Auto Crane EHC-4 NEXSTAR User manual

990800003-0121-A
http://www.autocrane.com
[email protected]
4707 N. Mingo Rd.
Tulsa, OK 74117-5904
Phone: [phone]
Fax: [phone]
OWNER’S MANUAL
EHC-4 NEXSTAR

At the time of publishing this manual is accurate to the best of our knowledge. Auto Crane reserves the
right to change any or all items, components and parts, necessary for any reason. This right does not
obligate Auto Crane to immediately update the manual. If in doubt, please call your local Auto Crane
distributor for the most up-to-date information. Auto Crane Company issues a limited warranty with each
unit sold. See warranty pages at the end of the manual.
Product Registration
Thank you for purchasing an Auto Crane® product and taking a few moments to register it online at
https://www.autocrane.com/product-registration/. Your registration helps us keep you up to date on
product information and gives 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 Warranty. For more information and a list of eligible products, visit our Warranty page
found at https://www.autocrane.com/warranty/.
Before You Register
What do I need to get started?
We’ll ask for:
• The product model and serial number for each product you purchased
• Your contact information so we can send conrmation of your registration and communicate
product bulletins
• The date you purchased the product, date of installation or in-service (e.g. copy of bill of sale)
• Truck VIN (if applicable)
• The name, address and phone number for the dealer who sold and installed your equipment
NOTE: Much of this information will be on the invoice provided by your dealer. If you need help, please
contact your installing dealer.

3
Table Of Contents
Product Registration ......................................................................................... 2
Table Of Contents.............................................................................................. 3
Safety Tips and Precautions .............................................................................. 5
Introduction ...................................................................................................... 6
General Specications ....................................................................................... 7
Dimensions............................................................................................................................. 7
Rating.................................................................................................................................... 7
Reach .................................................................................................................................... 7
Cable ..................................................................................................................................... 7
Line Speed ............................................................................................................................. 7
Chassis and Mounting Requirements .......................................................................................... 7
Electrical System Requirements ................................................................................................. 7
Rotation ................................................................................................................................. 7
General Dimensions .......................................................................................... 8
Load Chart - P/N 404242121............................................................................. 9
Load Chart - P/N 404243121........................................................................... 10
Qualications and Operating Practices ............................................................ 11
Operators ............................................................................................................................ 11
Qualications For Operators .................................................................................................... 11
Conduct Of Operators............................................................................................................. 11
Operating Practices/Handling The Load ..................................................................................... 12
Operating Near Electrical Power Lines....................................................................................... 13
Preparing The Crane For Operation .......................................................................................... 14
During Operation................................................................................................................... 16
After Operation ..................................................................................................................... 16
NexStar Operation........................................................................................... 17
General ................................................................................................................................ 17
Remote Control Unit............................................................................................................... 17
Remote Control Initialization ................................................................................................... 17
Pre-Operation Test ................................................................................................................ 17
Remote Control Layout........................................................................................................... 18
Display Screen Layout ............................................................................................................ 19
Menu Screen Layout .............................................................................................................. 20
Speed and Control Mode......................................................................................................... 21
Counterbalance Override Procedures ........................................................................................ 22
Control Valve Override Procedures ........................................................................................... 22
Tether Connection.................................................................................................................. 23
Low Remote Battery............................................................................................................... 24
Remote Layout...................................................................................................................... 25
NexStar Troubleshooting................................................................................. 27
NexStar Remote Troubleshooting Table ..................................................................................... 27
NexStar Error Code Table........................................................................................................ 29
Electrical Troubleshooting Table ............................................................................................... 32
Electrical Harness Schematic................................................................................................... 34
Hydraulic Troubleshooting Table............................................................................................... 35
EHC-4 NEXSTAR

