AutoCrane 2003 Owner's Manualautocrane.us/wp-content/uploads/2003-999951-022000.pdf · v use a...

OWNERS MANUAL2003 SERIESREVISION 2/2000

PART NO. 999951

SERIAL NO. __________________________

PO BOX 580697, TULSA, OK 74158-0697

4707 N. MINGO ROAD, TULSA, OK 74117-5904

PHONE (918) 836-0463

FAX (918) 834-5979

http://www.autocrane.com

WARNING! Federal law (49 cfr part 571) requires that the Final Stage Manufacturer ofa vehicle certify that the vehicle complies with all applicable federal regulations. Anymodifications performed on the vehicle prior to the final stage are also consideredintermediate stage manufacturing and must be certified as to compliance. The installer ofthis crane and body is considered one of the manufacturers of the vehicle. As such amanufacturer, the installer is responsible for compliance with all applicable federal andstate 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 OSHATruck Crane Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).

WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICALPOWER LINES! Death or serious injury will result from boom, line, or load contactingelectric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.

WARNING! NEVER .............................v EXCEED load chart capacities (centerline of rotation to hoist hook).v un-reel last 5 wraps of cable from drum!v wrap cable around load!v attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.v weld, modify, or use unauthorized components on any Auto Crane unit! This will void any

warranty or liability. Also failure of the crane may result.v place a chain link on the tip of the hook and try to lift a load!v use a sling bar or anything larger than the hook throat that could prevent the hook latch from

closing, thus negating the safety feature!v hold on any pendant Select Switch that will cause unsafe operating conditions!

WARNING! In using a hook with latch, ALWAYS make sure that the hook throat is closedbefore lifting a load! Proper attention and common sense applied to the use of the hoist hook andvarious slings will prevent possible damage to material being hoisted and may prevent injury topersonnel.

WARNING! Failure to correctly plumb and wire crane can cause inadvertent operation anddamage to crane and/or personnel!

WARNING! Auto Cr ane Company remote controlled cranes are not designed or intended tobe 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 isequipped with this type of device.

warning 9/98

WARNINGS - READ THIS PAGE!

LAST PAGEWARRANTY19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-1.0.0LOAD CHART18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-1.0.0TROUBLESHOOTING17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1.0.0ELECTRICAL SECTION16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-7.0.0JACK LEG ASSEMBLY15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-6.0.0POWER CABLE ASSEMBLY14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3.0.0HOIST ACTUATOR ASSEMBLY13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1.0.0GENERAL ASSEMBLY12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1.0.0LIFE OF WIRE LINE / WIRE LINE LUBRICATION11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1.0.0LUBRICATION & MAINTENANCE SCHEDULE10 . . . . . . . . . . . . . . . . . .

7-2.0.0OPERATING INSTRUCTIONS9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1.0.0INSTALLATION8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1.0.0GENERAL DIMENSIONS7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1.0.0SAFETY DECAL SECTION6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1.0.0INSPECTION, TESTING & MAINTENANCE5 . . . . . . . . . . . . . . . . . . . . .

3-1.0.0QUALIFICATIONS FOR OPERATORS4 . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2.0.0OPERATION OF UNIT / OUTRIGGERS3 . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1.0.0OPERATING PRACTICES & WARNINGS2 . . . . . . . . . . . . . . . . . . . . . . . .

1-1.0.0INTRODUCTION1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2003 SERIES - OWNER'S MANUAL

TABLE OF CONTENTS

PAGE

Auto Crane products have been engineered toprovide safe, trouble-free, dependable service for manyyears when these products are properly used andmaintained.

To assist you in obtaining the best service fromyour crane and to avoid untimely failure of the unit and/ or the vehicle on which it is mounted, the followingoperating and service instructions are herein published,and it is specifically recommended that all operatingand service personnel consider this manual asmandatory material for reading and study beforeoperating or servicing Auto Crane products. It ishighly recommended that crane owners, equipmentmanagers and supervisors also read this manual.

Auto Crane has incorporated several safety featuresin the 2003 series for your protection. The material andelectrical systems were designed to minimize weightand lengthen durability. For your convenience theoverall dimensions of the 2003 series are included onpage 6-1.0.0. Remember that the crane adds weight tothe vehicle and may change the driving and ridingcharacteristics of the vehicle on which it is mountedunless this weight is properly provided for withappropriate overload springs. The payload of thevehicle is also reduced by the amount that the craneweighs, and as the vehicle is loaded, care should beexercised not to overload the vehicle. Exercising carein distributing the payload on the vehicle will greatlyimprove the driving and riding characteristics of thevehicle.

The 2003 series cranes are attached directly to your12 volt truck electrical system. The power cable andretaining clips are included with the crane. A typicalpower cable mounting and hookup is shown on page7-1.0.0. The performance of your new crane dependson the truck electrical system. The use of the lowmaintenance battery is not recommended for use on anyAuto Crane product. The recommended alternator andbattery that will give the longest life with the mostuseful duty cycle is a 70 amp. alternator with a 625 coldcranking rated battery. These specifications should beconsidered minimum.

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

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 take

immediate corrective action. It is understandable thatAuto Crane company cannot assume responsibility ofliability when it is obvious that our products have beenabused, mis-used, 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 componentparts done 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.The customer service department also has the ability tobring a local distributor, a regional sales manager, or afactory serviceman into the solution of an equipmentproblem. If, through no fault of Auto Crane Company,it is necessary to send an experienced factoryserviceman on a field service call, the rates stated in theAuto Crane Distributor'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 yournearest Auto Crane Distributor. Our distributorssell authorized parts and have service departmentsthat can solve almost any needed repair.

NOTE: THIS MANUALSHOULD REMAIN WITH

THE CRANE AT ALL TIMES.This manual does not cover all maintenance,

operating, or repair instructions pertinent to allpossible situations. If you require additionalinformation, please contact the Auto CraneCompany at the following telephone number: (918)438-2760. The information contained in the manualis in effect at the time of this printing. Auto CraneCompany reserves the right to update this materialwithout notice or obligation.

