OWNERS MANUAL

2703 SERIES

REVISION 2/2000

PART NO.

999949

SERIAL NO. __________________________

PO BOX 580697, TULSA, OK 74158-0697

4707 N. MINGO ROAD, TULSA, OK 74117

PHONE (918) 836-0463

SALES FAX (918) 438-6688 SERVICE FAX (918) 834-5979 http://www.autocrane.com

WARNINGS -

READ THIS PAGE!

WARNING!

Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of a vehicle certify that the vehicle complies with all applicable federal regulations. Any modifications performed on the vehicle prior to the final stage are also considered intermediate stage manufacturing and must be certified as to compliance. The installer of this crane and body is considered one of the manufacturers of the vehicle. As such a manufacturer, the installer is responsible for compliance with all applicable federal and state regulations, and is required to certify that the vehicle is in compliance.

WARNING!

It is the further responsibility of the installer to comply with the OSHA

Truck Crane Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).

WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL

POWER LINES!

Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to

50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.

WARNING! NEVER

.............................

v EXCEED load chart capacities (centerline of rotation to hoist hook).

v un-reel last 5 wraps of cable from drum!

v wrap cable around load!

v attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.

v weld, modify, or use unauthorized components on any Auto Crane unit! This will void any warranty or liability. Also failure of the crane may result.

v place a chain link on the tip of the hook and try to lift a load!

v use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature!

v hold on any pendant Select Switch that will cause unsafe operating conditions!

WARNING!

In using a hook with latch, ALWAYS make sure that the hook throat is closed before lifting a load! Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.

WARNING!

Failure to correctly plumb and wire crane can cause inadvertent operation and damage to crane and/or personnel!

WARNING!

Auto Crane Company remote controlled cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel.

WARNING! ALWAYS

operate the crane in compliance with the load capacity chart.

Do not use the overload shutdown device to determine maximum rated loads, if your crane is

equipped with this type of device.

warning 9/98

2703 SERIES - OWNER'S MANUAL

TABLE OF CONTENTS

7

8

9

10

11

12

13

14

15

16

17

18

19

20

5

6

3

4

1

2

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING PRACTICES & WARNINGS . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION OF UNIT / OUTRIGGERS . . . . . . . . . . . . . . . . . . . . . . . . .

QUALIFICATIONS FOR OPERATORS . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION, TESTING, & MAINTENANCE

LIFE OF WIRE LINE / WIRE LINE LUBRICATION

LUBRICATION & MAINTENANCE SCHEDULE

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL ASSEMBLY

MANUAL BRAKE ASSEMBLY

TURNER ASSEMBLY

ELECTRICAL SECTION

RELAY ASSEMBLY

TROUBLESHOOTING

OUTRIGGERS

LOAD CHART

WARRANTY

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOIST ACTUATOR ASSEMBLY

SAFETY DECAL SECTION

GENERAL DIMENSIONS

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LAST PAGE

INTRODUCTION

2703 SERIES

Auto Crane products have been engineered to provide safe, trouble-free, dependable service for many years when these products are properly used and maintained.

To assist you in obtaining the best service from your crane and to avoid untimely failure of the unit and / or the vehicle on which it is mounted, the following operating and service instructions are herein published, and 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.

For your convenience the overall dimensions of the 2703 series crane are on the

General Dimension Drawing. Maximum turning radius is shown at the outside point of the hoist actuator (M model) and the outside edge of the rotation gear motor (MR & PR 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 2703 series cranes. Crane side jackleg should extend

45" from centerline of truck chassis.

The 2703 series cranes are attached directly to your 12 volt truck electrical system. The power cable and retaining clips are included with the crane. A typical power cable mounting and hookup is shown on page

2-1.0.0. 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 500 cold cranking rated 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

1-1.0.0

2703INT 3/98

INTRODUCTION

2703 SERIES

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:

THIS MANUAL

SHOULD REMAIN WITH

THE CRANE AT ALL TIMES.

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) 438-2760. 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.

1-1.0.1

2703INT 3/98

GENERAL SPECIFICATIONS

2703 SERIES

DIMENSIONS REACH

Width: [M]19.0 in (.48 m)

[MR]21.5 in (.55m)

[PR]21.5 in (.55m)

Second boom will reach from 6 ft to 10 ft

Third boom will reach from 10 ft to 14 ft

Height: 28.25 in (.72 m)

CABLE

Length: 6 ft 11 in (2.11 m)

[boom(s) stored]

62 ft (18.9 m) of 7/32 in diameter aircraft quality cable is standard [75 ft (22.86 m) optional]. This cable has a single line breaking strength of 5600 lbs (2540 kg).

