lable of Con.en.

s
Acknowlec;igment.....................................................................2
Foreword •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••3
Safe'ty' Alerts ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••4
A Word to the User/Operator ••••••••••••••••••••••••••••••••••••••••••••••••5
Types of Mobile Cranes ••••• ~ ••••••••••••••••••••••••••••••••.•••.•• 6
II!I •••••••••••

Follow a Safe'ty' Program •••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7

Prepare for Safe Operation •••••••••••••••••••••••••••••••••••••••••••••••••• 12
Start Safely •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 19
Operate Safely •••••••••••• ~ •••••••••••••••••••••••••••••••••••••••••••••••••••••••••22
Shut Down Safely •••••••••••••••••••••••••••••••••••••• ~ ••••••••••••••••••••••••••540
Perform Maintenance Safely •••••••••••••••••••••••••••••••••••••••·••••••••56·
Final Word to the User ••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 71
 Foreword
This safety manual is intended to point out some of the
basic safety situations that may be encountered during
the normal operation and maintenance of your machine
and to instruct you in safety practices for dealing with
these conditions. This manual is NOT a substitute for
the manufacturer's operating manual(s).
Additional precautions may be necessary, or some
instructions may not apply, depending on equipment,
attachments and conditions at the job site or in the
service area. The manufacturer has no direct control
over equipment application, operation, inspection or
maintenance. Therefore, it is YOUR responsibility to use
good safety practices in these areas.
The information provided in this manual supplements
the specific information about your machine that is
contained in the manufacturer's operating manual(s).
Other information that may affect the safe operation of
your machine may be contained on safety signs or in
insurance requirements, employer's safety and training
programs, safety codes, loCal, state/provincial and
federal laws, rules and regulations.
'{'1!f
~ead and understamt.
manuals before:..
4' operating .""
IMPORTANT! Before you operate this machine, make
sure you have the manufacturer'S manual(s) for this
machine and all attachments. If the manufacturer's
manuals are missing, obtain replacements from
your employer, equipment dealer or directly from
the manufacturer. Keep this safety manual and the
manufacturer's manuals with the machine at all times.
Read and understand all manuals, the crane load rating
chart, maintenance requirements, and information decals.
Safety videos and other training resources are available
from some manufacturers and dealers. Operators are
encouraged to periodically review these resources.
3
 Safety Alerts
Safety Alert Symbol
This Safety Alert Symbol means: "ATTENTION!
STAY ALERT! YOUR SAFETY IS INVOLVED!"
The Safety Alert Symbol identifies important safety
messages on equipment, safety signs, in manuals or
elsewhere. When you see this symbol, be alert to the
possibility of death or personal injury. Carefully read the
message that follovys and inform other operators. Follow
instructions in the safety message.
4
Signal Words
Signal words are distinctive words that will typically be
found on safety signs on the mobile crane and other job
site equipment. These words may also be found in this
manual and the manufacturer's manuals. These words
are intended to alert the operator to a hazard and the
degree of severity of the hazard.
DANGER indicates a hazardous
ADANGER situation that, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous
situation that, if not avoided, could
result in death or serious injury.
CAUTION indicates a hazardous .
IACAUTIONI situation that, if not avoided, may
result in minor or moderate injury.
NOTICE indicates a property
NOTICE damage message.
 A Word to the User/Operator
It IS YOUR responsibility to read and understand this
safety manual and the manufacturer's manuals before
operating this equipment. This safety manual takes you
step by step through the working day.
GraphiCS have been provided to help you understand
the text.
Hazard recognition and aCCident prevention depend
upon you being alert, careful and properly trained In the
Inspection, assembly, operation, transport, maintenance
and storage of this equipment.
~1l"jReaf'an~,;,1!'I
. "!f. understand alh~
";j,/safety signs - ,.•
~replace damage(b.
/ib;···~glli¥,"<4
Remember that YOU are the key to safety. Good
safety practices not only protect you but also protect
the people around you. Study thiS manual and the
manufacturer's operating manuals for the specific
machine. Make them a working part of your safety
program. Keep In mind that thiS safety manual IS written
only for mobile cranes.
After studYing the manufacturer's operating manual(s)
and thiS safety manual, please contact the equipment
manufacturer with any remaining questions.
Practice all usual and customary safe working
precautions and remember:
SAFE OPERATION IS UP TO YOU!
YOU CAN PREVENT DEATH OR SERIOUS INJURY
CAUSED BY UNSAFE WORK PRACTICES!
5
 Types of Mobile Cranes
A mobile crane IS a self-propelled machine fitted with
either wheels, tracks or IS mounted onto a truck for
use on different types of terrain. These different types
of cranes typically have either a lattice boom or a
telescopIc hydraulic boom.
When used normally, the mobile crane IS an effective
means of lifting heavy loads to varying heights. Mobile
cranes can be used for a wide variety of material
handling, Including pick and carry operations. All
safety precautions must be taken when performing any
operation with a mobile crane.

TelescopIc Hydraulic Boom

Lattice Boom

Truck Mounted
6
 Follow a Safety Program
For Safe Operation
"". . ''lIi\.
'Ii!"... .."",
You must be a qualified and authorized operator for safe .Never operate whUg..
operation of this machine. You must clearly understand ",jinpaired by alcoho\.
the written Instructions supplied by the manufacturer, be k;,. or drugs.a
certified or licensed by at least one of the following:
• an accredited crane operator testing organization.
An operator taking prescnptions or over-the-counter
• an audited employer program.
medication must consult a medical professional
• the U. S. Military or other government entity. regarding any side effects of the medication that would
In addition, you must know all state, local or provincial hinder their ability to safely operate this equipment.
regulations regarding crane operation, as well any
specific safety rules and regulations for the Job site. Be Alert!
It IS a good safety practice to pOint out and explain
Know where to get assistance. Keep emergency
safety signs and practices to others and to make sure
numbers for doctors, ambulance service, hospital and
they understand the Importance of following these
fire department near your telephone. Know how to use a
Instructions.
first aid kit and fire extingUisher/fire suppression system;
A WARNING! Death or serious Injury could result from know their location and practice getting to them. Ensure
operating machinery while Impaired by drugs or alcohol. they have been properly tested and maintained.
Drugs and alcohol affect operator alertness,
Let others know where you will be working, and what
coordination, and the ability to safely operate the
time you will be returning. In case of an emergency, you
equipment. Never operate the machine while
want others to know where to find you.
impaired by use of alcohol or drugs. Never
knowingly allow anyone to operate the machine
when their alertness or coordination is impaired.

7
 Follow a Safety Program
Protect Yourself
Wear all the personal protective clothing and Personal
Protective Equipment (PPE) Issued to you or called for
by Job conditions.
You may need:
• Hard hat
• Safety shoes
• Safety glasses, goggles, or face shield
• Heavy duty gloves
• Heanng protection
• Reflective clothing
• Wet weather gear Be Careful!
• Respirator or filter mask
Human error IS the result of many factors: carelessness,
Wear whatever IS needed to protect yourself - don't fatigue, sensory overload, preoccupation, unfamiliarity
take chances. with the machine or attachments, or drugs and alcohol,
A WARNING! Avoid death or senous injury from to name a few. You can aVOid death or senous injury
entanglement. Do not wear loose clothing or caused by these and other unsafe work practices. Be
accessories that could catch on moving parts or careful; never assume aCCidents cannot happen to you.
controls. Examples of items to aVOid Include: flopping For your safety and the safety of others, act safely and
cuffs, dangling neckties and scarves, wallets attached encourage your fellow workers to act safely as well.
to chains, Jewelry and wnst watches.

8
 Follow a Safety Program
Be Aware!
Safety Rules
Take advantage of training programs offered. e __ e __ W.o' ... ~

Know the proper response to a fire or chemical spill on

your machine.
e--
e--
e--
e--
e--

e--
e--
Know and understanll
i.
e - - .;.... rules of operation·i~

Know the Rules

Most job sites have rules governing equipment use and
maintenance. Before you start work at a new location,
check with the supervisor or safety coordinator. Ask
about the rules you will be expected to obey.
OSHA and MSHA enforce federal laws within the United
States that apply to the safe operation, application and
maintenance of equipment on some job sites. It IS the
employer's responsibility to comply with these laws. A
federal representative may penodically Inspect a job site
to see that these laws are being followed.
There may be other local, state/provincial, federal laws
or International organizations that regulate the use of
this eqUipment, along with specific job site or employer
rules. It IS Important that you know and comply with all
applicable laws and rules, including those requiring
operator training and certification.
These are some of the rules you must work by:
e Only licensed, qualified, and authonzed individuals
may operate this equipment
e Inspect the machine and attachments before each use
as specified by the manufacturer and your employer
e Check height, width, and weight restnctions for your
locality, and be sure the machine will not exceed
these limitations
e Know the operating charactenstics of your
equipment. Do not misuse it
e All shields, guards, air filters, access panels and
doors must be properly Installed while In use
e Never modify or remove any part of the machine
(except for service; then make sure the part IS re-
Installed or replaced if defective or worn out)
e Only use attachments and parts that are approved by
the manufacturer of your given machine

9
 Follow a Safety Progralll
• Never allow children to play near, ride on, or
operate the equipment.
• Keep bystanders well clear of the operation
• Know the work area before you use the equipment. .~~
Be aware of possible hazards 'Keep bystander
• Know the rules regarding traffic at your Job site. Know .1\ children aw
what all signs, flags, and markings mean. Know hand, 4.~. • . ,.,~
flag, horn, whistle, Siren, or bell signals, if used
• Do not allow unauthonzed nders
• Wear proper clothing and PPE. Check that others are
also weanng appropnate clothing
• Fasten seat belt or operator restraint before starting
• Dnve forward whenever possible ,..".
• iYfClsten seat b
• Always look In the direction of travel
1ir operator re
• Look before backing up 6fii¥c,• .,~
• Use three-point contact (handholds and steps) and
face the equipment when mounting or dismounting.
(See page 19, Mount and Dismount Properly)

