Gross Load, Deductions & Net Capacity

Gross capacity (also called rated capacity or chart capacity) is the maximum load the crane can handle at a given radius and boom configuration, as stated on the manufacturer's load chart. This number is established under ideal conditions — the crane standing level on a firm supporting surface with outriggers properly extended. ⚠️ CRITICAL: Gross capacity is NOT what you can put on the hook. You must subtract all required deductions to arrive at the usable net capacity. Per Operating Instruction #8: "Rated capacities include the weight of hook block, slings, bucket, magnet, and auxiliary devices. These must be subtracted."

Per the NCCCO TLL load chart (REV 01/23), the required deductions are: 1. HOOK BLOCK / HOOK BALL — Deduct whichever device is actually being used: • 60 Ton Hook Block: 1,100 lbs • 40 Ton Hook Block: 720 lbs • 8.5 Ton Hook Ball: 360 lbs (See hook block/ball for actual weight — these are the chart reference values.) 2. AUXILIARY HEAD ATTACHED: 150 lbs (when equipped/used) 3. BOOM EXTENSION (FLY) — Stowed or Erected, deducted from MAIN BOOM capacity: LIFTING FROM MAIN BOOM WITH: • 22 Ft. Fly Tip Stowed On Boom Base: 300 lbs • 34 Ft. Offset Fly Stowed On Boom Base: 900 lbs • 34 Ft. Offset Fly Erected But Not Used: 4,400 lbs • 56 Ft. Offset Fly Stowed On Boom Base: 1,200 lbs • 56 Ft. Offset Fly Erected But Not Used: 7,800 lbs LIFTING FROM 34 FT. OFFSET FLY WITH: • 22 Ft. Fly Tip Stowed On Boom Base: 300 lbs • 22 Ft. Tip Erected But Not Used: PROHIBITED • 22 Ft. Tip Stowed On 34 Ft. Offset Fly: PROHIBITED 4. SLINGS, BUCKET, MAGNET & AUXILIARY DEVICES — Their weight is part of the total suspended load and must be subtracted per Operating Instruction #8. ⚠️ KEY: The erected fly deductions are MASSIVE (4,400 lbs for 34 ft, 7,800 lbs for 56 ft). The stowed deductions are much smaller (300–1,200 lbs). Always confirm whether the fly is stowed or erected before applying the deduction.

For the TLL crane, the formula is: STEP 1 — FIND THE LIMITING FACTOR: Compare gross capacity (from the chart) to the allowable line pull for your reeving (from the Wire Rope Strength table). → Use WHICHEVER IS LOWER. This is your starting point. TLL Wire Rope Strength (3/4" Type RB — 18 X 19 Rotation Resistant): • 1-Part Line: 12,920 lbs • 2-Part Line: 25,840 lbs • 3-Part Line: 38,760 lbs • 4-Part Line: 51,680 lbs • 5-Part Line: 64,600 lbs • 6-Part Line: 77,520 lbs • 7-Part Line: 90,440 lbs • 8-Part Line: 103,360 lbs • 9-Part Line: 116,280 lbs • 10-Part Line: 129,200 lbs STEP 2 — APPLY DEDUCTIONS: NET CAPACITY = LIMITING FACTOR − Hook Block/Ball − Auxiliary Head (if used) − Boom Extension (stowed or erected, if applicable) − Slings/Bucket/Magnet/Aux Devices Net Capacity = the maximum actual load you can lift. Everything suspended below the hook (load + all rigging hardware) must fit within net capacity. QUICK CHECK: • If chart capacity < line pull → chart capacity is the limiting factor • If line pull < chart capacity → line pull is the limiting factor • Always take the LOWER number as your starting point ⚠️ NOTE: Winch performance varies by rope layer (16,266 lbs down to 11,434 lbs), but when using Type RB rope, reduce to 12,920 lbs. The Wire Rope Strength table values above are the governing limits.

