2000 CRANE USER MANUAL
Contents
1. 2000 3 7 MAIN ASSEMBLY 2000 3 75 MAIN ASSEMBLY Eu ne Be kreditt EL ELECTRICAL LAYOUT ALL 5 TRAVEL BEOCK ASSEMBLY ah ror ewig es Getta ee ee are ANTI I WO BEOCKSYSTEM ered XA E E LLEVE Ee LOAD SENSOR 4 SPARE PARTS ee TROUBLESHOOTING derre ead Shad erte sakene EFETIMEAWARRANTY oerte ce ect er rer 2000 5 5 5 PACKING LIST The following items are included with your RKI 2000 Series crane 1 Crane Assembly 1 Crane User Manual W0037 1 Carton with the following contents including Mounting Kit 43745 and other components 1 Hot Quill Power Cable 43295 25ft 2 Wire Assembly 1 Ground Cable 43738 3ft 2ga Wire Assembly from Service Body to Vehicle Frame 6 Cable Retaining Clips 43512 4 Mounting Bolts 19152 7 13 x 2 4 Grade 8 8 Flat Washers 07889 4 Lock Washers 03030 4 Nuts 43520 5 13 Grade 8 1 Remote Control 45148 12 heavy duty 2000 SERIES CRANES IMPORTANT NOTICE RKI Inc cannot possibly know or even anticipate all of the varied uses and applications that may be found for its crane products For2. 13 43816 TIE CABLE 03 91 BLK NYL MEINE 14 43908 1 WIRE ASY 2000 LOAD LIMIT ACTIVATE 15 44000 2 TERMINAL 14GA QD FEM HOIST DOWN CONNECTED 16 44127 1 WINCH PKG WARN DC 1200 TO GROUND 17 44248 1 REEL CORD 20FT 18 3 18 44249 2 EYE BOLT 25 20UNC 19 44719 2 NUT HX 86 32 NYLK 20 44798 3 CLAMP LOOM 3 8 MIG 21 45204 2 SWITCH PLUNGER SPDT BZ 22 45205 4 SCRW PAN 6 32 1 23 45225 BRKT ASY CORD REEL 2000 VIEW OF SONIAGISR FIN 48259 24 45238 1 WIRE ASY CONTACTOR GRND 26 2000 SERIES CRANES ELECTRICAL LAYOUT ALL MODELS W0079 Page 2 of 2 WHITE LEAD OF CONNECTED COM TERMINAL OF 01 BLACK LEAD OF CONNECTED NO TERMINAL OF 01 NC TERMINAL OF Q1 NOT USED INSIDE VIEW OF TURRET SHOWING LOAD LIMIT SWITCH NC TERMINAL WITH 7 CONNECTED TO WHITE LEAD OF 12 NO TERMINAL OF Q1 WITH 7 CONNECTED TO COM TERMINAL OF 01 VIEW OF BOOM END OF 61 NOT USED HOIST TERMINAL 2 NOT SHOWN HOIST TERMINAL 1 VIEW FROM REAR 27 2000 5 5 5 TRAVEL BLOCK ASSEMBLY ALL MODELS 45215 ITEM PART 4 QTY DESCRIPTION 1 07885 2 WASHER FLT 3 8 W 2 07886 2 WASHER LOCK 3 8 3 40911 2 BOLT HX 3 8 16X7 8 4 43041 1 PULLEY 4 0 OD 75BORE 5 43425 6 NUT
3. NYL 10 14938 1 SCRW STSKT 3 8CX1 50 DOG 1 ASY 2000 LOAD LIMIT 11 40911 2 BOLT HX 3 8 16 7 8 2 TERMINAL 14GA QD 12 40986 6 WASHER FLT 1 4 40986 2 POINTER DEGREE INDICATOR 13 41013 4 SCRW CPSKT 1 4 20 1 2 2 BOLT HX 3 8 16X3 4 LK 14 41014 3 SCRW CPSKT 1 4 20 3 4 1 SCREW ROT LOCK ASY 2000 15 41095 1 BOLT HX 1 4 20 1 G5 1 DECAL LIFT MOVE PEOPLE 16 41155 2 TERMINAL 18GA 10 RING 1 DECAL ANGLE 2000 3 7 17 41156 1 TERMINAL 18GA 31 RING 1 DECAL 2000 LOAD CAPACITY 18 43016 1 PIN QUICK 1 00 2 50 W L 1 WINCH PKG WARN DC1200 19 43019 2 BEARING CONE 2 750X4 438 1 JREEL CORD 20FT 18 3 20 43020 2 BEARING CUP 2 750 4 438 2 EYE BOLT 25 20UNC 2 43035 2000 2500 BRG 1 DECAL ANGLE 2000 3 7 LT 22 43040 1 SPACER 2000 2500 TOP 2 NUT HX 46 32 NYLK 23 43041 1 PULLEY 4 0 OD 75BORE 1 DECAL FREE FALL BOOM 24 43139 2 RING RTNG EXT 0 750 1P 1 DECAL STRUCTURE DAMAGE 25 43140 2 RING RTNG EXT 1 000 1 DECAL LOAD HANDLING 26 43156 1 DECAL CAUTION YELLOW 3 CLAMP LOOM 3 8 27 43157 2 DECAL STAY CLEAR LOAD 2 DECAL RKI LOGO 2 5X7 28 43158 2 DECAL DANGER BOOM 4 1 8 3 8 AL ST 46 29 43159 1 DECAL DANGER OPERATION I 5 BLANK 30 43160 1 DECAL LOAD SENSOR 1 GUARD SWITCH 2000 31 43166 1 PIN GRVD 0 75 1 37 2 SWITCH PLUNGER SPDT BZ 32 43196 1 PLATE 2500 CLAMP 4 SCRW PAN 6 32 1 33 43197 1 STRAP LOCKING 2
4. 35 43294 1 ASY 402 36 0 PLUG 1 BLOCK ASY 20 25 32 36 43345 1 PIN QUICK 1 00 4 00 W L 1 COVER CRANE A2B 37 43425 2 NUT HEX 250NC FLEX 1 RAIL PKG CRANE A2B 38 43604 1 BOOM 2000 3 5 MAIN 1 jBRKT ASY CORD REEL 2000 39 43607 PLATE 2000 SPRING SUPPORT 1 PLATE 20 25 BOOM STOP 40 43608 2000 SPRRING MTG 1 BOOM 2000 3 5 EXT 4 43611 1 TURRET 5 2000 1 ASY CONTACTOR GRND 42 43614 1 PIN GRVD 1 00 4 56 2000 SERIES CRANES 2000 3 7 CRANE MAIN ASSEMBLY 22 2000 SERIES CRANES 2000 3 7 CRANE BILL OF MATERIAL 23 ITEM PART QTY DESCRIPTION PART QTY DESCRIPTION 1 07769 2 BOLT HX 3 8 16X1 43 43620 SPRING 2000 BOOM ASSIST 2 07770 2 BOLT HX 3 8 16X1 1 4 1 ROPE WIRE 188 25FT EYE 3 07784 4 BOLT HX 1 2 13X1 2 PIN SPRNG 0 37 1 00 4 07843 2 NUT HX 1 4 20 1 BRAKESHOE 2000 5 07850 1 NUT HX 3 8 16 2 CLAMP LOOM 1 4 MIG 6 07882 7 WASHER LOCK 1 4 1 BASE 2000 3 7 7 07885 8 WASHER FLT 3 8 W 1 BOOM 2000 3 7 MAIN 8 07886 3 WASHER LOCK 3 8 1 P CR HDWR 500 9 07898 BOLT HX 1 4 20X3 4 1 TIE CABLE 03 9L BLK NYL 10 14938 1 SCRW STSKT 3 8CX1 50 DOG 1 WIRE ASY 2000 LOAD LIMIT 11 40911 2 BOLT HX 3 8 16X7 8 2 14 QD FEM 12 40986 6 WASHER FLT 1 4 40986 2 POINTE
