XGC180 Crawler Crane Operational Manual Safety Regulations

Ⅰ. Safety Regulations

1-1
Safety Regulations XGC180 Crawler Crane Operational Manual

1.01 Operational planning

Operational planning
The crane operator must be in possession of or procure all the necessary
information (such as the operation manual and basic knowledge of gas, electronic and
hydraulic transmission) before starting the crane, especially:
— Nature of work;
— Height and side clearances;
— Electrical overhead wires (complete with voltage data);
— Space requirements at the operating sites;
— Movement restrictions due to surrounding structures (whether there is another
crane working);
— Material, dimensions and weight of loads to be lifted;
— Required lifting height and radius;
— Load-bearing capacity of soil or surface to be operated upon.
The crane operator can then use this information to decide on the correct crane
operating equipment:
— Hook blocks/load blocks
— Fixed jib and luffing jib
— Lifting/slinging tackle
— Counterweight
Danger: if the crane operator does not possess all the necessary and required
information, it may prove impossible to carry out the intended work, or he may
be tempted to improvise, and accidents may be the result!
1.02 Safety-Technical notes
1. Requirements of the crane operator
The most important requirement of the crane operator is to control, operate and
adjust the crane so that there is no danger to the crane crew and/or third party.
65% of problems and damages involving vehicle cranes are caused by improper
crane operation. In order to fulfill this requirement, we would like to give you in the
following a few important safety notes.
Improper operating procedures most often carried out are:
— Slewing too quickly;
— Quick braking of the load;
— Cross pulling (slewing or traveling);

1-2
XGC180 Crawler Crane Operational Manual Safety Regulations

— Loose cable formations;

— Overloading;
— Driving too fast with a load, or setting up and loading on an uneven surface;
— Improperly slinging a load;
— Operating in unsuitable conditions, especially pulling at an angle or fixed loads
coming loose;
— Wind on suspended load;
— Collision with bridges, ceilings, high-voltage wires;
— Improper assembly/disassembly of telescopic booms.
20% of all accidents involving cranes are due to improper maintenance:
— Lack of oil, grease or antifreeze;
— Accumulation of too much dirt;
— Broken cables, worn parts;
— Emergency limit switch or load moment limiter not operational;
— Brake or transmission failure;
— Defects in the hydraulic systems, for example, tears in hoses;
— Loose screws.
Warning: in your interest and in the interest of others, please learn to
command your crane thoroughly and familiarize yourself with all the dangers
associated with the work to be carried out.
1.02.2 Selecting an operating site
To avoid accidents from the outset, the correct selection of an operating site is
extremely important. The operating site should be selected so that:
— crane operations can be carried out within the smallest possible radius.
— no obstacles hinder necessary movements.
— the ground at the operating site is able to support expected loads.
Danger: the most important requirement for safe crane operation is working
on firm ground with the capacity to support your loads.
Slopes and trenches
The crane must not be set up too close to slopes or trenches and depending on the
type; a safe distance must always be kept from them.
NOTE: Safe distance A is determined by measuring the depth of the trench and
combined with the condition of the working field:
Soft or backfilled soil = 2×depth of trench (A2 = 2×T)
Hard or grown soil = 1×depth of trench (A1 = 1×T)
1-3
Safety Regulations XGC180 Crawler Crane Operational Manual

Danger: if a safe distance cannot be kept, the slope or trench must be firmly
filled. Otherwise, there is a danger that the edge of the slope or trench will give
way.

Fig. 1-1 illustration of the safe distance of slop and trench

Table 1-1 permissible ground-bearing load

Type of soil N/m2

A) Bad soil, not artificially compacted 0 － 1000

B) Natural soil, apparently undisturbed

1. sludge, peat, marshy earth 0

2. non-cohesive, sufficiently firm soil:

medium sand 1500
coarse sand to clay 2000

3. cohesive soils:
loamy 0
soft soil 400
stiff soil 1000
semi solid 2000
4000
hard
4. rock with a minimum of fissures, in healthy, un-weathered
condition and favorably situated:
in densely packed strata 15000
solid or column formation 30000

C) Artificially compacted ground

1. asphalt road 5000 － 15000

2. concrete group B I 50000 － 250000

concrete group B II 350000 － 550000

Note: if there is any doubt as to the load-bearing capacity of the ground at the
operating site, the ground must be investigated and measured.