10
 Follow a Safety Program
Know the Equipment
Read and understand the DANGER, WARNING,
CAUTION and NOTICE safety labels and other 'Ii"'" "'~''''''~':'!f!
Informational signs on the machine and the Iil.ead and understalUl
attachments, and In the manufacturer's operating " manuals before "
manuals. Ask your supervisor or dealer to explain any operating
Information you do not understand. Failure to obey 1/.:" '"""
safety Instructions could result In death or senous inJury.
Know the following about your equipment:
• Function, purpose, and use of all controls
• Correct operation speeds
• Slope and uneven terrain capabilities and proper
operation
• Braking and steering charactenstics
• Turning radius and clearances
• How to properly and safely stop equipment In an
emergency
• Rated operating capacity
Keep In mind that wind, rain, snow, Ice,loose gravel,
soft ground, slopes, and other site conditions can affect
your machine's operating capabilities. Make sure you
are thoroughly familiar with your machine's stability,
braking, traction, and other handling characteristics
under any conditions you are likely to encounter. 11
 Prepare for Safe Operation
Check and Use All • Operator seat/restraint bar(s)/interlock control system
Available Safety Devices • Alternate exit (Window)
• Lights
To protect you and others around you, your crane may • Anti-skid tread/steps
be equipped with the safety equipment and operational • Safety signs
aids listed below. Additional equipment may be
required or some items may not apply, depending on • Horn
attachments used, Job site conditions, or applicable Job • Guards
site rules. Check that each required item IS securely In • Back-up alarm
place and In operating condition: • Fire extingUisher
• Signaling devlce(s) • First aid kit
• Crane level Indicator • Rotating beacon
• Boom stops, if equipped • Windshield Wiper/defroster
• Jib stops, if equipped Use them! Do not remove or disconnect any safety
• Load Indicating/limiting devices, if equipped device or operational aid unless it needs to be serviced.
• Boom hOist limiting device Replace Immediately.
• Boom angle Indicator
• Anti two-blocking device
• Boom angle or radius Indicator
• Boom length Indicator
• Jib angle Indicator, if equipped
• Luffing jib limiting device, if equipped
• Seat Belt
• Cab side-screens or windows
12
 Prepare for Safe 'Operation
Check the Machine
Before beginnIng your work day, Inspect the crane and
have all systems In good operational condition.
Perform daily and periodic service procedures as
Instructed by the equipment manufacturer. Report and
record all safety related defects for,lmmediate correction In
the crane log book. Do not operate crane until corrected.
!/!5"~'.
""''''f
"""r Inspect\:.
<Ii~he machine befo~~
",,;each work day,j..
lit" "~
Make sure to Inspect:
• For physical damage, such as: cracking, bending,
or deformation of plates or welds. Inspect carefully
for cracking or flaking of paint, which may Indicate
a crack In the structure beneath. Do not operate the
machine until repairs are made
• For broken, missing, loose, or damaged parts. Make
necessary repairs
• The tires or tracks for cuts, missing lugs, bulges, and
correct pressure or track tension
• All wire ropes for wear, kinking, or other damage.
Replace if necessary
• The parking brake for proper operation
• The air system lines, valves, drains, and other
components. See that air pressure IS correct and that
there are no air leaks
• That the steps and hand holds clean and free of
grease, oil, dirt, snow, or Ice
• That shielding IS properly Installed and In good
condition. Repair or replace if damaged or missing
• That work lights (if equipped) are kept clean. Check
that all lights work properly
• That the horn and back-up alarm (if equipped) are
operating correctly. Repair or replace if damaged
• That any Slow Moving Vehicle (SMV) signs, reflectors,
and warning lights are In good condition and can be
seen clearly. Repair or replace ,if daml:iged
• That all tools or loose objects arerenioved or
securely fastened while operating or transporting
the machine
• That the crane IS properly lubricated. Checkthat fuel,
lubricating oil; coolant, and hydraulic reservoirs are kept
at levels Indicated by the, manufacturer's Instructions
• For damaged or leaky hydraulic systems. Repair or
adjust as needed
13
 Prepare for Safe Operation
Load Rating Chart
Do not operate the machine without the proper crane
manufacturer's load rating chart.
Only use the official load rating chart for your machine.
Your machine may be fitted with special equipment
which would require a specific load rating chart.
Never exceed the crane manufacturer's·load ratings.
The stipulations noted on these charts must
always be observed. Ratings noted·are based
on a number of conditions, such as hydraulic,
mechanical, structural, and stability.
...
~.~" '
~Neverexceed
"ti'i:anes load cap
£;"~,,., . .'4
A WARNING! Tipprng the crane to determine capacity
always overloads the crane and is never approved. This
can cause death or senous InJury. It is always unsafe to
lift or move any load which is greater than the rated
load shown on your specific crane load rating chart.
14
Know the rated capacity of the machine. Only machrnes
of proper rated capacity and type should be assigned to
the Job.
Never operate with any other counterweight than what
IS recommended by the manufacturer. Unauthorized
reduction or addition of counterweight or ballast
constitutes a safety hazard.
Check for warnrng tags before starting the crane -
check around to know that the work area IS clear.
Never exceed boom or boom.andjib combination
lengths published on the crane manufacturer's load
rating chart.
Read and understand all the notes and warnings pnnted
on the crane load rating chart before raising the boom
and lifting a load.
Operational aids which Indicate load conditions by
visual or audible signal are not a substitute for strict
adherence to all safe operating procedures.
 Prepare for Safe Operation
Hydraulic Fluid Injection Hazard Wear proper hand and eye protection.

A WARNING! Accidental Injection of high-pressure oil

Into the hands or body IS dangerous and could result In
~~ ...

death or serious InjlJry. Use caution when checking

Wear hand and . :?'
hydraulic leaks as pressurized hydraulic fluid has .......... eye protection'"
enough force to penetrate skin, causing serious .." .:A
",v"~·"':.ii
personal injury.

",.' i!!1', •. ,..~'iil1J

"if' .'High pressure"·~ FlUid Injection injuries are not always obVIOUS. Victims
"", fluid can inject ,p. have reported such Injuries feel like a bee sting or
.ii". Into the body.~ splinter under the skin. If you suspect you have a flUid
~r~
Injection Injury, do not take chances. Seek proper
medical care Immediately. If any flUid IS Injected Into the
skin, it must be surgically removed within a few hours by
If a leak IS discovered: a doctor familiar with thiS type of Injury.
Ensure engine IS turned off; relieve pressure In hydraulic
Circuit. Check the Cooling System
Visually examine the hydraulic hose or flUid lines In the When checking the cooling system, make sure the
VICinity of the leak for breaks or cracks. Do not use your engine IS turned off and IS cool. Remove the key to
hand to check for leaks. prevent fans from unexpectedly starting. Ensure the
coolers and engine compartment are clean and free
Repair or replace hydraulic lines per manufacturer's
from debriS, which could Ignite and cause a fire.
recommendation.

15
 Prepare for Safe Operation
If the machine IS air-cooled, be sure the cooling unit
has an unobstructed air flow. If it IS liquid-cooled, check
coolant level (at overflow tank, if provided).
A WARNING! Allow the radiator to cool before
checking the'level. Hotradiator flUids could escape as
steam and burn you. (See page 61, Engine Coolant
Hazards.)

Attachment Assembly and
Disassembly
Assembly/Disassembly (AID) must be directed by a
competent and qualified person who has knowledge of
the assembly/disassembly procedures for the specific
crane. The AID director must provide crew Instructions
and address the hazards associated with assembly/
disassembly before starting the tasks.
Consult, understand, and follow the manufacturer's
manual of your crane for proper attachment assembly
and disassembly procedures. Consult with the
manufacturer or the AID director for further clarification.
When putting booms and rigging together or taking
them apart, stay out from under the boom sections and
other rigging.
16
Make sure all parts are supported before removing any
bolts or pins. If not properly supported, the boom or jib
will fall.
Before removing any pinS, the boom and jib, if
equipped, must be properly supported with the
crane's rigging or blocking In accordance with the
manufacturer's recommendations.
Block under or properly support the boom and jib, if
equipped, before dismantling. Never stand on or under
the boom dUring thiS work.
Use appropriate fall protection dUring assembly and
disassembly when at an elevated working position
 Prepare for Safe Operation
Clean Up
Clean Windows, lights, and safety signs.
Remove all window vandal guards before operation.
Make sure the operator's area, steering levers, pedals,
Joysticks, steps, and grab handles are clean. Oil, grease,
snow, Ice, mud, or debris In these areas could cause
you to slip and fall, or lose control of the machine. Clean
your boots of excess mud before entering the machine.
Remove all personal items or other objects from the
operator's area. Secure these items In a toolbox or
remove them from the machine.
Ultra-Low Sulfur Diesel (ULSD)
Fuel Hazard
Avoid Static Electricity Risk When Fueling
A WARNING! Ultra-Low Sulfur Diesel (ULSD) poses a
greater static Ignition hazard than earlier diesel
formulations. Avoid death or serious injury from fire or
explosion; consult with your fuel or fuel system
supplier to ensure the delivery system is in
compliance with fueling standards for proper
grounding and bonding practices.

Use Caution When Fueling

;'f">. """•.... >~~..
A WARNING! Avoid injury from fire or explosion. 'iV'
",~Static discharge""
""'!if

Never fill the fuel tank with the engine running, while ""during fueling cal'!~
smoking or when near an open flame. -".cause explosioJll\\
Oii-' ~... ;"'"
Never overfill the tank or spill fuel. If fuel IS spilled, clean
it up Immediately.
Be sure to use the correct type and grade of fuel.
Ground the fuel funnel or nozzle against the filler neck to
prevent sparks that could Ignite fuel vapors. Be sure to
replace the fuel fill cap (if equipped) when you are done. 17
 Prepare for Safe Operation
Hand Signals
A legible chart depicting and explaining the system of
signals used should be located on the outside of the
crane and/or at the Job site.
Confirm that the crane operator and signal person
clearly understand and agree on all hand signals.
The operator shall respond to operating signals only
from the appointed signal person but shall obey a stop
signal at any time from anybody. A signal person, fully
qualified by training al1d experience, shall be provided
when the pOint of operation IS not In full and direct view
of the operator, unless an effective signaling or control
device IS provided for safe direction of the operator.
The signal person must be In a sufficiently lit area and
clearly visible to the operator dUring nighttime operation.
18
Signal systems used In place of hand signals shall be
protected against unauthorized use, breakage, weather,
or obstruction which will Interfere with safe operation.
A complete set of hand signal illustrations can be found
later In this manual. (See page 49, Hand Signals Chart.)
Know the Working Area
Learn as much about your working area as possible.
Be sure the area IS safe for operation and blocked off
to keep bystanders and other employees clear of the
crane dUring operation. Follow OSHA gUidelines for
barricading the sWing radius of the crane.
Plan Your Work
Make sure you know where you will make your pickups,
lifts, and turns. Before you raise any load, know where
you will place it.
Check Overhead
Be aware of power lines, buildings, canopies, and all
overhead obstructions.
 Start Safely
Mount and Dismount Properly DUring mounting and dismounting:
• Use hand holds and step plates.
Always use three-poInt contact when mounting or
• Never use steering wheels, joysticks or controls as
dismounting the machIne. Three-point contact means
handholds.
one hand and two feet, or two hands and one foot, In
• Never Jump on or off the machine.
contact with the machIne at all times.
• Never mount or dismount from a movIng machIne.

~,»"~,,,>,,,>
Use three poil'lt§" Warn Personnel Before Starting
,,': of contact when::~
.." mounting or}~
Before starting, walk completely around the machIne.
"" 2isl1lounti~9/~ Make sure there is adequate clearance for tail swing
>'Oi'" '""", and no one is under the machine, onit, close to it,
or in any pinch points. Barricade the area to prevent
Never mount or dismount while carryIng tools or objects entry. Let others know you are starting up and don't
that prevent three-point contact. Put parts or tools start until everyone IS completely clear of the machine.
down. MaintaInIng proper contact, climb or dismount, As the equIpment operator, you are responsible for the
and then pIck up the object. safe use of the machine, so always make sure you have
communrcated your work plans to others on the site.
Face the machine when you enter or leave the machine.
Clean shoes and wIpe hands. Clean steps and 'I'!!">!IItc' .,.".
handholds of chemIcal resIdue, snow, Ice, mud or oil. "*,,, Before starting i 1P'
'walk completely~
around crane,.
,,"i

19
 Start Safely
Starting the Engine
A WARNING! Start the engine from the operator's seat
only. Never attempt to start the engine by shorting
across starter terminals. The machine may move
unexpectedly, which could cause serious Injury or death
to anyone In its path.
• Familiarize yourself with warning devices, gauges and
operating controls
• Make sure controls are In the neutral/locked position
• Clear the area of all persons
• Start the engine follOWing the Instructions In the
manufacturer's operating manual(s)
• If necessary to run the engine or operate the machine
In an enclosed area, be sure there IS proper ventilation
A WARNING! Exhaust fumes can kill. Do not breathe
exhaust fumes!

