Crane parts and operation precautions

1. Few Words About Crane
Few Words About Crane
1

2. TYPES OF CRANES
Telescopic Cranes
Overhead Gantry Crane
Mobile Cranes
Tower Cranes
Truck Mounted Crane
Rough Terrain Crane
Loader Crane
Floating Cranes
Harbor Cranes
Crawler Cranes
All Terrain Crane
Level Luffing Crane
Telescopic Handler Crane
Aerial Crane
Rail Road Crane
Many More Not Included Here
2
Telescopic Cranes
Overhead Gantry Crane
Mobile Cranes
Tower Cranes
Truck Mounted Crane
Rough Terrain Crane
Loader Crane
Floating Cranes
Harbor Cranes
Crawler Cranes
All Terrain Crane
Level Luffing Crane
Telescopic Handler Crane
Aerial Crane
Rail Road Crane
Many More Not Included Here

3. 1 2
6
5
4
3
10
8 9
7
3
11
14
12 13 15

4. DEFINITIONS
 Crane– Consists of a rotating structure for lifting and lowering horizontally on rubber tires or
crawler treads.
 Hoist- Used to lift and lower load.
 Boom – An inclined spar, strut, or other long member supporting the hoisting tackle.
 Boom stops– A device used to limit the angle of the boom at its highest position.
 Brake – To slow or stop motion by friction or power.
 Block– Sheaves or grooved pulleys in a frame with hook, eye and strap.
 Jib – Extension attached to the boom point to provide added boom length for
lifting specified loads.
 Crane– Consists of a rotating structure for lifting and lowering horizontally on rubber tires or
crawler treads.
 Hoist- Used to lift and lower load.
 Boom – An inclined spar, strut, or other long member supporting the hoisting tackle.
 Boom stops– A device used to limit the angle of the boom at its highest position.
 Brake – To slow or stop motion by friction or power.
 Block– Sheaves or grooved pulleys in a frame with hook, eye and strap.
 Jib – Extension attached to the boom point to provide added boom length for
lifting specified loads.
4

5. CRANE AND PARTS NAME
5

6. FEW PARTS NAME
6

7. FEW PARTS NAME
7

8. PULLEY AND COMPONENTS
8

9. MAJOR CAUSES OF CRANE ACCIDENTS
Crane rigging
failures.(Rope ,Chains,
wires, support etc)
Crane mechanic failures
Cranes colliding with
other buildings
Cranes colliding with
energized power lines.
Cranes hitting people with
heavy materials and objects
Cranes dropping heavy
materials and objects
9
Crane rigging
failures.(Rope ,Chains,
wires, support etc)
Crane mechanic failures
Cranes colliding with
other buildings
Cranes colliding with
energized power lines.
Cranes hitting people with
heavy materials and objects
Cranes dropping heavy
materials and objects

10. MAJOR CAUSES OF CRANE ACCIDENT
Cranes overturning
Boom collapse
Crane hook-lifting device failure
Improper crane selection
Instability – unsecured load, load capacity exceeded, or ground
not level or too soft beyond the radius and boom angle.
Stormy, rainy, windy, rough ,etc weather
Improper crane set up(out of reach, Drag loads, Side-load a
boom.)
Failing to comply with manufacturer specifications for crane
use.
Lack of communication - the point of operation is a distance
from the crane operator or not in full view of the operator
Lack of training
Inadequate maintenance or inspection
By pass the functioning Systems.
Modify or ignore safety devices.
Many more not included here.
10
Cranes overturning
Boom collapse
Crane hook-lifting device failure
Improper crane selection
Instability – unsecured load, load capacity exceeded, or ground
not level or too soft beyond the radius and boom angle.
Stormy, rainy, windy, rough ,etc weather
Improper crane set up(out of reach, Drag loads, Side-load a
boom.)
Failing to comply with manufacturer specifications for crane
use.
Lack of communication - the point of operation is a distance
from the crane operator or not in full view of the operator
Lack of training
Inadequate maintenance or inspection
By pass the functioning Systems.
Modify or ignore safety devices.
Many more not included here.

