with a rigged crane in this section). Make use of all of the devices on your truck crane that are designed to make off-road driving easier. Keep in mind that driving too quickly on rough terrain could cause damage to your truck crane. Do not take this risk. The rougher the terrain, the slower you should drive. Only tow the truck crane free in reverse driving direction!

30.03.2011

Only fasten the tow rope to the slinging points provided for this purpose. The truck crane may only be towed straight out of its own track in reverse direction. Pulling the truck crane in jolts or diagonally is strictly prohibited. Support the towing manoeuvre with engine power of the truck crane.

1 - 28

3 112 254 en

Safety Manual

4 Driving

Driving with a rigged truck crane

Only drive a rigged truck crane if this is explicitly stated in the operating instructions. You must know the load-bearing capacity of the route and the axle loads of your truck crane. Only drive if the route is a flat, even surface. The operating manual contains the conditions you must fulfil if you wish to drive the crane while it is rigged (e.g. position of the superstructure, telescoping or boom angle). The risk of overturning is particularly high when driving a rigged truck crane. Before driving, check the air pressure of the tyres when the tyres are cold. The tyres become hot when driving, which increases the tyre pressure. Do not let out any air pressure when the tyres are warm. When the air pressure in the tyres is too low, the tyres are under extreme pressure and the truck crane could overturn. You must extend the outriggers before beginning to drive in order to decrease the risk of overturning. Extend all four outrigger beams completely. Extend all outrigger cylinders until the outrigger pads are just above the ground. Monitor the wind speed when driving a rigged truck crane. You may only drive the truck crane if the maximum permissible wind speed is not exceeded. The maximum permissible wind speeds that apply to crane work also apply to driving a rigged truck crane.

You must have a banksman guide you when driving a rigged truck crane. Keep in mind that the steering behaviour of your truck crane will be different. Avoid jolting and braking suddenly. You may only drive at the prescribed speed. While driving, ensure that neither the outrigger nor any other part of your truck crane catches on an obstacle. Choose the largest possible turning radius if you must drive around a corner.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 29

4 Driving

Driving with a load on the hook

The following safety instructions only apply if your truck crane is authorized to drive with a load. The safety instructions that apply to driving a rigged truck crane generally apply to driving with a load on the hook. The following safety instructions must also be observed: Do not drive with a load on the hook unless this is explicitly stated in the lifting capacity table. Observe the lifting capacity table and the operating instructions. These contain the conditions you must fulfil (e.g. position of the superstructure, telescoping and RCL code) if you wish to drive with a load on the hook.

30.03.2011

Driving with a hanging load is particularly dangerous. You should therefore only drive with a load on the hook if absolutely necessary. Prevent the load from swinging using holding ropes. Keep the load as close to the ground and the truck crane as possible while driving. The load can be transported on the carrying deck of some Manitowoc Crane Group Germany GmbH truck cranes if they are properly secured.

1 - 30

3 112 254 en

Safety Manual

4 Driving

Driving from the crane cab

The following safety instructions only apply if your truck crane can be driven from the crane operator's cab. The truck crane may only be driven if the route does not have a steep incline or sloping ground. The truck crane may only be driven from the driver's cab under such conditions. Please note that the slewing direction on the steering wheel and the steering angle of the wheels must not always correspond (see Driving from inside the crane cab in the operating instructions). Lock the parking brake in the crane cab after driving.

Driving with allwheel steering

The following safety instructions only apply if your truck crane is equipped with all-wheel steering.

If all-wheel steering is activated, the rear axle lines and the front axle lines may be steered separately. Keep in mind that all-wheel steering changes the driving behaviour of your truck crane while driving. The turning circle of the truck crane will become smaller if you turn the wheels of the front and rear axle lines in opposite directions. The truck crane will move diagonally to the side if you turn the wheels of the front and rear axle lines in the same direction (crab travel mode). Return the truck crane to normal driving mode after driving with all-wheel steering. Ensure that all-wheel steering has actually been switched off, particularly before on-road driving. Risk of accidents.

30.03.2011

s Safety Manual

3 112 254 en

1 - 31

4 Driving

Driving with a trailer

Observe the regulations of the country in which you are working that apply to driving with a trailer. Working with a trailer is only permitted if the truck crane is registered for towing a trailer and has been equipped with the appropriate special equipment (e.g. towbar coupling) by the manufacturer. If this is the case, refer to the operating manual for further information about towing a trailer. Do not exceed the maximum permissible trailer load.

4.3

After driving Choose a suitable, safe place to park your truck crane. Do not park in areas in which the truck crane could slip or the ground could be washed out. Do not park on a hill. If you have no other place to park, secure the truck crane using wheel chocks to prevent it from rolling. Always lock the parking brake after driving. Your truck crane cannot be prevented from rolling by selecting a gear position. Lock the truck crane to prevent unauthorized use. Turn off the engine, remove the ignition key and keep the key with you.

