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Auto Crane HC-10 NEXSTAR Owner'S Manual Download Page 46

46

Maintenance

HC-10 NEXSTAR

General Repairs and Maintenance

Reference ASME B30.5 and OSHA 1910.180 for complete maintenance and repair 

requirements.

All repairs and maintenance shall be performed by designated personnel only. 

Establish a preventative maintenance program based on this section. Obtain all 

replacement parts from 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 requirement shall be corrected before operation 

of crane is resumed.

2.  Adjustments shall be maintained to assure correct of functioning of components, the following are 

examples:

A.  Function 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, broke, or excessively corroded.

C.  Crane hooks showing cracks, damage, or corrosion shall be taken out of service.

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.

NOTICE

!

WARNING

Summary of Contents for HC-10 NEXSTAR

Page 1: ...990800010 0121 A http www autocrane com actechsupport autocrane com 4707 N Mingo Rd Tulsa OK 74117 5904 Phone 1 800 777 2760 Fax 918 269 6688 OWNER S MANUAL HC 10 NEXSTAR...

Page 2: ...es you one of the strongest manufacturer s limited warranties available By completing the product registration you may be eligible for valuable supplemental coverage under Auto Crane s Limited Warrant...

Page 3: ...Operating Near Electrical Power Lines 12 Preparing The Crane For Operation 13 During Operation 15 After Operation 15 NexStar Operation 16 General 16 Remote Control Unit 16 Remote Control Initializatio...

Page 4: ...aintenance 51 Rotation Bearing Replacement 52 Hoist Operation 53 Rotation Gearbox Slewing Drive Maintenance 53 Eccentric Ring Adjustment 54 Installation 55 General Installation 55 General Hydraulic Sc...

Page 5: ...to comply with the OSHA Truck Crane Stability Requirements as specified by 29 CFR part 1910 180 C 1 In applications where the rotation of the load is hazardous a tag or restraint line should be used...

Page 6: ...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 ac...

Page 7: ...m reach 19 ft to 24 ft 6 in 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 lb 9 253 kg Line Speed 60 ft per minute Chas...

Page 8: ...8 11 9 13 16 24 6 38 3 16 18 3 4 12 5 16 26 9 16 34 13 16 31 1 16 21 11 16 7 5 8 18 3 4 1 15 16 4 PLCS FITTING 12 SAE JIC SWIVEL CORD CONNECTOR TOWARD CAB FITTING 10 SAE JIC SWIVEL CORD CONNECTOR 14 3...

Page 9: ...00 10000 10000 4540 5660 6510 7810 9100 10000 3381 4180 4674 5307 6121 7260 2730 3388 3794 4316 4988 5927 2433 3023 3389 3860 4466 5314 3274 4314 2636 L C Load Chart HC 10 NEXSTAR All load ratings are...

Page 10: ...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 test...

Page 11: ...son responsible for the job shall determine 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 Ensure the load is proper...

Page 12: ...failure B Of such thickness width and length as to completely support the stabilizer pad C Firm footing under all tires or individual stabilizer pads should be level Where such a footing is not other...

Page 13: ...e the clearance and warn the crane operator before approaching the Safe Operating Distance limits A Treat all overhead wires as energized until the person or utility owning the line verifies it is not...

Page 14: ...cle to the ground before crane operation B Ensure they are firmly positioned on solid ground C Stand clear of outriggers while being extended D If a curb or other object prevents the outrigger from be...

Page 15: ...m After Operation 1 After completing the lifting operations return the boom to the stowed position on the boom support 2 Replace remote control to its storage location 3 Return the Outriggers to the s...

Page 16: ...or OFF When not in use turn the remote control OFF Always store the remote control in a secure space when not in use Store spare remote controls in a secure space and only remove after the current re...

Page 17: ...the joystick down to lower the hook Press the joystick right to extend the boom Press the joystick left to retract the boom 7 Left Joystick Press the joystick up to raise the boom Press the joystick d...

Page 18: ...the Horn Start button has been pressed and remote is linked with receiver it will display green with no text Any alarms or warnings will be displayed here Box will be red with no text if there is no l...

Page 19: ...ically stows the crane back to home position Reference Auto Stow section in NexStar Operation 2 Maximum Speed Setting Displays the current maximum speed setting 3 Joystick Mode Displays the current mo...

