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EFFECTIVE SERIAL NO. 193-CH-988 OWNERS MANUAL 6006 SERIES REVISION 6/2000 PART NO. 999934 SERIAL NO. __________________________ PO BOX 580697, TULSA, OK 74158-0697 4707 N. MINGO ROAD, TULSA, OK 74117 PHONE (918) 836-0463 FAX (918) 834-5979 www.autocrane.com
Transcript
Page 1: AutoCrane 6006 Owner's Manual

EFFECTIVE SERIAL NO. 193-CH-988

OWNERS MANUAL6006 SERIES

REVISION 6/2000

PART NO. 999934

SERIAL NO. __________________________

PO BOX 580697, TULSA, OK 74158-0697

4707 N. MINGO ROAD, TULSA, OK 74117

PHONE (918) 836-0463

FAX (918) 834-5979

www.autocrane.com

Page 2: AutoCrane 6006 Owner's Manual
Page 3: AutoCrane 6006 Owner's Manual

{ 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 Crane 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!

Page 4: AutoCrane 6006 Owner's Manual

LAST PAGEWARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-9.9.9LOAD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1.0.0MISCELLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1.0.0HYDRAULIC SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2.0.0ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9.1.0HOIST ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7.0.0BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6.0.0TRAVELING BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5.0.0BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1.0.0GENERAL ASSEMBLY (PEDESTAL) . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6.0.0TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5.0.0LUBRICATION & MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . .

3-4.0.0LIFE OF WIRE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4.0.0GENERAL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3.0.0SAFETY DECAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6006 SERIES - OWNER'S MANUAL

TABLE OF CONTENTS

6TOC 6/2000

Page 5: AutoCrane 6006 Owner's Manual

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

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

Auto Crane has incorporated several safety featuresin the 6006 series cranes for your protection. Thematerial and electrical systems were designed tominimize weight and lengthen durability.

For your convenience the overall dimensions of the6006 series crane are included on the GeneralDimension Drawing. Rotation and turning radius arealso listed on that drawing.

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

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

The 6006 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. The 6006series is another highly efficient Auto Crane product.The use of our “B” actuator maximizes your workcapability for the least amperage draw from your truckbattery. 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 75 amp. alternator with a 500 coldcranking rated battery. These specifications should beconsidered minimum.

It has always been Auto Crane Company policy tohandle all warranty claims we receive as promptly aspossible. If a warranty claim involves discrepantmaterial or workmanship, Auto Crane will takeimmediate corrective action. It is understandable thatAuto Crane Company cannot assume responsibility ofliability when it is obvious that our products have beenabused, misused, overloaded or otherwise damaged byinexperienced persons trying to operate the equipmentwithout reading the manual.

Auto Crane will not assume responsibilityor liability for any modifications or changesmade to unit, or installation of 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. Thecustomer 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 your nearestAuto Crane Distributor. Our distributors sell authorizedparts and have service departments that can solvealmost 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 possiblesituations. If you require additional information, pleasecontact the Auto Crane Company at the followingtelephone number: (918) 836-0463. The informationcontained in the manual is in effect at the time of this

INTRODUCTION6006 SERIES

1-1.0.0 INTRO 6006 6/2000

Page 6: AutoCrane 6006 Owner's Manual

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.

1-2.0.0 SAFTIPS 2/98

Page 7: AutoCrane 6006 Owner's Manual

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.

1-3.0.0OPER 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.

Page 8: AutoCrane 6006 Owner's Manual

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 7/981-4.0.0

Page 9: AutoCrane 6006 Owner's Manual

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.

QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND

OPERATING PRACTICES

QUAL 7/981-4.1.0

Page 10: AutoCrane 6006 Owner's Manual

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.

QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND

OPERATING PRACTICES

QUAL 7/981-4.2.0

(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

Page 11: AutoCrane 6006 Owner's Manual

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 9/981-5.0.0

Page 12: AutoCrane 6006 Owner's Manual

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

INSPECTION, TESTING AND MAINTENANCE

GENERAL

INSP 9/981-5.1.0

Page 13: AutoCrane 6006 Owner's Manual

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

INSPECTION, TESTING AND MAINTENANCE

GENERAL

INSP 9/981-5.2.0

Page 14: AutoCrane 6006 Owner's Manual

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)

INSPECTION, TESTING AND MAINTENANCE

GENERAL

INSP 9/981-5.3.0

Page 15: AutoCrane 6006 Owner's Manual

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.

