Auto Crane 2003 Series User manual

OWNERS MANUAL
2003 SERIES
REVISION 2/2000
PART NO. 999951
SERIAL NO. __________________________
PO BOX 580697, TULSA, OK 74158-0697
4707 N. MINGO ROAD, TULSA, OK 74117-5904
PHONE [phone]
FAX [phone]
http://www.autocrane.com

WARNING! Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of
a vehicle certify that the vehicle complies with all applicable federal regulations. Any
modifications performed on the vehicle prior to the final stage are also considered
intermediate stage manufacturing and must be certified as to compliance. The installer of
this crane and body is considered one of the manufacturers of the vehicle. As such a
manufacturer, the installer is responsible for compliance with all applicable federal and
state regulations, and is required to certify that the vehicle is in compliance.
WARNING! It is the further responsibility of the installer to comply with the OSHA
Truck Crane Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).
WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL
POWER LINES! Death or serious injury will result from boom, line, or load contacting
electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to
50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.
WARNING! NEVER .............................
vEXCEED load chart capacities (centerline of rotation to hoist hook).
vun-reel last 5 wraps of cable from drum!
vwrap cable around load!
vattempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
vweld, modify, or use unauthorized components on any Auto Crane unit! This will void any
warranty or liability. Also failure of the crane may result.
vplace a chain link on the tip of the hook and try to lift a load!
vuse a sling bar or anything larger than the hook throat that could prevent the hook latch from
closing, thus negating the safety feature!
vhold on any pendant Select Switch that will cause unsafe operating conditions!
WARNING! In using a hook with latch, ALWAYS make sure that the hook throat is closed
before lifting a load! Proper attention and common sense applied to the use of the hoist hook and
various slings will prevent possible damage to material being hoisted and may prevent injury to
personnel.
WARNING! Failure to correctly plumb and wire crane can cause inadvertent operation and
damage to crane and/or personnel!
WARNING! Auto Cr ane Company remote controlled cranes are not designed or intended to
be used for any applications involving the lifting or moving of personnel.
WARNING! ALWAYS operate the crane in compliance with the load capacity chart.
Do not use the overload shutdown device to determine maximum rated loads, if your crane is
equipped with this type of device.
warning 9/98
WARNINGS - READ THIS PAGE!

LAST PAGE
WARRANTY19 .................................................
13-1.0.0LOAD CHART18 ................................................
12-1.0.0TROUBLESHOOTING17 .........................................
11-1.0.0ELECTRICAL SECTION16 .......................................
10-7.0.0JACK LEG ASSEMBLY15 ........................................
10-6.0.0POWER CABLE ASSEMBLY14 ...................................
10-3.0.0HOIST ACTUATOR ASSEMBLY13 ................................
10-1.0.0GENERAL ASSEMBLY12 ........................................
9-1.0.0LIFE OF WIRE LINE / WIRE LINE LUBRICATION11 ..............................................................
8-1.0.0LUBRICATION & MAINTENANCE SCHEDULE10 ..................
7-2.0.0OPERATING INSTRUCTIONS9..................................
7-1.0.0INSTALLATION8..............................................
6-1.0.0GENERAL DIMENSIONS7......................................
5-1.0.0SAFETY DECAL SECTION6....................................
4-1.0.0INSPECTION, TESTING & MAINTENANCE5.....................
3-1.0.0QUALIFICATIONS FOR OPERATORS4...........................
2-2.0.0OPERATION OF UNIT / OUTRIGGERS3..........................
2-1.0.0OPERATING PRACTICES & WARNINGS2........................
1-1.0.0INTRODUCTION1.............................................
2003 SERIES - OWNER'S MANUAL
TABLE OF CONTENTS
PAGE

