Auto Crane NEXSTAR III EHC-5 Owner's Manual
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Auto Crane NEXSTAR III EHC-5 Owner's Manual

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OWNER'S MANUAL
EHC - 5
NEXSTAR III
360683006-0120-C
Serial No.
Mailing Address:
Phone: 1-800-777-2760
Physical Address:
P.O. Box 580697
Fax: (918) 269-6688
4707 N. MIngo Rd.
Tulsa, OK
74158697
http://www.autocrane.com
Tulsa, OK 74117-5904

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Summary of Contents for Auto Crane NEXSTAR III EHC-5

  • Page 1 OWNER’S MANUAL EHC - 5 NEXSTAR III 360683006-0120-C Serial No. Mailing Address: Phone: 1-800-777-2760 Physical Address: P.O. Box 580697 Fax: (918) 269-6688 4707 N. MIngo Rd. Tulsa, OK 74158697 http://www.autocrane.com Tulsa, OK 74117-5904...
  • Page 3 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. If in doubt, please call your local Auto Crane distributor for the most up-to-date information.

  • Page 5: Table Of Contents

    Table of Contents SECTION PAGE Safety Tips And Precautions ............Introduction ................General Specifications ..............Dimensions ..............Capacity ............... Reach ................Cable ................Chassis And Mounting Requirements ......... Electrical System Requirements ........Rotation ................ Load Chart ................... 5 Qualifications And Operating Practices ........Operators ..............5.2 Qualifications For Operators ..........
  • Page 6 Table of Contents SECTION PAGE 8.2 Inspection Classification ..........Frequent Inspection ............Periodic Inspection ............Cranes Not In Regular Use ..........Inspection Records ............Testing Requirements ............. General Repairs And Maintenance ........Maintenance Precautions ..........8.10 Adjustments And Repairs ..........8.11 Lubrication ..............8.12 Rope Replacement ............
  • Page 7 Table of Contents SECTION PAGE Harness ..................Electrical Schematic ..............ANNEX PAGE Recommended Operating Temperature ........Eccentric Ring Adjustment ............EHC-5 NEXSTAR III...
  • Page 8 EHC-5 NEXSTAR III...

  • Page 9: Safety Tips And Precautions 1

    Do not attempt to lift or drag a load from the side! The boom can fail far below its rated capacity. WARNING 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 10: Introduction

    The cranes are attached to your 12-volt truck electrical system. The crane is another highly efficient Auto Crane product. The use of a maintenance-free battery is not recommended on any Auto Crane product. The recommended alternator and battery that will give the longest life with the most useful duty cycle is a 60-amp alternator with a 500 cold cranking amp battery. These specifications should be considered minimum.
  • Page 11 If you require additional information, please contact the Auto Crane Company at the following telephone 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.

  • Page 12: Dimensions

    3 General Specifications 3.1 DIMENSIONS • Width: 22.375 in (0.57 m) • Height: 35.75 in (0.91 m) • Length: 13 ft 1 in (3.99 m), stored length. • Weight: 1,470 lbs (667 kg) 3.2 CAPACITY • 25,000 ft-lbs (3.46 ton-m) • Ft-lbs = horizontal distance from center line of rotation to free hanging weight (feet) x amount of weight (pounds). 3.3 REACH • Second boom reach: 10 ft. 4 in. to 16 ft. 4 in. • Third boom reach: 16 ft. 4 in. to 20 ft. 4 in. 3.4 CABLE • 180 ft. (24.4 m) of 5/16 in. (8 mm) diameter aircraft quality cable. This cable has a single line breaking strength of 9,800 lbs. (4,445 kg). 3.5 CHASSIS AND MOUNTING REQUIREMENTS • 14,500 lbs. (6,577 kg) GVWR minimum. • 360,000 in-lbs. Resistive Bending Moment (RBM) • 7/8”, Grade 8-UNF Bolts. Tightened to 501 ft. lbs. • 9” Mounting hole to run electrical lines to the crane from the body. 3.6 ELECTRICAL SYSTEM REQUIREMENTS • Voltage: 12 VDC • Alternator: 150 amps minimum • Battery: 100 minute reserve capacity minimum. Maintenance Type battery...
  • Page 13 Load Chart 4 WARNING 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 14: Qualifications For Operators

    B. Possess the knowledge of emergency procedures and implement it. 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. EHC-5 NEXSTAR III...

