Auto Crane 6006H User manual

OWNERS MANUAL
6006H
REVISION 2/2000
PART NO. 999945
SERIAL NO. __________________________
PO BOX 580697, TULSA, OK 74158-0697
4707 N. MINGO ROAD, TULSA, OK 74117-5904
PHONE [phone]
SALES FAX [phone] SERVICE FAX [phone]

WARNING! Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of
a vehicle certify that the vehicle complies with all applicable federal regulations. Any
modifications performed on the vehicle prior to the final stage are also considered
intermediate stage manufacturing and must be certified as to compliance. The installer of
this crane and body is considered one of the manufacturers of the vehicle. As such a
manufacturer, the installer is responsible for compliance with all applicable federal and
state regulations, and is required to certify that the vehicle is in compliance.
WARNING! It is the further responsibility of the installer to comply with the OSHA
Truck Crane Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).
WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL
POWER LINES! Death or serious injury will result from boom, line, or load contacting
electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to
50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.
WARNING! NEVER .............................
vEXCEED load chart capacities (centerline of rotation to hoist hook).
vun-reel last 5 wraps of cable from drum!
vwrap cable around load!
vattempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
vweld, modify, or use unauthorized components on any Auto Crane unit! This will void any
warranty or liability. Also failure of the crane may result.
vplace a chain link on the tip of the hook and try to lift a load!
vuse a sling bar or anything larger than the hook throat that could prevent the hook latch from
closing, thus negating the safety feature!
vhold on any pendant Select Switch that will cause unsafe operating conditions!
WARNING! In using a hook with latch, ALWAYS make sure that the hook throat is closed
before lifting a load! Proper attention and common sense applied to the use of the hoist hook and
various slings will prevent possible damage to material being hoisted and may prevent injury to
personnel.
WARNING! Failure to correctly plumb and wire crane can cause inadvertent operation and
damage to crane and/or personnel!
WARNING! Auto Crane Company remote controlled cranes are not designed or intended to
be used for any applications involving the lifting or moving of personnel.
WARNING! ALWAYS operate the crane in compliance with the load capacity chart.
Do not use the overload shutdown device to determine maximum rated loads, if your crane is
equipped with this type of device.
warning 9/98
WARNINGS - READ THIS PAGE!

Auto Crane products are designed to provide many
years of safe, trouble-free, dependable service when
properly used and maintained.
To assist you in obtaining the best service from
your crane and to avoid untimely crane and/or vehicle
failure, this manual provides the following operating
and service instructions. It is specifically
recommended that all operating and service personnel
consider this manual as mandatory material for reading
and study before operating or servicing Auto Crane
products. It is highly recommended that crane owners,
equipment managers and supervisors also read this
manual.
Auto Crane has incorporated several safety features
in the 6006H series cranes for your protection. The
choice of materials and the design of the electrical
system minimizes weight and lengthens durability. The
hydraulic components meet or exceed a 3.5:1 safety
factor. Holding valves prevent the load from dropping
if a hose should fail. A 10u filter in the return line of
the hydraulic system removes dirt and grit that may
cause erratic operation. The reservoir has a 15u air
filter in the filler cap. The pump has a 40 mesh
strainer in the suction line.
For your convenience the overall dimensions of the
6006H series crane are on the General Dimension
Drawing. Maximum turning radius at both the hoist
motor and the rotation motor are also on that drawing.
Remember, the crane adds weight to the vehicle.
Adding weight may change the driving and riding
characteristics of the vehicle unless the appropriate
overload spring(s) are installed on the truck. The
payload of the vehicle is reduced by the weight of the
crane. The operator should exercise care when loading
the vehicle. Distributing the payload on the vehicle
evenly will greatly improve the driving and riding
characteristics of the vehicle. A minimum G.V.W. of
14,500 lbs. is recommended for mounting the 6006H
series cranes.
Auto Crane Company issues a limited
warranty certificate with each unit sold.
See last page for warranty policy.
It has always been Auto Crane Company policy to
handle all warranty claims we receive as promptly as
possible. If a warranty claim involves discrepant
material or workmanship, Auto Crane will take
immediate corrective action. It is understandable that
Auto Crane Company cannot assume responsibility of
liability when it is obvious that our products have been
abused, mis-used, overloaded or otherwise damaged by
inexperienced persons trying to operate the equipment
without reading the manual.
Auto Crane will not assume responsibility
or liability for any modifications or changes
made to unit, or installation of component
parts done without authorization.
Auto Crane maintains a strong distributor network
and a knowledgeable Customer Service Department. In
most cases, an equipment problem is solved via phone
conversation with our customer service department.
The customer service department also has the ability to
bring a local distributor, a regional sales manager, or a
factory serviceman into the solution of an equipment
problem. If, through no fault of Auto Crane Company,
it is necessary to send an experienced factory
serviceman on a field service call, the rates stated in the
Auto Crane Distributor's Flat Rate Manual will apply.
Auto Crane Company's extensive Research and
Development Program allow our customers to use the
best equipment on the market. Our Engineering Staff
and our knowledgeable sales people, are always
available to our customers in solving crane and
winch-type application problems. When in doubt, call
the Auto Crane factory.
DISTRIBUTOR ASSISTANCE:
Should you require any assistance not given in this
manual, we recommend that you consult your nearest
Auto Crane Distributor. Our distributors sell
authorized parts and have service departments that can
solve almost any needed repair.
NOTE: THIS MANUAL SHOULD REMAIN
WITH THE CRANE AT ALL TIMES.
This manual does not cover all maintenance,
operating, or repair instructions pertinent to all possible
situations. If you require additional information, please
contact the Auto Crane Company at the following
telephone number: [phone]. The information
contained in the manual is in effect at the time of this
printing. Auto Crane Company reserves the right to
update this material without notice or obligation.
INTRODUCTION
6006H SERIES
1-1.0.0 6HINTRO 3/98

