Auto Crane 2003 Series Owner's Manual
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Auto Crane 2003 Series Owner's Manual

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OWNERS MANUAL
2003 SERIES
REVISION 2/2000
PART NO. 999951
SERIAL NO. __________________________
PO BOX 580697, TULSA, OK 74158-0697
4707 N. MINGO ROAD, TULSA, OK 74117-5904
PHONE (918) 836-0463
FAX (918) 834-5979
http://www.autocrane.com

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  • Page 1 OWNERS MANUAL 2003 SERIES REVISION 2/2000 PART NO. 999951 SERIAL NO. __________________________ PO BOX 580697, TULSA, OK 74158-0697 4707 N. MINGO ROAD, TULSA, OK 74117-5904 PHONE (918) 836-0463 FAX (918) 834-5979 http://www.autocrane.com...
  • 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

    2003 SERIES - OWNER'S MANUAL TABLE OF CONTENTS PAGE INTRODUCTION ..........

  • Page 5: Introduction

    Auto Crane has incorporated several safety features bring a local distributor, a regional sales manager, or a in the 2003 series for your protection. The material and factory serviceman into the solution of an equipment electrical systems were designed to minimize weight problem.
  • Page 6 GENERAL SPECIFICATIONS 2003 SERIES DIMENSIONS CABLE Width: 19.0 in (.48 m) 50 ft (15.2 m) of 1/4 in diameter aircraft quality cable is standard. This cable has a single line Height: 21.0 in (.53 m) breaking strength of 7,000 lbs (3,175 kg).

  • Page 7: 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 8: 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 9: 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 10 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 11 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 12: 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 13 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 14 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 15 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 16 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 17 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.
  • Page 18 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"...

  • Page 19: Safety Decal Section

    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 upper boom PLACEMENT (see page 5-3.0.0, Item 1) FIG.
  • Page 20 SAFETY DECAL SECTION PART NO.: 040529 QUANTITY DECAL: ELECTROCUTION HAZARD Lower boom PLACEMENT FUNCTION: To inform the operator of the (see page 5-3.0.0, Item 10) hazard involved with contacting electrical power lines with crane boom. FIG. SD-4. PART NO.: 040579 DECAL: OPERATION INSTRUCTIONS FUNCTION:...
  • Page 21 DECAL DRAWING 9' BOOM - 2003 SERIES ITEM DESCRIPTION 040517 STAY CLEAR DECAL 600006 LOAD CHART 9' BOOM DECAL (see page 13-1.0.0) 330967 2003 DECAL 320318 ANGLE IND DECAL 040579 WORK RULES DECAL 040518 STAY CLEAR DECAL 600047 AUTO CRANE DECAL...
  • Page 22 DECAL DRAWING 14' BOOM - 2003 SERIES ITEM DESCRIPTION 040517 STAY CLEAR DECAL 600084 LOAD CHART 9' BOOM DECAL (see page 13-2.0.0) 330967 2003 DECAL 320318 ANGLE IND DECAL 040579 WORK RULES DECAL 040518 STAY CLEAR DECAL 600047 AUTO CRANE DECAL...
  • Page 23 9' BOOM GENERAL DIMENSIONS P/N 600000-009 - 2003 SERIES 6-1.0.0 AW631 3/98...
  • Page 24 14' BOOM GENERAL DIMENSIONS P/N 600000-014 - 2003 SERIES 6-2.0.0 AW632 3/98...
  • Page 25 ASSEMBLY & INSTALLATION INSTRUCTIONS 2003 SERIES NOTE: For mounting bolt hole pattern - see page 6-1.0.0. INSTALLATION - BATTERY CABLE 1. Drill 13/16" hole in floor. Install bushing, which is connected to cable, so it fits hole snug. 2. Run cable to positive battery terminal. Connect black cable to negative battery terminal or suitable chassis ground point.

  • Page 26: Operating Instructions

    OPERATING INSTRUCTIONS To Extend: Turn Brake Handle counter clock-wise to release brake and turn boom to a convenient location for extending boom. Tighten Brake by turning Brake Handle clock-wise. Use pendant control to let out more cable for boom extension. Remove Boom Extension Pin (2) in Lower Boom (3).
  • Page 27 LUBRICATION & MAINTENANCE SCHEDULE 2003 CRANE WEEKLY MONTHLY DAILY 6 MONTHS 1 YEAR SERVICE NOTES PERFORMED LOAD HOOK INSPECT HOOK & LATCH FOR DEFOR- MATION, CRACKS, & CORROSION MAKE SURE CABLE IS WOUND EVENLY CABLE DRUM ON DRUM CHECK FOR FLATTENING, KINKS, & HOIST CABLE BROKEN STRANDS, SEE MANUAL MOUNTING BOLTS...
  • Page 28 { Once a bolt has been torqued to its rated capacity and then removed; the bolt should be replaced with a new one. { Auto Crane Company recommends that this crane be serviced per “Crane Inspection Log” P/N 999978. These logs should be filled in at the intervals noted and kept as a permanent record. Additional copies are available from your local distributor.

