Risk Assessment, Procurement Reviews, Training, and Maintenance Checklists for Hiab Cranes Mounted on Heavy Vehicles
Risks & Hazards of Using a Hiab Crane on a Heavy Vehicle
- Overloading & Tipping – Risk of exceeding crane or vehicle weight limits.
- Mechanical Failures – Hydraulic leaks, worn cables, or failing stabilizers.
- Operator Error – Improper lifting, load mismanagement, or lack of training.
- Environmental Risks – Wind, uneven surfaces, or soft ground.
- Electrocution Hazard – Contact with power lines.
- Manual Handling Injuries – Lifting, operating controls, or improper ergonomics.
- Swing & Crush Hazards – Uncontrolled load movement.
Pre-Procurement Reviews for Mounting a Hiab Crane
- Verify Compliance with Australian Design Rules (ADR) and NHVR Vehicle Standards Bulletin 6 (VSB6).
- Assess Fit-for-Purpose Requirements – Identify load types, weight capacity, and frequency of use.
- Review Manufacturer Recommendations – Check mounting points, reinforcements, and installation procedures.
- Risk Assessment & Engineering Review – Engage an engineer to assess vehicle structural integrity post-installation.
- Check Maintenance & Servicing Support – Confirm access to certified maintenance personnel and spare parts.
Training an Operator to Use the Hiab Crane
- Formal Training & Licensing – HRWL (High Risk Work License) where necessary.
- Verification of Competency (VOC) – Practical session covering:
- On-the-Job Supervised Training – Initial supervised lifts before independent operation.
- Ongoing Training & Refresher Courses – Regular refresher training on updates and hazard awareness.
Benefits of a VOC for Hiab Crane Operators
- Ensures legal compliance with WHS & HVNL.
- Confirms practical competency in real-world scenarios.
- Reduces risk of incidents due to operator error.
- Provides documented evidence of safe work practices.
Risk Considerations for Allocators
- Site Conditions – Stability, overhead hazards, and access.
- Load Type & Weight – Ensure compatibility with crane specs.
- Weather Conditions – Wind, rain, and temperature effects.
- Operator Competency – Check VOC and experience.
- Fatigue Management – Operator hours and compliance with WHS & CoR laws.
Checklist for Mounting a Hiab Crane to a Vehicle
? Verify compliance with ADR & NHVR regulations.
? Check vehicle structural integrity for mounting.
? Ensure mounting bolts, brackets, and stabilizers meet manufacturer specifications.
? Conduct chassis reinforcement assessment if required.
? Ensure hydraulic and electrical connections are installed correctly.
? Confirm crane load chart and lifting capacity alignment with vehicle GVM/GCM.
? Perform load stability and tilt testing.
? Document installation with engineering certification.
Checklist for Hiab Crane Inspections
Driver Daily & Weekly Checks
? Check hydraulic fluid levels.
? Inspect hoses for leaks or wear.
? Test stabilizers and outriggers.
? Verify remote control and emergency stop functions.
? Ensure lifting hooks and slings are in good condition.
? Conduct function test for smooth operation.
Manager Monthly Checks
? Review operator logbooks and VOC records.
? Inspect crane mounting points for wear or damage.
? Ensure scheduled maintenance compliance.
? Check safety devices (e.g., load limiters, warning signals).
? Verify that emergency response procedures are in place.
Mechanic Periodic Checks (refer OEM standards for inspection)
? Conduct full hydraulic system inspection.
? Check structural integrity of boom, welds, and chassis.
? Lubricate moving components.
? Test load capacity under controlled conditions.
? Perform calibration of safety and overload sensors.
Maintenance Responsibility: Truck Mechanic vs. Specialist Crane Technician
- A truck mechanic may handle basic maintenance (fluid checks, mounting inspections). (the mechanic may not include the crane as part of regular maintenance so this should be considered as separate items in your maintenance register).
- A certified crane technician should perform hydraulic repairs, calibrations, and load testing.
- Appropriate maintenance plan:
- ? Routine checks by the driver & fleet manager.
- ? Periodic inspections by a certified crane technician.
- ? Annual certification & load testing as per manufacturer guidelines.
