frequently asked questions about vehicle loading cranes · so high that the inner boom cannot be...

Frequently Asked Questions About Vehicle Loading Cranes

Introduction

Types of Vehicle Loading Cranes

2 UNIC

3 Maxilift

3 Cobra

4 Effer

How to Select Crane Size

Telescopic or Knuckle Boom. Which Crane is best?

7 Telescopic Boom Advantages

8 Knuckle Boom Advantages

Caution - Lift Curve Graphs

How Do I Pick the Truck to Carry My Crane?

Rule of Thumb for Matching the Vehicle to the Crane

13 Guide to Suitable Crane / Truck Combination

What Are the Australian Standards?

Do I Need a Crane Operator’s Licence?

How Often Should My Crane Be Inspected?

1

2

5

7

9

11

13

14

17

18

CONTENTS

maxilift.com.au

INTRODUCTION

Over the past 30 years we have seen a quantum leap in the demand for improved OH&S and, with that, we have seen huge developments in crane technology – particularly – with safety related systems.

Unfortunately, Vehicle Loading Cranes (VLC’s) have also earned the title of “High Risk Plant” and this has come about through a number of sadly fatal accidents.

We all agree that VLC’s are a wonderful tool for greatly improved safety, productivity and effi ciency, however the choice of crane, and then the correct matching of crane to chassis is critical to the success of any crane/truck project.

In this booklet, we answer some of the frequently asked questions. They are all important and valid questions that you should be asking when buying or building any crane truck.

Maxilift Australia have hundreds of years of combined experience and passion for doing this well. We are always available to work with you on this process.

Bob DavisManaging Director

Frequently Asked Questions About Vehicle Loading Cranes1

These cranes take up no more chassis space than a folding boom crane, and their stored height is about the same. The boom can be stored over the cab or the tray, depending on preference.

Their capacity range is 4TM to 20TM.

TYPES OF VEHICLE LOADING CRANES

UNIC

UNIC Cranes are perfect for:

• Steel erection

• Signage work

• Underground work e.g. pumps and sumps

• Jetties and bridges

• Marine work

• Precision placement

• Heavy, in close lifting e.g. bobcats, scissor lifts and similar machinery

2Types of Vehicle Loading Cranes

Maxilift

Cobra

Maxilift material handling crane

Australia’s favourite small crane for the past 25 years.

Simple, reliable, powerful and robust all accurately describe Maxilift cranes.

Maxilift’s are found on utes and trucks in most councils, RTA Fleets, light delivery applications, airports and marine related industries.

There are also heavy duty versions for pipe-laying, mining and marine applications.

Capacity range is 0.5TM to 5TM.

Cobra cranes – also a straight boom winch design – are typically used on lighter vehicles for similar purposes to Unic. A great advantage of Cobra is they can be offset, bringing the crane closer to the load and freeing up tray space. Their capacity range is 1.7TM to 10TM.

It is also common to mount a cobra on top of tool boxes or lockers making even better use of available tray space.

Cobra service crane with built-in winch


EfferEffer knuckle-boom crane

Knuckle Booms are great for:

• Simple loading/unloading

• High placement work – with a fl y jib

• Bucket, grab or Auger work

Very large folding boom cranes are now starting to take the place of small mobile cranes. They offer large lift capacities, long reach hydraulically luffi ng fl y jibs, and if mounted on the right chassis, are comparable to a mobile crane with the added advantage of payload ability.

Capacity range is 3TM to 300TM.

4Types of Vehicle Loading Cranes

HOW TO SELECT CRANE SIZE

VLC’s are measured with the term Tonne Metre (T.M.). This is a measurement of force rather than weight.

The rated load x rated distance = the Tonne Metre capacity of that crane.

For example:

You will notice that all the weights on the load chart x the distance will come up with a similar fi gure – just dropping slightly the further out you go.

ie. 0.95T x 2.26m = 2.15 Tonne Metre 0.5T x 4.2m = 2.10 Tonne Metre

Why is this so?A crane must lift the weight of its boom before it lifts the load. So the longer the boom, the greater the ‘fall off’ of Tonne Metre at reach.

Handy Tip:Don’t buy more boom than necessary for your work. It costs money to buy, uses fuel and payload to carry and reduces the lift capacity of your crane.

One example of this is a typical 30TM crane with 3 boom sections reaching around 10.6m – such a crane has a capacity of 29TM.

With 6 boom extensions, reaching around 17m, the same crane is now down to 27.4TM – and weighs 440kg more.

