Auto Crane 8005H Owner's Manual
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Auto Crane 8005H Owner's Manual

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OWNERS MANUAL
8005H
REVISION 3/2000
PART NO. 999939
SERIAL NO. __________________________
PO BOX 580697, TULSA, OK 74158-0697
4707 N. MINGO ROAD, TULSA, OK 74117-5904
PHONE (918) 836-0463
FAX (918) 834-5979
http://www.autocrane.com

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  • Page 1 OWNERS MANUAL 8005H REVISION 3/2000 PART NO. 999939 SERIAL NO. __________________________ PO BOX 580697, TULSA, OK 74158-0697 4707 N. MINGO ROAD, TULSA, OK 74117-5904 PHONE (918) 836-0463 FAX (918) 834-5979 http://www.autocrane.com...
  • Page 3 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.

  • Page 4: Table Of Contents

    8005H SERIES - OWNER'S MANUAL TABLE OF CONTENTS INTRODUCTION ..........

  • Page 5: Introduction

    3.5:1 safety on a field service call, the rates stated in the Auto Crane factor. Holding valves prevent the load from dropping Distributor's Flat Rate Manual will apply.

  • Page 6: Operating Practices & Warnings

    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.

  • Page 7: Operation Of Unit / Outriggers

    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...

  • Page 8: Qualifications For Operators

    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.
  • Page 9 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.
  • Page 10 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.

  • Page 11: Inspection, Testing, & Maintenance

    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.
  • Page 12 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.
  • Page 13 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.
  • Page 14 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.
  • Page 15 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.

  • Page 16: Mounting And Installation

    MOUNTING and INSTALLATION 8005H 1. CHECK TO MAKE SURE THE FOLLOWING ITEMS ARE WITH YOUR CRANE: ITEM PART NO. DESCRIPTION 360603000 SWIVEL BLOCK 480157000 VENTED RELIEF VALVE 480022000 PUMP ASSEMBLY (OPTIONAL) 999939000 OWNERS MANUAL 015104000 BOLT -- 7/8 NF x 5", GRD 8, (4 REQ'D) 2.
  • Page 17 INSTALL AN IN-LINE FLOW METER BETWEEN THE CRANE AND THE RESERVOIR IN THE RETURN HOSE, OR CONFIRM PUMP SPEED IS CORRECT. THE PROPER SPEED FOR AUTO CRANE GEAR PUMP P/N 480022 IS 1000 RPM, FOR P/N 360030 IT IS 1265 RPM.

  • Page 18: General Dimensions

    GENERAL DIMENSIONS 8005H 2-1.2.0 Aw-085 3/2000...
  • Page 19 MOUNTING ORIENTATION 8005H 2-2.0.0 Aw-017 3/2000...
  • Page 20 BASE ASSEMBLY 8005H 2-3.0.0 Aw-019 3/2000...
  • Page 21 INSTALLATION & SETUP PROCEDURE DIGITAL PULSE WIDTH AMPLIFIER INSTALLATION: 1. Install amplifier at a convenient location near the proportional crane terminal strip (see Proportional Crane Wiring Diagrams) using two screws and lock nuts provided. 2. At the 12-station terminal block, disconnect all power to the system. 3.
  • Page 22 INSTALLATION & SETUP PROCEDURE DIGITAL PULSE WIDTH AMPLIFIER “Zero” is the maximum speed setting and “F” is the most reduced speed setting. To set the high range dial, turn CLOCKWISE direction for DECREASED FLOW; turn COUNTERCLOCKWISE direction for INCREASED FLOW. This operation adjusts the trigger “Dead Band”...
  • Page 23 OVERLOAD SYSTEM / ANTI-2-BLOCK TROUBLE SHOOTING GUIDE IF THE THREE FUNCTIONS, BOOM DOWN, HOIST UP AND EXTEND OUT, QUIT WORKING, the problem probably lies in either the Overload System or the Anti-2-block system or both. If these three functions are NOT WORKING and most other functions are, an investigation should be made as follows: (reference: Figure 1) functions which could cause additional 1 ANTI-2-BLOCK...
  • Page 24 OVERLOAD SYSTEM / ANTI-2-BLOCK TROUBLE SHOOTING GUIDE 2-6.0.1 OVLD 1/99...
  • Page 25 RELAY BOX ASSEMBLY P/N 366999 Aw366999 2/2000 2-6.1.0...
  • Page 26 RELAY BOX ASSEMBLY P/N 366999 ITEM DESCRIPTION 366990 PLASTIC ENCLOSURE W/ 6 DRILL HOLES 366968 CORD CONNECTOR 366967 SHIELDED CABLE 3-CONDUCTOR 18-20 320363 TERMINAL CONNECTOR PLUG 366980 PIGGY BACK TERMINAL INSULATED 18-20 320355 BOSCH DROP OUT RELAY 005901 HEX HD SCREW 1/4-20 NC x 1/2 LG 016300 LOCK NUT 1/4-20 NC 320357...