Weight:

M 6-10 365 lbs (166 kg)

M 6-10-14 430 lbs (195 kg)

MR 6-10 430 lbs (195 kg)

MR 6-10-14 460 lbs (209 kg)

PR 6-10 490 lbs (222 kg)

PR 6-10-14 520 lbs (236 kg)

[Add 5 lbs (2.25 kg) for cable length of 75

feet (23 m)]

CHASSIS REQUIREMENTS

8,000 lbs (3,628 kg) GVWR minimum

ELECTRICAL SYSTEM

Hoist Motor: 12 volt DC series wound

Rotation Gearmotor: 12 volt DC, PM type

CAPACITY

8,100 ft lbs (1.12

ton/m)

[ft lbs = horizontal distance from centerline of rotation to free hanging weight (feet) x amount of weight (pounds)]

ELECTRICAL SYSTEM

REQUIREMENTS

Alternator: 60 amp (minimum)

4

5

6

ft

3

7

8

LIFTING CAPACITIES lbs

2,700

ft

9

lbs

900

2,025

1,620

1,350

1,150

1,010

10

11

12

13

14

810

735

675

620

575

Battery: 100 minute reserve

capacity (minimum)

Maintenance type

ROTATION

M model: 360º Continuous manual rotation

MR model: 360º Continuous power rotation

PR model: 360º Continuous power rotation

1-1.1.0

2703SPEC 12/97

--- 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

2-1.0.0

--- 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.

2-3.0.0

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.

2-3.1.0

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.

2-3.2.0

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

1-3.1.0

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

1-3.2.0

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

1-3.3.0

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)

1-3.4.0

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.

1-3.5.0

INSP 9/98

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

LIFE OF WIRE LINE

So many variable factors can cause the deterioration of wire line cable that it is not possible to determine a definite life expectancy. Some of these factors are:

• Load being handled.

• Corrosive conditions.

• Maintenance of the unit:

Keep the sheaves turning freely.

Maintain tension on cable to insure proper spooling.

Avoid kinks in cable.

Avoid abrasive action and contact with sharp corner.

• Frequency of use.

Auto Crane units, up to 2,400 pound ratings use 3/16 inch diameter galvanized pre-formed 7 x 19 aircraft cable. This cable has a working strength, when new, of 4,200 pounds.

It is recommended when 1,200 pound loads are exceeded to use a two part line with a traveling block. This will ensure a 3.5 to 1 safety factor when the cable is new.

Keeping the above factor of safety in mind and knowing the kind of loads that will be handled, the user can determine by inspection of the cable as to when it should be replaced.

Items to look for while inspecting the cables are:

• Broken strands.

• Kinks and flattened sections.

• Corrosion and abrasion.

WIRE LINE LUBRICATION

Lubrication of the wire line serves two important purposes:

• Prevent corrosion.

• Reduce wear due to flexing and abrasion caused by contact with the sheaves, rollers, and cable on the drum.

Preparation

Remove rust and foreign matter with a wire brush and wipe clean. Be sure cable is dry.

Application

Method 1: Dip a brush into a light weight motor oil and apply. In some cases, dip a rag or a piece of sheepskin into the lubricant and swab the lubricant on to the rope.

Method 2: Apply a heavier lubricant such as a grease gun lubricant with hands while wearing leather gloves. (Leather gloves give greater protection and less penetration of the grease than canvas gloves.)

7-1.0.0

WIRE 1/2000

LUBRICATION & MAINTENANCE

SCHEDULE 2703 CRANE

SERVICE

PERFORMED

LOAD HOOK

DAY

WEEK MONTH

6 MOS YEAR

NOTES

CABLE DRUM

HOIST CABLE

MOUNTING BOLTS

X

X

X

X

INSPECT HOOK & LATCH FOR DEFORMA-

TION, CRACKS, & CORROSION

MAKE SURE CABLE IS WOUND EVENLY ON

DRUM

CHECK FOR FLATTENING, KINKS, &

BROKEN STRANDS, SEE MANUAL

CHECK-TORQUE TO 85 FT-LBS (DRY) AS

REQUIRED

CHECK TERMINALS FOR TIGHT

CONNECTIONS

MOTOR

CONNECTION

X

SHEAVE BEARINGS X

SEALED BEARING, REPLACE IF ROUGH OR

LOOSE

CHECK-TIGHTEN AS REQUIRED ALL OTHER BOLTS X

BOOM CYLINDER

BOOM CYLINDER

PINS

X

X

CHECK AROUND CYLINDER ROD FOR

EXCESS FLUID LEAKAGE

GREASE WITH MOBILPLEX EP-2 OR

EQUIVALENT @ ZERKS

BATTERY

CONNECTIONS

ROTATION BRAKE (M)

X

CHECK FOR CORROSION & TIGHT CONNEC-

TIONS. CLEAN & COAT AS REQUIRED

X

CHECK ADJUSTMENT

SAFETY DECALS

POWER CABLE

ROTATION GEAR

(MR) (PR)

X

X

X

INSPECT AND REPLACE AS NEEDED

CHECK INSULATION FOR DAMAGE OR

DETERIORATION

WATER PROOF BEARING GREASE OR DRY

MOLYLUBE IF DUSTY CONDITIONS

ROTATION WORM

BEARINGS (MR) (PR)

X

GREASE WITH MOBILPLEX EP-2 OR

EQUIVALENT @ ZERKS

HOIST GEARBOX

HYDRAULIC FLUID

ROTATION BEARINGS

X

X

WORM GEAR-EP GEAR LUBE SAE 80-90,

SPUR GEAR SAE 30 OIL

DRAIN, FLUSH, & REFILL WITH MOBIL

DTE 13, OR EQUIVALENT

SEALED BEARING-NO MAINTENANCE REQUIRED

1-7.0.0

2703MAIN 6/99

LUBRICATION & MAINTENANCE

SCHEDULE 2703 CRANE

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.

