3200 SERIES CRANES
Contents
1. 3200 SERIES CRANES Eg Commercial Grade USER MANUAL S PISI V IE a Models 3200 3ER15 3200 3ERX15 Serial Number Date RKI Inc 2301 Central Parkway Houston TX 77092 Phone 713 688 4414 Fax 713 688 8982 www rki us com 3200 SERIES CRANE TABLE OF CONTENTS Description Page PACKING LIST P ed cause ea eke ee ee ed ce ou 2 IMPORTANT NOTICE 3 SPEGIFIGATIONS uu L a ee tete Saw ie ed 4 OVERALDDDIMENSIONS a sca di ee au aka 5 3200 SERIES CAPACITY 6 INSTALLATION INSTRUCTIONS ns 7 OPERATING INSTRUCTIONS 9 LUBE HYDRAULIC FLUID SPECIFICATIONS 12 INSPECTION amp MAINTENANCE SCHEDULE 13 3200 3ER15 WIRING SCHEMATIC 14 3200 3ERX15 WIRING SCHEMATIC 15 3200 3ER15 ELECTRICAL ASSEMBLY 16 3200 3ERX15 ELECTRICAL ASSEMBLY 18 BOLT TORQUE CR dd a te 20 3200 3ER15 BOOM ASSEMBLY 22 3200 GERX 15 BOOM ASSEMBLY 24 TURRET ASSEMBLY ms aaa 26 3200 3ER2. SHLDR 0 5 x 1 5 8 31 43704 TURRET 3200 SERIES 1 32 43752 PIN W KPR 1 00 7 69 3200 1 33 43756 PIN W KPR 1 25 7 69 3200 1 34 43760 SPACER 3200 WORM 1 57 2 35 43761 SPACER 3200 TURRET ROT BRG 1 36 43762 COVER 3200 TURRET REAR 1 37 43763 SHAFT 08 WORM 3200 ROT 1 38 43767 BRACKET 3200 CONT ROT MT 1 39 43768 BRACKET MICROSWITCH MTG 1 40 43774 BRACKET 3200 HOSE RING 1 41 43831 WASHER FENDER 3 8 PLATED 2 42 44102 SCRW CP HX 1 4C x 1 1 2 43 44343 COVER PUMP 3200 CRANE 1 44 44504 SCREW CPHEX 0 25 1 25 1 Turret assembly 27 3200 SERIES CRANE 3200 3ER15 HYDRAULIC ASSEMBLY P N 43791 28 3200 3ER15 Hydraulic assembly 3200 SERIES CRANE 3200 3ER15 HYDRAULIC ASSEMBLY P N 43791 Part Number Description 1 40341 MOTOR HYDRAULIC 103 1028 1 2 43368 FITTING 56M TO 25FP ST 2 3 43374 FITTING 25FP 1 4 43376 FITTING 25MP 25FPS 90 6 5 43379 FITTING 25MP 25FP 90 1 6 43465 FITTING 56MS PLUG HEX TOP 2 7 43541 FITTING ADAPTER 50M TO 25F 2 8 43715 CYLINDER HYD 3 00B 14 50S 1 9 43775 FITTING 56MS 25FPS45 4 10 43779 HOSE HYDRAULIC 0 25D 25MP17 2L 2 11 43780 HYDRAULIC 0 25D 25MP34 0L 2 12 43799 FITTING 56MS 25FP 90 2 13 43801 FITTING 25MP 25FPS9006 1 14 43802 PUMP HYDRAULIC 3200 SERIES 12V 1 15 43906 VALVE COMPL 3200 COMPACT 1 16 43912 PLUG 3200 HYD VALVE BOTTOM 2 17 44231 HOSE HYDRAULIC
3. Specifications 12 000 10 000 t TYP a O gt Os MOUNTING HOLE PATTERN 21 250 34 500 3200 SERIES CRANE OVERALL DIMENSIONS 8 000 za CRANE CENTER OF GRAVITY BOOM ELEVATION 75 MAXIMUM 5 MINIMUM 83 000 FULLY RETRACTED 131 000 INTERMEDIATE POWER EXTENSION 4 125 179 000 COMPLETE EXTENSION Overall dimensions 5 3200 SERIES CRANE 3200 SERIES CAPACITY CHART Jis E 88 E 8 X NOTES 1 Overload Protection Limits Hoist Up Boom Extend and Boom Dow 2 2 000 Ibs Hoist Capacity 3 Use 2 Part Line Only EC PN BOOM HEIGHT FEET G LL LLL pe I e 27 N X m TT EN Le Ot se LM 2 A 21 e N e e N N N a N i N e e N lt o 9 2 9 5 2 9 9 5 2 9 9 69 BOOM RADIUS FEET amp CAPACITY LBS 6 3200 Series capacity chart 10 11 12 13 14 15 16 3200 SERIES CRANE INSTALLAT
4. While in transit with no load and boom lowered the clearance shall be as specified in Table 1 The crane is now in operating position and ready for handling the load No crane shall be loaded beyond the specifications of the load rated chart except for testing purposes The load to be lifted is to be within the rated capacity of the crane refer to the crane load capacity chart When loads which are not accurately known are 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 The hoist rope shall not be wrapped around the load The load shall be attached to the hook by means of slings or other devices of sufficient capacity The operator shall not leave the controls while the load is suspended Operating instructions 25 26 27 28 29 30 31 32 33 34 35 36 3200 SERIES CRANE OPERATING INSTRUCTIONS connue No person should be permitted to stand or pass under a suspended load Before starting to lift the following conditions should be noted a The hoist rope shall not be kinked b Part lines shall not be twisted around each other c The hook shall be brought over the load in such a manner as to minimize swinging d The effect of ambient wind on the load and on crane stability The person directing the lift shall see that a The crane i