5. 4 SCRW CPSKT 1 4 20 1 2 2 BOLT HX 3 8 16X3 4 LK 14 41014 3 SCRW CPSKT 1 4 20X3 4 1 SCREW ROT LOCK ASY 2000 15 41095 1 BOLT HX 1 4 20X1 G5 1 DECAL LIFT MOVE PEOPLE 16 41155 2 TERMINAL 18GA 10 RING 1 DECAL ANGLE 2000 3 7 RT 17 41156 1 TERMINAL 18GA 31 RING 1 DECAL 2000 LOAD CAPACITY 18 43016 1 PIN QUICK 1 00 2 50 W L 1 WINCH PKG WARN DC1200 19 43019 2 BEARING CONE 2 750X4 438 REEL CORD 20FT 18 3 20 43020 2 BEARING CUP 2 750 4 438 2 EYE BOLT 25 20UNC 21 43035 SPACER 2000 2500 BRG BTM 1 DECAL ANGLE 2000 3 7 LT 22 43040 1 SPACER 2000 2500 BRG TOP 2 NUT HX 86 32 23 43041 1 PULLEY 4 0 OD 75BORE 1 DECAL FREE FALL BOOM 24 43139 2 RING RTNG EXT 0 750 1 DECAL STRUCTURE DAMAGE 25 43140 2 RING RTNG EXT 1 000 IP 1 DECAL LOAD HANDLING 26 43156 1 DECAL CAUTION YELLOW 3 CLAMP LOOM 3 8 MIG 27 43157 2 DECAL STAY CLEAR LOAD 2 DECAL RKI LOGO 2 5X7 28 43158 2 DECAL DANGER BOOM 4 RIVET 1 8X3 8 AL ST AB46 29 43159 1 DECAL DANGER OPERATION 1 NAMEPLATE S N RVT BLANK 30 43160 1 DECAL LOAD SENSOR 1 GUARD SWITCH 2000 31 43166 1 PIN GRVD 0 75 1 37 2 SWITCH PLUNGER SPDT BZ 32 43196 1 PPLATE 2500 CLAMP 4 SCRW PAN 6 32 1 33 43197 1 ISTRAP LOCKING 2000 2500 1 PIN W KPR A2B 2000 2500 34 43263 WIRE 5 04 18 0 GRND 1 PIN W KPR 0 75 1 13 5 75 35 43294 WIRE ASY 02 36 0 PLUG 1 TRAV BLOCK ASY 20 25 32 36 43345 1 PI
6. 4 15 1 4 Height 63 5 8 30 3 8 69 5 8 30 3 8 Length 55 11 16 55 11 16 66 11 16 66 11 16 Overall length dimension is without the boom extended 2000 SERIES CRANES 2000 3 5 OVERALL DIMENSIONS 4X O15 0215 MOUNTING HOLE PATTERN G gt TNT p 5 012345678910 LOAD RADIUS FEET LOAD CAPACITY CHART ADJUSTABLE BOOM ELEVATIONS OF 0 25 50 OR 75 11413 ig 5775 2000 SERIES CRANES 2000 3 55 OVERALL DIMENSIONS G Dm 4X O15 0215 MOUNTING HOLE PATTERN NTT NT 012345678910 LOAD RADIUS FEET LOAD CAPACITY CHART CAPACITY POUNDS ADJUSTABLE BOOM ELEVATIONS OF 025 350 OR 75 2000 SERIES CRANES 2000 3 7 OVERALL DIMENSIONS 4X O15 0215 MOUNTING HOLE PATTERN 0123545678910 LOAD RADIUS FEET LOAD CAPACITY CHART CAPACITY POUNDS ADJUSTABLE BOOM ELEVATIONS OF 0 25 50 OR 75 142 2000 SERIES CRANES 2000 3 75 OVERALL DIMENSIONS G A i 4X O15 0215 MOUNTING HOLE PATTERN c 2 2 lt lt 0 012545678910 LOAD RADIUS FEET LOAD CAPA
7. HEX 250NC FLEX 6 43819 1 2 0 SWIVEL W L 7 43909 2 SPACER TB 3 80D 7 81 8 44002 6 BOLT HX 1 4 20 2 1 4 9 45212 2 PIN W KPR 0 75 1 31 3 50 10 45216 2 PLATE ASY TRAV BLOCK 28 2000 SERIES CRANES ANTI TWO BLOCK SYSTEM ALL MODELS Your RKI crane is equipped with an anti two block system per OSHA 29 CFR Part 1926 1416 d 3 to prevent damage from contact between the travel block and the boom tip If the travel block is allowed to contact the end of the boom continued operation could result in significant damage to the crane and possibly failure of the wire rope When the travel block comes in contact with the rail mechanism at the end of the boom the crane will disable the hoist up and boom out functions All other functions will operate as normal The microswitch located at the end of the boom head and the rail mechanism that engages it are pre set at the RKI factory No adjustment or resetting is necessary If either of the two following conditions exists then the crane requires service When the travel block compresses the rail mechanism and it comes in contact with the boom head and the crane hoist up function continues to operate When the travel block is not in contact with the rail mechanism or the boom head and all crane functions fail to operate particularly hoist up and boom out LOAD SENSOR CALIBRATION ALL MODELS Your crane is equipped with a torque reading load sensor whi
8. crane unless you have thoroughly read and understand the information in this manual Cranes shall be operated only by the following qualified personnel and crane operator certification per OSHA 29 CFR Part 1926 1427 1430 is available from local and national certifiers a Designated persons b Trainees under the direct supervision of a designated person Inspectors maintenance and test personnel when it is necessary in the performance of their duty No one other than the personnel specified in 2 above shall enter the crane s operating area with the exception of persons such as supervisors signal persons and those specific persons authorized by supervisors who duties require them to do so and then only in the performance of their duties and with the knowledge of the operator or other appointed persons The operator shall be familiar with the equipment and its proper care If adjustments or repairs are necessary the operator shall promptly report this to an appointed person and notify the next operator The operator at the start of each shift shall test all controls If any controls do not operate properly they shall be adjusted or repaired before operations are begun Seek the best possible work site for the operation when parking the crane mounted vehicle The parking location should be firm dry and level ground or pavement which can adequately reach the load by the rated capacity of the crane The crane mounted vehicle shall