4
Table Of Contents
Hydraulic Schematic .............................................................................................................. 36
Maintenance.................................................................................................... 37
Inspection Requirements ........................................................................................................ 37
Inspection Classication ......................................................................................................... 37
Frequent Inspection ............................................................................................................... 37
Periodic Inspection................................................................................................................. 38
Cranes Not In Regular Use ...................................................................................................... 39
Inspection Records ................................................................................................................ 39
Testing Requirements............................................................................................................. 39
General Repairs and Maintenance ............................................................................................ 40
Maintenance Precautions ........................................................................................................ 40
Adjustments and Repairs ........................................................................................................ 40
Lubrication ........................................................................................................................... 40
Rope Replacement ................................................................................................................. 41
Rope Installation and Maintenance........................................................................................... 41
Paint Finish Maintenance ........................................................................................................ 42
Lubrication and Maintenance Schedule ..................................................................................... 43
Lubrication Points .................................................................................................................. 44
NexStar Control Valve Cartridge Maintenance ............................................................................ 45
Hoist Operation ..................................................................................................................... 45
Rotation Bearing Replacement................................................................................................. 46
Installation ..................................................................................................... 47
General Installation ............................................................................................................... 47
General electrical hookup........................................................................................................ 50
Docking Station .................................................................................................................... 52
Stability Chart Installation ...................................................................................................... 53
Small EH Crane Serial Number Location.................................................................................... 55
Recommended Operating Temperature ..................................................................................... 56
Decal Layout - P/N 404243120 ....................................................................... 57
Decal Layout - P/N 404242120 ....................................................................... 59
General Assembly - P/N 404243003 ............................................................... 61
General Assembly - P/N 404242003 ............................................................... 63
Pedestal Assembly - P/N 404242050 .............................................................. 65
Hydraulic Valve Bank - P/N 320991251 .......................................................... 72
Wiring Harness - P/N 320992261 ................................................................... 74
Hoist Assembly - P/N 123331 ......................................................................... 75
Boom Assembly - P/N 404240100................................................................... 78
Boom Assembly - P/N 404189010................................................................... 82
Traveling Block Assembly - P/N 404211050.................................................... 85
Warranty ......................................................................................................... 86
EHC-4 NEXSTAR

5
Safety Tips and Precautions
EHC-4 NEXSTAR
Indicates a hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury.
Indicates information considered important, but not hazard-related.
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 modications performed on the vehicle prior to the nal state are also
considered intermediate stage manufacturing and must be certied 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 compliant.
It is the further responsibility of the installer to comply with the OSHA Truck
Crane Stability Requirements as specied 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, (ref. OSHA 1910.180(h)(3)(xvi)). To reduce the potential for the
load to rotate or rope twist, operate at minimal boom angles and extension.
This crane is designed for vertical lifts only. Do not attempt to lift or drag a load
from the side! The boom can fail far below its rated capacity.
Do not weld, modify, or use unauthorized components on any Auto Crane unit as
failure of the crane may occur. This will void any warranty or liability.
Failure to correctly plumb and wire crane can cause inadvertent operation and
damage to crane and/or personnel!
Auto Crane Company remote controlled cranes are not designed or intended
for use for any applications involving the lifting or moving of personnel when
not using authorized Auto Crane Company personnel attachments. Any such
unauthorized use is considered to be improper and the seller shall not be
responsible for any claims arising from such use. There is no implied warranty or
responsibility for such uses.
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
DANGER
!
CAUTION
!
WARNING
NOTICE
!
WARNING
!
WARNING

6
Introduction
EHC-4 NEXSTAR
Keep this manual with the crane at all times.
Auto Crane products are designed to provide many years of safe, trouble-free, dependable service when
properly used and maintained.
To assist you in obtaining the best service from your crane and to avoid untimely crane and/or vehicle
failure, this manual provides proper operating and service instructions. It is specically recommended
that all operating and service personnel consider this manual as mandatory material for reading and
study before operating or servicing Auto Crane products. It is highly recommended that crane owners,
equipment managers, and supervisors also read this manual.
In addition, the overall dimensions, rotation, and turning radius of the crane are included on the General
Dimension Drawing.
Remember, the crane adds weight to the vehicle which may change the driving and riding characteristics
of the vehicle unless the appropriate overload spring(s) are installed. The payload of the vehicle is reduced
by the weight of the crane. The operator should exercise care when loading the vehicle. Distributing the
payload on the vehicle evenly will greatly improve the driving and riding characteristics of the vehicle.
The cranes are electrically powered by a 12-volt DC electrical system. The use of a maintenance-free
battery is not recommended on any Auto Crane product. The recommended alternator and battery that
will give the longest life with the most useful duty cycle is a 60-amp alternator with a 500 cold cranking
amp battery. These specications should be considered minimum.
It has always been Auto Crane Company policy to handle all warranty claims we receive as promptly as
possible. If a warranty claim involves discrepant material or workmanship, Auto Crane will take immediate
corrective action. It is understandable that Auto Crane Company cannot assume responsibility of liability
when it is obvious that our products have been abused, misused, overloaded or otherwise damaged by
inexperienced persons trying to operate the equipment without reading the manual.
Auto Crane will not assume responsibility or liability for any modications or changes made to unit, or
installation of component parts without authorization.
Auto Crane maintains a strong distributor network and a knowledgeable Customer Service Department.
In most cases, an equipment problem is solved via phone conversation with our customer service
department. This department also has the ability to bring in a local distributor, regional sales manager, or
factory serviceman to help determine the solution to an equipment problem.
Auto Crane Company’s extensive Research and Development Program allow our customers to use the best
equipment on the market. Our engineering sta and knowledgeable salespeople are always available to
our customers in solving crane and service body application problems. When in doubt, call the Auto Crane
factory.
Should you require any assistance not given in this manual, we recommend that you consult your nearest
Auto Crane Distributor. Our distributors sell authorized parts and have service departments that can solve
almost any needed repair. This manual does not cover all maintenance, operating, or repair instructions
pertinent to all possible situations.
If you require additional information, please contact the Auto Crane Company at the following telephone
number: 1-800-777-2760
NOTICE