The ML230-3 (1.8T x 1.26m = 2.27 Tonne Metre)

The Effer 315 3S (29TM and 3,265kg tare weight) The Effer 315 6S (27.4TM and 3,705kg tare weight)


Caution: Heavy (in close) lifts have a complication.

If we say that we need to lift 2 tonne at 3 metres, we would look for a 6 tonne metre crane. But with high or long slung loads, this calculation can lead to an embarrassment!

You would need a crane rated at 6 tonne metres or better to do the job BUT it is important to consider the physical size of the load you are lifting. For example, look at Figure 1 below.

To handle a high load of near crane capacity, the inner boom must be vertical (or near to vertical), and the outer boom pointing down, with the hook above the centre of the load.

In this confi guration, only the outer boom can be raised. The operator may not get suffi cient hook height to clear the base of the load over the tray body.

The resulting increase in the radius can be substantial and is often suffi cient to over pressurize the luff rams and to activate the overload protection (if fi tted) which may prevent the crane moving into the required position.

With our example of 2 tonne at 3 metres, if the load or sling length causes the hook to be so high that the inner boom cannot be used for the lift, then probably an 8 tonne metre crane would be the size required.

A winch rope crane will give a vertical lift as seen in Figure 2 (therefore no increase in radius), so this consideration is not applicable to UNIC & Cobra telescopic boom cranes fi tted with winches.

NOW – what size crane do you need?

1. What are your known lift weights (including chains, spreader bars etc.)?

2. What is the maximum radius or hook height to place them?

3. Weight x Distance = Tonne Metre crane required

4. If using a knuckle boom crane – please refer to lift curve graphs on page 9.

5. Do you need a winch with running rope?

The working radius can increase when the load is lifted with a knuckle boom crane.

A winch crane with running rope makes a vertical lift keeping the radius constant.

(Figure 1) (Figure 2)

6How to Select Crane Size

Telescopic Boom Advantages

Buildings, walls, whatever, with Unic wire-rope cranes you get precise high-lift placement and safe, sure operation. Their dependability is all in their strength and design, original Unic features.

Higher performance, too, at lower depths. Unic wire-rope cranes handle heavy loads in deep-hole jobs with accuracy and stability. A wide range of models assures versatile matching to job requirements.

Tight places are the right places for Unic wire-rope cranes. In any operating situation their strong steel cables mean extra dependability and safety. High, low or tight, Unic wire-rope cranes are always right.

Heavy lifts with a winch rope crane An 8TM Unic easily lifts a 3 tonne cable drum. This is not possible even with a 9TM knuckle boom crane.

The lift curve graph of a typical 9TM knuckle boom crane shows it cannot - in practice - lift a 3 tonne load onto the tray.

TELESCOPIC OR KNUCKLE BOOM


Knuckle Boom Advantages

Which Crane is Best?

Knuckle boom cranes are very widely used in Australia.

Their typical application is delivery trucks i.e. loading/unloading work.

Effer knuckle boom cranes are also market leaders in cranes designed for earth auger and pole standing work. Certain models are built with a heavy duty inner boom to absorb the stresses of auger work.

With large capacity cranes (usually over 30TM) nothing matches the up and over reach ability of a hydraulic luffi ng (raise and lower) fl y jib.

Fly jibs and big capacity cranes are an Effer speciality.

8Telescopic or Knuckle Boom. Which Crane is Best?

CAUTION - LIFT CURVE GRAPHS

Note the 175 with twin links will lift 5,050kg to 11 metres height of hook (1) Whilst the 175 without the lever advantage can only place 3,160kg to the same height (2)

At reach, the 175 with links will place 1,255kg at 10 metre radius and 11 metre height of hook (3) Whilst the non-link crane is 1,200kg at 8m radius for the same height (4)

31

Load Chart 175.4S (With Twin Links)

42

Load Chart 175.4S (With No Linkage System)

Applies to Knuckle Boom Cranes Only

All knuckle boom cranes with fi xed hooks depend on their boom luffi ng (raising/lowering) cylinders to raise a load.

The angle of that cylinder to the boom greatly infl uences the leverage of the cylinder and – with that – the boom’s ability to lift the rated load.

Here is a typical 9 Tonne Metre Knuckle Boom lift curve chart. It shows you can lift 2,860kg at 3 metres. However, once the hook passes 2 metres above mounting level, the leverage drops away as does the crane’s ability to continue lifting that load any higher.

