Terex Franna AT-15 User manual

QPP147.1
RISK ASSESSMENT

QPP147 Inside Cover Revised: Mar07
RISK ASSESSMENT

QPP147 Contents/Introduction Revised Mar07
Risk Assessment
Contents Revision
Cover Mar07
Inside Cover Mar07
Contents / Introduction Mar07
Section 1 – General potential hazards and risk controls Mar07
Section 2 – Operational potential hazards and risk controls Mar07
Section 3 – Post operational potential hazards and risk controls Mar07
Section 4 – Inspection and maintenance potential hazards and risk controls Mar07
Appendix 1

RISK ASSESSMENT
QPP147 (Contents/Introduction) Page 1(Revised Mar 07)
As manufacturer of plant in Australia, Terex Lifting Pty. Ltd. is providing this
information, regarding hazard identification, risk assessment and recommendations on
risk control measures to be taken:
The information provided in this document is sourced from the manuals provided by
Terex Franna (the designer/manufacturer), and attachment manufacturers and from the
experience of technical personnel from Terex Franna and industry consultants.
Whilst the information in hazard identification, risk assessment and risk control
measures is not exhaustive, Terex Franna believes that the manual provides practical
guidance for the safe operation of the crane, provided that the crane is used in
accordance with the designers/manufacturer's recommendation for which the plant is
designed and manufactured.
A generic assessment has been carried out for classes or types of plant that have
similar functions and productive capacity and the procedures carried out for the class
of plant do not result in any person being subject to a different risk than if the
procedures were carried out for each individual item of plant. Any variations of
individual models of plant from the generic hazards will be identified if required.
This report identifies all the pre-operational, operational and post-operational hazards
and associated risk controls for all model Franna Cranes. In addition, hazards
associated with attachments are also included together with the recommended risk
controls.
This section lists the potential hazards and risk control precautions that should be
observed when operating or maintaining the Franna cranes.
The points raised here must be fully understood and observed to work safely. Read
and understand the operation and maintenance manuals.
Further precautions may be necessary due to the attachments in use or the site
conditions.
The user should re-evaluate the site conditions because the working environment has a
major influence on the risk associated with the use of the plant.

RISK ASSESSMENT
QPP147 (Contents/Introduction) Page 2(Revised Mar 07)
WARNING
DO NOT OPERATE OR WORK ON THE CRANE UNLESS YOU HAVE READ &
UNDERSTOOD THE INSTRUCTIONS & WARNINGS IN THE OPERATION &
MAINTENANCE MANUALS. FAILURE TO FOLLOW INSTRUCTIONS &
WARNINGS COULD RESULT IN DAMAGE TO THE CRANE, INJURY OR
EVEN DEATH

RISK ASSESSMENT
QPP147 Section 1 Rev. March 07
1. GENERAL POTENTIAL HAZARDS & RISK CONTROLS

RISK ASSESSMENT
QPP147 Section 1 Rev. March 07
A. GENERAL HAZARDS
A1. Unintended movement of plant
due to clothing getting caught
or tangled in control levers and
mechanical parts.
RISK CONTROLS & GENERAL PRECAUTIONS
A1. When driving or operating the machine, do not wear clothing with dangling parts, which might
catch on control levers or mechanical parts. Wear a helmet, protective goggles, safety boots, a
mask, gloves and other protective gear as necessary.
A2. Unintended movement of plant
from operating wrong controls
or errors in judgment.
A2. Do not operate the crane when you are excessively fatigued or unwell.
Read this Instruction Manual thoroughly and familiarize yourself with all the controls before
you start operating the crane.
Follow instructions and warnings in this Manual and on the plates and stickers mounted on the
machine. If there is something you do not understand have it explained to you. If the manual
is lost or a plate is illegible replace it.
A3. Fire and emergency response. A3. Carry a fire extinguisher and first aid kit in the crane. Learn how to use the fire extinguisher
before an actual emergency situation arises.
A4. Fire from handling chemicals. A4. Do not smoke or use fire near fuel, oil, antifreeze, batteries or other chemicals, which could
ignite.
Extinguish all fires and potential sources of ignition when handling these flammable materials.
Before refueling the crane, switch off the engine and check that there are no fires or potential
sources of ignition nearby.
After refueling securely fasten all fuel and oil caps and wipe off any spillage.
Refuel and change oil in a well-ventilated work area.

