Auto Crane 3203 PR: 3203 PRX User manual

3203 PR/PRX/
PRD/PRXD
OWNERS MANUAL
Manual No. 320950000
Rev. 9/2/2003
Serial No. __________________
Mailing Address:
P.O. Box 580697
Tulsa, OK 74158-0697
Physical Address: Phone [phone]
4707 N. Mingo Rd. Fax [phone]
Tulsa, OK 74117-5904 http://www.autocrane.com

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From: Date:
Re: Pages:
Name: Phone:
Address:
City: State: Zip:
Contact:
Name:
Address:
City: State: Zip:
Contact:
VIN #
ONE REGISTRATION FORM PER UNIT (CRANE OR BODY)
Registration form must be mailed or faxed within 15 days of customer installation.
Mail to:
Warranty Department
Auto Crane Company
P.O. Box 581510
Tulsa, OK 74158-0697
Date Product Delivered: Date Processed:*
* For Auto Crane use only
Product Information: (Required for Warranty Activation)
Model No.: Serial No.:
E-mail Address:
Distributor Information: (Required for Warranty Activation)
Product Registration
E-mail Address:
(Required for Warranty Activation)
Auto Crane Warranty Registration
[phone]Warranty Department
End User Information:
Fax Transmission
Warranty Registration Rev. 072403

3203 PR PRX PRD PRXD SERIES
OWNER’S MANUAL – REVISION RECORD
i
Revision
Date
Section(s)
Or
Page(s)
Description of Change
09/02/03 Last page New 2-year warranty policy to replace 1-year warranty policy

WARNINGS
READ THIS PAGE
Warnings 12/2002
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 state are also considered intermediate stage manufacturing and must
be certified as to compliance. The installer of this crane and body is considered on 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. SEE DANGER DECAL (P/N 040529)
in this Owner's Manual.
WARNING! NEVER.........................................
♦ EXCEED load chart capacities (centerline of rotation to hoist hook).
♦ Un-reel last 5 wraps of cable from drum!
♦ Wrap cable around load!
♦ Attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
♦ 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.
♦ Place a chain link on the tip of the hook and try to lift a load!
♦ Use a sling bar or anything larger than the hook throat that could prevent the hook latch from
closing, thus negating the safety feature!
♦ Hold 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 Crane 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 the crane is equipped with this
type of device.

TABLE OF CONTENTS
3203 PR/PRX SERIES
05/23/03
INTRODUCTION 1-1.0.0
OPERATING PRACTICES & WARNINGS 2-1.0.0
OPERATION OF UNIT / OUTRIGGERS 2-4.0.0
CONTROLLER OPERATION 2-5.0.0
QUALIFICATIONS FOR OPERATORS 2-7.0.0
INSPECTION, TESTING, & MAINTENANCE 2-10.0.0
DECAL SECTION 2-15.0.0
GENERAL DIMENSIONS 3-1.0.0
GENERAL SPECS. 3-2.0.0
MOUNTING AND INSTALLATION 3-3.0.0
LUBRICATION AND MAINTENANCE SCHEDULE 4-1.0.0
PEDESTAL ASSEMBLY 5-1.0.0
BOOM ASSEMBLY 5-6.0.0
HOIST ASSEMBLY 5-8.0.0
GENERAL ASSEMBLY 5-11.0.0
ELECTRICAL SCHEMATIC 6-1.0.0
RELAY PANEL ASSEMBLY 6-5.0.0
HYDRAULIC SECTION 7-1.0.0
TROUBLESHOOTING GUIDE - DIAGNOSTICS 8-1.0.0
LOAD CHART 9-1.0.0
WARRANTY LAST PAGE

