Stellar 15000 User Manual

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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: 641-923-2811

www.stellarindustries.com

Manual Part No. 37812 Last Revision: 12/14/07

15000 Manual Revisions

Date of Revision

October 5th, 2007

Section Revised

Hydraulics Electrical

Description of Revision

Updated Hydraulic Kit to reflect engineering changes.

Table of Contents i

Table of Contents

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Chapter 10 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

ii 15000 Owner’s Manual

Introduction

Stellar Cranes are designed to provide safe and dependable service for a variety of operations. With proper use and maintenance, these cranes 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 crane.

Once you feel comfortable with the material contained in this manual, strive to exercise your knowledge as you safely operate and maintain the crane. 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 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.

Please be aware that some sections of this manual contain information pertaining to

Stellar manufactured cranes 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 requirement or obligation for immediate mandatory 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 service@stellarindustries.com.

ATTENTION

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.

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 service@stellarindustries.com

Order Parts parts@stellarindustries.com

Warranty Information warranty@stellarindustries.com

Chapter 1 - Safety

Safety 1

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.

Safety should be the number one thought on every 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 putting the unit into operation.

Please take note that Stellar Industries, Inc. is not liable for accidents incurred by the crane because of non-fulfillment from the operator’s side of current rules, laws, and regulations.

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.

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.

Do not use controls and hoses as handholds. These parts move and cannot provide stable support.

Never allow anyone to ride the crane hook or load.

MAINTENANCE SAFETY

Never modify or alter any of the equipment, whether mechanical, electrical, or hydraulic, without explicit approval from Stellar Industries.

Do not perform any maintenance or repair work on the crane unless authorized and trained to do so.

Release system pressure before attempting to make any adjustments or repairs.

Do not attempt service or r engaged.

Failure to correctly plumb and wire the crane can cause a malfunction and damage to the crane and/or operator.

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. 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.

epair when the PTO is

PERSONAL SAFETY

Keep clear of all moving parts.

Always wear the prescribed personal safety devices.

Always wear approved accident-prevention clothing such as: protective helmets, anti-slip shoes with steel toes, protective gloves, anti-noise headphones, protective glasses, and reflective jackets with breathing apparatus. Consult your employer regarding current safety regulations and accidentprevention 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 crane.

Keep a first-aid box and a fir available on the truck. Regularly check to make sur

e extinguisher is fully char

the fir kit is stocked.

e extinguisher r

ged and the first-aid

eadily

STABILITY

Know the crane components and their capabilities and limitations. Overloading the crane may result in serious injury to self and others, and damage to the equipment and immediate surroundings.

Never exceed manufacturer’s load ratings. These ratings ar 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.

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 crane without making sur outriggers are positioned on stable, flat ground.

e based on the machine’s hydraulic,

e the

2 15000 Owner’s Manual

Set the parking brake and disengage the drive axle

efore attempting a lift.

LOAD SAFETY

Operate the crane in compliance with the load capacity chart at all times. Know the weight of the

oad being lifted. Do not rely on the overload device

l 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.

Crane Controls

1. Be familiar with the sequence and operation of the crane controls.

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.

eme cold, allow adequate time to war

In extr truck befor engine and over speed the hydraulic pumps as permanent damage to the pumps may occur. Follow the vehicle owner’s manual regar operating the vehicle in such adverse conditions.

e engaging the PTO. Do not r

m the

ev the truck

ding

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.

e all safety devices provided are in

Be sur

• place and in good operating condition.

ed for all situations. Keep fir

epar

Be pr

• extinguisher and first aid kit near.

egular maintenance has been

• Be sur

• Visually inspect all aspects of the crane for

• Check for fluid leaks.

• Make sure the outriggers are down and stable.

e all r

med.

for

per

physical damage.

In dusty work ar keep dust and sand out of the moving parts of the machinery.

In high humidity work ar possible and well lubricated.

eas, every ef

fort must be taken to

eas, keep parts as dry as

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

Chapter 2 - Operation

Operation 3

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.

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.

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

ed function.

desir

E. When operation is complete, stor

in a safe, dry location.

5. Store Outriggers

Retract outriggers using the control levers or switches marked ‘outrigger’.

PTO Switch

emote handle

e r

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

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

oller (as shown above) operates the following

contr 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.

Manual Operation

n case of radio failure, the crane can be

I operated using manual overrides located on the

alve 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.

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. The batteries should be recharged when they

3. fail to pr Never attempt to open the battery for any

4. reason.

oduce suf

ficient power

3. Switch Controls Off:

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

4. Have Unit Serviced.

Operation 5

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 dir

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.

ection.

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

e the vertical clearance is unknown.

wher

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

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. Never use a hook’s yield point as an

3. 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

oy the design pr

destr material.

7. Keep fingers, hands, body, and loose clothing from between the hook and the load.

void shock loading.

8. A Inspect the hook r

9. and maintain it in safe operating condition.

operties of the hook

egularly for excessive wear

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

ferentiation is required.

dif

C. Adequate hearing, with or

without a hearing aid.

D. No physical or emotional defects

that may create a hazar 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 requir 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.

ed for safe

d to the

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:

Do not load the crane beyond

the rated capacity.

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 sur

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.

e that the crane is stable

Chapter 3 - Maintenance

Maintenance 7

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 r their operating positions to relieve all pressures.

5. Keep the crane and service body clean and fr 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.

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.

ee from grease build-up, oil

epeatedly through

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.

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

essure.

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.

