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Auto Crane 3203 PR Owner's Manual

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3203 PR/PRX/
PRD/PRXD
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. 9/2/2003
Phone (918) 836-0463
Fax (918) 834-5979
http://www.autocrane.com

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  • Page 1 3203 PR/PRX/ PRD/PRXD OWNERS MANUAL Manual No. 320950000 Rev. 9/2/2003 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 2 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 3 3203 PR PRX PRD PRXD SERIES OWNER’S MANUAL – REVISION RECORD Section(s) Revision Description of Change Date Page(s) 09/02/03 Last page New 2-year warranty policy to replace 1-year warranty policy...
  • Page 4 ♦ 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 5: Table Of Contents

    TABLE OF CONTENTS 3203 PR/PRX SERIES INTRODUCTION 1-1.0.0 OPERATING PRACTICES & WARNINGS 2-1.0.0 OPERATION OF UNIT / OUTRIGGERS 2-4.0.0 CONTROLLER OPERATION 2-5.0.0 QUALIFICATIONS FOR OPERATORS 2-7.0.0 INSPECTION, TESTING, & MAINTENANCE 2-10.0.0 DECAL SECTION 2-15.0.0 GENERAL DIMENSIONS 3-1.0.0 GENERAL SPECS. 3-2.0.0 MOUNTING AND INSTALLATION 3-3.0.0...

  • Page 6: Introduction

    For your convenience the overall dimensions into the solution of an equipment problem. If, of the 3203 PR/PRX Series crane are included on through no fault of Auto Crane Company, it is the General Dimension Drawing. Rotation and necessary to send an experienced factory turning radius are also listed on that drawing.

  • Page 7: Operating Practices & Warnings

    Contact your local Distributor or the contacting electric lines. Do not use crane within 10 Auto Crane factory if any questions arise. feet (3.05m) of electric power lines carrying up to 50,000 volts. One foot additional clearance is required 3.
  • Page 8 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 9 --- IMPORTANT --- SAFETY TIPS AND PRECAUTIONS 31. Always store the crane in its stowed position for 41. Do not push down on anything with boom transportation. extensions, lift or outer boom function. 32. Remember the overall height of the entire unit for 42.

  • Page 10: Operation Of Unit / Outriggers

    Activate any area). crane power switches. For Auto Crane units 13. Return outriggers to stowed position. Make sure they requiring battery and hydraulic operation, engage are pinned in place or jacklegs are returned to emergency brake, place gear selector in neutral, compartment.

  • Page 11: Controller Operation

    CONTROLLER OPERATIONS 3203 SERIES Power: The power switch for both the hardwire pendants and the FM receiver is located on the rear of the relay panel which is on the street side of the crane. Transmitter Layout: The red light to the left of the Power On/Off button indicates low transmitter battery.
  • Page 12 CONTROLLER OPERATIONS 3203 SERIES The transmitter should be fully charged after approximately 6 to 8 hours of charging. It is not recommended to leave the transmitter charging for extended periods of time (3 or 4 days). Doing so will eventually degrade the battery and it will not keep a good charge. 2-6.0.0 05/22/2003...

  • Page 13: Qualifications For Operators

    QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES OPERATORS tendencies to dizziness or similar undesirable characteristics. 1. Crane operation shall be limited to personnel with 8. In addition to the above listed requirements, the the following minimum qualifications: operator shall: A.
  • Page 14 QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES The operator shall be familiar with the equipment 1. There is no sudden acceleration or deceleration of the moving load. and its proper care. If adjustments or repairs are necessary, the operator shall report the same 2.
  • Page 15 QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES MISCELLANEOUS 25. In transit with no load and boom lowered the clearance shall be specified in Table 1. OPERATING NEAR ELECTRICAL POWER 26. A qualified signalperson shall be assigned to LINES observe the clearance and give warning before approaching the above limits.

