Manitowoc GROVE GMK User guide

3 303 022 en
04.11.2020
Safety manual

04.11.2020
3 303 022 en Safety manual
Important note
Any type of duplication or excerpt from this document,
even in electronic form, is not subject to the revision
service of Manitowoc Crane Group Germany GmbH.
© Copyright reserved by
Manitowoc Crane Group Germany GmbH
Industriegelände West
D-26389 Wilhelmshaven, Germany
Phone: [phone]
Fax: [phone]
The distribution or duplication of this document as well as the utilisation and disclosure of its contents are prohibited unless
explicitlypermitted. Infringement willincur liability for compensation. All rights pertaining to registrationof patent or utility model
are reserved. The original language of this document is German.

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1 About this safety manual
2 General safety instructions
2.1 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Information on the applicable documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 You as the crane operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Required qualifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
The right working clothes! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Stay alert!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inform your replacement!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ensure cleanliness and tidiness! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 The helpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ensure the safety of your helpers!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Use a banksman!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Hand signals and other signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5.1 Horn signals by the crane operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5.2 Whistles by the banksman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.3 Hand signals by the banksman. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 Your truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.6.1 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.6.2 Improper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Information on driving
3.1 Before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Driving on public roads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2.1 Driving with trailer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.2 Driving with a dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3 Driving on non-public roads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3.1 Driving from the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3.2 Driving with separate steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3.3 Off-road driving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.4 Driving with a rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Driving with a lifted load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 After driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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4 Information on crane operation
4.1 Choice of a suitable positioning site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Ensure a safe distance from slopes and pits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Check if there are obstacles in the working range. . . . . . . . . . . . . . . . . . . . . . . . . 34
Determine the outrigger pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check the ground at the site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Determine the required support surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check the existing support surface and increase it’s size if necessary . . . . . . . . . 36
Earth the truck crane, if required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2 Before crane operation and before rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Planning the use of the crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Checks before operating the crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Checks on the outside of the truck crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Checks in the crane cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3 Information on rigging work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.3.1 Load-bearing equipment and lifting tackle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Safety-relevant parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Required checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Only use parts in perfect working order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3.2 Information on slinging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3.3 Basic information on rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Walking on the truck crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Only use the corresponding equipment parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.3.4 Outrigger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.3.5 Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
What to do when rigging the counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
When rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
When unrigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.3.6 Lattice extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Information on slinging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Information on rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Information on crane operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Two-hook operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.4 During crane operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.4.1 Rated capacity limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Observe the indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Overriding the rated capacity limiter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.4.2 Monitoring the working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Check whether the working area is clear! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Monitor your working area constantly!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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4.4.3 Do not overload your truck crane!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.4.4 Weather influences. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Wind. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Sunshine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.4.5 Crane operation in the free-on-wheels working position. . . . . . . . . . . . . . . . . . . . . . 62
4.4.6 Earthing the load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.4.7 Emergency operations and programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.4.8 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.5 Transporting persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Equipment for lifting persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.6 After crane operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.6.1 Work break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.7 Crane operation under special operating conditions . . . . . . . . . . . . . . . . . . . . . . 69
4.7.1 Working with the crane in extreme temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.7.2 Crane operation in case of danger due to static electricity charge. . . . . . . . . . . . . . 70
Earthing the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Earthing the truck crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.7.3 Crane operation in the vicinity of power lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.7.4 Crane operation with two truck cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.7.5 Crane operation in the vicinity of supply lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.8 Conduct in the event of malfunctions, accidents and fire. . . . . . . . . . . . . . . . . . . 75
4.8.1 Malfunction in road traffic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Information on wheel change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Tilting the driver's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.8.2 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Information on tow starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Information on towing free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Information on towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.8.3 Malfunctions during crane operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.8.4 Accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.8.5 Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5 Maintenance and repairs
5.1 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.1.1 Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.1.2 Workshop and personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.1.3 Spare parts and consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.1.4 General maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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5.2 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Information on welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.3 Information on electronic components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6 Transporting the truck crane
6.1 Loading the truck crane under its own force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.2 Loading the truck crane with another crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

