Stellar 15000 Manual

OWNER’S MANUAL

Safety, Installation, Maintenance, and Operation

15000 Articulating Crane

®

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: [phone]

www.stellarindustries.com

Subject to Change without Notification.	Manual Part No. 37812
© 2007 Stellar Industries, Inc.	Last Revision: 12/14/07

15000 Manual Revisions

Date of Revision	Section Revised	Description of Revision
October 5th, 2007	Hydraulics -	Updated Hydraulic Kit to reflect engineering
	Electrical	changes.

Table of Contents
	Table of Contents i
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . .ii
Chapter 1 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . .1
Chapter 2 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . .3
Unit Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . .3
Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . .4
Radio Remote Operation . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . .4
Hook Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . .5
Crane Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . .5
Crane Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . .5
Operator Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . .6
Chapter 3 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . .7
Lubrication Recommendations . . . . . . . . . . . . . . . . . . . . .	. . . . . . .9
Wire Rope Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .10
Torque Data Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .11
Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .11
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .12
Monthly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .13
Quarterly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .14
Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .16
Inspection Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .17
Chapter 4 - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .19
Capacity Chart - Decal PN 6853 . . . . . . . . . . . . . . . . . . . .	. . . . . .20
Chapter 5 - Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .21
Decals of Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .21
Outrigger Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .21
Crane Cover Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .23
Decal Kit Placement Kit 8720 . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .25
Chapter 6 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .27
Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .27
Installation Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .27
General Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .27
Mounting Kit Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .28
Chapter 7 - Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .29
Base Assembly - PN 20299 . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .29
Mast Assembly - PN 20300 . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .30
Boom Assembly - PN 20601 . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .31
Cylinder Assembly - PN 23575 . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .32
Pendant Box Assembly - PN 20602 . . . . . . . . . . . . . . . . . . .	. . . . . .33
Reservoir Assembly - PN 12960 . . . . . . . . . . . . . . . . . . . . . .	. . . . . .34
Chapter 8 - Hydraulics - Electrical . . . . . . . . . . . . . . . . . . . . .	. . . . . .35
Control Kit - PN 33943 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .36
Hydraulic Kit - PN 33942 . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .37
Chapter 9 - Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .39
Chapter 10 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .41
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .47

	ii	15000 Owner’s Manual
	Introduction
	Stellar Cranes are designed to provide safe		Stellar manufactured cranes in general and
	and dependable service for a variety of		may or may not apply to your specific
	operations. With proper use and		model.
	maintenance, these cranes will operate at
	peak performance for many years.		This manual is not binding. Stellar Industries,
			Inc. reserves the right to change, at any
	To promote this longevity, carefully study the		time, any or all of the items, components,
	information contained in this manual before		and parts deemed necessary for product
	putting the equipment into service. Though		improvement or commercial/production
	it is not intended to be a training manual for		purposes. This right is kept with no
	beginners, this manual should provide solid		requirement or obligation for immediate
	guidelines for the safe and proper usage of		mandatory updating of this manual.
	the crane.
	Once you feel comfortable with the		In closing:
	material contained in this manual, strive to		If more information is required or technical
	exercise your knowledge as you safely		assistance is needed, or if you feel that any
	operate and maintain the crane. This		part of this manual is unclear or incorrect,
	process is vital to the proper use of the unit.		please contact the Stellar Customer Service
			Department by phone at 800-321-3741 or
	A few notes on this manual:		email at [e-mail].
	A copy of this manual is provided with every
			ATTENTION
	crane and shall remain with the crane at all
	times. Information contained within this		Failure to adhere to the
	manual does not cover all maintenance,		instructions could result in
	operating, or repair instructions pertinent to
			property damage or even serious
	all possible situations.
			bodily injury to the operator or
	Please be aware that some sections of this		others close to the crane.
	manual contain information pertaining to

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	[e-mail]
Order Parts	[e-mail]
Warranty Information	[e-mail]

