Forklift , Pendant Crane & Manlift Training

Pendant Crane Crane , Forklift & Manlift Manlift Training

Meirc Saudi Arabia For Human Potential Development

Forklif , Pendant Crane & Manlift Training Presented to

MEIRC Saudi Arabia

Location

:

Jubail - MEIRC Training center

Dates

:

25-27 November , 2014

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Forklif , Pendant Crane & Manlift Training

MEIRC Saudi Arabia

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Forklif , Pendant Crane & Manlift Training

MEIRC Saudi Arabia

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Contents Course Objectives .........................................................................................................3 Module 1 .........................................................................................................................5 Introduction ...................................................................................................................5 Module 2 .......................................................................................................................10 Lift Truck Balance, Stability, Capacity ....................................................................10 And Operating Procedures ......................................................................................... 10 Module 3 .......................................................................................................................23 Safety Rules for Lift Truck Operators ......................................................................23 Module- 4 ......................................................................................................................44 O.E.T Cranes ...............................................................................................................44 Module-5 .......................................................................................................................53 Slinging & Rigging .......................................................................................................53 Module 6 ......................................................................................................................83 General Operating Characteristics Characteristics ...........................................................................83 Module 7 .......................................................................................................................93 Operating Procedures And Daily Inspection .......................................................... 93 Module 8 .....................................................................................................................110 Fall Protection Equipment. ......................................................................................110 Module 9 .....................................................................................................................118 Safety Precautions And Safe Operating Operating Tips ......................................................118 Do's And Dont's .........................................................................................................127

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Pendant Crane , Forklift & Manlift Training

Course Objectives Upon completion of this course, each participant will be able to: 

Identify the general operating characteristics of forklifts including abbreviations and major parts



Inspect and operate the FLT safely



Distinguish and explain signs & symbols related to FLT safe operations



Respect and follow safety rules for FLT operations

Who Should Attend? This course is intended for operators who already been trained to do the job of forklift safe operation and has the license issued for them but need to refresh their information and update them.

Executive Summary This course is designed to refresh forklift information’s and knowledge. It aims to

remind them the basics of the forklift stability and balance

maintain a good control on the machine when

to

operating it to avoid the

accidents which can be fatal sometimes. It also aims to refresh their information’s on the different signs those can lead the operator to avoid mistakes while operating and even when coming to park the machine safely.

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Curriculum Vitae

Personal Data: Name: Mohamed Awad Elkreem Nationality: Sudanese Religion: Muslim Birth date: August 1ih 1983 Education Primary School: AI-Tadamon Primary School 1990- 1997 SecondarySchool:WadAI-SahihSecondarySchool-1997-2002 University: Sudan University of Science and Technology. Experience From 2007-2008: Saria Industrial Complex (departmentofPlastic ) ( as a production engineer.) Freelancer: General home electrical connections ( 2009 -2013)

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Module 1 Introduction Powered Industrial Trucks 1.1 Powered Industrial Truck - Definition A mobile, power-propelled truck used to carry, push, pull, lift, stack or tier materials. [American Society of Mechanical Engineers (ASME) definition]. Excluded are

vehicles used for earth moving and over-the-road hauling.

Commonly known as forklifts, pallet trucks, rider trucks, fork trucks, or lift trucks, Can be powered through electric or combustion engines. Internal combustion engines are powered by diesel fuel, petrol or LP gas.. E D G LPG

-

Electric Power Diesel Power gasoline Power Liquefied Petroleum Gas Power

1. 2 Types of Powered Industrial Trucks: There are many different types of powered industrial trucks covered by the OSHA standard.

Commonly used types include: High lift trucks, counterbalanced trucks, cantilever trucks, rider trucks, forklift trucks, high lift trucks, high lift platform trucks, low lift trucks, motorized hand trucks, pallet trucks, straddle trucks, reach rider trucks, high lift order picker trucks, motorized hand/rider trucks, and counterbalanced front/side loader lift trucks. A single type of truck can only be described by calling it by all of its characteristics, (e.g., a high lift, counterbalanced, sit down rider truck).

1.3 Classes of Commonly- Used Powered Industrial Trucks* The Industrial Truck Association has placed powered industrial trucks into 7 classes. Class I - Electric motor rider trucks: Counterbalanced Rider, Cushion Tires, Sit Down . MEIRC Saudi Arabia

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Class II - Electric motor narrow aisle trucks High Lift Straddle.

Class III - Electric motor hand trucks or hand/rider trucks Low Lift Platform

Class IV - Internal combustion engine trucks (solid/cushion tires)

Class V - Internal combustion engine trucks (pneumatic tires) Fork, Counterbalanced (Pneumatic Tire).

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Class VI - Electric and internal combustion engine tractors Sit-Down Rider

Class VII - Rough terrain forklift trucks Variable reach type.

Note: that this classification refers to commonly-used vehicles and does not include all powered industrial trucks covered by the OSHA standard.

1- 4. Forklift’s Accidents Fork lift accidents come on top list of the accidents at the work sites, therefore it is essential for a on operator to be trained to work safely and avoid them. See the following graphs those show us the truth about the accidents results MEIRC Saudi Arabia

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Pendant Crane , Forklift & Manlift Training Forklift Fatalities, 1992-1996

120 86

1992

89

1993

1994

95

1995

114

1996

Here we have trend showing Workplace Injuries resulting from accidents involving forklifts from 2002 to 2006

Forklift Fatalities by Age Group 1992 -1996

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Under 20

12% 21%

5% 3%

20 - 24 25 - 34

10% 35 - 44 45 - 54 56 - 64

27%

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22% 65 & over

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Module 2 Lift Truck Balance, Stability, Capacity And Operating Procedures 2-1. Principle of balance The load carried in front of the vehicle is offset by the weight of the vehicle behind the drive tires.

2-2. Center of gravity: It is an imaginary point in the load around which all weight is evenly distributed

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2-3. Load center and center of gravity Distance from the load’s center of gravity to the face of the forks. Most lift trucks are rated at a 24 inch load center

Forklift Moment = (24” X 5000 LBS) = 120,000 inch-pounds Load Moment = (18” X 4000 LBS) = 72,000 inch-pounds The load is safe to lift because load moment is less than forklift moment.

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Avoid Off-Center Loading! Set the forks as far apart

as possible for

maximum support of the pallet or load. Too small a fork spread can cause unstable or off-center loading.

Lift truck center of gravity and combined center of gravity A lift truck also has a center of gravity. When a lift truck picks up a load, a combined center of gravity is produced.

2-4. The stability triangle The area contained inside a set of straight lines drawn between the

two drive tires and the center

point of the steer axle.

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Stability pyramid results when you add the element of lift height

Stability Pyramid Model Moving the center of gravity outside the stability triangle/pyramid Results in: • Loss of steering. • Loss of traction. • Unstable loads. • Potential for a tip over

2-5. Operation Procedures Flt. Pre-Operation Inspection A daily inspection before starting job should preceded to the forklift to be sure that it is ready to be used. Not only that, but it is important to do that at the beginning of every shift.

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Inspection Procedures Operator’s Daily Checklist Date:………………………………………………… Flt Type……………… Flt Serial No…………………Capacity……. ………… Operator Name……………………. Operator Bade No. ………………..

1ST; Visual Inspection Item

ok

Not ok

Add oil/grease

adjust

remarks

Fork condition Front end Tires condition Tires bolts /nuts Engine oil Hydraulic oil Brake oil Steering oil Engine Coolant Hyd. Hoses condition Oil leaks on floor Fan belt Air filter Seat cond. Fire ex. Battery terminals Battery cables condition Battery cables terminals Battery electrolyte Battery hood and restraint system

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2nd; Operational inspection. Item Starting system Engine noise Hydraulic system Transmission oil on automatic gears Foot brake Parking brake Horn Reverse alarm Head lights Signal lights Brake light Reverse light Steering system

ok

Not ok

Add oil/grease

adjust

remarks

Additional remarks…………………………………………………………………………………. ……………………………………………………………………………………………………………………………… ……………………………………………………………………………………………………………………………… ………………………………………………………………………………………………………………………………

Operators signature………………………………

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Upon completion of the inspection: 1. Report to the appropriate person 2. do not operate a machine that needs essential repair. 3. Do not do any repairs if not authorized. Note: Only forklift operators may operate the forklift. Do not use the Forklift if any of the following conditions exist: 1) the mast has broken or cracked weld-points; 2) the roller tracks are not greased or the chains are not free to travel; 3) the forks are unequally spaced or cracks exist along the blade or at the heels 4) hydraulic fluid levels are low; 5) the hydraulic lines and fittings have excessive wear or are crimped; 6) fluid is leaking from the lift or the tilt cylinders 7) the hardware on the cylinders is loose; 8) the tires are excessively worn or split, or have missing tire material; 9) air filled tires are not filled to the operating pressure indicated on the tire; 10) the batteries have cracks or holes, uncapped cells, frayed cables, broken cable insulation, loose connections or clogged vent caps.

2- 6: Signs & Symbols A professional operator must understand all signs and samples those him to do his job on the site safely and perfectly. Here are the

lead

important

signs and samples those can lead him do the job perfectly. They should be followed strictly.

2-6-A: Flammable Hazard Signs.

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2-6-B: Health Hazard Signs .

2-6-C: Traffic Signs. Traffic signs are public for all forklift drivers and other drivers they recognized and

should be

known. It will be considered violation if you fail to obey

these signs. Traffic light Traffic lights control road intersections should be strictly obeyed. When the light is read STOP behind the cross-walk. Wait until the light is green and do not make a right turn unless there is green arrow. When the light is yellow. SLOW DOWN AND PREPARE TO STOP. The light will turn red in only 3 to 5 seconds. When the light is green Wait For 2 Seconds Before Moving. Yield to pedestrians and vehicles that are still in the intersection.

Go in the direction of the arrow (right or left) always yield the right –of-way to the pedestrians and other vehicles. If there is no arrow I you must wait until the red right changes to green.

Go straight ahead only. Do not turn left or right. A red flashing light means STOP then proceed with extreme caution. Treat the same as a stop sign.

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A yellow flashing light means SLOW DOWN, look both ways, then drive with caution. Treat the same as a yield sign.

DIRECTION YOU MUST FOLLOW

DO NOT ENTER

PARKING PROHIBITED

ROUND ABOUT SIGN

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RESTRICTED STOPPING OR PARKING

PEDESTRIAN CROSSING

HOSPITAL

STOP SIGN

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MEDICAL FIRST STATION

PARKING

DO NOT USE YOUR HORN

CLOSED TO ALL VEHICLES IN BOTH DIRECTION

2- 6-D: Special signs for FLTS.

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2-6-E: Battery hazards signs

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Module 3 Safety Rules for Lift Truck Operators • Do not use bare forks as a man-lift platform. • Approach railroad tracks at a 45 angle when driving the forklift. • Steer the forklift wide when making turns. • Sound the forklift horn when approaching blind corners, doorways or aisles to alert other operators and pedestrians.

Lifting •

Do not exceed the lift capacity of the forklift; read the lift capacity plate on the forklift if you are unsure.

•

Follow the manufacturer's guidelines concerning changes in the lift capacity before adding an attachment to a forklift.

•

Lift the load an inch or two to test for stability; if the rear wheels are not in firm contact with the floor, take a lighter load or use a forklift that has a higher lift capacity.