5. 0 25 25MP20 0L 3 18 44232 NIPPLE M TOM 25 X 25 1 3200 3ER15 Hydraulic assembly 29 3200 SERIES CRANE 3200 3ERX15 HYDRAULIC ASSEMBLY P N 43790 gt A A g UCM lt M 5 7 30 3200 3ERX15 Hydraulic assembly 3200 SERIES CRANE 3200 3ERX15 HYDRAULIC ASSEMBLY P N 43790 Part Number Description 1 40341 MOTOR HYDRAULIC 103 1028 1 2 43368 FITTING 56M TO 25FP ST 2 3 43374 FITTING 25FP 2 4 43375 FITTING 25MP 37TB 90 2 5 43376 FITTING 25MP 25FPS 90 6 6 43379 FITTING 25MP 25FP 90 1 7 43541 FITTING 50MP 25FP ST 2 8 43708 CYLINDER HYD 2 00B 48 00S 1 9 43715 CYLINDER HYD 3 00B 14 505 1 10 43775 FITTING 56MS 25FPS45 6 11 43779 HOSE HYDRAULIC 0 25D 25MP17 2L 2 12 43780 HOSE HYDRAULIC 0 25D 25MP34 0L 2 13 43781 HOSE HYDRAULIC 0 25D 25MP50 0L 2 14 43799 FITTING 56MS 25FP 90 2 15 43801 FITTING 25MP 25FPS9006 2 16 43802 PUMP HYDRAULIC 3200 SERIES 12V 1 17 43906 VALVE COMPL 3200 COMPACT 1 18 44126 TUBE 3200 HYDRAULIC CYLINDER EXTEND 1 19 44184 FITTING 45 SWIVEL ELBOW 0 25 MALE PIPE TO 0 25 FEMALE PIPE 1 20 44231 HOSE HYDRAULIC 0 25 25MP20 0L 21 44232 NIPPLE M TOM 25 X 25 2 3200 3ERX15 Hydraulic assembly 31 3200 SERIES CRANE Installation Kit P N 43746 SWITCH ASSEMBLED TO BRACKET Item Pa
6. 3200 SERIES CRANE 4 SPECIFICATIONS Models 3200 3ERX15 3200 3ER15 Moment Rating 10 000 ft Ibs Lift Capacities 3 200 Ibs 3 ft 909 Ibs 11 ft 2 000 Ibs 5 ft 769 Ibs 13 ft 1 429 lbs 7 ft 667 Ibs 15 ft 1 111 Ibs 9 ft Boom Power telescoping boom extension ERX model only ranges 7 to 11 The boom angle varies from 5 to 75 Manual telescoping boom extension lengths 11 to 15 The boom angle varies from 5 to 75 Line Speed Over 13 7 feet per minute for single line first rope layer Multi Functions The crane configuration allows multiple electric and hydraulic functions to be performed simultaneously however multiple hydraulic functions are not possible Load Sensor A load sensor is standard to automatically protect overload Anti Two Block Anti two block feature prevents extending the boom against the traveling block and breaking the wire rope Winch Cable and Block 62 of 1 4 galvanized aircraft cable is supplied with traveling block for double line operation Electrical 12 V D C electrical solenoid valves control all the powered functions Safety Standards Meets OSHA 1910 180 requirements and ANSI B30 5 safety standards Specifications Weight 710 Ibs 3200 3ERX15 571 Ibs 3200 3ER15 Length 12 1 Width 1 9 Height 2 10 1 2 Base Plate Dimensions 12 x 12 Truck Requirements 10 000 Ibs GVWR Minimum Jack Leg p n JKL1 or equivalent
7. 7 2 8 43363 NUT HEX 4 40 2 9 43425 NUT HEX LOCK 1 4NC 2 10 43452 WIRE 4 18 5 BLK SOL 1 11 43454 WIRE 18 24 0 BLK GROUND 1 12 43683 MICROSWITCH 2000 SERIES 2 13 43690 CABLE 16 V03 CONDUCTR FT 8 14 43699 SCREW PSLT 2 75 4 15 43700 NUT HEX 2 56 4 16 43738 WIRE 2 36 BLK GROUND 2 17 43777 TERMINAL 2PT JUMPER 5 18 43804 WIRE 4 13 5 BLK ROT 1 19 43815 WIRE 18 26 RED SOL 1 20 43906 HYD VALVE ASSY 1 21 43915 WASHER LOCK INTERNAL 2 4 22 44234 BRACKET ELECTRICAL ASSY 1 23 44239 SOLENOID ASY CRANE 1 24 44248 CORD REEL 3200 CRANE 1 25 44451 CONTROL ERX W EMER STOP 1 26 44842 HARNESS ELECT 3200 ERX 1 INCLUDED IN CORD REEL ASSEMBLY KIT P N 44193 INCLUDED IN ASY P N 44842 26 3200 3ERX15 Electrical assembly 19 3200 SERIES CRANE BOLT TORQUE CHART COARSE THREAD BOLT SIZE GRADE 2 GRADE 5 GRADE 8 SOCKET HEAD Strength 60 000 PSI 105 000 PSI 150 000 PSI 170 000 PSI UNC FT LBS FT LBS FT LBS FT LBS 1 4 20 5 1 10 11 5 16 18 9 15 21 23 3 8 16 17 27 38 41 7 16 14 27 43 60 65 1 2 13 40 65 92 99 9 16 12 58 94 133 138 9 8 11 81 130 184 191 3 4 10 90 230 326 338 7 8 9 146 372 526 546 1 8 218 558 788 818 1 1 8 7 309 695 1116 1159 1 1 4 7 436 981 1575 1635 1 3 8 6 572 1286 2065 2144 1 1 2 6 759 1707 2740 2845 Notes 1 Torque values listed above are based on dry and plated threads 2 A bolt that has been torqued t
