Auto Crane 3203 PR: 3203 PRX User manual

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3203 PR/PRX/PRFX
OWNERS MANUAL
Serial No. __________________
Mailing Address:
P.O. Box 580697 Tulsa,
OK 74158-0697 Physical
Address: 4707 N. Mingo
Rd. Tulsa, OK 74117-5904
Phone [phone]
Fax [phone]
http://www.autocrane.com

Product Registration Rev 05152014
Auto Crane Registration
From: Date:
End User Information:
Company: Phone:
Address:
City: State: Zip:
Contact: E-mail:
Distributor Information:
Company: Phone:
Address:
City: State: Zip:
Contact: E-mail:
Product Information:
Model No: Serial No: Date Delivered:
VIN #:
ONE REGISTRATION FORM PER UNIT (CRANE, BODY, OR COMPRESSOR)
Please submit form within 15 days after installation
Online: www.autocrane.com | Resources | Warranties
Fax: [phone]
Mail: Product Registration, Auto Crane Company, PO Box 580697, Tulsa, OK 74158-0697

READ THIS PAGE
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 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. 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 for use 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.
WARNINGS

3203 PR/PRX/PRFX
TABLE OF CONTENTS
INTRODUCTION ……………………………………………………………… 1
GENERAL SPECIFICATIONS ……………………………………………………………… 3
SAFETY TIPS AND PRECAUTIONS ……………………………………………………………… 4
OPERATING PRACTICES & WARNINGS ……………………………………………………………… 6
QUALIFICATIONS FOR OPERATORS ……………………………………………………………… 7
OPERATION OF UNIT / OUTRIGGERS ……………………………………………………………… 11
INSPECTION ……………………………………………………………… 12
TESTING ……………………………………………………………… 15
MAINTENANCE ……………………………………………………………… 16
BATTERIES ……………………………………………………………… 18
LUBRICATION AND MAINTENANCE SCHEDULE ……………………………………………………………… 20
SINGLE LINE PROCEDURE ……………………………………………………………… 22
ROTATION BEARING REPLACEMENT ……………………………………………………………… 23
SAFETY DECAL SECTION ……………………………………………………………… 24
GENERAL DIMENSIONS ……………………………………………………………… 31
MOUNTING AND INSTALLATION ……………………………………………………………… 32
GENERAL ASSEMBLY, HARDWIRED ……………………………………………………………… 34
PEDESTAL ASSEMBLY ……………………………………………………………… 40
BOOM ASSEMBLY ……………………………………………………………… 52
HOIST ASSEMBLY ……………………………………………………………… 49
TRAVELING BLOCK ASSEMBLY ……………………………………………………………… 63
RELAY PANEL ASSEMBLY ……………………………………………………………… 65
ELECTRICAL SECTION, HARDWIRED ……………………………………………………………… 66
PENDANT ASSEMBLY ……………………………………………………………… 68
TWECO W/SWITCH MOUNT ……………………………………………………………… 71
HYDRAULIC SECTION ……………………………………………………………… 72
POWER UNIT ……………………………………………………………… 75
GENERAL ASSEMBLY, FM ……………………………………………………………… 76
FM CONTROL USE & CARE ……………………………………………………………… 82
TRANSMITTER ASSEMBLY, FM ……………………………………………………………… 83
ELECTRICAL SECTION, FM ……………………………………………………………… 85
FM, DIAGNOSTICS, TROUBLESHOOTING, AND ID PROG. ……………………………………………………………… 86
LOAD CHART ……………………………………………………………… 94
CONVERSION TO SINGLE LINE ................................................................ 95

1
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 instruc-
tions. 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 crane for your
protection.
For your convenience the overall dimensions
of the 3203 PR/PRX 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.
Auto Crane Company issues a limited
warranty certificate with each unit sold.
See last page for warranty.
The 3203 PR/PRX cranes are attached to your
truck electrical system through the Main Power
Switch provided. The
3203 PR/PRX is another highly efficient
Auto Crane product. The use of a maintenance-
free battery is not recommended on any Auto
Crane product. The recommended alternator
and battery
that will give the longest life with the most useful
duty cycle is a 125-amp alternator with a 500 cold
cranking amp battery. These specifications should
be considered minimum.
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 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.
Note: This manual should remain with the
crane at all times.
3203PR/PRX
INTRODUCTION

2
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. 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.
3203PR/PRX
INTRODUCTION

