3200 Series Owner’s Manual As of November 4,2004
3200 SERIES OWNER’S MANUAL SAFETY TABLE OF CONTENTS 1 SAFETY 2-4 OPERATION 5-8 MAINTENANCE 9-10 SPECIFICATIONS 11 TROUBLESHOOTING 12 MOUNTING INSTRUCTIONS 13-15 PARTS 16-26 SCHEMATICS 27-28 WARRANTY 29 FOR THE LOCATION OF YOUR NEAREST DISTRIBUTOR CALL 330-264-7441 Revision 6/04 s 2
SAFETY 3200 SERIES OWNER’S MANUAL - It is YOUR responsibility to maintain and operate this crane safely - The following words and symbols will be used in your owner’s manual: ! DANGER ! Indicates immediate danger and that special precautions are necessary. ! CAUTION ! Warns against potential hazards or cautions against unsafe practices. Your s crane is designed to meet all applicable government safety standards.
3200 SERIES OWNER’S MANUAL SAFETY GENERAL SAFE OPERATING PRACTICES ALWAYS inspect your crane daily, prior to use, for malfunctions, defects, or misuse. ALWAYS keep the vehicle as level as possible while loading or unloading. ALWAYS set the vehicle emergency brake before beginning crane operations. ALWAYS keep the load as close to the ground as possible. ALWAYS store the crane and hook when moving the truck. ALWAYS store the controller securely to avoid unauthorized use of the crane.
SAFETY 3200 SERIES OWNER’S MANUAL DECAL PLACEMENT Note locations of the DANGER, CAUTION, and LIFT CAPACITY decals on s 3200 cranes. Read and understand each of these decals before attempting to operate your crane. If any decals are missing or cannot be read, contact your s distributor for immediate replacement.
3200 SERIES OWNER’S MANUAL OPERATION LOAD CAPACITIES MEASURED IN POUNDS CRANE RATING : 10,000 FT./LB. DISTANCE IN FEET NOTE: Load capacities are based on 85% of tipping when all outriggers are extended and have firm contact with a solid surface. Vehicles must have proper axle load distribution and crane must be mounted in accordance with manufacturer’s instructions.
OPERATION 3200 SERIES OWNER’S MANUAL REMOTE CONTROL The crane remote control plugs into a receptacle. The blue line on the male plug on the remote control must line up with the flat spot on the receptacle at the base of the crane. Push the male plug onto the receptacle while turning the serrated portion of the male plug clockwise. Continue turning until the pin on the receptacle can be seen through the hole in the male plug and a “click” is felt. There are five switches on the remote control.
3200 SERIES OWNER’S MANUAL OPERATION The 3200 crane is designed to provide excellent service if operated within the maximum allowable load specifications stated on the unit’s “Angle Indicator Plate” located on either side of the boom. A load chart is also included on page 5. Load information charts should be studied before operating the crane. Exceeding the stated load limit can cause tipping or structural failure.
OPERATION 3200 SERIES OWNER’S MANUAL TASK PERFORMANCE 1. Position the 3200 crane as close to the job as possible on a firm, dry, and level surface. Avoid overhead obstruction on the work side of the unit. 2. Set the parking brake. 3. Extend and lower the outriggers until firm ground contact is made. On soft ground, use bearing pads to prevent sinking or tipping. 4. Run the winch line out before extending the boom. 5.
MAINTENANCE 3200 SERIES OWNER’S MANUAL Proper maintenance on a regular schedule is essential to keep the unit operating at peak efficiency. LUBRICATION Maintenance and proper lubrication schedule will vary with climate conditions and the amount of usage the unit receives. The lubrication chart below is intended to serve for a normal workload and moderate weather variance. Periods of heavy use shorten service intervals.
MAINTENANCE 3200 SERIES OWNER’S MANUAL PURGING AIR FROM THE SYSTEM Air that is trapped in the cylinder will cause an erratic “bumpy” condition. To expel the air, hold the affected control open after the function has “bottomed out”. Move the function in the opposite direction and again hold the control open. Attempt to operate the crane in a normal manner to determine if the air has been purged. When purging is complete, reevaluate hydraulic fluid level and add fluid if necessary.
