stellar labs 5521 User manual

Light-Duty
Telescopic Cranes
Owner’s Manual
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com
Subject to Change without Notication.
© 2017 Stellar Industries, Inc. Last Revision: 2/14/17
Safety • Operation • Maintenance • Troubleshooting
Model 4421
Model 5521
Model 3315
Notice: A copy of this manual must remain with the equipment at all times.
For a printable download copy, please visit: www.stellarindustries.com

Page ii | Stellar®Light-Duty Telescopic Crane Owner’s Manual
Light-Duty Manual Revisions
Date of Revsion Section Revised Description of Revision
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]

Stellar®Light-Duty Telescopic Crane Owner’s Manual | Page iii
Table of Contents
Introduction .............................................................................................................................................................iv
Chapter 1 - Operation ................................................................................................................................................ 1
General Operation ................................................................................................................................................. 1
Pre-Operation Inspection ...................................................................................................................................... 1
Job Site Setup ......................................................................................................................................................... 2
Step 1: Disengage drive axle and set the parking brake. ................................................................................. 2
Step 2: Engage the hydraulic power source. ..................................................................................................... 2
Step 3: Turn on power to the crane. ..................................................................................................................... 3
Step 4: Position the stabilizers. ............................................................................................................................... 3
Step 5: Operate the crane. ................................................................................................................................... 4
Step 6: Stow the crane. .......................................................................................................................................... 6
Step 7: Stow the stabilizers. .................................................................................................................................... 6
Step 8: Disengage hydraulic power source and deactivate power. .............................................................. 6
Step 9: Release the parking brake. ...................................................................................................................... 7
Radio Remote Control Functions .......................................................................................................................... 7
Radio Remote Control Features ........................................................................................................................... 8
Personal Fall Protection with Stellar® Equipment ................................................................................................. 9
Safety Decals of Note .......................................................................................................................................... 10
Body/Chassis ...................................................................................................................................................... 10
Stabilizers ............................................................................................................................................................ 10
Crane Compartment ........................................................................................................................................ 11
Main Boom ......................................................................................................................................................... 12
Crane Horse Head ............................................................................................................................................ 13
Valve Bank.......................................................................................................................................................... 13
Main Cylinder ..................................................................................................................................................... 13
Chapter 2 - Maintenance......................................................................................................................................... 15
General Maintenance Guidelines ...................................................................................................................... 15
Basic Crane Maintenance Schedule* ............................................................................................................... 15
Hydraulic Oil/Filter Maintenance ........................................................................................................................ 16
Washing the Crane............................................................................................................................................... 16
Paint Maintenance .............................................................................................................................................. 16
PTO and Pump Maintenance ............................................................................................................................. 16
Wire Rope Maintenance ..................................................................................................................................... 16
Winch Maintenance ............................................................................................................................................ 16
Extension Boom Maintenance ............................................................................................................................ 16
Counterbalance Valve Test Procedure ............................................................................................................. 16
Rotation Gear Bearing Maintenance ................................................................................................................ 17
Gear-Bearing Bolt Maintenance ........................................................................................................................ 18
Rotation Gear Bearing Thread Tightening Procedure ..................................................................................... 18
Rotation Gear Bearing Thread Tightening Procedure ..................................................................................... 19
Rotation Gear Bearing Tilt Test ............................................................................................................................ 20
Rotation Gear Bearing Worm End Play & Backlash .......................................................................................... 21
Face Seal/O-Ring Size Chart ............................................................................................................................... 22
Lubrication Recommendations .......................................................................................................................... 23
Chapter 3 - Troubleshooting..................................................................................................................................... 25
Radio Remote Troubleshooting .......................................................................................................................... 28
Transmitter Troubleshooting ................................................................................................................................. 29
Status LED Troubleshooting ............................................................................................................................... 29
Transmitter Repairs............................................................................................................................................. 29
Receiver Troubleshooting .................................................................................................................................... 29
Receiver Testing ................................................................................................................................................. 29
Manual Operation ................................................................................................................................................ 30

