h6400 manual 052009.qxp
Contents
1. 1 b ESI e Tm 222 1900 cal P ALD 5 31 IS 27 59 35 15 6 Overall dimensions H6400 SERIES CRANE CAPACITY CHART H6400 CAPACITY CHART LL 9 Lu Q o 10 12 27 59 BOOM RADIUS FEET FROM MTG BASE TE FOOI PROT CAPACITY IN POUNDS Capacity chart 7 H6400 SERIES CRANE INSTALLATION INSTRUCTIONS Vehicle must meet minimum GVW rating of 15 000 Ibs and MUST be equipped with an engine speed control and tachometer The crane mounting base and structure must be capable of safely supporting the crane assembly weight and its maximum capacity of 38 000 ft lbs loading The vehicle must be equipped with outriggers to provide stability Drill 4 29 32 diameter holes on a 14 75 square pattern and an 11 00 diameter cut out centered with the 4 holes of the crane mounting location See Page 6 Overall Dimensions diagram of user manual for mounting pattern Install the crane boom support in place and adjust to its lowest position Lift the crane in place and use four 7 8 diameter grade 8 bolts flat washers and loc2. i 2 gt 9 i Pd W 3 e A e 9 TA y 2 Item Part Number Number Description 1 W03030 WASHER LOCK 50 2 2 07784 SCREW CPHEX 50 X 1 00 2 3 W07889 WASHERC FLAT 50 2 4 W40902 SCREW CPHEX 25 2 75 4 5 W43425 NUT HEX 250NC FLEX 4 6 W44489 HOOK 3 0 TON SWIVEL W L 1 7 W44490 PULLEY 1 8 W44567 PLATE TRAVELING BLK 2 9 W44568 SPACER 4 10 W44569 PIN W KEEPER 2 30 Traveling block assembly H6400 SERIES CRANE ANTI TWO BLOCK ASSEMBLY P N 44611 Item Part Number Number Description Qty 1 01109 HOOK S 1 3 8 2 2 01111 CHAIN MACHINE STRAIGHT LINK 1 3 44612 WEIGHT ASS Y ANTI TWO BLOCKS 1 4 43017 MICROSWITCH STANDARD 1 5 43018 ACTUATOR MICROSWITCH 1 6 44675 1 7 44676 CLEVIS PIN 1 8 07848 NUT HEX 31 18UNC 1 9 07760 SCREW CPHEX 31 18UNC 1 0 LG 1 10 40022 COTTER PIN 3 32 X 1 1 11 44789 LEVER ARM ASSEMBLY 1 12 44790 GROMMET 5 16 I D X 5 8 O D 1 Anti two block assembly 31 H6400 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 yo
3. Item Part Number Number Description 1 44474 BOOM ELEVATION CYLINDER 1 2 44564 PIN BOOM ELEVATION CYLINDER 2 3 44563 MOUNTING PIN OUTER BOOM 1 4 44248 ELECT CORD REEL 1 5 44525 WIRE ROPE 3 8 DIA 1 6 44560 6 HOSE EXT CYLINDER 28 LG 2 7 44649 6 HOSE ELEV CYL 38 5 LG 2 8 44562 TRAVELING BLOCK ASSEMBLY 1 9 44561 CABLE CLAMP ANTI TWO BLOCK 1 10 44648 PRESSURE TRANSDUCER 1 11 44566 TURRET ASSEMBLY 1 12 03029 WASHER FLAT 38 DIA 4 13 07769 SCREW CPHEX 38UNC 1 0 4 14 44565 BOOM ASSEMBLY 1 15 44783 FITTING MALE Z6 SAE O RING TO JIC 2 16 44793 SLEEVE GUARD HYD HOSE NOT SHOWN 2 22 Top level assembly H6400 SERIES CRANE BOOM ASSEMBLY P N 44565 Item Part Number Number Description 1 44572 SIDE WEAR PAD MIDDLE BOOM 2 2 44573 BOTTOM WEAR PAD MIDDLE BOOM 1 3 44574 WEAR PAD COVER 4 4 44575 STOPPER 2 5 44576 OUTER BOOM 1 6 44591 MIDDLE BOOM 1 7 44598 INNER BOOM 1 8 44608 MTG PIN OUTER BOOM EXT CYLINDER 1 9 44609 MTG PIN INNER BOOM EXT CYLINDER 1 10 44522 CLEVIS PIN 1 000 DIA 1 11 03030 WASHER LOCK 50 DIA 12 12 07784 SCREW CPHEX 50 1 00 12 13 44610 SIDE WEAR PAD OUTER BOOM 2 14 44524 RING RTNG EXT 1 250 DIA 2 15 43140 RING RTNG EXT 1 00 DIA 2 16 44611 ANTI TWO BLOCK ASSEMBLY 1 17 44679 BOTTOM WEAR PAD OUTER BOOM 1 18 07882 WASHER LOCK 25 DIA 19 44684 S
4. 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 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 36 Lifetime Warranty This page is intentionally left blank Other RKI 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 gt Winches RKI manufactures special cr