1 About this safety manual
Safety manual 3 303 022 en 1
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1 About this safety manual
This safety manual is only valid for truck cranes produced by
Manitowoc Crane Group Germany GmbH. The safety manual is an integral
part of the supplied documentation of your truck crane.
You as the crane operator are responsible for the safe operation of your
truck crane!
This safety manual is intended to point out some of the dangers that occur during
the daily handling of your truck crane and to show you how to eliminate these
dangers from the outset or how to react to them correctly.
The safety manual contains
– Information on the untended use of your truck crane
– Information on the improper use of your truck crane
– General safety instructions
– Safety instructions for driving truck cranes
– Safety instructions for rigging and working with truck cranes
– Safety instructions for operating the crane in special operating conditions
– Rules of conduct in the event of malfunctions, accidents and fire
– Safety instructions for transporting the truck crane
The crane operator is obligedto read this safety manual, which is the prerequisite
for safe operation of the truck crane.
You should also keep this safety manual so that you can take it again from time
to time to reread one or two chapters.
However, the notes and measures included in this safety manual do not
protect you from all dangers that may possibly occur when using the truck
crane!
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1 About this safety manual
2 3 303 022 en Safety manual
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This safety manual only contains general safety instructions and general safety
precautions. They supplement the danger and safety instructions included in the
chapters of your operating manual(s), in the other documentation belonging to
your truck crane (lifting capacity table, outrigger pressure table, maintenance man-
ual) and on warning and information signs on and in your truck crane. You must
observe these safety instructions and warning signs in addition to the information
in the safety manual.
Depending on the corresponding operating conditions, further safety precautions
may also be necessary.
Follow all applicable national regulations and
laws!
There may be further safety instructions in terms
and conditions of insurance policies, company
directives, etc. They must also be observed.
The manufacturer of the truck crane shall not
be held liable in the event of accidents that occur
during the use of the truck crane if the user does
not comply with the laws, regulations, require-
ments and rules applicable to truck cranes.
The manufacturer has no direct influence on the
way you use, operate or service your truck crane.
You are therefore responsible yourself for ensur-
ing safety and compliance with all laws and
requirements.
If you have questions on the operation or safety of your truck crane, consult
Manitowoc Crane Care.

2 General safety instructions
2.1 Organisational measures
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2 General safety instructions
2.1 Organisational measures
The operating manual(s), the lifting capacity table(s) and the maintenance man-
ual must be kept in the truck crane for immediate access at all times, and must
not be removed from the truck crane. You must have read and understood the
operation and safety instructions in this operating manual and comply with them
when working.
In addition to the operating manual and the lifting capacity table, observe all gen-
eral, statutory and otherwise applicable regulations concerning accident preven-
tionandenvironmentalprotection.You must have read and understood themand
observe them.
They may include
– The safe and environmentally sound handling of hazardous substances.
– Wearing personal protective equipment.
– Following road traffic regulations.
– Following all applicable regulations concerning the operation of a truck
crane.
Only trained and qualified personnel may be used to operate the truck crane.
Only authorised personnel with the required qualifications may perform all work
on the truck crane;àYou as the crane operator, p. 2 - 5, àThe helpers, p. 2 - 8.
Keep all signs on the truck crane with safety instructions and hazard warnings in a
legible condition and replace damaged and no longer existing signs immediately.
Observe the operational organisation at the site. Report your arrival to site
management. Ask for the personnel authorised to instruct you.
Find out where the fire extinguishers are and how to operate them at every site.
Observe the fire alarm and fire-fighting options on site.
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2 General safety instructions
2.2 Information on the applicable documentation
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Should the operating performance of the truck crane change in such a manner
that safety is impaired or if you are in doubt about the operational safety of the
truck crane, stop the truck crane immediately and inform the responsible
departments or persons.
Do not make any changes to the programmable control systems (e.g. the rated
capacity limiter).
Do not modify or retrofit additional units to the truck crane without the approval of
Manitowoc Crane Group Germany GmbH if such changes would impair safety.
This also applies to the installation of safety devices and to the adjustment of
safety devices and safety valves.
2.2 Information on the applicable documentation
Only the documentation (operating manuals, maintenance manual, lifting capacity
tables, spare parts list and outrigger pressure tables) supplied with yourtruck crane
or specially subsequently acquired or provided for theserial number ofyour truck
crane via Manitowoc Crane Care applies to your truck crane.
All documents supplied with the truck crane are listedon the handover certificate
provided.
All print documents supplied are marked with theserial number of the truck crane
on the cover sheet.
In the event of a digital documentation, the serial number of the truck crane is to
be found on the start page of the USB flash drive.
Manitowoc Crane Group Germany GmbH provides the option of making the entire
documentation of your truck crane available on an online portal (if desired, con-
tact Manitowoc Crane Care).
On this portal, the documentation can only be viewed or downloaded after stating
the serial number. All pages of this documentation are generally marked with the
serial number of the truck crane.
Any other documentation procured in a different way is invalid and must not be
used under any circumstances for the operation of your truck crane.
There is a maximum risk of accidents!

