Stellar 6628 User Manual

OWNER’S MANUAL

31656

6628

Safety, Installation, Maintenance, and Operation

6628 Telescopic 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. 31709 Last Revision: 10/31/07

6628 Manual Revisions

Date of Revision

September 1, 2005

September 19, 2005

September 9, 2006

November 7, 2006

March 1, 2007

April 12, 2007

Section Revised

Chapter 7: Assembly Drawings

Chapter 7: Assembly Drawings Chapter 8: Hydraulics-Electrical

Chapter 8: Hydraulics-Electrical

Chapter 5: Decals Chapter 7: Assembly Drawings

Description of Revision

Updated Main Boom and Extension Boom drawings to reflect engineering changes.

Updated Cable and Hook assembly drawings to reflect engineering changes.

Updated Base assembly drawings and Hydraulic schematics to reflect engineering changes

Replaced Control Kit 18932 with Control Kit 10701

Updated Decal Kit. Updated assembly drawing for the extension cylinder per engineering changes.

Table of Contents i

Table of Contents

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Chapter 1 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crane Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Unit Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Chapter 2 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6 Function Hetronic Remote. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Operator Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 3 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

Wire Rope Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Torque Data Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Inspection Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Monthly Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Quarterly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Inspection Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Chapter 4 - Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Capacity Chart - Decal PN 31072. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chapter 5 - Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Decals of Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Decal Kit Placement - PN 31654 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Chapter 6 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Installation Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Stability Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Stability Capacity Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chapter 7 - Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Base Assembly - PN 17375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Mast Assembly - PN 17376 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Main Boom - PN 31647 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Extension Boom Assembly - PN 31649 . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Main Cylinder Assembly - PN 31648 . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Extension Cylinder Assembly - PN 37018 . . . . . . . . . . . . . . . . . . . . . . . . 40

Cable & Hook Assembly - PN 38183 . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Chapter 8 - Hydraulics - Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Control Kit - PN 10701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Control Kit (Power House 24) - PN 38989 . . . . . . . . . . . . . . . . . . . . . . . 44

Hydraulic Kit - PN 13042. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Valve Bank - PN 24685. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Hydraulic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Chapter 9 - Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Chapter 10 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6 Function Hetronic Radio Remote Troubleshooting. . . . . . . . . . . . . . 53

Transmitter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Receiver Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4 & 7 Function Hetronic Radio Remote Troubleshooting . . . . . . . . . . 55

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

ii 6628 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.

Do not wear rings, wristwatch, jewelry, loosefitting or hanging clothing such as ties, torn garments, scarves, unbuttoned jackets or unzipped overalls, which could get caught up in the moving parts of the crane.

Keep a first-aid box and a fire extinguisher readily available on the truck. Regularly check to make sure the fire extinguisher is fully charged and the first-aid kit is stocked.

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

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.

Trainees or untrained persons shall be under the direct supervision of qualified persons.

Do not operate equipment under the adverse influence of alcohol, drugs, or medication.

PERSONAL 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, antinoise headphones, protective glasses, and reflective jackets with breathing apparatus. Consult your employer regarding current safety regulations and accident-prevention equipment.

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

Do not attempt service or repair when the PTO is 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.

2 6628 Owner’s Manual

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 are based on the machine’s hydraulic, mechanical, and structural design rather than stability.

The supporting surface under the service truck must be able to support the weight of the machine and its load. Use outrigger pads if necessary.

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 sure the outriggers are positioned on stable, flat ground.

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. If the crane is picking more than

the maximum rated load, the overload

protection device may be malfunctioning. Discontinue use immediately and contact Stellar Customer Service for support.

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 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.

Do not leave a crane load suspended or unattended.

Safety 3

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.

Be familiar with your remote control and

how it works before operating the crane.

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.

4 6628 Owner’s Manual

Chapter 2 - Operation

Operation 5

This chapter contains information regarding the operation of Stellar manufactured telescopic 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.

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.

PTO Switch

6 6628 Owner’s Manual

6 Function Hetronic Remote

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.

NOTE: The radio control is an electri-

cal device. Please handle with care!

Variable Speed Trigger on remote.

The crane should not function until the trigger has been

activated. The speed of the crane will vary in direct

correlation with how much or how little the trigger is engaged.

Operation 7

MAIN

XTENSION

XTEND

RETRACT

MAIN

OWN

EXTENSION

OWN

ROT

PULL

PUSH

ONTROL

LOW

WINCH

Manual Operation

If the remote control malfunctions, follow these steps to operate the crane manually:

1. Activate Flow Control. Turn the override screw on flow control counter-clockwise. Full adjustment is between three and five turns. Operate Solenoids. Slide the knurled sleeve

2. out and then push or pull to operate, as shown below. Be sure the sleeve is in the center, locked, position before returning to remote operation.

3. Deactivate flow control. Turn the override screw clockwise until stopped. Full adjustment is between 3 and 5 turns.

4. Have unit serviced immediately to restore remote control functionality.

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

Manual Override Pull Function

The knurled sleeve is pulled all the way out together with the knob to manually override the pull solenoid function.

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

Manual Override Push Function

The knurled sleeve should first be pulled to unlatch the ball latching mechanism and then, while holding the sleeve back, the override knob should be pushed all the way in to override the push solenoid.

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.

8 6628 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.

Chapter 3 - Maintenance

Maintenance 9

WARNING - Read the Following before performing any maintenance on the

crane.