  • Page 27: Optimeter Troubleshooting

    D. If voltage is erratic and jumps up to truck voltage and back down during the trigger movement, replace potentiometer assembly. 5. Depress the manual operator pin on top of the valve with an allen wrench till valve closes completely. 2-7.0.0 8005H optimeter 3/2000...
  • Page 28 NOTE:Both switches on "F" will limit flow to a median value and not allow any change. 10. Set the two adjustment switches (hi and lo) to number “4”. (One side of the switch knob has an indicator.) 2-7.1.0 8005H optimeter 3/2000...
  • Page 29 THROTTLE SOLENOID ASSEMBLY 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).
  • Page 30 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.
  • Page 31 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...
  • Page 32 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’...
  • Page 33 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’...

  • Page 34: Life Of Wire Line

    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.
  • Page 35 HYDRAULICS - 8005H Counterbalance Valve Adjustment Notice: With PTO disengaged and boom properly In an EMERGENCY situation when it supported, remove O-ring plug (item 17) becomes necessary to lower the boom shown on Boom-Up illustration. Install a without flow present, the CB valve adjust- pressure gauge (0-2500 psi) into the port.
  • Page 36 HYDRAULICS - 8005H Vented Relief Valve Setting Proportional Relief Valve Setting The crane must receive 8 to 9 Gallons Per Minute (GPM) and 2000 psi. To assure The crane must receive 8 to 9 Gallons Per proper flow, install an in-line flow meter Minute (GPM) and 2000 PSI.
  • Page 37 High pressure oil can be injected through the skin causing severe injury, or death. The hydraulic system of the 8005H power version is electrically operated and requires a minimum of 12V for satisfactory performance. The hydraulic pump is bi-rotational with a pressure relief setting of 2000 psi (Ref.).
  • Page 38 Make sure pressure relief valve is correctly set. CAUTION The Auto Crane 8005H series cranes are manufactured with a standard overload protection system to prevent structural damage to the crane. When the crane load rating is exceeded, main boom down, extend out, and hoist up will not function.

  • Page 39: Lubrication & Maintenance Schedule

    LUBRICATION & MAINTENANCE SCHEDULE 8005H CRANE WEEKLY 3 MOS 6 MOS YEAR NOTES SERVICE PERFORMED LOAD HOOK INSPECT HOOK & LATCH FOR DEFORMATION, CRACKS, & CORROSION CABLE DRUM MAKE SURE CABLE IS WOUND EVENLY ON DRUM CHECK FOR FLATTENING, HOIST CABLE KINKS, &...
  • Page 40 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.
  • Page 41 LUBRICATION MAINTENANCE AW-015 RESERVOIR 1. SHEAVE ROLLER BEARINGS: 6. ROTATION ACTUATOR: SEALED TYPE, NO LUBE REQUIRED. MAINTAIN OIL LEVEL OF 1 1/2 PINTS OF EP GEAR LUBE, SAE 140. 2. BOOM PADS: REPLACE EVERY SIX MONTHS. IF REPLACED, GREASE UPON INSTALLATION WITH CHASSIS LUBRICANT.
  • Page 42 ROTATION BEARING MAINTENANCE AW-172 8, ETC. ROTATION STOP TOP MOUNTING BOLTS & WASHERS GREASE ZERK ROTATION TORQUE SEQUENCE BEARING ILLUSTRATION BASE BOTTOM MOUNTING BOLTS & WASHERS LUBRICATION OF ROTATION BEARING INSTALLATION OF ROTATION BEARING RACE 1. LUBRICATE BEARING RACE AT THE GREASE ZERK 1.
  • Page 43 PEDESTAL ASSEMBLY - 8005H NON REMOVABLE PENDANT P/N: 480000-002 Aw480001 3/2000 4-1.0.0...
  • Page 44 PEDESTAL ASSEMBLY - 8005H NON REMOVABLE PENDANT P/N: 480000-002 ITEM DESCRIPTION 480075-100 ACTUATOR HOIST 480050 PEDESTAL WELDMENT ASSEMBLY 480040 BASE PLATE ASSEMBLY 480023-002 BEARING ROTATION 480313 MANIFOLD BLOCK 480160 COVER VALVE 480028 GEAR BOX ROTATION 360162 RING ECCENTRIC 480027 MOTOR HYDRAULIC (ROTATION)
  • Page 45 PEDESTAL ASSEMBLY - 8005H NON REMOVABLE PENDANT P/N: 480000-002 ITEM DESCRIPTION 021500 WASHER SP LK 1/2 010201 SCREW HX HD 1/2 NC X 1 1/2 012198 SCREW HX HD 5/8 NC X 1 3/4 GR8 023902 WASHER FL 5/8 HARDENED...
  • Page 46 PEDESTAL ASSEMBLY - 8005H REMOVABLE PENDANT P/N: 480001-100 62 32 Aw480001-100 3/2000 4-2.0.0...
  • Page 47 PEDESTAL ASSEMBLY - 8005H REMOVABLE PENDANT P/N: 480001-100 ITEM DESCRIPTION 4800075-100 ACTUATOR HOIST 480050 PEDESTAL WELDMENT ASSEMBLY 480040 BASE PLATE ASSEMBLY 480023-002 BEARING ROTATION 480313 MANIFOLD BLOCK 480160 COVER VALVE 480028 GEAR BOX ROTATION 360162 RING ECCENTRIC 480027 MOTOR HYDRAULIC (ROTATION)
  • Page 48 PEDESTAL ASSEMBLY - 8005H REMOVABLE PENDANT P/N: 480001-100 ITEM DESCRIPTION 021500 WASHER SP LK 1/2 010201 SCREW HX HD 1/2 NC X 1 1/2 012198 SCREW HX HD 5/8 NC X 1 3/4 GR8 023902 WASHER FL 5/8 HARDENED 007402...