5. Na DA 22 BOOMASSEMBIY ks suma Sumu Via 23 TURRET ASSEMBLY RUOHEREMES UAE RENE 24 HYDRAULIC E ES 26 ELECTRICAL SWIVEL ASSEMBLY 27 HYDRAULIC MANIFOLD ASSEMBLY RR a RA 28 HYDRAULIC HOSE ASSEMBLY 29 TRAVELING BLOCK ASSEMBLY 255522255255 LES Sdn 30 ANTI TWO BLOCK ASSEMBLY 31 SPARE PART M C 32 TROUBLESHOOTING TRANSMITTER amp CONTROL MODULE 33 EMERGENCY DROP DOWN PROCEDURES 34 EMERGENCY VALVE OPERATION 35 LIFETIME WARRANTY 7 i1 BR tede pr Xd 36 Table of contents H6400 SERIES CRANE PACKING LIST H6400 SERIES CRANE The following items are included with your RKI H6400 series crane 1 Crane Assembly 1 User s Manual of H6400 Series Crane 1 Carton with the Following Contents 4 Ea P N 44823 8 Ea P N 43742 4 Ea P N 43743 4 Ea P N 43744 1 Ea P N 44701 1 Ea P N 44702 1 Ea P N 44704 1 Ea P N 44705 1 Ea P N 44449 1 Ea P N 43206 2 Packing list Mounting Bolt 7 8 x 4 0 gr 8 Flat Washer 7 8 gr 8 Lock Washer 7 8 gr 8 Hex Nut 7 8 gr 8 Transm
6. 6400 S E R S Grade CRANE USER MANUAL Truck Equipment Model H64006ERX20 Serial Number Date RKI Inc 2301 Central Parkway Houston TX 77092 Phone 713 688 4414 Fax 713 688 8982 www rki us com H6400 SERIES CRANE TABLE OF CONTENTS Description Page M 2 IMPORTANT 3 4 OVERALL DIMENSIONS OF CRANE 6 7 INSTALLATION INSTRUCTIONS 8 ELECTRICAL amp HYDRAULIC INSTALLATION 10 OPERATING INSTRUCTIONS Z yuz dd aede 11 TRANSMITTER amp CONTROL MODULE OPERATING INSTRUCTIONS 14 255 a 15 CONTROL MODULE CALIBRATION 16 LUBE amp HYDRAULIC FLUID SPECIFICATIONS 17 INSPECTION 8 MAINTENANCE SCHEDULE 18 ELECTRICAL SCHEMATIC 2 22 iX AE dies 19 BOET TORQUE CHARIS sc pe EE ETE 20 TOP LEVEL CRANE ASSEMBLY
7. Installation instructions H6400 SERIES CRANE 10 Electrical Hookup Cont d Connect the WHITE wire to engine fast wire on vehicle optional Connect the ORANGE wire to engine slow wire on vehicle optional f Connect the YELLOW wire to engine start wire on vehicle optional g Connect the BLUE wire to engine stop wire on vehicle optional 11 Start the vehicle s engine and engage PTO to circulate the hydraulic fluid through the system for 10 to 15 minutes Verify the flow is 8 GPM with a flow meter 12 One at a time operate the boom elevation cylinders and boom extension cylinder by full extension and full retraction to bleed air out from the system 13 Operate the crane rotation CW and CCW and winch up and down to bleed air out from the hydraulic motors 14 Return the boom back to the stow position 15 Disengage PTO and refill the reservoir to the top of sight glass 16 Inspect for any hydraulic leakage at the hose connectors 17 Load test the crane for proper functioning and truck stability per SAE J765 WARNING 1 FEDERAL LAW 49 CFR PART 571 REQUIRES THAT THE FINAL STAGE MANUFACTURE OF A VEHICLE CERTIFY THAT THE VEHICLE COMPLIES WITH ALL APPLICABLE REGULATIONS ANY MODIFICATIONS ON 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
8. REQUIRED TO CERTIFY THAT THE VEHICLE IS IN COMPLIANCE 2 ALSO 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 Installation Instructions 9 H6400 SERIES CRANE ELECTRICAL AND HYDRAULIC INSTALLATION OPTIONAL FOR VEHICLES AIR OPERATED EQUIPPED WITH REMOTE PARKING BRAKE ACCESS FUNCTION SWITCH TRANS NEUTRAL SAFETY SWITCH N Eu nom A IGNITION amp ON OFF FUSE A PTO 7 77707 ACCESSORY SWITCH 15 AMP SWITCH FUSE PANEL RETURN HOSE 10 JIC PRESSURE HOSE SWIVEL FEMALE FILTER HYDRAULIC 8 JIC 10 MICRONS RESERVOIR SWIVEL FEMALE 10 GALLON MIN RELIEF VALVE STRAINER SET AT 2800 PSI 8 HOSE 10 HOSE IOO MESID 10 Electrical and Hydraulic Installation H6400 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 a Designated persons b Trainees under the direct supervision of a designated person c Maintenance and test personnel when it is necessary in the performance of their duty d Inspectors crane 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 and those specific persons authorized by supervisors who duties require th
