8406 H

OWNERS MANUAL

Manual No. 480899

Rev. 9/2/2003

Serial No. __________________

Mailing Address:

P.O. Box 580697

Tulsa, OK 74158-0697

Phone 836-0463

Fax 834-5979

74117-5904

Auto Crane Warranty Registration

Fax Transmission

To:

From:

Re:

Warranty Department

Product Registration

Fax:

Date:

Pages:

(918) 834-5979

End User Information: (Required for Warranty Activation)

Name:

Address:

City:

Contact:

State:

E-mail Address:

Distributor Information: (Required for Warranty Activation)

Phone:

Name:

Address:

City:

Contact:

Product Information:

Model No.:

Date Product Delivered:

VIN #

State:

E-mail Address:

(Required for Warranty Activation)

Serial No.:

Date Processed:*

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.

Mail to:

Warranty Department

Auto Crane Company

P.O. Box 581510

Tulsa, OK 74158-0697

Warranty Registration Rev. 072403

8406H SERIES

OWNER’S MANUAL – REVISION RECORD

Revision

Date

Section(s)

Or

Page(s)

09/02/03 Last page

Description of Change

New 2-year warranty policy to replace 1-year warranty policy i

WARNINGS

WARNING! Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of a vehicle certify that the vehicle complies with all applicable federal regulations. Any modifications performed on the vehicle prior to the final state are also considered intermediate stage manufacturing and must be certified as to compliance. The installer of this crane and body is considered on of the manufacturers of the vehicle. As such a manufacturer, the installer is responsible for compliance with all applicable federal and state regulations, and is required to certify that the vehicle is in compliance.

WARNING! It is the further responsibility of the installer to comply with the OSHA Truck Crane

Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).

WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL POWER LINES!

Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. SEE DANGER DECAL (P/N 040529) in this Owner's Manual.

WARNING! NEVER.........................................

♦ EXCEED load chart capacities (centerline of rotation to hoist hook).

♦ Un-reel last 5 wraps of cable from drum!

♦ Wrap cable around load!

♦ Attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.

♦ Weld, modify, or use unauthorized components on any Auto Crane unit! This will void any warranty or liability. Also failure of the crane may result.

♦ Place a chain link on the tip of the hook and try to lift a load!

♦ Use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature!

♦ Hold on any pendant Select Switch that will cause unsafe operating conditions!

WARNING! In using a hook with latch, ALWAYS make sure that the hook throat is closed before lifting a load! Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.

WARNING! Failure to correctly plumb and wire crane can cause inadvertent operation and damage to crane and/or personnel!

WARNING! Auto Crane Company remote controlled cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel.

WARNING! ALWAYS operate the crane in compliance with the load capacity chart. DO NOT USE the overload shutdown device to determine maximum rated loads, if the crane is equipped with this type of device.

Warnings

READ THIS PAGE

12/2002

TABLE OF CONTENTS

8406H SERIES

INTRODUCTION

OPERATING PRACTICES & WARNINGS

OPERATION OF UNIT / OUTRIGGERS

CONTROLLER OPERATION

QUALIFCATIONS FOR OPERATORS

INSPECTION, TESTING, & MAINTENCE

DECAL SECTION

GENERAL DIMENSIONS

MOUNTING AND INSTALLATION

LUBRICATION AND MAINTENANCE SCHEDULE

PEDESTAL ASSEMBLY

BOOM ASSEMBLY

ROTATION GEAR BOX

HOIST ASSEMBLY

GENERAL ASSEMBLY

ELECTRICAL SCHEMATIC

WIRE HARNESS ASSEMBLY

HYDRAULIC SECTION

DIAGNOSTICS

LOAD CHART

HARD WIRED SERIES, SUPPLIMENTAL INFORMATION

WARRANTY

5-7

5-11

6-1

6-2

4-1

5-1

5-3

5-5

2-6

2-9

2-14

3-1

3-2

1-1

2-2

2-3

2-4

7-1

8-1

9-1

10-1

LAST PAGE

6/02/2003

INTRODUCTION

8406H SERIES

Auto Crane products are designed to provide many years of safe, trouble-free, dependable service when properly used and maintained.

To assist you in obtaining the best service from your crane and to avoid untimely crane and/or vehicle failure, this manual provides the following operating and service instructions. It is specifically

recommended that all operating and service personnel consider this manual as mandatory material for reading and study before operating or servicing Auto Crane products. It is highly recommended that crane owners, equipment managers and supervisors also read this manual.

Auto Crane has incorporated several safety features in the 8406H crane for your protection.

For your convenience the overall dimensions of the

8406H crane are included on the General Dimension

Drawing. Rotation and turning radius are also listed on that drawing.

Remember, the crane adds weight to the vehicle.

Adding weight may change the driving and riding characteristics of the vehicle unless the appropriate overload spring(s) are installed on the truck. The payload of the vehicle is reduced by the weight of the crane. The operator should exercise care when loading the vehicle. Distributing the payload on the vehicle evenly will greatly improve the driving and riding characteristics of the vehicle.

Auto Crane Company issues a limited warranty certificate with each unit sold.

See last page for warranty policy.

The 8406H cranes are attached directly to your 12 volt truck electrical system. The power cable is included with the crane. The 8406H is another highly efficient Auto Crane product. The use of a maintenance-free battery is not recommended for use on any Auto Crane product. The recommended alternator and battery that will give the longest life with the most useful duty cycle is a 75 amp alternator with a 500 cold cranking amp battery. These specifications should be considered minimum.

It has always been Auto Crane Company policy to handle all warranty claims we receive as promptly as possible. If a warranty claim involves discrepant material or workmanship, Auto Crane will take immediate corrective action. It is understandable that

Auto Crane Company cannot assume responsibility of liability when it is obvious that our products have been abused, misused, overloaded or otherwise damaged by inexperienced persons trying to operate the equipment without reading the manual.

Auto Crane will not assume responsibility or liability for any modifications or changes made to unit, or installation of component parts done without authorization.

Auto Crane maintains a strong distributor network and a knowledgeable Customer Service Department. In most cases, an equipment problem is solved via phone conversation with our customer service department. The customer service department also has the ability to bring a local distributor, a regional sales manager, or a factory serviceman into the solution of an equipment problem.

If, through no fault of Auto Crane Company, it is necessary to send an experienced factory serviceman on a field service call, the rates stated in the Auto Crane

Distributor's Flat Rate Manual will apply.

Auto Crane Company's extensive Research and

Development Program allow our customers to use the best equipment on the market. Our Engineering Staff and our knowledgeable sales people, are always available to our customers in solving crane and winch-type application problems. When in doubt, call the Auto Crane factory.

DISTRIBUTOR ASSISTANCE:

Should you require any assistance not given in this manual, we recommend that you consult your nearest

Auto Crane Distributor. Our distributors sell authorized parts and have service departments that can solve almost any needed repair.

NOTE:

THIS MANUAL SHOULD REMAIN

WITH THE CRANE

AT ALL TIMES.

This manual does not cover all maintenance, operating, or repair instructions pertinent to all possible situations. If you require additional information, please contact the Auto Crane Company at the following telephone number: (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.

1-1 INTRO 8406H 1/02

--- IMPORTANT ---

SAFETY TIPS AND PRECAUTIONS

1. No unqualified or unauthorized person shall be allowed to operate the crane.

2. WARNING: Never weld, modify, or use unauthorized components / parts on any Auto Crane unit. This will void any warranty or liability. Also, failure of the crane may result.

3. Make certain the vehicle meets minimum chassis requirements. (These requirements do not guarantee unit stability.)

4. Make certain the crane is installed per factory specifications. Contact your local distributor or the

Auto Crane factory if any questions arise.

5. Visual inspections and tests should be conducted at the beginning of each shift each day to ensure that the crane and all its operating systems are in good condition and working order before it is used.

6. Inspect hydraulic hoses frequently for signs of deterioration, and replace them as required.

7. If a hydraulic break occurs, leave the area of the break and do not attempt to stop the break by hand as the hydraulic oil may be hot and under high pressure which can cause serious injury. Shut the system down as soon as possible.

8. Check the hook at least every thirty days for distortions or cracks and replace it as required.

9. Oil gears as required.

10. Stop all operations when cleaning, adjusting or lubricating the machine.

11. Keep dirt and grit out of moving parts by keeping a crane clean. Make sure machine is free of excess oil, grease, mud and rubbish, thus reducing accidents and fire hazards.

12. When a new cable is installed, operate first with a light load to let the cable adjust itself.

13. Locate the vehicle at the work site for the best stability possible.

14. Keep the vehicle in a level position while loading or unloading.

15. Observe operating area for obstructions and/or power lines that might be a hazard.

16. WARNING: NEVER OPERATE THE CRANE

NEAR ELECTRICAL POWER LINES. Auto Crane

Company recommends that the crane never be any closer to a power line (including telephone lines) than

10 feet at any point.

17. Allow the vehicle engine to warm up before operating crane.

18. Know the weight of your rigging and load to avoid overloading the crane.

19. Deduct the weight of the load handling equipment from the load rating to determine how much weight can be lifted.

20. All load ratings are based on crane capacity, NOT the vehicle stability.

Remember in lifting a heavy load, the weight can create enough tipping moment to overturn the vehicle.

21. Always comply with load chart capacities, (centerline of rotation to hook).

22. Secure all loads before lifting.

23. Always set the emergency brake before beginning operation.

24. Keep objects and personnel clear of crane path during operation.

25. Operate control levers slowly and smoothly in order to meter oil flow for safe operation.

26. Always use outriggers from vehicle to the ground during crane operation. Ensure that they are firmly positioned on solid footings. Stand clear of outriggers while they are being extended.

27. If any outrigger, when extended, rests on a curb or other object that prevents it from extending to its maximum distance, shorten bearing or fulcrum point and reduce the maximum load accordingly.

28. When an outrigger will not reach the ground due to holes or grades, it shall be blocked up to provide level and firm support for the truck.

29. When working in soft earth, use wide pads under outrigger feet to prevent sinking.

30. Always store outriggers before transportation.

WARNING!

Auto Crane Company cranes are not designed or intended for use in lifting or moving persons. Any such use shall be considered to be improper and the seller shall not be responsible for any claims arising there from. This sale is made with the express understanding that there is no warranty that the goods shall be fit for the purpose of lifting or moving persons or other improper use and there is no implied warranty or responsibility for such purposes

2-1.0.0

8406HSAFT 06/02

--- IMPORTANT ---

SAFETY TIPS AND PRECAUTIONS

31. Always store the crane in its stowed position for transportation.

32. Remember the overall height of the entire unit for garage door clearance or when moving under objects with low overhead clearance.

33. Disengage power takeoff (PTO) before moving the vehicle.

34. Always walk around the vehicle before moving.

35. Never drive with a load suspended from crane.

36. Do not take your eyes off a moving load. Look in the direction you are moving.

37. Never swing a load over people.

38. Do not stop the load sharply in midair so that it swings like a pendulum. Meter the control levers to avoid this situation.

39. Crane boom length should be kept as short as possible for maximum lifting capacity and greater safety.

Longer booms require additional care in accelerating and decelerating the swing motion, and thus slow down the working cycle and reduce productivity.

40. Keep the load directly and vertically under the boom point at all times. Crane booms are designed primarily to handle vertical loads, not side lifts.