INTRODUCTION
3203 SERIES
1-1.0.0
05/22/2003
Auto Crane products are designed to provide
many years of safe, trouble-free, dependable
service when properly used and maintained.
To assist you in obtaining the best service
from your crane and to avoid untimely crane
and/or vehicle failure, this manual provides the
following operating and service instructions. 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 3203 PR/PRX Series cranes for
your protection.
For your convenience the overall dimensions
of the 3203 PR/PRX Series crane are included on
the General Dimension Drawing. Rotation and
turning radius are also listed on that drawing.
Remember, the crane adds weight to the
vehicle. Adding weight may change the driving
and riding characteristics of the vehicle unless
the appropriate overload spring(s) are installed
on the truck. The payload of the vehicle is
reduced by the weight of the crane. The operator
should exercise care when loading the vehicle.
Distributing the payload on the vehicle evenly
will greatly improve the driving and riding
characteristics of the vehicle.
The 3203 PR/PRX cranes are attached
directly to your 12 volt truck electrical system.
The power cable is included with the crane. The
use of a maintenance-free 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 60 amp alternator
with a 500 cold cranking amp battery. These
specifications should be considered minimum.
Auto Crane Company issues a
limited warranty certificate with each
unit sold. See last page for warranty
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, misused, 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:
[phone]. 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.

--- IMPORTANT ---
OPERATING PRACTICES AND WARNINGS
2-1.0.0
05/22/2003
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. Hydraulic hoses need to be inspected frequently for signs
of deterioration, and be replaced as required.
12. 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.
13. ALWAYS store outriggers before road travel.
14. 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.
15. WARNING! NEVER EXCEED load chart
capacities (centerline of rotation to hoist hook).
16. WARNING! NEVER un-reel last 5 wraps of cable
from drum!
17. WARNING! NEVER wrap cable around load!
18. WARNING! NEVER attempt to lift or drag a load
from the side! The boom can fail far below its rated
capacity.
19. 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.
20. WARNING! NEVER place a chain link on the tip of
the hook and try to lift a load!
21. 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!
22. 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. Switch on that will
cause unsafe operating conditions!
WARNING! NEVER hold any Control Select
Switch on that will cause unsafe operating conditions!
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.

--- IMPORTANT ---
SAFETY TIPS AND PRECAUTIONS
2-2.0.0
05/22/2003
1. No unqualified or unauthorized person shall be
allowed to operate the crane.
2. WARNING: Never weld, modify, or use
unauthorized components / parts on any Auto Crane
unit. This will void any warranty or liability. Also,
failure of the crane may result.
3. Make certain the vehicle meets minimum chassis
requirements. (These requirements do not guarantee
unit stability.)
4. Make certain the crane is installed per factory
specifications. Contact your local distributor or the
Auto Crane factory if any questions arise.
5. Visual inspections and tests should be conducted at
the beginning of each shift each day to ensure that the
crane and all its operating systems are in good
condition and working order before it is used.
6. Inspect hydraulic hoses frequently for signs of
deterioration, and replace them as required.
7. If a hydraulic break occurs, leave the area of the
break and do not attempt to stop the break by hand as
the hydraulic oil may be hot and under high pressure
which can cause serious injury. Shut the system
down as soon as possible.
8. Check the hook at least every thirty days for
distortions or cracks and replace it as required.
9. Oil gears as required.
10. Stop all operations when cleaning, adjusting or
lubricating the machine.
11. Keep dirt and grit out of moving parts by keeping a
crane clean. Make sure machine is free of excess oil,
grease, mud and rubbish, thus reducing accidents and
fire hazards.
12. When a new cable is installed, operate first with a
light load to let the cable adjust itself.
13. Locate the vehicle at the work site for the best
stability possible.
14. Keep the vehicle in a level position while loading or
unloading.
15. Observe operating area for obstructions and/or power
lines that might be a hazard
16. WARNING: NEVER OPERATE THE CRANE
NEAR ELECTRICAL POWER LINES. Auto Crane
Company recommends that the crane never be any
closer to a power line (including telephone lines) than
10 feet at any point.
17. Allow the vehicle engine to warm up before
operating crane.
18. Know the weight of your rigging and load to avoid
overloading the crane.
19. Deduct the weight of the load handling equipment
from the load rating to determine how much weight
can be lifted.
20. All load ratings are based on crane capacity, NOT the
vehicle stability.
Remember in lifting a heavy load, the weight can
create enough tipping moment to overturn the vehicle
21. Always comply with load chart capacities, (centerline
of rotation to hook).
22. Secure all loads before lifting.
23. Always set the emergency brake before beginning
operation.
24. Keep objects and personnel clear of crane path during
operation.
25. Operate control levers slowly and smoothly in order
to meter oil flow for safe operation.
26. Always use outriggers from vehicle to the ground
during crane operation. Ensure that they are firmly
positioned on solid footings. Stand clear of
outriggers while they are being extended.
27. If any outrigger, when extended, rests on a curb or
other object that prevents it from extending to its
maximum distance, shorten bearing or fulcrum point
and reduce the maximum load accordingly.
28. When an outrigger will not reach the ground due to
holes or grades, it shall be blocked up to provide
level and firm support for the truck.
29. When working in soft earth, use wide pads under
outrigger feet to prevent sinking.
30. Always store outriggers before transportation.
WARNING!
Auto Crane Company cranes are not designed or intended for use in lifting or moving persons. Any such use
shall be considered to be improper and the seller shall not be responsible for any claims arising there from.
This sale is made with the express understanding that there is no warranty that the goods shall be fit for the
purpose of lifting or moving persons or other improper use and there is no implied warranty or responsibility
for such purposes.