INTRODUCTION2003 SERIES

1-1.0.0 2003INT 2/98

DIMENSIONS

Width: 19.0 in (.48 m)

Height: 21.0 in (.53 m)

Length: 6 ft 2 in (1.88 m) 8 ft 11 in (2.72 m) [boom(s) stored]

Weight: 5-9 385 lbs (175 kg) 8-14 440 lbs (200 kg)

CAPACITY

6000 ft lbs (.8 Tm)[ft lbs = horizontal distance from centerline ofrotation to free hanging weight (feet) x amountof weight (pounds)]

6659

7608

8007

1,0006

1,1605

1,5654

2,0003

lbsft

LIFTING CAPACITIES

REACH

Manual boom will reach from 5 ft to 9 ftOptional manual boom will reach from 8 ft to14 ft

CABLE

50 ft (15.2 m) of 1/4 in diameter aircraft qualitycable is standard. This cable has a single linebreaking strength of 7,000 lbs (3,175 kg).

CHASSIS REQUIREMENTS

8,000 lbs (3,628 kg) GVWR minimum

ELECTRICAL SYSTEM

Hoist Motor: 12 volt DC series wound

ELECTRICAL SYSTEMREQUIREMENTS

Alternator: 70 amp (minimum)

Battery: 625 cold cranking amps 100 minute reserve capacity (minimum) Maintenance type

ROTATION

360º Continuous manual rotation

1

GENERAL SPECIFICATIONS2003 SERIES

1-2.0.0 SPEC 2/98

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 cancreate enough tipping momentum to overturn thevehicle.

10. ALWAYS keep load as close to ground as possible.

11. Oil gears as required.

12. Periodic adjustment of hoist worm brake may berequired (see automatic safety brake drawing in thismanual).

13. Hydraulic hoses need to be inspected frequently forsigns of deterioration, and be replaced as required.

14. The hoist hook is an important item that an operatorshould consider and use properly. It should bechecked on a daily basis for distortion or cracks.

15. ALWAYS store outriggers before road travel.

16. 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.

17. WARNING! NEVER EXCEED load chartcapacities (centerline of rotation to hoist hook).

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

19. WARNING! NEVER wrap cable around load!

20. WARNING! NEVER attempt to lift or drag a loadfrom the side! The boom can fail far below its ratedcapacity.

21. 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.

22. WARNING! NEVER place a chain link on the tipof the hook and try to lift a load!

23. WARNING! NEVER use a sling bar or anythinglarger than the hook throat that could prevent thehook latch from closing, thus negating the safetyfeature!

24. 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.

25. WARNING! NEVER hold any pendant 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.

2-1.0.0 SAFTIPS 2/98

26. Make sure this manual has been thoroughly read byall crane operating personnel and supervisors.

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

28. 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).

29. Keep the vehicle as level as possible during operation.

30. For electric cranes, engage emergency brake andleave 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.

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

32. Remove pendant control from cab or storage area. Onsmaller units, plug pendant into receptacle on crane.On larger units, remove pendant control from guardand unwrap cable from boom. Do not operate craneuntil cable is unwound completely. On all cranes,detach hook from dead man. Crane is now ready foroperation.

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

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

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

36. After completing lifting operations, return the boomto stowed position on the boom support. Avoidunneeded pressure on the boom support.

37. Store pendant control on proper location (in cab or oncrane).

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

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

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

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

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

43. Spray all electrical equipment with special corrosionresistant coating. This eliminates rust or corrosiondue to melting and freezing action of condensation.

2-2.0.0OPER 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 controlswitch. This will allow the hydraulic system tobuild pressure.

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.

OPERATORS

1 Crane operation shall be limited to personnel withthe following minimum qualifications:

A. designated persons

B. trainees under the direct supervision of a designatedperson

C. maintenance and test personnel (when it isnecessary 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 and20/50 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 forthe specific operation.

5 Evidence of physical defects or emotional instabilitywhich render a hazard to operator or others, whichin the opinion of the examiner could interfere withthe operator's performance may be sufficient causefor disqualification. In such cases, specialized clinicalor medical 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 interpretall 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 maintenancerequirements of crane.

F. Be thoroughly familiar with the crane and itscontrol functions.

G. Understand the operating procedures as outlined bythe 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 neutralposition.

QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND

OPERATING PRACTICES

QUAL 7/983-1.0.0

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

16 All controls shall be tested by the operator at thestart of each shift. If any controls do not operateproperly, they shall be adjusted or repaired beforeoperations are 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 load

A. No crane shall be loaded beyond the rated loadexcept for test purposes.

B. The load to be lifted is to be within the rated load ofthe crane and its existing configuration.

C. When loads which are not accurately known are tobe 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 loadis to be lifted.

19 Attaching the load

A. The load shall be attached to the hook by means ofslings 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, thevehicle/carrier is blocked properly.

C. The load is well secured and balanced in the sling orlifting 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 orelevator requirements. Therefore, no lifting,lowering, swinging or traveling shall be done whilea person is on the hook or load. Hook attachedsuspended work platforms (baskets) shall not beused with cranes covered by this standard. Workplatforms attached to the boom must be approved bycrane 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 tocompletely support the stabilizer pad.

K. Firm footing under all tires, or individual stabilizerpads should be level. Where such a footing is nototherwise supplied, it should be provided bytimbers, cribbing, or other structural members todistribute the load so as to not exceed allowablebearing capacity 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 onthe hook 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.


OPERATING PRACTICES

QUAL 7/983-2.1.0

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 thecrane) have been erected to prevent physical contactwith the 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 anenergized 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 thealternate procedure provides equivalent protectionand set forth 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.


OPERATING PRACTICES

QUAL 7/983-3.2.0

(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 beinspected by a designated person to insure compli-ance with provisions of this standard.

