Auto Crane 3203 PR, 3203 PRX, 3203 PRFX Owner's Manual

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3203 PR/PRX/PRFX

WNERS MANU

erial No. __________________

Mailing Address: P.O. Box 580697 Tulsa, OK 74158-0697 Physical Address: 4707 N. Mingo Rd. Tulsa, OK 74117-5904

Phone 1-800-777-2760 Fax (918) 269-6688 http://www.autocrane.com

OM-320950000-0-%

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Product Registration Rev 05152014

Auto Crane Registration

From: Date:

End User Information:

Company: Phone:

Address:

City: State: Zip:

Contact: E-mail:

Distributor Information:

Company: Phone:

Address:

City: State: Zip:

Contact: E-mail:

Product Information:

Model No: Serial No: Date Delivered:

VIN #:

ONE REGISTRATION FORM PER UNIT (CRANE, BODY, OR COMPRESSOR)

Please submit form within 15 days after installation

Online:

www.autocrane.com | Resources | Warranties

Fax: 918-234-2177

Mail: Product Registration, Auto Crane Company, PO Box 580697, Tulsa, OK 74158-0697

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WARNINGS

WARNING! Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of a vehicle certify that

hicle complies with all applicable federal regulations. Any modifications performed on the vehicle

the v prior to the final state 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. SEE DANGER DECAL (P/N 040529) in this Owner’s Manual.

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

♦ EXCEED load chart capacities (centerline of rotation to hoist hook). ♦ Un-reel last 5 wraps of cable from drum! ♦ Wrap cable around load! ♦ Attempt to lift or drag a load from the side! The boom can fail far below its rated capacity. ♦ Weld, modify, or use unauthorized components on any Auto Crane unit! This will void any warranty or

liability. Also failure of the crane may result.

♦ Place a chain link on the tip of the hook and try to lift a load! ♦ Use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing,

thus negating the safety feature!

♦ 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 for use 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 the crane is equipped with this type of device.

READ THIS PAGE

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3203 PR/PRX/PRFX

TABLE O

INTRODUCTION ……………………………………………………………… 1

GENERAL SPECIFICATIONS ……………………………………………………………… 3

SAFETY TIPS AND PRECAUTIONS ……………………………………………………………… 4

OPERATING PRACTICES & WARNINGS ……………………………………………………………… 6

QUALIFICATIONS FOR OPERATORS ……………………………………………………………… 7

OPERATION OF UNIT / OUTRIGGERS ……………………………………………………………… 11

INSPECTION ……………………………………………………………… 12

TESTING ……………………………………………………………… 15

MAINTENANCE ………………………………………………

BATTERIES ……………………………………………………………… 18

LUBRICATION AND MAINTENANCE SCHEDULE ……………………………………………………………… 20

SINGLE LINE PROCEDURE ……………………………………………………………… 22

ROTATION BEARING REPLACEMENT ……………………………………………………………… 23

SAFETY DECAL SECTION ……………………………………………………………… 24

F CONTENTS

……………… 16

GENERAL DIMENSIONS ……………………………………………………………… 31

MOUNTING AND INSTALLATION ……………………………………………………………… 32

GENERAL ASSEMBLY, HARDWIRED ……………………………………………………………… 3

PEDESTAL ASSEMBLY ……………………………………………………………… 40

BOOM ASSEMBLY ……………………………………………………………… 52

HOIST ASSEMBLY ……………………………………………………………… 49

TRAVELING BLOCK ASSEMBLY ……………………………………………………………… 63

RELAY PANEL ASSEMBLY ……………………………………………………………… 65

ELECTRICAL SECTION, HARDWIRED ……………………………………………………………… 66

PENDANT ASSEMBLY ……………………………………………………………… 68

TWECO W/SWITCH MOUNT ……………………………………………………………… 71

HYDRAULIC SECTION ………………………………………………………

POWER UNIT ……………………………………………………………… 75

GENERAL ASSEMBLY, FM ……………………………………………………………… 76

FM CONTROL USE & CARE ……………………………………………………………… 82

TRANSMITTER ASSEMBLY, FM ……………………………………………………………… 83

……… 72

ELECTRICAL SECTION, FM ……………………………………………………………… 85

FM, DIAGNOSTICS, TROUBLESHOOTING, AND ID PROG. ……………………………………………………………… 86

LOAD CHART …………

CONVERSION TO SINGLE LINE ................................................................ 95

…………………………………………………… 94

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3203PR/PRX

INT

Auto Crane products are designed to provide

y years of safe, trouble-free, dependable

ma service when properly used and maintained.

To assist you in obtaining the best service from your crane and to avoid untimely crane and/or vehicle failure, this manual provides the following operating and service instructions. It is specifically recommended that all operating and service personnel consider this manual as mandatory material for reading and study before operating or servicing Auto Crane products. It is highly recommended that crane owners, equipment managers, and supervisors also read this manual.

Auto Crane has incorporated several safety features in the 3203 PR/PRX crane for your protection.

For your convenience the overall dimensions of the 3203 PR/PRX crane are included on the General Dimension Drawing. Rotation and turning radius are also listed on that drawing.

Remember, the crane adds weight to the vehicle. Adding weight may change the driving and riding characteristics of the vehicle unless the appropriate overload spring(s) are installed on the truck. The payload of the vehicle is reduced by the weight of the crane. The operator should exercise care when loading the vehicle. Distributing the payload on the vehicle evenly will greatly improve the driving and riding characteristics of the vehicle.

Auto Crane Company issues a limited warranty certificate with each unit sold. See last page for warranty.

The 3203 PR/PRX cranes are attached to your truck electrical system through the Main Power Switch provided. The 3203 PR/PRX is another highly efficient Auto Crane product. The use of a maintenancefree battery is not recommended on any Auto Crane product. The recommended alternator and battery

RODUCTION

that will give the longest life with the most useful d

ty cycle is a 125-amp alternator with a 500 cold

u cranking amp battery. These specifications should be considered minimum. It has always been Auto Crane Company policy to handle all warranty claims we receive as promptly as possible. If a warranty claim involves discrepant material or workmanship, Auto Crane will take immediate corrective action. It is understandable that Auto Crane Company cannot assume responsibility of liability when it is obvious that our products have been abused, misused, overloaded or otherwise damaged by inexperienced persons trying to operate the equipment without reading the manual.

Auto Crane will not assume responsibility or liability for any modifications or changes made to unit, or installation of component parts without authorization.

Auto Crane maintains a strong distributor network and a knowledgeable Customer Service Department. In most cases, an equipment problem is solved via phone conversation with our customer service department. The customer service department also has the ability to bring a local distributor, a regional sales manager, or a factory serviceman into the solution of an equipment problem.

If, through no fault of Auto Crane Company, it is necessary to send an experienced factory serviceman on a field service call the rates stated in the Auto Crane Distributor’s Flat Rate Manual will apply.

Auto Crane Company’s extensive Research and Development Program allow our customers to use the best equipment on the market. Our Engineering Staff and our knowledgeable sales people are always available to our customers in solving crane and winch-type application problems. When in doubt, call the Auto Crane factory.

Note: This manual should remain with the crane at all times.

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3203PR/PRX

INT

DISTRIBUTOR ASSISTANCE :

uld you require any assistance not given in

ho this manual, we recommend that you consult your nearest Auto Crane Distributor. Our distributors sell authorized parts and have service departments that can solve almost any needed repair. This manual does not cover all maintenance, operating, or repair instructions pertinent to all possible situations. If you require

additional information, please contact the Auto Crane Company at the following telephone number: (918) 836-0463. The information

contained in the manual is in effect at the time of this printing. Auto Crane Company reserves the right to update this material without notice or obligation.

RODUCTION

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LIFTING CAPACITIES

Ō lbs Ō lbs

2 3,200 9 1,100 3 3,200 10 1,000 4 2,500 11 900 5 2,000 12 830 6 1,670 13 770 7 1,500 14 710 8 1,250 15 660

3203PR/PRX

NERAL SPECIFICATIONS

DIMENS

Height: 24.00 in (0.61 m)

Length: 9 ft 1-1/2 in (2.78 m)

[boom(s) stored]

Weight: 860 lbs (390kg)

CAPACITY

IONS

th: 21 in (0.53 m)

10,000 ft-lbs (1.38

[ft-lbs = horizontal distance from centerline

of rotation to free hanging weight (feet) x

amount of weight (pounds)]

tt-m)

REACH

cond boom will reach from 7 feet 4

e inches to 11 feet 4 inches. Third boom will reach from 11 feet 4 inches to 15 feet 4 inches.

CABLE

62 ft (18.9) of 7/32 in (5.56 mm) di aircraft quality cable. This cable has a single line breaking strength of 5,600 lbs (2,540 kg).

ameter

CHASSIS REQUIREMENTS

201,600 in-lbs (22,777 N 8,800 LBS (3,992 kg.) GVWR minimum

m) RBR minimum

ELECTRICAL SYSTEM REQUIREMENTS

ltage: 12 VDC

Alternator: 125 amp (minimum)

Battery: 130 minute reserve

capacity (minimum)

Maintenance type

ROTATION

360º Co

ntinuous

TANK OIL CAPACITY

2.4 GALLO

NS (9.08 LITERS)

Page 12

- IMPORTANT ---

SAFETY TIPS AND PRECAUTIONS

o unqualified or unauthorized person shall be

1. N

allowed to operate the crane.

2. WARNING: N

unauthorized components / parts on any Auto Crane unit. This will void any warranty or liability. Also, failure of the crane may result.

ake certain the vehicle meets minimum chassis

requirements. (These requirements do not guarantee unit stability.)

4. Make certain the crane is installed per factory

specifications. Contact your local distributor or the Auto Crane factory if any questions arise.

5. Visual inspections and tests should be conducted at

the beginning of each shift each day to insure that the crane and all its operating systems are in good condition and working order before it is used.

6. Inspect hydraulic hoses frequently for signs of

deterioration, and replace them as required.

7. If a hydraulic break occurs, leave the area of the

break and do not attempt to stop the break by hand as the hydraulic oil may be hot and under high pressure which can cause serious injury. Shut the system down as soon as possible.

8. Check the hook at least every thirty days for

distortions or cracks and replace it as required.

9. Oil gears as required.

10. Stop all operations when cleaning, adjusting or lubricating the machine.

11. Keep dirt and grit out of moving parts by keeping crane clean. Make sure machine is free of excess oil, grease, mud and rubbish, thus reducing accidents and fire hazards.

12. When a new cable is installed, operate first with a light load to let the cable adjust itself.

13. Locate the vehicle at the work site for the best stability possible.

14. Keep the vehicle in a level position while loading or unloading.

15. Observe operating area for obstructions and/or power lines that might be a hazard.

ver weld, modify, or use

16. WARNING: NEVER OPERATE THE CRANE

NEAR ELECTRICAL POWER LINES. A

Crane Company recommends that the crane never be any closer to a power line (including telephone lines) than 10 feet at any point.

ow the vehicle engine to warm up before

17. Al operating crane.

18. Know the weight of your rigging and load to avoid overloading the crane.

19. Deduct the weight of the load handling equipment from the load rating to determine how much weight can be lifted.

20. All load ratings are based on crane capacity, NOT the vehicle stability. Remember in lifting a heavy load, the weight can create enough tipping moment to overturn the vehicle

21. Always comply with load chart capacities, (centerline of rotation to hook).

22. Secure all loads before lifting.

23. Always set the emergency brake before beginning operation.

24. Keep objects and personnel clear of crane path during operation.

25. Operate control levers slowly and smoothly in order to meter oil flow for safe operation. (Not applicable to electric-hydraulic cranes.)

26. Always extend the outriggers from vehicle to the ground before crane operation. Insure that they are firmly positioned on solid footings. Stand clear of outriggers while they are being extended.

27. If any outrigger, when extended, rests on a curb or other object that prevents it from extending to its maximum distance, shorten bearing or fulcrum point and reduce the maximum load accordingly.

28. When an outrigger will not reach the ground due to holes or grades, it shall be blocked up to provide level and firm support for the truck.

29. When working in soft earth, use wide pads under outrigger feet to prevent sinking.

30. Always store outriggers before transportation.

WARNING!

Auto Crane Company cranes are not designed or intended for use in lifting or moving persons. Any such use sha

ll be considered to be improper and the seller shall not be responsible for any claims arising there from. This sale is made with the express understanding that there is no warranty that the goods shall be fit for the purpose of lifting or moving persons or other improper use and there is no implied warranty or responsibility for such purposes.

Page 13

--- IMPORTANT ---

SAF

31. Alway

32. Remember the overall height of the entire

33. Disengage power takeoff (PTO) before

34. Always walk around the vehicle before

35. Never drive with a load suspended from

36. Do not take your eyes off a moving load.

37. Never swing a load over people.

38. Do not stop the load sharply in midair so

39. Crane boom length should be kept as

40. Keep the load directly and vertically under

s store the crane in its stowed position for

transportation.

for garage door clearance or when moving under objects with low overhead clearance

moving the vehicle. (Not applicable to electric-hydraulic cranes.)

moving.

crane.

Look in the direction you are moving.

that it swings like a pendulum. Meter the control levers to avoid this situation.

(Not applicable to electric-hydraulic cranes.)

short as possible for maximum lifting capacity and greater safety. Longer booms require additional care in accelerating and decelerating the swing motion, and thus slow down the working cycle and reduce productivity.

the boom point at all times. Crane booms are designed to handle vertical loads, not side lifts.

ETY TIPS AND PRECAUTIONS

unit

WARNING: Never attempt to lift, drag, tow or

pull a load from the side. The boom can fail far below its rated capacity.

o no

41. D

42. Do not lift personnel with any wire rope

43. WARNING: In us

44. WARNING: Ne

45. WARNING: Ne

46. Do no

47. WARNING: Ne

t push down on anything with boom extensions; similarly do not lift anything with boom extensions.

attachment or hook. There is no implied warranty or responsibility for such purposes.

ing a safety hook, ALWAYS close the hook throat before lifting a load. Proper attention and common sense applied to the use of the hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.

ver place a chain link on the tip of the hook and try to lift a load with the hoist.

ver use a sling bar or anything larger than the hook throat which could prevent the safety latch from closing, thus negating the safety feature.

t wrap the wire rope around sharp

objects when using winch.

ver unreel last 5 wraps of cable from drum.

Page 14

--- IMPORTANT ---

ERATING PRACTICES AND WARNINGS

ake certain the vehicle meets minimum chassis

1. M requirements. (These requirements do not guarantee unit stability)

2. Make certain the crane is installed per factory specifications. Contact your local Distributor or the Auto Crane factory if any questions arise.

3. Keep the vehicle in as level a position as possible while loading or unloading.

4. ALWAYS set the vehicle emergency brake before beginning crane operations.

5. ALWAYS use outriggers from vehicle to the ground during crane operation. Make sure they are firmly positioned on solid footings.

6. All load ratings are based on crane capacity, NOT truck/ crane stability.

7. Keep objects and personnel clear of crane path during operation.

8. Keep hoist cable pulled tight at all times.

9. REMEMBER, in lifting a heavy load, the weight can create enough tipping momentum to overturn the vehicle.

10. ALWAYS keep load as close to ground as possible.

11. Hydraulic hoses need to be inspected frequently for signs of deterioration, and be replaced as required.

12. The hoist hook is an important item that an operator should consider and use properly. It should be checked on a daily basis for distortion or cracks.

13. ALWAYS store outriggers before road travel.

ARNING! NEVER OPERATE THE CRANE NEAR

14. W

LECTRICAL 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.

15. WARNING! NEVER EXCEED load chart

capacities (centerline of rotation to hoist hook).

16. WARNING! NEVER un-reel last 5 wraps of cable

from drum!

17. WARNING! NEVER wrap cable around load!

18. WARNING! NEVER attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.

19. WARNING! NEVER 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.

20. WARNING! NEVER place a chain link on the tip of the hook and try to lift a load!

21. WARNING! NEVER use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature!

22. WARNING! In using a hook with latch, ALWAYS insure 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! NEVER hold any Control Select Switch

on that will cause unsafe operating conditions!

