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EFFECTIVE SERIAL NO.
OWNERS MANUAL
5005EH
REVISION 2/2000
PART NO. 999955
SERIAL NO. __________________________
PO BOX 580697, TULSA, OK 74158-0697
4707 N. MINGO ROAD, TULSA, OK 74117-5904
PHONE (918) 836-0463
SALES FAX (918) 438-6688 SERVICE FAX (918) 834-5979 http://www.autocrane.com
Courtesy of Crane.Market
Courtesy of Crane.Market
WARNINGS -
READ THIS PAGE!
WARNING!
Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of a vehicle certify that the vehicle complies with all applicable federal regulations. Any modifications performed on the vehicle prior to the final stage are also considered intermediate stage manufacturing and must be certified as to compliance. The installer of this crane and body is considered one of the manufacturers of the vehicle. As such a manufacturer, the installer is responsible for compliance with all applicable federal and state regulations, and is required to certify that the vehicle is in compliance.
WARNING!
It is the further responsibility of the installer to comply with the OSHA
Truck Crane Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).
WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL
POWER LINES!
Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to
50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.
WARNING! NEVER
.............................
v EXCEED load chart capacities (centerline of rotation to hoist hook).
v un-reel last 5 wraps of cable from drum!
v wrap cable around load!
v attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
v weld, modify, or use unauthorized components on any Auto Crane unit! This will void any warranty or liability. Also failure of the crane may result.
v place a chain link on the tip of the hook and try to lift a load!
v use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature!
v hold on any pendant Select Switch that will cause unsafe operating conditions!
WARNING!
In using a hook with latch, ALWAYS make sure that the hook throat is closed before lifting a load! Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.
WARNING!
Failure to correctly plumb and wire crane can cause inadvertent operation and damage to crane and/or personnel!
WARNING!
Auto Crane Company remote controlled cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel.
WARNING!
ALWAYS
operate the crane in compliance with the load capacity chart.
Do not use the overload shutdown device to determine maximum rated loads, if your crane is equipped with this type of device.
warning 9/98
Courtesy of Crane.Market
5005EH SERIES - OWNER'S MANUAL
TABLE OF CONTENTS
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING PRACTICES & WARNINGS . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION OF UNIT / OUTRIGGERS . . . . . . . . . . . . . . . . . . . . . . . . . .
QUALIFICATIONS FOR OPERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION, TESTING & MAINTENANCE . . . . . . . . . . . . . . . . . . . . .
SAFETY DECAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTRIGGERS (STABILIZER ASSEMBLY) . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION & MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . .
LIFE OF WIRELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL ASSEMBLY (PEDESTAL) . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOIST ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC SAFETY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SOLENOID ASSEMBLY for HOIST ACTUATOR . . . . . . . . . . . . . . . . . .
ROTATION GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COVER INSTALLATION for POWER UNIT . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRAVELING BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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INTRODUCTION
5005EH 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 5005EH series cranes for your protection. The choice of materials and the design of the electrical system minimizes weight and lengthens durability. The hydraulic components meet or exceed a 3.5:1 safety factor . Holding valves prevent the load from dropping if a hose should fail. The reservoir has a 40 m air filter in the filler cap. The pump has a 100 mesh strainer in the suction line.
For your convenience the overall dimensions of the
5005EH series crane are in the General Dimension Section.
Maximum turning radius at both the hoist motor and the rotation motor are also on that drawing.
Remember, the crane adds weight to the vehicle. Adding weight may change the driving and riding characteristics of the vehicle unless the appropriate overload spring(s) are installed on the truck. The payload of the vehicle is reduced by the weight of the crane. The operator should exercise care when loading the vehicle. Distributing the payload on the vehicle evenly will greatly improve the driving and riding characteristics of the vehicle. A minimum G.V.W. of 10,500 lb with two rear jacklegs (or outriggers) is recommended for mounting the 5005EH series cranes.
The 5005EH series cranes are attached directly to your
12 volt truck electrical system. The power cable and retaining clips are included with the crane. A typical power cable mounting and hookup is shown in the installation section. The performance of your new crane depends on the truck electrical system. The use of maintenance free batteries is NOT recommended for use with any Auto Crane product. The recommended alternator and battery that will give the longest life with the most useful duty cycle is a 60 amp alternator with a 120 minute reserve capacity, deep cycle battery. These specifications should be considered minimum.
Auto Crane Company issues a limited warranty certificate with each unit sold.
See last page for warranty policy.
It has always been Auto Crane Company policy to handle all warranty claims we receive as promptly as possible. If a warranty claim involves discrepant material or workmanship,
Auto Crane will take immediate corrective action. It is understandable that Auto Crane Company cannot assume responsibility of liability when it is obvious that our products have been abused, 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)
438-2760 . The information contained in the manual is in effect at the time of this printing. Auto Crane Company reserves the right to update this material without notice or obligation.
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IMPORTANT
OPERATING PRACTICES & WARNINGS
1. Make certain the vehicle meets minimum chassis requirements. (These requirements do not guarantee unit stability)
2. Make certain the crane is installed per factory specifications. Contact your local Distributor or the
Auto Crane factory if any questions arise.
3. Keep the vehicle in as level a position as possible while loading or unloading.
4.
ALWAYS set the vehicle emergency brake before beginning crane operations.
5.
ALWAYS use outriggers from vehicle to the ground during crane operation. Make sure they are firmly positioned on solid footings.
6. All load ratings are based on crane capacity, NOT truck/crane stability.
7. Keep objects and personnel clear of crane path during operation.
8. Keep hoist cable pulled tight at all times.
9.
REMEMBER , in lifting a heavy load, the weight can create enough tipping momentum to overturn the vehicle.
10.
ALWAYS keep load as close to ground as possible.
11. Oil gears as required.
12. Periodic adjustment of hoist worm brake may be required (see automatic safety brake drawing in this manual).
13. Hydraulic hoses need to be inspected frequently for signs of deterioration, and be replaced as required.
14. The hoist hook is an important item that an operator should consider and use properly. It should be checked on a daily basis for distortion or cracks.
15.
ALWAYS store outriggers before road travel.
16.
WARNING! NEVER OPERATE THE CRANE
NEAR ELECTRICAL POWER LINES!
Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to
50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.
17.
WARNING!
NEVER EXCEED load chart capacities (centerline of rotation to hoist hook).
18.
WARNING! NEVER unreel last 5 wraps of cable from drum!
19.
WARNING! NEVER wrap cable around load!
20.
WARNING! NEVER attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
21.
WARNING! NEVER weld, modify, or use unauthorized components on any Auto Crane unit!
This will void any warranty or liability. Also failure of the crane may result.
22.
WARNING! NEVER place a chain link on the tip of the hook and try to lift a load!
23.
WARNING! NEVER use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature!
24.
WARNING!
In using a hook with latch, ALWAYS insure that the hook throat is closed before lifting a load! Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.
25.
WARNING! NEVER hold any pendant Select
Switch on that will cause unsafe operating conditions!
WARNING!
Auto Crane Company remote controlled, stiff boom cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel.
SafeTips 12/99 2-1.0.0
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--- IMPORTANT ---
OPERATION OF UNIT
26. Make sure this manual has been thoroughly read by all crane operating personnel and supervisors.
27. A routine inspection of the crane should be mandatory before each operating day. Any defects should be corrected immediately.
28. At a job site the vehicle should be positioned so that the crane can adequately reach the load within the rated capacity (centerline of rotation to hoist hook).
29. Keep the vehicle as level as possible during operation.
30. For electric cranes, engage emergency brake and leave ignition on with transmission in neutral (or in park for automatic transmissions). Activate any crane power switches. For Auto Crane units requiring battery and hydraulic operation, engage emergency brake, place gear selector in neutral, press clutch, activate PTO, release clutch and after hydraulic fluid is warm, set throttle control to proper engine speed.
31. Always use outriggers from the truck to the ground.
Be sure these are firm and adequately positioned.
When rotating, keep load as low to the ground as possible.
32. Remove pendant control from cab or storage area. On smaller units, plug pendant into receptacle on crane.
On larger units, remove pendant control from guard and unwrap cable from boom. Do not operate crane until cable is unwound completely. On all cranes, detach hook from dead man. Crane is now ready for operation.
33. Always boom up before rotating so the boom will clear the required boom support.
34. When extending the boom, always maintain clearance between the boom crown and the traveling block or hoist hook.
35. Always observe safe and practical operation to avoid possible accidents. Refer to Safety Tips and
Precautions.
36. After completing lifting operations, return the boom to stowed position on the boom support. Avoid unneeded pressure on the boom support.
37. Store pendant control on proper location (in cab or on crane).
38. Return outriggers to stowed position. Make sure they are pinned in place or jacklegs are returned to compartment.
39. Check work area for any tools or equipment not stored.
40. Release throttle control, depress clutch and disengage
PTO. Deactivate any crane power switches.
41. Report any unusual occurrence during crane operation that may indicate required maintenance or repair.
42.
NEVER use two cranes to support a load too large for either crane.
43. Spray all electrical equipment with special corrosion resistant coating. This eliminates rust or corrosion due to melting and freezing action of condensation.
