transmission & distribution centre truck operating 1 book 2/30... · and safety regulation 215...

�T R A I N I N G

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BoomTruck

Operating

Training Development Centre

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O P E R A T I N G

OBJECTIVE:Given this module, a boom truck, tools,equipment and a load to be moved, youwill be able to explain and demonstratehow to operate a boom truck.

WHY?You must be familiar with the operatingprocedures before attempting to operate aboom truck. Reaching this objective willprevent injuries and equipment damage.

LEARNING OBJECTIVES:1. Explain the pre-operating, shutdown and

post-operating procedures pertaining toa boom truck.

2. Explain boom truck stability.

3. Recognize how to use capacity charts.

4. Explain the necessary steps required tomove a load with a boom truck.

5. Recognize multi-crane lifts.

6. Demonstrate the pre-operating,shutdown and post-operating procedurespertaining to a boom truck.

7. Demonstrate how to interpret capacitycharts and move a load with a boomtruck.

INT Start Here

AEP

DIMTRA

LIF

RIGHYD

ACO

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ADO

BCO DDCDDOBTO

DUSBUS

(Core Modules)

(Digger Derrick Modules)

(Boom Truck Modules)

(Bucket Truck Modules)

Copyright © 1997 by the Training and Development Centre, SaskPower. All rights reserved. 0 4 / 2 7 / 0 0

IN THIS MODULE:1. Pre-Operating, Shutdown and Post-

Operating Procedures

2. Boom Truck Stability

3. Using Boom Truck Capacity Charts

4. Travelling and Work Sites

5. Making a Lift

6. Multi-Crane Lifts

RESOURCES:• IPT’s Crane and Rigging Training

Manual

ESTIMATED TIME:4 hours

PREREQUISITES:• Previous Modules of Mobile Equipment

Training Manual

LEARNING STEPS:1. Cover the module.

2. Clarify any questions you may have.

3. Complete the Knowledge Check.

4. Observe a demonstration on boom truckoperating.

5. Complete the Skills Practice.

6. Perform the Skills Check.

Copyright © 1997 by the Training and Development Centre, SaskPower. All rights reserved.0 4 / 2 7 / 0 0

Pre-Operating, Shutdown and Post-OperatingProcedures

Pre-Operating ProceduresBoom trucks are to be inspected daily before use. If your unit hasa load rating of greater than 5 tonnes, refer to Occupational Healthand Safety regulation 215 for more specific information. All units,regardless of their rated load, have a log book which is unit specificand contains a checklist for both chassis and equipment.

Checking the ComponentsThe components are to be checked for the following:

• cracks on the boom, outriggers, turret, etc.

• all visible welds are to be checked for stress cracks

• condition of all pins, bolts and keepers (missing, stretched, orother damage)

• cracks and oblong holes at all pivot and swivel joints

• condition and wear on the sheaves and winding drums

• condition and hook spread on the down-haul weights andreeving blocks

• necessary operating adjustments (referring to clutches,brakes, etc., and normally doesn’t apply to boom trucks)

• overall appearance and cleanliness

For further clarification of the regulations, refer to theOccupational Health and Safety regulations 134,155, 156, 215and 216.

Refer to the Daily Inspections and Maintenance module, pages 4to 9, for items which have to be checked on your unit.

4 T R A I N I N G M A N U A L .

0 4 / 2 7 / 0 0Copyright © 1997 by the Training and Development Centre, SaskPower. All rights reserved.

Hydraulic SystemThe hydraulic system is to be checked for the following:

• level and condition of the oil in the reservoir (all cylindersmust be in the stowed position for this check)

• condition of all fittings and hoses (cracks, tightness, etc.)

• operation of all controls (must return to neutral whenreleased)

Operation of Holding ValvesBefore the unit is used, all holding valves are to be checked toensure that they are working properly.

The procedure is as follows:

Outrigger Holding Valves• Lower the outriggers until a portion of the truck’s weight is

on the outriggers. It is not necessary to raise the wheels offthe ground.

• Divert hydraulic power from the outriggers. Shut off theengine, disengage the PTO or move the selector valve to“mainframe”.

