Auto Crane 9006 Crane Owner's Manual
Below you will find brief information for Crane 9006. The 9006 series cranes are designed to provide many years of safe, trouble-free, dependable service when properly used and maintained. The manual provides operating and service instructions. It's highly recommended that crane owners, equipment managers and supervisors also read this manual. The crane adds weight to the vehicle and reduces the payload. The operator should exercise care when loading the vehicle. The crane has several safety features including holding valves to prevent the load from dropping if a hose should fail.
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OWNERS MANUAL
9006
REVISION 1/2000
PART NO. 999990
SERIAL NO. __________________________
PO BOX 580697, TULSA, OK 74158-0697
4707 N. MINGO ROAD, TULSA, OK 74117
PHONE (918) 836-0463
SALES FAX (918) 438-6688 SERVICE FAX (918) 834-5979 http://www.autocrane.com
WARNINGS -
READ THIS PAGE!
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 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.
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.
WARNING! NEVER
.............................
v EXCEED load chart capacities (centerline of rotation to hoist hook).
v un-reel last 5 wraps of cable from drum!
v wrap cable around load!
v attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
v 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.
v place a chain link on the tip of the hook and try to lift a load!
v use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature!
v 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 your crane is equipped with this type of device.
warning 9/98
9006 SERIES - OWNER'S MANUAL
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING PRACTICES & WARNINGS . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION OF UNIT / OUTRIGGERS . . . . . . . . . . . . . . . . . . . . . . . . .
QUALIFICATIONS FOR OPERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION, TESTING, & MAINTENANCE . . . . . . . . . . . . . . . . . . . . .
SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOUNTING & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOOM SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMPLIFIER SETUP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERLOAD SYSTEM / ANTI-2-BLOCK TROUBLESHOOTING . . . .
OPTIMETER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC VALVES TROUBLESHOOTING . . . . . . . . . . . . . . . . . . .
LUBRICATION & MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . .
PEDESTAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC SAFETY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOIST ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESERVOIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRAVELING BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LAST PAGE
INTRODUCTION
9006 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 9006 series cranes for your protection. The choice of materials and the design of the electrical system minimizes weight and lengthens durability. The hydraulic components meet or exceed a 3.5:1 safety
factor. Holding valves prevent the load from dropping if a hose should fail. A 10u filter in the return line of the hydraulic system removes dirt and grit that may cause erratic operation. The reservoir has a 15u air
filter in the filler cap. The pump has a 40 mesh
strainer in the suction line.
For your convenience the overall dimensions of the
9006 series crane are on the General Dimension
Drawing. Maximum turning radius at both the hoist motor and the rotation motor are also 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. A minimum G.V.W. of
30,000 lbs. is recommended for mounting the 9006 series cranes.
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, mis-used, 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.
Auto Crane Company issues a limited warranty certificate with each unit sold.
See last page for warranty policy.
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
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) 438-2760. 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.
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9006int 11/99
GENERAL SPECIFICATIONS
9006 SERIES
DIMENSIONS
Width: 1 ft 10 in (.55 m)
Height: 3 ft 6 in (1.06 m)
Length: 13 ft 10 in (4.52 m)
Weight: 2000 lb (907 kg)
Base Plate Dimensions:
1 ft 9 in (.53m) x 1 ft 9 in (.53 m)
CABLE
Standard Cable Supplied: 120 ft (28.9 m) of
7/16 in diameter
CHASSIS REQUIREMENTS
Chassis: 30,000 lb (9,299 kg) GVWR minimum
CAPACITY
Capacity: 60,000 ft·lb ft·lb = horizontal distance from centerline of rotation to free hanging weight (feet) x amount of weight (pounds)]
(See Load Chart)
REACH
Main boom reach: 11 ft
Power boom extends to: 17 ft
Manual boom extends to: 22 ft
HYDRAULIC SYSTEM
Pressure: 2100 psi relief setting
Flow:10 gpm
Oil Type: Mobile DTE 13, Sun 2015
MOVEMENT SPEEDS
Proportional Maximum
Hoist: 25 fpm single line (no load)
ELECTRICAL SYSTEM
REQUIREMENTS
Control voltage: 12 V DC
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9006SPEC 12/99
--- 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. Oil gears as required.
12. Periodic adjustment of hoist worm brake may be required (see automatic safety brake drawing in this manual).
13. Hydraulic hoses need to be inspected frequently for signs of deterioration, and be replaced as required.
14. 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.
15. ALWAYS store outriggers before road travel.
16.
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.
17.
WARNING! NEVER EXCEED load chart capacities (centerline of rotation to hoist hook).
18.
WARNING! NEVER un-reel last 5 wraps of cable from drum!
19.
WARNING! NEVER wrap cable around load!
20.
WARNING! NEVER attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
21.
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.
22.
WARNING! NEVER place a chain link on the tip of the hook and try to lift a load!
23.
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!
24.
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.
25.
WARNING! NEVER hold any pendant 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.
SAFTIPS 2/98 1-2.0.0
--- IMPORTANT ---
OPERATION OF UNIT
26. Make sure this manual has been thoroughly read by all crane operating personnel and supervisors.
27. A routine inspection of the crane should be mandatory before each operating day. Any defects should be corrected immediately.
28. 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).
29. Keep the vehicle as level as possible during operation.
30. 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.
31. 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.
32. Remove pendant control from cab or storage area. On smaller units, plug pendant into receptacle on crane.
On larger units, remove pendant control from guard and unwrap cable from boom. Do not operate crane until cable is unwound completely. On all cranes, detach hook from dead man. Crane is now ready for operation.
33. Always boom up before rotating so the boom will clear the required boom support.
34. When extending the boom, always maintain clearance between the boom crown and the traveling block or hoist hook.
35. Always observe safe and practical operation to avoid possible accidents. Refer to Safety Tips and
Precautions.
36. After completing lifting operations, return the boom to stowed position on the boom support. Avoid unneeded pressure on the boom support.
37. Store pendant control on proper location (in cab or on crane).
38. Return outriggers to stowed position. Make sure they are pinned in place or jacklegs are returned to compartment.
39. Check work area for any tools or equipment not stored.
40. Release throttle control, depress clutch and disengage
PTO. Deactivate any crane power switches.
41. Report any unusual occurrence during crane operation that may indicate required maintenance or repair.
42. NEVER use two cranes to support a load too large for either crane.
43. Spray all electrical equipment with special corrosion resistant coating. This eliminates rust or corrosion due to melting and freezing action of condensation.
OPERATION OF
OUTRIGGERS
For hydraulic outriggers:
1. Shift crane/outrigger control valve to
"outrigger" position.
2. After outriggers are positioned, return crane/outrigger selector to "crane" position.
3. Crane is now ready to operate.
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9006OPER 1/99
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
OPERATORS
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
7 Operators and operator trainees should have normal depth perception, coordination, and no tendencies to dizziness or similar undesirable characteristics.
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).
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.
9 The operator shall not engage in any practice which will divert his attention while actually operating the crane.
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.
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.
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.
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.
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.
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.
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QUAL 7/98
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
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 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.
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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.
TABLE 1
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.
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
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.
1-3.1.2
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
27 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.
28 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
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
30 Deformed, cracked or corroded members in the crane structure and carrier.
31 Loose bolts, particularly mounting bolts.
32 Cracked or worn sheaves and drums.
33 Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and devices.
FREQUENT INSPECTION
34 Excessive wear on brake and clutch system parts and lining.
29 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
35 Crane hooks inspected for cracks.
36 Travel steering, braking, and locking devices, for malfunction.
37 Excessively worn or damaged tires.
38 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
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INSP 9/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL elements in contact or otherwise protect the components necessary to determine origin of the problem before corrective action can be taken.
39 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
43 Labels are to be in place and legible.
CRANES NOT IN REGULAR USE
44 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.
45 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.
40 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
41 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
42 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
INSPECTION RECORDS
46 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
47 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
1-3.2.1
INSP 9/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL tested by or under the direction of an appointed person.
A. functional operating mechanism
B. safety devices
C. control systems
48 Test loads shall not exceed 110% of the manufacturer's load ratings.
49 Written reports shall be maintained showing test procedures and confirming the adequacy of repairs.
MAINTENANCE
PREVENTIVE MAINTENANCE
50 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
55 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
56 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.
51 Warning or "OUT OF ORDER" signs shall be placed on the crane controls.
ROPE INSPECTION
52 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
53 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.
54 Adjustments shall be maintained to assure correct functioning of components, The following are examples:
57 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
1-3.2.2
INSP 9/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL
3. broken or cut strands;
4. number, distribution and type of visible broken wires. When such damage is discovered, the rope shall either be removed from service or given as inspection.
B. Care shall be taken when inspecting sections of rapid deterioration such as flange points, crossover points, and repetitive pickup points on drums.
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
58 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:
59 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.
60 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)
1-3.2.3
INSP 9/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL
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.
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.
65 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.
61 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.
66 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.
62 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.
67 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.
ROPE MAINTENANCE
63 Rope should be stored to prevent damage or deterioration.
68 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.
64 Unreeling or uncoiling of rope shall be done as recommended by the rope manufacturer and with care to avoid kinking or inducing twist.
