stellar labs CDT 5521 User manual

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Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: [phone]
www.stellarindustries.com Last Revision: 04/29/13
Subject to Change without Notification.
© 2013 Stellar Industries, Inc.
®
TM
odels:
5521
7621
7628
9621
9628
10621
10628
12621
12628
14528

Heavy-Duty Crane anual Revisions

Table of Contents (
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Chapter 1 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Decals of Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 2 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Job-Site Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pre-Operation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Step 1: Set the parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 2: Engage the PTO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 3: Turn on power to the crane. . . . . . . . . . . . . . . . . . . . . . . . 8
Step 4: Position the stabilizers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 5: Operate the crane.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Radio Remote Control Functions . . . . . . . . . . . . . . . . . . . . . . 10
Radio Remote Control Feedback and Boost Mode
(If applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Radio Remote Control Features . . . . . . . . . . . . . . . . . . . . . . . 12
Step 6: Stow the crane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Step 7: Stow the stabilizers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Step 8: Disengage the PTO and deactivate power. . . . . . . . . . 13
Step 9: Release the parking brake. . . . . . . . . . . . . . . . . . . . . . . . 13
Wire Rope/Sheave Configurations. . . . . . . . . . . . . . . . . . . . . . . . 14
Chapter 3 - aintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Crane Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ydraulic Oil/Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 16
Washing the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PTO and Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wire Rope Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Winch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Refer to winch manual supplied with crane. . . . . . . . . . . . . . . . 16
Extension Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rotation Gear Bearing Maintenance . . . . . . . . . . . . . . . . . . . . . 17
Torque Data Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gear-Bearing Bolt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lubrication Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Chapter 4 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Stellar® CDT™ Radio Remote Troubleshooting . . . . . . . . . . . . . 23
Synchronizing the Receiver and Transmitter . . . . . . . . . . . . . . . . 24
Receiver/Transmitter Identification Tag . . . . . . . . . . . . . . . . . . . . 24
Stellar ® CDT Radio Error Code Troubleshooting . . . . . . . . . . . . 25
Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

(( Stellar® Heavy-Duty Crane Owner’s Manual
Stellar® Cranes are designed to provide
safe and dependable service for a variety
of operations. With proper use and
maintenance, these cranes will operate at
peak performance for many years.
To promote this longevity, carefully study
the information contained in this manual
before putting the equipment into service.
Though it is not intended to be a training
manual for beginners, this manual should
provide solid guidelines for the safe and
proper usage of the crane.
Once you feel comfortable with the
material contained in this manual, strive to
exercise your knowledge as you safely
operate and maintain the crane. This
process is vital to the proper use of the unit.
A few notes on this manual:
A copy of this manual is provided with
every crane and can be found in the hard
plastic manual case that is installed on the
chassis. This manual shall remain with the
crane at all times.
Information contained within this manual
does not cover all maintenance, operating,
or repair instructions pertinent to all possible
situations.
Please be aware that some sections of this
manual contain information pertaining to
Stellar manufactured cranes in general and
may or may not apply to your specific
model.
This manual is not binding. Stellar Industries,
Inc. reserves the right to change, at any
time, any or all of the items, components,
and parts deemed necessary for product
improvement or commercial/production
purposes. This right is kept with no
requirement or obligation for immediate
mandatory updating of this manual.
In closing:
If more information is required or technical
assistance is needed, or if you feel that any
part of this manual is unclear or incorrect,
please contact the Stellar Customer Service
Department by phone at 800-321-3741 or
email at [email protected].
Introduction
ATTENTION
Failure to adhere to the instructions
could result in property damage or
even serious bodily injury to the
operator or others close to the
crane.
For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at
800-321-3741
ours: 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]