11. WHO IS AT RISK
 Operator
 Helper,Engineers,workers
at Crane Site.
11

12. CRANE HAZARDS
A hazard is any object,
situation, or behavior that has
the potential to cause injury, ill
health, or damage to property or
the environment.
HAZARD?
12
A hazard is any object,
situation, or behavior that has
the potential to cause injury, ill
health, or damage to property or
the environment.

13.  Improper load rating
 Excessive speeds
 Inadequate communication or
hand signals
 Inadequate inspection and
maintenance
 Unguarded parts
 Unguarded swing radius
 Working too close to power lines
 Improper exhaust system
 Shattered windows
 No steps/guardrails walkways
 No boom angle indicator
 Not using outriggers
 Inactive Limit Switch/ Asli/boom
Over Hoist switch
 Inexperienced and over experienced
operator, rigger
Crane Hazards
Hazards can be classified as:
Physical Hazards:Temperature, ionizing or
non-ionizing radiation, excessive noise, electrical exposure,
working from heights, and unguarded machinery.
Mechanical Hazards: Protruding
and moving parts.
Chemical Hazards: These appear when
a worker is exposed to chemicals in the workplace..
Biological Hazards:viruses, bacteria,
fungus, parasites, and any living organism that can
infect or transmit diseases to human beings.
Ergonomic Hazards: Total
physiological demands of the job upon the worker, even
beyond productivity, health, and safety.
Psychosocial Hazards: variety of
psychosocial factors that workers may find to be
unsatisfactory, frustrating, or demoralizing.
 Improper load rating
 Excessive speeds
 Inadequate communication or
hand signals
 Inadequate inspection and
maintenance
 Unguarded parts
 Unguarded swing radius
 Working too close to power lines
 Improper exhaust system
 Shattered windows
 No steps/guardrails walkways
 No boom angle indicator
 Not using outriggers
 Inactive Limit Switch/ Asli/boom
Over Hoist switch
 Inexperienced and over experienced
operator, rigger
13
Hazards can be classified as:
Physical Hazards:Temperature, ionizing or
non-ionizing radiation, excessive noise, electrical exposure,
working from heights, and unguarded machinery.
Mechanical Hazards: Protruding
and moving parts.
Chemical Hazards: These appear when
a worker is exposed to chemicals in the workplace..
Biological Hazards:viruses, bacteria,
fungus, parasites, and any living organism that can
infect or transmit diseases to human beings.
Ergonomic Hazards: Total
physiological demands of the job upon the worker, even
beyond productivity, health, and safety.
Psychosocial Hazards: variety of
psychosocial factors that workers may find to be
unsatisfactory, frustrating, or demoralizing.

14. PLANNING BEFORE START-UP
 Level the crane and ensure support surface
is firm and able to support the load
 Contact power suppliers and determine
precautions.
 Know the location and voltage of overhead
and under ground power lines.
 Know the basic crane capacities, limitations,
and job site restrictions, such as the location
of power lines, unstable soil, or high winds.
 Make other personnel aware of hoisting
activities.
 Barricade areas within swing radius.
 Ensure proper maintenance and inspections.
 Determine safe areas to store materials and
place machinery.
 Level the crane and ensure support surface
is firm and able to support the load
 Contact power suppliers and determine
precautions.
 Know the location and voltage of overhead
and under ground power lines.
 Know the basic crane capacities, limitations,
and job site restrictions, such as the location
of power lines, unstable soil, or high winds.
 Make other personnel aware of hoisting
activities.
 Barricade areas within swing radius.
 Ensure proper maintenance and inspections.
 Determine safe areas to store materials and
place machinery.
14

15. Hand Signals
15
An illustration of the signals must be posted at the job site

16. Competent Person
The competent person must
inspect all machinery and
equipment prior to each use,
and make sure it is in safe
operating condition.
If it needs fixing, take it out of
service and don’t use it until it is
fixed.
16
The competent person must
inspect all machinery and
equipment prior to each use,
and make sure it is in safe
operating condition.
If it needs fixing, take it out of
service and don’t use it until it is
fixed.