1-3.2.4
INSP 9/98
SAFETY DECAL SECTION
PART NO.:
DECAL:
FUNCTION:
040517
STAY CLEAR OF BOOM
To inform the operator of the hazard of proximity or contact with the crane boom during operation.
2 QUANTITY :
PLACEMENT : Both sides of crown
(see page 1-5.0.0, Item 10)
PART NO.:
DECAL:
FUNCTION:
040518
STAY CLEAR OF LOAD
To inform the operator of the hazard of proximity or contact with the crane load during operation.
2 QUANTITY :
PLACEMENT : Both sides of crown plate
(see page 1-5.0.0, Item 11)
FIG. SD-1.
FIG. SD-2.
PART NO.:
DECAL:
FUNCTION:
040519
SCISSORS POINT
To inform the operator of possible danger at scissors point on crane.
QUANTITY :
PLACEMENT :
1
Both sides of lift cylinder
(see page 1-5.0.0, Item 8)
FIG. SD-3.
1-4.0.0
9006DEC 11/99
SAFETY DECAL SECTION
PART NO.:
DECAL:
FUNCTION:
040529
ELECTROCUTION HAZARD
To inform the operator of the hazard involved with contacting electrical power lines with crane boom.
QUANTITY :
PLACEMENT :
2
Both sides of end of lower boom
(see page 1-5.0.0, Item 9)
PART NO.:
DECAL:
FUNCTION:
040580
OPERATOR TRAINING
To inform the operator of the need to receive proper training before using the crane .
QUANTITY : 1
PLACEMENT : Left Sideplate
(see page 1-5.0.0, Item 15)
FIG. SD-4.
1-4.1.0
FIG. SD-5.
9006DEC 11/99
SAFETY DECAL SECTION
PART NO.:
DECAL:
FUNCTION:
040579
OPERATION INSTRUCTIONS
To inform the operator of the proper procedure to follow for safe operation of the crane.
1 QUANTITY :
PLACEMENT : Left Side plate
(see page 1-5.0.0, Item 16)
FIG. SD-6.
PART NO.:
DECAL:
FUNCTION:
040587
LOAD SENSOR
To inform the operator that the load sensor is preset and that tampering with the sensor may cause potentially hazardous situation.
1 QUANTITY :
PLACEMENT : On the lift cylinder near the load sensor
(see page 1-5.0.0, Item 17)
PART NO.:
040632
DECAL:
FUNCTION:
TAMPERING WITH
OVERLOAD DEVICE
To inform the operator that tampering with the overload device may cause a unit failure or possible personnel injury.
1 QUANTITY :
PLACEMENT : Right side of lift cylinder
(see page 1-5.0.0, Item 13)
1-4.2.0
FIG. SD-7.
FIG. SD-8.
9006DEC 11/99
SAFETY DECAL SECTION
PART NO.:
DECAL:
FUNCTION:
367246
OPERATION INSTRUCTIONS
To inform the operator of the dangers associated with personnel riding on hook.
1 QUANTITY :
PLACEMENT : Left Sideplate
(see page 1-5.0.0, Item 12)
FIG. SD-9.
1-4.3.0
9006DEC 11/99
DECAL LAYOUT
P/N 454125
0
6
9
0
H
0
6
9
0
H
ITEM
7
8
9
10
11
12
13
14
15
16
17
3
4
5
6
1
2
1
2
2
2
2
1
1
1
1
2
1
1
2
2
1
7.9 ft
1
QUANTITY PART NUMBER DESCRIPTION
454126
454128
360034
040624
040620
480038
480039
040519
040529
040517
040518
367246
040632
330622
040580
040579
040587
9006 DECAL
LOAD CHART DECAL
MEDIUM “A” LOGO DECAL
AUTO CRANE DECAL
3M STRIPING DECAL
RIGHT ANGLE INDICATOR DECAL
LEFT ANGLE INDICATOR DECAL
SCISSORS POINT DANGER DECAL
ELECTROCUTION DANGER DECAL
STAY CLEAR OF BOOM DECAL
STAY CLEAR OF LOAD DANGER DECAL
NEVER RIDE ON HOOK DANGER DECAL
OVERLOAD TAMPERING WARNING DECAL
SERIAL NUMBER DECAL
MUST NOT OPERATE DECAL
WORK RULES DECAL
LOAD SENSOR DECAL
1-5.0.0
AW466210 11/99
MOUNTING and INSTALLATION for 9006
1. CHECK TO MAKE SURE THE FOLLOWING ITEMS ARE WITH YOUR CRANE:
ITEM
1.
2.
3.
4.
PART NO.
466230
367215
999990
015104
DESCRIPTION
5 TON SWIVEL BLOCK
PUMP ASSEMBLY (OPTIONAL)
9006 OWNERS MANUAL
CAPSCREW, 7/8 UNF x 5 in, Grade 8 (4 REQ'D)
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. EQUIVALENT
HOSES AND FITTINGS ARE ACCEPTABLE. (REFERENCE DWG AW-017 & AW-480150)
LOCATION
ITEM
HOSE
RETURN LINE HOSE
CRANE TO RESERVOIR
-12 SAE 100R2
2 WIRE BRAID
SUCTION HOSE
PUMP TO RESERVOIR
-20 SAE 100R4
HYDRAULIC SUCTION
PRESSURE LINE HOSE
PUMP TO CRANE BASE
-12 SAE 100R2
2 WIRE BRAID
FITTING -12 JIC 37° JIC
FEMALE SWIVEL
(CRANE END)
-20 37° JIC
FEMALE SWIVEL
PUSHON WITH CLAMP
-10 JIC 37° JIC
FEMALE SWIVEL
(CRANE END)
NOTE:
REFER TO OWNERS MANUAL FOR ADDITIONAL INSTALLATION INFORMATION, AND OTHER
RESERVOIR AND PUMP COMBINATIONS.
3. CRANE MUST BE PROVIDED WITH A FLOW OF 10 gpm @ 1100 PUMP rpm. EXCESSIVE FLOW WILL
CAUSE OVER HEATING & ERRATIC OPERATION, AND TOO LITTLE FLOW WILL CAUSE POOR CRANE
OPERATION.
4. MAKE SURE MOUNTING SURFACE IS PROPERLY REINFORCED TO WITHSTAND 66,000 ft-lb CAPACITY
LOADING OF CRANE AND THAT OUTRIGGERS ARE USED TO PROVIDE TOTAL STABILITY FOR THE
TRUCK.
5. MAKE SURE THE MOUNTING
CAPSCREWS ARE 7/8 UNF x 5 in, Grade 8.
TORQUE BOLTS TO 440 ft-lb (DRY).
6. WHEN CRANE IS NOT IN OPERATION, A
BOOM SUPPORT SHOULD ALWAYS BE
USED. TRAVELING BLOCK SHOULD BE
CONNECTED TO HOOK LOOP.
7. THE VEHICLE MUST BE EQUIPPED WITH
AN ENGINE SPEED CONTROL AND
TACHOMETER.
8. CHECK FOR PROPER PRESSURE AND
RETURN LINE HOOK-UP TO CRANE:
PRESSURE PORT IS ON THE RIGHT SIDE
AS VIEWED FROM THE REAR OF THE
CRANE.
9006mtg 11/99 2-1.0.0
MOUNTING and INSTALLATION for 9006
9. ELECTRICAL HOOK-UP:
A. CONNECT WIRES FROM BASE ON CRANE PER IN-COMPARTMENT (IC) PENDANT
INSTALLATION DRAWING.
B. CONNECT POWER CONDUCTOR FROM STARTER SOLENOID TO TERMINAL “L” ON THE
TERMINAL STRIP. USE THE IN-LINE FUSE PROVIDED.
WARNING!
FAILURE TO CORRECTLY PLUMB AND WIRE CRANE CAN CAUSE
INADVERTENT OPERATION AND DAMAGE TO CRANE AND/OR PERSONNEL!
10. 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 TO -12 JIC UNION AND
ENGAGE PTO WITH ENGINE RUNNING. ALLOW OIL TO CIRCULATE FOR 15 TO 20 MINUTES. THIS
CAUTION
- FAILURE TO USE CLEAN HYDRAULIC HOSES AND COMPONENTS MAY
CONTAMINATE THE CRANE AND HYDRAULIC SYSTEM AND VOID WARRANTY.
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 10 GALLONS PER MINUTE (gpm), INSTALL AN IN-LINE
FLOW METER BETWEEN THE CRANE AND THE RESERVOIR IN THE RETURN HOSE, OR CONFIRM
PUMP SPEED IS CORRECT. THE PROPER SPEED FOR AUTO CRANE GEAR PUMP P/N 367215 IS 1100
RPM.
11. PROPER PRESSURE SETTING CAN BE ACHIEVED BY, WITH THE PTO DISENGAGED, REMOVING THE
PIPE PLUG ON THE PROPORTIONAL VALVE AND INSTALLING A 3000 psi PRESSURE GAUGE. THE
TRIGGER SHOULD BE PULLED COMPLETELY BACK (ON). READ THE PRESSURE GAUGE AND ADJUST
RELIEF VALVE TO READ 2100 psi. RECHECK PRESSURE SETTING TO VERIFY ADJUSTMENT.
