The provided manual describes the Stellar Light-Duty Crane, specifically models 3315, 4420, and 5520. It serves as an owner's manual covering safety, operation, maintenance, and troubleshooting.
Function Description:
The Stellar Light-Duty Crane is designed to provide safe and dependable service for a variety of lifting operations. It is a telescopic crane, meaning its boom extends and retracts. The crane is operated via a radio remote control, which can be either non-proportional or fully-proportional, allowing for precise control over crane movements. Key functions include boom up/down, extension in/out, winch up/down, and rotation (clockwise/counterclockwise). The crane is typically mounted on a service truck and requires the vehicle's parking brake to be set and the Power Take-Off (PTO) to be engaged for operation. Stabilizers (outriggers) must be properly positioned on stable, flat ground to ensure stability during lifts.
Important Technical Specifications:
While specific load capacities are not detailed in the provided excerpts, the manual repeatedly emphasizes adherence to load capacity charts and warns against exceeding manufacturer's load ratings. It highlights that ratings are based on hydraulic, mechanical, and structural design, not solely stability. The crane utilizes a hydraulic system, with recommendations for specific hydraulic oils based on temperature (ISO 22, 32, or 46 AW hydraulic oil). The system includes a hydraulic reservoir and filters, with a first filter change recommended after 250 hours and subsequent changes every 1,000 hours. Hydraulic oil should be drained and replaced every 6,500 hours. The manual also specifies torque data for various bolt sizes (Grade 5, 8, and 9) in foot-pounds for both plain and plated bolts, emphasizing the use of Loctite Threadlocker sealant for new bolts.
Usage Features:
- Radio Remote Control: The primary method of operation. It features an E-Stop button for immediate crane shutdown, optional speed control/compressor start/stop, engine start/stop, boom up/down, extension in/out, winch up/down, and rotation controls.
- Proportional Control: Fully-proportional versions allow for variable speed control based on trigger engagement, enabling smoother and more precise movements.
- Simultaneous Functions: The radio remote allows for multiple functions to be operated concurrently (e.g., Extension Out/Winch Down).
- Power On Demand (P.O.D.): An optional feature where the crane controller automatically ramps the engine speed to high idle during active operation and returns to low idle during inactivity, optimizing fuel efficiency.
- Backup Cord: In case of radio remote malfunction, a backup control cord can be connected directly to the transmitter and receiver for continued operation.
- Manual Operation: A manual override system is available for troubleshooting or in case of remote control failure. This involves activating flow control and operating individual solenoid valves. However, a critical warning states that overload and anti-two block protection features are disabled during manual operation, and it should not be used for lifts.
- Job-Site Setup: Emphasizes thorough planning, positioning the vehicle on stable ground free from overhead obstructions, and maintaining safe clearances from power lines (in accordance with ANSI B30.5: 5-3.4.5). Stabilizers must be fully extended and make solid contact with the ground, ensuring the truck is as level as possible.
- Load Safety: Strict adherence to load capacity charts, knowing the load weight, using approved slings, and maintaining a minimum of 3 full wraps of wire rope on the winch drum are crucial. Warnings against side loads, dragging loads, and operating under suspended loads are provided.
Maintenance Features:
The manual outlines a comprehensive maintenance schedule and procedures:
- Daily Inspections: Vehicle checks (tire inflation, fluid levels), parking brake, hydraulic reservoir oil level, hoses and gearboxes for leaks, crane controls for wear/cleanliness, decals for legibility, securing hardware, crane hook/loose parts for damage, wire rope for damage, and safety guards.
- Scheduled Maintenance:
- Hydraulic Oil/Filter: First filter change at 250 hours, subsequent changes every 1,000 hours. Hydraulic oil replacement every 6,500 hours.
- Greasing:
- Rotation gear inner race bearings: Weekly (alternating positions).
- Rotation gear worm drive bearings: Every 3 months.
- Rotation gear open gear teeth: Monthly (using heavy Moly Lube grease, Stellar PN 4460).
- Cylinder pivot points: Monthly.
- Extension booms: Monthly (using aerosol lubricant, Stellar PN 44512).
- Winch gear grease level: Monthly.
- PTO and hydraulic pump shaft splines: Every 6 months (using Stellar PN 20885).
- Other: Tighten all hydraulic lines every 6 months.
- Washing: Important to cover the radio remote receiver on the crane mast to prevent water entry.
- Wire Rope & Winch: Refer to ANSI B30.5 for wire rope maintenance and the winch manual for winch-specific maintenance.
- Extension Boom: Lubricate if noisy during operation, especially due to the metal coating.
- Gear-Bearing Bolt Maintenance: Any removed gear-bearing bolt must be replaced with an identical new bolt, secured with Loctite Threadlocker sealant.
- General Procedures: Emphasizes performing maintenance only by qualified personnel, positioning the crane safely, lowering the boom, disengaging PTO, shutting off the engine, relieving hydraulic pressure, using Stellar® approved parts, and keeping the crane clean.
Safety Decals of Note:
The manual includes descriptions and locations of various safety decals, highlighting critical hazards:
- Electrocution Hazard: Warnings about contact with power lines, lack of insulation, and maintaining safe clearances (PN: 4186, C1179, C4545).
- Hoisting Personnel: Strict prohibition against lifting personnel (PN: 12451).
- Operation Hazard: Warnings about improper maintenance, unauthorized modifications, overloading, and the need for proper training (PN: 4190, 4189, C4540).
- Moving Boom Hazard: Warning to stand clear when stowing or unfolding the boom (PN: C4541).
- Two Block Hazard: Warning against the hook block contacting the boom tip (PN: 12300).
- Moving Outrigger/Foot Crushing Hazard: Warnings to ensure personnel are clear of stabilizers during operation (PN: C5918, C4795).
- Movement Hazard: Warning if valve bank manual overrides are not returned to neutral (PN: 25159).
- Overload Hazard: Warning against tampering with the overload device (PN: 28256).
- Free Falling Manual Boom Extension(s): Warning about removing retention pins (PN: 12452).
- Stow Hook Notice: Not to be used for lifting applications, only for hook stowage (PN: 24712).
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