NexStar Owners Manual (revised 6/17/10)

NexStar Owners Manual (revised 6/17/10)
10006
NEXSTAR
OWNERS MANUAL
Manual No. 460178010
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
10006H
OWNER’S MANUAL REVISION RECORD
Revision
Date
6/17/10
Section(s)
Or
Page(s)
4-9,5-6,6-1,6-3,
7-1,7-2
Description of Change
Changed light on crane. Revised artwork and BOM. Revised pressure to 15
to 19
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
10006H
TABLE OF CONTENTS
10006H
INTRODUCTION
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.
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 has incorporated several safety
features in the 10006H crane for your
protection.
For your convenience the overall
dimensions of the 10006H 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 10006H cranes are attached to your
12-volt truck electrical system through the
relay provided. The 10006H 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
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
8/25/05
10006H
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 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.
1-2.0
8/25/05
10006H
GENERAL SPECIFICATIONS
DIMENSIONS
REACH
Width:
24.5 in (0.62 m)
Height:
36.0 in (0.91 m)
Second boom will reach from 12 feet 4 inches
to 20 feet 4 inches.
Third boom will reach from 20 feet 4 inches to
25 feet 4 inches.
Length:
14 ft 8 in (4.47 m)
[Boom(s) stored]
Weight:
2,330 lbs (1057 kg)
CABLE
120 ft (36.6 m) of 7/16 in (11.1 mm) diameter
aircraft quality cable. This cable has a single
line breaking strength of 20,400 lbs (9,253 kg).
CAPACITY
CHASSIS REQUIREMENTS
60,000 ft-lbs (8.30 ton-m)
[ft-lbs = horizontal distance from centerline
of rotation to free hanging weight (feet) x
amount of weight (pounds)]
26,000 lbs (11,793 kg) GVWR minimum
900,000 in-lbs RBM
HYDRAULIC REQUIREMENTS
15 gpm flow @ 3,000 psi
ELECTRICAL SYSTEM REQUIREMENTS
Voltage:
12 VDC
Alternator:
60 amps (minimum)
Battery:
100 minute reserve
capacity (minimum)
Maintenance type
ROTATION
370º Rotation with electric stop.
1-3.0
12/17/09
—-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
10/16/06
—-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.
41.
42.
43.
44.
45.
46.
47.
2-2.0
WARNING: Never attempt to lift, drag, tow or
pull a load from the side. The boom can fail
far below its rated capacity.
Do not push down on anything with boom
extensions; similarly do not lift anything with
boom extensions.
Do not lift personnel with any wire rope attachment or hook. There is no implied warranty or responsibility for such purposes.
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.
WARNING: Never place a chain link on the
tip of the hook and try to lift a load with the
hoist.
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.
Do not wrap the wire rope around sharp objects when using winch.
WARNING: Never unreel last 5 wraps of cable from drum.
10/16/06
—-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
7/27/05
QUALIFICATIONS FOR AND CONDUCT OF
OPERATORS AND OPERATING PRACTICES
REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE QUALIFICATION REQUIREMENTS
OPERATORS
1. Crane operation shall be limited to personnel
with the following minimum qualifications:
A. Designated persons.
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
8/19/05
QUALIFICATIONS FOR AND CONDUCT OF
OPERATORS AND OPERATING PRACTICES
6.
7.
8.
9.
or neutral position and all personnel are in
the clear.
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.
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.
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.
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.
2. Attaching the load.
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
8/19/05
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
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.
OPERATING NEAR ELECTRICAL POWER
LINES
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
8/19/05
—-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
MANUAL 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.
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
8/19/05
CRANE OPERATION
TRANSMITTER LAYOUT
E-STOP SWITCH
MECHANICAL LATCHING
(TWIST TO UNLOCK)
SPEED
ON/OFF/MULTI SPEED
3 POSITION KEYSWITCH
OF
F
ON
LED INDICATORS
25%
50%
75%
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.
100%
BOOM DOWN
BOOM UP
ROTATE CCW
ROTATE CW
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.
HOIST UP
HOIST DOWN
BOOM EXTEND
BOOM RETRACT
AUXILIARY
(NEXSTAR II ONLY)
ENGINE FAST IDLE
(NEXSTAR II ONLY)
FAST
IDLE
AUX
ENGINE START
(NEXSTAR II ONLY)
ENGINE STOP
(NEXSTAR II ONLY)
ENG
STOP
ENG
START
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
12/21/09
CRANE OPERATION
E-STOP SWITCH
MECHANICAL LATCHING
(TWIST TO UNLOCK)
SPEED
ON/OFF/MULTI SPEED
3 POSITION KEYSWITCH
OF
F
ON
LED INDICATORS
25%
50%
75%
100%
DECREASE MAX
SPEED
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.
