Auto Crane 2703 M, MR, PR crane Owner's manual

270301-XXX-CP-XX-98
270303-XXX-CQ-XX-98
EFFECTIVE SERIAL NO. 270305-XXX-AAH-XX-98
OWNERS MANUAL
2703 SERIES
REVISION 8/98
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!
2703 SERIES
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 ..............e. nececonos
+ EXCEED load chart capacities (centerline of rotation to hoist hook).
* un-reel last 5 wraps of cable from drum!
* wrap cable around load!
« attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
« weld, modify, or use unauthorized components on any Auto Crane unit! This will void any
warranty or liability. Also failure of the crane may result.
* place a chain link on the tip of the hook and try to lift a load!
+ use a sling bar or anything larger than the hook throat that could prevent the hook latch from
closing, thus negating the safety feature!
+ hold on any pendant Select Switch that will cause unsafe operating conditions!
WARNING! In using a hook with latch, ALWAYS make sure that the hook throat is closed
before lifting a load! Proper attention and common sense applied to the use of the hoist hook and
various slings will prevent possible damage to material being hoisted and may prevent injury to
personnel.
WARNING! Failure to correctly plumb and wire crane can cause inadvertent operation and
damage to crane and/or personnel!
WARNING! Auto Crane Company remote controlled cranes are not designed or intended 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 3/98
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2703 SERIES - OWNER'S MANUAL
TABLE OF CONTENTS
INTRODUCTION .............eceor.enooveccocsorerocareceeaeco,
OPERATING PRACTICES & WARNING ..........e_ereoconaneoo
OPERATION OF UNIT / OUTRIGGERS ................... Lance
QUALIFICATIONS FOR OPERATORS ........ñeeeo.oeoocooanvoo
INSPECTION, TESTING, & MAINTENANCE ....................
LIFE OF WIRE LINE / WIRE LINE LUBRICATION ...............
LUBRICATION & MAINTENAN CESCHEDULE ..................
INSTALLATION ..........ñoe.e.eooccorerocacrcccasnorarenren.
SAFETY DECAL SECTION ..............eeocecvcoooccarorecono
GENERAL DIMENSIONS .... oii eerie
ELECTRICAL SECTION ..........eoecereosccoccecoserearorecm..
1-2.0.0
1-3.0.0
9-9.9.9
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
1-1.0.0
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
lability 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 fo 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
2703INT 3/98
ñ
INTRODUCTION
2703 SERIES
serviceman on a field service call, the rates
stated in the Auto Crane Distributors 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. Ош
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 3/08
DIMENSIONS
Width: [M]19.0 in (.48 m)
[MR]21.5 in (.55m)
[PR]21.5 in (.55m)
Height: 28.25 in (.72 m)
Length: 6ft11in (2.11 m)
[boom(s) stored]
Weight:
M 6-10
M 6-10-14
MR 6-10
MR 6-10-14
365 lbs (166 kg)
430 Ibs (195 kg)
430 lbs (195 kg)
460 Ibs (209 kg)
PR 6-10 490 lbs (222 kg)
PR 6-10-14 520 Ibs (236 kg)
[Add 5 Ibs (2.25 kg) for cable length of 75
feet (23 m)]
CAPACITY
8,100 ft lbs (1.12 ton/m)
[ft Ibs = horizontal distance from centerline of
rotation to free hanging weight (feet) x amount
of weight (pounds)]
| LIFTING CAPACITIES ]
1-1.1.0
GENERAL SPECIFICATIONS
2703 SERIES
REACH
Second boom will reach from 6 ft to 10 ft
Third boom will reach from 10 ft to 14 ft
ABLE
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 165 (2540 kg).
CHASSIS REQUIREMENTS
8,000 Ibs (3,628 kg) GVWR minimum
ELECTRICAL SYSTEM
Hoist Motor: 12 volt DC series wound
Rotation Gearmotor: 12 volt DC, PM type
ELECTRICAL SYSTEM
REQUIREMENTS
Alternator: 60 amp (minimum)
100 minute reserve
capacity (minimum)
Maintenance type
Battery:
ROTATION
M model: 360° Continuous manual rotation
MR model: 360° Continuous power rotation
PR model: 360° Continuous power rotation
2703SPEC 12/97
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 (sec 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.
WARNING!
— IMPORTANT —
OPERATING PRACTICES £ WARNINGS
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
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!
chart
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.
1-2.0.0
SAFTIPS 2508
1.
2.
— IMPORTANT —
OPERATION OF UNIT
Make sure this manual has been thoroughly read by
all crane operating personnel and supervisors.
A routine inspection of the crane should be mandatory
before each operating day. Any defects should be
corrected immediately.
. 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).
. Keep the vehicle as level as possible during operation.
. 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.
. 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.
. 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.
8. Always boom up before rotating so the boom will
clear the required boom support.
9. When extending the boom, always maintain clearance
between the boom crown and the traveling block or
hoist hook.
10. Always observe safe and practical operation to avoid
possible accidents. Refer to Safety Tips and
Precautions.
11. After completing lifting operations, return the boom
to stowed position on the boom support. Avoid
unneeded pressure on the boom support.
12. Store pendant contro! on proper location (in cab or on
crane).
13. Return outriggers to stowed position. Make sure they
are pinned in place or jacklegs are retumed to
compartment.
14. Check work area for any tools or equipment not
stored.
15. Release throttle control, depress clutch and disengage
PTO. Deactivate any crane power switches
16. Report any unusual occurrence during crane operation
that may indicate required maintenance or repair.
17. NEVER use two cranes to support a load too large for
cither crane,
18. 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 oufriggers are positioned, return
crane/outrigger selector to "crane" position.
4. Crane is now ready to operate.
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.
1-3.0.0
OPER 2/96
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
OPERATORS
7 Operators and operator trainees should have normal
depth perception, coordination, and no tendencies to
1 Crane operation shall be limited to personnel with dizziness or similar undesirable characteristics.
the following minimum qualifications: 8 In addition to the above listed requirements, the
A designated persons operator shall:
B. trainees under the direct supervision of a designated A. Demonstrate the ability to comprehend and interpret
person all labels, operator's manuals, safety codes and other
C. maintenance and test personnel (when it is information pertinent to correct crane operations.
necessary in the performance of their duties) B. Possess knowledge of emergency procedures and
D. inspectors (crane). implementation of same. ,
, C. Demonstrate to the employer the ability to opera
2 No one other than the personnel specified above shall the specific type of equipment.
enter the operating area of a crane with the exception
of persons such as oilers, supervisors, and those D. Be familiar with the applicable safety regulations.
specified persons authorized by supervisors whose E. Understand responsibility for maintenance
duties require them to do so and then only in the requirements of crane.
performance of their duties and with the knowledge F. Be thoroughly familiar with the crane and its
of the operator or other persons. control functions.
QUALIFICATIONS FOR OPERATORS G. Understand the operating procedures as outlined by
the manufacturer.
3 Operators shall be required by the employer to pass a CONDUCT OF OPERATORS
practical operating examination. Qualifications shall
be limited to the specific type of equipment for which
examined.