  • Page 16: Inspection, Testing, & Maintenance

    INSPECTION, TESTING AND MAINTENANCE GENERAL G. electrical apparatus for malfunctioning, signs of INSPECTION CLASSIFICATION excessive deterioration, dirt moisture accumulation 1. Initial inspection. Prior to initial use, all new, H. hydraulic system for proper oil level and leaks altered, modified or extensively repaired cranes daily shall be inspected by a designated person to insure compliance with provisions of this...
  • Page 17 INSPECTION, TESTING AND MAINTENANCE GENERAL 13. Hydraulic and pneumatic pumps and motors 19. A crane which has been idle for a period of inspection. over six months shall be given a complete inspection conforming with the initial-regular- A. loose bolts or fasteners frequent inspection requirements.
  • Page 18 INSPECTION, TESTING AND MAINTENANCE GENERAL 22. Test loads shall not exceed 110% of the 29. Repairs or replacements shall be provided as manufacturer's load ratings. needed for operation. 23. Written reports shall be maintained showing The following are examples: test procedures and confirming the adequacy A.
  • Page 19 INSPECTION, TESTING AND MAINTENANCE GENERAL B. Care shall be taken when inspecting sections ROPE REPLACEMENT of rapid deterioration such as flange points, crossover points, and repetitive pickup points 33. No precise rules can be given for determination on drums. of the exact time for replacement of rope, since 32.
  • Page 20 INSPECTION, TESTING AND MAINTENANCE GENERAL H. Replacement rope shall have a strength rating be cut to prevent unlaying of the strands. On at least as great as the original rope furnished pre-formed rope, one seizing on each side of or recommended by the crane manufacturer. the cut is required.

  • Page 21: Decal Section

    SAFETY DECAL SECTION 3203 SERIES 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:...
  • Page 22 SAFETY DECAL SECTION 3203 SERIES 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: Articulated & Stiff Boom Cranes QUANTITY: PLACEMENT: Both sides of end of lower boom PART NO.: 040517000 DECAL:...
  • Page 23 SAFETY DECAL SECTION 3203 SERIES 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: On the lift cylinder near the load sensor is pre-set and that tampering sensor with the sensor may cause potentially hazardous situation.
  • Page 24 DECAL STAY CLEAR OF BOOM 320321000 DECAL 3203 LOAD CHART 040587 DECAL WARNING LOAD SENSOR 330622 DECAL SERIAL NO 360034 DECAL AUTO CRANE LOGO 600047000 DECAL AUTO CRANE 040518 DECAL STAY CLEAR OF LOAD 320918000 DECAL 3203 HORIZONTAL 320318001 DECAL ANGLE IND RIGHT 2-17.0.0...

  • Page 25: General Dimensions

    GENERAL DIMENSIONS 3203 SERIES 11 1/2" 13/16" 16 3/4" 14 3/4" 14 1/8" DETAIL A 15'-1 3/4" 7" 11'-1 3/4" 13 1/2" 7'-2" 9 1/2" R18 3/4" 16 3/4" 8 1/4" 11" 2'-0" 3-1.0 2/2006...
  • Page 26 NOTES...

  • Page 27: 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) 3-3.0...
  • Page 28 MOUNTING AND INSTALLATION 3203 SERIES WARNING FEDERAL LAW (49 CFR PART 571) REQUIRES THAT THE FINAL STAGE MANUFACTURER OF A VEHICLE CERTIFY THAT HE 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.
  • Page 29 LUBRICATION & MAINTENANCE SCHEDULE 3203 SERIES SERVICE DAILY WEEKLY 3 MOS 6 MOS YEARLY NOTES PERFORMED INSPECT HOOK & LATCH FOR LOAD HOOK DEFORMATION, CRACKS, & CORROSION MAKE SURE CABLE IS WOUND CABLE DRUM EVENLY ON DRUM CHECK FOR FLATTENING, KINKS, & HOIST CABLE BROKEN STRANDS HYD.
  • Page 30 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: Pedestal Assembly

