RKI, Inc.
Contents
1. 4 SCREW CPSKT0 25 0 5 4 s 2 ho so w 0 os PACER 3200 BOOM HEAD OINTER DEGREE INDICATOR OLT HX 3 8 16X3 4 LK AGE WIRETWO BLOCK 3200 MICROSWITCH HOUSING BOOM 3200 3ERX 15 EXT OVER 3200ERX EXTEND CYL CREW CPHEX 0 25X 50 THD ASHER FLT 1 4 FENDER REEL CORD 20FT 18 3 EYE BOLT 25 20UNC CORD GUIDE 3200 CRANE WINCH WARN DC2000 BRACKET CABLE REEL CLAMP LOOM 3 8 MTG ISCREW CPSKT 0 25 10 34 2 SCREW CPSKTO 28 17 35 0 083 HEAT SHRINK 1X12 L 36 41 2 RING RING EXTO750 P 38 1 PIN GRVD 0 75 1 37 39 2 sPACER BOOM 3200 40 1 PIN QUICK 100 400 W L 41 4 NUTHEX 250NCFLEX 42 1 CLAMP LOOM 1 4MTG 43 EN EM O gt Bess as amp 5 Jd S ISIS FAAEE to W m Cn o W 3 WIRE 16 3 COND FEET 44 BOOM 3200 3ERX 15 MAIN 45 B e Cn b 3706 BOOM ASY 3200ERX IMDT BF sem 5 R BE MI SEM 10 RT 12 13 LE 15 EIS 18 EUM IMDT amp EXTENSION BOOMS FULLY EXTENDED 96 23 3200 SERIES CRANES TURRET ASSEMBLY P N 43793 Page 1 of 2 24 3200 SERIES CRANES TURRET ASSEMBLY P N 43793 Page 2 of 2 Item Part Number Number Description Qty2. NC CONNECTED TO WHITE LEAD OF CORD REEL CABLE C CONNECTED TO BLACK LEAD OF CORD REEL CABLE NO WIRE NOT USED TRIM SHORT amp TAPE END DETAIL C ANTI TWO BLOCK SCALE 1 1 PURPLE PIN E ROTATE RIGHT RED PIN I ROTATE LEFT BLACK PIN H CUTOFF BLUE PIN C CUTOFF ORANGE PIN J EMERGENCY STOP DETAIL A TERMINAL STRIPS SCALE 1 2 16 3200 SERIES CRANES WIRING SCHEMATIC ERX MODEL 12VDC l O O gt om Ry es GB ROTATE R E O ROTATE LEFT I Ww OVERLOAD 2 BLOCK SWITCH SWITCH W HOST UP o W W By WIRE LIST P N 45179 Connector Wire veg Usage Position Color E Green Hoist Down 52 S2 51 Boom Out BO 4 Blue Microswitch Gray Boom Up BU Purple Rotate Right RR _ Yellow Hoist Up 3 MOTOR g Brown Boom In BI Black Common Red Rotate Left RL Orange Emergency Stop No wire Ground Pink Emergency Stop lt ai z ja nim o o w gt White Boom Down BD 17 3200 SERIES CRANES ELECTRICAL LAYOUT ERX MODEL W0180 Page 1 of 2 BROWN Zu WHITE 4 RED 23 DETAIL D SOCKET SCALE 1 1 VIEW FROM OUTSIDE PURPLE WITH PIN LETTERS GRAY TAN L lllllllqchhB c ad1hao haa FF 2 TERMINAL 2 8 LOAD LIMIT SP WINCH TERMINAL I AN i UW WHT 1 i
3. GA BLK mo kok amp SOLENOID JL PER IN 7 La CR z PUMP 3 SOLENOID o AJJ A2B SWITCH z 200 9 3X2 i QUILL ANTI TWO BLOCK GREEN HOIST DOWN YELLOW HOIST UP GROUND BOLT ON MANIFOLD 18 3200 SERIES CRANES ELECTRICAL LAYOUT ERX MODEL W0180 Page 2 of 2 PART QTY DESCRIPTION id C CONNECTED TO WHITE 1 41150 j0 25 HEATSHRINK 1X12 L LEAD OF CORD REEL CABLE 2 41156 1 TERMINAL I8GA 31 RING 3 43100 0 5 WIRE 18 BULK BRN FEET 4 43263 1 WIRE ASY 402 16 0 GRND NO WIRE NOT USED 5 43362 2 SCRW PAN 4 40X3 4 TRIM SHORT amp TAPE END 43363 2 NUFHX 2440 NC CONNECTED WITH ORANGE 43452 WIRE ASY 02 18 5 PUMP WIRE TO TERMINAL STRIP 43683 2 MICROSWITCH 2000 SERIES 43690 8 WIRE 163 COND FEET DETAIL B LOAD LIMIT L SCRW PAN 2 56X3 4 SLOT SCALE 1 1 43700 NUT HX 2 56 NC CONNECTED TO 12 WIRE ASY 02 36 0 GRND WHITE LEAD OF 16 15 amp 81818818 SIS 437 437 43804 1 WIRE ASY 402 36 0 QUILL CORD REEL CABLE 43816 3 TIE CABLE 03 9L BLK NYL C CONNECTED TO 43905 3 CONNECTOR BUTT 14GA BLACK LEAD OF 43915 4 WASHER LOCK INTERNAL 2 CORD REEL CABLE 17 43916 2 WASHER LOCK INTERNAL 44 18 43999 4 TERMINAL 14GA 6FORK 19 44000 1 TERMINAL 14GA QD FEM NO WIRE NOT USED 20 44008 8 HEAT SHRINK 1 4 X3 4 L TRIM SHORT amp TAPE END 2
4. 1 03029 375 WASHER LOCK 4 2 07882 WASHER LOCK 1 4 3 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 1 29 43346 PAD MTG F CONNECTING ROD 1 30 43360 SCREW SKTHD 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
5. Meets OSHA 1910 180 requirements Specifications Weights 710 Ibs ERX model 571 Ibs ER model 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 sold separately 3200 SERIES CRANES OVERALL DIMENSIONS z I lt 4 O o z z 2 83 FULLY RETRACTED 131 INTERMEDIATE POWER EXTENSION 179 COMPLETE EXTENSION CRANE CENTER OF GRAVITY 3200 SERIES CRANES 3200 SERIES CAPACITY CHART NOTES 2576 1 Overload Protec Hoist Up Boo Ea nd p Boom gt Boom Down KU 2 2 000 Ibs city BA 1333 NG 3 Use 2 Part Line Only BOOM HEIGHT FEET NG a NA Ane NX LL Tee LLL D hr 0 9 0 9 9 CD 9 9 Qo W 2 3 4 9 i ILLI BOOM RADIUS FEET amp CAPACITY LBS 3200 SERIES CRANES 10 11 12 13 14 15 16 17 18 19 INSTALLATION 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 jacklegs extending out at least 42 from the centerline of vehicle Disconnect the gr