OPERATION OF
OUTRIGGERS
For hydraulic outriggers:
1. Shift crane/outrigger control valve to
"outrigger" position.
2. While operating the outrigger control valves
(located on the outrigger cylinders) simultaneously operate the boom-up control switch. This will allow the hydraulic system to build pressure.
3. After outriggers are positioned, return crane/outrigger selector to "crane" position.
4. Crane is now ready to operate.
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For manual outriggers:
1. Pull lock pins to release jack leg or drop down outrigger and move to outermost lock position.
2. Make sure lock pins are reinstalled properly.
3. Lower outrigger pad to firm ground and adjust foot to take out slack.
4. Crane is now ready to operate.
OPER 2/98
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QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
OPERATORS
2 No one other than the personnel specified above shall enter the operating area of a crane with the exception of persons such as oilers, supervisors, and those specified persons authorized by supervisors whose duties require them to do so and then only in the performance of their duties and with the knowledge of the operator or other persons.
QUALIFICATIONS FOR OPERATORS
7 Operators and operator trainees should have normal depth perception, coordination, and no tendencies to dizziness or similar undesirable characteristics.
1 Crane operation shall be limited to personnel with the following minimum qualifications:
A. designated persons
B. trainees under the direct supervision of a designated person
C. maintenance and test personnel (when it is necessary in the performance of their duties)
D. inspectors (crane).
8 In addition to the above listed requirements, the operator shall:
A. Demonstrate the ability to comprehend and interpret all labels, operator's manuals, safety codes and other information pertinent to correct crane operations.
B. Possess knowledge of emergency procedures and implementation of same.
C. Demonstrate to the employer the ability to operate the specific type of equipment.
D. Be familiar with the applicable safety regulations.
E. Understand responsibility for maintenance requirements of crane.
F. Be thoroughly familiar with the crane and its control functions.
G. Understand the operating procedures as outlined by the manufacturer.
CONDUCT OF OPERATORS
3 Operators shall be required by the employer to pass a practical operating examination. Qualifications shall be limited to the specific type of equipment for which examined.
9 The operator shall not engage in any practice which will divert his attention while actually operating the crane.
4 Operators and operator trainees shall meet the following physical qualifications:
A. Vision of at least 20/30 Snellen in one eye and
20/50 in the other, with or without corrective lenses.
B. Ability to distinguish colors, regardless of position, if colors differentiation is required for operation.
C. Adequate hearing with or without hearing aid for the specific operation.
10 Each operator shall be responsible for those operations under the operator's direct control.
Whenever there is any doubt as to safety, the operator shall consult with the supervisor before handling the loads.
11 The operator should not leave a suspended load unattended unless specific precautions have been instituted and are in place.
5 Evidence of physical defects or emotional instability which render a hazard to operator or others, which in the opinion of the examiner could interfere with the operator's performance may be sufficient cause for disqualification. In such cases, specialized clinical or medical judgment and tests may be required.
12 If there is a warning sign on the switch or engine starting controls, the operator shall not close the switch or start the engine until the warning sign has been removed by the appointed person.
6 Evidence that the operator is subject to seizures or loss of physical control shall be sufficient reason for disqualification. Specialized medical tests may be required to determine these conditions.
13 Before closing the switch or starting the engine, the operator shall see that all controls are in the "OFF" or neutral position and all personnel are in the clear.
14 If power fails during operation, the operator shall:
A. move power controls to the "OFF" or neutral position.
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QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
B. land the suspended load and boom, if practical.
15 The operator shall be familiar with the equipment and its proper care. If adjustments or repairs are necessary, the operator shall report the same promptly to the appointed person, and shall also notify the next operator.
16 All controls shall be tested by the operator at the start of each shift. If any controls do not operate properly, they shall be adjusted or repaired before operations are begun.
17 Stabilizers shall be visible to the operator while extending or setting unless operator is assisted by a signal person.
OPERATING PRACTICES
HANDLING THE LOAD
18 Size of load
A. No crane shall be loaded beyond the rated load except for test purposes.
B. The load to be lifted is to be within the rated load of the crane and its existing configuration.
C. When loads which are not accurately known are to be lifted, the person responsible for the job shall ascertain that the weight of the load does not exceed the crane rated load at the radius at which the load is to be lifted.
19 Attaching the load
A. The load shall be attached to the hook by means of slings or other devices of sufficient capacity.
B. Hoist rope shall not be wrapped around the load.
20 Moving the load
A. The operator shall determine that:
B. The crane is level and, where necessary, the vehicle/carrier is blocked properly.
C. The load is well secured and balanced in the sling or lifting device before it is lifted more than a few inches.
D. Means are provided to hold the vehicle stationary while operating the crane.
E. Before starting to lift, the hook shall brought over the load in such a manner as to minimize swinging.
F. During lifting care shall be taken that:
1.
there is no sudden acceleration or deceleration of the moving load.
2.
load, boom or other parts of the crane do not contact any obstruction.
G. Cranes shall not be used for dragging loads sideways.
H. This standard recognizes that articulating boom cranes are designed and intended for handling materials. They do not meet personnel lift or elevator requirements. Therefore, no lifting, lowering, swinging or traveling shall be done while a person is on the hook or load. Hook attached suspended work platforms (baskets) shall not be used with cranes covered by this standard. Work platforms attached to the boom must be approved by crane manufacturer.
I. The operator should avoid carrying loads over people.
J. When the crane is so equipped, the stabilizers shall be fully extended and set. Blocking under stabilizers shall meet the requirements as follows:
1.
strong enough to prevent crushing.
2.
of such thickness, width and length as to completely support the stabilizer pad.
K. Firm footing under all tires, or individual stabilizer pads should be level. Where such a footing is not otherwise supplied, it should be provided by timbers, cribbing, or other structural members to distribute the load so as to not exceed allowable bearing capacity or the underlying material.
L. In transit, the boom shall be carried in stowed position.
M. When rotating the crane, sudden starts and stops shall be avoided. rotational speed shall be such that the load does not swing out beyond the radius at which it can be controlled.
N. The crane shall not be transported with a load on the hook unless recommended by the manufacturer.
O. No person should be permitted to stand or pass under a suspended load.
21 Stowing procedure. Follow the manufacturer's procedure and sequence when stowing and un-stowing the crane.
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QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
MISCELLANEOUS
OPERATING NEAR ELECTRICAL POWER
LINES
25 In transit with no load and boom lowered the clearance shall be specified in Table 1.
26 A qualified signalperson shall be assigned to observe the clearance and give warning before approaching the above limits.
A. Any overhead wire shall be considered to be an energized line unless and until the person owning such line or the electrical utility authorities verify that it is not an energized line.
B. Exceptions to this procedure, if approved by the administrative or regulatory authority if the alternate procedure provides equivalent protection and set forth in writing.
C. Durable signs shall be installed at the operator's station and on the outside of the crane, warning that electrocution or serious bodily injury may occur unless a minimum clearance of 10 ft. (3.0m) between the crane or the load being handled and energized power lines. Greater clearances are required because of higher voltage as stated above.
These signs shall be revised but not removed when local jurisdiction requires greater clearances.
TABLE 1
22 Cranes shall be operated so that no part of the crane or load enters into the danger zone shown above.
EXCEPTIONS
minimum required clearance normal voltage, kV
(phase to phase) ft (m) when operating near high voltage power lines 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.
over to 50 over 50 to 200 over 200 to 350 over 350 to 500 over 500 to 750 over 750 to 1000
10
15
20
25
35
45
(3.05)
(4.6)
(6.1)
(7.62)
(10.67)
(13.72) while in transit with no load and boom lowered
23 For lines rated 50 kV or below, minimum clearance between the lines and any part of the crane or load
(including handling appendages) shall be 10 ft. (3m).
For higher voltages, see Table 1.
24 Caution shall be excercised when working near overhead lines, because they can move horizontally or vertically due to wind, moving the danger zone to new positions.
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over to 0.75
over 0.75 to 50 over 50 to 345 over 345 to 750 over 750 to 1000
4
6
10
16
20
(1.22)
(1.83)
(3.83)
(4.87)
(6.1)
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INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSPECTION CLASSIFICATION
27 Initial inspection. Prior to initial use, all new, altered, modified or extensively repaired cranes shall be inspected by a designated person to insure compliance with provisions of this standard.
28 Regular inspection. Inspection procedure for cranes in regular service is divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the components of the crane and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as "frequent" and
"periodic" with respective intervals between inspections as defined below.
A. frequent inspection - daily to monthly intervals
B. periodic inspection - one to twelve intervals, or as specifically recommended by the manufacturer
G. electrical apparatus for malfunctioning, signs of excessive deterioration, dirt and moisture accumulation
H. hydraulic system for proper oil level and leaks daily
I. tires for recommended inflation pressure, cuts and loose wheel nuts
J. connecting pins and locking device for wear and damage
PERIODIC INSPECTION
30 Deformed, cracked or corroded members in the crane structure and carrier.
31 Loose bolts, particularly mounting bolts.
32 Cracked or worn sheaves and drums.
33 Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and devices.