2000-R SERIES OWNER’S MANUAL MOUNTING INSTRUCTIONS FEATURES • Crane Rating: 10,000 ft/lb capacity. • Hydraulic extension boom provides reach up to 11’ with manual boom adding an additional 4’. • Electric winch for efficient operation. • Self-lubricating Nylatron™ bearing allows smooth operation of inner and outer booms. • Multifunction, removable remote control provides safe operation up to 25’ away. • Electrical solenoid-operated valves.
SPECIFICATIONS 13 3200 SERIES OWNER’S MANUAL SYMPTOM PROBABLE CAUSE Function fails to respond to controls Pressure switch malfunctioning Low hydraulic fluid Faulty hydraulic pump Short circuit in remote control Crane not grounded to truck Solenoid in control valve malfunctioning Bad ground on control valves Circuit breakers tripped Dead battery Optional anti-two block malfunctioning Slow down of functions speed Relief valve set too low Low hydraulic fluid Clogged filter/strainer Pump not providing e
3200 SERIES OWNER’S MANUAL MOUNTING INSTRUCTIONS ! CAUTION ! Improperly mounted cranes can injure people or damage property. These instructions describe installation of a s crane on a typical s service body. Contact the dealer for other service body/truck chassis combinations. ! CAUTION ! The truck chassis must be capable of safely supporting the entire chassis, body, crane, other equipment and the maximum capacity of the crane - 3200 pounds.
MOUNTING INSTRUSTIONS 3200 SERIES OWNER’S MANUAL 1. Layout the mounting holes on the mounting surface (refer to figure below). Drill four (4) 0.56” diameter holes and flame cut the two inch (2”) diameter hole. 2. Lift the crane into position. Make sure the power lead is fed through the two inch (2”) diameter hole. 3. Bolt the 3200 crane to the mounting surface with four (4) 0.50” grade eight bolts and four (4) grade eight lock nuts. Torque the 0.50” bolts to 100 foot pounds. Use of other than 0.
3200 SERIES OWNER’S MANUAL MOUNTING INSTRUCTIONS ! CAUTION ! -DISCONNECT NEGATIVE BATTERY CABLE BEFORE PROCEEDING5. Run the power lead to the front of the truck. Locate the lead so that it will be protected. Install cable clamps to hold the wire securely in place. 6. Connect the power wire to the positive terminal on the vehicle battery. A 250-amp in-line circuit breaker is required near the battery to protect harness from electrical shorts. 7. Reconnect the negative battery cable.
PARTS 3200 SERIES OWNER’S MANUAL TURRET AND BASE SERVICE PARTS - ILLUSTRATION (PLASTIC SHROUD OPTION) 17 s
PARTS 3200 SERIES OWNER’S MANUAL TURRET AND BASE SERVICE PARTS - PART LIST (PLASTIC SHROUD OPTION) ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 s QUANTITY 16 1 1 1 15 1 8 1 1 1 2 1 2 1 1 1 12 4 7 25’ 4 1 1 4 1 1 3’ 1 25’ 1 4 12 7 1 4 1 1 1 PART NUMBER 964050 95477-001 95483-001 95484-001 964047 95476-001 964049 95468-001-L 95468-001-R 95418-001 917453 95420-001 919874 95618-006 95403-001 961675 961676 961679 961677 961762 963941 963942 95699-014 95457-001 9
PARTS 3200 SERIES OWNER’S MANUAL TURRET AND BASE SERVICE PARTS - ILLUSTRATION (METAL SHROUD-STANDARD) 19 s
