Owner’s Manual 3315 Telescopic Crane Safety, Installation, Maintenance, and Operation

Owner’s Manual 3315 Telescopic Crane Safety, Installation, Maintenance, and Operation
Owner’s Manual
Safety, Installation, Maintenance, and Operation
3315 Telescopic Crane
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.
© 2006 Stellar Industries, Inc.
Manual Part No. 31705
Last Revision: 8/23/06
Telescopic Crane Manual Revisions
Date of Revision
Manuals Effected
Section Revised
September 1, 2005
6620, 6628, 9620,
9628, 10620,
10628, 14528
Chapter 7:
Assembly Drawings
Updated Main Boom and
Extension Boom drawings to
reflect engineering changes.
September 19, 2005
6620, 6628, 9620,
9628, 10620,
10628, 14528
Chapter 7:
Assembly Drawings
Updated Cable and Hook
assembly drawings to reflect
engineering changes.
May 8, 2006
6620, 6628
Chapter 7:
Assembly Drawings
Replaced Extension Cylinder
assembly drawings with the
updated version to reflect
engineering changes.
September 9, 2006
3315, 4420, 5520,
6620, 6628, 9620,
9628, 10620,
10628, 14528
Chapter 7:
Assembly Drawings
Updated Cable and Hook
assembly drawings to reflect
engineering changes.
i
Description of Revision
Introduction
Stellar cranes are designed to provide safe and
dependable service for a variety of operations.
With proper use and maintenance, Stellar
cranes will operate at peak performance for
many years.
improvement or commercial/production
purposes. This right is kept with no requirement
or obligation for immediate mandatory updating
of this manual.
This product manual is not intended as a
training manual for beginners or unskilled
operators. This manual offers guidelines for
correct and safe usage of the crane,
maintenance, and troubleshooting. If more
information is required or technical assistance is
needed, please contact the Stellar Customer
Service Department.
This manual contains information vital to the
safe use and efficient operation of this unit.
Following the information provided within this
manual can ensure the longevity of the crane.
Carefully read and study the operator’s manual
before using the unit. 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.
Some sections of this manual contain
information pertaining to all Stellar
manufactured cranes and may or may not apply
to your specific model.
A copy of this manual is provided with every
crane and 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. 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
If this manual becomes damaged, misplaced, or
unreadable at any point, or if you feel that any
part of this manual is unclear or incorrect,
please contact the Stellar Customer Service
Department at 800-321-3741 or email at
[email protected]
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
[email protected]
Order Parts
[email protected]
Warranty Information
[email protected]
© 2005 • Stellar Industries, Inc.
ii
Table of Contents
Chapter 1 - Safety
1-1
Chapter 2 - Operation
2-1
Chapter 3 - Maintenance
3-1
Chapter 4 - Specifications
4-1
Chapter 5 - Decals
5-1
Chapter 6 - Installation
6-1
Chapter 7 - Assembly Drawings
7-1
Chapter 8 - Hydraulics/Electrical
8-1
Chapter 9 - Replacement Parts
9-1
Chapter 10 - Troubleshooting
iii
10-1
Chapter 1 - Safety
regulations and accident-prevention equipment.
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.
Do not wear rings, wristwatch, jewelry, loosefitting 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.
Safety should be the number one thought on
every Stellar crane 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 beginning.
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.
Stellar Industries, Inc. is not liable for accidents
occurred during the usage of the crane caused
by non-fulfillment from the operator’s side of
current rules, laws, and regulations.
Never allow anyone to ride the crane hook or
load.
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.
MAINTENANCE SAFETY
Never modify or alter any of the equipment,
whether mechanical, electrical, or hydraulic,
without Stellar Industries’ approval.
Trainees or untrained persons shall be under the
direct supervision of qualified persons.
Do not perform any maintenance or repair work
on the crane unless authorized and trained to do
so.
Do not operate equipment under the adverse
influence of alcohol, drugs, or medication.
Release system pressure before attempting to
make adjustments or repairs.
PERSONAL SAFETY
Keep clear of all moving parts.
Do not attempt service or repair when PTO is
engaged.
Always wear the prescribed personal safety
devices.
Failure to correctly plmb and wire the crane can
cause a malfunction and damage to the crane
and/or operator.
Always wear approved accident-prevention
clothing such as: protective helmets, anti-slip
shoes with steel toes, protective gloves, antinoise headphones, protective glasses, and
reflective jackets with breathing apparatus.
Consult your employer regarding current safety
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 not
legible.
Chapter 1 - Safety
1-1
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. If necessary, replace them.
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.
STABILITY
Know the crane components and their
capabilities and limitations. Overloading the
crane may result in serious damage of self,
others, equipment or the surroundings.
Do not use the boom or the winch to drag a load.
No crane is designed for these types of loads.
Do not use the crane boom to push downward
onto anything.
Never exceed manufacturer’s load ratings.
These ratings are based on the machine’s
hydraulic, mechanical, and structural design
rather than stability.
ELECTROCUTION
Allow extra space for swaying power lines in
windy conditions.
The supporting surface under the service truck
must be able to support the weight of the
machine and its load. Use outrigger pads if
necessary.
Keep a minimum of ten feet between any portion
of the crane and an electrical line. Add an
additional 12" for every additional 30,000 Volts or
less.
Park the vehicle on level ground and extend the
outriggers fully out and then down.
Remember - Death or serious injury can occur
when working near power lines or during
electrical storms.
Keep feet and legs clear when lowering outrigger
jacks.
Use a signal person when operating near
electrical sources.
Never operate the crane without making sure the
outriggers are positioned on stable, flat ground.
ENVIRONMENT
Do not operate the crane during electrical
storms.
Set the parking break 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.
In extreme cold, allow adaquate 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.
Never use a sling bar or anything larger than the
hook throat that could prevent the hook latch
from closing, thus negating the safety feature.
In dusty work areas, every effort must be taken to
keep dust and sand out of the moving parts of the
machinery.
Do not apply side loads to the booms.
In high humidity work areas, keep parts as dry as
possible and well lubricated.
Do not leave a crane load suspended or
unattended.
Chapter 1 - Safety
1-2
CRANE CONTROLS
1. Be familiar with the sequence and
operation of the crane controls.
2. Each individual crane function should have
control function decals. Replace them
immediately if they are missing or illegible.
3. Keep hands, feet and control levers free
from mud, grease and oil.
4. Be familiar with the remote control and
how it operates before attempting to lift a
load.
5. Be prepared before beginning operation of
the crane:
• All protective guards must be in place.
• Be aware of the surroundings: low
branches, power lines, unstable ground.
• Be sure all safety devices provided are in
place and in good operating condition.
• Be prepared for all situations. Keep fire
extinguisher and first aid kit near.
• Be sure all regular maintenance has been
performed.
• Visually inspect all aspects of the crane
for physical damage.
• Check for fluid leaks.
• Make sure the outriggers are down and
stable.
ATTENTION
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
Be familiar with your remote control and how it works before operating
the crane.
Chapter 1 - Safety
1-3
Chapter 2 - Operation
Job-Site Set-Up
Thoroughly plan the lift before positioning
the vehicle. Consider the following:
1. The vehicle should be positioned in an area
free from overhead obstructions to eliminate the
need for repositioning.
2. Position the vehicle 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 of at least 10 feet
between any part of the crane, load line, or load,
and any electrical line or apparatus carrying up to
50,000 volts. One foot additional clearance is
required for every additional 30,000 volts or less.
Remember to allow for winds that cause power
lines to sway. It is recommended that a signal
person be used when the vehicle is set-up near
power lines.
3. The vehicle should also be positioned on a firm
and level surface that will provide adequate
support for the outrigger loading. Use extreme
caution when setting up near overhanging banks
or excavations.
4. The parking break must be set on the vehicle
and the drive axle disengaged before performing
a crane operation.
5. The outriggers must be extended to stabilize
the truck before beginning operation.
Unit Operation Overview
1.
2.
3.
4.
5.
6.
7.
Engage the PTO
Turn on Power to Crane
Position Outriggers
Operate Crane
Store Outriggers
Turn Off Power to Crane
Disengage the PTO
1. Engage the PTO
A. Engage the parking
brake.
B. Place the
transmission in the
Neutral position.
C. Make certain the
PTO switch is in the
‘off’ position.
PTO Switch
D. Start the vehicle engine.
E. Depress the clutch on manual transmission
vehicles.
F. Engage the PTO switch for cable and air
type shifters. Turn on dash switch for
electrical operated style. Consult vehicle
owner’s manual for location and operation of
OEM style in-dash PTO switch.
G. Slowly release the clutch on a manual
transmission vehicle.
H. Warm engine and hydraulic system oil. Let
system run for 10-20 minutes for warm-up.
This is especially important in cold weather.
I. Proceed with the outrigger and crane
operation.
2. Turn on Power to Crane
Activate power to the crane and outriggers.
The power switch is located on the control
panel in the vehicle cab.
3. Position Outriggers
Once the PTO is engaged, extend the
outriggers using the control levers or switches
marked ‘outrigger’. These may be located on
the crane base or in the compartment under
the crane. See photo below.
Outrigger control panel, located in the crane compartment.
Chapter 2 - Operation
2-1
6 Function Remote
This radio remote is the standard for the 5520, 6620, 6628, 9620, 9628, 10620, and 10628 model Stellar Cranes.
4.Operate Crane
A. Turn on necessary power to the crane.
B. Activate toggle switch for desired crane
function. See Figures 1-a, 1-b, 1-c, 1-d.
D. Activate the push button switch located off
of the index finger to operate the function.
E. When operation is complete, store remote
handle in a safe, dry location.
5. Store Outriggers
Retract outriggers using the control levers or
switches marked ‘outrigger’.
