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4004 H OWNERS MANUAL Manual No. 999997 Rev. 9/2/2003 Serial No. __________________ Mailing Address: P.O. Box 580697 Tulsa, OK 74158-0697 Physical Address: Phone (918) 836-0463 4707 N. Mingo Rd. Fax (918) 834-5979 Tulsa, OK 74117-5904 http://www.autocrane.com...
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Serial No.: Date Product Delivered: Date Processed:* VIN # * For Auto Crane use only ONE REGISTRATION FORM PER UNIT (CRANE OR BODY) Registration form must be mailed or faxed within 15 days of customer installation. Mail to: Warranty Department Auto Crane Company P.O.
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4004H SERIES OWNER’S MANUAL – REVISION RECORD Section(s) Revision Description of Change Date Page(s) 09/02/03 Last page New 2-year warranty policy to replace 1-year warranty policy...
♦ 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.
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4004H SERIES - OWNER'S MANUAL TABLE OF CONTENTS PAGE INTRODUCTION ..........1-1.0.0 OPERATING PRACTICES &...
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GENERAL SPECIFICATIONS 4004H SERIES DIMENSIONS CHASSIS REQUIREMENTS 10,500 lbs (4,763 kg) GVWR minimum Width: 19.25 in (.49 m) Height: 32.50 in (.83 m) HYDRAULIC SYSTEM Length: 11 ft 8 5/16 in (3.58 m) Weight: 1050 lbs (476 kg) Pressure: 2200psi (15,169 kPa) relief setting [Add 5 lbs (2.25 kg) for cable length of 75 feet (23 m)] Flow:...
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4004H SERIES Auto Crane products are designed to provide many years It has always been Auto Crane Company policy to handle of safe, trouble-free, dependable service when properly used all warranty claims we receive as promptly as possible. If a and maintained.
Switch on that will cause unsafe operating conditions! 15. ALWAYS store outriggers before road travel. WARNING! Auto Crane Company remote controlled, stiff boom cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel.
37. Store pendant control on proper location (in cab or on park for automatic transmissions). Activate any crane crane). power switches. For Auto Crane units requiring battery and hydraulic operation, engage emergency 38. Return outriggers to stowed position. Make sure they...
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QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES OPERATORS 7 Operators and operator trainees should have normal depth perception, coordination, and no tendencies to dizziness or similar undesirable characteristics. 1 Crane operation shall be limited to personnel with the following minimum qualifications: 8 In addition to the above listed requirements, the A.
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QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES B. land the suspended load and boom, if practical. F. During lifting care shall be taken that: 1. there is no sudden acceleration or 15 The operator shall be familiar with the equipment deceleration of the moving load.
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QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES MISCELLANEOUS 25 In transit with no load and boom lowered the clearance shall be specified in Table 1. OPERATING NEAR ELECTRICAL POWER 26 A qualified signalperson shall be assigned to observe LINES the clearance and give warning before approaching the above limits.
INSPECTION, TESTING AND MAINTENANCE GENERAL G. electrical apparatus for malfunctioning, signs of INSPECTION CLASSIFICATION excessive deterioration, dirt and moisture accumula- tion 27 Initial inspection. Prior to initial use, all new, altered, modified or extensively repaired cranes shall be H. hydraulic system for proper oil level and leaks daily inspected by a designated person to insure compli- I.
INSPECTION, TESTING AND MAINTENANCE GENERAL elements in contact or otherwise protect the necessary to determine origin of the problem before components corrective action can be taken. 39 Hydraulic and pneumatic pumps and motors 43 Labels are to be in place and legible. inspection.
INSPECTION, TESTING AND MAINTENANCE GENERAL tested by or under the direction of an A. functional operating mechanism appointed person. B. safety devices C. control systems 48 Test loads shall not exceed 110% of the manufac- turer's load ratings. 55 Repairs or replacements shall be provided as needed for operation.
INSPECTION, TESTING AND MAINTENANCE GENERAL 3. broken or cut strands; 1. sections in contact with saddles, equalizer sheaves, or other sheaves where rope travel 4. number, distribution and type of visible is limited broken wires. When such damage is discovered, the rope shall either be 2.
