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Auto Crane 3203 PR Owner's Manual

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3203 PR/PRX/PRFX
OWNERS MANUAL
Serial No. __________________
Mailing Address:
P.O. Box 580697 Tulsa,
OK 74158-0697 Physical
Address: 4707 N. Mingo
Rd. Tulsa, OK 74117-5904
Phone 1-800-777-2760
Fax (918) 269-6688
http://www.autocrane.com
OM-320950000-0
-

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  • Page 1 3203 PR/PRX/PRFX OWNERS MANUAL Serial No. __________________ Mailing Address: Phone 1-800-777-2760 P.O. Box 580697 Tulsa, OK 74158-0697 Physical Fax (918) 269-6688 Address: 4707 N. Mingo http://www.autocrane.com Rd. Tulsa, OK 74117-5904 OM-320950000-0...
  • Page 3 ONE REGISTRATION FORM PER UNIT (CRANE, BODY, OR COMPRESSOR) Please submit form within 15 days after installation Online: www.autocrane.com | Resources | Warranties Fax: 918-234-2177 Mail: Product Registration, Auto Crane Company, PO Box 580697, Tulsa, OK 74158-0697 Product Registration Rev 05152014...
  • Page 5 ♦ Attempt to lift or drag a load from the side! The boom can fail far below its rated capacity. ♦ Weld, modify, or use unauthorized components on any Auto Crane unit! This will void any warranty or liability. Also failure of the crane may result.

  • Page 7: Table Of Contents

    3203 PR/PRX/PRFX TABLE OF CONTENTS INTRODUCTION ……………………………………………………………… GENERAL SPECIFICATIONS ……………………………………………………………… SAFETY TIPS AND PRECAUTIONS ……………………………………………………………… OPERATING PRACTICES & WARNINGS ……………………………………………………………… QUALIFICATIONS FOR OPERATORS ……………………………………………………………… OPERATION OF UNIT / OUTRIGGERS ……………………………………………………………… INSPECTION ……………………………………………………………… TESTING ……………………………………………………………… MAINTENANCE ……………………………………………………………… BATTERIES ……………………………………………………………… LUBRICATION AND MAINTENANCE SCHEDULE ………………………………………………………………...

  • Page 9: Introduction

    For your convenience the overall dimensions of the 3203 PR/PRX crane are included on the Auto Crane maintains a strong distributor General Dimension Drawing. Rotation and network and a knowledgeable Customer Service turning radius are also listed on that drawing.
  • Page 10 Auto Crane Company at the following telephone number: (918) 836-0463 . The information contained in the manual is in effect at the time of this printing. Auto Crane Company reserves the right to update this material without notice or obligation.

  • Page 11: General Specifications

    3203PR/PRX GENERAL SPECIFICATIONS DIMENSIONS REACH 21 in (0.53 m) Width: Second boom will reach from 7 feet 4 inches to 11 feet 4 inches. Height: 24.00 in (0.61 m) Third boom will reach from 11 feet 4 inches to 15 feet 4 inches. Length: 9 ft 1-1/2 in (2.78 m) [boom(s) stored]...

  • Page 12: Safety Tips And Precautions

    30. Always store outriggers before transportation. WARNING! Auto Crane Company cranes are not designed or intended for use in lifting or moving persons. Any such use shall be considered to be improper and the seller shall not be responsible for any claims arising there from.
  • Page 13 --- IMPORTANT --- SAFETY TIPS AND PRECAUTIONS 31. Always store the crane in its stowed position for WARNING: Never attempt to lift, drag, tow or transportation. pull a load from the side. The boom can fail 32. Remember the overall height of the entire unit far below its rated capacity.

  • Page 14: Operating Practices & Warnings

    WARNING! NEVER hold any Control Select Switch on that will cause unsafe operating conditions! WARNING! Auto Crane Company remote controlled, stiff boom cranes are not designed or intended for use on any applications involving the lifting or moving of personnel.

  • Page 15: Qualifications For Operators

    QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE QUALIFICATION REQUIREMENTS OPERATORS tests may be required to determine these conditions. 5. Operators and operator trainees should have normal 1. Crane operation shall be limited to personnel depth perception, coordination, and no tendencies to with the following minimum qualifications: dizziness or similar undesirable characteristics.
  • Page 16 QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES or neutral position and all personnel are in the clear. C. Means are provided to hold the vehicle stationary while operating the crane. 6. If power fails during operation, the operator shall: D.
  • Page 17 QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES N. No person should be permitted to stand or 3. Caution shall be exercised when working near overhead pass under a suspended load. lines, because they can move horizontally or vertically due to wind, moving the danger zone to new positions.
  • Page 18 RANGE - SMALL EH CRANES RECOMMENDED OPERATING TEMPERATURE OIL TEMPERATURE 200° F (93.3°C) 180° F (82.2°C) 160° F (71.1° C) 140° F (60° C) 120° F (48.9°C) 5W20 ANTI-WEAR 100° F (37.8°C) HYDRAULIC OIL OR EQUIVALENT 80° F (26.7° C) HySyn ISO32 SYNTHETIC 60°...
  • Page 19 12. Store transmitter in proper location (in cab or park for automatic transmissions). Activate any crane storage area). power switches. For Auto Crane units requiring 13. Return outriggers to stowed position. Make sure battery and hydraulic operation, engage emergency they are pinned in place or jacklegs are returned to brake, place gear selector in neutral, press clutch, compartment.