RISK ASSESSMENT
QPP147 Section 1 Rev. March 07
B. GENERAL HAZARDS-
WORKING PROCEDURES
RISK CONTROLS & GENERAL PRECAUTIONS
B1. Unfamiliarity with site
conditions or scope of work
B1. Start planning for the mobile crane operations as early as possible. Planning should involve
inspection of the site, consultation with all persons involved in the work such as the principal
contractor, crane hirer, electricity entity, employer, dogman, spotter, site foreman and crane
operator.
B2. Not observing instructions on
warning plates could cause
operation beyond limitation of
plant.
B2. Observe all instructions on the warning plates. Ensure that all warning plates are clean and
legible. If the warning plates are damaged or illegible replace them.
B3. Collision with people or objects
in work area.
B3. Before starting work, check the work area for the presence of roads, overhead powerlines,
nearby structures, other cranes, aerial hazards and other obstructions.
Isolate the work area by using witches hats, temporary barriers or fencing. People, vehicles,
etc. should be prohibited from entering the isolated area. Consult the principal contractor, site
supervisor, the other crane operators and everyone involved with the work and prepare a safety
plan for the job.
Always be aware of your surroundings and the hazards while you work.

RISK ASSESSMENT
QPP147 Section 1 Rev. March 07
B4. Collision with other plant and
structures.
a. During slewing or
reversing
b. From dirty windows
and mirrors
c. From poor lighting.
d. From adverse weather
conditions.
B4. When sitting a mobile crane, consider hazards such as overhead powerlines, nearby structures,
other cranes, high obstructions and other mobile equipment within the crane working area.
a. When you need to slew or reverse in areas of restricted visibility place a guide and a
signaler and follow their instructions.
b. Keep the cab windows, mirrors, wipers and working lamps clean.
c. When working in areas with poor lighting switch on the lights. If required use
additional illumination. (Mobile lighting can be hired from equipment hire places)
d. When visibility is bad due to fog, snow, rain, or other adverse weather conditions stop
work and do not start again until conditions have improved.
B5. Collision with people or other
vehicles when working on
public roads
B5. When working on public roads, position a guide and erect fences, witches hats, etc.
Observe all the traffic rules and safety regulations and laws of the Country or State where the
crane is being used.
B6. Collision with objects and
people working in the work
area.
B6. Discuss your requirements with the site supervisor. If you consider that the people and
equipment in the area has to be removed before you operate the crane, discuss it with the site
supervisor so the necessary arrangements can be made.
B7. Electrocution from live
overhead conductors. If you
are working close to power
cables you can also receive a
shock even if the crane does
not physically come in contact
with the cables.
B7. Take the following precautions when working near power cables.
a. Contact the managing company in advance and arrange for electricity to be switched
off (if possible). If this is not possible, arrange for the cables to be fitted with
protective devices (such as tubular coverings) and warning signs.
b. Keep a safe distance between the machine and the power cables. Consult the
electricity authorities on the location and voltage of cables on the site and the minimum
isolation distance.