8. Blue Microswitch D Gray Boom Up BU E Purple Rotate Right RR F Yellow Hoist Up G Brown Boom In BI H Black Common Red Rotate Left RL J Orange Emergency Stop L Pink Emergency Stop M White Boom Down BD 3200 3ERX15 Electrical assembly 15 3200 SERIES CRANE 3200 3ER15 ELECTRICAL ASSEMBLY P N 43787 28 22 KE ol Do o 7118 20 SOL CHYD PUMP WINCH MOTOR TERM ND 2 24 ON 7 HYD PUMP 4 10 GROUND 16 3200 3ER15 Electrical assembly KZ 7 gt lt lt go n R o a 7 LOAD CUT OFF WITCH 3200 SERIES CRANE 3200 3ER15 ELECTRICAL ASSEMBLY P N 43787 Item Part Number Number Description 1 07898 SCRW CP HX 1 4CX 3 4 GR2 2 2 41150 HEAT SHRINK 1 LONG 1 3 43102 TERMINAL 18GA 6 STUD 11 4 43263 CABLE ASY 4GA 19 LG 1 5 43314 DIODE 6 AMP 200 V AXIA 4 6 43315 TERMINAL STRIP 8 ON 38 2 43362 SCREW PHSLT 4 0 7 2 8 43363 NUT HEX 4 40 2 9 43425 NUT HEX LOCK 1 4NC 2 10 43452 WIRE 04 18 5 BLK SOL 1 11 43454 WIRE 18 24
9. the master cut off switch 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 the cable insulation Cable should be supported at intervals to prevent sagging or dragging Use rubber grommets where the cable passes through the 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 ground cable to ground the crane base mounting base or service body to the truck chassis Use rubber grommets where the cable passes through bulkheads If the vehicle s negative ground cable is grounded to the vehicle s engine install a second cable from the negative post of the battery to the vehicle s frame The vehicle should be equipped with a minimum 105 amp alternator but larger is highly recommended Installation Instructions 7 3200 SERIES CRANE 17 To check if the battery and charging system is adequate start the vehicle s engine and allow it to run at a fast idle Measure the voltage at the crane s power connection Minimum voltage should be 13 volts at this connection If the measurement is less than 13 volts replace battery alternator or add an additional battery 18 Vehicle should be running during all crane operations 19 Circuit breakers are required for all crane installation
10. 0 BLK GROUND 1 12 43465 FITTINGS 56MS PLUG HEX TOP 2 13 43683 MICROSWITCH 2000 SERIES 2 14 43690 CABLE 16 V03 CONDUCTR FT 8 15 43699 SCREW PHSLT 2 75 4 16 43700 NUT HEX 2 56 4 17 43738 WIRE 02 36 BLK GROUND 2 18 43777 TERMINAL 2PT JUMPER 3 19 43804 WIRE 04 13 5 BLK ROT 1 20 43815 WIRE 18 26 0 RED SOL 1 21 43906 HYD VALVE ASSY 1 22 43912 PLUG 3200 HYD VALVE BOTTOM 2 23 43915 WASHER LOCK INTERNAL 2 4 24 44234 BRACKET ELECTRICAL ASSY 1 29 44239 SOLENOID ASY CRANE 1 26 44248 CORD REEL 3200 CRANE 1 27 44671 CONTROL CRN ER REM E STP 1 28 44908 CONNECTOR 16 PIN ASY SKT 1 INCLUDED IN CORD REEL ASSEMBLY KIT P N 44193 INCLUDED IN P N 44908 28 3200 3ER15 Electrical assembly 17 3200 SERIES CRANE 3200 3ERX15 ELECTRICAL ASSEMBLY P N 43786 fh BDI IRL eh WINCH MOTOR TERM NO 1 24 e HYD PUMP GROUND e 3200 3ERX15 Electrical assembly 3200 SERIES CRANE 3200 3ERX15 ELECTRICAL ASSEMBLY P N 43786 Item Part Number Number Description 1 07898 SCRW CP HX 1 4CX 3 4 GR2 2 2 41150 HEAT SHRINK 1 LONG 1 3 43102 TERMINAL 18GA 6 STUD 13 4 43263 CABLE ASY 4 GA 19 LG 1 5 43314 DIODE 6 AMP 200V AXIA 6 6 43315 TERMINAL STRIP 8 ON 38 2 7 43362 SCREW PHSLT 4 0
11. 15 HYDRAULIC ASSEMBLY 28 3200 3ERX15 HYDRAULIC ASSEMBLY 30 INSTALLATION KIT 32 TRAVELING BLOCK ASSEMBLY nes tala a Re RE E Redon 33 TRAVELING BLOCK MICROSWITCH 34 LOAD SENSOR CALIBRATION 3200 SERIES CRANES 35 SPAREPARIS Sd aa eee ee ee 36 TROUBLESHOOTING 25525542546 noce au 37 LIFETIME WARRANTY a ee ro 38 Table of contents 1 3200 SERIES CRANE PACKING LIST 3200 SERIES CRANE The following items are included with your RKI 3200 Series crane 1 Crane Assembly 1 Crane Instruction Manual 1 Carton with the Following Contents 1 45157 Hot Cable Wire Asy Switch 12 1 45158 Hot Cable Wire Asy Switch 25 1 45156 Switch Mstr Cutoff 1 45155 Bracket 3200 Switch Mstr 1 43738 Ground Cable 2 ga X 3 6 43512 Cable Retaining Clip 4 43739 Mounting Bolt 5 8 x 3 gr 8 8 07892 Flat Washer 5 8 4 03032 Lock Washer 5 8 4 43740 Hex Nut 5 8 gr 8 1 Remote Control Corresponding to Model Number 44451 ERX 18 with E Stop 44671 ER 18 with E Stop 2 Packing list 3200 SERIES CRANE IMPORTANT NOTICE RKI Inc cannot possibly know or even anticipate all of the varied uses and applications
