8406 H OWNERS MANUAL - Auto Craneautocrane.us/wp-content/uploads/8406H-Wireless-Hard-Wired-480899... · 8406 H OWNERS MANUAL Manual No. 480899 ... WIRE HARNESS ASSEMBLY 6-2 ... Auto

8406 HOWNERS MANUAL

Manual No. 480899Rev. 07/26/2004

Serial No. __________________

Mailing Address:P.O. Box 580697Tulsa, OK 74158-0697Physical Address: Phone (918) 836-04634707 N. Mingo Rd. Fax (918) 834-5979Tulsa, OK 74117-5904 http://www.autocrane.com

To: Fax:From: Date:Re: Pages:

Name: Phone:Address:City: State: Zip:Contact:

Name:Address:City: State: Zip:Contact:

VIN #

ONE REGISTRATION FORM PER UNIT (CRANE OR BODY)Registration form must be mailed or faxed within 15 days of customer installation.

Mail to:Warranty DepartmentAuto Crane Company

P.O. Box 581510Tulsa, OK 74158-0697

Date Product Delivered: Date Processed:** For Auto Crane use only

Product Information: (Required for Warranty Activation)

Model No.: Serial No.:

E-mail Address:

Distributor Information: (Required for Warranty Activation)

Product Registration

E-mail Address:

(Required for Warranty Activation)

Auto Crane Warranty Registration

(918) 834-5979Warranty Department

End User Information:

Fax Transmission

Warranty Registration Rev. 072403

8406H SERIESOWNER’S MANUAL – REVISION RECORD

i

RevisionDate

Section(s)Or

Page(s)Description of Change

09/02/03 Last page New 2-year warranty policy to replace 1-year warranty policy4/23/04 Page 3-2, 5-2 & 8-9 Updated receiver & transmitter to 2nd generation07/26/04 Pages 10-2.0.0, 10-

3.0.0, 10-5.0.0, 10-6.0.0, 10-9.0.0 &10-10-.0.0

Added voltage relay circuit

WARNINGS

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 state are also considered intermediate stage manufacturing and must

be certified as to compliance. The installer of this crane and body is considered on of the manufac-

turers 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 responsiblity of the installer to comply with the OSHA Truck Crane

Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).

* WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL POWER LINES!

Death or serious injury will result from boom, line, or load contacting electric lines. Do not use

crane within 10 feet (3.05m) of electric power lines carrying up to 50,000 volts. One foot additional

clearance is required for every additional 30,000 volts or less. SEE DANGER DECAL (P/N 040529)

in this Owner's Manual.

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

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

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

* Wrap cable around load!

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

* Weld, modify, or use unauthorized components on any Auto Crane unit! This will void any

warranty or liability. Also failure of the crane may result.

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

* Use a sling bar or anything larger than the hook throat that could prevent the hook latch from

closing, thus negating the safety feature!

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

* WARNING! In using a hook with latch, ALWAYS make sure that the hook throat is closed before

lifting a load! Proper attention and common sense applied to the use of the hoist hook and various

slings will prevent possible damage to material being hoisted and may prevent injury to personnel.

* WARNING! Failure to correctly plumb and wire crane can cause inadvertent operation and damage

to crane and/or personnel!

* WARNING! Auto Crane Company remote controlled cranes are not designed or intended to be

used for any applications involving the lifting or moving of personnell.

* WARNING! ALWAYS operate the crane in compliance with the load capacity chart. DO NOT

USE the overload shutdown device to determine maximum rated loads, if the crane is equipped

with this type of device.

TABLE OF CONTENTS 8406H SERIES

6/02/2003

INTRODUCTION 1-1

OPERATING PRACTICES & WARNINGS 2-2

OPERATION OF UNIT / OUTRIGGERS 2-3

CONTROLLER OPERATION 2-4

QUALIFCATIONS FOR OPERATORS 2-6

INSPECTION, TESTING, & MAINTENCE 2-9

DECAL SECTION 2-14

GENERAL DIMENSIONS 3-1

MOUNTING AND INSTALLATION 3-2

LUBRICATION AND MAINTENANCE SCHEDULE 4-1

PEDESTAL ASSEMBLY 5-1

BOOM ASSEMBLY 5-3

ROTATION GEAR BOX 5-5

HOIST ASSEMBLY 5-7

GENERAL ASSEMBLY 5-11

ELECTRICAL SCHEMATIC 6-1

WIRE HARNESS ASSEMBLY 6-2

HYDRAULIC SECTION 7-1

DIAGNOSTICS 8-1

LOAD CHART 9-1

HARD WIRED SERIES, SUPPLIMENTAL INFORMATION 10-1

WARRANTY LAST PAGE

Auto Crane products are designed to provide manyyears of safe, trouble-free, dependable service whenproperly used and maintained.

To assist you in obtaining the best service fromyour crane and to avoid untimely crane and/or vehiclefailure, this manual provides the following operatingand service instructions. It is specificallyrecommended that all operating and service personnelconsider this manual as mandatory material for readingand study before operating or servicing Auto Craneproducts. It is highly recommended that crane owners,equipment managers and supervisors also read thismanual.

Auto Crane has incorporated several safety featuresin the 8406H crane for your protection.

For your convenience the overall dimensions of the8406H crane are included on the General DimensionDrawing. Rotation and turning radius are also listed onthat drawing.

Remember, the crane adds weight to the vehicle.Adding weight may change the driving and ridingcharacteristics of the vehicle unless the appropriateoverload spring(s) are installed on the truck. Thepayload of the vehicle is reduced by the weight of thecrane. The operator should exercise care when loadingthe vehicle. Distributing the payload on the vehicleevenly will greatly improve the driving and ridingcharacteristics of the vehicle.

Auto Crane Company issues a limitedwarranty certificate with each unit sold.See last page for warranty policy.

The 8406H cranes are attached directly to your 12volt truck electrical system. The power cable isincluded with the crane. The 8406H is another highlyefficient Auto Crane product. The use of amaintenance-free battery is not recommended for use onany Auto Crane product. The recommended alternatorand battery that will give the longest life with the mostuseful duty cycle is a 75 amp alternator with a 500 coldcranking amp battery. These specifications should beconsidered minimum.

It has always been Auto Crane Company policy tohandle all warranty claims we receive as promptly aspossible. If a warranty claim involves discrepantmaterial or workmanship, Auto Crane will takeimmediate corrective action. It is understandable that

Auto Crane Company cannot assume responsibility ofliability when it is obvious that our products have beenabused, misused, overloaded or otherwise damaged byinexperienced persons trying to operate the equipmentwithout reading the manual.

Auto Crane will not assume responsibilityor liability for any modifications or changesmade to unit, or installation of component partsdone without authorization.

Auto Crane maintains a strong distributor networkand a knowledgeable Customer Service Department. Inmost cases, an equipment problem is solved via phoneconversation with our customer service department. Thecustomer service department also has the ability to bringa local distributor, a regional sales manager, or a factoryserviceman into the solution of an equipment problem.If, through no fault of Auto Crane Company, it isnecessary to send an experienced factory serviceman ona field service call, the rates stated in the Auto CraneDistributor's Flat Rate Manual will apply.

Auto Crane Company's extensive Research andDevelopment Program allow our customers to use thebest equipment on the market. Our Engineering Staffand our knowledgeable sales people, are alwaysavailable to our customers in solving crane andwinch-type application problems. When in doubt, callthe Auto Crane factory.

DISTRIBUTOR ASSISTANCE:Should you require any assistance not given in this

manual, we recommend that you consult your nearestAuto Crane Distributor. Our distributors sell authorizedparts and have service departments that can solve almostany 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 possiblesituations. If you require additional information, pleasecontact the Auto Crane Company at the followingtelephone number: (918) 836-0463. The informationcontained in the manual is in effect at the time of thisprinting. Auto Crane Company reserves the right toupdate this material without notice or obligation.

INTRODUCTION8406H SERIES

1-1 INTRO 8406H 1/02

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

2. WARNING: Never weld, modify, or use unauthorizedcomponents / parts on any Auto Crane unit. This willvoid any warranty or liability. Also, failure of thecrane may result.

3. Make certain the vehicle meets minimum chassisrequirements. (These requirements do not guaranteeunit stability.)

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

5. Visual inspections and tests should be conducted atthe beginning of each shift each day to ensure that thecrane and all its operating systems are in goodcondition and working order before it is used.

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

7. If a hydraulic break occurs, leave the area of the breakand do not attempt to stop the break by hand as thehydraulic oil may be hot and under high pressurewhich can cause serious injury. Shut the system downas soon as possible.

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

9. Oil gears as required.10. Stop all operations when cleaning, adjusting or

lubricating the machine.11. Keep dirt and grit out of moving parts by keeping a

crane clean. Make sure machine is free of excess oil,grease, mud and rubbish, thus reducing accidents andfire hazards.

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

13. Locate the vehicle at the work site for the best stabilitypossible.

14. Keep the vehicle in a level position while loading orunloading.

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

16. WARNING: NEVER OPERATE THE CRANENEAR ELECTRICAL POWER LINES. Auto CraneCompany recommends that the crane never be anycloser to a power line (including telephone lines) than10 feet at any point.

17. Allow the vehicle engine to warm up before operatingcrane.

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

19. Deduct the weight of the load handling equipmentfrom the load rating to determine how much weightcan be lifted.

20. All load ratings are based on crane capacity, NOT thevehicle stability.Remember in lifting a heavy load, the weight cancreate enough tipping moment to overturn the vehicle.

21. Always comply with load chart capacities, (centerlineof rotation to hook).

22. Secure all loads before lifting.23. Always set the emergency brake before beginning

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

operation.25. Operate control levers slowly and smoothly in order to

meter oil flow for safe operation.26. Always use outriggers from vehicle to the ground

during crane operation. Ensure that they are firmlypositioned on solid footings. Stand clear of outriggerswhile they are being extended.

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

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

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

30. Always store outriggers before transportation.

8406HSAFT 06/022-1.0.0

--- IMPORTANT --- SAFETY TIPS AND PRECAUTIONS

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

31. Always store the crane in its stowed position fortransportation.

32. Remember the overall height of the entire unit forgarage door clearance or when moving under objectswith low overhead clearance.

33. Disengage power takeoff (PTO) before moving thevehicle.

34. Always walk around the vehicle before moving.35. Never drive with a load suspended from crane.36. Do not take your eyes off a moving load. Look in the

direction you are moving.37. Never swing a load over people.38. Do not stop the load sharply in midair so that it swings

like a pendulum. Meter the control levers to avoid thissituation.

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

40. Keep the load directly and vertically under the boompoint at all times. Crane booms are designed primarilyto handle vertical loads, not side lifts.WARNING: Never attempt to lift, drag, tow or pull aload from the side. The boom can fail far below itsrated capacity.

41. Do not push down on anything with boom extensions,lift or outer boom function.

42. Do not lift personnel with any wire rope attachment orhook. There is no implied warranty or responsibilityfor such purposes.

43. WARNING: In using a safety hook, ALWAYS closethe hook throat before lifting a load. Proper attentionand common sense applied to the use of the hook andvarious slings will prevent possible damage to materialbeing hoisted and may prevent injury to personnel.

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

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

46. If the crane is equipped with an optional winch:do NOT allow personnel to ride on loadline,hook, load, or any other device attached to winchline.do NOT extend boom without reeling off line atthe same time when using winch.do pull load-block up against the boom tip.

47. Do not wrap the wire rope around sharp objects whenusing winch.

48. WARNING: Never unreel last 5 wraps of cable fromdrum.

8406HSAFT 06/02

--- IMPORTANT --- SAFETY TIPS AND PRECAUTIONS

2-1.1.0

1. Make certain the vehicle meets minimum chassisrequirements. (These requirements do not guaranteeunit stability)

2. Make certain the crane is installed per factoryspecifications. Contact your local Distributor or theAuto Crane factory if any questions arise.

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

4. ALWAYS set the vehicle emergency brake beforebeginning crane operations.

5. ALWAYS use outriggers from vehicle to the groundduring crane operation. Make sure they are firmlypositioned on solid footings.