Checking safety measures

— The load-bearing capacity of the ground is sufficient
— Safe distance is kept from slopes and trenches
1-4
XGC180 Crawler Crane Operational Manual Safety Regulations

— The crane is horizontally aligned

— It has been established that the crane is not in the vicinity of electrical
overhead wires?
— There are no obstacles in the area that will hinder necessary crane movements?
1.02.3. Crane operation with a load
Before beginning any work, the crane operator must be convinced that the crane is
in safe operating condition. The safety devices, such as load moment limiter, hoist
limit switch, brakes, and so forth, must all be operational.
— The load moment limiter must be set to the current operating status of the crane;
— The load capacities as given in the load capacity tables must be adhered to. The
crane must never be operated with a load exceeding the permissible load
capacities.
— Before beginning any operations, the crane operator must know the weight and
dimensions of the load.
— All hoisting cable and chains and fixed pulley blocks must meet the safety
requirements of the work to be carried out.
— It must be ensured that the weights of the hoisting, slinging and staying tackle
are taken from the load capacity table.
Example:

Max. permissible load capacity according to table 30,000kg

Weight of hook block 370kg

Weight of hoisting cable 40kg

Actual lifting load of the crane 29,590kg

In this case, the load to be lifted may not exceed 29,590kg.

1.02.4. Ballast
The required ballast is dependent on the load to be lifted and necessary boom radius
for operating with that load. Data in the corresponding load capacity table is decisive
in selecting ballast.
Danger: if the ballast is not mounted according to the load capacity table,
there is danger of the crane toppling over.
1.02.5. Hoisting gear, hoisting cable
The lifting capacity of the crane depends on the tensile force, or pull, of the
hoisting cable and the number of possible hoist reeving cables. When working with a
1-5
Safety Regulations XGC180 Crawler Crane Operational Manual

single cable, the crane can only lift as much as the hoisting gear pulls. If the load to be
lifted is greater than the pull of the hoisting gear, the hoisting cable must be reeved
between the pulley head on the boom and the hook block as many times as necessary
according to the principle of a block and pulley. When reeving, ensure that the data
given in the load capacity table and operation manual are observed and adhered to.
Danger: if the maximum tensile force is exceeded, there is the danger that the
cables may snap or that the hoisting gear and/or drive motor may be damaged.
1.02.6. Potential danger in crane operation
1. The load moment limiter is not set to the actual equipment status of the crane, and
as a result, cannot fulfill its function as a safety device.
2. The load moment limiter is defective or put out of operation.
3. The limiter switches are defective or put out of operation.
4. The angle indicators and tension sensor are not in function.
5. If the load is pulled at an angle. It is particularly dangerous when pulling to the
side since the telescopic boom has a lower torque resistance to the side, so the
load may not be pulled at an angle.
6. An excessive load is attached to the hook when the crane is working, which then
hangs freely on the crane when it is detached.
7. If loads which have become stuck are pulled free with the hook block. Even if the
weight of the load which is stuck is no greater than the permissible lifting load,
the crane may topple over backwards if the load is suddenly freed since the
tension created in the boom can cause it to jerk back violently.
8. Work is carried out in strong winds. Refer to the data given in the load capacity
table.
9. The crane is not aligned horizontally and the load is slewed toward the slope.
10. The hook load begins swinging because the crane operator has not properly
controlled the movements.
11. The loads and radii contained in the load capacity tables are exceeded.
12. When working in the vicinity of power cables, these are not isolated by electricity
engineers or if the hazardous area is not covered or fenced off. If it is not possible
to take such measures, a sufficient safety clearance must be maintained.
Table 1-2 the safe distance of power cables

Rated voltage Minimum distance (m)

Up to 1kV(1000V) 1.5
1-6
XGC180 Crawler Crane Operational Manual Safety Regulations

Above 1kV up to 15kV 3

Above 15kV up to 40kV 4

Above 40kV up to 100kV 5

Above 100kV up to 220kV 6

Note: if, despite all precautionary measures, a flashover occurs, observe the
following:
— Keep calm;
— Do not leave the crane operator’s cab;
— Warn all those around the crane to remain standing where they are and not to
touch the crane.
— Move the crane away from the danger area.
Danger: Not observing the above points can lead to (fatal) accidents and
damage!

