Auto Crane 5005H SERIES User manual

5005H
OWNERS MANUAL
Manual No. 360706000
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

5005H 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
12/30/03 Mounting & Instl.
(p. 3-2.0.0)
Lub. & Maintenance
(p.4-1.0.0)
Revised torque specs for mounting hardware for crane,
rotation bearing and rotation gear box.
4/23/04 Pages 3-2.0.0, 5-1.0.0
& 8-9.0.0
Updated receiver & transmitter to 2nd generation
07/26/04 Pages 10-1.0.0, 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
READ THIS PAGE
Warnings 12/2002
WARNING! Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of a vehicle
certify that the vehicle complies with all applicable federal regulations. Any modifications performed
on the vehicle prior to the final state are also considered intermediate stage manufacturing and must
be certified as to compliance. The installer of this crane and body is considered on of the
manufacturers of the vehicle. As such a manufacturer, the installer is responsible for compliance
with all applicable federal and state regulations, and is required to certify that the vehicle is in
compliance.
WARNING! It is the further responsibility of the installer to comply with the OSHA Truck Crane
Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).
WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL POWER LINES!
Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane
within 10 feet (3.05m) of electric power lines carrying up to 50,000 volts. One foot additional
clearance is required for every additional 30,000 volts or less. SEE DANGER DECAL (P/N 040529)
in this Owner's Manual.
WARNING! NEVER.........................................
♦ EXCEED load chart capacities (centerline of rotation to hoist hook).
♦ Un-reel last 5 wraps of cable from drum!
♦ Wrap cable around load!
♦ Attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
♦ Weld, modify, or use unauthorized components on any Auto Crane unit! This will void any
warranty or liability. Also failure of the crane may result.
♦ Place a chain link on the tip of the hook and try to lift a load!
♦ Use a sling bar or anything larger than the hook throat that could prevent the hook latch from
closing, thus negating the safety feature!
♦ Hold on any pendant Select Switch that will cause unsafe operating conditions!
WARNING! In using a hook with latch, ALWAYS make sure that the hook throat is closed before
lifting a load! Proper attention and common sense applied to the use of the hoist hook and various
slings will prevent possible damage to material being hoisted and may prevent injury to personnel.
WARNING! Failure to correctly plumb and wire crane can cause inadvertent operation and damage
to crane and/or personnel!
WARNING! Auto Crane Company remote controlled cranes are not designed or intended to be
used for any applications involving the lifting or moving of personnel.
WARNING! ALWAYS operate the crane in compliance with the load capacity chart. DO NOT USE
the overload shutdown device to determine maximum rated loads, if the crane is equipped with this
type of device.

TABLE OF CONTENTS
5005H SERIES
6/04/2003
INTRODUCTION 1-1.0.0
OPERATING PRACTICES & WARNINGS 2-2.0.0
OPERATION OF UNIT / OUTRIGGERS 2-3.0.0
CONTROLLER OPERATION 2-4.0.0
QUALIFCATIONS FOR OPERATORS 2-6.0.0
INSPECTION, TESTING, & MAINTENCE 2-9.0.0
DECAL SECTION 2-14.0.0
GENERAL DIMENSIONS 3-1.0.0
MOUNTING AND INSTALLATION 3-2.0.0
LUBRICATION AND MAINTENANCE SCHEDULE 4-1.0.0
PEDESTAL ASSEMBLY 5-1.0.0
BOOM ASSEMBLY 5-4.0.0
ROTATION GEAR BOX 5-6.0.0
HOIST ASSEMBLY 5-8.0.0
GENERAL ASSEMBLY 5-11.0.0
ELECTRICAL SCHEMATIC 6-1.0.0
WIRE HARNESS ASSEMBLY 6-2.0.0
HYDRAULIC SECTION 7-1.0.0
DIAGNOSTICS 8-1.0.0
LOAD CHART 9-1.0.0
HARD WIRED SERIES, SUPPLIMENTAL INFORMATION 10-1-0.0
WARRANTY LAST PAGE

NOTES

INTRODUCTION
5005H SERIES
1-1.0.0
12/2002
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 5005H crane for your protection.
For your convenience the overall dimensions
of the 5005H 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 5005H cranes are attached directly to
your 12 volt truck electrical system. The power
cable is included with the crane. The 5005H 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.