One solution is a linkage system between boom and column and the fi rst and second boom.

Not every manufacturer offers this system or it may be available on certain models only.

Here are 2 near identical 17TM Effer cranes, one without twin link system and the second one with twin links.


Telescopic or Knuckle Boom?

It really does depend on the type of work you need to do. If the information on the previous pages has left you unsure, talk to us. We can certainly help with expert advice and working demonstrations.

(please also see page 13 for selection chart guide)

So Which Crane is Best?

UNIC Telescopic Boom Crane

Effer Knuckle Boom

Maxilift Mono Boom Crane

10Telescopic or Knuckle Boom. Which Crane is Best?

HOW DO I PICK THE TRUCK TO CARRY MY CRANE?

This is important.

Always know the total load to be carried and the maximum load to be lifted, to what maximum radius and/or height.

With this critical information, the crane can be selected and only then – the truck.The truck must be able to (amongst other things):

• Carry the crane and total load without exceeding RTA axle load limits.

• Offer suffi cient counter weight effect for the crane to remain stable i.e. not tip over, during maximum lift work.

E.g. a crane required to lift 5 tonne at a radius of 4 metres (20 Tonne Metres) would normally require two axles (either bogey drive or twin steer) to legally carry the crane as well as to provide suffi cient counter weight to stabilise such a capacity crane.

Some truck combinations do not require detailed calculations. They are a norm with many similar examples working in the fi eld.

For a guide to these please see “Rule of Thumb” on page 13.

For projects outside of the rule of thumb, engineering calculations should be made before ordering the crane or truck.

Here is a typical preliminary axle loading calculation for a 22TM rear mounted crane – Effer model 220 6S

1245

6570 1320

7230

Theor. 7230

11340

2725

11200

-10802065

8321 kg

950

2 4 6 7

975 7900100

2865 =40%

2305

3346 { 24%} 5998 { 27%} 6000

10833 (5417+5417) 16502 (8251+8251) 16500 (8250+8250) 5524

14179 kgUnloadedloaded

= 14179 kg= 22500 kg

Max = 22500 kg

Notes: 1.Wheelbase has been extended to 6570mm 2.10mm sideplates installed 3.150 kg/m assumed for diagonal braced subframe (100x100x9) 4.Winch and rope included in this calculation (S15 winch) 5.Spare tyre included 100kg 6.Fuel load of 332kg used in calculation 7.Manual extension weight 70kg included in calculation 8.Tray is assumed to weigh 148kg/m 9.Drawing should not be scaled

10.These calculations are based on estimates 11.Vehicle Weights are based on manufacturers sp

MAXMAAXILI

FT AUSTRA

T AT AT AUS

FTLIF72307230

ILLI1

STUSTUSTTTSTRALIA

USUSAAL

AX55244

VISVISeor. 7230eor. 7230ISIO

N 010101010NON340340

ONIS


Our advice to this customer was to either extend the wheelbase or move the crane forward to increase the % of load on the front axle – to improve steering and road stability.

A stability calculation for the same truck and crane shows the unit to be stable – to our Australian Standards – full 360 degrees providing front mounted supplementary stabilisers were fi tted.

These calculations require:

• Accurate data i.e. garbage in, garbage out

• Engineers – experienced in road transport matters

Maxilift Australia’s very experienced engineering team love the challenge of getting it right.

2.0

1.8

1.6

1.4

1.2

1.0

0°

180°

90°

-250

3200 3200

6400

9423

3300

H

n = 1.93Rearwards

n = 1.78Right

n = 1.58Left

n = 4.43Forwards

40015_Marcus B_NSW_Effer 215-6S+Manual Ext_Mitsubishi fighter 2427

MITSUBISHI Fighter 2427 FN62/63/64..K 9 speed manual 6x2 /6x4 (ADR 80/03-Euro V)EFFER 220/6S STD 865 kg x 16770 mm

n = Maximum load

Rearwards 1.93 865 kgRight 1.78 865 kg

Left 1.58 865 kgForwards 4.43 865 kg

R max = 37.0 kN = Mdyn / H Mdyn= 237.5 kNm x 1.3 H=8341 mm

AXAXILXILXILIILIIILIF

ILILIFT

LIFLIFTIFT A

IFTFT AUS

FT AUSAU

LIFT

USAUAUAUAUAUA64006 UUAUAUAUUSUSSUSUSUUUUUUUUUUUSTUSSTSUSUUSUU

ALIA

RALIAALIARALIRALIRALRAL

TRASTRATRA

USTRSTRRALIA

STSTUSTSTUSUUS

RAL

UUUUUSUSTUSUUUUUU

+Manual+Manualual Ext_Mitual itsuit

62/63/64..K 9 speed 2/63/64..K 9 speed

AXMA

REVISI

ISIO

ISISIOSIO

ISSSIOSIO

NIOO

N ON 01ON N

01N

01ONON

1ONONN24

6x2 /6x4 (ADR 80/0

ISnn

VISRE

Mdyn= 237.5Mdyn= 237.5

Load testing: all installations must be load tested and certifi ed in accordance with AS1418.11