INSPECTION, TESTING AND MAINTENANCE

GENERAL

INSP 9/981-5.4.0

Page 16: AutoCrane 6006 Owner's Manual

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

ITEM PART NO. DESCRIPTION1. 366203000 Swivel Block2. 366212000 Vented Relief Valve (Non-proportional Units Only)3. 480525000 Control Valve Assembly (Proportional Units Only)4. 480018000 Pump Assembly (Optional)5. 999946000 Owners Manual6. 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 theinstaller and the lengths determined at installation.

REQUIREMENTS FOR INSTALLATION USING 8 GALLON RESERVOIR WITH RELIEF VALVE AND AUTOCRANE 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 BESIZE -12. HOSE END FITTINGS ARE -8 JIC FEMALE SWIVEL (CRANE END) AND -10 JIC FEMALESWIVEL (RESERVOIR END).

B. PRESSURE LINE FROM VENTED RELIEF VALVE TO CRANE: -8 SAE 100R2 (OR EQUIVALENT). HOSELENGTH 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) -16HOSE CLAMPS ON EACH END.

D. PRESSURE LINE FROM PUMP TO VENTED RELIEF VALVE (LOCATED ON RESERVOIR) : -12 SAE100R2 (OR EQUIVALENT). HOSE LENGTH IS DETERMINED BY INSTALLER. HOSE END FITTINGSARE BOTH -10 JIC FEMALE SWIVEL.

NOTE:REFER TO OWNERS MANUAL FOR ADDITIONAL INSTALLATION INFORMATION, AND OTHER RESERVOIRAND PUMP COMBINATIONS.

CAUTION - FAILURE TO USE CLEAN HYDRAULIC HOSES AND COMPONENTS MAYCONTAMINATE 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. Excessflow 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 ofcrane 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) foraccess 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 beconnected to hood loop.

10. Always use cable loops on side of boom and pendant guard on side of pedesal to store pendantassembly, if this type of storage applies.

6HMTG 3/98

MOUNTING and INSTALLATION 6006

2-1.0.0

Page 17: AutoCrane 6006 Owner's Manual

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 tothe 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 ATPENDANT 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 CAUSEINADVERTENT 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 (mobilDTE 13 or equal). Before operating crane, connect together the pressure and return hoses going tobase of crane using -8 JIC union and engage PTO wih engine running. Allow oil to circulate for 15to 20 minutes. This will flush contaminants from the system back to the return line filter. Operateall 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 AutoCrane 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 thepipe 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, thetrigger should be pulled completely back (on). Read the pressure gauge and adjust relief valve toread 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. (918) 836-0463(TULSA, OKLAHOMA)

6HMTG 3/98

MOUNTING and INSTALLATION 6006

2-1.1.0

Page 18: AutoCrane 6006 Owner's Manual

WARNINGFEDERAL LAW (49 CFR PART 571) REQUIRES THAT THE FINAL STAGE MANUFACTURER OF A VEHICLECERTIFY THAT THE VEHICLE COMPLIES WITH ALL APPLICABLE FEDERAL REGULATIONS. ANY MODIFICA-TIONS PERFORMED ON THE VEHICLE PRIOR TO THE FINAL STAGE ARE ALSO CONSIDERED INTERMEDIATESTAGE MANUFACTURING AND MUST BE CERTIFIED AS TO COMPLIANCE. THE INSTALLER OF THIS CRANEAND 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 OSHATRUCK CRANE STABILITY REQUIREMENTS AS SPECIFIED BY 29 CFR PART 1910.180 (C) (1).

6HMTG 3/98

MOUNTING and INSTALLATION 6006

2-1.2.0

Page 19: AutoCrane 6006 Owner's Manual

AUTO CRANE COMPANYTulsa, Oklahoma

Safety Decal Section6006Revision 8/97

SD-71WARNING, KEY OPERATION7

SD-62DANGER, STAY CLEAR OF LOAD6

SD-52DANGER, STAY CLEAR OF BOOM5

SD-42DANGER, ELECTROCUTION HAZARD4

SD-31CAUTION, TWECO3

SD-21DANGER, OPERATOR TRAINING2

SD-11CAUTION, WORK RULES1

FIGQTYDESCRIPTIONITEM

2-3.0.0

Page 20: AutoCrane 6006 Owner's Manual

Safety Decal Section6006 Revised 8/97

Back of cranePLACEMENT:

1QUANTITY:

6006 USED ON:

To inform the operator that the main powerfeeder (tweco) is "LIVE" when crane battery isconnected.

