OWNER’S MANUAL

Safety, Installation, Maintenance, and Operation

10629 Telescopic Crane

Manual # 700-20010
Revision Date 07/03/2017

Summit Truck Bodies

990 Vernon Road
Wathena, KS 66090
866-985-3100
Fax: 785-989-3563
www.summitbodies.com

Subject to Change without Notification

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 Summit Truck Bodies Warranty Registration
Fax Transmission

To: Warranty Department Fax: (785) 989-3563

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
REVISION RECORD

Date Section(s) or Description of Change

Page(s) Revised
06/15/09 Initial Release
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
09/14/12 Full Manual Updated for new crane design
06/12/15 Sections 2.6 & 2.7 & 2.8 Updated sections & added phase II
10/13/16 Page 73 Updated callouts on control valve view
07/03/17 Section 2.9 Added Phase III info and data

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 (866) 985-3100.

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

REVISION RECORD ................................................................................................................ 5
INTRODUCTION ...................................................................................................................... 9
SAFETY ................................................................................................................................... 10
SAFETY DECALS .................................................................................................................. 14
SPECIFICATION SHEET ....................................................................................................... 18
CRANE CAPACITY ................................................................................................................ 19
DIMENSIONS ......................................................................................................................... 20
SECTION 1 –INSTALLATION............................................................................................... 21
STABILITY CAPACITY CHART ........................................................................................... 24
SECTION 2 - OPERATION .................................................................................................... 25
2.1 GENERAL ...................................................................................................................... 25
2.2 LOAD LIMITS ............................................................................................................... 25
2.3 EQUIPMENT INSPECTION ......................................................................................... 25
2.4 OPERATING RESTRICTIONS ..................................................................................... 25
2.5 LOAD LIFTING ............................................................................................................. 26
2.6 OPERATION OF OUTRIGGERS .................................................................................. 26
2.7 PHASE I.......................................................................................................................... 27
2.8 PHASE II ........................................................................................................................ 29
2.9 PHASE III ....................................................................................................................... 47
2.10 MANUAL OPERATION .............................................................................................. 52
2.11 TASK PERFORMANCE .............................................................................................. 52
2.12 SHUTDOWN ................................................................................................................ 53
2.13 OPERATOR REQUIREMENTS .................................................................................. 53
2.14 OPERATOR CONDUCT.............................................................................................. 54
2.15 HANDLING THE LOAD............................................................................................. 54
2.16 CRANE PRECAUTIONS ............................................................................................ 55
2.17 HOOK PRECAUTIONS .............................................................................................. 55
SECTION 3 – MAINTENANCE ............................................................................................. 56
3.1 GENERAL ...................................................................................................................... 56
3.2 LUBRICATION ............................................................................................................. 57
3.3 HYDRAULIC FLUID SPECIFICATION ..................................................................... 57
3.4 HYDRAULIC OIL DETERIORATION ....................................................................... 57
3.5 HYDRAULIC SYSTEM PURGIN ................................................................................ 58
3.6 PURGING AIR FROM THE SYSTEM ........................................................................ 58
3.7 SYSTEM RELIEF PRESSURE ..................................................................................... 58
3.8 COUNTER BALANCE VALVE ................................................................................... 59
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 3.9 ROTATION GEAR ......................................................................................................... 59
3.10 PLANETARY WINCH ................................................................................................. 59
3.11 WIRE ROPE ................................................................................................................. 59
3.12 GEAR-BEARING BOLTS ........................................................................................... 61
3.13 INSPECTIONS ............................................................................................................ 62
Daily Inspection ........................................................................................................................................ 62
Weekly Inspection ..................................................................................................................................... 62
Monthly Inspection ................................................................................................................................... 62
Quarterly Inspection.................................................................................................................................. 63
LUBRICATION & MAINTENANCE SCHEDULE .............................................................. 63
SECTION 4 - TROUBLE-SHOOTING .................................................................................. 64
SECTION 5 – PARTS .............................................................................................................. 66
SECTION 6 – HYDRAULICS / CONTROLS ........................................................................ 73
SECTION 7 – WIRING HARNESS ........................................................................................ 76
Limited Warranty .................................................................................................................... 79

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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:

ASME B30.5a
Test Documented On: March 14, 2013
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: (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 10629 Crane
SPECIFICATION SHEET

Crane Rating: 60,000 ft-lbs (8.29 ton-meters)

Standard Boom Length: 13’0"(3.96 m) from CL of Crane
Boom Extension: 1st stage: Hydraulic 96"(243.8 cm)
2nd stage: Hydraulic 96"(243.8 cm)
Maximum Horizontal Reach: 29’0"(8.84 m) from CL of Crane
Maximum Vertical Lift: 30’6”(9.29 m)
(from crane base)
Boom Elevation: -5 to +80 degrees
Stowed Height (crane only) 39 1/2” (100.3 cm)
Mounting Space Required 21 x 25 inches (53.3 x 63.5 cm)
Approximate Shipping Weight 2620 lbs (1188 kg)
Controls Radio control standard for all functions.
Winch Specification
Rope Diameter: 7/16" (1.11 cm)
Line pull speed: 60 ft/min (18.29 m/min)
Max. single part line: 5000 lbs (2268 kg)
Max. double part line: 10000 lbs (4535 kg)
Rotation: (worm gear) 400 degree power
Lifting Capacities 10,000 lbs @ 5’0"(4535 kg @ 1.52m)
4875 lbs @ 13’0"(2210 kg @ 3.96m)
3910 lbs @ 17’0"(1770 kg @ 5.18m)
2950 lbs @ 21’0"(1335 kg @ 6.40m)
2530 lbs @ 25’0"(1147 kg @ 7.62m)
2115 lbs @ 29’0"(960 kg @ 8.84m)
Power Supply Required PTO & Pump
(8 gpm @ 2800 psi)

*Subject to change without notification

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CRANE CAPACITY

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DIMENSIONS

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 SECTION 1 –INSTALLATION

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.

There are many PTO and Pump combinations available; all vary depending upon the chassis,
transmission, and the flow requirements of the crane, air compressor or combination of the
two components. Please contact Summit Truck Bodies Customer Service for your individual
truck requirements.

1. The weight of the truck must coincide with the chassis requirements of the crane to be
installed. For the 10629 crane the following chassis requirements must be met: Minimum
Chassis GVW: 26,000 lbs; Minimum Cab to Axle: 80”; Body Length Nominal: 132”; Body
Width: 98”; Compartment Depth: 22”; Floor Width: 54”.
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.
5. To avoid injury, use a lifting device designed to bear the weight of the crane. Hydraulic hoses
and control wires are to pass through the 7.00” diameter clearance hole.
6. Lower the crane into place with the boom facing the rear. 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 eight bolts to 680 ft lbs.

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 7. The six strand power/auxiliary control cord on the hydraulic valve provides power to the
crane and feedback to auxiliary functions. It is accessible from the underside of the base plate
and should be connected.
8. Connect the hydraulic hoses to the crane. Two hydraulic connections are extended through the
crane base and are accessible from the underside of the base plate. Pressure connections are
“06 JIC” and Tank connections are “08 JIC” fittings. The factory set Pressure Relief Valve is
included in the crane valve. Recommended operating pressure between crack pressure and
full flow is 2800PSI.

NOTE: It is recommended that the return line be no less than 1/2”. Do not use the hose on the
hydraulic system of less than 100R1 rating.

9. After the crane has been installed, check all hydraulic lines for:
-Free movement through 400 degrees of crane rotation
-Sharp corners (which may cut into hose) and kinks
-Abrasions and chafing
-Tightness of fittings
-Leaks
-Check all bolts and pins
-Visually inspect all welds for cracks, holes, etc.
-Engage Power Take-Off
-Slowly operate crane through all functions. Inspect all hoses, cylinders and structural
members for proper operation
-Return crane boom to its support, and the unit is ready for operation

TESTING SHALL BE PERFORMED BY DESIGNATED PERSONNEL ONLY.

10. Prior to initial use, all new, altered, modified, or extensively repaired cranes shall be tested for
compliance with the operational requirements of this crane.

1. Test all functions to verify speed and operation.

2. Check that all safety devices are working properly.
3. Confirm operating controls comply with appropriate function labels.
4. Test loads shall not exceed 110% of the manufacturer’s load rating.
5. Written reports shall be maintained showing test procedures and confirming the adequacy
of repairs.
NOTE: Under federal law, all crane mountings must be tested for stability. Every truck loaded or
unloaded will have a different weight, thus affecting the stability of the truck when put under load.
Once you have your truck loaded to your approximate hauling capacity, you must comply with the
stability test for your truck weight.

To be in compliance, your truck must lift the weight designated on your capacity chart supplied with
the crane, until such time the load cannot be lifted or the truck is in danger of tipping over. Record
the actual test data on the stability chart, which must be stored in the truck by the operator for future
reference to ensure a safe lift by the operator in the various positions of the crane boom.
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The Stability Capacity Chart must be completed by the crane installation personnel. Summit Truck
Bodies takes no liability for the placement of a crane by an outside source. If you install a crane not
designed for the body or chassis, your crane and the stability of it will fail. Summit Truck Bodies has
completed an extensive testing of the crane and has formulated the Stability Chart to cover the truck
body and chassis on which it is mounted.

The following Stability Capacity Chart is to be used by the installer of the crane, who may be
unaware of the stability of Summit Truck Bodies cranes being mounted on unknown bodies and
chassis.

