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Auto Crane NEXSTAR III Owner's Manual

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NEXSTAR III OWNERS
Serial No.
Mailing Address:
P.O. Box 580697
Tulsa, OK 74158-0697
HC-8X
MANUAL
Physical Address:
4707 N. Mingo Rd.
Tulsa, OK 74117-5904
   
1
1
Phone: 1-800-777-2760
Fax: (918) 269-6688
http://www.autocrane.com
479823012-0217-A
Courtesy of CraneMarket.com

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  • Page 1 HC-8X NEXSTAR III OWNERS MANUAL Serial No. Mailing Address: Phone: 1-800-777-2760 Physical Address: Fax: (918) 269-6688 P.O. Box 580697 4707 N. Mingo Rd. http://www.autocrane.com Tulsa, OK 74158-0697 Tulsa, OK 74117-5904 479823012-0217-A     Courtesy of CraneMarket.com...
  • Page 2 At the time of publishing this manual is accurate to the best of our knowledge. Auto Crane reserves the right to change any or all items, components and parts, necessary for any reason. This right does not obligate Auto Crane to immedi- ately update the manual.

  • Page 3: Table Of Contents

    Table of Contents   1.1   WARNINGS .................................. 6    2.1   INTRODUCTION ................................ 7    3.1   GENERAL SPECIFICATIONS .............................. 8    DIMENSIONS ................................... 8    CAPACITY.................................. 8    REACH ..................................... 8    CABLE .................................... 8    CHASSIS AND MOUNTING REQUIREMENTS........................ 8    HYDRAULIC REQUIREMENTS............................ 8    ELECTRICAL SYSTEM REQUIREMENTS.......................... 8    ROTATION .................................. 8    3.2   HC‐8X NEXSTAR III, GENERAL DIMENSIONS ........................ 9    3.3   LOAD CHART................................  1 1    3.4   HC‐8X NEXSTAR III DECAL LAYOUT, P/N 479624050.................... 12    4.1   QUALIFICATIONS AND OPERATING PRACTICES. ...................... 14    4.2   OPERATORS ................................  1 4    4.3   QUALIFICATIONS FOR OPERATORS ...........................  1 4   ...
  • Page 4 5.6   OPERATION – VALVE OVERRIDE..........................  2 3    6.1   NEXSTAR III TROUBLESHOOTING .......................... 24    6.1.1   TROUBLESHOOTING FLOW CHART ........................  2 4    6.1.2   NEXSTAR III REMOTE CONTROL TROUBLESHOOTING TABLE  ................. 25    6.1.3   NEXSTAR III ERROR CODE TABLE ..........................  2 6    6.1.4   NEXSTAR III MECHANICAL TROUBLESHOOTING TABLE.................. 27    6.1.5   NEXSTAR III ELECTRICAL TROUBLESHOOTING TABLE.....................  2 8    7.1   MAINTENANCE ................................  3 0    7.1.1   INSPECTION REQUIREMENTS  .......................... 30    7.1.2   INSPECTION CLASSIFICATION  ..........................  3 0    7.1.3   FREQUENT INSPECTION ............................. 30    7.1.4  ...
  • Page 5 HC‐8X NEXSTAR III PEDESTAL ASSEMBLY P/N: 479200099....................  4 7    HC‐8X NEXSTAR III PEDESTAL ASSEMBLY P/N: 479200099....................  4 8    HC‐8X NEXSTAR III PEDESTAL ASSEMBLY P/N: 479200099....................  4 9    HC‐8X NEXSTAR III, BOOM ASSEMBLY P/N: 479200101 .................... 50    HC‐8X NEXSTAR III, BOOM ASSEMBLY P/N: 479200101  .................... 51    HC‐8X NEXSTAR III, BOOM ASSEMBLY P/N: 479200101  .................... 53    HC‐8X NEXSTAR III, HOIST ASSEMBLY P/N: 123341  ...................... 54    HC‐8X NEXSTAR III, HOIST ASSEMBLY P/N: 123341...................... 55    HC‐8X NEXSTAR III, HOIST ASSEMBLY P/N: 123341...................... 56    HC‐8X NEXSTAR III, TRAVELING BLOCK ASSEMBLY P/N: 480854001  ................ 57    HC‐8X NEXSTAR III, MAIN HARNESS P/N: 479200206....................... 59    HC‐8X NEXSTAR III, ELECTRICAL SCHEMATIC P/N: 479200207.................. 60    HC‐8X NEXSTAR III, HYDRUALIC CONTROL P/N: 366823251.....................  6 2   ...

