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Auto Crane 3203EH, Owner'S Manual, Page: 70 / 87

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Auto Crane 3203EH Owner'S Manual Download Page 70

3203 NEXSTAR POWER UNIT 

320991270 

ITEM 

NO.

QTY

PART 

NUMBER

DESCRIPTION

1

1

320991272 TANK, NEXSTAR 3203/4004EH

2

2

320991274 GLASS, SIGHT USED W/320991270

3

1

320991275 CAP,FILLER USED W/ 320991270

4

1

320991908 GAUGE, FILTER USED W/320991270

5

1

320991276 STARTER, MOTOR USED W/320991270

6

1

320991271 MOTOR, NEXSTAR 3203/4004EH

7

1

320991277 VALVE, RELIEF USED W/320991270

8

1

320991910 FILTER, ELEMENT SMALL EH NEXSTAR

8-9.0 

Summary of Contents for 3203EH

Page 1: ...MANUAL Manual No 320991031 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 h...

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Page 5: ...PDATED WIRING HARNESS 10 7 2013 Mtce Lub page REVISED Maintenance and Lube Schedule Notes 1 The information contained in this manual is in effect at the time of this printing It does not cover all ins...

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Page 7: ...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...

Page 8: ...ATTERIES 4 5 0 LUBRICATION AND MAINTENANCE SCHEDULE 4 7 0 SAFETY DECAL SECTION 5 1 0 GENERAL DIMENSIONS 6 1 0 MOUNTING AND INSTALLATION 6 3 0 GENERAL ASSEMBLY 7 1 0 PEDESTAL ASSEMBLY 7 3 0 BOOM ASSEMB...

Page 9: ...e most useful duty cycle is a 60 amp Auto Crane Company issues a limited warranty certificate with each unit sold See last page for warranty alternator with a 500 cold cranking amp battery These speci...

Page 10: ...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...

Page 11: ...1 3 0 3203EH GENERAL SPECIFICATIONS 1 27 11...

Page 12: ...ane 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...

Page 13: ...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...

Page 14: ...h 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...

Page 15: ...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...

Page 16: ...e 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 s...

Page 17: ...l 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 clea...

Page 18: ...equired 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 a...

Page 19: ...DRAULIC OIL OR EQUIVALENT HySyn ISO32 SYNTHETIC HYDRAULIC OIL OR EQUIVALENT CAUTION HYDRAULIC RESERVOIR OIL TEMPERATURE MUST NOT EX CEED 180 F OR DAMAGE TO CRANE MAY OCCUR THIS MAY AFFECT CRANE WARRAN...

Page 20: ...ONLY 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...

Page 21: ...transmitter to the START SPEED position and release Note The transmitter goes into sleep mode after 5 minutes of inactivity SPEED CONTROL 1 Rotate ON OFF SPEED switch to the SPEED position and hold 2...

Page 22: ...l 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 o...

Page 23: ...ted J1939 SIGNAL green 4 pulse second transmitter is on FUNCTIONS I E HOIST UP BOOM DOWN green proportional Activated when function is selected Blink rate is pro portional with function request ERROR...

Page 24: ...tions 5 Inspect hooks and latches for deformation chemi cal damage cracks and wear Refer to ANSI ASME B30 10 6 Inspect for proper rope reeving 7 Inspect electrical wiring and components for malfunctio...

Page 25: ...filters for evidence of rubber particles on the filter elements indicating possible hose O ring or other rubber component dete rioration Metal chips or pieces on the filter may denote failure in pumps...

Page 26: ...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 Co...

Page 27: ...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...

Page 28: ...structions below WARNING NEVER TRY TO REPAIR A ROTATION BEARING FOR A REPLACE MENT BEARING CONTACT YOUR LOCAL AUTHORIZED DISTRIBUTOR AXIAL PLAY ALLOWANCE CHECK PROCEDURE 1 Boom up to the max boom angl...

Page 29: ...d 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...

Page 30: ...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 t...

Page 31: ...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 seco...

Page 32: ...T ZERKS ROTATION GREASE WITH MOBILEPLEX EP 2 OR BEARING X EQUIVALENT ZERKS ROTATION CHECK TORQUE TO 170 FT LBS HEX HEAD 180 BEARING BOLTS X FT LBS SOCKET HEAD AS REQUIRED ROTATION GEAR BOX X CHECK TOR...