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

Component Location Recommendation

Engine Crankcase Apply Manufacturer’s

Recommendations

9Maintenance 9

Hydraulic System Below –5*F

-5*F to 90*F Above 90*F

Open Gears Hand Precision XL3 Moly EP 2 (NLGI 2 grease

Bearings, grease (including turntable bearing inner race)

Worm Drive Gearbox Gearbox Precision Synthetic EP 00 (NLGI 00)

Planetary Gearbox (including winch)

Reservoir

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

with moly)

Gun Precision XL EP 2 (NLGI 2)

Gearbox Traxon Synthetic 75W-90 (API GL-5)

Wear Pad Lubrication Spray Gearshield NC

Compressor Fluids

Reciprocating Single Stage Reciprocating Double Stage

Screw

-15˚F to 86˚F

-23˚F to 100˚F 32˚F to 113˚F

Crankcase Crankcase

Crankcase

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

Compr Compr Compro XL-S 68 (ISO68)

o XL-S 32 (ISO 32) o XL-S 46 (ISO46)

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.

Torque Data Chart

Grade 5

Plated

Size

DIA-TPI)

(

/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

Bolt DIA

Inches)

(

.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

Plain

Ft-Lb)

(

1 31 49

75 110 150 265 395 590 795

1120 1470 1950

Ft-Lb)

(

1 23 37 57

82 115 200 295 445 595 840 110

1460

When using the torque data in the charts above, the following rules should be observed.

Grade 8

Plated

Plain

Ft-Lb)

(

2 44

70 105 155 220 375 605 910

1290 1815 2380 3160

Ft-Lb)

(

1 33 52

80 115 160 280 455 680 965

1360 1780 2370

Grade 9

Plated

Ft-Lb)

(

2 39 63

96 139 192 340 549 823

1167 1646 2158 2865

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.

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 tor

que values in the charts by the factor .90. The use of Loctite does not affect the tor

que values listed

above.

5. Torque values for socket-head capscrews are the same as for Grade 8 capscrews.

Inspection Checklist

Maintenance 11

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.

Owner/Company: Contact Person: Crane Make/Model: Crane Serial:

Type of Inspection (check one)

Daily (if deficiency found)

Monthly

Date Inspected: Hour Meter Reading: Inspected by: ( Signature of Inspector:

print)

Quarterly

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 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.

. If operation

12 15000 Owner’s Manual

Daily Inspection

Frequency

Key

Decals

Controls

Station

Hydsystem

Hook

Rope

Pins

General

Operation

Remote Ctrls

Electrical

Inspection Description

All load charts, safety & warning Decals, & control Decals are present and

egible.

l Check all safety devices for proper operation.

Control mechanisms for proper operation of all functions, leaks, & cracks.

Hydraulic system (hoses, tubes, & fittings) for leakage & proper oil level.

Presence & proper operation of hook safety latches.

Proper reeving of wire rope on sheaves & winch drum.

Proper engagement of all connecting pins & pin retaining devices.

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.

Status

Anti 2-Blocking

Operation Aid

Operate anti 2-blocking device to check for proper operation.

Check presence of boom angle indicator.

Check overload device for proper operation.

Monthly Inspection

Maintenance 13

Frequency

Key

Daily

Cylinders

Valves

General

Electrical

Structure

Welds

Pins

Hardware

Wear Pads

Inspection Description

All Daily Inspections.

Visual inspection of cylinders for leakage at rod, fittings, & welds. Damage to rod & case. Holding valves for proper operation.

Control valve for leaks at fittings & between sections.

Control valve linkages for wear, smoothness of operation & tightness of fasteners. Relief valve for proper pressure settings. Bent, broken or significantly rusted/corroded parts.

Electrical systems for presence of dirt, moisture & frayed wires.

All structural members for damage.

All welds for breaks & cracks.

All pins for proper installation & condition.

All bolts, fasteners & retaining rings for tightness, wear & corrosion.

Condition of wear pads.

Status

Pump & Motor

PTO

Hyd Fluid

Hyd Lines

Hook

Rope

Manual

Chassis

Station

Hydraulic pumps & motors for leakage at fittings, seals & between sections. Check tightness of mounting bolts. Transmission/PTO for leakage, abnormal vibration & noise, alignment & mounting bolt torque. Quality of hydraulic fluid and for presence of water.

Hoses & tubes for leakage, abrasion damage, blistering, cracking, deterioration, fitting leakage, & secured properly. Load hook for abnormal throat distance, twist, wear, & cracks.

Condition of load line.

Presence of operator's manuals with the unit.

Tire wear and air pressure.

Working backup alarm.

Fire extinguisher at cab or machinery housing.

14 15000 Owner’s Manual

Quarterly Inspection

Frequency

Key

Daily

Monthly

Rotation Sys

Hardware

Structure

Inspection Description

All daily inspections.

All monthly inspections.

Rotation bearing for proper torque of all mounting bolts.

Base mounting bolts for proper torque.

All structural members for deformation, cracks, & corrosion.

Base

Outrigger beams & legs

Mast

Inner boom

Outer boom

Extension(s)

Jib boom

Status

Hardware

Jib extension(s)

Other

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

Quarterly Inspection Continued...

Maintenance 15

Frequency

Key

Hyd Lines

Pumps&Motors

Valves

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

Pumps and motors for loose bolts/fasteners, leaks, noise, vibration, loss of performance, heating and excess pressure. Winch motor(s)

Rotation motor(s)

Other

Hydraulic valves for cracks, spool return to neutral, sticking spools, relief valve failure. Main control valve

Status

Cylinders

Winch

Hyd Filter

Load holding valve(s)

Outrigger or auxiliary control valve(s)

Other

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

Winch, sheaves, & drums for damage, abnormal wear, abrasion, & other

egularities.

irr Hydraulic filters for r

eplacement per maintenance schedule.

16 15000 Owner’s Manual

Annual Inspection

Frequency

Key

Daily

Monthly

Quarterly

Hyd System

Controls

Valves

Rotation Sys

Lubrication

Hardware

Wear Pads

Loadline

Inspection Description

All daily inspection items.

All monthly inspection items.

All quarterly inspection items.

Hydraulic fluid change per maintenance schedule.

Control valve calibration for correct pressures & relief valve settings.

Safety valve calibration for correct pressures & relief valve settings

Valves for failure to maintain correct settings.