    PEDESTAL ASSEMBLY 3203 SERIES 37 36 33 47 CYLINDER SEAL KIT: 320845001 COUNTERBALANCE CARTRIDGE: 480188000 5-1.0.0 05/22/2003...
  • Page 32 PEDESTAL ASSEMBLY 3203 SERIES 5-2.0.0 05/22/2003...
  • Page 33 PEDESTAL ASSEMBLY 3203 SERIES ROTATION GEAR DETAIL 39 38 BRUSH/TWECO DETAIL 5-3.0.0 05/22/2003...
  • Page 34 PEDESTAL ASSEMBLY 3203 SERIES ITEM NO. QTY. PART NO. DESCRIPTION 320842000 BASE PLATE WELDMENT 320841000 PEDESTAL WELDMENT 320825000 POWER UNIT 110703 WINCH ASSEMBLY 320864000 RELAY PANEL ASSEMBLY 320870000 COVER, RELAY PANEL 320878000 ROTATION BEARING 320334 WORM GEAR 330472 CUP HOUSING W/CUPS 330420 WORM SHAFT 366440...
  • Page 35 PEDESTAL ASSEMBLY 3203 SERIES ITEM NO. QTY. PART NO. DESCRIPTION 021100 WASHER SPLK 3/8 330371 SCW HX 3/8 UNC X 1 GR8 011603 SCREW HEX .5-13 X 1.75 007401 SCW 5/16-18 X 1/2 LG 320917000 PRESSURE SWITCH, N.C. 1,900 PSI 200876 FITTING 6 SAE/6 JIC STRAIGHT 6F5OX 490198...
  • Page 36 NOTES...

  • Page 37: Boom Assembly

    BOOM ASSEMBLY 3203 SERIES 21 30 Cylinder Seal Kit - # 320835001 Counterbalance Cartridge - # 480188000 5-6.0.0 05/22/2003...
  • Page 38 BOOM ASSEMBLY 3203 SERIES ITEM NO. QTY. PART NO. DESCRIPTION 320831000 LOWER BOOM WELDMENT 320832000 MI D BOOM WELDMENT 320833000 UPPER BOOM WELDMENT 320871000 BAI L WELDMENT 320883000 SHEAVE ASSEMBLY I TEMS 6, 25 & 26 NOT USED ON PR MODELS 320835000 CYLI NDER, EXTENSI ON 320888000 RETAI NER EXTENSI ON CYLI NDER 360765000 WEAR PAD 2 .50 X 3 .25...
  • Page 39 HOIST ACTUATOR 3203 SERIES 38 65 5-8.0.0 05/22/2003...
  • Page 40 HOIST ACTUATOR 3203 SERIES QTY. ITEM PART NO. DESCRIPTION 360637 SPRING, FLAT 360331 PLATE, CAM 300041 COVER, GEAR HOUSING 300042 COVER, SPUR GEAR HOUSING 360450 COVER, BRAKE 300043 GEAR, IDLER 300044 GEAR, SPUR 300045 GEAR, WORM R.H. 300046 GEAR, PINION 360336 HOUSING, BRAKE 300047...
  • Page 41 HOIST ACTUATOR 3203 SERIES QTY. ITEM PART NO. DESCRIPTION 300068 O−RING 1" O.D. x 1/8 THICK 300069 REDUCER, −6 NPT / −2 NPT 300070 PLUG, PIPE −4 NPT SQ HD 300073 PLUG, PIPE −6 NPT HEX SOC HEADLESS 300074 REDUCER, −4 NPT / −2 NPT 300075 PIN, DOWEL 360364...

  • Page 42: General Assembly

    BOOM ASSEMBLY PRX/PRXD 320823000 PIVOT PIN 320824000 PIN, LIFT CYLINDER 320338 CABLE 320911000 DECAL LAYOUT 3203 320901000 SHIP KIT 3203 PR 320902000 SHIP KIT 3203 PRD 320915000 SHIP KIT 3203 PRX 320916000 SHIP KIT 3203 PRXD 021100 WASHER SPLK 3/8 008400...
  • Page 43 TRAVELING BLOCK 3203 SERIES ITEM DESCRIPTION ITEM DESCRIPTION 100309 SWIVEL HOOK 013512 360124 HITCH PIN 018200 NUT, HX HLF LK 5/8NC 320434 PIN, BLOCK 320404 BLOCK 320403 BLOCK, TRAVELING 330100 WASHER, FLAT 200909 SHEAVE ASSY 5-12.0.0 5/22/03...
  • Page 44 NOTES...