6. SCREW CPSKT 0 25 0 5 EN 4 SCREW CPSKT 0 25 1 0 13 14 43041 15 16 1 PIN GRVD 0 75 137 18 19 4 NUT HEX 250NCFLEX 1 WINGHWARNDC2000 1 CLAMP LOOM 4MIG 1 BRACKET CABLEREEL 43690 8 WIRE 163 COND FEET 42 44798 BOOM 3200 3ERX 15 EXT 2 SCREW CPHEX 0 25X 50 THD m E 1 WASHER FLT 1 4 FENDER 1 REEL CORD20FT 18 3 1 EYEBOLT 25 20UNC 1 CORDRELGUARD I I I I S 5 LB 33 35 38 40 41 EN IMDT 8 EXTENSION BOOMS FULLY EXTENDED 92 1 2 21 3200 SERIES CRANES BOOM ASSEMBLY ERX MODEL P N 43784 Page 1 of 2 22 3200 SERIES CRANES BOOM ASSEMBLY ERX MODEL P N 43784 Page 2 of 2 ITEM P N QTY DESCRIPTION ITEM P N QTY DESCRIPTION gt 1 07756 2 SCRW CPHEX0 2525GR2 24 4375 2 PIN W KPRO 75 1 62 3200 2 07882 17 WASHER LOCK1 4 25 43753 1 _ PIN W KPR 1 00 2 44 3200 07885 _1_ PIN W KPR 1 00 581 3200 WASHERLOCK3 8 WASHER LOCK 3 8 PIN W KPR 1 00 3 81 3200 5 8 6 WASHER FLT7 16N 28 PACER 3200 EXT CYL HEAD 8 2 M p w w NN tn m E amp os N N W N lt A BOLT HX 1 4 20X1 2 29 PACER 3200 EXT CYL ROD 2 FITTING GREASE 25NF 30 PACER 3200 EXT BOOM 8 sCREW CPHX 50UNCX 75 31 ASHER FLT 3 8 FENDER WASHER FLT 1 4 N 40986
7. cece eee cence a aar 22 23 TURRET ASSEMBLY Gina Srl er eer Sr A dE KA 24 25 HYDRAULIC LAYOUT ER MODEL L uuaaaaaaa aaa hrs 26 27 HYDRAULIC LAYOUT ERX arn 28 29 TRAVEL BLOCKASSEMBLY iura RR Rus p p EUER a 30 ANTI TWO BLOCK MICROSWITCH RESETTING 31 LOAD SENSOR CALIBRATION 0 0 cece RR rns 32 SPARE PARIS swo nbd ster Dee ew ihe ae aie Bees eh ee oe ee Seg 33 TROUBLESHOOTING te ca oss iranerne re eue da PR rare eru 34 LIFETIME WARRANTY GM EX ER TERCER ERU RT Sarees 35 3200 SERIES CRANES PACKING LIST The following items are included with your RKI 3200 Series crane 1 Crane Assembly 1 Crane User Manual W0053 1 Carton with Mounting Kit 43746 including the following contents 1 Hot Quill Power Cable 45157 12in H2ga Wire Assembly from Master Switch to Crane Quill 1 Hot Battery Power Cable 45158 25ft 2ga Wire Assembly from Vehicle Battery to Master Switch 1 Master Cutoff Switch 45156 1 Master Cutoff Switch Bracket 45155 1 Ground Cable 43738 3ft H2ga Wire Assembly from Service Body to Vehicle Frame 6 Cable Retaining Clips 43512 4 Mounting Bolts 43739 5 8 11 x 3 Grade 8 8 Flat Washers 07892 5 8 4 Lock Washers 03032 5 8 4 Hex Nuts 43740 5 8 11 Grade 8 1 Remote Control e ER models 44671 18ft with Emergency
8. included 3200 SERIES CRANES BATTERY Adequate battery power is a necessity for satisfactory crane operation Most original equipment vehicle batteries are designed for relatively light service of vehicle operation On vehicles with longer distances between battery and crane or if heavy or extended periods of operation are anticipated a heavy duty battery may be installed in the vehicle or a second 12 volt battery added to the vehicle system in order to increase available amperage The vehicle charging system should be functioning properly The battery charging system should supply a minimum of 13 volts DC at the crane with the vehicle engine running The voltage should not drop below 9 volts when any function of the crane is actuated It should also be noted that the performance of vehicle s alternators drops significantly with running idle speed and ambient temperature At standard truck idle speeds the alternator output can be as low as half of the rated capacity So it is recommended that the vehicle be running at an elevated idle during crane operation Normal operation of the crane should not require a second battery However if a second battery is used it should be connected to the first battery in parallel positive post to post and negative post to post GROUNDING Proper and adequate grounding of the crane is necessary to prevent poor performance or malfunction The 3200 Series cranes are grounded through the bottom mounting p