9. load chart You may need to reposition the truck closer to the load Check microswitches in turret and at the end of the boom by pressing the point on the microswitch If it does not click replace the microswitch Remote Control will not Check for any loose exposed or frayed wires Make sure the switch returns operate freely to the center position and is not sticking or loose Inspect the remote socket and connections for damage or corrosion Sporadic Functions Check the hot cable connections from the power source to the crane This includes the master cut off switch if applicable and the connection to the brass rod in the crane Check for proper ground with good clean metal to metal connections no paint etc With the truck engine running check the power source to confirm the crane is receiving 13 volts for proper operations replacement battery alternator or adding an additional battery may be necessary Always provide the serial number of the crane when contacting for further troubleshooting questions stamped in the nameplate located on the side of the turret 31 2000 5 5 5 LIFETIME WARRANTY This warranty applies to anything we have manufactured The warranty applies to the original owner of the product for as long as he or she owns the product If something goes wrong which we determine was our fault we will repair or replace your product The warranty doesn t apply to normal
10. other devices of sufficient capacity 25 The operator shall not leave the controls while the load is suspended 26 No person should be permitted to stand or pass under suspended load 27 Position end of boom directly over load Do not attempt to drag a load this may result in severe damage to the crane 28 Keep tension on the hoist line at all times to prevent the line from fouling on the drum 29 Never place a chain link on the tip of the hook in order to lift a load with the winch 30 Make sure the safety latch on the hook is closed before lifting a load 31 Before starting to lift the following conditions should be noted The hoist rope shall not be kinked The hook shall be brought over the load in such a manner as to minimize swinging a b Part lines shall not be twisted around each other The effect of ambient wind on the load stability 15 32 33 34 35 36 37 38 39 40 41 2000 SERIES CRANES OPERATING INSTRUCTIONS Page 3 of 3 The person directing the lift shall see that crane is level and where necessary blocked b The load is well secured and balanced in the sling or lifting device before it is lifted more than a few inches c The lift and swing path is clear of obstructions During lifting operations care shall be taken that a There is no sudden acceleration or deceleration of the moving load b Load boom or oth
11. that reason the company expressly disclaims any and all responsibility for the manner and methods used by the installer of these products The company recommends that the installer of its crane products follow sound engineering principles and comply fully with each and every applicable ANSI OSHA or other safety standard Safety Warning RKI Inc cranes are not intended to be used or incorporated as a component of any other equipment which may be used for the lifting or moving of people Any such use is absolutely and categorically contrary to RKI Inc s recommendation INTRODUCTION RKI cranes are designed and manufactured to provide you years of safe dependable performance This manual has been provided to give you specific information regarding the safe operation and upkeep of your crane It is very important that all who operate or service the crane should begin by thoroughly reading this manual In addition the supervisor and others concerned with the operation of the crane should read this manual Remember that an uninformed or careless operator can make the operation of any equipment dangerous The information in this manual helps to insure that your RKI crane is installed properly and operated safely However it is not a definitive guide to every possible situation or circumstance If you have any questions or require additional information please contact RKI 2000 5 5 5 SPECIFICATIONS Models 2000 3 5 200
12. the bolt torque for the Base Mounting Bolts amp X four mounting bolts and Other Bolts tighten other bolts as required bobm X inspect pads and replace as required To extend the life of cable clean it periodically with a wire brush and lubricate it lightly with oil All other bushings used are made of brass impregnated with an oil and graphite compound and require no maintenance Other parts may be lubricated with a few drops of oil as needed LUBRICATION SPECIFICATION 1 Rotational Bearings Mobil grease CM S or equivalent 17 2000 5 5 5 2000 3 5 MAIN ASSEMBLY 249 x 0 Ly hagi OL 7 2000 SERIES CRANES 2000 3 5 CRANE BILL OF MATERIAL 19 ITEM PART QTY DESCRIPTION ITEM PART QTY DESCRIPTION 1 07769 2 BOLT HX 3 8 16X1 43 43614 1 PIN GRVD 1 00 4 56 2 07770 2 BOLT HX 3 8 16X1 1 4 1 SLEEVE 2000 ADAPTOR 3 07784 4 BOLT HX 1 2 13X1 1 SPRING 2000 BOOM ASSIST 4 07843 2 NUT HX 1 4 20 1 ROPE WIRE 188 25FT EYE 5 07850 1 NUT HX 3 8 16 2 PIN SPRNG 0 37 1 00 6 07882 7 WASHER LOCK 1 4 1 BRAKESHOE 2000 7 07885 8 WASHER FLT 3 8 2 CLAMP LOOM 1 4 8 07886 3 WASHER LOCK 3 8 1 MTG HDWR 500 9 07898 1 BOLT HX 1 4 20 3 4 1 03 91