Rotation drive system for proper backlash clearance & abnormal wear, deformation, & cracks. Gear oil change in rotation drive system per maintenance schedule.

Check tightness of all fasteners and bolts.

Wear pads for excessive wear.

Loadline for proper attachment to drum.

Status

Historic Data

Monthly inspection records.

Maintenance records.

Repair and modification records.

Inspection Notes

Maintenance 17

18 15000 Owner’s Manual

Chapter 4 - Specifications

Model 15000 Crane

SPECIFICATION SHEET

Crane Rating: 150,000 ft-lbs (20.72 ton-meters)

Standard Boom Length: 13’ 2” (4.01 m) (From CL of Crane)

Boom Extension: Hydraulic 37" (93.98 cm)

Maximum Horizontal Reach: 16’ 3” (4.95 m) (From CL of Crane)

Maximum Vertical Lift: 22’ (6.71 m) (From Truck Frame)

Boom Elevation: -5 to +80 degrees

19Specifications 19

Cylinder Specifications

Inner Lift Cylinder: 6” (15.2 cm) bore with integral pilot

operated counterbalance valves.

Outer Lift Cylinder: 6” (15.2 cm) bore with integral pilot

operated counterbalance valves.

Extension Cylinder: 3 1⁄2 (8.9 cm) bore with integral pilot

operated counterbalance valves.

Rotation: 320 degree power

m gear with pinion)

(wor

Lifting Capacities: 15,000 lbs @ 10’ (6,804 kg @ 3.05 m)

om CL of T

(Fr

Power Supply Requir (PTO & Pump)

Controls: 25’cord with hand held control.

Stowed Height: 92” (233.68 cm) (Above T

ruck)

ed:

ruck Frame)

11,250 lbs @ 13’ 2” (5,103 kg @ 4.01 m) 9,000 lbs @ 16’ 6” (4,082 kg @ 4.95 m)

16 gpm @ 4200 psi (60.8 lpm @ 290 bar)

Mounting Space Required: 34” (86.39 cm)

Approximate Shipping Weight: 5,800 lbs (2,631 kg)

20 15000 Owner’s Manual

10’

3.05m

16’3”

4.95m

13’2”

4.01m

10’

3.05m

16’3”

4.95m

13’2”

4.01m

10’

3.05m

25’6”

7.77m

22’6”

6.86m

CAPACITY

CHART

15000 lbs

6805 kg

11250 lbs

5105 kg

9000 lbs

4080kg

0’

TRUCK

GROUND

0’

6853

190 STATE STREET GARNER, IA 50438

PHONE: (800) 321-3741 FAX: (641) 923-2812

15000

Capacity Chart - Decal PN 6853

Chapter 5 - Decals

Decals of Note

21Decals 21

Crane Compartment Cover Decals Crane Outrigger Decals

Outrigger Decals

Electrocution Hazard Decal

Location: Crane Base 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: C1

179

22 15000 Owner’s Manual

Outrigger Decals continued...

Foot Crushing Hazard Decal

Location: 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 Boom Hazard Decal

Location: Crane Base 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

Moving Outrigger Hazard Decal

Location: Outrigger Leg Function: To inform the operator of the hazard

associated with outrigger operation, the possible consequences should the hazard occur, and how to

avoid the hazard PN: C5918

Crane Cover Decals

23Decals 23

Operation Hazard Decal

Location: Crane Cover 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

Operation Hazard Decal

Location: Crane Cover Function: To inform the operator of the

need for proper training, familiarity with safe operating procedures and , the possible consequences without training. PN: C4540

Electrocution Hazard Decal

Location: Crane Cover Function: T

hazard associated with contact or proximity to electrical lines, the possible consequences should the hazard occur and how to avoid the hazard. PN: 4187

o inform the operator and other personnel in the work area of the

24 15000 Owner’s Manual

Crane Cover Decals Continued...

Operation Hazard Decal

Location: Crane Base 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

Operation Hazard Decal

Location: Crane Base 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

Electrocution Hazard Decal

Location: Crane Base 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: C1179

Decal Kit Placement Kit 8720

PN 8720

25Decals 25

26 15000 Owner’s Manual

Chapter 6 - Installation

SURGE PROTECTOR #34355 INCLUDED IN THIS KIT

ITEM PART DESCRIPTION QTY.

18900 TIE DOWN ROD 15000 8 28202 FRAME SUPPORT 15000 CRANE 4 3 8054 MTG BLOCK 15000 4 4 8978 NUT 1.25-7 HHGR8 16 5 8834 NUT 1.25-7 HHGR8 TOP LOCKING 8

PN 26030

Notice: Read this Page Before Installation of the Crane

27Installation 27

General Installation

This chapter is designed to serve as a general guide for the installation of a Stellar 15000 Articulating 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.

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.

Notice:

PTO and Pump installation instructions are provided by the corresponding manufacturers. For more information on which PTO and Pump fit your application, please contact your local Stellar Distributor or Stellar Customer Service.

Installation Notice

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.

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.

1. Relocate any obstructions on the frame that will be in the way of mounting the crane.

2. Measure the inside of the frame rails and cut the frame support to this length. Ensure that the frame supports have a tight fit between the frame rails.

Set the crane on the chassis and allow a minimum of 2” from the cab. Install the crane tie downs. Start at one cor

4. tie downs to 200 ft-lbs. Move to the diagonal set and tighten to 200 ft-lbs. Tighten the remaining 2 corners. Continue this pattern at 200 ft-lb increments until 650-700 ft-lbs is achieved. Be sure the mounting block stays perpendicular to the frame rail as they ar tightened down.

5. Connect the pressure and return lines per the hydraulic kit.

6. Connect the (+12V) power and ground wires.

7. Check the r

8. Operate the crane for several cycles.

Installation Overview

For more detail, please contact

Stellar Customer Service

ner and tighten both

eservoir for oil and fill if necessary.