FUNCTION:

CAUTION - TWECO/LIVEDECAL:

040530PART NO.:

Right side of cranePLACEMENT:

1QUANTITY:

All cranesUSED ON:

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

FUNCTION:

OPERATOR TRAININGDECAL:

040580PART NO.:

FIG.SD-1

FIG. SD-2

FIG. SD-3

2-3.1.0

Right side of cranePLACEMENT:

1QUANTITY:

All cranesUSED ON:

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

FUNCTION:

OPERATION INSTRUCTIONSDECAL:

040579PART NO.:

Page 21: AutoCrane 6006 Owner's Manual

Safety Decal Section6006 Revised 8/97

Both sides of end of boomPLACEMENT:

2QUANTITY:

All cranesUSED ON:

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

FUNCTION:

STAY CLEAR OF BOOMDECAL:

040517PART NO.:

Both sides of boomPLACEMENT:

2QUANTITY:

Articulated & Stiff Boom CranesUSED ON:

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

FUNCTION:

ELECTROCUTION HAZARDDECAL:

040529PART NO.:

FIG. SD-4

FIG. SD-5

2-3.2.0

FIG. SD-6Both sides ofblock

PLACEMENT:

2QUANTITY:

All cranesUSED ON:

To inform theoperator of thehazard ofproximity orcontact with thecrane load duringoperation.

FUNCTION:

STAY CLEAROF LOAD

DECAL:

040518PART NO.:

Page 22: AutoCrane 6006 Owner's Manual

Safety Decal Section6006 Revised 8/97

Right side of cranePLACEMENT:

1QUANTITY:

6006 USED ON:

To inform the operator of the properprocedure regarding key operation.

FUNCTION:

WARNING & CAUTIONDECAL:

040511 PART NO.:

FIG. SD-7

2-3.3.0

Page 23: AutoCrane 6006 Owner's Manual

AW1023 6/2000

GENERAL DIMENSIONS & DECAL LOCATION6006

2-4.0.0

Page 24: AutoCrane 6006 Owner's Manual

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.)