Check for warning tags. If there IS a warning tag on

the starting switch or engine starting controls, do not
operate the switch or start the engine until the warning
tag has been removed by the person who placed it
there or by someone authorized to do so.
Starting Aids
Know the exact starting procedure for your machine.
See the manufacturer's operating manual(s) for starting. If you have trouble starting the engine and need to use
Jumper cables, follow the Instructions In manufacture~'s
• Sit In the operator's seat and adjust the seat so you
operating manual(s). Never attempt to start the engine
can operate all the controls properly.
except from an approved operator's station.
• Fasten the seat belt/operator restraint.

20
 Start Safely
A WARNING! Improper JUinp-starting procedures may After Starting Engine
cause serious Injury or death from a battery explosion or Observe gauges, Instruments, and warning lights to
a run-away machine. Always use proper jump-starting assure that they are functioning and their readings are
procedure. (See page 64, Battery Hazards.) within the operating range.
Make sure the machine IS operating properly by dOing
the follOWing:
• Operate each pedal, lever, and Joystick to make sure
all controls operate properly
• Make sure all operational aids and limiters are
Installed and operating properly
Ether/cold start flUid is HIGHLY FLAMMABLE. Before • Test engine speed controls
uSing it, always read the Instructions on the ether/ • listen for unusual nOises
cold start fluid container and the Instructions In the
\1'
manufacturer's operating manual(s).
~f'F~
A WARNING! AVOId Injury from explosion or fire. If the
iiiiiI
~
engine IS equipped with a glow plug pre-heater or other
Intake manifold type pre-heater, follow manufacturer's
instructions before using ether/cold start fluid.

Run an Operating Check A WARNING! Before operating the machine under

working conditions, be certain you can control the
Do not use a machine that IS not In proper operating
speed and direction of the machine and load. Any
condition. It IS your responsibility to check the condition
loss of control could result In death or serious inJury.
of all systems and to run the check In a safe area.
21
 Operate Safely
Masked Visibility Areas Remember These Rules
Cranes have areas where the operator's visibility of Be alert while operating:
the job site can be affected by the machine itself. • Do not read
Attachments, the load, and even items In the cab could • Do not dnnk
limit your view of the surrounding area and possibly • Do not eat
mask hazards or people around you. These masked • Do not use your phone
visibility areas vary from machine to machine, and it
• Do not operate the crane while under the Influence
IS very Important you be aware of these areas before
of alcohol, drugs, or any substance that would affect
operating your machine.
your ability to operate the crane safely
Follow these safety precautions to reduce the hazards • Do not work if fatigue or excessive work reqUirements
posed by masked visibility areas: affect your ability to safely operate the crane
• Pay particular attention when raising or lowenng a • Keep your eyes on the moving load or signal person.
load or the boom/jib, if equipped, because masked • Pay attention to the your job. If you must turn
visibility areas can change. attention elsewhere, stop operations
• Look around the machine before operating. Objects
near the machine and close to the ground can be
difficult to see from the cab.
• Always look In the direction of travel, Including
~.;/I!r.'<'~
reverse. A back-up alarm IS no substitute for looking ~yattention to
behind you when operating the machine In reverse. ...Qgrson and folio ,. .
4,.. signals givenia
• Keep bystanders outside barricades, even if your
~,,~,.~."iiIli
machine is equipped with a back-up alarm.
• Follow signals from signal person or signal system.

22
 Operate Safely
Know the Working Range·of the Crane Level the Crane
Be sure the attachment, hook, or load doesn't catch The level of a crane IS critical to every lift. All cranes
on obstructions when sWinging, raising, or lowering the must be leveled according to the manufacturer's
boom or load; specifications. If the machine IS out-of-Ievel, the stability
Do not swing, brake, raise, or lower the boom or load and structural Integrity of the crane will be negatively
unnecessarily -fast. All can cause accidents. affected.

Be sure everyone IS In the clear all around the crane
before sWinging or moving In any direction. Never sWing
or position hook or load over personnel or vehicle cabs.
Remember Other People
Since outriggers proVide greater stability than tires,
machines with outriggers should have the outrigger
beams extended and set for lifting operations; consult
with the manufacturer's Instructions for on-rubber
operation.

Never allow an untrained or unqualified person to
operate the crane or act as the signal person. If
operated Improperly, thiS machine can cause serious
death or serious InJury.
A DANGER! A falling load or boom Will cause death or
serious injury - watch out for other personnel!
..... -
When uSing outriggers, set the outriggers' beams to
their properly extended position, always extending the
beams equallY,unless unequal extension IS approved
by the manufacturer. When uSing outriggers, be sure all
tires are clear of the ground and level the machine in all
directions, as specified by the manufacturer.
- ..•.. Keep these things In mind when uSing outriggers:
..... ....
'.~ "

-PI "'''.-
,"," ...~.
.
Rl!y attention to sigilli
"':'!I!f • If the machine IS equipped with a load weighing or
load Hmitingdevlce, make sure the device settings

~
.,,<. 4p'erson and follow.~jL. match the machine configuration you are uSing. Also
" . h,signalsgiven ,,~
. .' ." make sure it IS turned on, working, and matches the
load you will be lifting
23
 Opera'e Safely
• Set the outnggers to their fully extended position,
unless the load rating chart for your crane permits
partial outngger extension. Set and verify outngger
positions as specified by the load rating chart. Partial
outngger extension IS not allowed 'On all cranes
• Make sure the outngger pads are securely fastened
to the outngger Jacks when outnggers are In use
• If blocking must be built up to obtain height to level
a machine, make sure it IS stable, covers sufficient
ground, and won't topple, collapse, or sink Into the
ground when loads are applied
• Never block under outngger beams Inside the
outngger pads. This reduces stability of the machine
• Recheck outngger pads between lifts and reset them
if necessary. Machines can tip when swung over an
outngger that IS not set properly
• The supporting surface under each outngger pad
must always be level and solid enough to support the
loads that are being lifted
To level a machine working on crawlers or on tires,
the ground must be leveled or blocking must be used.
Check the level of the machine In all directions before
lifting. Do not operate the crane if it IS out-of-Ievel.
Check the level of the machine frequently dunng
24 operation and re-Ievel when necessary.
Ground or Support Conditions
The supporting surface underneath the machine must
be level, firm, and stable to support the weight of the
machine and its load. Use appropnate supporting
surface to avoid out-of-Ievel or tipping condition.
Verify that there are no underground hazards (e.g.,
vOids, tanks, utilities) In the area where the crane will be
set up and operated.
Where necessary, use timber mats or steel plates under
the outngger pads, the tires of rubber tired machines,
and the tracks of crawler machines to distribute the
load and ensure that the ground beanng capacity of the
supporting surface IS not exceeded.
~-~"~'
~oilsult job II
"If-management
-lI!l;blocking to k
1iiII"' _ _ _ !dII
A&""crane leveL /
............. .
-
The use of blocking properly IS the responsibility of Job
site management and IS dependenton conditions.
 Opera'e Safely
The surface area of the blocking under the outngger
pad must be greater than that of the pad surf~ce area.
Matenal used for blocking must have sufficient strength
to withstand the outngger, tires, or crawlers loading
without bending or cracking.
Follow Safe Operating Practices
Before starting to hOist a load, make sure:
• Only machines of proper rated capacity and type are
assigned to the Job
• The weight and radius of the load are known and
does not exceed the load rating chart
• The load IS well secured and properly balanced In the
sling or lifting device before it IS lifted more than a
few inches
• A minimum of a three-pomthitchls used to prevent a
top-heavy load from rolling or tipping
• The hook IS eqUippedwith a properly functioning
safety latch
• The load IS attached to the hookQY means of slings
or other approved deVice that IS In go09 condition
and of sufficient size < ;',
• The hOist line IS not wrapped around the'lol:idJn-place
of a sling or chain
• Multiple part lines are nottwlsted around each
other. The reeving must be In accordance with
manufacturer's Instructions
• The rope IS properly seated In the sheaves, tightly
spooled and seated on the drum; and free of
entanglements before a load or bucket IS moved
• Sufficient length of wire rope IS Installed such that
neither the load nor the boom can be lowered past
the pOint where a minimum number of wraps remain
on the drum, as specified by the manufacturer
• Capacity and wire rope length are checked each time
the rope or the boom length IS changed
• A practice run In tight areas IS made with a signal
person present. It will help you determine the safest
way to operate under eXisting conditions -
• The load IS within load chart rating for the boom length
and load radius of the machine. Know the load radius.
Load radius IS measured from the axiS of rotation to
the center of vertical hOist line with load applied
I"e" .-'~" "'~
~'" ~w
~:Calculate the totaP'"
""welght being lifte(i'.
~ ",A
""" ~', '<iiij""
25
 Opera'e Safely
• The total weight IS calculated by adding the weight Freely Suspended Loads
of the hook block, slings, and all matenal handling
All ratings are based on freely suspended loads. Side
devices to the weight being lifted. See manufacturer's
loading of the machine and load sWing out may cause
Instructions for all required reductions Incapacity
structural failure or crane tipping.
• To determine wind speed and consider the effect of
the wind on the load and attachment, since wind may Never use a crane to push or pull a load or object.
adversely affect the lifting capacity of the machine
Excessive side load can cause accidents and can be
• The hOist line IS vertical before starting to lift generated by'
• All personnel are clear before starting a lift. Make
• Lifting when not level
certain load IS securely attached
• SWinging when not level
• You do not attempt to start tipping the machine to
• Dragging a load
establish lifting capacity. Machine stability IS never to
be used to determine capacity • Sudden acceleration or deceleration In sWinging
• Wind forces on load and boom structure
A WARNING! Avoid Senous injury or death! Keep the • Pushing a load
crane level and stable at all times. Never tip a crane • Suspending a load under water (strong current)
to determine lifting capacity.
• Tilting up or rotating a load with two load lines