3
DIMENSIONS
Width: 21 in (0.53 m)
Height: 24.00 in (0.61 m)
Length: 9 ft 1-1/2 in (2.78 m)
[boom(s) stored]
Weight: 860 lbs (390kg)
CAPACITY
10,000 ft-lbs (1.38 tt-m)
[ft-lbs = horizontal distance from centerline
of rotation to free hanging weight (feet) x
amount of weight (pounds)]
REACH
Second boom will reach from 7 feet 4
inches to 11 feet 4 inches.
Third boom will reach from 11 feet 4
inches to 15 feet 4 inches.
CABLE
62 ft (18.9) of 7/32 in (5.56 mm) diameter
aircraft quality cable. This cable has a single
line breaking strength of
5,600 lbs (2,540 kg).
CHASSIS REQUIREMENTS
201,600 in-lbs (22,777 Nm) RBR minimum
8,800 LBS (3,992 kg.) GVWR minimum
ELECTRICAL SYSTEM
REQUIREMENTS
Voltage: 12 VDC
Alternator: 125 amp (minimum)
Battery: 130 minute reserve
capacity (minimum)
Maintenance type
ROTATION
360º Continuous
LIFTING CAPACITIES
Ōlbs Ōlbs
2 3,200 9 1,100
3 3,200 10 1,000
4 2,500 11 900
5 2,000 12 830
6 1,670 13 770
7 1,500 14 710
8 1,250 15 660
TANK OIL CAPACITY
2.4 GALLONS (9.08 LITERS)
3203PR/PRX
GENERAL SPECIFICATIONS

4
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 insure 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
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. (Not
applicable to electric-hydraulic cranes.)
26. Always extend the outriggers from vehicle to the
ground before crane operation. Insure 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.
SAFETY TIPS AND PRECAUTIONS
--- IMPORTANT ---

5
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.
(Not applicable to electric-hydraulic cranes.)
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.
(Not applicable to electric-hydraulic cranes.)
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 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; similarly do not lift anything with
boom extensions.
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. Do not wrap the wire rope around sharp
objects when using winch.
47. WARNING: Never unreel last 5 wraps of
cable from drum.
--- IMPORTANT ---
SAFETY TIPS AND PRECAUTIONS

6
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.W
ARNING! 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 5wraps 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
aload! Proper attention and common senseapplied
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! 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 for use on any applications involving the lifting or moving of personnel.
--- IMPORTANT ---
OPERATING PRACTICES AND WARNINGS

7
REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE QUALIFICATION
REQUIREMENTS
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
1. 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.
2. 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 color differentiation is required for
operation.
C. Adequate hearing with or without hearing aid
for the specific operation.
3. 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.
4. Evidence that 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.
5. Operators and operator trainees should have normal
depth perception, coordination, and no tendencies to
dizziness or similar undesirable characteristics.
6. 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. Posses the knowledge of emergency procedures
and implement it.
C. Demonstrate to the employer the ability to
operate the specific type of equipment.
D. Be familiar with the applicable safety regulations.
E. Understand the operating procedures as outlined
by the manufacturer.
F. Be thoroughly familiar with the crane and its
control functions.
G. Understand the operating procedures as outlined
by the manufacturer.
CONDUCT OF OPERATORS
1. The operator shall not engage in any practice, which
will divert his attention while actually operating the
crane.
2. 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.
3. The operator should not leave a suspended load
unattended unless specific precautions have been
instituted and are in place.
4. 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.
5. Before closing the switch or starting the engine, the
operator shall see that all controls are in the “OFF”
QUALIFICATIONS FOR AND CONDUCT OF
OPERATORS AND OPERATING PRACTICES

8
or neutral position and all personnel are in the clear.
6. 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.
7. 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.
8. The operator at the start of each shift shall test all
controls. If any controls do not operate properly, they
shall be adjusted or repaired before operations are
begun.
9. Stabilizers shall be visible to the operator while
extending or setting unless a signal person assists
operator.
OPERATING PRACTICES/HANDLING THE
LOAD
1. 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 that 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.
2. 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.
3. Moving the load.
The operator shall determine that:
A. The crane is level and, where necessary, the
vehicle/carrier is blocked properly.
B. The load is well secured and balanced in the
sling or lifting device before it is lifted more
than a few inches.
C. Means are provided to hold the vehicle
stationary while operating the crane.
D. Before starting to lift, the hook shall be
positioned over the load in such a manner as to
minimize swinging.
E. 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.
F. Cranes shall not be used for dragging loads
sideways.
G. This standard recognizes that telescopic 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. Crane manufacturer must approve
work platforms attached to the boom.
H. The operator should avoid carrying loads over
people.
I. 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.
J. Firm footing under all tires, or individual
stabilizer pads should be level. Where such
a footing is not otherwise supplied, timbers,
cribbing, or other structural members to
distribute the load so as to not exceed allowable
bearing capacity or the underlying material
should provide it.
K. In transit, the boom shall be carried in stowed
position.
L. 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.
M. The crane shall not be transported with a
load on the hook unless recommended by the
manufacturer.
QUALIFICATIONS FOR AND CONDUCT OF
OPERATORS AND OPERATING PRACTICES