  • Page 49: Pedestal Assembly

    PEDESTAL ASSEMBLY - 8005H PROPORTIONAL PENDANT P/N: 480570 62 32 70 71 72 73 Aw480571 3/2000 4-3.0.0...
  • Page 50 PEDESTAL ASSEMBLY - 8005H PROPORTIONAL PENDANT P/N: 480570 ITEM DESCRIPTION 480075-100 ACTUATOR HOIST 480050 PEDESTAL WELDMENT ASSEMBLY 480040 BASE PLATE ASSEMBLY 480023-002 BEARING ROTATION 480313 MANIFOLD BLOCK 480160 COVER VALVE 480028 GEAR BOX ROTATION 360162 RING ECCENTRIC 480027 MOTOR HYDRAULIC (ROTATION)
  • Page 51 PEDESTAL ASSEMBLY - 8005H PROPORTIONAL PENDANT P/N: 480570 ITEM DESCRIPTION 021500 WASHER SP LK 1/2 010201 SCREW HX HD 1/2 NC X 1 1/2 012198 SCREW HX HD 5/8 NC X 1 3/4 GR8 023902 WASHER FL 5/8 HARDENED 007402...
  • Page 52 PEDESTAL ASSEMBLY - 8005H PROPORTIONAL PENDANT P/N: 480570 ITEM DESCRIPTION 680037 PENDANT FOUR FUNCTION BAYONET 680038 PENDANT FOUR FUNCTION BAYONET- 680039 PENDANT FOUR FUNCTION BAYONET 680040 PENDANT FOUR FUNCTION BAYONET Aw480571 3/2000 4-3.3.0...
  • Page 53 PEDESTAL ASSEMBLY - 8005H IN COMPARTMENT (IC) PENDANT P/N: 480570-110 70 71 72 73 Aw480578 3/2000 4-4.0.0...
  • Page 54 PEDESTAL ASSEMBLY - 8005H IN COMPARTMENT (IC) PENDANT P/N: 480570-110 ITEM DESCRIPTION 480075-100 ACTUATOR HOIST 480050 PEDESTAL WELDMENT ASSEMBLY 480040 BASE PLATE ASSEMBLY 480023-002 BEARING ROTATION 480313 MANIFOLD BLOCK 480160 COVER VALVE 480028 GEAR BOX ROTATION 360162 RING ECCENTRIC 480027...
  • Page 55 PEDESTAL ASSEMBLY - 8005H IN COMPARTMENT (IC) PENDANT P/N: 480570-110 ITEM DESCRIPTION 021500 WASHER SP LK 1/2 010201 SCREW HX HD 1/2 NC X 1 1/2 012198 SCREW HX HD 5/8 NC X 1 3/4 GR8 023902 WASHER FL 5/8 HARDENED...
  • Page 56 PEDESTAL ASSEMBLY - 8005H IN COMPARTMENT (IC) PENDANT P/N: 480570-110 ITEM DESCRIPTION 680037 PENDANT FOUR FUNCTION BAYONET 680038 PENDANT FOUR FUNCTION BAYONET- 680039 PENDANT FOUR FUNCTION BAYONET 680040 PENDANT FOUR FUNCTION BAYONET Aw480578 3/2000...
  • Page 57 RELAY BOX & LOAD SENSOR LIMIT SWITCH ASSY - 8005H NOTE: SEE CRANE WIRING DIAGRAM FOR ELECTRICAL CONNECTIONS LOAD SENSOR LIMIT SWITCH ASSY INSTALLS UNDER BOLT THAT FASTENS WINCH ASSY TO PEDESTAL ASSY SEE VIEW "A-A" RELAY BOX (ITEM 2)