7
General Specications
EHC-4 NEXSTAR
Dimensions
• Width: 20.63 in. (0.52 m)
• Height: 24.00 in. (0.50 m)
• Length (16’ Boom): 9 ft 8 in. (2.95 m), stored length.
• Length (20’ Boom): 11 ft 9 in. (3.58 m), stored length.
• Weight (16’ Boom): 960 lb (435 kg)
• Weight (20’ Boom): 1040 lb (472 kg)
Rating
• Crane Capacity: 4,000 lb
Double Line: 4,000 lb maximum
Single Line: 2,000 lbs maximum
• 16,000 ft-lb (2.21 ton-m)
• Ft-lb = horizontal distance from center line of rotation to free hanging weight (feet) x
amount of weight (pounds).
Reach
• Second boom reach (16’ Boom): 8 ft. to 12 ft.
• Third boom reach (16’ Boom): 12 ft. to 16. ft.
• Second boom reach (20’ Boom): 10 ft. 4 in. to 16 ft. 4 in.
• Third boom reach (20’ Boom): 16 ft. 4 in. to 20 ft. 4 in.
Cable
• 80 ft. (24.4 m) of 5/16” in. (8 mm) diameter aircraft quality cable. This cable has a
single line breaking strength of 9,800 lb (4,445 kg).
Line Speed
• 30 ft. per minute (single line, no load)
Chassis and Mounting Requirements
• 10,500 lb (4,763 kg) GVWR minimum
• 201,600 in-lb Resistive Bending Moment (RBM)
• 3/4”, Grade 8-UNF Bolts. Tightened to 315 ft-lb
• 9” Mounting hole to run electrical lines to the crane from the body
Electrical System Requirements
• Voltage: 12 VDC
• Alternator: 165 amps minimum
• Battery: 130 minute reserve capacity minimum. Maintenance Type battery
An auxiliary battery may be installed to augment battery capacity.
Rotation
• 370º range

8
General Dimensions
EHC-4 NEXSTAR
14"
19 1/4"
25 9/16"
23 9/16"
11 13/16"
13 5/8"
7' 9"
15' 9"
31 3/4"
12 1/2" 13 1/4"
9' 9"
19' 9"
14"
19 1/4"
25 9/16"
21 7/16"
R15 15/16"
8 1/4"
21 7/16"
8 1/4"
R15 15/16"
13 1/2"
13/16"
16 3/4"
9"
11 1/2"
14 3/4"
1" 1"

9
Load Chart - P/N 404242121
EHC-4 NEXSTAR
All load ratings are based on crane capacity, not vehicle stability. When lifting
a heavy load, the 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 handling devices (i.e.
traveling block, hook, clevis, etc.) are part of the load and must be deducted
from the crane capacity.
!
WARNING
!
WARNING