• Move the outrigger valve back and forth from the “Up”position to the “Down” position to free any trapped air. Holdin the “Up” position for ten seconds. If you see anymovement in the outrigger after the initial operation, theholding valve is not working properly and must be fixed by aqualified mechanic before the unit is used any further.

Boom(s) Holding Valve• Raise the boom to a 45 degree angle.

• Divert hydraulic power from the boom control valve. Shutoff the engine, disengage the PTO or move the selector valveto the “Outrigger” position.

• Move the boom control valve back and forth to free anytrapped air and hold the control in the “Down” position forten seconds. If you see any movement in the boom after theinitial operation, the holding valve is not working properlyand must be fixed by a qualified mechanic before the unit isused any further.

B O O M T R U C K O P E R A T I N G 5 .

0 4 / 2 7 / 0 0 Copyright © 1997 by the Training and Development Centre, SaskPower. All rights reserved.

Extension Boom(s)• With the boom at a 45 degree angle, extend all hydraulic

booms.

• Divert hydraulic power from the boom(s). Shut off theengine, disengage the PTO or move the selector valve to the“Outrigger” position.

• Move the boom extension control valve back and forth tofree any trapped air and then hold in the “Retract” positionfor ten seconds. If there is any movement in the extensionboom(s) after the initial operation, the holding valve is notworking properly and must be fixed by a qualified mechanicbefore the unit is used any further.

Shutdown ProcedureWhen a boom truck is left unattended for whatever reason, youmust ensure that no unauthorized personnel will be able to operateit.

Consider the following procedures and, if available, follow themanufacturer’s specific recommendations for the particular craneinvolved.

• Lower the load to the ground (if possible).

• Place all controls in the “Neutral” position.

• Disconnect the PTO, master clutch or shut down the engine.

• Set all brakes and any locking devices (ensure the unit willnot move).

• Lock all doors.

For more clarification about leaving unattended or suspendedmachines, refer to the Occupational Health and Safetyregulations 136 and 211.

Now...Watch the Aerial Device training video (hydraulic systemcheck).



Post-Operating ProceduresAfter completing a job function, the following procedures must becompleted.

Tools and Apparatus• All hand tools used must be put in the proper place.

• Any rigging that may have been used is to be properlystored.

Boom(s)• All booms must be retracted and lowered onto the boom rest.

• The boom is to be secured down to prevent damage due toroad shock.

Outriggers• All outriggers are to be completely retracted for travel.

PTO• The PTO must be properly and fully disengaged before

driving away.

You should now go to the unit and observe a demonstration on pre-operating, shut down and post-operating procedures.

Remember, shutdown is when you leave the unit on the job site.The post-operating procedure is done after the job has beencompleted and you will be leaving the job site for good.



Boom Truck Stability

ConfigurationsBoom trucks are available with varying types of boom hoists andoutriggers. Different configurations will determine the capacityand stability of the unit. The following are some examples ofdifferent types of boom trucks.

Front Centre MountOn this particular model, the mainframe and boom are mounteddirectly behind the cab of the truck, with the boom in the centre ofthe truck chassis. This unit may be equipped with one set ofoutriggers, as well as optional rear stabilizers.



Rear MountOn a rear mount, the boom may be mounted at the rear centre ofthe frame. Some manufacturers also offer a rear corner mount,where the boom is mounted at the back of the chassis in eithercorner.



Operating QuadrantsThe quadrants of operation are defined as the lifting area specifiedby the manufacturer for a particular part of the circle of rotation.

Most load charts will include a small drawing of the crane showingthe shape and location of the machine’s quadrants of operation.Quadrants will differ depending on the crane manufacturer andmodel type. Check the quadrants of operation for your unit beforeusing it. Capacities can be affected as you move through the rangeof movement.

The following are some things which can affect the operatingquadrants of a boom truck.

• type of boom hoist (front, rear, corner mount)

• type and number of outriggers

• how far the outrigger spread is from the machine’s centre ofgravity

* Graphic courtesy of IPT



For more information on boom truck operating quadrants,consult IPT’s Crane and Rigging Training Manual, pages 460 to463 inclusive.