13. Prevention of step voltage. Step voltage is generally caused after high voltage

wires landing onto ground. The voltage is decreased from falling point to the distance.

There is certain voltage between two feet if a person stands within this area, the

higher the voltage the longer the distance between feet, so please try to avoid this area,

and jump off this area if one is already in this area. If walking within this area, reduce

the pace in order to reduce voltage difference between feet, so that there is no danger

of electrical shock.
1.02.7. Working near transmitters
If there is a transmitter near the job site, strong electro-magnetic fields may exist.
Danger: these electro-magnetic fields can pose direct or indirect danger to
persons or objects, for example:
— Effect on human organs due to temperature increase
— Danger of burns or inflammation due to temperature increase
— Spark or electric arc formation
— The interference of electromagnetic on electrical equipment operation
In any case, before working with the crane near transmitters, contact your XCMG,
Building Machinery Co. representative. In addition, consult a high frequency
specialist.

1-7
Safety Regulations XGC180 Crawler Crane Operational Manual

The high frequency rays from a transmitter require an increased working protection
and special guidelines for crane operator and crane personnel:
1 Every crane must be “totally” grounded. Check visually or with a simple tester to
ensure that ladder, cab and cable pulleys are grounded.
2 All persons working on the crane or on larger metal parts must carry special
protective gloves without metal connectors and suitable protective suits to protect
them from burns while working.
3 If one should feel an increase in temperature, there is no need for panic. Simply
act as if the affected tool, component or carrier is “hot”.
4 The temperature of the tools affected by high frequency depends on their “size”.
Cranes, carriers and coverings, for example, are “hotter”.
5 When moving the crane, do not allow it to touch other crane loads (light arcs).
Since burn nicks reduce the load carrying capacity of the cables significantly,
contact your supervisor (master) any time such a contact has occurred, so that the
cables can be checked and inspected.
6 An insulator must always be between the load hook of the crane and the tackle.
This insulator may not be removed.
7 The cable may not be touched above the insulator. This is strictly prohibited.
8 Never touch the crane with attached loads with unprotected body parts after lift
off or after set down.
9 Never work with exposed, unclothed upper body or short pants, this is
strictly prohibited!
10 If possible, transport larger loads in horizontal direction, to reduce high frequency
absorption!
11 Before carrying out any necessary manual work, ground the loads first or insulate
them (place a rubber cloth between the tool and the glove).
12 The temperature of the tool can be checked with a suitable tester.
If, for example 500V can be measured on a tool at a distance of 1 to 2cm, then
the tool may not be touched with bare hands. The larger the distance, the higher
the voltage is on the tool: at a distance of 10cm, the voltage is approx. 600V, at a
distance of 30cm, the voltage is approx. 2000V.
13 To prevent accidents, work on components located higher up may only be carried
out with a safety belt.
14 Handling explosive matter (such as refueling) may only be done at least 6m away

1-8
XGC180 Crawler Crane Operational Manual Safety Regulations

from the place where sparks could form due to handling of larger metal parts.
To refuel, use only appropriate and approved rubber hoses.
15 All accidents or special occurrences must be reported immediately to the local
construction supervisor and the safety engineer.
1.02.8. Hand signals
When performing any movements, the crane operator must always keep his eye on
the load, and when moving the crane without a load, he should observe the crane hook
or the lifting tackle. If this is not possible, he must only operate the crane according to
instructions given to him by a signaler. These instructions may be given in the form of
hand signals or over a two-way radio.
Danger: hand signals must first be discussed and agreed upon and then clearly
given. Misunderstandings can lead to serious accidents.
The operators must be familiar with operation signals such as hand signals, and be
consistent during the operation. It is up to users to use which signals in specific
country or region. Local regulations and conventions must be adhered to for overseas
operation, and stop the operation immediately if anyone in the area sends out
emergency stop signal.
Hand signal illustration:

READY (Attention) USE AUXILIARY HOOK BLOCK.

