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OWNERS MANUAL
5005H
REVISION 2/2000
PART NO. 999937
SERIAL NO. __________________________
AUTO CRANE COMPANY
P.O. Box 580697, Tulsa, OK 74158-0697
4707 North Mingo Road, Tulsa, OK 74117
Phone (918) 836-0463
Sales Fax (918) 438-6688 Service Fax (918) 834-5979
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
5005H SERIES - OWNER'S MANUAL
TABLE OF CONTENTS
6
7
8
9
10
3
4
5
11
12
13
14
15
16
17
18
19
20
1
2
21
22
23
24
25
26
27
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING PRACTICES & WARNINGS . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION OF UNIT / OUTRIGGERS . . . . . . . . . . . . . . . . . . . . . . . . . .
QUALIFICATIONS FOR & CONDUCT OF OPERATORS . . . . . . . . . . .
INSPECTION, TESTING & MAINTENANCE . . . . . . . . . . . . . . . . . . . . .
MOUNTING AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANE ORIENTATION & HYDRAULIC HOOKUP . . . . . . . . . . . . . . .
SAFETY DECAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AMPLIFIER SETUP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIMETER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC VALVES, TROUBLESHOOTING . . . . . . . . . . . . . . . . . . .
LIFE OF WIRE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION & MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . .
GENERAL ASSEMBLY (PEDESTAL) . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TWO-BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC SAFETY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROTATION GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOIST ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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HYDRAULIC SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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RESERVOIR ASSEMBLY
OUTRIGGERS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MISCELLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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LOAD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-9.9.9
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LAST PAGE
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Revision 12/97
Courtesy of Crane.Market
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 series cranes for your protection. The choice of materials and the design of the electrical system minimizes weight and lengthens durability. The hydraulic components meet or exceed a 3.5:1 safety factor . Holding valves prevent the load from dropping if a hose should fail. A 10u filter in the return line of the hydraulic system removes dirt and grit that may cause erratic operation. The reservoir has a 15u air filter in the filler cap. The pump has a 40 mesh strainer in the suction line.
For your convenience the overall dimensions of the
5005H series crane are on the General Dimension
Drawing. Maximum turning radius at both the hoist motor and the rotation motor are also on that drawing.
Remember, the crane adds weight to the vehicle.
Adding weight may change the driving and riding characteristics of the vehicle unless the appropriate overload spring(s) are installed on the truck. The payload of the vehicle is reduced by the weight of the crane. The operator should exercise care when loading the vehicle. Distributing the payload on the vehicle evenly will greatly improve the driving and riding characteristics of the vehicle. A minimum G.V.W. of
10,500 lbs. is recommended for mounting the 5005H series cranes.
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
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abused, mis-used, overloaded or otherwise damaged by inexperienced persons trying to operate the equipment without reading the manual.
Auto Crane will not assume responsibility or liability for any modifications or changes made to unit, or installation of component parts done without authorization.
Auto Crane maintains a strong distributor network and a knowledgeable Customer Service Department. In most cases, an equipment problem is solved via phone conversation with our customer service department.
The customer service department also has the ability to bring a local distributor, a regional sales manager, or a factory serviceman into the solution of an equipment problem. If, through no fault of Auto Crane Company, it is necessary to send an experienced factory serviceman on a field service call, the rates stated in the
Auto Crane Distributor's Flat Rate Manual will apply.
Auto Crane Company's extensive Research and
Development Program allow our customers to use the best equipment on the market. Our Engineering Staff and our knowledgeable sales people, are always available to our customers in solving crane and winch-type application problems. When in doubt, call the Auto Crane factory.
DISTRIBUTOR ASSISTANCE:
Should you require any assistance not given in this manual, we recommend that you consult your nearest
Auto Crane Distributor. Our distributors sell authorized parts and have service departments that can solve almost any needed repair.
NOTE:
THIS MANUAL SHOULD
REMAIN WITH THE CRANE AT ALL TIMES.
This manual does not cover all maintenance, operating, or repair instructions pertinent to all possible situations. If you require additional information, please contact the Auto Crane Company at the following telephone number: (918) 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.
REVISION 12/97
Courtesy of Crane.Market
--- 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.
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.
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.
17.
WARNING!
NEVER EXCEED load chart capacities (centerline of rotation to hoist hook).
18.
WARNING! NEVER un-reel last 5 wraps of cable from drum!
19.
WARNING! NEVER wrap cable around load!
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).
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!
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.
24.
WARNING!
In using a hook with latch, ALWAYS insure that the hook throat is closed before lifting a load! Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.
25.
WARNING! NEVER hold any pendant Select
Switch on that will cause unsafe operating conditions!
WARNING!
Auto Crane Company remote controlled, stiff boom cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel.
SAFTIPS 2/98 2-1.0.0
Courtesy of Crane.Market
--- 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
Courtesy of Crane.Market
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
OPERATORS
2 No one other than the personnel specified above shall enter the operating area of a crane with the exception of persons such as oilers, supervisors, and those specified persons authorized by supervisors whose duties require them to do so and then only in the performance of their duties and with the knowledge of the operator or other persons.
QUALIFICATIONS FOR OPERATORS
7 Operators and operator trainees should have normal depth perception, coordination, and no tendencies to dizziness or similar undesirable characteristics.
1 Crane operation shall be limited to personnel with the following minimum qualifications:
A. designated persons
B. trainees under the direct supervision of a designated person
C. maintenance and test personnel (when it is necessary in the performance of their duties)
D. inspectors (crane).
8 In addition to the above listed requirements, the operator shall:
A. Demonstrate the ability to comprehend and interpret all labels, operator's manuals, safety codes and other information pertinent to correct crane operations.
B. Possess knowledge of emergency procedures and implementation of same.
C. Demonstrate to the employer the ability to operate the specific type of equipment.
D. Be familiar with the applicable safety regulations.
E. Understand responsibility for maintenance requirements of crane.
F. Be thoroughly familiar with the crane and its control functions.
G. Understand the operating procedures as outlined by the manufacturer.
CONDUCT OF OPERATORS
3 Operators shall be required by the employer to pass a practical operating examination. Qualifications shall be limited to the specific type of equipment for which examined.
9 The operator shall not engage in any practice which will divert his attention while actually operating the crane.
4 Operators and operator trainees shall meet the following physical qualifications:
A. Vision of at least 20/30 Snellen in one eye and
20/50 in the other, with or without corrective lenses.
B. Ability to distinguish colors, regardless of position, if colors differentiation is required for operation.
C. Adequate hearing with or without hearing aid for the specific operation.
10 Each operator shall be responsible for those operations under the operator's direct control.
Whenever there is any doubt as to safety, the operator shall consult with the supervisor before handling the loads.
11 The operator should not leave a suspended load unattended unless specific precautions have been instituted and are in place.
5 Evidence of physical defects or emotional instability which render a hazard to operator or others, which in the opinion of the examiner could interfere with the operator's performance may be sufficient cause for disqualification. In such cases, specialized clinical or medical judgment and tests may be required.
12 If there is a warning sign on the switch or engine starting controls, the operator shall not close the switch or start the engine until the warning sign has been removed by the appointed person.
6 Evidence that the operator is subject to seizures or loss of physical control shall be sufficient reason for disqualification. Specialized medical tests may be required to determine these conditions.
13 Before closing the switch or starting the engine, the operator shall see that all controls are in the "OFF" or neutral position and all personnel are in the clear.
14 If power fails during operation, the operator shall:
A. move power controls to the "OFF" or neutral position.
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QUAL 7/98
Courtesy of Crane.Market
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)
QUAL 7/98
Courtesy of Crane.Market
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSPECTION CLASSIFICATION
27 Initial inspection. Prior to initial use, all new, altered, modified or extensively repaired cranes shall be inspected by a designated person to insure compliance with provisions of this standard.
28 Regular inspection. Inspection procedure for cranes in regular service is divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the components of the crane and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as "frequent" and
"periodic" with respective intervals between inspections as defined below.
A. frequent inspection - daily to monthly intervals
B. periodic inspection - one to twelve intervals, or as specifically recommended by the manufacturer
G. electrical apparatus for malfunctioning, signs of excessive deterioration, dirt and moisture accumulation
H. hydraulic system for proper oil level and leaks daily
I. tires for recommended inflation pressure, cuts and loose wheel nuts
J. connecting pins and locking device for wear and damage
PERIODIC INSPECTION
30 Deformed, cracked or corroded members in the crane structure and carrier.
31 Loose bolts, particularly mounting bolts.
32 Cracked or worn sheaves and drums.
33 Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and devices.
FREQUENT INSPECTION
34 Excessive wear on brake and clutch system parts and lining.
29 Inspection shall be performed by designated personnel.
A. control mechanisms for maladjustment interfering with proper operation - daily, when used
B. control mechanisms for excessive wear of components and contamination by lubricants or other foreign matter
C. safety devices for malfunction
D. all hydraulic hoses, particularly those which flex in normal operation of crane functions, should be visually inspected once every working day, when used
E. hooks and latches for deformation, chemical damage, cracks, and wear. Refer to ANSI/ASME
B30.10
F. rope reeving for compliance with crane manufacturer's specifications, if optional winch is used
35 Crane hooks inspected for cracks.
36 Travel steering, braking, and locking devices, for malfunction.
37 Excessively worn or damaged tires.
38 Hydraulic and pneumatic hose, fittings, and tubing inspection.
A. evidence of leakage at the surface of the flexible hose or its junction with metal and coupling
B. blistering, or abnormal deformation to the outer covering of the hydraulic or pneumatic hose
C. leakage at threaded or clamped joints that cannot be eliminated by normal tightening or recommended procedures
D. evidence or excessive abrasion or scrubbing on the outer surface of a hose, rigid tube, or fitting. Means shall be taken to eliminate the interference of
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INSP 9/98
Courtesy of Crane.Market
INSPECTION, TESTING AND MAINTENANCE
GENERAL elements in contact or otherwise protect the components necessary to determine origin of the problem before corrective action can be taken.