9 The operator shall not engage in any practice which
will divert his attention while actually operating the
4 Operators and operator trainees shall meet the crane.
following physical qualifications: 10 Each operator shall be responsible for those
A. Vision of at least 20/30 Snellen in one eye and operations under the operator's direct control.
20/50 in the other, with or without corrective lenses. Whenever there is any doubt as to safety, the
B. Ability to distinguish colors, regardless of position, operator shall consult with the supervisor before
if colors differentiation is required for operation. handling the loads.
C. Adequate hearing with or without hearing aid for
. 11 The operator should not leave a suspended load
the sr e operation. unattended unless specific precautions have been
S Evidence of physical defects or emotional instability instituted and are in place.
which render a hazard to operator or others, which
in the opinion of the examiner could interfere with
the eperator's performance may be sufficient cause
for disqualification. In such cases, specialized clinical
or medical judgement 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.
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,
6 Evidence that the operator is subject to seizures or
dess of physical control shall be sufficient reason for
disqualification. Specialized medical tests may be
required to determine these conditions. 14 If power fails during operation, the operator shall:
A. move power controls to the "OFF" or neutral
position.
1-4.0.0 QUAL 2/98
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 shail
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.
1-4.1.0
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,
QUAL 2/98
QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND
OPERATING PRACTICES
MISCELLANEOUS
OPERATING NEAR ELECTRICAL POWER
LINES
22 Except where the electrical distribution and
transmission lines have been de-energized and visibly
grounded at point of work or where insulating
barriers not a part of, or an attachment to, the crane
have been erected to prevent physical contact with
the lines, cranes shall operate so that no part of the
crane or load enters within 10 ft. (3m).
A. caution shall be exercised when working near
overhead lines having long spans as they tend to
move laterally or vertically due to the wind which
would breach the safety zone.
B. in transit with no load and boom lowered the
clearance shall be 10 ft. (3.0m)
C. a qualified signal person shall be assigned to
observe the 10 ft. (3.0m) clearance and give
warning before approaching above.
1-4.2.0
23 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,
24 Exceptions to this procedure, if approved by the
administrative or regulatory authority if the alternate
procedure provides equivalent protection and set
forth in writing,
25 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.
QUAL 2/98
INSPECTION, TESTING AND MAINTENANCE
GENERAL
INSPECTION CLASSIFICATION
1 Initial inspection. Prior to initial use, all new, altered,
modified or extensively repaired crames shall be
inspected by a designated person to insure compli-
ance with provisions of this standard.
2 Regular inspection. Inspection procedure for cranes
in regular service is divided into two general classifi-
cations 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 classi-
fications are herein designated as "frequent" and
"periodic" with respective intervals between inspec-
tions as defined below.
A. frequent inspection - daily to monthly intervals.
B. periodic inspection - one to twelve intervals, or as
specifically recommended by the manufacturer.
FREQUENT INSPECTION
3 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 compo-
nents 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 manufac-
turer's specifications, if optional winch is used;
1-5.0.0
G. electrical apparatus for malfunctioning, signs of
excessive deterioration, dirt and moisture accumula-
tion;
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
4 Deformed, cracked or corroded members in the
crane structure and carrier;
5 Loose bolts, particularly mounting bolts;
6 Cracked or worn sheaves and drums;
7 Worn, cracked, or distorted parts such as pins,
bearings, shafts, gears, rollers and devices;
8 Excessive wear on brake and clutch system parts and
lining;
9 Crane hooks inspected for cracks;
10 Travel steering, braking, and locking devices, for
malfunction;
11 Excessively worn or damaged tires;
12 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
INSP 10/97
shall be taken to eliminate the interference of
clements in contact or otherwise protect the
components.
13 Hydraulic and pneumatic pumps and motors
inspection
A. loose bolts or fasteners;
B. leaks at joints between sections;
. shaft seal leaks;
. unusual noises or vibrations;
loss of operating speed;
excessive heating of the fluid;
ое MW m © ©
. loss of pressure,
14 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.
15 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.
16 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
1-5.1.0
INSPECTION, TESTING AND MAINTENANCE
GENERAL
necessary to determine origin of the problem before
corrective action can be taken,
17 Labels are to be in place and legible.
CRANES NOT IN REGULAR USE
18 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 initial-
regular- frequent inspections.
19 A crane which has been idle for a period of over six
months shall be given a complete inspection conform-
ing with the initial-regular-frequent inspection
requirements,
INSPECTION RECORDS
20 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
21 Prior to initial use, all new, altered, modified, or
extensively repaired cranes shall be tested for compli-
ance 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;
. boom extension and retraction mechanisms;
. swing mechanisms;
safety devices;
4 E dao
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
INSP 10/97
tested by or under the direction of an
appointed person.
22 Test loads shall not exceed 110% of the manufac-
turer's load ratings.
23 Written reports shall be maintained showing test
procedures and confirming the adequacy of repairs.
MAINTENANCE
PREVENTIVE MAINTENANCE
24 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 interfer-
ence 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. relicve hydraulic oil pressure from all hydraulic
circuits before loosening or removing hydraulic
components.
25 Warning or "OUT OF ORDER" signs shall be placed
on the crane controls.
26 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 reacti-
vated, and maintenance equipment removed.
ADJUSTMENTS AND REPAIRS
27 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.
28 Adjustments shall be maintained to assure correct
functioning of components, The following are
examples:
1-5.2.0
INSPECTION, TESTING AND MAINTENANCE
GENERAL
A. functional operating mechanism;
B. safety devices;
C. control systems;
29 Repairs or replacements shall be provided as needed
for operation,
The following are examples:
À. critical parts of functional operating mechanisms
which are cracked, broken, corroded, bent, or exces-
sively 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.
30 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.
ROPE INSPECTION
31 Frequent Inspection
A. All running ropes in service should be visually
inspected once each working day. A visual inspec-
tion 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;
INSP 10/97
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.
32 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 desig-
nated 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 improp-
erly applied connections;
C. Care shall be taken when inspecting sections subject
to rapid deterioration such as the following:
1-5.3.0
INSPECTION, TESTING AND MAINTENANCE
GENERAL
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
33 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.
34 Conditions such as the following shall be reason for
questioning continued use of the rope or increasing
the frequency of inspection:
A. in nmning 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).
INSP 10/97
С. 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 construc-
tion shall be specified by a rope manufacturer, or a
qualified person.
35 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 infor-
mation before it is placed in service. This inspection
shall be for all types of deterioration and shall be
performed by a qualified person.
36 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.
ROPE MAINTENANCE
37 Rope should be stored to prevent damage or
deterioration.
38 Unreeling or uncoiling of rope shall be done as
recommended by the rope manufacturer and with
care to avoid kinking or inducing twist.
INSPECTION, TESTING AND MAINTENANCE
GENERAL
39 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.
40 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,
41 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 inspec-
tion. 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.
42 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.
1-5.4.0 INSP 1097
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 Ch
Many things affect the proper charge to a battery, such
as:
1 Regulator settings
2 Proper tightness of belts on the alternator
or generator
3 Good, clean connections of all cables
and wires at the following places:
A. Battery
B. Regulator
C. Starting motor
D. Alternator or generator
E. Ground connections (most important)
It is of extreme importance to keep the battery as fully
charged as possible without overcharging, especially
when vehicles are left outside for extended periods in
extremely cold climates. A battery can freeze.
