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Auto Crane HC-5 NEXSTAR Owner'S Manual Download Page 68

68

General Assembly - P/N 477000003

HC-7X NEXSTAR

D

D

20 17 18 19

11 12 12

13

9 6 6 7 8

A A

RETRACT

'RET' PORT

EXTEND

'EXT' PORT

3

14

25

15

16

B

C

SECTION A-A

DETAIL B

24 23 22

21

SLAVE

UNIT

DETAIL C

MASTER

UNIT

24 22

21

SECTION D-D

26

20

USE ZIP TIES TO

TIE DOWN LED LIGHT WIRES

Summary of Contents for HC-5 NEXSTAR

Page 1: ...990800015 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 7X 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: ...paring The Crane For Operation 13 During Operation 15 After Operation 15 NexStar Operation 16 General 16 Remote Control Unit 16 Remote Control Initialization 16 Pre Operation Test 16 Remote Control La...

Page 4: ...nance 51 Rotation Bearing Replacement 52 Hoist Operation 53 Rotation Gearbox Slewing Drive Maintenance 53 Installation 54 General Installation 54 General Hydraulic Schematic 56 General Hydraulic Schem...

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: ...reach 21 ft 6 7 8 in to 30 ft 5 3 4 in Cable 120 ft 36 6 m of 3 8 in 9 5 mm diameter aircraft quality cable This cable has a single line breaking strength of 14 400 lb 6 532 kg Line Speed 55 ft per m...

Page 8: ...8 General Dimensions HC 7X NEXSTAR 41 13 16 21 7 8 21 23 7 8 36 3 4 12 5 5 8 30 5 3 4 25 7 16 13 3 16 R24 9 16 19 19 15 16 14 3 4 14 3 4 2 1 8 2 1 8...

Page 9: ...he weight can create enough tipping moment to overturn the vehicle DO NOT USE the overload shutdown device to determine maximum rated loads Always comply with load chart capacities Weight of load hand...

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: ...Auto Stow the following initial conditions must be met 1 The boom is fully retracted 2 The hoist block is properly stowed on load hook 3 The boom is lowered to an elevation below the home position Re...

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 B UP LOW SIDE HOIST B COMMON BU BU BU BU BU NOT USED NOT USED NOT USED BU STOP_IN STOP_OUT PENDANT DATA PENDANT DATA PENDANT GROUND BATTERY POSITIVE PENDANT POWER CAN C HIGH CAN C LOW A1 A3 B1...

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: ...c 015 CW CCW RET ED BU BD HU HD 10 SAE 018 039 GAUGE 4 SAE PTH 4 SAE PTS 145 PSI 100 PSD 1 2 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 6 SAE 8 SAE 8 SAE 6 SAE 12 SAE P 10 SAE 3 2 1 1 2 3 1 2 1 2 2 3 1 1 2 3 1 2 3...

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 1 Rope should be stored to prevent damage and deterioration 2 Unreeli...

Page 48: ...cts with the following procedure 1 Sand the damaged area to bare metal 2 Use a solvent to clean the sanded area to remove sanding debris and residue 3 Wipe dry with a clean cloth to remove any remaini...

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 7X 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: ...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 55: ...16G 600V 1C YEL 6 634401000 WIRE TIE 7 INCHES LONG 6 750738000 WIRE TIE STICK ON RETAINER 5 320357000 CONNECTOR FEM POWER 1 340638000 CONDUCTOR POWER 1 320355000 POWER RELAY 1 320363000 PLUG RELAY 1 9...

Page 56: ...Installation HC 7X 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 57: ...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 58: ...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 59: ...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 60: ...e Power terminal 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 A...

Page 61: ...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 62: ...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 63: ...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 64: ...C 7X 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 SERIAL NUMBER DECAL SER...

Page 65: ...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 66: ...66 Decal Layout P N 477624050 HC 7X NEXSTAR A A 3 6 1 7 8 12 2 9 13 14 5 4 18 17 2 11 7 1 6 3 5 4 15 16 SECTION A A 10...

Page 67: ...2 040519000DECAL DANGER SCISSOR POINT 8 1 040587000DECAL WARNING LOAD SENSOR 9 1 330622000DECAL SERIAL NO 10 1 366823303 DECAL MANUAL OVERRIDE PROCEDURES GS HYDRAULICS HC 8X HC 7X PUSH IN UNLOADER VAL...

Page 68: ...7X NEXSTAR D D 20 17 18 19 11 12 12 13 9 6 6 7 8 A A RETRACT RET PORT EXTEND EXT PORT 3 14 25 15 16 B C SECTION A A DETAIL B 24 23 22 21 SLAVE UNIT DETAIL C MASTER UNIT 24 22 21 SECTION D D 26 20 USE...

Page 69: ...N 1 4 COTTERLESS RING 11 1 479200177 PIN 1 1 4 DIA 8 914 LG 12 2 480029000 RING RETAINING 13 1 477854000 TRAVELING BLOCK ASSEMBLY HC 7 14 1 479200199 WIRE ROPE ASSEMBLY 3 8 DIA 120 FT 15 1 360445000 C...

Page 70: ...bly P N 477200102 HC 7X NEXSTAR A B VALVE 480188100 12 28 5 3 2 3 4 11 10 9 25 38 37 40 39 38 14 7 8 6 56 59 42 44 31 42 53 24 38 38 61 DETAIL A TYP BOTH SIDES 13 13 21 22 35 35 74 38 25 DETAIL B 70 6...

