stellar labs 4500 User manual

Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com
Owner’s Manual
4500 Articulating Crane
Manual Part No. 37809
Last Revision: 4/6/09
Subject to Change without Notification.
©2009 Stellar Industries, Inc.
Safety, Installation, Maintenance, and Operation

Stellar 4500 Manual
b
4500 Manual Revisions
Date of Revision
October 22, 2008
Description of Revision
Updated Hydraulic Kit Versions to reflect engineering
changes (New Pressure Switch).
Section Revised
Chapter 8:
Hydraulics-Electrical
Chapter 9:
Replacement Parts

© 2007 • Stellar Industries, Inc.
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
Introduction
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.stellarindustries.com
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
[email protected]
Stellar Industries, Inc. reserves the right to
update this material without notice or obligation.
Technical Questions, and Information [email protected]
Order Parts [email protected]
Warranty Information [email protected]
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:

Stellar 4500 Manual
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
1-1
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 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.
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 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.

Stellar 4500 Manual
1-2
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.
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.
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.
No crane is designed for these types of loads.
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.

Stellar 4500 Manual
1-3
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.
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

2-1
Stellar 4500 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. 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.
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 Transmitter.
D. Activate the toggle on the remote unit.
E. Manipulate the crane operation transmitter toggle
switches to achieve desired results.
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.
Chapter 2 - Operation
PTO Switch
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.
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
NOTICE
The parking brake must be
fully engaged in order to
operate any Stellar Equipment.

2-2
Stellar 4500 Manual
Crane Radio
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:
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.
3. The batteries should be recharged when they fail to
produce sufficient power.
4. Never attempt to open the battery for any reason.
Manual Operation
In case of radio failure, the crane can be
operated using manual overrides located on
the valve bank.
Valve Manual Override Operation
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.
PULL
PUSH
ROTATION ROTATION
EXTENSION EXTENSION
CW
CCW
RETRACT
EXTEND
EXTEND
OUTER
OUTER
RETRACT
RETRACT
EXTEND
INNER INNER
PROPOR-
TIONAL
VALVE

2-3
Stellar 4500 Manual
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.
Crane Transport
Before 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.
The crane MUST be in the stored position before transporting.
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.

Stellar 4500 Manual
2-4
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
B30.2, 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.

Stellar 4500 Manual
3-1
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.

Stellar 4500 Manual
3-2
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.
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.
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 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 brakes 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.
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
3-3
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)
Stellar 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.

Stellar 4500 Manual
3-4
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.
Torque Data Chart
22
39
63
96
139
192
340
549
823
1167
1646
2158
2865
18
33
52
80
115
160
280
455
680
965
1360
1780
2370
Plated
(Ft-Lb)
Plated
(Ft-Lb)
25
44
70
105
155
220
375
605
910
1290
1815
2380
3160
Plain
(Ft-Lb)
13
23
37
57
82
115
200
295
445
595
840
110
1460
Plated
(Ft-Lb)
17
31
49
75
110
150
265
395
590
795
1120
1470
1950
Plain
(Ft-Lb)
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
Bolt DIA
(Inches)
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
Size
(DIA-TPI)
Grade 5 Grade 8 Grade 9
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.

Stellar 4500 Manual
3-5
Owner/Company:
Contact Person:
Crane Make/Model:
Crane Serial:
Type of Inspection (check one)
Stellar Industries Inspection Checklist for Articulating Boom Cranes
Use of this checklist is subject to terms of the Stellar
Warranty information. Note: Some checklist items may
not apply to your particular crane model. If questions
arise, please contact 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.

Stellar 4500 Manual
3-6
Daily Inspection
Frequency
D
D
D
D
D
D
D
D
D
D
D
D
Key
Decals
Controls
Station
Hydsystem
Hook
Pins
General
Operation
Remote Ctrls
Electrical
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 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.
Check overload device for proper operation.
Status

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3-7
Monthly Inspection
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 Frequency
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M

Stellar 4500 Manual
3-8
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
Quarterly Inspection
Frequency
Q
Q
Q
Q
Q
Q

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Quarterly Inspection Continued...
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 Frequency
Q
Q
Q
Q
Q
Q