Stahl 3200 Series User manual

3200 Series Owner’s Manual
A
s of November 4,2004
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SAFETY
3200 SERIES OWNER’S MANUAL
TABLE OF CONTENTS 1
SAFETY 2-4
OPERATION 5-8
MAINTENANCE 9-10
SPECIFICATIONS 11
TROUBLESHOOTING 12
MOUNTING INSTRUCTIONS 13-15
PARTS 16-26
SCHEMATICS 27-28
WARRANTY 29
FOR THE LOCATION OF YOUR NEAREST DISTRIBUTOR CALL 330-264-7441
Revision 6/04
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SAFETY 3200 SERIES OWNER’S MANUAL
- It is YOUR responsibility to maintain and operate this crane safely -
The following words and symbols will be used in your owner’s manual:
! DANGER ! Indicates immediate danger and that special precautions are necessary.
! CAUTION ! Warns against potential hazards or cautions against unsafe practices.
Your scrane is designed to meet all applicable government safety standards. Warranty will be voided if the
crane is misused due to:
• Overloading
• Abuse
• Lack of (or improper) maintenance
• Unauthorized modification
! CAUTION !
Operate your 3200 crane within the lifting capacities specified. Exceeding the lifting capacity for a given boom
length can cause tipping or structural failure. Only the s“New Machinery and Equipment” warranty shown
on the last page of this manual is valid with this crane. No other warranty—verbal, written, or implied—is valid with
this crane. Treat your scrane with respect and service it regularly. These two things can add up to a safer
working environment and longer equipment life.
! CAUTION !
Note locations of Danger, Caution, and Lift Capacity decals on the 3200 crane. Read and understand each of
these before attempting to operate the crane. If any of these labels are missing or cannot be read, contact your
sdistributor for immediate replacement.
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SAFETY
3200 SERIES OWNER’S MANUAL
GENERAL SAFE OPERATING PRACTICES
ALWAYS inspect your crane daily, prior to use, for malfunctions, defects, or misuse.
ALWAYS keep the vehicle as level as possible while loading or unloading.
ALWAYS set the vehicle emergency brake before beginning crane operations.
ALWAYS keep the load as close to the ground as possible.
ALWAYS store the crane and hook when moving the truck.
ALWAYS store the controller securely to avoid unauthorized use of the crane.
NEVER swing a load that passes over people.
NEVER operate the crane within ten feet of a power line.
NEVER exceed the rated lifting capacity. Deduct the weight of any load handling equipment from rated capacity.
NEVER leave a load suspended in the air.
NEVER use the winch to drag a load into position before lifting.
NEVER operate the crane during an electrical storm or when high wind conditions exist.
NEVER side load the boom by dragging a load from the side.
NEVER try to service or repair the crane while the crane is operating.
NEVER place yourself between the load and truck or other fixed object.
NEVER move the truck while operating the crane or with a load on the crane.
SAFETY CHECKLIST
STRUCTURAL SOUNDNESS: Inspect the unit for damaged members and loose fasteners.
CONTROLS: Make a short test for proper control and operation of all functions.
REPAIRS: Fix all problems before using your crane.
LEAKAGE: Examine all of the hydraulic lines for frays and blisters. Look for signs of lubricating or hydraulic oil
leakage.
HYDRAULIC OIL SUPPLY: With the crane in a stored position, and all cylinders retracted, check oil level in the
hydraulic reservoir.
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SAFETY 3200 SERIES OWNER’S MANUAL
DECAL PLACEMENT
Note locations of the DANGER, CAUTION, and LIFT CAPACITY decals on s 3200 cranes. Read and
understand each of these decals before attempting to operate your crane. If any decals are missing or cannot be
read, contact your s distributor for immediate replacement.
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OPERATION
3200 SERIES OWNER’S MANUAL
LOAD CAPACITIES
MEASURED IN POUNDS
CRANE RATING : 10,000 FT./LB.
DISTANCE IN FEET
NOTE: Load capacities are based on 85% of tipping when all outriggers are extended and have
firm contact with a solid surface. Vehicles must have proper axle load distribution and crane
must be mounted in accordance with manufacturer’s instructions.
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OPERATION 3200 SERIES OWNER’S MANUAL
REMOTE CONTROL
The crane remote control plugs into a receptacle. The blue line on the male plug on the remote control must line
up with the flat spot on the receptacle at the base of the crane. Push the male plug onto the receptacle while
turning the serrated portion of the male plug clockwise. Continue turning until the pin on the receptacle can be
seen through the hole in the male plug and a “click” is felt.