12. LOAD TEST THE CRANE TO ENSURE PROPER FUNCTIONING AND TRUCK STABILITY.
13. MAKE CERTAIN THE OWNER'S MANUAL IS DELIVERED TO THE CUSTOMER.
14. FOR ADDITIONAL HELP: CALL THE SERVICE DEPARTMENT AT THE AUTO CRANE COMPANY.
(918) 836-0463 (TULSA, OKLAHOMA)
WARNING
FEDERAL LAW (49 CFR PART 571) REQUIRES THAT THE FINAL STAGE MANUFACTURER OF A
VEHICLE CERTIFY THAT THE 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).
2-1.1.0
9006mtg 11/99
RECOMMENDED BOOM SUPPORT
P/N 766144
2-2.0.0
AW766144 5/99
INSTALLATION & SETUP PROCEDURE DIGITAL
PULSE WITH AMPLIFIER
INSTALLATION:
ATTACH WIRES IN THIS ORDER: (numbers are on 22-station terminal strip)
1.
Install decal 466253 & 22-station terminal stripin crane compartment.
2.
3.
Connect pig tail harness from crane to terminal strip as shown by decal.
Connect harness to right side of terminal strip as shown by decal.
Harness for In Compartment: P/N 466254
Harness for Crane Mounted: P/N 466255
4.
Plug pendant or FM receiver into bayonet connector.
5.
The amplifier is factory set, adjust only if necessary.
Observe all connections for proper installation before connecting power to the terminal block. Proceed to the setup procedure.
SETUP:
1.
Remove four screws on the back of the pendant.
2.
With power on, pull pendant trigger to full on position. Adjust potentiometer adjustment screw located next to the red light (see Figure 1) until light just turns off, then turn trim pot back until the light just comes on. The light should stay on during the full trigger movement. Clockwise rotation to the trim pot will turn light off. Counterclockwise rotation will turn the light on. This “tunes” the amplifier to the trigger potentiometer.
3.
After warming the hydraulic system oil, determine which function should be used to set the low position switch (ROTATE uses the least amount of pressure). Activate that function with trigger released, and turn the lower range setting dial (refer to Figure 1, marked with “L” on the circuit board) until the desired speed is reached. The “Zero” and the “F” on the dial are opposite ends of the switch. To adjust the low set point, turn
CLOCKWISE DIRECTION for INCREASED FLOW, COUNTER CLOCKWISE
DIRECTION for DECREASED FLOW. This adjusts the “Threshold Speed” for the trigger in the released position.
4.
Operate the boom up function with trigger pulled back to the maximum position. Turn the high range setting dial. (refer to Figure 1, marked with “H” on the circuit board) until there is a noticeable decrease in speed, then back up one or two notches as desired.
“Zero” is the maximum speed setting and “F” is the most reduced speed setting. To set the high range dial, turn CLOCKWISE DIRECTION for DECREASED FLOW,
COUNTER CLOCKWISE DIRECTION FOR INCREASED FLOW. This operation adjusts the trigger “Dead Band” at the fully pulled position.
5.
Replace cover and install screws.
2-3.0.0
ampsetup 1/2000
INSTALLATION & SETUP PROCEDURE DIGITAL
PULSE WITH AMPLIFIER
Figure 1
2-3.1.0
ampsetup 1/2000
OVERLOAD SYSTEM / ANTI-2-BLOCK
TROUBLE SHOOTING GUIDE
IF THE THREE FUNCTIONS, BOOM DOWN, HOIST UP AND
EXTEND OUT, QUIT WORKING,
the problem probably lies in either the Overload
System or the Anti-2-block system or both. If these three functions are NOT WORKING and most other functions are, an investigation should be made as follows: (refer to Figure 1)
1 ANTI-2-BLOCK
A. Unplug the anti-2-block system from the overload system and connect C and D to bypass the anti-2-block system.
1.
If the three functions work, check continuity of anti-2-block system using continuity tester at disconnected weather pack connectors, and investigate switch at end of boom, cable and cable reel.
2.
If the three functions do not work, continue on with section #2.
functions which could cause additional overload. In addition to this, when there is also a signal from the boom down solenoid to
RELAY B at the same time, RELAY B latches RELAY A so that even if the overload signal from the pressure switch to
RELAY A is removed, RELAY A will continue to be on and interrupt the ground circuit until the signal from the boom down solenoid and pressure switch are removed.
2.
The purpose of RELAY A is to interrupt the ground circuit and stop hoist up, boom down, and extend out functions from operating. The purpose of RELAY B is to stop boom bounce caused by the overload system cycling on and off.
2 LOAD SENSOR (Pressure Switch)
A. With crane unloaded, unplug weather pack connector on load sensor wire.
1.
If the three functions work, recheck the
Pressure Switch by taking an ohm reading on the two wires coming from the Switch.
The switch has normally open contacts, so the reading should be the maximum. If less than maximum ohm reading is indicated
(usually a dead short), replace the Switch.
2.
If the three functions do not work, continue with section #3.
3 RELAY BOX
A. Inside this box are two 320355 relays. Since these are inexpensive relays, the easiest way to trouble shoot this device is to replace both relays.
1.
The two relays are identical but serve different functions. RELAY A is the one with the most wires going to its connector.
RELAY A breaks the circuit between the ground side of the solenoid valves on boom down, extend out, and hoist up functions.
This happens whenever the overload switch on the lift cylinder senses more than normal pressure indicating an overload condition.
When overload happens then 12 volts is passed through the overload switch to pull in
RELAY A which then interrupts the ground circuit of the valves controlling those
4 OPERATIONAL TEST AND TROUBLE
SHOOTING OF RELAY BOX
A. After the anti-2-block test and the load sensor tests have been performed and the overload system still does not operate, check the relay box.
1.
Disconnect the weatherpak connector in the load sensor pressure switch wires going from the pressure switch to the relay box.
Disconnect the weatherpak connector between the cord reel and the relay box.
2.
Check for 12 volts at pin B of load sensor connector on relay box side of harness.
Short from pin A to pin B of weatherpak.
When pins A & B are shorted there should
NOT be continuity from the cord reel weatherpak on the relay box side of the connection to ground. When A & B are not shorted there should be continuity to ground. Replace relay A if these conditions are not met.
3.
If the boom tends to bounce when booming down due to intermittent cycling of the overload system, then RELAY B should be replaced after verifying that the sense wire from the relay box to the boom down solenoid valve control terminal is connected.
2-6.0.0
OVLD 1/2000
OVERLOAD SYSTEM / ANTI-2-BLOCK
TROUBLE SHOOTING GUIDE
Figure 1
2-6.0.1
OVLD 1/2000
OPTIMETER TROUBLESHOOTING
GUIDE for 9006
FOLLOW THE TROUBLESHOOTING SEQUENCE
1 Obtain the proper wiring diagram and check wiring.
2 With truck running, and master switch on, check terminal “L” voltage.
A. If 12 - 13.75 volts, proceed.
B. If not, check for blown fuse or broken wires.
3 Install pendant, turn system power on and check voltage between “T & N” should read less than
3 volts increasing to 9 volts when trigger is pulled.
A. If no voltage or low voltage (less than truck voltage), make sure the power switch on the eight switch pendant is in the "on" position.
B. Then, check for loose connection in the pendant or a broken wire in the pendant cable.
4 Disconnect bullet connectors on wires connecting from proportional valve din connector. Then ground brown wire to a chassis ground and connect blue wire to 12 volts. This should operate crane at maximum speed. If not, check proportional valve. This will send maximum current thru proportional valve and should close it completely.
OR
5 Depress the manual operator pin on top of the valve with an allen wrench till valve closes completely.
6 Check for proper crane operation.
A. If crane operates properly, proceed.
B. If not, check coil resistance from pin to pin
(should be 5.0 ohms) and from pin to ground ring on coil (should be infinite resistance). If resistance is much different than above, replace coil, then proceed.
C. Re-connect brown and blue wire.
7 Pull trigger and check for red light inside amplifier then perform the following adjustments with the trigger pulled to the maximum position:
A. Light off y Turn small trim pot screw ccw (left) till light just gets bright, then stop. (if 10 turns do not turn light on, look for more than 9 volts at term "m")
B. Light on y Turn small trim pot screw cw (right) till light just turns off, then turn ccw (left) till light just gets bright, then stop. (If
10 turns do not turn light off, look for less than 1 volt at term "m" )
8 Release trigger.
9 Set two adjustment switches ( hi & lo ) to number "4". (One side of the switch knob has an indicator)
10 The LO switch takes the "dead space" out of the beginning trigger activation, and will continue to raise the low signal to give half flow with the trigger at full released position. The higher the number or letter (0 thru f), the higher the flow to the crane with the trigger in the fully released position.
2-7.0.0
9006optrbl 11/99
OPTIMETER TROUBLESHOOTING
GUIDE for 9006
11 The HI switch takes the "dead space" out of the full trigger position, and will continue to lower the high signal to half the flow at the maximum trigger pulled position. The higher the number or letter (0 thru f), the lower the flow to the crane with the trigger in the fully pulled position.
12 A good starting position would be to have both switches on the number "4".
NOTE: Both switches on "F" will limit flow to a median value and not allow any change.