•

Do not raise or lower a load while you are en route; wait until you are in the loading area and have stopped before raising or lowering the load.

•

After picking up a load, adjust the forks so that the load is tilted slightly backward for added stability.

•

Raise the forks an additional two inches to avoid hitting or scraping the ramp surface as you approach the ramp.

Driving • Obey all traffic rules and signs. • Drive with the load at a ground clearance height of 4-6 inches at the tips and 2 inches at the heels in order to clear most uneven surfaces and debris. • Drive at a walking pace and apply the brakes slowly when driving on slippery surfaces such as icy or wet floors. • Do not drive into an area with a ceiling height that is lower than the height of the mast or overhead guard.

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• Do not drive up to anyone standing or working in front of a fixed object such as a wall. • Do not drive along the edge of an unguarded elevated surface such as a loading dock or staging platform. • Do not exceed a safe working speed of five miles per hour. Slow down in congested areas when driving the forklift. • Stay a minimum distance of three truck lengths from other operating mobile equipment. • Drive in reverse and use a signal person when your vision is blocked by the load. • Look in the direction that you are driving; proceed when you have a clear path. • Do not drive the forklift while people are on the attached man-lift platform. • Drive unloaded forklifts in reverse when going up a ramp and forward when going down a ramp. • Drive a loaded forklift in a forward gear when going up a ramp; upon approaching the ramp, raise the forks an additional two inches to avoid hitting or scraping the ramp surface. • Do not attempt to turn the forklift around on a ramp. • Do not use a gear for the opposite direction of travel as a means to slow down or stop the forklift. • Lower the mast completely, turn the engine off and set the parking brake before leaving your forklift.

Loading Docks • Keep the forklift clear of the dock edge while vehicles are backing up to the dock. • Do not begin loading or unloading until the supply truck has come to a complete stop, the engine has been turned off, the dock lock has been engaged and the wheels have been chocked. • Do not drive the forklift into the truck until the bridge or dock plate has been attached. MEIRC Saudi Arabia

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• Do not drive the forklift into a truck bed or onto a trailer that has "soft" or loose decking or other unstable flooring. • Drive straight across the bridge plates when entering or exiting the trailer. • Use dock lights or headlights when working in a dark trailer.

Dress Properly For The Job Avoid loose clothing or any accessory . Flopping cuffs, dangling neck ties and scarves, Or rings-that can catch in moving parts.

Know how to use a first aid kit and a fire extinguisher and where to get prompt assistance Pre- operation inspection should be carried out properly .

Checking oils is one of the important Checks those should take place beside others.

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Pendant Crane , Forklift & Manlift Training The restraint system is built to protect you. Do not forget to wear it if your machine is equipped with one.

The maximaum hight of the forks When starting

travelling should Not exceed 20 cm or 10

inches. And the minimum should be Round 15 cm or 6 inches

Do not raise or tilt or lower your forks while driving

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Follow these steps when performing a job. 1. ensure the load is balanced. 2. Drive with the load in its lowest position and do not forger the rule for that. 3. Take extra care when working on ramps, uneven or sloping surfaces. 4. Use extra caution when making sharp turns

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Pendant Crane , Forklift & Manlift Training Always stack the load square and straight

Never place arms, hands, legs, or head between the uprights of the mast or outside the limits or the truck’s body or cab. (except when hand signaling a turn or other maneuvers). A load backrest (LBR) must be provided when handling small objects or unbanded units. The LBR must be capable in size and strength to prevent the load, or any part of the load from falling toward the operator. MEIRC Saudi Arabia

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If operating in potentially flammable or explosive environments, please verify you are using the appropriate truck

One tire width minimum distance from the edge of any elevated dock or platform

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Make sure the load dock is strong enough to hold our truck with load

Before reversing check on both Sides for pedestrians or other Traffic.

Do not give such stupid rides. This is a big risck

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Do not stand, pass or work under the elevated portion of a forklift. Keep clear of forklift mast uprights and all other parts where shear and crushing hazards exist.

Do not raise anyone in the air with a lift-truck.

Do not speed rapidly . load will fall down, the machine can tip over and you can loose your life or at least injured

Do not stack loads above back rest. MEIRC Saudi Arabia

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Back rest extension must be used in this case.

Overloading prohibited. It will cause big losses.

People other than the operator are not allowed on the forklift. They can not represent extra wait at all. The counter weight is designed to balance the machine

This is a creasy and stupid attitude. avoid such behaviors

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Ensure that the trailers are properly chocked before loading or unloading a trailer.

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these always

1. slow down and sound horn where your vision is blocked such as at Blind corners and intersections. 2. look toward the travel pathe and keep a clear view of it . 3. stop when people cross the route being traveled and lower the load to ground then wait until clear. 4. keep slow driving to be able to avoid accidents easily. 5. raising the load or lowering it while traveling is prohibited.

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feet

25

Attended parking is only within 25 feet and full vision 1. lower forks to the ground 2. neutralize shifting lever 3. parking brake applied 4. engine running when using a lift truck instead of a man lift a special platform prepared for this purpose meeting OSHA specifications, should be used

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Follow this: 1. do not move the machine when workers are working on it while elevated 2. lift workers only in an approved and properly secured platform 3. the platform must be secured and attached to load basket

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Refueling safe procedures

LPG fuel is explosive and dangerous. Take care when dealing with it.

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Parking procedures.

1. chose a flat leve ground to park your machine. 2. Apply the parking brake. 3. Shift directional and speed levers to nuteral position. 4. Lower forks to the ground. 5. Shut off the engine. 6. Remove the ignition key from the switch and store it. Always park your truck in

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Notes Pages

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Pendant Crane

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Course Objectives: After completing this course participant will be able to: 

Identify Major parts of Overhead Traveling Cranes.



Operate the Overhead Traveling Cranes safely and efficiently.



Identify lifting equipment, lifting tackles and special load attachments used within the facility.



Identify the load handling capacities and capabilities of these lifting equipment.



Know hitching and load attachment procedures.



Understand load attachment and load attachment procedures.



Know and exercise standard communication signals.



Plan and prepare for a lift.



Exercise practical "hands on" application in controlling the lift and placement of different loads, on a remote controlled overhead crane.

1) Operational inspection for overhead traveling cranes 2) Inspection and selection of correct lifting tackles to be used 3) Using the correct types of hitch for the lift 4) Avoid and control swinging of loads during lifting 5) Single point lift 6) Irregular shapes of loads 7) Awkward loads 8) Use of Spreader Bars 9) Using Special Attachments

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Who Should Attend? This certificate program is suited for experienced Overhead Crane operators that have been previously certified and require a renewal of their certificate to comply with OSHA Standards and Guidelines.

Executive Summary This course is designed to refresh the knowledge of operators with the basic skills required to operate the designated crane perfectly and safely according to local and international standards (OSHA). The course introduces participant the components and controls. Attendees will refresh his knowledge on crane operation and will practice this operation on real cranes. Participants also will learn about standard signaling, lifting tackles and their selection.

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Module- 4 O.E.T Cranes

Overhead Traveling Cranes Introduction to Overhead Traveling Crane: Overhead Traveling Cranes are equipment used to lift, move or transfer many kinds of loads. It also demonstrate various safe slinging and rigging procedures, maneuvering techniques that are typical in many lifting operations. below:

.

Gantry crane MEIRC Saudi Arabia

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Major Components of Overhead Traveling Crane. There are many types of Overhead Traveling Cranes, but their three (3) basic components are similar.: A. The Runway resembles a railroad track. It is made of rails, beams, girders, and brackets, providing the framework and support for the crane. B. The Bridge travels on the runway. The bridge is made up of two or more girders, trucks (Wheels), and a drive mechanism to move. C. The Trolley is carried by the bridge and moves horizontally between the runways, providing support for the hoist mechanism. Trolley is consist of the following components:

major parts of overhead traveling crane C.1 Hoist Mechanism consists of the load block (sometimes referred block) and the drum. Wire ropes are connected to the

to as the lifting

drum and threaded

through the load block which is used to raise or lower the load. C.2 Wire Rope is wrapped around a motor driven drum as the load is raised or lowered. C.3 Drum is where the wire rope rides and wound. C.4 Limit Switch Actuator controls the maximum raise end travel of the hoist, preventing the crane from being damaged or the load being dropped.

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Hoist mechanism

Pendant Overhead Cranes Control Location: Pendant Control – is a small control box that hangs and extending from the cab on the bridge or trolley. The operator controls the bridge, trolley and hoist while walking along the bridge at floor level in any directions.

Inspection and Maintenance. Inspection. Daily inspection and testing of pendant control box is important and will ensure the safe operation of the crane. Inspection should include “emergency stop” and other safety devices and functions. If there is doubt, operation must be stopped immediately and problems must be solved before operation is resumed.

Maintenance. Always keep clean the pendant control box. and free from dirt so push buttons functions are readable. If any malfunction of the push buttons is detected notify immediately your supervisor. Maintenance personnel shall rectify the fault as soon as possible.

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Regulations And Conducts of Operators Operating Pendant Controlled Crane 1. While actually engaged in operating the crane, the operator shall not engage in any practice that will divert his attention. 2. When physically or otherwise unfit, an operator shall not engage in the operation of the equipment. 3. The operator shall respond to signals from the person who is directing the lift or from an appointed person. When a signal person or crane follower in not required as part of the of the crane operation, the operator then is responsible for the lift. However, the operator shall obey a stop signal at all times, no matter who gives it. 4. Each operator shall be responsible for those operation under the operator's direct control. Whenever there is doubts as to safety, the operator shall consult with responsible management before handling the loads. 5. If a warning device is furnish, it shall be activated each time before traveling and intermittently when approaching work persons. 6. Before leaving a crane unattended, the operator shall place controller in the "OFF" position and ensure that the main line disconnect device of the crane is open. 5. The operator shall not close the main line disconnect device until certain that no worker is on or adjacent to the crane. If there is tag , sign, or lock on device, it shall not be energized until the tag, sign, or lock is removed by the person who placed it there or by an authorized person. Facility-specific lock and tag procedures shall be strictly followed. 6. Before closing the main line disconnect device, the operator shall see to it that all controls are in the "OFF" position. 7. If power goes "OFF" during operation, the operator shall immediately place all controls in "OFF" position. Before reusing the crane, operating motions shall be checked in all direction. 8. The operator shall be familiar with the equipment and its proper care. If adjustment or repairs are necessary, or any defects are known, the operator shall report the same promptly to an appointed person responsible for the operation and maintenance repairs of the crane. The operator shall also notify the next operator of any remaining uncorrected defects at shift change. MEIRC Saudi Arabia 47

Pendant Crane , Forklift & Manlift Training 9. Contacts with runway stops or other cranes shall be made with extreme cautions. The operator shall do so with particular care for the safety of persons on of above the crane, and only after ensuring that any person on the other cranes are aware of what is being done. 10. Operators of outdoor cranes shall secure them when leaving. 11. When the wind-indicating alarm is given, the bridge or gantry on a 12. outside crane shall be anchored. 13. Before the operator performs any maintenance work on the crane, the operator shall ensure the main switch is locked and tagged in the deenergized position. 14. Facility-specific lock and tag procedures shall be strictly followed. 15. Controls shall be tested by the operator before beginning a new shift. If any controls do not operate properly, they should be perform by maintenance personnel., not by the operator. 16. Operators shall be familiar with operation and care of fire extinguishers provided.