9. 1 44239 CONTACTOR 3200 WARN34440 22 44248 REEL CORD 20FT 18 3 23 45176 1 MANIFOLD PKG 3200ERX V2 DETAIL C ANT TWO BLOCK 24 45179 1 HARNESS 3200 ERX 5195 SCALE 1 1 EE 8 EW 10 EIN pe 113 14 15 16 GRAY D PURPLE PIN E BOOM UP ROTATE RIGHT WHITE PIN M RED PIN I BOOM DOWN ROTATE LEFT TAN PIN B BLACK PIN H BOOM OUT CUTOFF BROWN PIN G BOOM IN BLUE PIN C CUTOFF RANGE PN FJ TERMINAL BLOCK EMERGENCY STOP 43315 rama Fr DETAIL A TERMINAL STRIPS SCALE 1 2 19 3200 SERIES CRANES BOOM ASSEMBLY ER MODEL P N 43785 Page 1 of 2 20 3200 SERIES CRANES BOOM ASSEMBLY ER MODEL P N 43785 Page 2 of 2 ITEM P N QTY DESCRIPTION ITEM P N QTY DESCRIPTION 1 07756 2 SCRW CPHEX0 252 5GR2 22 43751 2 PIN W KPRO 75 1 62 3200 2 07882 14 WASHER LOCK1 4 23 43753 1 _ PIN W KPR 1 00 2 44 3200 3 4 4 WASHERLOCK3 8 1 BOOM ASY 3200ER MAIN WASHER FLT 7 16 N 1 BOOM ASY 3200ER IMDT EUM 4 EE 2 2 amp 1 2 FITING GREASE 25NF 2 2 BOLT HX3 8 16X3 41K 1 CAGEWIRETWO BLOCK 3200 MICROSWICHHOUSING 1 8 4 SCREW CPHX 50UNC X 75 oe 10 WASHER FLT 1 4N 40986 10 4
10. 200ER 5195 27 3200 SERIES CRANES HYDRAULIC LAYOUT ERX MODEL W0186 Page 1 of 2 mor 6 8 HH 3200 SERIES CRANES HYDRAULIC LAYOUT ERX MODEL P N 43790 Page 2 of 2 G Q G S 43 02 80 82 HYDRAULIC PUMP AND OIL FILTER ITEM P N QTY DESCRIPTION P N QTY DESCRIPTION 1 7882 2 WASHER LOCKI 4 20 43781 2 HOSE HYDO 25D 25MP500L 2 7885 2 wasHERHT3 5N 21 43799 2 FITTG 56MS 25FP90 3 7886 2 WASHERLOCK3 8 22 43801 2 HITG 25MP 25FPSORF 4 7916 2 BOL HX1 4 20x1 2 23 43802 1 PUMPASY 3200HYDI2V 5 40341 1 103 1028 24 44126 1 TUBE 3200HYDCYLEXT 6 20911 2 BoLt HX3 8 16x7 8 25 44184 1 FITTING 25MP 25FPS45 7 40986 2 WASHER FLT 1 4N 40986 26 44231 1 HOSEHYDO 25D 25MP200L s 43370 4 FmrG 56mMS 37BST 27 44232 2 NIPPLE HEX 25MP 25M 9 43374 2 FNIG 25FPTEE 28 45176 MANIFOLDPKG 3200ERXV2 10 43375 2 ENIG 25MP 37iBc9o O 29 45182 2 HNG 56MS 38IBC90 11 43376 6 FITTG 25MP 25FP590 30 45184 1 TUBE 3200 HYD MAN FLIR 12 43379 1 FITTING 25MP 25FP90 31 45185 1 TUBE 3200 HYD FLIR PUMP 13 43469 2 BOLT HX5 16 18x3 3 4 32 45186 1 TUBE 3200 HYD PRESSURE 14 43541 2 50 25 5 33 45188 12 HEATSHRINK G Z XT L CLR 15 43708 1 CYL HYD2 008
11. 3200 SERIES CRANES Models 3200 3ER15 3200 3ERX15 USER MANUAL Effective Serial Numbers 5195 and beyond Serial Number Date RKI Inc 2301 Central Parkway Houston TX 77092 Phone 713 688 4414 Fax 713 688 8982 www rkius com W0053 Rev 03 17 14 3200 SERIES CRANES TABLE OF CONTENTS Description Page s PACKING UIST 2 2 od vC I SS emen dni eus da d die S 2 IMPORTANT NOTICE RIS AR ZPA Re ate ue Hu REIS GP EECE VIG Baie ee eee 3 SPECIFICATIONS rnb settene 4 OVERALEDIMENSIONS xx dw Iq MA S seis 5 CAPACITY CHART ae w asie oi A RP VES CPI RET xd ub bei a Re isse deris eec e Pis 6 INSTALLATION INSTRUCTIONS 7 8 MOUNTING KIT 24 sere peperen ka koder UY UR Cv Ue xm PA ea Ev eA 4 9 OPERATING INSTRUCTIONS eeee haha 10 12 INSPECTION amp MAINTENANCE SCHEDULE 13 LUBE 8 HYDRAULIC FLUID SPECIFICATIONS 13 WIRING SCHEMATIC ER MODEL 14 ELECTRICAL LAYOUT ERMODEL L uuaaaaaaaaa aaa aaa RR hrs 15 16 WIRING SCHEMATIC ERX MODEL L Luuaaaaaaaaaaaawawa wawa hrs 17 EEECTRICAL LAYOUT ERX MODEL eR va ae OPOLE AO W UN RE ERE BAG Rw EVEN 18 19 BOOM ASSEMBLY ER MODEL 0 0 cc cee cece en aas 20 21 BOOM ASSEMBLY ERX MODEL
12. 44102 SCRW CP HX 1 4C x 1 1 2 1 43 44343 COVER PUMP 3200 CRANE 1 44 44504 SCREW CPHEX 0 25 1 25 1 25 3200 SERIES CRANES HYDRAULIC LAYOUT ER MODEL W0187 Page 1 of 2 42 gt a 3200 SERIES CRANES HYDRAULIC LAYOUT ER MODEL P N 43791 Page 2 of 2 HYDRAULIC PUMP AND OIL FILTER ITEM P N QTY DESCRIPTION ITEM P N QTY DESCRIPTION 1 7882 2 WASHERLOCKI 4 17 43780 2 HOSE HYD0 25D 25MP340L 2 7885 2 WASHERFLT3 8N 18 43799 2 FITTG 56MS 25FP90 I 3 17886 2 WASHER LOCK38 19 43801 1 _ FITTG 25MP 25FPSORF 4 7916 2 BOLT HX1 420x1 2 1 20 43802 1 PUMPASY 3200HYDI2V 5 40341 1 MOTOR HYD 103 1028 21 44231 1 HOSEHYDO 25D 25MP200L 40911 2 BOLT HX3 8 16x7 8 22 44232 1 _ NIPPLE HEX 25MP 25MP 8 43370 4 _ FITTG 56MS 37TBST 24 45184 1 TUBE 3200 HYDMAN FLTR 1 jFITG 25FPTEE 25 45185 1 TUBE 3200HYDFLTR PUMP 6 FITTG 25MP 25FPS90 26 45186 1 _ TUBE 3200 HYD PRESSURE 1 jEITING 25MP 25FP90 _ 27 45188 8 HEATSHRINK 3 4XI LCIR 2 BOLT HX5 16 18x3 3 4 28 45189 1 _ BRKT 3200FLTER amp 2 j FIITG 50MP 25FPST 29 45190 1 FILTER HEAD HYDBF 060 1 CYL HYD 3 008 14 505 30 45191 1 _ FILTER HYDBE IO 18 2 jFIITING 56MS 25FPS45 31 45192 2 SPACER 3200 MANIFOLD 43779 2 HOSE HYD0 25D 25MP 17 21 32 45193 1 MANIFOLD PKG 3