WARNING!

o Crane Company remote controlled, stiff boom cranes are not designed or

A intended for use on any applications involving the lifting or moving of personnel.

Page 15

QUALIFICATIONS FOR AND CONDUCT OF

ERATORS AND OPERATING PRACTICES

REFERENCE A

ERATORS

1. C

rane operation shall be limited to personnel

ith the following minimum qualifications:

A. Designated persons.

B. Trainees under the direct supervision of a

designated person.

C. Maintenance and test personnel (when it is

necessary in the performance of their duties).

D. Inspectors (crane).

2. No one other than the personnel specified above

shall enter the operating area of a crane with the exception of persons such as oilers, supervisors, and those specified persons authorized by supervisors whose duties require them to do so and then only in the performance of their duties and with the knowledge of the operator or other persons.

SME B30.5a AND OSHA 1910.180 FOR COMPLETE QUALIFICATION

QUALIFICATIONS FOR OPERATORS

erators shall be required by the employer to pass

1. Op a practical operating examination. Qualifications shall be limited to the specific type of equipment for which examined.

2. Operators and operator trainees shall meet the

following physical qualifications:

A. Vision of at least 20/30 Snellen in one eye and

20/50 in the other, with or without corrective lenses.

B. Ability to distinguish colors, regardless of

position, if color differentiation is required for operation.

C. Adequate hearing with or without hearing aid

for the specific operation.

3. Evidence of physical defects or emotional

instability, which render a hazard to operator or others, which in the opinion of the examiner could interfere with the operator’s performance, may be sufficient cause for disqualification. In such cases, specialized clinical or medical judgment and tests may be required.

4. Evidence that operator is subject to seizures or loss

of physical control shall be sufficient reason for disqualification. Specialized medical

REQUIREMENTS

tests may be required to determine these conditions.

5. Operators and operator trainees should have normal

depth perception, coordination, and no tendencies to dizziness or similar undesirable characteristics.

6. In addition to the above listed requirements, the

operator shall:

A. Demonstrate the ability to comprehend and

B. Posses the knowledge of emergency procedures

C. Demonstrate to the employer the ability to

D. Be familiar with the applicable safety regulations.

E. Understand the operating procedures as outlined

F. Be thoroughly familiar with the crane and its

G. Understand the operating procedures as outlined

CONDUCT OF OPERATORS

1. The o

will divert his attention while actually operating the crane.

2. Each operator shall be responsible for those operations

under the operator’s direct control. Whenever there is any doubt as to safety, the operator shall consult with the supervisor before handling the loads.

3. The operator should not leave a suspended load

unattended unless specific precautions have been instituted and are in place.

4. If there is a warning sign on the switch or engine

starting controls, the operator shall not close the switch or start the engine until the warning sign has been removed by the appointed person.

5. Before closing the switch or starting the engine, the

operator shall see that all controls are in the “OFF”

interpret all labels, operator’s manuals, safety codes, and other information pertinent to correct crane operations.

and implement it.

operate the specific type of equipment.

by the manufacturer.

control functions.

by the manufacturer.

perator shall not engage in any practice, which

Page 16

QUALIFICATIONS FOR AND CONDUCT OF

ERATORS AND OPERATING PRACTICES

or neutral position and all personnel are in the clear.

f power fails during operation, the operator shall:

A. Move power controls to the “OFF” or neutral

position.

B. Land the suspended load and boom, if practical.

7. The operator shall be familiar with the

equipment and its proper care. If adjustments or repairs are necessary, the operator shall report the same promptly to the appointed person, and shall also notify the next operator.

8. The operator at the start of each shift shall test all

controls. If any controls do not operate properly, they shall be adjusted or repaired before operations are begun.

9. Stabilizers shall be visible to the operator while

extending or setting unless a signal person assists operator.

OPERATING PRACTICES/HANDLING THE LOAD

ize of load.

1. S

A. No crane shall be loaded beyond the rated load

except for test purposes.

B. The load to be lifted is to be within the rated load

of the crane and its existing configuration.

C. When loads that are not accurately known are

to be lifted, the person responsible for the job shall ascertain that the weight of the load does not exceed the crane rated load at the radius at which the load is to be lifted.

2. Attaching the load.

A. The load shall be attached to the hook by means

of slings or other devices of sufficient capacity.

B. Hoist rope shall not be wrapped around the load.

3. Moving the load.

The operator shall determine that:

A. The crane is level and, where necessary, the

vehicle/carrier is blocked properly.

B. The load is well secured and balanced in the

sling or lifting device before it is lifted more than a few inches.

C. Means are provided to hold the vehicle

stationary while operating the crane.

D. Before starting to lift, the hook shall be

positioned over the load in such a manner as to minimize swinging.

E. During lifting care shall be taken that:

1. There is no sudden acceleration or

deceleration of the moving load.

2. Load, boom or other parts of the crane do

not contact any obstruction.

F. Cranes shall not be used for dragging loads

sideways.

G. This standard recognizes that telescopic boom

cranes are designed and intended for handling materials. They do not meet personnel lift or elevator requirements. Therefore, no lifting, lowering, swinging or traveling shall be done while a person is on the hook or load. Hook attached suspended work platforms (baskets) shall not be used with cranes covered by this standard. Crane manufacturer must approve work platforms attached to the boom.

H. The operator should avoid carrying loads over

people.

I. When the crane is so equipped, the

stabilizers shall be fully extended and set. Blocking under stabilizers shall meet the requirements as follows:

1. Strong enough to prevent crushing.

2. Of such thickness, width and length as

to completely support the stabilizer pad.

J. Firm footing under all tires, or individual

stabilizer pads should be level. Where such a footing is not otherwise supplied, timbers, cribbing, or other structural members to distribute the load so as to not exceed allowable bearing capacity or the underlying material should provide it.

K. In transit, the boom shall be carried in stowed

position.

L. When rotating the crane, sudden starts and

stops shall be avoided. Rotational speed shall be such that the load does not swing out beyond the radius at which it can be controlled.

M. The crane shall not be transported with a

load on the hook unless recommended by the manufacturer.

Page 17

QUALIFICATIONS FOR AND CONDUCT OF

ERATORS AND OPERATING PRACTICES

o person should be permitted to stand or

N. N

pass under a suspended load.

4. Stowing procedure.

Follow the manufacturer’s procedure and sequence when stowing and un-stowing the crane.

MISCELLANEOUS

ERATING NEAR ELECTRICAL POWER

O LINES

3. Caution shall be exercised when working near overhead

lines, because they can move horizontally or vertically due to wind, moving the danger zone to new positions.

4. In transit with no load and boom lowered the clearance

shall be specified in Table 1.

5. 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 are allowed, if approved

by the administrative or regulatory authority provided the alternate procedure insures equivalent protection and is 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.

1. Cranes shall be operated so that no part of the crane

r load enters into the danger zone shown above.

EXCEPTIONS

A. The danger zone may be entered after

nfirmation by an appointed person that the

co electrical distribution and transmission lines have been de-energized and visibly grounded at the point of work; or

B. The danger zone may be entered if insulating

barriers (not a part of nor an attachment to the crane) have been erected to prevent physical contact with the lines.

2. For lines rated 50 kV or below, minimum clearance

between the lines and any part of the crane or load (including handling appendages) shall be 10-ft. (3m). For higher voltages, see Table 1.

BLE 1

minimum required

__clearance____

normal voltage, kV

phase to phase) ft (m)

(

when operating near high voltage power lines

over to 50 10 (3.50)

er 50 to 200 15 (4.6)

ov over 200 to 350 20 (6.1) over 350 to 500 25 (7.62) over 500 to 750 35 (10.67) over 750 to 1000 45 (13.72)

while in transit with no load and boom lowered

ov e r to 0.75 4 ( 1 . 2 2 ) ov er 0.75 t o 50 6 (1.83) ov e r 50 to 345 10 (3.83) ov e r 345 to 750 16 (4.87) over 750 to 1000 20 (6.1)

Page 18

RANGE - SMALL EH CRANES

RECO

MMENDED OPERATING TEMPERATURE

OIL TEMPERATURE

200° F (93.3°C)

180° F (82.2°C)

160° F (71.1° C) 140° F (60° C)

120° F (48.9°C)

100° F (37.8°C)

80° F (26.7° C)

60° F (15.6° C)

40° F (4.4°C)

20° F (-6.6°C)

0° F (-17.8 C)

-20° F (-28.9° C)

-40° F (-40°C)

5W20 ANTI-WEAR

AULIC OIL OR

HYDR

EQUIVALENT

HySyn ISO32 SYNTHETIC

HYDRAULIC OIL OR

EQUIVALENT

NOTES

1. In applications where low oil temperatures may exist (below -20°F), an ex ternal heating system may be required.

2. A symptom of excessively low temperatures is hydraulic motor operation but

no fluid flow from tank.

CAUTION! HYDRAULIC RESERVOIR OIL TEMPERATURE MUST NOT EX CEED

180°F OR DAMAGE TO CRANE MAY OCCUR. THIS MAY AFFECT

CRANE WARRANTY

Page 19

--- IMPORTANT ---

ERATION OF UNIT

ake sure this manual has been thoroughly read

1. M by all crane operating personnel and supervisors.

2. A routine inspection of the crane should be mandatory before each operating day. Any defects should be corrected immediately.

3. At a job site the vehicle should be positioned so that the crane can adequately reach the load within the rated capacity (centerline of rotation to hoist hook).

4. Keep the vehicle as level as possible during operation.

5. For electric cranes, engage emergency brake and leave ignition on with transmission in neutral (or in park for automatic transmissions). Activate any crane power switches. For Auto Crane units requiring battery and hydraulic operation, engage emergency

brake, place gear selector in neutral, press clutch,

activate PTO, release clutch and, after hydraulic fluid is warm, set throttle control to proper engine speed.

6. Always use outriggers from the truck to the ground. Be sure these are firm and adequately positioned. When rotating, keep load as low to the ground as possible.

7. Remove the transmitter from cab or storage area. Power transmitter on. Detach hook from dead man. Crane is now ready for operation.

OPERATION OF

8. Always boom up before rotating so the boom will clear

the required boom support.

9. When extending the boom, always maintain clearance between the boom crown and the traveling block or hoist hook.

10. Always observe safe and practical operation to avoid possible accidents. Refer to Safety Tips and Precautions.

11. After completing lifting operations, return the boom to stowed position on the boom support. Avoid unneeded pressure on the boom support.

12. Store transmitter in proper location (in cab or storage area).

13. Return outriggers to stowed position. Make sure they are pinned in place or jacklegs are returned to compartment.

14. Check work area for any tools or equipment not stored.

15. Release throttle control, depress clutch and disengage PTO. Deactivate any crane power switches.

16. Report any unusual occurrence during crane operation that may indicate required maintenance or repair.

17. NEVER use two cranes to support a load too large for either crane.

HYDRAULIC OUTRIGGERS

1. Shift crane/outrigger control valve to utrigger” position.

“o

2. Operate the outrigger control valves to

position the outriggers.

3. After outriggers are positioned, return

crane/outrigger selector to “crane” position.

4. Crane is now ready to operate.

TRIGGERS

MANUAL OUTRIGGERS

1. Pull lock pins to release jackleg or drop wn outrigger and move to outermost lock

do position.

2. Make sure lock pins are reinstalled

properly.

3. Lower outrigger pad to firm ground and

adjust foot to take out slack.

4. Crane is now ready to operate.

Page 20

INSPECTION

QUIREMENTS

REFERENCE A

ECTION CLASSIFICATION

INS

nitial inspection.

Prior to initial use, all new, altered, modified or extensively repaired cranes shall be inspected by a designated person to insure compliance with provisions of this standard.

2. Regular inspection.

Inspection procedure for cranes in regular service is divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the components of the crane and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as “frequent” and “periodic” with respective intervals between inspections as defined below.

A. Frequent inspection - daily or before each use

B. Periodic inspection - one to twelve-month

intervals or as specifically recommended by the manufacturer or qualified person.

DESIGNATED PERSONNEL SHALL

RFORM INSPECTIONS ONLY.

SME B30.5a AND OSHA 1910.180 FOR COMPLETE INSPECTION REQUIREMENTS

FREQUENT INSPECTION

pections should also occur during operation for

Ins any deficiencies that might appear between regular inspections. Any deficiencies, such as those listed below, shall be carefully examined and a determination made as to whether they constitute a hazard:

1. Inspect control mechanisms for maladjustment that

interferes with proper operation.

2. Inspect control mechanisms for excessive wear of

components and contamination by lubricants or other foreign matter.

3. Inspect safety devices for malfunction.

4. Visually inspect all hydraulic hoses, particularly

those that flex in normal operation of crane functions.

5. Inspect hooks and latches for deformation, chemical

damage, cracks, and wear. Refer to ANSI/ASME B30.10.

6. Inspect for proper rope reeving.

7. Inspect electrical wiring and components for

malfunctioning, signs of excessive deterioration, dirt and moisture accumulation.

8. Inspect hydraulic system for proper oil level and leaks.

9. Inspect tires for recommended inflation pressure, cuts

and loose wheel nuts.

10. Inspect connecting pins and locking device for wear

damage and loose retaining bolts.

11. Inspect rope for gross damage, such as listed below,

which may be an immediate hazard.

A. Distortion such as kinking, crushing, un stranding,

birdcaging, main strand displacement, or core protrusion. Loss of rope diameter in a short length or unevenness of outer strands should be replaced.

B. General corrosion.

C. Broken or cut strands.

D. Use care when inspecting sections of rapid

deterioration around flange points, crossover points, and repetitive pickup points on drums.

E. Inspect number, distribution, and type of visible

broken wires. Reference Rope Maintenance section in the owner’s manual.

Continued use of rope depends upon good judgment by a designated person in evaluating remaining strength in a used rope after allowance for deterioration disclosed by inspection. Continued rope operation depends upon this remaining strength.

Page 21

INSPECTION

QUIREMENTS

ODIC INSPECTION

PERI

Any deficiencies, such as those listed below, shall be c

refully examined and determination made as to

whether they constitute a hazard:

1. Inspect for deformed, cracked or corroded members in

the crane structure and entire boom.

2. Inspect for loose bolts, particularly mounting bolts.

3. Inspect for cracked or worn sheaves and drums.

4. Inspect for worn, cracked, or distorted parts such

as pins, bearings, shafts, gears, rollers and devices.

5. Inspect for excessive wear on brake and clutch system

parts and lining.

6. Inspect crane hooks for cracks.

7. Inspect travel steering, braking, and locking devices

for malfunction.

8. Inspect for excessively worn or damaged tires.

9. Inspect hydraulic hose, fittings, and tubing for the

following problems:

A. Evidence of leakage at the surface of the flexible

hose or its junction with metal and coupling.

B. Blistering, or abnormal deformation to the outer

covering of the hydraulic or pneumatic hose.

C. Leakage at threaded or clamped joints that

cannot be eliminated by normal tightening or recommended procedures.

D. Evidence of excessive abrasion or scrubbing on

the outer surface of a hose, rigid tube, or fitting. Means shall be taken to eliminate the interference of elements in contact or otherwise protect the components.

10. Inspect hydraulic pumps and motors for the following problems:

A. Loose bolts and fasteners.

B. Leaks at joints between sections.

C. Shaft seal leaks.

D. Unusual noises or vibrations.

E. Loss of operating speed.

F. Excessive heating of the fluid.

G. Loss of pressure.

11. Inspect hydraulic valves for the following problems:

A. Cracks in valve housing.

B. Improper return of spool to neutral position.

C. Leaks at spools or joints.

D. Sticking spools.

E. Failure of relief valves to attain or maintain

correct pressure setting.

F. Relief valve pressure shall be checked as specified by the

manufacturers.

12. Inspect hydraulic cylinders for the following problems:

A. Drifting caused by fluid leaking across piston.

B. Rod seals leaking.

C. Leaks at welding joints.

D. Scored, nicked, or dented cylinder rods.

E. Damaged case (barrel).

F. Loose or deformed rod eyes or connecting joints.

13. Inspect hydraulic filters for evidence of rubber particles on the filter elements indicating possible hose, O ring, or other rubber component deterioration. Metal chips or pieces on the filter may denote failure in pumps, motors, or cylinders. Further inspection will be necessary to determine the origin of the problem before corrective action can be taken.