Chapter 1 - Safety
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 n umber one thought on
every operator’s mind. Three factors should
exist for safe operation: a qualified operator,
well-maintained equipment, and the proper use
of this equipment. The following information
should be read and understood completely by
everyone working with or near the crane before
putting the unit into operation.
Please take note that Stellar Industries, Inc. is not
liable for accidents incurred by the crane
because of non-fulfillment from the operator’s
side of current rules, laws, and regulations.
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.
Operators must conform to the qualifications
specified in ANSI B30.5 - Chapter 5-3 Operation.
PERSONAL SAFETY
Keep clear of all moving parts. All protective
guards must be in place and in good operating
condition.
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.
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.
AINTENANCE SAFETY
Before operating the equipment, make sure all
regular maintenance has been performed.
Never modify or alter any of the equipment,
whether mechanical, electrical, or hydraulic,
without explicit approval from Stellar Industries.
Do not perform any maintenance or repair
work on the crane unless authorized and
trained to do so.
Release system pressure before attempting to
make any adjustments or repairs.
Do not attempt service or repair when the PTO
is engaged.
Failure to correctly plumb and wire the crane
can cause a malfunction and damage to the
crane and/or operator.
Decals are considered safety equipment. They
must be maintained, as would other safety
devices. Do not remove any decals. Replace
any decals that are missing, damaged, or
illegible.
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. Replace if necessary.

Stellar® Heavy-Duty Crane Owner’s Manual
STABILITY
Know the crane components and their
capabilities and limitations. Overloading the
crane may result in serious injury to self and
others, and damage to the equipment and
immediate surroundings.
Never exceed manufacturer’s load ratings.
These ratings are based on the machine’s
hydraulic, mechanical, and structural design
rather than stability.
The supporting surface under the service truck
must be able to support the weight of the
machine and its load. Use stabilizer pads if
necessary.
Park the vehicle on level ground and extend
the stabilizers fully out and then down.
Keep feet and legs clear when lowering
stabilizer jacks.
Never operate the crane without making sure
the stabilizers are positioned on stable, flat
ground.
Set the parking brake and disengage the drive
axle before attempting a lift.
LOAD SAFETY
Operate the crane in compliance with the load
capacity chart at all times. Know the weight of
the load being lifted. Do not rely on the
overload device to determine maximum rated
loads. If the crane is picking more than the
maximum rated load, the overload protection
device may be malfunctioning. Discontinue
use immediately and contact Stellar Customer
Service for support.
Never use a sling bar or anything larger than
the hook throat that could prevent the hook
latch from closing. This would negate the safety
feature.
Do not apply side loads to the booms.
Do not leave a crane load suspended or
unattended.
Do not walk under suspended loads.
Do not position any load over a person nor
should any person be permitted to place him or
herself under a load.
Do not use the boom or the winch to drag a
load.
Do not use the crane boom to push downward
onto anything.
ELECTROCUTION
Allow extra space for swaying power lines in
windy conditions. Maintain a clearance in
accordance with ANSI B30.5: 5-3.4.5 Operating
Near Electric Power Lines.
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.
ENVIRON ENT
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.

Safety 
Safety Decals of Note
DANGER
HOISTING PERSONNEL ON
BOOM, HOOK, LOAD OR LOADLINE
WILL RESULT IN
DEATH OR SERIOUS INJURY
Never hoist personnel on boom, hook, load
or any device attached to crane boom
or load line 12451
DANGER
ELECTROCUTION HAZARD
THIS CRANE IS NOT INSULATED
WILL RESULT FROM CONTACT
OR INADEQUATE CLEARANCE
• Maintain safe clearances from electrical lines. Allow for
boom, electrical line, and load line swaying.
• This crane does not provide protection from contact with
or proximity to an electrically charged conductor.
• Maintain a clearance of at least 10 feet between any part
of the crane, loadline or load and any electrical line
carrying up to 50,000 volts.
• One foot additional clearance is required for every
additional 30,000 volts or less.
C1179
DEATH OR SERIOUS INJURY
DANGER
This remote control box does
not provide you and others with
protection against
will result if the boom, load or
loadline should become
electrically charged.
MAINTAIN SAFE CLEARANCES
FROM POWER LINES
ELECTROCUTION
HAZARD
DEATH OR SERIOUS INJURY
4186
DANGER
ELECTROCUTION HAZARD
KEEP CLEAR OF TRUCK AND LOAD
C4545
DEATH OR SERIOUS INJURY will result
from contact with the load, the crane or the vehicle
if the boom or loadline should become electrically
charged.
Electrocution Hazard Decal
Location: Inside Crane Compartment, on
Compartment Door
Function: To inform the operator that the crane
is not insulated and the possible consequences
if the crane would come into contact with
power lines or electrically charged
conductors., and how to avoid the hazard.
PN: C1179
Hoisting Decal:
Location: Inside Crane Compartment, on
Compartment Door
Function: To inform the operator of the hazard
associated with lifting personnel with the boom,
boom hook, the load or winch loadline, the
possible consequences of lifting personnel, and
how to avoid the hazard.
PN: 12451
Electrocution Hazard Decal
Location: Each side of truck body, Front & Rear
Bumper
Function: To inform the operator and other
personnel in the work area of the hazard
associated with contact or proximity to electrical
lines, the possible consequences should the hazard
occur and how to avoid the hazard.
PN: C4545
Electrocution Hazard Decal
Location: Inside Crane Compartment, on
Compartment Door
Function: To inform the operator of the hazard
associated with contact or proximity to
electrical lines, the possible consequences
should the hazard occur and how to avoid the
hazard.
PN: 4186