Freezing points for various specific gravities of acid are
as follows:
Specific Gravity Freezing Temp.
(Corrected to 80°F) Degrees F.
1.280 -90°F
1.250 -62°F
1.200 -16°F
1.150 SF
1.100 19°F
As shown, a half-charged battery (about 1.200 specific
gravity) cannot stand for any length of time at 20°F or it
will freeze.
The main reason for keeping the battery as fully
charged as possible without over-charging is fo ensure
that power is available even though the vehicle has been
standing for some time.
1-5.5.0.
Keep Pro Filled with Water
The battery should a/ways be properly filled with water.
If the electrolyte level is allowed to fall below the top of
the plates, the results become threefold:
1 The exposed portion of the plate will become
sulfated.
2 The portion of the plate exposed is not usable.
3 That portion of the acid remaining becomes more
concentrated and may cause more rapid
deterioration of the remaining parts of the battery.
Keep A Relatively Clean Batt
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
A definite program of periodic maintenance of all
batteries should be conducted on a regular basis.
Periodic maintenance includes:
1 Checking belts for tightness on the charging
equipment
2 Checking battery electrolyte levels
3 Checking cables for good connections
4 Cleaning where corrosion is apparent
When corrosion is cleaned off, the cable terminals and
battery terminals should be coated with a light coating
of petroleum jelly before they are replaced. When
terminals are cleaned, the top of the battery should be
cleaned with a mild solution of soda water.
MAINTBAT 11/97
MAINTENANCE OF BATTERIES
Low Maintenance Batteries
{Maintenance Free)
Low maintenance batteries should not be used on Auto
Cranes or trucks equipped with Auto Cranes. The
batteries are not designed for “deep” discharge.
Testing Your Battery
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.
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
1-5.6.0.
should be attempted for an extended time. This usually
will recover a badly sulfated battery.
Replacing a Battery
If it is necessary to replace a battery, and a dry charge
battery is used, the following procedure applies:
1 Fill the battery with electrolyte of the proper
specific gravity.
2 Place the battery on charge according to the
manufacturer's instructions.
It is essential that the second step above be followed to
ensure that the battery going on the vehicle is fully
charged.
It is also very important that the battery hold-downs 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.
MAINTBAT 1197
LIFE OF WIRE LINE
2703 SERIES
So many variable factors can cause the Auto Crane units, 2,700 pound rating to 3,200
deterioration of wire line cable that it is not pound rating use 7/32 inch diameter galvanized
possible to determine a definite life expectancy. pre-formed 7 x 19 aircraft cable. This cable has a
Some of these factors are: working strength, when new, of 5,600 pounds. It
| is recommended when 1,600 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.
1. Load being handled.
2. Corrosive conditions.
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
3. Maintenance of the unit.
A. Keep the sheaves turning freely when it should be replaced.
B. Maintain tension on cable to insure
proper spooling Items to look for while inspecting the cables
C. Avoid kinks in cable are:
D. Avoid abrasive action and contact with
sharp corners
1. Broken strands.
2. Kinks and flattened sections.
4. Frequency of use. 3. Corrosion and abrasion.
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.
PREPARATION:
Remove rust and foreign matter with a wire brush
and wipe clean. Be sure cable is dry.
1-6.0.0
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.
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)
2703WIRE 4/98
LUBRICATION & MAINTENANCE
3) ANSI B30.5-1989
1-7.0.0
SCHEDULE 2703 CRANE
SERVICE DAY | WEEK | MONTE | 6 MOS | YEAR NOTES
PERFORMED
LOAD HOOK X INSPECT HOOK & LATCH FOR DEFORMA-
TION, CRACKS, & CORROSION
CABLE DRUM MAKE SURE CABLE IS WOUND EVENLY ON
DRUM
HOIST CABLE X CHECK FOR FLATTENING, KINKS, &
BROKEN STRANDS, SEE MANUAL
MOUNTING BOLTS X CHECK-TORQUE TO 85 FT-LBS (DRY) AS
REQUIRED
MOTOR CHECK TERMINALS FOR TIGHT
CONNECTION CONNECTIONS
SHEAVE BEARINGS | Xx SEALED BEARING, REPLACE IF ROUGH OR
LOOSE
ALL OTHER BOLTS X CHECK-TIGHTEN AS REQUIRED
BOOM CYLINDER X CHECK AROUND CYLINDER ROD FOR
EXCESS FLUID LEAKAGE
BOOM CYLINDER X GREASE WITH MOBILPLEX EP-2 OR
PINS EQUIVALENT @ ZERKS
BATTERY X CHECK FOR CORROSION & TIGHT CONNEC-
CONNECTIONS TIONS. CLEAN & COAT AS REQUIRED
ROTATION BRAKE (M) X CHECK ADJUSTMENT
SAFETY DECALS X INSPECT AND REPLACE AS NEEDED
POWER CABLE X CHECK INSULATION FOR DAMAGE OR
| DETERIORATION
ROTATION GEAR WATER PROOF BEARING GREASE OR DRY
(MR) (PR) MOLYLUBE IF DUSTY CONDITIONS
ROTATION WORM X GREASE WITH MOBILPLEX EP-2 OR
BEARINGS (MR) (PR) EQUIVALENT @ ZERKS
HOIST GEARBOX X WORM GEAR-EP GEAR LUBE SAE 80-90,
SPUR GEAR SAE 30 OIL |
HYDRAULIC FLUID X |DRAIN, FLUSH, & REFILL WITH MOBIL
DTE 13, OR EQUIVALENT
ROTATION BEARINGS SEALED BEARING-NO MAINTENANCE REQUIRED
BOOM SLIDE PADS PADS GREASED WHEN REPLACED
FOR ADDITIONAL 1) OWNER'S MANUAL
INFORMATION SEE: 2) OSHA SECTION 1910.180
2703MAIN 4/98
ASSEMBLY & INSTALLATION INSTRUCTIONS
2703 SERIES
NOTE: For mounting bolt hole pattern - see page 5-1.0.0.
NOTE:
FOR MOUNTING BOLT HOLE
PATTERN — SEE GENERAL
DIMENSION DRAWING AW-B631,
MAKE SURE HOIST ANCHOR IS USED
FOR OVER THE ROAD USE.
NO. BB-50 INSULATOR
DRILL 13/16 BUSHING ON CABLE
THRU FLOOR ASSEMBLY
POSITIVE POLE
STARTER
|
STARTER
NUT
BATTERY CABLE
FROM CRANE
GROUND FROM MOTOR
CHASSIS TO CHASSIS FRAME
FRAME
BATTERY CABLE
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 AVVOSS 4/08
BOOM SUPPORT
2703 SERIES
WARNING:
As with all Auto Crane power rotation units, the 2703 does require a boom support.