Install Kit (PN 26030)

28 15000 Owner’s Manual

ITEM P/N DESCRIPTION QTY ITEM P/N DESCRIPTION QTY

1 8978 Nut 1.25-7 HH GR8 16 4 8054 Mounting Block 4 2 8900 Tie Down Rod 8 5 8834 Nut 1.25-7 HH GR8 Top Locking 8

4 troppuS emarF 2028 3

Mounting Kit Drawing

.YTQNOITPIRCSEDTRAPMETI

100051 ESAB64561 2 6774 CYLINDER 15000 OUTRIGGER OUT 2 3 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 16

200051 REGGIRTUO34564

2T&D 31.11X00.2 NIP16131

200.9X00.

2 NIP56006

52.

X00.3X65.0 P

AC NIP54

157

8 0359 CAP SCR 0.50-13X1.50 HHGR5 4

618RG TALF 05.0 REHSAW0970D9

10 6773 CYLINDER 15000 OUTRIGGER 2

200051 GEL REGGIRTUO455611

200051 DAP REGGIRTUO155621

200.1X00.6X00.2 DAP RAEW243931

200051 DAP RAEW REVOC043941

15 10548 CAP SCR 0.50-13X1.50 HHGR8 12

252.7X00.2 NIP467

252.01X00.

2 NIP7966

800.2 EDISN

I GNI

R PANS

752

4002-00

27 00.2 G

NIR PANS

801

PN 20299

Chapter 7 - Assembly Drawings

Base Assembly - PN 20299

29Assembly Drawings 29

Note: Outrigger Out Cylinder

uses Stellar Seal Kit PN C6305

Note: Outrigger

Down Cylinder uses

Stellar Seal Kit PN

C6303

30 15000 Owner’s Manual

ITEM PART DESCRIPTION QTY.

1 6435 Mast 15000 1 2 6536 TURNTABLE BEARING 450-05135-1 1 3C6218 CAP SCR 0.75-10X4.00 HHGR8 ZY 30 4C6219 WASHER 0.75 SAE FLAT YELLOW GR8 68 5 4543 CAP SCR 0.75-10X2.00 HHGR8 ZY 29 6C1028 CAP SCR 0.75-10X3.00 HHGR8 ZY 5 7 6537 GEAR BOX 015-00120-1 1 8 8051 COVER GEAR BOX 15000 1

9 5311 MOTOR HYD ROSS MG140611AAAB 1 10 D0790 WASHER 0.50 FLAT GR8 2 11 9046 PLATE BASE COVER 15000 1 12 C0990 CAP SCR 0.50-13X0.75 HHGR5 4 13 0352 WASHER 0.50 USS FLAT ZINC 4 14 8611 PLATE SWITCH MTG 15000 CRANE 1 15 0478 CAP SCR 0.25-20X0.50 HHGR5 4 16 0340 WASHER 0.25 FLAT 4 17 8612 PLATE SWITCH MTG 15000 CRANE 1 18 21533 PLATE INSPECTION MAST 15000 1 19 0343 WASHER 0.31 USS FLAT ZINC 2 20 0484 CAP SCR 0.31-18 X 0.50 HHGR5 2 21 D1307 CAP SCR 0.50-13X1.25 SH 2 22 13309 HOSE CLAMP 15000 1 23 35097 CAP SCR 0.75-10X3.00 SHGR8 ZINC 4

PN 20300

Mast Assembly - PN 20300

7 6

PN 20601

.YTQNOITPI

RCSEDTRAP

MET

100051 MOOB RENNI945211 3 0865 BUSHING 48DXR32 GARLOCK 2 4 6509 TEAR DROP PIN 3.00X11.00 1 5 13315 PIN CAP 0.56X4.00X.25 1 6 0359 CAP SCR 0.50-13X1.50 HHGR5 57 7D0790 WASHER 0.50 FLAT GR8 62 8 9844 CAP SCR 0.50-13X0.75 HHGR8 5 9 6507 TEAR DROP PIN 2.50X11.00 1 10 8377 PIN CAP 0.56X3.50X.25 3 11 12834 PIN TEAR DROP 2.50X9.13 2 12 12145 OUTER BOOM 15000 B 1 13 12706 PIN TEAR DROP 2.00X12.25 1 14 4379 BUSHING 32DXR40 2.00X2.50 GARLOCK 2

1T&D 52.21X00.2 NIP8072151 16 5145 PIN CAP 0.56X3.00X.25 5

1T&D 00.21X05.2 NIP287671 18 0635 BUSHING 40DXR32 GARLOCK 6 19 8621 CLAMP HOSE/TUBE AG-3 6 20 0342 NUT 0.31-18 HH NYLOC 4 21 0343 WASHER 0.31 USS FLAT ZINC 4 22 12548 WEAR PAD 3.00X4.00X1.38 NYLATRON 8 23 12547 PLATE WEAR PAD COVER 15000 8

1B 00051 MOOB TXE8352142

00051 KNIL LEVIW

9665

2 26 9142 PIN CAP 0.56X2.50X.25 1 27 12546 PIN TEAR DROP 1.50X4.63 1 28 0498 CAP SCR 0.50-13X1.25 HHGR5 1 29 0352 WASHER 0.50 USS FLAT ZINC 1 30 12705 CYLINDER EXT 15000 1 31 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 4 32 6771 CYLINDER 15000 OUTER BOOM 1 33 23575 CYLINDER ASM 6.00X21.00 1

1T&D 13.7X00.2

NIP907214

3 35 6340 HOOK 8.50 TON SWIVEL 297413 1 36 0067 BUSHING QSI-2426-24 1 37 13641 WEAR PAD 2.21X3.21X1.38 2 38 c1592 ZERK 1/8 NPT STRAIGHT 3