9. Transmitter amp control module 33 H6400 SERIES CRANE EMERGENCY DROP DOWN PROCEDURE MANUALLY LOWER BOOM In case of EMERGENCY when the boom has to be lowered without the hydraulic flow The procedure below should be followed 1 2 Make sure the boom will be lowered on to a proper support Locate the counterbalance valve at the boom elevation cylinder manifold block Loosen the hex nut and slowly turn the Allen head screw clockwise note number of turns until the boom just begins to lower Remove tools and hands from the crane while the boom is lowering CAUTION Do not turn the adjustment screw too far it will damage the counterbalance valve After the boom is rested on the support turn the Allen head screw counter clockwise about the same number of turns that were made during lowering of the boom Tighten the hex nut to secure the adjustment screw in place After the problem has been fixed and proper hydraulic flow present re adjust the counterbalance valve by using the procedure in the previous page WARNING 34 Do not try to adjust the counterbalance valve while the boom is moving This may cause personal injury Troubleshooting Emergency drop down procedure H6400 SERIES CRANE EMERGENCY VALVE OPERATION In case electricity is no longer available to operate the crane or in the event the control system failed use the manual overrides on the hydraulic control valves to operate the crane 1 PROPORT
10. 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 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 24 25 26 27 28 29 30 31 32 33 34 H6400 SERIES CRANE 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 is level and where necessary blocked b The load is well secured
11. winch gearbox should be filled to the bottom of the fill level plug Change Lubrication Interval The initial lubricant should be changed after the first 10 hrs of operation During this breaking in period it is normal for the lubricant to contain minuscule black amp bronze particles Subsequent changes should be scheduled every 250 hours of operation or annually whichever come first Rotating Gearbox Lubrication Specification EP 0 grease Lubrication Level The unit was filled with 0 grease from the factory Slewing Bearing Lubrication Specification Shell Alvania EP 2 grease Hydraulic Fluid Fluid Specification Mobil DTE26 or equivalent premium grade hydraulic fluid Lube and hydraulic fluid specifications 17 H6400 SERIES CRANE INSPECTION amp MAINTENANCE SCHEDULE COMPONENT DAILY WEEKLY MONTHLY EVERY 3 YEARLY NOTES MONTHS Check Winch Fluid X Change 10 nours of initial service Change Winch Fluid X Replace fluid every 250 hours of operation or yearly Cable Drum X Make sure cable is wound evenly on drum Cable X Check for cut or broken strands kinking etc Check for any crack or Load Hook X deformation of hook or latch Sheaves and Bearings X Inspect Tor any damage and add grease to bearings Slewing Bearing X Add grease to bearing Rotating Gearbox X Add grease to rotating gearbox Check bolt torque for the 4 Base Mounting Bolts amp mtg bolts 450 ft lbs and Other Bolts tig
12. APTER 8 SAE TO 8 JIC LONG 2 TO PORTS B1 B2 4 44557 STRAIGHT ADAPTER 8 SAE TO 6 JIC LONG 2 TO PORTS amp 4 5 44538 STRAIGHT ADAPTER Z8 SAE TO Z6 JIC 2 TO PORTS B4 6 44647 MANIFOLD BRACKET WELDMENT 1 7 03029 LOCK WASHER 375 4 8 40911 SCREW CPHEX 3 8UNC X 75 4 9 44782 STRAIGHT ADAPTER 10 SAE TO 8 2 10 44781 ELBOW 8 SWIVEL FEMALE TO 8 MALE 2 28 Hydraulic manifold assembly HYDRAULIC HOSE ASSEMBLY TO EXT PORT ELEVATION CYLINDER PORT TO RET EXTENDED CYLINDER TO RET RET PORT ELEVATION CYLINDER TO EXT POR EXTENDED CYLINDER Item Part Number Number 1 44466 REDUCER GEARBOX REF 2 44470 HOIST WINCH HYDRAULIC REF 3 44535 FITTING 8 SAE TO 8 JIC 2 4 44553 8 HYDRAULIC SUPPLY HOSE WINCH 31 LONG 1 5 44554 8 HYDRAULIC RETURN HOSE WINCH 33 LONG 1 6 44555 8 HYDRAULIC REDUCER GEARBOX HOSE 25 LONG 2 7 1 8 1 9 2 Description 44558 8 HYDRAULIC SUPPLY HOSE 21 LONG 44559 8 HYDRAULIC RETURN HOSE 23 LONG 44560 6 HYDRAULIC EXTENDED CYCLE HOSE 24 LONG 10 44628 HYDRAULIC SWIVEL PIN ASSEMBLY REF 11 44646 HYDRAULIC MANIFOLD ASSEMBLY REF 12 44649 6 HYDRAULIC ELEVATION CYCLE HOSE 38 5 LONG 2 13 44781 ELBOW 8 JIC SWIVEL FEMALE TO MALE 2 14 44782 ADAPTER 10 O RING TO 8 JIC MALE 2 Hydraulic Hose Assembly 29 H6400 SERIES CRANE TRAVELING BLOCK ASSEMBLY P N 44562
