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5005H
OWNERS MANUAL
Manual No. 360706000
Rev. 07/26/2004
Serial No. __________________
Mailing Address:
P.O. Box 580697
Tulsa, OK 74158-0697
Physical Address:
4707 N. Mingo Rd.
Tulsa, OK 74117-5904
Phone (918) 836-0463
Fax (918) 834-5979 http://www.autocrane.com
Auto Crane Warranty Registration
Fax Transmission
To:
From:
Re:
Warranty Department
Product Registration
Fax:
Date:
Pages:
(918) 834-5979
End User Information: (Required for Warranty Activation)
Name:
Address:
City:
Contact:
State:
E-mail Address:
Distributor Information: (Required for Warranty Activation)
Phone:
Name:
Address:
City:
Contact:
Product Information:
Model No.:
Date Product Delivered:
VIN #
State:
E-mail Address:
(Required for Warranty Activation)
Serial No.:
Date Processed:*
Zip:
Zip:
* For Auto Crane use only
ONE REGISTRATION FORM PER UNIT (CRANE OR BODY)
Registration form must be mailed or faxed within 15 days of customer installation.
Mail to:
Warranty Department
Auto Crane Company
P.O. Box 581510
Tulsa, OK 74158-0697
Warranty Registration Rev. 072403
5005H SERIES
OWNER’S MANUAL – REVISION RECORD
Revision
Date
Section(s)
Or
Page(s)
09/02/03 Last page
Description of Change
12/30/03 Mounting & Instl.
(p. 3-2.0.0)
Lub. & Maintenance
(p.4-1.0.0)
4/23/04 Pages 3-2.0.0, 5-1.0.0
& 8-9.0.0
07/26/04 Pages 10-1.0.0, 10-3.0.0,
10-5.0.0, 10-6.0.0, 10-
9.0.0 & 10.10.0.0
New 2-year warranty policy to replace 1-year warranty policy
Revised torque specs for mounting hardware for crane, rotation bearing and rotation gear box.
Updated receiver & transmitter to 2 nd generation
Added voltage relay circuit i
WARNINGS
WARNING! Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of a vehicle certify that the vehicle complies with all applicable federal regulations. Any modifications performed on the vehicle prior to the final state are also considered intermediate stage manufacturing and must be certified as to compliance. The installer of this crane and body is considered on of the manufacturers of the vehicle. As such a manufacturer, the installer is responsible for compliance with all applicable federal and state regulations, and is required to certify that the vehicle is in compliance.
WARNING! It is the further responsibility of the installer to comply with the OSHA Truck Crane
Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).
WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL POWER LINES!
Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. SEE DANGER DECAL (P/N 040529) in this Owner's Manual.
WARNING! NEVER.........................................
♦ EXCEED load chart capacities (centerline of rotation to hoist hook).
♦ Un-reel last 5 wraps of cable from drum!
♦ Wrap cable around load!
♦ Attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
♦ Weld, modify, or use unauthorized components on any Auto Crane unit! This will void any warranty or liability. Also failure of the crane may result.
♦ Place a chain link on the tip of the hook and try to lift a load!
♦ Use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature!
♦ Hold on any pendant Select Switch that will cause unsafe operating conditions!
WARNING! In using a hook with latch, ALWAYS make sure that the hook throat is closed before lifting a load! Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.
WARNING! Failure to correctly plumb and wire crane can cause inadvertent operation and damage to crane and/or personnel!
WARNING! Auto Crane Company remote controlled cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel.
WARNING! ALWAYS operate the crane in compliance with the load capacity chart. DO NOT USE the overload shutdown device to determine maximum rated loads, if the crane is equipped with this type of device.
Warnings
READ THIS PAGE
12/2002
TABLE OF CONTENTS
5005H SERIES
INTRODUCTION
OPERATING PRACTICES & WARNINGS
OPERATION OF UNIT / OUTRIGGERS
CONTROLLER OPERATION
QUALIFCATIONS FOR OPERATORS
INSPECTION, TESTING, & MAINTENCE
DECAL SECTION
GENERAL DIMENSIONS
MOUNTING AND INSTALLATION
LUBRICATION AND MAINTENANCE SCHEDULE
PEDESTAL ASSEMBLY
BOOM ASSEMBLY
ROTATION GEAR BOX
HOIST ASSEMBLY
GENERAL ASSEMBLY
ELECTRICAL SCHEMATIC
WIRE HARNESS ASSEMBLY
HYDRAULIC SECTION
DIAGNOSTICS
LOAD CHART
HARD WIRED SERIES, SUPPLIMENTAL INFORMATION
WARRANTY
4-1.0.0
5-1.0.0
5-4.0.0
5-6.0.0
5-8.0.0
5-11.0.0
6-1.0.0
6-2.0.0
1-1.0.0
2-2.0.0
2-3.0.0
2-4.0.0
2-6.0.0
2-9.0.0
2-14.0.0
3-1.0.0
3-2.0.0
7-1.0.0
8-1.0.0
9-1.0.0
10-1-0.0
LAST PAGE
6/04/2003
NOTES
INTRODUCTION
5005H SERIES
Auto Crane products are designed to provide many years of safe, trouble-free, dependable service when properly used and maintained.
To assist you in obtaining the best service from your crane and to avoid untimely crane and/or vehicle failure, this manual provides the following operating and service instructions. It is specifically recommended that all operating and service personnel consider this manual as mandatory material for reading and study before operating or servicing Auto Crane products. It is highly recommended that crane owners, equipment managers and supervisors also read this manual.
Auto Crane has incorporated several safety features in the 5005H crane for your protection.
For your convenience the overall dimensions of the 5005H 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 5005H cranes are attached directly to your 12 volt truck electrical system. The power cable is included with the crane. The 5005H is another highly efficient Auto Crane product.
The use of a maintenance-free battery is not recommended for use on any Auto Crane product. The recommended alternator and battery that will give the longest life with the most useful duty cycle is a 75 amp alternator with a 500 cold cranking amp battery. These specifications should be considered minimum.
It has always been Auto Crane Company policy to handle all warranty claims we receive as promptly as possible. If a warranty claim involves discrepant material or workmanship,
Auto Crane will take immediate corrective action. It is understandable that Auto Crane
Company cannot assume responsibility of liability when it is obvious that our products
1-1.0.0 have been abused, misused, overloaded or otherwise damaged by inexperienced persons trying to operate the equipment without reading the manual.
Auto Crane will not assume responsibility or liability for any modifications or changes made to unit, or installation of component parts done without authorization.
Auto Crane maintains a strong distributor network and a knowledgeable
Customer Service Department. In most cases, an equipment problem is solved via phone conversation with our customer service department. The customer service department also has the ability to bring a local distributor, a regional sales manager, or a factory serviceman into the solution of an equipment problem. If, through no fault of Auto Crane Company, it is necessary to send an experienced factory serviceman on a field service call, the rates stated in the Auto Crane Distributor's Flat Rate Manual will apply.
Auto Crane Company's extensive
Research and Development Program allow our customers to use the best equipment on the market. Our Engineering Staff and our knowledgeable sales people, are always available to our customers in solving crane and winch-type application problems. When in doubt, call the
Auto Crane factory.
DISTRIBUTOR ASSISTANCE:
Should you require any assistance not given in this manual, we recommend that you consult your nearest Auto Crane Distributor. Our distributors sell authorized parts and have service departments that can solve almost any needed repair.
NOTE:
THIS MANUAL SHOULD REMAIN
WITH THE CRANE
AT ALL TIMES.
This manual does not cover all maintenance, operating, or repair instructions pertinent to all possible situations. If you require additional information, please contact the Auto Crane
Company at the following telephone number:
(918) 836-0463 . The information contained in the manual is in effect at the time of this printing. Auto Crane Company reserves the right to update this material without notice or obligation.
12/2002
--- IMPORTANT ---
SAFETY TIPS AND PRECAUTIONS
1. No unqualified or unauthorized person shall be allowed to operate the crane.
2. WARNING: Never weld, modify, or use unauthorized components / parts on any Auto Crane unit. This will void any warranty or liability. Also, failure of the crane may result.
3. Make certain the vehicle meets minimum chassis requirements. (These requirements do not guarantee unit stability.)
4. Make certain the crane is installed per factory specifications. Contact your local distributor or the
Auto Crane factory if any questions arise.
5. Visual inspections and tests should be conducted at the beginning of each shift each day to ensure that the crane and all its operating systems are in good condition and working order before it is used.
6. Inspect hydraulic hoses frequently for signs of deterioration, and replace them as required.
7. If a hydraulic break occurs, leave the area of the break and do not attempt to stop the break by hand as the hydraulic oil may be hot and under high pressure which can cause serious injury. Shut the system down as soon as possible.
8. Check the hook at least every thirty days for distortions or cracks and replace it as required.
9. Oil gears as required.
10. Stop all operations when cleaning, adjusting or lubricating the machine.
11. Keep dirt and grit out of moving parts by keeping a crane clean. Make sure machine is free of excess oil, grease, mud and rubbish, thus reducing accidents and fire hazards.
12. When a new cable is installed, operate first with a light load to let the cable adjust itself.
13. Locate the vehicle at the work site for the best stability possible.
14. Keep the vehicle in a level position while loading or unloading.
15. Observe operating area for obstructions and/or power lines that might be a hazard
16. WARNING: NEVER OPERATE THE CRANE
NEAR ELECTRICAL POWER LINES. Auto Crane
Company recommends that the crane never be any closer to a power line (including telephone lines) than
10 feet at any point.
17. Allow the vehicle engine to warm up before operating crane.
18. Know the weight of your rigging and load to avoid overloading the crane.
19. Deduct the weight of the load handling equipment from the load rating to determine how much weight can be lifted.
20. All load ratings are based on crane capacity, NOT the vehicle stability.
Remember in lifting a heavy load, the weight can create enough tipping moment to overturn the vehicle
21. Always comply with load chart capacities, (centerline of rotation to hook).
22. Secure all loads before lifting.
23. Always set the emergency brake before beginning operation.
24. Keep objects and personnel clear of crane path during operation.
25. Operate control levers slowly and smoothly in order to meter oil flow for safe operation.
26. Always use outriggers from vehicle to the ground during crane operation. Ensure that they are firmly positioned on solid footings. Stand clear of outriggers while they are being extended.
27. If any outrigger, when extended, rests on a curb or other object that prevents it from extending to its maximum distance, shorten bearing or fulcrum point and reduce the maximum load accordingly.
28. When an outrigger will not reach the ground due to holes or grades, it shall be blocked up to provide level and firm support for the truck.
29. When working in soft earth, use wide pads under outrigger feet to prevent sinking.
30. Always store outriggers before transportation.
WARNING!
Auto Crane Company cranes are not designed or intended for use in lifting or moving persons. Any such use shall be considered to be improper and the seller shall not be responsible for any claims arising there from.
This sale is made with the express understanding that there is no warranty that the goods shall be fit for the purpose of lifting or moving persons or other improper use and there is no implied warranty or responsibility for such purposes.
2-1.0.0
12/2002
--- IMPORTANT ---
SAFETY TIPS AND PRECAUTIONS
31. Always store the crane in its stowed position for transportation.
32. Remember the overall height of the entire unit for garage door clearance or when moving under objects with low overhead clearance
33. Disengage power takeoff (PTO) before moving the vehicle.
34. Always walk around the vehicle before moving.
35. Never drive with a load suspended from crane.
36. Do not take your eyes off a moving load. Look in the direction you are moving.
37. Never swing a load over people.
38. Do not stop the load sharply in midair so that it swings like a pendulum. Meter the control levers to avoid this situation.
39. Crane boom length should be kept as short as possible for maximum lifting capacity and greater safety. Longer booms require additional care in accelerating and decelerating the swing motion, and thus slow down the working cycle and reduce productivity.
40. Keep the load directly and vertically under the boom point at all times. Crane booms are designed primarily to handle vertical loads, not side lifts.
WARNING: Never attempt to lift, drag, tow or pull a load from the side. The boom can fail far below its rated capacity.
41. Do not push down on anything with boom extensions, lift or outer boom function.
42. Do not lift personnel with any wire rope attachment or hook. There is no implied warranty or responsibility for such purposes.
43. WARNING: In using a safety hook, ALWAYS close the hook throat before lifting a load. Proper do pull load-block up against the boom tip.
47. Do not wrap the wire rope around sharp objects when using winch.
2-1.1.0 attention and common sense applied to the use of the hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.
44. WARNING: Never place a chain link on the tip of the hook and try to lift a load with the hoist.
45. WARNING: Never use a sling bar or anything larger than the hook throat which could prevent the safety latch from closing, thus negating the safety feature.
46. If the crane is equipped with an optional winch: do NOT allow personnel to ride on loadline, hook, load, or any other device attached to winch line. do NOT extend boom without reeling off line at the same time when using winch.
48. WARNING: Never unreel last 5 wraps of cable from drum.
12/2002
--- IMPORTANT ---
OPERATING PRACTICES AND WARNINGS
1. Make certain the vehicle meets minimum chassis requirements. (These requirements do not guarantee unit stability)
2. Make certain the crane is installed per factory specifications. Contact your local Distributor or the
Auto Crane factory if any questions arise.
3. Keep the vehicle in as level a position as possible while loading or unloading.
4. ALWAYS set the vehicle emergency brake before beginning crane operations.
5. ALWAYS use outriggers from vehicle to the ground during crane operation. Make sure they are firmly positioned on solid footings.
6. All load ratings are based on crane capacity, NOT truck/crane stability.
7. Keep objects and personnel clear of crane path during operation.
8. Keep hoist cable pulled tight at all times.
9. REMEMBER , in lifting a heavy load, the weight can create enough tipping momentum to overturn the vehicle.
10. ALWAYS keep load as close to ground as possible.
11. Hydraulic hoses need to be inspected frequently for signs of deterioration, and be replaced as required.
12. The hoist hook is an important item that an operator should consider and use properly. It should be checked on a daily basis for distortion or cracks.
