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1. 26 ROTATE GEARBOX ASSEMBLY 28 HOIST WINCH ASSEMBLY an kingan as Gang ain 30 HYDRAULIC CONTROL VALVES ASSEMBLY 34 SPARE PARTS 35 MERCHANDISE RETURN POLICY 36 LIFETIME WARRANTY BACK INSIDE COVER Table of contents 3 H6400 SERIES CRANE INTRODUCTION amp SPECIFICATION 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 SPECIFICATIONS Model H6400 6ERX20 Moment Rating 38 000 ft Ibs Lift Capacities 6 400 lbs 6 ft 2 710 lbs 14 ft 4 750 lbs 8 ft 2 37
2. 16 3 14 14410 SUPPORT GEAR END 1 15 3700 RING RETAINER 2 3 8 x 078 THICK 1 16 14111 COUPLING SPLINE 1 17 9740 O RING 2 I D x 1 8 SECTION 1 18 13861 CABLE WEDGE 2 8 x 1 13 32 1 TULSA HOIST WINCH ASSEMBLY PART NUMBER K5BAS1L1B Hoist winch 31 H6400 SERIES CRANE HOIST WINCH P N 44470 MOTOR END INSTALLATION 1 10322 32 Hoist winch H6400 SERIES CRANE HOIST WINCH P N 44470 Item Tulsa Part Number Number Description Qty 1 13708 SUPPORT MOTOR END 1 2 70040 CARTRIDGE VALVE 1 3 13936 VALVE COUNTERBALANCE 1 B 9612 O RING 1 8 1 0 x 103 SECTION 1 3 2 9972 O RING 5 8 1 0 x 3 32 SECTION 1 4 70042 PLUG T11A 1 5 73212 MOTOR HYDRAULIC 1 6 13602 ADAPTER MOTOR 1 7 13603 PISTON BRAKE 3 8 3437 PIN DOWEL 3 8 x 5 8 4 9 13934 PLATE FRICTION BRAKE 3 10 13034 PLATE STATIONARY BRAKE 3 11 3607 SPRING BELLEVILLE 4 x 2 x 12 x 1 4 1 12 9851 O RING 5 3 8 1 0 x 3 16 SECTION 1 13 9852 RING BACKUP 5 278 1 0 x 076 1 14 9709 O RING 4 3 8 1 0 x 3 16 SECTION 1 15 9843 O RING 5 1 2 1 0 x 5 3 4 O D x 1 8 1 16 9846 RING BACKUP 5 1 2 I D 1 17 9621 O RING 1 8 I D x 103 SECTION 2 18 3440 PLUG HOLE EXPANDER 2 19 9637 O RING 3 1 4 1 0 x 3 32 SECTION 1 20 1167 CAPSCREW SOCKETHEAD 5 16 NC x 2 4 21 4076 CAPSCREW SOCKETHEAD 1 4 NC x 4 1 2 1 22 10708 TAG WARNING 1
3. 23 1454 CAPSCREW SOCKETHEAD 1 2 NC x 1 1 4 2 24 1144 WASHER LOCK 1 2 HI COLLAR 2 25 13933 BRAKE ASSEMBLY 1 26 4344 8 CAPSCREW FLAT SOCKETHEAD 3 6 NC x 7 8 GR 8 6 27 9600 O RING 4 3 4 I D x 5 1 8 O D x 3 16 SECTION 1 28 9711 RING BACKUP 4 3 4 1 0 x 183 SECTION 1 29 3460 RING RETAINER 3 4 x 035 THICK 1 TULSA HOIST WINCH ASSEMBLY PART NUMBER K5BAS1L1B Hoist winch 33 H6400 SERIES CRANE HYDRAULIC CONTROL VALVE ASSEMBLY P N 44646 Item Part Number Number Description Qty Note 1 44515 HYDRAULIC MANIFOLD 1 2 44541 STRAIGHT ADAPTER 10 SAE TO 10 JIC 2 VO PORN E dy 3 44537 90 DEG ELBOW ADAPTER 10 JIC 2 TO ITEM 2 4 44535 STRAIGHT ADAPTER 8 SAE TO 8 JIC 2 TO PORT 1 amp A2 5 44556 STRAIGHT ADAPTER 8 SAE TO 8 JIC LONG 2 TO PORT B1 amp B2 6 44557 STRAIGHT ADAPTER 8 SAE TO 6 JIC LONG 2 TO PORT amp 4 7 44538 STRAIGHT ADAPTER 8 SAE TO 6 JIC 2 TO PORT B3 amp 4 8 44647 MANIFOLD BRACKET WELDMENT 1 9 03029 LOCK WASHER 375 4 10 07769 SCREW 375 16UNC 1 0 LG 4 34 Hydraulic control valve assembly H6400 SERIES CRANE SPARE PARTS It is recommended that repair parts for your crane be obtained from your local AKI 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
4. 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 Transmitter 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 TABLE OF CONTENTS Description Page IMPORTANT NOTICE en dts maet tes shanties Samia sacs te 1 PACKING MST 2 INTRODUCTION AND SPECIFICATIONS 4 OVERALL DIMENSIONS OF CRANE towne ees 6 CAPACITY CHART ue icta dac we abaci je a esa 7 OPERATING INSTRUCTIONS 5 acd na ORE don ACERO ERR CR RES 8 INSTALLATION INSTRUCTIONS svn ee dn adeo nee Nera ei ee ndi mac es 11 ELEGTRICALE amp HYDRAULIC HOOKUP occae X PCR oie season 13 TRANSMITTER amp CONTROL MODULE OPERATING INSTRUCTIONS 14 HYDRAULIC SYSTEM OPERATING INSTRUCTIONS 17 ELECTRICAL SCHEMATIC seriada ne econ EO es eee 19 LUBE amp HYDRAULIC FLUID SPECIFICATIONS 20 INSPECTION amp MAINTENANCE SCHEDULE CR RR RR LR n 21 BOLT TORQUE CHARTS ia ajang ak n quitte pa 22 TOP LEVEL GRANE ASSEMBLY od ak 24 BOOM ASSEMBLY Tam e 25 TURRET cn
