HC 7 Nexstar OM 477823010 0314 B

HC-7
NEXSTAR
OWNERS MANUAL Manual No. 477823010
Serial No. __________________
Mailing Address:
P.O. Box 580697 Phone 1-800-777-2760
Tulsa, OK 74158-0697 Fax (918) 269-6688
Physical Address: http://www.autocrane.com
4707 N. Mingo Rd.
Tulsa, OK 74117-5904 OM 477823010-0314-B
Auto Crane Warranty Registration
Fax Transmission
To: Warranty Department Fax: (918) 834-5979

From: Date:
Re: Product Registration Pages:
End User Information: (Required for Warranty Activation)
Name: Phone:
Address:
City: State: Zip:
Contact: E-mail Address:
Distributor Information: (Required for Warranty Activation)
Name:
Address:
City: State: Zip:
Contact: E-mail Address:
Product Information: (Required for Warranty Activation)
Model No.: Serial No.:

Date Product Delivered: Date Processed:*
VIN # * For Auto Crane use only
ONE REGISTRATION FORM PER UNIT (CRANE OR BODY)

Registration form must be mailed or faxed within 15 days of customer installation.
Mail to: Warranty

Department Auto
Crane Company P.O.
Box 581510
Tulsa, OK 74158-0697
Warranty Registration Rev. 07240

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 clos-
ing, 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 latch throat is closed before lift-
ing 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

HC-7
TABLE OF CONTENTS
INTRODUCTION ………………………………………….. 1
GENERAL SPECIFICATIONS ………………………………………….. 3
SAFETY TIPS AND PRECAUTIONS ………………………………………….. 4
OPERATING PRACTICES & WARNINGS ………………………………………….. 6
QUALIFICATIONS FOR OPERATORS ………………………………………….. 7
OPERATION OF UNIT / OUTRIGGERS ………………………………………….. 10
CRANE OPERATION ………………………………………….. 11
TRANSMITTER SYNCHRONIZATION ………………………………………….. 14
INSPECTION ………………………………………….. 15
GENERAL REPAIRS AND MTCE ………………………………………….. 18
BATTERY MAINTENANCE ………………………………………….. 20
LUBRICATION & MTCE SCHEDULE ………………………………………….. 22
SAFETY DECAL SECTION ………………………………………….. 24
GENERAL DIMENSIONS ………………………………………….. 29
MOUNTING AND INSTALLATION ………………………………………….. 32
GENERAL ASSEMBLY ………………………………………….. 34
PEDESTAL ASSEMBLY ………………………………………….. 36
BOOM ASSEMBLY ………………………………………….. 37
ROTATION GEARBOX ………………………………………….. 42
HOIST ASSEMBLY ………………………………………….. 46
TRAVELING BLOCK ASSEMBLY ………………………………………….. 49
MAIN HARNES DIAGRAM ………………………………………….. 50
HYDRAULIC CONTROL VALVE ………………………………………….. 53
COUNTERBALANCE VALVE ADJ. ………………………………………….. 54
VALVE OVERRIDE ………………………………………….. 55
TROUBLESHOOTING CHART ………………………………………….. 56
ERROR CODE TROUBLESHOOTING ………………………………………….. 57
ELECTRICAL TROUBLESHOOTING ………………………………………….. 58
HYDRAULIC TROULBESHOOTING ………………………………………….. 60
HC-7 LOAD CHART ………………………………………….. 61
WARRANTY …………………………………………..LAST 2 PAGES
HC-7
INTRODUCTION
Auto Crane products are designed to alternator with a 500 cold cranking amp
provide many years of safe, trouble-free, battery. These specifications should be
dependable service when properly used and considered minimum.
maintained.
It has always been Auto Crane Company
To assist you in obtaining the best service policy to handle all warranty claims we receive
from your crane and to avoid untimely crane as promptly as possible. If a warranty claim
and/or vehicle failure, this manual provides involves discrepant material or workmanship,
the following operating and service Auto Crane will take immediate corrective
instructions. It is specifically recommended action. It is understandable that Auto Crane
that all operating and service personnel Company cannot assume responsibility of
consider this manual as mandatory material liability when it is obvious that our products have
for reading and study before operating or been abused, misused, overloaded or otherwise
servicing Auto Crane products. It is highly damaged by inexperienced persons trying to
recommended that crane owners, equip- operate the equipment without
ment reading the manual.
managers, and supervisors also read this
manual.
Auto Crane has incorporated several safety Auto Crane maintains a strong distributor
features in the HC-7 crane for your network and a knowledgeable Customer Service
protection. Department. In most cases, an equipment
problem is solved via phone conversation with
For your convenience the overall dimensions our customer service department. The customer
of the HC-7 crane are included on the service department also has the ability to bring a
General Dimension Drawing. Rotation and local distributor, a regional sales manager, or a
turning radius are also listed on that drawing. factory serviceman into the solution of an
equipment problem.
Remember, the crane adds weight to the
vehicle. Adding weight may change the If, through no fault of Auto Crane Company, it is
driving and riding characteristics of the necessary to send an experienced factory
vehicle unless the appropriate overload serviceman on a field service call the rates
spring(s) are installed on the truck. The stated in the Auto Crane Distributor’s Flat Rate
payload of the vehicle is reduced by the Manual will apply.
weight of the crane. The operator should
exercise care when loading the vehicle. Auto Crane Company’s extensive Research and
Distributing the payload on the vehicle evenly Development Program allow our customers to
will greatly improve the driving and riding use the best equipment on the market. Our
characteristics of the vehicle. 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
The HC-7 cranes are attached to your factory.
12-volt truck electrical system through the
relay provided. The HC-7 is another highly
efficient Auto Crane product. The use of
a maintenance-free battery is not recom-
mended 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
1
HC-7
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 num-
ber: 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.
2
HC-7
GENERAL SPECIFICATIONS
DIMENSIONS REACH
Width: 23.25 in. (0.59 m) Second boom will reach from 10 feet 6 inches
to 16 feet 6 inches.
Height: 32.75 in. (0.83 m) Third boom will reach from 16 feet 6 inches to
20 feet 6 inches.
Length: 13 ft 0-3/8 in (3.97 m)
[Boom(s) stored]
CABLE
Weight: 1,705 lbs (773 kg)
95 ft (28.9 m) of 3/8 in (9.5 mm) diameter air-
craft quality cable. This cable has a single line
breaking strength of 14,700 lbs (6,667.8 kg).
CAPACITY
CHASSIS REQUIREMENTS
38,000 ft-lbs (5.20 ton-m)
[ft-lbs = horizontal distance from centerline 14,500 lbs (6,577 kg) GVWR minimum
of rotation to free hanging weight (feet) x 360,000 in-lbs RBM
amount of weight (pounds)]
HYDRAULIC REQUIREMENTS
LIFTING CAPACITIES 8 gpm flow @ 2,750 psi
ANGLE RETRACTED MID EXT. EXTENDED
0 3,664 2,303 1,853 ELECTRICAL SYSTEM REQUIREMENTS
15 3,793 2,384 1,919
Voltage: 12 VDC
30 4,231 2,659 2,140
45 5,180 3,256 2,621 Alternator: 60 amps (minimum)
60 7,000 4,606 3,707
Battery: 100 minute reserve
75 7,000 7,000 6,115
capacity (minimum)
Maintenance type
ROTATION
370º Rotation with electric stop.
3
—-IMPORTANT—-
SAFETY TIPS AND PRECAUTIONS
1. No unqualified or unauthorized person shall 16. WARNING: NEVER OPERATE THE CRANE
be allowed to operate the crane. NEAR ELECTRICAL POWER LINES. Auto
2. WARNING: Never weld, modify, or use un- Crane Company recommends that the crane
authorized components / parts on any Auto never be any closer to a power line (including
Crane unit. This will void any warranty or telephone lines) than 10 feet at any point.
liability. Also, failure of the crane may result. 17. Allow the vehicle engine to warm up before
3. Make certain the vehicle meets minimum operating crane.
chassis requirements. (These requirements do 18. Know the weight of your rigging and load to
not guarantee unit stability.) avoid overloading the crane.
4. Make certain the crane is installed per factory 19. Deduct the weight of the load handling equip-
specifications. Contact your local distributor or ment from the load rating to determine how
the Auto Crane factory if any questions arise. much weight can be lifted.
5. Visual inspections and tests should be con- 20. All load ratings are based on crane capacity,
ducted at the beginning of each shift each day NOT the vehicle stability. Remember in lifting
to insure that the crane and all its operating a heavy load, the weight can create enough
systems are in good condition and working tipping moment to overturn the vehicle
order before it is used. 21. Always comply with load chart capacities,
6. Inspect hydraulic hoses frequently for signs of (centerline of rotation to hook).
deterioration, and replace them as required. 22. Secure all loads before lifting.
7. If a hydraulic break occurs, leave the area of 23. Always set the emergency brake before begin-
the break and do not attempt to stop the break ning operation.
by hand as the hydraulic oil may be hot and 24. Keep objects and personnel clear of crane
under high pressure which can cause seri- path during operation.
ous injury. Shut the system down as soon as
25. Operate control levers slowly and smoothly
possible.
in order to meter oil flow for safe operation.
8. Check the hook at least every thirty days for (Not applicable to electric-hydraulic cranes.)
distortions or cracks and replace it as re-
26. Always extend the outriggers from vehicle to
quired.
the ground before crane operation. Insure
9. Oil gears as required. that they are firmly positioned on solid foot-
10. Stop all operations when cleaning, adjusting ings. Stand clear of outriggers while they are
or lubricating the machine. being extended.
11. Keep dirt and grit out of moving parts by keep- 27. If any outrigger, when extended, rests on
ing crane clean. Make sure machine is free a curb or other object that prevents it from
of excess oil, grease, mud and rubbish, thus extending to its maximum distance, shorten
reducing accidents and fire hazards. bearing or fulcrum point and reduce the maxi-
12. When a new cable is installed, operate first mum load accordingly.
with a light load to let the cable adjust itself. 28. When an outrigger will not reach the ground
13. Locate the vehicle at the work site for the best due to holes or grades, it shall be blocked up
stability possible. to provide level and firm support for the truck.
14. Keep the vehicle in a level position while load- 29. When working in soft earth, use wide pads
ing or unloading. under outrigger feet to prevent sinking.
15. Observe operating area for obstructions and/ 30. Always store outriggers before transportation.
or power lines that might be a hazard.
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.
4
—-IMPORTANT—-
SAFETY TIPS AND PRECAUTIONS
31. Always store the crane in its stowed position WARNING: Never attempt to lift, drag, tow or
for transportation. pull a load from the side. The boom can fail
32. Remember the overall height of the entire far below its rated capacity.
unit for garage door clearance or when 41. Do not push down on anything with boom
moving under objects with low overhead extensions; similarly do not lift anything with
clearance boom extensions.
33. Disengage power takeoff (PTO) 42. Do not lift personnel with any wire rope
before moving the vehicle. attachment or hook. There is no implied war-
(Not applicable to electric-hydraulic cranes.) ranty or responsibility for such purposes.
34. Always walk around the vehicle before 43. WARNING: In using a safety hook, ALWAYS
moving. close the hook latch throat before lifting a
35. Never drive with a load suspended from load. Proper attention and common sense
crane. applied to the use of the hook and various
36. Do not take your eyes off a moving load. slings will prevent possible damage to mate-
Look in the direction you are moving. rial being hoisted and may prevent injury to
personnel.
37. Never swing a load over people.
44. WARNING: Never place a chain link on the
38. Do not stop the load sharply in midair so
tip of the hook and try to lift a load with the
that it swings like a pendulum. Meter the
hoist.
control levers to avoid this situation. (Not
applicable to electric-hydraulic cranes.) 45. WARNING: Never use a sling bar or any-
thing larger than the hook throat which could
39. Crane boom length should be kept as short
prevent the safety latch from closing, thus
as possible for maximum lifting capacity and
negating the safety feature.
greater safety. Longer booms require addi-
tional care in accelerating and decelerating 46. Do not wrap the wire rope around sharp
the swing motion, and thus slow down the objects when using winch.
working cycle and reduce productivity. 47. WARNING: Never unreel last 5 wraps of
40. Keep the load directly and vertically under cable from drum.
the boom point at all times. Crane booms
are designed to handle vertical loads, not
5
—-IMPORTANT—-
OPERATING PRACTICES AND WARNINGS
1. Make certain the vehicle meets minimum chassis re- 15. WARNING! NEVER OPERATE THE CRANE
quirements. (These requirements do not guar- NEAR ELECTRICAL POWER LINES! Death or
antee unit stability) serious injury will result from boom, line, or load
2. Make certain the crane is installed per factory contacting electric lines. Do not use crane within
specifications. Contact your local Distributor or the 10 feet (3.05m) of electric power lines carrying up
Auto Crane factory if any questions arise. to 50,000 volts. One foot additional clearance is
3. Keep the vehicle in as level a position as possible required for every additional 30,000 volts or less.
while loading or unloading. 16. WARNING! NEVER EXCEED load chart ca-
4. ALWAYS set the vehicle emergency brake before pacities (centerline of rotation to hoist hook).
beginning crane operations. 17. WARNING! NEVER un-reel last 5 wraps of
5. ALWAYS use outriggers from vehicle to the ground cable from drum!
during crane operation. Make sure they are firmly 18. WARNING! NEVER wrap cable around load!
positioned on solid footings.
19. WARNING! NEVER attempt to lift or drag a load
6. All load ratings are based on crane capacity, NOT from the side! The boom can fail far below its
truck/crane stability. rated capacity.
7. Keep objects and personnel clear of crane path
20. WARNING! NEVER weld, modify, or use un-
during operation.
authorized components on any Auto Crane unit!
8. Keep hoist cable pulled tight at all times. This will void any warranty or liability. Also failure
9. REMEMBER, in lifting a heavy load, the weight can of the crane may result.
create enough tipping momentum to overturn the
21. WARNING! NEVER place a chain link on the tip
vehicle.
of the hook and try to lift a load!
10. ALWAYS keep load as close to ground as possible.
22. WARNING! NEVER use a sling bar or anything
11. Hydraulic hoses need to be inspected frequently for
larger than the hook throat that could prevent the
signs of deterioration, and be replaced as required.
hook latch from closing, thus negating the safety
12. The hoist hook is an important item that an opera- feature!
tor should consider and use properly. It should be
23. WARNING! In using a hook with latch, ALWAYS
checked on a daily basis for distortion or cracks.
insure that the hook latch throat is closed before
13. ALWAYS store outriggers before road travel. lifting a load! Proper attention and common sense
14. In applications, where the rotation of the load is applied to the use of the hoist hook and various
hazardous a tag or restraint line should be used (ref slings will prevent possible damage to material
OSHA 1910.180(h)(3)(xvi)). To reduce the potential being hoisted and may prevent injury to per-
for the load to rotate or rope twist, operate at mini- sonnel.
mal boom angles and extension. If restraining the
WARNING! NEVER hold any Control Select
load and/or changing operation location is not an
Switch on that will cause unsafe operating
option,
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.
6
QUALIFICATIONS FOR AND CONDUCT OF
OPERATORS AND OPERATING PRACTICES
REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE QUALIFICATION RE-
QUIREMENTS
OPERATORS tests may be required to determine these

