Critical Safety Procedures for Crane Setup

This document outlines the critical safety procedures for crane setup, focusing on pre-lift inspections, ground conditions, and load chart verification to ensure safe crane operation.

Pre-Lift Inspections

A thorough pre-lift inspection is essential to identify any potential hazards or equipment malfunctions before crane operation begins. This inspection should be performed by a competent person and documented for future reference.

Walk-Around Inspection

Begin the walk-around inspection by ensuring the machine power is off to avoid possible injury. Inspect each item in sequence for any conditions listed in the checklist. On all components, ensure there are no loose or missing parts, that they are securely fastened, and no visible damage, leaks, or excessive wear exists in addition to any other criteria mentioned. [5] [1] [5]

Inspection Items:

Platform Assembly and Gate: Ensure the footswitch works properly and is not modified, disabled, or blocked. Verify the latch and hinges are in working condition.
Platform & Ground Control Consoles: Check that switches and levers return to neutral, decals/placards are secure and legible, and control markings are legible.
Rotator: Inspect for any issues as per the inspection note.
Jib: Inspect the jib for any issues as per the inspection note.
Dual Capacity Limit Switch (ANSI, Australia, if equipped); Transport Position Limit Switch (CE): Ensure it is properly secured, with no damage to the switch, the arm is free to move, and free from dirt and grease.
Power Track: Inspect for any issues as per the inspection note.
All Hydraulic Cylinders: Inspect for any issues as per the inspection note.
Drive Motor, Brake, and Hub: Inspect for any issues as per the inspection note.
Wheel/Tire Assemblies: Ensure they are properly secured with no missing lug nuts. Inspect for worn tread, cuts, tears, or other discrepancies. Inspect wheels for damage and corrosion.
Main Control Valve: Inspect for any issues as per the inspection note.
Turntable Bearing: Check for evidence of proper lubrication and no evidence of loose bolts or looseness between bearing and structure.
Manual Descent: Inspect for any issues as per the inspection note (if equipped).

[5] [5] [5] [5] [5] [5] [5] [5] [5] [5] [5] [5]

Function Checks

After completing the walk-around inspection, perform a function check of all systems in an area free of overhead and ground-level obstructions. Ensure all guards protecting the function switches or locks are in place and that all function controls and switches return to the "off" or neutral position when released. [2] [2]

Operational Checks:

Emergency Stop Button: Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in.
Boom Functionality: Raise the tower base boom to approximately 40 degrees, then lower the tower boom back to the below horizontal position. Observe the position of the upright, ensuring that it remains vertical relative to the chassis.
Auxiliary Power and Manual Descent System: Check for proper operation of the auxiliary power and manual descent system (if equipped). Operate each function control to ensure proper operation.
Brakes: Drive the machine on a grade, not to exceed the rated gradeability, and stop to ensure the brakes hold.
Tilt Indicator: Check the tilt indicator is illuminated to ensure proper operation.

[2] [2] [2] [4] [4]

Boom Control System Check

Perform the boom control system check with no load in the platform from the ground control console. Ensure all axles are fully extended. With the boom fully retracted, raise the boom off the boom rest to horizontal. Position the jib horizontally (if equipped) and platform level. Extend the boom until it stops. Push and hold the Boom Control System Test button. The lighting of the green Boom Control System Calibrated indicator indicates the system is functioning properly. No indicator light or the lighting of the red Boom Control System Warning indicator indicates the system must be repaired by JLG authorized Service Personnel before the machine can be used. [6] [6] [6] [6] [6] [6]

SkyGuard® Function Check

From the Platform Control Station in an area free from obstructions, operate the telescope-out function. Activate the SkyGuard SkyLine® sensor by pressing the rod to break the connection between the rod and the right bracket. Once the sensor has been activated, verify that the telescope-out function stops and the telescope-in function operates for a short duration, the horn sounds, and if equipped with a configured ClearSky CS550 or SkyGuard beacon, the beacon illuminates. Release controls, reattach the rod to the right bracket, and recycle the footswitch to ensure normal operation is available. If SkyGuard remains activated after function reversal or cutout, press and hold the SkyGuard Override Switch to allow normal use of machine functions until the sensor is deactivated. [6] [6] [6] [6] [6] [6]

Ground Conditions

The stability of the crane depends significantly on the ground conditions. Before setting up the crane, assess the ground for its ability to support the crane's weight and the load.

Assessment Criteria:

Smooth and Firm Surface: Ensure the machine is positioned on a smooth, firm surface.
Maximum Operating Slope: The machine should be within the limits of the maximum operating slope.
Gradeability: Do not exceed the rated gradeability.
Tilt Indicator: Check the tilt indicator to ensure proper operation.

[3] [4] [4] [4] Load Chart Verification

Verifying the load chart is crucial to ensure that the crane is not overloaded, which can lead to catastrophic failure. The load chart provides information on the crane's lifting capacity at various boom lengths and angles.

Verification Steps:

Determine the Load Weight: Accurately determine the weight of the load to be lifted.
Measure Boom Length and Angle: Measure the boom length and angle at which the load will be lifted.
Consult the Load Chart: Refer to the crane's load chart to determine the maximum allowable load for the measured boom length and angle.
Ensure Capacity: Ensure that the weight of the load does not exceed the maximum allowable load specified in the load chart.
Consider Additional Factors: Consider additional factors such as wind speed, ground conditions, and the presence of any obstructions that may affect the crane's lifting capacity.