13. wear and tear Be sure to call your local distributor if you have a problem We need the opportunity to talk to you about it We may ask you to email us pictures or ship the product back to us for inspection Parts that we use but don t manufacture are covered to the extent of the warranty we get from the company that does manufacture them No loss of use coverage No freight coverage Repairs have to be authorized by us in writing in advance No coverage if the product has been changed in any way To qualify for warranty the product must have been treated with respect in regard to normal installation maintenance and usage Accidents and acts of God aren t covered This warranty will be in effect until we decide to change it 32
14. 0 3 7 2000 3 55 2000 3 75 Moment Rating 6 000 ft Ibs Lift Capacities 2 000 Ibs 3 ft 1 500 Ibs 9 4 ft 1 200 105 5 ft 1 000 105 6 ft 850 Ibs O 7 ft Boom The boom angle includes lifting positions of 0 25 50 and 75 Manual boom extension ranges 5 models 12 intervals 40 13 16 52 13 16 64 13 16 7 models 17 51 13 16 69 5 16 86 13 16 Boom is spring counterbalanced to assist in lifting and adjustment Boom lowers to vertical position for storage and travel Line Speed Approximately 9 feet per minute first rope layer double line Load Sensor A load sensor is standard to automatically protect overload Anti Two Block Per OSHA 29 CFR Part 1926 1416 d 3 An anti two block feature is incorporated into the crane to prevent damage from contact between the travel block and the boom tip Winch Cable and Block Winch is planetary gear drive with permanent motor providing forward and reverse operation 25ft of 3 16 galvanized aircraft cable is supplied with traveling block with safety latch for double line operation Electrical 12 VDC required to operate the electric hoist winch Safety Standards Meets OSHA 1910 180 and OSHA 1926 1441 requirements Specifications 2000 3 5 2000 3 55 2000 3 7 2000 3 75 Product Weight 273 Ibs 247 lbs 296 Ibs 258 Ibs Shipping Weight 305 Ibs 279 165 328 Ibs 290 Ibs Width 15 1 4 15 1 4 15 1
15. 000 2500 1 PIN W KPR A2B 2000 2500 34 43263 1 ASY 04 18 0 GRND PIN W KPR 0 75 1 13 5 75 35 43294 1 ASY 402 36 0 PLUG 1 BLOCK ASY 20 25 32 36 43345 1 PIN QUICK 1 00 4 00 W L 1 COVER CRANE A2B 37 43425 2 NUT HEX 250NC FLEX 1 RAIL PKG CRANE A2B 38 43604 1 BOOM 2000 3 5 MAIN 1 jBRKT ASY CORD REEL 2000 39 43607 PLATE 2000 SPRING SUPPORT 1 PLATE 20 25 BOOM STOP 40 43608 2000 SPRRING MTG 1 BOOM 2000 3 5 EXT 4 43611 1 TURRET ASY 2000 1 ASY CONTACTOR GRND 42 43612 1 5 2000 3 5 2000 SERIES CRANES 2000 3 55 CRANE MAIN ASSEMBLY 2000 SERIES CRANES 2000 3 55 CRANE BILL OF MATERIAL 21 ITEM PART QTY DESCRIPTION ITEM PART QTY DESCRIPTION 1 07769 2 BOLT HX 3 8 16X1 43 43615 1 SLEEVE 2000 ADAPTOR 2 07770 2 BOLT HX 3 8 16X1 1 4 1 SPRING 2000 BOOM ASSIST 3 07784 4 BOLT HX 1 2 13X1 1 ROPE WIRE 188 25FT EYE 4 07843 2 NUT HX 1 4 20 2 PIN SPRNG 0 37 1 00 5 07850 1 NUT HX 3 8 16 I BRAKESHOE 2000 6 07882 7 WASHER LOCK 1 4 2 CLAMP LOOM 1 4 MIG 7 07885 8 WASHER FLT 3 8 1 5 2000 3 STUBBY 8 07886 3 WASHER LOCK 3 8 1 MTG HDWR 500 9 07898 1 BOLT HX 1 4 20 3 4 1 03 91 NYL 10 14938 1 SCRW STSKT 3 8CX1 50 DOG 1 ASY 2000 LOAD LIMIT 11 40911 2 BOLT HX 3 8 16 7
16. 2000 SERIES CRANES Models 2000 3 5 2000 3 55 2000 3 7 2000 3 75 USER MANUAL Effective Serial Number 5271 Serial Number Date RKI Inc 2301 Central Parkway Houston TX 77092 Phone 713 688 4414 Fax 713 688 8982 www rkius com W0037 Rev A 01 16 15 2000 SERIES CRANES TABLE OF CONTENTS Description PACKING LIST dad Ee AGE Id IMPORTANT NOTICE s dikterte daterer der dr SPECIFICATIONS ea ew r res AW 2000 3 5 OVERALL DIMENSIONS n nen 2000 3 55 OVERALL DIMENSIONS 2000 3 7 OVERALL DIMENSIONS 2000 3 75 OVERALL DIMENSIONS CAPACITY CHART iL b GE D ke CER E u an RECOMMENDED MOUNTING IN PICKUP BED INSTALLATION INSTRUCTIONS BATTERY amp GROUNDING vi bn SE PO On ee MOUNTING KIT 1 oed FE Kad eee BAER OPERATING INSTRUCTIONS n annen INSPECTION amp MAINTENANCE SCHEDULE 2000 3 5 MAIN ASSEMBLY 1 2000 3 55 MAIN 55
