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1. a WI 4 3 4 12 11 03 DECAL LAYOUT 10006H PIN 46008 7000 6 1 040579 DECAL OPERATION INSTRUCTIONS 8 2 040587 DECALWARNING LOAD SENSOR 9 1 040632 DECAL WARNING OVERLOAD 3 5 12111103 GENERAL DIMENSIONS 10006H SERIES 10 25 24 75 20 75 z 10 PRESSURE out RETURN PORT 33 50 A 5 9 00 Le 20 90 151 0 21 88 VI VD 1 4 va 1 S NOTE CG IS APPROXIMATED WITHOUT INCLUDING THE TRAVELING BLOCK 3 6 12 11 03 1 MOUNTING AND INSTALLATION 10006H SERIES Check to make sure the follovving items are vvith your crane Please note the different model specific quantities FM HW PART NO DESCRIPTION 4 6 6 634401 _ 56 6 750788 0 e 5 5 320357 TERMNANONNSSOWL e T T 340638 CONDUCTOR POWER 9 T T 320355 POWERRELAY 12 T 366500002 TRANSMITTE
2. WHT 44Y N PIN 21 J STING 5 15 025 035 ORGIBLK 1 2a ZA ur DO A OKO e PIN 13 4 REAR VIEW O OG i PIN 23 lt lt PROGRAM PLUG YQ 1 WHT BLK 1 ROT 18in 20 2 3 PIN 24 O BLU BLK 2 27 CCW ACAS 3 13 023 033 REAR VIEW 18 PIN 25 22 012 02 032 row 1 U E PIN 26 GRNIBLK 2 INSTALL ASSEMBLED BLANK 7 3 REAR VIEW INTO PROGRAM PLUG 1 021 31 sin 16 ATT 1 000 HD 22 PIN 27 ROTATION 6 718 AN SWITCH HOUSING 2 lt 26in 20 NOT PART OF HARNESS lt BOOM SWITCH HOUSING EN NOT PART HARNESS PIN 7 EN 3 pi 32in N e WHT PIN 35 RED 1 PIN 34 BLK 2 1 4 N INC sa BLK PIN SOS wur 5 ANO N GRN x y ze y gt EEE PIN 12 5 PIN 38 amp SHIELD VIEW 1 D SHIELD TERMINATED WITH PIN 11 wur COMMON in 24 OUTER SLEEVE 4 BLK PENDANT PLUG 13 480 d ROTATION SW 20 10in 2 ZR 719010 PIN 8 WHT ACA OSA PIN 10 O GRN B V j 18in 13 BLK c C REAR VIEW 15 y SOLDER WIRE ENDS HOME SW an wer 1 i BEFORE INSTALLING PIN 15 gt INSIDE ROTATION 1 2 G SWITCH HOUSING 4 GRN 4 TERMINATE SHIELD WITH OUTER SLEEVE THISEND FINS 51617 CONNECT BLK OPPOSITE END PRESS TRANSDUCER NN NOTE ALL C
3. 47 48 Do not push down on anything with boom extensions lift or outer boom function Do not lift personnel with any wire rope attachment or hook There is no implied warranty or responsibility for such purposes WARNING In using safety hook ALWAYS close the hook throat before lifting a load Proper attention and common sense applied to the use of the hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel WARNING Never place a chain link on the tip of the hook and try to lift load with the hoist WARNING Never use a sling bar or anything larger than the hook throat which could prevent the safety latch from closing thus negating the safety feature If the crane is equipped with an optional winch do NOT allow personnel to ride on loadline hook load or any other device attached to winch line do NOT extend boom without reeling off line at the same time when using winch e dopullload block up against the boom tip Do not wrap the wire rope around sharp objects when using winch WARNING Never unreel last 5 wraps of cable from drum 12 2002 IMPORTANT OPERATING PRACTICES AND WARNINGS 1 Make certain the vehicle meets minimum chassis requirements These requirements do not guarantee unit stability 2 Make certain the crane is installed per factory specifications Contact your local Distributor or the Auto Crane factory 1
4. 5 zk PWR OUT SCP 8 N SWITCH CCIN 9 A HOME 10 midd PWR OUT SCP 11 z m BOOM SWITCH 12 gk ZD 7 em PROG PIN 13 gt BOOM UP BOOMUP 14 5 w GROUND 15 BOOM DOWN 16 BBON GROUND 17 m DOWN RETRACT 18 GROUND 19 BOOMOUT 20 GROUND 21 22 GROUND 23 a CCW ROT 24 A HOISTUP 25 GROUND 26 ROTATE HOIST DOWN 27 L Aa CAN ENGINE FAST 28 A PROPOR 29 ROTATE AUXILIARY 30 mE ccw GROUND 31 ENGINE START 32 ENGINE STOP 33 HOIST UP PEND GRND 34 PEND PWR SCP 35 CAN DATA H 36 A s HOIST CAN DATA L 37 DOWN PEND SHLD 38 39 ENGINE FAST MAIN GRND 40 AUXILIARY L ENGINE START PROPORTIONAL L ENGINE STOP 1 um 9 1 01 12 04 MAIN HARNESS 6406 HI8406H FM P N 480879000 4 24344 PIN 14 A wir 1 PIN 17 BLU 2 V 8 BU 1 gt N REAR VIEW Sin 15 BLU 10 020 030 040 b LI PIN 16 2 7 S 1 02 BD gt 9 19 029 039 DS PNE REAR VIEW ARE WIRED 12 SEE TABLE 018 028 INITEM 12 Da 18 GRN 1 2 RET 3 T UO gt 5in 4 7 REAR VIEW gt 7 17 027 03 Ww x 19 PIN 5 GRN 1 Y 2 7 EXT 2 101 2 A2B 6 16 26 036 PIN 20 1 q REAR VIEW
5. B The load to be lifted is to be within the rated load of the crane and its existing configuration C When loads which are not accurately known are to be lifted the person responsible for the job shall ascertain that the vveight of the load does not exceed the crane rated load at the radius at which the load is to be lifted Attaching the load A The load shall be attached to the hook by means of slings or other devices of sufficient capacity B Hoist rope shall not be wrapped around the load Moving the load A The operator shall determine that B The crane is level and where necessary the vehicle carrier is blocked properly C The load is well secured and balanced in the sling or lifting device before it is lifted more than few inches D Means are provided to hold the vehicle stationary while operating the crane E Before starting to lift the hook shall brought over the load in such manner as to minimize swinging F During lifting care shall be taken that 21 2 6 1 There is no sudden acceleration deceleration of the moving load 2 Load boom or other parts of the crane do not contact any obstruction G Cranes shall not be used for dragging loads sideways H This standard recognizes that articulating boom cranes are designed and intended for handling materials They do not meet personnel lift or elevator requirements Therefore no lifting lowering swinging or traveling s
6. BOOM ASSEMBLY 10006H P N 460030000 QTY 2 3 4 5 6 1 460054000 __ TOP UPPER 8 4 360767000 PADBOOM150D 9 2 965351 11 2 11 2 34 14 8 021100 WASHERSPLKSO 18 6 48021 6 2 12 11 03 ROTATION GEARBOX 10006H P N 460060000 N NU 2 NA SS DR IR N N 7 1 01 12 04 ROTATION GEARBOX 10006H P N 460060000 6 1 460060006 METAL 005 8 1 46006008 SPACER 41 6 460060041 CAPSCR HXZD3 8NCX1 GR5 58 6 460060058 WASHR PLAIN HARD NDZD 3 8 69 2 460060069 HXZD 1 2NC X 1 GR5 01 12 04 HOIST ASSEMBLY 10006 H 12111103 HOIST ASSEMBLY 10006 H 6 1 338297 END BEARING GEAR HOUSING________________ 8 346045 PIN BRAKE 9 2 350704 PLATE 17 6 414303 CAPSCREW 3 8 16NC x 2 LG HX HD GR5 ZINC PLTD 18 8 414658 CAPSCREW 5 8 11NC x 1 LG HX HD GR5 ZINC PLTD 19 4 JOAPSOREW CAPSCREW 1 2 13NC x 1 4 LG SOCKET HD GR5 ZINC PLTD 45 6 494110 SPRING 47 1 TUBEASSEMBLY 48 1 VALVE MOTOR CONTROL 7 4 12 11 03 NOTES TRAVELING BLOCK ASSEMBLY PIN 466230 MODEL 11006 SEX ZZ NA Oj E Wo 1 1 M Hj NEN 1 22 5222 Ne ITEM QTY 1 1 2 1 3 2 4 1 5
7. 10006H SERIES OVVNERS MANUAL Manual No 460099 Rev 0171212004 Serial No Mailing Address Box 580697 Tulsa OK 74158 0697 Physical Address Phone 918 836 0463 4707 N Mingo Rd Fax 918 834 5979 Tulsa OK 74117 5904 http www autocrane com CRANE Auto Crane Warranty Registration Fax Transmission To Warranty Department From Re Product Registration End User Information Name Address City Contact Distributor Information Name Address City Contact Product Information Model No Date Product Delivered VIN Required for Warranty Activation State E mail Address Required for Warranty Activation State E mail Address Required for Warranty Activation Serial No Date Processed 918 834 5979 Zip Zip For Auto Crane use only ONE REGISTRATION FORM PER UNIT CRANE OR BODY Registration form must be mailed or faxed within 15 days of customer installation Warranty Registration Mail to Warranty Department Auto Crane Company P O Box 581510 Tulsa OK 74158 0697 Rev 072403 10006 SERIES ONNER S MANUAL REVISION RECORD Manual Section s Revision Or Description of Change Date 5 12 11 03 Initial Release New Manual 01 12 04 Table Of Contents Updated 01 12 04 FM Control Changed Section Title Operation 01 12 04 Mounting amp Incorporated Ha
8. DECAL FUNCTION USED QUANTITY PLACEMENT SAFETY DECAL SECTION 10006H SERIES 040579000 OPERATING INSTRUCTIONS To inform the operator of the proper procedure to follow for safe operation of the crane All Cranes 1 Right side plate 040580000 OPERATING TRAINING To inform the operator of the need to receive proper training before using the crane All Cranes 1 Right side plate 040632000 TAMPERING WITH OVERLOAD DEVICE To inform the operator that tamperating with the overload device may cause unit failure or possible personal injury All Cranes equiped with load sensor 1 Right side of valve sensor 3 1 ACAUTIO 1 INSPECT VEHICLE AND CRANE INCLUDING OPERATION PRIOR TO USE DAILY 2 DO NOT USE THIS EQUIPMENT EXCEPT ON SOLID LEVEL SURFACE WITH OUTRIGGERS PROPERLY EXTENDED AND GRANE MOUNTED ON FACTORY RECOMMENDED TRUCK 3 BEFORE OPERATING THE CRANE REFER TO MAXIMUM LOAD CAPACITY CHART ON CRANE FOR OPERATING LOAD LIMITATIONS 4 OPERA Te A CONTROLS SLOWLY AND SMOOTH 5 KEEP LOAD UNDER BOOM TIP DO NOT SIDE LOAD BOOM OR DRAG LOADS AVOID FREE SWINGING LOADS 6 DO NOT OPERATE WALK OR STAND BENEATH BOOM OR A SUSPENDED LOAI 7 An 5 MRAPS OF LOADLINE ON HOIS 8 FOR TRAVELING BOOM AND OUTRIGGERS MUST BE IN THE STOWED POSITION 9 ALL REMOVABLE PENDANTS MUST BE STORED IN CAB OR ee COMPARTMENT WHEN CRANE IS NOT IN USI P N
9. RE NUT INCLUDEDWITHSWITCH ________ 8 640300 BOOT TOGGLE E 9 1 4805566 TRIGGER 7 1 2 o 8 REF LOCK INCLUDED WITH SWITCH 12 6 01 12 04 PENDANT CABLE ASSEMBLY 10006H HW 6 13 002012 TERMINAL RING 6 18 22GA 7 6 490243 TUBING HEAT SHRINK 12 7 01 12 04 PROPORTIONAL ADJUSTMENT 10006H HW REFRENCE AUTO 366363001 RISING RAMP FALLING RAMP DITHER AMPLITUDE OUTPUT 2000mA MIN SETTING 0 500mA MINIMUM CURRENT SETTING 600 TO 2000mA CABLE LENGTH 6 FEET MAXIMUM CURRENT Minimum current adjustment Current is factory set at 150 mA no adjustment required at installation If adjustment is required set the minimum current before setting the maximum current Apply minimum input 0 VDC If the desired minimum current is greater adjust the trim pot CVV until the desired current is achieved Maximum current Current is factory set at 1600 mA no adjustment required at installation If adjustment is required apply maximum control 5 Turn the trim pot CCW to adjust the current setting downwards to the desired minimum Ramp and Dither Ramp and dither is adjusted at the factory and does not require any further adjustment 12 8 01 12 04 NOTES LOAD CHART 10006H P N 460075000 12111103 NOTES
10. AND OPERATING PRACTICES MISCELLANEOUS 25 In transit with no load and boom lowered the OPERATING NEAR ELECTRICAL POWER clearance shall be specified in Table 1 LINES 26 qualified signalperson shall be assigned to observe the clearance and give warning before approaching the above limits THIS AREA SHOULD BE AVOIDED overhead wire shall be considered to be an energized line unless and until the person owning such line or the electrical utility authorities verify that it 15 not an energized line B Exceptions to this procedure if approved by the administrative or regulatory authority if the alternate procedure provides equivalent protection and set forth in writing Durable signs shall be installed at the operator s station and on the outside of the crane warning that electrocution or serious bodily injury may occur unless minimum clearance of 10 ft 3 0m between the crane or the load being handled and energized power lines Greater clearances are required because of higher voltage as stated above These signs shall be revised but not removed vyhen local jurisdiction requires greater clearances TABLE 1 minimum required 22 Cranes shall be operated so that no part of the clearance crane or load enters into the danger zone shown above EXCEPTIONS normal voltage kV phase to phase ft m when operating near high voltage poower lines A The danger zone may be entered after confirma