Zone 1, if the boom reaches full extension without becoming unstable, the crane is stable for this
zone and 100% can be written in the Zone 1 data box.
If the truck becomes unstable prior to the crane achieving full extension, then retract the boom
until the truck becomes stable. Then measure the horizontal reach in this position (center of
rotation to end of boom). This is the stable horizontal location in this zone (stable horizontal
location divided by maximum horizontal location multiplied by 100 equates to the percentage
of rated capacity for this zone). Record this number in the data box for Zone 1 (this is the
revised load capacity for this zone due to stability of the service truck).
Repeat for each zone until the worksheet is completely filled out (this is the revised capacity based
on stability for this crane and service truck).
After the test has been completed, return the boom to the normal transport position.

11. Install all safety decals supplied with the crane in a visible area as close to the crane as
possible.

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STABILITY CAPACITY CHART

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 SECTION 2 - OPERATION

2.1 GENERAL

For ease of operation, become familiar with your crane and truck combination. Practice lifting
without a load, and then graduate to a small load, gradually becoming larger in load size. Do this
prior to actually going to the job site to perform the job task. As with all jobs, there is an element of
risk, so prepare the operator for emergency situations and, much like testing for a fire drill, they will
master the situation with each practice.

2.2 LOAD LIMITS

Know your lifting limits before you start. Study the charts supplied with your crane, the Load Chart
and the Angle Indicator Plate. Exceeding the limits within the radius of operation can result in
tipping of the truck and/or structure failure, voiding the warranty.

2.3 EQUIPMENT INSPECTION

OSHA Regulation 1910.180 calls for frequent and periodic inspections.
The inspection record must include the following:

1. Date of Inspection
2. Signature of the person doing the inspection
3. Serial number of the crane inspected
4. The certification record must be available upon request

Safety checks must be current and made prior to the operation of the crane. Follow the guidelines
listed above as well as the following:

1. Structural Soundness: Inspect the unit for damaged members and loose fasteners.
2. Hydraulic Oil Supply: With the crane in a stored position, and all cylinders retracted,
check the oil level.
3. Leakage: Examine all of the visible hydraulic lines for damage or hydraulic leakage.
4. Controls: Test for proper control operation.
5. Wire rope: Inspect for damaged, kinked or frayed winch wire rope.
6. Repairs: Correct all observed defects and malfunctions before putting the unit into service.

2.4 OPERATING RESTRICTIONS

Guidelines for operating the equipment:

1. The truck must be level for all loading and unloading with the crane.
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 2. The emergency brake must be engaged prior to any crane operation.
3. Engage the PTO while the truck is in a neutral position, and if the equipment is a manual,
shift with the clutch pedal engaged.
4. The outriggers must be extended and setting on solid footings before operating the crane.
5. The boom will drag the wire rope and break the stowing hook on the boom if you fail to
extend the wire rope prior to extending the boom.
6. Never lift the load any further off the ground than necessary.
7. Keeping the load close to the ground will help prevent lifting the load over the top of a
person or persons.
8. Rotating the load too quickly will result in an unstable load and could cause injury or
damage to the crane rotate gears.
9. Avoid power lines when at all possible; if you must make a lift near a power line, do so
with extreme caution, and make sure the boom at full extension clears the power line by at
least 10 feet.
10. Lifting the rated load capacity should be the norm; over lifting will result in a safety
failure or equipment breakage.
11. Never leave a load unattended.
12. Side loading of the load using the winch will result in damage to the crane assembly.
13. The crane is designed to lift a material load and should never be used to move people.
14. Due to the height of the crane, avoid electrical storms and/or high winds.
15. Do not attempt to make repairs to a crane while it is in operation.
16. Operate the crane rotate slowly, as the weight of the load will cause undue stress on both
the crane rotate and the load if you have to stop quickly. This could also cause injury or
death.
17. The crane will rotate up to 400 degrees; do not attempt a full speed stop with the rotation
gear and a full load, as undue stress will break the gears in the rotate.

2.5 LOAD LIFTING

85% of tipping is the normal computation for all load ratings. To ensure a safe lift, the crane must
meet all manufacturer’s required mounting procedures. All lifts are to be completed with full
extension of the outriggers, with the truck setting on a flat level surface. Follow your stability chart
for all lifting ratings.

2.6 OPERATION OF OUTRIGGERS

HYDRAULIC OUTRIGGERS:
1. Rotate locking pins into the unlocked position.
2. Start by going to the home screen on the control box.
3. Click on the ‘OUTRIGGERS’ button, this will take you to the outrigger control
screen.
4. To deploy the outriggers click the buttons ‘DS DEPLOY’ and ‘PS DEPLOY’.
5. To retract the outriggers click the buttons ‘DS RETRACT’ and ‘PS RETRACT’

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 MANUAL OUTRIGGERS:
1. Rotate locking pin to release outrigger leg.
2. Pull out outrigger leg and rotate locking pin to lock outrigger leg in position.
3. Lower outrigger leg until it has firm contact with the ground.
4. Repeat for the opposite side.

2.7 PHASE I

The crane comes standard with a Summit brand PGT Radio Remote Equipment Control. This system
has the option to be either wireless or tethered. The trigger at the upper portion of the pistol grip
controls the speed of the crane functions. The wireless functions allow the operator to control the
crane operation at a range of 0-200 ft., allowing for obstruction within the line of the remote to the
receiver.
As stated before, the trigger is proportional and allows the operator to control the speeds of the
selected operations by pulling back on the trigger, allowing for a gentle touch or a faster pace
depending on the needs of the operator. For best performance choose the function desired and pull
down on the toggle switch under that function. Then pull back on the trigger to allow for a smooth
operation of the function desired. If you do the process in reverse, the crane will not operate, as this
is a safety feature built into the remote.

CRANE WIRELESS REMOTE CONTROL INSTRUCTIONS

To set up the remote power:

1. Supply power to the crane receiver.

2. Hold the remote in your hand and make sure the Emergency switch on the remote is up.
3. Push the transmitter ON button after the status LED lights up
4. Once the status LED illuminates green the unit will run an initialization process, checking for
switches or motions that may be active. If any are detected the status LED will illuminate red
and the unit will turn off.
5. After initialization is completed successfully, the unit will enter Normal Operation Mode and
be ready to use

To shut down the remote:

Manual Shutoff—
The transmitter can be turned off by pressing the OFF-ON-START toggle switch down to the
OFF position.
Emergency Shutoff—
Pressing the Emergency Stop switch will immediately break all communications between the
transmitter and receiver and will stop electrical functions on the crane.
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Automatic Shutoff—
The transmitter will automatically power down after a programmable time of non-use.

A tether cord is supplied with the crane that can directly tie the transmitter to the receiver. The cord
attaches to the side of the transmitter, and the other end attaches to the receiver. There is a small
black plug for the cord in the crane compartment.
You may want to use the tether cord on the job sites that do not allow radio signals. Once installed
properly, the tether mode turns off the wireless transmissions and diverts signals through the tether
cable. The tether cable will not charge the battery of the transmitter. The optional NiMH battery of
the transmitter needs to be recharged in one of the Summit approved battery chargers. If the battery
level reaches 10% the status LED will illuminate read to indicate a low battery level.
NOTE: In order for the tether cord to work properly, the remote must be powered down and
repowered up following tether installation.

Study your remote and know your control panel and what functions each corresponds to within the
operation of the crane.
If your remote panel decal becomes damaged, call the service department for a replacement
Keeping the remote decal clean will ensure a safe operation of the remote.
Practice using the remote before lifting a load; know what you are doing before attempting a
lift.
Plan your lift, ensure the outriggers are down and on solid stable ground, and the crane is clear of
outside obstructions.
Follow a regular preventive maintenance schedule with your crane and truck to ensure maximum
performance of your equipment.
Prior to lift, give the crane one last visual inspection for leaks and clearance of outside obstructions,
and ensure that you have engaged the outriggers and that they are down. Do not skip this step, as it
could save you serious injury.

28
2.8 PHASE II

Phase II section guide

1. System overview
2. Screen navigation and control
3. Warning ribbon operation
4. Lighting operation
5. Aux operation
6. Hour meter operation
7. Engine start/stop operation
8. Engine idle control operation
9. PTO operation
10.Compressor operation
11.Tool circuit operation
12.Hydraulic oil temp monitoring
13.Hydraulic filter status monitoring
14.Outrigger operation
15.Crane operation
16.Pendant not stowed operation
17.APU Option
18.Open Center Option
19.Date/Time
20.Perimeter Protection
21.Software Addendum
22.Front outrigger control
23.Auto stow
24.Outrigger overrides
25.Chassis Integration
26.mVEC Integration
27.Fully proportional crane control

For Phase II menu structure see appendix A

29
1. System Overview

1.1. The control system for Summit Truck consists of a J1939 based Main Controller,
Engine Module, and Cab Switch Panel. The main controller normally resides in one of
the rear cabinets of the truck (this is sometimes referred to as the “rear control/switch
panel”). This controller has a (10) button user interface with color display. The
controller has various I/O which monitor and control several of the main functions on
the truck. A J1939 based engine module is mounted in the engine compartment and
operates/monitors various functions associated with that area of the truck. Inside the
cab of the truck there is a (6) button, J1939 based switch panel used to operate
various functions.

1.2. The system also includes several external J1939 nodes and devices. These devices
include a dual multi-axis inclinometer, a rotary encoder, high current I/O module, and a
radio remote system.

1.3. To operate the crane from a remote location there will be a radio remote system. This
system uses a transmitter which communicates via RF to a receiver. This receiver is
interfaced with the J1939 CAN bus transmitting and receiving data via this data link.
The transmitter has a screen which displays basic system info, boom load, current
operation, as well as a screen that directs the operator to the main control panel
(located in the rear passenger side cabinet) if any fault is present.

2. Screen Navigation and Control (reference Appendix A for screen layout)

2.1. Splash Screen (screen 1): Upon initial power up of the device a splash screen will
be displayed for 7 seconds. The splash screen Summit Truck Bodies Logo (centered)
and current software and hardware versions at the bottom. After that you will be at
the Home screen.

