Auto Crane 8406H Owner's Manual
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Auto Crane 8406H Owner's Manual

Hw w/horn
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8406H HW W/HORN
OWNERS MANUAL
Serial No. __________________
Mailing Address:
P.O. Box 580697
Tulsa, OK 74158-0697
Physical Address: 4707
N. Mingo Rd. Tulsa, OK
74117-5904
Phone 1-800-777-2760
Fax (918) 269-6688
http://www.autocrane.com
OM 480989011-0515-A

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  • Page 1 8406H HW W/HORN OWNERS MANUAL Serial No. __________________ Mailing Address: Phone 1-800-777-2760 P.O. Box 580697 Tulsa, OK 74158-0697 Fax (918) 269-6688 Physical Address: 4707 http://www.autocrane.com N. Mingo Rd. Tulsa, OK 74117-5904 OM 480989011-0515-A...
  • Page 3 ONE REGISTRATION FORM PER UNIT (CRANE, BODY, OR COMPRESSOR) Please submit form within 15 days after installation Online: www.autocrane.com | Resources | Warranties Fax: 918-234-2177 Mail: Product Registration, Auto Crane Company, PO Box 580697, Tulsa, OK 74158-0697 Product Registration Rev 05152014...
  • Page 5 1. The information contained in this manual is in effect at the time of this printing. It does not cover all instructions, configurations, accessories, etc. If you require ad ditional information, please contact Auto Crane Company at 1-800-777-2760. 2. Auto Crane Company reserves the right to update this material without notice or obligation.
  • Page 6 Attempt to lift or drag a load from the side! The boom can fail far below its rated capacity. Weld, modify, or use unauthorized components on any Auto Crane unit! This will void any warranty or liability. Also failure of the crane may result.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS 8406H HW W/HORN INTRODUCTION GENERAL SPECIFICATIONS SAFETY TIPS AND PRECAUTIONS OPERATING PRACTICES & WARNINGS QUALIFICATIONS FOR OPERATORS OPERATION OF UNIT I OUTRIGGERS CRANE OPERATION TRANSMITTER INSTRUCTIONS INSPECTION TESTING GENERAL MAINTENANCE BATTERIES LUBRICATION AND MAINTENANCE SCHEDULE SAFETY DECAL SECTION...

  • Page 8: Introduction

    The If, through no fault of Auto Crane Company, it is payload of the vehicle is reduced by the necessary to send an experienced factory weight of the crane.
  • Page 9 Auto Crane Company at the following tele- phone number: 1-800-777-2760. The information contained in the manual is in effect at the time of this printing. Auto Crane Company reserves the right to update this material without notice or obligation.

  • Page 10: General Specifications

    8406H HW W/HORN GENERAL SPECIFICATIONS...

  • Page 11: Safety Tips And Precautions

    WARNING! Auto Crane Company cranes are not designed or intended for use in lifting or moving persons. Any such use shall be considered to be improper and the seller shall not be responsible for any claims arising there from.
  • Page 12 — IMPORTANT— SAFETY TIPS AND PRECAUTIONS 31. Always store the crane in its stowed position WARNING: Never attempt to lift, drag, tow or for transportation. pull a load from the side. The boom can fail far below its rated capacity. 32.

  • Page 13: Operating Practices & Warnings

    WARNING! NEVER hold any Control Select Switch on that will cause unsafe operating conditions! WARNING! Auto Crane Company remote controlled, stiff boom cranes are not designed or intended for use on any applications involving the lifting or moving of personnel.

  • Page 14: Qualifications For Operators

    QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE QUALIFICATION RE- QUIREMENTS OPERATORS QUALIFICATIONS FOR OPERATORS CONDUCT OF OPERATORS...
  • Page 15 QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES or neutral position and all personnel are in C. Means are provided to hold the vehicle the clear. stationary while operating the crane. 6. If power fails during operation, the operator D.
  • Page 16 QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES N. No person should be permitted to stand or 3. Caution shall be exercised when working near pass under a suspended load. overhead lines, because they can move horizontally or vertically due to wind, moving the 4.

  • Page 17: Operation Of Unit I Outriggers

    (or in park for automatic they are pinned in place or jacklegs are returned transmissions). Activate any crane power to compartment. switches. For Auto Crane units requiring 14. Check work area for any tools or equipment not battery and hydraulic operation, engage stored.

