Gross Load, Deductions & Net Capacity

Gross capacity (sometimes called rated capacity or chart capacity) is the maximum load the crane can handle at a given radius and boom configuration, as stated in the manufacturer's load chart. This number is established under ideal conditions — level, solid ground with outriggers fully 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.

This is where most candidates go wrong: TSS (Telescopic Boom Crane — Fixed Cab) cranes have a very short deduction list compared to larger mobile cranes. For TSS cranes per the NCCCO load chart, the required deductions are: 1. HOOK/BALL/BLOCK WEIGHT — Deduct whichever device is actually being used: • Overhaul Ball: ~120 lbs (single-line operation) • Auxiliary Block: ~50 lbs • Single-Sheave Load Block: ~260 lbs • Double-Sheave Load Block: ~350 lbs 2. HOSE REEL — ~190 lbs (if equipped — check the chart footnotes) ❌ WIRE ROPE IS NOT DEDUCTED on TSS fixed cab cranes. The wire rope weight is already accounted for within the rated capacity figures on the chart. This is a critical difference from larger mobile cranes. ❌ RIGGING (slings, shackles, spreader bars) — While rigging weight is always part of your total suspended load that must not exceed gross capacity, the TSS NCCCO exam deduction table specifically lists only block/ball and hose reel as line items. Read the chart deduction table carefully — only deduct what the chart tells you to deduct. One exception: if the lift goes BELOW ground level, additional deductions may apply per the specific chart configuration.

For TSS cranes, the formula has TWO steps: STEP 1 — FIND THE LIMITING FACTOR: Compare gross capacity (from the chart) to the allowable line pull for your reeving (from the line pull table). → Use WHICHEVER IS LOWER. This is your starting point. STEP 2 — APPLY DEDUCTIONS: NET CAPACITY = LIMITING FACTOR − (Hook Block OR Ball weight) − (Hose Reel, if applicable) Do NOT deduct wire rope weight on TSS exams. 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 (most common trap)

EXAMPLE 1 — Gross Capacity Is the Limiting Factor: • Gross capacity from chart at given radius: 14,200 lbs (1-part line pull = 13,920 lbs) • Line pull check: 1 × 13,920 = 13,920 lbs — LOWER than gross capacity (14,200) • Limiting factor = 13,920 lbs (line pull governs!) • Overhaul ball: 120 lbs | Hose reel: 190 lbs → Net Capacity = 13,920 − 120 − 190 = 13,610 lbs EXAMPLE 2 — Gross Capacity Is the Limiting Factor (2-Part Line): • Gross capacity from chart: 18,400 lbs (1-part line pull = 13,920 lbs) • Line pull check: 2 × 13,920 = 27,840 lbs — HIGHER than gross capacity (18,400) • Limiting factor = 18,400 lbs (gross capacity governs) • Single-sheave load block: 260 lbs | No hose reel → Net Capacity = 18,400 − 260 = 18,140 lbs EXAMPLE 3 — Line Pull Is the Limiting Factor (2-Part Line): • Gross capacity from chart: 30,000 lbs (1-part line pull = 13,920 lbs) • Line pull check: 2 × 13,920 = 27,840 lbs — LOWER than gross capacity (30,000) • Limiting factor = 27,840 lbs (line pull governs!) • Double-sheave load block: 350 lbs | Hose reel: 190 lbs → Net Capacity = 27,840 − 350 − 190 = 27,300 lbs (NOT 30,000 − 350 − 190 = 29,460 — that would be WRONG and dangerous) EXAMPLE 4 — Checking if a Lift Is Safe (Line Pull Governs): • Gross capacity: 16,000 lbs | 1-part line pull: 13,920 lbs • Using 1-part line: line pull (13,920) < gross (16,000) → line pull governs • Overhaul ball: 120 lbs → Net Capacity = 13,920 − 120 = 13,800 lbs • Actual load: 13,500 lbs + slings/shackles: 400 lbs = 13,900 lbs total suspended load → 13,900 lbs EXCEEDS net capacity of 13,800 lbs — UNSAFE. Switch to 2-part line or reduce load.

The NCCCO TSS load chart includes an ALLOWABLE LINE PULL table — this is one of the most important and most missed concepts on the exam. WHAT IS LINE PULL? Line pull is the maximum force the hoist can exert on a single strand of rope. On TSS cranes, a typical 1-part line pull is approximately 13,920 lbs. HOW IT LIMITS CAPACITY: • 1-Part Line: Max lift = 1 × line pull (e.g., 13,920 lbs) • 2-Part Line: Max lift = 2 × line pull (e.g., 27,840 lbs) • 3-Part Line: Max lift = 3 × line pull (e.g., 41,760 lbs) • 4-Part Line: Max lift = 4 × line pull (e.g., 55,680 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 load line can actually pull. When this happens, the line pull 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 pull = 27,840 lbs. The crane CANNOT lift 30,000 lbs — the hoist is limited to 27,840 lbs total. You must take your deductions OFF the line pull limit (27,840 lbs), not the chart capacity. DEDUCTIONS ALWAYS COME OFF THE LIMITING FACTOR: Net Capacity = Limiting Factor (lower of gross capacity OR line pull) − Block/Ball − Hose Reel This is why you must check the line pull table EVERY TIME before calculating net capacity.

