Auto Crane NEXSTAR III HC-7X User manual

OWNER’S MANUAL
HC-7X
NEXSTAR III
Mailing Address:
P.O. Box 580697
Tulsa, OK 74158697
Phone: [phone]
Fax: [phone]
http://www.autocrane.com
Physical Address:
4707 N. MIngo Rd.
Tulsa, OK 74117-5904
477823015-0918-B
Serial No.

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.

1 Safety Tips And Precautions ........................................................
2 Introduction ................................................................................
3 GeneralSpecications .................................................................
3.1 Dimensions ...................................................................
3.2 Capacity .......................................................................
3.3 Reach ...........................................................................
3.4 Cable ...........................................................................
3.5 Chassis And Mounting Requirements .................................
3.6 Electrical System Requirements .......................................
3.7 Rotation ........................................................................
3.8 Hydraulic System Requirements .......................................
4 Load Chart ...................................................................................
5 QualicationsAndOperatingPractices........................................
5.1 Operators .....................................................................
  5.2 QualicationsForOperators.............................................
5.3 Conduct For Operators ....................................................
5.4 Operating Practices/Handling Of The Load .........................
5.5 Operating Near Electrical Power Lines ...............................
5.6 Preparing The Crane For Operation ...................................
6 NexStarlllOperation ...................................................................
6.1 General ........................................................................
6.2 Remote Control Unit .......................................................
6.3 Remote Control Initialization ............................................
6.4 Pre-Operation Test .........................................................
6.5 Remote Control Layout ...................................................
6.6 Display Screen Layout ....................................................
6.7 Speed Selection .............................................................
6.8 Mode Selection ..............................................................
6.9 Mode Description ...........................................................
6.10 Operation—Valve Override ...............................................
6.11 Transmitter Layout .........................................................
7 NexStarlllTroubleshooting .........................................................
7.1 Troubleshooting Flow Chart .............................................
7.2 NexStar lll Remote Control Troubleshooting Table ...............
7.3 NexStar lll Error Code Table .............................................
7.4 NexStar lll Electrical Troubleshooting Table .........................
7.5 NexStar lll Hydraulic Troubleshooting Table ........................
8 Maintenance ................................................................................
SECTION PAGE
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HC-7X NEXSTAR III 3
Table of Contents

8.1 Inspection Requirements .................................................
  8.2 InspectionClassication ..................................................
8.3 Frequent Inspection ........................................................
8.4 Periodic Inspection .........................................................
8.5 Cranes Not In Regular Use ..............................................
8.6 Inspection Records .........................................................
8.7 Testing Requirements .....................................................
8.8 General Repairs And Maintenance .....................................
8.9 Maintenance Precautions .................................................
8.10 Adjustments And Repairs ................................................
8.11 Lubrication ....................................................................
8.12 Rope Replacement ..........................................................
8.13 Rope Installation And Maintenance ...................................
8.14 Paint Finish Maintenance .................................................
8.15 Lubrication And Maintenance Schedule ..............................
8.16 Lubrication Points ...........................................................
8.17 NexStar lll Cartridge Maintenance .....................................
9 CraneMountingAndInstallation .................................................
9.1 Stability Chart Installation ...............................................
9.2 NexStar lll Counterbalance Valve Adjustment .....................
9.3 Emergency Crane Operation ............................................
10 Decal Layout ................................................................................
11 General Assembly ........................................................................
12 General Dimensions .....................................................................
13 Pedestal Assembly .......................................................................
14 Hoist Assembly ............................................................................
15 Boom Assembly ...........................................................................
16 TravelingBlockAssembly ............................................................
17 Hydraulic Power Unit ...................................................................
18 WiringHarness ............................................................................
19 Electrical Schematic .....................................................................
Table of Contents
SECTION PAGE
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30
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33
33
34
34
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64
4 HC-7X NEXSTAR III

HC-7X NEXSTAR III 5
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 in compliance.
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.
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! This will void any warranty or liability. Also, failure of the crane may
result.
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. Any
such use is considered to be improper and the seller shall not be responsible
for any claims arising from such use. This sale is made with the express understanding there is no
warrantythegoodsaretforthepurposeofliftingormovingpersonsorotherimproperuse.There
is no implied warranty or responsibility for such uses.
DANGER
WARNING
CAUTION
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
NOTICE
Safety Tips and Precautions 1

6 HC-7X NEXSTAR III
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 the following 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 crane owners, equipment managers, and supervisors also read this manual.
Auto Crane has incorporated several safety features in the crane for your protection.
For your convenience the overall dimensions of the crane are included on the General
Dimension Drawing. Rotation and turning radius are also listed on that drawing.
Remember, the crane adds weight to the vehicle. Adding weight may change the driving and riding
characteristics of the vehicle unless the appropriate overload spring(s) are installed on the truck.
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.
AutoCraneCompanyissuesalimitedwarrantycerticatewitheachunitsold.Seelastpagefor
warranty.
The cranes are attached to your 12-volt truck electrical system. The crane is another highly
efcientAutoCraneproduct.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.
NOTICE
2 Introduction