1. Crane operation shall be limited to person-
conditions.
nel with the following minimum qualifica- 5. Operators and operator trainees should have
tions: normal depth perception, coordination, and
A. Designated persons. no tendencies to dizziness or similar unde-
B. Trainees under the direct supervision of a sirable characteristics.
designated person.
6. In addition to the above listed requirements,
C. Maintenance and test personnel (when it
is necessary in the performance of their
the operator shall:
duties). A. Demonstrate the ability to comprehend
D. Inspectors (crane). and interpret all labels, operator’s manu-
2. No one other than the personnel specified als, safety codes, and other information
above shall enter the operating area of a pertinent to correct crane operations.
crane with the exception of persons such as B. Posses the knowledge of emergency pro-
oilers, supervisors, and those speci- cedures and implement it.
fied persons authorized by supervisors C. Demonstrate to the employer the ability
whose duties require them to do so and then to operate the specific type of equipment.
only in the performance of their duties and D. Be familiar with the applicable safety
with the knowledge of the operator or other regulations.
persons. E. Understand the operating procedures as
QUALIFICATIONS FOR OPERATORS outlined by the manufacturer.
F. Be thoroughly familiar with the crane and
1. Operators shall be required by the employer its control functions.
to pass a practical operating examination.
G. Understand the operating procedures as
Qualifications shall be limited to the specific type
of equipment for which examined. outlined by the manufacturer.
2. Operators and operator trainees shall meet the CONDUCT OF OPERATORS
following physical qualifications:
A. Vision of at least 20/30 Snellen in one eye and 1. The operator shall not engage in any prac-
20/50 in the other, with or without correc- tice, which will divert his attention while
tive lenses. actually operating the crane.
B. Ability to distinguish colors, regardless of 2. Each operator shall be responsible for
position, if color differentiation is required for those operations under the operator’s direct
operation. control. Whenever there is any doubt as to
C. Adequate hearing with or without hearing aid safety, the operator shall consult with the
for the specific operation. supervisor before handling the loads.
3. The operator should not leave a suspended
3. Evidence of physical defects or emotional
load unattended unless specific precautions
instability, which render a hazard to opera- have been instituted and are in place.
tor or others, which in the opinion of the 4. If there is a warning sign on the switch or
examiner could interfere with the operator’s engine starting controls, the operator shall
7
or neutral position and all personnel are in C. Means are provided to hold the vehicle
the clear. stationary while operating the crane.
6. If power fails during operation, the operator D. Before starting to lift, the hook shall be
shall: positioned over the load in such a manner
A. Move power controls to the “OFF” or as to minimize swinging.
neutral position. E. During lifting care shall be taken that:
B. Land the suspended load and boom, if 1. There is no sudden acceleration or
practical. deceleration of the moving load.
7. The operator shall be familiar with the equip- 2. Load, boom or other parts of the crane
ment and its proper care. If adjustments or do not contact any obstruction.
repairs are necessary, the operator shall F. Cranes shall not be used for dragging
report the same promptly to the appointed loads sideways.
person, and shall also notify the next G. This standard recognizes that telescopic
operator. boom cranes are designed and intended
8. The operator at the start of each shift shall for handling materials. They do not meet
test all controls. If any controls do not personnel lift or elevator requirements.
operate properly, they shall be adjusted or Therefore, no lifting, lowering, swinging
repaired before operations are begun. or traveling shall be done while a person
9. Stabilizers shall be visible to the operator is on the hook or load. Hook attached
while extending or setting unless a signal suspended work platforms (baskets) shall
person assists operator. not be used with cranes covered by this
standard. Crane manufacturer must ap-
OPERATING PRACTICES/HANDLING THE prove work platforms attached to the boom.
LOAD H. The operator should avoid carrying loads
over people.
1. Size of load.
I. When the crane is so equipped, the
A. No crane shall be loaded beyond the
stabilizers shall be fully extended and set.
rated load except for test purposes
Blocking under stabilizers shall meet the
B. The load to be lifted is to be within the requirements as follows:
rated load of the crane and its existing
1. Strong enough to prevent crushing.
configuration.
2. Of such thickness, width and length
C. When loads that are not accurately known
as to completely support the stabilizer
are to be lifted, the person responsible for
pad.
the job shall ascertain that the weight of
the load does not exceed the crane rated J. Firm footing under all tires, or individual
load at the radius at which the load is to stabilizer pads should be level. Where
be lifted. such a footing is not otherwise supplied,
timbers, cribbing, or other structural
2. Attaching the load.
members to distribute the load so as to not
A. The load shall be attached to the hook by exceed allowable bearing capacity or the
means of slings or other devices of suf- underlying material should provide it.
ficient capacity.
K. In transit, the boom shall be carried in
B. Hoist rope shall not be wrapped around stowed position.
the load.
L. When rotating the crane, sudden starts
3. Moving the load. and stops shall be avoided. Rotational
The operator shall determine that: speed shall be such that the load does not
A. The crane is level and, where necessary, swing out beyond the radius at which it can
the vehicle/carrier is blocked properly. be controlled.
M. The crane shall not be transported with a
load on the hook unless recommended by
8
N. No person should be permitted to stand or 3. Caution shall be exercised when working

