5005EH Hard Wired 999955 0200

EFFECTIVE SERIAL NO.
OWNERS MANUAL
5005EH
REVISION 2/2000
PART NO. 999955
SERIAL NO. __________________________
PO BOX 580697, TULSA, OK 74158-0697

4707 N. MINGO ROAD, TULSA, OK 74117-5904
PHONE (918) 836-0463
SALES FAX (918) 438-6688 SERVICE FAX (918) 834-5979
http://www.autocrane.com
WARNINGS - READ THIS PAGE!
WARNING! Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of
a vehicle certify that the vehicle complies with all applicable federal regulations. Any
modifications performed on the vehicle prior to the final stage are also considered
intermediate stage manufacturing and must be certified as to compliance. The installer of
this crane and 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 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 OSHA
Truck Crane Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).
WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL

POWER LINES! Death or serious injury will result from boom, line, or load contacting
electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to
50,000 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 closed
before lifting a load! Proper attention and common sense applied to the use of the hoist hook and
various slings will prevent possible damage to material being hoisted and may prevent injury to
personnel.
WARNING! Failure to correctly plumb and wire crane can cause inadvertent operation and
damage to crane and/or personnel!
WARNING! Auto Crane Company remote controlled cranes are not designed or intended to
be 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 is
equipped with this type of device.
warning 9/98
5005EH SERIES - OWNER'S MANUAL
TABLE OF CONTENTS
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1.0.0
OPERATING PRACTICES & WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . 1-2.0.0
OPERATION OF UNIT / OUTRIGGERS . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.0.0
QUALIFICATIONS FOR OPERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2.1.0
INSPECTION, TESTING & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 1-3.1.0
SAFETY DECAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1.1.0
GENERAL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1.0.0
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1.0.0
OUTRIGGERS (STABILIZER ASSEMBLY) . . . . . . . . . . . . . . . . . . . . . . 7-3.0.0
LUBRICATION & MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . 8-1.0.0
LIFE OF WIRELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1.0.0
GENERAL ASSEMBLY (PEDESTAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1.0.0
BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2.0.0
2-BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4.0.0
HOIST ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5.0.0
AUTOMATIC SAFETY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6.1.0
SOLENOID ASSEMBLY for HOIST ACTUATOR . . . . . . . . . . . . . . . . . . 10-7.0.0
ROTATION GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8.0.0
COVER INSTALLATION for POWER UNIT . . . . . . . . . . . . . . . . . . . . . . 10-9.0.0
HYDRAULIC SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1.0.0
ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1.1.1
TRAVELING BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1.0.0
LOAD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1.0.0
LAST PAGE
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION
5005EH 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. warranty claim involves discrepant material or workmanship,
To assist you in obtaining the best service from your Auto Crane will take immediate corrective action. It is
crane and to avoid untimely crane and/or vehicle failure, this understandable that Auto Crane Company cannot assume
manual provides the following operating and service responsibility of liability when it is obvious that our products
instructions. It is specifically recommended that all have been abused, misused, overloaded or otherwise damaged
operating and service personnel consider this manual as by inexperienced persons trying to operate the equipment
mandatory material for reading and study before operating or without reading the manual.
servicing Auto Crane products. It is highly recommended Auto Crane will not assume responsibility or
that crane owners, equipment managers and supervisors also liability for any modifications or changes made to
read this manual. unit, or installation of component parts done without
Auto Crane has incorporated several safety features in authorization.
the 5005EH series cranes for your protection. The choice of Auto Crane maintains a strong distributor network and a
materials and the design of the electrical system minimizes knowledgeable Customer Service Department. In most cases,
weight and lengthens durability. The hydraulic components an equipment problem is solved via phone conversation with
meet or exceed a 3.5:1 safety factor. Holding valves prevent our customer service department. The customer service
the load from dropping if a hose should fail. The reservoir has department also has the ability to bring a local distributor, a
a 40m air filter in the filler cap. The pump has a 100 mesh regional sales manager, or a factory serviceman into the
strainer in the suction line. solution of an equipment problem. If, through no fault of Auto
For your convenience the overall dimensions of the Crane Company, it is necessary to send an experienced
5005EH series crane are in the General Dimension Section. factory serviceman on a field service call, the rates stated in
Maximum turning radius at both the hoist motor and the the Auto Crane Distributor's Flat Rate Manual will apply.
rotation motor are also on that drawing. Auto Crane Company's extensive Research and
Remember, the crane adds weight to the vehicle. Adding Development Program allow our customers to use the best
weight may change the driving and riding characteristics of equipment on the market. Our Engineering Staff and our
the vehicle unless the appropriate overload spring(s) are knowledgeable sales people, are always available to our
installed on the truck. The payload of the vehicle is reduced customers in solving crane and winch-type application
by the weight of the crane. The operator should exercise care problems. When in doubt, call the Auto Crane factory.
when loading the vehicle. Distributing the payload on the
vehicle evenly will greatly improve the driving and riding DISTRIBUTOR ASSISTANCE:
characteristics of the vehicle. A minimum G.V.W. of 10,500 Should you require any assistance not given in this
lb with two rear jacklegs (or outriggers) is recommended manual, we recommend that you consult your nearest Auto
for mounting the 5005EH series cranes. Crane Distributor. Our distributors sell authorized parts and
The 5005EH series cranes are attached directly to your have service departments that can solve almost any needed
12 volt truck electrical system. The power cable and retaining repair.
clips are included with the crane. A typical power cable
mounting and hookup is shown in the installation section. The NOTE: THIS MANUAL SHOULD REMAIN
performance of your new crane depends on the truck electrical
system. The use of maintenance free batteries is NOT WITH THE CRANE AT ALL TIMES.
recommended for use with any Auto Crane product. The
recommended alternator and battery that will give the longest This manual does not cover all maintenance, operating,
life with the most useful duty cycle is a 60 amp alternator or repair instructions pertinent to all possible situations. If
with a 120 minute reserve capacity, deep cycle battery. These you require additional information, please contact the Auto
specifications should be considered minimum. Crane Company at the following telephone number: (918)
438-2760. The information contained in the manual is in
Auto Crane Company issues a limited effect at the time of this printing. Auto Crane Company
warranty certificate with each unit sold. reserves the right to update this material without notice or
obligation.
See last page for warranty policy.
1-1.0.0 Intro 12/99

IMPORTANT
OPERATING PRACTICES & WARNINGS
1. Make certain the vehicle meets minimum chassis 16. WARNING! NEVER OPERATE THE CRANE
requirements. (These requirements do not guarantee NEAR ELECTRICAL POWER LINES! Death or
unit stability) serious injury will result from boom, line, or load
2. Make certain the crane is installed per factory contacting electric lines. Do not use crane within 10
specifications. Contact your local Distributor or the feet (3.05m) of electric power lines carrying up to
Auto Crane factory if any questions arise. 50,000 volts. One foot additional clearance is required
for every additional 30,000 volts or less.
3. Keep the vehicle in as level a position as possible
while loading or unloading. 17. WARNING! NEVER EXCEED load chart
capacities (centerline of rotation to hoist hook).
4. ALWAYS set the vehicle emergency brake before
beginning crane operations. 18. WARNING! NEVER unreel last 5 wraps of cable
from drum!
5. ALWAYS use outriggers from vehicle to the ground
during crane operation. Make sure they are firmly 19. WARNING! NEVER wrap cable around load!
positioned on solid footings. 20. WARNING! NEVER attempt to lift or drag a load
6. All load ratings are based on crane capacity, NOT from the side! The boom can fail far below its rated
truck/crane stability. capacity.
7. Keep objects and personnel clear of crane path during 21. WARNING! NEVER weld, modify, or use
operation. unauthorized components on any Auto Crane unit!
This will void any warranty or liability. Also failure
8. Keep hoist cable pulled tight at all times.
of the crane may result.
9. REMEMBER, in lifting a heavy load, the weight can
22. WARNING! NEVER place a chain link on the tip of
create enough tipping momentum to overturn the
the hook and try to lift a load!
vehicle.
23. WARNING! NEVER use a sling bar or anything
10. ALWAYS keep load as close to ground as possible.
larger than the hook throat that could prevent the
11. Oil gears as required. hook latch from closing, thus negating the safety
12. Periodic adjustment of hoist worm brake may be feature!
required (see automatic safety brake drawing in this 24. WARNING! In using a hook with latch, ALWAYS
manual). insure that the hook throat is closed before lifting a
13. Hydraulic hoses need to be inspected frequently for load! Proper attention and common sense applied to
signs of deterioration, and be replaced as required. the use of the hoist hook and various slings will
14. The hoist hook is an important item that an operator prevent possible damage to material being hoisted and
should consider and use properly. It should be may prevent injury to personnel.
checked on a daily basis for distortion or cracks. 25. WARNING! NEVER hold any pendant Select
15. ALWAYS store outriggers before road travel. Switch on that will cause unsafe operating conditions!
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.
2-1.0.0 SafeTips 12/99