Page 20: ...other joystick will be available to use In 2 AXIS operation each joystick can perform two functions simultaneously 1 AXIS TRIGGER PROP 1PT Allows only one function to operate on each joystick The joy...

Page 21: ...es 1 Push in and hold the red unloader valve ULV button This will send hydraulic fluid to the valve block 2 Select the function valve desired and pull the knurled valve latching sleeve toward the end...

Page 22: ...3427 to the crane tether connection located in either the crane box or on the crane itself and the other to the tether connection located on the top of the remote If the tether connection is properly...

Page 23: ...t install 3 AA alkaline batteries into their respective places paying attention to how they should be oriented in the pack The battery pack can then be slid into place Use only alkaline batteries size...

Page 24: ...he hoist block will swing outwards Auto Deploy will not initiate if the boom is not in the home position To initiate Auto Deploy ensure that the crane is on and operational power hydraulics etc fully...

Page 25: ...ing Auto Stow the following initial conditions must be met The boom is fully retracted The hoist block is properly stowed on load hook The boom is lowered to an elevation below the home position Retra...

Page 26: ...osition the main screen will display a green Info Box and the boom will stop moving If the boom was rotated a full turn clockwise and is past the home position when Auto Stow is initiated the boom wil...

Page 27: ...home position usually the cradle 2 Enter the menu screen by fully depressing and holding the trigger then pressing the Engine Start Stop switch down to Engine Stop and then release trigger 3 Use the...

Page 28: ...EXSTAR 5 Carefully read the Caution note on the screen and if the conditions are met select CONFIRM and depress the trigger This will set the current rotation position to zero and save the current boo...

Page 29: ...To initiate Personnel Basket Mode 1 Ensure that the crane is on and operational power hydraulics etc and that the personnel basket has been deployed and attached to the crane per Auto Crane instructi...

Page 30: ...el Basket Active To end Personnel Basket Mode 1 Cycle electrical power to the crane 2 Cycle remote power While in Personnel Basket Mode remote can be turned off without disengaging Personnel Basket Mo...

Page 31: ...ction Down Boom Down Moving the joystick down activates boom down function Left Rotate CCW Moving the joystick to the left activates counterclockwise rotation function Right Rotate CW Moving the joyst...

Page 32: ...R Remote Layout DIRECTION FUNCTION GRAPHIC DESCRIPTION In Emergency Stop Activated Activates Emergency Stop Out Emergency Stop Deactivated Deactivated Emergency Stop In Horn Link Momentarily activates...

Page 33: ...OTING SECTION GO TO HYDRAULIC TROUBLESHOOTING SECTION GO TO HYDRAULIC TROUBLESHOOTING SECTION IS THERE AN ERROR CODE DOES THE CRANE MOVE UNEXPECTEDLY WHEN A FUNCTION IS NOT SELECTED DOES THE CRANE NOT...

Page 34: ...greater than one bar Remote control will not respond with base station when tethered System not in tether mode Ensure the remote is started up and initiated with the tether cable attached The tether c...

Page 35: ...alarm will clear ANTI 2 BLOCK Anti 2 Block is activated Traveling block has come into contact with boom tip Disables boom down extend and hoist up Move load away from boom tip either by retracting hoi...

Page 36: ...If stability test mode is required please contact Auto Crane technical support OIL TEMP WARNING Oil temperature has exceeded 180 F if applicable Normal Operation Disengage PTO to allow oil to cool If...

Page 37: ...g transmitter Disables all functions Disengage switch or trigger then push horn button to relink transmitter E004 LOW BATTERY Transmitter batteries are low Disables all functions and shuts down transm...

Page 38: ...hen E stop is active Pull E stop to release Turn transmitter off then back on Press horn button to relink Crane turned off Check crane status light It should be green Most cranes have a toggle switch...

Page 39: ...T ERR Verify that pressure transducer located on the lift cylinder valve block is plugged into harness Inspect wiring going to harness for damage Any one function is not operable Cut in wire or bad co...

Page 40: ...E HOIST A COMMON HOIST B DOWN LOW SIDE HOIST B UP LOW SIDE HOIST B COMMON BU BU BU BU BU BU BU BU BU STOP_IN STOP_OUT PENDANT DATA PENDANT DATA PENDANT GROUND BATTERY POSITIVE PENDANT POWER CAN C HIGH...