11. Box 580697 Tulsa 74158 0697 4707 918 836 0463 LIMITED VVARRANTY 2 YEAR PARTS AND LABOR Auto Crane vvill vvarranty to the consumer for a period of 2 years parts and labor from the date of purchase Each new Auto Crane unit they will be free under normal use and service from defects in material and workmanship Date of purchase will be honored as the date indicated on the Bill of Sale which must accompany the Warranty Registration and be on file with Auto Crane Absent a valid Warranty Registration and appropriate documentation the original date of manufacture as indicated by the serial number on the product will be used to determine the effective date of the 2 year warranty The obligation of Auto Crane under this warranty is limited to the replacement or repair of parts that appear to the manufacturer after review and or inspection to be defective and paid flat rate labor for replacing defective parts This warranty does not obligate Auto Crane to bear the travel time charges in connection with the replacement or repair of defective parts Responsibility for customer s claims arising from misapplication abuse misuse or alteration of equipment or parts lies with the distributor or user and no warranty obligation is assumed in these circumstances by Auto Crane Auto Crane will in no event be liable for any consequential damages or contingent liabilities arising out of the failure of any Auto C
12. Check plug in boom down solenoid on hydraulic control valve Check wires for damage that could cause break or short EC04 Boom in retract Short or open connection on boom in output Check plug in boom in solenoid on hydraulic control valve Check wires for damage that could cause break or short 9 6 12 11 03 CONTROLLER DIAGNOSTICS CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S 05 Boom out extend Short or open connection on boom out output Check plug in boom out solenoid on hydraulic control valve Check wires for damage that could cause break short 06 Rotate CVV Short or open connection on rotate CW output Check plug in rotate CW solenoid on hydraulic control valve Check wire for damage that could cause break or short 07 Rotate CCW Short or open connection on rotate CCW output Check plug in rotate CCW solenoid on hydraulic control valve Check wire for damage that could cause break or short EC08 Hoist up Short or open connection on hoist up output Check plug in hoist up solenoid on hydraulic control valve Check wire for damage that could cause break or short EC09 Hoist down S
13. Continued use in this respect depends upon good judgement by a designated person in evaluating remaining strength in a used rope after allowance for deterioration disclosed by inspection Continued rope operation depends upon this remaining strength 34 Conditions such as the following shall be reason for guestioning continued use of the rope or increasing the freguency of inspection A in running ropes six randomly distributed broken wires in one lay or three broken wires in one strand in one lay B one outer wire broken at the contact point with the core of the rope structure and protrudes or loops out of the rope structure Additional inspection of this section is reguired C wear of one third of the original diameter of the outside individual wire D kinking crushing birdcaging or any other damage resulting in distortion of the rope structure E evidence of any heat damage from any cause F reduction from nominal diameter of more than 1 64 in 0 4mm for diameters up to and including 5 16 in 8 mm 1 32 in 0 8 mm for diameter 3 8 in 9 5 mm to and including 1 2 in 13 mm 3 64 in 1 2 mm for diameter 9 16 in 14 5 mm to and including 3 4 in 19 mm 1 16 in 1 6 mm for diameter 7 8 in 22 mm to and including 11 8 in 29 mm 3 32 in 2 4 mm for diameters 11 4 in 32 mm to and including 11 2 in 38 mm In standing ropes more than two broken wires in one lay in sections beyond end connec
14. EXTEND OUT BLKANHT K RED WHITE C GRNWHT 5 EXTEND IN BLUANHT BLK RED BLACK U LA LNR IV WHT RED ORG RED PROP u CONTROL VALVE BLU RED 77 E v BLUE NOT USED WHITE NOT USED 3 222 a POWER RED gt AR 2 GROUND BLACK gt ENGINE FAST SLOW WHITE ya AUXILARY GREEN 2 5 5 ENGINE START BLUE ENGINE STOP ORANGE 26 ZNA 8 12 1 01 12 04 MAIN WIRING HARNESS 10006H HW WIR 9 PRESSURE SWITCH A2B SWITCH 8 SOLDER 5 B ROTATE SVVITCH 12 BOOM LIMIT A B VV RED VVIRE NOT USED FUNGTION PIN WIRE COLOR NOTES ITEM NO QTY PART NO DESCRIPTION 1 GREEN POWER HOIST UP gt WHITEIRED TO ADB GROUND 1 1 800632000 CABLE 16 10 SO BLACK HOISEDN 1 RED BLACK POWER 2 9 366367001 HOUSING DEUTSCH 2 PIN PLUG 2 REDMHITE GROUND 3 9 366367002 WEDGE DEUTSCH PLUG 2 PIN ROTATE CCW 3 BLACK TO CCW SWITCH 3 COND CABLE 4 27 366367003 CONTACT DEUTSCH SOCKET BOTASEEW 1 ORANGE POWER 5 1 360769001 HOUSING DEUTSCH 2 PIN RECEPTACLE 2 WHITE CW SWITCH 3 COND CABLE 6 1 360769002 WEDGE DEUTCH 2 PIN RECEPTACLE BOOM UP 3 BLACK BOOM SWITCH GABLE 7 2 366376003 CONTACT DEUTSC
15. any questions arise 3 Keep the vehicle in as level position as possible while loading or unloading 4 ALWAYS set the vehicle emergency brake before beginning crane operations 5 ALWAYS use outriggers from vehicle to the ground during crane operation Make sure they are firmly positioned on solid footings 6 All load ratings are based on crane capacity NOT truck crane stability 7 Keep objects and personnel clear of crane path during operation 8 Keep hoist cable pulled tight at all times 9 REMEMBER in lifting a heavy load the weight can create enough tipping momentum to overturn the vehicle 10 ALWAYS keep load as close to ground as possible 11 Hydraulic hoses need to be inspected frequently for signs of deterioration and be replaced as required 12 The hoist hook is an important item that an operator should consider and use properly It should be checked on daily basis for distortion or cracks 13 ALWAYS store outriggers before road travel WARNING 14 WARNING NEVER OPERATE THE CRANE NEAR ELECTRICAL POWER LINES Death or serious injury will result from boom line or load contacting electric lines Do not use crane within 10 feet 3 05m of electric power lines carrying up to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or less 15 WARNING NEVER EXCEED load chart capacities centerline of rotation to hoist hook 16 WARNING NEVER un reel
16. 040579 AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND ERS TO DEATH OR SERIOUS INJURY 1 YOU MUST HAVE BEEN TRAINED IN THE OPERATION OF THIS CRANE AND 2 YOU MUST KNOW AND FOLLOW THE SAFETY AND OPERATING RECOMMENDATIONS CONTAINED IN THE MANUFACTURER S MANUAL YOUR EMPLOYER S WORK RULES AND APPLICABLE GOVERNMENT REGULATIONS P N 040580 A WARNING TAMPERING WITH OVERLOAD DEVICE VOIDS WARRANTY OVERLOADED CRANE MAY HYDRAULICALLY RELEASE AND LET LOAD DOWN TO GROUND OVERLOAD PROTECTION DEVICE CANNOT FUNCTION WITH BOOM BELOW HORIZONTAL 0 HOIST UP BOOM DOWN AND EXTEND OUT WILL BE INOPERATIVE WHEN CRANE IS IN OVERLOAD CONDITION P N 040632 12 11 03 SAFETY DECAL SECTION 10006H SERIES PART DECAL FUNCTION USED QUANTITY PLACEMENT PART NO DECAL FUNCTION USED ON QUANTITY PLACEMENT PART NO DECAL FUNCTION USED ON QUANTITY PLACEMENT 040529000 ELECTROCUTION HAZARD To inform the operator of the hazard involved with contacting electrical power lines with crane boom Articulated amp Stiff Boom Cranes 2 Both sides of end of lower boom 040517000 STAY CLEAR OF BOOM To inform the operator of the hazard of proximity or contact with the crane boom during operation All Cranes 2 Both sides of crown 040518000 STAY CLEAR OF LOAD To inform the operator of the hazard of proximity or c
17. ACCESSORIES Component Receiver Transmitter Pendant Cable Antenna Antenna Extension Cable Cigarette Lighter Charger A C Charger Palm Diagnostic Unit Replacement Toggle Switch Transmitter Replacement Batteries Transmitter 9 13 Part Number 460077000 366500002 366500008 366500005 366500006 366504000 366505000 366510000 366500010 366500007 12 11 03 Extension Hoist Rotation Lift i DN 3 UP I 5 Cy 4 ED a Extension 5 6 7 8 3 1 2 4 M GPM 030 Proportional LL 20 is T 10 1 12 11 03 HYDRAULIC SECTION COUNTERBALANCE VALVE ADJUSTMENT Counterbalance Valve Adjustment Notice With PTO disengaged and boom properly In an EMERGENCY situation when it supported remove the plug on the counterbalance valve Install a pressure gauge 0 4000 PSI into the port Engage PTO and insure pump flow is 15 to 16 GPM With no load on boom boom up to an angle of 70 degrees Boom down and note pressure If pressure reading is n
18. DEUTSCH 2 PIN 15 5in 800594 VVIRE 16 1 COND BLU 16 800592 WIRE 16 GA 1 COND WHT 17 5 in A 800596 WIRE 16 GA 1 COND YEL 18 2 A 360755000 CAVITY PLUG DEUTSCH 19 8 in 800593 VVIRE 16 1 COND RED 20 54 in 800628 16 3 21 120 in 800629 16 6 22 68 in 800626 16 2 23 2 000101 TERMINAL RING 24 2in A 800590 VVIRE 16 GA 1 COND BLK 9 3 0 01112104 MAIN WIRE HARNESS MODIFICATIONS 10006H FM 6 366367000 CONTACT SOCKET ROTATION STOP CUT ROTATION LEADS TO 8 FROM HOME SWITCH LEG KEEP 4 OF GREEN WIRE TO MAKE THE JUMPER 3 STRIP SMALL AREA OF HARNESS GREEN WIRE AND SOLDER IN JUMPER 4 APPLY HEAT SHRINK OVER SOLDERED AREA 5 INSTALL DEUTSCH SOCKETS TO WHITE BLACK amp BOTH GREEN WIRES 6 INSTALL WIRES IN 4 PIN PLUG PER ELECTRICAL SCHEMATIC 7 INSTALL WEDGE IN PLUG pr HARNESS MODIFICATION ELECTRICAL SCHEMATIC ROTATION STOP 4 1 3 2 PLUG P N 320931001 GRN JUMPER WHT GRN MAIN WIRE HARNESS ROTATION SWITCH LEG 9 3 1 01 12 04 MAIN WIRE HARNESS MODIFICATIONS 10006H FM BOOM LIMIT SWITCH CUT RING TERMINALS OFF OF BOOM LIMIT SWITCH LEAD STRIP WHITE AND BLACK WIRES INSTALL DEUTSCH SOCKETS TO WHITE amp BLACK WIRES INSTALL WIRES IN 2 PIN PLUG PER ELECTRICAL SCHEMATIC INSTALL WEDGE IN PLUG