  • Page 6: Warnings

    Do not attempt to lift or drag a load from the side! The boom can fail far below its rated capacity. Do not weld, modify, or use unauthorized components on any Auto Crane unit! This will void any warranty or liability. Also failure of the crane may result.

  • Page 7: Introduction

    500 cold cranking amp battery. These specifications should be considered minimum. It has always been Auto Crane Company policy to handle all warranty claims we receive as promptly as possible. If a warranty claim involves discrepant material or workmanship, Auto Crane will take immediate corrective action. It is...

  • Page 8: General Specifications

    3.1 GENERAL SPECIFICATIONS DIMENSIONS Width: 25.5 in. (0.65 m) • Height: 36.75 in. (0.93 m) • Length: 15 ft. 3/8 in. (4.58 m), stored length. • Weight: 1,870 lbs. (848 kg) • CAPACITY 52,000 ft-lbs (7.92 ton-m) • Ft-lbs = horizontal distance from centerline of rotation to free hanging weight (feet) x amount of weight (pounds). •...

  • Page 9: Hc-8X Nexstar Iii, General Dimensions

    HC-8X NEXSTAR III, GENERAL DIMENSIONS Figure 1. General Dimensions  9  Courtesy of CraneMarket.com...
  • Page 10 10  Courtesy of CraneMarket.com...

  • Page 11: Load Chart

    3.3 LOAD CHART Figure 2. Load Chart  All load ratings are based on crane capacity, not the vehicle stability. When lifting a heavy load, the weight can create enough tipping moment to overturn the vehicle. DO NOT USE the overload shutdown device to determine maximum rated loads, if the crane is equipped with this type of device. Always comply with load chart capacities.
  • Page 12 HC-8X NEXSTAR III, DECAL LAYOUT P/N 479624050 12  Courtesy of CraneMarket.com...
  • Page 13 HC-8X NEXSTAR III, DECAL LAYOUT P/N 479624050 13  Courtesy of CraneMarket.com...

  • Page 14: Qualifications And Operating Practices

    C. Demonstrate to the employer the ability to operate the specific type of equipment. D. Be familiar with the applicable safety regulations. E. Understand the operating procedures as outlined by the Auto Crane. F. Be thoroughly familiar with the crane and its control functions.

  • Page 15: Operating Practices/Handling The Load

    5. Before closing the switch or starting the engine, the operator shall see that all controls are in the “OFF” or neutral position and all personnel are in the clear. 6. If power fails during operation, the operator shall: A. Move power controls to the “OFF” or neutral position. B. Land the suspended load and boom, if practical.

  • Page 16: Operating Near Electrical Power Lines

    4.6 OPERATING NEAR ELECTRICAL POWER LINES   Never operate the crane near electrical lines or in the danger zone area. Figure 3. Danger Zone 1. Do not place any part of the crane or load inside the Danger Zone. EXCEPTIONS: A.

  • Page 17: Preparing The Crane For Operation

    Leave the ignition on with the transmission in neutral (or park for automatic transmissions), c. Activate any crane power switches. 7. For Auto Crane units using electric and hydraulic operation: a. Engage the emergency brake, b. Place the transmission in neutral, c.