5. DIA 3 19 44684 SCREW CPSKB 25 X 50 BUTTON HEAD 3 20 44706 GUIDE WIRE CABLE 1 Boom assembly 25 H6400 SERIES CRANE TURRET ASSEMBLY P N 44566 Turret assembly 26 TURRET ASSEMBLY P N 44566 H6400 SERIES CRANE Item Part Number Number Description Qt 1 44618 BASE PLATE 1 2 W44465 BEARING 1 3 44632 COVER HYD SWIVEL PIN ASS Y 1 4 44636 BRACKET ANTI ROTATION SWL 1 5 44635 BRACKET LOCKING 1 6 44628 HYDRAULIC SWIVEL PIN ASS Y 1 7 44619 TURRET WELDMENT 1 8 44638 SPACER REDUCER 2 9 W44466B ECCENTRIC RING PART OF REDUCER 1 10 W44466A REDUCER 11 W44480 SCREW CPSKH 625 2 0 GR8 2 12 W44641 SCRW 50 13UNC 2 25 LG 4 13 W44484 ELBOW FITTING 8 SAE TO 8 JIC 4 14 44637 COVER PLATE 1 15 44651 COVER HYDRAULIC MANIFOLD 1 16 44646 HYDRAULIC MANIFOLD ASSEMBLY 1 17 W07889 WASHER FLAT 50 14 18 W07785 SCREW CPHEC 50 13UNC 1 25 LG 2 19 W44470 WINCH 1 20 W44481 SCREW CPHEX 50 13UNC 2 0 LG GR8 4 21 W03030 WASHER LOCK 50 11 22 W07858 NUT HEX 50 4 23 W44644 O RING INTERNAL 1 24 W44643 O RING EXTERNAL 1 25 W03029 WASHER LOCK 375 2 26 W07770 SCREW CPHEX 375 16UNC 1 25 LG 2 27 07786 SCREW CPHEX 50 13UNC 1 50 LG 3 28 W44473 SPHERICAL BEARING CYL LUG 1 29 W44558 HYDRAULIC HOSE 21 LG 1 30 W44559 HYDRAULIC HOSE 23 LG 1 31 W44555A 8 HYDRAULIC HOSE RE
6. GREEN WINCH L AT lt ENGINE START ip 5 RED GREEN 8 5 E BLUE BLACK WINGH mm BLACK RED DOWN 2 J GREEN BLACK ROTATE CW lt 2 c ROTATE I lt RED m POWER lt BLACK A3 gt A ALA GROUND 3 PROPORTIONAL WHITE BLACK TWO GREEN BLOCK SWITCH pz RED PRESSURE TRANSDUCER Electrical schematic 19 20 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 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 0 grease Lubrication Level The unit was
7. 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 manufactures special cranes 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 08 07 www rki ds com RKI Inc 2301 Central Parkway Houston Texas 77092 713 688 4414 FAX 713 688 8982 d 5933 Eden Drive Fort Worth Teras 76117 817 314 5159 FAX 817 831 4462
8. clockwise 3 BOOM DOWN BOOM IN ROTATE CCW amp WINCH DOWN Turn knob on their valves respectively counter clockwise WINCH UP PROPORTIONAL ROTATE BOOM CCW i Bw BOOM mu l Il UP 1 1 dri e BON d WINCH DOWN OUT ROTATE DOWN cw Hydraulic Valve Assembly 18 Hydraulic system operating instructions H6400 SERIES CRANE ELECTRICAL SCHEMATIC GREEN B3 3 GREEN BLACK WHITE WHITE RED BLACK BOOM B1 UP 82 RED BLACK WHITE E ORANGE BLACK BOOM DOWN ORANGE RED A12 WHITE RED 2 z OUT BLUE RED J 5 A11 lt WHITE BOOM 5 gt ENGINE FAST 5 BE ORANGE ORANGE
9. 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 Lubrication amp hydraulic fluid specifications H6400 SERIES CRANE INSPECTION amp MAINTENANCE SCHEDULE COMPONENT Check Winch Fluid Change Winch Fluid Cable Drum Cable Load Hook Sheaves and Bearings Slewing Bearing Rotating Gearbox Base Mounting Bolts amp Other Bolts Hydraulic Hoses Hydraulic Fluid Hydraulic Filter Hydraulic Reservoir Boom Wear Pads DAILY WEEKLY MONTHLY EVERY 3 MONTHS YEARLY NOTES Change fluid after 10 hours of initial service Replace fluid every 250 hours of operation or yearly