30
2.2. Home Screen (screen 2): Navigating from this to other screens is done with the (10)
buttons on the panel. The buttons are numbered 1-10 with 1-4 on the left (top to
bottom), 5-8 on the right (top to bottom), and 9/10 (left/right) on the bottom. This is the
screen you will be brought to anytime you press the “Home” button. There will also be
a button on this screen to perform engine start/stop (see paragraph 7 for details on
operation).

2.3. The LED light on each switch will change state from white to red when the function is
active. A 1Hz flash on the 6 pos switch panel indicates an error/warning. Errors and
warnings are displayed on the warning panel of the main display. Also a tone when
any navigation function is pressed.

2.4. Lighting (screen 3): This screen will allow you to select the lighting you wish to turn
on. All functions on this page operate as “toggle on/off” unless otherwise noted.
Button 8 will turn on all lights (except the strobe) when 0 or more lights are on. It will
turn off all lights (including strobe) when any light is on.

2.5. Aux (screen 4): This screen is used for 6 auxiliary functions and the pressurized
compartments. All functions on this page operate as “toggle on/off” unless otherwise
noted. By default the “spare” 2 buttons on the cab switch panel will also toggle the
aux outputs 1 and 2.

2.6. Hours (screen 5): This screen will look at hour meter values stored in EEPROM and
display them on this page.

2.7. Outriggers (screen 7): This is the default outrigger control; it will allow you to operate
the rear outriggers. All outrigger functions will be momentary. Button 10 will be used
to navigate to page 21 to use the auto-deploy feature.

2.8. Hydraulics (screen 8): This screen contains (6) functions that you can operate, and
(1) feedback zone for Hydraulic Oil Temp. All functions on this page operate as “toggle
on/off” unless otherwise noted. This screen has active fields that will appear or
disappear based on their selection from screen 25.

2.9. Crane (screen 9): This screen allows for operation of the crane from the control
panel. All functions on this page operate as “Momentary on” unless otherwise noted.
Button 10 will be used to navigate to screen 24.

2.10. Settings (screen 10): This screen allows you to navigate to several other screens
(See layout for details).

2.11. Diagnostics (screens 11-15, 28-29):

2.12. Network Information (screen 16): This screen will show the status of the following
items if they are available to monitor: Engine RPM, Oil Temp, Water Temp, Encoder
Position, Boom Angle, Master X axis, and Master Y axis.

31
2.13. Alarm History (screen 17): This screen logs warning ribbons and assigns a time
and date to them.

2.14. Boom Overload Pressure Setting (screen 18):

2.15. Zone Load De-rate Setting (screen 19):

2.16. Outriggers (screen 20): If “front outriggers” are selected on screen 25 this will be
the screen that is shown when you navigate to the outrigger page from the main menu
(instead of screen 7). It will look identical to screen 7, however it will include the
additional buttons to control the front outriggers.

2.17. Auto Deploy Caution (screen 21): If the auto deploy button is pressed on either
screen 7 or 20 it will navigate to this screen.

2.18. Settings Password Entry (screen 22):

2.19. New Password Entry (screen 23):

2.20. Auto Stow Caution (screen 24): If the auto stow feature is attempted from screen 9
it will navigate to this screen which contains a caution statement about using auto
stow.

2.21. Truck Options (screen 25):

2.22. Crane Settings (screen 26): This screen allows the operator to home the crane and
set a boom up limit angle. It also allows you to enable protection (follow the perimeter
protection routine), and enable novice mode, the states of both of these functions will
be saved in EEPROM, they will remain selected through a power cycle. If these
functions are true the associated button LED will be red, if these functions are false
the associated button LED will be false. Pressing “set perimeter” will navigate you to
screen 27.

2.23. Perimeter Program (screen 27): This screen will include a caution statement which defines
and warns about the use of the perimeter protection (also referred to as virtual fence). It is also
where you “program” the virtual fence boundaries.

2.24. Date/Time (screen 30): This screen allows navigation to other screens to set date
and time.

2.25. Date (screen 31): This screen allows the user to set the date using Day, Month, and
Year Up and Down buttons. The date will be displayed at the top of the screen.

2.26. Time (screen 32): This screen allows the user to set the time using Hour and Minute
Up and Down buttons. The time will be displayed at the top of the screen.

32
3. Warning Ribbon Operation

3.1. The display will have an area where warning ribbons will get presented. If multiple
warnings are in effect we will present one warning for 3 seconds, then present the next
warning for 3 seconds, etc. This operation will be for all warning ribbons unless
otherwise noted. The buzzer will also sound 3 times upon initial warning, then will
sound every 30 seconds until all warnings are false. If warning/alarms are true the
front switch panel lights and buzzer will go into alarm state. Warning ribbons have
been prioritized so that critical warnings will override informational or less significant
warnings. Based on the numbering system below ribbons 5, 7, 11, 12 , 14, 18, 20,
21, 22, 23, 25, and 26 are considered priority and will be shown before other ribbons.

3.2. The following is a list of the warning ribbons and how they are enabled.

3.2.1. Filter Service Required: If the input that monitors the hydraulic filter pressure
differential switch is true and the hydraulic oil temp is greater than 80 deg F this is true.

3.2.2. Hydraulic Fluid High Temp: If hydraulic oil temp transducer is reading a temperature
greater than 180 F this is true. This ribbon is reset when temperature falls below 172F.
This ribbon will not be shown if the Over Temp ribbon (3) is true.

3.2.3. Hydraulic Fluid Over Temp: If hydraulic oil temp transducer is reading a temperature
greater than 190 F this is true. Disengage the PTO or turn off APU. This ribbon is reset
when temperature falls below 182F.

3.2.4. Boom not stowed: If the boom is not stowed and the park brake input is false this is
true. The boom stow zone is derived by homing the crane (90.0 degrees inclination, ~0
degrees rotation). Therefore we know when the crane is out of its rest. A 5 second
debounce timer is required to avoid nuisance warnings while driving on rough surfaces.
This warning will also be displayed if attempting to auto deploy outriggers when the
crane is not stowed. It must be stowed for properly alignment when leveling.

3.2.5. Auto Deploy Successful: If auto deploy was attempted, the outriggers are deployed
(which is indicated by the outrigger prox inputs) and the vehicle is level this ribbon will
be true. Display for 3 seconds then set false.

3.2.6. Battery voltage low: If the chassis battery voltage is less than 10 Vdc this is true.

3.2.7. Crane Overload: If the transducer monitoring pressure in the Boom Up hydraulic
circuit is greater than the max boom pressure set point for that zone this is true.
Maximum crane load is based upon crane position so different zones have been
developed with unique limits. Limit operation of the following: Boom Extend, Boom
down, Winch up.

3.2.8. Reduced Rotate Speed:

33
3.2.9. Input / Output Fault: This is displayed when there is one or more output faults.
Output faults are reset by cycling main power.

3.2.10. Truck not level: If truck’s roll angle is +/- 4 degrees out of level, the PTO or APU is
on, and the crane if in operation this message is displayed. The warning is set at 4.2
degrees and reset at 3.8 degrees with a 1s reset debounce to account for slight truck
rocking. This warning does not include truck pitch with rear outrigger only. The
inclinometer is mounted on the boom turret that rotates, so this warning can only be
displayed when the boom is parallel with the roll axis of the truck.

3.2.11. No auto stow with load: If boom load exceeds 60% of the zone set point the auto
stow feature will not work and this will be true. Only true if the operator is attempting to
Auto Stow the crane.

3.2.12. Outriggers not deployed. If crane operation is attempted and the outriggers are not
planted this will be true. Only true if crane operation is attempted.

3.2.13. Pendant not in stow: If the pendant stow input is false and the park brake input is
false this is true. Flash 6 pos switch panel lights and buzzer.

3.2.14. Outriggers disabled:

3.2.15. Boom up limit angle reached: This will be handled by inclinometer data, the default
boom up value will be set in the program to 1000, it will remain the value until button 4
on screen 26 is pressed, when that button is pressed the operator will move the crane to
the maximum upward position and release the button, this will set that position as the
max up angle.

3.2.16. A2B switch: If the A2B switch (N/C) is false this is true. Disable winch up and boom
extend.

3.2.17. Unit in tether operation: This will only be displayed if the MBT is connected via tether
and a function is active. Operating the transmitter with the tether will disable RF, once
the tether is disconnected RF begin again. Cycle this, but don’t use the tone to notify
the operator.

3.2.18. Outriggers deployed: This is displayed if the outriggers are not retracted with the park
brake off.

3.2.19. Driver Side Outrigger Sensor Fail:

3.2.20. Crane homing successful: this is displayed when the crane has been successfully
homed. Display for 3 seconds then set false. Homing is the process of calibrating or
zeroing the inclinometer and encoder when the boom is stowed.

34
 3.2.21. Auto stow failed, please stow manually: This is displayed if the auto stow function is
not successful. Display for 3 seconds then set false.

3.2.22. Auto stow successful: this is displayed if the auto stow operation is successful. Show
for 3 seconds then set false.

3.2.23. Auto deploy failed: this is displayed if the auto deploy function fails. Display for 3
seconds then set false.

3.2.24. Load capacity reduced:

3.2.25. Auto stow in progress: this is displayed when the auto stow feature is under
operation.

3.2.26. Auto deploy in progress: this is displayed when the auto deploy feature is in
progress.

3.2.27. Low pump pressure: This is displayed if we do not receive pto pump pressure within
5 seconds of the PTO solenoid output becoming true.

