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O
WNER
Safety, Installation, Maintenance, and Operation
Subject to Change without Notification.
© 2009 Stellar Industries, Inc.
'
S
4420 Telescopic Crane
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
www.stellarindustries.com
M
ANUAL
4420
®
24700
Manual Part No. 31706
Last Revision: 10/10/09
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- Page 1 ’ WNER ANUAL Safety, Installation, Maintenance, and Operation 4420 Telescopic Crane 4420 ® 24700 Stellar Industries, Inc. 190 State Street PO Box 169 Garner, IA 50438 800-321-3741 Fax: 641-923-2811 www.stellarindustries.com Subject to Change without Notification. Manual Part No. 31706 © 2009 Stellar Industries, Inc.
- Page 2 4420 Manual Revisions Date of Revision Section Revised Description of Revision September 9, 2006 Chapter 7: Updated Cable and Hook assembly drawings to reflect Assembly Drawings engineering changes. November 7, 2006 Chapter 7: Assembly Drawings Updated Base assembly drawings and Hydraulic...
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Page 3: Table Of Contents
Chapter 8 - Hydraulics - Electrical ....45 Proportional Version 4420 Manual Override ......5 Control Kit (Corded Electrical Version) - Operator Information . -
Page 4: Introduction
4420 Owner’s Manual Introduction Stellar Cranes are designed to provide safe Please be aware that some sections of this and dependable service for a variety of manual contain information pertaining to operations. With proper use and Stellar manufactured cranes in general and... -
Page 5: Chapter 1 - Safety
Safety Chapter 1 - Safety Please Read the Following Carefully! This Do not wear rings, wristwatch, jewelry, loose- portion of the manual contains information fitting or hanging clothing such as ties, torn regarding all Stellar manufactured cranes. garments, scarves, unbuttoned jackets or Some items contained within this chapter unzipped overalls, which could get caught up may not apply to your specific equipment. - Page 6 4420 Owner’s Manual STABILITY Do not walk under suspended loads. Know the crane components and their capabilities and limitations. Overloading the Do not position any load over a person nor crane may result in serious injury to self and should any person be permitted to place him others, and damage to the equipment and or herself under a load.
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Page 7: Chapter 2 - Operation
Operation Chapter 2 - Operation Crane Controls This chapter contains information regarding the operation of Stellar manufactured 1. Be familiar with the sequence and telescopic cranes. Please study the operation of the crane controls. following pages to ensure your familiarity with the operation process. -
Page 8: Crane Operation
4420 Owner’s Manual Crane Operation 3. Position Outriggers 1. Engage the PTO Once the PTO is engaged, extend the outriggers A. Engage the parking brake. using the control levers or switches marked B. Place the transmission in the Neutral position. -
Page 9: Manual Operation
6. Do not drag loads with the crane. 7. Do not attempt to lift fixed loads. Proportional Version 4420 Manual Override 8. Do not load boom in a sideways direction. 1. Activate Flow Control. 9. Know the weight of the rigging and load to Turn the override screw on flow control counter- avoid overloading the crane. -
Page 10: Operator Information
4420 Owner’s Manual Operator Information OPERATOR REQUIREMENTS OPERATOR CONDUCT 1. Operation is limited to the following 1. Operators will not engage in any people: operation that would cause them to divert A. Designated individual. attention away from the operation of the B. -
Page 11: Chapter 3 - Maintenance
Maintenance Chapter 3 - Maintenance Daily Inspection WARNING - Read the Following before Daily Inspection should occur each day performing any maintenance on the before the crane is put into use. Each day, crane. inspect the crane for all of the following: 1. - Page 12 4420 Owner’s Manual Weekly Inspection Service Weekly Inspection should occur at the The following general suggestions should beginning of every work week. Each week, be helpful in analyzing and servicing your inspect the crane for all of the following: crane. Using the following systematic 1.