WARNING: Never attempt to lift, drag, tow or pull a load from the side. The boom can fail far below its rated capacity.

41. Do not push down on anything with boom extensions, lift or outer boom function.

42. Do not lift personnel with any wire rope attachment or hook. There is no implied warranty or responsibility for such purposes.

43. WARNING: In using a safety hook, ALWAYS close the hook throat before lifting a load. Proper attention and common sense applied to the use of the hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.

44. WARNING: Never place a chain link on the tip of the hook and try to lift a load with the hoist.

45. WARNING: Never use a sling bar or anything larger than the hook throat which could prevent the safety latch from closing, thus negating the safety feature.

46. If the crane is equipped with an optional winch: y do NOT allow personnel to ride on loadline, hook, load, or any other device attached to winch line.

y do NOT extend boom without reeling off line at the same time when using winch.

y do pull load-block up against the boom tip.

47. Do not wrap the wire rope around sharp objects when using winch.

48. WARNING: Never unreel last 5 wraps of cable from drum.

2-1.1.0

8406HSAFT 06/02

--- IMPORTANT ---

OPERATING PRACTICES &

WARNINGS

1. Make certain the vehicle meets minimum chassis requirements. (These requirements do not guarantee unit stability)

2. Make certain the crane is installed per factory specifications. Contact your local Distributor or the

Auto Crane factory if any questions arise.

3. Keep the vehicle in as level a position as possible while loading or unloading.

4. ALWAYS set the vehicle emergency brake before beginning crane operations.

5. ALWAYS use outriggers from vehicle to the ground during crane operation. Make sure they are firmly positioned on solid footings.

6. All load ratings are based on crane capacity, NOT truck/crane stability.

7. Keep objects and personnel clear of crane path during operation.

8. Keep hoist cable pulled tight at all times.

9. REMEMBER, in lifting a heavy load, the weight can create enough tipping momentum to overturn the vehicle.

10. ALWAYS keep load as close to ground as possible.

11. Hydraulic hoses need to be inspected frequently for signs of deterioration, and be replaced as required.

12. The hoist hook is an important item that an operator should consider and use properly. It should be checked on a daily basis for distortion or cracks.

13. ALWAYS store outriggers before road travel.

14.

WARNING! NEVER OPERATE THE CRANE

NEAR ELECTRICAL POWER LINES!

Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to

50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.

15.

WARNING! NEVER EXCEED load chart capacities

(centerline of rotation to hoist hook).

16.

WARNING! NEVER un-reel last 5 wraps of cable from drum!

17.

WARNING! NEVER wrap cable around load!

18.

WARNING! NEVER attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.

19.

WARNING! NEVER weld, modify, or use unauthorized components on any Auto Crane unit!

This will void any warranty or liability. Also failure of the crane may result.

20.

WARNING! NEVER place a chain link on the tip of the hook and try to lift a load!

21.

WARNING! NEVER use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature!

22.

WARNING! In using a hook with latch, ALWAYS insure that the hook throat is closed before lifting a load! Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel. Switch on that will cause unsafe operating conditions!

WARNING! NEVER hold any Control Select

Switch on that will cause unsafe operating conditions!

WARNING!

Auto Crane Company remote controlled, stiff boom cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel.

2 - 2 SAFTIPS 1/02

--- IMPORTANT ---

OPERATION OF UNIT

1. Make sure this manual has been thoroughly read by all crane operating personnel and supervisors.

2. A routine inspection of the crane should be mandatory before each operating day. Any defects should be corrected immediately.

3. At a job site the vehicle should be positioned so that the crane can adequately reach the load within the rated capacity (centerline of rotation to hoist hook).

4. Keep the vehicle as level as possible during operation.

5. For electric cranes, engage emergency brake and leave ignition on with transmission in neutral (or in park for automatic transmissions). Activate any crane power switches. For Auto Crane units requiring battery and hydraulic operation, engage emergency

brake, place gear selector in neutral, press clutch, activate PTO, release clutch and after hydraulic fluid is warm, set throttle control to proper engine speed.

6. Always use outriggers from the truck to the ground.

Be sure these are firm and adequately positioned.

When rotating, keep load as low to the ground as possible.

7. Remove the transmitter from cab or storage area.

Power transmitter on. Detach hook from dead man.

Crane is now ready for operation.

8. Always boom up before rotating so the boom will clear the required boom support.

9. When extending the boom, always maintain clearance between the boom crown and the traveling block or hoist hook.

10. Always observe safe and practical operation to avoid possible accidents. Refer to Safety Tips and

Precautions.

11. After completing lifting operations, return the boom to stowed position on the boom support. Avoid unneeded pressure on the boom support.

12. Store transmitter in proper location (in cab or storage area).

13. Return outriggers to stowed position. Make sure they are pinned in place or jacklegs are returned to compartment.

14. Check work area for any tools or equipment not stored.

15. Release throttle control, depress clutch and disengage

PTO. Deactivate any crane power switches.

16. Report any unusual occurrence during crane operation that may indicate required maintenance or repair.

17. NEVER use two cranes to support a load too large for either crane.

OPERATION OF

OUTRIGGERS

For hydraulic outriggers:

1. Shift crane/outrigger control valve to

"outrigger" position.

2. Operate the outrigger control valves (located on the outrigger cylinders) to position the outriggers.

3. After outriggers are positioned, return crane/outrigger selector to "crane" position.

4. Crane is now ready to operate.

For manual outriggers:

1. Pull lock pins to release jack leg or drop down outrigger and move to outermost lock position.

2. Make sure lock pins are reinstalled properly.

3. Lower outrigger pad to firm ground and adjust foot to take out slack.

4. Crane is now ready to operate.

2 - 3

OPER 1/02

CONTROLLER OPERATIONS

Transmitter Layout: The red light to the left of the Power On/Off button indicates low transmitter battery.

(see “Charging the Transmitter”)

The green light to the right of the Power On/Off button indicates that the unit is transmitting. This light will come on when a function is activated.

In addition to the two lights mentioned above there are four function toggle switches. These functions from left to right are used to raise and lower the boom, raise and lower the hoist cable, rotate the crane and extend and retract the boom. There are also buttons for auxiliary functions such as Engine Start/Stop and Engine Fast

Idle.

Power On/Off (E-Stop) Button: To turn the transmitter on, press and hold the Power On/Off button, release once the transmit light becomes solid. To turn the unit off, press and hold the power button, release once the transmit light stops flashing. When this button is pressed both the red battery low and the green transmit light will flash alternately and stop flashing once the unit is either on or off.

When turning the unit off, it will first send the emergency stop signal to the crane, then power down. When the transmitter is powered back up, the system will be in emergency stop mode and EC18 will be displayed when a function is activated. To exit E-Stop mode, press the red button once momentarily.

IMPORTANT – THE POWER ON/OFF BUTTON ALSO OPERATES AS AN E-STOP. PRESS THE

BUTTON MOMENTARILY TO DISABLE CRANE FUNCTIONS. THE E-STOP WILL NOT STOP

THE TRUCK ENGINE.

Function Switches: To operate a function, toggle one of the function switches with either the thumb of the hand holding the unit or the thumb or fingers of the opposite hand. Using the forefinger of the hand holding the unit, slowly pull the trigger back to start the function. The speed of the function increases as the trigger is pulled. More than one function can be activated at one time.

NOTE: A FUNCTION SWITCH MUST BE ACTIVATED BEFORE THE TRIGGER IS PULLED OR

THE CRANE WILL NOT OPERATE.

2 - 4

OPER 7/02

CONTROLLER OPERATION

Auxiliary Buttons:

Press the Engine Fast/Slow button to provide a maintained voltage to a throttle control if one is installed.

Press the Engine Start/Stop button to start and stop the engine if wired to do so.

Safety Features:

For safety reasons the speed of all functions, excluding the hoist, is reduced when the lift cylinder pressure exceeds a set pressure. This will occur under load or under boom down operation.

To limit slow operation of an unloaded crane, activate boom up momentarily after booming down to relieve cylinder pressure created by the counterbalance valve.

The crane is also equipped with an anti-bridging feature. The logic in the receiver will not allow the operator to rest the boom of the crane on a load supporting structure and lift a load. Doing so is dangerous and could damage the crane. When the crane is bridged, the receiver will display

‘RSBM’ which requires the boom to be raised. This feature is disabled when the crane is in the

‘HOME’ position to allow for stowing.

Operation Failure:

If the crane does not operate as expected, observe the readout through the window on the receiver and refer to the front panel for explanation. The codes are further explained in the Diagnostics section of this manual. Please note that ‘NRML’ is displayed when the crane is operating normally and ‘HOME’ is displayed when the crane is forward and in a position to be stowed.

“NRML” and “Home” will only be displayed when a function is activated, “EC01” is displayed when no function is activated.

Charging the Transmitter:

The transmitter can be charged using one of three methods. It can be charged with the cigarette lighter charger, the pendant cable or the optional AC adapter (P/N 366505000). To charge the transmitter with the pendant cable, the crane must have electrical power. The crane can be operated by pendant or by FM remote therefore the battery can be charged without suspending operation of the crane.

The transmitter should be fully charged after approximately 6 to 8 hours of charging. Charging the transmitter for extended periods (3 or 4 days) is not recommended. Doing so will eventually degrade the battery and it will not keep a good charge.

2 - 5

OPER 1/02

QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND

OPERATING PRACTICES

OPERATORS

1 Crane operation shall be limited to personnel with the following minimum qualifications:

A. designated persons

B. trainees under the direct supervision of a designated person

C. maintenance and test personnel (when it is necessary in the performance of their duties)

D. inspectors (crane).

2 No one other than the personnel specified above shall enter the operating area of a crane with the exception of persons such as oilers, supervisors, and those specified persons authorized by supervisors whose duties require them to do so and then only in the performance of their duties and with the knowledge of the operator or other persons.

QUALIFICATIONS FOR OPERATORS

8 In addition to the above listed requirements, the operator shall:

A. Demonstrate the ability to comprehend and interpret all labels, operator's manuals, safety codes and other information pertinent to correct crane operations.

B. Possess knowledge of emergency procedures and implementation of same.

C. Demonstrate to the employer the ability to operate the specific type of equipment.

D. Be familiar with the applicable safety regulations.

E. Understand responsibility for maintenance requirements of crane.

F. Be thoroughly familiar with the crane and its control functions.

G. Understand the operating procedures as outlined by the manufacturer.

CONDUCT OF OPERATORS

3 Operators shall be required by the employer to pass a practical operating examination. Qualifications shall be limited to the specific type of equipment for which examined.

4 Operators and operator trainees shall meet the following physical qualifications:

A. Vision of at least 20/30 Snellen in one eye and 20/50 in the other, with or without corrective lenses.

B. Ability to distinguish colors, regardless of position, if colors differentiation is required for operation.

C. Adequate hearing with or without hearing aid for the specific operation.

5 Evidence of physical defects or emotional instability which render a hazard to operator or others, which in the opinion of the examiner could interfere with the operator's performance may be sufficient cause for disqualification. In such cases, specialized clinical or medical judgment and tests may be required.

6 Evidence that the operator is subject to seizures or loss of physical control shall be sufficient reason for disqualification. Specialized medical tests may be required to determine these conditions.