  • Page 18: Crane Operation

    CRANE OPERATION TRANSMITTER LAYOUT E-stop Switch—Push to activated, Twist ON/OFF/MULTI SPEED to release. Shuts down all outputs from E-STOP SWITCH 3 POSITION KEYSWITCH receiver. MECHANICAL LATCHING (TWIST TO UNLOCK) On/Off/Multispeed— Detachable key, LED INDICATORS On, Off, Multispeed, & Start Switch. 100% BOOM DOWN BOOM UP...
  • Page 19 CRANE OPERATION ON/OFF/MULTI SPEED E-STOP SWITCH 3 POSITION KEYSWITCH MECHANICAL LATCHING (TWIST TO UNLOCK) LED INDICATORS 100% DECREASE MAX INCREASE MAX SPEED SPEED ACTIVATING E-STOP Press the E-stop Switch. Note: 1. When E-stop is active, the transmitter will remain on but will not operate any functions. This includes truck and crane functions.
  • Page 20 CRANE OPERATION RECEIVER LAYOUT CRANE STATUS AUXILIARY ACTIVE LIFT CYLINDER PRESSURE SYSTEM GOOD FUNCTION ACTIVATED Boom Pressure 174 Boom Down SP=100% SP - SPEED PERCENT HIGH IDLE AUX ENG XXX Boom Angle 43 (deg) HIGH IDLE ACTIVE Boom Load 7% BOOM ANGLE (DEGREES) 100% BOOM LOAD...

  • Page 21: Transmitter Instructions

    TRANSMITTER SYNCHRONIZATION INSTRUCTIONS 1. The receiver must be shut off and powered down The current address tag must be removed from the harness and the LEARN tag (366823955) will need to be put in its place. 2. After the LEARN tag has been put into place and the receiver is powered up, it will begin to search for the proper Channel and Serial Number of the transmitter.

  • Page 22: Inspection

    INSPECTION REQUIREMENTS REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE INSPECTION REQUIREMENTS INSPECTION CLASSIFICATION 6. Inspect for proper rope reeving. 7. Inspect electrical wiring and components for 1. Initial inspection. malfunctioning, signs of excessive deterioration, dirt Prior to initial use, all new, altered, modified or and moisture accumulation.
  • Page 23 INSPECTION REQUIREMENTS 6. Inspect crane hooks for cracks. 13. Inspect hydraulic filters for evidence of rubber particles on the filter elements indicating possible 7. Inspect travel steering, braking, and locking hose, “O” ring, or other rubber component dete- devices for malfunction. rioration.

  • Page 24: Testing

    TESTING REQUIREMENTS REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE INSPECTION REQUIREMENTS TESTING SHALL BE PERFORMED BY DESIGNATED PERSONNEL ONLY. Prior to initial use, all new, altered, modified, or extensively repaired cranes shall be tested for compliance with the operational requirements of this crane. Test requirements: 1.

  • Page 25: General Maintenance

    GENERAL REPAIRS AND MAINTENANCE REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE MAINTENANCE AND REPAIR REQUIREMENTS A preventative maintenance program should be 4. If bleeding the hydraulic system is required, run established based on this section and all replacement each crane function until smooth operation of that parts should be obtained from AutoCrane Company.
  • Page 26 GENERAL REPAIRS AND MAINTENANCE 2. Replacement rope shall have a strength rating at 4. During installation care should be exercised to least as great as the original rope furnished or avoid dragging of the rope in the dirt or around recommended by AutoCrane.

  • Page 27: Batteries

    MAINTENANCE OF BATTERIES always...
  • Page 28 MAINTENANCE OF BATTERIES If, after charging, it is noted that the specific gravity 2. Place the battery on charge according to the reading of one cell is 30 points less than any of the manufacturer's instructions. other cells, it may be assumed that the cell is bad and that the battery should be replaced.

  • Page 29: Lubrication And Maintenance Schedule

    8406H HW W/HORN LUBRICATION & MAINTENANCE SCHEDULE CAUTION: Routine maintenance insures trouble-free operation and protects your invest- ment. All warranties are void if maintenance is neglected. 4-8.0...
  • Page 30 2. Once a bolt has been torqued to its rated capacity and then removed; the bolt should be replaced with a new one. 3. Auto Crane Company recommends that this crane be serviced per “Crane Inspection Log” P/N 999978. These logs should be filled in at the intervals noted and kept as a permanent...
  • Page 31 ROTATION BEARING REPLACEMENT GUIDELINES - 5005 THRU 8406 All bearings can wear over time. This includes the main rotation bearing on the crane. No pre- cise rules can be given for replacement of the rotation bearing, since many factors are in- volved.