12How Do I Pick the Truck to Carry My Crane?

MATCHING THE VEHICLE TO THE CRANE

Rule of Thumb

Many years ago after observing hundreds of controlled and recorded load tests, we derived the following rule of thumb:

• Front Mounted Crane – if the crane capacity in TM is less than the payload rating (GVM – tare weight) of the vehicle the crane-truck combination would usually be suitable.

• Rear Mounted Crane – reduce the crane capacity by 1 TM in comparison to the payload rating.

• I.e. a 5 tonne payload truck would normally carry and be stable with:

• A 5TM crane mounted behind the cab OR

• A 4TM crane mounted at the rear of the chassis.

• Please note: this is only a ‘rule of thumb’. All installations should be carefully evaluated before starting the fi tment.

Truck Payload Size Maxilift Cobra UNIC Effer

(GVM - Tare Weight)

Behind Cab

Rear Mount

Behind Cab

Rear Mount

Behind Cab

Rear Mount

Behind Cab

RearMount

1 TonneM50

ML110M50 x x x x x x

2 TonneML150ML180

ML150 3300 x x x x x

3 TonneML230ML270

ML180 4400 3300 x x x x

4 TonneML330ML380

ML270 5500 4400 URW260 x 35 x

5 Tonne ML510 ML380 6600 5500 URW293 URW260 50 35

6-8 TonneAll of the

AboveML510 8000 6600

URW340URW370

x6580

5065

9-10 TonneAll of the

AboveML510

1100012000

800011000

URW500WURW540W

URW37080100

80

Dual Rear AxleAll of the

AboveAll of the

AboveAll of the

AboveAll of the

AboveAll of the

AboveUR805

135150

Large Capacity Cranes Subject to Calculations

Guide to Suitable Crane / Truck Comination *Indication Only


There are several Standards that relate to VLC’s however, the two key Standards to be familiar with are:

• AS1418.11 Vehicle Loading Cranes – covers design, installation and pre-delivery inspections.

• AS 2550.11 Safe use – Vehicle Loading Cranes – covers operating, maintenance and 10 year inspections.

These standards are regularly updated by a panel of industry experts, owners & users and government regulators for example a new version of AS1418.11 was released in 2014 and this new release took into consideration issues related to VLC’s occasionally being used without outriggers extended, subsequent accidents and the development of technology by manufacturers to reduce that risk.

The Maxilift Australia team pride themselves on standards knowledge and compliance.Ask us if not sure.

WHAT ARE THE AUSTRALIAN STANDARDS?

14What are the Australian Standards?

IF I FIT MY OWN CRANE, HOW DO I ENSURE IT COMPLIES WITH AUSTRALIAN STANDARDS?

Generally VLC’s should only be fi tted and commissioned by competent workshops with factory trained staff.

It can be a costly process to supply and fi t a PTO and pump, design, build and fi t a suitable subframe, fi t the crane and any accessories, supply hydraulic hoses and oil then load test, commission and provide training in this new crane to the operator.

It is not uncommon for an engineering company to want to save on that cost. The answer is if you want to do this you could:

• Seek agreement from the crane supplier along with his advice and specifi cations.

• Engage a competent person – well trained in VLC installations – to review the work whilst in progress, inspect the completed job and then to conduct and record load testing as per the current Australian Standard.

Please think very carefully before fi tting a modern VLC yourself.

Current chassis – behind the cab – are packed with battery boxes, catalytic converters, exhaust systems, fuel tanks and more. Finding places to get mounting bolts through, chassis anti-crush spacers and – where to store the outrigger legs – can be really challenging.

Current complying VLCs have overload protection systems and stability control systems – each requiring detailed and, sometimes complex load testing procedures. They also have a number of indicators wired to the cabin and, of course, the PTO must usually be programmed into the chassis CPU.