14. Inspect labels to confirm correct location and legibility. Reference decal layout in this manual for proper location of decals.

15. Rope Inspections need not be at equal calendar intervals and

should be more frequent as the rope approaches the end of useful life.

A qualified person shall inspect the wire rope based

on such factors as:

A. Expected rope life as determined by experience on the

particular installation or similar installations.

B. Severity of environment.

C. Percentage of capacity lifts.

D. Frequency rates of operation.

E. Exposure to shock loads.

This inspection shall cover the entire length of the rope. Only the surface wires need to be inspected and no attempt should be made to open the rope. Any deterioration resulting in appreciable loss of original strength shall be noted and determination made as to whether use of the rope would constitute a hazard. A few notable deterioration points are listed below:

Page 22

INSPECTION

QUIREMENTS

eduction of rope diameter below nominal

A. R

diameter due to loss of core support.

B. Internal or external corrosion.

C. Wear of outside wires.

D. Severely corroded, cracked, bent, worn, or

improperly applied connections.

CRANES NOT IN REGULAR USE

ne, which has been idle for a period of over one

A cra month or more, shall be given an inspection conforming to the “initial” and “regular” inspection requirements of this section.

INSPECTION RECORDS

ted records of periodic inspection should be made

Da on critical items such as brakes, crane hooks, rope, cylinders, and relief pressure valves.

Page 23

TESTING

QUIREMENTS

REFERENCE A

TESTING SHALL BE PERFORMED BY DESIGNATED PERSONNEL ONLY.

or to initial use, all new, altered, modified, or extensively repaired cranes shall be tested for compliance with

P the operational requirements of this crane.

Test requirements:

1. Test all functions to verify speed and operation.

2. Check that all safety devices are working properly.

3. Confirm operating controls comply with appropriate function labels.

4. Test loads shall not exceed 110% of the manufacturer’s load rating.

5. Written reports shall be maintained showing test procedures and confirming the adequacy of repairs.

SME B30.5a AND OSHA 1910.180 FOR COMPLETE TESTING REQUIREMENTS

Page 24

GENERAL

PAIRS AND MAINTENANCE

REFERENCE A

SME B30.5a AND OSHA 1910.180 FOR COMPLETE MAINTENANCE AND REPAIR

REQUIREMENTS

A preventative maintenance program should be

blished based on this section and all replacement

es parts should be obtained from AutoCrane Company. For

replacement parts contact your local authorized distributor.

MAINTENANCE PRECAUTIONS

lace crane where it will cause the least interference

1. P

with other equipment or operations.

2. Verify all controls are in the “off” position and all

operating features secured from inadvertent motion by brakes, pawls, or other means.

3. The means for starting the crane shall be rendered

inoperative.

4. The boom should be secured in place before

maintenance.

5. Relieve hydraulic oil pressure from all hydraulic circuits

before loosening or removing hydraulic components.

6. Warning or “OUT OF ORDER” signs shall be placed on

all crane controls.

7. After adjustments and repairs have been made,

the crane shall not be returned to service until all guards have been reinstalled, trapped air removed from hydraulic system (if required), safety devices reactivated, and maintenance equipment removed.

ADJUSTMENTS AND REPAIRS

ny hazardous conditions disclosed by the inspection

1. A

requirements shall be corrected before operation of crane is resumed. Only designated personnel shall do adjustments and repairs.

2. Adjustments shall be maintained to assure correct

functioning of components, the following are examples:

A. Functional operating mechanism.

B. Safety devices.

C. Control systems.

3. Repairs or replacements shall be provided as needed

for operation, the following are examples:

A. Critical parts of functional operating mechanisms

which are cracked, broken, corroded, bent, or excessively worn.

B. Critical parts of the crane structure which are

cracked, bent, broken, or excessively corroded.

C. Crane hooks showing cracks, damage, or corrosion

shall be taken out of service. Repairs by welding are not recommended.

4. If bleeding the hydraulic system is required, run each

crane function until smooth operation of that particular function is noticeable.

LUBRICATION

ving parts of the crane, for which lubrication

All mo is specified, should be regularly lubricated per the manufacturer’s recommendations and procedures.

Reference Lubrication and Maintenance Schedule in this manual.

ROPE REPLACEMENT

precise rules can be given for determination of the exact

No time for replacement of rope, since many variable factors are involved.

1. Conditions such as the following shall be reason for

questioning continued use of the rope or increasing the frequency of inspection:

A. In running ropes, six randomly distributed broken

wires in one lay or three broken wires in one strand in one lay.

B. One outer wire broken at the contact point with the

core of the rope structure and protrudes or loops out of the rope structure. Additional inspection of this section is required.

C. Wear of one third of the original diameter of the

outside individual wire.

D. Kinking, crushing, bird caging, or any other

damage resulting in distortion of the rope structure.

E. Evidence of any heat damage from any cause. F.

Reduction from nominal diameter of more than

1/64 in. (0.4mm) for diameters up to and including 5/16 in. (8 mm), 1/32 in. (0.8 mm) for diameter 3/8 in. (9.5 mm) to and including 1/2 in. (13 mm), 3/64 in. (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 diameter 7/8 in. (22

mm) to and including 11/8 in. (29 mm), 3/32 in.

Page 25

GENERAL

PAIRS AND MAINTENANCE

(2.4 mm) fo including 11/2 in. (38 mm).

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

one lay in sections beyond end connections or more than one broken wire at an end connection.

2. Replacement rope shall have a strength rating at least as

great as the original rope furnished or recommended by AutoCrane. A rope manufacturer, AutoCrane, or a qualified person shall specify any deviation from the original size, grade, or construction.

r diameters 11/4 in. (32 mm) to and

ROPE MAINTENANCE

ope should be stored to prevent damage or

1. R

deterioration.

2. Unreeling or uncoiling of rope shall be done as

recommended by the rope manufacturer and with care to avoid kinking or inducing twist.

3. Before cutting a rope, seizing shall be placed on each

side of the place where the rope is to be cut to prevent unlaying of the strands. On pre-formed rope, one seizing on each side of the cut is required. On non-preformed ropes of 7/8 in. (22

mm) diameter or smaller, two seizings on each

side of the cut are required, and for non-preformed rope 1 in. (25 mm) diameter or larger, three seizings on each side of the cut are required.

4. During installation care should be exercised to avoid

dragging of the rope in the dirt or around objects that will scrape, nick crush or induce sharp bends in it.

5. Rope should be maintained in a well-lubricated

condition. It is important that lubricant applied as a part of a maintenance program shall be compatible with the original lubricant and to this end the rope manufacturer should be consulted. Lubricant applied shall be the type that does not hinder visual inspection. Those sections of rope that are located over sheaves or otherwise hidden during inspection and maintenance procedures require special attention when lubricating rope. The object of rope lubrication is to reduce internal friction and to prevent corrosion.

6. When an operating rope shows greater wear or well-

defined localized areas than on the remainder of the rope, rope life can be extended in some cases by shifting the wear to different areas of the rope.

Page 26

MAINTENANCE OF

BATTERIES

intenance of Auto Crane unit batteries differs very

Ma little from the generally prescribed maintenance of any lead acid battery. All batteries must be kept properly charged, properly filled with water, and relatively clean.

Keep Properly Charged

ny things affect the proper charge to a battery,

as:

1. Regulator settings.

2. Proper tightness of belts on the alternator or generator.

3. Good, clean connections of all cables and wires at the following places:

such

deterioration of the remaining parts of the battery.

Keep A Relatively Clean Battery

The b

ttery should be kept clean. Batteries filled

with acid and which are not in use self-discharge to a limited degree because of the nature of the materials within the battery. If dirt is allowed to collect on the top of the battery (and this dirt absorbs moisture) and electrical path can be set up between the various terminals of the battery and the ground. Once such a path has been established, the self discharge of the battery is accelerated. This also accelerates corrosion of the battery cables at the terminals.

a. Battery. b. Regulator. c. Starting motor. d. Alternator or generator. e. Ground connections (most important).

It is of extreme importance to keep the battery as

fully charged as possible without overcharging, especially when vehicles are left outside for extended periods in extremely cold climates. A battery can freeze. Freezing points for various specific gravities of acid are as follows:

Specific Gravity Freezing Temp.

(Corrected to 80ºF) Degrees F.

1.280 -90ºF

1.250 -62ºF

1.200 -16ºF

1.150 5ºF

1.100 19ºF

As shown, a half-charged battery (about 1.100

specific gravity) cannot stand for any length of time at 20ºF or it will freeze. The main reason for keeping the battery as fully charged as possible without over-charging is to insure that power is available even though the vehicle has been standing for some time.

Periodic Maintenance is Needed

finite program of periodic maintenance of all

A de

batteries should be conducted on a regular basis. Periodic maintenance includes:

1. Checking belts for tightness on the charging

equipment.

2. Checking battery electrolyte levels.

3. Checking cables for good connections.

4. Cleaning where corrosion is apparent.

When corrosion is cleaned off, the cable terminals

and battery terminals should be coated with a light coating of petroleum jelly before they are replaced. When terminals are cleaned, the top of the battery should be cleaned with a mild solution of soda water.

Low Maintenance Batteries (Maintenance Free)

Low maintenance batteries should not be used on

toCrane Cranes or trucks equipped with AutoCrane

Au Cranes. The batteries are not designed for “deep” discharge.

Testing Your Battery

Keep Properly Filled with Water

The battery should always be p

roperly filled with water. If the electrolyte level is allowed to fall below the top of the plates, the results become threefold:

1. The exposed portion of the plate will become

sulfated.

2. The portion of the plate exposed is not usable.

3. That portion of the acid remaining becomes

more concentrated and may cause more rapid

ondition of the battery is in question, it should

If the c

removed from the vehicle, taken to the shop, and allowed to reach room temperature. It should then be recharged until specific gravity readings taken at one-half hour intervals. If the specific gravity readings are fairly uniform, the battery should be checked with a high rate tester. Use the tester in accordance with the manufacturer’s instructions. The high rate tester is the best method to test a questionable battery.

Page 27

MAINTENANCE OF

BATTERIES

, after charging, it is noted that the specific gravity

If reading of one cell is 30 points less than any of the other cells, it may be assumed that the cell is bad and that the battery should be replaced. If all cells are uniform but not up to full charge, a low rate of charge should be attempted for an extended time. This usually will recover a badly sulfated battery.

Replacing a Battery

t is necessary to replace a battery, and a dry

If i

charge battery is used, the following procedure applies:

1. Fill the battery with electrolyte of the proper

specific gravity.

2. Place the battery on charge according to the

manufacturer’s instructions.

It is essential that the second step above be followed to ensure that the battery going on the vehicle is fully charged.

It is also very important that the battery hold-downs

checked periodically to insure that the batteries are properly positioned to avoid vibration problems, breakage of cables or terminals. Care must be taken to avoid cracking or breaking containers or covers by tightening hold-down fixtures excessively. They also must not be so loose that breakage results from a holddown that is too loose.

Page 28

SERVICE PERFORMED

DAY WKLY 3 MOS 6 MOS YEAR NOTES

LOAD HOOK X

CABLE DRUM X

HOIST / BOOM CABLE HYD. HOSES HYD. FLUID

MOTOR CO

NNECTIONS

POWER CABLE

PIN RETAINING

BOLTS

MOUNTING BOLTS X

ROTATION RING GEAR SHEAVE BEARINGS

ALL OTHER BOLTS X

LIFT CYLINDER BEARINGS

ROTATION

BEARING

ROTATION

BEARING BOLTS

ROTATION WORM

BEARING

DRAULIC FLUID X

BOOM SLIDE PADS

FOR ADDITIONAL

INFORMATION

SEE:

1) OWNER’S MANUAL

2) OSHA SECTION 1910.180

3) ANSI B30.5-1989

INSPECT HOOK & LATCH FOR DEFORMATION,

CRACKS, & CORROSION

MAKE SURE CABLE IS WOUND EVENLY ON

DRUM

NEKORB & ,SKNIK ,GNINETTALF ROF KCEHCX

STRANDS, SEE MANUAL

NOITCEPSNI LAUSIVX

LEVEL DIULF KCEHCX

X CH

ECK TERMINALS FOR TIGHT CONNECTIONS

CHECK INSULATION FOR DAMAGE OR

DETERIORATION

CHECK TORQUE TO 23 FT-LBS (GRADE 5), 35 FT-

LBS (GRADE 8) AS REQUIRED

CHECK TORQUE TO 335 FT-LBS FOR 3/4-16

LUBE WITH MOBILETAC LL, OR LUBRIPLATE P/N 15263, OR EQUAL

SEALED BEARING, REPLACE IF ROUGH OR

LOOS

CHECK TIGHTEN AS REQUIRED

X GREASE WITH MOBILEPLEX EP-2 OR

EQUIVALENT @ ZERKS

X GREASE WITH MOBILEPLEX EP-2 OR

EQUIVALENT @ ZERKS

X CHECK TORQUE TO 170 FT-LBS (HEX HEAD)

X GREASE WITH MOBILEPLEX EP-2 OR

EQUIVALENT @ ZERKS

DRAIN, FLUSH, AND REFILL

WITH MOBILE

DTE 13 HYD. OIL

PADS GREASED WHEN REPLACED

1) OWNER’S MANUAL

2) OSHA SECTION 1910.180

3) ANSI B30.5-1989

CAUTION: Routine maintenance insures trouble-free operation and

protects your investment. All warranties are void if maintenance is neglected.

3203PR/PRX

LUB

RICATION & MAINTENANCE SCHEDULE

Page 29

3203PR/PRX

LUB

TES:

se only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not

1. 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.

RICATION & MAINTENANCE SCHEDULE

Page 30

CONVERTING FOR SINGLE LINE TO DOUBLE LINE ON 3203EH CRANES

This procedure gives step by step directions for taking a double line and converting to a single line. Keep

in mind when using a single line, the max capacity drops from 3200lbs to 1600lbs.

1. Remove hook from traveling block by removing pin

Figure 1

2. Remove traveling block from rope

3. Disconnect the rope from the crown by removing pin.

4. Pivot single line bars 180 degrees then attach hook to the bars using the pin removed in step 1

5. Attach the rope to the traveling block side plates using the pin removed in step 3. Reference

pictures below for proper configuration.

Remove this pin

Attach Rope Here

Single Line Bars

3203EH SINGLE LINE PROCEDURE

Page 31

3203PR/PRX/PRFX

BRA

KE ADJUSTMENT

ADJUS

The oil-cooled, fully adjustable, automatic safety brake operates in the worm housing lubricant, all p can be adjusted as follows:

If the brake does not respond to adjustment then a new leaf spring and brake disc is needed.

A torque wrench can be equipped with a special adapter to fit the input shaft (worm) of the winch. The adapter can be made by welding a nut to the end of a piece of tubing as shown in the following figure.

TING OIL COOLED WORM BRAKE

rt being submerged in oil. When the brake wears to the point that the load begins to drift, the brake

1. Loosen the lock nut on the adjusting screw.

2. Tighten the brake by turning the adjusting screw clockwise.

CAUTION:

use overheating, and damage to the brake parts. Tighten the lock nut after adjustment is

ca completed.

Only ¼ turn is usually required to adjust the brake. Over-tightening can

er welding the cap and nut to the tubing, slot the tubing as shown. This will allow the special

Aft adapter to slide over the keyway and then act as a large socket. A torque wrench can then be used to apply the proper torque. Turn the torque wrench so that the drum turns in the spool out direction or lowering direction. The torque ratings should be between 12-16 ft-lbs.

If the torque wrench does not show the proper value as it turns, then the worm brake adjusting bolt should be turned clockwise ¼ turn. Each time the adjusting bolt is turned, check the torque reading. Continue this procedure until the proper torque reading is achieved. Then tighten the lock nut.