19. flow will cause poor crane operation Vehicle should meet minimum GVW rating of 26 000 pounds The vehicle MUST be equipped with an engine speed control and tachometer Make sure mounting surface 15 properly reinforced to withstand 60 000 ft Ib capacity loading of crane and that outriggers are used to provide total stability for the truck A 12 dia hole should be cut out of mounting location centered with mounting blots for access to hydraulic connections 3 7 01 12 04 MOUNTING AND INSTALLATION 10006H SERIES 8 Make sure the mounting blots are 7 8 dia grade 8 Torque bolts to 501 ft lbs 9 When crane is not in operation a boom support should always be used Traveling block should be connected to hook loop 10 Electrical hookup Wiring FM cable from base of crane HW cable from junction box A CONNECT THE BLACK WIRE TO THE BATTERY NEGATIVE GROUND B CONNECT THE RED WIRE TO FUSED 12VDC POWER 12VDC POWER SHOULD BE SUPPLIED THROUGH DEDICATED SWITCH THAT IS POWERED ONLY WHEN THE IGNITION SWITCH IS ON OPTIONALLY USE THE WHITE WIRE FOR ENGINE FAST SLOW 12VDC MAINTAINED OPTIONALLY USE THE BLUE WIRE FOR ENGINE START OPTIONALLY USE THE ORANGE WIRE FOR ENGINE STOP OPTIONALLY USE THE GREEN WIRE FOR AUXILIARY 12VDC MAINTAINED moe NOTE ALL ELECTRICAL CONNECTIONS BETWEEN THE CRANE AND THE VEHICLE SHOULD BE MADE USING RELAYS TO ISOLATE THE ELECTRICAL SYSTEMS OF EACH AS MUCH AS POSS
20. m AD HARNESS MODIFICATION ELECTRICAL SCHEMATIC BOOM LIMIT SWITCH 0 e BLK PLUG P N 366367001 WHT BOOM LIMIT SWITCH LEAD 9 3 2 01 12 04 DIAGNOSTICS SITUATION POSSIBLE SOLUTION FLOW PRESENT BUT Check receiver for error code if error code is present while function is FUNCTION WILL being activated refer to the error code section on the following page If NOT WORK NRML appears in the code display on the receiver while the function is being activated operate the proportional override and push or pull the override on the directional control valve to operate the function If the function still does not operate see the NO FLOW paragraph in this section HYDRAULIC When a hydraulic function is engaged and causes the crane to chatter CHATTER check for error code on receiver display low pump pressure or air in the system NO FLOW OR Check for error code on receiver display see error code section Check for LIMITED FLOW TO adequate oil supply in reservoir Check operation of bypass system by CRANE operating the override on the proportional valve while operating crane If low flow condition continues to exist when the manual override is operated remove relief valve cartridge and check for dirt Other possible causes for a low flow condition are 1 Engine speed is too slow 2 A blocked pressure hose from pump This condition can be id
21. start the function The speed of the function increases as the trigger is pulled More than one function can be activated at one time NOTE A FUNCTION SWITCH MUST BE ACTIVATED BEFORE THE TRIGGER IS PULLED OR THE CRANE WILL NOT OPERATE 2 4 1 01 12 04 FM CONTROL SYSTEM OPERATION Auxiliary Buttons Functions described in this paragraph vvill not vvorked if not properly connected to the vehicle at the time of installation Press the Engine Slow Fast button to provide maintained voltage to a throttle control To stop the engine press the Engine StartiStop button To start the engine press the Engine StartiStop button a second time vvithin five 5 seconds of releasing it To activate the auxiliary function press the Engine Slow Fast and the Engine Start Stop buttons simultaneously Safety Features For safety reasons the speed of the rotation function is reduced vyhen the lift cylinder pressure exceeds set pressure This will occur under load or under boom down operation To limit slow operation of an unloaded crane activate boom up momentarily after booming down to relieve cylinder pressure created by the counterbalance valve The crane is also equipped with an anti bridging feature The logic in the receiver will not allow the operator to rest the boom of the crane on load supporting structure and lift load Doing so is dangerous and could damage the crane When the crane is bridged the receiver will display RSBM whic
22. 1 WARNING NEVER THE NEAR ELECTRICAL POWER LINES Auto Crane Company recommends that the crane never be any closer to power line including telephone lines than 10 feet at any point Allow the vehicle engine to warm up before operating crane Know the weight of your rigging and load to avoid overloading the crane Deduct the weight of the load handling equipment from the load rating to determine how much weight can be lifted All load ratings are based on crane capacity NOT the vehicle stability Remember in lifting heavy load the weight can create enough tipping moment to overturn the vehicle Always comply with load chart capacities centerline of rotation to hook Secure all loads before lifting Always set the emergency brake before beginning operation Keep objects and personnel clear of crane path during operation Operate control levers slowly and smoothly in order to meter oil flow for safe operation Always use outriggers from vehicle to the ground during crane operation Ensure that they are firmly positioned on solid footings Stand clear of outriggers while they are being extended If any outrigger when extended rests on curb or other object that prevents it from extending to its maximum distance shorten bearing or fulcrum point and reduce the maximum load accordingly When an outrigger will not reach the ground due to holes or grades it shall be blocked up to provid
23. 1 6 COIL P 369145000 1 FITTING STR8 SAE 8JIC 10 4 12 11 03 NOTES VALVE OVERRIDE OPERATION In the event that the electrical control system fails the crane can be operated using the manual overrides on the hydraulic control valve The overrides operate as follovvs 1 Proportional increase flow by turning clockwise 2 Extend Retract Boom Up Down Rotate CW CCW Push to operate boom down pull to operate boom up etc See graphics below 3 Hoist Up Down Push in to operate PROP Hu HD 8 HD ROT ROT CW cow H BD BU RET EXT DIRECTIONAL CONTROL VALVE IDENTIFICATION 10 5 12 11 03 PEDESTAL ASSEMBLY 10006H HW P N 460040001 HYDRAULICS PORT 1 HOIST DOWN REAR MOTOR PORT PORT 2 HOIST UP FRONT MOTOR PORT PORT 3 ROTATION CCW LOWER MOTOR PORT PORT 4 ROTATION CW UPPER MOTOR PORT PORT 5 LIFT CYL EXTEND PORT 6 LIFT CYL RETRACT PORT 7 EXT CYL EXTEND PORT 8 EXT CYL RETRACT CYLINDER SEAL KIT 460051001 C BAL CARTRIDGE 360153001 11 1 01 12 04 PEDESTAL ASSEMBLY 10006H HW P N 460040001 DESCRIPTION BASE PLATE WELD PEDESTAL WELD ROTATION BEARING SCW SOC HD 5 8 11 X 1 5 8 WASHER 5 8 FLAT HARDENED 6 15 490171 CAPSCREW 5 8 11X2 25GR8 8 1 460060000 ROTATIONGEARBOX __________ 9 1 460085000 SEALO RING 11 2 01 12 04 NOTES PEDESTAL ASSEMBLY 10006H HW P N 460040001 3
24. 1 6 4 7 2 8 1 9 2 10 2 490256 480026 466231 490313 018600 360124 466232 466233 811023 017301 8 1 0 0 19777725 X DESCRIPTION SHEAVE BLOCK ASSEMBLY 5 TON SWIVEL HOOK SIDE PLATE TRAVELING BLOCK SHEAVE BOLT w ZERK FITTING 3 4 NF x 4 HEX LOCK NUT 3 4 NF HITCH PIN PIN BLOCK 1 DIA ROUND TUBING 1 1 4 x 120W x 1 1 2 L SCREW 3 8 NC x 4 LOCK NUT 3 8 NC AW 466230 1 99 NOTES ELECTRICAL SCHEMATIC 10006H FM A A2B SWITCH a a ARE CCW ROTATION STOP SWITCH BOOM SWITCH mmm ZZ wa CW ROTATION T T STOP SWITCH BATTERY 1 PRESSURE BATTERY 2 __ _ 3 w PWR OUT SCP 3 sn TRANSDUCER Em PRES TRANS 4 a maa A2B 5 VERT
25. 1 The operator should not leave a suspended load unattended unless specific precautions have been instituted and are in place 12 If there is a warning sign on the switch or engine starting controls the operator shall not close the switch or start the engine until the warning sign has been removed by the appointed person 13 Before closing the switch or starting the engine the operator shall see that all controls are in the OFF or neutral position and all personnel in the clear 14 If power fails during operation the operator shall A move power controls to the OFF or neutral position B land the suspended load and boom if practical 2 5 12 2002 15 16 17 QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES The operator shall be familiar vvith the equipment and its proper care If adjustments or repairs are necessary the operator shall report the same promptly to the appointed person and shall also notify the next operator All controls shall be tested by the operator at the start of each shift If any controls do not operate properly they shall be adjusted or repaired before operations are begun Stabilizers shall be visible to the operator while extending or setting unless operator is assisted by a signal person OPERATING PRACTICES HANDLING THE LOAD 18 19 20 Size of load A crane shall be loaded beyond the rated load except for test purposes
26. 2 9 021100 WASHERSPLK3 60 4 320588 JWASHERFL12 66 1 460097000 LOAD SENSOR SWTICH 3100PSI 68 1 460096000 LOAD SENSOR SWTICH 2850PS 69 1 366473000 MAIN HARNESS ASSEMBLY HARD WIRED 11 3 01 12 04 ELECTRICAL SCHEMATIC 10006H HARD WIRED JUNCTION BOX 19 PIN CONNECTOR REFRENCE 680040 FOR PENDANT SCHEMATIC RED WHT x 12 PIN CONNECTOR J D 48 A2B 2 GREEN gt GREEN HOIST UP 2 REDIBLACK 5 I RED WHITE 3 WHITE BLACK BLACK 4 ORANGE 5 ORANGE N ROT SW CW HOIST DOWN A gt RED MANN ROT SW CCW BLK BLUE gt BLUE BLK RED 7 nm BLACK C GREEN BLACK gt GREEN BLACK ROTATE CCW 8 252 GRN ORANGE BLACK 2 ORANGE BLACK LAA gt 9 RED gt WHT RED M UN AE BLACK gt Power ROTATE CW lt GRN GREEN ii E wur 12 Z o 5 E I E JI 1 a P BLACK BOOM UP g 3 amp BOOM LIMIT SW pRESS SW2 WHT BLK C BOOM DOWN WHITE L BLU BLK M C SMN
27. Crane Company remote controlled cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel WARNING ALWAYS operate the crane in compliance with the load capacity chart DO NOT USE the overload shutdown device to determine maximum rated loads if the crane is equipped with this type of device READ THIS PAGE Warnings 12 2002 TABLE OF CONTENTS 10006H SERIES INTRODUCTION GENERAL SPECIFICATIONS SAFETY TIPS AND PRECAUTIONS OPERATING PRACTICES amp WARNINGS OPERATION OF UNIT OUTRIGGERS QUALIFICATIONS FOR OPERATORS INSPECTION TESTING AND MAINTENANCE SAFETY DECAL SECTION GENERAL DIMENSIONS MOUNTING AND INSTALLATION LUBRICATION AND MAINTENANCE SCHEDULE GENERAL ASSEMBLY PEDESTAL ASSEMBLY FM BOOM ASSEMBLY ROTATION GEARBOX HOIST ASSEMBLY TRAVELING BLOCK ASSEMBLY ELECTRICAL SCHEMATIG FM DIAGNOSTICS TROUBLESHOOTING HYDRAULICS PEDESTAL ASSEMBLY HARD WIRED ELECTRICAL SECTION HARD WIRED LOAD CHART WARRANTY 23 2 3 2 4 2 5 2 8 31 3 6 3 7 3 9 4 1 5 1 6 1 12 1 13 1 LAST PAGE 01112104 INTRODUCTION 10006H SERIES Auto Crane products are designed to provide many years of safe trouble free dependable service properly used and maintained To assist you in obtaining the best service from your crane and to avoid untimely crane vehicle failure this manual provides the following operating and service instructions It
28. ESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S RS1 Rotation switch tripped Rotation stop reached in clockwise direction This is not an error Rotate in opposite direction or check switch for interference RS2 Rotation switch tripped Rotation stop reached in counter clockwise direction This is not an error Rotate in opposite direction or check switch for interference A2B Anti two block Anti two block switch tripped Check switch if not mechanically tripped check continuity cross switch at plug If switch has continuity check voltage across transmitter side of A2B plug If low voltage is read power to the A2B switch the rotation switches or the pressure sensor may have a short RSBM Raise boom Pressure sensor is reading less than 80 psi Raise boom to ensure it is not resting on other structure and the lift cylinder is not bottomed out 9 10 12 11 03 CONTROLLER DIAGNOSTICS CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S readout CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S HOME Home position Crane is pointed forward ready to be stowed This is not an error It is a built in override of the above RSBM condition that will allow you to stow the cran