7 Operators and operator trainees should have normal depth perception, coordination, and no tendencies to dizziness or similar undesirable characteristics.

9 The operator shall not engage in any practice which will divert his attention while actually operating the crane.

10 Each operator shall be responsible for those operations under the operator's direct control.

Whenever there is any doubt as to safety, the operator shall consult with the supervisor before handling the loads.

11 The operator should not leave a suspended load unattended unless specific precautions have been instituted and are in place.

12 If there is a warning sign on the switch or engine starting controls, the operator shall not close the switch or start the engine until the warning sign has been removed by the appointed person.

13 Before closing the switch or starting the engine, the operator shall see that all controls are in the "OFF" or neutral position and all personnel are in the clear.

14 If power fails during operation, the operator shall:

A. move power controls to the "OFF" or neutral position.

B. land the suspended load and boom, if practical.

15 The operator shall be familiar with the equipment and its proper care. If adjustments or repairs are necessary, the operator shall report the same

2 - 6 QUAL 7/98

QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND

OPERATING PRACTICES

promptly to the appointed person, and shall also notify the next operator.

16 All controls shall be tested by the operator at the start of each shift. If any controls do not operate properly, they shall be adjusted or repaired before operations are begun.

17 Stabilizers shall be visible to the operator while extending or setting unless operator is assisted by a signal person.

OPERATING PRACTICES

HANDLING THE LOAD

18 Size of load

A. No crane shall be loaded beyond the rated load except for test purposes.

B. The load to be lifted is to be within the rated load of the crane and its existing configuration.

C. When loads which are not accurately known are to be lifted, the person responsible for the job shall ascertain that the weight of the load does not exceed the crane rated load at the radius at which the load is to be lifted.

19 Attaching the load

A. The load shall be attached to the hook by means of slings or other devices of sufficient capacity.

B. Hoist rope shall not be wrapped around the load.

20 Moving the load

A. The operator shall determine that:

B. The crane is level and, where necessary, the vehicle/carrier is blocked properly.

C. The load is well secured and balanced in the sling or lifting device before it is lifted more than a few inches.

D. Means are provided to hold the vehicle stationary while operating the crane.

E. Before starting to lift, the hook shall brought over the load in such a manner as to minimize swinging.

F. During lifting care shall be taken that:

1. there is no sudden acceleration or deceleration of the moving load.

2. load, boom or other parts of the crane do not contact any obstruction.

G. Cranes shall not be used for dragging loads sideways.

H. This standard recognizes that articulating boom cranes are designed and intended for handling materials. They do not meet personnel lift or elevator requirements. Therefore, no lifting, lowering, swinging or traveling shall be done while a person is on the hook or load. Hook attached suspended work platforms (baskets) shall not be used with cranes covered by this standard. Work platforms attached to the boom must be approved by crane manufacturer.

I. The operator should avoid carrying loads over people.

J. When the crane is so equipped, the stabilizers shall be fully extended and set. Blocking under stabilizers shall meet the requirements as follows:

1. strong enough to prevent crushing.

2. of such thickness, width and length as to completely support the stabilizer pad.

K. Firm footing under all tires, or individual stabilizer pads should be level. Where such a footing is not otherwise supplied, it should be provided by timbers, cribbing, or other structural members to distribute the load so as to not exceed allowable bearing capacity or the underlying material.

L. In transit, the boom shall be carried in stowed position.

M. When rotating the crane, sudden starts and stops shall be avoided. rotational speed shall be such that the load does not swing out beyond the radius at which it can be controlled.

N. The crane shall not be transported with a load on the hook unless recommended by the manufacturer.

O. No person should be permitted to stand or pass under a suspended load.

21 Stowing procedure. Follow the manufacturer's procedure and sequence when stowing and un-stowing the crane.

2 - 7 QUAL 7/98

QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND

OPERATING PRACTICES

MISCELLANEOUS

OPERATING NEAR ELECTRICAL POWER

LINES

25 In transit with no load and boom lowered the clearance shall be specified in Table 1.

26 A qualified signalperson shall be assigned to observe the clearance and give warning before approaching the above limits.

A. Any overhead wire shall be considered to be an energized line unless and until the person owning such line or the electrical utility authorities verify that it is not an energized line.

B. Exceptions to this procedure, if approved by the administrative or regulatory authority if the alternate procedure provides equivalent protection and set forth in writing.

C. Durable signs shall be installed at the operator's station and on the outside of the crane, warning that electrocution or serious bodily injury may occur unless a minimum clearance of 10 ft. (3.0m) between the crane or the load being handled and energized power lines. Greater clearances are required because of higher voltage as stated above.

These signs shall be revised but not removed when local jurisdiction requires greater clearances.

22 Cranes shall be operated so that no part of the crane or load enters into the danger zone shown above.

EXCEPTIONS

A. The danger zone may be entered after confirmation by an appointed person that the electrical distribution and transmission lines have been de-energized and visibly grounded at the point of work; or

B. The danger zone may be entered if insulating barriers (not a part of nor an attachment to the crane) have been erected to prevent physical contact with the lines.

23 For lines rated 50 kV or below, minimum clearance between the lines and any part of the crane or load

(including handling appendages) shall be 10 ft. (3m).

For higher voltages, see Table 1.

24 Caution shall be excercised when working near overhead lines, because they can move horizontally or vertically due to wind, moving the danger zone to new positions.

2 - 8

TABLE 1

minimum required clearance normal voltage, kV

(phase to phase) ft (m) when operating near high voltage power lines over to 50 over 50 to 200 over 200 to 350 over 350 to 500 over 500 to 750 over 750 to 1000

10

15

20

25

35

45

(3.05)

(4.6)

(6.1)

(7.62)

(10.67)

(13.72) while in transit with no load and boom lowered over to 0.75

over 0.75 to 50 over 50 to 345 over 345 to 750 over 750 to 1000

4

6

10

16

20

(1.22)

(1.83)

(3.83)

(4.87)

(6.1)

QUAL 7/98

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 a designated person to insure compliance with provisions of this standard.

2 Regular inspection. Inspection procedure for cranes in regular service is divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the components of the crane and the degree of their exposure to wear, deterioration, or malfunction. The two general 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

J. connecting pins and locking device for wear and damage

PERIODIC INSPECTION

4 Deformed, cracked or corroded members in the crane structure and carrier.

5 Loose bolts, particularly mounting bolts.

6 Cracked or worn sheaves and drums.

7 Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and devices.

8 Excessive wear on brake and clutch system parts and lining.

9 Crane hooks inspected for cracks.

10 Travel steering, braking, and locking devices, for malfunction.

11 Excessively worn or damaged tires.

12 Hydraulic and pneumatic hose, fittings, and tubing inspection.

A. evidence of leakage at the surface of the flexible hose or its junction with metal and coupling

B. blistering, or abnormal deformation to the outer covering of the hydraulic or pneumatic hose

C. leakage at threaded or clamped joints that cannot be eliminated by normal tightening or recommended procedures

D. evidence or excessive abrasion or scrubbing on the outer surface of a hose, rigid tube, or fitting. Means shall be taken to eliminate the interference of elements in contact or otherwise protect the components

2 - 9

INSP 9/98

INSPECTION, TESTING AND MAINTENANCE

GENERAL

13 Hydraulic and pneumatic pumps and motors inspection.

A. loose bolts or fasteners

B. leaks at joints between sections

C. shaft seal leaks

D. unusual noises or vibrations

E. loss of operating speed

F. excessive heating of the fluid

G. loss of pressure

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 initialregular- 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.

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.

INSPECTION RECORDS

20 Dated records for periodic inspection should be made on critical items such as brakes, crane hooks, rope, hydraulic and pneumatic cylinders, and hydraulic and pneumatic relief pressure valves. Records should be kept available to an appointed person.

OPERATIONAL TESTS

21 Prior to initial use, all new, altered, modified, or extensively repaired cranes shall be tested for compliance with the operational requirements of this section, including functions such as the following:

A. load lifting and lowering mechanisms

B. boom lifting and lowering mechanisms

C. boom extension and retraction mechanisms

D. swing mechanisms

E. safety devices

F. operating controls comply with appropriate function labels

Operational crane test results shall be made available to an appointed person.

RATED TEST LOAD

Prior to initial use, altered, modified, or extensively repaired cranes shall be load tested by or under the direction of an appointed person.

2 - 10

INSP 9/98

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 a crane, the following precautions shall be taken as applicable:

A. crane placed where it will cause the least interference with other equipment or operations

B. all controls at the "off" position

C. starting means rendered inoperative

D. boom lowered to the ground if possible or otherwise secured against dropping

E. relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components

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

C. crane hooks showing cracks, damage, or corrosion shall be taken out of service. Repairs by welding are not recommended

30 Instructions shall be provided by the manufacturer for the removal of air from hydraulic circuits.

LUBRICATION

All moving parts of the crane, for which lubrication is specified, should be regularly lubricated per the manufacturer's recommendations and procedures.

25 Warning or "OUT OF ORDER" signs shall be placed on the crane controls.

26 After adjustments and repairs have been made, the crane shall not be returned to service until all guards have been reinstalled, trapped air removed from hydraulic system (if required), safety devices reactivated, and maintenance equipment removed.

ADJUSTMENTS AND REPAIRS

27 Any hazardous conditions disclosed by the inspection requirements shall be corrected before operation of crane is resumed, Adjustments and repairs shall be done only by designated personnel.

28 Adjustments shall be maintained to assure correct functioning of components, The following are examples:

A. functional operating mechanism

B. safety devices

ROPE INSPECTION

31 Frequent Inspection

A. All running ropes in service should be visually inspected once each working day. A 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 a short length or unevenness of outer strands should be replaced

2. general corrosion

3. broken or cut strands;

4. number, distribution and type of visible broken wires. When such damage is

2 - 11 INSP 9/98

INSPECTION, TESTING AND MAINTENANCE

GENERAL discovered, the rope shall either be removed from service or given as inspection.

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 a qualified person and shall be based on such factors as:

1. expected rope life as determined by experience on the particular installation or similar installations

2. severity of environment

3. percentage of capacity lifts

4. frequency rates of operation

5. exposure to shock loads

Inspection need not be at equal calendar intervals and should be more frequent 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, equalizer 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.

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 questioning continued use of the rope or increasing the frequency 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 required

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)

G. 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.

2 - 12

INSP 9/98

INSPECTION, TESTING AND MAINTENANCE

GENERAL

H. Replacement rope shall have a 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 a rope manufacturer, or a qualified person.

39 Before cutting a rope, seizing shall be placed on each side of the place where the rope is to be cut to prevent unlaying of the strands. On pre-formed rope, one seizing on each side of the cut is required. On non-preformed ropes of 7/8 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.

35 Rope not in regular use: all rope which has been idle for a period of a month or more due to shutdown or storage of a crane on which it 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 a qualified person.

40 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.

36 Inspection records

A. frequent inspection- no records required

B. periodic inspections- in order to establish data as a basis for judging the proper time for replacement, a 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.

41 Rope should be maintained in a well-lubricated condition. It is important that lubricant applied as a part of a 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 rope lubrication is to reduce internal friction and to prevent corrosion.

42 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 a section at the worn end, and thus shifting the wear to different areas of the rope.