39 Hydraulic and pneumatic pumps and motors inspection.
A. loose bolts or fasteners
B. leaks at joints between sections
C. shaft seal leaks
D. unusual noises or vibrations
E. loss of operating speed
F. excessive heating of the fluid
G. loss of pressure
43 Labels are to be in place and legible.
CRANES NOT IN REGULAR USE
44 A crane which has been idle for a period of over one month or more, but not less than six months, shall be given an inspection conforming with the initialregular- frequent inspections.
45 A crane which has been idle for a period of over six months shall be given a complete inspection conforming with the initial-regular-frequent inspection requirements.
40 Hydraulic and pneumatic valves inspection.
A. cracks in valve housing
B. improper return of spool to neutral position
C. leaks at spools or joints
D. sticking spools
E. failure of relief valves to attain or maintain correct pressure setting
F. relief valve pressure shall be checked as specified by the manufacturers
41 Hydraulic and pneumatic cylinders inspection.
A. drifting caused by fluid leaking across piston
B. rod seals leaking
C. leaks at welding joints
D. scored, nicked, or dented cylinder rods
E. damaged case (barrel)
F. loose or deformed rod eyes or connecting joints
42 Hydraulic filters. Evidence of rubber particles on the filter elements may indicate hose, "O" ring, or other rubber component deterioration. Metal chips or pieces on the filter may denote failure in pumps, motors, or cylinders. Further checking will be
INSPECTION RECORDS
46 Dated records for periodic inspection should be made on critical items such as brakes, crane hooks, rope, hydraulic and pneumatic cylinders, and hydraulic and pneumatic relief pressure valves. Records should be kept available to an appointed person.
OPERATIONAL TESTS
47 Prior to initial use, all new, altered, modified, or extensively repaired cranes shall be tested for compliance with the operational requirements of this section, including functions such as the following:
A. load lifting and lowering mechanisms
B. boom lifting and lowering mechanisms
C. boom extension and retraction mechanisms
D. swing mechanisms
E. safety devices
F. operating controls comply with appropriate function labels
Operational crane test results shall be made available to an appointed person.
RATED TEST LOAD
Prior to initial use, altered, modified, or extensively repaired cranes shall be load
1-3.2.0
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
1-3.3.0
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)
1-3.4.0
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.
1-3.5.0
INSP 9/98
Courtesy of Crane.Market
MOUNTING and INSTALLATION 5005H
1. CHECK TO MAKE SURE THE FOLLOWING ITEMS ARE WITH YOUR CRANE:
ITEM
4.
5.
6.
1.
2.
3.
PART NO.
360602000
360247000
480525000
360030000
999937000
015104000
DESCRIPTION
Swivel Block
Vented Relief Valve (Non-proportional Units Only)
Control Valve Assembly (Proportional Units Only)
Pump Assembly (Optional)
Owners Manual
Bolt system: 7/8 NF x 5", Grade 8, (4 Req'd)
2. PRESSURE AND RETURN HOSES ARE NOT FURNISHED WITH THIS CRANE. THE HOSES MUST BE
PROVIDED BY THE INSTALLER AND THE LENGTHS DETERMINED AT INSTALLATION.
REQUIREMENTS FOR INSTALLATION USING 8 GALLON RESERVOIR WITH RELIEF VALVE AND AUTO
CRANE PROVIDED PUMP
(REF. DWG AW-023 & AW-480150)
A. RETURN LINE FROM CRANE TO RESERVOIR (IN COMPARTMENT): -8 SAE 100R2 (OR EQUIVALENT).
HOSE LENGTH IS DETERMINED BY INSTALLER. RETURN LINES LONGER THAN 6 FEET SHOULD BE
SIZE -12. HOSE END FITTINGS ARE -8 JIC FEMALE SWIVEL (CRANE END) AND -10 JIC FEMALE
SWIVEL (RESERVOIR END).
B. PRESSURE LINE FROM VENTED RELIEF VALVE TO CRANE: -8 SAE 100R2 (OR EQUIVALENT). HOSE
LENGTH IS DETERMINED BY INSTALLER. HOSE END FITTINGS ARE BOTH -8 JIC FEMALE SWIVEL.
NOTE: CRANE MUST USE RELIEF VALVE P/N 480157, WHICH IS PROVIDED.
C. SUCTION HOSE FROM PUMP TO RESERVOIR: -16 HYDRAULIC SUCTION HOSE WITH TOW (2) -16
HOSE CLAMPS ON EACH END.
D. PRESSURE LINE FROM PUMP TO VENTED RELIEF VALVE (LOCATED ON RESERVOIR) : -12 SAE
100R2 (OR EQUIVALENT). HOSE LENGTH IS DETERMINED BY INSTALLER. HOSE END FITTINGS
ARE BOTH -10 JIC FEMALE SWIVEL.
NOTE:
REFER TO OWNERS MANUAL FOR ADDITIONAL INSTALLATION INFORMATION, AND OTHER RESERVOIR
AND PUMP COMBINATIONS.
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 6 GALLONS PER MINUTE AND A PRESSURE OF 2200 PSI.
EXCESS FLOW WILL CAUSE ERRATIC OPERATION, AND TOO LITTLE FLOW WILL CAUSE POOR CRANE
OPERATION.
4. 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.
5. MAKE SURE THE MOUNTING BOLTS ARE 7/8x5, GRADE
8. TORQUE BOLTS TO 440 FT-LBS (DRY).
6. WHEN CRANE IS NOT IN OPERATION, A BOOM SUPPORT
SHOULD ALWAYS BE USED. TRAVELING BLOCK
SHOULD BE CONNECTED TO HOOK LOOP.
7. ALWAYS USE CABLE LOOPS ON SIDE OF BOOM AND
PENDANT GUARD ON SIDE OF PEDESTAL TO STORE
PENDANT ASSEMBLY, IF THIS TYPE OF STORAGE
APPLIES.
8. THE VEHICLE MUST BE EQUIPPED WITH AN ENGINE
SPEED CONTROL AND TACHOMETER.
FORWARD
2-1.0.0
Courtesy of Crane.Market
MOUNTING and INSTALLATION 5005H
(CONTINUED)
9. CHECK FOR PROPER PRESSURE AND RETURN LINE HOOK-UP TO CRANE: PRESSURE PORT IS ON
RIGHT SIDE AS VIEWED FROM THE REAR OF THE CRANE.
10. USE MEDIUM PRESSURE AUTO CRANE FILTER IN THE RETURN LINE UNLESS FILTER EXIT PORT IS
MOUNTED DIRECTLY TO THE RESERVOIR.
11. ELECTRICAL HOOKUP
NON-REMOVABLE PENDANT UNITS:
A. RUN THE FOLLOWING WIRES THROUGH HOLE IN BASE ASSEMBLY OF CRANE AND SEAL WITH
SILICONE RUBBER TO PREVENT WIRE CHAFING AND LEAKS.
B. CONNECT WIRE FROM DIRECTIONAL VALVE SOLENOID (P/N 480137) TO WHITE WIRE W/TRACER AT
PENDANT CABLE END (REF. AW-480093).
C. CONNECT POWER CONDUCTOR FROM STARTER SOLENOID TO BLACK WIRE AT BASE OF CRANE,
PASSING THROUGH THE MAIN POWER RELAY. USE THE IN-LINE FUSE PROVIDED.
REMOVABLE PENDANT UNITS:
A. OBTAIN THE PROPER WIRING DIAGRAM.
B. WIRE TERMINAL STRIP PER DIAGRAM AND PROTECT STRIP FROM ACCIDENTAL CONTACT.
WARNING!
FAILURE TO CORRECTLY PLUMB AND WIRE CRANE CAN CAUSE
INADVERTENT OPERATION AND DAMAGE TO CRANE AND/OR PERSONNEL!
12. ONCE CRANE AND PLUMBING ARE INSTALLED ON THE TRUCK, FILL THE RESERVOIR TO TOP OF SIGHT
GLASS (MOBIL DTE 13 or EQUAL). BEFORE OPERATING CRANE CONNECT TOGETHER THE PRESSURE
AND RETURN HOSES GOING TO BASE OF CRANE USING -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 6
GALLONS PER MINUTE (GPM), INSTALL AN IN-LINE FLOW METER BETWEEN THE CRANE AND THE
RESERVOIR IN THE RETURN HOSE, OR CONFIRM PUMP SPEED IS CORRECT. THE PROPER SPEED FOR
AUTO CRANE GEAR PUMP P/N 360030 IS 1000 RPM.