LAST PAGE
WARRANTY .................................................
9-9.9.9LOAD CHART ................................................
8-1.0.0MISCELLANEOUS ............................................
6-1.0.0HYDRAULIC SECTION ........................................
5-2.0.0ELECTRICAL SECTION .......................................
4-10.0.0HOIST ACTUATOR ...........................................
4-8.0.0ROTATION GEAR BOX .......................................
4-7.0.0AUTOMATIC SAFETY BRAKE .................................
4-5.0.0TWO-BLOCK ASSEMBLY .....................................
4-4.0.0BOOM ASSEMBLY ...........................................
4-1.0.0GENERAL ASSEMBLY (PEDESTAL) ...........................
3-5.0.0LUBRICATION & MAINTENANCE SCHEDULE ..................
3-4.0.0LIFE OF WIRE LINE ..........................................
3-1.0.0HYDRAULIC VALVES, TROUBLESHOOTING ...................
2-7.0.0OPTIMETER TROUBLESHOOTING .............................
2-5.0.0AMPLIFIER SETUP PROCEDURE ..............................
2-4.0.0GENERAL DIMENSIONS ......................................
2-3.0.0SAFETY DECAL SECTION ....................................
2-2.0.0CRANE ORIENTATION & HYDRAULIC HOOKUP ...............
2-1.0.0MOUNTING AND INSTALLATION .............................
1-5.0.0INSPECTION, TESTING & MAINTENANCE .....................
1-4.0.0QUALIFICATIONS FOR OPERATORS ...........................
1-3.0.0OPERATION OF UNIT / OUTRIGGERS ..........................
1-2.0.0OPERATING PRACTICES & WARNINGS ........................
1-1.0.0INTRODUCTION .............................................
6006H SERIES - OWNER'S MANUAL
TABLE OF CONTENTS
6HTOC 3/98

1.Make sure this manual has been thoroughly read by
all crane operating personnel and supervisors.
2.A routine inspection of the crane should be mandatory
before each operating day. Any defects should be
corrected immediately.
3.At a job site the vehicle should be positioned so that
the crane can adequately reach the load within the
rated capacity (centerline of rotation to hoist hook).
4.Keep the vehicle as level as possible during operation.
5.For electric cranes, engage emergency brake and
leave ignition on with transmission in neutral (or in
park for automatic transmissions). Activate any crane
power switches. For Auto Crane units requiring
battery and hydraulic operation, engage emergency
brake, place gear selector in neutral, press clutch,
activate PTO, release clutch and after hydraulic fluid
is warm, set throttle control to proper engine speed.
6.Always use outriggers from the truck to the ground.
Be sure these are firm and adequately positioned.
When rotating, keep load as low to the ground as
possible.
7.Remove pendant control from cab or storage area. On
smaller units, plug pendant into receptacle on crane.
On larger units, remove pendant control from guard
and unwrap cable from boom. Do not operate crane
until cable is unwound completely. On all cranes,
detach hook from dead man. Crane is now ready for
operation.
8.Always boom up before rotating so the boom will
clear the required boom support.
9.When extending the boom, always maintain clearance
between the boom crown and the traveling block or
hoist hook.
10.Always observe safe and practical operation to avoid
possible accidents. Refer to Safety Tips and
Precautions.
11.After completing lifting operations, return the boom
to stowed position on the boom support. Avoid
unneeded pressure on the boom support.
12.Store pendant control on proper location (in cab or on
crane).
13.Return outriggers to stowed position. Make sure they
are pinned in place or jacklegs are returned to
compartment.
14.Check work area for any tools or equipment not
stored.
15.Release throttle control, depress clutch and disengage
PTO. Deactivate any crane power switches.
16.Report any unusual occurrence during crane operation
that may indicate required maintenance or repair.
17.NEVER use two cranes to support a load too large for
either crane.
18.Spray all electrical equipment with special corrosion
resistant coating. This eliminates rust or corrosion
due to melting and freezing action of condensation.
1-3.0.0 OPER 2/98
--- IMPORTANT ---
OPERATION OF UNIT
OPERATION OF
OUTRIGGERS
For hydraulic outriggers:
1.Shift crane/outrigger control valve to
"outrigger" position.
2.While operating the outrigger control valves
(located on the outrigger cylinders)
simultaneously operate the boom-up control
switch. This will allow the hydraulic system to
build pressure.
3.After outriggers are positioned, return
crane/outrigger selector to "crane" position.
4.Crane is now ready to operate.
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.