2 - 13 INSP 9/98

SAFETY DECAL SECTION

8406H

Revised 1/02

PART NO.:

DECAL:

FUNCTION:

USED ON:

QUANTITY :

:

PLACEMENT

040579

OPERATION INSTRUCTIONS

To inform the operator of the proper procedure to follow for safe operation of the crane.

All cranes

1

Right side plate

FG. SD-1

PART NO.:

DECAL:

FUNCTION:

040580

OPERATOR TRAINING

To inform the operator of the need to receive proper training before using the crane.

USED ON:

QUANTITY :

All cranes

1

PLACEMENT : Right side plate

FIG. SD-2

PART NO.:

DECAL:

FUNCTION:

USED ON:

QUANTITY :

PLACEMENT :

040632

TAMPERING WITH OVERLOAD DEVICE

To inform the operator that tampering with the overload device may cause a unit failure or possible personnel injury.

All cranes equipped with a load sensor.

1

Right side of valve cover

2 - 14

FIG. SD-3

SAFETY DECAL SECTION

8406H

Revised 1/02

PART NO.:

DECAL:

FUNCTION:

USED ON:

040529

ELECTROCUTION HAZARD

To inform the operator of the hazard involved with contacting electrical power lines with crane boom.

Articulated & Stiff Boom

Cranes

QUANTITY :

PLACEMENT :

2

Both sides of end of lower boom

PART NO.: 040517

DECAL:

FUNCTION:

STAY CLEAR OF BOOM

To inform the operator of the hazard of proximity or contact with the crane boom during operation.

USED ON:

QUANTITY :

All cranes

2

PLACEMENT : Both sides of crown

FIG. SD-4

FIG. SD-5

2 - 15

SAFETY DECAL SECTION

8406H

Revised 1/02

PART NO.: 040587

DECAL:

FUNCTION:

LOAD SENSOR, DON'T TAMPER

To inform the operator that the load sensor is pre-set and that tampering with the sensor may cause potentially hazardous situation.

USED ON:

QUANTITY :

All cranes equipped with a load sensor.

1

PLACEMENT : On the lift cylinder near the load sensor

FIG. SD-7

PART NO.:

DECAL:

FUNCTION:

040519

SCISSORS POINT

To inform the operator of possible danger at scissors point on crane.

USED ON:

QUANTITY :

PLACEMENT :

All cranes

2

Both sides of the lift cylinder

FIG. SD-8

2 - 16

DECAL LAYOUT

8406H

2 - 17

Decal Layout 6/02

DECAL LAYOUT

8406H

ITEM NO. QTY. PART NO.

9

10

11

12

13

14

15

4

5

6

2

3

7

8

1

1

2

2

1

2

2

1

2

2

1

1

1

2

DESCRIPTION

040579 DECAL OPERATION INSTRUCTIONS

040632 DECAL WARNING - OVERLOAD

040580 DECAL TRAINED OPERATOR

040529 DECAL POWER LINE HAZARD

040517 DECAL STAY CLEAR OF BOOM

330622 DECAL SERIAL NO

040519 DECAL DANGER SCISSOR POINT

040587 DECAL WARNING LOAD SENSOR

480852000 DECAL LOAD CHART 8406H

480851000 DECAL 8406H

360034 DECAL AUTO CRANE LOGO

366389 DECAL AUTO CRANE

320318 DECAL ANGLE IND RIGHT

320318001 DECAL ANGLE IND LEFT

2 - 18

Decal Layout 6/02

GENERAL DIMENSIONS

8406H

3 - 1

General Dimensions 6/02

MOUNTING AND INSTALLATION 8406H

1. Check to make sure the following items are with your crane:

ITEM

1.

PART NO.

480854

DES CRIPTION

Swivel Block

2.

3.

4.

480899

015104

022200

Owners Manual

Bolt 7/8 NF x 5", Grade 8, (4 Req'd)

Washer Split Lock 7/8 (4 Req’d)

5. 366500002 Transmitter

6. 366500004 Pendant Cable

2. 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 8 GALLON RESERVOIR

A. RETURN LINE FROM CRANE TO RESERVOIR (IN COMPARTMENT): -10 SAE 100R2 (OR EQUIVALENT).

HOSE LENGTH IS DETERMINED BY INSTALLER. RETURN LINES LONGER THAN 6 FEET SHOULD BE

SIZE -12. HOSE END FITTINGS ARE -10 JIC FEMALE SWIVEL (CRANE END) AND -10 JIC FEMALE

SWIVEL (RESERVOIR END).

B. PRESSURE LINE FROM PUMP TO CRANE: -8 SAE 100R2 (OR EQUIVALENT). HOSE LENGTH IS

DETERMINED BY INSTALLER. HOSE END FITTINGS ARE BOTH -8 JIC 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 WARRAN

3. Crane must be provided with a flow of 13 gallons per minute and a pressure of 2,750 PSI. Excess flow will cause erratic operation, and too little flow will cause poor crane operation.

4. Vehicle should meet minimum GVW rating of 20,500 pounds.

5. The vehicle MUST be equipped with an engine speed control and tachometer.

6. Make sure mounting surface is properly reinforced to withstand 50,000 ft- lb capacity loading of crane and that outriggers are used to provide total stability for the truck.

7. A 13 1/2" dia. hole should be cut out of mounting location (centered with mounting bolts) for access to lower ring gear bolts and hydraulic connections.

8. Make sure the mounting bolts are 7/8x dia, grade 8. Torque bolts to 440 ft-lbs (dry).

9. When crane is not in operation, a boom support should always be used. Traveling block should be connected to hood loop.

10. Electrical hookup:

Wiring (cable from base of crane):

A. CONNECT THE BLACK WIRE TO THE BATTERY NEGATIVE (GROUND).

B. CONNECT THE RED WIRE TO THE BATTERY POSITIVE.

C. OPTIONALLY, USE THE WHITE WIRE FOR ENGINE FAST/SLOW.

D. OPTIONALLY, USE THE BLUE WIRE FOR ENGINE START.

E. OPTIONALLY, USE THE ORANGE WIRE FOR ENGINE STOP.

WARNING!

FAILURE TO CORRECTLY PLUMB AND WIRE CRANE CAN CAUSE

INADVERTENT OPERATION AND DAMAGE TO CRANE AND/OR PERSONNEL!

11. Once crane and plumbing are installed on the truck, fill the reservoir to top of sight glass (mobil DTE 13 or equal). Before operating crane, connect together the pressure and return hoses going to base of crane using 10-8 JIC union and engage

PTO wih 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 13 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.

3 - 2

MOUNTING AND INSTALLATION CONT.

13. Make certain the owner’s manual is delivered to the customer.

WARNING

FEDERAL LAW

(49 CFR PART 571) REQUIRES THAT THE FINAL STAGE MANUFACTURER OF A VEHICLE CERTIFY THAT THE VEHICLE

COM PLIES WITH ALL APPLICABLE FEDERAL REGULATIONS. ANY M ODIFICATIONS PERFORM ED ON THE VEHICLE PRIOR TO THE FINAL STAGE

ARE ALSO CONSIDERED INTERM EDIATE STAGE MANUFACTURING AND MUST BE CERTIFIED AS TO COM PLIANCE. THE INSTALLER OF THIS aaCRANE AND BODY IS CONSIDERED ONE OF THE MANUFACTURERS OF THE VEHICLE. AS SUCH A MANUFACTURER, THE INSTALLER IS

RESPONSIBLE FOR COM PLIANCE WITH ALL APPLICABLE FEDERAL AND STATE REGULATIONS, AND IS REQUIRED TO CERTIFY THAT THE

VEHICLE IS IN COM PLIANCE.

IT IS THE FURTHER RESPONSIBILITY OF THE INSTALLER OF THE CRANE TO COM PLY WITH THE

OSHA TRUCK CRANE STABILITY

REQUIREM ENTS AS SPECIFIED BY 29 CFR PART 1910.180 (C) (1).

3 - 3

LUBRICATION & MAINTENANCE SCHEDULE

8406H CRANE

SERVICE

PERFORMED

LOAD HOOK

CABLE DRUM

HOIST / BOOM

CABLE

HYD. HOSES

HYD. FLUID

MOUNTING

BOLTS

ROTATION

RING GEAR

SHEAVE

BEARINGS

ALL OTHER

BOLTS

ROTATION

BEARING

ROTATION

BEARING BOLTS

ROTATION

GEAR BOX

ROTATION

GEAR BOX

HYDRAULIC

FLUID

DAY

X

X

X

X

X

WEEKLY

X

X

X

X

3 MOS

X

X

X

6 MOS YEAR

X

NOTES

INSPECT HOOK & LATCH FOR

DEFORMATION, CRACKS, &

CORROSION

MAKE SURE CABLE IS WOUND

EVENLY ON DRUM

CHECK FOR FLATTENING,

KINKS, & BROKEN STRANDS,

SEE MANUAL

VISUAL INSPECTION

CHECK FLUID LEVEL

CHECK-TORQUE TO 440 FT-LBS

(DRY) AS REQUIRED

LUBE WITH MOBILETAC LL, OR

LUBRIPLATE P/N 15263, OR

EQUAL

SEALED BEARING, REPLACE IF

ROUGH OR LOOSE

CHECK-TIGHTEN AS REQUIRED

GREASE WITH MOBILPLEX EP-2

OR EQUIVALENT @ ZERKS

CHECK TORQUE TO 150 FT-LBS

(DRY) AS REQUIRED

CHECK TORQUE TO 85 FT-LBS

(DRY) AS REQUIRED

EP GEAR LUBE SAE 80-90

X

BOOM SLIDE

PADS

PADS GREASED WHEN REPLACED

FOR

ADDITIONAL

INFORMATION

SEE:

1) OWNER'S MANUAL

2) OSHA SECTION 1910.180

3) ANSI B30.5-1989

DRAIN, FLUSH, AND REFILL

WITH SUN 2105 HYD. OIL, SAE

5W-20

4-1 Lube & Maint 6/02

LUBRICATION & MAINTENANCE SCHEDULE

8406H CRANE

CAUTION:

Routine maintenance insures trouble-free operation and protects your investment. All warranties are void if maintenance is neglected.

NOTES:

1. Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability.

2. Once a bolt has been torqued to its rated capacity and then removed; the bolt should be replaced with a new one.

3. Auto Crane Company recommends that this crane be serviced per “Crane Inspection Log”

P/N 999978. These logs should be filled in at the intervals noted and kept as a permanent record. Additional copies are available from your local distributor.

4-2 Lube & Maint 6/02

PEDESTAL ASSEMBLY

8406H

Cylinder Seal Kit - #480838001

Counterbalance Cartridge - #480188

5 - 1

Pedestal Assy. 6/02

PEDESTAL ASSEMBLY

8406H

ITEM NO. QTY PART NO.