Boom Assembly - PN 20601

Note: Extension Cylinder uses

Stellar Seal Kit PN 36303

31Assembly Drawings 31

Note: Secondary Cylinder

uses Stellar Seal Kit PN 11377

Note: Main Lift Cylinder uses

Stellar Seal Kit PN 11377

32 15000 Owner’s Manual

.YTQNOITPIRCSEDTRAPMETI 16769 CYLINDER 15000 INNER BOOM 1 215995 MANIFOLD ASM DUAL T2A 5000PSI 1 3C2252 FTG ADAPT 8-10-F5OLO-S 2 4C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON 2

212.41X05.0 MSA EBUT675325 2S-OLO5F-8 TPADA GTF45516

70635 BUSHING 40DXR32 GARLOCK 4

PN 23575

Cylinder Assembly - PN 23575

Note: Cylinder uses Stellar

Seal Kit PN 11377

FILTER SHOWN AS REFERENCE

.YTQNOITPIRCSEDTRAPMETI 1 8066 COMPT, PENDANT 15000 CRANE 1 2 D0045 BACKUP ALARM .97 DECIBAL 1 3 0480 CAP SCR 0.25-20X1.00 HHGR5 11

8TALF 52.0 REHSAW04304

5 0333 NUT 0.25-20 HHGR5 NYLOC 5

00.4 THGIL EMOD279

6 7 0343 WASHER 0.31 USS FLAT ZINC 15 8 0485 CAP SCR 0.31-18X1.25 HHGR5 6 9 0342 NUT 0.31-18 HH NYLOC 6

10 13390 RECEIVER OMNEX RADIO 1 11 24904 VB 11 SECT HAWE 15000 CRANE 1 12 C0082 CLAMP 0.75 BLK VINYL 1 13 C1033 WASHER 0.25 USS FLAT ZINC 10 14 31923 SHEET COVER 15000 VB 1

352.2X04HCS 83.0 EPIP4

291

1 16 0479 CAP SCR 0.25-20X0.75 HHGR5 2 17 0490 CAP SCR 0.31-18X3.50 HHGR5 3 18 8068 DOOR AL OH 32.69X14.13 1 19 10638 HARDWARE ASM OH DOOR NOT SHOWN 1 20 9334 FILTER PRESSURE 15000 CRANE 1 21 11691 CAP SCR 0.38-24X1.00 HHGR8 4

PN 20602

Pendant Box Assembly - PN 20602

34 15000 Owner’s Manual

.YTQNOITPIRCSEDTRAPMETI

1LAG04

KNAT LIO6118

1 2 C4745 NIPPLE 1.25X8.00 BLK PIPE 1 3 C6228 FILTER HEAD SF120-25 1.3 1

1KLB GED 09 52.1 LE TS4964C4 101-

ES EGRA

L RETLIF5226C5

2XTF-02 TPNM/CIJM GTF890016 7 10096 TUBE ASM 1.25 CLR TO RSRVR 15000 1 8 8240 COOLER OIL BLISSFIELD #65155SPECIAL 1 9 24910 FTG MJIC/MSTR 90 20-C5OX MOD 1

10 10097 TUBE ASM 1.25 COMP/CRN/CLR 15000 1

1XTF-02 TPNM/CIJM GTF1590111

1LTS 52.1 EET0716C21

121-02-2010 UDER GTF5732

-OLF 21 TPADA GTF259

15 8241 FAN 16.00 PUSH 12 VOLT 1

4PZ TALF EAS 8# REHSAW092561

17 D0075 SCREW #6-32X2.75 RH HD MACHINE 2

COLYN HH 23-6# TUN6700D81

19 C0922 CAP SCR 0.31-18X1.00 HHGR5 6

6COLYN HH 81-13.0 TUN243002

21 0343 WASHER 0.31 USS FLAT ZINC 12 22 C6327 FILTER STRAINER 35GAL TF-2030 1

00.2 LLAB EVLAV0574C32

100.2 BRAB ESOH GTF0374C4

1KLB 00.4X00.2 ELPPIN3560D52

26 C4955 SIGHT GAUGE 3/4 NPT EYE 1 27 C1053 NIPPLE 0.75X2.50 BLK PIPE 1

KLB 57.0 RELPU

OC0395

1REHTAERB RELLIF PAC1512C92

30 D1263 FTG HOSE BARB 0.38 HOSE X 0.38 90DG 1 31 C2126 MAGNETIC PLUG DRAIN 3/4" 1 32 C4847 PLUG 2.00 NPT SQ HD BLK 1 33 C2282 FTG 1.25 NPT TO 1.25 BARB 1 34 16145 GAUGE PRES FILTER SERVICE CI20 1 35 D1862 SWITCH TEMP HT-2A-100R-.38NPT 25A 1 36 0352 WASHER 0.50 USS FLAT ZINC 12 37 0501 CAP SCR 0.50-13X2.00 HHGR5 6 38 C6106 NUT 0.50-13 HHGR5 NYLOC 6

TS GED 09 00

LE TS2560D93

PN 12960

Reservoir Assembly - PN 12960

Chapter 8 - Hydraulics - Electrical

35Hydraulics - Electrical 35

WARNING!

Please read the following section before

performing any work on the

hydraulic/electrical system of your crane.

This section contains vital safety information

and maintenance guidelines for your

crane. If questions should arise, please

contact Stellar Customer Service at 800-

321-3741

Never modify or alter any of the equipment, whether mechanical, electrical, or hydraulic, without Stellar Industries’ approval.

Release system pressure before attempting to make adjustments or repairs.

Do not attempt service or repair when PTO is engaged.

Disassemble and assemble hydraulic components on a clean surface.

Do not rely on the hydraulic fluid to support the boom or crane.

Contaminants in a hydraulic system affect operation and will result in serious damage to the system components. Dirty hydraulic systems are a major cause of component failures.

If evidence of foreign particles is found in the hydraulic system, flush the system.

When installing metal hydraulic tubes, tighten all bolts finger tight. Then , in order, tighten the bolts at the rigid end, the adjustable end, and the mounting brackets. After tubes are mounted, install the hoses. Connect both ends of the hose with all bolts finger tight. Position the hose so it does not rub the machine or another hose and has a minimum of bending and twisting. Tighten bolts in both couplings.