3.2.28. Passenger Side Outriggers Sensor Fail:

3.2.29. Crane Sensor Fail: If the sensor is out of its operation range this is true. Cycle.

3.2.30. Temp Sensor Fail: If the sensor is out of its operation range this is true. Cycle.

3.2.31. Comm Error – Engine: If communication is lost with this device this is true. Cycle.

3.2.32. Comm Error – FSP: If communication is lost with this device this is true. Cycle.

3.2.33. Comm Error Incline: If communication is lost with this device this is true. Cycle.

3.2.34. Comm Error – Encoder: If communication is lost with this device this is true. Cycle.

3.2.35. Comm Error – LCM:

3.2.36. Comm Error – Receiver: If communication is lost with this device this is true. Cycle.

3.2.37. Comm Error – PDM: If communication is lost with this device this is true. Cycle.

4. Lighting Operation

4.1. Rear Lights: These can be operated from either the cab switch panel or the rear
control panel. The switch operation is multiplexed and the functionality is toggle style,
35
 ex. If the switch in the cab is pressed to turn the lights on, you can press the switch in
the rear to turn the lights off. These are not interlocked with anything.

4.2. Strobe Lights: These lights share the same operation as the rear lights; however
there is no reset operation from the park brake input.

4.3. All Other Lights: The remaining lights are all toggle style operation. There are no
interlocks preventing operation of these lights, but we do reset the lights if we see the
falling edge of the park brake input.

4.4. All lights button: This will turn on all lights (but not the strobe) when no lights are on.
It will turn off all lights (including strobe) when any light is on.

5. Aux Operation

5.1. Aux1-6 buttons on screen 4 will toggle Aux outputs 1-6. These outputs will be mVEC
relays and the auxiliary digital outputs on the 32007 VDM. Aux 1-3 can also be
toggled on the 6 switch cab module using switches 4-6 respectively. Cab switch 6 will
be used to control pressurized compartments (mVEC Relay 8) if that option is enabled,
so Aux3 cannot be controlled from the cab in this situation.

6. Hour Meter Operation

6.1. PTO Hours: Whenever the PTO pressure switch input is true the system will
increment an hour meter. This value will be stored in EEPROM and will be displayed
in Screen 5. This is an active field that will appear or disappear based on the APU
selection on screen 25.

6.2. Compressor Hours: Whenever the compressor output is true the system will
increment the hour meter. This value will be stored in EEPROM and will be displayed
in Screen 5. This is an active field that will appear or disappear based on the APU
selection on screen 25.

6.3. Tool Circuit Hours: Whenever the tool circuit output is true the system will
increment the hour meter. This value will be stored in EEPROM and will be displayed
in Screen 5. This is an active field that will appear or disappear based on the Tool
Circuit selection on screen 25.

6.4. Hidden Hour Meters:

7. Engine Start/Stop Operation

7.1. From Switch Panel: If the PTO switch is true (Manual transmissions only) and the
Park Brake input is true you will be able to start and stop the engine via the rear
control panel.

36
 7.2. Interlock operation differs slightly depending on transmission type (Auto or Manual)
and hydraulic pump drive type (PTO or APU). The automatic transmission does not
require the clutch to be depressed to engage the PTO, so the engine can be started
without regard to PTO state. The PTO enable option is disabled on the rear panel
with manual transmissions because of the required clutch operation. Engine start is
disabled if the engine is already turning as indicated by engine speed monitored on
the J1939 CAN Bus. Refer to sections 7.7 and 17 for APU operation details.

7.3. If the engine is not running then pressing the button will close the K1 relay and the
Starter output will be true after a 1.5 second delay. Releasing the button at this time
will make the starter output false.

7.4. From Radio Remote: If the engine off switch on the remote is true we will open the
K1 relay and the engine will shut down.

7.5. If the engine start switch on the remote is true the K1 relay will close, this allows the
engine to run. If the PTO switch is true (manual transmission only) and the park brake
input is true at this time the starter output is true.

7.6.

7.7. APU Start/Stop: Refer to section 17 for details on APU start/stop processes.

7.8. Both Engine Start/Stop keys (screens 2 and 8) will be illuminated when the engine is
running.

8. Engine Idle Control Operation

8.1. On vehicles that accept J1939 throttle control: When the PTO output is true and
the park brake input is true the engine speed will automatically increase to the
LoRPMval setpoint (default 850RPM).

8.1.1. If either the high idle switch is pressed on the radio remote or the idle hi/lo button is
pressed on the rear control panel and the PTO interlocks (PTO on and Park Brake set)
are true the engine will ramp up to the HiRPMval RPM setpoint (default 1050 RPM). .

8.1.2. Using this feature will disable the in-cab throttle control.

8.1.3. If the PTO interlocks become false at any time the engine will return to its base RPM.
When reactivated the engine will ramp to the LoRPMval (default 850 RPM).

9. PTO Operation

37
 9.1. If the PTO switch is true and the park brake input is true the PTO output is true. This
has a multiplexed switch; there is one in the cab and one on the rear panel. The LED
light on the switches will be illuminated if the PTO switch is pressed, even if the
feedback switch indicates no pump pressure. The PTO will disabled with hydraulic
over temp.

10. Compressor Operation

10.1. If either the compressor switch is pressed on the radio remote or the rear control
panel, and the PTO interlocks (PTO on and Park Brake set) are true, then the
compressor output is true.

11. Tool Circuit Operation

11.1. If the PTO interlocks are active and the Tool Circuit On/Off switch is toggled on we
allow tool circuit operation. Once this is active the Tool Circuit FWD output is true, if
the Tool Circuit FWD/REV button is pressed the FWD output is false and the REV
output is true. These switches will be reset if a falling edge is detected from the PTO
interlocks. This is an active content option, it is enabled via screen 25. Outputs are
common to driver's side outrigger extension, so may not be available in the event both
options are requested.

12. Hydraulic Oil Temp

12.1. The hydraulic oil temp field on screen 8 will display the hydraulic oil temp as read from
a temp transducer into our controller. The controller will perform a scaling function to
take the 4-20mA value and scale it between 0 and 300 degrees F. This scaled value is
what gets displayed on the screen. When this value exceeds high setpoint then
trigger the warning ribbon. When value exceeds the over temp setpoint disengage the
PTO and APU and trigger a warning ribbon.

13. Hydraulic Filter Status

13.1.

14. Outrigger Operation

14.1. The outriggers can be operated in two ways. The first is direct operation using the
buttons on the rear control panel that are associated with the function you would like to
operate. These will operate if the PTO interlocks are true. The pushbutton functions
will be momentary. If the outriggers are deployed and the park brake input is false, the
front switch panel LED’s will be flashed at a 1Hz rate between white and red, the chirp
will also be pulsing on and off whenever the Red LED’s are on. In addition, display the
appropriate warning ribbon.

14.2. The second way to operate the outriggers is by using the auto leveling feature.

38
 14.3. Operation for one axis truck: Check pitch angle of vehicle to verify it is within 4
degrees of level, if not display warning ribbon 10 when operating the crane. Each
outrigger jack cylinder will have a normally closed proximity switch to indicate that the
outrigger has contacted the ground. The operator will hold the Auto Deploy button.
The outriggers will deploy until the proximity switch opens for each jack cylinder
indicating that the outriggers are just touching ground. Once both outriggers are
touching, both outriggers will be extended for a set period of time so that the
outriggers will be more firmly planted. The outriggers are extended together with the
goal that roll angle is not increased during leveling. This cannot be guaranteed
however due to other factors such as hydraulic system performance, load on each
outrigger, mechanical advantage, cargo loads, etc. There are no interlocks to disable
auto deploy if the angle is considered too steep. Once the extend timers are expired,
the outriggers will be considered “planted”. Once planted the truck will attempt to level
side to side by monitoring the roll angle of the vehicle. Based on this angle, the correct
outrigger will be extended until vehicle is “level” within 0.5 degrees. If level is not
reached, it is possible that a cylinder is bottomed out. The Auto Deploy Failed warning
will be displayed. Cylinders will never be retracted automatically as part of the auto
leveling process.

15. Crane Operation The open center system will use a single proportional flow control that feeds
directional valves for each of the 8 boom functions.

15.1. Crane Interlocks– The crane interlocks must be true for operation. This would include
that the PTO output is true, the outriggers must be planted for unlimited operation, and
the truck’s engine must be running.

If the A2B switch is false (N/C switch) the Winch Up PWM output and Boom Out PWM output
will be false.

If the Boom Up Angle Setpoint is active the Boom Up output will deactivate.

If the 4-20mA boom transducer input value is less than 3.61mA, do not allow crane
operation. This could indicate the transducer is disconnected

Boom extend and retract and winch up and down will be disabled if neither outrigger is
planted.

All crane functions except winch down and boom retract will be disabled if the outriggers are
partially planted. For example, one outrigger is planted and one is not.

Boom up, Boom Extend, Boom down, and Winch up operation will be disabled if the zone
overload pressure is exceeded.

If Novice Mode is true then the all crane speeds will be reduced by 57%.

The chart below summarizes crane interlocks based upon boom load and outrigger
conditions:
39
 15.2. Crane Control with Radio – The crane can be operated from the transmitter by either
RF or tethered communication; the functions will operate the same way regardless of
this. On the transmitter there are (2) 2-axis joysticks that control crane direction and
speed. The crane speed will be nearly proportional to the position of the joystick. A
10% deadband will be added to the joystick output to eliminate unintended activation
of the other function on the joystick. If the stop button is pressed on the transmitter it
will attempt to stop crane movement.

15.3. Boom Overload Setpoint:

15.4. Zone Load De-rating: The zone load de-rating system works based on the values
entered in screen 19 and associating those values with the (6) zones found in the 360
degree rotation of the screen. Based on the rotational position of the crane the boom
overload pressure will be multiplied by the de-rate value. A 7th "no load" zone exists
directly over the truck cab. The lowest value from zones 1 and 6 shall be used for the
no load zone.