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INSPECTION, TESTING AND MAINTENANCE GENERAL G. In standing ropes, more than two broken wires in 65 Before cutting a rope, seizing shall be placed on each one lay in sections beyond end connections or more side of the place where the rope is to be cut to prevent than one broken wire at an end connection.
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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 galvanized pre-formed 7 x 19 aircraft cable. This cable has a working strength, when new, of 4,200 pounds.
MAINTENANCE OF BATTERIES Maintenance of Auto Crane unit batteries differs very Keep Properly Filled with Water little from the generally prescribed maintenance of any lead acid battery. All batteries must be kept properly The battery should always be properly filled with water.
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MAINTENANCE OF BATTERIES Low Maintenance Batteries should be attempted for an extended time. This usually will recover a badly sulfated battery. (Maintenance Free) Replacing a Battery Low maintenance batteries should not be used on Auto Cranes or trucks equipped with Auto Cranes. If it is necessary to replace a battery, and a dry charge The batteries are not designed for "deep"...
SAFETY DECAL SECTION PART NO.: 040517 DECAL: STAY CLEAR OF BOOM FUNCTION: To inform the operator of the hazard of proximity or contact with the crane boom during operation. QUANTITY Both sides of crown PLACEMENT (see page 1-7.3.0/1-7.4.0, Item 12) FIG.
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SAFETY DECAL SECTION PART NO.: 040529 QUANTITY DECAL: ELECTROCUTION HAZARD Both sides of end of lower boom PLACEMENT FUNCTION: To inform the operator of the (see page 1-7.3.0/1-7.4.0, Item 11) hazard involved with contacting electrical power lines with crane boom. FIG.
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SAFETY DECAL SECTION PART NO.: 040579 DECAL: OPERATION INSTRUCTIONS FUNCTION: To inform the operator of the proper procedure to follow for safe operation of the crane. QUANTITY Left Sideplate PLACEMENT (see page 1-7.3.0/1-7.4.0, Item 1) FIG. SD-6. PART NO.: 040587 DECAL: LOAD SENSOR FUNCTION:...
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040632 WARNING “TAMPERING WITH OVERLOAD...” DECAL 360034 LOGO DECAL 320318 ANGLE INDICATOR DECAL 404088 ELECTRIC SCHEMATIC DECAL 040624 AUTO CRANE DECAL 11 FT 040620 STRIPING DECAL 040529 DANGER “ELECTROCUTION HAZARD” DECAL 040517 DANGER “STAY CLEAR OF BOOM” DECAL 040518 DANGER “ STAY CLEAR OF LOAD” DECAL 360480-100 BLOCK WEIGHT &...
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040632 WARNING “TAMPERING WITH OVERLOAD...” DECAL 360034 LOGO DECAL 320318 ANGLE INDICATOR DECAL 404088 ELECTRIC SCHEMATIC DECAL 040624 AUTO CRANE DECAL 11 FT 040620 STRIPING DECAL 040529 DANGER “ELECTROCUTION HAZARD” DECAL 040517 DANGER “STAY CLEAR OF BOOM” DECAL 040518 DANGER “ STAY CLEAR OF LOAD” DECAL 360480-100 BLOCK WEIGHT &...
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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 record. Additional copies are available from your local distributor.
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ASSEMBLY & INSTALLATION INSTRUCTIONS 4004H SERIES NOTE: For mounting bolt hole pattern - see GENERAL DIMENSIONS. 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 or suitable chassis ground point.
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BOOM SUPPORT 4004H SERIES WARNING: As with all Auto Crane power rotation units, the 4004H does require a boom support. Suggested Boom Support: Auto Crane P/N 726175 AW726175 7/98 2-2.0.0...
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GENERAL ASSEMBLY - UNIT LESS BOOM P/N 404065 - MODEL 4004H AW404065 1/2000 3-1.0.0...
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GENERAL ASSEMBLY - UNIT LESS BOOM P/N 404065 - MODEL 4004H AW404065 1/2000 3-1.1.0...
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GENERAL ASSEMBLY - UNIT LESS BOOM P/N 404065 - MODEL 4004H ITEM DESCRIPTION 404087 PEDESTAL 404020 SIDE PLATES/QUILL HOUSING WELDMENT 480075 HOIST ACTUATOR 320741 MOTOR HOIST 404017 ROTATION BEARING 404028 RETAINING RING GEAR 404016 WORM GEAR 404015 WORM 320740 ROTATION MOTOR 330484 SPACER 011603...