Clean all metal parts in a nonflammable cleaning fluid. Then lubricate all components to aid in assembly.

Hydraulic fluid expands when heated. This raises the pressure in an unventilated tank. Release the tank pressure before removing the cap completely. Failure to do so may cause the oil to shoot out of the tank very rapidly and cause severe burns.

Warning! If hydraulic fluid escapes, the boom or crane can fall immediately. Make sur

ound or blocking is supporting the boom

gr before performing any maintenance or repair.

e the

Due to manufacturing methods, there is a natural curvature to a hydraulic hose. The hose should be installed so any bend is with this curvature.

36 15000 Owner’s Manual

PN 33943

Control Kit - PN 33943

PN 33942

13861

TM CLAMP IN TM ROTATION CW

TM CLAMP CLOSE

FTG, ELBOW 6815-6-6

TM PAD ROTAT I ON CW

TM PAD ROTAT I ON CCW

39,40

-PORT

5,41,42

HOSE HYD 0.25 X 132

FTG ADAPT 8-F5OLO-S

FTG ADAPT 12-8 F5OLO-S

HIGH PRESSURE FILTER

FTG ADAPT 6-8 F5OLO-S

FTG ADAPT 6-8 V5OLO-S 45DEG

GAUGE OIL LF 2.5 0-5000 CBM

HOSE HYD 0.50 X 113

HOSE HYD 0.25 X 289

HOSE-HYD 0.38 X 258

DESCRIPTION

HOSE KIT,15000 CRANE (incl:2-14)

HOSE-HYD 0.38 X 217

ITEM

PART No.

9048

HOSE-HYD 0.38 X 93

HOSE-HYD 0.50X 20

9050

9049

16526

HOSE-HYD 0.38 X 48

HOSE-HYD 0.25 X 71

9093

9092

9094

HOSE-HYD 0.38 X 76

9096

9095

9097

TM PAD ROTAT I ON CW

TM PAD ROTAT I ON CCW

HOSE-HYD .75X72

39894

9104

7343

6397

7344

C1854

1554

PRESSURE SWITCH

9334

16974

QTY

2ref

1ref

2ref

4ref

2ref

6ref

1ref

TM ROTATION CW

O.R. CS UP

TM ROTATION CCW

TM CLAMP OPEN

O.R. CS IN

.R. SS UP

O.R. CS DOWN

O.R. CS OUT

O.R. SS DOWN

O.R. SS IN

ROTATION CCW

EXT RETRACT

OUTER RETRACT

.R. SS OUT

ROTATION CW

EXT EXTEND

OUTER EXTEND

INNER RETRACT

INNER EXTEND

TG ADAPT 8-12 F5OLO-S

FTG ADAPT 12 F5OLO-S

FTG ADAPT 12 C5OLO-S

QUICK COUPLER 2FFN38-12SAE-M

UICK COUPLER 2FFN38-12SAE-F

FTG ADAPT 8 C5OLO-S

FTG ADAPT 16-8 F5OG-S

QUICK COUPLER 2FFI14-38SAE-M

FTG, ADAPT 6-10 F5OLO-S

TG ADAPT MSTR/FNPT 12 - 0.25

FTG ADAPT 6-F5OLO-S

FTG ADAPT 4-6 F5OLO-S

QUICK COUPLER 2FFI14-38SAE-F

FTG ADAPT MSTR/FSTR 20-12F5OGS

EXTEND

RETRACT

M ROTATION CCWTM CLAMP OUT

ROTATION CCW

ROTATION CW

ROTATION

EXTENSION

13554

O.R. CS

DOWN

C4922

0279

C1855

766

13555

OUT

13557

3556

C1111

D1193

EXTEND

RETRACT

EXTENDEXT EXTEND

EXT RETRACT

OUTER RETRACT

OUTER EXTEND

OUTER

O.R. CS

C5968

C4227

D1311

O.R. SS

DOWN

TG MSTR/FNPT4-1/4

FTG 0.25 ML ELLC5908

C1180

691

EXTEND

RETRACT

INNER

INNER RETRACT

INNER EXTEND

O.R. SS

OUT

6,12

15776 FTG TEE ST TH BRANCH 12-G5G5JAO-S 1

17,3023,28

18 19

1111

3,27

3,28

09 17

07 17

32,33

23,27

17,29

23 23

2323

717

25 25

323

1717

25 25

From Pump

eturn to Tank

Hydraulic Kit - PN 33942

37Hydraulics - Electrical 37

38 15000 Owner’s Manual

Chapter 9 - Replacement Parts

39Replacement Parts 39

Hydraulic System Components

art#Description

397Oil pressure gauge

7829Solenoid valve ( Dump valve )

311Hydraulic rotation motor ( Crane rotation )

6974Pressure switch

3290Handle assembly ( Valve bank )

3 C6327 Filter Strainer ( Hydraulic reservoir ) C1090 Counter balance valve ( Cylinders)

2028O ring ( # 6 face seal ) ( hydraulic fittings )

C C2029 O ring ( # 8 face seal ) ( hydraulic fittings )

32223 O ring (#10 face seal ) ( hydraulic fittings ) D1244 O ring (#12 face seal ) ( hydraulic fittings ) D1245 O ring (# 4 SAE port side ) ( hydraulic fittings ) D1246 O ring (# 6 SAE port side ) ( hydraulic fittings ) D1247 O ring (# 8 SAE port side ) ( hydraulic fittings ) D1248 O ring (#10 SAE port side ) ( hydraulic fittings ) D1249 O ring (#12 SAE port side ) ( hydraulic fittings ) D1250 O ring (#16 SAE port side ) ( hydraulic fittings )

16158 Port tube asm - ( Secondary cylinder ) 15604 C6303 Seal kit - Outrigger cylinder ( 6773 ) C6305 Seal kit - Outrigger cylinder ( 6774 )