29. H 1 BLUE POVVER 8 5 1001104000 TERMINAL SPLICE 14 16 GA 2 AD 9 2 000101000 TERMINAL RING 5 32 14 16 GA 2 WHITE RED TO A2B GROUND 10 3 000501000 TERMINAL RING 5 16 14 16 GA RETRACT 1 ORANGE BLACK POWER 11 1 800628000 WIRE 3 CONDUCTOR 1 WHITERED TO PIN 1 PRESSURE SWITCH 12 111800626000 WIRE 2 CONDUCTOR A2B SWITCH 2 RED WHITE FROM BD EXT GND 13 31 800618000 16GA WHITE RED PRESSURE 1 RED WHITE GROUND 4 26 800617000 MIRE 16GA RED WHITE SWITCH 2 WHITE RED FROM A2B PIN 2 ROTATE SWITCH E BLACK PIN 2 ROTATE CCW PLUG WHITE 2 ON ROTATE CW PLUG SEONDEABLE NIA GREEN GROUND BOOM LIMIT WHITE PIN 2 ON BOOM UP PLUG 2 COND CABLE N A BLACK 12 2 01 12 04 JUNCTION BOX ASSEMBLY 10006H HW FUNCTION 1981 N ays w U z GND GND GND N O 10 lt 2 O O 2 2 O 12 12 3 01 12 04 JUNCTION BOX ASSEMBLY 10006H HW 1 1 366470000 JUNCTIONBOX __4 1 480594001 CABLE PENDANT 16 10 SO BLACK 5 1 1366471000 COVER JUNCTION BOX 6 1 1366524001 HOUSING DEUTSCH 12 PIN RECEPTACLE 8 4 1366519000 SELF CLINCHING 29 17 019600 WASHERSPIKK6 12 4 01 12 04 ASSEMBLY 8 FUNCTION 10006H HW 5 554 eo RR 01 12 04 PENDANT ASSEMBLY 8 FUNCTION 10006H HW 8
30. H AND REFILL WITH SUN 2105 HYD womuucruo X DU sae BOOM SLIDE PADS PADS GREASED WHEN REPLACED 1 OWNER S MANUAL 2 SECTION 1910 180 SEE 3 ANSI B30 5 1989 BEARINGS ALL OTHER BOLT CYLINDER BEARINGS ROTATION BEARING ROTATION BEARING BOLTS ROTATION GEAR BOX CAUTION Routine maintenance insures trouble free operation and protects your investment All warranties are void if maintenance is neglected 12 11 03 LUBRICATION amp MAINTENANCE SCHEDULE 10006H SERIES NOTES 1 2 Use only authorized parts damage malfunction caused by the use of unauthorized parts is not covered by VVarranty or Product Liability Once bolt has been torqued to its rated capacity and then removed the bolt should be replaced vvith a nevv one Auto Crane Company recommends that this crane be serviced per Crane Inspection Log 999978 These logs should be filled in at the intervals noted and kept as permanent record Additional copies are available from your local distributor 3 10 12 11 03 NOTES GENERAL ASSEMBLY 10006H SERIES FM P N 460000000 HW P N 460000001 QTY QTY ITEM FM HW PART NUMBER DESCRIPTION 1 46004000 PEDESTALASSY 1 460040001 PEDESTALASSY HARDWIRE 3 1 1 4600200 PIN PVOT 5_ 1 1 4600700 DECALLAYOUT 1 460089000 5 10000HFM 1 460095000 S
31. HIPKIT 10006H HARDWIRE 8 2 2 008702000 SCWHX3 6 16 X1 1 4 665 9 2 2 021100 WASHER SPLK 3 8 01 12 04 PEDESTAL ASSEMBLY 10006H FM P N 460040000 HYDRAULICS PORT 1 HOIST DOWN REAR MOTOR PORT PORT 2 HOIST UP FRONT MOTOR PORT PORT 3 ROTATION CCW LOWER MOTOR PORT PORT 4 ROTATION CW UPPER MOTOR PORT PORT 5 LIFT CYL EXTEND PORT 6 LIFT CYL RETRACT PORT 7 EXT CYL EXTEND PORT 8 EXT CYL RETRACT CYLINDER SEAL KIT 460051001 C BAL CARTRIDGE 360153001 5 1 01 12 04 PEDESTAL ASSEMBLY 10006H FM P N 460040000 DESCRIPTION BASE PLATE VVELD PEDESTAL VVELD ROTATION BEARING SCW SOC HD 5 8 11 X 1 5 8 VVASHER 5 8 FLAT HARDENED 15 490171 CAPSCREW 5 8 11 X 2 25 8 1 46006000 ROTATION GEARBOX __9 1 46008500 SEAL ORING___________________ 15 6 020601 JWASHERS 6LOCKZP 17 6 007807 SCW 5 16 18 3416 65 2 01 12 04 NOTES PEDESTAL ASSEMBLY 10006H FM P N 460040000 34 9 X 021100 X WASHERSPLKS8 _____ 60 1 460064000 PIN ROTATION STOP 66 1 460070000 PROXIMITY SWITCH 68 1 360705000 HOME SWITCH HARNESS 69 1 017301 NUTHXNYLONLOCK3 8NCCP 5 3 01 12 04 BOOM ASSEMBLY 10006H P N 460030000 AN APPLY LOCTITE 609 TO THREADS BEFORE INSTALLING CYL SEAL KIT P N 366331001 C BAL P N 360153001 6 1 12 11 03
32. IBLE WARNING FAILURE TO CORRECTLY PLUMB AND WIRE CRANE CAN CAUSE INADVERTENT OPERATION AND DAMAGE TO CRANE AND OR PERSONEL 11 Once crane and plumbing are installed on the truck fill the reservoir to top of sight glass mobile DTE 13 or equal Before operating crane connect together the pressure and return hoses going to base of crane using 10 12 JIC union and engage PTO with engine running Allow oil to circulate for 15 to 20 minutes This will flush contaminants from the system back to the return line filter Operate all cylinders to full extension and retraction a minimum of six times to bleed air from system Return all cylinders to the stored position and disengage PTO Refill reservoir to top sight glass To ensure 15 gallons per minute GPM install an in line flow meter between the crane and the reservoir in the return hose 12 Load test the crane to ensure proper functioning and truck stability 13 Make certain the owner s manual is delivered to the customer 14 For additional help call the service department at the Auto Crane Company 918 836 0463 Tulsa Oklahoma WARNING FEDERAL LAW 49 CFR PART 571 REQUIRES THAT THE FINAL STAGE MANUFACTURER OF A VEHICLE CERTIFY THAT HE VEHICLE COMPLIES WITH ALL APPLICABLE FEDERAL REGULATIONS ANY MODIFICATIONS PERFORMED ON THE VEHICLE PRIOR TO THE FINAL STAGE ARE ALSO CONSIDERED INTERMEDIATE STAGE MANUFACTURING AND MUST BE CERTIFIED AS TO COMPLIANCE THE INSTALLER OF THIS CRANE A
33. ND BODY IS CONSIDERED ONE OF THE MANUFACTURERS OF THE VEHICLE AS SUCH A MANUFACTURER THE INSTALLER IS RESPONSIBLE FOR COMPLIANCE WITH ALL APPLICABLE FEDERAL AND STATE REGULATIONS AND IS REQUIRED TO CERTIFY THAT THE VEHICLE IS IN COMPLIANCE IT IS THE FURTHER RESPONSIBILITY THE INSTALLER OF THE CRANE TO COMPLY WITH THE OSHA TRUCK CRANE STABILITY REQUIREMENTS AS SPECIFIED BY 29 CFR PART 1910 180 O 1 01 12 04 LUBRICATION amp MAINTENANCE SCHEDULE 10006H SERIES SERVICE or 000 00000 INSPECT HOOK 8 LATCH FOR DEFORMATION ES MM ME ME CRACKS 8 CORROSION CABLE SHURE CABLE IS VVOUND EVENLY HOIST BOOM x CHECK FOR FLATTENING KINKS amp BROKEN CABLE STRANDS SEE MANUAL HYD HOSES LX VISUAL INSPECTION CHECK FLUID LEVEL CHECK TORQUE TO 23 FT LBS GRADE 5 35 FT LBS GRADE 8 AS REQUIIRED CHECK TORQUE TO 501 FT LBS AS REQUIIRED LUBE WITH MOBILETAC LL OR LUBRIPLATE P N 15263 OR EQUAL SEALED BEARING REPLACE IF ROUGH OR LOOSE PZ E CHECK TIGHTEN AS REQUIRED STE ajo pic z o O 2 2 O UJ O 5 2 gt 2 2 2 GREASE VVITH MOBILEPLEX EP 2 OR EQUIVALENT Q ZERKS GREASE VVITH MOBILEPLEX EP 2 OR EQUIVALENT 0 ZERKS CHECK TORQUE TO 170 FT LBS HEX HEAD 180 FT LBS SOCKET HEAD AS REQUIRED CHECK TORQUE 80 FT LBS AS REQUIRED ROTATIONGEAR x EP GEARLUBE 80 00 DRAIN FLUS
34. ONNECTIONS OF THIS TYPE ARE NOTES HEF SERINK APELEED aii LABEL ALL PLUGS PER FUNCTION IDENTIFICATION ONLY ONE CONDUCTOR THROUGH RUBBER SEAL ON PLUGS PINA e 7 RED TO BATTERY 4 POS RED PIN2 6 PIN 28 6 WHT SLOW FAST 4in RED 49 AI PING m PIN 32 e amp u TOENGSTART 21 120in PIN 30 GRN TO AUX FUNC PROPORTIONAL gg 1 1 DE Ve PIN 29 PIN 33 ORG TO ENG STOP 4 REAR view 4 PIN 40 TO BATTERY GND 21314 36in 22 EIA Ni 22 CRANE WIRING NOTE SEE PAGES 9 3 1 amp 9 3 2 FOR MODIFICATIONS NECESSARY TO USE THIS HARNESS ON THE 10006H FM 9 2 0 01 12 04 MAIN HARNESS 6406 HI8406H FM P N 480879000 ITEM QTY DIS PART No DESCRIPTION 1 1 A 366377001 HOUSING DEUTSCH 40 PIN 2 11 A 366367001 HOUSING DEUTSCH PLUG 2 PIN 3 11 A 366367002 VVEDGE DEUTSCH PLUG 2 PIN 4 58 A 366367003 CONTACT DEUTSCH CONNECTOR SOCKET 5 1 A 366376001 HOUSING DEUTSCH RECEPTACLE 4 PIN 6 2 A 366376002 VVEDGE DEUTSCH 4 PIN 7 13 366376003 CONTACT DEUTSCH PIN 8 1 360768001 HOUSING DEUTSCH 4 BULKHEAD RECEPTACLE 9 1 A 360764001 HOUSING DEUTSCH 3 PIN RECEPTACLE 10 1 A 360764002 VVEDGE DEUTSCH 3 PIN 11 1 A 360769001 HOUSING DEUTSCH 2 PIN RECEPTACLE 12 36in A 800633 CABLE 16 GA 14 COND 13 66in A 750038 CABLE 18 GA 4 COND SHIELDED 14 1 A 360769002 VVEDGE
35. R KAR TECH 13 1 366500008 CABLE PENDANTICHARGE KAR TECH 714 1 366504000 BATTERY CHARGER CIGARETTE LIGHTER 718 14 5 HH GRS 18 1 360708000 BRACKET PENDANTPLUG 19 4 725321 NUTNYLONLOCK8 322 20 4 001302 SCREW 8 32 X 5 21 1 366520000 JUNCTION BOX ASSY 22 1 366466000 WIRE HARNESS TRUCKFUNCTIONS 23 1 680040 PENDANTASSEMBY Pressure and return hoses are not furnished with this crane The hoses must be provided by the installer and the lengths determined at installation REQUIREMENTS FOR INSTALLATION USING 23 GALLON RESERVOIR A RETURN LINE FROM CRANE TO RESERVOIR IN COMPARTMENT 12 SAE 100R2 OR EQUIVALENT HOSE LENGTH IS DETERMINED BY INSTALLER RETURN LINES LONGER THAT 6 FEET SHOULD BE SIZE 16 HOSE END FITTINGS ARE 12 JIC FEMALE SWIVEL CRANE END AND 12 JIC FEMALE SWIVEL RESERVOIR END B PRESSURE LINE FROM PUMP TO CRANE 10 SAE 100R12 OR EQUIVALENT WITH A 3 500 PSI MINIMUM WORKING PRESSURE HOSE LENGTHS IS DETERMINED BY INSTALLER HOSE END FITTINGS ARE BOTH 10 FEMALE SWIVEL NOTE REFER TO OWNERS MANUAL FOR ADDITIONAL INSTALLATION INFORMATION CAUTION FAILURE TO USE CLEAN HYDRAULIC HOSES AND COMPONENTS MAY CONTAMINATE THE CRANE AND HYDRAULIC SYSTEM AND VOID WARRANTY Crane must be provided with a flow of 15 gallons per minute and a pressure of 3 400 PSI Excess flow will cause erratic operation and too little
36. all be provided by the manufacturer for the removal of air from hydraulic circuits LUBRICATION All moving parts of the crane for which lubrication is specified should be regularly lubricated per the manufacturer s recommendations and procedures ROPE INSPECTION 31 Frequent Inspection A All running ropes in service should be visually inspected once each working day visual inspection shall consist of observation of all rope which can be in use during the days operations These visual observations should be considered with discovering gross damage such as listed below which may be an immediate hazard 1 distortion of the rope such as kinking crushing un stranding birdcaging main strand displacement or core protrusion Loss of rope diameter in short length or unevenness of outer strands should be replaced 2 general corrosion 3 broken or cut strands 4 number distribution and type of visible broken wires When such damage is discovered the rope shall either be removed from service or given as inspection 2 10 12111103 INSPECTION TESTING AND MAINTENANCE GENERAL B Care shall be taken when inspecting sections of rapid deterioration such as flange points crossover points and repetitive pickup points on drums 32 Periodic inspection A The inspection frequency shall be determined by qualified person and shall be based on such factors as 1 expected rope life as determined by e
