Auto Crane 3203EH Hard Wired 999947 0200

OWNERS MANUAL
3203 P/PR/PRX
REVISION 2/2000
PART NO. 999947
SERIAL NO. __________________________
AUTO CRANE COMPANY

PO BOX 580697, TULSA, OK 74158-0697
4707 N. MINGO ROAD, TULSA, OK 74117
PHONE (918) 836-0463
FAX (918) 834-5979
http://www.autocrane.com
WARNINGS - READ THIS PAGE!
WARNING! Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of
a vehicle certify that the vehicle complies with all applicable federal regulations. Any
modifications performed on the vehicle prior to the final stage are also considered
intermediate stage manufacturing and must be certified as to compliance. The installer of
this crane and body is considered one of the manufacturers of the vehicle. As such a
manufacturer, the installer is responsible for compliance with all applicable federal and
state regulations, and is required to certify that the vehicle is in compliance.
WARNING! It is the further responsibility of the installer to comply with the OSHA
Truck Crane Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).
WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL

POWER LINES! Death or serious injury will result from boom, line, or load contacting
electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to
50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.
WARNING! NEVER .............................

v EXCEED load chart capacities (centerline of rotation to hoist hook).
v un-reel last 5 wraps of cable from drum!
v wrap cable around load!
v attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
v weld, modify, or use unauthorized components on any Auto Crane unit! This will void any
warranty or liability. Also failure of the crane may result.
v place a chain link on the tip of the hook and try to lift a load!
v use a sling bar or anything larger than the hook throat that could prevent the hook latch from
closing, thus negating the safety feature!
v hold on any pendant Select Switch that will cause unsafe operating conditions!
WARNING! In using a hook with latch, ALWAYS make sure that the hook throat is closed
before lifting a load! Proper attention and common sense applied to the use of the hoist hook and
various slings will prevent possible damage to material being hoisted and may prevent injury to
personnel.
WARNING! Failure to correctly plumb and wire crane can cause inadvertent operation and
damage to crane and/or personnel!
WARNING! Auto Crane Company remote controlled cranes are not designed or intended to
be used for any applications involving the lifting or moving of personnel.
WARNING! ALWAYS operate the crane in compliance with the load capacity chart.
Do not use the overload shutdown device to determine maximum rated loads, if your crane is
equipped with this type of device.
warning 9/98
3203P/PR/PRX SERIES - OWNER'S MANUAL
TABLE OF CONTENTS
PAGE
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1.0.0
2 OPERATING PRACTICES & WARNINGS . . . . . . . . . . . . . . . . . . . . . . . 1-2.0.0
3 OPERATION OF UNIT / OUTRIGGERS ........................ 1-3.0.0
4 QUALIFICATIONS FOR OPERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4.0.0
5 INSPECTION, TESTING, & MAINTENANCE . . . . . . . . . . . . . . . . . . . . 1-5.0.0
6 LIFE OF WIRE LINE / WIRE LINE LUBRICATION . . . . . . . . . . . . . . . 1-6.0.0
7 SAFETY DECAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7.0.0
8 LUBRICATION & MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . 1-8.0.0
9 MOUNTING & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1.0.0
10 GENERAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1.0.0
11 2-BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2.0.0
12 HOIST ACTUATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3.0.0
13 TURNER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4.0.0
14 AUTOMATIC SAFETY BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 3-5.0.0
15 TRAVELING BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6.0.0
16 GENERAL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1.0.0
17 HYDRAULIC SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1.0.0
18 ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1.0.0
19 LOAD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1.0.0
20 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LAST PAGE

INTRODUCTION
3203P/PR/PRX SERIES
Auto Crane products are designed to provide many years It has always been Auto Crane Company policy to handle
of safe, trouble-free, dependable service when properly used all warranty claims we receive as promptly as possible. If a
and maintained. warranty claim involves discrepant material or workmanship,
To assist you in obtaining the best service from your Auto Crane will take immediate corrective action. It is
crane and to avoid untimely crane and/or vehicle failure, this understandable that Auto Crane company cannot assume
manual provides the following operating and service responsibility of liability when it is obvious that our products
instructions. It is specifically recommended that all have been abused, mis-used, overloaded or otherwise
operating and service personnel consider this manual as damaged by inexperienced persons trying to operate the
mandatory material for reading and study before operating or equipment without reading the manual.
servicing Auto Crane products. It is highly recommended Auto Crane will not assume responsibility or
that crane owners, equipment managers and supervisors also liability for any modifications or changes made to
read this manual. unit, or installation of component parts done without
Auto Crane has incorporated several safety features in authorization.
the 3203P/PR/PRX Series cranes for your protection. The Auto Crane maintains a strong distributor network and a
choice of materials and the design of the electrical system knowledgeable Customer Service Department. In most cases,
minimizes weight and lengthens durability. The hydraulic an equipment problem is solved via phone conversation with
components meet or exceed a 3.5:1 safety factor. Holding our customer service department. The customer service
valves prevent the load from dropping if a hose should fail. department also has the ability to bring a local distributor, a
The reservoir has a 40u air filter in the filler cap. The pump regional sales manager, or a factory serviceman into the
has a 100 mesh strainer in the suction line. solution of an equipment problem. If, through no fault of
For your convenience the overall dimensions of the Auto crane company, it is necessary to send an experienced
3203P/PR/PRX Series cranes are on the General Dimension factory serviceman on a field service call, the rates stated in
Drawing. Maximum turning radius is shown at the outside the Auto Crane Distributor's Flat Rate Manual will apply.
edge of the guard (PR/PRX models) and the outside point of Auto Crane Company's extensive Research and
the hoist actuator (P model). Development Program allow our customers to use the best
Remember, the crane adds weight to the vehicle. equipment on the market. Our Engineering Staff and our
Adding weight may change the driving and riding knowledgeable sales people, are always available to our
characteristics of the vehicle unless the appropriate overload customers in solving crane and winch-type application
spring(s) are installed on the truck. The payload of the problems. When in doubt, call the Auto Crane factory.
vehicle is reduced by the weight of the crane. The operator
should exercise care when loading the vehicle. Distributing
DISTRIBUTOR ASSISTANCE:
the payload on the vehicle evenly will greatly improve the Should you require any assistance not given in this
driving and riding characteristics of the vehicle. A minimum manual, we recommend that you consult your nearest Auto
G.V.W. of 8,000 lbs. with two rear jacklegs (or outriggers) Crane Distributor. Our distributors sell authorized parts and
is recommended for mounting the 3203P/PR/PRX crane. have service departments that can solve almost any needed
The 3203P/PR/PRX crane is attached directly to your repair.
12 volt truck electrical system. The performance of your new
crane depends on the truck electrical system. The use of the NOTE: THIS MANUAL SHOULD
low maintenance battery is not recommended for use on any
REMAIN WITH THE CRANE AT ALL
Auto Crane product. The recommended alternator and battery
that will give the longest life with the most useful duty cycle TIMES.
is a 60 amp. alternator with a 120 minute reserve capacity,
deep cycle battery. These specifications should be considered This manual does not cover all maintenance, operating,
minimum. or repair instructions pertinent to all possible situations. If
you require additional information, please contact the Auto
Auto Crane Company issues a limited Crane Company at the following telephone number: (918)
warranty certificate with each unit sold. 836-0463. The information contained in the manual is in
effect at the time of this printing. Auto Crane Company
See last page for warranty policy. reserves the right to update this material without notice or
obligation.
1-1.0.0 3203pintro 1/99

GENERAL SPECIFICATIONS
3203P/PR/PRX
Dimensions Reach
Width: [PR/PRX] 24 in (.61 m) Second boom will reach 7 ft to 11 ft
[P] 23.25 (.59 m) Third boom will reach from 11 ft to 15 ft
Height: [PR/PRX] 27.25 in (.69 m) Cable
[P] 31.13 in (.79 m)
Length: 8 ft 6 in (2.59 m) [boom(s) stored] 62 ft (18.9 m) of 7/32" diameter aircraft quality
Weight: P 7-11 470 lbs (213 kg) cable is standard (75 ft optional). This cable has a
P 7-11-15 530 lbs (240 kg) single line breaking strength of 5,600 lbs (2,540 kg).
PR 7-11 520 lbs (236 kg)
PR 7-11-15 550 lbs (250 kg) Chassis Requirements
PRX 7-11 630 lbs (286 kg) 8,800 lbs (3,992 kg) GVWR minimum
PRX 7-11-15 630 lbs (286 kg)
[Add 5 lbs (2. 5 kg) for cable length Hydraulic System
of 75 feet (23 m)]
Pressure: 2100 psi (1,448 kPa) relief setting
Flow: 0.7 to 9.1 gpm (2.65 to 9.1 lpm)
Capacity [output depends on psi]
10,000 ft lbs (1.4 ton/m) Filtration: Suction line strainer 100 mesh
[ft lbs = horizontal distance from centerline of Reservoir filler cap air filter 40u
rotation to free hanging weight (feet) x amount of Reservoir Capacity: 6 quarts (5.7 l)
weight (pounds)] Oil type: 10w Hydraulic Oil
[Mobile DTE 13, Sun 2015,
Dextron II]
LIFTING CAPACITIES Hoist Motor: 2.2 cid geroter
ft lbs ft lbs Rotation Motor: 11.3 cid geroter
3 3,200 10 1,000
4 2,500 11 900 Electrical System
5 2,000 12 830 Hoist Motor: 12 volt DC series wound
6 1,670 13 770 Pump Motor: 12 volt DC closed-coupled
7 1,500 14 710
8 1,250 15 660
Electrical System Requirements
9 1,100 Alternator: 60 amp (minimum)
Battery: 100 minute reserve capacity
(minimum) Maintenance type
1-1.1.0 3203Pspec 1/99

--- IMPORTANT ---
OPERATING PRACTICES & WARNINGS
1. Make certain the vehicle meets minimum chassis 16. WARNING! NEVER OPERATE THE CRANE
requirements. (These requirements do not guarantee NEAR ELECTRICAL POWER LINES! Death or
unit stability) serious injury will result from boom, line, or load
2. Make certain the crane is installed per factory contacting electric lines. Do not use crane within 10
specifications. Contact your local Distributor or the feet (3.05m) of electric power lines carrying up to
Auto Crane factory if any questions arise. 50,000 volts. One foot additional clearance is
required for every additional 30,000 volts or less.
3. Keep the vehicle in as level a position as possible
while loading or unloading. 17. WARNING! NEVER EXCEED load chart
capacities (centerline of rotation to hoist hook).
4. ALWAYS set the vehicle emergency brake before
beginning crane operations. 18. WARNING! NEVER un-reel last 5 wraps of cable
from drum!
5. ALWAYS use outriggers from vehicle to the ground
during crane operation. Make sure they are firmly 19. WARNING! NEVER wrap cable around load!
positioned on solid footings. 20. WARNING! NEVER attempt to lift or drag a load
6. All load ratings are based on crane capacity, NOT from the side! The boom can fail far below its rated
truck/crane stability. capacity.
7. Keep objects and personnel clear of crane path during 21. WARNING! NEVER weld, modify, or use
operation. unauthorized components on any Auto Crane unit!
This will void any warranty or liability. Also failure
8. Keep hoist cable pulled tight at all times.
of the crane may result.
9. REMEMBER, in lifting a heavy load, the weight can
22. WARNING! NEVER place a chain link on the tip
create enough tipping momentum to overturn the
of the hook and try to lift a load!
vehicle.
23. WARNING! NEVER use a sling bar or anything
10. ALWAYS keep load as close to ground as possible.
larger than the hook throat that could prevent the
11. Oil gears as required. hook latch from closing, thus negating the safety
12. Periodic adjustment of hoist worm brake may be feature!
required (see automatic safety brake drawing in this 24. WARNING! In using a hook with latch, ALWAYS
manual). insure that the hook throat is closed before lifting a
13. Hydraulic hoses need to be inspected frequently for load! Proper attention and common sense applied to
signs of deterioration, and be replaced as required. the use of the hoist hook and various slings will
14. The hoist hook is an important item that an operator prevent possible damage to material being hoisted and
should consider and use properly. It should be may prevent injury to personnel.
checked on a daily basis for distortion or cracks. 25. WARNING! NEVER hold any pendant Select
15. ALWAYS store outriggers before road travel. 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.
1-2.0.0 SAFTIPS 2/98