Stellar® Heavy-Duty Crane Owner’s Manual
Operation Hazard Decal
Location:Inside Crane Compartment, on
Compartment Door
Function: To inform the operator of the need
for proper training, familiarity with safe
operating procedures and, the possible
consequences without training.
PN: C4540
DANGER
FAILURE TO OBEY THE FOLLOWING
WILL RESULT IN
• Follow all recommended inspections and
maintenance practices listed in the equipment
manufacturer’s manuals. If manuals are
missing from this equipment, contact
manufacturer for replacement.
• Do not modify or alter this equipment without
written manufacturers approval. Use only
manufacturer approved attachments or parts
on this equiupment.
• Equipment must be mounted on factory
recommended chassis. If re-mounted or
rebuilt, the equipment must be re-certified.
4190
DEATH OR SERIOUS INJURY
DANGER
FAILURE TO OBEY THE FOLLOWING
WILL RESULT IN
INSTABILITY OR
STRUCTURAL DAMAGE
• Read, understand and follow the equipment
load and work area charts.
• Do not exceed winch or equipment ratings.
• Do not exceed jib load ratings at reduced
boom lengths.
• Weights of accessories attached to the
boom or loadline must be deducted from
the load chart ratings or be added to the
load weight.
4189
DEATH OR SERIOUS INJURY
DANGER
FAILURE TO OBEY THE FOLLOWING
WILL RESULT IN
• Inspect equipment and its operation daily.
• For equipment stability, use only on solid,
level surface with outriggers properly
extended.
• Equipment must be level.
• Operate all controls slowly and smoothly.
• Never operate the equipment with
personnel under boom or load.
• Keep load under boom tip. Do not side
load boom or drag loads. Avoid free
swinging loads.
• Keep at least 3 wraps of loadline on
winch drum.
• For travel, boom and outriggers must be
in stowed position.
C4544
DEATH OR SERIOUS INJURY
DANGER
AN UNTRAINED OPERATOR
SUBJECTS HIMSELF AND
OTHERS TO
YOU MUST NOT OPERATE
THIS EQUIPMENT UNLESS
• You have been trained in the safe
operation of this equipment.
• You read, understand and follow the
safety and operating recommendations
contained in the equipment manufacturer’s
manuals, your employer’s work rules and
applicable government regulations.
C4540
DEATH OR SERIOUS INJURY
Operation Hazard Decal
Location: Inside Crane Compartment, on
Compartment Door
Function: To inform the operator of the
hazard associated with overloading the
crane, the possible consequences should
the hazard occur, and how to avoid the
hazard.
PN: 4189
Operation Hazard Decal
Location: Inside Crane Compartment, on
Compartment Door
Function: To inform the operator and other
personnel in the work area of the hazard
associated with improper maintenance and
unauthorized modifications, the possible
consequences should the hazard occur, and
how to avoid the hazard.
PN: 4190
Training Decal:
Location:Inside Crane Compartment, on
Compartment Door
Function: To inform the operator of the need for
proper inspection procedures, and the possible
consequences of operation without inspection.
PN: C4544