			Safety 1
	Chapter 1 - Safety
			Do not use controls and hoses as handholds. These
	Please Read the Following Carefully!	This portion of
			parts move and cannot provide stable support.
	the manual contains information regarding all
	Stellar manufactured cranes. Some items		Never allow anyone to ride the crane hook or load.
	contained within this chapter may not apply to your
	specific equipment.		MAINTENANCE SAFETY
	Safety should be the number one thought on every		Never modify or alter any of the equipment, whether
			mechanical, electrical, or hydraulic, without explicit
	operator’s mind. Three factors should exist for safe
			approval from Stellar Industries.
	operation: a qualified operator, well-maintained
	equipment, and the proper use of this equipment.		Do not perform any maintenance or repair work on
	The following information should be read and
			the crane unless authorized and trained to do so.
	understood completely by everyone working with
	or near the crane before putting the unit into		Release system pressure before attempting to make
	operation.
			any adjustments or repairs.
	Please take note that Stellar Industries, Inc. is not		Do not attempt service or repair when the PTO is
	liable for accidents incurred by the crane because
			engaged.
	of non-fulfillment from the operator’s side of current
	rules, laws, and regulations.		Failure to correctly plumb and wire the crane can
	GENERAL		cause a malfunction and damage to the crane
			and/or operator.
	It is the responsibility of the owner to instruct the
	operator in the safe operation of your equipment		Decals are considered safety equipment. They must
	and to provide the operator with properly
			be maintained, as would other safety devices. Do
	maintained equipment.
			not remove any Decals. Replace any Decals that
	Trainees or untrained persons shall be under the		are missing, damaged, or not legible.
			The safety instruction plates, notices, load charts and
	direct supervision of qualified persons.
			any other sticker applied to the crane or service
	Do not operate equipment under the adverse		body must be kept legible and in good condition. If
			necessary, replace them.
	influence of alcohol, drugs, or medication.
	PERSONAL SAFETY		STABILITY
			Know the crane components and their capabilities
	Keep clear of all moving parts.
			and limitations. Overloading the crane may result in
	Always wear the prescribed personal safety devices.		serious injury to self and others, and damage to the
			equipment and immediate surroundings.
	Always wear approved accident-prevention clothing		Never exceed manufacturer’s load ratings. These
	such as: protective helmets, anti-slip shoes with steel
			ratings are based on the machine’s hydraulic,
	toes, protective gloves, anti-noise headphones,
			mechanical, and structural design rather than
	protective glasses, and reflective jackets with
			stability.
	breathing apparatus. Consult your employer
	regarding current safety regulations and accident-		The supporting surface under the service truck must
	prevention equipment.
			be able to support the weight of the machine and its
	Do not wear rings, wristwatch, jewelry, loose-fitting or		load. Use outrigger pads if necessary.
	hanging clothing such as ties, torn garments, scarves,		Park the vehicle on level ground and extend the
	unbuttoned jackets or unzipped overalls, which could
			outriggers fully out and then down.
	get caught up in the moving parts of the crane.
	Keep a first-aid box and a fire extinguisher readily		Keep feet and legs clear when lowering outrigger
			jacks.
	available on the truck. Regularly check to make sure
	the fire extinguisher is fully charged and the first-aid		Never operate the crane without making sure the
	kit is stocked.
			outriggers are positioned on stable, flat ground.

2 15000 Owner’s Manual

Set the parking brake 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.

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 crane load suspended 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 crane boom to push downward onto anything.

ELECTROCUTION

Allow extra space for swaying power lines in windy conditions.

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.

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.

ENVIRONMENT

Do not operate the crane 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 conditions.

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.

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

PTO Switch

	Operation 3
Chapter 2 - Operation

This chapter contains information regarding the operation of Stellar manufactured articulating cranes. Please study the following pages to ensure your familiarity with the operation process. This understanding is vital to the safe and efficient operation of the crane.

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 brake 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.

NOTICE

The parking brake must be fully engaged in order to operate any Stellar Equipment.

Unit Operation Overview

1. Engage the PTO

2. Turn on Power to Crane

3. Position Outriggers

4. Operate Crane

5. Store Outriggers

6. Turn Off Power to Crane

7. 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.

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 the 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. Allow a few moments to warm the hydraulic system oil. In cold weather, it is especially important to let the system run for a few minutes before operating.

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.

4.Operate Crane

A. Turn on necessary power to the crane.

B. Activate toggle switch for desired crane function. D. Activate the variable speed trigger to control the

desired 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.

4 15000 Owner’s Manual

Radio Remote Operation

The crane is operated by a radio control system which operates an electronic valve bank. The controller (as shown above) operates the following functions:

Main Boom Up and Down

Outer Boom Up and Down

Extension Boom In and Out

Rotation Clockwise and Counter-Clockwise

TireMan Clockwise and Counter-Clockwise

TireMan Open and Close

To operate the crane, activate the desired toggle switch. The crane will not function until the trigger on the remote handle is activated. The crane speed will change as the trigger is pulled or released.