--- IMPORTANT ---
SAFETY TIPS AND PRECAUTIONS
2-3.0.0
05/22/2003
31. Always store the crane in its stowed position for
transportation.
32. Remember the overall height of the entire unit for
garage door clearance or when moving under
objects with low overhead clearance
33. Disengage power takeoff (PTO) before moving
the vehicle.
34. Always walk around the vehicle before moving.
35. Never drive with a load suspended from crane.
36. Do not take your eyes off a moving load. Look
in the direction you are moving.
37. Never swing a load over people.
38. Do not stop the load sharply in midair so that it
swings like a pendulum. Meter the control levers
to avoid this situation.
39. Crane boom length should be kept as short as
possible for maximum lifting capacity and greater
safety. Longer booms require additional care in
accelerating and decelerating the swing motion,
and thus slow down the working cycle and reduce
productivity.
40. Keep the load directly and vertically under the
boom point at all times. Crane booms are
designed primarily to handle vertical loads, not
side lifts.
WARNING: Never attempt to lift, drag, tow or
pull a load from the side. The boom can fail far
below its rated capacity.
41. Do not push down on anything with boom
extensions, lift or outer boom function.
42. Do not lift personnel with any wire rope
attachment or hook. There is no implied
warranty or responsibility for such purposes.
43. WARNING: In using a safety hook, ALWAYS
close the hook throat before lifting a load. Proper
attention and common sense applied to the use of
the hook and various slings will prevent possible
damage to material being hoisted and may
prevent injury to personnel.
44. WARNING: Never place a chain link on the tip
of the hook and try to lift a load with the hoist.
45. WARNING: Never use a sling bar or anything
larger than the hook throat which could prevent
the safety latch from closing, thus negating the
safety feature.
46. If the crane is equipped with an optional winch:
 do NOT allow personnel to ride on
loadline, hook, load, or any other device
attached to winch line.
 do NOT extend boom without reeling off
line at the same time when using winch.
 do pull load-block up against the boom tip.
47. Do not wrap the wire rope around sharp objects
when using winch.
48. WARNING: Never unreel last 5 wraps of cable
from drum.