13. PROPER PRESSURE SETTING CAN BE ACHIEVED BY, WITH THE PTO DISENGAGED, REMOVING THE PIPE
PLUG ON THE VENTED RELIEF VALVE OR PROPORTIONAL VALVE AND INSTALLING A 2500 PSI PRESSURE
GAUGE. EXTEND THE BOOM "IN" ALL THE WAY AND CONTINUE HOLDING THE SWITCH ON. FOR
PROPORTIONAL SYSTEMS, THE TRIGGER SHOULD BE PULLED COMPLETELY BACK (ON). READ THE
PRESSURE GAUGE AND ADJUST RELIEF VALVE TO READ 2200 PSI. RECHECK PRESSURE SETTING TO
VERIFY ADJUSTMENT.
14. LOAD TEST THE CRANE TO ENSURE PROPER FUNCTIONING AND TRUCK STABILITY.
15. MAKE CERTAIN THE OWNER'S MANUAL IS DELIVERED TO THE CUSTOMER.
16. FOR ADDITIONAL HELP: CALL THE SERVICE DEPARTMENT AT THE AUTO CRANE COMPANY.
(918) 836-0463 (TULSA, OKLAHOMA)
WARNING
FEDERAL LAW (49 CFR PART 571) REQUIRES THAT THE FINAL STAGE MANUFACTURER OF A VEHICLE
CERTIFY THAT THE VEHICLE COMPLIES WITH ALL APPLICABLE FEDERAL REGULATIONS. ANY
MODIFICATIONS PERFORMED ON THE VEHICLE PRIOR TO THE FINAL STAGE ARE ALSO CONSIDERED
INTERMEDIATE STAGE MANUFACTURING AND MUST BE CERTIFIED AS TO COMPLIANCE. THE INSTALLER OF
THIS CRANE AND BODY IS CONSIDERED ONE OF THE MANUFACTURERS OF THE VEHICLE. AS SUCH A
MANUFACTURER, THE INSTALLER IS RESPONSIBLE FOR COMPLIANCE WITH ALL APPLICABLE FEDERAL AND
STATE REGULATIONS, AND IS REQUIRED TO CERTIFY THAT THE VEHICLE IS IN COMPLIANCE.
IT IS THE FURTHER RESPONSIBILITY OF THE INSTALLER OF THE CRANE TO COMPLY WITH THE OSHA
TRUCK CRANE STABILITY REQUIREMENTS AS SPECIFIED BY 29 CFR PART 1910.180 (C) (1).
2-1.1.0
REVISED 4/94
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
BOOM SUPPORT
5005H SERIES
WARNING:
As with all Auto Crane power rotation units, the 4004H does require a boom support.
Suggested Boom Support:
Auto Crane P/N 726175
2-2.2.0
AW726175 7/98
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
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Courtesy of Crane.Market
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INSTALLATION & SETUP PROCEDURE DIGITAL
PULSE WIDTH AMPLIFIER
INSTALLATION:
1. Install amplifier at a convenient location near the proportional crane terminal strip (see
Proportional Crane Wiring Diagrams) using two screws and lock nuts provided.
2. At the 12-station terminal block, disconnect all power to the system.
3. Connect the DIN connector plug to the proportional valve, making sure the gasket seals properly. Secure the plug to the proportional valve coil with screw. Attach wires per applicable wiring diagram.
ATTACH WIRES IN THIS ORDER: (numbers are on 22-station terminal strip)
1.
Attach the BLACK wire to terminal “N” (#13).
2.
Attach the RED wire to terminal “T” (#10).
3.
Attach the WHITE wire too terminal “M” (#12).
4.
Attach the GREEN wire to the BROWN wire from the proportional DIN connector plug using the bullet connector supplied.
Caution: Failure to do so may cause premature amplifier failure and void warranty.
Observe all connections for proper installation before connecting power to the terminal block. Proceed to the setup procedure.
SETUP:
1.
Remove four screws on the front plate of amplifier and remove front plate.
2.
With power on, pull pendant trigger to full on position. Adjust potentiometer adjustment screw located next to the red light (see Figure 1) until light just turns off, then turn trim pot back until the light just comes on. The light should stay on during the full trigger movement. Clockwise rotation to the trim pot will turn light off. Counterclockwise rotation will turn the light on. This “tunes” the amplifier to the trigger potentiometer.
3.
After warming the hydraulic system oil, determine which function should be used to set the low position switch (ROTATE uses the least amount of pressure). Activate that function with trigger released, and turn the lower range setting dial (See Figure 1, marked with “L” on circuit board) until the desired speed is reached. The “Zero” and the “F” on the dial are opposite ends of the switch. To adjust the low set point, turn CLOCKWISE direction for INCREASED FLOW; turn COUNTERCLOCKWISE direction for DECREASED FLOW.
This adjusts the “Threshold Speed” for the trigger in the released position.
4.
Operate the boom up function with trigger pulled back to the maximum position. Turn the high range setting dial (See Figure 1, marked with “H” on circuit board) until there is a noticeable decrease in speed, then back up one or two notches as desired.
2-5.0.0
AMP 2/2000
Courtesy of Crane.Market
INSTALLATION & SETUP PROCEDURE DIGITAL
PULSE WIDTH AMPLIFIER
“Zero” is the maximum speed setting and “F” is the most reduced speed setting. To set the high range dial, turn CLOCKWISE direction for DECREASED FLOW; turn
COUNTERCLOCKWISE direction for INCREASED FLOW. This operation adjusts the trigger “Dead Band” at the fully pulled position.
5.
Replace cover and install screws. Make sure the amplifier wiring is secured and does not interfere with rotating hoses and electrical wiring.
Figure 1
2-5.1.0
AMP 2/2000
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.
2-6.0.1
OVLD 1/99
Courtesy of Crane.Market
OVERLOAD SYSTEM / ANTI-2-BLOCK
TROUBLE SHOOTING GUIDE
2-6.0.0
OVLD 1/99
Courtesy of Crane.Market
RELAY BOX ASSEMBLY
P/N 366999
2-6.1.0
366999 3/98
Courtesy of Crane.Market
10
11
12
13
14
15
16
17
18
19
20
ITEM
1
2
3
6
7
8
9
4
5
-
-
11
1
1
1
1
1
3
1
1
QTY
1
12
2
2
2
-
2
2
1
RELAY BOX ASSEMBLY
P/N 366999
P/N
366990
366968
366967
320363
366980
320355
005901
-
016300
-
-
320357
341566
341564
341565
366248
366249
366250
000601
750737
DESCRIPTION
PLASTIC ENCLOSURE W/ 6 DRILL HOLES
CORD CONNECTOR
SHIELDED CABLE 3-CONDUCTOR 18-20
TERMINAL CONNECTOR PLUG
PIGGY BACK TERMINAL INSULATED 18-20
BOSCH DROP OUT RELAY
-
HEX HD SCREW 1/4-20 NC x 1/2 LG
-
LOCK NUT 1/4-20 NC
-
NON-INSULATED TERMINAL W/ LOCK DEVICE
WHT/BLK ELECTRICAL WIRE 18 AWG 600V
RED ELECTRICAL WIRE 18 AWG 600V
BLACK ELECTRICAL WIRE 18 AWG 600V
WEATHER PACK 1-WAY MALE 18-20
WEATHER PACK 1-WAY FEMALE 18-20
WEATHER PACK 1-WAY MALE 18-20
RING TERMINAL 10-3/8
CABLE TIE
2-6.2.0
366999 3/98
Courtesy of Crane.Market
OPTIMETER TROUBLE SHOOTING GUIDE
Follow the troubleshooting sequence.
1.
2.
Obtain the proper wiring diagram and check wiring.
With truck running, check terminal “L” voltage
A.
B.
If 12 - 13.75 volts, proceed.
If not, check for blown fuse or broken wires.
3.
Install pendant, turn system power on (8-switch pendants only), and check terminal “t” for truck voltage.
A. If truck voltage, proceed.
B. If no voltage or low voltage (less than truck voltage), make sure the power switch on the
8-switch pendant is in the "on" position. (Does not apply to 4-switch pendant.
C. Then, check for loose connection in the pendant or a broken wire in the pendant cable.
7.
Check terminal “m” for 0.5 volts with trigger released.
A. Solid truck voltage at terminal “m” means a loss of ground. Search the ground wire for bad connections or breaks and repair.
B. If more than 0.7 volts or less than 0.2 volts with trigger released, readjust trigger on pot shaft. (Note: care must be taken when handling the pot assembly to keep from breaking the wires at their attachment points.
C. If voltage is correct with trigger released, smoothly activate trigger looking for a smooth gradual increase of voltage near 5.0 volts at maximum pulled position (3.5 to 7 volts is
OK).
D. If voltage is erratic and jumps up to truck voltage and back down during the trigger movement, replace potentiometer assembly.
4.
Disconnect bullet connector on line connecting connecting green wire from amplifier to brown wire from proportional valve DIN connector.
Then ground brown wire to a chassis ground.
This will send maximum current thru proportional valve and should close it completely.
5.
6.
completely.
OR
Depress the manual operator pin on top of the valve with an allen wrench till valve closes
Check for proper crane operation.
A. If crane operates properly, proceed.
B. If not, check coil resistance from pin to pin
(should be 5.0 ohms) and from pin to ground ring on coil (should be infinite resistance). If resistance is much different than above, replace coil, then proceed.
C. Re-connect brown and green wire.
8.
9.
Pull trigger and check for red light inside amplifier then perform the following adjustments with the trigger pulled to the maximum position:
A. Light off
Turn small trim pot screw counterclockwise
(left) till light just gets bright, then stop. (If 10 turns do not turn light on, look for more than 9 volts at teminal “m”.)