2-7.1.0
9006optrbl 11/99
ENGINE START/STOP RELAY KIT
P/N 480533
ITEM
1
2
7
8
9
10
3
4
5
6
QUANTITY
2
2
6’
49’
17’
35’
10
2
3
3
PART NUMBER
320355
320363
320357
480495
000402
000501
800595
800590
800593
800594
DESCRIPTION
12V RELAY
RELAY PLUG
FEMALE SPADE LOCK CONNECTOR
FLANGED SPADE TERMINAL
1/4 TERMINAL RING
5/16 TERMINAL RING
GREEN 16 GA WIRE
BLACK 16 GA WIRE
RED 16 GA WIRE
BLUE 16 GA WIRE
2-9.0.0
AW480533 11/99
AUXILIARY RELAY KIT
P/N 480534
5
6
7
8
9
ITEM
1
2
3
4
QUANTITTY
2
2
5
2
1
1
38’
10’
25’
PART NUMBER
320355
320363
320357
000101
000402
000501
800595
800593
800592
DESCRIPTION
12V RELAY
RELAY PLUG
FEMALE SPADE LOCK CONNECTOR
#6 TERMINAL RING
1/4 TERMINAL RING
5/16 TERMINAL RING
GREEN 16 GA WIRE
RED 16 GA WIRE
WHITE 16 GA WIRE
2-9.1.0
AW480534 11/99
HYDRAULICS
Counterbalance Valve Adjustment
{ With PTO disengaged and boom properly supported, remove o-ring plug
(item 17) shown on AW-573 marked
"X" port (see CB valve diagram).
Install a pressure gauge (0-2500 PSI) into the port.
{ Engage PTO and insure pump flow is 10 gpm and main relief is set to 2100 psi.
With no load on boom, boom up to an angle of 70 degrees. Boom down and note pressure. If pressure reading is not approximately 1050 PSI, the counterbalance valve requires adjustment.
v To increase the CB valve setting, loosen nut and turn Allen head screw counter clockwise. (Reference item 16, located on the side of the
CB valve block towards the right side of the boom.) v To reduce the CB valve setting, loosen nut and turn Allen head screw clockwise.
9006
{ Tighten nut on adjustment screw and repeat procedure if needed to obtain the proper pressure setting.
{ Disengage PTO, remove the pressure gauge and install -6 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 heed warning may result in personal injury!
3-2.0.0
9006HYD 11/99
HYDRAULIC TROUBLESHOOTING
9006
CAUTION: Never check for hydraulic leaks by feeling around hoses, fittings, or any other components.
High pressure oil can be injected through the skin causing severe injury, or death.
The hydraulic system of the 9006 power version is electrically operated and requires a minimum of 12V DC for satisfactory performance. The hydraulic pump is bi-rotational with a pressure relief setting of 2100 psi (Ref.). Standard pump speed is 1100 rpm (Ref. Pump P/N 367215). This pump is for direct flange mounting only. It is not to be shaft driven unless it has the outboard bearing installed (367215003).
PROBLEM
SOLUTION
FLOW PRESENT BUT FUNCTION
WILL NOT WORK
Remove valve cover to gain access to the manual override on the end of the valve cartridge. If the pump is operating, operate the relief valve manual override or the proportional valve override and push and twist
(CCW) the directional control valve manual override to unlock, then pull to operate the function. If the function does operate, check for loose wire, low voltage or bad ground. If the problem is traced to no voltage at the valve cartridge, remove pendant and with the switch engaged, check for an open circuit with an ohmmeter. If the circuit is open, check for broken wiring or bad switch. If the function does not operate, see the "NO
FLOW" paragraph in this section.
HYDRAULIC "CHATTER"
When a hydraulic function is engaged and causes the crane to "chatter", check for loose wire, low voltage at valve cartridge, low pump pressure, or air in the system.
NO FLOW OR LIMITED FLOW TO
CRANE
Check for adequate oil supply in reservoir. Check operation of bypass system by using manual override on proportional valve operator on proportional valve while operating crane. If crane functions, follow proportional trouble shooting procedure for the proportional valve. 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 4 gpm or greater from 0 psi to
2000 psi is cause for pump investigation
3-3.0.0
9006hydtbl 11/99
HYDRAULIC TROUBLESHOOTING
9006
NO PRESSURE OR TOO LOW
PRESSURE
Check to maintain adequate oil in reservoir (approximately 18 gallons), using the sight gauge. Make sure pressure gauge is functioning correctly.
Possible relief valve stuck open. Check for excessive leakage and correct.
Check to ensure that pressure limit switch is correctly set.
TOO HIGH FLOW
TOO HIGH PRESSURE
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 9006 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.
3-3.1.0
9006hydtbl 11/99
LUBRICATION & MAINTENANCE
SCHEDULE for 9006
SERVICE
PERFORMED
LOAD HOOK
CABLE DRUM
HOIST CABLE
HYDRAULIC HOSES
HYDRAULIC FLUID
MOUNTING BOLTS
ROTATION RING
GEAR
SHEAVE BEARINGS
DAILY WEEKLY
X
X
X
X
MONTHLY YEARLY
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
X CHECK FLUID LEVEL
X
X
X
CHECK-TORQUE TO 440
FT-LBS (DRY) AS REQUIRED
LUBE WITH MOBILTAC LL, OR
LUBRIPLATE P/N 15263, OR
EQUIVALENT
SEALED BEARING, REPLACE
IF ROUGH OR LOOSE
ALL OTHER BOLTS
BOOM PIVOTS
BOOM CYLINDER
X
X
X
X
CHECK-TIGHTEN AS
REQUIRED
GREASE WITH MOBILPLEX
EP-2 OR EQUIV. @ ZERKS
CHECK AROUND CYLINDER
ROD FOR EXCESS FLUID
LEAKAGE
GREASE WITH MOBILPLEX
EP-2 OR EQUIV. @ ZERKS
BOOM CYLINDER
PINS
EXTENSION PIN
RETURN LINE
FILTER
HIGH PRESSURE
FILTER
ROTATION
BEARING
ROTATION
BEARING BOLTS
ROTATION GEAR
BOX
X
X
X
X
X
X
LUBE w/ WD-40
REPLACE ELEMENT
CLEAN AFTER FIRST WEEK,
THEN EVERY 3 MONTHS
(OPTIONAL EQUIPMENT)
GREASE WITH MOBILPLEX
EP-2 OR EQUIV. @ ZERKS
CHECK-TORQUE TO 150
FT-LBS (DRY) AS REQUIRED
CHECK-TORQUE TO 180
FT-LBS (DRY) AS REQUIRED
3-4.0.0
9006MTSCH 11/99
LUBRICATION & MAINTENANCE
SCHEDULE for 9006
SERVICE
PERFORMED
ROTATION GEAR
BOX
DAILY WEEKLY MONTHLY YEARLY
X
NOTES
EP GEAR LUBE GL-5, 85W-140
HOIST GEARBOX X WORM GEAR-EP GEAR LUBE
SAE 80-90
HYDRAULIC FLUID X DRAIN, FLUSH, & REFILL
WITH MOBIL DTE 13, OR
EQUIVALENT (more often under extreme service)
BOOM SLIDE PADS PADS GREASED WHEN REPLACED
FOR ADDITIONAL 1) OWNER’S MANUAL
INFORMATION SEE: 2) OSHA SECTION 1910.180
3) ANSI B30.5-1989
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.