Page 33: ...uct 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 Ins...

Page 34: ...tions below WARNING NEVER TRY TO REPAIR A ROTATION BEARING FOR A REPLACE MENT BEARING CONTACT YOUR LOCAL AUTHORIZED DISTRIBUTOR AXIAL PLAY ALLOWANCE CHECK PROCEDURE 1 Boom up to the max boom angle and...

Page 35: ...ERATING 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 TAMPERIN...

Page 36: ...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...

Page 37: ...pering with the sensor may cause potentially hazardous situation PLACEMENT Both sides of the lift cylinder near the load sensor USED ON All cranes equipped with a load sensor QUANTITY 1 PLACEMENTOn th...

Page 38: ...tem 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...

Page 39: ...3203EH DECAL LAYOUT P N 320991300 5 5 0 04 06 11...

Page 40: ...5 6 0 04 06 11 3203EH DECAL LAYOUT P N 320991300 TOP OF LABEL INSIDE COVER 20 17 21...

Page 41: ...3203EH GENERAL DIMENSIONS 6 1 0 1 27 11...

Page 42: ...make sure the following items are with your crane Please note the different model specific quantities NOTES 366823266 SHIPS WITH ALL FM PRX UNITS 366823940 SHIPS WITH ALL HW PRX UNITS 366823945 SHIPS...

Page 43: ...s per minute GPM install an in line flow meter between the crane and the reservoir in the return hose 13 Load test the crane to ensure proper functioning and truck stability 14 Make certain the owner...

Page 44: ...NOTES 6 4 0...

Page 45: ...7 1 0 1 27 11 3203EH GENERAL ASSEMBLY P N 320991XXX...

Page 46: ...3203EH GENERAL ASSEMBLY 7 2 0 1 27 11...

Page 47: ...7 3 0 1 27 11 3203EH PEDESTAL ASSEMBLY P N 3209912XX...

Page 48: ...7 4 0 1 27 11 3203EH PEDESTAL ASSEMBLY P N 3209912XX...

Page 49: ...3203EH PEDESTAL ASSEMBLY P N 3209912XX 7 5 0 1 27 11...

Page 50: ...3203EH PEDESTAL ASSEMBLY P N 3209912XX 7 6 0 1 27 11...

Page 51: ...3203EH PEDESTAL ASSEMBLY P N 3209912XX 7 7 0 1 27 11...

Page 52: ...7 8 0 1 12 10 NOTES...

Page 53: ...3203EH BOOM ASSEMBLY P N 320988100 101 PR PRX 7 9 0 1 12 10...

Page 54: ...7 10 0 1 27 11 3203EH BOOM ASSEMBLY P N 320988100 101 PR PRX...

Page 55: ...3203EH PRFX BOOM ASSEMBLY P N 320990100 PRFX 7 11 0 1 27 11...

Page 56: ...3203EH PRX BOOM ASSEMBLY P N 7 12 0 1 27 11 3203EH PRFX BOOM ASSEMBLY P N 320990100...

Page 57: ...3203EH PR PRX HOIST ASSEMBLY P N 126201 7 13 0 1 27 11...

Page 58: ...6406H HOIST ASSEMBLY P N 123314 7 14 0 1 27 11 3203EH PR PRX HOIST ASSEMBLY P N 126201...

Page 59: ...7 15 0 1 27 11 NOTES...

Page 60: ...7 16 0 1 27 11 3203EH TRAVELING BLOCK ASSEMBLY P N 320433000...

Page 61: ...NOTES...

Page 62: ...8 1 0 1 27 11 3203EH MAIN HARNESS TETHERED P N 320991267...

Page 63: ...8 2 0 1 27 11 3203EH MAIN HARNESS TETHERED P N 320991015...

Page 64: ...3203EH MAIN HARNESS FM P N 320991257 8 3 0...

Page 65: ...3203EH MAIN HARNESS FM P N 320991010 8 4 0...

Page 66: ...8 5 0 1 27 11 3203EH HYDRAULIC CONTROL VALVE NEXSTAR I P N 320991261...

Page 67: ...6406H HYDRAULIC CONTROL VALVE NEXSTAR I P N 366823261 8 6 0 1 27 11 3203EH HYDRAULIC CONTROL VALVE NEXSTAR I P N 320991261...