pass under a suspended load. near overhead lines, because they can move
4. Stowing procedure. horizontally or vertically due to wind, moving
the danger zone to new positions.
Follow the manufacturer’s procedure and
sequence when stowing and un-stowing 4. In transit with no load and boom lowered the
the crane. clearance shall be specified in Table 1.
5. A qualified signalperson shall be assigned
MISCELLANEOUS to observe the clearance and give warning
before approaching the above limits.
OPERATING NEAR ELECTRICAL POWER A. Any overhead wire shall be considered to
LINES 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 op-
erator’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 dan-
ger zone shown above.
EXCEPTIONS
A. The danger zone may be entered after
confirmation by an appointed person that
the electrical distribution and transmis-
sion 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
9
—-IMPORTANT—-
BEFORE OPERATING CRANE
1. Make sure this manual has been thoroughly 8. Always boom up before rotating so the boom will
read by all crane operating personnel and clear the required boom support.
supervisors. 9. When extending the boom, always maintain clear-
2. A routine inspection of the crane should be ance between the boom crown and the traveling
mandatory before each operating day. Any block or hoist hook.
defects should be corrected immediately. 10. Always observe safe and practical operation to
3. At a job site the vehicle should be positioned avoid possible accidents. Refer to Safety Tips
so that the crane can adequately reach the and Precautions.
load within the rated capacity (centerline of 11. After completing lifting operations, return the boom
rotation to hoist hook). to stowed position on the boom support. Avoid
4. Keep the vehicle as level as possible during unneeded pressure on the boom support.
operation. CANNOT EXCEED 10° SLOPE. 12. Store transmitter in proper location (in cab or stor-
5. For electric cranes, engage emergency brake age area).
and leave ignition on with transmission in neu- 13. Return outriggers to stowed position. Make sure
tral (or in park for automatic transmis- they are pinned in place or jacklegs are returned
sions). Activate any crane power switches. to compartment.
For Auto Crane units requiring battery and 14. Check work area for any tools or equipment not
hydraulic operation, engage emergency stored.
brake, place gear selector in neutral, press
15. Release throttle control, depress clutch and disen-
clutch, activate PTO, release clutch and after
gage PTO. Deactivate any crane power switches.
hydraulic fluid is warm, set throttle control to
proper engine speed. 16. Report any unusual occurrence during crane op-
eration that may indicate required maintenance or
6. Always use outriggers from the truck to the
repair.
ground. Be sure these are firm and adequate-
ly positioned. When rotating, keep load as 17. NEVER use two cranes to support a load too large
low to the ground as possible. for either crane.
7. Remove the transmitter from cab or storage
area. Power transmitter on. Detach hook
from dead man. Crane is now ready for op-
eration.
OPERATION OF OUTRIGGERS
HYDRAULIC OUTRIGGERS MANUAL OUTRIGGERS

1. Shift crane/outrigger control valve to “outrig- 1. Pull lock pins to release jackleg or drop down
ger” position. outrigger and move to outermost lock position.
2. Operate the outrigger control valves to po- 2. Make sure lock pins are reinstalled properly.
sition the outriggers. 3. Lower outrigger pad to firm ground and adjust foot
3. After outriggers are positioned, return crane/ to take out slack.
outrigger selector to “crane” position. 4. Crane is now ready to operate.
4. Crane is now ready to operate.
10
CRANE OPERATION
TRANSMITTER LAYOUT
E-stop Switch—Push to activated, Twist

to release. Shuts down all outputs from
receiver.
On/Off/Multispeed— Detachable key,

On, Off, Multispeed, & Start Switch.
Crane Controls—Proportional push

button. The function speed increases the
more the button is pressed. Func-
tions include Boom Up/Down, Rotate
CW-CCW, Hoist Up/Down, Boom Ex-
tend, Retract.
Engine Fast-idle - Activates Fast Idle on

Vehicle. (Can be latching or momentary)
Auxiliary - Sends a latched signal that

activates an auxiliary output to operate
an external component i.e. compressor,
worklights. (Must use a relay to sepa-
rate auxiliary crane circuit and external
component.)
Engine Stop - Sends a momentary sig-

nal from crane to shut down vehicle.
Engine Start - Sencs a momentary sig-

nal from crane to start vehicle.
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 counter-clock-
wise one position past the “off” position. Once the switch is one position past the “off” position then pull out the
switch from the transmitter.
11
CRANE OPERATION
ACTIVATING E-STOP
Press the E-stop Switch.
Note:
1. When E-stop is active, the transmitter will remain on but will not operate any functions. This includes truck
and crane functions.
2. Activating E-stop will not turn the truck off.
3. There will be an Error Code on the receiver stating “E-stop active”.
DEACTIVATING E-STOP
1. Twist to release E-stop.
2. Turn transmitter to the “OFF” position.
3. Once all lights turn off. Turn transmitter to the “ON” postion.
4. Turn transmitter to the “START”/”SPEED” position and release
Note:
There is very little height difference in a active and inactive E-stop. To verify E-stop switch is deactivated, twist
switch to release.
WAKING UP TRANSMITTER
Turn the transmitter to the “START”/”SPEED” position and release
Note:
The transmitter goes into sleep mode after 5 minutes of inactivity. All truck functions are still available and will
remain in the same state. (i.e. Aux function will remain on even when the unit goes to sleep if it was active be-
fore 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 decreases to the next 25% range.
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.
12
CRANE OPERATION
RECEIVER LAYOUT
CRANE STATUS
AUXILIARY ACTIVE
LIFT CYLINDER
PRESSURE
SYSTEM GOOD
FUNCTION ACTIVATED Boom Pressure 174
SP - SPEED PERCENT Boom Down SP=100%
HIGH IDLE AUX ENG XXX
HIGH IDLE ACTIVE Boom Angle 43 (deg)
Boom Load 7%
BOOM ANGLE (DEGREES) 9 80% 100%
BOOM LOAD
(% OF TOTAL LOAD)
ACTIVE SIGNALS ENGINE START (ENG ON) OR

FROM TRANSMITTER ENGINE STOP (ENG OFF)
ACTIVE
TRANSMITTER SIGNAL
STRENGTH WATCH DOG
BATTERY LIFE TIMER
% 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.
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.
AUXILIARY ACTIVE— Shows when the auxiliary function is active.

13
TRANSMITTER SYNCHRONIZATION
INSTRUCTIONS
1. The receiver must be shut off and powered down The current address tag must be removed from the harness
and the LEARN tag (366823955) will need to be put in its place.
2. After the LEARN tag has been put into place and the receiver is powered up, it will begin to search for the
proper Channel and Serial Number of the transmitter. Note: The transmitter must be powered up and the
start/speed button must be held in the “speed” position. Make sure the transmitter is blinking the
green led in the center. Reference figure 1 below for LCD screen display during this step. Reference
figure 2 below for transmitter switch position.
CURRENT CHANNEL BEING

SCANNED
CURRENT SET
CHANNEL
CURRENTLY IN LEARN MODE
S0. ESTOP ACTIVE
LearnMode sc= 6 rf=21
CURRENT SERIAL NUMBER Cur Rx Code 010020
New Rx Code 00
NEW SERIAL NUMBER Start transmitter
for new code GREEN
9 80% 100%
CURRENT STEP
INSTRUCTIONS
Figure 1—LCD screen display during step 2 Figure 2—Transmitter Switch Position
3, The receiver will start searching to find the channel and Serial Number. Once the numbers are found, it will
display it on the LCD screen and will state “Press <Function> to confirm code”. At this time, release “speed
position” and press then release the function shown on the screen. In the example below , press and release
the Swing Clockwise function. Reference figures below:
CHANNEL FOR NEW RELEASE THIS
SPEED
TRANSMITTER ON SWITCH
F
OF
CURRENT SET
CHANNEL
CURRENTLY IN LEARN MODE
SYSTEM GOOD
LearnMode sc= 7 rf=21
CURRENT SERIAL NUMBER Cur Rx Code 010020
New Rx Code 01157
NEW SERIAL NUMBER Press Swing CW
to confirm code
9 80% 100%
CURRENT STEP PRESS AND
INSTRUCTIONS RELEASE
THIS BUTTON
Figure 3—LCD screen display & transmitter during step 3
4. Once the code is confirmed, remove the LEARN tag from the harness. Then power the receiver off (main
crane power switch) - reference figure 5
SYSTEM GOOD SYSTEM GOOD

LearnMode sc= 7 rf=21 LearnMode sc= 7 rf=21
Cur Rx Code 010020 Cur Rx Code 010020
New Rx Code 01157 New Rx Code 01157
Rx Code confirmed New code saved
remove tag to save power rcvr off
9 80% 100% 9 80% 100%
BEFORE TAG IS REMOVED AFTER TAG IS REMOVED
Figure 5—LCD screen display during step 4
5. Re-attach the crane address tag to the harness and power up receiver. Confirm all functions are operational.
Note: If the LEARN tag was not removed before powering down the receiver, the new channel and
serial number will not be saved.
14
INSPECTION
REQUIREMENTS
REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE INSPECTION REQUIREMENTS
INSPECTION CLASSIFICATION 6. Inspect for proper rope reeving.