Auto Crane products have been engineered to
provide safe, trouble-free, dependable service for many
years when these products are properly used and
maintained.
To assist you in obtaining the best service from
your crane and to avoid untimely failure of the unit and
/ or the vehicle on which it is mounted, the following
operating and service instructions are herein published,
and it is specifically recommended that all operating
and service personnel consider this manual as
mandatory material for reading and study before
operating or servicing Auto Crane products. It is
highly recommended that crane owners, equipment
managers and supervisors also read this manual.
Auto Crane has incorporated several safety features
in the 2003 series for your protection. The material and
electrical systems were designed to minimize weight
and lengthen durability. For your convenience the
overall dimensions of the 2003 series are included on
page 6-1.0.0. Remember that the crane adds weight to
the vehicle and may change the driving and riding
characteristics of the vehicle on which it is mounted
unless this weight is properly provided for with
appropriate overload springs. The payload of the
vehicle is also reduced by the amount that the crane
weighs, and as the vehicle is loaded, care should be
exercised not to overload the vehicle. Exercising care
in distributing the payload on the vehicle will greatly
improve the driving and riding characteristics of the
vehicle.
The 2003 series cranes are attached directly to your
12 volt truck electrical system. The power cable and
retaining clips are included with the crane. A typical
power cable mounting and hookup is shown on page
7-1.0.0. The performance of your new crane depends
on the truck electrical system. The use of the low
maintenance battery is not recommended for use on any
Auto Crane product. The recommended alternator and
battery that will give the longest life with the most
useful duty cycle is a 70 amp. alternator with a 625 cold
cranking rated battery. These specifications should be
considered minimum.
Auto Crane Company issues a limited
warranty certificate with each unit sold.
See last page for warranty policy.
It has always been Auto Crane Company policy to
handle all warranty claims we receive as promptly as
possible. If a warranty claim involves discrepant
material or workmanship, Auto Crane will take
immediate corrective action. It is understandable that
Auto Crane company cannot assume responsibility of
liability when it is obvious that our products have been
abused, mis-used, overloaded or otherwise damaged by
inexperienced persons trying to operate the equipment
without reading the manual.
Auto Crane will not assume responsibility
or liability for any modifications or changes
made to unit, or installation of component
parts done without authorization.
Auto Crane maintains a strong distributor network
and a knowledgeable Customer Service Department. In
most cases, an equipment problem is solved via phone
conversation with our customer service department.
The customer service department also has the ability to
bring a local distributor, a regional sales manager, or a
factory serviceman into the solution of an equipment
problem. If, through no fault of Auto Crane Company,
it is necessary to send an experienced factory
serviceman on a field service call, the rates stated in the
Auto Crane Distributor's Flat Rate Manual will apply.
Auto Crane Company's extensive Research and
Development Program allow our customers to use the
best equipment on the market. Our Engineering Staff
and our knowledgeable sales people, are always
available to our customers in solving crane and
winch-type application problems. When in doubt, call
the Auto Crane factory.
DISTRIBUTOR ASSISTANCE:
Should you require any assistance not given in
this manual, we recommend that you consult your
nearest Auto Crane Distributor. Our distributors
sell authorized parts and have service departments
that can solve almost any needed repair.
NOTE: THIS MANUAL
SHOULD REMAIN WITH
THE CRANE AT ALL TIMES.
This manual does not cover all maintenance,
operating, or repair instructions pertinent to all
possible situations. If you require additional
information, please contact the Auto Crane
Company at the following telephone number: (918)
438-2760. The information contained in the manual
is in effect at the time of this printing. Auto Crane
Company reserves the right to update this material
without notice or obligation.
INTRODUCTION
2003 SERIES
1-1.0.0
2003INT
2/98

DIMENSIONS
Width: 19.0 in (.48 m)
Height: 21.0 in (.53 m)
Length: 6 ft 2 in (1.88 m)
8 ft 11 in (2.72 m)
[boom(s) stored]
Weight: 5-9 385 lbs (175 kg)
8-14 440 lbs (200 kg)
CAPACITY
6000 ft lbs (.8 Tm)
[ft lbs = horizontal distance from centerline of
rotation to free hanging weight (feet) x amount
of weight (pounds)]
6659
7608
8007
1,0006
1,1605
1,5654
2,0003
lbsft
LIFTING CAPACITIES
REACH
Manual boom will reach from 5 ft to 9 ft
Optional manual boom will reach from 8 ft to
14 ft
CABLE
50 ft (15.2 m) of 1/4 in diameter aircraft quality
cable is standard. This cable has a single line
breaking strength of 7,000 lbs (3,175 kg).
CHASSIS REQUIREMENTS
8,000 lbs (3,628 kg) GVWR minimum
ELECTRICAL SYSTEM
Hoist Motor: 12 volt DC series wound
ELECTRICAL SYSTEM
REQUIREMENTS
Alternator: 70 amp (minimum)
Battery: 625 cold cranking amps
100 minute reserve
capacity (minimum)
Maintenance type
ROTATION
360º Continuous manual rotation
1
GENERAL SPECIFICATIONS
2003 SERIES
1-2.0.0 SPEC 2/98

1.Make certain the vehicle meets minimum chassis
requirements. (These requirements do not guarantee
unit stability)
2.Make certain the crane is installed per factory
specifications. Contact your local Distributor or the
Auto Crane factory if any questions arise.
3.Keep the vehicle in as level a position as possible
while loading or unloading.
4.ALWAYS set the vehicle emergency brake before
beginning crane operations.
5.ALWAYS use outriggers from vehicle to the ground
during crane operation. Make sure they are firmly
positioned on solid footings.
6.All load ratings are based on crane capacity, NOT
truck/crane stability.
7.Keep objects and personnel clear of crane path during
operation.
8.Keep hoist cable pulled tight at all times.
9.REMEMBER, in lifting a heavy load, the weight can
create enough tipping momentum to overturn the
vehicle.
10.ALWAYS keep load as close to ground as possible.
11.Oil gears as required.
12.Periodic adjustment of hoist worm brake may be
required (see automatic safety brake drawing in this
manual).
13.Hydraulic hoses need to be inspected frequently for
signs of deterioration, and be replaced as required.
14.The hoist hook is an important item that an operator
should consider and use properly. It should be
checked on a daily basis for distortion or cracks.
15.ALWAYS store outriggers before road travel.
16.WARNING! NEVER OPERATE THE CRANE
NEAR ELECTRICAL POWER LINES! Death or
serious injury will result from boom, line, or load
contacting electric lines. Do not use crane within 10
feet (3.05m) of electric power lines carrying up to
50,000 volts. One foot additional clearance is
required for every additional 30,000 volts or less.
17.WARNING! NEVER EXCEED load chart
capacities (centerline of rotation to hoist hook).
18.WARNING! NEVER un-reel last 5 wraps of cable
from drum!
19.WARNING! NEVER wrap cable around load!
20.WARNING! NEVER attempt to lift or drag a load
from the side! The boom can fail far below its rated
capacity.
21.WARNING! NEVER weld, modify, or use
unauthorized components on any Auto Crane unit!
This will void any warranty or liability. Also failure
of the crane may result.
22.WARNING! NEVER place a chain link on the tip
of the hook and try to lift a load!
23.WARNING! NEVER use a sling bar or anything
larger than the hook throat that could prevent the
hook latch from closing, thus negating the safety
feature!
24.WARNING! In using a hook with latch, ALWAYS
insure that the hook throat is closed before lifting a
load! Proper attention and common sense applied to
the use of the hoist hook and various slings will
prevent possible damage to material being hoisted and
may prevent injury to personnel.
25.WARNING! NEVER hold any pendant Select
Switch on that will cause unsafe operating conditions!
--- IMPORTANT ---
OPERATING PRACTICES & WARNINGS
WARNING!
Auto Crane Company remote controlled, stiff boom cranes
are not designed or intended to be used for any applications
involving the lifting or moving of personnel.
2-1.0.0 SAFTIPS 2/98

