Summit Truck Bodies 4416 Owner's Manual

Journeyman electric crane

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OWNER'S MANUAL

Safety, Installation, Maintenance, and Operation

4416 Journeyman Electric

Crane

Manual # 700-20029

Revision Date 02/28/2020

Summit Truck Bodies

990 Vernon Road

Wathena, KS 66090

866-985-3100

Fax: 785-989-3563

www.summitbodies.com

Subject to Change without Notification

FOR SHIP-LOOSE KIT

REFERENCE 400-62491

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Page 1 OWNER’S MANUAL Safety, Installation, Maintenance, and Operation 4416 Journeyman Electric Crane Manual # 700-20029 Revision Date 02/28/2020 Summit Truck Bodies 990 Vernon Road Wathena, KS 66090 866-985-3100 Fax: 785-989-3563 www.summitbodies.com Subject to Change without Notification FOR SHIP-LOOSE KIT REFERENCE 400-62491...
Page 3: Summit Truck Bodies Warranty Registration
SUMMIT TRUCK BODIES WARRANTY REGISTRATION Fax Transmission Warranty Department Fax: (785) 989-3563 From: Date: Product Registration Pages: End user information: (Required for Warranty Activation) Name: Phone: Address: City: State: Zip: Contact: E-mail Address: Distributor Information (Required for Warranty Activation) Name:...
Page 5 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 Summit Truck Bodies at (866) 985-3100. Summit Truck Bodies reserves the right to update this material without notice or obligation.
Page 7: Table Of Contents
TABLE OF CONTENTS SUMMIT TRUCK BODIES WARRANTY REGISTRATION ..........3 INTRODUCTION ........................9 SAFETY DECALS ......................... 14 SPECIFICATION SHEET ..................... 17 GENERAL DIMENSIONS ....................18 INSTALLATION ........................19 1.1 GENERAL ........................19 1.2 ELECTRICAL ........................ 20 ...
Page 8 Limited Warranty ........................49 ...
Page 9: Introduction
If you require additional information, please contact Summit Truck Bodies at the situations. following telephone number: (866) 985-3100. The information contained in this manual is in effect at the time of this printing. Summit Truck Bodies reserves the right to update this material without notice or obligation.
Page 10 The operator must have a working knowledge of all safety and government regulations. You can refer to any OSHA manual for guidance. Summit Truck Bodies is not liable for accidents caused by the operation of the crane.
Page 11 Personal Safety The use of personal protective equipment (“PPE”) is critical to the safety of the operation and the wellbeing of the people operating the equipment. The use of the following (but not all inclusive) PPE in the safe operation should be worn by the operator: ...
Page 12 Be aware of your surroundings when lowering outrigger jacks. Keep feet and legs out from under jacks. Never operate the crane before the service truck is positioned on stable, level ground. Put the vehicle in park or neutral (for manual transmissions) and set the parking brake before attempting a lift.
Page 13 insurance that your machine will last a long time, affording you a good investment of your time and capital. Good common sense goes a long way in safety. Steel and electricity do not mix well, so avoid using the crane at the highest point on many job sites during a storm. Maintain the prescribed clearance from all power lines with your crane.
Page 14: Safety Decals
Description ….. Do not use the stow hook for lifting loads. Location …..lower boom section front of boom. Decal Number: 700-30373 Title: …………. White outline logo Description …. Identifies Summit Truck Bodies as the manufacturer of the crane. Location: ……. Lower boom section centered on the boom.
Page 15 Decal Number: 700-30131 Title: …………. Danger, scissor point Description: ... Tells the operator of a potential scissor point. Location: ……. Both sides of the lift cylinder. Decal Number: 700-30025 Title: …………. Warning, overload hazard. Description: …. Tells the operator not to tamper with the overload device.
Page 16 Use of the hydraulic solenoids on the pedestal. Location: ……. Cover panel of hydraulic control pack. Decal Number: 700-30999 Title: …………. Serial number plate, 4416 crane. Description: …. States the model and serial number of the crane. Location: ……. Cover panel of hydraulic control pack.
Page 17: Specification Sheet
Specifications Model 4416 Journeyman Electric Crane SPECIFICATION SHEET Crane Rating: 16,000 ft-lbs (21.69 kN-m) Standard Boom Length: 7’4 1/2"(2.3 m) from CL of Crane Boom Extension: 1st stage: Hydraulic 48"(1.2 cm) 2nd stage: Manual 48"(1.2 cm) Maximum Horizontal Reach: 16’(4.9 m) from CL of Crane Maximum Vertical Lift: 16’(4.9 m)
Page 18: General Dimensions
*Subject to change without notification GENERAL DIMENSIONS...
Page 19: Installation
The weight of the truck must coincide with the chassis requirements of the crane to be installed. For the 4416 crane the following chassis requirements must be met: Minimum Chassis GVW: 10,500 lbs 2.
Page 20: Electrical
5. To avoid injury, use a lifting device designed to bear the weight of the crane. 6. See mounting bolt pattern which show (4) 7/8” dia. holes. 7. Make sure the crane is resting properly on its base. Apply Loctite Thread locker #277 to the mounting bolts and install them from the underside of the mounting plate.
Page 21: Testing
The cranes electric system’s ground completes the electrical circuit through the ground cable back to the vehicle battery. The factory ground provided in the vehicle is NOT sufficient to carry the current required by the crane. Without the addition of this extra ground cable, your crane will not operate to its’...
Page 22 The Stability Capacity Chart must be completed by the crane installation personnel. Summit Truck Bodies takes no liability for the placement of a crane by an outside source. If you install a crane not designed for the body or chassis, your crane and the stability of it will fail.