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GENERAL ASSEMBLY - UNIT LESS BOOM P/N 404065 - MODEL 4004H ITEM DESCRIPTION 320725 MANIFOLD 404096 VALVE MOUNTING BRACKET 330371 CAPSCREW 3/8 UNC x 1 404132 HYDRAULIC SWIVEL BRACKET POWER CONDUCTOR (340638) 330372 HEX NUT 3/8 UNC GR5 005401 CAPSCREW 1/4 UNC x 5/8 020200 LOCK WASHER 1/4 404094...
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AUTOMATIC SAFETY BRAKE ASSEMBLY (OIL COOLED) HOIST ASSEMBLY INSTRUCTIONS: Winch has right hand worm and gear. Cable spools over drum. Use number one slots for brake balls(7) in cam plate(2). Install brake hub(5) through brake housing(4) on winch worm with key. Assemble balls(7) in cam plate(2) using hard grease to hold balls in place.
GENERAL DIMENSIONS 4004H 10-16 NOTES: A. MAX TURNING RADIUS AT ROTATION MOTOR = 13” B. MAX TURNING RADIUS AT HOIST ACTUATOR = 21 1/2” 4-2.0.0 AW371H 2/2000...
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GENERAL DIMENSIONS 4004H 10-16-20 NOTES: A. MAX TURNING RADIUS AT ROTATION MOTOR = 13” B. MAX TURNING RADIUS AT HOIST ACTUATOR = 21 1/2” 4-1.0.0 AW371 8/98...
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CRANE WIRING P/N 404117 - 4004H SERIES ITEM DESCRIPTION 404123 WIRING HARNESS 646900 SWITCH 404158 LOAD SENSOR ASSEMBLY 404142 TERMINAL BOARD BRACKET 404113 RELAY BOX ASSEMBLY 404141 WIRING HARNESS BRACKET 366097 PENDANT RECEPTACLE CAP 000404 PAN HD SCREW #6 x 5/8 019600 LOCK WASHER #6 015400...
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CRANE WIRING IC P/N 404149 - 4004H SERIES AW404149 1/2000 5-2.0.0...
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CRANE WIRING IC P/N 404149 - 4004H SERIES Notes: 1. Mount terminal board bracket, amplifier, & relay assembly with cap screw heads mounted behind wiring harness bracket. 2. 1/4 x1 1/2 cap screw that mounts terminal bracket is also ground for unit. 3.
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CRANE WIRING IC P/N 404149 - 4004H SERIES ITEM QUANTITY PART NUMBER DESCRIPTION 404123 WIRING HARNESS 646900 SWITCH 320543 LOAD SENSOR ASSEMBLY 404142 TERMINAL BOARD BRACKET 404113 RELAY BOX ASSEMBLY 404141 WIRING HARNESS BRACKET 404153 PENDANT RECEPTACLE COVER 000404 PAN HD SCREW #6 x 5/8 019600 LOCK WASHER #6 015400...
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IN-COMPARTMENT (IC) PENDANT P/N 404147 AW404147 2/2000 5-3.0.0...
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IN-COMPARTMENT (IC) PENDANT P/N 404147 ITEM DESCRIPTION 404148 CRANE PIGTAIL HARNESS 480490 22 STA TERMINAL BLOCK DECAL 480491-080 22 STA/19 PIN SOCKET HARNESS 480626 19 PIN PENDANT BRACKET 480493 22 STA TERMINAL BLOCK COVER 000404 RD HD SCREW #6 NC x 5/8 015400 HEX NUT #6 NC 019600...
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PROPORTIONAL 8 FUNCTION PENDANT ASSEMBLY P/N 680040 - 4004H AW680040 8/98 5-4.0.0...
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PROPORTIONAL 8 FUNCTION PENDANT ASSEMBLY P/N 680040 - 4004H ITEM DESCRIPTION PENDANT HOUSING COVER PLATE DECAL TOGGLE SWITCH BOOT HUBBELL CONNECTOR CORD GRIP SCREW #10 NC x 3/4 HEX LOCK NUT #10 NC POTENTIOMETER ASSEMBLY TRIGGER SOC HD SCREW #10 NF x 5/8 TOGGLE DPDT SWITCH BACK PLATE ST RD HD SCREW #6 x 3/4...