и
Suggested Boom Support:
Auto Crane P/N 725045
a BOOM
SUPPORT
2-2.2.0 AWOSE 4/98
GENERAL ASSEMBLY
P/N 270300 - 2703 M, 6-10-14 BOOM
AW270300 8/98
3-1.0.0
ITEM
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BN ZRALEBRALASRRERNSRER <SeasaduRrxoAunN ZB
E
GENERAL ASSEMBL Y
P/N
270432
270419
330192
330182
330471
330471-001
270380
270408
320423
270325
270325-001
270325-002
320379
330468
270389
320324
270403
270391
330519
270404
330470
270325-006
270325-007
340303
227401
370002
320328
320433
320338
320339
002614
005501
020200
320415
012200
018100
. 330185
019106
P/N 270300 - 2703 М, 6-10-14 BOOM
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
3-110 AW?270300 8/08
кекс носок - = к кои - - В
GENERAL ASSEMBLY
P/N
360038
016300
005500
015900
007807
020600
008401
REF
330370
330372
021100
330371
014400
018600
011200
017704
021500
P/N 270300 - 2703 M, 6-10-14 BOOM
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 GRS
NUT HEX 1/2-20 NF HEAVY
WASHER SP LK 1/2
3.1.2.0 AW270300 8/08
GENERAL ASSEMBLY
P/N 270302 - 2703 MR, 6-10-14 BOOM
AW270302 8/98
3-2.0.0
ITEM
1
2
3
4
5
6
7
8
9
N = ad od wh wh mh wh wh mh mb
© © © ~ Oh сл + © № «© ©
ER LERXEBRIZARZORN
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GENERAL ASSEMBLY
P/N 270302 - 2703 MR, 6-10-14 BOOM
P/N
270432
270419
330192
330182
270385
330471
330471-001
270380
320379
270389
330468
320324
270403
330313
270391
REF
680068
680052
330470
270325
270325-001
270325-002
270325-006
270325007
340303
270408
320415
320423
227401
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
ITEM
39
40
41
42
43
45
46
47
48
49
50
51
52
53
55
57
58
59
60
61
62
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 GRS
SCREW HEX HD 3/4 NF x 5 GRS
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 GRS
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
3-220 AW270302 8/98
GENERAL ASSEMBLY
P/N 270304 - 2703 PR, 6-10-14 BOOM
AW270304 8/58
3-2.3.0
ITEM
230040020]
© © Ga WW wo & NN N NR NN N N =® Le A =
GENERAL ASSEMBLY
P/N 270304 - 2703 PR, 6-10-14 BOOM
PIN
270432
270419
330192
330182
330471
330471-001
270380
270408
320423
330250
270325-001
270325-002
320379
330468
270389
320324
270403
008702
270410
270416
330470
370002
008401
340303
227401
340523
320328
320433
320338
320339
002614
005501
020200
320415
012200
018100
1 --—— 330185
1 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 1D
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
SCREWHEX 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 AW270:304 8/98
555855
49
20
51
*52
53
55
57
59
60
61
“63
65
= IABANNNIc=O rr sx ANNO LU © — В
GENERAL ASSEMBLY
РМ
360038
016300
005500
015900
007807
020600
REF
330370
330372
021100
330371
018600
014400
021500
REF
270385
330313
- 007805
330412
270324
006700
REF
005604
011200
017704
358985
241169
P/N 270304 - 2703 PR, 6-10-14 BOOM
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 НЕХ НО 1/2 № 2 1/2 СВ 5
NUT HEX 1/2 NF 20 GR 5
MANIFOLD SENSE VALVE
O-RING
“BASE MOUNTING HARDWARE TO TRUCK FRAME.
3-250 AW270304 888
=
covousen- li
=
GENERAL ASSEMBLY
P/N 2703501 - 2705 M, 6-10 BOOM
- P/N 270303 - 2703 MR, 6-10 BOOM
P/N 270305 - 2703 PR, 6-10 BOOM
PN
270380
270402
227401
012200
018100
320338
320339
320328
002614
aaa:
DESCRIPTION
LOWER BOOM WELDMENT
MANUAL BOOM w/ CROWN
SHEAVE ASSEMBLY (BEARING ONLY 200100)
SCREW HEX HD 5/8 x 1 3/4 NF GRS
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
AWE10BOOM 7/98
BRAKE ASSEMBLY
2703 M
0
hs
Y
e
„” LE
Uy
ITEM QTY PIN DESCRIPTION
1 1 270376 BRAKE BAND ASSEMBLY
2 1 330184 COMPRESSION SPRING
3 1 330490 SPACER
4 1 018301 NUT HEX 5/8 NC
5 1 330488 COMPRESSION SPRING
6 1 330489 SPACER
7 1 013503 SCREW HEX HD 5/8 NC x 7 GR5
8 1 330303 HANDLE GRIP
9 1 330136 BRAKE HANDLE
3-4.0.0 AWS42 4/98
TWECO ASSEMBLY
2703 SERIES
N
AOU AN
>.
O
E
Ш SIDE PLATES
un
"hu
Rt
[Lil QUILL
S
{LL
77 7 7777
nl
——
N
И
10 8 BASE PLATE
ITEM QTY PIN DESCRIPTION
1 1 320488 POWER CABLE ASSEMBLY
2 1 330212 UPPER TWECO BRACKET
3 1 REF MALE TWECO CONNECTOR
4 1 002900 SCREW HEX 1/4 x 3/8
5 1 000115 CLAMP
6 1 005500 SCREW HEX HD 1/4 NC x 3/4
7 1 015900 NUT HEX 1/4 NC
8 3 020200 WASHER SP LK 1/4
9 2 005401 SCREW HEX HD 1/4-20 x 5/8
10 1 REF FEMALE TWECO CONNECTOR
3.5.0.0 | AWO052 4/98
TURNER ASSEMBLY (ELECTRIC)
2703 SERIES
ELECTRIC MOTOR
330313 (REF)
O O oO YN + © N =
= uk oA od mh mi
O0 à GO №Юю — ©
aa ung
A
m
TI
— ab ak № — N MN) =
PIN
010201
330389
330504
330498
021500
017701
330500
330421
330486
330472
011603
239300
019000
3-6.0.0
DESCRIPTION
SCREW HEX HD 12-13 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 GRS
GREASE ZERK
SPACER
NUT HEX 7/8-14 NF
AWOOS 4/08
TRAVELING BLOCK ASSEMBLY
P/N 320433 - 2703 SERIES
ITEM QTY P/N DESCRIPTION
1 1 100309 SWIVEL HOOK
2 2 360124 HITCH PIN
3 2 320434 BLOCK PIN
4 2 320403 TRAVELING BLOCK
5 1 200909 SHEAVE ASSEMBLY
6 1 013512 SCREW HEX HD 5/8 NC x 3 1/2
7 1 018200 NUT HEX HALF LK 5/8 NC
8 2 320404 BLOCK
9 2 330100 WASHER FLAT
3.7.0.0 AW320433 4/98
HOIST ACTUATOR ASSEMBLY
| .