15.5. Crane Control from Rear Control Panel – The crane can be operated from the rear
control panel via screen 9. When a function is pressed it will operate the crane at a
predetermined speed (approx. 25-50% of max).

15.6. Auto Stow –

16. Pendant Not Stowed: If the pendant stow input is false and the park brake is disengaged,
the front switch panel lights and chirp will go into an alarm mode (identical to 14.1). Display the
corresponding warning ribbon on the display panel.

17. APU Option: The APU will use the PTO output (hydraulic on/off), high idle output, ignition
circuit, and starter output from the Engine module, and the compressor output from the 32007
VDM. Operation will be the same as PTO driven units, with the following exceptions. The APU
will have a running signal coming into the engine module that tells us if it is running instead of
using J1939 engine RPM. There is no pressure feedback device with the APU equivalent to the
PTO pressure switch. The APU has a built-in timeout feature that requires a power cycle before
starting the engine, so the K1 relay must be opened momentarily, and then closed before
cranking the engine. An oil pressure switch is used to determine if the APU engine is running.
40
18. Open Center Option: If open center option is selected the crane will operate using a single
proportional valve to control speed, and 8 digital valves to control direction. When multiple
functions are active the proportional valve will derive its value from the average proportional
value.

18.1. This option will also require the outriggers to sequence electronically. Up to 8
outrigger solenoid valves will be controlled: passenger side extend, retract, up, and
down, and driver side extend, retract, up, and down. Extend and retract are optional
for both driver and passenger side. All installed outrigger functions will have an
associated proximity switch that will indicate full travel has been reached.

18.2. When operating any outrigger function, an unloading valve will also need to be active
at that time.

19. Date/Time: The controller will have an on-board real time clock. This will be primarily used
for the tracking of warning ribbons in the system. It will also allow for the date and time to be
displayed on the screen. The time will need to be set on each module. This is done to prevent
the RTC battery from being enabled before the controller is on a truck. The user will be able to
change the time and date in their corresponding screens.

20. Perimeter Protection (virtual fence): The perimeter protection system creates a boundary in
software by monitoring the crane position sensors that when active does not let the crane pass
through. The intent is to limit collisions between the boom and other objects mounted on the
truck like compressors or welders. It is not intended for personal injury protection. Equipment
must be in good working order for this system to operate properly.

20.1. The perimeter is set or calibrated by pressing the “program” button on screen 27.
When program mode is true the operator will need to create the perimeter by
operating the crane with the radio remote, moving the crane in 360 degrees of rotation
at various desired angles keeping clear of obstructions (such as an air compressor).
The program button is maintained so that the operator is free to move about the truck
for better visibility.

20.2. Crane operation is forced to "novice mode" or half speed to insure proper fence data
capture. Non-critical functions including warning ribbons are disabled during
programming to minimize lost data. A missing data point can be filled in by averaging
with adjacent points, but two or more continuous missing points cannot be handled in
this manner. Missing data points are otherwise populated with a maximum value
equivalent to 90 degrees (straight up) resulting in a vertical fence wall. In other words,
if the operator fails to set a full 360 perimeter, no movement will be allowed into the
untraced area. If an area is retraced, the most recent data will be used. Since some
latitude is required to stow the crane, a window of 2 degrees will be created around
the stow or home position where movement is unrestricted. Caution: The proximity of
the exhaust stack to the boom stow position makes it nearly impossible to protect the
exhaust stack.

41
 20.3. The boom cannot be stopped instantaneously due to the momentum of the crane,
hydraulic system response, and electronic processing time among other factors.
Stopping distance will increase over time with mechanical wear of components. A
buffer will be added to the above perimeter to compensate for system response time.
The buffer specified by Summit is 5 degrees in both vertical and horizontal planes. For
example, if a perimeter is set at 30 degrees of vertical elevation, the electronic control
system will attempt to stop the crane if lowered to 30+5=35 degrees of elevation. The
distance will vary depending on inclination and length of the boom. For reference, at
10 feet from the center of the turret with a nearly horizontal boom, the buffer is
theoretically about 10".

20.4.

20.5. Once the perimeter is set it must be enabled by pressing the protection button on
screen 26. If this is true the perimeter protection will be active. Based on the rotational
and angular position of the crane, this system will attempt to prevent operation of the
crane if it passes through the fence buffer area. If the crane is stopped because it has
passed through the buffer, the operator must raise the crane until it is above the buffer
to resume operation.

21. Software Addendum

22. Front Outriggers 8 digital outputs for solenoid valves and 8 digital inputs for solid state
proximity switches will be required. At least one CAN port will be required to communicate to
the 32007 control module. A Front Outrigger option on/off button is already programmed on the
32007 display. When this option is on, Screen 20 provides control buttons for the front
outriggers. Operation will be similar to standard rear outriggers.

22.1. Hardware

(8) digital outputs minimum -

(8) digital inputs minimum -

22.2. Software

22.2.1. If the outriggers are deployed and the park brake input is false the front switch panel
LED’s will be flashed at a 1Hz rate between white and red, the chirp will also be pulsing
on and off whenever the Red LED’s are on. In addition display the appropriate warning
ribbon.

22.2.2. The outriggers can be operated in two ways. The first is direct operation using the
buttons on the rear control panel that are associated with the function you would like to
42
 operate - Driver side deploy, driver side retract, passenger side deploy, and passenger
side retract. These will operate if the PTO interlocks are true. The pushbutton functions
will be momentary.

22.2.3. The second way to operate the outriggers is by using the auto leveling feature. Each
outrigger jack cylinder will have a normally closed proximity switch to indicate that the
outrigger has contacted the ground. The operator will hold the Auto Deploy button. The
outriggers will deploy until each proximity switch opens and a timer has expired. The
timer will allow the outrigger to extend beyond the point where it just touches the ground.
In this condition, the outrigger will be considered “planted”. Once planted the truck will
attempt to level side to side by monitoring the roll angle of the vehicle. Based on the roll
angle, the correct pair of outriggers (driver side or passenger side) will be extended until
we are “level” within 0.5 degrees. Once level side to side, the truck will attempt to level
fore and aft by monitoring the pitch angle of the vehicle. Based on the pitch angle, the
correct pair of outriggers (front or rear) will be extended until we are “level” within 0.5
degrees. If level is not reached, it is possible that a cylinder is bottomed out The Auto
Deploy Failed warning will be displayed. Cylinders will never be retracted automatically
as part of the auto leveling process. If required, an outrigger could be lowered again if it
becomes unplanted during the auto deploy process. The crane must be stowed to use
auto deploy so that the inclinometer is properly aligned with the truck.

22.2.4.

22.2.5. All proximity switches are normally closed. However, the design of the mechanical
triggers for each will differ, so each must be verified. The typical state for each switch is
listed below:
Jack cylinder down (planted) - Open
Jack cylinder up - Open
Horizontal cylinder extended - Closed
Horizontal cylinder retracted - Open

22.2.6. Normally all cylinders will be present and sequencing of cylinder movements will be
controlled electronically as follows: Deploy - Extend horizontal cylinder until the extend
switch changes state, then lower the jack cylinder, Retract - Raise jack cylinder until the
jack cylinder up switch changes state, then retract the horizontal cylinder.

23. Auto Stow This feature shall automatically return the boom to the stowed position when the
button is pressed and held.

23.1. Before this process will work the boom position sensors need to get homed.
Move the crane to the “stow” position. Once stowed navigate to the Crane Settings
screen 26 and press the Home Crane button to home the encoder and inclination
sensors. The Crane Homed ribbon will be shown for 3 seconds when successful

43
 23.1.1. Crane speed during auto stow is approximately 50% of max. When
approaching changes in direction the crane will slow to 25% of max speed. When
approaching the stow position the crane will stow to 10% of max speed.

23.1.2. The first step in Auto stow is to press the auto stow button on Crane screen 9
which will navigate you to the Autostow screen 24.

23.1.3. After initiating the process the next step is to look at the cranes angular
position, if it is greater than our Auto Stow Angle, then the crane will lower itself until it
reaches that point. If the boom angle is less than the Auto Stow Angle then it will raise
itself to that point. Dead band for this setpoint is +/- 2 degrees.

23.1.4. Once it achieves the correct angular position we will look at the rotational
position. At this point the boom will rotate so it can return to the stow position in the
direction that it arrived to its current position. Dead band for this setpoint is +/- 1
degree.

23.1.5. When it is returned to the auto stow rotational home position the crane will
begin to lower until inclinometer reaches the “homed” set point. Once a
predetermined point has been reached the crane operation will slow to allow gentle
seating in the boom stow. Confirmation of stow can be obtained by monitoring the
boom angle.

24. Outrigger Override Due to space limitations at job sites, it is not always possible to fully
extend all outriggers with the horizontal cylinders. It is preferable however to lower the jack
cylinder and plant the outrigger even if not fully extended. An override is required that will allow
the operator to lower each outrigger jack cylinder at a position other than fully extended. A
maintained override button must be added to the default (rear only) outrigger control screen on
the 32007 display panel. When the override is enabled and an outrigger deploy button is
pressed, that outrigger will stop extending and immediately begin lowering the jack cylinder.
The override button will not be available on units with front outriggers.

24.1.1. Screen Changes - Add a maintained Extend Override button to Screen 7 as shown
below. No changes shall be made to Screen 20 that includes front outrigger controls.

44
 24.2. Zone Load Rating Reduction - Zone Load Ratings must be reduced if any outrigger
is not fully extended. This shall be determined by monitoring the outrigger proximity
switches. The default will be 45% for all zones.
24.3. Auto Deploy - If the extend override function is enabled, the auto deploy function will
lower the jack cylinders in their current position and attempt to level. The primary
difference is that no extension shall be performed with the horizontal cylinders.