Page iv | Stellar®Light-Duty Telescopic Crane Owner’s Manual
Introduction
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. A copy of this manual shall remain with the
crane at all times.
Throughout the manual, three signal words will be used to bring attention to important
items:
A NOTICE signal word indicates a practice not related to physical injury.
A WARNING signal word indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
A DANGER signal word indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Information contained within this manual does not cover all maintenance, operating, or
repair instructions pertinent to all possible situations. 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 specic 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].
WARNING
NOTICE
DANGER

Stellar®Light-Duty Telescopic Crane Owner’s Manual | Page 1
Chapter 1 - Operation
General Operation
Pre-Operation Inspection
Safety should be the n umber one thought on every operator’s mind. Three factors should
exist for safe operation: a qualied operator, well-maintained equipment, and the proper
use of this equipment.
This chapter contains information regarding the safety and operation of Stellar®
manufactured EC Series Telescopic Cranes and should be read and understood
completely by everyone working with or near the crane before putting the unit into
operation.
Failure to follow operating, maintenance, or safety instructions can result
in death or serious injury.
It is the responsibility of the owner to instruct the operator in the safe operation of the
equipment and to provide the operator with properly maintained equipment.
Stellar® Crane operators must conform to the qualications specied in
ANSI B30.5 - Chapter 5-3 Operation. Trainees or untrained persons shall be under the direct
supervision of qualied persons.
Operators shall consult with the owner of the equipment regarding current safety
regulations and required personal protective equipment.
Please take note that Stellar Industries, Inc. is not liable for accidents incurred by the crane
because of non-fulllment from the operator’s side of current rules, laws, and regulations.
Before operating the equipment, make sure all regular maintenance has been performed.
Each day, inspect the crane for all of the following:
• Vehicle for standard checks such as proper tire ination and uid levels.
• Parking brake operation.
• Hydraulic reservoir for proper oil level.
• Hoses and gearboxes for evidence of oil leaks.
• Crane controls for excessive wear, cleanliness and proper operation.
• Operational aids such as decals for placement and legibility.
• All securing hardware such as cotter pins, snap rings, hairpins, and pin keepers for proper
installation.
• Crane hook and other loose parts for damage to structures or weld.
• Anti-two block switch for proper function.
• Wire rope for broken wires, extensive wear, distortion, and heat damage.
• All safety guards for proper installation.
Replace/repair as necessary prior to operation. For a more detailed checklist of scheduled
inspection points, refer to the Stellar® Crane Inspection Log. This document is an essential
guide for the daily, monthly, quarterly and annual inspection tasks that will help maintain
the quality of your Stellar product.
WARNING
WARNING

Page 2 | Stellar®Light-Duty Telescopic Crane Owner’s Manual
Step 2: Engage the hydraulic power source.
Step 1: Disengage drive axle and set the parking brake.
Job Site Setup
1. Make certain that the transmission is in neutral/park.
2. Engage the hydraulic power source. If using a PTO, consult the PTO manual for specic
instructions if needed.
Note: Allow the hydraulic system oil to warm before operating any of the hydraulic
equipment, especially during cold weather.
The drive axle must be disengaged and the parking brake must be set before operating
any of the equipment.
Thoroughly plan the lift by understanding the work site area and your loads before
positioning the vehicle. For a complete and detailed description of job site setup, please
refer to the AEM Safety Manual (Form C-70-2). Consider the following:
• The vehicle should be positioned in an area free from bystanders and overhead
obstructions. Use a signal person if necessary.
• Always maintain safe clearance from high voltage power lines in
accordance with ANSI B30.5: 5-3.4.5 Operating Near Electric Power Lines. Death or serious
injury will result from inadequate clearance if crane, load, or vehicle becomes electrically
charged.
• Make certain that the vehicle is parked on stable, at ground as close to the job as
possible. The surface under the service truck must be able to support the weight of the
machine and its load.
• Use wheel chocks if parking the vehicle on a slope.
•Always park the vehicle with the grade. If cross-grade parking is required, the load
capacity must be decreased appropriately to mitigate tipping risk.
• Do not operate the crane during electrical storms.
• 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.
DANGER
WARNING