HC-7X NEXSTAR III 7
Introduction 2
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. The customer service department also has the ability to bring a
local distributor, a regional sales manager, or a factory serviceman into the solution of an
equipment problem.
If, through no fault of Auto Crane Company, it is necessary to send an experienced factory
servicemanonaeldservicecalltheratesstatedintheAutoCraneDistributor’sFlatRateManual
will apply.
AutoCraneCompany’sextensiveResearchandDevelopmentProgramallowourcustomerstouse
the best equipment on the market. Our 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 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
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.
NOTICE

3.1DIMENSIONS
•Width:25.5in.(0.65m)
•Height:36.75in.(0.93m)
•Length: 15ft.3/8in.(4.58m),storedlength
•Weight: 1,870lbs.(848kg)
3.2 CAPACITY
•43,000ft-lbs(6.55ton-m)
•Ft-lbs=horizontaldistancefromcenterlineofrotationtofreehangingweight(feet)x
amount of weight (pounds).
3.3 REACH
•Secondboomreach:12ft.5-3/8in.to21ft.6-7/8in.
•Thirdboomreach:21ft.6-7/8in.to30ft.5-3/4in.
3.4 CABLE
•120ft.(36.6m)of3/8in.(9.5mm)diameteraircraftqualitycable.Thiscablehasasingle
line breaking strength of 14,400 lbs. (6,531 kg).
3.5CHASSISANDMOUNTINGREQUIREMENTS
•14,500lbs.(6,577kg)GVWRminimum.
•360,000in-lbs.ResistiveBendingMoment(RBM)
•7/8”,Grade8-UNFBolts.Tightenedto475ft.lbs.
•13-1/2”Mountingholetorunhydraulicandelectricallinestothecranefromthebody.
3.6 ELECTRICAL SYSTEM REQUIREMENTS
•Voltage:12VDC
•Alternator:60ampsminimum
•Battery:100minutereservecapacityminimum.MaintenanceTypebattery
3.7ROTATION
•450ºRotationwithelectricstop
3.8 HYDRAULIC SYSTEM REQUIREMENTS
•Flow:8GPM
•Pressure:2750PSI
•Pressureandreturnhosesarenotfurnishedwiththiscrane.Theinstallermustprovide 
hoses and determine proper lengths at installation.
RETURN LINE: The Return Line from the crane to the reservoir (in compartment) must
be –10 SAE 100R2 or equivalent. The installer will determine the hose
length.Returnlineslongerthan6ft.mustbe-12insize.Hoseendttings
are -10JIC female swivel.
PRESSURE LINE: The Pressure Line from the pump to the crane must be –10SAE
R100R2 or equivalent. The installer will determine the hose length.
Hoseendttingsare-8JICfemaleswivel.
8 HC-7X NEXSTAR III
3 General Specications

HC-7X NEXSTAR III 9
Load Chart 4
All load ratings are based on crane capacity, not the 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, if the crane is equipped with this type of
device.
Always comply with load chart capacities.
WARNING
WARNING
477823001 A
HC-7X
DEDUCTED FROM THE
NOTE:
2. WEIGHT OF LOAD HANDLING
1. ALL CAPACITIES SHOWN IN (LBS)
LOAD AND MUST BE
DEVICES ARE PART OF THE
CAPACITY
1166
1125
29
30
2245
1591
4560
1955
1827
3230
6255
4612
30°
3851
60°
75°
45°
6260
7000
2294
31
29
30
27
28
25
23
24
26
21
19
20
17
15
16
18
13
11
12
9
7
8
10
14
DISTANCE IN FEET
22
ATTENTION!
OVER 3500 LBS.
1713
2723 2521191715
16 18 20 22 24 26
3581
15°
3427
139 11753
2 4 6 8 10 1412
DISTANCE IN FEET
5
3
4
1
2
0
0
1
USE DOUBLE LINE
6
28
1289

10 HC-7X NEXSTAR III
THIS IS ONLY AN OVERVIEW OF ALL APPLICABLE QUALIFICATION REQUIREMENTS. REFERENCE
ASME B30.5 AND OSHA 1910.180 FOR COMPLETE QUALIFICATION REQUIREMENTS.
5.1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.
5.2QUALIFICATIONS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 differentiation 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suf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suf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 operations.
B. Possess the knowledge of emergency procedures and implement it.
 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.
5 Qualications and Operating Practices

HC-7X NEXSTAR III 11
Qualications and Operating Practices 5
5.3CONDUCTOFOPERATORS
1. The operator shall not engage in any practice, which will divert his attention while actually
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 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:
 A.Movepowercontrolstothe“OFF”orneutralposition.
B. Land the suspended load and boom, if practical.
7. 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.
8. The operator at the start of each shift shall test all controls. If any controls do not operate
properly, they shall be adjusted or repaired before operations are begun.
9. Stabilizers shall be visible to the operator while extending or setting unless a signal person
assists operator.
5.4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
suf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.
CAUTION

