Summit Truck Bodies 4416 User manual

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FOR SHIP-LOOSE KIT
REFERENCE 400-62491
OWNER’S MANUAL
Safety, Installation, Maintenance, and Operation
4416 Journeyman Electric
Crane
Manual # 700-20029
Revision Date 02/28/2020
Summit Truck Bodies
990 Vernon Road
Wathena, KS 66090
866-985-3100
Fax: [phone]
www.summitbodies.com
Subject to Change without Notification

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SUMMIT TRUCK BODIES WARRANTY REGISTRATION
Fax Transmission
To: Warranty Department Fax: [phone]
From: Date:
Re:ProductRegistration Pages:
End user information: (Required for Warranty Activation)
Name: Phone:
Address:
City: State: Zip:
Contact: E-mailAddress:
Distributor Information (Required for Warranty Activation)
Name: Phone:
Address:
City: State: Zip:
Contact: E-mailAddress:
Product Information (Required for Warranty Activation)
ModelNumber: SerialNumber:
Date Product Delivered: Date Processed:*
VIN Number of Truck: *For Summit Use Only
ONE REGISTRATION FORM PER UNIT (CRANE OR BODY)
Registration form must be mailed or faxed within 15 days of customer installation.
Mail to:
Warranty Department
Summit Truck Bodies
990 Vernon Road
Wathena, KS 66090

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Summit Truck Bodies
Crane Owner’s Manual – Revision Record
REVISION RECORD
Date
Section(s) or
Page(s) Revised Description of Change
Initials
12/7/15 Initial Release Initial Release of Manual NA
1/5/16 all Updated graphics NA
02/28/20 TOC, SEC1, ALL Formatting, Ship Loose Kit CG
Notes:
1. The information contained in this manual is in effect at the time
of this printing. It does not cover all instructions, configurations,
accessories, etc. If you require additional information, please
contact Summit Truck Bodies at [phone].
2. Summit Truck Bodies reserves the right to update this material
without notice or obligation.

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TABLE OF CONTENTS
SUMMIT TRUCK BODIES WARRANTY REGISTRATION..............................................3
INTRODUCTION.....................................................................................................................9
SAFETY DECALS .................................................................................................................14
SPECIFICATION SHEET.....................................................................................................17
GENERAL DIMENSIONS ....................................................................................................18
INSTALLATION......................................................................................................................19
1.1 GENERAL......................................................................................................................19
1.2 ELECTRICAL................................................................................................................20
1.3 TESTING........................................................................................................................21
1.4 INSTALL KIT.................................................................................................................23
STABILITY CAPACITY CHART...........................................................................................24
OPERATION...........................................................................................................................26
2.1 GENERAL......................................................................................................................26
2.2 LOAD LIMITS...............................................................................................................26
2.3 EQUIPMENT INSPECTION.........................................................................................26
2.4 OPERATING RESTRICTIONS.....................................................................................26
2.5 LOAD LIFTING.............................................................................................................27
2.6 OPERATION OF OUTRIGGERS..................................................................................27
2.7 WIRELESS CONTROL INSTRUCTIONS...................................................................28
MAINTENANCE.....................................................................................................................29
3.1 GENERAL......................................................................................................................29
3.2 LUBRICATION..............................................................................................................29
3.3 HYDRAULIC FLUID....................................................................................................29
3.4 HYDRAULIC OIL DETERIORATION ........................................................................30
3.5 HYDRAULIC SYSTEM PURGING .............................................................................30
3.6 PURGING AIR FROM THE SYSTEM.........................................................................30
3.7 SYSTEM RELIEF PRESSURE .....................................................................................31
3.8 COUNTER BALANCE VALVE....................................................................................31
3.9 ROTATION GEAR.........................................................................................................31
3.10 PLANETARY WINCH.................................................................................................31
3.11 WIRE ROPE .................................................................................................................32
3.12 GEAR-BEARING BOLTS...........................................................................................33
3.13 INSPECTIONS.............................................................................................................34
LUBRICATION & MAINTENANCE SCHEDULE ...........................................................35
TROUBLE-SHOOTING ........................................................................................................36
PARTS .....................................................................................................................................38
ELECTRICAL SCHEMATICS..............................................................................................47
HYDRAULIC CONTROL VALVE SCHEMATIC................................................................48