17. Crane Check List
Equipment Name & Number: MOBILE CRANE
Note: Please write Yes or No in the given box and if some comments write in remarks column.
SN. Description Yes/No Remarks
1. Physical condition of body should be in sound manner.
2. No damage in tire (Bolts, crack, cuts & air pressure, etc.).
3. Head & tail light and indicators are in working condition.
4. Side mirror should be in good condition.
5. Safe work load (SWL) marked.
6. Hoist limit switch.
7. Wire rope free from damage.
8. Safety latch in hook.
9. Outrigger with spreader mat should be in good and working
condition.
10. Sprit level should be installed.
11. Boom condition while full extension (free from damage, crack &
jamming, etc.).
12. No oil leakage in hydraulic part.
13. Safe load indicator should be in working state.
14. Front, reverse and swing horn.
15. Fire extinguisher in operator cabin.
16. Operator should have valid and suitable license.
17. Crane simulator should be in working condition.
18. First aid kit should be available.
19. Crane should physically good & should have valid TPI. 17
Crane Check List
Equipment Name & Number: MOBILE CRANE
Note: Please write Yes or No in the given box and if some comments write in remarks column.
SN. Description Yes/No Remarks
1. Physical condition of body should be in sound manner.
2. No damage in tire (Bolts, crack, cuts & air pressure, etc.).
3. Head & tail light and indicators are in working condition.
4. Side mirror should be in good condition.
5. Safe work load (SWL) marked.
6. Hoist limit switch.
7. Wire rope free from damage.
8. Safety latch in hook.
9. Outrigger with spreader mat should be in good and working
condition.
10. Sprit level should be installed.
11. Boom condition while full extension (free from damage, crack &
jamming, etc.).
12. No oil leakage in hydraulic part.
13. Safe load indicator should be in working state.
14. Front, reverse and swing horn.
15. Fire extinguisher in operator cabin.
16. Operator should have valid and suitable license.
17. Crane simulator should be in working condition.
18. First aid kit should be available.
19. Crane should physically good & should have valid TPI.