Stability FactorsTo maintain a margin of safety against tipping, all mobile cranesare capacity rated at levels below the point at which the load willbegin to tip the machine. The manufacturer loads the crane anddetermines (for every situation listed in the load chart) the amountof weight required to make the crane tip. These loads are calledthe tipping loads.

Tipping loads are then reduced by a percentage set by nationalstandards to develop the rated loads listed on the capacity chart. Atypical boom truck is rated on the structural integrity of the unitand on an 85 percent stability tipping factor.

Depending on the configuration of the crane, lifting too much loador lowering or extending the boom with a load increases the radiusand can tip the machine or cause structural failure.

* Graphic courtesy of the Construction Safety Association of Ontario

Too much load orbooming down canresult in tipping or

structural failure




Telescoping out andincreasing the loadradius will result in

tipping or structuraldamage



To sum up stability, if you remember the basic principles ofleverage, you should have a good understanding of tipping factors.Below is an example of leverage.

Now...Watch the Aerial Device training video (stability).


A crane has abalance point

similar to a balancebeam



Using Boom Truck Capacity ChartsAs there are many manufacturers of boom trucks, and eachmanufacturer has different models, the load charts will vary. Theability to understand and correctly use the machine’s load chartsare critical to the safe operation of the unit.

The principle factors influencing the machine’s capacity and howthe chart is read include:

• type of boom (rear or front mount)

• quadrants of operation (where the load is picked up andwhere it has to go)

• boom length (amount of boom being used)

• boom angle

• load radius

• gross capacity deductions (stowed jibs, load block, etc.)

In addition to the previously mentioned information, the capacitychart should include warnings about swinging loads, wind, degreeof machine level, etc. as set out in Occupational Health and Safetyregulation 203.

* Graphic courtesy of the Operating Engineers Training Institute of Ontario

Pitman 1200Bcapacity chart



Stability chart -reduce capacities to

70% when in shadedareas

When determining the radius, if it falls between two markedpoints on the chart, use the next longest radius (33 ft. radius goesto 35 ft.). If the angle indicator is between two marked points,use the next marked lower angle (if 48 degrees, use the value for45 degrees).

* Graphic courtesy of the Operating Engineers Training Institute of Ontario

National Crane 800Series capacity chart



Examples Of How To Interpret Capacity ChartsGiven the Pitman 1200B capacity chart and the followinginformation, the answers to Question #1 and #2 can be determined.

• Jib erected 440 lbs. 200 kg

• Jib stowed 220 lbs. 100 kg

• 2 sheave block 155 lbs. 70.3 kg

• Single hook 70 lbs. 31.75 kg

• Single winch line 7,600 lbs. SWL 3,447 kg

Question 1Complete the calculations and determine if the lift can be made.

• Boom length 51 ft.

• Radius 28 ft.

• Rigging 50 lbs.

• Load weight 2,800 lbs.

• Jib is stowed

• Directly over outriggers

AnswerThe boom length is 51 ft. Looking at the chart, you know that youhave to go to the third stage boom readings. The radius is 28 ft.As there is no such number on the chart, go to a 30 ft radius in thethird stage boom. This will give you a boom capacity of 3200 lbs.

The load weight is 2800 lbs. so you can use the single hook whichonly weighs 70 lbs.

The weight for a stowed jib is 220 lbs.

Deductions:

• Load weight 2800 lbs.

• Rigging 50 lbs.

• Single hook 70 lbs.

• Jib 220 lbs.

• Total = 3140 lbs.

Yes, the lift can be made. 3200 - 3140 = 60 lbs. of capacity left.



Question 2Given the previous stability chart and all other factors remainingequal, can you safely make the same lift with the boom 35 degreesoff the centre line of the outriggers? Complete the calculations todetermine if the lift can be made.

AnswerNo, the lift cannot be made. 70 percent of 3200 is only 2240 lbs.The boom, being 35 degrees from the outriggers, results in aquadrant whereby the capacity must be reduced to 70 percent ofthe capacity of the unshaded area.