13. 48 005 34 45189 1 BRKT 3200FILTER 16 43715 1 CYl HYD3 008 14 505 X o 35 45190 1 FILTER HEAD HYDBF 060 17 43775 4 FNTING 56MS 25FPS45 36 45191 1 FILTER HYDBE I0 18 18 4377 2 HOSE HYD0 25D 25MP172L 37 45192 2 SPACER 3200MANFOLD 19 43750 2 HOSE HYD025D 25MP340L 29 3200 SERIES CRANES TRAVEL BLOCK ASSEMBLY P N 44090 Item Part Number Number Description Oty 1 03029 WASHER LOCK 3 8 2 2 07756 SCREW CP HX 4 20 X 2 5 2 3 07885 WASHER FLAT 3 8 2 4 40911 SCRW CP HX 5 16 18X3 4 2 5 43041 PULLEY 4 00D 75 BORE 1 6 43425 NUT HEX LOCK 44 20 2 7 43750 PIN W KPR 0 75 2 25 3200 2 8 43819 HOOK 2 TON SWIVEL WITH LATCH 1 9 43909 SPACER 2 10 44087 PLATE 3200 TRAV BLOCK 2 30 3200 SERIES CRANES ANTI TWO BLOCK MICROSWITCH RESETTING ALL MODELS Your RKI crane is equipped with an anti two block system per OSHA 29 CFR Part 1926 1416 d 3 to prevent damage from contact between the travel block and the boom tip If the travel block is allowed to contact the end of the boom continued operation could result in significant damage to the crane and possibly failure of the wire rope 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 and it comes in contact with the boom head and all the crane functions continue to operate When the block i
14. L W0181 Page 2 of 2 PART DESCRIPTION Cd 1 41150 0 25 HEATSHRINK IXIZL 2 41156 1 TERMINAL I8GA 31 RING 3 43100 0 5 WIRE 18 BULK BRNFEET 4 43263 1 WIRE ASY 402 16 0 GRND 5 43362 2 SCRW PAN 4 40X3 4 6 43363 2 NUT HX 44 40 7 43452 1 WIRE ASY 402 18 5 PUMP 8 43683 2 MICROSWITCH 2000 SERIES 9 43690 8 WIRE 16 3 COND FEET 10 43699 4 SCRW PAN 2 56 3 4 SLOT 11 43700 4 NUTHX 2 56 13 43804 1 WIRE ASY 402 360 QUILL 14 43816 3 TIE CABLE 03 91 NYL 15 43905 3 CONNECTOR BUITI4GA l 43915 4 WASHER LOCK INTERNAL 42 17 43916 2 WASHER LOCK INTERNAL 4 18 43999 4 TERMINAL I4GA 6 FORK 19 44000 1 TERMINAL 14GA QDFEM 20 44008 8 HEAT SHRINK 1 4 X3 4 L 21 44239 CONTACTOR 3200 WARN34440 22 44248 REEL CORD 20FT 18 3 23 45176 MANIFOLD PKG 3200ERX V2 45180 1 HARNESS 3200 ER 5195 GRAY D BOOM UP WHITE PIN M BOOM DOWN p 0 IT CL H TERMINAL BLOCK 43315 EM C C T S p T x V r 7 RD 8 C CONNECTED TO WHITE LEAD OF CORD REEL CABLE NO WIRE NOT USED TRIM SHORT amp TAPE END NC CONNECTED WITH ORANGE WIRE TO TERMINAL STRIP DETAIL B LOAD LIMIT SCALE 1 I
15. QUIRED 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 3200 SERIES CRANES MOUNTING KIT P N 43746 SWITCH ASSEMBLED TO BRACKET f Item Part Number Number Description Qty 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 402 36 0 GRND 1 5 43739 BOLT HX 5 8 11X3 G8 4 6 43740 NUT HX 5 8 11 G8 4 T 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 10 11 12 13 14 15 16 17 18 19 20 3200 SERIES CRANES OPERATING INSTRUCTIONS Page 1 of 3 Do not operate this crane unless you have thoroughly read and understand the information in this manual Cranes shall be operated only by the following qualified personnel and crane operator certification per OSHA 29 CFR Part 1926 1427 1430 is available from local and national certifiers a Designated persons b Trainees under the direct supervision of a designated person C Inspectors maintenance and test personnel when it is necessary in the performance of their duty No one other than the personnel specified in 2 above shall enter the crane s operating area with the excep
16. Stop e ERX models 44451 18ft with Emergency Stop 3200 SERIES CRANES IMPORTANT NOTICE RKI Inc cannot possibly know or even anticipate all of the varied uses and applications that may be found for its crane products 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 H
17. TE26 or equivalent premium grade hydraulic fluid 13 LUBRICATION amp HYDRAULIC FLUID SPECIFICATIONS 3200 SERIES CRANES WIRING SCHEMATIC ER MODEL 12VDC s LI ES EB ROTATE R E K om ROTATE LEFT OVERLOAD 2 BLOCK SWITCH SWITCH HOST UP F 37 gt 2 o 9 e HOIST DOWN RUN J 5 I STOP BOOM UP D O M HYDRAULIC PUMP MOTOR WIRE LIST P N 45180 Connector Wire Position Color Usage Green Hoist Down rm N A Not Used I Blue Microswitch MOIST Gray Boom Up BU o Purple Rotate Right RR Yellow Hoist Up 3 MOTOR 3 N A Not Used Black Common Red Rotate Left RL Orange Emergency Stop No wire Ground Pink Emergency Stop z ir aj zjo nim ojol w gt white Boom Down BD 14 3200 SERIES CRANES ELECTRICAL LAYOUT ER MODEL W0181 Page 1 of 2 NOTCH AT TOP FR WE ET P RED 23 DETAIL D SOCKET U SCALE 12 1 GROUND VIEW FROM OUTSIDE MANIFOLD PURPLE WITH PIN LETTERS PIN K GRAY p td FY 2 TERMINAL 2 8 LOAD LIMIT WINCH TERMINAL 1 AN WU WHT l 9 SOLENOID ap sk 18 PUMP I 63 SOLENOID o A2B SWITCH i QUILL ANTI TWO BLOCK GREEN HOIST DOWN YELLOW HOIST UP GROUND BOLT ON MANIFOLD 15 3200 SERIES CRANES ELECTRICAL LAYOUT ER MODE