--- IMPORTANT ---
SAFETY TIPS AND PRECAUTIONS
1. No unqualified or unauthorized person shall be
allowed to operate the crane.
2. WARNING: Never weld, modify, or use
unauthorized components / parts on any Auto Crane
unit. This will void any warranty or liability. Also,
failure of the crane may result.
3. Make certain the vehicle meets minimum chassis
requirements. (These requirements do not guarantee
unit stability.)
4. Make certain the crane is installed per factory
specifications. Contact your local distributor or the
Auto Crane factory if any questions arise.
5. Visual inspections and tests should be conducted at
the beginning of each shift each day to ensure that the
crane and all its operating systems are in good
condition and working order before it is used.
6. Inspect hydraulic hoses frequently for signs of
deterioration, and replace them as required.
7. If a hydraulic break occurs, leave the area of the
break and do not attempt to stop the break by hand as
the hydraulic oil may be hot and under high pressure
which can cause serious injury. Shut the system
down as soon as possible.
8. Check the hook at least every thirty days for
distortions or cracks and replace it as required.
9. Oil gears as required.
10. Stop all operations when cleaning, adjusting or
lubricating the machine.
11. Keep dirt and grit out of moving parts by keeping a
crane clean. Make sure machine is free of excess oil,
grease, mud and rubbish, thus reducing accidents and
fire hazards.
12. When a new cable is installed, operate first with a
light load to let the cable adjust itself.
13. Locate the vehicle at the work site for the best
stability possible.
14. Keep the vehicle in a level position while loading or
unloading.
15. Observe operating area for obstructions and/or power
lines that might be a hazard
16. WARNING: NEVER OPERATE THE CRANE
NEAR ELECTRICAL POWER LINES. Auto Crane
Company recommends that the crane never be any
closer to a power line (including telephone lines) than
10 feet at any point.
17. Allow the vehicle engine to warm up before
operating crane.
18. Know the weight of your rigging and load to avoid
overloading the crane.
19. Deduct the weight of the load handling equipment
from the load rating to determine how much weight
can be lifted.
20. All load ratings are based on crane capacity, NOT the
vehicle stability.
Remember in lifting a heavy load, the weight can
create enough tipping moment to overturn the vehicle
21. Always comply with load chart capacities, (centerline
of rotation to hook).
22. Secure all loads before lifting.
23. Always set the emergency brake before beginning
operation.
24. Keep objects and personnel clear of crane path during
operation.
25. Operate control levers slowly and smoothly in order
to meter oil flow for safe operation.
26. Always use outriggers from vehicle to the ground
during crane operation. Ensure that they are firmly
positioned on solid footings. Stand clear of
outriggers while they are being extended.
27. If any outrigger, when extended, rests on a curb or
other object that prevents it from extending to its
maximum distance, shorten bearing or fulcrum point
and reduce the maximum load accordingly.
28. When an outrigger will not reach the ground due to
holes or grades, it shall be blocked up to provide
level and firm support for the truck.
29. When working in soft earth, use wide pads under
outrigger feet to prevent sinking.
30. Always store outriggers before transportation.
WARNING!
Auto Crane Company cranes are not designed or intended for use in lifting or moving persons. Any such use
shall be considered to be improper and the seller shall not be responsible for any claims arising there from.
This sale is made with the express understanding that there is no warranty that the goods shall be fit for the
purpose of lifting or moving persons or other improper use and there is no implied warranty or responsibility
for such purposes.
2-1.0.0
12/2002