  • Page 29: Life Of Wire Line / Wire Line Lubrication

    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 30 2003 SERIES CRANE 9’ BOOM P/N:600000-009 10-1.0.0 AW600000-009 2/2000...
  • Page 31 2003 SERIES CRANE 9’ BOOM P/N:600000-009 10-1.0.1 AW600000-009 2/2000...
  • Page 32 2003 SERIES CRANE 9’ BOOM P/N 600000-009 P/N 370000 ITEM QUANTITY PART NUMBER DESCRIPTION 600007 BASE WELDMENT 600027 HOUSING WELDMENT 600021 BOOM LOWER WELDMENT 600023 BOOM UPPER WELDMENT 330192 BEARING BALL 3.343 ID 600013 MEMBER TWECO BRACKET UPPER 600037 CABLE 1/4 X 50 FT W/HOOK...
  • Page 33 2003 SERIES CRANE 9’ BOOM P/N 600000-009 P/N 370000 ITEM QUANTITY PART NUMBER DESCRIPTION 012200 SCREW HX HD 5/8-18 X 1 3/4 018100 HALF NUT 5/8-18 320442 GUARD CABLE RETAINER 600035 ACTUATOR ASSEMBLY 340523 KEY SQ 1/4 X 1/4 X 2 3/4...
  • Page 34 2003 SERIES CRANE 14’ BOOM P/N:600000-014 10-1.3.0 AW600000-014 2/2000...
  • Page 35 2003 SERIES CRANE 14’ BOOM P/N:600000-014 10-1.3.1 AW600000-014 2/2000...
  • Page 36 2003 SERIES CRANE 14’ BOOM P/N 600000-014 P/N 370000 ITEM QUANTITY PART NUMBER DESCRIPTION 600007 BASE WELDMENT 600092 HOUSING WELDMENT 14’ BOOM 600080 BOOM LOWER WELDMENT 600082 BOOM UPPER WELDMENT 330192 BEARING BALL 3.343 ID 600013 MEMBER TWECO BRACKET UPPER...
  • Page 37 2003 SERIES CRANE 14’ BOOM P/N 600000-014 P/N 370000 ITEM QUANTITY PART NUMBER DESCRIPTION 012200 SCREW HX HD 5/8-18 X 1 3/4 018100 HALF NUT 5/8-18 320442 GUARD CABLE RETAINER 600035 ACTUATOR ASSEMBLY 340523 KEY SQ 1/4 X 1/4 X 2 3/4...
  • Page 38 2003 SERIES CRANE 9’ BOOM W/LOAD SENSOR P/N:600053 10-2.0.0 AW600053 2/2000...
  • Page 39 2003 SERIES CRANE 9’ BOOM W/LOAD SENSOR P/N:600053 10-2.0.1 AW600053 2/2000...
  • Page 40 2003 SERIES CRANE 9’ BOOM W/LOAD SENSOR P/N 600053 P/N 370000 ITEM QUANTITY PART NUMBER DESCRIPTION 600007 BASE WELDMENT 600027 HOUSING WELDMENT 600070 BOOM LOWER WELDMENT 600023 BOOM UPPER WELDMENT 330192 BEARING BALL 3.343 ID 600013 MEMBER TWECO BRACKET UPPER...
  • Page 41 2003 SERIES CRANE 9’ BOOM W/LOAD SENSOR P/N 600053 P/N 370000 ITEM QUANTITY PART NUMBER DESCRIPTION 012200 SCREW HX HD 5/8-18 X 1 3/4 018100 HALF NUT 5/8-18 320442 GUARD CABLE RETAINER 600035 ACTUATOR ASSEMBLY 340523 KEY SQ 1/4 X 1/4 X 2 3/4...
  • Page 42 2003 SERIES CRANE 14’ BOOM W/LOAD SENSOR P/N:600052 10-2.3.0 AW600052 2/2000...
  • Page 43 2003 SERIES CRANE 14’ BOOM W/LOAD SENSOR P/N:600052 10-2.3.1 AW600052 2/2000...
  • Page 44 2003 SERIES CRANE 14’ BOOM W/LOAD SENSOR P/N 600052 P/N 370000 ITEM QUANTITY PART NUMBER DESCRIPTION 600007 BASE WELDMENT 600092 HOUSING WELDMENT 600071 BOOM LOWER WELDMENT 600082 BOOM UPPER WELDMENT 330192 BEARING BALL 3.343 ID 600013 MEMBER TWECO BRACKET UPPER...
  • Page 45 2003 SERIES CRANE 14’ BOOM W/LOAD SENSOR P/N 600052 P/N 370000 ITEM QUANTITY PART NUMBER DESCRIPTION 012200 SCREW HX HD 5/8-18 X 1 3/4 018100 HALF NUT 5/8-18 320442 GUARD CABLE RETAINER 600035 ACTUATOR ASSEMBLY 340523 KEY SQ 1/4 X 1/4 X 2 3/4...