  • Page 58: Boom Assembly

    BOOM ASSEMBLY - 8005H P/N: 480585 28 34 30 34 Aw480585 3/2000 4-6.0.0...
  • Page 59 BOOM ASSEMBLY - 8005H P/N: 480585 ITEM DESCRIPTION 480080 BOOM LOWER 480100 BOOM POWER 480310 BOOM MANUAL 366198 SHEAVE ASSEMBLY (BEARING ONLY - 366197) 360124 PIN HITCH 360125 PIN LOCK 014304 SCREW HX HD 3/4 NF X 6 018600 NUT LK 3/4 NF...
  • Page 60 BOOM ASSEMBLY - 8005H P/N: 480585 ITEM DESCRIPTION 480015 CYLINDER EXTENSION (COMPLETE) 480015-001 CASE ASSEMBLY 480015-002 SHAFT ASSEMBLY 480015-003 HEAD GLAND 480015-004 PISTON 480012 SEAL KIT 009100 SCREW HX HD 3/8 NF X 1 1/2 021100 WASHER SP LK 3/8...

  • Page 61: Automatic Safety Brake

    AUTOMATIC SAFETY BRAKE ASSEMBLY (OIL COOLED) HOIST ITEM DESCRIPTION 360367 FLAT SPRING 360331 CAM PLATE 360450 HOUSING COVER 360336 BRAKE HOUSING 360339 BRAKE HUB 360342 RETAINER PLATE 360345 BRAKE BALL 360453 CAPSCREW 1/4 NC x 1 360368 COIL SPRING 360456 CAPSCREW 3/8 NC x 1 1/2 360371 THREAD SEAL...
  • Page 62 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.

  • Page 63: Rotation Gear Box

    ROTATION GEAR BOX P/N: 480028 Aw480028 3/2000 4-8.0.0...
  • Page 64 ROTATION GEAR BOX P/N: 480028 ITEM DESCRIPTION 480240 ADAPTER 480241 BUSHING 480242 CAP BEARING 480243 COVER 480244 GEAR R.H. 480237 HOUSING GEAR 480246 480247 SHAFT OUTPUT 480248 WASHER THRUST 480249 WORM R.H. 480251 BEARING BALL 480252 BEARING NEEDLE 480253 BEARING NEEDLE 480254 BEARING THRUST 480255...
  • Page 65 2-BLOCK ASSEMBLY P/N: 480311-001 BACK-SIDE SEE 2-BLOCK ASSY DETAIL 8005H CORD REEL & 2-BLOCK ASSY WHITE BLACK REFERENCE-SWITCH WIRING SWITCH ASSY DETAIL SEE SWITCH ASSY DETAIL Aw480311-001 3/2000 4-9.0.0...
  • Page 66 2-BLOCK ASSEMBLY P/N: 480311-001 ITEM DESCRIPTION 366116-001 -BAIL 2-BLOCK CROWN BRACKET 366973-001 -CORD REEL ASSEMBLY 366196 -2- BLOCK ARM 016100 -NUT 1/4 NF 016200 -NUT LK 1/4 NF 002608 -SCREW HX HD SELF TAPPING 1/4 NC X 3/4 000115 -CLIP #15 007803 -SCREW HX HD 5/16 NC X 3 1/2 016801...

