Auto Crane Nexstar 14005H crane OWNER’S MANUAL
Below you will find brief information for crane Nexstar 14005H. The Auto Crane Nexstar 14005H is a crane designed for safe, trouble-free, dependable service for many years when properly used and maintained. The crane features a variety of safety features, including an overload shutdown device, and is attached to your 12-volt truck electrical system through the relay provided.
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14005H
NEXSTAR
OWNERS MANUAL
Manual No. 470102010
Serial No. __________________
Mailing Address:
P.O. Box 580697
Tulsa, OK 74158-0697
Physical Address:
4707 N. Mingo Rd.
Tulsa, OK 74117-5904
Phone 1-800-777-2760
Fax (918) 269-6688 http://www.autocrane.com
14005H
OWNER’S MANUAL REVISION RECORD
Revision
Date
Section(s)
Or
Page(s)
Description of Change
Notes:
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.
WARNINGS
WARNING! Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of a vehicle
certify that the vehicle complies with all applicable federal regulations. Any modifications performed on the vehicle prior to the final state are also considered intermediate stage manufacturing and must be certified as to compliance. The installer of this crane and body is considered one of the manufacturers of the vehicle. As such a manufacturer, the installer is responsible for compliance with all applicable federal and state regulations, and is required to certify that the vehicle is in compliance.
WARNING! It is the further responsibility of the installer to comply with the OSHA Truck Crane
Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).
WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL POWER LINES!
Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane
within 10 feet (3.05m) of electric power lines carrying up to 50,000 volts. One-foot additional clearance is required for every additional 30,000 volts or less. SEE DANGER DECAL (P/N 040529) in this Owner's Manual.
WARNING! NEVER.........................................
•
EXCEED load chart capacities (centerline of rotation to hoist hook).
•
Un-reel last 5 wraps of cable from drum!
•
Wrap cable around load!
•
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.
•
Place a chain link on the tip of the hook and try to lift a load!
•
Use a sling bar or anything larger than the hook throat that could prevent the hook latch from
• closing, thus negating the safety feature!
Hold on any pendant Select Switch that will cause unsafe operating conditions!
WARNING! In using a hook with latch, ALWAYS make sure that the hook throat is closed before
lifting a load! Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.
WARNING! Failure to correctly plumb and wire crane can cause inadvertent operation and damage
to crane and/or personnel!
WARNING! Auto Crane Company remote controlled cranes are not designed or intended for use for
any applications involving the lifting or moving of personnel.
WARNING! ALWAYS operate the crane in compliance with the load capacity chart. DO NOT USE
the overload shutdown device to determine maximum rated loads, if the crane is equipped with this type of device.
READ THIS PAGE
8/15/05
14005H
TABLE OF CONTENTS
6/15/10
Auto Crane products are designed to provide many years of safe, trouble-free, dependable service when properly used and maintained.
To assist you in obtaining the best service from your crane and to avoid untimely crane and/or vehicle failure, this manual provides the following operating and service instructions. It is specifically recommended that all operating and service personnel consider this manual as mandatory material for reading and study before operating or servicing Auto Crane products. It is highly recommended that crane owners, equipment managers, and supervisors also read this manual.
Auto Crane has incorporated several safety features in the 14005H crane for your protection.
For your convenience the overall dimensions of the 14005H crane are included on the General Dimension
Drawing. Rotation and turning radius are also listed on that drawing.
Remember, the crane adds weight to the vehicle. Adding weight may change the driving and riding characteristics of the vehicle unless the appropriate overload spring(s) are installed on the truck. The payload of the vehicle is reduced by the weight of the crane. The operator should exercise care when loading the vehicle.
Distributing the payload on the vehicle evenly will greatly improve the driving and riding characteristics of the vehicle.
Auto Crane Company issues a limited warranty certificate with each unit sold.
See last page for warranty.
The 14005H cranes are attached to your
12-volt truck electrical system through the relay provided. The 14005H 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
14005H
INTRODUCTION
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 understandable that Auto Crane
Company cannot assume responsibility of liability when it is obvious that our products have been abused, misused, overloaded or otherwise damaged by inexperienced persons trying to operate the equipment without reading the manual.
Auto Crane will not assume responsibility or liability for any modifications or changes made to unit, or installation of component parts without authorization.
Auto Crane maintains a strong distributor network and a knowledgeable Customer Service
Department. In most cases, an equipment problem is solved via phone conversation with our customer service department. The customer service department also has the ability to bring a local distributor, a regional sales manager, or a factory serviceman into the solution of an equipment problem.
If, through no fault of Auto Crane Company, it is necessary to send an experienced factory serviceman on a field service call the rates stated in the Auto Crane Distributor's Flat Rate
Manual will apply.
Auto Crane Company's extensive Research and
Development Program allow our customers to use the best equipment on the market. Our
Engineering Staff and our knowledgeable sales people are always available to our customers in solving crane and winch-type application problems. When in doubt, call the Auto Crane factory.
Note: This manual should remain with the crane at all times.
1-1.0
6/15/10
14005H
INTRODUCTION
DISTRIBUTOR ASSISTANCE:
Should you require any assistance not given in this manual, we recommend that you consult your nearest Auto Crane Distributor.
Our distributors sell authorized parts and have service departments that can solve almost any needed repair. This manual does not cover all maintenance, operating, or repair instructions pertinent to all possible situations. If you require additional
information, please contact the 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
6/15/10
14005H
GENERAL SPECIFICAIONS
1-3.0
6/15/10
—-IMPORTANT—-
SAFETY TIPS AND PRECAUTIONS
1. No unqualified or unauthorized person shall be allowed to operate the crane.
2. WARNING: Never weld, modify, or use unauthorized components / parts on any Auto
Crane unit. This will void any warranty or liability. Also, failure of the crane may result.
3. Make certain the vehicle meets minimum chassis requirements. (These requirements do not guarantee unit stability.)
4. Make certain the crane is installed per factory specifications. Contact your local distributor or the Auto Crane factory if any questions arise.
5. Visual inspections and tests should be conducted at the beginning of each shift each day to insure that the crane and all its operating systems are in good condition and working order before it is used.
6. Inspect hydraulic hoses frequently for signs of deterioration, and replace them as required.
7. If a hydraulic break occurs, leave the area of the break and do not attempt to stop the break by hand as the hydraulic oil may be hot and under high pressure which can cause serious injury. Shut the system down as soon as possible.
8. Check the hook at least every thirty days for distortions or cracks and replace it as required.
9. Oil gears as required.
10. Stop all operations when cleaning, adjusting or lubricating the machine.
11. Keep dirt and grit out of moving parts by keeping crane clean. Make sure machine is free of excess oil, grease, mud and rubbish, thus reducing accidents and fire hazards.
12. When a new cable is installed, operate first with a light load to let the cable adjust itself.
13. Locate the vehicle at the work site for the best stability possible.
14. Keep the vehicle in a level position while loading or unloading.
15. Observe operating area for obstructions and/ or power lines that might be a hazard.
16. WARNING: NEVER OPERATE THE CRANE
NEAR ELECTRICAL POWER LINES. Auto
Crane Company recommends that the crane never be any closer to a power line (including telephone lines) than 10 feet at any point.