7. Inspect electrical wiring and components for
1. Initial inspection. malfunctioning, signs of excessive deterioration, dirt
Prior to initial use, all new, altered, modified or and moisture accumulation.
extensively repaired cranes shall be inspected by a 8. Inspect hydraulic system for proper oil level and
designated person to insure compliance with pro- leaks.
visions of this standard
9. Inspect tires for recommended inflation pressure,
1. Regular inspection.
cuts and loose wheel nuts.
Inspection procedure for cranes in regular service
is divided into two general classifications based 10. Inspect connecting pins and locking device for wear
upon the intervals at which inspection should be damage and loose retaining bolts.
performed. The intervals in turn are dependent 11. Inspect rope for gross damage, such as listed below,
upon the nature of the components of the crane which may be an immediate hazard.
and the degree of their exposure to wear, dete- A. Distortion such as kinking, crushing,
rioration, or malfunction. The two general clas- un-stranding, birdcaging, main strand displace-
sifications are herein designated as “frequent” and ment, or core protrusion. Loss of rope diameter
“periodic” with respective intervals between inspec- in a short length or unevenness of outer strands
tions as defined below. should be replaced.
A. Frequent inspection - daily or before each use B. General corrosion.
B. Periodic inspection - one to twelve-month in-
C. Broken or cut strands.
tervals or as specifically recommended by the
manufacturer or qualified person. D. Use care when inspecting sections of rapid
deterioration around flange points, crossover
points, and repetitive pickup points on drums.
DESIGNATED PERSONNEL SHALL Inspect number, distribution, and type of visible broken wires.
PERFORM INSPECTIONS ONLY. Reference Rope Maintenance section in the owner’s manual.
Continued use of rope depends upon good judg-

ment by a designated person in evaluating remain-
FREQUENT INSPECTION ing strength in a used rope after allowance for de-
terioration disclosed by inspection. Continued rope
Inspections should also occur during operation for
operation depends upon this remaining strength.
any deficiencies that might appear between regular
inspections. Any deficiencies, such as those listed
below, shall be carefully examined and a determina-
tion made as to whether they constitute a hazard: PERIODIC INSPECTION
1. Inspect control mechanisms for maladjustment that Any deficiencies, such as those listed below, shall
interferes with proper operation. be carefully examined and determination made as to
2. Inspect control mechanisms for excessive wear of whether they constitute a hazard:
components and contamination by lubricants or
other foreign matter. 1. Inspect for deformed, cracked or corroded members
3. Inspect safety devices for malfunction. in the crane structure and entire boom.
4. Visually inspect all hydraulic hoses, particularly 2. Inspect for loose bolts, particularly mounting bolts.
those that flex in normal operation of crane func-
3. Inspect for cracked or worn sheaves and drums.
tions.
5. Inspect hooks and latches for deformation, chemi- 4. Inspect for worn, cracked, or distorted parts such as
cal damage, cracks, and wear. Refer to ANSI/ pins, bearings, shafts, gears, rollers and devices.
ASME B30.10. 5. Inspect for excessive wear on brake and clutch sys-
tem parts and lining.
15
INSPECTION
REQUIREMENTS
6. Inspect crane hooks for cracks. 13. Inspect hydraulic filters for evidence of rubber
7. Inspect travel steering, braking, and locking de- particles on the filter elements indicating possible
vices for malfunction. hose, “O” ring, or other rubber component dete-
8. Inspect for excessively worn or damaged tires. rioration. Metal chips or pieces on the filter may
denote failure in pumps, motors, or cylinders.
9. Inspect hydraulic hose, fittings, and tubing for the
Further inspection will be necessary to determine
following problems:
the origin of the problem before corrective action
A. Evidence of leakage at the surface of the can be taken.
flexible hose or its junction with metal and
14. Inspect labels to confirm correct location and leg-
coupling.
ibility. Reference decal layout in this manual for
B. Blistering, or abnormal deformation to the proper location of decals.
outer covering of the hydraulic or pneumatic
15. Rope Inspections need not be at equal calen-
hose.
dar intervals and should be more frequent as
C. Leakage at threaded or clamped joints that the rope approaches the end of useful life. A
cannot be eliminated by normal tightening or qualified person shall inspect the wire rope based
recommended procedures. on such factors as:
D. Evidence of excessive abrasion or scrubbing A. Expected rope life as determined by experi-
on the outer surface of a hose, rigid tube, or ence on the particular installation or similar
fitting. Means shall be taken to eliminate the installations.
interference of elements in contact or other-
B. Severity of environment.
wise protect the components.
C. Percentage of capacity lifts.
10. Inspect hydraulic pumps and motors for the fol-
lowing problems: D. Frequency rates of operation.
A. Loose bolts and fasteners. E. Exposure to shock loads.
B. Leaks at joints between sections. This inspection shall cover the entire length of
the rope. Only the surface wires need to be
C. Shaft seal leaks.
inspected and no attempt should be made to
D. Unusual noises or vibrations. open the rope. Any deterioration resulting in ap-
E. Loss of operating speed. preciable loss of original strength shall be noted
F. Excessive heating of the fluid. and determination made as to whether use of the
G. Loss of pressure. rope would constitute a hazard. A few notable
11. Inspect hydraulic valves for the following prob- deterioration points are listed below:
lems: A. Reduction of rope diameter below nominal
A. Cracks in valve housing. diameter due to loss of core support.
B. Improper return of spool to neutral position. B. Internal or external corrosion.
C. Leaks at spools or joints. C. Wear of outside wires.
D. Sticking spools. D. Severly corroded, cracked, bent, worn, or
E. Failure of relief valves to attain or maintain
correct pressure setting. CRANES NOT IN REGULAR USE
F. Relief valve pressure shall be checked as
specified by the manufacturers. A crane, which has been idle for a period of over one
12. Inspect hydraulic cylinders for the following prob- month or more, shall be given an inspection conform-
lems: ing to the “initial” and “regular” inspection require-
ments of this section.
A. Drifting caused by fluid leaking across piston.
B. Rod seals leaking.
C. Leaks at welded joints. INSPECTION RECORDS
D. Scored, nicked, or dented cylinder rods.
Dated records of periodic inspection should be made
E. Damaged case (barrel). on critical items such as brakes, crane hooks, rope,
F. Loose or deformed rod eyes or connecting cylinders, and relief pressure valves.
joints.
16
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
17
GENERAL
REPAIRS AND MAINTENANCE
REFERENCE ASME B30.5a AND OSHA 1910.180 FOR COMPLETE MAINTENANCE AND RE-
PAIR REQUIREMENTS
A preventative maintenance program should be es- 4. If bleeding the hydraulic system is required, run
tablished based on this section and all replacement each crane function until smooth operation of that
parts should be obtained from AutoCrane Com- particular function is noticeable.
pany. For replacement parts contact your local
authorized distributor.
LUBRICATION
All moving parts of the crane, for which lubrication
MAINTENANCE PRECAUTIONS is specified, should be regularly lubricated per the
1. Place crane where it will cause the least in- manufacturer’s recommendations and procedures.
terference with other equipment or operations. Reference Lubrication and Maintenance Schedule
in this manual.
2. Verify all controls are in the “off” position and all
operating features secured from inadvertent motion ROPE REPLACEMENT
by brakes, pawls, or other means.
3. The means for starting the crane shall be rendered No precise rules can be given for determination of
inoperative. the exact time for replacement of rope, since many
4. The boom should be secured in place before main- variable factors are involved.
tenance.
5. Relieve hydraulic oil pressure from all hydraulic 1. Conditions such as the following shall be reason for
circuits before loosening or removing hydraulic questioning continued use of the rope or increasing
components. the frequency of inspection:
6. Warning or “OUT OF ORDER” signs shall be placed A. In running ropes, six randomly distributed bro-
on all crane controls. ken wires in one lay or three broken wires in one
7. After adjustments and repairs have been made, strand in one lay.
the crane shall not be returned to service until all B. One outer wire broken at the contact point with
guards have been reinstalled, trapped air removed the core of the rope structure and protrudes
from hydraulic system (if required), safety devices or loops out of the rope structure. Additional
reactivated, and maintenance equipment removed. inspection of this section is required.
C. Wear of one third of the original diameter of the
ADJUSTMENTS AND REPAIRS outside individual wire.
1. Any hazardous conditions disclosed by the inspec- D. Kinking, crushing, bird caging, or any other dam-
tion requirements shall be corrected before opera- age resulting in distortion of the rope structure.
tion of crane is resumed. Only designated person- E. Evidence of any heat damage from any cause.
nel shall do adjustments and repairs. F. Reduction from nominal diameter of more than
2. Adjustments shall be maintained to assure correct 1/64 in. (0.4mm) for diameters up to and includ-
functioning of components, the following are ex- ing 5/16 in. (8 mm), 1/32 in. (0.8 mm) for di-
amples: ameter 3/8 in. (9.5 mm) to and including 1/2 in.
A. Functional operating mechanism. (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
B. Safety devices.
in. (1.6 mm) for diameter 7/8 in. (22 mm) to and
C. Control systems. including 11/8 in. (29 mm), 3/32 in. (2.4 mm) for
3. Repairs or replacements shall be provided as diameters 11/4 in. (32 mm) to and including 11/2
needed for operation, the following are examples: in. (38 mm).
A. Critical parts of functional operating mecha- G. In standing ropes, more than two broken wires
nisms which are cracked, broken, corroded, in one lay in sections beyond end connec-
bent, or excessively worn. tions or more than one broken wire at an end
B. Critical parts of the crane structure which are connection.
cracked, bent, broken, or excessively corroded.
C. Crane hooks showing cracks, damage, or cor-
rosion shall be taken out of service. Repairs by
18
GENERAL
REPAIRS AND MAINTENANCE
2. Replacement rope shall have a strength rating 4. During installation care should be exercised to
at least as great as the original rope furnished or avoid dragging of the rope in the dirt or around
recommended by AutoCrane. A rope manufactur- objects that will scrape, nick crush or induce
er, AutoCrane, or a qualified person shall specify sharp bends in it.
any deviation from the original size, grade, or 5. Rope should be maintained in a well-lubricated
construction. condition. It is important that lubricant applied
as a part of a maintenance program shall be
ROPE MAINTENANCE compatible with the original lubricant and to this
1. Rope should be stored to prevent damage or end the rope manufacturer should be consulted.
deterioration. Lubricant applied shall be the type that does not
hinder visual inspection. Those sections of rope
2. Unreeling or uncoiling of rope shall be done as
that are located over sheaves or otherwise hid-
recommended by the rope manufacturer and
den during inspection and maintenance proce-
with care to avoid kinking or inducing twist.
dures require special attention when lubricating
3. Before cutting a rope, seizing shall be placed rope. The object of rope lubrication is to reduce
on each side of the place where the rope is to internal friction and to prevent corrosion.
be cut to prevent unlaying of the strands. On
pre-formed rope, one seizing on each side of 6. When an operating rope shows greater wear or
the cut is required. On non-preformed ropes of well-defined localized areas than on the re-
7/8 in. (22 mm) diameter or smaller, two seiz- mainder of the rope, rope life can be extended
ings on each side of the cut are required, and in some cases by shifting the wear to different
for non-preformed rope 1 in. (25 mm) diameter areas of the rope.
or larger, three seizings on each side of the cut
are required.
19
MAINTENANCE
OF BATTERIES
Maintenance of Auto Crane unit batteries differs very 2. The portion of the plate exposed is not usable.
little from the generally prescribed mainte- 3. That portion of the acid remaining becomes more
nance of any lead acid battery. All batteries must be concentrated and may cause more rapid deteriora-
kept properly charged, properly filled with water, and tion of the remaining parts of the battery.
relatively clean.
Keep Properly Charged Keep A Relatively Clean Battery