26
 Opera'e Safely
Load swing-out
Rapid sWinging of a suspended load causes the load to
drift away from the machine. The Increase In radius can
cause the crane to tip forward or collapse the boom.
The same effect can be generated by sWinging long
booms without a load or sWinging from an over-the-end
to an over-the-slde position, especially when operating
on tires.
A WARNING! Avoid Senous injury or death! Swing
loads slowly and maintain control. SWinging a load
too qUickly or without control can cause the crane to tip
or the boom to collapse.
Use Attachments Safely
Boom and Jib
Longer booms require additional care In accelerating
and decelerating the sWing motion and dunng boom up
or down. Check the weather and wind conditions before
raising boom/jib combinations.
Never raise a boom and jib Into the air unless jib stops,
designed and approved by the manufacturer to restrain
the jib from pivoting over backwards, are Installed.
Boom and jib suspension must be reeved In accordance
with manufacturer's Instructions and wind restnction.
Adding a jib to the boom Increases the working range
but also reduces the lifting capacity. When uSing a jib,
particularly on a long boom, greater care IS reqUired
In accelerating and decelerating the sWing In order to
avoid whipping the jib sideways and damaging the
boom or jib.
All sections of a hydraulic telescoping boom shall
be extended according to the manufacturer's
specifications.
b.·· ·-'<.-O'·o."~
Follow manufactUfI!r's
"$.pecifications whe!t
~~endi:~:esc,~p,t"
..' ",F ~ 'iiII
...
27
 Opera'e Safely
Watch Out for Hazardous
Working Conditions
Boom Kickback
A WARNING! Avoid Senous injury or death! Keep
load on boom when a loaded pendant suspended
boom or jib is near boom stops. Otherwise kickback
can occur which can cause the boom and/or the jib to
bend backwards and collapse.
When a loaded pendant suspended boom or jib IS near
boom stops, do not relieve boom of load. Pendants
stretch when loaded and return to onglnal length
when unloaded. They have been known to pull booms
backwards against boom stops when unloaded. In severe
conditions, a kickback can cause the boom and/or jib to
collapse. 80th hOist machinery and boom mechanism
must be used In setting down a load In this position.
The load block and/or ball hook may move closer to the
boom/jib tip as the boom IS raised or lowered.
Use power lowenng whenever possible. When power
lowenng loads, keep drum brake as reserve.
The boom hOist pawl must be engaged on wire rope
suspended booms, except when raising or lowenng boom.
28
Two-Blocking
ANSI/ASME 830.5 requires that cranes be equipped
with a fully functional anti-two-block device or two-
block damage prevention device to avoid two-blocking.
Two-blocking IS when the hook block or weight ball
makes contact with the sheaves at the boom or jib tip.
This IS a very dangerous situation. The hOist rope can
break causing the hook and load to fall, the boom can
be pulled over backwards over the operator's cab, or
the jib can be pulled back over the boom.
A WARNING! Avoid two-blocking by making sure
the anti-two-block device or two-block damage
prevention device is working properly. The machine
can collapse or break if two-blocking occurs, causing
senous Injury or death.
Two-blocking occurs when the hook block contacts the
boom pOint, this can be caused by:
• Extending the boom or jib pOint without lowenng load
blocks.
• Lowering boom without lowering hook blocks.
• RaiSing hook blocks Into boom pOint.
Such contact between the hook block and boom pOint can
break the cable and cause the hook and weight ball to fall.
 Operate Safely
Pick and Carry Work If the user chooses to travel with a suspended load, he
must evaluate the prevailing conditions and determine
Pick and carry operations are when a crane IS used to
the safety precautions required In each Individual case.
pick up a load and then travel a distance with that load
The following should be considered before attempting
suspended In the air.
to pick and carry a load:
When cranes are used In pick and carry operations, • Never pick and carry unless authOrized by the load
traveling with suspended loads reqUires extreme caution rating chart and the operator's manual
due to factors such as rough terrain, boom length, • Consult the manufacturer's load chart for Instructions
overhead obstructions, and momentum In starting, on capacity, travel speed, working area, tire pressure,
stoPPing, and turning. and other Instructions
• Position the boom and load In line with direction of
travel whenever possible
• Care must be taken to avoid sudden starts and stops
• Turn only when necessary at the slowest possible
W('
"'" .'' "', ~. "''!Iff speed and at a very Wide turning radius
.lise extreme cautio,g.
..,when traveling witb» • Provide tag lines to prevent load from sWinging
a load .•~ • Use the shortest boom possible
"'. io>'~ ,''''1 • Keep the load as close to the ground as conditions
will allow
Lifting loads while on tires and moving with the load
may reqUIre different tire pressures than highway travel.
Check your operator's manual for proper Inflation
requirements.

29
 Operate Safely
Multi-Crane Lifts
Such operations must be carefully planned well In
advance and should only be attempted by skilled
personnel experienced In such procedures.
-4~..
'""
"'\i!;10evelop and use~
a lift plan;'"
Jiii;, ~,._.,,,;)j.
USing two or more cranes to lift one heavy or unwieldy
load must be done per the crane manufacturer's
Instructions. Use cranes with similar base ratings.
.",., ,~",. '~§9
.,;fake all precautio. .
..
~w,hen usmg multiplJ-.
manes to lift a 19B
~, ,~" '.~~
30
A multi-crane lift, if done Incorrectly, can Introduce
dangerous elements which Include: side loading of the
boom, overloading, operator error, differing ground
conditions, and many other hazards not normally
encountered In single crane lifts.
The user must Instruct personnel Involved In the proper
positioning, load rigging, and movements to be made:
• Each machine Involved In the lift must have a certified
and experienced operator properly seated at the
controls
• Use only one lift director. The person must coordinate
lifting plans with all machine operators and signal
person(s) before beginning the lift
• The lift director must know how much of the load will
be carned by each machine and be absolutely sure
that the slings are positioned to diVide the load as
planned
• Each crane's portion of the load, weight, must not
exceed the manufacturer's specifications dUring any
phases of the lifting operation
• Machine capacity IS based on freely suspended and
balanced loads. Keep the load line vertical and In the
same plane as the boom to avoid side loading
 Operate Safely
Load Handling Know the load, the boom length, and loaded radius
prior to lifting a load.
Do not sWing load over personnel. Barncade the work
zone. Restnct personnel from walking or working under Keep the crane and load from contacting any
any part of the machine or load. obstructions when lifting or sWinging. ,If the boom IS
struck by a load, swung Into anything, or IS damaged In
Only authorized personnel should be In the vIcinity of
any way, stop work Immediately.
the load.
Control the load at all times. To prevent excess motion,
Keep a sharp eye on personnel In elevated areas and be
use tag lines to gUide the load when necessary.
careful to keep clear of them.

~«,A-»~ :
~\"''''''''''''~
SOund a warriinl
signal when 'i)ll'
\f,':-'
!!!;": J'fr..

".-Stand clear of load~

...~
'r.
approaching JifI>' «",boom, and ngglDg1!>
wben using tag lioeS
personnel ".~
,"- "" '''''' ,,\iii '"". "''ilP''iili

Never hOist two or more separately rigged loads In one

lift, even if the combined load IS within rated capacity.
The ngglng may become fouled, causing damage or
load shift which IS hazardous.
Apply the travel brakes to hold crawler crane In position
while working.
Apply service and/or parking brakes to hold wheel
mounted crane In position.
A WARNING! When uSing tag lines to gUide a load, do
not wrap the line around any part of your body or
clothing. You may have to release the line quickly to
avoid serious injury.
For night operations the Job site should be adequately
lit so the operator and ground personnel can see all
movements of the crane, boom, jib, and load.
31
 Opera'e Safely
Pinch Points
Pinch pOints are areas that can pin or crush a person or
body part between a moving part and another object.
Keep personnel clear of pinch POints both on the crane
and external to the crane. External pinch pOints can occur
between the load and another object. The operator should
know where all personnel are when sWinging crane.
Prevent any motion between pinch pOints when
performing maintenance and to completely avoid these
areas when movement IS possible.
Keep hands, clothing, and fall protection harness
clear of sheaves and drums dunng crane operation,
assembly/disassembly, and maintenance.
Keep all body parts clear of telescoping components
unless the sections are securely anchored together and
power IS shut off.
32
Electrical Power Lines
Before working In the vIcinity of power lines:
• Contact the owners of the power lines or the nearest
electnc utility. Look them up In your local telephone
directory
• You and the electnc utility representative must JOintly
determine what specific precautions will be taken to
ensure safety
• Consider all lines to be power lines and treat all
power lines as energized, even if it IS known that the
power IS shut off and the line IS visibly grounded
• It IS the responsibility of the user and the electnc
utility to see that necessary precautions are taken
Working in the Vicinity of Power Lines
A DANGER! Contact with energized power lines will
cause serious injury or death. Never approach
overhead power lines with any part of your machine
unless all local, state/provincial, and national (OSHA)
required safety precautions have been taken. Always
use extreme caution around power lines.
 Operate Safely
You are working In the VIcinity of power lines when the Keep the crane the maximum possible distance from
attachment or load of your crane, In any position, can overhead lines. Watch your boom clearance when
reach Inside the required clearance specified by local, traveling. Uneven ground may cause the boom to
state/provincial, or federal regulations. contact power lines. If necessary to work near power
lines, check local, state/provincial and federal codes.
Required Clearance for Operation Near High-Voltage Power Lines
Normal Voltage kV Minimum Approach
(Phase to Phase) Distancet -«l
"'~
ft. (m) '1:\" .

-.,' Keep boom and,~

Up to 50 kV 10 (3.0) load clear of all .•~
Over 50 to 200 kV 15 (4.6) "l' power lines ..iA
jiij
...
.~

Over 200 to 350 kV 20 (6.1)

Over 350 to 500 kV 25 (7.6)
Over 500 to 750 kV 35 (10.7)
Caution all ground personnel to stand clear of the
Over 750 to 1,000 kV
Over 1,000 kV .
45
.
(13.7) machine and the load at all times. If the load must be
gUided Into place, consult your local electnc utility
tEnvlronmental conditions such as fog, smoke or precipitation may reqUire Increased clearances. company for specific precautions that must be taken.
"As established by the utility owner/operator or registered professional engineer who IS a qualHied Complete a practice run In tight area. It will help you
person with respect to electrical power transmission and distribution.
determine the easiest way to operate under eXisting
conditions.
Crane mounted cage-type boom guards, Insulating
It IS the responsibility of the Signal person to observe the
links, and proximity devices have limitations. The use of
crane and load to be sure neither approaches a power line.
such devices IS not a substitute for strict adherence to
The Signal person must be In direct communication with
all safe operator practices and procedures.
the operator, and the operator must pay close attention to
Treat all wires as energized. Store all matenals the the Signals. (See page 49, Hand Signals Chart)
maximum possible distance from all power lines. 33
 Operate Safely
Accidental Contact with Power Lines
A DANGER! If the crane comes in contact with
power lines, stay at the operator's station, if
possible, until the lines can be neutralized. The
surrounding ground around the equipment is also
electrically charged. Contact with electrically
charged parts of the equipment or surrounding
ground will result in death or serious injury.
High voltage contact will result In electrical current
flowing down the boom and through the crane to
ground. The ground will then be energized with a high
voltage near the crane and lower voltage farther away.
Grounding the crane will not protect workers on the
ground surrounding the crane.
Emergency Exit Procedure
A DANGER! It is advised that you stay in the
operator's station if contact is made with electrical
wires. Contact with differently electrically charged
parts of the machine or surrounding ground will
result in death or serious injury.
34
Wi!'.' ~'. .•.1<!1,'."3I
~void electrocuti'ollJ..
<IIi'! stay clear::;'"
.0£.", of power linelka
.. ....
~, ~ ,~ ...~
If the operator deCides to leave the operator's station,
the person must Jump clear of the crane. The person
must never step down allowing part of their body to
be In contact with the ground while any other part IS
touching the crane.
There IS a hazardous voltage differential In the ground,
so the operator must Jump with feet together, maintain
balance, and shuffle or hop slowly across the affected
area. Do not take large steps because it IS possible for
one foot to be In a high voltage area and the other to be
In a lower voltage area. The difference between the two
will cause death or serious InJury.
 Opera'e Safely
Buried Utility Lines
Before working In the vIcinity of utility lines:
• Always contact the owners of the utility lines or the
nearest utility before beginning work. Look them up In
your local telephone directory.
Working in a Pit or on a Bank
Job site personnel should beware of caving edges and
overhanging banks-undercut edges may give way-
banks may slide.