Make sure cable is wound evenly on drum Check for cut or broken strands kinking etc Check for any crack or deformation of hook or latch Inspect for any damage and add grease to bearings Add grease to bearing Add grease to rotating gearbox Check bolt torque for the 4 mtg bolts 450 ft lbs and tighten other bolts as required Inspect for any damage or leakage at fittings Check fluid level at the reservoir before each shift Check filter for bypass indication and replace as required Drain flush and refill with hydraulic fluid Inspect pads and replace as required Inspection amp maintenance schedule 21 H6400 SERIES CRAN
10. 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 trigger is a Proportional Control switch used in conjunction with a switch i e ROT CW The type of Proportional Control output is Current Control SETTING ID CODE 14 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
11. 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 Spare parts 35 H6400 SERIES CRANE MERCHANDISE RETURN POLICY Occasionally circumstances justify a customer returning merchandise to the factory No merchandise will be accepted without prior return authorization Request a Return Authorization through our Warranty Department Please provide the following information 1 Reason or reasons for return 2 Quantity 3 Model Number 4 Description 5 Original Invoice Number RKI will review the information If all criteria are met RKI will fax or mail a Return Authorization Form listing each item you request to return Material received at the factory with a proper Return Authorization will be inspected If all criteria are met the item will be repaired or a credit will be issued for the appropriate amount Due to insurance reasons winch and crane parts are not returnable New material is rarely accepted for return If it is approved to return it will not be credited at full net A minimum 20 restocking charge will apply Factors such as material handling cost repackaging charges and other conditions must be taken into consideration No custom products or one time only products may be returned No retu
12. 0 to 1000 0 Over 350 to 500 7 62 10 67 13 72 Operation in Transit With No Load and Boom Lowered to 0 75 22 Over 0 75 to 50 83 Over 50 10 350 05 87 10 CRANE SHALL NOT BE USED TO HANDLE MATERIALS IN THIS AREA Figure 1 Over 345 to 750 Over 750 to 1000 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 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 sufficien
13. 1 Release the Estop switch on the Transmitter see Figure 2 Transmitter and control module operating instructions CURRENT CONTROL MODULE CALIBRATION H6400 SERIES CRANE 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 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 FUSE ue 2 Status LED s replace the FUSE use 10A MINIG the circuit j i board has to be removed from the housing of the Control Module Releasing the two side tabs on the 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 SETUP SW1 Figure 1 Permits the user to adjust minimum and