26.Make sure this manual has been thoroughly read by
all crane operating personnel and supervisors.
27.A routine inspection of the crane should be mandatory
before each operating day. Any defects should be
corrected immediately.
28.At a job site the vehicle should be positioned so that
the crane can adequately reach the load within the
rated capacity (centerline of rotation to hoist hook).
29.Keep the vehicle as level as possible during operation.
30.For electric cranes, engage emergency brake and
leave ignition on with transmission in neutral (or in
park for automatic transmissions). Activate any crane
power switches. For Auto Crane units requiring
battery and hydraulic operation, engage emergency
brake, place gear selector in neutral, press clutch,
activate PTO, release clutch and after hydraulic fluid
is warm, set throttle control to proper engine speed.
31.Always use outriggers from the truck to the ground.
Be sure these are firm and adequately positioned.
When rotating, keep load as low to the ground as
possible.
32.Remove pendant control from cab or storage area. On
smaller units, plug pendant into receptacle on crane.
On larger units, remove pendant control from guard
and unwrap cable from boom. Do not operate crane
until cable is unwound completely. On all cranes,
detach hook from dead man. Crane is now ready for
operation.
33.Always boom up before rotating so the boom will
clear the required boom support.
34.When extending the boom, always maintain clearance
between the boom crown and the traveling block or
hoist hook.
35.Always observe safe and practical operation to avoid
possible accidents. Refer to Safety Tips and
Precautions.
36.After completing lifting operations, return the boom
to stowed position on the boom support. Avoid
unneeded pressure on the boom support.
37.Store pendant control on proper location (in cab or on
crane).
38.Return outriggers to stowed position. Make sure they
are pinned in place or jacklegs are returned to
compartment.
39.Check work area for any tools or equipment not
stored.
40.Release throttle control, depress clutch and disengage
PTO. Deactivate any crane power switches.
41.Report any unusual occurrence during crane operation
that may indicate required maintenance or repair.
42.NEVER use two cranes to support a load too large for
either crane.
43.Spray all electrical equipment with special corrosion
resistant coating. This eliminates rust or corrosion
due to melting and freezing action of condensation.
2-2.0.0 OPER 2/98
--- IMPORTANT ---
OPERATION OF UNIT
OPERATION OF
OUTRIGGERS
For hydraulic outriggers:
1.Shift crane/outrigger control valve to "outrigger"
position.
2.While operating the outrigger control valves
(located on the outrigger cylinders)
simultaneously operate the boom-up control
switch. This will allow the hydraulic system to
build pressure.
3.After outriggers are positioned, return
crane/outrigger selector to "crane" position.
4.Crane is now ready to operate.
For manual outriggers:
1.Pull lock pins to release jack leg or drop down
outrigger and move to outermost lock position.
2.Make sure lock pins are reinstalled properly.
3.Lower outrigger pad to firm ground and adjust
foot to take out slack.
4.Crane is now ready to operate.