28 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

29 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

30 Deformed, cracked or corroded members in thecrane 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 andlining.

35 Crane hooks inspected for cracks.

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

37 Excessively worn or damaged tires.

38 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 of

INSPECTION, TESTING AND MAINTENANCE

GENERAL

INSP 9/984-1.0.0

elements in contact or otherwise protect thecomponents

39 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

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 correctpressure setting

F. relief valve pressure shall be checked as specified bythe 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 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

necessary to determine origin of the problem beforecorrective 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 onemonth or more, but not less than six months, shall begiven an inspection conforming with the initial-regular- frequent inspections.

45 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

46 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

47 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 load


GENERAL

INSP 9/984-1.1.0

tested by or under the direction of anappointed person.

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

49 Written reports shall be maintained showing testprocedures 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 asapplicable:

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

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

52 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

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

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

A. functional operating mechanism

B. safety devices

C. control systems

55 Repairs or replacements shall be provided as neededfor operation.

The following are examples:

A. critical parts of functional operating mechanismswhich 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

56 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

57 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


GENERAL

INSP 9/984-1.2.0

3. broken or cut strands;

4. number, distribution and type of visiblebroken wires. When such damage isdiscovered, the rope shall either beremoved from service or given asinspection.

B. Care shall be taken when inspecting sections ofrapid deterioration such as flange points, crossoverpoints, and repetitive pickup points on drums.

58 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;severely corroded, cracked, bent, worn or improp-erly applied connections;

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 rope travelis limited

2. sections of the rope at or near terminal endswhere corroded or broken wires mayprotrude

ROPE REPLACEMENT

59 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.

60 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)


GENERAL

INSP 9/984-1.3.0

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.

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.

61 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.

62 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 points of deterioration listed above.

ROPE MAINTENANCE

63 Rope should be stored to prevent damage ordeterioration.

64 Unreeling or uncoiling of rope shall be done asrecommended by the rope manufacturer and withcare to avoid kinking or inducing twist.

65 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.

66 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.

67 Rope should be maintained in a well-lubricatedcondition. It is important that lubricant applied as apart of a maintenance program shall be compatiblewith the original lubricant and to this end the ropemanufacturer should be consulted. Lubricant appliedshall be the type which does not hinder visual inspec-tion. Those sections of rope which are located oversheaves or otherwise hidden during inspection andmaintenance procedures require special attentionwhen lubricating rope. The object of rope lubricationis to reduce internal friction and to prevent corrosion.

68 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 9/984-1.4.0

Maintenance of Auto Crane unit batteries differs verylittle from the generally prescribed maintenance of anylead acid battery. All batteries must be kept properlycharged, properly filled with water, and relativelyclean.

Keep Properly Charged

Many things affect the proper charge to a battery, suchas:

1 Regulator settings

2 Proper tightness of belts on the alternator or generator

3 Good, clean connections of all cablesand wires at the following places:A. BatteryB. RegulatorC. Starting motorD. Alternator or generatorE. Ground connections (most important)

It is of extreme importance to keep the battery as fullycharged as possible without overcharging, especiallywhen vehicles are left outside for extended periods inextremely cold climates. A battery can freeze.Freezing points for various specific gravities of acid areas follows:

Specific Gravity Freezing Temp.(Corrected to 80ºF) Degrees F.

1.280 -90ºF 1.250 -62ºF 1.200 -16ºF 1.150 5ºF 1.100 19ºF

As shown, a half-charged battery (about 1.200 specificgravity) cannot stand for any length of time at 20ºF or itwill freeze. The main reason for keeping the battery as fullycharged as possible without over-charging is to ensurethat power is available even though the vehicle has beenstanding for some time.

Keep Properly Filled with Water

The battery should always be properly filled with water.If the electrolyte level is allowed to fall below the top ofthe plates, the results become threefold:

1 The exposed portion of the plate will becomesulfated.

2 The portion of the plate exposed is not usable.

3 That portion of the acid remaining becomes moreconcentrated and may cause more rapiddeterioration of the remaining parts of the battery.

Keep A Relatively Clean Battery

The battery should be kept clean. Batteries filled withacid and which are not in use self-discharge to a limiteddegree because of the nature of the materials within thebattery. If dirt is allowed to collect on the top of thebattery (and this dirt absorbs moisture) and electricalpath can be set up between the various terminals of thebattery and the ground. Once such a path has beenestablished, the self-discharge of the battery isaccelerated. This also accelerates corrosion of thebattery cables at the terminals.

Periodic Maintenance is Needed

A definite program of periodic maintenance of allbatteries should be conducted on a regular basis.Periodic maintenance includes:

1 Checking belts for tightness on the chargingequipment

2 Checking battery electrolyte levels

3 Checking cables for good connections

4 Cleaning where corrosion is apparent

When corrosion is cleaned off, the cable terminals andbattery terminals should be coated with a light coatingof petroleum jelly before they are replaced. Whenterminals are cleaned, the top of the battery should becleaned with a mild solution of soda water.

MAINTBAT 9/98

MAINTENANCE OF BATTERIES

4-2.1.0.

Low Maintenance Batteries(Maintenance Free)

Low maintenance batteries should not be used onAuto Cranes or trucks equipped with Auto Cranes.The batteries are not designed for "deep" discharge.

Testing Your Battery

If the condition of the battery is in question, it should beremoved from the vehicle, taken to the shop, andallowed to reach room temperature. It should then berecharged until specific gravity readings taken atone-half hour intervals. If the specific gravity readingsare fairly uniform, the battery should be checked with ahigh rate tester. Use the tester in accordance with themanufacturer's instructions. The high rate tester is thebest method to test a questionable battery.

If, after charging, it is noted that the specific gravityreading of one cell is 30 points less than any of theother cells, it may be assumed that the cell is bad andthat the battery should be replaced. If all cells areuniform but not up to full charge, a low rate of charge

should be attempted for an extended time. This usuallywill recover a badly sulfated battery.