P/N 320324 - 2703 SERIES
3-8.0.0 AW320324 208
ITEM
© © A OO Ohh WN
W Ww LW WW NN NNN №) №3 ab oad md ak cd LD E oad =
— —
N ©
№ + OD = = фо В — 4»
HOIST ACTUATOR ASSEMBLY
P/N 320324 - 2703 SERIES
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 x1 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
SCREW HEX HD 1/4-20 NC x 3/4 LG NYLOCK
SCREW HEX HD 1/4-20 NC x 3/4 LG
SCREW HEX HD 1/4-20 NC x1 LG
SCREW HEX HD 3/8 x 1 1/2 LG ALL THREAD
SCREW HEX HD 1/4-20 NC x 1 LG
SCREW SOC HD 1/4-20 NC x 3/4 LG LOC-WEL
SETSCREW 1/4-20 NC x 5/16 LG LOC-WEL
NUT HEX JAM 3/8-16 NC
NUT HEX 3/8-24 NF
WASHER SP LK 1/4 MED SECT
WASHER FLAT 1/4 ALUM
3.8.1.0 AW320324 2/98
HOIST ACTUATOR ASSEMBLY
P/N 320324 - 2703 SERIES
P/N
021100
320314
320315
300062
300063
300064
360359
300065
300066
300067
300068
300069
300070
300073
300074
300075
360364
300076
300077
300078
360371
300079
360368
300080
300081
300082
360456
320382
DESCRIPTION
WASHER SP LK 3/8
ELBOW 90° 3/8-18 NPT BOTH ENDS
ELBOW 90° 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 2/98
11
—
A
с
AUTOMATIC SAFETY BRAKE ASSEMBLY
(OIL COOLED) HOIST - 2703 SERIES
14
=
оо чо кое № -
e dd]
©) с о © №Ю —= ©
Сл
= = ман нано м = а = = = = В
PIN
360367
360331
360336
360339
360342
360345
360453
360368
360371
360353
360465
360359
360364
3-9.0.0
DESCRIPTION
FLAT SPRING
CAM PLATE
HOUSING COVER
BRAKE HOUSING
BRAKE HUB
RETAINER PLATE
BRAKE BALL
CAPSCREW 1/4-20 NC x 1 LG GRS
COIL SPRING
CAPSCREW 3/8-16 NC x 1 1/2 LG GR5
THREAD SEAL
NUT HEX JAM 3/8-16 NC
THREAD SEAL
WASHER FLAT 1/4 ALUM
GASKET
THRUST PLATE
AW368 4/98
AUTOMATIC SAFETY BRAKE ASSEMBLY
(OIL COOLED) HOIST - 2703 SERIES
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 4/98
SAFETY DECAL SECTION
PART NO.:
DECAL:
FUNCTION:
QUANTITY:
PLACEMENT:
PART NO.:
DECAL:
FUNCTION:
QUANTITY:
PLACEMENT:
PART NO.:
DECAL:
FUNCTION:
040517
STAY CLEAR OF BOOM
To inform the operator of the hazard
of proximity or contact with the
A DANGER
Mi STAY CLEAR OF BOOM|
Both sides of crown ‘ AT ALL TIMES
| — PA 040517
(see page 4-2.0.0, Item 1)
040518
STAY CLEAR OF
LOAD
To inform the
operator of the
hazard of proximity
or contact with the
crane load during
operation.
2
Both sides of down -
haul weight FIG. SD-2.
(see page 4-2.0.0,
Item 12)
SN À DANGER
STAY CLEAR OF EOAC
AT ALL TIMES
Pil 040518
040519 QUANTITY: 1
SCISSORS POINT PLACEMENT: Both sides of lift cylinder
To inform the operator of (see page 4-2.0.0, Item 15)
possible danger at scissors point
DANGER
SCISSORS POINT
SERIOUS INJURY WILL RESULT
ar KEEP HANDS AND ARMS CLEAR AT ALL TIMES
PIN 040519
E a ae EEE умное de EA KA CE -
FIG. SD-3.
4-1.0.0 2703DEC 4/98
SAFETY DECAL SECTION
PART NO: 040529 QUANTITY: 2
DECAL: ELECTROCUTION HAZARD PLACEMENT: Both sides of lower boom
FUNCTION: To inform the operator of the (see page 4-2.0.0, Item 2)
hazard involved with contacting
electrical power lines with crane
boom,
CE EEE ere A
DEATH OR SERIOUS | INJURY
WILL RESULT FROM BOOM, LINE, OR LOAD. CONTACTING .
"ELECTRIC LINES. DO NOT USE CRANE WITHIN 10 FEET
‘OF ELECTRIC LINES CARRYING UP TO. 50,000 VOLTS,
ONE FOOT ADDITIONAL .CLEARANCE IS REQUIRED FOR
EVERY ADDITIONAL 30,000 VOLYS OR LESS.
FIG. SD-4.
PART NO.: 040579 1. INSPECT VEHICLE AND CRANE INCLUDING
OPERATION. PRIOR TO USE DALY.
DECAL: OPERATION INSTRUCTIONS > DONOT USE THIS EQUIPMENT EXCEPT ON
‚ . SOLID, LEVEL SURFACE WITH OUTRIGGERS
FUNCTION: To inform the operator of the PROPERLY EXTENDED AND CRANE MOUNTED
proper procedure to follow for ON FACTORY—RECOMMENDED TRUCK.
safe operation of the crane. 3. BEFORE OPERATING THE CRANE, REFER TO
, MAXIMUM LOAD (CAPACITY) CHART ON CRANE
QUANTITY: 1 FOR OPERATING (LOAD) LIMITATIONS.
PLACEMENT: Sideplate 4. OPERATE ALL CONTROLS SLOWLY AND
SMOOTHL Y.
(see page 4-2.0.0, Item 5)
5. KEEP LOAD UNDER BOOM TIP. DO NOT SIDE
LOAD BOOM OR DRAG LOADS. AVOID FREE
SWINGING LOADS.
6. DO NOT OPERATE. WALK OR STAND BENEATH
BOOM OR SUSPENDED LOAD.
7. KEEP AT LEAST 5 WRAPS OF LOADLINE ON
HOIST DRUM.
8. FOR TRAVELING. BOOM AND OUTRIGGERS
MUST BE IN THE STOWED POSITION.
9. ALL REMQVABLE PENDANTS MUST BE STORED
iN CAB OR TOOL COMPARTMENT WHEN CRANE
IS NOT IN USE.
Р ч 040579
FIG. SD-5.
4-1.1.0 2703DEC 4/98
PART NO.: 040580
DECAL: OPERATOR TRAINING
FUNCTION: To inform the operator of the
need to receive proper training LL OT
before using the crane. — AN UNTRAINED OPERATOR
SUBJECTS HIMSELF AND
QUANTITY: 1 OTHERS TO
PLACEMENT: Sideplate DEATH OR SERIOUS INJURY |
(see page 4-2.0.0, Item 6) i
1) YOU MUST HAVE BEEN TRAINED IN
THE OPERATION OF THIS CRANE, AND
2) YOU MUST KNOW AND FOLLOW THE
SAFETY AND OPERATING
RECOMMENDATIONS CONTAINED IN
THE MANUFACTURER'S MANUAL,
YOUR EMPLOYER'S WORK RULES
AND APPLICABLE GOVERNMENT
REGULATIONS. |
FIG. SD-7.