Many things affect the proper charge to a battery, The battery should be kept clean. Batteries filled with
such as: acid and which are not in use self-discharge to a limited
degree because of the nature of the materials within
1. Regulator settings. the battery. If dirt is allowed to collect on the top of the
2. Proper tightness of belts on the alternator or battery (and this dirt absorbs moisture) and electrical
generator. path can be set up between the various terminals of the
3. Good, clean connections of all cables and wires battery and the ground. Once such a path has been
at the following places: established, the self-discharge of the battery is accel-
erated. This also accelerates corrosion of the battery
a. Battery.
cables at the terminals.
b. Regulator.
c. Starting motor. Periodic Maintenance is Needed
d. Alternator or generator.
A definite program of periodic maintenance of all batter-
e. Ground connections (most impor-
ies should be conducted on a regular basis. Periodic
tant).
maintenance includes:
It is of extreme importance to keep the battery as
1. Checking belts for tightness on the charging equip-
fully charged as possible without overcharging, es-
ment.
pecially when vehicles are left outside for extended
periods in extremely cold climates. A battery can 2. Checking battery electrolyte levels.
freeze. Freezing points for various specific gravities 3. Checking cables for good connections.
of acid are as follows: 4. Cleaning where corrosion is apparent.
Specific Gravity Freezing Temp. When corrosion is cleaned off, the cable terminals and
(Corrected to 80ºF) Degrees F. battery terminals should be coated with a light coat-
ing of petroleum jelly before they are replaced. When
terminals are cleaned, the top of the battery should be
1.280 -90ºF
cleaned with a mild solution of soda water.
1.250 -62ºF
1.200 -16ºF Low Maintenance Batteries
1.150 5ºF (Maintenance Free)
1.100 19ºF
Low maintenance batteries should not be used on
As shown, a half-charged battery (about 1.100 spe- AutoCrane Cranes or trucks equipped with Auto-
cific gravity) cannot stand for any length of time at Crane Cranes. The batteries are not designed for
20ºF or it will freeze. “deep” discharge.
The main reason for keeping the battery as fully Testing Your Battery
charged as possible without over-charging is to in-
If the condition of the battery is in question, it should
sure that power is available even though the vehicle
be removed from the vehicle, taken to the shop, and
has been standing for some time.
allowed to reach room temperature. It should then
be recharged until specific gravity readings taken at
one-half 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
20
MAINTENANCE
OF BATTERIES
If, after charging, it is noted that the specific gravity 2. Place the battery on charge according to the
reading of one cell is 30 points less than any of the manufacturer’s instructions.
other cells, it may be assumed that the cell is bad
and that the battery should be replaced. If all cells It is essential that the second step above be followed
are uniform but not up to full charge, a low rate of to ensure that the battery going on the vehicle is fully
charge should be attempted for an extended time. charged.
This usually will recover a badly sulfated battery. It is also very important that the battery hold-downs
be checked periodically to insure that the batteries
Replacing a Battery are properly positioned to avoid vibration problems,
breakage of cables or terminals. Care must be taken
If it is necessary to replace a battery, and a dry to avoid cracking or breaking containers or covers by
charge battery is used, the following procedure ap- tightening hold-down fixtures excessively. They also
plies: 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.
2. Replacement rope shall have a strength rating 4. During installation care should be exercised to
at least as great as the original rope furnished or avoid dragging of the rope in the dirt or around
recommended by AutoCrane. A rope manufactur- objects that will scrape, nick crush or induce
er, AutoCrane, or a qualified person shall specify sharp bends in it.
any deviation from the original size, grade, or 5. Rope should be maintained in a well-lubricated
construction. condition. It is important that lubricant applied
as a part of a maintenance program shall be
ROPE MAINTENANCE compatible with the original lubricant and to this
1. Rope should be stored to prevent damage or end the rope manufacturer should be consulted.
deterioration. Lubricant applied shall be the type that does not
hinder visual inspection. Those sections of rope
2. Unreeling or uncoiling of rope shall be done as
that are located over sheaves or otherwise hid-
recommended by the rope manufacturer and
den during inspection and maintenance proce-
with care to avoid kinking or inducing twist.
dures require special attention when lubricating
3. Before cutting a rope, seizing shall be placed rope. The object of rope lubrication is to reduce
on each side of the place where the rope is to internal friction and to prevent corrosion.
be cut to prevent unlaying of the strands. On
pre-formed rope, one seizing on each side of 6. When an operating rope shows greater wear or
the cut is required. On non-preformed ropes of well-defined localized areas than on the re-
7/8 in. (22 mm) diameter or smaller, two seiz- mainder of the rope, rope life can be extended
ings on each side of the cut are required, and in some cases by shifting the wear to different
for non-preformed rope 1 in. (25 mm) diameter areas of the rope.
or larger, three seizings on each side of the cut
are required.
21
HC-7
LUBRICATION & MAINTENANCE SCHEDULE
SERVICE
DAY WKLY 3 MOS 6 MOS YEAR NOTES
PERFORMED
INSPECT HOOK & LATCH FOR DEFORMATION,
LOAD HOOK X
CRACKS, & CORROSION
MAKE SURE CABLE IS W OUND EVENLY ON
CABLE DRUM X
DRUM
HOIST / BOOM CHECK FOR FLATTENING, KINKS, & BROKEN
X
CABLE STRANDS, SEE MANUAL
HYD. HOSES X VISUAL INSPECTION
HYD. FLUID X CHECK FLUID LEVEL
PIN RETAINING CHECK TORQUE TO 23 FT-LBS (GRADE 5), 35 FT-
X
BOLTS LBS (GRADE 8) AS REQUIRED
MOUNTING BOLTS X CHECK TORQUE TO 501 FT-LBS AS REQUIRED
ROTATION RING LUBE WITH MOBILETAC LL, OR LUBRIPLATE P/N
X
GEAR 15263, OR EQUAL
SHEAVE SEALED BEARING, REPLACE IF ROUGH OR
X
BEARINGS LOOSE
ALL OTHER BOLTS X CHECK TIGHTEN AS REQUIRED
LIFT CYLINDER GREASE W ITH MOBILEPLEX EP-2 OR
X
BEARINGS EQUIVALENT @ ZERKS
ROTATION GREASE W ITH MOBILEPLEX EP-2 OR
X
BEARING EQUIVALENT @ ZERKS
ROTATION CHECK TORQUE TO 180 FT-LBS AS REQUIRED
X
BEARING BOLTS
ROTATION GEAR CHECK TORQUE TO 90 FT-LBS (SOCKET HEAD)
X
BOX AND 55 FT-LBS (HEX HEAD) AS REQUIRED
ROTATION GEAR
X EP GEAR LUBE SAE 80-90
BOX
DRAIN, FLUSH, AND REFILL W ITH MOBILE DTE
HYDRAULIC FLUID X
13 OIL OR EQUAL
BOOM SLIDE
PADS GREASED WHEN REPLACED
PADS
1) OWNER'S MANUAL
FOR ADDITIONAL
2) OSHA SECTION 1910.180
INFORMATION
3) ANSI B30.5-1989
SEE:
CAUTION: Routine maintenance insures trouble-free operation and protects

your investment. All warranties are void if maintenance is neglected.
22
HC-7
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 re-
placed 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.
23
HC-7
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
Left side
PLACEMENT: Right Plate
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
Right side
sidePlate
of valve sensor.
24
HC-7
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
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
hazard of proximity or contact
with the crane load during
operation.
USED ON: All Cranes
QUANTITY: 2
PLACEMENT: Both sides of traveling block
25
HC-7
PART NO: 040587000

DECAL LOAD SENSOR, DON'T TAMPER
FUNCTION: To inform the operator that the load sensor is
pre-set and that tampering with the sensor
may cause potenƟally hazardous situaƟon.
USED ON: All cranes equipped with load sensor.
QUANTITY 1
PLACEMENT: On liŌ cylinder near the load sensor.
PART NO.: 040519000 USED ON: All cranes.

