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Auto Crane Nexstar 14005H Owner's Manual

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OWNERS MANUAL
Serial No. __________________
Mailing Address:
P.O. Box 580697
Tulsa, OK 74158-0697
Physical Address:
4707 N. Mingo Rd.
Tulsa, OK 74117-5904
14005H
NEXSTAR
Manual No. 470102010
Phone 1-800-777-2760
Fax (918) 269-6688
http://www.autocrane.com

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  • Page 1 14005H NEXSTAR OWNERS MANUAL Manual No. 470102010 Serial No. __________________ Mailing Address: P.O. Box 580697 Phone 1-800-777-2760 Fax (918) 269-6688 Tulsa, OK 74158-0697 http://www.autocrane.com Physical Address: 4707 N. Mingo Rd. Tulsa, OK 74117-5904...
  • Page 5 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 ad- ditional information, please contact Auto Crane Company at 1-800-777-2760. 2. Auto Crane Company reserves the right to update this material without notice or obligation.

  • Page 7: Read This Page

    Attempt to lift or drag a load from the side! The boom can fail far below its rated capacity. • 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 8 14005H TABLE OF CONTENTS 3/15/11...
  • Page 9 The If, through no fault of Auto Crane Company, it is payload of the vehicle is reduced by the necessary to send an experienced factory weight of the crane.

  • Page 10: Distributor Assistance

    Auto Crane Company at the following tele- phone number: 1-800-777-2760. The information contained in the manual is in effect at the time of this printing. Auto Crane Company reserves the right to update this material without notice or obligation. 1-2.0...
  • Page 11 14005H GENERAL SPECIFICAIONS 1-3.0 6/15/10...
  • Page 12 WARNING! Auto Crane Company cranes are not designed or intended for use in lifting or moving persons. Any such use shall be considered to be improper and the seller shall not be responsible for any claims arising there from.
  • Page 13 —-IMPORTANT—- SAFETY TIPS AND PRECAUTIONS 31. Always store the crane in its stowed position WARNING: Never attempt to lift, drag, tow or for transportation. pull a load from the side. The boom can fail far below its rated capacity. 32. Remember the overall height of the entire unit for garage door clearance or when 41.
  • Page 14 Contact AutoCrane for rotation resistant wire conditions! rope for your application. WARNING! Auto Crane Company remote controlled, stiff boom cranes are not designed or intended for use on any applications involving the lifting or moving of personnel. 2-3.0 11/8/11...

  • Page 15: Qualifications For Operators

    QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE QUALIFICATION RE- QUIREMENTS tests may be required to determine these OPERATORS conditions. 1. Crane operation shall be limited to personnel 5. Operators and operator trainees should have with the following minimum qualifications: normal depth perception, coordination, and no A.
  • Page 16 QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES or neutral position and all personnel are in C. Means are provided to hold the vehicle the clear. stationary while operating the crane. 6. If power fails during operation, the operator D.
  • Page 17 QUALIFICATIONS FOR AND CONDUCT OF OPERATORS AND OPERATING PRACTICES N. No person should be permitted to stand or 3. Caution shall be exercised when working near pass under a suspended load. overhead lines, because they can move horizontally or vertically due to wind, moving the 4.
  • Page 18 (or in park for automatic they are pinned in place or jacklegs are returned transmissions). Activate any crane power to compartment. switches. For Auto Crane units requiring 14. Check work area for any tools or equipment not battery and hydraulic operation, engage stored.

  • Page 19: Crane Operation

    CRANE OPERATION TRANSMITTER LAYOUT E-stop Switch—Push to activated, Twist ON/OFF/MULTI SPEED to release. Shuts down all outputs from E-STOP SWITCH 3 POSITION KEYSWITCH receiver. MECHANICAL LATCHING (TWIST TO UNLOCK) On/Off/Multispeed— Detachable key, LED INDICATORS On, Off, Multispeed, & Start Switch. 100% BOOM DOWN BOOM UP...

  • Page 20: Speed Control

    CRANE OPERATION ON/OFF/MULTI SPEED E-STOP SWITCH 3 POSITION KEYSWITCH MECHANICAL LATCHING (TWIST TO UNLOCK) LED INDICATORS 100% DECREASE MAX INCREASE MAX SPEED SPEED ACTIVATING E-STOP Press the E-stop Switch. Note: 1. When E-stop is active, the transmitter will remain on but will not operate any functions. This includes truck and crane functions.