2703MAIN 6/99

ASSEMBLY & INSTALLATION INSTRUCTIONS

2703 SERIES

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

AW053 4/98

BOOM SUPPORT

2703 SERIES

WARNING:

As with all Auto Crane power rotation units, the 2703 does require a boom support.

Suggested Boom Support:

Auto Crane P/N 725045

2-2.2.0

AW058 4/98

GENERAL ASSEMBLY

P/N 270300 - 2703 M, 6-10-14 BOOM

3-1.0.0

AW270300 8/98

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

ITEM

1

2

5

6

7

8

9

3

4

10

11

12

13

1

1

2

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

7

1

1

1

1

1

QTY

1

1

1

1

1

1

1

2

1

1

1

1

1

GENERAL ASSEMBLY

P/N 270300 - 2703 M, 6-10-14 BOOM

330468

270389

320324

270403

270391

330519

270404

330470

270325-006

270325-007

340303

227401

370002

320328

320433

320338

P/N

270432

270419

330192

330182

330471

330471-001

270380

270408

320423

270325

270325-001

270325-002

320379

320339

002614

005501

020200

320415

012200

018100

330185

019106

DESCRIPTION

QUILL / BASE

QUILL HOUSING WELDMENT

SEALED BALL BEARING

SNAP RING

RIGHT PIVOT BOOM

LEFT PIVOT BOOM

LOWER WELDMENT BOOM

MID BOOM

MANUAL BOOM w/ CROWN

HYDRAULIC CYLINDER

SEAL KIT (FOR 270325 CYL)

REPAIR KIT (FOR 270325 CYL)

DRUM

COLLAR SP LK

CABLE GUARD

ACTUATOR ASSEMBLY

ACTUATOR BRACKET

REAR PANEL

PENDANT CONTROL

RELAY ASSEMBLY

BEARING FLANGE

PUMP HANDLE

GRIP HANDLE

SPACER

SHEAVE ASSEMBLY (BEARING ONLY 200100)

POSITION PIN

LONG POSITION PIN

TRAVELING BLOCK

62’ STANDARD CABLE ASSEMBLY

75’ OPTIONAL CABLE ASSEMBLY

SCREW HEX HD 5/16-18 x 5/8 SELF-TAP

SCREW HEX HD 1/4-28 NC x 3/4

WASHER SP LK 1/4

RETAINER MANUAL BOOM

SCREW HEX HD 5/8-18 NF x 1 3/4 GR5

NUT HEX HALF-LOCK 5/8-18 NF

SCREW HEX HD 1-12 NF x 5 1/2 GR5

NUT HEX 1-12 NF

3-1.1.0

AW270300 8/98

ITEM

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

QTY

1

1

4

4

1

5

5

1

12

19

19

6

1

4

4

1

4

GENERAL ASSEMBLY

P/N 270300 - 2703 M, 6-10-14 BOOM

P/N

360038

016300

005500

015900

007807

020600

008401

REF

330370

330372

021100

330371

014400

018600

011200

017704

021500

DESCRIPTION

ANGLE INDICATOR

NUT HEX LOCK 1/4-20 NC

SCREW HEX HD 1/4 NC x 3/4

NUT HEX 1/4-20 NC

SCREW HEX HD 5/16-18 NC x 3/4

WASHER SP LK 5/16

SCREW HEX HD 3/8 NC x 1/2

RECEPTACLE ASSEMBLY (see RELAY ASSEMBLY)

