Stellar 4500 User Manual

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Page 1

Owner’s Manual

Safety, Installation, Maintenance, and Operation

4500 Articulating Crane

Stellar Industries, Inc.

190 State Street

PO Box 169

50438

Garner

Fax: 641-923-2811

www.stellarindustries.com

, IA

800-321-3741

Manual Part No. 37809 Last Revision: 1/1

1/07

Page 2

Introduction

Stellar Articulating Cranes are designed to provide safe and dependable service for a variety of operations. With proper use and maintenance, these cranes will operate at peak performance for many years.

This manual contains information vital to the safe use and efficient operation of this unit. Following the information provided within this manual can ensure the longevity of the crane. Carefully read and study this operator’s manual before using the unit. Failure to adhere to the instructions could result in property damage or even serious bodily injury to the operator or others close to the crane.

A copy of this manual is provided with every crane and shall remain with the crane at all times. Information contained within this manual does not cover all maintenance, operating, or repair instructions pertinent to all possible situations. This manual is not binding. Stellar Industries, Inc. reserves the right to change, at any time, any or all of the items, components, and parts deemed necessary for product improvement or commercial/production purposes. This right is

kept with no requirement or obligation for immediate mandatory updating of this manual.

This product manual is not intended as a training manual for beginners or unskilled operators. This manual offers guidelines for correct and safe usage of the crane, maintenance, and troubleshooting. If more information is required or technical assistance is needed, please contact the Stellar Customer Service Department.

Some sections of this manual contain information pertaining to all Stellar manufactured cranes and may or may not apply to your specific model.

If this manual becomes damaged, misplaced, or unreadable at any point, feel free to download a copy at: http://www

If you feel that any part of this manual is unclear or incorrect, please contact the Stellar Customer Service Department at 800-321-3741 or email at service@stellarindustries.com

Stellar Industries, Inc. reserves the right to update this material without notice or obligation.

.stellarindustries.com

For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at

800-321-3741

Hours: Monday - Friday, 8:00 a.m. - 5:00 p.m. CST

Or email at the following addresses:

Technical Questions, and Information service@stellarindustries.com

Order Parts parts@stellarindustries.com

Warranty Information warranty@stellarindustries.com

Page 3

Table of Contents

Chapter 1 - Safety 1-1

Chapter 2 - Operation 2-1

Chapter 3 - Maintenance 3-1

Chapter 4 - Specifications 4-1

Chapter 5 - Decals 5-1

Chapter 6 - Installation 6-1

Chapter 7 - Assembly Drawings 7-1

Chapter 8 - Hydraulics/Electrical 8-1

Chapter 9 - Replacement Parts 9-1

Chapter 10 - Troubleshooting 10-1

Stellar 4500 Manual

Page 4

Chapter 1 - Safety

Please Read the Following Carefully! This

portion of the manual contains information regarding all Stellar manufactured cranes. Some items contained within this chapter may not apply to your specific equipment.

Safety should be the number one thought on every Stellar crane operator’s mind. Three factors should exist for safe operation: a qualified operator, well-maintained equipment, and the proper use of this equipment. The following information should be read and understood completely by everyone working with or near the crane before beginning.

Stellar Industries, Inc. is not liable for accidents occurred during the usage of the crane caused by non-fulfillment from the operator’s side of current rules, laws, and regulations.

GENERAL

It is the responsibility of the owner to instruct the operator in the safe operation of your equipment and to provide the operator with properly maintained equipment.

Trainees or untrained persons shall be under the direct supervision of qualified persons.

Do not operate equipment under the adverse influence of alcohol, drugs, or medication.

PERSONAL SAFETY

Keep clear of all moving parts.

Always wear the prescribed personal safety devices.

Always wear approved accident-prevention clothing such as: protective helmets, anti-slip shoes with steel toes, protective gloves, antinoise headphones, protective glasses, and reflective jackets with breathing apparatus. Consult your employer regarding current safety regulations and accident-prevention equipment.

Do not wear rings, wristwatch, jewelry, loosefitting or hanging clothing such as ties, torn garments, scarves, unbuttoned jackets or unzipped overalls, which could get caught up in the moving parts of the crane.

Keep a first-aid box and a fire extinguisher readily available on the truck. Regularly check to make sure the fire extinguisher is fully charged and the first-aid kit is stocked.

Do not use controls and hoses as handholds. These parts move and cannot provide stable support.

Never allow anyone to ride the crane hook or load.

MAINTENANCE SAFETY

Never modify or alter any of the equipment, whether mechanical, electrical, or hydraulic, without Stellar Industries’ approval.

Do not perform any maintenance or repair work on the crane unless authorized and trained to do so.

Release system pressure before attempting to make adjustments or repairs.

Do not attempt service or repair when PTO is engaged.

Decals are considered safety equipment. They must be maintained, as would other safety devices. Do not remove any decals. Replace any decals that are missing, damaged, or not legible.

The safety instruction plates, notices, load charts and any other sticker applied to the crane or service body must be kept legible and in good condition. If necessary, replace them.

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STABILITY

Know the crane components and their capabilities and limitations. Overloading the crane may result in serious damage of self, others, equipment or the surroundings.

Never exceed manufacturer’s load ratings. These ratings are based on the machine’s hydraulic, mechanical, and structural design rather than stability.

Do not position any load over a person nor should any person be permitted to place him or herself under a load.

Do not use the boom or the winch to drag a load. No crane is designed for these types of loads.

Do not use the crane boom to push downward onto anything.

The supporting surface under the service truck must be able to support the weight of the machine and its load. Use outrigger pads if necessary.

Park the vehicle on level ground and extend the outriggers fully out and then down.

Keep feet and legs clear when lowering outrigger jacks.

Never operate the crane without making sure the outriggers are positioned on stable, flat ground.

Set the parking brake and disengage the drive axle before attempting a lift.

LOAD SAFETY

Operate the crane in compliance with the load capacity chart at all times. Know the weight of the load being lifted. Do not rely on the overload device to determine maximum rated loads.

Never use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature.

ELECTROCUTION

Allow extra space for swaying power lines in windy conditions.

Keep a minimum of ten feet between any portion of the crane and an electrical line. Add an additional 12" for every additional 30,000 Volts or less.

Remember - Death or serious injury can occur when working near power lines or during electrical storms.

Use a signal person when operating near electrical sources.

ENVIRONMENT

Do not operate the crane during electrical storms.

In extreme cold, allow adequate time to warm the truck before engaging the PTO. Do not rev the truck engine and over speed the hydraulic pumps as permanent damage to the pumps may occur. Follow the vehicle owner’s manual regarding operating the vehicle in such adverse conditions.

Do not apply side loads to the booms.

Do not leave a crane load suspended or unattended.

Do not walk under suspended loads.

Stellar 4500 Manual

In dusty work areas, every effort must be taken to keep dust and sand out of the moving parts of the machinery.

In high humidity work areas, keep parts as dry as possible and well lubricated.

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CRANE CONTROLS

1. Be familiar with the sequence and operation of the crane controls.

2. Each individual crane function should have control function decals. Replace them immediately if they are missing or illegible.

3. Keep hands, feet and control levers free from mud, grease and oil.

4. Be familiar with the remote control and how it operates before attempting to lift a load.

5. Be prepared before beginning operation of the crane:

• All protective guards must be in place.

• Be aware of the surroundings: low branches, power lines, unstable ground.

• Be sure all safety devices provided are in place and in good operating condition.

• Be prepared for all situations. Keep fire extinguisher and first aid kit near.

• Be sure all regular maintenance has been performed.

• Visually inspect all aspects of the crane for physical damage.

• Check for fluid leaks.

• Make sure the outriggers are down and stable.

Be familiar with your remote control and how it works before operating the crane. Your remote may differ from those pictured above.

Stellar 4500 Manual

ATTENTION

Stellar Industries, Inc. is not

liable for accidents incurred by

the crane because of the

operator’s non-fulfillment of

current rules, laws and

regulations

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Page 7

Chapter 2 - Operation

Job-Site Set-Up

Thoroughly plan the lift before positioning the vehicle. Consider the following:

. The vehicle should be positioned in an area free from

overhead obstructions to eliminate the need for repositioning.

2. Position the vehicle so that it is impossible for any portion of the equipment to come within the minimum required safe distance of any power line. Maintain a clearance of at least 10 feet between any part of the crane, load line, or load, and any electrical line or apparatus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. Remember to allow for winds that cause power lines to sway. It is recommended that a signal person be used when the vehicle is set-up near power lines.

3. The vehicle should also be positioned on a firm and level surface that will provide adequate support for the outrigger loading. Use extreme caution when setting up near overhanging banks or excavations.

4. The parking brake must be set on the vehicle and the drive axle disengaged before performing a crane operation.

5. The outriggers must be extended to stabilize the truck before beginning operation.

1. Engage the PTO A. Engage the parking

brake.