  • Page 15: Conduct For Operators

    Qualifications and Operating Practices 5 5.3 CONDUCT OF OPERATORS 1. The operator shall not engage in any practice, which will divert his attention while actually operating the crane. 2. Each operator shall be responsible for those operations under the operator’s direct control. Whenever there is any doubt as to safety, the operator shall consult with the supervisor before handling the loads.

  • Page 16: Operating Near Electrical Power Lines

    5 Qualifications and Operating Practices 4. During lifting care shall be taken that: A. There is no sudden acceleration or deceleration of the moving load. B. When rotating the crane, sudden starts and stops shall be avoided. Rotational speed shall be such that the load does not swing out beyond the radius at which it can be controlled.
  • Page 17 Qualifications and Operating Practices 5 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. B. The Danger Zone may be entered if insulating barriers are erected to prevent physical contact with the lines. These can’t be a part of or attached to the crane.

  • Page 18: Preparing The Crane For Operation

    B. 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.
  • Page 19 Qualifications and Operating Practices 5 9. Remove the remote control from the cab or storage area. Power the remote control on. Detach the hook from the dead man. 10. The crane is now ready for operation. DURING OPERATION 1. Always boom up before rotating so the boom will clear the boom support. 2.

  • Page 20: Nexstar Lll Operation

    6 NexStar lll Operation This section describes the general operation for cranes with the NEXSTAR lll control system. WARNING 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. WARNING Never drive with a load suspended from the crane. WARNING Ensure personnel and objects are clear of the crane path during operation.

  • Page 21: Remote Control Layout

    NexStar lll Operation 6 6.5 REMOTE CONTROL LAYOUT Nextstar lll 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. 3.

  • Page 22: Display Screen Layout

    Watchdog Timer – The black dot should always be moving in a diagonal. If the timer stops, contact your Auto Crane representative. Signal Strength and Battery Life – Displays the signal strength coming from the crane. The approximate range is 300 ft. The battery displays the percent remote control battery life remaining.

  • Page 23: Speed Selection

    NexStar lll Operation 6 6.7 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. Move the Left Joystick down to decrease the max speed. 3.

  • Page 24: Operation-Valve Override

    6 NexStar lll Operation 6.10 COUNTERBALANCE VALVE ADJUSTMENT/OVERRIDE PROCEDURE 1. With PTO disengaged and boom properly supported, remove the plug on the counterbalance valve. Install a pressure gauge (0-3000 PSI) into the port. 2. Engage PTO and insure pump flow is 8 to 9 GPM. With no load on boom, boom up to an angle of 70 degrees. Boom down and note pressure. If pressure reading is not approximately 1300 PSI, the counterbalance valve requires adjustment.

  • Page 25: Transmitter Layout

    NexStar lll Operation 6 6.11 Transmitter Layout LABEL DIRECTION FUNCTION GRAPHIC DESCRIPTION Sends a 12VDC signal from crane to start vehicle Engine Start Down Engine Stop Sends a 12VDC signal from crane to stop vehicle Boom Up function Down Boom Down Rotate CCW Right Rotate CW...

  • Page 26: Nexstar Lll Troubleshooting

    7 NexStar lll Troubleshooting 7.1 TROUBLESHOOTING FLOW CHART CRANE DOES NOT OPERATE CORRECTLY IS THERE GO TO ERROR CODE AND ERROR TROUBLESHOOTING CODE? CHART DOES IT DOES THE CRANE GO TO ELECTRICAL STOPMOVING WHEN MOVE UNEXPECTEDLY TROUBLESHOOTING YOU UNPLUGTHE WHEN A FUNCTION IS CHART CORRESPONDING NOT SELECTED?

  • Page 27: Nexstar Lll Remote Control Troubleshooting Table

    NexStar lll Troubleshooting 7 7.2 NEXSTAR lll REMOTE CONTROL TROUBLESHOOTING TABLE PROBLEM POSSIBLE REASON ACTION REMOTE CONTROL WILL REMOTE CONTROL EMERGENCY STOP ENSURE THE E-STOP SWITCH IS NOT TURN ON SWITCH IS DOWN OR PRESSED. PULLED UP. BATTERIES ARE DEAD OR INSTALLED ENSURE ALL SWITCHES, BUTTONS, BACKWARDS;...