Page 32

ROTATION BEARING REPLACEMENT

GUIDELINES-2003-4004

l bearings can wear over time. This includes the ma

Al rules can be given for replacement of the rotation bearing, since many factors are in volved. However, there are common symptoms seen during crane operation that may be caused by rotation bearing wear. These symptoms include:

1. Excessive Noise

2. Rough rotation

3. Increased drive power required to rotate.

4. Metal particles in grease

REASONS FOR ROTATION BEARING REPLACEMENT

Any noticeable cracking in the bearing housing

2. Excessive axial play (reference axial play check instructions below)

WARNING! NEVER TRY TO REPAIR A ROTATION BEARING. FOR A REPLACE MENT

BEARING CONTACT YOUR LOCAL AUTHORIZED DISTRIBUTOR.

AXIAL PLAY ALLOWANCE CHECK PROCEDURE

Boom up to the max boom angle and measure the clearance between base plate and the rotation

1. bearing with a dial or filler gauge. Reference figure 1 for location.

2. Boom down to the horizontal position and measure the clearance between the base plate and the rotation bearing with a dial indicator or feeler gauge. Reference figure 1 for loca tion.

3. If the difference between the two measurements exceeds 1.5mm, replace bearing.

4. Rotate crane 45 degrees then repeat steps above until you reach 360 degrees of rotation.

in rotation bearing on the crane. No pre cise

Rotation bearing replacement kit part number is 320878010

WARNING! WHEN REPLACING ROTATION BEARING, USE NEW HARDWARE WHICH IS

INCLUDED IN THE KIT ABOVE.

Page 33

3203PR/PRX

SAF

ETY DECAL SECTION

T NO.: 040579000

PAR

DECAL: OPERATING INSTRUCTIONS

FUNCTION: To inform the operator of the proper procedure to follow for safe operation of the crane.

USED ON: All Cranes

QUANTITY: 1

PLACEMENT: Right side plate

T NO.: 040580000

PAR

DECAL: OPERATING TRAINING

FUNCTION: To inform the operator of the need to

receive proper training before using the crane. USED ON: All Cranes QUANTITY: 1 PLACEMENT: Right side plate

PART NO.: 040632000

DECAL: TAMPERING WITH OVERLOAD DEVICE

FUNCTION: To inform the operator that tamperating

h the overload device may cause a unit

failure or possible personal injury.

USED ON: All Cranes equiped with a load sensor

QUANTITY: 1

PLACEMENT: Right side of valve sensor.

Page 34

3203PR/PRX

SAF

ETY DECAL SECTION

T NO.: 040529000

PAR

DECAL: ELECTROCUTION HAZARD

FUNCTION: To inform the operator of the

hazard involved with contacting electrical power lines with crane boom.

USED ON: All Cranes

QUANTITY: 2

PLACEMENT: Both sides of end of lower boom

PART NO.: 040517000

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

PART NO.: 040518000 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 PLACEMENT: Both sides of traveling block

Page 35

3203PR/PRX

SAF

T NO.: 040587000 USED ON: All cranes equipped with a load

PAR

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.

ETY DECAL SECTION

sensor.

QUANTITY: 2

PLACEMENT: Both sides of the lift cylinder near

the load sensor

PART NO.: 040519000 USED ON: All cranes.

DECAL: SCISSORS POINT QUANTITY: 2

FUNCTION: To inform the operator of possible

danger at scissors point on crane.

PLACEMENT: Both sides of the lift cylinder

Page 36

REMOTE CONTROL SAFETY PRECAUTIONS

READ THE OPERATOR'S MANUAL before using the Remote Control System. Failur

e to follow the safety precautions may result in equipment failure or serious

personal injury.

MAKE SURE MACHINERY AND SUROUNDING AREA IS CLEAR BEFORE OPERATING REMOTE CONTROL SYSTEM. Do not activate the Remote Control System unless it is safe to do so.

TURN OFF THE RECEIVER POWER BEFORE WORKI

NG ON THE MACHINE. Always disconnect the Remote Control System before doing any maintenance to prevent accidental operation of the machine.

DO NOT MODIFY EQUIPMENT WITHOUT WRITTEN APPROVAL FROM THE MANUFACTURER.

CARE

KEEP DRY. Do not clean the Transmitter / Receiver under high pressure. If water or

other liquids get inside the Transmitter battery or Receiver compartment,

immediately dry the unit.

Remove the case and let the unit air dry.

Clean the unit after operation using a damp cloth to remove any mud, dirt, concrete, etc. from the unit and prevent clogging of buttons, switches, etc.

MAINTENANCE / WELDING

DISCONNECT THE RECEIVER BEFORE WELDING ON THIS MACNINE. Failure to di

sconnect will result in the destruction of the Receiver.

WARNING

3203PR/PRX

SAF

T NO.: 460169000 USED ON: All Cranes equiped with FM

PAR

ETY DECAL SECTION

controls.

DECAL: REMOTE CONTROL QUANTITY: 1

FUNCTION: To inform the operator of failure to

PLACEMENT: FRONT OF POWER UNIT

follow the saftey precautions may result in equipment failure or serious personal injury.

Page 37

FRONT OF RESERVOIR

3203PR/PRX DECAL LAYOUT

N: 320988004

Page 38

ITEM NO. QTY PART NUMBER DESCRIPTION

1 2 040517000 DECAL STAY CLEAR OF BOOM 2 2 040518000 DECAL STAY CLEAR OF LOAD 3 2 040519000 DECAL DANGER SCISSOR POINT 4 2 040529000

DECAL DANGER "ELECTROCUTION HAZARD" POWER LINE

5 1 040579000 DECAL OPERATION INSTRUCTIONS 6 1 040580000 DECAL TRAINED OPERATOR 7 1 040587000 DECAL WARNING LOAD SENSOR 8 1 330622000 DECAL SERIAL NO

9 1 40619001 DECAL AUTO CRANE LOGO 10 1 320318000 DECAL ANGLE INDICATOR CS 11 1 320318001 DECAL ANGLE INDICATOR SS 12 1 320988005 DECAL 3203 LOAD CHART 13 2 320433100 DECAL, TRAVELING BLOCK 3203 14 2 320918000 DECAL 3203 HORIZONTAL 15 1 360034000 DECAL AUTO CRANE LOGO 16 2 600047000 DECAL AUTO CR

ANE 17 1 460169000 DECAL WARNING, REMOTE CONTROL 18 1 040632000 DECAL WARNING - OVERLOAD 19 1 040824000

DECAL, AMERICAN FLAG, MADE IN THE U.S.A.

NEXT TO SWITCH

3203PR/PRX DECAL LAYOUT

P/N

: 320988004

Page 39

14 3/8" 7'-4 1/4"

15'-4/14"

19 3/4"

11 5/8"

19 1/8"

9'-1 5/8"

13 1/8"

Ø 9"

11 1/2"13 1/2"

14 3/4"

16 3/4"

Ø 7/8"

SERIAL NUMBER

R16 3/4"

3203PR/PRX

NERAL DIMENSIONS

Page 40

ITEM

QTY

PART NO DESCRIPTION

1 1 1 320433000 TRAVELING BLOCK ASSY 2 6 6 083800000 CLIP, CABLE 3838 (FRAME) 3 4 4 404226000 SCREW, HS HD,, 3/4 - 16UNF X 3" LG GRADE 8 4 4 4 404227000 NUT HX 3/4 - 16 UNF 5 4 022101000 WASHER, SP. LK 3/4 6 8 4 022102000 WASHER FL 3/4 7 1 1 320950000 OWNER'S MANUAL (3203 PR/PRX/PRFX) 8 1 1 404223020 COND ASSY 4 GA X 48" BLK

9 1 1 404223010 CABLE PWR, 25 FT 10 1 460157000 TRANSMITTER 11 1 460159000 TETHER CABLE, TRANSMITTER 12 1 1 40

4218000 TWECO CABLE ASSY W/MASTER SWITCH

13 1 680179000 PENDANT ASSY

3203PR/PRX

heck to make sure the following items are with your crane.

1. C

UNTING AND INSTALLATION

2. Vehicle should meet minimum GVW rating of 8,800pounds. (does not include bodies or acce- ries)

sso

3. Make sure mounting surface is properly reinforced to withstand 12,000  -lb capacity loading of

crane and that outriggers are used to provide total stability for the truck.

4. A 9” dia. hole should be cut out of mounting location (centered with mounting bolts) for access.

Reference general dimensions for bolt pattern.

5. Make sure the mounting bolts are 3/4”-16UNF, grade 8UNF. Torque bolts to 335  -lbs (dry).

6. When crane is not in operation, a boom support should always be used. Traveling block should

be connected to hook loop.

7. See the following page for installation.

8. See the following pages for additional electrical installation.

9. Load test the crane to ensure proper functioning and truck stability

10. Make certain the owner’s manual is delivered to the customer.

11. For additional help: call the service department at the Auto Crane Company. (918) 836-0463

(Tulsa,Oklahoma)

WARNING

FEDERAL LAW (49 CFR PART 571) REQUIRES THAT THE FINAL STAGE MANUFACTURER OF A

VEHICLE CERTIFY THAT HE 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. IT IS THE FURTHER RESPONSIBILITY OF THE INSTALLER OF THE CRANE TO COMPLY WITH THE OSHA TRUCK CRANE STABILITY REQUIREMENTS AS SPECIFIED BY 29 CFR

PART 1910.180 (C) (1).

Page 41

GENERAL ASSEMBLY

ITEM NO. QTY. PART NO. DESCRIPTION

1 1 320988203 PEDEST A L ASSEMBLY, 3203 PRX 2 1 320988102 BOOM ASSY 3203 PRX

3 1 320338002

CABLE ASS'Y , 7/32" x 62FT, THI MBLE

END 4 1 404220000 PIN WDMT BOOM/PED 5 1 320824000 PIN, LIFT CY LINDER 6 2 360678000 PIN, 3/16 COTT ERLESS RING 7* 1 320988004 DECAL LAY OUT, 3203 8* 1 320988012 SHI P KIT, 3203 PR/PRX, HW 9 1 239300000 ZERK, GREA SE

10 1 330371000

SCREW HX HD 3/8-16UNC X 1 LG

GR8

11 1 366159000

SCREW HX HD 3/8-16UNC X 1 1/2 LG

GR8

12 2 02110000

0 WASHER SP LK 3/8

13 2 021200000 WA SHER FL 3/8

14 1 330372000 NUT HX 3/8-16UNC

3203P

R CRANE

*NOT SHOWN FOR CLARITY

Page 42

3203PR GENERAL ASSEMBLY

HARD

Attach ground wire (404223020) to bottom of the crane. Run the ground wire

wn through the crane box. Locate cable so that it will be protected and avoid

d sharp edges. Attach ground from crane to chassis frame.

WIRED

Page 43

3203PRX GENERAL ASSEMBLY

HAR

DWIRED - P/N:320989002

Page 44

ITEM

NO.

QTY

PART

NUMBER

DESCRIPTION

1 1 320988203 PEDESTAL ASSEMBLY, 3203 PRX

2 1 320988102 BOOM ASSY 3203 PRX

3 1 320338002 CABLE ASS'Y, 7/32" x 62FT, THIMBLE END 4 1 404220000 PIN WDMT BOOM/PED 5 1 320824000 PIN, LIFT CYLINDER 6 2 360678000 PIN, 3/16 COTTERLESS RING 7* 1 320988004 DECAL LAYOUT, 3203 8* 1 320988012 SHIP KIT, 3203 PR/PRX, HW

9 1 239300000 ZERK, GREASE 10 1 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8 11 1 366159000

SCREW HX HD 3/8-16UNC X 1 1/2 LG GR8

12 2 021100000 WASHER SP LK 3/8 13 2 021200000 WASHER FL 3/8 14 1 330372000 NUT HX 3/8-16UNC

* NOT SHOWN FOR CLARITY

3203PRX GENERAL ASSEMBLY

HAR

DWIRED-P/N:320989002

Page 45

PLUG REG FROM 320990310 INTO COIL

TRAVELING BLOCK IS

SHOWN FOR REFERENCE AND IS LOCATED IN THE SHIP KIT

APPLY LOCK-TITE 242 OR 243 TO BOLT THREAD

3203PRFX GENERAL ASSEMBLY

HAR

DWIRED - P/N: 320990001

Page 46

ITEM NO. QTY PART NO. DESCRIPTION

1 1 320990200 PEDESTAL ASSEMBLY, 3203 PRFX 2 1 320990100 BOOM ASSY 3203PRFX 3 1 404220000 PIN WDMT BOOM/PED 4 1 320824000 PIN, LIFT CYLINDER 5 1 239300000 ZERK, GREASE 6 2 021200000 WASHER FL 3/8

7 2 021100000 WASHER SP LK 3/8

8 1 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8

9 1 330372000 NUT HX 3/8-16UNC

10 2 360678000 PIN, 3/16 COTTERLESS RING

11* 1 320988012 SHIP KIT, 3203 PR/PRX, HW

12* 1 320988004 DECAL LAYOUT, 3203

13 1 366159000 SCREW HX HD 3/8-16UNC X 1 1/2 LG GR8

14 1 320338002 CABLE ASS'Y, 7/32" x 62FT, THIMBLE END

* ITEM NOT SHOWN

3203PRFX GENERAL ASSEMBLY

HAR

DWIRED - P/N: 320990001

Page 47

3203PR PEDESTAL ASSEMBLY

ATTACH GROUND CABLE

ATTACH GROUND CABLES FROM:

HOIST (600317)

PUMP (600318) RELAY PANEL (BLACK WIRE)

251

P/N

: 320988204

HYDRAULICS: PORT PORT A-2 CCW BOTTOM MOTOR PORT PORT B-1 BOOM DOWN PORT B-2 CW TOP MOTOR PORT CYLINDER SEAL KIT: 320845002 C’BAL CARTRIDGE: 480188000

A-1 BOOM UP

Page 48

18 62

3203PR PEDESTAL ASSEMBLY

P/N

: 320988204

Page 49

ITEM NO. QTY PART NO. DESCRIPTION

1 1 320988210 PEDESTAL WELDMENT, 3203 PR / PRX / H

2 1 110703 WINCH-DCG8R FOR AUTOCRANE #3203 PRX

3 1 320991240 KIT, HOSE NEXSTAR 3203PRX/4004EH

4 1 320991237 BASE PLATE MACH 3203 LESS GROUND HOLE

5 1 320878000 ROTATION BEARING

6 1 340602000 KEY, 3/4 SQ X 1

7 1 320988253 GEAR, WORM, 4.00 ID, .75 KEY, 3203

8 1 404241285 MOTOR, HYD 8.0 CU IN, SAE 2-BOLT 1" SHAFT

9 1 320879000 SPACER ROTATION

10 1 330483000 SPACER

11 1 404015 WORM SHAFT

12 22 023902000 WASHER FL 5/8 HARDENED

13 22 012198000 SCREW HX HD 5/8-11UNC X 1 3/4 LG GR8

14 6 011603000 SCREW HX HD 1/2-13UNC X 1 3/4 LG

15 10 021500000 WASHER, SP LK 1/2

16 10 017701000 NUT HX 1/2-13UNC

17 2 009109000 SCREW HX HD 3/8-16UNC X 1 1/2 LG

18 7 021100000 WASHER SP LK 3/8

19 4 736274000 NUTSERT 3/8-16UNC X .027-.15 GRIP

20 4 330252000 SCREW HX HD 5/16-18UNC X 3/4 LG GR5

21 4 020601000 WASHER SP LK 5/16

22 3 010201000 SCREW HX HD 1/2-13UNC x 1 1/2 LG

23 4 006200000 SCREW HX HD 1/4-20UNC X 1 1/4 LG

24 4 020200000 WASHER SP LK 1/4

25 2 239300000 ZERK, GREASE

26 2 330372000 NUT HX 3/8-16UNC

27 1 360678000 PIN, 3/16 COTTERLESS RING

28 2 021200000 WASHER FL 3/8

29 1 330394000 SCREW HX HD 3/8-16UNC X 1 1/2 LG

30 3 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8

31 1 019000000 NUT HX NYLK 7/8-14UNF

32* 2 812026016 HOSE ASSY -4 HOSE -6 FEMALE JIC

33* 1 812209023 HOSE ASSY, SHORT, 23"

3203PR PEDESTAL ASSEMBLY

P/N

320988204

Page 50

ITEM NO. QTY PART NO. DESCRIPTION

34* 1 812209028 HOSE ASSY, SHORT, 28"