37. e level and firm support for the truck When working in soft earth use wide pads under outrigger feet to prevent sinking Always store outriggers before transportation 12 2002 31 32 33 34 35 36 37 38 39 40 IMPORTANT SAFETY TIPS AND PRECAUTIONS Always store the crane in its stowed position for transportation Remember the overall height of the entire unit for garage door clearance or when moving under objects with low overhead clearance Disengage power takeoff PTO before moving the vehicle Always walk around the vehicle before moving Never drive with load suspended from crane Do not take your eyes off a moving load Look in the direction you are moving Never swing load over people Do not stop the load sharply in midair so that it swings like pendulum Meter the control levers to avoid this situation Crane boom length should be kept as short as possible for maximum lifting capacity and greater safety Longer booms require additional care in accelerating and decelerating the swing motion and thus slow down the working cycle and reduce productivity Keep the load directly and vertically under the boom point at all times Crane booms are designed primarily to handle vertical loads not side lifts WARNING Never attempt to lift drag tow or pull load from the side The boom can fail far below its rated capacity 2 2 41 42 43 44 45 46
38. e is a 60 amp alternator with a 500 cold cranking amp battery These specifications should be considered minimum It has always been Auto Crane Company policy to handle all warranty claims we receive as promptly as possible If a warranty claim involves discrepant material or workmanship Auto Crane will take immediate corrective action It is understandable that Auto Crane Company cannot assume responsibility of liability when it is obvious that our products 1 1 have been abused misused overloaded or otherwise damaged by inexperienced persons trying to operate the equipment without reading the manual Auto Crane will not assume responsibility or liability for any modifications or changes made to unit or installation of component parts done without authorization Auto Crane maintains a strong distributor network and a knowledgeable Customer Service Department In most cases an equipment problem is solved via phone conversation with our customer service department The customer service department also has the ability to bring a local distributor a regional sales manager or a factory serviceman into the solution of an equipment problem If through no fault of Auto Crane Company it is necessary to send an experienced factory serviceman on a field service call the rates stated in the Auto Crane Distributor s Flat Rate Manual will apply Auto Crane Company s extensive Research and Development Program allow our customers to use
39. e ona boom support NRML Normal operating mode Crane is functioning properly This is not an error It is a standard normal operation SLOW Slow operating mode Crane is functioning properly if loaded or boom down activated This is not an error It is a standard slow operation readout If the crane is not loaded booming up should clear this code BLMT Boom limit Boom has reached maximum elevation This is not an error It only indicates boom position Lower the boom to deactivate the switch 12 11 03 TRANSMITTER RECIEVER SYNCHRONIZATION NOTE BEFORE PERFORMING THIS PROCEDURE CONFIRM THAT NO OTHER CRANES OF THIS TYPE ARE OPERATING IN THE AREA 1 Power on the transmitter and receiver 2 Locate the program plug on the crane This will be the unused plug near where the cord reel plugs into the wire harness There should be blank plug installed and the plug should be labeled 3 Using a jumper wire as shown below connect the two contacts in the plug 4 While the jumper is installed and the transmitter is unplugged from the pendant cable activate a function on the transmitter Note The crane must be electrically powered but it is not necessary to supply hydraulic power to complete synchronization 5 Remove the jumper wire Important The jumper wire should not be left installed Doing so could cause the crane to be operated by another transmitter 9 12 12 11 03 REMOTE PENDANT PARTS AND
40. entified by excessive lugging of engine and rapid overheating of oil 3 Collapsed or blocked suction hose to pump This condition is usually identified by pump cavitation noise 4 Bad pumps a bad pump will usually have some flow but the flow will drop off rapidly as pressure increases This condition will cause overheating of the system A drop of four 4 or more GPM from Zero 0 PSI to Two Thousand 2000 PSI is cause for pump investigation NO PRESSURE OR Check the sight gauge and maintain an adequate oil level in reservoir TOO LOW Make sure pressure gauge is functioning correctly Possible relief valve PRESSURE stuck open Check for excessive leakage and correct TOO HIGH FLOW Make sure pump size is correct and pump speed is not too fast Consult manufacturer s data sheet Check or replace flow control Check components for flow displacements High flow may cause erratic valve operation TOO HIGH Make sure pressure relief valve is correctly set PRESSURE CAUTION The Auto Crane 10006H series cranes are manufactured with a standard overload protection system to prevent structural damage to the crane When the crane load rating is exceeded main boom down extend out and hoist up will not function These operations cannot be used again until the load on the crane is reduced Also the main boom elevation will be limited in its operation as the crane becomes overloaded Attempting to raise the main boom with a load greatly exceedin
41. f position O starting means rendered inoperative D boom lowered to the ground if possible or otherwise secured against dropping E relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components 25 VVarning or OUT OF ORDER signs shall be placed on the crane controls 26 After adjustments and repairs have been made the crane shall not be returned to service until all guards have been reinstalled trapped air removed from hydraulic system if required safety devices reactivated and maintenance equipment removed ADJUSTMENTS AND REPAIRS 27 Any hazardous conditions disclosed by the inspection requirements shall be corrected before operation of is resumed Adjustments and repairs shall be done only by designated personnel 28 Adjustments shall be maintained to assure correct functioning of components The following are examples functional operating mechanism B safety devices C control systems 29 Repairs or replacements shall be provided as needed for operation The following are examples A critical parts of functional operating mechanisms which are cracked broken corroded bent or excessively worn B critical parts of the crane structure which are cracked bent broken or excessively corroded crane hooks showing cracks damage or corrosion shall be taken out of service Repairs by welding are not recommended 30 Instructions sh
42. f the fluid 1065 of pressure 14 Hydraulic and pneumatic valves inspection A cracks in valve housing B improper return of spool to neutral position C leaks at spools or joints D sticking spools E failure of relief valves to attain or maintain correct pressure setting F relief valve pressure shall be checked as specified by the manufacturers 15 Hydraulic and pneumatic cylinders inspection A drifting caused by fluid leaking across piston B rod seals leaking C leaks at welding joints D scored nicked or dented cylinder rods E damaged case barrel F loose or deformed rod eyes or connecting joints 16 Hydraulic filters Evidence of rubber particles on the filter elements may indicate hose O ring or other rubber component deterioration Metal chips or pieces on the filter may denote failure in pumps motors or cylinders Further checking will be necessary to determine origin of the problem before corrective action can be taken 17 Labels are to be in place and legible CRANES NOT IN REGULAR USE 18 A crane which has been idle for a period of over one month or more but not less than six months shall be given an inspection conforming with the initial regular frequent inspections 19 A crane which has been idle for a period of over six months shall be given a complete inspection conforming with the initial regular frequent inspection requirements INSPECTION RECORDS 20 Dated records for
43. f the strands On pre formed rope one seizing on each side of the cut is required On non preformed ropes of 718 in 22 mm diameter or smaller two seizings on each side of the cut are required and for non preformed rope 1 in 25 mm diameter or larger three seizings on each side of the cut are required During installation care should be exercised to avoid dragging of the rope in the dirt or around objects which will scrape nick crush or induce sharp bends in it Rope should be maintained in well lubricated condition It is important that lubricant applied as part of maintenance program shall be compatible with the original lubricant and to this end the rope manufacturer should be consulted Lubricant applied shall be the type which does not hinder visual inspection Those sections of rope which are located over sheaves or otherwise hidden during inspection and maintenance procedures require special attention when lubricating rope The object of lubrication is to reduce internal friction and to prevent corrosion When an operating rope shows greater wear or well defined localized areas than on the remainder of the rope rope life can be extended in cases where section at the worn end and thus shifting the wear to different areas of the rope 12 11 03 DECAL FUNCTION USED ON QUANTITY PLACEMENT PART NO DECAL FUNCTION USED QUANTITY PLACEMENT PART NO
44. g the crane rating will open the main relief valve resulting in no boom movement This problem can be resolved by moving the load closer to the crane pedestal or reducing the load 9 4 12 11 03 5 z O R lt Ry NOTE Always turn the power to crane off before removing fuse Fuse is on the ground circuit The fuse can be replaced with a 7 5 amp fuse EI 17 rt ni eri au nx im I Xn FUSE 9 5 12 11 03 CONTROLLER DIAGNOSTICS CODE DESCRIPTION POSSIBLE 0 5 POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S 1 Signal problem No signal from transmitter pendant or transmitter power off Check green transmit light on transmitter light should flash when function is activated If light does not flash make sure transmitter is on If light flashes and red low battery light is flashes charge unit If transmitter is plugged in as a pendant and transmit light comes on but code remains check cable connections and cable ECO2 Boom up Short or open connection on boom up output Check plug in boom up solenoid on hydraulic control valve Check vvires for damage that could cause break or short Boom dovvn Short or open connection on boom down output