B. Light on
Turn small trim pot screw clockwise (right) till light just turns off, then turn counterclockwise
(left) till light just gets bright, then stop. (If 10 turns do not turn light off, look for less than 1 volt at terminal “m”.)
Release trigger.
2-7.0.0
OPTIM 01/2000
Courtesy of Crane.Market
OPTIMETER TROUBLE SHOOTING GUIDE
10.
Set the two adjustment switches (hi and lo) to number “4”. (One side of the switch knob has an indicator.)
11.
the LO switch takes the "dead space" out of the beginning trigger activation, and will continue to raise the low signal to give half flow with the trigger at full released position. The higher the number or letter (0 thru f), the higher the flow to the crane with the trigger in the fully released position.
12.
The HI switch takes the "dead space" out of the full trigger position, and will continue to lower the high signal to half the flow at the maximum trigger pulled position.The higher the number or letter (0 thru f), the lower the flow to the crane with the trigger in the fully pulled position.
13.
A good starting position would be to have both switches on the number "4".
14.
NOTE:Both switches on "F" will limit flow to a median value and not allow any change.
2-7.1.0
OPTIM 01/2000
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SPEED CONTROL KIT,
P/N 751140
NOTES:
1. THIS DIAGRAM SHOWS SPEED CONTROL INSTALLTION
WITH OR WITHOUT AN AIR COMPRESSOR. DISREGARD
ISOLATOR BLOCK & PRESSURE SWITCH ON DIAGRAM IF
NOT USING AN AIR COMPRESSOR.
2. REMOVE METAL JUMPER CLIP FROM CONTROL MODULE
IF SO EQUIPPED (S500-A5).
3. THE WIRE SIZE AND LENGTH TO "AUX" TERMINAL IS NOT
CRITICAL BECAUSE OF LOW CURRENT; 16-18 GAGE WIRE
MAY BE USED.
2-8.4.0
751140 12/99
Courtesy of Crane.Market
ENGINE START/STOP RELAY KIT
P/N 480533
ITEM
1
2
3
4
5
6
7
8
9
10
QTY
2
2
10
2
3
3
6’
49’
17’
35’
P/N
320355
320363
320357
480495
000402
000501
800595
800590
800593
800594
DESCRIPTION
12V RELAY
RELAY PLUG
FEMALE SPADE LOCK CONNECTOR
FLANGED SPADE TERMINAL
1/4 TERMINAL RING
5/16 TERMINAL RING
GREEN 16 GA WIRE
BLACK 16 GA WIRE
RED 16 GA WIRE
BLUE 16 GA WIRE
2-9.0.0
AW480533 1/99
Courtesy of Crane.Market
AUXILIARY RELAY KIT
P/N 480534
ITEM
1
2
3
4
5
6
7
8
9
QTY
2
2
5
2
1
1
38’
10’
25’
P/N
320355
320363
320357
000101
000402
000501
800595
800593
800592
DESCRIPTION
12V RELAY
RELAY PLUG
FEMALE SPADE LOCK CONNECTOR
#6 TERMINAL RING
1/4 TERMINAL RING
5/16 TERMINAL RING
GREEN 16 GA WIRE
RED 16 GA WIRE
WHITE 16 GA WIRE
2-9.1.0
AW480534 1/99
Courtesy of Crane.Market
HYDRAULICS
Vented Relief Valve Setting
{ The crane must receive 6 to 7 Gallons
Per Minute (GPM) and 2200 PSI. To assure proper flow, install an in-line flow meter between the crane and the reservoir in the return hose, or confirm correct pump speed (or engine speed w/
PTO ratio multiplied). Proper pressure setting for units without proportional control can be achieved by, with PTO disengaged, removing the plug, item 5,
5005H
{ Disengage PTO. Remove gauge and reinstall the pipe plug. Crane is now ready for use.
Proportional Relief Valve Setting
{ The crane must receive 6 to 7 Gallons
Per Minute (GPM) and 2200 PSI. To assure proper flow, install an in-line flow meter between the crane and the reservoir in the return hose, or confirm correct pump speed (or engine speed w/PTO rotation multiplier).
{ Proper pressure setting for the proporand installing a 2500 psi gauge. Test the pressure by fully retracting the cylinder and holding Boom-In function while reading the gauge.
{ The boom can now be retracted fully and the switch held in retract position until full pressure is reached and the pressure gauge is checked. If the gauge is not 2200 PSI, adjust the vented relief valve (P/N 480135). Verify this setting by operating the retract switch a few times and checking the pressure setting.
3-1.0.0
tional control relief valve can be achieved by removing the -4 SAE plug
(with PTO disengaged), and installing a
2500 PSI gauge. Test the pressure by pulling the trigger all the way back towards the handle and operating the boom down switch while reading the gauge. Double check the setting by operating the manual override located on the top of the proportional valve
(using an Allen wrench or something
HYD5005H 2/2000
Courtesy of Crane.Market
HYDRAULICS
5005H
similar to press the steel button) and simultaneously operate the boom retract function. If the reading is higher, check the proportional system troubleshooting section of this manual to find out why the valve was not fully closing.
{ If it is the same, with PTO disengaged, remove the gauge and reinstall the plug.
The crane is now ready for use.
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 6 to 7 GPM and main relief is set to 2200
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 1200 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.
{ 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 do so may result in personal injury!
3-1.1.0
HYD5005H 2/2000
Courtesy of Crane.Market
HYDRAULICS - 5005H 16' MAN. EXT.
Vented Relief Valve Setting
{ The crane must receive 6 to 7 Gallons Per
Minute (GPM) and 2350 psi. To assure proper flow, install an in-line flow meter between the crane and the reservoir in the return hose, or confirm correct pump speed (or engine speed w/ PTO ratio multiplied). Proper pressure setting for units without proportional control can be achieved by, with PTO disengaged, removing the plug, item 5, and installing a 2500 psi gauge. Test the pressure by fully retracting the cylinder and holding Boom-In function while reading the gauge.
Proportional Relief Valve
Setting
{ The crane must receive 6 to 7 Gallons Per
Minute (GPM) and 2350 PSI. to assure proper flow, install an in-line flow meter between the crane and the reservoir in the return hose, or confirm correct pump speed (or engine speed w/PTO rotation multiplier).
{ Proper pressure setting for the proportional control relief valve can be achieved by, with
PTO disengaged, removing the -4 SAE plug, and installing a 2500 PSI gauge.
{ The boom can now be retracted fully and the switch held in retract position until full pressure is reached and the pressure gauge is checked. If the gauge is not 2350 PSI, adjust the vented relief valve (P/N 480135) . Verify this setting by operating the retract switch a few times and checking the pressure setting.
{ Disengage PTO. Remove gauge and re-install the pipe plug. Crane is now ready for use.
3-2.0.0
{ Test the pressure by pulling the trigger all the way back towards the handle and operating theboom down switch while reading the gauge.
Double check the setting by operating the manual override located on the top of the proportional valve (using an Allen wrench or something similar to press the steel button) and simultaneously operate the boom retract function. If the reading is higher, check the proportional system troubleshooting section of this manual to find out why the valve was not fully closing.
{ If it is the same, with PTO disengaged, remove the gauge and re-install the plug. The crane is now ready for use.
REVISION 8/97
Courtesy of Crane.Market
HYDRAULICS - 5005H 16' MAN. EXT.
REF. :AW-093 COUNTERBALANCE VALVE ADJUSTMENT 5005
H
Counterbalance Valve Adjustment
{ (Figure 1) With PTO disengaged and boom properly supported, remove pipe plug. Install a pressure gauge (0-2500 psi) into the port.
{ (Figure 3) Loosen locking set screw on flow regulator valve and turn adjustment knob all the way counter clockwise for maximum flow.
{ (Figure 4) Remove cap and loosen adjustment nut on relief valve below manifold. Turn allen head adjustment screw all the way clockwise to raise the relief setting to the maximum (DO
NOT OVER TIGHTEN).
{ Engage PTO and insure pump flow is 6 to 7
GPM and main relief is set to 2350 psi. With no load on boom, boom up to an angle of 70 degrees. Boom down and note pressure. If pressure reading is not 550 - 600 PSI, the counterbalance valve requires adjustment
(Figure 4).
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.
{ 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, re-adjust the counterbalance valve using the procedure in this manual.
Relief Valve (Fig 4) Setting
{ With PTO disengaged and boom properly supported, remove cap from pressure gauge fitting and install a 0-2500 psi pressure gauge.
{ Close flow regulator valve by turning adjustment knob all the way clockwise (Figure 3).
CAUTION: DO NOT OVER TIGHTEN!
{ With no load on boom, boom up to an angle of
70 degrees. Boom down and note pressure. If pressure reading is not 750 - 800 PSI, the pressure relief valve requires adjustment
(Figure 4).
v With cap removed from allen head adjustment screw, loosen the adjustment nut.
v To increase the pressure relief setting, turn the Allen head adjustment screw clockwise.
v To decrease the pressure relief setting, turn the allen head adjustment screw counterclockwise.
{ Tighten nut on adjustment screw, and reinstall cap. Repeat procedure if needed to obtain proper pressure setting.
{ Disengage PTO, remove pressure gauge and reinstall pipe plug.
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 crane while boom is lowering.