6. All load ratings are based on crane capacity, NOTtruck/crane stability.

7. Keep objects and personnel clear of crane path duringoperation.

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 thevehicle.

10. ALWAYS keep load as close to ground as possible.11. Hydraulic hoses need to be inspected frequently for

signs of deterioration, and be replaced as required.12. The hoist hook is an important item that an operator

should consider and use properly. It should bechecked on a daily basis for distortion or cracks.

13. ALWAYS store outriggers before road travel.

14. WARNING! NEVER OPERATE THE CRANENEAR ELECTRICAL POWER LINES! Death orserious injury will result from boom, line, or loadcontacting electric lines. Do not use crane within 10feet (3.05m) of electric power lines carrying up to50,000 volts. One foot additional clearance isrequired for every additional 30,000 volts or less.

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

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

17. WARNING! NEVER wrap cable around load!18. WARNING! NEVER attempt to lift or drag a load

from the side! The boom can fail far below its ratedcapacity.

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

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

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

22. WARNING! In using a hook with latch, ALWAYSinsure that the hook throat is closed before lifting aload! Proper attention and common sense applied tothe use of the hoist hook and various slings willprevent possible damage to material being hoisted andmay prevent injury to personnel. Switch on that willcause unsafe operating conditions! WARNING! NEVER hold any Control SelectSwitch on that will cause unsafe operating conditions!

--- IMPORTANT --- OPERATING PRACTICES & WARNINGS

WARNING!Auto Crane Company remote controlled, stiff boom cranesare not designed or intended to be used for any applicationsinvolving the lifting or moving of personnel.

2 - 2 SAFTIPS 1/02

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

2. A routine inspection of the crane should be mandatorybefore each operating day. Any defects should becorrected immediately.

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

4. Keep the vehicle as level as possible during operation.5. For electric cranes, engage emergency brake and

leave ignition on with transmission in neutral (or inpark for automatic transmissions). Activate any cranepower switches. For Auto Crane units requiringbattery and hydraulic operation, engage emergencybrake, place gear selector in neutral, press clutch,activate PTO, release clutch and after hydraulic fluidis warm, set throttle control to proper engine speed.

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

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

8. Always boom up before rotating so the boom willclear the required boom support.

9. When extending the boom, always maintain clearancebetween the boom crown and the traveling block orhoist hook.

10. Always observe safe and practical operation to avoidpossible accidents. Refer to Safety Tips andPrecautions.

11. After completing lifting operations, return the boom tostowed position on the boom support. Avoidunneeded pressure on the boom support.

12. Store transmitter in proper location (in cab or storagearea).

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

14. Check work area for any tools or equipment notstored.

15. Release throttle control, depress clutch and disengagePTO. Deactivate any crane power switches.

16. Report any unusual occurrence during crane operationthat may indicate required maintenance or repair.

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

2 - 3OPER 1/02

--- IMPORTANT --- OPERATION OF UNIT

OPERATION OF OUTRIGGERS

For hydraulic outriggers:1. Shift crane/outrigger control valve to

"outrigger" position.2. Operate the outrigger control valves (located on

the outrigger cylinders) to position theoutriggers.

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

4. Crane is now ready to operate.

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.

Transmitter Layout: The red light to the left of the Power On/Off button indicates low transmitter battery.(see “Charging the Transmitter”)

The green light to the right of the Power On/Off button indicates that the unit is transmitting. This light willcome on when a function is activated.

In addition to the two lights mentioned above there are four function toggle switches. These functions fromleft to right are used to raise and lower the boom, raise and lower the hoist cable, rotate the crane and extendand retract the boom. There are also buttons for auxiliary functions such as Engine Start/Stop and Engine FastIdle.

Power On/Off (E-Stop) Button: To turn the transmitter on, press and hold the Power On/Off button, releaseonce the transmit light becomes solid. To turn the unit off, press and hold the power button, release once thetransmit light stops flashing. When this button is pressed both the red battery low and the green transmit lightwill flash alternately and stop flashing once the unit is either on or off.

When turning the unit off, it will first send the emergency stop signal to the crane, then power down. Whenthe transmitter is powered back up, the system will be in emergency stop mode and EC18 will be displayedwhen a function is activated. To exit E-Stop mode, press the red button once momentarily.

IMPORTANT – THE POWER ON/OFF BUTTON ALSO OPERATES AS AN E-STOP. PRESS THEBUTTON MOMENTARILY TO DISABLE CRANE FUNCTIONS. THE E-STOP WILL NOT STOPTHE TRUCK ENGINE.

Function Switches: To operate a function, toggle one of the function switches with either the thumb of thehand holding the unit or the thumb or fingers of the opposite hand. Using the forefinger of the hand holdingthe unit, slowly pull the trigger back to start the function. The speed of the function increases as the trigger ispulled. More than one function can be activated at one time.

NOTE: A FUNCTION SWITCH MUST BE ACTIVATED BEFORE THE TRIGGER IS PULLED ORTHE CRANE WILL NOT OPERATE.

2 - 4OPER 7/02

CONTROLLER OPERATIONS

Auxiliary Buttons:

Press the Engine Fast/Slow button to provide a maintained voltage to a throttle control if oneis installed.

Press the Engine Start/Stop button to start and stop the engine if wired to do so.

Safety Features:

For safety reasons the speed of all functions, excluding the hoist, is reduced when the liftcylinder pressure exceeds a set pressure. This will occur under load or under boom down operation.To limit slow operation of an unloaded crane, activate boom up momentarily after booming down torelieve cylinder pressure created by the counterbalance valve.

The crane is also equipped with an anti-bridging feature. The logic in the receiver will notallow the operator to rest the boom of the crane on a load supporting structure and lift a load. Doingso is dangerous and could damage the crane. When the crane is bridged, the receiver will display‘RSBM’ which requires the boom to be raised. This feature is disabled when the crane is in the‘HOME’ position to allow for stowing.

Operation Failure:

If the crane does not operate as expected, observe the readout through the window on thereceiver and refer to the front panel for explanation. The codes are further explained in the Diagnos-tics section of this manual. Please note that ‘NRML’ is displayed when the crane is operatingnormally and ‘HOME’ is displayed when the crane is forward and in a position to be stowed.“NRML” and “Home” will only be displayed when a function is activated, “EC01” is displayed whenno function is activated.

Charging the Transmitter:

The transmitter can be charged using one of three methods. It can be charged with thecigarette lighter charger, the pendant cable or the optional AC adapter (P/N 366505000). To chargethe transmitter with the pendant cable, the crane must have electrical power. The crane can beoperated by pendant or by FM remote therefore the battery can be charged without suspending opera-tion of the crane.

The transmitter should be fully charged after approximately 6 to 8 hours of charging. Charg-ing the transmitter for extended periods (3 or 4 days) is not recommended. Doing so will eventuallydegrade the battery and it will not keep a good charge.

2 - 5OPER 1/02

CONTROLLER OPERATION

OPERATORS

1 Crane operation shall be limited to personnel with thefollowing 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).

2 No one other than the personnel specified above shallenter the operating area of a crane with the exceptionof persons such as oilers, supervisors, and thosespecified persons authorized by supervisors whoseduties require them to do so and then only in theperformance of their duties and with the knowledgeof the operator or other persons.

QUALIFICATIONS FOR OPERATORS

3 Operators shall be required by the employer to pass apractical operating examination. Qualifications shallbe limited to the specific type of equipment for whichexamined.

4 Operators and operator trainees shall meet thefollowing physical qualifications:A. Vision of at least 20/30 Snellen in one eye and 20/50

in the other, with or without corrective lenses.B. Ability to distinguish colors, regardless of position,

if colors differentiation is required for operation. C. Adequate hearing with or without hearing aid for the

specific operation.

5 Evidence of physical defects or emotional instabilitywhich render a hazard to operator or others, which inthe opinion of the examiner could interfere with theoperator's performance may be sufficient cause fordisqualification. In such cases, specialized clinical ormedical judgment and tests may be required.

6 Evidence that the operator is subject to seizures orloss of physical control shall be sufficient reason fordisqualification. Specialized medical tests may berequired to determine these conditions.

7 Operators and operator trainees should have normaldepth perception, coordination, and no tendencies todizziness or similar undesirable characteristics.

8 In addition to the above listed requirements, theoperator shall:A. Demonstrate the ability to comprehend and interpret

all labels, operator's manuals, safety codes and otherinformation pertinent to correct crane operations.

B. Possess knowledge of emergency procedures andimplementation of same.

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

D. Be familiar with the applicable safety regulations. E. Understand responsibility for maintenance

requirements of crane. F. Be thoroughly familiar with the crane and its control

functions. G. Understand the operating procedures as outlined by

the manufacturer.

CONDUCT OF OPERATORS

9 The operator shall not engage in any practice whichwill divert his attention while actually operating thecrane.

10 Each operator shall be responsible for thoseoperations under the operator's direct control.Whenever there is any doubt as to safety, theoperator shall consult with the supervisor beforehandling the loads.

11 The operator should not leave a suspended loadunattended unless specific precautions have beeninstituted and are in place.

12 If there is a warning sign on the switch or enginestarting controls, the operator shall not close theswitch or start the engine until the warning sign hasbeen removed by the appointed person.

13 Before closing the switch or starting the engine, theoperator 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. B. land the suspended load and boom, if practical.

15 The operator shall be familiar with the equipmentand its proper care. If adjustments or repairs arenecessary, the operator shall report the same

QUALIFICATIONS FOR AND CONDUCT OF OPERATORS ANDOPERATING PRACTICES

QUAL 7/982 - 6

promptly to the appointed person, and shall alsonotify the next operator.

16 All controls shall be tested by the operator at the startof each shift. If any controls do not operate properly,they shall be adjusted or repaired before operationsare begun.

17 Stabilizers shall be visible to the operator whileextending or setting unless operator is assisted by asignal person.

OPERATING PRACTICES

HANDLING THE LOAD

18 Size of loadA. 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 shallascertain that the weight of the load does not exceedthe crane rated load at the radius at which the load isto be lifted.

19 Attaching the loadA. 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 loadA. 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 fewinches.

D. Means are provided to hold the vehicle stationarywhile operating the crane.

E. Before starting to lift, the hook shall brought overthe load in such a manner as to minimize swinging.

F. During lifting care shall be taken that:

1. there is no sudden acceleration ordeceleration of the moving load.

2. load, boom or other parts of the crane donot contact any obstruction.

G. Cranes shall not be used for dragging loadssideways.

H. This standard recognizes that articulating boomcranes are designed and intended for handlingmaterials. They do not meet personnel lift or elevatorrequirements. Therefore, no lifting, lowering,swinging or traveling shall be done while a person ison the hook or load. Hook attached suspended workplatforms (baskets) shall not be used with cranescovered by this standard. Work platforms attached tothe boom must be approved by crane manufacturer.

I. The operator should avoid carrying loads overpeople.

J. When the crane is so equipped, the stabilizers shallbe fully extended and set. Blocking under stabilizersshall 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 nototherwise supplied, it should be provided by timbers,cribbing, or other structural members to distributethe load so as to not exceed allowable bearingcapacity or the underlying material.

L. In transit, the boom shall be carried in stowedposition.

M. When rotating the crane, sudden starts and stopsshall be avoided. rotational speed shall be such thatthe load does not swing out beyond the radius atwhich it can be controlled.

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

O. No person should be permitted to stand or passunder a suspended load.

21 Stowing procedure. Follow the manufacturer'sprocedure and sequence when stowing andun-stowing the crane.


QUAL 7/982 - 7

MISCELLANEOUS

OPERATING NEAR ELECTRICAL POWERLINES

22 Cranes shall be operated so that no part of the craneor load enters into the danger zone shown above.

EXCEPTIONS

A. The danger zone may be entered after confirmationby an appointed person that the electricaldistribution and transmission lines have beende-energized and visibly grounded at the point ofwork; or

B. The danger zone may be entered if insulatingbarriers (not a part of nor an attachment to the crane)have been erected to prevent physical contact withthe lines.