Replacing a Battery

If it is necessary to replace a battery, and a dry chargebattery is used, the following procedure applies:

1 Fill the battery with electrolyte of the properspecific gravity.

2 Place the battery on charge according to themanufacturer's instructions.

It is essential that the second step above be followed toensure that the battery going on the vehicle is fullycharged.

It is also very important that the battery hold-downs bechecked periodically to ensure that the batteries areproperly positioned to avoid vibration problems,breakage of cables or terminals. Care must be taken toavoid cracking or breaking containers or covers bytightening hold-down fixtures excessively. They alsomust not be so loose that breakage results from ahold-down that is too loose.

MAINTBAT 9/98

MAINTENANCE OF BATTERIES

4-2.2.0.

2003DEC 2/98

SAFETY DECAL SECTION

(see page 5-3.0.0, Item 1)

Both sides of upper boomPLACEMENT:

2QUANTITY:

To inform the operator of the hazardof proximity or contact with thecrane boom during operation.

FUNCTION:

STAY CLEAR OF BOOMDECAL:

040517PART NO.:

(see page 5-3.0.0,Item 6)

Down hall weightPLACEMENT:

2QUANTITY:

To inform theoperator of thehazard of proximityor contact with thecrane load duringoperation.

FUNCTION:

STAY CLEAR OFLOAD

DECAL:

040518PART NO.:

FIG. SD-1.

(see page 5-3.0.0, Item 9)To inform the operator ofpossible danger at scissors pointon crane.

FUNCTION:

Lower boomPLACEMENT:SCISSORS POINTDECAL:

1QUANTITY: 040519PART NO.:

FIG. SD-3.

FIG. SD-2.

5-1.0.0

2003DEC 2/98

SAFETY DECAL SECTION

FIG. SD-4.

(see page 5-3.0.0, Item 5)

Housing weldmentPLACEMENT:

1QUANTITY:

To inform the operator of theproper procedure to follow forsafe operation of the crane.

FUNCTION:

OPERATION INSTRUCTIONSDECAL:

040579PART NO.:

FIG. SD-5.

5-2.0.0

(see page 5-3.0.0, Item 10)To inform the operator of thehazard involved with contactingelectrical power lines with craneboom.

FUNCTION:

Lower boomPLACEMENT:ELECTROCUTION HAZARDDECAL:

2QUANTITY: 040529PART NO.:

5-3.0.0 AW600048 3/98

DECAL DRAWING

9' BOOM - 2003 SERIES

1/4" WIDE STRIPING TAPE600066 .5'12

STRIPING040620 2'11

DANGER ELECT DECAL040529 210

SCISSORS POINT DECAL040519 19

A/C LOGO DECAL040619 18

AUTO CRANE DECAL600047 27

STAY CLEAR DECAL040518 26

WORK RULES DECAL040579 15

ANGLE IND DECAL320318 14

2003 DECAL330967 13

LOAD CHART 9' BOOM DECAL(see page 13-1.0.0)

60000612


DESCRIPTIONP/NQTYITEM

5-4.0.0 AW600049 3/98

DECAL DRAWING

14' BOOM - 2003 SERIES

1/4" WIDE STRIPING TAPE600066 .5'12

STRIPING040620 7.5'11

DANGER ELECT DECAL040529 210

SCISSORS POINT DECAL040519 19

A/C LOGO DECAL040619 18

AUTO CRANE DECAL600047 27


WORK RULES DECAL040579 15

ANGLE IND DECAL320318 14

2003 DECAL330967 13

LOAD CHART 9' BOOM DECAL(see page 13-2.0.0)

60008412



9' BOOM GENERAL DIMENSIONS

P/N 600000-009 - 2003 SERIES

AW631 3/986-1.0.0

AW632 3/98

14' BOOM GENERAL DIMENSIONS

P/N 600000-014 - 2003 SERIES

6-2.0.0

NOTE:For mounting bolt hole pattern - see page 6-1.0.0.

INSTALLATION - BATTERY CABLE

1. Drill 13/16" hole in floor. Install bushing, which is connected to cable, so it fits hole snug.

2. Run cable to positive battery terminal. Connect black cable to negative battery terminal orsuitable chassis ground point. Locate cables so that they will be protected. Avoid sharpedges. Use the No. 083800 frame clips provided to hold cables securely in place.

3. If the battery is grounded to the engine it may be necessary to add an additional groundcable from the engine to the chassis frame to obtain maximum power at crane

AW087 2/98

ASSEMBLY & INSTALLATION INSTRUCTIONS

2003 SERIES

7-1.0.0

To Extend:Turn Brake Handle (1) counterclock-wise to release brake and turnboom to a convenient location forextending boom. Tighten Brake byturning Brake Handle clock-wise. Usependant control to let out more cablefor boom extension. Remove BoomExtension Pin (2) in Lower Boom (3).Slide Upper Boom out of Lower Boomuntil a new set of pin holes in UpperBoom appear in pin hole in LowerBoom. Replace Pin in Lower Boom.

Boom is now ready to raise.

To Raise:Use pendant control to let out morecable for boom elevation. RemoveHitch Clip from Boom Elevation Pin(4) in Boom Housing (5). Placehand on Lower Boom Handle (6) andgently pull down on handle. PullBoom Elevation Pin out of Boom andBoom Housing. Raise Boom todesired elevation. Align tube inBoom with holes in Housing andreplace Boom Elevation Pin.Replace Hitch Clip on BoomElevation Pin.

The crane is now ready to lift theload.

CAUTION:DO NOT STAND DIRECTLY UNDER BOOM WHEN RAISING OR LOWERING BOOMOR SERIOUS INJURY MAY RESULT.