12. 3200 CRANE 1 42 44364 WINCH WARN DC2000 1 43 44640 BRACKET CABLE REEL 1 3200 3ERX15 Boom assembly 25 3200 SERIES CRANE TURRET ASSEMBLY P N 43793 26 Turret assembly 3200 SERIES CRANE TURRET ASSEMBLY P N 43793 Part Number Description 1 03029 375 WASHER LOCK 4 2 07882 WASHER LOCK 1 4 3 07885 WASHER FLAT 3 8 2 4 40006 KEY 08 WORM 0 18 2 37 1 5 40014 PLUG 08 BRG COVER 1 6 40034 WORM 08 36 1 LH 1 7 40078 COVER 08 BRG 1 8 40082 GREASE FITTING 1 8NPT 1 9 40156 BEARING CONE 08 0 87 ID 2 10 40157 BEARING CUP 08 2 12 OD 2 11 40605 SCREW STSKT 0 37 0 4 OVL 1 12 40816 ADAPTER HYD 08 2 BOLT A 1 13 40900 SCREW CPHEX 0 25 x 0 6 7 14 40911 SCREW CPHEX 0 37 0 7 4 15 40986 WASHER FLAT 1 4 SAE 7 16 40992 WASHER LOCK HI COLLAR 25 6 17 41013 SCREW CPSKT 0 25 0 5 1 18 41016 SCREW CAP SKT 25 x 1 75 6 19 41095 SCREW CAP HEX HD 25 x 1 0 6 20 41124 PIN ROLL 0 125 x 1 000 1 21 41967 GASKET BEARING HOLDER 2 22 43090 NUT HEX 250NC SELF LOG 1 23 43201 CONNECTOR CABLE FEM PANL 1 24 43297 BEARING CONE 3200 3 37 ID 2 25 43298 BEARING CUP 3200 5 37 OD 2 26 43305 BASE 3200 SERIES 1 27 43327 GEAR 3200 36 1 LH 1 28 43336 ROD 3200 ELEC ROD CONNECT 29 43346 PAD MTG F CONNECTING ROD 1 30 43360 SCREW SKTHD
13. 5 SCREW CAP SKT 25 x 1 75 2 11 43139 RING RTNG EXT 0 750 1P 2 12 43166 PIN GRVD 0 75 1 37 1 13 43331 SPACER BOOM 3200 amp 6000 2 14 43345 PIN QUICK 1 00 4 00 W L 2 15 43425 NUT HEX LOCK 1 4NC 4 16 43634 CLAMP LOOM 375 I D 1 17 43751 PIN KPR 0 75 1 62 3200 2 18 43753 PIN W KPR 1 00 2 24 3200 1 19 43783 SPACER 3200 EXT BOOM 1 20 43820 BOOM 3200 3ER15 MAIN 1 21 43821 BOOM 3200 3ER15 INT 1 22 43831 WASHER FENDER 3 8 PLATED 2 23 43834 WIRE ROPE 1 4 7x19 GALV 1 24 43909 SPACER 3200 BOOM HEAD 2 25 43986 VASHER FLAT 1 4 SAE 8 26 44009 POINTER DEGREE INDICATOR 2 27 44031 SCRW CP HX 3 8 16 x 7 2 28 44085 CAGE WIRE TWO BLOCK 3200 1 29 44086 MICROSWITCH HOUSING 1 30 44088 BOOM 3200 3ER15 EXT 1 31 44090 P CR 3200 ER TRAV BLOCK 1 32 44102 SCRW CP HX 1 4Cx1 1 2 5 33 44112 WASHER FENDER 3 8 PLATED 1 34 44248 CORD REEL 3200 CRANE 1 39 44249 EYE BOLT 25 20UNC 2 36 44364 WINCH WARN ASY 3200 1 37 44444 CORD GUIDE 3200ER CRANE 1 38 44640 BRACKET CABLE REEL 1 3200 3ER15 Boom assembly 23 3200 SERIES CRANE 3200 3ERX15 BOOM ASSEMBLY P N 43784 NOTE 1 P N 40005 IS ACOMPONENT WITHIN 43705 SHOWN HERE FOR REFERENCE ONLY 24 3200 3ERX15 Boom assembly 3200 SERIES CRANE 3200 3ERX15 BOOM ASSEMBLY P N 43784 Item Part Number Number Description 1 03029 375
14. ION INSTRUCTIONS Vehicle should meet minimum GVW rating of 10 000 Ibs The crane mounting base must be capable of safely supporting the crane assembly and its maximum capacity of 10 000 ft lbs loading The support structure for the mounting base must be tied directly to the main frame members of the vehicle The vehicle must be equipped with at minimum jacklegs extending out at least 42 from the centerline of vehicle Disconnect the ground cable from the battery Drill 4 holes with 21 32 diameter and a 1 diameter hole center with the 4 holes of the crane mounting location Install crane boom support in place and adjust to its lowest position Lift crane in place and install mounting bolts with nuts and washers Note use only bolts nuts and washers provided with crane Do not substitute Install master cut off switch bracket Line up bracket with the two inner bolts so that bracket is on the far side of the cabinet Tighten bolts in a criss cross pattern alternating until all are torqued to 200 ft lbs no lubrication on threads If crane is being installed on a service or utility body seal around all holes and bolts with silicone or equivalent sealer Adjust the boom support to contact with the boom and secure the crane hook to the hook ring Install the power cord in the crane Attach 12 power cord from the crane s quill to either terminal of the master cut off switch Connect the power cord to the other terminal of