6. Turn Off Power to Crane
Deactivate power to crane and outriggers.
7. Disengage the PTO
A. On manual transmission vehicles, depress
the clutch pedal completely.
B. Disengage the PTO switch.
C. If vehicle is a manual transmission, release
the clutch pedal gradually.
Chapter 2 - Operation
2-2
NOTE: The radio control is
an electrical device. Please
Handle With Care!
1
Variable Speed Trigger on remote.
The crane should not function until the trigger has been
activated. Thespeed of the crane will vary in direct
correlation with how much or how little the trigger is
engaged.
4 Function Remote
This corded remote is the standard for the 3315 and 4420 model Stellar Cranes.
6 Function Remote
This remote is the standard for the 14528 model Stellar Cranes.
Chapter 2 - Operation
2-3
Manual Operation
If the remote control malfunctions, follow
these steps to operate the crane manually:
1. Activate Flow Control. Turn the override
screw on flow control counter-clockwise. Full
adjustment is between three and five turns.
2. 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.
3. Deactivate flow control. Turn the override
screw clockwise until stopped. Full adjustment
is between 3 and 5 turns.
4. Have unit serviced immediately to restore
remote control functionality.
PULL
PUSH
WINCH
DOWN
WINCH
UP
EXTENSION
RETRACT
EXTENSION
EXTEND
MAIN
MAIN
DOWN
UP
ROT
ROT
CW
CCW
FLOW
CONTROL
Manual Override Pull
Function
The knurled sleeve is pulled all
the way out together with the
knob to manually override the
pull solenoid function.
Manual Override Push
Function
The knurled sleeve should first
be pulled to unlatch the ball
latching mechanism and then,
while holding the sleeve back,
the override knob should be
pushed all the way in to
override the push solenoid.
Crane Precautions
1. Movement of the control levers should be
slow and smooth to meter oil flow for safe
operation. Avoid jerky and sudden
movements.
2. The crane controls should be clearly marked
with decals. If these are missing or
illegible,replace immediately. (See Chapter 5:
Decals)
3. Lift load slightly off the ground to check the
safety of the cargo. Do not use stability to
determine the safety. Consult the capacity
charts and strictly adhere to them.
4. Be constantly aware of the boom position
when operating the controls.
5. The boom tip should be centered directly over
the load before making the lift to avoid
swinging.
6. Do not drag loads with the crane.
7. Do not attempt to lift fixed loads.
8. Do not load boom in a sideways direction.
9. Know the weight of the rigging and load to
avoid overloading the crane.
10. Do not extend or rotate a load over anyone.
11. Wear protective gear such as hardhat, safety
glasses, steel-toed boots, and gloves.
Hook Precautions
1. Hooks are designed and manufactured to lift
specific loads. The specified rated load of a
hook applies to loads held uniformly in direct
tension and does not take into account shock
loads, hook tip loading, side loading, bending,
torsional, or related loads.
2. Do not attempt to lift a load that is larger than
the load rating of the hook.
3. Never use a hook’s yield point as an indicator
of its capacity.
4. Do not use a hook to lift personnel.
5. Know the rated load of the hook in use.
6. Never weld attachments to a finished hook in
field applications. This will alter and destroy
the design properties of the hook material.
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.
Chapter 2 - Operation
2-4
Operator Information
OPERATOR REQUIREMENTS
OPERATOR CONDUCT
1. Operation is limited to the following
people:
A. Designated individual.
B. Trainees under direct supervision of
the designated individual.
C. Test or maintenance individual.
D. Crane Inspector.
1. Operators will not engage in any operation
that would cause them to divert attention away
from the operation of the crane.
2. Operators are responsible for all operations
under their direct control.
3. Operators will not leave a suspended load
unattended.
4. Operators will be familiar with the equipment
and the maintenance required for proper care.
2. Operators must meet the following
physical qualifications:
A. Vision of at least 20/30 Snellen in
one eye and 20/50 in the other, with
or without corrective lenses.
B. Ability to distinguish colors if color
differentiation is required.
C. Adequate hearing, with or without a
hearing aid.
D. No physical or emotional defects
that may create a hazard to the
operator or others.
E. Normal depth perception and
coordination.
3. In addition to the physical qualifications,
Operators must:
A. Demonstrate the ability to
understand all decals, the owner’s
manual, and any other information
required for safe operation of the
crane.
B. Be able to demonstrate the ability to
safely control the crane.
C. Know all safety regulations.
D. Be responsible for maintenance
requirements.
E. Understand and be fully capable of
implementing all emergency
procedures.
F. Understand the operating procedures
as outlined by this manual, Ansi
B30.5, and Federal/State Laws.
HANDLING THE LOAD
1. Size of the load:
A. Do not load the crane beyond the
rated capacity.
B. It is the responsibility of the operator
to know the weight of the handled
load.
2. Attaching the load:
A. Attach the load to the hook by
means of slings or other approved
devices.
B. Do not wrap the hoist rope around
the load.
3. Moving the load:
A. Make certain that the crane is level
and properly blocked.
B. Ensure that the load is secure and
balanced within the sling before
moving it.
C. Be sure that the crane is stable
before moving the load. Use
stabilizer pads to ensure the proper
distribution of weight.
D. Do not drag the load sideways.
E. Make sure the hook is brought over
the load to minimize swinging.
F. No suspended load should pass over
a person.
G. Avoid sudden starts and stops when
moving a load.
Chapter 2 - Operation
2-5
Chapter 3 - Maintenance
Daily Inspection
Daily Inspection should occur each day before
the crane is put into use. Each day, inspect
the crane for all of the following:
1. Hydraulic oil level.
2. Loose parts or damage to structures or
weld.
3. Cylinder movement due to leakage.
4. Hoses and gearboxes for evidence of oil
leaks.
5. Controls, including hand throttle for
malfunction or adjustment.
6. Truck hand brake operation.
7. All securing hardware such as cotter pins,
snap rings, hairpins, and pin keepers for
proper installation.
8. All safety covers for proper installation.
9. Cylinder holding valves for proper
operation.
10. Wire rope for broken wires, extensive
wear, distortion, and heat damage.
WARNING - Read the Following before
performing any maintenance on the
crane.
1. Only authorized service personnel are to
perform maintenance on the crane.
2. Disengage the PTO before any service
or repair is performed.
3. Do not disconnect hydraulic hoses while
there is still pressure in those
components.
4. Before disconnecting hydraulic
components, place the boom on the
ground or have it supported, shut off the
engine, release any air pressure on the
hydraulic reservoir, and move pedals and
control levers repeatedly through their
operating positions to relieve all
pressures.
5. Keep the crane and service body clean
and free from grease build-up, oil and dirt
to prevent slippery conditions.
6. Perform all safety and maintenance
checks before each period of use.
7. Replace parts with Stellar Industries, Inc.
approved parts only.
8. Immediately repair or have repaired any
components found to be inadequate.
Periodic Inspection
Periodic Inspection should occur while the
crane is in use. For the duration of the usage,
inspect the crane for all of the following:
1. Loose bolts and fasteners.
2. All pins, bearings, shafts, and gears for
wear, cracks, or distortion to include all
pivots, outriggers, sheave pins, and
bearings.
3. Hydraulic systems for proper operating
pressure.
4. Main frame mount bolts.
5. Cylinders for:
A. Damaged rods.
B. Dented barrels.
C. Drift from oil leaking internally.
D. Leaks at rod seals or holding valves.
6. PTO drive line system for proper alignment,
lubrication, and tightness.
7. Hydraulic hose and tubing for evidence of
damage such as blistering, crushing, or
abrasion.
Maintenance Procedures
1. Position the crane where it will be out of the
way of other operations or vehicles in the
area.
2. Be sure boom is lowered to the ground or
otherwise secured from dropping.
3. Place all controls in the off position and
secure operating features from inadvertent
motion.
4. Disconnect power source.
5. Relieve hydraulic oil pressure from all
hydraulic circuits before loosening or
removing hydraulic components.
6. Label or tag parts when disassembling.
Chapter 3 - Maintenance
3-1
Weekly Inspection
Weekly Inspection should occur at the
beginning of every work week. Each week,
inspect the crane for all of the following:
1. Lubrication of points required by lubrication
chart. See chart at the end of this chapter.
2. Proper operation of load hook safety latch.
3. Presence of this owner’s manual.
Monthly Inspection
Monthly Inspection should occur at the
beginning of every work month. Each month,
inspect the crane for all of the following:
1. Frame bolt tightness - turn barrel nuts and
mounting bolts during the first month of
operation on new machines and then
quarterly thereafter.
2. Cylinders and valves for leaks.
3. Lubrication.
4. Load hook for cracks or having more than
15 percent normal throat opening or 10
degrees twist.
5. Structural members for bends, cracks, or
broken members.
6. All welds for breaks and cracks.
7. A ll pins and keepers for proper
installation.
8. All control, safety, and capacity placards
for readability and secure attachment.
9. Inspect all electrical wires and connections
for worn, cut, or deteriorated insulation
and bare wire. Replace or repair wires as
required.
10. Tightness of all boom wear, pad-retaining
bolts.
Service
The following general suggestions should
be helpful in analyzing and servicing your
crane. Using the following systematic
approach should be helpful in finding and
fixing problems:
1. Determine the problem.
2. List and record possible causes.
3. Devise checks.
4. Conduct checks in a logical order to
determine the cause.
5. Consider the remaining service life of
components against the cost of parts and
labor necessary to replace them.
6. Make the necessary repair.
7. Recheck to ensure that nothing has been
overlooked.
8. Functionally test the new part in its
system.
Inspection Checklist
For a more detailed outline of scheduled
inspection points, refer to the Stellar
Inspection Checklist at the end of this chapter.