OPERATORS
1Crane operation shall be limited to personnel with
the following minimum qualifications:
A.designated persons
B.trainees under the direct supervision of a designated
person
C.maintenance and test personnel (when it is
necessary in the performance of their duties)
D.inspectors (crane).
2No one other than the personnel specified above shall
enter the operating area of a crane with the exception
of persons such as oilers, supervisors, and those
specified persons authorized by supervisors whose
duties require them to do so and then only in the
performance of their duties and with the knowledge
of the operator or other persons.
QUALIFICATIONS FOR OPERATORS
3Operators shall be required by the employer to pass a
practical operating examination. Qualifications shall
be limited to the specific type of equipment for which
examined.
4Operators and operator trainees shall meet the
following physical qualifications:
A.Vision of at least 20/30 Snellen in one eye and
20/50 in the other, with or without corrective lenses.
B.Ability to distinguish colors, regardless of position,
if colors differentiation is required for operation.
C.Adequate hearing with or without hearing aid for
the specific operation.
5Evidence of physical defects or emotional instability
which render a hazard to operator or others, which
in the opinion of the examiner could interfere with
the operator's performance may be sufficient cause
for disqualification. In such cases, specialized clinical
or medical judgment and tests may be required.
6Evidence that the operator is subject to seizures or
loss of physical control shall be sufficient reason for
disqualification. Specialized medical tests may be
required to determine these conditions.
7Operators and operator trainees should have normal
depth perception, coordination, and no tendencies to
dizziness or similar undesirable characteristics.
8In addition to the above listed requirements, the
operator shall:
A.Demonstrate the ability to comprehend and interpret
all labels, operator's manuals, safety codes and other
information pertinent to correct crane operations.
B.Possess knowledge of emergency procedures and
implementation of same.
C.Demonstrate to the employer the ability to operate
the specific type of equipment.
D.Be familiar with the applicable safety regulations.
E.Understand responsibility for maintenance
requirements of crane.
F.Be thoroughly familiar with the crane and its
control functions.
G.Understand the operating procedures as outlined by
the manufacturer.
CONDUCT OF OPERATORS
9The operator shall not engage in any practice which
will divert his attention while actually operating the
crane.
10 Each operator shall be responsible for those
operations under the operator's direct control.
Whenever there is any doubt as to safety, the
operator shall consult with the supervisor before
handling the loads.
11 The operator should not leave a suspended load
unattended unless specific precautions have been
instituted and are in place.
12 If there is a warning sign on the switch or engine
starting controls, the operator shall not close the
switch or start the engine until the warning sign has
been removed by the appointed person.
13 Before closing the switch or starting the engine, the
operator shall see that all controls are in the "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.
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
QUAL 7/98
1-3.1.0