35 1 202756000 ADAPTER, STRAIGHT 8SAE(M)-6JIC(M)

36 1 320988258 UPPER TWECO BRACKET WLDMT, 3203

37 1 320991279 POWER UNIT, ENTRY LEVEL 3203/4004 EH

38 1 404187000 SPRING PLATE, GROUND BRUSH, 4004

39* 1 320988300 RELAY PANEL ASSEMBLY, 3203

40 1 404198000 SCREW HX HD 3/8-16UNC X 1 1/2 LG, BRONZE

41 1 404213000 SEAL, 2.50 OD X 1.5 ID

42 1 320858000 BEARING, SPHERICAL 1.00 ID

43 1 404028000 RETAINING RING, SNAP RING

44 1 320845000 CYLINDER, LIFT

45 1 320824000 PIN, LIFT CYLINDER

46 2 480024000 MOUNT PENDANT CABLE RETAINER

47 1 320917000 PRESSURE SWITCH, N.C. 1,900 PSI

48* 1 200876000 FITTING 6 SAE/6 JIC STRAIGHT

49* 3 490198000 FITTING 10SAE(M)/6JIC ELBOW 90

50 1 320988270 KIT, HYDRAULIC, 3203 PR

51 1 680156100 KIT-ELECTRICAL, 3203 PR/PRX

52 2 002901000 TERMINAL, RING #4 - 3/8

53 1 002702000 TERMINAL, RING #4 - 5/16

54* 1 660116000 CABLE ASSY, 6 AWG, 16 1/4 " WIRE LGTH

55* 1 600318000 CABLE ASSY, 6 AWG, 11" WIRE LGTH

56 1 002900000 SCREW SET 0.25-20 X 0.25

57* 1 645000000 TWECO, MALE MODIFIED

58 1 320988261 VALVE, FLOW REGULATOR, IN-LINE

59 1 320989204 UPPER VALVE BRACKET, 3203H

60 1 320989203 LOWER VALVE BRACKET, 3203H

61 1 320989420 VALVE ASSY, 3 SPOOL, NON-PROP., 12 VOLT

62 1 366688000 COVER, REAR

63* 2 360447000 FITTING, CAP, JIC, -6

64 1 320989235 BRACKET, POWER UNIT

65* 2 480194000 FITTING 6JIC/6JIC ELBOW 90

66 1 330478000 BEARING HOUSING ASSY

* ITEMS NOT SHOWN

3203PR PEDESTAL ASSEMBLY

P/N

320988204

Page 51

ATTACH GROUND CABLES FROM: HOIST (600317) PUMP (600318) RELAY PANEL (BLACK WIRE)

Attach Ground Cable

03PRX PEDESTAL ASSEMBLY

P/N: 320988203

HYDR PORT A-1 RETRACT PORT A-2 BOOM DOWN PORT A-3 CCW BOTTOM MOTOR PORT PORT B-1 EXTEND PORT B-2 BOOM UP PORT B-3 CW TOP MOTOR PORT

CYLINDER SEAL KIT: 320845002 C’BAL CARTRIDGE: 480188000

AULICS:

Page 52

19 20 18

ATTACH GROUND CABLE

3203

PRX PEDESTAL ASSEMBLY

P/N: 320988203

Page 53

3203PRX PEDESTAL ASSEMBLY

ITEM NO QTY PART NO. DESCRIPTION

1 1 320988210 PEDESTAL WELDMENT, 3203 PR / PRX / H 2 1 320991237 BASE PLATE MACH 3203 LESS GROUND HOLE

3 1 110703 WINCH-DCG8R FOR AUTOCRANE #3203 PRX 4 1 320878000 ROTATION BEARING 5 1 340602000 KEY, 3/4 SQ X 1 6 1 320988253 GEAR, WORM, 4.00 ID, .75 KEY, 3203 7 1 404241285 MOTOR, HYD 8.0 CU IN, SAE 2-BOLT 1" SHAFT 8 1 320879000 SPACER ROTATION 9 1 330483000 SPACER

10 1 404015000 WORM SHAFT 11 24 023902000 WASHER FL 5/8 HARDENED 12 24 012198000 SCREW HX HD 5/8-11UNC X 1 3/4 LG GR8 13 6 011603000 SCREW HX HD 1/2-13UNC X 1 3/4 LG B 14 10 021500000 WASHER, SP LK 1/2 15 9 017701000 NUT HX 1/2-13UNC 16 2 009109000 SCREW HX HD 3/8-16UNC X 1 1/2 LG 17 5 021100000 WASHER SP LK 3/8 18 4 736274000 NUTSERT 3/8-16UNC X .027-.15 GRIP 19 5 330252000 SCREW HX HD 5/16-18UNC X 3/4 LG GR5 20 4 020601000 WASHER SP LK 5/16 21 3 010201000 SCREW HX HD 1/2-13UNC x 1 1/2 LG 22 4 006200000 SCREW HX

HD 1/4-20UNC X 1 1/4 LG 23 4 0202000000 WASHER SP LK 1/4 24 2 239300000 ZERK, GREASE 25 2 330372000 NUT HX 3/8-16UNC 26 1 360678000 PIN, 3/16 COTTERLESS RING 27 1 320976000 WASHER, FLAT, 3/8 SAE HARDENED 28 1 09116000 SCREW HX HD 3/8-16UNC X 2 GR5 29 3 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8 30 1 019000000 NUT HX NYLK 7/8-14UNF 31 1 320988300 RELAY PANEL ASSEMBLY, 3203 32 1 320988258 UPPER TWECO BRACKET WLDMT, 3203 33 1 404187000 SPRIN

G PLATE, GROUND BRUSH, 4004

34 1 404198000 SCREW HX HD 3/8-16UNC X 1 1/2 LG, BRONZE

P/N

320988203

Page 54

3203PRX PEDESTAL ASSEMBLY

ITEM NO QTY PART NO. DESCRIPTION

35 1 404213000 SEAL, 2.50 OD X 1.5 ID 36 1 320858000 BEARING, SPHERICAL 1.00 ID 37 1 404028000 RETAINING RING, SNAP RING 38 1 320845000 CYLINDER, LIFT 39 1 320824000 PIN, LIFT CYLINDER 40 2 480024000 MOUNT PENDANT CABLE RETAINER 41 1 320917000 PRESSURE SWITCH, N.C. 1,900 PSI 42 16 374085000 NYLON HOSE SLEEVE 43 1 812209028 HOSE ASSY, -6 HOSE, -6 JICF / -6 JICF 90DEG 44 1 812209023 HOSE ASSY, -6 HOSE, -6 JICF / -6 JICF 90DEG 45 2 81203701

8 HOSE ASSEMBLY, -6 JIC 90/-4 HOSE 46 1 812037031 HOSE ASSY, -6 JICF/ -6 90 DEG ELL, -4 HOSE x 47 1 812037027 HOSE ASSY, -6 JICF/ -6 90 DEG ELL, -4 HOSE x 48 2 812026016 HOSE ASSY -4 HOSE -6 FEMALE JIC 49 1 202756000 ADAPTER, STRAIGHT 8SAE(M)-6JIC(M) 50 2 200876000 FITTING 6 SAE/6 JIC STRAIGHT 51 2 490198000 FITTING 10SAE(M)/6JIC ELBOW 90 52 1 320988251 KIT, HYDRAULIC, 3203 PRX/ 4004 55 1 660116000 CABLE ASSY, 6 AWG, 16 1/4"

WIRE LGTH, ø3/8

56 1 600318100

CABLE ASSY, 6 AWG, 24" WIRE LGTH, ø3/8 TMNL, ø5

57 1 002900000 SCREW SET 0.25-20 X 0.25 58 1 645000000 TWECO, MALE MODIFIED 59 1 320988261 VALVE, FLOW REGULATOR, IN-LINE 60 1 320989204 UPPER VALVE BRACKET, 3203H 61 1 320989203 LOWER VALVE BRACKET, 3203H 62 1 320989420 VALVE ASSY, 3 SPOOL, NON-PROP., 12 VOLT 63 1 366688000 COVER, REAR 64 1 320991279 POWER UNIT, ENTRY LEVEL 3203/4004 EH B 65 1 320989235 BRACKET, POWER UNIT 66 1 680156100 KIT-ELECTRICAL, 3203 PR/PRX 67 1 017301000 NUT

HX NYLK 3/8-16UNC CP

68 1 330478000 BEARING HOUSING ASSY

P/N

320988203

Page 55

3203PRFX PEDESTAL ASSEMBLY

32 17

ATTACH GROUND CABLES FROM: HOIST (600317) PUMP (600318) RELAY PANEL (BLACK WIRE)

P/N

: 320990200

HYDRAULICS:

T A-1 RETRACT

POR PORT A-2 BOOM DOWN PORT A-3 CCW BOTTOM MOTOR PORT PORT B-1 EXTEND PORT B-2 BOOM UP PORT B-3 CW TOP MOTOR PORT

CYLINDER SEAL KIT: 320845002 C’BAL CARTRIDGE: 480188000

Page 56

5338

3203PRFX PEDESTAL ASSEMBLY

P/N

: 320990200

Page 57

ITEM

NO.

QTY

PART

NUMBER

DESCRIPTION

1 2 320991240 KIT, HOSE NEXSTAR 3203PRX/4004EH

2 1 404187000 SPRING PLATE, GROUND BRUSH, 4004

3 1 320988258 UPPER TWECO BRACKET WLDMT, 3203

4 1 320988210 PEDESTAL WELDMENT, 3203 PR / PRX / H

5 1 110703 WINCH-DCG8R FOR AUTOCRANE #3203 PRX

6 1 320878000 ROTATION BEARING

7 1 320991237 BASE PLATE MACH 3203 LESS GROUND HOLE

8 1 340602 KEY, 3/4 SQ X 1

9 1 320988253 GEAR, WORM, 4.00 ID, .75 KEY, 3203

10 1 320879000 SPACER ROTATION

11 1 330483 SPACER

12 1 404015 WORM SHAFT

13 1 404198000 SCREW HX HD 3/8-16UNC X 1 1/2 LG, BRONZE

14 1 404213000 SEAL, 2.50 OD X 1.5 ID

15 1 320858000 BEARING, SPHERICAL 1.00 ID

16 1 320824000 PIN, LIFT CYLINDER

17 1 320917000 PRESSURE SWITCH, N.C. 1,900 PSI

18 1 320845000 CYLINDER, LIFT

19 1 404241285 MOTOR, HYD 8.0 CU IN, SAE 2-BOLT 1" SHAFT

20 1 320988261 VALVE, FLOW REGULATOR, IN-LINE

21* 1 812209028

HOSE ASSY, -6 HOSE, -6 JICF / -6 JICF 90DEG SHORT, 28" LONG

22* 1 812209023

HOSE ASSY, -6 HOSE, -6 JICF / -6 JICF 90DEG SHORT,

23" LONG

23* 2 812026016 HOSE ASSY -4 HOSE -6 FEMALE JIC

24* 1 812037027 HOSE ASSY, -6 JICF/ -6 90 DEG ELL, -4 HOSE x 27" LG

25* 1 812037031 HOSE ASSY, -6 JICF/ -6 90 DEG ELL, -4 HOSE x 31" LG

26* 2 812037018 HOSE ASSEMBLY, -6 JIC 90/-4 HOSE

27* 16 374085000 NYLON HOSE SLEEVE

28* 1 480194000 FITTING 6JIC/6JIC ELBOW 90

29* 1 202756000 ADAPTER, STRAIGHT 8SAE(M)-6JIC(M)

30 1 320988251 KIT, HYDRAULIC, 3203 PRX/ 4004

31* 2 490198 FITTING 10SAE(M)/6JIC ELBOW 90

32* 2 200876 FITTING 6 SAE/6 JIC STRAIGHT

33 1 680156100 KIT-ELECTRICAL, 3203 PR/PRX

34** 1 660116000

CABLE ASSY, 6 AWG, 16 1/4" WIRE LGTH, ø3/8 TMNL,

ø5/16 TMNL

35** 1 600318100

CABLE ASSY, 6 AWG, 24" WIRE LGTH, ø3/8 TMNL, ø5/16 TMNL

3203PRFX PEDESTAL ASSEMBLY

P/N

: 320990200

Page 58

ITEM

NO.

QTY

PART

NUMBER

DESCRIPTION

36** 1 645000000 TWECO, MALE MODIFIED

37** 1 320988300 RELAY PANEL ASSEMBLY, 3203

38 6 021100000 WASHER SP LK 3/8

39 1 017301000 NUT HX NYLK 3/8-16UNC CP

40 2 320976000 WASHER, FLAT, 3/8 SAE HARDENED

41 1 8702000 SCREW HX HD 3/8-16UNC X 1 1/4 LG GR5

42 1 009116000 SCREW HX HD 3/8-16UNC X 2 GR5

43 2 480024000 MOUNT PENDANT CABLE RETAINER

44 3 330372000 NUT HX 3/8-16UNC

45 4 020601000 WASHER SP LK 5/16

46 5 330252000 SCREW HX HD 5/16-18UNC X 3/4 LG GR5

47 23 012198000 SCREW HX HD 5/8-11UNC X 1 3/4 LG GR8

48 23 023902000 WASHER FL 5/8 HARDENED

49 3 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8

50 1 002900000 SCREW SET 0.25-20 X 0.25

51 4 006200000 SCREW HX HD 1/4-20UNC X 1 1/4 LG

52 1 404028000 RETAINING RING, SNAP RING

53 2 09109000 SCREW HX HD 3/8-16UNC X 1 1/2 LG

54 4 736274000 NUTSERT 3/8-16UNC X .027-.15 GRIP

55 5 011603000 SCREW HX HD 1/2-13UNC X 1 3/4 LG

56 8 021500000 WASHER, SP LK 1/2

57 8 017701000 NUT HX 1/2-13UNC

58 3 010201000 SCREW HX HD 1/2-13UNC x 1 1/2 LG

59 4 020200000 WASHER SP LK 1/4

60 2 023930000 ZERK, GREASE

61 1 360678000 PIN, 3/16 COTTERLESS RING

62 1 019000000 NUT HX NYLK 7/8-14UNF

63 1 320990310 HARNESS, WIRE, REGENERATIVE CIRCUIT, 3203PRFX

64 1 320990201 PRESSURE SWITCH, NC, 1450 PSI, 10 AMP

65 1 320989420 VALVE ASSY, 3 SPOOL, NON-PROP., 12 VOLT

66 1 320989204 UPPER VALVE BRACKET, 3203H

67 1 320989203 LOWER VALVE BRACKET, 3203H

68 1 366688000 COVER, REAR

69 1 320991279 POWER UNIT, ENTRY LEVEL 3203/4004 EH

70 1 320989235 BRACKET, POWER UNIT

71 1 330478000 BEARING HOUSING ASSY

* HYDRAULIC KIT 320988251

** ELECTRICAL KIT 680156100

3203PRFX PEDESTAL ASSEMBLY

P/N

: 320990200

Page 59

27 28 25

15 27 28 25

172021

9 22 26 21

11 12

5 23

ADD WASHERS BETWEEN

BAIL

AND CROWN ALSO

3203PR BOOM ASSEMBLY

P/N

: 320988103

NOTE:

APPLY LOCTITE 242

8 PLC’S BEFORE INSTALLING

CYLINDER SEAL KIT: 320835002

C’BAL

CARTRIDGE: 480188000

TO BOLT THREADS.

Page 60

ITEM

NO.

QTY.