3-4.1.0
9006MTSCH 11/99
PEDESTAL ASSEMBLY
P/N 454140 for 9006 SERIES
4-1.1.0
AW454140 12/99
PEDESTAL ASSEMBLY
P/N 454140 for 9006 SERIES
4-1.1.1
AW454140 12/99
PEDESTAL ASSEMBLY
P/N 454140 for 9006 SERIES
4-1.1.2
AW454140 12/99
PEDESTAL ASSEMBLY
P/N 454140 for 9006 SERIES
4
5
6
7
8
9
10
11
12
13
14
15
16
ITEM
1
2
3
17
18
19
20
21
22
23
24
25
26
27
30
35
36
37
38
39
40
41
42
43
47
48
49
50
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
6
4
1
1
6
6
6
10
16
10
46
3
37
2
2
2
1
1
1
1
1
6
2
2
5
6
1
4
4
4
PART NUMBER
466143
372064
466145
466185
367005
367158
466101
466151
466235
454130
466183
005500
020300
466152
366159
021100
330372
007804
016500
020601
020901
023902
490172
490171
012198
367200
006205
374103
008401
466196
466198
466203
008701
002615
480024
015900
020200
REFERENCE
021200
002609
015600
DESCRIPTION
BASE PLATE
ROTATION BEARING
PEDESTAL WELDMENT
SWING DRIVE SPACER PLATE
SWING DRIVE
4.5 IN.
3 /REV HYDRAULIC MOTOR (SWING DRIVE)
BOOM UP CYLINDER
VALVE BANK MOUNTING PLATE
ELECTRIC DIRECTIONAL VALVE
WINCH ASSEMBLY
PEDESTAL COVER PLATE
CAPSCREW 1/4 UNC x 3/4
FLAT WASHER 1/4
PEDESTAL PIN WELDMENT
CAPSCREW 3/8 UNC x 1 1/2 GR 8
LOCK WASHER 3/8
NUT 3/8 UNC
CAPSCREW 5/16 UNC x 1 1/4 GR 8
NUT 5/16
LOCK WASHER 5/16
FLAT WASHER 5/16
HARDENED FLAT WASHER 5/8
CAPSCREW 5/8 UNC x 1 1/2 GR 8
CAPSCREW 5/8 UNC x 2 1/4 GR 8
CAPSCREW 5/8 UNC x 1 3/4 GR 8
SOCKET HEAD SCREW 5/8 UNC x 2 1/4
SOCKET HEAD SCREW 5/8 UNC x 1 1/4
HYDRAULIC MOTOR O-RING (SWING DRIVE)
CAPSCREW 3/8 UNC x 1/2
ROTATION STOP
SWITCH COVER
SWITCH PANEL ASSEMBLY
CAPSCREW 3/8 UNC x 1
SELF TAPPING CAPSCREW 1/4 UNC x 3/8
CABLE RETAINER
NUT 1/4 UNC
WASHER 1/4
ELECTRICAL SCHEMATIC (466190)
FLAT WASHER 3/8
ROUND HEAD SCREW #10 UNF X 5/8
NUT #10 UNF
4-1.1.3
AW454140 12/99
PEDESTAL ASSEMBLY
P/N 454140 for 9006 SERIES
ITEM
64
65
69
71
72
73
74
90
91
92
93
94
95
51
52
53
54
60
61
62
63
96
98
99
101
102
103
104
105
107
108
109
110
111
112
1
1
1
4
1
1
1
1
1
1
1
1
2
QUANTIT
Y
4
1
2
2
1
1
1
1
4
1
1
4
6
2
2
2
2
2
2
1
1
1
PART NUMBER DESCRIPTION
019800
466246
367185
021500
466195
466209
466236
466194
466193
466237
466220
015500
370433
000601
466184
REFERENCE
360223
REFERENCE
REFERENCE
367124
REFERENCE
367163
466182
374079
362020
202756
480198
480194
200876
372044
369127
REFERENCE
374068
REFERENCE
REFERENCE
LOCK WASHER #10
HOLE PLUG 1 1/8 DIAMETER
SOCKET HEAD SCREW ½ -13 UNC X 1 1/4
LOCK WASHER 1/2
CRANE PIGTAIL WIRING HARNESS
LOAD SENSOR ASSEMBLY
RELAY BOX ASSEMBLY
GROUND WIRE ASSEMBLY
CONDUCTOR ASSEMBLY
DIN PLUG ASSEMBLY
WIRE ASSEMBLY WITH WEATHER PAC
NUT #8 UNC
CORD CONNECTOR
TERMINAL RING 14-3/8
CONDUIT NUT 3/4
POWER EXTENSION CYLINDER (466100)
COUNTERBALANCE VALVE CARTRIDGE (LIFT CYLINDER)
HYDRAULIC MOTOR WINCH
COUNTERBALANCE VALVE (EXTENSION CYLINDER) (367407)
COUNTERBALANCE VALVE ROTATION
CAPSCREW 1/4-20 UNC X 1 ¾ (005810)
SOCKET HEAD SCREW 5/16 -18 UNC X 2 1/4
BULKHEAD ADAPTER -10 JIC(M)/-10 JIC(M)
BULKHEAD ADAPTER -12 JIC(M)/-12 JIC(M)
90° ELBOW -8 JIC (M)/-8 OR(M)
ADAPTER -8 OR(M)/-6 JIC(M)
90° ELBOW -10 OR(M)/-6 JIC(M)
90° ELBOW -6 JIC SWIVEL/-6 JIC(M) LG
STRAIGHT ADAPTER -8 OR(M)/-8 JIC(M)
90° ELBOW -10 OR(M)/-8 JIC(M)
90° ELBOW -4 JIC/-4 JIC(M)
45° ELBOW -6 JIC(M)/-8 JIC SWIVEL (330647)
SWING DRIVE HOSE ASSEMBLY
90° ELBOW -6 NPT/-6 JIC(M) (200892
TEE -6 OR(M)/-6 JIC(M) RUN (241168)
AW454140 12/99 4-1.1.4
PEDESTAL ASSEMBLY
P/N 454140 for 9006 SERIES
ITEM
113
114
115
116
117
118
119
120
121
122
123
QUANTITY
1
1
1
1
1
2
1
1
1
1
1
PART NUMBER
REFERENCE
812328-016
812327-016
812312-016
812309-020
812209-036
812209-033
812206-033
812206-016
812206-015
466239
DESCRIPTION
TUBE ASSEMBLY (480212)
HOSE ASSEMBLY -10(F)/-8 JIC(F) 90° ELBOW (SHORT) X 16
HOSE ASSEMBLY -12(F)/-8 JIC(F) 90°E LBOW X 15
HOSE ASSEMBLY (M)JIC/(F)JIC 90° ELBOW (LONG) X 16
HOSE ASSEMBLY (F)JIC SWIVEL/(F)JIC 90° ELBOW (SHORT) X 20
HOSE ASSEMBLY (F)JIC SWIVEL/(F)JIC 90° ELBOW (SHORT) X 36
HOSE ASSEMBLY (F)JIC SWIVEL/(F)JIC 90° ELBOW (SHORT) X 33
HOSE ASSEMBLY (F)JIC/(F)JIC 90° ELBOW (LONG) X 33
HOSE ASSEMBLY (F)JIC/(F)JIC 90° ELBOW (LONG) X 16
HOSE ASSEMBLY (F)JIC/(F)JIC 90° ELBOW (LONG) X 15
TUBE ASSEMBLY -8 HOIST
Note: Item Numbers not used: 28, 29, 31, 32, 33, 34, 44, 45, 46, 55, 56, 57, 58, 59, 66, 67, 68, 70, 75,
76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 97, 100, 106.
Valve Bank Cover, P/N 466200, not shown.
