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Auto Crane 3203 PR: 3203 PRX 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
Manual No. 320950000
Rev. 4/22/09
Phone (918) 836-0463
Fax (918) 834-5979
http://www.autocrane.com

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  • Page 1 3203 PR/PRX/PRFX OWNERS MANUAL Manual No. 320950000 Rev. 4/22/09 Serial No. __________________ Mailing Address: P.O. Box 580697 Tulsa, OK 74158-0697 Physical Address: Phone (918) 836-0463 4707 N. Mingo Rd. Fax (918) 834-5979 Tulsa, OK 74117-5904 http://www.autocrane.com...
  • Page 3 Serial No.: Date Product Delivered: Date Processed:* VIN # * For Auto Crane use only ONE REGISTRATION FORM PER UNIT (CRANE OR BODY) Registration form must be mailed or faxed within 15 days of customer installation. Mail to: Warranty Department Auto Crane Company P.O.
  • Page 5 1. The information contained in this manual is in effect at the time of this printing. It does not cover all instructions, configurations, accessories, etc. If you require additional information, please contact Auto Crane Company at (918) 836-0463. 2. Auto Crane Company reserves the right to update this material without notice or obligation.
  • Page 7 ♦ 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 9: Table Of Contents

    3203 PR/PRX/PRFX TABLE OF CONTENTS INTRODUCTION 1-1.0 GENERAL SPECIFICATIONS 1-3.0 SAFETY TIPS AND PRECAUTIONS 2-1.0 OPERATING PRACTICES & WARNINGS 2-3.0 QUALIFICATIONS FOR OPERATORS 2-4.0 OPERATION OF UNIT / OUTRIGGERS 2-7.0 INSPECTION 3-1.0 TESTING 3-4.0 MAINTENANCE 3-5.0 BATTERIES 3-7.0 LUBRICATION AND MAINTENANCE SCHEDULE 3-9.0 SAFETY DECAL SECTION 4-1.0...

  • Page 11: Introduction

    The operator should If, through no fault of Auto Crane Company, it exercise care when loading the vehicle. is necessary to send an experienced factory Distributing the payload on the vehicle...
  • Page 12 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. 1-2.0...

  • Page 13: General Specifications

    3203PR/PRX GENERAL SPECIFICATIONS DIMENSIONS REACH Width: 20.63 in (0.52 m) Second boom will reach from 7 feet 4 inches to 11 feet 4 inches. Height: 24.00 in (0.60 m) Third boom will reach from 11 feet 4 inches to 15 feet 4 inches. Length: 15 ft 4 in (4.68 m) [boom(s) stored]...

  • Page 14: 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 15 --- IMPORTANT --- SAFETY TIPS AND PRECAUTIONS 31. Always store the crane in its stowed position WARNING: Never attempt to lift, drag, tow or for transportation. pull a load from the side. The boom can fail far below its rated capacity. 32.

  • Page 16: Operating Practices & Warnings

    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. 2-3.0...

  • Page 17: Qualifications For Operators

    QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE QUALIFICATION REQUIREMENTS tests may be required to determine these OPERATORS conditions. 1. Crane operation shall be limited to personnel 5. Operators and operator trainees should have with the following minimum qualifications: normal depth perception, coordination, and no tendencies to dizziness or similar undesirable...
  • Page 18 QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES or neutral position and all personnel are in the C. Means are provided to hold the vehicle clear. stationary while operating the crane. 6. If power fails during operation, the operator shall: D.
  • Page 19 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 pass under a suspended load. overhead lines, because they can move horizontally or vertically due to wind, moving the 4.

  • Page 20: Operation Of Unit / Outriggers

    --- IMPORTANT --- OPERATION OF UNIT 1. Make sure this manual has been thoroughly 8. Always boom up before rotating so the boom will read by all crane operating personnel and clear the required boom support. supervisors. 9. When extending the boom, always maintain 2.