  • Page 32: Safety Decal Section

    8406H HW W/HORN SAFETY DECAL SECTION PART NO.: 040579000 DECAL: OPERATING INSTRUCTIONS FUNCTION: To inform the operator of the proper procedure to follow for safe operation of the crane. USED ON: All Cranes QUANTITY: PLACEMENT: Left side plate PART NO.:...
  • Page 33 8406H HW W/HORN SAFETY DECAL SECTION PART NO.: 040529000 DECAL: ELECTROCUTION HAZARD FUNCTION: To inform the operator of the hazard involved with contacting electrical power lines with crane boom. USED ON: All Cranes QUANTITY: PLACEMENT: Both sides of end of lower boom PART NO.:...
  • Page 34 8406H HW W/HORN SAFETY DECAL SECTION...
  • Page 35 8406H HW W/HORN DECAL LAYOUT P/N: 480988021 4-5.0...
  • Page 36 330622000 DECAL SERIAL NO 360034000 DECAL AUTO CRANE LOGO 480851000 DECAL 8406H 460169000 DECAL WARNING, REMOTE CONTROL 480988022 DECAL, LOAD CHART 8406H 040518000 DECAL STAY CLEAR OF LOAD 480853000 DECAL MAX BLOCK LOAD 040824000 DECAL, AMERICAN FLAG, MADE IN THE U.S.A.

  • Page 37: General Dimensions

    8406H HW W/HORN GENERAL DIMENSIONS NOTE: C.G. IS APPROXIMATE 5-1.0 8/8/08...

  • Page 38: Mounting And Installation

    320357000 CONNECTOR FEM SPD 320363000 PLUG RELAY 340638000 CONDUCTOR POWER 320355000 POWER RELAY 480988011 MANUAL, 8406H, HW, W/ HORN 480988022 DECAL, LOAD CHART, 8406H 680040001 PENDANT ASSY, 8 FUNC., 366520003 JUNCTION BOX ASS'Y W/ UNLOAD 366466000 WIRE HARNESS, TRUCK FUNCTIONS * ITEMS ARE IN ELECTRICAL KIT 2.
  • Page 39 12. Load test the crane to ensure proper functioning and truck stability. 13. Make certain the owner’s manual is delivered to the customer. 14. For additional help: call the service department at the Auto Crane Company (918) 836-0463 (Tulsa, Oklahoma).
  • Page 40 NOTES...

  • Page 41: General Assembly

    8406H HW W/HORN GENERAL ASSEMBLY P/N: 480988002...
  • Page 42 WIRE ROPE ASSEMBLY 3/8 HEAVY DUTY 480854000 TRAVELING BLOCK ASSEMBLY 360124000 PIN HITCH 470076000 PIN, 1 DIA 4-11/16 LG 480988026 SHIP KIT, 8406H, HW, W/ HORN 480988025 VALVE COVER 480988021 DECAL LAYOUT/KIT 8406H 330622000 DECAL SERIAL NO 366719115 DISC, HORN, ELECTRIC. VOLTAGE 12...

  • Page 43: Pedestal Assembly

    8406H HW W/HORN PEDESTAL ASSEMBLY P/N: 480988202 49 HD VALVE BANK HOSING DETAIL TORQUE TO 200 FT-LBS DRY (NO THREAD LUBE) TORQUE TO 200 FT-LBS DRY (NO THREAD LUBE) HYDRAULICS: “HD” PORT: HOIST DOWN “HU” PORT: HOIST UP “CW” PORT: ROTATION CW “CCW”...
  • Page 44 8406H HW W/HORN PEDESTAL ASSEMBLY P/N: 480988202 VALVE 480188100 TORQUE TO 200 FT-LBS DRY (NO THREAD LUBE) ADD 6 INC WHERE IT RUBS AGAINST T ADD 6 INC WHERE IT RUBS AGAINST T ADD 6 INCHES OF NYLON HOSE SLEEVE TO 812303023...
  • Page 45 SCREW HX HD 1/4UNC X 1 1/4 GR5 490171000 SCREW HX HD 5/8-11UNC X 2 1/4 LG GR8 366333000 BEARING, SPHERICAL 1.25 ID 480988250 CYLINDER, LIFT, 8406H, STROKE - 27.81 360676000 PIN, CYLINDER 366159000 SCREW HX HD 3/8-16UNC X 1 1/2 LG GR8 021100000...
  • Page 46 8406H HW W/HORN PEDESTAL ASSEMBLY P/N: 480988202 ITEM PART DESCRIPTION NUMBER 366673000 PIN, ROTATION STOP 017301 NUT HX NYLK 3/8-16UNC CP 366671000 ARM, ROTATION STOP 460079000 BEARING, ROTATION STOP 320588000 WASHER, FL 1/2, HARDENED 017701000 NUT HX 1/2-13UNC 460177250 PLATE, MANIFOLD MOUNT, LARGE CRANE...