17. Allow the vehicle engine to warm up before operating crane.
18. Know the weight of your rigging and load to avoid overloading the crane.
19. Deduct the weight of the load handling equipment from the load rating to determine how much weight can be lifted.
20. All load ratings are based on crane capacity,
NOT the vehicle stability. Remember in lifting a heavy load, the weight can create enough tipping moment to overturn the vehicle
21. Always comply with load chart capacities,
(centerline of rotation to hook).
22. Secure all loads before lifting.
23. Always set the emergency brake before beginning operation.
24. Keep objects and personnel clear of crane path during operation.
25. Operate control levers slowly and smoothly in order to meter oil flow for safe operation.
(Not applicable to electric-hydraulic cranes.)
26. Always extend the outriggers from vehicle to the ground before crane operation. Insure that they are firmly positioned on solid footings. Stand clear of outriggers while they are being extended.
27. If any outrigger, when extended, rests on a curb or other object that prevents it from extending to its maximum distance, shorten bearing or fulcrum point and reduce the maximum load accordingly.
28. When an outrigger will not reach the ground due to holes or grades, it shall be blocked up to provide level and firm support for the truck.
29. When working in soft earth, use wide pads under outrigger feet to prevent sinking.
30. Always store outriggers before transportation.
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. This sale is made with the express understanding that there is no warranty that the goods shall be fit for the purpose of lifting or moving persons or other improper use and there is no implied warranty or responsibility for such purposes.
2-1.0
6/15/10
—-IMPORTANT—-
SAFETY TIPS AND PRECAUTIONS
31. Always store the crane in its stowed position for transportation.
32. Remember the overall height of the entire unit for garage door clearance or when moving under objects with low overhead clearance
33. Disengage power takeoff (PTO) before moving the vehicle.
(Not applicable to electric-hydraulic cranes.)
34. Always walk around the vehicle before moving.
35. Never drive with a load suspended from crane.
36. Do not take your eyes off a moving load.
Look in the direction you are moving.
37. Never swing a load over people.
38. Do not stop the load sharply in midair so that it swings like a pendulum. Meter the control levers to avoid this situation. (Not applicable to electric-hydraulic cranes.)
39. Crane boom length should be kept as short as possible for maximum lifting capacity and greater safety. Longer booms require additional care in accelerating and decelerating the swing motion, and thus slow down the working cycle and reduce productivity.
40. Keep the load directly and vertically under the boom point at all times. Crane booms are designed to handle vertical loads, not side lifts.
WARNING: Never attempt to lift, drag, tow or pull a load from the side. The boom can fail far below its rated capacity.
41. Do not push down on anything with boom extensions; similarly do not lift anything with boom extensions.
42. Do not lift personnel with any wire rope attachment or hook. There is no implied warranty or responsibility for such purposes.
43. WARNING: In using a safety hook, ALWAYS close the hook throat before lifting a load.
Proper attention and common sense applied to the use of the hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.
44. WARNING: Never place a chain link on the tip of the hook and try to lift a load with the hoist.
45. WARNING: Never use a sling bar or anything larger than the hook throat which could prevent the safety latch from closing, thus negating the safety feature.
46. Do not wrap the wire rope around sharp objects when using winch.
47. WARNING: Never unreel last 5 wraps of cable from drum.
2-2.0
6/15/10
—-IMPORTANT—-
OPERATING PRACTICES AND WARNINGS
1. Make certain the vehicle meets minimum chassis requirements. (These requirements do not guarantee unit stability)
2. Make certain the crane is installed per factory specifications. Contact your local Distributor or the
Auto Crane factory if any questions arise.
3. Keep the vehicle in as level a position as possible while loading or unloading.
4. ALWAYS set the vehicle emergency brake before beginning crane operations.
5. ALWAYS use outriggers from vehicle to the ground during crane operation. Make sure they are firmly positioned on solid footings.
6. All load ratings are based on crane capacity, NOT truck/crane stability.
7. Keep objects and personnel clear of crane path during operation.
8. Keep hoist cable pulled tight at all times.
9. REMEMBER, in lifting a heavy load, the weight can create enough tipping momentum to overturn the vehicle.
10. ALWAYS keep load as close to ground as possible.
11. Hydraulic hoses need to be inspected frequently for signs of deterioration, and be replaced as required.
12. The hoist hook is an important item that an operator should consider and use properly. It should be checked on a daily basis for distortion or cracks.
13. ALWAYS store outriggers before road travel.
14. WARNING! NEVER OPERATE THE CRANE
NEAR ELECTRICAL POWER LINES! Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane within
10 feet (3.05m) of electric power lines carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.
15. WARNING! NEVER EXCEED load chart capacities (centerline of rotation to hoist hook).
16. WARNING! NEVER un-reel last 5 wraps of cable from drum!
17. WARNING! NEVER wrap cable around load!
18. WARNING! NEVER attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.
19. WARNING! NEVER 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.
20. WARNING! NEVER place a chain link on the tip of the hook and try to lift a load!
21. WARNING! NEVER use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature!
22. WARNING! In using a hook with latch, ALWAYS insure that the hook throat is closed before lifting a load! Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.
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
6/15/10
QUALIFICATIONS FOR AND CONDUCT OF
OPERATORS AND OPERATING PRACTICES
REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE QUALIFICATION RE-
QUIREMENTS
OPERATORS
1. Crane operation shall be limited to personnel with the following minimum qualifications:
B. Trainees under the direct supervision of a designated person.
C. Maintenance and test personnel (when it is necessary in the performance of their duties).
D. Inspectors (crane).
2. No one other than the personnel specified above shall enter the operating area of a crane with the exception of persons such as oilers, supervisors, and those specified persons authorized by supervisors whose duties require them to do so and then only in the performance of their duties and with the knowledge of the operator or other persons.
QUALIFICATIONS FOR OPERATORS
1. Operators shall be required by the employer to pass a practical operating examination.
Qualifications shall be limited to the specific type of equipment for which examined.
2. Operators and operator trainees shall meet the following physical qualifications:
A. Vision of at least 20/30 Snellen in one eye and 20/50 in the other, with or without corrective lenses.
B. Ability to distinguish colors, regardless of position, if color differentiation is required for operation.
C. Adequate hearing with or without hearing aid for the specific operation.
3. Evidence of physical defects or emotional instability, which render a hazard to operator or others, which in the opinion of the examiner could interfere with the operator’s performance, may be sufficient cause for disqualification. In such cases, specialized clinical or medical judgment and tests may be required.
4. Evidence that operator is subject to seizures or loss of physical control shall be sufficient reason for disqualification. Specialized medical tests may be required to determine these conditions.
5. Operators and operator trainees should have normal depth perception, coordination, and no tendencies to dizziness or similar undesirable characteristics.
6. In addition to the above listed requirements, the operator shall:
A. Demonstrate the ability to comprehend and interpret all labels, operator’s manuals, safety codes, and other information pertinent to correct crane operations.
B. Posses 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 manufacturer.
F. Be thoroughly familiar with the crane and its control functions.
G. Understand the operating procedures as outlined by the manufacturer.
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.
3. The operator should not leave a suspended load unattended unless specific precautions have been instituted and are in place.
4. If there is a warning sign on the switch or engine starting controls, the operator shall not close the switch or start the engine until the warning sign has been removed by the appointed person.