23 For lines rated 50 kV or below, minimum clearancebetween 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 nearoverhead lines, because they can move horizontally orvertically due to wind, moving the danger zone to newpositions.

25 In transit with no load and boom lowered theclearance shall be specified in Table 1.

26 A qualified signalperson shall be assigned to observethe clearance and give warning before approachingthe above limits.A. Any overhead wire shall be considered to be an

energized line unless and until the person owningsuch line or the electrical utility authorities verifythat it is not an energized line.

B. Exceptions to this procedure, if approved by theadministrative or regulatory authority if the alternateprocedure provides equivalent protection and setforth in writing.

C. Durable signs shall be installed at the operator'sstation and on the outside of the crane, warning thatelectrocution or serious bodily injury may occurunless a minimum clearance of 10 ft. (3.0m)between the crane or the load being handled andenergized power lines. Greater clearances arerequired because of higher voltage as stated above.These signs shall be revised but not removed whenlocal jurisdiction requires greater clearances.


QUAL 7/982 - 8

(6.1)20over 750 to 1000(4.87)16over 345 to 750(3.83)10over 50 to 345(1.83)6over 0.75 to 50(1.22)4over to 0.75

while in transit with no load and boom lowered

(13.72)45over 750 to 1000(10.67)35over 500 to 750(7.62)25over 350 to 500(6.1)20over 200 to 350(4.6)15over 50 to 200

(3.05)10over to 50

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

normal voltage, kVclearance

minimum required

TABLE 1

INSPECTION CLASSIFICATION

1 Initial inspection. Prior to initial use, all new, altered,modified or extensively repaired cranes shall beinspected by a designated person to insure compliancewith provisions of this standard.

2 Regular inspection. Inspection procedure for cranesin regular service is divided into two general classifi-cations based upon the intervals at which inspectionshould be performed. The intervals in turn aredependent upon the nature of the components of thecrane and the degree of their exposure to wear,deterioration, or malfunction. The two general classi-fications are herein designated as "frequent" and"periodic" with respective intervals between inspec-tions as defined below.

A. frequent inspection - daily to monthly intervals

B. periodic inspection - one to twelve intervals, or asspecifically recommended by the manufacturer

FREQUENT INSPECTION

3 Inspection shall be performed by designatedpersonnel.

A. control mechanisms for maladjustment interferingwith proper operation - daily, when used

B. control mechanisms for excessive wear of compo-nents and contamination by lubricants or otherforeign matter

C. safety devices for malfunction

D. all hydraulic hoses, particularly those which flex innormal operation of crane functions, should bevisually inspected once every working day, whenused

E. hooks and latches for deformation, chemicaldamage, cracks, and wear. Refer to ANSI/ASMEB30.10

F. rope reeving for compliance with crane manufac-turer's specifications, if optional winch is used

G. electrical apparatus for malfunctioning, signs ofexcessive deterioration, dirt and moisture accumula-tion

H. hydraulic system for proper oil level and leaks daily

I. tires for recommended inflation pressure, cuts andloose wheel nuts

J. connecting pins and locking device for wear anddamage

PERIODIC INSPECTION

4 Deformed, cracked or corroded members in the cranestructure and carrier.

5 Loose bolts, particularly mounting bolts.

6 Cracked or worn sheaves and drums.

7 Worn, cracked, or distorted parts such as pins,bearings, shafts, gears, rollers and devices.

8 Excessive wear on brake and clutch system parts andlining.

9 Crane hooks inspected for cracks.

10 Travel steering, braking, and locking devices, formalfunction.

11 Excessively worn or damaged tires.

12 Hydraulic and pneumatic hose, fittings, and tubinginspection.

A. evidence of leakage at the surface of the flexiblehose or its junction with metal and coupling

B. blistering, or abnormal deformation to the outercovering of the hydraulic or pneumatic hose

C. leakage at threaded or clamped joints that cannot beeliminated by normal tightening or recommendedprocedures

D. evidence or excessive abrasion or scrubbing on theouter surface of a hose, rigid tube, or fitting. Meansshall be taken to eliminate the interference ofelements in contact or otherwise protect thecomponents

INSPECTION, TESTING AND MAINTENANCE

GENERAL

INSP 9/982 - 9

13 Hydraulic and pneumatic pumps and motorsinspection.

A. loose bolts or fasteners

B. leaks at joints between sections

C. shaft seal leaks

D. unusual noises or vibrations

E. loss of operating speed

F. excessive heating of the fluid

G. loss of pressure

14 Hydraulic and pneumatic valves inspection.

A. cracks in valve housing

B. improper return of spool to neutral position

C. leaks at spools or joints

D. sticking spools

E. failure of relief valves to attain or maintain correctpressure setting

F. relief valve pressure shall be checked as specified bythe manufacturers

15 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

16 Hydraulic filters. Evidence of rubber particles on thefilter elements may indicate hose, "O" ring, or otherrubber component deterioration. Metal chips orpieces on the filter may denote failure in pumps,motors, or cylinders. Further checking will be neces-sary to determine origin of the problem beforecorrective action can be taken.

17 Labels are to be in place and legible.

CRANES NOT IN REGULAR USE

18 A crane which has been idle for a period of over onemonth or more, but not less than six months, shall begiven an inspection conforming with the initial-regular- frequent inspections.

19 A crane which has been idle for a period of over sixmonths shall be given a complete inspection conform-ing with the initial-regular-frequent inspectionrequirements.

INSPECTION RECORDS

20 Dated records for periodic inspection should be madeon critical items such as brakes, crane hooks, rope,hydraulic and pneumatic cylinders, and hydraulicand pneumatic relief pressure valves. Records shouldbe kept available to an appointed person.

OPERATIONAL TESTS

21 Prior to initial use, all new, altered, modified, orextensively repaired cranes shall be tested for compli-ance with the operational requirements of thissection, 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 functionlabels

Operational crane test results shall be madeavailable to an appointed person.

RATED TEST LOADPrior to initial use, altered, modified, orextensively repaired cranes shall be loadtested by or under the direction of anappointed person.


GENERAL

INSP 9/982 - 10

22 Test loads shall not exceed 110% of the manufac-turer's load ratings.

23 Written reports shall be maintained showing testprocedures and confirming the adequacy of repairs.

MAINTENANCE

PREVENTIVE MAINTENANCE

24 Before adjustment and repairs are started on a crane,the following precautions shall be taken as applicable:

A. crane placed where it will cause the least interfer-ence 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 otherwisesecured against dropping

E. relieve hydraulic oil pressure from all hydrauliccircuits before loosening or removing hydrauliccomponents

25 Warning or "OUT OF ORDER" signs shall be placedon the crane controls.

26 After adjustments and repairs have been made, thecrane shall not be returned to service until all guardshave been reinstalled, trapped air removed fromhydraulic system (if required), safety devices reacti-vated, and maintenance equipment removed.

ADJUSTMENTS AND REPAIRS

27 Any hazardous conditions disclosed by the inspectionrequirements shall be corrected before operation ofcrane is resumed, Adjustments and repairs shall bedone only by designated personnel.

28 Adjustments shall be maintained to assure correctfunctioning of components, The following areexamples:

A. functional operating mechanism

B. safety devices

C. control systems

29 Repairs or replacements shall be provided as neededfor operation.

The following are examples:A. critical parts of functional operating mechanisms

which are cracked, broken, corroded, bent, or exces-sively worn

B. critical parts of the crane structure which arecracked, bent, broken, or excessively corroded

C. crane hooks showing cracks, damage, or corrosionshall be taken out of service. Repairs by welding arenot recommended

30 Instructions shall be provided by the manufacturerfor the removal of air from hydraulic circuits.

LUBRICATIONAll moving parts of the crane, for whichlubrication is specified, should be regularlylubricated per the manufacturer'srecommendations and procedures.

ROPE INSPECTION

31 Frequent Inspection

A. All running ropes in service should be visuallyinspected once each working day. A visual inspec-tion shall consist of observation of all rope whichcan be in use during the days operations. Thesevisual observations should be considered withdiscovering gross damage such as listed below,which may be an immediate hazard.

1. distortion of the rope such as kinking,crushing, un-stranding, birdcaging, mainstrand displacement, or core protrusion.Loss of rope diameter in a short length orunevenness of outer strands should bereplaced

2. general corrosion 3. broken or cut strands; 4. number, distribution and type of visible

broken wires. When such damage is


GENERAL

INSP 9/982 - 11

discovered, the rope shall either beremoved from service or given asinspection.

B. Care shall be taken when inspecting sections of rapiddeterioration such as flange points, crossover points,and repetitive pickup points on drums.

32 Periodic inspection

A. The inspection frequency shall be determined by aqualified person and shall be based on such factorsas:

1. expected rope life as determined byexperience on the particular installation orsimilar 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 calendarintervals and should be more frequent as therope approaches the end of it's service life.This inspection shall be made at leastannually.

B. Periodic inspection shall be performed by a desig-nated person. This inspection shall cover the entirelength of the rope. Only the surface wires need beinspected. No attempt should be made to open therope. Any deterioration results in appreciable loss oforiginal strength, such as described below, shall benoted and determination made as to whether use ofthe rope would constitute a hazard: points listedabove reduction of rope diameter below nominaldiameter due to loss of core support, internal orexternal corrosion, or wear of outside wires; severelycorroded, cracked, bent, worn or improperly appliedconnections;

C. Care shall be taken when inspecting sections subjectto rapid deterioration such as the following:

1. sections in contact with saddles, equalizersheaves, or other sheaves where ropetravel is limited

2. sections of the rope at or near terminalends where corroded or broken wires mayprotrude

ROPE REPLACEMENT

33 No precise rules can be given for determination of theexact time for replacement of rope, since manyvariable factors are involved.

Continued use in this respect depends upongood judgement by a designated person inevaluating remaining strength in a used ropeafter allowance for deterioration disclosed byinspection. Continued rope operation dependsupon this remaining strength.

34 Conditions such as the following shall be reason forquestioning continued use of the rope or increasingthe frequency of inspection:

A. in running ropes, six randomly distributed brokenwires in one lay or three broken wires in one strandin one lay

B. one outer wire broken at the contact point with thecore of the rope structure and protrudes or loops outof the rope structure. Additional inspection of thissection is required

C. wear of one third of the original diameter of theoutside individual wire

D. kinking, crushing, birdcaging, or any other damageresulting in distortion of the rope structure

E. evidence of any heat damage from any cause

F. reduction from nominal diameter of more than 1/64in. (0.4mm) for diameters up to and including 5/16in. (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 andincluding 3/4 in. (19 mm). 1/16 in. (1.6 mm) fordiameter 7/8 in. (22 mm) to and including 11/8 in.(29 mm), 3/32 in. (2.4 mm) for diameters 11/4 in.(32 mm) to and including 11/2 in. (38 mm)

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


GENERAL

INSP 9/982 - 12

H. Replacement rope shall have a strength rating atleast as great as the original rope furnished orrecommended by the crane manufacturer. Anydeviation from the original size, grade, or construc-tion shall be specified by a rope manufacturer, or aqualified person.

35 Rope not in regular use: all rope which has been idlefor a period of a month or more due to shutdown orstorage of a crane on which it is installed, shall begiven and inspection in accordance with above infor-mation before it is placed in service. This inspectionshall be for all types of deterioration and shall beperformed by a qualified person.

36 Inspection records

A. frequent inspection- no records required

B. periodic inspections- in order to establish data as abasis for judging the proper time for replacement, adated report condition at each periodic inspectionshould be kept on file. This report shall cover pointsof deterioration listed above.

ROPE MAINTENANCE

37 Rope should be stored to prevent damage ordeterioration.

38 Unreeling or uncoiling of rope shall be done as recom-mended by the rope manufacturer and with care toavoid kinking or inducing twist.

39 Before cutting a rope, seizing shall be placed on eachside of the place where the rope is to be cut to preventunlaying of the strands. On pre-formed rope, oneseizing on each side of the cut is required. Onnon-preformed ropes of 7/8 in. (22 mm) diameter orsmaller, two seizings on each side of the cut arerequired, and for non-preformed rope 1 in. (25 mm)diameter or larger, three seizings on each side of thecut are required.