--- IMPORTANT ---
OPERATION OF UNIT
26. Make sure this manual has been thoroughly read by 33. Always boom up before rotating so the boom will
all crane operating personnel and supervisors. clear the required boom support.
27. A routine inspection of the crane should be mandatory 34. When extending the boom, always maintain clearance
before each operating day. Any defects should be between the boom crown and the traveling block or
corrected immediately. hoist hook.
28. At a job site the vehicle should be positioned so that 35. Always observe safe and practical operation to avoid
the crane can adequately reach the load within the possible accidents. Refer to Safety Tips and
rated capacity (centerline of rotation to hoist hook). Precautions.
29. Keep the vehicle as level as possible during operation. 36. After completing lifting operations, return the boom
30. For electric cranes, engage emergency brake and to stowed position on the boom support. Avoid
leave ignition on with transmission in neutral (or in unneeded pressure on the boom support.
park for automatic transmissions). Activate any crane 37. Store pendant control on proper location (in cab or on
power switches. For Auto Crane units requiring crane).
battery and hydraulic operation, engage emergency 38. Return outriggers to stowed position. Make sure they
brake, place gear selector in neutral, press clutch, are pinned in place or jacklegs are returned to
activate PTO, release clutch and after hydraulic fluid compartment.
is warm, set throttle control to proper engine speed.
39. Check work area for any tools or equipment not
31. Always use outriggers from the truck to the ground. stored.
Be sure these are firm and adequately positioned.
40. Release throttle control, depress clutch and disengage
When rotating, keep load as low to the ground as
PTO. Deactivate any crane power switches.
possible.
41. Report any unusual occurrence during crane operation
32. Remove pendant control from cab or storage area. On
that may indicate required maintenance or repair.
smaller units, plug pendant into receptacle on crane.
On larger units, remove pendant control from guard 42. NEVER use two cranes to support a load too large for
and unwrap cable from boom. Do not operate crane either crane.
until cable is unwound completely. On all cranes, 43. Spray all electrical equipment with special corrosion
detach hook from dead man. Crane is now ready for resistant coating. This eliminates rust or corrosion
operation. due to melting and freezing action of condensation.
OPERATION OF
OUTRIGGERS
For hydraulic outriggers: For manual outriggers:
1. Shift crane/outrigger control valve to "outrigger" 1. Pull lock pins to release jack leg or drop down
position. outrigger and move to outermost lock position.
2. While operating the outrigger control valves 2. Make sure lock pins are reinstalled properly.
(located on the outrigger cylinders) 3. Lower outrigger pad to firm ground and adjust
simultaneously operate the boom-up control foot to take out slack.
switch. This will allow the hydraulic system to
build pressure. 4. Crane is now ready to operate.
3. After outriggers are positioned, return
crane/outrigger selector to "crane" position.
4. Crane is now ready to operate.
1-3.0.0
OPER 2/98
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 operate
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
9 The operator shall not engage in any practice which
examined.
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 specific operation.
unattended unless specific precautions have been
5 Evidence of physical defects or emotional instability instituted and are in place.
which render a hazard to operator or others, which
12 If there is a warning sign on the switch or engine
in the opinion of the examiner could interfere with
starting controls, the operator shall not close the
the operator's performance may be sufficient cause
switch or start the engine until the warning sign has
for disqualification. In such cases, specialized clinical
been removed by the appointed person.
or medical judgment and tests may be required.
13 Before closing the switch or starting the engine, the
6 Evidence that the operator is subject to seizures or
operator shall see that all controls are in the "OFF"
loss of physical control shall be sufficient reason for
or neutral position and all personnel are in the clear.
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 7/98

OPERATING PRACTICES
B. land the suspended load and boom, if practical. F. During lifting care shall be taken that:
1. there is no sudden acceleration or
15 The operator shall be familiar with the equipment deceleration of the moving load.
and its proper care. If adjustments or repairs are
necessary, the operator shall report the same 2. load, boom or other parts of the crane do
promptly to the appointed person, and shall also not contact any obstruction.
notify the next operator. G. Cranes shall not be used for dragging loads
sideways.
16 All controls shall be tested by the operator at the H. This standard recognizes that articulating boom
start of each shift. If any controls do not operate cranes are designed and intended for handling
properly, they shall be adjusted or repaired before materials. They do not meet personnel lift or
operations are begun. elevator requirements. Therefore, no lifting,
lowering, swinging or traveling shall be done while
17 Stabilizers shall be visible to the operator while
a person is on the hook or load. Hook attached
extending or setting unless operator is assisted by a
suspended work platforms (baskets) shall not be
signal person.
used with cranes covered by this standard. Work
OPERATING PRACTICES platforms attached to the boom must be approved by
crane manufacturer.
HANDLING THE LOAD I. The operator should avoid carrying loads over
people.
J. When the crane is so equipped, the stabilizers shall
18 Size of load
be fully extended and set. Blocking under stabilizers
A. No crane shall be loaded beyond the rated load shall meet the requirements as follows:
except for test purposes.
1. strong enough to prevent crushing.
B. The load to be lifted is to be within the rated load of
2. of such thickness, width and length as to
the crane and its existing configuration.
completely support the stabilizer pad.
C. When loads which are not accurately known are to
K. Firm footing under all tires, or individual stabilizer
be lifted, the person responsible for the job shall
pads should be level. Where such a footing is not
ascertain that the weight of the load does not exceed
otherwise supplied, it should be provided by
the crane rated load at the radius at which the load
timbers, cribbing, or other structural members to
is to be lifted.
distribute the load so as to not exceed allowable
bearing capacity or the underlying material.
19 Attaching the load
L. In transit, the boom shall be carried in stowed
A. The load shall be attached to the hook by means of
position.
slings or other devices of sufficient capacity.
M. When rotating the crane, sudden starts and stops
B. Hoist rope shall not be wrapped around the load.
shall be avoided. rotational speed shall be such that
20 Moving the load the load does not swing out beyond the radius at
which it can be controlled.
A. The operator shall determine that:
N. The crane shall not be transported with a load on
B. The crane is level and, where necessary, the the hook unless recommended by the manufacturer.
vehicle/carrier is blocked properly.
O. No person should be permitted to stand or pass
C. The load is well secured and balanced in the sling or under a suspended load.
lifting device before it is lifted more than a few
inches. 21 Stowing procedure. Follow the manufacturer's
D. Means are provided to hold the vehicle stationary procedure and sequence when stowing and
while operating the crane. un-stowing 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 QUAL 7/98

OPERATING PRACTICES
MISCELLANEOUS 25 In transit with no load and boom lowered the
clearance shall be specified in Table 1.
OPERATING NEAR ELECTRICAL POWER
LINES 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 minimum required

or load enters into the danger zone shown above. clearance
EXCEPTIONS normal voltage, kV
(phase to phase) ft (m)
A. The danger zone may be entered after confirmation when operating near high voltage power lines
by an appointed person that the electrical
distribution and transmission lines have been over to 50 10 (3.05)
de-energized and visibly grounded at the point of over 50 to 200 15 (4.6)
work; or over 200 to 350 20 (6.1)
B. The danger zone may be entered if insulating over 350 to 500 25 (7.62)
barriers (not a part of nor an attachment to the over 500 to 750 35 (10.67)
crane) have been erected to prevent physical contact
over 750 to 1000 45 (13.72)
with the lines.
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 over to 0.75 4 (1.22)
(including handling appendages) shall be 10 ft. (3m). over 0.75 to 50 6 (1.83)
For higher voltages, see Table 1. over 50 to 345 10 (3.83)
24 Caution shall be excercised when working near over 345 to 750 16 (4.87)
overhead lines, because they can move horizontally or over 750 to 1000 20 (6.1)
vertically due to wind, moving the danger zone to new
positions.
1-4.2.0 QUAL 7/98

INSPECTION, TESTING AND MAINTENANCE
GENERAL
G. electrical apparatus for malfunctioning, signs of

INSPECTION CLASSIFICATION
excessive deterioration, dirt and moisture accumula-
27 Initial inspection. Prior to initial use, all new, altered, tion
modified or extensively repaired cranes shall be H. hydraulic system for proper oil level and leaks daily
inspected by a designated person to insure compli-
ance with provisions of this standard. I. tires for recommended inflation pressure, cuts and
loose wheel nuts
28 Regular inspection. Inspection procedure for cranes J. connecting pins and locking device for wear and
in regular service is divided into two general classifi- damage
cations based upon the intervals at which inspection
should be performed. The intervals in turn are PERIODIC INSPECTION
dependent upon the nature of the components of the
crane and the degree of their exposure to wear, 30 Deformed, cracked or corroded members in the
deterioration, or malfunction. The two general classi- crane structure and carrier.
fications are herein designated as "frequent" and
"periodic" with respective intervals between inspec- 31 Loose bolts, particularly mounting bolts.
tions as defined below.
A. frequent inspection - daily to monthly intervals 32 Cracked or worn sheaves and drums.
B. periodic inspection - one to twelve intervals, or as
specifically recommended by the manufacturer 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
29 Inspection shall be performed by designated lining.
personnel.
35 Crane hooks inspected for cracks.
A. control mechanisms for maladjustment interfering
with proper operation - daily, when used
36 Travel steering, braking, and locking devices, for
B. control mechanisms for excessive wear of compo- malfunction.
nents and contamination by lubricants or other
foreign matter 37 Excessively worn or damaged tires.
C. safety devices for malfunction
38 Hydraulic and pneumatic hose, fittings, and tubing
D. all hydraulic hoses, particularly those which flex in inspection.
normal operation of crane functions, should be
visually inspected once every working day, when A. evidence of leakage at the surface of the flexible
used hose or its junction with metal and coupling
E. hooks and latches for deformation, chemical B. blistering, or abnormal deformation to the outer
damage, cracks, and wear. Refer to ANSI/ASME covering of the hydraulic or pneumatic hose
B30.10 C. leakage at threaded or clamped joints that cannot be
F. rope reeving for compliance with crane manufac- eliminated by normal tightening or recommended
turer's specifications, if optional winch is used procedures
D. evidence or excessive abrasion or scrubbing on the
outer surface of a hose, rigid tube, or fitting. Means
shall be taken to eliminate the interference of
1-5.0.0 INSP 9/98

GENERAL
elements in contact or otherwise protect the necessary to determine origin of the problem before
components corrective action can be taken.
39 Hydraulic and pneumatic pumps and motors 43 Labels are to be in place and legible.
inspection.
CRANES NOT IN REGULAR USE
A. loose bolts or fasteners
B. leaks at joints between sections 44 A crane which has been idle for a period of over one
month or more, but not less than six months, shall be
C. shaft seal leaks given an inspection conforming with the initial-
D. unusual noises or vibrations regular- frequent inspections.
E. loss of operating speed 45 A crane which has been idle for a period of over six
F. excessive heating of the fluid months shall be given a complete inspection conform-
ing with the initial-regular-frequent inspection
G. loss of pressure requirements.
40 Hydraulic and pneumatic valves inspection. INSPECTION RECORDS