B. Place the transmission in

the Neutral position.

C. Make certain the PTO

switch is in the ‘off’ position.

D. Depress the clutch on

manual transmission vehicles. E. Start the vehicle engine. F. Engage the PTO switch for cable and air type shifters.

Turn on dash switch for electrical operated style. Consult vehicle owner’s manual for location and operation of OEM style in-dash PTO switch.

G. Slowly release the clutch on a manual transmission

vehicle.

H. Warm engine and hydraulic system oil. Let system run

for 10-20 minutes for warm-up. This is especially

important in cold weather. I. Proceed with the outrigger and crane operation.

2. Turn on Power to Crane

Activate power to the crane and outriggers. The power switch is located on the control panel in the vehicle cab.

3. Position Outriggers

Once the PTO is engaged, extend the outriggers using the control levers or switches marked ‘outrigger’. These may be located on the crane base or in the compartment under the crane.

PTO Switch

NOTICE

The parking brake must be

fully engaged in order to

operate any Stellar Equipment.

Unit Operation Overview

1. Engage the PTO

2. Turn on Power to Crane

3. Position Outriggers

4. Operate Crane

5. Store Outriggers

6. Turn Off Power to Crane

7. Disengage the PTO

Stellar 4500 Manual

4.Operate Crane

A. Position the main power switch on the control panel

inside the chassis to the on position B. Pull out the E-stop button on Radio D. Activate the toggle on the remote unit.

Manipulate the crane operation transmitter toggle

switches to achieve desired results.

5. Store Outriggers

Retract outriggers using the control levers or switches marked ‘outrigger’.

urn Off Power to Crane

6. T

Deactivate power to crane and outriggers.

7. Disengage the PT

A. On manual transmission vehicles, depress

the clutch pedal completely.

B. Disengage the PT

If vehicle is a manual transmission, release the clutch

pedal gradually.

2-1

O switch.

Transmitter.

Page 8

Crane Radio

ULL

PUSH

ROTATION

EXTENSION

CCW

RETRACT

EXTEND

OUTER

UTER

RETRACT

ETRACT

EXTEND

INNER

PROPORT

IONAL

VALVE

Manual Operation

Remote Operation

The crane is operated by a radio control system which operates an electronic valve bank. The controller (as shown above) operates the following functions:

In case of radio failure, the crane can be operated using manual overrides located on the valve bank.

Valve Manual Override Operation

Main Boom Up and Down Outer Boom Up and Down Extension Boom In and Out Rotation Clockwise and Counter-Clockwise

To operate the crane, activate the desired toggle switch. The crane will not function until the trigger on the remote handle is activated. The crane speed will change as the trigger is pulled or released.

Note: If the crane does not operate, check the batteries located in the remote handle and replace if necessary.

Note About Battery Condition

The batteries included with this equipment may be rechargeable. To keep rechargeable batteries in optimal working condition, follow these simple guidelines:

1. Keep battery away from moisture. Store in a cool, dry location.

2. Do not store or carry battery so that metal objects can contact exposed metal end. Keep battery cap on when not in use. The batteries should be recharged when they fail to

3. produce suf Never attempt to open the battery for any reason.

ficient power

1. Activate Flow Control (Proportional Valve):

Turn override screw on flow control out.

2. Operate Solenoids:

Unlatch then push or pull to operate.

3. Deactivate Flow Control:

Turn override screw on flow control in.

4. Have Unit Serviced.

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Crane Precautions

Crane Transport

. Movement of the control levers should be slow

and smooth to meter oil flow for safe operation. Avoid jerky and sudden movements.

2. The crane controls should be clearly marked with decals. If these are missing or illegible,replace immediately. (See Chapter 5: Decals)

3. Lift load slightly off the ground to check the safety of the cargo. Do not use stability to determine the safety. Consult the capacity charts and strictly adhere to them.

4. Be constantly aware of the boom position when operating the controls.

5. The boom tip should be centered directly over the load before making the lift to avoid swinging.

6. Do not drag loads with the crane.

7. Do not attempt to lift fixed loads.

8. Do not load boom in a sideways direction.

9. Know the weight of the rigging and load to avoid overloading the crane.

10. Do not extend or rotate a load over anyone. Wear protective gear such as hard hat, safety

11. glasses, steel-toed boots, and gloves.

efore transporting the crane, do the following:

1. The crane must be in the stored position.

2. Outriggers must be securely stowed and not extended horizontally or vertically.

3. Hook and sheave assemblies must be securely fastened to prevent swinging.

4. All loose accessories, tools, and remote controls must be securely stored in their respective compartments or fasteners.

5. The PTO must be disengaged.

6. The parking brake must not be released until all of the above procedures are completed.

7. Do not drive the carrier vehicle while a load is present on the hook.

8. Do not drive the carrier vehicle with less than proper tire inflation.

9. Do not drive the carrier vehicle in areas where the vertical clearance is unknown.

10. Do not allow personnel to ride on the

equipment during transport.

Hook Precautions

1. Hooks are designed and manufactured to lift specific loads. The specified rated load of a hook applies to loads held uniformly in direct tension and does not take into account shock loads, hook tip loading, side loading, bending, torsional, or related loads. Do not attempt to lift a load that is larger than the

2. load rating of the hook.

3. Never use a hook’s yield point as an indicator of its capacity

4. Do not use a hook to lift personnel.

5. Know the rated load of the hook in use.

6. Never weld attachments to a finished hook in field applications. This will alter and destroy the design properties of the hook material. Keep fingers, hands, body

7. from between the hook and the load.

8. Avoid shock loading.

9. Inspect the hook regularly for excessive wear and maintain it in safe operating condition.

, and loose clothing

The crane MUST be in the stored position before transporting.

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Page 10

Operator Information

OPERATOR REQUIREMENTS

1. Operation is limited to the following people:

A. Designated individual. B. Trainees under direct supervision of

the designated individual. C. Test or maintenance individual. D. Crane Inspector.

2. Operators must meet the following physical qualifications:

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 if color

differentiation is required.

C. Adequate hearing, with or without a

hearing aid.

D. No physical or emotional defects

that may create a hazard to the operator or others.

E. Normal depth perception and

coordination.

3. In addition to the physical qualifications,

Operators must:

A. Demonstrate the ability to

understand all decals, the owner’s manual, and any other information required for safe operation of the crane.

B. Be able to demonstrate the ability to

safely control the crane. C. Know all safety regulations. D. Be responsible for maintenance

requirements. E. Understand and be fully capable of

implementing all emergency

procedures. F. Understand the operating procedures

as outlined by this manual, Ansi B30.5, and Federal/State Laws.

OPERATOR CONDUCT

1. Operators will not engage in any operation that would cause them to divert attention away from the operation of the crane.

2. Operators are responsible for all operations under their direct control.

3. Operators will not leave a suspended load unattended.

4. Operators will be familiar with the equipment and the maintenance required for proper care.

HANDLING THE LOAD

1. Size of the load:

A. Do not load the crane beyond the

rated capacity.

B. It is the responsibility of the operator

to know the weight of the handled load.

2. Attaching the load:

A. Attach the load to the hook by

means of slings or other approved devices.

B. Do not wrap the hoist rope around

the load.

3. Moving the load:

A. Make certain that the crane is level

and properly blocked.

B. Ensure that the load is secure and

balanced within the sling before moving it.

C. Be sure that the crane is stable

before moving the load. Use stabilizer pads to ensure the proper

distribution of weight. D. Do not drag the load sideways. E. Make sure the hook is brought over

the load to minimize swinging. F. No suspended load should pass over

a person.

G. Avoid sudden starts and stops when

moving a load.

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Page 11

Chapter 3 - Maintenance

WARNING - Read the Following before performing any maintenance on the crane.

1. Only authorized service personnel are to perform maintenance on the crane.

2. Disengage the PTO before any service or repair is performed.

3. Do not disconnect hydraulic hoses while there is still pressure in those components.

4. Before disconnecting hydraulic components, place the boom on the ground or have it supported, shut off the engine, release any air pressure on the hydraulic reservoir, and move pedals and control levers repeatedly through their operating positions to relieve all pressures.

5. Keep the crane and service body clean and free from grease build-up, oil and dirt to prevent slippery conditions.

6. Perform all safety and maintenance checks before each period of use.

7. Replace parts with Stellar Industries, Inc. approved parts only.

8. Immediately repair or have repaired any components found to be inadequate.

Maintenance Procedures

1. Position the crane where it will be out of the way of other operations or vehicles in the area.

2. Be sure boom is lowered to the ground or otherwise secured from dropping.

3. Place all controls in the off position and secure operating features from inadvertent motion.

4. Disconnect power source.

5. Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components.