18. ULE EVERY 3 COMPONENT DAILY WEEKLY MONTHLY MONTHS YEARLY NOTES Motor Brushes X Check Make sure the cable is wound Cable Drum X evenly on the drum Cable X Check or broken strands kinking etcetera Ckeck for any cracks or Load Hook X deformation of the hook or latch Inspect for any damage and Sheaves and Bearings X add grease to bearings Make sure the sheaves turn freely X Add grease to the bearing Or more Rotational Bearing often under severe conditions Check the bolt torque for the Base Mounting Bolts amp X four mounting bolts and Other Bolts tighten other bolts as required tf d Hydraulic Hoses X JARO any ARBELA leakage at fittings Hvdraulic Fluid X Check fluid level at the Y reservoir before each shift Drain flush and refill with Hydraulic Reservoir X A B Se hydraulic fluid Hydraulic Oil Filter X Replace Spin On Oil Filter AA Wear pads X pads and replace as required X Add grease to fittings Or more Boom Pivots often under severe conditions To extend the life of cable clean it periodically with a wire brush and lubricate it lightly with oil All other bushings used are made of brass impregnated with an oil and graphite compound and require no maintenance Other parts may be lubricated with a few drops of oil as needed 1 Rotational Bearings Mobil grease CM S or equivalent 2 Hydraulic Fluid Mobil D
19. e and start the engine Vehicle should be running during all crane operations and it is recommended that it run at an elevated idle Turn the master cutoff switch to the ON position to provide power to the crane Lower the winch to detach the crane hook from the tie down eye on the boom support Always boom up to clear the boom support and truck before you rotate or extend boom to desired position When operating near electric power lines comply with the requirements of OSHA 29 CFR Part 1426 1408 Summarized in Figure 1 and Table 1 no part of the crane or load may enter the danger zone For power lines rate 50 kV or below minimum clearance between the lines and any part of the crane or load including handling appendages shall be 10 ft 3 m For higher voltages see Table 1 Caution shall be exercised when working near overhead power lines because they can move horizontally or vertically due to wind moving the danger zone to new position While in transit with no load and boom lowered the clearance shall be as specified in Table 1 The 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 The load to be lifted is to be within the rated capacity of the crane refer to the crane load capacity chart 10 3200 SERIES CRANES Z 11 2 LELE ALLL OPERATING INSTRUCTIONS Page 2 of 3 Figure 1 Table 1 UA Normal Voltage kV Mini
20. he 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 35
21. irecting the lift shall see that a b The crane is level and where necessary blocked The load is well secured and balanced in the sling or lifting device before it is lifted more than a few inches The lift and swing path is clear of obstructions 28 29 30 31 32 33 34 35 36 3200 SERIES CRANES OPERATING INSTRUCTIONS Page 3 of 3 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 12 3200 SERIES CRANES INSPECTION amp MAINTENANCE SCHED
22. is exceeded the load sensor deactivates all winch functions except rotation boom in and hoist down Remove the load from the crane and the overload sensor is AUTOMATICALLY reset returning full function to the crane If the load sensor gets out of adjustment see instructions for its recalibration below Occasionally it may be necessary to recalibrate the load sensing device The following is the proper procedure 1 10 11 The load sensing device is located in the upper right hand section of the crane turret housing It consists of a microswitch fastened to a bracket which in turn is secured to an upright bar welded into the crane turret The plunger on the microswitch may be