  • Page 20: Inspection

    INSPECTION REQUIREMENTS REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE INSPECTION REQUIREMENTS 3. Inspect safety devices for malfunction. INSPECTION CLASSIFICATION 4. Visually inspect all hydraulic hoses, particularly 1. Initial inspection. those that flex in normal operation of crane functions. Prior to initial use, all new, altered, modified or 5.
  • Page 21 INSPECTION REQUIREMENTS PERIODIC INSPECTION B. Improper return of spool to neutral position. C. Leaks at spools or joints. Any deficiencies, such as those listed below, shall be D. Sticking spools. carefully examined and determination made as to E. Failure of relief valves to attain or maintain whether they constitute a hazard: correct pressure setting.
  • Page 22 INSPECTION REQUIREMENTS A. Reduction of rope diameter below nominal diameter due to loss of core support. B. Internal or external corrosion. C. Wear of outside wires. D. Severely corroded, cracked, bent, worn, or improperly applied connections. CRANES NOT IN REGULAR USE A crane, which has been idle for a period of over one month or more, shall be given an inspection conforming to the “initial”...

  • Page 23: Testing

    TESTING REQUIREMENTS REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE TESTING REQUIREMENTS TESTING SHALL BE PERFORMED BY DESIGNATED PERSONNEL ONLY. Prior to initial use, all new, altered, modified, or extensively repaired cranes shall be tested for compliance with the operational requirements of this crane. Test requirements: 1.

  • Page 24: Maintenance

    GENERAL REPAIRS AND MAINTENANCE REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE MAINTENANCE AND REPAIR REQUIREMENTS A preventative maintenance program should be B. Critical parts of the crane structure which are established based on this section and all replacement cracked, bent, broken, or excessively corroded. parts should be obtained from AutoCrane Company.
  • Page 25 GENERAL REPAIRS AND MAINTENANCE (2.4 mm) for diameters 11/4 in. (32 mm) to and side of the cut are required, and for non-preformed including 11/2 in. (38 mm). rope 1 in. (25 mm) diameter or larger, three seizings on each side of the cut are required. G.

  • Page 26: Batteries

    MAINTENANCE OF BATTERIES Maintenance of Auto Crane unit batteries differs very deterioration of the remaining parts of the little from the generally prescribed maintenance of any battery. lead acid battery. All batteries must be kept properly Keep A Relatively Clean Battery charged, properly filled with water, and relatively clean.
  • Page 27 MAINTENANCE OF BATTERIES If, after charging, it is noted that the specific gravity 2. Place the battery on charge according to the manufacturer’s instructions. reading of one cell is 30 points less than any of the other cells, it may be assumed that the cell is bad It is essential that the second step above be followed and that the battery should be replaced.
  • Page 28 3203PR/PRX LUBRICATION & MAINTENANCE SCHEDULE SERVICE NOTES DAY WKLY 3 MOS 6 MOS YEAR PERFORMED INSPECT HOOK & LATCH FOR DEFORMATION, LOAD HOOK CRACKS, & CORROSIO N MAKE SURE CABLE IS WOUND EVENLY ON CABLE DRUM DRU M HOIST / BOOM &...
  • Page 29 2. Once a bolt has been torqued to its rated capacity and then removed; the bolt should be replaced with a new one. 3. 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.

  • Page 30: Single Line Procedure

    3203EH SINGLE LINE PROCEDURE CONVERTING FOR SINGLE LINE TO DOUBLE LINE ON 3203EH CRANES This procedure gives step by step directions for taking a double line and converting to a single line. Keep in mind when using a single line, the max capacity drops from 3200lbs to 1600lbs. 1.
  • Page 31 3203PR/PRX/PRFX BRAKE ADJUSTMENT ADJUSTING OIL COOLED WORM BRAKE The oil-cooled, fully adjustable, automatic safety brake operates in the worm housing lubricant, all part being submerged in oil. When the brake wears to the point that the load begins to drift, the brake can be adjusted as follows: 1.

  • Page 32: Rotation Bearing Replacement

    ROTATION BEARING REPLACEMENT GUIDELINES-2003-4004 All bearings can wear over time. This includes the main rotation bearing on the crane. No pre cise rules can be given for replacement of the rotation bearing, since many factors are in volved. However, there are common symptoms seen during crane operation that may be caused by rotation bearing wear.