11377 Seal kit - Main lift cylinder ( 23575 )

11377 Seal kit - Secondary cylinder ( 6771) C6303 Seal kit - Extension cylinder ( 12705 )

Structural Parts

Part# Description

#0635 Bushing 2.50" x 2.00" #0865 Bushing 3.00" x 2.00"

4381 Bushing 2.00" x 2.00"

#0067 Bushing 1.50" x 1.50"

4379 Bushing 2.00" x 2.50" 8377 Pin Cap 0.56 x 3.50" x .25 SS

13315 Pin Cap 0.69 x 4.00" x .25 SS

9142 Pin Cap 0.56 x 2.50" x .25 SS 5145 Pin Cap 0.56 x 3.00" x .25 SS

10172 Cap Scr D0790 Washer 0.50 Flat Gr 8 C1592 Grease Zerk 1/8 NPT

9342 Wear Pad 2.00" x 6.00" x 1.00" 13641 W 12548 Wear Pad 3.00" x 5.00" x 1.75"

ew 0.50-13 x 1.00 Gr 8

ear Pad 2.21" x 3.21" x 1.38"

Compressor Components

art#Description

853Pilot valve 145/175 psi (SHD245 cprsr)

4913Solenoid valve (SHD245 cprsr)

4914Pressure Relief valve (SHD245 cprsr)

0864Hobbs air pressure switch (SHD245 cprsr)

3731Low pressure intake valve asm (SHD245 cprsr)

1 13733 High pressure intake valve asm (SHD245 cprsr)

Service Kits/Filters/Lubrication

Part# Description

4562 Air filter (SHD245 cprsr) 9335 High pressure hydraulic filter (28000 Crane)

C6225 Hydraulic return filter (Crane / cprsr)

32893 Service Kit - 200 hour (SHD245 cprsr) 14532 Service Kit - 1 year (Crane / cprsr )

4460 Molube grease-external gear teeth for swing gears

TM6120 Tire Man Components

Part# Description

D1204 Hydraulic rotation motor (Tireman pad rotation)

21151 Hydraulic rotation motor gasket 13555 Hydraulic quick coupler 13554 Hydraulic quick coupler 13557 Hydraulic quick coupler 13556 Hydraulic quick coupler

4482 Combination flow divider

38975 Seal Kit - Tireman clamp in / clamp out cylinders

Miscellaneous Components

Part# Description

12341 Flood lights ( Crane & Body )

5033 Stobe light ( Crane & Body )

14022 Compartment light

Call 800-321-3741 to Order

Electrical Components

Part# Description

8241 Fan 16.00 push 12 V ( Hydraulic reservoir )

6394 Toggle switch ( Outrigger operation )

8623 Toggle switch ( Outrigger operation )

C4815 Toggle switch ( Outrigger operation ) D1862 Temperature switch ( Hydraulic reservoir )

11291 9.6 V Makita battery ( Radio Transmitter ) 22921 E-stop switch ( Crane panic bar ) 38978 Standar 38979 Dump valve Din connector VB 14941 Paddle controller ( Omnex radio transmitter )

d Din connector (functional cut-out) VB

40 15000 Owner’s Manual

Chapter 10 - Troubleshooting

41Troubleshooting 41

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.

• 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 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 flow 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 s ure they are not tarnished or corroded. Clean contact points and recharge or replace the battery.

• When battery voltage is acceptable, the power LED light on the transmitter will be solid. If the voltage becomes low, the LED light will begin to blink and the battery will need to be charged or replaced.

If problems persist, please contact

Stellar Customer Service at:

1-800-321-3741

42 15000 Owner’s Manual

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.

Problem: Crane will operate manually but will not operate electronically. Solutions:

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 defective, 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 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. Check the twin solenoid for polarity, if solenoid does not magnetize, replace the twin solenoid.

Troubleshooting continued...

Problem Possible Cause Possible Solution

Vibrations and jerking in hydraulic cylinder during the first maneuvers.

The temperature of the hydraulic oil is too low.

lack of oil in reservoir.

43Troubleshooting 43

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

Add hydraulic oil.

Vibrations with every function when oil is hot.

All crane movements are slow, loaded and unloaded.

The hydraulic extension is not extending.

Crane rotation not regular Inadequate grease.

Lack of oil in reservoir.

air in hydraulic system.

Suction hose from oil tank crushed or obstructed.

Dump valve malfunctioning.

The pump is drawing in air.

Bad lubrication.

Wear pads are worn.

Sequence valve on extension cylinder has to be adjusted.

The truck is not level.

Worn rotation motor.

Add hydraulic oil to the tank.

Operate the control carrying the cylinders to stroke end several times in both directions.

Replace or clean the suction hose.

Manually override system to detect

Tighten suction hose connections.

Lubricate the wear pads

Replace wear pads.

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

Grease gear bearing.

Level the truck.

Replace rotation motor.

Gear bearings worn.

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

The crane lifts the load, but cannot hold it.

Noise coming from Articulation points. Lack of lubrication.

Defective hydraulic pump.

Incorrect settings of the valves.

Hydraulic cylinder seals are worn.

Incorrect relief setting.

Faulty holding valve.

Incorrect settings of the valves.

Hydraulic cylinder seals are worn.

Worn pin.

orn bushing.

Replace gear.

Replace the pump.

Adjust valve settings.

Replace worn seals.

Contact Stellar customer service for proper setting. Replace holding valve.

Adjust valve settings.

Replace worn seals.

Grease articulation points.

Replace pin.

Replace bushing.

44 15000 Owner’s Manual

Problem Possible Cause Possible Solution

Hydraulic legs do not hold under load. Defective holding valves

Worn seals in the stabilizer cylinder.

Crane does not function. Truck battery discharged

Electric connections are damaged or corroded.

Control handle turned off.

Crane does not function - Continued Battery charge low.

Burned fuses

Dump valve not operating properly.

