stellar labs 4420 User manual

Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com
4420 Telescopic Crane
Manual Part No. 31706
Last Revision: 10/10/09
Subject to Change without Notification.
© 2009 Stellar Industries, Inc.
Safety, Installation, Maintenance, and Operation
OWNER’SMANUAL
4420
24700
®

4420 Manual Revisions
Date of Revision
September 9, 2006
November 7, 2006
April 12, 2007
June 25, 2007
March 18, 2008
October 22, 2008
Description of Revision
Updated Cable and Hook assembly drawings to reflect
engineering changes.
Updated Base assembly drawings and Hydraulic
schematics to reflect engineering changes
Updated Operation to reflect new 5-Function Hetronic
Remote. Updated decal kit drawing. Updated Control Kit
Assembly to reflect the new 5-Function Hetronic Remote.
Added the Hetronic Troubleshooting section.
Updated Main Cylinder assembly drawings to reflect
engineering changes.
Updated Mast assembly and Control Kit drawings to
reflect engineering changes.
Updated Hydraulic Kit Versions to reflect engineering
changes (New Pressure Switch).
Section Revised
Chapter 7:
Assembly Drawings
Chapter 7:
Assembly Drawings
Chapter 8:
Hydraulics-Electrical
Chapter 2: Operation
Chapter 5: Decals
Chapter 8:
Hydraulics-Electrical
Chapter 10:
Troubleshooting
Chapter 7:
Assembly Drawings
Chapter 7:
Assembly Drawings
Chapter 8:
Hydraulics-Electrical
Chapter 8:
Hydraulics-Electrical
Chapter 9:
Replacement Parts

Table of Contents i
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Chapter 1 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Chapter 2 - Operation . . . . . . . . . . . . . . . . . . . . . . . . .3
Crane Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Standard 4420
Manual Override . . . . . . . . . . . . . . . . . . . . . . . . . .5
Proportional Version 4420
Manual Override . . . . . . . . . . . . . . . . . . . . . . . . . .5
Operator Information . . . . . . . . . . . . . . . . . . . . . . . .6
Chapter 3 - Maintenance . . . . . . . . . . . . . . . . . . . . . .7
Lubrication Recommendations . . . . . . . . . . . . . . . .9
Wire Rope Maintenance . . . . . . . . . . . . . . . . . . . . .10
Torque Data Chart . . . . . . . . . . . . . . . . . . . . . . . . . .11
Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . .12
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .13
Monthly Inspection . . . . . . . . . . . . . . . . . . . . . . .14
Quarterly Inspection . . . . . . . . . . . . . . . . . . . . . .15
Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . .17
Inspection Notes . . . . . . . . . . . . . . . . . . . . . . . . .18
Chapter 4 - Specifications . . . . . . . . . . . . . . . . . . . . .19
Capacity Chart - Decal PN 24701 . . . . . . . . . . . . .20
Chapter 5 - Decals . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Decals of Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Decal Kit Placement - PN 24332 . . . . . . . . . . . . . .26
Chapter 6 - Installation . . . . . . . . . . . . . . . . . . . . . . . .27
Installation Overview . . . . . . . . . . . . . . . . . . . . . . . .28
Installation Details . . . . . . . . . . . . . . . . . . . . . . . . . .29
Stability Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .30
Stability Capacity Chart . . . . . . . . . . . . . . . . . . . . .31
Chapter 7 - Assembly Drawings . . . . . . . . . . . . . . . .33
Base Assembly - PN 19998 . . . . . . . . . . . . . . . . . . . .33
Mast Assembly (Corded Remote Version) -
PN 19999 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Mast Assembly (Radio Remote Version) -
PN 44647 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Mast Assembly (Proportional Version) -
PN 50596 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Power Unit Assembly (Electric Version) -
PN 20432 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Main Boom Assembly - PN 24568 . . . . . . . . . . . . . .38
Extension Boom Assembly - PN 24570 . . . . . . . . . .39
Extension Boom Assembly (Optional) -
PN 30790 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Main Cylinder Assembly - PN 25160 . . . . . . . . . . . .41
Extension Cylinder Assembly -
PN 25881 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Cable & Hook Assembly - PN 38203 . . . . . . . . . . .43
Basket Cable & Hook Assembly (Optional)
PN 48109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Chapter 8 - Hydraulics - Electrical . . . . . . . . . . . . . .45
Control Kit (Corded Electrical Version) -
PN 20435 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Control Kit (Radio Electrical Version) -
PN 44737 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Control Kit (Corded Hydraulic Version) -
PN 24331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Control Kit (Radio Hydraulic Version) -
PN 44739 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Control Kit (Radio Version) -
PN 41051 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Control Kit (Proportional Version) -
PN 43693 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Hydraulic Kit (Electrical Version) -
PN 25882 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Hydraulic Kit (Hydraulic Version) -
PN 25885 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Hydraulic Kit (Proportional Version) -
PN 50604 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Valve Bank (Standard Hydraulic Version) -
PN 24957 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Valve Bank (Proportional Version) -
PN 24960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Hydraulic Installation . . . . . . . . . . . . . . . . . . . . . . . .56
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Chapter 9 - Replacement Parts . . . . . . . . . . . . . . . . .59
Chapter 10 - Troubleshooting . . . . . . . . . . . . . . . . . .61
5 Function Hetronic Radio Remote
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .63
Receiver Troubleshooting . . . . . . . . . . . . . . . . . . . .64
Transmitter Troubleshooting . . . . . . . . . . . . . . . . . .64
6 Function Hetronic Radio Remote
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .65
Receiver Troubleshooting . . . . . . . . . . . . . . . . . . . .66
Transmitter Troubleshooting . . . . . . . . . . . . . . . . . .66
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . .68