45. h requires the boom to be raised This feature is disabled when the crane is in the HOME position to allow for stowing Operation Failure If the crane does not operate as expected observe the readout through the window on the receiver and refer to the front panel for explanation The codes are further explained in the Diagnostics section of this manual Please note that NRML is displayed when the crane is operating normally HOME is displayed when the crane is forward and in a position to be stowed and SLOW is displayed when functions are slowed due to load will be displayed if no function is activated on the transmitter Charging the Transmitter The transmitter can be charged using one of three methods It can be charged with the cigarette lighter charger the pendant cable or the optional AC adapter P N 366505000 To charge the transmitter with the pendant cable the crane must have electrical power The crane can be operated by pendant or by FM remote therefore the battery can be charged without suspending operation of the crane The transmitter should be fully charged after approximately 6 to 8 hours of charging It is not recommended to leave the transmitter charging for extended periods of time 3 or 4 days Doing so will eventually degrade the battery and it will not keep a good charge 2 4 2 01 12 04 QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES OPERATORS 1 Crane
46. hall be done while a person is on the hook or load Hook attached suspended work platforms baskets shall not be used with cranes covered by this standard Work platforms attached to the boom must be approved by crane manufacturer I The operator should avoid carrying loads over people J When the crane is so equipped the stabilizers shall be fully extended and set Blocking under stabilizers shall meet the requirements as follows 1 Strong enough to prevent crushing 2 Ofsuch thickness width and length as to completely support the stabilizer pad K Firm footing under all tires or individual stabilizer pads should be level Where such a footing is not otherwise supplied it should be provided by timbers cribbing or other structural members to distribute the load so as to not exceed allowable bearing capacity or the underlying material L In transit the boom shall be carried in stowed position When rotating the crane sudden starts and stops shall be avoided rotational speed shall be such that the load does not swing out beyond the radius at which it can be controlled N crane shall not be transported with a load on the hook unless recommended by the manufacturer O No person should be permitted to stand or pass under a suspended load Stowing procedure Follow the manufacturer s procedure and sequence when stowing and un stowing the crane 12 2002 QUALIFICATIONS FOR AND CONDUCT OF OPERATORS
47. hort or open connection on hoist down output Check plug in hoist down solenoid on hydraulic control valve Check wire for damage that could cause break or short 9 7 12 11 03 CONTROLLER DIAGNOSTICS CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S EC10 Incorrect ID Signal received from transmitter with incorrect ID code Confirm that transmitter being used is for use with this unit Follow New Transmitter procedure in the transmitter operation section of this manual EC11 Ground missing Fuse in receiver may be blown Check the fuse in the receiver fuse is on the ground circuit do not check for voltage EC12 Short circuit in power circuit Power provided to the switches etc is shorted to ground Check the wiring on the pendant cable the anti two block the pressure sensor the boom limit switch the home switch and the rotation stop for short to ground EC13 Auxiliary not wired Short or open connection on auxiliary This error should only be seen on Palm unit and should only occur when the auxiliary function is not connected EC15 Pressure sensor Pressure sensor problem Check plugs and wires coming from pres
48. ins and locking device for wear damage and loose retaining bolts PERIODIC INSPECTION Deformed cracked or corroded members in the crane structure and carrier Loose bolts particularly mounting bolts Cracked or worn sheaves and drums 7 Worn cracked or distorted parts such as pins 1 12 bearings shafts gears rollers and devices Excessive wear on brake and clutch system parts and lining Crane hooks inspected for cracks 10 Travel steering braking and locking devices for malfunction Excessively worn or damaged tires Hydraulic and pneumatic hose fittings and tubing inspection A evidence of leakage at the surface of the flexible hose or its junction with metal and coupling B A blistering or abnormal deformation to the outer covering of the hydraulic or pneumatic hose C A leakage at threaded or clamped joints that cannot be eliminated by normal tightening or recommended procedures A evidence or excessive abrasion or scrubbing on the outer surface of a hose rigid tube or fitting Means shall be taken to eliminate the interference of elements in contact or otherwise protect the components 12 11 03 INSPECTION TESTING AND MAINTENANCE GENERAL 13 Hydraulic and pneumatic pumps and motors inspection A loose bolts or fasteners leaks at joints between sections shaft seal leaks unusual noises or vibrations loss of operating speed excessive heating o
49. is specifically recommended that all operating and service personnel consider this manual as mandatory material for reading and study before operating or servicing Auto Crane products It is highly recommended that crane owners equipment managers and supervisors also read this manual Auto Crane has incorporated several safety features in the 10006H crane for your protection For your convenience the overall dimensions of the 10006H are included on the General Dimension Drawing Rotation and turning radius are also listed on that drawing Remember the crane adds weight to the vehicle Adding weight may change the driving and riding characteristics of the vehicle unless the appropriate overload spring s are installed on the truck The payload of the vehicle is reduced by the weight of the crane The operator should exercise care when loading the vehicle Distributing the payload on the vehicle evenly will greatly improve the driving and riding characteristics of the vehicle Auto Crane Company issues a limited warranty certificate with each unit sold See last page for warranty The 10006H cranes are attached to your 12 volt truck electrical system through the relay provided The 10006H is another highly efficient Auto Crane product The use of a maintenance free battery is not recommended for use on any Auto Crane product The recommended alternator and battery that will give the longest life with the most useful duty cycl
50. last 5 wraps of cable from drum 17 WARNING NEVER wrap cable around load 18 WARNING NEVER attempt to lift or drag load from the side The boom can fail far below its rated capacity 19 WARNING NEVER weld modify or use unauthorized components on any Auto Crane unit This will void any warranty or liability Also failure of the crane may result 20 WARNING NEVER place chain link on the tip of the hook and try to lift a load WARNING NEVER use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing thus negating the safety feature 22 WARNING In using hook with latch ALWAYS insure that the hook throat is closed before lifting load Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel Switch on that will cause unsafe operating conditions WARNING NEVER hold any Control Select Switch on that will cause unsafe operating conditions 2 Auto Crane Company remote controlled stiff boom cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel 2 3 1212002 For hydraulic outriggers IMPORTANT OPERATION OF UNIT Make sure this manual has been thoroughly read by all crane operating personnel and supervisors routine inspection of the crane sho
51. leave the area of the break and do not attempt to stop the break by hand as the hydraulic oil may be hot and under high pressure which can cause serious injury Shut the system down as soon as possible Check the hook at least every thirty days for distortions or cracks and replace it as required Oil gears as required Stop all operations when cleaning adjusting or lubricating the machine Keep dirt and grit out of moving parts by keeping crane clean Make sure machine is free of excess oil grease mud and rubbish thus reducing accidents and fire hazards When new cable is installed operate first with light load to let the cable adjust itself Locate the vehicle at the work site for the best stability possible Keep the vehicle in a level position while loading or unloading Observe operating area for obstructions and or power lines that might be hazard WARNING Auto Crane Company cranes not designed or intended for use in lifting or moving persons Any such use shall be considered to be improper and the seller shall not be responsible for any claims arising there from This sale is made with the express understanding that there is no warranty that the goods shall be fit for the purpose of lifting or moving persons or other improper use and there is no implied warranty or responsibility for such purposes 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 2
52. nches Third boom vvill reach from 20 feet 4 inches to 25 feet 4 inches CABLE 120 ft 36 6 m of 7 16 in 11 1 mm diameter aircraft quality cable This cable has a single line breaking strength of 20 400 Ibs 9 253 kg CHASSIS REQUIREMENTS 26 000 Ibs 11 793 kg GVWR minimum 900 000 in lbs RBM ELECTRICAL SYSTEM REQUIREMENTS Voltage 12 VDC Alternator 60 amp minimum Battery 100 minute reserve capacity minimum Maintenance type ROTATION 370 Rotation with electric stop 12 11 03 IMPORTANT SAFETY TIPS AND PRECAUTIONS 10 11 12 13 14 15 No unqualified or unauthorized person shall be allowed to operate the crane WARNING Never weld modify or use unauthorized components parts on any Auto Crane unit This will void any warranty or liability Also failure of the crane may result Make certain the vehicle meets minimum chassis requirements These requirements do not guarantee unit stability Make certain the crane is installed per factory specifications Contact your local distributor or the Auto Crane factory if any questions arise Visual inspections and tests should be conducted at the beginning of each shift each day to ensure that the and all its operating systems in good condition and working order before it is used Inspect hydraulic hoses frequently for signs of deterioration and replace them as required If a hydraulic break occurs
53. ntervals at which inspection should be performed The intervals in turn are dependent upon the nature of the components of the crane and the degree of their exposure to wear deterioration or malfunction The two general classifications are herein designated as frequent and periodic with respective intervals between inspections as defined below A frequent inspection daily to monthly intervals B periodic inspection one to twelve intervals or as specifically recommended by the manufacturer FREQUENT INSPECTION 3 Inspection shall be performed by designated personnel A control mechanisms for maladjustment interfering with proper operation daily when used B control mechanisms for excessive wear of components and contamination by lubricants or other foreign matter C safety devices for malfunction D all hydraulic hoses particularly those which flex in normal operation of crane functions should be visually inspected once every working day when used E hooks and latches for deformation chemical damage cracks and wear Refer to ANSI ASME B30 10 F rope reeving for compliance with crane manufacturer s specifications if optional winch is used G electrical apparatus for malfunctioning signs of excessive deterioration dirt and moisture accumulation H hydraulic system for proper oil level and leaks daily I tires for recommended inflation pressure cuts and loose wheel nuts connecting p