B.land the suspended load and boom, if practical.
15 The operator shall be familiar with the equipment
and its proper care. If adjustments or repairs are
necessary, the operator shall report the same
promptly to the appointed person, and shall also
notify the next operator.
16 All controls shall be tested by the operator at the
start of each shift. If any controls do not operate
properly, they shall be adjusted or repaired before
operations are begun.
17 Stabilizers shall be visible to the operator while
extending or setting unless operator is assisted by a
signal person.
OPERATING PRACTICES
HANDLING THE LOAD
18 Size of load
A.No crane shall be loaded beyond the rated load
except for test purposes.
B.The load to be lifted is to be within the rated load of
the crane and its existing configuration.
C.When loads which are not accurately known are to
be lifted, the person responsible for the job shall
ascertain that the weight of the load does not exceed
the crane rated load at the radius at which the load
is to be lifted.
19 Attaching the load
A.The load shall be attached to the hook by means of
slings or other devices of sufficient capacity.
B.Hoist rope shall not be wrapped around the load.
20 Moving the load
A.The operator shall determine that:
B.The crane is level and, where necessary, the
vehicle/carrier is blocked properly.
C.The load is well secured and balanced in the sling or
lifting device before it is lifted more than a few
inches.
D.Means are provided to hold the vehicle stationary
while operating the crane.
E.Before starting to lift, the hook shall brought over
the load in such a manner as to minimize swinging.
F.During lifting care shall be taken that:
1.there is no sudden acceleration or
deceleration of the moving load.
2.load, boom or other parts of the crane do
not contact any obstruction.
G.Cranes shall not be used for dragging loads
sideways.
H.This standard recognizes that articulating boom
cranes are designed and intended for handling
materials. They do not meet personnel lift or
elevator requirements. Therefore, no lifting,
lowering, swinging or traveling shall be done while
a person is on the hook or load. Hook attached
suspended work platforms (baskets) shall not be
used with cranes covered by this standard. Work
platforms attached to the boom must be approved by
crane manufacturer.
I.The operator should avoid carrying loads over
people.
J.When the crane is so equipped, the stabilizers shall
be fully extended and set. Blocking under stabilizers
shall meet the requirements as follows:
1.strong enough to prevent crushing.
2.of such thickness, width and length as to
completely support the stabilizer pad.
K.Firm footing under all tires, or individual stabilizer
pads should be level. Where such a footing is not
otherwise supplied, it should be provided by
timbers, cribbing, or other structural members to
distribute the load so as to not exceed allowable
bearing capacity or the underlying material.
L.In transit, the boom shall be carried in stowed
position.
M.When rotating the crane, sudden starts and stops
shall be avoided. rotational speed shall be such that
the load does not swing out beyond the radius at
which it can be controlled.
N.The crane shall not be transported with a load on
the hook unless recommended by the manufacturer.
O.No person should be permitted to stand or pass
under a suspended load.
21 Stowing procedure. Follow the manufacturer's
procedure and sequence when stowing and
un-stowing the crane.
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
QUAL 7/98
1-3.2.0

MISCELLANEOUS
OPERATING NEAR ELECTRICAL POWER
LINES
22 Cranes shall be operated so that no part of the crane
or load enters into the danger zone shown above.
EXCEPTIONS
A.The danger zone may be entered after confirmation
by an appointed person that the electrical
distribution and transmission lines have been
de-energized and visibly grounded at the point of
work; or
B.The danger zone may be entered if insulating
barriers (not a part of nor an attachment to the
crane) have been erected to prevent physical contact
with the lines.
23 For lines rated 50 kV or below, minimum clearance
between the lines and any part of the crane or load
(including handling appendages) shall be 10 ft. (3m).
For higher voltages, see Table 1.
24 Caution shall be excercised when working near
overhead lines, because they can move horizontally or
vertically due to wind, moving the danger zone to new
positions.
25 In transit with no load and boom lowered the
clearance shall be specified in Table 1.
26 A qualified signalperson shall be assigned to observe
the clearance and give warning before approaching
the above limits.
A.Any overhead wire shall be considered to be an
energized line unless and until the person owning
such line or the electrical utility authorities verify
that it is not an energized line.
B.Exceptions to this procedure, if approved by the
administrative or regulatory authority if the
alternate procedure provides equivalent protection
and set forth in writing.
C.Durable signs shall be installed at the operator's
station and on the outside of the crane, warning that
electrocution or serious bodily injury may occur
unless a minimum clearance of 10 ft. (3.0m)
between the crane or the load being handled and
energized power lines. Greater clearances are
required because of higher voltage as stated above.
These signs shall be revised but not removed when
local jurisdiction requires greater clearances.
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
QUAL 7/98
1-3.3.0
(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, kV clearance
minimum required
TABLE 1