PARTS 3200 SERIES OWNER’S MANUAL TURRET AND BASE SERVICE PARTS - PART LIST (METAL SHROUD-STANDARD) ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 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 39 40 s QUANTITY 16 1 1 1 15 1 1 6 1 2 2 1 1 1 20 1 4 1 1 2 2 2 2 8 4 1 1 1 1 1 4 12 7 1 1 1 1 12 4 7 1 4 1 1 1 6’ PART NUMBER 964050 95477-001 95483-001 95484-001 964047 95476-001 95468-004 962111 95499-024 917453 919874 95420-001 95907-195 95453-001 961767 95699-014 95457-001 95472-001 95419-001
PARTS 3200 SERIES OWNER’S MANUAL BOOM ASSEMBLY SERVICE PARTS - ILLUSTRATION 21 s
3200 SERIES OWNER’S MANUAL PARTS BOOM ASSEMBLY SERVICE PARTS - PARTS LIST ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 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 39 40 41 42 43 44 45 46 s QUANTITY 8 1 2 2 6 6 1 1 2 2 2 2 1 1 1 1 2 1 1 1 1 1 3 3 1 2 1 2 1 2 2 1 2 1 6 1 1 1 1 1 2 2 4 1 5 1 PART NUMBER 95456-001 95499-023 95415-001 95417-001 95079-001 95421-001 95431-001 95475-001 95459-001 917494 919003 95480-001 95416-001 95416-002 95435-001 95461-001 95458-001 95499-001 95499-003
PARTS 3200 SERIES OWNER’S MANUAL HYDRAULIC COMPONENT SERVICE PARTS - ILLUSTRATION 23 s
PARTS 3200 SERIES OWNER’S MANUAL HYDRAULIC COMPONENT SERVICE PARTS - PARTS LIST ITEM QUANTITY PART NUMBER DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 1 2 4 1 1 1 1 1 1 2 1 1 2 4 1 7 1 2 1 1 1 1 1 1 8 1 1 95484-001 95420-001 95488-003 95488-005 95498-005 95498-007 95498-008 95498-006 95488-004 95419-001 95488-010 938814 938815 95498-010 95488-001 95408-001 95488-006 95482-001 95498-009 95407-001 95498-001 95498-002 95498-004 95498-003 95488-009 903124 95907
PARTS 3200 SERIES OWNER’S MANUAL HYDRAULIC POWER UNIT SERVICE PARTS - ILLUSTRATIONARTS LIST OLDER SERIES PUMP SERIAL NUMBERS 1990-C4432007 & C4432009-C44320026 NEW STYLE PUMP SERIAL NUMBERS C4432008 & C4432027-PRESENT 25 ITEM QUANTITY PART NUMBER DESCRIPTION 1 2 3 4 5 6 7 1 1 1 1 1 1 1 95907-517 95907-519 95907-518 95907-516 95907-522 95907-521 95907-520 Reservoir -1 gallon Breather cap – reservoir Starter solenoid Motor 12 volt Valve manifold Mounting bracket Pump 8 9 10 11 12 1 1 1 1 1 9590
PARTS 3200 SERIES OWNER’S MANUAL WINCH SERVICE PARTS - ILLUSTRATION MODEL # DC2000-LF SERIAL C4632052 THRU C4632061 SERIAL C4632067 THRU C4932046 MODEL # DC1600 SERIAL C4432001 THRU C4632051 SERIAL C4632062 THRU C4632066 SERIAL C4932047 THRU CURRENT s 26
PARTS 3200 SERIES OWNER’S MANUAL ANTI TWO-BLOCK PARTS ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 27 QUANTITY 1 1 1 3 4 1 1 1 1 2 1 2 1 1 6 1 1 1 1 1 2 PART NUMBER 95467-001 95493-012 927204 95493-006 95493-005 95422-005 95493-015 95424-001 95493-002 919717 95493-003 917144 95493-007 95493-004 962110 960802 919001 95493-013 917092 95493-011 962111 DESCRIPTION Cord reel Bushing bracket—winch Bushing Bracket bushing – main Short bushing Clevis pin Cable Guide Weldment Cotter pin Waterproof
3200 SERIES OWNER’S MANUAL SCHEMATICS HYDRAULIC SCHEMATIC s 28
SCHEMATICS 3200 SERIES OWNER’S MANUAL WIRING DIAGRAM 29 s
ONE – YEAR LIMITED WARRANTY COVERED PRODUCTS: s Crane – One (1) year from the date of purchase by the original owner of record for s parts including the structural integrity of the crane boom assembly, turret assembly, and base plate weldment. Product(s) not made of galvaneal steel are warranted to the original owner of record for 180 days from the date of purchase.