Standard Communication Signals. Communication Signals are very important to the slinger, rigger, signaler and crane Operator. They must be able to communicate to each other correctly and efficiently. This allows the safe and timely movement of a load. Sometimes special hand signals are used. It must be agreed upon between the crane operator and the one giving the hand signals for the proper movement of the crane.

Standard Hand Signals: Hand signals are used to communicate. The Slinger or Rigger is responsible for the proper rigging of the load. By using the appropriate hand signals, the slinger, rigger and signaler could direct the movement of the load. Hand Signals used in this course are taken from the American National Standard Institute (ANSI), Overhead and Gantry Cranes, ANSI B30.2.0. - 1976.

Note: The crane operator must take signals only from one person. He should be clearly identifiable by wearing a brightly colored waistcoat and hardhat. If this is not possible, he must make himself known to the crane operator.

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Hand Signals Must Be: 

Clear and Unmistakable



Understood by both of you and the person giving them to you



Clearly visible to you



Continuous

her than for an emergency stop, you should accept signals from one person only having established who that person is.

Overhead Crane Standard Communication Hand Signals (Asme 30)

Lower: With arm extended downward, forefinger Hoist: With forearm vertical, forefinger pointing pointing down, move hand in small horizontal up, move hand in small horizontal circle. circles.

Bridge Travel: Arm extended forward, hand open and slightly raised, make pushing motion in direction of travel.

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Trolley Travel: Palm up, fingers closed, thumb pointing in direction of motion, jerk hand horizontally.

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Emergency Stop: Both arms extended, palms down, move arms back and forth horizontally. Stop: Arm extended, palm down, move arm back and forth horizontally.

Multiple Trolleys: Hold up one finger for block marked "1" and two fingers for block marked "2." Regular signals follow.

Move Slowly: Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal.

Magnet is Disconnected: Crane operator spreads both hands apart--palms up.

the standard signals for OET CRANES

Operational Inspection of Overhead Traveling Crane Operational inspection of the overhead traveling crane components must be done periodically and should be properly documented to ensure the safe used of the equipment. The following components to be inspected:

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Pendant Crane , Forklift & Manlift Training A) Load Block is lowered to where a close visual inspection can be made: A.1)

Hook is checked for spreading and twisting, and the gate to be checked if it operates freely.

A.2)

Wire Rope must be free from defects and must ride properly in its sheaves and must wound-up properly into the drum.

A.3)

Drum must be securely fastened and that the wire rope must be properly wound-up into the drum while the load is lifted and is played out if the load lowered.

A.4)

Limit Switch Actuator must trip automatically at the maximum raise end travel, preventing damage of crane's component and dropping of the load.

B) Trolley should move smoothly with no hesitation. The positive ends stops are tested as the trolley runs from one end of the ridge to the other. As the trolley approaches the positive end stops, a limit switch de-energizes the trolley motor and actuates the brakes.

the

trolley

C) Bridge should be running smoothly with no hesitation. The proper operation of the brakes must be observed as it approaches the end stops of the runways. The bridge must be free and clear from any obstructions. D) Runway must be clear and free from any obstruction so that there will be proper movement of the bridge. E) Documentations: ( Samples found at last pages of the textbook). E.1)

Operator's Daily Checklist.

E.2)

Operational Deficiency Report

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Safe Working Load (S.W.L.) Safe Working Load (S. W. L.)

Is the guaranteed rated load capacity, the manufacturer certifies for the safe working performance of specific lifting equipment, tackles and gears. The safe working load limit must not be exceeded so that damage of equipment, tackles and gears are prevented. The manufacturer on every lifting equipment, tackles and gears marks SWL with test certificates provided by them.

Safe Working Load is usually one fifth of the Breaking load capacity, or the Breaking load is five times that of the Safe Working Load.

Conversion Table 1 ton, metric 1 kg 1 kg 1 lb 1 Ton

= = = = =

1000 kg 1000 gm 11/5 lbs = 2.2 lbs 0.454 kg = 2200 lbs

454 gm

Example: The S.W.L of O.E.T.CRANE is 2900 lbs, what is the capacity per Ton? Answer 1 Ton SWL

= = = =

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2200 lbs 2900 lbs 2900 Ton 2200 29/22 =

1.32 Ton

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Module-5 Slinging & Rigging

(I) Introduction to Slinging and Rigging Crane rigging, erection and de-rigging must be carried out under the supervision of a competent, qualified and experienced person, normally the rigger. The correct, safe procedures is set out in every operating instruction manuals supplied by the manufacturer. It is most important the recommendations regarding sequence, safety precautions, etc., are strictly observed and followed, for both rigging and de-rigging. Checking of all safety devices, limiting switches must be done for completeness and Serviceability before and after rigging. Ensure that all ropes are of correct length, and that the number of reeves selected is appropriate for the lifting operations. Observance of all safety devices must be done carefully, be alert to their warnings and take The necessary actions to prevent the crane from being overloaded in any position. The overload alarm should never sound during a lifting operation. If it does, the lifting Supervisor should investigate and direct the rigger to take effective and immediate actions, To make a safe operation.

NOT ASSUME THAT ALL IS CORRECT - CONFIRM IT

IF YOU HAVE ANY DOUBTS - DO NOT OPERATE THE CRANE

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(Ii) Lifting Tackles And Their Functions: Lifting tackles are the components used in any lifting procedures.

ENSURE THAT ALL LIFTING TACKLES ARE CAPABLE OF LIFTING THE LOADCONFIRM THEIR SAFE WORKING LOAD (SWL) CAPACITIES

A.) SLINGS: The sling is the most common lifting tackles used and the most abused. The common materials used to fabricate slings are the following: (I) Wire ropes or Cables - are made of tempered steel wire (strands) around a core, the core may be either metal of fiber. They are classified according to the number of wire strand around the core, and by the number of wires per strand. A (6/19) w ire rope has (6) strands of wires around the core, each strand has (19) wires. Wire Rope Grade is the quality of steel used in the wire. The most common grades are: (I) IPS - Improved Plow Steel (ii) XIP - Extra Improved Plow Steel  15% more tougher & stronger than IPS Lay of wire is the distance in which one strand is made to a complete spiral around the circumference of the rope. It may be either left or right according to the direction of the lay. Performed is the process in which the wires are formed into spiral shapes being laid around the core. It prevents the rope from rooming out if cut.

Types of Wire Rope Slings

Typical Wire Rope Body. (I)

Eye-Eye type

(II)

Endless Type

(III)

Metal-Eye Type

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Pendant Crane , Forklift & Manlift Training Eye- Eye Type Wire Rope Additional Type of Wire Rope Slings

Common Defects, Why Wire Rope Slings Should Be Discarded: Wire rope construction 1. Six

(6) broken wires in one strand of a lay.

2. Three (3) broken wires in one strand of a lay. 3. Wear or scraping of 1/3 of the original diameter of wire rope. 4. KINKING is the sharp permanent bending of the wire rope. 5. CRUSHING occurs when there is severe pressing and bumping marks of the wire rope. 6. BIRD-CAGING (or NESTING) occurs when the wire rope is loaded and then the load is suddenly released. 7. HEAT DAMAGE occurs when the wire rope is expose high temperature environment. 8. SEVERE CORROSION occurs normally deep within the wire rope. 9. UNLAYING occurs when the strand at the end of the wire rope starts to separate. MEIRC Saudi Arabia

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The Right Way To Measure The Diameter of Wire Rope

(ii) Chain Slings

Fig. 2-6. typical chain sling.

They are made from steel. A number of grades of chains are manufactured. They are dependent on the properties of the steel itself and the heat treatment during manufacturing process. Each grade of steel has its own strength and shock absorbing properties. It follows that the chain sling manufactured from different steel have differing safe working load limit capacities.

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(iii)

Nylon or Polyester (Web Slings)

Different types of web slings They are slings woven in flat form from either nylon or polyester fiber. They are usually supplied in single ply or in two-ply thickness. The Safe Working Load (SWL) for a two-ply sling is twice that of a single ply sling of the same width. Sometimes they come in round form consisting of a polyester yarn with a protective covering. Depending on the capacity of the sling many cores are wound together to form an endless sling. 1. Nylon is the strongest webbing material and the most popular for heavy duty lifting. Not recommended for use around acids, but resist alkalis exceptionally well. Temperature limit is 200 centigrade. Nylon web sling will stretch approximately 10% of their length and capacity.

Two types of nylon slings

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Pendant Crane , Forklift & Manlift Training 2. Polyester is highly resistance to acids conditions, completely rot and waterproof, a very durable material but not as strong as nylon. Temperature

limit is 200

centigrade. Polyester slings stretch much less than nylon slings, approximately 3% of their length and rated capacity. Both the flat webbing and round slings are ideal for lifting, products with machined or polished surfaces, such as gear, compressor or pump interiors, soft metals or f ragile loads that must be protected from scratching of the slightest of damage.

Two types of polyester slings These types of slings are also very flexible and adapt to the shape of the load being lifted, they do however damage easily and must be protected from sharp edges. The webbing sling is the perfect pipe-lifting sling. Sometimes web slings are colored coded for their Safe Working Load capacities shown on the sling itself. This capacity data

is often

illegible after long used. Be aware not to confuse Safe Working Load capacities color coding with that of periodic on site certified lifting tackles color coding, which is usually an annual procedure done to ensure only certified lifting tackled are to be used.

Endless web sling, length limits

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C.HOOKS

Fig.2-20. a typical hook with gate Hook is used to attach the load to the hoist. It is m ade of forged steel so that if there is an overload, the hook will just bend rather than breaks. In this case, equipment damage and personal injury are reduced and prevented. For this reason the load hook is the weakest member in the lifting equipment and the other component used in any lifting operation. Common types of Hooks:

a. gated hook

b. un-gated hook

common types of hooks a. and b. The hook must be checked periodically, of the following: 1. If the gate is un-gated performed (Mousing is the process of securing a load so that it will not slip out from the hook. See figure below). 2. Hook's mouth spreading is the widening of the mouth. Spreading should exceed the maximum allowable of fifteen percent from original measurement recorded. MEIRC Saudi Arabia

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Pendant Crane , Forklift & Manlift Training 3. Twisting is a bending of the hook or eye to the side. Maximum twist is not more than 10% 4. The hook is checked to see that it swivels freely. a) Spreading

b) Twisting

hooks defections, spreading and twisting

Performing mousing for un-gated hook

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E. Shackles Shackles are used to connect the slings to the load and the other end to the hoist's hook. There are two common types of shackles:

Anchor type shackle

Dee type Shackle

Fig.2-28. shackle with bolts screwed into its body. he former is suitable for attaching one or more lifting devices, such as hooks or slings, the later is designed for connecting to a single lifting device. Both types are checked and inspected in the same manner, for cracks, surface defects, such as gauge and wear. The shackle pin is checked and inspected for wear or thread damage. Shackle washers are often used as spacers to prevent a load from shifting and sliding on the shackle.

Shackle with bolts screwed into its body.

Shackle with bolt and nut secured by a cirri-clip.