FREQUENT INSPECTION
34 Excessive wear on brake and clutch system parts and lining.
29 Inspection shall be performed by designated personnel.
A. control mechanisms for maladjustment interfering with proper operation - daily, when used
B. control mechanisms for excessive wear of components and contamination by lubricants or other foreign matter
C. safety devices for malfunction
D. all hydraulic hoses, particularly those which flex in normal operation of crane functions, should be visually inspected once every working day, when used
E. hooks and latches for deformation, chemical damage, cracks, and wear. Refer to ANSI/ASME
B30.10
F. rope reeving for compliance with crane manufacturer's specifications, if optional winch is used
35 Crane hooks inspected for cracks.
36 Travel steering, braking, and locking devices, for malfunction.
37 Excessively worn or damaged tires.
38 Hydraulic and pneumatic hose, fittings, and tubing inspection.
A. evidence of leakage at the surface of the flexible hose or its junction with metal and coupling
B. blistering, or abnormal deformation to the outer covering of the hydraulic or pneumatic hose
C. leakage at threaded or clamped joints that cannot be eliminated by normal tightening or recommended procedures
D. evidence or excessive abrasion or scrubbing on the outer surface of a hose, rigid tube, or fitting. Means shall be taken to eliminate the interference of
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INSPECTION, TESTING AND MAINTENANCE
GENERAL elements in contact or otherwise protect the components necessary to determine origin of the problem before corrective action can be taken.
39 Hydraulic and pneumatic pumps and motors inspection.
A. loose bolts or fasteners
B. leaks at joints between sections
C. shaft seal leaks
D. unusual noises or vibrations
E. loss of operating speed
F. excessive heating of the fluid
G. loss of pressure
43 Labels are to be in place and legible.
CRANES NOT IN REGULAR USE
44 A crane which has been idle for a period of over one month or more, but not less than six months, shall be given an inspection conforming with the initialregular- frequent inspections.
45 A crane which has been idle for a period of over six months shall be given a complete inspection conforming with the initial-regular-frequent inspection requirements.
40 Hydraulic and pneumatic valves inspection.
A. cracks in valve housing
B. improper return of spool to neutral position
C. leaks at spools or joints
D. sticking spools
E. failure of relief valves to attain or maintain correct pressure setting
F. relief valve pressure shall be checked as specified by the manufacturers
41 Hydraulic and pneumatic cylinders inspection.
A. drifting caused by fluid leaking across piston
B. rod seals leaking
C. leaks at welding joints
D. scored, nicked, or dented cylinder rods
E. damaged case (barrel)
F. loose or deformed rod eyes or connecting joints
42 Hydraulic filters. Evidence of rubber particles on the filter elements may indicate hose, "O" ring, or other rubber component deterioration. Metal chips or pieces on the filter may denote failure in pumps, motors, or cylinders. Further checking will be
INSPECTION RECORDS
46 Dated records for periodic inspection should be made on critical items such as brakes, crane hooks, rope, hydraulic and pneumatic cylinders, and hydraulic and pneumatic relief pressure valves. Records should be kept available to an appointed person.
OPERATIONAL TESTS
47 Prior to initial use, all new, altered, modified, or extensively repaired cranes shall be tested for compliance with the operational requirements of this section, including functions such as the following:
A. load lifting and lowering mechanisms
B. boom lifting and lowering mechanisms
C. boom extension and retraction mechanisms
D. swing mechanisms
E. safety devices
F. operating controls comply with appropriate function labels
Operational crane test results shall be made available to an appointed person.
RATED TEST LOAD
Prior to initial use, altered, modified, or extensively repaired cranes shall be load
4-1.1.0
INSP 9/98
Courtesy of Crane.Market
INSPECTION, TESTING AND MAINTENANCE
GENERAL tested by or under the direction of an appointed person.
A. functional operating mechanism
B. safety devices
C. control systems
48 Test loads shall not exceed 110% of the manufacturer's load ratings.
49 Written reports shall be maintained showing test procedures and confirming the adequacy of repairs.
MAINTENANCE
PREVENTIVE MAINTENANCE
50 Before adjustment and repairs are started on a crane, the following precautions shall be taken as applicable:
A. crane placed where it will cause the least interference with other equipment or operations
B. all controls at the "off" position
C. starting means rendered inoperative
D. boom lowered to the ground if possible or otherwise secured against dropping
E. relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components
55 Repairs or replacements shall be provided as needed for operation.
The following are examples:
A. critical parts of functional operating mechanisms which are cracked, broken, corroded, bent, or excessively worn
B. critical parts of the crane structure which are cracked, bent, broken, or excessively corroded
C. crane hooks showing cracks, damage, or corrosion shall be taken out of service. Repairs by welding are not recommended
56 Instructions shall be provided by the manufacturer for the removal of air from hydraulic circuits.
LUBRICATION
All moving parts of the crane, for which lubrication is specified, should be regularly lubricated per the manufacturer's recommendations and procedures.
51 Warning or "OUT OF ORDER" signs shall be placed on the crane controls.
ROPE INSPECTION
52 After adjustments and repairs have been made, the crane shall not be returned to service until all guards have been reinstalled, trapped air removed from hydraulic system (if required), safety devices reactivated, and maintenance equipment removed.
ADJUSTMENTS AND REPAIRS
53 Any hazardous conditions disclosed by the inspection requirements shall be corrected before operation of crane is resumed, Adjustments and repairs shall be done only by designated personnel.
54 Adjustments shall be maintained to assure correct functioning of components, The following are examples:
57 Frequent Inspection
A. All running ropes in service should be visually inspected once each working day. A visual inspection shall consist of observation of all rope which can be in use during the days operations. These visual observations should be considered with discovering gross damage such as listed below, which may be an immediate hazard.
1. distortion of the rope such as kinking, crushing, un-stranding, birdcaging, main strand displacement, or core protrusion.
Loss of rope diameter in a short length or unevenness of outer strands should be replaced
2. general corrosion
4-1.2.0
INSP 9/98
Courtesy of Crane.Market
INSPECTION, TESTING AND MAINTENANCE
GENERAL
3. broken or cut strands;
4. number, distribution and type of visible broken wires. When such damage is discovered, the rope shall either be removed from service or given as inspection.
B. Care shall be taken when inspecting sections of rapid deterioration such as flange points, crossover points, and repetitive pickup points on drums.
1. sections in contact with saddles, equalizer sheaves, or other sheaves where rope travel is limited
2. sections of the rope at or near terminal ends where corroded or broken wires may protrude
ROPE REPLACEMENT
58 Periodic inspection
A. The inspection frequency shall be determined by a qualified person and shall be based on such factors as:
1. expected rope life as determined by experience on the particular installation or similar installations
2. severity of environment
3. percentage of capacity lifts
4. frequency rates of operation
5. exposure to shock loads
Inspection need not be at equal calendar intervals and should be more frequent as the rope approaches the end of it's service life.
This inspection shall be made at least annually.
B. Periodic inspection shall be performed by a designated person. This inspection shall cover the entire length of the rope. Only the surface wires need be inspected. No attempt should be made to open the rope. Any deterioration results in appreciable loss of original strength, such as described below, shall be noted and determination made as to whether use of the rope would constitute a hazard: points listed above reduction of rope diameter below nominal diameter due to loss of core support, internal or external corrosion, or wear of outside wires; severely corroded, cracked, bent, worn or improperly applied connections;
C. Care shall be taken when inspecting sections subject to rapid deterioration such as the following:
59 No precise rules can be given for determination of the exact time for replacement of rope, since many variable factors are involved.
Continued use in this respect depends upon good judgement by a designated person in evaluating remaining strength in a used rope after allowance for deterioration disclosed by inspection. Continued rope operation depends upon this remaining strength.
60 Conditions such as the following shall be reason for questioning continued use of the rope or increasing the frequency of inspection:
A. in running ropes, six randomly distributed broken wires in one lay or three broken wires in one strand in one lay
B. one outer wire broken at the contact point with the core of the rope structure and protrudes or loops out of the rope structure. Additional inspection of this section is required
C. wear of one third of the original diameter of the outside individual wire
D. kinking, crushing, birdcaging, or any other damage resulting in distortion of the rope structure
E. evidence of any heat damage from any cause
F. reduction from nominal diameter of more than 1/64 in. (0.4mm) for diameters up to and including 5/16 in. (8 mm), 1/32 in. (0.8 mm) for diameter 3/8 in.
(9.5 mm) to and including 1/2 in. (13 mm), 3/64 in.
(1.2 mm) for diameter 9/16 in. (14.5 mm) to and including 3/4 in. (19 mm). 1/16 in. (1.6 mm) for diameter 7/8 in. (22 mm) to and including 11/8 in.
(29 mm), 3/32 in. (2.4 mm) for diameters 11/4 in.
(32 mm) to and including 11/2 in. (38 mm)
4-1.3.0
INSP 9/98
Courtesy of Crane.Market
INSPECTION, TESTING AND MAINTENANCE
GENERAL
G. In standing ropes, more than two broken wires in one lay in sections beyond end connections or more than one broken wire at an end connection.