  • Page 67: Hoist Actuator

    HOIST ACTUATOR P/N 480075 AW480075 10/98 4-10.0.0...
  • Page 68 HOIST ACTUATOR P/N 480075 ITEM DESCRIPTION 360450 WORM BRAKE COVER 360359 GASKET 360368 SPRING 360367 FLAT SPRING 360342 RETAINER PLATE 360364 THRUST PLATE 360331 CAM PLATE 360345 BRAKE BALL 360339 BRAKE HUB 360336 BRAKE HOUSING 360358 GASKET 360346 BEARING 480078 OUTPUT SHAFT 480094 KEY 3/8 SQ...
  • Page 69 HOIST ACTUATOR P/N 480075 ITEM DESCRIPTION 360463 SOC HD CAPSCREW 1/4 NC x 7/8 360453 HEX HD w/ NYLOCK CAPSCREW 1/4 NC x 1 GR5 360456 HEX HD CAPSCREW 1/8 NC x 1 1/2 GR5 360465 THREAD SEAL 360353 HEX JAM NUT 3/8 NC 360371 THREAD SEAL 360455...
  • Page 70 IN-COMPARTMENT (IC) PENDANT INSTALLATION AW-178 AW178 12/98 4-11.0.0...
  • Page 71 IN-COMPARTMENT (IC) PENDANT INSTALLATION AW-178 ITEM DESCRIPTION 480490 22 STATION TERMINAL BLOCK DECAL 480491-080 22 STATION / 19 PIN SOCKET HARNESS BAYONET 480626 PENDANT BRACKET 480493 22 STATION TERMINAL BLOCK COVER 000404 ROUND HEAD SCREW #6-32 NC x 5/8 015400 HEX NUT #6-32 NC 019600 SPLIT LOCK WASHER #6...
  • Page 72 FM REMOTE INSTALLATION AW-179 AW179 3/98 4-12.0.0...
  • Page 73 FM REMOTE INSTALLATION AW-179 ITEM DESCRIPTION 480492 CRANE PIGTAIL HARNESS 480490 22 STATION TERMINAL BLOCK DECAL 480491-080 22 STATION / 19 PIN SOCKET HARNESS (BAYONET) 480626 PENDANT BRACKET 480493 22 STATION TERMINAL BLOCK COVER 000404 RD HD #6-32 NC x 5/8 015400 HEX NUT #6-32 NC 019600...
  • Page 74 ELECTRICAL ASSEMBLY P/N:480095 Aw480095 3/2000 5-1.0.0...
  • Page 75 ELECTRICAL ASSEMBLY P/N:480095 ITEM DESCRIPTION 646900 SWITCH 480379 LOAD SENSOR ASSEMBLY 480380 LOAD SENSOR LIMIT SWITCH ASSEMBLY 366989 RELAY BOX ASSEMBLY 480099 CONDUCTOR ASSEMBLY (POWER EXT) 480384 CONDUCTOR ASSEMBLY 480385 CONDUCTOR ASSEMBLY 480697 CONDUCTOR CABLE (REF) 340638 CONDUCTOR POWER 366030 CONDUCTOR 366995 SHRINK TBG 1/4 X 3...
  • Page 76 ELECTRICAL ASSEMBLY W/4 & 8 FUNCTION PROPORTIONAL (-200,-400) Aw-117 3/2000 5-3.0.0...
  • Page 77 ELECTRICAL ASSEMBLY W/4 & 8 FUNCTION PROPORTIONAL (-200,-400) ITEM DESCRIPTION 646900 SWITCH 480379 LOAD SENSOR ASSEMBLY 480380 LOAD SENSOR LIMIT SWITCH ASSEMBLY 366999 RELAY BOX ASSEMBLY 680044 RECEPTACLE ASSEMBLY BAYONET 366097 CAP PENDANT RECEPTACLE BAYONET 000404 SCREW RD HD #6-32 X 5/8 019600 WASHER SP LK #6 015400...
  • Page 78 ELECTRICAL ASSEMBLY W/4 & 8 FUNCTION LESS/PROPORTIONAL (-100,-300) Aw-120 3/2000 5-4.0.0...
  • Page 79 ELECTRICAL ASSEMBLY W/4 & 8 FUNCTION LESS/PROPORTIONAL (-100,-300) ITEM DESCRIPTION 646900 SWITCH 480379 LOAD SENSOR ASSEMBLY 480380 LOAD SENSOR LIMIT SWITCH ASSEMBLY 366999 RELAY BOX ASSEMBLY 680044 RECEPTACLE ASSEMBLY BAYONET 366097 CAP PENDANT RECEPTACLE BAYONET 000404 SCREW RD HD #6-32 X 5/8 019600 WASHER SP LK #6 015400...
  • Page 80 ELECTRICAL ASSEMBLY W/4 & 8 FUNCTION PROP IC (-210,-410,-411,-412) Aw-144 3/2000 5-5.0.0...
  • Page 81 ELECTRICAL ASSEMBLY W/4 & 8 FUNCTION PROP IC (-210,-410,-411,-412) ITEM DESCRIPTION 480386 HARNESS CRANE PIGTAIL 646900 SWITCH 480379 LOAD SENSOR ASSEMBLY 480380 LOAD SENSOR LIMIT SWITCH ASSEMBLY 366999 RELAY BOX ASSEMBLY 480626 BRACKET PENDANT RECEPTACLE 366097 CAP PENDANT RECEPTACLE BAYONET 000404 SCREW RD HD #6-32 X 5/8 019600...
  • Page 82 ELECTRICAL ASSEMBLY W/4 & 8 FUNCTION LESS/PROP IC (-110,-310) Aw-147 3/2000 5-6.0.0...