OPERATORS
1Crane operation shall be limited to personnel with
the following minimum qualifications:
A.designated persons
B.trainees under the direct supervision of a designated
person
C.maintenance and test personnel (when it is
necessary in the performance of their duties)
D.inspectors (crane).
2No one other than the personnel specified above shall
enter the operating area of a crane with the exception
of persons such as oilers, supervisors, and those
specified persons authorized by supervisors whose
duties require them to do so and then only in the
performance of their duties and with the knowledge
of the operator or other persons.
QUALIFICATIONS FOR OPERATORS
3Operators shall be required by the employer to pass a
practical operating examination. Qualifications shall
be limited to the specific type of equipment for which
examined.
4Operators and operator trainees shall meet the
following physical qualifications:
A.Vision of at least 20/30 Snellen in one eye and
20/50 in the other, with or without corrective lenses.
B.Ability to distinguish colors, regardless of position,
if colors differentiation is required for operation.
C.Adequate hearing with or without hearing aid for
the specific operation.
5Evidence of physical defects or emotional instability
which render a hazard to operator or others, which
in the opinion of the examiner could interfere with
the operator's performance may be sufficient cause
for disqualification. In such cases, specialized clinical
or medical judgment and tests may be required.
6Evidence that the operator is subject to seizures or
loss of physical control shall be sufficient reason for
disqualification. Specialized medical tests may be
required to determine these conditions.
7Operators and operator trainees should have normal
depth perception, coordination, and no tendencies to
dizziness or similar undesirable characteristics.
8In addition to the above listed requirements, the
operator shall:
A.Demonstrate the ability to comprehend and interpret
all labels, operator's manuals, safety codes and other
information pertinent to correct crane operations.
B.Possess knowledge of emergency procedures and
implementation of same.
C.Demonstrate to the employer the ability to operate
the specific type of equipment.
D.Be familiar with the applicable safety regulations.
E.Understand responsibility for maintenance
requirements of crane.
F.Be thoroughly familiar with the crane and its
control functions.
G.Understand the operating procedures as outlined by
the manufacturer.
CONDUCT OF OPERATORS
9The operator shall not engage in any practice which
will divert his attention while actually operating the
crane.
10 Each operator shall be responsible for those
operations under the operator's direct control.
Whenever there is any doubt as to safety, the
operator shall consult with the supervisor before
handling the loads.
11 The operator should not leave a suspended load
unattended unless specific precautions have been
instituted and are in place.
12 If there is a warning sign on the switch or engine
starting controls, the operator shall not close the
switch or start the engine until the warning sign has
been removed by the appointed person.
13 Before closing the switch or starting the engine, the
operator shall see that all controls are in the "OFF"
or neutral position and all personnel are in the clear.
14 If power fails during operation, the operator shall:
A.move power controls to the "OFF" or neutral
position.
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
QUAL 7/98
3-1.0.0

B.land the suspended load and boom, if practical.
15 The operator shall be familiar with the equipment
and its proper care. If adjustments or repairs are
necessary, the operator shall report the same
promptly to the appointed person, and shall also
notify the next operator.
16 All controls shall be tested by the operator at the
start of each shift. If any controls do not operate
properly, they shall be adjusted or repaired before
operations are begun.
17 Stabilizers shall be visible to the operator while
extending or setting unless operator is assisted by a
signal person.
OPERATING PRACTICES
HANDLING THE LOAD
18 Size of load
A.No crane shall be loaded beyond the rated load
except for test purposes.
B.The load to be lifted is to be within the rated load of
the crane and its existing configuration.
C.When loads which are not accurately known are to
be lifted, the person responsible for the job shall
ascertain that the weight of the load does not exceed
the crane rated load at the radius at which the load
is to be lifted.
19 Attaching the load
A.The load shall be attached to the hook by means of
slings or other devices of sufficient capacity.
B.Hoist rope shall not be wrapped around the load.
20 Moving the load
A.The operator shall determine that:
B.The crane is level and, where necessary, the
vehicle/carrier is blocked properly.
C.The load is well secured and balanced in the sling or
lifting device before it is lifted more than a few
inches.
D.Means are provided to hold the vehicle stationary
while operating the crane.
E.Before starting to lift, the hook shall brought over
the load in such a manner as to minimize swinging.
F.During lifting care shall be taken that:
1.there is no sudden acceleration or
deceleration of the moving load.
2.load, boom or other parts of the crane do
not contact any obstruction.
G.Cranes shall not be used for dragging loads
sideways.
H.This standard recognizes that articulating boom
cranes are designed and intended for handling
materials. They do not meet personnel lift or
elevator requirements. Therefore, no lifting,
lowering, swinging or traveling shall be done while
a person is on the hook or load. Hook attached
suspended work platforms (baskets) shall not be
used with cranes covered by this standard. Work
platforms attached to the boom must be approved by
crane manufacturer.
I.The operator should avoid carrying loads over
people.
J.When the crane is so equipped, the stabilizers shall
be fully extended and set. Blocking under stabilizers
shall meet the requirements as follows:
1.strong enough to prevent crushing.
2.of such thickness, width and length as to
completely support the stabilizer pad.
K.Firm footing under all tires, or individual stabilizer
pads should be level. Where such a footing is not
otherwise supplied, it should be provided by
timbers, cribbing, or other structural members to
distribute the load so as to not exceed allowable
bearing capacity or the underlying material.
L.In transit, the boom shall be carried in stowed
position.
M.When rotating the crane, sudden starts and stops
shall be avoided. rotational speed shall be such that
the load does not swing out beyond the radius at
which it can be controlled.
N.The crane shall not be transported with a load on
the hook unless recommended by the manufacturer.
O.No person should be permitted to stand or pass
under a suspended load.
21 Stowing procedure. Follow the manufacturer's
procedure and sequence when stowing and
un-stowing the crane.
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
QUAL 7/98
3-2.1.0