25. Chassis Integration

25.1.

25.1.1.

25.1.2.

25.1.3.

25.1.4.
25.2.

25.2.1.

25.2.2.

25.3.

26. mVEC Integration

45
 26.1. mVEC Features and Functionality

26.1.1. Relay Control –

26.1.2. Communication Check –

26.1.3. Relay State –

26.1.4. Relay Status –

26.1.5. Fuse Status -

27. Fully Proportional Crane Control

46
2.9 PHASE III
2.9.1 Remote Functions and Screen Displays

47
48
49
50
2.9.2 Data Panel with LMI data

The circled button on the main screen, above, will take you to the Crane Control screen, below, that
relays the LMI data. The data that appears on the remote is the same data that is displayed here.

51
2.10 MANUAL OPERATION
To override the remote, go to a manual operation of your crane. To do so, follow the guideline
below:

1. To activate the flow control solenoid using a small screw driver, insert tip into the hole of the manual
override on the end of the solenoid matching the direction you want to go and press in.
2. Take the truck in for service as soon as possible to prevent future damage to equipment or
yourself.

2.11 TASK PERFORMANCE

Before using the crane it must be tested for the operational requirements of this crane.

1. Testing of all functions of the crane.

2. All safety devices must be operational.
3. All functional labels of the crane must match the operations of the crane.
4. When testing the load capacity, the load shall not exceed 110% of the recommended load
ratings for the manufacturer.
5. Written reports for maintenance and repairs must be kept for future reference.

Think about the lift prior to making the actual lift with the crane:

Get your truck and crane into a position as near to the job site as possible. Choose a solid level
surface, and set your outriggers. In a more sandy soil you may want to use additional support under
the outrigger legs, such as wooden cribbing. Know your surroundings; look for overhead power
52
lines, tree limbs and/or any solid surface with which you may come into contact in the performance
of the lift. To keep you and your equipment out of danger, give yourself a minimum clearance of the
crane fully extended and a clearance of the obstructions at the job site.

Note: Power lines with the capacity of 50,000 volts or more require ten additional feet of clearance
for any part of the crane body. With each additional 30,000 volts or less, an additional one foot of
clearance is required. When working near power lines, give them wide berth and make use of a
secondary signal man at the job site if you do not have a clear field of vision.

You are now ready to put your truck/crane into action:

1. Engage the PTO.

2. Extend and lower the outriggers until firm ground contact is made. On soft ground, use
bearing pads to prevent sinking. Use extreme caution when setting up near overhanging
banks or excavations. The outriggers must be extended to stabilize the truck before
beginning operation.
3. Before extending the boom, always pay out the winch cable. Failure to do so may result in
damaging the cable and cable failure. Summit Truck Bodies cranes are equipped with
counter balance valves located in the manifold block welded on the lift cylinder. This
valve functions as a deceleration control and serves as a safety device locking the load in
case of a hydraulic line breakage or in the event of accidental or unauthorized operation of
the directional valve when the pump is not operating. The valve is equipped with a manual
load release, which is to be used only in case of an emergency.

2.12 SHUTDOWN

1. Retract the boom and cable, making sure cable is properly wrapped on winch spool.
2. Secure the Snatch Block and Hook to the hook attachment loop on the boom.
3. Stow the boom into the boom cradle.
4. Retract the outriggers.
5. Disengage the PTO.

2.13 OPERATOR REQUIREMENTS

The crane should not be operated by just anyone on the job site. For your safety and liability
prevention, you should limit the operation to people meeting the following scope of
operation:

1. The person operating the crane must be trained and certified as an operator.
2. If the person is a trainee, he or she must be accompanied by a certified trained
operator.
53
 3. A crane inspector on the job site may have a need to inspect and operate your crane;
he or she should have credentials establishing that he or she is qualified to do the
inspection.
4. To perform the preventative maintenance on your equipment, your maintenance crew
will have to be certified and trained on the proper operations of the crane.
5. The operator must be competent and have a working knowledge of the crane, the
safe operation of the crane and the owner’s manual.
6. The operator should know your safety policy as well as the policies dictated by state
or federal regulations, (ANSI B30.5), as well as job site guidelines for safety.
7. The operator must be able to perform all controls of the crane in a safe manner,
realizing how to implement an emergency procedure if needed.
8. A good PM starts with the use of the crane and the competency of the operator in the
use and maintenance of his or her equipment.
9. The operator must read and understand all guidelines.

2.14 OPERATOR CONDUCT

As outlined above, the operator is responsible for the safety and welfare of themselves and others at
the job site. They should follow the rules of conduct listed below:

1. A suspended load must never be left unattended.

2. When lifting a load the operator must give his or her full attention to the lifting of the load.
3. All operations of the crane are directly in the control of the operator at the time of the lift.
4. A good PM policy must be followed by the operator for the safety and maintenance of the
crane.

2.15 HANDLING THE LOAD

1. Know your crane and the lifting capacity of the equipment you are using.
2. Measure the load you are going to lift and ensure the load weight and the crane capacity
match so that you can perform the lift without damaging the equipment or injuring
personnel.
3. When lifting the load use only approved lifting straps or lifting devices, secured to the crane
hook.
4. The crane is equipped with wire rope intended to do a lift and rotate on the sheave of the
travel block; never use this device to wrap around the load.
5. Before lifting the load, set the outriggers of the truck and stabilize the truck base.
6. Balance the load evenly with the hoist rope directed to the center of the load.
7. Lift slightly insuring the load is both stable and centered.
8. Do not attempt to drag the load sideways; this is side loading and will result in damage to the
rotation gear of the crane.
9. Keep the load stable and avoid swinging the load, as this produces an unsafe lift that could
result in injury.

54
10. A suspended load must be clear; never pass a suspended load over a person or persons.
11. Smooth, gentle operation of the controls allows for a safe lift and movement; do not use
sharp, jerking motions with a load.

2.16 CRANE PRECAUTIONS

To avoid an accident or injury, avoid the following situations:

1. Be sure your equipment is neat, clean and clearly marked; if any thing is damaged, have it
replaced.
2. Look at your capacity and stability charts before making a lift of the load, use a minimum
lifting height and understand the load is moving, which can alter your stability and capacity.
3. Know your load and the crane tip locations at all times during the lift.
4. Center the load directly under the crane tip to give you a safe, smooth lift.
5. Do not allow the lift to swing from side to side, which causes an unsafe and uncontrolled load
to shift.
6. As with any piece of equipment, your crane has limits; do not attempt to over lift the capacity,
and never try to lift a stationary or fixed object.
7. Side loading of the crane will result in damage and/or failure of your crane rotation system.
8. Keep the lifted load away from people; never suspend the load over a person.
9. Make use of your PPE.

2.17 HOOK PRECAUTIONS

Each crane hook is rated with a specific load rating. Do not exceed the rated capacity of the hook
with any lift and/or load attempted lift.

Avoid side loading of the crane or lifting with only the crane tip, as this will result in damage to
the equipment. The tip is designed to do a straight direct upward lift only.

Look at your equipment and know the rating of the hook with which you are lifting. Ensure that
it matches your load weight. If it does not, do not attempt to perform the lift.

Part of your PM for the hook should include visual inspection of the hook for stress wear, a worn
safety latch. Do not attempt to repair a hook by welding; the heat from the weld will compromise the
integrity of the hook material, causing it to fail and resulting in an injury or accident.

55
 SECTION 3 – MAINTENANCE

WARNING: Read the Following before maintaining any part of the crane. Only authorized and trained
service personnel are to perform maintenance on the crane.

3.1 GENERAL

To prevent damage to the equipment, a daily, weekly, monthly, and quarterly PM should be
established within your company to keep the equipment operating at maximum levels. Follow all
safety practices before undergoing maintenance on your equipment.

1. Set the emergency brake, and lower the crane to a resting position, keeping it supported by
the crane cradle on the truck or a stationary support on the ground level. Remember your
crane goes to -5 degrees.
2. Disable the PTO by shutting it off our pulling the handle out of gear to disengage.
3. Manually attempt to override the remote, allowing for all reserve hydraulic pressure to
be released.
4. Perform your company’s designated PM on the equipment.
5. Replacement parts are available through Summit Truck Bodies.
6. Any worn or broken parts should be replaced at this time.

Service

To better service your crane, you may find it helpful to follow these guidelines:

1. Identify (knowing what the problem is generally helps you find the solution).
2. Troubleshoot (identify multiple causes and use Form 1-10 to determine the cause of the
problem).
3. Repair or replace the worn items depending on which solution is the most cost effective for
your repair.
4. Do (make the necessary repairs and or adjustments).
5. Check (function all operations of the equipment to ensure that all components are working
properly).
6. Put the crane back into service.

56
3.2 LUBRICATION

Follow the guidelines established in the manual for all lubrication requirements. Extreme heat or
cold can adversely affect the life of the lubricant. Pay special attention to periods of heavy use of the
equipment, as this will also shorten lubricant life.

3.3 HYDRAULIC FLUID SPECIFICATION

Minimum viscosity specifications for hydraulic oil to be used in the crane should be Conoco Super
Hydraulic Oil 46 or equivalent to eliminate the necessity of seasonal oil changes under normal
temperature conditions. For operations in extremely cold temperature, use a hydraulic fluid having a
viscosity of 3000 SSU’s at the lowest temperature encountered. Operating temperature of the
hydraulic fluid should be within the range of 120° to 160° F(49° to 82° C).

In addition to conforming to the viscosity requirements, hydraulic fluid used in the system should
contain the following additives: Anti-foam, Anti-oxidant inhibitors Rust resistant, Anti-wear
additives.