  • Page 33: Safety Decal Section

    3203PR/PRX SAFETY DECAL SECTION PART NO. : 040579000 DECAL : OPERATING INSTRUCTION S FUNCTION : To inform the operator of the proper procedure to follow for safe operation of the crane. USED ON : All Cranes QUANTITY : PLACEMENT : Right side plate PART NO.: 040580000 DECAL:...
  • Page 34 3203PR/PRX SAFETY DECAL SECTION PART NO. : 040529000 DECAL : ELECTROCUTION HAZAR D FUNCTION : To inform the operator of the hazard involved with contacting electrical power lines with crane boom. USED ON : All Cranes QUANTITY : PLACEMENT : Both sides of end of lower boom PART NO.: 040517000 DECAL:...
  • Page 35 3203PR/PRX SAFETY DECAL SECTION PART NO. : 040587000 USED ON : All cranes equipped with a load sensor. QUANTITY : DECAL : LOAD SENSOR, DON’T TAMPE R FUNCTION : To inform the operator that the load PLACEMENT : Both sides of the lift cylinder near sensor is pre-set and that tampering the load sensor with the sensor may cause potentially...
  • Page 36 3203PR/PRX SAFETY DECAL SECTION PART NO. : 460169000 USED ON : All Cranes equiped with FM controls. DECAL : REMOTE CONTROL QUANTITY : FUNCTION : To inform the operator of failure to PLACEMENT : FRONT OF POWER UNI T follow the saftey precautions may result in equipment failure or serious personal injury.
  • Page 37 3203PR/PRX DECAL LAYOUT P/N: 320988004 17 FRONT OF RESERVOIR...
  • Page 38 DECAL OPERATION INSTRUCTIONS 040580000 DECAL TRAINED OPERATOR 040587000 DECAL WARNING LOAD SENSOR 330622000 DECAL SERIAL NO 40619001 DECAL AUTO CRANE LOGO 320318000 DECAL ANGLE INDICATOR CS 320318001 DECAL ANGLE INDICATOR SS 320988005 DECAL 3203 LOAD CHART 320433100 DECAL, TRAVELING BLOCK 3203...

  • Page 39: General Dimensions

    3203PR/PRX GENERAL DIMENSIONS...

  • Page 40: Mounting And Installation

    9. Load test the crane to ensure proper functioning and truck stability 10. Make certain the owner’s manual is delivered to the customer. 11. For additional help: call the service department at the Auto Crane Company. (918) 836-0463 (Tulsa,Oklahoma) WARNING...
  • Page 41 320824000 PIN, LIFT CYLINDER 360678000 PIN, 3/16 COTTERLESS RING 320988004 DECAL LAYOUT, 3203 320988012 SHIP KIT, 3203 PR/PRX, HW 239300000 ZERK, GREASE SCREW HX HD 3/8-16UNC X 1 LG 330371000 SCREW HX HD 3/8-16UNC X 1 1/2 LG 366159000 021100000...

  • Page 42: General Assembly, Hardwired

    3203PR GENERAL ASSEMBLY HARDWIRED Attach ground wire (404223020) to bottom of the crane. Run the ground wire down through the crane box. Locate cable so that it will be protected and avoid sharp edges. Attach ground from crane to chassis frame.
  • Page 43 3203PRX GENERAL ASSEMBLY HARDWIRED - P/N:320989002...
  • Page 44 320824000 PIN, LIFT CYLINDER 360678000 PIN, 3/16 COTTERLESS RING 320988004 DECAL LAYOUT, 3203 320988012 SHIP KIT, 3203 PR/PRX, HW 239300000 ZERK, GREASE 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8 366159000 SCREW HX HD 3/8-16UNC X 1 1/2 LG GR8...
  • Page 45 3203PRFX GENERAL ASSEMBLY HARDWIRED - P/N: 320990001 TRAVELING BLOCK IS SHOWN FOR REFERENCE AND IS LOCATED IN THE SHIP KIT APPLY LOCK-TITE 242 OR 243 TO BOLT THREAD PLUG REG FROM 320990310 INTO COIL...
  • Page 46 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8 330372000 NUT HX 3/8-16UNC 360678000 PIN, 3/16 COTTERLESS RING 320988012 SHIP KIT, 3203 PR/PRX, HW 320988004 DECAL LAYOUT, 3203 366159000 SCREW HX HD 3/8-16UNC X 1 1/2 LG GR8 320338002 CABLE ASS'Y, 7/32" x 62FT, THIMBLE END...
  • Page 47 3203PR PEDESTAL ASSEMBLY P/N: 320988204 ATTACH GROUND CABLES FROM: ATTACH GROUND CABLE PUMP (600318) RELAY PANEL (BLACK WIRE) 15 16 HYDRAULICS: PORT A-1 BOOM UP PORT A-2 CCW BOTTOM MOTOR PORT PORT B-1 BOOM DOWN PORT B-2 CW TOP MOTOR PORT CYLINDER SEAL KIT: 320845002 C’BAL CARTRIDGE: 480188000...