--- IMPORTANT ---
SAFETY TIPS AND PRECAUTIONS
31. Always store the crane in its stowed position for
transportation.
32. Remember the overall height of the entire unit for
garage door clearance or when moving under
objects with low overhead clearance
33. Disengage power takeoff (PTO) before moving
the vehicle.
34. Always walk around the vehicle before moving.
35. Never drive with a load suspended from crane.
36. Do not take your eyes off a moving load. Look
in the direction you are moving.
37. Never swing a load over people.
38. Do not stop the load sharply in midair so that it
swings like a pendulum. Meter the control levers
to avoid this situation.
39. Crane boom length should be kept as short as
possible for maximum lifting capacity and greater
safety. Longer booms require additional care in
accelerating and decelerating the swing motion,
and thus slow down the working cycle and reduce
productivity.
40. Keep the load directly and vertically under the
boom point at all times. Crane booms are
designed primarily to handle vertical loads, not
side lifts.
WARNING: Never attempt to lift, drag, tow or
pull a load from the side. The boom can fail far
below its rated capacity.
41. Do not push down on anything with boom
extensions, lift or outer boom function.
42. Do not lift personnel with any wire rope
attachment or hook. There is no implied
warranty or responsibility for such purposes.
43. WARNING: In using a safety hook, ALWAYS
close the hook throat before lifting a load. Proper
attention and common sense applied to the use of
the hook and various slings will prevent possible
damage to material being hoisted and may
prevent injury to personnel.
44. WARNING: Never place a chain link on the tip
of the hook and try to lift a load with the hoist.
45. WARNING: Never use a sling bar or anything
larger than the hook throat which could prevent
the safety latch from closing, thus negating the
safety feature.
46. If the crane is equipped with an optional winch:
 do NOT allow personnel to ride on
loadline, hook, load, or any other device
attached to winch line.
 do NOT extend boom without reeling off
line at the same time when using winch.
 do pull load-block up against the boom tip.
47. Do not wrap the wire rope around sharp objects
when using winch.
48. WARNING: Never unreel last 5 wraps of cable
from drum.
2-1.1.0
12/2002

--- IMPORTANT ---
OPERATING PRACTICES AND WARNINGS
1. Make certain the vehicle meets minimum chassis
requirements. (These requirements do not guarantee unit
stability)
2. Make certain the crane is installed per factory
specifications. Contact your local Distributor or the
Auto Crane factory if any questions arise.
3. Keep the vehicle in as level a position as possible while
loading or unloading.
4. ALWAYS set the vehicle emergency brake before
beginning crane operations.
5. ALWAYS use outriggers from vehicle to the ground
during crane operation. Make sure they are firmly
positioned on solid footings.
6. All load ratings are based on crane capacity, NOT
truck/crane stability.
7. Keep objects and personnel clear of crane path during
operation.
8. Keep hoist cable pulled tight at all times.
9. REMEMBER, in lifting a heavy load, the weight can
create enough tipping momentum to overturn the
vehicle.
10. ALWAYS keep load as close to ground as possible.
11. Hydraulic hoses need to be inspected frequently for signs
of deterioration, and be replaced as required.
12. The hoist hook is an important item that an operator
should consider and use properly. It should be checked
on a daily basis for distortion or cracks.
13. ALWAYS store outriggers before road travel.
14. WARNING! NEVER OPERATE THE CRANE
NEAR ELECTRICAL POWER LINES! Death or
serious injury will result from boom, line, or load
contacting electric lines. Do not use crane within 10
feet (3.05m) of electric power lines carrying up to
50,000 volts. One foot additional clearance is required
for every additional 30,000 volts or less.
15. WARNING! NEVER EXCEED load chart
capacities (centerline of rotation to hoist hook).
16. WARNING! NEVER un-reel last 5 wraps of cable
from drum!
17. WARNING! NEVER wrap cable around load!
18. WARNING! NEVER attempt to lift or drag a load
from the side! The boom can fail far below its rated
capacity.
19. WARNING! NEVER weld, modify, or use
unauthorized components on any Auto Crane unit!
This will void any warranty or liability. Also failure
of the crane may result.
20. WARNING! NEVER place a chain link on the tip of
the hook and try to lift a load!
21. WARNING! NEVER use a sling bar or anything
larger than the hook throat that could prevent the hook
latch from closing, thus negating the safety feature!
22. WARNING! In using a hook with latch, ALWAYS
insure that the hook throat is closed before lifting a
load! Proper attention and common sense applied to
the use of the hoist hook and various slings will
prevent possible damage to material being hoisted and
may prevent injury to personnel. Switch on that will
cause unsafe operating conditions!
WARNING! NEVER hold any Control Select
Switch on that will cause unsafe operating conditions!
WARNING!
Auto Crane Company remote controlled, stiff boom
cranes are not designed or intended to be used for any
applications involving the lifting or moving of personnel.
2-2.0.0
12/2002