This list is an excellent guide for the
inspection tasks that will help maintain the
quality of your Stellar product. Feel free to
photocopy the checklist as needed.
Cleanliness
An important item in preserving
the long life of the crane is
keeping dirt, grime, and corrosive
material out of the working parts.
Thoroughly wash the crane
periodically.
Follow these guidelines to maintain the quality of your Stellar product.
Chapter 3 - Maintenance
3-2
Stellar Lubrication Recommendations :
Component
Location
Recommendation
Engine
Crankcase
Hydraulic System
Below –5*F
-5*F to 90*F
Above 90*F
Open Gears
Reservoir
Bearings, grease
(including turntable bearing inner
race)
Gun
Precision XL EP 2 (NLGI 2)
Worm Drive Gearbox
Gearbox
Precision Synthetic EP 00 (NLGI 00)
Planetary Gearbox
(including winch)
Gearbox
Traxon Synthetic 75W-90 (API GL-5)
Wear Pad Lubrication
Spray
Gearshield NC
Crankcase
Crankcase
Crankcase
Compro 100 (ISO 100)
Compro 100 (ISO 100)
Hand
Apply Manufacturer’s
Recommendations
Petro-Canada Arctic MV 15 (ISO 22)
Petro-Canada HYDREX 32 (ISO 32)
Petro-Canada HYDREX 46 (ISO 46)
Precision XL3 Moly EP 2 (NLGI 2 grease
with moly)
Compressor Fluids
Reciprocating Single Stage
Reciprocating Double Stage
Screw
-15˚F to 86˚F
-23˚F to 100˚F
32˚F to 113˚F
Compro XL-S 32 (ISO 32)
Compro XL-S 46 (ISO46)
Compro XL-S 68 (ISO68)
Greasing the Crane
Lubricate all grease gun points with Extreme Pressure Grease - Stellar P/N:
22059.
Chapter 3 - Maintenance
3-3
Wire Rope Maintenance
Wire Rope Inspection Points
While inspection of the entire rope is required,
attention should be directed to these critical
points:
1. Pick-up Points for signs of wear due to
stress from repeated lifts.
2. End Attachments for corrosion and broken
wires at both ends of the rope.
3. Drums for signs of corrugation and wear
that may lead to wire damage.
4. Sheaves to ensure that each sheave has
the proper groove size and contour.
5. Abuse Points for heavy amounts of
scuffing and scraping.
It is important to perform detailed inspections of
all ropes associated with the crane. These
inspections can be divided into two types:
1. Frequent Inspection
A. All running ropes should be inspected
once each working day. These visual
observations will be concerned with
discovering damage that may be an
immediate hazard. The following
concerns should be addressed:
1. Distortion of the rope.
2. General corrosion.
3. Broken or cut strands.
B. Use caution while inspecting sections of
rapid deterioration.
C. Use caution while inspecting boom hoist
ropes. Proper inspection is critical but
difficult.
2. Periodic Inspection
A. Inspection frequency will be determined
by a qualified person and will be based
on such factors as expected rope life,
environment conditions, capacity of
typical lifts, rates of usage, and exposure
to shock loads. Periodic inspection
needs to be performed at least annually.
B. Periodic inspections will be performed by
a qualified individual and will cover the
entire length of the rope.
Only the surface wires of the rope need
to be inspected. This inspection will be
concerned with discovering damage that
may be an immediate hazard. The
following concerns should be addressed:
1. Distortion of the rope.
2. General corrosion.
3. Broken or cut strands.
4. Reduction of rope diameter.
5. Corroded or broken wires at end
connections.
6. Corroded, cracked, bent, worn, or
improperly applied end connections.
C. Use caution when inspecting the
following:
1. Sections in contact with saddles,
equalizer sheaves, or other sheaves
where rope travel is limited.
2. Sections of the rope at or near ends
with corroded or broken wires.
Wire Rope Replacement
Rope replacement guidelines are as follows:
1. Broken wires, including standing ropes with
more than two broken wires in one lay or
more than one broken wire at an end
connection.
2. Wear of one-third the original diameter of the
outside wires.
3. Distortion of the rope structure.
4. Evidence of heat damage.
5. Reductions from nominal diameters of more
than 1/64 in. (0.4 mm) for diameters from 5/16
in.(19.0 mm) and 1/32 in. (0.8 mm) for
diameters from 3/8 in. (9.5 mm) to and including
1/2 in. (13.0 mm).
Wire Rope Maintenance
Proper maintenance is key in ensuring a long
lasting rope. These three tips will help:
1. Store the rope to prevent damage.
2. Avoid objects that may scrape, bend, or crush
the wires of the rope.
3. Always keep the rope well-lubricated.
Chapter 3 - Maintenance
3-4
Holding Valve Inspection Procedure
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 valve is
checked in the following manner:
1. Identify the cylinder in question.
2. Identify the holding valves and the cylinder
direction in question.
a. Cylinder Extend.
b. Cylinder Retract.
3. Place the machine so that the cylinder will
be located in the appropriate testing
position.
4. Pick the load (Do not exceed capacity, rated
or stability).
5. Disengage hydraulics.
6. Operate crane functions.
A. If the cylinder creeps (lowering the
load), replace the holding valve.
B. If the cylinder does not creep (load
stays suspended), the valve is
operational.
Gear-Bearing Bolt Maintenance
Anytime a gear-bearing bolt is removed, it
must be replaced with a new bolt of the
identical grade and size. 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!
Failure to replace gear-bearing
bolts may result in bolt failure
due to metal fatigue causing
serious injury or even death.
Torque Data Chart
Grade 5
Grade 8
Grade 9
Plated Plated
Size
Bolt DIA
Plain
Plated
Plain
(DIA-TPI)
(Inches)
(Ft-Lb)
(Ft-Lb)
(Ft-Lb)
(Ft-Lb)
(Ft-Lb)
5/16-18
3/8-16
7/16-14
1/2-13
9/16-12
5/8-11
3/4-10
7/8-9
1-8
1 1/8-7
1 1/4-7
1 3/8-6
1 1/2-6
0.3125
0.3750
0.4375
0.5000
0.5625
0.6250
0.7500
0.8750
1.000
1.1250
1.2500
1.3750
1.500
17
31
49
75
110
150
265
395
590
795
1120
1470
1950
13
23
37
57
82
115
200
295
445
595
840
110
1460
25
44
70
105
155
220
375
605
910
1290
1815
2380
3160
18
33
52
80
115
160
280
455
680
965
1360
1780
2370
22
39
63
96
139
192
340
549
823
1167
1646
2158
2865
When using the torque data in the charts
above, the following rules should be observed.
1. Bolt manufacturer’s particular specifications
should be consulted when provided.
2. Flat washers of equal strength must be used.
3. All torque measurements are given in
foot-pounds. To convert to inch-pounds,
multiply by 12.
4. Torque values specified are for bolts with
residual oils or no special lubricants applied.
If special lubricants of high stress ability,
such as Never-Seez compound graphite and
oil, molybdenum disulphite, colloidal copper
or white lead are applied, multiply the torque
values in the charts by the factor .90. The
use of Loctite does not affect the torque
values listed above.
5. Torque values for socket-head capscrews
are the same as for Grade 8 capscrews.
Chapter 3 - Maintenance
3-5
Stellar Industries Inspection Checklist for Telescopic Boom Cranes
Use of this checklist is subject to terms of the Stellar
Warranty information. Additional copies of this checklist
can be obtained by contacting Stellar Customer Service
at (800) 321-3741 or by download at:
http://www.stellarindustries.com/pages/downloads.htm
Type of Inspection (check one)
Quarterly
Daily (if deficiency found)
Owner/Company:
Contact Person:
Crane Make/Model:
Crane Serial:
Date Inspected:
Hour Meter Reading:
Inspected by: (print)
Signature of Inspector:
Monthly
Annual
Type of Inspection Information
Daily and monthly inspections are to be performed by a “designated” person, who has been
selected by the employer or the employer’s representative as being competent to perform specific
duties.
Quarterly and annual inspections are to be performed by a “qualified” person who, by possession
of a recognized degree in an applicable field or certificate of professional standing, or who, by
extensive knowledge, training and experience has successfully demonstrated the ability to solve or
resolve problems related to the subject matter and work.
One hour of normal crane operation assumes 20 complete cycles per hour. If operation exceeds
20 cycles per hour, inspection frequency should be increased accordingly.
Consult the Stellar Owner’s Manual for additional inspection items.
Before inspecting and operating the crane, make certain that t he crane is set up away from power
lines and leveled with outriggers fully extended.
Daily (D): Before each day of operation, those items with a (D) must be inspected. This
inspection need not be recorded unless a deficiency is found.
Monthly (M): Monthly inspections or 100 hours of normal operation (which ever comes first)
includes all daily and monthly inspection items plus items designated with a (Q). This inspection
must be recorded.
Quarterly (Q): Every three months or 300 hours of normal operation (which ever comes first)
includes all daily and monthly inspection items plus items designated with an (M). This inspection
must be recorded.
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.
Chapter 3 - Maintenance
3-6
Daily Inspection
Frequency
Key
D
Decals
Inspection Description
All load charts, safety & warning decals, & control decals are present and legible.
Check all safety devices for proper operation.
D
Controls
Control mechanisms for proper operation of all functions, leaks, & cracks.
D
Station
Control mechanisms for proper operation of all functions, leaks, & cracks.
D
Hydsystem
Hydraulic system (hoses, tubes, & fittings) for leakage & proper oil level.
D
Hook
Presence & proper operation of hook safety latches.
D
Rope
Proper reeving of wire rope on sheaves & winch drum.