There are five switches on the remote control. Each is labeled as to the function and direction. For example: To
activate the winch, push up on the switch to “winch up”; push down on the switch to “winch down”.
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OPERATION
3200 SERIES OWNER’S MANUAL
The 3200 crane is designed to provide excellent service if operated within the maximum allowable load
specifications stated on the unit’s “Angle Indicator Plate” located on either side of the boom. A load chart is also
included on page 5. Load information charts should be studied before operating the crane. Exceeding the stated
load limit can cause tipping or structural failure. You should familiarize yourself with proper operation procedures
to avoid overloading the crane. As an example: If a load of 3200 pounds is lifted at an 11’ boom length at 75°,
lowering the boom would cause an overload situation.
The 3200 crane is relatively simple to operate. Prior to field use, you should familiarize yourself with the controls
and how the unit reacts to the controls. Practice operations should be performed with a light test weight
progressing to a heavier test weight.
LIFTING OVER 1,600 POUNDS
A “two-part” line must be used whenever the load is 1,600 pounds or greater. In order to “two-part” the line:
• Connect the winch cable eye to the pin on the bottom of the manually extendible boom section.
• Insert cable through the snatch block by removing the cotter pin and disassembling.
• Reassemble the snatch block. Be sure to reinsert the cotter pin in the snatch block.
You should also use a “two-part” line for loads under 1,600 pounds if you want to slow down the line speed of
the cable.
LOAD LIFTING
It must be understood that all load ratings are formulated on 85% of tipping. Tipping is defined as a tire breaking
contact with the ground. Further, all load ratings are dependent upon compliance with the following:
• The unit has been correctly installed in accordance with chassis requirements and truck body manufacturer’s
specifications.
• The intended operation is carried out on a level, solid surface with proper outrigger placement.
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OPERATION 3200 SERIES OWNER’S MANUAL
TASK PERFORMANCE
1. Position the 3200 crane as close to the job as possible on a firm, dry, and level surface. Avoid overhead
obstruction on the work side of the unit.
2. Set the parking brake.
3. Extend and lower the outriggers until firm ground contact is made. On soft ground, use bearing pads to
prevent sinking or tipping.
4. Run the winch line out before extending the boom.
5. Make sure the connection to the load is secure and will not come loose when lifting the load.
OVERLOAD PROTECTION
The 3200 crane is equipped with a counterbalance valve inside the lift cylinder to protect against overloading. In
an overload condition, the boom will not elevate. Attempts to winch the load will cause a downward feathering of
the boom until the overload condition is reduced. The counterbalance valve will also keep the boom from coming
down in the unlikely event of a rupture to the hydraulic hoses that supply oil to the lift cylinder.
A pressure sensitive switch is located in the lifting cylinder. It can sense an overload situation. This causes a
shutdown of the winch up, boom extension out, and boom elevation functions, and automatically resets after the
crane has been moved out of the overload position.
An anti-two block feature is provided on the LRX models, and optional on all others.
RELIEF VALVES
The 3200 crane has a relief valve located on the hydraulic power unit. This is the main system relief. It is factory
set at 2550 PSI. The main function of this relief valve is to prevent overloading of the system if the boom is
inadvertently rotated against an immovable object, while one of the other hydraulic functions is also being used.
The relief valves would not normally require adjustment, but if the correct relief valve setting is suspect, refer to
the maintenance section of this manual for the proper adjustment and testing procedure.
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MAINTENANCE
3200 SERIES OWNER’S MANUAL
Proper maintenance on a regular schedule is essential to keep the unit operating at peak efficiency.
LUBRICATION
Maintenance and proper lubrication schedule will vary with climate conditions and the amount of usage the unit
receives. The lubrication chart below is intended to serve for a normal workload and moderate weather variance.
Periods of heavy use shorten service intervals.