  • Page 18: After Operation

    AFTER OPERATION 1. After completing the lifting operations, return the boom to the stowed position on the boom support. 2. Replace remote control to its storage location. 3. Return the Outriggers to the stowed position. Ensure they are pinned in place or jacklegs are returned to the storage compartment.

  • Page 19: Nexstar Iii Operation

    After powering on the remote control, the LCD Display Screen turns on and will perform a self-test. During the self- test, the Nexstar III remote control scans for any switches, buttons, and joysticks are in the OFF position. If any switches, buttons, or joysticks are on, the failure displays on the Display Screen and the remote control powers down.

  • Page 20: Remote Control Layout

    5.3 REMOTE CONTROL LAYOUT 1. Emergency Stop Button – Push to activate. Pull to release. When activated the Emergency Stop Button stops all outputs from the receiver. 2. Display Screen – LCD screen that displays many crane operating parameters. See Figure 4. 3.

  • Page 21: Display Screen Layout

    5.4 DISPLAY SCREEN LAYOUT 1. Capacity – The current load on the boom as a percentage of total capacity. The unloaded value of the boom may be higher than 0% due to the boom weight beyond the retracted position. 2. Aux – AUX will display on the screen when active. 3.

  • Page 22: Speed And Mode Selection

    5.5 SPEED AND MODE SELECTION 5.5.1 SPEED SELECTION 1. Press and hold the Link Switch in the up position. 2. While holding the Link Switch in the up position: a. Move the Left Joystick up to increase the max speed. b.

  • Page 23: Operation-Valve Override

    5.6 OPERATION—VALVE OVERRIDE 1. Push the unloader valve (ULV) red button. This will send hydraulic fluid to the valve block. 2. Select the desired function. 3. Close the gap between the collar and the end on the override button. 4. Push or pull the override button for the desired direction of movement. The farther the button is pressed or pulled, the faster the function will operate.

  • Page 24: Nexstar Iii Troubleshooting

    6.1 NEXSTAR III TROUBLESHOOTING 6.1.1 TROUBLESHOOTING FLOW CHART   24  Courtesy of CraneMarket.com...

  • Page 25: Nexstar Iii Remote Control Troubleshooting Table

    6.1.2 NEXSTAR III REMOTE CONTROL TROUBLESHOOTING TABLE   Problem  Possible Reason  Action      Remote control Emergency Stop Switch is   Ensure the E-Stop switch is pulled up.     down or pressed.     Replace the battery pack with the label  ...

  • Page 26: Nexstar Iii Error Code Table

    6.1.3 NEXSTAR III ERROR CODE TABLE   Error Code  Cause  Effect  Solution      S1 CAN RX TO Reception of a can message All outputs will be disabled Determine why messages are not     timed out being received. When problem is  ...
  • Page 27 Engage PTO     located in the cab NO FUNCTION   Engage crane diverter valve Crane diverter valve not Is using Auto Crane outriggers, check OPERATES ON   engaged the crane diverter valve located at the   THE CRANE  ...
  • Page 28 6.1.5 NEXSTAR III ELECTRICAL TROUBLESHOOTING TABLE   Problem  Cause  Effect  Solution    Jammed transmitter button Activate e-stop to see if movement Verify that nothing had de-   stops pressed the button at the time of movement. If it was not de- pressed, replace the transmit-  ...
  • Page 29 Problem  Cause  Effect  Solution      Reached limit for cw rotation Check screen for error code. It will Verify the CW limit switch is not     display "CW limit" activated. This should normally   ROTATE CW IS be closed.  ...

  • Page 30: Maintenance

    7.1 MAINTENANCE 7.1.1 INSPECTION REQUIREMENTS   Reference ASME B30.5a and OSHA 1910.180 for complete inspection requirements. All inspections shall be performed by designated personnel only. 7.1.2 INSPECTION CLASSIFICATION 1. Initial Inspection a. Prior to initial use, all new, altered, modified, or extensively repaired cranes shall be inspected by a designated person to ensure compliance with provisions of this standard.