H. Replacement rope shall have a strength rating at least as great as the original rope furnished or recommended by the crane manufacturer. Any deviation from the original size, grade, or construction shall be specified by a rope manufacturer, or a qualified person.
65 Before cutting a rope, seizing shall be placed on each side of the place where the rope is to be cut to prevent unlaying of the strands. On pre-formed rope, one seizing on each side of the cut is required. On non-preformed ropes of 7/8 in. (22 mm) diameter or smaller, two seizings on each side of the cut are required, and for non-preformed rope 1 in. (25 mm) diameter or larger, three seizings on each side of the cut are required.
61 Rope not in regular use: all rope which has been idle for a period of a month or more due to shutdown or storage of a crane on which it is installed, shall be given and inspection in accordance with above information before it is placed in service. This inspection shall be for all types of deterioration and shall be performed by a qualified person.
66 During installation care should be exercised to avoid dragging of the rope in the dirt or around objects which will scrape, nick crush or induce sharp bends in it.
62 Inspection records
A. frequent inspection- no records required
B. periodic inspections- in order to establish data as a basis for judging the proper time for replacement, a dated report condition at each periodic inspection should be kept on file. This report shall cover points of deterioration listed above.
67 Rope should be maintained in a well-lubricated condition. It is important that lubricant applied as a part of a maintenance program shall be compatible with the original lubricant and to this end the rope manufacturer should be consulted. Lubricant applied shall be the type which does not hinder visual inspection. Those sections of rope which are located over sheaves or otherwise hidden during inspection and maintenance procedures require special attention when lubricating rope. The object of rope lubrication is to reduce internal friction and to prevent corrosion.
ROPE MAINTENANCE
63 Rope should be stored to prevent damage or deterioration.
68 When an operating rope shows greater wear or well defined localized areas than on the remainder of the rope, rope life can be extended in cases where a section at the worn end, and thus shifting the wear to different areas of the rope.
64 Unreeling or uncoiling of rope shall be done as recommended by the rope manufacturer and with care to avoid kinking or inducing twist.
4-1.3.0.
INSP 9/98
Courtesy of Crane.Market
Safety Decal Section
5005EH
PART NO.:
DECAL:
FUNCTION:
USED ON:
040579
OPERATION INSTRUCTIONS
To inform the operator of the proper procedure to follow for safe operation of the crane.
All Cranes
QUANTITY : 1
PLACEMENT : Left side plate (5005EH)
FIG.
SD-1
PART NO.:
DECAL:
040580
OPERATOR TRAINING
FUNCTION: To inform the operator of the need to receive proper training before using the crane.
USED ON:
QUANTITY :
All Cranes
1
PLACEMENT : Left side plate (5005EH)
FIG. SD-2
PART NO.:
DECAL:
FUNCTION:
USED ON:
040632
TAMPERING WITH OVERLOAD DEVICE
To inform the operator that tampering with the overload device may cause a unit failure or possible personnel injury.
5005EH
QUANTITY : 1
PLACEMENT : Right side of lift cylinder
FIG. SD-3
5-1.1.0
Decal 12/99
Courtesy of Crane.Market
Safety Decal Section
5005EH
PART NO.:
DECAL:
040529
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 FIG. SD-4
PART NO.: 040517
DECAL:
FUNCTION:
STAY CLEAR OF BOOM
To inform the operator of the hazard of proximity or contact with the crane boom during operation.
USED ON:
QUANTITY :
All cranes
2
PLACEMENT : Both sides of crown
PART NO.:
DECAL:
FUNCTION:
040518
STAY CLEAR
OF LOAD
To inform the operator of the hazard of proximity or contact with the crane load during operation.
USED ON:
QUANTITY :
All cranes
2
PLACEMENT : Both sides of crown plate
5-1.2.0
FIG. SD-5
FIG. SD-6
Decal 12/99
Courtesy of Crane.Market
Safety Decal Section
5005EH
PART NO.: 040587
DECAL:
FUNCTION:
LOAD SENSOR, DON'T TAMPER
To inform the operator that the load sensor is pre-set and that tampering with the sensor may cause potentially hazardous situation.
USED ON: All cranes equipped with a load sensor.
QUANTITY : 1
PLACEMENT : On the lift cylinder near the load sensor
FIG. SD-7
PART NO.:
DECAL:
FUNCTION:
040519
SCISSORS POINT
To inform the operator of possible danger at scissors point on crane.
USED ON:
QUANTITY :
PLACEMENT :
All cranes
2
Both sides of the lift cylinder
FIG. SD-8
5-1.3.0
Decal 12/99
Courtesy of Crane.Market
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INSTALLATION (CRANE COMPARTMENT)
MODEL 5005EH
7-1.1.0
AW-350-1 12/99
Courtesy of Crane.Market
BOOM SUPPORT
5005EH SERIES
WARNING:
As with all Auto Crane power rotation units, the 5005EH does require a boom support.
Suggested Boom Support:
Auto Crane P/N 726175
7-2.0.0
AW726175 12/99
Courtesy of Crane.Market
LUBRICATION & MAINTENANCE SCHEDULE
5005EH CRANE
SERVICE
PERFORMED
LOAD HOOK
CABLE DRUM
HOIST CABLE
HYD. HOSES
HYD. FLUID
MOUNTING BOLTS
ROTATION RING
GEAR
SHEAVE
BEARINGS
ALL OTHER BOLTS
BOOM PIVOTS
BOOM CYLINDER
DAY WEEKLY 3 MOS 6 MOS YEAR
X
X
X
X
X
X
X
X
X
X
X
NOTES
INSPECT HOOK & LATCH FOR DEFORMA-
TION, CRACKS, & CORROSION
MAKE SURE CABLE IS WOUND EVENLY
ON DRUM
CHECK FOR FLATTENING, KINKS, &
BROKEN STRANDS, SEE MANUAL
VISUAL INSPECTION
CHECK FLUID LEVEL
CHECK-TORQUE TO 440 FT-LBS (DRY) AS
REQUIRED
LUBE WITH MOBILETAC LL, OR LUBRI-
PLATE P/N 15263, OR EQUAL
SEALED BEARING, REPLACE IF ROUGH OR
LOOSE
CHECK-TIGHTEN AS REQUIRED
GREASE WITH MOBILPLEX EP-2 OR
EQUIVALENT @ ZERKS
CHECK AROUND CYLINDER ROD FOR
EXCESS FLUID LEAKAGE
GREASE WITH MOBILPLEX EP-2 OR
EQUIVALENT @ ZERKS
LUBE DETENT SPRING & BALL W/ WD-40
BOOM CYLINDER
PINS
EXTENSION
DETENT PIN
ROTATION
BEARING
ROTATION
BEARING BOLTS
ROTATION GEAR
BOX
ROTATION GEAR
BOX
HOIST GEARBOX
X
X
X
X
X
X
GREASE WITH MOBILPLEX EP-2 OR
EQUIVALENT @ ZERKS
CHECK TORQUE TO 150 FT-LBS (DRY) AS
REQUIRED
CHECK TORQUE TO 85 FT-LBS (DRY) AS
REQUIRED
EP GEAR LUBE SAE 140
HYDRAULIC FLUID
X
X
EP GEAR-EP GEAR LUBE SAE 80-90, SPUR
GEAR SAE 30 OIL
DRAIN, FLUSH, AND REFILL WITH
SUN2105 HYD. OIL, SAE 5W-20
BOOM SLIDE PADS PADS GREASED WHEN REPLACED
8-1.0.0
5005EHmtsc 4/99
Courtesy of Crane.Market
LUBRICATION & MAINTENANCE SCHEDULE
5005EH CRANE
SERVICE
PERFORMED
FOR ADDITIONAL
INFORMATION
SEE:
DAY WEEKLY 3 MOS 6 MOS YEAR
1) OWNER'S MANUAL
2) OSHA SECTION 1910.180
3) ANSI B30.5-1989
NOTES
CAUTION:
Routine maintenance insures trouble-free operation and protects your investment. All warranties are void if maintenance is neglected.
NOTES:
1. Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability.
2. Once a bolt has been torqued to its rated capacity and then removed; the bolt should be replaced with a new one.
3. Auto Crane Company recommends that this crane be serviced per “Crane Inspection Log” P/N 999978.
These logs should be filled in at the intervals noted and kept as a permanent record. Additional copies are available from your local distributor.
8-1.1.0
5005EHmtsc 4/99
Courtesy of Crane.Market
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MAINTENANCE OF BATTERIES
Maintenance of Auto Crane unit batteries differs very little from the generally prescribed maintenance of any lead acid battery. All batteries must be kept properly charged, properly filled with water, and relatively clean .
Keep Properly Filled with Water
The battery should always be properly filled with water.
If the electrolyte level is allowed to fall below the top of the plates, the results become threefold:
Keep Properly Charged 1 The exposed portion of the plate will become sulfated.
Many things affect the proper charge to a battery, such as:
2 The portion of the plate exposed is not usable.
1 Regulator settings
3 That portion of the acid remaining becomes more concentrated and may cause more rapid deterioration of the remaining parts of the battery.