13. CREW CPSKB 25 50 BUTTON HEAD 3 20 44706 GUIDE WIRE CABLE 1 Boom assembly 23 H6400 SERIES CRANE TURRET ASSEMBLY P N 44566 INCLUDED IN GEAR REDUCER P N 44466 WHEN PURCHASED NOT AVAILABLE FOR PURCHASE SEPARATELY Turret assembly 24 H6400 SERIES CRANE TURRET ASSEMBLY P N 44566 Item Part Number Number Description Qt 1 03029 WASHER LOCK 375 2 2 03030 WASHER LOCK 50 11 3 07770 SCREW CPHEX 375 16UNC 1 25 LG 2 4 07785 SCREW CPHEC 50 13UNC 1 25 LG 2 5 07786 SCREW CPHEX 50 13UNC 1 50 LG 3 6 07858 NUT HEX 50 4 7 07882 WASHER LOCK 25 4 8 07884 WASHER LOCK 312 7 9 40082 FITTING GREASE 125 NPT 1 10 40986 WASHER FLAT 25 STD 2 11 41015 SCREW CPSKT 25 20UNC 75 LG 2 12 44463 SCREW CPHEX 625 11UNC 2 0 LG 24 13 44465 BEARING 1 14 44466 REDUCER GEARBOX 1 15 44470 HOIST WINCH 1 16 44473 SPHERICAL BEARING CYL LUG 1 17 44480 SCREW CPSKH 625 2 0 GR8 2 18 44481 SCREW CPHEX 50 13UNC 2 0 LG 4 19 44535 FITTING 8 SAE TO 8 JIC 2 20 44514 CONTROL MODULE ASSEMBLY H6400 1 21 44553 8 HYDRAULIC HOSE WINCH 31 LG 1 22 44554 8 HYDRAULIC HOSE WINCH 33 LG 1 23 44555 8 HYDRAULIC HOSE REDUCER 28 LG 2 24 44558 8 HYDRAULIC HOSE 21 LG 1 25 44559 8 HYDRAULIC HOSE 23 LG 1 26 44618 BASE PLATE 1 27 44619 TURRET WELDMENT 1 28 44628 HYDRAULIC SWIVEL P
14. IN ASS Y 1 29 44632 COVER HYD SWIVEL PIN ASS Y 1 30 44635 BRACKET LOCKING 1 31 44636 BRACKET ANTI ROTATION SWL PIN 1 32 44637 COVER PLATE 1 33 44638 SPACER REDUCER 2 34 44639 WASHER FLAT 625 HARDEN 38 35 44641 SCRW CPHEX 50 13UNC 2 25 LG 4 36 44642 SCREW CPHEX 312 18UNC 75 LG 37 44643 O RING EXTERNAL 1 38 44644 O RING INTERNAL 1 39 44645 SCREW CPSKT 625 11UNC 2 50 LG 14 40 44646 HYDRAULIC MANIFOLD ASSEMBLY 1 41 44651 COVER HYDRAULIC MANIFOLD 1 42 44681 ELECT WIRE ASSEMBLY NOT SHOWN 1 43 44717 COVER CONTROL MODULE 1 44 44721 SCREW CPSKB 25UNC 50 BUTTON HEAD 4 45 44780 WASHER FLAT 53 ID 1 06 OD 14 46 44781 FITTING ELBOW 8 FEMALE TO 8 MALE 2 47 44782 FITTING M ADAPTER 10 O RING TO 8 2 48 44837 GROMMET 5 ID X 1 0 OD 1 49 44843 GROMMET 1 0 ID X 1 5 OD 2 Turret assembly 25 H6400 SERIES CRANE HYDRAULIC SWIVEL ASSEMBLY P N 44628 FULL DETAIL OF P N 44813 Item Part Number Number Description 1 44629 SWIVEL PIN 1 2 44487 O RING BACKUP RING PARBAK 232 6 3 44486 O RING 2 232 3 4 44630 HOUSING SWIVEL PIN 1 5 44485 RETAINING RING EXTERNAL 5102 0325 1 6 44484 FITTING 90 DEG ELL 8 O RING JIC 2 7 44631 STUD 38 16UNC X 3 75 LONG 2 8 07848 NUT HEX 38 16UNC 2 9 44616 FITTING 8 SAE O RING TO 10 1 10 08014 SCREW STSKT 0 25 20UNC 0 2 OVL 5 11 44535 FITTING 8 SAE O RING TO 8 JIC 1 12 44813 ELECTRICAL SWIVE
15. IONAL Increase hydraulic flow by turning knob clockwise Decrease hydraulic flow by turning knob counter clock wise 2 BOOM UP BOOM OUT ROTATE CW amp WINCH UP Turn knob on their valves respectively clockwise 3 BOOM DOWN BOOM IN ROTATE CCW amp WINCH DOWN Turn knob on their valves respectively counter clockwise WINCH UP PROPORTIONAL ROTATE BOOM CEW IN BOOM UB imn ll i E m e BOOM DOWN OUT WINCH ROTATE DOWN cw HYDRAULIC VALVE ASSEMBLY Note Any time you manually override the crane operations you must reset the valves back to their original settings after correcting the problem with the crane Original settings on all valves including proportional valves are completely open all the way out Troubleshooting Emergency valve operation 35