D
Pins
Proper engagement of all connecting pins & pin retaining devices.
D
General
D
Operation
D
Remote Ctrls
D
Electrical
D
Overall observation of crane for damage or missing parts, cracked welds &
presence of safety covers.
During operation, observe crane for abnormal performance, unusual wear. If
observed, discontinue use & determine cause & severity of hazard.
Operate remote control devices to check for proper operation.
Operate all lights, alarms, etc. to check for proper operation.
Anti 2-Blocking Operate anti 2-blocking device to check for proper operation.
D
Operation Aid
Check presence of boom angle indicator.
D
Operation Aid
Check overload device for proper operation.
Chapter 3 - Maintenance
3-7
Status
Monthly Inspection
Frequency
Key
Inspection Description
M
Daily
All Daily Inspections.
M
Cylinders
M
Valves
Visual inspection of cylinders for leakage at rod, fittings, & welds. Damage to
rod & case.
Holding valves for proper operation.
M
Valves
Control valve for leaks at fittings & between sections.
M
Valves
M
General
Control valve linkages for wear, smoothness of operation & tightness of
fasteners. Relief valve for proper pressure settings.
Bent, broken or significantly rusted/corroded parts.
M
Electrical
Electrical systems for presence of dirt, moisture & frayed wires.
M
Structure
All structural members for damage.
M
Welds
M
Pins
M
Hardware
M
Wear Pads
M
M
M
All welds for breaks & cracks.
All pins for proper installation & condition.
All bolts, fasteners & retaining rings for tightness, wear & corrosion.
Condition of wear pads.
Pump & Motor Hydraulic pumps & motors for leakage at fittings, seals & between sections.
Check tightness of mounting bolts.
Transmission/PTO for leakage, abnormal vibration & noise, alignment &
PTO
mounting bolt torque.
Hyd Fluid
Quality of hydraulic fluid and for presence of water.
M
Hyd Lines
M
Hook
Hoses & tubes for leakage, abrasion damage, blistering, cracking, deterioration,
fitting leakage, & secured properly.
Load hook for abnormal throat distance, twist, wear, & cracks.
M
Rope
Condition of load line.
M
Manual
Presence of operator's manuals with the unit.
M
Chassis
Tire wear and air pressure.
M
Chassis
Working backup alarm.
M
Station
Fire extinguisher at cab or machinery housing.
Chapter 3 - Maintenance
3-8
Status
Quarterly Inspection
Frequency
Key
Inspection Description
Q
Daily
All daily inspections.
Q
Monthly
Q
Rotation Sys
Q
Hardware
Base mounting bolts for proper torque.
Q
Structure
All structural members for deformation, cracks, & corrosion.
All monthly inspections.
Rotation bearing for proper torque of all mounting bolts.
Base
Outrigger beams & legs
Mast
Inner boom
Outer boom
Extension(s)
Jib boom
Jib extension(s)
Other
Other
Q
Hardware
Pins, bearings, shafts, gears, rollers, & locking devices for wear, cracks,
corrosion, & distortion.
Inner boom pivot pin(s) & retainer(s)
Outer boom pivot pin(s) & retainer(s)
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
Chapter 3 - Maintenance
3-9
Status
Quarterly Inspection Continued...
Frequency
Key
Q
Hyd Lines
Inspection Description
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
Pressure line(s) from control valve to each function
Load holding valve pipe(s) and hose(s)
Other
Q
Pumps&Motors Pumps and motors for loose bolts/fasteners, leaks, noise, vibration, loss of
performance, heating and excess pressure.
Winch motor(s)
Rotation motor(s)
Other
Q
Valves
Hydraulic valves for cracks, spool return to neutral, sticking spools, relief valve
failure.
Main control valve
Load holding valve(s)
Outrigger or auxiliary control valve(s)
Other
Q
Cylinders
Hydraulic cylinders for drifting & leakage. Rods for nicks, scores, & dents.
Castor damage. Case & rod ends for damage & abnormal wear.
Outrigger cylinder(s)
Inner boom cylinder(s)
Outer boom cylinder(s)
Extension cylinder(s)
Rotation cylinder(s)
Jib lift cylinder(s)
Jib extension cylinder(s)
Other
Q
Winch
Q
Hyd Filter
Winch, sheaves, & drums for damage, abnormal wear, abrasion, & other
irregularities.
Hydraulic filters for replacement per maintenance schedule.
Chapter 3 - Maintenance
3-10
Status
Annual Inspection
Frequency
Key
Inspection Description
A
Daily
All daily inspection items.
A
Monthly
All monthly inspection items.
A
Quarterly
All quarterly inspection items.
A
Hyd System
A
Controls
A
Valves
Safety valve calibration for correct pressures & relief valve settings
A
Valves
Valves for failure to maintain correct settings.
A
Rotation Sys
A
Lubrication
Rotation drive system for proper backlash clearance & abnormal wear,
deformation, & cracks.
Gear oil change in rotation drive system per maintenance schedule.
A
Hardware
Check tightness of all fasteners and bolts.
A
Wear Pads
A
Loadline
A
Historic Data
Monthly inspection records.
A
Historic Data
Maintenance records.
A
Historic Data
Repair and modification records.
Hydraulic fluid change per maintenance schedule.
Control valve calibration for correct pressures & relief valve settings.
Wear pads for excessive wear.
Loadline for proper attachment to drum.
Chapter 3 - Maintenance
3-11
Status
Inspection Notes
Chapter 3 - Maintenance
3-12
Chapter 4 - Specifications
Model 3315 Crane
SPECIFICATION SHEET
Crane Rating:
11,500 ft-lbs (1.59 ton-meters)
Standard Boom Length:
7’ (2.13 m) from CL of Crane
Boom Extension:
1st stage: Hydraulic 48" (121.9 cm)
2nd stage: Manual 48" (121.9 cm)
Maximum Horizontal Reach:
15’ (4.57 m) from CL of Crane
Maximum Vertical Lift:
(from crane base)
16’ 9” (5.11 m)
Boom Elevation:
-5 to +80 degrees
Stowed Height:
(crane only)
32.5” (82.6 cm)
Mounting Space Required:
18” x 15” (45.7 x 38.1 cm)
Approximate Shipping Weight:
800 lbs (360 kg)
Controls:
20’ (6.1 m) cord with hand held control.
Winch Specifications
Rope Diameter:
Line pull speed:
Max. single part line:
Max. double part line:
1/4" (.64 cm)
30 ft/min (9.1 m/min)
1600 lbs (725 kg)
3200 lbs (1450 kg)
Rotation:
(worm gear)
370 degree power
Lifting Capacities:
1625 lbs @ 7’ (737 kg @ 2.1 m)
750 lbs @ 15’ (340 kg @ 4.6 m)
Power Supply Required:
12 volt power unit
(2.0 gpm @ 2300 psi)
(7.57 lpm @ 159 bars)
*Subject to change without notification
Chapter 4 - Specificaitons
4-1
REACH IN FEET/METERS
CAPACITY IN POUNDS/KILOGRAMS
Maximum 1−part line capacity is
1600 lbs (725 kg).
For greater loads, use 2−part line.
Weight of load handling devices
are part of the load lifted and must
be deducted from the capacity.
STELLAR 3315
Chapter 4 - Specificaitons
4-2
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.
PN: C4795
Moving Outrigger Hazard Decal
Location: On each outrigger
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
Instructional Decal
Location: At Stow Hook area
Function: To caution the operator not to use the stow
hook for any lifting applications. PN: 24712
Chapter 5 - Decals
5-1
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
Chapter 5 - Decals
5-2
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 tampering
with the overload device may cause a unit
failure.
PN: 28256
Chapter 5 - Decals
5-3
Free Falling Manual Boom Decal
Electrocution Hazard 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
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: C1179
Operation Hazard Decal
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
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
Chapter 5 - Decals
5-4
Operation Hazard Decal
Moving 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
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
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
Training 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 of
operation without training. PN: C4544
Chapter 5 - Decals
5-5
Decal Placement
Chapter 5 - Decals
5-6
Chapter 6 - Installation
Notice: Read this Page Before Installation of the Crane
General Installation
Installation Notice
This chapter is designed to serve as a general
guide for the installation of a Stellar 3315
Telescopic Crane on a Stellar Service Body.
Each installation is considered unique so certain
portions of this chapter may or may not apply to
your direct application. If a question should arise
during the installation process, please contact
Stellar Customer Service at (800) 321 3741.
According to Federal Law (49 cfr part 571), each
final-stage manufacturer shall complete the
vehicle in such a manner that it conforms to the
standards in effect on the date of manufacture of
the incomplete vehicle, the date of final
completion, or a date between those two dates.
This requirement shall, however, be superseded
by any conflicting provisions of a standard that
applies by its terms to vehicles manufactured in
two or more stages.
This crane is designed for use with a Stellar
Service Body installed on a vehicle that meets
the minimum chassis requirements of the crane.
Check with Stellar Industries before installing this
crane on a body other than a Stellar Service
Body.
WARNING!
The use of this crane on a body not
capable of handling the loads
imposed on it may result in serious
injury or death.
Optimal Service Body for
the 3315 Crane:
T1-11 Service Body
Applicable Chassis:
16000 GVWR to
19000 GVWR
Cab to Axle:
84” (213.36 cm)
Body Length Nominal: 133” (337.82 cm)
Body Height:
44” (111.76 cm)
Body Width:
94” (238.76 cm)
Compartment Depth: 22” (55.88 cm)
Floor Width:
50” (127 cm)
Net Weight:
3220 lbs (1460.37 kg)
Therefore, the installer of Stellar cranes and
bodies is considered one of the manufacturers of
the vehicle. As such a manufacturer, the installer
is responsible for compliance with all applicable
federal and state regulations. They are required
to certify that the vehicle is in compliance with the
Federal Motor Vehicle Safety Standards and
other regulations issued under the National
Traffic and Motor Vehicle Safety Act.