5. Before closing the switch or starting the engine, the operator shall see that all controls are in the
"OFF"
2-4.0
6/15/10
QUALIFICATIONS FOR AND CONDUCT OF
OPERATORS AND OPERATING PRACTICES
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. Land the suspended load and boom, if practical.
7. The operator shall be familiar with the equipment and its proper care. If adjustments or repairs are necessary, the operator shall report the same promptly to the appointed person, and shall also notify the next operator.
8. The operator at the start of each shift shall test all controls. If any controls do not operate properly, they shall be adjusted or repaired before operations are begun.
9. Stabilizers shall be visible to the operator while extending or setting unless a signal person assists operator.
OPERATING PRACTICES/HANDLING THE
LOAD
1. Size of load.
A. No crane shall be loaded beyond the rated load except for test purposes
B. The load to be lifted is to be within the rated load of the crane and its existing configuration.
C. When loads that are not accurately known are to be lifted, the person responsible for the job shall ascertain that the weight of the load does not exceed the crane rated load at the radius at which the load is to be lifted.
A. The load shall be attached to the hook by means of slings or other devices of sufficient capacity.
B. Hoist rope shall not be wrapped around the load.
3. Moving the load.
The operator shall determine that:
A. The crane is level and, where necessary, the vehicle/carrier is blocked properly.
B. The load is well secured and balanced in the sling or lifting device before it is lifted more than a few inches.
C. Means are provided to hold the vehicle stationary while operating the crane.
D. Before starting to lift, the hook shall be positioned over the load in such a manner as to minimize swinging.
E. During lifting care shall be taken that:
1. There is no sudden acceleration or deceleration of the moving load.
2. Load, boom or other parts of the crane do not contact any obstruction.
F. Cranes shall not be used for dragging loads sideways.
G. This standard recognizes that telescopic boom cranes are designed and intended for handling materials. They do not meet personnel lift or elevator requirements.
Therefore, no lifting, lowering, swinging or traveling shall be done while a person is on the hook or load. Hook attached suspended work platforms (baskets) shall not be used with cranes covered by this standard. Crane manufacturer must approve work platforms attached to the boom.
H. The operator should avoid carrying loads over people.
I. When the crane is so equipped, the stabilizers shall be fully extended and set.
Blocking under stabilizers shall meet the requirements as follows:
1. Strong enough to prevent crushing.
2. Of such thickness, width and length as to completely support the stabilizer pad.
J. Firm footing under all tires, or individual stabilizer pads should be level. Where such a footing is not otherwise supplied, timbers, cribbing, or other structural members to distribute the load so as to not exceed allowable bearing capacity or the underlying material should provide it.
K. In transit, the boom shall be carried in stowed position.
L. 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.
M. The crane shall not be transported with a load on the hook unless recommended by the manufacturer.
2-5.0
6/15/10
QUALIFICATIONS FOR AND CONDUCT OF
OPERATORS AND OPERATING PRACTICES
N. No person should be permitted to stand or pass under a suspended load.
4. Stowing procedure.
Follow the manufacturer's procedure and sequence when stowing and un-stowing the crane.
MISCELLANEOUS
OPERATING NEAR ELECTRICAL POWER
LINES
3. Caution shall be exercised when working near overhead lines, because they can move horizontally or vertically due to wind, moving the danger zone to new positions.
4. In transit with no load and boom lowered the clearance shall be specified in Table 1.
5. A qualified signalperson shall be assigned to observe the clearance and give warning before approaching the above limits.
A. Any overhead wire shall be considered to be an energized line unless and until the person owning such line or the electrical utility authorities verify that it is not an energized line.
B. Exceptions to this procedure are allowed, if approved by the administrative or regulatory authority provided the alternate procedure insures equivalent protection and is set forth in writing.
C. Durable signs shall be installed at the operator's station and on the outside of the crane, warning that electrocution or serious bodily injury may occur unless a minimum clearance of 10 ft. (3.0m) between the crane or the load being handled and energized power lines. Greater clearances are required because of higher voltage as stated above.
These signs shall be revised but not removed when local jurisdiction requires greater clearances.
1. Cranes shall be operated so that no part of the crane or load enters into the danger zone shown above.
EXCEPTIONS
A. The danger zone may be entered after confirmation by an appointed person that the electrical distribution and transmission lines have been de-energized and visibly grounded at the point of work; or
B. The danger zone may be entered if insulating barriers (not a part of nor an attachment to the crane) have been erected to prevent physical contact with the lines.
2. For lines rated 50 kV or below, minimum clearance between the lines and any part of the crane or load (including handling appendages) shall be 10-ft. (3m). For higher voltages, see Table 1.
2-6.0
6/15/10
—-IMPORTANT—-
BEFORE OPERATING CRANE
1. Make sure this manual has been thoroughly read by all crane operating personnel and supervisors.
2. A routine inspection of the crane should be mandatory before each operating day. Any defects should be corrected immediately.
3. At a job site the vehicle should be positioned so that the crane can adequately reach the load within the rated capacity (centerline of rotation to hoist hook).
4. Keep the vehicle as level as possible during operation. CANNOT EXCEED 10° SLOPE.
5. For electric cranes, engage emergency
brake and leave ignition on with transmission in neutral (or in park for automatic transmissions). Activate any crane power switches. For Auto Crane units requiring battery and hydraulic operation, engage
emergency brake, place gear selector in neutral, press clutch, activate PTO, release clutch and after hydraulic fluid is warm, set throttle control to proper engine speed.
6. Always use outriggers from the truck to the ground. Be sure these are firm and adequately positioned. When rotating, keep load
as low to the ground as possible.
7. Remove the transmitter from cab or storage area. Power transmitter on. Detach hook from dead man. Crane is now ready for operation.
8. Always boom up before rotating so the boom will clear the required boom support.
9. When extending the boom, always maintain clearance between the boom crown and the traveling block or hoist hook.
10. Always observe safe and practical operation to avoid possible accidents. Refer to Safety Tips and Precautions.
11. After completing lifting operations, return the boom to stowed position on the boom support.
Avoid unneeded pressure on the boom support.
12. Store transmitter in proper location (in cab or storage area).
13. Return outriggers to stowed position. Make sure they are pinned in place or jacklegs are returned to compartment.
14. Check work area for any tools or equipment not stored.
15. Release throttle control, depress clutch and disengage PTO. Deactivate any crane power switches.
16. Report any unusual occurrence during crane operation that may indicate required maintenance or repair.
17. NEVER use two cranes to support a load too large for either crane.
OPERATION OF OUTRIGGERS
HYDRAULIC OUTRIGGERS
1. Shift crane/outrigger control valve to
"outrigger" position.