  • Page 28: Nexstar Lll Error Code Table

    7 NexStar lll Troubleshooting 7.3 ERROR CODE TABLE ERROR CAUSE DIAGNOSIS SOLUTION CODE S0. E-STOP E-STOP ACTIVATED ALL OUTPUTS DEACTIVATE E-STOP PER OPERATION ACTIVE WILL BE PROCEDURES. DISABLED S1. CAN RX TO RECEPTION OF A CAN ALL OUTPUTS DETERMINE WHY MESSAGE(S) IS MESSAGE TIMED OUT WILL BE (ARE) NOT BEING RECEIVED.
  • Page 29 NexStar lll Troubleshooting 7 7.3 ERROR CODE TABLE ERROR CAUSE EFFECT SOLUTION CODE A8. 100% REACHED 100% OF RATED DISABLES REDUCE LOAD BY EITHER RETRACTING, LOAD ALARM CAPACITY BOOM DOWN, BOOMING UP, OR HOISTING DOWN. EXTEND, AND HOIST UP A9. SLOW LIFT CYLINDER HAS REDUCES THIS IS A SAFETY FEATURE THAT ROTATE ACT...

  • Page 30: Nexstar Lll Electrical Troubleshooting Table

    7 NexStar lll Troubleshooting 7.4 ELECTRICAL TROUBLESHOOTING TABLE ERROR CAUSE EFFECT SOLUTION CODE CRANE MOVES JAMMED ACTIVATE E-STOP TO SEE IF VERIFY THAT NOTHING WAS UNEXPECTEDLY TRANSMITTER MOVEMENT STOPS. ACTIVATING THE FUNCTION AT THE BUTTON TIME OF MOVEMENT. IF IT WAS NOT ACTIVATED THEN REPLACE TRANSMITTER.
  • Page 31 NexStar lll Troubleshooting 7 7.4 ELECTRICAL TROUBLESHOOTING TABLE ERROR CAUSE EFFECT SOLUTION CODE ANTI-2 BLOCK CHECK SCREEN FOR ERROR VERIFY THAT THE TRAVELING BLOCK FOLLOWING CODE. IT WOULD READ ANTI-2 IS NOT IN CONTACT WITH BAIL. IF FUNCTIONS BLOCK ERROR. SO, HOIST DOWN AND CHECK FUNCTIONS AGAIN.
  • Page 32 7 NexStar lll Troubleshooting 7.4 ELECTRICAL TROUBLESHOOTING TABLE ERROR CAUSE EFFECT SOLUTION CODE CRANE IS AT OR OVER 90% OF THIS IS A SAFETY FEATURE TO FUNCTIONS OVERLOAD IT’S RATED CAPACITY PREVENT GETTING INTO AN UNSAFE OPERATE ACTIVATED CONDITION (SUDDEN MOVEMENT OF SLOWLY HEAVY LOAD). 90% OVERLOAD WILL REMAIN ACTIVATED UNTIL LOAD IS DECREASED.

  • Page 33: Nexstar Lll Hydraulic Troubleshooting Table

    TRY TO MANUALLY OVERRIDE REPLACE CARTRIDGE UNEXPECTEDLY CARTRIDGE VALVE IF UNABLE TO MOVE STEM. CARTRIDGE IS JAMMED. COUNTERBALANCE ADJUST THE COUNTER-BALANCE CONTACT AUTO CRANE FOR SET TOO LOW OUT TO SEE IF MOVEMENT PROPER SETTING OF (BOOM-UP & STOPS. COUNTERBALANCE. YOU MAY BOOM-DN) NEED TO REPLACE COUNTERBALANCE.

  • Page 34: Maintenance

    8 Maintenance 8.1 INSPECTION REQUIREMENTS NOTICE Reference ASME B30.5 and OSHA 1910.180 for complete inspection requirements. WARNING All inspections shall be performed by the designated personnel only. 8.2 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. 2.