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a. Spreading of the shackle

b. Use of washers

H. Eye Bolts And Eye Nuts

Typical eye bolt and nut Eye bolts and eye nuts are threaded into the equipment to provide a place to connect the load hook. The size of the eye bolt is determined by measuring the diameter of the threaded shank. Standard threads of eye bolts and eye nuts comes in English and Metric dimensions. There are number of simple rules to remember when fitting an eye bolt or an eye nut to a load or machine to be lifted. 1. Make sure the threads match, do not force the eyebolt or eye nut into the thread. 2. Do not over tight the eye bolts and eye nuts into the threads. 3. Make sure the shoulder of the eye bolts and eye nuts are properly secured before with the lift.

Eye bolts & Eye nuts come in several styles. The two common types:

1)The shoulder(collared) type

2) The plain (un-collared) type

Fig.2-32. two types of eye bolts MEIRC Saudi Arabia

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Inspection of Lifting Tackles Each day before being used, the Slings and all fastenings and attachments shall be inspected for damage or defects by a professional

authorized person. Additional

inspections should be performed during sling use, where service conditions. Warrant, damaged or defective slings shall be immediately removed from service. In addition, a thorough periodic inspection of alloy steel chain slings in use shall be determined on the basis of: 1) Frequency of sling use. 2) Severity of service conditions 3) Nature of lifts being made 4) Experience gained on the service life of slings used in similar circumstances. Such inspections shall be in no event being at intervals greater than once every one year.

(I) Slings (I) normal wire rope sling

(Ii) Damaged Wire Rope Slings KINKING

BIRD –NESTING

UNLAYING

(B) Shackles (I) Normal Shackles

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(ii) Damaged Shackles

SPREADING

BENT PIN

Chains Inspection Chains must be inspected thoroughly before it can be used. Each links should be checked For cracks or broken welds. The chain links may become elongated, or stretched, as a result of normal wears. The used chain should not exceed the maximum allowable elongation of 1-1/2 % longer than a new one with same size, grade, and capacity. If it exceeds the maximum allowable, the chain must be replaced. See Figure.

a).Cracks on chain link unit

b).elongation of chainlink unit

c). Deformation of chain link units

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Hooks Normal Hook

Damaged Hook

Twisting

Spreading

Turnbuckles (I) Normal

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Eyebolts (I)Normal

(Ii) Damaged Threads

Selecting Lifting Procedures CENTRE OF GRAVITY (I)Correct

(I) Correct

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(I) Correct

(Ii) Incorrect

(I) Correct (Ii)Incorrect

(I) Correct

I) Correct

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(I) Correct

(I)Correct

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(Ii) Incorrect

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(I) Correct

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(II) Common Hitches & How To Use Them

Single-vertical hitch.

Single & Double Choker Hitch

The choker hitch tightens, as the load is lifted due to the nose formed at the point of choke. The single choker hitch does not provide full 360° contact with the load and should not be used to lift loose bundles. MEIRC Saudi Arabia

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Pendant Crane , Forklift & Manlift Training A double wrap choker hitch is in full contact with the load because the choker is wrapped completely around the load before it is hooked into the vertical part of the sling and should be used when lifting loose bundles of materials such as pipe. The double choker hitch is made up of two single choker that are spread and attached to the load. This makes a much more stable load. The hooks must be pointing out, as indicated in the figure below. The double choker hitch does not provide full 360° contact with the load and should not be used to lift loose bundles of materials such as pipe. Note: A choker hitch is rated 75% of a single vertical

Double Choker Hitch

Illustration is a method of supporting A load by wrapping the sling around the load, and securing both ends of the sling on the hook. Do not use this .hitch on the loads those are difficult to balance . Do not spread the slings too far as this will create extra stress on the legs.

Single Basket Hitch:

Illustration is a basket hitch completely wrapped around the load, rather than just supporting. It is excellent for pipes and tubes. The hitch exerts a full 360 contact and pulls the load together. NOTE: A full basket hitch is rated at 200% of a single vertical hitch. MEIRC Saudi Arabia

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Double Wrap Basket Hitch

Determining Basket and Choker Values Most sling chart tables give three values: they are a Single Vertical Hitch, a Basket Hitch and a Choker Hitch. The vertical hitch capacity is the basis for the other two; a vertical Hitch is rated at 1, a basket hitch is rated at 2 and the choker hitch is rated at 3/4. The question is often asked, "What is a true basket to give full double rating?". The answer to this is usually distorted as a true basket is not often used, plus there are different types of. sling wrapped around a rectangular surface is not a true basket. A true basket is one in Which a wire rope sling is lifting a round surface which has a diameter of 20 or more rope Diameters. With a flat synthetic sling, the capacity of the sling would have to cross Referenced to an equivalent strength wire rope sling, and the load diameter equal to 20 wire rope diameters.

Note: A wire rope hooked around an object of equal diameter, such as another wire rope or a bolt, will have a breaking strength rating of 50%. This small diameter bend causes a shearing effect. The capacity increases as the bend diameter Increases, until at 20 diameters in which it has a 200% rating.

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Endless Slings or Grommet Slings

Endless slings are used for all three types of basic hitches as shown above. They are made from wire ropes, chains and synthetic materials. They are flexible but tend to wear faster than other slings because normally they are not fitted with fittings and deforms when bent over hooks.

Vertical ,Basket & Choker Values

Sling Angle Safe Working Loads

Using Sling to Determine Lift Point

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Recommended Safe Lifting Angle The recommended SAFE lifting angle for sling legs is 60 (the minimum lifting angle is 45 or higher). The 60 angles are easily determined by using the actual sling of choker for measuring. Lifting at a 60 angle creates an equilateral triangle, where the three sides are of the same length. The center of load is determined, the sling is laid across the load, and the two end are marked as the pick-up points.

Hooking Back on Choker Hooking back when choking a load with one sling should be avoided, as it creates extra localized stress into the sling When a load is choked and tension is applied to the sling, the two portion of the choker Coming off the load have a natural tendency to lift up to as high an angle as possible. See Illustration 8A A very common occurrence for the person hooking up the load is to grab Whatever is near-by and pound the eye down as close as possible to the load. See Illustration. This forms an extremely low sling angle and creates extra localized stress in the sling. See illustration 8C. This situation applies to round loads such as pipe, as the sling angle formed a triangle from the pipe points of tangency. See illustration

Hooking Back With Choker

te: Do not force the choked eye down close to the load

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Planning For A Safe Lift The recommended steps shall be followed in planning for a safe and efficient lift: 1. Test proper crane operation. 2. Check/verify crane's Safe Working Load (S.W.L.) 3. Know the weight of your load. 4. Inspection and selection of correct lifting tackles. 5. Proper slinging and rigging must be followed. 6. Use the correct type of hitches. 7. Use standard hand signals and special hand signals agreed upon on the respective facility. 8. Secure the area by placing warning signs, barriers, and barricades. 9. Position Crane's hook vertically to the load confirming the load is properly balanced. 10. Test Lifting of load 11. Attached taglines while moving the loads at all times. 12. If possible use the "lowest" speed in moving the load.

Duties of Personnel Involved in Lifting Operations Your special attention is drawn to the Saudi Iron & Steel Co. (HADEED) COMPANY COMMON HEALTH AND SAFETY PROCEDURE: PR - IS12 - 07 dated 16 March 1996 MATERIAL HANDLING AND STORING AND SAFE LIFTING. PR - IS12 - 10 dated 16 march 1996 -- CRANES. The above Procedures have been prepared especially for your safety at work and contain essential information relating to your involvement in safely slinging a load to be lifted within HADEED.

Please therefore refer to the information contained therein: Appointed Person The appointed person nominated by management to be in overall control of the lifting operations must have had adequate training and experience and be competent. His duties should include the following: To make sure that: 

The lifting operation is properly planned and carried out



Accurate weights, radii, heights, etc., are established



Suitable cranes and other equipment are provided

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

The ground is made suitable for taking the loads to be imposed



Suitable access is provided to the site and any area required for



Erection And dismantling



All hazards such as services (gas, water, electricity, etc.) above or



Below ground are identified and suitable precautions are taken



Competent, properly trained personnel are provided and that they



are fully briefed.



All cranes and other equipment are properly maintained, inspected, Examined and tested and that all necessary paperwork is correct.

Lifting Techniques. Single point lift 

Preparing for the lift



Determine weight, center of gravity and attachment parts



Select, inspect, and attach rigging gears.

Positioning the crane 

Allow for crane operator response



Position bridge, then trolley



Remain in clear view of the operator



Stand clear of large equipment or bright lights



Stand clear of land

Mooring the load 

Attach land to load hook



Take up slack, check and adjust rigging



Rinse land



Lift land only as high as necessary



Lower land onto cribbing



Remove, inspect, and store rigging equipment

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Using spreader bars



Plan for safe lift



It provides two point lift



Allows slings to be farther apart



It gives grater stability to the load as it is lifted.



Rigger must determine for himself the safe advantage of it, in as specified lifting operation.

Lifting irregular shaped loads 

Plan for safe lift



Use additional slings, as necessary, to control the load]



Use caution when connecting loads to prevent damage



Uses come alone to give rigging an adjustable feature



Adjust rigging when slack is taken out

Lifting a long, balance load 

Use continuous nylon sling



Attach sling to load at center of gravity



Test, lift load and adjust



Use tag line



Move load to new location



Remove rigging, inspect, and store.

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Safety Rules While Doing Lifting Jobs Using Overhead Crane 1.

Always ensure that the load is balance.

2.

Inspect the lifting equipment and all the slings.

3.

Never stand below the load.

4.

Give a correct signal when using overhead lifting equipment or crane.

5.

Always appoint one rigger & signalman who are qualified.

6.

Always secure the area during lifting operation.

7.

In night lifting always have the proper illumination.

8.

The operator of a crane of hoist must act only on directions from a designated and competent signaler whenever the operator does not have a clear and obstructed view of the load hook and load throughout the whole range of the hoisting operation.

9.

The hand signal used between the signaler and operator to control hoisting operations must be heeded standard signals.

10. The operator of a crane or hoist must not attempt to move a load if there is any doubt the load can be safely handed. 11. A load must not contact the crane or hoist and the load must not contact a structure. 12. If contact ad described in subsection (11) occurs, a qualified person must inspect the point of contact, and visible damage such as cracked weld or a bent or dented member must be assessed, repaired as necessary, and the damaged or repaired area certified by a professional engineer as safe for use. 13. A worker must not remain within range of the swing of the load or equipment when the swing movement of the load, or any part of the crane or hoist creates a hazard, and the operator must not move the equipment when any worker is exposed. 14. Hook must be positioned so that no moving part of the equipment will come within 60 cm(2ft) of any obstruction in any area accessible to workers

15. If the clearance required by section (14) cannot be provided, entry to such areas must be prevented by barriers or other effective means. 16. A load must not be left suspended from the load hook of a crane or hoist when an operator is not at the control. 17. The hook or load block of a crane or hoist must be positioned over the load to prevent side loading of the crane when the load is hoisted.