DECAL: SCISSORS POINT QUANTITY: 2
FUNCTION: To inform the operator of possible PLACEMENT: Both sides of the lift cylinder
danger at scissors point on crane.
26
NOTES
27
HC-7
PART NO. 460169000 USED ON: All Cranes equiped with FM controls
DECAL: REMOTE CONTROL QUANTITY: 1
FUNCTION: To inform the operator of failure to PLACEMENT: LEFT SIDE PLATE
follow the safety precauƟons may result
in equipment failure or serious personal
injury.
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.
28
HC-7 DECAL LAYOUT
P/N: 477823300
1
3
4 4
18 18
5
5
16 6
10
9
15
9
8
11
14
17
29
HC-7 DECAL LAYOUT
P/N: 477823300
13
12
ITEM
NO. QTY PART NO DESCRIPTION
1 2 477399000 DECAL, MAX BLOCK LOAD HC-7
2 2 040518000 DECAL STAY CLEAR OF LOAD
3 2 040517000 DECAL STAY CLEAR OF BOOM
DECAL DANGER "ELECTROCUTION HAZARD" POWER
4 2 040529000
LINE
5 2 040519000 DECAL DANGER SCISSOR POINT
6 1 040587000 DECAL WARNING LOAD SENSOR
7 1 460169000 DECAL WARNING, REMOTE CONTROL
8 1 040579000 DECAL OPERATION INSTRUCTIONS
9 2 477823000 DECAL, LOAD CHART HC-7
10 1 320318001 DECAL ANGLE INDICATOR SS
11 1 330622000 DECAL SERIAL NO
12 2 360034000 DECAL AUTO CRANE LOGO
13 1 040824000 DECAL, AMERICAN FLAG, MADE IN THE U.S.A.
14 1 040632000 DECAL WARNING - OVERLOAD
15 1 040580000 DECAL TRAINED OPERATOR
16 1 320318000 DECAL ANGLE INDICATOR CS
DECAL, MANUAL OVERRIDE PROCEDURES, GS
17 1 366823301
HYDRAULICS, LARGE H-MODELS
18 2 477624000 DECAL, BOOM, HC-7, NEXSTAR
30
HC-7
GENERAL DIMENSIONS
NOTE: C.G. IS APPROXIMATE
31
HC-7
MOUNTING AND INSTALLATION
1. Check to make sure the following items are with your crane. Please note the different, model specific,
quantities.
QTY. PART NO. DESCRIPTION

4 015100000 7/8-14 X 4 HH GR 8
4 022200000 WASHER SP LK 7/8
4 018900000 NUT HX 7/8 NFCP GR8
1 480689000 FUSE 15 AMP TIME-DELAY
1 480688000 FUSE HOLDER IN-LINE WATERPROOF
120 in 800596000 WIRE 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 PLAY
1 320363000 PLUG RELAY
1 477823010 MANUAL, HC-7, NEXSTAR II
1 477823000 DECAL, LOAD CHART, HC-7, FM, NEXSTAR II
*REF. 366823256 TRANSMITTER, 12 BUTTON FULL PROP.
*REF. 477854000 TRAVELING BLOCK ASSEMBLY, HC-7
*ITEMS NOT SHOWN REFERENCE ONLY
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 23 GALLON RESERVOIR(*)
A. RETURN LINE FROM CRANE TO RESERVOIR (IN COMPARTMENT): -10 SAE 100R2 (OR EQUIVA-
LENT ). HOSE LENGTH IS DETERMINED BY INSTALLER. RETURN LINES LONGER THAN 6 FEET
SHOULD BE SIZE –12. HOSE END FITTINGS ARE –10 JIC FEMALE SWIVEL (CRANE END) AND –10
JIC FEMALE SWIVEL (RESERVOIR END).
B. PRESSURE LINE FROM PUMP TO CRANE: -8 SAE 100R12 (OR EQUIVALENT) WITH A 3,000 PSI
MINIMUM WORKING PRESSURE. HOSE LENGTHS IS DETERMINED BY INSTALLER. HOSE END FIT-
TINGS ARE BOTH –8 JIC FEMALE SWIVEL.
IMPORTANT: The recommended hydraulic reservoir size for the average industry application CRANE
ONLY installation is two times the crane hydraulic flow rate. For crane applications requiring more
than 25% crane operation time while the PTO is engaged and/or additional equipment is operated
by the same hydraulic system, it is recommended that an appropriate sized larger hydraulic reser-
voir and/or forced air, hydraulic oil cooler be installed. The addition of other auxiliary 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 8 to 12 gallons per minute and a pressure of 2750 PSI. Excess
flow will cause erratic operation, and too little flow will cause poor crane operation.
CAUTION— HYDRAULIC RESERVOIR OIL TEMPERATURE MUST NOT EXCEED 180°F OR
CRANE PERFORMANCE MAY BE ADVERSELY AFFECTED.
4. Vehicle should meet minimum GVW rating of 14,500 pounds.
5. The vehicle MUST be equipped with an engine speed control and tachometer.
6. Make sure mounting surface is properly reinforced to withstand 38,000 ft-lb capacity loading of crane
and that outriggers are used to provide total stability for the truck.
*Note: 23 GALLON RESEVOIR IS MINIMUM REQUIREMENT FOR CRANE ONLY.
32
HC-7
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 (FM – 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 ( OR BROWN) WIRE FOR ENGINE FAST/SLOW (12VDC MAIN-
TAINED-FM ONLY).
D. OPTIONALLY, USE THE BLUE ( OR YELLOW) WIRE FOR ENGINE START.
E. OPTIONALLY, USE THE ORANGE (OR GREEN) WIRE FOR ENGINE STOP.
F. OPTIONALLY, USE THE GREEN OR BLUE) WIRE FOR AUXILIARY (12VDC MAINTAINED-FM
ONLY).
NOTE: IF YOU HAVE A BROWN, USE THE COLORS IN PARENTHESIS.
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 DAM-
AGE 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 us-
ing 10-12 JIC union and engage PTO with engine running. Allow oil to circulate for 15 to 20 minutes. This will
flush any 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 dis-
engage PTO. Refill reservoir to top sight glass. To ensure 8 gallons per
minute (GPM), install an in-line flow meter between the crane and the reservoir in the return hose.
12. Load test the crane to ensure proper functioning and truck stability.
13. Make certain the owner’s manual is delivered to the customer.
14. For additional help: call the service department at the Auto Crane Company (918) 836-0463 (Tulsa,
Oklahoma).
WARNING
FEDERAL LAW (49 CFR PART 571) REQUIRES THAT THE FINAL STAGE MANUFACTURER OF A VEHICLE CERTIFY THAT
HE VEHICLE COMPLIES WITH ALL APPLICABLE FEDERAL REGULATIONS. ANY MODIFICATIONS PERFORMED ON THE
VEHICLE PRIOR TO THE FINAL STAGE ARE ALSO CONSIDERED INTERMEDIATE STAGE MANUFACTURING AND MUST
BE CERTIFIED AS TO COMPLIANCE. THE INSTALLER OF THIS CRANE AND BODY IS CONSIDERED ONE OF THE MANU-
FACTURERS OF THE VEHICLE. AS SUCH A MANUFACTURER, THE INSTALLER IS RESPONSIBLE FOR COMPLIANCE
WITH ALL APPLICABLE FEDERAL AND STATE REGULATIONS, AND IS REQUIRED TO CERTIFY THAT THE VEHICLE IS IN
COMPLIANCE.
IT IS THE FURTHER RESPONSIBILITY OF THE INSTALLER OF THE CRANE TO COMPLY WITH THE OSHA TRUCK CRANE
STABILITY REQUIREMENTS AS SPECIFIED BY 29 CFR PART 1910.180 (C) (1).
33
HC-7 GENERAL ASSEMBLY
P/N 477000000
20 19
19 22
21
2 20 2
12 1110
8 9
7
28 27
28 27
15 15 3
17
13 14 15 16
24
RETRACT EXTEND
'RET' PORT 'EXT'PORT
23
34
HC-7 GENERAL ASSEMBLY
ITEM PART
NO. QTY NUMBER DESCRIPTION
1 1 477823200 PEDESTAL ASS'Y HC-7 NEXSTAR II
2 1 480988101 BOOM ASSEMBLY, 8406H & 6406H W/LIGHT
3 1 480988020 PIN, PIVOT, 8406H
4 1 366823254 SENSOR, TRI-AXIS
5 2 015500000 NUT HX #8-32UNC CP
6 4 019700000 WASHER SP LK #8
7 1 360676000 PIN, CYLINDER
8 1 360678000 PIN, 3/16 COTTERLESS RING
9 1 239300000 ZERK, GREASE
10 1 366159000 SCREW HX HD 3/8-16UNC X 1 1/2 LG GR8
11 1 021100000 WASHER SP LK 3/8
12 1 320976000 WASHER, FLAT, 3/8 SAE HARDENED
13 1 017701000 NUT HX 1/2-13UNC
14 1 021500000 WASHER, SP LK 1/2
15 1 021600000 WASHER FL 1/2
18 4 001302000 SCREW RD HD #8-32UNC X 7/8 LG
19 1 477854000 TRAVELING BLOCK ASSEMBLY, HC-7
20 1 480841000 ROPE ASSY
21 1 360124000 PIN HITCH
22 1 470076000 PIN, 1 DIA 4-11/16 LG
23 1 360445000 CAP, 8 JIC
24 1 367238000 CAP, 10 JIC
25 1 477823300 DECAL LAYOUT HC-7
26 1 477823023 SHIP KIT, HC-7, NEXSTAR II
27 1 002902000 SCREW SOC HD 1/4UNC X 1/2 GR8
28 1 366823236 LIGHT, LED (RED, GREEN, YELLOW)
29 2 772043000 ZIP TIE STRAP, 12 IN, NYLON, BLACK
35
HC-7 PEDESTAL ASSEMBLY
P/N 477823200
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
36
P/N 477823200
37
ITEM PART
1 1 480988220 BASE PLATE WELDMENT
2 1 480988210 PEDESTAL WELD, LARGE CRANE
3 1 360676000 PIN, CYLINDER
5 1 366822250 CYLINDER, LIFT, 6406H, STROKE - 27.81
6 2 320976000 WASHER, FLAT, 3/8 SAE HARDENED
7 1 021100000 WASHER SP LK 3/8
9 1 366333000 BEARING, SPHERICAL 1.25 ID
10 1 239300000 ZERK, GREASE
11 1 480023002 BEARING ROTATION 5005-8005
12 36 023902000 WASHER FL 5/8 HARDENED
15 4 006205000 SCREW SOC HD 5/8-11UNC X 1 1/4 LG
16 1 160407 GEAR BOX, ROTATION
17 1 366440000 ROTATION MOTOR
18 1 360162000 RING, ECCENTRIC
19 1 360207000 RETAINER ECCENTRIC RING
20 1 480011000 SEAL ROTATION BOX
21 1 020601000 WASHER SP LK 5/16
22 1 007807000 SCREW HX HD 5/16-18UNC X 3/4 LG GR5
23 2 011202000 SCREW HX HD 1/2-20UNF X 2 3/4 LG GR5
24 16 021500000 WASHER, SP LK 1/2
25 2 017704000 NUT HX HVY 1/2-20UNF
38
ITEM PART
26 2 021502000 WASHER SP LK 1/2 HI COLLAR
27 2 012197000 SCREW SOC HD 1/2-13UNC X 1/2 LG
28 2 009118000 SCREW SOC HD 1/2-13UNC X 2 LG
29 12 320588000 WASHER, FL 1/2, HARDENED
30 8 011609000 SCREW 1/2 X 2 1/2NC GR5
31 1 123340 WINCH- RPH 3000 W/RELIEF VALVE
32 2 368121000 SCREW HX HD 5/8UNC X 2-1/2 CP GR8
33 4 011608000 SCREW HX HD 1/2UNC X 2 GR5
34 1 460110100 ROTATION STOP SWITCH ASSEMBLY, 24"
35 1 366676000 COVER, ROTATION STOP
36 1 460079000 BEARING, ROTATION STOP
37 1 366671000 ARM, ROTATION STOP
38 1 366675000 WASHER, NYLON
39 1 366673000 PIN, ROTATION STOP
40 1 480988255 BRACKET, ROT STOP
41 2 017301000 NUT HX NYLK 3/8-16UNC CP
42 1 813013000 KIT, HOSE 5005H-6406H FULLY PROP
43 1 480201000 HOSE ASSY 8 STR X 21.5
44 1 812403022 HOSE ASSY 10 JIC STR
46 2 480205000 HOSE ASSY 6 STR X 19.25
47 1 369611000 ADAPTER, STR -6 ORM/ -4 ORF
48 2 200876000 FITTING 6 SAE/6 JIC STRAIGHT
49 2 490198000 FITTING 10SAE(M)/6JIC ELBOW 90
50 2 372041000 FITTING 8JIC/10SAE STRAIGHT 8-10 F5OX
51 1 490199000 FITTING STR 10-SAE/10-JIC
52 1 367145000 FITTING STR 8-SAE/8-JIC
39
ITEM PART
54 2 812203022 HOSE ASSY, -6 JIC FEM, STR
55 1 374086000 NYLON HOSE SLEEVE, 1.81" ID
56 4 020600000 WASHER 5/16 LOCK SS
57 4 020901000 WASHER FL 5/16
58 4 01770100 NUT HX 1/2-13UNC
59 4 07811000 SCREW HX HD 5/16-18UNC X 1 LG GR5
60 2 366823210 BRACKET, VALVE MTG
61 4 366823211 SPACER, VALVE BANK
62 4 460094000 SCREW, SOC HD, #10-24 X 1"L, ZPL
63 4 020000000 WASHER FL #10 ZP
64 4 015801000 NUT HX NYLK #10-24UNC ZP
65 1 366823212 BRACKET, RECEIVER MTG
66 1 366823252 RECEIVER, PROPORTIONAL W/LCD
67 4 020400000 WASHER FL SAE 1/4
68 2 016300000 NUT HX NYLK 1/4-20UNC
69 2 005604000 SCREW HX HD 1/4-20UNC X 1 LG
70 2 366823240 PIN, 3/16 W/LANYARD
71 1 366823025 COVER, VALVE, REAR MTD FM
72 1 366823250 KIT, ELEC/HYD NEXSTAR II
73 1 366823251 VALVE BANK, 8 GPM W/FILTER SENSOR
74 1 366359000 FITTING, -8 SAE / -8 JIC, SWIVEL, STR
75 1 366508000 CORD GRIP HUBBLE F-3 SHC 1036
76 1 366358000 FITTING, -10 SAE / -10 JIC, SWIVEL, STR
77 1 366823253 TAG, ID HC-7
78 1 366823255 TRANSDUCER, PRESSURE 0-3000 PSI
79 1 366698000 CORD GRIP .375-.500 3/4" HUB
80 1 366823257 HARNESS, 5005H-14005H FULLY PROP
81 4 6210000 CAPSCREW-#8-32 X 7/8 LG SOC HD Z/P
82 4 019700000 WASHER SP LK #8
83 4 725321000 NUT HX NYLK #8-32UNC
40
NOTES
41
HC-7 BOOM ASSEMBLY
P/N: 480988101
CYL SEAL KIT P/N: 480988151