3-4.0.0 WIRE 1/2000

LIFE OF WIRE LINE

WIRE LINE LUBRICATION

Page 25: AutoCrane 6006 Owner's Manual

AW1001 6/2000

LUBRICATION CHART6006

3-5.0.0

Page 26: AutoCrane 6006 Owner's Manual

TROUBLESHOOTING6006 SERIES

6006trbl 6/20003-6.0.0

Page 27: AutoCrane 6006 Owner's Manual

TROUBLESHOOTING6006 SERIES

6006trbl 6/20003-7.0.0

Page 28: AutoCrane 6006 Owner's Manual

AW180000 6/2000

GENERAL ASSEMBLY 6006 12/24 VP/N 180000

4-1.0.0

Page 29: AutoCrane 6006 Owner's Manual

AW180003 6/2000

GENERAL ASSEMBLY 6006 220/110P/N 180003

4-2.0.0

Page 30: AutoCrane 6006 Owner's Manual

AW180002 6/2000

GENERAL ASSEMBLY 6006 HYDP/N 180002

4-3.0.0

Page 31: AutoCrane 6006 Owner's Manual

BASE ASSEMBLY & MAINTENANCE6006

M115 6/20004-4.0.0

Page 32: AutoCrane 6006 Owner's Manual

BASE ASSEMBLY & MAINTENANCE6006

M115 6/20004-4.1.0

Page 33: AutoCrane 6006 Owner's Manual

AW031 6/2000

17’ BOOM ASSEMBLY6006

4-5.0.0

Page 34: AutoCrane 6006 Owner's Manual

AW032 6/2000

20’ BOOM ASSEMBLY6006

4-5.1.0

Page 35: AutoCrane 6006 Owner's Manual

10’-16’ EXTENDABLE BOOMP/N 241197

AW241197 6/20004-5.2.0

Page 36: AutoCrane 6006 Owner's Manual

10’-16’ EXTENDABLE BOOMP/N 241197

AW241197 6/20004-5.2.1

Page 37: AutoCrane 6006 Owner's Manual

14’-20’ EXTENDABLE BOOMP/N 240200

AW240200 6/20004-5.3.0

Page 38: AutoCrane 6006 Owner's Manual

14’-20’ EXTENDABLE BOOMP/N 240200

AW240200 6/20004-5.3.1

Page 39: AutoCrane 6006 Owner's Manual

10’-16’ EXTENDABLE BOOM HYDP/N 240258

AW240258 6/20004-5.4.0

Page 40: AutoCrane 6006 Owner's Manual

10’-16’ EXTENDABLE BOOM HYDP/N 240258

AW240258 6/20004-5.4.1

Page 41: AutoCrane 6006 Owner's Manual

14’-20’ EXTENDABLE BOOM HYDP/N 240257

AW240257 6/20004-5.5.0

Page 42: AutoCrane 6006 Owner's Manual

M-124 6/2000

INSTALLATION OF CABLE CLAMPM-124

4-5.5.2

Page 43: AutoCrane 6006 Owner's Manual

AW200161 6/2000

TRAVELING SWIVEL BLOCK ASSEMBLYP/N 200161

4-6.0.0

Page 44: AutoCrane 6006 Owner's Manual

AW360602 6/2000

TRAVELING BLOCK ASSEMBLYP/N 360602

4-6.1.0

Page 45: AutoCrane 6006 Owner's Manual

BRAKE ASSEMBLY 12 VP/N 308201

AW308201 6/2000

4-7.0.0

Page 46: AutoCrane 6006 Owner's Manual

AW304601 6/2000

TWECO BASE ASSEMBLYP/N 304601

4-9.0.0

Page 47: AutoCrane 6006 Owner's Manual

MODBACT 6/2000

MODEL “B” ACTUATOR6006

4-9.1.0

Page 48: AutoCrane 6006 Owner's Manual

MODEL “B” ACTUATOR ASSEMBLYP/N 300002

AW300002 6/20004-9.2.0

Page 49: AutoCrane 6006 Owner's Manual

TURNER ACTUATOR ASSEMBLYP/N 315302

AW315302 6/20004-9.3.0

Page 50: AutoCrane 6006 Owner's Manual

MAINTENANCE OF TURNERACTUATOR ASSEMBLY

MAINTURN 6/20004-9.4.0

Page 51: AutoCrane 6006 Owner's Manual

Aw676106 3/2000

RELAY PANEL ASSEMBLY6006 SERIES

5-1.0.0

Page 52: AutoCrane 6006 Owner's Manual

Aw676106 3/2000

RELAY PANEL ASSEMBLY6006 SERIES

5-1.1.0

Page 53: AutoCrane 6006 Owner's Manual

BM676106 6/2000

RELAY PANEL ASSEMBLY6006 SERIES

5-1.2.0

Page 54: AutoCrane 6006 Owner's Manual

Aw699012 6/2000