30.03.2011

If you leave your truck crane for longer periods of time (e.g. overnight or weekends) you must also turn off the battery master switch and remove the spindle-shaped button. Lock the crane cab and the driver's cab and keep the keys with you.

1 - 32

3 112 254 en

Safety Manual

5 Crane work

5

Crane work The following safety instructions and precautionary measures for working with the crane supplement the safety instructions and precautionary measures contained in the operating manual.

5.1

Before crane work Cooperate with your supervisor and follow his instructions. Report to your supervisor upon arrival at the site, have him explain the applicable safety regulations for the site and ask about the safety precautions required for your work.

Choose a location on the site that will provide the truck crane with a firm and secure holding and allow you to work safely. Familiarize yourself with your work area and its surroundings before setting up your truck crane. In particular, check whether electric cables, supply lines (e.g. gas or oil) or other obstacles are hazardous for crane work. Mark these locations as conspicuously as possible. Park the truck crane as close as possible to the load that is to be lifted while keeping a safe distance away from slopes and pits.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 33

5 Crane work

The ground under the truck crane must be stable enough to withstand the loads produced during crane work. If the ground under the truck crane gives way, it could cause the truck crane to tip or overturn. The ground under the truck crane should also be even in order to facilitate the correct alignment of the crane. Mark the entire danger zone of your truck crane using cordons, marker tape, warning signs or other suitable materials. Support the truck crane on outriggers before rotating the superstructure. The truck crane may only be turned when it is not on outriggers if it is allowed to carry out freestanding work in a slewing range of 360°, see operating instructions. Observe the lifting capacity and outrigger pressure tables of your truck crane. The surface pressure of the outrigger pads must never be greater than the load bearing capacity of the ground. The truck crane may overturn. The prescribed span may be found in the lifting capacity table. All outrigger beams must always be extended to the same span unless otherwise stipulated in the operating manual. If you are forced to work with the truck crane at a location at which the load bearing capacity of the ground is insufficient, you must enlarge the surface area of the outriggers using packing made of stable material (e.g. wooden planks). The packing material must be able to withstand the outrigger pressure during crane work. Monitor the movement of the outrigger beams and outrigger cylinders when extending the outrigger. Risk of crushing.

30.03.2011

Use the outrigger cylinders to compensate for uneven ground. Do not extend one outrigger cylinder significantly more than the others. If the packing material presses into the ground, the outrigger cylinders must have sufficient remaining stroke in order to re-level the truck crane.

1 - 34

3 112 254 en

Safety Manual

5 Crane work

Ensure that your truck crane is horizontally aligned before carrying out crane work. Check that the truck crane is properly aligned using the circular spirit level. Never attempt to tilt your truck crane to increase the working radius. The truck crane must always be aligned horizontally. The truck crane may overturn. Use only the steps and ladders when getting on and off your truck crane. Use only the handles provided to keep a firm hold. Never hold onto control levers, hoses or cables. Always make sure you have a solid foot-hold and firm grip, particularly in wet conditions. Never jump from your truck crane unless it is an emergency. Never reach into movable components unless these are securely locked against each other and the engines of both the vehicle and the crane are shut off. Inspect your truck crane. Walk around the truck crane before beginning crane work. Do not assume that everything is in working order simply because it was in working order when work was last completed. Check that all necessary safety devices (e.g. guards, covers and lighting) are properly secured and in good working order. Ensure that no fluids (e.g. oil, fuel or water) have leaked or are leaking. Take the appropriate measures. Seal the leak and dispose of the leaked material accordingly. If screws or nuts are loose, retighten the connection and replace missing parts. This also applies to line connections. Use only the original spare parts provided by the manufacturer.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 35

5 Crane work

Check the level of the fuel, engine oil, coolant, hydraulic oil and all other consumables and lubricants. Only authorized consumables and lubricants may be used for refilling. Ensure that the seals, e.g. filler-necks and outlet sleeves, on all systems are in place and secured properly. Warning tags may be located in or on the truck crane. Never start the engine if you find one of these tags anywhere. Wait until the warning sign is removed by either the person who put it there or someone who knows why it was put there. Check in particular the hoist rope for wear, bends and other damage. Replace a worn or damaged hoist rope immediately. A description of possible hoist rope damage may be found in the maintenance manual. Ensure that the hoist ropes are not knotted or entangled. The hoist ropes must be properly attached to the deflection sheave and reeled on the hoist drum in the prescribed manner. Remove any loose objects from the truck crane. Loose objects may fall off the truck crane during crane work. Risk of accidents.

Even objects used by others (e.g. tools or beverage bottles) may not remain on the truck crane. Remove these objects in order to prevent others from walking into the danger zone during crane work. Provide your banksman with a board containing the signals and hand signs that are to be used during crane work.

30.03.2011

Exhaust fumes are deadly. Ensure that you have sufficient ventilation if you must start the engine in a closed room.