DESCRIPTION

36

37

38

39

32

33

34

35

40

5

6

7

3

4

1

2

1 480842000 PEDESTAL WELD

1 480838000 CYL, LIFT

1 160407 GEAR BOX, ROTATION

1 480839000 VALVE BANK ASSY

1 123308 HOIST RPH4200

1 480857000 BASE PLATE WELD

1 366500001 CONTROLER, KAR-TECH

10

11

8

9

1 480864000 MAIN HARNESS WIRE ASSY 6406H/8406H

1 366500006 CABLE, ANTENNA EXTENSION

1 366506000 BRACKET ANTENNA

1 366333 BEARING, SPHERICAL 1.25 ID

12 1 480023002 BEARING, ROTATION

13 38 023902 WASHER, 5/8 FLAT HARDENED

14 14

15 2

366393

366364

HEX HEAD 5/8-11 X 2.5 GR8

PLATE, VALVE MOUNTING

20

21

22

23

16

17

18

19

24

25

26

27

28 1

29 11

30 11

31 1

2

1

2

1

2 812209-022 HOSE ASSY 6 STR/90

1 812203-028 HOSE ASSY 6 STR

1 812203-030 HOSE ASSY 6 STR

2 480205 HOSE ASSY 6 STR X 19.25

2 480203 HOSE ASSY 8 STR X 24.75

1 812309-024 HOSE ASSY 8 STR/90

1 812409-024 HOSE ASSY 10 STR/90

2 490198 FITTING 10SAE(M)/6JIC ELBOW 90

200876

366477

372041

367145

490199

021100

008400

366440

FITTING 6 SAE/6 JIC STRAIGHT 6F5OX

PRESSURE TRANDUCER

FITTING 8JIC/10SAE STRAIGHT 8-10 F5OX

FITTING STR 8-SAE/8-JIC

FITTING STR 10-SAE/10-JIC

WASHER SPLK 3/8

SCW HEX HD 3/8-16 UNC X 3/4 GR 5

ROTATION MOTOR

2

2

4

2

4

2

4

6

1

320588 WASHER FL 1/2

021500 WASHER SP LK 5/16 NC

366391 HEX HD 1/2-13 X 2 1/4

009118 SOC HD 1/2 UNC X 2

006205 SOC HD 5/8 X 1 1/4

021502 WASHER SP/LK 1/2 HI COLLAR

021601 WASHER FL 1/2

012197 SOC HD 1/2-13

370433 CORD CONNECTOR HUBBLE F-3

5 - 2

Pedesal Assy. 7/02

PEDESTAL ASSEMBLY

8406H

ITEM NO. QTY.PART NO.

DESCRIPTION

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

41

42

43

44

5 020601 WASHER 5/16 LOCK

5 007401 SCW 5/16-18 X 1/2 LG

2 480024 MOUNT PENDANT CABLE RETAINER

1 366359 FITTING 8 SAE/JIC SWIVEL PS810503-8-8

45

46

1 366358 FITTING 10SAE/JIC SWIVEL PS810503-10-10

1 366423 MAGNET, PROX PICKUP

47 48 374086 NYLON HOSE SLEEVE

48 1 480011 SEAL ROTATION BOX

49 24 490306 HX HD 5/8-11 X 2.00 GR8

50 2 642908 CORD CONNECTOR

2

2

2

2

2

1

011202

017704

020000

019800

330679

SCW HX HD 1/2-20 X 2 3/4

NUT HX HVY 1/2 NF

1 366338 HARNESS WIRE ROTATION

1 366492 PIN 1.25<MOD-DIAM> X 3.00 LG

1 366419 SWITCH, LIMIT ROTATION

1 480856000 LIMIT SWITCH ARM

1 366424 BRACKET, PROX SWITCH

10 SAE FLAT WASHER

10 SPLIT LOCK

1 480865000 BRACKET BOOM SWITCH

654100

SCW BT HD SOCKET 10-32 X 1/2

SWITCH LIMIT BZ-2RW80-A2

2 000602 SCW PN #6 NC X 1

2 019600 WASHER SP LK #6

2 015400 NUT HX #6-32

5 - 2.1

Pedestal Assy. 07/02

BOOM ASSEMBLY

Cylinder Seal Kit - #366331001

Counterbalance Cartridge - #480188

5 - 3

Boom Assy. 6/02

BOOM ASSEMBLY

ITEM NO. QTY. PART NO.

21

22

23

24

25

15

16

17

18

19

20

26

27

28

29

30

31

32

37

38

39

40

41

42

33

34

35

36

8

9

10

11

12

13

14

3

4

1

2

5

6

7

DESCRIPTION

1

5

1

1

2

1

1

1 480831000 BOOM WELDMENT, LOWER

4 366385 PLATE, LOWER BOOM PAD COVER

2 366201 WEAR PAD 3 .75 X 2.00 X .313

1 480832000 BOOM WELDMENT, UPPER

1 366331 CYLINDER EXTENSION

1 366445000 BOOM WELDMENT MID

2 366184 RETAINER EXTENSION CYLINDER

366353

366499

366485

366483

366354

366493

646900

PAD WEAR 5.25 X 2.63 X .38

PAD BOOM 2 X 4

PAD, BOOM TOP

PLATE, WEAR PAD .25 X 2 X 4

WEAR PAD

PIN 1<MOD-DIAM> X 5.03 LG

SWITCH, LIMIT ANTI-TWO BLOCK

1

1

6

4

3

2

2

18

20

8

8

10

1

2

1

1

1 480834000 BAIL WELDMENT

1 007804 SCW HX 5/16 NC X 1 1/4 CP

366185

366394

366333

366400

PAD, BOOM TOP

BEARING, PIVOT

BEARING, SPHERICAL 1.25 ID

PIN 1.25<MOD-DIAM> X 8.063

021100

008400

WASHER SPLK 3/8

SCW HEX HD 3/8-16 UNC X 3/4 GR 5

020200 WASHER SPLIT LOCK 1/4

005406 SCW HX 1/4-28 X 1/2

021200 WASHER FL 3/8

008100 SCW HEX3/8-24 X 5/8

008800 SCW HEX 3/8-24 X 1

366198 SHEAVE ASSY 3/8

007803 SCW 5/16 NC 3 1/2 LG

016801 NUT HEX-LOCK 5/16 NC

480029 RING RETAINING

360122 RING RETAINING 5100-98

1

1

2

1

2

1

2

2

480194 FITTING 6 SWIVEL NUT ELBOW

200876 FITTING 6 SAE/6 JIC STRAIGHT 6F5OX

1 366973-003 CORD REEL ASSY

1 642908 CORD CONNECTOR

320554

022102

014400

SPRING RETURN

WASHER FL 3/4

CAPSCREW, .75-16 NF X 5

018600 NUT, NYLON LOCK .75-16 NF

016300 NUT HX NY-LOCK 1/4-20

366351 PAD, WEAR 1 1/2 X 1 1/2 X 3/4

5 - 4

Boom Assy. 06/02

ROTATION GEAR BOX

P/N: 480028

5 - 5 Rot. Gear Box 6/02

7

8

9

10

ITEM

1

2

3

4

5

6

11

12

13

14

15

16

17

23

24

25

26

27

28

29

30

31

18

19

20

21

22

QTY

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

6

8

1

1

2

4

1

1

1

2

1

2

6

6

1

2

P/N

480240

480241

480242

480243

480244

480237

480246

480247

480248

480249

480251

480252

480253

480254

480255

007400

480238

011508

480256

480258

480259

480260

480250

480262

480239

480263

480264

480265

480266

480268

480269

ROTATION GEAR BOX

P/N: 480028

DESCRIPTION

ADAPTER

BUSHING

CAP BEARING

COVER

GEAR R.H.

HOUSING GEAR

KEY

SHAFT OUTPUT

WASHER THRUST

WORM R.H.

BEARING BALL

BEARING NEEDLE

BEARING NEEDLE

BEARING THRUST

COVER

SCREW HX HD 5/16 NC X 1

SCREW HX HD 5/16 NC X 1 ¼

NYLOC HVY PATCH

SCREW HX HD 1/2 NC X 3/4

SCREW SOC HD 5/16 NC X 1

WASHER LK 5/16 MED SECT

ELL 90 DEG

GASKET

GASKET

FITTING RELIEF

O-RING

REDUCER

PLUG PIPE

PIN DOWEL

SEAL OIL

WASHER THRUST

PLUG EXPANSION

5 - 6 Rot. Gear Box 6/02

HOIST ASSEMBLY

8406H

5 - 7

Hoist Assy. 6/02

ITEM QTY PART #

1

1

1

1

6

2

4

1

8

2

1

1

4

1

2

1

1

1

1

11

12

9

10

13

14

17

18

15

16

19

1

6

7

8

4

5

2

3

402120

402121

412084

412085

414303

414948

414548

414854

414129

414926

416016

234189

306042

338300

338301

338302

346045

357513

474065

HOIST ASSEMBLY

8406H - PART NO. #123308

DESCRIPTION

DRUM ASSEMBLY

PISTON, BRAKE

END BEARING, MOTOR

END BEARING, GEAR HOUSING

HOUSING, BRAKE

PIN, BRAKE

INPUT SHAFT, SUN GEAR

PLATE, TIE

BEARING, GEAR HOUSING

BEARING, MOTOR

BUSHING, DRUM (MOTOR END)

BUSHING, DRUM (GEAR HOUSING END)

CAPSCREW, 3/8-16NC x 2 ½ LG HX HD GR5 ZINC PLTD

CAPSCREW, 1/2-13NC x 1 ¼ LG SOCKET HD GR5 ZINC PLTD

CAPSCREW, 1/2-13NC x 1 ½ LG HX HD GR5 ZINC PLTD

CAPSCREW, 1/4-20NC x 1/2 LG RD HD SLOT ZINC PLTD

CAPSCREW, 5/16-18NC x 3.0 LG SOCKET HD GR5 ZINC PLTD

SETSCREW, 3/8-16NC x 1.0 LG SOCKET, NYLON

SETSCREW, 1/4-20NC x 1/4 LG HEX SOCKET HD CUP

5 - 8

1

1

1

1

4

1

2

1

2

1

1

1

1

1

1

1

1

1

1

29

30

31

27

28

25

26

22

23

20

21

24

36

37

38

34

35

32

33

431015

432018

432026

438022

442220

442223

444085

416080

418036

418088

418218

426048

456038

458121

462046

462056

462057

462058

462059

HOIST ASSEMBLY

8406H - PART NO. #123308

ITEM QTY PART # DESCRIPTION

SETSCREW, 5/8-18NF x 1.0 LG HEX SOCKET HD CUP

NUT, JAM 3/8-16NC HEX ZINC PLTD

NUT, JAM 5/8-18NF HEX ZINC PLTD

LOCKWASHER, 1/2 I.D. MEDIUM SECTION ZINC PLTD

PLUNGER

COUPLING, MOTOR

FITTING, 7/16 ELBOW (90 DEGREE)

FITTING, BLEEDER

DISC, BRAKE

GASKET, BRAKE

GASKET, MOTOR

GEAR, RING

FITTING, VENT

MOTOR, HYDRAULIC

O-RING, DRUM

O-RING

O-RING

O-RING

O-RING BACKUP

5 - 9

Hoist Assy. 6/02

1

1

1

1

1

6

4

5

1

1

1

1

2

4

1

48

49

50

46

47

44

45

41

42

39

40

43

51

52

53

494110

494112

509019

516028

518037

518047

518052

462060

472052

474111

486080

490037

362283

362284

315004

HOIST ASSEMBLY

8406H - PART NO. #123308

ITEM QTY PART # DESCRIPTION

O-RING BACKUP

PLUG

PLATE, SEPERATOR

SEAL, GEAR HOUSING

SNAP RING

SPRING, BRAKE

SPRING

TUBE ASSEMBLY

VALVE, MOTOR CONTROL

THRUST WASHER

THRUST WASHER

THRUST WASHER

SPACER, FOOT MOUNTING

SPACER, TIE PLATE

CABLE ANCHOR

5 - 10

Hoist Assy. 6/02

GENERAL ASSEMBLY

8406H

5 - 11

General Assy. 6/02

GENERAL ASSEMBLY

8406H

ITEM NO.