13. ALWAYS store outriggers before road travel.
14. WARNING! NEVER OPERATE THE CRANE
NEAR ELECTRICAL POWER LINES!
Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to
50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.
15. WARNING!
NEVER EXCEED load chart capacities (centerline of rotation to hoist hook).
16. WARNING! NEVER un-reel last 5 wraps of cable from drum!
17. WARNING! NEVER wrap cable around load!
18. WARNING! NEVER attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
19. WARNING! NEVER weld, modify, or use unauthorized components on any Auto Crane unit!
This will void any warranty or liability. Also failure of the crane may result.
20. WARNING! NEVER place a chain link on the tip of the hook and try to lift a load!
21. WARNING! NEVER use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature!
22. WARNING!
In using a hook with latch, ALWAYS insure that the hook throat is closed before lifting a load! Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel. Switch on that will cause unsafe operating conditions!
WARNING! NEVER hold any Control Select
Switch on that will cause unsafe operating conditions!
WARNING! cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel.
Auto Crane Company remote controlled, stiff boom
2-2.0.0
12/2002
--- IMPORTANT ---
OPERATION OF UNIT
1. Make sure this manual has been thoroughly read by all crane operating personnel and supervisors.
2. A routine inspection of the crane should be mandatory before each operating day. Any defects should be corrected immediately.
3. At a job site the vehicle should be positioned so that the crane can adequately reach the load within the rated capacity (centerline of rotation to hoist hook).
4. Keep the vehicle as level as possible during operation.
5. For electric cranes, engage emergency brake and leave ignition on with transmission in neutral (or in park for automatic transmissions). Activate any crane power switches. For Auto Crane units requiring battery and hydraulic operation, engage emergency brake, place gear selector in neutral, press clutch, activate PTO, release clutch and after hydraulic fluid is warm, set throttle control to proper engine speed.
6. Always use outriggers from the truck to the ground.
Be sure these are firm and adequately positioned.
When rotating, keep load as low to the ground as possible.
7. Remove the transmitter from cab or storage area.
Power transmitter on. Detach hook from dead man.
Crane is now ready for operation.
8. Always boom up before rotating so the boom will clear the required boom support.
9. When extending the boom, always maintain clearance between the boom crown and the traveling block or hoist hook.
10. Always observe safe and practical operation to avoid possible accidents. Refer to Safety Tips and
Precautions.
11. After completing lifting operations, return the boom to stowed position on the boom support. Avoid unneeded pressure on the boom support.
12. Store transmitter in proper location (in cab or storage area).
13. Return outriggers to stowed position. Make sure they are pinned in place or jacklegs are returned to compartment.
14. Check work area for any tools or equipment not stored.
15. Release throttle control, depress clutch and disengage
PTO. Deactivate any crane power switches.
16. Report any unusual occurrence during crane operation that may indicate required maintenance or repair.
17. NEVER use two cranes to support a load too large for either crane.
OPERATION OF
OUTRIGGERS
For hydraulic outriggers:
1. Shift crane/outrigger control valve to
"outrigger" position.
2. Operate the outrigger control valves (located on the outrigger cylinders) to position the outriggers.
3. After outriggers are positioned, return crane/outrigger selector to "crane" position.
4. Crane is now ready to operate.
2-3.0.0
For manual outriggers:
1. Pull lock pins to release jack leg or drop down outrigger and move to outermost lock position.
2. Make sure lock pins are reinstalled properly.
3. Lower outrigger pad to firm ground and adjust foot to take out slack.
4. Crane is now ready to operate.
12/2002
CONTROLLER OPERATIONS
Transmitter Layout: The red light to the left of the Power On/Off button indicates low transmitter battery. As the battery runs down, the light will begin to flash. It will flash increasingly faster as the battery power decreases. (see “Charging the Transmitter”)
The green light to the right of the Power On/Off button indicates that the unit is transmitting. This light will flash when a function is activated.
In addition to the two lights mentioned above there are four function toggle switches.
These functions from left to right are used to raise and lower the boom, raise and lower the hoist cable, rotate the crane and extend and retract the boom. There are also buttons for auxiliary functions such as Engine Start/Stop and Engine Fast Idle.
Power On/Off (E-Stop) Button: To turn the transmitter on, press and hold the Power On/Off button, release once the transmit light becomes solid. To turn the unit off, press and hold the power button, release once the transmit light stops flashing. When this button is pressed both the red battery low and the green transmit light will flash alternately and stop flashing once the unit is either on or off.
IMPORTANT – THE POWER ON/OFF BUTTON ALSO OPERATES AS AN E-STOP.
PRESS THE BUTTON MOMENTARILY TO DISABLE CRANE FUNCTIONS. THE E-
STOP WILL NOT STOP THE TRUCK ENGINE.
Function Switches: To operate a function, toggle one of the function switches with either the thumb of the hand holding the unit or the thumb or fingers of the opposite hand. Using the forefinger of the hand holding the unit, slowly pull the trigger back to start the function. The speed of the function increases as the trigger is pulled. More than one function can be activated at one time.
NOTE: A FUNCTION SWITCH MUST BE ACTIVATED BEFORE THE TRIGGER IS
PULLED OR THE CRANE WILL NOT OPERATE.
2-4.0.0
12/2002
CONTROLLER OPERATIONS
Auxiliary Buttons:
Functions described in this paragraph will not worked if not properly connected to the vehicle at the time of installation. Press the Engine Fast/Slow button to provide a maintained voltage to a throttle control. To stop the engine, press the Engine Start/Stop button. To start the engine, press the Engine Start/Stop button a second time within five (5) seconds of releasing it.
To activate the auxiliary function, press the Engine Fast/Slow and the Engine Start/Stop buttons simultaneously.
Safety Features:
For safety reasons the speed of all functions, excluding the hoist, is reduced when the lift cylinder pressure exceeds a set pressure. This will occur under load or under boom down operation. To limit slow operation of an unloaded crane, activate boom up momentarily after booming down to relieve cylinder pressure created by the counterbalance valve.
The crane is also equipped with an anti-bridging feature. The logic in the receiver will not allow the operator to rest the boom of the crane on a load supporting structure and lift a load.
Doing so is dangerous and could damage the crane. When the crane is bridged, the receiver will display ‘RSBM’ which requires the boom to be raised. This feature is disabled when the crane is in the ‘HOME’ position to allow for stowing. When in the ‘HOME’ position, the hoist is also slowed to prevent inadvertent damage to the crane or boom support.
Operation Failure:
If the crane does not operate as expected, observe the readout through the window on the receiver and refer to the front panel for explanation. The codes are further explained in the
Diagnostics section of this manual. Please note that ‘NRML’ is displayed when the crane is operating normally, ‘HOME’ is displayed when the crane is forward and in a position to be stowed and ‘SLOW’ is displayed when functions are slowed due to load.
Charging the Transmitter:
The transmitter can be charged using one of three methods. It can be charged with the cigarette lighter charger, the pendant cable or the optional AC adapter (P/N 366505000). To charge the transmitter with the pendant cable, the crane must have electrical power. The crane can be operated by pendant or by FM remote therefore the battery can be charged without suspending operation of the crane.
The transmitter should be fully charged after approximately 6 to 8 hours of charging. It is not recommended to leave the transmitter charging for extended periods of time (3 or 4 days).
Doing so will eventually degrade the battery and it will not keep a good charge.
2-5.0.0
12/2002
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS
AND OPERATING PRACTICES
OPERATORS
1. Crane operation shall be limited to personnel with the following minimum qualifications:
B. Trainees under the direct supervision of a designated person.
C. Maintenance and test personnel (when it is necessary in the performance of their duties).
2. No one other than the personnel specified above shall enter the operating area of a crane with the exception of persons such as oilers, supervisors, and those specified persons authorized by supervisors whose duties require them to do so and then only in the performance of their duties and with the knowledge of the operator or other persons.
QUALIFICATIONS FOR OPERATORS
3. Operators shall be required by the employer to pass a practical operating examination.
Qualifications shall be limited to the specific type of equipment for which examined. and following physical qualifications:
A. Vision of at least 20/30 Snellen in one eye and
20/50 in the other, with or without corrective lenses.
B. Ability to distinguish colors, regardless of position, if colors differentiation is required for operation.
C. Adequate hearing with or without hearing aid for the specific operation.
5. Evidence of physical defects or emotional instability which render a hazard to operator or others, which in the opinion of the examiner could interfere with the operator's performance may be sufficient cause for disqualification. In such cases, specialized clinical or medical judgment and tests may be required.
6. Evidence that the operator is subject to seizures or loss of physical control shall be sufficient reason for disqualification. Specialized medical tests may be required to determine these conditions.
7. Operators normal depth perception, coordination, and no tendencies to dizziness or similar undesirable characteristics.
8. In addition to the above listed requirements, the operator shall:
A. Demonstrate the ability to comprehend and interpret all labels, operator's manuals, safety codes and other information pertinent to correct crane operations.
B. Possess knowledge of emergency procedures and implementation of same.
C. Demonstrate to the employer the ability to operate the specific type of equipment.
D. Be familiar with the applicable safety regulations.
E. Understand responsibility for maintenance requirements of crane.
F. Be thoroughly familiar with the crane and its control functions.
G. Understand the operating procedures as outlined by the manufacturer.
CONDUCT OF OPERATORS
9. The operator shall not engage in any practice, which will divert his attention while actually operating the crane.
10. Each operator shall be responsible for those operations under the operator's direct control.
Whenever there is any doubt as to safety, the operator shall consult with the supervisor before handling the loads.
11. The operator should not leave a suspended load unattended unless specific precautions have been instituted and are in place.
12. If there is a warning sign on the switch or engine starting controls, the operator shall not close the switch or start the engine until the warning sign has been removed by the appointed person.
13. Before closing the switch or starting the engine, the operator shall see that all controls are in the
14. If power fails during operation, the operator shall:
"OFF" or neutral position and all personnel are in the clear.
A. move power controls to the "OFF" or neutral position.
B. land the suspended load and boom, if practical.
2-6.0.0
12/2002
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS
AND OPERATING PRACTICES
15. The operator shall be familiar with the equipment and its proper care. If adjustments or repairs are necessary, the operator shall report the same promptly to the appointed person, and shall also notify the next operator.
16. All controls shall be tested by the operator at the start of each shift. If any controls do not operate properly, they shall be adjusted or repaired before operations are begun
17. Stabilizers shall be visible to the operator while extending or setting unless operator is assisted by a signal person.
OPERATING PRACTICES
HANDLING THE LOAD
1. There is no sudden acceleration or deceleration of the moving load.
2. Load, boom or other parts of the crane do not contact any obstruction.
G. Cranes shall not be used for dragging loads sideways.
H. This standard recognizes that articulating boom cranes are designed and intended for handling materials. They do not meet personnel lift or elevator requirements. Therefore, no lifting, lowering, swinging or traveling shall be done while a person is on the hook or load. Hook attached suspended work platforms (baskets) shall not be used with cranes covered by this standard. Work platforms attached to the boom must be approved by crane manufacturer.
18. Size of load
A. No crane shall be loaded beyond the rated load except for test purposes.
B. The load to be lifted is to be within the rated load of the crane and its existing configuration.
C. When loads which are not accurately known are to be lifted, the person responsible for the job shall ascertain that the weight of the load does not exceed the crane rated load at the radius at which the load is to be lifted.
19. Attaching the load
A. The load shall be attached to the hook by means of slings or other devices of sufficient capacity.
B. Hoist rope shall not be wrapped around the load.
20. Moving the load
A. The operator shall determine that:
B. The crane is level and, where necessary, the vehicle/carrier is blocked properly.
C. The load is well secured and balanced in the sling or lifting device before it is lifted more than a few inches.
D. Means are provided to hold the vehicle stationary while operating the crane.
E. Before starting to lift, the hook shall brought over the load in such a manner as to minimize swinging.
F. During lifting care shall be taken that:
I. The operator should avoid carrying loads over people.
J. When the crane is so equipped, the stabilizers shall be fully extended and set. Blocking under stabilizers shall meet the requirements as follows:
1. Strong enough to prevent crushing.
2. Of such thickness, width and length as to completely support the stabilizer pad.
K. Firm footing under all tires, or individual stabilizer pads should be level. Where such a footing is not otherwise supplied, it should be provided by timbers, cribbing, or other structural members to distribute the load so as to not exceed allowable bearing capacity or the underlying material.
L. In transit, the boom shall be carried in stowed position.
M. When rotating the crane, sudden starts and stops shall be avoided. rotational speed shall be such that the load does not swing out beyond the radius at which it can be controlled.
N. The crane shall not be transported with a load on the hook unless recommended by the manufacturer.
O. No person should be permitted to stand or pass under a suspended load.
21. Stowing procedure. Follow the manufacturer's procedure and sequence when stowing and unstowing the crane
2-7.0.0
12/2002
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS
AND OPERATING PRACTICES
MISCELLANEOUS
OPERATING NEAR ELECTRICAL POWER
LINES
25. In transit with no load and boom lowered the clearance shall be specified in Table 1.
26. A qualified signalperson shall be assigned to observe the clearance and give warning before approaching the above limits.
A. Any overhead wire shall be considered to be an energized line unless and until the person owning such line or the electrical utility authorities verify that it is not an energized line.
B. Exceptions to this procedure, if approved by the administrative or regulatory authority if the alternate procedure provides equivalent protection and set forth in writing.
C. Durable signs shall be installed at the operator's station and on the outside of the crane, warning that electrocution or serious bodily injury may occur unless a minimum clearance of 10 ft.
(3.0m) between the crane or the load being handled and energized power lines. Greater clearances are required because of higher voltage as stated above. These signs shall be revised but not removed when local jurisdiction requires greater clearances.