40 During installation care should be exercised to avoiddragging of the rope in the dirt or around objectswhich will scrape, nick crush or induce sharp bendsin it.

41 Rope should be maintained in a well-lubricated condi-tion. It is important that lubricant applied as a part ofa maintenance program shall be compatible with theoriginal lubricant and to this end the rope manufac-turer should be consulted. Lubricant applied shall bethe type which does not hinder visual inspection.Those sections of rope which are located over sheavesor otherwise hidden during inspection and mainte-nance procedures require special attention whenlubricating rope. The object of rope lubrication is toreduce internal friction and to prevent corrosion.

42 When an operating rope shows greater wear or welldefined localized areas than on the remainder of therope, rope life can be extended in cases where asection at the worn end, and thus shifting the wear todifferent areas of the rope.


GENERAL

INSP 9/982 - 13

SAFETY DECAL SECTION8406H

Revised 1/02

Right side of valve coverPLACEMENT:1QUANTITY:All cranes equipped with a load sensor.USED ON:

To inform the operator that tampering with theoverload device may cause a unit failure orpossible personnel injury.

FUNCTION:

TAMPERING WITH OVERLOAD DEVICEDECAL: 040632PART NO.:

Right side platePLACEMENT:1QUANTITY:All cranesUSED ON:

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

FUNCTION:

OPERATOR TRAININGDECAL: 040580PART NO.:

FG. SD-1

FIG. SD-2

FIG. SD-32 - 14

Right side plate PLACEMENT:

1QUANTITY:All cranesUSED ON:

To inform the operator of the properprocedure to follow for safe operationof the crane.

FUNCTION:OPERATION INSTRUCTIONSDECAL:

040579PART NO.:


Revised 1/02

Both sides of crownPLACEMENT:2QUANTITY:All cranesUSED ON:

To inform the operator of thehazard of proximity or contactwith the crane boom duringoperation.

FUNCTION:

STAY CLEAR OF BOOMDECAL: 040517PART NO.:

Both sides of end of lower boomPLACEMENT:2QUANTITY:

Articulated & Stiff BoomCranes

USED ON:

To inform the operator of thehazard involved with contactingelectrical power lines with craneboom.

FUNCTION:

ELECTROCUTION HAZARDDECAL: 040529PART NO.:

FIG. SD-4

FIG. SD-5

2 - 15


Revised 1/02

Both sides of the lift cylinderPLACEMENT:To inform the operator ofpossible danger at scissorspoint on crane.

FUNCTION:2QUANTITY:SCISSORS POINTDECAL:

All cranesUSED ON: 040519PART NO.:

FIG. SD-8

On the lift cylinder near the load sensorPLACEMENT:1QUANTITY:All cranes equipped with a load sensor.USED ON:

To inform the operator that the loadsensor is pre-set and that tamperingwith the sensor may cause potentiallyhazardous situation.

FUNCTION:LOAD SENSOR, DON'T TAMPERDECAL:

040587PART NO.:

FIG. SD-7

2 - 16

2 - 17Decal Layout 6/02

DECAL LAYOUT8406H

2 - 18Decal Layout 6/02

DECAL LAYOUT8406H

ITEM NO. QTY. PART NO. DESCRIPTION

2 1 040579 DECAL OPERATION INSTRUCTIONS3 1 040632 DECAL WARNING - OVERLOAD4 1 040580 DECAL TRAINED OPERATOR5 2 040529 DECAL POWER LINE HAZARD6 2 040517 DECAL STAY CLEAR OF BOOM7 1 330622 DECAL SERIAL NO8 2 040519 DECAL DANGER SCISSOR POINT9 1 040587 DECAL WARNING LOAD SENSOR10 2 480852000 DECAL LOAD CHART 8406H11 2 480851000 DECAL 8406H12 2 360034 DECAL AUTO CRANE LOGO13 2 366389 DECAL AUTO CRANE14 1 320318 DECAL ANGLE IND RIGHT15 1 320318001 DECAL ANGLE IND LEFT

3 - 1General Dimensions 6/02

GENERAL DIMENSIONS8406H

3 - 2

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

ITEM PART NO. DES CRIPTION

1. 480854 Swivel Block

2. 480899 Owners Manual

3. 015104 Bolt 7/8 NF x 5", Grade 8, (4 Req'd)

4. 022200 Washer Split Lock 7/8 (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 RESERVOIRA. RETURN LINE FROM CRANE TO RESERVOIR (IN COMPARTMENT): -10 SAE 100R2 (OR EQUIVALENT).

HOSE LENGTH IS DETERMINED BY INSTALLER. RETURN LINES LONGER THAN 6 FEET SHOULD BE

SIZE -12. HOSE END FITTINGS ARE -10 JIC FEMALE SWIVEL (CRANE END) AND -10 JIC FEMALESWIVEL (RESERVOIR END).

B. PRESSURE LINE FROM PUMP TO CRANE: -8 SAE 100R2 (OR EQUIVALENT). HOSE LENGTH IS

DETERMINED BY INSTALLER. HOSE END FITTINGS ARE BOTH -8 JIC FEMALE SWIVEL.

NOTE:

REFER TO OWNERS MANUAL FOR ADDITIONAL INSTALLATION INFORMATION.

CAUTION

- FAILURE TO USE CLEAN HYDRAULIC HOSES AND COMPONENTS MAY

CONTAMINATE THE CRANE AND HYDRAULIC SYSTEM AND VOID WARRAN

3. Crane must be provided with a flow of 13 gallons per minute and a pressure of 2,750 PSI. Excess flow will cause erratic

operation, and too little flow will cause poor crane operation.

4. Vehicle should meet minimum GVW rating of 20,500 pounds.

5. The vehicle MUST be equipped with an engine speed control and tachometer.

6. Make sure mounting surface is properly reinforced to withstand 50,000 ft- lb capacity loading of crane and that outriggers

are used to provide total stability for the truck.

7. A 13 1/2" dia. hole should be cut out of mounting location (centered with mounting bolts) for access to lower ring gear

bolts and hydraulic connections.

8. Make sure the mounting bolts are 7/8x dia, grade 8. Torque bolts to 440 ft-lbs (dry).

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

10. Electrical hookup:

Wiring (cable from base of crane):

A. CONNECT THE BLACK WIRE TO THE BATTERY NEGATIVE (GROUND).

B. CONNECT THE RED WIRE TO THE BATTERY POSITIVE.

C. OPTIONALLY, USE THE WHITE WIRE FOR ENGINE FAST/SLOW.

D. OPTIONALLY, USE THE BLUE WIRE FOR ENGINE START.

E. OPTIONALLY, USE THE ORANGE WIRE FOR ENGINE STOP.

WARNING! FAILURE TO CORRECTLY PLUMB AND WIRE CRANE CAN CAUSE

INADVERTENT OPERATION AND DAMAGE TO CRANE AND/OR PERSONNEL!

11. 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 10-8 JIC union and engage

PTO wih engine running. Allow oil to circulate for 15 to 20 minutes. This will flush contaminants from the system back tothe 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 13 gallons per

minute (GPM), install an in-line flow meter between the crane and the reservoir in the return hose.

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

MOUNTING AND INSTALLATION 8406H

5. 366500002 Transmitter

6. 366500004 Pendant Cable

3 - 3

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

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

WARNING

FEDERAL LAW (49 CFR PART 571) REQUIRES THAT THE FINAL STAGE MANUFACTURER OF A VEHICLE CERTIFY THAT 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

aaCRANE 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).

MOUNTING AND INSTALLATION CONT.

1) OWNER'S MANUAL 2) OSHA SECTION 1910.180 3) ANSI B30.5-1989

FORADDITIONAL

INFORMATIONSEE:

PADS GREASED WHEN REPLACED BOOM SLIDEPADS

DRAIN, FLUSH, AND REFILLWITH SUN 2105 HYD. OIL, SAE5W-20

XHYDRAULICFLUID

EP GEAR LUBE SAE 80-90XROTATIONGEAR BOX

CHECK TORQUE TO 85 FT-LBS(DRY) AS REQUIRED

XROTATIONGEAR BOX

CHECK TORQUE TO 150 FT-LBS(DRY) AS REQUIRED

XROTATIONBEARING BOLTS

GREASE WITH MOBILPLEX EP-2OR EQUIVALENT @ ZERKS

XROTATIONBEARING

CHECK-TIGHTEN AS REQUIREDXALL OTHERBOLTS

SEALED BEARING, REPLACE IFROUGH OR LOOSE

XSHEAVEBEARINGS

LUBE WITH MOBILETAC LL, ORLUBRIPLATE P/N 15263, OREQUAL

XROTATIONRING GEAR

CHECK-TORQUE TO 440 FT-LBS(DRY) AS REQUIRED

XMOUNTINGBOLTS

CHECK FLUID LEVELXHYD. FLUID

VISUAL INSPECTIONXHYD. HOSES

CHECK FOR FLATTENING,KINKS, & BROKEN STRANDS,SEE MANUAL

XHOIST / BOOMCABLE

MAKE SURE CABLE IS WOUNDEVENLY ON DRUM

XCABLE DRUM

INSPECT HOOK & LATCH FORDEFORMATION, CRACKS, &CORROSION

XLOAD HOOK

NOTESYEAR6 MOS3 MOSWEEKLYDAYSERVICE PERFORMED

Lube & Maint 6/02

LUBRICATION & MAINTENANCE SCHEDULE8406H CRANE

4-1

CAUTION: Routine maintenance insures trouble-free operation and protects yourinvestment. 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 bereplaced 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 permanentrecord. Additional copies are available from your local distributor.

Lube & Maint 6/02

LUBRICATION & MAINTENANCE SCHEDULE8406H CRANE

4-2

Cylinder Seal Kit - #480838001

Counterbalance Cartridge - #480188

5 - 1Pedestal Assy. 6/02

PEDESTAL ASSEMBLY8406H

5 - 2Pedesal Assy. 7/02


ITEM NO. QTY PART NO. DESCRIPTION

1 1 480842000 PEDESTAL WELD2 1 480838000 CYL, LIFT3 1 160407 GEAR BOX, ROTATION4 1 480839000 VALVE BANK ASSY5 1 123308 HOIST RPH42006 1 480857000 BASE PLATE WELD7 1 366500001 CONTROLER, KAR-TECH8 1 480864000 MAIN HARNESS WIRE ASSY 6406H/8406H9 1 366500006 CABLE, ANTENNA EXTENSION

10 1 366506000 BRACKET ANTENNA11 1 366333 BEARING, SPHERICAL 1.25 ID12 1 480023002 BEARING, ROTATION13 38 023902 WASHER, 5/8 FLAT HARDENED14 14 366393 HEX HEAD 5/8-11 X 2.5 GR815 2 366364 PLATE, VALVE MOUNTING16 2 812209-022 HOSE ASSY 6 STR/9017 1 812203-028 HOSE ASSY 6 STR18 1 812203-030 HOSE ASSY 6 STR19 2 480205 HOSE ASSY 6 STR X 19.2520 2 480203 HOSE ASSY 8 STR X 24.7521 1 812309-024 HOSE ASSY 8 STR/9022 1 812409-024 HOSE ASSY 10 STR/9023 2 490198 FITTING 10SAE(M)/6JIC ELBOW 9024 2 200876 FITTING 6 SAE/6 JIC STRAIGHT 6F5OX25 1 366477 PRESSURE TRANDUCER26 2 372041 FITTING 8JIC/10SAE STRAIGHT 8-10 F5OX27 1 367145 FITTING STR 8-SAE/8-JIC28 1 490199 FITTING STR 10-SAE/10-JIC29 11 021100 WASHER SPLK 3/830 11 008400 SCW HEX HD 3/8-16 UNC X 3/4 GR 531 1 366440 ROTATION MOTOR32 4 320588 WASHER FL 1/233 6 021500 WASHER SP LK 5/16 NC34 4 366391 HEX HD 1/2-13 X 2 1/435 2 009118 SOC HD 1/2 UNC X 236 4 006205 SOC HD 5/8 X 1 1/437 2 021502 WASHER SP/LK 1/2 HI COLLAR38 2 021601 WASHER FL 1/239 2 012197 SOC HD 1/2-1340 1 370433 CORD CONNECTOR HUBBLE F-3