C’BAL P/N: 360153001
42
HC-7 BOOM ASSEMBLY
P/N: 480988101
ITEM PART
1 1 480988115 LOWER BOOM WELD, 8406H W/LIGHT
2 1 480988120 MID BOOM WELD, 8406H
3 1 480988130 UPPER BOOM WELD, 8406H
4 1 460053000 WEAR PAD, BOTTOM UPPER
5 2 460177160 WEAR PAD, 5.13X3X.25, BOSS 1X3
6 11 360767000 PAD BOOM 1.5 O.D.
7 1 480988150 CYLINDER, EXTENSION, STROKE - 48/72
9 1 460177161 PIN, 1.25OD, 7.81 GRIP
10 2 480029000 RING RETAINING
11 1 366333000 BEARING, SPHERICAL 1.25 ID
12 2 366394000 BEARING, PIVOT
13 2 460081000 WEAR PAD, CABLE
14 2 460082000 PLATE, WEAR PAD RETAINER
15 4 460177163 SCREW SOC HD CTRSNK 5/16-24UNF X 5/8 LG
16 1 470110160 BAIL WELDMENT W/ 2 IN TRIP BAR
17 2 007807000 SCREW HX HD 5/16-18UNC X 3/4 LG GR5
18 2 016801000 NUT HX NYLK 5/16-18UNC CP
19 1 366198000 SHEAVE ASSY 3/8
20 1 014400000 SCREW HX HD 3/4-16UNF X 5 LG GR5
21 2 022102000 WASHER FL 3/4
22 1 018600000 NUT HX NYLK 3/4-16UNF CP
23 1 646900000 SWITCH, LIMIT ANTI-TWO BLOCK
24 1 642918000 CORD CONNECTOR
25 1 360759001 CORD REEL ASSY
26 1 366678000 SPRING, EXTENSION
27 1 360882000 NUT, PUSH-ON TYPE (.161-.164DIA)
28 2 460177162 SCREW SOC HD 5/8-11UNC X 3/4 LG
29 1 470076000 PIN, 1 DIA 4-11/16 LG
30 4 460177164 SHIM, 1.31 OD X 0.9 ID X 0.04 TH, NYLON
31 1 360124000 PIN HITCH
32 1 374400000 FITTING, -8 ORB, -8 ORB, STRAIGHT
33 1 460177180 VALVE, IN-LINE RELIEF, 400PSI
35 1 812234017 HOSE ASSY, -8 JICF/-8 JICF, -6 HOSE, 17LG
36 1 366669000 WEAR PAD, BOTTOM MID
43
HC-7 ROTATION GEARBOX
P/N: 160407
44
HC-7 ROTATION GEARBOX
P/N: 160407
ITEM NO. QTY. PART NO. DESCRIPTION

1 1 300058 ADAPTER
2 1 308085 BUSHING
3 1 316092 CAP BEARING
4 1 328126 COVER
5 1 334016 GEAR R.H.
6 1 338261 HOUSING GEAR
7 2 342120 KEY
8 1 357139 SHAFT OUTPUT
9 1 366019 WASHER THRUST
10 1 368183 WORM R.H.
11 1 402044 BEARING BALL
12 1 402105 BEARING NEEDLE
13 1 402106 BEARING NEEDLE
14 1 402107 BEARING THRUST
15 1 413013 COVER
SCREW HX HD 5/16 NC X 1 1/4 GR5
16 14 414146
(NYLON HEAVY PATCH)
17 1 530101 PLUG - EXPANSION
18 2 414581 SCREW HX HD 1/2 NC X 3/4 GR5
19 6 414869 SCREW SOC HD 5/16 NC X 1
20 6 418163 WASHER LK 5/16 MED SECT
21 1 432011 ELL 90 DEG
22 2 442182 GASKET
23 1 442187 GASKET
24 1 456008 FITTING RELIEF
25 1 462029 O-RING
26 1 468002 REDUCER
27 2 468018 PLUG PIPE
28 4 470062 PIN DOWEL
29 1 486071 SEAL OIL
30 2 518026 WASHER THRUST
45
HC-7 HOIST ASSEMBLY
P/N: 123340
SEAL KIT #246048
46
HC-7 HOIST ASSEMBLY
P/N: 123340