22. Cranes shall be operated so that no part of the crane or load enters into the danger zone shown above.
EXCEPTIONS
A. The danger zone may be entered after confirmation by an appointed person that the electrical distribution and transmission lines have been de-energized and visibly grounded at the point of work; or
B. The danger zone may be entered if insulating barriers (not a part of nor an attachment to the crane) have been erected to prevent physical contact with the lines.
23. For lines rated 50 kV or below, minimum clearance between the lines and any part of the crane or load (including handling appendages) shall be 10-ft. (3m). For higher voltages, see
Table1.
24. 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.
2-8.0.0
TABLE 1 minimum required
____clearance____ normal voltage, kV
(phase to phase) ft (m) when operating near high voltage poower 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)
12/2002
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSPECTION CLASSIFICATION G. electrical apparatus for malfunctioning, signs of excessive deterioration, dirt and moisture accumulation
1. Initial inspection. Prior to initial use, all new, altered, modified or extensively repaired cranes shall be inspected by a designated person to insure compliance with provisions of this standard.
H. hydraulic system for proper oil level and leaks daily
I. tires for recommended inflation pressure, cuts and loose wheel nuts
2. Regular inspection. Inspection procedure for cranes in regular service is divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the components of the crane and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as "frequent" and "periodic" with respective intervals between inspections as defined below.
J. connecting pins and locking device for wear and damage
PERIODIC INSPECTION
4. Deformed, cracked or corroded members in the crane structure and carrier
5. Loose bolts, particularly mounting bolts.
6. Cracked or worn sheaves and drums.
A. frequent inspection - daily to monthly intervals
B. periodic inspection - one to twelve intervals or as specifically recommended by the manufacturer
7. Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and devices.
8. Excessive wear on brake and clutch system parts and lining.
9. Crane hooks inspected for cracks.
FREQUENT INSPECTION
3. Inspection shall be performed by designated personnel. control mechanisms for maladjustment interfering with proper operation - daily, when used
11. Excessively worn or damaged tires.
12. Hydraulic and pneumatic hose, fittings, and tubing inspection.
A. evidence of leakage at the surface of the flexible hose or its junction with metal and coupling
B. control mechanisms for excessive wear of components and contamination by lubricants or other foreign matter
C. safety devices for malfunction
B. A. blistering, or abnormal deformation to the outer covering of the hydraulic or pneumatic hose
D. all hydraulic hoses, particularly those which flex in normal operation of crane functions, should be visually inspected once every working day, when used
E. hooks and latches for deformation, chemical damage, cracks, and wear. Refer to
ANSI/ASME B30.10
F. rope reeving for compliance with crane manufacturer's specifications, if optional winch is used
10. Travel steering, braking, and locking devices, for malfunction.
C. A. leakage at threaded or clamped joints that cannot be eliminated by normal tightening or recommended procedures
D. A. evidence or excessive abrasion or scrubbing on the outer surface of a hose, rigid tube, or fitting. Means shall be taken to eliminate the interference of elements in contact or otherwise protect the components
2-9.0.0
12/2002
INSPECTION, TESTING AND MAINTENANCE
GENERAL
13. Hydraulic and pneumatic pumps and motors inspection.
A. loose bolts or fasteners
B. leaks at joints between sections
C. shaft seal leaks
D. unusual noises or vibrations
E. loss of operating speed
F. excessive heating of the fluid
G. loss of pressure
14. Hydraulic and pneumatic valves inspection
A. cracks in valve housing
B. improper return of spool to neutral position
C. leaks at spools or joints
D. sticking spools
E. failure of relief valves to attain or maintain correct pressure setting
F. relief valve pressure shall be checked as specified by the manufacturers
15. Hydraulic and pneumatic cylinders inspection.
A. drifting caused by fluid leaking across piston
B. rod seals leaking
C. leaks at welding joints
19. A crane which has been idle for a period of over six months shall be given a complete inspection conforming with the initial-regularfrequent inspection requirements.
INSPECTION RECORDS
20. Dated records for periodic inspection should be made on critical items such as brakes, crane hooks, rope, hydraulic and pneumatic cylinders, and hydraulic and pneumatic relief pressure valves. Records should be kept available to an appointed person.
OPERATIONAL TESTS
21. Prior to initial use, all new, altered, modified, or extensively repaired cranes shall be tested for compliance with the operational requirements of this section, including functions such as the following:
A. load lifting and lowering mechanisms
B. boom lifting and lowering mechanisms
C. boom extension and retraction mechanisms
D. swing mechanisms
D. scored, nicked, or dented cylinder rods
E. damaged case (barrel)
F. loose or deformed rod eyes or connecting joints
F. operating controls comply with appropriate function labels
16. Hydraulic filters. Evidence of rubber particles on the filter elements may indicate hose, "O" ring, or other rubber component deterioration.
Metal chips or pieces on the filter may denote failure in pumps, motors, or cylinders. Further checking will be necessary to determine origin of the problem before corrective action can be taken.
Operational crane test results shall be made available to an appointed person.
RATED TEST LOAD
17. Labels are to be in place and legible.
CRANES NOT IN REGULAR USE
18. A crane which has been idle for a period of over one month or more, but not less than six months, shall be given an inspection conforming with the initial-regular- frequent inspections
2-10.0.0
Prior to initial use, altered, modified, or extensively repaired cranes shall be load tested by or under the direction of an appointed person.
12/2002
INSPECTION, TESTING AND MAINTENANCE
GENERAL
22. Test loads shall not exceed 110% of the manufacturer's load ratings.
23. Written reports shall be maintained showing test procedures and confirming the adequacy of repairs.
MAINTENANCE
PREVENTIVE MAINTENANCE
24. Before adjustment and repairs are started on a crane, the following precautions shall be taken as applicable:
A. crane placed where it will cause the least interference with other equipment or operations
B. all controls at the "off" position
C. starting means rendered inoperative
D. boom lowered to the ground if possible or otherwise secured against dropping
E. relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components
25. Warning or "OUT OF ORDER" signs shall be placed on the crane controls.
26. After adjustments and repairs have been made, the crane shall not be returned to service until all guards have been reinstalled, trapped air removed from hydraulic system (if required), safety devices reactivated, and maintenance equipment removed.
ADJUSTMENTS AND REPAIRS
27. Any hazardous conditions disclosed by the inspection requirements shall be corrected before operation of crane is resumed,
Adjustments and repairs shall be done only by designated personnel.
28. Adjustments shall be maintained to assure correct functioning of components, The following are examples:
A. functional operating mechanism
C. control systems
29. Repairs or replacements shall be provided as needed for operation.
The following are examples: critical parts of functional operating mechanisms which are cracked, broken, corroded, bent, or excessively worn
B. critical parts of the crane structure which are cracked, bent, broken, or excessively corroded
C. crane hooks showing cracks, damage, or corrosion shall be taken out of service. Repairs by welding are not recommended
30. Instructions shall be provided by the manufacturer for the removal of air from hydraulic circuits.
LUBRICATION
All moving parts of the crane, for which lubrication is specified, should be regularly lubricated per the manufacturer's recommendations and procedures.
ROPE INSPECTION
31. Frequent Inspection
A. All running ropes in service should be visually inspected once each working day. A visual inspection shall consist of observation of all rope which can be in use during the days operations. These visual observations should be considered with discovering gross damage such as listed below, which may be an immediate hazard.
1. distortion of the rope such as kinking, crushing, un-stranding, birdcaging, main strand displacement, or core protrusion.
Loss of rope diameter in a short length or unevenness of outer strands should be replaced
3. broken or cut strands;
4. number, distribution and type of visible broken wires. When such damage is discovered, the rope shall either be removed from service or given as inspection.
2-11.0.0
12/2002
INSPECTION, TESTING AND MAINTENANCE
GENERAL
B. Care shall be taken when inspecting sections of rapid deterioration such as flange points, crossover points, and repetitive pickup points on drums.
32. Periodic inspection
A. The inspection frequency shall be determined by a qualified person and shall be based on such factors as
1. expected rope life as determined by experience on the particular installation or similar installations
2. severity of environment
3. percentage of capacity lifts
4. frequency rates of operation
5. exposure to shock loads
ROPE REPLACEMENT
Inspection need not be at equal calendar intervals and should be more frequent as the rope approaches the end of it's service life.
This inspection shall be made at least annually.
B. Periodic inspection shall be performed by a designated person. This inspection shall cover the entire length of the rope. Only the surface wires need be inspected. No attempt should be made to open the rope. Any deterioration results in appreciable loss of original strength, such as described below, shall be noted and determination made as to whether use of the rope would constitute a hazard: points listed above reduction of rope diameter below nominal diameter due to loss of core support, internal or external corrosion, or wear of outside wires; severely corroded, cracked, bent, worn or improperly applied connections;
C. Care shall be taken when inspecting sections subject to rapid deterioration such as the following:
1. sections in contact with saddles, equalizer sheaves, or other sheaves where rope travel is limited
2. sections of the rope at or near terminal ends where corroded or broken wires may protrude
2-12.0.0
33. No precise rules can be given for determination of the exact time for replacement of rope, since many variable factors are involved.
Continued use in this respect depends upon good judgement by a designated person in evaluating remaining strength in a used rope after allowance for deterioration disclosed by inspection.
Continued rope operation depends upon this remaining strength.
34. Conditions such as the following shall be reason for questioning continued use of the rope or increasing the frequency of inspection:
A. in running ropes, six randomly distributed broken wires in one lay or three broken wires in one strand in one lay
B. one outer wire broken at the contact point with the core of the rope structure and protrudes or loops out of the rope structure. Additional inspection of this section is required
C. wear of one third of the original diameter of the outside individual wire
D. kinking, crushing, birdcaging, or any other damage resulting in distortion of the rope structure
E. evidence of any heat damage from any cause
F. reduction from nominal diameter of more than
1/64 in. (0.4mm) for diameters up to and including 5/16 in. (8 mm), 1/32 in. (0.8 mm) for diameter 3/8 in. (9.5 mm) to and including 1/2 in. (13 mm), 3/64 in. (1.2 mm) for diameter
9/16 in. (14.5 mm) to and including 3/4 in. (19 mm). 1/16 in. (1.6 mm) for diameter 7/8 in. (22 mm) to and including 11/8 in. (29 mm), 3/32 in.
(2.4 mm) for diameters 11/4 in. (32 mm) to and including 11/2 in. (38 mm)
G. In standing ropes, more than two broken wires in one lay in sections beyond end connections or more than one broken wire at an end connection.
12/2002
INSPECTION, TESTING AND MAINTENANCE
GENERAL
H. Replacement rope shall have a strength rating at least as great as the original rope furnished or recommended by the crane manufacturer.
Any deviation from the original size, grade, or construction shall be specified by a rope manufacturer, or a qualified person.
35. Rope not in regular use: all rope which has been idle for a period of a month or more due to shutdown or storage of a crane on which it is installed, shall be given and inspection in accordance with above information before it is placed in service. This inspection shall be for all types of deterioration and shall be performed by a qualified person.
36. Inspection records
A. required
B. A. periodic inspections- in order to establish data as a basis for judging the proper time for replacement, a dated report condition at each periodic inspection should be kept on file. This report shall cover points of deterioration listed above. 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.
40. During installation care should be exercised to avoid dragging of the rope in the dirt or around objects which will scrape, nick crush or induce sharp bends in it.
41. Rope should be maintained in a well-lubricated condition. It is important that lubricant applied as a part of a maintenance program shall be compatible with the original lubricant and to this end the rope manufacturer should be consulted. Lubricant applied shall be the type which does not hinder visual inspection. Those sections of rope which are located over sheaves or otherwise hidden during inspection and maintenance procedures require special attention when lubricating rope. The object of rope lubrication is to reduce internal friction and to prevent corrosion.
ROPE MAINTENANCE
37. Rope should be stored to prevent damage or deterioration.
38. Unreeling or uncoiling of rope shall be done as recommended by the rope manufacturer and with care to avoid kinking or inducing twist.
39. Before cutting a rope, seizing shall be placed on each side of the place where the rope is to
2-13.0.0
42. When an operating rope shows greater wear or well defined localized areas than on the remainder of the rope, rope life can be extended in cases where a section at the worn end, and thus shifting the wear to different areas of the rope.
12/2002
SAFETY DECAL SECTION
5005H SERIES
PART NO.:
DECAL:
40579000
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.
2-14.0.0
12/2002
SAFETY DECAL SECTION
5005H SERIES
PART NO.:
DECAL:
040529000
ELECTROCUTION HAZARD
FUNCTION: To inform the operator of the hazard involved with contacting electrical power lines with crane boom.
USED ON:
QUANTITY:
Articulated & Stiff Boom 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: All Cranes
QUANTITY: 2
PLACEMENT: Both sides of crown
2-15.0.0
12/2002
SAFETY DECAL SECTION
5005H SERIES
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:
QUANTITY:
All cranes equipped with a load sensor.
1
PLACEMENT: On 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.