10
Load Chart - P/N 404243121
EHC-4 NEXSTAR
15°
DISTANCE IN FEET
ATTENTION!
30°
DISTANCE IN FEET FROM BASE OF CRANE
5
0
1
2
4
3
OVER 2000 LBS
USE DOUBLE LINE
0
L
C
1 2 5
4
3 6 7
15
10
6
7
9
8
12
11
14
13
17
16
75°
45°
60°
8 9 10 11
P/N 404243121 A
12 13 14 15 16
THE CAPACITY.
BE DEDUCTED FROM
THE LOAD AND MUST
WEIGHT OF LOAD HANDLING
DEVICES ARE PART OF
NOTE:
17 18 19 20 21
18
19
20
21
10'5" 16'5" 20'5"
1535 970 780
1590
1770
2170
3075
4000
3375
3035
1565
1950 1105
1375
905
1125
1005
810
EHC-4 20'
All load ratings are based on crane capacity, not vehicle stability. When lifting
a heavy load, the 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 handling devices (i.e.
traveling block, hook, clevis, etc.) are part of the load and must be deducted
from the crane capacity.
!
WARNING
!
WARNING

11
Qualications and Operating Practices
EHC-4 NEXSTAR
THIS IS ONLY AN OVERVIEW OF ALL APPLICABLE QUALIFICATION REQUIREMENTS. REFERENCE ASME
B30.5 AND OSHA 1910.180 FOR COMPLETE QUALIFICATION REQUIREMENTS.
Operators
1. Crane operation shall be limited to personnel with the following minimum qualications:
A. Designated persons.
B. Trainees under the direct supervision of a designated person.
C. Maintenance and test personnel (when it is necessary in the performance of their duties).
D. Inspectors (crane).
2. No one other than the personnel specied above shall enter the operating area of a crane with the
exception of persons such as oilers, supervisors, and those specied persons authorized by supervisors
whose duties require them to do so, and then only in the performance of their duties and with the
knowledge of the operator or other persons.
Qualications For Operators
1. Operators shall be required by the employer to pass a practical operating examination.
2. Qualications shall be limited to the specic type of equipment for which examined.
3. Operators and operator trainees shall meet the following physical qualications:
A. Vision of at least 20/30 Snellen in one eye and 20/50 in the other, with or without corrective
lenses.
B. Ability to distinguish colors, regardless of position, if color dierentiation is required for operation.
C. Adequate hearing with or without hearing aid for the specic operation.
4. Evidence of physical defects or emotional instability, which render a hazard to operator or others,
which in the opinion of the examiner could interfere with the operator’s performance, may be sucient
cause for disqualication. In such cases, specialized clinical or medical judgment and tests may be
required.
5. Evidence that operator is subject to seizures or loss of physical control shall be sucient reason for
disqualication. Specialized medical tests may be required to determine these conditions.
6. Operators and operator trainees should have normal depth perception, coordination, and no tendencies
to dizziness or similar undesirable characteristics.
7. In addition to the above listed requirements, the operator shall:
A. Demonstrate the ability to comprehend and interpret all labels, operator’s manuals, safety codes,
and other information pertinent to correct crane operation.
B. Possess the knowledge of emergency procedures and be able to implement them.
C. Demonstrate to the employer the ability to operate the specic type of equipment.
D. Be familiar with the applicable safety regulations.
E. Understand the operating procedures as outlined by the Auto Crane.
F. Be thoroughly familiar with the crane and its control functions.
Conduct Of Operators
1. The operator shall not engage in any practice which will divert his attention while operating the crane.
2. Each operator shall be responsible for those operations under the operator’s direct control. Whenever
there is any doubt as to safety, the operator shall consult with the supervisor before handling the
loads.
3. The operator should not leave a suspended load unattended unless specic precautions have been
instituted and are in place.
4. If there is a warning sign on the switch or engine starting controls, the operator shall not close the

