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OWNERS MANUAL
4004H
REVISION 2/2000
PART NO.
999997
SERIAL NO. __________________________
PO BOX 580697, TULSA, OK 74158-0697
4707 N. MINGO ROAD, TULSA, OK 74117-5904
PHONE (918) 836-0463
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
4004H SERIES - OWNER'S MANUAL
TABLE OF CONTENTS
7
8
9
10
11
12
13
14
15
16
17
18
19
20
5
6
3
4
1
2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING PRACTICES & WARNINGS . . . . . . . . . . . . . . . . . . . . . . . .
PAGE
1-1.0.0
1-2.0.0
OPERATION OF UNIT / OUTRIGGERS . . . . . . . . . . . . . . . . . . . . . . . . .
QUALIFICATIONS FOR OPERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION, TESTING, & MAINTENANCE . . . . . . . . . . . . . . . . . . . . .
LIFE OF WIRE LINE / WIRE LINE LUBRICATION . . . . . . . . . . . . . . . .
SAFETY DECAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3.0.0
1-4.0.0
1-5.0.0
1-6.0.0
LUBRICATION & MAINTENANCE SCHEDULE
INSTALLATION
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7.0.0
1-8.0.0
2-1.0.0
3-1.0.0
GENERAL ASSEMBLY (PEDESTAL) . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOIST ACTUATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC SAFETY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURNER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRAVELING BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4.0.0
3-5.0.0
3-6.0.0
3-7.0.0
3-8.0.0
GENERAL DIMENSIONS
ELECTRICAL SECTION
HYDRAULIC SECTION
LOAD CHART
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1.0.0
5-1.0.0
6-1.0.0
9-1.0.0
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LAST PAGE
GENERAL SPECIFICATIONS
4004H SERIES
6
7
8
9 ft
3
4
5
10
11
DIMENSIONS CHASSIS REQUIREMENTS
Width: 19.25 in (.49 m)
Height: 32.50 in (.83 m)
Length: 11 ft 8 5/16 in (3.58 m)
Weight: 1050 lbs (476 kg)
[Add 5 lbs (2.25 kg) for cable length
of 75 feet (23 m)]
10,500 lbs (4,763 kg) GVWR minimum
HYDRAULIC SYSTEM
Pressure: 2200psi (15,169 kPa) relief setting
Flow: 5 gpm (19 lpm)
CAPACITY
Filtration: High pressure 10 micron in
manifold 16,000 ft lbs (2.31 ton/m)
[ft lbs = horizontal distance from centerline of rotation to free hanging weight (feet) x amount of weight (pounds)]
Oil Type: 10w Hydraulic Oil
[Mobile DTE 13, Sun 2015,
Dextron II]
REACH
LIFTING CAPACITIES lbs
4,000
4,000
3,200 ft
12
13
14 lbs
1,333
1,231
1,143
2,666
2,286
2,000
1,778
1,600
1,455
15
16
17
18
19
20
Main boom reaches 10 ft
Power boom will extend to16 ft
Manual boom will extend to 20 ft
1,067
1,000
941
889
842
800
CABLE
80 ft (24.3 m) of 5/16 in diameter aircraft quality cable is standard [75 ft (22.86 m) optional].
MOVEMENT SPEEDS:
(Proportional Maximum)
Hoist: 34 fpm single line (no load)
31 fpm single line (1000 lbs)
Boom Up: 9 sec
Boom Down: 8 sec
Extend Out: 11 sec
Extend In: 9 sec
Rotation: 40 sec/revolution
ELECTRICAL SYSTEM
REQUIREMENTS
Control voltage: 12 volt DC
Alternator: 90 amp (minimum)
Battery: 100 minute reserve
capacity (minimum)
Maintenance type
1-1.1.0
4HSPEC 8/98
INTRODUCTION
4004H 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 4004EH 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. The reservoir has a 40u air filter in the filler cap. The pump has a 100
mesh strainer in the suction line.
For your convenience the overall dimensions of the
4004H series crane are in the General Dimension Section.
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 10,500 lbs. with two rear jacklegs (or outriggers) is recommended for mounting the 4004H series cranes.
The 4004H series cranes are attached directly to your 12 volt truck electrical system. The power cable and retaining clips are included with the crane. A typical power cable mounting and hookup is shown in the installation section.
The performance of your new crane depends on the truck electrical system. The use of maintenance free batteries is
NOT recommended for use with any Auto Crane product.
The recommended alternator and battery that will give the longest life with the most useful duty cycle is a 60 amp.
alternator with a 120 minute reserve capacity, deep cycle battery. These specifications should be considered minimum.
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 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.
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.
1-1.0.0
4HINTRO 6/98
--- 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. While operating the outrigger control valves
(located on the outrigger cylinders) simultaneously operate the boom-up control switch. This will allow the hydraulic system to build pressure.
3. After outriggers are positioned, return crane/outrigger selector to "crane" position.
4. Crane is now ready to operate.
1-3.0.0
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.
OPER 2/98
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.
1-4.0.0
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.
1-4.1.0
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.
1-4.2.0
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
1-5.0.0
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
1-5.1.0
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
1-5.2.0
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)
1-5.3.0
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.
1-5.4.0
INSP 9/98
LIFE OF WIRE LINE
So many variable factors can cause the deterioration of wire line cable that it is not possible to determine a definite life expectancy. Some of these factors are:
• Load being handled.
• Corrosive conditions.
• Maintenance of the unit:
Keep the sheaves turning freely.
Maintain tension on cable to insure proper spooling.
Avoid kinks in cable.
Avoid abrasive action and contact with sharp corner.
• Frequency of use.
Auto Crane units, up to 2,400 pound ratings use 3/16 inch diameter galvanized pre-formed 7 x 19 aircraft cable. This cable has a working strength, when new, of 4,200 pounds.
It is recommended when 1,200 pound loads are exceeded to use a two part line with a traveling block. This will ensure a 3.5 to 1 safety factor when the cable is new.
Keeping the above factor of safety in mind and knowing the kind of loads that will be handled, the user can determine by inspection of the cable as to when it should be replaced.
Items to look for while inspecting the cables are:
• Broken strands.
• Kinks and flattened sections.
• Corrosion and abrasion.
WIRE LINE LUBRICATION
Lubrication of the wire line serves two important purposes:
• Prevent corrosion.
• Reduce wear due to flexing and abrasion caused by contact with the sheaves, rollers, and cable on the drum.
Preparation
Remove rust and foreign matter with a wire brush and wipe clean. Be sure cable is dry.
Application
Method 1: Dip a brush into a light weight motor oil and apply. In some cases, dip a rag or a piece of sheepskin into the lubricant and swab the lubricant on to the rope.
Method 2: Apply a heavier lubricant such as a grease gun lubricant with hands while wearing leather gloves. (Leather gloves give greater protection and less penetration of the grease than canvas gloves.)
1-6.0.0
WIRE 1/2000
MAINTENANCE OF BATTERIES
Maintenance of Auto Crane unit batteries differs very little from the generally prescribed maintenance of any lead acid battery. All batteries must be kept properly charged, properly filled with water, and relatively clean .
Keep Properly Filled with Water
The battery should always be properly filled with water.
If the electrolyte level is allowed to fall below the top of the plates, the results become threefold:
Keep Properly Charged
1 The exposed portion of the plate will become sulfated.
Many things affect the proper charge to a battery, such as:
2 The portion of the plate exposed is not usable.
1 Regulator settings
3 That portion of the acid remaining becomes more concentrated and may cause more rapid deterioration of the remaining parts of the battery.
2 Proper tightness of belts on the alternator or generator
Keep A Relatively Clean Battery
3 Good, clean connections of all cables and wires at the following places:
A. Battery
B. Regulator
C. Starting motor
D. Alternator or generator
E. Ground connections (most important)
It is of extreme importance to keep the battery as fully charged as possible without overcharging, especially when vehicles are left outside for extended periods in extremely cold climates. A battery can freeze.
Freezing points for various specific gravities of acid are as follows:
The battery should be kept clean. Batteries filled with acid and which are not in use self-discharge to a limited degree because of the nature of the materials within the battery. If dirt is allowed to collect on the top of the battery (and this dirt absorbs moisture) and electrical path can be set up between the various terminals of the battery and the ground. Once such a path has been established, the self-discharge of the battery is accelerated. This also accelerates corrosion of the battery cables at the terminals.
Periodic Maintenance is Needed
Specific Gravity Freezing Temp.
(Corrected to 80ºF) Degrees F.
A definite program of periodic maintenance of all batteries should be conducted on a regular basis.
Periodic maintenance includes:
1.280 -90ºF
1.250 -62ºF
1.200 -16ºF
1.150 5ºF
1.100 19ºF
1
2
Checking belts for tightness on the charging equipment
Checking battery electrolyte levels
3 Checking cables for good connections
As shown, a half-charged battery (about 1.200 specific gravity) cannot stand for any length of time at 20ºF or it will freeze.
The main reason for keeping the battery as fully charged as possible without over-charging is to ensure that power is available even though the vehicle has been standing for some time.
4 Cleaning where corrosion is apparent
When corrosion is cleaned off, the cable terminals and battery terminals should be coated with a light coating of petroleum jelly before they are replaced. When terminals are cleaned, the top of the battery should be cleaned with a mild solution of soda water.
1-6.1.0.
MAINTBAT 9/98
MAINTENANCE OF BATTERIES
Low Maintenance Batteries
(Maintenance Free) should be attempted for an extended time. This usually will recover a badly sulfated battery.
Low maintenance batteries should not be used on
Auto Cranes or trucks equipped with Auto Cranes.
The batteries are not designed for "deep" discharge.
Replacing a Battery
If it is necessary to replace a battery, and a dry charge battery is used, the following procedure applies:
Testing Your Battery
1 Fill the battery with electrolyte of the proper specific gravity.
If the condition of the battery is in question, it should be removed from the vehicle, taken to the shop, and allowed to reach room temperature. It should then be recharged until specific gravity readings taken at one-half hour intervals. If the specific gravity readings are fairly uniform, the battery should be checked with a high rate tester. Use the tester in accordance with the manufacturer's instructions. The high rate tester is the best method to test a questionable battery.
2 Place the battery on charge according to the manufacturer's instructions.
It is essential that the second step above be followed to ensure that the battery going on the vehicle is fully charged.
If, after charging, it is noted that the specific gravity reading of one cell is 30 points less than any of the other cells, it may be assumed that the cell is bad and that the battery should be replaced. If all cells are uniform but not up to full charge, a low rate of charge
It is also very important that the battery hold-downs be checked periodically to ensure that the batteries are properly positioned to avoid vibration problems, breakage of cables or terminals. Care must be taken to avoid cracking or breaking containers or covers by tightening hold-down fixtures excessively. They also must not be so loose that breakage results from a hold-down that is too loose.
1-6.2.0.
MAINTBAT 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 1-7.3.0/1-7.4.0, Item 12)
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 1-7.3.0/1-7.4.0,
Item 13)
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 1-7.3.0/1-7.4.0, Item 17)
FIG. SD-3.
1-7.0.0
4HDEC 8/98
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 1-7.3.0/1-7.4.0, Item 11)
FIG. SD-4.
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 1-7.3.0/1-7.4.0, Item 4)
1-7.1.0
FIG. SD-5.
4HDEC 8/98
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 Sideplate
(see page 1-7.3.0/1-7.4.0, Item 1)
FIG. SD-6.
PART NO.:
DECAL:
FUNCTION:
040587
LOAD SENSOR
To inform the operator that the load sensor is pre-set and that tampering with the sensor may cause potentially hazardous situation.
1 QUANTITY :
PLACEMENT : On the lift cylinder near the load sensor
(see page 1-7.3.0/1-7.4.0, Item 15)
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 1-7.3.0/1-7.4.0, Item 5)
1-7.2.0
FIG. SD-7.
FIG. SD-8.
4HDEC 8/98
DECAL DRAWING
4004H 10-16-20 BOOM
8
9
10
11
12
13
14
15
16
17
ITEM
1
2
3
4
5
6
7
1
2
11 FT
2
2
1
1
2
2
2
QTY
1
2
1
1
1
1
1
P/N
040579
404122
404121
040580
040632
360034
320318
404088
040624
040620
040529
040517
040518
360480-100
040587
330622
040519
DESCRIPTION
CAUTION “INSPECT VEHICLE...” DECAL
4004H DECAL
4004H LOAD CHART (10-16-20) DECAL
DANGER “AN UNTRAINED OPERATOR...” DECAL
WARNING “TAMPERING WITH OVERLOAD...” DECAL
LOGO DECAL
ANGLE INDICATOR DECAL
ELECTRIC SCHEMATIC DECAL
AUTO CRANE DECAL
STRIPING DECAL
DANGER “ELECTROCUTION HAZARD” DECAL
DANGER “STAY CLEAR OF BOOM” DECAL
DANGER “ STAY CLEAR OF LOAD” DECAL
BLOCK WEIGHT & MAX. LOAD DECAL
WARNING “LOAD SENSOR PRESET” DECAL
SERIAL NUMBER DECAL
DANGER “SCISSORS POINT” DECAL
1-7.3.0
AW404143 8/98
DECAL DRAWING
4004H 10-16 BOOM
8
9
10
11
12
13
14
15
16
17
ITEM
1
2
3
4
5
6
7
1
2
11 FT
2
2
1
1
2
2
2
QTY
1
2
1
1
1
1
1
P/N
040579
404122
404120
040580
040632
360034
320318
404088
040624
040620
040529
040517
040518
360480-100
040587
330622
040519
DESCRIPTION
CAUTION “INSPECT VEHICLE...” DECAL
4004H DECAL
4004H LOAD CHART (10-16) DECAL
DANGER “AN UNTRAINED OPERATOR...” DECAL
WARNING “TAMPERING WITH OVERLOAD...” DECAL
LOGO DECAL
ANGLE INDICATOR DECAL
ELECTRIC SCHEMATIC DECAL
AUTO CRANE DECAL
STRIPING DECAL
DANGER “ELECTROCUTION HAZARD” DECAL
DANGER “STAY CLEAR OF BOOM” DECAL
DANGER “ STAY CLEAR OF LOAD” DECAL
BLOCK WEIGHT & MAX. LOAD DECAL
WARNING “LOAD SENSOR PRESET” DECAL
SERIAL NUMBER DECAL
DANGER “SCISSORS POINT” DECAL
1-7.4.0
AW404144 8/98
LUBRICATION & MAINTENANCE
SCHEDULE for 4004H
SERVICE PERFORMED
LOAD HOOK
CABLE DRUM
HOIST CABLE
HYDRAULIC HOSES
HYDRAULIC FLUID
MOUNTING BOLTS
ROTATION WORM
GEAR
SHEAVE BEARINGS
ALL OTHER BOLTS
BOOM PIVOTS
BOOM CYLINDER
BOOM SLIDE PADS
CAUTION
DAILY WEEKLY 6 MOS
X
X
X
X
X
X
X
YEAR
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 AS REQ.
(DRY)
LUBE WITH MOBILTAC LL, OR LUBRIPLATE
P/N 15263, OR EQUIVALENT
X
X
X
X
X
SEALED BEARING, REPLACE IF ROUGH OR
LOOSE
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 DETENT
PIN
HOIST GEARBOX
HYDRAULIC FLUID
X LUBE DETENT SPRING & BALL w/ WD-40
X WORM GEAR-EP GEAR LUBE SAE 80-90, SPUR
GEAR SAE 30 OIL
X DRAIN, FLUSH, & REFILL WITH SUN 2105 HYD.
OIL, SAE 5W-20
PADS GREASED WHEN REPLACED
{ 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.
1-8.0.0
4HMTSCH 6/99
ASSEMBLY & INSTALLATION INSTRUCTIONS
4004H SERIES
NOTE: For mounting bolt hole pattern - see GENERAL DIMENSIONS.
INSTALLATION - BATTERY CABLE
1. Drill 13/16" hole in floor. Install bushing, which is connected to cable, so it fits hole snug.
2. Run cable to positive battery terminal. Connect black cable to negative battery terminal or suitable chassis ground point. Locate cables so that they will be protected. Avoid sharp edges. Use the No. 083800 frame clips provided to hold cables securely in place.
3. If the battery is grounded to the engine it may be necessary to add an additional ground cable from the engine to the chassis frame to obtain maximum power at crane
2-1.0.0
4HINSTL 9/98
BOOM SUPPORT
4004H SERIES
WARNING:
As with all Auto Crane power rotation units, the 4004H does require a boom support.
Suggested Boom Support:
Auto Crane P/N 726175
2-2.0.0
AW726175 7/98
GENERAL ASSEMBLY - UNIT LESS BOOM
P/N 404065 - MODEL 4004H
3-1.0.0
AW404065 1/2000
GENERAL ASSEMBLY - UNIT LESS BOOM
P/N 404065 - MODEL 4004H
3-1.1.0
AW404065 1/2000
GENERAL ASSEMBLY - UNIT LESS BOOM
P/N 404065 - MODEL 4004H
ITEM
1
2
3
8
9
10
11
12
13
14
4
5
7
21
22
23
24
25
26
27
28
29
30
31
32
33
34
15
16
17
18
19
20
1
1
1
2
2
4
4
1
2
2
QTY
1
1
1
1
1
1
1
3
19
4
1
1
2
2
1
1
2
2
2
1
2
1
1
P/N
404087
404020
480075
320741
404017
404028
404016
404015
320740
330484
011603
021500
017701
330486
330485
330472
010201
330483
019000
239300
340602
404005
360624
366158
021100
404081
404128
360543
480094
480073
400500
330468
360848
DESCRIPTION
PEDESTAL
SIDE PLATES/QUILL HOUSING WELDMENT
HOIST ACTUATOR
MOTOR HOIST
ROTATION BEARING
RETAINING RING GEAR
WORM GEAR
WORM
ROTATION MOTOR
SPACER
CAPSCREW 1/2 UNC x 1 3/4
LOCK WASHER 1/2
NUT 1/2 UNC
OIL SEAL
BEARING
HOUSING
CAPSCREW 1/2 UNC x 1 1/2
SPACER
HEX LOCK NUT 7/8 NF
GREASE ZERK
KEY 3/4 SQ x 1
BOOM UP CYLINDER
PEDESTAL/CYLINDER PIN
CAPSCREW 3/8 UNC x 3/4 G8
LOCK WASHER 3/8
SOCKET HEAD SCREW 3/8 UNC x 7/8
VALVE COVER
HOIST DRUM
KEY 3/8 SQ x 6 1/4
WINCH SHAFT SPACER
BEARING
SPLIT-LOCK COLLAR
PLASTIC PLUG - FOR 1 HOLE
3-1.2.0
AW404065 1/2000
GENERAL ASSEMBLY - UNIT LESS BOOM
P/N 404065 - MODEL 4004H
ITEM
35
36
37
41
42
43
44
45
46
47
38
39
40
48
49
50
51
52
53
54
55
57
58
59
*60
5
8
2
14
4
3
1
1
1
2
QTY
1
1
2
1
1
1
1
1
1
1
1.651ft
2
2
2
1
P/N
320725
404096
330371
404132
REF
330372
005401
020200
404094
008401
021200
000115
404098
404103
371024
404134
404135
330370
404146
404130
750743
002006
020400
019800
REF
DESCRIPTION
MANIFOLD
VALVE MOUNTING BRACKET
CAPSCREW 3/8 UNC x 1
HYDRAULIC SWIVEL BRACKET
POWER CONDUCTOR (340638)
HEX NUT 3/8 UNC GR5
CAPSCREW 1/4 UNC x 5/8
LOCK WASHER 1/4
WORM GEAR COVER
CAPSCREW 3/8 UNC x 1 1/2
FLAT WASHER 3/8
JIFFY CLIP #115
LEFT HAND PEDESTAL COVER
RIGHT HAND PEDESTAL COVER
RUBBER GROMMET
SLIDE STOP PIN
SLIDE STOP WASHER
CAPSCREW 3/8 UNC x 7/8 GR8
GROUND WIRE HARNESS
ROTATION STOP PLATE
DOOR GASKET
SELF TAPPING CAPSCREW #10 x 1/2
FLAT WASHER 1/4
LOCK WASHER #10
LIMIT SWITCH PANEL ASSEMBLY (404155)+
*Base mounting hardware to truck frame
Item Numbers not used: 6, 56.
AW404065 1/2000 3-1.3.0
PEDESTAL ASSEMBLY
MODEL 4004H
ITEM
1
2
3
4
5
6
QTY
1
1
2
1
2
1
P/N
404025
404020
404017
340602
404028
404016
DESCRIPTION
PEDESTAL
SIDE PLATES/QUILL HOUSING
ROTATION BEARING
KEY 3/4 SQ x 1
GEAR RETAINING RING
WORM GEAR
3-2.0.0
AW374 1/99
BOOM ASSEMBLY (10-16-20)
P/N 404110 - MODEL 4004H
3-3.0.0
AW404110 1/99
26
27
28
29
30
20
21
22
23
24
25
31
32
33
34
35
36
37
ITEM
1
2
3
7
8
9
10
11
12
13
4
5
6
14
15
16
17
18
19
1
2
2
12
6
1
2
1
1
1
1
6
6
6
4
2
A/R
1
1
1
1
1
2
3
2
1
1
1
QTY
1
1
1
1
1
1
1
2
2
BOOM ASSEMBLY (10-16-20)
P/N 404110 - MODEL 4004H
360814
360124
360038
366158
480120
239000
016300
011511
017700
008400
007808
005406
008800
021100
021200
020600
480037
360849
P/N
404083
404085
404035
360152
366183
366112
366201
366202
366199
366187
480036
366186
366184
366190
360819
360625
366193
480029
240236
DESCRIPTION
LOWER BOOM
CENTER BOOM
MANUAL BOOM
BOOM EXTENSION CYLINDER
CENTER BOOM STOP
UPPER BOOM STOP
BOOM TOP PAD
BOOM TOP PAD
BOOM PAD
RETAINER LOWER PAD
CENTER BOOM TOP PAD
CENTER BOOM PAD
EXTENSION CYLINDER RETAINER
PIN ASSEMBLY w/ LANYARD
BOOM CYLINDER PIN
LOWER BOOM PIVOT PIN
EXTENSION CYLINDER PIN
RETAINING RING
SHEAVE ASSEMBLY
CROWN PIN
HITCH PIN
ANGLE INDICATOR
HEX HD SCREW 3/8 NC x 3/4 GR8
BOOM PAD
GREASE ZERK
HEX LOCK NUT 1/4 NC
HEX HD SCREW 1/2 NF x 2 1/4 GR5
HEX LOCK NUT 1/2 NF
HEX HD SCREW 3/8 NC x 3/4
HEX HD SCREW 5/16 NC x 1/2
HEX HD SCREW 1/4 NF x 1/2
HEX HD SCREW 3/8 NC x 1
LOCK WASHER 3/8
FLAT WASHER 3/8
LOCK WASHER 5/16
SHIM
PLASTIC SPACER 1/4 Ø
3-3.1.0
AW404110 1/99
BOOM ASSEMBLY (10-16)
P/N 404115 - MODEL 4004H
3-3.3.0
AW404115 1/99
16
17
18
19
20
21
22
23
24
25
9
10
11
12
13
14
15
26
27
28
29
30
31
32
33
34
ITEM
1
2
3
4
5
6
7
8
2
2
1
1
1
2
1
1
1
1
2
2
2
1
1
1
1
1
2
2
12
4
4
6
6
4
QTY
1
1
2
1
1
4
1
1
BOOM ASSEMBLY (10-16)
P/N 404115 - MODEL 4004H
330603
366187
480036
366186
366184
360849
360819
360625
366193
480029
240236
360814
360124
360038
366158
480120
239000
016300
011511
017700
008400
007808
005406
008800
021100
021200
P/N
404083
404085
000115
360152
366183
366108
366201
320551
DESCRIPTION
LOWER BOOM
CENTER BOOM
CLIP (not included)
BOOM EXTENSION CYLINDER
CENTER BOOM STOP
D-RING (not included)
BOOM TOP PAD
CORD REEL BRACKET (not included)
SEAL KIT
RETAINER LOWER PAD
CENTER BOOM TOP PAD
CENTER BOOM PAD
EXTENSION CYLINDER RETAINER
PLASTIC SPACER 1/4 Ø
BOOM CYLINDER PIN
LOWER BOOM PIVOT PIN
EXTENSION CYLINDER PIN
RETAINING RING
SHEAVE ASSEMBLY
CROWN PIN
HITCH PIN
ANGLE INDICATOR
HEX HD SCREW 3/8 NC x 3/4 GR8
BOOM PAD
GREASE ZERK
HEX LOCK NUT 1/4 NC
HEX HD SCREW 1/2 NF x 2 1/4 GR5
HEX LOCK NUT 1/2 NF
HEX HD SCREW 3/8 NC x 3/4
HEX HD SCREW 5/16 NC x 1/2
HEX HD SCREW 1/4 NF x 1/2
HEX HD SCREW 3/8 NC x 1
SP LK WASHER 3/8 SAE
FL WASHER 3/8
3-3.4.0
AW404115 1/99
2-BLOCK ASSEMBLY
MODEL 4004H
8
9
10
11
5
6
7
ITEM
1
2
3
4
2
2
1
1
1
1
2
QTY
1
1
1
2
P/N
360823
366973-001
360824
360852
009800
017400
000610
019600
015400
646900
642908
DESCRIPTION
2-BLOCK WELDMENT
CORD REEL ASSY w/WEATHER PACK CONNECTORS
2-BLOCK SPRING
PLASTIC SPACER 3/8 Ø
CAPSCREW 3/8 NF x 3 1/2
LOCK NUT 3/8 NF
ROUND HEAD SCREW #6 NC x 1 1/2
LOCK WASHER #6
NUT #6 NC
SWITCH
CORD CONNECTOR
3-4.0.0
AW373 8/98
HOIST ACTUATOR
P/N 480075 - MODEL 4004H
3-5.0.0
AW480075 10/98
ITEM
1
*2
3
7
8
9
10
*11
12
13
4
5
6
14
15
16
17
18
*19
26
27
28
*29
30
31
32
33
34
20
21
22
23
24
25
1
2
1
1
2
2
1
1
1
1
QTY
1
1
1
1
4
1
1
1
1
1
1
1
1
1
10
1
2
4
1
1
2
1
1
1
HOIST ACTUATOR
P/N 480075 - MODEL 4004H
P/N
360450
360359
360368
360367
360342
360364
360331
360345
360339
360336
360358
360346
480078
480094
360464
360360
360361
360344
360365
360330
360332
360363
360461
360362
360348
360369
360460
360462
360459
360458
360350
360466
010202
360352
DESCRIPTION
WORM BRAKE COVER
GASKET
SPRING
FLAT SPRING
RETAINER PLATE
THRUST PLATE
CAM PLATE
BRAKE BALL
BRAKE HUB
BRAKE HOUSING
GASKET
BEARING
OUTPUT SHAFT
KEY 3/8 SQ
BARTH KEY
RELIEF FITTING
REDUCER
RIGHT HAND WORM
OIL SEAL
ADAPTER
COUPLING
SPIROL PIN
GEAR HOUSING
PIPE PLUG
BUSHING
THRUST WASHER
RIGHT HAND GEAR
BUSHING
GASKET
COVER
HEX HD CAPSCREW 1/4 NC x 3/4 GR5
THRUST WASHER
HEX HD CAPSCREW 1/2 NC x 1
SOC HD CAPSCREW 1/4 NC x 1 3/4 GR5
3-5.1.0
AW480075 10/98
ITEM
35
36
37
38
*39
40
*41
42
43
44
*45
46
-
4
1
1
2
1
1
-
2
QTY
4
6
1
HOIST ACTUATOR
P/N 480075 - MODEL 4004H
P/N
360463
360453
360456
-
360465
360353
360371
360455
-
360341
360366
480306
DESCRIPTION
SOC HD CAPSCREW 1/4 NC x 7/8
HEX HD w/ NYLOCK CAPSCREW 1/4 NC x 1 GR5
HEX HD CAPSCREW 1/8 NC x 1 1/2 GR5
-
THREAD SEAL
HEX JAM NUT 3/8 NC
THREAD SEAL
FLAT ALUMINUM WASHER 1/4
-
KEY
OIL SEAL
SEAL AND GASKET KIT
NOTE: ITEMS MARKED WITH AN ASTERISK (*) ARE INCLUDED IN SEAL & GASKET KIT P/N
480306 (ITEM 46).
3-5.2.0
AW480075 10/98
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 1/99
3-6.1.0
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
DESCRIPTION
FLAT SPRING
CAM PLATE
HOUSING COVER
BRAKE HOUSING
BRAKE HUB
RETAINER PLATE
BRAKE BALL
CAPSCREW 1/4 NC x 1
COIL SPRING
CAPSCREW 3/8 NC x 1 1/2
THREAD SEAL
JAM NUT 3/8 NC
THREAD SEAL
WASHER FLAT 1/4 ALUM
GASKET
THRUST PLATE
3-6.0.0
AW368 1/99
HYDRAULIC TURNER ASSEMBLY
MODEL 4004H
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
QTY
4
4
2
2
1
2
2
1
1
1
2
1
1
P/N
017701
021500
330484
011603
404015
330486
330485
320760
010201
239300
330483
019000
320740
DESCRIPTION
NUT 1/2 NC
LOCK WASHER 1/2
SPACER
CAPSCREW 1/2 NC x 1 3/4
WORM SHAFT ASSEMBLY
OIL SEAL
BEARING
BEARING HOUSING
CAPSCREW 1/2 NC x 1 1/2
GREASE ZERK
SPACER
LOCK NUT 7/8 NF
ROTATION MOTOR
3-7.0.0
4hturn 8/98
TRAVELING BLOCK ASSEMBLY
P/N 360480 - MODEL 4004H
ITEM
1
2
7
8
9
10
3
4
5
6
QTY
2
1
2
1
3
2
1
1
1
1
P/N
480362
240236
480364
480371
480372
017800
480367
480368
360124
360480-100
DESCRIPTION
SIDE PLATE
SHEAVE ASSEMBLY
LOWER TACKLE
SWIVEL HOOK - 3 TON
BOLT x 3 1/4 GR8 w/ GREASE ZERK
LOCK NUT 1/2 NC
BLOCK PIN
SWIVEL HOOK PIN
HITCH PIN
MAXIMUM LOAD DECAL
3-8.0.0
AW360480 8/98
GENERAL DIMENSIONS
4004H 10-16-20
NOTES:
A. MAX TURNING RADIUS AT ROTATION MOTOR = 13”
B. MAX TURNING RADIUS AT HOIST ACTUATOR = 21 1/2”
4-1.0.0
AW371 8/98
GENERAL DIMENSIONS
4004H 10-16
NOTES:
A. MAX TURNING RADIUS AT ROTATION MOTOR = 13”
B. MAX TURNING RADIUS AT HOIST ACTUATOR = 21 1/2”
4-2.0.0
AW371H 2/2000
CRANE WIRING
P/N 404117 - 4004H SERIES
5-1.0.0
AW404117 1/99
CRANE WIRING
P/N 404117 - 4004H SERIES
5-1.1.0
AW404117 1/99
ITEM
1
2
3
7
8
9
10
11
12
13
4
5
6
20
21
*22
23
24
25
26
27
28
29
30
31
32
33
14
15
16
17
18
19
1
4
4
4
1
1
1
1
1
1
QTY
REF
1
1
1
1
1
5
3
1
1
1
7
5
1
1
7
7
1
1
1
1
1
4
CRANE WIRING
P/N 404117 - 4004H SERIES
* DECAL IS LOCATED INSIDE OF COVER
P/N
404123
646900
404158
404142
404113
404141
366097
000404
019600
015400
404118
404119
750167
404137
320355
480549
340638
001002
005500
636600
480494
REF
001102
320363
320357
404114
366973-001
002603
015800
019900
020200
005800
404138
DESCRIPTION
WIRING HARNESS
SWITCH
LOAD SENSOR ASSEMBLY
TERMINAL BOARD BRACKET
RELAY BOX ASSEMBLY
WIRING HARNESS BRACKET
PENDANT RECEPTACLE CAP
PAN HD SCREW #6 x 5/8
LOCK WASHER #6
HEX NUT #6
WIRE HARNESS w/ WEATHER PACK
GROUND WIRE HARNESS
IN LINE 30 AMP FUSE
PROPORTIONAL AMPLIFIER ASSEMBLY
RELAY POWER
16 GA BLACK CONDUCTOR
POWER CONDUCTOR
RING TERMINAL
HEX HD SCREW 1/4 NC x 3/4
JUMPER
22 STATION TERMINAL BLOCK
ELECTRICAL SCHEMATIC DECAL
2RC-10 TERMINAL WIRE
RELAY PLUG
NON-INSULATED SPADE CONNECTOR
WIRING HARNESS
CORD REEL ASSEMBLY
RD HD SCREW #10-32 NF x 2
HEX NUT #10-32 NF
FLAT WASHER #10
LOCK WASHER 1/4
HEX HD SCREW 1/4 NC x 1 1/2
DIN CONNECTOR ASSEMBLY
5-1.2.0
AW404117 1/99
CRANE WIRING IC
P/N 404149 - 4004H SERIES
5-2.0.0
AW404149 1/2000
CRANE WIRING IC
P/N 404149 - 4004H SERIES
Notes:
1. Mount terminal board bracket, amplifier, & relay assembly with cap screw heads mounted behind wiring harness bracket.
2. 1/4 x1 1/2 cap screw that mounts terminal bracket is also ground for unit.
3. *Decal is located inside of cover.
4. Mount cover pendant receptacle (Item 7) to bracket on side plate.
5. Similar to 404117.
6. The wiring on this crane are color coded. Do not paint wiring.
5-2.1.0
AW404149 1/2000
CRANE WIRING IC
P/N 404149 - 4004H SERIES
7
8
9
10
11
12
13
14
15
16
17
ITEM
1
2
3
4
5
6
21
*22
23
24
18
19
20
28
29
30
31
32
33
34
35
25
26
27
1
8
8
8
1
1
1
1
1
1
1
QUANTITY
1
1
1
1
1
1
1
1
1
1
1
4
3
7
7
7
5
1
1
1
1
5
1
1
PART NUMBER
404123
646900
320543
404142
404113
404141
404153
000404
019600
015400
404118
404119
750167
404137
320355
480549
340638
001002
005500
636600
480494
404088
001102
320363
320357
680040
366973-001
002603
015800
019900
020200
005800
404138
404148
404155
DESCRIPTION
WIRING HARNESS
SWITCH
LOAD SENSOR ASSEMBLY
TERMINAL BOARD BRACKET
RELAY BOX ASSEMBLY
WIRING HARNESS BRACKET
PENDANT RECEPTACLE COVER
PAN HD SCREW #6 x 5/8
LOCK WASHER #6
HEX NUT #6
WIRE HARNESS w/ WEATHER PACK
GROUND WIRE HARNESS
IN LINE 30 AMP FUSE
PROPORTIONAL AMPLIFIER ASSEMBLY
RELAY POWER
16 GA BLACK CONDUCTOR
POWER CONDUCTOR
RING TERMINAL
HEX HD SCREW 1/4 NC x 3/4
JUMPER
22 STATION TERMINAL BLOCK
ELECTRICAL SCHEMATIC DECAL (not included)
2RC-10 TERMINAL WIRE
RELAY PLUG
NON-INSULATED SPADE CONNECTOR
WIRING HARNESS (Located inside of cover)
CORD REEL ASSEMBLY
ROUND HEAD SCREW #10 x 3/4
NUT #10
LOCK WASHER #10
LOCK WASHER 1/4
CAPSCREW 1/4 UNC x 1 1/2
DIN CONNECTOR ASSEMBLY
WIRING HARNESS
LIMIT SWITCH PANEL ASSEMBLY
AW404149 1/2000 5-2.2.0
IN-COMPARTMENT (IC) PENDANT
P/N 404147
5-3.0.0
AW404147 2/2000
IN-COMPARTMENT (IC) PENDANT
P/N 404147
ITEM
1
2
3
7
8
9
10
4
5
6
11
12
13
14
15
16
4
4
1
6
1
1
4
QTY
REF
1
1
6
3
2
2
2
1
P/N
404148
480490
480491-080
480626
480493
000404
015400
019600
366097
750738
634401
330038
020200
005500
015900
480494
DESCRIPTION
CRANE PIGTAIL HARNESS
22 STA TERMINAL BLOCK DECAL
22 STA/19 PIN SOCKET HARNESS
19 PIN PENDANT BRACKET
22 STA TERMINAL BLOCK COVER
RD HD SCREW #6 NC x 5/8
HEX NUT #6 NC
SP LK WASHER #6
19 PIN RECEPTACLE CAP
STICK ON RETAINER WIRE TIE
7” WIRE TIE
HEX HD SELF DRILLING SCREW #10 x 3/4
SP LK WASHER 1/4
HEX HD SCREW 1/4 NC x 3/4 GR5
HEX NUT 1/4 NC
22 STA TERMINAL BLOCK
5-3.1.0
AW404147 2/2000
PROPORTIONAL 8 FUNCTION PENDANT ASSEMBLY
P/N 680040 - 4004H
5-4.0.0
AW680040 8/98
PROPORTIONAL 8 FUNCTION PENDANT ASSEMBLY
P/N 680040 - 4004H
ITEM
1
2
5
6
3
4
7
8
9
10
11
12
18
19
20
21
22
23
24
25
26
13
14
15
16
17
QTY
1
1
1
2
8
8
1
1
4
1
2
1
4
4
3
1
1
1
3
1
2
4
1
8
3
1
DESCRIPTION
PENDANT HOUSING
COVER PLATE DECAL
NUT
TOGGLE SWITCH BOOT
HUBBELL CONNECTOR CORD GRIP
SCREW #10 NC x 3/4
HEX LOCK NUT #10 NC
POTENTIOMETER ASSEMBLY
TRIGGER
SOC HD SCREW #10 NF x 5/8
TOGGLE DPDT SWITCH
BACK PLATE
ST RD HD SCREW #6 x 3/4
CABLE ASSEMBLY
LOCK WASHER
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY
TRIGGER RETURN SPRING
PAN HD ST SCREW #6 x 3/8
JUMPER
CONDUCTOR ASSEMBLY 2 1/8
CONDUCTOR ASSEMBLY 3 1/8
TOGGLE SPDT SWITCH
TOGGLE ON/OFF SWITCH
CONDUCTOR ASSEMBLY
CABLE TIE
NOTES:
1. Items 5 & 14 may be purchased as replacement Cable Assembly using P/N 380000.
2. Items 6, 7, 8, 9, 10, 18, & 19 may be purchased as a replacement Potentiometer Kit using P/N
380003.
3. Items 1, 2, 12, & 13 may be purchased as a replacement Housing Kit using P/N 380002.
4. Items 3, 4, 11, & 15 may be purchased as a replacement DPDT Switch Kit using P/N 380005.
5. Items 3, 4, 15, & 24 may be purchased as a replacement On/Off Switch Kit using P/N 380001.
6. Items 3, 4, 11, & 23 may be purchased as a replacement SPDT Switch Kit using P/N 380004.
AW680040 8/98
5-4.1.0
THROTTLE SOLENOID ASSEMBLY
P/N 751140
4
5
6
7
ITEM
1
2
3
QTY
1
1
8
15 FT
1
1
1
P/N
751159
751143-001
000101
800603
751140-999
751140-999
751140-999
DESCRIPTION
12V DC SOLENOID w/ CONTROL MODULE
ISOLATOR MODULE ASSEMBLY
RING TERMINAL #6
16 GA WHITE WIRE w/ BLACK TRACER x 15’
WIRING DIAGRAM
INSTALLATION INSTRUCTIONS
TROUBLESHOOTING HINTS
5-5.0.0
AW751140A 10/98
THROTTLE CONTROL SOLENOID
INSTALLATION
LOCATION 1. Mount the solenoid and control module according to the recommendations in the
“LOCATION” instructions Follow these simple rules to properly locate your throttle control kit:
1. Mount the solenoid off the engine but within
46 inches of the throttle lever, to avoid engine vibration and high temperature components (more than 257 ºF [125 ºC]).
2. Electrically connect the solenoid to the control module and power source according to the wiring diagram.
2. Mount control module out of the engine compartment if possible. If not possible, mount the module as far away from high temperature components as possible.
Maximum temperature range is 185 ºF (85
ºC).
3. Mount the cable bracket and fasten the cable sheathe to the bracket using the collar nut so the sheath does not turn during idle adjustment.
SET HIGH ENGINE IDLE SPEED NOTE:
Do not leave the aluminum adjustment nut tight against the solenoid body since this does not allow the cable to float.
3. Route the flexible cable away from high temperature (220 ºF [105 ºC]) components such as exhaust manifolds.
1. Make sure the jam nut is loose and turn the aluminum adjustment nut clockwise until the high engine idle speed is reached.
4. Avoid sharp bends in flexible cable. Bends should form a smooth arc (360º maximum) with a radius of 5 inches minimum.
2. Tighten the jam nut.
CONTROLLING THE SOLENOID
THROTTLE KIT
The throttle kit can be controlled remotely by applying a low current 12 VDC signal to the module “AUX” terminal.
Examples of activating signals are an air compressor pressure switch or a crane “dump valve” coil.
MOUNTING PROCEDURES
Use the following procedure to mount your throttle controller:
3. Check the throttle speed controller operation by rechecking the “normal” engine idle speed with the solenoid deactivated and the high engine idle speed with the solenoid activated.
SYSTEM OPERATION
The control module allows the solenoid to operate as a continuous duty device. When the module is wired as recommended, applying 12
VDC to the “AUX” terminal applies voltage to the hold-in and pull-in coil of the solenoid.
After 0.5 to 0.75 seconds, power is automatically removed from the pull-in coil.
Power will remain at the hold-in coil until the
AW751140A 10/98 5-5.1.0
THROTTLE CONTROL SOLENOID
INSTALLATION
12 VDC signal is removed from the “AUX” terminal.
WARNING!! To avoid control module damage, always disconnect the module when you jump-start the vehicle with voltages that exceed 32 VDC.
TROUBLESHOOTING HINTS
If solenoid will not engage, check the following:
1. Check the stranded pull cable for damage
(e.g., melted or crimped sheath)
GND
+HOT
+AUX
CONTROL MODULE VOLTAGE
MEASUREMENTS
A RED
B WHT
C BLK
Chassis Ground
12 VDC at all times
12 VDC required to activate solenoid
12 VDC when signal is present at
“AUX” terminal
12 VDC for 0.5 to 0.75 seconds after signal at “AUX” terminal is present
Common for solenoid
2. Check the stranded pull cable for binding.
3. Check system voltage at the “+HOT” and
“+AUX” terminals.
4. Check module terminals for proper voltage and operation. If the module does not meet the specifications shown below, replace it.
5. Check solenoid resistance (remove wires from module). If resistance is not within specifications listed below, replace the
A. White to Black - 0.17 ohms
B. Red to Black wire - 13 ohms solenoid.
6. Make sure you have used the recommended wire length and gage.
7. Be sure cable is not bent beyond guidelines.
8. Check for proper adjustments.
9. Contact Auto Crane Company if you are unable to resolve the problem.
5-5.2.0
AW751140A 10/98
SPEED CONTROL KIT,
P/N 751140
NOTES:
1. THIS DIAGRAM SHOWS SPEED CONTROL INSTALLTION
WITH OR WITHOUT AN AIR COMPRESSOR. DISREGARD
ISOLATOR BLOCK & PRESSURE SWITCH ON DIAGRAM IF
NOT USING AN AIR COMPRESSOR.
2. REMOVE METAL JUMPER CLIP FROM CONTROL MODULE
IF SO EQUIPPED (S500-A5).
3. THE WIRE SIZE AND LENGTH TO "AUX" TERMINAL IS NOT
CRITICAL BECAUSE OF LOW CURRENT; 16-18 GAGE WIRE
MAY BE USED.
5-5.3.0
751140 12/99
ENGINE START/STOP RELAY KIT
P/N 480533
ITEM
1
2
7
8
9
10
3
4
5
6
QTY
2
2
6’
49’
17’
35’
10
2
3
3
P/N
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
5-5.4.0
AW480533 1/99
AUXILIARY RELAY KIT
P/N 480534
5
6
7
8
9
ITEM
1
2
3
4
1
1
38’
10’
25’
QTY
2
2
5
2
P/N
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
5-5.4.1
AW480534 1/99
HYDRAULIC ASSEMBLY
P/N 404089 - MODEL 4004H
PORT 2 PORT 1
View of Hydraulic Swivel from Bottom of Crane
CAUTION:
Reversing tank and pressure hoses will damage pump.
6-1.0.0
AW404089 1/2000
HYDRAULIC ASSEMBLY
P/N 404089 - MODEL 4004H
6-1.1.0
AW404089 1/2000
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
ITEM
1
2
3
4
5
6
7
8
9
10
11
8
5
4
3
1
1
1
3
1
1
3
4
1
1
2
1
1
1
1
QTY
-
-
-
-
-
2
2
1
2
1
1
HYDRAULIC ASSEMBLY
P/N 404089 - MODEL 4004H
P/N
REF
REF
REF
REF
REF
404108
404109
812209-036
812209-033
812209-013
812209-029
200876
373047
480194
490198
372042
480195
200892
241168
480212
330647
404104
320714
008400
021100
021200
008401
480188
404112
812210-013
DESCRIPTION
HYDRAULIC MANIFOLD ASSEMBLY (320725)
CYLINDER BOOM (404005)
CYLINDER EXTENSION (360152)
MOTOR ROTATION (320740)
MOTOR HOIST (320741)
TUBE ASSEMBLY
TUBE ASSEMBLY
HOSE ASSEMBLY x 36
HOSE ASSEMBLY x 33
HOSE ASSEMBLY x 13
HOSE ASSEMBLY x 29
STRAIGHT ADAPTER -6ORM/-6JICM
STRAIGHT LONG ADAPTER -6OR/-6JICM
90º ELBOW -6 SWIVEL/-6JIC
90º ELBOW -10ORM/-6JICM
90º ELBOW EXTRA LONG -10NPTM/-8JICM
45º ELBOW -6 OR/-6JIC
ELBOW 3/8EXT/9/16JIC EXT
TEE OR/JIC RUN 9/16-18
TUBE ASSEMBLY EXTENSION
45º ELBOW SWIVEL -6JIC
EXTRA LONG ADAPTER -6ORM/-6JICM
HYDRAULIC SWIVEL
CAPSCREW 3/8 NC x 3/4
LOCK WASHER 3/8
FLAT WASHER 3/8
HEX HD SCREW 3/8 NC x 1/2
COUNTERBALANCE CARTRIDGE
SWIVEL BRACKET
HOSE ASSEMBLY x 13
AW404089 1/2000 6-1.2.0
HYDRAULICS
4004H SERIES
CAUTION:
IF COUNTERBALANCE VALVE IS REPLACED, THE CORRECT PRESSURE
SETTING MUST BE MADE BEFORE CRANE IS IN SAFE WORKING
CONDITION.
IMPORTANT
Crane boom must be supported and pump system disengaged during the removal and installation of the pressure gage port plug, pressure gage, pressure switch and counterbalance valve.
Valve Setting
To set counterbalance valve:
2. Boom up until boom cylinder is fully elevated.
3. Boom down in small increments while reading pressure gauge.
4. Loosen the 9/16” nut on end of valve, adjust
5/32” Allen screw and then retighten nut.
Repeat procedure until pressure reading is a constant 900 psi. If valve is not set and boom reaches the full down position, boom up and keep trying.
5. Support boom, remove gauge and replace plug when adjustment is complete.
1. With boom supported, remove -6 ORP plug on cylinder block next to valve and install a pressure gauge; 2500 psi capacity minimum.
4HHYD 8/98
6-2.0.0
4004H TROUBLESHOOTING GUIDE
1 CRANE FAILS TO OPERATE (ALL
FUNCTIONS)
A. Make sure power switch is set to the "on" position on the pendant.
B. Check power to crane by checking for truck voltage at terminal #11 on terminal strip.
white harness wire.
1. If truck voltage, then go to C.
2. If not check continuity back to battery.
C. If there is power at terminal #11 and no functions are operable, find proportional valve on the right side of the hydraulic assembly and screw the manual override clockwise to provide flow to manifold.
operate a function with the manual override
(push or pull).
1. If that function operates properly, then the problem is in the control circuit power wire (pendant or receptacle).
Go to D.
2. If that function does not operate properly, go to E.
D. Electrical problem solutions: pick a specific function and check voltage at the terminal strip by energizing that function using the pendant switch.
1. If voltage is present, then check the ground circuit for continuity.
2. If voltage is not present, then check pendant and harness wiring for a break in the white power wire or the colored function wire.
E. Hydraulic problem solutions:
1. Make sure the PTO and/or the flow control device(s) are engaged and operable. Noise in pump system or excessive heat in the hydraulic system may indicate a worn or broken pump.
2. Check the compensator valve for contamination.
2 HOIST UP, BOOM DOWN, AND EXTEND
(OUT) DON'T OPERATE (ALL OTHER
FUNCTIONS DO OPERATE). THESE
THREE FUNCTIONS ARE TIED INTO
THE ANTI-TWO BLOCK AND CRANE
OVERLOAD SENSOR SYSTEMS. THE
CRANE IS SHUT DOWN WHEN THE
SENSORS OPEN THE GROUND CIRCUIT
FROM THE FUNCTIONS.
A. Unplug the anti-two-block system and reconnect din connectors to allow overload system to function (as shown in the manual).
1. If the three functions work, go to B.
2. If the three functions do not work, go to C.
B. With anti-two-block reconnected, check antitwo-block bail and switch at end of boom to verify they move freely. Switch should make audible click when operated. Try operating crane while pulling cord out of cord reel to check for possible bad spots in cord reel slip rings. Check cord for breaks. A ohmmeter can be used on the two din connectors to test this system while it is unplugged. The system is normally open.
C. Check load sensor pressure switch by unplugging the din connector and checking for a closed circuit.
1. If circuit is closed and boom is unloaded, replace switch and reconnect anti-twoblock circuit.
CAUTION:
BE SURE BOOM IS
SUPPORTED BEFORE REMOVING
SWITCH OR BOOM WILL FALL.
2. If circuit is open, go to D.
6-3.0.0
4HTRBL 8/98
4004H TROUBLESHOOTING GUIDE
D. Locate timing relay box on back of crane and open lid. Disconnect yellow wire on terminal
#1 of the time delay relay.
1. If the three functions do not work, check the ground for overload system through the relay. (The relay may be operated by touching the yellow wire to any ground.)
2. If three functions work, clean terminals
#6 and #7 on time delay relay, reconnect yellow wire to #1 terminal and retry the three functions.
i. If the three functions still do not work, replace the time delay relay.
ii. If the three functions work, spray the terminals with a protective coating and keep them clean.
3. The time delay relay may be operated by removing the connectors from terminals
#6 and #7 and shorting the two terminals with a jumper. The interval between make and brake is approximately ¾ second.
CAUTION:
CONNECTING THE
POWER TERMINAL #3 TO TERMI-
NAL #6 MAY CAUSE RELAY
FAILURE.
3 SINGLE HYDRAULIC FUNCTION DOES
NOT WORK.
A. With trigger pulled, operate the function using the manual override.
1. If it works, check power and ground going to coil at weather pack connector.
i. Verify ground circuit.
ii. Verify function power circuit.
2. If it does not work, then remove valve, clean and inspect it.
3. If it still does not work, then check cylinder or motor and connecting hoses for obstructions or failure.
B. Test the proportional activation system also by operating the proportional manual override screw instead of the trigger on the pendant. Be sure to restore the override to the full out position before using the crane.
C. If boom retract or boom down functions don't work, then check for low hydraulic pressure at pump. These two functions have the highest pressure requirements for an unloaded crane because they must overcome the pressure settings of the counter balance valves.
D. If hydraulic functions are more intermittent when cylinders are extended, then check hydraulic fluid level.
E. Boom locks up and won't come down when fully raised-this is caused by having the pump relief pressure higher than the pressure that causes the overload system to activate. Set relief pressure to the correct setting of 2200 psi. Unlock boom by using the manual override of the boom down function. If pressure is correct and problem continues, then replace overload pressure switch.
7-3.2.0
4HTRBL 8/98
HYDRAULIC DIRECT MOUNT PUMP
P/N 360029 - 4004H SERIES
Adapter: SAE “A” 2 bolt flange (direct mount only).
Shaft: Straight shaft key 3/4 dia. x 2 3/4 long.
3/16 sq. key x 1 5/8 long.
NOTES:
1. Pump speed - 800 RPM for 4004H and 950 RPM for 5005H.
2. To order HYDRAULIC PUMP ASSEMBLY use P/N 360030 - which consists of
HYDRAULIC PUMP (P/N 360029), 3/4-14NPT/1-5/16-12 JIC ADAPTER (P/N 360055)
SUCTION AND 3/4-14 NPT/ 1 1/16-12 JIC (750399) PRESSURE.
3. For SEAL KIT use P/N 480018-001.
4. For SERVICE KIT use P/N 480018-002.
6-4.0.0
AW360029 10/98
LOAD CHART 10-16-20
P/N 404121 - 4004H SERIES
9-1.0.0
AW404121 8/98
LOAD CHART 10-16
P/N 404120 - 4004H SERIES
9-2.0.0
AW404120 7/98
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