4-1.1.5
AW454140 12/99
PEDESTAL ASSEMBLY
P/N 454150 for 9006 SERIES
4-1.2.0
AW454150 12/99
PEDESTAL ASSEMBLY
P/N 454150 for 9006 SERIES
4-1.2.1
AW454150 12/99
PEDESTAL ASSEMBLY
P/N 454150 for 9006 SERIES
4-1.2.2
AW454150 12/99
PEDESTAL ASSEMBLY
P/N 454150 for 9006 SERIES
4
5
6
7
8
9
10
11
12
13
14
15
16
ITEM
1
2
3
17
18
19
20
21
22
23
24
25
26
27
30
35
36
37
38
39
40
41
42
43
47
48
49
50
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
6
4
1
1
6
6
6
10
16
10
46
3
37
2
2
2
1
1
1
1
1
6
2
2
5
6
1
4
4
4
PART NUMBER
466143
372064
466145
466185
367005
367158
466101
466151
466235
454130
466183
005500
020300
466152
366159
021100
330372
007804
016500
020601
020901
023902
490172
490171
012198
367200
006205
374103
008401
466196
466198
466203
008701
002615
480024
015900
020200
REFERENCE
021200
002609
015600
DESCRIPTION
BASE PLATE
ROTATION BEARING
PEDESTAL WELDMENT
SWING DRIVE SPACER PLATE
SWING DRIVE
4.5 IN.
3 /REV HYDRAULIC MOTOR (SWING DRIVE)
BOOM UP CYLINDER
VALVE BANK MOUNTING PLATE
ELECTRIC DIRECTIONAL VALVE
WINCH ASSEMBLY
PEDESTAL COVER PLATE
CAPSCREW 1/4 UNC x 3/4
FLAT WASHER 1/4
PEDESTAL PIN WELDMENT
CAPSCREW 3/8 UNC x 1 1/2 GR 8
LOCK WASHER 3/8
NUT 3/8 UNC
CAPSCREW 5/16 UNC x 1 1/4 GR 8
NUT 5/16
LOCK WASHER 5/16
FLAT WASHER 5/16
HARDENED FLAT WASHER 5/8
CAPSCREW 5/8 UNC x 1 1/2 GR 8
CAPSCREW 5/8 UNC x 2 1/4 GR 8
CAPSCREW 5/8 UNC x 1 3/4 GR 8
SOCKET HEAD SCREW 5/8 UNC x 2 1/4
SOCKET HEAD SCREW 5/8 UNC x 1 1/4
HYDRAULIC MOTOR O-RING (SWING DRIVE)
CAPSCREW 3/8 UNC x 1/2
ROTATION STOP
SWITCH COVER
SWITCH PANEL ASSEMBLY
CAPSCREW 3/8 UNC x 1
SELF TAPPING CAPSCREW 1/4 UNC x 3/8
CABLE RETAINER
NUT 1/4 UNC
WASHER 1/4
ELECTRICAL SCHEMATIC (466190)
FLAT WASHER 3/8
ROUND HEAD SCREW #10 UNF X 5/8
NUT #10 UNF
4-1.2.3
AW454150 12/99
PEDESTAL ASSEMBLY
P/N 454150 for 9006 SERIES
ITEM
64
65
69
71
72
73
74
90
91
92
93
94
95
51
52
53
54
60
61
62
63
96
98
99
101
102
103
104
105
107
108
109
110
111
112
1
1
1
4
1
1
1
1
1
1
1
1
2
QUANTIT
Y
4
1
2
2
1
1
1
1
4
1
1
4
6
2
2
2
2
2
2
1
1
1
PART NUMBER DESCRIPTION
019800
466246
367185
021500
466195
466209
466236
466194
466193
466237
466220
015500
370433
000601
466184
REFERENCE
360223
REFERENCE
REFERENCE
367124
REFERENCE
367163
466182
374079
362020
202756
480198
480194
200876
372044
369127
REFERENCE
374068
REFERENCE
REFERENCE
LOCK WASHER #10
HOLE PLUG 1 1/8 DIAMETER
SOCKET HEAD SCREW ½ -13 UNC X 1 1/4
LOCK WASHER 1/2
CRANE PIGTAIL WIRING HARNESS
LOAD SENSOR ASSEMBLY
RELAY BOX ASSEMBLY
GROUND WIRE ASSEMBLY
CONDUCTOR ASSEMBLY
DIN PLUG ASSEMBLY
WIRE ASSEMBLY WITH WEATHER PAC
NUT #8 UNC
CORD CONNECTOR
TERMINAL RING 14-3/8
CONDUIT NUT 3/4
POWER EXTENSION CYLINDER (466100)
COUNTERBALANCE VALVE CARTRIDGE (LIFT CYLINDER)
HYDRAULIC MOTOR WINCH
COUNTERBALANCE VALVE (EXTENSION CYLINDER) (367407)
COUNTERBALANCE VALVE ROTATION
CAPSCREW 1/4-20 UNC X 1 ¾ (005810)
SOCKET HEAD SCREW 5/16 -18 UNC X 2 1/4
BULKHEAD ADAPTER -10 JIC(M)/-10 JIC(M)
BULKHEAD ADAPTER -12 JIC(M)/-12 JIC(M)
90° ELBOW -8 JIC (M)/-8 OR(M)
ADAPTER -8 OR(M)/-6 JIC(M)
90° ELBOW -10 OR(M)/-6 JIC(M)
90° ELBOW -6 JIC SWIVEL/-6 JIC(M) LG
STRAIGHT ADAPTER -8 OR(M)/-8 JIC(M)
90° ELBOW -10 OR(M)/-8 JIC(M)
90° ELBOW -4 JIC/-4 JIC(M)
45° ELBOW -6 JIC(M)/-8 JIC SWIVEL (330647)
SWING DRIVE HOSE ASSEMBLY
90° ELBOW -6 NPT/-6 JIC(M) (200892
TEE -6 OR(M)/-6 JIC(M) RUN (241168)
AW454150 12/99 4-1.2.4
PEDESTAL ASSEMBLY
P/N 454150 for 9006 SERIES
ITEM
113
114
115
116
117
118
119
120
121
122
123
QUANTITY
1
1
1
1
1
2
1
1
1
1
1
PART NUMBER
REFERENCE
812328-016
812327-016
812312-016
812309-020
812209-036
812209-033
812206-033
812206-016
812206-015
466239
DESCRIPTION
TUBE ASSEMBLY (480212)
HOSE ASSEMBLY -10(F)/-8 JIC(F) 90° ELBOW (SHORT) X 16
HOSE ASSEMBLY -12(F)/-8 JIC(F) 90°E LBOW X 15
HOSE ASSEMBLY (M)JIC/(F)JIC 90° ELBOW (LONG) X 16
HOSE ASSEMBLY (F)JIC SWIVEL/(F)JIC 90° ELBOW (SHORT) X 20
HOSE ASSEMBLY (F)JIC SWIVEL/(F)JIC 90° ELBOW (SHORT) X 36
HOSE ASSEMBLY (F)JIC SWIVEL/(F)JIC 90° ELBOW (SHORT) X 33
HOSE ASSEMBLY (F)JIC/(F)JIC 90° ELBOW (LONG) X 33
HOSE ASSEMBLY (F)JIC/(F)JIC 90° ELBOW (LONG) X 16
HOSE ASSEMBLY (F)JIC/(F)JIC 90° ELBOW (LONG) X 15
TUBE ASSEMBLY -8 HOIST
Note: Item Numbers not used: 28, 29, 31, 32, 33, 34, 44, 45, 46, 55, 56, 57, 58, 59, 66, 67, 68, 70, 75,
76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 97, 100, 106.
Valve Bank Cover, P/N 466200, not shown.
4-1.2.5
AW454150 12/99
BOOM ASSEMBLY
P/N 454120 - 9006 SERIES
4-2.0.0
AW454120 12/99
BOOM ASSEMBLY
P/N 454120 - 9006 SERIES
4-2.1.0
AW454120 12/99
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
ITEM
1
2
3
4
5
6
7
8
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
1
1
1
10
1
4
4
6
1
2
1
2
1
2
1
QTY
1
1
1
1
1
1
1
1
2
2
2
16
4
4
4
8
4
28
8
1
1
1
1
1
BOOM ASSEMBLY
P/N 454120 - 9006 SERIES
018600
480030
466218
480037
480118
480036
480032
480033
366201
480105
REF
466186
239000
480121
480129
P/N
454100
454110
466116
480015
466130
360124
360125
014400
480029
360038
016300
005102
005601
005501
005406
010201
020300
020200
021500
REF
REF
466135
366973-001
466243
DESCRIPTION
LOWER BOOM
POWER BOOM
MANUAL BOOM
POWER EXTENSION CYLINDER
SHEAVE ASSEMBLY 7/16 ROPE
HITCH PIN
BLOCK PIN
CAPSCREW ¾ UNF x 5
NUT ¾ UNF
MANUAL BOOM PIN
STEEL PAD 3 x 2 x 5/16 THICK
SMALL SHIM .032 THICK (use as required)
POWER BOOM PAD
SMALL NYLATRON BOOM PAD
LARGE NYLATRON BOOM PAD
LARGE SHIM .032 THICK
BOOM PAD
EXTENSION CYLINDER RETAINER
BOOM / CYLINDER PIN (466126)
STEEL-POWER BOOM PAD
GREASE ZERK
SPACER
EXTENSION CYLINDER PIN
RETAINING RING
ANGLE INDICATOR
HEX LOCK NUT ¼ UNC
CAPSCREW ¼ UNF x 5/8
CAPSCREW ¼ UNF x 1
CAPSCREW ¼ UNF x 3/4
CAPSCREW ¼ UNF x 1/2
CAPSCREW ¼ UNF x 1 1/2
FLAT WASHER 1/4
LOCK WASHER 1/4
LOCK WASHER 1/2
CAPSCREW 3/8 UNC x 1 1/2 GR8 (366159)
NYLOCK NUT 3/8 UNC (370538)
2-BLOCK WELDMENT
REEL CORD ASSEMBLY
2-BLOCK SWITCH ASSEMBLY
4-2.2.0
AW454120 12/99
ITEM
41
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
1
1
1
1
1
2
1
1
QTY
7
3
1
2
2
1
1
2
1
1
BOOM ASSEMBLY
P/N 454120 - 9006 SERIES
P/N
REF
000115
009116
330372
360824
466167
480212
016801
020901
642918
330412
020200
005810
480194
200876
330647
200892
241168
DESCRIPTION
D-RING
#15 CLIP
CAPSCREW 3/8 UNF x 2
NUT 3/8 UNC
RETURN SPRING
CAPSCREW 5/16 UNC x 7
TUBE ASSEMBLY
HEX LOCK NUT 5/16UNC
FLAT WASHER 5/16
CORD CONNECTOR
EXTENSION CYLINDER COUNTERBALANCE VALVE
LOCK WASHER 1/4
CAPSCREW ¼ UNC x 1 3/4
90º ELBOW -6 JIC SWIVEL/-6 JIC(M) LONG
STRAIGHT ADAPTER -6 OR(M)/-6 JIC(M)
45º ELBOW -6 JIC(M)/-6 JIC(M) SWIVEL
90º ELBOW -6 NPT/-6 JIC(M)
TEE -6 OR(M)/-6 JIC(M) RUN
4-2.3.0
AW454120 12/99
AUTOMATIC SAFETY BRAKE ASSEMBLY
(OIL COOLED) HOIST
ASSEMBLY INSTRUCTIONS:
1.
Winch has right hand worm and gear. Cable spools over drum. Use number one slots for brake balls(7) in cam plate(2).
2.
Install brake hub(5) through brake housing(4) on winch worm with key.
3.
Assemble balls(7) in cam plate(2) using hard grease to hold balls in place.
4.
Place cam plate(2) on brake hub(5), matching its holes with the balls.
5.
Install thrust plate(16).
6.
Thread capscrew(10) with jam nut (12) and thread seal (11) through housing cover(3).
7.
Place gasket(15) on housing cover(3).
8.
Install coil spring(9) on capscrew(10).
9.
Install flat spring(1) on capscrew(10).
10.
Secure retainer plate(6) and flat spring(1) to housing cover(3) using capscrews(8) and washers(14).
11.
Using capscrews(8) and thead seals(13) attach housing cover(3) to brake housing(4).
12.