Safety 
Two Block Hazard Decal
Location: At Boom Tip
Function: To inform the operator of the hazard
associated with bringing the sheave(s) into
contact with the hook, snatch block or load, the
possible consequences should the hazard occur
and how to avoid the hazard. PN: 12300
oving Stabilizer Hazard Decal
Location: On each stabilizer
Function: To inform the operator of the hazard
associated with stabilizer operation, the possible
consequences should the hazard occur, and how
to avoid the hazard. PN: C5918
Foot Crushing Hazard Decal
Location: On each stabilizer leg.
Function: To inform the operator and other
personnel in the work area of the hazard
associated with the operation of the stabilizers, the
possible consequences should the hazard occur,
and how to avoid the hazard. PN: C4795
oving Boom Hazard Decal
Location:Inside Crane Compartment, on
Compartment Door
Function: To inform the operator and other
personnel in the work area of the hazard
associated with a moving boom, especially
while stowing and unfolding the crane, the
possible consequences should the hazard
occur, and how to avoid the hazard.
PN: C4541
DANGER
STOWING & UNFOLDING BOOM
WILL CAUSE
Stand on the opposite side of the boom
when unfolding or stowing the crane.
C4541
DEATH OR SERIOUS INJURY
DANGER
TWO BLOCKING THE CRANE WILL CAUSE
12300
Do not allow the hook block to contact the
boom tip by hoisting up, extending or
lowering the boom.
DEATH, SERIOUS INJURY
OR PROPERTY DAMAGE
DANGER
OUTRIGGERS WILL CAUSE
C4795
SERIOUS CRUSHING INJURY
STAND CLEAR
DANGER
A MOVING OUTRIGGER
WILL CAUSE
SERIOUS CRUSHING INJURY
Do not operate any outrigger unless you or a signal
person can see that all personnel are clear of the
outrigger and its ground contact point.
C5918

Stellar® Heavy-Duty Crane Owner’s Manual
WARNING
MOVEMENT HAZARD
Failure to return the valve
bank manual overrides to
the neutral position can
result in unexpected
crane movement.
25159
WARNING
OVERLOAD HAZARD
Tampering with overload
device voids warranty.
Overloaded crane may let the
load down to the ground.
Winch up, boom down, and
extend out will be
inoperative when thecrane
is in overload condition.
28256
Overload Hazard Decal
Location: At Overload Switch
Function: To inform the operator that
tampering with the overload device may
cause a unit failure.
PN: 28256
DANGER
FREE FALLING
MANUAL BOOM EXTENSION(S)
WILL CAUSE
DEATH OR SERIOUS INJURY
• Do not stand in front of extension(s) when removing retention pin(s)
• Do not let extension(s) free fall.
• Properly install retention pin(s) prior to operation.
12452
Free Falling anual Boom Decal
Location: Inside Crane Compartment, on
Compartment Door
Function: To inform the operator of the hazard
associated with free falling manual boom
extensions, the possible consequences should
the hazard occur, and how to avoid the
hazard.
PN: 12452
-NOTICE-
Do not use the stow hook
for any lifting applications.
For hook stowage only. 24712
Instructional Decal
Location: At Stow ook area
Function: To caution the operator not to use the
stow hook for any lifting applications.
PN: 24712
ovement Hazard Decal
Location: Below Override Controls
Function: To inform the operator that failure
to return the manual overrides to the neutral
position may result in unexpected crane
movement.
PN: 25159


