Summit Truck Bodies 6629 Setup guide

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OWNER’S MANUAL
Safety, Installation, Maintenance, and Operation
6629 Telescopic Crane
Manual # 700-20014
Revision Date 09/20/12
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: Product Registration Pages:
End user information: (Required for Warranty Activation)
Name: Phone:
Address:
City: State: Zip:
Contact: E-mail Address:
Distributor Information (Required for Warranty Activation)
Name: Phone:
Address:
City: State: Zip:
Contact: E-mail Address:
Product Information (Required for Warranty Activation)
Model Number: Serial Number:
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
Date
Section(s) or
Page(s) Revised Description of Change
06/15/09 Initial Release Initial Release of Manual
03/01/10 1,3,13,15,17,18,21,23,26,27,28,52 Updated Logo and various pictorials
07/15/10 1,8,9-12,17,20-22,29-31,34-39,44 Reworded the verbiage for clarification
07/26/10 11-14,22-24,26-42 Reworded verbiage for clarification
08/03/10 Full Manual Edited typographical errors
09/20/12 Full Manual Updated for new crane design
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
Warranty Registration……………………………………………….….… Page 3
Revision Record……………………………………………………………Page 5
Introduction………………………………………………………………..Page 9
Safety……………………………………………………………………... Page 10
Safety Decals………………………………………………………………Page 14
Specifications………………………………………………………………Page 18
Crane Capacity………………………………………………………….…Page 19
Dimensions………………………………………………………………...Page 20
Section 1 – Installation……………………………………………….……Page 21
Stability Capacity Chart……………………………………………...……Page 24
Section 2 Operation………………………………………………….…….Page 25
2.1 General……………………………………………………...…Page 25
2.2 Load Limits…………………….……...………………………Page 25
2.3 Equipment Inspections…………………...……………………Page 25
2.4 Operating Restrictions…………………………………………Page 26
2.5 Load Lifting……………………………………………………Page 26
2.6 Operation of Outriggers………………………………………..Page 26
2.7 Remote Control Operation…………………………………….Page 27
2.8 Indicator Bank…………………………………………………Page 30
2.9 Manual Operation…………………………………...…………Page 30
2.10 Task Performance……………………………………….....…Page 30
2.11 Shutdown………………………………………………..........Page 31
2.12 Operator Requirements……….………………………………Page 32
2.13 Operator Conduct……………….……………………………Page 32
2.14 Handling the Load……………………………………………Page 32
2.15 Crane Precautions…………………………….………………Page 33
2.16 Hook Precautions……………………………….…………… Page 33
Section 3 – Maintenance………………………………………..…………Page 34
3.1 General………………………………………………...……… Page 34
3.2 Lubrication………………………………………………….… Page 35

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3.3 Hydraulic Fluid Specification………………………………… Page 35
3.4 Hydraulic Oil Deterioration……………...…………………… Page 35
3.5 Hydraulic System Purging………………...………………… Page 36
3.6 Purging Air from the System………………...……………… Page 36
3.7 System Relief Pressure…………………………...……………Page 36
3.8 Counter Balance Valve……………………………...…………Page 37
3.9 Rotation Gear……………………………………….………… Page 37
3.10 Planetary Winch……………………………………...……… Page 37
3.11 Wire Rope……………………………………………….……Page 37
3.12 Gear-Bearing Bolts………………………………………...…Page 39
3.13 Inspections……………………………………………………Page 40
Periodic Inspection……………...…………………………Page 40
Daily Inspection………………...………………………… Page 40
Weekly Inspection………………………………………… Page 40
Monthly Inspection…………………………...……………Page 41
Lubrication and Maintenance Schedule……………………………………Page 41
Section 4 – Trouble Shooting……………………………………...………Page 42
Section 5 – Parts………………………………………………………...…Page 44
Section 6 – Hydraulic / Controls…………………………………………..Page 50
Section 7 – Wiring Harness………………………………………………..Page 53
Limited Warranty…………………………………………………………. Page 54

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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.
DistributorAssistance:
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: (866)
985-3100. 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 insurance that your machine will last a
long time, affording you a good investment of your time and capital.

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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

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Specifications Model 6629 Crane
SPECIFICATION SHEET
Crane Rating: 38,000 ft-lbs (5.25 ton-meters)
Standard Boom Length: 13’0”(3.96 m) from CL of Crane
Boom Extension: 1st stage: Hydraulic 90"(228.6 cm)
2nd stage: Hydraulic 90"(228.6 cm)
Maximum Horizontal Reach: 29’0"(8.84 m) from CL of Crane
Maximum Vertical Lift: 29’4”(8.94 m)
(from crane base)
Boom Elevation: -5 to +80 degrees
Stowed Height (crane only) 40.25” (82.6cm)
Mounting Space Required 21 x 25 inches (53.3 x 63.5 cm)
Approximate Shipping Weight 2250 lbs (1020 kg)
Controls Radio control standard for all functions.
Winch Specification
Rope Diameter: 3/8" (.953 cm)
Line pull speed: 60 ft/min (18.29 m/min)
Max. single part line: 3000 lbs (1360 kg)
Max. double part line: 6000 lbs (2720 kg)
Rotation: (worm gear) 400 degree power
Lifting Capacities 6,000 lbs @ 5’0"(2720 kg @ 1.52m)
2925 lbs @ 13’0"(1325 kg @ 3.96m)
2385 lbs @ 17’0"(1080 kg @ 5.18m)
1850 lbs @ 21’0"(840 kg @ 6.40m)
1600 lbs @ 25’0"(725 kg @ 7.62m)
1350 lbs @ 29’0"(610 kg @ 8.84m)
Power Supply Required PTO & Pump
(8 gpm @ 2800 psi)
*Subject to change without notification

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