--- IMPORTANT ---
OPERATION OF UNIT
26. Make sure this manual has been thoroughly read by 33. Always boom up before rotating so the boom will
all crane operating personnel and supervisors. clear the required boom support.
27. A routine inspection of the crane should be mandatory 34. When extending the boom, always maintain clearance
before each operating day. Any defects should be between the boom crown and the traveling block or
corrected immediately. hoist hook.
28. At a job site the vehicle should be positioned so that 35. Always observe safe and practical operation to avoid
the crane can adequately reach the load within the possible accidents. Refer to Safety Tips and
rated capacity (centerline of rotation to hoist hook). Precautions.
29. Keep the vehicle as level as possible during operation. 36. After completing lifting operations, return the boom
30. For electric cranes, engage emergency brake and to stowed position on the boom support. Avoid
leave ignition on with transmission in neutral (or in unneeded pressure on the boom support.
park for automatic transmissions). Activate any crane 37. Store pendant control on proper location (in cab or on
power switches. For Auto Crane units requiring crane).
battery and hydraulic operation, engage emergency 38. Return outriggers to stowed position. Make sure they
brake, place gear selector in neutral, press clutch, are pinned in place or jacklegs are returned to
activate PTO, release clutch and after hydraulic fluid compartment.
is warm, set throttle control to proper engine speed.
39. Check work area for any tools or equipment not
31. Always use outriggers from the truck to the ground. stored.
Be sure these are firm and adequately positioned.
40. Release throttle control, depress clutch and disengage
When rotating, keep load as low to the ground as
PTO. Deactivate any crane power switches.
possible.
41. Report any unusual occurrence during crane operation
32. Remove pendant control from cab or storage area. On
that may indicate required maintenance or repair.
smaller units, plug pendant into receptacle on crane.
On larger units, remove pendant control from guard 42. NEVER use two cranes to support a load too large for
and unwrap cable from boom. Do not operate crane either crane.
until cable is unwound completely. On all cranes, 43. Spray all electrical equipment with special corrosion
detach hook from dead man. Crane is now ready for resistant coating. This eliminates rust or corrosion
operation. due to melting and freezing action of condensation.
OPERATION OF
OUTRIGGERS
For hydraulic outriggers: For manual outriggers:
1. Shift crane/outrigger control valve to 1. Pull lock pins to release jack leg or drop down
"outrigger" position. outrigger and move to outermost lock position.
2. While operating the outrigger control valves 2. Make sure lock pins are reinstalled properly.
(located on the outrigger cylinders) 3. Lower outrigger pad to firm ground and adjust
simultaneously operate the boom-up control foot to take out slack.
switch. This will allow the hydraulic system to
build pressure. 4. Crane is now ready to operate.
3. After outriggers are positioned, return
crane/outrigger selector to "crane" position.
4. Crane is now ready to operate.
2-2.0.0
OPER 2/98
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
1 Crane operation shall be limited to personnel with dizziness or similar undesirable characteristics.
the following minimum qualifications:
8 In addition to the above listed requirements, the
A. designated persons operator shall:
B. trainees under the direct supervision of a designated A. Demonstrate the ability to comprehend and interpret
person all labels, operator's manuals, safety codes and other
C. maintenance and test personnel (when it is information pertinent to correct crane operations.
necessary in the performance of their duties) B. Possess knowledge of emergency procedures and
D. inspectors (crane). implementation of same.
C. Demonstrate to the employer the ability to operate
2 No one other than the personnel specified above shall the specific type of equipment.
enter the operating area of a crane with the exception
of persons such as oilers, supervisors, and those D. Be familiar with the applicable safety regulations.
specified persons authorized by supervisors whose E. Understand responsibility for maintenance
duties require them to do so and then only in the requirements of crane.
performance of their duties and with the knowledge F. Be thoroughly familiar with the crane and its
of the operator or other persons. control functions.
QUALIFICATIONS FOR OPERATORS G. Understand the operating procedures as outlined by
the manufacturer.
3 Operators shall be required by the employer to pass a CONDUCT OF OPERATORS

practical operating examination. Qualifications shall
be limited to the specific type of equipment for which
9 The operator shall not engage in any practice which
examined.
will divert his attention while actually operating the
4 Operators and operator trainees shall meet the crane.
following physical qualifications:
10 Each operator shall be responsible for those
A. Vision of at least 20/30 Snellen in one eye and operations under the operator's direct control.
20/50 in the other, with or without corrective lenses. Whenever there is any doubt as to safety, the
B. Ability to distinguish colors, regardless of position, operator shall consult with the supervisor before
if colors differentiation is required for operation. handling the loads.
C. Adequate hearing with or without hearing aid for
11 The operator should not leave a suspended load
the specific operation.
unattended unless specific precautions have been
5 Evidence of physical defects or emotional instability instituted and are in place.
which render a hazard to operator or others, which
12 If there is a warning sign on the switch or engine
in the opinion of the examiner could interfere with
starting controls, the operator shall not close the
the operator's performance may be sufficient cause
switch or start the engine until the warning sign has
for disqualification. In such cases, specialized clinical
been removed by the appointed person.
or medical judgment and tests may be required.
13 Before closing the switch or starting the engine, the
6 Evidence that the operator is subject to seizures or
operator shall see that all controls are in the "OFF"
loss of physical control shall be sufficient reason for
or neutral position and all personnel are in the clear.
disqualification. Specialized medical tests may be
required to determine these conditions. 14 If power fails during operation, the operator shall:
A. move power controls to the "OFF" or neutral
position.
3-1.0.0 QUAL 7/98

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.
and its proper care. If adjustments or repairs are
necessary, the operator shall report the same 2. load, boom or other parts of the crane do
promptly to the appointed person, and shall also not contact any obstruction.
notify the next operator. G. Cranes shall not be used for dragging loads
sideways.
16 All controls shall be tested by the operator at the H. This standard recognizes that articulating boom
start of each shift. If any controls do not operate cranes are designed and intended for handling
properly, they shall be adjusted or repaired before materials. They do not meet personnel lift or
operations are begun. elevator requirements. Therefore, no lifting,
lowering, swinging or traveling shall be done while
17 Stabilizers shall be visible to the operator while
a person is on the hook or load. Hook attached
extending or setting unless operator is assisted by a
suspended work platforms (baskets) shall not be
signal person.
used with cranes covered by this standard. Work
OPERATING PRACTICES platforms attached to the boom must be approved by
crane manufacturer.
HANDLING THE LOAD I. The operator should avoid carrying loads over
people.
J. When the crane is so equipped, the stabilizers shall
18 Size of load
be fully extended and set. Blocking under stabilizers
A. No crane shall be loaded beyond the rated load shall meet the requirements as follows:
except for test purposes.
1. strong enough to prevent crushing.
B. The load to be lifted is to be within the rated load of
2. of such thickness, width and length as to
the crane and its existing configuration.
completely support the stabilizer pad.
C. When loads which are not accurately known are to
K. Firm footing under all tires, or individual stabilizer
be lifted, the person responsible for the job shall
pads should be level. Where such a footing is not
ascertain that the weight of the load does not exceed
otherwise supplied, it should be provided by
the crane rated load at the radius at which the load
timbers, cribbing, or other structural members to
is to be lifted.
distribute the load so as to not exceed allowable
bearing capacity or the underlying material.
19 Attaching the load
L. In transit, the boom shall be carried in stowed
A. The load shall be attached to the hook by means of
position.
slings or other devices of sufficient capacity.
M. When rotating the crane, sudden starts and stops
B. Hoist rope shall not be wrapped around the load.
shall be avoided. rotational speed shall be such that
20 Moving the load the load does not swing out beyond the radius at
which it can be controlled.
A. The operator shall determine that:
N. The crane shall not be transported with a load on
B. The crane is level and, where necessary, the the hook unless recommended by the manufacturer.
vehicle/carrier is blocked properly.
O. No person should be permitted to stand or pass
C. The load is well secured and balanced in the sling or under a suspended load.
lifting device before it is lifted more than a few
inches. 21 Stowing procedure. Follow the manufacturer's
D. Means are provided to hold the vehicle stationary procedure and sequence when stowing and
while operating the crane. un-stowing the crane.
E. Before starting to lift, the hook shall brought over
the load in such a manner as to minimize swinging.
3-1.1.0 QUAL 7/98