ii 4420 Owner’s Manual
Stellar 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.
To promote this longevity, carefully study the
information contained in this manual before
putting the equipment into service. Though
it is not intended to be a training manual for
beginners, this manual should provide solid
guidelines for the safe and proper usage of
the crane.
Once you feel comfortable with the
material contained in this manual, strive to
exercise your knowledge as you safely
operate and maintain the crane. This
process is vital to the proper use of the unit.
A few notes on this manual:
A copy of this manual is provided with every
crane and can be found in the hard plastic
manual case that is installed on the chassis.
This manual 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.
Introduction
Please be aware that some sections of this
manual contain information pertaining to
Stellar manufactured cranes in general and
may or may not apply to your specific
model.
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.
In closing:
If more information is required or technical
assistance is needed, or if you feel that any
part of this manual is unclear or incorrect,
please contact the Stellar Customer Service
Department by phone at 800-321-3741 or
email at [email protected].
ATTENTION
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.
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 [email protected]
Order Parts [email protected]
Warranty Information [email protected]

Safety 1
Do not wear rings, wristwatch, jewelry, loose-
fitting 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 explicit approval from Stellar Industries.
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 any adjustments or repairs.
Do not attempt service or repair when the PTO
is engaged.
Failure to correctly plumb and wire the crane
can cause a malfunction and damage to the
crane and/or operator.
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.
Chapter 1 - Safety
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, anti-
noise headphones, protective glasses, and
reflective jackets with breathing apparatus.
Consult your employer regarding current
safety regulations and accident-prevention
equipment.
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 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
putting the unit into operation.
Please take note that Stellar Industries, Inc.
is not liable for accidents incurred by the
crane because of non-fulfillment from the
operator’s side of current rules, laws, and
regulations.

24420 Owner’s Manual
STABILITY
Know the crane components and their
capabilities and limitations. Overloading the
crane may result in serious injury to self and
others, and damage to the equipment and
immediate surroundings.
Never exceed manufacturer’s load ratings.
These ratings are based on the machine’s
hydraulic, mechanical, and structural design
rather than stability.
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. If the crane is picking more than
the maximum rated load, the overlord
protection device may be malfunctioning.
Discontinue use immediately and contact
Stellar Customer Service for support.
Never use a sling bar or anything larger than
the hook throat that could prevent the hook
latch from closing. This would negate the
safety feature.
Do not apply side loads to the booms.
Do not leave a crane load suspended or
unattended.
Do not walk under suspended loads.
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.
Do not use the crane boom to push
downward onto anything.
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.
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.

