LCS # Safety Instructions for Overhead Crane Operators

Safety Instructions
For
Overhead Crane Operators

Contents

Forward -----------------------------------------------------------------------------------------1
Qualifications --------------------------------------------------------------------------------------1
Permits -----------------------------------------------------------------------------------------1
Sample Permit -----------------------------------------------------------------------------2
Training -----------------------------------------------------------------------------------------2
Personal Protective Equipment ---------------------------------------------------------------3
General Conduct of Operators ----------------------------------------------------------------3
Table 2 Shift/Operator Inspection Checks ------------------------------------3
Table 1 Standard Hand Signals for Controlling
Overhead and Gantry Cranes ------------------------------------------5
Inspection 6
Maintenance ---------------------------------------------------------------------------------------6
 LCS # Safety Instructions for Overhead Crane Operators

Safety Manual for Overhead Crane Operators

Forward
An overhead crane operator’s job is very important. It is a position of responsibility that you
must be authorized to hold. There are rules and regulations you must obey and responsibilities
you must accept.

This manual may be used as a tool in the overall training and authorization of a prospective
overhead crane operator.

Employers and employees need to be aware that all cranes are different and may have specific
operating, safety, inspection and maintenance requirements. It is essential that you have the
manufacturers operating manuals and are familiar with your particular crane.

QualificationsThe minimum qualifications for an employee selected to operate a crane are as

follows:

• Have corrected vision that meets the same requirements as vision for a valid Driver’s
license.
• Have effective use of all 4 limbs.
• Be of sufficient height to operate the controls and to have an unobstructed view over
the controls into the work area.
• Have coordination between eyes, hands, and feet.
• Be free of known convulsive disorders and episodes of unconsciousness.
The employee must also have the ability to understand signs, labels, and instructions. The
employee must be examined for these qualifications at least once every 3 years.

Permits
You must be trained and tested before you can operate an overhead crane. Upon passing this
test and meeting other operator requirements (including demonstrating proficiency in running
the crane) a permit will be issued to you. It is to be carried by you or be available upon request.

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 LCS # Safety Instructions for Overhead Crane Operators

Sample Permit

CRANE OPERATOR PERMIT

(Firm Name)
Operator’s Name
Operator’s Number
Is Authorized To Operate: (Insert Type of Crane(s) Authorized)
Restrictions: (Explanation of Restrictions)
Date Issued: (Month-Day-Year)
Date Expiring (Month-Day-Year)

By Issuing Authority: _______________________________________________

Title

Training
Training of all operators will include the following:
• Capacities of equipment and attachments.
• Purpose, use and limitation of controls.
• How to make daily checks.
• The energizing sequences, including pneumatic, hydraulic, and electrical sequences.
• Start-up and shutdown procedures.
• Emergency shutdown procedures.
• General operating procedures.
• All basic signaling procedures, including hand, radio, or telephone signals, where
required.
• Practice in operating the assigned equipment through the mechanical functions
necessary to perform the required task.
• Maximum rated capacity of the crane.
Training of all riggers will include the following:
• Maximum capacity of the crane.
• Rigging procedures.
• Company rules and regulations.
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 LCS # Safety Instructions for Overhead Crane Operators

Personal Protective Equipment

When your employer conducts a personal protective equipment hazard assessment .( Personal
Protective Equipment), they should include overhead cranes in their review.

An operator and any employee directing a lift must use the PPE required in the area. If the top
of the load is lifted to a height greater than 5 feet, then the load is considered an overhead
hazard and head protection needs to be worn.

When an employee is performing maintenance on an overhead or gantry crane, and a standard

barrier or platform is not provided, the employee must wear an approved safety harness and
lanyard, or a fall arrest device as prescribed in Construction Safety Standard, Part 45. Fall
Protection.

General Conduct of Operators

At the beginning of each shift during which a crane is used, a visual inspection must be made in
accordance with Table 2 below. A visual inspection is limited to that which can be made from a
catwalk or other safe observation point. Any defects must be reported to a supervisor.

TABLE 2
Shift/Operator Inspection Checks
Inspection Item Description of Inspection Check Points
Tagged Crane or Hoist Check that crane or hoist is not tagged with an out-of-order sign.
Control Devices Test run that all motions agree with control device markings.
Brakes Check that all motions do not have excessive drift and that stopping
distances are normal.
Hook Check for damage, cracks, nicks, gouges, deformations of the throat
opening, wear on saddle or load bearing point, and twist. Refer to the
manual furnished by the original manufacturer of the crane.
Hook Latch If a hook latch is required, check for proper operation.
Wire Rope Check for broken wires, broken strands, kinks, and any deformation or
damage to the rope structure.