6. Label or tag parts when disassembling.

Daily Inspection

Daily Inspection should occur each day before the crane is put into use. Each day, inspect the crane for all of the following:

1. Hydraulic oil level.

2. Loose parts or damage to structures or weld.

3. Cylinder movement due to leakage.

4. Hoses and gearboxes for evidence of oil leaks.

5. Controls, including hand throttle for malfunction or adjustment.

6. Truck hand brake operation.

7. All securing hardware such as cotter pins, snap rings, hairpins, and pin keepers for proper installation.

8. All safety covers for proper installation.

9. Cylinder holding valves for proper operation.

Periodic Inspection

Periodic Inspection should occur while the crane is in use. For the duration of the usage, inspect the crane for all of the following:

1. Loose bolts and fasteners.

2. All pins, bearings, shafts, and gears for wear, cracks, or distortion to include all pivots, outriggers, sheave pins, and bearings.

3. Hydraulic systems for proper operating pressure.

4. Main frame mount bolts.

5. Cylinders for:

A. Damaged rods. B. Dented barrels. C. Drift from oil leaking internally. D. Leaks at rod seals or holding valves.

6. PTO drive line system for proper alignment, lubrication, and tightness.

7. Hydraulic hose and tubing for evidence of damage such as blistering, crushing, or abrasion.

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Page 12

Weekly Inspection

Weekly Inspection should occur at the beginning of every work week. Each week, inspect the crane for all of the following:

1. Lubrication of points required by lubrication chart. See chart at the end of this chapter.

2. Proper operation of load hook safety latch.

3. Presence of this owner’s manual.

Monthly Inspection

Monthly Inspection should occur at the beginning of every work month. Each month, inspect the crane for all of the following:

1. Frame bolt tightness - turn barrel nuts and mounting bolts during the first month of operation on new machines and then quarterly thereafter.

2. Cylinders and valves for leaks.

3. Lubrication.

4. Load hook for cracks or having more than 15 percent normal throat opening or 10 degrees twist.

5. Structural members for bends, cracks, or broken members.

6. All welds for breaks and cracks.

7. All pins and keepers for proper installation.

8. All control, safety, and capacity placards for readability and secure attachment.

9. Inspect all electrical wires and connections for worn, cut, or deteriorated insulation and bare wire. Replace or repair wires as required.

10. Tightness of all boom wear, pad-retaining

bolts.

Service

The following general suggestions should be helpful in analyzing and servicing your crane. Using the following systematic approach should be helpful in finding and fixing problems:

1. Determine the problem.

2. List and record possible causes.

3. Devise checks.

4. Conduct checks in a logical order to determine the cause.

5. Consider the remaining service life of components against the cost of parts and labor necessary to replace them.

6. Make the necessary repair.

7. Recheck to ensure that nothing has been overlooked.

8. Functionally test the new part in its system.

Inspection Checklist

For a more detailed outline of scheduled inspection points, refer to the Stellar Inspection Checklist at the end of this chapter. This list is an excellent guide for the inspection tasks that will help maintain the quality of your Stellar product. Feel free to photocopy the checklist as needed.

CLEANLINESS

An important item in

preserving the long life of the

crane is keeping dirt, grime,

and corrosive material out of

the working parts. Thoroughly

wash the crane periodically.

Stellar 4500 Manual

ATTENTION

Every six (6) months, remove

the hydraulic pump from the

PTO and lubricate the splines

using Chelsea Lubricant

#379831 or Stellar PN 20885.

Failure to lubricate shaft

splines will cause damage to

the PTO and Hydraulic pump.

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Page 13

Stellar Lubrication Recommendations :

Component Location Recommendation

Engine Crankcase Apply Manufacturer’s

Recommendations

Hydraulic System Below –5*F

-5*F to 90*F Above 90*F

Open Gears Hand Precision XL3 Moly EP 2 (NLGI 2 grease

Bearings, grease (including turntable bearing inner race)

Worm Drive Gearbox Gearbox Precision Synthetic EP 00 (NLGI 00)

Planetary Gearbox (including winch)

Reservoir

Petro-Canada Arctic MV 15 (ISO 22) Petro-Canada HYDREX 32 (ISO 32) Petro-Canada HYDREX 46 (ISO 46)

with moly)

Gun Precision XL EP 2 (NLGI 2)

Gearbox Traxon Synthetic 75W-90 (API GL-5)

Wear Pad Lubrication Spray Gearshield NC

Compressor Fluids

Reciprocating Single Stage Reciprocating Double Stage

Screw

-15˚F to 86˚F

-23˚F to 100˚F 32˚F to 113˚F

Crankcase Crankcase

Crankcase

Compro 100 (ISO 100) Compro 100 (ISO 100)

Compro XL-S 32 (ISO 32) Compro XL-S 46 (ISO46) Compro XL-S 68 (ISO68)

Greasing the Crane

Lubricate all grease gun points with Extreme Pressure Grease - Stellar P/N:

22059.

Stellar 4500 Manual

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Page 14

Holding Valve Inspection Procedure

The cylinders are equipped with holding valves that prevent sudden movement of the cylinder rods in the event of a hydraulic hose or hydraulic component failure. The valve is checked in the following manner:

1. Identify the cylinder in question.

2. Identify the holding valves and the cylinder direction in question.

a. Cylinder Extend. b. Cylinder Retract.

3. Place the machine so that the cylinder will be located in the appropriate testing position.

4. Pick the load (Do not exceed capacity, rated or stability).

5. Disengage hydraulics.

6. Operate crane functions.

A. If the cylinder creeps (lowering the

load), replace the holding valve.

B. If the cylinder does not creep (load

stays suspended), the valve is operational.

Torque Data Chart

13 2 37 57 82

Grade 8

Plain

(Ft-Lb)

70 105 155 220 375 605 910

1290 1815 2380 3160

Plated

Ft-Lb)

(

3 52 80

115 160 280 455 680 965

1360 1780 2370

Grade 9

Plated

Ft-Lb)

(

22 3 63

96 139 192 340 549 823

1167 1646 2158 2865

Grade 5

17 3 49 75

110 150 265 395 590 795

Plated

(Ft-Lb)

115 200 295 445 595 840 110

1460

Size

(DIA-TPI)

5/16-18

/8-16

7/16-14

1/2-13

9/16-12

5/8-11 3/4-10

7/8-9

1-8 1 1/8-7 1 1/4-7 1 3/8-6 1 1/2-6

Bolt DIA

(Inches)

0.3125 .3750

0.4375

0.5000

0.5625

0.6250

0.7500

0.8750

1.000

1.1250

1.2500

1.3750

1.500

Plain

(Ft-Lb)

1120 1470 1950

When using the torque data in the charts above, the following rules should be observed.

Gear-Bearing Bolt Maintenance

Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical grade and size. Once a bolt has been torqued to 75% of its proof load and then removed, the torque coefficient may no longer be the same as when the bolt was new thus giving indeterminate damp loads after torquing.

Warning!

Failure to replace gear-bearing bolts may result in bolt failure due to metal fatigue causing serious injury or even death.

1. Bolt manufacturer’s particular specifications should be consulted when provided.

2. Flat washers of equal strength must be used.

3. All torque measurements are given in foot-pounds. To convert to inch-pounds, multiply by 12.

4. Torque values specified are for bolts with

residual oils or no special lubricants applied.

If special lubricants of high stress ability,

such as Never-Seez compound graphite and

oil, molybdenum disulphite, colloidal copper

or white lead are applied, multiply the torque

values in the charts by the factor .90. The use of Loctite does not affect the torque values listed above.

5. Torque values for socket-head capscrews are the same as for Grade 8 capscrews.

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Stellar Industries Inspection Checklist for Articulating Boom Cranes

se of this checklist is subject to terms of the Stellar

U Warranty information. Note: Some checklist items may

ot apply to your particular crane model. If questions

n arise, please contact Stellar Customer Service at (800) 321-3741.

Type of Inspection (check one)

Daily (

if deficiency found)

Monthly

Quarterly

Annual

Owner/Company: Contact Person: Crane Make/Model: Crane Serial:

Date Inspected: Hour Meter Reading: Inspected by: (

print)

Signature of Inspector:

Type of Inspection Information

Daily and monthly inspections are to be performed by a “designated” person, who has been selected by the employer or the employer’s representative as being competent to perform specific duties.

Quarterly and annual inspections are to be performed by a “qualified” person who, by possession of a recognized degree in an applicable field or certificate of professional standing, or who, by extensive knowledge, training and experience has successfully demonstrated the ability to solve or resolve problems related to the subject matter and work.

One hour of normal crane operation assumes 20 complete cycles per hour. If operation exceeds 20 cycles per hour, inspection frequency should be increased accordingly.

Consult the Stellar Owner’s Manual for additional inspection items.

Before inspecting and operating the crane, make certain that t he crane is set up away from power lines and leveled with outriggers fully extended.

Daily (D): Before each day of operation, those items with a (D) must be inspected. This inspection need not be recorded unless a deficiency is found.