16. L ASSEMBLY 1 13 44857 COVER ELECTRICAL SLIP RING 1 14 44858 BRACKET ELECTRICAL SLIP RING 1 15 43139 RTNG RING EXT 75 DIA 1 16 44860 CAP NUT 8 JIC 1 17 44861 CAP NUT 10 JIC 1 26 Hydraulic swivel assembly H6400 SERIES CRANE ELECTRICAL SWIVEL ASSEMBLY P N 44813 USE CONNECTORS SUPPLIED Q WITH ITEM 1 BOTH ENDS o ROTATE Qr BOTH ENDS O PLCS mm LOOK TO END OF ITEM 1 NOTES 4 RED POWER SUPPLY YELLOW ENGINE START BLUE ENGINE STOP WHITE ENGINE FAST Item Part Number Number Description Qty 1 44482 ELECTRICAL SLIP RING 1 2 44791 ELECTRICAL TERMINAL MALE 4 3 44799 ELECT WIRE 16 GA 36 0 RED 1 4 44800 ELECT WIRE 18 GA 36 0 YELLOW 1 5 44802 ELECT WIRE 18 GA 36 0 WHITE 1 6 44803 ELECT WIRE 18 GA 36 0 BLUE 1 7 44804 ELECT WIRE 16 GA 35 0 RED 1 8 44805 ELECT WIRE 18 GA 34 0 YELLOW 1 9 44807 ELECT WIRE 18 GA 32 0 WHITE 1 10 44808 ELECT WIRE 18 GA 31 0 BLUE 1 11 44859 TUBE HEAT SHRINK 3 8 X 6 0 LG 2 Electrical swivel assembly 27 H6400 SERIES CRANE HYDRAULIC MANIFOLD ASSEMBLY P N 44646 PORT PORT A2 PORT A3 PORT A4 PORT B3 PORT B4 Item Part Number Number Description Qty Note 1 44515 HYDRAULIC MANIFOLD 1 2 44535 STRAIGHT ADAPTER 8 SAE TO 8 JIC 2 TO PORTS 1 amp 2 3 44556 STRAIGHT AD
17. PSI 170 000 PSI UNC FT LBS FT LBS FT LB FT LBS 1 4 20 5 7 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 5 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 13 8 6 572 1286 2065 2144 11 2 6 759 1707 2740 2845 Notes 1 Torque values listed above are based on dry and plated threads 2 Abolt that has been torqued to its rated value and then removed should be replaced 20 Bolt torque chart H6400 SERIES CRANE BOLT TORQUE CHART FINE THREAD BOLT SIZE GRADE 2 GRADE 5 GRADE 8 5 HEAD Strength 60 000 PSI 105 000 PSI 150 000 PSI 170 000 PSI UNC FT LBS FT LBS FT LB FT LBS 1 4 28 5 14 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 8 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 H6400 SERIES CRANE TOP LEVEL ASSEMBLY P N 44650
18. 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 Operating instructions 13 H6400 SERIES CRANE TRANSMITTER AND CONTROL MODULE OPERATING INSTRUCTIONS FCC Rules and Compliance This device complies with part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 this device must accept any interference received includi
19. anes consult your nearest dealer with your custom needs IN ORDER TO PROVIDE YOU WITH THE MOST INNOVATIVE AND PROGRESSIVE EQUIPMENT SPECIFICATIONS AND DESIGNS ARE SUBJECT TO CHANGE WITHOUT NOTICE 05 15 09 www rki s com RKI Inc 2301 Central Parkway Houston Texas 77092 713 688 4414 FAX 713 688 8982 5933 Drive Fort Worth Texas 76117 817 314 5159 FAX 817 831 4462
20. em 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 positioned engage emergency brake start the engine place transmission in neutral position activate PTO to circulate and warm hydraulic fluid and set the throttle control to proper engine speed Ac
21. er second This confirms the Transmitter is sending Calibration Data to the Control Module Select and hold one of the Proportional Function With the trigger OFF fully released the MIN level is set The MIN level may be increased by toggling the ENGINE FAST SLOW switch to FAST position up or decreased by toggling the ENGINE FAST SLOW switch to SLOW position down Select and hold one of the Proportional Function With the trigger ON fully engaged the level is set The MAX level may be increased by toggling the ENGINE FAST SLOW switch to FAST position up or decreased by toggling the ENGINE FAST SLOW switch to SLOW position down To reset the MIN and MAX settings to the factory default hold either the ENGINE FAST SLOW switch in either FAST or SLOW position up or down for 5 seconds 10 To exit press the Estop switch Control module calibration H6400 SERIES CRANE LUBRICATION amp HYDRAULIC FLUID SPECIFICATIONS Winch Gearbox Lubrication Specifications Temperature Lubrication Viscosity cSt F Type 40 100 C 10 to 120 85W140 341 25 25 to 40 80W90 145 15 50 to 30 ISO 31 6 Low temperature lubricant is available from Oils Unlimited 1 800 324 115 Syngear G 32 GL5 Note Unless otherwise requested the gear oil in the winch gearbox was shipped with GL5 80W90 Lubrication Level The oil level should be checked with the winch gearbox centerline horizontal The