Please reference the Code of Federal
Regulations, title 49 - Transportation, Volume 5
(400-999), for further information, or visit
http://www.gpoaccess.gov/nara/index.html for
the full text of Code of Federal Regulations.
Notice:
PTO and Pump installation instructions are
provided by the proper manufacturers. For
more information on which PTO and Pump fit
your application, please contact your local
Stellar Distributor or Stellar Customer Service.
The following pages will give a basic overview
of the installation process for the Stellar 3315.
Please read thru them entirely and obtain a
clear understanding of the process before
proceeding.
Chapter 6 - Installation
6-1
Installation Overview
1. Determine that the mounting location for the 3315 crane is at least 18” x 15” (45.7 x 38.1 cm).
2. Use the detail on page 6-2 to drill .938” diameter holes into the mounting plate. Run tap on the threads of the base to
be sure they are clean.
3. Use a crane or lifting device capable of lifting the weight of the Stellar crane. The Stellar 3315 weighs approximately
800 lbs (360 kg). Note: cranes are shipped with rotation positioned at 180 degrees from normal stowed travel
position (See photo above). This will allow for easy installation of the crane and permanent connection of all hydraulic
and electrical components prior to repositioning into the crane saddle.
4. Connect straps
from the lifting device to the lifting rings on the Stellar 3315.
1
7 or chain
5. Use four (4) ⁄8 x 2 ⁄4 #8 bolts and four (4) #8 flat washers.
6. Install a washer on each bolt.
7. Apply Loctite Thread locker #277 to the bolts.
8. Using the lifting device, lower the Stellar 3315 just above the crane compartment and start the bolts. Have someone
assist in leveling the crane. Note: the rotation motor should be to the door side of crane compartment and the
boom should be extended back over the rear bumper.
9. Secure the crane using the mounting hardware provided (see the detail on page 6-2). Note: longer or shorter cap
screws may be required – recommended thread engagement into crane base is 1.00” – use grade 8, zinc
plated cap screws only.
10. Torque the cap screws to 454 ft-lbs.
11. Remove supporting crane.
12. 12. Hook-up hydraulics and electrical using the schematics provided in Chapter 8 - Hydraulics - Electrical. Note: If
questions should arise during any portion of this installation, please contact Stellar Customer Service at
(800) 321-3741.
Ø0.938
4 Places
FRONT
Ø5.00
MOTOR
10.00
5.00
2
1
7.37
14.75
Hole Mounting Detail
CAP SCR 0.88-9x2.25 HHGR8
WASHER 0.88 SAE GR8
Chapter 6 - Installation
6-2
Installation Details
1. Determine that the
mounting location for
the 3315 crane is at
least 18” x 15” (45.7
x 38.1 cm).
2. Use the detail on
page 6-2 to drill
.938” diameter holes
into the mounting
plate. Run tap on the
threads of the base
to be sure they are
clean.
3. Use a crane or lifting device capable of lifting the weight of the Stellar crane. The Stellar 3315
weighs approximately 800 lbs (360 kg). Note: cranes are shipped with rotation positioned
at 180 degrees from normal stowed travel position (See photo above). This will allow for
easy installation of the crane and permanent connection of all hydraulic and electrical
components prior to repositioning into the crane saddle.
4. Connect straps or chain from the lifting device to the lifting
rings on the Stellar 3315.
5. Use four (4) 7⁄8 x 2 1⁄4 #8 bolts and four (4) #8 flat washers.
6. Install a washer on each bolt.
7. Apply Loctite Thread locker #277 to the bolts.
8. Using the lifting device, lower the Stellar 3315 just above
the crane compartment and start the bolts. Have
someone assist in leveling the crane. Note: the rotation
motor should be to the door side of crane
compartment and the boom should be extended
back over the rear bumper.
Chapter 6 - Installation
6-3
Installation Details Continued...
9. Secure the crane using the mounting hardware
provided (see the detail on page 6-2). Note:
longer or shorter cap screws may be required
– recommended thread engagement into
crane base is 1.00” – use grade 8, zinc plated
cap screws only.
10. Torque the cap screws to 454 ft-lbs.
11. Remove supporting crane.
12. Hook-up hydraulics and electrical using the schematics provided in Chapter 8 - Hydraulics Electrical.
Note: If questions should arise during any portion of this installation, please
contact Stellar Customer Service at (800) 321-3741.
Chapter 6 - Installation
6-4
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. The actual test data must be recorded and supplied with the truck at the
time of in-service and should be kept with the truck at all times. The following procedure will test
the truck package for stability and will provide a stability capacity chart. The load limit information
shown on the stability capacity chart is formulated on 85% tipping.
Set Up:
1. Locate the truck on a test course in position for loading and engage travel brakes.
2. Set outriggers so that they make contact with firm, level footings.
3. Operate the crane under partial load to assure operator proficiency and proper machine function.
3315 Stability Data
Max Horizontal Reach: 180” (From the center of rotation to boom tip)
Stability Test Weight: 875 lbs.
Test Procedure
1. Rotate the crane into Zone 1 position.
2. With the crane fully retracted and the boom horizontal, winch the test weight off the ground. Note:
Keep weight within six inches of the ground at all times.
3. Extend the boom outward until full extension has been reached or until the truck becomes
unstable (Again, use the winch to keep the weight within six inches of the ground.)
4. If the boom goes full extension without becoming unstable, the crane is termed stable for this
zone and 100% can be written in the Zone 1 data box.
5. If the truck becomes unstable prior to going full extension, retract the boom until the truck
becomes stable and measure the horizontal reach in this position (center of rotation to boom tip).
This is the stable horizontal reach for this zone. Stable horizontal reach divided by Maximum
horizontal reach multiplied by 100 equals the percentage of rated capacity for this zone. Use the
following formula to determine the percentage of rated capacity:
6. Record this number in the data box for Zone 1. This is the revised capacity due to stability for
this zone.
7. Repeat this procedure for each zone until the worksheet is completed.
8. This is the revised capacity based on stability of this package.
Chapter 6 - Installation
6-5
STABILITY CAPACITY CHART
For a decal version of this capacity chart, please contact Stellar Customer Service at (800) 321-3741
Chapter 6 - Installation
6-6
Chapter 7 - Assembly Drawings
Base Assembly
7
10
8
9
5
15
6
2
3
4
1
11
12
13
14
P/N 19998
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART
16653
D1204
D0790
D1307
211 64
17750
1894 5
18948
0 340
0479
D0240
2 2 3 93
C2256
D1345
2 1 15 1
DESCRIPTION
QTY.
BEARING SWING DRIVE CAST
1
ROTATION MOTOR 5520
1
2
WASHER 0.50 FLAT GR8
CAP SCR 0.50-13X1.25 SH
2
P LATE CAST BASE 552 0
1
STOP 3515
1
GU A RD TT B 5 5 2 0 C RA N E
1
C AP S CR 0.88-9 X .63 PLAS TIC
2
WA S HE R 0. 2 5 F LA T
2
C A P S CR 0 . 2 5 - 2 0 X 0 . 7 5 H H G R5
2
FTG ELL 0.13 CPRSN TUBE TO NPT
1
T U BE AI R
1
1
FTG COUPLER PIPE 0.13
FTG CPRSN 0.12NPT/0.25 TUBE
1
G ASK E T MO TO R 0 0 8 - 1 0 0 56 - 1
1
GASKET SHOWN AS REFERENCE
D0240 SHOWN AS REFERENCE
(INCLUDED WITH GEAR BEARING)
Chapter 7 - Assembly Drawings
7-1
Mast Assembly
3
6
2
1
7
9
8
7
5
4
P/N 19999
ITEM
1
2
3
4
5
6
7
8
9
PART
20428
D0178
D1711
C5902
C1026
2 45 61
21810
24957
0489
DESCRIPTION
COVER VB 33 15
WA S HE R # 10 S A E FL A T Z IN C
C A P S C R # 10 - 24 X 0 . 50 B T N H D S S
WASHER 0.63 SAE FLAT YELLOW GR8
C A P SC R 0 . 6 3 - 1 1X 2. 50 H H G R 8 ZY
MA S T 3 31 5 RE V A
B U S H IN G GS I -2 42 6 - 12 1. 5 0X 0 .7 5
V B 4 S ECT E LEC T ON /OF F ST ERL ING 4GPM
C A P S C R 0 . 3 1 - 1 8 X 2 . 5 0 H H G R5
Chapter 7 - Assembly Drawings
7-2
Q TY.
1
2
2
10
10
1
4
1
2
Power Unit Assembly
*Note: Electric Versions Only
10
3
9
11
12
6
13
4
7
5
1
8
14
2
P/N 20432
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PART
1 71 32
1 6 99 4
19997
0343
C0922
03 4 2
0 35 2
C6106
18472
17771
18468
0340
0479
0 501
DESCRIPTION
B RK T P O WER UN IT 5 5 20
PO W E R U N IT 12 V 55 2 0 H O R Z
COVER POW ER U NIT 5 52 0
WA SHE R 0 .31 U S S F L A T ZI NC
C A P S C R 0 .3 1 - 1 8 X 1 . 0 0 H H G R 5
NUT 0.31-18 HH NYLOC
WA SHE R 0 .5 0 U S S F LA T Z I NC
N UT 0 . 5 0 - 1 3 HH G R 5 N Y L O C
DEC AL MA NU AL O PERA TION 5 52 0
S W I TC H P US H BU T T ON 9 2 1 6 - 0 3
SOLE NOID 12V 2 00 AMP CONT 24143
WASHER 0.25 FLAT
CA P S CR 0. 25 -2 0 X 0 . 7 5 HH G R 5
C A P S C R 0 .5 0-1 3X 2 . 00 HH GR 5
Chapter 7 - Assembly Drawings
7-3
Q TY.
