stellar labs 4500 Owner's Manual

Articulating crane

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Owner's manual (43 pages)

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Owner's Manual

Safety, Installation, Maintenance, and Operation

Subject to Change without Notification.

4500 Articulating Crane

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com

Manual Part No. 37809

Last Revision: 4/6/09

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Page 1 Owner’s Manual Safety, Installation, Maintenance, and Operation 4500 Articulating Crane Stellar Industries, Inc. 190 State Street PO Box 169 Garner, IA 50438 800-321-3741 Fax: 641-923-2811 www.stellarindustries.com Manual Part No. 37809 Subject to Change without Notification. © 2009 Stellar Industries, Inc.
Page 2 4500 Manual Revisions Date of Revision Section Revised Description of Revision October 22, 2008 Chapter 8: Updated Hydraulic Kit Versions to reflect engineering Hydraulics-Electrical changes (New Pressure Switch). Chapter 9: Replacement Parts Stellar 4500 Manual...
Page 3 Introduction Stellar Articulating Cranes are designed to kept with no requirement or obligation for provide safe and dependable service for a variety immediate mandatory updating of this manual. operations. With proper maintenance, these cranes will operate at peak This product manual is not intended as a training performance for many years.
Page 4: Table Of Contents
Chapter 2 - Operation Chapter 3 - Maintenance Chapter 4 - Specifications Chapter 5 - Decals Chapter 6 - Installation Chapter 7 - Assembly Drawings Chapter 8 - Hydraulics/Electrical Chapter 9 - Replacement Parts Chapter 10 - Troubleshooting 10-1 Stellar 4500 Manual...
Page 5: Chapter 1 - Safety
If necessary, replace them. Consult your employer regarding current safety regulations and accident-prevention equipment. Stellar 4500 Manual...
Page 6 Do not leave a crane load suspended or machinery. unattended. In high humidity work areas, keep parts as dry as Do not walk under suspended loads. possible and well lubricated. Stellar 4500 Manual...
Page 7 Be familiar with your remote control and how it works before operating the crane. Your remote may differ from those pictured above. Stellar 4500 Manual...
Page 8: Chapter 2 - Operation
A. On manual transmission vehicles, depress 5. Store Outriggers the clutch pedal completely. B. Disengage the PTO switch. 6. Turn Off Power to Crane C. If vehicle is a manual transmission, release the clutch 7. Disengage the PTO pedal gradually. Stellar 4500 Manual...
Page 9 2. Do not store or carry battery so that metal objects can contact exposed metal end. Keep battery cap on when not in use. 3. The batteries should be recharged when they fail to produce sufficient power. 4. Never attempt to open the battery for any reason. Stellar 4500 Manual...
Page 10 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. The crane MUST be in the stored position before transporting. Stellar 4500 Manual...
Page 11 F. Understand the operating procedures the load to minimize swinging. as outlined by this manual, ANSI F. No suspended load should pass over B30.2, and Federal/State Laws. a person. G. Avoid sudden starts and stops when moving a load. Stellar 4500 Manual...
Page 12: Chapter 3 - Maintenance
5. Relieve hydraulic oil pressure from all lubrication, and tightness. hydraulic circuits before loosening or 7. Hydraulic hose and tubing for evidence of removing hydraulic components. damage such as blistering, crushing, or 6. Label or tag parts when disassembling. abrasion. Stellar 4500 Manual...
Page 13 #379831 or Stellar PN 20885. and corrosive material out of Failure to lubricate shaft the working parts. Thoroughly splines will cause damage to wash the crane periodically. the PTO and Hydraulic pump. Stellar 4500 Manual...