17. 8 2 TERMINAL 14GA QD 12 40986 6 WASHER FLT 1 4 40986 2 POINTER DEGREE INDICATOR 13 41013 4 SCRW CPSKT 1 4 20 1 2 2 BOLT HX 3 8 16X3 4 LK 14 41014 3 SCRW CPSKT 1 4 20 3 4 1 SCREW ROT LOCK ASY 2000 15 41095 1 BOLT HX 1 4 20 1 G5 1 DECAL LIFT MOVE PEOPLE 16 41155 2 TERMINAL 18GA 10 RING 1 DECAL ANGLE 2000 3 7 17 41156 1 TERMINAL 18GA 31 RING 1 DECAL 2000 LOAD CAPACITY 18 43016 1 PIN QUICK 1 00 2 50 W L 1 WINCH PKG WARN DC1200 19 43019 2 BEARING CONE 2 750X4 438 1 JREEL CORD 20FT 18 3 20 43020 2 BEARING CUP 2 750 4 438 2 EYE BOLT 25 20UNC 2 43035 2000 2500 BRG 1 DECAL ANGLE 2000 3 7 LT 22 43040 1 SPACER 2000 2500 TOP 2 NUT HX 46 32 NYLK 23 43041 1 PULLEY 4 0 OD 75BORE 1 DECAL FREE FALL BOOM 24 43139 2 RING RTNG EXT 0 750 1P 1 DECAL STRUCTURE DAMAGE 25 43140 2 RING RTNG EXT 1 000 1 DECAL LOAD HANDLING 26 43156 1 DECAL CAUTION YELLOW 3 CLAMP LOOM 3 8 27 43157 2 DECAL STAY CLEAR LOAD 2 DECAL RKI LOGO 2 5X7 28 43158 2 DECAL DANGER BOOM 4 1 8 3 8 AL ST 46 29 43159 1 DECAL DANGER OPERATION I 5 BLANK 30 43160 1 DECAL LOAD SENSOR 1 GUARD SWITCH 2000 31 43166 1 PIN GRVD 0 75 1 37 2 SWITCH PLUNGER SPDT BZ 32 43196 1 PLATE 2500 CLAMP 4 SCRW PAN 6 32 1 33 43197 1 STRAP LOCKING 2000 2500 1 PIN W KPR A2B 2000 2500 34 43263 1 ASY 04 18 0 GRND PIN W KPR 0 75 1 13 5 75
18. CITY CHART ADJUSTABLE BOOM ELEVATIONS OF 0 25 50 OR 75 ll Mg me 2 24 te 303 2000 SERIES CRANES CAPACITY CHART ALL MODELS 1 Overload Protection Limits Hoist Up 3 Use 2 Part Line Only i NOTES 1333 LHDI3H e 9 9 amp V mM 198 000 002 BOOM RADIUS amp CAPACITY LBS 2000 SERIES CRANES RECOMMENDED MOUNTING SYSTEM 2000 SERIES CRANE MOUNTED IN PICKUP BED FILLER MATERIAL BETWEEN RIBS IN PLATE AREA MOUNTING PLATES AND GUSSETS FRAME RAILS SUPPORT CROSSMEMBER FORE amp MOUNTING PLATE AND GUSSETS DO NOT WELD TO FRAME OF TRUCK MOUNTING MUST WITHSTAND 2000 LBS VERTICAL LOAD AND 6000 FT LBS MOMENT 2000 SERIES CRANES 11 10 11 12 13 14 INSTALLATION INSTRUCTIONS The crane mounting base must be capable of safely supporting the crane assembly and its maximum capacity of 6 000 ft Ibs loading The support structure for the mounting base must be tied directly to the main frame members of the vehicle Disconnect the ground cable from the vehicle s battery ies Drill 4 holes 9 16 diameter on 10 square pattern and an off center hole 2 5 16 diameter on the crane mounting location Refer to the Mounting Hole Patterns shown on the Overall Dimension pages Grind b
19. N QUICK 1 00 4 00 W L 1 COVER CRANE A2B 37 43425 2 NUT HEX 250NC FLEX 1 RAIL PKG CRANE A2B 38 43607 1 PLATE 2000 SPRING SUPPORT 1 BRKT ASY CORD REEL 2000 39 43608 BRACKET 2000 SPRRING MTG 1 PLATE 20 25 BOOM STOP 40 43611 1 TURRET ASY 2000 1 2000 3 7 41 43614 1 PIN GRVD 1 00 4 56 1 ASY CONTACTOR GRND 42 43615 1 SLEEVE 2000 BRG ADAPTOR 2000 5 5 5 ELECTRICAL LAYOUT ALL MODELS W0079 Page 1 1 of 2 HOIST HOIST TERMINAL TERMINAL 2 1 O POWER IN SWITCH FOR LOAD LIMIT BLACK BLACK LEAD GROUND 9 Hi NO SWITCH FOR ON TU tk TWO BLOCK WHITE LEAD GREEN N 9 BLACK LEAD e WHITE BLA BLACK AN CONTACTOR lt WIRE LEADS WHITE GREEN 17 ELECTRICAL LAYOUT ITEM PART QTY DESCRIPTION POWER TO HOIST 1 07843 2 NUT HX 1 4 20 TERMINAL 2 2 07882 1 WASHER LOCK 1 4 POWER TO HOIST 3 07898 1 BOLT HX 1 4 20 3 4 TERMINAL 1 4 40986 4 WASHER FLT 1 4 40986 5 41014 1 SCRW CPSKT 1 4 20 3 4 p 6 41095 1 BOLT HX 1 4 20X1 G5 7 41155 2 TERMINAL 18GA 10 RING 8 41156 1 TERMINAL 18GA 31 RING EE 9 43263 1 WIRE ASY 04 18 0 GRND U 10 43294 1 WIRE ASY 02 36 0 PLUG 11 43425 2 NUT HEX 250NC FLEX GROUND 12 43634 2 CLAMP LOOM 1 4
20. R DEGREE INDICATOR 13 41013 4 SCRW CPSKT 1 4 20 1 2 2 BOLT HX 3 8 16X3 4 LK 14 41014 3 SCRW CPSKT 1 4 20X3 4 1 SCREW ROT LOCK ASY 2000 15 41095 1 BOLT HX 1 4 20X1 G5 1 DECAL LIFT MOVE PEOPLE 16 41155 2 TERMINAL 18GA 10 RING 1 DECAL ANGLE 2000 3 7 RT 17 41156 1 TERMINAL 18GA 31 RING 1 DECAL 2000 LOAD CAPACITY 18 43016 1 PIN QUICK 1 00 2 50 W L 1 WINCH PKG WARN DC1200 19 43019 2 BEARING CONE 2 750X4 438 REEL CORD 20FT 18 3 20 43020 2 BEARING CUP 2 750 4 438 2 EYE BOLT 25 20UNC 21 43035 SPACER 2000 2500 BRG BTM 1 DECAL ANGLE 2000 3 7 LT 22 43040 1 SPACER 2000 2500 BRG TOP 2 NUT HX 86 32 23 43041 1 PULLEY 4 0 OD 75BORE 1 DECAL FREE FALL BOOM 24 43139 2 RING RTNG EXT 0 750 1 DECAL STRUCTURE DAMAGE 25 43140 2 RING RTNG EXT 1 000 IP 1 DECAL LOAD HANDLING 26 43156 1 DECAL CAUTION YELLOW 3 CLAMP LOOM 3 8 MIG 27 43157 2 DECAL STAY CLEAR LOAD 2 DECAL RKI LOGO 2 5X7 28 43158 2 DECAL DANGER BOOM 4 RIVET 1 8X3 8 AL ST AB46 29 43159 1 DECAL DANGER OPERATION 1 NAMEPLATE S N RVT BLANK 30 43160 1 DECAL LOAD SENSOR 1 GUARD SWITCH 2000 31 43166 1 PIN GRVD 0 75 1 37 2 SWITCH PLUNGER SPDT BZ 32 43196 1 PPLATE 2500 CLAMP 4 SCRW PAN 6 32 1 33 43197 1 ISTRAP LOCKING 2000 2500 1 PIN W KPR A2B 2000 2500 34 43263 WIRE 5 04 18 0 GRND 1 PIN W KPR 0 75 1 13 5 75 35 43294 WIRE ASY 02 36 0 PLUG 1 TRAV BLOCK A
21. SY 20 25 32 36 43345 1 PIN QUICK 1 00 4 00 W L 1 COVER CRANE A2B 37 43425 2 NUT HEX 250NC FLEX 1 RAIL PKG CRANE A2B 38 43607 1 PLATE 2000 SPRING SUPPORT 1 BRKT ASY CORD REEL 2000 39 43608 BRACKET 2000 SPRRING MTG 1 PLATE 20 25 BOOM STOP 40 43611 1 TURRET ASY 2000 1 2000 3 7 41 43614 1 PIN GRVD 1 00 4 56 1 ASY CONTACTOR GRND 42 43615 1 SLEEVE 2000 BRG ADAPTOR 2000 5 5 5 2000 3 75 CRANE MAIN ASSEMBLY 2000 SERIES CRANES 2000 3 75 CRANE BILL OF MATERIAL 25 ITEM PART QTY DESCRIPTION ITEM PART QTY DESCRIPTION 1 07769 2 BOLT HX 3 8 16X1 43 43620 SPRING 2000 BOOM ASSIST 2 07770 2 BOLT HX 3 8 16X1 1 4 1 ROPE WIRE 188 25FT EYE 3 07784 4 BOLT HX 1 2 13X1 2 PIN SPRNG 0 37 1 00 4 07843 2 NUT HX 1 4 20 1 BRAKESHOE 2000 5 07850 1 NUT HX 3 8 16 2 CLAMP LOOM 1 4 MIG 6 07882 7 WASHER LOCK 1 4 1 BOOM 2000 3 7 MAIN 7 07885 8 WASHER FLT 3 8 W 1 BASE 2000 3 STUBBY 8 07886 3 WASHER LOCK 3 8 1 P CR MTG HDWR 500 9 07898 BOLT HX 1 4 20X3 4 1 03 9L NYL 10 14938 1 SCRW STSKT 3 8CX1 50 DOG 1 WIRE 5 2000 LOAD LIMIT 11 40911 2 BOLT HX 3 8 16X7 8 2 TERMINAL 14GA QD FEM 12 40986 6 WASHER FLT 1 4 40986 2 POINTER DEGREE INDICATOR 13 41013