  • Page 48: Pedestal Assembly

    3203PR PEDESTAL ASSEMBLY P/N: 320988204...
  • Page 49 3203PR PEDESTAL ASSEMBLY P/N 320988204 ITEM NO. PART NO. DESCRIPTION 320988210 PEDESTAL WELDMENT, 3203 PR / PRX / H 110703 WINCH-DCG8R FOR AUTOCRANE #3203 PRX 320991240 KIT, HOSE NEXSTAR 3203PRX/4004EH 320991237 BASE PLATE MACH 3203 LESS GROUND HOLE 320878000 ROTATION BEARING 340602000 KEY, 3/4 SQ X 1 320988253 GEAR, WORM, 4.00 ID, .75 KEY, 3203...
  • Page 50 480024000 MOUNT PENDANT CABLE RETAINER 320917000 PRESSURE SWITCH, N.C. 1,900 PSI 200876000 FITTING 6 SAE/6 JIC STRAIGHT 490198000 FITTING 10SAE(M)/6JIC ELBOW 90 320988270 KIT, HYDRAULIC, 3203 PR 680156100 KIT-ELECTRICAL, 3203 PR/PRX 002901000 TERMINAL, RING #4 - 3/8 002702000 TERMINAL, RING #4 - 5/16 660116000 CABLE ASSY, 6 AWG, 16 1/4 "...
  • Page 51 3203PRX PEDESTAL ASSEMBLY P/N: 320988203 Attach Ground Cable ATTACH GROUND CABLES FROM: HOIST (600317) PUMP (600318) RELAY PANEL (BLACK WIRE) 40 27 HYDRAULICS: PORT A-1 RETRACT PORT A-2 BOOM DOWN PORT A-3 CCW BOTTOM MOTOR PORT PORT B-1 EXTEND PORT B-2 BOOM UP PORT B-3 CW TOP MOTOR PORT CYLINDER SEAL KIT: 320845002 C’BAL CARTRIDGE: 480188000...
  • Page 52 3203PRX PEDESTAL ASSEMBLY P/N: 320988203 ATTACH GROUND CABLE...
  • Page 53 3203PRX PEDESTAL ASSEMBLY P/N 320988203 ITEM NO PART NO. DESCRIPTION 320988210 PEDESTAL WELDMENT, 3203 PR / PRX / H 320991237 BASE PLATE MACH 3203 LESS GROUND HOLE 110703 WINCH-DCG8R FOR AUTOCRANE #3203 PRX 320878000 ROTATION BEARING 340602000 KEY, 3/4 SQ X 1 320988253 GEAR, WORM, 4.00 ID, .75 KEY, 3203...
  • Page 54 LOWER VALVE BRACKET, 3203H 320989420 VALVE ASSY, 3 SPOOL, NON-PROP., 12 VOLT 366688000 COVER, REAR 320991279 POWER UNIT, ENTRY LEVEL 3203/4004 EH B 320989235 BRACKET, POWER UNIT 680156100 KIT-ELECTRICAL, 3203 PR/PRX 017301000 NUT HX NYLK 3/8-16UNC CP 330478000 BEARING HOUSING ASSY...
  • Page 55 3203PRFX PEDESTAL ASSEMBLY P/N: 320990200 ATTACH GROUND CABLES FROM: HOIST (600317) PUMP (600318) RELAY PANEL (BLACK WIRE) 47 12 20 32 17 HYDRAULICS: PORT A-1 RETRACT PORT A-2 BOOM DOWN PORT A-3 CCW BOTTOM MOTOR PORT PORT B-1 EXTEND PORT B-2 BOOM UP PORT B-3 CW TOP MOTOR PORT CYLINDER SEAL KIT: 320845002 C’BAL CARTRIDGE: 480188000...
  • Page 56 3203PRFX PEDESTAL ASSEMBLY P/N: 320990200 49 38...
  • Page 57 KIT, HOSE NEXSTAR 3203PRX/4004EH 404187000 SPRING PLATE, GROUND BRUSH, 4004 320988258 UPPER TWECO BRACKET WLDMT, 3203 320988210 PEDESTAL WELDMENT, 3203 PR / PRX / H 110703 WINCH-DCG8R FOR AUTOCRANE #3203 PRX 320878000 ROTATION BEARING 320991237 BASE PLATE MACH 3203 LESS GROUND HOLE...
  • Page 58 3203PRFX PEDESTAL ASSEMBLY P/N: 320990200 ITEM PART NUMBER DESCRIPTION 36** 645000000 TWECO, MALE MODIFIED 37** 320988300 RELAY PANEL ASSEMBLY, 3203 021100000 WASHER SP LK 3/8 017301000 NUT HX NYLK 3/8-16UNC CP 320976000 WASHER, FLAT, 3/8 SAE HARDENED 8702000 SCREW HX HD 3/8-16UNC X 1 1/4 LG GR5 009116000 SCREW HX HD 3/8-16UNC X 2 GR5 480024000 MOUNT PENDANT CABLE RETAINER 330372000 NUT HX 3/8-16UNC...
  • Page 59 3203PR BOOM ASSEMBLY P/N: 320988103 14 27 28 25 15 27 28 25 11 12 5 23 ADD WASHERS BETWEEN BAIL AND CROWN ALSO 9 22 26 21 NOTE: APPLY LOCTITE 242 TO BOLT THREADS. 8 PLC’S BEFORE INSTALLING CYLINDER SEAL KIT: 320835002 C’BAL CARTRIDGE: 480188000...