Monthly (M): Monthly inspections or 100 hours of normal operation (which ever comes first) includes all daily and monthly inspection items plus items designated with a (Q). This inspection must be recorded.

Quarterly (Q): Every three months or 300 hours of normal operation (which ever comes first) includes all daily and monthly inspection items plus items designated with an (M). This inspection must be recorded.

Annual (A): Each year or 1200 hours of normal operation (which ever comes first) includes all items on this form which encompasses daily, monthly, and quarterly inspections plus those items designated by (A). this inspection must be recorded.

Stellar 4500 Manual

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Daily Inspection

requency

Decals

Controls

Station

Hydsystem

Hook

Pins

General

Operation

Remote Ctrls

Electrical

Operation Aid

nspection Description

All load charts, safety & warning decals, & control decals are present and legible.

Check all safety devices for proper operation.

Control mechanisms for proper operation of all functions, leaks, & cracks.

Hydraulic system (hoses, tubes, & fittings) for leakage & proper oil level.

Presence & proper operation of hook safety latches.

Proper engagement of all connecting pins & pin retaining devices.

Overall observation of crane for damage or missing parts, cracked welds & presence of safety covers. During operation, observe crane for abnormal performance, unusual wear. If observed, discontinue use & determine cause & severity of hazard. Operate remote control devices to check for proper operation.

Operate all lights, alarms, etc. to check for proper operation.

Check presence of boom angle indicator.

tatus

Operation Aid

Check overload device for proper operation.

Stellar 4500 Manual

3-6

Page 17

Monthly Inspection

requency

Daily

Cylinders

Valves

General

Electrical

Structure

Welds

Pins

Hardware

Wear Pads

nspection Description

All Daily Inspections.

Visual inspection of cylinders for leakage at rod, fittings, & welds. Damage to rod

case.

& Holding valves for proper operation.

Control valve for leaks at fittings & between sections.

Control valve linkages for wear, smoothness of operation & tightness of fasteners. Relief valve for proper pressure settings. Bent, broken or significantly rusted/corroded parts.

Electrical systems for presence of dirt, moisture & frayed wires.

All structural members for damage.

All welds for breaks & cracks.

All pins for proper installation & condition.

All bolts, fasteners & retaining rings for tightness, wear & corrosion.

Condition of wear pads.

tatus

Pump & Motor

PTO

Hyd Fluid

Hyd Lines

Hook

Rope

Manual

Chassis

Station

Hydraulic pumps & motors for leakage at fittings, seals & between sections. Check tightness of mounting bolts. Transmission/PTO for leakage, abnormal vibration & noise, alignment & mounting bolt torque. Quality of hydraulic fluid and for presence of water.

Hoses & tubes for leakage, abrasion damage, blistering, cracking, deterioration, fitting leakage, & secured properly. Load hook for abnormal throat distance, twist, wear, & cracks.

Condition of load line.

Presence of operator's manuals with the unit.

ire wear and air pressure.

orking backup alarm.

Fire extinguisher at cab or machinery housing.

Stellar 4500 Manual

3-7

Page 18

Quarterly Inspection

requency

aily

Monthly

Rotation Sys

Hardware

Structure

nspection Description

ll daily inspections.

All monthly inspections.

Rotation bearing for proper torque of all mounting bolts.

Base mounting bolts for proper torque.

All structural members for deformation, cracks, & corrosion.

Base

Outrigger beams & legs

Mast

Inner boom

Outer boom

Extension(s)

Jib boom

tatus

Jib extension(s)

Other

Hardware

Pins, bearings, shafts, gears, rollers, & locking devices for wear, cracks, corrosion, & distortion. Inner boom pivot pin(s) & retainer(s)

Outer boom pivot pin(s) & retainer(s)

Inner boom cylinder pin(s) & retainer(s)

Outer boom cylinder pin(s) & retainer(s)

Extension cylinder pin(s) & retainer(s)

Jib boom pin(s) & retainer(s)

Jib cylinder pin(s) & retainer(s)

Jib extension cylinder pin(s) & retainer(s)

Boom tip attachments

Other

Stellar 4500 Manual

3-8

Page 19

Quarterly Inspection Continued...

requency

Hyd Lines

Pumps&

Motors

Valves

nspection Description

Hoses, fittings, & tubing for proper routing, leakage, blistering, deformation, & excessive abrasion. Pressure line(s) from pump to control valve

Return line(s) from control valve to reservoir

Suction line(s) from reservoir to pump

Pressure line(s) from control valve to each function

Load holding valve pipe(s) and hose(s)

Other

Pumps and motors for loose bolts/fasteners, leaks, noise, vibration, loss of performance, heating and excess pressure. Winch motor(s)

Rotation motor(s)

Other

Hydraulic valves for cracks, spool return to neutral, sticking spools, relief valve failure. Main control valve

tatus

Load holding valve(s)

Outrigger or auxiliary control valve(s)

Other

Cylinders

Winch

Hyd Filter

Hydraulic cylinders for drifting & leakage. Rods for nicks, scores, & dents. Castor damage. Case & rod ends for damage & abnormal wear. Outrigger cylinder(s)

Inner boom cylinder(s)

Outer boom cylinder(s)

Extension cylinder(s)

Rotation cylinder(s)

Jib lift cylinder(s)

Jib extension cylinder(s)

Other

Winch, sheaves, & drums for damage, abnormal wear, abrasion, & other irregularities. Hydraulic filters for replacement per maintenance schedule.

Stellar 4500 Manual

3-9

Page 20

Annual Inspection

requency

Daily

Monthly

Quarterly

Hyd System

Controls

Valves

Rotation Sys

Lubrication

Hardware

Wear Pads

Loadline

nspection Description

All daily inspection items.

All monthly inspection items.

All quarterly inspection items.

Hydraulic fluid change per maintenance schedule.

Control valve calibration for correct pressures & relief valve settings.

Safety valve calibration for correct pressures & relief valve settings

Valves for failure to maintain correct settings.

Rotation drive system for proper backlash clearance & abnormal wear, deformation, & cracks. Gear oil change in rotation drive system per maintenance schedule.

Check tightness of all fasteners and bolts.

Wear pads for excessive wear.

Loadline for proper attachment to drum.

tatus

Historic Data

Monthly inspection records.

Maintenance records.

Repair and modification records.

Stellar 4500 Manual

3-10

Page 21

Inspection Notes

Stellar 4500 Manual

3-11

Page 22

Chapter 4 - Specifications

Model 4500 Crane

SPECIFICATION SHEET

Crane Rating: 45,000 ft-lbs (6.22 ton-meters)

Standard Boom Length: 11’ (3.35 m) from CL of Crane

14’ (4.27 m) from CL of Truck

Boom Extension: Hydraulic 32" (81.2 cm)

Maximum Horizontal Reach: 14’ (4.27 m) from CL of Crane

17’ (5.18 m) from CL of Truck

Maximum Vertical Lift: 20’ (6.10 m) from Truck Frame

Stowed Height: 71” (180.3 cm)

Mounting Space Required: 26” (66.04 cm)

Approximate Shipping Weight: 2,400 lbs (1,090 kg)

Controls: Proportional Radio Controls Standard for All Functions

Cylinder Specifications

Inner Lift Cylinder: 5

Outer Lift Cylinder: 5 1⁄2” (14.0 cm) bore with integral pilot operated counterbalance

Extension Cylinder: 3” (7.62 cm) bore with integral pilot operated counterbalance

Rotation: 290 degree power (worm gear)

Lifting Capacities: 7,500 lbs @ 9’ (3,400 kg @ 2.74 m)

Power Supply Required: PTO & Pump

⁄2” (14.0 cm) bore with integral pilot operated counterbalance

valves.