1
PLACEMENT: Both sides of the lift cylinder
2-16.0.0
12/2002
6 5
DECAL LAYOUT
5005H SERIES
13
15 7
2
12
APPROX 2.00 TYP
14
8
9
11
13 5
10
6
10
3 4
11
12
13
14
15
8
9
10
11
ITEM
2
3
6
7
4
5
1
1
2
2
2
2
2
1
QTY
1
1
2
1
1
2
8
PART NO DESCRIPTION
040579 DECAL OPERATION INSTRUCTIONS
040632 DECAL WARNING - OVERLOAD
040580
040529
040517
330622
DECAL TRAINED OPERATOR
DECAL POWER LINE HAZARD
DECAL STAY CLEAR OF BOOM
DECAL SERIAL NO
040519
040587
DECAL DANGER SCISSOR POINT
DECAL WARNING LOAD SENSOR
360705000 LOAD CHART 5005H
360033000 DECAL 5005H
360034
366389
DECAL AUTO CRANE LOGO
DECAL AUTO CRANE
320318 DECAL ANGLE IND RIGHT
320318001 DECAL ANGLE IND LEFT
2-17.0.0
12/2002
12
NOTES
GENERAL DIMINEIONS
5005H SERIES
23 1/16"
10 1/16"
R23 1/8"
22 7/16" 10'
37 1/16"
33 3/16"
26 9/16"
13 1/8"
.94
(4 PLCS)
16 3/4" 14 3/4"
14 3/4"
#10 SAE RETURN
FITTING
TOWARD CAB >>>
#8 SAE PRESSURE
FITTING
3-1.0.0
16'
20'
8 1/16"
12/2002
MOUNTING AND INSTALLATION
5005H SERIES
1. Check to make sure the following items are with your crane.
QTY QTY
ITEM
1
FM
1
HW PART NO. DESCRIPTION
1 480689 FUSE 15 AMP TIME-DELAY
14
15
16
17
18
19
9
10
11
12
13
7
8
5
6
2 1 1
3 120" 120"
4 6 6
6
5
1
1
1
1
6
5
4
1
1
1
4
1
4
4
1
1
1
4
1
4
480688
800596
634401
018900
FUSE HOLDER IN-LINE WATERPROOF
WIRE 16G 600V 1C YEL
TIE CABLE - MEDIUM
750738 STICK-ON
320357 TERMINAL NON-INS S/O W/L
320363 PLUG TERMINAL CONNECTOR
340638 CONDUCTOR POWER
320355 POWER RELAY
NUT HX 7/8 NF GR8
022200 WASHER SP LK 7/8
460100002 TRANSMITTER KAR-TECH
366500009 CABLE PENDANT/CHARGE KAR-TECH
4
366504000 BATTERY CHARGER CIGARETTE LIGHTER
015104 7/8-14 X 5 HH GR8
1 360705000 DECAL LOAD CHART 5005H
1 360706000 MANUAL 5005H
360708000 BRACKET PENDANT PLUG
725321 NUT NYLON LOCK 8-32
20
21
22
4 001302 SCREW 8-32 X .5
1 366520000 JUNCTION BOX ASSY
1 366466000 WIRE HARNESS, TRUCK FUNCTIONS
23 1 680040 PENDANT ASSEMBLY
2. Pressure and return hoses are not furnished with this crane. The hoses must be provided by the installer and the lengths determined at installation.
REQUIREMENTS FOR INSTALLATION USING 10 GALLON RESERVOIR
A. RETURN LINE FROM CRANE TO RESERVOIR (IN COMPARTMENT): -10 SAE 100R2 (OR EQUIVALENT).
HOSE LENGTH IS DETERMINED BY INSTALLER. RETURN LINES LONGER THAT 6 FEET SHOULD BE
SIZE –12. HOSE END FITTINGS ARE –10 JIC FEMALE SWIVEL (CRANE END) AND –10 JIC FEMALE
SWIVEL (RESERVOIR END).
B. PRESSURE LINE FROM PUMP TO CRANE: -8 SAE 100R2 (OR EQUIVALENT). HOSE LENGTHS IS
DETERMINED BY INSTALLER. HOSE END FITTINGS ARE BOTH –8 JIC FEMALE SWIVEL.
NOTE:
REFER TO OWNERS MANUAL FOR ADDITIONAL INSTALLATION INFORMATION.
CAUTION – FAILURE TO USE CLEAN HYDRAULIC HOSES AND COMPONENTS
MAY CONTAMINATE THE CRANE AND HYDRAULIC SYSTEM AND VOID
WARRANTY
3. Crane must be provided with a flow of 8 gallons per minute and a pressure of 2,750PSI. Excess flow will cause erratic operation, and too little flow will cause poor crane operation.
4. Vehicle should meet minimum GVW rating of 14,500 pounds.
5. The vehicle MUST be equipped with an engine speed control and tachometer.
6. Make sure mounting surface is properly reinforced to withstand 25,000 ft-lb capacity loading of crane and that outriggers are used to provide total stability for the truck.
7. A 13 ½” dia. hole should be cut out of mounting location (centered with mounting blots) for access to lower ring gear bolts and hydraulic connections.
3-2.0.0
4/23/04
MOUNTING AND INSTALLATION
5005H SERIES
8. Make sure the mounting blots are 7/8”-dia., grade 8. Torque bolts to 501 ft-lbs (dry).
9. When crane is not in operation, a boom support should always be used. Traveling block should be connected to hood loop.
10. Electrical hookup:
Wiring (cable from base of crane):
A. CONNECT THE BLACK WIRE TO THE BATTERY NEGATIVE (GROUND).
B. CONNECT THE RED WIRE TO FUSED 12VDC POWER. 12VDC POWER SHOULD BE
SUPPLIED THROUGH A DEDICATED SWITCH THAT IS POWERED ONLY WHEN THE IGNITION
SWITCH IS ON.
C. OPTIONALLY, USE THE WHITE WIRE FOR ENGINE FAST/SLOW.
D. OPTIONALLY, USE THE BLUE WIRE FOR ENGINE START.
E. OPTIONALLY, USE THE ORANGE WIRE FOR ENGINE STOP.
F. OPTIONALLY, USE THE GREEN WIRE FOR AUXILIARY.
WARNING!
FAILURE TO CORRECTLY PLUMB AND WIRE CRANE CAN CAUSE INADVERTENT
OPERATION AND DAMAGE TO CRANE AND/OR PERSONEL!
11. Once crane and plumbing are installed on the truck, fill the reservoir to top of sight glass (mobile DTE 13 or equal). Before operating crane, connect together the pressure and return hoses going to base of crane using 10-8 JIC union and engage PTO with engine running. Allow oil to circulate for 15 to 20 minutes. This will flush contaminants from the system back to the return line filter. Operate all cylinders to full extension and retraction a minimum of six times, to bleed air from system. Return all cylinders to the stored position and disengage PTO. Refill reservoir to top sight glass. To ensure 8 to 9 gallons per minute (GPM), install an in-line flow meter between the crane and the reservoir in the return hose.
12. Load test the crane to ensure proper functioning and truck stability
13. Make certain the owner’s manual is delivered to the customer.
14. For additional help: call the service department at the Auto Crane Company. (918) 836-0463 (Tulsa,
Oklahoma)
WARNING
FEDERAL LAW
(49 CFR PART 571) REQUIRES THAT THE FINAL STAGE MANUFACTURER OF A
VEHICLE CERTIFY THAT HE VEHICLE COMPLIES WITH ALL APPLICABLE FEDERAL REGULATIONS.
ANY MODIFICATIONS PERFORMED ON THE VEHICLE PRIOR TO THE FINAL STAGE ARE ALSO
CONSIDERED INTERMEDIATE STAGE MANUFACTURING AND MUST BE CERTIFIED AS TO
COMPLIANCE. THE INSTALLER OF THIS CRANE 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).
3-3.0.0
4/23/04
LUBRICATION & MAINTENANCE SCHEDULE
5005H SERIES
SERVICE
PERFORMED
LOAD HOOK
CABLE DRUM
HOIST / BOOM
CABLE
HYD. HOSES
HYD. FLUID
MOUNTING
DAY WEEKLY 3 MOS 6 MOS YEAR
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 501 FT-LBS
BOLTS
ROTATION
RING GEAR
SHEAVE
BEARINGS
ALL OTHER
BOLTS
ROTATION
X
X
X
X
(DRY) AS REQUIIRED
LUBE WITH MOBILETAC LL, OR
LUBRIPLATE P/N 15263, OR EQUAL
SEALED BEARING, REPLACE IF
ROUGH OR LOOSE
CHECK-TIGHTEN AS REQUIRED
BEARING
ROTATION
BEARING
BOLTS
X
X
GREASE WITH MOBILEPLEX EP-2
OR EQUIVALENT @ ZERKS
CHECK TORQUE TO
(DRY) AS REQUIRED
180 FT-LBS
ROTATION
GEAR BOX
X
CHECK TORQUE TO 90 FT-LBS
(SOCKET HEAD) AND 55 FT-LBS
(HEX HEAD) AS REQUIRED
ROTATION
GEAR BOX
HYDRAULIC
FLUID
X
X
EP GEAR LUBE SAE 80-90
DRAIN, FLUSH, AND REFILL WITH
SUN 2105 HYD. OIL, SAE 5W-20
BOOM SLIDE
PADS
FOR
ADDITIONAL
INFORMATION
SEE:
PADS GREASED WHEN REPLACED
1) OWNER'S MANUAL
2) OSHA SECTION 1910.180
3) ANSI B30.5-1989
4-1.0.0
12/30/03
LUBRICATION & MAINTENANCE SCHEDULE
5005H SERIES
CAUTION:
Routine maintenance ensures trouble-free operation and protects your investment. All warranties are void if maintenance is neglected.
NOTES:
1. Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability
2. Once a bolt has been torqued to its rated capacity and then removed; the bolt should be replaced with a new one.
3. Auto Crane Company recommends that this crane be serviced per “Crane
Inspection Log” P/N 999978. These logs should be filled in at the intervals noted and kept as a permanent record. Additional copies are available from your local distributor.
4-2.0.0
12/2002
PEDESTAL ASSEMBLY
5005H SERIES
7
36 21
53
70
50
52
51
49
8
13
17
34
60
58
57
55 21
9 25 48 47
62
61
36 21
12
26 21
28
35
4
31 32
71
47 48 46
20
39
5
29 30
27
67
63
44
45
22
HYDRAULIC VALVE KEY
23 24
PORT #1: HOIST DOWN
PORT #2: HOIST UP
PORT #3: ROTATION CCW
PORT #4: ROTATION CW
PORT #5: LIFT CYL EXTEND
PORT #6: LIFT CYL RETRACT
PORT #7: EXT CYL EXTEND
PORT #8: EXT CYL RETRACT
CYL SEAL KIT: 360720000
C'BAL. CART.: 480188000
55 21
10
1
2
18
18
3
19
33
69
65 66
5-1.0.0
64
41
42 40
43
1
54
59
56
11
21
26
15
37
16
38
6
54
14
4/23/2004
PEDESTAL ASSEMBLY
5005H SERIES
4
4
2
2
2
2
1
5
12
2
8
2
1
38
14
4
2
1
48
1
24
2
8
5
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
ITEM NO. QTY.
PART NO.
DESCRIPTION
29
30
31
32
25
26
27
28
21
22
23
24
17
18
19
20
37
38
39
40
33
34
35
36
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
360717000 BASE PLATE WELD
480023002 BEARING, ROTATION
360772000 PEDESTAL WELD
160407 GEAR BOX, ROTATION
366440 ROTATION MOTOR
360788000 CYLINDER LIFT
366370000 VALVE CONTROL ASSY
123309 HOIST RPH2500
460100003 RECEIVER, 2ND GEN W/5005H PROGRAM
360728000 BRACKET, PROX SWITCH
360729000 BRACKET MAGNET
366364 PLATE, VALVE MOUNTING
366506000 BRACKET ANTENNA
366423 MAGNET, PROX PICKUP
366492 PIN 1.25 DIA X 3.00 LG
366333 BEARING, SPHERICAL 1.25 ID
366500006 CABLE, ANTENNA EXTENSION
023902 WASHER, 5/8 FLAT HARDENED
490171 CAPSCREW 5/8-11 X 2.25 GR8
006205 SOC HD 5/8 X 1 1/4
021100 WASHER SPLK 3/8
011202 SCW HX HD 1/2-20 X 2 3/4
021500 WASHER SP LK 1/2
017704 NUT HX HVY 1/2 NF
360750000 MAIN HARNESS WIRE ASSY 5005H
330371 SCW HX 3/8 UNC X 1 GR8
009118 SOC HD 1/2 UNC X 2
490198 FITTING 10SAE(M)/6JIC ELBOW 90
021502 WASHER SP/LK 1/2 HI COLLAR
012197 SOC HD 1/2-13
320588 WASHER FL 1/2
366391 HEX HD 1/2-13 X 2 1/4
012198 CAPSCREW 5/8-11 X 1.75 GR8
372041 FITTING 8JIC/10SAE STRAIGHT 8-10 F5OX
407314000 WASHER FL 5/8 X 1 5/16 OD HARDENED
008702000 SCW HX 3/8-16 X 1 1/4 GR5
200876 FITTING 6 SAE/6 JIC STRAIGHT
366478000 PRESSURE TRANDUCER 4000 PSI
374086 NYLON HOSE SLEEVE
642918 CORD CONNECTOR
5-2.0.0
4/23/2004
NOTES
PEDESTAL ASSEMBLY
5005H SERIES
ITEM NO. QTY.
PART NO.
DESCRIPTION
69
70
71
72
73
65
66
67
68
61
62
63
64
57
58
59
60
53
54
55
56
49
50
51
52
45
46
47
48
41
42
43
44
2 812209-022 HOSE ASSY 6 STR/90
2
1 812203-028 HOSE ASSY 6 STR
1 812203-030 HOSE ASSY 6 STR
2
1
1
1
1
1
1
2
1
2
2
1
1
1
1
1
2
5
5
1
1
1
1
1
1
1
1
5
366358 FITTING 10SAE/JIC SWIVEL PS810503-10-10
366359 FITTING 8 SAE/JIC SWIVEL PS810503-8-8
366508000 CORD GRIP HUBBLE F-3 SHC 1036
490199 FITTING STR 10-SAE/10-JIC
367145 FITTING STR 8-SAE/8-JIC
480024 MOUNT PENDANT CABLE RETAINER
020601 WASHER 5/16 LOCK
007401 SCW 5/16-18 X 1/2 LG
480205 HOSE ASSY 6 STR X 19.25
480203 HOSE ASSY 8 STR X 24.75
360724000 ARM ROTATION STOP
008400 SCW HEX HD 3/8-16 UNC X 3/4 GR 5
360122 RING RETAINING 5100-98
360709000 BRACKET BOOM SW WDMT
654100 SWITCH LIMIT BZ-2RW80-A2
360690000 BEARING, FLANGED
000602 SCW PN #6 NC X 1
019600 WASHER SP LK #6
015400 NUT HX #6-32
360162 RING, ECCENTRIC
360207 RETAINER ECCENTRIC RING
020600 WASHER 5/16 LOCK SS
007807 SCW HEX 5/16-18 3/4LG GR5
480011 SEAL ROTATION BOX
020901 WASHER FL 5/16
360703000 HOME SWITCH HARNESS
1 812309-024 HOSE ASSY 8 STR/90
812409-022 HOSE ASSY 10 STR/90
480875000 BOOT DEUTSCH 40-PIN CONNECTOR
320976000 WASHER, FLAT, 3/8 SAE HARDENED
5-3.0.0
4/23/2004
8
27
35
11
27
BOOM ASSEMBLY
5005H SERIES
29
10
28
26
10
7
6
29
10
28
26 9
25
21
39
34
11
10
7
5
16
33
37
20
22
36
30
31
3
2
13
19
13
38
14
15 18
13
12
17
13
4
13
23
24
Cylinder Seal Kit - # 360719000
Counterbalance Cartridge - # 480188000
5-4.0.0
12/2002
BOOM ASSEMBLY
5005H SERIES
29
30
31
32
33
34
35
36
37
38
39
23
24
25
26
27
28
13
14
15
16
17
18
19
20
21
22
ITEM NO. QTY.