INSPECTION CLASSIFICATION
27 Initial inspection. Prior to initial use, all new, altered,
modified or extensively repaired cranes shall be
inspected by a designated person to insure compli-
ance with provisions of this standard.
28 Regular inspection. Inspection procedure for cranes
in regular service is divided into two general classifi-
cations based upon the intervals at which inspection
should be performed. The intervals in turn are
dependent upon the nature of the components of the
crane and the degree of their exposure to wear,
deterioration, or malfunction. The two general 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 as
specifically recommended by the manufacturer
FREQUENT INSPECTION
29 Inspection shall be performed by designated
personnel.
A.control mechanisms for maladjustment interfering
with proper operation - daily, when used
B.control mechanisms for excessive wear of compo-
nents and contamination by lubricants or other
foreign matter
C.safety devices for malfunction
D.all hydraulic hoses, particularly those which flex in
normal operation of crane functions, should be
visually inspected once every working day, when
used
E.hooks and latches for deformation, chemical
damage, cracks, and wear. Refer to ANSI/ASME
B30.10
F.rope reeving for compliance with crane manufac-
turer's specifications, if optional winch is used
G.electrical apparatus for malfunctioning, signs of
excessive deterioration, dirt and moisture accumula-
tion
H.hydraulic system for proper oil level and leaks daily
I.tires for recommended inflation pressure, cuts and
loose wheel nuts
J.connecting pins and locking device for wear and
damage
PERIODIC INSPECTION
30 Deformed, cracked or corroded members in the
crane structure and carrier.
31 Loose bolts, particularly mounting bolts.
32 Cracked or worn sheaves and drums.
33 Worn, cracked, or distorted parts such as pins,
bearings, shafts, gears, rollers and devices.
34 Excessive wear on brake and clutch system parts and
lining.
35 Crane hooks inspected for cracks.
36 Travel steering, braking, and locking devices, for
malfunction.
37 Excessively worn or damaged tires.
38 Hydraulic and pneumatic hose, fittings, and tubing
inspection.
A.evidence of leakage at the surface of the flexible
hose or its junction with metal and coupling
B.blistering, or abnormal deformation to the outer
covering of the hydraulic or pneumatic hose
C.leakage at threaded or clamped joints that cannot be
eliminated by normal tightening or recommended
procedures
D.evidence or excessive abrasion or scrubbing on the
outer surface of a hose, rigid tube, or fitting. Means
shall be taken to eliminate the interference of
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSP 9/98
1-5.0.0

elements in contact or otherwise protect the
components
39 Hydraulic and pneumatic pumps and motors
inspection.
A.loose bolts or fasteners
B.leaks at joints between sections
C.shaft seal leaks
D.unusual noises or vibrations
E.loss of operating speed
F.excessive heating of the fluid
G.loss of pressure
40 Hydraulic and pneumatic valves inspection.
A.cracks in valve housing
B.improper return of spool to neutral position
C.leaks at spools or joints
D.sticking spools
E.failure of relief valves to attain or maintain correct
pressure setting
F.relief valve pressure shall be checked as specified by
the manufacturers
41 Hydraulic and pneumatic cylinders inspection.
A.drifting caused by fluid leaking across piston
B.rod seals leaking
C.leaks at welding joints
D.scored, nicked, or dented cylinder rods
E.damaged case (barrel)
F.loose or deformed rod eyes or connecting joints
42 Hydraulic filters. Evidence of rubber particles on the
filter elements may indicate hose, "O" ring, or other
rubber component deterioration. Metal chips or
pieces on the filter may denote failure in pumps,
motors, or cylinders. Further checking will be
necessary to determine origin of the problem before
corrective action can be taken.
43 Labels are to be in place and legible.
CRANES NOT IN REGULAR USE
44 A crane which has been idle for a period of over one
month or more, but not less than six months, shall be
given an inspection conforming with the initial-
regular- frequent inspections.
45 A crane which has been idle for a period of over six
months shall be given a complete inspection conform-
ing with the initial-regular-frequent inspection
requirements.
INSPECTION RECORDS
46 Dated records for periodic inspection should be made
on critical items such as brakes, crane hooks, rope,
hydraulic and pneumatic cylinders, and hydraulic
and pneumatic relief pressure valves. Records should
be kept available to an appointed person.
OPERATIONAL TESTS
47 Prior to initial use, all new, altered, modified, or
extensively repaired cranes shall be tested for compli-
ance with the operational requirements of this
section, including functions such as the following:
A.load lifting and lowering mechanisms
B.boom lifting and lowering mechanisms
C.boom extension and retraction mechanisms
D.swing mechanisms
E.safety devices
F.operating controls comply with appropriate function
labels
Operational crane test results shall be made
available to an appointed person.
RATED TEST LOAD
Prior to initial use, altered, modified, or
extensively repaired cranes shall be load
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSP 9/98
1-5.1.0