OPERATING PRACTICES
MISCELLANEOUS 25 In transit with no load and boom lowered the
clearance shall be specified in Table 1.
OPERATING NEAR ELECTRICAL POWER
LINES 26 A qualified signalperson shall be assigned to observe
the clearance and give warning before approaching
the above limits.
A. Any overhead wire shall be considered to be an
energized line unless and until the person owning
such line or the electrical utility authorities verify
that it is not an energized line.
B. Exceptions to this procedure, if approved by the
administrative or regulatory authority if the
alternate procedure provides equivalent protection
and set forth in writing.
C. Durable signs shall be installed at the operator's
station and on the outside of the crane, warning that
electrocution or serious bodily injury may occur
unless a minimum clearance of 10 ft. (3.0m)
between the crane or the load being handled and
energized power lines. Greater clearances are
required because of higher voltage as stated above.
These signs shall be revised but not removed when
local jurisdiction requires greater clearances.
TABLE 1
22 Cranes shall be operated so that no part of the crane minimum required

or load enters into the danger zone shown above. clearance
EXCEPTIONS normal voltage, kV
(phase to phase) ft (m)
A. The danger zone may be entered after confirmation when operating near high voltage power lines
by an appointed person that the electrical
distribution and transmission lines have been over to 50 10 (3.05)
de-energized and visibly grounded at the point of over 50 to 200 15 (4.6)
work; or over 200 to 350 20 (6.1)
B. The danger zone may be entered if insulating over 350 to 500 25 (7.62)
barriers (not a part of nor an attachment to the over 500 to 750 35 (10.67)
crane) have been erected to prevent physical contact
over 750 to 1000 45 (13.72)
with the lines.
while in transit with no load and boom lowered
23 For lines rated 50 kV or below, minimum clearance
between the lines and any part of the crane or load over to 0.75 4 (1.22)
(including handling appendages) shall be 10 ft. (3m). over 0.75 to 50 6 (1.83)
For higher voltages, see Table 1. over 50 to 345 10 (3.83)
24 Caution shall be excercised when working near over 345 to 750 16 (4.87)
overhead lines, because they can move horizontally or over 750 to 1000 20 (6.1)
vertically due to wind, moving the danger zone to new
positions.
3-1.2.0 QUAL 7/98

INSPECTION, TESTING AND MAINTENANCE
GENERAL
G. electrical apparatus for malfunctioning, signs of

INSPECTION CLASSIFICATION
excessive deterioration, dirt and moisture accumula-
27 Initial inspection. Prior to initial use, all new, altered, tion
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-
ance with provisions of this standard. I. tires for recommended inflation pressure, cuts and
loose wheel nuts
28 Regular inspection. Inspection procedure for cranes J. connecting pins and locking device for wear and
in regular service is divided into two general classifi- damage
cations based upon the intervals at which inspection
should be performed. The intervals in turn are PERIODIC INSPECTION
dependent upon the nature of the components of the
crane and the degree of their exposure to wear, 30 Deformed, cracked or corroded members in the
deterioration, or malfunction. The two general classi- crane structure and carrier.
fications are herein designated as "frequent" and
"periodic" with respective intervals between inspec- 31 Loose bolts, particularly mounting bolts.
tions as defined below.
A. frequent inspection - daily to monthly intervals 32 Cracked or worn sheaves and drums.
B. periodic inspection - one to twelve intervals, or as
specifically recommended by the manufacturer 33 Worn, cracked, or distorted parts such as pins,
bearings, shafts, gears, rollers and devices.
FREQUENT INSPECTION
34 Excessive wear on brake and clutch system parts and
29 Inspection shall be performed by designated lining.
personnel.
35 Crane hooks inspected for cracks.
A. control mechanisms for maladjustment interfering
with proper operation - daily, when used
36 Travel steering, braking, and locking devices, for
B. control mechanisms for excessive wear of compo- malfunction.
nents and contamination by lubricants or other
foreign matter 37 Excessively worn or damaged tires.
C. safety devices for malfunction
38 Hydraulic and pneumatic hose, fittings, and tubing
D. all hydraulic hoses, particularly those which flex in inspection.
normal operation of crane functions, should be
visually inspected once every working day, when A. evidence of leakage at the surface of the flexible
used hose or its junction with metal and coupling
E. hooks and latches for deformation, chemical B. blistering, or abnormal deformation to the outer
damage, cracks, and wear. Refer to ANSI/ASME covering of the hydraulic or pneumatic hose
B30.10 C. leakage at threaded or clamped joints that cannot be
F. rope reeving for compliance with crane manufac- eliminated by normal tightening or recommended
turer's specifications, if optional winch is used procedures
D. evidence or excessive abrasion or scrubbing on the
outer surface of a hose, rigid tube, or fitting. Means
shall be taken to eliminate the interference of
4-1.0.0 INSP 9/98

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.
CRANES NOT IN REGULAR USE
A. loose bolts or fasteners
B. leaks at joints between sections 44 A crane which has been idle for a period of over one
month or more, but not less than six months, shall be
C. shaft seal leaks given an inspection conforming with the initial-
D. unusual noises or vibrations regular- frequent inspections.
E. loss of operating speed 45 A crane which has been idle for a period of over six
F. excessive heating of the fluid months shall be given a complete inspection conform-
ing with the initial-regular-frequent inspection
G. loss of pressure requirements.
40 Hydraulic and pneumatic valves inspection. INSPECTION RECORDS

A. cracks in valve housing 46 Dated records for periodic inspection should be made
on critical items such as brakes, crane hooks, rope,
B. improper return of spool to neutral position
hydraulic and pneumatic cylinders, and hydraulic
C. leaks at spools or joints and pneumatic relief pressure valves. Records should
be kept available to an appointed person.
D. sticking spools
E. failure of relief valves to attain or maintain correct OPERATIONAL TESTS
pressure setting
47 Prior to initial use, all new, altered, modified, or
F. relief valve pressure shall be checked as specified by extensively repaired cranes shall be tested for compli-
the manufacturers ance with the operational requirements of this
section, including functions such as the following:
41 Hydraulic and pneumatic cylinders inspection.
A. load lifting and lowering mechanisms
A. drifting caused by fluid leaking across piston
B. boom lifting and lowering mechanisms
B. rod seals leaking
C. boom extension and retraction mechanisms
C. leaks at welding joints
D. swing mechanisms
D. scored, nicked, or dented cylinder rods
E. safety devices
E. damaged case (barrel)
F. operating controls comply with appropriate function
F. loose or deformed rod eyes or connecting joints labels
Operational crane test results shall be made
42 Hydraulic filters. Evidence of rubber particles on the
available to an appointed person.
filter elements may indicate hose, "O" ring, or other
rubber component deterioration. Metal chips or
pieces on the filter may denote failure in pumps,
RATED TEST LOAD
motors, or cylinders. Further checking will be Prior to initial use, altered, modified, or
extensively repaired cranes shall be load
4-1.1.0 INSP 9/98
GENERAL
tested by or under the direction of an A. functional operating mechanism

