Auto Crane 3203EH Owner's Manual
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Auto Crane 3203EH 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
3203EH
NEXSTAR
Manual No. 320991031
Phone 1-800-777-2760
Fax (918) 269-6688
http://www.autocrane.com

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  • Page 1 3203EH NEXSTAR OWNERS MANUAL Manual No. 320991031 Serial No. __________________ Mailing Address: P.O. Box 580697 Phone 1-800-777-2760 Tulsa, OK 74158-0697 Fax (918) 269-6688 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 additional 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 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: Table Of Contents

    3203EH TABLE OF CONTENTS INTRODUCTION 1-1.0 GENERAL SPECIFICATIONS 1-4.0 SAFETY TIPS AND PRECAUTIONS 2-1.0 OPERATING PRACTICES & WARNINGS 2-3.0 QUALIFICATIONS FOR OPERATORS 2-4.0 OPERATION OF UNIT / OUTRIGGERS 3-1.0 TEMPERATURE RANGE 3.1.1 CRANE OPERATION 3-3.0 INSPECTION 4-1.0 TESTING 4-3.0 MAINTENANCE 4-4.0...

  • Page 9: Introduction

    The operator should If, through no fault of Auto Crane Company, it is exercise care when loading the vehicle. necessary to send an experienced factory Distributing the payload on the vehicle evenly...
  • Page 10 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: General Specifications

    3203EH GENERAL SPECIFICATIONS 1-3.0 1/27/11...

  • Page 12: Safety Tips And Precautions

    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: Operating Practices & Warnings

    WARNING! NEVER hold any Control Select Switch on that will cause unsafe operating conditions! 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...

  • 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: Operation Of Unit / Outriggers

    (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 RECOMMENDED OPERATING TEMPERATURE RANGE—SMALL EH CRANES OIL TEMPERATURE 200° F (93.3°C) 180° F (82.2°C) 160° F (71.1° C) 140° F (60° C) 120° F (48.9°C) 5W20 ANTI-WEAR HYDRAULIC OIL OR 100° F (37.8°C) EQUIVALENT 80° F (26.7° C) HySyn ISO32 SYNTHETIC HYDRAULIC OIL OR 60°...

  • Page 20: Crane Operation

    CRANE OPERATION TRANSMITTER LAYOUT E-stop Switch—Push to activated, Twist to release. Shuts down all outputs from receiver. On/Off/Multispeed— Detachable key, On, Off, Multispeed, & Start Switch. Crane Controls—Proportional push but- ton. The function speed increases the more the button is pressed. Functions include Boom Up/Down, Rotate CW-CCW, Hoist Up/Down, Boom Extend, Retract.
  • Page 21 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 22 CRANE OPERATION RECEIVER LAYOUT (FM UNITS ONLY) CRANE STATUS—shows current status of the crane. If any alarms are occurring they will be displayed here. Otherwise, it will say system good. Note: Reference Troubleshooting section for alarm descriptions. LIFT CYLINDER PRESSURE—Current pressure in the lift cylinder in PSI FUNCTION ACTIVATED SP-SPEED PERCENT—Current function activated and percent of max speed for that particular function.
  • Page 23 CRANE OPERATION RECEIVER LAYOUT (TETHERED UNITS ONLY) POWER—(steady green) turns on with power. CRANE ENABLED—(green 1 pulse/second) Crane enable “Inactive” Need to wake up transmitter before hitting function (green 4 pulse/second) Crane enable “Active” Ready for a function to be selected J1939 SIGNAL—...

  • Page 24: Inspection

    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 25 INSPECTION REQUIREMENTS 13. Inspect hydraulic filters for evidence of rubber 6. Inspect crane hooks for cracks. 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 26: Testing

    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 27 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 28 ROTATION BEARING REPLACEMENT GUIDELINES—2003-4004 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 29 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 30: Maintenance

    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 31 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 32 3203EH LUBRICATE AND MAINTENANCE SCHEDULE SERVICE PERFORMED NOTES DAY WKLY 3 MOS 6 MOS YEAR INSPECT HOOK & LATCH FOR DEFORMATION, LOAD HOOK CRACKS, & CORROSION MAKE SURE CABLE IS WOUND EVENLY ON CABLE DRUM DRUM HOIST / BOOM CHECK FOR FLATTENING, KINKS, & BROKEN...