  • Page 45: Electrical Schematic

    ELECTRICAL SCHEMATICS 3203 SERIES GENERAL MACHINE SCHEMATIC (ORG) ROT CW (WHT/RED) ROT CW (ORG) (GRN/ ROT CCW (WHT/RED) ROT CCW BLK) EXTEND (GRN/BLK) RETRACT (ORG/BLK) (ORG/BLK) EXTEND PUMP (WHT/ BLK) RETRACT (YEL) BOOM UP (YEL) BOOM DOWN (BLU) PUMP (BLU) HOIST UP (GRN) HOIST DOWN (RED/BLK)
  • Page 46 ELECTRICAL SCHEMATICS 3203 SERIES CONTINUATION FROM PREVIOUS PAGE PUMP PUMP MOTOR HOIST MOTOR (BLK 6 GA) ARMATURE BATTERY TWECO 6-2.0.0 07/10/2003...
  • Page 47 ELECTRICAL SCHEMATICS 3203 SERIES HARDWIRE PENDANT SCHEMATIC PENDANT HEAD CW (ORG) CCW (WHT/RED) EXTEND (GRN/BLK) RETRACT (ORG/BLK) PUMP (WHT/BLK) BOOM UP (WHT) BOOM DN (BLU) HOIST UP (GRN) CANNON HOIST DN (RED/BLK) PLUG + (RED) NOTE: PRX MODEL DOES NOT HAVE EXTEND AND RETRACT SWITCH 6-3.0.0 07/10/2003...
  • Page 48 ELECTRICAL SCHEMATICS 3203 SERIES FM HARNESS SCHEMATIC (RS-232 Optional) (BLK) (GRN/WHT) (ORG/RED) (RED/WHT) P1 (GREY PLUG) (BLK/WHT) GROUND CAN H CAN L ATB SWITCH PROGRAM ID (BLU/BLK) BOOM LMT SW (BLU/RED) PRESS. SW. BAT. VOLTAGE (BLU/WHT) POWER(+) (RED) (WHT) (BLU) (ORG/BLK) P2 (BLACK PLUG) (GRN/BLK)

  • Page 49: Relay Panel Assembly

    RELAY PANEL ASSEMBLY 3203 SERIES BOOTS REQUIRED BOOTS REQUIRED A, C & D A & B ITEM NO. QTY. PART NO. DESCRIPTION 320919000 RELAY PANEL WELDMENT 320589 RELAY, HOIST 320584 RELAY, POWER UNIT 320355 RELAY, BOSCH 320804 MODIFIED TERMINAL STRIP 10 736272 NUTSERT .25UNC X .027-.165 GRIP 366095...
  • Page 50 RELAY PANEL ASSEMBLY 3203 SERIES FROM FROM END COLOR GAGE LENGTH TO END TO LABEL CANNON PLUG - A SOLDER YELLOW STRIP TERMINAL BLOCK - 15 DEUTSCH CONTACT - 0462-201- DEUTSCH DT06-2S, PIN - 1, VALVE TERMINAL BLOCK - 5 STRIP YELLOW 16141...
  • Page 51 RELAY PANEL ASSEMBLY 3203 SERIES FROM FROM END COLOR GAGE LENGTH TO END TO LABEL FEMALE SPADE (BOSCH HOIST RELAY - 2 FEMALE SPADE WHITE PLUG) BOSCH RELAY - 30 HOIST RELAY - 3 FEMALE SPADE WHITE 1/4" RING TERMINAL GROUND HOIST RELAY - A 5/16"...
  • Page 52 NOTES...
  • Page 53 HYDRAULIC CONTROL VALVE 3203 SERIES INSIDE PORT ON POWER UNIT (PRESSURE) EXTEND PORT RETRACT PORT (EXT) (RET) EXTEND COIL RETRACT COIL BOOM DOWN COL BOOM UP COIL ROTATE CCW ROTATE CW COIL COIL B OOM DOWN BOOM UP PORT (RET) PORT (EXT) TO FRONT MOTOR TO REAR MOTOR...
  • Page 54 COUNTER BALANCE ADJUSTMENT 3203 SERIES Notice: Counterbalance Valve Adjustment ♦ With pump system disengaged and boom ♦ In an EMERGENCY situation when it properly supported, remove the plug on becomes necessary to lower the boom the counterbalance valve. Install a without flow present, the CB valve pressure gauge (0-2,500 PSI) into the adjustment can be turned in until the...
  • Page 55 POWER UNIT 3203 SERIES ITEM DESCRIPTION 320825001 RESERVOIR KIT 200545000 BREATHER CAP 320825002 RELIEF VALVE KIT 320335005 MOTOR 320336002 RETURN PORT PLUG KIT 320825003 ADAPTER KIT 320335003 PUMP KIT 320335010 O-RING 7-3.0.0 05/23/2003...