EXAMPLE 1 — Gross Capacity Is the Limiting Factor: • Gross capacity from chart at given radius: 45,000 lbs (using 4-part line) • Wire rope strength check: 4 × 12,920 = 51,680 lbs — HIGHER than gross capacity (45,000) • Limiting factor = 45,000 lbs (gross capacity governs) • 60 Ton Hook Block: 1,100 lbs | No fly | No aux head → Net Capacity = 45,000 − 1,100 = 43,900 lbs EXAMPLE 2 — Wire Rope Strength Is the Limiting Factor (2-Part Line): • Gross capacity from chart: 30,000 lbs (using 2-part line) • Wire rope strength check: 2 × 12,920 = 25,840 lbs — LOWER than gross capacity (30,000) • Limiting factor = 25,840 lbs (wire rope strength governs!) • 40 Ton Hook Block: 720 lbs → Net Capacity = 25,840 − 720 = 25,120 lbs (NOT 30,000 − 720 = 29,280 — that would be WRONG and dangerous) EXAMPLE 3 — With 34 Ft. Offset Fly Stowed: • Gross capacity: 52,000 lbs (5-part line, wire rope strength = 64,600 — higher) • Limiting factor = 52,000 lbs (gross capacity governs) • 60 Ton Hook Block: 1,100 lbs • 34 Ft. Offset Fly STOWED: 900 lbs → Net Capacity = 52,000 − 1,100 − 900 = 50,000 lbs EXAMPLE 4 — With 34 Ft. Offset Fly ERECTED: • When the fly is ERECTED but not used, and you are lifting off the main boom, the erected fly weight is a major deduction. • 34 Ft. Offset Fly ERECTED: 4,400 lbs • Gross capacity: 48,000 lbs | 60 Ton block: 1,100 lbs → Net Capacity = 48,000 − 1,100 − 4,400 = 42,500 lbs ⚠️ That 4,400 lb erected fly deduction is one of the biggest traps on the TLL exam. EXAMPLE 5 — With 56 Ft. Offset Fly ERECTED: • 56 Ft. Offset Fly ERECTED: 7,800 lbs (the largest single deduction on this chart) • Gross capacity: 42,000 lbs | 40 Ton block: 720 lbs → Net Capacity = 42,000 − 720 − 7,800 = 33,480 lbs ⚠️ The 56 ft erected fly deduction (7,800 lbs) is enormous — don't forget it. EXAMPLE 6 — Checking if a Lift Is Safe: • Gross capacity: 35,000 lbs | 2-part line wire rope strength: 25,840 lbs → wire rope governs • 8.5 Ton Hook Ball: 360 lbs | No fly | No aux head • Net Capacity = 25,840 − 360 = 25,480 lbs • Actual load: 24,800 lbs + slings/shackles: 500 lbs = 25,300 lbs total suspended load → 25,300 < 25,480 — SAFE, but barely. Always compare total suspended load to net capacity.

The NCCCO TLL load chart includes a WIRE ROPE STRENGTH table — this is one of the most important and most missed concepts on the exam. WHAT IS WIRE ROPE STRENGTH LIMIT? The Wire Rope Strength table gives the "Maximum Lifting Capacities Based On Wire Rope Strength" for 3/4" Type RB wire rope (18 X 19 Rotation Resistant — Extra Improved Plow Steel — Preformed Right Lay — Regular Lay, Swaged). HOW IT LIMITS CAPACITY: • 1-Part Line: Max lift = 12,920 lbs • 2-Part Line: Max lift = 25,840 lbs • 3-Part Line: Max lift = 38,760 lbs • 4-Part Line: Max lift = 51,680 lbs • 5-Part Line: Max lift = 64,600 lbs • 6-Part Line: Max lift = 77,520 lbs • 7-Part Line: Max lift = 90,440 lbs • 8-Part Line: Max lift = 103,360 lbs • 9-Part Line: Max lift = 116,280 lbs • 10-Part Line: Max lift = 129,200 lbs THE KEY RULE — ALWAYS USE THE LOWER NUMBER: The load chart may show a gross capacity at a given radius that is HIGHER than what the wire rope can actually handle. When this happens, the wire rope strength IS the limiting factor — not the chart capacity. Example: Chart shows 30,000 lbs gross capacity at a certain radius on 2-part line. 2-part line wire rope strength = 25,840 lbs. The crane CANNOT lift 30,000 lbs — the wire rope is limited to 25,840 lbs total. You must take your deductions OFF the wire rope limit (25,840 lbs), not the chart capacity. DEDUCTIONS ALWAYS COME OFF THE LIMITING FACTOR: Net Capacity = Limiting Factor (lower of gross capacity OR wire rope strength) − Hook Block − Aux Head − Fly − Slings ⚠️ NOTE: Use of a swivel end with 1 part of line is not recommended. ⚠️ Winch performance varies by rope layer, but when using Type RB rope, reduce to 12,920 lbs per part.