Arm straights up, over the head, five fingers One hand fist, elbow upward, tap the elbow
open, palm faces forward and hold on. with another hand.

PREPARE(ATTETION). Arms straight

overhead, fingers stretched, palms forward,
keep it still.

READY (Attention)
Arm straights up, over the head, five fingers
open, palm faces forward and hold on.

PREPARE(ATTETION). Arms straight

overhead, fingers stretched, palms forward,
keep it still.

1-9
Safety Regulations XGC180 Crawler Crane Operational Manual

HOOK BLOCK HOIST UP.

USE MAIN HOOK BLOCK
One small arm straight side-upward, fingers
One hand fist, put it overhead and tap
stretched, higher than shoulder, swing around
head with the fist.
elbow.

HOOK BLOCK HOIST DOWN.

INDICATE LAND POSITION.
Arms straight downward approximately 30 °
Fingers stretched, indicate the position
with body, fingers stretched, swing around
for load to land.
waist .

HOOK MOVE HORINZONTALLY.

Small arm straight side-upward, palm forward, swing small arm to load land position.

1-10
XGC180 Crawler Crane Operational Manual Safety Regulations

EMERGENCY STOP. WORK COMPLITED.

Arms horizontally closed before chest, fingers Fingers stretched, and cross before head.
stretched, palms down, move arms back
horizontally.

RAISE BOOM. LOWER BOOM.

Arm extended, fingers closed, thumb Arm extended, fingers closed, thumb
pointing upward, arm swinging up. pointing downward, arm swinging down.

SWING.
Arm extended, point with finger in direction of swing of boom.

1-11
Safety Regulations XGC180 Crawler Crane Operational Manual

1.02.9. Observing wind conditions

It is essential to adhere to the information given in the load capacity tables
regarding the maximum permissible wind speed. Crane operations must be stopped
and the boom lowered as soon as the wind speed exceeds 9.8m/s (scale 5).
Danger: before any operation, crane operator must receive information on the
expected wind speeds from the responsible meteorological authorities. If
impermissible wind speed are forecast, hoisting a load is prohibited..
Table1-3 Wind speed

Wind force Wind speed

Beaufort Effects of wind in the inland
Description [m/s] [km/h]
degree
0 Calm 0-0.2 1 No wind, smoke rises straight up
Slight air Wind direction is shown only by observing
1 0.3–1.5 1-5
(draft) the trail of smoke, not by the wind sock
Wind can be felt on the face, the leaves
2 Light breeze 1.6-3.3 6–11
rustle, wind sock moves slightly
Gentle Leaves and thin twigs move
3 3.4-5.4 12-19
breeze Wind extends a small breeze slightly
Moderate Swirls up dust and loose paper, moves
4 5.5-7.9 20-28
breeze twigs and thin branches
Small deciduous trees begin to sway, foam
5 Fresh breeze 8-10.7 29-38
forms at sea
Thicker branches move
6 Strong wind 10.8-13.8 39-49 Telephone lines begin to whistle, umbrellas
are difficult to use
Entire trees swaying; difficult to walk into
7 Stiff wind 13.9-17.1 50-61
wind
Gale force Breaks twigs off trees, walking becomes
8 17.2-20.7 62-74
wind difficult
Minor damage to property (chimney tops
9 Gale 20.8-24.4 75-88
and roofing tile are blown off)
Trees are uprooted, significant damage to
10 Severe gale 24.5-28.4 89-102
property
Violent
11 28.5-32.6 103-117 Extensive, widespread storm damage
storm
12 Hurricane 32.7-36.9 118-133 Major destruction

1-12
XGC180 Crawler Crane Operational Manual Safety Regulations

Memorandum

1-13