22. ch prevents overloading If the crane s load capacity is exceeded the load sensor deactivates the hoist up function Remove the load from the crane and the overload sensor is AUTOMATICALLY reset returning full function to the crane If the load sensor gets out of adjustment see instructions for its recalibration below Occasionally it may be necessary to recalibrate the load sensing device The following is the proper procedure 1 Theload sensing device is located in the lower front section of the crane turret housing It consists of a microswitch fastened to a bracket which in turn is welded into the crane turret 2 The plunger on the microswitch may be adjusted by means of the adjacent set screw Loosen the nut securing the set screw to the plate across the bottom of the turret 4 With the boom retracted and in the horizontal position connect a dynamometer scale In this position the distance from the center of the turret to the hook is approximately 41 for the 2000 3 5 amp 2000 3 5S and approximately 52 for the 2000 3 7 amp 2000 3 7S 5 Raise the hook by operating the hoist up switch on the remote control until the dynamometer reads either 1 764 155 for the 2000 3 5 2000 3 55 or 1 390 Ibs for the 2000 3 7 amp 2000 3 75 All 2000 series cranes are rated for 6 000 ft lbs of total capacity thus different boom lengths require different load settings 6 Ifa dynamometer is not available the same results can be obta
23. er parts of the machine do not contact any obstruction Side loading of boom shall be limited to freely suspended loads Crane shall not be used for dragging loads sideways The operator should never carry loads over people Neither the load nor boom shall be lowered below the point where less than five full wraps of rope remain on the winch drum When rotating the crane sudden starts and stops shall be avoided Rotating speed shall be such that the load does not swing out beyond the radius at which it can be controlled A tag or restraint line should be used during rotation to control the load Personnel shall not be permitted to ride the bare hook or a load of material suspended from the hook Do not move the vehicle when the crane is being used The crane shall be in stowed position before traveling Make sure the remote control is properly stored in a dry area 16 2000 SERIES CRANES INSPECTION amp MAINTENANCE SCHEDULE EVERY 3 COMPONENT DAILY WEEKLY MONTHLY MONTHS YEARLY NOTES Motor Brushes X Check Make sure the cable is wound Cable Drum X evenly on the drum Cable X Check for cut or broken strands kinking etcetera Ckeck for any cracks or Load Hook X deformation of the hook or latch Inspect for any damage and Sheaves and Bearings X add grease to bearings Make sure the sheaves turn freely X Add grease to the bearing Or more Rotational Bearing often under severe conditions Check
24. hassis frame or the engine to the chassis frame Maintain a regular schedule to ensure that the battery remains in good working condition Clean all connections check electrolyte levels check for loose belts and make sure that your vehicle charging system is operating properly WARNING 1 FEDERAL LAW 49 CFR PART 571 REQUIRES THAT THE FINAL STAGE MANUFACTURER OF A VEHICLE CERTIFY THAT THE VEHICLE COMPLIES WITH ALL APPLICABLE REGULATIONS ANY MODIFICATIONS OF THE VEHICLE PRIOR TO THE FINAL STAGE ARE ALSO CONSIDERED INTERMEDIATE STAGE MANUFACTURING AND MUST BE CERTIFIED AS TO COMPLIANCE THE INSTALLER IS RESPONSIBLE FOR COMPLIANCE WITH ALL APPLICABLE FEDERAL AND STATE REGULATIONS AND REQUIRED TO CERTIFY THAT THE VEHICLE IS IN COMPLIANCE 2 THE INSTALLER OF THE CRANE IS RESPONSIBLE TO COMPLY WITH THE OSHA TRUCK CRANE STABILITY REQUIREMENTS AS SPECIFIED BY 29 CFR PART 1910 180 c i 12 2000 SERIES CRANES MOUNTING KIT P N 43745 ALL MODELS ITEM PART QTY DESCRIPTION 1 03030 4 WASHER LOCK 1 2 2 07889 8 WASHER FLT 1 2 W 3 19152 4 1 2 13 2 5 GR8 4 43295 1 WIRE 5 02 25 SCT 5 43512 6 CLIP BODY 6 43520 4 NUT HX 1 2 13 G8 43738 1 WIRE ASY 02 36 0 GRND 13 10 11 12 13 14 15 16 17 18 19 20 2000 5 5 5 OPERATING INSTRUCTIONS Page 1 of 3 Do not operate this