RELAY PANEL ASSEMBLY220/24V 110/24V

5-2.0.0

Page 55: AutoCrane 6006 Owner's Manual

Aw699012 6/2000

RELAY PANEL ASSEMBLY220/24V 110/24V

5-2.1.0

Page 56: AutoCrane 6006 Owner's Manual

BM699012 6/2000

RELAY PANEL ASSEMBLY220/24V 110/24V

5-2.2.0

Page 57: AutoCrane 6006 Owner's Manual

BM699012 6/2000

RELAY PANEL ASSEMBLY220/24V 110/24V

5-2.3.0

Page 58: AutoCrane 6006 Owner's Manual

AW676105 6/2000

RELAY PANEL ASSEMBLYFOR REMOVABLE PENDANT

5-3.0.0

Page 59: AutoCrane 6006 Owner's Manual

AW676105 6/2000

RELAY PANEL ASSEMBLYFOR REMOVABLE PENDANT

5-3.1.0

Page 60: AutoCrane 6006 Owner's Manual

AW676105 6/2000

RELAY PANEL ASSEMBLYFOR REMOVABLE PENDANT

5-3.2.0

Page 61: AutoCrane 6006 Owner's Manual

Aw630912 6/2000

SUPPLEMENTAL WIRING DIAGRAMFOR HYD BOOM EXTENSION

CONDUCTOR ASSEMBLY63091313

CONDUCTOR ASSEMBLY63090812

CONDUCTOR ASSEMBLY63090711

DESCRIPTIONP/NQTYITEM

5-4.0.0

Page 62: AutoCrane 6006 Owner's Manual

Aw026 6/2000

ELECTRICAL SCHEMATIC12/24 VOLT

5-5.0.0

Page 63: AutoCrane 6006 Owner's Manual

Aw064 6/2000

ELECTRICAL SCHEMATIC12/24 VOLT POWER EXTENSION

5-6.0.0

Page 64: AutoCrane 6006 Owner's Manual

Aw301013 6/2000

ELECTRICAL SCHEMATIC24 VOLT

5-7.0.0

Page 65: AutoCrane 6006 Owner's Manual

Aw330070 6/2000

VOLTAGE CONVERTER ASSEMBLYA/W-330070

5-8.0.0

Page 66: AutoCrane 6006 Owner's Manual

Aw699011 6/2000

VOLTAGE CONVERTER ASSEMBLY220VAC / 24VDC

5-9.0.0

Page 67: AutoCrane 6006 Owner's Manual

Aw699023 6/2000

RECTIFIER24 VOLT

5-10.0.0

Page 68: AutoCrane 6006 Owner's Manual

TRBL VOLT CONV 6/2000

TROUBLE SHOOTINGTHE VOLTAGE CONVERTER

5-11.0.0

Page 69: AutoCrane 6006 Owner's Manual

Aw330007 3/2000

POWER CABLEAW-330007

CONDUCTOR 4 GA34121614

BUSHING W/NUT00280113

TERMINAL00500012

CONDUCTOR SWIVEL-FEMALE66920011

DESCRIPTIONP/NQTYITEM

5-12.0.0

Page 70: AutoCrane 6006 Owner's Manual

VOLTAGE SWITCHING UNIT6006 SERIES

Aw301015 6/20005-13.0.0

Page 71: AutoCrane 6006 Owner's Manual

PENDANT ASSEMBLY3 FUNCTION

Aw480399 6/20005-14.0.0

Page 72: AutoCrane 6006 Owner's Manual

PENDANT ASSEMBLY3 FUNCTION

Aw480399 6/2000

TERMINAL STRIP635301119

CONDUTCOR ASSY 3 1/8622347218

CONDUCTOR ASSY 2 1/8622346317

SCREW PN HD #8 X 1 1/2004700116

3/4 WIDE OKONITE RUBBER TAPE80058021 IN15

WASHER SP LK #8 019700314

O-RING642100313

NUT675271312

TERMINALS T & B000101811

JUMPER636600310

TY-RAP CABLE TIE63440129

CONDUCTOR CABLE (23 FT) STD80063023 FT8

CABLE ADAPTER63380117

SCREW PN HD #8 X 1 1/400510126

SCREW PN HD #8 X 3/4005001105

BOOT-TOGGLE SWITCH64030234

TOGGLE SWITCH63420033

BOTTOM COVER63170012

PENDANT HOUSING 63160211

DESCRIPTIONP/NQTYITEM

5-14.1.0

Page 73: AutoCrane 6006 Owner's Manual

PENDANT ASSEMBLY4 FUNCTION

Aw480799 6/20005-15.0.0

Page 74: AutoCrane 6006 Owner's Manual

PENDANT ASSEMBLY4 FUNCTION

Aw480799 6/2000

TERMINAL STRIP635301119

CONDUTCOR ASSY 3 1/8622347318

CONDUCTOR ASSY 2 1/8622346417

SCREW PN HD #8 X 1 1/2004700116

3/4 WIDE OKONITE RUBBER TAPE80058021 IN15