QTY.

PART NO.

DESCRIPTION

4

5

6

7

8

9

10

11

1

2

3

1 480840000 PEDESTAL ASSY

1

1

1 480830000 BOOM ASSEMBLY

1 366430000 COVER 6406

366492 PIN 1.25<MOD-DIAM> X 3.00 LG

366491 PIN 2<MOD-DIAM> X 10.5 LG

1 480841000 ROPE ASSY

2

2

021100

008701

WASHER SPLK 3/8

3/8-16 X 7/8 GR5 PLATED HEX CAP SCREW

1 480870000 SHIP KIT W/ FM CONTROL

1 480850000 DECAL LAYOUT

1 480854000 TRAVELING BLOCK

5 - 12

General Assy. 06/02

ELECTRICAL SCHEMATIC

6 - 1

Elec. Schematic 6/02

MAIN WIRING HARNESS

6 - 2

Main Wiring Harness

6/02

HYDRAULIC SCHEMATIC

7 - 1

Hyd. Schematic 6/02

HYDRAULIC

8406H

Counterbalance Valve Adjustment

{ With PTO disengaged and boom properly supported, remove the plug on the counterbalance valve. Install a pressure gauge (0-3000 PSI) into the port.

{ Engage PTO and insure pump flow is 13 to 14 GPM . With no load on boom, boom up to an angle of 70 degrees.

Boom down and note pressure. If pressure reading is not approximately

1300 PSI, the counterbalance valve requires adjustment.

v To increase the CB valve setting, loosen nut and turn Allen head screw counter clockwise. v To reduce the CB valve setting, 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.

Notice:

{ In an EMERGENCY situation when it 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.

{ Turning adjustment screw too far will cause valve to come apart on the inside.

This condition is not repairable

{ After boom is lowered, turn adjustment 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.

Failure to do so may result in personal injury!

7 - 2

Hydraulic 7/02

HYDRAULIC CONTROL VALVE

8406H

7 - 3

Hyd. Control Valve 6/02

HYDRAULIC CONTROL VALVE

8406H PARTS LIST

ITEM

FR1

PV1

RV1

SV3, SV4, SV5

SV1, SV2

CL1

CL2

CL3

QTY DESCRIPTION

1

2

3

2

6

1

1

1

FLOW CONTROL

PROPORTIONAL VALVE

RELIEF VALVE

CARTRIDGE VALVE

CARTRIDGE VALVE

COIL

COIL

COIL

AC P/N

480839002

480839003

366365004

320725001

480839004

320725005

480839005

366365001

ITEM

FTG1

FTG2

FTG3

FTG4

FTG5

FTG6

QTY DESCRIPTION AC P/N

2

1

1

2

2

2

FITTING 45 8-SAE/8-JIC

FITTING 90 6-SAE/6-JIC

374017000

241175000

FITTING 90 6-SAE/6-JIC LONG 330645000

FITTING STR 8-SAE/8-JIC

FITTING STR 10-SAE/10-JIC

FITTING 45 6-SAE/6-JIC

367145000

490199000

480195000

7 - 4

Hyd. Control Valve 6/02

DIAGNOSTICS

FLOW PRESENT BUT

FUNCTION WILL

NOT WORK

HYDRAULIC

“CHATTER”

NO FLOW OR

LIMITED FLOW TO

CRANE

NO PRESSURE OR

TOO LOW

PRESSURE

TOO HIGH FLOW

TOO HIGH

PRESSURE

Check receiver for error code, if error code is present while function is being activated, refer to the error code section on the following page. If

“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.

When a hydraulic function is engaged and causes the crane to “chatter”, check for error code on receiver display, low pump pressure or air in the system.

Check for error code on receiver display (see error code section). Check for adequate oil supply in reservoir. Check operation of bypass system by 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 identified 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

Check the sight gauge and maintain an adequate oil level in reservoir.

Make sure pressure gauge is functioning correctly. Possible relief valve stuck open. Check for excessive leakage and correct.

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.

Make sure pressure relief valve is correctly set.

CAUTION

The Auto Crane 8406H 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 it's operation as the crane becomes overloaded. Attempting to raise the main boom with a load greatly exceeding 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.

8 - 1

CONTROLLER DIAGNOSTICS

CODE:

DESCRIPTION:

EC01

Signal problem

POSSIBLE CAUSE(S):

POSSIBLE SOLUTION(S): function is activated. If light does not come on, make sure transmitter is on. If light comes on and red low battery light is on, charge unit. If transmitter is plugged in as a pendant and transmit light comes on but code remains, check cable connections and cable.

CODE: EC02

DESCRIPTION: Boom up

POSSIBLE CAUSE(S): Short or open connection on boom up output.

POSSIBLE SOLUTION(S):Check plug in boom up solenoid on hydraulic control valve. Check wires for damage that could cause break or short.

CODE:

DESCRIPTION:

EC03

Boom down

POSSIBLE CAUSE(S): Short or open connection on boom down output.

POSSIBLE SOLUTION(S):Check plug in boom down solenoid on hydraulic control valve. Check wires for damage that could cause break or short.

CODE: EC04

DESCRIPTION: Boom in (retract)

POSSIBLE CAUSE(S): Short or open connection on boom in output.

POSSIBLE SOLUTION(S):Check plug in boom in solenoid on hydraulic control valve. Check wires for damage that could cause break or short.

8 -2

Diagnostics 6/02

CODE:

DESCRIPTION:

EC05

Boom out (extend)

POSSIBLE CAUSE(S): Short or open connection on boom out output.

POSSIBLE SOLUTION(S):Check plug in boom out solenoid on hydraulic control valve. Check wires for damage that could cause break or short.

CODE: EC06

DESCRIPTION: Rotate CW

POSSIBLE CAUSE(S): Short or open connection on rotate CW output.

POSSIBLE SOLUTION(S):Check plug in rotate CW solenoid on hydraulic control valve. Check wire for damage that could cause break or short.

CODE:

DESCRIPTION:

EC07

Rotate CCW

POSSIBLE CAUSE(S): Short or open connection on rotate CCW output.

POSSIBLE SOLUTION(S):Check plug in rotate CCW solenoid on hydraulic control valve. Check wire for damage that could cause break or short.

CODE: EC08

DESCRIPTION: Hoist up

POSSIBLE CAUSE(S): Short or open connection on hoist up output.

POSSIBLE SOLUTION(S):Check plug in hoist up solenoid on hydraulic control valve. Check wire for damage that could cause break or short.

8 - 3

Diagnostics 6/02

CONTROLLER DIAGNOSTICS

CODE:

DESCRIPTION:

EC09

Hoist down

POSSIBLE CAUSE(S): Short or open connection on hoist down output.

POSSIBLE SOLUTION(S):Check plug in hoist down solenoid on hydraulic control valve. Check wire for damage that could cause break or short.

CODE:

DESCRIPTION:

EC10

Incorrect ID

POSSIBLE CAUSE(S):

POSSIBLE SOLUTION(S):Confirm that transmitter being used is for use with this unit. Follow

“Transmitter/Receiver Sync.” procedure in the transmitter operation section of this manual.

CODE:

DESCRIPTION:

EC15

Pressure sensor

POSSIBLE CAUSE(S): Pressure sensor problem.

POSSIBLE SOLUTION(S):Check plugs and wires coming from pressure sensor mounted in the lift cylinder counterbalance valve.

CODE:

DESCRIPTION:

EC16

Trigger

POSSIBLE CAUSE(S): Transmitter trigger problem.

POSSIBLE SOLUTION(S):Check trigger for damage, contamination or incorrect adjustment.

8 - 4

Diagnostics 6/02

CONTROLLER DIAGNOSTICS

CODE:

DESCRIPTION:

EC17

Trigger logic error

POSSIBLE CAUSE(S):

POSSIBLE SOLUTION(S):Confirm that trigger is released and returned to full off position, activate function and reactivate trigger.

CODE:

DESCRIPTION:

EC18

E-STOP

POSSIBLE CAUSE(S): E-STOP activated.

POSSIBLE SOLUTION(S):Push E-STOP will power the unit off.

CODE:

DESCRIPTION:

EC19

Rotation error

POSSIBLE CAUSE(S): Rotation proximity switch error.

POSSIBLE SOLUTION(S):Check plugs and wiring. Check for debris around switch or magnet.

CODE:

DESCRIPTION:

LBV

Low battery

POSSIBLE CAUSE(S): Low battery power to to receiver.

POSSIBLE SOLUTION(S):Check connections to the battery. Charge battery. NOTE: It is recommended that the crane be powered off if battery is charged with battery charger.

8 - 5

Diagnostics 6/02

CONTROLLER DIAGNOSTICS

CODE:

DESCRIPTION:

OVL1

Over load 1

POSSIBLE CAUSE(S): Pressure overload with extend or hoist activated.

POSSIBLE SOLUTION(S):Retract boom, hoist down or otherwise alleviate overload condition.

Refer to load chart for rated load. If the error persists with seemingly t cylinder psi.

Pressure sensor can give false readings if not properly grounded.

CODE: OVL2

DESCRIPTION: Over load 2

POSSIBLE CAUSE(S): Pressure overload with boom up or down activated.

POSSIBLE SOLUTION(S):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 2,750 psi.

Pressure sensor can give false readings if not properly grounded.

CODE:

DESCRIPTION:

A2B

Anti-two block

POSSIBLE CAUSE(S): Anti-two block switch tripped.

POSSIBLE SOLUTION(S):Check switch, if not mechanically tripped, check continuity across 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,

8 - 6

Diagnostics 6/02

CONTROLLER DIAGNOSTICS

CODE:

DESCRIPTION:

RSBM

Raise boom

POSSIBLE CAUSE(S): Pressure sensor is reading less than 80 psi.

POSSIBLE SOLUTION(S):Raise boom to ensure it is not resting on other structure and the lift cylinder is not bottomed out.

CODE:

DESCRIPTION:

HOME

Home position

POSSIBLE CAUSE(S): Crane is pointed forward ready to be stowed.

POSSIBLE SOLUTION(S): RSBM condi-

CODE: NRML

DESCRIPTION: Normal operating mode

POSSIBLE CAUSE(S): Crane is functioning properly.

POSSIBLE SOLUTION(S):This is not an error. It is a standard normal operation readout.

CODE: BLMT

DESCRIPTION: Boom Limit

POSSIBLE CAUSE(S): Boom has reach maximum elevation.

POSSIBLE SOLUTION(S):This is not an error. It only indicates boom position.

8 - 7

Diagnostics 6/02

TRANSMITTER / RECEIVER

SYNCHRONIZATION

8 - 8

Trans / Rec Sync 6/02

REMOTE/PENDANT

PARTS AND ACCESSORIES

Component

Receiver

Transmitter

Pendant Cable

Antenna

Antenna Extension Cable

Cigarette Lighter Charger

A/C Charger

Palm Diagnostic Unit

Part Number

366500001

366500002

366500004

366500005

366500006

366504000

366505000

366510000

8 - 9

Remote/Pend 6 /02

VALVE OVERRIDE OPERATION

8 - 10

Valve Override 6/02

FUSE INFORMATION

8406H

NOTE: Always turn power to crane off before removing fuse.