2 Proper tightness of belts on the alternator or generator
Keep A Relatively Clean Battery
3 Good, clean connections of all cables and wires at the following places:
A. Battery
B. Regulator
C. Starting motor
D. Alternator or generator
E. Ground connections (most important)
It is of extreme importance to keep the battery as fully charged as possible without overcharging, especially when vehicles are left outside for extended periods in extremely cold climates. A battery can freeze.
Freezing points for various specific gravities of acid are as follows:
The battery should be kept clean. Batteries filled with acid and which are not in use self-discharge to a limited degree because of the nature of the materials within the battery. If dirt is allowed to collect on the top of the battery (and this dirt absorbs moisture) and electrical path can be set up between the various terminals of the battery and the ground. Once such a path has been established, the self-discharge of the battery is accelerated. This also accelerates corrosion of the battery cables at the terminals.
Periodic Maintenance is Needed
Specific Gravity Freezing Temp.
(Corrected to 80ºF) Degrees F.
A definite program of periodic maintenance of all batteries should be conducted on a regular basis.
Periodic maintenance includes:
1.280 -90ºF
1.250 -62ºF
1.200 -16ºF
1.150 5ºF
1.100 19ºF
1
2
Checking belts for tightness on the charging equipment
Checking battery electrolyte levels
3 Checking cables for good connections
As shown, a half-charged battery (about 1.200 specific gravity) cannot stand for any length of time at 20ºF or it will freeze.
The main reason for keeping the battery as fully charged as possible without over-charging is to ensure that power is available even though the vehicle has been standing for some time.
4 Cleaning where corrosion is apparent
When corrosion is cleaned off, the cable terminals and battery terminals should be coated with a light coating of petroleum jelly before they are replaced. When terminals are cleaned, the top of the battery should be cleaned with a mild solution of soda water.
8-4.0.0.
MAINTBAT 9/98
Courtesy of Crane.Market
MAINTENANCE OF BATTERIES
Low Maintenance Batteries
(Maintenance Free) should be attempted for an extended time. This usually will recover a badly sulfated battery.
Low maintenance batteries should not be used on
Auto Cranes or trucks equipped with Auto Cranes.
The batteries are not designed for "deep" discharge.
Replacing a Battery
If it is necessary to replace a battery, and a dry charge battery is used, the following procedure applies:
Testing Your Battery
1 Fill the battery with electrolyte of the proper specific gravity.
If the condition of the battery is in question, it should be removed from the vehicle, taken to the shop, and allowed to reach room temperature. It should then be recharged until specific gravity readings taken at one-half hour intervals. If the specific gravity readings are fairly uniform, the battery should be checked with a high rate tester. Use the tester in accordance with the manufacturer's instructions. The high rate tester is the best method to test a questionable battery.
2 Place the battery on charge according to the manufacturer's instructions.
It is essential that the second step above be followed to ensure that the battery going on the vehicle is fully charged.
If, after charging, it is noted that the specific gravity reading of one cell is 30 points less than any of the other cells, it may be assumed that the cell is bad and that the battery should be replaced. If all cells are uniform but not up to full charge, a low rate of charge
It is also very important that the battery hold-downs be checked periodically to ensure that the batteries are properly positioned to avoid vibration problems, breakage of cables or terminals. Care must be taken to avoid cracking or breaking containers or covers by tightening hold-down fixtures excessively. They also must not be so loose that breakage results from a hold-down that is too loose.
8-4.1.0
MAINTBAT 9/98
Courtesy of Crane.Market
LIFE OF WIRE LINE
So many variable factors can cause the deterioration of wire line cable that it is not possible to determine a definite life expectancy. Some of these factors are:
• Load being handled.
• Corrosive conditions.
• Maintenance of the unit:
Keep the sheaves turning freely.
Maintain tension on cable to insure proper spooling.
Avoid kinks in cable.
Avoid abrasive action and contact with sharp corner.
• Frequency of use.
Auto Crane units, up to 2,400 pound ratings use 3/16 inch diameter galvanized pre-formed 7 x 19 aircraft cable. This cable has a working strength, when new, of 4,200 pounds.
It is recommended when 1,200 pound loads are exceeded to use a two part line with a traveling block. This will ensure a 3.5 to 1 safety factor when the cable is new.
Keeping the above factor of safety in mind and knowing the kind of loads that will be handled, the user can determine by inspection of the cable as to when it should be replaced.
Items to look for while inspecting the cables are:
• Broken strands.
• Kinks and flattened sections.
• Corrosion and abrasion.
WIRE LINE LUBRICATION
Lubrication of the wire line serves two important purposes:
• Prevent corrosion.
• Reduce wear due to flexing and abrasion caused by contact with the sheaves, rollers, and cable on the drum.
Preparation
Remove rust and foreign matter with a wire brush and wipe clean. Be sure cable is dry.
Application
Method 1: Dip a brush into a light weight motor oil and apply. In some cases, dip a rag or a piece of sheepskin into the lubricant and swab the lubricant on to the rope.
Method 2: Apply a heavier lubricant such as a grease gun lubricant with hands while wearing leather gloves. (Leather gloves give greater protection and less penetration of the grease than canvas gloves.)
9-1.0.0
WIRE 1/2000
Courtesy of Crane.Market
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BOOM ASSEMBLY (10-16)
P/N 360860 - MODEL 5005H/EH
10-3.0.0
aw360860 4/99
Courtesy of Crane.Market
ITEM
12
13
14
15
16
8
9
6
7
10
11
1
2
3
4
5
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
QTY
4
2
1
1
2
1
1
1
1
1
2
1
1
1
1
1
2
2
2
4
2
6
2
2
2
1
2
1
1
1
5
1
BOOM ASSEMBLY (10-16)
P/N 360860 - MODEL 5005H/EH
P/N
360861
360862
360152
360545
360167
480032
480033
360121
360621
360625
360120
360122
240236
360814
360124
360038
366158
020200
016300
011511
017700
005406
005901
021100
360849
015900
360069
360070
360075
360091
360092
360153
DESCRIPTION
LOWER BOOM
UPPER BOOM
BOOM EXTENSION CYLINDER
INNER BOOM RETAINER
LOWER SLIDE PAD RETAINER
BOOM PAD
LARGE SHIM .032 THICK
UPPER BOOM EXTENSION CYLINDER PIN
BOOM/CYLINDER PIN
LOWER BOOM PIVOT PIN
LOWER BOOM EXTENSION CYLINDER PIN
RETAINING RING
SHEAVE ASSEMBLY
CROWN PIN
HITCH PIN
ANGLE INDICATOR
CAPSCREW 3/8-16NC x 3/4
SPLIT LOCK WASHER 1/4
HEX LOCK NUT 1/4-20NC
CAPSCREW 1/2-20NF x 2 1/4
HEX LOCK NUT 1/2-20NC
CAPSCREW 1/4-28NF x 1/2
CAPSCREW 1/4-20NC x 1/2
SPLIT LOCK WASHER 3/8
PLASTIC SPACER
HEX NUT 1/4-20NC
EXTENSION CYLINDER TUBE ASSEMBLY
EXTENSION CYLINDER TUBE ASSEMBLY
EXTENSION CYLINDER HOSE ASSEMBLY
U-BOLT
CLAMP
COUNTERBALANCE VALVE
10-3.1.0
aw360860 4/99
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
OVERLOAD SYSTEM / ANTI-2-BLOCK
TROUBLE SHOOTING GUIDE
IF THE THREE FUNCTIONS, BOOM DOWN, HOIST UP AND
EXTEND OUT, QUIT WORKING,
the problem probably lies in either the Overload
System or the Anti-2-block system or both. If these three functions are NOT WORKING and most other functions are, an investigation should be made as follows: (reference: Figure 1)
1 ANTI-2-BLOCK
A. Unplug the anti-2-block system from the overload system and connect A and B to bypass the anti-2-block system.
1.
If the three functions work, check continuity
2.
of anti-2-block system using continuity tester at disconnected.
Weather pack connectors, and investigate switch at end of boom, cable and cable reel.
If the three functions do not work, continue on with section #2.
functions which could cause additional overload. In addition to this, when there is also a signal from the boom down solenoid to
RELAY B at the same time, RELAY B latches RELAY A so that even if the overload signal from the pressure switch to
RELAY A is removed, RELAY A will continue to be on and interrupt the ground circuit until the signal from the boom down solenoid and pressure switch are removed.
2.
The purpose of RELAY A is to interrupt the ground circuit and stop hoist up, boom down, and extend out functions from operating. The purpose of RELAY B is to stop boom bounce caused by the overload system cycling on and off.
2 LOAD SENSOR (Pressure Switch)
A. With crane unloaded, unplug weather pack connector on load sensor wire.
1.
If the three functions work, recheck the
2.
Pressure Switch by taking a ohm reading on the two wires coming from the Switch. The switch has normally open contacts, so the reading should be the maximum. If less than maximum ohm reading is indicated
(usually a dead short), replace the Switch.
If the three functions do not work, continue with section #3.
3 RELAY BOX
A. Inside this box are two 320355 relays. Since these are inexpensive relays, the easiest way to trouble shoot this device is to replace both relays.
1.