1 - 36

3 112 254 en

Safety Manual

5 Crane work

Check all operating elements in the crane cab before starting the engine for crane operation. Ensure that all operating elements are clean, dry, accessible and operable. Remove any loose objects from the cab floor. All operating elements that may cause the inadvertent movement of the truck crane when the engine is started must be in zero position. All pedals must be clean and dry. Keep the cab floor free of dirt and moisture to prevent your feet from slipping off of the pedals. Ensure that none of the vent grilles in the crane cab are covered (e.g. by pieces of clothing or bags). Adjust the seat in the crane cab and the mirror used to monitor rope running accordingly. Do not start the engine until you are sure that all preparatory work inside, outside and in particular under the truck crane has been completed. You may not start the engine unless you are sitting in the seat of the crane cab. This is the only position from which you have control of all operating elements and can quickly and properly react to potential danger. Monitor all warning and indicator lamps as well as the control instruments when the engine is started. Further information may be found in the operating instructions. Do not begin rigging and crane work until the hydraulic oil has reached its operating temperature and you have checked all crane functions. Check, without a load on the hook, whether all crane functions (e.g. raise, lower and telescope boom, slew superstructure, hoists, rapid motion, engine speed and brakes) are in good working order.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 37

5 Crane work

Use only equipment that belongs to your particular truck crane (e.g. counterweight). The equipment of your truck crane was made to fit your truck crane only. Your truck crane and its equipment have the same serial number. The truck crane may only be operated with this equipment. Observe the information in the lifting capacity table of your truck crane. If your truck crane can be operated with different weights, the counterweight sections may only be combined as defined in the lifting capacity table. Other combinations are prohibited.

30.03.2011

Use particular caution when stacking and lowering the counterweight sections. Ensure that no body parts or other objects get caught between the counterweight sections. Keep a sufficient distance away. Risk of crushing.

1 - 38

3 112 254 en

Safety Manual

5 Crane work

Ensure that the equipment is slung securely. The equipment of the truck crane (e.g. auxiliary hoist and counterweight) are provided with holders specifically for this purpose. The equipment is to be slung using these holders only. If your truck crane is equipped with removable counterweight sections, you may only sling one counterweight section at a time. The safety instructions that apply to slinging loads also apply to slinging the truck crane equipment (see section During crane work).

Only mount the equipment as described in the operating manual of your truck crane. Observe the prescribed assembly sequence. Remove any loose objects from the equipment. Loose objects may fall off the truck crane during crane work. Risk of accidents. Check that all safety devices (e.g. RCL and lifting limit switch) are in good working order. You cannot begin rigging and crane work unless all safety devices are in good working order.

5.2

Rigging lattice extensions Your truck crane may be equipped with various lattice extension systems: two-stage swing-away lattice extension, telescopic swing-away lattice extension, power tilt jib, boom extension or luffing lattice extension. All lattice extensions increase the reach and thus the application possibilities of your truck crane. However, they also require special safety precautions, both during rigging and crane work.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 39

5 Crane work

When rigging the lattice extension, observe the specifications concerning the required counterweights and outriggers, the permitted superstructure position and the telescoping status of the main boom contained in the operating manual. Use the enclosed extendable ladder when rigging and unrigging the lattice extension if you need to reach higher areas. Never climb on the main boom or the lattice extension unless they are equipped with walkways or steps. Never lean the extendable ladder against the lattice extension, rather against the head of the main boom, especially when rigging the power tilt jib, as the power tilt jib moves during rigging.

Do not support yourself on moveable parts (e.g. hydraulic hoses) when carrying out rigging work on the ladder. Do not grasp bore holes or other narrow areas. When carrying out rigging work on the power tilt jib, find a holding position which is as far away as possible from the locking cylinders so as to prevent your fingers or hands from being crushed. An auxiliary crane is necessary for the installation of the boom extension or the luffing jib. An auxiliary crane is also required for swing-away lattice extensions and the power tilt jib in order to mount the lattice extension sections on the main boom. When raising the lattice extension sections, use only the lifting gear that corresponds to the load. Fasten them to the slinging points provided for this purpose (if applicable).

30.03.2011

If no fixed slinging points are provided, observe the centre of distribution of the individual lattice extension sections specified in the operating manual.

1 - 40

3 112 254 en

Safety Manual

5 Crane work

Always insert the connecting pins from the outside inward. Fasten the pins using retaining pins. When rigging, ensure that the hoses and lines that lead from the main boom to the lattice extension are laid in such a way that they cannot be damaged. Connect the hoses and lines only as described in the operating manual. Check that all safety devices (e.g. lifting limit switch) are in good working order after rigging. Overriding the lifting limit switch is strictly prohibited.

