Telescopic Crane Manual

Owner’s Manual

Last Revision: 08/01/12Subject to Change without Notification.

© 2011 Stellar Industries, Inc.

Safety • Assembly • Maintenance • Parts

TireMan 16160

Stellar Industries, Inc.190 State Street

PO Box 169Garner, IA 50438

800-321-3741 Fax: 641-923-2811

www.stellarindustries.com

TM16160 Manual Revisions

Date of Revision Description of RevisionSection Revised

Table of Contents i

TM16160

Table of ContentsAn Overview about Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

TM16160 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TM16160 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

TM16160 Dimensional Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

TireMan Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Stellar Safety Decal - PN 16732 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

TM16160 Decal Kit - PN 37845 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

TM16160 Assembly - PN 37835 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

TM16160 Mounting Kit - PN 22280 . . . . . . . . . . . . . . . . . . . . . . . . . . .9

TM16160 Hydraulic Kit - PN 16668 . . . . . . . . . . . . . . . . . . . . . . . . . . .10

TM16160 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Lubrication Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

TM16160 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

BMS-2 Receiver Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

ii Stellar TM16160 Owner’s Manual

As the owner or employer, it is your responsibility to instruct the operator in the safe opera-

tion of this equipment and to provide the operator with properly maintained equipment.

Failure to read this manual by anyone who will operate, service, or work around this tire

manipulator is a misuse of the equipment. Death or serious injury will result from improper

use or maintenance of this machine.

Occupational safety is a prime concern of Stellar Industries in the design and production

of this tire manipulator. Our goal in writing this manual was the safety of the operator and

others who work around this equipment.

It is your responsibility to know the specific requirements, governmental regulations, pre-

cautions and work hazards that exist in the operation and maintenance of this tire manip-

ulator. You shall make these available and known to all personnel working with and

around the equipment, so that all of you will take the necessary and required safety pre-

cautions.

FAILURE TO HEED THESE INSTRUCTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.

It is also your responsibility to operate and maintain your tire manipulator with caution, skill,

and good judgment. Following the recognized safety procedures will help you avoid

accidents. Modification to any part of his tire manipulator can create a safety hazard

and therefore shall not be made without the manufacturer’s written approval. Use only

factory approved accessories, options, and parts on this equipment. The rebuilding or

remounting of this equipment requires the mounting procedures and retesting to be in

accordance with factory instructions. Safety covers and devices must remain installed

and maintained in proper working condition. Safety decals must be maintained, be com-

pletely legible, and be properly located. If safety covers, devices, or decals are missing,

they must be replaced with the proper designated Stellar part.

Be capable, careful, and concerned! Make safety your everyday business!

An Overview about Safety

Attention!According to Federal Law (49 cfr part 571),

each final-stage manufacturer shall com-

plete 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 manu-

factured in two or more stages.

Therefore, the installer of Stellar tire manipu-

lators is considered one of the manufactur-

ers of the vehicle. As such a manufacturer,

the installer is responsible for compliance

with all applicable federal and state regu-

lations. 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

www.gpoaccess.gov/nara/index.html for

the full text of Code of Federal Regulations.

Page 1

TM16160

For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at

800-321-3741Hours: 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]

The Stellar TireMan is designed to provide

safe and dependable service. With proper

use and maintenance, these tire manipula-

tors will operate at peak performance for

many years.

To promote this longevity, carefully study

the information contained in this manual

before putting the equipment into service.

Though it is not intended to be a training

manual for beginners, this manual should

provide solid guidelines for the safe and

proper usage of the tire handler.

Once you feel comfortable with the materi-

al contained in this manual, strive to exer-

cise your knowledge as you safely operate

and maintain the tire manipulator. This

process is vital to the proper use of the unit.

A few notes on this manual:

A copy of this manual is provided with

every tire manipulator and shall remain with

the tire manipulator at all times.

Information contained within this manual

does not cover all maintenance, operating,

or repair instructions pertinent to all possible

situations.

Please be aware that some sections of this

manual contain information pertaining to

Stellar manufactured tire manipulators in

general and may or may not apply to your

specific model.

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

improvement or commercial/production

purposes. This right is kept with no require-

ment or obligation for immediate mandato-

ry updating of this manual.