SCREW HEX HD 3/8-16 NC x 7/8

NUT HEX 3/8-16 NF

WASHER SP LK 3/8

SCREW HEX HD 3/8-16 NC x 1 GR8

SCREW HEX HD 3/4-16 NC x 5 GR5

NUT HEX LOCK 3/4-16 NF

SCREW HEX HD 1/2-20 NF x 2 1/2 GR5

NUT HEX 1/2-20 NF HEAVY

WASHER SP LK 1/2

3-1.2.0

AW270300 8/98

GENERAL ASSEMBLY

P/N 270302 - 2703 MR, 6-10-14 BOOM

3-2.0.0

AW270302 8/98

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

ITEM

1

2

5

6

7

8

9

3

4

10

11

12

13

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

3

1

1

1

QTY

1

1

1

1

1

1

1

2

1

1

1

1

2

GENERAL ASSEMBLY

P/N 270302 - 2703 MR, 6-10-14 BOOM

330313

270391

REF

680068

680052

330470

270325

270325-001

270325-002

270325-006

270325-007

340303

270408

320415

320423

227401

P/N

270432

270419

330192

330182

270385

330471

330471-001

270380

320379

270389

330468

320324

270403

320338

320339

370002

320328

320433

002614

005501

020200

012200

DESCRIPTION

QUILL / BASE

QUILL HOUSING WELDMENT

SEALED BALL BEARING

SNAP RING

WORM GEAR

RIGHT PIVOT BOOM

LEFT PIVOT BOOM

LOWER WELDMENT BOOM

DRUM

CABLE GUARD

COLLAR SP LK

ACTUATOR ASSEMBLY (see page 3-8.0.0)

ACTUATOR BRACKET

12V MOTOR GEAR

REAR PANEL

RECEPTACLE ASSEMBLY (see RELAY ASSEMBLY)

PENDANT CONTROL (see page 6-2.0.0)

RELAY ASSEMBLY (see page 6-5.0.0)

BEARING FLANGE

HYDRAULIC CYLINDER

SEAL KIT (FOR 270325 CYLINDER)

REPAIR KIT (FOR 270325 CYLINDER)

PUMP HANDLE

HANDLE GRIP

SPACER

MID MANUAL BOOM

RETAINER MANUAL BOOM

MANUAL BOOM w/ CROWN

SHEAVE ASSEMBLY (BEARING ONLY 200100)

62’ STANDARD CABLE ASSEMBLY

75’ OPTIONAL CABLE ASSEMBLY

PIN ASSEMBLY w/ LANYARD

POSITION PIN (LONG)

TRAVELING BLOCK

SCREW HEX HD 5/16-18 NF x 5/8 SELF-TAP

SCREW HEX HD 1/4-28 NF x 3/4

WASHER SP LK 1/4

SCREW HEX HD 5/8-18 NF x 1 3/4 GR5

3-2.1.0

AW270302 8/98

43

44

45

46

47

48

49

50

51

ITEM

39

40

41

42

52

53

54

55

56

57

58

59

60

61

62

1

6

19

19

4

4

4

2

2

2

12

3

3

4

10

6

1

QTY

1

1

1

1

-

1

1

GENERAL ASSEMBLY

P/N 270302 - 2703 MR, 6-10-14 BOOM

P/N

018100

330185

019106

360038

016300

008401

-

005500

015900

007807

020600

007805

014400

018600

330371

330372

021100

011200

17704

21500

404

019600

015400

330370

DESCRIPTION

NUT HEX HALF-LOCK 5/8-18 NF

SCREW HEX HD 1-12 NF x 5 1/2 GR 5

NUT HEX 1-12 NF

ANGLE INDICATOR

NUT HEX LOCK 1/4-20 NC

SCREW HEX HD 3/8 NC x 1/2

-

SCREW HEX HD 1/4-20 NC x 3/4

NUT HEX1/4-20 NC

SCREW HEX HD 5/16-18 NC x 3/4

WASHER SP LK 5/16

SCREW HEX HD 5/16-18 NC x 1 1/2 GR5

SCREW HEX HD 3/4 NF x 5 GR5

NUT HEX 3/4-16 NF

SCREW HEX HD 3/8-16 NC x 1 GR8

NUT HEX 3/8-16 NC

WASHER SP LK 3/8

SCREW HEX HD 1/2-20 NF x 2 1/2 GR5

NUT HEX 1/2-20 NF HEAVY

WASHER SP LK 1/2

SCREW RD HD #6-32 NC x 5/8

WASHER SP LK #6

NUT HEX #6-32 NC

SCREW HEX HD 3/8-16 NC x 7/8

3-2.2.0

AW270302 8/98

GENERAL ASSEMBLY

P/N 270304 - 2703 PR, 6-10-14 BOOM

3-2.3.0

AW270304 8/98

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

ITEM

1

2

5

6

7

8

9

3

4

10

11

12

13

1

1

2

1

1

1

1

1

2

1

1

1

1

1

1

1

1

5

1

13

1

1

1

1

1

QTY

1

1

1

1

1

1

1

2

1

1

1

1

1

GENERAL ASSEMBLY

P/N 270304 - 2703 PR, 6-10-14 BOOM

330468

270389

320324

270403

008702

270410

270416

330470

370002

008401

340303

227401

340523

320328

320433

320338

P/N

270432

270419

330192

330182

330471

330471-001

270380

270408

320423

330250

270325-001

270325-002

320379

320339

002614

005501

020200

320415

012200

018100

330185

019106

DESCRIPTION

QUILL / BASE

QUILL HOUSING WELDMENT

SEALED BALL BEARING 5.9055 OD

SNAP RING

RIGHT PIVOT BOOM

LEFT PIVOT BOOM

LOWER BOOM WELDMENT

MANUAL MID BOOM

MANUAL BOOM w/ CROWN

HYDRAULIC CYLINDER

SEAL KIT FOR 270325 CYL (not shown)