12
Qualications and Operating Practices
EHC-4 NEXSTAR
switch or start the engine until the warning sign has been removed by the appointed person.
5. Before closing the switch or starting the engine, the operator shall see that all controls are in the “OFF”
or neutral position and all personnel are in the clear.
6. If power fails during operation, the operator shall:
7. Move power controls to the “OFF” or neutral position.
8. Land the suspended load and boom, if practical.
9. The operator shall be familiar with the equipment and its proper care. If adjustments or repairs are
necessary, the operator shall report the same promptly to the appointed person and shall also notify
the next operator.
10. At the start of each shift, the operator shall test all controls. If any controls do not operate properly,
they shall be adjusted or repaired before operations are begun.
11. Stabilizers shall be visible to the operator while extending or setting unless a signal person assists
operator.
Operating Practices/Handling The Load
Never use two cranes to support a load too large for either crane.
1. Size of load.
A. No crane shall be loaded beyond the rated load except for test purposes.
B. The load to be lifted is to be within the rated load of the crane and its existing conguration.
C. Know the weight of the rigging and deduct from the load rating to prevent overloading the crane.
D. When loads that are not accurately known are to be lifted, the person 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 properly attached to the hook by means of slings or other devices of sucient
capacity.
B. Ensure the vehicle is in a level position when loading or unloading.
C. Hoist rope shall not be wrapped around the load.
3. The operator shall determine that:
A. The crane is level and, where necessary, the vehicle/carrier is blocked properly.
B. The load is well secured and balanced in the sling or lifting device before it is lifted more than a few
inches.
C. Means are provided to hold the vehicle stationary while operating the crane.
D. Before starting to lift, the hook shall be positioned over the load in such a manner as to minimize
swinging.
4. During lifting care shall be taken that:
A. There is no sudden acceleration or deceleration of the moving load.
B. When rotating the crane, sudden starts and stops shall be avoided. Rotational speed shall be such
that the load does not swing out beyond the radius at which it can be controlled.
C. Load, boom or other parts of the crane do not contact any obstruction.
D. Cranes shall not be used for dragging loads sideways.
E. ASME B30.5 recognizes that mobile and locomotive cranes are designed and intended for handling
materials and not generally personnel. However, personnel are permitted to ride in an Auto Crane
authorized, boom-mounted, personnel platform when used in accordance with the requirements of
ASME B30.23 and Auto Crane’s instructions. The crane shall not be used for other purposes while
!
CAUTION

13
Qualications and Operating Practices
EHC-4 NEXSTAR
handling personnel (Refer to ASME B30.23). Hook attached suspended work platforms (baskets)
shall not be used with Auto Crane cranes.
F. The operator should avoid carrying loads over people.
5. When the crane is so equipped, the stabilizers shall be fully extended and set. Blocking under
stabilizers shall meet the requirements as follows:
A. Sucient strength to prevent crushing, bending, or shear 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
otherwise supplied, timbers, cribbing, or other structural members to distribute the load so as to
not exceed allowable bearing capacity or the underlying material should provide it.
6. In transit, the boom shall be carried in stowed position.
7. The crane shall not be transported with a load on the hook.
Operating Near Electrical Power Lines
Never operate the crane near electrical lines or in the danger zone area.
DANGER ZONE
AREA
AVOID THIS AREA
!
DANGER

14
Qualications and Operating Practices
EHC-4 NEXSTAR
1. Do not place any part of the crane or load inside the Danger Zone.
Exceptions:
A. The Danger Zone may be entered after conrmation by an appointed person the electrical
distribution and transmission lines are de-energized and visibly grounded at the point work.
B. The Danger Zone may be entered if insulating barriers are erected to prevent physical contact with
the lines. These can’t be a part of or attached to the crane.
2. For the minimum safe distance between electrical lines and any part of the crane or load (including
handling appendages), or while in the transit with the boom stowed, see Safe Operating Distance Table
below.
3. Exercise caution when working near overhead lines. They can move horizontally and vertically due to
wind, shifting the location of the Danger Zone.
4. Assign a qualied, signal person to observe 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 veries it is not
energized.
B. Exceptions ensuring equivalent protection are allowed, if approved by the administrative or
regulatory authority in writing.
C. Install durable signs at the operator’s station and on the outside of the crane, warning that
electrocution or serious bodily injury may occur if the Safe Operating Distance Table limits are not
adhered to.
Preparing The Crane For Operation
Safe Operating Distance for Cranes Near Electrical Lines
Normal Voltage,
kv (Phase to
Phase)
Specied Clearance, ft (m)
During Operation
Up to 50 10 (3)
Over 50 to 200 15 (4.6)
Over 200 to 350 20 (6.1)
Over 350 to 500 25 (7.6)
Over 500 to 750 35 (10.7)
Over 750 to 1,000 45 (13.7)
Over 1,000 Determine specic clearance after consultation with
utility owner/operator
During Transit or Travel With No Load and Boom or Mast Lowered
Up to 0.75 4 (1.2)
Over 0.75 to 50 6 (1.8)
Over 50 to 345 10 (3.1)
Over 345 to 750 16 (4.9)

