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Table of Contents
Troubleshooting
Related Manuals for Auto Crane HC-8X
Summarization of Contents
1.1 WARNINGS
DANGER
Indicates a hazardous situation resulting in death or serious injury.
WARNING
Indicates a hazardous situation resulting in death or serious injury.
CAUTION
Indicates a hazardous situation resulting in minor or moderate injury.
Federal law (49 CFR Part 571)
Manufacturer certification requirements for vehicle compliance.
OSHA Truck Crane Stability Requirements
Installer responsibility for OSHA stability requirements.
Not designed or intended for personnel lifting
Warning against using crane for personnel lifting.
2.1 INTRODUCTION
Keep this manual with the crane at all times.
Instruction to keep the manual accessible with the crane.
Auto Crane Company issues a limited warranty
Information about the limited warranty provided with the unit.
Auto Crane will not assume responsibility or liability for any modifications
Disclaimer regarding unauthorized modifications.
Auto Crane maintains a strong distributor network
Information on distributor network and customer service.
Call the Service Department at the Auto Crane Company
Contact information for assistance.
3.1 GENERAL SPECIFICATIONS
DIMENSIONS
Physical measurements of the crane.
CAPACITY
Lifting capacity rating of the crane.
HYDRAULIC REQUIREMENTS
Specifications for the hydraulic system.
ELECTRICAL SYSTEM REQUIREMENTS
Requirements for the electrical system.
3.2 HC-8X NEXSTAR III, GENERAL DIMENSIONS
Figure 1. General Dimensions
Visual representation of crane dimensions.
3.3 LOAD CHART
ZONE A CAPACITIES
Load capacities for Zone A.
ZONE B CAPACITIES
Load capacities for Zone B.
ATTENTION! OVER 4000 LBS. USE DOUBLE LINE
Special instruction for heavy loads.
WARNING All load ratings are based on crane capacity, not the vehicle stability.
Warning about vehicle stability vs. crane capacity.
3.4 HC-8X NEXSTAR III, DECAL LAYOUT
DECAL DANGER "ELECTROCUTION HAZARD" POWER LINE
Warning decal for electrical hazards.
DECAL, LOAD CHART, HC-8X
Decal displaying the load chart.
DECAL WARNING, REMOTE CONTROL
Decal related to remote control warnings.
4.1 QUALIFICATIONS AND OPERATING PRACTICES
REFERENCE ASME B30.5a AND OSHA 1910.180
References for qualification requirements.
4.2 OPERATORS
Information on who is qualified to operate the crane.
4.3 QUALIFICATIONS FOR OPERATORS
Detailed physical and skill requirements for operators.
4.4 CONDUCT OF OPERATORS
Guidelines for operator behavior and responsibilities.
4.5 OPERATING PRACTICES/HANDLING THE LOAD
CAUTION Never use two cranes to support a load too large
Warning against using multiple cranes for oversized loads.
Attaching the load.
Proper methods for attaching loads.
The operator shall determine that
Operator's checks before lifting.
Telescopic boom cranes are designed for material handling, not personnel lift
Crane intended use for material handling, not personnel.
Proper use of stabilizers.
Procedures for stabilizer deployment and use.
4.6 OPERATING NEAR ELECTRICAL POWER LINES
DANGER Never operate the crane near electrical lines
Strict prohibition of operating near power lines.
Do not place any part of the crane or load inside the Danger Zone.
Rule against entering the danger zone.
Table 1. Safe Operating Distance
Table of minimum safe distances.
Assign a qualified, signal person observe the clearance
Role of a signal person for clearance observation.
4.7 PREPARING THE CRANE FOR OPERATION
Perform a routine inspection of the crane before operation
Daily inspection procedure.
NOTICE At a 10° slope, speed limitations
Speed and function limitations based on slope.
For all outrigger usage:
Procedures for outrigger deployment and use.
DURING OPERATION
Guidelines for safe operation.
Always use slow and smooth movements
Smooth operation to prevent load swing.
AFTER OPERATION
return the boom to the stowed position
Stowing the boom after use.
Replace remote control to its storage location.
Storing the remote control.
Return the Outriggers to the stowed position.
Stowing the outriggers.
Record any unusual occurrence during crane operation
Logging operational anomalies.
5.1 NEXSTAR III OPERATION
WARNING Before operating the Remote Control, read and understand all safety information
Importance of reading safety information.
WARNING Never drive with a load suspended from the crane.
Prohibition of driving with suspended loads.
5.2.1 REMOTE CONTROL UNIT
Details and handling of the remote control unit.
5.2.3 PRE-OPERATION TEST
Essential checks before operating the crane.
5.3 REMOTE CONTROL LAYOUT
Figure 4. Nexstar III Remote Control
Diagram of the remote control layout.
Emergency Stop Button
Function and operation of the emergency stop button.
On/Off/Link Switch
Switch for power, linking, and mode selection.
Right Joystick
Function and operation of the right joystick.