3,200 lbs @ 17’ (1,450 kg @ 5.18 m)

(5.0 gpm @ 2,800 psi) (18.9 lpm @ 193 bars)

Stellar 4500 Manual

4-1

Page 23

9’

2.74m

11’

3.35m

17’

5.18m

14’

4.27m

9’

2.74m

11’

3.35m

17’

5.18m

14’

4.27m

10’

3.05m

23’

7.01m

20’

6.10m

CAPACITY

CHART

7500 lbs

3400 kg

5600 lbs

2540 kg

4100 lbs

1860 kg

3200 lbs

1450 kg

0’

3’

.914m

TRUCK

CRANE

GROUND

0’

20038

190 STATE STREET GARNER, IA 50438

PHONE: (800) 321-3741 FAX: (641) 923-2812

4500

Stellar 4500 Manual

4-2

Page 24

Chapter 5 - Decals

Crane Cover Decals

Crane Base Decals

Crane Outrigger Decals

Stellar 4500 Manual

5-1

Page 25

Crane Cover Decals

Electrocution Hazard Decal

Location: Crane Cover Function: To inform the operator and other personnel in the work area of the

hazard associated with contact or proximity to electrical lines, the possible consequences should the hazard occur and how to avoid the hazard. PN: 4187

Crane Cover Decals

Operation Hazard Decal

Location: Crane Base Function: T

proper training, familiarity with safe operating procedures, and the possible consequences of operation without training. PN: C4544

o inform the operator of the need for

Operation Hazard Decal

Location: Crane Cover Function: To inform the operator of the

need for proper training, familiarity with safe operating procedures and , the possible consequences without training. PN: C4540

Stellar 4500 Manual

5-2

Page 26

Crane Base Decals

Operation Hazard Decal

Location: Crane Cover Function: To inform the operator and other

personnel in the work area of the hazard associated with improper maintenance and unauthorized modifications, the possible consequences should the hazard occur, and how to avoid the hazard. PN: 4190

Operation Hazard Decal

Location: Crane Base Function: To inform the operator of the hazard

associated with overloading the crane, the possible consequences should the hazard occur, and how to avoid the hazard. PN: 4189

Electrocution Hazard Decal

Location: Crane Base Function: T

hazard associated with contact or proximity to electrical lines, the possible consequences should the hazard occur and how to avoid the hazard. PN: C1

o inform the operator and other personnel in the work area of the

179

Stellar 4500 Manual

5-3

Crane Base Decals

Page 27

Outrigger Decals

Foot Crushing Hazard Decal

Location: Outrigger Leg Function: To inform the operator and other

personnel in the work area of the hazard associated with the operation of the outriggers, the possible consequences should the hazard occur, and how to avoid the hazard. PN: C4795

Moving Boom Hazard Decal

Location: Crane Base Function: To inform the operator and other personnel

in the work area of the hazard associated with a moving boom, especially while stowing and unfolding the crane, the possible consequences should the hazard occur, and how to avoid the hazard. PN: C4541

Moving Outrigger Hazard Decal

Location: Outrigger Leg Function: T

associated with outrigger operation, the possible consequences should the hazard occur, and how to

avoid the hazard PN: C5918

o inform the operator of the hazard

Crane Outrigger Decals

Stellar 4500 Manual

5-4

Page 28

Decal Placement

PN 20054

Stellar 4500 Manual

5-5

Page 29

Chapter 6 - Installation

PN 5195

Notice: Read this Page Before Installation of the Crane

General Installation

This chapter is designed to serve as a general guide for the installation of a Stellar 4500 Articulating Crane on a Stellar Service Body. Each installation is considered unique so certain portions of this chapter may or may not apply to your direct application. If a question should arise during the installation process, please contact Stellar Customer Service at (800) 321 3741.

This crane is designed for use with a Stellar Service Body installed on a vehicle that meets the minimum chassis requirements of the crane. Check with Stellar Industries before installing this crane on a body other than a Stellar Service Body.

WARNING!

The use of this crane on a body not capable

of handling the loads imposed on it may

result in serious injury or death.

Notice:

PTO and Pump installation instructions are provided by the proper manufacturers. For more information on which PTO and Pump fit your application, please contact your local Stellar Distributor or Stellar Customer Service.

Installation Notice

According to Federal Law (49 cfr part 571), each finalstage manufacturer shall complete the vehicle in such a manner that it conforms to the standards in effect on the date of manufacture of the incomplete vehicle, the date of final completion, or a date between those two dates. This requirement shall, however, be superseded by any conflicting provisions of a standard that applies by its terms to vehicles manufactured in two or more stages.

Therefore, the installer of Stellar cranes and bodies 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. They are required to certify that the vehicle is in compliance with the Federal Motor Vehicle Safety Standards and other regulations issued under the National Traffic and Motor Vehicle Safety Act.

Please reference the Code of Federal Regulations, title 49

- Transportation, Volume 5 (400-999), for further information, or visit:

http://www

for the full text of the Code of Federal Regulations.

.gpoaccess.gov/nara/index.html

Installation Overview

Installation Guidelines (For more detail, please contact Stellar Customer Service)

1. Locate mounting brackets and clamp to chassis1” (min) from rear of cab (or desired location). Set crane on chassis and check for

2. interferences.

3. Using mounting bracket as a guide, mark holes to be drilled into truck frame.

4. Remove mounting brackets and drill holes.

5. Mount brackets using 3/4” Grade 8 bolts, flast washers, and nyloc nuts.

6. Lower crane onto mounting brackets.

7. Mount crane using 1” Grade 8 bolt, flat washers, and nyloc nuts.

8. Connect pressure and return lines per hydraulic kit.

9. Connect (+12V) Power and ground wires inside crane box.

10. Check reservoir for oil and fill if necessary.

11. Operate crane several cycles.

Installation Kit (PN 5195)

Stellar 4500 Manual

6-1

Page 30

C4759

FOR REFERENCE

2) TRIM EDGE IS NOTED BY IT'S PART NUMEBER

C5470(2)

NOTES:

1) GASKET SHOWN

C4739

.YT

QNOI

TPIRCS

TRAPMETI

054 ES

AB4989

1 212648PC SADDLE, 2200 NON ADJUSTABLE 1

X83

3 KCO

MUB5

RGHH

00.3X3

-0

.0 R

CS P

AC4050

1CNIZ T

ALF S

U 0

5.0

HSAW

530

6COLYN 5RGHH 31-05.0 TUN

6016C

5RGHH 5

7.1X31-05.0

RCS P

7 8C5902 WASHER 0.63 SAE FLAT YELLOW GR8 28

628RGHH 05.3X11-36.0 RCS PAC2131D9

10 D0955 BEARING SWING DRIVE S-SW-65-85-A-R 1

3942-101 NOTAE DYH ROTOMP3541D11

12 3783 CYLINDER 2.00X18.75 PAINTED BLK 1

105.52X00.2 REDNILYC3770D31 2T&D52.6X00.1 NIP8861141 4

SS 52.0X57.1X44.0 PAC NIP023951

48RG TALF 83.0 REHSAW3536C61 48RGHH 00.1X61-83.0 RCS PAC3753171 1

06 SC GEL

GGIRTUO

618

157.3X00.1 NIP7790D91 4LANRETNI 00.1 GNIR PANS578302 1

0006

GGI

TUO7184

152.3X00.1 NIP219422 1

MSA P

AC REGGIRTUO

8429

212 B

DRAUGCP8271D42

6CNIZ TALF SSU 13.0 REHSAW343052

26 0484 CAP SCR 0.31-18 X 0.50 HHGR5 4

10023 NOITATOR POTSCP470472 2COLYN HH 11-36.0 TUN628282 2

RG TALF 05.0 REHSAW097

52.1X31-05.0 RCS PAC7031

3 31 10974 VB 2 SECT W/PB VDM6-4-4-YE-HP 1

25RGHH 05.2X81-13.0 RCS PAC984023 2COLYN HH 81-13.0 TUN243033 14123 GTM HCTIWS ETALPCP280443 2TALF 52.0 REHSAW043

5RGHH 57.0X02-52.0 RCS

PAC974063

31.0 EPIP RELPUOC GTF6522C73 1THGIARTS TPN 8/1 KREZ2951c83

39 D1810 TBE AIR SAEJ844 TYPE A .25 (28") 1 40 D1345 FTG CPRSN 0.12NPT/0.25 TUBE 2

1-65001-8

00 ROTOM T

EKSAG15112

DETA

LP LEKCIN 05.0 GULP1

437

PN 20049

Cylinder Seal Kit Part # 1099

Chapter 7 - Assembly Drawings

Base Assembly - PN 20049

Stellar 4500 Manual

7-1

Page 31

C4739

C5470

C4758

NOTES:

1) RADIO RECEIVER SHOWN FOR REFERENCE

2) TRIM EDGE IS NOTED

BY IT'S PART NUMBER

.YT

OITPIRCSE

METI

10054 TS

M9889

2C5902 WASHER 0.63

SAE FLAT YELLOW GR8 14 3C1026 CAP SCR 0.63-11X2.50 HHGR8 ZY 14 4 0490 CAP SCR 0.31-18X3.50 HHGR5 2

100

54 BV DRA

340

25 6 0343 WASHER 0.31 USS FLAT ZINC 4 7 0420 CAP SCR 0.31-18X0.75 HHGR5 4 824685 VB 4 SECT ELECT W/PROP STERLING8GPM 1 934103 RECEIVER RADIO CONTROL 6 FCTN H2 1

S TALF 52

.0 REHSAW7190D

1 11 0480 CAP SCR 0.25-20X1.00 HHGR5 2

PN 20050

Mast Assembly (w/Hetronic Radio Receiver) - PN 20050

Stellar 4500 Manual

7-2

Page 32

C4739

C4758

C5470

NOTES:

1) RADIO RECEIVER SHOWN FOR REFERENCE

2) TRIM EDGE NOTED BY IT'S PART NUMBER

.YTQNOITPIRCSEDTRAP

ETI

10054 TSAM988911 2 C5902 WASHER 0.63 SAE FLAT YELLOW GR8 14 3 C1026 CAP SCR 0.63-11X2.50 HHGR8 ZY 14 4 0490 CAP SCR 0.31-18X3.50 HHGR5 2 5 0343 WASHER 0.31 USS FLAT ZINC 4 6 0420 CAP SCR 0.31-18X0.75 HHGR5 4 724685 VB 4 SECT ELECT W/PROP STERLING8GPM 1 833004 GUARD VB 4500 OMNEX RADIO 1 9 28836 RECEIVER RADIO CONTROL 6 FCTN OMNEX 1

2SS TALF 52.0 REHSAW7190D01

11 0480 CAP SCR 0.25-20X1.00 HHGR5 2

PN 33003

Mast Assembly (w/Omnex Radio Receiver) - PN 33003

Stellar 4500 Manual

7-3

Page 33

.YTQ

NOITPIRCSED

TRAPMETI

119887 INNER BOOM 4500 CRANE 1

200.61x05.5 REDNILYC740

022

1T&D 83.01X00.2 NIP3400

0152.X00.3X65.0 PAC NIP54154 5D0790 WASHER 0.50 FLAT GR8 10 6 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 10

1T&D 31.21X00.2 NIP240027 1T&D 05.31X00.2 NIP948118 2T&D 00.01X00.2 NIP981419

10 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 10

PN 20051

Cylinder Seal Kit

Part # 33463

Main Boom Assembly - PN 20051

Stellar 4500 Manual

7-4

Page 34

.YTQNOITPIRCSEDTRAPMETI

0054

MOOB RETU

O2889

10054 MOOB TX

E67

891

2 3 4658 CYLINDER EXT 60 SERIES 1

261-5323-ISQ GNIHSUB91884 5 9363 WEAR PAD 1.12X2.00 RND NYLATRON 4 6C6353 WASHER 0.38 FLAT GR8 16 7 9843 CAP SCR 0.38-16X0.75 HHGR8 16 8 6252 WEAR PAD 0.34X2.50 RND NYLATRON 4 9 4541 CAP SCR 1.00-8X5.00 HHGR5 1

10 21154 CAP SCR 1.00-8X2.00 SHGR8 ZY 1

10023 KOOH GNIHSUB584411

1COLYN HH 00.1 TUN199021

1NOT 5 KOOH368331

1T&D 00.7X00.2 NIP0914141

2.X00.3X6

5.0 PAC NIP

541

1 16 D0790 WASHER 0.50 FLAT GR8 2 17 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 2 18 9361PC PLATE WEAR PAD COVER 3200 4

PN 20052

ylinder Seal Kit

art # 1100

Extension Boom Assembly - PN 20052

Stellar 4500 Manual

7-5

Page 35

Chapter 8 - Hydraulics - Electrical

Please Read the Following Carefully! This

portion of the manual contains information regarding the Hydraulic/Electrical system of all Stellar manufactured articulating cranes. Some items contained within this chapter may not apply to your specific equipment.

Release system pressure before attempting to make adjustments or repairs.

Hydraulic fluid expands when heated. This raises the pressure in an unventilated tank. Release the tank pressure before removing the cap completely. Failure to do so may cause the oil to shoot out of the tank very rapidly and cause severe burns.

Warning! If hydraulic fluid escapes, the boom or crane can fall immediately. Make sure the ground or blocking is supporting the boom before performing any maintenance or repair rely on the hydraulic fluid to support the boom or crane.

. Do not

Disassemble and assemble hydraulic components on a clean surface.

Clean all metal parts in a nonflammable cleaning fluid. Then lubricate all components to aid in assembly.

When installing metal hydraulic tubes, tighten all bolts finger tight. Then , in order, tighten the bolts at the rigid end, the adjustable end, and the mounting brackets. After tubes are mounted, install the hoses. Connect both ends of the hose with all bolts finger tight. Position the hose so it does not rub the machine or another hose and has a minimum of bending and twisting. Tighten bolts in both couplings.

Due to manufacturing methods, there is a natural curvature to a hydraulic hose. The hose should be installed so any bend is with this curvature.

Contaminants in a hydraulic system affect operation and will result in serious damage to the system components. Dirty hydraulic systems are a major cause of component failures.

If evidence of foreign particles is found in the hydraulic system, flush the system.

Stellar 4500 Manual

8-1

Page 36

Control Kit (Hetronic Version) - PN 12484

PN 12484

Stellar 4500 Manual

8-2

Page 37

Control Kit (Omnex Version) - PN 32611

PN 32611

Stellar 4500 Manual

8-3

Page 38

PN 20441

Hydraulic Kit - PN 20441

Stellar 4500 Manual

8-4

Page 39

Chapter 9 - Replacement Parts

HYDRAULIC SYSTEM COMPONENTS

PART# DESCRIPTION

397

4960FLOW VALVE (PROPORTIONAL)

25369 SEAL KIT (FLOW VALVE)

5367RELIEF VALVE

25368 SEAL KIT (RELIEF VALVE)

5371SOLENOID VALVE (TANDEM)

25372 SOLENOID VALVE (OPEN) - ROTATION FUNCTION

5373SEAL KIT (TANDEM AND OPEN VALVES)

25370 COIL (FLOW VALVE AND SOLENOID VALVES)

3862 PRESSURE SWITCH (OVERLOAD)

803

D1453 HYDRAULIC SWING MOTOR

1151GASKET (HYDRAULIC SWING MOTOR)

2027O RING (#4 F

2028O RING (#6 FACE SEAL) (HYDRAULIC FITTINGS)

C2029 O RING (#8 FACE SEAL) (HYDRAULIC FITTINGS)

32223 O RING (#10 FACE SEAL) (HYDRAULIC FITTINGS)

D1245 O RING (#4 SAE PORT SIDE) (HYDRAULIC FITTINGS)

D1246 O RING (#6 SAE PORT SIDE) (HYDRAULIC FITTINGS)

D1247 O RING (#8 SAE PORT SIDE) (HYDRAULIC FITTINGS)

D1248 O RING (#10 SAE PORT SIDE) (HYDRAULIC FITTINGS)

1099 SEAL KIT (OUTRIGGER CYLINDER)

33463 SEAL KIT (MAIN AND SECONDARY CYLINDERS)

1100 SEAL KIT (EXTENSION CYLINDER)

IL PRESSURE GAUGE

OUNTER BALANCE VALVE (CYLINDERS)

ACE SEAL) (HYDRAULIC FITTINGS)

ASSEMBLY COMPONENT PARTS

PART# DESCRIPTION

4381 BUSHING 2.00" X 2.00"

8819 BUSHING 2.00" X 1.00"

9320 PIN CAP 0.44" X 1.75" X0.25"

5145 PIN CAP 0.56" X3.00" X 0.25"

10172 CAP

D0790 WASHER 0.50-13 SAE FLAT GRADE 8

C1592 GREASE ZERK 1/8 NPT STRAIGHT

9363 WEAR P

6252 WEAR PAD 0.34" X 2.50" ROUND

3863 HOOK 5-TON

4485 BUSHING-HOOK

10710 SAFETY

27183 WORM GEAR (ROTATION GEAR BEARING)

27184 BEARING AND SEAL KIT (ROTATION GEAR BEARING)

3945 BUMPER DOCK

SCREW 0.50-13 X 1.00" GRADE 8

AD 1.12" X 2.00" ROUND

TCH

ELECTRICAL COMPONENTS

ART#

2600

31661 TOGGLE SWITCH (OMNEX RADIO REMOTE)

16975 E-STOP SWITCH (HETRONIC RADIO REMOTE)

5433

35447 HANDLE / TRIGGER ASM (HETRONIC RADIO REMOTE)

31662 HANDLE / TRIGGER ASM (OMNEX RADIO REMOTE)

5916

8832

31663 BATTERY COVER (OMNEX RADIO REMOTE)

35441 BATTERY TUBE (HETRONIC RADIO REMOTE)

0045

34102 TRANSMITTER (HETRONIC RADIO SYSTEM)

34103 RECEIVER (HETRONIC RADIO SYSTEM

28837 TRANSMITTER (OMNEX RADIO SYSTEM)

28836 RECEIVER (OMNEX RADIO SYSTEM)

C4815 TOGGLE SWITCH (OPTIONAL FLOODLIGHTS AND SPEED CONTROL)

ESCRIPTION

OGGLE SWITCH (HETRONIC RADIO REMOTE)

-STOP SWITCH (OMNEX RADIO REMOTE)

ABLE BACK UP (HETRONIC RADIO REMOTE)

ABLE BACK UP (OMNEX RADIO REMOTE)

LARM (OVERLOAD)

COMPRESSOR COMPONENTS (SHD66 OPTIONAL)

PART# DESCRIPTION

3853 PILOT VALVE 145/175 PSI

C4913 SOLENOID VALVE (SHD66 COMPRESSOR)