PART

NUMBER

DESCRIPTION

1 1 320988110 LOWER BOOM WELDMENT, 3203 PR/PRX

2 1 320988165 MID BOOM WMT, 3203

3 1 320988160 UPPER BOOM WLDMT 3203

4 1 320858000 BEARING, SPHERICAL 1.00 ID

5 1 320883000 SHEAVE ASSEMBLY

6 1 366112000 STOP UPPER BOOM

7 1 366183000 STOP CENTER BOOM

8 2 366190000 PIN ASSY W/LANYARD

9 1 320871000 BAIL WELDMENT

10 1 404205000 CORD REEL ASSY

11 1 646900000 SWITCH, ANTI-TWO BLOCK

12 1 642918000 CORD CONNECTOR

13 1 366678000 SPRING, EXTENSION

14 1 366201000 WEAR PAD 3 .75 X 2.00 X .313

15 1 366202000 PAD, BOOM TOP

16 1 320988155 BOOM PAD 4.50 X 2.50 X .50, 3203

17 1 320990104 WEAR PAD, 2 X 4 X .25, W/ CSINK HOLES

18 3 407203000 PAD, BOOM, 2.50 O.D. x .563 THK

19 1 239000000 ZERK DRIVE GR

20 2 320990105 SCREW, FLAT HEAD, 5/16-18 UNC X 1, ZP

21 3 016801000 NUT HX NYLK 5/16-18UNC CP

22 1 811029000 SCREW HX HD 5/16-18UNC X 2 1/2 LG

23 1 366393000 SCREW HX HD 5/8-11UNC X 2 1/2 LG GR8

24 1 018200000 NUT HX NY LK 5/8-11UNC

25 4 738733100 SCREW HX HD 3/8-24UNF X 7/8 LG

26 4 020901000 WASHER FL 5/16

27 8 021200000 WASHER FL 3/8

28 4 021100000 WASHER SP LK 3/8

3203PR BOOM ASSEMBLY

P/N

: 320988103

Page 61

20 33

21333431

2326

1527 32

1112

1030

17 18

5 28 29

ADD WASHERS BETWEEN

BAIL AND CROWN ALSO

3203PRX BOOM ASSEMBLY

P/N

: 320988102

NOTE: APPLY LOCTITE 242 TO BOLT

CYLINDER S C’BAL CARTRIDGE: 480188000

THREADS. 8 PLC’S BEFORE INSTALLING

EAL KIT: 320835002

Page 62

ITEM NO. QTY

PART

NUMBER

DESCRIPTION

1 1 320988110 LOWER BOOM WELDMENT, 3203 PR/PRX

2 1 320988165 MID BOOM WMT, 3203

3 1 320988160 UPPER BOOM WLDMT 3203

4 1 320858000 BEARING, SPHERICAL 1.00 ID

5 1 320883000 SHEAVE ASSEMBLY

6 1 366112000 STOP UPPER BOOM

7 1 366183000 STOP CENTER BOOM

8 1 366190000 PIN ASSY W/LANYARD

9 1 320988142 EXTENSION CYLINDER, 3203

10 2 320888001 RETAINER, EXTENSION CYLINDER

11 1 320988115 PIN 1 DIA X 6.905 LG, 3203

12 2 360122000 RING RETAINING 5100-98

13 2 330645000 FITTING 90 6-SAE/6-JIC LONG

14 11 016801000 NUT HX NYLK 5/16-18UNC CP

15 1 320871000 BAIL WELDMENT

16 1 404205000 CORD REEL ASSY

17 1 646900000 SWITCH, ANTI-TWO BLOCK

18 1 642918000 CORD CONNECTOR

19 1 366678000 SPRING, EXTENSION

20 1 366201000 WEAR PAD 3 .75 X 2.00 X .313

21 1 366202000 PAD, BOOM TOP

22 1 320988155 BOOM PAD 4.50 X 2.50 X .50, 3203

23 1 320990104 WEAR PAD, 2 X 4 X .25, W/ CSINK HOLES

24 3 407203000 PAD, BOOM, 2.50 O.D. x .563 THK

25 1 239000000 ZERK DRIVE GR

26 2 320990105 SCREW, FLAT HEAD, 5/16-18 UNC X 1, ZP

27 1 811029 SCREW HX HD 5/16-18UNC X 2 1/2 LG

28 1 366393000 SCREW HX HD 5/8-11UNC X 2 1/2 LG GR8

29 1 018200000 NUT HX NY LK 5/8-11UNC

30 8 007804000 SCREW HX HD 5/16-18UNC X 1 1/4 LG CP

31 4 738733100 SCREW HX HD 3/8-24UNF X 7/8 LG

32 4 020901000 WASHER FL 5/16

33 8 021200000 WASHER FL 3/8

34 4 021100000 WASHER SP LK 3/8

3203PRX BOOM ASSEMBLY

P/N

: 320988102

Page 63

1 19

3203PRFX BOOM ASSEMBLY

P/N

: 320990100

CYLINDER SEAL KIT: 320988146

BAL CARTRIDGE: 480188000

C’

Page 64

ITEM

NO.

QTY

PART

NUMBER

DESCRIPTION

1 1 320988145

CYLINDER, TELESCOPIC, 48" FIRST STAGE, 48" SECOND STAGE, 3-3/8 OD

2 1 320990110 LOWER BOOM WMT 3203 PRFX

3 1 320990120 MID BOOM WMT 3203 PRFX

4 1 738732000 PIN 1n X 4.063 LG

5 1 320988115 PIN 1 DIA X 6.905 LG, 3203

6 1 239000000 ZERK DRIVE GR

7 1 320858000 BEARING, SPHERICAL 1.00 ID

8 1 320871000 BAIL WELDMENT

9 1 646900000 SWITCH, ANTI-TWO BLOCK

10 1 642918000 CORD CONNECTOR

11 1 404205000 CORD REEL ASSY

12 1 366678000 SPRING, EXTENSION

13 2 330645000 FITTING 90 6-SAE/6-JIC LONG

14 2 366483000 PLATE, WEAR PAD .25 X 2 X 4

15 1 320988156 BOOM PAD WITH NUTS, 4.75 X 3 X .313, 3203

16 1 320990104 WEAR PAD, 2 X 4 X .25, W/ CSINK HOLES

17 2 366201000 WEAR PAD 3 .75 X 2.00 X .313

18 1 320988155 BOOM PAD 4.75 X 2.50 X .50, 3203

19 8 360767000 PAD BOOM 1.5 O.D.

20 1 407202000 PAD BOOM 2.50 O.D.

21 1 320883000 SHEAVE ASSEMBLY

22 4 360122000 RING RETAINING 5100-98

23 2 460177162 SCREW SOC HD 5/8-11UNC X 3/4 LG

24 1 811029000 SCREW HX HD 5/16-18UNC X 2 1/2 LG

25 3 016801000 NUT HX NYLK 5/16-18UNC CP

26 1 366393000 SCREW HX HD 5/8-11UNC X 2 1/2 LG GR8

27 1 018200000 NUT HX NY LK 5/8-11UNC

28 4 020901000 WASHER FL 5/16

29 4 005406000 SCREW HX HD 1/4-28UNF X 1/2 LG

30 4 738733000 SCREW HX HD 3/8-24UNF X 3/4 LG

31 1 320990101

VALVE, SPOOL, 3-WAY, W/ COIL & DEUTSCH

CONNECTION

32 2 320990105 SCREW, FLAT HEAD, 5/16-18 UNC X 1, ZP 33 1 320990140 UPPER BOOM WMT 3203 PRFX 34 1 470048000 PAD, BOOM 2.50 O.D. X 0.063 THICK

3203PRFX BOOM ASSEMBLY

P/N

: 320990100

Page 65

910

ITEM NO. QTY PART NO. DESCRIPTION

1 1 320836 WINCH MOUNTING BRACKET CS 2 1 320837 WINCH MOUNTING BRACKET SS 3 1 320838 WINCH TIE BAR 4 1 320839 WINCH TIE BAR, FRONT 5 2 320887 BEARING, BRONZE 6 1 320379 DRUM 7 8 418163 WASHER SP LK 5/16 8 7 414136 SCREW HX HD 5/16-18UNC X 1 1/4 LG CP

9 1 412003 FLANGE BEARING 10 1 338053 WINCH END BEARING 11 1 414865 CAPSCREW-5/16-18NCX1LG HX SOC HD 12 1 296907 HSG ASSY-SPUR GEAR

13* 1 262037 MTR ASS'Y-12V, 2.5 HP

*In

cluded with Item No. 12

3203PR/PRX HOIST ASSEMBLY

P/N

: 110703

Page 66

5 38 65 31

51 28

3203PR/PRX HOIST ACTUATOR

Page 67

ITEM NO. QT Y. PART NO. DESCRIPTION

1 1 306034 SPRING FLAT

2 1 314008 PLATE CAM

3 1 328009 COVER GEAR HOUSING

4 1 328106 COVER WORM GEAR HOUSING

5 1 328128 COVER BRAKE

6 1 334001 IDLER GEAR

7 2 334003 SPUR GEAR

8 1 334007 GEAR WORM RH

10 1 338007 HOUSING BRAKE

11 1 338203 SPUR GEAR HOUSING

12 1 338238 GEAR HOUSING

13 1 340002 HUB BRAKE

14 1 342023 KEY 3/16 SQ X 1/2 LG

15 1 342027 KEY 3/16 SQ X 1 LG

16 1 342033 KEY 3/16 SQ X 1 7/16 LG

17 1 342198 KEY 1/4 SQ X 2 1/8 LG

18 2 342075 KEY RD 5/16 X 5/16 X 15/16 LG

19 1 352022 PLATE RETAINER

20 1 356901 SPUR GEAR SHAFT

21 1 357515 OUTPUT SHAFT

22 1 368192 WORM R.H.

23 2 400003 BALL

24 3 402001 BEARING NEEDLE

25 2 402002 BEARING BALL

26 1 412003 BUSHING

27 1 412046 BUSHING 28 8 414020 SCREW HX HD 1/4-20UNC X 3/4 LG NY LK

29 12 414038 SCREW HX HD 1/4-20UNC X 3/4 LG

30 4 414039 SCREW HX HD 1/4-20UNC X 1 LG

31 1 414224 SCREW HX HD 3/8-16UNC X 1 1/2 LG ALL THD

32 4 414821 SCREW BTN HD 1/4-20UNC X 7/8 LG

33 4 414845 SCREW SOC HD 1/4-20UNC X 1 LG

35 1 418036 NUT JAM 3/8-16UNC

36 3 418040 NUT HX 3/8-24UNF

37 4 486070 WASHER SP LK 1/4 MED SECT

38 2 418154 WASHER FL 1/4 ALUM

39 3 418177 WASHER SP LK 3/8

40 1 432011 ELL 90 DEG 3/8-18 NPT BOTH ENDS

41 1 432012 ELL 90 DEG 1/4-18 NPT BOTH ENDS

42 2 442184 GASKET BEARING

43 1 442185 GASKET SPUR GEAR HOUSING

44 1 442186 GASKET GEAR HOUSING COVER

NOT USED

3203PR/PRX HOIST ACTUATOR

Page 68

ITEM NO.

QTY. PART NO. DESCRIPTION

44 1 442186 GASKET GEAR HOUSING COVER

45 1 442189 GASKET BRAKE COVER

47 2 456008 FITTING RELIEF

50 1 468002 REDUCER -6NPT/-2NPT

51 2 468010 PLUG PIPE -4NPT SQ HD

52 1 468018 PLUG PIPE -6NPT HX SOC HEADLESS

53 1 468024 REDUCER -4NPT/-2NPT

54 2 470001 PIN DOWELL

55 1 474001 PLATE THRUST

56 1 486009 OIL SEAL 3/4 ID X 1 1/4 OD X 1/4 THK

57 1 486017 OIL SEAL 1 1/4 ID X 1 3/4 OD X 1/4 THK

58 1 486023 OIL SEAL 1 1/2 ID X 2 1/4 OD X 5/16 THK

60 1 490003 SNAP RING

61 1 494007 SPRING

62 3

518002 WASHER THRUST

63 1 518015 WASHER THRUST

64 1 518018 WASHER FIBER

65 1 414021 SCREW HX HD 1/4-20UNC X 1 LG NYLK

66 2 468017 PIPE PLUG SOC HD -4NPT

NOT USED

3203PR/PRX HOIST ACTUATOR

Page 69

ITEM

NO. QTY

PART

NUMBER

DESCRIPTION

1 1 100309000 SWIVEL HOOK ASSY W/LATCH

2 2 320403000 SIDE PLATE, 3203

3 1 200909000 SHEAVE ASSEMBLY

4 2 320404000 BLOCK TRAVELING

5 2 320434001 PIN, 3/4 X 2-3/4LG

6 1 018200000 NUT HX NY LK 5/8-11UNC

7 1 013512000 SCREW HX HD 5/8-11UNC X 3 1/2 LG

8 2 366813000 PIN HITCH

9 2 330100000 WASHER, FL 5/8 X 7/8 OD

10 2 320433100 DECAL, TRAVELING BLOCK 3203

11 2 040518000 DECAL STAY CLEAR OF LOAD

03 TRAVELING BLOCK ASSEMBLY

P/N: 320433000

Page 70

NOTE

Page 71

REF FOR REPLACEMENT PART ONLY (680178000) RECEPTACLE W/WIRE PIGTAIL

7 5

ITEM NO. QTY PART NO. DESCRIPTION

1 1 320988256 BULKHEAD ELECTRICAL PLATE 2 1 320589000 RELAY, HOIST 3 1 320584000 RELAY, POWER UNIT 4 1 320988399 TERMINAL STRIP 8 5 10 736272000 NUTSERT 1/4-20UNC X .027-.165 GRIP 6 1 320562000 RECEPTACLE, 11 PIN, 1/4 TURN, BAYONET 7 6 360493000 SCREW HX WHIZ-LK 1/4-20UNC X 1/2 LG 8 1 371024000 GROMET 3/4" I.D.

9 1 320988255 ELECTRICAL BOX, 8X8X4 10 7 366367000 DEUTSCH 2 PIN Assembly 11 1 360769001 HOUSING, DEUTSCH 2-PIN RECEPTACLE 12 1 320564000 CAP WITH CHAIN (FOR RECEPTACLE) 13 1 750282000 GROMMET, RUBBER, 1.375 OD, 1.00 ID

3203PR/PRX RELAY PANEL ASSEMBLY

P/N

: 320988300

Page 72

3203PR/PRX ELECTRICAL SCHEMATIC

DETAIL A

P/N

: 320988300

Page 73

ITEM NO. PART NO. COLOR GAGE

1 REF YELLOW 16 2 REF GREEN 16 3 REF ORANGE 16 4 REF RED 16 5 REF WHITE/RED 16 6 REF RED/BLACK 16 7 REF GREEN/BLACK 16 8 REF WHITE/BLACK 16

9 REF BLUE 16 10 REF BLACK 16 11 REF ORANGE/BLACK 16 12 REF WHITE 16 13 REF

ORANGE

16 14 REF WHITE/RED 16 15 REF GREEN/BLACK 16 16 REF ORANGE/BLACK 16 17 REF BLUE 16 18 REF YELLOW 16 19 REF RED 16 20 REF GREEN/WHITE 16

22 23 REF WHITE 16 24 REF WHITE 16 25 REF RED/WHITE 16 26 REF BLUE/WHITE 16 27 REF WHITE 16 28 REF WHITE/RED 16 29 REF WH

ITE 16 30 REF WHITE 16 31 320988331 BLACK 6 32 320988332 BLACK 6 33 320988333 BLACK 6 34 320988334 BLACK 6 35 320988335 BLACK 6 36 320988336 BLACK 6 37 REF WHITE 16 38 320988338 BLACK 16

NOT USED NOT USED

3203PR/PRX ELECTRICAL SCHEMATIC

P/N

: 320988300

Page 74

RETRACT (ORG/BLK)

CCW (BLK)

CANNON

PLUG

CW (ORG)

EXTEND (GRN/BLK)

BOOM UP (WHT)

BOOM DN (BLU)

PUMP (WHT/BLK)

PENDANT HEAD

POWER

D D

+ (RED)

HOIST UP (GRN)

HOIST DN (RED/BLK)

3203PR/PRX PENDANT ASSEMBLY

P/N

: 680179000

Page 75

ITEM

NO.

QTY.

