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OWNERS MANUAL
Serial No. _______________________________________
Mailing Address:
P.O. Box 580697
Tulsa, OK 74158-0697
HC-12S
NEXSTAR III
Physical Address:
4707 N. Mingo Rd.
Tulsa, OK 74117-5904
1
Phone: 1-800-777-2760
Fax: (918) 269-6688
http://www.autocrane.com
475000103-0816-A
Courtesy of CraneMarket.com
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Summary of Contents for Auto Crane HC-12S
- Page 1 HC-12S NEXSTAR III OWNERS MANUAL Serial No. _______________________________________ Phone: 1-800-777-2760 Mailing Address: Physical Address: P.O. Box 580697 4707 N. Mingo Rd. Fax: (918) 269-6688 http://www.autocrane.com Tulsa, OK 74158-0697 Tulsa, OK 74117-5904 475000103-0816-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 immediately update the manual.
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Page 3: Table Of Contents
ROTATION ..................................8 3.2 HC-12S NEXSTAR III, GENERAL DIMENSIONS ......................9 3.3 LOAD CHART ................................10 3.4 HC-12S NEXSTAR III DECAL LAYOUT, P/N 460179026 ....................11 4.1 QUALIFICATIONS AND OPERATING PRACTICES ......................12 4.2 OPERATORS ................................12 4.3 QUALIFICATIONS FOR OPERATORS ........................... 12 4.4 CONDUCT OF OPERATORS ............................ - Page 4 7.6.2 AXIAL PLAY ALLOWANCE CHECK PROCEDURE ....................35 7.7 HC-12S NEXSTAR III, CARTRIDGE MAINTENANCE ..................... 36 8.1 CRANE MOUNTING AND INSTALLATION ........................37 8.1.1 HC-12S NEXSTAR III, COUNTERBALANCE VALVE ADJUSTMENT ................39 8.2 EMERGENCY CRANE OPERATION ..........................39 9.1 DRAWINGS AND ASSEMBLIES ............................40 HC-12S NEXSTAR III, GENERAL ASSEMBLY P/N: 475000003 .....................
- Page 5 HC-12S NEXSTAR III, HOIST ASSEMBLY P/N: 123435 ......................52 HC-12S NEXSTAR III, HOIST ASSEMBLY P/N: 123435 ......................53 HC-12S NEXSTAR III, TRAVELING BLOCK ASSEMBLY P/N: 475000300 ................54 HC-12S NEXSTAR III, MAIN HARNESS P/N: 366823220 ..................... 55 HC-12S NEXSTAR III, ELECTRICAL SCHEMATIC P/N: 366823221 ..................56 HC-12S NEXSTAR III, HYDRUALIC CONTROL P/N: 480989251 ...................
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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
60-amp alternator with a 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: 24.5 in. (0.62 m) • Height: 36.0 in. (0.91 m) • Length: 14 ft. 8 in. (4.47 m), stored length. • Weight: 2,023 lbs. (918 kg) CAPACITY • 60,000 ft-lbs (8.3 ton-m) • Ft-lbs = horizontal distance from centerline of rotation to free hanging weight (feet) x amount of weight (pounds). REACH •... -
Page 9: Hc-12S Nexstar Iii, General Dimensions
3.2 HC-12S NEXSTAR III, GENERAL DIMENSIONS Figure 1. General Dimensions Courtesy of CraneMarket.com... -
Page 10: 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. -
Page 11: Hc-12S Nexstar Iii Decal Layout, P/N 460179026
3.4 HC-12S NEXSTAR III DECAL LAYOUT, P/N 460179026 Courtesy of CraneMarket.com... -
Page 12: 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 13: 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. -
Page 14: 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. The Danger Zone may be entered after confirmation by an appointed person the electrical distribution and transmission lines are de-energized and visibly grounded at the point work. -
Page 15: 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 16: 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 17: Nexstar Iii Operation