  • Page 31: Periodic Inspection

    7.1.4 PERIODIC INSPECTION Any deficiencies, such as those listed below, shall be carefully examined and determination made as to whether they constitute a hazard: 1. Inspect for deformed, cracked or corroded members in the crane structure and entire boom. 2. Inspect for loose bolts, particularly mounting bolts. 3.

  • Page 32: Cranes Not In Regular Use

    7.1.5 CRANES NOT IN REGULAR USE A crane, which has been idle for a period of more than one month or more, shall be given an inspection conforming to the “initial” and “periodic” inspection requirements of this section. 7.1.6 INSPECTION RECORDS Dated records of periodic inspection should be made on critical items such as brakes, crane hooks, rope, cylinders, and relief pressure valves.

  • Page 33: Adjustments And Repairs

    Replacement rope shall have a strength rating at least as great as the original rope furnished or recommended by Auto Crane. A rope manufacturer, Auto Crane, or a qualified person shall specify any deviation from the original size, grade, or construction.
  • Page 34 34  Courtesy of CraneMarket.com...

  • Page 35: Paint Finish Maintenance

    During periods when the truck is exposed to salt or other corrosive chemicals, wash Auto Crane products weekly. Inspect the paint finish monthly or when washed. Immedi- ately repair any exposed bare metal or rust. Repair damaged paint on Auto Crane products with the following proce- dure: 1.

  • Page 36: Lubrication And Maintenance Schedule

    7.4 LUBRICATION AND MAINTENANCE SCHEDULE   INSTRUCTIONS  DAILY  WEEKLY  3 MONTHS  6 MONTHS  YEARLY  SERVICE PERFORMED      Load Hook Inspect hook and latch for deformation,               cracks, and corrosion.       Cable Drum Ensure cable is wound evenly on drum.

  • Page 37: Lubrication Points

    2. Once a bolt has been tightened to specification then removed, the bolt should be replaced with a new one. 3. Auto Crane Company recommends this crane be serviced per the “Crane Inspection Log” P/N 999978. Fill these logs in at the intervals noted and kept as a permanent record. Additional copies are available from your local distributor.

  • Page 38: Hc-8X Nexstar Iii, Cartridge Maintenance

    7.7 HC-8X NEXSTAR III, CARTRIDGE MAINTENANCE   VERIFY MOVEMENT IN PORTS WHILE MANUALLY OVERRIDING CARTRIDGE   Table 8. Cartridge Maintenance Use the following procedure to inspect the cartridge for proper opertion. 1. Clean the area around the valve spool before it is removed from the valve bank.

  • Page 39: Crane Mounting And Installation

    8.1 CRANE MOUNTING AND INSTALLATION   For information specific to your crane, such as mounting hole diameter, bolt size and grade, and hydraulic requirements, see General Dimensions. 1. Refer to the Bill of Materials included with your ship kit. Ensure all items listed on the Bill of Materials are included with your crane.
  • Page 40 21. Ensure the Owner’s Manual is delivered to the customer. 22. For additional help: Call the Service Department at the Auto Crane Company, 1-800-777-2760, located in Tulsa, IMPORTANT! FEDERAL LAW (49 CFR PART 571) REQUIRES THAT THE FINAL STAGE MANUFACTURER OF A VEHICLE CERTIFY THAT HE VEHICLE COMPLIES WITH ALL APPLICABLE FEDERAL REGULATIONS.

  • Page 41: Stability Chart Installation

    8.1.1 STABILITY CHART INSTALLATION STABILITY CHART DECAL INSTALLATION   There is a stability chart included in the ship kit. This decal is typically installed on the inside of the  door of the crane box. This decal is to alert the user of the available crane capaci es around the  vehicle.    479824001 decal will be installed  on an Auto Crane body that was ou i ed with an                Auto Crane crane and Auto Crane outriggers.  Auto Crane has designed the body, crane and  outrigger to have stability based on the chart below:  41  Courtesy of CraneMarket.com...
  • Page 42 42  Courtesy of CraneMarket.com...