Stellar®Light-Duty Telescopic Crane Owner’s Manual | Page 3
Step 4: Position the stabilizers.
Step 3: Turn on power to the crane.
Extend the stabilizers using the control levers or switches marked ‘stabilizer’ or ‘outrigger’.
These may be located in the compartment under the crane or on the rear bumper.
1. Locate the street side stabilizer control handle (labeled
“SS”). Push the lever down to lower the stabilizer leg on the
street side of the truck. While looking under the rear of the
truck, you will see the street side stabilizer leg lowering to the
ground. When the stabilizer makes solid contact with the
ground, release the control lever.
2. Locate the extension stabilizer lever. Push the extension
lever down to fully extend the curb side stabilizer.
3. Locate the curb side stabilizer control handle (labeled
“CS”). Push the CS lever down to lower the stabilizer to the ground. Release the lever when
the stabilizer has made solid contact with the ground.
Keep clear of stabilizer legs during operation. Moving stabilizers can
cause serious crushing injuries. Make certain that all personnel are clear of the stabilizer
and the ground contact point before operating.
Do not raise the rear tires of the truck off the ground with the stabilizers.
Conrm that the stabilizers are positioned on stable, at ground and that the truck is as
level as possible both front to rear and side to side. Use stabilizer pads to ensure the proper
distribution of weight.
To initiate electrical power to the crane, activate the button
labeled ‘Main Power’ on the VEC control panel. The VEC
control panel is commonly mounted on the oor in the middle
of the vehicle cab. Feel free to activate any other button
functions needed for the job.
Note: For non-VEC control panels, consult the manufacturers’
documentation of operation.
WARNING
WARNING

Page 4 | Stellar®Light-Duty Telescopic Crane Owner’s Manual
Step 5: Operate the crane.
Operators should have a rm understanding of ANSI B30.5 - Section 5-3.2 Operating
Practices and AEM Safety Manual (Form C-70-2)prior to operation of the crane.
Using the Radio Remote:
To operate the crane using the radio remote control:
Non-Proportional Remote Control Version
1. Activate the desired toggle function.
Fully-Proportional Remote Control Version
1. Activate and hold the desired toggle switch.
2. While holding the toggle, gently pull the variable speed trigger until the crane begins to
move. The speed of the crane will vary in direct correlation to how much or how little the
trigger is engaged.
The radio remote allows for simultaneous functions. With practice, it is possible to use
more than one toggle at the same time (Extension Out/Winch Down for example). See
the Radio Remote Control Functions and Features pages later in this chapter for more
information.
Unstowing the Crane:
To unstow the crane and prepare it for a lift:
• Winch down slightly.
• Raise the boom high enough to clear the boom rest and any other obstructions.
• Rotate the crane until it clears the side of the truck body.
• Winch down to create slack in the wire rope and remove the snatch block from the stow
hook.
Attaching the load:
• Position the crane with the hook centered directly over the load avoid side loading.
• Attach the load to the hook by means of slings or other approved devices.
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.
• Maintain a minimum of 3 full wraps of wire rope on the winch drum at all times.
Do not wrap the wire rope around the load.
Lifting the load:
Lift the load slightly off the ground to check the safety of the cargo. Consider the following:
WARNING
WARNING

Stellar® Light-Duty Telescopic Crane Owner’s Manual | Page 5
• Make certain that the stabilizers are positioned on at, stable ground.
• Never exceed manufacturer’s capacity charts and ratings. These
ratings are based on the machine’s hydraulic, mechanical, and structural design rather
than stability.
• Never perform a lift that can induce a dynamic force greater than the capacity of the
crane.
• It is the responsibility of the operator to know the weight of both the rigging and the
handled load to avoid overloading the crane. Do not rely on the overload device
to determine maximum rated loads. If the crane is picking more than the maximum
rated load, the overload protection device may be malfunctioning. Discontinue use
immediately and contact Stellar Customer Service for support.
• Do not use a crane to lift personnel without factory approved lifting
device.
• Do not attempt to lift xed loads.
Moving the load:
Ensure that the load is secure and balanced within the sling before moving. Consider the
following:
• Be sure that the crane is level and stable before moving the load.
• Always look for any changes to the surroundings since the job site setup. Be aware of
any new or missed overhead obstructions (branches, power lines, etc) and bystanders.
Use a signal person if necessary.
• Never operate the crane with personnel under any part the boom
or load. Do not extend or rotate a load over anyone. Never allow personnel to place
themselves under any part of the boom or load.
• Never leave a crane load suspended or unattended.
• Do not use the boom or the winch to drag a load.
• Do not use the crane boom to push downward onto anything.
• Avoid sudden starts and stops when moving a load.
WARNING
WARNING
WARNING
WARNING