Note: If the crane does not operate, check the batteries located in the remote handle and replace if necessary.

Note About Battery Condition

The batteries included with this equipment may be rechargeable. To keep rechargeable batteries in optimal working condition, follow these simple guidelines:

1.Keep battery away from moisture. Store in a cool, dry location.

2.Do not store or carry battery so that metal objects can contact exposed metal end. Keep battery cap on when not in use.

3.The batteries should be recharged when they fail to produce sufficient power.

4.Never attempt to open the battery for any reason.

Manual Operation

In case of radio failure, the crane can be operated using manual overrides located on the valve bank.

Valve Manual Override Operation

1.Switch to Manual Operation:

Flip the toggle switch (shown below) up to

“Manual”

2.Operate Levers on the Valve Bank:

Push or pull levers to operate listed function.

3.Switch Controls Off:

Flip the toggle switch to the middle “Off” position.

4.Have Unit Serviced.

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 hard hat, 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.

Operation 5

Crane Transport

Before transporting the crane, do the following:

1.The crane must be in the stored position.

2.Outriggers must be securely stowed and not extended horizontally or vertically.

3.Hook and sheave assemblies must be securely fastened to prevent swinging.

4.All loose accessories, tools, and remote controls must be securely stored in their respective compartments or fasteners.

5.The PTO must be disengaged.

6.The parking brake must not be released until all of the above procedures are completed.

7.Do not drive the carrier vehicle while a load is present on the hook.

8.Do not drive the carrier vehicle with less than proper tire inflation.

9.Do not drive the carrier vehicle in areas where the vertical clearance is unknown.

10.Do not allow personnel to ride on the equipment during transport.

The crane MUST be in the stored position before transporting.

6 15000 Owner’s Manual

Operator Information

OPERATOR REQUIREMENTS

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.

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.

OPERATOR CONDUCT

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.

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.

				Maintenance 7
	Chapter 3 - Maintenance
		Daily Inspection
	WARNING - Read the Following before
		Daily Inspection should occur each day
	performing any maintenance on the
		before the crane is put into use. Each day,
	crane.
		inspect the crane for all of the following:
	1. Only authorized service personnel are
		1.	Hydraulic oil level.
	to perform maintenance on the crane.
		2.	Loose parts or damage to structures or
	2. Disengage the PTO before any service
			weld.
	or repair is performed.
		3.	Cylinder movement due to leakage.
	3. Do not disconnect hydraulic hoses
		4.	Hoses and gearboxes for evidence of oil
	while there is still pressure in those
			leaks.
	components.
		5.	Controls, including hand throttle for
	4. Before disconnecting hydraulic
			malfunction or adjustment.
	components, place the boom on the
		6.	Truck hand brake operation.
	ground or have it supported, shut off the
		7.	All securing hardware such as cotter pins,
	engine, release any air pressure on the
			snap rings, hairpins, and pin keepers for
	hydraulic reservoir, and move pedals
			proper installation.
	and control levers repeatedly through
		8.	All safety covers for proper installation.
	their operating positions to relieve all
		9.	Cylinder holding valves for proper
	pressures.
			operation.
	5. Keep the crane and service body
		10. Wire rope for broken wires, extensive
	clean and free from grease build-up, oil
			wear, distortion, and heat damage.
	and dirt to prevent slippery conditions.
	6. Perform all safety and maintenance
	checks before each period of use.	Periodic Inspection
	7. Replace parts with Stellar Industries, Inc.
		Periodic Inspection should occur while the
	approved parts only.
		crane is in use. For the duration of the
	8. Immediately repair or have repaired
		usage, inspect the crane for all of the
	any components found to be
		following:
	inadequate.
		1.	Loose bolts and fasteners.
	Maintenance Procedures	2.	All pins, bearings, shafts, and gears for
			wear, cracks, or distortion to include all
	1. Position the crane where it will be out of		pivots, outriggers, sheave pins, and
	the way of other operations or vehicles in		bearings.
	the area.	3.	Hydraulic systems for proper operating
	2. Be sure boom is lowered to the ground or		pressure.
	otherwise secured from dropping.	4.	Main frame mount bolts.
	3. Place all controls in the off position and	5.	Cylinders for:
	secure operating features from		A. Damaged rods.
	inadvertent motion.		B. Dented barrels.
	4. Disconnect power source.		C. Drift from oil leaking internally.
	5. Relieve hydraulic oil pressure from all		D. Leaks at rod seals or holding valves.
	hydraulic circuits before loosening or	6.	PTO drive line system for proper
	removing hydraulic components.		alignment, lubrication, and tightness.
	6. Label or tag parts when disassembling.	7.	Hydraulic hose and tubing for evidence of
			damage such as blistering, crushing, or
			abrasion.