2. Operate the outrigger control valves to position the outriggers.
3. After outriggers are positioned, return crane/ outrigger selector to "crane" position.
4. Crane is now ready to operate.
MANUAL OUTRIGGERS
1. Pull lock pins to release jackleg or drop down outrigger and move to outermost lock position.
2. Make sure lock pins are reinstalled properly.
3. Lower outrigger pad to firm ground and adjust foot to take out slack.
4. Crane is now ready to operate.
3-1.0
6/15/10
CRANE OPERATION
TRANSMITTER LAYOUT
E-STOP SWITCH
MECHANICAL LATCHING
(TWIST TO UNLOCK)
BOOM DOWN
ROTATE CW
HOIST DOWN
BOOM RETRACT
ENGINE FAST IDLE
(NEXSTAR II ONLY)
ENGINE STOP
(NEXSTAR II ONLY)
O
FF
ON
SPEED
25% 50% 75% 100%
FAST
IDLE
ENG
STOP
AUX
ENG
START
ON/OFF/MULTI SPEED
3 POSITION KEYSWITCH
LED INDICATORS
BOOM UP
ROTATE CCW
HOIST UP
BOOM EXTEND
AUXILIARY
(NEXSTAR II ONLY)
ENGINE START
(NEXSTAR II ONLY)
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 button. The function speed increases the more the button is pressed.
Functions include Boom Up/Down,
Rotate CW-CCW, Hoist Up/Down, Boom
Extend, Retract.
Engine Fast-idle (Nexstar II Only) -
Activates Fast Idle on Vehicle. (Can be latching or momentary)
Auxiliary (Nexstar II Only) - Sends a latched signal that activates an auxiliary output to operate an external component i.e. compressor, worklights. (Must use a relay to separate auxiliary crane circuit and external component.)
Engine Stop (Nexstar II Only) - Sends a momentary signal from crane to shut down vehicle.
Engine Start (Nexstar II Only) - Sencs a momentary signal from crane to start vehicle.
BELT CLIP
TURNING OFF TRANSMITTER— Move the On/Off/Multi-speed switch to the “off” position
TURNING ON TRANSMITTER— Move the On/Off/Multi-speed switch to the “on” position, then move the On/Off/
Multi-speed switch to the “Multi-speed” or “start” position momentarily. The status light should be blinking green when active with no buttons depressed.
REMOVING KEY— Move the On/Off/Multi-speed switch to the “off” position, then move the switch counterclockwise one position past the “off” position. Once the switch is one position past the “off” position then pull out the switch from the transmitter.
3-2.0
6/15/10
E-STOP SWITCH
MECHANICAL LATCHING
(TWIST TO UNLOCK)
DECREASE MAX
SPEED
CRANE OPERATION
O
FF
ON
SPEED
25% 50% 75% 100%
ON/OFF/MULTI SPEED
3 POSITION KEYSWITCH
LED INDICATORS
INCREASE MAX
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.
2. Activating E-stop will not turn the truck off.
3. There will be an Error Code on the receiver stating “E-stop active”.
DEACTIVATING E-STOP
1. Twist to release E-stop.
2. Turn transmitter to the “OFF” position.
3. Once all lights turn off. Turn transmitter to the “ON” postion.
4. Turn transmitter to the “START”/”SPEED” position and release
Note:
There is very little height difference in a active and inactive E-stop. To verify E-stop switch is deactivated, twist switch to release.
WAKING UP TRANSMITTER
Turn the transmitter to the “START”/”SPEED” position and release
Note:
The transmitter goes into sleep mode after 5 minutes of inactivity. All truck functions are still available and will remain in the same state. (i.e. Aux function will remain on even when the unit goes to sleep if it was active before unit went to sleep.)
SPEED CONTROL
1. Rotate “ON/OFF/SPEED” switch to the “SPEED” position and hold
2. Press the Boom Up switch in increase max speed or press Boom Down button to decrease. Each time the button is actuated, the max speed increases or decrease by 25%.
3. Release “ON/OFF/SPEED” switch once the desired speed is selected.
Note:
1. Slower speed decreases the max speed and gives more finite control of the proportional push button.
2. Faster speed increases the max speed but give less finite control of the load
3. The LED indicators show the current speed setting of the transmitter.
3-3.0
6/15/10
CRANE OPERATION
RECEIVER LAYOUT
CRANE STATUS
AUXILIARY ACTIVE
LIFT CYLINDER
PRESSURE
FUNCTION ACTIVATED
SP - SPEED PERCENT
HIGH IDLE ACTIVE
BOOM ANGLE (DEGREES)
BOOM LOAD
(% OF TOTAL LOAD)
SYSTEM GOOD
Boom Pressure 174
Boom Down SP=100%
HIGH IDLE AUX ENG XXX
Boom Angle 43 (deg)
Boom Load 7%
9 80%
100%
ACTIVE SIGNALS
FROM TRANSMITTER
TRANSMITTER SIGNAL
STRENGTH
BATTERY LIFE
% LEFT
WATCH DOG
TIMER
ENGINE START (ENG ON) OR
ENGINE STOP (ENG OFF)
ACTIVE
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. Note: If multi-functioning, only last function selected will be displayed.
HIGH IDLE ACTIVE—Shown only when the high idle function is active (Nexstar II Only)
BOOM ANGLE (DEGREES) - Current boom angle in degrees. Note this value may not match the boom angle decal
attached to side of boom since the decal is referenced to the ground not the pedestal.
BOOM LOAD—Current percent of crane capacity used. Note: Unloaded this value may be higher than 0% due to
boom weight beyond the retracted position.
ACTIVE SIGNALS FROM TRANSMITTER—Shows current status of transmitter. 0 means the transmitter is not active. It must be turned on, e-stop deactivated, or taken out of sleep mode. 5-6 means the transmitter is active but no function is currently being selected. Receiver is waiting on a command from the user. 9-10 means the transmitter is sending crane function signals to start operating the crane. The user is sending a command for the crane to operate.
TRANSMITTER SIGNAL STRENGTH—Shows the strength of signal coming from transmitter. Note: approx. distance of
transmitter is 300 feet.
BATTERY LIFE—Percent of transmitter battery life remaining
WATCH DOG TIMER— Should always be spinning. If timer stops spinning contact your AutoCrane representative
ENGINE START/STOP—Shows when the Engine Start or Engine Stop button is being selected. Should only be visible when the corresponding button is being depressed. (Nexstar II Only)
AUXILIARY ACTIVE— Shows when the auxiliary function is active. (Nexstar II Only)
3-4.0
6/15/10
INSPECTION
REQUIREMENTS
REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE INSPECTION REQUIREMENTS
INSPECTION CLASSIFICATION
Prior to initial use, all new, altered, modified or extensively repaired cranes shall be inspected by a designated person to insure compliance with provisions of this standard
Inspection procedure for cranes in regular service is divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the components of the crane and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as "frequent" and "periodic" with respective intervals between inspections as defined below.
A. Frequent inspection - daily or before each use
B. Periodic inspection - one to twelve-month intervals or as specifically recommended by the manufacturer or qualified person.
DESIGNATED PERSONNEL SHALL
PERFORM INSPECTIONS ONLY.
6. Inspect for proper rope reeving.
7. Inspect electrical wiring and components for malfunctioning, signs of excessive deterioration, dirt and moisture accumulation.
8. Inspect hydraulic system for proper oil level and leaks.
9. Inspect tires for recommended inflation pressure, cuts and loose wheel nuts.
10. Inspect connecting pins and locking device for wear damage and loose retaining bolts.
11. Inspect rope for gross damage, such as listed below, which may be an immediate hazard.
A. Distortion such as kinking, crushing, un-stranding, birdcaging, main strand displacement, or core protrusion. Loss of rope diameter in a short length or unevenness of outer strands should be replaced.
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. Reference Rope Maintenance section in the owner’s manual.