This is one of the most critical rules on the TLL exam and a major source of wrong answers. TLL OPERATING INSTRUCTION #13: "For main boom capacities, if radius or boom length is between values, go to the next longer boom length or next larger radius (whichever is smaller)." WHAT THIS MEANS IN PLAIN ENGLISH: Load charts list capacities at specific boom lengths (e.g., 35.5 ft, 45 ft, 55 ft, 65 ft...) and specific radii (e.g., 10 ft, 12 ft, 15 ft, 20 ft...). If your actual operating radius or boom length falls BETWEEN two listed values, you must NEVER interpolate or estimate — you go to the MOST CONSERVATIVE (lowest) capacity. RADIUS BETWEEN VALUES → Use the NEXT LARGER radius: • If your radius is 14 ft and the chart lists 12 ft and 15 ft → use the 15 ft radius capacity (the larger radius = lower capacity). BOOM LENGTH BETWEEN VALUES → Use the NEXT LONGER boom length: • If your boom is 50 ft and the chart lists 45 ft and 55 ft → use the 55 ft boom length capacity (the longer boom = lower capacity). BOTH BETWEEN VALUES → Go to the next longer boom length OR next larger radius, whichever gives the SMALLER (lower) capacity. Take the most conservative option. WHY THIS MATTERS: Going to a longer boom or larger radius always reduces capacity. The rule ensures you never overestimate what the crane can handle. Interpolating between values would give a false, higher capacity — that's dangerous and wrong on the exam. 🔑 REMEMBER: When in doubt, go to the LOWEST capacity. Never round up. Never interpolate. Always be conservative.

The TLL has three fly configurations: 22 ft Fly Tip, 34 ft Offset Fly, and 56 ft Offset Fly. Each has different stowed and erected deductions. This is a heavily tested area. ───────────────────────────────────────── LIFTING FROM MAIN BOOM WITH: ───────────────────────────────────────── • 22 Ft. Fly Tip Stowed On Boom Base: 300 lbs • 34 Ft. Offset Fly Stowed On Boom Base: 900 lbs • 34 Ft. Offset Fly Erected But Not Used: 4,400 lbs • 56 Ft. Offset Fly Stowed On Boom Base: 1,200 lbs • 56 Ft. Offset Fly Erected But Not Used: 7,800 lbs ───────────────────────────────────────── LIFTING FROM 34 FT. OFFSET FLY WITH: ───────────────────────────────────────── • 22 Ft. Fly Tip Stowed On Boom Base: 300 lbs • 22 Ft. Tip Erected But Not Used: PROHIBITED • 22 Ft. Tip Stowed On 34 Ft. Offset Fly: PROHIBITED KEY RULES: 1. When the fly is STOWED and you are lifting off the MAIN BOOM → deduct the stowed weight (300–1,200 lbs). This is a smaller deduction. 2. When the fly is ERECTED but not used and you are lifting off the MAIN BOOM → deduct the erected weight (4,400 or 7,800 lbs). This is a MASSIVE deduction and a major exam trap. 3. When lifting from the 34 ft Offset Fly → the 22 ft Tip Erected and 22 ft Tip Stowed On 34 ft Fly are both PROHIBITED. Only the 22 ft Tip Stowed On Boom Base (300 lbs) is allowed. 4. FLY OFFSET ANGLES: The 34 ft and 56 ft Offset Flies can be set at 1°, 15°, or 30° offset angles. Each offset angle has its own capacity column on the chart. Greater offset = lower capacity. ⚠️ The erected fly deductions (4,400 and 7,800 lbs) are the biggest single deductions on the TLL exam. Many candidates forget to apply them or use the stowed weight instead of the erected weight. Always check: is the fly stowed or erected? ⚠️ CAPACITY DEDUCTIONS ARE FOR MANUFACTURER-SUPPLIED EQUIPMENT ONLY.