In closing:

If more information is required or technical

assistance is needed, or if you feel that any

part of this manual is unclear or incorrect,

please contact the Stellar Customer Service

Department by phone at 800-321-3741 or

email at [email protected].

ATTENTIONFailure to adhere to the instructions could result in property damage or

even serious bodily injury to the operator or others close to the tiremanipulator.

TM16160 Introduction

2 Stellar TM16160 Owner’s Manual

TM16160 Specifications

Capacity: 16,500 lbs @15 ft (7,484 kg @ 4.57m)Clamping Span: 56” to 162” (142 cm to 411 cm)Clamp Cylinders: 4.5” (11.43 cm) bore with pilot operated check valvesTilt Cylinder: Provided by crane extension boomBody Rotation: 315º powerRotation System: Worm gearClamping Pad Rotation: Continuous 360º powerTireMan Tilt: +80º to -20ºHydraulic Controls: Incorporated with the crane controlsApproximate Shipping Weight: 6000 lbs (2,722 kg)

15’(4.57m)16500lbs(7484kg)

ROTATION

17’(5.18m)14000lbs(6350kg)

20’(6.10m)12000lbs(5443kg)

MAXIMUM RATED LOAD

16500 LBSEXCEEDING MAXIMUM RATED LOAD WILL

DAMAGE EQUIPMENT AND VOID WARRANTY37847

7484 KG

Page 3

TM16160

TM16160 Dimensional Layout

162

56


TireMan Safety NotesGeneral 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.

Trainees or untrained persons shall be under

the direct supervision of qualified persons.

Do not operate equipment under the

adverse influence of alcohol, drugs, or

medication.

Personal SafetyKeep clear of all moving parts.

Always wear the prescribed personal safety

devices.

Always wear approved accident-preven-

tion clothing such as: protective helmets,

anti-slip shoes with steel toes, protective

gloves, anti-noise headphones, protective

glasses, and reflective jackets with breath-

ing apparatus. Consult your employer

regarding current safety regulations and

accident-prevention equipment.

Do not wear rings, wristwatch, jewelry,

loose-fitting 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

tire manipulator.

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 hand-

holds. These parts move and cannot pro-

vide stable support.

Never allow anyone to ride the tire manipu-

lator arms or load.

Maintenance SafetyNever modify or alter any of the equip-

ment, whether mechanical, electrical, or

hydraulic, without explicit approval from

Stellar Industries.

Do not perform any maintenance or repair

work on the tire manipulator unless author-

ized and trained to do so.

Release system pressure before attempting

to make any adjustments or repairs.

Do not attempt service or repair when the

PTO is engaged.

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, dam-

aged, or not legible.

The safety instruction plates, notices, load

charts and any other sticker applied to the

tire manipulator, crane or service body must

be kept legible and in good condition. If

necessary, replace them.

StabilityKnow the tire manipulator components and

their capabilities and limitations.

Overloading the tire manipulator may result

in serious injury to self and others, and dam-

age to the equipment and immediate sur-

roundings.

Never exceed manufacturer’s load ratings.

These ratings are based on the machine’s

hydraulic, mechanical, and structural

design rather than stability.

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.

Page 5

TM16160

TireMan Safety Notes Continued...Park the vehicle on level ground and

extend the outriggers fully out and then

down.

Keep feet and legs clear when lowering

outrigger jacks.

Never operate the tire manipulator without

making sure the outriggers are positioned

on stable, flat ground.

Set the parking brake and disengage the

drive axle before attempting a lift.

Load SafetyOperate the tire manipulator 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.

Never use a sling bar or anything larger

than the hook throat that could prevent the

hook latch from closing. This would negate

the safety feature.

Do not apply side loads to the booms.

Do not leave a tire manipulator load sus-

pended or unattended.

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.

Do not use the boom or the winch to drag

a load.

Do not use the tire manipulator arms to

push downward onto anything.

ElectrocutionAllow extra space for swaying power lines in

windy conditions.

Keep a minimum of ten feet between any

portion of the tire manipulator and an elec-

trical line. Add an additional 12” for every

additional 30,000 Volts or less.

Remember - Death or serious injury can

occur when working near power lines or

during electrical storms.

Use a signal person when operating near

electrical sources.

EnvironmentDo not operate the tire manipulator during

electrical storms.