  • Page 35: Periodic Inspection

    Maintenance 8 B. General corrosion. C. Broken or cut strands. D. Use care when inspecting sections of rapid deterioration around flange points crossover points, and repetitive pickup points on drums. E. Inspect number, distribution, and type of visible broken wires. NOTICE Continued use of rope depends upon good judgment by a designated person in evaluating remaining strength in a used rope after allowance for deterioration disclosed by inspection.

  • Page 36: Cranes Not In Regular Use

    8 Maintenance 12. Inspect hydraulic cylinders for the following problems: A. Driving caused by fluid leaking across piston. B. Rod seals leaking. C. Leaks at welding joints. D. Scored, nicked, or dented cylinder rods. E. Damaged case (barrel). F. Loose or deformed rod eyes or connecting joints. 13. Inspect hydraulic filters for evidence of rubber particles on the filter elements indicating possible hose, O-ring, or other rubber component deterioration.

  • Page 37: General Repairs And Maintenance

    Maintenance 8 WARNING All testing shall be performed by designated personnel only. 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. 1. Test all functions to verify speed and operation. 2. Ensure all safety devices are working properly. 3. Confirm operating controls comply with appropriate function labels.

  • Page 38: Lubrication

    8 Maintenance B. Critical parts of the crane structure which are cracked, bent, broke, or excessively corroded. C. Crane hooks showing cracks, damage, or corrosion shall be taken out of service. Repairs by welding are recommended. 4. If bleeding the hydraulic system is required, run each crane function until smooth operation of that particular function is noticeable.

  • Page 39: 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. Inspect the paint finish monthly or when washed. Immediately repair any exposed bare metal or rust. Repair damaged paint on Auto Crane products with the following procedure: 1.

  • Page 40: Lubrication And Maintenance Schedule

    8 Maintenance 8.15 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, Cable kinks, broken strands. Hyd. Hoses Visual inspection.

  • Page 41: Lubrication Points

    1. Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability. 2. Once a bolt has been tightened to specification then removed, the bolt should be replaced with a new one. 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 42: Brake Adjustment

    8 Maintenance 8.17 BRAKE ADJUSTMENT The oil-cooled, fully adjustable, automatic safety brake operates in the worm housing lubricant, all part being submerged in oil. When the brake wears to the point that the load begins to drift, the brake can be adjusted as follows: 1.

  • Page 43: Nexstar Lll Cartridge Maintenance

    Maintenance 8 8.18 NEXSTAR lll CARTRIDGE MAINTENANCE Verify movement in ports while manually overriding cartridge 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. 2.

  • Page 44: Rotation Bearing Replacement

    8 Maintenance 8.19 ROTATION BEARING REPLACEMENT All bearings wear over time, including the main rotation bearing of the crane. There are no precise rules for replacing the main rotation bearing because of many variable factors. There are common symptoms during crane operation that may indicate rotation bearing wear. These include: 1.

  • Page 45: Hoist Maintenance

    Maintenance 8 8.20 HOIST MAINTENANCE NOTICE Adhering to the following maintenance schedule will keep your hoist in top condition and performing as it should with a minimum of repair. WEEKLY 1. Check the oil level and maintain it to the oil level plug. If oil is leaking out, determine location and repair.

  • Page 46: Crane Mounting And Installation

    9. Ensure the Owner’s Manual is delivered to the customer. 10. Install voltage switching unit inside compartment safe from weather and contamination. 11. See following page for additional electrical installation. 12. For additional help: Call the Service Department at the Auto Crane Company, 1-800-777-2760, located in Tulsa, OK. IMPORTANT!

  • Page 47: Stability Chart Installation

    This decal is to alert the user of the available crane capacities around the vehicle. • 479824002 decal will be installed on an Auto Crane body that was outfitted 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: EHC-5 NEXSTAR III...
  • Page 48 9 Crane Mounting and Installation • 479824003 decal will be installed on an Auto Crane body that was not outfitted 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. The stability chart provides lines to write in the tested stability percentage at each section below:...

  • Page 49: Nexstar Lll Counterbalance Valve Adjustment

    Crane Mounting and Installation 9 9.2 NEXSTAR lll COUNTERBALANCE VALVE ADJUSTMENT WARNING Do not try to adjust valves while the boom is moving 1. Ensure the PTO is disengaged and the boom is properly supported. 2. Remove the plug on the counterbalance valve. 3.