REPAIR KIT FOR 270325 CYL (not shown)

CABLE DRUM

COLLAR 1 1/4 ID

CABLE GUARD

ACTUATOR ASSEMBLY (see page 3-8.0.0)

ACTUATOR BRACKET

SCREW HEX HD 3/8 NC x 1 1/4

PENDANT CONTROL (see page 6-1.0.0)

RELAY ASSEMBLY (see page 6-6.0.0)

BEARING FLANGE

PIN ASSEMBLY w/ LANYARD

SCREW HEX HD 3/8 NC x 1/2

SPACER

SHEAVE ASSEMBLY (BEARING ONLY 200100)

KEY 1/4 x 1/4 x 2 3/4

LONG POSITION PIN

TRAVELING BLOCK (see page 3-7.0.0)

62’ STANDARD CABLE ASSEMBLY

75’ OPTIONAL CABLE ASSEMBLY

SCREW HEX HD 5/16-18 x 5/8 SELF-TAP

SCREW HEX HD 1/4-28 NC x 3/4

LOCK WASHER 1/4

RETAINER MANUAL BOOM

SCREW HEX HD 5/8-18 NF x 1 3/4 GR8

NUT HEX LOCK 5/8-18 NF

SCREW HEX HD 1-12 NF x 5 1/2 GR5

NUT HEX 1-12 NF

3-2.4.0

AW270304 8/98

*52

53

54

55

56

57

58

59

60

61

*62

*63

64

65

ITEM

39

40

41

42

43

44

45

46

47

48

49

50

51

1

6

1

1

4

1

1

4

4

1

1

2

2

2

QTY

1

3

8

8

4

10

1

14

22

25

9

2

2

GENERAL ASSEMBLY

P/N 270304 - 2703 PR, 6-10-14 BOOM

021500

REF

270385

330313

007805

330412

270324

006700

REF

005604

011200

017704

368985

241169

P/N

360038

016300

005500

015900

007807

020600

REF

330370

330372

021100

330371

018600

014400

DESCRIPTION

ANGLE INDICATOR

NUT HEX LOCK 1/4-20 NC

SCREW HEX HD 1/4 NC x 3/4

NUT HEX 1/4-20 NC

SCREW HEX HD 5/16-18 NC x 3/4

LOCK WASHER 5/16

TURNER ASSEMBLY (not shown, see page 3-6.0.0)

SCREW HEX HD 3/8-16 NC x 7/8

NUT HEX 3/8-16 NF

LOCK WASHER 3/8

SCREW HEX HD 3/8-16 NC x 1 GR8

NUT HEX 3/4-16 NF

SCREW HEX HD 3/4-16 NC x 1 GR8

LOCK WASHER

RECEPTACLE ASSEMBLY (see RELAY ASSEMBLY)

WORM GEAR

12V MOTOR GEAR

SCREW HEX HD 5/16-18 NC x 1 1/2 GR5

HOLDING VALVE

HYDRAULIC PUMP

SCREW HEX HD 1/4 NC x 2 1/2

RELAY DROP OUT

SCREW HEX HD 1/4 NC x 1

SCREW HEX HD 1/2 NF 2 1/2 GR 5

NUT HEX 1/2 NF 20 GR 5

MANIFOLD SENSE VALVE

O-RING

*BASE MOUNTING HARDWARE TO TRUCK FRAME.

AW270304 8/98

3-2.5.0

GENERAL ASSEMBLY

P/N 270301 - 2703 M, 6-10 BOOM

P/N 270303 - 2703 MR, 6-10 BOOM

P/N 270305 - 2703 PR, 6-10 BOOM

5

6

7

8

9

ITEM

1

2

3

4

1

1

1

1

1

QTY

1

1

1

1

P/N

270380

270402

227401

012200

018100

320338

320339

320328

002614

DESCRIPTION

LOWER BOOM WELDMENT

MANUAL BOOM w/ CROWN

SHEAVE ASSEMBLY (BEARING ONLY 200100)