Boom Down Speed Setting
{ (Figure 3) Engage PTO and insure pump flow is 6 to 7 GPM and main relief is set to 2350 psi.
With no load on boom, boom up to an angle of
75 degrees. Boom down and adjust the flow regulator adjustment knob to achieve a boom down time of 37 seconds from 75 to 0 degrees.
v To increase boom down speed, turn adjustment knob counterclockwise.
3-2.1.0
REVISION 8/97
Courtesy of Crane.Market
v To decrease boom down speed, turn adjustment knob clockwise.
v Use locking set screw on adjustment knob to hold desired position.
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HYDRAULIC TROUBLESHOOTING 5005H
Issue Date: October, 1994
CAUTION: Never check for hydraulic leaks by feeling around hoses, fittings, or any other components.
High pressure oil can be injected through the skin causing severe injury, or death.
The hydraulic system of the 5005H power version is electrically operated and requires a minimum of 12V for satisfactory performance. The hydraulic pump is bi-rotational with a pressure relief setting of 2200 psi (2350 psi for 16' manual.). Standard pump speed is 1000 RPM (Ref. Pump P/N 360029). This pump is for direct flange mounting only.
It is not to be shaft driven unless an outboard bearing is installed, Auto Crane Kit P/N 480006.
PROBLEM
SOLUTION
FLOW PRESENT BUT FUNCTION
WILL NOT WORK
Remove valve cover to gain access to the manual override on the end of the valve cartridge. If the pump is operating, operate the relief valve manual override or the proportional valve override and push and twist
(CCW) the directional control valve manual override to unlock, then pull to operate the function. If the function does operate, check for loose wire, low voltage or bad ground. If the problem is traced to no voltage at the valve cartridge, remove pendant and with the switch engaged, check for an open circuit with an ohmmeter. If the circuit is open, check for broken wiring or bad switch. If the function does not operate, see the "NO
FLOW" paragraph in this section.
When a hydraulic function is engaged and causes the crane to "chatter", check for loose wire, low voltage at valve cartridge, low pump pressure, or air in the system.
HYDRAULIC "CHATTER"
NO FLOW OR LIMITED FLOW TO
CRANE
Check for adequate oil supply in reservoir. Check operation of bypass system by pressing manual override on solenoid valve operator on vented relief valve or proportional valve while operating crane. If crane functions, check for 12V at vented relief valve solenoid when operating a function, or follow proportional trouble shooting procedure for the proportional valve. If low flow condition continues to exist when the manual override is operated, remove relief valve cartridge and check for dirt. Other possible causes for a low flow condition are:
1.
Engine speed is too slow.
2.
A blocked pressure hose from pump. This condition can be identified by excessive lugging of engine and rapid overheating of oil.
3.
Collapsed or blocked suction hose to pump. This condition is usually identified by pump cavitation noise.
4.
Bad pumps: a bad pump will usually have some flow but the flow will drop off rapidly as pressure increases. This condition will cause overheating of the system. A drop of four (4) or more GPM from Zero
(0) PSI to Two Thousand (2000) PSI is cause for pump investigation
3-3.0.0
Courtesy of Crane.Market
HYDRAULIC TROUBLESHOOTING 5005H
Issue Date: October, 1994
PROBLEM SOLUTION
NO PRESSURE OR TOO LOW
PRESSURE
TOO HIGH FLOW
TOO HIGH PRESSURE
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. Check to ensure that pressure limit switch is correctly set.
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 opera-
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 it's operation as the crane becomes overloaded. Attempting to raise the main boom with a load greatly exceeding the crane rating will open the main relief valve resulting in no boom movement. This problem can be resolved by moving the load closer to the crane pedestal, or reducing the load.
3-3.1.0
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.)
3-4.0.0
WIRE 1/2000
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LUBRICATION & MAINTENANCE SCHEDULE
5005H 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
BOOM CYLINDER
PINS
EXTENSION
DETENT PIN
RETURN LINE
FILTER
HI-PRES. FILTER
ROTATION
BEARING
ROTATION
BEARING BOLTS
ROTATION GEAR
BOX
ROTATION GEAR
BOX
HOIST GEARBOX
DAY WEEKLY 3 MOS 6 MOS YEAR
X
X
X
X
X
X
X
X
X
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
REPLACE ELEMENT
CLEAN AFTER FIRST WEEK, THEN EVERY
3 MONTHS (OPT EQUIP)
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
EP GEAR-EP GEAR LUBE SAE 80-90, SPUR
GEAR SAE 30 OIL
5005Hmtsc 6/99 3-5.0.0
Courtesy of Crane.Market
LUBRICATION & MAINTENANCE SCHEDULE
5005H CRANE
SERVICE
PERFORMED
HYDRAULIC FLUID
DAY WEEKLY 3 MOS 6 MOS YEAR
X
NOTES
DRAIN, FLUSH, AND REFILL WITH DTE 13,
OR EQUIVALENT
BOOM SLIDE PADS PADS GREASED WHEN REPLACED
FOR ADDITIONAL
INFORMATION
SEE:
1) OWNER'S MANUAL
2) OSHA SECTION 1910.180
3) ANSI B30.5-1989
CAUTION:
Routine maintenance insures trouble-free operation and protects your investment. All warranties are void if maintenance is neglected.
NOTES:
1. Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability.
2. Once a bolt has been torqued to its rated capacity and then removed; the bolt should be replaced with a new one.
3. Auto Crane Company recommends that this crane be serviced per “Crane Inspection Log” P/N 999978.
These logs should be filled in at the intervals noted and kept as a permanent record. Additional copies are available from your local distributor.
3-5.1.0
5005Hmtsc 6/99
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BOOM ASSEMBLY (10-16)
P/N 360860 - MODEL 5005H/EH
4-4.1.0
aw360860 4/99
Courtesy of Crane.Market
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
12
13
14
15
16
ITEM
1
4
5
2
3
8
9
6
7
10
11
2
2
2
4
2
6
2
2
2
1
2
1
1
1
5
1
4
2
1
1
2
QTY
1
1
1
1
1
1
1
1
1
1
2
BOOM ASSEMBLY (10-16)
P/N 360860 - MODEL 5005H/EH
360122
240236
360814
360124
360038
366158
020200
016300
011511
017700
005406
005901
021100
360849
015900
360069
360070
360075
360091
360092
360153
P/N
360861
360862
360152
360545
360167
480032
480033
360121
360621
360625
360120
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
4-4.1.1
aw360860 4/99
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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).
4-7.0.0
AW368 1/99
Courtesy of Crane.Market
AUTOMATIC SAFETY BRAKE ASSEMBLY
(OIL COOLED) HOIST
4
5
6
7
8
ITEM
1
2
3
9
10
11
12
13
14
15
16
1
1
1
2
6
QTY
1
1
1
1
1
1
1
1
1
4
2
P/N
360367
360331
360450
360336
360339
360342
360345
360453
360368
360456
360371
360353
360465
360455
360359
360364
4-7.1.0
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
AW368 1/99
Courtesy of Crane.Market
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HOIST ACTUATOR
P/N 480075
4-10.0.0
AW480075 10/98
Courtesy of Crane.Market
ITEM
1
*2
5
6
3
4
7
8
9
10
*11
12
13
14
15
16
17
24
25
26
27
28
*29
30
31
32
33
34
18
*19
20
21
22
23
QTY
1
1
1
1
1
1
1
1
2
2
1
2
1
1
4
1
1
2
1
1
1
1
10
1
2
4
1
1
1
1
1
1
1
1
HOIST ACTUATOR
P/N 480075
P/N
360450
360359
360368
360367
360342
360364
360331
360345
360339
360336
360358
360346
480078
480094
360464
360360
360361
360344
360365
360330
360332
360363
360461
360362
360348
360369
360460
360462
360459
360458
360350
360466
010202
360352
DESCRIPTION
WORM BRAKE COVER
GASKET
SPRING
FLAT SPRING
RETAINER PLATE
THRUST PLATE
CAM PLATE
BRAKE BALL
BRAKE HUB
BRAKE HOUSING
GASKET
BEARING
OUTPUT SHAFT
KEY 3/8 SQ
BARTH KEY
RELIEF FITTING
REDUCER
RIGHT HAND WORM
OIL SEAL
ADAPTER
COUPLING
SPIROL PIN
GEAR HOUSING
PIPE PLUG
BUSHING
THRUST WASHER
RIGHT HAND GEAR
BUSHING
GASKET
COVER
HEX HD CAPSCREW 1/4 NC x 3/4 GR5
THRUST WASHER
HEX HD CAPSCREW 1/2 NC x 1
SOC HD CAPSCREW 1/4 NC x 1 3/4 GR5
4-10.1.0
AW480075 10/98
Courtesy of Crane.Market
ITEM
35
36
37
38
*39
40
*41
42
43
44
*45
46
QTY
4
6
4
1
1
-
-
2
1
1
1
2
HOIST ACTUATOR
P/N 480075
P/N
360463
360453
360456
-
360465
360353
360371
360455
-
360341
360366
480306
DESCRIPTION
SOC HD CAPSCREW 1/4 NC x 7/8
HEX HD w/ NYLOCK CAPSCREW 1/4 NC x 1 GR5
-
HEX HD CAPSCREW 1/8 NC x 1 1/2 GR5
THREAD SEAL
HEX JAM NUT 3/8 NC
THREAD SEAL
FLAT ALUMINUM WASHER 1/4
-
KEY
OIL SEAL
SEAL AND GASKET KIT
NOTE: ITEMS MARKED WITH AN ASTERISK (*) ARE INCLUDED IN SEAL & GASKET KIT P/N
480306 (ITEM 46).