  • Page 60: Boom Assembly

    3203PR BOOM ASSEMBLY P/N: 320988103 ITEM PART QTY. NUMBER DESCRIPTION 320988110 LOWER BOOM WELDMENT, 3203 PR/PRX 320988165 MID BOOM WMT, 3203 320988160 UPPER BOOM WLDMT 3203 320858000 BEARING, SPHERICAL 1.00 ID 320883000 SHEAVE ASSEMBLY 366112000 STOP UPPER BOOM 366183000 STOP CENTER BOOM...
  • Page 61 3203PRX BOOM ASSEMBLY P/N: 320988102 20 33 34 31 2133 34 31 5 28 29 17 18 1527 32 14 ADD WASHERS BETWEEN BAIL AND CROWN ALSO NOTE: APPLY LOCTITE 242 TO BOLT THREADS. 8 PLC’S BEFORE INSTALLING CYLINDER SEAL KIT: 320835002 C’BAL CARTRIDGE: 480188000...
  • Page 62 3203PRX BOOM ASSEMBLY P/N: 320988102 PART ITEM NO. NUMBER DESCRIPTION 320988110 LOWER BOOM WELDMENT, 3203 PR/PRX 320988165 MID BOOM WMT, 3203 320988160 UPPER BOOM WLDMT 3203 320858000 BEARING, SPHERICAL 1.00 ID 320883000 SHEAVE ASSEMBLY 366112000 STOP UPPER BOOM 366183000 STOP CENTER BOOM...
  • Page 63 3203PRFX BOOM ASSEMBLY P/N: 320990100 CYLINDER SEAL KIT: 320988146 C’BAL CARTRIDGE: 480188000...
  • Page 64 3203PRFX BOOM ASSEMBLY P/N: 320990100 ITEM PART NUMBER DESCRIPTION CYLINDER, TELESCOPIC, 48" FIRST STAGE, 48" 320988145 SECOND STAGE, 3-3/8 OD 320990110 LOWER BOOM WMT 3203 PRFX 320990120 MID BOOM WMT 3203 PRFX 738732000 PIN 1n X 4.063 LG 320988115 PIN 1 DIA X 6.905 LG, 3203 239000000 ZERK DRIVE GR 320858000...

  • Page 65: Hoist Assembly

    3203PR/PRX HOIST ASSEMBLY P/N: 110703 ITEM NO. PART NO. DESCRIPTION 320836 WINCH MOUNTING BRACKET CS 320837 WINCH MOUNTING BRACKET SS 320838 WINCH TIE BAR 320839 WINCH TIE BAR, FRONT 320887 BEARING, BRONZE 320379 DRUM 418163 WASHER SP LK 5/16 414136 SCREW HX HD 5/16-18UNC X 1 1/4 LG CP 412003 FLANGE BEARING 338053 WINCH END BEARING 414865 CAPSCREW-5/16-18NCX1LG HX SOC HD...
  • Page 66 3203PR/PRX HOIST ACTUATOR 5 38 65 56 42 25...
  • Page 67 3203PR/PRX HOIST ACTUATOR ITEM NO. QTY. PART NO. DESCRIPTION 306034 SPRING FLAT 314008 PLATE CAM 328009 COVER GEAR HOUSING 328106 COVER WORM GEAR HOUSING 328128 COVER BRAKE 334001 IDLER GEAR 334003 SPUR GEAR 334007 GEAR WORM RH NOT USED 338007 HOUSING BRAKE 338203 SPUR GEAR HOUSING 338238 GEAR HOUSING 340002 HUB BRAKE...
  • Page 68 3203PR/PRX HOIST ACTUATOR ITEM NO. QTY. PART NO. DESCRIPTION 442186 GASKET GEAR HOUSING COVER 442189 GASKET BRAKE COVER NOT USED 456008 FITTING RELIEF NOT USED NOT USED 468002 REDUCER -6NPT/-2NPT 468010 PLUG PIPE -4NPT SQ HD 468018 PLUG PIPE -6NPT HX SOC HEADLESS 468024 REDUCER -4NPT/-2NPT 470001 PIN DOWELL 474001 PLATE THRUST...

  • Page 69: Traveling Block Assembly

    3203 TRAVELING BLOCK ASSEMBLY P/N: 320433000 PART ITEM NUMBER DESCRIPTION 100309000 SWIVEL HOOK ASSY W/LATCH 320403000 SIDE PLATE, 3203 200909000 SHEAVE ASSEMBLY 320404000 BLOCK TRAVELING 320434001 PIN, 3/4 X 2-3/4LG 018200000 NUT HX NY LK 5/8-11UNC 013512000 SCREW HX HD 5/8-11UNC X 3 1/2 LG 366813000 PIN HITCH 330100000 WASHER, FL 5/8 X 7/8 OD 320433100 DECAL, TRAVELING BLOCK 3203...
  • Page 70 NOTES...