In extreme cold, allow adequate 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 con-

ditions.

In dusty work areas, every effort must be

taken to keep dust and sand out of the

moving parts of the machinery.

In high humidity work areas, keep parts as

dry as possible and well lubricated.

ATTENTIONStellar Industries, Inc. is not liable for accidents incurred by the tire

manipulator because of the operator’s non-fulfillment of current rules, lawsand regulations.


Stellar Safety Decal - PN 16732

DANGER

NEVER handle tires filled with ballast. Instability and structural failure will result.

NEVER operate the unit while persons not required for operation are in the work area.

NEVER drag the tire - the unit is designed to lift and position.

NEVER clamp an uninflated tire and then inflate - Damage or injury will result.

NEVER use the outer cylinder to push objects with the TireMan - Damage to the equipment will result.

NEVER use the unit for any jacking, pulling, or dragging operation involving an object or another vehicle.

Damage to the equipment will result.

16732

NEVER use one arm of the TireMan to break beads.Damage to the equipment will result.

NEVER use one arm of the TireMan to sling a load.Damage to the equipment will result.

FAILURE TO OBEY THE FOLLOWING WILL RESULT INDEATH OR SERIOUS INJURY

INSTABILITY OR EQUIPMENT DAMAGE.IMPROPER OPERATION WILL VOID WARRANTY

Page 7

TM16160

TM16160 Decal Kit - PN 37845

2

2

04 22618 DECAL- GREASE WEEKLY

DESCRIPTION

DECAL - STELLAR LOGO 8.00X22.25

PART No.ITEM

06 37847

05 54589

DECAL - STELLAR LOGO 6.00X16.5052681

DECAL- RATED LOAD

QTY

2

1

DECAL- TM 16160 IDENTIFICATION

DECAL- ROATATION BEARING

01 54854

03 22617

02

2

1

07

38976 DECAL- RATED LOAD 2

1

7

3

5

6 6

4

2

PN 37845


TM16160 Assembly - PN 37835

19

16

31

3418

17

10

8

16

35

1

8

15

11

10 154

5

15

15

11

15

15

10

8

15

810

3

6

9

87

1413

2

4

23

810

15

15

4

11

19

21

38

1921

19 37

15

5

15

20

810

15

15

11

14133

6

6

78

9

4

2

24

10

8

12

2218

812

812

8

12

812

25

13

23

13

11

8 12

28

29

18

27

26

32

32

32

GASKETS SHOWN AS REFERENCE

PN 37835

1212

12

12

12

11 12

4

3938

3736

3615

33

39

.YTQNOITPIRCSEDTRAPMETI106161MT YDOB248731206141MT MRA623512

3 15152 PAD TIRE GRIPPING TM14160 2806161MT/06141 MT KNIL938734231.91X05.4 REDNILYC584515

6 D0955 BEARING SWING DRIVE 3200 27 22275 MOTOR HYD EATON 103-1085 2

028RG TALF 05.0 REHSAW0970D89 10548 CAP SCR 0.50-13X1.50 HHGR8 410 15625ZP PIN TEAR DROP 2.50X18.38 8

891.0X05.3X65.0 PAC NIP77381112 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 1613 C5902 WASHER 0.63 SAE FLAT YELLOW GR8 8414 8522 CAP SCR 0.63-11X4.50 HHGR8 3615 5739 BUSHING 40DXR48 GARLOCK 24

106141MT ESAB062226117 22277 CAP SCR 0.75-10X4.00 HHGR9 ZY 3018 17150 WASHER 0.75 SAE FLAT YELLOW GR9 56

8S-OLO5F-6 TPADA GTF97209120 15822 MANIFOLD DOUBLE T11A 5000 PSI 221 15888 TUBE ASM 0.38X7.22 TM14160 YZ 422 17149 CAP SCR 0.75-10X4.50 HHGR9 ZY 2223 D1312 CAP SCR 0.63-11X3.50 HHGR8 4824 0343 WASHER 0.31 USS FLAT ZINC 625 22258 TURNTABLE BEARING 450-05110-1 1

11-02100-510 XOB RAEG73566227 11298 CAP SCR 0.75-10X3.50 SHGR8 428 5311 MOTOR HYD ROSS MG140611AAAB 129 D1307 CAP SCR 0.50-13X1.25 SH 230 22272PC GEAR GUARD TM14160B 131 0420 CAP SCR 0.31-18X0.75 HHGR5 632 21151 GASKET MOTOR 008-10056-1 3