5 - 2.1Pedestal Assy. 07/02


ITEM NO. QTY.PART NO. DESCRIPTION

41 5 020601 WASHER 5/16 LOCK42 5 007401 SCW 5/16-18 X 1/2 LG43 2 480024 MOUNT PENDANT CABLE RETAINER44 1 366359 FITTING 8 SAE/JIC SWIVEL PS810503-8-845 1 366358 FITTING 10SAE/JIC SWIVEL PS810503-10-1046 1 366423 MAGNET, PROX PICKUP47 48 374086 NYLON HOSE SLEEVE48 1 480011 SEAL ROTATION BOX49 24 490306 HX HD 5/8-11 X 2.00 GR850 2 642908 CORD CONNECTOR51 2 011202 SCW HX HD 1/2-20 X 2 3/452 2 017704 NUT HX HVY 1/2 NF53 1 366338 HARNESS WIRE ROTATION54 1 366492 PIN 1.25<MOD-DIAM> X 3.00 LG55 1 366419 SWITCH, LIMIT ROTATION56 1 480856000 LIMIT SWITCH ARM57 1 366424 BRACKET, PROX SWITCH58 2 020000 10 SAE FLAT WASHER59 2 019800 10 SPLIT LOCK60 2 330679 SCW BT HD SOCKET 10-32 X 1/261 1 480865000 BRACKET BOOM SWITCH62 1 654100 SWITCH LIMIT BZ-2RW80-A263 2 000602 SCW PN #6 NC X 164 2 019600 WASHER SP LK #665 2 015400 NUT HX #6-32

Cylinder Seal Kit - #366331001

Counterbalance Cartridge - #480188

5 - 3Boom Assy. 6/02

BOOM ASSEMBLY

5 - 4Boom Assy. 06/02

BOOM ASSEMBLY

ITEM NO. QTY. PART NO. DESCRIPTION

1 1 480831000 BOOM WELDMENT, LOWER2 4 366385 PLATE, LOWER BOOM PAD COVER3 2 366201 WEAR PAD 3 .75 X 2.00 X .3134 1 480832000 BOOM WELDMENT, UPPER5 1 366331 CYLINDER EXTENSION6 1 366445000 BOOM WELDMENT MID7 2 366184 RETAINER EXTENSION CYLINDER8 1 366353 PAD WEAR 5.25 X 2.63 X .389 1 366499 PAD BOOM 2 X 410 1 366485 PAD, BOOM TOP11 5 366483 PLATE, WEAR PAD .25 X 2 X 412 2 366354 WEAR PAD13 1 366493 PIN 1<MOD-DIAM> X 5.03 LG14 1 646900 SWITCH, LIMIT ANTI-TWO BLOCK15 1 480834000 BAIL WELDMENT16 1 007804 SCW HX 5/16 NC X 1 1/4 CP17 1 366185 PAD, BOOM TOP18 2 366394 BEARING, PIVOT19 1 366333 BEARING, SPHERICAL 1.25 ID20 1 366400 PIN 1.25<MOD-DIAM> X 8.06321 18 021100 WASHER SPLK 3/822 20 008400 SCW HEX HD 3/8-16 UNC X 3/4 GR 523 8 020200 WASHER SPLIT LOCK 1/424 8 005406 SCW HX 1/4-28 X 1/225 10 021200 WASHER FL 3/826 6 008100 SCW HEX3/8-24 X 5/827 4 008800 SCW HEX 3/8-24 X 128 1 366198 SHEAVE ASSY 3/829 1 007803 SCW 5/16 NC 3 1/2 LG30 3 016801 NUT HEX-LOCK 5/16 NC31 2 480029 RING RETAINING32 2 360122 RING RETAINING 5100-9833 2 480194 FITTING 6 SWIVEL NUT ELBOW34 2 200876 FITTING 6 SAE/6 JIC STRAIGHT 6F5OX35 1 366973-003 CORD REEL ASSY36 1 642908 CORD CONNECTOR37 1 320554 SPRING RETURN38 2 022102 WASHER FL 3/439 1 014400 CAPSCREW, .75-16 NF X 540 1 018600 NUT, NYLON LOCK .75-16 NF41 1 016300 NUT HX NY-LOCK 1/4-2042 2 366351 PAD, WEAR 1 1/2 X 1 1/2 X 3/4

ROTATION GEAR BOXP/N: 480028

Rot. Gear Box 6/025 - 5

ROTATION GEAR BOXP/N: 480028

Rot. Gear Box 6/02

PLUG EXPANSION480269131WASHER THRUST480268230SEAL OIL 480266129PIN DOWEL480265428PLUG PIPE480264227REDUCER480263126O-RING480239125FITTING RELIEF480262124GASKET480250123GASKET480260222ELL 90 DEG480259121WASHER LK 5/16 MED SECT480258620SCREW SOC HD 5/16 NC X 1480256619SCREW HX HD 1/2 NC X 3/4 011508218

SCREW HX HD 5/16 NC X 1 ¼ NYLOC HVY PATCH

480238817SCREW HX HD 5/16 NC X 1007400616COVER480255115BEARING THRUST480254114BEARING NEEDLE480253113BEARING NEEDLE480252112BEARING BALL480251111WORM R.H.480249110WASHER THRUST48024819SHAFT OUTPUT48024718KEY48024627HOUSING GEAR48023716GEAR R.H.48024415COVER48024314CAP BEARING48024213BUSHING48024112ADAPTER48024011DESCRIPTIONP/NQTYITEM

5 - 6

5 - 7Hoist Assy. 6/02

HOIST ASSEMBLY8406H

ITEM QTY PART # DESCRIPTION

1 1 234189 DRUM ASSEMBLY

2 1 306042 PISTON, BRAKE

3 1 338300 END BEARING, MOTOR

4 1 338301 END BEARING, GEAR HOUSING

5 1 338302 HOUSING, BRAKE

6 4 346045 PIN, BRAKE

7 1 357513 INPUT SHAFT, SUN GEAR

8 2 474065 PLATE, TIE

9 1 402120 BEARING, GEAR HOUSING

10 1 402121 BEARING, MOTOR

11 1 412084 BUSHING, DRUM (MOTOR END)

12 1 412085 BUSHING, DRUM (GEAR HOUSING END)

13 6 414303 CAPSCREW, 3/8-16NC x 2 ½ LG HX HD GR5 ZINC PLTD

14 2 414948 CAPSCREW, 1/2-13NC x 1 ¼ LG SOCKET HD GR5 ZINC PLTD

15 8 414548 CAPSCREW, 1/2-13NC x 1 ½ LG HX HD GR5 ZINC PLTD

16 2 414854 CAPSCREW, 1/4-20NC x 1/2 LG RD HD SLOT ZINC PLTD

17 4 414129 CAPSCREW, 5/16-18NC x 3.0 LG SOCKET HD GR5 ZINC PLTD

18 1 414926 SETSCREW, 3/8-16NC x 1.0 LG SOCKET, NYLON

19 1 416016 SETSCREW, 1/4-20NC x 1/4 LG HEX SOCKET HD CUP

Hoist Assy. 6/025 - 8

Hoist Assy. 6/02

HOIST ASSEMBLY8406H - PART NO. #123308


20 1 416080 SETSCREW, 5/8-18NF x 1.0 LG HEX SOCKET HD CUP

21 1 418036 NUT, JAM 3/8-16NC HEX ZINC PLTD

22 1 418088 NUT, JAM 5/8-18NF HEX ZINC PLTD

23 2 418218 LOCKWASHER, 1/2 I.D. MEDIUM SECTION ZINC PLTD

24 1 426048 PLUNGER

25 1 431015 COUPLING, MOTOR

26 2 432018 FITTING, 7/16 ELBOW (90 DEGREE)

27 1 432026 FITTING, BLEEDER

28 4 438022 DISC, BRAKE

29 1 442220 GASKET, BRAKE

30 1 442223 GASKET, MOTOR

31 1 444085 GEAR, RING

32 1 456038 FITTING, VENT

33 1 458121 MOTOR, HYDRAULIC

34 1 462046 O-RING, DRUM

35 1 462056 O-RING

36 1 462057 O-RING

37 1 462058 O-RING

38 1 462059 O-RING BACKUP

Hoist Assy. 6/02


5 - 9


39 1 462060 O-RING BACKUP

40 1 472052 PLUG

41 5 474111 PLATE, SEPERATOR

42 1 486080 SEAL, GEAR HOUSING

43 1 490037 SNAP RING

44 6 494110 SPRING, BRAKE

45 4 494112 SPRING

46 1 509019 TUBE ASSEMBLY

47 1 516028 VALVE, MOTOR CONTROL

48 1 518037 THRUST WASHER



51 2 362283 SPACER, FOOT MOUNTING

52 4 362284 SPACER, TIE PLATE

53 1 315004 CABLE ANCHOR

Hoist Assy. 6/02


5 - 10

5 - 11General Assy. 6/02

GENERAL ASSEMBLY8406H

TRAVELING BLOCK480854000111

DECAL LAYOUT480850000110

SHIP KIT W/ FM CONTROL48087000019

3/8-16 X 7/8 GR5 PLATED HEX CAP SCREW00870128

WASHER SPLK 3/802110027

ROPE ASSY48084100016

PIN 2<MOD-DIAM> X 10.5 LG36649115

PIN 1.25<MOD-DIAM> X 3.00 LG36649214

COVER 640636643000013

BOOM ASSEMBLY48083000012

PEDESTAL ASSY48084000011

DESCRIPTIONPART NO.QTY.ITEM NO.

5 - 12General Assy. 06/02

GENERAL ASSEMBLY8406H

6 - 1Elec. Schematic 6/02

ELECTRICAL SCHEMATIC

6 - 2Main Wiring Harness

6/02

MAIN WIRING HARNESS

7 - 1Hyd. Schematic 6/02

HYDRAULIC SCHEMATIC

Counterbalance Valve Adjustment{ With PTO disengaged and boom

properly supported, remove the plug onthe counterbalance valve. Install apressure gauge (0-3000 PSI) into theport.

{ Engage PTO and insure pump flow is 13to 14 GPM . With no load on boom,boom up to an angle of 70 degrees.Boom down and note pressure. Ifpressure reading is not approximately1300 PSI, the counterbalance valverequires adjustment.v To increase the CB valve setting,

loosen nut and turn Allen headscrew counter clockwise.

v To reduce the CB valve setting,loosen nut and turn Allen headscrew clockwise.

{ Tighten nut on adjustment screw andrepeat procedure if needed to obtain theproper pressure setting.

{ Disengage PTO, remove the pressuregauge and install plug. Crane is nowready for operation.

Notice:{ In an EMERGENCY situation when it

becomes necessary to lower the boom

without flow present, the CB valveadjustment can be turned in until theboom begins to descend. Make sure theboom will lower onto a proper support.Loosen the lock nut and carefully turnadjustment screw clockwise! Count thenumber of turns. Turn slowly until theboom just begins to lower, and removehand/arm/fingers from cranes whileboom is lowering.

{ Turning adjustment screw too far willcause valve to come apart on the inside.This condition is not repairable

{ After boom is lowered, turn adjustmentscrew counter clockwise the approxi-mate number of turns made duringlowering procedure. After the problemis corrected, readjust the counterbal-ance valve using the procedure in thismanual.

WARNING: DO NOT TRY TO ADJUST VALVESWHILE BOOM IS MOVING. Failureto do so may result in personal injury!