Page 41: ...Hydraulic tank is low or empty Visually inspect the hydraulic oil level in the tank Fill tank to proper level Vehicle is not running Verify engine is running Start vehicle PTO is not engaged Verify PT...

Page 42: ...S HU 4 SAE PTH 4 SAE 8 SAE 2750 015 10 SAE 018 039 145 PSI 100 PSD 1 2 4 2 1 3 12 SAE 3 2 1 1 2 3 1 2 1 2 2 3 1 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 4 2 1 3 4 2 1 3 4 2 1 3 4 2 1 3 PSI 6 SAE CW CCW RET ED BU...

Page 43: ...s 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 contro...

Page 44: ...c hose fittings and tubing for the following problems A Evidence of leakage at the surface of the flexible hose or its junctions with the metal and coupling B Blistering or abnormal deformation to the...

Page 45: ...ngth 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 1 Reduction of rope diameter below nominal diamet...

Page 46: ...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...

Page 47: ...in one lay in sections beyond end connections or more than one broken wire at an end connection Rope Installation and Maintenance 8 Rope should be stored to prevent damage and deterioration 1 Unreeli...

Page 48: ...ucts with the following procedure 2 Sand the damaged area to bare metal 3 Use a solvent to clean the sanded area to remove sanding debris and residue 4 Wipe dry with a clean cloth to remove any remain...

Page 49: ...s required X Lift Cylinder Bearings Grease with MobilePlex EP 2 or equivalent at zerk fittings X Rotation Bearing Grease with MobilePlex EP 2 or equivalent at zerk fittings X Rotation Bearing Bolts Ch...

Page 50: ...50 Maintenance HC 10 NEXSTAR Lubrication Points Use only authorized parts lubrication Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability...

Page 51: ...off the shelf automotive brake cleaning fluid to remove any visible debris from the valve spool Wear skin and eye protection while spraying the valve spool clean 4 Inspect the O rings for damage Repl...

Page 52: ...ation bearing For a replacement bearing contact your local authorized distributor Axial Play Allowance Procedure 1 Raise the boom to the maximum angle and measure the clearance between base plate and...

Page 53: ...nd HC 12S models Check the gearbox oil level to ensure gearbox is well lubricated and stays in good operating condition In order to extend gearbox operating life it is recommended that the gearbox oil...

Page 54: ...0 007 at the blue green mark on the rotation bearing This can be checked using Plastigauge 3 Once adjusted reattach eccentric ring retaining clip by inserting into one of the holes on the eccentric r...

Page 55: ...not furnished with the crane and must be supplied by the installer with lengths determined at installation Reference General Specifications for pressure and flow requirements Maintain ISO 18 16 13 flu...

Page 56: ...401000 TIE CABLE MEDIUM 8 6 750738000 STICK ON CABLE TIE MOUNT 9 5 320357000 TERMINAL NON INS S O W L 10 1 340638000 CONDUCTOR POWER 11 1 320355000 RELAY DROP OUT 12 1 320363000 PLUG TERMINAL CONNECTO...

Page 57: ...Installation HC 10 NEXSTAR General Hydraulic Schematic PTO Transmission A5 B5 A1 A3 B3 A4 B4 A2 B2 SEE CRANE MANUAL FOR DETAILED SCHEMATIC OUTRIGGER CONTROL VALVE HIGH PRESSURE FILTER LOW PRESSURE FIL...

Page 58: ...Diverter Valve PTO Transmission A5 B5 A1 A3 B3 A4 B4 A2 B2 SEE COMPRESSOR MANUAL FOR DETAILED SCHEMATIC SEE CRANE MANUAL FOR DETAILED SCHEMATIC FLOW REGULATOR IF REQUIRED OUTRIGGER CONTROL VALVE DIVER...

Page 59: ...always hot only 7 E Stop wire provides 12 VDC when emergency stop on remote is activated If E stop out is not used ensure that the wire end is sealed and or away from anything it can ground to if the...

Page 60: ...tem back to the return line filter 11 Disengage PTO and stop engine 12 Connect Operate all cylinders to full extension and retraction a minimum of six times to bleed air from system 13 Return all cyli...

Page 61: ...to the vehicle Terminal 1 and Terminal 2 will be equal when the remote is not in the docking station Terminal 2 is used only as a signal and should not be used with any type of load Auto Crane offers...

Page 62: ...line to the outrigger control valve body 3 With all personnel clear of the vehicle start the engine and engage the vehicle PTO Let the hydraulic oil warm until it reaches 100 F 4 While watching the h...