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Pendant Crane Crane , Forklift & Manlift Manlift Training 18. A load on a crane or hoist load hook must be safely landed and supported, before being unhooked. 19. A worker must not ride on a load, hook or any other rigging equipment. 20. A fire extinguisher having at least 10 kg,. rating must be immediately available for each crane. 21. Do not engage in any practice that will divert your attention while operating the crane. 22. Respond to signals only from the person who is directing the lift, or any appointed signal person. Obey an emergency stop signal at all times, no matter who gives it. 23. Do not move a load over people. People shall not be placed in jeopardy by being under a suspended load. Also, do not work under a suspended load unless blocks, jacks, or solid footing that will safely support the entire weight supports the load. Have a crane or hoist operator remain at the controls or lock open and tag the main electrical disconnect switch. 24. Ensure that the rated load capacity of a crane's bridge, individual hoist, or any sling or fitting is not exceeded. Know the weight of the object being lifted or use a dynamometer or load cell to determine the weight. 25. Check that all controls are in the off position before closing the main line disconnect switch. 26. If spring-loaded reels are provided to lift pendants clear off the area, ease the pendant up into the stop to prevent damaging the wire. 27. Avoid side pulls. These can cause the hoist rope to slip out of the drum groove, damaging the rope or destabilizing the crane or hoist. 28. To prevent shock loading, avoid sudden stops or starts. Shock loading can occur when a suspended load is accelerated or decelerated, and can overload the crane or hoist. When completing an upward or downward motion ease the load slowly to a stop.

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Do’s & Don’ts Do’s Do Do

stand back and “size up” the job

determine the weight of the load and the S.W.L. of the lifting appliance and

slinging gear. Allow for the weight of the gear where appropriate. Do

check the center of gravity of the load.

Do

use the correct gear (length, construction, strength, suitability).

Do

check the condition of the gear.

Do

protect gear against sharp edges, corners, etc. By use of packing.

Do

check that shackles have correct pins and are suitable for the load.

Do

check that shackle pins are screwed hard home.

Do

ensure that any sling legs not in use are hooked up.

Do

warn those nearby before lifting.

Do

"hand tight" before lifting away.

Do

ensure sufficient room for work and safety at the slinging pitch.

Don’ts Don't

drag the gear along the ground.

Don't

use unauthorized or "homemade" gear.

Don't

land the load on slings where this may result in sling damage.

Don't

bend rope around sharp points.

Don't

guess load weights.

Don't

shorten chain slings by knotting, using bolts or wiring together.

Don't

ride on sling loads.

Don't

leave gear on the hook when it is not needed.

Don't

leave damaged or condemned gear near the pitch. Remove it well away to

the store.

Remember  The

S.W.L. decreased as the angle of the sling increases.

 Shortening

fiber ropes reduces their efficiency.

 Make

sure that the signaler is clearly visible to everyone involved.

 Avoid

snatch or shock loading.

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Manlift

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Course Objectives: Upon completion of this course modules each participate: 

Know the definitions,terms and specifpcations of manlifts.



Know the different types of manlifts.



Know how to select the right Manlift for certain job.



Know the general operating characteristics.



Know how to operate Aerial safely.



Know fall protection.



Know the daily inspections

 

Practice safe operation of manlifts Understand and practice emergency procedures of manlifts

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Module 6 General Operating Characteristics Introduction: Manlift (or Aerial) platform is used for reaching up and over machinery, equipment and other obstacles mounted on floors, and for reaching other elevated positions not easily approached. To operate a Manlift the operator should know very well the big four safety issues .

The “big four” safety issues include: tip-over: it is the turnig over of the machine resluted of many causes such like loosing the vehicle balance and stability, therefore a proffessional operator should know how to control his vehicle properly to avoid such accidents. Fall : it is the falling of the labor from the platform of the machine as a result of neglecting to follow the safety procedures such like using the safety harness. Collision: it is the accident which can take place between two vehicles those moving within the same area or between the vehicle and pedestrains resulted by neglection of following the trafic rules or the safety precautions. Electrocution: it is the death caused by electric shock. High tension voltage cables those the truck boom can touch should be avoided and high precaution should be taken when existing. Other sources can exist and affect .

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Basic components , typical control layouts & vehicle capacities

Definitions: a) Platform Height: Platform height is the maximum height to which the operator can reach plus his own height given in foot (or meter), e.g.[ (34 ft, 2inch) (10.41 meter)].

b) "Work basket" size: Platform size is the "work basket" dimensions given in feet (or meter), "work basket" is mounted on top of the "Articulated" or

"scissors"

assembly, it is

constructed of steel frame and have a diamond steel floor plate with a removable steel rail & toe board. MEIRC Saudi Arabia

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Pendant Crane , Forklift & Manlift Training The size of the "work basket" is (30 X 60 inch i.e. (0.76 X 2.5 M) for model 34HA JIG as an example).

c) Lift capacity: It is the unrestricted capacit y for the Manlift loaded in the "work basket" given in

Lbs (e.g. 500 Lbs (227Kg) including operator and other tools. This value is always stamped in the manufactuerer’s serial number plate at the side of the equipment. Note: Never exceed the rated platform capacity

d) Horizontal out reach at up and over height:Is the maximum horizontal distance from the platform rotation axis, Reached by the basket at the up and over platform height

e) Up and over height: Is the maximum height at maximum horizontal reach

f) Gross vehicle weight: Is the weight of the vehicle plus the unrestricted capacity (e.g. 9,800 Lbs) (4445 Kg).

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1. Specifications: i.

Overall width: Is the overall width of the vehicle when the platform is in its normal position (not positions for side work) given in feet (or m) e.g. ( 6 feet, 6 inch) (1.98 meter )

ii. Stowed length: Is the total overall lenght of the vehicle and platform when the "work basket" at its minimum horizontal out reach. iii.

Stowed height: This is the minimum height of the vehicle and platform when the "work basket" is in its ideal position.

iv.

Turning Radius: There are applicable for the articulates models:1- Outside Turning Radius:This is the distance from the equipment rear tyre to the outer edge of the basket at idle position. 2- Inside Turning Radius: This is the distance from the equipment rear tyre to the inner edge of the basket at idle position/

v.

Power source: Is the engine power source, diesel, electrical LPG or dual.

vi.

Gradability: Is the grade climbing capability of the machine given in percentage and degrees

2. Electrical system:The electrical system is 12 volt system consisting of alternator and one lead-acid battery. The system is the single wire ground return type, utilizing the platform structure as ground. Consists of the following:

Ignition switch.



Drive control lever (in electrical powered models).



Lift control lever (in electrical models).



Drive and backup light switch. Electrical brakes (optional). Generator switch (optional).

 

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Pendant Crane , Forklift & Manlift Training 13. Work Basket controls:

Steer control lever.



High/low left / right drive switch. High/Low will control the speed range of the drive motor.



Outrigger switch. In / out to direct outriggers to the desired direction.



Emergency lowering control.



Emergency stop button.



Lift control.



Drive control.



Upper / Lower override select lever for the upper or lower control console selection.

14.

Ground station controls:

Outrigger switch.



Lift control.



Drive control



Steer control.



Upper / Lower override select control



Ignition switch.



Hour meter



Parking brake.



Lower emergency lowering.



Voltmeter



Water temperature



Oil pressure

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3. Different Types Of Manlift:There are majorly five different designs for the Manlift, each is designed to meet specific industrial requirements they are: (i)

Articulating Boom Lifts:

Fig. 1

Articulating boom lifts (knuckle booms) are used for reaching up and over machinery, equipment, and other obstacles mounted on floors, and for reaching other elevated positions not easily approached by a straight telescopic boom lift. The machine's turn table may be rotated 360 degrees in either direction. The boom can be raised or lowered from vertical to below horizontal, and extended (telescoped) while the work platform remains horizontal and stable. It can be maneuvered forward or backward and steered in any direction by the operator from the work platform, even while the basket is elevated. All articulating models are derivable at full elevation and have chassis widths that provide access to narrow industrial aisleways and congested work areas. (A) Features: 1. Platform heights are available from 34 feet (10.36 m) to 150 feet (45.72 m). 2. Operators controls are common to the different models for the same manufacturers. MEIRC Saudi Arabia

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Pendant Crane , Forklift & Manlift Training 3. Fast lift and drive speeds enhance operator productivity. 4. 2 Wheel or 4-wheel drive some are also 4-wheel steer, provide operator with a higher level of access and productivity. 5. Power source most are dual fuel, diesel. (B) Typical Applications:

(ii)



Building construction and maintenance.



Mechanical, electrical utility and painting contractors.



Manufacturing and industrial facilities (steel, automotive and aircraft plants).



Petroleum and chemical refineries.



Textile, food processing and fabricating plants.



Sports and entertainment facilities.



Rough terrain job sites.



Up-and-over applications.

Electric Articulating Boom Lifts.

Fig. 2 Electric articulating boom lifts (knuckle booms) are used primarily on indoor and slab applications for reaching up and over machinery, equipment, and other obstacles mounted on floors, and for reaching other elevated positions.

Electric boom lifts are powered by batteries that are

rechargeable through a standard 110 V electric outlet. All articulating models are derivable at full elevation and have chassis widths that provide access to narrow industrial aisleways and congested work areas.

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Pendant Crane , Forklift & Manlift Training (iii)

Telescopic Boom Lift:-

Telescopic (straight or stick boom) boom lifts are especially useful for applications that require high reach capability. The machine's turntable can be rotated 360 degrees in either direction for easy positioning. The boom can be raised or lowered from vertical to below horizontal and extended while the work platform remains straight and stable. The operator in the platform can maneuver and steer in any direction, even while the boom is extended. (A) Features:

Largest telescopic product with available platform heights upto 120 ft. (36.58 m).



Oscillating axle available in the 80 feet (24.38 m).



Smooth controls combined with fast lifts and drive speeds.



1,000 lbs. (454 kg) capacity telescopic boom lifts available.



Power source:- Dual fuel, Diesel.

Fig. 3 (B) Typical Applications: 

Construction (commercial buildings

and infrastructure).

Mechanical, electrical, utility and painting contractors.



Manufacturing and industrial facilities, including automotive and aircraft plant.



Petroleum and chemical refineries.



Textile, food processing and fabricating plants.



Entertainment facilities.

(iv) Scissor Lifts. Scissors lifts are used where less reach and height, but more workspace and lifting capacity, are required. They are designed to provide larger platform work areas and generally to allow for heavier loads than boom lifts. Scissors lifts may be maneuvered in a manner similar to boom lifts, but the platform may be raised only vertically except for an available option that extends the deck horizontally up to 6 feet (1.83 m). Scissors lifts are available in various electric and gas powered (rough terrain) models with maximum platform heights of up to 50 feet MEIRC Saudi Arabia

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(V) Vertical Personnel Lifts:Vertical personnel lifts consist of a work platform attached to an aluminum mast that extends vertically, which in turn is mounted on a steel base. These machines can be rolled in their retracted position through standard door openings, yet reach platform heights of up to 41 feet (12.5 m) when fully extended most is derivable at full height and is available with platform heights of 10 feet (3.2 m) 15 feet (4.2 m) and 19 feet 9 inch (6 m).

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Pendant Crane , Forklift & Manlift Training WHAT DO I NEED TO KNOW BEFORE SELECTING A LIFT ? By answering a few questions, you can quickly determine the type of lift you require. Those questions include: 

What is the maximum work height I need to reach ?



What is the maximum capacity required (material and people) ?



How large of a platform will be necessary ?



Will I need to travel in narrow aisleways ?



Do I need a tight turning radius ?



Will I need to move the lift from one floor to another ?



Will I be working inside ?



Do I want the ability to drive the machine when elevated ?