1
1
1
8
4
4
6
3
1
1
1
2
2
3
Main Boom
3
4
10
18
30
19
8
21
10
10
15
6
9
9
28
10
15 25
11
9
11
20
13
11
21
7
20
5
11
17
16
26
27
24
10
9
24
9
?
1
2
10
14
4
11
P/N 20000
12
ITEM PART
1 19496
2 19 497
3 1 951 1
4 5591
5 2117 0
6 0067
7 16067
8 90 86
9 7403
10 C6353
11 984 3
12 042 0
13 3 2 67
14 1 9 51 4
15 034 0
16 1 98 8 1
17 03 33
1 8 115 44
1 9 0 47 8
2 0 0 337
2 1 0 22 0
22 24563
2 4 195 12
25 8 62 2
2 6 03 4 3
27 C0922
28 C5606
2 9 256 7 6
3 0 256 7 7
11
29
DESCRIPTION
WEA R PAD .88X1. 38 RND
PLATE 1ST EXT 3 31 5 WE AR PA D
W I N C H 1 6 00 3 3 1 5 C R A N E
WASHER 0.31 SAE FLAT YELLOW GR8
CA P S CR 0. 31 - 1 8 X 1 . 00 HH G R8
BUS HI NG QSI- 242 6-2 4
B U SH I N G Q SI - 24 26 -1 6
P IN 1. 25 X4 . 6 9 D &T
PIN CA P 0. 44X2. 50X .252
WASHER 0.38 FLAT GR8
C A P S C R 0 .3 8-1 6X 0 . 7 5 HH GR 8
C A P S C R 0 .3 1-1 8 X 0 . 7 5 HH GR 5
PL A T E C Y LIN DE R MT G
PI N 1. 5 0X 5 .5 0 D &T
WASHER 0.25 FLAT
PLAT E AN GL E IN DICAT OR 331 5
N UT 0 . 2 5 -2 0 HH G R 5 N Y L O C
CORD REEL 6 620
C AP SC R 0 . 2 5 - 2 0 X 0 . 50 H H G R 5
H OS E C LA MP LN 4 19 0 P P
C AP SC R 0 . 2 5 -2 0 X 1. 5 0 H HG R 5
INN ER BOOM 33 15 REV A
P IN 1 . 5 0 X 1 0 . 5 0 D & T
C LAMP HOSE/ TUBE AG-2
W A S H E R 0 .3 1 U S S F LA T ZI N C
CAP SCR 0.31-18X1.00 HHGR5
CLAMP 0.25 BLK VINYL
C Y L I N D E R A S M 3 .0 0 X 1 9. 88
C YL I N D E R A S M 2 .0 0 X4 8. 0 0
Chapter 7 - Assembly Drawings
7-4
QTY.
2
2
1
16
8
2
2
1
8
12
12
8
2
1
6
2
2
1
2
2
2
1
2
1
1
1
1
1
1
Extension Boom Assembly
2
?
2
9
8
7
3
17
4
5
11
6
10
18
12
13
14
15
16
P/N 20001
ITEM PART
1 19010
2 194 57
3 19496
4 19 49 7
5
5591
6
0 42 0
7
0337
8
0220
9 C5629
10 1 9 00 7
11 C0930
1 2 0 34 2
1 3 1 63 6 3
14 19996
15 0 3 4 3
1 6 0 48 4
17 1 70 07
18 27 719
DESCRIPTION
QTY.
EXT BOOM 3315 1ST
1
W E A R PAD 0. 2 5X 1 . 38 R ND
4
W E AR P AD . 8 8X1 .3 8 RN D
2
PLATE 1ST EX T 331 5 WE AR PAD
2
WASHER 0.31 SAE FLAT YELLOW GR8 8
C A P S C R 0 .3 1 - 18 X 0 .7 5 H H GR 5
8
HOSE CLAMP LN 4190 PP
1
C AP SC R 0 .2 5-2 0 X 1. 5 0 H HG R 5
1
PIN HITCH 0.50X5.50
1
EXT BOO M 2N D 3 31 5
1
CAP SCR 0.31-18X3.00 HHGR5
2
NUT 0.31-18 HH NYLOC
2
S HE A V E 3 51 5 5. 5 0 DI A .2 5 R /1 . 94 TH K
2
P IN T EAR DR OP .7 5 X2 . 88
2
WA S H ER 0. 31 U SS FLAT Z IN C
2
C AP SC R 0 .3 1-1 8 X 0. 50 H HG R 5
2
P I N H I T C H 0 . 7 5X 4 . 0 0
1
SPACER BOOM TI P 6620 UHMW
2
Chapter 7 - Assembly Drawings
7-5
Main Cylinder Assembly
3
6
Note: Main Cylinder uses
Stellar Seal Kit P/N 11378
3
5
4
7
3
2
3
7
6
1
Cylinder
Serial Tag
Location
7
7
P/N 25676
ITEM
1
2
3
4
5
6
7
PART
19 0 17
15110
027 9
15 11 1
13080
19363
0067
DESCRIPTION
CY L I N D E R 3. 00 X1 9 .8 8
VALVE CHECK SINGLE W/ ORIFICE
FTG A DA PT 6-F5 OLO - S
F T G A D A P T M S T H / F S T H 6- 4 - F 5 0 G 5
MANIFOLD A SM 6620 INN ER H OLD ING
TUB E ASM 0 .38X 5.69 331 5
BUSHING QSI-2426 -24
QTY.
1
1
4
1
1
2
4
NOTE:
CYLINDER BUSHINGS FOR REFERENCE ONLY
Chapter 7 - Assembly Drawings
7-6
Extension Cylinder Assembly
2
Note: Extension Cylinder uses
Stellar Seal Kit P/N 1099
4
6
2
3
5
2
1
2
P/N 25677
Cylinder
Serial Tag
Location
ITEM
1
2
3
4
5
6
PART
1950 7
0 27 9
16154
17009
12 15 8
1 4929
DESCRIPTION
C Y L I ND E R 2. 0 0 X 48 . 0 0
F T G A DA P T 6 - F5 O LO- S
MA NIF OLD DOU BLE T1 1 A 3 500 P SI
TU B E A S M 0. 38 X 33 . 00 E X T C Y L 3 51 5
TU B E ASM 0. 38 X8. 88 M A IN CY L 6 62 0
C L AM P 0. 38 PO R T TU BE
Chapter 7 - Assembly Drawings
7-7
QTY.
1
4
1
1
1
1
Cable & Hook Assembly
20
2
21
1
4
14
3
5
23
6
22
9
11
10
8
18
13
12
12
7
16
17
7
19
P/N 20002
IT E M PAR T
1
11938
2
D1711
3
10972
4
C4956
5
0530
6
0347
7
16495
8
16494
9
19996
10
0343
11
0484
12
0352
13
5468
14 17006
15
9263
16 D1300
17 25842
18 27810
19 16607
20 33749
21 33081
22 35264PC
23 37850
QTY.
D E S CR I P T I O N
SWITCH LIMIT A2B FURNAS 3SE3170
1
CAP SCR #10-24X0.50 BTNHD SS
1
CHAIN 0.105 (RM) 2607-21201
1
NUT #10-24 HH NYLOC SS
1
CAP SCR 0.38-16X2.75 HHGR5
1
NUT 0.38-16 HH NYLOC
1
PLATE 3515 SNATCH BLOCK
2
SHEAVE 3515 5.25 DIA .25R/1.12 THK
1
PIN TEAR DROP .75X2.88
1
WASHER 0.31 USS FLAT ZINC
1
CAP SCR 0.31-18 X 0.50 HHGR5
1
WASHER 0.50 USS FLAT ZINC
6
NUT 0.50-13 HHGR8 NYLOC
3
WIRE ROPE 1/4 6X19 IWRC-XIP 65FT
1
PIN .38X3.00 QUICK RELEASE
1
CAP SCR 0.50-13X3.75 HHGR5
3
HOOK 3 TON SWIVEL CROSBY 1028618 1
SPACER 3315 SNATCH BLOCK UHMW
2
SPACER 3315 SNATCH BLOCK
1
SCREW #10-24X1.75 SHGR8 ZINC
4
COVER ANTI 2 BLOCK
1
WEIGHT ANTI 2 BLOCK
1
CONNECTOR QUICK LINK 0.13
1
Chapter 7 - Assembly Drawings
7-8
Chapter 8 - Hydraulics - Electrical
Control Kit - Electrical Version
P/N 20435
Chapter 8 - Hydraulics - Electrical
8-1
Control Kit - Hydraulic Version
Chapter 8- Hydraulics - Electrical
8-2
Control Kit - Radio Version
P/N 29216
Chapter 8 - Hydraulics/Elecrical
8-3
Hydraulic Kit - Electrical Version
P/N 20433
Chapter 8 - Hydraulics-Electrical
8-4
Hydraulic Kit - Hydraulic Version
P/N 23181
Chapter 8 - Hydraulics-Electrical
8-5
Valve Bank
P/N 24957
1
2
4
2
4
3
Valve Identification
Valve Item #2 P/N 25377-G02571
Valve Item #3 P/N 25378-G02591
ITE M PART
25375
1
25376
2
25377
3
25378
25379
4
25380
DE SCRIPTION
RE LIE F VALV E 24957
SE AL K IT 25375
VA LVE SOLND 3 POS 4 W A Y TA ND G02571
VA LVE SOLND 3 POS 4 W A Y OPEN G02591
SE AL K IT 25377/ 25378
COIL 12VDC P ACK ARD MALE 24957
QTY
1
3
1
8
HYDRAULIC SCHEMATIC
Chapter 8 - Hydraulics - Electrical
8-6
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.