5.4 DISPLAY SCREEN LAYOUT
Figure 5. Display Screen Layout
Diagram of the display screen elements.
Capacity
Current load as a percentage of total capacity.
Mode
Current operating mode selected.
Boom Angle
Current boom angle in degrees.
5.5 SPEED AND MODE SELECTION
5.5.1 SPEED SELECTION
Procedure for adjusting the crane's operating speed.
5.5.2 MODE SELECTION
Procedure for selecting the crane's operating mode.
5.5.3 MODE DESCRIPTION
Explanation of different operating modes.
2-AXIS operation description
Description of 2-AXIS operation.
5.6 OPERATION—VALVE OVERRIDE
Push the unloader valve (ULV) red button.
Step to activate the valve override.
Push or pull the override button for the desired direction
Operating the override button.
When the manual operation is complete, release the ULV
Resetting the override.
6.1 NEXSTAR III TROUBLESHOOTING
6.1.1 TROUBLESHOOTING FLOW CHART
Diagnostic tool for troubleshooting crane issues.
CRANE DOES NOT OPERATE CORRECTLY
Initial troubleshooting step for incorrect operation.
IS THERE AN ERROR CODE
Check for error codes as a diagnostic step.
GO TO ELECTRICAL TROUBLESHOOTING CHART
Referral to electrical troubleshooting guide.
6.1.2 NEXSTAR III REMOTE CONTROL TROUBLESHOOTING TABLE
Remote control will not turn on
Troubleshooting for unresponsive remote control.
Remote control will not respond with the receiver
Issues with remote-receiver communication.
Remote control will not turn on in tether mode
Problems in tethered operation.
Remote control will not respond with the receiver in wireless mode
Wireless communication problems.
6.1.3 NEXSTAR III ERROR CODE TABLE
S1 CAN RX TO
Error code for CAN message timeout.
S2 TEMP OUT OF RANGE
Error code for temperature out of range.
A1 BOOM PSI LOW
Error code for low boom pressure.
A6. ANTI 2-BLOCK
Error code for anti-two-block activation.
6.1.4 NEXSTAR III MECHANICAL TROUBLESHOOTING TABLE
CRANE MOVES UNEXPECTEDLY
Troubleshooting unexpected crane movement.
NO FUNCTION OPERATES ON THE CRANE
Issues with functions not operating.
ALL FUNCTIONS OPERATE SLOWLY
Slow operation of all functions.
EXCESSIVE HEAT DURING OPERATION
Overheating issues during use.
6.1.5 NEXSTAR III ELECTRICAL TROUBLESHOOTING TABLE
CRANE MOVES UNEXPECTEDLY
Troubleshooting unexpected crane movement.
NO FUNCTION OPERATES ON THE CRANE
Issues with functions not operating.
BOOM DOWN, EXTEND, AND HOIST UP ARE INOPERABLE
Specific boom/hoist functions inoperable.
EXTEND, RETRACT, HOIST UP, BOOM UP, ROTATE CW, ROTATE CCW ARE INOPERABLE
Multiple functions inoperable.
7.1 MAINTENANCE
7.1.1 INSPECTION REQUIREMENTS
Requirements for crane inspections.
7.1.2 INSPECTION CLASSIFICATION
Classification of inspections into types and intervals.
7.1.3 FREQUENT INSPECTION
Details of daily inspections and checks during operation.
Inspect hydraulic system for proper oil level and leaks.
Checking hydraulic fluid levels and for leaks.
7.1.4 PERIODIC INSPECTION
Inspect for deformed, cracked or corroded members
Inspecting structural members for damage.
Inspect hydraulic hose, fittings, and tubing
Inspecting hydraulic hoses and fittings for issues.
Inspect hydraulic pumps and motors
Inspecting hydraulic pumps and motors for issues.
Inspect hydraulic valves
Inspecting hydraulic valves for issues.
7.2 TESTING REQUIREMENTS
WARNING All testing shall be performed by designated personnel only.
Personnel qualification for testing.
Test all functions to verify speed and operation.
Testing crane functions for speed and operation.
Ensure all safety devices are working properly.
Verification of safety devices functionality.
Test loads shall not exceed 110% of the manufacturer's load rating.
Load testing limits.
7.3.2 ADJUSTMENTS AND REPAIRS
Any hazardous conditions disclosed by the inspection requirement shall be corrected
Correcting hazardous conditions before resuming operation.
Adjustments shall be maintained to assure correct of functioning of components
Maintaining component function through adjustments.
7.3.4 ROPE REPLACEMENT
Replacement rope shall have a strength rating at least as great as the original rope
Requirements for replacement rope strength.
Conditions such as the following shall be reason for questioning continued the rope
Reasons to question rope condition.
7.3.6 PAINT FINISH MAINTENANCE
Immediately repair any exposed bare metal or rust.
Prompt repair of exposed bare metal or rust.
Repair damaged paint on Auto Crane products with the following procedure:
Procedure for repairing damaged paint.