Page 6 | Stellar®Light-Duty Telescopic Crane Owner’s Manual
Step 8: Disengage hydraulic power source and deactivate power.
• Disengage the hydraulic power source. If using a PTO, consult the PTO manual for
specic instructions if needed.
• Turn off all switches on the VEC control panel. Note: For non-VEC control panels, consult
the manufacturers’ documentation of operation.
Step 7: Stow the stabilizers.
After stowing the crane:
• Return to the stabilizer controls and pull up on the CS and SS levers and fully retract the
stabilizers. Note: Both levers can be used at the same time.
• Pull up on the extension lever to fully retract and store the curb-side stabilizer.
Step 6: Stow the crane.
Once you have performed your lift and are ready to shut down the work site:
• Retract all extensions.
• Winch up to bring the snatch block within 3 feet of the boom tip.
• Lower the crane boom down far enough so that the snatch block is within comfortable
reach.
• Hook the snatch block to the stow hook on the main boom. Maintain control to avoid
personal injury or damage to any equipment.
Never use the stow hook for anything other than stowing the snatch
block.
• Tighten the winch line so that the snatch block comes within a few inches of the main
boom. Avoid activating the anti-two block switch when tightening slack.
• Raise the boom slightly above the boom rest.
• Rotate the boom counter-clockwise until it aligns with the boom rest.
• Lower the boom gently into the boom rest.
• Store the radio remote control, preferably in the cab of the truck.
WARNING

Stellar®Light-Duty Telescopic Crane Owner’s Manual | Page 7
The parking brake must be released before moving the truck.
Make certain that any air tanks are completely drained before moving
the truck.
WARNING
Radio Remote Control Functions
A. Optional Speed Control/Compressor Start/Stop Toggle: Push up to start or stop the
option al speed control. Push down to start or stop the compressor.
B. E-Stop Button: Push in/down to immediately stop all crane functionality. Pull up/out to
restore functionality.
C. Engine Start/Stop Toggle: Push to start or stop the engine.
D. Boom Up/Down Toggle: Push up to raise the boom. Push down to lower the boom.
E. Extension In/Out Toggle: Push up to extend the extension. Push down to retract the
extension.
F. Winch Up/Down Toggle: Push up to raise the winch. Push down to lower the winch.
G. Rotate Clockwise/Counterclockwise: Push up to rotate the boom clockwise. Push
down to rotate the boom counterclockwise.
Step 9: Release the parking brake.

Page 8 | Stellar®Light-Duty Telescopic Crane Owner’s Manual
Radio Remote Control Features
Radio Remote Sleep Mode
The radio remote control enters sleep mode after about 15 seconds of inactivity. Activate
a toggle switch to re-link the transmitter to the receiver. After re-linking, activate the
desired toggle to continue operation.
E-Stop Button
The Radio remote control is equipped with an emergency stop button. If a situation
arises that requires the immediate stoppage of crane functionality, press down on the red
Emergency Stop button located in the center of the remote control.
The E-stop button is not intended to be an on/off switch. This is also the
rst item to check if the crane is not responding to toggle and trigger activation. Make
sure the red E-Stop button is in the up or disengaged position.
Radio Remote Battery Replacement
Occasionally the batteries in the handheld transmitter will need
to be changed. The AA Alkaline batteries are located in the
handle portion of the radio transmitter. Release the button and
slide the battery holder out. Replace the batteries and return
the holder back into the handheld transmitter until the button
latches.
Radio Remote Backup Cord
If the handheld transmitter has a system problem that makes the radio function un-usable,
use of the back-up cord may be necessary.
Death or serious injury will result from touching tethered remote if the
crane, load, or vehicle becomes electrically charged. Always maintain safe clearance
from high voltage power sources.
1. Locate the backup control cord. Most likely it is in the crane compartment, or in the cab
behind the seat.
2. Remove the battery holder from the remote handle and place
the similar looking end of the back-up cord in the bottom of the
transmitter handle.
3. Attach the other end of the back-up cord to the connector
currently used by the antenna on the control receiver. The control
receiver is located on the back of the crane mast.
NOTICE
DANGER