1 1 234189 DRUM ASSEMBLY
2 1 306042 PISTON-BRAKE
3 1 315004 ANCHOR- CABLE
4 1 338300 END BRG-MOTOR END
5 1 338301 END BRG-GEAR HSG.
6 1 338302 HSG-BRAKE
7 4 346045 PIN-BRAKE
8 1 357513 SHAFT- INPUT
9 2 357513 SPACER - FOOT MTG
10 4 362284 SPACER - TIE PLATE
11 1 402120 BEARING-GARLOK BRG.#12U16 OR EQUIV.
12 1 402121 BEARING-RPH12,GARLOCK BRG#16DU08/EQ
13 1 412084 BUSHING-DRUM,MOTOR END
14 1 412085 BUSHING-DRUM,GEAR END
15 4 414129 CAPSCREW 5/16-18NCX3 LG HX HD GR-5
16 6 414303 BOLT-3/8-16NC X2 1/2,HXHD,GR-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 1 416016 SETSCREW1/4-20NCX1/4 HX SOCK HD CUP
22 1 416080 SETSCREW-5/8-18NF X1 LG,HXSOCHD,CUP
23 1 418036 NUT-3/8-16 NC,HEX JAM,Z/P
24 1 418088 NUT-JAM 5/8-18NF HEX HD,ZINC PLT
25 2 418218 LOCKWASHER-1/2 ID MED SECT,ZINC PLT
26 1 426048 PLUNGER-CLUTCH,BLOCKED,RPH12/15000
27 1 431015 COUPLING-MOTOR,P/M, RPH-12000
28 2 432018 FITTING #4-C5OX-S T-LOK, 7/16-20 90 degree
29 4 438022 DISC-BRAKE
30 1 442220 GASKET-BRAKE HSG.,RPH12000,#VCN-60
31 1 442223 GASKET-MOTOR FLANGE,RPH12000
32 1 444085 GEAR-RING,P/M,RPH-12000
33 1 456038 FITTING-VENT,BREATHER,#ASP-1BV/EQIV
34 1 458119 MOTOR-HYDRAULIC, W/COUNTERBALANCE
35 1 462046 O-RING 1/8X2 1/4 OD X 2, AS-568-226
36 1 462056 O-RING-AS-568-214
37 1 462057 O-RING-AS-568-256
38 1 462058 O-RING-AS-568-259
47
HC-7 HOIST ASSEMBLY
P/N: 123340

41 1 472052 PLUG-SAE O-RING,.562-18NF,HXSOC
42 2 474065 TIE PLT-7GAX2.25X10.25,W/Y-DM,IPH8Y
43 5 474111 PLATE-SEPARATOR,BRAKE,RPH-12000
44 1 486080 SEAL-GH,MIKRON #RWH-675,MB-2590,RPH
45 1 490037 SNAP RING-TRUARC #5100-93,OR EQUIV.
46 6 494110 SPRING-BRAKE,ASSOC#CV1000-1000-158
47 4 494112 SPRING-RPH12000,PRESSURE TO BRAKE
48 1 509009 TUBE ASSY-1/4OD,HYD.BRK.,RPH-12000
49 1 516069 VALVE-MOTOR CONTROL SUN#YCCW-LIN-GK
50 1 518037 THRUST WASHER-TORRINGTON #TRA-1018
51 1 518047 THRUST WASHER,0.063 THK.X1.50 OD
52 1 518052 THRUST WASHER,1.37 O.D.,RPH-12000
48
HC-7 TRAVELING BLOCK ASSEMBLY
P/N: 477854000
2 4
6
2 5
7
7
9
8
10 1
ITEM PART
1 1 480860000 TACKLE LOWER
2 2 480859000 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 CP
7 2 360605000 PIN, BLOCK
8 2 366813000 PIN HITCH
9 1 480368000 PIN SWIVEL HOOK
10 1 360124000 PIN HITCH
49
HC-7 MAIN HARNESS
P/N: 366823257
50
HC-7 MAIN HARNESS
P/N: 366823257
51
HC-7 HYDRAULIC CONTROL VALVE
NEXSTAR II P/N: 366823251
52
HC-7 HYDRAULIC CONTROL VALVE
P/N: 366823251
53
HC-7
COUNTERBALANCE VALVE ADJUSTMENT
Counterbalance Valve Adjustment Notice:

1. In an EMERGENCY situation when it
1. With PTO disengaged and boom properly becomes necessary to lower the boom without flow
supported, remove the plug on the present, the CB valve adjustment can be turned in until
counterbalance valve. Install a pressure the boom begins to descend. Make sure the boom will
gauge (0-3000 PSI) into the port. lower onto a proper support. Loosen the lock nut and
2. Engage PTO and insure pump flow is 8 to 9 carefully turn adjustment screw clockwise! Count the
GPM. With no load on boom, boom up to an number of turns. Turn slowly until the boom just begins
angle of 70 degrees. Boom down and note to lower, and remove hand/arm/fingers from cranes
pressure. If pressure reading is not while boom is lowering.
approximately 1300 PSI, the counterbalance 2. Turning adjustment screw too far will cause valve to
valve requires adjustment. come apart on the inside. This condition is not repair-
A. To increase the CB valve setting, loosen able
nut and turn Allen head screw counter 3. After boom is lowered, turn adjustment screw counter
clockwise the approximate number of turns made dur-
clockwise.
B. To reduce the CB valve setting, loosen ing lowering procedure. After the problem is corrected,
nut and turn Allen head screw readjust the counterbalance valve using the procedure
clockwise. in this manual.
3. Tighten nut on adjustment screw and repeat

procedure if needed to obtain the proper
pressure setting.
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!
54
HC-7
VALVE OVERRIDE OPERATION
55
HC-7
TROUBLESHOOTING CHART
56
HC-7
57
HC-7
58
HC-7
59
HC-7
60
HC-7 LOAD CHART
P/N 477823000
HC-7
22 6115 NOTE:
21 WEIGHT OF LOAD HANDLING
DEVICES ARE PART OF THE
20 6668 3707 LOAD AND MUST BE
19 DEDUCTED FROM
7000
18 4222 THE CAPACITY
DISTANCE IN FEET FROM BASE OF CRANE
17 4606
7000 2621
16
15 2985
7000 5428
14 3256
13 7000 6333
12 75° 3840 2140
11 7000
60° 4536 2437
10 2659
5180
9 45° 3134
8 3696 1919
7 ATTENTION! 30° 4231
2185
6 OVER 3500 LBS 2384
5 USE DOUBLE LINE 2810
15°37933314
4
3
2
1 3664 2714 2111
0 3197 2303 1853
CL
1 3 5 7 9 11 13 15 17 19
0 2 4 6 8 10'6" 12 14 16'6" 18 20'6"
DISTANCE IN FEET P/N 477823000 A
61
NOTES
Note: This manual should remain with the
crane at all times.
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 Company issues a limited warranty certif-

icate with each unit sold. See last page for warranty.

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HC-7

Serial No. __________________

To: Warranty Department Fax: (918) 834-5979

End User Information: (Required for Warranty Activation)

Distributor Information: (Required for Warranty Activation)

Product Information: (Required for Warranty Activation)

Model No.: Serial No.:

ONE REGISTRATION FORM PER UNIT (CRANE OR BODY)

Mail to: Warranty

Warranty Registration Rev. 07240

WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL POWER LINES!

READ THIS PAGE

Should you require any assistance not given

370º Rotation with electric stop.

OPERATORS tests may be required to determine these

N. No person should be permitted to stand or 3. Caution shall be exercised when working

1. Cranes shall be operated so that no part

HYDRAULIC OUTRIGGERS MANUAL OUTRIGGERS

E-stop Switch—Push to activated, Twist

On/Off/Multispeed— Detachable key,

Crane Controls—Proportional push

Engine Fast-idle - Activates Fast Idle on

Auxiliary - Sends a latched signal that

Engine Stop - Sends a momentary sig-

Engine Start - Sencs a momentary sig-

ACTIVE SIGNALS ENGINE START (ENG ON) OR

LIFT CYLINDER PRESSURE—Current pressure in the lift cylinder in PSI

BATTERY LIFE—Percent of transmitter battery life remaining

AUXILIARY ACTIVE— Shows when the auxiliary function is active.

CURRENT CHANNEL BEING

Figure 3—LCD screen display & transmitter during step 3

SYSTEM GOOD SYSTEM GOOD

BEFORE TAG IS REMOVED AFTER TAG IS REMOVED

Figure 5—LCD screen display during step 4

INSPECTION CLASSIFICATION 6. Inspect for proper rope reeving.

Continued use of rope depends upon good judg-

TESTING SHALL BE PERFORMED BY DESIGNATED PERSONNEL ONLY.

Keep Properly Charged Keep A Relatively Clean Battery

CAUTION: Routine maintenance insures trouble-free operation and protects

PART NO.: 040579000

PART NO.: 040580000

PART NO.: 040632000

USED ON: All Cranes equiped with a load sensor

PART NO.: 040529000

PART NO.: 040517000

PART NO.: 040518000

PART NO: 040587000

PART NO.: 040519000 USED ON: All cranes.

MAKE SURE MACHINERY AND SUROUNDING AREA IS CLEAR BEFORE

TURN OFF THE RECEIVER POWER BEFORE WORKING ON THE MACHINE.

DO NOT MODIFY EQUIPMENT WITHOUT WRITTEN APPROVAL FROM THE

DISCONNECT THE RECEIVER BEFORE WELDING ON THIS MACNINE. Failure

NOTE: C.G. IS APPROXIMATE

QTY. PART NO. DESCRIPTION

“RET” PORT: EXT CYL RETRACT CYLINDER SEAL KIT:

CYL SEAL KIT P/N: 480988151

ITEM NO. QTY. PART NO. DESCRIPTION

SEAL KIT #246048

ITEM NO. QTY. PART NO. DESCRIPTION