14. 5 lbs 16 ft 3 800 105 10 ft 2 110 lbs 18 ft 3 165 lbs 12 ft 1 900 16 20 ft Boom Power telescoping boom extension from 10 to 16 and from 16 to 20 The boom angle varies from 5 to 75 FM Remote or Remote Control Pendant FM remote or 25 tether pendant controls all powered functions Both configurations offer full proportional control with status display 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 Over 55 per minute for single line 4 Introduction and specification H6400 SERIES CRANE Multi Functions The hydraulic configuration allows multiple functions to be performed simultaneously Hydraulic System Proportional hydraulic control system with manual override and pressure compensated flow control system 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 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 fo
15. 982 BEARING HFG938D 2 16 21128 FITTING GREASE ZERK 1 17 996515 CONE BEARING 2 18 12208 BUSHING PIPE 1 19 43537 CAPSCREW SOCKET HEAD 2 20 43467 CAP END 900D 2 21 32566 O RING 3 22 43465 CAP END MOTOR 900D 1 23 41299 LOCKWASHER 1 24 41024 CAPSCREW 2 25 996516 CUP BEARING 2 26 42366 SHIM G1600D 2 27 26528 LOCKNUT 1 28 24180 SEAL OIL 1 29 42367 SHIM G1600D 2 30 42368 SHIM G1600D 2 31 24943 CAPSCREW 4 22 13050 BREATHER 1 33 32220 PLUG PIPE 2 34 40622 RING ECCENTRIC FG945 1 TULSA GEARBOX ASSEMBLY PART NUMBER 81881 Rotate gearbox assembly 29 H6400 SERIES CRANE 30 Hoist winch HOIST WINCH P N 44470 FOR USE WITH 5 16 DIA WIRE ROPE amp LARGER 1 30156 INSTALLATION FOR USE WITH 3 8 DIA WIRE ROPE amp LARGER H6400 SERIES CRANE HOIST WINCH P N 44470 1 30156 INSTALLATION Item Tulsa Part Number Number Description Qty 1 13942 GEAR SUN 18 TEETH 1 2 81488 BRG BALL 130 1 0 x 165 O D x 18 1 3 81489 BRG BALL 80 I D x 110 OD x 16 1 4 13709 DRUM 1 5 9714 SEAL OIL DOUBLELIP 140 I D x 170 O D 1 6 52688 CABLE WEDGE 7 16 THICK x 1 06 1 7 9614 SEAL OIL 3 3 8 1 0 1 8 13710 GEAR RING 56 TEETH 1 9 13695 ASSEMBLY CARRIER PRIMARY 1 10 14113 ASSEMBLY CARRIER SECONDARY 1 11 13692 GEAR SUN 16 TEETH 1 12 13702 WASHER THRUST 2 3 4 I D x3 1 2 O D x 135 2 13 76146 PLUG O RING SAE 8 SOCKET HEAD 3 4
16. DUCER 28 LG 1 W44555B 8 HYDRAULIC HOSE REDUCER 28 LG 1 33 W44554 8 HYDRAULIC HOSE WINCH 33 LG 1 34 W44553 8 HYDRAULIC HOSE WINCH 31 LG 11 35 W07884 WASHER LOCK 312 7 36 W44642 SCREW CPHEX 312 180 75 LG 7 37 W44514 CONTROL MODULE Includes control module remote control wiring harness and tether 1 38 W40986 WASHER ELAT 25 STD 2 39 W41015 SCREW CPSKT 25 20UNC 75 LG 12 40 W44639 WASHER FLAT 625 HARDEN 38 41 W44645 SCREW CPHEX 625 1 1 UNC 2 50 LG 14 42 W44463 SCREW CPHEX 625 1 1 UNC 2 0 LG 24 Turret assembly 27 H6400 SERIES CRANE ROTATE GEARBOX ASSEMBLY P N 444667 W gt lo s TULS ps 28 QA 20 L 17 25 28 Rotate gearbox assembly H6400 SERIES CRANE ROTATE GEARBOX ASSEMBLY P N 444667 Item Tulsa Part Number Number Description 1 41983 CUP BEARING HFG938D 2 2 33155 SEAL OIL 1 3 43945 SHAFT OUTPUT PINION HFG945D 1 4 43492 HOUSING 900D 1 5 42765 MOTOR HYDRAULIC C L H 1 6 42000 COVER HFG938D 1 7 41979 SEAL OIL HFG938D 1 8 43745 WORM SR HFG945D 1 9 42578 GEAR S R HFG945D 1 10 40547 O RING 1 11 40407 CAPSCREW 6 12 17451 BUSHING HFG900D 1 13 40510 WASHER THRUST 2 14 40518 2 15 41
17. E 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 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 22 Bolt torque chart BOLT TORQUE CHART H6400 SERIES CRANE 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 UNC 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 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 remove
18. H6400 SERIES B CRANE lt USER MANUAL Kk Commercial Grade Model H6400 6ERX20 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 IMPORTANT NOTICE 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 RKI Inc s recommendation H6400 SERIES CRANE PACKING LIST H6400 SERIES CRANE The following items are included with your 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 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
