HEO Crawler Crane NC III cheat sheet

Walk-around sequence: undercarriage and track shoes, then carbody, then superstructure, then boom/jib sections, then wire rope and rigging, then cab and controls, then load chart and decals.

Track inspection: measure shoe height and grouser height against the manufacturer's wear limit; reject shoes worn past limit or with cracked, missing, or loose grousers.

Wire rope removal criteria (ISO 4309 style): broken outer wires, valley or crown breaks, diameter reduction, corrosion, kinking, crushing, bird-caging, and end-attachment damage each justify removal regardless of other conditions.

Sheave inspection: check groove diameter and wear, flange condition, freedom of rotation, and lubrication; a worn groove pinches rope and accelerates fatigue; a cracked flange requires sheave replacement.

Hydraulic checks before start: reservoir level within marks, no visible leaks at cylinders, hoses, swivels, and fittings, and no bulging or chafed hose covers; tag out any leaking component.

Safety devices to verify functional: load moment indicator (LMI) or rated capacity limiter, boom angle indicator, anti-two-block device, level indicator, travel alarm, and horn; a defective LMI or anti-two-block places the crane out of service.

Brake and clutch checks: swing brake holding, travel brake holding on a slight grade, drum pawl and ratchet engagement, and free-fall clutch function where fitted.

Records check: verify the crane's logbook, previous inspection findings, and the validity of the periodic (third-party) inspection certificate before releasing the unit for work.

Ground bearing rule: required bearing pressure = total crane plus load reaction divided by the effective bearing area of mats or cribbing; mat area must exceed this so soil capacity is not exceeded.

Use crane mats or steel plates sized so pressure under the mat stays below the geotechnical allowable bearing capacity; soft spots, backfilled trenches, and buried utilities are disqualifying until proven.

Sling angle effect: tension per leg = load / (number of legs x sin of angle from horizontal); at 30 degrees from horizontal each leg carries the full load, at 60 degrees about 0.577 of the load.

Rigging inspection: reject slings with broken wires, cuts, burns, knots, or missing tags; reject shackles with worn pins or threads and hooks with spread throats exceeding 15 percent or missing safety latches.

Center of gravity: the hook must be directly above the load's center of gravity; an off-center pick causes load swing and uncontrolled rotation when lifted.

Exclusion zone: define a radius equal to the swing radius of the counterweight plus a margin, and barricade it before any slewing; no personnel under a suspended load at any time.

Wind limits: consult the manufacturer's chart for the maximum permissible wind speed for the boom length and load; stop when wind exceeds limits or when the load's sail area makes it uncontrollable.

Lift plan content: load weight and rigging weight, crane configuration, radius and boom angle, percent of capacity, ground condition, travel path, signal person, and contingency for power loss.

Assemble on firm, level ground; level the carbody with the manufacturer's level indicator within tolerance (commonly 1 degree or less) before extending boom or lifting.

Track configuration for lift: set tracks parallel to the direction of the load or as the load chart specifies; lifting over the side of the tracks reduces capacity compared with over the end.

Boom assembly: match boom sections to the load chart's permitted combinations; never mix sections from different booms or exceed the maximum boom plus jib length for the configuration.

Boom backstops and boom hoist limiter: confirm the boom stop is set for the working boom angle range and the boom hoist limit switch stops raising before the boom contacts the stops.

Counterweight: install the exact counterweight specified in the load chart for the boom/jib configuration; adding or removing counterweight changes capacity and must follow the chart.

Pendant or guy rope tension: check for equal tension and no damaged strands; slack or mismatched pendants change boom geometry and invalidate the chart.

Anti-two-block: set the weight and switch for the actual boom/jib combination; the device must stop hoisting and boom lowering before block-to-sheave contact.

After assembly: perform a no-load function test of hoist, boom, swing, and travel, then a trial lift of a known weight slightly off the ground to verify stability and brake holding.

Smooth control rule: accelerate and decelerate hoist, swing, and travel gradually; sudden stops increase dynamic load and can exceed the chart's static rating.

Swing with the load kept as low as practical and lead the load with the swing; do not drag the load sideways or use the boom to pull a load off vertical.

Travel with a suspended load only where the load chart and manufacturer permit it; keep the boom low, the load trailing, and use a tag line to control rotation.

Tag lines: use at least one, preferably two, for loads with large sail area or off-center rigging; personnel handling tag lines stay outside the fall zone and clear of the swing path.

Two-blocking prevention: stop hoisting when the anti-two-block alarm sounds; never lower the boom while hoisting or raise the boom while booming down in a way that reduces the block-to-boom-tip distance.

Side load and boom strength: the load chart assumes vertical loading; any side pull, boom drag, or out-of-plane force reduces capacity and can buckle the boom lattice.