OPERATING INSTRUCTIONS

7-2.0.0 AW633 2/98

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

FOR ADDITIONAL INFORMATION SEE:

PADS GREASED WHEN REPLACED BOOM SLIDE PADS

WORM GEAR-EP GEAR LUBE SAE 80-90,SPUR GEAR SAE 30 OIL

XHYDRAULIC FLUID

WORM GEAR-EP GEAR LUBE SAE 80-90,SPUR GEAR SAE 30 OIL

XHOIST GEARBOX

GREASE WITH MOBILPLEX EP-2 OREQUIV. @ ZERKS

XROTATION WORMBEARINGS (MR)

WATER PROOF BEARING GREASE ORDRY MOLYLUBE IF DUSTY

XROTATION GEAR(MR)

CHECK INSULATION FOR DAMAGE ORDETERIORATION

XPOWER CABLE

CHECK ADJUSTMENTXROTATION BRAKE(M)

LUBE DETENT SPRING & BALL W/ WD-40XEXTENSION DETENTPIN

CHECK FOR CORROSION & TIGHTCONNECTIONS. CLEAN & COAT ASREQUIRED

XBATTERY CONNECTIONS

GREASE WITH MOBILPLEX EP-2 OREQUIV. @ ZERKS

XBOOM CYLINDERPINS

CHECK AROUND CYLINDER ROD FOREXCESS FLUID LEADAGE

XBOOM CYLINDER

CHECK-TIGHTEN AS REQUIREDXALL OTHER BOLTS

SEALED BEARING, REPLACE IF ROUGHOR LOOSE

XSHEAVE BEARINGS

CHECK TERMINALS FOR TIGHTCONNECTIONS

XMOTORCONNECTION

CHECK-TORQUE TO 85 FT-LBS (DRY) ASREQUIRED

XMOUNTING BOLTS

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

XHOIST CABLE

MAKE SURE CABLE IS WOUND EVENLYON DRUM

XCABLE DRUM

INSPECT HOOK & LATCH FOR DEFOR-MATION, CRACKS, & CORROSION

XLOAD HOOK

NOTES1 YEAR6 MONTHSMONTHLYWEEKLYDAILYSERVICE PERFORMED

LUBRICATION & MAINTENANCESCHEDULE 2003 CRANE

MAINSCHE 6/998-1.0.0

CAUTIONv Routine maintenance insures trouble-free operation and protects your investment. All warranties are void if

maintenance is neglected.

NOTES:{ Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not

covered by Warranty or Product Liability.{ Once a bolt has been torqued to its rated capacity and then removed; the bolt should be replaced with a

new one.{ Auto Crane Company recommends that this crane be serviced per “Crane Inspection Log” P/N 999978.

These logs should be filled in at the intervals noted and kept as a permanent record. Additional copiesare available from your local distributor.

LUBRICATION & MAINTENANCESCHEDULE 2003 CRANE

MAINSCHE 6/998-1.1.0

So many variable factors can cause the deterioration of wire line cable that it is notpossible to determine a definite life expectancy. Some of these factors are:

• Load being handled.

• Corrosive conditions.

• Maintenance of the unit: Keep the sheaves turning freely. Maintain tension on cable to insure proper spooling. Avoid kinks in cable. Avoid abrasive action and contact with sharp corner.

• Frequency of use.

Auto Crane units, up to 2,400 pound ratings use 3/16 inch diameter galvanizedpre-formed 7 x 19 aircraft cable. This cable has a working strength, when new, of 4,200 pounds.It is recommended when 1,200 pound loads are exceeded to use a two part line with a travelingblock. This will ensure a 3.5 to 1 safety factor when the cable is new.

Keeping the above factor of safety in mind and knowing the kind of loads that will behandled, the user can determine by inspection of the cable as to when it should be replaced.

Items to look for while inspecting the cables are:

• Broken strands.

• Kinks and flattened sections.

• Corrosion and abrasion.

Lubrication of the wire line serves two important purposes: • Prevent corrosion. • Reduce wear due to flexing and abrasion caused by contact with the sheaves, rollers, and

cable on the drum.

PreparationRemove rust and foreign matter with a wire brush and wipe clean. Be sure cable is dry.

ApplicationMethod 1: Dip a brush into a light weight motor oil and apply. In some cases, dip a rag or a piece

of sheepskin into the lubricant and swab the lubricant on to the rope.Method 2: Apply a heavier lubricant such as a grease gun lubricant with hands while wearing

leather gloves. (Leather gloves give greater protection and less penetration of the grease thancanvas gloves.)