1. Only authorized service personnel are to perform maintenance on the crane.

2. Disengage the PTO before any service or repair is performed.

3. Do not disconnect hydraulic hoses while there is still pressure in those components.

4. Before disconnecting hydraulic

components, place the boom on the ground or have it supported, shut off the engine, release any air pressure on the hydraulic reservoir, and move pedals and control levers repeatedly through their operating positions to relieve all pressures.

5. Keep the crane and service body clean and free from grease build-up, oil and dirt to prevent slippery conditions.

6. Perform all safety and maintenance checks before each period of use.

7. Replace parts with Stellar Industries, Inc. approved parts only.

8. Immediately repair or have repaired any components found to be inadequate.

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.

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

pressure.

4. Main frame mount bolts.

5. Cylinders for:

A. Damaged rods. B. Dented barrels. C. Drift from oil leaking internally. D. Leaks at rod seals or holding valves.

6. PTO drive line system for proper

alignment, lubrication, and tightness.

7. Hydraulic hose and tubing for evidence of

damage such as blistering, crushing, or abrasion.

10 6628 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.

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,

Stellar Industries recommends the first

filter change to occur after the first 250

hours of service.* The second, and

every subsequent change, should

occur after every 1,000 hours of

service. By following these guidelines,

the hydraulic oil should last up to

6,500 hours.

*Note: These recommendations are based on normal

working parameters. If operating in less than favorable

conditions (excessive dust, moisture, etc.), be sure to check

the filter gauge often for filter change notice.

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

Maintenance 11

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)

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

Greasing the Crane

Lubricate all grease gun points with

Extreme Pressure Grease - Stellar P/N: 22059.

12 6628 Owner’s Manual

Wire Rope Maintenance

Wire Rope Inspection Points

While inspection of the entire rope is required, attention should be directed to these critical points:

1. Pick-up Points for signs of wear due to stress from repeated lifts.

2. End Attachments for corrosion and broken wires at both ends of the rope. Drums for signs of corrugation and wear

3. that may lead to wire damage. Sheaves to ensure that each sheave has

4. the proper groove size and contour.

5. Abuse Points for heavy amounts of scuffing and scraping.

It is important to perform detailed inspections of all ropes associated with the crane. These inspections can be divided into two types:

1. Frequent Inspection

A. All running ropes should be inspected

once each working day. These visual observations will be concerned with discovering damage that may be an immediate hazard. The following concerns should be addressed:

1. Distortion of the rope.

2. General corrosion.

3. Broken or cut strands.

B. Use caution while inspecting sections of

rapid deterioration.

C. Use caution while inspecting boom

hoist ropes. Proper inspection is critical but difficult.

Periodic Inspection

A. Inspection frequency will be

determined by a qualified person and will be based on such factors as expected rope life, environment conditions, capacity of typical lifts, rates of usage, and exposure to shock loads. Periodic inspection needs to be performed at least annually.

B. Periodic inspections will be performed

by a qualified individual and will cover the entire length of the rope. Only the

surface wires of the rope need to be inspected. This inspection will be concerned with discovering damage that may be an immediate hazard. The following concerns should be addressed:

1. Distortion of the rope.

2. General corrosion.

3. Broken or cut strands.

4. Reduction of rope diameter.

5. Corroded or broken wires at end connections.

6. Corroded, cracked, bent, worn, or improperly applied end connections.

C. Use caution when inspecting the

following:

1. Sections in contact with saddles, equalizer sheaves, or other sheaves where rope travel is limited.

2. Sections of the rope at or near ends with corroded or broken wires.

Wire Rope Replacement

Rope replacement guidelines are as follows:

1. Broken wires, including standing ropes with more than two broken wires in one lay or more than one broken wire at an end connection.

2. Wear of one-third the original diameter of the outside wires.

3. Distortion of the rope structure.

4. Evidence of heat damage.

5. Reductions from nominal diameters of more than 1/64 in. (0.4 mm) for diameters from 5/16 in.(19.0 mm) and 1/32 in. (0.8 mm) for diameters from 3/8 in. (9.5 mm) to and including 1/2 in. (13.0 mm).

Wire Rope Maintenance

Proper maintenance is key in ensuring a long lasting rope. These three tips will help:

1. Store the rope to prevent damage.

2. Avoid objects that may scrape, bend, or crush the wires of the rope.

3. Always keep the rope well-lubricated.

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.

Maintenance 13

Torque Data Chart

Grade 5

Plated

Size

(DIA-TPI)

5/16-18

3/8-16

7/16-14

1/2-13

9/16-12

5/8-11 3/4-10

7/8-9

1-8 1 1/8-7 1 1/4-7 1 3/8-6 1 1/2-6

Bolt DIA

(Inches)

0.3125

0.3750

0.4375

0.5000

0.5625

0.6250

0.7500

0.8750

1.000

1.1250

1.2500

1.3750

1.500

Plain

(Ft-Lb)

17 31 49

75 110 150 265 395 590 795

1120 1470 1950

(Ft-Lb)

13 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

Plain

(Ft-Lb)

25 44

70 105 155 220 375 605 910

1290 1815 2380 3160

Plated

(Ft-Lb)

18 33 52

80 115 160 280 455 680 965

1360 1780 2370

Grade 9

Plated

(Ft-Lb)

22 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 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.

14 6628 Owner’s Manual

Inspection Checklist

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. 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.

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