  • Page 33: Lubrication And Maintenance Schedule

    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 34 ROTATION BEARING REPLACEMENT GUIDELINES—2003-4004 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 35: Safety Decal Section

    3203EH 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:...
  • Page 36 3203EH 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.:...
  • Page 37 3203EH 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...
  • Page 38 3203EH 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 39 3203EH DECAL LAYOUT P/N: 320991300 5-5.0 04/06/11...
  • Page 40 3203EH DECAL LAYOUT P/N: 320991300 TOP OF LABEL INSIDE COVER 5-6.0 04/06/11...

  • Page 41: General Dimensions

    3203EH GENERAL DIMENSIONS 6-1.0 1/27/11...

  • Page 42: Mounting And Installation

    3203EH MOUNTING AND INSTALLATION 1. Check to make sure the following items are with your crane. Please note the different, model specific, quantities. NOTES: 366823266 SHIPS WITH ALL FM PRX UNITS, 366823940 SHIPS WITH ALL HW PRX UNITS, 366823945 SHIPS WITH ALL HW PR UNITS, 320991266 SHIPS WITH ALL FM PR UNITS 6-2.0...
  • Page 43 13. Load test the crane to ensure proper functioning and truck stability. 14. Make certain the owner’s manual is delivered to the customer. 15. For additional help: call the service department at the Auto Crane Company (918) 836-0463 (Tulsa, Oklahoma).
  • Page 44 NOTES 6-4.0...

  • Page 45: General Assembly

    3203EH GENERAL ASSEMBLY P/N 320991XXX 7-1.0 1/27/11...
  • Page 46 3203EH GENERAL ASSEMBLY 7-2.0 1/27/11...

  • Page 47: Pedestal Assembly

    3203EH PEDESTAL ASSEMBLY P/N 3209912XX 7-3.0 1/27/11...
  • Page 48 3203EH PEDESTAL ASSEMBLY P/N 3209912XX 7-4.0 1/27/11...
  • Page 49 3203EH PEDESTAL ASSEMBLY P/N 3209912XX 7-5.0 1/27/11...
  • Page 50 3203EH PEDESTAL ASSEMBLY P/N 3209912XX 7-6.0 1/27/11...
  • Page 51 3203EH PEDESTAL ASSEMBLY P/N 3209912XX 7-7.0 1/27/11...
  • Page 52 NOTES 7-8.0 1/12/10...

  • Page 53: Boom Assembly

    3203EH BOOM ASSEMBLY P/N: 320988100/101 PR,PRX 7-9.0 1/12/10...
  • Page 54 3203EH BOOM ASSEMBLY P/N: 320988100/101 PR,PRX 7-10.0 1/27/11...
  • Page 55 3203EH PRFX BOOM ASSEMBLY P/N: 320990100 PRFX 7-11.0 1/27/11...
  • Page 56 3203EH PRX BOOM ASSEMBLY 3203EH PRFX BOOM ASSEMBLY P/N: P/N: 320990100 7-12.0 1/27/11...
  • Page 57 3203EH PR/PRX HOIST ASSEMBLY P/N: 126201 7-13.0 1/27/11...
  • Page 58 6406H HOIST ASSEMBLY 3203EH PR/PRX HOIST ASSEMBLY P/N: 123314 P/N: 126201 7-14.0 1/27/11...
  • Page 59 NOTES 7-15.0 1/27/11...

  • Page 60: Traveling Block Assembly

    3203EH TRAVELING BLOCK ASSEMBLY P/N: 320433000 7-16.0 1/27/11...
  • Page 61 NOTES...
  • Page 62 3203EH MAIN HARNESS TETHERED P/N: 320991267 8-1.0 1/27/11...
  • Page 63 3203EH MAIN HARNESS TETHERED P/N: 320991015 8-2.0 1/27/11...
  • Page 64 3203EH MAIN HARNESS FM P/N: 320991257 8-3.0...
  • Page 65 3203EH MAIN HARNESS FM P/N: 320991010 8-4.0...
  • Page 66 3203EH HYDRAULIC CONTROL VALVE NEXSTAR I P/N: 320991261 8-5.0 1/27/11...
  • Page 67 6406H HYDRAULIC CONTROL VALVE 3203EH HYDRAULIC CONTROL VALVE NEXSTAR I P/N: 366823261 NEXSTAR I P/N: 320991261 8-6.0 1/27/11...
  • Page 68 3203EH HYDRAULIC CONTROL VALVE NEXSTAR II P/N: 320991251 8-7.0 1/27/11...
  • Page 69 6406H HYDRAULIC CONTROL VALVE 3203EH HYDRAULIC CONTROL VALVE P/N: 366823251 NEXSTAR II P/N: 320991251 8-8.0 1/27/11...