22. formed simultaneously There will be a slight delay when performing multiple simultaneous functions Hydraulic System Proportional hydraulic control system with manual override and pressure compensated flow control system A series control circuit is used 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 Specification H6400 SERIES CRANE Winch Cable and Block 95 of 3 8 galvanized aircraft cable is supplied with traveling block for double line operation The swivel hook incorporates a roller thrust bearing for easier turning movement 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 1 750 Ibs Length 12 3 Width 1 6 3 4 Height 2 11 Base Plate Dimensions 16 3 4 16 3 4 Hydraulic System Requirements 8 gpm flow rate and 2 800 psi max pressure Truck Requirements 15 000 lbs GVWR Minimum Outrigger p n 894 or equivalent Specifications 5 H6400 SERIES CRANE OVERALL DIMENSIONS Y 4 75 A ir 9 911 00 CUTOUT T l 14 75 121 28 Ly pe 14 75 CRANE INTERFACE
23. hten other bolts as required Hydraulic Hoses X Inspect for any damage or leakage at fittings Check fluid level at the Hydraulic Fluid ye reservoir before each shift Check filter for bypass Hydraulic Filter X indication and replace as required Hydraulic Reservoir X Drain flush and refill with hydraulic fluid Inspect pads and replace as Boom Wear Pads X required 18 Inspection and maintenance schedule ELECTRICAL SCHEMATIC po GREEN B3 gt GREEN BLACK WHITE WHITE RED BLACK i RED BLACK WHITE i ORANGE BLACK 50 ORANGE RED AD WHITE RED BLUE RED a 9 L pes IE ENGINE FAST ORANGE EZ ORANGE GREEN ENGINE STAR 19 Pam ENGINE STOP p BLUE BLACK p Al BLACK RED B12 gt GREEN BLACK l 1 RED POWER 4 1 lt GROUND am E WHITE ANTI TWO BLUE BLOCK SWITCH BROWN PRESSURE TRANSDUCER H6400 SERIES CRANE BOOM UP BOOM DOWN BOOM OUT BOOM IN WINCH UP WINCH DOWN ROTATE CW ROTATE CCW 00 PROPORTIONAL XQ gt XQ gt Electrical schematic 19 H6400 SERIES CRANE BOLT TORQUE CHART COARSE THREAD BOLT SIZE GRADE 2 GRADE 5 GRADE 8 5 HEAD Strength 60 000 PSI 105 000 PSI 150 000
24. is ready to receive Configuration Data from the Transmitter Release the SETUP button after the STATUS LED begins flashing rapidly Momentarily toggle the ENGINE FAST SLOW switch to the FAST position this enables the Transmitter to send Configuration Data to the Control Module Once the ACTIVE LED is off power up the Transmitter and verify there is a link between the Control Module and the Transmitter In order to program the Control Module or replace the FUSE use 10A MINI FUSE Status LED s the circuit board has to be removed from the housing of the Control Module P Releasing the two side tabs on the GERENTE Deu R CB housing and sliding the connector block and circuit board out of the housing until the four STATUS LED s are visible and the SETUP SW1 button is accessible See Figure 1 ISETUP SW1 Figure 1 Control Module Figure 2 Transmitter Layout Setting ID Code 15 H6400 SERIES CRANE CONTROL MODULE CALIBRATION 16 Permits the user to adjust minimum and maximum current of the Proportional Control 1 2 Release the Estop on the Transmitter see Figure 2 Hold the ENGINE FAST SLOW switch in the SLOW position press and release the Estop switch Release the ENGINE FAST SLOW switch The ACTIVE LED will flash once per second Transmitter Layout Toggle the ENGINE FAST SLOW switch to the SLOW position The ACTIVE and LOW BATT LED s will flash alternately once p
25. itter FM Remote Control 25 Tether for Transmitter Inline Fuse Holder Blade Style 15 Amp Fuse Blade Style Toggle Switch Seal Toggle Switch H6400 SERIES CRANE 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 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 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 infor