4-10.2.0
AW480075 10/98
Courtesy of Crane.Market
IN-COMPARTMENT (IC) PENDANT INSTALLATION
5005H SERIES
4-11.0.0
AW178 12/98
Courtesy of Crane.Market
IN-COMPARTMENT (IC) PENDANT INSTALLATION
5005H SERIES
ITEM
1
4
5
2
3
8
9
6
7
10
11
12
13
14
15
QTY
-
1
1
1
1
4
1
6
6
4
4
3
2
2
2
P/N
-
480490
48091-080
480626
480493
000404
015400
019600
366097
750738
634401
330038
005500
015900
020200
-
DESCRIPTION
22 STATION TERMINAL BLOCK DECAL
22 STATION / 19 PIN SOCKET HARNESS
PENDANT BRACKET
22 STATION TERMINAL BLOCK COVER
ROUND HEAD SCREW #6-32 NC x 5/8
HEX NUT #6-32 NC
SPLIT LOCK WASHER #6
19 PIN RECEPTACLE CAP
WIRE TIE STICK ON RETAINER
WIRE TIE x 7"
CAPSCREW #10-24 NC x 3/4 SELF TAPPING
CAPSCREW 1/4-20 NC x 3/4 G5
HEX NUT 1/4-20 NC
SPLIT LOCK WASHER 1/4
4-11.1.0
AW178 12/98
Courtesy of Crane.Market
FM REMOTE INSTALLATION
5005H
4-12.0.0
AW179 3/98
Courtesy of Crane.Market
17
18
19
20
21
22
23
12
13
14
15
16
ITEM
1
4
5
2
3
8
9
6
7
10
11
4
1
1
4
2
2
1
3
2
2
2
1
QTY
1
1
1
1
1
4
1
6
6
4
4
FM REMOTE INSTALLATION
5005H
P/N
480492
480490
480491-080
480626
480493
000404
015400
019600
366097
750738
634401
330038
005500
015900
020200
480629
(SEE NOTE)
002607
015801
480537
002200
015800
680048
DESCRIPTION
CRANE PIGTAIL HARNESS
22 STATION TERMINAL BLOCK DECAL
22 STATION / 19 PIN SOCKET HARNESS
PENDANT BRACKET
22 STATION TERMINAL BLOCK COVER
RD HD #6-32 NC x 5/8
HEX NUT #6-32 NC
WASHER SP LK #6
19 PIN RECEPTACLE CAP
WIRE TIE STICK ON RETAINER
WIRE TIE x 7"
HEX HD SCREW #10-24 NC x 3/4 SELF TAPPING
HEX HD SCREW 1/4-20 NC x 3/4 G5
HEX NUT 1/4-20 NC
WASHER SP LK 1/4
FM REMOTE TRANSMITTER / RECEIVER ASSEMBLY
ANTENNA (STD)
RD HD SCREW #10-24 NC x 3/4
HEX LOCK NUT #10-24 NF x 3/4
PROPORTIONAL AMPLIFIER
RD HD SCREW #10-32 NF x 3/4
HEX LOCK NUT #10-32 NF x 3/4
CONTROL CABLE FM
NOTE: Standard antenna comes with transmitter / receiver assembly; - antenna with magnetic base (P/N 480608) can be ordered as an extra cost option.
4-12.1.0
AW179 3/98
Courtesy of Crane.Market
Courtesy of Crane.Market
ELECTRICAL ASSEMBLY
P/N 366200
ITEM
2
4
5
6
7
8
9
10
11
QTY
1
1
1
1
1
1
1
1
2
P/N
REFERENCE
REFERENCE
REFERENCE
REFERENCE
REFERENCE
REFERENCE
REFERENCE
REFERENCE
REFERENCE
DESCRIPTION
LOAD SENSOR
RELAY BOX ASSEMBLY
CONDUCTOR BOX ASSEMBLY
CONDUCTOR BOX ASSEMBLY
CONDUCTOR BOX ASSEMBLY
CONDUCTOR CABLE
POWER CONDUCTOR
CONDUCTOR
SHRINK TUBING ¼ IN. X 3 IN.
5-2.0.0
366200 2/2000
Courtesy of Crane.Market
CRANE WIRING w/ 4 & 8 FUNCTION PENDANTS
PROPORTIONAL (-200, -400)
5-3.0.0
AW353 12/97
Courtesy of Crane.Market
17
18
19
20
21
22
23
24
25
12
13
14
15
16
ITEM
1
4
5
2
3
8
9
6
7
10
11
15
1
1
1
1
1
2
1
5
1
1
1
1
1
QTY
1
1
1
1
-
4
4
1
1
1
4
CRANE WIRING w/ 4 & 8 FUNCTION PENDANTS
PROPORTIONAL (-200, -400)
750167
366973-001
480522
320355
480549
800657-009
001002
480495
636600
635200
360610
001102
320363
320357
P/N
646900
320543
-
366999
680044
366097
000404
019600
015400
480384
360549
DESCRIPTION
SWITCH
-
LOAD SENSOR ASSEMBLY
RELAY BOX ASSEMBLY
RECEPTACLE ASSEMBLY
PENDANT RECEPTACLE CAP
RD HD SCREW #6-32 x 5/8
WASHER SP LK #6
HX NUT #6-32
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY
30 AMP IN-LINE FUSE
CORD REEL ASSEMBLY
PROPORTIONAL AMPLIFIER ASSEMBLY
POWER RELAY
CONDUCTOR 16GA ST BLACK
POWER CONDUCTOR
RING TERMINAL
FLANGED SPADE 16-14 WRE TERMINAL
JUMPER
TERMINAL BLOCK
DECAL TERMINAL I.D.
WR 2RC-10 TERMINAL
RELAY PLUG
SPD LOCKING NON-INS CONNECTOR
5-3.1.0
AW353 12/97
Courtesy of Crane.Market
CRANE WIRING w/ 4 & 8 FUNCTION PENDANTS
PROPORTIONAL (-200, -400)
AW353 12/97
Courtesy of Crane.Market
CRANE WIRING w/ 4 & 8 FUNCTION PENDANTS
LESS PROPROTIONAL (-100, -300)
5-4.0.0
AW354 12/97
Courtesy of Crane.Market
5
6
7
8
9
ITEM
1
2
3
4
16
17
18
19
20
21
22
23
24
10
11
12
13
14
15
1
1
4
4
4
QTY
1
1
-
1
1
1
10
1
1
5
1
1
1
1
1
1
1
1
1
CRANE WIRING w/ 4 & 8 FUNCTION PENDANTS
LESS PROPROTIONAL (-100, -300)
P/N
646900
320543
-
366999
680044
366097
000404
019600
015400
480384
360549
750167
366973-001
366212
320355
800657-009
001002
480495
635200
360610
001102
320363
320357
480549
DESCRIPTION
SWITCH
LOAD SENSOR ASSEMBLY
-
RELAY BOX ASSEMBLY
RECEPTACLE ASSEMBLY
PENDANT RECEPTACLE CAP
RD HD SCREW #6-32 x 5/8
WASHER SP LK #6
HX NUT #6-32
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY
30 AMP IN-LINE FUSE
CORD REEL ASSEMBLY
RELIEF VALVE ASSEMBLY w/ SOLENOID
POWER RELAY
POWER CONDUCTOR
RING TERMINAL
FLANGED SPADE 16-14 WRE TERMINAL
TERMINAL BLOCK
DECAL TERMINAL I.D.
WR 2RC-10 TERMINAL
RELAY PLUG
SPD LOCKING NON-INS CONNECTOR
CONDUCTOR 16GA ST BLACK
5-4.1.0
AW354 12/97
Courtesy of Crane.Market
CRANE WIRING w/ 4 & 8 FUNCTION PENDANTS
PROP. IC (-210, -410, -411, -412)
5-5.0.0
AW355 12/97
Courtesy of Crane.Market
CRANE WIRING w/ 4 & 8 FUNCTION PENDANTS
PROP. IC (-210, -410, -411, -412)
16
17
18
19
20
10
11
12
13
14
15
25
*26
27
21
22
23
24
5
6
7
8
9
ITEM
1
2
3
4
1
1
1
36
3
1
1
1
1
4
1
1
1
1
1
5
1
1
1
1
1
4
4
QTY
1
1
1
-
*NOTE: Item 26 includes items 19, 20, & 21.