appointed person. B. safety devices
48 Test loads shall not exceed 110% of the manufac- C. control systems
turer's load ratings.
55 Repairs or replacements shall be provided as needed
49 Written reports shall be maintained showing test for operation.
procedures and confirming the adequacy of repairs.
The following are examples:
MAINTENANCE A. critical parts of functional operating mechanisms
which are cracked, broken, corroded, bent, or exces-
PREVENTIVE MAINTENANCE sively worn
50 Before adjustment and repairs are started on a crane, B. critical parts of the crane structure which are
the following precautions shall be taken as cracked, bent, broken, or excessively corroded
applicable:
C. crane hooks showing cracks, damage, or corrosion
A. crane placed where it will cause the least interfer- shall be taken out of service. Repairs by welding are
ence with other equipment or operations not recommended
B. all controls at the "off" position
56 Instructions shall be provided by the manufacturer
C. starting means rendered inoperative for the removal of air from hydraulic circuits.
D. boom lowered to the ground if possible or otherwise
LUBRICATION
secured against dropping
All moving parts of the crane, for which
E. relieve hydraulic oil pressure from all hydraulic lubrication is specified, should be regularly
circuits before loosening or removing hydraulic lubricated per the manufacturer's
components
recommendations and procedures.
51 Warning or "OUT OF ORDER" signs shall be placed ROPE INSPECTION
on the crane controls.
57 Frequent Inspection
52 After adjustments and repairs have been made, the
crane shall not be returned to service until all guards A. All running ropes in service should be visually
have been reinstalled, trapped air removed from inspected once each working day. A visual inspec-
hydraulic system (if required), safety devices reacti- tion shall consist of observation of all rope which
vated, and maintenance equipment removed. can be in use during the days operations. These
visual observations should be considered with
ADJUSTMENTS AND REPAIRS discovering gross damage such as listed below,
which may be an immediate hazard.
53 Any hazardous conditions disclosed by the inspection 1. distortion of the rope such as kinking,
requirements shall be corrected before operation of
crushing, un-stranding, birdcaging, main
crane is resumed, Adjustments and repairs shall be
strand displacement, or core protrusion.
done only by designated personnel.
Loss of rope diameter in a short length or
54 Adjustments shall be maintained to assure correct
unevenness of outer strands should be
functioning of components, The following are replaced
examples: 2. general corrosion
4-1.2.0 INSP 9/98

GENERAL
3. broken or cut strands; 1. sections in contact with saddles, equalizer

4. number, distribution and type of visible sheaves, or other sheaves where rope travel
broken wires. When such damage is is limited
discovered, the rope shall either be 2. sections of the rope at or near terminal ends
removed from service or given as where corroded or broken wires may
inspection. protrude
B. Care shall be taken when inspecting sections of
ROPE REPLACEMENT
rapid deterioration such as flange points, crossover
points, and repetitive pickup points on drums. 59 No precise rules can be given for determination of the
exact time for replacement of rope, since many
58 Periodic inspection variable factors are involved.
A. The inspection frequency shall be determined by a Continued use in this respect depends upon
qualified person and shall be based on such factors good judgement by a designated person in
as: evaluating remaining strength in a used rope
1. expected rope life as determined by after allowance for deterioration disclosed by
experience on the particular installation or inspection. Continued rope operation depends
similar installations upon this remaining strength.
2. severity of environment
60 Conditions such as the following shall be reason for
3. percentage of capacity lifts questioning continued use of the rope or increasing
4. frequency rates of operation the frequency of inspection:
5. exposure to shock loads A. in running ropes, six randomly distributed broken
wires in one lay or three broken wires in one strand
Inspection need not be at equal calendar
in one lay
intervals and should be more frequent as the
rope approaches the end of it's service life. B. one outer wire broken at the contact point with the
This inspection shall be made at least core of the rope structure and protrudes or loops out
annually. of the rope structure. Additional inspection of this
section is required
B. Periodic inspection shall be performed by a desig-
nated person. This inspection shall cover the entire C. wear of one third of the original diameter of the
length of the rope. Only the surface wires need be outside individual wire
inspected. No attempt should be made to open the
D. kinking, crushing, birdcaging, or any other damage
rope. Any deterioration results in appreciable loss of
resulting in distortion of the rope structure
original strength, such as described below, shall be
noted and determination made as to whether use of E. evidence of any heat damage from any cause
the rope would constitute a hazard: points listed
above reduction of rope diameter below nominal F. reduction from nominal diameter of more than 1/64
diameter due to loss of core support, internal or in. (0.4mm) for diameters up to and including 5/16
external corrosion, or wear of outside wires; in. (8 mm), 1/32 in. (0.8 mm) for diameter 3/8 in.
severely corroded, cracked, bent, worn or improp- (9.5 mm) to and including 1/2 in. (13 mm), 3/64 in.
erly applied connections; (1.2 mm) for diameter 9/16 in. (14.5 mm) to and
including 3/4 in. (19 mm). 1/16 in. (1.6 mm) for
C. Care shall be taken when inspecting sections subject diameter 7/8 in. (22 mm) to and including 11/8 in.
to rapid deterioration such as the following: (29 mm), 3/32 in. (2.4 mm) for diameters 11/4 in.
(32 mm) to and including 11/2 in. (38 mm)
4-1.3.0 INSP 9/98

GENERAL
G. In standing ropes, more than two broken wires in

one lay in sections beyond end connections or more 65 Before cutting a rope, seizing shall be placed on each
than one broken wire at an end connection. side of the place where the rope is to be cut to prevent
unlaying of the strands. On pre-formed rope, one
H. Replacement rope shall have a strength rating at seizing on each side of the cut is required. On
least as great as the original rope furnished or non-preformed ropes of 7/8 in. (22 mm) diameter or
recommended by the crane manufacturer. Any smaller, two seizings on each side of the cut are
deviation from the original size, grade, or construc- required, and for non-preformed rope 1 in. (25 mm)
tion shall be specified by a rope manufacturer, or a diameter or larger, three seizings on each side of the
qualified person. cut are required.
61 Rope not in regular use: all rope which has been idle 66 During installation care should be exercised to avoid
for a period of a month or more due to shutdown or dragging of the rope in the dirt or around objects
storage of a crane on which it is installed, shall be which will scrape, nick crush or induce sharp bends
given and inspection in accordance with above infor- in it.
mation before it is placed in service. This inspection
shall be for all types of deterioration and shall be 67 Rope should be maintained in a well-lubricated
performed by a qualified person. condition. It is important that lubricant applied as a
part of a maintenance program shall be compatible
62 Inspection records with the original lubricant and to this end the rope
manufacturer should be consulted. Lubricant applied
A. frequent inspection- no records required shall be the type which does not hinder visual inspec-
B. periodic inspections- in order to establish data as a tion. Those sections of rope which are located over
basis for judging the proper time for replacement, a sheaves or otherwise hidden during inspection and
dated report condition at each periodic inspection maintenance procedures require special attention
should be kept on file. This report shall cover when lubricating rope. The object of rope lubrication
points of deterioration listed above. is to reduce internal friction and to prevent corrosion.
ROPE MAINTENANCE 68 When an operating rope shows greater wear or well

defined localized areas than on the remainder of the
63 Rope should be stored to prevent damage or rope, rope life can be extended in cases where a
deterioration. section at the worn end, and thus shifting the wear to
different areas of the rope.
64 Unreeling or uncoiling of rope shall be done as
recommended by the rope manufacturer and with
care to avoid kinking or inducing twist.
4-1.3.0. INSP 9/98

Safety Decal Section
5005EH
PART NO.: 040579

DECAL: OPERATION INSTRUCTIONS
FUNCTION: To inform the operator of the proper
procedure to follow for safe operation
of the crane.
USED ON: All Cranes
QUANTITY: 1
PLACEMENT: Left side plate (5005EH)
FIG.
SD-1
PART NO.: 040580

DECAL: OPERATOR TRAINING
FUNCTION: To inform the operator of the need to receive
proper training before using the crane.
USED ON: All Cranes
QUANTITY: 1
PLACEMENT: Left side plate (5005EH)
FIG. SD-2
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.
USED ON: 5005EH
QUANTITY: 1
PLACEMENT: Right side of lift cylinder
FIG. SD-3
5-1.1.0
Decal 12/99
5005EH
PART NO.: 040529
DECAL: ELECTROCUTION HAZARD
FUNCTION: To inform the operator of the
hazard involved with contacting
electrical power lines with crane
boom.
USED ON: Articulated & Stiff Boom Cranes
QUANTITY: 2
PLACEMENT: Both sides of end of lower boom FIG. SD-4
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.
USED ON: All cranes
QUANTITY: 2
PLACEMENT: Both sides of crown
FIG. SD-5
PART NO.: 040518
DECAL: STAY CLEAR
OF LOAD
FUNCTION: To inform the
operator of the
hazard of
proximity or
contact with the
crane load during
operation.
USED ON: All cranes
QUANTITY: 2 FIG. SD-6
PLACEMENT: Both sides of
crown plate 5-1.2.0 Decal 12/99
5005EH
PART NO.: 040587

DECAL: LOAD SENSOR, DON'T TAMPER
FUNCTION: To inform the operator that the load
sensor is pre-set and that tampering
with the sensor may cause potentially
hazardous situation.
USED ON: All cranes equipped with a load sensor.
QUANTITY: 1
FIG. SD-7
PLACEMENT: On the lift cylinder near the load sensor
PART NO.: 040519 USED ON: All cranes

