Advertisement
Advertisement
OWNERS MANUAL
3203 P/PR/PRX
REVISION 2/2000
PART NO. 999947
SERIAL NO. __________________________
AUTO CRANE COMPANY
PO BOX 580697, TULSA, OK 74158-0697
4707 N. MINGO ROAD, TULSA, OK 74117
PHONE (918) 836-0463
FAX (918) 834-5979 http://www.autocrane.com
WARNINGS -
READ THIS PAGE!
WARNING!
Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of a vehicle certify that the vehicle complies with all applicable federal regulations. Any modifications performed on the vehicle prior to the final stage are also considered intermediate stage manufacturing and must be certified as to compliance. The installer of this crane and body is considered one of the manufacturers of the vehicle. As such a manufacturer, the installer is responsible for compliance with all applicable federal and state regulations, and is required to certify that the vehicle is in compliance.
WARNING!
It is the further responsibility of the installer to comply with the OSHA
Truck Crane Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).
WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL
POWER LINES!
Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to
50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.
WARNING! NEVER
.............................
v EXCEED load chart capacities (centerline of rotation to hoist hook).
v un-reel last 5 wraps of cable from drum!
v wrap cable around load!
v attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
v weld, modify, or use unauthorized components on any Auto Crane unit! This will void any warranty or liability. Also failure of the crane may result.
v place a chain link on the tip of the hook and try to lift a load!
v use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature!
v hold on any pendant Select Switch that will cause unsafe operating conditions!
WARNING!
In using a hook with latch, ALWAYS make sure that the hook throat is closed before lifting a load! Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.
WARNING!
Failure to correctly plumb and wire crane can cause inadvertent operation and damage to crane and/or personnel!
WARNING!
Auto Crane Company remote controlled cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel.
WARNING!
ALWAYS
operate the crane in compliance with the load capacity chart.
Do not use the overload shutdown device to determine maximum rated loads, if your crane is equipped with this type of device.
warning 9/98
3203P/PR/PRX SERIES - OWNER'S MANUAL
TABLE OF CONTENTS
5
6
3
4
1
2
7
8
9
10
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING PRACTICES & WARNINGS . . . . . . . . . . . . . . . . . . . . . . .
OPERATION OF UNIT / OUTRIGGERS . . . . . . . . . . . . . . . . . . . . . . . .
QUALIFICATIONS FOR OPERATORS . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION, TESTING, & MAINTENANCE . . . . . . . . . . . . . . . . . . . .
LIFE OF WIRE LINE / WIRE LINE LUBRICATION . . . . . . . . . . . . . . .
SAFETY DECAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION & MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . .
MOUNTING & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
2-BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOIST ACTUATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 TURNER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
15
AUTOMATIC SAFETY BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . .
TRAVELING BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
17
GENERAL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
20
LOAD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7.0.0
1-8.0.0
2-1.0.0
3-1.0.0
3-2.0.0
3-3.0.0
3-4.0.0
3-5.0.0
3-6.0.0
4-1.0.0
6-1.0.0
7-1.0.0
9-1.0.0
LAST PAGE
PAGE
1-1.0.0
1-2.0.0
1-3.0.0
1-4.0.0
1-5.0.0
1-6.0.0
INTRODUCTION
3203P/PR/PRX SERIES
Auto Crane products are designed to provide many years of safe, trouble-free, dependable 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 3203P/PR/PRX Series cranes for your protection. The choice of materials and the design of the electrical system minimizes weight and lengthens durability. The hydraulic components meet or exceed a 3.5:1 safety factor . Holding valves prevent the load from dropping if a hose should fail.
The reservoir has a 40 u air filter in the filler cap. The pump has a 100 mesh strainer in the suction line.
For your convenience the overall dimensions of the
3203P/PR/PRX Series cranes are on the General Dimension
Drawing. Maximum turning radius is shown at the outside edge of the guard (PR/PRX models) and the outside point of the hoist actuator (P model).
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. A minimum
G.V.W. of 8,000 lbs. with two rear jacklegs (or outriggers) is recommended for mounting the 3203P/PR/PRX crane.
The 3203P/PR/PRX crane is attached directly to your
12 volt truck electrical system. The performance of your new crane depends on the truck electrical system. The use of the low maintenance battery is not recommended for use on any
Auto Crane product. The recommended alternator and battery that will give the longest life with the most useful duty cycle is a 60 amp. alternator with a 120 minute reserve capacity, deep cycle battery. These specifications should be considered minimum.
Auto Crane Company issues a limited warranty certificate with each unit sold.
See last page for warranty policy.
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, mis-used, 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 done 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.
DISTRIBUTOR ASSISTANCE:
Should you require any assistance not given in 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.
NOTE:
TIMES.
THIS MANUAL SHOULD
REMAIN WITH THE CRANE
AT ALL
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.
1-1.0.0
3203pintro 1/99
GENERAL SPECIFICATIONS
3203P/PR/PRX
Dimensions Reach
4
5
6 ft
3
7
8
9
Width:
Height:
[PR/PRX] 24 in (.61 m)
[P] 23.25 (.59 m)
[PR/PRX] 27.25 in (.69 m)
[P] 31.13 in (.79 m)
8 ft 6 in (2.59 m) [boom(s) stored] Length:
Weight: P 7-11
P 7-11-15
PR 7-11
470 lbs (213 kg)
530 lbs (240 kg)
520 lbs (236 kg)
PR 7-11-15 550 lbs (250 kg)
PRX 7-11 630 lbs (286 kg)
PRX 7-11-15 630 lbs (286 kg)
[Add 5 lbs (2. 5 kg) for cable length
of 75 feet (23 m)]
Second boom will reach 7 ft to 11 ft
Third boom will reach from 11 ft to 15 ft
Cable
62 ft (18.9 m) of 7/32" diameter aircraft quality cable is standard (75 ft optional). This cable has a single line breaking strength of 5,600 lbs (2,540 kg).
Chassis Requirements
8,800 lbs (3,992 kg) GVWR minimum
Hydraulic System
Capacity
10,000 ft lbs (1.4 ton/m)
[ft lbs = horizontal distance from centerline of rotation to free hanging weight (feet) x amount of weight (pounds)]
Pressure: 2100 psi (1,448 kPa) relief setting
Flow: 0.7 to 9.1 gpm (2.65 to 9.1 lpm)
[output depends on psi]
Filtration: Suction line strainer 100 mesh
Reservoir filler cap air filter 40 u
Reservoir Capacity: 6 quarts (5.7 l)
Oil type: 10w Hydraulic Oil
[Mobile DTE 13, Sun 2015,
Dextron II]
Hoist Motor: 2.2 cid geroter
Rotation Motor: 11.3 cid geroter
LIFTING CAPACITIES lbs
3,200 ft
10
2,500
2,000
1,670
1,500
1,250
1,100
11
12
13
14
15 lbs
1,000
900
830
770
710
660
Electrical System
Hoist Motor:
Pump Motor:
12 volt DC series wound
12 volt DC closed-coupled
Electrical System Requirements
Alternator:
Battery:
60 amp (minimum)
100 minute reserve capacity
(minimum) Maintenance type
1-1.1.0
3203Pspec 1/99
--- IMPORTANT ---
OPERATING PRACTICES & WARNINGS
1. Make certain the vehicle meets minimum chassis 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. Oil gears as required.
12. Periodic adjustment of hoist worm brake may be required (see automatic safety brake drawing in this manual).
13. Hydraulic hoses need to be inspected frequently for signs of deterioration, and be replaced as required.
14. 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.
15.
ALWAYS store outriggers before road travel.
16.
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.
17.
WARNING!
NEVER EXCEED load chart capacities (centerline of rotation to hoist hook).
18.
WARNING! NEVER un-reel last 5 wraps of cable from drum!
19.
WARNING! NEVER wrap cable around load!
20.
WARNING! NEVER attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
21.
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.
22.
WARNING! NEVER place a chain link on the tip of the hook and try to lift a load!
23.
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!
24.
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.
25.
WARNING! NEVER hold any pendant Select
Switch on that will cause unsafe operating conditions!
WARNING!
Auto Crane Company remote controlled, stiff boom cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel.
SAFTIPS 2/98 1-2.0.0
--- IMPORTANT ---
OPERATION OF UNIT
26. Make sure this manual has been thoroughly read by all crane operating personnel and supervisors.
27. A routine inspection of the crane should be mandatory before each operating day. Any defects should be corrected immediately.
28. 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).
29. Keep the vehicle as level as possible during operation.
30. 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.
31. 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.
32. Remove pendant control from cab or storage area. On smaller units, plug pendant into receptacle on crane.
On larger units, remove pendant control from guard and unwrap cable from boom. Do not operate crane until cable is unwound completely. On all cranes, detach hook from dead man. Crane is now ready for operation.
33. Always boom up before rotating so the boom will clear the required boom support.
34. When extending the boom, always maintain clearance between the boom crown and the traveling block or hoist hook.
35. Always observe safe and practical operation to avoid possible accidents. Refer to Safety Tips and
Precautions.
36. After completing lifting operations, return the boom to stowed position on the boom support. Avoid unneeded pressure on the boom support.
37. Store pendant control on proper location (in cab or on crane).
38. Return outriggers to stowed position. Make sure they are pinned in place or jacklegs are returned to compartment.
39. Check work area for any tools or equipment not stored.
40. Release throttle control, depress clutch and disengage
PTO. Deactivate any crane power switches.
41. Report any unusual occurrence during crane operation that may indicate required maintenance or repair.
42.
NEVER use two cranes to support a load too large for either crane.
43. Spray all electrical equipment with special corrosion resistant coating. This eliminates rust or corrosion due to melting and freezing action of condensation.
OPERATION OF
OUTRIGGERS
For hydraulic outriggers:
1. Shift crane/outrigger control valve to "outrigger" position.
2. While operating the outrigger control valves
(located on the outrigger cylinders) simultaneously operate the boom-up control switch. This will allow the hydraulic system to build pressure.
3. After outriggers are positioned, return crane/outrigger selector to "crane" position.
4. Crane is now ready to operate.
1-3.0.0
For manual outriggers:
1. Pull lock pins to release jack leg or drop down outrigger and move to outermost lock 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.
OPER 2/98
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
OPERATORS
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.
QUALIFICATIONS FOR OPERATORS
7 Operators and operator trainees should have normal depth perception, coordination, and no tendencies to dizziness or similar undesirable characteristics.
1 Crane operation shall be limited to personnel with the following minimum qualifications:
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).
8 In addition to the above listed requirements, the operator shall:
A. Demonstrate the ability to comprehend and interpret all labels, operator's manuals, safety codes and other information pertinent to correct crane operations.
B. Possess knowledge of emergency procedures and implementation of same.
C. Demonstrate to the employer the ability to operate the specific type of equipment.
D. Be familiar with the applicable safety regulations.
E. Understand responsibility for maintenance requirements of crane.
F. Be thoroughly familiar with the crane and its control functions.
G. Understand the operating procedures as outlined by the manufacturer.
CONDUCT OF OPERATORS
3 Operators shall be required by the employer to pass a practical operating examination. Qualifications shall be limited to the specific type of equipment for which examined.
9 The operator shall not engage in any practice which will divert his attention while actually operating the crane.
4 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 colors differentiation is required for operation.
C. Adequate hearing with or without hearing aid for the specific operation.
10 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.
11 The operator should not leave a suspended load unattended unless specific precautions have been instituted and are in place.
5 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.
12 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.