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. Continued rope operation depends upon this remaining strength.
FREQUENT INSPECTION
Inspections should also occur during operation for any deficiencies that might appear between regular inspections. Any deficiencies, such as those listed below, shall be carefully examined and a determination made as to whether they constitute a hazard:
1. Inspect control mechanisms for maladjustment that interferes with proper operation.
2. Inspect control mechanisms for excessive wear of components and contamination by lubricants or other foreign matter.
3. Inspect safety devices for malfunction.
4. Visually inspect all hydraulic hoses, particularly those that flex in normal operation of crane functions.
5. Inspect hooks and latches for deformation, chemical damage, cracks, and wear. Refer to ANSI/
ASME B30.10.
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. Inspect for cracked or worn sheaves and drums.
4. Inspect for worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers and devices.
5. Inspect for excessive wear on brake and clutch system parts and lining.
4-1.0
6/15/10
INSPECTION
REQUIREMENTS
6. Inspect crane hooks for cracks.
7. Inspect travel steering, braking, and locking devices for malfunction.
8. Inspect for excessively worn or damaged tires.
9. Inspect hydraulic hose, fittings, and tubing for the following problems:
A. Evidence of leakage at the surface of the flexible hose or its junction with metal and coupling.
B. Blistering, or abnormal deformation to the outer covering of the hydraulic or pneumatic hose.
C. Leakage at threaded or clamped joints that cannot be eliminated by normal tightening or recommended procedures.
D. Evidence of excessive abrasion or scrubbing on the outer surface of a hose, rigid tube, or fitting. Means shall be taken to eliminate the interference of elements in contact or otherwise protect the components.
10. Inspect hydraulic pumps and motors for the following problems:
A. Loose bolts and fasteners.
B. Leaks at joints between sections.
C. Shaft seal leaks.
D. Unusual noises or vibrations.
E. Loss of operating speed.
F. Excessive heating of the fluid.
G. Loss of pressure.
11. Inspect hydraulic valves for the following problems:
A. Cracks in valve housing.
B. Improper return of spool to neutral position.
C. Leaks at spools or joints.
E. Failure of relief valves to attain or maintain correct pressure setting.
F. Relief valve pressure shall be checked as specified by the manufacturers.
12. Inspect hydraulic cylinders for the following problems:
A. Drifting caused by fluid leaking across piston.
C. Leaks at welding joints.
D. Scored, nicked, or dented cylinder rods.
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. Metal chips or pieces on the filter may denote failure in pumps, motors, or cylinders.
Further inspection will be necessary to determine the origin of the problem before corrective action can be taken.
14. Inspect labels to confirm correct location and legibility. Reference decal layout in this manual for proper location of decals.
15. Rope Inspections need not be at equal calen-
dar intervals and should be more frequent as
the rope approaches the end of useful life. A qualified person shall inspect the wire rope based on such factors as:
A. Expected rope life as determined by experience on the particular installation or similar installations.
B. Severity of environment.
C. Percentage of capacity lifts.
D. Frequency rates of operation.
E. Exposure to shock loads.
This inspection shall cover the entire length of the rope. Only the surface wires need to be inspected and no attempt should be made to open the rope. Any deterioration resulting in appreciable loss of original strength shall be noted and determination made as to whether use of the rope would constitute a hazard. A few notable deterioration points are listed below:
A. Reduction of rope diameter below nominal diameter due to loss of core support.
B. Internal or external corrosion.
C. Wear of outside wires.
D. Severly corroded, cracked, bent, worn, or improperly applied connections.
CRANES NOT IN REGULAR USE
A crane, which has been idle for a period of over one month or more, shall be given an inspection conforming to the “initial” and “regular” inspection requirements of this section.
INSPECTION RECORDS
Dated records of periodic inspection should be made on critical items such as brakes, crane hooks, rope, cylinders, and relief pressure valves.
4-2.0
6/15/10
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. Test all functions to verify speed and operation.
2. Check that all safety devices are working properly.
3. Confirm operating controls comply with appropriate function labels.
4. Test loads shall not exceed 110% of the manufacturer’s load rating.
5. Written reports shall be maintained showing test procedures and confirming the adequacy of repairs
4-3.0
6/15/10
GENERAL
REPAIRS AND MAINTENANCE
REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE MAINTENANCE AND
REPAIR REQUIREMENTS
A preventative maintenance program should be established based on this section and all replacement parts should be obtained from AutoCrane Company.
For replacement parts contact your local
authorized distributor.
MAINTENANCE PRECAUTIONS
1. Place crane where it will cause the least interference with other equipment or operations.
2. Verify all controls are in the "off" position and all operating features secured from inadvertent motion by brakes, pawls, or other means.
3. The means for starting the crane shall be rendered inoperative.
4. The boom should be secured in place before maintenance.
5. Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components.
6. Warning or "OUT OF ORDER" signs shall be placed on all crane controls.
7. After adjustments and repairs have been made, the crane shall not be returned to service until all guards have been reinstalled, trapped air removed from hydraulic system (if required), safety devices reactivated, and maintenance equipment removed.
ADJUSTMENTS AND REPAIRS
1. Any hazardous conditions disclosed by the inspection requirements shall be corrected before operation of crane is resumed. Only designated personnel shall do adjustments and repairs.
2. Adjustments shall be maintained to assure correct functioning of components, the following are examples:
A. Functional operating mechanism.
3. Repairs or replacements shall be provided as needed for operation, the following are examples:
A. Critical parts of functional operating mechanisms which are cracked, broken, corroded, bent, or excessively worn.
B. Critical parts of the crane structure which are cracked, bent, broken, or excessively corroded.
C. Crane hooks showing cracks, damage, or corrosion shall be taken out of service. Repairs by welding are not recommended.
4-4.0
4. If bleeding the hydraulic system is required, run each crane function until smooth operation of that particular function is noticeable.
LUBRICATION
All moving parts of the crane, for which lubrication is specified, should be regularly lubricated per the manufacturer's recommendations and procedures.
Reference Lubrication and Maintenance Schedule in this manual.
ROPE REPLACEMENT
No precise rules can be given for determination of the exact time for replacement of rope, since many variable factors are involved.
1. Conditions such as the following shall be reason for questioning continued use of the rope or increasing the frequency of inspection:
A. In running ropes, six randomly distributed broken wires in one lay or three broken wires in one strand in one lay.
B. One outer wire broken at the contact point with the core of the rope structure and protrudes or loops out of the rope structure. Additional inspection of this section is required.
C. Wear of one third of the original diameter of the outside individual wire.
D. Kinking, crushing, bird caging, or any other damage resulting in distortion of the rope structure.
E. Evidence of any heat damage from any cause.
F. Reduction from nominal diameter of more than
1/64 in. (0.4mm) for diameters up to and including 5/16 in. (8 mm), 1/32 in. (0.8 mm) for diameter 3/8 in. (9.5 mm) to and including 1/2 in.
(13 mm), 3/64 in. (1.2 mm) for diameter 9/16 in.
(14.5 mm) to and including 3/4 in. (19 mm). 1/16 in. (1.6 mm) for diameter 7/8 in. (22 mm) to and including 11/8 in. (29 mm), 3/32 in. (2.4 mm) for diameters 11/4 in. (32 mm) to and including 11/2 in. (38 mm).