Page 14 -15˚F to 86˚F Compro XL-S 32 (ISO 32) -23˚F to 100˚F Compro XL-S 46 (ISO46) 32˚F to 113˚F Compro XL-S 68 (ISO68) Greasing the Crane Lubricate all grease gun points with Extreme Pressure Grease - Stellar P/N: 22059. Stellar 4500 Manual...
Page 15 Failure to replace gear-bearing values listed above. bolts may result in bolt failure 5. Torque values for socket-head capscrews due to metal fatigue causing are the same as for Grade 8 capscrews. serious injury or even death. Stellar 4500 Manual...
Page 16 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. Stellar 4500 Manual...
Page 17 Remote Ctrls Operate remote control devices to check for proper operation. Electrical Operate all lights, alarms, etc. to check for proper operation. Operation Aid Check presence of boom angle indicator. Operation Aid Check overload device for proper operation. Stellar 4500 Manual...
Page 18 Load hook for abnormal throat distance, twist, wear, & cracks. Rope Condition of load line. Manual Presence of operator's manuals with the unit. Chassis Tire wear and air pressure. Chassis Working backup alarm. Station Fire extinguisher at cab or machinery housing. Stellar 4500 Manual...
Page 19 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 Stellar 4500 Manual...
Page 20 Inner boom cylinder(s) Outer boom cylinder(s) Extension cylinder(s) Rotation cylinder(s) Jib lift cylinder(s) Jib extension cylinder(s) Other Winch Winch, sheaves, & drums for damage, abnormal wear, abrasion, & other irregularities. Hyd Filter Hydraulic filters for replacement per maintenance schedule. Stellar 4500 Manual...
Page 21 Check tightness of all fasteners and bolts. Wear Pads Wear pads for excessive wear. Loadline Loadline for proper attachment to drum. Historic Data Monthly inspection records. Historic Data Maintenance records. Historic Data Repair and modification records. Stellar 4500 Manual 3-10...
Page 22 Inspection Notes Stellar 4500 Manual 3-11...
Page 23: Chapter 4 - Specifications
Chapter 4 - Specifications Model 4500 Crane SPECIFICATION SHEET Crane Rating: 45,000 ft-lbs (6.22 ton-meters) Standard Boom Length: 11’ (3.35 m) from CL of Crane 14’ (4.27 m) from CL of Truck Boom Extension: Hydraulic 32" (81.2 cm) Maximum Horizontal Reach: 14’...
Page 24 7500 lbs 5600 lbs 4100 lbs 3200 lbs 3400 kg 2540 kg 1860 kg 1450 kg 0’ 3’ 4500 .914m ® TRUCK CRANE GROUND 0’ 190 STATE STREET GARNER, IA 50438 PHONE: (800) 321-3741 FAX: (641) 923-2812 20038 Stellar 4500 Manual...
Page 25: Chapter 5 - Decals
Chapter 5 - Decals Crane Cover Decals Crane Base Decals Crane Outrigger Decals Stellar 4500 Manual...
Page 26 Function: To inform the operator of the need for need for proper training, familiarity with safe proper training, familiarity with safe operating operating procedures and , the possible procedures, and the possible consequences of consequences without training. operation without training. PN: C4540 PN: C4544 Stellar 4500 Manual...
Page 27 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 Crane Base Decals consequences should the hazard occur and how to avoid the hazard. PN: C1179 Stellar 4500 Manual...
Page 28 Moving Outrigger Hazard Decal Location: Outrigger Leg Function: To inform the operator of the hazard associated with outrigger operation, the possible consequences should the hazard occur, and how to avoid the hazard PN: C5918 Crane Outrigger Decals Stellar 4500 Manual...
Page 29 Decal Placement PN 20054 Stellar 4500 Manual...
Page 30: Chapter 6 - Installation
This chapter is designed to serve as a general guide for the According to Federal Law (49 cfr part 571), each final- installation of a Stellar 4500 Articulating Crane on a Stellar stage manufacturer shall complete the vehicle in such a Service Body.