9-1.0.0 WIRE 1/2000

LIFE OF WIRE LINE

WIRE LINE LUBRICATION

2003 SERIES CRANE 9’ BOOM P/N:600000-009

AW600000-009 2/200010-1.0.0


AW600000-009 2/200010-1.0.1

2003 SERIES CRANE 9’ BOOM P/N 600000-009

P/N 370000

10-1.1.0 BM600000-009 2/2000

SHEAVE ASSEMBLY227401133

PAD EXTENSION600025132

SCREW HX HD 1/4-20 X 1/2 005901231

NUT HX LK 1/4-20016300530

SCREW HX HD 1/4-20 X 3/4005500329

WASHER SP LK 1/4 STAINLESS020200528

SCREW HX HD 1/4-20 X 5/8 005401227

SNAP RING EXTERNAL 3 1/4 ID330182126

ZERK GREASE239000225

DRUM 2003 3 3/4 DIA320379124

DOWN HAUL BLOCK600060123

CAPSCREW 5/8-11 X 7 1/2600044122

SPACER330489121

SPRING COMPRESSION320509120

SPACER600029119

BRAKE HANDLE WELDMENT600057118

SCREW HX HD 3/8-20 X 1 1/2 ZP330394817

WASHER SP LK 3/8 CP021100816

SPRING GAS600031115

BEARING BALL 1.25 ID400500214

PIVOT BOOM320411213

PIN ASSEMBLY W/LANYARD600026112

PIN LOCKING BOOM EXTENSION370002111

BEARING RETAINER320368110

POWER CABLE ASSY60001619

BRAKE BAND WELDMENT60004318

CABLE 1/4 X 50 FT W/HOOK60003717

MEMBER TWECO BRACKET UPPER60001316


BOOM UPPER WELDMENT60002314

BOOM LOWER WELDMENT 60002113

HOUSING WELDMENT60002712

BASE WELDMENT60000711

DESCRIPTIONPART NUMBERQUANTITYITEM


P/N 370000

10-1.2.0 BM600000-009a 2/2000

TIE CABLE-MEDIUM634401158

INSULATOR BOOT BLACK270326357

WASHER FL 1/4 020300256

PENDANT330519155

PIN HITCH CLIP366813254

DECAL LAYOUT600048153

ROLL PIN 1/8 DIA023700152

HANDLE GRIP600058151

NUT 5/8-11018201150

WASHER 5/16020600449

SCREW HX HD 5/16-18 X 3/4007807448

---47

SHIP KIT NEW 2003 CRANE600073146

GROMMET WIRE GUIDE600039145

BRACKET ACTUATOR600034144

GAS SPRING PIN600077243

RELAY ASSEMBLY600099142

TWECO MALE POWER CONDUCTOR600078141

INNER TUBE SPACER 2003600003140

INDICATOR ANGLE 3203320453139

KEY SQ 1/4 X 1/4 X 2 3/4 340523138

ACTUATOR ASSEMBLY600035137

GUARD CABLE RETAINER320442136

HALF NUT 5/8-18018100135

SCREW HX HD 5/8-18 X 1 3/4012200134



AW600000-014 2/200010-1.3.0


AW600000-014 2/200010-1.3.1


P/N 370000

10-1.4.0 BM600000-014 2/2000



SCREW HX HD 1/4-20 X 1/2 005901231

NUT HX LK 1/4-20016300530

SCREW HX HD 1/4-20 X 3/4005500329


SCREW HX HD 1/4-20 X 5/8 005401227



DRUM 2003 3 3/4 DIA320379124


CAPSCREW 5/8-11 X 7 1/2600044122

SPACER330489121


SPACER600029119


SCREW HX HD 3/8-20 X 1 1/2 ZP330394817


SPRING GAS600086115


PIVOT BOOM320411213











HOUSING WELDMENT 14’ BOOM60009212




P/N 370000

10-1.5.0 BM600000-014a 2/2000



WASHER FL 1/4 020300256

PENDANT330519155





NUT 5/8-11018201150

WASHER 5/16020600449

SCREW HX HD 5/16-18 X 3/4007807448

---47









KEY SQ 1/4 X 1/4 X 2 3/4 340523138



HALF NUT 5/8-18018100135

SCREW HX HD 5/8-18 X 1 3/4012200134


2003 SERIES CRANE 9’ BOOM W/LOAD SENSOR P/N:600053

AW600053 2/200010-2.0.0


AW600053 2/200010-2.0.1

2003 SERIES CRANE 9’ BOOM W/LOAD SENSOR P/N 600053

P/N 370000

10-2.1.0 BM600053 2/2000



SCREW HX HD 1/4-20 X 1/2 005901231

NUT HX LK 1/4-20016300530

SCREW HX HD 1/4-20 X 3/4005500329


SCREW HX HD 1/4-20 X 5/8 005401227



DRUM 2003 3 3/4 DIA320379124


CAPSCREW 5/8-11 X 7 1/2600044122

SPACER330489121


SPACER600029119


SCREW HX HD 3/8-20 X 1 1/2 ZP330394817


SPRING GAS600031115


PIVOT BOOM320411213















P/N 370000

10-2.2.0 BM600053a 2/2000



WASHER FL 1/4 020300256

PENDANT330519155





NUT 5/8-11018201150

WASHER 5/16020600449

SCREW HX HD 5/16-18 X 3/4007807448

DECAL040587147









KEY SQ 1/4 X 1/4 X 2 3/4 340523138



HALF NUT 5/8-18018100135

SCREW HX HD 5/8-18 X 1 3/4012200134



AW600052 2/200010-2.3.0


AW600052 2/200010-2.3.1


P/N 370000

10-2.4.0 BM600052 2/2000



SCREW HX HD 1/4-20 X 1/2 005901231

NUT HX LK 1/4-20016300530

SCREW HX HD 1/4-20 X 3/4005500329


SCREW HX HD 1/4-20 X 5/8 005401227



DRUM 2003 3 3/4 DIA320379124


CAPSCREW 5/8-11 X 7 1/2600044122

SPACER330489121


SPACER600029119


SCREW HX HD 3/8-20 X 1 1/2 ZP330394817


SPRING GAS600086115


PIVOT BOOM320411213















P/N 370000

10-2.5.0 BM600052a 2/2000



WASHER FL 1/4 020300256

PENDANT330519155





NUT 5/8-11018201150

WASHER 5/16020600449

SCREW HX HD 5/16-18 X 3/4007807448

DECAL040587147









KEY SQ 1/4 X 1/4 X 2 3/4 340523138



HALF NUT 5/8-18018100135

SCREW HX HD 5/8-18 X 1 3/4012200134


HOIST ACTUATOR ASSEMBLY

2003 SERIES P/N 600035

AW600035 2/200010-3.0.0


2003 SERIES P/N 600035

AW600035 2/2000

FLAT WASHER 1/4 ALUM360455 238

SPLIT LOCK WASHER 1/4 MED SECT360354 437

HEX NUT 3/8-24 NF071012 336