61GED 09 TPN 8/1 KREZ7951C331B06141MT BTT DRAUGCP8622243

35 51592 LIGHT FLOOD 3.50X4.0 HELLA ASM 22GED 09 31.0 LE TS9322C632KLB 05.1X31.0 ELPPIN0522C73231.0 EPIP RELPUOC GTF6522C832THGIARTS TPN 8/1 KREZ2951c93

Page 9

TM16160

TM16160 Mounting Kit - PN 22280

.YTQNOITPIRCSEDTRAPMETI106141MT ESAB0622211B06141MT KNIL952222

3 15770ZP PIN TEAR DROP 3.00X10.38 14 22273ZP TEAR DROP PIN 3.00X16.63 2

391.0X05.3X65.0 PAC NIP773856 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 3

58RG TALF 05.0 REHSAW0970D78 0350 CAP SCR 0.50-13X1.00 HHGR5 29 2227 BUSHING 48DXR48 GARLOCK 6

100082 MOOB TXE8835101100082 MOOB RETUO3935111206141MT PMALC ESOHCP2408121

13 0343 WASHER 0.31 USS FLAT ZINC 214 0485 CAP SCR 0.31-18X1.25 HHGR5 2

47

8

8

74

9

2

9

5

7

6

12

13

14

6

7

59

93

9

9

6 7

5

SHOWN AS REFERENCE

SHOWN AS REFERENCE

PN 22280


TM16160

TM16160 Hydraulic Kit - PN 16668

PN 16668

Page 11

TM16160TM16160

Greasing the TireMan

Lubricate all grease gun points with extreme pressure grease - Stellar PN: 22059

Lubrication Recommendations

Component Location RecommendationEngine Crankcase Apply Manufacturerer’s

RecommendationsHydraulic System

Below –5*F-5*F to 90*FAbove 90*F

ReservoirPetro-Canada Arctic MV 15 (ISO 22)Petro-Canada HYDREX 32 (ISO 32)Petro-Canada HYDREX 46 (ISO 46)

Open Gears Hand Precision XL3 Moly EP 2 (NLGI 2 grease with moly)

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 NCCompressor Fluids

Reciprocating Single StageReciprocating Double Stage

CrankcaseCrankcase

Compro 100 (ISO 100)Compro 100 (ISO 100)

Screw-15˚F to 86˚F -23˚F to 100˚F32˚F to 113˚F

CrankcaseCompro XL-S 32 (ISO 32)Compro XL-S 46 (ISO46)Compro XL-S 68 (ISO68)

TM16160 Maintenance


TM16160 Replacement Parts

Part Description22275 Hydraulic rotation motor (TireMan pad rotation)5311 Hydraulic rotation motor (TireMan rotation)21151 Hydraulic rotation motor gasket13555 Hydraulic quick coupler13554 Hydraulic quick coupler13557 Hydraulic quick coupler13556 Hydraulic quick coupler4482 Combination flow divider35648 Seal Kit - TireMan clamp in/clamp out cylinders5739 Bushing 2.50” x 3.00”8455 Pin Cap 0.69” x 3.50” x 0.25 SS

Call 800-321-3741 to Order

Page 13

TM16160TM16160

TroubleshootingThis chapter will list a number of potential

problems that may occur while operating

the crane/TireMan. Most problems are eas-

ily 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.

• Make sure that the transmitter batteries

are fully charged. (Rechargeable batter-

ies 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 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 propor-

tional valve is operating.

• Make sure the proportional valve is

receiving 12V power when operating a

function.

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.

• 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.

• Make sure the “Power” LED is on outside

the receiver door cover. This light is the

upper light on the receiver door. If the

light does not come on, check wiring

back to the fuse. If the fuse is OK, check

system ground wires and connections.

• Make sure the green LED on the receiver

door is lit green. This light will come on

when the red e-stop is pulled upward

and the toggle switch is activated on the

transmitter. If the radio system does not

link up and no green light is lit on the

receiver - make sure that the battery is

fully charged, check the battery contact

points to make sure they are not tar-

nished or corroded. Clean contact

points and recharge or replace the bat-

tery.