6 Evidence that the operator is subject to seizures or loss of physical control shall be sufficient reason for disqualification. Specialized medical tests may be required to determine these conditions.
13 Before closing the switch or starting the engine, the operator shall see that all controls are in the "OFF" or neutral position and all personnel are in the clear.
14 If power fails during operation, the operator shall:
A. move power controls to the "OFF" or neutral position.
1-4.0.0
QUAL 7/98
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
B. land the suspended load and boom, if practical.
15 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.
16 All controls shall be tested by the operator at the start of each shift. If any controls do not operate properly, they shall be adjusted or repaired before operations are begun.
17 Stabilizers shall be visible to the operator while extending or setting unless operator is assisted by a signal person.
OPERATING PRACTICES
HANDLING THE LOAD
18 Size of load
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 which 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.
19 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.
20 Moving the load
A. The operator shall determine that:
B. The crane is level and, where necessary, the vehicle/carrier is blocked properly.
C. The load is well secured and balanced in the sling or lifting device before it is lifted more than a few inches.
D. Means are provided to hold the vehicle stationary while operating the crane.
E. Before starting to lift, the hook shall brought over the load in such a manner as to minimize swinging.
F. 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.
G. Cranes shall not be used for dragging loads sideways.
H. This standard recognizes that articulating 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. Work platforms attached to the boom must be approved by crane manufacturer.
I. The operator should avoid carrying loads over people.
J. 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.
K. Firm footing under all tires, or individual stabilizer pads should be level. Where such a footing is not otherwise supplied, it should be provided by timbers, cribbing, or other structural members to distribute the load so as to not exceed allowable bearing capacity or the underlying material.
L. In transit, the boom shall be carried in stowed position.
M. 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.
N. The crane shall not be transported with a load on the hook unless recommended by the manufacturer.
O. No person should be permitted to stand or pass under a suspended load.
21 Stowing procedure. Follow the manufacturer's procedure and sequence when stowing and un-stowing the crane.
1-4.1.0
QUAL 7/98
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
MISCELLANEOUS
OPERATING NEAR ELECTRICAL POWER
LINES
25 In transit with no load and boom lowered the clearance shall be specified in Table 1.
26 A qualified signalperson shall be assigned to observe the clearance and give warning before approaching the above limits.
A. Any overhead wire shall be considered to be an energized line unless and until the person owning such line or the electrical utility authorities verify that it is not an energized line.
B. Exceptions to this procedure, if approved by the administrative or regulatory authority if the alternate procedure provides equivalent protection and set forth in writing.
C. Durable signs shall be installed at the operator's station and on the outside of the crane, warning that electrocution or serious bodily injury may occur unless a minimum clearance of 10 ft. (3.0m) between the crane or the load being handled and energized power lines. Greater clearances are required because of higher voltage as stated above.
These signs shall be revised but not removed when local jurisdiction requires greater clearances.
TABLE 1
22 Cranes shall be operated so that no part of the crane or load enters into the danger zone shown above.
EXCEPTIONS
A. The danger zone may be entered after confirmation by an appointed person that the 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.
minimum required clearance normal voltage, kV
(phase to phase) ft (m) when operating near high voltage power lines over to 50 over 50 to 200 over 200 to 350 over 350 to 500 over 500 to 750 over 750 to 1000
10
15
20
25
35
45
(3.05)
(4.6)
(6.1)
(7.62)
(10.67)
(13.72) while in transit with no load and boom lowered
23 For lines rated 50 kV or below, minimum clearance between the lines and any part of the crane or load
(including handling appendages) shall be 10 ft. (3m).
For higher voltages, see Table 1.
24 Caution shall be excercised when working near overhead lines, because they can move horizontally or vertically due to wind, moving the danger zone to new positions.
1-4.2.0
over to 0.75
over 0.75 to 50 over 50 to 345 over 345 to 750 over 750 to 1000
4
6
10
16
20
(1.22)
(1.83)
(3.83)
(4.87)
(6.1)
QUAL 7/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSPECTION CLASSIFICATION
27 Initial 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.
28 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 to monthly intervals
B. periodic inspection - one to twelve intervals, or as specifically recommended by the manufacturer
G. electrical apparatus for malfunctioning, signs of excessive deterioration, dirt and moisture accumulation
H. hydraulic system for proper oil level and leaks daily
I. tires for recommended inflation pressure, cuts and loose wheel nuts
J. connecting pins and locking device for wear and damage
PERIODIC INSPECTION
30 Deformed, cracked or corroded members in the crane structure and carrier.
31 Loose bolts, particularly mounting bolts.
32 Cracked or worn sheaves and drums.
33 Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and devices.
FREQUENT INSPECTION
34 Excessive wear on brake and clutch system parts and lining.
29 Inspection shall be performed by designated personnel.
A. control mechanisms for maladjustment interfering with proper operation - daily, when used
B. control mechanisms for excessive wear of components and contamination by lubricants or other foreign matter
C. safety devices for malfunction
D. all hydraulic hoses, particularly those which flex in normal operation of crane functions, should be visually inspected once every working day, when used
E. hooks and latches for deformation, chemical damage, cracks, and wear. Refer to ANSI/ASME
B30.10
F. rope reeving for compliance with crane manufacturer's specifications, if optional winch is used
35 Crane hooks inspected for cracks.
36 Travel steering, braking, and locking devices, for malfunction.
37 Excessively worn or damaged tires.
38 Hydraulic and pneumatic hose, fittings, and tubing inspection.
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 or excessive abrasion or scrubbing on the outer surface of a hose, rigid tube, or fitting. Means shall be taken to eliminate the interference of
1-5.0.0
INSP 9/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL elements in contact or otherwise protect the components necessary to determine origin of the problem before corrective action can be taken.
39 Hydraulic and pneumatic pumps and motors inspection.
A. loose bolts or 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
43 Labels are to be in place and legible.
CRANES NOT IN REGULAR USE
44 A crane which has been idle for a period of over one month or more, but not less than six months, shall be given an inspection conforming with the initialregular- frequent inspections.
45 A crane which has been idle for a period of over six months shall be given a complete inspection conforming with the initial-regular-frequent inspection requirements.
40 Hydraulic and pneumatic valves inspection.
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
41 Hydraulic and pneumatic cylinders inspection.
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
42 Hydraulic filters. Evidence of rubber particles on the filter elements may indicate hose, "O" ring, or other rubber component deterioration. Metal chips or pieces on the filter may denote failure in pumps, motors, or cylinders. Further checking will be
INSPECTION RECORDS
46 Dated records for periodic inspection should be made on critical items such as brakes, crane hooks, rope, hydraulic and pneumatic cylinders, and hydraulic and pneumatic relief pressure valves. Records should be kept available to an appointed person.
OPERATIONAL TESTS
47 Prior to initial use, all new, altered, modified, or extensively repaired cranes shall be tested for compliance with the operational requirements of this section, including functions such as the following:
A. load lifting and lowering mechanisms
B. boom lifting and lowering mechanisms
C. boom extension and retraction mechanisms
D. swing mechanisms
E. safety devices
F. operating controls comply with appropriate function labels
Operational crane test results shall be made available to an appointed person.
RATED TEST LOAD
Prior to initial use, altered, modified, or extensively repaired cranes shall be load
1-5.1.0
INSP 9/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL tested by or under the direction of an appointed person.
A. functional operating mechanism
B. safety devices
C. control systems
48 Test loads shall not exceed 110% of the manufacturer's load ratings.
49 Written reports shall be maintained showing test procedures and confirming the adequacy of repairs.
MAINTENANCE
PREVENTIVE MAINTENANCE
50 Before adjustment and repairs are started on a crane, the following precautions shall be taken as applicable:
A. crane placed where it will cause the least interference with other equipment or operations
B. all controls at the "off" position
C. starting means rendered inoperative
D. boom lowered to the ground if possible or otherwise secured against dropping
E. relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components
55 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
56 Instructions shall be provided by the manufacturer for the removal of air from hydraulic circuits.
LUBRICATION
All moving parts of the crane, for which lubrication is specified, should be regularly lubricated per the manufacturer's recommendations and procedures.
51 Warning or "OUT OF ORDER" signs shall be placed on the crane controls.
ROPE INSPECTION
52 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
53 Any hazardous conditions disclosed by the inspection requirements shall be corrected before operation of crane is resumed, Adjustments and repairs shall be done only by designated personnel.
54 Adjustments shall be maintained to assure correct functioning of components, The following are examples:
57 Frequent Inspection
A. All running ropes in service should be visually inspected once each working day. A visual inspection shall consist of observation of all rope which can be in use during the days operations. These visual observations should be considered with discovering gross damage such as listed below, which may be an immediate hazard.
1. distortion of the rope 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
2. general corrosion
1-5.2.0
INSP 9/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL
3. broken or cut strands;
4. number, distribution and type of visible broken wires. When such damage is discovered, the rope shall either be removed from service or given as inspection.
B. Care shall be taken when inspecting sections of rapid deterioration such as flange points, crossover points, and repetitive pickup points on drums.
1. sections in contact with saddles, equalizer sheaves, or other sheaves where rope travel is limited
2. sections of the rope at or near terminal ends where corroded or broken wires may protrude
ROPE REPLACEMENT
58 Periodic inspection
A. The inspection frequency shall be determined by a qualified person and shall be based on such factors as:
1. expected rope life as determined by experience on the particular installation or similar installations
2. severity of environment
3. percentage of capacity lifts
4. frequency rates of operation
5. exposure to shock loads
Inspection need not be at equal calendar intervals and should be more frequent as the rope approaches the end of it's service life.
This inspection shall be made at least annually.
B. Periodic inspection shall be performed by a designated person. This inspection shall cover the entire length of the rope. Only the surface wires need be inspected. No attempt should be made to open the rope. Any deterioration results in appreciable loss of original strength, such as described below, shall be noted and determination made as to whether use of the rope would constitute a hazard: points listed above reduction of rope diameter below nominal diameter due to loss of core support, internal or external corrosion, or wear of outside wires; severely corroded, cracked, bent, worn or improperly applied connections;
C. Care shall be taken when inspecting sections subject to rapid deterioration such as the following:
59 No precise rules can be given for determination of the exact time for replacement of rope, since many variable factors are involved.
Continued use in this respect depends upon good judgement 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.
60 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, birdcaging, 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. (2.4 mm) for diameters 11/4 in.
(32 mm) to and including 11/2 in. (38 mm)
1-5.3.0
INSP 9/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL
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.
H. Replacement rope shall have a strength rating at least as great as the original rope furnished or recommended by the crane manufacturer. Any deviation from the original size, grade, or construction shall be specified by a rope manufacturer, or a qualified person.
65 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.
61 Rope not in regular use: all rope which has been idle for a period of a month or more due to shutdown or storage of a crane on which it is installed, shall be given and inspection in accordance with above information before it is placed in service. This inspection shall be for all types of deterioration and shall be performed by a qualified person.
66 During installation care should be exercised to avoid dragging of the rope in the dirt or around objects which will scrape, nick crush or induce sharp bends in it.
62 Inspection records
A. frequent inspection- no records required
B. periodic inspections- in order to establish data as a basis for judging the proper time for replacement, a dated report condition at each periodic inspection should be kept on file. This report shall cover points of deterioration listed above.
67 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 which does not hinder visual inspection. Those sections of rope which 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.
ROPE MAINTENANCE
63 Rope should be stored to prevent damage or deterioration.
68 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 cases where a section at the worn end, and thus shifting the wear to different areas of the rope.