PTO not fully engaged.

Control box lights do not operate (green LED out)

Discharged battery.

Burned fuses.

Disconnected electrical cord.

Corroded or loose electrical connections.

Clean or replace holding valves.

Replace worn seals.

Charge battery.

Check electrical wiring, terminals, connections and their integrity.

Turn on control handle

Charge transmitter battery.

Replace the fuses.

Bypass electrical circuit

Check for full engagement.

Recharge battery.

Replace fuses.

Join correctly the connection, replace the electric coupling. Check electrical connections.

Faulty manual/remote switch.

A crane function does not work. Defective switch.

Faulty solenoid.

Locked valve cartridge.

Damaged electric connection.

Operations at high or low speed do not work.

Controls fail to respond with control box.

Operation slow down. Hydraulic oil supply is low.

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

Batteries dead in wireless handle.

Handle on/of

Manual/remote switch is in manual position.

Hydraulic pump is operating at a reduced speed.

f button isn’t turned on.

Replace switch.

Replace the switch.

Replace the solenoid.

Disassemble and clean the valve cartridge. Check continuity of the circuit.

Contact Stellar customer service department.

Recharge or replace batteries in remote handle.

urn on on/of

T dle. Position manual/remote switch in remote position.

Add hydraulic oil.

Engine idle speed may be too slow increase speed.

f button on remote han

Relief valve is set too low.

Pump or cylinder is worn.

Check relief with gauge.

Replace cylinder seals.

Problem Possible Cause Possible Solution

45Troubleshooting 45

Operation slow down - con’t Pump is slipping due to excessive oil

temperature, this is a factor which will increase with worn components.

Filters are dirty.

Obstruction has occurred in boom holding valve.

Operation slow down - con’t Defective flow valve. Replace valve.

Boom drifts when loaded and controls neutralized.

Unusual noise in operation. Cavitation is occurring due to low

Hydraulic oil is bypassing at piston seal.

Main or secondary cylinder holding valves are defective or contaminated.

hydraulic oil supply.

Restriction or collapse of suction line has occurred.

Suction line screen is clogged and requires replacement.

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

Replace filters.

Replace or clean holding valve.

Replace cylinder.

Clean or replace holding valves.

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

Inspect suction line for damage.

Replace or clean screen.

Unusual noise in operation - con’t Bypass settings on relief valve are too

low.

Relief valve is damaged.

Outriggers fail to retract Control valve is inoperative.

Cylinder seals or holding valve are defective

Hydraulic lines are restricted or ruptured.

Outriggers fail to retract-con’t Broken electrical wire going to outrig-

ger switch to the valve bank.

Outriggers yield or drift. Control valve is inoperative.

Contact customer service for correct relief setting.

Replace relief valve.

If outriggers retract using manual function, it is a probable electrical problem check continuity.

Replace seals or holding valve.

Inspect and replace hydraulic lines.

Check continuity of circuit.

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.

46 15000 Owner’s Manual

BMS-2 Receiver Troubleshooting

Available on some systems. Consult BMS-2 Operator Manual for details.

Problem Probable Cause Correction

System will not initialize after normal start-up procedure.

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

Transmitter is transmitting (Power LED flashing), but crane will not respond.

E-Stop reset

Joystick or paddle lever not in center position.

E-Stop switch engaged.

Battery fully discharged.

No power to the receiver.

Battery is discharged.

Coder board fuse.

Broken key switch.

Coder board failure.

E-Stop switch engaged.

Transmitter out of range.

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

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.

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

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

Check battery to ensure a full charge. Replace with fully charged battery if necessary.

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.

Replace battery with a fully charged battery.

Check fuse and replace if necessary.

Check wiring on key switch. Replace key switch, wiring or contact element.

Contact Hetronic or your Dealer.

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

Take the transmitter back into the range of the receiver. Press the Start/Horn pushbutton.

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

All crane/machine motions operate intermittently

Some crane/machine motions operate intermittently

Receiver power off.

Blown fuse in receiver.

E-Stop failure in transmitter.

E-Stop failure in receiver. Red EStop LED illuminated.

E-Stop module failure.

Receiver antenna loose or missing.

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

Connector wiring too close to power wiring.

Connector inside receiver is loose.

Crane/machine motion wiring may be loose.

Connector inside receiver is loose.

on decoder board is

Turn on power to receiver.

Check all fuses. Replace if necessary.

Check E-Stop pushbutton for damage. Check wiring to contact element for broken or disconnected wires. Repair or replace E-stop pushbutton or wiring.

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

Replace E-Stop module.

Tighten or replace antenna.

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

Control wiring must be run separately from power wiring.

Check all connectors, reseat if necessary

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

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 under proper use and maintenance. Products must be installed and operated in accordance with Stellar’s written instructions and capacities. The warranty period shall cover the following:

Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date of manufacture, 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 of manufacture, and Thirty-six (36) month warranty on all Stellar Crane and Hooklift structural parts from the date recorded by Stellar as the in-service date, not to extend beyond forty-eight (48) months from date of manufacture.

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, the factory 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 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 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: February 2007 Document Number: 37040

Stellar 15000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

Chapter 1 - Safety

Chapter 2 - Operation

Unit Operation Overview

Radio Remote Operation

Manual Operation

Crane Precautions

Crane Transport

Hook Precautions

Operator Information

Chapter 3 - Maintenance

Lubrication Recommendations

Chapter 4 - Specifications

Capacity Chart - Decal PN 6853

Chapter 5 - Decals

Decals of Note

Outrigger Decals

Crane Cover Decals

Decal Kit Placement Kit 8720

Chapter 6 - Installation

General Installation

Installation Notice

Installation Overview

Mounting Kit Drawing

Chapter 7 - Assembly Drawings

Base Assembly - PN 20299

Mast Assembly - PN 20300

Boom Assembly - PN 20601

Cylinder Assembly - PN 23575

Pendant Box Assembly - PN 20602