tested by or under the direction of an
appointed person.
48 Test loads shall not exceed 110% of the manufac-
turer's load ratings.
49 Written reports shall be maintained showing test
procedures and confirming the adequacy of repairs.
MAINTENANCE
PREVENTIVE MAINTENANCE
50 Before adjustment and repairs are started on a crane,
the following precautions shall be taken as
applicable:
A.crane placed where it will cause the least 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 otherwise
secured against dropping
E.relieve hydraulic oil pressure from all hydraulic
circuits before loosening or removing hydraulic
components
51 Warning or "OUT OF ORDER" signs shall be placed
on the crane controls.
52 After adjustments and repairs have been made, the
crane shall not be returned to service until all guards
have been reinstalled, trapped air removed from
hydraulic system (if required), safety devices reacti-
vated, and maintenance equipment removed.
ADJUSTMENTS AND REPAIRS
53 Any hazardous conditions disclosed by the inspection
requirements shall be corrected before operation of
crane is resumed, Adjustments and repairs shall be
done only by designated personnel.
54 Adjustments shall be maintained to assure correct
functioning of components, The following are
examples:
A.functional operating mechanism
B.safety devices
C.control systems
55 Repairs or replacements shall be provided as needed
for operation.
The following are examples:
A.critical parts of functional operating mechanisms
which are cracked, broken, corroded, bent, or exces-
sively worn
B.critical parts of the crane structure which are
cracked, bent, broken, or excessively corroded
C.crane hooks showing cracks, damage, or corrosion
shall be taken out of service. Repairs by welding are
not recommended
56 Instructions shall be provided by the manufacturer
for the removal of air from hydraulic circuits.
LUBRICATION
All moving parts of the crane, for which
lubrication is specified, should be regularly
lubricated per the manufacturer's
recommendations and procedures.
ROPE INSPECTION
57 Frequent Inspection
A.All running ropes in service should be visually
inspected once each working day. A visual inspec-
tion shall consist of observation of all rope which
can be in use during the days operations. These
visual observations should be considered with
discovering gross damage such as listed below,
which may be an immediate hazard.
1.distortion of the rope such as kinking,
crushing, un-stranding, birdcaging, main
strand displacement, or core protrusion.
Loss of rope diameter in a short length or
unevenness of outer strands should be
replaced
2.general corrosion
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSP 9/98
1-5.2.0

3.broken or cut strands;
4.number, distribution and type of visible
broken wires. When such damage is
discovered, the rope shall either be
removed from service or given as
inspection.
B.Care shall be taken when inspecting sections of
rapid deterioration such as flange points, crossover
points, and repetitive pickup points on drums.
58 Periodic inspection
A.The inspection frequency shall be determined by a
qualified person and shall be based on such factors
as:
1.expected rope life as determined by
experience on the particular installation or
similar installations
2.severity of environment
3.percentage of capacity lifts
4.frequency rates of operation
5.exposure to shock loads
Inspection need not be at equal calendar
intervals and should be more frequent as the
rope approaches the end of it's service life.
This inspection shall be made at least
annually.
B.Periodic inspection shall be performed by a desig-
nated person. This inspection shall cover the entire
length of the rope. Only the surface wires need be
inspected. No attempt should be made to open the
rope. Any deterioration results in appreciable loss of
original strength, such as described below, shall be
noted and determination made as to whether use of
the rope would constitute a hazard: points listed
above reduction of rope diameter below nominal
diameter due to loss of core support, internal or
external corrosion, or wear of outside wires;
severely corroded, cracked, bent, worn or improp-
erly applied connections;
C.Care shall be taken when inspecting sections subject
to rapid deterioration such as the following:
1.sections in contact with saddles, equalizer
sheaves, or other sheaves where rope travel
is limited
2.sections of the rope at or near terminal ends
where corroded or broken wires may
protrude
ROPE REPLACEMENT
59 No precise rules can be given for determination of the
exact time for replacement of rope, since many
variable factors are involved.
Continued use in this respect depends upon
good judgement by a designated person in
evaluating remaining strength in a used rope
after allowance for deterioration disclosed by
inspection. Continued rope operation depends
upon this remaining strength.
60 Conditions such as the following shall be reason for
questioning continued use of the rope or increasing
the frequency of inspection:
A.in running ropes, six randomly distributed broken
wires in one lay or three broken wires in one strand
in one lay
B.one outer wire broken at the contact point with the
core of the rope structure and protrudes or loops out
of the rope structure. Additional inspection of this
section is required
C.wear of one third of the original diameter of the
outside individual wire
D.kinking, crushing, birdcaging, or any other damage
resulting in distortion of the rope structure
E.evidence of any heat damage from any cause
F.reduction from nominal diameter of more than 1/64
in. (0.4mm) for diameters up to and including 5/16
in. (8 mm), 1/32 in. (0.8 mm) for diameter 3/8 in.
(9.5 mm) to and including 1/2 in. (13 mm), 3/64 in.
(1.2 mm) for diameter 9/16 in. (14.5 mm) to and
including 3/4 in. (19 mm). 1/16 in. (1.6 mm) for
diameter 7/8 in. (22 mm) to and including 11/8 in.
(29 mm), 3/32 in. (2.4 mm) for diameters 11/4 in.
(32 mm) to and including 11/2 in. (38 mm)
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSP 9/98
1-5.3.0