15. Mobil DTE26 or equivalent premium grade hydraulic fluid 12 Lubrication amp hydraulic fluid specifications 3200 SERIES CRANE INSPECTION amp MAINTENANCE SCHEDULE Be sure to perform thorough and routine inspections and maintenance on your crane and truck just as you would with any other very expensive and very useful tool COMPONENT DAILY WEEKLY MONTHLY FERT YEARLY NOTES MONTHS Sheaves and Bearings Check Make sure the cable is wound evenly on the drum Check for cut or broken strands kinking et cetera Check for any cracks or deformation of the hook or latch Inspect for any damage and add grease to bearings Make sure the sheaves turn freely X X Or more often under severe conditions X X Rotational Bearing Add grease to the bearing Check the bolt torque for the four mounting bolts and tighten other bolts as required Base Mounting Bolts amp Other Bolts Inspect for any damage or Hydraulic Hoses leakage at fittings Check fluid level at the reservoir before each shift Hydraulic Fluid Drain flush and refill with Hydraulic Reservoir hydraulic fluid Boom Wear Pads Inspect pads and replace as required Or more Boom Pivot often under Add grease to fittings severe conditions 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 oi
16. ND DESIGNS ARE SUBJECT TO CHANGE WITHOUT NOTICE www rkius com RKI Inc 2301 Central Parkway Houston Texas 77092 713 688 4414 FAX 713 688 8982
17. WASHER LOCK 8 2 07756 SCRW CP HX 1 4C x 2 5 2 3 07882 WASHER LOCK 1 4 16 4 07885 WASHER FLAT 3 8 4 5 07887 WASHER FLAT 7 16 6 6 40080 GREASE FITTING 2 7 40911 SCRW CP HX 5 16C x 3 4 8 8 41013 SCREW CPSKT 0 25 0 5 8 9 43041 PULLEY 4 00D 75BORE 2 10 43135 SCREW CAP SKT 25 x 1 75 2 11 43139 RING RTNG EXT 0 750 1P 2 12 43166 1 13 43331 SPACER BOOM 3200 amp 6000 2 14 43345 PIN QUICK 1 00 4 00 W L 2 15 43425 NUT HEX LOCK 114NC 4 16 43634 CLAMP LOOM 375 I D 1 17 43705 BOOM 3200 3ERX 15 MAIN includes two 40005 Bronze Bushings 1 18 43706 BOOM 3200 3ERX 15 IMDT 1 19 43751 PIN W KPR 0 75 1 62 3200 2 20 43753 PIN W KPR 1 00 2 24 3200 1 21 43754 PIN W KPR 1 00 5 81 3200 1 22 43755 PIN W KPR 1 00 3 81 3200 1 23 43758 SPACER 3200 EXT CYL HEAD 2 24 43759 SPACER 3200 EXT CYL ROD 2 25 43783 SPACER 3200 EXT BOOM 1 26 43831 WASHER FENDER 3 8 PLATED 4 21 43834 WIRE ROPE 1 4 7x19 GALV 1 28 43909 SPACER 3200 BOOM HEAD 2 29 43986 WASHER FLAT 1 4 SAE 12 30 44009 POINTER DEGREE INDICATOR 2 31 44031 SCRW CP HX 3 8 16 x 7 2 32 44085 CAGE WIRE TWO BLOCK 3200 1 33 44086 MICROSWITCH HOUSING 1 34 44088 BOOM 3200 3ERX 15 15 EXT 1 35 44090 P CR 3200ERX TRAV BLOCK 1 36 44093 COVER 3200ERX EXTEND CYL 1 37 44102 SCRW CP HX 1 4C x 1 1 2 9 38 44112 WASHER FENDER 3 8 PLATED 1 39 44248 CORD REEL 3200 CRANE 1 40 44249 EYE BOLT 25 20UNC 2 41 44258 CORD GUIDE
18. e nut securing the setscrew should be tightened If the load sensor does not engage properly follow the procedure in 6 until the proper setting is attained NOTE dynamometer is not available the same results can be obtained by using a known weight 3 200 Ibs and a known radius 3 ft Another example would be 2 000 Ibs 5 ft Load Sensor Calibration 172 05 35 3200 SERIES CRANE SPARE PARTS It is recommended that repair parts for your crane be obtained from your local distributor Please note that unauthorized servicing or alteration of your crane will void the warranty Each crane is assigned a serial number which is located on the base plate 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 a copy of your invoice for future reference If your crane should need service this information will be required 36 Spare parts Problem Crane slowly stops while lifting 3200 SERIES CRANE TROUBLESHOOTING Solution Check for weak battery or bad connctions Cranes only operable functions are rotation and hoist down Overload sensor may be set off Lower load to ground and switch will automatically reset If power boom is extended check the boom head to determine if wire cage is in contact with microswitch If there is contact all functions can be returned tby either hoisting down or retracting the boom in Load se