The two relays are identical but serve different functions. RELAY A is the one with the most wires going to its connector.
RELAY A breaks the circuit between the ground side of the solenoid valves on boom down, extend out, and hoist up functions.
This happens whenever the overload switch on the lift cylinder senses more than normal pressure indicating an overload condition.
When overload happens then 12 volts is passed through the overload switch to pull in
RELAY A which then interrupts the ground circuit of the valves controlling those
4 OPERATIONAL TEST AND TROUBLE
SHOOTING OF RELAY BOX
A. After the anti-2-block test and the load sensor tests have been perform and the overload system still does not operate, check the relay box.
1.
Disconnect the weatherpak connector in the load sensor pressure switch wires going from the pressure switch to the relay box.
Disconnect the weatherpak connector between the cord reel and the relay box.
2.
Check for 12 volts at pin B of load sensor connector on relay box side of harness.
Short from pin A to pin B of weatherpak.
When pins A & B are shorted there should
NOT be continuity from the cord reel weatherpak on the relay box side of the connection to ground. When A & B are not shorted there should be continuity to ground. Replace relay A if these conditions are not met.
3.
If the boom tends to bounce when booming down due to intermittent cycling of the overload system, then RELAY B should be replaced after verifying that the sense wire from the relay box to the boom down solenoid valve control terminal is connected.
10-4.2.0
OVLD 1/99
Courtesy of Crane.Market
OVERLOAD SYSTEM / ANTI-2-BLOCK
TROUBLE SHOOTING GUIDE
10-4.3.0
OVLD 1/99
Courtesy of Crane.Market
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AUTOMATIC SAFETY BRAKE ASSEMBLY
(OIL COOLED) HOIST
ITEM
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
QTY
1
1
2
6
1
1
4
2
1
1
1
1
1
1
1
1
P/N
360367
360331
360450
360336
360339
360342
360345
360453
360368
360456
360371
360353
360465
360455
360359
360364
DESCRIPTION
FLAT SPRING
CAM PLATE
HOUSING COVER
BRAKE HOUSING
BRAKE HUB
RETAINER PLATE
BRAKE BALL
CAPSCREW 1/4 NC x 1
COIL SPRING
CAPSCREW 3/8 NC x 1 1/2
THREAD SEAL
JAM NUT 3/8 NC
THREAD SEAL
WASHER FLAT 1/4 ALUM
GASKET
THRUST PLATE
10-6.0.0
AW368 1/99
Courtesy of Crane.Market
AUTOMATIC SAFETY BRAKE ASSEMBLY
(OIL COOLED) HOIST
ASSEMBLY INSTRUCTIONS:
1.
Winch has right hand worm and gear. Cable spools over drum. Use number one slots for brake balls(7) in cam plate(2).
2.
Install brake hub(5) through brake housing(4) on winch worm with key.
3.
Assemble balls(7) in cam plate(2) using hard grease to hold balls in place.
4.
Place cam plate(2) on brake hub(5), matching its holes with the balls.
5.
Install thrust plate(16).
6.
Thread capscrew(10) with jam nut (12) and thread seal (11) through housing cover(3).
7.
Place gasket(15) on housing cover(3).
8.
Install coil spring(9) on capscrew(10).
9.
Install flat spring(1) on capscrew(10).
10.
Secure retainer plate(6) and flat spring(1) to housing cover(3) using capscrews(8) and washers(14).
11.
Using capscrews(8) and thead seals(13) attach housing cover(3) to brake housing(4).
12.
Test brake by shifting winch to UP then DOWN to see if brake is working in proper rotation. If not, remove housing cover(3) and locate brake balls(7) in opposite set of slots of cam plate(2).
13.
Adjust to suit by tightening or loosening capscrew(10) on outside of housing cover(3). When proper adjustment is obtained, secure capscrew(10) with jam nut(12).
10-6.1.0
AW368 1/99
Courtesy of Crane.Market
SOLENOID ASSEMBLY
P/N 360467 - MODEL 5005EH
ITEM
3
4
5
1
2
6
7
8
9
10
11
QTY
2
2
2
3
1
1
2
2
4
2
2
P/N
360470
360471
360472
360473
200182
360474
360475
360476
360477
360478
360479
DESCRIPTION
BLACK WIRE ASSEMBLY #6 GA x 11 1/2
RED WIRE ASSEMBLY #16 GA x 1 1/2
COPPER STRAP
COPPER STRAP
12V SOLENOID
SOLENOID MOUNTING BRACKET
RD HD SCREW #10 NC x 1/2
NUT #10 NC
FLAT WASHER #10
TERMINAL TAB
SOLENOID TERMINAL COVER
10-7.0.0
AW360467 9/98
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
HYDRAULICS
Counterbalance Valve Adjustment
{ With PTO disengaged and boom properly supported, remove O-ring plug
(item 17) shown on AW-573 marked
"X" port (see CB valve diagram).
Install a pressure gauge (0-2500 PSI) into the port.
{ Engage PTO and insure pump flow is 10
GPM and main relief is set to 2500 PSI.
With no load on boom, boom up to an angle of 70 degrees. Boom down and note pressure. If pressure reading is not approximately 1050 PSI, the counterbalance valve requires adjustment.
v To increase the CB valve setting, loosen nut and turn Allen head screw counter clockwise. (Reference item 16, located on the side of the
CB valve block towards the right side of the boom.) v To reduce the CB valve setting, loosen nut and turn Allen head screw clockwise.
5005EH
{ Tighten nut on adjustment screw and repeat procedure if needed to obtain the proper pressure setting.
{ Disengage PTO, remove the pressure gauge and install -6 plug. Crane is now ready for operation.
Notice:
{ In an EMERGENCY situation when it becomes necessary to lower the boom without flow present, the CB valve adjustment can be turned in until the boom begins to descend. Make sure the boom will lower onto a proper support.
Loosen the lock nut and carefully turn adjustment screw clockwise! Count the number of turns. Turn slowly until the boom just begins to lower, and remove hand/arm/fingers from cranes while boom is lowering.
{ Turning adjustment screw too far will cause valve to come apart on the inside.
This condition is not repairable
{ After boom is lowered, turn adjustment screw counter clockwise the approximate number of turns made during lowering procedure. After the problem is corrected, readjust the counterbalance valve using the procedure in this manual.
WARNING:
DO NOT TRY TO ADJUST VALVES
WHILE BOOM IS MOVING.
Failure to heed warning may result in personal injury!