"'-"'. . '-~,
"Someone must'
,.~
",,'.,
., "~""

..,:,Keep crane cleai'~

"'!If

"'contact 811 and';"" " •. ,of banks that can,:;'

'tItility owners beforlt ."collapse or slidQ;I.
Wbrli!l1g nearllW}tiils
""'
() ~,., 'iil,iY4ii

Keep machine away from banks or edges at all times.

• Determine together what specific precautions must
be taken to ensure safety.
• Slow down the operating cycle. Reaction time may be
too slow and distances may be misJudged.
~" ,.~ ""~
• Use a signal person. The sole responsibility of the "", Operate ',"9
signal person IS to observe, from the best vantage """perpendicular to1!Y
pOint, the approach of any part of the machine or 6a~nks-stay back frpRt
Jf;;, the edge, •
.. ~, ", ... ~
attachment to a utility line. The signal person must
be In direct communication with the operator, and the
operator must pay close attention to the signals. (See
page 49, Hand Signals Chart)

35
 Operate Safely
Using a Magnet
A DANGER! Be careful, electromagnet power is
high voltage and can be dangerous. Electrocution
will result in death or serious injury.
Be sure to take these precautions for safe operation
while uSing a magnet:
• Keep terminal box cover tightly closed
• Stay within the manufacturer's specifications for Draglines and Clamshells
maximum boom lengths
In a dragline or clamshell operation, keep the boom
• Be especially careful of personnel. Never permit them
length to a minimum for maximum stability. Stay within
to touch the magnet or the load
the manufacturer's specifications for boom length,
• Open magnet switch and shut off all power before bucket Size, and counterweight.
connecting or disconnecting magnet leads
• If necessary to position a load, make sure a non- Keep a tight closing line when hOisting a clamshell
conductive device IS used bucket until you are ready to dump.
• Sound warning signal prior to every load move and Do not overfill the bucket. This will avoid spillage and
keep sounding it until personnel are well clear of path consequent danger to personnel.
• Keep loads away from personnel. Never permit
anyone to be under loads or between loads and the Keep the weight of bucket and contents within the
magnet manufacturer's recommendations.
• Stay In the operator's station until you have landed Load the truck only once the driver IS In a safe place. Do
the magnet securely on the ground or supporting not pass the load over front of truck. Trucks should be
platform and turned off the power source loaded evenly so that nothing overhangs the sides.

36
 Operate Safely
Personnel Handling
Never allow anyone to nde the hook or load. This IS an
unlawful and an extremely dangerous practice.
OSHA regulations prohibit the handling of personnel
with cranes, unless it IS the least hazardous way to
perform the operation. If a crane IS utilized to handle
personnel, it must be equipped and In compliance with
OSHA regulations, as well as state/provincial and local
regulations.
,'"'..•.•"!!\.
Only handle perSolfhel
""if it is the safesf""
",oway to perform th~"
~.. .. . operation .",""
&<i'.. ~: ••.if$'"
Operate the crane from the operator's station at all times
when the engine IS running or personnel are suspended.
Operating from any other position constitutes a safety
hazard. Senous Injury to personnel can result.
Set and lock all brakes and engage all locking deVices
when handling personnel.
General Precautions
Mobile cranes are deSigned and Intended for handling
matenals, not personnel. Mobile cranes are not
elevators.
A WARNING! AVOid senous Injury or death. Only
handle personnel if it is the safest way to perform
the operation.
If handling personnel IS the safest way to complete the
operation, then you must follow these precautions:
• Personnel platforms are to be supported by the
crane load line attachment. ThiS can Include the use
of boom mounted baskets. Always follow the crane
manufacturer's Instructions for either system
• Do not use pin-on baskets on luffing jibs
'··4
• HOisting of the personnel platform shall be performed
In a slow, controlled, cautious manner. The lifting or
lowenng speed shall not exceed 100 ftlmln (0.51 m/s)
• Wind speeds must be below 20 MPH dunng the
entire process of handling personnel
• Load lines shall be capable of supporting, without
failure, at least seven times the maximum Intended
load. Rotation resistant rope, if used, shall have
at least ten times the capacity for the maximum
Intended load
37
 Operate Safely
• Load and boom hOIst drum brakes, sWIng brakes,
and lockIng devIces shall be engaged when the
occupIed platform IS In a stationary working position
• The load line hOIst drum shall have controlled load
lowering. Automatic brake shall apply In neutral
position. Free fall IS prohibited
• The crane shall be uniformly level withIn one percent
of level grade and on firm footing. Cranes equIpped
with outriggers shall have them all fully deployed,
followIng the manufacturer's specifications, and on
firm footing
• The total weIght to Include personnel platform,
ngglng, occupants, and tools or materials shall not
exceed fifty percent of the rated crane capacity
for the radius and configuration used. Do not lift or
suspend a second load while handling personnel
• The use of cranes having live booms (those In whIch
lowering IS controlled by a brake only) IS prohibited
• Cranes with vanable angle booms shall be equIpped
with a boom angle Indicator
• Cranes with telescopIng booms shall be equIpped
with a devIce to Indicate the boom's extended length
• An accurate determInation of the load radius to be used
dunng lift shall be made prior to hOIsting personnel
• An anti-two-blocklng devIce shall be used
38
• Hooks shall be of a type that can be closed and
locked, elimInating the hook throat from opening.
,.,'
~ .. .• ~... "~.,,,,
"!!1Perform a trialll~
~i before hoisting.
Jki;"" personnel;;.
1\ii;:"~'~'iiIi
Trial Lifts
• Perform a tnallift with the unoccupIed personnel
platform loaded with ballast 125% the Intended load,
Including personnel, at each location at whIch the
personnel platform IS to be hOIsted and positioned
• The operator shall ensure the crane IS reeved such
that the crane's hOIst IS under fifty percent (50%) of
its capacity
• A trial lift shall be performed for each location that IS
to be reached from a sIngle setup position
• The trial lift shall be repeated prior to hOIsting employees
whenever the crane IS moved, set up In a new location,
or returned to a prevIously used location
 Operate Safely
Inspection
After the trial lift, and Just prior to hOisting personnel, the
platform shall be hOisted a few Inches and Inspected to
ensure that it IS secure and properly balanced.
A visual Inspection of the crane, rigging, personnel
platform, and the crane base support and/or ground
shall be conducted Immediately after the trial lift to
determine whether the test has exposed any defect or
produced any adverse effect upon any component and/
or structure.

.~
Any defects found dUring Inspection must be corrected
.Complete inspectiog. before handling personnel.
"", before handling . ')-
"" personnel
~, ~' 's;i
Lifting with Personnel
Tag lines shall be used unless their use creates an
unsafe condition.
Employees shall not be hOisted unless the following
The crane operator shall remain at the controls at all
conditions are determined to eXist:
times when the crane engine IS running and the platform
• HOist ropes shall be free of kinks
IS occupied.
• Multiple part lines'shall not be tWisted around
• The primary attachment shall be centered over the HOisting of employees shall be promptly discontinued
platform upon Indication of any dangerous weather conditions or
• If the load rope IS slack, the hOisting system shall be other Impending danger.
Inspected to ensure all ropes are properly seated on Employees being hoisted shall remain In continuous
drums and In sheaves sight of and In direct communication with the operator
• All safety devices and position Indicators are and/or signal person.
functioning correctly

39
 Operate Safely
Employees must stand firmly on the floor of the work platform
and shall not sit or climb on the edge of the work platform or
use planks, ladders, or other devices for a work platform.
Personnel must wear a body harness and lanyard
attached to the boom or the basket when working from
a work platform aenal lift.
No lifts shall be made on any other of the crane's load
lines while personnel are suspended on a platform.
HOisting of personnel while traveling IS prohibited.
1J!:t",,~"''''''~''''~,.,~
~ep crane stationaljJ
~whenever handling.
.." personnel ,At.
~. '"v
A meeting attended by the crane operator, signal
person(s) (if necessary for the lift), employee(s) to be
lifted, and the person responsible for the task to be
performed shall be held to review the appropriate
requirements and the procedures to be followed. This
meeting shall be held prior to the tnallift at each new
work location and shall be repeated for any employee
newly assigned to the operation.
40
Work Platform
Brake or lock mechanism must be released dunng travel
to ensure the basket remains level.
Belting off to an adjacent pole, structure, or equipment
while working from a work platform shall not be
permitted.
Safety harnesses and lanyards shall be used only
for employee safeguarding. Any safety harness or
lanyard actually subjected to in-service loading,
as distinguished from static load testing, shall be
Immediately removed from service and shall not be used
again for safeguarding.
The safety harness and lanyard shall be Inspected
before each use and must be In good condition with
no cuts, abrasions, burns, or chemical damage. If any
damage IS found, that safety harness or lanyard should
not be used ever again.
The snaps, nvets, grommets, threads, and buckets must
be examined for broken, looseness, or eVidence of cuts
and cracks. They must be removed from service if any
damage IS apparent and replaced before the basket IS
used again.
 Operate Safely
Cold Weather • Heater fuel containers are handled In the manner
prescribed by your supplier
Consult manufacturer's operating manual for proper • To watch out for falling snow and Ice that can cause
starting and operating procedures. serious Injury
Before operating, be sure:
• The sheaves and pinS are not frozen Traveling on Job site
• The load, tracks, and outrigger supports are not
Make sure there IS adequate clearance between the
frozen to the ground or to the supporting structure
crane and bridges, power lines, and obstacles.
• There IS no snow or Ice covering the boom. The extra
weight may cause overload, structural damage, or Use a signal person whenever you travel a crane on
tip-over a Job site, In a congested area, or around people. The
• To use crane and wire rope lubricants approved for signal person shall be responsible for determining and
cold or arctic conditions controlling speed and safety of movement. (See page
49, Hand Signal Chart.)
While operating, be sure:
• To operate slowly until hydraulic oil IS warmed to
correct operating temperature !!",>,o o"~
",.. .0.'' '
• To aVOid Impact loading U.se a signal person1lP
• To not touch any metal parts of the machine with .,JIuide travel througbs.
iii. difficult areas,~
damp or wet exposed flesh, as the flesh will freeze to •. ;.!iiI
v'v
the metal and cause Injury
• To not store cold weather starting aid containers or any
flammable materials on the machine. Keep all such
Know the weight of your crane and the load limitations
materials away from heat, sparks, or open flame. Do
of the travel route.
not puncture or burn containers. They could explode
41
 Opera'e Safely
Travel Safely When starting up a steep grade or passing over the
crest of a hill, keep the boom lowered as close to
Make certain no person or property will be endangered
the ground as practical. But be sure there IS enough
before you travel or sWing the crane. When traveling or
clearance beneath boom that it does not contact the
sWinging the crane, slow down to prevent losing control.
ground when breaking over a nse.
Consult manufacturer's operating manual for travel
procedures.
A WARNING! Avoid death or senous inJury. Travel up
and down slopes with the boom as low as practically
Don't obstruct your vIsion when traveling or working. possible and pointed uphill.
(See page 22, Masked Visibility Areas.)
Signal your Intention to move or stop by sounding the
A WARNING! AVOId death or senous InJury. Make sure horn - one blast for stop, two blasts for a forward
you can see where you are going. move, and three for a reverse move.
Stay at the operator's station whenever the crane IS In
motion or the engine IS running.
A WARNING! Avoid senous injury or death. Keep the
~('A )~
( • )
Sbund"""~"'~
a warnifill
;' signal to alert'~
""',pers,onnel of you~
boom as low as possible for maximum stability and ""'" ,i!1tention,~.",a
lilt "'iitif ijj
visibility