  • Page 21: Inspection

    INSPECTION REQUIREMENTS REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE INSPECTION REQUIREMENTS INSPECTION CLASSIFICATION 3. Inspect safety devices for malfunction. 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 extensively repaired cranes shall be inspected by a 5.
  • Page 22 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 23 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 24: 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 25 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 26 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 27: Maintenance

    MAINTENANCE OF BATTERIES Maintenance of Auto Crane unit batteries differs deterioration of the remaining parts of the very little from the generally prescribed battery. maintenance of any lead acid battery. All batteries Keep A Relatively Clean Battery must be kept properly charged, properly filled with water, and relatively clean.
  • Page 28 MAINTENANCE OF BATTERIES If, after charging, it is noted that the specific gravity 2. Place the battery on charge according to the reading of one cell is 30 points less than any of the manufacturer's instructions. other cells, it may be assumed that the cell is bad and that the battery should be replaced.
  • Page 29 3203PR/PRX LUBRICATION & MAINTENANCE SCHEDULE SERVICE DAY WKLY 3 MOS 6 MOS YEAR NOTES PERFORMED INSPECT HOOK & LATCH FOR DEFORMATION, LOAD HOOK CRACKS, & CORROSION MAKE SURE CABLE IS WOUND EVENLY ON CABLE DRUM DRUM HOIST / BOOM CHECK FOR FLATTENING, KINKS, & BROKEN CABLE STRANDS, SEE MANUAL HYD.

  • Page 30: Lubrication And Maintenance Schedule

    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 31: Safety Decal Section

    3203PR/PRX SAFETY DECAL SECTION PART NO.: 040579000 DECAL: OPERATING INSTRUCTIONS 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: OPERATING TRAINING FUNCTION: To inform the operator of the need to...
  • Page 32 3203PR/PRX SAFETY DECAL SECTION PART NO.: 040529000 DECAL: ELECTROCUTION HAZARD 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 33 3203PR/PRX SAFETY DECAL SECTION PART NO.: 040587000 USED ON: All cranes equipped with a load sensor. DECAL: LOAD SENSOR, DON'T TAMPER QUANTITY: 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 hazardous situation.
  • Page 34 NOTES...
  • Page 35 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 UNIT follow the saftey precautions may result in equipment failure or serious personal injury.
  • Page 36 3203PR/PRX DECAL LAYOUT P/N: 320988004 17 FRONT OF RESERVOIR 4-5.0 10/16/06...
  • Page 37 DECAL OPERATION INSTRUCTIONS 040580000 DECAL TRAINED OPERATOR 040587000 DECAL WARNING LOAD SENSOR 330622000 DECAL SERIAL NO 040619001 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 38: General Dimensions

    3203PR/PRX GENERAL DIMENSIONS NOTE: CG IS APPROXIMATE 5-1.0 10/16/06...

  • Page 39: 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)
  • Page 40 3203PR GENERAL ASSEMBLY HARDWIRED – P/N: 320988003 APPLY LOCTITE 242 OR 243 TO THREADS OF BOLTS 7 6 10 6-1.0 10/16/06...