Hydraulic 7/02

HYDRAULIC 8406H

7 - 2

7 - 3Hyd. Control Valve 6/02

HYDRAULIC CONTROL VALVE 8406H

7 - 4Hyd. Control Valve 6/02

HYDRAULIC CONTROL VALVE8406H PARTS LIST

ITEM QTY DESCRIPTION AC P/N

FR1 1 FLOW CONTROL 480839002PV1 1 PROPORTIONAL VALVE 480839003RV1 1 RELIEF VALVE 366365004

SV3, SV4, SV5 3 CARTRIDGE VALVE 320725001SV1, SV2 2 CARTRIDGE VALVE 480839004

CL1 1 COIL 320725005CL2 2 COIL 480839005CL3 6 COIL 366365001

ITEM QTY DESCRIPTION AC P/N

FTG1 2 FITTING 45 8-SAE/8-JIC 374017000FTG2 2 FITTING 90 6-SAE/6-JIC 241175000FTG3 2 FITTING 90 6-SAE/6-JIC LONG 330645000FTG4 1 FITTING STR 8-SAE/8-JIC 367145000FTG5 1 FITTING STR 10-SAE/10-JIC 490199000FTG6 2 FITTING 45 6-SAE/6-JIC 480195000

DIAGNOSTICS

CAUTION The Auto Crane 8406H 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.

8 - 1

SITUATION POSSIBLE SOLUTION FLOW PRESENT BUT FUNCTION WILL NOT WORK

Check receiver for error code, if error code is present while function is being activated, refer to the error code section on the following page. If “NRML” appears in the code display on the receiver while the function is being activated, operate the proportional override and push or pull the override on the directional control valve to operate the function. If the function still does not operate, see the “NO FLOW” paragraph in this section.

HYDRAULIC “CHATTER”

When a hydraulic function is engaged and causes the crane to “chatter”, check for error code on receiver display, low pump pressure or air in the system.

NO FLOW OR LIMITED FLOW TO CRANE

Check for error code on receiver display (see error code section). Check for adequate oil supply in reservoir. Check operation of bypass system by operating the override on the proportional valve while operating crane. If low flow condition continues to exist when the manual override is operated, remove relief valve cartridge and check for dirt. Other possible causes for a low flow condition are:

1. Engine speed is too slow. 2. A blocked pressure hose from pump. This condition can be

identified by excessive lugging of engine and rapid overheating of oil.

3. Collapsed or blocked suction hose to pump. This condition is usually identified by pump cavitation noise.

4. Bad pumps: a bad pump will usually have some flow but the flow will drop off rapidly as pressure increases. This condition will cause overheating of the system. A drop of four (4) or more GPM from Zero (0) PSI to Two Thousand (2000) PSI is cause for pump investigation

NO PRESSURE OR TOO LOW 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.

TOO HIGH FLOW Make sure pump size is correct and pump speed is not too fast (Consult manufacturer's data sheet). Check or replace flow control. Check components for flow displacements. High flow may cause erratic valve operation.

TOO HIGH PRESSURE

Make sure pressure relief valve is correctly set.

CODE: EC01

DESCRIPTION: Signal problem

POSSIBLE CAUSE(S):

POSSIBLE SOLUTION(S):function is activated. If light does not come on, make sure transmitteris on. If light comes on and red low battery light is on, charge unit. Iftransmitter is plugged in as a pendant and transmit light comes on butcode remains, check cable connections and cable.

CODE: EC02

DESCRIPTION: Boom up

POSSIBLE CAUSE(S): Short or open connection on boom up output.

POSSIBLE SOLUTION(S):Check plug in boom up solenoid on hydraulic control valve. Checkwires for damage that could cause break or short.

CODE: EC03

DESCRIPTION: Boom down

POSSIBLE CAUSE(S): Short or open connection on boom down output.

POSSIBLE SOLUTION(S):Check plug in boom down solenoid on hydraulic control valve. Checkwires for damage that could cause break or short.

CODE: EC04

DESCRIPTION: Boom in (retract)

POSSIBLE CAUSE(S): Short or open connection on boom in output.

POSSIBLE SOLUTION(S):Check plug in boom in solenoid on hydraulic control valve. Checkwires for damage that could cause break or short.

Diagnostics 6/02

8 -2

CONTROLLER DIAGNOSTICS

CODE: EC05

DESCRIPTION: Boom out (extend)

POSSIBLE CAUSE(S): Short or open connection on boom out output.

POSSIBLE SOLUTION(S):Check plug in boom out solenoid on hydraulic control valve. Checkwires for damage that could cause break or short.

CODE: EC06

DESCRIPTION: Rotate CW

POSSIBLE CAUSE(S): Short or open connection on rotate CW output.

POSSIBLE SOLUTION(S):Check plug in rotate CW solenoid on hydraulic control valve. Checkwire for damage that could cause break or short.

CODE: EC07

DESCRIPTION: Rotate CCW

POSSIBLE CAUSE(S): Short or open connection on rotate CCW output.

POSSIBLE SOLUTION(S):Check plug in rotate CCW solenoid on hydraulic control valve. Checkwire for damage that could cause break or short.

CODE: EC08

DESCRIPTION: Hoist up

POSSIBLE CAUSE(S): Short or open connection on hoist up output.

POSSIBLE SOLUTION(S):Check plug in hoist up solenoid on hydraulic control valve. Checkwire for damage that could cause break or short.

Diagnostics 6/02


8 - 3


CODE: EC09

DESCRIPTION: Hoist down

POSSIBLE CAUSE(S): Short or open connection on hoist down output.

POSSIBLE SOLUTION(S):Check plug in hoist down solenoid on hydraulic control valve. Checkwire for damage that could cause break or short.

CODE: EC10

DESCRIPTION: Incorrect ID

POSSIBLE CAUSE(S):

POSSIBLE SOLUTION(S):Confirm that transmitter being used is for use with this unit. Follow“Transmitter/Receiver Sync.” procedure in the transmitter operationsection of this manual.

CODE: EC15

DESCRIPTION: Pressure sensor

POSSIBLE CAUSE(S): Pressure sensor problem.

POSSIBLE SOLUTION(S):Check plugs and wires coming from pressure sensor mounted in the liftcylinder counterbalance valve.

CODE: EC16

DESCRIPTION: Trigger

POSSIBLE CAUSE(S): Transmitter trigger problem.

POSSIBLE SOLUTION(S):Check trigger for damage, contamination or incorrect adjustment.

Diagnostics 6/02


8 - 4

CODE: EC17

DESCRIPTION: Trigger logic error

POSSIBLE CAUSE(S):

POSSIBLE SOLUTION(S):Confirm that trigger is released and returned to full off position,activate function and reactivate trigger.

CODE: EC18

DESCRIPTION: E-STOP

POSSIBLE CAUSE(S): E-STOP activated.

POSSIBLE SOLUTION(S):Push E-STOPwill power the unit off.

CODE: EC19

DESCRIPTION: Rotation error

POSSIBLE CAUSE(S): Rotation proximity switch error.

POSSIBLE SOLUTION(S):Check plugs and wiring. Check for debris around switch or magnet.

CODE: LBV

DESCRIPTION: Low battery

POSSIBLE CAUSE(S): Low battery power to to receiver.

POSSIBLE SOLUTION(S):Check connections to the battery. Charge battery. NOTE: It is recom-mended that the crane be powered off if battery is charged with batterycharger.

Diagnostics 6/02


8 - 5

CODE: OVL1

DESCRIPTION: Over load 1

POSSIBLE CAUSE(S): Pressure overload with extend or hoist activated.

POSSIBLE SOLUTION(S):Retract boom, hoist down or otherwise alleviate overload condition.Refer to load chart for rated load. If the error persists with seemingly

t cylinderpsi.

Pressure sensor can give false readings if not properly grounded.

CODE: OVL2

DESCRIPTION: Over load 2

POSSIBLE CAUSE(S): Pressure overload with boom up or down activated.

POSSIBLE SOLUTION(S):Retract boom, hoist down or otherwise alleviate overload condition.Refer to load chart for rated load. If the error persists with seeminglylight loads, install pressure gage in plugged port of lift cylindercounterbalance valve to confirm pressures in excess of 2,750 psi.Pressure sensor can give false readings if not properly grounded.

CODE: A2B

DESCRIPTION: Anti-two block

POSSIBLE CAUSE(S): Anti-two block switch tripped.

POSSIBLE SOLUTION(S):Check switch, if not mechanically tripped, check continuity acrossswitch at plug. If switch has continuity check voltage across transmit-ter side of A2B plug. If low voltage is read, power to the A2B switch,

Diagnostics 6/02

8 - 6


CODE: RSBM

DESCRIPTION: Raise boom

POSSIBLE CAUSE(S): Pressure sensor is reading less than 80 psi.

POSSIBLE SOLUTION(S):Raise boom to ensure it is not resting on other structure and the liftcylinder is not bottomed out.

CODE: HOME

DESCRIPTION: Home position

POSSIBLE CAUSE(S): Crane is pointed forward ready to be stowed.

POSSIBLE SOLUTION(S): RSBM condi-

CODE: NRML

DESCRIPTION: Normal operating mode

POSSIBLE CAUSE(S): Crane is functioning properly.

POSSIBLE SOLUTION(S):This is not an error. It is a standard normal operation readout.

CODE: BLMT

DESCRIPTION: Boom Limit

POSSIBLE CAUSE(S): Boom has reach maximum elevation.

POSSIBLE SOLUTION(S):This is not an error. It only indicates boom position.

Diagnostics 6/02


8 - 7

8 - 8Trans / Rec Sync 6/02

TRANSMITTER / RECEIVERSYNCHRONIZATION

Component Part Number

Receiver 366500001

Transmitter 366500002

Pendant Cable 366500004

Antenna 366500005

Antenna Extension Cable 366500006

Cigarette Lighter Charger 366504000

A/C Charger 366505000

Palm Diagnostic Unit 366510000

8 - 9Remote/Pend 6 /02

REMOTE/PENDANTPARTS AND ACCESSORIES

8 - 10Valve Override 6/02

VALVE OVERRIDE OPERATION

NOTE: Always turn power to crane off before removing fuse.

Fuse is on ground circuit. The fuse can be replaced with a 7.5 amp fuse.

8 - 11Fuse Info. 6/02

FUSE INFORMATION8406H

9 - 1Load Chart 6/02

LOAD CHART8406H

SUPPLIMENTAL INFORMATION HARD WIRED SERIES

The following section refers to hardwire specific information only. Refer to the previous sections for information common to both crane versions.

10-0.0.0 6/02/2003

GENERAL ASSEMBLY8406H HARD WIRED SERIES

1

3 6 5

265

9 7

8

4

11

10

EXTENDPORT #7

RETRACTPORT #8

10-1.0.007/26/04

GENERAL ASSEMBLY8406H HARD WIRED SERIES

ITEM NO. QTY. PART NO. DESCRIPTION1 1 480821000 PEDESTAL ASSY, 8406H HARD WIRED2 1 366491 PIN 2 DIA X 10.5 LG3 1 366492 PIN 1.25 DIA X 3.00 LG4 1 480830000 BOOM ASSEMBLY5 2 021100 WASHER SPLK 3/86 2 008701 SCW HX 3/8 UNC X 7/8 GR57 1 480841000 ROPE ASSY8 1 366430000 COVER 64069 1 *480854000 TRAVELING BLOCK ASSY 8406H10 1 *366520001 JUNCTION BOX ASSEMBLY11 1 *366466000 WIRE HARNESS, TRUCK FUNCTIONS

* included in crane ship kit, ref P/N: 480882000

10-2.0.007/26/04

MOUNTING AND INSTALLATION8406H HARD WIRED SERIES

1. Check to make sure the following items are with your crane.ITEM QTY PART NO. DESCRIPTION

1 1 480854000 TRAVELING BLOCK, 8406H2 1 480899 OWNERS MANUAL3 4 015104000 BOLT 7/8 NF x 5" GRADE 8 (4 REQ'D)4 4 022200000 WASHER SPLIT LOCK 7/8 (4 REQ'D)5 1 680040000 PEMDANT ASSEMBLY6 1 366466000 WIRE HARNESS, TRUCK FUNCTIONS7 1 366520001 JUNCTION BOX ASSEMBLY8 4 018900 NUT, HEX 7/8 NF9 1 320355 POWER RELAY

10 1 480689 FUSE 15 AMP TIME DELAY11 1 480688 FUSE HOLDER WATERPROOF12 120" 800596 CONDUCTOR 16GA YELLOW X 120 INCHES LONG13 6 634401 WIRE TIE 7 INCHES LONG14 6 750738 WIRE TIE STICK ON RETAINER15 5 320357 CONNECTOR FEM SPD16 1 320363 PLUG RELAY17 1 480852000 LOAD CHART DECAL, 8406H18 1 340638 CONDUCTOR POWER

2. Pressure and return hoses are not furnished with this crane. The hoses must be provided by theinstaller and the lengths determined at installation.REQUIREMENTS FOR INSTALLATION USING 10 GALLON RESERVOIRA. RETURN LINE FROM CRANE TO RESERVOIR (IN COMPARTMENT): -10 SAE 100R2 (OR EQUIVALENT).