18. Load Capacity
TÀiArrc 200 .is
13
CRANE~ANGED~GRAM
sors
(a) Ratings are as per
IS 4573, i.e 75% of
t pping ìoad for forward
.stab ity and 70% for
backwardstab lity.
(b) Capacities include the
weiqnt of the hook
... ;
block, slings, etc.
(e) Capacities are tor
"?· : rnachlne standard on
firm, level uniform
supporting surfaceand
depend upon the
~- mountinq, Ground,
boom ength, radius of
./
operation and proper
;fi handliilg all of which
/
must be taken nto
account by the user
(d) Deduct 680 kg tor
6 10m-jib and 910 kg
for 9 14m jib'.
CAUTION
Mach nèmust not be used
tor fting operations with
. 16.76 . ~··.r .05~s:· 8,460. 8255 8120 7915 7160 7575 7440 7235 7095
18.29 7685 7550 7345 ;1210 7005 6870 6665 6530 6325 6190
1s:01 ... W35 6530 6395 6190 60!?5 . 58.50 57t5 5510 5375
. 21.34 6055 5850 5715 5510 5375 5170 5035 4830 4695
24.38 •• ··~ j
····· 4850 4715 4510 4375 4170 4035 3830 3695
27.43 ····• ' 3900 3895 3550 3355 3220 3015 2880
30:48 ....... 3060 2925 2720 2585 2480 2245
· 33.53 2220 2085 1880 1745
36.85 1425 ,290
• ' ' . ! '
. I
TATA TFC · 280 · 45
Max
.. Lifting caoacìty ''.'''. _75 Tonnes
Boom Length ; ,... 15.24 • 45.72 metres
Lattice FLy Jìb , 9.14 metres
Crawler Qrane -Loadchart
RATED CRANE LOADS IN KG (ÀS PER IS 4573).
Qpèr;itlng . J 5.24 rn JS.29,m . ?L.3!1m 24.38m . 27,43m 30.48m 33.53m . 36.58m · ~9.62m 42.67m 45.72m
.. radlus boom 'boom. boom
I
boom .boom boom boom boom boom boom boom
3,67
4.57 ·
a:10
7.62
.9,.14
i6.$i
1°2.19
13.72
15.24
75066
.·. 5216$ ...
3266$
24()4.
J9005
···1ssoo
13155:
11340
. 9885
. l
. 519.60. . .....
324.55. 32320 32115 31980
23835 23700 23495 23360 23155 23020
18800 · 18665 18460 18325 18120 17985 17780
15400 ,5260 15060 14920 :14720 14580 14380 14240
1295ò 12815 12610 1247'5 12270 12130 11930 11790
,111.35 11000 10795 10660 10455 10320 10115 · 9980
9555 ... 9545. 9345 ·9205 9005 8865 8660 8525
14040
11590 11450
9775 9640
8320 8185
.
'
.
i
il
i
. .
l
.
;
ì
.
.
.
i
• li
. RA.~ ll'AO
MCENY~E~ H<>tATfON
· •
the gantry in lowered
positlon.
1
1 ··
i
 Make sure the crane
operator can see the:
 Rated Load Capacities
angle
 Operating Speeds
 Special Hazard
 Warning or Instruction
 Clear signal
18
TÀiArrc 200 .is
13
CRANE~ANGED~GRAM
sors
(a) Ratings are as per
IS 4573, i.e 75% of
t pping ìoad for forward
.stab ity and 70% for
backwardstab lity.
(b) Capacities include the
weiqnt of the hook
... ;
block, slings, etc.
(e) Capacities are tor
"?· : rnachlne standard on
firm, level uniform
supporting surfaceand
depend upon the
~- mountinq, Ground,
boom ength, radius of
./
operation and proper
;fi handliilg all of which
/
must be taken nto
account by the user
(d) Deduct 680 kg tor
6 10m-jib and 910 kg
for 9 14m jib'.
CAUTION
Mach nèmust not be used
tor fting operations with
. 16.76 . ~··.r .05~s:· 8,460. 8255 8120 7915 7160 7575 7440 7235 7095
18.29 7685 7550 7345 ;1210 7005 6870 6665 6530 6325 6190
1s:01 ... W35 6530 6395 6190 60!?5 . 58.50 57t5 5510 5375
. 21.34 6055 5850 5715 5510 5375 5170 5035 4830 4695
24.38 •• ··~ j
····· 4850 4715 4510 4375 4170 4035 3830 3695
27.43 ····• ' 3900 3895 3550 3355 3220 3015 2880
30:48 ....... 3060 2925 2720 2585 2480 2245
· 33.53 2220 2085 1880 1745
36.85 1425 ,290
• ' ' . ! '
. I
TATA TFC · 280 · 45
Max
.. Lifting caoacìty ''.'''. _75 Tonnes
Boom Length ; ,... 15.24 • 45.72 metres
Lattice FLy Jìb , 9.14 metres
Crawler Qrane -Loadchart
RATED CRANE LOADS IN KG (ÀS PER IS 4573).
Qpèr;itlng . J 5.24 rn JS.29,m . ?L.3!1m 24.38m . 27,43m 30.48m 33.53m . 36.58m · ~9.62m 42.67m 45.72m
.. radlus boom 'boom. boom
I
boom .boom boom boom boom boom boom boom
3,67
4.57 ·
a:10
7.62
.9,.14
i6.$i
1°2.19
13.72
15.24
75066
.·. 5216$ ...
3266$
24()4.
J9005
···1ssoo
13155:
11340
. 9885
. l
. 519.60. . .....
324.55. 32320 32115 31980
23835 23700 23495 23360 23155 23020
18800 · 18665 18460 18325 18120 17985 17780
15400 ,5260 15060 14920 :14720 14580 14380 14240
1295ò 12815 12610 1247'5 12270 12130 11930 11790
,111.35 11000 10795 10660 10455 10320 10115 · 9980
9555 ... 9545. 9345 ·9205 9005 8865 8660 8525
14040
11590 11450
9775 9640
8320 8185
.
'
.
i
il
i
. .
l
.
;
ì
.
.
.
i
• li
. RA.~ ll'AO
MCENY~E~ H<>tATfON
· •
the gantry in lowered
positlon.
1
1 ··
i
 Make sure the crane
operator can see the:
 Rated Load Capacities
angle
 Operating Speeds
 Special Hazard
 Warning or Instruction
 Clear signal