This chapter contains information regarding the operation of Stellar® Telescopic Cranes.
Please study the following pages to ensure your familiarity with the operation process. This
understanding is vital to the safe and efficient operation of the crane.
Operation 
ATTENTION
Operators of Stellar® Telescopic Cranes must conform to the qualifications
specified in ANSI B30.5 - Chapter 5-3 Operation. 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.
Thoroughly plan the lift by understanding your loads and distances before positioning the
vehicle. For a complete and detailed description of job site set-up, please refer to the
AEM Safety Manual (Form C-70-2). Consider the following:
1. The vehicle should be positioned in an area free from overhead obstructions to
eliminate the need for repositioning. The vehicle should be placed 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 in accordance with ANSI B30.5: 5-
3.4.5 Operating Near Electric Power Lines.
2. Make certain that vehicle is parked on stable ground as close to the job as possible.
The supporting surface under the service truck must be able to support the weight of
the machine and its load.
Each day, inspect the crane for all of the following:
1. Vehicle for standard checks such as proper tire inflation and fluid levels.
2. Parking brake operation.
3. ydraulic reservoir for proper oil level.
4. oses and gearboxes for evidence of oil leaks.
5. Crane controls for excessive wear, cleanliness and proper operation.
6. Operational aids such as decals for placement and legibility.
7. All securing hardware such as cotter pins, snap rings, hairpins, and pin keepers for
proper installation.
8. Crane hook and other loose parts for damage to structures or weld.
9. Wire rope for broken wires, extensive wear, distortion, and heat damage.
10. 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.
Pre-Operation Inspection
Job-Site Setup
Chapter 2 - Operation

Stellar® Heavy-Duty Crane Owner’s Manual
The parking brake must be set before any operation.
1. Make certain that the transmission is in neutral/park and that the PTO switch is in the
‘off’ position.
2. Start the vehicle engine.
3. Depress the clutch on manual transmission vehicles.
4. Engage the PTO. Consult the PTO manual for specific instructions if needed.
5. Slowly release the clutch on a manual transmission vehicle.
6. Allow the hydraulic system oil to warm before operating hydraulic equipment.
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 floor 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.
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.
Note: Do not raise the rear tires of the truck off the ground with the stabilizers and pay
particular attention that the truck is as level as possible both front to rear and side to side.
WARNING
oving stabilizers can cause serious crushing injury. ake certain that all
personnel are clear of the stabilizer and the ground contact point before
operating.
Step 4: Position the stabilizers.
Step 3: Turn on power to the crane.
Step 2: Engage the PTO.
Step 1: Set the parking brake.

Operation 
Step 5: Operate the crane.
Operators should have a firm 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:
1. Activate and hold the desired toggle
switch (See next page for details).
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.
Note: The radio remote allows for
simultaneous functions. ith practice, it is
possible to use more than one toggle at the
same time (Extension Out/ inch Down for
example).
Unstowing the Crane:
To unstow the crane and prepare it for a lift:
1. Winch down slightly to disengage the
anti-two block feature.
2. Raise the boom high enough to clear the
boom rest and any other obstructions
from the chassis.
3. Rotate the crane until it clears the side of
the truck body.
4. Lower the crane boom down far enough
so that the snatch block is within
comfortable reach.
5. Winch down to create slack in the wire
rope and unhook the snatch block. Be
very cautious when releasing the snatch
block. Maintain control to avoid personal
injury or damage to any equipment.
Attaching the load:
1. Make sure the hook is centered directly
over the load to minimize swinging.
2. Attach the load to the hook by means of
slings or other approved devices.
3. Know the rated load of the hook used to
pick the load.
4. Do not use a hook to lift personnel.
5. Do not wrap the hoist rope around the
load.
6. Maintain a minimum of 3 full wraps of
wire rope on the winch drum at all times.
Note: Do not load the crane beyond the
rated capacity. It is the responsibility of the
operator to know the weight of both the
rigging and the handled load to avoid
overloading the crane. ,+/1)00'$
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Lifting the load:
1. Lift load slightly off the ground to check
the safety of the cargo. Do not use
stability to determine the safety.
2. Do not attempt to lift fixed loads.
oving the load:
1. Ensure that the load is secure and
balanced within the sling before moving.
2. Be sure that the crane is level and stable
before moving the load. Use stabilizer
pads to ensure the proper distribution of
weight.
3. Be aware of the surroundings: low
branches, power lines, unstable ground,
etc.
4. Do not drag loads with the crane.
5. Do not extend or rotate a load over
anyone.
6. Avoid sudden starts and stops when
moving a load.