A. cracks in valve housing 46 Dated records for periodic inspection should be made
on critical items such as brakes, crane hooks, rope,
B. improper return of spool to neutral position
hydraulic and pneumatic cylinders, and hydraulic
C. leaks at spools or joints and pneumatic relief pressure valves. Records should
be kept available to an appointed person.
D. sticking spools
E. failure of relief valves to attain or maintain correct OPERATIONAL TESTS
pressure setting
47 Prior to initial use, all new, altered, modified, or
F. relief valve pressure shall be checked as specified by extensively repaired cranes shall be tested for compli-
the manufacturers ance with the operational requirements of this
section, including functions such as the following:
41 Hydraulic and pneumatic cylinders inspection.
A. load lifting and lowering mechanisms
A. drifting caused by fluid leaking across piston
B. boom lifting and lowering mechanisms
B. rod seals leaking
C. boom extension and retraction mechanisms
C. leaks at welding joints
D. swing mechanisms
D. scored, nicked, or dented cylinder rods
E. safety devices
E. damaged case (barrel)
F. operating controls comply with appropriate function
F. loose or deformed rod eyes or connecting joints labels
Operational crane test results shall be made
42 Hydraulic filters. Evidence of rubber particles on the
available to an appointed person.
filter elements may indicate hose, "O" ring, or other
rubber component deterioration. Metal chips or
pieces on the filter may denote failure in pumps,
RATED TEST LOAD
motors, or cylinders. Further checking will be Prior to initial use, altered, modified, or
extensively repaired cranes shall be load
1-5.1.0 INSP 9/98
GENERAL
tested by or under the direction of an A. functional operating mechanism

appointed person. B. safety devices
48 Test loads shall not exceed 110% of the manufac- C. control systems
turer's load ratings.
55 Repairs or replacements shall be provided as needed
49 Written reports shall be maintained showing test for operation.
procedures and confirming the adequacy of repairs.
The following are examples:
MAINTENANCE A. critical parts of functional operating mechanisms
which are cracked, broken, corroded, bent, or exces-
PREVENTIVE MAINTENANCE sively worn
50 Before adjustment and repairs are started on a crane, B. critical parts of the crane structure which are
the following precautions shall be taken as cracked, bent, broken, or excessively corroded
applicable:
C. crane hooks showing cracks, damage, or corrosion
A. crane placed where it will cause the least interfer- shall be taken out of service. Repairs by welding are
ence with other equipment or operations not recommended
B. all controls at the "off" position
56 Instructions shall be provided by the manufacturer
C. starting means rendered inoperative for the removal of air from hydraulic circuits.
D. boom lowered to the ground if possible or otherwise
LUBRICATION
secured against dropping
All moving parts of the crane, for which
E. relieve hydraulic oil pressure from all hydraulic lubrication is specified, should be regularly
circuits before loosening or removing hydraulic lubricated per the manufacturer's
components
recommendations and procedures.
51 Warning or "OUT OF ORDER" signs shall be placed ROPE INSPECTION
on the crane controls.
57 Frequent Inspection
52 After adjustments and repairs have been made, the
crane shall not be returned to service until all guards A. All running ropes in service should be visually
have been reinstalled, trapped air removed from inspected once each working day. A visual inspec-
hydraulic system (if required), safety devices reacti- tion shall consist of observation of all rope which
vated, and maintenance equipment removed. can be in use during the days operations. These
visual observations should be considered with
ADJUSTMENTS AND REPAIRS discovering gross damage such as listed below,
which may be an immediate hazard.
53 Any hazardous conditions disclosed by the inspection 1. distortion of the rope such as kinking,
requirements shall be corrected before operation of
crushing, un-stranding, birdcaging, main
crane is resumed, Adjustments and repairs shall be
strand displacement, or core protrusion.
done only by designated personnel.
Loss of rope diameter in a short length or
54 Adjustments shall be maintained to assure correct
unevenness of outer strands should be
functioning of components, The following are replaced
examples: 2. general corrosion
1-5.2.0 INSP 9/98

GENERAL
3. broken or cut strands; 1. sections in contact with saddles, equalizer

4. number, distribution and type of visible sheaves, or other sheaves where rope travel
broken wires. When such damage is is limited
discovered, the rope shall either be 2. sections of the rope at or near terminal ends
removed from service or given as where corroded or broken wires may
inspection. protrude
B. Care shall be taken when inspecting sections of
ROPE REPLACEMENT
rapid deterioration such as flange points, crossover
points, and repetitive pickup points on drums. 59 No precise rules can be given for determination of the
exact time for replacement of rope, since many
58 Periodic inspection variable factors are involved.
A. The inspection frequency shall be determined by a Continued use in this respect depends upon
qualified person and shall be based on such factors good judgement by a designated person in
as: evaluating remaining strength in a used rope
1. expected rope life as determined by after allowance for deterioration disclosed by
experience on the particular installation or inspection. Continued rope operation depends
similar installations upon this remaining strength.
2. severity of environment
60 Conditions such as the following shall be reason for
3. percentage of capacity lifts questioning continued use of the rope or increasing
4. frequency rates of operation the frequency of inspection:
5. exposure to shock loads A. in running ropes, six randomly distributed broken
wires in one lay or three broken wires in one strand
Inspection need not be at equal calendar
in one lay
intervals and should be more frequent as the
rope approaches the end of it's service life. B. one outer wire broken at the contact point with the
This inspection shall be made at least core of the rope structure and protrudes or loops out
annually. of the rope structure. Additional inspection of this
section is required
B. Periodic inspection shall be performed by a desig-
nated person. This inspection shall cover the entire C. wear of one third of the original diameter of the
length of the rope. Only the surface wires need be outside individual wire
inspected. No attempt should be made to open the
D. kinking, crushing, birdcaging, or any other damage
rope. Any deterioration results in appreciable loss of
resulting in distortion of the rope structure
original strength, such as described below, shall be
noted and determination made as to whether use of E. evidence of any heat damage from any cause
the rope would constitute a hazard: points listed
above reduction of rope diameter below nominal F. reduction from nominal diameter of more than 1/64
diameter due to loss of core support, internal or in. (0.4mm) for diameters up to and including 5/16
external corrosion, or wear of outside wires; in. (8 mm), 1/32 in. (0.8 mm) for diameter 3/8 in.
severely corroded, cracked, bent, worn or improp- (9.5 mm) to and including 1/2 in. (13 mm), 3/64 in.
erly applied connections; (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
C. Care shall be taken when inspecting sections subject diameter 7/8 in. (22 mm) to and including 11/8 in.
to rapid deterioration such as the following: (29 mm), 3/32 in. (2.4 mm) for diameters 11/4 in.
(32 mm) to and including 11/2 in. (38 mm)
1-5.3.0 INSP 9/98

GENERAL
G. In standing ropes, more than two broken wires in

one lay in sections beyond end connections or more 65 Before cutting a rope, seizing shall be placed on each
than one broken wire at an end connection. side of the place where the rope is to be cut to prevent
unlaying of the strands. On pre-formed rope, one
H. Replacement rope shall have a strength rating at seizing on each side of the cut is required. On
least as great as the original rope furnished or non-preformed ropes of 7/8 in. (22 mm) diameter or
recommended by the crane manufacturer. Any smaller, two seizings on each side of the cut are
deviation from the original size, grade, or construc- required, and for non-preformed rope 1 in. (25 mm)
tion shall be specified by a rope manufacturer, or a diameter or larger, three seizings on each side of the
qualified person. cut are required.
61 Rope not in regular use: all rope which has been idle 66 During installation care should be exercised to avoid
for a period of a month or more due to shutdown or dragging of the rope in the dirt or around objects
storage of a crane on which it is installed, shall be which will scrape, nick crush or induce sharp bends
given and inspection in accordance with above infor- in it.
mation before it is placed in service. This inspection
shall be for all types of deterioration and shall be 67 Rope should be maintained in a well-lubricated
performed by a qualified person. condition. It is important that lubricant applied as a
part of a maintenance program shall be compatible
62 Inspection records with the original lubricant and to this end the rope
manufacturer should be consulted. Lubricant applied
A. frequent inspection- no records required shall be the type which does not hinder visual inspec-
B. periodic inspections- in order to establish data as a tion. Those sections of rope which are located over
basis for judging the proper time for replacement, a sheaves or otherwise hidden during inspection and
dated report condition at each periodic inspection maintenance procedures require special attention
should be kept on file. This report shall cover when lubricating rope. The object of rope lubrication
points of deterioration listed above. is to reduce internal friction and to prevent corrosion.
ROPE MAINTENANCE 68 When an operating rope shows greater wear or well

defined localized areas than on the remainder of the
63 Rope should be stored to prevent damage or rope, rope life can be extended in cases where a
deterioration. section at the worn end, and thus shifting the wear to
different areas of the rope.
64 Unreeling or uncoiling of rope shall be done as
recommended by the rope manufacturer and with
care to avoid kinking or inducing twist.
1-5.4.0 INSP 9/98

LIFE OF WIRE LINE
So many variable factors can cause the Auto Crane units, up to 2,400 pound ratings, use
deterioration of wire line cable that it is not 3/16 inch diameter galvanized pre-formed 7 x 19
possible to determine a definite life expectancy. aircraft cable. This cable has a working strength,
Some of these factors are: 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
1. Load being handled.
3.5 to 1 safety factor when the cable is new.
2. Corrosive conditions.
Keeping the above factor of safety in mind and
knowing the kind of loads that will be handled, the
3. Maintenance of the unit.
user can determine by inspection of the cable as to
when it should be replaced.
A. Keep the sheaves turning freely
B. Maintain tension on cable to insure Items to look for while inspecting the cables
proper spooling are:
C. Avoid kinks in cable
D. Avoid abrasive action and contact with 1. Broken strands.
sharp corners
2. Kinks and flattened sections.
3. Corrosion and abrasion.

4. Frequency of use.
WIRE LINE LUBRICATION
Lubrication of the wire line serves two APPLICATION:

important purposes: (1) helps to prevent
corrosion; (2) lubricates the cable strands to Method 1: A light weight motor oil may be used
reduce wear due to flexing and abrasion caused by dipping a brush into the lubricant and applying.
by contact with the sheaves, rollers, and cable on In some cases, a rag or piece of sheepskin is
the drum. dipped in the lubricant and used to swab the
lubricant on to the rope.
PREPARATION:
Method 2: A heavier lubricant such as a grease
Remove rust and foreign matter with a wire brush gun lubricant may be used by applying with hands
and wipe clean. Be sure cable is dry. while wearing leather gloves. (Leather gloves are
preferred to canvas because of greater protection
and less penetration of the grease)
1-6.0.0 WIRELIF 10/98

MAINTENANCE OF BATTERIES
Maintenance of Auto Crane unit batteries differs very Keep Properly Filled with Water
little from the generally prescribed maintenance of any
lead acid battery. All batteries must be kept properly The battery should always be properly filled with water.
charged, properly filled with water, and relatively If the electrolyte level is allowed to fall below the top of
clean. 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
2 The portion of the plate exposed is not usable.
as:
3 That portion of the acid remaining becomes more
1 Regulator settings
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: The battery should be kept clean. Batteries filled with
A. Battery acid and which are not in use self-discharge to a limited
B. Regulator degree because of the nature of the materials within the
C. Starting motor battery. If dirt is allowed to collect on the top of the
D. Alternator or generator battery (and this dirt absorbs moisture) and electrical
E. Ground connections (most important) path can be set up between the various terminals of the
battery and the ground. Once such a path has been
It is of extreme importance to keep the battery as fully established, the self-discharge of the battery is
charged as possible without overcharging, especially accelerated. This also accelerates corrosion of the
when vehicles are left outside for extended periods in battery cables at the terminals.
extremely cold climates. A battery can freeze.
Freezing points for various specific gravities of acid are Periodic Maintenance is Needed
as follows:
A definite program of periodic maintenance of all
Specific Gravity Freezing Temp. batteries should be conducted on a regular basis.
(Corrected to 80ºF) Degrees F. Periodic maintenance includes:
1.280 -90ºF 1 Checking belts for tightness on the charging