2.
3.
4.
Twist to release E-stop.
Turn transmitter to the “OFF” position.
Once all lights turn off. Turn transmitter to the “ON” postion.
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
12/21/09
CRANE OPERATION
RECEIVER LAYOUT
CRANE STATUS
LIFT CYLINDER
PRESSURE
FUNCTION ACTIVATED
SP - SPEED PERCENT
HIGH IDLE ACTIVE
BOOM ANGLE (DEGREES)
BOOM LOAD
(% OF TOTAL LOAD)
AUXILIARY ACTIVE
SYSTEM GOOD
Boom Pressure 174
Boom Down
SP=100%
HIGH IDLE AUX ENG XXX
Boom Angle 43 (deg)
Boom Load 7%
100%
9
80%
ENGINE START (ENG ON) OR
ENGINE STOP (ENG OFF)
ACTIVE
ACTIVE SIGNALS
FROM TRANSMITTER
TRANSMITTER SIGNAL
STRENGTH
WATCH DOG
TIMER
BATTERY LIFE
% LEFT
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
12/21/09
INSPECTION
REQUIREMENTS
REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE INSPECTION REQUIREMENTS
6. Inspect for proper rope reeving.
INSPECTION CLASSIFICATION
1. Initial inspection.
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
1. Regular inspection.
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.
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.
DESIGNATED PERSONNEL SHALL
PERFORM INSPECTIONS ONLY.
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.
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.
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
8/16/05
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.
D. Sticking spools.
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.
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. 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 calendar 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
8/16/05
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
8/16/05
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.
4. If bleeding the hydraulic system is required, run
each crane function until smooth operation of that
particular function is noticeable.
MAINTENANCE PRECAUTIONS
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.
LUBRICATION
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.
B. Safety devices.
C. Control systems.
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.
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.
C. Crane hooks showing cracks, damage, or
corrosion shall be taken out of service. Repairs
by welding are not recommended.
4-4.0
8/16/05
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
8/16/05
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.
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 Properly Charged
Keep A Relatively Clean Battery
Many things affect the proper charge to a battery,
such as:
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.
1. Regulator settings.
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.
c. Starting motor.
d. Alternator or generator.
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
(Corrected to 80ºF)
1.280
1.250
1.200
1.150
1.100
Freezing Temp.
Degrees F.
-90ºF
-62ºF
-16ºF
5ºF
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.
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 AutoCrane 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
8/16/05
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:
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.
1. Fill the battery with electrolyte of the proper
specific gravity.
4-7.0
8/16/05
10006H
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
1/12/10
10006H
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
6/17/10
10006H
SAFETY DECAL SECTION
PART NO.:
040579000
DECAL:
OPERATING INSTRUCTIONS
FUNCTION:
To inform the operator of the proper
procedure to follow for safe operation
of the crane.
USED ON:
All Cranes
QUANTITY:
1
PLACEMENT: Right side plate
PART NO.:
040580000
DECAL:
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.:
040632000
DECAL:
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
1/12/10
10006H
SAFETY DECAL SECTION
PART NO.:
040529000
DECAL:
ELECTROCUTION HAZARD
FUNCTION:
To inform the operator of the
hazard involved with contacting
electrical power lines with crane
boom.
USED ON:
All Cranes
QUANTITY:
2
PLACEMENT: Both sides of end of lower boom
PART NO.:
040517000
DECAL:
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
1/12/10
10006H
SAFETY DECAL SECTION
PART NO.:
040587000
USED ON:
DECAL:
LOAD SENSOR, DON'T TAMPER
QUANTITY:
All cranes equipped with a load
sensor.
2
FUNCTION: To inform the operator that the load
PLACEMENT: Both sides of the lift cylinder
sensor is pre-set and that tampering
near the load sensor
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
PART NO.:
040519000
USED ON:
All cranes.
DECAL:
SCISSORS POINT
QUANTITY:
2
FUNCTION: To inform the operator of possible
danger at scissors point on crane.
5-3.0
PLACEMENT: Both sides of the lift cylinder
1/12/10
10006H
SAFETY DECAL SECTION
PART NO.:
460169000
USED ON:
DECAL:
REMOTE CONTROL
QUANTITY:
FUNCTION: To inform the operator of failure to
follow the saftey precautions may
result in equipment failure or serious
personal injury.
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
1/12/10
NOTES
5-5.0
1/12/10
10006H DECAL LAYOUT
P/N: 460178021
5-6.0
6/17/10
10006H DECAL LAYOUT
P/N: 460178021
5-7.0
1/12/10
10006H
GENERAL DIMENSIONS
6-1.0
1/12/10
NOTES
6-2.0
1/12/10
10006H
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 EQUIVALENT ). 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 –10
JIC FEMALE SWIVEL (RESERVOIR END).