11-1.0.0
HYD 12/99
Courtesy of Crane.Market
HYDRAULIC ASSEMBLY (10-16-20)
P/N 360803 - MODEL 5005EH
11-2.0.0
aw360803 4/99
Courtesy of Crane.Market
HYDRAULIC ASSEMBLY (10-16-20)
P/N 360803 - MODEL 5005EH
ITEM
12
13
14
15
16
8
9
6
7
10
11
1
2
3
4
5
23
24
25
26
27
17
18
19
20
21
22
28
29
30
31
32
33
34
35
QTY
4
1
2
1
1
4
1
6
2
4
4
1
3
1
1
4
2
2
2
2
4
1
1
3
3
1
7
1
1
2
2
1
1
1
2
P/N
202710
REF
320393
320392
002614
007811
020600
016500
360544
002608
320489
480208
812203-013
360573
320543
330412
200892
480194
241168
480212
200876
330647
005810
020200
202759
330272
202756
202755
330072
320336-002
241175
REF
241170
480188
812203-014
DESCRIPTION
MANIFOLD
DIRECTIONAL VALVE ASSEMBLY (300204)
BOTTOM MANIFOLD BRACKET
TOP MANIFOLD BRACKET
CAPSCREW 5/16-NC x 5/8
CAPSCREW 5/16-NC x 1
SPLIT LOCK WASHER 5/16
HEX HEAD NUT 5/16-NC
VALVE COVER
CAPSCREW 1/4-NC x 3/4
TUBE ASSEMBLY
HOSE ASSEMBLY
HOSE ASSEMBLY
HOSE ASSEMBLY
LOAD SENSOR
COUNTERBALANCE VALVE
90º ELBOW -6 NPT/-6 JIC
90º ELBOW -6 JIC SWIVEL/-6 JIC
TEE -6 ORB/-6 JIC RUN
TUBE ASSEMBLY
ADAPTER -6 ORB/-6 JIC
45º ELBOW -6 JIC SWIVEL
CAPSCREW 1/4-NC x 1 3/4
SPLIT LOCK WASHER 1/4
90º ELBOW -8 NPT/-6 JIC
90º ELBOW -8 ORB/-6 JIC
ADAPTER -8 ORB/-6 JIC
ADAPTER -10 ORB/-6 JIC
HEX HEAD PLUG -10 ORB
RETURN PORT PLUG
90º ELBOW -6 ORB/-6 JIC
POWER UNIT (360798)
UNION -6 JIC
COUNTERBALANCE VALVE CARTRIDGE
HOSE ASSEMBLY
11-2.1.0
aw360803 4/99
Courtesy of Crane.Market
ITEM
36
37
38
39
40
QTY
1
-
1
1
1
HYDRAULIC ASSEMBLY (10-16-20)
P/N 360803 - MODEL 5005EH
P/N
330645
-
REF
REF
REF
DESCRIPTION
90º EXTRA LONG ELBOW -6 ORB/-6 JIC
-
PLUG -6 O-RING
BOOM UP CYLINDER (360805)
EXTENSION CYLINDER (366162)
11-2.2.0
aw360803 4/99
Courtesy of Crane.Market
HYDRAULIC ASSEMBLY (10-16)
P/N 360866 - MODEL 5005EH
11-3.0.0
aw360866 4/99
Courtesy of Crane.Market
HYDRAULIC ASSEMBLY (10-16)
P/N 360866 - MODEL 5005EH
ITEM
12
13
14
15
16
8
9
6
7
10
11
1
2
3
4
5
23
24
25
26
27
17
18
19
20
21
22
28
29
30
31
32
33
34
35
QTY
4
1
2
1
1
4
1
6
2
4
4
1
3
1
1
4
2
2
2
2
4
1
1
2
5
1
6
1
1
2
2
1
1
1
2
P/N
202710
REF
320393
320392
002614
007811
020600
016500
360544
002608
320489
480208
812203-013
360573
320543
360069
360070
480194
360091
360092
200876
360042
015900
020200
202759
330272
202756
202755
330072
320336-002
241175
REF
241170
480188
812203-014
DESCRIPTION
MANIFOLD
DIRECTIONAL VALVE ASSEMBLY (300204)
BOTTOM MANIFOLD BRACKET
TOP MANIFOLD BRACKET
CAPSCREW 5/16-NC x 5/8
CAPSCREW 5/16-NC x 1
SPLIT LOCK WASHER 5/16
HEX HEAD NUT 5/16-NC
VALVE COVER
CAPSCREW 1/4-NC x 3/4
TUBE ASSEMBLY
HOSE ASSEMBLY
HOSE ASSEMBLY
HOSE ASSEMBLY
LOAD SENSOR
TUBE ASSEMBLY
TUBE ASSEMBLY
90º ELBOW -6 JIC SWIVEL/-6 JIC
U-BOLT
CLAMP
ADAPTER -6 ORB/-6 JIC
ADAPTER -6 NPT/-6 JIC
HEX HEAD NUT 1/4-NC
SPLIT LOCK WASHER 1/4
90º ELBOW -8 NPT/-6 JIC
90º ELBOW -8 ORB/-6 JIC
ADAPTER -8 ORB/-6 JIC
ADAPTER -10 ORB/-6 JIC
HEX HEAD PLUG -10 ORB
RETURN PORT PLUG
90º ELBOW -6 ORB/-6 JIC
POWER UNIT (360798)
UNION -6 JIC
COUNTERBALANCE VALVE CARTRIDGE
HOSE ASSEMBLY
11-3.1.0
aw360866 4/99
Courtesy of Crane.Market
ITEM
39
40
41
42
36
37
38
QTY
1
1
1
2
1
1
1
HYDRAULIC ASSEMBLY (10-16)
P/N 360866 - MODEL 5005EH
P/N
330645
360153
200892
REF
REF
REF
330647
DESCRIPTION
90º EXTRA LONG ELBOW -6 ORB/-6 JIC
COUNTERBALANCE VALVE
90º ELBOW -6 NPT/-6 JIC
BOOM UP CYLINDER (360805)
EXTENSION CYLINDER (360152)
PLUG -6 O-RING
45º ELBOW -6 JIC SWIVEL
11-3.2.0
aw360866 4/99
Courtesy of Crane.Market
HYDRAULIC PUMP & RESERVOIR
P/N 360798
ITEM
3
4
5
6
1
2
7
8
9
QTY
1
1
1
1
1
1
1
1
1
P/N
360808-003
320336-002
360808-001
320336-003
360808-002
360799
320335-008
200545
330630
DESCRIPTION
ADAPTER KIT
RETURN PORT PLUG KIT
PUMP KIT
RELIEF VALVE KIT
MOTOR
RESERVOIR KIT
ELBOW FITTING
BREATHER CAP
SOLENOID
11-4.0.0
AW360798 4/99
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
ELECTRICAL SCHEMATIC
12-1.1.1
366801-1 2/2000
Courtesy of Crane.Market
ELECTRICAL SCHEMATIC
ITEM
53
54
55
56
57
58
50
51
52
59
60
61
62
63
64
QTY
1
3
1
1
1
2
1
3
1
1
1
1
3
6 FT
1
P/N
REFERENCE
300204
320543
366999
360872
360844-001
360011
360846
642908
360857
360843
750736
360844-002
DESCRIPTION
VOLTAGE SWITCHING UNIT (360802-001)
DIRECTIONAL CONTROL VALVE
LOAD SENSOR ASSEMBLY
RELAY BOX ASSEMBLY
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY (WITH FEMALE TWECO)
CONDUCTOR ASSEMBLY (SUPPLIED WITH HOIST)
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY (SUPPLIED WITH POWER
UNIT)
CONDUCTOR ASSEMBLY
CONDUCTOR CORD
POWER CABLE PLUG ASSEMBLY
CONDUCTOR ASSEMBLY
CONVOLUTED LOOM
CONDUCTOR ASSEMBLY (WITH MALE TWECO)
366801-1 2/2000
Courtesy of Crane.Market
PENDANT
P/N 680050
12-3.0.0
680050 4/99
Courtesy of Crane.Market
PENDANT
P/N 680050
QTY
1
1
1
2
6
6
1
4
2
4
1
1
2
1
2
1
2
1
6
3
4
4
ITEM
1
2
5
6
3
4
7
8
9
10
16
17
18
19
20
21
22
11
12
13
14
15
P/N
-
-
-
-
480567
-
-
-
-
-
680041
-
660302
636600
622346
622347
-
-
480526
750737
-
-
DESCRIPTION
PENDANT HOUSING
DECAL/COVER PLATE
NUT
TOGGLE BOOT
HUBBELL CONNECTOR CORD GRIP
CAPSCREW #10-24 NC x 3/4
HEX LOCK NUT #10-24 NC
TOGGLE DPDT SWITCH
HOUSING BACK PLATE
SELF THREADING ROUND HEAD SCREW #6 x 3/4
BAYONET CABLE ASSEMBLY
LOCK WASHER
CONDUCTOR ASSEMBLY
JUMPER
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY
TOGGLE SPDT SWITCH
TOGGLE ON/OFF SWITCH
CONDUCTOR ASSEMBLY
CABLE TIE
TRIGGER OPENING COVER
PLASTIC 1/2” PLUG (see note 4)
NOTES:
1.Tie-off the following unused conductors with Item #20 inside of pendnat.
Blue w/ Red T Orange w/ Red T Black w/ White T
2. Before installing Item #21 (Cover), add RTV Sealant between cover & Pendant Housing.
3. Securely wrap unused power connector terminals (Ref. Item #19) with electrical tape; terminals must be unwrapped when adding switches for options.
4. Item #22 (Plastic Plugs) are to be installed in any unused holes in Cover Plate Item #2.
5. Items 3, 4, 8, & 12 may be purchased as a REPLACEMENT DPDT SWITCH KIT using P/N
380005 .
6. Items 3, 4, 12, & 18 may be purchased as a REPLACEMENT ON/OFF SWITCH KIT using P/N
380001 .
7. Items 1, 2, 6, 7, 9, 10, 21, & 22 may be purchased as a REPLACEMENT HOUSING KIT using
P/N 380002 .
8. Items 3, 4, 12, & 17 may be purchased as a REPLACEMENT SPDT KIT using P/N 380004 .
12-3.1.0
680050 4/99
Courtesy of Crane.Market
PENDANT
P/N 680008
12-4.0.0
aw680008 12/99
Courtesy of Crane.Market
ITEM
1
2
5
6
3
4
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
QTY
1
1
1
2
6
8
1
4
2
4
1
6
3
4
4
3
1
2
1
2
1
P/N
-
-
-
-
480567
-
-
-
-
-
680041
-
660302
636600
622346
622347
-
-
480526
750737
-
PENDANT
P/N 680008
DESCRIPTION
PENDANT HOUSING
DECAL/COVER PLATE
NUT
TOGGLE BOOT
HUBBELL CONNECTOR CORD GRIP
CAPSCREW #10-24 NC x 3/4
HEX LOCK NUT #10-24 NC
TOGGLE DPDT SWITCH
HOUSING BACK PLATE
SELF THREADING ROUND HEAD SCREW #6 x 3/4
BAYONET CABLE ASSEMBLY
LOCK WASHER
CONDUCTOR ASSEMBLY
JUMPER
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY
TOGGLE SPDT SWITCH
TOGGLE ON/OFF SWITCH
CONDUCTOR ASSEMBLY
CABLE TIE
TRIGGER OPENING COVER
NOTES:
1.Tie-off the following unused conductors with Item #20 inside of pendant.
Blue w/ Red T Orange w/ Red T Black w/ White T
2. Before installing Item #21 (Cover), add RTV Sealant between cover & Pendant Housing.
3. Securely wrap unused power connector terminals (Ref. Item #19) with electrical tape; terminals must be unwrapped when adding switches for options.