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Page 13: Lubrication Recommendations
Maintenance Lubrication Recommendations Component Location Recommendation Engine Crankcase Apply Manufacturer’s Recommendations Hydraulic System Reservoir Below –5*F Petro-Canada Arctic MV 15 (ISO 22) -5*F to 90*F Petro-Canada HYDREX 32 (ISO 32) Above 90*F Petro-Canada HYDREX 46 (ISO 46) Open Gears Hand Precision XL3 Moly EP 2 (NLGI 2 grease with moly) Bearings, grease... -
Page 14: Wire Rope Maintenance
4420 Owner’s Manual Wire Rope Maintenance surface wires of the rope need to be inspected. This inspection will be concerned with discovering damage Wire Rope Inspection Points that may be an immediate hazard. The While inspection of the entire rope is... -
Page 15: Torque Data Chart
Maintenance Holding Valve Inspection Procedure Torque Data Chart 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 Grade 5 Grade 8 Grade 9 valve is checked in the following manner: 1. -
Page 16: Inspection Checklist
4420 Owner’s Manual Inspection Checklist Type of Inspection (check one) Use of this checklist is subject to terms of the Daily Quarterly Stellar Warranty information. Additional copies of (if deficiency found) this checklist can be obtained by contacting Monthly Annual Stellar Customer Service at (800) 321-3741. -
Page 17: Daily Inspection
Maintenance Daily Inspection Frequency Inspection Description Status Decals All load charts, safety & warning Decals, & control Decals are present and legible. Check all safety devices for proper operation. Controls Control mechanisms for proper operation of all functions, leaks, & cracks. Station Control mechanisms for proper operation of all functions, leaks, &... -
Page 18: Monthly Inspection
4420 Owner’s Manual Monthly Inspection Frequency Inspection Description Status Daily All Daily Inspections. Cylinders Visual inspection of cylinders for leakage at rod, fittings, & welds. Damage to rod & case. Valves Holding valves for proper operation. Valves Control valve for leaks at fittings & between sections. -
Page 19: Quarterly Inspection
Maintenance Quarterly Inspection Frequency Inspection Description Status Daily All daily inspections. Monthly All monthly inspections. Rotation Sys Rotation bearing for proper torque of all mounting bolts. Hardware Base mounting bolts for proper torque. Structure All structural members for deformation, cracks, & corrosion. Base Outrigger beams &... - Page 20 4420 Owner’s Manual Quarterly Inspection Continued... Frequency Inspection Description Status Hyd Lines Hoses, fittings, & tubing for proper routing, leakage, blistering, deformation, & excessive abrasion. Pressure line(s) from pump to control valve Return line(s) from control valve to reservoir Suction line(s) from reservoir to pump...
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Page 21: Annual Inspection
Maintenance Annual Inspection Frequency Inspection Description Status Daily All daily inspection items. Monthly All monthly inspection items. Quarterly All quarterly inspection items. Hyd System Hydraulic fluid change per maintenance schedule. Controls Control valve calibration for correct pressures & relief valve settings. Valves Safety valve calibration for correct pressures &... -
Page 22: Inspection Notes
4420 Owner’s Manual Inspection Notes... -
Page 23: Chapter 4 - Specifications
Specifications Chapter 4 - Specifications Model 4420 Crane SPECIFICATION SHEET Crane Rating: 16,000 ft-lbs (2.23 ton-meters) Standard Boom Length: 10’ (3.05 m) from CL of Crane Boom Extension: 1st stage: Hydraulic 60" (152.4 cm) 2nd stage: Manual 60" (152.4 cm) Maximum Horizontal Reach: 20’... -
Page 24: Capacity Chart - Decal Pn 24701
4420 Owner’s Manual Capacity Chart - Decal PN 24701 3500# 1590 kg 3075# 21'6'' 1395 kg 6.55 m 1600# 725 kg 4000# 5.49 m 4000# 1815 kg 1125# 1815 kg 510 kg 2125# 4.57 m 965 kg 1500# 4000# 680 kg... -
Page 25: Chapter 5 - Decals
Decals Chapter 5 - Decals Decals of Note Foot Crushing Hazard Decal Location: On each outrigger leg. Function: To inform the operator and other personnel in the work area of the hazard associated with the operation of the outriggers, the possible consequences should the hazard occur, and how to avoid the hazard. - Page 26 4420 Owner’s Manual 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.
- Page 27 Decals 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 Instructional Decal Location: At Overload Switch Function: To inform the operator that...