  • Page 21: Receiver Layout

    CRANE OPERATION RECEIVER LAYOUT CRANE STATUS AUXILIARY ACTIVE LIFT CYLINDER PRESSURE SYSTEM GOOD FUNCTION ACTIVATED Boom Pressure 174 SP - SPEED PERCENT Boom Down SP=100% HIGH IDLE AUX ENG XXX Boom Angle 43 (deg) HIGH IDLE ACTIVE Boom Load 7% BOOM ANGLE (DEGREES) 100% BOOM LOAD...
  • Page 22 TRANSMITTER SYNCHRONIZATION INSTRUCTIONS 1. The receiver must be shut off and powered down The current address tag must be removed from the harness and the LEARN tag (366823955) will need to be put in its place. 2. After the LEARN tag has been put into place and the receiver is powered up, it will begin to search for the proper Channel and Serial Number of the transmitter.

  • Page 23: Inspection Requirements

    INSPECTION REQUIREMENTS REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE INSPECTION REQUIREMENTS INSPECTION CLASSIFICATION 6. Inspect for proper rope reeving. 7. Inspect electrical wiring and components for 1. Initial inspection. malfunctioning, signs of excessive deterioration, dirt Prior to initial use, all new, altered, modified or and moisture accumulation.

  • Page 24: Inspection Records

    INSPECTION REQUIREMENTS 6. Inspect crane hooks for cracks. 13. Inspect hydraulic filters for evidence of rubber particles on the filter elements indicating possible 7. Inspect travel steering, braking, and locking hose, “O” ring, or other rubber component dete- devices for malfunction. rioration.

  • Page 25: Testing Requirements

    TESTING REQUIREMENTS REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE INSPECTION REQUIREMENTS TESTING SHALL BE PERFORMED BY DESIGNATED PERSONNEL ONLY. Prior to initial use, all new, altered, modified, or extensively repaired cranes shall be tested for compliance with the operational requirements of this crane. Test requirements: 1.

  • Page 26: Maintenance Precautions

    GENERAL REPAIRS AND MAINTENANCE REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE MAINTENANCE AND REPAIR REQUIREMENTS A preventative maintenance program should be 4. If bleeding the hydraulic system is required, run established based on this section and all replacement each crane function until smooth operation of that parts should be obtained from AutoCrane Company.
  • Page 27 GENERAL REPAIRS AND MAINTENANCE 2. Replacement rope shall have a strength rating at 4. During installation care should be exercised to least as great as the original rope furnished or avoid dragging of the rope in the dirt or around recommended by AutoCrane.

  • Page 28: Maintenance Of Batteries

    MAINTENANCE OF BATTERIES Maintenance of Auto Crane unit batteries differs 2. The portion of the plate exposed is not usable. very little from the generally prescribed 3. That portion of the acid remaining becomes more maintenance of any lead acid battery. All batteries...
  • Page 29 MAINTENANCE OF BATTERIES If, after charging, it is noted that the specific gravity 2. Place the battery on charge according to the reading of one cell is 30 points less than any of the manufacturer's instructions. other cells, it may be assumed that the cell is bad and that the battery should be replaced.
  • Page 30 14005H LUBRICATION & MAINTENANCE SCHEDULE CAUTION: Routine maintenance insures trouble-free operation and protects your invest- ment. All warranties are void if maintenance is neglected. 4-8.0 6/15/10...
  • Page 31 2. Once a bolt has been torqued to its rated capacity and then removed; the bolt should be replaced with a new one. 3. Auto Crane Company recommends that this crane be serviced per “Crane Inspection Log” P/N 999978. These logs should be filled in at the intervals noted and kept as a permanent record.
  • Page 32 ROTATION BEARING REPLACEMENT GUIDELINES—14005H All bearings can wear over time. This includes the main rotation bearing on the crane. No pre- cise rules can be given for replacement of the rotation bearing, since many factors are in- volved. However, there are common symptoms seen during crane operation that may be caused by rotation bearing wear.