64 Unreeling or uncoiling of rope shall be done as recommended by the rope manufacturer and with care to avoid kinking or inducing twist.
1-5.4.0
INSP 9/98
LIFE OF WIRE LINE
So many variable factors can cause the deterioration of wire line cable that it is not possible to determine a definite life expectancy.
Some of these factors are:
1. Load being handled.
Auto Crane units, up to 2,400 pound ratings, use
3/16 inch diameter galvanized pre-formed 7 x 19 aircraft cable. This cable has a working strength, when new, of 4,200 pounds. It is recommended when 1,200 pound loads are exceeded to use a two part line with a traveling block. This will ensure a
3.5 to 1 safety factor when the cable is new.
2. Corrosive conditions.
3. Maintenance of the unit.
Keeping the above factor of safety in mind and knowing the kind of loads that will be handled, the user can determine by inspection of the cable as to when it should be replaced.
A. Keep the sheaves turning freely
B. Maintain tension on cable to insure proper spooling
C. Avoid kinks in cable
D. Avoid abrasive action and contact with sharp corners
Items to look for while inspecting the cables are:
1. Broken strands.
2. Kinks and flattened sections.
3. Corrosion and abrasion.
4. Frequency of use.
WIRE LINE LUBRICATION
Lubrication of the wire line serves two important purposes: (1) helps to prevent corrosion; (2) lubricates the cable strands to reduce wear due to flexing and abrasion caused by contact with the sheaves, rollers, and cable on the drum.
APPLICATION:
Method 1: A light weight motor oil may be used by dipping a brush into the lubricant and applying.
In some cases, a rag or piece of sheepskin is dipped in the lubricant and used to swab the lubricant on to the rope.
PREPARATION:
Remove rust and foreign matter with a wire brush and wipe clean. Be sure cable is dry.
Method 2: A heavier lubricant such as a grease gun lubricant may be used by applying with hands while wearing leather gloves. (Leather gloves are preferred to canvas because of greater protection and less penetration of the grease)
1-6.0.0
WIRELIF 10/98
MAINTENANCE OF BATTERIES
Maintenance of Auto Crane unit batteries differs very 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 Filled with Water
The battery should always be properly filled with water.
If the electrolyte level is allowed to fall below the top of the plates, the results become threefold:
Keep Properly Charged
1 The exposed portion of the plate will become sulfated.
Many things affect the proper charge to a battery, such as:
2 The portion of the plate exposed is not usable.
1 Regulator settings
3 That portion of the acid remaining becomes more concentrated and may cause more rapid deterioration of the remaining parts of the battery.
2 Proper tightness of belts on the alternator or generator
Keep A Relatively Clean Battery
3 Good, clean connections of all cables and wires at the following places:
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:
The battery 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.
Periodic Maintenance is Needed
Specific Gravity Freezing Temp.
(Corrected to 80ºF) Degrees F.
A definite program of periodic maintenance of all batteries should be conducted on a regular basis.
Periodic maintenance includes:
1.280 -90ºF
1.250 -62ºF
1.200 -16ºF
1.150 5ºF
1.100 19ºF
1
2
Checking belts for tightness on the charging equipment
Checking battery electrolyte levels
3 Checking cables for good connections
As shown, a half-charged battery (about 1.200 specific gravity) cannot stand for any length of time at 20ºF or it will freeze.
The main reason for keeping the battery as fully charged as possible without over-charging is to ensure that power is available even though the vehicle has been standing for some time.
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.
1-6.1.0.
MAINTBAT 9/98
MAINTENANCE OF BATTERIES
Low Maintenance Batteries
(Maintenance Free) should be attempted for an extended time. This usually will recover a badly sulfated battery.
Low maintenance batteries should not be used on
Auto Cranes or trucks equipped with Auto Cranes.
The batteries are not designed for "deep" discharge.
Replacing a Battery
If it is necessary to replace a battery, and a dry charge battery is used, the following procedure applies:
Testing Your Battery
1 Fill the battery with electrolyte of the proper specific gravity.
If the condition of the battery is in question, it should be removed from the vehicle, taken to the shop, and 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.
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.
If, after charging, it is noted that the specific gravity 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
It is also very important that the battery hold-downs be checked periodically to ensure 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 hold-down that is too loose.
1-6.2.0.
MAINTBAT 9/98
SAFETY DECAL SECTION
PART NO.:
DECAL:
FUNCTION:
QUANTITY :
040517
STAY CLEAR OF BOOM
To inform the operator of the hazard of proximity or contact with the crane boom during operation.
2
PLACEMENT : Both sides of crown
FIG. SD-1.
PART NO.:
DECAL:
FUNCTION:
QUANTITY :
040518
STAY CLEAR OF
LOAD
To inform the operator of the hazard of proximity or contact with the crane load during operation.
2
PLACEMENT : Both sides of crown plate
FIG. SD-2.
PART NO.:
DECAL:
FUNCTION:
040519
SCISSORS POINT
To inform the operator of possible danger at scissors point on crane.
QUANTITY :
PLACEMENT :
1
Both sides of lift cylinder
FIG. SD-3.
1-7.0.0
3203pdec 1/99
SAFETY DECAL SECTION
PART NO.:
DECAL:
FUNCTION:
040529
ELECTROCUTION HAZARD
To inform the operator of the hazard involved with contacting electrical power lines with crane boom.
QUANTITY :
PLACEMENT :
2
Both sides of end of lower boom
FIG. SD-4.
PART NO.:
040579
DECAL:
FUNCTION:
QUANTITY :
OPERATION INSTRUCTIONS
To inform the operator of the proper procedure to follow for safe operation of the crane.
1
PLACEMENT : Left Sideplate
1-7.1.0
FIG. SD-5.
3203pdec 1/99
SAFETY DECAL SECTION
PART NO.:
DECAL:
FUNCTION:
040580
OPERATOR TRAINING
To inform the operator of the need to receive proper training before using the crane .
QUANTITY : 1
PLACEMENT : Left Sideplate
PART NO.:
040587
DECAL:
FUNCTION:
LOAD SENSOR
To inform the operator that the load sensor is pre-set and that tampering with the sensor may cause potentially hazardous situation.
1 QUANTITY :
PLACEMENT : On the lift cylinder near the load sensor
FIG. SD-7.
FIG. SD-8.
1-7.2.0
3203pdec 1/99
DECAL DRAWING
3203P/PR/PRX
8
9
10
11
12
13
14
15
16
ITEM
1
4
5
6
7
2
3
2
6.5 FT
1
1
2
1
1
1
2
QTY
2
1
1
1
1
2
2
040624
040620
320321
040552
040518
999948
330622
040587
040519
P/N
040517
040529
320317
040622
040579
040580
320318
DESCRIPTION
DANGER “STAY CLEAR OF BOOM” DECAL
DANGER “ELECTROCUTION HAZARD” DECAL
3203 DECAL
A/C LOGO DECAL
CAUTION “INSPECT VEHICLE...” DECAL
DANGER “AN UNTRAINED OPERATOR...” DECAL
ANGLE INDICATOR DECAL
3M AUTO CRANE DECAL
3M STRIPING DECAL
3203 LOAD CHART DECAL
RELAY DECAL
DANGER “STAY CLEAR OF LOAD” DECAL
INSTALLATION CHECKLIST CARD (not shown)
SERIAL NUMBER DECAL
WARNING “LOAD SENSOR PRE-SET” DECAL
DANGER “SCISSORS POINT” DECAL
1-7.3.0
3203Play 2/99
LUBRICATION & MAINTENANCE
SCHEDULE 3203P/PR/PRX
SERVICE
PERFORMED
LOAD HOOK
CABLE DRUM
HOIST CABLE
HYD. HOSES
MOUNTING BOLTS
DAY
X
X
X
X
MOTOR
CONNECTION
SHEAVE
BEARINGS
ALL OTHER BOLTS
BOOM CYLINDER
BOOM CYLINDER
PINS
EXTENSION
CYLINDER
BOOM PIVOT
EXT. CYLINDER
BOLTS
BATTERY
CONNECTIONS
ROTATION GEAR
EXT. CYLINDER
BOLTS
SAFETY DECALS
POWER CABLE
ROTATION WORM
BEARINGS
HOIST GEARBOX
WEEK MONTH 6 MOS YEAR
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
NOTES
INSPECT HOOK & LATCH FOR DEFORMA-
TION, CRACKS, & CORROSION
MAKE SURE CABLE IS WOUND EVENLY
ON DRUM
CHECK FOR FLATTENING, KINKS, &
BROKEN STRANDS, SEE MANUAL
VISUAL INSPECTION
CHECK-TORQUE TO 85 FT-LBS (DRY) AS
REQUIRED
CHECK TERMINALS FOR TIGHT
CONNECTIONS
SEALED BEARING, REPLACE IF ROUGH OR
LOOSE
CHECK-TIGHTEN AS REQUIRED
CHECK AROUND CYLINDER ROD FOR
EXCESS FLUID LEAKAGE
GREASE WITH MOBILPLEX EP-2 OR
EQUIVALENT @ ZERKS
CHECK AROUND CYLINDER ROD FOR
EXCESS FLUID LEAKAGE
GREASE WITH MOBILPLEX EP-2 OR
EQUIVALENT @ ZERKS
CHECK TIGHTNESS
CHECK FOR CORROSION & TIGHT
CONNECTIONS. CLEAN & COAT AS
REQUIRED
WATER PROOF BEARING GREASE OR DRY
MOLYLUBE IF DUSTY
GREASE WITH MOBILPLEX EP-2 OR
EQUIVALENT
INSPECT AND REPLACE AS NEEDED
CHECK INSULATION FOR DAMAGE OR
DETERIORATION
GREASE WITH MOBILPLEX EP-2 OR
EQUIVALENT @ ZERKS
WORM GEAR-EP GEAR LUBE SAE 80-90,
SPUR GEAR SAE 30 OIL
1-8.0.0
3203PMAIN 6/99
LUBRICATION & MAINTENANCE
SCHEDULE 3203P/PR/PRX
SERVICE
PERFORMED
DAY WEEK MONTH 6 MOS YEAR NOTES
HYDRAULIC FLUID
ROTATION
BEARINGS
X DRAIN, FLUSH, & REFILL WITH MOBIL
DTE 13, OR EQUIVALENT
SEALED BEARING-NO MAINTENANCE REQUIRED
BOOM SLIDE PADS PADS GREASED WHEN REPLACED
FOR ADDITIONAL
INFORMATION
SEE:
1) OWNER'S MANUAL
2) OSHA SECTION 1910.180
3) ANSI B30.5-1989
CAUTION
v Routine maintenance insures trouble-free operation and protects your investment. All warranties are void if maintenance is neglected.
NOTES:
{ Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability.
{ Once a bolt has been torqued to its rated capacity and then removed; the bolt should be replaced with a new one.
{ Auto Crane Company recommends that this crane be serviced per “Crane Inspection Log” P/N 999978.
These logs should be filled in at the intervals noted and kept as a permanent record. Additional copies are available from your local distributor.
1-8.1.0
3203PMAIN 6/99
ASSEMBLY & INSTALLATION INSTRUCTIONS
3203P/PR/PRX
NOTE: For mounting bolt hole pattern - see page 5-1.0.0.
INSTALLATION - BATTERY CABLE
1. Drill 13/16" hole in floor. Install bushing, which is connected to cable, so it fits hole snug.
2. Run cable to positive battery terminal. Connect black cable to negative battery terminal or suitable chassis ground point. Locate cables so that they will be protected. Avoid sharp edges. Use the No. 083800 frame clips provided to hold cables securely in place.