G.In standing ropes, more than two broken wires in
one lay in sections beyond end connections or more
than one broken wire at an end connection.
H.Replacement rope shall have a strength rating at
least as great as the original rope furnished or
recommended by the crane manufacturer. Any
deviation from the original size, grade, or construc-
tion shall be specified by a rope manufacturer, or a
qualified person.
61 Rope not in regular use: all rope which has been idle
for a period of a month or more due to shutdown or
storage of a crane on which it is installed, shall be
given and inspection in accordance with above infor-
mation before it is placed in service. This inspection
shall be for all types of deterioration and shall be
performed by a qualified person.
62 Inspection records
A.frequent inspection- no records required
B.periodic inspections- in order to establish data as a
basis for judging the proper time for replacement, a
dated report condition at each periodic inspection
should be kept on file. This report shall cover
points of deterioration listed above.
ROPE MAINTENANCE
63 Rope should be stored to prevent damage or
deterioration.
64 Unreeling or uncoiling of rope shall be done as
recommended by the rope manufacturer and with
care to avoid kinking or inducing twist.
65 Before cutting a rope, seizing shall be placed on each
side of the place where the rope is to be cut to prevent
unlaying of the strands. On pre-formed rope, one
seizing on each side of the cut is required. On
non-preformed ropes of 7/8 in. (22 mm) diameter or
smaller, two seizings on each side of the cut are
required, and for non-preformed rope 1 in. (25 mm)
diameter or larger, three seizings on each side of the
cut are required.
66 During installation care should be exercised to avoid
dragging of the rope in the dirt or around objects
which will scrape, nick crush or induce sharp bends
in it.
67 Rope should be maintained in a well-lubricated
condition. It is important that lubricant applied as a
part of a maintenance program shall be compatible
with the original lubricant and to this end the rope
manufacturer should be consulted. Lubricant applied
shall be the type which does not hinder visual inspec-
tion. Those sections of rope which are located over
sheaves or otherwise hidden during inspection and
maintenance procedures require special attention
when lubricating rope. The object of rope lubrication
is to reduce internal friction and to prevent corrosion.
68 When an operating rope shows greater wear or well
defined localized areas than on the remainder of the
rope, rope life can be extended in cases where a
section at the worn end, and thus shifting the wear to
different areas of the rope.
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSP 9/98
1-5.4.0

1.Check to make sure the following items are with your crane:
ITEM PART NO. DESCRIPTION
1.366203000 Swivel Block
2.366212000 Vented Relief Valve (Non-proportional Units Only)
3.480525000 Control Valve Assembly (Proportional Units Only)
4.480018000 Pump Assembly (Optional)
5.999946000 Owners Manual
6.015104000 Bolt system: 7/8 NF x 5", Grade 8, (4 Req'd)
2.Pressure and return hoses are not furnished with this crane. The hoses must be provided by the
installer and the lengths determined at installation.
REQUIREMENTS FOR INSTALLATION USING 8 GALLON RESERVOIR WITH RELIEF VALVE AND AUTO
CRANE PROVIDED PUMP
A.RETURN LINE FROM CRANE TO RESERVOIR (IN COMPARTMENT): -8 SAE 100R2 (OR EQUIVALENT).
HOSE LENGTH IS DETERMINED BY INSTALLER. RETURN LINES LONGER THAN 6 FEET SHOULD BE
SIZE -12. HOSE END FITTINGS ARE -8 JIC FEMALE SWIVEL (CRANE END) AND -10 JIC FEMALE
SWIVEL (RESERVOIR END).
B.PRESSURE LINE FROM VENTED RELIEF VALVE TO CRANE: -8 SAE 100R2 (OR EQUIVALENT). HOSE
LENGTH IS DETERMINED BY INSTALLER. HOSE END FITTINGS ARE BOTH -8 JIC FEMALE SWIVEL.
NOTE: CRANE MUST USE RELIEF VALVE P/N 366212, WHICH IS PROVIDED.
C.SUCTION HOSE FROM PUMP TO RESERVOIR: -16 HYDRAULIC SUCTION HOSE WITH TWO (2) -16
HOSE CLAMPS ON EACH END.
D.PRESSURE LINE FROM PUMP TO VENTED RELIEF VALVE (LOCATED ON RESERVOIR) : -12 SAE
100R2 (OR EQUIVALENT). HOSE LENGTH IS DETERMINED BY INSTALLER. HOSE END FITTINGS
ARE BOTH -10 JIC FEMALE SWIVEL.
NOTE:
REFER TO OWNERS MANUAL FOR ADDITIONAL INSTALLATION INFORMATION, AND OTHER RESERVOIR
AND PUMP COMBINATIONS.
CAUTION - FAILURE TO USE CLEAN HYDRAULIC HOSES AND COMPONENTS MAY
CONTAMINATE THE CRANE AND HYDRAULIC SYSTEM AND VOID WARRANTY.
3.Crane must be provided with a flow of 8 gallons per minute and a pressure of 2200 PSI. Excess
flow will cause erratic operation, and too little flow will cause poor crane operation.
4.Vehicle should meet minimum GVW rating of 14,500 pounds.
5.The vehicle MUST be equipped with an engine speed control and tachometer.
6.Make sure mounting surface is properly reinforced to withstand 36,000 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.Always use cable loops on side of boom and pendant guard on side of pedesal to store pendant
assembly, if this type of storage applies.
6HMTG 3/98
MOUNTING and INSTALLATION 6006H
2-1.0.0