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Limited Warranty....................................................................................................................49

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INTRODUCTION
READ CAREFULLY
Congratulations on your purchase. You are the owner of what we consider to be one of the
leading cranes in the service body field. This crane will provide you with both quality and
safety if you follow the guidelines of working with a well-maintained piece of equipment in a
safe manner using the correct personal protective equipment (“PPE”) for your work
environment. Your crane carries a five (5) year warranty on all parts, weldments, and a
three year warranty on the remote system.
For continued quality service, carefully read the information contained in this manual before
operating the equipment. This manual provides basic guidelines for the safe and proper
operation of the crane. After you have read and understood the material in this manual,
work with your crane by learning basic operations, safely.
To prevent injury to yourself or others, maintain your crane, and operate it safely by
knowing your surroundings. Look out for such things as overhead wiring, overloading of the
crane, side loading of the crane and wearing of the prescribed PPE.
The users must have a working knowledge of existing Federal, State and Local codes
and regulations governing the safe use and maintenance of this crane.
This crane was tested to conform to the following code:
ANSI – ASME B30.5a – 2002
MOBILE AND LOCOMOTIVE CRANES
The American Society of Mechanical Engineers
This crane carries a five (5) year warranty, but the warranty will be null and void if the crane
is misused or abused by overloading, side loading, pulling a load through open terrain, lack
of maintenance as directed in this manual, or making modifications to the crane without the
express permission of Summit Truck Bodies.
Treat the equipment with respect and service it regularly.
These two things can add up to a safer working environment, longer
equipment life, and prevention of loss of life and limb.
Summit Truck Bodies issues a limited warranty certificate with each unit sold.
See last page for warranty.
Distributor Assistance:
Should you require any assistance not given in this manual, we recommend that you consult your nearest Summit
Truck Bodies Distributor. Our distributors sell authorized parts and have service departments that can solve almost any
needed repair. This manual does not cover all maintenance, operating, or repair instructions pertinent to all possible
situations. If you require additional information, please contact Summit Truck Bodies at the
following telephone number: [phone]. The information contained in this manual is in effect at the
time of this printing. Summit Truck Bodies reserves the right to update this material without notice or obligation.

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SAFETY
Of all the pages within this manual pay particular attention to this chapter. It could prevent
serious injury, or worse, loss of life, to you or the people with whom you are working. After
reading this chapter, put safety into practice on the job while operating your equipment or
any other piece of machinery.
The first priority of any job must always be a safe working environment. You will eliminate
personal pain and suffering to yourself and to others on the job site. Know your surroundings,
power lines, loose soil not allowing for solid footing and lack of PPE, and maintain a mindset
of working safely, from the beginning to the end of each job. This is not an all-inclusive list,
so the owner of the machinery may want to supply its own list of safety precautions as well.
However, follow the safety requirements listed and you will have the basic knowledge of
safety on the job.
To qualify as a safe operator you should first know and understand your equipment, knowing
its limitations and strengths. Maintenance of the equipment is second priority; as with any
piece of machinery, if not kept clean and in working order, the equipment will likely
malfunction. Follow a preventive maintenance schedule with your machine and a routine
visual inspection of the equipment before you start any job.
The operator must have a working knowledge of all safety and government regulations. You
can refer to any OSHA manual for guidance. Summit Truck Bodies is not liable for accidents
caused by the operation of the crane.
You may want to follow a couple of safety tips. Equipment on your truck should include a fire
extinguisher and a first aid kit. Use best practices of PPE and avoid any type of body jewelry
that might get caught on moving objects.
The truck is equipped with a working surface on the bumper. Avoid using moving parts of the
truck as a foothold or handhold; use the grab bars and steps designed for this purpose.
Avoid walking under a load, and never use the crane as a mode of transportation from the
ground level to an elevated surface.
General
Being the owner of the equipment, it is your responsibility to establish a training process for
your operators by qualified people before starting the job. As with any equipment, be it a
motor vehicle or machinery, this equipment cannot be operated by anyone under the
influence of alcohol, drugs, or prescription medication that impairs the operator physically,
mentally or physiologically.