1.250 -62ºF equipment
1.200 -16ºF
1.150 5ºF 2 Checking battery electrolyte levels
1.100 19ºF
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 4 Cleaning where corrosion is apparent
will freeze.
When corrosion is cleaned off, the cable terminals and
The main reason for keeping the battery as fully battery terminals should be coated with a light coating
charged as possible without over-charging is to ensure of petroleum jelly before they are replaced. When
that power is available even though the vehicle has been terminals are cleaned, the top of the battery should be
standing for some time. cleaned with a mild solution of soda water.
1-6.1.0. MAINTBAT 9/98

MAINTENANCE OF BATTERIES
Low Maintenance Batteries should be attempted for an extended time. This usually
(Maintenance Free) will recover a badly sulfated battery.
Low maintenance batteries should not be used on Replacing a Battery

Auto Cranes or trucks equipped with Auto Cranes.
The batteries are not designed for "deep" discharge. 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 2 Place the battery on charge according to the
allowed to reach room temperature. It should then be manufacturer's instructions.
recharged until specific gravity readings taken at
one-half hour intervals. If the specific gravity readings It is essential that the second step above be followed to
are fairly uniform, the battery should be checked with a ensure that the battery going on the vehicle is fully
high rate tester. Use the tester in accordance with the charged.
manufacturer's instructions. The high rate tester is the
best method to test a questionable battery. It is also very important that the battery hold-downs be
checked periodically to ensure that the batteries are
If, after charging, it is noted that the specific gravity properly positioned to avoid vibration problems,
reading of one cell is 30 points less than any of the breakage of cables or terminals. Care must be taken to
other cells, it may be assumed that the cell is bad and avoid cracking or breaking containers or covers by
that the battery should be replaced. If all cells are tightening hold-down fixtures excessively. They also
uniform but not up to full charge, a low rate of charge must not be so loose that breakage results from a
hold-down that is too loose.
1-6.2.0. MAINTBAT 9/98

SAFETY DECAL SECTION
PART NO.: 040517

DECAL: STAY CLEAR OF BOOM
FUNCTION: To inform the operator of the hazard
of proximity or contact with the
crane boom during operation.
QUANTITY: 2
PLACEMENT: Both sides of crown
FIG. SD-1.
PART NO.: 040518

DECAL: STAY CLEAR OF
LOAD
FUNCTION: To inform the operator of
the hazard of proximity
or contact with the crane
load during operation.
QUANTITY: 2
PLACEMENT: Both sides of crown plate
FIG. SD-2.
PART NO.: 040519 QUANTITY: 1

DECAL: SCISSORS POINT PLACEMENT: Both sides of lift cylinder
FUNCTION: To inform the operator of
possible danger at scissors point
on crane.
FIG. SD-3.
1-7.0.0 3203pdec 1/99

PART NO.: 040529 QUANTITY: 2

DECAL: ELECTROCUTION HAZARD PLACEMENT: Both sides of end of lower boom
FUNCTION: To inform the operator of the
hazard involved with contacting
electrical power lines with crane
boom.
FIG. SD-4.
PART NO.: 040579

DECAL: OPERATION INSTRUCTIONS
proper procedure to follow for
safe operation of the crane.
QUANTITY: 1
PLACEMENT: Left Sideplate
FIG. SD-5.
1-7.1.0 3203pdec 1/99

PART NO.: 040580

DECAL: OPERATOR TRAINING
need to receive proper training
before using the crane.
QUANTITY: 1
PLACEMENT: Left Sideplate
FIG. SD-7.
PART NO.: 040587
DECAL: LOAD SENSOR
FUNCTION: To inform the operator that the
load sensor is pre-set and that
tampering with the sensor may
cause potentially hazardous
situation.
QUANTITY: 1
PLACEMENT: On the lift cylinder near the load
sensor
FIG. SD-8.
1-7.2.0 3203pdec 1/99

DECAL DRAWING
3203P/PR/PRX
ITEM QTY P/N DESCRIPTION

1 2 040517 DANGER “STAY CLEAR OF BOOM” DECAL
2 2 040529 DANGER “ELECTROCUTION HAZARD” DECAL
3 2 320317 3203 DECAL
4 1 040622 A/C LOGO DECAL
5 1 040579 CAUTION “INSPECT VEHICLE...” DECAL
6 1 040580 DANGER “AN UNTRAINED OPERATOR...” DECAL
7 1 320318 ANGLE INDICATOR DECAL
8 2 040624 3M AUTO CRANE DECAL
9 6.5 FT 040620 3M STRIPING DECAL
10 1 320321 3203 LOAD CHART DECAL
11 1 040552 RELAY DECAL
12 2 040518 DANGER “STAY CLEAR OF LOAD” DECAL
13 1 999948 INSTALLATION CHECKLIST CARD (not shown)
14 1 330622 SERIAL NUMBER DECAL
15 1 040587 WARNING “LOAD SENSOR PRE-SET” DECAL
16 2 040519 DANGER “SCISSORS POINT” DECAL
1-7.3.0 3203Play 2/99

LUBRICATION & MAINTENANCE
SCHEDULE 3203P/PR/PRX
DAY WEEK MONTH 6 MOS YEAR NOTES
SERVICE
PERFORMED
LOAD HOOK X INSPECT HOOK & LATCH FOR DEFORMA-
TION, CRACKS, & CORROSION
CABLE DRUM X MAKE SURE CABLE IS WOUND EVENLY
ON DRUM
HOIST CABLE X CHECK FOR FLATTENING, KINKS, &
BROKEN STRANDS, SEE MANUAL
HYD. HOSES X VISUAL INSPECTION
MOUNTING BOLTS X CHECK-TORQUE TO 85 FT-LBS (DRY) AS
REQUIRED
MOTOR X CHECK TERMINALS FOR TIGHT
CONNECTION CONNECTIONS
SHEAVE X SEALED BEARING, REPLACE IF ROUGH OR

BEARINGS 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
EXTENSION X CHECK AROUND CYLINDER ROD FOR

CYLINDER EXCESS FLUID LEAKAGE
BOOM PIVOT X GREASE WITH MOBILPLEX EP-2 OR

EQUIVALENT @ ZERKS
EXT. CYLINDER X CHECK TIGHTNESS
BOLTS
BATTERY X CHECK FOR CORROSION & TIGHT
CONNECTIONS CONNECTIONS. CLEAN & COAT AS
REQUIRED
ROTATION GEAR X WATER PROOF BEARING GREASE OR DRY
MOLYLUBE IF DUSTY
EXT. CYLINDER X GREASE WITH MOBILPLEX EP-2 OR
BOLTS EQUIVALENT
SAFETY DECALS X INSPECT AND REPLACE AS NEEDED

POWER CABLE X CHECK INSULATION FOR DAMAGE OR
DETERIORATION
ROTATION WORM X GREASE WITH MOBILPLEX EP-2 OR
BEARINGS EQUIVALENT @ ZERKS
HOIST GEARBOX X WORM GEAR-EP GEAR LUBE SAE 80-90,

SPUR GEAR SAE 30 OIL
1-8.0.0 3203PMAIN 6/99

LUBRICATION & MAINTENANCE
SCHEDULE 3203P/PR/PRX
DAY WEEK MONTH 6 MOS YEAR NOTES
SERVICE
PERFORMED
HYDRAULIC FLUID X DRAIN, FLUSH, & REFILL WITH MOBIL
DTE 13, OR EQUIVALENT
ROTATION SEALED BEARING-NO MAINTENANCE REQUIRED

BEARINGS
BOOM SLIDE PADS PADS GREASED WHEN REPLACED
FOR ADDITIONAL 1) OWNER'S MANUAL
INFORMATION 2) OSHA SECTION 1910.180
SEE: 3) ANSI B30.5-1989
CAUTION
v Routine maintenance insures trouble-free operation and protects your investment. All warranties are void if
maintenance is neglected.
NOTES:
{ Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not
covered by Warranty or Product Liability.
{ Once a bolt has been torqued to its rated capacity and then removed; the bolt should be replaced with a
new one.
{ Auto Crane Company recommends that this crane be serviced per “Crane Inspection Log” P/N 999978.
These logs should be filled in at the intervals noted and kept as a permanent record. Additional copies
are available from your local distributor.
1-8.1.0 3203PMAIN 6/99

ASSEMBLY & INSTALLATION INSTRUCTIONS
3203P/PR/PRX
NOTE: For mounting bolt hole pattern - see page 5-1.0.0.
INSTALLATION - BATTERY CABLE
1. Drill 13/16" hole in floor. Install bushing, which is connected to cable, so it fits hole snug.
2. Run cable to positive battery terminal. Connect black cable to negative battery terminal or
suitable chassis ground point. Locate cables so that they will be protected. Avoid sharp
edges. Use the No. 083800 frame clips provided to hold cables securely in place.
3. If the battery is grounded to the engine it may be necessary to add an additional ground
cable from the engine to the chassis frame to obtain maximum power at crane
2-1.0.0 3203PINST 2/99

SUGGESTED BOOM SUPPORT
P/N 725045
Suggested Boom Support

Auto Crane P/N 725045
2-2.0.0 AW725045 3/99

GENERAL ASSEMBLY
P/N 320301 - 3203P 7-11-15
3-1.0.0 AW320301 2/99

GENERAL ASSEMBLY
P/N 320301 - 3203P 7-11-15
3-1.0.1 AW320301 2/99

GENERAL ASSEMBLY
P/N 320301 - 3203P 7-11-15
1 1 320710 PEDESTAL
2 1 320428 SIDE PLATE / HOUSING
3 1 018600 HALF LOCK NUT 3/4 NF
4 1 014304 CAPSCREW 3/4 NF x 6 GR 5
5 1 320320 BOOM CYLINDER
6 1 320432 LOWER WELDMENT BOOM
7 1 320328 LONG POSITION PIN
8 2 480036 NYLATRON BOOM PAD
9 11 020200 SPLIT LOCK WASHER 1/4
10 1 320368 REARING RETAINER
11 1 320449 MANUAL MID BOOM
12 1 370002 PIN ASSEMBLY w/ LANYARD
13 1 REF TRAVELING BLOCK (320433)
14 62 FT 320338 CABLE HOIST
15 1 320423 MANUAL BOOM
16 1 320415 MANUAL BOOM RETAINER
17 1 005501 CAPSCREW 1/4-28 NF x 3/4
18 1 320391 MANUAL MID BOOM RETAINER
19 6 005406 CAPSCREW 1/4-28 NF x 1/2
20 1 320453 ANGLE INDICATOR
21 1 016300 HEX LOCK NUT 1/4 NC
22 3 008400 CAPSCREW 3/8-16 NC x 3/4 GR 8
24 8 330394 CAPSCREW 3/8-16 NC x 1 1/2
25 1 320506 SPACER
26 1 680055 RELAY PANEL ASSEMBLY
27 1 320335 HYDRAULIC PUMP & RESERVOIR
28 2 400500 BOOM PIVOT BEARING
29 2 320411 BOOM PIVOT
30 1 200545 BREATHER CAP
31 1 200547 90º STREET ELBOW 3/8 NPT
32 1 - PUMP BRACKET
33 1 012200 CAPSCREW 5/8-18 NF x 1 3/4 GR 5
35 1 227401 SHEAVE ASSEMBLY (REF BEARING ONLY #200100)
36 1 330185 CAPSCREW 1 NF x 5 1/2 GR 5
37 1 019106 HALF LOCK NUT 1 NF
38 1 320324 ACTUATOR ASSEMBLY
3-1.0.2 AW320301 2/99

