MODELS 78102 2 TON, 78106 2500 LB., 78600 & 78605 3 TON CAPACITY
PROFESSIONAL LIFTING EQUIPMENT
®
SHOP CRANES AND 78204 1/2 TON CAPACITY TRUCK CRANE
SETUP • OPERATING • MAINTENANCE INSTRUCTIONS
Note: Revision letters (A, B, C, D etc.) after model numbers have been omitted as they do not affect the setup,
operating and maintenance instructions of a particular jack unless otherwise noted.
IMPORTANT: READ THESE INSTRUCTIONS BEFORE OPERATING
BEFORE USING THIS CRANE, READ THIS MANUAL AND
THE ADDITIONAL INSTRUCTION MANUALS ON THE PUMP
(MODELS 78600, 78605, AND CRANES USING OPTIONAL AIR
PUMPS) AND WINCH (MODEL 78204A ONLY) COMPLETELY
AND THOROUGHLY, UNDERSTAND THEIR OPERATING
PROCEDURES, SAFETY WARNINGS AND MAINTENANCE
REQUIREMENTS. FAILURE TO DO SO COULD CAUSE
ACCIDENTS RESULTING IN SERIOUS OR FATAL PERSONAL
INJURY AND/OR PROPERTY DAMAGE.
The use of shop cranes is subject to certain hazards that cannot
be prevented by mechanical means, but only by the exercise of
intelligence, care, and common sense. It is therefore essential to
have owners and personnel involved in the use and operation of
equipment who are careful, competent, trained, and qualied in
the safe operation of the equipment and its proper use. Examples
of hazards are dropping, tipping, or slipping of loads caused
primarily by improperly securing loads, overloading, off- centered
WARNING
Inspect the crane before each use. Do not use the crane if it is •
damaged, altered, modied, in poor condition, leaking hydraulic
uid, or has loose or missing hardware or components. Take
corrective action before using the crane.
Do not use crane beyond its rated capacity and that capacity is •
determined by the boom position. Consult the product label for
exact capacity at the boom position.
Wear approved eye protection.•
Stay out from underneath a load that is being lifted or •
suspended.
Use only on a hard level surface. Use extreme caution when •
loads, lifting or moving a load that has a center of gravity that
extends beyond the crane’s wheels, use on other than a hard
level surface, and using equipment for a purpose for which it was
not designed. It is the responsibility of the owner to make sure all
personnel read these manuals prior to using this device. It is also
the responsibility of the device owner to keep these manuals intact
and in a convenient location for all to see and read. If the manuals
are lost or not legible, contact Norco Industries, Inc. for free
replacements. If the operator is not uent in English, the product
and safety instructions shall be read to and discussed with the
operator in the operator’s native language by the purchaser/owner
or his designee, making sure that the operator comprehends its
contents.
WARRANTY
This product is covered by a Limited Lifetime Warranty. For details
see the back cover of Norco’s product catalog.
moving a loaded crane around a corner. A load can swing out
beyond the wheels and cause the crane to tip over. Do not
allow a load to swing or drop violently while lowering or moving.
The crane legs must always extend beyond the end of the •
boom before a load is lifted. Do not lift or move a load that has
a center of gravity that extends beyond the crane’s front wheels
or the width of the back of the crane.
Before moving the crane, lower the load to the lowest possible •
point.
Use only slings or chains with a rated capacity greater than the •
weight of the load to be lifted.
Cranes that include air/hydraulic foot pumps must be connected 1.
to an air line that does not exceed 120 P.S.I. of input air pressure.
The model 78605 crane includes an electrohydraulic pump which
must be plugged into a 110/115 VAC outlet in accordance with the
instructions in the pump manual.
Air/hydraulic and electrohydraulic pumps have vent plugs that 2.
must be opened in accordance with the instructions given in the
pumps manuals before operating the cranes.
Sometimes air gets trapped in the hydraulic system causing 3.
the ram to extend in sporadic increments instead of one smooth
extension.
PURGING AIR FROM THE MANUAL PUMP SYSTEM
(Models 78102, 78106 and 78204)
Open the release valve by turning the release valve knob in a.
a counterclockwise direction two full turns.
Pump the handle ten full strokes.b.
Close the release valve by turning the release valve knob in c.
a clockwise direction until tight.
SETUP
Pump the jack until the ram is extended to maximum height.d.
If the condition remains, repeat steps “a” through “d” until air e.
is purged from the system.
PURGING AIR FROM THE AIR/HYDRAULIC FOOT PUMP
SYSTEM (Model 78600 and any other model using an optional
air/ hyd. foot pump)
Press down on the “pump” end of the pedal on the air/ a.
hydraulic foot pump with one hand while simultaneously
depressing the button located under the “release” end of the
pedal with a nger of the other hand. Hold this position for
10 to 15 seconds and then release both hand and nger.
Now depress the “pump” end of the pedal with your foot and b.
raise the jack to maximum height. If the condition remains,
repeat steps “a” and “b” until air is purged from the system.
PURGING AIR FROM THE ELECTROHYDRAULIC SYSTEM
Run the system through several complete cycles without a.
a load on the ram. When the ram advances and retracts
without hesitation, the air is purged from the system.
OPERATING INSTRUCTIONS
Models 78102, 78106 and 78204 are equipped with long stroke 1.
bottle jacks. Install the two-piece handle into the pump receiver
when activating the pump. The release valve knob must be turned
in a clockwise direction until tight before the jack can be pumped.