4-1.2.0 2703DEC 4/08
DECAL DRAWING
2703 SERIES
a
A
\ |
9 10
|
—/
ITEM Qry
1 2
2 2
3 2
4 1
5 1
6 1
7 1
8 1
9 1
10 2
11 10'
12 2
13 1
14 1
15 2
PIN
040517
040529
270321
330622
040579
040552
040624
040620
040518
330624
270322
040519
4-2.0.0
—
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
AW270395 4/08
GENERAL DIMENSIONS
2703 M 6-10-14
11 3/4
TURNING
RADIUS
FULL 360" ROTATION
| ; | 4 4 1/4"
E]
3 1/7 MIN. INSTALLATION
ROLE REQUIRED
— Y
7 1/16"
i
all
ъ
nie. mall
a
=
—
Non |
№
i
Oo
LP | \ ©
5/8" 14 3/47 Ш N 9/16” DIA. HOLES (USE 1/2" NF. GR 8
MOUNTING BOLTS)
16”
5-1.0.0 | AW054 8/98
GENERAL DIMENSIONS
2703 M 6-10
tt 3/4
TURNING
RADIUS
FULL 360" ROTATION
—-—- —#+-—-—-—-—-—-—-—-— ks ==
10 - m2 7/0
Ё' nl
$
!
Zee № 7 1/8”
@ |
| 10 7/8"
20"
| |
o 1/2" MIN. INST/ AT
7 3 1/2" MIN, INSTALLATION
14 | 18" | HOLE REQUIRED
| 11 1/7 — 1 7
| 7 1/16”
15 3/47
a i
5/8" eb 14 3/4" _ N 9/16" DIA. HOLES (USE 1/2" N.F. GR 8
MOUNTING BOLTS)
5-1.1.0 AVOS5 6/58
GENERAL DIMENSIONS
2703 MR 6-10-14
16 1/2"
TURNING
RADIUS
FULL 360" ROTATION
#2 — — НН E
OF ROTATION
Г 14' 2 7/8”
' 10°
| e i
В Ё 1
ll IN a E > A 7 1/6"
© о |
| 10 7/8"
! 20° |-- 15 1/47 —
| | | 10 а T 11 1/7
| | | с +4 | TT
Le Lae! |
3 1/27 MIN. INSTALLATION
HOLE REQUIRED
7 1/16"
9/16" CA, HOLES (USE 1/2" NF. GR B
MOUNTING BOLTS)
51.2.0 AWOS6 8/98
GENERAL DIMENSIONS
2703 MR 6-10
16 1/27
TURNING
RADIUS
FULL 360° ROTATION
ed
OF ROTATION
| 10' 2 7/8"
| ¢ |
——
| | © > o 7 ° 21 © 7 1/8"
N o ON о
28 3/4" Ч
27° | Г. 15 1/4" — 10 7/8"
аз) | ро © repr
В Lo Do
E 4 CUVE / ZN }
ha La | o 7 1/8"
1 5/6 q 7 oN,
W | ° 3 1/2" MIN. INSTALLATION
14 | ув | } НОЕ REQUIRED ‚
"1/7 ay 15 3/4
| | 7 1/16” =
A +
5/8° = 14 3/4" N 9/16” DIA. HOLES (USE 1/2" NF. GR 8
MOUNTING BGLTS
16" ERONT VIEW
51.3.0 AWOST 8/08
GENERAL DIMENSIONS
2703 PR 6-10-14
FULL 360° ROTATION
ze —-“ — t= ==
#
e
AN ZA N e
ue
28 3/4"
L 15 1/4 10 7/8
3/4”
| e
I LT
| Г. EC
3 1/2" MIN. INSTALLATION
HOLE REGUIRED
167
| | 71
5/8" 14 3/4" —
Sa
71
9/16" DIA. HOLES (USE 1/2" NF. GR 8
MOUNTING BOLTS)
16°
5.1.4.0 AW640 8/28
GENERAL DIMENSIONS
2703 PR 6-10
FULL 360° ROTATION
{
о
‚> $ fe 7 1/8"
DD
|-- 15 1/4" — 2
I
CT 14 1/27 7 ©
T нЕ
| EA
1 8/16” ma
3 Г
o | a -
3 1/2" MIN. INSTALLATION
va | pe | aT HOLE REQUIRED
"1/2" ——+
| 7 1/16"
8 4
IN SE
5/8" ea 14 3/4" 9/16" DIA. HOLES (USE 1/2" NF. GR 8
MOUNTING BOLTS)
5-1.5.0 AW641 6/08
PENDANT ASSEMBLY BAYONET w/ 18' LG CABLE
P/N 270410 - 2703 PR
13 7 8
wm
A
GREEN (UF) (6) uP (HOIST)
8 RIGHT (TURN)
COM HOIST RN
ЗЕ HOT
HOT (WHITE)
-9 +
2 e BLACK © HYD. PUMP
T LEFT (TURN)
19 RED W/TR (7) DOWN (HOIST)
| BLUE (UP) ava (©) UP (BOOM)
WHY, W/TR
759)
VIEW FROM IT
6-1.0.0 AW270410 8/08
PENDANT ASSEMBLY BAYONET w/ 18' LG CABLE
P/N 270410 - 2703 PR
ITEM QTY P/N DESCRIPTION
1 1 631602 PENDANT HOUSING
2 1 631700 BOTTOM COVER
3 2 622000 TOGGLE SWITCH
4 3 640300 BOOT-TOGGLE SWITCH
5 10 001004 SCREW ST SLT PAN HD #6 x 3/4
6 2 005101 SCREW ST SLT PAN HD #8 x 1 1/4
7 1 633801 CABLE ADAPTER
8 18' 800630 CONDUCTOR CABLE
9 2 634401 TY-RAP CABLE TIE
10 1 320563 11 PIN BAYONET PLUG
11 15 000101 TERMINALS T & B
12 - - -
13 3 642100 O-RING
14 4 019700 WASHER SP LK #8 PLATED
15 1.75 800580 3/4 WIDE OKONITE RUBBER TAPE
16 1 004700 SCREW ST SLT PAN HD # x 1 12
17 1 480515 CABLE CLAMP
18 1 634200 TOGGLE SWITCH
19 2 636600 JUMPER BAR
20 0.25 800592 WHITE WIRE 16GA x 3
21 6" 480243 HEAT SHRINK TUBING
AW270410 8/98
6-1.1.0
PENDANT ASSEMBLY
P/N 680068 - 2703 MR
A
= а
3
GREEN "UP" _ —(6) —
+ = ee =r
© 21.9 © 2703 MR
© о
E ANTE o TURN ET
ITEM QTY PIN DESCRIPTION
1 1 370130 PENDANT BOX
2 1 370131 PENDANT COVER
3 1 370132 PENDANT HOUSING GASKET
4 2 622000 TOGGLE SWITCH
5 17 800629 CONDUCTOR CABLE
6 4 001207 RECESSED CROSS PAN HD SCREW #8 x1"
7 2 640302 BOOT
8 7 000101 TERMINAL RING
9 2 370135 PINION GEAR
10 1 320563 11 PIN BAYONET PLUG
11 1 480515 CABLE CLAMP
12 6" 490243 HEAT SHRINK TUBING
6-2.0.0
AWG680068 3/98
HOIST CONTROL PENDANT
P/N 330519 - 2703 М
—
ITEM 1 QIY P/N DESCRIPTION
1 1 675271 HEXNUT
2 1 675281 ~~ WASHER TANG
3 1 675206 HOUSING KIT
4 1 675202 SWITCH w/ SEAL NUT
5 1 675201 HOUSING
6 1 675261 SEAL
7 1 675291 CABLE PENDANT
8 1 330518 FEMALE PLUG
6-3.0.0 AW330519 7/96
©
or
5
=
2 Da
о
=
= 9 10 11
m
& 14 15
7
12 rad
e К
5 re
o
PRESSURE TANK
ITEM QTY P/N
1 1 270324
2 1 330250
3 1 812203-014
4 1 200892
5 2 812206-041
6 1 330412
7 1 200877
8 1 241175
9 1 368985
10 1 241169
11 1 320543
12 1 200876
13 1 330645
14 2 _ 006700
15 2 020200
6-4.0.0
HYDRAULIC ASSEMBLY
2703 PR
DESCRIPTION
HYDRAULIC PUMP
HYDRAULIC CYLINDER
HOSE ASSEMBLY x 14
ELBOW 90° 3/8 NPT /-8 JIC
HOSE ASSEMBLY x 41
HOLDING VALVE
TEE STRAIGHT THREAD RUN
ELBOW 90° -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
AW643 8/98
RELAY ASSEMBLY BAYONET
P/N 680052 - 2703 MR
4 1 POWER CABLE 4 1 19 ?