G. In standing ropes, more than two broken wires in one lay in sections beyond end connections or more than one broken wire at an end connection.
6/15/10
GENERAL
REPAIRS AND MAINTENANCE
2. Replacement rope shall have a strength rating at least as great as the original rope furnished or recommended by AutoCrane. A rope manufacturer, AutoCrane, or a qualified person shall specify any deviation from the original size, grade, or construction.
ROPE MAINTENANCE
1. Rope should be stored to prevent damage or deterioration.
2. Unreeling or uncoiling of rope shall be done as recommended by the rope manufacturer and with care to avoid kinking or inducing twist.
3. Before cutting a rope, seizing shall be placed on each side of the place where the rope is to be cut to prevent unlaying of the strands. On pre
-formed rope, one seizing on each side of the cut is required. On non-preformed ropes of 7/8 in. (22 mm) diameter or smaller, two seizings on each side of the cut are required, and for nonpreformed rope 1 in. (25 mm) diameter or larger, three seizings on each side of the cut are required.
4. During installation care should be exercised to avoid dragging of the rope in the dirt or around objects that will scrape, nick crush or induce sharp bends in it.
5. Rope should be maintained in a well-lubricated condition. It is important that lubricant applied as a part of a maintenance program shall be compatible with the original lubricant and to this end the rope manufacturer should be consulted. Lubricant applied shall be the type that does not hinder visual inspection. Those sections of rope that are located over sheaves or otherwise hidden during inspection and maintenance procedures require special attention when lubricating rope. The object of rope lubrication is to reduce internal friction and to prevent corrosion.
6. When an operating rope shows greater wear or well-defined localized areas than on the remainder of the rope, rope life can be extended in some cases by shifting the wear to different areas of the rope.
4-5.0
6/15/10
MAINTENANCE
OF BATTERIES
Maintenance of Auto Crane unit batteries differs very little from the generally prescribed maintenance of any lead acid battery. All batteries must be kept properly charged, properly filled with water, and relatively clean.
Keep Properly Charged
Many things affect the proper charge to a battery, such as:
2. Proper tightness of belts on the alternator or generator.
3. Good, clean connections of all cables and wires at the following places: a. Battery. b. Regulator. e. Ground connections (most important).
It is of extreme importance to keep the battery as fully charged as possible without overcharging, especially when vehicles are left outside for extended periods in extremely cold climates. A battery can freeze. Freezing points for various specific gravities of acid are as follows:
Specific Gravity Freezing Temp.
(Corrected to 80ºF) Degrees F.
1.280 -90ºF
1.250 -62ºF
1.200 -16ºF
1.150 5ºF
1.100 19ºF
As shown, a half-charged battery (about 1.100 specific gravity) cannot stand for any length of time at 20ºF or it will freeze.
The main reason for keeping the battery as fully charged as possible without over-charging is to insure that power is available even though the vehicle has been standing for some time.
Keep Properly Filled with Water
The battery should always be properly filled with water. If the electrolyte level is allowed to fall below the top of the plates, the results become threefold:
1. The exposed portion of the plate will become sulfated.
2. The portion of the plate exposed is not usable.
3. That portion of the acid remaining becomes more concentrated and may cause more rapid deterioration of the remaining parts of the battery.
Keep A Relatively Clean Battery
The battery should be kept clean. Batteries filled with acid and which are not in use self-discharge to a limited degree because of the nature of the materials within the battery. If dirt is allowed to collect on the top of the battery (and this dirt absorbs moisture) and electrical path can be set up between the various terminals of the battery and the ground. Once such a path has been established, the self-discharge of the battery is accelerated. This also accelerates corrosion of the battery cables at the terminals.
Periodic Maintenance is Needed
A definite program of periodic maintenance of all batteries should be conducted on a regular basis. Periodic maintenance includes:
1. Checking belts for tightness on the charging equipment.
2. Checking battery electrolyte levels.
3. Checking cables for good connections.
4. Cleaning where corrosion is apparent.
When corrosion is cleaned off, the cable terminals and battery terminals should be coated with a light coating of petroleum jelly before they are replaced. When terminals are cleaned, the top of the battery should be cleaned with a mild solution of soda water.
Low Maintenance Batteries
(Maintenance Free)
Low maintenance batteries should not be used on
AutoCrane Cranes or trucks equipped with Auto-
Crane Cranes. The batteries are not designed for
"deep" discharge.
Testing Your Battery
If the condition of the battery is in question, it should be removed from the vehicle, taken to the shop, and allowed to reach room temperature. It should then be recharged until specific gravity readings taken at onehalf hour intervals. If the specific gravity readings are fairly uniform, the battery should be checked with a high rate tester. Use the tester in accordance with the manufacturer's instructions. The high rate tester is the best method to test a questionable battery.
4-6.0
6/15/10
MAINTENANCE
OF BATTERIES
If, after charging, it is noted that the specific gravity reading of one cell is 30 points less than any of the other cells, it may be assumed that the cell is bad and that the battery should be replaced. If all cells are uniform but not up to full charge, a low rate of charge should be attempted for an extended time.
This usually will recover a badly sulfated battery.
Replacing a Battery
If it is necessary to replace a battery, and a dry charge battery is used, the following procedure applies:
1. Fill the battery with electrolyte of the proper specific gravity.
2. Place the battery on charge according to the manufacturer's instructions.
It is essential that the second step above be followed to ensure that the battery going on the vehicle is fully charged.
It is also very important that the battery hold-downs be checked periodically to insure that the batteries are properly positioned to avoid vibration problems, breakage of cables or terminals. Care must be taken to avoid cracking or breaking containers or covers by tightening hold-down fixtures excessively. They also must not be so loose that breakage results from a hold-down that is too loose.
4-7.0
6/15/10
14005H
LUBRICATION & MAINTENANCE SCHEDULE
CAUTION: Routine maintenance insures trouble-free operation and protects your investment. All warranties are void if maintenance is neglected.
4-8.0
6/15/10
14005H
LUBRICATION & MAINTENANCE SCHEDULE
NOTES:
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 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. Additional copies are available from your local distributor.
4-9.0
6/15/10
14005H
SAFETY DECAL SECTION
PART NO.:
DECAL:
040579000
OPERATING INSTRUCTIONS
FUNCTION: To inform the operator of the proper procedure to follow for safe operation of the crane.
USED ON: All Cranes
QUANTITY: 1
PLACEMENT: Right side plate
PART NO.:
DECAL:
040580000
OPERATING TRAINING
FUNCTION: To inform the operator of the need to receive proper training before using the crane.
USED ON: All Cranes
QUANTITY: 1
PLACEMENT: Right side plate
PART NO.:
DECAL:
040632000
TAMPERING WITH OVERLOAD DEVICE
FUNCTION: To inform the operator that tampering with the overload device may cause a unit failure or possible personal injury.
USED ON: All Cranes equiped with a load sensor
QUANTITY: 1
PLACEMENT: Right side of valve sensor.
5-1.0
6/15/10
14005H
SAFETY DECAL SECTION
PART NO.:
DECAL:
040529000
ELECTROCUTION HAZARD
FUNCTION: To inform the operator of the hazard involved with contacting electrical power lines with crane boom.