MISCELLANEOUS
OPERATING NEAR ELECTRICAL POWER
LINES
22 Cranes shall be operated so that no part of the crane
or load enters into the danger zone shown above.
EXCEPTIONS
A.The danger zone may be entered after confirmation
by an appointed person that the electrical
distribution and transmission lines have been
de-energized and visibly grounded at the point of
work; or
B.The danger zone may be entered if insulating
barriers (not a part of nor an attachment to the
crane) have been erected to prevent physical contact
with the lines.
23 For lines rated 50 kV or below, minimum clearance
between the lines and any part of the crane or load
(including handling appendages) shall be 10 ft. (3m).
For higher voltages, see Table 1.
24 Caution shall be excercised when working near
overhead lines, because they can move horizontally or
vertically due to wind, moving the danger zone to new
positions.
25 In transit with no load and boom lowered the
clearance shall be specified in Table 1.
26 A qualified signalperson shall be assigned to observe
the clearance and give warning before approaching
the above limits.
A.Any overhead wire shall be considered to be an
energized line unless and until the person owning
such line or the electrical utility authorities verify
that it is not an energized line.
B.Exceptions to this procedure, if approved by the
administrative or regulatory authority if the
alternate procedure provides equivalent protection
and set forth in writing.
C.Durable signs shall be installed at the operator's
station and on the outside of the crane, warning that
electrocution or serious bodily injury may occur
unless a minimum clearance of 10 ft. (3.0m)
between the crane or the load being handled and
energized power lines. Greater clearances are
required because of higher voltage as stated above.
These signs shall be revised but not removed when
local jurisdiction requires greater clearances.
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
QUAL 7/98
3-3.2.0
(6.1)20over 750 to 1000 (4.87)16over 345 to 750 (3.83)10over 50 to 345 (1.83)6over 0.75 to 50 (1.22)4over to 0.75
while in transit with no load and boom lowered
(13.72)45over 750 to 1000 (10.67)35over 500 to 750 (7.62)25over 350 to 500 (6.1)20over 200 to 350 (4.6)15over 50 to 200 (3.05)10over to 50
when operating near high voltage power lines
(m)ft(phase to phase)
normal voltage, kV clearance
minimum required
TABLE 1

INSPECTION CLASSIFICATION
27 Initial inspection. Prior to initial use, all new, altered,
modified or extensively repaired cranes shall be
inspected by a designated person to insure compli-
ance with provisions of this standard.
28 Regular inspection. Inspection procedure for cranes
in regular service is divided into two general classifi-
cations based upon the intervals at which inspection
should be performed. The intervals in turn are
dependent upon the nature of the components of the
crane and the degree of their exposure to wear,
deterioration, or malfunction. The two general classi-
fications are herein designated as "frequent" and
"periodic" with respective intervals between inspec-
tions as defined below.
A.frequent inspection - daily to monthly intervals
B.periodic inspection - one to twelve intervals, or as
specifically recommended by the manufacturer
FREQUENT INSPECTION
29 Inspection shall be performed by designated
personnel.
A.control mechanisms for maladjustment interfering
with proper operation - daily, when used
B.control mechanisms for excessive wear of compo-
nents and contamination by lubricants or other
foreign matter
C.safety devices for malfunction
D.all hydraulic hoses, particularly those which flex in
normal operation of crane functions, should be
visually inspected once every working day, when
used
E.hooks and latches for deformation, chemical
damage, cracks, and wear. Refer to ANSI/ASME
B30.10
F.rope reeving for compliance with crane manufac-
turer's specifications, if optional winch is used
G.electrical apparatus for malfunctioning, signs of
excessive deterioration, dirt and moisture accumula-
tion
H.hydraulic system for proper oil level and leaks daily
I.tires for recommended inflation pressure, cuts and
loose wheel nuts
J.connecting pins and locking device for wear and
damage
PERIODIC INSPECTION
30 Deformed, cracked or corroded members in the
crane structure and carrier.
31 Loose bolts, particularly mounting bolts.
32 Cracked or worn sheaves and drums.
33 Worn, cracked, or distorted parts such as pins,
bearings, shafts, gears, rollers and devices.
34 Excessive wear on brake and clutch system parts and
lining.
35 Crane hooks inspected for cracks.
36 Travel steering, braking, and locking devices, for
malfunction.
37 Excessively worn or damaged tires.
38 Hydraulic and pneumatic hose, fittings, and tubing
inspection.
A.evidence of leakage at the surface of the flexible
hose or its junction with metal and coupling
B.blistering, or abnormal deformation to the outer
covering of the hydraulic or pneumatic hose
C.leakage at threaded or clamped joints that cannot be
eliminated by normal tightening or recommended
procedures
D.evidence or excessive abrasion or scrubbing on the
outer surface of a hose, rigid tube, or fitting. Means
shall be taken to eliminate the interference of
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSP 9/98
4-1.0.0