PART NO. DESCRIPTION
1 1 360776000 BOOM WELD LOWER 5005
2
3
4
5
1
1
1
1
360778000 BOOM WELD MID 5005
360781000 UPPER BOOM WELD
360789000 CYLINDER EXTENSION
366198 SHEAVE ASSY 3/8
9
10
11
12
6
7
8
2
4
1
1
12
14
1
366354
366385
WEAR PAD
PLATE, LOWER BOOM PAD COVER
360791000 WEAR PAD 4.5 X 2.63 X .375
360792000 WEAR PAD 2 X 3.5 X 3/8
021100 WASHER SPLK 3/8
008400 SCW HEX HD 3/8-16 UNC X 3/4 GR 5
366184 RETAINER EXTENSION CYLINDER
2
7
1
6
1
2
1
1
1
1
2
2
1
2
2
4
4
1
1
1
1
1
1
1
1
2
2
360767000 PAD BOOM 1.5 O.D.
366193 PIN 1 X 7.66 LG
360793000 BEARING PIVOT
366351 PAD, WEAR 1 1/2 X 1 1/2 X 3/4
007401 SCW 5/16-18 X 1/2 LG
360766000 WEAR PAD 4.25 X 3.00
360765000 WEAR PAD 2 .50 X 3 .25
360712000 PIN 1 X 4.33 LG
646900 SWITCH, LIMIT ANTI-TWO BLOCK
360718000 BAIL WELDMENT
200876 FITTING 6 SAE/6 JIC STRAIGHT 6F5OX
480194 FITTING 6 SWIVEL NUT ELBOW
366333 BEARING, SPHERICAL 1.25 ID
366201 WEAR PAD 3 .75 X 2.00 X .313
366483 PLATE, WEAR PAD .25 X 2 X 4
021200 WASHER FL 3/8
008800 SCW HEX 3/8-24 X 1
007803 SCW 5/16 NC 3 1/2 LG
016801 NUT HEX-LOCK 5/16 NC
360759000 CORD REEL ASSY
022102 WASHER FL 3/4
360756000 NUT, NYLON LOCK .75-10 NC
642908 CORD CONNECTOR
320554 SPRING RETURN
367366 CAPSCREW, .75-10 NC X 3-1/2
480029 RING RETAINING
360122 RING RETAINING 5100-98
5-5.0.0
12/2002
ROTATION GEAR BOX
P/N: 160407
5-6.0.0
12/2002
ROTATION GEAR BOX
P/N: 160407
28
29
30
25
26
27
18
19
20
21
22
23
24
15
16
17
11
12
13
14
6
7
8
9
10
ITEM QTY PART NO.
DESCRIPTION
1 1 480240000 ADAPTER
2
3
4
5
1
1
1
1
480241000 BUSHING
480242000 CAP BEARING
480243000 COVER
480244000 GEAR R.H.
1
2
1
1
1
480237000 HOUSING GEAR
480246000 KEY
480247000 SHAFT OUTPUT
480248000 WASHER THRUST
480249000 WORM R.H.
1
6
8
1
1
1
1
2
6
6
1
2
4
1
2
1
1
2
1
1
480251000 BEARING BALL
480252000 BEARING NEEDLE
480253000 BEARING NEEDLE
480254000 BEARING THRUST
480255000 COVER
007400000 SCREW HX HD 5/16 NC X 1
480238000 SCREW HX HD 5/16 NC X 1 1/4
(NYLON HEAVY PATCH)
011508000 SCREW HX HD 1/2 NC X 3/4
480256000 SCREW SOC HD 5/16 NC X 1
480258000 WASHER LK 5/16 MED SECT
480259000 ELL 90 DEG
480260000 GASKET
480250000 GASKET
480262000 FITTING RELIEF
480239000 O-RING
480263000 REDUCER
480264000 PLUG PIPE
480265000 PIN DOWEL
480266000 SEAL OIL
480268000 WASER THRUST
5-7.0.0
12/2002
HOIST ASSEMBLY
5005H SERIES
5-8.0.0
12/2002
HOIST ASSEMBLY
5005H SERIES
33
34
35
36
37
38
39
40
27
28
29
30
31
32
17
18
19
20
21
22
23
24
25
26
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
4
1
1
1
2
2
1
10
11
12
7
8
9
13
14
15
16
ITEM QTY PART NO.
DESCRIPTION
1 1 234189 DRUM ASSEMBLY
2 1 306042 PISTON BRAKE
5
6
3
4
1
1
1
4
338300
338301
338302
346045
END BEARING MOTOR
END BEARING GEAR HOUSING
HOUSING BRAKE
PIN BRAKE
1
2
1
1
1
1
6
2
8
2
357513
474065
402120
402121
412084
412085
414303
414948
414548
414854
INPUT SHAFT SUN GEAR
PLATE TIE
BEARING GEAR HOUSING
BEARING MOTOR
BUSHING DRUM (MOTOR END)
BUSHING DRUM (GEAR HOUSING END)
SCREW HX HD 3/8NC X 2 1/2 LG
SCREW SOC HD 1/2NC X 1 1/4 LG
SCREW HX HD 1/2NC X 1 1/2 LG
SCREW RD HD 1/4NC X 1/2 LG
414129
414926
416016
416080
418036
418088
418218
426048
431015
432018
432026
438022
442220
442223
444085
456038
458124
462046
462056
462057
462058
462059
462060
472052
SCREW SOC HD 5/16NC X 3 LG
SCREW SET 3/8NC X 1 LG SOC NYLON
SCREW SET 1/4NC X 1/4 LG SOC HD CUP
SCREW SET 5/8NF X 1 LG SOC HD CUP
NUT JAM 3/8NC
NUT JAM 5/16NC
WASHER LK 1/2 ID
PLUNGER
COUPLER MOTOR
FITTING 7/16 ELBOW 90 DEG
FITTING BLEEDER
DISC BRAKE
GASKET BRAKE
GASKET MOTOR
GEAR RING
FITTING VENT
MOTOR HYDRAULIC
O-RING DRUM
O-RING
O-RING
O-RING
O-RING BACKUP
O-RING BACKUP
PLUG
5-9.0.0
NOTES
HOIST ASSEMBLY
5005H SERIES
ITEM QTY PART NO.
DESCRIPTION
41
42
5
1
474111
486080
PLATE SEPERATOR
SEAL GEAR HOUSING
43
44
45
46
47
48
49
50
51
52
53
1
6
4
1
1
1
1
1
2
4
1
490037
494110
494112
509019
516028
518037
518047
518052
362283
362284
315004
SNAP RING
SPRING BRAKE
SPEING
TUBE ASSEMBLY
VALVE MOTOR CONTROL
THRUST WASHER
THRUST WASHER
THRUST WASHER
SPACER FOOT MOUNTING
SPACER TIE PLATE
CABLE ANCHOR
5-10.0.0
12/2002
12/2002
+
-
BATTERY
BATTERY
PWR OUT (SCP)
PRES-TRANS
A2B
VOLT-MONITR
PWR OUT (SCP)
HOME
PWR OUT (SCP)
BOOM SWITCH
PROG-PIN
BOOM UP
GROUND
BOOM DOWN
GROUND
RETRACT
GROUND
BOOM OUT
GROUND
CW ROT.
GROUND
CCW ROT.
HOIST UP
GROUND
HOIST DOWN
ENGINE FAST
PROPOR.
AUXILIARY
GROUND
ENGINE START
ENGINE STOP
PEND-GRND
PEND-PWR(SCP)
CAN DATA-H
34
35
36
CAN DATA-L
PEND-SHLD
MAIN GRND
37
38
39
40
26
27
28
29
30
31
32
33
18
19
20
21
22
23
24
25
10
11
12
13
14
15
16
17
5
6
7
8
9
1
2
3
4
ELECTRICAL SCHEMATIC
A2B SWITCH
BOOM SWITCH
4
3
2
1
PRESSURE
TRANSDUCER
A
B
A
B
B
A
ENGINE FAST
AUXILIARY
ENGINE START
ENGINE STOP
A
B
B
A
B
A
B
A
B
A
B
A
A
B
C
BOOM UP
BOOM
DOWN
RETRACT
EXTEND
ROTATE
CW
ROTATE
CCW
HOIST UP
HOIST
DOWN
A
B
C
D
HOME
SWITCH
A
B
PROPORTIONAL
6-1.0.0
12/2002
MAIN WIRING HARNESS
10
9
8
7
6
5
4
3
2
1
20
19
18
17
16
15
14
13
12
11
4
30
29
28
27
26
25
24
23
22
21
40
39
38
37
36
35
34
33
32
31
2 3 4
5in
PIN-17
15
PIN-14
BLU
WHT
BLU
1
2
1 2
REAR VIEW
BU
PIN NO,S 14,
16 THRU 27
ARE WIRED
IN ITEM-12
12
PIN-18
PIN-16
RED
SEE TABLE
GRN
2
1
1
2
5in 17
YEL
PIN-19
PIN-20
GRN/WHT
ORG
2
1
1 2
REAR VIEW
1
REAR VIEW
1
2
2
REAR VIEW
1
PIN-21
PIN-22
ORG/BLK
BLK
BD
RET
EXT
1
2
1 2
REAR VIEW
ROT
CW
PIN-23
PIN-24
WHT/BLK
BLU/BLK
1
2
1 2
REAR VIEW
ROT
CCW
5in
PIN-25
PIN-26
16
RED/WHT
GRN/BLK
WHT
1
2
1 2
REAR VIEW
HU
PIN-27
BLK/WHT
2
1
1 2
REAR VIEW
HD
PIN-35
PIN-34
PIN-36
PIN-37
6
RED
BLK
WHT
GRN
7
1
2
3
4
8
1
2
4
3
PIN-38
OUTER SLEEVE
SHIELD
SHIELD TERMINATED WITH
PENDANT PLUG
REAR VIEW
13 48in
PIN-5
2in
2 3 4
16
GRN
WHT
1
2
1 2
REAR VIEW
A2B
7 11 14
PIN-8
PIN-10
PIN-15
PIN-11
PIN-13
WHT
BLK
18in 20
2
1
1 2
REAR VIEW
PROGRAM PLUG
2
18 18in
20
WHT
GRN
BLK
1
2
3
10in
1
2
3
REAR VIEW
7
HOME SW
13
9 10
32in
PIN-12
PIN-11
22
23
BLK
WHT
INSTALL ASSEMBLED BLANK
INTO PROGRAM PLUG
CONNECT SHIELD TO BLK THIS END
TERMINATE WITH OUTER SLEEVE OPPOSITE END
PIN-15
PIN-4
BLK
WHT
3
4
1
2
1
2
4
3
GRN
PIN-3 REAR VIEW
PRESS TRANSDUCER
5 6 7
BOOM SWITCH HOUSING
(NOT PART OF HARNESS)
N.C.
N.O.
COMMON
NOTE: ALL CONNECTIONS OF
THIS TYPE ARE TO BE
SOLDERED AND
HEAT SHRINK APPLIED
4in
PIN-1
PIN-2
PIN-6
RED
4in
RED
RED
19
PROPORTIONAL
1 2
REAR VIEW
1
2
2 3 4 36in 22
BLK
WHT
NOTES:
LABEL ALL PLUGS PER FUNCTION IDENTIFICATION.
ONLY ONE CONDUCTOR THROUGH RUBBER SEAL ON PLUGS.
TO BATTERY (+) POS
PIN-29
PIN-28
PIN-32
PIN-30
PIN-33
PIN-40
WHT
BLU
GRN
ORG
TO ENG SLOW/FAST
TO ENG START
TO AUX FUNC.
TO ENG STOP
BLK
TO BATTERY (-) GND
CRANE WIRING
6-2.0.0
21
120in
12//2002
NOTES
MAIN WIRING HARNESS
14
15
16
17
18
19
20
21
22
23
10
11
8
9
12
13
ITEM
1
4
5
2
3
6
7
1
10 in
15 in
5 in
2
1
1
1
1
36 in
66 in
4 in
54 in
120 in
68 in
2
QTY
1
10
10
58
1
2
13
PART No.