  • Page 33: Safety Decal Section

    14005H SAFETY DECAL SECTION PART NO.: 040579000 DECAL: OPERATING INSTRUCTIONS FUNCTION: To inform the operator of the proper procedure to follow for safe operation of the crane. USED ON: All Cranes QUANTITY: PLACEMENT: Right side plate PART NO.: 040580000 DECAL: OPERATING TRAINING FUNCTION: To inform the operator of the need to...
  • Page 34 14005H SAFETY DECAL SECTION PART NO.: 040529000 DECAL: ELECTROCUTION HAZARD FUNCTION: To inform the operator of the hazard involved with contacting electrical power lines with crane boom. USED ON: All Cranes QUANTITY: PLACEMENT: Both sides of end of lower boom PART NO.: 040517000 DECAL:...
  • Page 35 14005H SAFETY DECAL SECTION PART NO.: 040587000 USED ON: All cranes equipped with a load sensor. DECAL: LOAD SENSOR, DON'T TAMPER QUANTITY: FUNCTION: To inform the operator that the load PLACEMENT: Both sides of the lift cylinder sensor is pre-set and that tampering near the load sensor with the sensor may cause potentially hazardous situation.
  • Page 36 14005H SAFETY DECAL SECTION PART NO.: 460169000 USED ON: All Cranes equiped with FM controls. DECAL: REMOTE CONTROL QUANTITY: FUNCTION: To inform the operator of failure to PLACEMENT: FRONT OF POWER UNIT follow the saftey precautions may result in equipment failure or serious personal injury.
  • Page 37 NOTES 5-5.0 6/15/10...
  • Page 38 14005H DECAL LAYOUT P/N: 470102021 5-6.0 12/30/10...
  • Page 39 14005H DECAL LAYOUT P/N: 470102021 5-7.0 12/30/10...

  • Page 40: General Dimensions

    14005H GENERAL DIMENSIONS 6-1.0 6/15/10...
  • Page 41 NOTES 6-2.0 6/15/10...

  • Page 42: Mounting And Installation

    14005H MOUNTING AND INSTALLATION 1. Check to make sure the following items are with your crane. Please note the different, model specific, quantities. 2. Pressure and return hoses are not furnished with this crane. The hoses must be provided by the installer and the lengths determined at installation.
  • Page 43 12. Load test the crane to ensure proper functioning and truck stability. 13. Make certain the owner’s manual is delivered to the customer. 14. For additional help: call the service department at the Auto Crane Company (918) 836-0463 (Tulsa, Oklahoma).
  • Page 44 14005H GENERAL ASSEMBLY P/N 470102XXX 7-1.0 6/15/10...
  • Page 45 14005H GENERAL ASSEMBLY 7-2.0 6/15/10...
  • Page 46 14005H PEDESTAL ASSEMBLY NEXSTAR-P/N 4701022XX HYDRAULICS: “HD” PORT: HOIST DOWN “HU” PORT: HOIST UP “CW” PORT: ROTATION CW “CCW” PORT: ROTATION CCW “BU” PORT: LIFT CYL EXTEND “BD” PORT: LIFT CYL RETRACT “EXT” PORT: EXT CYL EXTEND “RET” PORT: EXT CYL RETRACT CYLINDER SEAL KIT: 480988251 (CTD) COUNTER BALANCE CARTRIDGE: 480188100 7-3.0...
  • Page 47 14005H PEDESTAL ASSEMBLY NEXSTAR-P/N: 4701022XX 7-4.0 6/15/10...
  • Page 48 14005H PEDESTAL ASSEMBLY NEXSTAR P/N 4701022XX 7-5.0 6/15/10...
  • Page 49 14005H PEDESTAL ASSEMBLY 4701022XX 7-6.0 6/15/10...
  • Page 50 14005H PEDESTAL ASSEMBLY 4701022XX 7-7.0 6/15/10...
  • Page 51 NOTES 7-8.0 6/15/10...
  • Page 52 14005H BOOM ASSEMBLY P/N: 470050000 CYL SEAL KIT P/N: 480988151 C’BAL P/N: 360153001 7-9.0 6/15/10...
  • Page 53 14005H BOOM ASSEMBLY P/N: 470050000 7-10.0 6/15/10...
  • Page 54 14005H ROTATION GEARBOX P/N: 470003000 7-11.0 6/15/10...
  • Page 55 14005H ROTATION GEARBOX P/N: 470003000 7-12.0 6/15/10...
  • Page 56 14005H HOIST ASSEMBLY P/N: 123416 7-13.0 6/15/10...
  • Page 57 14005H HOIST ASSEMBLY P/N: 123416 7-14.0 6/15/10...
  • Page 58 14005H HOIST ASSEMBLY P/N: 123416 7-15.0 6/15/10...
  • Page 59 14005H TRAVELING BLOCK ASSEMBLY P/N: 470025000 7-16.0 6/15/10...
  • Page 60 14005H MAIN HARNESS P/N: 366823257 [2134] [1346] [1017] [940] 36.5 [927] 33.5 [851] [813] 31.5 [800] 30.5 [775] [610] 21 20 15.5 ENGINE STOP POWER/ENGINE ENGINE STA RT POWER GROUND HIGH IDLE CONNECTOR ID CONNECTOR DESCRIPTION RECIEVER 18 PIN CONNECTION RECIEVER 30 PIN CONNECTION USB CONNECTION CAN CONNECTOR...
  • Page 61 14005H MAIN HARNESS P/N: 366823257 CONN 1 USB PROGRAMMING J3 USB+ PROGRAMMING USB- PROGRAMMING CANH1 GROUND CANL1 NOT USED POWER CANH2 CANL2 DIRTY FILTER J22 BOOM PT J21 +5V VREF SENSOR SUPPLY VOLTAGE VREF COM SENSOR RETURN NOT USED VBATTERY +V BAT FROM IGNITION COMMON -V BAT...
  • Page 62 14005H HYDRAULIC CONTROL VALVE NEXSTAR I P/N: 480989261 8-3.0 6/15/10...
  • Page 63 14005H HYDRAULIC CONTROL VALVE NEXSTAR I P/N: 480989261 8-4.0 12/22/10...
  • Page 64 14005HHYDRAULIC CONTROL VALVE NEXSTAR II P/N: 480959251 8-5.0 6/15/10...
  • Page 65 14005HHYDRAULIC CONTROL VALVE P/N: 480989251 8-6.0 12/22/10...
  • Page 66 14005H COUNTERBALANCE VALVE ADJUSTMENT Counterbalance Valve Adjustment Notice: 1. In an EMERGENCY situation when it 1. With PTO disengaged and boom properly becomes necessary to lower the boom without flow supported, remove the plug on the present, the CB valve adjustment can be turned in counterbalance valve.