HEX JAM NUT 3/8-16 NC360353 135

SETSCREW 1/4-20 NC x 5/16 LG LOC-WEL300061 134

SOCKET HEAD SCREW 1/4-20 NC x 3/4 LG LOC-WEL300060 433

CAPSCREW 1/4-20 NC x 1 LG320310 432

CAPSCREW 3/8 x 1 1/2 LG ALL THREAD320311 131

CAPSCREW 1/4-20 NC x 1 LG005604 430

CAPSCREW 1/4-20 NC x 3/4 LG005500 1229

CAPSCREW 1/4-20 NC x 3/4 LG NYLOCK320313 1028

BUSHING300059 127

BUSHING300058 126

BALL BEARING300057 225

NEEDLE BEARING 300056 324

BALL360345 223

RIGHT HAND WORM GEAR320312 122

OUTPUT SHAFT320323 121

SPUR GEAR SHAFT300053 120

RETAINER PLATE360342 119

KEY RD 5/16 x 5/16 x 15/16 LG300052 218

KEY 1/4 SQ x 2 3/4 LG341561 117

KEY 3/16 SQ x 1 9/16 LG300050 116

---15

KEY 3/16 SQ x 1/2 LG300049 114

BRAKE HUB360339 113

GEAR HOUSING300048 112

SPUR GEAR HOUSING300047 111

BRAKE HOUSING360336 110

PINION GEAR300046 19

WORM R.H. GEAR300045 18

SPUR GEAR300044 27

IDLER GEAR300043 16

BRAKE COVER360450 15

SPUR GEAR HOUSING COVER300042 14

GEAR HOUSING COVER300041 13

CAM PLATE360331 12

FLAT SPRING360637 11


10-4.0.0


2003 SERIES P/N 600035

AW600035 2/2000

PIPE PLUG320382 266

SCREW 1/4-20 NC x 1 LG ALL THREAD360456 265

FIBER WASHER300082 164

THRUST WASHER300081 163

THRUST WASHER300080 362

SPRING360368 161

SNAP RING300079 160

THREAD SEAL360371 159

OIL SEAL 1 1/2 ID x 2 1/4 OD x 5/16 THICK300078 158

OIL SEAL 1 1/4 ID x 1 3/4 OD x 1/4 THICK300077 157

OIL SEAL 3/4 ID x 1 1/4 OD x 1/4 THICK300076 156

THRUST PLATE360364 255

DOWEL PIN300075 254

REDUCER -4 NPT / -2 NPT300074 153

PLUG PIPE -6 NPT HEX SOC HEADLESS300073 152

PLUG PIPE -4 NPT SQ HD300070 251

REDUCER -6 NPT / -2 NPT300069 150

O-RING 1 OD x 1/8 THICK300068 149

12V MOTOR300067 148

RELIEF FITTING 300066 247

WOODRUFF KEY300065 146

BRAKE COVER GASKET360359 145

GEAR HOUSING COVER GASKET300064 144

SPUR GEAR HOUSING GASKET300063 143

GASKET BEARING300062 242

-- -41

90º ELBOW 3/8-18 NPT BOTH ENDS320314 140

SPLIT LOCK WASHER 3/8021100 339


10-5.0.0

ASSEMBLY INSTRUCTIONS:1. Winch has right hand worm and gear. Cable spools over drum. Use number

one slots for brake balls(7) in cam plate(2).2. Install brake hub(5) through brake housing(4) on winch worm with key.3. Assemble balls(7) in cam plate(2) using hard grease to hold balls in place.4. Place cam plate(2) on brake hub(5), matching its holes with the balls.5. Install thrust plate(16).6. Thread capscrew(10) with jam nut (12) and thread seal (11) through housing

cover(3).7. Place gasket(15) on housing cover(3).8. Install coil spring(9) on capscrew(10).9. Install flat spring(1) on capscrew(10).

10. Secure retainer plate(6) and flat spring(1) to housing cover(3) usingcapscrews(8) and washers(14).

11. Using capscrews(8) and thead seals(13) attach housing cover(3) to brakehousing(4).

12. Test brake by shifting winch to UP then DOWN to see if brake is working inproper rotation. If not, remove housing cover(3) and locate brake balls(7) inopposite set of slots of cam plate(2).

13. Adjust to suit by tightening or loosening capscrew(10) on outside of housingcover(3). When proper adjustment is obtained, secure capscrew(10) with jamnut(12).

AUTOMATIC SAFETY BRAKE ASSEMBLY

(OIL COOLED) HOIST 2003 SERIES

AW368 1/9910-5.2.0

AUTOMATIC SAFETY BRAKE ASSEMBLY

(OIL COOLED) HOIST 2003 SERIES

AW368 1/99

THRUST PLATE360364 116

GASKET360359 115

WASHER FLAT 1/4 ALUM360455 214


JAM NUT 3/8 NC360353 112


CAPSCREW 3/8 NC x 1 1/2 360456 110

COIL SPRING360368 19

CAPSCREW 1/4 NC x 1 360453 68

BRAKE BALL360345 27

RETAINER PLATE360342 16

BRAKE HUB360339 15

BRAKE HOUSING360336 14

HOUSING COVER360450 13

CAM PLATE360331 12

FLAT SPRING360367 11


10-5.1.0

10-6.0.0 AW600016 2/98

POWER CABLE ASSEMBLY

2003 SERIES P/N 600016

WASHER SP LK 1/4020200 211

SCREW HEX HD 1/4 NC x 5/8005401 210

LOWER TWECO BRACKET600015 19

WASHER FL 1/4 CP020300 18

SCREW HEX HD 1/4 NC x 3/4005500 17

CONDUCTOR 600V x 29"341219 16

MALE TWECO CONNECTOR669300 25

SCREW SOC HD 1/4 NC x 3/8 GR8002900 14

TWECO POWER CONDUCTOR330258 13

TWECO BRACKET600015 12

FEMALE TWECO CONNECTOR669200 11


* Included in Power Cable Assembly - P/N 600016.

JACK LEG INSTALLATION INSTRUCTIONS

1. Make sure truck is parked on level surface. Weld pocket (Item 4) to truck body at rearjust inside bumper, or desirable location. End of pocket should be flush with outside ofthe truck body. Be sure the pocket is welded securely. Next, slide insert (Item 3) intopocket. Make sure leg assembly is fully inserted in pocket.