Summit Truck Bodies recommends the first filter change to occur after the first 25 hours of service.*
The second, and every subsequent change, should occur after every 500 hours of service. By
following these guidelines, the hydraulic oil should last up to 3,000 hours.

*NOTE: These recommendations are based on normal working parameters. If operating in less than
favorable conditions (excessive dust, moisture, etc.), be sure to check the filter gauge often for filter
change notice.

3.4 HYDRAULIC OIL DETERIORATION

Hydraulic oil can and will break down over time and/or excessive use. To avoid contamination of
the oil and possible damage to your hydraulic components, take a sample of the suspected oil and
check for the following:

1. Using a clean glass jar, put in a sample of the suspected oil.

2. The oil may smell burnt or have a foul odor.
3. If the oil is not clear and clean, it may be contaminated; contaminated oil generally has a
cloudy appearance or is very dark.
4. If after a few minutes you find water at the bottom of the glass jar, it is time to change the oil.

Any of the above-listed issues will be cause for oil replacement.

57
3.5 HYDRAULIC SYSTEM PURGIN

The oil should be changed after 3,000 hours of operation or every year, whichever occurs
first. Follow these guidelines to purge the hydraulic system:

1. Put the truck into an area that allows for the full rotation of the crane.
2. The PTO should be disengaged, and the reservoir should then be drained.
3. The bottom of the tank contains two wire mesh strainers; remove both and clean them.
4. After cleaning the filters and reassembling them to the reservoir, reinstall the hoses.
5. Reinstall the drain plug and fill with new fluid.
6. Engage the PTO after starting the truck engine.
7. Top off the reservoir after the system has cycled for 5 to 10 minutes. Fill to the full mark.

3.6 PURGING AIR FROM THE SYSTEM

If you have air in your system, you will detect a choppy, erratic condition within the system. If the
condition is only prevalent on one system, then hold the operation of that system open until the cycle
is complete. Move the operation in the opposite direction, holding the control in the open position.
This should eliminate the air. Operate the crane to check the performance. If the system operates
smoothly, then it is purged. If the system does not operate smoothly, follow the process again.

If air is trapped in the cylinder, it will cause an erratic “bumpy” condition. To remove 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. Operate the crane in a normal manner to determine if the
air has been purged. If not, repeat procedure.

NOTE: Do not purge the system for the winch circuit function.

3.7 SYSTEM RELIEF PRESSURE

If you want to ensure that the relief pressure setting is correct, there is a pressure gauge in the -4 O-
ring near the front bottom side of valve manifold. The test can be performed by utilizing the extend
cylinder. Fully retract either cylinder and hold in while observing pressure reading on gauge.

1. Start the truck engine, engage the PTO and allow the system to idle until it reaches
operating temperature.
2. Extend the boom until the cylinder is fully extended. Continue to hold the valve open and
read the pressure on a pressure gauge. A reading of less than normal should be corrected
by increasing the pressure. If the pressure reading is too high or too low, it will be
necessary to adjust the relief valve set screw.
3. Adjustments are made by unlocking the jam nut and turning set screw clockwise to
increase pressure and counterclockwise to decrease pressure. Recommended pressure is
2800 PSI.
58
3.8 COUNTER BALANCE VALVE
Your crane is equipped with hydraulic cylinders that have counter balance valves. These prevent
the failure of the cylinder rods in a downward motion in the event there is a component failure
within the hydraulic system.

Find the cylinder you suspect to be the problem. Now define the two valves; one is for retraction
and one is for extension. Test the cylinder with the crane intact. Safely lift a lighter load than the
crane has capacity for, and then disengage the hydraulic system. If the cylinder fails and allows the
load to lower, it is time to replace the counter balance valve. If the cylinder does not lower, then the
counter balance valve is operational and you have another issue that must be identified.

3.9 ROTATION GEAR

All Summit Cranes are equipped with a gear products rotation gear. Gear products have a very good
reputation in the industry, and it is recommend that no adjustments be made to the rotation system
without prior approval. The suggested gear lube of choice is Castrol Molub-Alloy, 936 SF Heavy
Lubricant or equivalent to grease the worm and/or ring gear.

3.10 PLANETARY WINCH

No adjustments are to be made to the planetary winch without prior consultation with the factory.
The planetary winch is only to be serviced by a trained technician, through the service department.

3.11 WIRE ROPE

The entire safety of the crane and the lifting of loads will be determined by one item on your
crane, namely, the condition of the wire rope. To do a thorough visual inspection goes without
saying. This should be completed daily, as it requires very little time and could prevent injury.

Look at the entire rope as it is unwound from the winch, looking for worn or frayed cables within
the rope. Check each end of the rope at the attachment points. Pay close attention to the ends for
breakage and/or rust.

While the rope is unwound, check the winch drum for wear, as well as the sheaves for any
unusual wear that may result in wire damage.

Good PM is required with the wire, as it is all important to the safety of the operator and the
equipment.

A daily inspection of the wire rope should include a visual inspection for rust, frayed wire strands, a
twist in the wire rope, and form of weakness that may have been the result of the wire rubbing on a
porous surface.
59
Quarterly inspections are suggested for the safety of the personnel working on the job site. This
inspection involves more than the suggested visual inspection done daily. The quarterly inspector
can be the operator if you deem him to be a competent person with knowledge of the equipment and
its features and functions.

1. The wire rope should be inspected for defects from start to finish of the rope. The wire rope
should be replaced if there is evidence of wear, rust, and/or defects of any nature, such as
twisted rope, frayed cables or broken wires. Making use of a micrometer is necessary when
judging the diameter of the wire rope to determine the life expectancy of the rope.

2. The rope has weight associated with it so be cautious when near the ends of the rope.

When you have any, or a combination of, the following defects, the wire rope should be replaced:

1. Broken or frayed wires within the rope or at the ends of the rope
2. If upon micrometer inspection you determine the wear pattern of the wire diameters to be
more than 1/32 inches
3. If the wire has been exposed to an extreme heat, it needs replacement
4. A distorted twist in the rope
5. If you detect any stretching of the wire rope compromising the diameter of the original wire
diameter

In order to properly maintain your wire rope, always keep it stored in the winch off the crane body,
and a monthly lubrication with WD-40 will extend the rope life. Avoid using the rope over sharp
objects that may cause it to be scraped, or situations where the rope can become caught crushed.

60
3.12 GEAR-BEARING BOLTS

Do not reuse any of the gear bearing bolts. These must be replaced using a bolt of
identical specifications for size and grade. Reuse of the old bolt will result in a
compromise of bolt integrity and could lead to a severe accident, causing loss of life
and/or limb.

U.S. BOLT TORQUE SPECIFICATIONS

Torque in pounds-foot
Socket Socket
head head
cap cap
5 5 8 8 screw screw
Bolt Thread
Dia. per inch Dry Oiled Dry Oiled Dry Oiled
1/4 20 8 6 12 9 14 11
5/16 18 17 13 25 18 29 23
3/8 16 30 23 45 35 49 39
7/16 14 50 35 70 55 76 61
1/2 13 75 55 110 80 113 90
9/16 12 110 80 150 110 163 130
5/8 11 150 110 220 170 230 184
3/4 10 260 200 380 280 400 320
7/8 9 430 320 600 460 640 510
1 8 645 515 910 725 960 770
1 1/8 7 795 635 1290 1030 1375 1100
1 1/4 7 1120 900 1875 1500 1980 1585
1 3/8 6 1470 1175 2380 1900 2535 2030
1 1/2 6 1950 1560 3160 2525 3340 2670

BOLT TORQUE FACTORS

LUBRICANT OR PLATING TORQUE CHANGES
Oil Reduce torque 15% to 25%
Dry Film (Teflon or moly based) Reduce torque 50%
Chrome plating No change
Cadmium plating Reduce torque 25%
Zinc plating Reduce torque 15%

The use of Loctite does not affect the torque values listed above.

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3.13 INSPECTIONS

Daily Inspection
Before going to the job site each day, a visual inspection of the following will help prevent
unnecessary maintenance:

1. All fluid levels are within the tolerances set by the manufacturers, such as air compressor,
crane and engine
2. Evidence of broken structural components such as welds and loose fasteners
3. Leaking cylinder seals
4. Oil leaks at the engine, transmission, PTO and pump, power steering and hydraulic reservoir
5. Wire rope inspection for excessive wear patterns
6. Excessive wear to the counter balance valves to ensure the crane load will not be
compromised
7. Outriggers operate as specified
8. All safety devices are in place, in good working order and legible

Weekly Inspection
This inspection should be a routine and often easy inspection if daily inspections are being
completed by competent personnel.

1. General inspection of lubrication capacities and levels

2. General inspection of all crane components for wear and tear

Monthly Inspection
Establish a set time every month within which the monthly inspections will occur. The
inspection should occur at the same time every month.