  • Page 46: Hoist Actuator Assembly

    HOIST ACTUATOR ASSEMBLY 2003 SERIES P/N 600035 AW600035 2/2000 10-3.0.0...
  • Page 47 HOIST ACTUATOR ASSEMBLY 2003 SERIES P/N 600035 ITEM DESCRIPTION 360637 FLAT SPRING 360331 CAM PLATE 300041 GEAR HOUSING COVER 300042 SPUR GEAR HOUSING COVER 360450 BRAKE COVER 300043 IDLER GEAR 300044 SPUR GEAR 300045 WORM R.H. GEAR 300046 PINION GEAR...
  • Page 48 HOIST ACTUATOR ASSEMBLY 2003 SERIES P/N 600035 ITEM DESCRIPTION 021100 SPLIT LOCK WASHER 3/8 320314 90º ELBOW 3/8-18 NPT BOTH ENDS 300062 GASKET BEARING 300063 SPUR GEAR HOUSING GASKET 300064 GEAR HOUSING COVER GASKET 360359 BRAKE COVER GASKET 300065 WOODRUFF KEY...
  • Page 49 AUTOMATIC SAFETY BRAKE ASSEMBLY (OIL COOLED) HOIST 2003 SERIES 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.
  • Page 50 AUTOMATIC SAFETY BRAKE ASSEMBLY (OIL COOLED) HOIST 2003 SERIES 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...
  • Page 51 POWER CABLE ASSEMBLY 2003 SERIES P/N 600016 Included in Power Cable Assembly - P/N 600016. ITEM DESCRIPTION 669200 FEMALE TWECO CONNECTOR 600015 TWECO BRACKET 330258 TWECO POWER CONDUCTOR 002900 SCREW SOC HD 1/4 NC x 3/8 GR8 669300 MALE TWECO CONNECTOR 341219 CONDUCTOR 600V x 29"...

  • Page 52: Jack Leg Assembly

    JACK LEG ASSEMBLY 2003 SERIES Note: These jack legs all use the standard jack leg toggles & sleeves. SMALL JACK LEGS JACK LEG ASSY LEG w/ BASE LENGTH 700320 **200454 14" 700321 200255 15" 700322 200456 16" 700323 200457 17"...
  • Page 53 WIRING DIAGRAM 2003 SERIES ITEMS 3, AND 5-9 ARE INCLUDED IN ITEM 10. ITEM DESCRIPTION 330519 HOIST CONTROL PENDANT 330517 FEMALE SOCKET 600016 POWER CABLE ASSEMBLY (see page 10-6.0.0 622323 CONDUCTOR 6GA 600V BLACK x 26" 622327 CONDUCTOR 6GA 600V BLACK x 28"...
  • Page 54 WIRING DIAGRAM W/LOAD SENSOR 2003 SERIES ITEMS 3, AND 5-9 ARE INCLUDED IN ITEM 10. ITEM DESCRIPTION 330519 HOIST CONTROL PENDANT 330517 FEMALE SOCKET 600016 POWER CABLE ASSEMBLY (see page 10-6.0.0 622323 CONDUCTOR 6GA 600V BLACK x 26" 622327 CONDUCTOR 6GA 600V BLACK x 28"...
  • Page 55 TROUBLESHOOTING 2003 PROBLEM CAUSE/SOLUTION CAUSE: CRANE WILL NOT HOIST UP. Bad relay, crane not grounded properly, or power cable not connected to 12V power source. Bad switch in pendant, broken wire in pendant CRANE WILL NOT HOIST DOWN. connector, pendant not plugged together properly, wire on relay not in proper place or lead wires to motor not connected properly.
  • Page 56 TROUBLESHOOTING 2003 should let relay return to its normal position. Using HOW TO CHECK RELAY: your ohm meter or test light again, check the relay Our relays are normally closed across the bottom posts across posts (A & B). If relay is working correctly, you (C &...
  • Page 57 LOAD CHART FOR 9' BOOM 2003 SERIES - P/N 600006 HORIZONTAL REACH IN FEET CAPACITY IN POUNDS AW600006 2/98 13-1.0.0...
  • Page 58 LOAD CHART FOR 14' BOOM 2003 SERIES - P/N 600084 HORIZONTAL REACH IN FEET CAPACITY IN POUNDS AW600084 2/98 13-2.0.0...

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