3. If the battery is grounded to the engine it may be necessary to add an additional ground cable from the engine to the chassis frame to obtain maximum power at crane
2-1.0.0
3203PINST 2/99
SUGGESTED BOOM SUPPORT
P/N 725045
Suggested Boom Support
Auto Crane P/N 725045
2-2.0.0
AW725045 3/99
GENERAL ASSEMBLY
P/N 320301 - 3203P 7-11-15
3-1.0.0
AW320301 2/99
GENERAL ASSEMBLY
P/N 320301 - 3203P 7-11-15
3-1.0.1
AW320301 2/99
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
ITEM
1
2
3
4
5
6
7
8
9
10
32
33
34
35
36
37
38
27
28
29
30
31
1
1
1
62 FT
1
1
1
1
1
3
6
1
11
8
1
1
QTY
1
1
1
1
1
1
1
2
11
1
1
1
1
1
1
1
1
1
2
2
1
1
GENERAL ASSEMBLY
P/N 320301 - 3203P 7-11-15
320449
370002
REF
320338
320423
320415
005501
320391
005406
320453
016300
008400
021100
330394
320506
680055
P/N
320710
320428
018600
014304
320320
320432
320328
480036
020200
320368
320335
400500
320411
200545
200547
-
012200
019100
227401
330185
019106
320324
DESCRIPTION
PEDESTAL
SIDE PLATE / HOUSING
HALF LOCK NUT 3/4 NF
CAPSCREW 3/4 NF x 6 GR 5
BOOM CYLINDER
LOWER WELDMENT BOOM
LONG POSITION PIN
NYLATRON BOOM PAD
SPLIT LOCK WASHER 1/4
REARING RETAINER
MANUAL MID BOOM
PIN ASSEMBLY w/ LANYARD
TRAVELING BLOCK (320433)
CABLE HOIST
MANUAL BOOM
MANUAL BOOM RETAINER
CAPSCREW 1/4-28 NF x 3/4
MANUAL MID BOOM RETAINER
CAPSCREW 1/4-28 NF x 1/2
ANGLE INDICATOR
HEX LOCK NUT 1/4 NC
CAPSCREW 3/8-16 NC x 3/4 GR 8
SPLIT LOCK WASHER 3/8
CAPSCREW 3/8-16 NC x 1 1/2
SPACER
RELAY PANEL ASSEMBLY
HYDRAULIC PUMP & RESERVOIR
BOOM PIVOT BEARING
BOOM PIVOT
BREATHER CAP
90º STREET ELBOW 3/8 NPT
PUMP BRACKET
CAPSCREW 5/8-18 NF x 1 3/4 GR 5
HALF LOCK NUT 5/8 NF
SHEAVE ASSEMBLY (REF BEARING ONLY #200100)
CAPSCREW 1 NF x 5 1/2 GR 5
HALF LOCK NUT 1 NF
ACTUATOR ASSEMBLY
3-1.0.2
AW320301 2/99
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
ITEM
39
40
41
42
43
44
45
46
47
48
70
71
72
73
74
75
76
65
66
67
68
69
6
1
1
4
1
1
1
2
1
1
1
1
1
1
1
1
QTY
4
4
3
1
2
45
1
1
4
1
1
1
1
2
1
1
2
1
1
1
1
1
GENERAL ASSEMBLY
P/N 320301 - 3203P 7-11-15
REF
011510
021500
320372
320488
005401
320343
301103
330584
320465
REF
REF
320508
320332
320509
320370
P/N
007807
020600
330372
320379
320330
REF
002620
320442
320448
320515
320342
320344
320340
320560
083803
320464
330468
340602
320459
320502
330636
800084
DESCRIPTION
CAPSCREW 5/16-18 NC x 3/4
SPLIT LOCK WASHER 5/16
HEX NUT 3/8 NC
DRUM
SEALED BALL BEARING
SQUARE KEY 1/4 x 2 3/4 (340523)
SELF TAPPING CAPSCREW 5/16 NC x 7/8
CABLE RETAINER GUARD
BACK UP RETAINER
UPPER TWECO BRACKET
MALE TRECO CONNECTOR
CAPSCREW 1/2-13 NC x 1 1/4
SPLIT LOCK WASHER 1/2
UPPER TWECO CLAMP
POWER CABLE ASSEMBLY
CAPSCREW 1/4-20 NC x 5/8
FLOW REGULATOR
VELOCITY FUSE
BREATHER FILTER
HOSE ASSEMBLY
PENDANT
SEAL KIT
SPACER
RETAINING RING BEARING
COMPRESSION SPRING
90º ELBOW -6 ORB/3/8 MALE NPT
90º ELBOW -6 ORB/-6 JIC
TEE -6 ORB/ -6 ORP FEM-RUN/ -6 ORM (M)
ADAPTER -6 ORB/3/8 NPT (FEM)
LOAD SENSOR
HOSE CLAMP -6
ACTUATOR BRACKET
SPLIT LOCK COLLAR
SQUARE KEY 3/4 x 1 1/2
BRAKE DRUM
BRAKE BAND ASSEMBLY
MALE NIPPLE 3/8 NPT
SPACER BAR x 15 IN LONG
3-1.0.3
AW320301 2/99
81
82
83
84
85
86
87
88
89
ITEM
77
78
79
80
1
1
1
3
1
1
1
2
6
QTY
2
6
1
1
GENERAL ASSEMBLY
P/N 320301 - 3203P 7-11-15
P/N
012197
017701
018302
013502
320507
320495
320333
750282
000115
320371
320369
239000
015900
DESCRIPTION
CAPSCREW 1/2 NC x 1 1/2
HEX NUT 1/2 NC
HEX NUT 5/8 NF
CAPSCREW 5/8 NF
BRAKE WRENCH
BRAKE GUIDE PLATE
SNAP RING
GROMMET
CLIP
THREAD CUTTING SCREW #10-24 NC x 3/4
COVER PLATE
GREASE ZERK
NUT 1/4-20 NC
3-1.0.4
AW320301 2/99
GENERAL ASSEMBLY
P/N 320303 - 3203PR 7-11-15
3-1.1.0
AW320303 2/99
GENERAL ASSEMBLY
P/N 320303 - 3203PR 7-11-15
3-1.1.1
AW320303 2/99
7
8
9
10
11
12
13
14
ITEM
1
2
3
4
5
6
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
1
1
1
1
1
1
1
1
QTY
1
1
2
1
1
1
3
11
1
1
4
1
1
1
4
4
2
8
2
1
1
1
62 FT
1
1
1
1
1
1
2
GENERAL ASSEMBLY
P/N 320303 - 3203PR 7-11-15
P/N
320710
320428
320330
320333
320432
320449
320336
320325
019106
330185
014304
018600
480027
REF
008400
021100
680054
320395
320396
320431
002605
320324
007807
020600
320411
330394
400500
227401
012200
018100
320338
320379
REF
REF
320453
320328
320444
330072
DESCRIPTION
PEDESTAL
SIDE PLATE / HOUSING
SEALED BALL BEARING
SNAP RING
LOWER WELDMENT BOOM
MANUAL MID BOOM
HYDRAULIC PUMP & RESERVOIR
HYDRAULIC LIFT CYLINDER
HALF LOCK NUT 1
CAPSCREW 1 x 5 1/2 NC
CAPSCREW 3/4 x 6 NC
HALF LOCK HEX NUT 3/4
HYDRAULIC ROTATION MOTOR
PUMP BRACKET
CAPSCREW 3/8 x 3/4 NC GR 8
SPLIT LOCK WASHER 3/8 ZP
RELAY PANEL ASSEMBLY
LEFT RELAY PANEL BRACKET
RIGHT RELAY PANEL BRACKET
COVER
SELF TAPPING CAPSCREW #12 x 1/2
ACTUATOR ASSEMBLY
CAPSCREW 5/16-18 NC x 3/4 NC
SPLIT LOCK WASHER 5/16
BOOM PIVOT
CAPSCREW 3/8-16 x 1 1/2
BOOM PIVOT BEARING
SHEAVE ASSEMBLY (REF BEARING ONLY #200100)
CAPSCREW 5/8 x 1 3/4 NF
HALF LOCK NUT 5/8 NF
HOIST CABLE
DRUM
TRAVELING BLOCK (320433) furnished in SHIP KIT #680061)
PENDANT CONTROL (680064)
ANGLE INDICATOR
POSITION PIN
DECAL KIT
HEX HEAD PLUG -10 ORB
3-1.1.2
AW320303 2/99
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
ITEM
39
40
41
42
43
44
45
46
47
48
70
71
72
73
74
75
76
65
66
67
68
69
4
2
1
2
1
1
2
1
1
1
2
1
2
4
8
1
QTY
2
1
1
17
1
2
1
6
1
1
1
1
1
2
1
2
1
6
3
1
1
1
GENERAL ASSEMBLY
P/N 320303 - 3203PR 7-11-15
005501
330468
005604
010201
239000
320334
340602
016300
300204
330306
320392
320393
002614
320515
011603
021500
P/N
480036
370002
000115
020200
REF
005810
REF
REF
320391
005406
017701
330372
320423
320415
320368
330472
330485
330483
239300
019000
330486
330420
DESCRIPTION
PAD
PIN ASSEMBLY w/ LANYARD
CLIP
SPLIT LOCK WASHER 1/4
SQUARE KEY 1/4 x 2 3/4 (340523)
CAPSCREW 1/4-20 NC x 1 3/4
BREATHER CAP (200545) included with item 7
90º STRAIGHT ELBOW 3/8 NPT (200547)
BOOM RETAINER
CAPSCREW 1/4-28 x 1/2
CAPSCREW 1/4-28 x 3/4
SPLIT LOCK COLLAR
CAPSCREW 1/4 x 1 NC
CAPSCREW 1/2 x 1 1/2 NC
ZERK
WORM GEAR
GEAR KEY
HEX LOCK NUT 1/4 NC
DIRECTIONAL VALVE ASSEMBLY
MANIFOLD SERIES
TOP VALVE BANK BRACKET
BOTTOM VALVE BANK BRACKET
CAPSCREW 5/16 NC x 5/8
UPPER TWECO BRACKET
CAPSCREW 1/2 NC x 1 3/4
SPLIT LOCK WASHER 1/2
HEX NUT 1/2 NC
HEX NUT 3/8 NC
MANUAL BOOM
BOOM RETAINER
BEARING RETAINER
HOUSING w/ CUPS
CONE BEARING
SPACER
GREASE ZERK #1610-8
NUT 7/8-14
OIL SEAL
TURNER SHAFT
3-1.1.3
AW320303 2/99
83
84
85
86
87
88
89
90
ITEM
77
78
79
80
81
82
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