DECAL: SCISSORS POINT QUANTITY: 2
FUNCTION: To inform the operator of PLACEMENT: Both sides of the lift cylinder
possible danger at scissors
point on crane.
FIG. SD-8
5-1.3.0 Decal 12/99

INSTALLATION (CRANE COMPARTMENT)
MODEL 5005EH
7-1.1.0 AW-350-1 12/99

BOOM SUPPORT
5005EH SERIES
WARNING:
As with all Auto Crane power rotation units, the 5005EH does require a boom support.
Suggested Boom Support:

Auto Crane P/N 726175
7-2.0.0 AW726175 12/99

LUBRICATION & MAINTENANCE SCHEDULE
5005EH CRANE
DAY WEEKLY 3 MOS 6 MOS YEAR NOTES
SERVICE
PERFORMED
LOAD HOOK X INSPECT HOOK & LATCH FOR DEFORMA-
TION, CRACKS, & CORROSION
CABLE DRUM X MAKE SURE CABLE IS WOUND EVENLY
ON DRUM
HOIST CABLE X CHECK FOR FLATTENING, KINKS, &
BROKEN STRANDS, SEE MANUAL
HYD. HOSES X VISUAL INSPECTION
HYD. FLUID X CHECK FLUID LEVEL
MOUNTING BOLTS X CHECK-TORQUE TO 440 FT-LBS (DRY) AS
REQUIRED
ROTATION RING X LUBE WITH MOBILETAC LL, OR LUBRI-
GEAR PLATE P/N 15263, OR EQUAL
SHEAVE X SEALED BEARING, REPLACE IF ROUGH OR

BEARINGS LOOSE
ALL OTHER BOLTS X CHECK-TIGHTEN AS REQUIRED

BOOM PIVOTS X GREASE WITH MOBILPLEX EP-2 OR
EQUIVALENT @ ZERKS
BOOM CYLINDER X CHECK AROUND CYLINDER ROD FOR
EXCESS FLUID LEAKAGE
BOOM CYLINDER X GREASE WITH MOBILPLEX EP-2 OR
PINS EQUIVALENT @ ZERKS
EXTENSION X LUBE DETENT SPRING & BALL W/ WD-40

DETENT PIN
ROTATION X GREASE WITH MOBILPLEX EP-2 OR
BEARING EQUIVALENT @ ZERKS
ROTATION X CHECK TORQUE TO 150 FT-LBS (DRY) AS

BEARING BOLTS REQUIRED
ROTATION GEAR X CHECK TORQUE TO 85 FT-LBS (DRY) AS

BOX REQUIRED
ROTATION GEAR X EP GEAR LUBE SAE 140

BOX
HOIST GEARBOX X EP GEAR-EP GEAR LUBE SAE 80-90, SPUR
GEAR SAE 30 OIL
HYDRAULIC FLUID X DRAIN, FLUSH, AND REFILL WITH
SUN2105 HYD. OIL, SAE 5W-20
BOOM SLIDE PADS PADS GREASED WHEN REPLACED
8-1.0.0 5005EHmtsc 4/99

LUBRICATION & MAINTENANCE SCHEDULE
5005EH CRANE
DAY WEEKLY 3 MOS 6 MOS YEAR NOTES
SERVICE
PERFORMED
FOR ADDITIONAL 1) OWNER'S MANUAL
INFORMATION 2) OSHA SECTION 1910.180
SEE: 3) ANSI B30.5-1989
CAUTION: Routine maintenance insures trouble-free operation and protects your investment. All
warranties are void if maintenance is neglected.
NOTES:
1. Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered
by Warranty or Product Liability.
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.
8-1.1.0 5005EHmtsc 4/99

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.
charged, properly filled with water, and relatively If the electrolyte level is allowed to fall below the top of
clean. the plates, the results become threefold:
Keep Properly Charged 1 The exposed portion of the plate will become
sulfated.
Many things affect the proper charge to a battery, such
2 The portion of the plate exposed is not usable.
as:
3 That portion of the acid remaining becomes more
1 Regulator settings
concentrated and may cause more rapid
deterioration of the remaining parts of the battery.
2 Proper tightness of belts on the alternator
or generator
Keep A Relatively Clean Battery
3 Good, clean connections of all cables
and wires at the following places: The battery should be kept clean. Batteries filled with
A. Battery acid and which are not in use self-discharge to a limited
B. Regulator degree because of the nature of the materials within the
C. Starting motor battery. If dirt is allowed to collect on the top of the
D. Alternator or generator battery (and this dirt absorbs moisture) and electrical
E. Ground connections (most important) path can be set up between the various terminals of the
battery and the ground. Once such a path has been
It is of extreme importance to keep the battery as fully established, the self-discharge of the battery is
charged as possible without overcharging, especially accelerated. This also accelerates corrosion of the
when vehicles are left outside for extended periods in battery cables at the terminals.
extremely cold climates. A battery can freeze.
Freezing points for various specific gravities of acid are Periodic Maintenance is Needed
as follows:
A definite program of periodic maintenance of all
Specific Gravity Freezing Temp. batteries should be conducted on a regular basis.
(Corrected to 80ºF) Degrees F. Periodic maintenance includes:
1.280 -90ºF 1 Checking belts for tightness on the charging

1.250 -62ºF equipment
1.200 -16ºF
1.150 5ºF 2 Checking battery electrolyte levels
1.100 19ºF
3 Checking cables for good connections
As shown, a half-charged battery (about 1.200 specific
gravity) cannot stand for any length of time at 20ºF or it 4 Cleaning where corrosion is apparent
will freeze.
When corrosion is cleaned off, the cable terminals and
The main reason for keeping the battery as fully battery terminals should be coated with a light coating
charged as possible without over-charging is to ensure of petroleum jelly before they are replaced. When
that power is available even though the vehicle has been terminals are cleaned, the top of the battery should be
standing for some time. cleaned with a mild solution of soda water.
8-4.0.0. MAINTBAT 9/98

MAINTENANCE OF BATTERIES
Low Maintenance Batteries should be attempted for an extended time. This usually
(Maintenance Free) will recover a badly sulfated battery.
Low maintenance batteries should not be used on Replacing a Battery

Auto Cranes or trucks equipped with Auto Cranes.
The batteries are not designed for "deep" discharge. If it is necessary to replace a battery, and a dry charge
battery is used, the following procedure applies:
Testing Your Battery 1 Fill the battery with electrolyte of the proper
specific gravity.
If the condition of the battery is in question, it should be
removed from the vehicle, taken to the shop, and 2 Place the battery on charge according to the
allowed to reach room temperature. It should then be manufacturer's instructions.
recharged until specific gravity readings taken at
one-half hour intervals. If the specific gravity readings It is essential that the second step above be followed to
are fairly uniform, the battery should be checked with a ensure that the battery going on the vehicle is fully
high rate tester. Use the tester in accordance with the charged.
manufacturer's instructions. The high rate tester is the
best method to test a questionable battery. It is also very important that the battery hold-downs be
checked periodically to ensure that the batteries are
If, after charging, it is noted that the specific gravity properly positioned to avoid vibration problems,
reading of one cell is 30 points less than any of the breakage of cables or terminals. Care must be taken to
other cells, it may be assumed that the cell is bad and avoid cracking or breaking containers or covers by
that the battery should be replaced. If all cells are tightening hold-down fixtures excessively. They also
uniform but not up to full charge, a low rate of charge must not be so loose that breakage results from a
hold-down that is too loose.
8-4.1.0 MAINTBAT 9/98

LIFE OF WIRE LINE
So many variable factors can cause the deterioration of wire line cable that it is not
possible 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 galvanized
pre-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 traveling
block. 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 be
handled, 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.
WIRE LINE LUBRICATION
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.
Preparation
Remove rust and foreign matter with a wire brush and wipe clean. Be sure cable is dry.
Application
Method 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 than
canvas gloves.)
9-1.0.0 WIRE 1/2000