Stellar®Light-Duty Telescopic Crane Owner’s Manual | Page 9
Personal Fall Protection with Stellar®Equipment
OSHA Provisions
Before proceeding, all users must read, understand, and follow the provisions located
in OSHA 29 CFR 1926.1423, specically paragraphs (g) Anchorage criteria, (j) Anchoring
to the load line, and (k) Training. Please note that OSHA sections 1926.502(d)(15) and
1926.502(e)(2) are cross-referenced in this section and need to be read, understood, and
followed by each user.
Other Provisions
While the above OSHA provisions specically cover requirements for personal fall
protection, all users of Stellar products are required to read, understand, and follow all
OSHA, industry, and employer regulations for the use of each product, which includes,
but is not limited to, 29 CFR 1926.1423. All users must also follow Stellar warnings and
instructions. No part of this document is to be interpreted as excusing non-compliance
with all of the above requirements.
Personal Fall Protection Instructions
Requirements:
• Two-part line with installed snatch block
• Hook with original safety latch
• 5,000 pound (or above) rated crane
• Fall of less than 6-feet
• No swinging fall
Attach personal fall protection equipment to hook* on snatch block. If the safety latch on
the hook is not original, or is damaged, missing, or not functioning properly, DO NOT use
Stellar equipment.
ONLY attach personal fall protection equipment to hook. Never attach to wire-rope or any
other part of the crane or snatch block.
Failure to comply to any of the above regulations or to all applicable OSHA, industry,
employer, and Stellar warnings and instructions can result in injury or death.
*Crane hook should only be used if there are no other suitable anchor points.

Page 10 | Stellar®Light-Duty Telescopic Crane Owner’s Manual
Stabilizers
Body/Chassis
Safety Decals of Note
Safety decals serve to inform the viewer of the hazard type, how to avoid the hazard, and
the consequences of not avoiding the hazard.
Decals are considered safety equipment. They must be maintained, as would other safety
devices. All safety instruction plates, notices, capacity charts and any other decal applied
to the crane or service body must be kept legible and in good condition. Replace any
decals that are missing, damaged, or illegible.
Detailed below are a number of key safety decals related to this equipment. Use the
decal placement drawing in the Installation, Assembly Drawings, and Parts Manual to note
the actual location of the safety decals on the equipment.
DANGER
Electrocution Hazard
Death or serious injury will result from inadequate
clearance if crane, load, or vehicle becomes electrically
charged.
• Maintain safe clearance from high voltage power sources.
• Never approach vehicle or load if equipment is near a
high voltage power source.
C4545
WARNING
Crush Hazard
Keep clear of stabilizer legs during
operation.
Failure to keep clear of moving
stabilizer legs can result in death or
serious injury.
C4795 - Rev B
Decal Part Number: C4545
Decal Location: Four corners of the body/chassis
Hazard Type: Electrocution Hazard
Consequences: Will result in death or serious injury.
Avoidance: Maintain safe clearance from high
voltage power sources. Never approach vehicle
or load if equipment is near a high voltage power
source.
Decal Part Number: C4795
Decal Location: Each stabilizer leg
Hazard Type: Crush Hazard
Consequences: Can result in death or serious injury.
Avoidance: Keep clear of stabilizer legs during
operation.

Stellar®Light-Duty Telescopic Crane Owner’s Manual | Page 11
Crane Compartment
DANGER
Death or serious injury will
result from touching tethered
remote if crane, load, or vehicle
becomes electrically charged.
Maintain safe clearance from
high voltage power sources.
Electrocution Hazard
4186
WARNING
4189
Do not exceed equipment load charts and ratings.
Failure to follow equipment load charts and ratings
can result in death or serious injury.
Overload Hazard
WARNING
Read and understand all
manuals and safety signs
before operating or servicing
this equipment.
Failure to follow operating,
maintenance, or safety
instructions can result in
death or serious injury.
Untrained Operator Hazard
68024
Decal Part Number: 68024
Decal Location: Crane Compartment
Hazard Type: Untrained Operator Hazard
Consequences: Can result in death or serious injury.
Avoidance: Read and understand all manuals
and safety signs before operating or servicing
equipment.
Decal Part Number: 4189
Decal Location: Crane Compartment
Hazard Type: Movement Hazard
Consequences: Can result in death or serious injury.
Avoidance: Do not exceed equipment capacity
charts and ratings.
Decal Part Number: 4186
Decal Location: Crane Compartment
Hazard Type: Electrocution Hazard
Consequences: Will result in death or serious injury.
Avoidance: Maintain safe clearance from high
voltage power sources.