1
1
1
1
1
1
1
1
QTY
1
1
1
2
3
2
1
1
1
2
1
1
1
1
2
1
2
8
3
1
1
2
1
1
3
2
GENERAL ASSEMBLY
P/N 320303 - 3203PR 7-11-15
P/N
320442
320448
330258
011510
320371
005401
320488
320469
330484
320407
320408-001
320409
320410
320491
320490
320467
330058
320472
330412
330274
241168
241175
241170
015900
005500
320332
200876
320350
202759
330272
202756
480194
320464
320372
DESCRIPTION
CABLE RETAINER GUARD
CABLE RETAINER BACKUP
MALE TWECO CONNECTOR
CAPSCREW 1/2 x 1 1/4 NC
THREAD CUTTING SCREW #10-24 NC x 3/4 NC
CAPSCREW 1/4-20 x 5/8 NC
POWER CABLE ASSEMBLY
BOOM CYLINDER HYDRAULIC TUBE ASSEMBLY
SPACER
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
REDUCER 7/8-14/-6 ORP
LOAD SENSOR
COUNTER BALANCE VALVE
REDUCER -10 ORB/-8 ORP
TEE -6 ORB (M) RUN/-6 JIC (FEM) RUN/-6 JIC (M)
90º ELBOW -6 ORB/-6 JIC
BULKHEAD FITTING
NUT 1/4-20 NC
SCREW 1/4-20 x 3/4 NC
BEARING RETAINING RING
ADAPTER -6 ORB/-6 JIC
45º ELBOW (1/2 NPTM/-6 JIC
90º ELBOW (1/2 NPTM/-6 JIC)
90º ELBOW -8 ORB/-6 JIC
ADAPTER
90º ELBOW -6 SWIVEL/-6 JIC
ACTUATOR BRACKET
UPPER TWECO BRACKET
AW320303 2/99 3-1.1.4
GENERAL ASSEMBLY
P/N 320304 - 3203PRX 7-11-15
3-1.2.0
AW320304 2/2000
GENERAL ASSEMBLY
P/N 320304 - 3203PRX 7-11-15
3-1.2.1
AW320304 2/2000
7
8
9
10
11
12
13
14
ITEM
1
2
3
4
5
6
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
35
36
37
38
31
32
33
34
1
1
1
1
2
2
23
1
QTY
1
1
2
1
2
1
1
62 FT
1
1
2
2
3
1
1
2
1
4
1
1
1+2
3
4
6
1
1
12
8
4
2
GENERAL ASSEMBLY
P/N 320304 - 3203PRX 7-11-15
P/N
320710
320428
320330
320333
330412
018600
014304
320325
320420
320368
480036
000115
020200
370002
REF
320338
320423-001
320415
005501
320421
015017
022502
320391
005406
202711
005401
320464
320453
016300
008400
021100
330394
002605
011603
021500
017701
320457-200
320392
DESCRIPTION
PEDESTAL
SIDE PLATE / HOUSING
SEALED BALL BEARING
SNAP RING
COUNTERBALANCE VALVE
HALF LOCK NUT 3/4 NF
CAPSCREW 3/4 x 6 NC
HYDRAULIC LIFT CYLINDER
LOWER BOOM
BEARING RETAINER
NYLATRON BOOM PAD
CLIP
SPLIT LOCK WASHER 1/4
PIN ASSEMBLY w/ LANYARD
TRAVELING BLOCK
HOIST CABLE
MANUAL BOOM w/ CROWN
MANUAL BOOM RETAINER
CAPSCREW 1/4-28 NF x 3/4
MID BOOM
CAPSCREW 1-8 NC x 1 1/8
FLAT WASHER 1
MID BOOM RETAINER
CAPSCREW 1/4-28 NF x 1/2
EXTENSION CYLINDER
CAPSCREW 1/4-20 x 5/8
ACTUATOR BRACKET
ANGLE INDICATOR
HEX LOCK NUT 1/4-20 NC
CAPSCREW 3/8-16 NC x 3/4 GR 8
SPLIT LOCK WASHER 3/8
CAPSCREW 3/8-16 x 1 1/2
SELF TAPPING CAPSCREW #12 x 1/2
CAPSCREW 1/2-13 x 1 3/4
SPLIT LOCK WASHER 1/2
HEX NUT 1/2-13 NC
RELAY PANEL ASSEMBLY
TOP VALVE BANK
3-1.2.2
AW320304 2/2000
45
46
47
48
49
50
51
52
ITEM
39
40
41
42
43
44
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
1
1
8
1
1
1
2
2
QTY
4
-
1
3
1
1
1
1
1
1
2
1
1
1
4
4
1
1
1
2
1
1
1
2
2
1
1
1
1
1
GENERAL ASSEMBLY
P/N 320304 - 3203PRX 7-11-15
P/N
005604
-
320431
300204
202710
320393
002614
480027
320336
320396
400500
320411
REF
REF
REF
330057
019105
012701
018100
227401
002905
330185
019106
320324
007807
020600
320395
330072
320379
340602
340523
330484
330420
330486
330485
3302472
019000
239300
DESCRIPTION
CAPSCREW 1/4-20 NC x 1
-
COVER
DIRECTIONAL VALVE ASSEMBLY
MANIFOLD-SERIES
BOTTOM MANIFOLD BRACKET
SELF TAPPING CAPSCREW 5/16 NC x 5/8
HYDRAULIC ROTATION MOTOR
HYDRAULIC PUMP & RESERVOIR
RIGHT RELAY PANEL BRACKET
BOOM PIVOT BEARING
BOOM PIVOT
BREATHER CAP 200545 (furnished with item 47)
STRAIGHT 90º ELBOW 3/8 NPT 200547 (furnished with item 47)
PUMP BRACKET
CAPSCREW 1-8 NC x 4
HEX NUT 1-8 NC
CAPSCREW 5/8-18 NF x 3
HALF LOCK NUT 5/8-18 NF
SHEAVE ASSEMBLY ( ref bearing only # 200100)
SET SCREW
CAPSCREW 1 NF x 5 1/2
HALF LOCK NUT 1
ACTUATOR ASSEMBLY
CAPSCREW 5/16-18 NC x 1 3/4
SPLIT LOCK WASHER 5/16
LEFT RELAY PANEL BRACKET
HEX HEAD PLUG -10 ORB
DRUM
SQUARE KEY 3/4
SQUARE KEY 1/4
SPACER
WORM SHAFT
OIL SEAL
CONE BEARING
HOUSING w/ CUPS
HEX NUT 7/8-14 NF
GREASE ZERK
3-1.2.3
AW320304 2/2000
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
81
82
83
84
85
86
87
88
89
ITEM
77
78
79
80
1
2
1
1
1
2
1
1
1
1
-
1
4
-
4
1
-
1
1
3
2
2
2
-
2
1
1
4
1
1
1
1
1
QTY
1
1
1
1
GENERAL ASSEMBLY
P/N 320304 - 3203PRX 7-11-15
320408-001
320409
320410
320489
320491
320490
-
320467
320466
320332
320445
200876
REF
320473
241170
-
241168
-
-
320350
202759
330272
480194
241175
P/N
330483
320334
320442
320448
320372
320488
011510
320515
330258
005810
330275
320469
320407
DESCRIPTION
SPACER
WORM GEAR
CABLE RETAINER GUARD
BACK-UP RETAINER
UPPER TWECO CLAMP
POWER CABLE ASSEMBLY
CAPSCREW 1/2-13 NC x 1 1/4
UPPER TWECO BRACKET
MALE TWECO CONNECTOR
CAPSCREW 1/4-20 NC x 1 3/4
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
-
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC HOSE ASSEMBLY (EXT. OUT)
BEARING RETAINING RING
DECAL DRAWING
HYDRAULIC FITTING-ADAPTER
PENDANT (680067)
-
HYDRAULIC HOSE ASSEMBLY (EXT. OUT
BULKHEAD UNION
-
SPECIAL TEE -6 ORB/-6 JIC-MALE
-
45º ELBOW -1/2 NPTM/-6 JIC
90º ELBOW -1/2 NPTM/-6 JIC
90º ELBOW -8 NPTM/-6 JIC
90º ELBOW -6 SWIVEL/-6 JIC
90º ELBOW -6 ORB/-6 JIC
3-1.2.4
AW320304 2/2000
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
ITEM
114
115
116
117
118
119
120
121
122
123
1
2
10
4
3
1
1
1
-
1
1
1
2
1
2
1
QTY
1
4
1
1
2
2
3
1
3
1
GENERAL ASSEMBLY
P/N 320304 - 3203PRX 7-11-15
320483
239000
015900
005500
320556
009104
021200
017400
340295
320521
-
000302
000101
320554
016300
330038
P/N
330274
202756
330058
320472
010201
330468
320372
320480
320371
680058
DESCRIPTION
REDUCER -10 ORB/-8 ORP
ADAPTER 3/4 ORB/ 9/16 37º JIC
REDUCER -10 ORB/-6 ORP
LOAD SENSOR
CAPSCREW 1/2 NC x 1 1/2
SPLIT LOCK COLLAR
HEX NUT 3/8 NC
SOLENOID VALVE ASSEMBLY WIRING DIAGRAM
THREAD CUTTING SCREW #10-24 x 3/4
SHIP KIT
HYDRAULIC TUBING BRACKET
DRIVE ZERK
NUT 1/4-20
SCREW 1/4-20 x 3/4
BAIL / SWITCH ASSEMBLY
CAPSCREW 3/8 NF x 2 1/2
FLAT SAE WASHER 3/8
HEX LOCK NUT 3/8 NF
ROUND TUBING 1 1/16 x .188W x 1 3/16
CABLE REEL
-
WIRE TERMINAL (BUTT SPLICE) 2RB14
HYDRAULIC HOSE ASSEMBLY (EXT. OUT)
RETURN SPRING
HEX LOCK NUT 1/4 NC
#10 SELF DRILLING & THREADING HEX HEAD SLOT 3/4
3-1.2.5
AW320304 2/2000
GENERAL ASSEMBLY
P/N 320300/302 - 3203P/PR 7-11
ITEM
1
2
5
6
7
8
3
4
9
10
11
12
13
14
QTY
1
1
1
1
1
1
2
1
6
6
1
1
1
1
P/N
320422
320432
480036
320391
320328
227401
012200
018100
005406
020200
320453
016300
019106
330185
DESCRIPTION
MANUAL BOOM w/ CROWN
LOWER BOOM
NYLATRON PAD
BOOM RETAINER
POSITION PIN
SHEAVE ASSEMBLY (REF BEARING ONLY #200100)