26. k washers to secure the crane Tighten 7 8 diameter bolts in a crisscross pattern and torque the bolts to 450 ft lbs no lubrication on threads Adjust the boom support to contact with the boom and secure the crane hook to the hook ring Hydraulic plumbing a Use 10 gallon reservoir and 10 micron filter b Use 8 SAE 100R2 hydraulic hose or equivalent for PRESSURE line from the PTO pump to crane and 8 JIC swivel female hose end for connecting the crane Installer will determine other fittings and hose lengths as required c Use 10 SAE 100R2 hydraulic hose or equivalent for RETURN line from the crane to oil filter from oil filter to reservoir and SUCTION line from reservoir to PTO pump The return line hose end for connecting to the crane is a 10 JIC female swivel Installer will determine other fittings and hose lengths as required d Fill the reservoir with Mobil DTE26 hydraulic fluid or equivalent to the top of sight glass Electrical Hookup a If the battery negative is grounded to the vehicle s engine install a second cable from the battery negative post to the vehicle s frame or from the engine to the vehicle s frame b Connect the RED wire to in line fuse holder provided and to the battery positive 12 VDC c Install 15 Amp fuse provided to the fuse holder NOTE If the vehicle is equipped with Remote Access Function continue with steps d e f and g 8 Otherwise proceed to step 11
27. mation 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 H6400 SERIES CRANE 4 SPECIFICATIONS SPECIFICATIONS Model H64006ERX20 Moment Rating 38 000 ft Ibs Lift Capacities 6 400 Ibs 6 ft 2 710 Ibs 14 ft 4 750 105 8 ft 2 375 Ibs 16 ft 3 800 Ibs 10 ft 2 110 Ibs 18 ft 3 165 Ibs 12 ft 1 900 Ibs 20 ft Boom Power telescoping boom extension from 10 to 16 and from 16 to 20 The boom angle varies from 5 to 75 Fully hydraulic sequential extension and retracting Control System FM wireless remote with backup 25 tether for areas with frequency interference emergency stop engine start stop engine speed adjusting and proportional control trigger Control module with indicator lights for ease of troubleshooting Two Speed Rotation Two speed rotation is a standard feature While unloaded the rotation speed is doubled to provide quick access to the load When at under loaded condition the rotation speed is reduced automatically to eliminate load swing and facilitate safe operation The 360 continuous unlimited rotation is standard Line Speed 55 per minute for single line Multi Functions The hydraulic configuration allows multiple functions to be per
28. ng interference that may cause undesired operation Change or modification not expressly approved by RKI Inc will limit the user s ability to operate the equipment This product is intended for fixed installation applications In order to comply with FCC ISC adopted RF exposure requirements installation of this system s antennas must be performed in a manner that will provide at least 6 feet clearance from the front radiating aperture to anyone FCC 15 247 ISC RSS 210 INSTALL BATTERIES Remove the battery cover on the back of the Transmitter and install four AA alkaline batteries POWER UP Activation of any switch will cause the Transmitter to power up However as a Safety feature the EStop switch must be pressed and released or if already pressed released within 10 seconds for the unit to remain powered up USING THE TRANSMITTER The ACTIVE LED will flash two times per second indicating the Transmitter is transmitting to the Control Module When a function switch is used the ACTIVE LED will flash brightly upon activation of the switch and return to flashing at a rate of two times per seconds when there is no switch activity During normal operation the LOW BATT LED will flash to indicate a low battery condition The Estop button is used for both an emergency shutdown as well as way of powering down the Transmitter after operation Each switch has a device specific label to identify its function The t