  • Page 83 ELECTRICAL ASSEMBLY W/4 & 8 FUNCTION LESS/PROP IC (-110,-310) ITEM DESCRIPTION 480386 HARNESS CRANE PIGTAIL 646900 SWITCH 480379 LOAD SENSOR ASSEMBLY 480380 LOAD SENSOR LIMIT SWITCH ASSEMBLY 366999 RELAY BOX ASSEMBLY 480626 BRACKET PENDANT RECEPTACLE 366097 CAP PENDANT RECEPTACLE BAYONET 000404 SCREW RD HD #6-32 X 5/8 019600...
  • Page 84 ELECTRICAL ASSEMBLY W/FM REMOTE PROPORTIONAL (-500,-520) Aw-150 3/2000 5-7.0.0...
  • Page 85 ELECTRICAL ASSEMBLY W/FM REMOTE PROPORTIONAL (-500,-520) ITEM DESCRIPTION 480386 HARNESS CRANE PIGTAIL 646900 SWITCH 480379 LOAD SENSOR ASSEMBLY 480380 LOAD SENSOR LIMIT SWITCH ASSEMBLY 366999 RELAY BOX ASSEMBLY 480626 BRACKET PENDANT RECEPTACLE 366097 CAP PENDANT RECEPTACLE BAYONET 000404 SCREW RD HD #6-32 X 5/8 019600 WASHER SP LK #6 015400...
  • Page 86 ELECTRICAL ASSEMBLY (-510,-530) W/8 FUNCTION PROP PENDANT & 12 FUNCTION FM REMOTE Aw-176 3/2000 5-8.0.0...
  • Page 87 ELECTRICAL ASSEMBLY (-510,-530) W/8 FUNCTION PROP PENDANT & 12 FUNCTION FM REMOTE ITEM DESCRIPTION 480386 HARNESS CRANE PIGTAIL 646900 SWITCH 480379 LOAD SENSOR ASSEMBLY 480380 LOAD SENSOR LIMIT SWITCH ASSEMBLY 366999 RELAY BOX ASSEMBLY 480626 BRACKET PENDANT RECEPTACLE 366097 CAP PENDANT RECEPTACLE BAYONET 000404 SCREW RD HD #6-32 X 5/8 019600...
  • Page 88 PENDANT RECEPTACLE ASSEMBLY AW-680044 ITEM DESCRIPTION 366095 19 PIN RECEPTACLE 480515 CABLE CLAMP 480594 19 PIN CONDUCTOR CABLE 480385 CONDUCTOR ASSEMBLY 001105 BUTT CONNECTOR TERMINAL NON-INSS 10-12 GA 002012 RING TERMINAL #6 / 18-22 GA 4" 490243 HEAT SHRINK TUBING 5-9.0.0 Aw680044 3/2000...
  • Page 89 PENDANT ASSEMBLY 4 FUNCTION REMOVABLE W/19 PIN BAYONET P/N 680083 AW680083 7/98 5-10.0.0...
  • Page 90 PENDANT ASSEMBLY 4 FUNCTION REMOVABLE W/19 PIN BAYONET P/N 680083 ITEM DESCRIPTION 631301 PENDANT HOUSING 631700 BOTTOM COVER 634200 TOGGLE SWITCH 640300 BOOT-TOGGLE SWITCH 005001 ST SLT PAN HD SCREW #8 x 3/4 005101 ST SLT PAN HD SCREW #8 x 1 1/4 633801 CABLE ADAPTER 30’...
  • Page 91 STANDARD 4 FUNCTION PENDANT ASSEMBLY P/N 680037 AW680037 3/98 5-12.0.0...
  • Page 92 STANDARD 4 FUNCTION PENDANT ASSEMBLY P/N 680037 ITEM DESCRIPTION 480501 PENDANT HOUSING 480513 COVER PLATE DECAL *REF 640300 TOGGLE SWITCH BOOT 480567 HUBBELL CONNECTOR CORD GRIP 002607 SCREW #10-24 NC x 3/4 015801 HEX LOCK NUT #10-24 NC 634200 TOGGLE DPDT SWITCH 480504 BACK PLATE 480516...
  • Page 93 PROPORTIONAL 4 FUNCTION PENDANT ASSEMBLY P/N 680038 AW680038 3/98 5-13.0.0...
  • Page 94 PROPORTIONAL 4 FUNCTION PENDANT ASSEMBLY P/N 680038 ITEM DESCRIPTION 480501 PENDANT HOUSING 480513 COVER PLATE DECAL *REF 640300 TOGGLE SWITCH BOOT 480567 HUBBELL CONNECTOR CORD GRIP 002607 SCREW #10-24 NC x 3/4 015801 HEX LOCK NUT #10-24 NC 480507 POTENTIOMETER ASSEMBLY 480506 TRIGGER 480517...
  • Page 95 STANDARD 8 FUNCTION PENDANT ASSEMBLY P/N 680039 AW680039 3/98 5-14.0.0...
  • Page 96 STANDARD 8 FUNCTION PENDANT ASSEMBLY P/N 680039 ITEM DESCRIPTION 480501 PENDANT HOUSING 480513 COVER PLATE DECAL *REF 640300 TOGGLE SWITCH BOOT 480567 HUBBELL CONNECTOR CORD GRIP 002607 SCREW #10-24 NC x 3/4 015801 HEX LOCK NUT #10-24 NC 634200 TOGGLE DPDT SWITCH 480504 BACK PLATE 480516...
  • Page 97 PROPORTIONAL 8 FUNCTION PENDANT ASSEMBLY P/N 680040 NOTES: 5-15.0.0 AW680040 8/98...
  • Page 98 PROPORTIONAL 8 FUNCTION PENDANT ASSEMBLY P/N 680040 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...