54. on In such cases specialized clinical or medical judgment and tests may be required Evidence that the operator is subject to seizures or loss of physical control shall be sufficient reason for disqualification Specialized medical tests may be required to determine these conditions Operators and operator trainees should have normal depth perception coordination and no tendencies to dizziness or similar undesirable characteristics In addition to the above listed requirements the operator shall A Demonstrate the ability to comprehend and interpret all labels operator s manuals safety codes and other information pertinent to correct crane operations Possess knowledge of emergency procedures and implementation of same Demonstrate to the employer the ability to operate the specific type of equipment Be familiar with the applicable safety regulations Understand responsibility for maintenance requirements of crane Be thoroughly familiar with the crane and its control functions G Understand the operating procedures as outlined by the manufacturer CONDUCT OF OPERATORS 9 The operator shall not engage in any practice which will divert his attention while actually operating the crane 10 Each operator shall be responsible for those operations under the operator s direct control Whenever there is any doubt as to safety the operator shall consult with the supervisor before handling the loads 1
55. ontact with the crane load during operation All Cranes 2 Both sides of traveling block 3 2 DEATH OR SERIOUS INJURY MILL RESULT FROM BOOM LINE OR LOAD CONTACTING ELECTRIC LINES DO NOT USE HAN kle 10 FEET OF ELECTRIC LINES CARRYING UP TO 50 000 VOLTS ONE FOOT ADDITIONAL CLEARANCE IS REQUIRED FOR EVERY ADDITIONAL 30 000 VOLTS OR LESS P N 040528 11116 K 124 CER 208 GER STAY CLEAR OF BOOM AT ALL TIMES P N 040517 12 11 03 PART DECAL FUNCTION PART DECAL FUNCTION SAFETY DECAL SECTION 10006H SERIES 040587000 USED ON All cranes equipped with load sensor LOAD SENSOR DON T TAMPER QUANTITY 2 To inform the operator that the load PLACEMENT Both sides of the lift cylinder near sensor is pre set and that tampering the load sensor vvith the sensor may cause potentially hazardous situation ix LOAD SENSOR FACTORY PRE SET DO NOT TAMPER P N 040587 040519000 USED ON All cranes SCISSORS POINT QUANTITY 2 To inform the operator of possible PLACEMENT Both sides of the lift cylinder danger at scissors point on crane SERIOUS INJURY WILL RESULT KEEP HANDS AND ARMS CLEAR AT ALL TIMES P N 040519 3 3 12 11 03 DECAL LAYOUT 10006H PIN 46008 7000
56. operation shall be limited to personnel vvith the follovving minimum qualifications A Designated persons B Trainees under the direct supervision ofa designated person Maintenance and test personnel when it is necessary in the performance of their duties D Inspectors crane No one other than the personnel specified above shall enter the operating area of a crane with the exception of persons such as oilers supervisors and those specified persons authorized by supervisors whose duties require them to do so and then only in the performance of their duties and with the knowledge of the operator or other persons QUALIFICATIONS FOR OPERATORS 3 Operators shall be required by the employer to pass practical operating examination Qualifications shall be limited to the specific type of equipment for which examined Operators and operator trainees shall meet the following physical qualifications Vision of at least 20 30 Snellen in one eye and 20 50 in the other with or without corrective lenses B Ability to distinguish colors regardless of position if colors differentiation is required for operation C Adequate hearing with or without hearing aid for the specific operation Evidence of physical defects or emotional instability which render a hazard to operator or others which in the opinion of the examiner could interfere with the operator s performance may be sufficient cause for disqualificati
57. ort Avoid unneeded pressure on the boom support 12 Store transmitter in proper location in cab or storage area 13 Return outriggers to stowed position Make sure they are pinned in place or jacklegs are returned to compartment 14 Check work area for any tools or equipment not stored 15 Release throttle control depress clutch and disengage PTO Deactivate any crane power switches 16 Report any unusual occurrence during crane operation that may indicate required maintenance or repair 17 NEVER use two cranes to support a load too large for either crane OPERATION OF OUTRIGGERS 1 Shift crane outrigger control valve to outrigger position 2 Operate the outrigger control valves to position the outriggers After outriggers are positioned return crane outrigger selector to crane position 4 Crane is now ready to operate 2 4 For manual outriggers 1 Pull lock pins to release jack leg or drop down outrigger and move to outermost lock position 2 Make sure lock pins are reinstalled properly 3 Lower outrigger pad to firm ground and adjust foot to take out slack 4 Crane is now ready to operate 12 11 03 FM CONTROL SYSTEM OPERATION Transmitter Layout The red light to the left of the Power On Off button indicates low transmitter battery As the battery runs down the light will begin to flash It will flash increasingly faster as the battery power decreases
58. ot approximately 1000 PSI the counterbalance valve requires adjustment gt To increase the CB valve setting becomes necessary to lower the boom without flow present the CB valve adjustment can be turned in until the boom begins to descend Make sure the boom will lower onto a proper support Loosen the lock nut and carefully turn adjustment screw clockwise Count the number of turns Turn slowly until the boom just begins to lower and remove hand arm fingers from cranes while boom is lowering loosen nut and turn Allen head Turning adjustment screw too far will screw counter clockwise cause valve to come apart on the inside This condition is not repairable gt To reduce the CB valve setting After boom is lowered turn adjustment loosen nut and turn Allen head screw clockwise Tighten nut on adjustment screw and repeat procedure if needed to obtain the proper pressure setting Disengage PTO remove the pressure gauge and install plug Crane is now ready for operation screw counter clockwise the approximate number of turns made during lowering procedure After the problem is corrected readjust the counterbalance valve using the procedure in this manual WARNING DO NOT TRY TO ADJUST VALVES WHILE BOOM IS MOVING Doing so may result in personal injury 10 2 12 11 03 HYDRAULIC CONTROL VALVE 10006H SERIES 10 3 12111103 HYDRAULIC CONTROL VALVE 10006H SERIES 480839005 2 36636500
59. periodic inspection should be made on critical items such as brakes crane hooks rope hydraulic and pneumatic cylinders and hydraulic and pneumatic relief pressure valves Records should be kept available to an appointed person OPERATIONAL TESTS 21 Prior to initial use all new altered modified or extensively repaired cranes shall be tested for compliance with the operational requirements of this section including functions such as the following A load lifting and lowering mechanisms boom lifting and lowering mechanisms boom extension and retraction mechanisms swing mechanisms safety devices operating controls comply with appropriate function labels SER Operational crane test results shall be made available to an appointed person RATED TEST LOAD Prior to initial use altered modified or extensively repaired cranes shall be load tested by or under the direction of an appointed person 2 9 12 11 03 INSPECTION TESTING AND MAINTENANCE GENERAL 22 Test loads shall not exceed 110 of the manufacturer s load ratings 23 Written reports shall be maintained showing test procedures and confirming the adequacy of repairs MAINTENANCE PREVENTIVE MAINTENANCE 24 Before adjustment and repairs are started on crane the following precautions shall be taken as applicable A crane placed where it will cause the least interference with other equipment operations B allcontrols at the of
60. rane Product or parts to operate properly Auto Crane makes no warranty in respect to component accessories it being subject to the warranties of their respective manufacturers If field service at the request of the distributor is rendered and fault is found not to be with Auto Crane s product the distributor shall pay the time and expense of the field representative Claims for service labor or other expenses that have incurred by the buyer without approval or authorization or Auto Crane will not be accepted When applying for warranty claims may be handled by contacting your nearest authorized Auto Crane Distributor All claims are to be filed in writing on an Auto Crane Warranty Claim Form AUTO CRANE COMPANY IS UNDER NO OLIGATION TO EXTEND THIS WARRANTY TO ANY CUSTOMER FOR WHICH AN AUTO CRANE DELIVERY REPORT FORM HAS NOT BEEN COMPLETED AND ON FILE WITH AUTO CRANE COMPANY Limited Warranty 2 Years Effective September 2 2003
61. rd Wire Version Information ECN 603 Installation Changed Pendant Cable Part Number ECN 617 01 12 04 General Assembly Incorporated Hard Wire Version and Added Caps 01 12 04 Pedestal Assembly Miscellaneous Hardware Changes Moved Rotation and Boom Limit Switches to Sub assemblies ECN 617 01 12 04 Electrical Section Corrected Electrical Schematic Added Note to Main Wire Harness Added Pages for Main Wire Harness Modifications ECN 617 01 12 04 Hard Wired Crane Added Hard Wired Crane Section 603 01 12 04 Rotation Gearbox Added Parts Breakdown NARNINGS WARNING Federal law 49 cfr part 571 requires that the Final Stage Manufacturer of vehicle certify that the vehicle complies with all applicable federal regulations Any modifications performed on the vehicle prior to the final state are also considered intermediate stage manufacturing and must be certified as to compliance The installer of this crane and body is considered on of the manufacturers of the vehicle As such manufacturer the installer is responsible for compliance with all applicable federal and state regulations and is required to certify that the vehicle is in compliance WARNING It is the further responsibility of the installer to comply with the OSHA Truck Crane Stability Requirements as specified by 29 CFR part 1910 180 C 1 WARNING NEVER OPERATE THE CRANE NEAR ELECTRICAL POWER LINES Death or serious inj