 Stellar® Heavy-Duty Crane Owner’s Manual
Radio Remote Control Functions
A. Optional Speed Control/Compressor
Start/Stop Toggle: Push up to start or stop
the optional speed control. Push down to
start or stop the compressor.
B. E-Stop Button: Push to immediately stop
all crane functionality. Note: The E-stop
button is not intended to be an on/off
switch. This is also the first 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.
C. Engine Start/Stop Toggle: Push to start or
stop the engine.
D. Link/Boost Button: Push and hold for 5
seconds to engage boost mode (See the
following page for details on ‘Boost
Mode’). If the remote loses connection
with the transmitter, use this button to
reconnect.
E. Boom Up/Down Toggle: Push up to raise
the boom. Push down to lower the
boom.
F. Extension In/Out Toggle: Push up to
extend the extension. Push down to
retract the extension.
G. Winch Up/Down Toggle: Push up to raise
the winch. Push down to lower the
winch.
H. Rotate Clockwise/Counterclockwise:
Push up to rotate the boom clockwise.
Push down to rotat the boom
counterclockwise.

Operation 
CDT Remote Feedback
If the crane starts to approach full capacity
or an overload situation, the Stellar CDT
sensory feedback system will respond:
0-79% Capacity
LEDs: Green Steady
Vibration: None
System Function: Normal
80-89% Capacity
LEDs: Green Steady, Yellow
Flashing
Vibration: Short Pulsing
System Function: Normal
90-99% Capacity
LEDs: Green Steady, Yellow and
Red Flashing
Vibration: Long Pulsing
System Function: Normal
100% Capacity
LEDs: Green
Steady, Yellow
and Red
Alternate Flashing
Vibration: Long
Pulsing
System Function:
Overload
Shutdown.
When the crane reaches 100% capacity, an
overload shutdown will be initiated. The
operator will need to set the load down
and reposition the truck or activate the
Stellar CDT Boost Mode (If equipped).
Activating Boost ode (If applicable)
Boost Mode allows the crane to operate at
118% of its rated capacity for 30 seconds.
This will give the operator adequate time to
move the crane out of the shutdown
condition without having to set the load
down and reposition the truck.
Follow the steps below to activate boost
mode:
1. Press and hold the Link/Boost Button for 5
seconds. This button is located on the
right side of the handheld controller. You
will know that boost mode is activated by
an indicator light located near the
boost/link button.
2. The crane will go from the ‘standard
mode’ to ‘boost mode’ for 30 seconds.
3. During this minute, the capacity of the
crane is increased to 118% of standard
capacity.
Note: Boost Mode can be reset multiple
times after a 15 second delay.
See the troubleshooting section of this
manual for information regarding
troubleshooting the Stellar® CDT Remote
System.
ATTENTION
If the 118% capacity boost is not
enough to temporarily suspend the
overload shutdown, the operator
will need to set the load down and
reposition the truck.
Radio Remote Feedback and Boost ode

 Stellar® Heavy-Duty Crane Owner’s Manual
Radio Remote Sleep ode
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. Then 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.
Note: The E-stop button is not intended to
be an on/off switch. This is also the first 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.
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.
Radio Remote Control Features
Power On Demand ode (P.O.D.)
When the optional engine speed control is
toggled on, the crane controller will
automatically ramp the engine speed up to
high idle while the crane is actively being
operated. During periods of inactivity the
engine speed will be returned to low idle.
See the Installation, Assembly Drawings, and
Parts Manual for mode selection wiring.