Do I need a platform extension to reach over obstacles ?



Do I need a scissor lift for straight up vertical work ?



Do I need a boom lift for reach ?



Do I need an articulating boom for up-and-over clearance ?



Will I be doing on-or off-slab work ?



Do I need side reach ?

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Module 7 Operating Procedures And Daily Inspection General This section outlines the necessary precautions for proper and safe machine usage and maintenance. In order to promote proper machine usage, it is mandatory that a daily routine is established based on the content of the manual book. A maintenance program, using the information provided the Service and Maintenance Manual, must also be established by a qualified person and must be followed to ensure that the machine is safe to operate. The user of the machine should not accept operating responsibility until the manual book has been read, training is accomplished, and operation of the machine has been completed under the supervision of an experienced and qualified appointed person. An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons. Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the unit. Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in the manual book. Ensure that the machine is to be used in a manner which is within the scope of its intended application as determined by the manufacturer. All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in the book. Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to your utilization and application of the machine.

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Read and understand the owners manual book

Workplace Inspection Precautions to avoid all hazards in the work area must be taken by the user before operation of the machine. Do not operate or raise the platform from a position on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless the application is approved in writing by the apropriate person. Before operation, check work area for overhead hazards such as electric lines, bridge cranes, and other potential overhead obstructions. Check floor surfaces for holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards. Check the work area for hazardous locations.

Do not operate the machine in

hazardous environments unless approved for that purpose . Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel. Do not operate the machine when wind conditions exceed 30 mph (12.5 m/s). o F to 104o F (-20oo C to 40 The machine can be operated in nominal ambient temperatures of 0 C). Consult the manufacturer to optimize operation outside of this temperature range

Chechlist A. Chassis: 1. Check front tires and wheel assemblies for loose or worn spindles, components and hardware for security, tires for wear and damage. 2. Check steering assembly for loose or bent tie rod, cylinder and lines for leaks and security, and hardware for proper installation.

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Pendant Crane , Forklift & Manlift Training 3. Check rear tires and wheel assemblies for security, tires f or wear and damage. 4. Check drive hubs, hydraulic motors, brakes and lines f or damage and leaks. 5. Check oil level in drive hub by removing pipe plug on side and feeling for oil level. Note:Torque hubs should be one-half full of lubricant. 6. Check oscillating axle (if equipped) for loose, missing and worn parts, pivot pin and lockout cylinder pins for security, lockout cylinders and hydraulic hose for damage and leaks. 7. Check counterbalance and flow divider valves, hydraulic swivel assembly and lines for damage, leakage and security. 8. B. Turntable: 9. Check turntable and lock for damage, loose or missing parts, and security. Check lift cylinder (articulating cylinder) and hydraulic lines for damage, leakage and security. Check swing drive hub, hydraulic motor, and brake for damage, loose or missing parts, hydraulic lines and component housings for evidence of leakage; pinion for proper mesh with swing gear. 10. Check swing bearing for damage, wear, lubrication and loose or missing bearing bolts. 11. Check solenoid valves and lines for damage, leakage, security and electrical connections for corrosion and tightness. 12. Check ground controls for damage, loose or missing parts, security, electrical connections for corrosion and tightness and wiring for insulation damage. Assure that all switches function properly. 13. Check battery for damage, loose or missing parts, security, electrical connections for corrosion and tightness electrolyte for proper level. 14. Check engine and accessories for damage, loose or missing parts, leakage and security. Check throttle solenoid and linkage for damage, electrical connections for corrosion and tightness and wiring for insulation damage. 15. Check fuel lines for damage, leakage and security. 16. Check all cowl and access doors for damage, proper operation of latches, props and security. 17. Check fuel tank for damage, leakage and filler cap for security. 18. Check hydraulic reservoir and lines for damage, leakage and security. Replace elements as required.

Note Manufacturers recommends replacing the hydraulic filter element after the first 40 hours of operation and then every 250 hours thereafter, unless unusual operating conditions require earlier replacement.

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Pendant Crane , Forklift & Manlift Training 1. Check tower boom pivot bushings for lubrication and wear. Lubricate after every 50 hours of operation. 2. Check tower boom lift cylinder and hydraulic lines for damage, leakage and security. Check lift cylinder cross pins for damage, wear and security. 3. Check all pin and shaft retaining hardware for security and wear. 4. Check all electrical cables for defects, damage, loose or corroded connections. C. Boom 1

Check tower boom pivot shaft and lift cylinder shaft retainer screws for damage and security. Lubricate after every 50 hours of operation.

2

Check all pin and shaft retaining hardware to security and wear.

3

Check hydraulic lines, electrical cable and track assemblies for damage, missing parts and security.

4

Check hydraulic and electrical lines in cable track for damage and leaks.

5

Check upright leveling cylinder, cross pins and hydraulic lines for damage, wear, lubrication, leakage and security.

6

Check upright for damage, wear, lubrication and security.

7

Check main boom lift cylinder and cross pins and hydraulic lines for damage, wear, lubrication, leakage and security.

Lubricate after every 50 hours of

operation. 8

Check main boom pivot pin for damage, wear, lubrication and security. Lubricate after every 50 hours of operation.

9

Check main boom for damage, missing parts and security.

10 Check main boom wear pads for damage, wear and security. 11 Check main boom telescope cylinder, cross pins and hydraulic lines for damage, wear, lubrication, leakage and security. 12 Check platform leveling cylinder cross pins, and hydraulic lines for damage, wear, lubrication, leakage and security.

Lubricate after every 50 hours of

operation. 13 Check limit switches, check valves and hydraulic lines mounted on upright for damage, leakage and security, and electrical connections for corrosion and tightness.

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Fig. 2.1 Boom Nomenclature.

D. Platform: 1

Check platform and control console for damage, loose or missing parts and security.

2

Check control switches and levers for damage, loose or missing parts and security. Assure that levers and lever lever locks function properly.

3

Check control switches, levers and electrical connections for corrosion and tightness, and wiring wiring for defects and chafing chafing damage. Assure that switches switches function properly.

4

Check access gate hinges and latch for operation, damage and security

Note Check all warning, caution, danger and instruction i nstruction placards for legibility and security around the entire machine.

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Daily Walk-Around Inspection It is the user's responsibility to inspect the machine before the the start of each workday. workday. It is recommended that each user inspect the machine before operation, even if the machine has already been put into service under another another user. This Daily Walk-Around inspection is the preferred method of inspection. In addition to the Daily Walk-Around W alk-Around Inspection, be sure to include the following as part of the daily inspection:

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Pendant Crane Crane , Forklift & Manlift Manlift Training 1

Overall cleanliness. Check all standing surface for oil, fuel and hydraulic oil spillage and foriegn objects. Ensure overall cleanliness.

2

Placards. Keep all information and operating placards placards clean and unobstructed. Cover when spray painting or shot blasting to protect legibility.

3

Operator's and Safety Manual

Ensure a copy of this t his manual and the Service and Maintenance manual are enclosed in the manual storage box. 4

Machine Log

Ensure a machine operating record or log is kept, check to see that it is current and that no entries have been left uncleared, leaving machine in an unsafe condition for operation. 5 Start each each day with a full fuel tank.

High engine, drive speed, function speed Begin your "Walk -Around Inspection" at item 1, as noted on the diagram.

Continue to your right right (counter clockwise clockwise

viewed from top) checking each item in sequence for the conditions listed in the following checklist. WARNING ;To avoid injury do not operate a machine until all malfunctions have been corrected. Use of a malfunctioning malfunctioning machine is a safety violation. Note :Check boom horizontal limit switch for proper operation and security both visually and manually. Switch must shut down: Warining To avoid injury do not operate machine until all malfunctions have been corrected. Use of a malfunctioning machine is a safety violation. To avoid possible injury, be sure machine power is "off" during "walk-around inspection". Note Do not overlook visual visual inspection of chassis underside. underside. Checking this area often often results in discovery of conditions which could cause extensive machine damage.

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Operating Characteristics And Limitations: a. General A through knowledge of the operating characteristics and limitations of the machine is always the first requirements of any user, regardless of user's experience with similar types of equipment. 

Do not use the machine for any purpose other than positioning personnel, their tools, and equipment.



Before operation, the user must be familiar with the machine capabilities and operating characteristics of all functions



Never operate a malfunctioning machine. If a malfunctions occurs, shut down the machine. Remove the unit from service and notify the proper authorities.



Do not remove, modify, or disable the footswitch or any other safety devices.



Never slam a control switch or lever through neutral to an opposite direction. Always return switch to neutral and stop before moving the switch to the next function. Operate controls with slow and even pressure.



Hydraulic cylinders should never be left at end of travel (fully extended or fully retracted) before shutdown or for long.



Do not allow personne to tamper with or operate the machine from the ground with personnel in the platform ecxept in an emegency.



Do not carry materials directly on platform railing unless approved by Manufacturer.



When two or more persons are in the platform, the operator shall be responsible for all machine operations.



Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area.



When driving, always position boom over rear axle in line with the direction of travel. Remember , if boom is over the front axle, the direction of steer and drive will be opposite from normal operation.



Do not assist a stuck or disabled machine by pushing, pulling, or by using boom functions. Assist only by pulling at the chassis tie-down lugs.



Do not place boom or platform against any structure to steady the platform or to support the structure.



Stow boom and shut off all power before leaving machine

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Pendant Crane , Forklift & Manlift Training b. Placards. Important points to remember during operation are provided at the control stations by DANGER, WARNING, CAUTION, IMPORTANT and INSTRUCTION placards. This Information is placed at various locations for the express purpose of alerting personnel of Potential hazards constituted by the operating characteristics and load limitations of the Machine. c. Capacities. Raising boom above horizontal and / or extension of boom beyond retracted position with or without any load in platform, is based on the following criteria: (1) Machine is positioned on a smooth, firm and level surface. (2) Load is within manufacturer's rated design capacity. (3) All machine systems are functioning properly. d. Stability. This machine when operated within its rated capacity on a smooth, firm and level supporting surface provides a stable aerial platform for all platform position. Machine stability is based on two positions which are called FORWARD STABILITY and BACKWARD STABILITY. The machines position of least forward stability is shown in Figure 2.3 its position of least backward stability is shown in figure 2.4. 3.1 Control And Indicators:- Some machines may be equipped with control panels that use symbols instead of words To indicate control functions. Refer to Table 2.1 for these symbols and the Corresponding functions. WARNING

To avoid forward or backward upset, do not overload machine or operate on an out-of-level surface.

a. Ground Control Station. (See figure 2.5) WARNING Do not operate from ground control station with personnel in the platform except in an emergency. Perform as many pre-operational checks and inspections from the ground control station as possible. Note

When the machine is shut down the ignition switch must be placed to the "off" position to prevent draining the battery.

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Pendant Crane , Forklift & Manlift Training 1

Ignition / Emergency Stop. A combined IGNITION / EMERGENCY STOP switch. The guarded-type switch Serves as the ignition switch when positioned to IGNITION ON and as an EMERGENCY STOP switch when the Red Guard is pushed down.

2

Start Button A Momentary contact, push button type switch that supplies electrical power to the Starter solenoid, when the key switch and ignition switch are in the ON position, and the start button is depressed.

3

Platform /Ground Key Select Switch. A three position, center off, key activated PLATFORM / GROUND SELECT switch supplies power to the platform control console when positioned to PLATFORM. With the switch in GROUND position, power is shut off to the platform station, and only the controls on the ground control panel are operable.