elements in contact or otherwise protect the
components
39 Hydraulic and pneumatic pumps and motors
inspection.
A.loose bolts or fasteners
B.leaks at joints between sections
C.shaft seal leaks
D.unusual noises or vibrations
E.loss of operating speed
F.excessive heating of the fluid
G.loss of pressure
40 Hydraulic and pneumatic valves inspection.
A.cracks in valve housing
B.improper return of spool to neutral position
C.leaks at spools or joints
D.sticking spools
E.failure of relief valves to attain or maintain correct
pressure setting
F.relief valve pressure shall be checked as specified by
the manufacturers
41 Hydraulic and pneumatic cylinders inspection.
A.drifting caused by fluid leaking across piston
B.rod seals leaking
C.leaks at welding joints
D.scored, nicked, or dented cylinder rods
E.damaged case (barrel)
F.loose or deformed rod eyes or connecting joints
42 Hydraulic filters. Evidence of rubber particles on the
filter elements may indicate hose, "O" ring, or other
rubber component deterioration. Metal chips or
pieces on the filter may denote failure in pumps,
motors, or cylinders. Further checking will be
necessary to determine origin of the problem before
corrective action can be taken.
43 Labels are to be in place and legible.
CRANES NOT IN REGULAR USE
44 A crane which has been idle for a period of over one
month or more, but not less than six months, shall be
given an inspection conforming with the initial-
regular- frequent inspections.
45 A crane which has been idle for a period of over six
months shall be given a complete inspection conform-
ing with the initial-regular-frequent inspection
requirements.
INSPECTION RECORDS
46 Dated records for periodic inspection should be made
on critical items such as brakes, crane hooks, rope,
hydraulic and pneumatic cylinders, and hydraulic
and pneumatic relief pressure valves. Records should
be kept available to an appointed person.
OPERATIONAL TESTS
47 Prior to initial use, all new, altered, modified, or
extensively repaired cranes shall be tested for compli-
ance with the operational requirements of this
section, including functions such as the following:
A.load lifting and lowering mechanisms
B.boom lifting and lowering mechanisms
C.boom extension and retraction mechanisms
D.swing mechanisms
E.safety devices
F.operating controls comply with appropriate function
labels
Operational crane test results shall be made
available to an appointed person.
RATED TEST LOAD
Prior to initial use, altered, modified, or
extensively repaired cranes shall be load
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSP 9/98
4-1.1.0

tested by or under the direction of an
appointed person.
48 Test loads shall not exceed 110% of the manufac-
turer's load ratings.
49 Written reports shall be maintained showing test
procedures and confirming the adequacy of repairs.
MAINTENANCE
PREVENTIVE MAINTENANCE
50 Before adjustment and repairs are started on a crane,
the following precautions shall be taken as
applicable:
A.crane placed where it will cause the least interfer-
ence with other equipment or operations
B.all controls at the "off" position
C.starting means rendered inoperative
D.boom lowered to the ground if possible or otherwise
secured against dropping
E.relieve hydraulic oil pressure from all hydraulic
circuits before loosening or removing hydraulic
components
51 Warning or "OUT OF ORDER" signs shall be placed
on the crane controls.
52 After adjustments and repairs have been made, the
crane shall not be returned to service until all guards
have been reinstalled, trapped air removed from
hydraulic system (if required), safety devices reacti-
vated, and maintenance equipment removed.
ADJUSTMENTS AND REPAIRS
53 Any hazardous conditions disclosed by the inspection
requirements shall be corrected before operation of
crane is resumed, Adjustments and repairs shall be
done only by designated personnel.
54 Adjustments shall be maintained to assure correct
functioning of components, The following are
examples:
A.functional operating mechanism
B.safety devices
C.control systems
55 Repairs or replacements shall be provided as needed
for operation.
The following are examples:
A.critical parts of functional operating mechanisms
which are cracked, broken, corroded, bent, or exces-
sively worn
B.critical parts of the crane structure which are
cracked, bent, broken, or excessively corroded
C.crane hooks showing cracks, damage, or corrosion
shall be taken out of service. Repairs by welding are
not recommended
56 Instructions shall be provided by the manufacturer
for the removal of air from hydraulic circuits.
LUBRICATION
All moving parts of the crane, for which
lubrication is specified, should be regularly
lubricated per the manufacturer's
recommendations and procedures.
ROPE INSPECTION
57 Frequent Inspection
A.All running ropes in service should be visually
inspected once each working day. A visual inspec-
tion shall consist of observation of all rope which
can be in use during the days operations. These
visual observations should be considered with
discovering gross damage such as listed below,
which may be an immediate hazard.
1.distortion of the rope such as kinking,
crushing, un-stranding, birdcaging, main
strand displacement, or core protrusion.
Loss of rope diameter in a short length or
unevenness of outer strands should be
replaced
2.general corrosion
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSP 9/98
4-1.2.0