CAPSCREW 5/8 x 1 3/4 NF
HEX NUT 1/4 x 3/4 NF
CAPSCREW 1/4 x 1/2 NF
SPLIT LOCK WASHER 1/4
ANGLE INDICATOR
HEX NUT 1/4 NC
HALF LOCK NUT 1
CAPSCREW 1 x 5 1/2 NC
3-1.3.0
320300302 2/99
GENERAL ASSEMBLY
P/N 320308 - 3203PRX 7-11
8
9
10
11
5
6
7
ITEM
1
2
3
4
4
4
1
1
2
2
1
QTY
1
1
1
2
P/N
320517
019105
330057
480036
015017
022502
320391
020200
005406
202711
320420
DESCRIPTION
BOOM
HEX NUT 1-8 NC
CAPSCREW 1 x 4 NC
NYLATRON BOOM PAD
CAPSCREW 1 x 1 1/8
FLAT WASHER 1
BOOM RETAINER
SPLIT LOCK WASHER 1/4
CAPSCREW 1/4 x 1/2 NF
EXTENSION CYLINDER
LOWER BOOM
3-1.4.0
AW320308 2/99
2-BLOCK ASSEMBLY
3203PRX & 3203H SERIES
3-2.0.0
AW220 2/2000
7
8
5
6
9
10
11
12
13
ITEM
1
2
3
4
1
2
2
2
1
1
1
1
1
QTY
1
1
1
1
2-BLOCK ASSEMBLY
3203PRX & 3203H SERIES
P/N
320546
646900
320550
642918
320554
005604
016300
000101
002602
019600
009104
021200
017400
DESCRIPTION
BAIL WELDMENT
LOAD SENSOR SWITCH
SWITCH COVER
STRAIGHT CORD CONNECTOR
RETURN SPRING
HEX HD SCREW 1/4-20NC x 1
HEX LOCK NUT 1/4-20NC
WR-14-16 TERMINAL
RD HD SCREW #6-32NC x 1 1/4
LOCK WASHER #6
HEX HD SCREW 3/8-24NF x 2 1/2
FLAT WASHER SAE 3/8
HEX LOCK NUT 3/8-24NF
3-2.1.0
AW220 2/2000
2-BLOCK REEL INSTALLATION
3203PRX
ITEM
3
4
5
1
2
6
7
QTY
3
5
2
1
1
1
3 FT
P/N
320521
320551
000115
320570
000302
000300
800626
DESCRIPTION
CABLE REEL
REEL MOUNT BRACKET
#15 JIFFY CLIP
D-RING
BUTT SPLICE WIRE TERMINAL
WIRE TERMINAL
16GA 2 CONDUCTOR CABLE 300V TYPE SJO BLACK
3-2.2.0
AW221P 2/2000
HOIST ACTUATOR ASSEMBLY
P/N 320324
3-3.0.0
AW320324 2/99
7
8
9
10
11
12
13
14
ITEM
1
2
3
4
5
6
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
1
1
2
1
1
1
1
1
QTY
1
1
1
1
1
1
1
2
-
1
2
3
1
1
1
1
2
1
1
10
12
4
1
1
1
3
4
2
4
4
HOIST ACTUATOR ASSEMBLY
P/N 320324
P/N
360637
360331
300041
300042
360450
300043
300044
300045
300046
360336
300047
300048
360339
300049
-
300050
341561
300052
360342
300053
320323
320312
360345
300056
300057
300058
300059
320313
005500
005604
320311
320310
300060
300061
360353
071012
360354
360455
DESCRIPTION
FLAT SPRING
CAM PLATE
GEAR HOUSING COVER
SPUR GEAR HOUSING COVER
BRAKE COVER
IDLER GEAR
SPUR GEAR
WORM R.H. GEAR
PINION GEAR
BRAKE HOUSING
SPUR GEAR HOUSING
GEAR HOUSING
BRAKE HUB
KEY 3/16 SQ x 1/2 LG
-
KEY 3/16 SQ x 1 9/16 LG
KEY 1/4 SQ x 2 3/4 LG
KEY RD 5/16 x 5/16 x 15/16 LG
RETAINER PLATE
SPUR GEAR SHAFT
OUTPUT SHAFT
RIGHT HAND WORM GEAR
BALL
NEEDLE BEARING
BALL BEARING
BUSHING
BUSHING
CAPSCREW 1/4-20 NC x 3/4 LG NYLOCK
CAPSCREW 1/4-20 NC x 3/4 LG
CAPSCREW 1/4-20 NC x 1 LG
CAPSCREW 3/8 x 1 1/2 LG ALL THREAD
CAPSCREW 1/4-20 NC x 1 LG
SOCKET HEAD SCREW 1/4-20 NC x 3/4 LG LOC-WEL
SETSCREW 1/4-20 NC x 5/16 LG LOC-WEL
HEX JAM NUT 3/8-16 NC
HEX NUT 3/8-24 NF
SPLIT LOCK WASHER 1/4 MED SECT
FLAT WASHER 1/4 ALUM
3-3.1.0
AW320324 2/99
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
ITEM
39
40
41
42
43
44
45
46
47
48
2
1
1
1
2
1
1
2
1
1
1
1
1
1
2
2
1
3
QTY
3
1
1
2
1
1
2
1
1
1
HOIST ACTUATOR ASSEMBLY
P/N 320324
300068
300069
300070
300073
300074
300075
360364
300076
300077
300078
360371
300079
360368
300080
300081
300082
360456
320382
P/N
021100
320314
320315
300062
300063
300064
360359
300065
300066
300067
DESCRIPTION
SPLIT LOCK WASHER 3/8
90º ELBOW 3/8-18 NPT BOTH ENDS
90º ELBOW 1/4-18 NPT BOTH ENDS
GASKET BEARING
SPUR GEAR HOUSING GASKET
GEAR HOUSING COVER GASKET
BRAKE COVER GASKET
WOODRUFF KEY
RELIEF FITTING
12V MOTOR
O-RING 1 OD x 1/8 THICK
REDUCER -6 NPT / -2 NPT
PLUG PIPE -4 NPT SQ HD
PLUG PIPE -6 NPT HEX SOC HEADLESS
REDUCER -4 NPT / -2 NPT
DOWEL PIN
THRUST PLATE
OIL SEAL 3/4 ID x 1 1/4 OD x 1/4 THICK
OIL SEAL 1 1/4 ID x 1 3/4 OD x 1/4 THICK
OIL SEAL 1 1/2 ID x 2 1/4 OD x 5/16 THICK
THREAD SEAL
SNAP RING
SPRING
THRUST WASHER
THRUST WASHER
FIBER WASHER
SCREW 1/4-20 NC x 1 LG ALL THREAD
PIPE PLUG
3-3.2.0
AW320324 2/99
TURNER ASSEMBLY (HYDRAULIC)
3203P/PR/PRX
4
5
6
7
8
ITEM
1
2
3
9
10
11
12
2
1
2
2
1
1
1
2
1
QTY
4
4
1
P/N
017701
021500
330484
011603
330420
330486
330485
330472
010201
239300
330483
019000
DESCRIPTION
HEX NUT 1/2-13NC
LOCK WASHER 1/2
SPACER
CAPSCREW 1/2-13NC x 1 3/4
SHAFT ASSEMBLY
OIL SEAL
BEARING
HOUSING
CAPSCREW 1/2-13NC x 1 1/2
GREASE ZERK
SPACER
HEX LOCK NUT 7/8-14NF
3-4.0.0
AW005 2/99
TRAVELING BLOCK ASSEMBLY
P/N 320433
ITEM
1
2
5
6
7
8
9
3
4
QTY
1
2
1
1
1
2
2
2
2
P/N
100309
360124
320434
320403
200909
013512
018200
320404
330100
DESCRIPTION
SWIVEL HOOK
HITCH PIN
BLOCK PIN
TRAVELING BLOCK
SHEAVE ASSEMBLY w/ BEARING
HEX HD SCREW 5/8 NC x 3 1/2
HEX HALF LOCK NUT 5/8 NC
BLOCK
FLAT WASHER
NOTE: STANDARD 62’ CABLE ASSEMBLY MAY BE ORDERED USING P/N 320338 .
OPTIONAL 75’ CABLE ASSEMBLY MAY BE ORDERED USING P/N 320339 .
3-5.0.0
AW320433 9/98
AUTOMATIC SAFETY BRAKE ASSEMBLY
(OIL COOLED) HOIST
8
9
10
11
12
13
14
15
16
ITEM
1
4
5
6
7
2
3
6
1
1
1
1
1
1
4
2
QTY
1
1
1
1
2
1
1
360453
360368
360456
360371
360353
360465
360455
360359
360364
P/N
360367
360331
360450
360336
360339
360342
360345
DESCRIPTION
FLAT SPRING
CAM PLATE
HOUSING COVER
BRAKE HOUSING
BRAKE HUB
RETAINER PLATE
BRAKE BALL
CAPSCREW 1/4 NC x 1
COIL SPRING
CAPSCREW 3/8 NC x 1 1/2
THREAD SEAL
JAM NUT 3/8 NC
THREAD SEAL
WASHER FLAT 1/4 ALUM
GASKET
THRUST PLATE
3-6.0.0
AW368 1/99
AUTOMATIC SAFETY BRAKE ASSEMBLY
(OIL COOLED) HOIST
ASSEMBLY INSTRUCTIONS:
1.
Winch has right hand worm and gear. Cable spools over drum. Use number one slots for brake balls(7) in cam plate(2).
2.
Install brake hub(5) through brake housing(4) on winch worm with key.
3.
Assemble balls(7) in cam plate(2) using hard grease to hold balls in place.
4.
Place cam plate(2) on brake hub(5), matching its holes with the balls.
5.
Install thrust plate(16).
6.
Thread capscrew(10) with jam nut (12) and thread seal (11) through housing cover(3).
7.
Place gasket(15) on housing cover(3).
8.
Install coil spring(9) on capscrew(10).
9.
Install flat spring(1) on capscrew(10).
10.
Secure retainer plate(6) and flat spring(1) to housing cover(3) using capscrews(8) and washers(14).
11.
Using capscrews(8) and thead seals(13) attach housing cover(3) to brake housing(4).
12.
Test brake by shifting winch to UP then DOWN to see if brake is working in proper rotation. If not, remove housing cover(3) and locate brake balls(7) in opposite set of slots of cam plate(2).
13.
Adjust to suit by tightening or loosening capscrew(10) on outside of housing cover(3). When proper adjustment is obtained, secure capscrew(10) with jam nut(12).