Page 12 | Stellar®Light-Duty Telescopic Crane Owner’s Manual
Main Boom
12451
WARNING
Hoisting personnel on boom,
hook, load, or loadline can result
in death or serious injury.
• Never use crane to hoist
personnel.
• Never ride the boom, hook,
load, or any device attached
to crane boom or load line.
Fall Hazard
12452
WARNING
Free falling manual boom
extensions can result in death or
serious injury.
• Properly install retention pins
prior to operation.
• Do not stand in front of
extension when removing
retention pin.
• Do not allow extensions to
free fall.
Free Falling Boom Hazard
WARNING
24712
Do not use stow hook for any lifting applications.
Using the stow hook for anything other than hook
stowage can result in death or serious injury.
Misuse Hazard
DANGER
Electrocution Hazard
Death or serious injury will result from
inadequate clearance if crane, load,
or vehicle becomes electrically
charged.
• Maintain safe clearance from high
voltage power sources.
• Never approach vehicle or load if
equipment is near a high voltage
power source.
C1179
Decal Part Number: 24712
Decal Location: Main Boom
Hazard Type: Misuse Hazard
Consequences: Can result in death or serious injury.
Avoidance: Do not use stow hook for any lifting
applications.
Decal Part Number: C1179
Decal Location: Main Boom
Hazard Type: Electrocution Hazard
Consequences: Will result in death or serious injury.
Avoidance: Maintain safe clearance from high
voltage power sources. Never approach vehicle
or load if equipment is near a high voltage power
source.
Decal Part Number: 12452
Decal Location: Main Boom
Hazard Type: Free Falling Boom Hazard
Consequences: Can result in death or serious injury.
Avoidance: Properly install retention pins prior to
operation. Do not stand in front of extension when
removing retention pin. Do not allow extensions to
free fall.
Decal Part Number: 12451
Decal Location: Main Boom
Hazard Type: Fall Hazard
Consequences: Can result in death or serious injury.
Avoidance: Never use the crane to hoist
personnel. Never ride the boom, hook, load, or
any device attached to the crane boom or load
line.

Stellar®Light-Duty Telescopic Crane Owner’s Manual | Page 13
Main Cylinder
Valve Bank
Crane Horse Head
WARNING
28256
Overload Hazard
Bypassing the overload condition
by tampering with the overload
device can result in death or
serious injury.
Never tamper with overload
device.
WARNING
25159
After stowing the crane, always return the valve
bank manual overrides to the neutral position.
Failure to return the manual overrides to the neutral
position can result in death or serious injury.
Movement Hazard
WARNING
Misuse Hazard
Two blocking the crane can result in death
or serious injury.
Never allow the hook block to contact the
boom tip by hoisting up, extending or
lowering the boom.
12300
Winch Pull
Boom Extending
Boom
Down
Decal Part Number: 12300
Decal Location: Crane Horse Head
Hazard Type: Misuse Hazard
Consequences: Can result in death or serious injury.
Avoidance: Never allow the hook block to contact
the boom tip by hoisting up, extending or lowering
the boom.
Decal Part Number: 25159
Decal Location: Valve Bank
Hazard Type: Movement Hazard
Consequences: Can result in death or serious injury.
Avoidance: After stowing the crane, always return
the valve bank manual overrides to the neutral
position.
Decal Part Number: 28256
Decal Location: Main Cylinder
Hazard Type: Overload Hazard
Consequences: Can result in death or serious injury.
Avoidance: Never tamper with the overload
device.