  • Page 41: Pedestal Assembly

    3203PR GENERAL ASSEMBLY HARDWIRED – P/N: 320988003 ITEM NO. QTY. PART NO. DESCRIPTION 320988200 PEDESTAL ASSEMBLY, 3203 PR 320988101 BOOM ASSY 3203 PR 404220000 PIN WDMT BOOM/PED 320824000 PIN, LIFT CYLINDER 239300000 ZERK, GREASE 021200000 WASHER FL 3/8 021100000 WASHER SP LK 3/8 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8 009109000...
  • Page 42 3203PRX GENERAL ASSEMBLY HARDWIRED – P/N: 320988002 APPLY LOCTITE 242 OR 243 TO THREADS OF BOLTS 7 6 10 6-3.0 10/16/06...
  • Page 43 3203PRX GENERAL ASSEMBLY HARDWIRED – P/N: 320988002 ITEM NO. QTY. PART NO. DESCRIPTION 320988201 PEDESTAL ASSEMBLY, 3203 PRX 320988100 BOOM ASSY 3203 PRX 404220000 PIN WDMT BOOM/PED 320824000 PIN, LIFT CYLINDER 239300000 ZERK, GREASE 021200000 WASHER FL 3/8 021100000 WASHER SP LK 3/8 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8 009109000...
  • Page 44 3203PRFX GENERAL ASSEMBLY HARDWIRED – P/N: 320990001 6-4.1 4/22/09...
  • Page 45 3203PRFX GENERAL ASSEMBLY HARDWIRED – P/N: 320990001 ITEM NO. QTY. PART NO. DESCRIPTION 320990200 PEDESTAL ASSEMBLY, 3203 PRFX 320990100 BOOM ASSY 3203PRFX 404220000 PIN W DMT BOOM/PED 320824000 PIN, LIFT CYLINDER 239300000 ZERK, GREASE 021200000 W ASHER FL 3/8 021100000 W ASHER SP LK 3/8 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8...
  • Page 46 3203PR PEDESTAL ASSEMBLY P/N: 320988200 ATTACH GROUND CABLE 26 30 28 40 ATTACH GROUND CABLES FROM: HOIST (600317) PUMP (600318) RELAY PANEL (BLACK WIRE) 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 6-5.0...
  • Page 47 3203PR PEDESTAL ASSEMBLY P/N: 320988200 30 26 53 27 21 28 ATTACH GROUND CABLE 6-6.0 10/16/06...
  • Page 48 3203PR PEDESTAL ASSEMBLY P/N: 320988200 ITEM NO. QTY. PART NO. DESCRIPTION 320988210 PEDESTAL WELDMENT, 3203 404193000 BASE WLDMNT, 4004 110703 WINCH ASSEMBLY 340602000 KEY, 3/4 SQ X 1 320878000 ROTATION BEARING 320988253 GEAR, WORM, 4.00 ID, .75 KEY, 3203 320879000 SPACER, ROTATION 330486000 SEAL, OIL...
  • Page 49 3203PR PEDESTAL ASSEMBLY P/N: 320988200 ITEM NO. QTY. PART NO. DESCRIPTION 320827000 VALVE ASSEMBLY PR 404213000 SEAL, 2.50 OD X 1.5 ID 320858000 BEARING, SPHERICAL 1.00 ID 404028000 RETAINING RING, SNAP RING 320845000 CYLINDER, LIFT 320824000 PIN, LIFT CYLINDER 480024000 MOUNT PENDANT CABLE RETAINER 320988254 PRESSURE SWITCH, NC, 2100 PSI, 10 AMP...
  • Page 50 3203PRX PEDESTAL ASSEMBLY P/N: 320988201 ATTAC H GR OU N D C ABLE 26 30 28 40 ATTAC H GR OU N D C ABLES FR OM: H OIST (600317) PU MP (600318) R ELAY PAN EL (BLAC K W IR E) HYDRAULICS: PORT A-1 RETRACT PORT A-2 BOOM DOWN...
  • Page 51 3203PRX PEDESTAL ASSEMBLY P/N: 320988201 21 28 ATTACH GROUND CABLE 6-10.0 10/16/06...
  • Page 52 3203PRX PEDESTAL ASSEMBLY P/N: 320988201 ITEM NO. QTY. PART NO. DESCRIPTION 320988210 PEDESTAL WELDMENT, 3203 404193000 BASE WLDMNT, 4004 110703 WINCH ASSEMBLY 340602000 KEY, 3/4 SQ X 1 320878000 ROTATION BEARING 320988253 GEAR, WORM, 4.00 ID, .75 KEY, 3203 320879000 SPACER, ROTATION 330486000 SEAL, OIL...
  • Page 53 3203PRX PEDESTAL ASSEMBLY P/N: 320988201 ITEM NO. QTY. PART NO. DESCRIPTION 404213000 SEAL, 2.50 OD X 1.5 ID 320858000 BEARING, SPHERICAL 1.00 ID 404028000 RETAINING RING, SNAP RING 320845000 CYLINDER, LIFT 320824000 PIN, LIFT CYLINDER 480024000 MOUNT PENDANT CABLE RETAINER 320917000 PRESSURE SWITCH, NC, 1900 PSI, 10 AMP 200876000...