19. HOW TO CALCULATE % CRANE LIFTING CAPACITY
% crane lifting Capacity = Hook load + weight of Lifted Load
X 100
Chart rated capacity
19

20. BEFORE LIFTING CHECK THE THINGS
 Method statement, lifting plan, risk and
hazard evaluation and other legal
documents.
 Ensure lift calculations are correct
 Ensure ASLI, Over hoist limit swtich,Boom
limit switch.
 Ensure load is within load chart rating for
boom length and load radius of crane.
 Crane is rated by the maximum weight it
will lift at a minimum radius and minimum
boom length and Required Counter Weight
and boom angle.
 Method statement, lifting plan, risk and
hazard evaluation and other legal
documents.
 Ensure lift calculations are correct
 Ensure ASLI, Over hoist limit swtich,Boom
limit switch.
 Ensure load is within load chart rating for
boom length and load radius of crane.
 Crane is rated by the maximum weight it
will lift at a minimum radius and minimum
boom length and Required Counter Weight
and boom angle.
20

21. LOAD LIMITING FACTORS
 Not level
 Wind
 Side loads
 On its wheels
 Lifting over the side
 Use of extensions, jibs and other attachments
 Limits of wire rope, slings and lifting devices
 Not level
 Wind
 Side loads
 On its wheels
 Lifting over the side
 Use of extensions, jibs and other attachments
 Limits of wire rope, slings and lifting devices
21

22. FOUR BASIC LIFTING PRINCIPLES THAT GOVERN A CRANE'S
MOBILITY AND SAFETY DURING LIFTING OPERATIONS
Center of Gravity (Itisthepointintheobjectaroundwhichitsweightisevenlydistributed)
 Leverage (Rotation of the upper works (cab, boom, counterweight, load)
 Stability (Stability Is the relationship of the load weight, angle of the
boom and its radius (distance from the cranes center of rotation to the center
of load) to the center of gravity of the load. The stability of a crane could also
be effected by the support on which the crane is resting)
 Structural Integrity (The crane's main frame, crawler track and/or outrigger
supports, boom sections, and attachments are all considered part of the structural
integrity of lifting. In addition, all wire ropes, including stationary supports or attachment
points)
Center of Gravity (Itisthepointintheobjectaroundwhichitsweightisevenlydistributed)
 Leverage (Rotation of the upper works (cab, boom, counterweight, load)
 Stability (Stability Is the relationship of the load weight, angle of the
boom and its radius (distance from the cranes center of rotation to the center
of load) to the center of gravity of the load. The stability of a crane could also
be effected by the support on which the crane is resting)
 Structural Integrity (The crane's main frame, crawler track and/or outrigger
supports, boom sections, and attachments are all considered part of the structural
integrity of lifting. In addition, all wire ropes, including stationary supports or attachment
points)
22