- Page 28 4420 Owner’s Manual Free Falling Manual Boom Decal Electrocution Hazard Decal Location: Inside Crane Compartment, on Location: Inside Crane Compartment, on Compartment Door Compartment Door Function: To inform the operator of the hazard Function: To inform the operator of the hazard...
- Page 29 Decals Operation Hazard Decal Moving Boom Hazard Decal Location:Inside Crane Compartment, on Location:Inside Crane Compartment, on Compartment Door Compartment Door Function: To inform the operator of the need Function: To inform the operator and other for proper training, familiarity with safe personnel in the work area of the hazard operating procedures and, the possible associated with a moving boom, especially...
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Page 30: Decal Kit Placement - Pn 24332
4420 Owner’s Manual Decal Kit Placement - PN 24332 PN 24332... -
Page 31: Chapter 6 - Installation
According to Federal Law (49 cfr part 571), general guide for the installation of a Stellar each final-stage manufacturer shall 4420 Telescopic Crane on a Stellar Service complete the vehicle in such a manner that Body. Each installation is considered unique... -
Page 32: Installation Overview
Installation Overview 1. Determine that the mounting location for the 4420 crane is at least 18” x 15” (45.7 x 38.1 cm). 2. Use the detail below to drill .938” diameter holes into the mounting plate. Run tap on the threads of the base to be sure they are clean. -
Page 33: Installation Details
Installation Installation Details 1. Determine that the mounting location for the 4420 crane is at least 18” x 15” (45.7 x 38.1 cm). 2. Use the detail on the previous page to drill .938” diameter holes into the mounting plate. Run tap on the threads of the base to be sure they are clean. -
Page 34: Stability Procedure
4420 Owner’s Manual Stability Procedure Definition of Stability for the Stellar Telescopic Crane Products: A truck is stable until the load cannot be lifted off the ground with the winch, without tipping over the truck. Every Stellar crane installed must be tested for stability to determine the actual load capacity of the final truck package. -
Page 35: Stability Capacity Chart
Installation Stability Capacity Chart STABILITY CAPACITY CHART For a decal version of this capacity chart, please contact Stellar Customer Service at (800) 321-3741... - Page 36 4420 Owner’s Manual...
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Page 37: Chapter 7 - Assembly Drawings
Assembly Drawings Chapter 7 - Assembly Drawings Base Assembly - PN 19998 GASKET SHOWN AS REFERENCE D0240 SHOWN AS REFERENCE (INCLUDED WITH GEAR BEARING) PN 19998 16653 BEARING SWING DRIVE CAST D1307 CAP SCR 0.50-13X1.25 SH 18948 CAP SCR 0.88-9 X .63 PLASTIC 0479 CAP SCR 0.25-20X0.75 HHGR5 D0240... -
Page 38: Mast Assembly (Corded Remote Version)
4420 Owner’s Manual Mast Assembly (Corded Remote Version) - PN 19999 PN 19999... -
Page 39: Mast Assembly (Radio Remote Version)
Assembly Drawings Mast Assembly (Radio Remote Version) - PN 44647 PN 44647 D0178 WASHER #10 SAE FLAT ZINC D1711 CAP SCR #10-24X0.50 BTNHD SS C5902 WASHER 0.63 SAE FLAT YELLOW GR8 C1026 CAP SCR 0.63-11X2.50 HHGR8 ZY 21810 BUSHING GSI-2426-12 1.50X0.75 24957 VB 4 SECT ELECT ON/OFF STERLING4GPM 0489... -
Page 40: Mast Assembly (Proportional Version)