PART

NO. DESCRIPTION

1 1 480501000 PENDANT HOUSING

2 1 366719000 DECAL, PENDANT 8 FUNC W/PWR

3 1 480504000 PENDANT BACK PLATE

4 1 600820000 CORD GRIP, 3/4 NPT, .50-.625" CORD

5 1 680179001 PENDANT CABLE, 11 PIN BAYONET

6 1 480598000 COVER TRIGGER OPENING

7 1 750090000 TOGGLE SWITCH, 1 POLE, 2 POSITION

8 4 634200000 TOGGLE SWITCH KIT

9 4 001004000 SCREW PN HD #6 X 3/4 LG

10 2 002607000 SCREW RD HD #10-24UNC X 3/4 LG CP

11 2 015801000 NUT HX NYLK #10-24UNC ZP

03PR/PRX PENDANT ASSEMBLY

P/N: 680179000

Page 76

NOTE

Page 77

ITEM NO. QTY PART NO. DESCRIPTION

1 1 404217000 LOWER TWECO WELD WITH SWITCH MOUNT 2 1 404224000 CABLE ASSY 11 IN, TWECO TO TERMINAL 3 1 002900000 SCREW SET 1/4-20UNC X 1/4 LG 4 1 404216000 MASTER SWITCH 5 1 404219000 DECAL, CRANE POWER

3203PR/PRX TWECO W/SWITCH MOUNT

P/N

: 404218000

Page 78

5 TYP

1 76

SEAL KIT P/N 320989424

ITEM

NO.

HYTOS

QTY

PARKER

QTY.

PART NUMBER DESCRIPTION

1 1 1 320989421 MANIFOLD BLOCK, DO3

3 - 320989428 VALVE, DO3 STACK TYPE, HYTOS

- 3 320989422 VALVE, DO3 STACK TYPE, PARKER

- 320989429 COIL, 12V-2.7A HYTOS, FOR 320989420

320989423 COIL, 12V-2.5A PARKER, FOR 320989420 4 2 2 330072000 PLUG, #10 SAE 5 6 6 202756000 FITTING 6-8 STRAIGHT

6 2 2 202755000 FITTING, -10 SAE/-6 JIC, STR

7 1 1

751034000 PLUG, -6ORB

REPLACEMENT COILS: (BLACK) = 320989423 (STEEL) = 320989429

3203PR/PRX HYDRAULIC CONTROL VALVE

P/N

: 320989420

Page 79

3203 POWER UNIT

ITEM

NO. QTY

PART

NUMBER DESCRIPTION

1 1 320991272 TANK, NEXSTAR 3203/4004EH

2 1 320991908 GAUGE, FILTER USED W/320991270

3 2 320991274 GLASS, SIGHT USED W/320991270

4 1 320991284 BASE ASSEMBLY USED W/320991270

5 1 320991271 MOTOR, NEXSTAR 3203/4004EH

6 1 320991275 CAP,FILLER USED W/ 320991270

7* 1 320991277 VALVE, RELIEF USED W/320991270

8* 1 320991910 FILTER, ELEMENT SMALL EH NEXSTAR

9* 1 320991285 O-RING USED W/ 320991270

10* 1 3209912

86 PUMP, 3203/4004EH

* NOT SHOWN

P/N

320991279

Page 80

3203PR GENERAL ASSEMBLY

APPLY LOCTITE 242 OR 243 TO THREADS OF BOLTS

- P/N: 320989005

Page 81

ITEM

NO.

QTY

PART

NUMBER

DESCRIPTION

1 1 320988204 PEDESTAL ASSEMBLY, 3203 PR

2 1 320988103 BOOM ASSY 3203 PR

3 1 320824000 PIN, LIFT CYLINDER

4 1 404220000 PIN WDMT BOOM/PED

5 2 360678000 PIN, 3/16 COTTERLESS RING

6 1 320338002 CABLE ASS'Y, 7/32" x 62FT, THIMBLE END

7 1 361102001 MOUNTING BRACKET, OMNEX PENDANT PLUG

8 1 460158000 RECEIVER, NON-PROPORTIONAL,

9 1 680180000 HARNESS, FM, 3203PR(X)

10* 1 320988013 SHIP KIT, 3203 PR/PRX, FM

11* 1 320988004 DECAL LAYOUT, 3203

12 1 23

9300000 ZERK, GREASE

13 2 005604000 SCREW HX HD 1/4-20UNC X 1 LG

14 1 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8

15 1 366159000 SCREW HX HD 3/8-16UNC X 1 1/2 LG GR8

16 2 020200000 WASHER SP LK 1/4

17 2 021200000 WASHER FL 3/8

18 2 021100000 WASHER SP LK 3/8

19 1 330372000 NUT HX 3/8-16UNC

* NOT SHOWN

3203PR GENERAL ASSEMBLY

- P/N: 320989005

Page 82

3203PRX GENERAL ASSEMBLY

1789

15 12

APPLY LOCK-TITE

242 OR 243 T

BOLT

THREAD

- P/N: 320989004

Page 83

ITEM NO. QTY PART NO. DESCRIPTION

1 1 320988203 PEDESTAL ASSEMBLY, 3203 PRX 2 1 320988102 BOOM ASSY 3203 PRX 3 1 404220000 PIN WDMT BOOM/PED 4 1 320824000 PIN, LIFT CYLINDER 5 2 360678000 PIN, 3/16 COTTERLESS RING 6 1 320338002

CABLE ASS'Y, 7/32" x 62FT, THIMBLE END

7 1 680180000 HARNESS, FM, 3203PR(X) 8 1 361102001

MOUNTING BRACKET, OMNEX PENDANT PLUG

9 1 460158000 RECEIVER, NON-PROPORTIONAL, 10* 1 320988004 DECAL LAYOUT, 3203 11* 1 320988013 SHIP KIT, 3203 PR/PRX, FM

12 1 000239300 ZERK, GREASE 13 2 005604000 SCREW HX HD 1/4-20UNC X 1 LG 14 1 366159000 SCREW HX HD 3/8-16UNC X 1 1/2 LG 15 1 330371000 SCREW HX HD 3/8-16UNC X 1 LG 16 2 021100000 WASHER SP LK 3/8 17 2 020200000 WASHER SP LK 1/4 18 2 021200000 WASHER FL 3/8 19 1 330372000 NUT HX 3/8-16UNC

*NOT SHOWN

3203PRX GENERAL ASSEMBLY

- P/N: 320989004

Page 84

PLUG REG FROM 320990310 INTO COIL

TRAVELING BLOCK IS

SHOWN FOR REFERENCE

AND IS LOCATED IN THE

SHIP KIT

APPLY LOCK-TITE

242 OR 243 TO

BOLT THREAD

3203PRFX GENERAL ASSEMBLY

- P/N: 320990000

Page 85

ITEM

NO.

QTY

PART

NUMBER

DESCRIPTION

1 1 320990200 PEDESTAL ASSEMBLY, 3203 PRFX

2 1 320990100 BOOM ASSY 3203PRFX

3 1 404220000 PIN WDMT BOOM/PED

4 1 320824000 PIN, LIFT CYLINDER

5 1 239300000 ZERK, GREASE

6 2 021200000 WASHER FL 3/8

7 2 021100000 WASHER SP LK 3/8

8 1 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8

9 1 460158000 RECEIVER, NON-PROPORTIONAL,

10 2 020200000 WASHER SP LK 1/4

11 2 005604000 SCREW HX HD 1/4-20UNC X 1 LG

12 1 330372000 NUT HX 3/8-16UNC

13 2 360678000 PIN, 3/16 COTTERLESS RING

14 1 680180000 HARNESS, FM, 3203PR(X)

15 1 361102001 MOUNTING BRACKET, OMNEX PENDANT PLUG

16 1 320988013 SHIP KIT, 3203 PR/PRX, FM

17 1 320988004 DECAL LAYOUT, 3203

18 1 366159000 SCREW HX HD 3/8-16UNC X 1 1/2 LG GR8

19 1 320338002 CABLE ASS'Y, 7/32" x 62FT, THIMBLE END

3203PRFX GENERAL ASSEMBLY

- P/N: 320990000

Page 86

FM CONTROL

E AND CARE

TRANSMITTER LAYOUT

nd a y

There is a red light to the left of the ON/OFF Toggle switch a battery runs down, the red light will begin to flash as well as the yellow light.

If the yellow light is rapidly flashing this indicates that the unit is transmitting. Refer to the Transmitter Diagnostics Section for a detailed explanation of each light combination.

In addition to the two lights mentioned above there are four function toggle switches. These functions from left to right are to be used to raise and lower the boom, raise and lower the hoist cable, rotate the crane and extend and retract the boom.

ellow light to the right. As the

POWER O

The transmitter is powered by 4-AA alkaline batteries, located under the back cover of the housing.

urn the transmitter on, press and hold the Power On Toggle, release once the transmit light

To t starts blinking. To turn the unit off, press and hold the power off toggle, release after the transmit light stops flashing.

N/OFF TOGGLE SWITCH

FUNCTION SWITCHES

To operate a function, toggle one of the function switches with either the thumb of the hand holding the unit o one time.

CARE

KEEP D inside the transmitter battery or receiver compartment, immediately dry the unit. Remove the case and let the unit air dry.

WELDING

DISCONNECT THE RADIO RECEIVER BEFORE WELDING on the crane, load, or truck. Failure to disconnect will result in the destruction of the radio receiver.

r the thumb or fingers of the opposite hand. More than one function can be activated at

RY. Do not clean the transmitter / receiver under high pressure. If water or other liquids get

Page 87

TRA

NSMITTER - P/N: 460157000

FM CONTROL

Page 88

3203PR/PRX ELECTRICAL SCHEMATIC

ROTATE CW

ROTATE CCW

WINCH UP

WINCH DOWN

BOOM UP

BOOM DOWN

PEND (A) PEND (B)

1 2 3 4 5 6 7 8

9 10 11 12

B (BLACK PLUG)

(WHT/BLK)

(BLK)

(RED)

PUMP

GROUND

POWER W/LINK

POWER

EXTEND

RETRACT

1 2 3 4 5 6 7 8

9 10 11 12

A (GREY PLUG)

CANNON PLUG

(GRN/BLK)

(ORG)

(WHT/RED)

(GRN)

(RED/BLK)

(WHT)

(BLU)

(BRN)

(BLU)

13 5

(GRY)

(BLK)

PENDANT

PLUG

(ORG/BLK)

(WHT)

P/N

: 680180000

Page 89

3203EH

TROUBLESHOOTING CHART

CRANE DOES NOT OPERATE

CORRECTL

THIS

CRANE

DOES THE

CRANE OPERATE

UNEXPECT

A FUNCTION IS

NOT SELECTED?

DOES THE CRANE NOT MOVE WHEN

IS SELECTED?

ADLY WHEN

A FUNCTION

YES

DOES THE LED

LIGHTS SHOW NOR-

OPERA

MAL

WHEN YOU UNPLUG THE CORRESPONDING COIL?

WHEN YOU MANAULLY

TION ON

RECEIVER

(REF PAGE 83)

DOES IT

MOVING

STOP

DOES IT

T MOVING

STAR

OVERRIDE?

REF. PAGE 88

YES

LIGHTS SHOW NORMAL

GO TO TRANSMITTER TROUBLE SHOOTING SECTION—P

GO TO RECEIVER TROUBLE SHOOTING SECTION— PAGE

GO TO ELECTRICAL TROUBLE SHOOTING SECTION— PAGE 82

GO TO HYDRAULIC TROUBLE SHOOTING SECTION— PAGE 89

YES

GO TO ELECTRICAL TROUBLE SHOOTING SECTION— PAGE 82

DOES THE LED

OPERA

TION ON TRANSMITTER (REF PAGE 83)

AGE 86

YES

DOES THE

CRANE MOVE SLOW OR

ERRATIC

A FUNCTION

WHEN

IS SELECTED?

IS THERE

EXCESSIVE AMP

OR WIRES HEATING UP?

DRAW

YES

SOUND LIKE THE POWER

UNIT

DOES IT

T MOVING

STAR NORMALLY WHEN YOU MANAULLY OVERRIDE?

REF. PAGE 88

DOES IT

IS GOING OVER

RELIEF

CONTACT AN AUTOCRANE REPRESENTATIVE FOR MORE DETAILED TROUBLE-SHOOTING

YES

GO TO HYDRAULIC TROUBLE SHOOTING SECTION— PAGE 89

YES

GO TO ELECTRICAL TROUBLE SHOOTING SECTION— PAGE 82

GO TO HYDRAULIC TROUBLE SHOOTING SECTION— PAGE 89

GO TO ELECTRICAL TROUBLE SHOOTING SECTION— PAGE 82

Page 90

3203EH

ELECTRICAL TROUBLESHOOTING CHAR

PROBLEM POSSIBLE CAUSE DIAGNOSIS SOLUTION

CRANE OPERA UNEXPECT

NO FUNCTION OPERATES ON THE CRANE.

TES

ADLY

DAMAGED TOGGLE SWITCH TURN OFF OR UNPLUG PENDANT. SEE

SHORT IN HARNESS UNEXPECTED MOVEMENT WOULD

HOIST FUNCTION ALWAYS RUNNING (HOIST UP OR DOWN)

POWER UNIT ALWAYS ACTIVE

PENDANT TURNED OFF VERIFY TOGGLE SWITCH ON PENDANT

TRANSMITTER/ RECEVIER NOT SYNCHRONIZED (FM UNITS ONLY)

CRANE TURNED OFF CHECK MAIN DISCONNECT SWITCH

IF MOVEMENT STOPS

ONLY OCCUR WHEN MULTI-FUNCTIONING FOR HYDRAULIC FUNCTIONS. UNPLUG COIL TO SEE IF MOVEMENT STOPS. CHECK FOR VOLTAGE AT THE COIL CONTACTS.

WITHOUT HOIST BEING SELECTED, THE HOIST FUNCTION IS OPERATIONAL

IF NO FUNCTION IS SELECTED BUT THE POWR UNIT IN RUNNING ON WHEN NO FUNCTION IS SELECTED

IS IN THE “ON POSITION” - HW UNITS VERIFY YELLOW LIGHT IS FLASHING— FM UNITS

CHECK LED LIGHTS WITH TRANSMITTER TURNED ON. LINK LIGHT & STATUS LIGHT SHOULD BE GREEN

LOCATED IN CRANE BOX AND VERIFY IT IS IN THE ON POSITION.

VERIFY THAT NOTHING WAS ACTIVATING TOGGLE SWITCH AT TIME OF MOVEMENT. IF NOT ACTIVATED THEN REPLACE SWITCH

TRACE WIRE BACK TO 1/4 TURN BAYONET PLUG. VERIFY NO DAMAGE TO THE WIRE. CHECK CONNECTORS, THEY SHOULD BE CLEAR OF DEBRIS AND WATER.

CHECK HOIST RELAY CHECK WIRING FOR A SHORT

CHECK POWER UNIT RELAY CHECK WIRING FOR SHORT GOING TO POWER UNIT

TURN ON TRANSMITTER BY TOGGLING THE POWER SWITCH INTO THE “ON” POSITION.

SYNCHRONIZE TRANSMITTER—REFERENCE ID CODE PROGRAMMING SECTION IN MANUAL

TURN SWITCH INTO THE “ON” POSITION

THE FOLLOWING FUNCTIONS ARE INOPERABLE BOOM DOWN, EXTEND, HOIST UP

CRANE ROTATES SLOWLY

LOW TRANSMITTER BATTERY (FM UNITS ONLY)

LOST GROUND USING A VOLTMETER CHECK MAIN

LOW TRUCK BATTERY VOLTAGE

POWER UNIT NOT ACTIVATING

ANTI-2 BLOCK CHECK CONTINUITY AT A2B PLUG IN

CRANE OVERLOAD CHECK CONTINUITY AT THE PRESSURE

ADEQUATE OPERATING CLEARANCES BETWEEN WORM GEAR AND WORM

WHILE THE TRANSMITTER IS TURNED ON, CHECK THE YELLOW LED ON TRANSMITTER SHOULD BE FLASHING SLOWLY. RED FLASHING IS LOW BATTERY

POWER WIRE AT RELAY PANEL USING GROUND ON CRANE. THEN CHECK TO SEE IF SAME VOLTAGE FROM CHASSIS GROUND & RELAY PANEL POWER.

WHEN RUNNING A FUNCTION, CHECK VOLTAGE AT HOIST OR HYDRAULIC POWER UNIT. SHOULD NOT DROP BELOW 10V.