HOSE LENGTH IS DETERMINED BY INSTALLER. RETURN LINES LONGER THAT 6 FEET SHOULD BESIZE –12. HOSE END FITTINGS ARE –10 JIC FEMALE SWIVEL (CRANE END) AND –10 JIC FEMALESWIVEL (RESERVOIR END).

B. PRESSURE LINE FROM PUMP TO CRANE: -8 SAE 100R2 (OR EQUIVALENT). HOSE LENGTHS ISDETERMINED BY INSTALLER. HOSE END FITTINGS ARE BOTH –8 JIC FEMALE SWIVEL.

NOTE:REFER TO OWNERS MANUAL FOR ADDITIONAL INSTALLATION INFORMATION.

CAUTION – FAILURE TO USE CLEAN HYDRAULIC HOSES AND COMPONENTSMAY CONTAMINATE THE CRANE AND HYDRAULIC SYSTEM AND VOID WARRAN

3. Crane must be provided with a flow of 13 gallons per minute and a pressure of 2,750PSI. Excess flowwill cause erratic operation, and too little flow will cause poor crane operation.

4. Vehicle should meet minimum GVW rating of 20,500 pounds.5. The vehicle MUST be equipped with an engine speed control and tachometer.6. Make sure mounting surface is properly reinforced to withstand 50,000 ft-lb capacity loading of crane

and that outriggers are used to provide total stability for the truck.7. A 13 ½” dia. Hole should be cut out of mounting location (centered with mounting blots) for access to

lower ring gear bolts and hydraulic connections.8. Make sure the mounting blots are 7/8” dia, grade 8. Torque bolts to 440 ft-lbs (dry).9. When crane is not in operation, a boom support should always be used. Traveling block should be

connected to hood loop.

10. Install junction box inside compartment safe from weather and contamination.

10-3.0.007/26/04

MOUNTING AND INSTALLATION8406H HARD WIRED SERIES

11. Electrical hookup:Wiring (cable from junction box):A. CONNECT THE BLACK WIRE TO THE BATTERY NEGATIVE (GROUND).B. CONNECT THE RED WIRE TO FUSED 12VDC POWER. 12VDC POWER SHOULD BE

SUPPLIED THROUGH A DEDICATED SWITCH THAT IS POWERED ONLY WHEN THE IGNITIONSWITCH IS ON. A RELAY IS PROVIDED TO SEPARATE POWER SOURCES.

C. OPTIONALLY, USE THE WHITE WIRE FOR ENGINE FAST/SLOW.D. OPTIONALLY, USE THE BLUE WIRE FOR ENGINE START.E. OPTIONALLY, USE THE ORANGE WIRE FOR ENGINE STOP.F. OPTIONALLY, USE THE GREEN WIRE FOR AUXILIARY.

WARNING! FAILURE TO CORRECTLY PLUMB AND WIRE CRANE CAN CAUSE INADVERTENTOPERATION AND DAMAGE TO CRANE AND/OR PERSONEL!

12. Once crane and plumbing are installed on the truck, fill the reservoir to top of sight glass (mobile DTE 13or equal). Before operating crane, connect together the pressure and return hoses going to base ofcrane using 10-8 JIC union and engage PTO with engine running. Allow oil to circulate for 15 to 20minutes. This will flush contaminants from the system back to the return line filter. Operate all cylindersto full extension and retraction a minimum of six times, to bleed air from system. Return all cylinders tothe stored position and disengage PTO. Refill reservoir to top sight glass. To ensure 8 gallons perminute (GPM), install an in-line flow meter between the crane and the reservoir in the return hose.

13. Load test the crane to ensure proper functioning and truck stability14. Make certain the owner’s manual is delivered to the customer.15. For additional help: call the service department at the Auto Crane Company. (918) 836-0463 (Tulsa,

Oklahoma)

WARNING

FEDERAL LAW (49 CFR PART 571) REQUIRES THAT THE FINAL STAGE MANUFACTURER OF AVEHICLE CERTIFY THAT HE VEHICLE COMPLIES WITH ALL APPLICABLE FEDERAL REGULATIONS.ANY MODIFICATIONS PERFORMED ON THE VEHICLE PRIOR TO THE FINAL STAGE ARE ALSOCONSIDERED INTERMEDIATE STAGE MANUFACTURING AND MUST BE CERTIFIED AS TOCOMPLIANCE. THE INSTALLER OF THIS CRANE AND BODY IS CONSIDERED ONE OF THEMANUFACTURERS OF THE VEHICLE. AS SUCH A MANUFACTURER, THE INSTALLER ISRESPONSIBLE 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 TOCOMPLY WITH THE OSHA TRUCK CRANE STABILITY REQUIREMENTS AS SPECIFIED BY 29 CFRPART 1910.180 (C) (1).

10-4.0.007/26/04

ELECTRICAL SCHEMATICHARD WIRED CRANE

HOIST UP

HOIST DOWN

ROTATE CCW

ROTATE CW

BOOM UP

BOOM DOWN

EXTEND (OUT)

EXTEND(IN)

WHT

WHT/RED

RED/WHITE

PROPCONTROL

VALVE

ORANGE/BLACK

GREEN

RED/BLACK

WHITE/BLACK

ORANGE

WHITE

BLUE

GREEN/BLACK

RED

BLACK

GREEN

BLUE (NOT USED)WHITE (NOT USED)

RED

BLACK

WHITE

GREEN

BLUE

ORANGE

C

D

A

B

E

F

G

H

J

K

L

M

N

P

R

S

T

U

V

12

RED

GREEN

ORANGE

BLACK

RED/BLACK

BLUE

ORANGE/BLACK

GREEN/BLACK

WHT/RED

BLU/BLK

BLK/WHT

WHITE

RED

/WH

ITE

GRN/WHT

BLU/WHT

BLK/RED

BLAC

K/W

HIT

E

BLK/WHT

JUNCTION BOX

BLACK

RED/WHT

WHT/BLK

ORG/RED

BLU/RED

12 PIN CONNECTOR

19 P

IN C

ON

NEC

TOR

REF

REN

CE

680

040

FOR

PEN

DAN

T SC

HEM

ATIC

RED/WHITE

BRO

WN

BLACK

GRN

POWER

GROUND

ENGINE FAST/SLOW

AUXILARY

ENGINE START

ENGINE STOP

3 3

4 4

2 2

1 1

ROT SW CCW

ROT SW CW

BLK

RED

GRN

BLKRED

PRESS SW1

BOOM LIMIT SW

A2B

WH

T/R

ED

WHT

1

2

3

4

5

6

7

8

9

10

11

1

2

3

4

5

6

7 (N/A)

8 (N/A)

BOSCH RELAY

86

85

30 87

BOSCHRELAY

BLAC

K

RED

10-5.0.007/26/04

PEDESTAL ASSEMBLY8406H HARD WIRED SERIES

416

668

17

53 3

1817

61

62 46

10

8

64

33

6566

4241

56 57 58

36 36 37 38

55

27

69 70

73 72 71

11

67

5

40

20

2

447

399

8

1

22

22

26

19 17

HYDRAULIC VALVE KEY

PORT #1: HOIST DOWNPORT #2: HOIST UPPORT #3: ROTATION CCWPORT #4: ROTATION CWPORT #5: LIFT CYL EXTENDPORT #6: LIFT CYL RETRACTPORT #7: EXT CYL EXTENDPORT #8: EXT CYL RETRACT

CYLINDER SEAL KIT: 480838001COUNTER BALANCE CARTRIDGE: 480188000

10-6.0.0

07/26/04


ITEM NO. QTY. PART NO. DESCRIPTION1 1 480847000 PEDESTAL WELD2 1 160407 GEAR BOX, ROTATION3 1 366492 PIN 1.25<MOD-DIAM> X 3.00 LG4 1 480838000 CYL, LIFT5 1 480839000 VALVE BANK ASSY6 1 366333 BEARING, SPHERICAL 1.25 ID7 1 480023002 BEARING, ROTATION8 38 023902 WASHER, 5/8 FLAT HARDENED9 24 012198 CAPSCREW 5/8-11 X 1.75 GR810 14 490171 CAPSCREW 5/8-11 X 2.25 GR811 2 366364 PLATE, VALVE MOUNTING12 2 812209-022 HOSE ASSY 6 STR/9013 2 480205 HOSE ASSY 6 STR X 19.2514 1 812203-028 HOSE ASSY 6 STR15 1 812203-030 HOSE ASSY 6 STR16 2 200876 FITTING 6 SAE/6 JIC STRAIGHT17 10 021100 WASHER SPLK 3/818 5 008400 SCW HEX HD 3/8-16 UNC X 3/4 GR 519 4 330371 SCW HX 3/8 UNC X 1 GR820 1 366440 ROTATION MOTOR21 2 480202 HOSE ASSY 8 STR X 21.522 1 123308 HOIST RPH420023 4 320588 WASHER FL 1/224 8 021500 WASHER SP LK 1/225 4 366391 HEX HD 1/2-13 X 2 1/426 2 009118 SOC HD 1/2 UNC X 227 4 006205 SOC HD 5/8 X 1 1/428 2 372041 FITTING 8JIC/10SAE STRAIGHT 8-10 F5OX29 1 490199 FITTING STR 10-SAE/10-JIC30 1 367145 FITTING STR 8-SAE/8-JIC31 2 021502 WASHER SP/LK 1/2 HI COLLAR32 2 012197 SOC HD 1/2-1333 1 370433 CORD CONNECTOR HUBBLE F-334 1 812309-024 HOSE ASSY 8 STR/9035 1 812409-022 HOSE ASSY 10 STR/9036 1 480024 MOUNT PENDANT CABLE RETAINER37 1 020601 WASHER 5/16 LOCK38 1 007401 SCW 5/16-18 X 1/2 LG39 1 480857000 BASE PLATE WELD

10-7.0.007/2


ITEM NO QTY PART NO DESCRIPTION41 1 366359 FITTING 8 SAE/JIC SWIVEL PS810503-8-842 1 366358 FITTING 10SAE/JIC SWIVEL PS810503-10-1043 48 374086 NYLON HOSE SLEEVE44 1 480011 SEAL ROTATION BOX45 1 366419 SWITCH, LIMIT ROTATION46 1 480856000 LIMIT SWITCH ARM47 1 642908 CORD CONNECTOR48 2 020000 10 SAE FLAT WASHER49 2 019800 10 SPLIT LOCK50 2 330679 SCW BT HD SOCKET 10-32 X 1/251 2 011202 SCW HX HD 1/2-20 X 2 3/452 2 017704 NUT HX HVY 1/2 NF53 1 008702000 SCW HX 3/8-16 X 1 1/4 GR554 1 642918 CORD CONNECTOR55 1 360162 RING, ECCENTRIC56 1 360207 RETAINER ECCENTRIC RING57 1 020600 WASHER 5/16 LOCK SS58 1 007807 SCW HEX 5/16-18 3/4LG GR559 1 480865000 BRACKET BOOM SWITCH60 1 654100 SWITCH LIMIT BZ-2RW80-A261 2 000602 SCW PN #6 NC X 162 2 015400 NUT HX #6-3263 1 366472000 LOAD SENSOR SWITCH, 2600 PSI64 1 460120000 MAIN HARNESS ASSEMBLY, HARD WIRED65 1 366522001 HOUSING, PLUG, DEUTSCH 12-PIN66 1 366522002 WEDGE, DEUTSCH PLUG, 12 SOCKET67 1 366363001 AMP MODIFICATION, CONNECTORS68 5 320976000 WASHER, FLAT, 3/8 SAE HARDENED69 1 320355 RELAY, BOSCH70 1 006200 SCW HX HED 1/4-20 X 1-1/471 1 020300 WASHER FL SAE 1/472 1 020200 WASHER SPLIT LOCK 1/473 1 015900 NUT 1/4 NC