19. LESHOOTING 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 16 Transmitter and control module operating instructions H6400 SERIES CRANE HYDRAULIC SYSTEM OPERATING INSTRUCTIONS MANUALLY LOWER BOOM In case of EMERGENCY when the boom has to be lowered without the hydraulic flow The pr
20. R 10 HOSE DIFFUSER N HYDRAULIC RESERVOIR lt 3 pu IGNITION amp ON OFF ACCESSORY FUSE PANEL FILTER 10 MICRONS RELIEF VALVE 10 HOSE STRAINER SET AT 2800 PSI 8 HOSE 100 MESH Notes 1 Required 8 JIC female swivel hose end for the supply line 2 Required 10 JIC female swivel hose end for the return line 3 Required 16 gauge electrical wire red color for the power supply 4 Do not connect these wires if your truck is not equipped with these functions Electrical and hydraulic installation 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 including interference that may cause undesired operation Change or modification not expressly approved by 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 Part 15 247 ISC RSS 210 INSTALL BATTERIES Remove the battery cover on the back
21. S FEET FROM MTG BASE CAPACITY IN POUNDS Capacity chart 7 H6400 SERIES CRANE 8 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 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 o
22. d should be replaced Bolt torque chart 23 H6400 SERIES CRANE TOP LEVEL ASSEMBLY P N 44650 Item Part Number Number Description Qty 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 HYD HOSE EXT CYLINDER 28 LG 2 7 44649 6 HYD 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 13 07769 SCREW 38UNC 1 0 3 14 44565 BOOM ASSEMBLY 1 24 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 07784 SCREW 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
23. f 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 Activate 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 20 21 22 23 H6400 SERIES CRANE Table 1 BE AVOIDED Normal Voltage kV Minimum Required Phase to Phase Clearance ft m PROHIBITTED ZONE SEE TABLE 1 Operation near High Voltage Power Line to 50 b 3 05 Over 50 to 200 5 4 60 Over 200 to 350 6 10 Over 500 to 750 Over 75
24. l 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 H6400 SERIES CRANE INSTALLATION INSTRUCTIONS Vehicle should meet minimum GVW rating of 14 500 lbs 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 holes with 29 32 diameter and an 11 00 diameter cut out center with the 4 holes of the crane mounting location 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 lock washers to secure the crane Tighten 7 8 diameter bolts in a criss cross 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 8 gallon reservoir and 10 microns filter b Use 8 SAE 100R2 hydraulic hose or equivalent for PRESSURE
25. 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 length 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 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 Connect RED wire to the inline fuse holder provided and to the battery positive 12 VDC Connect the WHITE wire to engine fast optional Connect the ORANGE wire to engine slow optional Connect the YELLOW wire to engine start optional Connect the BLUE wire to engine stop optional g Install 15 Amp fuse provided to the fuse holder 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 an in flow meter Installation instructions 11 H6400 SERIES CRANE 12 One at a time operate the boom elevation cylinder and boom extension cylinder by full ex