Page 23: Install Kit
1.4 INSTALL KIT...
Page 24: Stability Capacity Chart
STABILITY CAPACITY CHART...
Page 26: Operation
SECTION 2 OPERATION 2.1 GENERAL REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE MAINTENANCE AND REPAIR REQUIREMENTS For ease of operation, become familiar with your crane and truck combination. Practice lifting without a load, and then graduate to a small load, gradually becoming larger in load size.
Page 27: Load Lifting
1. The truck must be level for all loading and unloading with the crane. 2. The emergency brake must be engaged prior to any crane operation. 3. The outriggers must be extended and setting on solid footings before operating the crane. 4.
Page 28: Wireless Control Instructions
2.7 WIRELESS CONTROL INSTRUCTIONS The crane comes standard with a wireless control system. At the bottom center is a green button “POWER ON” for powering up the transmitter. To turn the transmitter on, press the green “ON” button. Horn should sound anytime the “ON” button is pressed. Once released the transmit (TX) light in the upper left starts blinking.
Page 29: Maintenance
Remember your crane goes to -5 degrees. 2. Perform your company’s designated PM on the equipment. 3. Replacement parts are available through Summit Truck Bodies. 4. Any worn or broken parts should be replaced at this time. Service To better service your crane, you may find it helpful to follow these guidelines: 1.
Page 30: Hydraulic Oil Deterioration
System oil is automatic transmission oil, Dextron II/III Mercon or equivalent. Level should be periodically checked and maintained at a full level for proper crane operation *NOTE: These recommendations are based on normal working parameters. If operating in less than favorable conditions (excessive dust, moisture, etc.), be sure to check fluid level more frequently and fill as necessary 3.4 HYDRAULIC OIL DETERIORATION Hydraulic oil can and will break down over time and/or excessive use.
Page 31: System Relief Pressure
3.7 SYSTEM RELIEF PRESSURE There is an additional pressure port on the crane hydraulic manifold. This port can be used as a pressure gauge port if pressure reading is required. The test can be performed by utilizing the extend cylinder. Fully retract extend cylinder and hold in while observing pressure reading on gauge.
Page 32: Wire Rope
3.11 WIRE ROPE The entire safety of the crane and the lifting of loads will be determined by one item on your crane, namely, the condition of the wire rope. To do a thorough visual inspection goes without saying. This should be completed daily, as it requires very little time and could prevent injury.
Page 33: Gear-Bearing Bolts
In order to properly maintain your wire rope, always keep it stored in the winch off the crane body, and a monthly lubrication with a quality chain and wire rope lubricant will extend the rope life. Avoid using the rope over sharp objects that may cause it to be scraped or situations where the rope can become caught, crushed or kinked 3.12 GEAR-BEARING BOLTS Do not reuse any of the gear bearing bolts.
Page 34: Inspections
3.13 INSPECTIONS Daily Inspection Before going to the job site each day, a visual inspection of the following will help prevent unnecessary maintenance: 1. All fluid levels are within the tolerances set by the manufacturers, such as air compressor, crane and engine 2.
Page 35: Lubrication & Maintenance Schedule
Quarterly Inspection This inspection should include, but not be limited to, the following: 1. Any loose bolts on the crane body 2. Any bolts mounting the crane to the main body of the truck pedestal 3. The hydraulic system pressures to the cylinders, main block assembly, and cartridges 4.
Page 36: Trouble-Shooting
TROUBLE-SHOOTING The following is meant as a reference in diagnosing on-the-job-malfunctions. SYMPTOM PROBABLE CAUSE Crane will not operate 1. Parking brake is not engaged 2. Radio receiver does not have 12V power 3. Transmitter not on 4. Transmitter batteries have low voltage Crane will not rotate 1.
Page 37 Rotation speed too fast or too 1. Air in the system slow 2. Pump not delivering rated oil volume The holding valves are not operating 4. Hydraulic fluid low 5. Pressure relieve valve sticking open...
Page 38: Parts
PARTS Summit 4416 Journeyman Pedestal Assembly...
Page 39 Summit 4416 Journeyman Pedestal Assembly BOM...
Page 40 Summit 4416 Journeyman Base Boom Assembly...
Page 41 Summit 4416 Journeyman Base Boom Assembly BOM...
Page 42 Summit 4416 Journeyman Base Boom End Assembly Details...
Page 43 Summit 4416 Journeyman Winch contactor Assembly Details...
Page 44 Summit 4416 Journeyman Stinger Assembly...
Page 45 Summit 4416 Journeyman Stinger Assembly BOM...
Page 46 Summit 4416 Journeyman Traveling Block Assembly & BOM...
Page 47: Electrical Schematics
ELECTRICAL SCHEMATICS...
Page 48: Hydraulic Control Valve Schematic
HYDRAULIC CONTROL VALVE SCHEMATIC...
Page 49 The retail purchaser is required to keep documented evidence that these services were performed. The Summit Truck Bodies, LLC Limited Warranty may be subject to cancellation if the above requirements are not performed.
Page 50 specification. New cranes delivered to the retail purchaser in which the warranty registration is not returned within fourteen (14) days from the date of delivery. Any defect which was caused (in Summit’s sole judgment) by operation of the crane not abiding by standard operating procedures outlined in the Operator’s Manual.
Page 51 No person is authorized to give any other warranty or assume any additional obligation on Summit’s behalf. SUMMIT TRUCK BODIES IS UNDER NO OBLIGATION TO EXTEND THIS WARRANTY TO ANY CUSTOMER FOR WHICH AN SUMMIT CRANE WARRANTY FORM HAS NOT BEEN...