10-8.0.007/26/04

MAIN WIRING HARNESS

HU

HD

CCW

CW

BU

BD

EXT

RET

A2B SWITCH

PRESS SWITCH -1

ROTATE SWITCH

8 6 7

43

5

9

10

5

1

1

2

12

RED WIRENOT USED

13

A

A

B

B

BA

WHT/RED 3.5"

WHT/RED 4.5"

RED/WHT9.0"

RED/WHT 5.0" RED/WHT

2.5"

R/W5.0"

WHT

GRNWHT

BLK

BLK

BOOM LIMIT

SOLDER TIPS

86

87

30

87A 85

11

WHT/RED 10.0"

RED/WHT 4.0"

BLK5.0"

WHT/RED 10.0"

9

14BLK10.0"

11

BLK10.0"

BLK

15

2

FUNCTION PIN WIRE COLOR NOTES1 GREEN POWER2 WHITE/RED TO A2B GROUND1 RED/BLACK POWER2 RED/WHITE GROUND1 WHITE/BLACK POWER2 WHITE TO CCW SWITCH (3 COND CABLE)1 ORANGE POWER2 BLACK TO CW SWITCH (3 COND CABLE)1 WHITE POWER2 BLACK BOOM SWITCH CABLE1 BLUE POWER2 WHITE/RED TO A2B GROUND1 GREEN/BLACK POWER2 WHITE/RED TO A2B GROUND1 ORANGE/BLACK POWER2 RED/WHITE GROUND1 WHITE/RED TO PIN 1, PRESSURE SWITCH2 RED/WHITE FROM HU, BD, EXT GND1 RED/WHITE GROUND2 WHITE/RED FROM A2B PIN 2* WHITE *PIN 2 ON ROTATE CCW PLUG** BLACK **PIN 2 ON ROTATE CW PLUG

N/A GREEN GROUND*** WHITE ***PIN 2 ON BOOM UP PLUGN/A BLACK

BOOM LIMIT2 COND CABLE

HOIST UP

HOIST DN

ROTATE CCW

ROTATE CW

A2B SWITCH

PRESSURE SWITCH

ROTATE SWITCH3 COND CABLE

BOOM UP

BOOM DN

EXTEND

RETRACT

ITEM NO. QTY. PART NO. DESCRIPTION1 1 800632000 CABLE, 16/10 SO BLACK2 8 366367000 DEUTCH 2-PIN ASSEMBLY3 1 366367001 HOUSING, DEUTSCH 2-PIN PLUG4 1 366367002 WEDGE, DEUTCH 2-PIN PLUG5 11 366367003 CONTACT, DEUTSCH SOCKET6 1 360769001 HOUSING, DEUTSCH 2-PIN RECEPTACLE7 1 360769002 WEDGE, DEUTCH 2-PIN RECEPTACLE8 2 366376003 CONTACT, DEUTSCH 9 6 001104000 TERMINAL SPLICE, 14-16 GA

10 2 000101000 TERMINAL RING, 5/32, 14-16 GA11 2 000501000 TERMINAL RING, 5/16, 14-16 GA12 1 800628000 WIRE, 3 CONDUCTOR13 1 800626000 WIRE, 2 CONDUCTOR14 4 320357 FEMALE SPADE, NON-INSULATED15 1 320363 PLUG SPADE, NOINSULATED16 31in 800618000 WIRE, 16GA, WHITE/RED17 26in 800617000 WIRE, 16GA, RED/WHITE

10-9.0.007/26/04

JUNCTION BOX ASSEMBLYHARD WIRED SERIES

109

16

911

28

1

10

911

6

12

13

3

119 15

5

14

10

7

FUNCTION 19 PIN 8 PIN 12 P IN GND W IRE COLORBOOM UP A 5 REDHOIST UP B 1 GREEN

ROTATE CW C 4 ORANGEENGINE FAST D 3 RED/W HITEROTATE CCW E 3 BLACK

HOIST DN F 2 RED/BLACKBOOM DN G 6 BLUERETRACT H 8 ORANGE/BLACKEXTEND J 7 GREEN/BLACK

NOT USED K - - W HITE/BLACKPOW ER L 1 W HITE

PROP +0 TO 5V M 11 BLUE/BLACKGROUND N GND BLACK/W HITE

AUXILARY P 4 GREEN/W HITEENGINE START R 5 BLUE/W HITEENGINE STOP S 6 BLACK/REDPROP POW ER T 9 W HITE/RED

NOT USED U - - ORANGE/REDNOT USED V - - BLUE/REDGROUND 10 GND BLACK/W HITEGROUND 2 GND BLACK/W HITEGROUND 12 RED

10-10.0.007/26/04

JUNCTION BOX ASSEMBLYHARD WIRED SERIES

ITEM NO. QTY. PART NO. DESCRIPTION1 1 366470000 JUNCTION BOX2 1 366095 RECEPTACLE, 19 PIN3 1 366523001 HOUSING, DEUTSCH 8-PIN RECEPTACLE4 1 480594001 CABLE, PENDANT, 16/10 SO BLACK5 1 366471000 COVER, JUNCTION BOX6 1 366524001 HOUSING, DEUTSCH 12-PIN RECEPTACLE7 1 366097000 CAP W/CHAIN (FOR RECEPTACLE)8 4 366519000 NUT, SELF CLINCHING9 17 019600 WASHER SP LK #610 16 001004000 SCW PN HD #6 X 3/4 LG11 13 015400 NUT HX #6-3212 1 366524002 WEDGE, DEUTSCH RECEPTACLE, 12 PIN13 1 366523002 WEDGE, DEUTSCH RECEPTACLE, 8 PIN14 18 366376003 CONTACT, DEUTSCH15 3 000101000 TERMINAL RING, 5/32, 14-16 GA16 1 366469000 DECAL, JUNCTION BOX WIRING

10-11.0.007/26/04

PENDANT ASSEMBLY, 8 FUNCTION HARD WIRED SERIES

10-11.0.0 6/02/2003

PENDANT ASSEMBLY, 8 FUNCTION HARD WIRED SERIES

ITEM QTY PART NO. DESCRIPTION

1 1 480501 HOUSING, PROP. PENDANT MACHINED2 1 480518 DECAL/COVER PLATE3 8 REF NUT (INCLUDED WITH SWITCH)4 8 640300 BOOT, TOGGLE5 1 480567 CORD GRIP, HUBBELL CONNECTOR6 2 002607 SCREW, HX HD #10-24 NC X 3/4 LG7 2 015801 NUT, HEX, LOCKING, #10-24 NC8 1 480507 POTENTIOMETER ASSEMBLY9 1 480506 TRIGGER

10 1 480517 SCREW, SOC HD, #10-32 NF X 5/8 LG11 4 634200 SWITCH, TOGGLE DPDT12 1 480504 BACK PLATE, HOUSING13 4 001004 SCREW, PAN HD, #6-32 X 3/4 LG14 1 680113 CABLE ASSEMBLY, BAYONET15 8 REF WASHER, LOCK (INCLUDED WITH SWITCH)16 3 660302 CONDUCTOR ASSEMBLY17 1 480524 CONDUCTOR ASSEMBLY18 1 480523 SPRING, TRIGGER RETURN19 1 005003 SCREW, S.T. PAN HD, #6-32 X 3/8 LG20 4 636600 JUMPER21 4 622346 CONDUCTOR ASSEMBLY22 3 622347 CONDUCTOR ASSEMBLY23 1 622000 SWITCH, TOGGLE SPDT24 3 750090 SWITCH, TOGGLE ON/OFF25 1 480526 CONDUCTOR ASSEMBLY26 2 750737 TIE, CABLE

10-12.0.0 6/02/2003

PENDANT CABLE ASSEMBLY HARD WIRED SERIES

ITEM QTY PART NO. DESCRIPTION1 1 366098 PLUG, CONNECTOR2 1 480515 CLAMP, CABLE3 30' 480594 CABLE, CONDUCTOR (19 COND)4 2 000101 TERMINAL RING #6 / 14-16 GA5 2 480510 CONNECTOR, BULLET, FEMALE6 13 002012 TERMINAL RING #6 / 18-22 GA7 6" 490243 TUBING, HEAT SHRINK

10-13.0.0 6/02/2003

PROPORTIONAL VALVE CONTROLLER/AMP HARD WIRED SERIES

REFRENCE AUTO CRANE P/N 366363001

FALLING RAMP

RISING RAMP

DITHER FREQDITHER AMPLITUDE

MINIMUM CURRENT

MAXIMUM CURRENT

OUTPUT: 2000mA MAXI-MIN SETTING: 0 TO 500mAI-MAX SETTING: 600 TO 2000mACABLE LENGTH: 6 FEET

Minimum current adjustment: Current is factory set at 150 mA, no adjustment required at installation. If adjustment is required, set the minimum current before setting the maximum current. Apply minimum input (0 VDC). If the desired minimum current is greater, adjust the trim pot CW until the desired current is achieved. Maximum current: Current is factory set at 1600 mA, no adjustment required at installation. If adjustment is required, apply maximum control (5 VDC). Turn the trim pot CCW to adjust the current setting downwards to the desired minimum. Ramp and Dither Ramp and dither is adjusted at the factory and does not require any further adjustment.

10-14.0.0 6/02/2003

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

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

LIMITED WARRANTY 2 YEAR PARTS AND LABOR

Auto Crane will warranty to the consumer for a period of (2) years parts and labor from the date of purchase. Each new Auto Crane unit they sell will be free under normal use and service from defects in material and workmanship. Date of purchase will be honored as the date indicated on the Bill of Sale, which must accompany the Warranty Registration and be on file with Auto Crane. Absent a valid Warranty Registration and appropriate documentation, the original date of manufacture, as indicated by the serial number on the product, will be used to determine the effective date of the 2 year warranty. The obligation of Auto Crane under this warranty is limited to the replacement or repair of parts that appear to the manufacturer after review and/or inspection to be defective and paid flat rate labor for replacing defective parts. This warranty does not obligate Auto Crane to bear the travel time charges in connection with the replacement or repair of defective parts. Responsibility for customer's claims arising from misapplication, abuse, misuse or alteration of equipment or parts lies with the distributor or user and no warranty obligation is assumed in these circumstances by Auto Crane. Auto Crane will in no event be liable for any consequential damages or contingent liabilities arising out of the failure of any Auto Crane Product or parts to operate properly. Auto Crane makes no warranty in respect to component accessories, it being subject to the warranties of their respective manufacturers. If field service, at the request of the distributor, is rendered and fault is found not to be with Auto Crane's product, the distributor shall pay the time and expense of the field representative. Claims for service labor or other expenses that have incurred by the buyer without approval or authorization or Auto Crane will not be accepted. When applying for warranty, claims may be handled by contacting your nearest authorized Auto Crane Distributor. All claims are to be filed in writing on an Auto Crane Warranty Claim Form. AUTO CRANE COMPANY IS UNDER NO OLIGATION TO EXTEND THIS WARRANTY TO ANY CUSTOMER FOR WHICH AN AUTO CRANE DELIVERY REPORT FORM HAS NOT BEEN COMPLETED AND ON FILE WITH AUTO CRANE COMPANY

Limited Warranty 2 Years Effective September 2, 2003

8406 H OWNERS MANUAL - Auto Craneautocrane.us/wp-content/uploads/8406H-Wireless-Hard-Wired-480899... · 8406 H OWNERS MANUAL Manual No. 480899 ... WIRE HARNESS ASSEMBLY 6-2 ... Auto

Documents