Please observe the following special instructions for the power tilt jib: You should under all circumstances follow the sequence of working steps set out in the operating manual, as the power tilt jib may otherwise collapse. When swinging the main jib to the front, only telescopic part II should be extended. Extending any other telescopic part will damage the truck crane. This applies to both rigging methods of the power tilt jib. When rigging the hydraulic hoses, ensure that the hoses that lead from the hose drum are kept under tensile stress, particularly when changing the retaining plate with the hydraulic quick couplings. You should therefore ensure that the ladder is stable and that you have a good foothold on the ladder.

Before swinging back the power tilt jib laterally to the main jib, plug the hydraulic hose holders into the mountings for main jib operation to protect them from potential damage.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 41

5 Crane work

Please observe the following special instructions for the boom extension and the luffing jib: You may only extend the boom extension or the luffing jib to the length combinations that are specified in the operating manual as permissible combinations. Other combinations are prohibited.

30.03.2011

The rigging crew must pay particular attention and use extreme caution when raising the boom extension or the luffing jib.

1 - 42

3 112 254 en

Safety Manual

5 Crane work

5.3

During crane work Never carry out crane work without the lifting capacity table of your truck crane. Never exceed the values specified in the lifting capacity table. All specified lifting capacity values only apply to free-hanging loads. Note the conditions (e.g. boom length, telescoping or RCL code) under which the values may be reached. The hoisting capacity of the crane depends on the tractive force of the hoist and the number of reevings on the hook block. Further information may be found in the operating instructions. When determining the required lifting capacity, please note that the weight of the hook block and the lifting gear must be added to the load. The actual payload of the crane is therefore smaller than the value specified in the table. For increased operational safety the truck crane is equipped with a rated capacity limiter (RCL). The rated capacity limiter prevents the permissible load bearing capacity of the truck crane from being exceeded. However, the RCL cannot replace safe, responsible conduct. Never use the RCL as a scale to determine the weight of loads. The RCL does not automatically assimilate all information in crane operation required to calculate the load limit. Some of this information must be entered on the RCL control unit. Set these values according to the actual rigging mode of the truck crane. If the incorrect information is entered, the maximum load capacity calculated by the RCL will not correspond with the actual permissible load capacity. Risk of accidents.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 43

5 Crane work

The RCL only protects one-hook operation (load hangs from one hook block). The RCL does not protect two-hook operation (load hangs from two hook blocks and is lifted using two independent hoisting gears). Two-hook operation is therefore particularly dangerous. It is strictly prohibited to operate the crane if the rated capicity limiter is switched off, overridden, out of operation or defective! The key for RCL overriding may not be left in the key switch during crane operation. You may only override the RCL if the operating manual or maintenance manual explicitly require you to do so. If the RCL malfunctions during crane operation, you may override the RCL in order to set down the load. Under no circumstances are you to continue working with an overridden RCL. If a load is still hanging from the hook, do not perform any movements which increase the load moment (extending the telescope, lowering the boom, slewing out of a restricted slewing range). The truck crane may overturn. Always remove the key from the RCL override key switch after overriding. Repairs to the RCL may only be carried out by properly qualified personnel. Ensure that the load is properly slung. Observe the regulations of the country in which you are working that apply to lifting tackle.

30.03.2011

Establish the weight of the load before you sling it. Keep in mind that the weight of hook blocks, ropes, chains, crossheads and other lifting tackle must be added to the weight of the load. The lifting capacity of your truck crane must be sufficient to lift the total load.

1 - 44

3 112 254 en

Safety Manual

5 Crane work

Make sure that the fail-safe device fitted to the hook block is in perfect working order. Use only suitable, undamaged lifting tackle with a sufficient loading capacity for slinging the load. Never use the hoist rope to secure the load. Never lift several loads simultaneously, even if the lifting capacity of your truck crane is sufficient to lift the load combination. This could be hazardous.

The load must be slung in such a way that it is properly balanced and cannot tip or fall. Use the slinging points provided for this purpose (if applicable). Take care not to damage the load or its packaging when slinging the load. This applies in particular to loads that could release harmful materials. Align the boom so that the hoist rope hangs directly over the load. Ensure that the lifting tackle and the load do not get caught anywhere when slinging the load. Check whether the load is fixed to the ground or the base. Never attempt to pull off a fixed load. The truck crane may overturn. Do not lift the load until the slinger gives the signal. Never pull a load diagonally over the ground, even if it is on rollers. The resulting tension could damage the boom and overload your truck crane. Dragging is strictly prohibited.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 45

5 Crane work

The entire working area of your truck crane must be properly illuminated for night-time operation. You and those around you must be able to see the movements of the crane and the load clearly. Keep a close eye on your working area at all times. Everyone on the site must be a safe distance away before you may drive your truck crane, turn the superstructure or move the load. Sound your horn if anyone approaches the working area of your truck crane or the load. Stop working if those in the danger zone do not move a safe distance away. Never leave the crane cab while a load is hanging. Never switch off the crane engine while a load is hanging. Always keep your hand near the control lever while a load is hanging. This enables you to react correspondingly at all times. Always put the load down before you stop work.