  • Page 50: Decal Layout

    10 Decal Layout P/N: 360682001 SECTION A-A EHC-5 NEXSTAR III...
  • Page 51 Decal Layout P/N: 360682001 10 ITEM NO. PART NUMBER DESCRIPTION 600047017 DECAL, AUTO CRANE EHC-5 NS LOGO, FLATTENED OVAL, 53 IN LONG 360838002 DECAL, LOAD CHART, EHC-5, NEXSTAR 040517000 DECAL STAY CLEAR OF BOOM 040518000 DECAL STAY CLEAR OF LOAD 360480100...
  • Page 52 11 General Assembly P/N: 360645007 SLAVE MASTER UNIT UNIT SECTION A-A DETAIL B DETAIL C SECTION D-D DETAIL E DETAIL F EHC-5 NEXSTAR III...
  • Page 53 General Assembly P/N: 360645007 11 ITEM NO. PART NO. DESCRIPTION 360648008 PEDESTAL ASSEMBLY, EHC-5 NEXSTAR III 360647010 BOOM ASSEMBLY, 5005 EH, 5005H 360676000 PIN, CYLINDER 239300000 ZERK, GREASE 320976000 WASHER, FLAT, 3/8 SAE HARDENED 021100000 WASHER SP LK 3/8 366159000 SCREW HX HD 3/8-16 UNC X 1-1/2 LG GR8 480988020 PIN, PIVOT, 8406H 021500000...

  • Page 54: General Dimensions

    12 General Dimensions EHC-5 NEXSTAR III...
  • Page 55 Pedestal Assembly P/N: 360648008 13 VALVE 480188100 HOSING DETAIL 67 64 EHC-5 NEXSTAR III...
  • Page 56 13 Pedestal Assembly P/N: 360648008 95 32 32 94 HORN DETAIL EHC-5 NEXSTAR III...
  • Page 57 Pedestal Assembly P/N: 360648008 13 ITEM NO. PART NO. DESCRIPTION 366832100 BASE PLATE WELDMENT 360648300 PEDESTAL WELD, EH LARGE CRANE 480023002 BEARING ROTATION 5005-8005 023902000 WASHER FL 5/8 HARDENED 012198000 SCREW HX HD 5/8-11 UNC X 1-3/4 LG GR8 366393000 SCREW HX HD 5/8-11 UNC X 2-1/2 LG GR8 490171000 SCREW HX HD 5/8-11 UNC X 2-1/4 LG GR8 006205000...
  • Page 58 13 Pedestal Assembly P/N: 360648008 ITEM NO. PART NO. DESCRIPTION 011603000 SCREW HX HD 1/2-13 UNC X 1-3/4 LG 366800205 VALVE BLOCK, LARGE EH CRANE, NEXSTAR 002614000 SCREW HX HD 5/16 UNC X 5/8 CP GR3 SELF TAP 366800206 BRACKET, VALVE BLOCK AND RECEIVER 366333000 BEARING, SPHERICAL 1.25 ID 366698000...
  • Page 59 Pedestal Assembly P/N: 360648008 13 ITEM NO. PART NO. DESCRIPTION 005500000 SCREW HX HD 1/4-20 UNC X 3/4 LG 738058008 NUT HX 1/2-13 UNC 010201000 SCREW HX HD 1/2-13 UNC x 1-1/2 LG 366800213 KIT, ELECTRICAL, LARGE EH CRANES, NEXSTAR III 360648009 TAG, ID, EHC-5 EHC-5 NEXSTAR III...
  • Page 60 14 Hoist Assembly P/N: 113001 ITEM NO. PART NO. DESCRIPTION 242177 HOIST FRAME 297025 GEAR HSG/SPUR GEAR HSG/MTR 436037 DRUM WELDMENT 479016 COLLAR, SPLIT 1.25” I.D. 518063 BEARING, BRONZE 402128 BEARING 1.25” I.D. 448100 TIE BAR, HOIST ASSEMBLY 418177 WASHER SPLK 3/8” 414316 SCW HX 3/8” UNC X 1-1/4” GR8 342199 KEY, 5/16” X 7-1/2” 414294 SCREW, 3/8”-16 NC X 7/8” LG EHC-5 NEXSTAR III...
  • Page 61 Hoist Actuator P/N: 297025 15 22 59 EHC-5 NEXSTAR III...
  • Page 62 15 Hoist Actuator P/N: 297025 ITEM NO. PART NO. DESCRIPTION 306034 SPRING FLAT 314008 PLATE CAM 324106 COVER SPUR GEAR HOUSING 328128 COVER BRAKE 328134 COVER WORM GEAR HOUSING 334001 IDLER GEAR 334003 SPUR GEAR 334129 PINION GEAR 334163 GEAR WORM RH 338007 HOUSING BRAKE 338203...
  • Page 63 Hoist Actuator P/N: 297025 15 ITEM NO. PART NO. DESCRIPTION 468011 PIPE PLUG SQ HD 468017 PIPE PLUG SOC HD 468018 PIPE PLUG SOC HD 470001 474001 PLATE THRUST 486009 OIL SEAL 486017 OIL SEAL 486023 OIL SEAL 486069 THREAD SEAL 486070 THREAD SEAL 490003 SNAP RING...
  • Page 64 16 Rotation Gearbox P/N: 160407 ITEM NO. PART NO. DESCRIPTION 300058 ADAPTER 308085 BUSHING 316004 CAP-BEARING 328126 COVER 334016 GEAR-R.H. 338261 HOUSING-GEAR 342120 357139 SHAFT-OUTPUT 366019 WASHER-THRUST 368183 WORM-R.H. 402044 BEARING-BALL 402105 BEARING-NEEDLE 402106 BEARING-NEEDLE 402107 BEARING-THRUST 413013 COVER 414143 CAPSCREW 414581 CAPSCREW 414869 CAPSCREW...
  • Page 65 Boom Assembly P/N: 360647010 17 EHC-5 NEXSTAR III...
  • Page 66 17 Boom Assembly P/N: 360647010 ITEM NO. PART NO. DESCRIPTION 008800000 SCREW HX HD 3/8-24 UNF X 1 LG 008400000 SCREW HX HD 3/8-16 UNC X 3/4 LG GR 5 021100000 WASHER SP LK 3/8 021200000 WASHER FL 3/8 016801000 NUT HX NYLK 5/16-18 UNC CP 022102000 WASHER FL 3/4 360756000...