P/N
480386
646900
320543
-
366999
480626
366097
000404
019600
015400
480384
360549
750167
480522
320355
480549
800657-009
001002
480495
636600
480494
480490
001102
320363
320357
480491-080
366973-001
DESCRIPTION
CRANE PIGTAIL HARNESS
SWITCH
-
LOAD SENSOR ASSEMBLY
RELAY BOX ASSEMBLY
PENDANT RECEPTACLE BRACKET
PENDANT RECEPTACLE CAP
RD HD SCREW #6-32 x 5/8
WASHER SP LK #6
HEX NUT #6-32
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY POWER EXT
IN-LINE 30 AMP FUSE
PROP AMPLIFIER ASSEMBLY
POWER RELAY
CONDUCTOR 16GA BLACK
POWER CONDUCTOR
RING TERMINAL
FLANGED SPADE 16-14 WIRE TERMINAL
JUMPER
TERMINAL BLOCK 22 STA
DECAL 2 STA TERMINAL BLOCK
WR 2RC-10 TERMINAL
RELAY PLUG
SPD LOCKING NON-INS CONNECTOR
HARNESS ASSEMBLY
CORD REEL ASSEMBLY
5-5.1.0
AW355 12/97
Courtesy of Crane.Market
CRANE WIRING w/ 4 & 8 FUNCTION PENDANTS
LESS PROP. IC (-110, -310)
5-6.0.0
AW356 12/97
Courtesy of Crane.Market
CRANE WIRING w/ 4 & 8 FUNCTION PENDANTS
LESS PROP. IC (-110, -310)
1
1
1
34
3
1
1
1
1
4
1
1
1
1
1
5
1
1
1
1
1
4
4
QTY
1
1
1
-
16
17
18
19
20
10
11
12
13
14
15
25
*26
27
21
22
23
24
5
6
7
8
9
ITEM
1
2
3
4
P/N
480386
646900
320543
-
366999
480626
366097
000404
019600
015400
480384
360549
750167
366212
320355
480549
800657-009
001002
480495
636600
480494
480490
001102
320363
320357
480491-080
366973-001
*NOTE: Item 26 includes items 19, 20, & 21.
DESCRIPTION
CRANE PIGTAIL HARNESS
SWITCH
-
LOAD SENSOR ASSEMBLY
RELAY BOX ASSEMBLY
PENDANT RECEPTACLE BRACKET
PENDANT RECEPTACLE CAP
RD HD SCREW #6-32 x 5/8
WASHER SP LK #6
HEX NUT #6-32
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY POWER EXT
IN-LINE 30 AMP FUSE
RELIEF VALVE ASSEMBLY w/ SOLENOID
POWER RELAY
CONDUCTOR 16GA BLACK
POWER CONDUCTOR
RING TERMINAL
FLANGED SPADE 16-14 WIRE TERMINAL
JUMPER
TERMINAL BLOCK 22 STA
DECAL 2 STA TERMINAL BLOCK
WR 2RC-10 TERMINAL
RELAY PLUG
SPD LOCKING NON-INS CONNECTOR
HARNESS ASSEMBLY
CORD REEL ASSEMBLY
5-6.1.0
AW356 12/97
Courtesy of Crane.Market
CRANE WIRING w/ 8 FUNCTION PENDANT
PROP. IC & 12 FUNCTION FM REMOTE (-510,-530)
5-7.0.0
AW357 12/97
Courtesy of Crane.Market
CRANE WIRING w/ 8 FUNCTION PENDANT
PROP. IC & 12 FUNCTION FM REMOTE (-510,-530)
13
14
15
16
17
18
19
20
21
22
23
24
25
*26
27
28
8
9
10
11
12
ITEM
1
4
5
6
7
2
3
1
1
1
1
1
1
34
3
1
1
5
1
1
1
1
1
4
4
4
1
1
QTY
1
-
1
1
1
1
1
*NOTE: Item 26 includes items 19, 20, & 21.
P/N
480386
646900
320543
-
366999
480626
366097
000404
019600
015400
480384
360549
750167
480522
320355
480549
800657-009
001002
480495
636600
480494
480490
001102
320363
320357
480491-080
366973-001
480613
DESCRIPTION
CRANE PIGTAIL HARNESS
SWITCH
LOAD SENSOR ASSEMBLY
-
RELAY BOX ASSEMBLY
PENDANT RECEPTACLE BRACKET
PENDANT RECEPTACLE CAP
RD HD SCREW #6-32 x 5/8
WASHER SP LK #6
HEX NUT #6-32
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY POWER EXT
IN-LINE 30 AMP FUSE
PROP AMPLIFIER ASSEMBLY
POWER RELAY
CONDUCTOR 16GA BLACK
POWER CONDUCTOR
RING TERMINAL
FLANGED SPADE 16-14 WIRE TERMINAL
JUMPER
TERMINAL BLOCK 22 STA
DECAL 2 STA TERMINAL BLOCK
WR 2RC-10 TERMINAL
RELAY PLUG
SPD LOCKING NON-INS CONNECTOR
HARNESS ASSEMBLY
CORD REEL ASSEMBLY
DIN CONNECTOR w/ CORD
5-7.1.0
AW357 12/97
Courtesy of Crane.Market
CRANE WIRING w/ FM REMOTE, PROPORTIONAL
(-500,-520)
5-8.0.0
AW358 12/97
Courtesy of Crane.Market
CRANE WIRING w/ FM REMOTE, PROPORTIONAL
(-500,-520)
ITEM
1
4
5
6
7
2
3
8
9
10
11
12
24
25
*26
27
19
20
21
22
23
13
14
15
16
17
18
QTY
1
-
1
1
1
1
1
4
4
4
1
1
34
3
1
1
1
1
1
1
5
1
1
1
1
1
1
*NOTE: Item 26 includes items 19, 20, & 21.
P/N
480386
646900
320543
-
366999
480626
366095
000404
019600
015400
480384
360549
750167
480612
320355
480549
800657-009
001002
480495
636600
480494
480490
001102
320363
320357
480491-080
366973-001
DESCRIPTION
CRANE PIGTAIL HARNESS
SWITCH
LOAD SENSOR ASSEMBLY
-
RELAY BOX ASSEMBLY
PENDANT RECEPTACLE BRACKET
PENDANT RECEPTACLE CAP
RD HD SCREW #6-32 x 5/8
WASHER SP LK #6
HEX NUT #6-32
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY POWER EXT
IN-LINE 30 AMP FUSE
DIN PLUG ASSEMBLY
POWER RELAY
CONDUCTOR 16GA BLACK
POWER CONDUCTOR
RING TERMINAL
FLANGED SPADE 16-14 WIRE TERMINAL
JUMPER
TERMINAL BLOCK 22 STA
DECAL 2 STA TERMINAL BLOCK
WR 2RC-10 TERMINAL
RELAY PLUG
SPD LOCKING NON-INS CONNECTOR
HARNESS ASSEMBLY
CORD REEL ASSEMBLY
5-8.1.0
AW358 12/97
Courtesy of Crane.Market
PENDANT RECEPTACLE ASSEMBLY
P/N 680044
ITEM
1
2
3
4
5
6
7
QTY
1
1
8'
1
1
-
4"
P/N
366095
480515
480594
480385
001105
002012
490243
DESCRIPTION
19 PIN RECEPTACLE
CABLE CLAMP
19 PIN CONDUCTOR CABLE
CONDUCTOR ASSEMBLY
BUTT CONNECTOR TERMINAL NON-INSS 10-12 GA
RING TERMINAL #6 / 18-22 GA
HEAT SHRINK TUBING
AW680044 3/98
5-9.0.0
Courtesy of Crane.Market
REMOVABLE 4 FUNCTION 19 PIN PENDANT
ASSEMBLY P/N 680083
5-10.0.0
AW680083 3/98
Courtesy of Crane.Market
REMOVABLE 4 FUNCTION 19 PIN PENDANT
ASSEMBLY P/N 680083
13
14
15
16
17
18
19
20
21
22
8
9
10
11
12
ITEM
1
4
5
6
7
2
3
4
4
21"
1
9
1
1
6"
4
3
30'
2
4
2
4
QTY
1
4
10
2
1
1
4
P/N
631601
631700
634200
640300
005001
005101
633801
480594
634401
536600
000101
675271
642100
019700
800580
004700
622346
622347
002012
366098
480515
490243
DESCRIPTION
PENDANT HOUSING
BOTTOM COVER
TOGGLE SWITCH
TOGGLE SWITCH BOOT
ST SLT PAN HD SCREW #8 x 3/4
ST SLT PAN HD SCREW #8 x 1 1/4
CABLE ADAPTER
19 PIN CONDUCTOR CABLE
TY-RAP CABLE TIE
JUMPER
RING TERMINAL #6 / 14-16 GA
NUT
O-RING
SPLIT LOCK WASHER #8 PLATED
3/4 WIDE OKONITE RUBBER TAPE
ST SLT PAN HD SCREW #8 x 1 1/2
CONDUCTOR ASSEMBLY 2 1/8
CONDUCTOR ASSEMBLY 3 1/8
RING TERMINAL #6 / 18-22 GA
19 PIN PLUG
CABLE CLAMP
HEAT SHRINK TUBING
5-10.1.0
AW680083 3/98
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
STANDARD 4 FUNCTION PENDANT ASSEMBLY
P/N 680037
5-12.0.0
AW680037 3/98
Courtesy of Crane.Market
*8
9
6
7
10
11
12
13
14
15
16
17
18
19
ITEM
1
4
5
2
3
4
1
4
1
2
2
5
4
4
1
1
2
4
3
QTY
1
5
1
1
5
STANDARD 4 FUNCTION PENDANT ASSEMBLY
P/N 680037
P/N
480501
480513
*REF
640300
480567
002607
015801
634200
480504
480516
680042
*REF
660302
636600
622346
622,347
480598
750090
750737
DESCRIPTION
PENDANT HOUSING
COVER PLATE DECAL
NUT
TOGGLE SWITCH BOOT
HUBBELL CONNECTOR CORD GRIP
SCREW #10-24 NC x 3/4
HEX LOCK NUT #10-24 NC
TOGGLE DPDT SWITCH
BACK PLATE
ST RD HD SCREW #6 x 3/4
CABLE ASSEMBLY
LOCK WASHER
CONDUCTOR ASSEMBLY
JUMPER
CONDUCTOR ASSEMBLY 2 1/8
CONDUCTOR ASSEMBLY 3 1/8
TRIGGER OPENING COVER
TOGGLE ON/OFF SWITCH
CABLE TIE
*NOTE: Item 8 includes items 3 & 12.