ITEM WHERE INTERVAL LUBRICATION
PRODUCT
Slewing Ring Grease Fitting 1 Month Chevron Moly Grease #2
Winch Cable Surface 6 Months Light Oil
Pulley Block Not Required - - - - - - - - - -
The Worm and
Gear Mesh Directly on Gears 1 Month Mobiltac “C”, Shell
Cardium EP Silver Streak
200, Mollube Alloy 936
Sheave Bushing Not Required - - - - - - - - - -
Cylinder Pin Bushing Not Required - - - - - - - - - -
Turret to Boom Bushing Grease Fitting 6 Months Chevron Moly Grease #2
HYDRAULIC FLUID SPECIFICATION
Minimum viscosity specifications for hydraulic oil to be used in the crane should be Chevron AW68 or equivalent
to eliminate the necessity of seasonal oil changes under normal temperature conditions. For operations in below
freezing temperature, use a hydraulic fluid having a viscosity of 3000 SSU’s.
Operating temperature of the hydraulic fluid should be within the range of 120°F—160°F (49°C—82°C).
NOTE: Arctic conditions present special requirements and considerations. Consult your oil supplier for the proper
fluid for working under these severe conditions.
In addition to meeting the viscosity requirements, hydraulic fluid used in the system should contain the following
additives:
• Anti-foam inhibitors
• Antioxidant inhibitors
• Anti-wear additives
• Rust resistant additives
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MAINTENANCE 3200 SERIES OWNER’S MANUAL
PURGING AIR FROM THE SYSTEM
Air that is trapped in the cylinder will cause an erratic “bumpy” condition. To expel the air, hold the affected
control open after the function has “bottomed out”. Move the function in the opposite direction and again hold
the control open. Attempt to operate the crane in a normal manner to determine if the air has been purged.
When purging is complete, reevaluate hydraulic fluid level and add fluid if necessary.
REMOTE CONTROL
The remote control is subject to corrosion and must be checked at least twice a year and more often if operated
in severe, wet conditions. To check for corrosion:
1. Remove the cover plate and inspect for lack of luster. Metal should appear bright and untarnished.
2. Spray the inside of the box with an ignition sealer such as Krylon.
3. Check all connections to make sure they are tight.
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MOUNTING INSTRUCTIONS
2000-R SERIES OWNER’S MANUAL
FEATURES
• Crane Rating: 10,000 ft/lb capacity.
• Hydraulic extension boom provides reach up to 11’ with manual boom adding an additional 4’.
• Electric winch for efficient operation.
• Self-lubricating Nylatron™bearing allows smooth operation of inner and outer booms.
• Multifunction, removable remote control provides safe operation up to 25’ away.
• Electrical solenoid-operated valves.
SPECIFICATIONS
• Extension: Electric to 11’ - with manual extension to 15’.
• Lifting Height Above Base: 15’
• Weight: 800 lbs.
• Length: 104.00”
• Width: 19.00”
• Height: 33.50”
• Base Dimensions: 14.00” x 16.00” (10.50” x 14.75” bolt pattern)
• Rotation System: 360°continuous hydraulic - turntable bearing w/planetary drive & dynamic brake.
• Remote Control: Lightweight remote control unit with 25’ cable.
• Winch Cable: 62’ of 1/4” aircraft cable, with latch hook traveling block and down haul weight.
• Rotation Speed: 1 RPM.
• Boom Elevation Speed: -5°to +75°- 15 seconds.
• Boom Extension Speed: 11’ to 15’ - 18 seconds.
• Winch Line Speed: 15’ per minute - single line.
• Min. Chassis Req.: 8000 GVWR.
OUTRIGGER REQUIREMENT
Jackleg or outrigger available.
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SPECIFICATIONS 3200 SERIES OWNER’S MANUAL
SYMPTOM PROBABLE CAUSE
Function fails to respond to controls
Pressure switch malfunctioning
Low hydraulic fluid
Faulty hydraulic pump
Short circuit in remote control
Crane not grounded to truck
Solenoid in control valve malfunctioning
Bad ground on control valves
Circuit breakers tripped
Dead battery
Optional anti-two block malfunctioning
Slow down of functions speed
Relief valve set too low
Low hydraulic fluid
Clogged filter/strainer
Pump not providing enough GPM
Boom drifts under load Cylinder piston seals leaking
Counterbalance valve defective
Crane is overloaded
Boom or winch will not lift load
Restriction in hydraulic line
Cylinder piston seals leaking
Relief valve not set properly
Pump losing prime
Overload condition
Filter clogged
Counterbalance valve defective
Cable mis-wrap Loose cable being wound on drum
Unusual noise during operation
Cavitation due to low hydraulic oil
Load is excessive
Suction line filter is clogged
Relief valve set too low
Relief valve defective
Air in the lines
Winch motor runs but fails to wind cable Gear train is damaged
Erratic operation of hydraulic function Air in hydraulic system
Crane will not rotate Low hydraulic fluid Hydraulic motor defective
Bad ground on control valve
Rotation speed too fast or too slow Flow controls set incorrectly
Control valve defective
13 s
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MOUNTING INSTRUCTIONS
3200 SERIES OWNER’S MANUAL
! CAUTION !