  • Page 67: Traveling Block Assembly

    Traveling Block Assembly P/N: 360649000 18 ITEM NO. PART NO. DESCRIPTION 480363000 SHORT BLOCK SIDE PLATE 480130000 SHEAVE ASSY 480364000 TACKLE LOWER 480372000 BOLT, SHEAVE W/ ZERK FITTING 480371000 HOOK SWIVEL 3 METRIC TON 480367000 PIN BLOCK 480368000 PIN SWIVEL HOOK 017800000 NUT, HX LK 1/2-20 UNF 366813000 PIN HITCH...

  • Page 68: Hydraulic Power Unit

    19 Hydraulic Power Unit P/N: 366650000 “P” OUTLET PORT 9/16-18 #6 SAE (PLASTIC PLUG) “T” RETURN PORT 9/16-18 #6 SAE (PLASTIC PLUG) [ 140 ] [ 19 ] 5 1/2" 3/4" VIEW WITH RESERVOIR NOT ALL PARTS SHOWN REMOVED [ 19 ] [ 67 ] 3/4"...

  • Page 69: Hydraulic Control Valve

    Hydraulic Control Valve P/N: 366800205 20 5/16-18 x .63 DEEP (x2) 2.69 3.00 6.00 2.38 3.50 5/16-18 x .63 DEEP (x2) 3.00 2.38 3.50 ITEM NO. PART NO. DESCRIPTION 320991916 VALVE, CARTRIDGE PROPORTIONAL 3203/4004 NEXSTAR, FLOATING CENTER, 5 GPM 320991912 VALVE, CARTRIDGE PROPOTIONAL 3203/4004 NEXSTAR CLOSED CENTER 320991901 COIL, SOLENOID 12VDC 1/2” DIA 320991905...