USED ON: All Cranes
QUANTITY: 2
PLACEMENT: Both sides of end of lower boom
PART NO.:
DECAL:
040517000
STAY CLEAR OF BOOM
FUNCTION: To inform the operator of the hazard of proximity or contact with the crane boom during operation.
USED ON: All Cranes
QUANTITY: 2
PLACEMENT: Both sides of crown
PART NO.: 040518000
DECAL: STAY CLEAR OF LOAD
FUNCTION: To inform the operator of the hazard of proximity or contact with the crane load during operation.
USED ON: All Cranes
QUANTITY: 2
PLACEMENT: Both sides of traveling block
5-2.0
6/15/10
14005H
SAFETY DECAL SECTION
PART NO.:
DECAL:
040587000 USED ON: All cranes equipped with a load sensor.
LOAD SENSOR, DON'T TAMPER QUANTITY: 2
FUNCTION: To inform the operator that the load sensor is pre-set and that tampering with the sensor may cause potentially hazardous situation.
USED ON: All cranes equipped with a load sensor.
QUANTITY: 1
PLACEMENTOn the lift cylinder near the load sensor
PLACEMENT: Both sides of the lift cylinder near the load sensor
PART NO.: 040519000
DECAL: SCISSORS POINT
FUNCTION: To inform the operator of possible danger at scissors point on crane.
USED ON: All cranes.
QUANTITY: 2
PLACEMENT: Both sides of the lift cylinder
5-3.0
6/15/10
14005H
SAFETY DECAL SECTION
PART NO.: 460169000
DECAL: REMOTE CONTROL
FUNCTION: To inform the operator of failure to follow the saftey precautions may result in equipment failure or serious personal injury.
USED ON:
QUANTITY:
All Cranes equiped with FM controls.
1
PLACEMENT: FRONT OF POWER UNIT
WARNING
REMOTE CONTROL SAFETY PRECAUTIONS
READ THE OPERATOR'S MANUAL before using the Remote Control System.
Failure to follow the safety precautions may result in equipment failure or serious personal injury.
MAKE SURE MACHINERY AND SUROUNDING AREA IS CLEAR BEFORE
OPERATING REMOTE CONTROL SYSTEM. Do not activate the Remote Control
System unless it is safe to do so.
TURN OFF THE RECEIVER POWER BEFORE WORKING ON THE MACHINE.
Always disconnect the Remote Control System before doing any maintenance to prevent accidental operation of the machine.
DO NOT MODIFY EQUIPMENT WITHOUT WRITTEN APPROVAL FROM THE
MANUFACTURER.
CARE
KEEP DRY. Do not clean the Transmitter / Receiver under high pressure. If water or other liquids get inside the Transmitter battery or Receiver compartment, immediately dry the unit. Remove the case and let the unit air dry.
Clean the unit after operation using a damp cloth to remove any mud, dirt, concrete, etc. from the unit and prevent clogging of buttons, switches, etc.
MAINTENANCE / WELDING
DISCONNECT THE RECEIVER BEFORE WELDING ON THIS MACNINE. Failure to disconnect will result in the destruction of the Receiver.
5-4.0
6/15/10
NOTES
5-5.0
6/15/10
14005H DECAL LAYOUT
P/N: 470102021
5-6.0
6/15/10
8406H DECAL LAYOUT
P/N: 470102021
5-7.0
6/15/10
14005H
GENERAL DIMENSIONS
6-1.0
6/15/10
NOTES
6-2.0
6/15/10
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.
REQUIREMENTS FOR INSTALLATION USING 36 GALLON RESERVOIR(*)
A. RETURN LINE FROM CRANE TO RESERVOIR (IN COMPARTMENT): -12 SAE 100R2 (OR EQUIVA-
LENT ). HOSE LENGTH IS DETERMINED BY INSTALLER. RETURN LINES LONGER THAN 6 FEET
SHOULD BE SIZE –12. HOSE END FITTINGS ARE –10 JIC FEMALE SWIVEL (CRANE END) AND –12
JIC FEMALE SWIVEL (RESERVOIR END).
B. PRESSURE LINE FROM PUMP TO CRANE: -8 SAE 100R12 (OR EQUIVALENT) WITH A 2,850 PSI
MINIMUM WORKING PRESSURE. HOSE LENGTHS IS DETERMINED BY INSTALLER. HOSE END
FITTINGS ARE BOTH –10 JIC FEMALE SWIVEL.
(*) NOTE: 36 GAL RESERVOIR IS MINIMUM REQUIREMENT FOR CRANE ONLY. THE ADDITION OF
OTHER AUXILLARY EQUIPMENT WILL REQUIRE ADDITIONAL CAPACITY.
CAUTION
–FAILURE TO USE CLEAN HYDRAULIC HOSES AND COMPONENTS
MAY CONTAMINATE THE CRANE AND HYDRAULIC SYSTEM AND VOID
WARRANTY.
3. Crane must be provided with a flow of 15 to 19 gallons per minute and a pressure of 2,800 PSI.
Excess flow will cause erratic operation, and too little flow will cause poor crane operation.
4. Vehicle should meet minimum GVW rating of 29,000 pounds.
5. The vehicle MUST be equipped with an engine speed control and tachometer.
6. Make sure mounting surface is properly reinforced to withstand 70,000 ft-lb capacity loading of crane and that outriggers are used to provide total stability for the truck.
6-3.0
6/15/10
14005H
MOUNTING AND INSTALLATION
7. A 15” diameter hole should be cut out of mounting location (centered with mounting bolts) for access
to hydraulic connections.
8. Make sure the mounting bolts are 7/8” dia, grade 8-UNF. Torque bolts to 501 ft-lbs.
9. When crane is not in operation, a boom support should always be used. Traveling block should be connected to hook loop.
10. Electrical hookup:
Wiring-cable from base of crane.
A. CONNECT THE BLACK WIRE TO THE BATTERY NEGATIVE (GROUND).
B. CONNECT THE RED WIRE TO FUSED 12VDC POWER. 12VDC POWER SHOULD BE SUPPLIED
THROUGH A DEDICATED SWITCH THAT IS POWERED ONLY WHEN THE IGNITION
SWITCH IS ON.
C. OPTIONALLY, USE THE WHITE WIRE FOR ENGINE FAST/SLOW (12VDC MAINTAINED-FM
ONLY).
D. OPTIONALLY, USE THE BLUE WIRE FOR ENGINE START.
E. OPTIONALLY, USE THE ORANGE WIRE FOR ENGINE STOP.
F. OPTIONALLY, USE THE GREEN WIRE FOR AUXILIARY (12VDC MAINTAINED-FM ONLY).
NOTE: ALL ELECTRICAL CONNECTIONS BETWEEN THE CRANE AND THE VEHICLE SHOULD BE
MADE USING RELAYS TO ISOLATE THE ELECTRICAL SYSTEMS OF EACH AS MUCH AS POSSIBLE.
WARNING!
FAILURE TO CORRECTLY PLUMB AND WIRE CRANE CAN CAUSE INADVERTENT OPERATION AND
DAMAGE TO CRANE AND/OR PERSONNEL!