BOOM ASSEMBLY (10-16)
P/N 360860 - MODEL 5005H/EH
10-3.0.0 aw360860 4/99

BOOM ASSEMBLY (10-16)
P/N 360860 - MODEL 5005H/EH
ITEM QTY P/N DESCRIPTION

1 1 360861 LOWER BOOM
2 1 360862 UPPER BOOM
3 1 360152 BOOM EXTENSION CYLINDER
4 1 360545 INNER BOOM RETAINER
5 1 360167 LOWER SLIDE PAD RETAINER
6 1 480032 BOOM PAD
7 2 480033 LARGE SHIM .032 THICK
8 1 360121 UPPER BOOM EXTENSION CYLINDER PIN
9 1 360621 BOOM/CYLINDER PIN
10 1 360625 LOWER BOOM PIVOT PIN
11 1 360120 LOWER BOOM EXTENSION CYLINDER PIN
12 4 360122 RETAINING RING
13 2 240236 SHEAVE ASSEMBLY
14 1 360814 CROWN PIN
15 1 360124 HITCH PIN
16 2 360038 ANGLE INDICATOR
17 2 366158 CAPSCREW 3/8-16NC x 3/4
18 6 020200 SPLIT LOCK WASHER 1/4
19 2 016300 HEX LOCK NUT 1/4-20NC
20 2 011511 CAPSCREW 1/2-20NF x 2 1/4
21 2 017700 HEX LOCK NUT 1/2-20NC
22 4 005406 CAPSCREW 1/4-28NF x 1/2
23 2 005901 CAPSCREW 1/4-20NC x 1/2
25 2 360849 PLASTIC SPACER
26 5 015900 HEX NUT 1/4-20NC
27 1 360069 EXTENSION CYLINDER TUBE ASSEMBLY
28 1 360070 EXTENSION CYLINDER TUBE ASSEMBLY
29 2 360075 EXTENSION CYLINDER HOSE ASSEMBLY
30 1 360091 U-BOLT
31 1 360092 CLAMP
32 1 360153 COUNTERBALANCE VALVE
10-3.1.0 aw360860 4/99

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 overload. In addition to this, when there is
A. Unplug the anti-2-block system from the overload also a signal from the boom down solenoid to
system and connect A and B to bypass the RELAY B at the same time, RELAY B
anti-2-block system. latches RELAY A so that even if the
1. If the three functions work, check continuity overload signal from the pressure switch to
of anti-2-block system using continuity RELAY A is removed, RELAY A will
tester at disconnected. continue to be on and interrupt the ground
Weather pack connectors, and investigate circuit until the signal from the boom down
switch at end of boom, cable and cable reel. solenoid and pressure switch are removed.
2. If the three functions do not work, continue 2. The purpose of RELAY A is to interrupt the
on with section #2. ground circuit and stop hoist up, boom
down, and extend out functions from
2 LOAD SENSOR (Pressure Switch) operating. The purpose of RELAY B is to
A. With crane unloaded, unplug weather pack stop boom bounce caused by the overload
connector on load sensor wire. system cycling on and off.
1. If the three functions work, recheck the 4 OPERATIONAL TEST AND TROUBLE
Pressure Switch by taking a ohm reading on SHOOTING OF RELAY BOX
the two wires coming from the Switch. The
A. After the anti-2-block test and the load sensor tests
switch has normally open contacts, so the
have been perform and the overload system still
reading should be the maximum. If less
does not operate, check the relay box.
than maximum ohm reading is indicated
(usually a dead short), replace the Switch. 1. Disconnect the weatherpak connector in the
load sensor pressure switch wires going
2. If the three functions do not work, continue
from the pressure switch to the relay box.
with section #3.
Disconnect the weatherpak connector
3 RELAY BOX between the cord reel and the relay box.
A. Inside this box are two 320355 relays. Since these 2. Check for 12 volts at pin B of load sensor
are inexpensive relays, the easiest way to trouble connector on relay box side of harness.
shoot this device is to replace both relays. Short from pin A to pin B of weatherpak.
When pins A & B are shorted there should
1. The two relays are identical but serve NOT be continuity from the cord reel
different functions. RELAY A is the one weatherpak on the relay box side of the
with the most wires going to its connector. connection to ground. When A & B are not
RELAY A breaks the circuit between the shorted there should be continuity to
ground side of the solenoid valves on boom ground. Replace relay A if these conditions
down, extend out, and hoist up functions. are not met.
This happens whenever the overload switch
on the lift cylinder senses more than normal 3. If the boom tends to bounce when booming
pressure indicating an overload condition. down due to intermittent cycling of the
When overload happens then 12 volts is overload system, then RELAY B should be
passed through the overload switch to pull in replaced after verifying that the sense wire
RELAY A which then interrupts the ground from the relay box to the boom down
circuit of the valves controlling those solenoid valve control terminal is connected.
10-4.2.0 OVLD 1/99

OVERLOAD SYSTEM / ANTI-2-BLOCK
TROUBLE SHOOTING GUIDE
10-4.3.0 OVLD 1/99

AUTOMATIC SAFETY BRAKE ASSEMBLY
(OIL COOLED) HOIST

1 1 360367 FLAT SPRING
2 1 360331 CAM PLATE
3 1 360450 HOUSING COVER
4 1 360336 BRAKE HOUSING
5 1 360339 BRAKE HUB
6 1 360342 RETAINER PLATE
7 2 360345 BRAKE BALL
8 6 360453 CAPSCREW 1/4 NC x 1
9 1 360368 COIL SPRING
10 1 360456 CAPSCREW 3/8 NC x 1 1/2
11 1 360371 THREAD SEAL
12 1 360353 JAM NUT 3/8 NC
13 4 360465 THREAD SEAL
14 2 360455 WASHER FLAT 1/4 ALUM
15 1 360359 GASKET
16 1 360364 THRUST PLATE
AW368 1/99
10-6.0.0
AUTOMATIC SAFETY BRAKE ASSEMBLY
(OIL COOLED) HOIST
ASSEMBLY INSTRUCTIONS:
1. Winch has right hand worm and gear. Cable spools over drum. Use number
one slots for brake balls(7) in cam plate(2).
2. Install brake hub(5) through brake housing(4) on winch worm with key.
3. Assemble balls(7) in cam plate(2) using hard grease to hold balls in place.
4. Place cam plate(2) on brake hub(5), matching its holes with the balls.
5. Install thrust plate(16).
6. Thread capscrew(10) with jam nut (12) and thread seal (11) through housing
cover(3).
7. Place gasket(15) on housing cover(3).
8. Install coil spring(9) on capscrew(10).
9. Install flat spring(1) on capscrew(10).
10. Secure retainer plate(6) and flat spring(1) to housing cover(3) using
capscrews(8) and washers(14).
11. Using capscrews(8) and thead seals(13) attach housing cover(3) to brake
housing(4).
12. Test brake by shifting winch to UP then DOWN to see if brake is working in
proper rotation. If not, remove housing cover(3) and locate brake balls(7) in
opposite set of slots of cam plate(2).
13. Adjust to suit by tightening or loosening capscrew(10) on outside of housing
cover(3). When proper adjustment is obtained, secure capscrew(10) with jam
nut(12).
AW368 1/99
10-6.1.0
SOLENOID ASSEMBLY
P/N 360467 - MODEL 5005EH

1 3 360470 BLACK WIRE ASSEMBLY #6 GA x 11 1/2
2 1 360471 RED WIRE ASSEMBLY #16 GA x 1 1/2
3 2 360472 COPPER STRAP
4 2 360473 COPPER STRAP
5 2 200182 12V SOLENOID
6 1 360474 SOLENOID MOUNTING BRACKET
7 2 360475 RD HD SCREW #10 NC x 1/2
8 2 360476 NUT #10 NC
9 2 360477 FLAT WASHER #10
10 2 360478 TERMINAL TAB
11 4 360479 SOLENOID TERMINAL COVER
10-7.0.0 AW360467 9/98