  • Page 56: Troubleshooting Guide - Diagnostics

    TROUBLESHOOTING GUIDE 3203 SERIES 1 CRANE FAILS TO OPERATE If receptacle tests are ok, then fault (ALL FUNCTIONS) is in pendant hot wire. Either a break in the wire or it is not attached inside of the Check power to crane - 12v to pendant (goes to center terminal of ground at upper left power terminal of rotation switch from pin "D").
  • Page 57 TROUBLESHOOTING GUIDE 3203 SERIES If there is no power at A2 only on WARNING: BE SURE hoist down then put test light across BOOM IS SUPPORTED bottom power terminals of hoist up relay. BEFORE REMOVING SWITCH If light comes on when hoist down is picked, then hoist up relay is bad.
  • Page 58 TROUBLESHOOTING GUIDE 3203 SERIES Select inoperable function with pendant switch and push manual override of valve in question-if function works use procedure 1.C. to check receptacle and pendant. If receptacle checks out and function can not be run by using jumper at receptacle, then valve or harness may be bad.
  • Page 59 CONTROLLER DIAGNOSTICS 3203 SERIES On the receiver the green light indicates that a signal is being received, the red indicates the status or error. Below are a list of the error codes both as they would be displayed on a Palm handheld and on the receiver.
  • Page 60 CONTROLLER DIAGNOSTICS 3203 SERIES CODE: 4 Flashes/LBV DESCRIPTION: Low battery POSSIBLE CAUSE(S): Low battery power to to receiver. POSSIBLE SOLUTION(S): Check connections to the battery. Charge battery. NOTE: It is recommended that the crane be powered off if battery is charged with battery charger. CODE: 5 Flashes/BLMT DESCRIPTION:...
  • Page 61 CONTROLLER DIAGNOSTICS 3203 SERIES POSSIBLE SOLUTION(S): Check plug in boom down solenoid on hydraulic control valve. Check wires for damage that could cause break or short. CODE: 9 Flashes EC04 DESCRIPTION: Boom in (retract) POSSIBLE CAUSE(S): Short or open connection on boom in output. POSSIBLE SOLUTION(S): Check plug in boom in solenoid on hydraulic control valve.
  • Page 62 CONTROLLER DIAGNOSTICS 3203 SERIES POSSIBLE CAUSE(S): Short or open connection on hoist up output. POSSIBLE SOLUTION(S): Check plug in hoist up solenoid on hydraulic control valve. Check wire for damage that could cause break or short. CODE: 14 Flashes/EC09 DESCRIPTION: Hoist down POSSIBLE CAUSE(S): Short or open connection on hoist down output.
  • Page 63 TRANSMITTER / RECIEVER SYNCHRONIZATION 1. Power on the transmitter and receiver. 2. Locate the program plug on the crane. This will be the unused plug near where the cord reel plugs into the wire harness. 3. Using a jumper wire, as shown below, connect the two contacts in the plug. 4.
  • Page 64 REMOTE / PENDANT PARTS AND ACCESSORIES Component Part Number Receiver 320920001 Transmitter PRX 320920002 Transmitter PR 320920004 Pendant Cable 366500009 Antenna 366500005 Cigarette Lighter Charger 366504000 A/C Charger 366505000 Palm Diagnostic Unit 366510000 Receiver Harness 320920003 Hardwire Pendant PRX 320921000 Hardwire Pendant PR 320922000 8-9.0.0...
  • Page 65 NOTES...

  • Page 66: Load Chart

    LOAD CHART 3203 SERIES 2665 VERTICAL AND HORIZ. 1345 DISTANCE IN FEET BOOM PIVOT AT 7 FT. ABOVE GND. 3200 3203 PRX 1845 1290 3200 2930 75° 60° 1050 2040 45° OVER 1600 LBS. 1655 USE DOUBLE LINE 30° RATED CAPACITY 3200 LBS.

  • Page 67: Warranty

    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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