  • Page 43: Hc-8X Nexstar Iii, Counterbalance Valve Adjustment

    8. Tighten the nut on the adjustment screw and repeat steps 6 and 7 until the proper pressure reading is obtained. f the proper pressure reading cannot be obtained, please contact your Auto Crane distributor for assistance.  ...

  • Page 44: Drawings And Assemblies

    9.1 DRAWINGS AND ASSEMBLIES HC-8X NEXSTAR III, GENERAL ASSEMBLY P/N: 479000003 NOTES:  1.  APPLY LOCTITE 242 OR EQUIVALENT TO  THREADS BEFORE INSTALLATION  44  Courtesy of CraneMarket.com...
  • Page 45 HC-8X NEXSTAR III, GENERAL ASSEMBLY P/N: 479000003 45  Courtesy of CraneMarket.com...
  • Page 46 HC-8X NEXSTAR III, PEDESTAL ASSEMBLY P/N: 479200099 46  Courtesy of CraneMarket.com...
  • Page 47 HC-8X NEXSTAR III, PEDESTAL ASSEMBLY P/N: 479200099 47  Courtesy of CraneMarket.com...
  • Page 48 HC-8X NEXSTAR III, PEDESTAL ASSEMBLY P/N: 479200099 48  Courtesy of CraneMarket.com...
  • Page 49 HC-8X NEXSTAR III, PEDESTAL ASSEMBLY P/N: 479200099 49  Courtesy of CraneMarket.com...
  • Page 50 HC-8X NEXSTAR III, BOOM ASSEMBLY P/N: 479200101 50  Courtesy of CraneMarket.com...
  • Page 51 HC-8X NEXSTAR III, BOOM ASSEMBLY P/N: 479200101 51  Courtesy of CraneMarket.com...
  • Page 52 52  Courtesy of CraneMarket.com...
  • Page 53 HC-8X NEXSTAR III, BOOM ASSEMBLY P/N: 479200101 53  Courtesy of CraneMarket.com...
  • Page 54 HC-8X NEXSTAR III, HOIST ASSEMBLY P/N: 123341 54  Courtesy of CraneMarket.com...
  • Page 55 HC-8X NEXSTAR III, HOIST ASSEMBLY P/N: 123341         Item Quantity Part No. Description     234189   DRUM ASSEMBLY           306042 PISTON-BRAKE     315004   ANCHOR- CABLE         END BEARING-MOTOR END  ...
  • Page 56 HC-8X NEXSTAR III, HOIST ASSEMBLY P/N: 123341         Item Quantity Part No. Description         462057 O-RING         462058 O-RING         462059 O-RING BACK-UP         462060 O-RING BACK-UP  ...
  • Page 57 HC-8X NEXSTAR III, TRAVELING BLOCK ASSEMBLY P/N: 480854001 57  Courtesy of CraneMarket.com...
  • Page 58 58  Courtesy of CraneMarket.com...
  • Page 59 HC-8X NEXSTAR III, MAIN HARNESS P/N: 479200206 59  Courtesy of CraneMarket.com...
  • Page 60 HC-8X NEXSTAR III, ELECTRICAL SCHEMATIC P/N: 479200207 60  Courtesy of CraneMarket.com...
  • Page 61 HC-8X NEXSTAR III, ELECTRICAL SCHEMATIC P/N: 479200207 61  Courtesy of CraneMarket.com...
  • Page 62 HC-8X NEXSTAR III, HYDRAULIC CONTROL P/N: 366823251 62  Courtesy of CraneMarket.com...
  • Page 63 HC-8X NEXSTAR III, HYDRAULIC CONTROL P/N: 366823251 63  Courtesy of CraneMarket.com...

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