THROTTLE CONTROL SOLENOID INSTALLATION LOCATION 1. Mount the solenoid and control module according to the recommendations in the Follow these simple rules to properly locate “LOCATION” instructions your throttle control kit: 2. Electrically connect the solenoid to the 1. Mount the solenoid off the engine but within control module and power source according 46 inches of the throttle lever, to avoid to the wiring diagram.
12 VDC when signal is present at 8. Check for proper adjustments. “AUX” terminal B WHT 12 VDC for 0.5 to 0.75 seconds 9. Contact Auto Crane Company if you are after signal at “AUX” terminal is unable to resolve the problem. present C BLK...
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SPEED CONTROL KIT, P/N 751140 NOTES: 1. THIS DIAGRAM SHOWS SPEED CONTROL INSTALLTION WITH OR WITHOUT AN AIR COMPRESSOR. DISREGARD ISOLATOR BLOCK & PRESSURE SWITCH ON DIAGRAM IF NOT USING AN AIR COMPRESSOR. 2. REMOVE METAL JUMPER CLIP FROM CONTROL MODULE IF SO EQUIPPED (S500-A5).
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ENGINE START/STOP RELAY KIT P/N 480533 ITEM DESCRIPTION 320355 12V RELAY 320363 RELAY PLUG 320357 FEMALE SPADE LOCK CONNECTOR 480495 FLANGED SPADE TERMINAL 000402 1/4 TERMINAL RING 000501 5/16 TERMINAL RING 6’ 800595 GREEN 16 GA WIRE 49’ 800590 BLACK 16 GA WIRE 17’...
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AUXILIARY RELAY KIT P/N 480534 ITEM DESCRIPTION 320355 12V RELAY 320363 RELAY PLUG 320357 FEMALE SPADE LOCK CONNECTOR 000101 #6 TERMINAL RING 000402 1/4 TERMINAL RING 000501 5/16 TERMINAL RING 38’ 800595 GREEN 16 GA WIRE 10’ 800593 RED 16 GA WIRE 25’...
HYDRAULIC ASSEMBLY P/N 404089 - MODEL 4004H PORT 2 PORT 1 View of Hydraulic Swivel from Bottom of Crane CAUTION: Reversing tank and pressure hoses will damage pump. AW404089 1/2000 6-1.0.0...
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HYDRAULIC ASSEMBLY P/N 404089 - MODEL 4004H ITEM DESCRIPTION HYDRAULIC MANIFOLD ASSEMBLY (320725) CYLINDER BOOM (404005) CYLINDER EXTENSION (360152) MOTOR ROTATION (320740) MOTOR HOIST (320741) 404108 TUBE ASSEMBLY 404109 TUBE ASSEMBLY 812209-036 HOSE ASSEMBLY x 36 812209-033 HOSE ASSEMBLY x 33 812209-013 HOSE ASSEMBLY x 13 812209-029...
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HYDRAULICS 4004H SERIES CAUTION: IF COUNTERBALANCE VALVE IS REPLACED, THE CORRECT PRESSURE SETTING MUST BE MADE BEFORE CRANE IS IN SAFE WORKING CONDITION. 2. Boom up until boom cylinder is fully IMPORTANT elevated. Crane boom must be supported 3. Boom down in small increments while and pump system disengaged reading pressure gauge.
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4004H TROUBLESHOOTING GUIDE 2. Check the compensator valve for 1 CRANE FAILS TO OPERATE (ALL contamination. FUNCTIONS) A. Make sure power switch is set to the "on" 2 HOIST UP, BOOM DOWN, AND EXTEND position on the pendant. (OUT) DON'T OPERATE (ALL OTHER FUNCTIONS DO OPERATE).
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4004H TROUBLESHOOTING GUIDE D. Locate timing relay box on back of crane and 1. If it works, check power and ground open lid. Disconnect yellow wire on terminal going to coil at weather pack connector. #1 of the time delay relay. i.
2 YEAR PARTS AND LABOR Auto Crane will warranty to the consumer for a period of (2) years parts and labor from the date of purchase. Each new Auto Crane unit they sell will be free under normal use and service from defects in material and workmanship.
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