RISK ASSESSMENT
QPP147 Section 1 Rev. March 07
B8. Electromagnetic radiation from
high-power electromagnetic
emitters (used for radio,
television, radar and mobile
phones transmission) could be
painful and have dangerous
consequences.
B8. Take the following precautions when operating the crane near high-power electromagnetic
wave emitters.
a. Contact the relevant authorities before starting work. Discuss the safety requirements
and precautions to be taken with the authorities. Ensure that all the safety precautions
are observed.
B9. Electrocution from lightning
strikes. A crane with a long
boom is prone to lightning
strikes.
B9. If thunderstorms are approaching, lower the boom, turn off the crane and get out of the crane.
Resume work when the thunderstorm activities ceases.
B10. Inadvertent movement from
poor signaler. If the signaler
does not signal appropriately
with the sling handler and other
workers there could be an
accident.
B10. Work according to signals. Choose one person to be the signaler. Before starting the job the
controller, the signaler, the sling handler and other workers should confer on signal procedures
in order to work safely under the direction of the signaler.
B11. Collision between two cranes
working together.
B11. Determine signals for joint operations in advance. If two or more cranes are working together
on a site ensure that all parties involved discuss the work plan and clearly define the lines of
communications.

RISK ASSESSMENT
QPP147 Section 1 Rev. March 07
B12. The crane could tip over due to:
a. Strong windy conditions.
Loads with large volumes
or surface areas have larger
wind forces acting on them.
The wind forces and the
loads from the suspended
objects act on the crane and
could cause the crane to tip
over.
b. Poor ground conditions.
c. Rapid slewing.
B12.
a. Stop work in strong windy conditions. If the wind has a gust speed of 10m/s or more,
retract the boom, turn off the crane and get out of the machine. Resume work when the
gust speed is below 10m/s.
b. Check that the ground conditions are stable. Do not operate the crane on unstable
ground.
c. Slew the crane slowly and smoothly.

RISK ASSESSMENT
QPP147 Section 1 Rev. March 07
C. HAZARDS -
PRE-OPERATION
RISK CONTROLS & PRE-OPERATIONAL PRECAUTIONS
C1. Inadvertent operation of plant
due to poor housekeeping.
C1. Keep the area of the operator's cabin and seat clean and tidy. Do not leave parts, tools or other
objects in the area of the operator's seat. These can cause unexpected accidents while you are
working.
C2. Stress and tiredness from poor
sitting position and posture.
C2. Adjust the operator's seat so that you can sit comfortably with good posture, and all control
levers are within easy reach without having to lean or strain your body. Check that you can
reach the foot pedals comfortably with your back resting against the back of the seat.
C3. Accidental operation of plant if
operated by more than one
operator. . Passengers may
collide with obstructions or be
thrown off the machine, or they
may cause a hazard by
obstructing the operator's field
of view
C3. Before and during work nobody other than the operator should sit in the operator's seat or climb
onto the crane.

RISK ASSESSMENT
QPP147 Section 1 Rev. March 07
C4. Slips, trips and falls when
getting on or off the plant.
C4. Take the following precautions when you get in and off the crane.
a. Check that all guards and covers on the machine are fastened correctly. Tighten any
loose bolts or repair any damage.
b. Wipe off any mud, oil or snow on the steps before you start work.
c. Do not jump onto or off the machine.
d. Do not hold onto the seat, control box, control levers or anything other than the hand-
grips provided when you get on or off the machine.
e. Do not get on and off the machine while it is moving.
C5. Dropping of load C5. Check safety devices. The AT-20 & MAC-25 are fitted with an over-hoisting detector and
other safety devices which should be checked before starting work.
C6. Crane overload or tip over in
adverse working
configuration.
C6. Check the operation of weigh gauge according to the pre-operational check procedure
described in the weight gauge Operation Manual (this manual should be kept in the Cab).
C7. Failure of controls and/or
mechanical parts of plant.
C7. Before operating the crane check the machine according to the pre-operational checking
procedure detailed in this Manual, and check the operation of the control levers while the crane
is not carrying any load.
Allow the crane to warm up before carrying full load.
Ensure that the crane is serviced regularly in accordance with the requirements in this manual.