62. see Charging the Transmitter The green light to the right of the Power On Off button indicates that the unit is transmitting This light will flash when a function is activated The rate at which if flashes depends on the mode of transmission When transmitting using the pendant cable the green light will flash noticeably faster than when unplugged In addition to the two lights mentioned above there are four function toggle switches These functions from left to right are used to raise and lower the boom raise and lower the hoist cable rotate the crane and extend and retract the boom There are also buttons for auxiliary functions such as Engine Start Stop and Engine Fast Idle POWER ON OFF 3 ENGINE ENGINE SLOW FAST START STOP DOWN cw DOWN OUT uP ccw uP HOIST ROTATE IN BOOM EXTEND Power On Off Button To turn the transmitter on press and hold the Power On Off button release once the transmit light becomes solid To turn the unit off press and hold the power button release once the transmit light stops flashing When this button is pressed both the red battery low and the green transmit light will flash alternately and stop flashing once the unit is either on or off Function Switches To operate a function toggle one of the function switches with either the thumb of the hand holding the unit or the thumb or fingers of the opposite hand Using the forefinger of the hand holding the unit slowly pull the trigger back to
63. sure sensor mounted in the lift cylinder counterbalance valve 9 8 12 11 03 CONTROLLER DIAGNOSTICS CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S EC16 Trigger Transmitter trigger problem Check trigger for damage contamination or incorrect adjustment EC17 Trigger logic error Trigger was activated before function switch was activated Confirm that trigger is released and returned to full off position activate function and reactivate trigger LBV Low battery Low battery power to to receiver Check connections to the battery Charge battery NOTE It is recommended that the crane be powered off if battery is charged with battery charger OVL Overload Pressure overload Retract boom hoist down or otherwise alleviate overload condition Refer to load chart for rated load If the error persists with seemingly light loads install pressure gage in plugged port of lift cylinder counterbalance valve to confirm pressures in excess of 2 800 psi Pressure sensor can give false readings if not properly grounded 9 9 12 11 03 CONTROLLER DIAGNOSTICS CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE DESCRIPTION POSSIBLE CAUSE S POSSIBLE SOLUTION S CODE D
64. the best equipment on the market Our Engineering Staff and our knowledgeable sales people are always available to our customers in solving crane and winch type application problems When in doubt call the Auto Crane factory DISTRIBUTOR ASSISTANCE Should you require any assistance not given in this manual we recommend that you consult your nearest Auto Crane Distributor Our distributors sell authorized parts and have service departments that can solve almost any needed repair NOTE THIS MANUAL SHOULD REMAIN WITH THE CRANE AT ALL TIMES This manual does not cover all maintenance operating or repair instructions pertinent to all possible situations If you require additional information please contact the Auto Crane Company at the following telephone number 918 836 0463 The information contained in the manual is in effect at the time of this printing Auto Crane Company reserves the right to update this material without notice or obligation 12 11 03 GENERAL SPECIFICATIONS 10006H DIMENSIONS Width 24 5 in 0 62 m Height 36 0 in 0 91 m Length 14 ft 8 in 4 47 m boom s stored Weight 2 330 Ibs 1057 kg CAPACITY 60 000 ft lbs 8 30 ton m ft lbs horizontal distance from centerline of rotation to free hanging weight feet x amount of weight pounds Ts amp 10 000 8 7 500 9 6 667 JI REACH Second boom vvill reach from 12 feet 4 inches to 20 feet 4 i
65. tion by an appointed person that the electrical distribution over to 50 10 3 50 and transmission lines have been de energized and over 50 to 200 15 4 6 visibly grounded at the point of work or over 200 to 350 20 6 1 B The danger zone may be entered if insulating over 350 to 500 25 7 62 barriers not a part of nor an attachment to the crane 500 to 750 35 10 67 have been erected to prevent physical contact vvith over 750 to 1000 45 13 72 the lines 1 o while in transit with no load and boom lowered 23 For lines rated 50 kV or below minimum AAA Y AAA AAA clearance between the lines and any part of the crane or load including handling appendages over to 0 75 4 1 22 shall be 10 ft 3m For higher voltages see over 075 to 50 6 1 83 Tablel over 50 to 345 10 3 83 over 345 to 750 16 4 87 24 Caution shall be exercised when working near over 750 to 1000 20 6 1 overhead lines because they can move horizontally or vertically due to wind moving the danger zone to new positions 2 7 12 2002 INSPECTION TESTING AND MAINTENANCE GENERAL INSPECTION CLASSIFICATION 1 Initial inspection Prior to initial use all new altered modified or extensively repaired cranes shall be inspected by designated person to insure compliance with provisions of this standard Regular inspection Inspection procedure for cranes in regular service is divided into two general classifications based upon the i
66. tions or more than one broken wire at an end connection 12 11 03 INSPECTION TESTING AND MAINTENANCE GENERAL H Replacement rope shall have strength rating at least as great as the original rope furnished or recommended by the crane manufacturer Any deviation from the original size grade or construction shall be specified by rope manufacturer or qualified person 35 Rope not in regular use all rope which has been idle for period of month or more due to shutdown or storage of a crane on which is installed shall be given and inspection in accordance with above information before it is placed in service This inspection shall be for all types of deterioration and shall be performed by qualified person 36 Inspection records frequent inspection no records required B A periodic inspections in order to establish data as basis for judging the proper time for replacement dated report condition at each periodic inspection should be kept on file This report shall cover points of deterioration listed above ROPE MAINTENANCE 37 Rope should be stored to prevent damage or deterioration 38 Unreeling or uncoiling of rope shall be done as recommended by the rope manufacturer and with care to avoid kinking or inducing twist 39 Before cutting a rope seizing shall be placed on each side of the place where the rope is to 40 41 42 2 12 be cut to prevent unlaying o
67. uld be mandatory before each operating day Any defects should be corrected immediately job site the vehicle should be positioned so that the crane can adequately reach the load within the rated capacity centerline of rotation to hoist Keep the vehicle as level as possible during operation For electric cranes engage emergency brake and leave ignition on vvith transmission in neutral or in park for automatic transmissions Activate any crane power switches For Auto Crane units requiring battery and hydraulic operation engage emergency brake place gear selector in neutral press clutch activate PTO release clutch and after hydraulic fluid is warm set throttle control to proper engine speed Always use outriggers from the truck to the ground Be sure these are firm and adequately positioned When rotating keep load as low to the ground as possible Remove the transmitter from cab or storage area Power transmitter on Detach hook from dead man Crane is now ready for operation 8 Always boom up before rotating so the boom will clear the required boom support 9 When extending the boom always maintain clearance between the boom crown and the traveling block or hoist hook 10 Always observe safe and practical operation to avoid possible accidents Refer to Safety Tips and Precautions 1 After completing lifting operations return the boom to stowed position on the boom supp
68. ury will result from boom line or load contacting electric lines Do not use crane within 10 feet 3 05m of electric power lines carrying up to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or less SEE DANGER DECAL P N 040529 in this Owner s Manual WARNING NEVER EXCEED load chart capacities centerline of rotation to hoist hook Un reel last 5 wraps of cable from drum Wrap cable around load Attempt to lift or drag a load from the side The boom can fail far below its rated capacity Weld modify or use unauthorized components on any Auto Crane unit This will void any warranty or liability Also failure of the crane may result Place a chain link on the tip of the hook and try to lift a load Use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing thus negating the safety feature Hold on any pendant Select Switch that will cause unsafe operating conditions WARNING In using a hook with latch ALWAYS make sure that the hook throat is closed before lifting a load Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel WARNING Failure to correctly plumb and wire crane can cause inadvertent operation and damage to crane and or personnel WARNING Auto
69. xperience on the particular installation or similar installations severity of environment percentage of capacity lifts Bon freguency rates of operation 5 exposure to shock loads Inspection need not be at egual calendar intervals and should be more freguent as the rope approaches the end of it s service life This inspection shall be made at least annually B Periodic inspection shall be performed by a designated person This inspection shall cover the entire length of the rope Only the surface wires need be inspected No attempt should be made to open the rope Any deterioration results in appreciable loss of original strength such as described below shall be noted and determination made as to whether use of the rope would constitute a hazard points listed above reduction of rope diameter below nominal diameter due to loss of core support internal or external corrosion or wear of outside wires severely corroded cracked bent worn or improperly applied connections C Care shall be taken when inspecting sections subject to rapid deterioration such as the following 1 sections in contact with saddles egualizer sheaves or other sheaves where rope travel is limited 2 sections of the rope at or near terminal ends where corroded or broken wires may protrude ROPE REPLACEMENT 33 No precise rules can be given for determination of the exact time for replacement of rope since many variable factors are involved

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