8 15000 Owner’s Manual

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 located in 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. All 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.

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.

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.

ATTENTION

Every six (6) months, remove the hydraulic pump from the PTO and lubricate the splines using Chelsea Lubricant #379831 or Stellar PN 20885. Failure to lubricate shaft splines will cause damage to the PTO and Hydraulic pump.

Lubrication Recommendations Maintenance 9

Component		Location	Recommendation
Engine		Crankcase	Apply Manufacturer’s
			Recommendations
Hydraulic System		Reservoir
Below –5*F			Petro-Canada Arctic MV 15 (ISO 22)
-5*F to 90*F			Petro-Canada HYDREX 32 (ISO 32)
Above 90*F			Petro-Canada HYDREX 46 (ISO 46)
Open Gears		Hand	Precision XL3 Moly EP 2 (NLGI 2 grease
			with moly)
Bearings, grease		Gun	Precision XL EP 2 (NLGI 2)
(including turntable bearing
inner race)
Worm Drive Gearbox		Gearbox	Precision Synthetic EP 00 (NLGI 00)
Planetary Gearbox		Gearbox	Traxon Synthetic 75W-90 (API GL-5)
(including winch)
Wear Pad Lubrication		Spray	Gearshield NC
Compressor Fluids
Reciprocating Single Stage		Crankcase	Compro 100 (ISO 100)
Reciprocating Double Stage		Crankcase	Compro 100 (ISO 100)
Screw-15˚F to 86˚F		Crankcase	Compro XL-S 32 (ISO 32)
-23˚F to 100˚F			Compro XL-S 46 (ISO46)
32˚F to 113˚F			Compro XL-S 68 (ISO68)
	Greasing the Crane
Lubricate all grease gun points with
Extreme Pressure Grease - Stellar P/N: 22059.

10 15000 Owner’s Manual

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

Size	Bolt DIA	Plain	Plated	Plain	Plated	Plated
(DIA-TPI)	(Inches)	(Ft-Lb)	(Ft-Lb)	(Ft-Lb)	(Ft-Lb)	(Ft-Lb)
5/16-18	0.3125	17	13	25	18	22
3/8-16	0.3750	31	23	44	33	39
7/16-14	0.4375	49	37	70	52	63
1/2-13	0.5000	75	57	105	80	96
9/16-12	0.5625	110	82	155	115	139
5/8-11	0.6250	150	115	220	160	192
3/4-10	0.7500	265	200	375	280	340
7/8-9	0.8750	395	295	605	455	549
1-8	1.000	590	445	910	680	823
1 1/8-7	1.1250	795	595	1290	965	1167
1 1/4-7	1.2500	1120	840	1815	1360	1646
1 3/8-6	1.3750	1470	110	2380	1780	2158
1 1/2-6	1.500	1950	1460	3160	2370	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.

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 [phone].

Owner/Company:

Contact Person: Crane Make/Model: Crane Serial:

Type of Inspection Information

				Maintenance 11
	Type of Inspection (check one)
			Daily (if deficiency found)		Quarterly
			Monthly		Annual
	Date Inspected:
	Hour Meter Reading:
	Inspected by: (print)
	Signature of Inspector:

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.

12	15000 Owner’s Manual
			Daily Inspection
Frequency		Key	Inspection Description	Status
	D	Decals	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	Overall observation of crane for damage or missing parts, cracked welds &
			presence of safety covers.
	D	Operation	During operation, observe crane for abnormal performance, unusual wear.
			If observed, discontinue use & determine cause & severity of hazard.
	D	Remote Ctrls	Operate remote control devices to check for proper operation.
	D	Electrical	Operate all lights, alarms, etc. to check for proper operation.
	D	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.