IF RECEIVER HAS POWER BUT THE POWR UNIT DOESN’T TURN ON WHEN A FUNCTION IS SELECTED

THE PEDESTAL WHEN DISCONNECTED ON THE CORD REEL SIDE. SHOULD BE A CLOSED CIRCUIT

SWITCH WHEN DISCONNECTED ON THE PRESSURE SWITCH SIDE. SHOULD BE A CLOSED CIRCUIT

ROTATION WILL SLOW AT A PARTICULAR POINT ON THE WORM GEAR

REPLACE TRANSMITTER BATTERIES. IT REQUIRES (4) AA BATTERIES

USING OHMMETER CHECK RESISTANCE ACROSS ALL COMPONENTS IN THE GROUND CIRCUIT. PAY SPECIAL ATTENTION TO GROUND CONTACTING WORM GEAR. REPLACE OR REMOVE IMPEDENCE FROM CIRCUIT.

VERIFY TRUCK IS RUNNING WHILE OPERATING CRANE CHECK VEHICLE BATTERY FLUID LEVEL CHECK FOR ADEQUATE WIRE SIZING FOR LENGTH AND AMPERAGE REQUIREMENTS

CHECK POWER UNIT RELAY CHECK GROUNDING WIRE FROM RELAY TO PUMP CHECK MAIN GROUNDING WIRE FROM PUMP TO GROUNDING BOLT ON PEDESTAL

VERIFY THAT THE TRAVELING BLOCK IS NOT IN CONTACT WITH BAIL. IF SO, HOIST DN AND CHECK FUNCTIONS AGAIN. INSPECT END OF BOOM TO VERIFY BAIL IS IN CONTACT WITH ANTI-2 BLOCK SWITCH. CHECK BAIL SPRING. CHECK CORD REEL & WIRE ON SIDE OF CRANE FOR DAMAGE.

VERIFY LOAD ON CRANE DOES NOT EXCEED MOMENT RATING. REFERENCE LOAD CHART. CHECK PRESSURE ON CYLINDER IN GAUGE PORT—BOOM MUST BE SUPPORTED BEFORE REMOVING GAUGE PORT PLUG. VERIFY SWITCH IS PLUGGED INTO HARNESS.

SLIGHTLY LOOSEN BOLTS ATTACHING TAPERED BEARINGS TO PEDESTAL. TAP THE BEARING HOUSING USING A HAMMER AWAY FROM THE WORM GEAR. RETIGHTEN BOLTS.

ALL FUNCTIONS OPERATE SLOWLY

LOW TRUCK BATTERY VOLTAGE

WHEN RUNNING A FUNCTION, CHECK VOLTAGE AT HOIST OR HYDRAULIC POWER UNIT. SHOULD NOT DROP BELOW 10V.

VERIFY TRUCK IS RUNNING WHILE OPERATING CRANE CHECK VEHICLE BATTERY FLUID LEVEL CHECK FOR ADEQUATE WIRE SIZING FOR LENGTH AND AMPERAGE REQUIREMENTS

Page 91

FM CONTROL

Light Legend

Solid

Slow Flash

Fast Flash

Red Light

Green Light

Alternating Red & Green Light

Yellow Light

Tether connection detected

Low battery. Unit will run approximately 10 hours after Battery light starts flashing.

Flashing rapidly for 10 seconds indicates a transmitter failure.

Normal Operation

The Active light will flash several times per second, indicating that the transmitter is sending signals to the receiver. The Active light will remain on momentarily whenever a function changes

Normal Operation

The transmitter is in Download Mode.

Stuck switch detected. Ensure that all switches are in a centered position. The transmitter will not power up when a function is ON.

On Power Down

Unit is still powered. Check for stuck switches, as the transmitter will not power down when a function is ON. Alternating flash means that the transmitter is in Calibration Mode.

TRA

NSMITTER TROUBLESHOOTING

Page 92

Light Legend

Solid

Slow Flash

Fast Flash

Red Light

Green Light

Alternating Red & Green Light

Yellow Light

Normal Operation

Transmitter is OFF If the transmitter is off, the receiver is operating properly.

Transmitter is ON When the transmitter is turned on, the Link light (fast flashing) and E-Stop (GREEN) indicates the receiver is operating properly

Transmitter is in Operation When a function is activated on the transmitter, the Fault light will turn on GREEN. This indicates the receiver is operating properly

Transmitter is OFF When a latched function is activated then the transmitter is turned off, the Fault light will stay on GREEN. If the system was intentionally designed this way, the receiver is operating properly, if not call for service.

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

Indicator Lights Description Solution

Transmitter is ON The reason is the transmitter is not communicating with the receiver.

Refer to Trouble Shooting Chart #3 for solutions

Transmitter is ON A low battery condition has been detected.

To detect intermittent conditions caused by poor or corroded ground or power circuits, the GREEN light will continue to flash for 30 seconds after the condition has been removed.

Transmitter is ON An internal fault with the E-Stop has been detected.

Check fuse, if OK then: Inspect E-Stop wiring for short circuit. Disconnect E-Stop wire as close to the receiver output as possible. If the Status light changes to:

t GREEN, a short occurs after disconnection point.

t Stays flashing RED, send it in for service .

Transmitter is ON A short to ground or excessive current draw on an output. It is most likely caused by a wiring fault.

Ensure transmitter is functioning properly, check status of each output connection: Press each function button and observe Fault Light.

t If GREEN, everything is OK.

t If RED, there is a short in that connection.

Transmitter is ON E-Stop output is connected with one of the other outputs or one of the outputs is shorted to power

Turn off transmitter, if condition clears follow E-Stop wire and check for connections with other wires. If condition remains one of the outputs is shorted to power. Test all outputs wires for power.

Transmitter is OFF A wiring short to the battery has been detected.

Refer to Trouble Shooting Chart #1 for solutions

Transmitter is OFF The receiver has detected an internal fault.

Refer to Trouble Shooting Chart #1 for solutions

Transmitter is ON Blown fuse detected. (not functional with proportional units)

Refer to Page 8 for instructions on how to open the receiver case to access fuse. Check wiring for shorts or bare spots. If fuses continue to blow, call for service.

A setup failure has occurred.

Either hold the Setup button for 5 seconds to return to Setup mode or cycle power to return to the normal operating mode.

Transmitter is OFF The receiver is powered incorrectly.

Most likely cause of this condition is that an output wire or the E-Stop wire has been connected to a power source while the power wire is disconnected from the Power Input (A6). I.E. Receiver is being powered from an output and not Power Input.

Trouble Indicators

Note: In some cases, the indicator lights will be different depending on whether the transmitter is on or off. Please note the transmitter status in the “Description” column for each case.

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

FM CONTROL

CEIVER TROUBLESHOOTING

Page 93

Start

Initial Condition: Turn transmitter off (all lights are off—press [POWER] OFF) Cycle power to receiver (turn off and back on)

What is the state

of the lights on

the receiver?

OK state: Status—GREEN Link—RED Fault—OFF E-Stop—RED

Note: If there is a short to ground on an output, it is not indicated at this stage. To test for short to ground, refer to the “*Fault Light is RED*” procedure at the bottom of this page and follow the instructions.

Problem state: Status—RED

Go to Chart 2

What is the

state of the E-

Stop light ?

OK state:

E-Stop—RED

Problem state:

E-Stop— Flashing RED

Is the Status light flashing

RED?

Fuse is blown, change fuse

1. Inspect wiring looking for short circuits (e.g. bare wires)

2. If problem re-occurs, call for service.

YES

Inspect E-Stop wiring looking for short circuits (e.g. bare wires) Disconnect the E-Stop output as close to the receiver output as possible. If the Status light changes to:

t GREEN, there is a short is the wiring after the discon-

nection point.

t Stays flashing RED, call for service .

What is the state of the Fault light ?

Fault Light is

OFF

Fault Light is

Flashing RED

*Fault Light is

RED*

Call for service.

There is a short to supply.

1. Disconnect A & B connectors from receiver and check all outputs for power (e.g. bare wires, improper connections) make the correct adjustments

2. Call for service.

There is a short to ground. Note: This should only occur when the transmitter is on and a function button is pressed. In this case the Status light will be GREEN and will turn RED at the same time as the Fault light.

Go to Chart 2 to test the transmitter. If the transmitter is functioning properly, proceed to check the status of each of the output connections:

Press each of the function buttons and observe the Fault Light. If the light turn GREEN, everything is OK. If the Light turns RED, there is a short in that connection.

Test the Receiver—R160

Problem state: Status—flashing GREEN & RED

The system is wired incorrectly. Most likely cause is one of the input/output wires has been connected to the power source.

FM CONTROL

CEIVER TROUBLESHOOTING

Page 94

What is the state of

the lights?

Active light is flashing rapidly and Battery light flashing slowly

Low Battery—Change Batteries

Note: Low batteries will last approximately 10 hours once the Low Battery light begins to flash. Replace batteries by next shift.

Battery light and Active light flash alternately.

The transmitter is in Calibration mode

1. Turn unit OFF, then turn back ON

2. If condition persists, call for service.

Test the Transmitter—T150

Turn off the receiver Ensure there are good batteries in the transmitter Turn on the transmitter

OK state: Active light—steady for about 3 seconds then goes to fast flash. Battery light—OFF

Go to Chart 3

Activate a

function

Does the Active

light go to solid

YELLOW?

YES

Either the switch/trigger is defective or the switch/trigger connection to the circuit board is broken.

Call for service

Complete the following steps in order:

1. Check battery orientation

2. Clean battery contacts

3. Check or Replace batteries

4. Call for service

Stuck switch:

1. Return all switches to neutral (OFF) position

2. Toggle the switch a few times

3. Call for service

No light comes on at any time

Both the Active light and the Battery light flash at the same time

Press and release E-Stop if the condition persists, then either there is a faulty EStop or transmitter failure—call for service

Battery light flashes for 10 seconds then all lights are OFF

FM CONTROL

TRA

NSMITTER TROUBLESHOOTING

Page 95

FM CONTROL

Testing the Transmitter / Receiver Communication

What is the status of the lights of both the

transmitter and

receiver?

Transmitter: Active light is flashing

Receiver: Status—GREEN Link—Flashing GREEN Fault—OFF E-Stop—GREEN

Transmitter: Active light is flashing

Receiver: Status—GREEN Link—RED Fault—OFF E-Stop—RED

There is no link between the transmitter and receiver

Do you have a

matched set? (i.e. the

transmitter and re-

ceiver should have

identical ID codes

YES

Was the transmitter

accidentally swapped

with another one on

the job site?

Search the job site for the correct transmitter.

POSSIBLY

Transmitter and receiver should be working properly. The problem may rest with the machine instead of the radio system

Call for service

Was it found?

Turn on the transmitter to check if the units function correctly. If not, proceed to Chart 1

YES

The transmitter code may need to be re-downloaded to the receiver

!!Caution!!

Note: Before you proceed with the Download ID procedure located on Page 8, great

care and caution must be adhered to.

If by accident, the transmitters have been switched with another unit, by downloading the ID code to a new receiver, it is possible for the transmitter to operate 2 units at the same time (if the original receiver unit is still on the job site). Therefore it must be certain that the transmitter / receiver pair are the correct set.

Secondly, once the download procedure is completed, ensure all other units on the job site are stopped. Test the operation of the n

ewly configured set to ensure no other

machines on the site work with the same transmitter.

Once you are certain that the transmitter / receiver pair are a unique set, continue normal operations.

Call for service.

OUBLESHOOTING CHART 3

Page 96

3203EH

PROBLEM POSSIBLE CAUSE DIAGNOSIS SOLUTION

JAMMED CARTRIDGE

TRY TO MANUALLY OVERRIDE VALVE IF UNABLE TO MOVE STEM. CARTRIDGE IS JAMMED

REPLACE CARTRIDGE

COUNTER-BALANCE SET TOO LOW (BOOM-UP & BOOM-DN )

ADJUST THE COUNTER-BALANCE OUT TO SEE IF MOVEMENT STOPS.

CONTACT AUTOCRANE FOR PROPER SETTING OF COUNTER-BALANCE. YOU MAY NEED TO REPLACE COUNTER-BALANCE.

CONTAMINATE IN CARTRIDGE VALVE STICKS IN CERTAIN POSITIONS

CLEAN CARTRIDGE

NO FUNCTION OPERATES ON CRANE

HYDRAULIC TANK IS LOW OR EMPTY

VISUALLY INSPECT THE HYDRAULIC OIL LEVEL IN THE TANK

FILL TANK TO PROPER LEVEL.

ALL FUNCTIONS OPERATE SLOWLY

FILTER CLOGGED

CHECK FILTER GAUGE LOCATED ON FILTER HOUSING

REPLACE FILTER

EXCESSIVE HEAT DURING OPERATION

OPERATION TIME

CRANE OPERATION IS GENERALLY DESIGNED FOR INTERMITTENT DUTY (7 MIN. LOADED / 30 MIN. COOLDOWN)

REDUCE USE OF CRANE TO ALLOW OIL TO COOL

CRANE MOVES UNEXPECTEDLY

HYDRAULIC TROUBLESHOOTING CHART

Page 97

3203EH

MANUAL OVERRIDE PROCEDURE

MANUAL OVERRIDE PROCEDURES

1. APPL

2. APPLY GROUND FROM BATTERY TO GROUNDING CONNECTION

3. SELECT THE FUNCTION DESIRED, THEN PUSH IN OVERRIDE LOCATED ON THE END

CAUTION: MANUALLY OVERRIDING CRANE BYPASSES ALL SAFETY FEATURES. DURING OPERATION MAKE SURE LOAD DOES NOT EXCEED CRANE CAPACITY AND THE TRAVELING BLOCK DOES NOT COME INTO CONTACT WITH BOOM TIP.

Y 12VDC FROM BATTERY TO PUMP POWER TERMINAL

OF THE COIL USING A PUNCH OR OTHER SMALL OBJECT

Page 98

FM CONTROL

ID CODE PROGRAMMING

Download ID Code (

ote: Before attempting reprogramming with another transmitter, understand that re-

programming the receiver with another transmitter, could result in two receivers on the job site responding to the one transmitter. If the original transmitter was sent in for repair, disconnect the receiver (disconnect connector A) to continue using the machine without remote capability and without fear of inadvertently operating the machine with the other transmitter.

Reprogramming Tips:

se a pointy instrument to depress the Setup button on the receiver (i.e. a pen) as the button is relatively small

1. U

2. Follow each step as laid out in the procedure

3. Never lay the receiver circuit board down on anything metallic (there are contact points on the back which could con tact the metal and damage the receiver)

llow these steps to download the transmitter’s unique ID Code into the receiver. This will allow the receiver to establish

Fo a radio link with that transmitter.

Refer to the Light Legend below for diagram details.

NOTE: It is necessary to download the ID Code when replacing either the transmitter or the receiver.

NOTE: If the transmitter is connected to the receiver with a Tether Cable, completing only steps 3 and 5 is necessary (it is not necessary to open the R160 case and press the Setup button).

Use in case of Link Test failure)

!!Caution!!

Connector A

1. Opening the Receiver Case

p is held on by two plastic tabs at

The ca opposing sides, which can be unlatched as shown using a screwdriver. Once the cap is free, the R160 can slide open.

Use a small slotted screwdriver to press the Side Tabs inward.

2. Prepare Transmitter, Power Receiver

A. Press [POWER] OFF

B. Supply power to the receiver

Page 99

ID CODE PROGRAMMING (CONT.)

3. Power Transmitter into Configuration Mode

A. Press & hold [BOOM] switch in the UP position

B. Press & release [POWER] switch in the OFF position

C. Release [BOOM] switch

The ACTIVE LED will flash once per second.

4. Put Receiver into Setup

A. Press & hold [Setup] button until (Status) light goes from slow flash to fast flash B. Release [Setup] button.

(Status) light goes to solid GREEN, (Link) light turns off

CONTROL

NOTE: If left idle in Setup Mode for over 30 seconds, the receiver will time out. The (Link) light and (Status) light will flash RED rap- idly. To return to Setup Mode, repeat step 4.

Download ID Code

A. Press & release [BOOM]

switch in the UP position

B. The R160 (Link) light goes to

GREEN. Once complete, (Link) light goes to RED as the transmitter turns off

Page 100

NOTE