stellar labs 5521 Owner's Manual

Light-duty telescopic cranes

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Owner's manual (42 pages)

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Page 1 Light-Duty Telescopic Cranes Owner’s Manual Safety • Operation • Maintenance • Troubleshooting Model 5521 Model 4421 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 Stellar Industries, Inc.
Page 2 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 service@stellarindustries.com Order Parts parts@stellarindustries.com...
Page 3: Table Of Contents
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.
Page 4: Introduction
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.
Page 5: Chapter 1 - Operation
Chapter 1 - Operation 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. 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.
Page 6: Job Site Setup
Job Site Setup 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: •...
Page 7: Step 3: Turn On Power To The Crane
Step 3: Turn on power to the crane. 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.
Page 8: Step 5: Operate The Crane
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: Non-Proportional Remote Control Version 1.
Page 9 • Make certain that the stabilizers are positioned on flat, stable ground. WARNING • 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.
Page 10: Step 6: Stow The Crane
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.
Page 11: Step 9: Release The Parking Brake
Step 9: Release the parking brake. The parking brake must be released before moving the truck. WARNING Make certain that any air tanks are completely drained before moving the truck. Radio Remote Control Functions A. Optional Speed Control/Compressor Start/Stop Toggle: Push up to start or stop the option al speed control.
Page 12: Radio Remote Control Features
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.
Page 13: Personal Fall Protection With Stellar ® Equipment
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, specifically 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.
Page 14: Safety Decals Of Note
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.
Page 15: Crane Compartment
Crane Compartment DANGER Decal Part Number: 4186 Electrocution Hazard Decal Location: Crane Compartment Death or serious injury will Hazard Type: Electrocution Hazard result from touching tethered Consequences: Will result in death or serious injury. remote if crane, load, or vehicle Avoidance: Maintain safe clearance from high becomes electrically charged.
Page 16: Main Boom
Main Boom WARNING Decal Part Number: 12451 Decal Location: Main Boom Fall Hazard Hazard Type: Fall Hazard Hoisting personnel on boom, Consequences: Can result in death or serious injury. hook, load, or loadline can result in death or serious injury. Avoidance: Never use the crane to hoist personnel.
Page 17: Crane Horse Head
Crane Horse Head WARNING 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 Misuse Hazard the boom.
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Page 19: Chapter 2 - Maintenance
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. General Maintenance Guidelines Before performing any maintenance to the crane, •...
Page 20: Hydraulic Oil/Filter Maintenance
Hydraulic Oil/Filter Maintenance Stellar Industries recommends the first filter change to occur after the first 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.
Page 21: Rotation Gear Bearing Maintenance
Rotation Gear Bearing Maintenance Rotation Worm Gear and Open Gear Teeth Use a heavy Moly Lube grease (Stellar PN 4460) to lubricate the worm gear and open gear teeth of the rotation bearing. Slowly rotate the crane while pumping the grease between the worm and rotation gear.
Page 22: Gear-Bearing Bolt Maintenance
Gear-Bearing Bolt Maintenance 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 Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical grade and size.
Page 23: Rotation Gear Bearing Thread Tightening Procedure
Rotation Gear Bearing Thread Tightening Procedure GRADE 5 GRADE 8 GRADE 9 Size Bolt DIA Plain Plated Plain Plated Plated (DIA-TPI) (Inches) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) 5/16-18 0.3125 3/8-16 0.3750 7/16-14 0.4375 1/2-13 0.5000 9/16-12 0.5625 5/8-11 0.6250 3/4-10 0.7500 7/8-9 0.8750...
Page 24: Rotation Gear Bearing Tilt Test
Step 5: Check and record the dial indicator change. It should not exceed the following tilt measurements: • Stellar Models 3315-5521 = 0.060” (1.524 mm) Step 6: Return the crane to vertical position. The dial indicator should return to calibration. Page 20 | Stellar Light-Duty Telescopic Crane Owner’s Manual...
Page 25: Rotation Gear Bearing Worm End Play & Backlash
Rotation Gear Bearing Worm End Play & Backlash Stellar Telescopic Cranes have an integral base and worm drive rotation system. ® Backlash is the shortest distance between non-driving tooth surfaces in mating gears. Measure backlash using a feeler gauge at or near the pitch diameter and tangent to the gear. Locate High Tooth To set both Worm End Play and Backlash, first locate the high tooth on the gear.
Page 26: Face Seal/O-Ring Size Chart
Face Seal/O-Ring Size Chart Hose Fitting Face Seal (A) O-ring Boss (B) Size Size Stellar Stellar ® ® 1/4” C2027 D1245 3/8” C2028 D1246 1/2” C2029 D1247 5/8” 32223 D1248 3/4” D1244 D1249 Page 22 | Stellar Light-Duty Telescopic Crane Owner’s Manual ®...
Page 27: Lubrication Recommendations
Lubrication Recommendations Crane Lubrication Component Location Recommendation Reservoir Below –5˚F High VI, low pour, ISO 22, AW hydraulic oil Hydraulic System -5˚F to 90˚F High VI, low pour, ISO 32, AW hydraulic oil Above 90˚F ISO 46, AW hydraulic oil Open Gear Teeth Crane Rotation Gear Moly Grease 936SF Heavy (Stellar PN 4460)
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Page 29: Chapter 3 - Troubleshooting
Chapter 3 - Troubleshooting This chapter will list a number of potential problems that may occur while operating the crane. Most problems are easily solved using the solutions portion of this chapter. If problems persist, please contact Customer Service at Stellar Industries 1-800-321-3741. Serial Tag Location ®...
Page 30 loose ground connection. Refer to radio remote troubleshooting guide at the end of this chapter. • Make sure that the parking brake is engaged. • Make sure that the parking brake switch is working properly. Check the parking brake switch by performing a continuity test. If the switch is defective, simply replace it. Problem: Not all crane functions operate using the radio remote transmitter or crane operates intermittently.
Page 31 Solutions: • Check the level of hydraulic fluid in the reservoir. Add fluid as needed. • Check hydraulic fluid temperature. Problem: Winch “Up”, Main Cylinder “Down”, and Extension Cylinder “Out” are the only functions that don’t operate. Solutions: • Make sure that the anti-two block limit switch on the end of the boom is adjusted properly or operating per adjustment (If applicable).
Page 32: Radio Remote Troubleshooting
Radio Remote Troubleshooting If the system does not operate after normal start-up, follow the recommended troubleshooting sequence to help isolate the cause and determine corrective action. Transmitter Receiver • Is the E-Stop pushbutton pulled out? • Is the antenna plug securely connected? •...
Page 33: Transmitter Troubleshooting
Transmitter Troubleshooting Notice: When testing the transmitter, the receiver may become active resulting in system operation. Always assume the system is working and will respond when testing a transmitter. Status LED Troubleshooting LED Indication Possible Cause LED is off Transmitter is off. LED flashes Transmitter is operationg in a normal mode.
Page 34: Manual Operation
Manual Operation If the remote control malfunctions, follow these steps to operate the crane manually: Non-Proportional Control Version 1. 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.
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4421 3315

stellar labs 5521 Owner's Manual

Chapter 1 - Operation

Chapter 2 - Maintenance

Chapter 3 - Troubleshooting

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