Page 31: Chapter 7 - Assembly Drawings
CAP SCR 0.31-18 X 0.50 HHGR5 10974 VB 2 SECT W/PB VDM6-4-4-YE-HP NOTES: 1) GASKET SHOWN 2) TRIM EDGE IS NOTED BY IT'S PART NUMEBER D1810 TBE AIR SAEJ844 TYPE A .25 (28") D1345 FTG CPRSN 0.12NPT/0.25 TUBE Stellar 4500 Manual...
Page 32 C1026 CAP SCR 0.63-11X2.50 HHGR8 ZY 0490 CAP SCR 0.31-18X3.50 HHGR5 0343 WASHER 0.31 USS FLAT ZINC 0420 CAP SCR 0.31-18X0.75 HHGR5 24685 VB 4 SECT ELECT W/PROP STERLING8GPM 34103 RECEIVER RADIO CONTROL 6 FCTN H2 0480 CAP SCR 0.25-20X1.00 HHGR5 Stellar 4500 Manual...
Page 33 0490 CAP SCR 0.31-18X3.50 HHGR5 0343 WASHER 0.31 USS FLAT ZINC 0420 CAP SCR 0.31-18X0.75 HHGR5 24685 VB 4 SECT ELECT W/PROP STERLING8GPM 33004 GUARD VB 4500 OMNEX RADIO 28836 RECEIVER RADIO CONTROL 6 FCTN OMNEX 0480 CAP SCR 0.25-20X1.00 HHGR5 Stellar 4500 Manual...
Page 34 Main Boom Assembly - PN 20051 Cylinder Seal Kit Part # 54579 PN 20051 19887 INNER BOOM 4500 CRANE & D0790 WASHER 0.50 FLAT GR8 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY & & & 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK Stellar 4500 Manual...
Page 35 CAP SCR 0.38-16X0.75 HHGR8 6252 WEAR PAD 0.34X2.50 RND NYLATRON 4541 CAP SCR 1.00-8X5.00 HHGR5 21154 CAP SCR 1.00-8X2.00 SHGR8 ZY & D0790 WASHER 0.50 FLAT GR8 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 9361PC PLATE WEAR PAD COVER 3200 Stellar 4500 Manual...
Page 36: Chapter 8 - Hydraulics/Electrical
Contaminants in a hydraulic system affect operation and will result in serious damage to the system components. Dirty hydraulic systems are a major cause of component failures. If evidence of foreign particles is found in the hydraulic system, flush the system. Stellar 4500 Manual...
Page 37 Control Kit (Hetronic Version) - PN 12484 PN 12484 Stellar 4500 Manual...
Page 38 Control Kit (Omnex Version) - PN 32611 PN 32611 Stellar 4500 Manual...
Page 39 Hydraulic Kit - PN 20441 PN 20441 SWITCH PRES OVERLD CD-11C-2900R/WD 49315 Stellar 4500 Manual...
Page 40: Chapter 9 - Replacement Parts
SAFETY LATCH PART# DESCRIPTION 27183 WORM GEAR (ROTATION GEAR BEARING) 12341 FLOOD LIGHTS (CRANE AND BODY) 27184 BEARING AND SEAL KIT (ROTATION GEAR BEARING) 5033 STROBE LIGHT (CRANE AND BODY) 3945 BUMPER DOCK Call 800-321-3741 to Order Stellar 4500 Manual...
Page 41: Chapter 10 - Troubleshooting
If the • Check to see if the manual override on the switch is defective, simply replace it. proportional valve is turned out. Turn the manual override on the flow valve in. Continued... Stellar 4500 Manual 10-1...
Page 42 Stellar see if the solenoid coil is magnetizing. If no polarity is present, replace the coil. If coil is Customer Service at: magnetizing, remove the stem valve, 1-800-321-3741 thoroughly clean, lubricate, and reinstall the valve. Stellar 4500 Manual 10-2...
Page 43 Minimum diameter of grounded to chassis. conductor ground is 12 AWG. Some crane motions operate Crane motion wiring may be Check wiring from receiver to plug and from plug intermittently loose. to crane motion actuator. Stellar 4500 Manual 10-3...
Page 44 Receiver Action LED on continuous Receiver operating voltage is present, no signal is being received. LED flashes Signal is being received that matches the decoders address. LED goes off Signal is being received, but address is wrong. Stellar 4500 Manual 10-4...
Page 45 Check the anti-2-blocking electrical circuit (Limit switch, cord reel, and pressure switch - if applicable) for proper operation. b. If problem cannot be determined, contact customer service at Stellar Industries. Stellar 4500 Manual 10-5...
Page 46 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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