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.
The boom can fail far below its rated capacity. WARNING 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.
These specifications 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.
• 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 EHC-4 NEXSTAR...
DO NOT USE the overload shutdown device to determine maximum rated loads. WARNING 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. EHC-4 NEXSTAR...
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. WARNING traveling block, hook, clevis, etc.) are part of the load and must be deducted from the crane capacity. EHC-4 NEXSTAR...
C. Demonstrate to the employer the ability to operate the specific 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.
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 EHC-4 NEXSTAR...
Qualifications and Operating Practices 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.
Over 1,000 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) EHC-4 NEXSTAR...
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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.).
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. EHC-4 NEXSTAR...
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. EHC-4 NEXSTAR...
9. Engine Start/Engine Stop Switch - Press the switch up to start the vehicle engine. Press the switch down to turn off the vehicle engine. 10. Battery LED - Solid green if online, slow flash if remote battery is low. EHC-4 NEXSTAR...
7. Battery Level - Will display remaining transmitter battery in increments of 25%. 8. Joystick Mode - Displays current control configuration 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. EHC-4 NEXSTAR...
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.
2-AXIS, TRIGGER EN (2PJ) – Allows two functions to operate on each joystick. The speed is controlled by the joystick. The more the joystick is moved in the direction of the desired function, the faster the function will operate. EHC-4 NEXSTAR...
Turning adjustment screw too far will cause valve to come apart on the inside. This condition is not repairable, and the counterbalance valve must be replaced. WARNING Do not try to adjust any valves while boom is moving. Doing so may result in personal injury! Control Valve Override Procedures EHC-4 NEXSTAR...
If the tether connection is properly established, a cable icon will replace the transmitter icon on the main screen. NOTICE FM radio transmission/reception is disabled when remote is tethered to crane. EHC-4 NEXSTAR...
NOTICE If immediate use of a discharged remote is needed, it is recommended to use the tether connection. This will allow for both use of the transmitter as well as charging the remote battery. EHC-4 NEXSTAR...
The remote goes to sleep after a certain amount of time. If the remote goes to sleep, it can be “woken up” by depressing the trigger, or moving either joystick in any direction. EHC-4 NEXSTAR...
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NexStar Operation Remote Layout DIRECTION FUNCTION GRAPHIC DESCRIPTION Emergency Stop Activates Emergency Stop Activated Emergency Stop Deactivated Emergency Stop Deactivated Momentarily activates an audible signal and red Horn/Link light EHC-4 NEXSTAR...
TROUBLESHOOTING SECTION IS THERE DOES IT DOES IT GO TO ELECTRICAL EXCESSIVE HEAT OCCUR WHEN OCCUR WHEN NO TROUBLESHOOTING BUILD-UP IN UNLOADER COIL FUNCTION IS SECTION HYDRAULIC OIL? UNPLUGGED? SELECTED? CONTACT AN AUTOCRANE REPRESENTATIVE FOR MORE DETAILED TROUBLE-SHOOTING EHC-4 NEXSTAR...
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System not in wireless mode. Ensure that the startup Remote control will not procedure is initiated withing communicate with the base 100 feet from the base station. station in wireless mode Ensure the signal strength indicator is greater than one bar. EHC-4 NEXSTAR...
Check mounting. The arrow should be facing the tip of the crane. BOOM PT ERR Boom pressure All functions are Check connections to pressure transducer transducer error disabled except boom located on lift cylinder. Check wiring harness down and hoist down. for breaks. EHC-4 NEXSTAR...
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CAUSE EFFECT SOLUTION DIRTY FILTER Filter is dirty if oil Operates normally. Replace filter. Auto Crane part number is temperature is at 366823910. least 100 °F ADDRESS TAG Crane does not All outputs are disabled. Check connection at address tag. Check for...
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E007 ESTOP E-stop has been Disables all functions. Pull E-stop to release. Turn transmitter off ACTIVE depressed then back on. Press horn button to relink. EHC-4 NEXSTAR...
Left LED light on base station Turn off crane. Leave off for 2 minutes communication should be solid green. then turn power back on. If problem persists, contact Auto Crane technical support. Controller Status light on controller Turn off crane. Leave off for 2 minutes...
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SENSOR ERR” base. Max speed Check screen for speed Reference section 6.8 of this function is lower setting in bottom right of operations manual to change speed than 100% screen. The value shown is selection. the max speed EHC-4 NEXSTAR...
Replace valve cartridge. valve. If unable to move stem, cartridge is jammed. Counterbalance valve set Adjust the Contact Auto Crane too low (boom up and counterbalance out to for proper adjustment boom down) see if movement stops. and setting of Crane moves counterbalance valve.
A. Distortion such as kinking, crushing, un-stranding, birdcaging, main strand displacement, or core protrusion. Loss of rope diameter in a short length or unevenness of outer strands should be replaced. B. General corrosion. C. Broken or cut strands. EHC-4 NEXSTAR...
F. Relief valve pressure shall be checked as specified by the manufacturer. 12. Inspect hydraulic cylinders for the following problems: A. Driving caused by fluid leaking across piston. B. Rod seals leaking. C. Leaks at welding joints. D. Scored, nicked, or dented cylinder rods. E. Damaged case (barrel). EHC-4 NEXSTAR...
2. Ensure 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. EHC-4 NEXSTAR...
4. If bleeding the hydraulic system is required, run each crane function until smooth operation of that particular function is noticeable. Lubrication All moving parts of the crane, for which lubrication is specified, should be regularly lubricated per the manufacturer’s recommendations and procedures. EHC-4 NEXSTAR...