HYDRAULICS
5005EH
Counterbalance Valve Adjustment { Tighten nut on adjustment screw and
repeat procedure if needed to obtain the
{ With PTO disengaged and boom proper pressure setting.
properly supported, remove O-ring plug
(item 17) shown on AW-573 marked { Disengage PTO, remove the pressure
"X" port (see CB valve diagram). gauge and install -6 plug. Crane is now
Install a pressure gauge (0-2500 PSI) ready for operation.
into the port. Notice:
{ Engage PTO and insure pump flow is 10 { In an EMERGENCY situation when it
becomes necessary to lower the boom
without flow present, the CB valve
adjustment can be turned in until the
boom begins to descend. Make sure the
boom will lower onto a proper support.
Loosen the lock nut and carefully turn
adjustment screw clockwise! Count the
number of turns. Turn slowly until the
boom just begins to lower, and remove
hand/arm/fingers from cranes while
boom is lowering.
{ Turning adjustment screw too far will
GPM and main relief is set to 2500 PSI. cause valve to come apart on the inside.
With no load on boom, boom up to an This condition is not repairable
angle of 70 degrees. Boom down and { After boom is lowered, turn adjustment
note pressure. If pressure reading is not screw counter clockwise the approxi-
approximately 1050 PSI, the counterbal- mate number of turns made during
ance valve requires adjustment. lowering procedure. After the problem
v To increase the CB valve setting, is corrected, readjust the counterbal-
loosen nut and turn Allen head ance valve using the procedure in this
screw counter clockwise. (Reference manual.
item 16, located on the side of the WARNING:
CB valve block towards the right
side of the boom.)
DO NOT TRY TO ADJUST VALVES
WHILE BOOM IS MOVING. Failure
v To reduce the CB valve setting,
loosen nut and turn Allen head to heed warning may result in personal
screw clockwise. injury!
11-1.0.0 HYD 12/99

HYDRAULIC ASSEMBLY (10-16-20)
P/N 360803 - MODEL 5005EH
11-2.0.0 aw360803 4/99

P/N 360803 - MODEL 5005EH

1 1 202710 MANIFOLD
2 3 REF DIRECTIONAL VALVE ASSEMBLY (300204)
3 1 320393 BOTTOM MANIFOLD BRACKET
4 1 320392 TOP MANIFOLD BRACKET
5 4 002614 CAPSCREW 5/16-NC x 5/8
6 4 007811 CAPSCREW 5/16-NC x 1
8 4 016500 HEX HEAD NUT 5/16-NC
9 1 360544 VALVE COVER
10 6 002608 CAPSCREW 1/4-NC x 3/4
11 2 320489 TUBE ASSEMBLY
12 4 480208 HOSE ASSEMBLY
13 1 812203-013 HOSE ASSEMBLY
15 1 320543 LOAD SENSOR
17 1 200892 90º ELBOW -6 NPT/-6 JIC
18 7 480194 90º ELBOW -6 JIC SWIVEL/-6 JIC
19 1 241168 TEE -6 ORB/-6 JIC RUN
21 3 200876 ADAPTER -6 ORB/-6 JIC
22 3 330647 45º ELBOW -6 JIC SWIVEL
23 2 005810 CAPSCREW 1/4-NC x 1 3/4
25 2 202759 90º ELBOW -8 NPT/-6 JIC
26 2 330272 90º ELBOW -8 ORB/-6 JIC
27 4 202756 ADAPTER -8 ORB/-6 JIC
28 2 202755 ADAPTER -10 ORB/-6 JIC
29 2 330072 HEX HEAD PLUG -10 ORB
30 1 320336-002 RETURN PORT PLUG
31 1 241175 90º ELBOW -6 ORB/-6 JIC
32 1 REF POWER UNIT (360798)
33 2 241170 UNION -6 JIC
34 1 480188 COUNTERBALANCE VALVE CARTRIDGE
11-2.1.0 aw360803 4/99

P/N 360803 - MODEL 5005EH

36 1 330645 90º EXTRA LONG ELBOW -6 ORB/-6 JIC
37 - - -
38 1 REF PLUG -6 O-RING
39 1 REF BOOM UP CYLINDER (360805)
40 1 REF EXTENSION CYLINDER (366162)
11-2.2.0 aw360803 4/99

HYDRAULIC ASSEMBLY (10-16)
P/N 360866 - MODEL 5005EH
11-3.0.0 aw360866 4/99

P/N 360866 - MODEL 5005EH

1 1 202710 MANIFOLD
2 3 REF DIRECTIONAL VALVE ASSEMBLY (300204)
3 1 320393 BOTTOM MANIFOLD BRACKET
4 1 320392 TOP MANIFOLD BRACKET
5 4 002614 CAPSCREW 5/16-NC x 5/8
6 4 007811 CAPSCREW 5/16-NC x 1
8 4 016500 HEX HEAD NUT 5/16-NC
9 1 360544 VALVE COVER
10 6 002608 CAPSCREW 1/4-NC x 3/4
15 1 320543 LOAD SENSOR
18 6 480194 90º ELBOW -6 JIC SWIVEL/-6 JIC
19 1 360091 U-BOLT
20 1 360092 CLAMP
21 2 200876 ADAPTER -6 ORB/-6 JIC
22 5 360042 ADAPTER -6 NPT/-6 JIC
23 2 015900 HEX HEAD NUT 1/4-NC
25 2 202759 90º ELBOW -8 NPT/-6 JIC
26 2 330272 90º ELBOW -8 ORB/-6 JIC
27 4 202756 ADAPTER -8 ORB/-6 JIC
28 2 202755 ADAPTER -10 ORB/-6 JIC
29 2 330072 HEX HEAD PLUG -10 ORB
30 1 320336-002 RETURN PORT PLUG
31 1 241175 90º ELBOW -6 ORB/-6 JIC
32 1 REF POWER UNIT (360798)
33 2 241170 UNION -6 JIC
34 1 480188 COUNTERBALANCE VALVE CARTRIDGE
11-3.1.0 aw360866 4/99

P/N 360866 - MODEL 5005EH

36 1 330645 90º EXTRA LONG ELBOW -6 ORB/-6 JIC
38 1 200892 90º ELBOW -6 NPT/-6 JIC
39 1 REF BOOM UP CYLINDER (360805)
40 1 REF EXTENSION CYLINDER (360152)
41 1 REF PLUG -6 O-RING
42 2 330647 45º ELBOW -6 JIC SWIVEL
11-3.2.0 aw360866 4/99

HYDRAULIC PUMP & RESERVOIR
P/N 360798

1 1 360808-003 ADAPTER KIT
2 1 320336-002 RETURN PORT PLUG KIT
3 1 360808-001 PUMP KIT
4 1 320336-003 RELIEF VALVE KIT
5 1 360808-002 MOTOR
6 1 360799 RESERVOIR KIT
7 1 320335-008 ELBOW FITTING
8 1 200545 BREATHER CAP
9 1 330630 SOLENOID
11-4.0.0 AW360798 4/99

ELECTRICAL SCHEMATIC
12-1.1.1 366801-1 2/2000

ELECTRICAL SCHEMATIC

50 1 REFERENCE VOLTAGE SWITCHING UNIT (360802-001)
51 3 300204 DIRECTIONAL CONTROL VALVE
52 1 320543 LOAD SENSOR ASSEMBLY
53 1 366999 RELAY BOX ASSEMBLY
54 2 360872 CONDUCTOR ASSEMBLY
55 1 360844-001 CONDUCTOR ASSEMBLY (WITH FEMALE TWECO)
56 3 CONDUCTOR ASSEMBLY (SUPPLIED WITH HOIST)
58 1 CONDUCTOR ASSEMBLY (SUPPLIED WITH POWER
UNIT)
60 3 642908 CONDUCTOR CORD
61 1 360857 POWER CABLE PLUG ASSEMBLY
63 6 FT 750736 CONVOLUTED LOOM
64 1 360844-002 CONDUCTOR ASSEMBLY (WITH MALE TWECO)
12-1.1.1
12-1.1.2 366801-1 2/2000
PENDANT
P/N 680050
12-3.0.0 680050 4/99

PENDANT
P/N 680050
1 1 - PENDANT HOUSING
2 1 - DECAL/COVER PLATE
3 6 - NUT
4 6 - TOGGLE BOOT
5 1 480567 HUBBELL CONNECTOR CORD GRIP
6 2 - CAPSCREW #10-24 NC x 3/4
7 2 - HEX LOCK NUT #10-24 NC
8 4 - TOGGLE DPDT SWITCH
9 1 - HOUSING BACK PLATE
10 4 - SELF THREADING ROUND HEAD SCREW #6 x 3/4
11 1 680041 BAYONET CABLE ASSEMBLY
12 6 - LOCK WASHER
14 4 636600 JUMPER
17 1 - TOGGLE SPDT SWITCH
18 1 - TOGGLE ON/OFF SWITCH
20 2 750737 CABLE TIE
21 1 - TRIGGER OPENING COVER
22 2 - PLASTIC 1/2” PLUG (see note 4)
NOTES:
1.Tie-off the following unused conductors with Item #20 inside of pendnat.
Blue w/ Red T Orange w/ Red T Black w/ White T
2. Before installing Item #21 (Cover), add RTV Sealant between cover & Pendant Housing.
3. Securely wrap unused power connector terminals (Ref. Item #19) with electrical tape; terminals
must be unwrapped when adding switches for options.
4. Item #22 (Plastic Plugs) are to be installed in any unused holes in Cover Plate Item #2.
5. Items 3, 4, 8, & 12 may be purchased as a REPLACEMENT DPDT SWITCH KIT using P/N
380005.
6. Items 3, 4, 12, & 18 may be purchased as a REPLACEMENT ON/OFF SWITCH KIT using P/N
380001.
7. Items 1, 2, 6, 7, 9, 10, 21, & 22 may be purchased as a REPLACEMENT HOUSING KIT using
P/N 380002.
8. Items 3, 4, 12, & 17 may be purchased as a REPLACEMENT SPDT KIT using P/N 380004.
12-3.1.0 680050 4/99