Test brake by shifting winch to UP then DOWN to see if brake is working in proper rotation. If not, remove housing cover(3) and locate brake balls(7) in opposite set of slots of cam plate(2).
13.
Adjust to suit by tightening or loosening capscrew(10) on outside of housing cover(3). When proper adjustment is obtained, secure capscrew(10) with jam nut(12).
AW368 12/99
4-3.1.0
AUTOMATIC SAFETY BRAKE ASSEMBLY
(OIL COOLED) HOIST
5
6
7
8
9
ITEM
1
2
3
4
10
11
12
13
14
15
16
1
1
2
6
1
QTY
1
1
1
1
1
4
1
1
2
1
1
P/N
360367
360331
360450
360336
360339
360342
360345
360453
360368
360456
360371
360353
360465
360455
360359
360364
4-3.0.0
DESCRIPTION
FLAT SPRING
CAM PLATE
HOUSING COVER
BRAKE HOUSING
BRAKE HUB
RETAINER PLATE
BRAKE BALL
CAPSCREW 1/4 UNC x 1
COIL SPRING
CAPSCREW 3/8 UNC x 1 1/2
THREAD SEAL
JAM NUT 3/8 UNC
THREAD SEAL
WASHER FLAT 1/4 ALUM
GASKET
THRUST PLATE
AW368 12/99
HOIST ACTUATOR
P/N 454135 - MODEL 9006
4-4.0.0
AW454135 1/2000
HOIST ACTUATOR
P/N 454135 - MODEL 9006
ITEM
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
QUANTITY
2
2
1
1
1
4
1
2
1
1
1
1
1
1
6
6
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
2
2
2
1
4
8
2
2
1
PART NUMBER
466175025
466175026
466175027
466175028
466175029
466175030
466175031
466175032
466175033
466175034
466175035
466175036
466175037
466175038
466175039
466175040
466175041
466175042
466175043
466175001
466175002
466175003
466175004
466175005
466175006
466175007
466175008
466175009
466175010
466175011
466175012
466175013
466175014
466175015
466175016
466175017
466175018
466175019
466175020
466175021
466175022
466175023
466175024
DESCRIPTION
MOTOR ADAPTER
FLAT SPRING
BUSHING
WORM BRAKE CAM PLATE
COUPLING
GEAR HOUSING COVER
BRAKE COVER
RIGHT HAND GEAR
GEAR HOUSING
BRAKE HOUSING
BRAKE HUB
WORM ROUND END KEY
PRIMARY ROUND END KEY
BRAKE RETAINER PLATE
OUTPUT SHAFT
RIGHT HAND WORM
BALL
BALL BEARING
HYDRAULIC ADAPTER COVER
CAPSCREW 5/16-18 UNC X 1
CAPSCREW 5/16-18 UNC X ¾ HEAVY/ PATCH NYLON
CAPSCREW 3/8-24 UNF X 1 ALL THREAD
CAPSCREW 1/2-13 UNC X 1 ¾ LOW CARBON
CAPSCREW 1/2-20 UNF X ¾ ALL THREAD
SOCKET HEAD SCREW 5/16-18 UNC X 1 HEAD
SOCKET HEAD SCREW 5/16-18 UNC X 1 ¼ LOK-WELL
JAM NUT 1/2-20 UNF
MEDIUM SECTION ZINC PLATED LOCK WASHER 5/16
ALUMINUM FLAT WASHER 3/8 I.D. X 5/8 O.D. X 1/16
BRAKE HOUSING GASKET
GEAR COVER GASKET
BRAKE HOUSING COVER GASKET
RELIEF FITTING
QUAD RING
REDUCER
GEAR HOUSING FILL SQUARE HEAD PIPE PLUG
GEAR HOUSING DRAW SQUARE HEAD PIPE PLUG
ROLL PIN
THRUST PLATE
OIL SEAL
THREAD SEAL
SPRING
VENT PLUG COVER
4-4.1.0
AW454135 1/2000
PENDANT RECEPTACLE ASSEMBLY IC
P/N 466254 - MODEL 9006
ITEM
1
2
3
6
7
4
5
QTY
1
3 FT
1
4
3
18
4 IN
P/N
366095
480459
480494
002013
636600
002010
490243
DESCRIPTION
19 PIN FEMALE BAYONET RECEPTACLE
16/19 COLD WEATHER CABLE PENDANT
22 STATION TERMINAL BLOCK
16-14 GA WIRE SPADE TERMINAL BLOCK
JUMPER
22-18 GA WIRE SPADE TERMINAL BLOCK
HEAT SHRINK TUBING x 4
5-2.0.0
AW466254 12/99
PENDANT RECEPTACLE ASSEMBLY IC
P/N 466255 - MODEL 9006
8
VIEW A-A
TRIM AS
REQUIRED
(2" MAX)
SOLDER CONNECTIONS &
PROTECT WITH SILICONE RTV
WIRING GUIDE
4
5
6
7
8
ITEM
1
2
3
QUANTITY
1
4.5 ft
.3 ft
1
4
4
4
1
PART NUMBER
366095
480459
490243
466252
000404
019600
015400
366097
DESCRIPTION
22 STATION/19 PIN FEMALE RECEPTACLE (BAYONET)
16/19 COLD WEATHER CABLE PENDANT
HEAT SHRINK TUBING
PENDANT RECEPTACLE BRACKET
ROUND HEAD SCREW #6-32 X 5/8
LOCK WASHER #6
NUT #6-32
BAYONET CAP
5-2.1.0
AW466254 12/99
PROPORTIONAL PENDANT CABLE ASSEMBLY
P/N 680128 - MODEL 9006
ITEM
1
2
3
4
5
6
QUANTITY
1
1
2
7
1
1
PART NUMBER
466192
680129
750737
640300
480567
001104
DESCRIPTION
22 STATION 16 FUNCTION PENDANT HEAD WITH AMP
BAYONET CABLE ASSEMBLY (COLD WEATHER)
CABLE TIE
TOGGLE BOOT
HUBBEL CONNECTOR CORD GRIP
BUTT CONNECTOR
5-3.0.0
AW680128 12/99
PROPORTIONAL PENDANT CABLE ASSEMBLY
P/N 680128 - MODEL 9006
NOTES:
1. TIE OFF THE FOLLOWING UNUSED CONDUCTORS WITH THE CABLE TIE (ITEM #3) INSIDE
THE PENDANT:
M - BLUE WITH BLACK
P - YELLOW WITH RED
2. BEFORE INSTALLING THE COVER, ADD RTV SEALANT BETWEEN THE COVER AND THE
PENDANT HOUSING.
5-3.1.0
AW680128 12/99
PROPORTIONAL PENDANT CABLE ASSEMBLY
P/N 680128 - MODEL 9006
AW680128 12/99
COLD WEATHER PENDANT CABLE ASSEMBLY
P/N 680129 - MODEL 9006
ITEM
1
2
3
4
5
6
7
QUANTITY
1
1
30 FT
1
1
17
.500 FT
PART NUMBER
366098
480515
480459
000101
480510
002012
490243
DESCRIPTION
CONNECTOR BAYONET PLUG
CABLE CLAMP
19 CONDUCTOR CABLE
TERMINAL RING #6 / 14-16 GA
FEMALE BULLET CONNECTOR
TERMINAL RING #6 / 18-22 GA
HEAT SHRINK TUBING
5-4.0.0
AW680129 12/99
IN-COMPARTMENT PENDANT INSTALLATION
9006 SERIES
ITEM
2
3
4
5
6
7
8
9
10
11
12
13
14
15
QUANTITY
1
1
1
1
4
4
4
1
6
6
3
2
2
2
PART NUMBER
466253
466254
480626
480493
000404
015400
019600
366097
750738
634401
330038
005500
015900
020200
DESCRIPTION
22 STATION TERMINAL BLOCK DECAL
PENDANT RECEPTACLE ASSEMBLY
PENDANT BRACKET
22 STATION TERMINAL BLOCK COVER
ROUND HEAD SCREW #6-32 UNC x 5/8
HEX NUT #6-32 UNC
SPLIT LOCK WASHER #6
19 PIN RECEPTACLE CAP
WIRE TIE STICK ON RETAINER
WIRE TIE x 7in.
SELF TAPPING CAPSCREW #10-24 UNC x 3/4
CAPSCREW 1/4-20 UNC x 3/4 Gr 5
HEX NUT 1/4-20 UNC
LOCK WASHER 1/4
Note: Item Number not used: 1.
5-5.0.0
AW178A 1/2000
IN-COMPARTMENT PENDANT INSTALLATION
9006 SERIES
AW178A 1/2000
CRANE MOUNTED PENDANT INSTALLATION
9006 SERIES
TO VALVES
CRANE WIRING
HARNESS
MOUNT ON
PEDESTAL BASE
7 8
CRANE BASE
9
SHIPPED
LOOSE
13
BACK WALL
OF CRANE
COMPARTMENT
6
15
14
5
2
3
7 8
NOTES:
1) SEE WIRING DIAGRAM, PAGE 5-6.0.0.