29. rigger is a Proportional Control switch used in conjunction with a switch i e ROT CW The type of Proportional Control output is Current Control 25 TETHER PENDANT CONTROL 14 The 25 tether line is to be used in operating areas where you may experience frequency interference with your transmitter receiving a good signal from the control module The tether line does not bypass the transmitter or control module it only provides a direct link from the control module to the transmitter Transmitter and control module operating instructions H6400 SERIES CRANE SETTING ID CODE Required when replacing either Transmitter or the Control Module The Transmitter has its ID Code factory programmed Its matching Control Module needs to have this same code programmed into it To do this the Control Module needs to have its cover removed refer to Figure 1 Follow the procedure below to program the Control Module ID Code to match its corresponding Transmitter 1 2 Release the Estop switch on the Transmitter see Figure 2 Hold the ENGINE FAST SLOW switch in the FAST position press and release the Estop switch Release the ENGINE FAST SLOW switch The ACTIVE LED will flash one per second Press and hold the SETUP button see Figure 1 on the Control Module for 5 seconds The STATUS LED on the Control Module will flash once per second while depressed and then begin flashing rapidly indicating that the Control Module
30. tivate the Transmitter See Transmitter Control Module operation for more details 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 Operating instructions 11 H6400 SERIES CRANE 2 22 23 12 THIS AREA SHOULD Table 1 BE AVOIDED Normal Voltage kV Minimum Required Phase to Phase Clearance ft m Operation near High Voltage Power Line PROHIBITED ZONE SEE TABLE 1 to 50 10 3 05 Over50 to 200 15 4 60 of jo 200 350 20 6 10 c Over 350 to 500 25 7 62 Over500 to 750 35 10 67 Over 750 to 1000 45 13 72 Operation in Transit With No Load and Boom Lowered to 0 75 Over 0 75 to 50 Over 50 to 350 CRANE SHALL USED Over 345 to 750 HANDLE MATERIALS IN THIS AREA Over 750 to 1000 2 NS 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 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 the
31. ur serial number and retain a copy of your invoice for future reference If your crane should need service this information will be required 32 Spare parts H6400 SERIES CRANE TROUBLESHOOTING TRANSMITTER amp CONTROL MODULE The Control Module has four LED s that are used to indicate device status ESTOP LED GREEN Indicates RUN normal RED Indicates ESTOP Flashing RED Indicates fuse blown or relay fault FUNCTION FAULT LED GREEN Indicates function ON no fault RED Indicates no voltage to relay short to ground or blown fuse Flashing RED Indicates short to supply or shorted output relay Not lit Indicates no function LINK LED GREEN Indicates LINK RED Indicates NO LINK STATUS LED GREEN Indicates STATUS normal RED Indicates unrecoverable fault requiring factory authorized service Flashing RED Indicates low battery The Transmitter has two LED s that display the mode and status of the device ACTIVE LED Momentary ON or Flashing indicates POWER UP procedure or Program status LED will flash with each function during normal operation indicating Transmit Status to the Module Control is good LOW BATT LED Momentary ON or Flashing indicates Power Up procedure or Programming status During normal operation this LED will only flash to indicate battery low Battery life is 1 year ACTIVE and LOW BATT LED S Both LED s flashing in sync indicates one of the switches is stuck Troubleshooting
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