GENERAL ASSEMBLY
P/N 320301 - 3203P 7-11-15
39 4 007807 CAPSCREW 5/16-18 NC x 3/4
41 3 330372 HEX NUT 3/8 NC
42 1 320379 DRUM
43 2 320330 SEALED BALL BEARING
44 45 REF SQUARE KEY 1/4 x 2 3/4 (340523)
45 4 002620 SELF TAPPING CAPSCREW 5/16 NC x 7/8
46 1 320442 CABLE RETAINER GUARD
47 1 320448 BACK UP RETAINER
48 1 320515 UPPER TWECO BRACKET
49 1 REF MALE TRECO CONNECTOR
50 4 011510 CAPSCREW 1/2-13 NC x 1 1/4
52 1 320372 UPPER TWECO CLAMP
53 1 320488 POWER CABLE ASSEMBLY
54 2 005401 CAPSCREW 1/4-20 NC x 5/8
55 1 320343 FLOW REGULATOR
56 1 301103 VELOCITY FUSE
57 1 330584 BREATHER FILTER
58 1 320465 HOSE ASSEMBLY
59 1 REF PENDANT
60 1 REF SEAL KIT
61 1 320508 SPACER
62 1 320332 RETAINING RING BEARING
63 1 320509 COMPRESSION SPRING
64 1 320370 90º ELBOW -6 ORB/3/8 MALE NPT
65 1 320342 90º ELBOW -6 ORB/-6 JIC
66 1 320344 TEE -6 ORB/ -6 ORP FEM-RUN/ -6 ORM (M)
67 1 320340 ADAPTER -6 ORB/3/8 NPT (FEM)
68 1 320560 LOAD SENSOR
69 1 083803 HOSE CLAMP -6
70 1 320464 ACTUATOR BRACKET
71 2 330468 SPLIT LOCK COLLAR
72 1 340602 SQUARE KEY 3/4 x 1 1/2
73 1 320459 BRAKE DRUM
74 1 320502 BRAKE BAND ASSEMBLY
75 1 330636 MALE NIPPLE 3/8 NPT
76 2 800084 SPACER BAR x 15 IN LONG
3-1.0.3 AW320301 2/99

GENERAL ASSEMBLY
P/N 320301 - 3203P 7-11-15
77 2 012197 CAPSCREW 1/2 NC x 1 1/2
78 6 017701 HEX NUT 1/2 NC
79 1 018302 HEX NUT 5/8 NF
80 1 013502 CAPSCREW 5/8 NF
81 1 320507 BRAKE WRENCH
82 1 320495 BRAKE GUIDE PLATE
83 1 320333 SNAP RING
84 1 750282 GROMMET
85 1 000115 CLIP
86 3 320371 THREAD CUTTING SCREW #10-24 NC x 3/4
87 1 320369 COVER PLATE
88 2 239000 GREASE ZERK
89 6 015900 NUT 1/4-20 NC
3-1.0.4 AW320301 2/99

GENERAL ASSEMBLY
P/N 320303 - 3203PR 7-11-15
3-1.1.0 AW320303 2/99

GENERAL ASSEMBLY
P/N 320303 - 3203PR 7-11-15
3-1.1.1 AW320303 2/99

GENERAL ASSEMBLY
P/N 320303 - 3203PR 7-11-15
1 1 320710 PEDESTAL
4 1 320333 SNAP RING
5 1 320432 LOWER WELDMENT BOOM
6 1 320449 MANUAL MID BOOM
8 1 320325 HYDRAULIC LIFT CYLINDER
9 1 019106 HALF LOCK NUT 1
10 1 330185 CAPSCREW 1 x 5 1/2 NC
11 1 014304 CAPSCREW 3/4 x 6 NC
12 1 018600 HALF LOCK HEX NUT 3/4
13 1 480027 HYDRAULIC ROTATION MOTOR
14 1 REF PUMP BRACKET
15 3 008400 CAPSCREW 3/8 x 3/4 NC GR 8
16 11 021100 SPLIT LOCK WASHER 3/8 ZP
17 1 680054 RELAY PANEL ASSEMBLY
18 1 320395 LEFT RELAY PANEL BRACKET
19 1 320396 RIGHT RELAY PANEL BRACKET
20 1 320431 COVER
21 4 002605 SELF TAPPING CAPSCREW #12 x 1/2
23 4 007807 CAPSCREW 5/16-18 NC x 3/4 NC
26 8 330394 CAPSCREW 3/8-16 x 1 1/2
29 1 012200 CAPSCREW 5/8 x 1 3/4 NF
31 62 FT 320338 HOIST CABLE
32 1 320379 DRUM
33 1 REF TRAVELING BLOCK (320433) furnished in SHIP KIT #680061)
34 1 REF PENDANT CONTROL (680064)
36 1 320328 POSITION PIN
37 1 320444 DECAL KIT
38 2 330072 HEX HEAD PLUG -10 ORB
3-1.1.2 AW320303 2/99

GENERAL ASSEMBLY
P/N 320303 - 3203PR 7-11-15
39 2 480036 PAD
41 1 000115 CLIP
43 1 REF SQUARE KEY 1/4 x 2 3/4 (340523)
44 2 005810 CAPSCREW 1/4-20 NC x 1 3/4
45 1 REF BREATHER CAP (200545) included with item 7
46 1 REF 90º STRAIGHT ELBOW 3/8 NPT (200547)
47 1 320391 BOOM RETAINER
48 6 005406 CAPSCREW 1/4-28 x 1/2
49 1 005501 CAPSCREW 1/4-28 x 3/4
51 4 005604 CAPSCREW 1/4 x 1 NC
52 2 010201 CAPSCREW 1/2 x 1 1/2 NC
53 2 239000 ZERK
54 1 320334 WORM GEAR
55 1 340602 GEAR KEY
56 1 016300 HEX LOCK NUT 1/4 NC
57 2 300204 DIRECTIONAL VALVE ASSEMBLY
58 1 330306 MANIFOLD SERIES
59 1 320392 TOP VALVE BANK BRACKET
60 1 320393 BOTTOM VALVE BANK BRACKET
61 8 002614 CAPSCREW 5/16 NC x 5/8
63 2 011603 CAPSCREW 1/2 NC x 1 3/4
65 6 017701 HEX NUT 1/2 NC
66 3 330372 HEX NUT 3/8 NC
67 1 320423 MANUAL BOOM
69 1 320368 BEARING RETAINER
70 1 330472 HOUSING w/ CUPS
71 2 330485 CONE BEARING
72 1 330483 SPACER
73 1 239300 GREASE ZERK #1610-8
74 1 019000 NUT 7/8-14
75 2 330486 OIL SEAL
76 1 330420 TURNER SHAFT
3-1.1.3 AW320303 2/99

GENERAL ASSEMBLY
P/N 320303 - 3203PR 7-11-15
78 1 320448 CABLE RETAINER BACKUP
79 1 330258 MALE TWECO CONNECTOR
80 2 011510 CAPSCREW 1/2 x 1 1/4 NC
81 3 320371 THREAD CUTTING SCREW #10-24 NC x 3/4 NC
82 2 005401 CAPSCREW 1/4-20 x 5/8 NC
84 1 320469 BOOM CYLINDER HYDRAULIC TUBE ASSEMBLY
85 1 330484 SPACER
86 1 320407 HYDRAULIC TUBE ASSEMBLY
87 1 320408-001 HYDRAULIC TUBE ASSEMBLY
93 1 330058 REDUCER 7/8-14/-6 ORP
95 1 330412 COUNTER BALANCE VALVE
96 1 330274 REDUCER -10 ORB/-8 ORP
97 1 241168 TEE -6 ORB (M) RUN/-6 JIC (FEM) RUN/-6 JIC (M)
98 1 241175 90º ELBOW -6 ORB/-6 JIC
99 2 241170 BULKHEAD FITTING
100 8 015900 NUT 1/4-20 NC
101 2 005500 SCREW 1/4-20 x 3/4 NC
102 1 320332 BEARING RETAINING RING
103 3 200876 ADAPTER -6 ORB/-6 JIC
104 1 320350 45º ELBOW (1/2 NPTM/-6 JIC
105 1 202759 90º ELBOW (1/2 NPTM/-6 JIC)
106 3 330272 90º ELBOW -8 ORB/-6 JIC
107 2 202756 ADAPTER
108 2 480194 90º ELBOW -6 SWIVEL/-6 JIC
3-1.1.4 AW320303 2/99

GENERAL ASSEMBLY
P/N 320304 - 3203PRX 7-11-15
3-1.2.0 AW320304 2/2000

GENERAL ASSEMBLY
P/N 320304 - 3203PRX 7-11-15
3-1.2.1 AW320304 2/2000

GENERAL ASSEMBLY
P/N 320304 - 3203PRX 7-11-15
1 1 320710 PEDESTAL
4 1 320333 SNAP RING
5 2 330412 COUNTERBALANCE VALVE
7 1 014304 CAPSCREW 3/4 x 6 NC
8 1 320325 HYDRAULIC LIFT CYLINDER
9 1 320420 LOWER BOOM
10 1 320368 BEARING RETAINER
12 2 000115 CLIP
15 1 REF TRAVELING BLOCK
16 62 FT 320338 HOIST CABLE
17 1 320423-001 MANUAL BOOM w/ CROWN
18 1 320415 MANUAL BOOM RETAINER
19 3 005501 CAPSCREW 1/4-28 NF x 3/4
20 1 320421 MID BOOM
21 2 015017 CAPSCREW 1-8 NC x 1 1/8
22 2 022502 FLAT WASHER 1
23 1 320391 MID BOOM RETAINER
24 4 005406 CAPSCREW 1/4-28 NF x 1/2
25 1 202711 EXTENSION CYLINDER
26 2 005401 CAPSCREW 1/4-20 x 5/8
29 1+2 016300 HEX LOCK NUT 1/4-20 NC
30 3 008400 CAPSCREW 3/8-16 NC x 3/4 GR 8
32 8 330394 CAPSCREW 3/8-16 x 1 1/2
33 4 002605 SELF TAPPING CAPSCREW #12 x 1/2
34 2 011603 CAPSCREW 1/2-13 x 1 3/4
36 6 017701 HEX NUT 1/2-13 NC
37 1 320457-200 RELAY PANEL ASSEMBLY
38 1 320392 TOP VALVE BANK
3-1.2.2 AW320304 2/2000

GENERAL ASSEMBLY
P/N 320304 - 3203PRX 7-11-15
39 4 005604 CAPSCREW 1/4-20 NC x 1
40 - - -
41 1 320431 COVER
42 3 300204 DIRECTIONAL VALVE ASSEMBLY
43 1 202710 MANIFOLD-SERIES
44 1 320393 BOTTOM MANIFOLD BRACKET
45 8 002614 SELF TAPPING CAPSCREW 5/16 NC x 5/8
46 1 480027 HYDRAULIC ROTATION MOTOR
48 1 320396 RIGHT RELAY PANEL BRACKET
51 1 REF BREATHER CAP 200545 (furnished with item 47)
52 1 REF STRAIGHT 90º ELBOW 3/8 NPT 200547 (furnished with item 47)
53 1 REF PUMP BRACKET
54 1 330057 CAPSCREW 1-8 NC x 4
55 1 019105 HEX NUT 1-8 NC
56 1 012701 CAPSCREW 5/8-18 NF x 3
57 1 018100 HALF LOCK NUT 5/8-18 NF
58 1 227401 SHEAVE ASSEMBLY (ref bearing only #200100)
59 2 002905 SET SCREW
60 1 330185 CAPSCREW 1 NF x 5 1/2
63 4 007807 CAPSCREW 5/16-18 NC x 1 3/4
65 1 320395 LEFT RELAY PANEL BRACKET
67 1 320379 DRUM
68 1 340602 SQUARE KEY 3/4
69 1 340523 SQUARE KEY 1/4
70 1 330484 SPACER
71 1 330420 WORM SHAFT
72 2 330486 OIL SEAL
73 2 330485 CONE BEARING
74 1 3302472 HOUSING w/ CUPS
75 1 019000 HEX NUT 7/8-14 NF
3-1.2.3 AW320304 2/2000