"",,,,.fC" ,f"', ,'"!!\",,'1!1!1

(~ep boom as low¥-
apssible for maximqgl
$lability and vlsilljJjty
~" ,~",~,,,,,.
Never allow a crane to be used to transport personnel.
A WARNING! USing a crane to transport personnel IS
extremely dangerous and can cause death or senous
InJury. Never allow a crane to be used to transport
personnel under any circumstance.

42
 Operate Safely
Watch for narrow spots and low clearances:
• Use a signal person when maneuvering in tight
quarters and/or clearances are close
• Know your crane's height and width
• Know bridge load limits, and don't exceed them
• Know your slope and ground support limitations
• Be sure of tail sWing clearances In narrow spots
• Reduce travel speed when maneuvering In tight
quarters
If sWinging IS reqUired dUring traveling with a friction
(mechanical) crane without Independent sWing, engage
sWing clutch before releasing brakes. Always release
sWing brake as you engage sWing lever.
Be sure crawlers are blocked to prevent downhill
movement before shifting steering clutches if crane IS
not equipped with automatic traction brakes.
~.,~. ,~
"".' ""'If
IUock crawlers befq\i8
""shifting steering ••
.<iK.... clutches,:;;i
... ~"'''4'",...
Travel with the boom In the direction of travel whenever
possible. Make sure there are no obstructions and keep
the boom and gantry/mast as low as possible.
Watch boom clearance when traveling or transporting.
Uneven ground may cause the boom to move enough
to contact power lines or other obstructions.
~" .~
"r::~" '-:"'!IiJY
'" Watch boom'!!'
<i;' clearance ,~
,.,ilI.
Cross obstacles at an angle and at slow speed. Be alert
for the Jolt when the crane crosses the obstacle.
If the crane must travel with the boom elevated, if
possible, extend outriggers and keep pads close to the
ground. The ground surface IS to be uniform and free
of obstacles. This will help stabilize the crane should
tipping occur. Be alert of obstacles .
Do not travel with the boom so high that it can contact
the boom stops and bounce back over the cab.
43
 Opera'e Safely
Rules of the Road Stop at all railroad crossings and look both ways before
proceeding. Never park In traffic areas. If it IS necessary
When traveling on public roads or streets, obey all traffic to stop at night, pull off the road and set up flares or
regulations applicable to your machine. reflectors. When driving at night, use appropriate lights.
Be aware of machine height, bndge heights, and axel
loads. Make sure there IS enough boom clearance from
structures, especially when cornering.
If a tire blows out while traveling, do not apply the
brakes hard. Steer to maintain control and slow down
gradually.

Make sure lights and warning signs are In place and J¥'!c,A . . ~.
visible. Make sure a Slow Moving Vehicle (SMV) emblem .Q.l~ot brake quillJ.
IS Installed and visible to any vehicle approaching from .~ in the case of a· ...
the rear. 4, blown tire )~
1iilic"."",,.ii1-iiJIiI
Obtain the proper load permits and find out if you must
use an escort vehicle. Approach Intersections with
caution; observe speed and traffic control signs. Avoid
panic stops and sharp turns.
Watch Out for Obstacles
Like any responsible operator, be considerate of other
Adjust your speed to conditions. Go around rocks and
drivers. If traffic backs up behind you, it IS a good Idea
stumps. Avoid crossing ditches, curbs or exposed
to pull over periodically and allow traffic to pass when it
railroad tracks. If obstacles are unavoidable, reduce
IS safe to do so.
speed and cross at an angle.
44
 O:perale Safe.IY
Keep your machIne under control. Keep speed to a
mlnrmum when VIsibility IS poor.
Before entenngunderpasses, tunnels or bunkers, make
sure you have more than enough boom clearance and
check for oncomIng traffic or obstructions.
Back up Safely
:.. .
Check that the back-up alarm, if~(tuippe9,)S workIng
properly. Dnve forward whenev~r'possible:lf you must
back up, use a sIgna:l person that must remain In sIght
and/or communrcation with the op$rato(at all times.
~,~,~ «I'~',,.
ll!;ie a signal pers(ji\~
...guide travel throuQ).
sii". difficult areas~i.
jIiii,.~~'i4
Transporting Safety Tips
General
When towIng a crane on a tra.iler, or a crane eqUIpped
with portability or transport wheels, always use a
hauling vehicle of sufficient weIght,' horsepower, and
brakIng capacity to maIntaIn proper control.
Never attempt to tow a trailer or machIne if the hitchIng
deVIces are of insuffiCIent or questionable capacity,
Improperly matched 'in sIze or shape, or positioned at
Improper heIghts.
When towing a machIne equIpped with portability or
transport wheels, always follow the manufacturer's
towing Instructions. .
It IS recommended to use a three-poInt hitch when
towing a crane without brakes.
45
 Operate Safely
Before Towing
When connecting a trailer to a hauling vehicle, block
under the trailer's tongue before attempting to make the
connection. Never attempt to lift heavy tongues or move
heavy trailers by hand. Never get any part of your body
under the tongues when hitching or unhitching.
When loading or unloading a crane to/from a trailer
or railroad car, always use a ramp. If a ramp IS not
available, use blocking to build one. The ramp must be
solid and of sufficient size and strength to support the
weight of the m a c h i n e . ' .' -.
When loading andunloading, make>sure you set the
brakes, block the tires, and are on level ground.
46
Block the tires or crawlers of the crane before
disconnecting the propel mechanisms.
Check all tires for proper pressure, excessive or
abnormal wear,and potentially dangerous cuts,
brUises or bulges. Have any problems corrected before
proceeding.
,~".~......~
~heck tiresalflF
~iNheels for propliilJ'
4!l; pressure and an.
~'" dam ..r....;,'-
~-.
Use tow bars between the hauling vehicle and trailer
or towed machine. Be sure the chains are properly and
securely connected at both ends.;Cross the chains under
the tongues when connecting to the hauling vehicle.
Make sure electrical and other connections between the
hauling vehicle and trailer or towed machine are properly
and securely made. After connecting, check the lights
for proper operation. If the towed trailer or machine IS
equipped with brakes operable from the hauling vehicle,
check to make sure they are operating properly.
 Operate Safely
Always be sure the portability or transport wheels, if
equipped, are locked In the lowered position.
Make sure the hitch pin IS of the proper size and
securely locked In place before towiri~~
Towing
Use care when towing a trailer or crane when:
• Maneuvering In tight places .....,'*'
"'.... 'N
• Backing (visibility IS reduced, and Jackknifing must ... ChaIR and block.
4,(. crane securely!~
be aVOIded) for transport . . iiI.
• Towing on steep grades "'''~i' --<liii

Know and obey all local, state and!edetal laws and

regulations. .
Do not travel at speeds above those recommended by
the manufacturer.
Do not allow anyone to ride on a trailer or towed
machine.
When necessary to disconnect and park a trailer or
towed crane, select a location that IS level and, if
possible, where children are unlikely to:bepresent.
Before disconnecting a trailer, block the front AND rear
of the wheels and block under the tongues.
47
 Operate Safely
Exhaust Fumes in a Closed Space Can Kill
Vent exhaust and assure a flow of fresh air when an
Internal combustion engine IS used In a closed space.
A WARNING! Exhaust fumes from diesel, gasoline or
LP gas engines can kill. Do not breath exhaust fumes
from any kind of engine.

Operating in Flammable/Explosive Atmospheres

A WARNING! Do not operate a standard machine
equipped with a spark arrestor/spark arresting muffler In
flammable or explosive atmospheres. USing them In
explosive atmospheres can result In fires and/or
explosions which could cause senous Injury or death.
Use only an approved crane with a label designation
of G, GS, D, DS, DY, LP, LPS, G/LP, or GS/LPS. See
~"~'...4
Code of Federal Regulations (OSHA) 29 CFR Part 'Ro smoking amf
1910.178 to determine permissible areas where these "no open flames i'
1fammable/explos
machines can be operated. ~~jtm.:p:; ",

48
 Opera.eSafely
Hand Si nal Chart
Ci

Hoist: With forearm vertical, forefinger pOinting upward, Use Main Hoist: Tap fist on head; then use regular Signals.
move hand In small hOrizontal circle.

Lower Boom: Arm extended, fingers closed, thumb Raise Boom: Arm extended, fingers closed, thumb
pOinting downward. pointing upward.
49
 Operate Safely
Hand Si nal Chart

/A\ '
Lower: With arm extended downward, forefinger pOinting Use Whip Line {Auxiliary Hoist}: Tap elbow with one hand;
down, move hand In small hOrizontal circles. then use regular signals.

Lower the Boom and Raise the Load: With arm Raise the Boom and Lower the Load: With arm
extended, thumb pointing down, flex fingers in and out as extended, thumb pOinting up. Flex fingers In and out as
Ion as load movement IS desired. Ion as load movement IS desired.
50
 Operate· Safely

•
Travel: Arm extended forward, hand open and slightly
raised, make pushing motion In direction of travel.
ffl
Move Slowly: Use one hand to give any motion signal
and place other hand motionless In front of hand giving
the motion Sl nal. HOist slowl shown as exam Ie.

Travel One Track: Lock the track on side Indicated by raised Travel Both Tracks: Use both fists In front of body, making
fist. Travel opposite track in direction indicated by circular a circular motion, about each other, Indicating direction of
motion of either fist, rotated vertically In front of body. travel; forward or backward. (For land cranes only.)
51
 Operate Safely
Hand Si

Stop: Arm extended, palm down, move arm back and forth Emergency Stop: Both arms extended, palms down,
hOrizontally. move arms back and forth hOrizontally.

Swing: Arm extended, pOint with finger In direction of Dog Everything: Clasp hands In front of body.
sWing of boom.
52
 Operale Safely

Retract Boom: (Telescoping Boom) One

Extend Boom: (Telescoping Boom) One Hand Signal. One fist In front of chest,
Hand Signal. One fist In front of chest with thumb pOinting outward and heel of fist
thumb tapping chest. tapping chest.