12 HC-7X NEXSTAR III
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. This standard recognizes that telescopic boom cranes are designed and intended for
handling materials. They do not meet personnel lift or elevator requirements. Therefore,
no lifting, lowering, swinging or traveling shall be done while a person is on the hook or
load. Hook attached suspended work platforms (baskets) shall not be used with cranes
covered by this standard.
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. Strong enough to prevent crushing.
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.
5.5OPERATINGNEARELECTRICALPOWERLINES
Never operate the crane near electrical lines or in the danger zone area.
DANGER
DANGER ZONE
AREA
AVOID THIS AREA
5 Qualications and Operating Practices

HC-7X NEXSTAR III 13
SafeOperatingDistanceforCranesNearElectricalLines
Whenoperatingnearhighvoltagepowerlines
Normal Voltage, kV - (phase to phase) Minimum Required Clearance
Ft. (m)
0 - 50 10 (3.5)
50 - 200 15 (4.6)
200 - 350 20 (6.1)
350 - 500 25 (7.62)
500 - 750 35 (10.67)
750 - 1000 45 (13.72)
When in transit with no load and boom stowed
0 - 0.75 4 (1.22)
0.75 - 50 6 (1.83)
50 - 345 10 (3.83)
345 - 750 16 (4.87)
750 - 1000 20 (6.1)
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 below Table
Safe Operating Distance.
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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 Table 1 Safe Operating
Distancelimitsaren’tadheredto.
Qualications and Operating Practices 5
TABLE 1

14 HC-7X NEXSTAR III
5.6PREPARINGTHECRANEFOROPERATION
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. Correct 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 neutral (or park for automatic
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 neutral.
C. Press the clutch in.
D. Activate PTO (Power Take Off).
E. Release the clutch.
 F. Allowsufcienttimeforthehydraulicuidtowarmup.
G. 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.
Ensuretheyarermlypositionedonsolidground.
B. Stand clear of outriggers while being extended.
C. 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.
D. 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.
E. If working in soft ground, use wide pads under the outrigger feet to prevent sinking.
F. 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.
4. With the Outriggers properly positioned, return the diverter valve to the
Crane position.
NOTICE
5 Qualications and Operating Practices

HC-7X NEXSTAR III 15
9. Remove the remote control from the cab or storage area. Power the remote control on. Detach
the hook from the dead man.
10. The crane is now ready for operation.
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. 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, press the clutch in, and disengage the PTO. Deactivate any crane
power switches.
6. Check vehicle surroundings before moving.
7. Record any unusual occurrence during crane operation which may indicate required maintenance
or repair.
Qualications and Operating Practices 5

16 HC-7X NEXSTAR III
ThissectiondescribesthegeneraloperationforcraneswiththeNEXSTARlll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.
6.1 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.
6.2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.
6.3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 lll remote control scans for any switches, buttons, and joysticks
are in the OFF position. If any switches, buttons, or joysticks are on, the failure displays on the
Display Screen and the remote control powers down.
After a successful self-test, the Nexstar lll remote control will enter the Normal Operating Mode.
6.4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
6 NexStar lll Operation

HC-7X NEXSTAR III 17
NexStar lll Operation 6
6.5REMOTECONTROLLAYOUT
1. Emergency Stop Button – Push to activate. Pull to release. When activated the emergency stop
button stops all outputs from the receiver.
2. Display Screen – LCD screen that displays many crane operating parameters. See Figure 4.
3. On/Off/Link Switch – Turns the Remote control on and off. Press and release the switch up to
linktheremotecontroltothetruck.“Link”theremotecontroltothetruckeverytimeitisturned
on. Press and hold the switch up to access the speed and mode selection screen.
4. High Idle/Aux Switch – Press the toggle down to activate the high idle on the vehicle. Aux
activates an optional feature.
5. Horn Button – Activates the horn on the vehicle.
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 and 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 boom clockwise. Press the joystick left to rotate the
boom counterclockwise.
8. Start/Stop Switch – Press the switch up to start the engine of the vehicle. Press the switch down
to turn off the engine of the vehicle.
Nextstar lll Remote Control

18 HC-7X NEXSTAR III
6.6DISPLAYSCREENLAYOUT
1. Capacity – The current load on the boom as a percentage of total capacity. The unloaded value
of the boom may be higher than 0% due to the boom weight beyond the retracted position.
2. Aux – AUX will display on the screen when active.
3. Communication Status – LINKED will display when the remote control is communicating with
the crane.
4. Watchdog Timer – The black dot should always be moving in a diagonal. If the timer stops,
contact your Auto Crane representative.
5. Signal Strength and Battery Life – Displays the signal strength coming from the crane. The
approximate range is 300 ft. The battery displays the percent remote control battery life
remaining.
6. Mode – Displays the current mode selected.
7. Max Speed Setting – Displays the current max speed setting.
8. High Idle – HIGH IDLE will display when activated.
9. Boom Angle – Displays the current boom angle in degrees.
10. Crane Status – Displays the current status of the crane. Alarms will be displayed here.
Nextstar lll Display Screen Layout
6 NexStar lll Operation