GENERAL ASSEMBLY
P/N 320304 - 3203PRX 7-11-15
77 1 330483 SPACER
78 1 320334 WORM GEAR
80 1 320448 BACK-UP RETAINER
83 2 011510 CAPSCREW 1/2-13 NC x 1 1/4
85 1 330258 MALE TWECO CONNECTOR
86 4 005810 CAPSCREW 1/4-20 NC x 1 3/4
96 - - -
98 1 320466 HYDRAULIC HOSE ASSEMBLY (EXT. OUT)
99 1 320332 BEARING RETAINING RING
100 1 320445 DECAL DRAWING
101 4 200876 HYDRAULIC FITTING-ADAPTER
102 1 REF PENDANT (680067)
103 1 320473 HYDRAULIC HOSE ASSEMBLY (EXT. OUT
104 4 241170 BULKHEAD UNION
105 - - -
106 2 241168 SPECIAL TEE -6 ORB/-6 JIC-MALE
107 - - -
108 - - -
109 1 320350 45º ELBOW -1/2 NPTM/-6 JIC
110 1 202759 90º ELBOW -1/2 NPTM/-6 JIC
111 3 330272 90º ELBOW -8 NPTM/-6 JIC
113 2 241175 90º ELBOW -6 ORB/-6 JIC
3-1.2.4 AW320304 2/2000

GENERAL ASSEMBLY
P/N 320304 - 3203PRX 7-11-15
114 1 330274 REDUCER -10 ORB/-8 ORP
115 4 202756 ADAPTER 3/4 ORB/ 9/16 37º JIC
116 1 330058 REDUCER -10 ORB/-6 ORP
118 2 010201 CAPSCREW 1/2 NC x 1 1/2
120 3 320372 HEX NUT 3/8 NC
121 1 320480 SOLENOID VALVE ASSEMBLY WIRING DIAGRAM
122 3 320371 THREAD CUTTING SCREW #10-24 x 3/4
123 1 680058 SHIP KIT
124 1 320483 HYDRAULIC TUBING BRACKET
125 2 239000 DRIVE ZERK
126 10 015900 NUT 1/4-20
127 4 005500 SCREW 1/4-20 x 3/4
128 1 320556 BAIL / SWITCH ASSEMBLY
129 1 009104 CAPSCREW 3/8 NF x 2 1/2
130 3 021200 FLAT SAE WASHER 3/8
131 1 017400 HEX LOCK NUT 3/8 NF
132 1 340295 ROUND TUBING 1 1/16 x .188W x 1 3/16
133 1 320521 CABLE REEL
134 - - -
135 1 000302 WIRE TERMINAL (BUTT SPLICE) 2RB14
136 2 000101 HYDRAULIC HOSE ASSEMBLY (EXT. OUT)
137 1 320554 RETURN SPRING
138 2 016300 HEX LOCK NUT 1/4 NC
139 1 330038 #10 SELF DRILLING & THREADING HEX HEAD SLOT 3/4
3-1.2.5 AW320304 2/2000

GENERAL ASSEMBLY
P/N 320300/302 - 3203P/PR 7-11

1 1 320422 MANUAL BOOM w/ CROWN
3 2 480036 NYLATRON PAD
5 1 320328 POSITION PIN
7 1 012200 CAPSCREW 5/8 x 1 3/4 NF
8 1 018100 HEX NUT 1/4 x 3/4 NF
9 6 005406 CAPSCREW 1/4 x 1/2 NF
12 1 016300 HEX NUT 1/4 NC
14 1 330185 CAPSCREW 1 x 5 1/2 NC
3-1.3.0 320300302 2/99

GENERAL ASSEMBLY
P/N 320308 - 3203PRX 7-11

1 1 320517 BOOM
2 1 019105 HEX NUT 1-8 NC
3 1 330057 CAPSCREW 1 x 4 NC
5 2 015017 CAPSCREW 1 x 1 1/8
6 2 022502 FLAT WASHER 1
9 4 005406 CAPSCREW 1/4 x 1/2 NF
10 1 202711 EXTENSION CYLINDER
3-1.4.0 AW320308 2/99

2-BLOCK ASSEMBLY
3203PRX & 3203H SERIES
AW220 2/2000
3-2.0.0
2-BLOCK ASSEMBLY
3203PRX & 3203H SERIES
1 1 320546 BAIL WELDMENT
2 1 646900 LOAD SENSOR SWITCH
3 1 320550 SWITCH COVER
4 1 642918 STRAIGHT CORD CONNECTOR
5 1 320554 RETURN SPRING
6 1 005604 HEX HD SCREW 1/4-20NC x 1
7 1 016300 HEX LOCK NUT 1/4-20NC
8 2 000101 WR-14-16 TERMINAL
9 2 002602 RD HD SCREW #6-32NC x 1 1/4
10 2 019600 LOCK WASHER #6
11 1 009104 HEX HD SCREW 3/8-24NF x 2 1/2
12 1 021200 FLAT WASHER SAE 3/8
13 1 017400 HEX LOCK NUT 3/8-24NF
AW220 2/2000
3-2.1.0
2-BLOCK REEL INSTALLATION
3203PRX

1 1 320521 CABLE REEL
2 1 320551 REEL MOUNT BRACKET
3 3 000115 #15 JIFFY CLIP
4 5 320570 D-RING
5 2 000302 BUTT SPLICE WIRE TERMINAL
6 1 000300 WIRE TERMINAL
7 3 FT 800626 16GA 2 CONDUCTOR CABLE 300V TYPE SJO BLACK
AW221P 2/2000
3-2.2.0
HOIST ACTUATOR ASSEMBLY
P/N 320324
3-3.0.0 AW320324 2/99

P/N 320324
1 1 360637 FLAT SPRING
2 1 360331 CAM PLATE
3 1 300041 GEAR HOUSING COVER
4 1 300042 SPUR GEAR HOUSING COVER
5 1 360450 BRAKE COVER
6 1 300043 IDLER GEAR
7 2 300044 SPUR GEAR
8 1 300045 WORM R.H. GEAR
9 1 300046 PINION GEAR
10 1 360336 BRAKE HOUSING
11 1 300047 SPUR GEAR HOUSING
12 1 300048 GEAR HOUSING
13 1 360339 BRAKE HUB
14 1 300049 KEY 3/16 SQ x 1/2 LG
15 - - -
16 1 300050 KEY 3/16 SQ x 1 9/16 LG
17 1 341561 KEY 1/4 SQ x 2 3/4 LG
18 2 300052 KEY RD 5/16 x 5/16 x 15/16 LG
19 1 360342 RETAINER PLATE
20 1 300053 SPUR GEAR SHAFT
21 1 320323 OUTPUT SHAFT
22 1 320312 RIGHT HAND WORM GEAR
23 2 360345 BALL
24 3 300056 NEEDLE BEARING
25 2 300057 BALL BEARING
26 1 300058 BUSHING
27 1 300059 BUSHING
28 10 320313 CAPSCREW 1/4-20 NC x 3/4 LG NYLOCK
29 12 005500 CAPSCREW 1/4-20 NC x 3/4 LG
30 4 005604 CAPSCREW 1/4-20 NC x 1 LG
31 1 320311 CAPSCREW 3/8 x 1 1/2 LG ALL THREAD
32 4 320310 CAPSCREW 1/4-20 NC x 1 LG
33 4 300060 SOCKET HEAD SCREW 1/4-20 NC x 3/4 LG LOC-WEL
34 1 300061 SETSCREW 1/4-20 NC x 5/16 LG LOC-WEL
35 1 360353 HEX JAM NUT 3/8-16 NC
36 3 071012 HEX NUT 3/8-24 NF
37 4 360354 SPLIT LOCK WASHER 1/4 MED SECT
38 2 360455 FLAT WASHER 1/4 ALUM
3-3.1.0 AW320324 2/99

P/N 320324
40 1 320314 90º ELBOW 3/8-18 NPT BOTH ENDS
41 1 320315 90º ELBOW 1/4-18 NPT BOTH ENDS
42 2 300062 GASKET BEARING
43 1 300063 SPUR GEAR HOUSING GASKET
44 1 300064 GEAR HOUSING COVER GASKET
45 1 360359 BRAKE COVER GASKET
46 1 300065 WOODRUFF KEY
47 2 300066 RELIEF FITTING
48 1 300067 12V MOTOR
49 1 300068 O-RING 1 OD x 1/8 THICK
50 1 300069 REDUCER -6 NPT / -2 NPT
51 2 300070 PLUG PIPE -4 NPT SQ HD
52 1 300073 PLUG PIPE -6 NPT HEX SOC HEADLESS
53 1 300074 REDUCER -4 NPT / -2 NPT
54 2 300075 DOWEL PIN
55 2 360364 THRUST PLATE
56 1 300076 OIL SEAL 3/4 ID x 1 1/4 OD x 1/4 THICK
57 1 300077 OIL SEAL 1 1/4 ID x 1 3/4 OD x 1/4 THICK
58 1 300078 OIL SEAL 1 1/2 ID x 2 1/4 OD x 5/16 THICK
59 1 360371 THREAD SEAL
60 1 300079 SNAP RING
61 1 360368 SPRING
62 3 300080 THRUST WASHER
63 1 300081 THRUST WASHER
64 1 300082 FIBER WASHER
65 2 360456 SCREW 1/4-20 NC x 1 LG ALL THREAD
66 2 320382 PIPE PLUG
3-3.2.0 AW320324 2/99

TURNER ASSEMBLY (HYDRAULIC)
3203P/PR/PRX

1 4 017701 HEX NUT 1/2-13NC
2 4 021500 LOCK WASHER 1/2
3 1 330484 SPACER
4 2 011603 CAPSCREW 1/2-13NC x 1 3/4
5 1 330420 SHAFT ASSEMBLY
6 2 330486 OIL SEAL
7 2 330485 BEARING
8 1 330472 HOUSING
9 2 010201 CAPSCREW 1/2-13NC x 1 1/2
11 1 330483 SPACER
12 1 019000 HEX LOCK NUT 7/8-14NF
3-4.0.0 AW005 2/99

TRAVELING BLOCK ASSEMBLY
P/N 320433

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 w/ BEARING
6 1 013512 HEX HD SCREW 5/8 NC x 3 1/2
7 1 018200 HEX HALF LOCK NUT 5/8 NC
8 2 320404 BLOCK
9 2 330100 FLAT WASHER
NOTE: STANDARD 62’ CABLE ASSEMBLY MAY BE ORDERED USING P/N 320338.
OPTIONAL 75’ CABLE ASSEMBLY MAY BE ORDERED USING P/N 320339.
3-5.0.0 AW320433 9/98

AUTOMATIC SAFETY BRAKE ASSEMBLY
(OIL COOLED) HOIST

1 1 360367 FLAT SPRING
2 1 360331 CAM PLATE
3 1 360450 HOUSING COVER
4 1 360336 BRAKE HOUSING
5 1 360339 BRAKE HUB
6 1 360342 RETAINER PLATE
7 2 360345 BRAKE BALL
8 6 360453 CAPSCREW 1/4 NC x 1
9 1 360368 COIL SPRING
10 1 360456 CAPSCREW 3/8 NC x 1 1/2
12 1 360353 JAM NUT 3/8 NC
14 2 360455 WASHER FLAT 1/4 ALUM
15 1 360359 GASKET
16 1 360364 THRUST PLATE
AW368 1/99
3-6.0.0
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).
AW368 1/99
3-6.1.0
TWECO
ASSEMBLY

3 1 330258 TWECO POWER CONNECTOR
5 2 011510 CAPSCREW 1/2 NC x 1 1/4
6 2 017701 HEX NUT 1/2 NC
8 1 000115 CLIP
9 3 320371 SELF-TAP SCREW 1/4 NC x 5/8
10 2 005401 CAPSCREW 1/4 NC x 5/8
3-7.0.0 AW040 2/99