(Reprinted from ASME B30.5-2011, by permission of

The American Society of Mechanical Engineers. All rights reserved.)

53
 Shu' Down Safely
Select a Proper Parking Site Safe Shutdown
The shutdown procedure will vary for different cranes;

always follow the manufacturer's Instructions for
shutting down.
When shutting down, select the proper parking location.
Park on level ground whenever possible. If you must
park on a slope or Incline, position the machine with the
boom In line with the slope, engage the parking brake,
and block the wheels or tracks.
AVOid parking where there IS a chance of a bank caving
In or In low spots where heavy rains may wash away the
crane's footing.
w ~".
",,:t~ad operat '.
~inanualfor prope,JIo-
slmtdown proce~Uiie
~.,,,,,.'<4
The detailed shutdown procedure IS given In your
manufacturer's manual(s). In general, this Includes:
• Stop machine
• Ensure all wheels or parts of tracks are on the ground
• Position controls In neutral or locked position
• Engage parking brake
• Lower or secure the boom
• Idle engine for short cool-down penod
• Stop engine and remove Ignition key, if equipped
• Cycle hydraulic controls to eliminate pressure
• Raise operator seat/restraint bar(s), if equipped
• Make sure controls are locked In neutral, if equipped
• Unbuckle seat belt/restraint

54
 Shut DownSa'ely
• Lock covers and enclosures
• Shut off master electnc switch, if eqUipped
• When you leave the machine, always maintain three-
pOint contact with the steps and grab handles.
Face the machine as you dismount. Never Jump off
machine
• Block wheels or tracks if on a slope or Incline
A WARNING! Avoid death or senous inJury. Never
leave a machine unattended with the engine running
or a load is suspended.
Be sure to lock the Ignition or starting circuit to prevent
unauthonzed starting and remove the key.
~~".'
~ Shut engmeoHr,'ii1I'
I ..,' lock ignition, '.'~
.,,,and remove k~y.""
fii.o... 'V'''v·4
. .'
Lower or secure the boom. Sesure all controlshave
been relieved so that all elements are at rest.
Place all controls In the neutral or parking condition.
Engage the boom hOist pawls and set the sWing lock!
brake, the drum parking brake, and the parking/traction
brake/lock to prevent crane movement.
Disengage the master clutch, when provided, and shut
off the engine. Never leave the operator's cab when the
engine IS running or a load IS suspended.
Lock the machine cab and Install vandal guards, when
available.
Do not leave blocks, balls, or ngglng tackle in a position
where the Wind may sWing them to cause damage to
the boom, jib, or nearby objects.
Do not shut down the crane and leave it unattended for
extended penods of time; e.g. overnight, with the boom
positioned over other structures or the crane itself. The
boom could cause damage if it lowered.
See the manufacturers Instructions for leaVing the crane
unattended with the boom elevated, if permitted.
55
 Perform Maintenance Safely
Know What You're Doing Protect Yourself
Maintenance on this type of machine IS not for Wear all the personal protective clothing and PPE
inexperienced or untrained personnel. It can be Issued to you or called for by Job conditions.
hazardous unless performed properly. Be sure you have
You may need:
the necessary skill, Information, correct tools and proper
equipment to do the Job safely. • Hard hat
• Safety shoes
Be sure to maintain the equipment according to the • Safety glasses, goggles or face shield
manufacturer's·lnstructions. Regularly check to make • Heavy duty gloves
sure all operational aids, guards and shields, and safety
• Hearing protection
devices are present and working properly.
• Reflective clothing
Do not perform any work on a machine unless you are • Wet weather gear
authorized and qualified to do so. • Respirator or filter mask
If you have been authorized to perform maintenance, read Wear whatever IS needed to protect yourself. Do not
the manufacturer's operating and service manuals. take chances.
Study the Instructions: check the lubrication charts,
examine all the Instruction messages on the machine.

''f!
't':'" ··'llP
""aintain equlpme~
,., •. ,4"·

56
 Perform Maintenance Safely
A WARNING! Avoid death or senous Injury from
entanglement. Do not wear loose clothing or
accessories. Stay away from all rotating components
when the engine is running. Contact, wrapping or ~, J!!b ,"""
entanglement with rotating or moving parts could result In -'"",..
death or senous InJury. ~void rotating pa~
Wear a rubber apron and rubber gloves when working
with corrosives. Wear gloves and safety shoes when
handling wooden blocks or sharp-edged metal.
Always use safety glasses, goggles or a face shield.
They provide eye protection from flUids under pressure,
dunng gnnding and while servicing battenes. Protection
IS also needed from flYing debns, liqUids and loose
matenal produced by eqUipment, tools and pressunzed
air/water.
Wear a face shield and follow manufacturer's Instructions
"1.. f!fIr
when you disassemble spnng-Ioaded components or work ...Wear eye protectiol),.
with battery aCids. Keep pockets free of all objects that £;, ii
~.,
could fall out and drop Into machinery. ''\i>''

Handle tools and heavy parts sensibly, with regard for

the safety of yourself and others. Lower items; don't
drop them.

57
 Perform Maintenance Safely
Prepare the Work Area
• Position the machine In a level area out of the way of
other working equipment
• Ensure there IS adequate light, ventilation, and
clearance
• Remove oil, grease, and water to eliminate any
slippery surfaces
.~
• Clean around the area to be serviced to minimize
contamination. Remove all flammable material In the
vicinity of welding and/or burning operations.
• Wear fall protection when working at elevation.
Prepare the Machine
Stored energy sources (electrical, mechanical, hydraulic,
pneumatic, chemical, thermal, etc.) must be controlled
or reduced to a practical minimum before performing
any maintenance, repair or service procedures.
58
Safety practices to prevent potential Injuries from
energy-releasing sources Include:
• Place controls In NEUTRAL or LOCKED position
before shutting off engine
• Set parking brake or block wheels
• Allow all moving parts to stop
• Shut off engine
• Relieve hydraulic system pressure, see manufacturers
Instructions for proper procedure
• Lock Ignition, remove key (if equipped), and take it
with you
• Look and listen for eVidence of moving parts before
dismounting
• Shut off master electrical switch, if equipped
• Securely support or block up machine before working
underneath machine or other lifted components
• Securely support, block up, or lock up other
components with approved locking devices before
working near or underneath them
• Relieve pressure before disconnecting or
disassembling any pressurized system
• Block or relieve spring pressure before disassembling
any spring-loaded mechanism
 Perform Maintenance Safely
Avoid flames, sparks, or smoking near any fuel,
hydraulic fluid or other flammable matenal such as
spraying debns.
Attach a "DO NOT OPERATE" warning tag to the control
levers. Follow the lock out/tag out procedures according
to the manufacturer's operating manual. If there IS a key,
remove it and take it with you.
i!'\!", .. ,~.,~,
""<f
Use a "DO NOT'", ..
OPERATE" tag
Install approved support devlce(s} when working under
or near raised equipment.
A WARNING! Unsupported raised machines or other
equipment may drop unexpectedly. Never go under
equipment when raised unless supported by an
approved support device{s). Death or senous crushing
injury could result from falling equipment.
Remove only guards or covers that prOVide access to
the area being serviced. Replace all guards and covers
when work IS complete.
A WARNING! Avoid Injury or death. Never work on a
crane with the engine running unless instructed by
the manufacturer's manuals for specific service.
Keep hands; clothing, and all body parts well away from
moving parts while engine IS running.
Use proper nonflammable cleaning solvents. Follow
solvent manufacturer's Instructions for use.
Keep the brake and clutch linings free from oil and grease.
Keep crane In proper adjustment at all times. Senous
injury could result if adjustments are neglected.
After adjustments/repairs have been made to brakes
or clutches, a lift test shall be done to assure that the
adjustments/repairs are correct. Refer to the operator's
manual or contact the manufacturer for correct procedure.
59
 Perform Maintenance Safely
Common Maintenance Use Jacks and Hoists Carefully
Safety Practices Safety stands or blocks must be located on a rigid part
of the machine. Do not position stands under axles or
Use Proper Ventilation wheel supports that may rotate.
If it IS necessary to run an engine In an enclosed area, A WARNING! Prevent crushing injury. Never use
remove the exhaust fumes from the area with an concrete blocks for supports. They could collapse
exhaust pipe extension. under even light loads.
If you do not have an exhaust pipe extension, make sure
you open doors and Windows to get plenty of outside air
Into the area.

~'~"~"~"~
'IIIi"
..Yentilate work are~
....
r ~r
,,-
'~
Jif"",;ia
~,'.,.;:4
If you must work beneath raised equipment, always
use wood blocks, jack-stands or other rigid and stable
supports. When uSing Jacks or hOiStS, always be sure
A WARNING! Exhaust fumes contain carbon they are adequately supported.
monoxide which could be deadly if Inhaled. Never
operate any type of engine without proper Make sure the hOists or jacks you use are In good repair.
ventilation. EXHAUST FUMES CAN KILL. Never use jacks with cracked, bent, or tWisted parts.
Never use frayed, tWisted, or pinched cables. Never use
bent or distorted hooks.

60
 Perforlll Maintenance Safely
Fuel Hazards
A WARNING! AvoId serious injury or death. Always
use approved fuel containers and/or fuel dispensing
equipment to reduce the risk of explosion or fire.
Always. observe these practices to reduce the possibility
of a serious aCCIdent:
• Shut off engine and Ignition dUring refueling
• Turn off all electrical switches
• Ground the fuel nozzle agaInst the filler neck
• Keep sparks and open flames away from fuel. Do
not smoke while refueling or when handling fuel
contaIners
• Do not cut or weld on or near fuel lines, tanks or
contaIners
• Do not overfill the tank or spill fuel. Clean up spilled
fuel Immediately. Clean spills Immediately
Ulra-Low Sulfur Diesel (ULSD) Hazard
A WARNING! Ultra,.Low Sulfur Diesel (ULSD) poses a
greater static Ignition hazard than earlier diesel
formulations with hIgher sulfur content. AVOId death or
serious Injury from fire or explosIon; consult with your
fuel or fuel system supplier to ensure the delivery
system is in compliance with fueling standards for
proper grounding and bonding practices.
Engine Coolant Hazards
A WARNING! AVOId serious injury or death. LIqUId
cooling systems build up pressure as the engIne gets
hot, so use extreme caution before removing the
radiator cap.
• Stop the engine and wait for the system to cool.
• Wear protective clothIng and safety glasses.
• Turn the radiator cap slowly to the first stop to allow
the pressure to escape before removing completely.
'\\1" '71%
"""'Remove radiator~
",;.. cap slowly .•~
~"
61
 Perform Maintenance Safely
Hydraulic System Hazards The boom IS held In position by a trapped column of
hydrauliC flUid under high pressure. The same IS true
Be sure to follow manufacturer's Instructions for relieving
of a machine supported on hydraulic outriggers. It is
fluid pressure before performing any maintenance. The
Important to lower the boom or crane to the ground or
hydraulic system IS pressurized whenever the engine IS
block it In position before attempting maintenance or
on and may hold pressure even after the engine IS shut
repairs.
off. Cycle hydraulic controls, Including auxiliary hydraulic
control (if equipped), after the engine IS shut off.