  • Page 47: Boom Assembly

    8406H HW W/HORN BOOM ASSEMBLY P/N: 480988101 4 PLACES VALVE 480188000 2 PLACES SHIM TO FIT (ORIENT ARROW CONNECT TO TOWARDS CROWN) RETRACT CYL. TUBE SHIM TO FIT WIRING (REVERSIBLE) 7 7 7 BLACK TO N.O. WHITE TO COMMON NOTES: APPLY LOCTITE 609 TO THREADS BEFORE INSTALLING.
  • Page 48 8406H HW W/HORN BOOM ASSEMBLY P/N: 480988101 ITEM NO. PART NO. DESCRIPTION 480988115 LOWER BOOM WELD, 8406H W/LIGHT 480988120 MID BOOM WELD, 8406H 480988130 UPPER BOOM WELD, 8406H 366669000 WEAR PAD, BOTTOM MID 460053000 WEAR PAD, BOTTOM UPPER 460177160 WEAR PAD, 5.13X3X.25, BOSS 1X3 360767000 PAD BOOM 1.5 O.D.

  • Page 49: Rotation Gearbox

    8406H HW W/HORN GEAR BOX P/N: 160407...
  • Page 50 8406H HW W/HORN GEAR BOX P/N: 160407...

  • Page 51: Hoist Assembly

    8406H HW W/HORN HOIST ASSEMBLY P/N: 123315 6-11.0 8/8/08...
  • Page 52 8406H HW W/HORN GEAR BOX P/N: 123315 ITEM NO. QTY. PART NO. DESCRIPTION 234189 DRUM ASSEMBLY 306042 PISTON-BRAKE 315004 ANCHOR- CABLE 338300 END BRG-MOTOR END 338301 END BRG-GEAR HSG. 338302 HSG-BRAKE 346045 PIN-BRAKE 357513 SHAFT- INPUT 362291 SPACER - FOOT MOUNTING...
  • Page 53 8406H HW W/HORN P/N: 123315 ITEM NO. QTY. PART NO. DESCRIPTION 472052 PLUG 474065 TIE PLATE 474111 PLATE-SEPARATOR, BRAKE 486080 SEAL 490037 SNAP RING 494110 SPRING-BRAKE 494112 SPRING 509009 TUBE ASSY 516033 VALVE-MOTOR CONTROL 518037 THRUST WASHER 518047 THRUST WASHER...

  • Page 54: Traveling Block Assembly

    8406H HW W/HORN TRAVELING BLOCK ASSEMBLY P/N: 480854000 ITEM NO. QTY PART NUMBER DESCRIPTION 480860000 TACKLE LOWER 480859000 SIDE PLATE TRAVELING BLOCK 480366000 HOOK SWIVEL 6 METRIC 480861000 SHEAVE ASSY 3/8 ROPE 490313000 BOLT, SHEAVE W/ZERK FITTING 018600000 NYLK 3/4-16UNF CP...

  • Page 55: Electrical Schematic

    8406H HW W/HORN ELECTRICAL SCHEMATIC P/N: 680195003 BOSCH RELAY...

  • Page 56: Main Wiring Harness

    8406H HW W/HORN MAIN WIRING HARNESS P/N: 680195002 RED/WHT 21.0"...
  • Page 57 8406H HW W/HORN MAIN HARNESS FUNCTION P/N: 680195002 FUNCTION WIRE COLOR NOTES GREEN TO PIN 1 (MAIN) HOIST UP WHITE/RED TO A2B GROUND RED/BLACK TO PIN 2 (MAIN) HOIST DN RED/WHITE GROUND WHITE/BLACK TO PIN 3 (MAIN) ROTATE CCW BLACK...