15
Qualications and Operating Practices
EHC-4 NEXSTAR
1. Ensure the manual has been thoroughly read by all crane operating and maintenance personnel, and
supervisors.
2. Perform a routine inspection of the crane before operation each day, correcting any defects
immediately.
3. At the job site, position the vehicle so the crane can reach the load within the rated capacity (center
line of rotation to hoist hook).
4. Keep the vehicle as level as possible during operation.
At a 10% slope, all crane functions are limited to 50% speed. At a 15% slope, all
crane functions are disabled.
5. Allow the vehicle engine to warm up before operation.
6. For Auto Crane units using only electric operation:
A. Engage the emergency brake.
B. Leave the ignition on with the transmission in park (or neutral for manual transmissions).
C. Activate any crane power switches.
7. For Auto Crane units using electric and hydraulic operation:
A. Engage the emergency brake.
B. Place the transmission in park (automatic trans.) or neutral (manual trans.).
C. Activate PTO (Power Take O).
D. Allow sucient time for the hydraulic uid to warm up.
E. Set the throttle control to the proper engine speed.
8. For all outrigger usage:
A. Always extend the outriggers from the vehicle to the ground before crane operation.
B. Ensure they are rmly positioned on solid ground.
C. Stand clear of outriggers while being extended.
D. If a curb or other object prevents the outrigger from begin fully extended, shorten the bearing or
fulcrum point and reduce the maximum load accordingly.
E. If an outrigger will not reach the ground because of holes or grades, block up the outrigger pad to
provide level and rm support to the vehicle.
F. If working in soft ground, use wide pads under the outrigger feet to prevent sinking.
G. Always store the outriggers before transportation.
i. For Auto Crane units with Manual Outriggers:
1. Pull the lock pins to release the jackleg or drop down outrigger. Move to the outermost lock
position.
2. Ensure lock pins are reinstalled properly.
3. Lower the Outrigger pad to rm ground and adjust the foot to remove slack.
ii. For Auto Crane units with Hydraulic Outriggers:
1. Shift the diverter valve to the Outrigger position.
2. Extend the Outriggers to their horizontal limit.
3. Extend the Outriggers vertically until they make solid contact with the ground with the
ground and the truck is approximately level side-to-side.
9. With the Outriggers properly positioned, return the diverter valve to the “Crane” position.
10. Remove the remote control from the cab or storage area. Power the remote control on. Detach the
hook from the hook stow.
11. The crane is now ready for operation.
NOTICE

16
Qualications and Operating Practices
EHC-4 NEXSTAR
During Operation
1. Always boom up before rotating so the boom will clear the boom support.
2. Always maintain clearance between the boom crown and the traveling block or hook hoist during boom
extension.
3. Always observe all relevant safe policies and procedures during crane operation.
4. Always use slow and smooth movements with the crane to avoid causing the load to swing like a
pendulum.
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 stowed position (ensure they are pinned in place or jack legs are returned
to the storage compartment).
4. Always store the crane in its stowed position for transportation.
5. Release the throttle control.
6. Press the clutch in (manual trans.).
7. Disengage the PTO.
8. Deactivate any crane power switches.
9. Check vehicle surroundings before moving.
10. Record any unusual occurrence(s) during crane operation which may indicate required maintenance or
repair.