W,,!~'~""'~"4,
<if' . Check.lor
~!eaks and msp
~" hoses .
~,,~-.,.-

DUring Inspection of the hydraulic system:

A WARNINGllf the hydraulic flUid escapes, the boom
or the crane can fall Immediately, endangering anyone
• Wait for flUid to cool before disconnecting the lines. or anything below. Make sure the ground or blocking
Hot hydraulic flUid can cause SEVERE BURNS is actually fully supporting the boom before doing
• Wear appropriate eye protection. Hydraulic flUid can any maintenance on the hydraulic system.
cause permanent eye injury
• When venting or filling the hydraulic system, loosen
the filler cap slowly and remove it gradually
• Never reset any relief valve In the hydraulic system
to a pressure higher than recommended by the
manufacturer
62
 Perform Maintenance Safely
Hydraulic Fluid Injection Hazard FlUid Injection Injunes are not always obvIous. Victims
have reported such Injunes feel like a bee sting or
A WARNING! Accidental Injection ()f high-pressure oil
splinter under the skin. If you suspect you have a flUid
Into the hands or body IS dangerous and could result In
Injection Injury, do not take chances. Seek proper
death or senous injury. Use caution when checking
medical care Immediately. If any flUid IS Injected Into the
hydraulic leaks as pressurized hydraulic fluid has
skin, it must be surgically removed within a few hours by
enough force to penetrate skin, causing serious
a doctor familiar with this type of injury.
personal injury.

Electrical System Hazards

~"", ~;'\"~~';"~'\'W
..,High pressureflul~
<,; can inject into? Light Bulbs and Illumination
"",the,body,;it.
,<iii Some machines are equipped with High-Intensity
Discharge (HID) Xenon light bulbs which operate at very
high voltage. Do not begin Installation of HID-Xenon
If a leak IS discovered: lamps unless the lamps are turned off, the engine IS
• Ensure engine IS turned off; relieve pressure In turned off, the key IS removed Of equipped), and you are
hydraulic circuit weanng appropnate eye protection.
• Wear proper hand and eye protection A WARNING! Do not look directly into HID-Xenon
• Visually examine the hydraulic hoses or flUid lines In lamps. Eye damage could occur.
the VICinity of the leak for breaks or cracks. Do not
Wear gloves and safety glasses when handling bulbs.
use your hand to check for leaks
Dangerous voltage sparks may occur and cause Injury
• Repair or replace hydraulic lines according to the
or damage to the connector. See manufacturer's
manufacturer's recommendations
warnings packaged with replacement bulbs.

63
 Perforlll Maintenance Safely
Before working on the electrical system, disconnect the If liquid from the battery contacts your eyes, flush
battery cable(s). Immediately with clean water and get medical attention.
Wear chemical-resistant gloves and protective clothing
Remove the battery negative (-) cable(s) first.
to keep liquid off your skin. If liquid contacts exposed
When reconnecting the battery, connect the battery skin or clothing, wash off Immediately with clean water.
negative (-) cable(s) last. If liquid is ingested, drink large quantities of water or
milk. DO NOT Induce vomiting. Seek medical attention
Battery Hazards Immediately.
The liquid In batteries contains aCid, which IS a POISON
and could cause SEVERE CHEMICAL BURNS.
Avoid InJury'
• Wear a face shield to prevent contact with your eyes
• Wear chemical-resistant gloves and clothing to keep
electrolyte off your skin and regular clothing
A WARNING! Electrolyte will damage eyes or skin on
contact. Always wear a face shield to avoid
electrolyte in eyes.

64
 Perform Maintenance Safely
Avoid Explosion Safety rules dunng battery Jump-starting:
• Follow the Instructions for proper battery Jump-
A WARNING! Avoid serious injury from explosion.
starting, as specified In the manufacturer's manual.
Lead-acid' batteries produce extremely explosive gases
especially when being charged. Keep arcs, sparks, • Be sure the machines are not touching
flames and lighted tobacco away. • Observe the polarity of the battenes and connections
• Do not smoke near battenes • Make the final cable connection to the engine or
• Keep them away from arcs, sparks and open flames the furthest ground pOint away from the battery.
Never make the final connection at the starter or
• Provide adequate ventilation
dead battery. Sparks may Ignite the explosive gases
11>' ~, ~
present at the battery
."" ..~,,-.,p,<:' t- ":";:\~O" '. •

Avoid sparks ",. 't!r • When disconnecting cables, remove the cables In
I <" and open flames ,~ reverse order of connection (e.g., final connection first)
",.; near batteries.~
~c •••• '.\i

Never check the battery by plaCing a metal object

across the battery posts. The resulting spark could
cause an explosion.
A WARNING! Avoid senous injury from battery
explosion. Do not charge a battery or jump-start the
engine if the battery is frozen.
Warm to 60°F (15.5°C) or the battery may explode and
could cause serious inJury.
65
 Perforlll Maintenance Safely
Tire and Wheel Maintenance A WARNING! The types of wheels and tires usually
found on this eqUipment reqUire special care when
Check your tires and wheels daily because the stability
servicing to prevent death or serious InJury. Do not
of the machine can be dramatically affected by tire
pressure or damage to tires or wheels. inflate the tires above the recommended pressure.

Check tires for·

• Correct pressure
• Cuts and bulges
~~~'- --._-""", -
..
..Check tires an
• Nails or other punctures ·wheels for dam
• Uneven or excessive wear ·'Iii'.'i\iiif',JiI
• Condition of valve stems and caps
Check wheels for·
• Damage to the rims
• Missing or loose lug nuts or bolts 'I)\!!""'-
• Misalignment "!l11-'Mamtain pro
~i-' tire pressu
All tire service should be performed by a qualified tire
service center or by an authorized service person who
&~. • . . •
has been properly trained In the procedures and use of
safety equipment deSigned for tire servicing.

66
 Perform Maintenance Safely
Keep wheel lug nuts tightened to manufacturer's
recommendations.
An Increase In tire pressure dUring operation IS normal,
and should NOT be reduced.
Never reinflate a tire that has been run flat or seriously
under-Inflated without removing the tire from the wheel.
Have the tire and wheel closely Inspected for damage
before remounting.
Never cut or weld on a wheel with an Inflated
tire mounted on it. This could cause explosive
decompression.
Check that the tire size and wheel are correctly matched.
When replacing the tires, ensure the tires are of the
appropriate rating specified by the manufacturer.
A WARNING! Avoid death or serious InJury. Always
use a safety cage or cable restraints when reinflating
a repaired tire.
Tires should not be operated at speeds higher than their
rated speed.

When adding air toa tire, do so from a distance. Always

use a long hose with a self-attaching chuck; stand away
from the tire sidewall and to one side as far as possible.
Do not Inflate tires with flammable gases or from
systems uSing an alcohol Injector.

67
 Perform Maintenance Safely
Track Maintenance
Track tension IS Important for good track performance,
reducing excessive track wear and preventing tracks
from derailing.
Tracks under tension can store an Incredible amount of
energy, and although some machines have automatic
track tensloners, special tools and procedures may be
required to check or adjust track tension. Wire Rope Maintenance
Removing and Installing tracks also requires following Protect your wire rope. With proper handling and routine
safe and proper servicing procedures. Always follow the lubrication, it will last much longer. Your rope supplier can
manufacturer's Instructions for track maintenance and provide more lubrication hiformation.
servicing, Including adjusting track tension.
Wire rope replacement may vary according to Federal,
A WARNING! Most track tensioning systems have State and/or Local codes and In accordance to the
compressed springs or pressurized fluid (oil or grease). type of rope used. For specific Information on the care,
Improperly releasing track tension forces could Inspection, and replacement of wire rope, refer to the
cause serious injury or death. Always follow the crane manufacturer's recommendation.
manufacturer's warnings and Instructions for track
adjustment and other maintenance and servicing Some general gUidelines for wire rope replacement
procedures. uSing steel sheaves are the follOWing:
• In running ropes, SIX randomly distributed broken wires
In one lay or three broken wires one strand In one lay
• Wear of one-third the original diameter of the outside
IndiVidual wires
68
 Perform Maintenance Safely
• Broken Wires, In rotation resistant ropes, two
randomly distributed broken wires In SIX rope
diameters or four randomly distributed broken wires
In thirty rope diameters. For special conditions,
refer to OSHA Crane Safety Standards on rotation
resistant rope
• One outer broken at the pOint of contact with the
core of the rope which has worked its way out of the
rope structure and protrudes or loops out from the
rope structure. Additional Inspection of this section IS
reqUired
• Kinking, crushing, blrdcaglng, or any other damage
resulting In distortion of the rope structure
• EVidence of any heat damage from any cause
• Arc Strikes
• Rust which IS pitting the Individual wires
• Reduction from nominal diameter of more than 5%
• In standing ropes, more than two broken wires In one
lay In sections beyond end connections or more than
one broken wire at an end connection
• When eVidence of core failure In rotation resistant
ropes IS recognized by lengthening of the lay and a
localized reduction In diameter
• Inspect sheave grooves for wear and broken parts
Installing Wire Rope
Only use wire rope specified by the crane manufacturer.
• When Installing wire rope sockets correctly, the live
end must be In a straight line pull with the eye of the
socket and a clip correctly Installed on the dead end
• DimenSions between the socket and the clip should
be such that the wedge cannot loosen In the socket
• This does not preclude the use of devices specially
designed for the dead end of wire rope
• If the wire rope IS put In backwards or a clip IS
Installed around both the live end and dead end, a
kink will develop and rope strength will be reduced
• Always wear gloves when handling wire rope
• Do not gUide wire rope on drums with your hands
• After a new wire rope IS Installed, operate first with a
light load to let wire rope adjust itself
• Follow rope manufacturer's Instructions for lubrication
Unreeling Wire Rope
When unreeling wire rope, it IS Imperative that the coil or
reel rotates as the rope unwinds. If the coil or reel does
not rotate, the wire will be tWisted as it IS uncoiled and
kinking will result. A kinked rope IS severely damaged
and unsafe for service.
69
 Perform Maintenance Safely

Complete Service and Repairs Before

Machine is Released
Tighten all bolts, fittings, and connections to torques
specified by the manufacturer.
Are there any missing cotter pinS, washers, locknuts,
etc.? Are there any parts left over?
Start the engine and check for leaks. (See page 62,
Hydraulic System Hazards.) Operate all controls to ~,,~,,~
~r ".~
make sure the machine IS functiomng properly. Test
the machine if necessary. After testing, shut down and
wor"
~erify service
.iwhen completed';;•
check the work you performed. ...." ",iA
iil<.' ~,,~,;~
Recheck all flUid levels before releaSing the equipment
for operation.
All parts should be Inspected dUring repair and replaced
if worn, cracked or damaged. Excessively worn or
damaged parts could fail and cause Injury or death.
Install all guards, covers, and shields after servicing.
Refill and recharge pressure systems only with
manufacturer-approved or recommended fluids.

70