4420 Owner’s Manual Mast Assembly (Proportional Version) - PN 50596 RECEIVER SHOWN AS REFERENCE PN 50596 50597 MAST 3315 HYD PROP H2 C5902 WASHER 0.63 SAE FLAT YELLOW GR8 C1026 CAP SCR 0.63-11X2.50 HHGR8 ZY 21810 BUSHING GSI-2426-12 1.50X0.75 C0930 CAP SCR 0.31-18X3.00 HHGR5... -
Page 41: Power Unit Assembly (Electric Version)
Assembly Drawings Power Unit Assembly (Electric Version Only) - PN 20432 PN 20432... -
Page 42: Main Boom Assembly - Pn 24568
4420 Owner’s Manual Main Boom Assembly - PN 24568 PN 24568 & & &... -
Page 43: Extension Boom Assembly - Pn 24570
Assembly Drawings Extension Boom Assembly - PN 24570 PN 24570 19457 WEAR PAD 0.25X1.38 RND 19496 WEAR PAD .88X1.38 RND 19497PC PLATE 1ST EXT 3315 WEAR PAD 5591 WASHER 0.31 SAE FLAT YELLOW GR8 0420 CAP SCR 0.31-18X0.75 HHGR5 0337 HOSE CLAMP LN 4190 PP 0220 CAP SCR 0.25-20 X 1.50 HHGR5... -
Page 44: Extension Boom Assembly (Optional)
CAP SCR 0.31-18X0.75 HHGR5 0337 HOSE CLAMP LN 4190 PP 0220 CAP SCR 0.25-20 X 1.50 HHGR5 30791 EXT BOOM 2ND 4420 SUMMIT 27719 SPACER BOOM TIP 6620 UHMW 12178 CAP SCR 0.31-18X3.25 HHGR5 11545 SHEAVE 6620 6.75 DIA .31R/1.94 THK 9706 PIN TEAR DROP 1.00X3.25... -
Page 45: Main Cylinder Assembly - Pn 25160
Assembly Drawings Main Cylinder Assembly - PN 25160 Note: Main Cylinder uses Stellar Seal Kit P/N 35652 Cylinder Serial Tag Location CYLINDER BUSHINGS FOR REFERENCE ONLY PN 25160 24699 CYLINDER 3.50X19.88 0279 FTG ADAPT 6-F5OLO-S 19363 TUBE ASM 0.38X5.69 3315 13080 MANIFOLD SINGLE T11A 3500 PSI 15173... -
Page 46: Extension Cylinder Assembly
4420 Owner’s Manual Extension Cylinder Assembly - PN 25881 Note: Extension Cylinder uses Stellar Seal Kit P/N 35653 PN 25881 Cylinder Serial Tag Location... -
Page 47: Cable & Hook Assembly - Pn 38203
Assembly Drawings Cable & Hook Assembly - PN 38203 P/N 38203 11934 SHEAVE 6620 6.50 DIA .31R/1.12 THK 37120PC PLATE 6620 SNATCH BLOCK 27812 SPACER 6620 SNATCH BLOCK UHMW 11666PC SPACER 5520 SNATCH BLOCK 4975 CAP SCR 0.75-10X3.50 HHGR8 ZY C6219 WASHER 0.75 SAE FLAT YELLOW GR8 C0538... -
Page 48: Basket Cable & Hook Assembly (Optional)
4420 Owner’s Manual Basket Cable & Hook Assembly (Optional) - PN 48109 PN 48109 11934 SHEAVE 6620 6.50 DIA .31R/1.12 THK 27812 SPACER 6620 SNATCH BLOCK UHMW 11666PC SPACER 5520 SNATCH BLOCK 4975 CAP SCR 0.75-10X3.50 HHGR8 ZY C6219 WASHER 0.75 SAE FLAT YELLOW GR8 9263 PIN .38X3.00 QUICK RELEASE... -
Page 49: Chapter 8 - Hydraulics - Electrical
Hydraulics - Electrical Chapter 8 - Hydraulics - Electrical Control Kit (Corded Electrical Version) - PN 20435 PN 20435... -
Page 50: Control Kit (Radio Electrical Version)
4420 Owner’s Manual Control Kit (Radio Electrical Version) - PN 44737 SWITCH PRESSURE SWITCH RADIO CONTROL (TRANSMITTER) PUSH BUTTON ROT CCW INNER INNER DOWN SOLENOID NOTE: 1)HEAT SHRINK TO BE CUT TO 3" PIECES WINCH 2)FOR SHIP OUT CABLE CONNECTORS... -
Page 51: Control Kit (Corded Hydraulic Version)
Hydraulics - Electrical Control Kit (Corded Hydraulic Version) - PN 24331 PN 24331... -
Page 52: Control Kit (Radio Hydraulic Version)
4420 Owner’s Manual Control Kit (Radio Hydraulic Version) - PN 44739 SWITCH PRESSURE SWITCH RADIO CONTROL (TRANSMITTER) ROT CCW INNER INNER DOWN WINCH See Note 1 WINCH UP DOWN NOTES: 1.) PLUG INTO STELLAR WIRE HARNESS OR RUN 12GA WIRE TO THE BATTERY. -
Page 53: Control Kit (Radio Version)
Hydraulics - Electrical Control Kit (Radio Version) - PN 41051 PN 41051... -
Page 54: Control Kit (Proportional Version)
4420 Owner’s Manual Control Kit (Proportional Version) - PN 43693 PN 43693... -
Page 55: Hydraulic Kit (Electrical Version)