  • Page 99 PENDANT CABLE ASSEMBLY P/N 680041 ITEM DESCRIPTION 366098 19 PIN BAYONET PLUG 480515 CABLE CLAMP 480594 19 PIN CONDUCTOR CABLE 000101 RING TERMINAL #6 / 14-16 GA 002012 RING TERMINAL #6 / 18-22 GA 6" 490243 HEAT SHRINK TUBING x 6" AW680041 3/98 5-16.0.0...
  • Page 100 PENDANT CABLE ASSEMBLY P/N 680113 ITEM DESCRIPTION 366098 19 PIN BAYONET PLUG 480515 CABLE CLAMP 480594 19 PIN CONDUCTOR CABLE 000101 RING TERMINAL #6 / 14-16 GA 480510 RING TERMINAL #6 / 14-16 GA 002012 FEMALE BULLET CONNECTOR 6" 490243 HEAT SHRINK TUBING x 6"...
  • Page 101 PENDANT CABLE ASSEMBLY P/N 680042 ITEM DESCRIPTION 366098 19 PIN BAYONET PLUG 480515 CABLE CLAMP 480594 19 PIN CONDUCTOR CABLE 000101 RING TERMINAL #6 / 14-16 GA 002012 RING TERMINAL #6 / 18-22 GA 6" 490243 HEAT SHRINK TUBING x 6" AW680042 3/98 5-18.0.0...
  • Page 102 PENDANT CABLE ASSEMBLY P/N 680043 ITEM DESCRIPTION 366098 19 PIN BAYONET PLUG 480515 CABLE CLAMP 480594 19 PIN CONDUCTOR CABLE 000101 RING TERMINAL #6 / 14-16 GA 480510 FEMALE BULLET CONNECTOR 002012 RING TERMINAL #6 / 18-22 GA 6" 490243 HEAT SHRINK TUBING x 6"...
  • Page 103 CARTRIDGE VALVE P/N 480184 1.75 Ø 3/4" 1" HEX 5.595 REF 7/8-14 NOTES: FOR SEAL KIT, ORDER PART NO. 480184-002 FOR REPLACEMENT COIL, ORDER PART NO. 480184-003 5-20.0.0 Aw480184 3/2000...
  • Page 104 HYDRAULIC ASSEMBLY P/N: 480573 ROTATION HOIST (2nd SPOOL FROM TOP) (TOP SPOOL) SEE DETAIL "A" BOOM-UP (BOTTOM SPOOL) PRESSURE / RETURN EXTENSION (3rd SPOOL FROM TOP) 36 8 DETAIL "A" VALVE BANK Aw480573 3/2000 6-1.0.0...
  • Page 105 HYDRAULIC ASSEMBLY P/N: 480573 ITEM DESCRIPTION 480377 CYLINDER BOOM 480181 VALVE BANK ASSEMBLY 008701 SCREW HX HD 3/8 NC X 1 017100 NUT 3/8 NC 021100 WASHER SP LK 3/8 480024 MOUNT PENDANT RETAINER 480379 LOAD SENSOR ASSEMBLY 020200 WASHER SP LK 1/4 480211 TUBE ASSEMBLY 480200...
  • Page 106 HYDRAULIC SCHEMATIC P/N: 480653 6-3.0.0 Aw480653 3/2000...
  • Page 107 HYDRAULIC SCHEMATIC PROPORTIONAL 6-3.1.0 Aw-125 3/2000...
  • Page 108 VENTED RELIEF VALVE ASSEMBLY W/SOLENOID NOTE: RELIEF VALVE MUST BE LOCATED BETWEEN PUMP AND ANY OTHER VALVES AND ACCESSORIES. RETURN TO RESERVOIR PRESSURE TO CRANE FROM PUMP BLUE WIRE = POWER + 12VDC BROWN WIRE = NEG. (GROUND) ITEM DESCRIPTION 480135 VALVE VENTED RELIEF 2000 PSI 480135-001...
  • Page 109 HYDRAULIC MANIFOLD ASSEMBLY PROPORTIONAL ITEM DESCRIPTION 480521 MANIFOLD BLOCK 360157-002 VALVE RELIEF 480522 AMPLIFIER PROP (IN SHIP KIT) 480520 VALVE SOLENOID 000211 PLUG -4 SAE O-RING 480529 DIN CONNECTOR ASSEMBLY 6-5.0.0 Aw480525 3/2000...
  • Page 110 QUANTITY Both sides of crown plate PLACEMENT PART NO.: 040519 QUANTITY DECAL: SCISSORS POINT Both sides of lift cylinder PLACEMENT FUNCTION: To inform the operator of possible danger at scissors point on crane. 8-1.0.0 8005H Decal 3/2000...
  • Page 111 PART NO.: 040580 DECAL: OPERATOR TRAINING FUNCTION: To inform the operator of the need to receive proper training before using the crane QUANTITY Left Sideplate PLACEMENT 8-1.1.0 8005H Decal 3/2000...
  • Page 112 PART NO.: 040632 DECAL: TAMPERING WITH OVERLOAD DEVICE FUNCTION: To inform the operator that tampering with the overload device may cause a unit failure or possible personnel injury. QUANTITY Right side of lift cylinder PLACEMENT 8-1.2.0 8005H Decal 3/2000...
  • Page 113 SAFETY DECAL SECTION PART NO.: 040634 DECAL: HYDRAULIC REQUIREMENTS FUNCTION: To inform the operator of the hydraulic requirements for proper crane operation. QUANTITY On the hydraulic reservoir PLACEMENT 8-1.3.0 8005H Decal 3/2000...