  • Page 71: Relay Panel Assembly

    3203PR/PRX RELAY PANEL ASSEMBLY P/N: 320988300 REF FOR REPLACEMENT PART ONLY (680178000) RECEPTACLE W/WIRE PIGTAIL ITEM NO. PART NO. DESCRIPTION 320988256 BULKHEAD ELECTRICAL PLATE 320589000 RELAY, HOIST 320584000 RELAY, POWER UNIT 320988399 TERMINAL STRIP 8 736272000 NUTSERT 1/4-20UNC X .027-.165 GRIP 320562000 RECEPTACLE, 11 PIN, 1/4 TURN, BAYONET 360493000 SCREW HX WHIZ-LK 1/4-20UNC X 1/2 LG 371024000 GROMET 3/4"...
  • Page 72 3203PR/PRX ELECTRICAL SCHEMATIC P/N: 320988300 DETAIL A...
  • Page 73 3203PR/PRX ELECTRICAL SCHEMATIC P/N: 320988300 ITEM NO. PART NO. COLOR GAGE YELLOW GREEN ORANGE WHITE/RED RED/BLACK GREEN/BLACK WHITE/BLACK BLUE BLACK ORANGE/BLACK WHITE ORANGE WHITE/RED GREEN/BLACK ORANGE/BLACK BLUE YELLOW GREEN/WHITE NOT USED NOT USED WHITE WHITE RED/WHITE BLUE/WHITE WHITE WHITE/RED WHITE WHITE 320988331 BLACK...

  • Page 74: Pendant Assembly

    3203PR/PRX PENDANT ASSEMBLY P/N: 680179000 PENDANT HEAD CW (ORG) CCW (BLK) EXTEND (GRN/BLK) RETRACT (ORG/BLK) PUMP (WHT/BLK) BOOM UP (WHT) BOOM DN (BLU) HOIST UP (GRN) HOIST DN (RED/BLK) CANNON PLUG + (RED) POWER...
  • Page 75 3203PR/PRX PENDANT ASSEMBLY P/N: 680179000 ITEM PART QTY. DESCRIPTION 480501000 PENDANT HOUSING 366719000 DECAL, PENDANT 8 FUNC W/PWR 480504000 PENDANT BACK PLATE 600820000 CORD GRIP, 3/4 NPT, .50-.625" CORD 680179001 PENDANT CABLE, 11 PIN BAYONET 480598000 COVER TRIGGER OPENING 750090000 TOGGLE SWITCH, 1 POLE, 2 POSITION 634200000 TOGGLE SWITCH KIT 001004000 SCREW PN HD #6 X 3/4 LG 002607000 SCREW RD HD #10-24UNC X 3/4 LG CP...
  • Page 76 NOTES...

  • Page 77: Tweco W/Switch Mount

    3203PR/PRX TWECO W/SWITCH MOUNT P/N: 404218000 ITEM NO. PART NO. DESCRIPTION 404217000 LOWER TWECO WELD WITH SWITCH MOUNT 404224000 CABLE ASSY 11 IN, TWECO TO TERMINAL 002900000 SCREW SET 1/4-20UNC X 1/4 LG 404216000 MASTER SWITCH 404219000 DECAL, CRANE POWER...
  • Page 78 3203PR/PRX HYDRAULIC CONTROL VALVE P/N: 320989420 SEAL KIT P/N 320989424 ITEM HYTOS PARKER PART NUMBER DESCRIPTION QTY. 320989421 MANIFOLD BLOCK, DO3 320989428 VALVE, DO3 STACK TYPE, HYTOS 320989422 VALVE, DO3 STACK TYPE, PARKER 320989429 COIL, 12V-2.7A HYTOS, FOR 320989420 320989423 COIL, 12V-2.5A PARKER, FOR 320989420 330072000 PLUG, #10 SAE 202756000 FITTING 6-8 STRAIGHT 202755000 FITTING, -10 SAE/-6 JIC, STR...