7.4 LUBRICATION AND MAINTENANCE SCHEDULE
Table 7. Lubrication and Maintenance Schedule
Schedule for lubrication and maintenance tasks.
7.5 LUBRICATION POINTS
Figure 6. Lubrication Points
Diagram indicating lubrication points on the crane.
Use only authorized parts.
Use of authorized parts for service.
7.7 HC-8X NEXSTAR III, CARTRIDGE MAINTENANCE
Table 8. Cartridge Maintenance
Table detailing cartridge maintenance procedures.
Use the following procedure to inspect the cartridge for proper opertion.
Procedure for inspecting cartridge operation.
Inspect the O-rings for damage.
Inspecting O-rings for any damage.
8.1 CRANE MOUNTING AND INSTALLATION
CAUTION Failure to use clean hydraulic hoses and components
Caution on using clean components for hydraulic system.
Install the correct sized and length of hydraulic hose.
Installing correct hydraulic hoses.
CAUTION Hydraulic reservoir oil temperature must not exceed 180 °F
Caution on hydraulic oil temperature limits.
Ensure the outriggers are used to provide total stability for the truck.
Using outriggers for truck stability.
WARNING Failure to correctly plumb and wire crane
Fill the reservoir to the top of the sight glass
Filling hydraulic reservoir with specified fluid.
Operate all cylinders to the fully extended and fully retracted positions
Operating cylinders to bleed air from the system.
If there is sufficient flow to the crane, perform a load test
Performing a load test to ensure proper operation.
FEDERAL LAW (49 CFR PART 571) REQUIRES THAT THE FINAL STAGE MANUFACTURER
Federal law regarding vehicle certification.
8.1.1 STABILITY CHART INSTALLATION
STABILITY CHART DECAL INSTALLATION
Procedure for stability chart decal installation.
ZONE A, MAXIMUM CAPACITY 52,750 FT.-LBS.
Maximum capacity for Zone A.
ZONE B, MAXIMUM CAPACITY 43,000 FT.-LBS.
Maximum capacity for Zone B.
ZONE C, NO LIFT ZONE
Zone where lifting is prohibited.
8.1.2 HC-8X NEXSTAR III, COUNTERBALANCE VALVE ADJUSTMENT
WARNING Do not try to adjust valves while the boom is moing.
Warning against adjusting valves while the boom is moving.
CAUTION If the proper pressure reading cannot be obtained, please contact your Auto Crane distributor.
Contacting distributor for assistance with pressure readings.
8.2 EMERGENCY CRANE OPERATION
If for any reason hydraulic flow or pressure is lost to the crane
Procedure for lost hydraulic flow/pressure.
In an emergency situation when it becomes necessary to lower the boom without hydraulic assistance
Lowering boom without hydraulic assistance.
9.1 DRAWINGS AND ASSEMBLIES
HC-8X NEXSTAR III, GENERAL ASSEMBLY P/N: 479000003
Assembly diagram for the main unit.
SECTION A-A
Section view identifier.
DETAIL B
Detail view identifier.
NOTES: APPLY LOCTITE 242 OR EQUIVALENT TO THREADS BEFORE INSTALLATION
Note on thread locking compound usage.
HC-8X NEXSTAR III, PEDESTAL ASSEMBLY P/N: 479200099
DETAIL B
Detail view identifier.
DETAIL A
Detail view identifier.
ORIENT ARROW TOWARDS FRONT
Orientation indicator.
ROUTE WIRE THROUGH SLOT
Wire routing instruction.
HC-8X NEXSTAR III, PEDESTAL ASSEMBLY P/N: 479200099
DETAIL C
Detail view identifier.
77 RETURN
Hydraulic port designation.
76 PRESSURE
Hydraulic port designation.
HC-8X NEXSTAR III, BOOM ASSEMBLY P/N: 479200101
NOTES:
Notes regarding assembly.
SHIM WITH P/N 479200106 AS NECESSARY
Shim part number.
SHIM WITH P/N 479200107 AS NECESSARY
Shim part number.
HC-8X NEXSTAR III, BOOM ASSEMBLY P/N: 479200101
DETAIL A
Detail view identifier.
TRAVELING BLOCK WEAR PAD DETAIL
Detail of wear pad for traveling block.
HC-8X NEXSTAR III, MAIN HARNESS P/N: 479200206
CONNECTOR ID
Identifier for connectors.
DESCRIPTION
Description of connector functions.
USB CONNECTION
Description of USB connection.
BOOM DOWN
Connector for boom down function.
HC-8X NEXSTAR III, ELECTRICAL SCHEMATIC P/N: 479200207
CONN 1
Connector designation.
USB PROGRAMMING
USB programming interface.
GROUND
Electrical ground connection.
POWER
Power connection.
HC-8X NEXSTAR III, HYDRAULIC CONTROL P/N: 366823251
#6 SAE GAUGE PORT
Designation of a gauge port.
#6 JIC TYP (6) PLCS
Fitting type and quantity.
#8 JIC TYP (2) PLCS
Fitting type and quantity.
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