3.broken or cut strands;
4.number, distribution and type of visible
broken wires. When such damage is
discovered, the rope shall either be
removed from service or given as
inspection.
B.Care shall be taken when inspecting sections of
rapid deterioration such as flange points, crossover
points, and repetitive pickup points on drums.
58 Periodic inspection
A.The inspection frequency shall be determined by a
qualified person and shall be based on such factors
as:
1.expected rope life as determined by
experience on the particular installation or
similar installations
2.severity of environment
3.percentage of capacity lifts
4.frequency rates of operation
5.exposure to shock loads
Inspection need not be at equal calendar
intervals and should be more frequent as the
rope approaches the end of it's service life.
This inspection shall be made at least
annually.
B.Periodic inspection shall be performed by a desig-
nated person. This inspection shall cover the entire
length of the rope. Only the surface wires need be
inspected. No attempt should be made to open the
rope. Any deterioration results in appreciable loss of
original strength, such as described below, shall be
noted and determination made as to whether use of
the rope would constitute a hazard: points listed
above reduction of rope diameter below nominal
diameter due to loss of core support, internal or
external corrosion, or wear of outside wires;
severely corroded, cracked, bent, worn or improp-
erly applied connections;
C.Care shall be taken when inspecting sections subject
to rapid deterioration such as the following:
1.sections in contact with saddles, equalizer
sheaves, or other sheaves where rope travel
is limited
2.sections of the rope at or near terminal ends
where corroded or broken wires may
protrude
ROPE REPLACEMENT
59 No precise rules can be given for determination of the
exact time for replacement of rope, since many
variable factors are involved.
Continued use in this respect depends upon
good judgement by a designated person in
evaluating remaining strength in a used rope
after allowance for deterioration disclosed by
inspection. Continued rope operation depends
upon this remaining strength.
60 Conditions such as the following shall be reason for
questioning continued use of the rope or increasing
the frequency of inspection:
A.in running ropes, six randomly distributed broken
wires in one lay or three broken wires in one strand
in one lay
B.one outer wire broken at the contact point with the
core of the rope structure and protrudes or loops out
of the rope structure. Additional inspection of this
section is required
C.wear of one third of the original diameter of the
outside individual wire
D.kinking, crushing, birdcaging, or any other damage
resulting in distortion of the rope structure
E.evidence of any heat damage from any cause
F.reduction from nominal diameter of more than 1/64
in. (0.4mm) for diameters up to and including 5/16
in. (8 mm), 1/32 in. (0.8 mm) for diameter 3/8 in.
(9.5 mm) to and including 1/2 in. (13 mm), 3/64 in.
(1.2 mm) for diameter 9/16 in. (14.5 mm) to and
including 3/4 in. (19 mm). 1/16 in. (1.6 mm) for
diameter 7/8 in. (22 mm) to and including 11/8 in.
(29 mm), 3/32 in. (2.4 mm) for diameters 11/4 in.
(32 mm) to and including 11/2 in. (38 mm)
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSP 9/98
4-1.3.0

G.In standing ropes, more than two broken wires in
one lay in sections beyond end connections or more
than one broken wire at an end connection.
H.Replacement rope shall have a strength rating at
least as great as the original rope furnished or
recommended by the crane manufacturer. Any
deviation from the original size, grade, or construc-
tion shall be specified by a rope manufacturer, or a
qualified person.
61 Rope not in regular use: all rope which has been idle
for a period of a month or more due to shutdown or
storage of a crane on which it is installed, shall be
given and inspection in accordance with above infor-
mation before it is placed in service. This inspection
shall be for all types of deterioration and shall be
performed by a qualified person.
62 Inspection records
A.frequent inspection- no records required
B.periodic inspections- in order to establish data as a
basis for judging the proper time for replacement, a
dated report condition at each periodic inspection
should be kept on file. This report shall cover
points of deterioration listed above.
ROPE MAINTENANCE
63 Rope should be stored to prevent damage or
deterioration.
64 Unreeling or uncoiling of rope shall be done as
recommended by the rope manufacturer and with
care to avoid kinking or inducing twist.
65 Before cutting a rope, seizing shall be placed on each
side of the place where the rope is to be cut to prevent
unlaying of the strands. On pre-formed rope, one
seizing on each side of the cut is required. On
non-preformed ropes of 7/8 in. (22 mm) diameter or
smaller, two seizings on each side of the cut are
required, and for non-preformed rope 1 in. (25 mm)
diameter or larger, three seizings on each side of the
cut are required.
66 During installation care should be exercised to avoid
dragging of the rope in the dirt or around objects
which will scrape, nick crush or induce sharp bends
in it.
67 Rope should be maintained in a well-lubricated
condition. It is important that lubricant applied as a
part of a maintenance program shall be compatible
with the original lubricant and to this end the rope
manufacturer should be consulted. Lubricant applied
shall be the type which does not hinder visual inspec-
tion. Those sections of rope which are located over
sheaves or otherwise hidden during inspection and
maintenance procedures require special attention
when lubricating rope. The object of rope lubrication
is to reduce internal friction and to prevent corrosion.
68 When an operating rope shows greater wear or well
defined localized areas than on the remainder of the
rope, rope life can be extended in cases where a
section at the worn end, and thus shifting the wear to
different areas of the rope.
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSP 9/98
4-1.4.0