GENERAL DIMENSIONS
3203P
5-1.0.0 3203Pdim 2/99

GENERAL DIMENSIONS
3203PR
5-2.0.0 3203PRdim 2/99

GENERAL DIMENSIONS
3203PRX
5-3.0.0 3203PRXdim 2/99

HYDRAULIC ASSEMBLY
3203PRX
6-1.0.0 AW038 2/99

HYDRAULIC ASSEMBLY
3203PRX
1 1 202710 MANIFOLD (REF)
2 1 202711 EXTENSION CYLINDER (REF)
3 1 320325 BOOM CYLINDER (REF)
4 1 320336 HYDRAULIC PUMP & RESERVOIR (REF)
5 1 480027 HYDRAULIC ROTATION MOTOR (REF)
7 4 200876 ADAPTER -6 ORB/-6 JIC
8 - - -
9 - - -
10 - - -
11 2 241175 90º ELBOW -6 ORB/-6 JIC
12 1 330058 REDUCER -10 ORB/-6 ORP
13 3 330272 90º ELBOW -8 ORB/-6 JIC
14 1 330274 REDUCER -10 ORB/-8 ORP
18 1 320350 45º ELBOW -8 NPTM/-6 JIC
19 1 202759 90º ELBOW -8 NPTM/-6 JIC
23 4 202756 ADAPTER -8 ORB/-6 JIC
30 1 320472 LOAD SENSOR ASSEMBLY
31 2 320467 HYDRAULIC HOSE ASSEMBLY
32 2 241168 TEE -6 ORB/-6 JIC RUN
36 4 005810 CAPSCREW 1/4-20 NC x 1 3/4
6-1.1.0 AW038 2/99

HYDRAULIC ASSEMBLY
3203PR
6-2.0.0 AW039 2/99

HYDRAULIC ASSEMBLY
3203PR
1 1 202710 MANIFOLD (REF)
2 1 320352 BOOM CYLINDER (REF)
3 1 320336 HYDRAULIC PUMP & RESERVOIR (REF)
4 1 480027 HYDRAULIC ROTATION MOTOR (REF)
5 3 200876 ADAPTER -6 ORB/-6 JIC
6 - - -
7 - - -
8 - - -
9 1 330274 REDUCER -10 ORB/-8 ORP
10 3 330272 90º ELBOW -8 ORB/-6 JIC
11 1 330058 REDUCER -10 ORB/-6 ORP
12 2 241175 90º ELBOW -6 ORB/-6 JIC
17 1 320350 45º ELBOW -8 NPTM/-6 JIC
18 1 202759 90º ELBOW -8 NPTM/-6 JIC
21 2 202756 ADAPTER -8 ORB/-6 JIC
25 2 320467 HYDRAULIC HOSE ASSEMBLY
27 1 241168 TEE -6 ORB/-6 JIC RUN
28 2 005810 CAPSCREW 1/4-20 NC x 1 3/4
30 1 320472 LOAD SENSOR ASSEMBLY
6-2.1.0 AW039 2/99

HYDRAULIC ASSEMBLY
3203P

2 1 320343 FLOW REGULATOR
3 1 340344 TEE
5 1 083803 HOSE CLAMP -6
6 1 320370 90º ELBOW -6 ORB/-6 NPTM
7 1 301103 VELOCITY FUSE
8 1 330596 90º ELBOW -6 NPTF/-6 JIC
9 1 320340 ADAPTER -6 ORB
10 1 330584 BREATHER FILTER
11 1 320465 HOSE ASSEMBLY
6-3.0.0 AW048 2/99

HYDRAULIC PUMP & RESERVOIR
P/N 320335

1 1 320335-001 ADAPTER KIT
2 1 320335-002 RELEASE VALVE KIT
3 1 320335-003 PUMP KIT
4 1 320335-004 RELIEF VALVE KIT
5 1 320335-005 MOTOR
6 1 320335-006 RESERVOIR KIT
7 1 320335-007 MOUNTING BRACKET KIT
8 1 320335-008 ELBOW FITTING
9 1 320335-010 O-RING
6-5.0.0 aw320335 2/99

HYDRAULIC PUMP & RESERVOIR
P/N 320336

1 1 320336-005 ADAPTER KIT
2 1 320336-002 RETURN PORT PLUG KIT
3 1 320335-003 PUMP KIT
4 1 320336-003 RELIEF VALVE KIT
5 1 320335-005 MOTOR
6 1 320336-006 RESERVOIR KIT
7 1 320335-007 MOUNTING BRACKET KIT
8 1 320335-008 ELBOW FITTING
9 1 320335-010 O-RING
6-6.0.0 aw320336 2/99

COUNTERBALANCE VALVE SETTING
3203 SERIES
CAUTION:
IF COUNTERBALANCE VALVE IS REPLACED, THE CORRECT
PRESSURE SETTING MUST BE MADE BEFORE CRANE IS IN
SAFE WORKING CONDITION.
After installed, boom up until boom cylinder is fully
IMPORTANT elevated. Next, boom down in small increments
while reading pressure gauge. Loosen nut on end
No load must be on crane boom and of valve and adjust 3/16" Allen screw and then
booms must not be extended during re-tighten nut. Proceed again until pressure
gauge installation and removal reading is a constant 1000 psi. If valve is not set
procedure. and boom reaches the full down position, boom up
and keep trying.
Valve Setting
Remove gauge and replace plug when adjustment
is complete.
To set counterbalance valve (330412), remove
plug (5/16" Allen wrench) from port "A" of Note: 3203 PRX extendible boom cylinder
hydraulic pump. Install a pressure gauge of 2500 (202711) requires no adjustment to counter
psi capacity minimum into the port (-6 O-ring balance valve if replaced.
port).
6-7.0.0 32cbset 2/99

TROUBLESHOOTING GUIDE
3203 PRX
to center terminal of rotation switch from pin
1 CRANE FAILS TO OPERATE (ALL
"D").
FUNCTIONS)
A.Check power to crane - 12v to ground at 2 HOIST UP, BOOM DOWN, & EXTEND
upper left power terminal of pump relay (OUT) DON'T OPERATE BUT ALL
OTHER FUNCTIONS OPERATE. PUMP
1. If ok go to B.
RUNS WHEN BOOM DOWN AND
2. If not check continuity back to battery at EXTEND FUNCTIONS ARE TRIED.
Tweco and battery connections. THESE FUNCTIONS ARE TIED INTO THE
ANTI-TWO BLOCK AND CRANE
B.If there is power at pump relay (left side) and
OVERLOAD SENSOR SYSTEMS. THE
no functions are operable the most likely
cause is in the control circuits (pendant or CRANE IS SHUT DOWN WHEN THE
receptacle). SENSORS OPEN THE GROUND CIRCUIT
FROM THE FUNCTIONS.
1. Verify by touching jumper from hot side
of pump relay to left side control A.Check two-block bail and switch at end of
terminal(small) on pump relay. Pump boom to verify they move freely. Switch
should run but crane should not move should make audible click when operated.
unless a valve is stuck open. Also test Try operating crane while pulling cord out of
by jumping from hot side of pump relay cord reel to check for possible bad spots in
to left side control terminal of hoist cord reel slip rings.
down relay. hoist should operate down. B.Check load sensor pressure switch - locate
C.If previous tests are ok, then remove pendant timing relay on lower right hand corner of
and check at receptacle on crane with jumper relay panel. Disconnect wire coming from
and test light. pressure switch at terminal #6 of timing
relay. If crane operates replace pressure
1. Check for voltage from pin "D" of switch.
socket to ground.
i. If not successful, then receptacle
assembly is bad. WARNING: BE SURE BOOM IS
ii. If ok, jumper from "D" to "F" (hoist SUPPORTED BEFORE REMOVING
down), or "D" to "J" (pump). Other SWITCH OR BOOM WILL FALL.
functions can be checked also by
probing receptacle with jumper. See
P/N 680065 pg 7-6.0.0. Hydraulic C.If previous test fails, then test timing relay by
functions require that pump and removing wire from terminal #1 of timing
valve are both activated. relay. If successful, clean the area around
D.If receptacle tests are ok, then fault is in terminals 6 and 7 and recheck. If test still
pendant hot wire. Either a break in the wire or fails, replace timing relay.
it is not attached inside of the pendant (goes D.Test drop out relay - pull orange wire from
terminal #1 on the timing relay. If crane
operates, ground orange wire to verify drop
6-8.0.0 32trbl 2/99
3203 PRX
out relay is working, then reattach to terminal and pick hoist down. If light comes on,
#1. If crane still does not operate, pull socket replace hoist down relay.
off relay. Find where wire from cord reel
feeds into relay socket. Jumper from this NOTE: THERE ARE OTHER WAYS TO
terminal of socket to ground. If crane TEST FOR CIRCUIT CONTINUITY SUCH AS
operates, replace relay. If crane still does not USING VOLT METER OR TEST LIGHT AND
operate, then check continuity through cord FOLLOWING CIRCUIT THROUGH BY
reel and two-block switch. TESTING AT EACH POINT FOR VOLTAGE
TO GROUND.
3 HOIST FAILS TO OPERATE IN EITHER
DIRECTION BUT ALL HYDRAULIC
4 ALL HYDRAULIC FUNCTIONS
FUNCTIONS OPERATE.
INOPERABLE.
A.Listen for relay click for hoist up and hoist
A.Pump does not run, pump relay does not
down. If relay doesn't click check for voltage
click. Jumper from upper left power terminal
at left side control terminal(small) when
of pump relay to left side relay control termi-
function is selected, if no voltage then use
nal. If relay doesn't click, replace relay. If
procedure for checking receptacle and
relay clicks and pump runs, check receptacle
pendant given in 1.C.
and pendant. (see 1.C.)
B.Check terminal A2 of hoist motor for power
B.If relay clicks but pump doesn't run, check for
when operating either hoist up or hoist down.
voltage at pump motor terminal. If no voltage
If there is voltage but motor does not try to
replace pump relay. If voltage is present,
run or get hot then motor is bad. If motor
pump motor is bad or pump is locked. If
tries to run or gets hot then voltage reading at
pump is locked motor will get hot and voltage
A2 will be less than 12 volts and motor may
at motor terminal will much lower than 12
be dirty or have oil in it from failed oil seal.
volts.
C.If there is no power at A2 only on hoist up,
then put test light across bottom power termi- 5 PUMP RUNS BUT SINGLE HYDRAULIC
nals of hoist down relay. If light comes on FUNCTION DOESN'T WORK.
when hoist up is picked, then hoist down relay
is bad. If test light doesn't light, put light A.Select inoperable function with pendant
across upper power terminals of hoist up relay switch and push manual override of valve in
and pick hoist up. If light comes on, replace question-if function works use procedure 1.C.
hoist up relay. to check receptacle and pendant. If recepta-
cle checks out and function can not be run by
D.If there is no power at A2 only on hoist down using jumper at receptacle, then valve or
then put test light across bottom power termi- harness may be bad. Check for 12 volt at
nals of hoist up relay. If light comes on when valve junction box. If no voltage present-
hoist down is picked, then hoist up relay is check for loose wire at back of receptacle or
bad. If test light doesn't light, put light across terminal strip.
upper power terminals of hoist down relay
B.If voltage is present at valve, then valve may
be bad. This can be checked by swapping
6-8.1.0 32trbl 2/99

3203 PRX
valve positions on manifold but leaving wiring D.If hydraulic functions are more intermittent
attached. If trouble moves with valve, then when cylinders are extended, then check
valve is bad. hydraulic fluid level.
C.If boom retract or boom down functions don't E.Boom locks up and won't come down when
work, then check for low hydraulic pressure fully raised. This is caused by too high pump
at pump. These two functions have the pressure which causes overload system to
highest pressure requirements for an unloaded activate. Set relief pressure at 2100 psi.
crane because they must overcome the set Unlock boom by disconnecting wire from
pressures of the counter balance valves. terminal #6 of timing relay. Reconnect wire
after boom is moved. If pressure is correct
and problem continues, then replace overload
pressure switch.
6-8.2.0 32trbl 2/99