--- IMPORTANT ---
OPERATION OF UNIT
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.
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.
2-3.0.0
12/2002

CONTROLLER OPERATIONS
Transmitter Layout: The red light to the left of the Power On/Off button indicates low
transmitter battery. As the battery runs down, the light will begin to flash. It will flash increasingly
faster as the battery power decreases. (see “Charging the Transmitter”)
The green light to the right of the Power On/Off button indicates that the unit is
transmitting. This light will flash when a function is activated.
In addition to the two lights mentioned above there are four function toggle switches.
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.
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.
2-4.0.0
12/2002

CONTROLLER OPERATIONS
Auxiliary Buttons:
Functions described in this paragraph will not worked if not properly connected to the
vehicle at the time of installation. Press the Engine Fast/Slow button to provide a maintained
voltage to a throttle control. To stop the engine, press the Engine Start/Stop button. To start the
engine, press the Engine Start/Stop button a second time within five (5) seconds of releasing it.
To activate the auxiliary function, press the Engine Fast/Slow and the Engine Start/Stop buttons
simultaneously.
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. When in the ‘HOME’ position, the hoist is also slowed
to prevent inadvertent damage to the crane or boom support.
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
Diagnostics section of this manual. Please note that ‘NRML’ is displayed when the crane is
operating normally, ‘HOME’ is displayed when the crane is forward and in a position to be stowed
and ‘SLOW’ is displayed when functions are slowed due to load.
Charging the Transmitter:
The transmitter can be charged using one of three methods. It can be charged with the
cigarette lighter charger, the pendant cable or the optional AC adapter (P/N 366505000). To
charge the transmitter with the pendant cable, the crane must have electrical power. The crane
can be operated by pendant or by FM remote therefore the battery can be charged without
suspending operation of the crane.
The transmitter should be fully charged after approximately 6 to 8 hours of charging. It is
not recommended to leave the transmitter charging for extended periods of time (3 or 4 days).
Doing so will eventually degrade the battery and it will not keep a good charge.
2-5.0.0
12/2002

QUALIFICATIONS FOR AND CONDUCT OF OPERATORS
AND OPERATING PRACTICES
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.
2-6.0.0
12/2002