366377001
366367001
366367002
366367003
366376001
366376002
366376003
360768001
360764001
360764002
360769001
800633
750038
360769002
800594
800592
800596
360755000
800593
800628
800629
800626
000101
DESCRIPTION
HOUSING DEUTSCH 40-PIN
HOUSING DEUTSCH PLUG 2-PIN
WEDGE DEUTSCH PLUG 2-PIN
CONTACT DEUTSCH CONNECTOR (SOCKET)
HOUSING DEUTSCH RECEPTACLE 4-PIN
WEDGE DEUTSCH 4-PIN
CONTACT DEUTSCH CONNECTOR (PIN)
HOUSING DEUTSCH 4-PIN BULKHEAD RECEPTACLE
HOUSING DEUTSCH 3-PIN RECEPTACLE
WEDGE DEUTSCH 3-PIN
HOUSING DEUTSCH 2-PIN RECEPTACLE
CABLE 16 GA 14 COND
CABLE 18 GA 4 COND SHIELDED
WEDGE DEUTSCH 2-PIN
WIRE 16 GA 1 COND BLU
WIRE 16 GA 1 COND WHT
WIRE 16 GA 1 COND YEL
CAVITY PLUG DEUTSCH
WIRE 16 GA 1 COND RED
CABLE 16 GA 3 COND
CABLE 16 GA 6 COND
CABLE 16 GA 2 COND
TERMINAL, RING
6-2.1.0
12//2002
HYDRAULIC SCHEMATIC
1
DN
Hoist
UP
2
3 1
2 4
Rotation
3
CC CW
4
2 4
3 1
4 GPM
5
Lift
6
7
.
.
8
Secondary
Extension
Primary
Extension
.015
.
Proportional
. .
.
..
GA P
.
.
.
.
.
T CD
7-1.0.0
12/2002
HYDRAULIC SCHEMATIC
Counterbalance Valve Adjustment
♦ With PTO disengaged and boom properly supported, remove the plug on the counterbalance valve. Install a pressure gauge (0-3000 PSI) into the port.
♦ Engage PTO and insure pump flow is 8 to
9 GPM. With no load on boom, boom up to an angle of 70 degrees. Boom down and note pressure. If pressure reading is not approximately 1300 PSI, the counterbalance valve requires adjustment. v To increase the CB valve setting, loosen nut and turn Allen head screw counter clockwise. v To reduce the CB valve setting, loosen nut and turn Allen head screw clockwise.
♦ Tighten nut on adjustment screw and repeat procedure if needed to obtain the proper pressure setting.
♦ Disengage PTO, remove the pressure gauge and install plug. Crane is now ready for operation.
WARNING:
Notice:
♦ In an EMERGENCY situation when it becomes necessary to lower the boom without flow present, the CB valve adjustment can be turned in until the boom begins to descend. Make sure the boom will lower onto a proper support.
Loosen the lock nut and carefully turn adjustment screw clockwise! Count the number of turns. Turn slowly until the boom just begins to lower, and remove hand/arm/fingers from cranes while boom is lowering.
♦ Turning adjustment screw too far will cause valve to come apart on the inside.
This condition is not repairable
♦ After boom is lowered, turn adjustment screw counter clockwise the approximate number of turns made during lowering procedure. After the problem is corrected, readjust the counterbalance valve using the procedure in this manual.
DO NOT TRY TO ADJUST VALVES WHILE BOOM IS MOVING.
Failure to do so may result in personal injury!
7-2.0.0
12/2002
HYDRAULIC CONTROL VALVE
5005H SERIES
7-3.0.0
12/2002
HYDRAULIC CONTROL VALVE
5005H SERIES
ITEM A/C P/N QTY DESCRIPTION
CL2
PV1
CL1
FR1
RV1
SV1,SV2
SV3,SV4,SV5
ORF1
PLG4
NOT SHOWN
BLK
PORT #'S
366365001
366365002
366365006
366365003
366365004
366365005
320725001
A/C P/N
6 COIL
1 PROP VALVE
1 COIL
1 FLOW CONTROL
1 RELIEF VALVE
2 CART VALVE
3 CART VALVE
ORIFICE PLUG
PORT PLUG
PLUG
BLOCK
FITTING TABLE
QTY DESCRIPTION
1,2
3,5
4,6
P
T
7,8
GA
GA
374017000
241175000
330645000
369145000
490199000
480195000
369127
330348
2 FITTING 45 8-SAE/8-JIC
2 FITTING 90 6-SAE/6-JIC
2 FITTING 90 6-SAE/6-JIC LONG
1 FITTING STR 8-SAE/8-JIC
1 FITTING STR 10-SAE/10-JIC
2 FITTING 45 6-SAE/6-JIC
1 FITTING 90 4-SAE/4-JIC
1 FITTING CAP 4-JIC
7-4.0.0
12/2002
NOTES
DIAGNOSTICS
FLOW PRESENT BUT
FUNCTION WILL
NOT WORK
HYDRAULIC
“CHATTER”
NO FLOW OR
LIMITED FLOW TO
CRANE
NO PRESSURE OR
TOO LOW
PRESSURE
TOO HIGH FLOW
TOO HIGH
PRESSURE
Check receiver for error code, if error code is present while function is being activated, refer to the error code section on the following page. If
“NRML” appears in the code display on the receiver while the function is being activated, operate the proportional override and push or pull the override on the directional control valve to operate the function. If the function still does not operate, see the “NO FLOW” paragraph in this section.
When a hydraulic function is engaged and causes the crane to “chatter”, check for error code on receiver display, low pump pressure or air in the system.
Check for error code on receiver display (see error code section). Check for adequate oil supply in reservoir. Check operation of bypass system by operating the override on the proportional valve while operating crane. If low flow condition continues to exist when the manual override is operated, remove relief valve cartridge and check for dirt.
Other possible causes for a low flow condition are:
1. Engine speed is too slow.
2. A blocked pressure hose from pump. This condition can be identified by excessive lugging of engine and rapid overheating of oil.
3. Collapsed or blocked suction hose to pump. This condition is usually identified by pump cavitation noise.
4. Bad pumps: a bad pump will usually have some flow but the flow will drop off rapidly as pressure increases. This condition will cause overheating of the system. A drop of four (4) or more GPM from Zero (0) PSI to Two Thousand (2000) PSI is cause for pump investigation
Check the sight gauge and maintain an adequate oil level in reservoir.
Make sure pressure gauge is functioning correctly. Possible relief valve stuck open. Check for excessive leakage and correct.
Make sure pump size is correct and pump speed is not too fast (Consult manufacturer's data sheet). Check or replace flow control. Check components for flow displacements. High flow may cause erratic valve operation.
Make sure pressure relief valve is correctly set.
CAUTION
The Auto Crane 5005H series cranes are manufactured with a standard overload protection system to prevent structural damage to the crane. When the crane load rating is exceeded, main boom down, extend out, and hoist up will not function. These operations cannot be used again until the load on the crane is reduced. Also, the main boom elevation will be limited in its operation as the crane becomes overloaded. Attempting to raise the main boom with a load greatly exceeding the crane rating will open the main relief valve resulting in no boom movement. This problem can be resolved by moving the load closer to the crane pedestal, or reducing the load.
8-1.0.0
12/2002
CONTROLLER DIAGNOSTICS
CODE: EC01
DESCRIPTION: Signal
POSSIBLE CAUSE(S): No signal from transmitter/pendant or transmitter power off.
POSSIBLE SOLUTION(S): Check transmit light on transmitter, light should flash when function is activated. If light does not flash, make sure transmitter is on. If light flashes and red low battery light is flashes, charge unit. If transmitter is plugged in as a pendant and transmit light comes on but code remains, check cable connections and cable.
CODE: EC02
DESCRIPTION: Boom
POSSIBLE CAUSE(S): Short or open connection on boom up output.
POSSIBLE SOLUTION(S): Check plug in boom up solenoid on hydraulic control valve.
Check wires for damage that could cause break or short.
CODE: EC03
DESCRIPTION: Boom
POSSIBLE CAUSE(S): Short or open connection on boom down output.
POSSIBLE SOLUTION(S): Check plug in boom down solenoid on hydraulic control valve. Check wires for damage that could cause break or short.
CODE:
DESCRIPTION:
POSSIBLE CAUSE(S):
EC04
Boom in (retract)
Short or open connection on boom in output.
POSSIBLE SOLUTION(S): Check plug in boom in solenoid on hydraulic control valve.
Check wires for damage that could cause break or short.
8-2.0.0
12/2002
CONTROLLER DIAGNOSTICS
CODE:
DESCRIPTION:
POSSIBLE CAUSE(S):
EC05
Boom out (extend)
Short or open connection on boom out output.
POSSIBLE SOLUTION(S): Check plug in boom out solenoid on hydraulic control valve. Check wires for damage that could cause break or short.
CODE: EC06
DESCRIPTION: Rotate
POSSIBLE CAUSE(S): Short or open connection on rotate CW output.
POSSIBLE SOLUTION(S): Check plug in rotate CW solenoid on hydraulic control valve. Check wire for damage that could cause break or short.
CODE: EC07
DESCRIPTION: Rotate
POSSIBLE CAUSE(S): Short or open connection on rotate CCW output.
POSSIBLE SOLUTION(S): Check plug in rotate CCW solenoid on hydraulic control valve. Check wire for damage that could cause break or short.
CODE: EC08
DESCRIPTION: Hoist
POSSIBLE CAUSE(S): Short or open connection on hoist up output.
POSSIBLE SOLUTION(S): Check plug in hoist up solenoid on hydraulic control valve.
Check wire for damage that could cause break or short.
CODE: EC09
DESCRIPTION: Hoist
POSSIBLE CAUSE(S): Short or open connection on hoist down output.
POSSIBLE SOLUTION(S): Check plug in hoist down solenoid on hydraulic control valve.
Check wire for damage that could cause break or short.
8-3.0.0
12/2002
CONTROLLER DIAGNOSTICS
CODE: EC10
DESCRIPTION: Incorrect
POSSIBLE CAUSE(S): Signal received from transmitter with incorrect ID code.
POSSIBLE SOLUTION(S): Confirm that transmitter being used is for use with this unit.
Follow ‘New Transmitter’ procedure in the transmitter operation section of this manual.
CODE: EC11
DESCRIPTION: Ground
POSSIBLE CAUSE(S): Fuse in receiver may be blown.
POSSIBLE SOLUTION(S): Check the fuse in the receiver, fuse is on the ground circuit do not check for voltage.
CODE:
DESCRIPTION:
POSSIBLE CAUSE(S):
EC12
Short circuit in power circuit
Power provided to the switches etc. is shorted to ground.
POSSIBLE SOLUTION(S): Check the wiring on the pendant cable, the anti-two block, the pressure sensor, the boom limit switch, the home switch and the rotation stop for a short to ground.
CODE:
DESCRIPTION:
EC13
Auxiliary not wired
POSSIBLE CAUSE(S): Short or open connection on auxiliary.
POSSIBLE SOLUTION(S): This error should only be seen on a Palm unit and should only occur when the auxiliary function is not connected.
CODE: EC15
DESCRIPTION: Pressure
POSSIBLE CAUSE(S): Pressure sensor problem.
POSSIBLE SOLUTION(S): Check plugs and wires coming from pressure sensor mounted in the lift cylinder counterbalance valve.
8-4.0.0
12/2002
CONTROLLER DIAGNOSTICS
CODE: EC16
DESCRIPTION: Trigger
POSSIBLE CAUSE(S): Transmitter trigger problem.
POSSIBLE SOLUTION(S): Check trigger for damage, contamination or incorrect adjustment.
CODE: EC17
DESCRIPTION: Trigger error
POSSIBLE CAUSE(S): Trigger was activated before function switch was activated.
POSSIBLE SOLUTION(S): Confirm that trigger is released and returned to full off position,
CODE: activate function and reactivate trigger.
LBV
DESCRIPTION: Low
POSSIBLE CAUSE(S): Low battery power to to receiver.
POSSIBLE SOLUTION(S): Check connections to the battery. Charge battery. NOTE: It is recommended that the crane be powered off if battery is charged with battery charger.
CODE: OVL
DESCRIPTION: Overload
POSSIBLE CAUSE(S): Pressure
POSSIBLE SOLUTION(S): Retract boom, hoist down or otherwise alleviate overload condition. Refer to load chart for rated load. If the error persists with seemingly light loads, install pressure gage in plugged port of lift cylinder counterbalance valve to confirm pressures in excess of 2,500 psi. Pressure sensor can give false readings if not properly grounded.
8-5.0.0
12/2002
CONTROLLER DIAGNOSTICS
CODE:
DESCRIPTION:
POSSIBLE CAUSE(S):
RS1
Rotation switch tripped.
Rotation stop reached in clockwise direction.
POSSIBLE SOLUTION(S): This is not an error. Rotate in opposite direction or check switch for interference.
CODE:
DESCRIPTION:
RS2
Rotation switch tripped.
POSSIBLE CAUSE(S): Rotation stop reached in counter-clockwise direction.
POSSIBLE SOLUTION(S): This is not an error. Rotate in opposite direction or check switch for interference.
CODE: A2B
DESCRIPTION: Anti-two
POSSIBLE CAUSE(S): Anti-two block switch tripped.
POSSIBLE SOLUTION(S): Check switch, if not mechanically tripped, check continuity cross switch at plug. If switch has continuity check voltage across transmitter side of A2B plug. If low voltage is read, power to the A2B switch, the rotation switches or the pressure sensor may have a short.
CODE: RSBM
DESCRIPTION: Raise
POSSIBLE CAUSE(S): Pressure sensor is reading less than 80 psi.
POSSIBLE SOLUTION(S): Raise boom to ensure it is not resting on other structure and the lift cylinder is not bottomed out.
8-6.0.0
12/2002
CONTROLLER DIAGNOSTICS
CODE: HOME
DESCRIPTION: Home
POSSIBLE CAUSE(S): Crane is pointed forward ready to be stowed.
POSSIBLE SOLUTION(S): This is not an error. It is a built-in override of the above RSBM condition that will allow you to stow the crane on a boom support.
DESCRIPTION:
POSSIBLE CAUSE(S):
Normal operating mode
Crane is functioning properly.
POSSIBLE SOLUTION(S): This is not an error. It is a standard normal operation readout.
CODE:
DESCRIPTION:
SLOW
Slow operating mode
POSSIBLE CAUSE(S): Crane is functioning properly if loaded or boom down activated.