SOLENOID VALVES WIRING DIAGRAM
P/N 320480 - 3203PRX

1 - REF SOLENOID VALVE 300204
2 3 642908 CORD CONNECTOR
3 1 001102 WIRE TERMINAL 2RC-10
5 8 000302 WIRE TERMINAL 2R814
7-1.0.0 AW320480 2/99

SOLENOID VALVES WIRING DIAGRAM
P/N 320481 - 3203PR

1 - REF SOLENOID VALVE 300204
2 2 642908 CORD CONNECTOR
3 1 001102 WIRE TERMINAL 2RC-10
5 5 000302 WIRE TERMINAL 2R814
7-2.0.0 AW320481 2/99

PENDANT ASSEMBLY
P/N 680068 - 3203P

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
7-4.0.0 AW680068 2/99

PENDANT ASSEMBLY
P/N 680064 - 3203PR
7-5.0.0 AW680064 2/99

PENDANT ASSEMBLY
P/N 680064 - 3203PR

1 1 631602 PENDANT HOUSING
2 1 631700 BOTTOM COVER
4 3 640300 BOOT-TOGGLE SWITCH
5 10 001004 PAN HEAD SCREW #6 x 3/4
6 2 005101 PAN HEAD SCREW #8 x 1 1/4
7 1 633801 CABLE ADAPTER
8 18 FT 800630 CONDUCTOR CABLE
9 2 634401 TY-RAP CABLE TIE
11 15 000101 TERMINALS T & B
12 - - -
13 3 642100 O-RING
14 1 019700 SPLIT LOCK WASHER #8 PLATED
15 1.750 800580 3/4” WIDE OKONITE RUBBER TAPE
16 1 004700 PAN HEAD SCREW #8 x 1 1/2
19 2 636600 JUMPER BAR
20 .250 800592 WHITE 16GA x 3 IN WIRE
21 6” 490243 TUBING HEAT SHRINK
7-5.1.0 AW680064 2/99

PENDANT ASSEMBLY
P/N 680065 - 3203PRX
7-6.0.0 AW680065 2/99

PENDANT ASSEMBLY
P/N 680065 - 3203PRX

1 1 631601 PENDANT HOUSING
2 1 631700 BOTTOM COVER
4 4 640300 BOOT-TOGGLE SWITCH
5 10 001004 PAN HEAD SCREW #6 x 3/4
6 2 005101 PAN HEAD SCREW #8 x 1 1/4
7 1 633801 CABLE ADAPTER
8 18 FT 800632 CONDUCTOR CABLE
9 2 634401 TY-RAP CABLE TIE
10 3 636600 JUMPER
11 24 000101 TERMINALS T & B
12 - - -
13 4 642100 O-RING
14 1 800592 WHITE 16GA 600V 1C WIRE
15 1.750 800580 3/4” WIDE OKONITE RUBBER TAPE
16 1 004700 PAN HEAD SCREW #8 x 1 1/2
17 3 622346 CONDUCTOR ASSEMBLY 2 1/8
18 2 622347 CONDUCTOR ASSEMBLY 3 1/8
22 6” 490243 TUBING HEAT SHRINK
7-6.1.0 AW680065 2/99

RELAY ASSEMBLY
P/N 680055 - 3203P
7-7.0.0 AW680055 2/99

RELAY ASSEMBLY
P/N 680055 - 3203P
1 3 200182 RELAY
2 1 REF POWER CABLE (TWECO MALE) 330258
3 2 622323 CONDUCTOR
7 - - -
10 1 680057 3203P RECEPTACLE ASSEMBLY
11 6 015600 HEX NUT #10-32 NF
12 6 020001 WASHER #10
14 7 015900 HEX NUT 1/4-20 NC
15 7 005901 CAPSCREW 1/4-20 NC x 1/2
16 1 320564 RECEPTACLE CAP
17 1 000302 TERMINAL RB-14-10 (REF)
18 1 320560 LOAD SENSOR ASSEMBLY (REF)
19 2 019600 LOCK WASHER #6
20 2 015400 HEX NUT #6-32 NC
21 2 000404 ROUND HEAD SCREW #6-32 x 5/8
22 1 000300 TERMINAL RB-14-10
23 1 680056 3203P RELAY PANEL
24 1 320355 BOSCH DROP OUT RELAY
7-7.1.0 AW680055 2/99

RELAY ASSEMBLY
P/N 680054 - 3203PR
7-8.0.0 AW680054 2/99

RELAY ASSEMBLY
P/N 680054 - 3203PR
1 3 200182 RELAY
3 1 680118 RECEPTACLE ASSEMBLY
7 1 320355 DROP OUT RELAY
9 1 330258 TWECO CONNECTOR ASSEMBLY (REF)
11 1 320479 RELAY PANEL PLATE
12 1 635203 TERMINAL BOARD
13 2 001102 TERMINAL WIRE SPLICE
14 1 330261 CONDUCTOR ASSEMBLY-16” BOOM
15 1 002602 CAPSCREW #6-32 x 1 1/2
16 1 330259 CONDUCTOR ASSEMBLY-14” TURN
17 1 330249-200 RELAY PANEL BRACKET
18 6 015900 NUT 1/4-20
20 4 005901 CAPSCREW 1/4-20 x 1/2
21 1 320351 SOLID STATE TIMING RELAY
22 5 015400 HEX NUT #6-32
23 5 019600 SPLIT LOCK WASHER #6
24 1 320564 RECEPTICAL CAP
25 4 000404 CAPSCREW #6-32 x 5/8
26 1 320358 DROP OUT RELAY PLUG
30 2 005500 CAPSCREW 1/4-20 x 3/4
7-8.1.0 AW680054 2/99

RELAY ASSEMBLY
P/N 320457-200 - 3203PRX
7-9.0.0 AW320457200 2/99

RELAY ASSEMBLY
P/N 320457-200 - 3203PRX
1 3 200182 RELAY
3 1 330256-200 RECEPTACLE ASSEMBLY
7 1 320355 DROP OUT RELAY
9 1 330258 TWECO CONNECTOR ASSEMBLY (REF)
11 1 320479 RELAY PANEL PLATE
12 1 635203 TERMINAL BOARD
13 2 001102 TERMINAL WIRE SPLICE
14 1 330261 CONDUCTOR ASSEMBLY-16” BOOM
15 1 002602 CAPSCREW #6-32 x 1 1/2
16 1 330259 CONDUCTOR ASSEMBLY-14” TURN
17 1 330249-200 RELAY PANEL BRACKET
18 6 015900 NUT 1/4-20
20 4 005901 CAPSCREW 1/4-20 x 1/2
21 1 320351 SOLID STATE TIMING RELAY
22 5 015400 HEX NUT #6-32
23 5 019600 SPLIT LOCK WASHER #6
24 1 320564 RECEPTICAL CAP
25 4 000404 CAPSCREW #6-32 x 5/8
26 1 320358 DROP OUT RELAY PLUG
30 1 002602 CAPSCREW #6-32 x 1 1/2
31 2 005500 CAPSCREW 1/4-20 x 3/4
32 3 FT 800626 #16 AWG 2/C, 300V TYPE SJO 90ºC
33 1 000302 WIRE TERMINAL (BUTT SPLICE) 2RB14
34 1 000300 WIRE TERMINAL RB14-10
7-9.1.0 AW320457200 2/99

RELAY CHECKING PROCEDURE
NOTE: 12V– on the remaining post F & E. Using an

The following procedure is performed with ohm meter or test light, check across posts A &
relays completely disconnected from all B. You should get an ohm reading or your test
wires on motor circuits and ground wires. light should be on when you have the relay
These circuits can give you false readings activated. With the relay still activated, check
sometimes. across posts C & D. You should have no ohm
reading or test light at this point with relay
HOW TO CHECK RELAY: activated. At this point, disconnect 12V+ and
Checking a relay on this or any Auto Crane 12V– from posts F & E. This should let relay
product is done in the same way, but there may return to its normal position. Using your ohm
be a difference in physical appearance of the meter or test light again, check the relay across
relay. Shown below are two types of relays posts A & B. If relay is working correctly, you
used by Auto Crane. Our relays are normally should have no reading at all. Then check
closed across the bottom posts C & D and across posts C & D. You should have an ohm
normally open across the A & B posts. When reading or test light should be on. If you get
activated, they will open across C & D and the above results, relay is okay. If you get any
close across A & B. To activate these relays, variation in the above explanation on the relay
use 12V positive (+) and 12V negative (–) you are checking, check the relay again. If it
wires and place them on posts F & E. You may still shows a difference, the relay is bad and
place 12V+ on post F or E as long as you place should be replaced.
7-13.0.0 RELAYCHK 9/98

LOAD CHART
3203P/PR/PRX
9-9.9.9 320321 2/99

Auto Crane 3203EH Hard Wired 999947 0200

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OWNERS MANUAL

SERIAL NO. __________________________

AUTO CRANE COMPANY

WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL

WARNING! NEVER .............................

2 OPERATING PRACTICES & WARNINGS . . . . . . . . . . . . . . . . . . . . . . . 1-2.0.0

3 OPERATION OF UNIT / OUTRIGGERS ........................ 1-3.0.0

4 QUALIFICATIONS FOR OPERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4.0.0

5 INSPECTION, TESTING, & MAINTENANCE . . . . . . . . . . . . . . . . . . . . 1-5.0.0

6 LIFE OF WIRE LINE / WIRE LINE LUBRICATION . . . . . . . . . . . . . . . 1-6.0.0

7 SAFETY DECAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7.0.0

8 LUBRICATION & MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . 1-8.0.0

9 MOUNTING & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1.0.0

10 GENERAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1.0.0

11 2-BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2.0.0

12 HOIST ACTUATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3.0.0

13 TURNER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4.0.0

14 AUTOMATIC SAFETY BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 3-5.0.0

15 TRAVELING BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6.0.0

16 GENERAL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1.0.0

17 HYDRAULIC SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1.0.0

18 ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1.0.0

19 LOAD CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1.0.0

20 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LAST PAGE

1-1.0.0 3203pintro 1/99

1-1.1.0 3203Pspec 1/99

1-2.0.0 SAFTIPS 2/98

3 Operators shall be required by the employer to pass a CONDUCT OF OPERATORS

1-4.0.0 QUAL 7/98

1-4.1.0 QUAL 7/98

22 Cranes shall be operated so that no part of the crane minimum required

1-4.2.0 QUAL 7/98

G. electrical apparatus for malfunctioning, signs of

1-5.0.0 INSP 9/98

40 Hydraulic and pneumatic valves inspection. INSPECTION RECORDS

tested by or under the direction of an A. functional operating mechanism

1-5.2.0 INSP 9/98

3. broken or cut strands; 1. sections in contact with saddles, equalizer

1-5.3.0 INSP 9/98

G. In standing ropes, more than two broken wires in

ROPE MAINTENANCE 68 When an operating rope shows greater wear or well

1-5.4.0 INSP 9/98

3. Corrosion and abrasion.

WIRE LINE LUBRICATION

Lubrication of the wire line serves two APPLICATION:

1-6.0.0 WIRELIF 10/98

1.280 -90ºF 1 Checking belts for tightness on the charging

1-6.1.0. MAINTBAT 9/98

Low maintenance batteries should not be used on Replacing a Battery

1-6.2.0. MAINTBAT 9/98

PART NO.: 040517

PART NO.: 040518

PART NO.: 040519 QUANTITY: 1

1-7.0.0 3203pdec 1/99

PART NO.: 040529 QUANTITY: 2

PART NO.: 040579

1-7.1.0 3203pdec 1/99

PART NO.: 040580

1-7.2.0 3203pdec 1/99

ITEM QTY P/N DESCRIPTION