  • Page 79: Power Unit

    3203 POWER UNIT P/N 320991279 ITEM PART NUMBER DESCRIPTION 320991272 TANK, NEXSTAR 3203/4004EH 320991908 GAUGE, FILTER USED W/320991270 320991274 GLASS, SIGHT USED W/320991270 320991284 BASE ASSEMBLY USED W/320991270 320991271 MOTOR, NEXSTAR 3203/4004EH 320991275 CAP,FILLER USED W/ 320991270 320991277 VALVE, RELIEF USED W/320991270 320991910 FILTER, ELEMENT SMALL EH NEXSTAR 320991285...
  • Page 80 3203PR GENERAL ASSEMBLY FM - P/N: 320989005 APPLY LOCTITE 242 OR 243 TO THREADS OF BOLTS...
  • Page 81 CABLE ASS'Y, 7/32" x 62FT, THIMBLE END 361102001 MOUNTING BRACKET, OMNEX PENDANT PLUG 460158000 RECEIVER, NON-PROPORTIONAL, 680180000 HARNESS, FM, 3203PR(X) 320988013 SHIP KIT, 3203 PR/PRX, FM 320988004 DECAL LAYOUT, 3203 239300000 ZERK, GREASE 005604000 SCREW HX HD 1/4-20UNC X 1 LG 330371000...
  • Page 82 3203PRX GENERAL ASSEMBLY FM - P/N: 320989004 APPLY LOCK-TITE 242 OR 243 T O BOLT THREAD...
  • Page 83 361102001 MOUNTING BRACKET, OMNEX PENDANT PLUG 460158000 RECEIVER, NON-PROPORTIONAL, 320988004 DECAL LAYOUT, 3203 320988013 SHIP KIT, 3203 PR/PRX, FM 000239300 ZERK, GREASE 005604000 SCREW HX HD 1/4-20UNC X 1 LG 366159000 SCREW HX HD 3/8-16UNC X 1 1/2 LG 330371000...
  • Page 84 3203PRFX GENERAL ASSEMBLY FM - P/N: 320990000 TRAVELING BLOCK IS SHOWN FOR REFERENCE AND IS LOCATED IN THE SHIP KIT APPLY LOCK-TITE 242 OR 243 TO BOLT THREAD PLUG REG FROM 320990310 INTO COIL...
  • Page 85 PIN, 3/16 COTTERLESS RING 680180000 HARNESS, FM, 3203PR(X) 361102001 MOUNTING BRACKET, OMNEX PENDANT PLUG 320988013 SHIP KIT, 3203 PR/PRX, FM 320988004 DECAL LAYOUT, 3203 366159000 SCREW HX HD 3/8-16UNC X 1 1/2 LG GR8 320338002 CABLE ASS'Y, 7/32" x 62FT, THIMBLE END...

  • Page 86: Fm Control Use & Care

    FM CONTROL USE AND CARE TRANSMITTER LAYOUT There is a red light to the left of the ON/OFF Toggle switch and a yellow light to the right. As the battery runs down, the red light will begin to flash as well as the yellow light. If the yellow light is rapidly flashing this indicates that the unit is transmitting.
  • Page 87 TRANSMITTER - P/N: 460157000 FM CONTROL...
  • Page 88 3203PR/PRX ELECTRICAL SCHEMATIC P/N: 680180000 (WHT/BLK) (BLK) A (GREY PLUG) PUMP GROUND (RED) POWER W/LINK POWER EXTEND (GRN/BLK) RETRACT (ORG/BLK) (WHT) (ORG) (WHT/RED) (GRN) B (BLACK PLUG) (RED/BLK) ROTATE CW (WHT) ROTATE CCW WINCH UP WINCH DOWN BOOM UP BOOM DOWN (BLU) PEND (A) PEND (B)
  • Page 89 3203EH TROUBLESHOOTING CHART CRANE DOES NOT OPERATE DOES THE LED CORRECTLY LIGHTS SHOW NOR- MAL OPERATION ON TRANSMITTER (REF PAGE DOES THE LED LIGHTS SHOW NOR- THIS A FM MAL OPERATION ON GO TO TRANSMITTER CRANE RECEIVER TROUBLE SHOOTING SEC- (REF PAGE 83) TION—PAGE GO TO RECEIVER TROUBLE...
  • Page 90 3203EH ELECTRICAL TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE DIAGNOSIS SOLUTION CRANE OPERATES DAMAGED TOGGLE SWITCH TURN OFF OR UNPLUG PENDANT. SEE VERIFY THAT NOTHING WAS ACTIVATING TOGGLE UNEXPECTADLY IF MOVEMENT STOPS SWITCH AT TIME OF MOVEMENT. IF NOT ACTI- VATED THEN REPLACE SWITCH SHORT IN HARNESS UNEXPECTED MOVEMENT WOULD TRACE WIRE BACK TO 1/4 TURN BAYONET PLUG.
  • Page 91 FM CONTROL TRANSMITTER TROUBLESHOOTING Tether connection detected Low battery. Unit will run approximately 10 hours after Battery light starts flashing. Flashing rapidly for 10 seconds indicates a transmitter failure. Normal Operation The Active light will flash several times per second, indicating that the transmitter is sending signals to the receiver.
  • Page 92 FM CONTROL RECEIVER TROUBLESHOOTING Normal Operation ESTOP FAULT LINK STATUS Transmitter is OFF If the transmitter is off, the receiver is operating properly. Transmitter is ON ESTOP FAULT LINK STATUS When the transmitter is turned on, the Link light (fast flashing) and E-Stop (GREEN) indicates the receiver is operating properly Transmitter is in Operation ESTOP...
  • Page 93 FM CONTROL RECEIVER TROUBLESHOOTING Test the Receiver—R160 OK state: Start Status—GREEN Initial Condition: Link—RED What is the state Turn transmitter off (all lights are off—press Fault—OFF of the lights on [POWER] OFF) E-Stop—RED the receiver? Cycle power to receiver (turn off and back on) Note: If there is a short to ground on an output, it is not indicated at this stage.
  • Page 94 FM CONTROL TRANSMITTER TROUBLESHOOTING Test the Transmitter—T150 Turn off the receiver Ensure there are good batteries in the transmitter Turn on the transmitter OK state: Active light—steady for Activate a What is the state of about 3 seconds then function the lights? goes to fast flash.
  • Page 95 FM CONTROL TROUBLESHOOTING CHART 3 Testing the Transmitter / Receiver Communication Transmitter: Transmitter: Active light is flashing Active light is flashing Receiver: What is the status of Receiver: Status—GREEN the lights of both the Status—GREEN Link—RED transmitter and Link—Flashing GREEN Fault—OFF receiver? Fault—OFF...
  • Page 96 3203EH HYDRAULIC TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE DIAGNOSIS SOLUTION CRANE MOVES JAMMED CARTRIDGE TRY TO MANUALLY OVERRIDE VALVE REPLACE CARTRIDGE UNEXPECTEDLY IF UNABLE TO MOVE STEM. CARTRIDGE IS JAMMED COUNTER-BALANCE SET ADJUST THE COUNTER-BALANCE OUT CONTACT AUTOCRANE FOR PROPER SETTING TOO LOW (BOOM-UP &...
  • Page 97 3203EH MANUAL OVERRIDE PROCEDURE MANUAL OVERRIDE PROCEDURES 1. APPLY 12VDC FROM BATTERY TO PUMP POWER TERMINAL 2. APPLY GROUND FROM BATTERY TO GROUNDING CONNECTION 3. SELECT THE FUNCTION DESIRED, THEN PUSH IN OVERRIDE LOCATED ON THE END OF THE COIL USING A PUNCH OR OTHER SMALL OBJECT CAUTION: MANUALLY OVERRIDING CRANE BYPASSES ALL SAFETY FEATURES.
  • Page 98 FM CONTROL ID CODE PROGRAMMING Download ID Code (Use in case of Link Test failure) !!Caution!! Note: Before attempting reprogramming with another transmitter, understand that re- programming the receiver with another transmitter, could result in two receivers on the job site responding to the one transmitter.
  • Page 99 ID CODE PROGRAMMING (CONT.) FM CONTROL 3. Power Transmitter into Configuration Mode A. Press & hold [BOOM] switch in the UP position B. Press & release [POWER] switch in the OFF position C. Release [BOOM] switch The ACTIVE LED will flash once per second. 4.
  • Page 100 NOTES...
  • Page 101 PREVENTATIVE MAINTENANCE PAINT FINISH PREVENTIVE MAINTENANCE INSTRUCTIONS The paint finish on Auto Crane products can become damaged during normal use when chipped, scratched, exposed to harsh chemicals, cleaned with high pressure washers, etc. During periods when the truck is exposed to salt or other corrosive chemicals, Auto Crane products should be washed weekly.