Page 63: ...the inside of the door of the crane box This decal is to alert the user of the available crane capacities around the vehicle 479824002 decal will be installed on an Auto Crane body that was outfitted...

Page 64: ...479824003 decal will be installed on an Auto Crane body that was not outfitted with an Auto Crane crane and Auto Crane outriggers The stability chart provides lines to write in the tested stability pe...

Page 65: ...65 Installation HC 10 NEXSTAR Large Crane Serial Number Location The serial number is stamped into the left top side plate of the pedestal as well as the decal on left side plate as shown below...

Page 66: ...w from tank Hydraulic reservoir oil temperatures must not exceed 180 F or damage to crane may occur This may affect crane warranty SYNTHETIC HYDRAULIC OIL VISCOSITY 40 C 27 5 VISCOSITY INDEX 160 SAE G...

Page 67: ...67 Decal Layout P N 460179021 HC 10 NEXSTAR 7 4 11 15 12 14 5 6 2 9 8 10 3 16 1 2 3 4 6 5 7 10 13 15 A A 18 SECTION A A BOTTOM OF DECAL 17 14...

Page 68: ...7 2 040519000 DECAL DANGER SCISSOR POINT 8 1 040579000 DECAL OPERATION INSTRUCTIONS 9 1 040580000 DECAL TRAINED OPERATOR 10 2 040587000 DECAL WARNING LOAD SENSOR 11 1 040632000 DECAL WARNING OVERLOAD...

Page 69: ...5 HC 10 NEXSTAR 18 19 1 DETAIL D 11 3 12 14 13 SECTION A A B C 25 26 24 26 25 24 SLAVE UNIT DETAIL B 28 29 SECTION F F 5 15 28 27 1 2 D E F F 3 20 31 SEE NOTE 2 A A CONNECTION DETAIL C 26 MASTER UNIT...

Page 70: ...0000 WASHER SP LK 1 2 13 1 017701000 NUT HX 1 2 13UNC 14 1 738642000 SCREW HX HD 1 2 13UNC X 1 3 4 LG GR8 15 1 460125000 TRAVELING BLOCK ASSEMBLY 16 1 360124000 PIN HITCH 17 1 470076000 PIN 1 DIA 4 11...

Page 71: ...72 480188100 27 27 11 16 20 21 T 17 HD 10 18 73 73 30 31 HU 45 9 14 34 35 40 OF VALVE BLOCK 9 32 66 33 18 32 38 37 37 39 40 14 34 35 33 18 32 66 32 DETAIL B TYP BOTH SIDES 54 37 22 26 28 19 36 2 23 25...

Page 72: ...72 Pedestal Assembly P N 460179205 HC 10 NEXSTAR 44 41 51 7 50 67 74 74 75 84 42 8 15 14 4 5 13 65 3 EXT 64 RET VALVE BANK HOSING DETAIL 78 78 HD 76 HU 76 CW 77 CCW 77 BU 70 BD 70 RET EXT 85...

Page 73: ...73 Pedestal Assembly P N 460179205 HC 10 NEXSTAR 87 37 57 58 33 46...

Page 74: ...WASHER FL 5 16 15 1 020601000 WASHER SP LK 5 16 16 1 480011000 SEAL ROTATION BOX 17 6 320588000 WASHER FL 1 2 HARDENED 18 8 021500000 WASHER SP LK 1 2 19 4 011608000 SCREW HX HD 1 2 13UNC X 2 LG 20 2...

Page 75: ...C X 1 1 4 LG GR5 52 1 366440000 HYD MOTOR 5 9 CI REV 1 KEYED SHAFT 2 BOLT FLANGE 53 1 739316143 HARNESS ADAPTER PROXIMITY ROTATION SWITCHES 54 2 460179232 BRACKET VALVE MTG 10 12S LONG BOWL 55 1 36682...

Page 76: ...76000 FITTING STR 6 SAE 6 JIC 75 1 369611000 ADAPTER STR 6 ORM 4 ORF 76 2 480205000 HOSE ASSY ROTATION 77 2 812203038 HOSE ASSY 6 STR 78 2 480203000 HOSE ASSY 8 STR X 24 75 79 1 812503023 HOSE ASSY 12...

Page 77: ...77 Hydraulic Valve Bank P N 480989251 HC 10 NEXSTAR 16 2 1 5 1 9 9 8 6 9 9 8 2 2...