Fuse is on ground circuit. The fuse can be replaced with a 7.5 amp fuse.

8 - 11

Fuse Info. 6/02

LOAD CHART

8406H

9 - 1

Load Chart 6/02

SUPPLIMENTAL INFORMATION

HARD WIRED SERIES

The following section refers to hardwire specific information only. Refer to the previous sections for information common to both crane versions.

10-0.0.0

6/02/2003

EXTEND

PORT #7

GENERAL ASSEMBLY

8406H HARD WIRED SERIES

1

8

10

5 6 2

RETRACT

PORT #8

11

3 6 5

4

9 7

10-1.0.0

6/02/2003

GENERAL ASSEMBLY

8406H HARD WIRED SERIES

ITEM NO. QTY.

1

2

1

1

PART NO.

480821000

366491

3

4

1 366492

1 480830000

8

9

10

11

5

6

7

2

2

1

021100

008701

480841000

1 366430000

1 *480854000

1 *366520000

1 *366466000

DESCRIPTION

PEDESTAL ASSY, 8406H HARD WIRED

PIN 2 DIA X 10.5 LG

PIN 1.25 DIA X 3.00 LG

BOOM ASSEMBLY

WASHER SPLK 3/8

SCW HX 3/8 UNC X 7/8 GR5

ROPE ASSY

COVER 6406

TRAVELING BLOCK ASSY 8406H

JUNCTION BOX ASSEMBLY

WIRE HARNESS, TRUCK FUNCTIONS

* included in crane ship kit, ref P/N: 480882000

10-2.0.0

6/02/2003

MOUNTING AND INSTALLATION

8406H HARD WIRED SERIES

1. Check to make sure the following items are with your crane.

ITEM QTY PART NO.

DESCRIPTION

1 1 480854000 TRAVELING BLOCK, 8406H

8

9

6

7

10

4

5

2

3

1

4

1

1

1

1

1

4

4

480899 Owners Manual

015104000 Bolt 7/8 NF x 5" Grade 8 (4 Req'd)

022200000 Washer Split Lock 7/8 (4 Req'd)

680040000 Pendant assembly

366466000 WIRE HARNESS, TRUCK FUNCTIONS

366520000 JUNCTION BOX ASSEMBLY

018900

320355

480689

NUT, HEX 7/8 NF

POWER RELAY

FUSE 15 AMP TIME DELAY

11

12

13

14

15

16

17

1

120"

6

6

5

1

1

480688

800596

634401

750738

320357

320363

FUSE HOLDER WATERPROOF

CONDUCTOR 16GA YELLOW X 120 INCHES LONG

WIRE TIE 7 INCHES LONG

WIRE TIE STICK ON RETAINER

CONNECTOR FEM SPD

PLUG RELAY

480852000 LOAD CHART DECAL, 8406H

18 1 340638 CONDUCTOR POWER

2. 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 10 GALLON RESERVOIR

A. RETURN LINE FROM CRANE TO RESERVOIR (IN COMPARTMENT): -10 SAE 100R2 (OR EQUIVALENT).

HOSE LENGTH IS DETERMINED BY INSTALLER. RETURN LINES LONGER THAT 6 FEET SHOULD BE

SIZE –12. HOSE END FITTINGS ARE –10 JIC FEMALE SWIVEL (CRANE END) AND –10 JIC FEMALE

SWIVEL (RESERVOIR END).

B. PRESSURE LINE FROM PUMP TO CRANE: -8 SAE 100R2 (OR EQUIVALENT). HOSE LENGTHS IS

DETERMINED BY INSTALLER. HOSE END FITTINGS ARE BOTH –8 JIC 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 WARRAN

3. Crane must be provided with a flow of 13 gallons per minute and a pressure of 2,750PSI. Excess flow will cause erratic operation, and too little flow will cause poor crane operation.

4. Vehicle should meet minimum GVW rating of 20,500 pounds.

5. The vehicle MUST be equipped with an engine speed control and tachometer.

6. Make sure mounting surface is properly reinforced to withstand 50,000 ft-lb capacity loading of crane and that outriggers are used to provide total stability for the truck.

7. A 13 ½” dia. Hole should be cut out of mounting location (centered with mounting blots) for access to lower ring gear bolts and hydraulic connections.

8. Make sure the mounting blots are 7/8” dia, grade 8. Torque bolts to 440 ft-lbs (dry).

9. When crane is not in operation, a boom support should always be used. Traveling block should be connected to hood loop.

10. Install junction box inside compartment safe from weather and contamination.

10-3.0.0

6/02/2003

MOUNTING AND INSTALLATION

8406H HARD WIRED SERIES

11. Electrical hookup:

Wiring (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 A DEDICATED SWITCH THAT IS POWERED ONLY WHEN THE IGNITION

SWITCH IS ON. A RELAY IS PROVIDED TO SEPARATE POWER SOURCES.

C. OPTIONALLY, USE THE WHITE WIRE FOR ENGINE FAST/SLOW.

D. OPTIONALLY, USE THE BLUE WIRE FOR ENGINE START.

E. OPTIONALLY, USE THE ORANGE WIRE FOR ENGINE STOP.

F. OPTIONALLY, USE THE GREEN WIRE FOR AUXILIARY.

WARNING!

FAILURE TO CORRECTLY PLUMB AND WIRE CRANE CAN CAUSE INADVERTENT

OPERATION AND DAMAGE TO CRANE AND/OR PERSONEL!

12. 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 10-8 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 8 gallons per minute (GPM), install an in-line flow meter between the crane and the reservoir in the return hose.

13. Load test the crane to ensure proper functioning and truck stability

14. Make certain the owner’s manual is delivered to the customer.

15. 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 AND 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

OF THE INSTALLER OF THE CRANE TO

COMPLY WITH THE OSHA TRUCK CRANE STABILITY REQUIREMENTS AS SPECIFIED BY 29 CFR

PART 1910.180 (C) (1).

10-4.0.0

6/02/2003

ELECTRICAL SCHEMATIC

HARD WIRED CRANE

RED/WHITE

PRES

SWITCH

A2B HOIST UP

GREEN

RED/WHITE

ROTATE LIMIT

SWITCH

4

3

CCW

6

CW

5

HOIST DOWN

WHITE

ROTATE CCW

WHITE/RED

BLACK

ROTATE CW

BLACK

BOOM LIMIT

SWITCH

WHITE

BOOM UP

BOOM DOWN

12 PIN CONNECTOR

GREEN

RED/BLACK

WHITE/BLACK

ORANGE

WHITE

BLUE

GREEN/BLACK

ORANGE/BLACK

RED

BLACK

GREEN

6

7

4

5

1

2

3

10

11

8

9

12

JUNCTION BOX

GREEN

RED

BLUE

GREEN/BLACK

ORANGE/BLACK

BLACK

RED/BLACK

ORANGE

RED/WHITE

BLACK

EXTEND (OUT)

EXTEND(IN)

PROP

CONTROL

VALVE

POWER

GROUND

ENGINE FAST/SLOW

AUXILARY

ENGINE START

ENGINE STOP

BLUE (NOT USED)

WHITE (NOT USED)

RED

BLACK

WHITE

GREEN

BLUE

ORANGE

NOT USED

NOT USED

7

8

5

6

3

4

1

2

NOT USED

NOT USED

WHITE/BLACK

(NOT USED)

WHITE

BLUE/BLACK

BLACK/WHITE

GREEN/WHITE

BLUE/WHITE

BLACK/RED

WHITE/RED

ORANGE/RED

(NOT USED)

BLUE/RED

(NOT USED)

R

S

N

P

T

U

V

L

M

J

K

G

H

E

F

C

D

A

B

10-5.0.0

6/04/2003

PEDESTAL ASSEMBLY

8406H HARD WIRED SERIES

40

14

35

47

25

81

12

79

37

76

78

80

65

29

27

51

86

87

26

85

60

HYDRAULIC VALVE KEY

PORT #1: HOIST DOWN

PORT #2: HOIST UP

PORT #3: ROTATION CCW

PORT #4: ROTATION CW

PORT #5: LIFT CYL EXTEND

PORT #6: LIFT CYL RETRACT

PORT #7: EXT CYL EXTEND

PORT #8: EXT CYL RETRACT

57

27

28

CYLINDER SEAL KIT: 480838001

COUNTER BALANCE CARTRIDGE: 480188000

10-6.0.0

72

46

73 74 75

30

3

41

42

54 55 56

30

88

15

9

38

59

61 37

36

63

45

6/02/2003

39

40

41

42

43

34

35

36

37

38

44

45

46

47

29

30

31

32

33

24

25

26

27

28

16

17

18

19

20

21

22

23

11

12

13

14

15

ITEM NO. QTY.

1

2

3

4

5

1

1

1

1

1

PART NO.

480847000

160407

366492

480838000

366365000

6

7

8

9

10

1

1

38

24

14

366333

480023002

23902

12198

490171

2

2

2

1

1

4

6

366364

812209-022

480205

812203-028

812203-030

2 200876

10 21100

10 8400

1 366440

2 480202

1 123307

320588

21500

4 366391

2 9118

4 6205

2 372041

1 490199

1 367145

2 21502

2 21601

2 12197

1 370433

1 812309-024

1 812409-022

1 480024

1 20601

1 7401

1 480857000

2 490198

1 366359

1 366358

48 374086

1 480011

1 366419

1 480856000

2 642908

PEDESTAL ASSEMBLY

8406H HARD WIRED SERIES

DESCRIPTION

PEDESTAL WELD

GEAR BOX, ROTATION

PIN 1.25 DIA X 3.00 LG

CYL, LIFT

VALVE CONTROL ASSY

BEARING, SPHERICAL 1.25 ID

BEARING, ROTATION

WASHER, 5/8 FLAT HARDENED

CAPSCREW 5/8-11 X 1.75 GR8

CAPSCREW 5/8-11 X 2.25 GR8

PLATE, VALVE MOUNTING

HOSE ASSY 6 STR/90

HOSE ASSY 6 STR X 19.25

HOSE ASSY 6 STR

HOSE ASSY 6 STR

FITTING 6 SAE/6 JIC STRAIGHT 6F5OX

WASHER SPLK 3/8

SCW HEX HD 3/8-16 UNC X 3/4 GR 5

ROTATION MOTOR

HOSE ASSY 8 STR X 21.5

HOIST RPH4201233080

WASHER FL 1/2

WASHER SP LK 1/2

HEX HD 1/2-13 X 2 1/4

SOC HD 1/2 UNC X 2

SOC HD 5/8 X 1 1/4

FITTING 8JIC/10SAE STRAIGHT 8-10 F5OX

FITTING STR 10-SAE/10-JIC

FITTING STR 8-SAE/8-JIC

WASHER SP/LK 1/2 HI COLLAR

WASHER FL 1/2

SOC HD 1/2-13

CORD CONNECTOR HUBBLE F-3

HOSE ASSY 8 STR/90

HOSE ASSY 10 STR/90

MOUNT PENDANT CABLE RETAINER

WASHER 5/16 LOCK

SCW 5/16-18 X 1/2 LG

BASE PLATE WELD

FITTING 10SAE(M)/6JIC ELBOW 90

FITTING 8 SAE/JIC SWIVEL PS810503-8-8

FITTING 10SAE/JIC SWIVEL PS810503-10-10

NYLON HOSE SLEEVE

SEAL ROTATION BOX

SWITCH, LIMIT ROTATION

LIMIT SWITCH ARM

CORD CONNECTOR

10-7.0.0

6/02/2003

PEDESTAL ASSEMBLY

8406H HARD WIRED SERIES

59

60

61

62

63

55

56

57

58

64

65

ITEM NO. QTY.