5.1 NEXSTAR III OPERATION This section describes the general operation for cranes with the NEXSTAR III control system. Before operating the Remote Control, read and understand all safety information in this manual, any manual supplements, and any applicable local, state, or federal rules and regulations. Never drive with a load suspended from the crane. -
Page 18: Remote Control Layout
5.3 REMOTE CONTROL LAYOUT Figure 4. Nexstar III Remote Control 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 19: Display Screen Layout
5.4 DISPLAY SCREEN LAYOUT Figure 5. 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. -
Page 20: 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 21: 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. -
Page 22: Nexstar Iii Troubleshooting
6.1 NEXSTAR III TROUBLESHOOTING 6.1.1 TROUBLESHOOTING FLOW CHART Table 2. Troubleshooting Flow Chart Courtesy of CraneMarket.com... -
Page 23: 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 Batteries are dead or installed backwards; facing out. -
Page 24: 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 corrected the alarm will clear S2 TEMP OUT OF Outside of operating temperature All outputs will be disabled... -
Page 25: Nexstar Iii Mechanical Troubleshooting Table
Pto not engaged Check PTO activation light, usually Engage PTO located in the cab NO FUNCTION Crane diverter valve not Is using Auto Crane outriggers, check Engage crane diverter valve OPERATES ON engaged the crane diverter valve located at the THE CRANE... -
Page 26: Nexstar Iii Electrical Troubleshooting Table
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 stops depressed the button at the time of movement. If it was not depressed, replace the transmitter Short in wiring harness Unexpected movement would only Verify there is no damage to the... - Page 27 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. INOPERABLE Bad coil or damaged wire Screen will display 0% next to sp but the Switch coil with another function.
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Page 28: 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 29: 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 30: 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 31: 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 32: Paint Finish Maintenance
7.3.6 PAINT FINISH MAINTENANCE The paint finish on Auto Crane products can become damaged during normal use when chipped, scratch, exposed to harsh chemicals, cleaned with pressure washers, or similar. During periods when the truck is exposed to salt or other corrosive chemicals, wash Auto Crane products weekly. -
Page 33: Lubrication And Maintenance Schedule
7.4 LUBRICATION AND MAINTENANCE SCHEDULE SERVICE INSTRUCTIONS DAILY WEEKLY 3 MONTHS 6 MONTHS YEARLY PERFORMED Load Hook Inspect hook and latch for deformation, cracks, and corrosion. Cable Drum Ensure cable is wound evenly on drum. Hoist/Boom Check for flattening, kinks, broken Cable strands. -
Page 34: 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 35: Rotation Bearing Replacement
3. If the difference between the two measurements exceeds the specification, replace the bearing. Crane Model Axial Play Allowance Rotation Bearing Replacement Kit 2003/3203/4004 1.5 mm 320878010 HC-12S, HC-6, HC-7, HC-8, HC-9, 1/16 in. 480023010 8406 HC10 1.8 mm 372064010 HC-12, HC-14 2.3 mm... -
Page 36: Hc-12S Nexstar Iii, Cartridge Maintenance
7.7 HC-12S 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 operation. 1. Clean the area around the valve spool before it is removed from the valve bank. -
Page 37: 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 38 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.