Maintenance of Auto Crane unit batteries differs very
little from the generally prescribed maintenance of any
lead acid battery. All batteries must be kept properly
charged, properly filled with water, and relatively
clean.
Keep Properly Charged
Many things affect the proper charge to a battery, such
as:
1 Regulator settings
2Proper tightness of belts on the alternator
or generator
3Good, clean connections of all cables
and wires at the following places:
A. Battery
B. Regulator
C. Starting motor
D. Alternator or generator
E. Ground connections (most important)
It is of extreme importance to keep the battery as fully
charged as possible without overcharging, especially
when vehicles are left outside for extended periods in
extremely cold climates. A battery can freeze.
Freezing points for various specific gravities of acid are
as follows:
Specific Gravity Freezing Temp.
(Corrected to 80ºF) Degrees F.
1.280 -90ºF
1.250 -62ºF
1.200 -16ºF
1.150 5ºF
1.100 19ºF
As shown, a half-charged battery (about 1.200 specific
gravity) cannot stand for any length of time at 20ºF or it
will freeze.
The main reason for keeping the battery as fully
charged as possible without over-charging is to ensure
that power is available even though the vehicle has been
standing for some time.
Keep Properly Filled with Water
The battery should always be properly filled with water.
If the electrolyte level is allowed to fall below the top of
the plates, the results become threefold:
1 The exposed portion of the plate will become
sulfated.
2The portion of the plate exposed is not usable.
3That portion of the acid remaining becomes more
concentrated and may cause more rapid
deterioration of the remaining parts of the battery.
Keep A Relatively Clean Battery
The battery should be kept clean. Batteries filled with
acid and which are not in use self-discharge to a limited
degree because of the nature of the materials within the
battery. If dirt is allowed to collect on the top of the
battery (and this dirt absorbs moisture) and electrical
path can be set up between the various terminals of the
battery and the ground. Once such a path has been
established, the self-discharge of the battery is
accelerated. This also accelerates corrosion of the
battery cables at the terminals.
Periodic Maintenance is Needed
A definite program of periodic maintenance of all
batteries should be conducted on a regular basis.
Periodic maintenance includes:
1 Checking belts for tightness on the charging
equipment
2Checking battery electrolyte levels
3Checking cables for good connections
4Cleaning where corrosion is apparent
When corrosion is cleaned off, the cable terminals and
battery terminals should be coated with a light coating
of petroleum jelly before they are replaced. When
terminals are cleaned, the top of the battery should be
cleaned with a mild solution of soda water.
MAINTBAT 9/98
MAINTENANCE OF BATTERIES
4-2.1.0.

Low Maintenance Batteries
(Maintenance Free)
Low maintenance batteries should not be used on
Auto Cranes or trucks equipped with Auto Cranes.
The batteries are not designed for "deep" discharge.
Testing Your Battery
If the condition of the battery is in question, it should be
removed from the vehicle, taken to the shop, and
allowed to reach room temperature. It should then be
recharged until specific gravity readings taken at
one-half hour intervals. If the specific gravity readings
are fairly uniform, the battery should be checked with a
high rate tester. Use the tester in accordance with the
manufacturer's instructions. The high rate tester is the
best method to test a questionable battery.
If, after charging, it is noted that the specific gravity
reading of one cell is 30 points less than any of the
other cells, it may be assumed that the cell is bad and
that the battery should be replaced. If all cells are
uniform but not up to full charge, a low rate of charge
should be attempted for an extended time. This usually
will recover a badly sulfated battery.
Replacing a Battery
If it is necessary to replace a battery, and a dry charge
battery is used, the following procedure applies:
1 Fill the battery with electrolyte of the proper
specific gravity.
2Place the battery on charge according to the
manufacturer's instructions.
It is essential that the second step above be followed to
ensure that the battery going on the vehicle is fully
charged.
It is also very important that the battery hold-downs be
checked periodically to ensure that the batteries are
properly positioned to avoid vibration problems,
breakage of cables or terminals. Care must be taken to
avoid cracking or breaking containers or covers by
tightening hold-down fixtures excessively. They also
must not be so loose that breakage results from a
hold-down that is too loose.
MAINTBAT 9/98
MAINTENANCE OF BATTERIES
4-2.2.0.

2003DEC 2/98
SAFETY DECAL SECTION
(see page 5-3.0.0, Item 1)
Both sides of upper boom
PLACEMENT:
2
QUANTITY:
To inform the operator of the hazard
of proximity or contact with the
crane boom during operation.
FUNCTION:
STAY CLEAR OF BOOM
DECAL:
040517
PART NO.:
(see page 5-3.0.0,
Item 6)
Down hall weight
PLACEMENT:
2
QUANTITY:
To inform the
operator of the
hazard of proximity
or contact with the
crane load during
operation.
FUNCTION:
STAY CLEAR OF
LOAD
DECAL:
040518
PART NO.:
FIG. SD-1.
(see page 5-3.0.0, Item 9)
To inform the operator of
possible danger at scissors point
on crane.
FUNCTION:
Lower boom
PLACEMENT:
SCISSORS POINT
DECAL:
1
QUANTITY:040519
PART NO.:
FIG. SD-3.
FIG. SD-2.
5-1.0.0

2003DEC 2/98
SAFETY DECAL SECTION
FIG. SD-4.
(see page 5-3.0.0, Item 5)
Housing weldment
PLACEMENT:
1
QUANTITY:
To inform the operator of the
proper procedure to follow for
safe operation of the crane.
FUNCTION:
OPERATION INSTRUCTIONS
DECAL:
040579
PART NO.:
FIG. SD-5.
5-2.0.0
(see page 5-3.0.0, Item 10)
To inform the operator of the
hazard involved with contacting
electrical power lines with crane
boom.
FUNCTION:
Lower boom
PLACEMENT:
ELECTROCUTION HAZARD
DECAL:
2
QUANTITY:040529
PART NO.: