Auto Crane 6006EH crane Owners Manual

6006EH

OWNERS MANUAL

Manual No. 366904000

Rev. 04/16/07

Serial No. __________________

Mailing Address:

P.O. Box 580697

Tulsa, OK 74158-0697

Phone 836-0463

Fax 834-5979

74117-5904

Auto Crane Warranty Registration

Fax Transmission

To:

From:

Re:

Warranty Department

Product Registration

Fax:

Date:

Pages:

(918) 834-5979

End User Information:

(Required for Warranty Activation)

Name:

Address:

City:

Contact:

State:

E-mail Address:

Distributor Information:


Phone:

Name:

Address:

City:

Contact:

Product Information:

Model No.:

Date Product Delivered:

VIN #

State:

E-mail Address:


Serial No.:

Date Processed:*

Zip:

Zip:

* For Auto Crane use only

ONE REGISTRATION FORM PER UNIT (CRANE OR BODY)

Registration form must be mailed or faxed within 15 days of customer installation.

Mail to:

Warranty Department

Auto Crane Company

P.O. Box 581510

Tulsa, OK 74158-0697

Warranty Registration Rev. 072403

Revision

Date

6006EH

OWNER’S MANUAL REVISION RECORD

Section(s)

Or

Page(s)

Description of Change

02/03/05 2-4.1, 5-1.1, 6-2,1

& Sect 8

09/12/05

04/21/06

All

Sect 4, 7, 9, 10,

& 11

Added FM Crane

General revision: added FM/Hardwire Less Slip Ring

Updated safety decals, relay panels, pendant, FM section

& load chart

& 9.1-9.4

04/16/07 6-1.0, 6-5.0 & 71.0 Updated general assy, pedestal & schematic

Notes:

1. The information contained in this manual is in effect at the time of this printing. It does not cover all instructions, configurations, accessories, etc. If you require additional information, please contact Auto Crane Company at (918) 836-0463.

2. Auto Crane Company reserves the right to update this material without notice or obligation.

WARNINGS

WARNING! Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of a vehicle certify that the vehicle complies with all applicable federal regulations. Any modifications performed on the vehicle prior to the final state are also considered intermediate stage manufacturing and must be certified as to compliance. The installer of this crane and body is considered 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. SEE DANGER DECAL (P/N 040529) in this Owner's Manual.

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

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

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

♦ Wrap cable around load!

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

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

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

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

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

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

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

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

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

READ THIS PAGE

8/15/05

6006EH

TABLE OF CONTENTS

INTRODUCTION 1-1.0

GENERAL SPECIFICATIONS

SAFETY TIPS AND PRECAUTIONS

OPERATING PRACTICES & WARNINGS

1-3.0

2-1.0

2-3.0

QUALIFICATIONS FOR OPERATORS

OPERATION OF UNIT / OUTRIGGERS

INSPECTION

TESTING

MAINTENANCE

BATTERIES

LUBRICATION AND MAINTENANCE SCHEDULE

SAFETY DECAL SECTION

GENERAL DIMENSIONS

MOUNTING AND INSTALLATION 5-2.0

GENERAL ASSEMBLY, HARDWIRED (W/SLIP RING & W/O SLIP RING) 6-1.0

PEDESTAL ASSEMBLY, HARDWIRED

BOOM ASSEMBLY

ROTATION GEARBOX

6-5.0

6-13.0

6-15.0

HOIST ASSEMBLY

TRAVELING BLOCK ASSEMBLY

ELECTRICAL SECTION, HARDWIRED

PENDANT CABLE ASSEMBLY

HYDRAULIC SECTION

6-17.0

6-20.0

7-1.0

7-9.0

8-1.0

2-4.0

2-7.0

3-1.0

3-4.0

3-5.0

3-7.0

3-9.0

4-1.0

5-1.0

4/21/06

6006EH

TABLE OF CONTENTS

GENERAL ASSEMBLY, FM, (W/SLIP RING & W/O SLIP RING)

PEDESTAL ASSEMBLY, FM

FM CONTROL USE & CARE

TRANSMITTER ASSEMBLY, FM

DIAGNOSTICS, FM

TROUBLESHOOTING, FM

ID CODE PROGRAMMING

LOAD CHART

WARRANTY

9-1.0

9-5.0

10-1.0

10-2.0

10-4.0

10-6.0

10-9.0

11-1.0

LAST PAGE

4/21/06

6006EH

INTRODUCTION

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 6006EH crane for your protection.

For your convenience the overall dimensions of the 6006EH crane are included on the General Dimension

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

Remember, the crane adds weight to the vehicle. Adding weight may change the driving and riding characteristics of the vehicle unless the appropriate overload spring(s) are installed on the truck. The payload of the vehicle is reduced by the weight of the crane. The operator should exercise care when loading the vehicle.

Distributing the payload on the vehicle evenly will greatly improve the driving and riding characteristics of the vehicle.

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

See last page for warranty.

The 6006EH cranes are attached to your truck electrical system through the Voltage

Switching Unit provided. The 6006EH is another highly efficient Auto Crane product.

The use of a maintenance-free battery is not recommended on any Auto Crane product.

The recommended alternator and battery that will give the longest life with the most useful duty cycle is a 75-amp alternator with a 500 cold cranking amp battery. These specifications should be considered minimum.

It has always been Auto Crane Company policy to handle all warranty claims we receive as promptly as possible. If a warranty claim involves discrepant material or workmanship,

Auto Crane will take immediate corrective action. It is understandable that Auto Crane

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

Auto Crane will not assume responsibility or liability for any modifications or changes made to unit, or installation of component parts 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.

Note: This manual should remain with the crane at all times.

1-1.0

9/12/05

6006EH

INTRODUCTION

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. 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.

1-2.0

9/12/05

6006EH

GENERAL SPECIFICATIONS

7

8

9

10

11

5

6

3

4

DIMENSIONS

Width: 21.75 in (0.55 m)

Height: 35.88 in (0.91 m)

Length: 13 ft 1 in (3.99 m)

[boom(s) stored]

Weight:

1,670 lbs (758 kg)

CAPACITY

36,000 ft-lbs (4.98

ton-m)

[ft-lbs = horizontal distance from centerline of rotation to free hanging weight (feet) x amount of weight (pounds)]

LIFTING CAPACITIES

ft lbs ft lbs

6,000

6,000

6,000

6,000

5,143

4,500

4,000

3,600

3,273

16

17

18

19

20

12

13

14

15

3,000

2,769

2,571

2,400

2,250

2,118

2,000

1,895

1,800

REACH

Second boom will reach from 10 feet 4 inches to 16 feet 4 inches.

Third boom will reach from 16 feet 4 inches to 20 feet 4 inches.

CABLE

95 ft (28.9 m) of 3/8 in (9.5 mm) diameter aircraft quality cable. This cable has a single line breaking strength of

14,400 lbs (6,531 kg).

CHASSIS REQUIREMENTS

14,500 lbs (6,577 kg) GVWR minimum

360,000 in-lbs RBM

ELECTRICAL SYSTEM

REQUIREMENTS

Alternator: 75 amp (minimum)

Battery: 130 minute reserve

capacity (minimum)

Maintenance type

ROTATION

370º Rotation With Electrical Stop

Continuous Rotation With Slip Ring

1-3.0

09/12/05

--- IMPORTANT ---

SAFETY TIPS AND PRECAUTIONS

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

2. WARNING: Never weld, modify, or use unauthorized components / parts on any Auto

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

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

4. Make certain the crane is installed per factory specifications. Contact your local distributor or the Auto Crane factory if any questions arise.

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

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

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

Shut the system down as soon as possible.

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

9. Oil gears as required.

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

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

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

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

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

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

16. WARNING: NEVER OPERATE THE CRANE

NEAR ELECTRICAL POWER LINES. Auto

Crane Company recommends that the crane never be any closer to a power line (including telephone lines) than 10 feet at any point.

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

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

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

20. All load ratings are based on crane capacity,

NOT the vehicle stability. Remember in lifting a heavy load, the weight can create enough tipping moment to overturn the vehicle

21. Always comply with load chart capacities,

(centerline of rotation to hook).

22. Secure all loads before lifting.

23. Always set the emergency brake before beginning operation.

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

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

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

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

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

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

30. Always store outriggers before transportation.

WARNING!

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

2-1.0

8/16/05

--- IMPORTANT ---

SAFETY TIPS AND PRECAUTIONS

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

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

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

34. Always walk around the vehicle before moving.

35. Never drive with a load suspended from crane.

36. Do not take your eyes off a moving load.

Look in the direction you are moving.

37. Never swing a load over people.

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

39. Crane boom length should be kept as short as possible for maximum lifting capacity and greater safety. Longer booms require additional care in accelerating and decelerating the swing motion, and thus slow down the working cycle and reduce productivity.

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

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

41. Do not push down on anything with boom extensions; similarly do not lift anything with boom extensions.

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

43. WARNING: In using a safety hook, ALWAYS close the hook throat before lifting a load.

Proper attention and common sense applied to the use of the hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.

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

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

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

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

2-2.0

8/16/05

--- IMPORTANT ---

OPERATING PRACTICES AND WARNINGS

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

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

Auto Crane factory if any questions arise.

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

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

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

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

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

8. Keep hoist cable pulled tight at all times.

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

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

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

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

13. ALWAYS store outriggers before road travel.

14. WARNING! NEVER OPERATE THE CRANE

NEAR ELECTRICAL POWER LINES! Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane within

10 feet (3.05m) of electric power lines carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.

15. WARNING! NEVER EXCEED load chart capacities (centerline of rotation to hoist hook).

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

17. WARNING! NEVER wrap cable around load!

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

19. WARNING! NEVER weld, modify, or use unauthorized components on any Auto Crane unit! This will void any warranty or liability. Also failure of the crane may result.

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

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

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

WARNING! NEVER hold any Control Select

Switch on that will cause unsafe operating conditions!

WARNING!

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

2-3.0

7/27/05

QUALIFICATIONS FOR AND CONDUCT OF

OPERATORS AND OPERATING PRACTICES

REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE QUALIFICATION

REQUIREMENTS

OPERATORS

tests may be required to determine these conditions.

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

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

B. Trainees under the direct supervision of a designated person.

6. In addition to the above listed requirements, the operator shall:

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

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

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.

B. Posses the knowledge of emergency procedures and implement it.

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

D. Be familiar with the applicable safety regulations.

QUALIFICATIONS FOR OPERATORS

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

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

1. 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.

2. Operators and operator trainees shall meet the following physical qualifications:

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

CONDUCT OF OPERATORS

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

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

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

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

2. 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.

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

3. 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.

4. Evidence that operator is subject to seizures or loss of physical control shall be sufficient reason for disqualification. Specialized medical

4. 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.

5. Before closing the switch or starting the engine, the operator shall see that all controls are in the "OFF"

2-4.0

8/19/05



or neutral position and all personnel are in the clear.

6. If power fails during operation, the operator shall:

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

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

7. 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.

8. The operator at the start of each shift shall test all controls. If any controls do not operate properly, they shall be adjusted or repaired before operations are begun.

9. Stabilizers shall be visible to the operator while extending or setting unless a signal person assists operator.

OPERATING PRACTICES/HANDLING THE

LOAD

1. 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 that 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.

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.

3. Moving the load.

The operator shall determine that:

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

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

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

D. Before starting to lift, the hook shall be positioned over the load in such a manner as to minimize swinging.

E. 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.

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

G. This standard recognizes that telescopic 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.

Crane manufacturer must approve work platforms attached to the boom.

H. The operator should avoid carrying loads over people.

I. 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.

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

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

L. 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.

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

2-5.0

8/19/05



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

4. Stowing procedure.

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

MISCELLANEOUS

OPERATING NEAR ELECTRICAL POWER

LINES

1. 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.

2. 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.

2-6.0

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

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

5. 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 are allowed, if approved by the administrative or regulatory authority provided the alternate procedure insures equivalent protection and is 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

minimum required

____clearance____ normal voltage, kV

(phase to phase) ft (m) when operating near high voltage power lines over over over over over over to 50

50 to 200

200 to 350

350 to 500

500 to 750

750 to 1000 while in transit with no load and boom lowered over to 0.75

over 0.75

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

4

6

10

16

20

10

15

20

25

35

45

(3.50)

(4.6)

(6.1)

(7.62)

(10.67)

(13.72)

(1.22)

(1.83)

(3.83)

(4.87)

(6.1)

8/19/05

--- IMPORTANT ---

OPERATION OF UNIT

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

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

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

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

5. For electric cranes, engage emergency brake and leave ignition on with transmission in neutral (or in park for automatic transmissions).

Activate any crane power switches. For Auto

Crane units requiring battery and hydraulic operation, engage emergency brake, place gear selector in neutral, press clutch, activate

PTO, release clutch and after hydraulic fluid is warm, set throttle control to proper engine speed.

6. Always use outriggers from the truck to the ground. Be sure these are firm and adequately positioned. When rotating, keep load as low to

the ground as possible.

7. Remove the transmitter from cab or storage area. Power transmitter on. Detach hook from dead man. Crane is now ready for operation.

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

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

10. Always observe safe and practical operation to avoid possible accidents. Refer to Safety Tips and Precautions. boom to stowed position on the boom support.

Avoid unneeded pressure on the boom support. storage area).

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

14. Check work area for any tools or equipment not stored. disengage PTO. Deactivate any crane power switches. operation that may indicate required maintenance or repair.

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

OPERATION OF

OUTRIGGERS

HYDRAULIC OUTRIGGERS

1. Shift crane/outrigger control valve to

"outrigger" position.

2. Operate the outrigger control valves to position the outriggers.

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

4. Crane is now ready to operate.

MANUAL OUTRIGGERS

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

2. Make sure lock pins are reinstalled properly.

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

4. Crane is now ready to operate.

2-7.0

8/19/05

INSPECTION

REQUIREMENTS

REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE INSPECTION REQUIREMENTS

3. Inspect safety devices for malfunction.

INSPECTION CLASSIFICATION

1. Initial inspection.

4. Visually inspect all hydraulic hoses, particularly those that flex in normal operation of crane functions.

Prior to initial use, all new, altered, modified or extensively repaired cranes shall be inspected by a designated person to insure compliance with provisions of this standard.

2. Regular inspection.

5. Inspect hooks and latches for deformation, chemical damage, cracks, and wear. Refer to

ANSI/ASME B30.10.

6. Inspect for proper rope reeving.

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.

7. Inspect electrical wiring and components for malfunctioning, signs of excessive deterioration, dirt and moisture accumulation.

8. Inspect hydraulic system for proper oil level and leaks.

9. Inspect tires for recommended inflation pressure, cuts and loose wheel nuts.

10. Inspect connecting pins and locking device for wear damage and loose retaining bolts.

A. Frequent inspection - daily or before each use

B. Periodic inspection - one to twelve-month intervals or as specifically recommended by the manufacturer or qualified person.

DESIGNATED PERSONNEL SHALL

PERFORM INSPECTIONS ONLY.

11. Inspect rope for gross damage, such as listed below, which may be an immediate hazard.

A. Distortion such as kinking, crushing, unstranding, birdcaging, main strand displacement, or core protrusion. Loss of rope diameter in a short length or unevenness of outer strands should be replaced.

B. General corrosion.

C. Broken or cut strands.

D. Use care when inspecting sections of rapid deterioration around flange points, crossover points, and repetitive pickup points on drums.

FREQUENT INSPECTION

Inspections should also occur during operation for any deficiencies that might appear between regular inspections. Any deficiencies, such as those listed below, shall be carefully examined and a determination made as to whether they constitute a hazard:

1. Inspect control mechanisms for maladjustment that interferes with proper operation.

2. Inspect control mechanisms for excessive wear of components and contamination by lubricants or other foreign matter.

E. Inspect number, distribution, and type of visible broken wires. Reference Rope Maintenance section in the owner’s manual.

Continued use of rope depends upon good judgment 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.

3-1.0

8/16/05

INSPECTION

REQUIREMENTS

PERIODIC INSPECTION

Any deficiencies, such as those listed below, shall be carefully examined and determination made as to whether they constitute a hazard:

1. Inspect for deformed, cracked or corroded members in the crane structure and entire boom.

2. Inspect for loose bolts, particularly mounting bolts.

3. Inspect for cracked or worn sheaves and drums.

4. Inspect for worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and devices.

5. Inspect for excessive wear on brake and clutch system parts and lining.

6. Inspect crane hooks for cracks.

7. Inspect travel steering, braking, and locking devices for malfunction.

8. Inspect for excessively worn or damaged tires.

9. Inspect hydraulic hose, fittings, and tubing for the following problems:

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

10. Inspect hydraulic pumps and motors for the following problems:

A. Loose bolts and 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.

11. Inspect hydraulic valves for the following problems:

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.

12. Inspect hydraulic cylinders for the following problems:

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.

13. Inspect hydraulic filters for evidence of rubber particles on the filter elements indicating possible hose, “O” ring, or other rubber component deterioration. Metal chips or pieces on the filter may denote failure in pumps, motors, or cylinders.

Further inspection will be necessary to determine the origin of the problem before corrective action can be taken.

14. Inspect labels to confirm correct location and legibility. Reference decal layout in this manual for proper location of decals.

15. Rope Inspections need not be at equal calendar

intervals and should be more frequent as the

rope approaches the end of useful life. A qualified person shall inspect the wire rope based on such factors as:

A. Expected rope life as determined by experience on the particular installation or similar installations.

B. Severity of environment.

C. Percentage of capacity lifts.

D. Frequency rates of operation.

E. Exposure to shock loads.

This inspection shall cover the entire length of the rope. Only the surface wires need to be inspected and no attempt should be made to open the rope.

Any deterioration resulting in appreciable loss of original strength shall be noted and determination made as to whether use of the rope would constitute a hazard. A few notable deterioration points are listed below:

3-2.0

8/16/05

INSPECTION

REQUIREMENTS

A. Reduction of rope diameter below nominal diameter due to loss of core support.

B. Internal or external corrosion.

C. Wear of outside wires.

D. Severely corroded, cracked, bent, worn, or improperly applied connections.

CRANES NOT IN REGULAR USE

A crane, which has been idle for a period of over one month or more, shall be given an inspection conforming to the “initial” and “regular” inspection requirements of this section.

INSPECTION RECORDS

Dated records of periodic inspection should be made on critical items such as brakes, crane hooks, rope, cylinders, and relief pressure valves.

3-3.0

8/16/05

TESTING

REQUIREMENTS

REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE TESTING REQUIREMENTS

TESTING SHALL BE PERFORMED BY DESIGNATED PERSONNEL ONLY.

Prior to initial use, all new, altered, modified, or extensively repaired cranes shall be tested for compliance with the operational requirements of this crane.

Test requirements:

1. Test all functions to verify speed and operation.

2. Check that all safety devices are working properly.

3. Confirm operating controls comply with appropriate function labels.

4. Test loads shall not exceed 110% of the manufacturer’s load rating.

5. Written reports shall be maintained showing test procedures and confirming the adequacy of repairs.

3-4.0

8/16/05

GENERAL

REPAIRS AND MAINTENANCE

REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE MAINTENANCE AND REPAIR

REQUIREMENTS

A preventative maintenance program should be established based on this section and all replacement parts should be obtained from AutoCrane Company.

For replacement parts contact your local

authorized distributor.

MAINTENANCE PRECAUTIONS

1. Place crane where it will cause the least interference with other equipment or operations.

B. Critical parts of the crane structure which are cracked, bent, broken, or excessively corroded. corrosion shall be taken out of service. Repairs by welding are not recommended.

4. If bleeding the hydraulic system is required, run each crane function until smooth operation of that particular function is noticeable.

2. Verify all controls are in the "off" position and all operating features secured from inadvertent motion by brakes, pawls, or other means.

3. The means for starting the crane shall be rendered inoperative.

4. The boom should be secured in place before maintenance.

5. Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components.

6. Warning or "OUT OF ORDER" signs shall be placed on all crane controls.

7. 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.

LUBRICATION

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

Reference Lubrication and Maintenance Schedule in this manual.

ROPE REPLACEMENT

No precise rules can be given for determination of the exact time for replacement of rope, since many variable factors are involved.

ADJUSTMENTS AND REPAIRS

1. Any hazardous conditions disclosed by the inspection requirements shall be corrected before operation of crane is resumed. Only designated personnel shall do adjustments and repairs.

2. Adjustments shall be maintained to assure correct functioning of components, the following are examples:

A. Functional operating mechanism.

3. Repairs or replacements shall be provided as needed for operation, the following are examples: mechanisms which are cracked, broken, corroded, bent, or excessively worn.

1. 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, bird caging, 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.

3-5.0

8/16/05

GENERAL

REPAIRS AND MAINTENANCE

(2.4 mm) for diameters 11/4 in. (32 mm) to and including 11/2 in. (38 mm).

G. In standing ropes, more than two broken wires in one lay in sections beyond end connections or more than one broken wire at an end connection.

2. Replacement rope shall have a strength rating at least as great as the original rope furnished or recommended by AutoCrane. A rope manufacturer, AutoCrane, or a qualified person shall specify any deviation from the original size, grade, or construction.

ROPE MAINTENANCE

1. Rope should be stored to prevent damage or deterioration.

2. Unreeling or uncoiling of rope shall be done as recommended by the rope manufacturer and with care to avoid kinking or inducing twist.

3. 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.

4. During installation care should be exercised to avoid dragging of the rope in the dirt or around objects that will scrape, nick crush or induce sharp bends in it.

5. 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 that does not hinder visual inspection. Those sections of rope that 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.

6. 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 some cases by shifting the wear to different areas of the rope.

3-6.0

8/16/05

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 Charged

Many things affect the proper charge to a battery, such as:

2. Proper tightness of belts on the alternator or generator.

3. Good, clean connections of all cables and wires at the following places: a. Battery. b. Regulator. 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:

Specific Gravity Freezing Temp.

(Corrected to 80ºF) Degrees F.

1.280 -90ºF

1.250 -62ºF

1.200 -16ºF

1.150 5ºF

1.100 19ºF

As shown, a half-charged battery (about 1.100 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 insure that power is available even though the vehicle has been standing for some time.

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:

1. The exposed portion of the plate will become sulfated.

2. The portion of the plate exposed is not usable.

3. That portion of the acid remaining becomes more concentrated and may cause more rapid

3-7.0 deterioration of the remaining parts of the battery.

Keep A Relatively Clean Battery

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 selfdischarge of the battery is accelerated. This also accelerates corrosion of the battery cables at the terminals.

Periodic Maintenance is Needed

A definite program of periodic maintenance of all batteries should be conducted on a regular basis.

Periodic maintenance includes:

1. Checking belts for tightness on the charging equipment.

2. Checking battery electrolyte levels.

3. Checking cables for good connections.

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.

Low Maintenance Batteries

(Maintenance Free)

Low maintenance batteries should not be used on AutoCrane Cranes or trucks equipped with

AutoCrane Cranes. The batteries are not designed for "deep" discharge.

Testing Your Battery

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.

8/16/05

MAINTENANCE

OF BATTERIES

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 should be attempted for an extended time.

This usually will recover a badly sulfated battery.

Replacing a Battery

If it is necessary to replace a battery, and a dry charge battery is used, the following procedure applies:

1. Fill the battery with electrolyte of the proper specific gravity.

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.

It is also very important that the battery hold-downs be checked periodically to insure 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.

3-8.0

8/16/05

6006EH

LUBRICATION & MAINTENANCE SCHEDULE

SERVICE

PERFORMED

LOAD HOOK

CABLE DRUM

HOIST / BOOM

CABLE

HYD. HOSES

HYD. FLUID

PIN RETAINING

BOLTS

DAY WKLY 3 MOS 6 MOS YEAR

X

X

X

X

X

X

NOTES

INSPECT HOOK & LATCH FOR DEFORMATION,

CRACKS, & CORROSION

MAKE SURE CABLE IS WOUND EVENLY ON

DRUM

CHECK FOR FLATTENING, KINKS, & BROKEN

STRANDS, SEE MANUAL

VISUAL INSPECTION

CHECK FLUID LEVEL

CHECK TORQUE TO 23 FT-LBS (GRADE 5), 35 FT-

LBS (GRADE 8) AS REQUIRED

MOUNTING BOLTS

ROTATION RING

GEAR

SHEAVE

BEARINGS

ALL OTHER BOLTS

LIFT CYLINDER

BEARINGS

ROTATION

BEARING

ROTATION

BEARING BOLTS

ROTATION GEAR

BOX

X

X

X

X

X

X

X

X

CHECK TORQUE TO 501 FT-LBS AS REQUIRED

LUBE WITH MOBILETAC LL, OR LUBRIPLATE P/N

15263, OR EQUAL

SEALED BEARING, REPLACE IF ROUGH OR

LOOSE

CHECK TIGHTEN AS REQUIRED

GREASE WITH MOBILEPLEX EP-2 OR

EQUIVALENT @ ZERKS

GREASE WITH MOBILEPLEX EP-2 OR

EQUIVALENT @ ZERKS

CHECK TORQUE TO 170 FT-LBS (HEX HEAD) 180

FT-LBS (SOCKET HEAD) AS REQUIRED

CHECK TORQUE TO 90 FT-LBS (SOCKET HEAD)

AND 55 FT-LBS (HEX HEAD) AS REQUIRED

ROTATION GEAR

BOX

X EP GEAR LUBE SAE 80-90

HYDRAULIC FLUID X

DRAIN, FLUSH, AND REFILL WITH MOBILE DTE

13 HYD. OIL

BOOM SLIDE

PADS GREASED WHEN REPLACED

PADS

FOR ADDITIONAL

1) OWNER'S MANUAL

INFORMATION

2) OSHA SECTION 1910.180

SEE:

3) ANSI B30.5-1989

CAUTION:

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

3-9.0

9/12/05

6006EH

LUBRICATION & MAINTENANCE SCHEDULE

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.

3-10.0

9/12/05

6006EH

SAFETY DECAL SECTION

PART NO.:

DECAL:

040579000

OPERATING INSTRUCTIONS

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

USED ON:

QUANTITY:

All Cranes

1

PLACEMENT: Right side plate

PART NO.:

DECAL:

FUNCTION:

040580000

OPERATING TRAINING

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

USED ON:

QUANTITY:

All Cranes

1

PLACEMENT: Right side plate

PART NO.:

DECAL:

FUNCTION:

040632000

TAMPERING WITH OVERLOAD DEVICE

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

USED ON: All Cranes equiped with a load sensor

QUANTITY: 1

PLACEMENT: Right side of valve sensor.

4-1.0

4/21/06

6006EH


PART NO.:

DECAL:

FUNCTION:

040529000

ELECTROCUTION HAZARD

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

USED ON:

QUANTITY:

All Cranes

2

PLACEMENT: Both sides of end of lower boom

PART NO.:

DECAL:

FUNCTION:

040517000

STAY CLEAR OF BOOM

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

USED ON:

QUANTITY:

All Cranes

2

PLACEMENT: Both sides of crown

PART NO.:

DECAL:

FUNCTION:

040518000

STAY CLEAR OF LOAD

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

USED ON:

QUANTITY:

All Cranes

2

PLACEMENT: Both sides of traveling block

4-2.0

4/21/06

6006EH


PART NO.: 040587000

DECAL: LOAD SENSOR, DON'T TAMPER

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

USED ON: All cranes equipped with a load sensor.

2 QUANTITY:

PLACEMENT: Both sides of the lift cylinder near the load sensor

PART NO.: 040519000

DECAL: SCISSORS POINT

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

USED ON:

QUANTITY:

All cranes.

2

PLACEMENT: Both sides of the lift cylinder

4-3.0

4/21/06

NOTES

6006EH


PART NO.: 460169000

DECAL: REMOTE CONTROL

USED ON:

QUANTITY:

All Cranes equiped with FM controls.

1

FUNCTION: To inform the operator of failure to follow the saftey precautions may result

PLACEMENT: FRONT OF POWER UNIT in equipment failure or serious personal injury.

WARNING

REMOTE CONTROL SAFETY PRECAUTIONS

READ THE OPERATOR'S MANUAL before using the Remote Control System.

Failure to follow the safety precautions may result in equipment failure or serious personal injury.

MAKE SURE MACHINERY AND SUROUNDING AREA IS CLEAR BEFORE

OPERATING REMOTE CONTROL SYSTEM. Do not activate the Remote Control

System unless it is safe to do so.

TURN OFF THE RECEIVER POWER BEFORE WORKING ON THE MACHINE.

Always disconnect the Remote Control System before doing any maintenance to prevent accidental operation of the machine.

DO NOT MODIFY EQUIPMENT WITHOUT WRITTEN APPROVAL FROM THE

MANUFACTURER.

CARE

KEEP DRY. Do not clean the Transmitter / Receiver under high pressure. If water or other liquids get inside the Transmitter battery or Receiver compartment, immediately dry the unit. Remove the case and let the unit air dry.

Clean the unit after operation using a damp cloth to remove any mud, dirt, concrete, etc. from the unit and prevent clogging of buttons, switches, etc.

MAINTENANCE / WELDING

DISCONNECT THE RECEIVER BEFORE WELDING ON THIS MACNINE. Failure to disconnect will result in the destruction of the Receiver.

4-4.0

4/21/06

1

4

8

6006EH DECAL LAYOUT

P/N: 366704000

12

16

15

17

11

5

6

7

3

10

13

3

7

9

1

15

4-5.0

4

8

4/21//06

6006EH DECAL LAYOUT

P/N: 366704000

14

2

13

ITEM NO.

QTY.

PART NO.

DESCRIPTION

4

9

10

11

12

7

8

5

6

13

14

15

16

1

2

3

2

2

2

2

1

1

2

2

1

1

1

1

2

2

2

1

040517000

040518000

DECAL STAY CLEAR OF BOOM

DECAL STAY CLEAR OF LOAD

040519000 DECAL DANGER SCISSOR POINT

DECAL DANGER "ELECTROCUTION HAZARD"

040529000

POWER LINE

040579000 DECAL OPERATION INSTRUCTIONS

040580000 DECAL TRAINED OPERATOR

040587000 DECAL WARNING LOAD SENSOR

040624000 DECAL AUTO CRANE

040632000 DECAL WARNING - OVERLOAD

320318000 DECAL ANGLE INDICATOR CS

320318001 DECAL ANGLE INDICATOR SS

330622000 DECAL SERIAL NO

360034000 DECAL AUTO CRANE LOGO

366063100 DECAL, TRAVELING BLOCK 6006H

366710000 DECAL, LOAD CHART 6006EH

366804000 DECAL 6006 EH

4-6.0

4/21//06

6006EH

GENERAL DIMENSIONS

5-1.0

NOTE: CG IS APPROXIMATE

9/12/05

6006EH

MOUNTING AND INSTALLATION

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

ITEM

Q T Y

1 4

PART NO .

DESCRIPTIO N

015104000 SCREW , HX . HD, 7/8-14NF X 5" LG . G RADE 8

5

6

7

2

3

4

1

1

1

4

4

6

022200000 W ASHER, SP. LK. 7/8

018900000 NUT , HEX 7/8-14NF

083800000 CLIP, CABLE #838 (FRAME)

366904000 O W NER'S MANUAL (6006EH)

366692000 VSU ASSEM BLY

366709001 PENDANT

8 1 366699000 SLIP RING INST ALLAT IO N (SLIP RING VERSIO N O NLY)

2. Vehicle should meet minimum GVW rating of 14,500 pounds. (does not include bodies or accessories)

3. Make sure mounting surface is properly reinforced to withstand 36,000 ft-lb capacity loading of crane and that outriggers are used to provide total stability for the truck.

4. A 12” dia. hole should be cut out of mounting location (centered with mounting bolts) for access.

Reference general dimensions for bolt pattern.

5. Make sure the mounting blots are 7/8” dia, grade 8UNF. Torque bolts to 501 ft-lbs (dry).

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

7. Install Voltage switching unit inside compartment safe from weather and contamination.

See following page for installation.

8. See the following pages for additional electrical installation.

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

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

11. For additional help: call the service department at the Auto Crane Company. (918) 836-0463 (Tulsa,

Oklahoma)

WARNING

FEDERAL LAW

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

VEHICLE CERTIFY THAT HE VEHICLE COMPLIES WITH ALL APPLICABLE FEDERAL REGULATIONS.

ANY MODIFICATIONS PERFORMED ON THE VEHICLE PRIOR TO THE FINAL STAGE ARE ALSO

CONSIDERED INTERMEDIATE STAGE MANUFACTURING AND MUST BE CERTIFIED AS TO

COMPLIANCE. THE INSTALLER OF THIS CRANE AND BODY IS CONSIDERED ONE OF THE

MANUFACTURERS OF THE VEHICLE. AS SUCH A MANUFACTURER, THE INSTALLER IS

RESPONSIBLE FOR COMPLIANCE WITH ALL APPLICABLE FEDERAL AND STATE REGULATIONS,

AND IS REQUIRED TO CERTIFY THAT THE VEHICLE IS IN COMPLIANCE.

IT IS THE FURTHER RESPONSIBILITY

OF THE INSTALLER OF THE CRANE TO

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

PART 1910.180 (C) (1).

5-2.0

09/12/05

6006EH


W/O SLIP RING

VOLTAGE SWITCHING UNIT

P/N 366692000

1/4-20NC x 1" LG

BOLTS (P/N 005604000) w/ NUTS (P/N 015900000)

AND LOCKWASHERS

(P/N 020200000)

3 PIN PLUG

TWECO CONNECTOR

-

CHASSIS

GROUND

+

AUXILIARY

BATTERY

NOTICE:

WE RECOMMEND REPLACING ANY

NO-MAINTENANCE TRUCK BATTERY

WITH A MAINTENANCE TYPE

TRUCK BATTERY

QUICK DISCONNECT (OPTIONAL)

BATTERY P/N 360830000

VENTED BATTERY BOX

P/N 360888000

CAUTION:

AUXILLARY BATTERY IS FOR CRANE

USE ONLY. NO OTHER ELECTRICAL

CONNECTIONS SHOULD BE MADE TO

THE AUXILLARY BATTERY. DOING SO

WILL SHORT OUT THE ELECTRICAL

SYSTEM.

+

CHASSIS POWER

(TO POSITIVE POLE OF

BATTERY)

NOTE:

SEE ELECTRICAL SECTION

FOR WIRING DIAGRAMS

5-3.0

09/12/05

6006EH


3/8 X 1NC BOLT (P/N 330371000)

FLATWASHER 3/8 (P/N 320976000)

LOCKWASHER 3/8 (P/N 021100000)

WITH SLIP RING

ATTACH GROUND WIRE TO THIS BOLT

5/16-24 X 1/2 BOLT (P/N 007808000)

LOCKWASHER 3/8 (P/N 020601000)

4 AWG CONNECTOR FROM SLIP RING

(INSERT SLEEVE (P/N 366703000) OVER

BARE WIRE BEFORE INSERTING CONNECTOR)

3 PIN PLUG

STOP, SLIP RING (P/N 366700000)

SLIP RING ASSY (P/N 366665000)

1/2 X 2 1/2NC GR5 BOLT

(P/N 011609000)

APPLY LOCTITE 242 TO

THREADS BEFORE INSTALLATION

1/4-20NC x 1" LG

BOLTS (P/N 005604000) w/ NUTS (P/N 015900000)

AND LOCKWASHERS

(P/N 020200000)


P/N 366692000

3 PIN PLUG

TWECO CONNECTOR

-

CHASSIS

GROUND

+

AUXILIARY

BATTERY

NOTICE:

WE RECOMMEND REPLACING ANY

NO-MAINTENANCE TRUCK BATTERY

WITH A MAINTENANCE TYPE

TRUCK BATTERY

QUICK DISCONNECT (OPTIONAL)

BATTERY P/N 360830000

VENTED BATTERY BOX

P/N 360888000

CAUTION:

AUXILLARY BATTERY IS FOR CRANE

USE ONLY. NO OTHER ELECTRICAL

CONNECTIONS SHOULD BE MADE TO

THE AUXILLARY BATTERY. DOING SO

WILL SHORT OUT THE ELECTRICAL

SYSTEM.

+

CHASSIS POWER

(TO POSITIVE POLE OF

BATTERY)

NOTE:

SEE ELECTRICAL SECTION

FOR WIRING DIAGRAMS

5-4.0

09/12/05

6006EH GENERAL ASSEMBLY

HARDWIRED W/SLIP RING – P/N: 366600002

5

4

4

5

2

2

7 9

APPLY LOCITE 242

TO THREADS BEFORE

INSTALLATION

7 11 13

1

8 6

3 10

RETRACT

PORT #8

ELECTRICAL SCHEMATIC P/N: 366684001

HYDRAULIC SCHEMATIC P/N: 366785000

6-1.0

11 13 6

EXTEND

PORT #7

3

12 10

1

11/27/06


HARDWIRED W/SLIP RING – P/N: 366600002

ITEM NO.

QTY.

PART NO.

DESCRIPTION

1

1

1

1

1

2

2

2

1

1

1

1

1

6

1

1

2

2

7

8

9

10

11

3

4

5

6

1

2

12

13

14

15

16

17

18

366640001 PEDESTAL ASSEMBLY, 6006EH

480891000 BOOM ASSEMBLY

320976000 WASHER, FLAT, 3/8 SAE HARDENED

021100000 WASHER SP LK 3/8

008702000 SCREW HX HD 3/8-16UNC X 1 1/4 LG GR5

360676000 PIN, CYLINDER

360675000 PIN, BOOM PIVOT

239300000 ZERK, GREASE

366063000 TRAVELING BLOCK

480031000 WIRE ROPE ASSEMBLY 3/8"

366697000 SHIP KIT 6006EH CRANE

366704000 DECAL LAYOUT 6006EH

366688000 COVER, REAR

020601000 WASHER SP LK 5/16

007807000 SCREW HX HD 5/16-18UNC X 3/4 LG GR5

360678000 PIN, 3/16 COTTERLESS RING


366718000 TRIM-LOK 75B3X1/8

6-2.0

11/27/06

6006EH GENERAL ASSEMBLY HARDWIRED

W/O SLIP RING – P/N: 366780000

12

13

13

12

11

5

8

5

10 9 6 7

APPLY LOCTITE 242

TO THREADS BEFORE

INSTALLATION

3

16

4

17 18

1

RETRACT

PORT #8



6-3.0

2 6 9 10

EXTEND

PORT #7

4

1

07/07/06

6006EH GENERAL ASSEMBLY HARDWIRED

W/O SLIP RING – P/N: 366780000

ITEM NO.

QTY.

4

5

6

1

2

3

7

8

9

10

11

12

13

14

15

16

17

18

1

1

2

1

1

1

2

2

1

1

1

1

6

2

2

1

1

1

PART NO.

DESCRIPTION









021100000 WASHER SP LK 3/8





366784000 SHIP KIT 6006EH CRANE


366718000 TRIM-LOK 75B3X1/8

020601000 WASHER SP LK 5/16


6-4.0

07/07/06

6006EH PEDESTAL ASSEMBLY

W/SLIP RING - P/N: 366640001

29

46

8

6

10

4

49

3

5

41

9

13

12

1

16

38

37

HYDRAULICS:

PORT B-1 RETRACT

PORT B-2 BOOM UP

PORT B-3 CCW REAR MOTER

PORT A-1 EXTEND

PORT A-2 BOOM DOWN

PORT A-3 CCW FRONT MOTOR

CYLINDER SEAL KIT: 360681001 (THI)

CYLINDER SEAL KIT: 360381002 (CTD)

C'BAL CARTRIDGE: 480188000

6-5.0

11/27/06

38

37

39


W/SLIP RING - P/N: 366640001

29

5

30

8

8

7

33

21

23

7

45

43

18

16

43

16

19

20

42

22

16

42

55

57

20

27

16

43

54

43 56

36

51

24

6

16

17

28

6-6.0

34

49

40

50

34

11

6

7

14

12

1

11/27/06

35

6

7

32

32


W/SLIP RING - P/N: 366640001

4

2

2

2

1

4

2

1

2

2

4

4

1

1

1

1

1

2

2

8

1

1

14

24

4

9

1

1

1

38

1

4

11

3

1

1

1

1

ITEM NO.

QTY.

PART NO.

DESCRIPTION

29

30

31

32

33

34

25

26

27

28

35

36

37

38

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

366641000 BASE PLATE WELDMENT

366642000 PEDESTAL WELDMENT



366652000 CYLINDER, LIFT


021100000 WASHER SP LK 3/8


366333000 BEARING, SPHERICAL 1.25 ID


480023002 BEARING, ROTATION

023902000 WASHER FL 5/8 HARDENED



006205000 SCREW SOC HD 5/8-11UNC X 1 1/4 LG

020601000 WASHER SP LK 5/16


160407000 GEAR BOX, ROTATION

011202000 SCREW HX HD 1/2-20UNF X 2 3/4 LG GR5

021500000 WASHER SP LK 1/2

480011000 SEAL ROTATION BOX

017704000 NUT HX HVY 1/2-20UNF

360162000 RING, ECCENTRIC

360207000 RETAINER ECCENTRIC RING

021502000 WASHER SP LK 1/2 HI COLLAR

012197000 SCREW SOC HD 1/2-13UNC X 1/2 LG

009118000 SCREW SOC HD 1/2-13UNC X 2 LG

366440000 ROTATION MOTOR

113001000 HOIST ASSEMBLY

011608000 SCREW HX HD 1/2-13UNC X 2 LG

017701000 NUT HX 1/2-13UNC

009116000 SCREW HX HD 3/8-16UNC X 2 GR5

460113000 SCREW HX HD 3/8-16UNC X 1-3/4 LG GR8

366651000 BAR, POWER UNIT MOUNT

366650000 HYDRAULIC POWER UNIT

366698000 CORD GRIP .375-.500 3/4" HUB

360493000 SCREW HX WHIZ-LK 1/4-20UNC X 1/2 LG

007400000 SCREW HX HD 5/16-18UNC X 1 LG GR5

6-7.0

11/27/06


W/SLIP RING - P/N: 366640001

50

51

52

53

54

46

47

48

49

ITEM NO.

QTY.

PART NO.

DESCRIPTION

39 1 366687001 COVER, RELAY PANEL

40

41

1

1

642908000

480880000

CORD CONNECTOR

LOAD SENSOR SWITCH, 2500 PSI

42

43

44

45

2

4

1

4

366653000

330252000

320826000

008400000

BRACKET, VALVE MOUNT

SCREW HX HD 5/16-18UNC X 3/4 LG GR5

VALVE ASSEMBLY PRX

SCREW HX HD 3/8-16UNC X 3/4 LG GR 5

55

56

57

58

1

1

1

3

1

2

1

1

2

3

1

2

1

366682002

366509000

813001000

200876000

330645000

490198000

330072000

367162000

812026018

812026016

812026014

812026031

374085000

RELAY PANEL ASSY

GROUND WIRE ASSY

KIT, HOSE, 5005EH, 6006EH

FITTING 6 SAE/6 JIC STRAIGHT

FITTING 90 6-SAE/6-JIC LONG

FITTING 10SAE(M)/6JIC ELBOW 90

FTG HYD 10MB-10MJ

FTG HYD 8MB-8MJ

HOSE ASSY

HOSE ASSY -4 HOSE -6 FEMALE JIC

HOSE ASSY

HOSE ASSY -4 HOSE -6 FEMALE JIC

NYLON HOSE SLEEVE .90 ID

6-8.0

11/27/06


W/O SLIP RING – P/N: 366781000

31

38

39

11 8 3

4

7

6

10

50

9

58

64

61

65

56

55

HYDRAULICS:

PORT B-1 RETRACT

PORT B-2 BOOM UP

PORT B-3 CCW REAR MOTOR

PORT A-1 EXTEND

PORT A-2 BOOM DOWN

PORT A-3 CC FRONT MOTOR

CYLINDER SEAL KIT: 366342001 (THI)

CYLINDER SEAL KIT: 366652002 (CTD)

C’BAL CARTRIDGE: 480188000

6-9.0

66

60

59

57

54

13 14

41

44

2

9/12/05

17 42

43

47

46

19

22

24

28


W/O SLIP RING – P/N: 366781000

31

5

7

8

23 20 32

37

38

48

33 21

46

9

7

36

7

49 7

26

29

21

40

37

34

45

12

6

7

35

25

6

30

17

18

27

13 15

1

6-10.0

9/12/05


W/O SLIP RING – P/N: 366781000

1

4

4

1

2

1

2

2

1

2

2

1

2

2

2

1

8

1

1

2

9

1

38

14

24

4

1

1

3

1

1

4

11

3

1

1

1

1

ITEM NO.

QTY.

PART NO.

DESCRIPTION

29

30

31

32

33

34

25

26

27

28

35

36

37

38

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

366721000 BASE PLATE WELDMENT

366642000 PEDESTAL WELDMENT



366652000 CYLINDER, LIFT


021100000 WASHER SP LK 3/8


200876000 FITTING 6 SAE/6 JIC STRAIGHT

366333000 BEARING, SPHERICAL 1.25 ID


480023002 BEARING, ROTATION

023902000 WASHER FL 5/8 HARDENED



006205000 SCREW SOC HD 5/8-11UNC X 1 1/4 LG

020601000 WASHER SP LK 5/16


160407 GEAR BOX, ROTATION

011202000 SCREW HX HD 1/2-20UNF X 2 3/4 LG GR5

021500000 WASHER SP LK 1/2

480011000 SEAL ROTATION BOX

017704000 NUT HX HVY 1/2-20UNF

360162000 RING, ECCENTRIC

360207000 RETAINER ECCENTRIC RING

021502000 WASHER SP LK 1/2 HI COLLAR

012197000 SCREW SOC HD 1/2-13UNC X 1/2 LG

490198000 FITTING 10SAE(M)/6JIC ELBOW 90

009118000 SCREW SOC HD 1/2-13UNC X 2 LG

366440000 ROTATION MOTOR

113001 HOIST ASSEMBLY

011608000 SCREW HX HD 1/2-13UNC X 2 LG

017701000 NUT HX 1/2-13UNC

330645000 FITTING 90 6-SAE/6-JIC LONG

009116000 SCREW HX HD 3/8-16UNC X 2 GR5

460113000 SCREW HX HD 3/8-16UNC X 1-3/4 LG GR8

366651000 BAR, POWER UNIT MOUNT

366650000 HYDRAULIC POWER UNIT

6-11.0

9/12/05


W/O SLIP RING – P/N: 366781000

ITEM NO.

QTY.

PART NO.

DESCRIPTION

43

44

45

46

39

40

41

42

1

2

1

1

4

4

1

1

366509000 GROUND WIRE ASSY

366698000 CORD GRIP .375-.500 3/4" HUB


007400000 SCREW HX HD 5/16-18UNC X 1 LG GR5

366687000 COVER, RELAY PANEL

366782000 RELAY PANEL ASSY, 6006EH

642908000 CORD CONNECTOR

366653000 BRACKET, VALVE MOUNT

47

48

49

50

4

1

4

1


320826000 VALVE ASSEMBLY PRX

008400000 SCREW HX HD 3/8-16UNC X 3/4 LG GR 5

366672000 BRACKET, ROTATION STOP

*51 2

*52 1

*53

54

55

56

57

58

59

60

61

*62

*63

64

65

66

*

2

1

1

1

4

4

4

1

1

1

1

1

1

1

812026018

812026014

HOSE

HOSE

812026031 HOSE ASSY -4 HOSE -6 FEMALE JIC

366677000 STOP, ROTATION

366673000

366671000

PIN, ROTATION STOP

ARM, ROTATION STOP

015801000 NUT HX NYLON LOCK #10-24UNC ZP

020000000 WASHER FL #10 ZP

460093000

366676000

SCREW RD HD SL #10-24UNC X 1 LG ZP

COVER, ROTATION STOP

480880000 LOAD SENSOR SWITCH, 2500 PSI

330072000 FTG HYD 10MB-10MJ

367162000

366675000

460079000

460110000

ITEM NOT SHOWN

FTG HYD 8MB-8MJ

WASHER, NYLON

BEARING, ROTATION STOP

ROTATION STOP SWITCH ASSEMBLY

6-12.0

9/12/05

BOOM ASSEMBLY

P/N: 480891000

CYL SEAL KIT P/N: 366331001 (THI)

CYL SEAL KIT P/N: 366331002 (CTD)

C’BAL P/N: 360153001

6.13.0

07/07/06

BOOM ASSEMBLY

P/N: 480891000

26

27

28

29

22

23

24

25

30

31

32

33

34

18

19

20

21

14

15

16

17

35

36

37

38

39

40

1

2

2

1

1

1

2

2

2

1

1

1

20

1

4

2

1

5

1

2

6

2

1

8

4

1

1

ITEM NO.

QTY.

PART NO.

DESCRIPTION

1

2

1

1

366631000

480892000

LOWER BOOM WELDMENT

BOOM WELDMENT, MID

3

4

5

1

1

1

480897000 UPPER BOOM WELDMENT

366331000 CYLINDER EXTENSION DUAL

366198000 SHEAVE ASSY 3/8

10

11

12

13

8

9

6

7

1

1

1

2

2

1

1

1

360718000

646900000

642918000

366184000

366394000

366333000

360759001

366669000

BAIL WELDMENT

SWITCH, LIMIT ANTI-TWO BLOCK

CORD CONNECTOR

RETAINER, EXTENSION CYLINDER

BEARING, PIVOT

BEARING, SPHERICAL 1.25 ID

CORD REEL ASSY

WEAR PAD, BOTTOM MID

460081000 WEAR PAD, CABLE

366666000 WEAR PAD, SIDE

360767000 PAD BOOM 1.5 O.D.

460054000 WEAR PAD, TOP UPPER

407277000 PAD BOOM 1.5 O.D.

366667000 WEAR PAD, TOP MID

366648000 WEAR PAD, BOTTOM UPPER

366696000 COVER, WEAR PAD

460082000 PLATE, WEAR PAD RETAINER

366706000 SPACER, EXTENSION CYLINDER

360125000 PIN, BLOCK

360124000 PIN HITCH

738734000 RING RETAINING 5100-100

366400000 PIN 1.25n X 8.063

366493000

480029000

200876000

366678000

007803000

016801000

008400000

360882000

PIN 1n X 5.03 LG

RING RETAINING

FITTING 6 SAE/6 JIC STRAIGHT

SPRING RETURN

SCREW HX HD 5/16-18UNC X 3-1/2 GR5

NUT HX NYLK 5/16-18UNC CP

SCREW HX HD 3/8-16UNC X 3/4 LG GR 5

021100000 WASHER SP LK 3/8

460083000 SCREW SOC HD CTRSNK 5/16-24UNF X 3/4

022102000 WASHER FL 3/4

014400000 SCREW HX HD 3/4-16UNF X 5 LG GR5

018600000 NUT HX NYLK 3/4-16UNF CP

NUT, PUSH-ON TYPE (.161-.164DIA)

6.14.0

07/07/06

6006H ROTATION GEARBOX

P/N: 160407

6-15.0

9/12/05

6006H ROTATION GEARBOX

P/N: 160407

ITEM NO.

QTY.

PART NO.

DESCRIPTION

9

10

11

12

13

14

15

7

8

5

6

3

4

1

2

16

25

26

27

28

29

30

21

22

23

24

17

18

19

20

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

14

1

2

6

6

1

2

1

1

1

1

2

4

1

2

300058

308085

316092

328126

334016

338261

342120

357139

366019

368183

402044

402105

402106

402107

413013

414146

530101

414581

414869

418163

432011

442182

442187

456008

462029

468002

468018

470062

486071

518026

ADAPTER

BUSHING

CAP BEARING

COVER

GEAR R.H.

HOUSING GEAR

KEY

SHAFT OUTPUT

WASHER THRUST

WORM R.H.

BEARING BALL

BEARING NEEDLE

BEARING NEEDLE

BEARING THRUST

COVER

SCREW HX HD 5/16 NC X 1 1/4 GR5

(NYLON HEAVY PATCH)

PLUG - EXPANSION

SCREW HX HD 1/2 NC X 3/4 GR5

SCREW SOC HD 5/16 NC X 1

WASHER LK 5/16 MED SECT

ELL 90 DEG

GASKET

GASKET

FITTING RELIEF

O-RING

REDUCER

PLUG PIPE

PIN DOWEL

SEAL OIL

WASHER THRUST

6-16.0

9/12/05

6006EH ACTUATOR ASSEMBLY

P/N: 297025

6-17.0

09/12/05


P/N: 297025

1

1

3

2

4

4

1

6

22

1

3

1

2

1

2

3

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

ITEM NO.

QTY.

PART NO.

DESCRIPTION

29

30

31

32

33

34

25

26

27

28

35

36

21

22

23

24

17

18

19

20

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

352022

356901

357145

368022

400003

402001

402002

412044

412045

414021

414038

414224

414821

414845

416029

418036

418040

418154

418177

432011

306034

314008

328106

328128

328134

334001

334003

334129

334163

338007

338203

338273

340002

342023

342027

342033

SPRING - FLAT

PLATE - CAM

COVER - SPUR GEAR HSG.

COVER - BRAKE

COVER - WORM GEAR HSG.

IDLER GEAR

SPUR GEAR

PINION GEAR

GEAR - WORM., R.H.

HOUSING - BRAKE

SPUR GEAR HOUSING

GEAR HOUSING

HUB - BRAKE

KEY - SQ. END

KEY - RD. END

KEY - SQ. END

PLATE - RETAINER

SHAFT - SPUR

SHAFT - OUTPUT

WORM - R.H. 46:1

BALL

BEARING - NEEDLE

BEARING - BALL

BUSHING - COVER

BUSHING - HOUSING

SCW HH 1/4-20 X 1 GR 5 NYLOK HVY PATCH

SCW HH 1/4-20 X 3/4 GR 5

SCW HH 3/8-16 X 1-1/2 GR 5 FULL THD

SCW BTN HD SOC 1/4-20 X 7/8

SCW 1/4-20 X 1 SOC HD LOC-WEL

SETSCREW

NUT JAM 3/8-16

NUT 3/8-24

WASHER 1/4 FLAT ALUM.

LOCKWASHER

ELBOW 90 DEGREE

6-18.0

09/12/05


P/N: 297025

ITEM NO.

QTY.

PART NO.

DESCRIPTION

1

1

1

1

2

2

2

1

2

2

1

1

4

1

1

2

1

1

1

1

3

1

4

1

1

1

49

50

51

52

53

45

46

47

48

41

42

43

44

37

38

39

40

58

59

60

61

62

54

55

56

57

442184

442185

442189

442205

450001

450016

456008

458005

462015

468002

468011

468017

468018

470001

474001

486009

486017

486023

486069

486070

490003

494007

518002

518015

518018

518040

GASKET

GASKET

GASKET

GASKET

KEY - WOODRUFF

KEY - BARTH

RELIEF FITTING

MOTOR - 24V

O-RING

REDUCER

PIPE PLUG SQ HD

PIPE PLUG SOC HD

PIPE PLUG SOC HD

PIN

PLATE - THRUST

OIL SEAL

OIL SEAL

OIL SEAL

THREAD SEAL

THREAD SEAL

SNAP RING

SPRING

THRUST WASHER

THRUST WASHER

FIBER WASHER

WASHER - THRUST

6-19.0

09/12/05

6006EH TRAVELING BLOCK ASSEMBLY

P/N: 366063000

1

12

2

1

11

1

8

4

9

9

5

10

3

7

6

ITEM NO.

QTY.

PART NO.

DESCRIPTION

1

2

2

1

480362000

480130000

SHORT BLOCK SIDE PL WDMT

SHEAVE ASSY

5

6

3

4

1

1

2

1

480364000

480372000

480367000

480371000

TACKLE LOWER

BOLT, SHEAVE W/ ZERK FITTING

PIN BLOCK

HOOK SWIVEL 3 METRIC TON

7

8

9

10

11

12

1

1

2

1

2

2

480368000

017800000

366813000

360124000

040518000

366036100

PIN SWIVEL HOOK

NUT, HX LK 1/2-20UNF

PIN HITCH

PIN HITCH

DECAL STAY CLEAR OF LOAD

DECAL, TRAVELING BLOCK 6006H

6-20

9/12/05

6006EH ELECTRICAL SCHEMATIC

W/SLIP RING – P/N: 366684001

PUMP (WHT/BLK)

BOOM DOWN (BLU)

RETRACT (ORG/BLK)

BOOM UP (BLU/BLK)

HOIST UP (GRN)

BATT. VOLTAGE

(BLU/WHT)

PUMP

30

BOOM DOWN BR1

87

VSU (WHT/BLK)

RETRACT

BOOM UP

HOIST UP

(H1)

30

BR1

87

AC

AC

DIODE

SET

+

SIGNAL TO

VSU

PRESSURE SW

(BLU/RED)

L M A

J

K

T

U N

V P

B

C

H S R D

G F E

A2B

(RED/WHT)

ROT CW (ORG) d

ROT CW

+ (RED)

ROT CCW (WHT/RED)

ROT CCW

VSU (BLK/RED)

HOIST DOWN (RED/BLK)

EXTEND (GRN/BLK)

HOIST DN

(H2)

- (BLK)

(WHT/RED)

CO

A2B

PRESSURE

SWITCH

NO

(ORG)

EXTEND

30

BR1

87

85

(RED)

86

BOSCH 1

(BR1)

+12V

TO CRANE

(RED 16 GA)

SLIP RING a

b

c d

GROUND TO

SLIP RING

(BLK 4 GA)

SLIP RING

TO

CRANE

(BLK 4 GA) e

CHASSIS f

CRANE

RIGHT SIDE OF SCHEMATIC CONTINUED ON NEXT PAGE

7-1

11/27/06


W/SLIP RING – P/N: 366684001

LEFT SIDE OF SCHEMATIC ON PREVIOUS PAGE

+24V

TO

RELAYS

(BLK 4 GA)

B

A

PUMP

B

H1

H2

D

HOIST

RELAY

C

H1

A

H2

M

PUMP

ARMATURE

F2

M

A

F1

HOIST

CASE a f e d b c

+24V TO SLIP RING (BLK 4 GA)

+12V TO

SLIP RING

(16 GA)

SIGNAL TO VSU

VSU

GROUND

TO VSU

(BLK 4 GA)

TRUCK

BATTERY

AUX.

BATTERY

TRUCK BATTERY

TO CHASSIS

7-2

11/27/06


W/O SLIP RING - P/N: 366783000

PUMP (WHT/BLK)

BOOM DOWN (BLU)

RETRACT (ORG/BLK)

BOOM UP (BLU/BLK)

HOIST UP (GRN)

BATT. VOLTAGE

(BLU/WHT)

PUMP

30

BOOM DOWN BR1

87

VSU (WHT/BLK)

RETRACT

BOOM UP

HOIST UP

(H1)

30

BR1

87

PRESSURE SW

(BLU/RED)

PROG. PIN

(BLK/WHT)

BLANK

PLUG

J

K

L M

U N

A

B

T V P C

H S R D

G F E

A2B

(RED/WHT)

CAN L (ORG/RED)

CAN H (GRN/WHT)

ROT CW

(ORG) a

ROT SW

CW

PENDANT

PLUG

ROT CW

+ (RED)

ROT CCW (WHT/

RED)

ROT SW

CCW

ROT CCW

VSU (BLK/RED)

(BLK)


EXTEND (GRN/BLK)

HOIST DN

(H2)

- (BLK)

(WHT/RED)

CO

A2B

PRESSURE

SWITCH

NO

(ORG)

EXTEND

30

BR1

87

85

(RED)

86

BOSCH 1

(BR1)

(RED/

BLK)

(RED)

AC

AC

DIODE

SET b a

+

CRANE

RIGHT SIDE OF SCHEMATIC CONTINUED ON NEXT PAGE

7-3.0

9/12/05


W/O SLIP RING - P/N: 366783000

LEFT SIDE OF SCHEMATIC CONTINUED ON PREVIOUS PAGE

b a

SIGNAL TO

VSU

B

A

PUMP

B

H1

H2

D

HOIST

RELAY

C

H1

A

H2

M

PUMP

ARMATURE

F2

M

A

F1

HOIST

+24 V

TO

RELAYS

(BLK 4 GA)

CASE

CHASSIS

+12V

TO CRANE

(RED 16 GA)

GROUND

TO VSU

(BLK 4 GA)

VSU

TRUCK

BATTERY

7-4.0

AUX.

BATTERY

TRUCK BATTERY

TO CHASSIS

9/12/05

2

5005EH RELAY PANEL ASSEMBLY

P/N: 366682002

BOOTS REQUIRED A, C & D

1

BOOTS REQUIRED A, B

3

6

5

8

9

RELAY PANEL

GND BOLT #1

RELAY PANEL

GND BOLT #2

INDIVIDUAL HEAT SHRINK

TUBING ON BACK SIDE OF

CANNON PLUG

4

7

REF FOR REPLACEMENT PART ONLY

(680173000 RECEPTACLE/WIRE PIGTAIL)

ITEM NO.

QTY.

PART NO.

DESCRIPTION

7

8

5

6

9

3

4

1

2

1

1

1

1

1

13

1

9

1

366683001

320589000

320584000

320355000

366708000

736272000

366095000

360493000

751138000

BACK PLANE, RELAY PANEL

RELAY, HOIST

RELAY, POWER UNIT

RELAY, BOSCH

TERMINAL BLOCK ASSEMBLY

NUTSERT 1/4-20UNC X .027-.165 GRIP

PLUG, 19 PIN

SCREW HX WHIZ-LK 1/4-20UNC X 1/2 LG

RECTIFIER, BRIDGE 25 AMP

7-5.0

11/27/06

PUMP (WHT/BLK)

BOOM DOWN (BLU)


P/N: 366682002

BATT. VOLTAGE

(BLU/WHT)

PUMP

30

BOOM DOWN BR1

87

VSU (WHT/BLK)

AC

RETRACT (ORG/BLK)

BOOM UP (BLU/BLK)

HOIST UP (GRN)

RETRACT

BOOM UP

HOIST UP

(H1)

30

BR1

87

AC

DIODE

SET

+

SIGNAL TO

VSU

PRESSURE SW

(BLU/RED)

J

K

L

U

M A

N B

T V P C

H S R D

G F E

A2B

(RED/WHT)

ROT CW (ORG) d

ROT CW

+ (RED)

ROT CCW (WHT/RED)

ROT CCW

VSU (BLK/RED)


EXTEND (GRN/BLK)

HOIST DN

(H2)

- (BLK)

(WHT/RED)

CO

A2B

PRESSURE

SWITCH

NO

(ORG)

EXTEND

30

BR1

87

85

(RED)

86

BOSCH 1

(BR1)

+12V

TO CRANE

(RED 16 GA)

SLIP RING a

b

c d

GROUND TO

SLIP RING

(BLK 4 GA)

SLIP RING

TO

CRANE

(BLK 4 GA) e

CHASSIS f

CRANE

7-6.0

11/27/06


W/O SLIP RING - P/N: 366782000

2

BOOTS REQUIRED A, C & D

1

BOOTS REQUIRED A, B

3

10

5

7

4

RELAY PANEL

GND BOLT #1

RELAY PANEL

GND BOLT #2

8

6

INDIVIDUAL HEAT SHRINK

TUBING ON BACK SIDE OF

CANNON PLUG

REF FOR REPLACEMENT PART ONLY

(680173000 RECEPTACLE/WIRE PIGTAIL)

ITEM NO.

QTY.

PART NO.

DESCRIPTION

7

8

5

6

3

4

1

2

9

10

1

1

1

1

13

1

9

1

1

1

366683000

320589000

320584000

320355000

736272000

366095000

360493000

360768001

751138000

366708000

BACK PLANE, RELAY PANEL

RELAY, HOIST

RELAY, POWER UNIT

RELAY, BOSCH

NUTSERT .25UNC X .027-.165 GRIP

PLUG, 19 PIN

SCREW HX WHIZ-LK 1/4-20UNC X 1/2 LG

DEUTSCH DT04-4P-L012

RECTIFIER, BRIDGE 25 AMP

TERMINAL BLOCK ASSEMBLY

7-7.0

4/21/06


W/O SLIP RING - P/N: 366782000

PUMP RELAY

BOOM DOWN

30

BR1

87

RELAY MOUNT

HOIST RELAY

TERM 3

RETRACT

BOOM UP

HOIST

RELAY

BLANK

PLUG

30

BR1

87

RELAY PNL

BOLT - 2

J

K

L

U

M A

N B

T V P C

H S R D

G F E

PENDANT

PLUG

ROT SW CW

RELAY PNL

BOLT - 1

ROT CW

RELAY PNL

BOLT - 2

ROT SW CCW

ROT CCW

RELAY PNL

BOLT - 1

HOIST DN

(H2)

HOIST RELAY

BOLT

EXTEND

30

BR1

87

RELAY PNL

BOLT - 1

A

PUMP

B

M

PUMP

B

D

H1

HOIST RELAY

H2

C

H1

H2

A

F1

M

A

F2

HOIST

AC

AC

DIODE

SET

+

WHITE

BLACK

GREEN

(FOR FUTURE USE)

CASE

RECEPTACLE

3 PIN

(PLUG IS TO BE SHIPPED LOOSE

AND INSTALLED IN ASSEMBLY)

RELAY PNL

BOLT - 2

CO

A2B

NO 85

BOSCH 1

(BR1)

86

PRESSURE

SWITCH

7-8.0

4/21/06

6006EH PENDANT 8 FUNCTION W/ ON/OFF

SWITCH - P/N: 366709001

PENDANT HEAD

CW (ORG)

CCW (WHT/RED)

H

M

J

C

E

C

E

H

M

J

EXTEND (GRN/BLK)

RETRACT (ORG/BLK)

PUMP (WHT/BLK)

BOOM UP (WHT)

BOOM DN (BLU)

HOIST UP (GRN)

HOIST DN (RED/BLK)


(WHT/RED)

B

F

A

K

R

A

K

B

F

R

D D

+ (RED)

POWER

CANNON

PLUG

7-9.0

03/20/06

3

6006EH PENDANT 8 FUNCTION W/ ON/OFF

SWITCH - P/N: 366709001

12

6

9

2

7

8

1

4

11

10

5

ITEM NO.

QTY.

PART NO.

DESCRIPTION

7

8

5

6

3

4

1

2

9

10

11

12

1

1

1

1

1

1

1

4

5

4

2

2

480501000

366719000

480504000

370433000

680172000

480598000

750090000

634200000

640300000

001004000

002607000

015801000

PENDANT HOUSING

DECAL, PENDANT 8 FUNC W/PWR

PENDANT BACK PLATE

CORD CONNECTOR HUBBLE F-3

PENDANT CABLE, 19 PIN BAYONET

COVER TRIGGER OPENING

TOGGLE SWITCH (ON-OFF)

TOGGLE SWITCH KIT

BOOT, TOGGLE-URETHANE-MID

SCW PN HD #6 X 3/4 LG

SCREW RD HD #10-24UNC X 3/4 LG CP

NUT HX NYLON LOCK #10-24UNC ZP

7-10.0

03/20/06

6006EH VOLTAGE SWITCHING UNIT

P/N: 366692000

1

7

3 6

5

RELAY

1

RELAY

3

RELAY

2

3 6

2

1

OUTSIDE INSULATION OF CORD

SHOULD EXTEND 1" PAST

GROMMET AND ZIP TIE

INSTALLED TO RETAIN CORD.

LOCATE DECAL

IN CENTER OF LID

INSTALL SCHEMATIC DECAL TO

UNDERSIDE OF LID. DECAL

SHOULD BE RIGHT SIDE UP

WHEN LID IS OPENED

DOWNWARD.

15 16 17

10

2

19

10

1

9

8

7-11.0

4/21/06


P/N: 366692000

19

20

POWER

SWITCH

A B

11

A

9

RELAY - 1

C D

B

C

RELAY - 2

10

D

18

18

21

POWER

LIGHT

3

30

1

BR1

2

F

RELAY - 3

E

F E

RELAY - 1

87

6

F

RELAY - 2

E

86 85

BR1

7

13

4

8

5

22

16

14

A

12

RELAY - 3

B

C D

15

AUX.

BATTERY

17

18

16/3

CONDUCTOR

CORD

TRUCK

BATTERY

PANEL GROUND

A B C

CHASSIS GROUND

LARGE RELAY

TOP VIEW

LARGE RELAY

BOTTOM VIEW

7-12.0

BOSCH RELAY

BOTTOM VIEW

4/21/06

NOTES


P/N: 366692000

ITEM NO.

QTY.

PART NO.

DESCRIPTION

7

8

5

6

3

4

1

2

3

2

1

8

8

4

1

1

366693000 ENCLOSURE, VOLTAGE SWITCHING UNIT

367242001 DECAL, THIS END UP

736272000 NUTSERT .25UNC X .027-.165 GRIP

001900000 SCREW RD HD #10-32UNF X 3/8 LG

320355000 RELAY, BOSCH


404167000 SOLENOID, SEALED

750169000 GROMMET, RUBBER

16

17

18

19

*

9

10

*11 1

*12 1

1

1

*13 3

14

15

1

1

750282000

750090000

360763001

360763002

GROMMET 1 3/8 OD

TOGGLE SWITCH (ON-OFF)

HOUSING 3-PIN

WEDGE, DEUTSCH 3-PIN

366367003 CONTACT, SOCKET

366705000 DECAL, VSU SCHEMATIC

750171000 LAMP SOCKET, INDICATOR

1

1

1

1

750173000

366707000

366717000

366516000

NOT SHOWN

BULB, 12V TYPE T-2

LENS, GREEN FLUTED

TWECO CONNECTOR, FEMALE 1MPC2

DECAL, ON/OFF

7-13.0

4/21/06

6006EH HYDRAULIC SCHEMATIC

P/N: 366785000

8-1.0

9/12/05

6006EH HYDRAULIC CONTROL VALVE

P/N: 320826000

RETRACT COIL

EXTEND PORT

(EXT)

INSIDE PORT ON

POWER UNIT

(PRESSURE)

RETRACT PORT

(RET)

EXTEND COIL

BOOM UP COIL

ROTATE CCW

COIL

BOOM DOWN COL

ROTATE CW

COIL

BOOM DOWN

PORT (RET)

TO FRONT MOTOR

PORT (CW)

BOOM UP

PORT (EXT)

TO OUTSIDE PORT ON

POWER UNIT (RETURN)

TO REAR MOTOR

PORT (CCW)

QTY DESCRIPTION A/C P/N

3 SPOOL VALVE, 4WK06G-12X-0-0-N 320826001

6 SOLENOID COIL, 12DN-50-1836

HYDAC P/N

320826002 03091665

8-2.0

9/12/05

6006EH HYDRAULIC POWER UNIT

P/N: 366650000

8-3.0

9/12/05

6006EH HYDRAULIC POWER UNIT

P/N: 366650000

NOTE: SOME PARTS AVAILABLE ONLY IN THEIR RESPECTIVE KITS.

6A

6B

6C

6D

6E

6F

6G

6H

6J

4A

4B

4C

4D

4E

4F

4G

2A

2B

2C

2D

2E

2F

2G

1A

1B

1C

1D

1E

1F

1G

1H

1J

ITEM PART NO. DESCRIPTION

1

360808001 PUMP AND PARTS

PUMP ASSEMBLY

O-RING

O-RING

O-RING

SCREW

SCREW

LOCKING SPRING

RETAINER

COUPLING

2

366650001 RELIEF VALVE KIT

CAP

GASKET

ADJ SCREW

O-RING

SPRING

PLUNGER

SEAT ASSEMBLY

3

3A

3B

366650002 MOTOR KIT

MOTOR 24V DC

GROUND STRAP

4

366650004 ADAPTER KIT

SEAL

SCREW

CHECK VALVE ASSEMBLY

ADAPTER

RETAINER

PLUG

PLUG

5

366650003 RESERVOIR KIT

5A

5B

5C

SCREW

RESERVOIR

STRAINER

5D 200545000 BREATHER

5E MAGNET

6

366650004 TUBE KIT

O-RING

O-RING

WASHER

RETAINING RING

RETAINING RING

TUBE

TUBE

TUBE

SPACER

7

7A

7B

7C

7D

320336002 RETURN PORT ASSEMBLY

RETURN PORT BODY

O-RING

O-RING

BACK-UP RING

QTY.

1

1

1

1

-

1

1

1

1

1

-

1

1

1

1

-

1

1

1

2

1

1

1

-

4

1

1

1

1

1

1

1

1

-

1

1

1

-

1

1

4

1

1

1

1

-

1

1

1

1

8-4.0

9/12/05


FM - W/SLIP RING - P/N: 366600001

9

10

10

9

4

4

5 6 7

19

8

APPLY LOCTITE 242

TO THREADS BEFORE

INSTALLATION

1

18

13

14

20

17

22 21 23

15 16

RETRACT

PORT #8

EXTEND

PORT #7



9-1.0

2 6 5 3

20

21 22

17

1

07/07/06


FM - W/SLIP RING - P/N: 366600001

18

19

20

21

22

14

15

16

17

ITEM NO.

QTY.

PART NO.

DESCRIPTION

1

2

1

1

366640000 PEDESTAL ASSEMBLY


7

8

9

3

4

5

6

10

11

12

13

2

1

2

2

1

1

1

1

1

1

1



021100000 WASHER SP LK 3/8






366697001 SHIP KIT 6006EH FM CRANE


366715000 BRACKET ASSEMBLY, RECEIVER MOUNT

1

4

4

1

1

1

1

2

2

460158000 RECEIVER, NON-PROPORTIONAL

020200000 WASHER SP LK 1/4

005500000 SCREW HX HD 1/4-20UNC X 3/4 LG

366602000 HARNESS, FM, 5005EH, 6006EH




020601000 WASHER SP LK 5/16


9-2.0

07/07/06


FM W/O SLIP RING P/N: 366790000

9

10

10

9

18

2

8

2

4 5 6 7

APPLY LOCTITE 242

TO THREADS BEFORE

INSTALLATION

1

17

12

19

16

20 21

22

14 15

RETRACT

PORT # 8



9-3.0

EXTEND

PORT # 7

16

4 5 6 3

1

4/21/06


FM W/O SLIP RING P/N: 366790000

18

19

20

21

22

13

14

15

16

17

ITEM NO.

QTY.

1 1

2

3

1

1

7

8

9

4

5

6

10

11

12

1

1

1

1

1

1

2

2

2

1

1

2

2

1

1

4

4

1

1

PART NO.

DESCRIPTION





021100000 WASHER SP LK 3/8







366715000 BRACKET ASSEMBLY, RECEIVER MOUNT

460158000 RECEIVER, NON-PROPORTIONAL

020200000 WASHER SP LK 1/4

005500000 SCREW HX HD 1/4-20UNC X 3/4 LG

366602000 HARNESS, FM, 5005EH, 6006EH




020601000 WASHER SP LK 5/16


680150001 KIT, ELEC, 6006EH W/ROTATION STOP

9-4.0

4/21/06

FM CONTROL

USE AND CARE

TRANSMITTER LAYOUT

There is a red light to the left of the ON/OFF Toggle switch and a yellow light to the right. As the battery runs down, the red light will begin to flash as well as the yellow light.

If the yellow light is rapidly flashing this indicates that the unit is transmitting. Refer to the

Transmitter Diagnostics Section for a detailed explanation of each light combination.

In addition to the two lights mentioned above there are four function toggle switches. These functions from left to right are to be used to raise and lower the boom, raise and lower the hoist cable, rotate the crane and extend and retract the boom.

POWER ON/OFF TOGGLE SWITCH

The transmitter is powered by 4-AA alkaline batteries, located under the back cover of the housing. To turn the transmitter on, press and hold the Power On Toggle, release once the transmit light starts blinking. To turn the unit off, press and hold the power off toggle, release after the transmit light stops flashing.

FUNCTION SWITCHES

To operate a function, toggle one of the function switches with either the thumb of the hand holding the unit or the thumb or fingers of the opposite hand. More than one function can be activated at one time.

CARE

KEEP DRY. Do not clean the transmitter / receiver under high pressure. If water or other liquids get inside the transmitter battery or receiver compartment, immediately dry the unit. Remove the case and let the unit air dry.

WELDING

DISCONNECT THE RADIO RECEIVER BEFORE WELDING on the crane, load, or truck. Failure to disconnect will result in the destruction of the radio receiver.

10-1.0

2/15/05

FM CONTROL

TRANSMITTER - P/N: 460157000

1

3

2

4

ITEM NO.

QTY.

PART NO.

DESCRIPTION

1 5 460166000 TOGGLE SWITCH KIT (OMNEX)

2

3

4

1

1

1

460168000

460163000

HANDLE, TRANSMITTER W/O TRIGGER

COVER, TRANSMITTER BATTERY W/MAGNET

460162000 GUARD, TRIGGER (OMNEX)

TOGGLE SWITCH WIRING CHART

FUNCTION WIRE COLOR

POWER ON

POWER OFF

BOOM UP

BOOM DN

YELLOW

GREEN (FROM 8 PIN CONNECTOR)

RED

ORANGE

BOOM EXTEND GREEN (FROM 10 PIN CONNECTOR)

BOOM RETRACT BLUE

ROTATE CW

ROTATE CCW

VIOLET

GREY

HOIST UP

HOIST DN

COMMON

WHITE

BROWN

BLACK

TERMINAL POSITION

BOTTOM

TOP

BOTTOM

TOP

BOTTOM

TOP

BOTTOM

TOP

BOTTOM

TOP

MIDDLE

10-2.0

02/15/06

ELECTRICAL SCHEMATIC

FM – P/N: 404206000

A (GREY PLUG)

PUMP

GROUND

POWER W/LINK

POWER

EXTEND 10

11

RETRACT 12

7

8

5

6

9

3

4

1

2

(WHT/BLK)

(BLK)

(RED)

(GRN/BLK)

(RED)

H

M

J

G

D

B (BLACK PLUG)

ROTATE CW

ROTATE CCW

WINCH UP

WINCH DOWN

BOOM UP

BOOM DOWN

1

2

3

4

5

PEND (A)

PEND (B)

6

7

8

9

10

VSU 11

12

(ORG)

(WHT/RED)

(WHT)

(GRN)

(RED/BLK)

(WHT)

(BLU)

(BLU)

(BRN)

3

2

5

4

1

PENDANT

PLUG

(BLK) (GRY)

(BLK/RED)

K

R

B

F

C

E

A

CANNON PLUG

B

F

C

E

A

K

R

H

M

J

G

D

10-3.0

4/21/06

FM CONTROL

TRANSMITTER DIAGNOSTICS

RED

Tether connection detected

RED

YELLOW

Low battery. Unit will run approximately 10 hours after Battery light starts flashing.

RED

Flashing rapidly for 10 seconds indicates a transmitter failure.

YELLOW

Normal Operation

The Active light will flash several times per second, indicating that the transmitter is sending signals to the receiver. The Active light will remain on momentarily whenever a function changes

YELLOW


The transmitter is in Download Mode.

RED

YELLOW

Stuck switch detected. Ensure that all switches are in a centered position. The transmitter will not power up when a function is ON.

RED

YELLOW

On Power Down

Unit is still powered. Check for stuck switches, as the transmitter will not power down when a function is ON. Alternating flash means that the transmitter is in Calibration Mode.

Light Legend

Solid

Slow

Flash

Fast

Flash

Red

Light

10-4.0

Green

Light

Yellow

Light

02/15/06

FM CONTROL

RECEIVER DIAGNOSTICS


ESTOP FAULT LINK STATUS

RED - RED GRN

Transmitter is OFF

If the transmitter is off, the receiver is operating properly.

GRN

GRN

RED

- GRN GRN

GRN GRN GRN

GRN RED GRN

Transmitter is ON

When the transmitter is turned on, the Link light (fast flashing) and E-Stop (GREEN) indicates the receiver is operating properly

Transmitter is in Operation

When a function is activated on the transmitter, the Fault light will turn on GREEN. This indicates the receiver is operating properly

Transmitter is OFF

When a latched function is activated then the transmitter is turned off, the Fault light will stay on GREEN. If the system was intentionally designed this way, the receiver is operating properly, if not call for service.

Trouble Indicators

Note: In some cases, the indicator lights will be different depending on whether the transmitter is on or off. Please note the transmitter status in the

“Description” column for each case.

Indicator Lights

RED - RED GRN

GRN

RED

GRN

RED

RED

- GRN GRN

- GRN RED

RED GRN RED

- RED RED

- RED RED

Description

Transmitter is ON

The reason is the transmitter is not communicating with the receiver.

Transmitter is ON

A low battery condition has been detected.

Transmitter is ON

An internal fault with the E-Stop has been detected.

Transmitter is ON

A short to ground or excessive current draw on an output. It is most likely caused by a wiring fault.

Solution

Refer to Trouble Shooting Chart #3 for solutions

To detect intermittent conditions caused by poor or corroded ground or power circuits, the GREEN light will continue to flash for

30 seconds after the condition has been removed.

Check fuse, if OK then: Inspect E-Stop wiring for short circuit. Disconnect E-Stop wire as close to the receiver output as possible. If the

Status light changes to:

•

GREEN, a short occurs after disconnection point.

•

Stays flashing RED, send it in for service .

Ensure transmitter is functioning properly, check status of each output connection: Press each function button and observe Fault Light.

•

If GREEN, everything is OK.

•

If RED, there is a short in that connection.

Transmitter is OFF

The receiver has detected an internal fault.

Transmitter is ON

Blown fuse detected. (not functional with proportional units)

Refer to Trouble Shooting Chart #1 for solutions

Refer to ID Code Section for instructions on how to open the receiver case to access fuse. Check wiring for shorts or bare spots. If fuses continue to blow, call for service.

- RED RED RED

A setup failure has occurred.

Either hold the Setup button for 5 seconds to return to Setup mode or cycle power to return to the normal operating mode.

RED

Transmitter is OFF

The receiver is powered incorrectly.

Most likely cause of this condition is that an output wire or the E-Stop wire has been connected to a power source while the power wire is disconnected from the Power Input (A6). I.E. Receiver is being powered from an output and not Power Input.

Light Legend

Solid

Slow

Flash

Fast

Flash

Red

Light

10-5.0

Green

Light

Yellow

Light

02/15/06

Problem state:

Status—RED

FM CONTROL

TROUBLESHOOTING CHART 1

Test the Receiver—R160

Start

Initial Condition:

Turn transmitter off (all lights are off—press

[POWER] OFF)

Cycle power to receiver (turn off and back on)

What is the state of the lights on the receiver?

OK state:

Status—GREEN

Link—RED

Fault—OFF

E-Stop—RED

Note: If there is a short to ground on an output, it is not indicated at this stage. To test for short to ground, refer to the “*Fault Light is RED*” procedure at the bottom of this page and follow the instructions.

Go to Chart 2

Problem state:

Status—flashing

GREEN & RED

The system is wired incorrectly.

Most likely cause is one of the input/output wires has been connected to the power source.

Is the Status light flashing

RED?

NO

YES

What is the state of the E-

Stop light ?

Fuse is blown, change fuse

1. Inspect wiring looking for short circuits (e.g. bare wires)

2. If problem re-occurs, call for service.

Problem state:

E-Stop— Flashing

RED

Inspect E-Stop wiring looking for short circuits (e.g. bare wires)

Disconnect the E-Stop output as close to the receiver output as possible.

If the Status light changes to:

•

GREEN, there is a short is the wiring after the disconnection point.

•

Stays flashing RED, call for service .

OK state:

E-Stop—RED

Fault Light is

OFF

Call for service.

What is the state of the

Fault light ?

*Fault Light is

RED*

There is a short to ground.

Note: This should only occur when the transmitter is on and a function button is pressed. In this case the Status light will be

GREEN and will turn RED at the same time as the Fault light.

Go to Chart 2 to test the transmitter. If the transmitter is functioning properly, proceed to check the status of each of the output connections:

Press each of the function buttons and observe the Fault Light.

If the light turn GREEN, everything is OK.

If the Light turns RED, there is a short in that connection.

10-6.0

02/15/06

FM CONTROL


Test the Transmitter—T150

Turn off the receiver

Ensure there are good batteries in the transmitter

Turn on the transmitter

What is the state of the lights?

OK state:

Active light—steady for about 3 seconds then goes to fast flash.

Battery light—OFF

Activate a function

No light comes on at any time

Both the Active light and the Battery light flash at the same time

Go to Chart 3

Complete the following steps in order:

1. Check battery orientation

2. Clean battery contacts

3. Check or Replace batteries

4. Call for service

Stuck switch:

1. Return all switches to neutral (OFF) position

2. Toggle the switch a few times

3. Call for service

YES

Does the Active light go to solid

YELLOW?

NO

Either the switch/trigger is defective or the switch/trigger connection to the circuit board is broken.

Call for service

Active light is flashing rapidly and Battery light flashing slowly

Low Battery—Change Batteries

Note: Low batteries will last approximately 10 hours once the Low Battery light begins to flash.

Replace batteries by next shift.

Battery light and

Active light flash alternately.

The transmitter is in Calibration mode

1. Turn unit OFF, then turn back ON

2. If condition persists, call for service.

Battery light flashes for 10 seconds then all lights are OFF

Press and release E-Stop if the condition persists, then either there is a faulty E-

Stop or transmitter failure—call for service

10-7.0

02/15/06

FM CONTROL


Testing the Transmitter / Receiver Communication

Transmitter:

Active light is flashing

Receiver:

Status—GREEN

Link—RED

Fault—OFF

E-Stop—RED

What is the status of the lights of both the transmitter and receiver?

Transmitter:

Active light is flashing

Receiver:

Status—GREEN

Link—Flashing GREEN

Fault—OFF

E-Stop—GREEN

There is no link between the transmitter and receiver

Transmitter and receiver should be working properly.

The problem may rest with the machine instead of the radio system

Call for service

Do you have a matched set? (i.e. the transmitter and receiver should have identical ID codes

NO

YES

Call for service.

Was the transmitter accidentally swapped with another one on the job site?

POSSIBLY

Search the job site for the correct transmitter.

NO

NO

Was it found?

YES

Turn on the transmitter to check if the units function correctly. If not, proceed to Chart 1

The transmitter code may need to be re-downloaded to the receiver

See ID Code Section

10-8.0

02/15/06

FM CONTROL

ID CODE PROGRAMMING

Download ID Code

(Use in case of Link Test failure)

!!Caution!!

Note: Before attempting reprogramming with another transmitter, understand that reprogramming the receiver with another transmitter, could result in two receivers on the job site responding to the one transmitter. If the original transmitter was sent in for repair, disconnect the receiver (disconnect connector A) to continue using the machine without remote capability and without fear of inadvertently operating the machine with the other transmitter.

Connector A

Reprogramming Tips:

1. Use a pointy instrument to depress the Setup button on the receiver (i.e. a pen) as the button is relatively small

2. Follow each step as laid out in the procedure

3. Never lay the receiver circuit board down on anything metallic (there are contact points on the back which could contact the metal and damage the receiver)

Follow these steps to download the transmitter’s unique ID Code into the receiver. This will allow the receiver to establish a radio link with that transmitter.

Refer to the Light Legend below for diagram details.

NOTE: It is necessary to download the ID Code when replacing either the transmitter or the receiver.

NOTE: If the transmitter is connected to the receiver with a Tether Cable, completing only steps 3 and 5 is necessary (it is not necessary to open the R160 case and press the Setup button).

1. Opening the Receiver Case

The cap is held on by two plastic tabs at opposing sides, which can be unlatched as shown using a screwdriver. Once the cap is free, the R160 can slide open.

Use a small slotted screwdriver to press the

Side Tabs inward.


2. Prepare Transmitter, Power Receiver

A.

A. Press [POWER] OFF

B. Supply power to the receiver

B.


Light Legend

Solid

Slow

Flash

Fast

Flash

Red

Light

10-9.0

Green

Light

Yellow

Light

02/15/06

FM CONTROL

ID CODE PROGRAMMING (CONT.)

3. Power Transmitter into Configuration Mode

A. Press & hold [BOOM] switch in the UP position

B. Press & release [POWER] switch in the OFF position

C. Release [BOOM] switch

The ACTIVE LED will flash once per second.

A.

YELLOW

B. C.

YELLOW YELLOW

4. Put Receiver into Setup

A. Press & hold [Setup] button until (Status) light goes from slow flash to fast flash

B. Release [Setup] button.

(Status) light goes to solid

GREEN, (Link) light turns off

A.

Setup

Button


B.

Setup

Button


NOTE: If left idle in Setup Mode for over 30 seconds, the receiver will time out. The (Link) light and (Status) light will flash RED rapidly. To return to Setup Mode, repeat step 4.

5. Download ID Code

A. Press & release [BOOM] switch in the UP position

B. The R160 (Link) light goes to

GREEN. Once complete, (Link) light goes to RED as the transmitter turns off

A.

YELLOW

B.


NOTE:

When replacing the receiver cover, ensure the cover snaps completely into place to create a weather proof seal around the base of the receiver.

Light Legend

Solid

Slow

Flash

Fast

Flash

Red

Light

10-10.0

Green

Light

Yellow

Light

02/15/06

6006EH LOAD CHART

P/N: 366710000

22

21

20

19

18

17

16

15

14

13

12

11

10

9

6

5

4

8

7

3

2

1

0

6000

6000

6000

4110

6006EH

NOTE:

WEIGHT OF LOAD HANDLING

3625

DEVICES ARE PART OF THE

LOAD AND MUST BE

DEDUCTED FROM

THE CAPACITY

2525

4640

6000

2860

6000

5325

3220

75°

6000

6000

60°

6000

ATTENTION!

OVER 3000 LBS

USE DOUBLE LINE

4315

3685

2315

2050

45°

5025

4050

3485

30°

2985

2610

2665

2330

2070

15°

3610

3110

1830

3480

3000

2570

2250

2000

1770

C

L

1

0 2

3

4

5

6

7

8

9 11

10'-4" 12

13

DISTANCE IN FEET

14

15

16

17

18

19

20'-4"

P/N 366710000 C

11-1.0

4/21/06

NOTES

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

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

LIMITED WARRANTY

2 YEAR PARTS AND LABOR

Auto Crane will warranty to the consumer for a period of (2) years parts and labor from the date of purchase. Each new Auto Crane unit they sell will be free under normal use and service from defects in material and workmanship. Date of purchase will be honored as the date indicated on the Bill of Sale, which must accompany the Warranty Registration and be on file with Auto Crane.

Absent a valid Warranty Registration and appropriate documentation, the original date of manufacture, as indicated by the serial number on the product, will be used to determine the effective date of the 2 year warranty.

The obligation of Auto Crane under this warranty is limited to the replacement or repair of parts that appear to the manufacturer after review and/or inspection to be defective and paid flat rate labor for replacing defective parts. This warranty does not obligate Auto Crane to bear the travel time charges in connection with the replacement or repair of defective parts. Responsibility for customer's claims arising from misapplication, abuse, misuse or alteration of equipment or parts lies with the distributor or user and no warranty obligation is assumed in these circumstances by Auto

Crane.

Auto Crane will in no event be liable for any consequential damages or contingent liabilities arising out of the failure of any Auto Crane Product or parts to operate properly.

Auto Crane makes no warranty in respect to component accessories, it being subject to the warranties of their respective manufacturers.

If field service, at the request of the distributor, is rendered and fault is found not to be with Auto

Crane's product, the distributor shall pay the time and expense of the field representative.

Claims for service labor or other expenses that have incurred by the buyer without approval or authorization or Auto Crane will not be accepted.

When applying for warranty, claims may be handled by contacting your nearest authorized Auto

Crane

Distributor. All claims are to be filed in writing on an Auto Crane Warranty Claim

Form.

AUTO CRANE COMPANY IS UNDER NO OLIGATION TO EXTEND THIS WARRANTY

TO ANY CUSTOMER FOR WHICH AN AUTO CRANE DELIVERY REPORT FORM HAS

NOT BEEN COMPLETED AND ON FILE WITH AUTO CRANE COMPANY

Limited Warranty 2 Years Effective September 2, 2003

Auto Crane 6006EH crane Owners Manual

Assistant Bot

6006EH

OWNERS MANUAL

Serial No. __________________

Auto Crane Warranty Registration

End User Information:

Distributor Information:

Product Information:

ONE REGISTRATION FORM PER UNIT (CRANE OR BODY)

WARNINGS

READ THIS PAGE

DIMENSIONS

CAPACITY

LIFTING CAPACITIES

REACH

CABLE

CHASSIS REQUIREMENTS

ELECTRICAL SYSTEM

REQUIREMENTS

ROTATION

WARNING!

WARNING!

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

TABLE 1

DESIGNATED PERSONNEL SHALL

PERFORM INSPECTIONS ONLY.

TESTING SHALL BE PERFORMED BY DESIGNATED PERSONNEL ONLY.

MAINTENANCE PRECAUTIONS

LUBRICATION

ROPE REPLACEMENT

ADJUSTMENTS AND REPAIRS

ROPE MAINTENANCE

Keep Properly Charged

Keep Properly Filled with Water

Keep A Relatively Clean Battery

Periodic Maintenance is Needed

Low Maintenance Batteries

(Maintenance Free)

Testing Your Battery

Replacing a Battery

CAUTION:

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

NOTES:

WARNING

REMOTE CONTROL SAFETY PRECAUTIONS

CARE

MAINTENANCE / WELDING

WARNING

FEDERAL LAW

IT IS THE FURTHER RESPONSIBILITY

W/O SLIP RING

WITH SLIP RING

RIGHT SIDE OF SCHEMATIC CONTINUED ON NEXT PAGE

LEFT SIDE OF SCHEMATIC ON PREVIOUS PAGE

RIGHT SIDE OF SCHEMATIC CONTINUED ON NEXT PAGE

LEFT SIDE OF SCHEMATIC CONTINUED ON PREVIOUS PAGE

NOTE: SOME PARTS AVAILABLE ONLY IN THEIR RESPECTIVE KITS.

Light Legend

Normal Operation

Trouble Indicators

Light Legend

Test the Receiver—R160

Test the Transmitter—T150

Testing the Transmitter / Receiver Communication

Download ID Code

(Use in case of Link Test failure)

Light Legend

Light Legend

6006EH

LIMITED WARRANTY

2 YEAR PARTS AND LABOR

AUTO CRANE COMPANY IS UNDER NO OLIGATION TO EXTEND THIS WARRANTY

TO ANY CUSTOMER FOR WHICH AN AUTO CRANE DELIVERY REPORT FORM HAS

NOT BEEN COMPLETED AND ON FILE WITH AUTO CRANE COMPANY

Key Features

Frequently Answers and Questions

What is the capacity of the 6006EH crane?

How long is the cable on the 6006EH crane?

What are the rotation capabilities of the 6006EH crane?