30.03.2011

You must never swing or hold a load or the hook block over those on the site. Keep in mind that people may also be sitting in driver's cabs or other rooms. Ensure that no one is standing or working under the load or any other part of your truck crane during crane work.

1 - 46

3 112 254 en

Safety Manual

5 Crane work

Never overload your truck crane. Listen for any unusual noises during crane work. Accelerate and brake all crane movements slowly. Sudden acceleration or braking will cause the load to swing or derrick. The boom could buckle or your truck crane could overturn. Ensure that your truck crane is horizontally aligned at all times. Your truck crane must always be horizontal during crane work. Sudden acceleration or braking or quick slewing movements could cause the truck crane to overturn if the boom length is long, even if the hook does not have a load. Never lift the load by raising the boom, as the RCL does not function when this is carried out.

Dragging with the hoist rope is prohibited. When lifting a load, the hoist rope must hang directly over the load throughout the entire procedure, from the time the load is picked up until it is set down. The truck crane may overturn. Some Manitowoc Crane Group Germany GmbH truck cranes allow you to telescope the main boom with a load on the hook block. You should not do this unless the operating conditions make it absolutely necessary. Do not carry out any other crane movements when telescoping with a load. Do not allow the crane movements to be shut off by the safety devices (e.g. RCL, lifting limit switch and lowering limit switch). Stop the respective movement in good time.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 47

5 Crane work

Strong winds, particularly gusts, can overload the truck crane. Monitor the wind speed on the anemometer continuously during crane work or inquire about this at the meteorological office in your area. The permissible wind speed for a fully loaded truck crane may be found in the lifting capacity table. The appropriate measures for excessive wind speeds and wind surfaces may be found in the operating instructions. Do not overload the hoist rope. Take care that no objects hit against the loaded hoist rope. This can damage the rope.

Ensure that slack-rope does not occur when reeling off the hoist rope during crane work. Slack-rope causes rope loops to form on the hoist drum which can lead to load slipping and thus damage the hoist rope. Ensure that the working area is clear before every crane movement. Do not touch any other parts when moving the load and the boom or turning the superstructure. Crane work must be terminated immediately if you touch other equipment or parts of your truck crane during the movement. Check your truck crane for damage. Do not continue to work unless your truck crane is operationally safe.

30.03.2011

Keep an eye on the load at all times during crane work. Restrict the movement of the load using holding ropes. Holding ropes must never be wrapped around any part of the person(s) holding them, as the ropes must be released quickly to avoid injury in potentially dangerous situations.

1 - 48

3 112 254 en

Safety Manual

5 Crane work

Never lift people with the hook block or the load. This is extremely dangerous and thus strictly prohibited. Only use authorized means for transporting and lifting persons (such as working cages).

Crane operation with a lattice extension

When operating the crane with lattice extensions, you must keep in mind that the truck crane is more sensitive to braking and accelerating crane movements than under normal conditions. You should therefore avoid movements that could be shut of by the RCL when working with lattice extensions. Automatic shutdown by the RCL may cause swinging that could overload the truck crane. Perform all crane movements as smoothly as possible in order to avoid overloading and swinging. When working with lattice extensions, observe the specifications concerning the required counterweights and outriggers and the telescoping status of the main boom contained in the operating manual. Telescoping the main boom with a load on the lattice extension is strictly prohibited. A hook block may be reeved on the main boom during operation with the power tilt jib. No load, however, may be attached to this hook block. The lifting capacity at the power tilt jib must then be reduced according to the lifting capacity table. The power tilt jib may be derricked and telescoped during operation with a loaded hook.

30.03.2011

s Safety Manual

3 112 254 en

1 - 49

5 Crane work

The lifting capacity on the power tilt jib is fixed for certain angles of the PTJ (fixed angles) and lengths of the PTJ (fixed lengths). The lifting capacity is lower between the fixed angles and fixed lengths (refer to the lifting capacity table). The main boom can also be derricked with a load on the hook of the power tilt jib. When working with the lattice extension, the lifting capacity of the lattice extension decreases if a hook block remains reeved to the main boom. This applies in particular if the lattice extension remains mounted to the main boom when working with the main boom. The specific lifting capacity reductions for both of these cases may be found in the comments of the lifting capacity tables. Two-hook operation in connection with the lattice extension and the main boom is prohibited. The RCL does not protect two-hook operation! Twohook operation can cause the truck crane to overload. You may not override the RCL during crane work with lattice extensions.

30.03.2011

When working with the lattice extension, it is imperative that you observe the permissible wind speed specified in the lifting capacity table and the operating manual. You must stop working and take the appropriate safety precautions (e.g. turn the truck crane into the wind) if the wind is too strong.