• When battery voltage is acceptable, the

power LED light on the transmitter will be


TM16160

Troubleshooting Continued...solid. If the voltage becomes low, the

LED light will begin to blink and the bat-

tery will need to be charged or replaced.

Problem: Not all crane functions operate

using the radio remote transmitter or crane

operates intermittently.

Solutions:

• Make sure that the function switch is

working properly. If the switch is defec-

tive, simply replace it.

• Make sure that there is power going from

the valve bank twin solenoid or to the

function that will not operate. If no

power is going to the twin solenoid,

check wiring connections on wire har-

ness 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. Check the

twin solenoid for polarity, if solenoid does

not magnetize, replace the twin solenoid.

Problem: Cylinder drifts outward or down-

ward.

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 cylin-

ders slowly so air is pushed thru the sys-

tem to the reservoir. Repeat this cycle 2-

3 times.

• Make sure the holding valves are operat-

ing properly. Remove, clean, and then

inspect each holding valve. When

removing a holding valve, always relieve

the pressure inside the cylinder by loosen-

ing 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 dam-

aged. If they show signs of damage,

install a new cylinder seal kit.

Problem: Outer “Extend” and Extension In

and Out will not operate Manually or

Remotely.

Solutions:

• Check to see if the functional cut out

connector, located on the valve section

is lit. Note: Functional cut out connec-

tors will have an LED light on when elec-

trical power is present

• Check to see if there is 12 volt power

going to functional cut out connector.

• Check to make sure the Bosch relay is

functioning properly. It is located just

behind the panic bar E-stop switch. If

functional cut out connector is lighting

properly, check to make sure the con-

nector is tight.

If problems persist, please contact Stellar Customer Service at:

1-800-321-3741

Page 15

TM16160TM16160

Troubleshooting Chart

Problem Possible Cause Possible Solution

Vibrations and jerking in hydraulic cyl-inder during the first maneuvers.

The temperature of the hydraulic oil is too low.

Perform maneuvers without loads for several minutes to warm up the oil.

Lack of oil in reservoir. Add hydraulic oil.

Vibrations with every function when oil is hot.

Lack of oil in reservoir. Add hydraulic oil to the tank.

Air in hydraulic system.Operate the control carrying the cylin-ders to stroke end several times in both

directions.

All crane movements are slow, loaded and unloaded.

Suction hose from oil tank crushed or obstructed.

Replace or clean the suction hose.

Dump valve malfunctioning. Manually override system to detect.

The pump is drawing in air. Tighten suction hose connections.

The hydraulic extension is not extend-ing.

Bad lubrication. Lubricate the wear pads.

Wear pads are worn. Replace wear pads.

Sequence valve on extension cylin-der has to be adjusted.

Check to see if there is 12V power going to the extension function.

Crane rotation not regular.

Inadequate grease. Grease gear bearing.

The truck is not level. Level the truck.

Worn rotation motor. Replace rotation motor.

Gear bearings worn. Replace gear.

The crane does not lift the loads on the load chart.

Defective hydraulic pump. Replace the pump.

Incorrect settings of the valves. Adjust valve settings.

Hydraulic cylinder seals are worn. Replace worn seals.

The crane lifts the load, but cannot hold it.

Incorrect relief setting.Contact Stellar customer service for

proper setting.

Faulty holding valve. Replace holding valve.

Incorrect settings of the valves. Adjust valve settings.

Hydraulic cylinder seals are worn. Replace worn seals.

Noise coming from Articulation points.

Lack of lubrication. Grease articulation points.

Worn pin. Replace pin.

Worn bushing. Replace bushing.

Hydraulic legs do not hold under load.Defective holding valves. Clean or replace holding valves.

Worn seals in the stabilizer cylinder. Replace worn seals.

Crane does not function.

Truck battery discharged. Charge battery.

Electric connections are damaged or corroded.

Check electrical wiring, terminals, con-nections and their integrity.

Control handle turned off. Turn on control handle.

Battery charge low. Charge transmitter battery.

Burned fuses. Replace the fuses.

Dump valve not operating properly. Bypass electrical circuit.

PTO not fully engaged. Check for full engagement.

Control box lights do not operate (green LED out)

Discharged battery. Recharge battery.