1. Check the entire truck for leaks, engine, transmission, crane, outriggers, hydraulic reservoir
and all cylinders on the truck components
2. Lubrication levels are within specifications set by the manufacturer
3. Inspection of the crane hook and safety latch for wear and tear
4. Check entire structure of the truck and components for broken welds, worn fasteners and
missing fasteners
5. All safety devices are in good working condition and legible
6. Inspect all wiring and lights on the truck for correct operations and functions
7. Replacement of any non-conforming issues

62
Quarterly Inspection
This inspection should include, but not be limited to, the following:

1. Any loose bolts on the crane body

2. Any bolts mounting the crane to the main body of the truck pedestal
3. The hydraulic system pressures to the cylinders, main block assembly, and cartridges
4. Lubrication of the pivot points of the crane such as the bearings, cylinders, and shafts
5. Wear and tear of the hydraulic hoses such as fraying, crushing and leaks
6. Undue wear of the PTO; follow the manufacturer’s maintenance manual
7. Both the lift cylinder and the extend cylinder for leaks, drifting of the cylinders, and any
damage external of the cylinders

LUBRICATION & MAINTENANCE SCHEDULE

SERVICE
3 MONTH

6 MONTH
WEEKLY

YEAR

PERFORMED
DAY

NOTES
Hydraulic Fluid X Check Fluid Level
Hydraulic Hoses X Visual inspection for leaks, cracks, wear
Load Hook X Inspect Hook & Latch for Deformation
Winch Cable X Check for Broken Strands, Flattening, Deformation
Cable Drum X Make sure cable is wound evenly on drum
Pin Retaining Bolts X Check bolts for Proper Torque
Rotation Ring Gear Lube with Castrol Molub – Alloy, 936 SF Heavy Lubricant or
X
Equivalent
Sheaves X Inspect for wear and bearing fatigue
Mounting Bolts X Check torque to 680 ft lbs
All other Bolts X Check and Tighten as required
Rotation Gear Box X Grease zerks with multipurpose grease
Hydraulic Fluid X Drain, Flush and Refill with ISO 46 Hydraulic Oil

Caution: Routine maintenance insures trouble-free operation and protects your

investment. All warranties are void if maintenance is neglected.
Notes:
1. Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not
covered under Warranty or Product Liability.
2. Once a bolt has been torqued to its rated capacity and then removed, the bolt should be replaced with a new
one.

63
 SECTION 4 - TROUBLE-SHOOTING
The following is meant as a reference in diagnosing on-the-job-malfunctions.

PROBABLE CAUSE
SYMPTOM
1. Parking brake is not engaged
Crane will not operate 2. PTO is not engaged
3. Radio receiver does not have 12V power
4. Transmitter not on
5. Transmitter batteries have low voltage
6. Hydraulic pump not operating at rated pressure

1. Hydraulic fluid level low

Crane will not rotate 2. Obstruction in control valve solenoid
3. Adjustable speed set improperly
4. Bad ground on the control valves
5. Rotation direction slope is too extreme (not on level ground)

1. Radio receiver does not have 12V power

Crane will operate manually but will 2. Transmitter not on
not operate electrically. 3. Radio/Receiver not functioning properly
4. Parking brake is not engaged.
5. Parking brake switch is not working properly.

1. The toggle switch is not working properly

Function does not respond to controls 2. Hydraulic fluid low
3. PTO not engaged
4. Ruptured/obstructed pressure line
5. Faulty hydraulic pump
6. Short circuit in remote control
7. Broken wire in remote control
8. Crane is not grounded to truck
9. Solenoid in control valve malfunctioning
10. Bad ground on the control valve

1. An obstruction in the solenoid control valve

Two functions operate at the same time 2. The toggle switch has failed and is stuck in the “on” function
while only toggling one function.

1. Hydraulic pump operating at reduced speed

2. Relief valve set too low
Slowdown of functions 3. Flow control valve not functioning properly
4. Proportional trigger on remote not functioning properly
5. Low hydraulic fluid
6. Dirty filter/strainer
7. Obstruction in solenoid control valve

1. Cavitation due to low hydraulic oil supply

Unusual noise in operation 2. Excessive loading
3. Restriction/collapse of suction line
4. Flow control valve not functioning properly
5. Suction line filter dirty
6. Relief valve set too low
7. Relief valve defective
8. Air in the lines

1. Adjustment speed set improperly

Outriggers won’t react 2. Control valve defective
3. Loss of power and/or ground to coil

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 Boom drifts under load
1. Cylinder piston seals leaking
2. Counterbalance valve defective
Boom or winch won’t lift
1. Restriction in the line
2. Relief valve is not set properly
3. Overload condition
4. Counterbalance valve is malfunctioning or defective
Rotation speed too fast or too slow
1. Hydraulic lines restricted or ruptured
2. Hydraulic motor defective
Winch brake will not hold
1. The back pressure on the return line of the winch is greater than 50 psi
2. Excessive loading
3. The winch relief valve not set properly
4. Counter balance valve not set properly
Crane operates slowly
1. Air in the system
2. Pump not delivering rated oil volume
3. The holding valves are not operating
4. Hydraulic fluid low
5. Flow control valve restricted
6. Pressure relieve valve sticking open
7. Speed control option not engaged

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SECTION 5 – PARTS

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SECTION 6 – HYDRAULICS / CONTROLS

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SECTION 7 – WIRING HARNESS
Phase I

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Phase II

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Phase III

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 990 Vernon Rd • Wathena, KS 66090
Phone (866) 985-3100 • Fax (785) 989-3563

Summit Truck Bodies, LLC

Limited Warranty
Warranty Period: 60 Months

Summit Truck Bodies, LLC (hereinafter “Summit”) warrants each new crane of Summit’s manufacture to be free
from defects in material and workmanship, under normal use and service for a period of five (5) years after
initial purchase as derived from a completed warranty registration card. This Limited Warranty shall apply only
to cranes of Summit’s manufacture. Parts are covered by a separate limited warranty. EQUIPMENT AND
ACCESSORIES NOT OF SUMMIT’S MANUFACTURE ARE WARRANTED ONLY TO THE EXTENT
OF THE ORIGINAL MANUFACTURER’S WARRANTY AND ARE SUBJECT TO THEIR
ALLOWANCE TO SUMMIT ONLY IF FOUND TO BE DEFECTIVE BY SUCH MANUFACTURER.

Warranty Terms

During the Limited Warranty period specified above, any defect in material and workmanship in any warranted
item of Summit bodies not excluded below shall be repaired or replaced at Summit’s option by a Summit
representative or approved repair facility. Summit will pay for replacement parts and such approved repair
shop’s labor in accordance with Summit’s labor reimbursement policy. Summit reserves the right to supply
remanufactured replacement parts as it deems appropriate.

Retail Purchaser Responsibility

This Limited Warranty requires proper maintenance and periodic inspections of the crane as indicated in the
Operator’s Manual furnished with each new Summit crane. The cost of routine maintenance and services is the
responsibility of the retail purchaser. The retail purchaser is required to keep documented evidence that these
services were performed.

The Summit Truck Bodies, LLC Limited Warranty may be subject to cancellation if the above requirements are
not performed.

Summit cranes with known failed or defective parts must be immediately removed from service.

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 Exclusions and Limitations

The warranties contained herein shall NOT APPLY TO:

1. Any defect which was caused (in Summit’s sole judgment) by other than normal use and service of the
crane or by any of the following: (i) accidents including but not limited to collision (ii) misuse or
negligence (iii) overloading (iv) lack of reasonable and proper maintenance (v) improper repair or
installation (vi) unsuitable storage (vii) non-Summit alteration or modification (viii) natural calamities
(ix) vandalism

2. Any crane whose identification numbers or marks have been altered or removed.

3. Any crane which any of the required or recommended periodic inspection or services have been
performed using parts not manufactured or supplied by Summit or meeting Summit specification.

4. New cranes delivered to the retail purchaser in which the warranty registration is not returned within
fourteen (14) days from the date of delivery.

5. Any defect which was caused (in Summit’s sole judgment) by operation of the crane not abiding by
standard operating procedures outlined in the Operator’s Manual.

6. Costs incurred by Summit for replacement parts for items not of Summit manufacture will be invoiced to
the customer. To be considered for warranty, the failed part must be returned, at the discretion of
Summit, to Summit or the manufacturer of the part within thirty (30) calendar days. The part will be
evaluated and if warranty is approved by the manufacturer credit will be issued to the customer in the
form of
a. Credit to a Summit account if one exists or
b. Credit back to a charge card or
c. Check to the customer.

7. Transportation costs, if any, of transporting unit to an approved repair facility.

8. In no event shall Summit’s liability exceed the original purchase price of the product.

9. Summit shall not be liable to any person under any circumstances for any incidental or consequential
damages (including but not limited to loss of profits and out of service time) occurring for any reason at
any time.

10. Diagnostic and overtime premiums are not covered under this Limited Warranty Policy.

11. Depreciation caused by normal wear, lack of reasonable maintenance, failure to follow operating
instructions, misuse, or lack of proper protection during storage.

12. Accessory systems and electronics not of Summit’s manufacture are warranted only to the extent of such
manufacturer’s respective Limited Warranty, if any.

13. Any installation of a crane on chassis other than original factory installation.

Parts Warranty

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 Replacement parts after the original warranty period are warranted to be free from defects in material for
ninety (90) days or the part will be repaired or replaced without labor coverage for removal or installation.

Summit Labor Reimbursement Policy

Summit will consider labor reimbursement during the defined warranty period provided that the repair is pre-
approved. Contact the Service Department at Summit for details.

Shipping Costs

Summit will pay for shipping of warranty parts by ground carrier. Expedited freight delivery is available at the
expense of the owner. Shipping for the return of parts for warranty consideration will be at the owners’ expense
but will be reimbursed if the parts in question are deemed defective by Summit or by the manufacturer of the
part and a legible copy of the invoice is provided.

Exclusion of Warranties

Except for the warranties expressly and specifically made herein, Summit makes no other warranties, and any
possible liability of Summit hereunder is in lieu of all other warranties, expressed, implied, or statutory including
but not limited to any warranties of merchantability or fitness for particular purpose. Summit reserves the right
to modify, alter, and improve any product previously sold without incurring any obligation to replace any
product previously sold without such modification. No person is authorized to give any other warranty or
assume any additional obligation on Summit’s behalf.

SUMMIT TRUCK BODIES IS UNDER NO OBLIGATION TO EXTEND THIS WARRANTY TO ANY

CUSTOMER FOR WHICH AN SUMMIT CRANE WARRANTY FORM HAS NOT BEEN
COMPLETED AND ON FILE WITH SUMMIT TRUCK BODIES.

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