adjusted by means of the adjacent set screw Loosen the nut securing the set screw 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 feet from the center of rotation then connect a dynamometer scale Raise the hook by operating the hoist up switch on the control handle until the dynamometer reads 3 200 Ibs If you do not have a dynamometer please see the note below Adjust the set screw so that it rests against the end of the plunger Turning the setscrew counterclockwise increases the load capacity while turning it clockwise decreases capacity Relieve the pull on the winch line by operating the hoist down switch on the control handle until the dynamometer read
23. late A good ground must be established between the crane s lower mounting base and the vehicle battery For service or utility body mounting this grounding typically goes through the service body mounting plate to the service or utility body and then to the vehicle frame Ensure that a good metal to metal contact is made between the crane s lower base and the service body mounting plate If the body is mounted to the truck on wood runners or rubber mounts a 2 gauge ground cable must be added between the body and the chassis frame The vehicle battery and second battery if used must be grounded directly to the chassis frame If the vehicle battery is grounded to the engine block a second 2 gauge minimum ground cable must be added from the battery to the chassis frame or the engine to the chassis frame Maintain a regular schedule to ensure that the battery remains in good working condition Clean all connections check electrolyte levels check for loose belts and make sure that your vehicle charging system is operating properly WARNING 1 FEDERAL LAW 49 CFR PART 571 REQUIRES THAT THE FINAL STAGE MANUFACTURER OF A VEHICLE CERTIFY THAT THE VEHICLE COMPLIES WITH ALL APPLICABLE REGULATIONS ANY MODIFICATIONS OF THE VEHICLE PRIOR TO THE FINAL STAGE ARE ALSO CONSIDERED INTERMEDIATE STAGE MANUFACTURING AND MUST BE CERTIFIED AS TO COMPLIANCE THE INSTALLER IS RESPONSIBLE FOR COMPLIANCE WITH ALL APPLICABLE FEDERAL AND STATE REGULATIONS AND RE
24. mum Required Clearance Phase to Phase feet meters Operation near High Voltage Power Line PROHIBITTED ZONE Up to 50 10 3 05 SEE TABLE 1 Over 50 to 200 15 4 57 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 Operation in Transit With No Load and Boom Lowered Up to 0 75 4 1 22 Over 0 75 to 50 6 1 83 Over 50 to 350 10 3 05 Over 345 to 750 16 4 88 Over 750 to 1000 20 6 10 CRANE SHALL NOT BE USED TO HANDLE MATERIALS IN THIS AREA 21 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 22 23 24 25 26 27 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 No person should be permitted to stand or pass under a suspended load Before starting to lift the following conditions should be noted a b c d The hoist rope shall not be kinked Part lines shall not be twisted around each other The hook shall be brought over the load in such a manner as to minimize swinging The effect of ambient wind on the load and on crane stability The person d
25. n the crane s quill to either terminal of the master cutoff switch Connect the 25ft power cord to the other terminal of the master cutoff 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 or cut the cable insulation The cable should be supported at intervals to prevent sagging or dragging Use rubber grommets when cable passes through bulkheads Cut cable to the minimum required length and connect it to the positive post of the vehicle s battery with the appropriate lug or clamp connection Use the supplied 3ft ground cable to ground the crane base mounting base or service body to the truck chassis Use rubber grommets where the cable passes through bulkheads If the vehicle s negative ground cable is grounded only to the vehicle s engine then install a second ground cable from the negative post of the battery to the vehicle s frame The vehicle should be equipped with a minimum 125 amp alternator but a larger capacity is highly recommended Note alternator performance is significantly affected by vehicle RPM and temperature At standard truck idle speeds the alternator output can be as low as half of rated capacity The vehicle should be running during crane operation and it is recommended that it run at an elevated idle A 150 amp circuit breaker is required for all crane installations not