C4914 PRESSURE RELIEF VALVE (SHD66 COMPRESSOR)

C0864 AIR PRESSURE SWITCH -HOBBS (SHD66 COMPRESSOR)

7471 LOW PRESSURE INTAKE VALVE ASSEMBLY (SHD66 COMPRESSOR)

7472 HIGH PRESSURE INTAKE VALVE ASSEMBLY (SHD66 COMPRESSOR)

SERVICE KITS / FILTERS / LUBRICATION

PART# DESCRIPTION

4559 AIR FIL

C6227 HYDRAULIC RETURN FIL

8825 SERVICE KIT - 200 HOUR (SHD66 COMPRESSOR)

8823 SER

4460 MOLUBE GREASE-EXTERNAL GEAR TEETH FOR SWING GEAR BEARINGS)

C0087 SYNTHETIC COMPRESSOR OIL

TER (SHD66 COMPRESSOR)

TER (CRANE / COMPRESSOR)

VICE KIT

- 1-YEAR (CRANE / COMPRESSOR)

( 1 QT

)

MISCELLANEOUS COMPONENTS

PART# DESCRIPTION

12341 FLOOD LIGHTS (CRANE AND BODY)

5033 STROBE LIGHT (CRANE AND BODY)

Call 800-321-3741 to Order

Stellar 4500 Manual

9-1

Page 40

Chapter 10 - Troubleshooting

This chapter will list a number of potential problems that may occur while operating the crane. Most problems are easily solved using the solutions portion of this chapter. If problems persist, please contact Customer Service at Stellar Industries 1-800-321-3741.

Problem: Crane will not operate. Solutions:

• Make sure that the parking brake is engaged.

• Make sure that the PTO is engaged.

• Make sure that there is 12V power going to the radio receiver. If there is no power going to the receiver, trace back to the power source and check for a blown fuse or loose ground connection. Refer to radio remote troubleshooting guide at the end of this chapter.

• Make sure that the transmitter batteries are fully charged. (Rechargeable batteries are good for 11 months or 200 charges)

• Make sure that the hydraulic pump is operating at its rated flow or GPMs. Check the flow by using the flow meter to determine the GPMs. It is possible that the hydraulic pump is getting weak. If this is suspected, contact Stellar Customer Service.

Problem: Not all crane functions operate using the radio remote transmitter or crane operates intermittently. Solutions:

• Make sure that the toggle switch is working properly. If the switch is defective, simply replace it.

• Make sure that there is power going from the valve bank coil solenoid or to the function that will not operate. If no power is going to the coil solenoid, check wiring connections on wire harness plug connector for broken wires, loose connection or poor crimp. If power is going to the solenoid valve, it may not be opening to allow hydraulic oil to the function that is not operating. Check the coil for polarity, if coil does not magnetize, replace the coil. If the coil is functioning, remove stem valve, thoroughly clean, lubricate, and reinstall valve. Do not over tighten. If the valve will not close, simply replace it.

Problem: Crane will operate manually but will not operate electrically. Solutions:

• Make sure that there is 12V power going to the radio receiver. If there is no power going to the receiver source and check for a blown fuse or loose ground connection. Refer to radio remote troubleshooting guide at the end of this chapter.

• Make sure that the parking brake is engaged.

• Make sure that the parking brake switch is working properly. Check the parking brake switch by performing a continuity test. If the switch is defective, simply replace it.

, trace back to the power

Stellar 4500 Manual

Problem: Crane only operates at full speed. Solutions:

• Check to see if there is 12V power constantly going to the proportional valve. If 12 volts are showing up at the proportional valve without pulling on the transmitter trigger handle/trigger assembly may be defective. If 8 volts are showing at the proportional valve, it is possible that the valve is stuck open and will not close. Remove the valve, clean it thoroughly and reinstall. Do not over tighten. If the problem persists, replace the proportional valve.

• Check to see if the manual override on the proportional valve is turned out. Turn the manual override on the flow valve in.

Continued...

10-1

, the

Page 41

Problem: Two functions operate at the same time while only toggling one function. Solutions:

• Make sure that the solenoid valves manual override sleeves are all in the center position and do not move when operating a function. If manual overrides have movement when operating the crane with the remote, replace the valves.

• Determine the function that is operating on its own. Check to see if there is power going to the solenoid valve from a function that should not be operating. If voltage is present at the solenoid valve without operating the function, the toggle switch has failed and is stuck in the “on” function. If no voltage is present, the solenoid valve may be partially open. Remove the stem valve, thoroughly clean, lubricate, and reinstall the valve. Do not over tighten. If valve will not close, simply replace it.

Problem: Crane operates slowly. Solutions:

• Make sure that the crane is receiving the recommended GPMs to operate.

• Check the level of hydraulic fluid in the reservoir. Add fluid as needed.

• Check to see if the valve bank orifice is plugged. If so, replace the orifice. Call Stellar Customer Service for instructions.

• Make sure the proportional valve is receiving 12V power when fully engaging the transmitter trigger. If there is not 12V power while pulling the trigger, check for loose connections inside the transmitter or replace the handle trigger assembly. If the proportional valve is receiving 12 volts, loosen the solenoid holding nut and check to see if the solenoid coil is magnetizing. If no polarity is present, replace the coil. If coil is magnetizing, remove the stem valve, thoroughly clean, lubricate, and reinstall the valve.

Problem: Cylinder drifts outward or downward. Solutions:

• Check to see if there is air in the hydraulic system. Operate all cylinders connected to the hydraulic system. Start with the extension cylinder, then operate the main boom, winch, rotation, and ending with the hydraulic outriggers, if installed. When operating, extend each cylinder halfway out, retract all the way in, and then extend until the cylinder rod is at the end of its stroke. Operate cylinders slowly so air is pushed thru the system to the reservoir. Repeat this cycle 2-3 times.

• Make sure the holding valves are operating properly. Remove, clean, and then inspect each holding valve. When removing a holding valve, always relieve the pressure inside the cylinder by loosening jam nut of the holding valve and turning set screw inward/clockwise. Count the number of turns until the set screw is seated. When reinstalling the holding valve, make sure the valve is reset by turning the set screw the number of turns it took to relieve the pressure. Finish by tightening the jam nut.

• Check the cylinder rod for scratches. If a scratch is located on the cylinder rod, hydraulic fluid can pass thru and cause a loss of pressure. Replace cylinder rod or cylinder.

• Check to see if the piston seals are damaged. If they show signs of damage, install a new cylinder seal kit.

If problems persist,

please contact Stellar

Customer Service at:

1-800-321-3741

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6 Function Hetronic Radio Remote Troubleshooting

If the system does not operate after normal start-up, follow the recommended troubleshooting

sequence to help isolate the cause and determine corrective action.

Transmitter

• Is the E-Stop pushbutton pulled out?

• Are all the switches in their center (neutral) position.

• Are the batteries in the transmitter fully charged?

• Is the transmitter inside its operating range?

PROBLEM

System will not operate after normal start-up procedure.

PROBABLE CAUSE

E-Stop switch engaged

Batteries fully discharged

No power to the receiver

Receiver

• Is the antenna plug securely connected?

• If there is an external antenna, is the antenna connection assembly outside the enclosure secure?

• Are the power supply and ground wires securely fastened?

• Are the signal wires separated from the power supply wires?

CORRECTION

Pull out E-Stop switch.

Check batteries to ensure a full charge. Replace with new batteries if necessary.

Check the diagnostic LED on the receiver to be sure power is applied. Ensure that the system is properly grounded.

Transmitter is transmitting (Power LED flashing), but crane will not respond

All crane motions operate intermittently

Some crane motions operate intermittently

E-Stop switch engaged

Transmitter out of range

Receiver power off

E-Stop failure in transmitter

Receiver antenna is loose or missing

External antenna (if used) has loose connection, poor grounding or interference

Ground wiring is poor. Conductor is too small, or receiver is grounded to chassis.

Crane motion wiring may be loose.

Pull out the E-Stop push button and activated switch on transmitter.

Take the transmitter back into the range of the receiver.

Turn on power to receiver.

Check E-Stop pushbutton for damage. Check wiring to contact element for broken or disconnected wires. Repair or replace E-Stop push button or wiring.

Tighten or replace antenna.

Tighten antenna and ground connection.

Ground wiring must be connected to machine power source ground. Minimum diameter of conductor ground is 12 AWG.

Check wiring from receiver to plug and from plug to crane motion actuator.

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Transmitter Troubleshooting

otice: When testing the transmitter, the receiver may become active resulting in system operation. Always assume

N the system is working and will respond when testing a transmitter.

Status LED Troubleshooting

LED Indication

LED is off LED flashes LED will not light when any button is pushed, or LED remains on continuously

Transmitter is off Transmitter is operating in a normal mode Replace batteries. If this does not correct the problem, the transmitter must be returned for repair.