  • Page 70: Voltage Switching Unit

    21 Relay Panel Assembly P/N: 366800211 RECTIFIER BRIDGE BOOTS REQUIRED A, C, & D ORIENTATION BOOTS REQUIRED A, B RELAY PANEL GND BOLT #1 8 10 8 ATTACH WITH (2) M5 X 12 SCREWS AND WASHERS (NOT SHOWN) ITEM NO. PART NO. DESCRIPTION 320589000 RELAY, HOIST...
  • Page 71 Relay Panel Assembly P/N: 366800211 21 TO TWECO PUMP RELAY PANEL HOIST PUMP RELAY RELAY PUMP HOIST RELAY RELAY GROUND TO PUMP RELAY BOLT GROUND TO HOIST RELAY BOLT PLUG RELAY PANEL BOLT 1 HOIST SIDE PLATE 6 PIN BULKHEAD CONNECTOR GROUND BOLT EHC-5 NEXSTAR III...
  • Page 72 22 Voltage Switching Unit P/N: 366692000 RELAY-1 RELAY-2 OUTSIDE INSULATION OF CORD SHOULD EXTEND 1" PAST GROMMET AND ZIP TIE INSTALLED TO RETAIN CORD. RELAY-3 LOCATE DECAL IN CENTER OF LID 14 15 16 INSTALL SCHEMATIC DECAL TO UNDERSIDE OF LID. DECAL SHOULD BE RIGHT SIDE UP WHEN LID IS OPENED DOWNWARD.
  • Page 73 Voltage Switching Unit P/N: 366692000 22 POWER SWITCH POWER LIGHT RELAY-1 RELAY-2 RELAY-1 RELAY-3 RELAY-1 RELAY-2 RELAY-3 AUX. BATTERY 16/3 TRUCK BATTERY CONDUCTOR CORD PANEL GROUND A B C CHASSIS GROUND LARGE RELAY LARGE RELAY BOSCH RELAY TOP VIEW BOTTOM VIEW BOTTOM VIEW EHC-5 NEXSTAR III...
  • Page 74 23 Harness P/N: 366800215 EHC-5 NEXSTAR III...
  • Page 75 Harness P/N: 366800215 23 ITEM NO. PART NO. DESCRIPTION 581-01-18-023 18 POSITION CONN 581-01-30-029 30 POSITION CONN 425-00-00-873/PCS SOCKET CONTACT 16-18 AWG GXL 425-00-00-872/PCS SOCKET CONTACT 18-20 AWG TXL WPCVR-USB-1394 WATERPROOF COVER, USB SP44180 CABLE, WATERPROOF, USBB-F, 2PR X 22 AWG DT06-22 DEUTSCH DT PLUG, 2 POLE “A” KEY DEUTSCH DT WEDGELOCK, 2-POLE 12065287-B...
  • Page 76 24 Electrical Schematic P/N: 366800214 EHC-5 NEXSTAR III...
  • Page 77 ANNEX A RECOMMENDED OPERATING TEMPERATURE 1. In applications where low oil temperatures may exist (below -20° F), an external heating system may be required. 2. A symptom of excessively low temperatures is hydraulic motor/PTO operation but no fluid flow from tank. CAUTION Hydraulic reservoir oil temperature must not exceed 180° F or damage to crane may occur. This may affect crane warranty. OIL TEMPERATURE 200 F (93.3 C) 180 F (82.2 C)
  • Page 78 ANNEX B ECCENTRIC RING ADJUSTMENT 1. Remove retaining clip from bottom of crane 2. Rotate Eccentric Ring to tighten or loosen backlash. Eccentric ring hole is offset from the outside diameter by 1/16”.) NOTICE IMPORTANT: The tooth gap should be between 0.005 and 0.007 at the blue/green mark. This can be checked using Plastigage. 3.
  • Page 80 LIMITED WARRANTY 1 YEAR PURCHASED REPLACEMENT PARTS Auto Crane will warranty to the consumer for a period of (1) year from the date that a new Auto Crane replacement part was purchased from an authorized Auto Crane distributor. Each new Auto Crane part they sell will be free under normal use and service from defects in material and workmanship.
  • Page 81 2 YEAR PARTS AND LABOR Auto Crane will warranty to the consumer for a period of (2) years parts and labor from the date of purchase. Each new Auto Crane unit they sell will be free under normal use and service from defects in material and workmanship.
  • Page 84 EHC-5 NEXSTAR III...

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