RISK ASSESSMENT
QPP147 Section 1 Rev. March 07
C8. Dropping of load C8. Check all safety and warning devices. In addition the AT-20 & MAC-25 are fitted with an
over-hoisting detector and other safety devices, which should be checked before starting work.
Carry out regular servicing of the crane in accordance with the recommendations in this
manual.
C9. Falling objects (during erecting
and dismantling activities)
could damage property and
present a risk of injury to
workers and members of the
public.
C9. Erect and maintain effective barricades around the mobile crane. Only allow persons who are
directly involved in erecting and dismantling activities inside the area.
Schedule the erecting and dismantling of the crane to occur when the movement of other
persons and mobile plant at the workplace is at a minimum.

RISK ASSESSMENT
QPP147 Section 2 Rev. March 07
2. OPERATIONAL POTENTIAL HAZARDS & RISK CONTROLS

RISK ASSESSMENT
QPP147 Section 2 Rev. March 07
A. HAZARDS - STARTING
THE ENGINE
RISK CONTROLS & GENERAL PRECAUTIONS
A1. Carbon monoxide poisoning
from the exhaust fumes when
the engine is running indoors.
A1. If the engine has to be started indoors, open all doors and windows to ensure good ventilation.
If necessary connect an additional pipe to the exhaust pipe and expel the exhaust gases to the
outside.
A2. Fire from spills. A2. Keep the engine and surroundings clean. Do not leave tools, rags, or anything else in the
engine compartment.
After inspection and maintenance wipe off any spilled oil or fuel.
Check that flammable material is not scattered about or piled up near the engine.
A3. Accidental movement of the
crane.
A3. Always start the engine when seated in the operator’s seat.
A4. Operating the crane when it is
being serviced or repaired.
A4. Always attach warning tags on control levers of the machine when it is being serviced or
repaired.
A5. Collision with people and
objects
A5. Check for people and objects near the crane before you start the engine. Concentrate on the job
and always look out for people and equipment approaching the crane. (Note: If the work area is
effectively isolated using temporary barriers, unauthorized people should not be entering the
work area).
A6. Unintended movement of the
crane on start up.
A6. Before starting the engine check that all levers, pedals and switches are in their neutral or OFF
positions.

RISK ASSESSMENT
QPP147 Section 2 Rev. March 07
B. HAZARDS WHEN
OPERATING THE CRANE
RISK CONTROLS & GENERAL PRECAUTIONS
B1. Structural failure or tip over of
the crane during operation.
B1. Do not exceed the lifting capacity of the crane. If unsure of the lifting capacity, always check
the rated lifting capacity chart. Lifting capacity varies with the boom length and working
radius.
Always check that all safety devices and warning systems are functioning properly. Do not
operate a crane if any of the safety devices and warning systems is faulty.
B2. Collision from swinging load or
reduced stability of the crane.
B2. Avoid sudden movement or violent operation of the crane. Operate the levers and pedals
smoothly. Start, accelerate, decelerate, slew and stop the crane smoothly and securely.
When lifting long loads tie a guide rope to each end of the load. This will prevent the load
from swinging whilst it is being lifted.
Compound operations, such as combining winch hoisting, slewing, boom derricking and
lowering will be slower than the individual operations. When switching from compound to
single operation, work the controls slowly and smoothly with no sudden change in speed or
direction.
B3. Crane damage and tip over from
using counterweights that are
not specified.
B3. Never use counterweights that do not conform to the specifications - this is forbidden (for
MAC-25 & AT-15 (N.Z. Spec.)). Counterweights not included in the specifications will
subject the crane to unreasonable strain and damage it.
B4. Collision if operator is not
concentrating on the job.
B4. Do not operate the crane if you are tired or cannot concentrate on the job.
Always be alert and watch that the boom or the suspended load does not collide with people or
buildings and the load does not collide with the boom.