TWECÓ 9 20
a |
14 15 16
|
HOIST UP
Pu
Mu
@
7
(Sx
CI
\
A
A ¥ 3
Æ 5
7
р |
GRN ms
pd: TT 170 BLACK
= E MOTOR LEAD
3
3 N 8 2
/ -
DS 23
U 12
N — 110 RED
y MOTOR LEAD
A 13
"т —Su ss o ———-—o—_ ——— o; — ===. = = ===
TO TWECO
GRN BLK
F2 = L BLK TO MOTOR
HOIST UP
A2
GRN BLU
e Соб, Е RED TO MOTOR
— = = |
HOIST DN TURN L.
+F A
SCHEMATIC
6-5.0.0 AW6S0052 3/08
REIAY ASSEMBLY BAYONET
P/N 680052 - 2703 MR
ITEM QTY PIN DESCRIPTION
1 4 200182 RELAY
2 4 658300 CONDUCTOR
3 2 658400 CONDUCTOR
4 4 659904 CONDUCTOR
5 2 022323 CONDUCTOR
6 1 622327 CONDUCTOR
7 1 000300 TERMINAL WIRE RB-14-10
8 2 600304 CONDUCTOR
9 1 REF TWECO ASSEMBLY
10 1 330386 CONDUCTOR
11 1 330388 CONDUCTOR
12 1 330387 CONDUCTOR
13 1 680053 CONDUCTOR
14 8 020200 CONDUCTOR
15 8 015900 CONDUCTOR
16 8 005604 CONDUCTOR
17 16 016800 CONDUCTOR
18 16 020700 TERMINAL WIRE RB-14-10
19 8 015600 CONDUCTOR
20 8 020001 TWECO ASSEMBLY
21 1 320564 CONDUCTOR
22 1 330415
CONDUCTOR
6-5.1.0
AW680052 3/88
REIAY ASSEMBLY BAYONET
P/N 270416 - 2703 PR
[OVERLOAD
SWITCH
TO MANFOLO BLOCK
ÓN CYLNDER
“T6 MOTOR
PUMP
#CETO PUMP
SOLENOID
— — dd — — ны кн кн — === === ен dn EE EN O E, ЧЕ
RIGHT
TURN
PELA Y bout
= Omang
TO PUMP subes
SOLENOID (12)
RE
ROTATION ` ит EF =
— TH г АСК ===
6-6.0.0 AW270416 7/98
3
=
3
cosonsens|
NN wh eb — mk ah mk ak ak ak ob
KER Ее ЗЕ ЧЕН Зе сосать со
BOO 00 00 a = om ed ed) = к к к № ©
a
NN
e fh = adh eh wh ak =k № = (2 62 = = a OO
RELAY ASSEMBLY BAYONET
P/N 270416 - 2703 PR
P/N DESCRIPTION
200182 RELAY
658300 RELAY CONDUCTOR
658400 RELAY CONDUCTOR
659904 WHITE CONDUCTOR 16GA x 4
622323 BLACK CONDUCTOR 6GA WELD x 26
622327 BLACK CONDUCTOR 6GA WELD x 28
320355 DROP OUT BOSCH RELAY
600304 BLACK CONDUCTOR 6GA WELD x 4
330258 TWECO ASSEMBLY (REF)
270421 WIRE HARNESS x 3
270434 BLACK CONDUCTOR 4GA WELD x 14
270422 WIRE HARNESS 7 & 7
270417 PENDANT CONDUCTOR ASSEMBLY
020200 LOCK WASHER 1/4
015900 NUT 1/4-20
005604 SCREW HEX HD 1/4-20 x 1
016800 NUT HEX HALF 5/16 NF
020700 LOCK WASHER INTERNAL 5/16
015600 NUT #10-32
020001 LOCK WASHER INTERNAL #10
320564 BAYONET RECEPTACLE CAP (REF)
270423 WIRE HARNESS x 24
270424 WIRE HARNESS x 15
320363 TERMINAL CONNECTOR PLUG
750737 CABLE TIE
320543 LOAD SENSOR SWITCH
366250 CONNECTION WEATHERPACK 2-WAY MALE 18-20
270411 WIRE HARNESS 4 & 15
270425 WIRE HARNESS x 15
270426 WIRE HARNESS 7 & 20
366251 CONNECTION WEATHER PACK 2-WAY FEMALE 18-20
270427 WIRE HARNESS x4
270428 WIRE HARNESS x 4
270326 INSULATOR BOOT BLACK
270435 WIRE HARNESS x 11
66.1.0 AW270416 7/08
PROBLEM
CRANE WILL NOT HOIST UP OR
DOWN.
WITH LOAD SENSOR (OPT.)
CRANE WILL NOT HOIST UP OR
BOOM UP AND DOWN.
CRANE RUNS UP OR DOWN ANY
TIME POWER SOURCE IS
CONNECTED.
TROUBLESHOOTING 2703
CAUSE/SOLUTION
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.
CAUSE;
Crane is overloaded.
Sensor switch is bad.
Bad connection to relays.
SOL :
Hoist down. Do not overload crane. Replace sensor switch. Check for
loose or damaged wiring.
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 4/88
TROUBLESHOOTING 2703
PROBLEM CAUSE/SOLUTION
CRANE WILL NOT BOOM UP OR CAUSE;
DOWN. 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 ED). You shouid 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
ED
F
Al
give you false readings sometimes.
N
ED
E
1 11 B
AJ
e
M
—
IN:
7-1.2.0
2703TRBL 4/98
STABILIZER ASSEMBLY
P/N 360300 - 2703 SERIES
BODY CROSS MEMBER
CURB SIDE
ADDITIONAL 3/4" HOLES MAY BE DRILLED
IN THE LEG ASSEMBLIES FOR PROPER
HEIGHTS. (DEPENDING ON INDIVIDUAL
APPLICATIONS.)