  • Page 54 3203PRFX PEDESTAL ASSEMBLY P/N: 320990200 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 6-12.1 4/22/09...
  • Page 55 3203PRFX PEDESTAL ASSEMBLY P/N: 320990200 6-12.2 4/22/09...
  • Page 56 3203PRFX PEDESTAL ASSEMBLY P/N: 320990200 ITEM NO. QTY. PART NO. DESCRIPTION 404187000 SPRING PLATE, GROUND BRUSH, 4004 320988264 LOW ER VALVE BRACKET, 3203 PRX 404199000 UPPER VALVE BRACKET, 4004 404201000 COVER, VALVE, 4004 / 3203 320988258 UPPER TWECO BRACKET WLDMT, 3203 404193000 BASE WLDMNT, 4004 320988210 PEDESTAL WELDMENT, 3203 PR / PRX / H 110703...
  • Page 57 3203PRFX PEDESTAL ASSEMBLY P/N: 320990200 ITEM NO. QTY. PART NO. DESCRIPTION 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8 330252000 SCREW HX HD 5/16-18UNC X 3/4 LG GR5 330372000 NUT HX 3/8-16UNC 002900000 SCREW SET 0.25-20 X 0.25 006200000 SCREW HX HD 1/4-20UNC X 1 1/4 LG 404028000 RETAINING RING, SNAP RING...
  • Page 58 3203PR BOOM ASSEMBLY P/N: 320988101 6-13.0 10/16/06...
  • Page 59 3203PR BOOM ASSEMBLY P/N: 320988101 ITEM NO. QTY. PART NO. DESCRIPTION 320988110 LOWER BOOM WELDMENT, 3203 320988120 MID BOOM WLDMNT, 3203 320988130 UPPER BOOM WLDMT 3203 320988155 BOOM PAD 4.75 X 2.50 X .50, 3203 404205000 CORD REEL ASSY 239000000 ZERK DRIVE GR 320858000 BEARING, SPHERICAL 1.00 ID 320888000 RETAINER, EXTENSION CYLINDER 366201000 WEAR PAD 3 .75 X 2.00 X .313...
  • Page 60 3203PRX BOOM ASSEMBLY P/N: 320988100 CYLINDER SEAL KIT: 320835002 C’BAL CARTRIDGE: 480188000 6-15.0 10/16/06...
  • Page 61 3203PRX BOOM ASSEMBLY P/N: 320988100 ITEM NO. QTY. PART NO. DESCRIPTION 320988110 LOWER BOOM WELDMENT, 3203 320988120 MID BOOM WLDMNT, 3203 320988130 UPPER BOOM WLDMT 3203 320988155 BOOM PAD 4.75 X 2.50 X .50, 3203 320988142 EXTENSION CYLINDER, 3203 320988115 PIN 1 DIA X 6.905 LG, 3203 404205000 CORD REEL ASSY 023900000 ZERK DRIVE GR 320858000 BEARING, SPHERICAL 1.00 ID...
  • Page 62 3203PRFX BOOM ASSEMBLY P/N: 320990100 CYLINDER SEAL KIT: 320988146 C’BAL CARTRIDGE: 480188000 6-16.1 4/22/09...
  • Page 63 3203PRFX BOOM ASSEMBLY P/N: 320990100 ITEM NO. QTY. PART NO. DESCRIPTION CYLINDER, TELESCOPIC, 48" FIRST STAGE, 48" 320988145 SECOND STAGE, 3-3/8 OD 320990110 LOWER BOOM WELDMENT, 3203PRFX 320990120 MID BOOM WLDMNT, 3203PRFX 320990130 UPPER BOOM WLDMT 3203PRFX 738732000 PIN 1n X 4.063 LG 320988115 PIN 1 DIA X 6.905 LG, 3203 239000000 ZERK DRIVE GR 320858000 BEARING, SPHERICAL 1.00 ID...
  • Page 64 NOTES...
  • Page 65 3203PR/PRX HOIST ASSEMBLY P/N: 110703 ITEM NO. QTY. PART NO. DESCRIPTION 320836000 WINCH MOUNTING BRACKET CS 320837000 WINCH MOUNTING BRACKET SS 320838000 WINCH TIE BAR 320838001 WINCH TIE BAR, FRONT 320887000 BEARING, BRONZE 320379000 DRUM 020601000 WASHER SP LK 5/16 007804000 SCREW HX HD 5/16-18UNC X 1 1/4 LG CP 412003...
  • Page 66 3203PR/PRX HOIST ACTUATOR 6-18.0 4/24/10...
  • 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 334129 GEAR PINION 338007 HOUSING BRAKE 338203...
  • Page 68 3203PR/PRX HOIST ACTUATOR ITEM NO. QTY. PART NO. DESCRIPTION 442189 GASKET BRAKE COVER 450001 KEY WOODRUFF 456008 FITTING RELIEF 458071 MOTOR 12V 462015 O-RING 1" OD X 1/8 THK 468002 REDUCER -6NPT/-2NPT 468010 PLUG PIPE -4NPT SQ HD 468018 PLUG PIPE -6NPT HX SOC HEADLESS 468024 REDUCER -4NPT/-2NPT 470001...
