Auto Crane 3203H User manual

3203H
OWNERS MANUAL
Manual No. 999954
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

To: Fax:
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

3203H 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.

LAST PAGE
WARRANTY20 ...............................................
9-1.0.0LOAD CHART19 ..............................................
7-1.0.0HYDRAULIC SECTION18 ......................................
6-1.0.0ELECTRICAL SECTION17 ......................................
4-1.0.0GENERAL DIMENSIONS16 .....................................
3-6.0.0TRAVELING BLOCK ASSEMBLY15 .............................
3-5.0.0AUTOMATIC SAFETY BRAKE ASSEMBLY14 ....................
3-4.0.0TURNER ASSEMBLY13 ........................................
3-3.0.0HOIST ACTUATOR ASSEMBLY12 ..............................
3-2.0.02-BLOCK ASSEMBLY11 .......................................
3-1.0.0GENERAL ASSEMBLY10 ......................................
2-1.0.0MOUNTING & INSTALLATION9 ...............................
1-8.0.0LUBRICATION & MAINTENANCE SCHEDULE8 .................
1-7.0.0SAFETY DECAL SECTION7 ...................................
1-6.0.0LIFE OF WIRE LINE / WIRE LINE LUBRICATION6 ...............
1-5.0.0INSPECTION, TESTING, & MAINTENANCE5 ....................
1-4.0.0QUALIFICATIONS FOR OPERATORS4 ..........................
1-3.0.0OPERATION OF UNIT / OUTRIGGERS3 ........................
1-2.0.0OPERATING PRACTICES & WARNINGS2 .......................
1-1.0.0INTRODUCTION1 ............................................
3203H SERIES - OWNER'S MANUAL
TABLE OF CONTENTS
PAGE

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
3203H Series cranes for your protection. The choice of
materials and the design of the electrical system minimizes
weight and lengthens durability. The hydraulic components
meet or exceed a 3.5:1 safety factor. Holding valves prevent
the load from dropping if a hose should fail. The hydraulic
manifold has a 10 micron strainer with relief at the inlet.
For your convenience the overall dimensions of the
3203H Series crane are on the General Dimension Drawing.
Maximum turning radius is shown at the outside edge of the
back cover.
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. A minimum G.V.W. of 8,000
lbs. with two rear jacklegs (or outriggers) is recommended
for mounting the 3203H crane.
The 3203H crane is attached directly to your truck
hydraulic power supply. The performance of your new crane
depends on the truck hydraulic system. The system should
supply 5 gpm at 2200 psig. Although this unit is fully
proportional, any flow above 5.75 gpm will automatically
bypass back to tank. This process will add heat to the
hydraulic system. For more information please read the
hydraulic section of this manual.
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: [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.
3203Hintro 8/02
INTRODUCTION
3203H SERIES
1-1.0.0

Dimensions
Width: 24 in (.61 m)
23.25 (.59 m)
Height: 27.25 in (.69 m)
31.31 in (.80 m)
Length: 8 ft 6 in (2.59 m) [boom(s) stored]
Weight: 630 lbs (286 kg)
[Add 5 lbs (2.25 kg) for cable length
of 75 feet (23 m)]
Capacity
10,500LBS. (1.5 TON/M)
[ft lbs = horizontal distance from centerline of
rotation to free hanging weight (feet) x amount of
weight (pounds)]
1,1669
700151,3158
750141,5007
808131,7506
875122,1005
955112,6254
1,050103,2003
lbsftlbsft
LIFTING CAPACITIES
Reach
Main boom reaches 7 ft
Power boom will extend to 11 ft
Manual boom will extend to 15 ft
Cable
62 ft (18.9 m) of 7/32" diameter aircraft quality
single line breaking strength of 5,600 lbs (2,540
kg).
Chassis Requirements
8,000 lbs (3,629 kg) GVWR minimum
Hydraulic System
Pressure: 2200 psi (15,173 kPa) relief setting
Flow: 5 gpm (19 lpm)
Filtration: High pressure 10 micron in
manifold
Oil type: 10w Hydraulic Oil
[Mobile DTE 13, Sun 2015,
Pennzbell AWX, Dextron II]
Hoist Motor: 2.2 cid geroter
Rotation Motor: 11.3 cid geroter
Movement Speeds: (Proportional Maximum)
Hoist: 34 fpm single line (no load)
31 fpm single line (1000 lbs)
Boom Up: 7 sec
Boom Dn: 6 sec
Extend out: 9 sec
Extend in: 7 sec
Rotation: 23 sec / revolution
Electrical System Requirements
Control voltage: 12 volt DC
GENERAL SPECIFICATIONS
3203H
3203HSPEC 8/02
1-1.1.0

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.
1-2.0.0 SAFTIPS 2/98

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 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.
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 pendant control on proper location (in cab or on
crane).
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.
18. Spray all electrical equipment with special corrosion
resistant coating. This eliminates rust or corrosion due
to melting and freezing action of condensation.
1-3.0.0
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
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.
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
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
QUAL 7/98
1-4.0.0

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
1-4.1.0

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
1-4.2.0
(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
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 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
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 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
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. 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
elements in contact or otherwise protect the
components
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSP 9/98
1-5.0.0

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 neces-
sary 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 conform-
ing 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 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
tested by or under the direction of an
appointed person.
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSP 9/98
1-5.1.0

22 Test loads shall not exceed 110% of the manufac-
turer'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 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
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 reacti-
vated, 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 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
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 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
3. broken or cut strands;
4. number, distribution and type of visible
broken wires. When such damage is
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSP 9/98
1-5.2.0