19. eturning 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 10 The load sensing device is located in the upper right hand section of the crane housing It consists of a micro switch fastened to a bracket which in turn is secured to an upright bar welded into the crane turret The plunger on the micro switch may be adjusted by means of the adjacent setscrew Loosen the nut securing the setscrew to the bar across the back of the turret Adjust the boom elevation and extension until the centerline of hook is at a position exactly 3 from the center of rotation then connect a dynamometer Raise the hook by operating the up position switch on the control handle until the dynamometer reads 3 200 Ibs f you do not have a dynamometer please see the note below Adjust the setscrew so that it rests against the end of the plunger Turning the setscrew counter clockwise increases the load capacity while turning it clockwise decreases capacity Relieve the pull on the winch line by operating the down position on the control handle until the dynamometer reads 0 Ibs Again follow the procedure in 6 When the pull reads 3 200 158 the load sensor should stop the winch If the load sensor engages at the proper pull it is set correctly and th
20. he 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 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 38 Merchandise return policy 3200 SERIES CRANE NOTES Notes 39 Other Quality Products gt Aluminum Treadplate and Steel Truck Boxes for Pick Up Trucks and Flatbeds gt Canopy Bodies gt Custom Truck Boxes and Service Bodies gt Line Bodies gt Saddle Compartments gt Service Bodies gt Space Packs gt Versatile Storage Systems gt Window Grilles RKI manufactures special cranes consult your nearest dealer with your custom needs IN ORDER TO PROVIDE YOU WITH THE MOST INNOVATIVE AND PROGRESSIVE EQUIPMENT SPECIFICATIONS A
21. l as needed To extend the life of cable clean it periodically with a wire brush and lubricate it lightly with oil Inspection amp maintenance schedule 13 3200 SERIES CRANE 3200 3ER15 WIRING SCHEMATIC 12VDC O O W ES C9 ROTATE R E O ds O O RL ROTATE LEFT OVERLOAD 2 BLOCK gt SWITCH SWITCH HOIST UP F c O O Q O Q A O HOIST DOWN RUN J O D BOOM UP D HOIST UP 2 az iG pa M 63 BOOM DOWN 62 P HYDRAULIC PUMP MOTOR 52 52 51 Connector HOIST Position M2 H 9 B N A N A S3 MOTOR S3 C Blue Microswitch D Gray Boom Up BU E Purple Rotate Right RR F Yellow Hoist Up G N A N A H Black Common Red Rotate Left RL J Orange Emergency Stop Pink Emergency Stop M White Boom Down BD 14 3200 3ER15 Wiring schematic OVERLOAD SWITCH 3200 3ERX15 WIRING SCHEMATIC 3200 SERIES CRANE ROTATE R 1 ce ROTATE LEFT HOIST UP F O HOIST UP HYDRAULIC PUMP MOTOR I T a o HOIST DOWN I RUN O lt lt M 21 STOP BOOM UP D Fe t M Lies BOOM DOWN BOOM OUT B O 69 gt LO gt I Connector Position Hoist Down B Tan Boom Out BO C
22. maged by being bent out of shape The microswitch should be aligned with the small strike plate on the wire cage The wire cage should be centered with the boom head as viewed from the end and hang down with approximately 3 4 to 1 space below If it is not it may be reshaped by carefully bending by hand Otherwise a new wire cage may be required 2 the wire cage is in good condition or has been replaced or straightened the two socket head screws on the microswitch housing should be loosened and the switch positioned so that it has a gap with the thickness of a credit card or less between it and the small strike flat on the wire cage Then tighten the two microswitch housing screws firmly 3 