2. Jack leg is ready for use. Upon use, make sure jack leg has adequate tension(self-determining), before self-locking in place.

10-7.0.0 AW700320 2/98

JACK LEG ASSEMBLY

2003 SERIES

JACK LEG POCKET (SLEEVE)200372 14

JACK LEG INSERT200282 13

JACK LEG TOGGLE200074 12

JACK LEG w/ BASESEE CHART 11


**STANDARD

30"200476 700336

25"200465 700331

24"200464 700330

23"200463 700329

22"200462 700328

20"200460 700326

19"200459 700325

18"200458 700324

17"200457 700323

16"200456 700322

15"200255 700321

14"**200454 700320

LENGTHLEG w/ BASEJACK LEG ASSY

SMALL JACK LEGS

(SEE CHARTFOR LENGTH)

Note:These jack legs all use thestandard jack leg toggles& sleeves.

ITEMS 3, AND 5-9 ARE INCLUDED IN ITEM 10.

11-1.0.0AW634 2/2000

WIRING DIAGRAM

2003 SERIES

RELAY ASSEMBLY600099 110

12V RELAY330033 29

CONDUCTOR 16GA ST BLACK x 1 1/4" 600063 18

CONDUCTOR 16GA ST WHITE x 2 3/4" 600062 17

CONDUCTOR 16GA ST GREEN x 2 3/4" 600061 36

CONDUCTOR 6GA 600V BLACK x 28" 622327 25

CONDUCTOR 6GA 600V BLACK x 26"622323 14

POWER CABLE ASSEMBLY (see page 10-6.0.0)600016 13

FEMALE SOCKET 330517 12

HOIST CONTROL PENDANT330519 11


ITEMS 3, AND 5-9 ARE INCLUDED IN ITEM 10.

11-2.0.0AW634LS 2/2000

WIRING DIAGRAM W/LOAD SENSOR

2003 SERIES

RELAY ASSEMBLY600087 112

LOAD SENSOR666400111

CABLE 2C 16GA 300V S10 BLACK X 54”600064 110

12V RELAY330033 29

CONDUCTOR 16GA ST BLACK x 1 1/4" 600063 18

CONDUCTOR 16GA ST WHITE x 2 3/4" 600062 17

CONDUCTOR 16GA ST GREEN x 2 3/4" 600061 36

CONDUCTOR 6GA 600V BLACK x 28" 622327 25

CONDUCTOR 6GA 600V BLACK x 26"622323 14

POWER CABLE ASSEMBLY (see page 10-6.0.0)600016 13

FEMALE SOCKET 330517 12

HOIST CONTROL PENDANT330519 11


PROBLEM CAUSE/SOLUTION

CRANE WILL NOT HOIST UP.

CRANE WILL NOT HOIST DOWN.

WITH LOAD SENSOR (OPT.)

CRANE WILL NOT HOIST UP.

CRANE RUNS UP OR DOWN ANYTIME POWER SOURCE IS

CONNECTED.

2003TRBL 2/98

TROUBLESHOOTING 2003

CAUSE:Bad relay, crane not grounded properly, or power cable not connected to12V power source. Bad switch in pendant, broken wire in pendantconnector, pendant not plugged together properly, wire on relay not inproper place or lead wires to motor not connected properly.

SOLUTION:Problems can be solved by replacing bad relay, grounding the craneproperly to the truck chassis, connecting the power cable properly to 12V+power source, switch in pendant can be replaced, cord in remote controlcan be replaced, check connector on cord to make sure of contact of all theprongs on it are plugged together correctly, make sure wires on relays areaccording to the wiring print supplied with each new crane in the ownerbook and also wires going to motor are connected properly. NOTE: 12Vmust pass through opposite relay to complete circuit.

CAUSE:Crane is overloaded.Sensor switch is bad.Bad connection to relays.

SOLUTION:Hoist down. Do not overload crane. Replace sensor switch. Check forloose or damaged wiring.

12-1.0.0

CAUSE:Relay stuck in run position which will let crane run up or down any time12V power is connected. Wires shorted together in remote control. Leador cable can also cause this problem. Wires jumped across relay in wrongplace can cause crane to run all the time.

SOLUTION:Problem can be solved by checking the relays and replacing the bad oneor removing jumper wires from the relays or replacing the remote controlcord or switch.

2003TRBL 2/98

TROUBLESHOOTING 2003

HOW TO CHECK RELAY:Our relays are normally closed across the bottom posts(C & D). When activated, they will open across (C &D) and close across A & B). To activate these relays,use 12V positive and 12V negative wires and placethem on posts (F & E). You may place 12V+ on post For E as long as you place 12V on the remaining post (F& E) using an ohm meter or test light. Check acrossposts (A & B). You should get an ohm reading or yourtest light should be on when you have the relayactivated. With the relay still activated, check acrossposts (C & D). You should have no ohm reading or testlight at this point with relay activated. (At this point,disconnect 12V+ and 12V– from posts (F & E). This

should let relay return to its normal position. Usingyour ohm meter or test light again, check the relayacross posts (A & B). If relay is working correctly, youshould have no reading at all. Then check across posts(C & D). You should have an ohm reading or test lightshould be on. If you get the above results, relay is okay.If you get any variation in the above explanation on therelay you are checking, check the relay again. If it stillshows a difference, the relay is bad and should bereplaced. NOTE: The above explanation is withrelays completely disconnected from all wires onmotor circuits and ground wires. These circuits cangive you false readings sometimes.

12-2.0.0

A BE

D

F

C

HORIZONTAL REACH IN FEETCAPACITY IN POUNDS

13-1.0.0 AW600006 2/98

LOAD CHART FOR 9' BOOM

2003 SERIES - P/N 600006

HORIZONTAL REACH IN FEETCAPACITY IN POUNDS

13-2.0.0 AW600084 2/98

LOAD CHART FOR 14' BOOM

2003 SERIES - P/N 600084

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