  • Page 58: Junction Box

    8406H HW W/HORN JUNCTION BOX ASSEMBLY P/N: 366520003 10 8 SECTION A-A SCALE 1 : 3 HEAT SHRINK AND SEAL WIRE BUNDLE ONCE ALL CONNECTIONS ARE MADE INDIVIDUAL HEAT SHRINK TUBING ON BACK SIDE OF CANNON PLUG 19 PIN 8 PIN 12 PIN 2 PIN GND...
  • Page 59 8406H HW W/HORN JUNCTION BOX ASSEMBLY P/N: 366520003 ITEM NO. PART NO. DESCRIPTION 366470000 JUNCTION BOX 366095000 PLUG, 19 PIN 366523001 HOUSING, DEUTSCH 8-PIN RECEPTACLE 366471000 COVER, JUNCTION BOX 366524001 HOUSING, DEUTSCH 12-PIN RECEPTACLE 366097000 CAP W/CHAIN (FOR RECEPTACLE) 366517000...

  • Page 60: Pendant Assembly

    8406H HW W/HORN PENDANT ASSEMBLY P/N: 680040001 HORN START STOP ENGINE POWER IDLE EXTEND ROTATE SLOW BOOM DOWN FAST WHITE HOIST AS VIEWED FROM DOWN BACKSIDE OF PENDANT. POTENTIOMETER...
  • Page 61 8406H HW W/HORN PENDANT ASSEMBLY P/N: 680040001 ITEM NO. PART NO. DESCRIPTION 480501000 PENDANT HOUSING 480518001 DECAL, PENDANT ASSY, 8 FUNC. 480504000 PENDANT BACK PLATE 600820000 CORD GRIP, 3/4 NPT, .50-.625" CORD 680113000 PENDANT CABLE BAYONET 480507000 POTENTIOMETER ASSY, W/ BRACKET...
  • Page 62 8406H HW W/HORN PENDANT CABLE ASSEMBLY P/N: 680113000 INSTALL ON: INSTALL ON: ORANGE WHITE GREEN WHITE W/ RED T BLUE BLACK RED W/BLACK T ORANGE W/BLACK T GREEN W/BLACK T INSTALL ON: WHITE W/BLACK T BLUE W/BLACK T RED W/WHITE T...

  • Page 63: Hydraulic Section

    8406H HW W/HORN HYDRAULIC SCHEMATIC P/N: 460140000 8-1.0...
  • Page 64 8406H HW W/HORN HYDRAULIC CONTROL VALVE P/N: 460140000 8-2.0...
  • Page 65 8406H HW W/HORN HYDRAULIC CONTROL VALVE P/N: 460140000 ITEM PART NO. DESCRIPTION 480839002 FLOW CONTROL 480839003 PROP VALVE 366365004 RELIEF VALVE 460160001 UNLOAD VALVE SV3, SV4, SV5 320725001 CART VALVE SV1, SV2 480839004 CART VALVE 366370001 COIL 460160002 COIL 480839005 COIL...

  • Page 66: Counterbalance Valve

    8406H HW W/HORN COUNTERBALANCE VALVE ADJUSTMENT Counterbalance Valve Adjustment Notice: 1. In an EMERGENCY situation when it 1. With PTO disengaged and boom properly becomes necessary to lower the boom without flow supported, remove the plug on the present, the CB valve adjustment can be turned in counterbalance valve.

  • Page 67: Valve Override Operation

    8406H HW W/HORN VALVE OVERRIDE OPERATION In the event that the electrical control system fails the crane can be operated using the manual overrides on the hydraulic control valve. The overrides operate as follows: 1. Proportional – increase flow by turning clockwise.

  • Page 68: Load Chart

    8406H HW W/HORN LOAD CHART P/N: 480988022...

  • Page 69: Warranty

    2 YEAR PARTS AND LABOR Auto Crane will warranty to the consumer for a period of (2) years parts and labor from the date of purchase. Each new Auto Crane unit they sell will be free under normal use and service from...
  • Page 70 Note: This manual should remain with the crane at all times. Auto Crane will not assume responsibility or liability for any modifi cations or changes made to unit, or installation of component parts without authorization. Auto Crane Company issues a limited warranty cer-...

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