Note

With the Platform/Key Select Switch in the center position, power is shut off to controls at both operating stations. 4

Auxiliary Power Switch A toggle type AUXILIARY POWER control switch, energizes the electrically operated auxiliary hydraulic pump, when actuated. (Switch must be held ON for duration of auxiliary pump use).

a.

It should be noted that the functions will operate at a slower than normal rate because of the lower LPM delivered.

Note

When operating on auxiliary power, do not operate more than one function at a time. Simultaneous operation can overload the 12 Volt auxiliary pump motor.

b.

Position PLATFORM / GROUND SELECT switch to GROUND.

c.

Position IGNITION / EMERGENCY STOP switch to ON.

d.

Operate appropriate switch for desired function and direction.

e.

e Position AUXILIARY POWER switch to ON and hold

f.

Release both AUXILIARY POWER switch and selected function switch.

g.

g Position IGINITION / EMERGENCY STOP switch to OFF.

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WARNING To avoid serious injury, do not operate machine if any control levers or toggle switches controlling platform movement do not return to the off position when released.

Platform Station (Fig. 2.6) For engine starting, the footswitch must be in the released (up) position. Footswitch must be actuated in order for controls to function. (1) Footswitch A Safety features makes it necessary to depress the footswitch to allow Operation of the controls. WARNING To avoid serious injury, do not remove, modify or disable the footswitch by blocking or any other means.

Engine Opertion Note Initial starting should always be performed from the Ground Control station. a Starting Procedure

Check engine oil, if necessary, and oil in accordance with the Engine Manufacturer's manual. 1. Check fuel level. Add fuel if necessary. 2.

Check that air cleaner components are in place and securely fastened.

CAUTION If engine fails to start promptly, do not crank for an extended period. Should engine fail to start once again, allow starter to "cool off" for 2-3 minutes if engine fails after several attempts, refer to engine maintenance manual

3.Place engine speed control switch on platform control console to low position. Note :Footswitch must be in released (up) position before starter will operate. If starter operates with footswitch in the depressed position DO NOT OPERATE MACHINE.

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Caution Allow engine to warm-up for a few minutes at low speed before applying any load. 1. Turn key of SELECT switch to GROUND. Position IGNITION switch to ON, then depress and hold START button until engine start s. 2. After engine has had sufficient time to warm up, position ENGINE SPEED control switch to desired setting. b.

Shutdown Procedures.

Caution. If an engine malfunction necessitates unscheduled shutdown, determine any correct cause before resuming any operation. 1 Position ENGINE SPEED control switch on platform control console to LOW. 2 Remove all load and allow engine to operate at low speed setting for 35 minutes; this allows for further reduction of internal engine temperature. 3 Position IGNITION switch to OFF 4 Turn key of SELECT switch to OFF position.

Travelling (Driving). Do not drive with boom extended or above horizontal except on a smooth, firm and level surface. to avoid loss of travel control or upset on grades and side slopes, do not drive machine on grades or side slopes exceeding those specified on caution placard at platform. Assure that turntable lock is engaged before beginning any extended traveling.Avoid any terrain features which could cause the machine to upset. Travel grades in "low" wheel motor speed and "high" engine speed only. Use extreme caution when driving in reverse and at all times when driving with platform elevated and especially when driving with any part of machine within 1.83 m of an obstruction. Do not use drive to maneuver platform close to an obstruction. Use one of boom function. WARNING

CAUTION : Before driving, make sure boom is positioned over rear axle. If boom is over steer wheels, steer and drive controls will move in opposite directions machine motion.

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Operating Lift from the Basket Before entering the basket, the Operator must have on an OSHA approved full body harness. Before operating the lift the Operator must have already performed a walk through of the area where the work will be performed. Follow these steps in operating the lift from within the basket: 1. Get in the basket, and make sure that the door on the cage latches properly and securely.Immediately clip the lanyard on to the provided tie off point in the basket. 2. Place the right foot inside the safety device that is provided on the floor of the basket. The mechanical components of the lift will not work without first compressing the edal that is in the box.

NOTE: Before operating the lift, look for other moving vehicles and workers that might have started working in the area .

3.

Use the switch shown in the picture to start the lift from the basket. (If it does not seem to have power, make sure that the redemergency cut of switch is pulled out on the panel in the basket; if this is not the problem, check the key to make sure that it is turned to the on position at the main body of the manlift.

To increase or decrease

the movement speed of the manlift, turn the dial in the desired direction.

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4.

When traveling in the lift and there is a need to turn the wheels, use the switch located on top of the handle. Depress the left side to turn the wheels left or depress it to the right in order to turn the wheels right. (There is a silver safety switch just under the handle that must be pulled up in order to use this feature.)

5.

If the lift needs to be moved to a different location, lift up on the silver part of the handle and push the handle forward to move the lift forward or pull it back to move the lift backwards.

6.

To operate the boom using the joy stick, the Operator must first pull up on the handle then maneuver it forward or back to lift the boom up or down, or left or right to swing the boom left or right.

7.

To swing the basket to the left or right use the switch that has the basket highlighted above it.

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8. To raise or lower the lower half of the telescopic arm, use the switch that has a picture

of the boom above it with the lower half highlighted. 9 To tilt the basket

up or down, use the switch that is located in the upper left hand corner

Operating Lift from the Ground: For different reasons the aerial platform may need to be operated from the ground. Perhaps the Operator in the basket is in a tight spot and needs the aid of a co-worker on the ground. Or the Operator in the lift may have been injured. What ever the reason, the lift can be operated from the ground by using the step shown in this section. WARNING Make sure that the Operator and occupants in the basket are aware of your intentions 1. Place the key into the ignition and turn it to the on position.

2. Make sure that the red safety button is pulled out before attempting to operate the lift .

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3. To start the lift’s engine, lift up on the switch that is to the immediate left of the red emergency cut off switch.

4.

To lift the basket up or down, use the switch

that is located to the far right, second

from the bottom.

5. To swing the whole unit left or right, use the switch that is in the bottom right hand corner.

6. To lift or drop the boom, use the switch that is shown at the elbow of the boom.

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7. To extend or retract the boom use the switch that is placed in the middle of the boom.

8. To swing the basket to the left or to the right, use the switch located just above the picture of the basket indicating motion from side to side.

9. To tilt the basket down or back, use the switch that resides in front of the picture of the basket showing an up and down motion.

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Module 8 Fall Protection Equipment. Fall Protection Introduction OSHA requires the use of personnel protective equipment (PPE) to reduce employees exposures to hazards when engineering the administrative controls are not feasible or effective in reducing this exposures to acceptable levels. All (PPE ) will be of safe design and construction for the work to be performed and shall be maintained in a sanitry and reliable condition; Only those items meet NIOSH and ANSI standards will be acceptable for use. Safety Accessories:

Safety Belts.



Harnesses.



Lanyards.



Gloves.



Safety Glasses.



Hard hats. Fig: a set of lanyards

F i g .h a r n e s s u s i n g

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Body Belts And Safety Staps Life lines and fall arrest equipment shall be used when working at elevated locations above thae ground , if other fall protection has not been provided It should be inspected before use each day to determine that the eqipment is in safe working condition,defective equipment may not be used. All Harnesses and safety belts are lightweight, yet are constructed

of

durable

domestic

raw

material,

for

unsurpassed quality. Webbing is resin treated to help prevent abrasion and is dyed to help shield ultra violet rays. Breaking strength is 6500 lbs. All harnesses are sewn to international. All lanyards have double locking snap hooks.

Hardware complies with ANSI 10.14

guidelines for salt spray resistance, plating and proof testing. Web lanyards are constructed of flat webbing 1" wide with a latex treatment to help prevent abrasion. Their scores are excellent on all strength and force tests, following ANSI standards to the letter. Products should be shipped heat sealed in plastic for shelf life cleanliness.

Friction Buckle Harness:

Fig. friction buckle harness

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Pendant Crane , Forklift & Manlift Training Light weight full body harness with easily adjustable tongue buckle leg, waist, and shoulder straps. An adjustable single D-ring is centered on the back. Harness & Belt sizes: Small

32" - 40" waist.

Medium

36"-44" waist

Large

40"-48" waist.

X Large

44"-52" waist

Tongue Buckle Harness:Lightweight full body harness with easily adjustable leg, waist and shoulder straps. Adjustable D-ring is located on the center of the back.

Fig . tongu e buckle harness

F i g .f r i c t i o n w i t h 6 l a y a r d s

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Pendant Crane , Forklift & Manlift Training Friction Buckle Harness with 6' Web Lanyard:Lightweight full body harness with friction buckle adjustable leg, waist, and shoulder straps. An adjustable single D-ring is located on back of harness with at 6' permanently attached web lanyard.

Belt: Extremely lightweight safety belt and body pad with single D ring located on the back of the belt. A drop-forged steel friction buckle for secure fastening.

6' Rope Lanyard: Synthetic rope 1/2" X 3 strand. Double locking snap hooks are drop forged steel proof loaded to 5,000 lbs. All hardware applied over plastic thimbles.

6' Soft Stop Lanyard: Double locking snap hooks.

Shock absorbing device when activated during a fall

reduces the applied force to a falling body by approximately 505 or more.

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Pendant Crane , Forklift & Manlift Training 4"or 6" Web Lanyard: 1" webbing that features a breaking strength of 6,000 pounds.

Double locking drop

forged snap hooks.

Hard Hat:Head protection is necessary when hazard from falling or fixed objects, or electrical shock are present. Durable, lightweight, one-piece injection-molded high-density polyethylene construction. High dielectric strength (class B). Compatible with faceshields, hearing protection or welding helmets. The suspension system is easily adjustable, comfortable, provides a secure fit and essential crown clearance to absorb impact energy. Meets ANSI Z89.1.

Eye Protection In hazardous areas, eye wear is a must to Prevent eye injuries from flying particles.

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Slimline Glasses with Clear or Smoke Lens: Single slimline lens embraces face to prevent intrusion from flying particles while providing large, panoramic view for unobstructed vision.

Ergonomically designed

featherlight frame with adjustable temple gives comfortable, customized fit.

Clear or

smoke impact resistant, polycarbonate lens blocks 100% of harmful UV radiation. Meets ANSI Z87.1 standards.

Charcoal frame with adjustable click-to-fit temples that are

standard.

Fig. Slimline Glasses with Clear or Smoke Lens

Angle-Lens Glasses (Clear Lens): Single durable, scratch-resistant, clear polycarbonate lens.

Hazard protection that

combines safety with comfort. Black frame that feature adjustable temples. Meets ANS IZ87.1 standards.

F i g . 1 5: A n g l e - L e n s G l a s s e s

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Hand Protection Suitable golves shall be worn when hazards from cuts ,burns, falls and harmfull temperatures or objects are present

Lightweight Glove: Many choices of a durable but lightweight work glove. Features a split cowhide leather palm and full leather index finger and finger tips to insure exceptional durability. A cotton back makes the glove lightweight, cool and comfortable.

Insulated Leather Glove: A lined leather work glove that provides warmth, comfort and durability. Constructed of natural tan split cowhide for flexibility. A tapered cuff with shirred elastic back for a snug fit ensures a comfortable glove.

