stellar labs 9628 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
9628 Telescopic Crane
Manual Part No. 31711
Last Revision: 7/20/06
Subject to Change without Notification.
© 2006 Stellar Industries, Inc.
Safety, Installation, Maintenance, and Operation

ii
© 2005 • Stellar Industries, Inc.
Stellar cranes are designed to provide safe and
dependable service for a variety of operations.
With proper use and maintenance, Stellar
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 the 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
Introduction
improvement or commercial/production
purposes. This right is kept with no requirement
or obligation for immediate mandatory updating
of this manual.
This product manual is not intended as a
training manual for beginners or unskilled
operators. This manual offers guidelines for
correct and safe usage of the crane,
maintenance, and troubleshooting. If more
information is required or technical assistance is
needed, please contact the Stellar Customer
Service Department.
Some sections of this manual contain
information pertaining to all Stellar
manufactured cranes and may or may not apply
to your specific model.
If this manual becomes damaged, misplaced, or
unreadable at any point, or 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]
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:

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
iii

regulations and accident-prevention equipment.
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.
Failure to correctly plmb 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.
Chapter 1 - Safety
1-1
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
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.

Chapter 1 - Safety
1-2
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.
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 break 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 adaquate 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.

Chapter 1 - Safety
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.
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

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 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. See photo below.
2-1
Chapter 2 - Operation
Chapter 2 - Operation
PTO Switch
Outrigger control panel, located in the crane compartment.
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 break must be set on the vehicle
and the drive axle disengaged before performing
acrane 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

Chapter 2 - Operation
2-2
4.Operate Crane
A. Turn on necessary power to the crane.
B. Activate toggle switch for desired crane
function. See Figures 1-a, 1-b, 1-c, 1-d.
D. Activate the push button switch located off
of the index finger to operate the function.
E. 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.
Variable Speed Trigger on remote.
The crane should not function until the trigger has been
activated. Thespeed of the crane will vary in direct
correlation with how much or how little the trigger is
engaged.
NOTE: The radio control is
an electrical device. Please
Handle With Care!
1
6Function Remote
This radio remote is the standard for the 5520, 6620, 6628, 9620, 9628, 10620, and 10628 model Stellar Cranes.

Chapter 2 - Operation
2-3
4Function Remote
This corded remote is the standard for the 3315 and 4420 model Stellar Cranes.
6Function Remote
This remote is the standard for the 14528 model Stellar Cranes.

Chapter 2 - Operation
2-4
MAIN
EXTENSION
EXTEND
RETRACT
ROT
CW
MAIN
DOWN
EXTENSION
DOWN
ROT
CCW
UP
UP
PULL PUSH
CONTROL
FLOW
WINCH WINCH
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.
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 hardhat, safety
glasses, steel-toed boots, and gloves.
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:
1. Activate Flow Control.Turn the override
screw on flow control counter-clockwise. Full
adjustment is between three and five turns.
2. 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.
3. Deactivate flow control. Turn the override
screw clockwise until stopped. Full adjustment
is between 3 and 5 turns.
4. Have unit serviced immediately to restore
remote control functionality.

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
aperson.
G. Avoid sudden starts and stops when
moving a load.
Chapter 2 - Operation
2-5

Chapter 3 - Maintenance
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. PTOdrive 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.

Chapter 3 - Maintenance
3-2
Weekly Inspection
Weekly Inspection should occur at the
beginning of every work week. Each week,
inspect the crane for all of the following:
1. Lubrication of points required by lubrication
chart. See chart at the end of this chapter.
2. Proper operation of load hook safety latch.
3. Presence of this owner’s manual.
Monthly Inspection
Monthly Inspection should occur at the
beginning of every work month. Each month,
inspect the crane for all of the following:
1. Frame bolt tightness - turn barrel nuts and
mounting bolts during the first month of
operation on new machines and then
quarterly thereafter.
2. Cylinders and valves for leaks.
3. Lubrication.
4. Load hook for cracks or having more than
15 percent normal throat opening or 10
degrees twist.
5. Structural members for bends, cracks, or
broken members.
6. All welds for breaks and cracks.
7. A ll 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.
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.
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.
Follow these guidelines to maintain the quality of your Stellar product.

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)
Chapter 3 - Maintenance
3-3
Component Location Recommendation
Greasing the Crane
Lubricate all grease gun points with Extreme Pressure Grease - Stellar P/N:
22059.

Chapter 3 - Maintenance
3-4
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
aqualified 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

Chapter 3 - Maintenance
3-5
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.
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. Toconvert 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
11/8-7
11/4-7
13/8-6
11/2-6
Size
(DIA-TPI)
Grade 5 Grade 8 Grade 9

Chapter 3 - Maintenance
3-6
Owner/Company:
Contact Person:
Crane Make/Model:
Crane Serial:
Type of Inspection (check one)
Stellar Industries Inspection Checklist for Telescopic Boom Cranes
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] or by download at:
http://www.stellarindustries.com/pages/downloads.htm
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.

Chapter 3 - Maintenance
3-7
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

Chapter 3 - Maintenance
3-8
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/PTOfor 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.
StatusFrequency
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M

Chapter 3 - Maintenance
3-9
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