  • Page 102: Load Chart

    3203PR/PRX LOAD CHART P/N: 320988005 3203PR 3203PRX 2200 NOTE: WEIGHT OF LOAD HANDLING DEVICES ARE PART OF 1345 THE LOAD AND MUST BE DEDUCTED FROM THE CAPACITY. 2860 1670 1215 3200 75° 2500 60° 1000 1820 45° ATTENTION! 1520 30° OVER 1600 LBS USE DOUBLE LINE 1395...

  • Page 103: Conversion To Single Line

    3203PR/PRX CONVERSION TO SINGLE LINE The following pertains to the purchase of the kit for Single Line 3203 Cranes. Instructions and decals are provided for conversion to single line cranes SINGLE LINE KIT , 3203 P/N: 320988015 ITEM NO. PART NO. DESCRIPTION 320988011 3203EH SINGLE LINE INSTRUCTIONS...
  • Page 104 3203PR/PRX CONVERSION TO SINGLE LINE CONVERTING TO SINGLE LINE ON 3203EH CRANES 1. REMOVE HOOK FROM TRAVELING BLOCK BY REMOVING PIN 2. REMOVE TRAVELING BLOCK FROM ROPE 3. DISCONNECT THE ROPE FROM THE CROWN BY REMOVING PIN 4. PIVOT SINGLE LINE BARS 180 DEGREES THEN ATTACH HOOK TO THE BARS USING THE PIN REMOVED IN STEP 1 5.
  • Page 105 3203PR/PRX LOAD CHART SINGLE LINE P/N: 320988010 3203PR 3203PRX 1600 NOTE: WEIGHT OF LOAD HANDLING DEVICES ARE PART OF 1345 THE LOAD AND MUST BE DEDUCTED FROM THE CAPACITY. 1600 1600 1215 1600 75° 1600 60° 1000 1600 45° ATTENTION! 1520 30°...
  • Page 107 Auto Crane makes no warranty in respect to component accessories, it being subject to the warranties of their respective manufacturers. If field service, at the request of the distributor, is rendered and fault is found not to be with Auto Crane’s product, the distributor shall pay the time and expense of the field representative.
  • Page 108 Auto Crane will not assume responsibility or liability for any modifi cations or changes made to unit, or installation of component parts without authorization. Auto Crane Company issues a limited warranty certifi - cate with each unit sold. See last page for warranty.

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