1 - 50

3 112 254 en

Safety Manual

5 Crane work

Two-hook operation

In two-hook operation, the load hangs on two hook blocks and is lifted using two independently operated hoists. Working simultaneously with two hook blocks on the boom is particularly dangerous. Observe all applicable regulations of the country in which you are working for two-hook operation. The RCL only protects crane operation when one hook block is on the boom. Two-hook operation is not protected by the RCL. The stability of the truck crane is at risk without RCL monitoring. You should therefore move the load at the lowest possible speed and use extreme caution when working in two-hook operation. This prevents the truck crane from overloading.

Working with a free-standing truck crane

Do not work with a truck crane which is free on wheels (i.e. which is not on outriggers) unless this is explicitly permitted in the lifting capacity table. Observe the lifting capacity table and the operating instructions. These contain the conditions you must fulfil (e.g. slewing range of the superstructure, telescoping and RCL code) when working with a free-standing crane. Leave all four outrigger beams completely extended when working with a truck crane which is free on wheels. Extend all outrigger cylinders until the outrigger pads are just above the ground. Before beginning crane work, check the air pressure of the tyres when the tyres are cold. The tyres become hot when driving, which increases the tyre pressure. Do not let out any air pressure when the tyres are warm. When the air pressure in the tyres is too low, the tyres are under extreme pressure and the truck crane could overturn.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 51

5 Crane work

Working with attached solenoid

Working with an attached solenoid is only permitted if the truck crane has been equipped with the appropriate special equipment by the manufacturer (e.g. power failure safety device or lifting capacity table). Observe the regulations of the country in which you are working that apply working with an attached solenoid. Never lift fixed loads when working with an attached solenoid.

Working with two cranes

Working with two cranes is particularly dangerous. Should it be necessary to work with two cranes, both cranes should have the same characteristics (truck cranes with telescopic booms) if possible. The weight of the load should not exceed 2/3 of the overall lifting capacity of both cranes. Do not overload one of the two cranes. The maximum lifting capacity of each individual crane must not be exceeded.

Always have someone guide you. Only one banksman should give the signals for both cranes. Before commencing work, sit down together and plan how you will proceed. Ensure that neither crane pulls the load diagonally. The hoist rope of each of the two cranes must always hang vertically.

1 - 52

3 112 254 en

Safety Manual

30.03.2011

Distribute the load on both cranes according to the respective lifting capacities. This applies in particular when the distribution of the weight of the load is unequal or an asymmetrical crosshead is used.

5 Crane work

5.4 Work break

After crane work Always put down the load before you stop work. Never leave the crane cab while a load is hanging on the hook block. Retract the boom as far as possible if leaving the crane for over 8 hours. Lock the truck crane when you leave the cab to prevent unauthorized use during your work break. Turn off the engine, remove the ignition key and keep the key with you. If you leave your truck crane for longer periods of time (e.g. overnight or weekends), turn off the battery master switch and remove the spindle-shaped button. Lock the crane cab and the driver's cab and keep the keys with you.

Unrigging the truck crane

Ensure that the truck crane is in the prescribed transport condition. All of the steps that you must carry out may be found in the respective sections of the operating manual. Keep in mind that you may not retract the outrigger until the superstructure has been turned forward to driving direction and the main boom has been set down on the boom support. The truck crane is most likely not on outriggers if it can work in a free on wheels condition with a slewing range of 360°. If the crane is not on outriggers, the superstructure may not be turned unless this is explicitly stated in the operating instructions. Monitor the movement of the outrigger beams and outrigger cylinders when retracting the outrigger. Risk of crushing. Retract the outrigger cylinders alternately by a maximum of 10 cm. The truck crane may overturn.

30.03.2011

Do not retract the outrigger beams until all outrigger pads are lifted off the ground.

Safety Manual

3 112 254 en

1 - 53

5 Crane work

30.03.2011

Blank page

1 - 54

3 112 254 en

Safety Manual

6 Crane operation under special operating conditions

6

Crane operation under special operating conditions The following safety instructions and precautionary measures for crane operation under special operating conditions supplement the instructions contained in the operating manual.

6.1

During the winter Special measures must be taken to protect the truck crane if the outdoor temperature exceeds or falls below the permissible temperature range for crane work. The specific steps that you must carry out are described in the operating manual. In extreme frost, do not touch any metal surfaces with moist or wet skin, as the skin will freeze immediately. Remove all snow and ice from the truck crane before beginning crane work. Ice and snow must also be removed from the boom and the load. The additional weight can overload your truck crane. Do not store any full or empty containers with cold-start agents or any other inflammable liquid on the truck crane. Keep any such containers away from heat, sparks and open flames. Do not smoke when working with cold-start agents or any other inflammable liquids. Empty containers may explode if they are punctured or burned.

You may only wear gloves made of soft leather and a thin lining when driving and working with the crane. You cannot work the operating instruments properly if you are wearing mittens or thick working gloves, and your fingers could slip when wearing gloves made of wool or synthetic material.