Test the microswitch function by either booming out or hoisting up until the traveling block comes in contact with the wire cage After contact with the wire cage but before the block hits the bottom head all functions except rotation boom in and hoist down should fail to operate Now boom in or line out and all functions should again operate 34 Traveling Block Microswitch Resetting 282 03 3200 SERIES CRANE LOAD SENSOR CALIBRATION RKI 3200 SERIES CRANES Your RKI crane is equipped with a torque reading load sensor which prevents overloading If the crane s load capacity is exceeded the load sensor deactivates all winch functions except rotation and hoist down Remove the load from the crane and the overload sensor is AUTOMATICALLY reset r
23. ne operations If the unit is equipped with a power disconnect switch turn on power to the crane Lower the winch to detach the crane hook from the tie down eye Always boom up to clear the boom support before you rotate and extend boom to desired position When operated near electric power lines no part of the crane or load enters into danger zone shown in Figure 1 For power lines rate 50 kV or below minimum clearance between the lines and any parts of the crane or load including handling appendages shall be 10 ft 3 m For higher voltages see Table 1 Operating instructions 9 3200 SERIES CRANE 16 M 18 19 20 21 22 23 24 10 OPERATING INSTRUCTIONS connue Table 1 THIS AREA SHOULD Normal Voltage kV Minimum Required Phase to Phase Clearance ft m RR A Sr Ds 7 PI Operation near High Voltage Power Line SEE TABLE 1 to 50 10 3 05 Over 50 to 200 15 4 60 Over 200 to 350 20 6 10 Over 350 to 500 25 7 62 Over 500 to 750 35 10 67 Over 750 to 1000 45 13 72 N Operation in Transit With No Load and Boom Lowered to 0 75 Over 0 75 to 50 Over 50 to 350 CRANE SHALL NOT BE USED TO Over 345 to 750 7 HANDLE MATERIALS IN THIS AREA Over 750 to 1000 Figure 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
24. nsor gets out of adjustment See instructions to recalibrate Microswitch gets out of adjustment See instructions for traveling block microswitch resetting Crane will not lift load Load may exceed crane capacity Refer to the 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 operate Check for any loose exposed or frayed wires Make sure the switches return freely to the center position and are not sticking or loose Inspect the plug pins for damage Sporadic Functions Check the hot cable connections from the power source to the crane This includes the quick disconnect 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 A replacement battery alternator or adding an additional battery may be necessary Always provide the serial number of the crane stamped on baseplate for further troubleshooting questions Troubleshooting 37 3200 SERIES CRANE RKI 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 t
25. o its rated value and then removed should be replaced 20 Bolt torque chart 3200 SERIES CRANE BOLT TORQUE CHART FINE THREAD BOLT SIZE GRADE 2 GRADE 5 GRADE 8 SOCKET HEAD Strength 60 000 PSI 105 000 PSI 150 000 PSI 170 000 PSI UNF FT LBS FT LBS FT LB FT LBS 1 4 28 5 11 12 13 5 16 24 10 22 24 25 3 8 24 19 40 43 46 7 16 20 30 62 68 73 1 2 20 46 96 104 112 9 16 18 65 137 148 154 5 8 18 91 192 208 216 3 4 16 159 336 364 378 7 8 14 200 534 579 601 1 14 244 815 883 917 1 1 8 12 347 1011 1252 1300 1 1 4 12 483 1408 1744 1811 1 3 6 12 651 1899 2351 2441 1 1 2 12 854 2490 3083 3202 Notes 1 Torque values listed above are based on dry and plated threads 2 A bolt that has been torqued to its rated value and then removed should be replaced Bolt torque chart 21 3200 SERIES CRANE 3200 3ER15 BOOM ASSEMBLY P N 43785 22 3200 3ER15 Boom assembly 3200 SERIES CRANE 3200 3ER15 BOOM ASSEMBLY P N 43785 Item Part Number Number Description 1 03029 375 WASHER LOCK 4 2 07756 SCRW CP HX 1 4C x 2 5 2 3 07882 WASHER LOCK 1 4 12 4 07885 WASHER FLAT 3 8 2 5 07887 WASHER FLAT 7 16 6 6 40080 GREASE FITTING 2 7 40911 SCRW CP HX 5 16Cx3 4 4 8 41013 SCREW CPSKT 0 25 0 5 8 9 43041 PULLEY 4 00D 75BORE 2 10 4313