25. he cable passes through bulkheads If the vehicle s negative ground cable is grounded only to the vehicle s engine then install a second ground cable from the negative post of the battery to the vehicle s frame The vehicle should be equipped with a minimum 125 amp alternator but a larger capacity is highly recommended Note alternator performance is significantly affected by vehicle RPM and temperature At standard truck idle speeds the alternator output can be as low as half of rated capacity The vehicle should be running during crane operation and it is recommended that it run at an elevated idle A 150 amp circuit breaker is required for all crane installations not included 2000 5 5 5 BATTERY Adequate battery power is a necessity for satisfactory crane operation Most original equipment vehicle batteries are designed for relatively light service of vehicle operation On vehicles with longer distances between battery and crane or if heavy or extended periods of operation are anticipated a heavy duty battery may be installed in the vehicle or a second 12 volt battery added to the vehicle system in order to increase available amperage The vehicle charging system should be functioning properly The battery charging system should supply a minimum of 13 volts DC at the crane with the vehicle engine running The voltage should not drop below 9 volts when any function of the crane is actuated It should also be no
26. ined by using a known weight 2 000 Ibs and a known radius 3 feet Another example would be 1 000 Ibs 6 ft Any combination where the multiplication of the load and the radius length equates 6 000 ft lbs is acceptable 7 Adjust the set screw so that it rests against the end of the plunger Turning the setscrew counterclockwise increases the load capacity while turning it clockwise decreases capacity 8 Relieve the pull on the winch line by operating the hoist down switch on the remotel control until the dynamometer reads 0 zero 105 9 Repeat procedure 45 When the pull reads the appropriate weight the load sensor should stop the winch 10 If the load sensor engages at the proper pull it is set correctly and the nut securing the set screw should be tightened 11 If the load sensor does not engage properly follow the procedure in 5 until the proper setting is attained 29 2000 SERIES CRANES SPARE PARTS It is recommended that repair parts for your crane be obtained from your local RKI distributor Please note that unauthorized servicing or alteration of your crane will void the warranty Each crane is assigned serial number which is stamped on nameplate located on the side of the turret The serial number can also be found in the owner s manual that is provided with the crane Please record your serial number and retain copy of your invoice for future reference If your crane should need service this infor
27. mation will be required Below is a list of miscellaneous parts not previously listed in this manual Part Part Description Number Comment Contactor 44239 4 Post Contactor Assembly Cover Contactor 45139 Cover for solenoid on Warn winch s n 4909 amp later Motor Winch 12 44242 Motor only 2post Remote 12 Control 45148 Remote s n 4909 amp later 30 2000 SERIES CRANES TROUBLESHOOTING Crane slowly stops while Check for weak battery or bad connections Remove any corrosion from both lifting ground and positive posts Cranes only operable Overload sensor may be set off Lower load to ground and switch will function is hoist down automatically reset Anti Two Block switch may be disengaged When the travel block is not in contact with the rail system the rail system should be in its home position compressing the switch If the rail system does not pivot freely the anti two block system is not operating correctly Contact your distributor or the RKI factory for further assistance Load sensor gets out of See instructions to recalibrate in this manual adjustment Anti Two Block microswitch The anti two block system and its switch are preset at the RKI factory No gets out of adjustment adjustment or re setting is necessary If the anti two block system is not operating correctly contact your distributor or the RKI factory for assistance Crane will not lift load Load may exceed crane capacity Refer to the
28. ne is now in operating position and ready for handling the load No crane shall be loaded beyond the specifications of the load rated chart The load to be lifted is to be within the rated capacity of the crane refer to the crane load capacity chart Pay special attention to the advisory decals attached to the crane 14 2000 SERIES CRANES OPERATING INSTRUCTIONS Page 2 of 3 2 THIS AREA SHOULD BE AVOIDED 77 PROHIBITTED ZONE SEE TABLE 1 CRANE SHALL NOT BE USED TO HANDLE MATERIALS IN THIS AREA bike 2 21 When loads which accurately known to be lifted the person responsible for the job lift shall ascertain that the weight of the load does not exceed the crane ratings at the maximum radius at which the load is to be handled 22 Always adjust the rotation handbrake Table 1 Normal Voltage kV Phase to Phase Minimum Required Clearance feet meters Operation near High Voltage Power Line Up to 50 Over 50 to 200 Over 200 to 350 Over 350 to 500 Over 500 to 750 Over 750 to 1000 10 3 05 15 4 57 20 6 10 25 7 62 35 10 67 45 13 72 Operation in Transit With No Load and Boom Lowered Up to 0 75 Over 0 75 to 50 Over 50 to 350 Over 345 to 750 Over 750 to 1000 4 1 22 6 1 83 10 3 05 16 4 88 20 6 10 23 The hoist rope shall not be wrapped around the load 24 The load shall be attached to the hook by means of slings or