4. Items 3, 4, 8, & 12 may be purchased as a REPLACEMENT DPDT SWITCH KIT using P/N
380005 .
5. Items 3, 4, 12, & 18 may be purchased as a REPLACEMENT ON/OFF SWITCH KIT using P/N
380001 .
6. Items 1, 2, 6, 7, 9, 10, & 21 may be purchased as a REPLACEMENT HOUSING KIT using
P/N 380002.
7. Items 3, 4, 12, & 17 may be purchased as a REPLACEMENT SPDT KIT using P/N 380004 .
12-4.1.0
aw680008 12/99
Courtesy of Crane.Market
PENDANT
P/N 680009
12-5.0.0
aw680009 12/99
Courtesy of Crane.Market
PENDANT
P/N 680009
QTY
1
1
1
2
6
6
1
4
2
4
1
1
2
1
2
1
3
1
6
3
4
4
ITEM
1
2
5
6
3
4
7
8
9
10
16
17
18
19
20
21
22
11
12
13
14
15
P/N
-
-
-
-
480567
-
-
-
-
-
680041
-
660302
636600
622346
622347
-
-
480526
750737
-
-
DESCRIPTION
PENDANT HOUSING
DECAL/COVER PLATE
NUT
TOGGLE BOOT
HUBBELL CONNECTOR CORD GRIP
CAPSCREW #10-24 NC x 3/4
HEX LOCK NUT #10-24 NC
TOGGLE DPDT SWITCH
HOUSING BACK PLATE
SELF THREADING ROUND HEAD SCREW #6 x 3/4
BAYONET CABLE ASSEMBLY
LOCK WASHER
CONDUCTOR ASSEMBLY
JUMPER
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY
TOGGLE SPDT SWITCH
TOGGLE ON/OFF SWITCH
CONDUCTOR ASSEMBLY
CABLE TIE
TRIGGER OPENING COVER
PLASTIC 1/2” PLUG (see note 4)
NOTES:
1.Tie-off the following unused conductors with Item #20 inside of pendant.
Blue with Red T Orange with Red T Black with White T
2. Before installing Item #21 (Cover), add RTV Sealant between cover & Pendant Housing.
3. Securely wrap unused power connector terminals (Ref. Item #19) with electrical tape; terminals must be unwrapped when adding switches for options.
4. Item #22 (Plastic Plugs) are to be installed in any unused holes in Cover Plate Item #2.
5. Items 3, 4, 8, & 12 may be purchased as a REPLACEMENT DPDT SWITCH KIT using P/N
380005 .
6. Items 3, 4, 12, & 18 may be purchased as a REPLACEMENT ON/OFF SWITCH KIT using P/N
380001 .
7. Items 1, 2, 6, 7, 9, 10, 21, & 22 may be purchased as a REPLACEMENT HOUSING KIT using
P/N 380002 .
8. Items 3, 4, 12,& 17 may be purchased as a REPLACEMENT SPDT KIT using P/N 380004 .
12-5.1.0
aw680009 12/99
Courtesy of Crane.Market
PENDANT
P/N 680010
12-6.0.0
aw680010 4/99
Courtesy of Crane.Market
PENDANT
P/N 680010
QTY
1
1
1
2
6
6
1
4
2
4
1
1
2
-
2
1
3
1
6
3
4
4
ITEM
1
2
5
6
3
4
7
8
9
10
16
17
18
19
20
21
22
11
12
13
14
15
P/N
-
-
-
-
480567
-
-
-
-
-
680041
-
660302
636600
622346
622347
-
-
480526
750737
-
-
DESCRIPTION
PENDANT HOUSING
DECAL/COVER PLATE
NUT
TOGGLE BOOT
HUBBELL CONNECTOR CORD GRIP
CAPSCREW #10-24 NC x 3/4
HEX LOCK NUT #10-24 NC
TOGGLE SWITCH DPDT
HOUSING BACK PLATE
SELF THREADING ROUND HEAD SCREW #6 x 3/4
BAYONET CABLE ASSEMBLY
LOCK WASHER
CONDUCTOR ASSEMBLY
JUMPER
CONDUCTOR ASSEMBLY
-
CONDUCTOR ASSEMBLY
TOGGLE ON/OFF SWITCH
CONDUCTOR ASSEMBLY
CABLE TIE
TRIGGER OPENING COVER
PLASTIC 1/2” PLUG (see note 4)
NOTES:
1. Before installing Item 21 (Cover), add RTV Sealant between cover & Pendant Housing.
2. Securely wrap unused power connector terminals (Ref. Item #19) with electrical tape; terminals must
be unwrapped when adding switches for options.
3. Item #22 (Plastic Plugs) are to be installed in any unused holes in Cover Plate Item #2.
4. Items 3, 4, 8, & 12 may be purchased as a REPLACEMENT DPDT SWITCH KIT using P/N380005 .
5. Items 3, 4, 12, & 18 may be purchased as a REPLACEMENT ON/OFF SWITCH KIT using P/N380001 .
6. Items 1, 2, 6, 7, 9, 10, 21, & 22 may be purchased as a REPLACEMENT HOUSING KIT using P/N
380002 .
12-6.1.0
aw680010 4/99
Courtesy of Crane.Market
PENDANT
P/N 680021
12-7.0.0
aw680021 12/99
Courtesy of Crane.Market
PENDANT
P/N 680021
QTY
1
1
1
2
6
6
1
4
2
4
1
1
2
-
2
1
3
1
6
3
4
4
ITEM
1
2
5
6
3
4
7
8
9
10
16
17
18
19
20
21
22
11
12
13
14
15
P/N
-
-
-
-
480567
-
-
-
-
-
680041
-
660302
636600
622346
622347
-
-
480526
750737
-
-
DESCRIPTION
PENDANT HOUSING
DECAL/COVER PLATE
NUT
TOGGLE BOOT
HUBBELL CONNECTOR CORD GRIP
CAPSCREW #10-24 NC x 3/4
HEX LOCK NUT #10-24 NC
TOGGLE SWITCH DPDT
HOUSING BACK PLATE
SELF THREADING ROUND HEAD SCREW #6 x 3/4
BAYONET CABLE ASSEMBLY
LOCK WASHER
CONDUCTOR ASSEMBLY
JUMPER
CONDUCTOR ASSEMBLY
-
CONDUCTOR ASSEMBLY
TOGGLE ON/OFF SWITCH
CONDUCTOR ASSEMBLY
CABLE TIE
TRIGGER OPENING COVER
PLASTIC 1/2” PLUG (see note 4)
NOTES:
1. Tie-off the following unused conductors with Item 20 inside of pendant:
Blue with Red T Orange with Red T Black with White T
2. Before installing Item 21 (Cover), add RTV Sealant between cover & Pendant Housing.
3. Securely wrap unused power connector terminals (Ref. Item #19) with electrical tape; terminals must be unwrapped when adding switches for options.
4. Item #22 (Plastic Plugs) are to be installed in any unused holes in Cover Plate Item #2.
5. Items 3, 4, 8, & 12 may be purchased as a REPLACEMENT DPDT SWITCH KIT using P/N
380005 .
6. Items 3, 4, 12, & 18 may be purchased as a REPLACEMENT ON/OFF SWITCH KIT using P/N
380001 .
12-7.1.0
aw680021 12/99
Courtesy of Crane.Market
PENDANT
P/N 680021
7. Items 1, 2, 6, 7, 9, 10, 21, & 22 may be purchased as a REPLACEMENT HOUSING KIT using
P/N 380002 . aw680021 12/99
Courtesy of Crane.Market
PENDANT CABLE ASSEMBLY
P/N 680041
ITEM
5
6
3
4
1
2
QTY
1
1
30'
2
13
6"
P/N
366098
480515
480594
000101
002012
490243
DESCRIPTION
19 PIN BAYONET PLUG
CABLE CLAMP
19 PIN CONDUCTOR CABLE
RING TERMINAL #6 / 14-16 GA
RING TERMINAL #6 / 18-22 GA
HEAT SHRINK TUBING x 6"
12-8.0.0
AW680041 3/98
Courtesy of Crane.Market
TRAVELING BLOCK ASSEMBLY
P/N 360480
ITEM
3
4
5
6
1
2
7
8
9
10
QTY
1
1
1
1
2
1
2
1
3
2
P/N
480362
240236
480364
480371
480372
017800
480367
480368
360124
360480-100
DESCRIPTION
SIDE PLATE
SHEAVE ASSEMBLY
LOWER TACKLE
SWIVEL HOOK - 3 TON
BOLT x 3 1/4 GR8 w/ GREASE ZERK
LOCK NUT 1/2 NC
BLOCK PIN
SWIVEL HOOK PIN
HITCH PIN
MAXIMUM LOAD DECAL
13-1.0.0
AW360480 8/98
Courtesy of Crane.Market
LOAD CHART 10-16-20 BOOM
MODEL 5005EH
14-1.0.0
AW340M 4/99
Courtesy of Crane.Market
Courtesy of Crane.Market
Powered by TCPDF (www.tcpdf.org)
Courtesy of Crane.Market
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