Hydraulics - Electrical Hydraulic Kit (Electrical Version) - PN 25882 PN 25882 49315 SWITCH PRES OVERLD CD-11C-2900R/WD... -
Page 56: Hydraulic Kit (Hydraulic Version)
4420 Owner’s Manual Hydraulic Kit (Hydraulic Version) - PN 25885 PN 25885 49315 SWITCH PRES OVERLD CD-11C-2900R/WD... -
Page 57: Hydraulic Kit (Proportional Version)
Hydraulics - Electrical Hydraulic Kit (Proportional Version) - PN 50604 PN 50604... - Page 58 4420 Owner’s Manual Valve Bank (Standard Hydraulic Version) - PN 24957 P/N 24957 Valve Identification Valve Item #2 P/N 25377 G02571 Valve Item #3 P/N 25378 G02591...
- Page 59 Hydraulics - Electrical Valve Bank (Proportional Version) - PN 24960 P/N 24960 Valve Identification Valve Item #3 P/N 25371 GS0457 Valve Item #4 P/N 25378 GS0459...
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Page 60: Hydraulic Installation
4420 Owner’s Manual Hydraulic Installation 1. After mounting, locate the pressure and return lines. Note: Pressure line is 3/8” hose; Return line is 1/2” hose. Hoses are terminated using swivel fittings. 2. Install hydraulic lines per diagram below. Note: Outrigger valve supplies oil to crane using the Power Beyond feature. -
Page 61: Hydraulic System
Hydraulics - Electrical Hydraulic System... - Page 62 4420 Owner’s Manual...
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Page 63: Chapter 9 - Replacement Parts
Replacement Parts Chapter 9 - Replacement Parts PART# DESCRIPTION D1204 HYDRAULIC SWING MOTOR 25375 RELIEF VALVE 25376 SEAL KIT - RELIEF VALVE 26196 FLOW CONTROL VALVE 25377 SOLENOID VALVE TAND G02571 25378 SOLENOID VALVE OPEN G02591 25379 SEAL KIT - SOLENOID VALVE 25380 COIL - 12VDC 15110... - Page 64 4420 Owner’s Manual...
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Page 65: Chapter 10 - Troubleshooting
Troubleshooting Chapter 10 - Troubleshooting This chapter will list a number of Problem: Not all crane functions operate using potential problems that may occur while the radio remote transmitter or crane operates intermittently. operating the crane. Most problems are Solutions: easily solved using the solutions portion •... - Page 66 4420 Owner’s Manual Problem: Winch will not hold load. Problem: Winch “Up”, Main Cylinder “Down”, Solutions: and Extension Cylinder “Out” are the only functions that don’t operate. • Make sure that the object being lifted does not exceed the rated capacity of the winch.
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Page 67: Function Hetronic Radio Remote
Troubleshooting 5 Function Hetronic 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 •... -
Page 68: Receiver Troubleshooting
4420 Owner’s Manual 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... -
Page 69: Troubleshooting
6 Function Hetronic 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 •... -
Page 70: Receiver Troubleshooting
4420 Owner’s Manual 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... -
Page 72: Warranty Information
Limited Warranty Statement Stellar Industries, Inc. (Stellar) warrants products designed and manufactured by Stellar to be free from defects in material and workmanship under proper use and maintenance. Products must be installed and operated in accordance with Stellar’s written instructions and capacities. The warranty period shall cover the following: Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date of manufacture,...
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