LORRY LOADERS

The recommendations and advice in this work instruction are based on specifications, procedures
and other information, which has been collated from existing standards and manufacturer’s
instructions.

The information contained applies to all configurations of Lorry Loaders- BS 7121 Pt 4. However,
there are a wide variety of situations where lorry loaders may be used, consequently in all cases the
suitability and safety of this guidance must be determined by the person seeking to apply it on the
basis of his own judgement, in the light of the conditions in which use is envisaged and subject to all
relevant statutory requirements.

It includes thorough examination of the lifting parts of the machine(s) (covered by LOLER 98,
regulation 9) as well as inspection of other safety critical parts, which are not directly part of the
lifting mechanism (covered by PUWER 98, regulation 6).

Attention is drawn to statutory requirements for the inspection; testing and examination of cranes
see BS1757 AND BS 7121: Part 2. Carry out the examination as per the manufacturer’s handbook.

SAFETY INSPECTIONS

Check that all ropes are correctly positioned on their sheaves and that drums have not been
displaced. All rope terminations, swivel pins and retaining devices are in good working order. Check
for broken wires, flatting, basket distortion and other signs of damage, excessive wear and surface
corrosion.

Visually check that no electrical equipment is exposed to contamination by oil, grease water or dirt.

Visually check, by inspecting relevant levels and/or components, that no loss of fluids such as
lubricating oil and coolant is apparent.

Check the operation of all limit switches or cut outs and the dead man’s handle or lever. Check with
caution, in case of malfunction.

Check that the automatic safe-load indicator is functional and that the manufacturer’s daily test is
carried out.

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Check that the load plate is appropriate and legible.

By varying the radius of the load lifting attachment without load, check that the movement of the
equipment is correct.

Check that the correct air pressure is maintained in any pneumatic control system.

Check that any lights, windscreen wiper(s) and washers fitted to the control station operate
efficiently.

Without load, check that all lorry loader controls function correctly.

Check that all audible warning devices operate satisfactorily.

Check for damage e.g. bulges, indentations and unusual rubbing marks on telescopic jibs, cracked
welds and loose fasteners.

Check hooks and other load-lifting attachments, safety catches and swivels for damage or wear.
Check the hook shank thread and securing nut for undue movement, which may indicate wear or
corrosion.

On hydraulic machines, check for creep of hydraulic rams.

Check the slew lock, if fitted.

Examine all control linkages for evidence of seizure or partial seizure and ensure that there is correct
lubrication.

BRAKING SYSTEMS Visually inspect all hydraulic or pneumatic hoses, piping or components for
leaks, corrosion and signs of potential failure. Also check security of mountings.

Check the mechanical condition of brake operating pedals and levers. Carry out functional testing of
the brake controls to ensure that they move freely, as expected, when the brakes are operated.

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STEERING SYSTEMS

Visually inspect all visible mechanical components, including cables, drive belts, linkages for damage,
excessive wear, signs of failure and corrosion, also check security of mountings.

Visually inspect all hydraulic components, including steering unit, cylinders and hoses for leaks,
damage and signs of potential failure. Also check security of mountings.

Manoeuvre the lorry loader to check the steering response and operation, particularly at slow speed
input from the steering wheel.

GENERAL STRUCTURE

Visually check the chassis for signs of corrosion and damage e.g. bulges, indentations and
deformation. Check all bolts and fastenings used to attach the crane to the subframe and the
subframe to the lorry.

Visually inspect the security of the seat mountings and the panels to which it is attached. Account
should be taken of any corrosion. The seat and any other operator restraint should be visually
examined for damage.

The stabilisers should be visually examined for wear, security. The cam locks and automatic catches
on the beams, that prevent inadvertent extension, should be visually examined to ensure that they
are free from wear and corrosion. The jacks should be extended and visually checked to ensure that
they move smoothly and that when left supporting the lorry and crane they do not creep.

For lorries that travel on public roads, check the hand brake interlock disengages the power take off
when the hand brake is released. Carry out a functional check of the travelling height warning
device. Visually check that there is a label in the cab showing the travelling height of the crane and
lorry.

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