WASHER SP LK #8 019700314

O-RING642100413

NUT675271412

TERMINALS T & B0001011011

JUMPER636600410

TY-RAP CABLE TIE63440129

CONDUCTOR CABLE 80063026 FT8

CABLE ADAPTER63380117

SCREW PN HD #8 X 1 1/400510126

SCREW PN HD #8 X 3/4005001105

BOOT-TOGGLE SWITCH64030244

TOGGLE SWITCH63420043

BOTTOM COVER63170012

PENDANT HOUSING 63160111

DESCRIPTIONP/NQTYITEM

5-15.1.0

Page 75: AutoCrane 6006 Owner's Manual

PENDANT ASSEMBLY3 FUNCTION REMOVABLE

Aw480400 6/20005-16.0.0

Page 76: AutoCrane 6006 Owner's Manual

PENDANT ASSEMBLY3 FUNCTION REMOVABLE

Aw480400 6/2000

CABLE CLAMP300412120

PLUG ELECTRICAL300411119

CONDUTCOR ASSY 3 1/8622347218

CONDUCTOR ASSY 2 1/8622346317

SCREW PN HD #8 X 1 1/2004700116

3/4 WIDE OKONITE RUBBER TAPE80058021 IN15

WASHER SP LK #8 019700314

O-RING642100313

NUT675271312

TERMINALS T & B000101811

JUMPER636600310

TY-RAP CABLE TIE63440129

CONDUCTOR CABLE 80063023 FT8

CABLE ADAPTER63380117

SCREW PN HD #8 X 1 1/400510126

SCREW PN HD #8 X 3/4005001105

BOOT-TOGGLE SWITCH64030234

TOGGLE SWITCH63420033

BOTTOM COVER63170012

PENDANT HOUSING 63160211

DESCRIPTIONP/NQTYITEM

5-16.1.0

Page 77: AutoCrane 6006 Owner's Manual

PENDANT ASSEMBLY4 FUNCTION REMOVABLE

Aw480800 6/20005-17.0.0

Page 78: AutoCrane 6006 Owner's Manual

PENDANT ASSEMBLY4 FUNCTION REMOVABLE

Aw480800 6/2000

CABLE CLAMP300412120

PLUG ELECTRICAL300411119

CONDUTCOR ASSY 3 1/8622347318

CONDUCTOR ASSY 2 1/8622346417

SCREW PN HD #8 X 1 1/2004700116

3/4 WIDE OKONITE RUBBER TAPE80058021 IN15

WASHER SP LK #8 019700414

O-RING642100413

NUT675271412

TERMINALS T & B0001011011

JUMPER636600410

TY-RAP CABLE TIE63440129

CONDUCTOR CABLE 80063027 FT8

CABLE ADAPTER63380117

SCREW PN HD #8 X 1 1/400510126

SCREW PN HD #8 X 3/4005001105

BOOT-TOGGLE SWITCH64030244

TOGGLE SWITCH63420043

BOTTOM COVER63170012

PENDANT HOUSING 63160111

DESCRIPTIONP/NQTYITEM

5-17.1.0

Page 79: AutoCrane 6006 Owner's Manual

PENDANT ASSEMBLY 220/24VA/W-243045 & A/W-642420

Aw243045 6/20005-18.0.0

Page 80: AutoCrane 6006 Owner's Manual

REMOVABLE PENDANT KIT6006 SERIES

Aw066 6/20005-19.0.0

Page 81: AutoCrane 6006 Owner's Manual

REMOVABLE PENDANT KIT6006 SERIES

Aw066 6/2000

PENDANT ASSY (4 FUNCTION REMOVABLE)480800112

PENDANT ASSY (3 FUNCTION REMOVABLE)480400111

REMOVABLE PENDANT CONDUCTOR ASSY (4 FUNCTION)330663110

REMOVABLE PENDANT CONDUCTOR ASSY (3 FUNCTION)33066219

SCREW HX 1/4 X 3/4REF28

GUARD RELAY PANEL33066017

SCREW RD HD #6-32 X 1/200060326

WASHER SP LK #601960025

NUT HX #6-3201540024

CAP RECEPTACLE30041313

RECEPTACLE MOUNT PLATE33066112

RECEPTACLE FEMALE 10 PIN30041011

DESCRIPTIONP/NQTYITEM

5-19.1.0

Page 82: AutoCrane 6006 Owner's Manual

LOAD LIMIT SWITCH ASSEMBLY6006 SERIES

Aw241138 6/20005-20.0.0

Page 83: AutoCrane 6006 Owner's Manual

LOAD LIMIT SWITCH ASSEMBLY6006 SERIES

Aw241138 6/2000

TERM WIRE000300122

TERM WIRE000302121

TERM WIRE000101220

SCREW HX HD 3/8-24 X 1 1/2 009100119

NUT HALF LK 3/8-24017400118