17
NexStar Operation
EHC-4 NEXSTAR
This section describes the general operation for cranes with the NEXSTAR control system.
Before operating the remote control, read and understand all safety information
in this manual, any manual supplements, and any applicable local, state, or
federal rules and regulations.
Never drive with a load suspended from the crane.
Ensure personnel and objects are clear of the crane path during operation.
Do not move loads over personnel.
General
Radio controlled equipment operates in several directions. Frequently there are other pieces of equipment
and personnel in close proximity. The operator must exercise extreme caution at all times.
Only properly trained operators should operate the radio controlled equipment. This includes knowing and
following all applicable operating and maintenance manuals, safety procedures, regulatory requirements,
and industry standards and codes.
Remote Control Unit
Never mechanically block the switches ON 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 remote control has been turned OFF, taken out of the service area,
and secured. Before disposing of batteries, consult local and governmental regulatory requirements for
instructions on proper disposal.
Remote Control Initialization
After powering on the remote control, the LCD display screen turns on and will perform a self-test. During
the self-test, the Nexstar remote control scans for any switches, buttons, triggers that are in the OFF
position. If any switches, buttons, or triggers are on, the “E002 ACTIVITY” failure displays on the display
screen and the remote control powers down.
After a successful self-test, the Nexstar remote control will enter the Normal Operating Mode.
Pre-Operation Test
Before operating the crane, or when a new operator takes control of the equipment, operators should
perform the following checks of the equipment before making a lift:
- Test all warning devices.
- Test all functions.
- Test the remote control E-Stop function.
!
WARNING
!
WARNING
!
WARNING

18
NexStar Operation
EHC-4 NEXSTAR
Remote Control Layout
1. Emergency Stop - Push to activate, pull to release, then cycle remote power to reset. When
activated, E-Stop stops all outputs from receiver.
2. Link LED - O during normal operation. Solid yellow if oine, slow ash if remote battery is low.
3. On/O Switch - Turns remote on and o. Pull locking lever out prior to lever up (On) or down (O).
4. Display Screen - LED screen that displays many crane operating parameters, codes, and functions.
5. Horn/Start Button - Used to activate horn once remote is linked, used to link remote to receiver.
6. Right Joystick - Press the joystick up to raise the hook. Press 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 down to lower the boom.
Press the joystick right to rotate the crane clockwise. Press the joystick left to rotate the crane
counterclockwise.
8. High Idle/Aux Switch - Press the switch up to activate vehicle high idle. Press the switch up
once more to deactivate vehicle high idle. Press the switch down to activate an optional feature (air
compressor, etc.). Press the switch down once again to deactivate the optional feature.
9. Engine Start/Engine Stop Switch - Press the switch up to start the vehicle engine. Press the switch
down to turn o the vehicle engine.
10. Battery LED - Solid green if online, slow ash if remote battery is low.
1
3
2
5
10
4
6 7
8
9

19
NexStar Operation
EHC-4 NEXSTAR
Display Screen Layout
1. Load Ribbon - Displays current crane load as a percentage of total capacity. Ribbon will be green
between 0% and 90% capacity. The value displayed when the crane is unloaded may be higher than
0% due to the weight of the boom.
2. 90% Load - Between 90% and 100% load ribbon will display yellow indicating crane is nearing full
capacity.
3. 100% Load - Will display red if load meets or exceeds 100% of crane capacity.
4. Info-Box - Will display green with text upon start-up. Once 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 link between the remote and receiver.
5. Speed Setting - Displays current maximum crane operation speed setting.
6. Transmitter Icon - Will have line through if no link is present. Will display cord if remote is tethered.
7. Battery Level - Will display remaining transmitter battery in increments of 25%.
8. Joystick Mode - Displays current control conguration selected.
9. High Idle/Aux - Displays respective icon if High Idle and/or Aux has been activated.
10. Boom Angle - Displays the current boom angle in degrees.
13 2
5
10 4
67
8
9

20
NexStar Operation
EHC-4 NEXSTAR
Menu Screen Layout
To enter the menu screen, rst fully depress and hold the trigger, then press the Engine Start/Stop switch
down to Engine Stop and then release the trigger. The screen above will be displayed. The left joystick
is used to navigate through the menu. To enter into the Diagnostics and Set Up sub menus, highlight
them and depress the trigger. To back out of the menu(s), Engine Start/Stop switch down to Engine Stop
(unless directed otherwise via on-screen instructions).
1. Crane Auto-Stow – Automatically 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 mode selected.
4. Personnel Basket – For use when Auto Crane Personnel Basket is attached to crane. Reference
Personnel Basket Mode section in NexStar Operation.
5. Diagnostics - Displays four options (Active Alarms, Joystick Inputs, Switch Inputs, and Outputs) to
help aid in troubleshooting.
6. Set Up - Displays two usable options: Adjust Brightness of screen and Adjust Sleep Timer for remote
auto shut-o. “Set Home Position” is part of the Crane Auto Stow program. Reference Auto Stow
section in NexStar Operation.
7. Stability Test Mode – For dealer use only.