SCREW HEX HD 5/8 x 1 3/4 NF GR5

LOCK NUT 5/8 NF

62’ STANDARD CABLE ASSEMBLY

75’ OPTIONAL CABLE ASSEMBLY

POSITION PIN

SCREW HEX HD 5/16 ST

3-3.0.0

AW610BOOM 7/98

BRAKE ASSEMBLY

2703 M

5

6

7

8

9

ITEM

1

2

3

4

1

1

1

1

1

QTY

1

1

1

1

P/N

270376

330184

330490

018301

330488

330489

013503

330303

330136

DESCRIPTION

BRAKE BAND ASSEMBLY

COMPRESSION SPRING

SPACER

NUT HEX 5/8 NC

COMPRESSION SPRING

SPACER

SCREW HEX HD 5/8 NC x 7 GR5

HANDLE GRIP

BRAKE HANDLE

3-4.0.0

AW642 4/98

TWECO ASSEMBLY

2703 SERIES

5

6

7

8

9

10

ITEM

1

2

3

4

1

1

1

3

2

1

QTY

1

1

1

1

P/N

320488

330212

REF

002900

000115

005500

015900

020200

005401

REF

DESCRIPTION

POWER CABLE ASSEMBLY

UPPER TWECO BRACKET

MALE TWECO CONNECTOR

SCREW HEX 1/4 x 3/8

CLAMP

SCREW HEX HD 1/4 NC x 3/4

NUT HEX 1/4 NC

WASHER SP LK 1/4

SCREW HEX HD 1/4-20 x 5/8

FEMALE TWECO CONNECTOR

3-5.0.0

AW052 4/98

TURNER ASSEMBLY (ELECTRIC)

2703 SERIES

ITEM

1

4

5

2

3

8

9

6

7

10

11

12

13

14

15

QTY

2

1

4

3

1

4

REF

1

2

2

1

2

1

1

1

P/N

010201

330389

330504

330498

021500

017701

330500

330421

330486

330485

330472

011603

239300

330483

019000

DESCRIPTION

SCREW HEX HD 1/2-13 NC x 1 1/2 GR5

SCREW FLAT HD 1/4-20 NC x 1/2

MOTOR MOUNT

MOTOR MOUNT ASSEMBLY

WASHER SP LK 1/2

NUT HEX 1/2-13 NC

BEARING

WORM

OIL SEAL

CONE BEARING

BEARING HOUSING

SCREW HEX HD 1/2-13 NC x 1 3/4 GR5

GREASE ZERK

SPACER

NUT HEX 7/8-14 NF

3-6.0.0

AW006 4/98

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.

3-7.0.0

AW320433 9/98

HOIST ACTUATOR ASSEMBLY

P/N 320324

3-8.0.0

AW320324 2/99

ITEM

1

2

5

6

7

8

9

3

4

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

35

36

37

38

32

33

34

QTY

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

-

1

1

2

1

3

2

1

2

10

12

4

1

1

1

4

2

1

3

4

4

1

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

3-8.1.0

AW320324 2/99

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

49

50

51

2

2

1

1

1

1

1

1

3

1

1

1

1

2

2

QTY

3

1

1

1

1

1

2

1

2

1

2

1

1

HOIST ACTUATOR ASSEMBLY

P/N 320324

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

300068

300069

300070

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

3-8.2.0

AW320324 2/99

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

3-9.0.0

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).

3-9.1.0

AW368 1/99

SAFETY DECAL SECTION

PART NO.:

DECAL:

FUNCTION:

040517

STAY CLEAR OF BOOM

To inform the operator of the hazard of proximity or contact with the crane boom during operation.

2

QUANTITY

:

PLACEMENT

:

Both sides of crown

(see page 4-2.0.0, Item 1)

PART NO.:

DECAL:

FUNCTION:

040518

STAY CLEAR OF

LOAD

To inform the operator of the hazard of proximity or contact with the crane load during operation.

2

QUANTITY

:

PLACEMENT

:

Both sides of down haul weight

(see page 4-2.0.0,

Item 12)

FIG. SD-1.

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

(see page 4-2.0.0, Item 15)

FIG. SD-3.

4-1.0.0

2703DEC 4/98

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 lower boom

(see page 4-2.0.0, Item 2)

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

:

Sideplate

(see page 4-2.0.0, Item 5)

4-1.1.0

FIG. SD-5.

2703DEC 4/98

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

:

Sideplate

(see page 4-2.0.0, Item 6)

FIG. SD-7.

4-1.2.0

2703DEC 4/98

DECAL DRAWING

2703 SERIES

ITEM

1

4

5

2

3

8

9

6

7

10

11

12

13

14

15

QTY

2

1

1

2

2

1

1

1

1

2

10'

2

1

1

2

P/N

040517

040529

270321

330622

040579

040580

040622

040552

360036

040624

040620

040518

330624

270322

040519

DESCRIPTION

STAY CLEAR DECAL

DANGER ELECTROCUTION DECAL

2703 DECAL

SERIAL NO DECAL

WORK RULES DECAL

DANGER DECAL

A/C LOGO DECAL

RELAY

ANGLE INDICATOR DECAL

AUTO CRANE DECAL

STRIPING DECAL

STAY CLEAR DECAL

LOWER BOOM DECAL

LOAD CHART DECAL

SCISSORS POINT DECAL

4-2.0.0

AW270395 4/98

GENERAL DIMENSIONS

2703 M 6-10-14

5-1.0.0

AW054 8/98

GENERAL DIMENSIONS

2703 M 6-10

5-1.1.0

AW055 8/98

GENERAL DIMENSIONS

2703 MR 6-10-14

5-1.2.0

AW056 8/98

GENERAL DIMENSIONS

2703 MR 6-10

5-1.3.0

AW057 8/98

GENERAL DIMENSIONS

2703 PR 6-10-14

5-1.4.0

AW640 8/98

GENERAL DIMENSIONS

2703 PR 6-10

5-1.5.0

AW641 8/98

PENDANT ASSEMBLY BAYONET w/ 18' LG CABLE

P/N 270410 - 2703 PR

6-1.0.0

AW270410 8/98

4

5

6

7

8

9

ITEM

1

2

3

10

11

12

13

18

19

20

21

14

15

16

17

3

10

2

1

18'

