Auto Crane 8406H NEXSTAR User manual

8406 H
OWNERS MANUAL
Manual No. 480899
Rev. 07/26/2004
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

8406H 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
4/23/04 Page 3-2, 5-2 & 8-9 Updated receiver & transmitter to 2nd generation
07/26/04 Pages 10-2.0.0, 10-
3.0.0, 10-5.0.0, 10-
6.0.0, 10-9.0.0 &
10-10-.0.0
Added voltage relay circuit

WARNINGS
WARNINGS
READ THIS PAGE!
*WARNING!
Federal law
(
49 cfr
p
art 571
)
re
q
uires that the Final Sta
g
e 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 manufac-
turers 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 res
p
onsiblit
y
of the installer to com
p
l
y
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 in
j
ur
y
will result from boom
,
line
,
or load contactin
g
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 re
q
uired for ever
y
additional 30
,
000 volts or less. SEE DANGER DECAL
(
P/N 040529
)
in this Owner's Manual.
* WARNING! NEVER.........................................
* EXCEED load chart ca
p
acities
(
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 usin
g
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 correctl
y
p
lumb and wire crane can cause inadvertent o
p
eration and dama
g
e
to crane and/or personnel!
* WARNING! Auto Crane Com
p
an
y
remote controlled cranes are not desi
g
ned or intended to be
used for any applications involving the lifting or moving of personnell.
* WARNING! ALWAYS o
p
erate the crane in com
p
liance with the load ca
p
acit
y
chart. DO NOT
USE the overload shutdown device to determine maximum rated loads
,
if the crane is e
q
ui
pp
ed
with this t
yp
e of device.

TABLE OF CONTENTS
8406H SERIES
6/02/2003
INTRODUCTION 1-1
OPERATING PRACTICES & WARNINGS 2-2
OPERATION OF UNIT / OUTRIGGERS 2-3
CONTROLLER OPERATION 2-4
QUALIFCATIONS FOR OPERATORS 2-6
INSPECTION, TESTING, & MAINTENCE 2-9
DECAL SECTION 2-14
GENERAL DIMENSIONS 3-1
MOUNTING AND INSTALLATION 3-2
LUBRICATION AND MAINTENANCE SCHEDULE 4-1
PEDESTAL ASSEMBLY 5-1
BOOM ASSEMBLY 5-3
ROTATION GEAR BOX 5-5
HOIST ASSEMBLY 5-7
GENERAL ASSEMBLY 5-11
ELECTRICAL SCHEMATIC 6-1
WIRE HARNESS ASSEMBLY 6-2
HYDRAULIC SECTION 7-1
DIAGNOSTICS 8-1
LOAD CHART 9-1
HARD WIRED SERIES, SUPPLIMENTAL INFORMATION 10-1
WARRANTY LAST 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 8406H crane for your protection.
For your convenience the overall dimensions of the
8406H 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 policy.
The 8406H cranes are attached directly to your 12
volt truck electrical system. The power cable is
included with the crane. The 8406H is another highly
efficient Auto Crane product. 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 75 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
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.
INTRODUCTION
8406H SERIES
1-1 INTRO 8406H 1/02

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.
8406HSAFT 06/02
2-1.0.0
--- IMPORTANT ---
SAFETY TIPS AND PRECAUTIONS
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

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:
ydo NOT allow personnel to ride on loadline,
hook, load, or any other device attached to winch
line.
ydo NOT extend boom without reeling off line at
the same time when using winch.
ydo 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.
8406HSAFT 06/02
--- IMPORTANT ---
SAFETY TIPS AND PRECAUTIONS
2-1.1.0

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. 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!
--- IMPORTANT ---
OPERATING PRACTICES & WARNINGS
WARNING!
Auto Crane Company remote controlled, stiff boom cranes
are not designed or intended to be used for any applications
involving the lifting or moving of personnel.
2 - 2 SAFTIPS 1/02

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 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 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.
2 - 3
OPER 1/02
--- IMPORTANT ---
OPERATION OF UNIT
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.

Transmitter Layout: The red light to the left of the Power On/Off button indicates low transmitter battery.
(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
come on when a function is activated.
In addition to the two lights mentioned above there are four function toggle switches. 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. There are also buttons for auxiliary functions such as Engine Start/Stop and Engine Fast
Idle.
Power On/Off (E-Stop) Button: To turn the transmitter on, press and hold the Power On/Off button, release
once the transmit light becomes solid. To turn the unit off, press and hold the power button, release once the
transmit light stops flashing. 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.
When turning the unit off, it will first send the emergency stop signal to the crane, then power down. When
the transmitter is powered back up, the system will be in emergency stop mode and EC18 will be displayed
when a function is activated. To exit E-Stop mode, press the red button once momentarily.
IMPORTANT – THE POWER ON/OFF BUTTON ALSO OPERATES AS AN E-STOP. PRESS THE
BUTTON MOMENTARILY TO DISABLE CRANE FUNCTIONS. THE E-STOP WILL NOT STOP
THE TRUCK ENGINE.
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. Using the forefinger of the hand holding
the unit, slowly pull the trigger back to start the function. The speed of the function increases as the trigger is
pulled. More than one function can be activated at one time.
NOTE: A FUNCTION SWITCH MUST BE ACTIVATED BEFORE THE TRIGGER IS PULLED OR
THE CRANE WILL NOT OPERATE.
2 - 4
OPER 7/02
CONTROLLER OPERATIONS

Auxiliary Buttons:
Press the Engine Fast/Slow button to provide a maintained voltage to a throttle control if one
is installed.
Press the Engine Start/Stop button to start and stop the engine if wired to do so.
Safety Features:
For safety reasons the speed of all functions, excluding the hoist, is reduced when the lift
cylinder pressure exceeds a set pressure. This will occur under load or under boom down operation.
To limit slow operation of an unloaded crane, activate boom up momentarily after booming down to
relieve cylinder pressure created by the counterbalance valve.
The crane is also equipped with an anti-bridging feature. The logic in the receiver will not
allow the operator to rest the boom of the crane on a load supporting structure and lift a load. Doing
so is dangerous and could damage the crane. When the crane is bridged, the receiver will display
‘RSBM’ which requires the boom to be raised. This feature is disabled when the crane is in the
‘HOME’ position to allow for stowing.
Operation Failure:
If the crane does not operate as expected, observe the readout through the window on the
receiver and refer to the front panel for explanation. The codes are further explained in the Diagnos-
tics section of this manual. Please note that ‘NRML’ is displayed when the crane is operating
normally and ‘HOME’ is displayed when the crane is forward and in a position to be stowed.
“NRML” and “Home” will only be displayed when a function is activated, “EC01” is displayed when
no function is activated.
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 opera-
tion of the crane.
The transmitter should be fully charged after approximately 6 to 8 hours of charging. Charg-
ing the transmitter for extended periods (3 or 4 days) is not recommended. Doing so will eventually
degrade the battery and it will not keep a good charge.
2 - 5
OPER 1/02
CONTROLLER OPERATION

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
2 - 6

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
2 - 7

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
2 - 8
(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