  • Page 114: Decal Layout

    DECAL LAYOUT P/N: 480021 (BOTH SIDES) SERIAL NUMBER IS STAMPED INTO TOP OF SIDE PLATE RESERVOIR Aw 480021 3/2000 8-3.0.0...
  • Page 115 DECAL LAYOUT P/N: 480021 ITEM DESCRIPTION 480034 DECAL 8005H 480010 LOAD CHART 480038 DECAL ANGLE INDICATOR RIGHT 480039 DECAL ANGLE INDICATOR LEFT 8 FT 040620 STRIPING 040624 DECAL AUTO CRANE 040529 DECAL DANGER ELECTRIC 040517 DECAL STAY CLEAR OF BOOM 040580 DECAL MUST NOT...

  • Page 116: Traveling Block Assembly

    TRAVELING BLOCK ASSEMBLY P/N: 360603 Aw360603 3/2000 8-4.0.0...
  • Page 117 TRAVELING BLOCK ASSEMBLY P/N: 360603 ITEM DESCRIPTION 480130 SHEAVE ASSEMBLY 480026 HOOK SWIVEL 360601 BLOCK SIDE PLATE 240237 SPACER BUSHING 1 O.D. 006801 SCREW HX HD 1/2 NF X 4 017800 NUT LK 1/2 NF 360124 PIN HITCH 360605 PIN BLOCK Aw360603 3/2000 8-4.1.0...
  • Page 118 TRAVELING BLOCK ASSEMBLY (SHORT) P/N: 480360 Aw480360 3/2000 8-5.0.0...
  • Page 119 TRAVELING BLOCK ASSEMBLY (SHORT) P/N: 480360 ITEM DESCRIPTION 480362 SIDE PLATE TRAVELING BLOCK 480130 SHEAVE ASSEMBLY 480365 TACKEL LOWER 480366 HOOK SWIVEL 6 TON 480372 BOLT SHEAVE W/ZERK FITTING 017800 NUT LK 1/2 NF 480367 PIN BLOCK 480368 PIN SWIVEL HOOK 360124 PIN HITCH HAIR PIN 040518...

  • Page 120: Load Chart

    LOAD CHART 8005H P/N: 480010 9-9.9.9 Aw480010 3/2000...

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