2

1

15

-

3

QTY

1

1

2

4

1.75

1

1

1

2

0.25

6"

PENDANT ASSEMBLY BAYONET w/ 18' LG CABLE

P/N 270410 - 2703 PR

P/N

631602

631700

622000

640300

001004

005101

633801

800630

634401

320563

000101

-

642100

019700

800580

004700

480515

634200

636600

800592

480243

DESCRIPTION

PENDANT HOUSING

BOTTOM COVER

TOGGLE SWITCH

BOOT-TOGGLE SWITCH

SCREW ST SLT PAN HD #6 x 3/4

SCREW ST SLT PAN HD #8 x 1 1/4

CABLE ADAPTER

CONDUCTOR CABLE

TY-RAP CABLE TIE

11 PIN BAYONET PLUG

TERMINALS T & B

-

O-RING

WASHER SP LK #8 PLATED

3/4 WIDE OKONITE RUBBER TAPE

SCREW ST SLT PAN HD #8 x 1 1/2

CABLE CLAMP

TOGGLE SWITCH

JUMPER BAR

WHITE WIRE 16GA x 3

HEAT SHRINK TUBING

6-1.1.0

AW270410 8/98

PENDANT ASSEMBLY

P/N 680068 - 2703 MR

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

6-2.0.0

AW680068 3/98

HOIST CONTROL PENDANT

P/N 330519 - 2703 M

6

7

8

4

5

ITEM

1

2

3

1

1

1

1

1

QTY

1

1

1

P/N

675271

675281

675206

675202

675201

675261

675291

330518

DESCRIPTION

HEX NUT

WASHER TANG

HOUSING KIT

SWITCH w/ SEAL NUT

HOUSING

SEAL

CABLE PENDANT

FEMALE PLUG

6-3.0.0

AW330519 7/98

HYDRAULIC ASSEMBLY

2703 PR

ITEM

1

4

5

6

7

2

3

8

9

10

11

12

13

14

15

QTY

1

1

2

1

1

1

1

1

1

1

1

2

2

1

1

P/N

270324

330250

812203-014

200892

812206-041

330412

200877

241175

368985

241169

320543

200876

330645

006700

020200

DESCRIPTION

HYDRAULIC PUMP

HYDRAULIC CYLINDER

HOSE ASSEMBLY x 14

ELBOW 90º 3/8 NPT / -6 JIC

HOSE ASSEMBLY x 41

HOLDING VALVE

TEE STRAIGHT THREAD RUN

ELBOW 90º -6 ORB / -6 JIC

MANIFOLD SENSE VALVE

O-RING

PRESSURE SWITCH (REF)