3Operation 3
Job-Site Set-Up
Thoroughly plan the lift before positioning
the vehicle. Consider the following:
1. 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.
This chapter contains information regarding
the operation of Stellar manufactured
telescopic cranes. Please study the
following pages to ensure your familiarity
with the operation process. This
understanding is vital to the safe and
efficient operation of the crane.
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.
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.
Chapter 2 - Operation

44420 Owner’s Manual
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. Start the vehicle engine.
E. Depress the clutch on manual transmission
vehicles.
F. Engage the PTO switch for cable and air type
shifters. Turn on the 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. Allow a few moments to warm the hydraulic
system oil. In cold weather, it is especially
important to let the system run for a few minutes
before operating.
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.
Proportional Speed
Trigger on remote:
The speed of the
crane will vary in
direct correlation
with how much or
how little the trigger
is engaged.
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.
4.Operate Crane
A. Turn on necessary power to the crane.
B. Activate toggle switch for desired crane function.
C. When operation is complete, store remote handle
in a safe, dry location.
5. Store Outriggers
Retract outriggers using the control levers or switches
marked ‘outrigger’.
6. Turn Off Power to Crane
Deactivate power to crane and outriggers.
7. Disengage the PTO
A. On manual transmission vehicles, depress the
clutch pedal completely.
B. Disengage the PTO switch.
C. If vehicle is a manual transmission, release the
clutch pedal gradually.
5 Function Hetronic Remote5 Function Hetronic Remote
Crane Operation

5Operation 5
Crane Precautions
1. 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.
11. Wear protective gear such as hard hat,
safety glasses, steel-toed boots, and gloves.
12. Maintain a minimum of 5 full wraps of wire
rope on the winch drum at all times.
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.
2. Do not attempt to lift a load that is larger
than the 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.
7. Keep fingers, hands, body, and loose
clothing 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.
Manual Operation
If the remote control malfunctions, follow
these steps to operate the crane manually:
Standard 4420 Manual Override
1. Operate Solenoids.
Slide the knurled
sleeve out and then
push or pull to
operate, as shown
below. Be sure the
sleeve is in the center,
locked, position before
returning to remote
operation. Note: 12V
Power Units must push
the manual override button to allow oil to flow to
the valve banks.
2. Have unit serviced immediately to restore remote
control functionality.
Proportional Version 4420 Manual Override
1. Activate Flow Control.
Turn the override screw on flow control counter-
clockwise.Full adjustment is between three and
fiveturns.
2. Operate Solenoids.
Slide the knurled
sleeveout and then
push or pull to
operate, asshown
below. Be sure the
sleeve is in thecenter,
locked, position before
returning toremote
operation.
3. Deactivate flow control. Turn the overridescrew
clockwise until stopped. Fulladjustment is
between 3 and 5 turns.
4. Have unit serviced immediately to restoreremote
control functionality.
Manual Override Pull Function
The knurled sleeve is pulled all the way
out together with the knob to manually
override the pull solenoid function.
Manual Override Push Function
The knurled sleeve should first be pulled
to unlatch the ball latching mechanism
and then, while holding the sleeve
back, the override knob should be
pushed all the way in to override the
push solenoid.
WARNING
Failure to return the valve bank manual overrides to the
neutral position can result in unexpected crane
movement.

64420 Owner’s Manual
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 Information
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.

7Maintenance 7
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.
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.
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.
10. Wire rope for broken wires, extensive
wear, distortion, and heat damage.