26. maximum current Control Module 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 Figure 2 Transmitter Layout Toggle the ENGINE FAST SLOW switch to the SLOW position The ACTIVE and LOW LED s will flash alternately once 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 Transmitter and control module operating instructions 15 H6400 SERIES CRANE 7 Select and hold one of the Proportional Function 8 With the trigger ON fully engaged the MAX 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 9 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 TROUB
27. ocedure below should be followed 1 Make sure the boom will be lowered on to a proper support 2 Locate the counterbalance valve at the boom elevation cylinder manifold block 3 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 4 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 5 Tighten the hex nut to secure the adjustment screw in place 6 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 Do not try to adjust the counterbalance valve while the boom is moving This may cause personal injury Hydraulic system operating instructions 17 H6400 SERIES CRANE MANUAL OVERRIDE 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 PROPORTIONAL 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
28. r 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 lbs Length 12 3 Width 1 6 3 4 Height 2 11 Base Plate Dimensions 16 3 4 x 16 3 4 Hydraulic System Requirements 8 gpm flow rate and 2 800 psi max pressure Truck Requirements 14 500 lbs GVWR Minimum Outrigger p n ORMM894 or equivalent Introduction amp specifications 5 H6400 SERIES CRANE OVERALL DIMENSIONS 011 00 CUTOUT 7 38 121 28 re 14 75 CRANE MTG INTERFACE 2 4 B E 4 53 5 1 e 19 73 Ca EB Wi p 438 6 Overall dimensions H6400 SERIES CRANE CAPACITY CHART H6400 CAPACITY CHART 6400 LLI LLI LL a LU 2759 0 BOOM RADIU
29. rns are allowed after 30 days from the date on the invoice The material must be received within 30 days of the faxing or mailing from RKI of the AUTHORIZATION FOR RETURN If the material is not received within this time period the AUTHORIZATION FOR RETURN is voided 36 Merchandise return policy 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 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 Other RKI Quality Products gt Aluminum Treadplate and Steel Truck Boxes for Pick Up Trucks
30. t capacity The operator shall not leave the controls while the load is suspended Operating instructions 9 H6400 SERIES CRANE 24 25 26 27 28 29 30 31 32 33 34 10 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 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 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 shal
31. tension 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 MANUFACTURER 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 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 Installation instructions H6400 SERIES CRANE ELECTRICAL AND HYDRAULIC INSTALLATION A POWER SUPPLY RED WIRE ENGINE START YELLOW WIRE C ENGINE STOP BLUE WIRE AIR OPERAT D ENGINE FAST WHITE WIRE Pea ret loj SWITCH TRANS NEUTRAL 1 Orne SAFETY SWITCH SEE NOTE 4 k RED WIRE Hix FUSE EU PTO sd SWITCH 15 AMP SWITCH FILLER BREATHE

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