Turning the release valve knob very slowly in a counterclockwise
direction lowers the load in a safe controlled manner. There
should never be a reason to turn the release valve knob in a
counterclockwise direction more than two full turns at any time.
Become familiar with the pedal operation of the air/hydraulic 2.
foot pump on Model 78600 and all cranes using the optional air/
hydraulic foot pump before using the crane under load. Depressing
the foot pedal end marked “pump” raises the crane boom. To raise
the boom a small distance it is necessary to use incremental taps
of your foot on the foot pedal until the boom reaches the desired
height. Lowering the boom is accomplished by depressing the foot
pedal end marked “release”. The pump is equipped with a twospeed release mechanism. Gently depressing the foot pedal end
marked “release” lowers the boom slower than if you depress the
pedal all the way down. If you want to lower the load slower than
the slow speed release, use gentle incremental taps of your foot
on the “release” pedal.
IMPORTANT: Heavier loads will require slower and more
controlled lowering of the load. Optional poppet valves are
available and easily installed in the foot pump. Poppet valves
meter the return of uid back to the pump when the load is
released. Although the standard release mechanism on the
foot pump offers a more than adequate lowering control feature,
poppet valves offer an added measure of load release control.
Contact the Norco Customer Service Department for additional
information.
Before lifting, determine the weight of the load to be lifted. 3.
Extend the boom to its required length making sure the capacity at
that extension exceeds the weight of the load to be lifted. Secure
the telescopic boom tubes together with the bolts or pins provided.
If the crane is equipped with telescopic legs make sure the wheels
on the front legs are extended and secured beyond the reach
of the boom and the wheels on the rear legs are extended and
secured to their maximum length for side to side stability. Do not
lift or move a load with a center of gravity that extends either to the
side beyond the width of the frame or back legs or the front beyond
the front wheels.
The models 78600 and 78605 are equipped with telescopic 4.
front legs that can be extended by using the pry bar provided.
Position the pry bar underneath the outer tube where the inner
tube comes out and pull down on the bar. Remove the leg pin and
extend the inner tube out to its desired position. Insert the leg pin
to secure the telescopic tubes together. Repeat this step on the
opposite leg. Remove the pry bar when nished and store it in its
holder.
The models 78600 and 78605 are equipped with a feature that 5.
allows the boom to be locked in the straight ahead position or 10°
right or left of center for gaining access into some tight places.
Disengage the lock pin to move the boom left or right. Once the
boom is in the desired position secure it with the lock pin.
The model 78106 foldable oor crane can be congured in 6.
the storage position by removing the wing bolts that secure the
crane base frame to the legs. Pull each leg out from its receiver
and rotate it out to its respective side. Once a leg clears the base
frame, rotate it up until it touches the handle bar. Rotate the handle
bar lock so the cutout in the lock ts over the threads of the hex
head bolt on the inboard side of the leg. Tighten the hex head bolt
and repeat this step with the other leg.
The model 78204 truck crane is equipped with a winch. Read 7.
the winch operations manual that accompanied this crane for
instructions on the proper use and care of the winch. The winch
is used in conjunction with the hydraulically activated boom.
Always remember to have excess cable at the end of the boom
as operating the boom hydraulically sometimes uses some of the
cable length.
PREVENTATIVE MAINTENANCE
Always store the crane in a well protected area where it will 1.
not be exposed to inclement weather, corrosive vapors, abrasive
dust, or any other harmful elements. The crane must be cleaned of
water, snow, sand, or grit before using.
Lubricate moving parts once a month with a general purpose 2.
grease.
It should not be necessary to rell or top off the reservoir with 3.
hydraulic uid unless there is an external leak. An external leak
requires immediate repair which must be performed in a dirt-
free environment by qualied hydraulic repair personnel who are
familiar with this equipment. Norco Authorized Service Centers are
recommended. IMPORTANT: In order to prevent seal damage
and hydraulic failure, never use alcohol, hydraulic brake uid,
or transmission oil in the hydraulic system.
REPAIR SERVICE
If your Norco product requires service or repair, contact the Norco
Customer Service Department for the location of the nearest Norco
Authorized Service Center.
Norco Industries, Inc.
365 West Victoria St.
Compton, CA 90220
(310) 639-4000 • Fax: (310) 639-7411
www.norcoindustries.com
Every crane owner is responsible for keeping the crane label 4.
clean and readable. Use a mild soap solution to wash external
surfaces of the crane but not any moving hydraulic components.
Contact Norco Industries for a replacement label if your crane
label is unreadable.
Inspect the crane before each use. Do not use the crane if any 5.
component is cracked, broken, bent, shows sign of damage, or
leaks hydraulic uid. Do not use the crane if it has loose or missing
hardware or components, or is modied in any way. Take corrective
action before using the crane again.
Do not attempt to make any hydraulic repairs unless you 6.
are a qualied hydraulic repair person that is familiar with this
equipment.
It will be necessary to provide the Norco Authorized Service Center
with a copy of the bill of sale if requesting warranty repair. If the
authorized service center determines your product is eligible for
warranty repair, the repair will be made at no charge and returned
freight prepaid. The cost of non-warrantable service, repair, and
return freight is the customer’s responsibility.
78102 / 78106 / 78600 / 78605 / 78204
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