Travelling and Work SitesWhen using a boom truck to make a lift, the two basic checkswhich have to be made are route of travel and site of operation.

Route of TravelTo get a crane to the job site, the following items must be checked.

Overhead Clearances• Overpasses and bridges which are to low to permit the unit

to safely travel under them.

• Overhead lines (power, telephone, etc.) which have limitedclearances.

Ground Conditions• The slope of the ground may be too steep. This may cause

the unit to tip.

• The ground may be uneven with rocks, ruts, etc., which canmake travel virtually impossible.

• Soft soil conditions may cause the unit to become stuckbecause of the weight of the machine.

• There may be buried obstacles such as sewer and water lines,culverts, etc., which may collapse with the weight of themachine.

Other Obstructions• narrow roads (machine may slip over the side)

• narrow bridges

• open trenches (ground may cave in when driving besidetrenches)

• buildings (may be too close together for safe passage)



Site of OperationThe following items must be checked on a site survey:

Ground Conditions• Slope of the ground (will you require blocking to level the

machine?)

• Soil condition (is the ground firm enough to support theweight of the machine and the load on the outriggers? Softsoil will greatly affect the capacity and stability of the unit.You may have to use pads under the outriggers.)

Traffic and Personnel Control• Is traffic control needed? (what is needed)

• Do barricades have to be erected to keep unauthorizedpersons away from any dangers?

For additional clarification on soil types, refer to OccupationalHealth and Safety regulations 257.



Other Obstructions• underground obstructions such as culverts, sewer and water,

etc. (may collapse under the weight of the machine and it’sload)

• open trenches (parking too close to an open trench maycause the walls to collapse and tip the machine)

• buildings, structures, etc. (may interfere with the task you aredoing)

• power, telephone, overhead lines, etc.

For clarification regarding allowable clearances when workingaround power lines, refer to Occupational Health and Safetyregulation 465, as well as Table 22 of the regulations.

For additional clarification on underground and open trenchobstructions, refer to Occupational Health and Safetyregulations 259 and 260.



Making a Lift

Determine the Weight of the Load to be Lifted

Check the Capacity ChartTo determine if the load can be lifted safely, you will need to dothe following:

• Determine what the gross capacity will be throughout theentire range of movement (use stability and capacity charts).

• Calculate the required deductions for rigging, hook weightand load weight (anything that is hanging on the winch line).

• Calculate the required deductions for the auxiliary jibs. Thededuction for a mounted jib (mounted on the end of theboom and ready for use) differs from when it is stowed (sideof the boom and not in use).

Machine Set Up• Position the truck so that it will be possible to complete the

task without having to reposition the unit.

• Lower all outriggers firmly to the ground.

• Level the machine out. Move the boom throughout the rangeof motion to check for continuous level readings.

For information on cranes equipped with outriggers, refer toOccupational Health and Safety regulation 212.

Refer to the Introduction to Lifting Capability module formethods of determining weights.



There are various types of leveling devices available to determineif your machine is level:

• Winch line (use as a last resort)

• Bulls-eye level

• Vernier level

• Carpenter level

A vernier level is most likely the superior leveling device, as youcan turn it to check the levels from the side as well as the length ofthe machine.

Two carpenter levels, checking at the rotation bearing for levelness,can also be used.

Vernier level

Bulls-eye level


Copyright © 1997 by the Training and Development Centre, SaskPower. All rights reserved.0 4 / 2 7 / 0 0

Move the LoadThe lifting of the load is very important. These steps should befollowed:

• Ensure the load is properly rigged. Improperly rigged loadsmay result in overloading the boom if they slip or becomeunbalanced.

• Position the load line over the center of the load. This willeliminate any side pulls or dragging of the load which cancause abnormal loading on the boom.

• Slowly raise the load slightly off the ground and stop. Thisshould be done to ensure the winch brake will hold the load.

• Using the proper controls, smoothly move the load to therequired location.

• When working near energized power lines, observe the boomclearances.

Clearances for boom trucks, cranes, etc., can be found in theOperator’s Manual, as well as Table 22 of the OccupationalHealth and Safety regulations.