2. WELD ITEM 3 TO FRAME EXTENSIONS
AND CROSS MEMBER EXTENSIONS.
TAZA
LA
— сл
еее 7
STREET SIDE
ITEM QTY PIN DESCRIPTION
` 1 2 360301 LEG ASSEMBLY
2 1 360302 SOCKET / PULL PIN ASSEMBLY
3 1 360303-001 OR SOCKET / PULL PIN ASSEMBLY
4 1 360325 SOCKET / PULL PIN ASSEMBLY
5 2 040581 DANGER CRUSHING DECAL
6 2 759017 CAUTION DECAL
8-1.0.0 AW360300 4/98
STABILIZER ASSEMBLY
P/N 725570 - 2703 SERIES
BODY CROSS MEMBER
CURE DE
NOTES:
1. ADDITIONAL 3/4" HOLES MAY BE DRILLED
IN THE LEG ASSEMBLIES FOR PROPER
HEIGHTS. (DEPENDING ON INDIVIDUAL
APPLICATIONS.)
2. WELD ITEM 3 TO FRAME EXTENSIONS
AND CROSS MEMBER EXTENSIONS.
5
1
STREET SIDE
ITEM QTY P/N DESCRIPTION
1 2 360301 LEG ASSEMBLY
2 1 725588 CURB SIDE SOCKET / PULL PIN ASSEMBLY
3 1 360303-001 OR SOCKET / PULL PIN ASSEMBLY
4 1 725589 STREET SIDE SOCKET / PULL PIN ASSEMBLY
5 2 040581 DANGER CRUSHING DECAL
6 2 759017 CAUTION DECAL
8-2.0.0 AW725570 4/08
STABILIZER ASSEMBLY w/ CRANKDOWN LEGS
P/N 725572 - 2703 SERIES
BODY CROSS MEMBER
THREAD LUBRICATION
ACCESS HOLE
NOTES:
1. WELD ITEM 2 TO FRAME EXTENSIONS
AND CROSS MEMBER EXTENSIONS.
ITEMS 5 & 6 5
STREET & CURB
SIDE <p
ITEM QTY P/N DESCRIPTION
1 1 725592 CURB SIDE LEG ASSEMBLY
2 1 360303-001 OR SOCKET / PULL PIN ASSEMBLY
3 1 725593 STREET SIDE LEG ASSEMBLY
4 2 759017 CAUTION DECAL
5 2 725962 DANGER DECAL
6 2 040581 DANGER CRUSHING DECAL
8-3.0.0 AW725572 4/08
MANUAL OUTRIGGER w/ CRANKDOWN LEG
ASSEMBLY
P/N 725562 - 2703 SERIES
1 THREAD LUBRICATION
/ ACCESS MOLE
11
o 5 1 6
A
1 NN + za A
= . “че ее
5 À EAA —] — 4
e X a1 Bu
—— . -— APROX APPROX.
© © { > - НН LOC.
— 5
2 | | Loc APPROX.
— — — | — LOC.
QTY PIN DESCRIPTION
1 725200 WELDMENT BUMPER
1 725593 STREET SIDE SLIDE w/ CRANKDOWN LEG
1 725592 CURB SIDE SLIDE w/ CRANKDOWN LEG
2 040581 DANGER CRUSHING DECAL
2 040581 CAUTION DECAL
2 040581 DANGER DECAL
оо ком - @
=
8-4.0.0 AW725562 4/98
LOAD CHART
2703 SERIES
22" (6.7M) | |
700LBS (1224KG) | VERTICAL AND HORIZONTAL
DISTANCE IN FEET (METERS)
20" (6.0M) /` |
1180LBS (535KG) |
BOOM PIVOT AT
7 (2.1M) ABOVE GROUND
18” (5.4M) 7 X |
825LBS (374KG)
2700185 (1224KG)
16" (4.8M) >La N
Ш / De
| 7 N
ESOLES (294KG)
1160LES (526KG
14' (4.2M) / ) A
[2700185 | (1224KG) DA
75° XL 2700185 (1224K6) N
12° (3.6M) 60° | / 920LES (417KG) —
Mo
ÍB00LES (B16KG)
45° 60CLBS (272KG)
|
OVER 1600LBS (725KG) _
10" (3.0M) — USE DOUBLE LINE
R25LBS (374KG) |
RATED CAPACITY 15° \M390tES (630KG)
‘[ — 2700 LES (1224kG) |
E (24M) —AT 3 FT (.9M) |
‘ого —_— | |
7 (2.1M) N | | Le)
1350LBS B10LBS 575LBS
(612KG) (367KG) (260KG)
5° 3" (1,5M)- <= 2 (6M) «4 (1.24) 6 (1.8M) 8 (24M) 10 (3.04) 12 (36M) 14 (43M)
¢
2703 SERIES LOAD CHART
9-999 AW270322 8/06
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AUTO CRANE COMPANY
P, O. BOX 581510 a TULSA, OKLAHOMA 74158
i
E
E Y
"A E.
MT
АН
Limited Warranty
Ч
Ll
de
E
a Les
Auto Crane will warranty to consumer for a period of twelve months from date of
purchase thateach new Auto Crane product it sells will be free under normal use and
service, from defects in material and workmanship. Date of purchase will be
honored as either date of purchase by distributor or his date of sale of the product
as substantiated by Distributor Delivery Report.
Fa . a
НЙ i
АНУ;
Fea
LY
1
Obligation of Auto Crane under this warranty is limited to replacement or repair of
parts that appear to manufacturer after review and/ or inspection to be defective.
This warranty does does not obligate Auto Crane to bear the cost of labor or
transportation charges in connection with the replacement or repair of defective
parts. Responsibility for customer's claims arising fram misapplication, abuse,
misuse or alteration of equipment or parts lies with the distributor or user and no
warranty obligation is assumed in the circumstances by Auto Crane.
PET + F de
cr
|]
ря
М Y
Er НЫЙ
т
Л
ok чи EA
EA
Auto Crane will in no event be linble for any consequential damages or contingent
liabilities arising out of the failure of any Auto Crane product or parts to operate
properly,
he
TE NON АН (ЗЫау
ы!
! P a
Auto Crane makes no warranty in respect to component accessories, same being
subject to the warranties of their respective manufacturers,
PTH PTE EL rer a
=
[f field service, at the request of buyer, is rendered and fault is found not to be with
Auto Crane's product, the buyer shall pay the time and expense of the field
representative. Claims for service labor or other expenses that have been incurred
by the buyer without approval or authorization of Auto Crane will not be accepted.
Pel
Lt
Li ht,
que ep Af e
AUTO CRANE COMPANY [S UNDER NO OBLICATION TO EXTEND THIS
WARRANTY TO ANY CUSTOMER FOR WHICH AN AUTO CRANE WAR-
RANTY REGISTRATION CARD HAS NOT BEEN COMPLETED AND MAILED
TO AUTO CRANE COMPANY WITHIN FIFTEEN (15) DAYS AFTER DATE OF
PURCHASE,
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