Page 78: ...IZE 4W 3P FLOAT CTR 6 1 366823905 VALVE RELIEF DIRECT ACTING 2750PSI 9 2 480195000 FITTING 45 6 SAE 6 JIC 8 2 330645000 FITTING 90 6 SAE 6 JIC LONG 9 2 374017000 FITTING 45 8 SAE 8 JIC 10 1 750420000...

Page 79: ...3 J14 J16 J22 18 18 18 CAP 30 13 1 16 7 8 8 7 18 8 7 MESH LOOM J27 33 28 21 19 11 14 18 13 CONNECTOR ID CONNECTOR DESCRIPTION CONNECTOR DESCRIPTION C1 MC43 CONNECTOR C1 J15 ANTI 2 BLOCK C2 MC43 CONNEC...

Page 80: ...Assembly P N 123449 HC 10 NEXSTAR 52 35 21 21 27 33 29 30 49 17 27 34 47 30 18 5 39 32 43 47 31 46 2 45 19 10 9 51 8 6 9 38 19 40 37 8 14 36 12 11 23 25 24 28 42 50 22 7 44 4 13 20 3 1 16 41 15 48 26...

Page 81: ...ZK 18 6 414303 SCREW HX HD 3 8 16UNC x 2 1 2 GR5 ZP 19 8 414658 SCREW HX HD 5 8 11UNC x 1 1 2 LG GR5 ZP 20 1 414926 SCREW SOC 3 8 16UNC x 1 NYLON 21 2 414952 SCREW SOC 1 2 13UNC x 1 1 2 LG ZP 22 1 41...

Page 82: ...SAE 0 RING 562 18 UNF HXSOCKET 43 5 474111 PLATE SEPERATOR BRAKE 44 1 486101 SEAL GEAR HOUSING 45 1 490037 SNAP RING 46 6 494110 SPRING BRAKE 47 4 494112 SPRING 48 1 509126 TUBE HYDRAULIC BRAKE RELEA...

Page 83: ...83 Rotation Gearbox P N 160248 HC 10 NEXSTAR 3 30 4...

Page 84: ...RWN CUP TORR B 3016 13 1 402106 BEARING NEEDLE TORRINGTON NB 4012 14 1 402107 BEARING THRUST TORRINGTON NTA2435 15 1 413013 COVER PLATE 16 1 413145 COVER PLATE 2 35 17 14 414143 CAPSCREW 5 16 18 X 1 1...

Page 85: ...K TO N O WHITE TO COMMON 47 43 16 3 5 8 5 9 36 11 1 14 32 2 4 15 13 12 1 10 37 34 18 6 15 13 14 27 17 20 6 25 18 28 6 28 6 SHIM TO FIT SHIM TO FIT 3 26 480188000 33 30 31 29 VALVE ORIENT ARROW TOWARDS...

Page 86: ...LE 14 2 460082000 PLATE WEAR PAD RETAINER 15 4 460177163 SCREW SOC HD CTRSNK 5 16 24UNF X 5 8 LG 16 1 466130000 SHEAVE ASSY 3 8 17 1 014400000 SCREW HX HD 3 4 16UNF X 5 LG GR5 18 2 022102000 WASHER FL...

Page 87: ...360759004 CORD REEL ASSEMBLY 37 2 200876000 FITTING STR 6 SAE 6 JIC 38 7 470049001 EDGE TRIM 3 8 39 1 479200154 OPEN LOAD HOOK BOLT ON 40 4 479200169 3 8 24 HHCS 3 4 LG ZINC PLATED GR 5 41 4 021100000...

Page 88: ...00 SIDE PLATE TRAVELING BLOCK 3 1 480366000 HOOK SWIVEL 6 METRIC TON 4 1 490256000 SHEAVE ASSY 7 16 ROPE 5 1 490313000 BOLT SHEAVE W ZERK FITTING 6 1 018600000 NUT HX NYLK 3 4 16UNF 7 2 360605000 PIN...

Page 89: ...he defective parts or travel time charges in connection with the replacement or repair of defective parts Responsibility for customer s claims arising from misapplication abuse misuse or alteration of...

Page 90: ...stomer s claims arising from misapplication abuse misuse or alteration of equipment or parts lies with the distributor or user and no warranty obligation is assumed in these circumstances by Auto Cran...

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