The TLL crane has two boom telescoping modes. You must know which mode you're in — it determines which capacity chart applies. BOOM MODE "A" — Only Inner Mid Section Telescopes: • Available boom lengths: 35.5 ft, 45 ft, 55 ft, 60.3 ft • Only the inner mid section extends (298" stroke) • Used for shorter boom applications • Has its own dedicated capacity chart BOOM MODE "B" — Inner Mid, Outer Mid, and Tip Sections Telescope Simultaneously: • Available boom lengths: 35.5 ft, 45 ft, 55 ft, 65 ft, 75 ft, 85 ft, 95 ft, 105 ft, 110 ft • All three telescoping sections extend together (each 298" stroke) • Used for longer boom applications • Has its own dedicated capacity chart (different from Mode A) KEY POINTS: • The 35.5 ft, 45 ft, and 55 ft boom lengths appear in BOTH modes — but the capacities may differ! Always check which mode you're operating in. • Mode A maxes out at 60.3 ft. Mode B goes up to 110 ft. • The fly configurations (34 ft and 56 ft Offset Fly) are only available in Boom Mode "B". • Clamshell/magnet operations are PROHIBITED in Mode A. ⚠️ Using the wrong mode's chart is a critical error. Always confirm the boom mode before reading capacities.

These are the most commonly missed items on the TLL exam — know them cold: 1. WIRE ROPE STRENGTH IS THE LIMITING FACTOR — The #1 missed concept. If gross capacity exceeds allowable wire rope strength for that number of parts, wire rope governs. Always check both numbers. TLL line pull = 12,920 lbs per part (Type RB rope). 2. BETWEEN VALUES → GO TO LOWEST CAPACITY — If radius or boom length falls between listed values, go to the next longer boom length or next larger radius, whichever is smaller. Never interpolate. Always be conservative. 3. FLY ERECTED vs. STOWED — The erected fly deduction (4,400 lbs for 34 ft, 7,800 lbs for 56 ft) is massive. The stowed deduction (300–1,200 lbs) is small. Know which configuration you're in. This is a top exam trap. 4. USE THE RIGHT HOOK BLOCK WEIGHT — 60 Ton (1,100 lbs), 40 Ton (720 lbs), 8.5 Ton Hook Ball (360 lbs). Use the block/ball that's actually on the crane. See the hook block for actual weight. 5. AUXILIARY HEAD — 150 lbs when attached. Don't forget this small deduction when auxiliary head machinery is used. 6. TOTAL SUSPENDED LOAD — Net capacity is the limit for EVERYTHING below the hook: the load itself plus all slings, shackles, bucket, magnet, and rigging hardware. Per Operating Instruction #8, rated capacities include these weights and they must be subtracted. 7. WORKING RADIUS — Measured from the center of rotation (axis of rotation) to the center of the vertical hoist line with load applied. Not from the front of the crane or the boom foot. 8. SHADED AREAS / BOLD LINES — Shaded areas (above bold lines) are based on structural or hydraulic limitations. Below the bold line, stability (tipping) governs. Some capacities below the bold line are limited by the 78° max boom angle. 9. DON'T OPERATE AT UNLISTED POSITIONS — Per Operating Instruction #11: "Do not operate at radii or lengths not listed." If it's not on the chart, you can't lift there — period. 10. STABILITY PERCENTAGES — Outriggers fully extended or intermediate extended: capacities do not exceed 85% of tipping load. Outriggers retracted or on tires: capacities do not exceed 75% of tipping load (SAE J-765A). 11. CLAMSHELL/MAGNET LIMITS — Max weight of 7,000 lbs OR 80% of rated lifting capacity, whichever is LESS. Max boom length 55 ft. Min boom angle 35°. Prohibited with fly erected or in Mode A. 12. ON TIRES — Max 76° boom angle when operating on tires. Tires must be at recommended pressure (65 psi at 2.5 mph, 75 psi stationary for 29.5 X 25 – 28 PR tires). 13. PONTOON LOADINGS — Maximum pontoon load is 94,000 lbs. Maximum pontoon ground bearing pressure is 208 psi. 14. OUTRIGGER SPREAD — Fully retracted: 108.75" (9'–.75"). Intermediate: 186" (15'–6"). Fully extended: 264" (22'–0"). 15. FLY WARNINGS — Do not lower the 34 ft Offset Fly below 26° unless main boom is 98 ft or less. Do not lower the 56 ft Offset Fly below 34.5° unless main boom is 89 ft or less. Loss of stability will occur causing a tipping condition.