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Foot Protection Safety shoes shall be worn where carrying or handling materials such as , packages,parts or heavy tools ,which could be dropped, and where objects might fall onto the feet.

All foot wear shall comply with ANSI – Z41-1991.

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Module 9 Safety Precautions And Safe Operating Tips Introduction: A most important fact to remember is that any equipment is only as safe as those who operate it. Danger, warning, caution, important, instructions and note definitions. Since safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING, CAUTION, IMPORTANT, INSTRUCTIONS and NOTES are inserted throughout this manual to emphasize these areas. areas. They are defined as follows:follows:DANGER

If not correctly followed there is a high probability of serious injury or death to personnel.

WARNING OR CAUTION

If not correctly followed there is some possibility of serious injury or death to personnel. The "safety alert symbol" is used to call attention to potential hazards which may lead to death or serious injury if ignored.

Important Or Instructio Instructions; ns; Denotes procedures essential to safe operation and prevention of damage to destruction of machine. Note:Provides information of special interest to illustrate the text.

Maintain a safe clearance from electricalLines and apparatus.

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Electrocution Hazard Table Minimum safe approach distance (m.s.a.d.) To energized (exposed or i nsulated) power lines and part.

VOLTAGE RANGE(Phase to Phase)

MINIMUM SAFE APPROACH DISTANCE (Meters)

0 to 300V

AVOID CONTACE

Over 300V to 50KV

3

Over 50KV to 200KV

5

Over 200 KV to 350KV

6

Over 350KV to 500KV

8

Over 500KV to 750 KV

11

Over 750 KV to 1000KV

14

Danger: do Danger: do not maneuver machine or personnel inside prohibited zone. Assume all electrical parts and wiring are energized unless known otherwise.

Maintain safe clearance from electrical lines and apparatus. Allow for boom way, rock or sag and electrical line line swaying. The machine does not provide protection from contact with or proximity to an electrically charged conductor.

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Pendant Crane Crane , Forklift & Manlift Manlift Training Maintain a clearance of at least 3.05 m between any part of the machine or its load and any electrical lien or apparatus carrying up to 50,000 volts. 0.3048 m additional clearance is required for every additional 30,000 volts or less.

Standard and emergency ground controls Tipping Hazards: 

Ensure that the ground conditions are maximum tire load

adequate to support the

indicated on the machine. Do not travel on

unsupported surfaces 

Do not elevate platform or drive with platform elevated while on a sloping, uneven, or soft surface.

Ensure

machine is positioned on a firm, level and uniformly uniformly supported surface before elevating elevating platform or driving with the platform in the elevated elevated position.

Surface conditions: 

Before driving on floors, bridges, trucks, and other surfaces CHECK allowable capacity of the surfaces.



Never exceed the maximum work load as specified on the the platform.



Distribute loads evenly on platform floor. Keep all loads within the confines of the platform, unless authorized by the manufacturer ( eg.>JLG).



The user should should be familiar with the driving driving surface before driving. Do not not exceed exceed the allowable side-slope and grade while driving.



Ensure that the ground conditions are adequate to support the maximum tire load indicated on the machine. Do not travel on unsupported surfaces.



Avoid accumulation of debris on platform floor. Keep mud, oil, grease, and other slippery substances from footwear and platform deck.



Keep the chassis of the machine a minimum distance of 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.



Wheel chocks provide additional protection against accidental vehicle movement. Chocks prevent accidental movement or slippage of vehicles by bracing the wheel on both sides. This is important during boom and and basket movement when when shifting weight can affect wheel placement.

Chocks must be utilized before operating an aerial lift that is positioned on an incline.

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Pedestrian safety 

Operators must be constantly aware of their surroundings.



Aerial lift operators are responsible for the safety of people in the vicinity of the lifting equipment.



In the event that aerial lift work needs to be conducted in the vicinity of pedestrian traffic, operators must take special precautions to ensure that the work is isolated from pedestrian traffic.

Operating in tight areas 

Use the equipment ONLY for its intended purpose.



Operate the equipment in tight quarters ONLY as per the manufacturer’s recommendations.



When operating equipment from the bucket or platform, always wear a safety harness and safety line.



Always look in the direction of movement and exercise caution in close areas.



Use low speed function when in restricted or close quarters.

Traveling rules 

Do not travel with the boom elevated or extended. However, it may be necessary to extend the boom while moving a few feet to position it.



Aerial lifts may not be "field modified" for uses other than those intended by the manufacturer.

 

Do not exceed the machine placard maximum platform load. Always look in the direction you are moving the unit, and be aware of everything above, below and around you.

 

Never move the unit without a ground person. Do not attach wires or cables to the platform. Many aerial lifts have a place to plug in an electrical cord cord.



Other personnel should be restricted from passing or working underneath the raised platform.



A malfunctioning lift shall be shutdown and removed from service until repaired.

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Damage to equipment and facilities 

A pre-operation inspection should be performed in advance to every new shift by the operator and signed.



After completing the inspection the operator should report it to the appropriate person.



It is not the operator’s reponsblity to perform any repairs on his machine if not authorised but he can perorm the light maintenance ( i.e. topping up fluid levels, tightening wheel bolt/nuts,)



Any damage equipment should be tagged out immediately untill it is repaired by the autorised persons.



The equimment should be checked by the operator after its repair to make sure it is actually ready to do the job.

Ramp operation



slope (over 5 degrees). If the boom is above horizon tal and the machine is on a 5 degree slope, an alarm will sound and CREEP is automatically activated.

The following rules apply to all operations on the ramp: •

Always be aware of your surroundings.

•

Always wear personal protective equipment (PPE).

•

No smoking.

•

No alcoholic drinks or any drugs, legal or illegal, that are likely to impair performance or judgment.

•

No rough or boisterous play; practical jokes may lead to injury or damage.

•

Report all injuries, equipment damage and near-collisions to a supervisor.

•

Do not operate any equipment that has been declared unserviceable.

Keep the ramp area clear of foreign object debris (FOD). MEIRC Saudi Arabia •

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•

Only a trained operator may drive a vehicle or operate its controls.

•

Always obey speed limits.

•

Do not operate vehicles or equipment in the no-drive zone.

•

Never drive over fuel or fluid hoses.

Proper fueling procedures Refueling •

Shut off and cool the engine and any electrical equipment before fueling.

•

Ensure the fueling area is well ventilated.

•

Do not smoke while refueling. Keep open flames and sparks away from area.

•

Do not use gasoline or diesel fuel for cleaning parts.

•

Know where the fire extinguishers are located.

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Do's And Dont's 

Before operation, check work area for bare overhead electric lines, machine traffic such as bridge cranes, highway, railway and construction equipment.



Precautions to avoid all known hazards in the work area must be taken by the operator and his supervisor before starting the work.



Do not operate this machine unless it has been serviced and maintained according to the manufacturers specifications and schedule.



Ensure daily inspection and function check is operated prior to placing machine into operation.



Never disable or modify the footswitch or any other safety device. Any modification of the machine is a safety violation and is a violation of OSHA rules.



Do not operate machine when wind conditions exceed 48 km/h.



Never operate or raise boom when machine is on a truck, other vehicle or above ground structure.



Approved head gear must be worn when required by all operating and ground personnel.



Read and obey all warnings, cautions and operating instructions on machine and in this manual.



Be familiar with location and operation of ground station controls.



Watching for obstructions around machine and overhead when driving.



Always position boom over rear (drive) axle in line with direction of travel remember, if boom is over front (steer) axle, direction of steer and drive movement will be opposite from normal operation.



Always post a lookout and sound horn when driving in areas where vision is obstructed.



Do not use drive function to position platform close to obstacles. Use telescope or swing instead.



Check travel path for persons, holes, bumps, drop-offs, obstructions, debris, and coverings, which may conceal holes and other engine only.



Travel is permitted on grades and side slopes no greater than those indicated in caution placard at machine platform.

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

Operation with either boom raised is restricted to firm, level and uniform surface.



Before driving on floors, bridges, trucks and other surfaces check allowable capacity of surfaces.



Do not travel on soft or uneven surfaces, as tipping will occur.



Do not drive machine near pits, loading docks or other drop-offs.



Do not use high-speed drive when in restricted or close quarters or when driving in reverse.



Be aware of stopping distances when traveling in high and low speeds.



Always post a lookout and sound horn when driving in areas where vision is obstructed.



Towing with the optional tow package is permitted only on the job site for short distances. Do no tow at speeds over 8.05 km/h.



Keep non-operating personnel at least 1.83 m away from machine during driving operations.

Thorou ghly ch eck all clearances before Positioning p latform.



Do not operate any machine on which danger, warning, caution or instruction placards or decals are missing or illegible.



Machine must always be shut down when refueling. 'No smoking' is mandatory. Never refuel during an electrical storm. Ensure that fuel cap is closed and secure at all other times.



Prior to entering and exiting platform at ground level, fully lower tower and main booms. Extend main boom until end of fly boom contacts ground with boom lift in this configuration, enter and / or exit plat from through gate opening.



OSHA requires all persons in the platform to wear safety belts.

Secure belt

lanyard to proper attach bar on platform. Keep gate closed at all times. 

If platform or boom is caught so that one or more wheels are off the floor, all personnel must be removed from platform before operating ground controls to free machine stability with lift truck or crane.



Check clearance above, on sides and bottom of platform when raising, lowering, swinging, and telescoping boom.

K e e p h a n d s a n d ar m s o u t o f t o w e r b o o m A n d u p r i g h t m e c h an i s m .

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Pendant Crane , Forklift & Manlift Training 

Never place hands or arms in tower boom or upright mechanism.



The operator is responsible to avoid operating over ground personnel and to warn them not to work, walk or stand under a r aised boom or platform.



Never 'slam' a control switch or lever through neutral to opposite direction. Always return switch to neutral and stop then move switch to the desired position operate levers with slow, even pressure.



Do not carry materials on platform railing unless approved.



Never push or pull the machine or other objects by telescoping the boom.



Never use boom for any purpose other than positioning personnel, their tools and equipment.



Never exceed manufacturers rated platform capacity refer to capacity decal on machine distribute loads evenly on platform fl oor.



Never operate a malfunctioning machine if a malfunction occurs, shut down the machine, red tag it, and notify proper authorities.

K e e p E v e r y O n e C l ea r O f A W o r k i n g P l a t f o r m B e w a r e o f o t h e r m o v i n g m a c h i n e r y i n y o u r a r ea o f o p e r a ti o n K n o w y o u r c a p a c i ty a n d o p e r a te w i t h i n i t . 

Ensure machine is positioned on a firm, level and uniform supporting surface before raising or extending boom.



Observe extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in platform.



Ensure that operators of other overhead and floor machines are aware of the aerial platform presence. Disconnect power to overhead cranes barricade floor if necessary.

U s e s a fe t y b e l t a n d k e e p g a t e L at c h e d o r y o u m a y g o d o w n i n h i s t o r y . 

Do not remove, modify, or disable footswitch by blocking or any other means.



Do not assist a stuck or disabled machine by pushing or pulling except by pulling at chassis the down lugs.



Never attempt using boom as a crane structural damage or tipping may occur.



Never position ladders, steps, or similar items on unit to provide additional reach for any purpose.



Stow boom and shut off all power before leaving machine.

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Forklift , Pendant Crane & Manlift Training

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