3. Install hydraulic reservoir with return filter.
Attach pump pressure line to valve, return
link to tank.
4. Fill system with hydraulic oil (Mobil DTE13M is recommended).
Chapter 8 - Hydraulics/Elecrical
8-7
Hydraulic System
Chapter 8 - Hydraulics-Electrical
8-8
Chapter 9 - Replacement Parts
PART#
D1204
25375
25376
25377
25378
25379
25380
15110
13080
9803
11991
16154
11378
1099
18452
6397
C2027
C2028
D1245
D1246
19363
12158
17009
21810
#0067
16067
19496
19457
7403
C6353
9843
16363
16494
9610
17007
C5629
9263
29085
29199
27710
11544
20436
18468
17771
10709
DESCRIPTION
HYDRAULIC SWING MOTOR
RELIEF VALVE
SEAL KIT - RELIEF VALVE
SOLENOID VALVE TAND G04571
SOLENOID VALVE OPEN G04591
SEAL KIT - SOLENOID VALVE
COIL - 12VDC
CHECK VALVE
MANIFOLD ASM - MAIN CYLINDER
C-BALANCE VALVE
PLUG - C-BALANCE
MANIFOLD ASM - EXTENSION CYLINDER
SEAL KIT - MAIN LIFT CYLINDER
SEAL KIT - EXTENSION CYLINDER
PRESSURE SWITCH
HYD PRESSURE GUAGE
O'RING - # 4 FACE SEAL
O'RING - # 6 FACE SEAL
O'RING - # 4 SAE
O'RING - # 6 SAE
TUBE ASM - MAIN CYLINDER
TUBE ASM - EXTENSION CYLINDER
TUBE ASM - EXTENSION CYLINDER
BUSHING 1.50" X 0.75"
BUSHING 1.50" X 1.50"
BUSHING 1.50" X 1.00"
WEAR PAD 0.88" X 1.38" RND
WEAR PAD 0.25" X 1.38" RND
PIN CAP .44 X 2.50 X .25
WASHER 0.38 FLAT GR8
CAP SCR. 0.38-16 X 0.75"
SHEAVE
SHEAVE
WIRE ROPE
HITCH PIN 0.75" X 4.00"
HITCH PIN 0.50" X 5.50"
QUICK RELEASE PIN .38 X 3.00"
LIMIT SWITCH
CRADLE RUBBER CAP
ANTI-2-BLOCK
CORD REEL
CONTOLLER HANDLE ASM.
12V SOLENOID (12volt hydraulic system)
PUSH BUTTON (12volt hydraulic system)
SAFETY LATCH FOR 3 TON HOOK
Chapter 9 - Replacement Parts
9-1
SUGGESTED QTY
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
4
4
4
4
1
1
1
2
2
2
2
2
2
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
Chapter 10 - 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.
Problem: Crane will not operate.
Solutions:
• Make sure that the parking brake is engaged.
• Make sure that the PTO is engaged.
• Make sure that there is 12V power going to
the radio receiver. If there is no power going to
the receiver, trace back to the power source
and check for a blown fuse or loose ground
connection. Refer to radio remote
troubleshooting guide at the end of this
chapter.
• Make sure that the transmitter batteries are
fully charged. (Rechargeable batteries are
good for 11 months or 200 charges)
• Make sure that the hydraulic pump is
operating at its rated flow or GPMs. Check the
flow by using the flow meter to determine the
GPMs. It is possible that the hydraulic pump is
getting weak. If this is suspected, contact
Stellar Customer Service.
Problem: Crane will operate manually but
will not operate electrically.
Solutions:
• Make sure that there is 12V power going to
the radio receiver. If there is no power going to
the receiver, trace back to the power source
and check for a blown fuse or 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.
Solutions:
• Make sure that the toggle switch is working
properly. If the switch is defective, simply
replace it.
• Make sure that there is power going from the
valve bank coil solenoid or to the function that
will not operate. If no power is going to the coil
solenoid, check wiring connections on wire
harness plug connector for broken wires, loose
connection or poor crimp. If power is going to
the solenoid valve, it may not be opening to
allow hydraulic oil to the function that is not
operating. Remove stem valve, thoroughly
clean, lubricate, and reinstall valve. Do not
over tighten. If the valve will not close, simply
replace it.
Problem: Two functions operate at the same
time while only toggling one function.
Solutions:
• Make sure that the solenoid valves are all in
the center position.
• Determine the function that is operating on
its own. Check to see if there is power going
to the solenoid valve from a function that
should not be operating. If voltage is present
at the solenoid valve without operating the
function, the toggle switch has failed and is
stuck in the “on” function. If no voltage is
present, the solenoid valve may be partially
open. Remove the stem valve, thoroughly
clean, lubricate, and reinstall the valve. Do not
over tighten. If valve will not close, simply
replace it.
Problem: Winch brake will not hold.
Solutions:
• Check to see if the back pressure on the
return line of the winch is greater than 50 psi.
Try operating a function other than the winch.
Operate the function both ways and then stop.
Now operate the winch. If the brake still does
not hold, contact Customer Service at Stellar.
Chapter 10 - Troubleshooting
10-1
Problem: Winch will not hold load.
Solutions:
• Make sure that the object being lifted does
not exceed the rated capacity of the winch.
Refer to the capacity chart. If the object is
within the rated capacity, reposition the truck
and try to lift the object without using the crane
boom extensions.
• Make sure that the relief valve on the winch
is set correctly. Readjust the relief valve if
necessary.
Problem: Crane only operates at full speed.
Solutions:
• Check to see if there is 12V power constantly
going to the proportional valve. If 12 volts are
showing up at the proportional valve without
pulling on the transmitter trigger, the
handle/trigger assembly may be defective. If 8
volts are showing at the proportional valve, it is
possible that the valve is stuck open and will
not close. Remove the valve, clean it
thoroughly and reinstall. Do not over tighten.
If the problem persists, replace the proportional
valve.
• Check to see if the manual override on the
proportional valve is turned out. Turn the
manual override on the flow valve in.
Problem: Crane operates slowly.
Solutions:
• Make sure that the crane is receiving the
recommended GPMs to operate.
• Check the level of hydraulic fluid in the
reservoir. Add fluid as needed.
• Check to see if the valve bank orifice is
plugged. If so, replace the orifice. Call Stellar
Customer Service for instructions.
• Make sure the proportional valve is receiving
12V power when fully engaging the transmitter
trigger. If there is not 12V power while pulling
the trigger, check for loose connections inside
the transmitter or replace the handle trigger
assembly. If the proportional valve is receiving
12 volts, loosen the solenoid holding nut and
check to see if the solenoid coil is magnetizing.
If no polarity is present, replace the coil. If coil
is magnetizing, remove the stem valve,
thoroughly clean, lubricate, and reinstall the
valve.
Problem: Winch “Up”, Main Cylinder
“Down”, and Extension Cylinder “Out” are
the only functions that don’t operate.
Solutions:
• Make sure that the unit 2-block weight and
chain on the end of the boom are straight so
they slide easily along the wire rope cable.
• Make sure that the limit switch is working
properly. Disconnect the two wires connected
to the limit switch and tie them together. If all
functions operate, replace the limit switch.
• Make sure that the cord for the cord reel is
undamaged. Check the continuity of the cord.
Disconnect the cord reel from the crane
harness and bypass the harness connection. If
the crane operates properly, replace cord reel.
Problem: Cylinder drifts outward or
downward.
Solutions:
• Check to see if there is air in the hydraulic
system. Operate all cylinders connected to the
hydraulic system. Start with the extension
cylinder, then operate the main boom, winch,
rotation, and ending with the hydraulic
outriggers, if installed. When operating, extend
each cylinder halfway out, retract all the way in,
and then extend until the cylinder rod is at the
end of its stroke. Operate cylinders slowly so
air is pushed thru the system to the reservoir.
Repeat this cycle 2-3 times.
• Make sure the holding valves are operating
properly. Remove, clean, and then inspect
each holding valve. When removing a holding
valve, always relieve the pressure inside the
cylinder by loosening jam nut of the holding
valve and turning set screw inward/clockwise.
Count the number of turns until the set screw is
seated. When reinstalling the holding valve,
make sure the valve is reset by turning the set
screw the number of turns it took to relieve the
pressure. Finish by tightening the jam nut.
• Check the cylinder rod for scratches. If a
scratch is located on the cylinder rod, hydraulic
fluid can pass thru and cause a loss of
pressure. Replace cylinder rod or cylinder.
• Check to see if the piston seals are
damaged. If they show signs of damage,
install a new cylinder seal kit.
Chapter 10 - Troubleshooting
10-2
Remtron Radio Remote Maintenance and Troubleshooting
Monthly Inspection Schedule
• Inspect the transmitter for damage to keypad and case.
• Inspect all electrical and antenna connections to ensure they are clean and tight.
Transmitter Troubleshooting
WARNING!
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 Chart
LED Indication
Possible Cause
LED is off
Transmitter is off.
LED flashes
Transmitter is operating in a normal mode.
LED will not light when any button is pushed, or
LED remains on continuously
Replace batteries. If this does not correct the
problem, the transmitter must be returned for
repair.
Transmitter Repairs
CAUTION!
The transmitter electronic components are exposed when the back of the case is removed.
Take caution to prevent dirt or other contaminants from entering the case. Do not allow the
circuit to be scraped or damaged in any way.
ID# 28008C
Battery Replacement
Printed
Circuit Board
Assembly
1. Remove the screws on the back of the
transmitter and remove the back of the case.