PENDANT
P/N 680008
12-4.0.0 aw680008 12/99

PENDANT
P/N 680008
3 6 - NUT
4 8 - TOGGLE BOOT
6 2 - CAPSCREW #10-24 NC x 3/4
12 6 - LOCK WASHER
14 4 636600 JUMPER
20 2 750737 CABLE TIE
NOTES:
1.Tie-off the following unused conductors with Item #20 inside of pendant.
Blue w/ Red T Orange w/ Red T Black w/ White T
380005.
380001.
6. Items 1, 2, 6, 7, 9, 10, & 21 may be purchased as a REPLACEMENT HOUSING KIT using
P/N 380002.
7. Items 3, 4, 12, & 17 may be purchased as a REPLACEMENT SPDT KIT using P/N 380004.
12-4.1.0 aw680008 12/99

PENDANT
P/N 680009
12-5.0.0 aw680009 12/99

PENDANT
P/N 680009
3 6 - NUT
4 6 - TOGGLE BOOT
6 2 - CAPSCREW #10-24 NC x 3/4
12 6 - LOCK WASHER
14 4 636600 JUMPER
20 2 750737 CABLE TIE
NOTES:
1.Tie-off the following unused conductors with Item #20 inside of pendant.
Blue with Red T Orange with Red T Black with White T
3. Securely wrap unused power connector terminals (Ref. Item #19) with electrical tape;
terminals must be unwrapped when adding switches for options.
380005.
380001.
P/N 380002.
8. Items 3, 4, 12,& 17 may be purchased as a REPLACEMENT SPDT KIT using P/N 380004.
12-5.1.0 aw680009 12/99
PENDANT
P/N 680010
12-6.0.0 aw680010 4/99

PENDANT
P/N 680010
3 6 - NUT
4 6 - TOGGLE BOOT
6 2 - CAPSCREW #10-24 NC x 3/4
8 4 - TOGGLE SWITCH DPDT
12 6 - LOCK WASHER
14 4 636600 JUMPER
17 - - -
20 2 750737 CABLE TIE
NOTES:
1. Before installing Item 21 (Cover), add RTV Sealant between cover & Pendant Housing.
2. Securely wrap unused power connector terminals (Ref. Item #19) with electrical tape; terminals must
be unwrapped when adding switches for options.
4. Items 3, 4, 8, & 12 may be purchased as a REPLACEMENT DPDT SWITCH KIT using P/N380005.
5. Items 3, 4, 12, & 18 may be purchased as a REPLACEMENT ON/OFF SWITCH KIT using P/N380001.
6. Items 1, 2, 6, 7, 9, 10, 21, & 22 may be purchased as a REPLACEMENT HOUSING KIT using P/N
380002.
12-6.1.0 aw680010 4/99

PENDANT
P/N 680021
12-7.0.0 aw680021 12/99

PENDANT
P/N 680021
3 6 - NUT
4 6 - TOGGLE BOOT
6 2 - CAPSCREW #10-24 NC x 3/4
8 4 - TOGGLE SWITCH DPDT
12 6 - LOCK WASHER
14 4 636600 JUMPER
17 - - -
20 2 750737 CABLE TIE
NOTES:
1. Tie-off the following unused conductors with Item 20 inside of pendant:

Blue with Red T Orange with Red T Black with White T
2. Before installing Item 21 (Cover), add RTV Sealant between cover & Pendant Housing.
380005.
380001.
12-7.1.0 aw680021 12/99

PENDANT
P/N 680021
P/N 380002.
aw680021 12/99
PENDANT CABLE ASSEMBLY
P/N 680041

1 1 366098 19 PIN BAYONET PLUG
2 1 480515 CABLE CLAMP
3 30' 480594 19 PIN CONDUCTOR CABLE
4 2 000101 RING TERMINAL #6 / 14-16 GA
5 13 002012 RING TERMINAL #6 / 18-22 GA
6 6" 490243 HEAT SHRINK TUBING x 6"
AW680041 3/98
12-8.0.0
TRAVELING BLOCK ASSEMBLY
P/N 360480

1 2 480362 SIDE PLATE
2 1 240236 SHEAVE ASSEMBLY
3 1 480364 LOWER TACKLE
4 1 480371 SWIVEL HOOK - 3 TON
5 1 480372 BOLT x 3 1/4 GR8 w/ GREASE ZERK
6 1 017800 LOCK NUT 1/2 NC
7 2 480367 BLOCK PIN
8 1 480368 SWIVEL HOOK PIN
9 3 360124 HITCH PIN
10 2 360480-100 MAXIMUM LOAD DECAL
13-1.0.0 AW360480 8/98

LOAD CHART 10-16-20 BOOM
MODEL 5005EH
14-1.0.0 AW340M 4/99

5005EH Hard Wired 999955 0200

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EFFECTIVE SERIAL NO.

SERIAL NO. __________________________

PO BOX 580697, TULSA, OK 74158-0697

WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL

WARNING! NEVER .............................

1-1.0.0 Intro 12/99

2-1.0.0 SafeTips 12/99

3 Operators shall be required by the employer to pass a CONDUCT OF OPERATORS

3-1.0.0 QUAL 7/98

3-1.1.0 QUAL 7/98

22 Cranes shall be operated so that no part of the crane minimum required

3-1.2.0 QUAL 7/98

G. electrical apparatus for malfunctioning, signs of

4-1.0.0 INSP 9/98

40 Hydraulic and pneumatic valves inspection. INSPECTION RECORDS

tested by or under the direction of an A. functional operating mechanism

4-1.2.0 INSP 9/98

3. broken or cut strands; 1. sections in contact with saddles, equalizer

4-1.3.0 INSP 9/98

G. In standing ropes, more than two broken wires in

ROPE MAINTENANCE 68 When an operating rope shows greater wear or well

4-1.3.0. INSP 9/98

PART NO.: 040579

PART NO.: 040580

PART NO.: 040632

PART NO.: 040517

PART NO.: 040587

PART NO.: 040519 USED ON: All cranes

5-1.3.0 Decal 12/99

7-1.1.0 AW-350-1 12/99

Suggested Boom Support:

7-2.0.0 AW726175 12/99

SHEAVE X SEALED BEARING, REPLACE IF ROUGH OR

ALL OTHER BOLTS X CHECK-TIGHTEN AS REQUIRED

EXTENSION X LUBE DETENT SPRING & BALL W/ WD-40

ROTATION X CHECK TORQUE TO 150 FT-LBS (DRY) AS

ROTATION GEAR X CHECK TORQUE TO 85 FT-LBS (DRY) AS

ROTATION GEAR X EP GEAR LUBE SAE 140

8-1.0.0 5005EHmtsc 4/99

8-1.1.0 5005EHmtsc 4/99

1.280 -90ºF 1 Checking belts for tightness on the charging

8-4.0.0. MAINTBAT 9/98

Low maintenance batteries should not be used on Replacing a Battery

8-4.1.0 MAINTBAT 9/98

Items to look for while inspecting the cables are:

WIRE LINE LUBRICATION

Lubrication of the wire line serves two important purposes:

9-1.0.0 WIRE 1/2000

10-3.0.0 aw360860 4/99

ITEM QTY P/N DESCRIPTION

10-3.1.0 aw360860 4/99

IF THE THREE FUNCTIONS, BOOM DOWN, HOIST UP AND

10-4.2.0 OVLD 1/99

10-4.3.0 OVLD 1/99

ITEM QTY P/N DESCRIPTION

ITEM QTY P/N DESCRIPTION

10-7.0.0 AW360467 9/98

11-1.0.0 HYD 12/99