If the wind velocity increases when a load is beingmoved, extreme caution is to be taken. High windscan tip the crane, as well as move the load around.This puts added weight on the boom and may cause itto collapse.

!



The following diagram illustrates a properly set up unit.

You should now go to the unit and observe a demonstration oninterpreting capacity charts and preparing the machine to make alift.




Multi-Crane LiftsLifts which involve two or more cranes are complex operationsrequiring considerable skill and planning.

It is absolutely critical that a detailed procedure be drawn up. Thelift must be planned and carried out under qualified supervision.

Crane capacity must be calculated before every lift. To compensatefor load shifting, only 75% of the crane capacity can be used.

For additional information pertaining to multi-crane lifts, referto IPT’s Crane and Rigging Training Manual, pages 397 to 408.



SummaryTo summarize this module, you have learned:

• How to do a pre-operation and post-operation inspection.

• Factors affecting stability.

• How to use capacity charts.

• How to do travel and site checks.

• How to set up a boom truck to move a load.

• What multi-crane lifts are.

Now...

• Complete the Review Questions.

• Correct the Review Questions and clarify the answers ifneeded.

• Complete the Knowledge Check.

• Complete the Skills Practice.

• Perform the Skills Check.



REVIEW QUESTIONS

Boom Truck Operating

Explain the pre-operating, shutdown andpost-operating procedures pertaining to aboom truck.Answer true or false to the following statements.

T / F 1. Boom trucks are to be inspected daily before use.

T / F 2. All sheaves and winding drums are to be checked for wear andcondition.

T / F 3. Down-haul weights are to be checked for hook spread.

T / F 4. The outriggers must be extended fully when checking the level ofthe oil in the reservoir.

T / F 5. Hydraulic controls do not have to return to the “Neutral” positionwhen released.

T / F 6. The operator may adjust holding valves which are malfunctioning.

T / F 7. During the shutdown procedure, all loads must be lowered, ifpossible, to the ground.

T / F 8. All rigging must be properly stored when completing a post-operation procedure.

T / F 9. It is not necessary to secure the boom while in transport.

This section is a practice for your module Knowledge Check.Complete the questions, and verify your answers with theReview Question Solutions located at the end of this module.



Explain boom truck stability.Multiple choice. Choose the best answer.

10. On a front centre mount, the boom and mainframe are mounted:

a) at the rear corner of the truck.

b) behind the cab in the centre of the truck chassis.

c) in the centre at the rear of the truck chassis.

11. The factor(s) which effect the stability of a boom truck are:

a) the type of boom hoist.

b) the number of outriggers.

c) the outrigger spread.

d) all of the above.

12. A typical boom truck is rated on the structural integrity of the unitand a:

a) 95 percent tipping factor.

b) 85 percent tipping factor.

c) 75 percent tipping factor.

Recognize how to use capacity charts.Answer true or false to the following statements.

T / F 13. The ability to understand and correctly use a unit’s load charts arenot critical to the safe operation of the unit.

T / F 14. The load radius can change with the amount of boom beingutilized.

T / F 15. Load charts are identical, regardless of the manufacturer.



16. Using the National Crane 800 series capacity chart and theinformation provided, determine if you can safely make the lift.

Deductions:

• Jib stowed 220 lbs.

• Jib mounted 440 lbs.

• Single hook 90 lbs.

• Two-part block 182 lbs.

• SWL, single line 5000 lbs.

The second section is fully extended with a 22 foot radius. Thejib is erected, but not in use. The weight of the load to be movedis 5300 lbs.

Explain the necessary steps required tomove a load with a boom truck.Multiple choice. Choose the best answer.

17. The capacity and stability of a boom truck is greatly affected by:

a) overhead obstructions.

b) traffic control measures.

c) soft soil.



18. When calculating gross capacity, you must take intoconsideration:

a) the deductions of the stowed or mounted jib.

b) the deduction of the personnel platform.

c) the radius and angle of the boom.

Recognize multi-crane lifts.Multiple choice. Select the best answer.