Possible Cause

Transmitter Repairs

Notice: The transmitter electronic components are exposed when the back of the case is removed. Take caution to prevent dirt or other contaminants from entering the case. Do not allow the circuit to be scraped or damaged in any way.

Receiver Troubleshooting

The following steps should be followed when troubleshooting the receiver.

1. Check the LED indicator. If it is not lit: a. Make sure 12 VDC and ground is present at the connecting wires. b. If using the AC power, check for AC power on the connecting wires. c. If input power is present and the LED is off, check the fuse inside the receiver case. d. If input power is present and the LED is off, and the fuse inside the receiver case is OK, contact Customer Service at

Stellar Industries.

2. Activate the transmitter by pressing any command switch. a. If the receiver LED does not flash, test the transmitter. b. Verify the identity code is the same for the transmitter and receiver. use the learn button to re-program the receiver for

the transmitter.

c. Contact Customer Service at Stellar Industries.

3. Only some functions are operating: a. Check to make sure the common wires for the relays are connected properly. (See Installation drawings for details. b. Check output voltage of the respective wires and the electrical circuits. c. Check the fuses inside the receiver case.

Check the receiver label to verify the function has been programmed to the needs of the equipment.

4. You are experiencing intermittent operation: a. Check antenna connections and antenna location. b. On AC systems, ensure noise suppression devices have been placed across the coils of all contacts. c. Ensure you are inside the operating range of the receiver and have line of sight to the receiver antenna.

5. Operating Range is short: a. Check all antenna connections and transmitter operation. b. On new installations, verify the receiver antenna is placed properly. If necessary, use an antenna mounting kit to

relocate the antenna to a more favorable location.

LED on continuous

LED flashes

LED goes off

LED Indication

Receiver Testing

Receiver operating voltage is present, no signal is being received. Signal is being received that matches the decoders address. Signal is being received, but address is wrong.

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Receiver

Action

Page 44

4 & 7 Function Hetronic Radio Remote Troubleshooting

roblem:

P Transmitter will not communicate with the Receiver.

(Note: Make sure the PTO is fully engaged when troubleshooting the problem.)

1. Is the main power switch on? (Control panel located inside the cab.)

2. Is the emergency brake engaged? . Is the transmitter battery fully charged? (Note: When the battery is fully charged, there should be a quick beep

sound from the transmitter when toggling a function. A longer or constant steady beep indicates that the battery charge is weak or going dead.)

4. Is the E-Stop switch button pulled out or engaged?

Check the receiver functions.

(Note: Remove the receiver cover located on the crane mast) With the main power on, check the following functions:

1. Is the yellow light flashing in the upper left hand corner of the receiver?

a. Yes –

i. Check the signal functions using the transmitter toggle functions - go to step 2.

b. No –

i. Check the 7.5 fuse located inside the receiver. Replace the fuse if it has blown. ii. If the 7.5 fuse is ok, check the crane power fuse. (Usually located under the chassis hood near the

300 amp continuous duty solenoid.)

2. Does the green light in the upper left hand corner of the receiver flash when operating a toggle switch on

the transmitter?

a. Yes –

i. Go to step 3.

b. No –

i. Carefully remove the switch face plate housing from the transmitter and check the following areas:

1. Check to see if a jumper spade, from the CS458 TX-RF module, is loose or laying inside the transmitter, either laying on, or beneath the coder board.

2. Check for broken wires on the CS458 TX-RF Module. (Blue, Red, and White with blue stripes - Three wires total.

3. Check to make sure that the E-Stop 2 Wire connector plug (Located in the upper right hand corner of the coder board) isn’t loose or disconnected. (Usually a grey and white with brown stripe wire.)

4. Check for loose, corroded, or broken wires on the toggle switches. Note: If the green light inside the receiver flashed constantly without engaging a toggle switch, the coder board has failed or a toggle switch may be weak or broken.

Are the red LED function lights coming on when activating a toggle on the transmitter?

es –

a. Y

i. Go to Step 4.

b. No –

The E-Stop switch or coder board has failed.

4. All lights are working properly?

a. Note: Radio system is functioning correctly - check the following areas:

i. Check for loose ground wires. ii. Check for loose or broken wires on the crane valve bank wiring harness. iii. Check to make sure the flow control valve on the valve bank is actuating properly, using the

trigger assembly of the transmitter

Check the anti-2-blocking electrical circuit (Limit switch, cord reel, and pressure switch - if

applicable) for proper operation.

b. If problem cannot be determined, contact customer service at Stellar Industries.

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Limited Warranty Statement

Stellar Industries, Inc. (Stellar) warrants products designed and manufactured by Stellar to be free from defects in material and workmanship under proper use and maintenance. Products must be installed and operated in accordance with Stellar’s written instructions and capacities. The warranty period shall cover the following:

Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date of manufacture, Twelve (12) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) month from date of manufacture, and Thirty-six (36) month warranty on all Stellar Crane and Hooklift structural parts from the date recorded by Stellar as the in-service date, not to extend beyond forty-eight (48) months from date of manufacture.

The in-service date will be derived from the completed warranty registration card. In the event a warranty registration card is not received by Stellar, the factory ship date will be used.

Stellar’s obligation under this warranty is limited to, and the sole remedy for any such defect shall be, the repair and/or replacement (at Stellar’s option) of the unaltered part and/or component in question. Stellar after-sales service personnel must be notified by telephone, fax, or letter of any warranty-applicable damage within fourteen (14) days of its occurrence. If at all possible, Stellar will ship the replacement part within 24hours of notification by the most economical, yet expedient, means possible. Expedited freight delivery will be at the expense of the owner

Warranty claims must be submitted and shall be processed in accordance with Stellar’s established warranty claim procedure. Stellar after-sales service personnel must be contacted prior to any warranty claim. A return materials authorization (RMA) account number must be issued to the claiming party prior to the return of any warranty parts. Parts returned without prior authorization will not be recognized for warranty consideration. All damaged parts must be returned to Stellar freight prepaid; freight collect returns will be refused. Freight reimbursement of returned parts will be considered as part of the warranty claim.

Warranty service will be performed by any Stellar new equipment distributor, or by any Stellar-recognized service center authorized to service the type of product involved, or by the Stellar factory in the event of a direct sale. At the time of requesting warranty service, the owner must present evidence of date of delivery of the product. The owner shall be obligated to pay for any overtime labor requested of the servicing company by the owner, any field service call charges, and any towing and/or transportation charges associated with moving the equipment to the designated repair/service provider.

All obligations of Stellar and its authorized dealers and service providers shall be voided if someone other than an authorized Stellar dealer provides other than routine maintenance service without prior written approval from Stellar. In the case repair work is performed on a Stellarmanufactured product, original Stellar parts must be used to keep the warranty in force. The warranty may also be voided if the product is modified or altered in any way not approved, in writing, by Stellar.

The owner/operator is responsible for furnishing proof of the date of original purchase of the Stellar product in question. Warranty registration is the ultimate responsibility of the owner and may be accomplished by the completion and return of the Stellar product registration card provided with the product. If the owner is not sure of registration, he is encouraged to contact Stellar at the address below to confirm registration of the product in question. This warranty covers only defective material and workmanship. It does not cover depreciation or damage caused by normal wear and tear and maintenance duties as stated in Stellar’s written instructions, recommendations, and specifications. Any damage resulting from owner/operator failure to perform such duties shall void the coverage of this warranty. The owner will pay the cost of labor and supplies associated with routine maintenance.

The only remedies the owner has in connection with the breach or performance of any warranty on the Stellar product specified are those set above. In no event will Stellar, the Stellar distributor/dealer, or any company affiliated with Stellar be liable for business interruptions, costs of

, or for any special, indirect, incidental, or consequential costs or damages. Such costs may include, but are not limited to, loss of time, loss

delay of revenue, loss of use, wages, salaries, commissions, lodging, meals, towing, hydraulic fluid, or any other incidental cost.

All products purchased by Stellar from outside vendors shall be covered by the warranty offered by that respective manufacturer only. Stellar does not participate in, or obligate itself to, any such warranty.

Stellar reserves the right to make changes in design or improvement upon its products without imposing upon itself the same upon its products theretofore manufactured.

This warranty will apply to all Stellar Hooklifts, Stellar Service Trucks, & Truck-mounted Cranes shipped from Stellar’s factory after July 1, 2005. The warranty is for the use of the original owner only and is not transferable without prior written permission from Stellar

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANT PROVISION OF MATERIAL AND SERVICES, AS SPECIFIED HEREIN. STELLAR INDUSTRIES, INC. IS NOT RESPONSIBLE FOR INCIDENT

, accident, mishap, untrained operators, or improper or unintended use.

ABILITY OR FITNESS FOR A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE

OR CONSEQUENTIAL

DAMAGES.

The owner has the obligation of performing routine care

Revision Date: February 2007 Document Number: 37040