  • Page 70: Power Unit

    3203 NEXSTAR POWER UNIT 320991270 ITEM PART DESCRIPTION NUMBER 320991272 TANK, NEXSTAR 3203/4004EH 320991274 GLASS, SIGHT USED W/320991270 320991275 CAP,FILLER USED W/ 320991270 320991908 GAUGE, FILTER USED W/320991270 320991276 STARTER, MOTOR USED W/320991270 320991271 MOTOR, NEXSTAR 3203/4004EH 320991277 VALVE, RELIEF USED W/320991270 320991910 FILTER, ELEMENT SMALL EH NEXSTAR 8-9.0...

  • Page 71: Counterbalance Valve

    3203EH 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 72 3203EH MANUAL OVERRIDE PROCEDURE 9-2.0 3/15/11...
  • Page 73 3203EH TROUBLESHOOTING CHART CRANE DOES NOT OPERATE CORRECTLY DOES THE CONTROL GO TO ERROR CODE BOX SHOW REFERENCE TABLE AN ERROR? PAGE 9.4—FM UNITS PAGE 9.5—TH UNITS DOES IT DOES THE STOP MOVING GO TO ELECTRICAL CRANE MOVE TROUBLE SHOOTING...
  • Page 74 3203EH ERROR CODE TROUBLESHOOTING CHART FM UNITS ONLY 9-4.0 1/27/11...
  • Page 75 3203EH ERROR CODE TROUBLESHOOTING CHART TETHERED UNITS ONLY LED LABEL COLOR FLASH CAUSE SOLUTION RATE ERROR STEADY VEHICLE BATTERY VOLTAGE BELOW 9 VOLTS CHECK BATTERY FLUID LEVEL CHECK VOLTAGE DROP ACROSS POWER WIRE MAY NEED TO INCREASE WIRE SIZE VERIFY TRUCK IS RUNNING WHILE OPERATING...
  • Page 76 3203EH ELECTRICAL TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE DIAGNOSIS SOLUTION CRANE MOVES JAMMED TRANSMITTER ACTIVATE E-STOP TO SEE IF VERIFY THAT NOTHING WAS DEPRESSING THE UNEXPECTADLY BUTTON MOVEMENT STOPS BUTTON AT THE TIME OF MOVEMENT. IF IT WAS NOT DEPRESSED THEN REPLACE TRANSMITTER...
  • Page 77 3203EH ELECTRICAL TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE DIAGNOSIS SOLUTION ALL FUNCTIONS ARE PESSURE TRANSDUCER IS CHECK LCD SCREEN. IT WOULD READ VERIFY THAT PRESSURE TRANSDUCER LOCATED INOPERABLE EXCEPT UNPLUGGED (FM UNITS) “BOOM PT ERROR” ON THE LIFT CYLINDER VALVE BLOCK IS...
  • Page 78 3203EH HYDRAULIC TROUBLESHOOTING CHART PROBLEM POSSIBLE CAUSE DIAGNOSIS SOLUTION CRANE MOVES JAMMED CARTRIDGE TRY TO MANUALLY OVERRIDE VALVE REPLACE CARTRIDGE 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 CARTRIDGE 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.
  • Page 79 3203H 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 80 3203EH LOAD CHART P/N 320988005 9-10.0 1/27/11...
  • Page 81 Single Line 3203 Cranes. Instructions and decals are provided for conversion to single line cranes SINGLE LINE KIT , 3203 P/N: 320988015 ITEM NO. PART NO. DESCRIPTION 320988011 3203EH SINGLE LINE INSTRUCTIONS 320988010 DECAL, LOAD CHART 3203PR/PRX/H SINGLE LINE 10-1.0 05/12/17...
  • Page 82 3203PR/PRX CONVERSION TO SINGLE LINE CONVERTING TO SINGLE LINE ON 3203EH CRANES 1. REMOVE HOOK FROM TRAVELING BLOCK BY REMOVING PIN 2. REMOVE TRAVELING BLOCK FROM ROPE 3. DISCONNECT THE ROPE FROM THE CROWN BY REMOVING PIN 4. PIVOT SINGLE LINE BARS 180 DEGREES THEN ATTACH HOOK TO THE BARS USING THE PIN REMOVED IN STEP 1 5.
  • Page 83 3203PR/PRX LOAD CHART SINGLE LINE P/N: 320988010 3203PR 3203PRX 1600 NOTE: WEIGHT OF LOAD HANDLING DEVICES ARE PART OF 1345 THE LOAD AND MUST BE DEDUCTED FROM THE CAPACITY. 1600 1600 1215 1600 75° 1600 60° 1000 1600 45° ATTENTION! 1520 30°...

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