26. ound cable from the vehicle s battery ies Drill 4 holes 11 16 diameter and a center hole 2 diameter centered on the crane mounting location Install crane boom support in place and adjust to its lowest position To prevent damage do not support the crane under the hydraulic cylinders support the crane s main boom directly Grind both the crane lower mounting base and the service body s top mounting plate removing any paint primer or sealants The crane is electrically grounded through the base plate thus it is important that there is a good metal to metal contact between the crane and the mounting location Lift crane in place and install Grade 8 mounting bolts with nuts and washers Note use only bolts nuts and washers provided with crane Do not substitute and do not reuse bolts that have been previously torqued Install master cutoff switch bracket Line up bracket with the two rear bolts so that the bracket is along the far side of the crane compartment Install the master cutoff switch to the bracket and set to OFF position Tighten Grade 8 bolts in a criss cross pattern alternating until all are torqued to 200 ft lbs dry bolt If crane is being installed on a service or utility body seal around all holes and bolts with silicone or equivalent sealer Also seal around crane mounting plate Adjust the boom support to contact with the main boom and secure the crane hook to the hook ring Attach the 12 power cord betwee
27. owever it is not a definitive guide to every possible situation or circumstance If you have any questions or require additional information please contact RKI 3200 SERIES CRANES SPECIFICATIONS Models 3200 3ER15 3200 3ERX15 Moment Rating 10 000 ft Ibs Lift Capacities 3 200 lbs 3 ft 2 000 Ibs 5 ft 1 429 165 7 ft 1 111 Ibs 9 ft 909 Ibs 11 ft 769 Ibs 13 ft 667 Ibs 15 ft Boom The boom angle varies from 5 to 75 1 stage telescoping boom extension ranges from 7 to 11 Manual on ER model Power on ERX model gn stage telescoping boom extension ranges from 11 to 15 Manual on both models Line Speed Approximately 7 feet per minute first rope layer double line Multi Functions The crane configuration allows multiple electric and hydraulic functions to be performed simultaneously however multiple hydraulic functions are limited Load Sensor A load sensor is standard to automatically protect overload Anti Two Block Per OSHA 29 CFR Part 1926 1416 d 3 An anti two block feature is incorporated into the crane to prevent damage from contact between the travel block and the boom tip Winch Cable and Block 62ft of 1 4 galvanized aircraft cable is supplied with traveling block for double line operation Electrical 12 VDC required to operate the electrical solenoid valves control all the hydraulic functions and the contactor for the hoist winch Safety Standards
28. s 0 zero Ibs Again follow the procedure in 86 When the pull reads 3 200 Ibs the load sensor should stop the winch If the load sensor engages at the proper pull it is set correctly and the nut securing the set screw should be tightened If the load sensor does not engage properly follow the procedure in 46 until the proper setting is attained NOTE If a dynamometer is not available the same results can be obtained by using a known weight 3 200 Ibs and a known radius 3 feet Another example would be 2 000 Ibs 5 ft 32 3200 SERIES CRANES SPARE PARTS It is recommended that repair parts for your crane be obtained from your local RKI distributor Please note that unauthorized servicing or alteration of your crane will void the warranty Each crane is assigned a serial number which is a nameplate located near the bottom of the rear cover 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 Below is a list of miscellaneous parts not previously listed in this manual Part Part Description Number Comment Bronze Bushing 40005 Main boom pivots Cord Reel Package 44193 Includes cord reel micro switches cable and hardware Counterbalance Valve 44344 Hydraulic cylinder C B