48

49

50

2

2

2

PART NO.

20000

19800

330679

51

52

53

54

2

2

1

1

11202

17704

360162

360207

1

1

1

1

2

2

1

1

1

1

1

20600

7807

480865000

654100

602

15400

480880000

366473000

366522001

366522002

366363001

DESCRIPTION

10 SAE FLAT WASHER

10 SPLIT LOCK

SCW BT HD SOCKET 10-32 X 1/2

SCW HX HD 1/2-20 X 2 3/4

NUT HX HVY 1/2 NF

RING, ECCENTRIC

RETAINER ECCENTRIC RING

WASHER SP LK 5/16 NC

SCW HEX 5/16-18 3/4LG GR5

BRACKET BOOM SWITCH

SWITCH LIMIT BZ-2RW80-A2

SCW PN #6 NC X 1

NUT HX #6-32

LOAD SENSOR SWITCH, 2500 PSI

MAIN HARNESS ASSEMBLY, HARD WIRED

HOUSING, PLUG, DEUTSCH 12-PIN

WEDGE, DEUTSCH PLUG, 12 SOCKET

AMP MODIFICATION, CONNECTORS

10-8.0.0

6/02/2003

4

A

MAIN WIRING HARNESS

W/R

8.0"

10

7

1

B

RED WIRE

NOT USED

2

1

2

R/W

2.5"

W/R

3.5"

W/R

12.0"

HU

HD

R/W

9.0"

CCW

K

CW

BU

BD

EXT

W/R

3.5"

W/R

4.5"

W

RET

R/W

5.0"

8

4

5

2

PRESSURE SWITCH

3

A2B SWITCH

K

A B

ROTATE SWITCH

G

12

W

A

BOOM LIMIT

B

R/W

5.0"

11

SOLDER TIPS

9

R/W

2.5"

6

10

FUNCTION

HOIST UP

HOIST DN

ROTATE CCW

ROTATE CW

BOOM UP

BOOM DN

EXTEND

RETRACT

A2B SWITCH

PRESSURE

SWITCH

ROTATE SWITCH

3 COND CABLE

BOOM LIMIT

2 COND CABLE

2

*

**

N/A

***

N/A

2

1

2

1

PIN WIRE COLOR

1 GREEN

2

1

WHITE/RED

RED/BLACK

2

1

2 RED/WHITE

1 WHITE/BLACK

WHITE

ORANGE

2

1

2

1

BLACK

WHITE

BLACK

BLUE

2 WHITE/RED

1 GREEN/BLACK

2 WHITE/RED

1 ORANGE/BLACK

RED/WHITE

WHITE/RED

RED/WHITE

RED/WHITE

WHITE/RED

WHITE

BLACK

GREEN

WHITE

BLACK

NOTES

POWER

TO A2B GROUND

POWER

GROUND

POWER

TO CCW SWITCH (3 COND CABLE)

POWER

TO CW SWITCH (3 COND CABLE)

POWER

BOOM SWITCH CABLE

POWER

TO A2B GROUND

POWER

TO A2B GROUND

POWER

GROUND

TO PIN 1, PRESSURE SWITCH

FROM HU, BD, EXT GND

GROUND

FROM A2B PIN 2

*PIN 2 ON ROTATE CCW PLUG

**PIN 2 ON ROTATE CW PLUG

GROUND

***PIN 2 ON BOOM UP PLUG

10-9.0.0

ITEM NO. QTY. PART NO.

1

DESCRIPTION

1 800632000 CABLE, 16/10 SO BLACK

2

3

4

9 366367001 HOUSING, DEUTSCH 2-PIN PLUG

9 366367002 WEDGE, DEUTSCH PLUG, 2 PIN

27 366367003 CONTACT, DEUTSCH SOCKET

10

11

12

13

14

7

8

5

6

9

1

1

2

5

2

360769001 HOUSING, DEUTSCH 2-PIN RECEPTACLE

360769002 WEDGE, DEUTCH 2-PIN RECEPTACLE

366376003 CONTACT, DEUTSCH

001104000 TERMINAL SPLICE 14-16 GA

000101000 TERMINAL RING, 5/32, 14-16 GA

3 000501000 TERMINAL RING, 5/16, 14-16 GA

1 800628000 WIRE, 3 CONDUCTOR

1 800626000 WIRE, 2 CONDUCTOR

31" 800618000 WIRE, 16GA, WHITE/RED

26" 800617000 WIRE, 16GA, RED/WHITE

6/02/2003

JUNCTION BOX ASSEMBLY

HARD WIRED SERIES

16

5

14

10

9

11

9 15

11

9

6

3

9

11 8

2

7

12

13

10

10

F U N C T IO N

B O O M U P

H O IS T U P

R O T A T E C W

E N G IN E FA S T

R O T A T E C C W

H O IS T D N

B O O M D N

R E T R A C T

E X T E N D

N O T U S E D

P O W E R

P R O P +0 T O 5V

G R O U N D

A U XILA R Y

E N G IN E S T A R T

E N G IN E S T O P

P R O P P O W E R

N O T U S E D

N O T U S E D

G R O U N D

G R O U N D

G R O U N D

1

19 P IN 8 P IN 12 P IN G N D

A

B

C

D

E

R

S

T

M

N

P

U

V

J

K

L

F

G

H

3

-

1

4

5

6

5

1

4

3

2

6

8

7

-

11

-

-

9

-

-

10

2

12

10-10.0.0

G N D

G N D

G N D

G N D

W IR E C O LO R

R E D

G R E E N

O R A N G E

R E D /W H IT E

B LA C K

R E D /B LA C K

B LU E

O R A N G E /B LA C K

G R E E N /B LA C K

W H IT E /B LA C K

W H IT E

B LU E /B LA C K

B LA C K /W H IT E

G R E E N /W H IT E

B LU E /W H IT E

B LA C K /R E D

W H IT E /R E D

O R A N G E /R E D

B LU E /R E D

B LA C K /W H IT E

B LA C K /W H IT E

B LA C K /W H IT E

6/02/2003

JUNCTION BOX ASSEMBLY

HARD WIRED SERIES

ITEM NO.

QTY.

PART NO.

3

4

1

2

5

1

1

366470000 JUNCTION BOX

366095

DESCRIPTION

RECEPTACLE, 19 PIN

1 366523001 HOUSING, DEUTSCH 8-PIN RECEPTACLE

1 480594001 CABLE, PENDANT, 16/10 SO BLACK

1 366471000 COVER, JUNCTION BOX

10

11

12

13

14

8

9

6

7

15

16

1

1

4

17

366524001 HOUSING, DEUTSCH 12-PIN RECEPTACLE

366097000 CAP W/CHAIN (FOR RECEPTACLE)

366519000 NUT, SELF CLINCHING

019600 WASHER SP LK #6

16 001004000 SCW PN HD #6 X 3/4 LG

13

3

1

015400 NUT HX #6-32

1 366524002 WEDGE, DEUTSCH RECEPTACLE, 12 PIN

1 366523002 WEDGE, DEUTSCH RECEPTACLE, 8 PIN

18 366376003 CONTACT, DEUTSCH

000101000 TERMINAL RING, 5/32, 14-16 GA

366469000 DECAL, JUNCTION BOX WIRING

10-11.0.0

6/02/2003

PENDANT ASSEMBLY, 8 FUNCTION

HARD WIRED SERIES

10-11.0.0

6/02/2003

PENDANT ASSEMBLY, 8 FUNCTION

HARD WIRED SERIES

17

18

19

20

21

22

23

24

25

26

10

11

12

7

8

9

13

14

15

16

ITEM QTY PART NO.

DESCRIPTION

1 1 480501 HOUSING, PROP. PENDANT MACHINED

2 1 480518 DECAL/COVER PLATE

5

6

3

4

8

8

1

2

REF

640300

480567

002607

NUT (INCLUDED WITH SWITCH)

BOOT, TOGGLE

CORD GRIP, HUBBELL CONNECTOR

SCREW, HX HD #10-24 NC X 3/4 LG

2

1

1

1

4

1

4

1

8

3

015801

480507

480506

480517

634200

480504

001004

680113

REF

660302

NUT, HEX, LOCKING, #10-24 NC

POTENTIOMETER ASSEMBLY

TRIGGER

SCREW, SOC HD, #10-32 NF X 5/8 LG

SWITCH, TOGGLE DPDT

BACK PLATE, HOUSING

SCREW, PAN HD, #6-32 X 3/4 LG

CABLE ASSEMBLY, BAYONET

WASHER, LOCK (INCLUDED WITH SWITCH)

CONDUCTOR ASSEMBLY

4

4

3

1

1

1

1

2

1

3

480524

480523

005003

636600

622346

622347

622000

750090

480526

750737

CONDUCTOR ASSEMBLY

SPRING, TRIGGER RETURN

SCREW, S.T. PAN HD, #6-32 X 3/8 LG

JUMPER

CONDUCTOR ASSEMBLY

CONDUCTOR ASSEMBLY

SWITCH, TOGGLE SPDT

SWITCH, TOGGLE ON/OFF

CONDUCTOR ASSEMBLY

TIE, CABLE

10-12.0.0

6/02/2003

PENDANT CABLE ASSEMBLY

HARD WIRED SERIES

6

7

4

5

ITEM QTY PART NO. DESCRIPTION

1

2

3

1

1

30'

366098

480515

480594

PLUG, CONNECTOR

CLAMP, CABLE

CABLE, CONDUCTOR (19 COND)

2

2

13

6"

000101 TERMINAL RING #6 / 14-16 GA

480510 CONNECTOR, BULLET, FEMALE

002012 TERMINAL RING #6 / 18-22 GA

490243 TUBING, HEAT SHRINK

10-13.0.0

6/02/2003

PROPORTIONAL VALVE CONTROLLER/AMP

HARD WIRED SERIES

REFRENCE AUTO CRANE P/N 366363001

RISING RAMP

FALLING RAMP

DITHER AMPLITUDE DITHER FREQ

OUTPUT: 2000mA MAX

I-MIN SETTING: 0 TO 500mA

I-MAX SETTING: 600 TO 2000mA

CABLE LENGTH: 6 FEET

MINIMUM CURRENT

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

CW 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 VDC). 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.

10-14.0.0

6/02/2003

P.O. Box 580697 * Tulsa, OK 74158-0697

4707 N. Mingo Rd. * Phone (918) 836-0463

LIMITED WARRANTY

2 YEAR PARTS AND LABOR

Auto Crane will warranty to the consumer for a period of (2) years parts and labor from the date of purchase. Each new Auto Crane unit they sell 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 Crane 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