3-6.1.0
AW368 1/99
TWECO
ASSEMBLY
ITEM
1
2
3
4
5
6
7
8
9
10
11
QTY
1
1
1
1
2
2
3
2
2
2
1
P/N
320488
320515
330258
320372
011510
017701
021500
000115
320371
005401
020200
DESCRIPTION
POWER CABLE ASSEMBLY
UPPER TWECO BRACKET
TWECO POWER CONNECTOR
UPPER TWECO CLAMP
CAPSCREW 1/2 NC x 1 1/4
HEX NUT 1/2 NC
SPLIT LOCK WASHER 1/2
CLIP
SELF-TAP SCREW 1/4 NC x 5/8
CAPSCREW 1/4 NC x 5/8
SPLIT LOCK WASHER 1/4
3-7.0.0
AW040 2/99
GENERAL DIMENSIONS
3203P
5-1.0.0
3203Pdim 2/99
GENERAL DIMENSIONS
3203PR
5-2.0.0
3203PRdim 2/99
GENERAL DIMENSIONS
3203PRX
5-3.0.0
3203PRXdim 2/99
HYDRAULIC ASSEMBLY
3203PRX
6-1.0.0
AW038 2/99
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
7
8
5
6
9
10
11
12
13
14
15
16
17
18
ITEM
1
2
3
4
1
1
4
4
1
2
1
1
1
1
1
1
2
2
1
1
4
4
4
-
-
-
1
2
2
1
3
1
1
1
1
2
QTY
1
1
1
1
HYDRAULIC ASSEMBLY
3203PRX
202759
480194
320407
320410
202756
241170
320473
320466
320489
320490
320491
320472
320467
241168
320469
330275
020200
005810
P/N
202710
202711
320325
320336
480027
330412
200876
-
-
-
241175
330058
330272
330274
330072
320408-001
320409
320350
DESCRIPTION
MANIFOLD (REF)
EXTENSION CYLINDER (REF)
BOOM CYLINDER (REF)
HYDRAULIC PUMP & RESERVOIR (REF)
-
-
HYDRAULIC ROTATION MOTOR (REF)
COUNTERBALANCE VALVE
-
ADAPTER -6 ORB/-6 JIC
90º ELBOW -6 ORB/-6 JIC
REDUCER -10 ORB/-6 ORP
90º ELBOW -8 ORB/-6 JIC
REDUCER -10 ORB/-8 ORP
HEX HEAD PLUG -10 ORB
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
45º ELBOW -8 NPTM/-6 JIC
90º ELBOW -8 NPTM/-6 JIC
90º ELBOW -6 SWIVEL/-6 JIC
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
ADAPTER -8 ORB/-6 JIC
BULKHEAD UNION
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
LOAD SENSOR ASSEMBLY
HYDRAULIC HOSE ASSEMBLY
TEE -6 ORB/-6 JIC RUN
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
SPLIT LOCK WASHER 1/4
CAPSCREW 1/4-20 NC x 1 3/4
6-1.1.0
AW038 2/99
HYDRAULIC ASSEMBLY
3203PR
6-2.0.0
AW039 2/99
7
8
5
6
9
10
11
12
13
14
15
16
17
18
ITEM
1
2
3
4
19
20
21
22
23
24
25
26
27
28
29
30
31
-
-
1
3
3
-
1
2
2
2
1
1
1
1
QTY
1
1
1
1
2
2
1
1
1
1
1
2
2
1
1
2
1
HYDRAULIC ASSEMBLY
3203PR
P/N
202710
320352
320336
480027
200876
-
-
-
330274
330272
330058
241175
330072
320409
320408-001
480194
320350
202759
320410
320407
202756
241170
320490
320491
320467
330412
241168
005810
020200
320472
320469
DESCRIPTION
MANIFOLD (REF)
BOOM CYLINDER (REF)
HYDRAULIC PUMP & RESERVOIR (REF)
HYDRAULIC ROTATION MOTOR (REF)
-
-
-
ADAPTER -6 ORB/-6 JIC
REDUCER -10 ORB/-8 ORP
90º ELBOW -8 ORB/-6 JIC
REDUCER -10 ORB/-6 ORP
90º ELBOW -6 ORB/-6 JIC
HEX HEAD PLUG -10 ORB
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
90º ELBOW -6 SWIVEL/-6 JIC
45º ELBOW -8 NPTM/-6 JIC
90º ELBOW -8 NPTM/-6 JIC
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
ADAPTER -8 ORB/-6 JIC
BULKHEAD UNION
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
HYDRAULIC HOSE ASSEMBLY
COUNTERBALANCE VALVE
TEE -6 ORB/-6 JIC RUN
CAPSCREW 1/4-20 NC x 1 3/4
SPLIT LOCK WASHER 1/4
LOAD SENSOR ASSEMBLY
HYDRAULIC TUBE ASSEMBLY
6-2.1.0
AW039 2/99
HYDRAULIC ASSEMBLY
3203P
8
9
10
11
5
6
7
ITEM
1
2
3
4
1
1
1
1
1
1
1
QTY
1
1
1
1
P/N
241175
320343
340344
320560
083803
320370
301103
330596
320340
330584
320465
DESCRIPTION
90º ELBOW -6 SWIVEL/-6 JIC
FLOW REGULATOR
TEE
LOAD SENSOR
HOSE CLAMP -6
90º ELBOW -6 ORB/-6 NPTM
VELOCITY FUSE
90º ELBOW -6 NPTF/-6 JIC
ADAPTER -6 ORB
BREATHER FILTER
HOSE ASSEMBLY
6-3.0.0
AW048 2/99
HYDRAULIC PUMP & RESERVOIR
P/N 320335
ITEM
1
2
3
6
7
4
5
8
9
10
1
1
1
1
1
1
1
QTY
1
1
1
P/N
320335-001
320335-002
320335-003
320335-004
320335-005
320335-006
320335-007
320335-008
320335-010
200545
DESCRIPTION
ADAPTER KIT
RELEASE VALVE KIT
PUMP KIT
RELIEF VALVE KIT
MOTOR
RESERVOIR KIT
MOUNTING BRACKET KIT
ELBOW FITTING
O-RING
BREATHER CAP
6-5.0.0
aw320335 2/99
HYDRAULIC PUMP & RESERVOIR
P/N 320336
ITEM
1
2
3
6
7
4
5
8
9
10
1
1
1
1
1
1
1
QTY
1
1
1
P/N
320336-005
320336-002
320335-003
320336-003
320335-005
320336-006
320335-007
320335-008
320335-010
200545
DESCRIPTION
ADAPTER KIT
RETURN PORT PLUG KIT
PUMP KIT
RELIEF VALVE KIT
MOTOR
RESERVOIR KIT
MOUNTING BRACKET KIT
ELBOW FITTING
O-RING
BREATHER CAP
6-6.0.0
aw320336 2/99
COUNTERBALANCE VALVE SETTING
3203 SERIES
CAUTION:
IF COUNTERBALANCE VALVE IS REPLACED, THE CORRECT
PRESSURE SETTING MUST BE MADE BEFORE CRANE IS IN
SAFE WORKING CONDITION.
IMPORTANT
No load must be on crane boom and booms must not be extended during gauge installation and removal procedure.
After installed, boom up until boom cylinder is fully elevated. Next, boom down in small increments while reading pressure gauge. Loosen nut on end of valve and adjust 3/16" Allen screw and then re-tighten nut. Proceed again until pressure reading is a constant 1000 psi. If valve is not set and boom reaches the full down position, boom up and keep trying.
Valve Setting
Remove gauge and replace plug when adjustment is complete.
To set counterbalance valve (330412), remove plug (5/16" Allen wrench) from port "A" of hydraulic pump. Install a pressure gauge of 2500 psi capacity minimum into the port (-6 O-ring port).
Note:
3203 PRX extendible boom cylinder
(202711) requires no adjustment to counter balance valve if replaced.
6-7.0.0
32cbset 2/99
TROUBLESHOOTING GUIDE
3203 PRX
1 CRANE FAILS TO OPERATE (ALL
FUNCTIONS)
A.
Check power to crane - 12v to ground at upper left power terminal of pump relay
1.
If ok go to B.
2.
If not check continuity back to battery at
Tweco and battery connections.
B.
If there is power at pump relay (left side) and no functions are operable the most likely cause is in the control circuits (pendant or receptacle).
1.
Verify by touching jumper from hot side of pump relay to left side control terminal(small) on pump relay. Pump should run but crane should not move unless a valve is stuck open. Also test by jumping from hot side of pump relay to left side control terminal of hoist down relay. hoist should operate down.
C.
If previous tests are ok, then remove pendant and check at receptacle on crane with jumper and test light.
1.
Check for voltage from pin "D" of socket to ground. to center terminal of rotation switch from pin
"D").
2 HOIST UP, BOOM DOWN, & EXTEND
(OUT) DON'T OPERATE BUT ALL
OTHER FUNCTIONS OPERATE. PUMP
RUNS WHEN BOOM DOWN AND
EXTEND FUNCTIONS ARE TRIED.
THESE FUNCTIONS ARE TIED INTO THE
ANTI-TWO BLOCK AND CRANE
OVERLOAD SENSOR SYSTEMS. THE
CRANE IS SHUT DOWN WHEN THE
SENSORS OPEN THE GROUND CIRCUIT
FROM THE FUNCTIONS.
A.
Check two-block bail and switch at end of boom to verify they move freely. Switch should make audible click when operated.
Try operating crane while pulling cord out of cord reel to check for possible bad spots in cord reel slip rings.
B.
Check load sensor pressure switch - locate timing relay on lower right hand corner of relay panel. Disconnect wire coming from pressure switch at terminal #6 of timing relay. If crane operates replace pressure switch.
i.
If not successful, then receptacle assembly is bad.
ii.
If ok, jumper from "D" to "F" (hoist down), or "D" to "J" (pump). Other functions can be checked also by probing receptacle with jumper. See
P/N 680065 pg 7-6.0.0. Hydraulic functions require that pump and valve are both activated.
D.
If receptacle tests are ok, then fault is in pendant hot wire. Either a break in the wire or it is not attached inside of the pendant (goes
WARNING:
BE SURE BOOM IS
SUPPORTED BEFORE REMOVING
SWITCH OR BOOM WILL FALL.
C.
If previous test fails, then test timing relay by removing wire from terminal #1 of timing relay. If successful, clean the area around terminals 6 and 7 and recheck. If test still fails, replace timing relay.
6-8.0.0
D.
Test drop out relay - pull orange wire from terminal #1 on the timing relay. If crane operates, ground orange wire to verify drop
32trbl 2/99
TROUBLESHOOTING GUIDE
3203 PRX
out relay is working, then reattach to terminal
#1. If crane still does not operate, pull socket off relay. Find where wire from cord reel feeds into relay socket. Jumper from this terminal of socket to ground. If crane operates, replace relay. If crane still does not operate, then check continuity through cord reel and two-block switch.
and pick hoist down. If light comes on, replace hoist down relay.
NOTE:
THERE ARE OTHER WAYS TO
TEST FOR CIRCUIT CONTINUITY SUCH AS
USING VOLT METER OR TEST LIGHT AND
FOLLOWING CIRCUIT THROUGH BY
TESTING AT EACH POINT FOR VOLTAGE
TO GROUND.
3 HOIST FAILS TO OPERATE IN EITHER
DIRECTION BUT ALL HYDRAULIC
FUNCTIONS OPERATE.
A.
Listen for relay click for hoist up and hoist down. If relay doesn't click check for voltage at left side control terminal(small) when function is selected, if no voltage then use procedure for checking receptacle and pendant given in 1.C.
B.
Check terminal A2 of hoist motor for power when operating either hoist up or hoist down.
If there is voltage but motor does not try to run or get hot then motor is bad. If motor tries to run or gets hot then voltage reading at
A2 will be less than 12 volts and motor may be dirty or have oil in it from failed oil seal.
C.
If there is no power at A2 only on hoist up, then put test light across bottom power terminals of hoist down relay. If light comes on when hoist up is picked, then hoist down relay is bad. If test light doesn't light, put light across upper power terminals of hoist up relay and pick hoist up. If light comes on, replace hoist up relay.
D.
If there is no power at A2 only on hoist down then put test light across bottom power terminals of hoist up relay. If light comes on when hoist down is picked, then hoist up relay is bad. If test light doesn't light, put light across upper power terminals of hoist down relay
4 ALL HYDRAULIC FUNCTIONS
INOPERABLE.
A.
Pump does not run, pump relay does not click. Jumper from upper left power terminal of pump relay to left side relay control terminal. If relay doesn't click, replace relay. If relay clicks and pump runs, check receptacle and pendant. (see 1.C.)
B.
If relay clicks but pump doesn't run, check for voltage at pump motor terminal. If no voltage replace pump relay. If voltage is present, pump motor is bad or pump is locked. If pump is locked motor will get hot and voltage at motor terminal will much lower than 12 volts.
5 PUMP RUNS BUT SINGLE HYDRAULIC
FUNCTION DOESN'T WORK.
A.
Select inoperable function with pendant switch and push manual override of valve in question-if function works use procedure 1.C.
to check receptacle and pendant. If receptacle checks out and function can not be run by using jumper at receptacle, then valve or harness may be bad. Check for 12 volt at valve junction box. If no voltage presentcheck for loose wire at back of receptacle or terminal strip.
B.
If voltage is present at valve, then valve may be bad. This can be checked by swapping
6-8.1.0
32trbl 2/99
TROUBLESHOOTING GUIDE
3203 PRX
valve positions on manifold but leaving wiring attached. If trouble moves with valve, then valve is bad.
C.
If boom retract or boom down functions don't work, then check for low hydraulic pressure at pump. These two functions have the highest pressure requirements for an unloaded crane because they must overcome the set pressures of the counter balance valves.
D.
If hydraulic functions are more intermittent when cylinders are extended, then check hydraulic fluid level.
E.
Boom locks up and won't come down when fully raised. This is caused by too high pump pressure which causes overload system to activate. Set relief pressure at 2100 psi.