84420 Owner’s Manual
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 located in 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 the following:
a. Cracks or having more than 5%
normal throat opening.
b. Any visible bend or twist from the
plane of the unbent hook.
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.
Stellar Industries recommends the first
filter change to occur after the first 250
hours of service.* The second, and
every subsequent change, should
occur after every 1,000 hours of
service. By following these guidelines,
the hydraulic oil should last up to
6,500 hours.
*Note: These recommendations are based on normal
working parameters. If operating in less than favorable
conditions (excessive dust, moisture, etc.), be sure to check
the filter gauge often for filter change notice.
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.
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.
Important: Prior to washing the Stellar
crane, the radio remote receiver located
on the crane mast must be covered to
prevent any water from entering the
plastic housing. Avoid any direct water
pressure to the radio remote receiver.

9Maintenance 9
Engine Crankcase Apply Manufacturer’s
Recommendations
Hydraulic System
Below –5*F
-5*F to 90*F
Above 90*F
Reservoir
Petro-Canada Arctic MV 15 (ISO 22)
Petro-Canada HYDREX 32 (ISO 32)
Petro-Canada HYDREX 46 (ISO 46)
Open Gears Hand Precision XL3 Moly EP 2 (NLGI 2 grease
with moly)
Bearings, grease
(including turntable bearing
inner race)
Gun Precision XL EP 2 (NLGI 2)
Worm Drive Gearbox Gearbox Precision Synthetic EP 00 (NLGI 00)
Planetary Gearbox
(including winch)
Gearbox Traxon Synthetic 75W-90 (API GL-5)
Wear Pad Lubrication Spray Gearshield NC
Compressor Fluids
Reciprocating Single Stage
Reciprocating Double Stage
Crankcase
Crankcase
Compro 100 (ISO 100)
Compro 100 (ISO 100)
Lubrication Recommendations
Screw
-15˚F to 86˚F
-23˚F to 100˚F
32˚F to 113˚F
Crankcase
Compro XL-S 32 (ISO 32)
Compro XL-S 46 (ISO46)
Compro XL-S 68 (ISO68)
Component Location Recommendation
Greasing the Crane
Lubricate all grease gun points with
Extreme Pressure Grease - Stellar P/N: 22059.

10 4420 Owner’s Manual
Wire Rope Inspection Points
While inspection of the entire rope is
required, attention should be directed to
these critical points:
1. Pick-up Points for signs of wear due to
stress from repeated lifts.
2. End Attachments for corrosion and broken
wires at both ends of the rope.
3. Drums for signs of corrugation and wear
that may lead to wire damage.
4. Sheaves to ensure that each sheave has
the proper groove size and contour.
5. Abuse Points for heavy amounts of
scuffing and scraping.
It is important to perform detailed
inspections of all ropes associated with the
crane. These inspections can be divided
into two types:
1. Frequent Inspection
A. All running ropes should be inspected
once each working day. These visual
observations will be concerned with
discovering damage that may be an
immediate hazard. The following
concerns should be addressed:
1. Distortion of the rope.
2. General corrosion.
3. Broken or cut strands.
B. Use caution while inspecting sections of
rapid deterioration.
C. Use caution while inspecting boom
hoist ropes. Proper inspection is critical
but difficult.
2. Periodic Inspection
A. Inspection frequency will be
determined by a qualified person and
will be based on such factors as
expected rope life, environment
conditions, capacity of typical lifts,
rates of usage, and exposure to shock
loads. Periodic inspection needs to be
performed at least annually.
B. Periodic inspections will be performed
by a qualified individual and will cover
the entire length of the rope. Only the
surface wires of the rope need to be
inspected. This inspection will be
concerned with discovering damage
that may be an immediate hazard. The
following concerns should be
addressed:
1. Distortion of the rope.
2. General corrosion.
3. Broken or cut strands.
4. Reduction of rope diameter.
5. Corroded or broken wires at end
connections.
6. Corroded, cracked, bent, worn, or
improperly applied end
connections.
C. Use caution when inspecting the
following:
1. Sections in contact with saddles,
equalizer sheaves, or other sheaves
where rope travel is limited.
2. Sections of the rope at or near ends
with corroded or broken wires.
Wire Rope Replacement
Rope replacement guidelines are as follows:
1. Broken wires, including standing ropes
with more than two broken wires in one
lay or more than one broken wire at an
end connection.
2. Wear of one-third the original diameter of
the outside wires.
3. Distortion of the rope structure.
4. Evidence of heat damage.
5. Reductions from nominal diameters of
more than 1/64 in. (0.4 mm) for diameters
from 5/16 in.(19.0 mm) and 1/32 in. (0.8
mm) for diameters from 3/8 in. (9.5 mm) to
and including 1/2 in. (13.0 mm).
Wire Rope Maintenance
Proper maintenance is key in ensuring a
long lasting rope. These three tips will help:
1. Store the rope to prevent damage.
2. Avoid objects that may scrape, bend, or
crush the wires of the rope.
3. Always keep the rope well-lubricated.
Wire Rope Maintenance