29. s not in contact with the wire cage and or boom head and all crane functions fail to operate except rotation boom in and hoist line out The following is the proper procedure 1 Make sure that the wire cage has not been damaged 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 If 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 plate on the wire cage Then tighten the two microswitch housing screws 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 hoist line out and all functions should again operate 31 3200 SERIES CRANES LOAD SENSOR CALIBRATION ALL MODELS Your RKI crane is equipped with a torque reading load sensor which prevents overloading If the crane s load capacity
30. the boom in Load sensor gets out of See instructions to recalibrate in this manual adjustment Microswitch gets out of See instructions for traveling block microswitch resetting adjustment 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 Check for any loose exposed or frayed wires Make sure the switches operate 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 when contacting RKI for further troubleshooting questions stamped in the nameplate located near bottom of rear cover 34 3200 SERIES CRANES RKI LIFETIME WARRANTY This warranty applies to anything we have manufactured The warranty applies to t
31. tion of persons such as supervisors signal persons and those specific persons authorized by supervisors who duties require them to do so and then only in the performance of their duties and with the knowledge of the operator or other appointed persons The operator shall be familiar with the equipment and its proper care If adjustments or repairs are necessary the operator shall promptly report this to an appointed person and notify the next operator The operator at the start of each shift shall test all controls If any controls do not operate properly they shall be adjusted or repaired before operations are begun Seek the best possible work site for the operation when parking the crane mounted vehicle The parking location should be firm dry and level ground or pavement which can adequately reach the load by the rated capacity of the crane The crane mounted vehicle shall not be parked on uneven rocky or muddy terrain steep grades or overhead obstructed locations Fully extend the outriggers or jacklegs out at least 42 from the centerline of vehicle and to the ground to provide firm support and keep the crane mounted vehicle as level as possible during the operation When operating on soft terrain use wider pads or boards under the outrigger feet Blocking under the outrigger feet shall be of sufficient strength to prevent crushing bending or shear failure After the vehicle has been properly positioned engage the emergency brak
32. valve same for both cylinders Decal Kit 44357 Includes all decals for crane Dipstick 44727 Oil Reservoir Dust Cap 43507 Cover remote socket with chain Manifold ERX model 45177 Hydraulic manifold only for ERX model Manifold ER model 45194 Hydraulic manifold only for ER model Motor Hydraulic Pump 45015 Motor only of 43802 Motor Winch 44516 Motor only 2 post Oil Filter 45191 Spin On 10 micron Oil Reservoir 44998 Reservoir only includes o ring and breather H2 SAE Plug 45181 O Ring Plug for hydraulic manifold Seal Kit Boom In Out Cylinder 45159 Seal kit for 43708 extension cylinder Seal Kit Boom Up Down Cylinder 45160 Seal kit for 43715 elevation cylinder Socket Remote 43391 Socket only of wiring harness in turret Solenoid Hydraulic Pump 45004 Starter solenoid only of 43802 pump Terminal Boot 41376 Rubber Cap for winch motor terminals Valve Hydraulic Solenoid 45178 Cartridge valve only for manifold H2 SAE Plug 45181 O Ring Plug for hydraulic manifold 33 3200 SERIES CRANES TROUBLESHOOTING Problem Solution Crane slowly stops while Check for weak battery or bad connections lifting Cranes only operable Overload sensor may be set off Lower load to ground and switch will functions are rotation boom automatically reset in or hoist down 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 by either hoisting down or retracting
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