Improperly mounted cranes can injure people or damage property. These instructions describe installation of a
scrane on a typical sservice body. Contact the dealer for other service body/truck chassis
combinations.
! CAUTION !
The truck chassis must be capable of safely supporting the entire chassis, body, crane, other equipment and the
maximum capacity of the crane - 3200 pounds.
s3200 cranes must be installed on a truck chassis with a GVWR of at least 8000 pounds. The GVWR must
exceed the curb weight of the complete vehicle by at least the rated load of the crane (3200lbs). The curb weight
is the total weight of the chassis, body, crane, and other equipment. (See example below.)
GVWR = 8800LBS
CURB WT. = BODY WT. (1200 LBS) + CRANE WT. (800 LBS) + CHASSIS WT. (3500 LBS) = 5500 LBS
GVWR (8800 LBS) – CURB WT. (5500 LBS) = 3300 LBS > 3200 LBS
! CAUTION !
Never attach, change, or use unauthorized components on your scrane. This could result in failure
of the crane and/or possible injuries and voids any warranty or liability.
! CAUTION !
MOST SERVICE BODIES ARE NOT STRONG ENOUGH TO MOUNT A CRANE!
You must reinforce the compartment and floor before you mount the crane. Get help from the truck dealer or
distributor if the s3200 crane is installed on a non-sbody, in another body/chassis combination or
in a different location. It is recommended that a scrane body and outriggers be used with the 3200 crane.
Consult the distributor for the proper body required for your application.
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MOUNTING INSTRUSTIONS 3200 SERIES OWNER’S MANUAL
1. Layout the mounting holes on the mounting surface (refer to figure below). Drill four (4) 0.56” diameter
holes and flame cut the two inch (2”) diameter hole.
2. Lift the crane into position. Make sure the power lead is fed through the two inch (2”) diameter hole.
3. Bolt the 3200 crane to the mounting surface with four (4) 0.50” grade eight bolts and four (4) grade eight
lock nuts. Torque the 0.50” bolts to 100 foot pounds. Use of other than 0.50” grade eight bolts and lock nuts
may result in the crane breaking loose from the mounting surface when in use. Additionally, star washers
should be used between mounting bolts and crane mounting plate to ensure crane is grounded to body.
4. It is necessary to support the boom in the stored position. The boom support should also have a place to
secure the hook in the stored position. The figure below shows a typical boom support.
15 s
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MOUNTING INSTRUCTIONS
3200 SERIES OWNER’S MANUAL
! CAUTION !
-DISCONNECT NEGATIVE BATTERY CABLE BEFORE PROCEEDING-
5. Run the power lead to the front of the truck. Locate the lead so that it will be protected. Install cable clamps
to hold the wire securely in place.
6. Connect the power wire to the positive terminal on the vehicle battery. A 250-amp in-line circuit breaker is
required near the battery to protect harness from electrical shorts.
7. Reconnect the negative battery cable. The 3200 crane is self-grounding and does not require an additional
ground cable.
! CAUTION !
IF THE POWER WIRE IS ROUTED SO THAT IT PASSES THROUGH ANY BODY OR CHASSIS SHEET METAL, A
GROMMET MUST BE USED TO PROTECT WIRES FROM BEING CUT. IF THE POWER WIRE COMES INTO CONTACT
WITH A GROUNDED SURFACE, A DEAD SHORT WILL OCCUR POSSIBLY CAUSING DAMAGE TO THE CRANE,
VEHICLE BATTERY OR ELECTRICAL SYSTEM.