11Maintenance 11
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.
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.
Torque Data Chart
When using the torque data in the charts
above, the following rules should be
observed.
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.
Plated
(Ft-Lb)
22
39
63
96
139
192
340
549
823
1167
1646
2158
2865
Plated
(Ft-Lb)
18
33
52
80
115
160
280
455
680
965
1360
1780
2370
Plain
(Ft-Lb)
25
44
70
105
155
220
375
605
910
1290
1815
2380
3160
Plated
(Ft-Lb)
13
23
37
57
82
115
200
295
445
595
840
1100
1460
Plain
(Ft-Lb)
17
31
49
75
110
150
265
395
590
795
1120
1470
1950
Bolt DIA
(Inches)
0.3125
0.3750
0.4375
0.5000
0.5625
0.6250
0.7500
0.8750
1.000
1.1250
1.2500
1.3750
1.500
Size
(DIA-TPI)
5/16-18
3/8-16
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
Grade 5 Grade 8 Grade 9

12 4420 Owner’s Manual
Owner/Company:
Contact Person:
Crane Make/Model:
Crane Serial:
Type of Inspection (check one)
Inspection Checklist
Use of this checklist is subject to terms of the
Stellar Warranty information. Additional copies of
this checklist can be obtained by contacting
Stellar Customer Service at [phone].
Date Inspected:
Hour Meter Reading:
Inspected by: (print)
Signature of Inspector:
Daily (if deficiency found)
Monthly
Quarterly
Annual
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.

13Maintenance 13
Daily Inspection
Frequency
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Key
Decals
Controls
Station
Hydsystem
Hook
Rope
Pins
General
Operation
Remote Ctrls
Electrical
Anti 2-Blocking
Operation Aid
Operation Aid
Inspection 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.
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 reeving of wire rope on sheaves & winch drum.
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.
Operate anti 2-blocking device to check for proper operation.
Check presence of boom angle indicator.
Check overload device for proper operation.
Status

14 4420 Owner’s Manual
Monthly Inspection
Frequency
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
Key
Daily
Cylinders
Valves
Valves
Valves
General
Electrical
Structure
Welds
Pins
Hardware
Wear Pads
Pump & Motor
PTO
Hyd Fluid
Hyd Lines
Hook
Rope
Manual
Chassis
Chassis
Station
Inspection 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.
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.
Tire wear and air pressure.
Working backup alarm.
Fire extinguisher at cab or machinery housing.
Status

15Maintenance 15
Quarterly Inspection
Frequency
Q
Q
Q
Q
Q
Q
Key
Daily
Monthly
Rotation Sys
Hardware
Structure
Hardware
Inspection Description
All 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
Jib extension(s)
Other
Other
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
Other
Status

16 4420 Owner’s Manual
Quarterly Inspection Continued...
Frequency
Q
Q
Q
Q
Q
Q
Key
Hyd Lines
Pumps&Motors
Valves
Cylinders
Winch
Hyd Filter
Inspection 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
Load holding valve(s)
Outrigger or auxiliary control valve(s)
Other
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.
Status