B. PRESSURE LINE FROM PUMP TO CRANE: -10 SAE 100R12 (OR EQUIVALENT) WITH A 3,000 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 3,400 PSI. Excess
flow will cause erratic operation, and too little flow will cause poor crane operation.
4. Vehicle should meet minimum GVW rating of 26,000 pounds.
5. The vehicle MUST be equipped with an engine speed control and tachometer.
6. Make sure mounting surface is properly reinforced to withstand 60,000 ft-lb capacity loading of
crane and that outriggers are used to provide total stability for the truck.
6-3.0
1/12/10
10006H
MOUNTING AND INSTALLATION
7. A 13 1/2” 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
10-12 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 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.
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
1/12/10
10006H GENERAL ASSEMBLY
P/N 460178XXX
7-1.0
1/12/10
10006H GENERAL ASSEMBLY
7-2.0
1/12/10
10006H PEDESTAL ASSEMBLY
NEXSTAR—P/N 460178XXX
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: 366822251
COUNTER BALANCE CARTRIDGE: 480188000
7-3.0
1/12/10
10006H PEDESTAL ASSEMBLY
7-4.0
1/12/10
10006H PEDESTAL ASSEMBLY
460178XXX
7-5.0
1/12/10
10006H PEDESTAL ASSEMBLY
460178XXX
7-6.0
1/12/10
10006H PEDESTAL ASSEMBLY
460178XXX
7-7.0
1/12/10
NOTES
7-8.0
10006H BOOM ASSEMBLY
P/N: 460178100
CYL SEAL KIT P/N: 480988151
C’BAL P/N: 360153001
7-9.0
1/12/10
10006H BOOM ASSEMBLY
P/N: 460178100
7-10.0
1/12/10
10006H ROTATION GEARBOX
P/N: 160414
7-11.0
1/12/10
10006H ROTATION GEARBOX
P/N: 160414
7-12.0
1/12/10
10006H HOIST ASSEMBLY
P/N: 123428
7-13.0
1/12/10
10006H HOIST ASSEMBLY
P/N: 123428
7-14.0
1/12/10
10006H HOIST ASSEMBLY
P/N: 123428
7-15.0
1/12/10
10006H TRAVELING BLOCK ASSEMBLY
P/N: 460125000
7-16.0
1/12/10
10006H MAIN HARNESS
P/N: 366823257
84
[2134]
53
[1346]
40
[1017]
37
[940]
36.5
[927]
33.5
[851]
32
[813]
31.5
[800]
30.5
[775]
24
[610]
5
J3
22
8
15.5
15
22 21 20
CAP
J4
6
13
J19
7
8 19
22 23 24
J24
J15
J17
7
8 19
16
J21
11 15 19
9 10
1 3 4 18
J1
J23
8 19 7
J20
J5
J6
J7
J8
J9
J10
19 8 7
2 3
J11
J12
J2
13
J13
J14
CAP
17
6.0
ENGINE STOP
ENGINE START
POWER
GROUND
AUX
POWER/ENGINE
HIGH IDLE
19
7
8
12
J16
J22
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
14
J18
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
4707 NORTH MINGO ROAD
8-1.0
1/12/10
10006H MAIN HARNESS
P/N: 366823257
8-2.0
1/12/10
10006H HYDRAULIC CONTROL VALVE
NEXSTAR I P/N: 480989261
8-3.0
1/12/10
10006H HYDRAULIC CONTROL VALVE
NEXSTAR I P/N: 480989261
8-4.0
1/12/10
10006H HYDRAULIC CONTROL VALVE
NEXSTAR II P/N: 480959251
8-5.0
1/12/10
10006H HYDRAULIC CONTROL VALVE
P/N: 480989251
8-6.0
1/12/10
10006H
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
pressure setting.
Notice:
1. In an EMERGENCY situation when it
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.
2. Turning adjustment screw too far will cause valve to
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.
4. Disengage PTO, remove the pressure
gauge and install plug. Crane is now ready
for operation.
WARNING:
DO NOT TRY TO ADJUST VALVES WHILE BOOM IS MOVING.
Doing so may result in personal injury!
9-1.0
1/12/10
10006H
VALVE OVERRIDE OPERATION
9-2.0
1/12/10
10006H
TROUBLESHOOTING CHART
9-3.0
1/12/10
10006H
ERROR CODE TROUBLESHOOTING CHART
9-4.0
1/12/10
10006H
ELECTRICAL TROUBLESHOOTING CHART
9-5.0
1/12/10
10006H
ELECTRICAL TROUBLESHOOTING CHART
9-6.0
1/12/10
10006H
HYDRAULIC TROUBLESHOOTING CHART
9-7.0
1/12/10
10006H LOAD CHART
P/N 460178026
9-8.0
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