2 General safety instructions
2.3 You as the crane operator
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2.3 You as the crane operator
The supplied operating manual is not a training manual for prospective crane
operators! All descriptions are written explicitly for crane operators who have
been trained to operate truck cranes.
Personnel in training may only operate the truck crane under supervision.
Required qualifications
To drive or work with a truck crane, you must meet the requirements listed here!
•You must meet all the necessary requirements for operating cranes in accord-
ance with the rules and regulations currently in force in the country of use –
e.g. the minimum age.
•You must be in good physical and mental condition, have unrestricted vision
and hearing, good reaction and coordination skills. Have regular medical
check-ups.
•You must be physically able to handle all the operating elements of the truck
crane.
•Youmustpossessadrivinglicenceforthistype
of vehicle that is valid in the country in which
you are working.
•You must have general knowledge of crane
operation and any qualifications that may be
required by the country in which you are
working.
•You must possess and carry the legally
required authorization certificates.
•You must have read and understood the docu-
mentation of your truck crane and all warning
and information signs on and in your truck
crane.
•You must be familiar with and understand the accident prevention regulations
that apply in the country in which you are working.
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2 General safety instructions
2.3 You as the crane operator
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•You must know and understand the signals and hand signals for
communicating with banksmen, slingers and other persons;
àHand signals and other signals, p. 2 - 10.
•You must be able to manage all operating procedures, be able to operate all
safety devices and know the behaviour of your truck crane. Prior to initial use,
you must make yourself familiar with the operation and special features of your
crane. Take part in a training course for crane operators if you have no experi-
ence with truck cranes.
HManitowoc Crane Group Germany GmbH conducts general and type-specific
crane operator courses and technical courses.
•You must be able to assess safety risks for yourself and others and act accord-
ingly. You must in particular strive to comply with rules and regulations and
follow instructions.
•You must also act in a level-headed manner and responsibly under stress and
in incidents. If a malfunction occurs, you must be able to prevent consequential
damage.
•Your responsibilities as a crane operator (including those concerning traffic
requirements) must be clearly defined. You must be in a position to refuse
instructions given to you by third parties if they violate the safety regulations.
•Youmust beabletoprovide first aidintheeventofanaccidentandknowwhere
to get more help.
•You need to be able to use the right equipment in the event of a fire, use a fire
extinguisher and know where to get additional help.

2 General safety instructions
2.3 You as the crane operator
Safety manual 3 303 022 en 7
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The right working clothes!
Always wear the right working clothes! Always use safety gloves made of thick
leather when handling ropes and chains. Wear protective gloves if possible for all
work outside the crane cab.
Wear tight-fitting clothing and no loose, long hair.
Avoid open jackets and shirt sleeves, fluttering
scarves, rings, necklaces and other things that
could get caught on the operating elements and
moving parts of your truck crane.
Always wear the required and prescribed person-
al protective equipment (e.g. helmet, hearing pro-
tection, reflective clothing, safety boots, reflective
jacket) during work.
Stay alert!
Do not operate your truck crane under the influence of alcohol, drugs or
medication.
Always keep your eyes on the load or the banks-
man. Only concentrate on your work and do not
letyourselfbedistracted.Neverread,drink,eator
smoke during work. Switch off your mobile phone
when you do not need it for work, e.g. for commu-
nication with a banksman.
Stop working if you get tired and can no longer
ensure the safe operation of your truck crane.
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2 General safety instructions
2.4 The helpers
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Inform your replacement!
In the event of a change of crane operator, you must inform your replacement
about the condition of the crane and all agreements made.
Ensure cleanliness and tidiness!
The truck crane is your workplace. Keep it clean!
Clean your shoes and hands before climbing on
to or getting into your truck crane.
Remove any dirt, fluids, oil and grease. Pay spe-
cial attention to the cleanliness of steps, ladders
and stepping areas, warning and information
signs, windows, mirrors and video systems, as
well as all surfaces that can be walked on.
You should also clean the driver's cab and the
crane cab at regular intervals.
Do not leave lifting gear (chains, ropes, slings)
lying around on the deck of the truck crane. They
pose an increased trip hazard. Always stow lifting
gear properly that is not needed.
2.4 The helpers
The helpers are persons outside the crane cab involved in crane operation. They
include banksmen, slingers and persons who secure the load with a guide rope.
Qualifications
Only experienced personnel who are familiar with the valid accident prevention
regulations and the rigging personnel are authorised to sling loads and guide the
crane operator. Make sure that these persons are provided with the required
information in the form of instructions prior to starting work. Use well-trained,
qualified and experienced helpers.