Page 14 | Stellar®Light-Duty Telescopic Crane Owner’s Manual
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Stellar® Light-Duty Telescopic Crane Owner’s Manual | Page 15
Chapter 2 - Maintenance
Maintenance is an important part of extending the life of any Stellar® Telescopic Crane.
Performing key maintenance items on a scheduled program will prevent unnecessary
downtime.
* For a more detailed outline of scheduled inspection points, refer to the Stellar® Crane Inspection Log. The Stellar®Crane Inspection
Log is an essential guide for the daily, monthly, quarterly and annual inspection tasks that will help maintain the quality of your Stellar
product.
Maintenance Operation Daily Weekly Monthly Hourly
Check hydraulic reservoir oil level. X
Grease rotation gear inner race bearings. X
Grease rotation gear worm drive bearings. 3 months
Grease rotation gear open gear teeth. X
Grease all cylinder pivot points. X
Lubricate extension booms. X
Check winch gear grease level. X
Drain and replace hydraulic oil. 6500
Tighten all hydraulic lines
.6
months
Basic Crane Maintenance Schedule*
Before performing any maintenance to the crane,
consider the following:
• Only qualied service
personnel are to perform maintenance on
the crane. Never modify or alter any of the
equipment, whether mechanical, electrical, or
hydraulic, without explicit approval from Stellar
Industries.
• Position the crane where it will be out of the way
of other operations or vehicles in the area.
• Lower the boom fully or stow in the cradle to
prevent uncontrolled movement.
• Place all controls in the off position and secure
operating features from inadvertent motion.
Follow all company directed lockout/tagout
procedures.
• Before any service or repair is performed,
disengage the hydraulic power source and shut
off the engine.
• Allow systems to cool before performing any
maintenance.
• Before performing any maintenance on
electrical components, disconnect the power
source.
• Before performing any maintenance on
hydraulic components, relieve hydraulic oil
pressure from all hydraulic circuits. Move pedals
and control levers repeatedly through their
operating positions to relieve all pressures.
• Do not disconnect hydraulic
hoses while there is still pressure in those
components.
• Replace parts with Stellar® approved parts only.
• Keep the crane and service body clean and
free from grease build-up, oil and dirt to prevent
slippery conditions.
• Label or tag parts when disassembling.
• Immediately repair or have repaired any
components found to be inadequate.
WARNING
WARNING
General Maintenance Guidelines

Page 16 | Stellar®Light-Duty Telescopic Crane Owner’s Manual
Stellar Industries recommends the rst lter change to occur after the rst 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 lter gauge often for lter
change notice.
Important: Prior to washing the Stellar crane, all electrical components must be covered to prevent
any water from being injected into the plastic housing. Avoid any direct water pressure to any of
the electrical components.
Touch up any chips or scratches to prevent further paint damage.
While operating the crane, extend and retract the extension booms. If the extension weldments
are noisy during operation, it is necessary to lubricate the booms. Stellar® Model Cranes feature a
metal coating which will require an aerosol lubricant. Stellar Industries recommends aerosol style
lubricant Stellar PN 44512.
Fully extend a load (65-70% of crane’s rated capacity) at a boom angle of approximately 60º.
With the load at 3-5 inches off the ground, use a tape measure to mark the load from a specic
at/level spot on the ground (Note: Use a board/pad if necessary). Also at this time, use a grease
pen to make a temporary mark on the main cylinder rod and another mark on the winch drum in
reference to the housing. Finally, measure the stabilizer legs from the ground.
After waiting ve minutes, measure the load from the same specic spot on the ground. If the load
movement is within 1/4”, the test has passed. If the load has moved more than 1/4”, wait another
ve minutes and re-measure. If the load continues to move, check the other marks (main cylinder
rod, winch drum) and re-measure the stabilizers to narrow down the potential drifting issue. Please
refer to the troubleshooting section at the end of this manual for further detailed instructions.
Every six (6) months, remove the hydraulic pump from the PTO and lubricate the splines using Stellar
PN 20885. Failure to lubricate shaft splines will cause damage to the PTO and Hydraulic pump.
Proper maintenance is key in ensuring a long lasting rope. Refer to ANSI B30.5 for details on
maintaining your wire rope.
Refer to winch manual supplied with crane.
Hydraulic Oil/Filter Maintenance
Washing the Crane
Paint Maintenance
Extension Boom Maintenance
Load Hold Test Procedure
PTO and Pump Maintenance
Wire Rope Maintenance
Winch Maintenance