Page 68: ...3203EH HYDRAULIC CONTROL VALVE NEXSTAR II P N 320991251 8 7 0 1 27 11...

Page 69: ...8 8 0 1 27 11 6406H HYDRAULIC CONTROL VALVE P N 366823251 3203EH HYDRAULIC CONTROL VALVE NEXSTAR II P N 320991251...

Page 70: ...2 2 320991274 GLASS SIGHT USED W 320991270 3 1 320991275 CAP FILLER USED W 320991270 4 1 320991908 GAUGE FILTER USED W 320991270 5 1 320991276 STARTER MOTOR USED W 320991270 6 1 320991271 MOTOR NEXSTA...

Page 71: ...remove the pressure gauge and install plug Crane is now ready for operation Notice 1 In an EMERGENCY situation when it becomes necessary to lower the boom without flow present the CB valve adjustment...

Page 72: ...9 2 0 3 15 11 3203EH MANUAL OVERRIDE PROCEDURE...

Page 73: ...ING WHEN YOU MANAULLY OVERRIDE REF PAGE 9 2 GO TO ELECTRICAL TROUBLE SHOOTING SECTION PAGE 9 6 YES GO TO HYDRAULIC TROUBLE SHOOTING SECTION PAGE 9 8 NO DOES THE CRANE MOVE SLOW OR ERRATIC WHEN A FUNCT...

Page 74: ...9 4 0 1 27 11 3203EH ERROR CODE TROUBLESHOOTING CHART FM UNITS ONLY...

Page 75: ...CONTACT WITH SWITCH PLUNGER UNDER NORMAL CONDITIONS 90 LOAD AMBER STEADY CRANE REACHES 90 OF RATED CAPACITY REDUCES SPEED OF ALL FUNCTIONS BY 50 REDUCE LOAD TO CLEAR ALARM 100 LOAD RED STEADY CRANES...

Page 76: ...E TRANSMITTER BATTERIES IT RE QUIRES 2 AA BATTERIES RECEIVER LOCKED UP FM UNITS ONLY BOTTOM RIGHT CORNER IS A CIRCLE WITH AN ARROW THIS SHOULD BE ROTATING AT ALL TIMES FM UNITS IF THE ARROW STOPS ROTA...

Page 77: ...BEARING HOUSING USING A HAMMER AWAY FROM THE WORM GEAR RETIGHTEN BOLTS ALL FUNCTIONS OPERATE SLOWLY WRONG SPEED FUNCTION IS SELECTED CHECK THE TRANSMITTER THERE SHOULD BE A GREEN LED DIRECTLY BELOW TH...

Page 78: ...VERIFY ENGINE IS RUNNING START VEHICLE FAST IDLE NOT ACTIVATED IF VEHICLE IS MANUAL TRANSMISSION VERIFY FAST IDLE IS SHOWN IN THE LCS SCREEN ACTIVATE FAST IDLE FILTER CLOGGED IF NEXSTAR II CHECK LCS...

Page 79: ...remove any visible debris from the valve spool The recommended cleaning fluid is off the shelf automotive brake cleaning fluid It is recommended the skin and eye protection be worn when spraying the...

Page 80: ...9 10 0 1 27 11 3203EH LOAD CHART P N 320988005...

Page 81: ...the kit for Single Line 3203 Cranes Instructions and decals are provided for conversion to single line cranes SINGLE LINE KIT 3203 P N 320988015 ITEM NO QTY PART NO DESCRIPTION 1 1 320988011 3203EH S...

Page 82: ...E 3 DISCONNECT THE ROPE FROM THE CROWN BY REMOVING PIN 4 PIVOT SINGLE LINE BARS 180 DEGREES THEN ATTACH HOOK TO THE BARS USING THE PIN REMOVED IN STEP 1 5 ATTACH THE ROPE TO THE TRAVELING BLOCK SIDE P...

Page 83: ...16 14 15 650 1 0 13 7 5 9 11 15 3 670 1395 740 1520 910 1600 1345 1600 1600 1600 0 1 14 2 4 68 10 12 THE CAPACITY BE DEDUCTED FROM THE LOAD AND MUST WEIGHT OF LOAD HANDLING DEVICES ARE PART OF NOTE DI...

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