30.03.2011

The operating instructions explain the proper procedure for starting the truck crane in low temperatures. Do not begin crane work until the hydraulic oil has reached its operating temperature. Before lifting the load, check whether it has frozen to the ground or the base. Never attempt to pull off a frozen load. The truck crane may overturn.

Safety Manual

3 112 254 en

1 - 55

6 Crane operation under special operating conditions

6.2

Working near electric cables Crane work carried out in the vicinity of electric cables is dangerous and requires special precautionary measures. Observe all applicable regulations of the country in which you are working when carrying out work in the vicinity of electric cables. Contact the responsible electricity company. Inquire about the voltage and the required safe distances. Establish the necessary safety precautions for the banksman. It is your responsibility to ensure that the necessary precautionary measures be introduced. Before commencing work, inform everyone that they are not to touch the crane or the load when working near electric cables. Tell your helpers (banksmen, slingers) what to do if someone suffers an electric shock. Further information may be found in the operating instructions.

Always have a banksman guide you when working near electric cables. The banksman must be able to monitor the movement of the truck crane from a suitable location and inform you if the truck crane or the load approaches electric cables. The banksman must be able to communicate with you directly and you must concentrate on the signs and signals he gives you. Always maintain a safe distance when working near electric cables.

30.03.2011

You must always carry out all prescribed safety measures, even if your truck crane is equipped with a high voltage warning device. However, the RCL cannot replace safe, responsible conduct.

1 - 56

3 112 254 en

Safety Manual

6 Crane operation under special operating conditions

6.3

Working near strong high-frequency transmitters or in potentially stormy weather Both the truck crane and the load may become electrostatically charged when working within the range of strong high-frequency transmitters or in potentially stormy weather. This applies in particular if the truck crane is equipped with synthetic outrigger pads or the outrigger pads are packed with insulated material (e.g. wooden planks). It is therefore necessary to earth your truck crane. Ensure that the connection between the truck crane and the ground is a faultless, electrically conductive connection. Fasten the earth cable on the truck crane to the welded parts of the boom or the superstructure only. Do not fasten the cable to screwed on parts (e.g. valves, cover plates, engines or transmissions). Contact the broadcaster before commencing work within the range of highfrequency transmitters. The earthed truck crane can disturb transmission. Tell your helpers (banksmen, slingers) what to do if someone suffers an electric shock. Further information may be found in the operating instructions. The load on the hook of your truck crane may also become electrostatically charged when working within the range of strong high-frequency transmitters or in potentially stormy weather. This applies in particular if a hook block is used with synthetic sheaves and non-conducting lifting tackle (e.g. synthetic or manila hemp rope). You should therefore earth the load. Use only a metal rod with an insulated handle to earth the load. The metal rod is to be held by the insulated handle only. Accidents may occur due to an electric shock.

30.03.2011

Tell your helpers (banksmen, slingers) that they must not touch the load until after it has been earthed. Accidents may occur due to an electric shock.

Safety Manual

3 112 254 en

1 - 57

6 Crane operation under special operating conditions

6.4

Working near supply lines (e.g. oil or gas) Crane work carried out in the vicinity of supply lines is dangerous and requires special precautionary measures. Observe all applicable regulations of the country in which you are working when carrying out work in the vicinity of supply lines. You must contact the responsible supply company if harmful materials are transported in a supply line. Discuss suitable safety measures with the supply company. and establish the necessary safety precautions for the banksman. It is the responsibility of you and the supply company to ensure that the necessary precautionary measures be introduced. Always have a banksman guide you when working near supply lines in which harmful materials are transported. The banksman must be able to monitor the movement of the truck crane from a suitable location and inform you if the truck crane or the load approaches the supply line. The banksman must be able to communicate with you directly and you must concentrate on the signs and signals he gives you.

30.03.2011

Always keep a safe distance away from the lines. You must always assume that the lines are under pressure, even if they have been interrupted.

1 - 58

3 112 254 en

Safety Manual

7 Proper conduct in the event of malfunctions, accidents and fires

7

Proper conduct in the event of malfunctions, accidents and fires The following safety instructions and precautionary measures for malfunctions, accidents and fires supplement the instructions contained in the operating manual.

Fuse change

7.1

Always replace a blown fuse with a fuse of the same strength. Never repair a blown fuse with a nail, wire or aluminium foil. Risk of fire.

Breakdown in road traffic Observe all applicable regulations of the country in which you are working for proper conduct in the event of a breakdown. If your truck crane breaks down, do not stop in a tunnel or around a corner unless absolutely necessary, as the risk of accidents is much higher. Activate the hazard warning lights and safeguard the truck crane. Use the appropriate signs and devices to indicate that your vehicle has broken down. Safeguard the area around your vehicle. Warning Triangles, signal lamps and torches must be set up in front of the breakdown area in such a way as to prevent rear-end collisions, particularly in curves. Do not try to repair the damage yourself until the area has been safeguarded. Do not attempt any repair work if the truck crane is parked in a tunnel. Risk of accidents.