ADAPTER ST-6JIC

ELBOW JIC6/ORB6 LONG

HEX HD SCREW 1/4 x 2 1/2

LOCK WASHER 1/4

6-4.0.0

AW643 8/98

RELAY ASSEMBLY BAYONET

P/N 680052 - 2703 MR

6-5.0.0

AW680052 3/98

4

5

6

7

8

9

ITEM

1

2

3

10

11

12

13

14

15

19

20

21

22

16

17

18

4

2

1

1

2

1

1

1

8

8

1

1

QTY

4

4

2

8

8

1

1

8

16

16

RELAY ASSEMBLY BAYONET

P/N 680052 - 2703 MR

P/N

200182

658300

658400

659904

622323

622327

000300

600304

REF

330386

330388

330387

680053

020200

015900

005604

016800

020700

015600

020001

320564

330415

DESCRIPTION

RELAY

CONDUCTOR

CONDUCTOR

CONDUCTOR

CONDUCTOR

CONDUCTOR

TERMINAL WIRE RB-14-10

CONDUCTOR

TWECO ASSEMBLY

CONDUCTOR

CONDUCTOR

CONDUCTOR

CONDUCTOR

CONDUCTOR

CONDUCTOR

CONDUCTOR

CONDUCTOR

TERMINAL WIRE RB-14-10

CONDUCTOR

TWECO ASSEMBLY

CONDUCTOR

CONDUCTOR

6-5.1.0

AW680052 3/98

RELAY ASSEMBLY BAYONET

P/N 270416 - 2703 PR

6-6.0.0

AW270416 7/98

16

17

18

19

20

10

11

12

13

14

15

27

28

29

30

31

32

33

34

35

21

22

23

24

25

26

4

5

6

7

8

9

ITEM

1

2

3

8

14

14

6

6

3

1

8

8

1

1

2

1

1

1

1

4

1

1

1

1

3

3

1

1

1

1

1

1

3

1

1

QTY

3

2

1

RELAY ASSEMBLY BAYONET

P/N 270416 - 2703 PR

270421

270434

270422

270417

020200

015900

005604

016800

020700

015600

020001

320564

270423

270424

320363

750737

320543

366250

270411

270425

270426

366251

270427

270428

270326

270435

P/N

200182

658300

658400

659904

622323

622327

320355

600304

330258

DESCRIPTION

RELAY

RELAY CONDUCTOR

RELAY CONDUCTOR

WHITE CONDUCTOR 16GA x 4

BLACK CONDUCTOR 6GA WELD x 26

BLACK CONDUCTOR 6GA WELD x 28

DROP OUT BOSCH RELAY

BLACK CONDUCTOR 6GA WELD x 4

TWECO ASSEMBLY (REF)

WIRE HARNESS x 3

BLACK CONDUCTOR 4GA WELD x 14

WIRE HARNESS 7 & 7

PENDANT CONDUCTOR ASSEMBLY

LOCK WASHER 1/4

NUT 1/4-20

SCREW HEX HD 1/4-20 x 1

NUT HEX HALF 5/16 NF

LOCK WASHER INTERNAL 5/16

NUT #10-32

LOCK WASHER INTERNAL #10

BAYONET RECEPTACLE CAP (REF)

WIRE HARNESS x 24

WIRE HARNESS x 15

TERMINAL CONNECTOR PLUG

CABLE TIE

LOAD SENSOR SWITCH

CONNECTION WEATHERPACK 2-WAY MALE 18-20

WIRE HARNESS 4 & 15

WIRE HARNESS x 15

WIRE HARNESS 7 & 20

CONNECTION WEATHER PACK 2-WAY FEMALE 18-20

WIRE HARNESS x 4

WIRE HARNESS x 4

INSULATOR BOOT BLACK

WIRE HARNESS x 11

AW270416 7/98

6-6.1.0

TROUBLESHOOTING 2703

PROBLEM CAUSE/SOLUTION

CRANE WILL NOT HOIST UP OR

DOWN.

CAUSE:

Bad relay, crane not grounded properly, or power cable not connected to

12V power source. Bad switch in pendant, broken wire in pendant connector, pendant not plugged together properly, wire on relay not in proper place or lead wires to motor not connected properly.

SOLUTION:

Problems can be solved by replacing bad relay, grounding the crane properly to the truck chassis, connecting the power cable properly to 12V+ power source, switch in pendant can be replaced, cord in remote control can be replaced, check connector on cord to make sure of contact of all the prongs on it are plugged together correctly, make sure wires on relays are according to the wiring print supplied with each new crane in the owner book and also wires going to motor are connected properly. NOTE: 12V

must pass through opposite relay to complete circuit.

WITH LOAD SENSOR (OPT.)

CRANE WILL NOT HOIST UP OR

BOOM UP AND DOWN.

CAUSE:

Crane is overloaded.

Sensor switch is bad.

Bad connection to relays.

SOLUTION:

Hoist down. Do not overload crane. Replace sensor switch. Check for loose or damaged wiring.

CRANE RUNS UP OR DOWN ANY

TIME POWER SOURCE IS

CONNECTED.

CAUSE:

Relay stuck in run position which will let crane run up or down any time

12V power is connected. Wires shorted together in remote control. Lead or cable can also cause this problem. Wires jumped across relay in wrong place can cause crane to run all the time.

SOLUTION:

Problem can be solved by checking the relays and replacing the bad one or removing jumper wires from the relays or replacing the remote control cord or switch.

7-1.0.0

2703TRBL 4/98

TROUBLESHOOTING 2703

PROBLEM CAUSE/SOLUTION

CRANE WILL NOT BOOM UP OR

DOWN.

CAUSE:

Bad pump, crane not grounded properly, or power cable not connected to

12V power source. Bad switch in pendant, broken wire in pendant connector, pendant not plugged together properly, wire on relay not in proper place or lead wires to motor not connected properly.

SOLUTION:

Problems can be solved by replacing bad pump, grounding the crane properly to the truck chassis, connecting the power cable properly to 12V+ power source, switch in pendant can be replaced, cord in remote control can be replaced, check connector on cord to make sure of contact of all the prongs on it are plugged together correctly, make sure wires on relays are according to the wiring print supplied with each new crane in the owner book and also wires going to motor are connected properly.

7-1.1.0

2703TRBL 4/98

TROUBLESHOOTING 2703

HOW TO CHECK RELAY:

Our relays are normally closed across the bottom posts

(C & D). 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. NOTE: The above explanation is with

relays completely disconnected from all wires on motor circuits and ground wires. These circuits can give you false readings sometimes.

A

F

E

B

C D

7-1.2.0

2703TRBL 4/98

LOAD CHART

2703 SERIES

9-9.9.9

AW270322 8/98