5-12.1.0
AW680037 3/98
Courtesy of Crane.Market
PROPORTIONAL 4 FUNCTION PENDANT ASSEMBLY
P/N 680038
5-13.0.0
AW680038 3/98
Courtesy of Crane.Market
PROPORTIONAL 4 FUNCTION PENDANT ASSEMBLY
P/N 680038
17
18
19
20
21
22
23
24
12
13
14
15
16
ITEM
1
4
5
2
3
8
9
6
7
10
*11
1
4
1
1
2
1
4
3
1
4
1
4
4
QTY
1
4
1
1
4
1
1
1
4
2
2
480504
480516
680043
*REF
660302
480524
480523
005003
636600
622346
622347
750737
750090
P/N
480501
480513
*REF
640300
480567
002607
015801
480507
480506
480517
634200
*NOTE: Item 11 includes items 3 & 15.
DESCRIPTION
PENDANT HOUSING
COVER PLATE DECAL
NUT
TOGGLE SWITCH BOOT
HUBBELL CONNECTOR CORD GRIP
SCREW #10-24 NC x 3/4
HEX LOCK NUT #10-24 NC
POTENTIOMETER ASSEMBLY
TRIGGER
SOC HD SCREW #10-32 NF x 5/8
TOGGLE DPDT SWITCH
BACK PLATE
ST RD HD SCREW #6 x 3/4
CABLE ASSEMBLY
LOCK WASHER
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY
TRIGGER RETURN SPRING
PAN HD ST SCREW #6 x 3/8
JUMPER
CONDUCTOR ASSEMBLY 2 1/8
CONDUCTOR ASSEMBLY 3 1/8
CABLE TIE
TOGGLE ON/OFF SWITCH
5-13.1.0
AW680038 3/98
Courtesy of Crane.Market
STANDARD 8 FUNCTION PENDANT ASSEMBLY
P/N 680039
5-14.0.0
AW680039 3/98
Courtesy of Crane.Market
*8
9
6
7
10
11
12
13
14
15
16
17
18
19
20
21
ITEM
1
4
5
2
3
4
1
4
1
2
2
8
3
4
1
3
1
2
1
4
3
QTY
1
8
1
1
8
STANDARD 8 FUNCTION PENDANT ASSEMBLY
P/N 680039
P/N
480501
480513
*REF
640300
480567
002607
015801
634200
480504
480516
680041
*REF
660302
636600
622346
622347
622000
750090
480526
750737
480598
DESCRIPTION
PENDANT HOUSING
COVER PLATE DECAL
NUT
TOGGLE SWITCH BOOT
HUBBELL CONNECTOR CORD GRIP
SCREW #10-24 NC x 3/4
HEX LOCK NUT #10-24 NC
TOGGLE DPDT SWITCH
BACK PLATE
ST RD HD SCREW #6 x 3/4
CABLE ASSEMBLY
LOCK WASHER
CONDUCTOR ASSEMBLY
JUMPER
CONDUCTOR ASSEMBLY 2 1/8
CONDUCTOR ASSEMBLY 3 1/8
TOGGLE SPDT SWITCH
TOGGLE ON/OFF SWITCH
CONDUCTOR ASSEMBLY
CABLE TIE
TRIGGER OPENING COVER
*NOTE: Item 8 includes items 3 & 12.
5-14.1.0
AW680039 3/98
Courtesy of Crane.Market
PROPORTIONAL 8 FUNCTION PENDANT ASSEMBLY
P/N 680040
Notes:
5-15.0.0
AW680040 8/98
Courtesy of Crane.Market
PROPORTIONAL 8 FUNCTION PENDANT ASSEMBLY
P/N 680040
ITEM
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
3
4
5
6
1
2
7
8
9
10
QTY
4
1
4
1
8
3
1
1
1
4
4
3
1
3
1
2
8
8
1
2
1
1
2
1
1
1
PART NUMBER
634200
480504
001004
680113
*REF
660302
480524
480523
005003
636600
622346
622347
622000
750090
480526
750737
480501
480518
*REF
640300
480567
002607
015801
480507
480506
480517
DESCRIPTION
PENDANT HOUSING
COVER PLATE DECAL
NUT
TOGGLE SWITCH BOOT
HUBBELL CONNECTOR CORD GRIP
SCREW #10 NC x 3/4
HEX LOCK NUT #10 NC
POTENTIOMETER ASSEMBLY
TRIGGER
SOC HD SCREW #10 NF x 5/8
TOGGLE DPDT SWITCH
BACK PLATE
ST RD HD SCREW #6 x 3/4
CABLE ASSEMBLY
LOCK WASHER
CONDUCTOR ASSEMBLY
CONDUCTOR ASSEMBLY
TRIGGER RETURN SPRING
PAN HD ST SCREW #6 x 3/8
JUMPER
CONDUCTOR ASSEMBLY 2 1/8
CONDUCTOR ASSEMBLY 3 1/8
TOGGLE SPDT SWITCH
TOGGLE ON/OFF SWITCH
CONDUCTOR ASSEMBLY
CABLE TIE
1.
Items 5 & 14 may be purchased as replacement cable assembly using P/N 380000.
2.
Items 6, 7, 8, 9, 10, 18, & 19 may be purchased as a replacement potentiometer kit using P/N 380003.
3.
Items 1, 2, 12, & 13 may be purchased as a replacement housing kit using P/N 380002.
4.
Items 3, 4, 11, & 15 may be purchased as a replacement dpdt switch kit using P/N 380005.
5.
Items 3, 4, 15, & 24 may be purchased as a replacement on/off switch kit using P/N 380001.
6.
Items 3, 4, 11, & 23 may be purchased as a replacement spdt switch kit using P/N 380004.
5-15.1.0
AW680040 8/98
Courtesy of Crane.Market
PENDANT CABLE ASSEMBLY
P/N 680041
ITEM
1
2
5
6
3
4
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"
5-16.0.0
AW680041 3/98
Courtesy of Crane.Market
PENDANT CABLE ASSEMBLY
P/N 680113
ITEM
1
2
3
6
7
4
5
QTY
1
1
30'
2
2
13
6"
P/N
366098
480515
480594
000101
480510
002012
490243
DESCRIPTION
19 PIN BAYONET PLUG
CABLE CLAMP
19 PIN CONDUCTOR CABLE
RING TERMINAL #6 / 14-16 GA
RING TERMINAL #6 / 14-16 GA
FEMALE BULLET CONNECTOR
HEAT SHRINK TUBING x 6"
5-17.0.0
AW680113 3/98
Courtesy of Crane.Market
PENDANT CABLE ASSEMBLY
P/N 680042
ITEM
3
4
5
6
1
2
QTY
1
1
30'
2
9
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"
5-18.0.0
AW680042 3/98
Courtesy of Crane.Market
PENDANT CABLE ASSEMBLY
P/N 680043
ITEM
1
4
5
6
7
2
3
QTY
1
1
30'
2
2
9
6"
P/N
366098
480515
480594
000101
480510
002012
490243
DESCRIPTION
19 PIN BAYONET PLUG
CABLE CLAMP
19 PIN CONDUCTOR CABLE
RING TERMINAL #6 / 14-16 GA
FEMALE BULLET CONNECTOR
RING TERMINAL #6 / 18-22 GA
HEAT SHRINK TUBING x 6"
5-19.0.0
AW680043 3/98
Courtesy of Crane.Market
Courtesy of Crane.Market
FM REMOTE TRANSMITTER
P/N 480623
ITEM
1
2
4
QTY
1
6
1
P/N
480621-002
640300
480605
DESCRIPTION
FM Remote Transmitter (Toggle Pistol Grip)
Toggle Boot
4 Volt Battery
5-21.0.0
AW480623 2/2000
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
HYDRAULIC DIRECT MOUNT PUMP
P/N 360029 - 4004H SERIES
Adapter: SAE “A” 2 bolt flange (direct mount only).
Shaft: Straight shaft key 3/4 dia. x 2 3/4 long.
3/16 sq. key x 1 5/8 long.
NOTES:
1. Pump speed - 800 RPM for 4004H and 950 RPM for 5005H.
2. To order HYDRAULIC PUMP ASSEMBLY use P/N 360030 - which consists of
HYDRAULIC PUMP (P/N 360029), 3/4-14NPT/1-5/16-12 JIC ADAPTER (P/N 360055)
SUCTION AND 3/4-14 NPT/ 1 1/16-12 JIC (750399) PRESSURE.
3. For SEAL KIT use P/N 480018-001 .
4. For SERVICE KIT use P/N 480018-002 .
6-8.0.0
AW360029 10/98
Courtesy of Crane.Market
Courtesy of Crane.Market
TRAVELING BLOCK ASSEMBLY
P/N 360480
ITEM
1
2
3
4
5
6
7
8
9
10
QTY
2
1
1
1
1
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
8-2.0.0
AW360480 8/98
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
Courtesy of Crane.Market
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