POSSIBLE SOLUTION(S): This is not an error. It is a standard slow operation readout. If t he crane is not loaded booming up should clear this code.
CODE:
DESCRIPTION: Boom
POSSIBLE CAUSE(S): Boom has reached maximum elevation.
POSSIBLE SOLUTION(S): This is not an error. It only indicates boom position. Lower the boom to deactivate the switch.
8-7.0.0
12/2002
TRANSMITTER / RECEIVER
SYNCHRONIZATION
1. Power on the transmitter and receiver.
2. Locate the program plug on the crane. This will be the unused plug near where the cord reel plugs into the wire harness.
3. Using a jumper wire, as shown below, connect the two contacts in the plug.
4. With the jumper is installed and the transmitter is unplugged from the pendant cable, activate a function on the transmitter.
Note: The crane must be electrically powered but it is not necessary to supply hydraulic power to complete synchronization.
Important: The jumper wire should not be left installed. Doing so could cause the crane to be operated by another transmitter.
8-8.0.0
12/2002
REMOTE / PENDANT
PARTS AND ACCESSORIES
Component
Receiver
Pendant
Antenna
Cigarette Lighter Charger
Palm
Replacement Toggle Switch (Transmitter)
Replacement Batteries (Transmitter)
Part Number
366500010
366500007
Transmitter Receiver
8-9.0.0
4/23/04
VALVE OVERRIDE OPERATION
In the event that the electrical control system fails the crane can be operated using the manual overrides on the hydraulic control valve.
The overrides operate as follows:
1. Proportional – increase flow by turning clockwise.
2. Extend/Retract, Boom Up/Down, Rotate CW/CCW – Push to operate boom down, pull to operate boom up etc. See graphics below.
3. Hoist Up/Down – Push in, rotate counterclockwise, release.
PROP PROP
HU
HD HD
ROT
CW
ROT
CCW
BD BU
RET EXT
DIRECTIONAL CONTROL
8-10.0.0
12/2002
FUSE INFORMATION
5005H SERIES
NOTE: Always turn the power to crane off before removing fuse.
Fuse is on the ground circuit. The fuse can be replaced with a 7.5 amp fuse.
8-11.0.0
12/2002
NOTES
LOAD CHART
5005H SERIES
24
23
22
21
20
19
18
28
27
26
25
17
16
15
14
9
8
7'-8"
13
12
11
10
5000
5000
5000 2574
2869
5005H
NOTE:
1. DISTANCE FROM
1789
BASE OF CRANE
TO CRANE OF
BOOM PIVOT
IS 25.5" 5000 3306
3725
1990
75°
5000
5000
60°
5000
45°
OVER 2500 LBS
USE DOUBLE LINE
2243
4377
2569
1449
3622
3006
2075
1814
1611
30° 2912
2423
15°
2593
2160
1851
1619
1439
1295
0
360705000
1
2
3
4
5
2500 1785 1388
6
2083 1562 1250
7
8
9
10
11
12
13
DISTANCE IN FEET
14
15
16
17
18
19
20
9-1.0.0
12/2002
NOTES
SUPPLIMENTAL INFORMATION
HARD WIRED SERIES
The following section refers to hardwire specific information only. Refer to the previous sections for information common to both crane versions.
10-0.0.0
6/02/2003
EXTEND
PORT #7
GENERAL ASSEMBLY
5005H HARD WIRED SERIES
RETRACT
PORT #8
5 6 3
9
1
12
13
4 6 5
2
7 8
10-1.0.0
07/26/04
GENERAL ASSEMBLY
5005H HARD WIRED SERIES
ITEM NO.
QTY.
1 1
PART NO.
360693000
2
3
1 360775000
1 360715000
6
7
8
4
5
1
3
366492
021100
PEDESTAL ASSEMBLY
BOOM ASSEMBLY
PIVOT PIN
DESCRIPTION
PIN 1.25 DIA X 3.00 LG
WASHER SPLK 3/8
3 008400 SCW HEX HD 3/8-16 UNC X 3/4 GR 5
1 *366398000 TRAVELING BLOCK ASSY 6406H
1 360758000 ROPE ASSY
9
10
11
12
13
1 360747000
1 360713000
1 360714000
COVER 5005
SHIP KIT 5005H
DECAL LAYOUT
1 *366520001 JUNCTION BOX ASSEMBLY
1 *366466000 WIRE HARNESS, TRUCK FUNCTIONS
* included in crane ship kit, ref P/N: 360694000
10-2.0.0
07/26/04
MOUNTING AND INSTALLATION
5005H HARD WIRED SERIES
1. Check to make sure the following items are with your crane.
1
120"
6
6
1
1
1
4
5
1
1
1
QTY
1
1
4
4
1
1
14
15
16
17
18
10
11
12
13
ITEM
1
2
5
6
3
4
7
8
9
PART NO.
DESCRIPTION
366398000 TRAVELING BLOCK, 6406H
360706000 OWNERS MANUAL
015104000 BOLT 7/8 NF x 5" GRADE 8 (4 REQ'D)
022200000 WASHER SPLIT LOCK 7/8 (4 REQ'D)
680040000 PENDANT ASSEMBLY
366466000 WIRE HARNESS, TRUCK FUNCTIONS
366520001 JUNCTION BOX ASSEMBLY
018900 NUT, HEX 7/8 NF
320355 POWER RELAY
480689
480688
800596
634401
750738
320357
320363
360705
340638
FUSE 15 AMP TIME DELAY
FUSE HOLDER WATERPROOF
CONDUCTOR 16GA YELLOW X 120 INCHES LONG
WIRE TIE 7 INCHES LONG
WIRE TIE STICK ON RETAINER
CONNECTOR FEM SPD
PLUG RELAY
LOAD CHART DECAL, 5005H
CONDUCTOR POWER
2. Pressure and return hoses are not furnished with this crane. The hoses must be provided by the installer and the lengths determined at installation.
REQUIREMENTS FOR INSTALLATION USING 10 GALLON RESERVOIR
A. RETURN LINE FROM CRANE TO RESERVOIR (IN COMPARTMENT): -10 SAE 100R2 (OR EQUIVALENT).
HOSE LENGTH IS DETERMINED BY INSTALLER. RETURN LINES LONGER THAT 6 FEET SHOULD BE
SIZE –12. HOSE END FITTINGS ARE –10 JIC FEMALE SWIVEL (CRANE END) AND –10 JIC FEMALE
SWIVEL (RESERVOIR END).
B. PRESSURE LINE FROM PUMP TO CRANE: -8 SAE 100R2 (OR EQUIVALENT). HOSE LENGTHS IS
DETERMINED BY INSTALLER. HOSE END FITTINGS ARE BOTH –8 JIC FEMALE SWIVEL.
NOTE:
REFER TO OWNERS MANUAL FOR ADDITIONAL INSTALLATION INFORMATION.
CAUTION – FAILURE TO USE CLEAN HYDRAULIC HOSES AND COMPONENTS
MAY CONTAMINATE THE CRANE AND HYDRAULIC SYSTEM AND VOID WARRAN
3. Crane must be provided with a flow of 8 gallons per minute and a pressure of 2,750PSI. Excess flow will cause erratic operation, and too little flow will cause poor crane operation.
4. Vehicle should meet minimum GVW rating of 14,500 pounds.
5. The vehicle MUST be equipped with an engine speed control and tachometer.
6. Make sure mounting surface is properly reinforced to withstand 25,000 ft-lb capacity loading of crane and that outriggers are used to provide total stability for the truck.
7. A 13 ½” dia. Hole should be cut out of mounting location (centered with mounting blots) for access to lower ring gear bolts and hydraulic connections.
8. Make sure the mounting blots are 7/8” dia, grade 8. Torque bolts to 440 ft-lbs (dry).
9. When crane is not in operation, a boom support should always be used. Traveling block should be connected to hood loop.
10. Install junction box inside compartment safe from weather and contamination.
10-3.0.0
07/26/04
MOUNTING AND INSTALLATION
5005H HARD WIRED SERIES
11. Electrical hookup:
Wiring (cable from junction box):
A. CONNECT THE BLACK WIRE TO THE BATTERY NEGATIVE (GROUND).
B. CONNECT THE RED WIRE TO FUSED 12VDC POWER. 12VDC POWER SHOULD BE
SUPPLIED THROUGH A DEDICATED SWITCH THAT IS POWERED ONLY WHEN THE IGNITION
SWITCH IS ON. A RELAY IS PROVIDED TO SEPARATE POWER SOURCES.
C. OPTIONALLY, USE THE WHITE WIRE FOR ENGINE FAST/SLOW.
D. OPTIONALLY, USE THE BLUE WIRE FOR ENGINE START.
E. OPTIONALLY, USE THE ORANGE WIRE FOR ENGINE STOP.
F. OPTIONALLY, USE THE GREEN WIRE FOR AUXILIARY.
WARNING!
FAILURE TO CORRECTLY PLUMB AND WIRE CRANE CAN CAUSE INADVERTENT
OPERATION AND DAMAGE TO CRANE AND/OR PERSONEL!
12. Once crane and plumbing are installed on the truck, fill the reservoir to top of sight glass (mobile DTE 13 or equal). Before operating crane, connect together the pressure and return hoses going to base of crane using 10-8 JIC union and engage PTO with engine running. Allow oil to circulate for 15 to 20 minutes. This will flush contaminants from the system back to the return line filter. Operate all cylinders to full extension and retraction a minimum of six times, to bleed air from system. Return all cylinders to the stored position and disengage PTO. Refill reservoir to top sight glass. To ensure 8 gallons per minute (GPM), install an in-line flow meter between the crane and the reservoir in the return hose.
13. Load test the crane to ensure proper functioning and truck stability
14. Make certain the owner’s manual is delivered to the customer.
15. For additional help: call the service department at the Auto Crane Company. (918) 836-0463 (Tulsa,
Oklahoma)
WARNING
FEDERAL LAW
(49 CFR PART 571) REQUIRES THAT THE FINAL STAGE MANUFACTURER OF A
VEHICLE CERTIFY THAT HE VEHICLE COMPLIES WITH ALL APPLICABLE FEDERAL REGULATIONS.
ANY MODIFICATIONS PERFORMED ON THE VEHICLE PRIOR TO THE FINAL STAGE ARE ALSO
CONSIDERED INTERMEDIATE STAGE MANUFACTURING AND MUST BE CERTIFIED AS TO
COMPLIANCE. THE INSTALLER OF THIS CRANE AND BODY IS CONSIDERED ONE OF THE
MANUFACTURERS OF THE VEHICLE. AS SUCH A MANUFACTURER, THE INSTALLER IS
RESPONSIBLE FOR COMPLIANCE WITH ALL APPLICABLE FEDERAL AND STATE REGULATIONS,
AND IS REQUIRED TO CERTIFY THAT THE VEHICLE IS IN COMPLIANCE.
IT IS THE FURTHER RESPONSIBILITY
OF THE INSTALLER OF THE CRANE TO
COMPLY WITH THE OSHA TRUCK CRANE STABILITY REQUIREMENTS AS SPECIFIED BY 29 CFR
PART 1910.180 (C) (1).
10-4.0.0
07/26/04
NOTES
ELECTRICAL SCHEMATIC
5005H HARD WIRED CRANE
RED/WHITE
WHT
BLK
RED
GRN
1
2
3
4
1
2
3
4
BLACK
GRN
HOIST UP
HOIST DOWN
ROTATE CCW
WHT
WHT/RED
ROTATE CW
GREEN
RED/BLACK
WHITE/BLACK
ORANGE
WHITE
BLUE
GREEN/BLACK
ORANGE/BLACK
RED
BLACK
GREEN
BOOM LIMIT SW
BLACK
BOOM UP
BOOM DOWN
BOSCH
RELAY
30 87
RED/WHITE
EXTEND (OUT)
EXTEND(IN)
PRESS SW1
RED/
WHT
A2B
85
BOSCH
RELAY
86
PROP
CONTROL
VALVE
POWER
GROUND
ENGINE FAST/SLOW
AUXILARY
ENGINE START
ENGINE STOP
BLUE (NOT USED)
WHITE (NOT USED)
RED
BLACK
WHITE
GREEN
BLUE
ORANGE
1
2
3
4
5
6
7 (N/A)
8 (N/A)
9
10
11
JUNCTION BOX
3
4
5
6
7
8
12 PIN CONNECTOR
1
2
GREEN
RED
BLUE
GREEN/BLACK
ORANGE/BLACK
BLACK
ORANGE
RED/BLACK
12
H
J
WHT/BLK
K
WHITE
L
BLU/BLK
M
BLK/WHT
N
GRN/WHT
P
BLU/WHT
R
BLK/RED
S
WHT/RED
T
ORG/RED
U
BLU/RED
V
E
F
G
A
B
C
D
10-5.0.0
07/26/04
PEDESTAL ASSEMBLY
5005H HARD WIRED SERIES
64
7
28
9
73 72
3
8 27
15 19
24 25
39
5
60
20
56
37
38
HYDRAULIC VALVE KEY
PORT #1: HOIST DOWN
PORT #2: HOIST UP
PORT #3: ROTATION CCW
PORT #4: ROTATION CW
PORT #5: LIFT CYL EXTEND
PORT #6: LIFT CYL RETRACT
PORT #7: EXT CYL EXTEND
PORT #8: EXT CYL RETRACT
CYLINDER SEAL KIT: 360720000
COUNTER BALANCE CARTRIDGE: 480188000
1
3
17 18 26 12 59 58 57
55 15
32
69 70
3
31
68
10
11
30
15
29
6
52
49
50
53
54
66
67
35
36
33
47
51
48
65
34
10-6.0.0
07/26/04
PEDESTAL ASSEMBLY
5005H HARD WIRED SERIES
34
35
36
37
30
31
32
33
26
27
28
29
22
23
24
25
42
43
44
45
46
38
39
40
41
18
19
20
21
14
15
16
17
10
11
12
13
8
9
6
7
ITEM NO. QTY. PART NO.