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Personal Safety
The use of personal protective equipment (“PPE”) is critical to the safety of the operation
and the wellbeing of the people operating the equipment. The use of the following (but not
all inclusive) PPE in the safe operation should be worn by the operator:
Protective helmets
Safety shoes (preferably steel toed)
Cut proof gloves, preferably snug fitting
Ear plugs or any form of hearing protection
Safety glasses or shields
Reflective vests
Follow your established safety rules and regulations. If you do not have those, consult
your OSHA manual. Routine inspection of the safety decals is a must for the safety of
the operator; be sure all decals are legible and in good condition. Replace any and all
decals that are missing from your truck body or in need of repair.
For the safety of the operators, follow these safety guidelines:
Disengage the power source before working on the equipment.
Remember there is stored hydraulic pressure in the hydraulic lines of the truck; this
must be released prior to working on the crane components or any part of the
hydraulic system.
Stay clear of all moving parts of the equipment; your body could be crushed or
severely pinched.
Routine maintenance should be recorded and maintained by only trained and
competent personnel.
Bypassing parts of the wiring and/or plumbing can cause the crane serious damage
and injury to the operator.
Stability
The service truck should be parked on solid level ground. If unable to park on such a
surface, outrigger pads may need to be used to level and support the truck and its load.
Never exceed the crane capacity chart nor the stability chart for the service truck. These
ratings are based on tested capacities of the service truck and the structural design and
mechanical abilities of the components on the crane.
Be aware of the abilities and limitations of your crane. Improper use of the crane could
damage the crane, service truck, lifted load, surroundings or even cause injury or death.
Park the vehicle on as level ground as possible. Use outrigger pads if needed, and always
extend the outriggers fully out and then down.

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Be aware of your surroundings when lowering outrigger jacks. Keep feet and legs out from
under jacks.
Never operate the crane before the service truck is positioned on stable, level ground.
Put the vehicle in park or neutral (for manual transmissions) and set the parking brake
before attempting a lift.
Load Safety
Before lifting a load know the weight you are preparing to lift. Also, consult your capacity
chart located on the rear of the truck, comparing the two to ensure the crane will safely
handle the job.
The crane has a safety built into the remote and receiver to prevent an overload, but like
any mechanical device, it can be overridden by an operator. Please be advised that if this
happens, your warranty is null and void. Consult with our service department to return
the crane safety features back to the required setting established at the plant.
The traveling block is equipped with a safety hook at the point of attachment to a load.
Always make sure the load is secured to the hook with the safety latch in the closed
position on the hook prior to lifting the load. You can find directions in any OSHA manual.
The gear rotation mechanism is equipped with a ring and pinion gear; these are
not designed for side loading of the crane, and side loading will result in failure of
the gears.
A load suspended overhead should be avoided; never walk under one.
When you leave the truck for a break or lunch, lower the load to the ground, as it
can result in injury if the load were to become unstable in your absence.
Keep all people away from the suspended load; never position the load over a
person.
Dragging the load with either the winch or the boom will result in damage to the
equipment and could cause injury to the people around the load.
The crane boom is designed to lift; it is not intended to be used to force a
downward pressure on any type of operation.
Environment
The equipment you have purchased operates at maximum performance if you have a
good preventive maintenance program in place. The work site is generally full of
contaminants, so weekly washing of the truck and or crane is a good prevention tool. The
use of lubricants on mechanical parts on the equipment should be followed on a weekly,
monthly and quarterly basis. Prevention of the general wear and tear due to corrosives is