(Remove These
Screws to Replace
Keypad)
2. Remove and replace the batteries with the
same type (9V or AA). Replace the back of
the case and the screws. Make sure the
battery wires don’t get pinched between the
case halves. Tighten the screws snugly.
Programming
Plug
+
+
Transmitter with Back Removed.
Chapter 10 - Troubleshooting
10-3
Changing the Transmitter Keypad
1. Remove the screws in the back of the transmitter and remove the back of the case.
2. Remove the batteries from the holder or battery clip.
3. Remove the two screws holding the printed circuit board assembly and remove the board from
the case.
4. Remove the nuts from the studs holding the support plate to the case front.
5. Remove the backing plate and rubber keypad from the case front.
6. Install the new rubber keypad onto the backing plate, making sure the tabs are pulled through
each slot.
7. Install the keypad and backing plate into the case front.
8. Apply a small amount of Torque Seal® to the threads on the studs and install the nuts on the
studs finger tight plus 180 degree turn. DO NOT use locktite as most formulations will cause the
plastic to become brittle.
9. Replace the back of the case and the screws. Make sure the battery wires do not get pinched
between the case halves. Tighten the screws snugly.
Receiver Testing
Receiver LEDs. Refer to Figure 2 for the location of the decoder diagnostic LED on the receiver
cabinet.
Possible Cause
LED Indication
LED on continuous
Receiver operating voltage is present, no signal
is being received.
LED flashes
Signal is being received that matches the
decoder’s address.
LED goes off
Signal is being received, but address is wrong.
Chapter 10 - Troubleshooting
10-4
Receiver Troubleshooting
The following steps should be followed when troubleshooting the receiver.
1. Check the LED indicator. If it is not lit:
•Make sure 12 VDC and ground is present at the connecting wires.
•If using the AC power, check for AC power on the connecting wires.
•If input power is present and the LED is off, check the fuse inside the receiver case.
•If input power is present and the LED is off, and the fuse inside the receiver case is OK,
send the receiver to Remtron for repair.
2.Activate the transmitter by pressing any command switch.
•If the receiver LED does not flash, test the transmitter.
•Verify the identity code is the same for the transmitter and receiver. Use the learn button to
re-program the receiver for the transmitter.
•Send the receiver to Remtron for repair.
3.Only some functions are operating:
•Check to make sure the common wires for the relays are connected properly.(See
installation)
•Check output voltage of the respective wires and the electrical circuits.
•Check the fuses inside the receiver case.
•Check the receiver label to verify the function has been programmed to the needs of the
equipment.
4.You are experiencing intermittent operation:
•Check antenna connections and antenna location.
•On AC systems, ensure noise suppression devices have been placed across the coils of all
contactors.
•Ensure you are inside the operating range of the receiver and have line of sight to the
receiver antenna.
5.Operating Range is short:
•Check all antenna connections and transmitter operation.
•On new installations, verify the receiver antenna is placed properly. If necessary,use an
antenna mounting kit to relocate the antenna to a more favorable location.
Receiver ID Code Programming
The receiver learns it’s ID Code from a compatible transmitter. The receiver is programmed at the
factory and does not need initial programming. If a replacement transmitter is to be used with the
receiver, the receiver must be programmed to recognize the replacement transmitters ID Code.
Chapter 10 - Troubleshooting
10-5
WARNING!
Once the receiver is linked to a transmitter it will respond to commands from that
transmitter. Make sure that all equipment attached to the receiver is safe from any
unintended movement.
For hydraulic systems, shut off the vehicle engine and relieve all hydraulic pressure before using the
Auto-Link function.
Using Auto-Link to change the Receiver ID Code
3.50
Test
LED
1. Be sure power is applied to the receiver.
POWER/OPERATE
Note: Be sure no other compatible transmitters are being
used in the area when performing Auto-Link
programming.
1916 W. MISSION RD.
ESCONDIDO, CA. 92029
Wiring Diagram
VIO
BLU
8.25
2. Press and hold the Learn button on the bottom of the
receiver (next to the antenna connector).
BOOM
UP
DOWN
YEL
RIGHT
ORG
LEFT
PNK
OUT
BRN
IN
GRY
WINCH
UP
GRN
DOWN
TAN
3. While holding the Learn button, press any command on the
transmitter. When the receiver records the transmitter’s ID
Code, the test LED will flash rapidly.
RED
WHT
BLK
DUMP
VALVE
+12VDC
+12VDC
GND
1916 W. MISSION RD.
ESCONDIDO, CA. 92029
This device complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions:
(1) This device may not cause harmful interference,
and (2) This device must accept any interference
received, including interference that may cause
undesired operation.
4. Release the Learn button. The receiver will now respond
only to the transmitter whose code was learned.
TNC Antenna
Connector
Learn
Button
.25" D
(4 PLCS)
Receiver (Example)
Replacing the fuse in the Receiver.
To replace a fuse on the circuit board:
Circuit Board
1. Ensure power is turned off to all receiver
power inputs.
1916 W. MISSION
2. Remove the receiver from it’s mounting.
This device complies with Part 15 of the
FCC Rules.
Operation is subject to the following two
conditions:
3. Remove the four screws on the end of
the receiver by the wiring connector.
4. Gently pull the end cap and receiver
board out of the case about 5 inches to
expose the fuse on the circuit board.
F1
Remove four (4) screws
Receiver fuse location.
5. Replace the fuse with a GMC .25 Amp (Remtron P/N 458028) fuse.6.Reposition the end cap and
board and snugly tighten the four screws.7.Re-Install the receiver.
Chapter 10 - Troubleshooting
10-6
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,
Twelve (12) month repair labor, and
Thirty-six (36) month warranty on all Stellar Crane and Hooklift structural parts.
The warranty period shall begin from the date recorded by Stellar as the in-service date. This date will be derived from the completed warranty
registration card. In the event a warranty registration card is not received by Stellar, the factory ship date will be used. Regardless of in-service
date, warranty coverage does not extend beyond twenty-four (24) months from date of manufacture.
Stellar’s obligation under this warranty is limited to, and the sole remedy for any such defect shall be, the repair and/or replacement (at Stellar’s
option) of the unaltered part and/or component in question. Stellar after-sales service personnel must be notified by telephone, fax, or letter of
any warranty-applicable damage within fourteen (14) days of its occurrence. If at all possible, Stellar will ship the replacement part within 24hours of notification by the most economical, yet expedient, means possible. Expedited freight delivery will be at the expense of the owner.
Warranty claims must be submitted and shall be processed in accordance with Stellar’s established warranty claim procedure. Stellar after-sales
service personnel must be contacted prior to any warranty claim. A return materials authorization (RMA) account number must be issued to the
claiming party prior to the return of any warranty parts. Parts returned without prior authorization will not be recognized for warranty consideration.
All damaged parts must be returned to Stellar freight prepaid; freight collect returns will be refused. Freight reimbursement of returned parts will
be considered as part of the warranty claim.
Warranty service will be performed by any Stellar new equipment distributor, or by any Stellar-recognized service center authorized to service the
type of product involved, or by the Stellar factory in the event of a direct sale. At the time of requesting warranty service, the owner must present
evidence of date of delivery of the product. The owner shall be obligated to pay for any overtime labor requested of the servicing company by the
owner, any field service call charges, and any towing and/or transportation charges associated with moving the equipment to the designated
repair/service provider.
All obligations of Stellar and its authorized dealers and service providers shall be voided if someone other than an authorized Stellar dealer
provides other than routine maintenance service without prior written approval from Stellar. In the case repair work is performed on a Stellarmanufactured product, original Stellar parts must be used to keep the warranty in force. The warranty may also be voided if the product is
modified or altered in any way not approved, in writing, by Stellar.
The owner/operator is responsible for furnishing proof of the date of original purchase of the Stellar product in question. Warranty registration is
the ultimate responsibility of the owner and may be accomplished by the completion and return of the Stellar product registration card provided
with the product. If the owner is not sure of registration, he is encouraged to contact Stellar at the address below to confirm registration of the
product in question. This warranty covers only defective material and workmanship. It does not cover depreciation or damage caused by normal
wear and tear, accident, mishap, untrained operators, or improper or unintended use. The owner has the obligation of performing routine care
and maintenance duties as stated in Stellar’s written instructions, recommendations, and specifications. Any damage resulting from
owner/operator failure to perform such duties shall void the coverage of this warranty. The owner will pay the cost of labor and supplies
associated with routine maintenance.
The only remedies the owner has in connection with the breach or performance of any warranty on the Stellar product specified are those set
above. In no event will Stellar, the Stellar distributor/dealer, or any company affiliated with Stellar be liable for business interruptions, costs of
delay, or for any special, indirect, incidental, or consequential costs or damages. Such costs may include, but are not limited to, loss of time, loss
of revenue, loss of use, wages, salaries, commissions, lodging, meals, towing, hydraulic fluid, or any other incidental cost.
All products purchased by Stellar from outside vendors shall be covered by the warranty offered by that respective manufacturer only. Stellar
does not participate in, or obligate itself to, any such warranty.
Stellar reserves the right to make changes in design or improvement upon its products without imposing upon itself the same upon its products
theretofore manufactured.
This warranty will apply to all Stellar Hooklifts, Stellar Tire Service Trucks, & Truck-mounted Cranes shipped from Stellar’s factory after July 1,
2005. The warranty is for the use of the original owner only and is not transferable without prior written permission from Stellar.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE
PROVISION OF MATERIAL AND SERVICES, AS SPECIFIED HEREIN. STELLAR INDUSTRIES, INC. IS NOT RESPONSIBLE FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Revision Date: March 2006
Document Number: 37040
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