26. persons such as supervisors 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 shall 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 truck mounted crane 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 truck mounted crane shall not be parked on uneven rocky or muddy terrain steep grades and obstructed overhead locations Fully extend the outriggers out and to the ground to provide firm support and keep the truck mounted crane as level as possible during the operation When operating on soft terrain use wider pads or boards under the outrigger feet Blocking under the outrigger feet shall be of sufficient strength to prevent crushing bending or shear failure After the truck mounted crane has been properly position engage the emergency brake and start the engine Vehicle should be running during all cra
27. rt Number Number Description 1 03032 WASHER LOCK 5 8 4 2 07892 WASHER FLT 5 8 W 8 3 43512 CLIP BODY F BATTERU CABL 6 4 43738 WIRE ASY 02 36 0 GRND 1 5 43739 BOLT HX 5 8 11X3 G8 4 6 43740 NUT HX 5 8 11 G8 4 7 45155 BRACKET 3200 SWITCH MSTR 1 8 45156 SWITCH MSTR CUTOFF 1 9 45157 WIRE ASY PWR CRANE 12 1 10 45158 WIRE ASY PWR BATTERY 25 1 11 45174 FACEPLATE SWITCH MSTR 1 12 43211 CONNECTOR CABLE FEM SK 1 INCLUDED IN CRANE POWER WIRE ASY 32 Installation Kit 3200 SERIES CRANE TRAVELING BLOCK ASSEMBLY P N 44090 Item Part Number Number Description Qty 1 03029 3 5 WASHER LOCK 2 2 07756 SCRW CP HX 1 4C X 2 5 2 3 07885 WASHER FLAT 3 8 2 4 40911 SCRW CP HX 5 16CX3 4 2 5 43041 4 00D 75 BORE 1 6 43425 NUT HEX LOCK 1 4NC 2 7 43750 PIN W KPR 0 75 2 25 3200 2 8 43819 HOOK 2 TON SWIVEL W L 1 9 43909 SPACER 2 10 44087 PLATE 3200ERX TRAV BLOCK 2 Traveling block assembly 33 3200 SERIES CRANE RKI 3200 ERX CRANE TRAVELING BLOCK MICROSWITCH RESETTING The microswitch located on the boom head needs to be adjusted in either of the following conditions When the traveling block compresses the wire cage until it comes in contact with the boom head and all the crane functions continue to operate When the block is not in contact with the wire cage and or boom head and all crane functions fail to operate except rotation and lineout 1 Make sure that the wire cage has not been da
28. s Distributor Furnished Item Circuit breakers for 2000 2500 and 3200 Series Cranes are to be 150 amps 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 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 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 chassis frame or engine to the chassis frame 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 Main
29. s 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 other 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 Operating instructions 11 3200 SERIES CRANE LUBRICATION amp HYDRAULIC FLUID SPECIFICATIONS 1 Rotational Bearing Lubrication Specification Mobil grease CM S 3200 crane 2 Hydraulic Fluid a Fluid Specification
30. tain 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 RESONSIBLE TO COMPLY WTH THE OSHA TRUCK CRANE STABILITY REQUIREMENTS AS SPECIFIED BY 29 CFR PART 1910 180 C I 8 Installation instructions 10 11 12 13 14 15 3200 SERIES CRANE OPERATING INSTRUCTIONS Do not operate this crane unless you have thoroughly read and understand the information contained in this manual Cranes shall be operated only by the following qualified personnel Designated persons Trainees under the direct supervision of a designated person Maintenance and test personnel when it is necessary in the performance of their duty Inspectors crane o o No one other than the personnel specified in 2 above shall enter the crane s operating area with the exception of
31. that may be found for its crane products For 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 Important notice 3
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