2 General safety instructions
2.4 The helpers
Safety manual 3 303 022 en 9
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Ensure the safety of your helpers!
Make sure that all helpers are outside the danger area at all times. This applies
in particular to persons who secure the load with a guide rope.
Use a banksman!
The banksman checks the movements of the truck crane and of the load and
helps you if you:
– Cannot see the entire working area
– Cannot see the load constantly or with sufficient precision
Coordinate the signs and signals used with your banksman. Do not start operat-
ing the crane until you yourself and your banksman know the meaning of all the
signs and signals you use. Guidance can be given by whistling, using hand
signals or walkie-talkies.
Definetheresponsibilities if more than onepersonisrequiredasa helper. Always
only one person may give the required instructions to which you as the crane
operator must react.
Only follow the (hand) signals of your banksman! However, you must obey
a stop signal at all times, including by other persons!
You must interrupt crane operation if you can no longer see your banksman or
have lost contact with him.
During night-time operation, your banksman must always stand in a sufficiently
illuminated area so that you can see him clearly.

2 General safety instructions
2.5 Hand signals and other signals
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2.5 Hand signals and other signals
HHand signals and other signals are suggested in this section.
There may be different horn signals, whistles and hand signals, dependingon the
country in which you are working. Deviations are also permitted. It is important
that any deviating hand signals are unmistakable and have been agreed on
between the operator and the crane operator before the crane is used.
Signal systems not based on hand signals
(e.g. walkie-talkies) must be adequately protected
against unauthorised use, damage, the effects of
the weather and all influences that impair the
safety of work.
2.5.1 Horn signals by the crane operator
You can use the horn of your truck crane for communication with the banksman.
To rule out any confusion, horn signals by the crane operator are suggested in
the table:
I have understood your signal
or – I am following your signal 1 short tone
Repeat your signal
or – give me signals 2 short tones
I cannot follow your signal
or – I have a malfunction Continuous tone
Caution, you are in danger Long tones with short pauses

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2.5 Hand signals and other signals
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2.5.2 Whistles by the banksman
The banksman can communicate with the crane operator by whistling with a
signal whistle. To rule out any confusion, whistles for the banksman are
suggested in the table:
2.5.3 Hand signals by the banksman
The banksman and the crane operatorcan also communicate using hand signals.
The banksman indicates the movement to be carried out with the truck crane with
an appropriate hand signal. The crane operator carries out the indicated move-
ment with the truck crane until the banksman gives the Stop hand signal for the
end of the movement.
All hand signals must be clearly recognisable, even if the banksman is standing
at a distance. Therefore, for some hand signals, the banksman must keep his
arms next to his body. When his arms are held in front of his body, the signs are
no longer visible from a distance.
To rule out any confusion, hand signals are suggested at this point. An overview
of hand signals and their meaning is also to be found on the truck crane.
The banksman is in the field of vision of the crane operator.
Stop all movements in the event of danger
(emergency stop)
Upward and downward movements with both
arms outstretched at the sides.
s
Attract attention 1 very long whistle
Stop movement 1 long whistle
Lift load 2 short whistles – pause – 2 short whistles
Lower load 3 short whistles – pause – 3 short whistles

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2.5 Hand signals and other signals
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Stop all movements (halt)
Upward and downward movement with one arm
outstretched at the side.
Drive back
Hand movements with angled arm – in direction
of travel.
Move slowly
Hold the outstretched hand over the current hand
signal.

2 General safety instructions
2.5 Hand signals and other signals
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Move main hoist
Place your fist on the helmet.
After that, normal signals.
Move auxiliary hoist
Hold the hand under the angled arm.
After that, normal signals.
Lift load
Circular movements with the hand pointing up.
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2.5 Hand signals and other signals
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Lower load
Circular movements with the hand pointing down.
Raise main boom
Outstretched arm – thumb up.
Lower main boom
Outstretched arm – thumb down.