  • Page 69 3203 TRAVELING BLOCK ASSEMBLY P/N: 320433000 ITEM NO. QTY. PART NO. DESCRIPTION 100309000 SWIVEL HOOK ASSY W/LATCH 320403000 SIDE PLATE, 3203 200909000 SHEAVE ASSEMBLY 320404000 BLOCK TRAVELING 320434001 PIN TRAVELING BLOCK 018200000 NUT HX NY LK 5/8-11UNC 013512000 SCREW HX HD 5/8-11UNC X 3 1/2 LG 366813000 PIN HITCH 360124001...
  • Page 70 NOTES...
  • Page 71 3203PR/PRX RELAY PANEL ASSEMBLY P/N: 320988300 5 4 PLCS REF FOR REPLACEMENT PART ONLY (680178000) RECEPTACLE W/WIRE PIGTAIL ITEM NO. QTY. PART NO. DESCRIPTION 320988256 BULKHEAD ELECTRICAL PLATE 320589000 RELAY, HOIST 320584000 RELAY, POWER UNIT 320988399 TERMINAL STRIP 9 736272000 NUTSERT 1/4-20UNC X .027-.165 GRIP 320562000 RECEPTACLE, 11 PIN, 1/4 TURN, BAYONET...
  • Page 72 3203PR/PRX ELECTRICAL SCHEMATIC P/N: 320988300 TO HOIST 'F2' TO HOIST 'F1' TO TWECO TO HOIST 'A' TO PUMP GRND GRND TO PEDESTAL GRND BM EXT GRND PANEL BM RET GRND BM DN BM UP GRND P. SW (N.C.) GRND (N.C.) 7-2.0 10/16/06...
  • 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 WHITE WHITE RED/WHITE BLUE/WHITE WHITE WHITE/RED WHITE WHITE 320988331 BLACK 320988332 BLACK 320988333 BLACK...
  • Page 74 3203PR/PRX PENDANT ASSEMBLY P/N: 681179000 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 7-3.0 10/16/06...
  • Page 75 3203PR/PRX PENDANT ASSEMBLY P/N: 681179000 ITEM NO. QTY. PART NO. 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 480598000 COVER TRIGGER OPENING 750090000 TOGGLE SWITCH (ON-OFF) 634200000 TOGGLE SWITCH KIT 640300000...
  • Page 76 NOTES...
  • Page 77 3203PR/PRX TWECO W/SWITCH MOUNT P/N: 404218000 ITEM NO. QTY. PART NO. DESCRIPTION 404217000 LOWER TWECO WELD WITH SWITCH MOUNT 404224000 CABLE ASSY 11 IN, TWECO TO TERMINAL 002900 SCREW SET 1/4-20UNC X 1/4 LG 404216000 MASTER SWITCH 404219000 DECAL, CRANE POWER 7-5.0 10/16/06...
  • Page 78 3203PR HYDRAULIC CONTROL VALVE P/N: 320827000 INSIDE PORT ON POWER UNIT (PRESSURE) BOOM DOWN MOTOR BOOM UP PORT PORT (CW) (EXT) BOOM DOWN BOOM UP COIL COIL ROTATE CCW ROTATE CW COIL COIL TO REAR (BOTTOM) MOTOR PORT (CCW) TO FRONT (TOP) MOTOR PORT (CW) TO OUTSIDE PORT ON POWER UNIT (RETURN)
  • Page 79 3203PRX HYDRAULIC CONTROL VALVE P/N: 320826000 INSIDE PORT ON POWER UNIT (PRESSURE) RETRACT PORT EXTEND PORT (RET) (EXT) RETRACT COIL EXTEND COIL BOOM DOWN BOOM UP COIL COIL ROTATE CCW ROTATE CW COIL COIL BOOM UP PORT BOOM DOWN (EXT) PORT (RET) TO REAR (BOTTOM) MOTOR PORT (CCW)
  • Page 80 3203 POWER UNIT P/N: 320825000 ITEM NO. QTY. PART NO. DESCRIPTION 320825001 RESERVOIR KIT 200545000 BREATHER CAP 320825002 RELIEF VALVE KIT 320335005 MOTOR 320336005 RETURN PORT PLUG KIT 320825003 ADAPTOR KIT 320335003 PUMP KIT 320335010 O-RING 8-3.0 10/16/06...
  • Page 81 3203 POWER UNIT P/N: 320825100 ITEM NO. QTY. PART NO. DESCRIPTION 320825110 RESERVOIR KIT 200545000 BREATHER CAP 320825002 RELIEF VALVE KIT 320335005 MOTOR 320336005 RETURN PORT PLUG KIT 320825003 ADAPTOR KIT 320335003 PUMP KIT 320335010 O-RING 8-4.0 4/22/09...
  • Page 82 3203PR GENERAL ASSEMBLY FM – P/N: 320988001 APPLY LOCTITE 242 OR 243 TO THREADS OF BOLTS 7 6 13 9-1.0 10/16/06...
  • Page 83 3203PR GENERAL ASSEMBLY FM – P/N: 320988001 ITEM NO. QTY. PART NO. DESCRIPTION 320988200 PEDESTAL ASSEMBLY, 3203 PR 320988101 BOOM ASSY 3203 PR 404220000 PIN WDMT BOOM/PED 320824000 PIN, LIFT CYLINDER 239300000 ZERK, GREASE 021200000 WASHER FL 3/8 021100000 WASHER SP LK 3/8 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8 460158000...