Shutdown sequence: land the load, retract and stow per manufacturer, set swing and travel brakes, lower boom to the specified rest, shut down, and record the hours and any faults.

Rated capacity is the lesser of the structural limit and the stability (tipping) limit for the given radius, boom length, and configuration; always use the governing lower value.

Radius is measured horizontally from the center of rotation (slewing axis) to the center of the hoist line, not to the boom tip or the load's near edge.

Net capacity = gross chart capacity minus the weight of all lifting attachments below the boom tip: hook block, slings, shackles, spreader, and any jib or auxiliary head.

Deductions for jib: when the jib is fitted, the jib and its rigging weight is deducted from the main boom capacity per the chart's notes.

Interpolation between chart radii or boom lengths is allowed only if the manufacturer's notes permit it; otherwise use the next longer radius or boom length (the more conservative value).

Quadrant and travel: apply the chart's reduction for pick-and-carry, for travel with load, and for operation over the side or corner of the crawler; some charts prohibit travel with load entirely.

Dynamic and wind allowance: add for dynamic effects when accelerating, and reduce capacity for wind acting on the load's sail area; the chart values assume no wind and no side load.

Verification: compute percent of capacity = total load (load plus rigging) / net chart capacity x 100; a lift plan typically requires a higher-level review above a defined threshold, commonly 75 percent.

Standard hand signals: raise/lower load, raise/lower boom, swing, travel, stop, emergency stop; one designated signal person only, and any person may give an emergency stop signal.

Voice or radio signals must use a dedicated channel with a tested link; if communication fails, the operator stops and holds until direct visual contact is re-established.

Exclusion zone: barricade the full swing radius including counterweight tail swing; the counterweight can swing into a walkway and crush personnel even with no load.

Power line rule: maintain the required minimum clearance from energized lines for the crane's voltage class; if clearance cannot be maintained, de-energize and ground the line, and use a spotter.

Rigging and fall protection: use the crane's designated access ladders and platforms; do not climb the boom lattice unless the manufacturer provides a rated climbing system.

Environmental limits: stop operations when wind, lightning, or visibility exceeds the manufacturer's or site's limits; note that wind speed at boom height is higher than at ground level.

Emergency procedures: know the location of the emergency lowering system, fire extinguisher, first aid, and the site's emergency contact; never leave a suspended load unattended.

Personal protective equipment and personnel: hard hat, safety footwear, high-visibility clothing, and gloves; no rider on the load, hook, or sling, and no personnel in the fall zone.

Lubrication schedule: follow the manufacturer's interval chart for wire rope, sheaves, boom foot pins, swing gear, and track rollers; record each service in the logbook.

Wire rope maintenance: inspect at the specified interval and after any shock load or two-block event; lubricate with the recommended product, never mix incompatible lubricants.

Hydraulic troubleshooting sequence: check fluid level, filter indicator, pump pressure at test ports, and cylinder drift; isolate a leaking circuit before continued operation.

Brake adjustment: adjust swing and travel brakes to the manufacturer's clearance; a brake that drifts under load is a stop-work condition, not a maintenance deferral.

LMI and anti-two-block calibration: recalibrate after any boom change, rope change, or sensor replacement; record the calibration date and the technician's identification.

Shutdown procedure: land and secure the load, lower the boom to the rest position, set all brakes and locks, chock the tracks if on a slope, shut down, and lock out the cab.

Fault reporting: record the symptom, the conditions, the action taken, and parts replaced; a fault affecting a safety device requires the crane to be tagged out until corrected.

Post-shutdown checks: inspect for leaks, loose fasteners, and hot spots, and confirm fuel and fluid levels for the next shift before leaving the machine.

Daily inspection checklist: record the date, machine serial number, hour meter reading, items checked, defects found, and the inspector's name and signature.

Lift plan document: include load weight, rigging weight, crane model and configuration, radius, boom length and angle, chart capacity, percent of capacity, and approvals.

Load test and periodic inspection certificates must be current and available on site; note the certificate number, issuing body, test date, and next due date.

Defect reporting: a defect affecting a safety device (LMI, anti-two-block, brakes) must be recorded, the crane tagged out, and the defect escalated to the responsible person.

Operator logbook entries: shift start and end, hours, lifts performed where required, incidents, near misses, and any maintenance or adjustment made during the shift.

Incident and near-miss report: time, location, equipment, personnel involved, sequence of events, damage, and corrective action; report near misses with the same rigor as incidents.

Handover record: state the crane's condition, outstanding defects, configuration, and any restrictions so the incoming operator starts from verified information.

Retention: keep inspection, maintenance, and lift records for the period required by the site and the applicable regulation, and make them available to the authorized inspector on request.