Operation 
Once you have performed your lift and are ready to shut down the work site:
1. Retract all extensions.
2. Winch up to bring the snatch block within 3 feet of the boom tip.
3. Lower the crane boom down far enough so that the snatch block is within comfortable
reach.
4. ook the snatch block to the stow ring on the main boom. Maintain control to avoid
personal injury or damage to any equipment.
5. Tighten the winch line so that the snatch block comes within a few inches of the main
boom. Note: hen tightening slack, avoid activating the
anti-two block switch.
6. Raise the boom slightly above the boom rest.
7. Rotate the boom counter-clockwise until it aligns with the
boom rest. Note: Use alignment arrows located on the
crane base to properly align the boom with the boom rest.
8. Lower the boom gently into the boom rest.
9. Store the radio remote control, preferably in the cab of the
truck.
After stowing the crane:
1. 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.
2. Pull up on the extension lever to fully retract and store the
curb-side stabilizer.
1. Depress the clutch on manual transmission vehicles.
2. Disengage the PTO. Consult the PTO manual for specific instructions if needed.
3. Slowly release the clutch on a manual transmission vehicle. Note: Make sure the PTO
indicator light turns off.
4. Turn off all switches on the VEC control panel. Note: For non-VEC control panels, consult
the manufacturers’ documentation of operation.
The parking brake must be released before moving the truck.
WARNING
Before moving the truck, make certain
that the air tank is completely drained,
even if the compressor was not in use.
Step 9: Release the parking brake.
Step 8: Disengage the PTO and deactivate power.
Step 7: Stow the stabilizers.
Step 6: Stow the crane.

 Stellar® Heavy-Duty Crane Owner’s Manual
PIN "A"
PIN "B"
PIN "A"
PIN "B"
PIN "A"
PIN "B"
Standard 2-Part Line
Sheave Flipped Down
Capacities as shown on load chart.
Single Part Line
Sheave Flipped Down
1) Remove PIN “A” from boom tip.
2) Route wire rope through snatch block.
3) Pin wire rope to snatch block as shown with PIN “A”
Single Part Line
Sheave Flipped Up
1) Remove PIN “B”.
2) Flip sheave.
3) Insert PIN “B” with sheave in upright position.
Wire Rope/Sheave Configurations

Maintenance 
Maintenance is an important part of
extending the life of any Stellar® Telescopic
Crane. Greasing pivot points and rotation
gear bearing on a scheduled maintenance
program will prevent unnecessary
downtime.
Note: Only qualified service personnel are
to perform maintenance on the crane.
General aintenance Procedures
Read the following before performing any
maintenance on the crane:
1. Position the crane where it will be out of
the way of other operations or vehicles in
the area.
2. Lower the boom fully or stow in the
cradle to prevent uncontrolled
movement.
3. Before any service or repair is performed:
A. Disengage the PTO
B. Shut off the engine.
4. Place all controls in the off position and
secure operating features from
inadvertent motion.
5. Before performing any maintenance on
electrical components, disconnect the
power source.
6. 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.
7. Replace parts with Stellar® approved
parts only.
8. Keep the crane and service body clean
and free from grease build-up, oil and dirt
to prevent slippery conditions.
9. Perform all safety and maintenance
checks before each period of use.
10. Label or tag parts when disassembling.
11. Immediately repair or have repaired any
components found to be inadequate.
Inspection Checklist
For a more detailed outline 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.
Crane aintenance Schedule
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
Replace hydraulic return filter. 1000
Hydraulic reservoir suction strainer. 6500
Drain and replace hydraulic oil. 6500
Lubricate PTO and hydraulic pump shaft splines. 6 months
Tighten all hydraulic lines. 6 months
Chapter 3 - aintenance

 Stellar® Heavy-Duty Crane Owner’s Manual
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.
Extension Boom aintenance
Refer to winch manual supplied with crane.
Winch aintenance
Proper maintenance is key in ensuring a long lasting rope. Refer to ANSI B30.5 for details on
maintaining your wire rope.
Wire Rope aintenance
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
ydraulic pump.
PTO and Pump aintenance
Washing the Crane
Important: Prior to washing the Stellar crane, the radio remote receiver located on the
crane mast must be covered to prevent any water from entering the plastic housing.
Avoid any direct water pressure to the radio remote receiver.
Stellar Industries recommends the first filter change to occur after the first 250 hours of serv-
ice. The second, and every subsequent change, should occur after every 1,000 hours of
service. By following these guidelines, the hydraulic oil should last up to 6,500 hours.
Note: These recommendations are based on normal working parameters. If operating in
less than favorable conditions excessive dust, moisture, etc.), be sure to check the filter
gauge often for filter change notice.
Hydraulic Oil/Filter aintenance