1
DESCRIPTION
1 360717000 BASE PLATE WELD
4
5
2
3
1 480023002 BEARING, ROTATION
1 360772000 PEDESTAL WELD
1
1
160407
366440
GEAR BOX, ROTATION
ROTATION MOTOR
1 360788000 CYLINDER LIFT
1 366365000 VALVE CONTROL ASSY
1 123309
2 366364
1 366492
1 366333
38 023902
14 490171
4 006205
10 021100
2 011202
8 021500
2 017704
4 330371
2 009118
2 490198
2 021502
2 012197
HOIST RPH2500
PLATE, VALVE MOUNTING
PIN 1.25 DIA X 3.00 LG
BEARING, SPHERICAL 1.25 ID
WASHER, 5/8 FLAT HARDENED
CAPSCREW 5/8-11 X 2.25 GR8
SOC HD 5/8 X 1 1/4
WASHER SPLK 3/8
SCW HX HD 1/2-20 X 2 3/4
WASHER SP LK 1/2
NUT HX HVY 1/2 NF
SCW HEX HD 3/8-16 UNC X 1 GR 8
SOC HD 1/2 UNC X 2
FITTING 10SAE(M)/6JIC ELBOW 90
WASHER lk 1/2
SOC HD 1/2-13
4 320588
4 366391
24 012198
2 372041
WASHER FL 1/2
HEX HD 1/2-13 X 2 1/4
CAPSCREW 5/8-11 X 1.75 GR8
FITTING 8JIC/10SAE STRAIGHT 8-10 F5OX
8 407314000 WASHER FL 5/8 X 1 5/16 OD HARDENED
2 200876 FITTING 6 SAE/6 JIC STRAIGHT 6F5OX
1 360692000 LOAD SENSOR SWITCH, 2200 PSI
5 008702
48 374086
1 642918
1 366358
SCW HX 3/8 UNC X 1 1/4
NYLON HOSE SLEEVE
CORD CONNECTOR
FITTING 10SAE/JIC SWIVEL PS810503-10-10
1 366359 FITTING 8 SAE/JIC SWIVEL PS810503-8-8
1 366508000 CORD GRIP HUBBLE F-3 SHC 1036
1 490199
1 367145
1 480024
1 020601
FITTING STR 10-SAE/10-JIC
FITTING STR 8-SAE/8-JIC
MOUNT PENDANT CABLE RETAINER
WASHER 5/16 LOCK
1 007401 SCW 5/16-18 X 1/2 LG
2 812209-022 HOSE ASSY 6 STR/90
2 480205 HOSE ASSY 6 STR X 19.25
1 812203-028 HOSE ASSY 6 STR
1 812203-030 HOSE ASSY 6 STR
2 480203 HOSE ASSY 8 STR X 24.75
10-7.0.0
07/26/04
PEDESTAL ASSEMBLY
5005H HARD WIRED SERIES
62
63
64
65
66
57
58
59
60
61
ITEM NO. QTY. PART NO.
47
DESCRIPTION
1 812309-024 HOSE ASSY 8 STR/90
48
49
1 812409-022 HOSE ASSY 8 STR/90
1 360724000 ARMRORATION STOP
50
51
52
53
54
55
56
1 360122 RING, ECCENTRIC
1 360709000 BRACKET BOOM SW WDMT
1 654100 SWITCH LIMIT BZ-2RW80-A2
1 360690000 BEARING FLANGE
2 000602 SCWPN #6 NC x 1
2 019600
2 015400
WASHER SP LK #6
NUT HX #6-32
70
71
72
73
67
68
69
1 008400
1 360162
1 360207
1 020600
1 007807
1 480011
1 020901
SCW HX HD 3/8-16UNC x 3/4
RING, ECCENTRIC
RETAINER ECCENTRIC RING
WASHER FL 5/16
SCW HEX HD 5/16-18 x 34 LG GR 5
SEAL ROTATION BOX
WASHER FL 5/16
1 366363001 AMP MODIFICATION, CONNECTORS
1 366522001 HOUSING, PLUG, DEUTSCH 12-PIN
1 366522002 WEDGE, DEUTSCH PLUG, 12 SOCKET
5 320976000 WASHER, FLAT, 3/8 SAE HARDENED
1 320355
1 006200
1 020300
1 020200
RELAY, BOSCH
SCW HEX HD 1/4 x 1-1/4
WASHER FL SAE 1/4
WASHER SPLIT LOCK 1.4
1 015900 NUT 1/4NC
1 360391001 MAIN HARNESS ASSEMBLY, HARD WIRED
10-8.0.0
07/26/04
4
A
MAIN WIRING HARNESS
5005H HARD WIRED SERIES
BLK
10.0"
12 15 10
WHT/RED
10.0"
WHT/RED
10.0"
86
87
87A 85
30
BLK
5.0"
7
8
BLK
RED/WHT
4.0"
4
5 6
2
PRESSURE SWITCH
3
A2B SWITCH
1
2
8
1
B
RED WIRE
NOT USED
HU
HD
RED/WHT
9.0"
CCW
RED/WHT
4.5"
CW
BU
RED/WHT
4.5"
BD
WHT/RED
4.5"
EXT
RET
WHT/RED
4.5"
RED/WHT
2.5"
BLK
11
A
BOOM LIMIT
B
WHT
9
RED/WHT
5.0"
WHT/RED
4.5"
RED/WHT
2.5"
10
RED/WHT
5.0"
FUNCTION
HOIST UP
HOIST DN
ROTATE CCW
ROTATE CW
BOOM UP
BOOM DN
EXTEND
RETRACT
A2B SWITCH
PRESSURE
SWITCH
BOOM LIMIT
2 COND CABLE
1
2
1
2
***
N/A
1
2
1
2
PIN WIRE COLOR
1
2
GREEN POWER
NOTES
WHITE/RED TO A2B GROUND
1
2
RED/BLACK POWER
RED/WHITE GROUND
WHITE/BLACK POWER
RED/WHITE
ORANGE
RED/WHITE
GROUND
POWER
GROUND
1
2
1
2
WHITE
BLACK
POWER
BOOM SWITCH CABLE
BLUE POWER
WHITE/RED TO A2B GROUND
1
2
GREEN/BLACK POWER
WHITE/RED TO A2B GROUND
1 ORANGE/BLACK POWER
2 RED/WHITE GROUND
WHITE/RED TO PIN 1, PRESSURE SWITCH
RED/WHITE FROM HU, BD, EXT GND
RED/WHITE GROUND
WHITE/RED FROM A2B PIN 2
BLACK ***PIN 2 ON BOOM UP PLUG
WHITE
10-9.0.0
10
11
12
13
8
9
6
7
14
15
ITEM NO. QTY. PART NO. DESCRIPTION
1
4
5
2
3
1 800632000 CABLE, 16/10 SO BLACK
9 366367001 HOUSING, DEUTSCH 2-PIN PLUG
9 366367002 WEDGE, DEUTSCH PLUG, 2 PIN
27 366367003 CONTACT, DEUTSCH SOCKET
1 360769001 HOUSING, DEUTSCH 2-PIN RECEPTACLE
1 360769002 WEDGE, DEUTCH 2-PIN RECEPTACLE
2 366376003 CONTACT, DEUTSCH
6 001104000 TERMINAL SPLICE 14-16 GA
2 000101000 TERMINAL RING, 5/32, 14-16 GA
2 000501000 TERMINAL RING, 5/16, 14-16 GA
1 800626000 WIRE, 2 CONDUCTOR
1 320363000 PLUG TERMINAL CONNECTOR
26" 800617000 WIRE, 16GA, RED/WHITE
31" 800618000 WIRE, 16GA, WHITE/RED
4 320357000 FEMALE SPADE, NON-INSULATED
07/26/04
JUNCTION BOX ASSEMBLY
HARD WIRED SERIES
16
5
14
10
9
11
9 15
11
9
6
3
9
11 8
2
7
12
13
10
1
FU N C TIO N
B O O M U P
H O IS T U P
R O TA TE C W
E N G IN E FA S T
R O TA TE C C W
H O IS T D N
B O O M D N
R E TR A C T
E XTE N D
N O T U S E D
P O W E R
P R O P +0 TO 5V
G R O U N D
A U XILA R Y
E N G IN E S TA R T
E N G IN E S TO P
P R O P P O W E R
N O T U S E D
N O T U S E D
G R O U N D
G R O U N D
G R O U N D
19 P IN 8 P IN 12 P IN G N D
A 5
B
C
F
G
H
J
D
E
S
T
P
R
K
L
M
N
U
V
3
-
1
4
5
6
1
4
3
2
6
8
7
-
11
-
-
9
-
-
10
2
12
10-10.0.0
G N D
G N D
G N D
W IR E C O LO R
R E D
G R E E N
O R A N G E
R E D /W H ITE
B LA C K
R E D /B LA C K
B LU E
O R A N G E /B LA C K
G R E E N /B LA C K
W H ITE /B LA C K
W H ITE
B LU E /B LA C K
B LA C K /W H ITE
G R E E N /W H ITE
B LU E /W H ITE
B LA C K /R E D
W H ITE /R E D
O R A N G E /R E D
B LU E /R E D
B LA C K /W H ITE
B LA C K /W H ITE
R E D
10
07/26/04
JUNCTION BOX ASSEMBLY
HARD WIRED SERIES
ITEM NO.
QTY.
PART NO.
3
4
1
2
5
1
1
366470000 JUNCTION BOX
366095
DESCRIPTION
RECEPTACLE, 19 PIN
1 366523001 HOUSING, DEUTSCH 8-PIN RECEPTACLE
1 480594001 CABLE, PENDANT, 16/10 SO BLACK
1 366471000 COVER, JUNCTION BOX
10
11
12
13
14
8
9
6
7
15
16
1
1
4
17
366524001 HOUSING, DEUTSCH 12-PIN RECEPTACLE
366097000 CAP W/CHAIN (FOR RECEPTACLE)
366519000 NUT, SELF CLINCHING
019600 WASHER SP LK #6
16 001004000 SCW PN HD #6 X 3/4 LG
13
1
015400 NUT HX #6-32
1 366524002 WEDGE, DEUTSCH RECEPTACLE, 12 PIN
1 366523002 WEDGE, DEUTSCH RECEPTACLE, 8 PIN
18 366376003 CONTACT, DEUTSCH
3 000101000 TERMINAL RING, 5/32, 14-16 GA
366469000 DECAL, JUNCTION BOX WIRING
10-11.0.0
07/26/04
PENDANT ASSEMBLY, 8 FUNCTION
HARD WIRED SERIES
10-11.0.0
6/02/2003
PENDANT ASSEMBLY, 8 FUNCTION
HARD WIRED SERIES
17
18
19
20
21
22
23
24
25
26
10
11
12
7
8
9
13
14
15
16
ITEM QTY PART NO.
DESCRIPTION
1 1 480501 HOUSING, PROP. PENDANT MACHINED
2 1 480518 DECAL/COVER PLATE
5
6
3
4
8
8
1
2
REF
640300
480567
002607
NUT (INCLUDED WITH SWITCH)
BOOT, TOGGLE
CORD GRIP, HUBBELL CONNECTOR
SCREW, HX HD #10-24 NC X 3/4 LG
2
1
1
1
4
1
4
1
8
3
015801
480507
480506
480517
634200
480504
001004
680113
REF
660302
NUT, HEX, LOCKING, #10-24 NC
POTENTIOMETER ASSEMBLY
TRIGGER
SCREW, SOC HD, #10-32 NF X 5/8 LG
SWITCH, TOGGLE DPDT
BACK PLATE, HOUSING
SCREW, PAN HD, #6-32 X 3/4 LG
CABLE ASSEMBLY, BAYONET
WASHER, LOCK (INCLUDED WITH SWITCH)
CONDUCTOR ASSEMBLY
4
4
3
1
1
1
1
2
1
3
480524
480523
005003
636600
622346
622347
622000
750090
480526
750737
CONDUCTOR ASSEMBLY
SPRING, TRIGGER RETURN
SCREW, S.T. PAN HD, #6-32 X 3/8 LG
JUMPER
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY
SWITCH, TOGGLE SPDT
SWITCH, TOGGLE ON/OFF
CONDUCTOR ASSEMBLY
TIE, CABLE
10-12.0.0
6/02/2003
PENDANT CABLE ASSEMBLY
HARD WIRED SERIES
6
7
4
5
ITEM QTY PART NO. DESCRIPTION
1
2
3
1
1
30'
366098
480515
480594
PLUG, CONNECTOR
CLAMP, CABLE
CABLE, CONDUCTOR (19 COND)
2
2
13
6"
000101 TERMINAL RING #6 / 14-16 GA
480510 CONNECTOR, BULLET, FEMALE
002012 TERMINAL RING #6 / 18-22 GA
490243 TUBING, HEAT SHRINK
10-13.0.0
6/02/2003
PROPORTIONAL VALVE CONTROLLER/AMP
HARD WIRED SERIES
REFRENCE AUTO CRANE P/N 366363001
RISING RAMP
FALLING RAMP
DITHER AMPLITUDE DITHER FREQ
OUTPUT: 2000mA MAX
I-MIN SETTING: 0 TO 500mA
I-MAX SETTING: 600 TO 2000mA
CABLE LENGTH: 6 FEET
MINIMUM CURRENT
MAXIMUM CURRENT
Minimum current adjustment:
Current is factory set at 150 mA, no adjustment required at installation. If adjustment is required, set the minimum current before setting the maximum current. Apply minimum input (0 VDC). If the desired minimum current is greater, adjust the trim pot
CW until the desired current is achieved.
Maximum current:
Current is factory set at 1600 mA, no adjustment required at installation. If adjustment is required, apply maximum control (5 VDC). Turn the trim pot CCW to adjust the current setting downwards to the desired minimum.
Ramp and Dither
Ramp and dither is adjusted at the factory and does not require any further adjustment.
10-14.0.0
6/02/2003
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
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