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insurance that your machine will last a long time, affording you a good investment of your
time and capital.
Good common sense goes a long way in safety. Steel and electricity do not mix well, so
avoid using the crane at the highest point on many job sites during a storm. Maintain the
prescribed clearance from all power lines with your crane.
If you are operating the truck in extreme cold, follow these guidelines to prevent
equipment failure or damage to the components of the hydraulic system of the truck:
Start the truck and let it run for 15 minutes before engaging the PTO.
With the PTO engaged, wait an additional 15 minutes prior to starting the air
compressor or crane; this allows the systems to warm up before putting them
under pressure.
Revving the truck engine with the PTO engaged will damage your hydraulic pump
and parts of the hydraulic system.
There are specific guidelines attached in the owner’s manual for extreme cold
conditions; read and follow to allow maximum performance of your truck.
Maintenance Safety
Your Summit truck or crane is designed to give you years of use. Do not modify the
components or the systems of the truck, as this will cause damage to the equipment and
impede the functions of the truck.
Electrocution
Use extra personnel to signal when operating near electrical.
Keep at least ten feet between any portion of the crane and an electrical line. Add an
additional 12" for every additional 30,000 volts or less.
Allow extra space during windy conditions for swaying power lines.
Death or serious injury can occur when working during electrical storms or near power
lines.

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SAFETY DECALS
Decal Number: 700-30347
Title: ………... Danger, Two Blocking the Crane
Description: ... to inform the operator to not allow the hook
block to come into contact with the boom tip
tip by hoisting it up.
Location: ….. boom tip.
Decal Number: 700-30340
Title: ………… Lubricate worm gear.
Description: … lubricate the worm gear, do not run worm
gear dry.
Location: ……. Rotation gear for crane.
Decal Number: 700-30339
Title: …………. Do not use stow hook for lifting.
Description ….. Do not use the stow hook for lifting loads.
Location …....... lower boom section front of boom.
Decal Number: 700-30373
Title: …………. White outline logo
Description …. Identifies Summit Truck Bodies as the
manufacturer of the crane.
Location: ……. Lower boom section centered on the
boom.

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Decal Number: 700-30131
Title: …………. Danger, scissor point
Description: ... Tells the operator of a potential scissor
point.
Location: ……. Both sides of the lift cylinder.
Decal Number: 700-30025
Title: …………. Warning, overload hazard.
Description: …. Tells the operator not to tamper with
the overload device.
Location: …….. Both sides of the lift cylinder.
Decal Number: 700-30342
Title: …………. Notice, crane design Spec.
Description: … Informs the operator that this crane has
designed and manufactured to
ASME/ANSI specifications.
Location: ……. Crane pedestal.
Decal Number: 700-30353
Title: …………. Angle indicator LH.
Description: … Tells the operator the angle of the boom.
Location: ……. Left hand side of base boom.
Decal Number: 700-30018
Title: ………… Angle indicator RH.
Description: ... Tells the operator the angle of the boom.
Location: …… Right hand side of base boom.

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Decal Number: 700-30411
Title: …………. Crane control, hydraulic solenoids.
Description: …. How to manually control the crane by
Use of the hydraulic solenoids on the
pedestal.
Location: ……. Cover panel of hydraulic control pack.
Decal Number: 700-30999
Title: …………. Serial number plate, 4416 crane.
Description: …. States the model and serial number
of the crane.
Location: ……. Cover panel of hydraulic control pack.
Decal Number: 700-30589
Title: …………. Crane certification statement
Description: … State that the crane has been tested
And passed all federal requirements.
Location: …… Pedestal side plate.
Decal Number: 700-31000
Title: …………. Cranes Series
Description: .... States the crane size and series.
Location: ……. Base boom, central both sides.

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Specifications Model 4416 Journeyman Electric Crane
SPECIFICATION SHEET
Crane Rating: 16,000 ft-lbs (21.69 kN-m)
Standard Boom Length: 7’4 1/2"(2.3 m) from CL of Crane
Boom Extension: 1st stage: Hydraulic 48"(1.2 cm)
2nd stage: Manual 48"(1.2 cm)
Maximum Horizontal Reach: 16’(4.9 m) from CL of Crane
Maximum Vertical Lift: 16’(4.9 m)
(from crane base)
Boom Elevation: -5 to +80 degrees
Stowed Height (crane only) 34 9/16” (87.8cm)
Mounting Space Required 14” x14” (35.56 x 35.56 cm)
A
pproximate Shipping Weight 825 lbs. (375 kg)
Controls Radio control standard for all functions.
Winch Specification
Rope Diameter: 1/4" (.63 cm)
Line pull speed: 22 ft/min (6.7 m/min)
Rotation: (worm gear) Continuous 360° power
Hydraulic System 2800 psi max
Oil Type Dexron II,III, or Mercon ATF
Lifting Capacities 2010 lbs @ 8’0"(912 kg @ 2.44m)
1340 lbs @ 12’0"(608 kg @ 3.66m)
1050 lbs @ 16’0"(476 kg @ 4.88m)
Power Supply Required 12V Electric over Hydraulic Power Supply
(1.3 gpm @ 2800 psi)