29. not be parked on uneven rocky or muddy terrain steep grades or overhead obstructed locations Fully extend the jacklegs to the ground to provide firm support and keep the crane mounted vehicle as level as possible during the operation When operating on soft terrain use wider pads or boards under the jackleg foot Blocking under the jackleg foot shall be of sufficient strength to prevent crushing bending or shear failure After the vehicle has been properly positioned engage the emergency brake and start the engine Connect the remote control to the crane making sure the connector is properly engaged If the unit is equipped with a master cutoff switch turn on power to the crane Vehicle should be running during all crane operations and it is recommended that it run at an elevated idle When operating near electric power lines comply with the requirements of OSHA 29 CFR Part 1426 1408 Summarized in Figure 1 and Table 1 no part of the crane or load may enter the danger zone For power lines rate 50 kV or below minimum clearance between the lines and any part of the crane or load including handling appendages shall be 10 ft 3 m For higher voltages see Table 1 Caution shall be exercised when working near overhead power lines because they can move horizontally or vertically due to wind moving the danger zone to new position While in transit with no load and boom lowered the clearance shall be as specified in Table 1 The cra
30. oth the crane lower mounting base and the service body s top mounting plate removing any paint primer or sealants The crane is electrically grounded through the base plate thus it is important that there is a good metal to metal contact between the crane and the mounting location Lift in place and install Grade 8 mounting bolts with nuts and washers Note use only bolts nuts and washers provided with crane Do not substitute and do not reuse bolts that have been previously torqued Tighten Grade 8 bolts in criss cross pattern alternating until all are torqued to 95 ft Ibs dry bolt If crane is being installed on a service or utility body seal around all holes and bolts with silicone or equivalent sealer Also seal around crane mounting plate Connect the 25ft power cord to the crane s quill then route the cord along the vehicle s frame rail to the vehicle s battery Care must be taken so that the power cable is not positioned against burrs sharp edges or anything that would chafe or cut the cable insulation The cable should be supported at intervals to prevent sagging or dragging Use rubber grommets when cable passes through bulkheads Cut cable to the minimum required length and connect it to the positive post of the vehicle s battery with the appropriate lug or clamp connection Use the supplied 3ft ground cable to ground the crane base mounting base or service body to the truck chassis Use rubber grommets where t
31. ted that the performance of vehicle s alternators drops significantly with running idle speed and ambient temperature At standard truck idle speeds the alternator output can be as low as half of the rated capacity So it is recommended that the vehicle be running at an elevated idle during crane operation Normal operation of the crane should not require a second battery However if a second battery is used it should be connected to the first battery in parallel positive post to post and negative post to post GROUNDING Proper and adequate grounding of the crane is necessary to prevent poor performance or malfunction The 2000 Series cranes are grounded through the bottom mounting plate good ground must be established between the crane s lower mounting base and the vehicle battery For service or utility body mounting this grounding typically goes through the service body mounting plate to the service or utility body and then to the vehicle frame Ensure that a good metal to metal contact is made between the crane s lower base and the service body mounting plate If the body is mounted to the truck on wood runners or rubber mounts a 2 gauge ground cable must be added between the body and the chassis frame The vehicle battery and second battery if used must be grounded directly to the chassis frame If the vehicle battery is grounded to the engine block a second 2 gauge minimum ground cable must be added from the battery to the c
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