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PARTS 3200 SERIES OWNER’S
MANUAL
TURRET AND BASE SERVICE PARTS - ILLUSTRATION (PLASTIC SHROUD OPTION)
17 s
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PARTS
3200 SERIES OWNER’S MANUAL
TURRET AND BASE SERVICE PARTS - PART LIST (PLASTIC SHROUD OPTION)
ITEM QUANTITY PART NUMBER DESCRIPTION
1 16 964050 5/8”-11 x 2.00” screw
2 1 95477-001 Base weldment
3 1 95483-001 Slewing ring
4 1 95484-001 Rotation drive
5 15 964047 5/8” - 11 x 3.00” SCREW
6 1 95476-001 Turret weldment
7 8 964049 1/4” - 20 x 1/4” ss screw
8 1 95468-001-L Crane cover-left hand
9 1 95468-001-R Crane cover-right hand
10 1 95418-001 Harness
11 2 917453 1/2” -13 x 2.00” screw
12 1 95420-001 Hydraulic motor
13 2 919874 1/2 “ Lock washer
14 1 95618-006 Dust cap
15 1 95403-001 Remote control
16 1 961675 Male plug
- 12 961676 16 gauge socket
- 4 961679 12 gauge socket
- 7 961677 Seal plug
17 25’ 961762 Cable
18 4 963941 Rocker switch-spdt-(on/off/on)
19 1 963942 Rocker switch-spst-(on/off)
20 1 95699-014 Angle-power rotation
21 4 95457-001 Clamp-hose
22 1 95472-001 Angle-power rotation upper
23 1 960680 Copper lug
24 3’ 961758 Cable-1 gauge-red
25 1 95453-001 Tweco-connector assembly
26 25’ 961758 Cable-1 gauge -red
27 1 95618-007 Receptacle
- 4 95618-009 12 gauge pin
- 12 95618-010 16 gauge pin
- 7 95618-008 Seal plug
28 1 95907-400 Remote control (new style)
29 4 95907-424 Switch-momentary
30 1 95907-425 Switch-maintained
31 1 95907-426 Cable-remote control
32 1 95907-429 Casing-remote control
18
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PARTS 3200 SERIES OWNER’S
MANUAL
TURRET AND BASE SERVICE PARTS - ILLUSTRATION (METAL SHROUD-STANDARD)
19 s
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PARTS
3200 SERIES OWNER’S MANUAL
TURRET AND BASE SERVICE PARTS - PART LIST (METAL SHROUD-STANDARD)
ITEM QUANTITY PART NUMBER DESCRIPTION
1 16 964050 5/8”-11 x 2.00” screw
2 1 95477-001 Base weldment
3 1 95483-001 Slewing ring
4 1 95484-001 Rotation drive
5 15 964047 5/8” - 11 x 3.00” SCREW
6 1 95476-001 Turret weldment
7 1 95468-004 Shroud base
8 6 962111 Self tapping screw – 10-24 x 3/8
9 1 95499-024 Shroud – valve cover
10 2 917453 1/2” -13 x 2.00” screw
11 2 919874 ½” lock washer
12 1 95420-001 Hydraulic motor
13 1 95907-195 Seal kit-hydraulic motor
14 1 95453-001 Tweco connector assembly
15 20 961767 Cable-1 gauge -red
16 1 95699-014 Angle-power rotation weldment
17 4 95457-001 Clamp-hose
18 1 95472-001 Angle-power rotation upper
19 1 95419-001 12-volt hydraulic power unit
20 2 917351 3/8-16 x ¾ hex head cap screw
21 2 152608 3/8 external tooth lock washer
22 2 917353 3/8-16 x 1.25 hex head cap screw
23 2 917352 3/8-16 x 1.00 hex head cap screw
24 8 919870 3/8 flat washer
25 4 919723 3/8-16 lock nut
26 1 95907-136 Bracket-pump mounting
27 1 95419-012 Grommet
28 1 95168-022 Shroud – solenoid
29 1 95418-001 Harness
30 1 95618-007 Receptacle
- 4 95618-009 12 gauge pin
- 12 95618-010 16 gauge pin
- 7 95618-008 Seal plug
31 1 95618-006 Dust cap
32 1 95907-400 Remote control (new style)
33 1 95907-426 Cable-remote control
34 1 961675 Male plug
- 12 961676 16 gauge socket
- 4 961679 12 gauge socket
- 7 961677 Seal plug
35 1 95907-425 Switch-maintained
36 4 95907-424 Switch-momentary
37 1 95907-429 Casing-remote control
38 1 95907-467 Face plate
39 1 960680 Copper solder lug
40 6’ 961758 Cable-1 gauge-red
20
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