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*Subject to change without notification
GENERAL DIMENSIONS

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SECTION 1
INSTALLATION
1.1 GENERAL
Your crane may have been purchased separately, and if you intend to mount it to your truck
body, please follow the instructions to avoid accidents and/or injury to yourself and others.
If you have a manual for your particular truck body, it likely has an instruction guide to help
you in the mounting of the crane. Knowing your truck’s capacity will allow you to make the
best installation possible for your application. Pay particular attention to the following:
1. Chassis capacity
2. Total GVW after the crane is installed
3. Whether your truck body has a crane mounted to it, and what weight it will hold
4. Your crane weight depends upon which size crane you purchased, so the truck body
will have
requirements as well; find out what the body manufacturer recommends before
mounting your crane.
5. Disregarding these issues can result in serious injury or death to yourself or your
operator
Before installing the crane to your truck body read and understand the guidelines
established under federal law (Title 49 cfr part 568.6). Pay particular attention to Sec.
567.5 of the law. As the end user and installer of the crane to your truck body, you are
required to certify the vehicle in compliance with Federal Motor Vehicle Safety Standards
and other regulations issued under the National Traffic and Motor Vehicle Safety Act. You
can go online at http://www.gpoaccess.gov/nara/index.html for further information. You
are responsible for the truck to comply with all applicable federal and state regulations.
1. The weight of the truck must coincide with the
chassis requirements of the crane to be installed.
For the 4416 crane the following chassis
requirements must be met: Minimum Chassis GVW:
10,500 lbs
2. Any modifications made to the truck body must be
approved by the body manufacturer and will
properly and safely support the weight of the crane
you have chosen to install.
3. Any components used to modify the crane and/or
Summit Body will void the warranty and liability of
the manufacturer.
4. The crane boom must be supported during
transportation; thus, a boom cradle is required on the body.

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5. To avoid injury, use a lifting device designed to bear the weight of the crane.
6. See mounting bolt pattern which show (4) 7/8” dia. holes.
7. Make sure the crane is resting properly on its base. Apply Loctite Thread locker #277
to the mounting bolts and install them from the underside of the mounting plate.
Torque the (4) Grade 8, 3/4”bolts to 380 ft lbs.
1.2 ELECTRICAL
Once mounted your Journeyman crane should be connected to the vehicle’s 12VDC
electrical system using the 30’ power cable supplied with the crane. The following parts
are included in the electrical kit shipped with the crane.
a) Fuse Holder and Fuse
b) Remote Controller
c) Qty 4 ea. ¾-10 x 2.25 Grade 8 Mounting Bolts
d) Qty 4ea. ¾-10 Nylon Insert Lock Nuts
e) 30’ power cable
Run the 30’ of power cable through the truck frame and up into the engine
compartment. Attach the cable power eyelet to the center bolt position in the union
under the pedestal as shown above. Attach the ground strap to the ¼-20 hole just to
the side of center (see illustration above). Tighten the fasteners. Care should be
taken to protect the power cable from abrasion, flying gravel, hot exhaust pipes etc.
by fastening it inside the frame channel and using protective covering (loom, conduit
etc.). Be sure to use
rubber grommets or other
protection when running
power cable through steel
bulkheads, etc.
Mount the 250 amp Fuse
Holder as close as
possible to the battery
and connect it to the
positive (+) post of the
battery. When installing
the fuse holder, it should
be easily accessible in
the event fuse
replacement should
become necessary.
Install the parallel Cable
from the negative terminal
of the battery to the crane
ground position making
sure that good metal to
metal contact is made.