THIMBLE 5/16 WIRE ROPE023600117

WASHER LK 1/4 020200116

SCREW HX HD 1/4-28 X 1 1/2 005702115

CONDUCTOR (655636)REF114

SENSING ARM SCREW002905113

SPACER646700112

PIN ROLL 1/8 X 3/4 023700111

SENSING ARM650205110

SCREW 3/8 NF X 3 1/2 00980019

NUT HALF LK 3/8 NF01740028

BRACKET24110517

CLAMP64290816

GUARD24114715

SWITCH64690014

SCREW 5/8 NF X 7 1/2 (013301) REF13

NUT HALF LK 5/8 NF (018100)REF12

CLEVIS10080111

DESCRIPTIONP/NQTYITEM

5-20.0.0

Page 84: AutoCrane 6006 Owner's Manual

SWING LIMIT SENSOR ASSEMBLY6006 SERIES

Aw650000 3/20005-21.0.0

Page 85: AutoCrane 6006 Owner's Manual

ELECTRIC MOTOR6006 SERIES

Aw300105 6/20005-22.0.0

Page 86: AutoCrane 6006 Owner's Manual

ELECTRIC MOTOR6006 SERIES

Aw300105 6/20005-22.1.0

Page 87: AutoCrane 6006 Owner's Manual

ELECTRIC MOTOR 750 “S” MSX DUNMORE6006 SERIES

Aw300105-001 6/20005-23.0.0

Page 88: AutoCrane 6006 Owner's Manual

ELECTRIC MOTOR MSI (6027)6006 SERIES

Aw300105-002 6/20005-24.0.0

Page 89: AutoCrane 6006 Owner's Manual

ELECTRIC MOTOR MSI (6027)6006 SERIES

Aw300105-002 6/20005-24.1.0

Page 90: AutoCrane 6006 Owner's Manual

Aw008 6/2000

MAINTENCE INSTRUCTIONSMOTOR BRUSHES

5-25.0.0

NOTE: IF MOTOR LOSES POWER IT MAY BE BECAUSE THE BRUSHES HAVEBECOME TIGHT IN THE BRUSH HOLDER. TO CORRECT THIS CONDITION,FOLLOW THE INSTRUCTIONS BELOW:REF. MOTOR AW-300105.

STEP INSTRUCTIONS 1. DISCONNECT MOTOR LEADS. 2. REMOVE BAND (P/N: 300162) BY LOOSENING SCREW (P/N: 300161). 3. RAISE BRUSH SPRING (P/N: 300165) WITH SCREWDRIVER ANDREMOVE BRUSHES. 4. DRESS FACE OF BRUSHES LIGHTLY WITH FILE.

ASSEMBLE IN REVERSE SEQUENCE AND TEST.

Page 91: AutoCrane 6006 Owner's Manual

Aw330607 6/2000

HYDRAULIC PUMPP/N: 330607

SEE NOTE #1REF-9

SOLENOID330631-8

RESERVOIR ADAPTER330629-7

CAP BREATHER200545-6

O-RING330628-5

RESERVOIR 330627-4

PUMP KIT330626-3

COUPLING330409-2

MOTOR PUMP330625-1

DESCRIPTIONP/NQTYITEM

6-1.0.0

Page 92: AutoCrane 6006 Owner's Manual

Aw330608 6/2000

HYDRAULIC PUMPP/N: 330608

SOLENOID330631-8

RESERVOIR ADAPTER330629-7

CAP BREATHER200545-6

O-RING330628-5

RESERVOIR 330627-4

PUMP KIT330626-3

COUPLING330409-2

MOTOR PUMP330625-1

DESCRIPTIONP/NQTYITEM

6-2.0.0

Page 93: AutoCrane 6006 Owner's Manual

AW200745 6/2000

JACKLEG ASSEMBLYP/N 200745

---7

POCKET TUBE70004716

HORIZONTAL MEMBER20008115

TOGGLE20008514

CAPSCREW HX HD 1/2 NF x 400680123

LOCKNUT HX 1/2 NF01780022

BASE ASSEMBLY20004111

DESCRIPTIONP/NQTYITEM

8-1.0.0

Page 94: AutoCrane 6006 Owner's Manual

GUARD ASSEMBLY 24 VP/N 306000-1

AW3030001 6/2000

8-2.0.0

Page 95: AutoCrane 6006 Owner's Manual

CABLE GUIDE ASSEMBLYP/N 240263

AW240263 6/2000

NUT HX HALF LK 3/801740025

SCREW HX HD 3/8 x 1 1/400910824

SHEAVE ASSEMBLY20091023

SHEAVE PLATE24026512

SHEAVE PLATE24026411

DESCRIPTIONP/NQTYITEM

8-3.0.0

Page 96: AutoCrane 6006 Owner's Manual

AW040611 6/2000

6006 LOAD CHARTP/N 040611

9-9.9.9

Page 97: AutoCrane 6006 Owner's Manual

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