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 LCS # Safety Instructions for Overhead Crane Operators

Reeving Check that the wire rope is properly reeved and that rope parts are not
twisted about each other.
Limit Switches Check that the upper limit device stops lifting motion of the hoist load
block before striking any part of the hoist or crane.
Oil Leakage Check for any sign of oil leakage on the crane and on the floor area
beneath the crane.
Unusual Sounds Check for any unusual sounds from the crane or hoist mechanism
while operating the crane or hoist.
Warning and Safety Check that warning and other safety labels are not missing and that
Labels they are legible.
Housekeeping and Check area for accumulation of material, trip or slip hazards, and poor
Lighting lighting.

A hoisting limit switch on a crane or hoisting device must not be used as an operating control,
unless the crane is also equipped with a backup limit switch.

A load must not be lowered below a point where less than 2 full wraps of wire rope remain on
the hoisting drum. If there is doubt concerning the safety of a crane or hoisting means, the
operator must immediately stop the crane, and report the condition creating the doubt to the
supervisor.

In the event of power failure, the operator must place all controllers in the “off” position.
When an operator leaves a crane unattended he or she must land any attached load, place the
controllers in the “off” position, and open the main switch. Before closing a main switch the
operator must make sure all controllers are in the “off” position. The main switch does not
need to be opened on a pendant-controlled crane if the crane is left unattended for short
periods.

An operator must only respond to signals from the employee directing the lift. Except for an
emergency stop signal, which must be obeyed when given from any employee. The signals
given to an operator must conform to table 1 below.

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 LCS # Safety Instructions for Overhead Crane Operators

Table 1
Standard Hand Signals For Controlling Overhead
And Gantry Cranes

HOIST. With forearm vertical, LOWER. With arm extended BRIDGE TRAVEL. Arm extended
forefinger pointing up, move hand in downward, forefinger pointing forward, hand open and slightly
small horizontal circle down, move hand in small horizontal raised, make pushing motion in
circle. direction of travel.

TROLLEY TRAVEL. Palm up, fingers STOP. Arm extended, palm down, EMERGENCY STOP. Arm extended,
closed, thumb pointing in direction hold position rigidly. palm down, move hand rapidly right
of motion, jerk hand horizontally. and left.

MULTIPLE TROLLEYS. Hold up one MOVE SLOWLY. Use one hand to MAGNET IS DISCONNECTED. Crane
finger for block marked “1” and two give any motion signal and place operator spreads both hands apart –
fingers for block marked “2”. other hand motionless in front of palms up.
Regular signals follow. hand giving the motion signal. (Hoist
Slowly shown as an example.)

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 LCS # Safety Instructions for Overhead Crane Operators

An operator must not carry a load over another person.

A crane must not be used to make a side pull (except where it has been specifically authorized
by a qualified person after making specific determinations).

Compressed gases can only be lifted by a cradle or enclosed platform.

An employee cannot ride a hoisting device, such as a magnet, hook, ball, or load. The only
exception is a work platform that meets all the requirements in the Construction Safety
Standard Part 10. Lifting & Digging Equipment.

When attaching or moving a load, the operator, rigger, or hooker must make sure of all of the
following:

• The hoisting rope or chain is free of kinks or twist and not wrapped around the load.
• The load is attached to the load block hook by means of a sling or other approved
device.
• The sling and load will clear all obstacles or obstructions.
• The load is balanced and secured before lifting the load more than a few inches.
• Multiple lines are not twisted around each other.
• The hook is brought over the load in a manner to prevent swinging.
• There is no sudden acceleration or deceleration of the moving load.

Inspection

The inspection procedure for cranes in regular service is divided into 2 general classifications:

• Frequent inspections are done monthly to quarterly or at intervals of 100 hours of use,
whichever comes first.
• Periodic inspections are done annually or at intervals of 500 hours of use, whichever
comes first.

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 LCS # Safety Instructions for Overhead Crane Operators

The inspections cover topics outlined in the standard or manufacturers guidelines.

Maintenance

The employer must maintain a crane and its accessories in a condition that will not endanger an
operator or other employee.

A preventative maintenance program will be established and the program will be based on the
manufacturer’s recommendations and for the application as reviewed by a qualified person.

Before adjustments or repairs are made on a crane, all of the following precautions must be
taken:

• The crane will be moved to a location where it will cause the least interference with
other moving equipment on the track or rails and operations in the area.
• Controllers will be placed in the “off” position.
• The main switch will be placed in the “off” position or “open” position and LOCKED
OUT, except where power is necessary to adjust or service the crane.
• A warning sign or “out of order” sign will be placed at the operator control station.
• Illumination of 15 footcandles intensity will be provided while maintenance is
performed on the crane.