--- IMPORTANT ---
OPERATION OF UNIT
2-4.0.0
05/22/2003
1. Make sure this manual has been thoroughly read by
all crane operating personnel and supervisors.
2. A routine inspection of the crane should be
mandatory before each operating day. Any defects
should be corrected immediately.
3. 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).
4. Keep the vehicle as level as possible during
operation.
5. 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.
6. 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.
7. Remove the transmitter/pendant from cab or storage
area. Power transmitter/pendant on. Detach hook
from dead man. Crane is now ready for operation.
8. Always boom up before rotating so the boom will
clear the required boom support.
9. When extending the boom, always maintain clearance
between the boom crown and the traveling block or
hoist hook.
10. Always observe safe and practical operation to avoid
possible accidents. Refer to Safety Tips and
Precautions.
11. After completing lifting operations, return the boom to
stowed position on the boom support. Avoid
unneeded pressure on the boom support.
12. Store transmitter in proper location (in cab or storage
area).
13. Return outriggers to stowed position. Make sure they
are pinned in place or jacklegs are returned to
compartment.
14. Check work area for any tools or equipment not
stored.
15. Release throttle control, depress clutch and disengage
PTO. Deactivate any crane power switches.
16. Report any unusual occurrence during crane operation
that may indicate required maintenance or repair.
17. NEVER use two cranes to support a load too large for
either crane.
OPERATION OF
OUTRIGGERS
For hydraulic outriggers:
1. Shift crane/outrigger control valve to
"outrigger" position.
2. Operate the outrigger control valves (located
on the outrigger cylinders) to position the
outriggers.
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.

CONTROLLER OPERATIONS
3203 SERIES
2-5.0.0
05/22/2003
Power: The power switch for both the hardwire pendants and the FM receiver is located on the
rear of the relay panel which is on the street side of the crane.
Transmitter Layout: The red light to the left of the Power On/Off button indicates low
transmitter battery. As the battery runs down, the light will begin to flash. It will flash increasingly
faster as the battery power decreases. (see “Charging the Transmitter”)
The green light to the right of the Power On/Off button indicates that the unit is
transmitting. This light will flash when a function is activated.
In addition to the two lights mentioned above there are four function toggle switches
(three on PR models). These functions from left to right are used to raise and lower the boom,
raise and lower the hoist cable, rotate the crane and extend and retract the boom.
Power On/Off Button: To turn the transmitter on, press and release the Power On/Off button.
To turn the unit off, press and release the power button again. When this button is pressed both
the red battery low and the green transmit light will flash alternately and stop flashing once the
unit is either on or off.
Function Switches: To operate a function, toggle one of the function switches with either the
thumb of the hand holding the unit or the thumb or fingers of the opposite hand.
Operation Failure:
If the crane does not operate as expected, observe the red light on the receiver and refer
to the front panel for explanation. The codes are further explained in the Diagnostics section of
this manual.
Charging the Transmitter:
The transmitter can be charged using one of three methods. It can be charged with the
cigarette lighter charger, the pendant cable or the optional AC adapter (P/N 366505000). To
charge the transmitter with the pendant cable, the crane must have electrical power. The crane
can be operated by pendant or by FM remote therefore the battery can be charged without
suspending operation of the crane.

CONTROLLER OPERATIONS
3203 SERIES
2-6.0.0
05/22/2003
The transmitter should be fully charged after approximately 6 to 8 hours of charging. It is
not recommended to leave the transmitter charging for extended periods of time (3 or 4 days).
Doing so will eventually degrade the battery and it will not keep a good charge.

QUALIFICATIONS FOR AND CONDUCT OF OPERATORS
AND OPERATING PRACTICES
2-7.0.0
05/23/2003
OPERATORS
1. Crane 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).
2. No 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
3. Operators 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.
4. Operators 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.
5. Evidence 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.
6. Evidence 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.
7. Operators and operator trainees should have
normal depth perception, coordination, and no
tendencies to dizziness or similar undesirable
characteristics.
8. In 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
9. The 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.
B. land the suspended load and boom, if practical.

QUALIFICATIONS FOR AND CONDUCT OF OPERATORS
AND OPERATING PRACTICES
2-8.0.0
05/23/2003
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
2-9.0.0
05/23/2003
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
Table1.
24. Caution shall be exercised 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.
normal voltage, kV
(phase to phase) ft (m)
over to 50 10 (3.50)
over 50 to 200 15 (4.6)
over 200 to 350 20 (6.1)
over 350 to 500 25 (7.62)
over 500 to 750 35 (10.67)
over 750 to 1000 45 (13.72)
over to 0.75 4 (1.22)
over 0.75 to 50 6 (1.83)
over 50 to 345 10 (3.83)
over 345 to 750 16 (4.87)
over 750 to 1000 20 (6.1)
while in transit with no load and boom lowered
TABLE 1
minimum required
____clearance____
when operatin
g
near hi
g
h volta
g
e poower lines

INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSPECTION CLASSIFICATION
1. Initial inspection. Prior to initial use, all new,
altered, modified or extensively repaired cranes
shall be inspected by a designated person to
insure compliance with provisions of this
standard.
2. Regular inspection. Inspection procedure for
cranes in regular service is divided into two
general classifications 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 classifications are
herein designated as "frequent" and "periodic"
with respective intervals between inspections
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
3. 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
components 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
manufacturer's specifications, if optional winch
is used
G. electrical apparatus for malfunctioning, signs of
excessive deterioration, dirt and moisture
accumulation
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
4. Deformed, cracked or corroded members in the
crane structure and carrier
5. Loose bolts, particularly mounting bolts.
6. Cracked or worn sheaves and drums.
7. Worn, cracked, or distorted parts such as pins,
bearings, shafts, gears, rollers and devices.
8. Excessive wear on brake and clutch system
parts and lining.
9. Crane hooks inspected for cracks.
10. Travel steering, braking, and locking devices,
for malfunction.
11. Excessively worn or damaged tires.
12. 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. A. blistering, or abnormal deformation to the
outer covering of the hydraulic or pneumatic
hose
C. A. leakage at threaded or clamped joints that
cannot be eliminated by normal tightening or
recommended procedures
D. A. 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 elements in contact or otherwise
protect the components
2-10.0.0
05/23/2003

INSPECTION, TESTING AND MAINTENANCE
GENERAL
13. 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
14. 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
15. 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
16. 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.
17. Labels are to be in place and legible.
CRANES NOT IN REGULAR USE
18. 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
19. A crane which has been idle for a period of
over six months shall be given a complete
inspection conforming with the initial-regular-
frequent inspection requirements.
INSPECTION RECORDS
20. 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
21. Prior to initial use, all new, altered, modified, or
extensively repaired cranes shall be tested for
compliance 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
tested by or under the direction of an
appointed person.
2-11.0.0
05/23/2003

INSPECTION, TESTING AND MAINTENANCE
GENERAL
22. Test loads shall not exceed 110% of the
manufacturer's load ratings.
23. Written reports shall be maintained showing
test procedures and confirming the adequacy
of repairs.
MAINTENANCE
PREVENTIVE MAINTENANCE
24. 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
interference 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
25. Warning or "OUT OF ORDER" signs shall be
placed on the crane controls.
26. 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 reactivated, and maintenance
equipment removed.
ADJUSTMENTS AND REPAIRS
27. 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.
28. Adjustments shall be maintained to assure
correct functioning of components, The
following are examples:
A. functional operating mechanism
B. safety devices
C. control systems
29. 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 excessively 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
30. 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
31. Frequent Inspection
A. All running ropes in service should be visually
inspected once each working day. A visual
inspection 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
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.
2-12.0.0
05/23/2003

INSPECTION, TESTING AND MAINTENANCE
GENERAL
B. Care shall be taken when inspecting sections
of rapid deterioration such as flange points,
crossover points, and repetitive pickup points
on drums.
32. 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
designated 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 improperly 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
33. 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.
34. 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)
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.
2-13.0.0
05/23/2003

INSPECTION, TESTING AND MAINTENANCE
GENERAL
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
construction shall be specified by a rope
manufacturer, or a qualified person.
35. 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 information before it is
placed in service. This inspection shall be for
all types of deterioration and shall be
performed by a qualified person.
36. Inspection records
A. A. frequent inspection- no records
required
B. A. 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
37. Rope should be stored to prevent damage or
deterioration.
38. Unreeling or uncoiling of rope shall be done as
recommended by the rope manufacturer and
with care to avoid kinking or inducing twist.
39. 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.
40. 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.
41. 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 inspection. 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.
42. 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.
2-14.0.0
05/23/2003