2) USE DECAL (ITEM 2) AS A DRILL TEMPLATE WHEN MOUNTING TERMINAL BLOCK AND COVER
3) MOUNT PENDANT BRACKET (ITEM 4) INSIDE CRANE COMPARTMENT WITH SCREWS SHOWN OR
WELD IN PLACE. IN AUTO CRANE BODIES, USE HOLES AS SHOWN TO MOUNT BRACKET IN
UPPER RIGHT REAR CORNER.
ITEM
2
3
5
6
7
8
9
10
11
12
13
14
15
QUANTITY
1
1
1
2
2
2
1
6
6
3
2
2
2
PART NUMBER
466253
466255
480493
000404
015400
019600
366097
750738
634401
330038
005500
015900
020200
Note: Item Numbers not used: 1, 4.
DESCRIPTION
22 STATION TERMINAL BLOCK DECAL
PENDANT RECEPTACLE ASSEMBLY
22 STATION TERMINAL BLOCK COVER
ROUND HEAD SCREW #6-32 UNC x 5/8
HEX NUT #6-32 UNC
SPLIT LOCK WASHER #6
19 PIN RECEPTACLE CAP
WIRE TIE STICK ON RETAINER
WIRE TIE x 7in.
SELF TAPPING CAPSCREW #10 UNC x 3/4
CAPSCREW 1/4 UNC x 3/4 Gr 5
HEX NUT 1/4 UNC
LOCK WASHER 1/4
5-5.1.0
AW178Acm 1/2000
9006
WIRING
5-6.0.0
WIRINGCRT 10/99
20 GALLON BULKHEAD RESERVOIR TANK
P/N 725550
ITEM
1
2
3
4
5
6
P/N
725552
360150
360285
750707
750708
750477
DESCRIPTION
RESERVOIR
RESERVOIR SIGHT PLUG
FILLER ASSEMBLY
SUCTION STRAINER
DIFFUSER STRAINER
PIPE PLUG
6-8.0.0
725550 1/99
18 GALLON RESERVOIR
P/N 750690
9
10
7
8
4
5
6
ITEM
1
2
3
11
12
1
1
1
1
2
2
2
2
1
QTY
1
1
1
P/N
750691
750712
750709
750716
750711
360151
750707
360150
750708
750477
009108
017400
DESCRIPTION
RESERVOIR WELDMENT
COVER
BAFFLE ADAPTER
CRUSH WASHER
END COVER BOLT
FILLER ASSEMBLY
SUCTION STRAINER
SIGHT PLUG
DIFFUSER STRAINER
PIPE PLUG -8
CAPSCREW 3/8 NC x 1 1/4
HEX LOCK NUT 3/8 NC
6-9.0.0
AW750690 10/98
HYDRAULIC OUTRIGGERS
CURBSIDE CRANE - P/N 766081
C D
7-1.0.0
AW766081 12/99
HYDRAULIC OUTRIGGERS
CURBSIDE CRANE - P/N 766081
16
17
18
19
20
21
22
23
24
10
11
12
13
14
15
25
26
27
28
29
30
31
32
33
34
5
6
7
8
9
ITEM
1
2
3
4
1
4
4
4
4
2
2
1
2
1
1
1
1
4
3
2
2
1
2
2
6
3
3
3
4
1
2
4
2
1
QTY
1
1
1
1
812026-081
021802
023800
330647
330645
241175
REF
812026-016
367136
320734
480194
766128
766046
759016
759017
040581
480195
008401
360445
369394
362020
811029
020601
016500
320371
P/N
REF
766174
766173
766172
766109
008300
021100
330372
490171
DESCRIPTION
BODY WELDMENT (766016)
STREET SIDE SLIDE ASSEMBLY
CURB SIDE SLIDE ASSEMBLY
VALVE BANK
TRUNNION MOUNT
FLAT HEAD SCREW 3/8 x 1
LOCK WASHER 3/8
NUT 3/8
CAPSCREW 5/8UNC x 2 1/4
HOSE ASSEMBLY -6 (F)/-6 (F)
FLAT WASHER 5/8 x 1 3/4
LOCK WASHER 5/8
45º SWIVEL ELBOW ADAPTER -6 JIC
90º EXTRA LONG ELBOW ADAPTER -6 JIC/-6 JIC (M)
90º ELBOW ADAPTER -6 ORM/-6 JIC (M)
90º ELBOW HOSE ASSEMBLY -6 (F)/-6 (F) (812209-018)
HOSE ASSEMBLY -6 (F)/-6 (F)
90º BULK HEAD ADAPTER -6 (M)/-6 (M)
BULK HEAD STRAIGHT ADAPTER -6 (M)/-6 (M)
90º ADAPTER -6 JIC (M)/-6 JIC SWIVEL
VALVE COVER
STREET/CURB COVER
DANGER DECAL
CAUTION DECAL
CAUTION “STAND CLEAR” DECAL
45º ADAPTER -6 ORB/-6 JIC
CAPSCREW 3/8UNC x 1/2
CAP -8
45º ADAPTER -8 SWIVEL /-8 JIC (M)
90º ADAPTER -8 JIC(M)/-8 OR(M)
CAPSCREW 5/16
`WASHER 5/16
NUT 5/16
SELF TAPPING SCREW #10-24 x 3/4
AW766081 12/99 7-1.1.0
HYDRAULIC OUTRIGGERS
STREETSIDE CRANE - P/N 766202
C D
7-1.2.0
AW766202 12/99
HYDRAULIC OUTRIGGERS
STREETSIDE CRANE - P/N 766202
16
17
18
19
20
21
22
23
24
10
11
12
13
14
15
25
26
27
28
29
30
31
32
33
34
5
6
7
8
9
ITEM
1
2
3
4
1
4
4
4
4
2
2
1
2
1
1
1
1
4
3
2
2
1
2
2
6
3
3
3
4
1
2
4
2
1
QTY
1
1
1
1
812026-081
021802
023800
330647
330645
241175
REF
812026-016
367136
320734
480194
766128
766046
759016
759017
040581
480195
008401
360445
369394
362020
811029
020601
016500
320371
P/N
REF
766174
766173
766172
766109
008300
021100
330372
490171
DESCRIPTION
BODY WELDMENT (766400)
STREET SIDE SLIDE ASSEMBLY
CURB SIDE SLIDE ASSEMBLY
VALVE BANK
TRUNNION MOUNT
FLAT HEAD SCREW 3/8 x 1
LOCK WASHER 3/8
NUT 3/8
CAPSCREW 5/8UNC x 2 1/4
HOSE ASSEMBLY -6 (F)/-6 (F)
WASHER 5/8 x 1 3/4
LOCK WASHER 5/8
45º SWIVEL ELBOW ADAPTER -6 JIC
90º EXTRA LONG ELBOW ADAPTER -6 JIC/-6 JIC (M)
90º ELBOW ADAPTER -6 ORM/-6 JIC (M)
90º ELBOW HOSE ASSEMBLY -6 (F)/-6 (F) (812209-018)
HOSE ASSEMBLY -6 (F)/-6 (F)
90º BULK HEAD ADAPTER -6 (M)/-6 (M)
BULK HEAD STRAIGHT ADAPTER -6 (M)/-6 (M)
90º ADAPTER -6 JIC (M)/-6 JIC SWIVEL
VALVE COVER
STREET/CURB COVER
DANGER DECAL
CAUTION DECAL
CAUTION “STAND CLEAR” DECAL
45º ADAPTER -6 ORB/-6 JIC
CAPSCREW 3/8UNC x 1/2
CAP -8
45º ADAPTER -8 SWIVEL /-8 JIC (M)
90º ADAPTER -8 JICM/-8 OR(M)
CAPSCREW 5/16
LOCK WASHER 5/16
NUT 5/16
SELF TAPPING SCREW #10-24 x 3/4
AW766202 12/99 7-1.3.0
HYDRAULIC OUTRIGGERS FLOW DIAGRAM
9006 SERIES
STREET SIDE
OUTRIGGER
CURB SIDE
OUTRIGGER
STREET SIDE
OUTRIGGER
CURB SIDE
OUTRIGGER
HANDLE SIDE
SELECTOR VALVE
P/N 480236
TANK
7-2.0.0
AW766081b 6/99
TRAVELING BLOCK ASSEMBLY
P/N 466230 - MODEL 9006
5
6
7
8
9
10
ITEM
1
2
3
4
QUANTITY
1
1
2
1
1
4
2
1
2
2
PART NUMBER
490256
480026
466231
490313
018600
360124
466232
466233
811023
017301
DESCRIPTION
SHEAVE BLOCK ASSEMBLY
5.5 TON SWIVEL HOOK
SIDE PLATE TRAVELING BLOCK
SHEAVE BOLT WITH ZERK FITTING 3/4 UNF x 4
HEX LOCK NUT 3/4 UNF
HITCH PIN
PIN BLOCK 1 DIA
ROUND TUBING 1 1/4 x .120W x 1 1/2 L
SCREW 3/8 UNC x 4
LOCK NUT 3/8 UNC
8-1.0.0
AW466230 12/99
LOAD CHART
P/N 454128 - 9006 SERIES
9-9.9.9
AW454128 11/99
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Key Features
- Safe, trouble-free, dependable service
- Holding valves prevent load from dropping
- 10u filter removes dirt and grit
- 15u air filter in filler cap
- 40 mesh strainer in suction line