The two TSS cranes on the NCCCO exam handle jib/boom extension very differently. Know which crane you are reading the chart for. ───────────────────────────────────────── BRODERSON (Carry Deck) TSS ───────────────────────────────────────── The Broderson has NO jib deduction from the main boom gross capacity — whether the boom extension is stowed or not. ✅ LIFTING OFF THE MAIN BOOM with the jib stowed → NO deduction. ✅ LIFTING OFF THE JIB (boom extension) → Use the separate 20 ft. Boom Extension Capacity Table. NO deduction from the main boom chart. ONE EXCEPTION — ON RUBBER WITH JIB: • When using the boom extension while on rubber tires, there IS a 120 lb deduction applied per the chart notes. • This is the only Broderson jib-related deduction — and only applies when on rubber, not on outriggers. Note: The Broderson chart lists: • Overhaul (Headache) Ball = 180 lbs • Load Block = 440 lbs These are the Broderson-specific device weights — different from the Terex. ───────────────────────────────────────── TEREX (Manitex Boom Truck) TSS ───────────────────────────────────────── The Terex DOES have a stowed jib deduction. The deduction table lists: • Swing-Around Jib (Stowed): "See Load Chart Rating" There is NO single fixed number — the stowed jib deduction varies by boom length and is read directly from the load chart rating table for the boom length being used. 🔑 BETWEEN BOOM LENGTHS RULE (Terex): If the actual boom length falls between two listed boom lengths in the chart, use the HIGHEST (most conservative) stowed jib deduction of the two surrounding entries. Never interpolate — always take the larger penalty. The Terex chart also carries this explicit warning: ⚠️ "Lifting off the main boom point while the swing-around jib is erected is not intended or approved." ✅ LIFTING OFF THE JIB TIP (erected jib) → Use the jib capacity table. No stowed jib deduction from the main boom chart. ❌ Lifting off the main boom with the jib erected → NOT APPROVED on the Terex. SUMMARY COMPARISON: • Broderson jib stowed, lifting off main boom: NO deduction • Broderson lifting off jib (on outriggers): Use boom extension table — NO main boom deduction • Broderson lifting off jib (on rubber): 120 lb deduction per chart • Terex jib stowed, lifting off main boom: Deduct "See Load Chart Rating" — use highest if between boom lengths • Terex lifting off jib tip: Use jib table — NO main boom deduction • Terex lifting off main boom with jib erected: NOT APPROVED per the chart

These are the most commonly missed items — know them cold: 1. LINE PULL IS THE LIMITING FACTOR — The #1 missed concept on TSS exams. If gross capacity exceeds allowable line pull for that number of parts, line pull governs. Always check both numbers. 2. WIRE ROPE IS NOT A TSS DEDUCTION — Do not subtract wire rope weight. It is already in the chart. This trips up many candidates who studied general mobile crane deductions. 3. USE THE RIGHT BLOCK WEIGHT — Ball vs. auxiliary block vs. single-sheave vs. double-sheave all have different weights. Use what's on the specific chart. 4. HOSE REEL — Only deduct if the crane has one. Check footnotes and the deduction table in the actual chart being used. 5. TOTAL SUSPENDED LOAD — Your net capacity is the limit for EVERYTHING below the hook: the load itself plus all slings, shackles, and any other rigging hardware. Even if rigging isn't a line-item deduction, its weight still counts against your net capacity. 6. WORKING RADIUS — Always measured from the center of crane rotation to the center of the load, not from the front of the truck or boom foot. 7. LEVEL GROUND ASSUMPTION — Charts assume level, firm ground with outriggers fully extended. Any deviation reduces safe capacity. 8. SIDE LOADING — Load charts are based on vertical loading only. Side loading is never permitted within chart ratings. 9. JIB DEDUCTIONS DIFFER BY CRANE — Broderson (carry deck) has NO jib deduction from gross capacity. The only Broderson jib deduction is 120 lbs when operating the jib on rubber tires. Terex DOES deduct for a stowed jib — the amount is "See Load Chart Rating" and varies by boom length; if between listed boom lengths, use the HIGHEST. Neither crane deducts anything when lifting off the jib tip itself. 10. LIFT BELOW GROUND — If the hook path goes below grade (e.g., lifting from a pit), the chart may have additional deductions or restrictions. Always check the chart for the specific configuration.