11.CHECK FOR PROPER PRESSURE AND RETURN LINE HOOK-UP TO CRANE:
PRESSURE PORT IS ON RIGHT SIDE AS VIEWED FROM THE REAR OF THE CRANE.
12.Use medium pressure Auto Crane filter in the return line unless filter exit port is mounted directly to
the reservoir.
13.Electrical hookup:
NON-REMOVABLE PENDANT UNITS:
A.RUN THE FOLLOWING WIRES THROUGH HOLE IN BASE ASSEMBLY OF CRANE AND SEAL WITH
SILICONE RUBBER TO PREVENT WIRE CHAFING AND LEAKS.
B.CONNECT WIRE FROM DIRECTIONAL VALVE SOLENOID (P/N 480137) TO WHITE WIRE W/ TRACER AT
PENDANT CABLE END.
C.CONNECT POWER CONDUCTOR FROM STARTER SOLENOID TO BLACK WIRE AT BASE OF CRANE,
PASSING THROUGH THE MAIN POWER RELAY. USE THE IN-LINE FUSE PROVIDED.
removable pendant units:
A.OBTAIN THE PROPER WIRING DIAGRAM.
B.WIRE TERMINAL STRIP PER DIAGRAM AND PROTECT STRIP FROM ACCIDENTAL CONTACT.
WARNING! FAILURE TO CORRECTLY PLUMB AND WIRE CRANE CAN CAUSE
INADVERTENT OPERATION AND DAMAGE TO CRANE AND/OR PERSONNEL!
14.Once crane and plumbing are installed on the truck, fill the reservoir to top of sight glass (mobil
DTE 13 or equal). Before operating crane, connect together the pressure and return hoses going to
base of crane using -8 JIC union and engage PTO wih engine running. Allow oil to circulate for 15
to 20 minutes. This will flush contaminants from the system back to the return line filter. Operate
all cylinders to full extension and retraction a minimum of six times, to bleed air from system.
Return all cylinders to the stored position and disengage PTO. Refill reservoir to top sight glass.
To ensure 8 gallons per minute (GPM), install an in-line flow meter between the crane and the reser-
voir in the return hose, or confirm pump speed pump speed is correct. The proper speed for Auto
Crane gear pump P/N 480018 is 1000 RPM.
15.Proper pressure setting can be achieved by, with the PTO disengaged, removing the pipe plug on the
pipe plug on the vented relief valve or proportional valve and installing a 2500 PSI pressure gauge.
Extend the boom "in" all the way and continue holding the switch on. For proportional systems, the
trigger should be pulled completely back (on). Read the pressure gauge and adjust relief valve to
read 2200 PSI. Recheck pressure setting to verify adjustment.
16.Load test the crane to ensure proper functioning and truck stability.
17.Make certain the owner’s manual is delivered to the customer.
18.For additional help: call the service department at the Auto Crane Company. [phone]
(TULSA, OKLAHOMA)
6HMTG 3/98
MOUNTING and INSTALLATION 6006H
2-1.1.0

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 MODIFICA-
TIONS PERFORMED ON THE VEHICLE PRIOR TO THE FINAL STAGE ARE ALSO CONSIDERED INTERMEDIATE
STAGE MANUFACTURING AND MUST BE CERTIFIED AS TO COMPLIANCE. THE INSTALLER OF THIS CRANE
AND BODY IS CONSIDERED ONE OF THE MANUFACTURERS OF THE VEHICLE. AS SUCH A MANUFACTURER,
THE INSTALLER IS RESPONSIBLE FOR COMPLIANCE WITH ALL APPLICABLE FEDERAL AND STATE REGULA-
TIONS, 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).
6HMTG 3/98
MOUNTING and INSTALLATION 6006H
2-1.2.0