Unlock boom by disconnecting wire from terminal #6 of timing relay. Reconnect wire after boom is moved. If pressure is correct and problem continues, then replace overload pressure switch.
6-8.2.0
32trbl 2/99
SOLENOID VALVES WIRING DIAGRAM
P/N 320480 - 3203PRX
ITEM
1
2
3
4
5
QTY
-
3
1
2
8
P/N
REF
642908
001102
000300
000302
DESCRIPTION
SOLENOID VALVE 300204
CORD CONNECTOR
WIRE TERMINAL 2RC-10
WIRE TERMINAL
WIRE TERMINAL 2R814
7-1.0.0
AW320480 2/99
SOLENOID VALVES WIRING DIAGRAM
P/N 320481 - 3203PR
ITEM
1
2
3
4
5
QTY
-
2
1
1
5
P/N
REF
642908
001102
000300
000302
DESCRIPTION
SOLENOID VALVE 300204
CORD CONNECTOR
WIRE TERMINAL 2RC-10
WIRE TERMINAL
WIRE TERMINAL 2R814
7-2.0.0
AW320481 2/99
PENDANT ASSEMBLY
P/N 680068 - 3203P
ITEM
1
2
3
4
5
9
10
11
12
6
7
8
QTY
1
1
1
2
17'
2
1
1
6"
4
2
7
P/N
370130
370131
370132
622000
800629
001207
640302
000101
370135
320563
480515
490243
DESCRIPTION
PENDANT BOX
PENDANT COVER
PENDANT HOUSING GASKET
TOGGLE SWITCH
CONDUCTOR CABLE
RECESSED CROSS PAN HD SCREW #8 x1"
BOOT
TERMINAL RING
PINION GEAR
11 PIN BAYONET PLUG
CABLE CLAMP
HEAT SHRINK TUBING
7-4.0.0
AW680068 2/99
PENDANT ASSEMBLY
P/N 680064 - 3203PR
7-5.0.0
AW680064 2/99
PENDANT ASSEMBLY
P/N 680064 - 3203PR
5
6
7
8
9
ITEM
1
2
3
4
10
11
12
13
14
15
16
17
18
19
20
21
10
2
1
18 FT
2
1
15
-
3
QTY
1
1
1
3
1
1.750
1
1
2
2
.250
6”
P/N
631602
631700
622000
640300
001004
005101
633801
800630
634401
320563
000101
-
642100
019700
800580
004700
480515
634200
636600
800592
490243
DESCRIPTION
PENDANT HOUSING
BOTTOM COVER
TOGGLE SWITCH
BOOT-TOGGLE SWITCH
PAN HEAD SCREW #6 x 3/4
PAN HEAD SCREW #8 x 1 1/4
CABLE ADAPTER
CONDUCTOR CABLE
TY-RAP CABLE TIE
11 PIN BAYONET PLUG
TERMINALS T & B
-
O-RING
SPLIT LOCK WASHER #8 PLATED
3/4” WIDE OKONITE RUBBER TAPE
PAN HEAD SCREW #8 x 1 1/2
CABLE CLAMP
TOGGLE SWITCH
JUMPER BAR
WHITE 16GA x 3 IN WIRE
TUBING HEAT SHRINK
7-5.1.0
AW680064 2/99
PENDANT ASSEMBLY
P/N 680065 - 3203PRX
7-6.0.0
AW680065 2/99
PENDANT ASSEMBLY
P/N 680065 - 3203PRX
5
6
7
8
9
ITEM
1
2
3
4
10
11
12
13
14
15
16
17
18
19
20
21
22
10
2
1
18 FT
2
3
24
-
4
QTY
1
1
1
4
1
1.750
1
3
2
1
1
3
6”
P/N
631601
631700
622000
640300
001004
005101
633801
800632
634401
636600
000101
-
642100
800592
800580
004700
622346
622347
320563
480515
634200
490243
DESCRIPTION
PENDANT HOUSING
BOTTOM COVER
TOGGLE SWITCH
BOOT-TOGGLE SWITCH
PAN HEAD SCREW #6 x 3/4
PAN HEAD SCREW #8 x 1 1/4
CABLE ADAPTER
CONDUCTOR CABLE
TY-RAP CABLE TIE
JUMPER
TERMINALS T & B
-
O-RING
WHITE 16GA 600V 1C WIRE
3/4” WIDE OKONITE RUBBER TAPE
PAN HEAD SCREW #8 x 1 1/2
CONDUCTOR ASSEMBLY 2 1/8
CONDUCTOR ASSEMBLY 3 1/8
11 PIN BAYONET PLUG
CABLE CLAMP
TOGGLE SWITCH
TUBING HEAT SHRINK
7-6.1.0
AW680065 2/99
RELAY ASSEMBLY
P/N 680055 - 3203P
7-7.0.0
AW680055 2/99
7
8
5
6
9
10
11
12
13
ITEM
1
2
3
4
14
15
16
17
18
19
20
21
22
23
24
25
26
-
2
2
1
1
3
6
6
7
QTY
3
1
2
1
1
1
1
7
7
2
1
1
1
1
1
2
2
P/N
200182
REF
622323
622327
622325
600304
-
658300
659904
680057
015600
020001
020200
015900
005901
320564
000302
320560
019600
015400
000404
000300
680056
320355
320558
320559
RELAY ASSEMBLY
P/N 680055 - 3203P
DESCRIPTION
RELAY
POWER CABLE (TWECO MALE) 330258
CONDUCTOR
CONDUCTOR
CONDUCTOR
CONDUCTOR
-
CONDUCTOR
CONDUCTOR
3203P RECEPTACLE ASSEMBLY
HEX NUT #10-32 NF
WASHER #10
SPLIT LOCK WASHER 1/4
HEX NUT 1/4-20 NC
CAPSCREW 1/4-20 NC x 1/2
RECEPTACLE CAP
TERMINAL RB-14-10 (REF)
LOAD SENSOR ASSEMBLY (REF)
LOCK WASHER #6
HEX NUT #6-32 NC
ROUND HEAD SCREW #6-32 x 5/8
TERMINAL RB-14-10
3203P RELAY PANEL
BOSCH DROP OUT RELAY
CONDUCTOR
CONDUCTOR
7-7.1.0
AW680055 2/99
RELAY ASSEMBLY
P/N 680054 - 3203PR
7-8.0.0
AW680054 2/99
7
8
5
6
9
10
11
12
13
14
15
16
17
18
ITEM
1
2
3
4
19
20
21
22
23
24
25
26
27
28
29
30
1
1
1
2
2
1
1
1
2
1
1
6
1
1
QTY
3
3
1
2
1
5
5
1
4
1
6
4
1
2
1
1
RELAY ASSEMBLY
P/N 680054 - 3203PR
P/N
200182
658300
680118
659904
622323
622324
320355
330257
330258
600304
320479
635203
001102
330261
002602
330259
330249-200
015900
020200
005901
320351
015400
019600
320564
000404
320358
320472
320365
320366
005500
DESCRIPTION
RELAY
CONDUCTOR
RECEPTACLE ASSEMBLY
CONDUCTOR
CONDUCTOR
CONDUCTOR
DROP OUT RELAY
CONDUCTOR
TWECO CONNECTOR ASSEMBLY (REF)
CONDUCTOR
RELAY PANEL PLATE
TERMINAL BOARD
TERMINAL WIRE SPLICE
CONDUCTOR ASSEMBLY-16” BOOM
CAPSCREW #6-32 x 1 1/2
CONDUCTOR ASSEMBLY-14” TURN
RELAY PANEL BRACKET
NUT 1/4-20
SPLIT LOCK WASHER 1/4
CAPSCREW 1/4-20 x 1/2
SOLID STATE TIMING RELAY
HEX NUT #6-32
SPLIT LOCK WASHER #6
RECEPTICAL CAP
CAPSCREW #6-32 x 5/8
DROP OUT RELAY PLUG
LOAD SENSOR ASSEMBLY (REF)
CONDUCTOR
CONDUCTOR
CAPSCREW 1/4-20 x 3/4
7-8.1.0
AW680054 2/99
RELAY ASSEMBLY
P/N 320457-200 - 3203PRX
7-9.0.0
AW320457200 2/99
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
7
8
5
6
9
10
11
12
13
ITEM
1
2
3
4
1
1
6
1
1
1
5
5
1
6
4
1
1
1
4
1
1
2
3 FT
1
1
1
1
1
2
2
1
1
1
2
QTY
3
3
1
2
RELAY ASSEMBLY
P/N 320457-200 - 3203PRX
330261
002602
330259
330249-200
015900
020200
005901
320351
015400
019600
320564
000404
320358
320472
320365
320366
002602
005500
800626
000302
000300
P/N
200182
658300
330256-200
659904
622323
622324
320355
330257
330258
600304
320479
635203
001102
DESCRIPTION
RELAY
CONDUCTOR
RECEPTACLE ASSEMBLY
CONDUCTOR
CONDUCTOR
CONDUCTOR
DROP OUT RELAY
CONDUCTOR
TWECO CONNECTOR ASSEMBLY (REF)
CONDUCTOR
RELAY PANEL PLATE
TERMINAL BOARD
TERMINAL WIRE SPLICE
CONDUCTOR ASSEMBLY-16” BOOM
CAPSCREW #6-32 x 1 1/2
CONDUCTOR ASSEMBLY-14” TURN
RELAY PANEL BRACKET
NUT 1/4-20
SPLIT LOCK WASHER 1/4
CAPSCREW 1/4-20 x 1/2
SOLID STATE TIMING RELAY
HEX NUT #6-32
SPLIT LOCK WASHER #6
RECEPTICAL CAP
CAPSCREW #6-32 x 5/8
DROP OUT RELAY PLUG
LOAD SENSOR ASSEMBLY (REF)
CONDUCTOR
CONDUCTOR
CAPSCREW #6-32 x 1 1/2
CAPSCREW 1/4-20 x 3/4
#16 AWG 2/C, 300V TYPE SJO 90ºC
WIRE TERMINAL (BUTT SPLICE) 2RB14
WIRE TERMINAL RB14-10
7-9.1.0
AW320457200 2/99
RELAY CHECKING PROCEDURE
NOTE:
The following procedure is performed with relays completely disconnected from all wires on motor circuits and ground wires.
These circuits can give you false readings sometimes.
HOW TO CHECK RELAY:
Checking a relay on this or any Auto Crane product is done in the same way, but there may be a difference in physical appearance of the relay. Shown below are two types of relays used by Auto Crane. Our relays are normally closed across the bottom posts C & D and normally open across the A & B posts. When activated, they will open across C & D and close across A & B. To activate these relays, use 12V positive (+) and 12V negative (–) wires and place them on posts F & E. You may place 12V+ on post F or E as long as you place
12V– on the remaining post F & E. Using an ohm meter or test light, check across posts A &
B. You should get an ohm reading or your test light should be on when you have the relay activated. With the relay still activated, check across posts C & D. You should have no ohm reading or test light at this point with relay activated. At this point, disconnect 12V+ and
12V– from posts F & E. This should let relay return to its normal position. Using your ohm meter or test light again, check the relay across posts A & B. If relay is working correctly, you should have no reading at all. Then check across posts C & D. You should have an ohm reading or test light should be on. If you get the above results, relay is okay. If you get any variation in the above explanation on the relay you are checking, check the relay again. If it still shows a difference, the relay is bad and should be replaced.
7-13.0.0
RELAYCHK 9/98
LOAD CHART
3203P/PR/PRX
9-9.9.9
320321 2/99
Advertisement