  • Page 84 3203PRX GENERAL ASSEMBLY FM – P/N: 320988000 APPLY LOCTITE 242 OR 243 TO THREADS OF BOLTS 7 6 13 9-3.0 10/16/06...
  • Page 85 3203PRX GENERAL ASSEMBLY FM – P/N: 320988000 ITEM NO. QTY. PART NO. DESCRIPTION 320988201 PEDESTAL ASSEMBLY, 3203 PRX 320988100 BOOM ASSY 3203 PRX 404220000 PIN WDMT BOOM/PED 320824000 PIN, LIFT CYLINDER 239300000 ZERK, GREASE 021200000 WASHER FL 3/8 021100000 WASHER SP LK 3/8 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8 460158000...
  • Page 86 3203PRFX GENERAL ASSEMBLY FM – P/N: 320990000 9-5.0 4/22/09...
  • Page 87 3203PRFX GENERAL ASSEMBLY FM – P/N: 320990000 ITEM NO. QTY. PART NO. DESCRIPTION 320990200 PEDESTAL ASSEMBLY, 3203 PRFX 320990100 BOOM ASSY 3203PRFX 404220000 PIN WDMT BOOM/PED 320824000 PIN, LIFT CYLINDER 239300000 ZERK, GREASE 021200000 WASHER FL 3/8 021100000 WASHER SP LK 3/8 330371000 SCREW HX HD 3/8-16UNC X 1 LG GR8 460158000...
  • Page 88 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 89 FM CONTROL TRANSMITTER - P/N: 460157000 ITEM NO. QTY. PART NO. DESCRIPTION 460166000 TOGGLE SWITCH KIT (OMNEX) 460168000 HANDLE, TRANSMITTER W/O TRIGGER 460163000 COVER, TRANSMITTER BATTERY W/MAGNET 460162000 GUARD, TRIGGER (OMNEX) TOGGLE SWITCH WIRING CHART FUNCTION WIRE COLOR TERMINAL POSITION POWER ON YELLOW BOTTOM...
  • Page 90 NOTES...
  • Page 91 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 ROTATE CCW (WHT) WINCH UP WINCH DOWN BOOM UP BOOM DOWN (BLU) PEND (A) PEND (B)
  • Page 92 FM CONTROL TRANSMITTER DIAGNOSTICS YELLOW YELLOW Tether connection detected YELLOW Low battery. Unit will run approximately 10 hours after Battery light starts flashing. Flashing rapidly for 10 seconds indicates a transmitter failure. Normal Operation YELLOW The Active light will flash several times per second, indicating that the transmitter is sending signals to the receiver.
  • Page 93 FM CONTROL RECEIVER DIAGNOSTICS Normal Operation ESTOP FAULT LINK STATUS Transmitter is OFF If the transmitter is off, the receiver is operating properly. Transmitter is ON 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 When a function is activated on the transmitter, the Fault light will turn on GREEN.
  • Page 94 FM CONTROL TROUBLESHOOTING CHART 1 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 95 FM CONTROL TROUBLESHOOTING CHART 2 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 96 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 97 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. If the original transmitter was sent in for repair, disconnect the receiver (disconnect connector A) to continue using the machine without remote capability and without fear of inadvertently operating the machine with Connector A...
  • Page 98 FM CONTROL ID CODE PROGRAMMING (CONT.) 3. Power Transmitter into Configuration Mode A. Press & hold [BOOM] switch in the UP position YELLOW YELLOW YELLOW B. Press & release [POWER] switch in the OFF position C. Release [BOOM] switch The ACTIVE LED will flash once per second. 4.
  • Page 99 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 100 NOTES...
  • Page 101 2 YEAR PARTS AND LABOR Auto Crane will warranty to the consumer for a period of (2) years parts and labor from the date of purchase. Each new Auto Crane unit they sell will be free under normal use and service from defects in material and workmanship.

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