Burned fuses. Replace fuses.

Disconnected electrical cord.Join correctly the connection, replace

the electric coupling.

Corroded or loose electrical connec-tions.

Check electrical connections.

Faulty manual/remote switch. Replace switch.


TM16160

Troubleshooting Chart Continued...


A crane function does not work.

Defective switch. Replace the switch.

Faulty solenoid. Replace the solenoid.

Locked valve cartridge.Disassemble and clean the valve car-tridge.

Damaged electric connection. Check continuity of the circuit.

Operations at high or low speed do not work.

Parameters of control box (receiver) set incorrectly or have failed.

Contact Stellar customer service depart-ment.

Controls fail to respond with control box.

Batteries dead in wireless handle.Recharge or replace batteries in remote handle.

Handle on/off button isn’t turned on. Turn on on/off button on remote handle.

Manual/remote switch is in manual position.

Position manual/remote switch in remote position.

Operation slow down.

Hydraulic oil supply is low. Add hydraulic oil.

Hydraulic pump is operating at a reduced speed.

Engine idle speed may be too slow, in-crease speed.

Relief valve is set too low. Check relief with gauge.

Pump or cylinder is worn. Replace cylinder seals.

Pump is slipping due to excessive oil temperature, this is a factor which will increase with worn components.

Check pump GPM with flow meter if it is suspected to be faulty.

Filters are dirty. Replace filters.

Obstruction has occurred in boom holding valve.

Replace or clean holding valve.

Defective flow valve. Replace valve.

Boom drifts when loaded and controls neutralized.

Hydraulic oil is bypassing at piston seal.

Replace cylinder.

Main or secondary cylinder holding valves are defective or contaminated.

Clean or replace holding valves.

Unusual noise in operation.

Cavitation is occurring due to low hydraulic oil supply.

Add oil and cycle cylinders to get air out of system.

Restriction or collapse of suction line has occurred.

Inspect suction line for damage.

Suction line screen is clogged and requires replacement.

Replace or clean screen.

Bypass settings on relief valve are too low.

Contact customer service for correct relief setting.

Relief valve is damaged. Replace relief valve.

Outriggers fail to retract.

Control valve is inoperative.If outriggers retract using manual func-tion, it is a probable electrical problem - check continuity.

Cylinder seals or holding valve are defective.

Replace seals or holding valve.

Hydraulic lines are restricted or rup-tured.

Inspect and replace hydraulic lines.

Broken electrical wire going to outrig-ger switch to the valve bank.

Check continuity of circuit.

Outriggers yield or drift.

Control valve is inoperative.Clean or replace pulsar solenoid valve.Replace holding valve.

Cylinder or check valve is defective.Hydraulic lines are restricted or rup-tured.

Check hoses for damage and replace.

Page 17

TM16160TM16160

BMS-2 Receiver Troubleshooting


System will not initialize after normal start-up

procedure.

E-Stop reset.Push the Start button again. If the system is being initialized from an E-Stop condition, the Start button must be pressed

twice - first to clear the E-Stop, then again, to start the system.

Joystick or paddle lever not in center position.

Be sure that all joysticks and paddle levers are in center posi-tion when the Start button is activated.

E-Stop switch engaged. Pull out E-Stop switch. Restart system by pressing Start twice.

Battery fully discharged.Check battery to ensure a full charge. Replace with fully

charged battery if necessary.

No power to the receiver.

Check the diagnostic Display on the side of the receiver to be sure power is applied. Ensure that the system is securely

grounded to the negative battery terminal. The Display also indicates normal transmitter communication, interference,

and E-Stop conditions.

The transmitter is turned on, but does not transmit (Power

LED not flashing)

Battery is discharged. Replace battery with a fully charged battery.

Coder board fuse. Check fuse and replace if necessary.

Broken key switch.Check wiring on key switch. Replace key switch, wiring or

contact element.

Coder board failure. Contact Hetronic or your Dealer.

Transmitter is transmit-ting (Power LED flash-

ing), but crane will not respond.

E-Stop switch engaged.Pull out the E-Stop pushbutton and press the Start/Horn push-

button.

Transmitter out of range.Take the transmitter back into the range of the receiver. Press

the Start/Horn pushbutton.

Joystick, paddle lever or switch not in center position when transmitter turned on.