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Page 39: Hc-12S 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. If the proper pressure reading cannot be obtained, please contact your Auto Crane distributor for assistance. 9. Disengage the PTO. -
Page 40: Drawings And Assemblies
9.1 DRAWINGS AND ASSEMBLIES HC-12S NEXSTAR III, GENERAL ASSEMBLY P/N: 475000003 Courtesy of CraneMarket.com... -
Page 41: Hc-12S Nexstar Iii, General Assembly P/N: 475000003
HC-12S NEXSTAR III, GENERAL ASSEMBLY P/N: 475000003 Courtesy of CraneMarket.com... -
Page 42: Hc-12S Nexstar Iii Pedestal Assembly P/N: 475200003
HC-12S NEXSTAR III PEDESTAL ASSEMBLY P/N: 475200003 Courtesy of CraneMarket.com... -
Page 43: Hc-12S Nexstar Iii Pedestal Assembly P/N: 475200003
HC-12S NEXSTAR III PEDESTAL ASSEMBLY P/N: 475200003 Courtesy of CraneMarket.com... -
Page 44: Hc-12S Nexstar Iii Pedestal Assembly P/N: 475200003
HC-12S NEXSTAR III PEDESTAL ASSEMBLY P/N: 475200003 Courtesy of CraneMarket.com... -
Page 45: Hc-12S Nexstar Iii Pedestal Assembly P/N: 475200003
HC-12S NEXSTAR III PEDESTAL ASSEMBLY P/N: 475200003 Courtesy of CraneMarket.com... -
Page 46: Hc-12S Nexstar Iii Pedestal Assembly P/N: 475200003
HC-12S NEXSTAR III PEDESTAL ASSEMBLY P/N: 475200003 Courtesy of CraneMarket.com... -
Page 47: Hc-12S Nexstar Iii, Boom Assembly P/N: 460178100
HC-12S NEXSTAR III, BOOM ASSEMBLY P/N: 460178100 Courtesy of CraneMarket.com... -
Page 48: Hc-12S Nexstar Iii, Boom Assembly P/N: 460178100
HC-12S NEXSTAR III, BOOM ASSEMBLY P/N: 460178100 Courtesy of CraneMarket.com... -
Page 49: Hc-12S Nexstar Iii, Rotation Gearbox P/N: 160414
HC-12S NEXSTAR III, ROTATION GEARBOX P/N: 160414 Courtesy of CraneMarket.com... -
Page 50: Hc-12S Nexstar Iii, Rotation Gearbox P/N: 160414
HC-12S NEXSTAR III, ROTATION GEARBOX P/N: 160414 328165 Courtesy of CraneMarket.com... -
Page 51: Hc-12S Nexstar Iii, Hoist Assembly P/N: 123435
HC-12S NEXSTAR III, HOIST ASSEMBLY P/N: 123435 Courtesy of CraneMarket.com... -
Page 52: Hc-12S Nexstar Iii, Hoist Assembly P/N: 123435
HC-12S NEXSTAR III, HOIST ASSEMBLY P/N: 123435 Courtesy of CraneMarket.com... -
Page 53: Hc-12S Nexstar Iii, Hoist Assembly P/N: 123435
HC-12S NEXSTAR III, HOIST ASSEMBLY P/N: 123435 Courtesy of CraneMarket.com... -
Page 54: Hc-12S Nexstar Iii, Traveling Block Assembly P/N: 475000300
HC-12S NEXSTAR III, TRAVELING BLOCK ASSEMBLY P/N: 475000300 Courtesy of CraneMarket.com... -
Page 55: Hc-12S Nexstar Iii, Main Harness P/N: 366823220
HC-12S NEXSTAR III, MAIN HARNESS P/N: 366823220 96" 78" 56" 48" 32" 24" ENGINE S ENGINE S TAR T POW ER GROUND HIGH IDLE POWER/ ENGI NE 15" 27" J24 ON LY MESH LOOM 6" 19 8 7 TAPE GASKET &... -
Page 56: Hc-12S Nexstar Iii, Electrical Schematic P/N: 366823221
SENSOR J17 ALARM LIGHT J19 HORN J25 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 SUPP LY VO LTAGE VREF COM SENSOR RETURN NOT USED VBATTERY... -
Page 57: Hc-12S Nexstar Iii, Hydrualic Control P/N: 480989251
HC-12S NEXSTAR III, HYDRUALIC CONTROL P/N: 480989251 Courtesy of CraneMarket.com... -
Page 58: Hc-12S Nexstar Iii, Hydrualic Control P/N: 480989251
HC-12S NEXSTAR III, HYDRUALIC CONTROL P/N: 480989251 Courtesy of CraneMarket.com...
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