  • Page 67: Valve Override Operation

    14005H VALVE OVERRIDE OPERATION 9-2.0 6/15/10...

  • Page 68: Troubleshooting Chart

    14005H TROUBLESHOOTING CHART SECTION UNDER DEVELOPMENT 9-3.0 6/15/10...
  • Page 69 14005H ERROR CODE TROUBLESHOOTING CHART 9-4.0 6/15/10...

  • Page 70: Electrical Troubleshooting Chart

    14005H ELECTRICAL TROUBLESHOOTING CHART 9-5.0 6/15/10...
  • Page 71 14005H ELECTRICAL TROUBLESHOOTING CHART 9-6.0 6/15/10...
  • Page 72 14005H HYDRAULIC TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE DIAGNOSIS SOLUTION CRANE MOVES JAMMED CARTRIDE TRY TO MANUALLY OVERRIDE VALVE REPLACE CARTRIGE UNEXPECTEDLY IF UNABLE TO MOVE STEM. CARTRIDGE IS JAMMED COUNTER‐BALANCE SET ADJUST THE COUNTER‐BALANCE OUT CONTACT AUTOCRANE FOR PROPER SETTING  TOO LOW (BOOM‐UP & TO SEE IF MOVEMENT STOPS. OF COUNTER‐BALANCE. YOU MAY NEED TO  BOOM‐DN ) REFERENCE PG. 9.1 FOR PROCESS. REPLACE COUTER‐BALANCE. CONTAMINATE IN CARTRIGE VALVE STICKS IN CERTAIN POSITIONS REFERENCE PG. 9‐8 FOR  CLEANING PROCEDURE NO FUNTION  PTO NOT ENGAGED CHECK PTO ACTIVATION LIGHT ENGAGE PTO OPERATES ON CRANE USALLY LOCATED IN CAB CRANE DIVERTER VALVE IF USING AUTOCRANE OUTRIGGERS, ENGAGE CRANE DIVERTER VAVLE NOT ENGAGED  CHECK CRANE DIVERTER VALVE  LOCATED AT THE OUTRIGGER VALVE. HYDRAULIC TANK IS LOW ...
  • Page 73 14005H CARTRIDGE MAINTENANCE • Clean the area around the valve spool to be removed from the valve bank • Remove the valve spool from the valve bank being careful not to touch or hit surrounding objects • Carefully remove any visible debris from the valve spool •...
  • Page 74 14005H LOAD CHART P/N 470102026 9-9.0 6/15/10...
  • Page 76 PREVENTATIVE MAINTENANCE PAINT FINISH PREVENTIVE MAINTENANCE INSTRUCTIONS The paint finish on Auto Crane products can become damaged during normal use when chipped, scratched, exposed to harsh chemicals, cleaned with high pressure washers, etc. During periods when the truck is exposed to salt or other corrosive chemicals, Auto Crane products should be washed weekly.

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