30.03.2011

s

Safety Manual

3 112 254 en

1 - 59

7 Proper conduct in the event of malfunctions, accidents and fires

Tyre change

Change the tyre on the flattest possible area of the traffic lane. The chosen location should not impede traffic or pose danger to you or the vehicle. Use only the original spare wheel of your truck crane. Have someone help you change the tyre if possible. You should use the supplied spur-wheel chain hoist to lift the spare wheel. The truck crane wheel is heavy and could cause injury. Move back quickly if the wheel slips off the hub. Check the wheel rim, the wheel, the wheel nuts, the pressure plates and the wheel bolts for damage before mounting the spare wheel. Do not use any damaged parts when mounting the spare wheel.

Retighten the wheel nuts of the mounted wheel after travelling approx. 50 km and again after approx. 150 km (see maintenance manual).

Tilting the driver's cab

The driver's cab of some Manitowoc Crane Group Germany GmbH truck cranes must be tilted in order to reach the vehicle engine. You must first remove all loose objects from the driver's cab and remove the front grille under the windscreen before tilting the driver's cab. Raise the main boom far enough that the driver's cab will not hit the main boom when it is tilted. If the engine fails and your truck crane is a single-engine truck crane (only one engine for driving and crane operation), you may use the emergency facility to lower the hook block and raise the main boom. The driver's cab may then be tilted. Ensure that the windscreen of the driver's cab does not press against the hook block.

30.03.2011

You may only work under the tilted driver's cab if it has been tilted forward completely and the lifting cylinder of the driver's cab tipper device is pulled under tension.

1 - 60

3 112 254 en

Safety Manual

7 Proper conduct in the event of malfunctions, accidents and fires

7.2 Towing away

Towing Observe the regulations of the country in which you are working that apply to towing. You may only tow the truck crane short distances. If the parking brake was mechanically released before towing, you must secure your truck crane using chocks. Otherwise, it could roll away.

If the vehicle engine, the steering and the service brake are still in good working order, you may tow the truck crane with a truck and tow-rod. If the vehicle engine, the steering and the service brake are no longer in good working order, you must tow the truck crane with a towing vehicle and a tow-rod. Ensure that the braking force of the towing vehicle is sufficient to brake both vehicles and that the air supply of the tractor-vehicle is sufficient for both vehicles. The towing vehicle must start driving slowly. Avoid jolting and accelerating quickly. Drive carefully when towing.

The diesel engine cannot be started by tow starting due to the automatic transmission.

30.03.2011

Tow starting

Safety Manual

3 112 254 en

1 - 61

7 Proper conduct in the event of malfunctions, accidents and fires

7.3

Crane operation malfunctions Put down the load immediately, if possible. Retract the boom completely and set it down on the boom rest. Put up an appropriate warning sign in the crane cab. Always remove the ignition key before leaving the crane. Accidents may occur if you are unable to set down the load due to a malfunction. In this case, remove the ignition key before leaving the crane and safeguard the danger area.

7.4

Accident If an accident occurs, you must be able to give first aid and know where to find additional help.

7.5

Fire

30.03.2011

In the event of a fire, you must know how to use the appropriate equipment and a fire extinguisher and know where to find additional help.

1 - 62

3 112 254 en

Safety Manual

8 Transporting the truck crane on a separate vehicle

8

Transporting the truck crane on a separate vehicle The following safety instructions and precautionary measures for transport supplement the instructions contained in the operating manual. Observe all applicable regulations of the country in which you are working that apply to truck crane transport. In addition, please observe the prescribed safety measures of the shipper (e.g. the carrying agent or railway company). Ensure that the truck crane is in the prescribed condition for on-road driving before loading it onto the transport vehicle. The truck crane may only be transported on a vehicle with sufficient load bearing capacity.

8.1

Loading the truck crane yourself Use extreme caution when loading and unloading the truck crane. Use chocks to prevent the truck crane from rolling in both directions when loading it onto and unloading it from the transport vehicle.

Loading and unloading must be carried out on flat, even ground. Use only ramps with sufficient load bearing capacity when driving onto and off the transport vehicle. 30.03.2011

Secure the truck crane on the transport vehicle using chocks and a suitable chain both lengthwise and crosswise. Secure all loose objects both in and on the truck crane.

Safety Manual

3 112 254 en

1 - 63

8 Transporting the truck crane on a separate vehicle

8.2

Loading the truck crane with another crane

30.03.2011

Use only suitable lifting gear with sufficient load bearing capacity to load the truck crane. Be careful not to damage the truck crane when attaching the lifting gear. Further information may be found in the operating instructions.

1 - 64

3 112 254 en

Safety Manual