9
N. No person should be permitted to stand or
pass under a suspended load.
4. Stowing procedure.
Follow the manufacturer’s procedure and sequence
when stowing and un-stowing the crane.
MISCELLANEOUS
OPERATING NEAR ELECTRICAL POWER
LINES
1. 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.
2. 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.
3. 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.
4. In transit with no load and boom lowered the clearance
shall be specified in Table 1.
5. 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 are allowed, if approved
by the administrative or regulatory authority
provided the alternate procedure insures equivalent
protection and is 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 operating near high voltage power lines
QUALIFICATIONS FOR AND CONDUCT OF
OPERATORS AND OPERATING PRACTICES

10
200° F (93.3°C)
180° F (82.2°C)
160° F (71.1° C)
140° F (60° C)
120° F (48.9°C)
100° F (37.8°C)
80° F (26.7° C)
60° F (15.6° C)
40° F (4.4°C)
20° F (-6.6°C)
0° F (-17.8 C)
-20° F (-28.9° C)
-40° F (-40°C)
5W20 ANTI-WEAR
HYDRAULIC OIL OR
EQUIVALENT
HySyn ISO32 SYNTHETIC
HYDRAULIC OIL OR
EQUIVALENT
CAUTION! HYDRAULIC RESERVOIR OIL TEMPERATURE MUST NOT EXCEED
180°F OR DAMAGE TO CRANE MAY OCCUR. THIS MAY AFFECT
CRANE WARRANTY
NOTES
1. In applications where low oil temperatures may exist (below -20°F), an external
heating system may be required.
2. A symptom of excessively low temperatures is hydraulic motor operation but
no fluid flow from tank.
OIL TEMPERATURE
RANGE - SMALL EH CRANES
RECOMMENDED OPERATING TEMPERATURE

11
1. Make sure this manual has been thoroughly read
by all crane operating personnel and supervisors.
2. Aroutine 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 enginespeed.
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 from cab or storage area.
Power transmitter 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 powerswitches.
16. Report any unusual occurrence during crane
operation that may indicate required maintenance or
repair.
17.NEVER use two cranes to support aload too large
for either crane.
HYDRAULIC OUTRIGGERS
1. Shift crane/outrigger control valve to
“outrigger” position.
2. Operate the outrigger control valves to
position the outriggers.
3. After outriggers are positioned, return
crane/outrigger selector to “crane”
position.
4. Crane is now ready to operate.
MANUAL OUTRIGGERS
1. Pull lock pins to release jackleg 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.
OPERATION OF
OUTRIGGERS
--- IMPORTANT ---
OPERATION OF UNIT

12
REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE INSPECTION REQUIREMENTS
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 or before each use
B. Periodic inspection - one to twelve-month
intervals or as specifically recommended by the
manufacturer or qualified person.
FREQUENT INSPECTION
Inspections should also occur during operation for
any deficiencies that might appear between regular
inspections. Any deficiencies, such as those listed below,
shall be carefully examined and a determination made as
to whether they constitute a hazard:
1. Inspect control mechanisms for maladjustment that
interferes with proper operation.
2. Inspect control mechanisms for excessive wear of
components and contamination by lubricants or other
foreign matter.
3. Inspect safety devices for malfunction.
4. Visually inspect all hydraulic hoses, particularly
those that flex in normal operation of crane functions.
5. Inspect hooks and latches for deformation, chemical
damage, cracks, and wear. Refer to ANSI/ASME B30.10.
6. Inspect for proper rope reeving.
7. Inspect electrical wiring and components for
malfunctioning, signs of excessive deterioration, dirt
and moisture accumulation.
8. Inspect hydraulic system for proper oil level and leaks.
9. Inspect tires for recommended inflation pressure, cuts
and loose wheel nuts.
10. Inspect connecting pins and locking device for wear
damage and loose retaining bolts.
11. Inspect rope for gross damage, such as listed below,
which may be an immediate hazard.
A. Distortion such as kinking, crushing, unstranding,
birdcaging, main strand displacement, or core
protrusion. Loss of rope diameter in a short length or
unevenness of outer strands should be replaced.
B. General corrosion.
C. Broken or cut strands.
D. Use care when inspecting sections of rapid
deterioration around flange points, crossover points,
and repetitive pickup points on drums.
E. Inspect number, distribution, and type of visible
broken wires. Reference Rope Maintenance section
in the owner’s manual.
Continued use of rope depends upon good
judgment 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.
DESIGNATED PERSONNEL SHALL
PERFORM INSPECTIONS ONLY.
INSPECTION
REQUIREMENTS