QUALIFICATIONS FOR AND CONDUCT OF OPERATORS
AND OPERATING PRACTICES
15. The operator shall be familiar with the equipment
and its proper care. If adjustments or repairs are
necessary, the operator shall report the same
promptly to the appointed person, and shall also
notify the next operator.
16. All controls shall be tested by the operator at the
start of each shift. If any controls do not operate
properly, they shall be adjusted or repaired
before operations are begun
17. Stabilizers shall be visible to the operator while
extending or setting unless operator is assisted by
a signal person.
OPERATING PRACTICES
HANDLING THE LOAD
18. Size of load
A. No crane shall be loaded beyond the rated load
except for test purposes.
B. The load to be lifted is to be within the rated load
of the crane and its existing configuration.
C. When loads which are not accurately known are
to be lifted, the person responsible for the job
shall ascertain that the weight of the load does not
exceed the crane rated load at the radius at which
the load is to be lifted.
19. Attaching the load
A. The load shall be attached to the hook by means
of slings or other devices of sufficient capacity.
B. Hoist rope shall not be wrapped around the load.
20. Moving the load
A. The operator shall determine that:
B. The crane is level and, where necessary, the
vehicle/carrier is blocked properly.
C. The load is well secured and balanced in the
sling or lifting device before it is lifted more
than a few inches.
D. Means are provided to hold the vehicle
stationary while operating the crane.
E. Before starting to lift, the hook shall brought
over the load in such a manner as to minimize
swinging.
F. During lifting care shall be taken that:
1. There is no sudden acceleration or
deceleration of the moving load.
2. Load, boom or other parts of the crane do
not contact any obstruction.
G. Cranes shall not be used for dragging loads
sideways.
H. This standard recognizes that articulating boom
cranes are designed and intended for handling
materials. They do not meet personnel lift or
elevator requirements. Therefore, no lifting,
lowering, swinging or traveling shall be done
while a person is on the hook or load. Hook
attached suspended work platforms (baskets)
shall not be used with cranes covered by this
standard. Work platforms attached to the boom
must be approved by crane manufacturer.
I. The operator should avoid carrying loads over
people.
J. When the crane is so equipped, the stabilizers
shall be fully extended and set. Blocking under
stabilizers shall meet the requirements as
follows:
1. Strong enough to prevent crushing.
2. Of such thickness, width and length as to
completely support the stabilizer pad.
K. Firm footing under all tires, or individual
stabilizer pads should be level. Where such a
footing is not otherwise supplied, it should be
provided by timbers, cribbing, or other structural
members to distribute the load so as to not
exceed allowable bearing capacity or the
underlying material.
L. In transit, the boom shall be carried in stowed
position.
M. When rotating the crane, sudden starts and stops
shall be avoided. rotational speed shall be such
that the load does not swing out beyond the
radius at which it can be controlled.
N. The crane shall not be transported with a load on
the hook unless recommended by the
manufacturer.
O. No person should be permitted to stand or pass
under a suspended load.
21. Stowing procedure. Follow the manufacturer's
procedure and sequence when stowing and un-
stowing the crane
2-7.0.0
12/2002

QUALIFICATIONS FOR AND CONDUCT OF OPERATORS
AND OPERATING PRACTICES
MISCELLANEOUS
OPERATING NEAR ELECTRICAL POWER
LINES
22. Cranes shall be operated so that no part of the
crane or load enters into the danger zone shown
above.
EXCEPTIONS
A. The danger zone may be entered after confirmation
by an appointed person that the electrical distribution
and transmission lines have been de-energized and
visibly grounded at the point of work; or
B. The danger zone may be entered if insulating
barriers (not a part of nor an attachment to the crane)
have been erected to prevent physical contact with
the lines.
23. For lines rated 50 kV or below, minimum
clearance between the lines and any part of the
crane or load (including handling appendages)
shall be 10-ft. (3m). For higher voltages, see
Table1.
24. Caution shall be exercised when working near
overhead lines, because they can move
horizontally or vertically due to wind, moving the
danger zone to new positions.
25. In transit with no load and boom lowered the
clearance shall be specified in Table 1.
26. A qualified signalperson shall be assigned to
observe the clearance and give warning before
approaching the above limits.
A. Any overhead wire shall be considered to be an
energized line unless and until the person
owning such line or the electrical utility
authorities verify that it is not an energized line.
B. Exceptions to this procedure, if approved by the
administrative or regulatory authority if the
alternate procedure provides equivalent
protection and set forth in writing.
C. Durable signs shall be installed at the operator's
station and on the outside of the crane, warning
that electrocution or serious bodily injury may
occur unless a minimum clearance of 10 ft.
(3.0m) between the crane or the load being
handled and energized power lines. Greater
clearances are required because of higher
voltage as stated above. These signs shall be
revised but not removed when local jurisdiction
requires greater clearances.
normal voltage, kV
(phase to phase) ft (m)
over to 50 10 (3.50)
over 50 to 200 15 (4.6)
over 200 to 350 20 (6.1)
over 350 to 500 25 (7.62)
over 500 to 750 35 (10.67)
over 750 to 1000 45 (13.72)
over to 0.75 4 (1.22)
over 0.75 to 50 6 (1.83)
over 50 to 345 10 (3.83)
over 345 to 750 16 (4.87)
over 750 to 1000 20 (6.1)
while in transit with no load and boom lowered
TABLE 1
minimum required
____clearance____
when operatin
g
near hi
g
h volta
g
e poower lines
2-8.0.0
12/2002