Page 71: ...477200102 HC 7X NEXSTAR 33 32 30 29 45 46 58 75 26 53 53 44 31 28 26 42 14 48 48 EXT RET 49 47 BU BD 52 52 HD HU 50 51 CW CCW 54 55 RETURN VALVE BANK HOSING DETAIL 62 PRESSURE POWER ENGINE PENDANT ROT...

Page 72: ...72 Pedestal Assembly P N 477200102 HC 7X NEXSTAR C DETAIL C 73 38 71 21 21 13 74 38 73 73 38...

Page 73: ...TING RIGHT 17 1 366823251 VALVE BANK 8 GPM W FILTER SENSOR 18 2 021100000 WASHER SP LK 3 8 19 2 330372000 NUT HX 3 8 NC GR5 20 2 750224000 SCREW HX HD 3 8 16UNC X 1 1 4 LG GR5 21 2 460113000 SCREW HX...

Page 74: ...G 55 1 812306011 HOSE ASSY 8 JICF STRAIGHT 8 JICF 90 DEG LONG ELL 11 LONG 56 2 490198000 FITTING 90 10 SAE 6 JIC 57 1 477100253 TAG ID HC 7X 58 1 370433000 CORD CONNECTOR HUBBLE F 3 59 1 366823028 COV...

Page 75: ...RTRIDGE SIZE 4W 3P FLOAT CTR 6 1 366823905 VALVE RELIEF DIRECT ACTING 2750PSI 7 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 3...

Page 76: ...X 75 DEEP TYP 2 PLCS 6 SAE GAUGE PORT 15 4 1 2 1 1 3 10 50 11 01 5 00 27MM HEX 1 5 2 1 1 16 2 1 15 11 10 1 4 13 12 17 66 2 09 3 16 4 69 7 31 8 84 8 JIC TYP 2 PLCS 6 JIC TYP 6 PLCS 8 9 9 10 11 17 8 7...

Page 77: ...J26 33 21 21 19 11 14 18 13 15 28 24 LOOM 44 48 LOOM 23 22 24 J23 35 J13 J14 MESH LOOM 19 23 1 2 17 3 4 17 20 24 CONNECTOR ID CONNECTOR DESCRIPTION CONNECTOR DESCRIPTION C1 MC43 CONNECTOR C1 J15 ANTI...

Page 78: ...t Assembly P N 123340 52 34 20 20 25 31 27 28 49 15 25 33 47 28 16 6 39 30 43 47 29 46 2 45 8 51 7 4 42 38 17 40 35 37 7 12 36 13 19 14 11 32 44 18 5 21 50 41 26 23 24 22 42 17 10 9 9 10 3 1 48 HC 7X...

Page 79: ...5 Z P 17 8 414548 CAPSCREW 1 2 13NCX1 1 2 HXHD Z P G5 18 2 414854 SCREW 1 4 20NCX1 2LG RDHD SLOT Z PL 19 1 414926 SETSCREW 3 8 16NC X1 SOCKET NYLON 20 2 414948 CAPSCREW 1 2 13NCX1 1 4LG SOCKET HD 21...

Page 80: ...UP 40 1 462060 O RING BACK UP 41 1 472052 PLUG 42 2 395426 TIE PLATE 43 5 474111 PLATE SEPARATOR BRAKE 44 1 486080 SEAL 45 1 490037 SNAP RING 46 6 494110 SPRING BRAKE 47 4 494112 SPRING 48 1 509126 TU...

Page 81: ...0101 HC 7X NEXSTAR A 1 2 47 48 46 39 45 45 26 26 31 3 15 14 36 37 35 14 17 11 12 13 25 20 19 18 28 9 43 12 13 27 44 42 10 26 27 32 33 51 34 26 27 26 3 29 7 8 52 7 22 49 50 22 11 23 22 40 21 41 BAIL WE...

Page 82: ...82 Boom Assembly P N 479200101 HC 7X NEXSTAR DETAIL A 24 35 11 12 13 14 17 6 5 4 38 36 14 16 27 25 1 20 19 18 28 9 TRAVELING BLOCK WEAR PAD DETAIL...

Page 83: ...C PLATED GR 5 14 8 320588000 WASHER FL 1 2 HARDENED 15 2 479200167 1 2 13 HHCS 6 3 4 IN ZINC PLATED GR 5 16 2 479200168 1 2 13 HHCS 6 IN ZINC PLATED GR 5 17 4 017699000 HEX NUT 1 2 13 UNC NYON LOCK ZP...

Page 84: ...CORD REEL ASSEMBLY 40 1 646900000 SWITCH LIMIT ANTI TWO BLOCK 41 1 642918000 CORD CONNECTOR 42 1 366678000 SPRING EXTENSION 43 1 479200153 OPEN LOAD HOOK X BOOM BOLT ON 44 1 479200173 BAIL WELDMENT LO...

Page 85: ...SIDE PLATE TRAVELING BLOCK 3 1 480366000 HOOK SWIVEL 6 METRIC TON 4 1 480861000 SHEAVE ASSY 3 8 ROPE 5 1 490313000 BOLT SHEAVE W ZERK FITTING 6 1 018600000 NUT HX NYLK 3 4 16UNF 7 2 360605000 PIN BLO...

Page 86: ...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 87: ...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...

Page 88: ......

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