Ensure that all control devices are in center (neutral) position when the Start button is activated.

Receiver power off. Turn on power to receiver.

Blown fuse in receiver. Check all fuses. Replace if necessary.

E-Stop failure in transmitter.

Check E-Stop pushbutton for damage. Check wiring to con-tact element for broken

or disconnected wires. Repair or replace E-stop pushbutton or wiring.

.reviecer ni eruliaf potS-ERed E-Stop LED on decoder

board is illuminated.

Check wiring on E-Stop module, decoder module, E-Stop de-coder module. Secure any loose connections.

E-Stop module failure. Replace E-Stop module.

All crane/machine motions operate inter-

mittently.

Receiver antenna loose or missing.

Tighten or replace antenna.

External antenna (if used) has loose connection, poor grounding or interference.

Tighten antenna and ground connection. See “Connecting an External Antenna” Section for operational precautions.

Connector wiring too close to power wiring.

Control wiring must be run separately from power wiring.

Connector inside receiver is loose.

Check all connectors, reseat if necessary.

Some crane/machine motions operate inter-

mittently.

Crane/machine motion wir-ing may be loose.

Check wiring from receiver to plug and from plug to crane/machine motion actuator.

Connector inside receiver is loose.

Check all connectors, reseat if necessary.

Connector wiring too close to power wiring.

Control wiring must be run separately from power wiring.

Limited Warranty Statement

Stellar Industries, Inc. (Stellar) warrants products designed and manufactured by Stellar to be free from defects in material and workmanship underproper use and maintenance. Products must be installed and operated in accordance with Stellar’s written instructions and capacities. This warrantyshall cover the following:

Stellar Cranes, Stellar Hooklift Hoists, Stellar Cable Hoists, Stellar Container Carriers, Stellar Service Trucks, and Stellar X-Tra-Lift Systems: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 dateof manufacture,Twelve (12) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) month from date ofmanufacture, andThirty-six (36) month warranty on all Stellar Manufactured structural parts from the date recorded by Stellar as the in-service date, not to extend beyondforty-eight (48) months from date of manufacture.

Stellar Tarper Systems: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 dateof manufacture andThree (3) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond fifteen (15) month from date ofmanufacture.

The in-service date will be derived from the completed warranty registration card. In the event a warranty registration card is not received by Stellar, thefactory ship date will be used.

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 24-hours of notification bythe 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 servicepersonnel must be contacted prior to any warranty claim. A return materials authorization (RMA) account number must be issued to the claiming partyprior to the return of any warranty parts. Parts returned without prior authorization will not be recognized for warranty consideration. All damaged partsmust be returned to Stellar freight prepaid; freight collect returns will be refused. Freight reimbursement of returned parts will be considered as part ofthe warranty claim.

Warranty service will be performed by any Stellar new equipment distributor, or by any Stellar-recognized service center authorized to service the typeof 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 evidenceof 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, anyfield service call charges, and any towing and/or transportation charges associated with moving the equipment to the designated repair/serviceprovider.

All obligations of Stellar and its authorized dealers and service providers shall be voided if someone other than an authorized Stellar dealer providesother than routine maintenance service without prior written approval from Stellar. In the case repair work is performed on a Stellar-manufacturedproduct, 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 anyway 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 theultimate responsibility of the owner and may be accomplished by the completion and return of the Stellar product registration card provided with theproduct. If the owner is not sure of registration, he is encouraged to contact Stellar at the address below to confirm registration of the product inquestion. 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 maintenanceduties as stated in Stellar’s written instructions, recommendations, and specifications. Any damage resulting from owner/operator failure to perform suchduties 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 anyspecial, 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 notparticipate 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 productstheretofore manufactured.

This warranty will apply to all Stellar Cranes, Stellar Hooklift Hoists, Stellar Cable Hoists, Stellar Container Carriers, Stellar Service Trucks, Stellar X-Tra-LiftSystems, and Stellar Tarper Systems shipped from Stellar’s factory after January 1st, 2010. The warranty is for the use of the original owner only and is nottransferable 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 FORA PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES, AS SPECIFIED HEREIN. STELLARINDUSTRIES, INC. IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Revision Date: February 2010 Document Number: 37040

Documents

Telescopic Crane Manual