11. Once crane and plumbing are installed on the truck, fill the reservoir to top of sight glass (mobile DTE 13 or equal). Before operating crane, connect together the pressure and return hoses going to base of crane using
12-12 JIC union and engage PTO with engine running. Allow oil to circulate for 15 to 20 minutes. This will flush contaminants from the system back to the return line filter. Operate all cylinders to full extension and retraction a minimum of six times, to bleed air from system. Return all cylinders to the stored position and disengage
PTO. Refill reservoir to top sight glass. To ensure 15 gallons per minute (GPM), install an in-line flow meter between the crane and the reservoir in the return hose.
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).
WARNING
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. ANY MODIFICATIONS PERFORMED ON THE
VEHICLE PRIOR TO THE FINAL STAGE ARE ALSO CONSIDERED INTERMEDIATE STAGE MANUFACTURING AND MUST
BE CERTIFIED AS TO COMPLIANCE. THE INSTALLER OF THIS CRANE AND BODY IS CONSIDERED ONE OF THE MANU-
FACTURERS OF THE VEHICLE. AS SUCH A MANUFACTURER, THE INSTALLER IS RESPONSIBLE FOR COMPLIANCE
WITH ALL APPLICABLE FEDERAL AND STATE REGULATIONS, AND IS REQUIRED TO CERTIFY THAT THE VEHICLE IS IN
COMPLIANCE.
IT IS THE FURTHER RESPONSIBILITY OF THE INSTALLER OF THE CRANE TO COMPLY WITH THE OSHA TRUCK CRANE
STABILITY REQUIREMENTS AS SPECIFIED BY 29 CFR PART 1910.180 (C) (1).
6-4.0
6/15/10
14005H GENERAL ASSEMBLY
P/N 470102XXX
7-1.0
6/15/10
14005H GENERAL ASSEMBLY
7-2.0
6/15/10
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
6/15/10
14005H PEDESTAL ASSEMBLY
NEXSTAR-P/N: 4701022XX
7-4.0
6/15/10
14005H PEDESTAL ASSEMBLY
NEXSTAR P/N 4701022XX
7-5.0
6/15/10
14005H PEDESTAL ASSEMBLY
4701022XX
7-6.0
6/15/10
14005H PEDESTAL ASSEMBLY
4701022XX
7-7.0
6/15/10
NOTES
7-8.0 6/15/10
14005H BOOM ASSEMBLY
P/N: 470050000
CYL SEAL KIT P/N: 480988151
C’BAL P/N: 360153001
7-9.0
6/15/10
14005H BOOM ASSEMBLY
P/N: 470050000
7-10.0
6/15/10
14005H ROTATION GEARBOX
P/N: 470003000
7-11.0
6/15/10
14005H ROTATION GEARBOX
P/N: 470003000
7-12.0
6/15/10
14005H HOIST ASSEMBLY
P/N: 123416
7-13.0
6/15/10
14005H HOIST ASSEMBLY
P/N: 123416
7-14.0
6/15/10
14005H HOIST ASSEMBLY
P/N: 123416
7-15.0
6/15/10
14005H TRAVELING BLOCK ASSEMBLY
P/N: 470025000
7-16.0
6/15/10
14005H MAIN HARNESS
P/N: 366823257
1
3
4 18
J1
2 3
J2
6
15
15.5
22
24
[610]
84
[2134]
53
[1346]
40
[1017]
37
[940]
36.5
[927]
32
[813]
30.5
[775]
31.5
[800]
33.5
[851]
22 23 24
J3
5
8 13
CAP
J4
J23
J20
7 8 19
J24
7 8 19
J15
11 15 19
19 8 7
J19
22 21 20
J13
J14
J11
J12
8
19 7
J5
J6
J7
J8
J9
J10
13
CAP
17
J17
16
J21 9 10
19 7
8
J16
J22
14
CONNECTOR
J1
J2
J3
J4
J5
J6
J7
J8
J9
J10
J11
J12
J13
J14
J15
J16
J17
J18
J19
J20
J21
J22
J23
J24
4707 NORTH MINGO ROAD
CONNECTOR ID
DESCRIPTION
RECIEVER 18 PIN CONNECTION
RECIEVER 30 PIN CONNECTION
USB CONNECTION
CAN CONNECTOR
BOOM UP
BOOM DOWN
SWING CW
SWING CCW
BOOM RETRACT
BOOM EXTEND
HOIST A DOWN
HOIST A UP
HOIST B DOWN
HOIST B UP
ANTI-2 BLOCK
DUMP VALVE
BOOM ANGLE SENSOR
PENDANT CONNECTION
ALARM LIGHT
ADDRESS
BOOM PT
DIRTY FILTER
SWING LIMIT SWITCHES
FAST IDLE MOMENTARY
8-1.0
6.0
ENGINE STOP
ENGINE START
POWER
GROUND
AUX
HIGH IDLE
POWER/ENGINE
12
J18
6/15/10
14005H MAIN HARNESS
P/N: 366823257
8-2.0
6/15/10
14005H HYDRAULIC CONTROL VALVE
NEXSTAR I P/N: 480989261
8-3.0
6/15/10
14005H HYDRAULIC CONTROL VALVE
NEXSTAR I P/N: 480989261
8-4.0
6/15/10
14005HHYDRAULIC CONTROL VALVE
NEXSTAR II P/N: 480959251
8-5.0
6/15/10
14005HHYDRAULIC CONTROL VALVE
P/N: 480989251
8-6.0
6/15/10
14005H
COUNTERBALANCE VALVE ADJUSTMENT
Counterbalance Valve Adjustment
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.
A. To increase the CB valve setting, loosen nut and turn Allen head screw counter
clockwise.
B. To reduce the CB valve setting, loosen nut and turn Allen head screw
clockwise.
3. Tighten nut on adjustment screw and repeat procedure if needed to obtain the proper
4. Disengage PTO, remove the pressure gauge and install plug. Crane is now ready
Notice:
becomes necessary to lower the boom without flow present, the CB valve adjustment can be turned in until the boom begins to descend. Make sure the boom will lower onto a proper support. Loosen the lock nut and carefully turn adjustment screw clockwise! Count the number of turns. Turn slowly until the
boom just begins to lower, and remove hand/arm/
fingers from cranes while boom is lowering. come apart on the inside. This condition is not repairable
3. After boom is lowered, turn adjustment screw counter clockwise the approximate number of turns made during lowering procedure. After the problem is corrected, readjust the counterbalance valve using the procedure in this manual.
WARNING:
DO NOT TRY TO ADJUST VALVES WHILE BOOM IS MOVING.
Doing so may result in personal injury!
9-1.0
6/15/10
14005H
VALVE OVERRIDE OPERATION
9-2.0
6/15/10
14005H
TROUBLESHOOTING CHART
SECTION UNDER DEVELOPMENT
9-3.0
6/15/10
14005H
ERROR CODE TROUBLESHOOTING CHART
9-4.0
6/15/10
14005H
ELECTRICAL TROUBLESHOOTING CHART
9-5.0
6/15/10
14005H
ELECTRICAL TROUBLESHOOTING CHART
9-6.0
6/15/10
14005H
HYDRAULIC TROUBLESHOOTING CHART
9-7.0
6/15/10
14005H LOAD CHART
P/N 470102026
9-8.0
6/15/10
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Key features
- Overload shutdown device
- 12-volt truck electrical system
- Safety features
- Multiple boom lengths
- Variable lifting capacities
- Easy to operate
- Durable construction