19. The use of two or more cranes may result in the boom:

a) having an unbalanced load.

b) sideloading.

c) all of the above.

20. When completing a tandem lift, the capacity of each crane shouldbe:

a) 85 percent.

b) 75 percent.

c) 50 percent.



SKILLS PRACTICE


Demonstrate the pre-operating, shutdownand post-operating procedures pertaining toa boom truck.

1. Using a boom truck, demonstrate the pre-operating, shutdown andpost-operating procedures.

Pre-Operating Equipment - check for the following:

___ Cracks on the components and accessories (boom, outriggers,turret, etc.)

___ All visible welds for stress cracks (if the paint is chipped ordiscolored, inspect thoroughly)

___ Condition of all visible pins, bolts and keepers (missingkeepers, loose or stretched bolts, etc.)

___ Cracks and oblong holes at all pivot and swivel joints

___ Condition of all sheaves and winding drums (wear and nicksthat may damage the hoisting cable)

___ Condition of the down-haul weight and reeving blocks (wearand nicks on the reeving block, cracks or distortion of thehook)

___ Overall appearance and cleanliness

Hydraulic System - check for the following:

___ Level and condition of the oil in the reservoir (all cylindersmust be in the stowed position)

___ Condition of all visible fittings and hoses (cracks, tightness,scoring, etc.)

This section is a practice for your module Skills Check. Performeach task, as described, under the direction and observation of acompetent person. They will complete the checklist and giveyou appropriate feedback.



___ Operation of all controls (operating smoothly, returning toneutral if designed to do so)

___ Outrigger valves are functioning properly (complete thecheck)

___ Boom(s) holding valves are functioning properly (completethe check)

Shutdown - ensure that:

___ Load is lowered (if possible)

___ Boom is lowered (if possible)

___ All outriggers are raised (if possible)

___ Controls are inoperative (shut off the PTO or lockout thecontrols if able to do so)

___ Brakes are engaged (may need wheel chocks)

___ Doors are locked (prevents unauthorized persons from startingor moving the truck)

Post-operating - ensure that:

___ Tools and rigging are properly stored

___ All booms are retracted, lowered to the boom rest and secureddown

___ All outriggers are fully retracted

___ PTO is properly disengaged

Demonstrate how to interpret capacity chartsand move a load with a boom truck.

2. Using a boom truck, demonstrate the steps to move a load.

Route of Travel - check for the following:

___ Overhead obstructions (overpasses, bridges, power lines, etc.)

___ Ground conditions (slope, rough terrain, soft soil, etc.)

___ Buried obstacles (culverts, sewer lines, etc.)

___ Obstructions (narrow roads, buildings, etc.)



Site of Operation - check the following:

___ Slope of the ground (may need blocking to level the unit)

___ Soil condition (may need pads, etc., if the soil is soft)

___ Other obstructions (buildings, overhead lines, buried cables,culverts, etc.)

Determine the Weight of the Load

___ Refer to the Introduction to Lifting Capability module (howto determine the weight).

Capacity Chart

___ Determine the capacity of the boom throughout the entirerange of movement

___ Make the correct deductions (rigging, etc.)

Machine Set Up

___ Position the truck to accomplish the task without having tomove

___ Level the machine (is blocking or outriggers required)

___ Perform a dry run (check the capacity chart and ensure theunit remains level)

Move the Load

___ Ensure the load is properly rigged (load will not shift, SWL’snot exceeded)

___ Ensure the winch will hold the load (raise a foot off the groundand stop)

___ Use the proper controls to move the load





1. True

2. True

3. True

4. False

5. False

6. False

7. True

8. True

9. False

10. b

11. d

12. b

13. False

14. True

15. False

16. Gross capacity at a 22 footradius is 6300 lbs.The load weight is 5300lbs.The jib mounted but notused is 440 lbs.The two-sheave block is182 lbs.Total deductions are 5922lbs. (under 6300 lbs.). Yes,the lift can be made.

17. c

18. c

19. c

20. b

REVIEW QUESTION SOLUTIONS


transmission & distribution centre truck operating 1 book 2/30... · and safety regulation 215...

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