RISK ASSESSMENT
QPP147 Section 2 Rev. March 07
B5. Operating the crane by reaching
in through the door or window.
(The operator is not in full
control of the crane and could
cause the crane to collide with
people, buildings and other
objects).
B5. Only operate the crane while seated in the operator’s seat.
B6. Dropping of the load from an
unattended crane.
B6. Never leave a suspended load on an unattended crane. When leaving the crane, always lower
the load to the ground, switch off the engine, lock the crane and take the keys with you.
B7. Dropping of load, damage or tip
over of the crane due to
overloading or unstable load.
B7. Carry out the following checks before lifting a load.
•Check that the total weight of the load (including the weight of slings, hook and
attachments) is below the rated capacity of the crane?
•Check that the number of parts of line on the main winding wire rope is a standard number
according to the rated lifting capacity?
•Check that the slings are properly positioned to lift the load above its center of gravity?
•Check that the main winding wire rope is hanging vertically?
When the load just leaves the ground pause until it stops swinging. Confirm that the load is
stable before continuing to hoist.
B8. Dropping of load from insecure
slings or hook.
B8. To prevent the load from falling off or slipping out of the slings, pay attention to the following
points when arranging the sling.
•The slings or chains should be of the right capacity and in good condition.
•Arrange the slings so that they do not get tangled with each other.
•The hook is fitted with a retainer to prevent the slings from slipping out. Check that the
hook is in good condition and the retainer is operating correctly.
•Place a protector (some soft material) to prevent the rope from damage where it comes into
contact with the corner of the load, and elsewhere where the sling is prone to damage.

RISK ASSESSMENT
QPP147 Section 2 Rev. March 07
B9. Damage to the crane or reduced
stability when working with a
heavy load with a long boom.
B9. When lifting a load the boom flexes and increases the working radius. This is more noticeable
with a very heavy load or long boom. Allow an extra margin below the rated lifting capacity to
compensate for the increased working radius.
B10. Overload due the increased
flexure of the boom when the
load is lifted suddenly.
B10. Lift the load off the ground carefully. Hoist the load vertically and pause briefly when the load
is just off the ground to confirm the sling and that there is no overload. Then resume hoisting.
B11 Damage to crane or reduced
stability if the load is lifted off
the ground by derricking or
extending the boom.
B11. Never lift the load off the ground by derricking or extending the boom. Wait until the load is
just off the ground before derricking or extending the boom.
B12 Collision with people under the
load when slewing. People
under the load or in contact
with the slewing load or crane
parts could be killed or
seriously injured.
B12 Before moving the load sideways check that it is safe to do so. The path of the load or crane
should be clear of people or obstructions.
B13 Collision or dropping of load on
people.
B13. Do not move the suspended load above people’s head.

RISK ASSESSMENT
QPP147 Section 2 Rev. March 07
B14 Collision with obstacles from
entanglement of wire rope
during hoisting or slewing.
(When hoisting or slewing a
load and the wire rope could
become entangled with an
obstacle)
B14. If the wire rope becomes entangled with an obstacle, carefully disentangle it without further hoisting or
slewing. Place the load back on the ground and check that the wire rope is not damaged before resuming.
B15 Overload and tip over of the
crane by sudden raising or
lowering of the boom.
B15 Lower the load to the ground using the winch. Avoid sudden raising and lowering of the boom as it makes
the crane prone to tipping over.
B16 People falling from height. B16 Only lift people using a Franna approved man basket. A safety harness must be worn. Different states and
countries have different safety regulations and laws. Always observe the laws of the state or country you
are in.
B17 Damage to the boom or tip over
of the crane if the load is not
lifted from a position above its
center of gravity.
B17 Never drag a load sideways, hoist it diagonally or drag it towards the crane. Using boom lowering and
derricking or winch operation to drag the load sideways or lift it diagonally subjects the boom and slewing
mechanism to forces they were not designed for. These additional forces will damage the boom and
slewing mechanism or cause the crane to tip over.
Follow the signaler and lift the load vertically.