Replacement rope shall have a strength rating at least as great as the original rope furnished or recommended by Auto Crane. A rope manufacturer, Auto Crane, or a qualified NOTICE person shall specify any deviation from the original size, grade, or construction.
During periods when the truck is exposed to salt or other corrosive chemicals, wash Auto Crane products weekly. Inspect the paint finish monthly or when washed. Immediately repair any exposed bare metal or rust. Repair damaged paint on Auto Crane products with the following procedure: 1.
(All Others) EP-140 gear oil Boom Slide Pads Pads greased when replaced Replace annually, every 200 hours of operation, or as directed by the dirty Filter, Valve Block filter sensor For additional information, see OSHA 1910.180 and ASME B30.5 EHC-4 NEXSTAR...
Maintenance Lubrication Points Use only authorized parts/lubrication. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability. EHC-4 NEXSTAR...
If this happens, reverse the winch to relieve the load and move your anchor point further to the center of the vehicle. After the job is done you can unspool and rewind for a neat lay of the cable. EHC-4 NEXSTAR...
3. Ensure the mounting surface is properly reinforced to withstand the capacity loading of the crane. Ensure the outriggers are used to provide total stability for the truck. 4. If not using an Auto Crane body, cut the proper sized hole in the mounting location (centered with mounting bolts) for access to hydraulic connections.
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366823406 BATTERY PACK, AA ALKALINE (X3), NEXSTAR 366823427 CABLE, TETHER, 10 M, NEXSTAR Please check to make sure the above items have been supplied with your crane. If any items are missing, please notify your dealer, or contact Auto Crane. EHC-4 NEXSTAR...
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366823406 BATTERY PACK, AA ALKALINE (X3), NEXSTAR 366823427 CABLE, TETHER, 10 M, NEXSTAR Please check to make sure the above items have been supplied with your crane. If any items are missing, please notify your dealer, or contact Auto Crane. EHC-4 NEXSTAR...
Failure to correctly plumb and wire crane can cause inadvertent operation and damage to crane and/or personnel. IMPORTANT: Follow all federal laws pertaining to final stage manufacturers and crane stability requirements. Reference the Safety Tips and Precautions section for specifics. EHC-4 NEXSTAR...
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Installation POWER CABLE FROM CRANE CABLE FROM "+" TERMINAL ON BATTERY GROUND ATTACHMENT LOCATIONS* *ATTACH OTHER END OF GROUND CABLE TO VEHICLE FRAME EHC-4 NEXSTAR...
Terminal 2 is used only as a signal and should not be used with any type of load. Auto Crane offers a cradle kit, P/N 366823460, that includes a chime that indicates that the remote has not been returned to its cradle when not in use.
This decal is to alert the user of the available crane capacities around the vehicle. 479824002 decal will be installed on an Auto Crane body that was outfitted with an Auto Crane crane and Auto Crane outriggers. Auto Crane has designed the body, crane and outrigger to have stability based on...
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Installation 479824003 decal will be installed on an Auto Crane body that was not outfitted with an Auto Crane crane and Auto Crane outriggers. The stability chart provides lines to write in the tested stability percentage at each section below:...
Installation Small EH Crane Serial Number Location The serial number is stamped into top of the of the baseplate weldment as well as the decal on left side plate as shown below. SERIAL NUMBER STAMP SERIAL NUMBER DECAL EHC-4 NEXSTAR...
60 F (15.6 C) SAE GRADE - 10 ISO VISCOSITY GRADE - 32 40 F (4.4 C) POUR POINT - (-65 F) 20 F (-6.6 C) 0 F (-17.8 C) -20 F (-28.9 C) -40 F (-40 C) EHC-4 NEXSTAR...
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404212000 DECAL MAX BLOCK LOAD 4004 040619001 DECAL AUTO CRANE LOGO 320992121 DECAL, MANUAL OVERRIDE PROCEDURES, SMALL EH-MODELS 600047016 DECAL, AUTO CRANE EHC-4 NS LOGO, FLATTENED OVAL, 33.25 IN LONG 404242121 LOAD CHART, EHC-4 460169000 DECAL WARNING, REMOTE CONTROL 330622000 DECAL, SERIAL NO.
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Pedestal Assembly - P/N 404242050 USE CAULK TO FILL APPLY THIN LAYER OF HOLE AROUND ALL GREASE TO WORM GEAR CABLES IN QUILL DETAIL A DETAIL B SECTION C-C EHC-4 NEXSTAR...
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Pedestal Assembly - P/N 404242050 (ON VALVE) 812026028 812026028 (ON VALVE) (ON VALVE) (ON VALVE) 812026028 812026028 812026014 812026017 812026016 812026018 812026016 TANK 812206027 812026014 PRESSURE 812206027 EHC-4 NEXSTAR...
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021200000 WASHER FL 3/8 008400000 SCREW HX HD 3/8-16UNC X 3/4 LG GR 5 010201000 SCREW HX HD 1/2-13UNC x 1 1/2 LG 404241253 TAG, ID 4004EH 460094000 SCREW, SOC HD, #10-24 X 1”L, ZPL 015801000 NUT HX NYLK #10-24UNC ZP EHC-4 NEXSTAR...
LIMITED WARRANTY 1 YEAR PURCHASED REPLACEMENT PARTS Auto Crane will warranty to the consumer for a period of (1) year from the date that a new Auto Crane replacement part was purchased from an authorized Auto Crane distributor. Each new Auto Crane part they sell will be free under normal use and service from defects in material and workmanship.
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2 YEAR PARTS AND LABOR Auto Crane will warranty to the consumer for a period of (2) years parts and labor from the date of purchase. Each new Auto Crane unit they sell will be free under normal use and service from defects in material and workmanship.
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