Please – unless you are right up to date on all these things – leave it with professionals.

Typical Big Crane Subframe Quality Handover Training is Important

Photo courtesy of Aaron Nicholson, Vic Cranes Sales & Service

Anthony Steel, long term Unic dealer – conducts training on a new Unic in Broken Hill


WHAT OTHER REGULATIONS OR LAWS DO I NEED TO FOLLOW?

Each state Road Traffi c Authority specifi es allowable axle loadings and vehicle dimensions. Your crane supplier should be familiar with these. If he is undertaking the installation in his workshop he would normally accept responsibility for compliance.

CAUTION: Vehicles can commonly vary in weight from the manufacturer’s brochures. If the installation is made by yourself or by a third party i.e. outside of your crane supplier’s control, he cannot be responsible for knowing the exact weights and axle spacings for your vehicle and therefore cannot reasonably be responsible for the outcome in terms of RTA compliance.

The axle load limits have increased for some trucks only. The trucks must be equipped with a Front Underrun Protection System (FUPS). The majority of trucks on our roads are FUPS equipped but there are still a few that are not. The Front Underrun Protections are barriers integrated into the front of trucks or built as specially designed bull bars. The regulation outlines several requirements that the FUPS must meet. Your truck dealer will be able to explain this in detail.

Some states have a ‘blue plate’ or modifi ed vehicle inspection scheme. Your crane supplier will advise on this.

It is the owner’s and driver’s responsibility to ensure that the gross mass of a vehicle or combination vehicle and its load doesn’t exceed the lesser of the following as outlined by regulators.

For example:

• The GVM and GCM on the registration certifi cate and label

• The sum of the mass limits for axles and axle groups

• The mass limit applicable to the vehicle’s registration confi guration code

• The axle spacing mass limits for a particular vehicle or combination vehicles.

All such information is also available from your relevant RTA offi ce or website.

16What are the Australian Standards?

DO I NEED A CRANE OPERATOR’S LICENCE?

If the crane is of less than 10 Tonne/Metre capacity i.e. where any point on the load chart Tonnes x Radius is less than 10 TM, then a licence is not required.

However, most OH&S legislation, and good practice, would dictate that any crane operator should receive quality training in the proper care and use of their crane.

Where the crane capacity x radius is greater than 10 TM the minimum class CV licence is required. A higher mobile crane rating e.g. class C2 or C6 etc. also covers VLC work.

The load chart to the left shows its largest capacity as:

• 3,510 kg x 2.43 m = 8.53TM and

• 2,500 kg x 3.64m = 9.1 TM and

• 1,750 kg x 5.23m = 9.15 TM

Therefore this crane does not require a licensed operator – although good practice would ensure that all operators are well trained.

In order to obtain a CV licence the appropriate training must be undertaken and then you must be assessed by an accredited Assessor. Information regarding licencing, training and assessment can be obtained from your state’s safe work offi ce.


Australian Standard AS2550.11 and your manufacturer’s advice – found in your crane’s operators manual – will dictate this. Normally, crane inspection regimes are:

• Daily visual check by the operator. Record to be kept in the truck’s cabin i.e. logbook or similar and this record should be readily available to any interested party.

• Detailed inspection by a competent person* following any incident such as a lightning strike, shock load or road accident.

• Annually by a competent person*

• After 10 years of service, the AS2550.11 requires the crane to be thoroughly inspected by a competent person or engineer. This will usually require a complete strip down, NDT testing of welds and key stress areas and, at this time, any upgrades to bring this crane into line with current Australian Standards should be considered.

• Modern cranes are equipped with a number of electronic safety systems and (frequently) also remote controls. Technicians should be well trained in the particular systems they are being asked to inspect or repair.

* A competent person is defi ned in AS1418.11 as being: A person who has acquired through training, qualifi cation, experience or a combination of these, the knowledge and skill enabling that person to correctly perform the required task.

HOW OFTEN SHOULD MY CRANE BE INSPECTED?

18How Often Should My Crane Be Inspected?

NOTES


OTHER OPTIONS FROM MAXILIFT AUSTRALIA

maxilift.com.au

www.maxilift.com.auVISIT OUR WEBSITE:

MAXILIFT AUSTRALIA PTY. LTD.HEAD OFFICE

12-16 Dorset StreetLonsdale, South Australia

Phone: (08) 8326 6300Fax: (08) 8326 4685

frequently asked questions about vehicle loading cranes · so high that the inner boom cannot be...

Documents