23. FEW UNSAFE PRACTICE
Broken
Wires
and
strand
23

24. Swing Radius
24
Stay out of the swing radius of the crane –
Make sure there are barrier guards showing swing radius

25. Power Lines
Stay clear
from power
lines at
least 10
feet
25

26. Operator Visibility
Broken
Window
26

27. Suspended Loads
Don’t stand
under
suspended
loads
27
Don’t stand
under
suspended
loads

28. Sheaves
The grooves
must be
smooth and
free from
surface
defects which
could cause
rope damage
28

29. Guard Moving Parts
Unguarded
Chain Drive
29
Guard moving parts such as gears or belts

30. Ladders
30
Ladder
Use ladders to get to the upper portion of the cab

31. Guardrails
31
Runways and steps need to have guardrails,
handholds and slip resistant surfaces

32. Boom Angle Indicator
32
A boom angle indicator must be on the crane

33. Supporting Surface
33
Cranes must be on a firm supporting
surface and level within 1 percent

34. Rigging Equipment Slings
Types of slings include alloy steel chain, wire rope,
metal mesh, natural or synthetic fiber rope, and
synthetic web.
34
Chain Wire rope Metal mesh Synthetic

35. Annual Inspections
Inspection of the
hoisting machinery
must be made by a
competent person
The employer must
maintain a record of
these inspections
35
Inspection of the
hoisting machinery
must be made by a
competent person
The employer must
maintain a record of
these inspections Crane wasn’t inspected
and tipped over

36. WHAT TO INSPECT
 TPI /Insurance/Operator competency certificates
 Asli/Limit Switch/Boom over hoist limit switch.
 Radius/load chat/ground condition
 Correct air pressure and no leaks
 Adequate Communication medium.
 Tires properly inflated
 Clearance for tail swing
 Wire rope wear
 Physical damage to crane
 Loose or missing hardware, nuts, or bolts
 Fluid leaks
 TPI /Insurance/Operator competency certificates
 Asli/Limit Switch/Boom over hoist limit switch.
 Radius/load chat/ground condition
 Correct air pressure and no leaks
 Adequate Communication medium.
 Tires properly inflated
 Clearance for tail swing
 Wire rope wear
 Physical damage to crane
 Loose or missing hardware, nuts, or bolts
 Fluid leaks
36

37. Remove From Service
37
Immediately remove damaged or
defective slings from service

38. Damaged wire rope
Crushed Rope
38
Broken Strands
Damaged wire rope must be taken out of service
Crushed Rope

39. Conduct regular
inspections
of tires for
excessive wear
or damage
Tyre Inspections
39
Conduct regular
inspections
of tires for
excessive wear
or damage

40. WHAT TO INSPECT
 Operators:
 must qualify on specific crane, Job
Hazard -control measure details and
Environment
 Must include on-the-job training
 Supervisor / competent person
 Operators:
 must qualify on specific crane, Job
Hazard -control measure details and
Environment
 Must include on-the-job training
 Supervisor / competent person
40

41. Summary
• An unstable load, lack of communication, lack of
training, and inadequate maintenance or inspection are
major contributors to crane accidents.
• Operators or others working in the area can be
victims to “struck by" and "caught in" injuries.
• Contact with power lines causes many accidents.
• A competent person must inspect a crane regularly
to insure it is in proper order.
•Fulfill legal Documents and requirement.
• Planning and training reduces accidents.
41
• An unstable load, lack of communication, lack of
training, and inadequate maintenance or inspection are
major contributors to crane accidents.
• Operators or others working in the area can be
victims to “struck by" and "caught in" injuries.
• Contact with power lines causes many accidents.
• A competent person must inspect a crane regularly
to insure it is in proper order.
•Fulfill legal Documents and requirement.
• Planning and training reduces accidents.

42. Thank You
A presentation By
Soumen Makar
42
Thank You
A presentation By
Soumen Makar