Stellar 9000 User Manual

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Page 1

OWNER’S MANUAL

Safety, Installation, Maintenance, and Operation

9000 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. 37811 Last Revision: 4/30/07

Page 2

9000 Manual Revisions

Date of Revision Description of RevisionSection Revised

Page 3

Table of Contents i

Table of Contents

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

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

Chapter 2 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Unit Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Radio Remote Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Crane Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Manual Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Hook Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Crane Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Operator Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Chapter 3 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Lubrication Recommendations . . . . . . . . . . . . . . . . . . . . . . . . 9

Torque Data Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Monthly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Quarterly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Inspection Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4 - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Capacity Chart - Decal PN 29559. . . . . . . . . . . . . . . . . . . . . 20

Chapter 5 - Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Decals of Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Crane Cover Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Crane Base Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Outrigger Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Decal Kit Placement Kit 30488 . . . . . . . . . . . . . . . . . . . . . . . . 25

Chapter 6 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

General Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Installation Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Chapter 7 - Assembly Drawings. . . . . . . . . . . . . . . . . . . . . . . . . 29

Base Assembly - PN 29349 . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Mast Assembly - PN 29350 . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Main Boom Assembly - PN 29354. . . . . . . . . . . . . . . . . . . . . . 31

Extension Boom Assembly - PN 29359 . . . . . . . . . . . . . . . . . . 32

Chapter 8 - Hydraulics - Electrical. . . . . . . . . . . . . . . . . . . . . . . 33

Control Kit - PN 29556 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Hydraulic Kit - PN 29557

Chapter 9 - Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . 37

Chapter 10 - Troubleshooting

Omnex Diagnostics and Troubleshooting

Warrany Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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

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

. . . . . . . . . . . . . . . 41

Page 4

ii 9000 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

Page 5

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

Page 6

2 9000 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

Page 7

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.

Page 8

4 9000 Owner’s Manual

EXTENSION

FLOW

XTENSION

ONTROL

USH

ULL

INNER

NNER

OUTER

UTER

DOWN

ROT C

LOSE

TM ROT

OPEN

CCW

ROT

OUT

DOWN

Radio Remote Operation

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

ol system

Manual Operation

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

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

eleased.

Note: If the crane does not operate, check the batteries located in the r

eplace if necessary.

Note About Battery Condition

The batteries included with this equipment may be

emote handle and

rechargeable. To keep rechargeable batteries in optimal working condition, follow these simple guidelines:

1. Keep battery away from moisture. Store in a

2. Do not store or carry battery so that metal

cool, dry location.

objects can contact exposed metal end. Keep battery cap on when not in use.

The batteries should be recharged when they fail to pr Never attempt to open the battery for any

oduce suf

ficient power

reason.

Valve Manual Override Operation

1. Activate Flow Control:

Turn override screw on flow control out.

2. Operate Solenoids:

Unlatch then push or pull to operate.

3. Deactivate Flow Control:

n override screw on flow control in.

4. Have Unit Serviced.

Page 9

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.

Page 10

6 9000 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

Page 11

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.

Page 12

8 9000 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.

Page 13

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.

Page 14

10 9000 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.

Page 15

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

Page 16

12 9000 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.

Page 17

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.

Page 18

14 9000 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

Page 19

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.

Page 20

16 9000 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.

Page 21

Inspection Notes

Maintenance 17

Page 22

18 9000 Owner’s Manual

Page 23

Chapter 4 - Specifications

Model 9000 Crane

SPECIFICATION SHEET

Crane Rating: 90,000 ft-lbs (12.44 ton meters)

Standard Boom Length: 12’ 11” (3.94 m) from CL of Crane

Boom Extension: Hydraulic 37" (94 cm)

Maximum Horizontal Reach: 16’ (4.87 m) from CL of Crane

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

Cylinder Specifications

Inner Lift Cylinder: 6” (15.24 cm) bore with integral

pilot operated counterbalance valves.

Outer Lift Cylinder: 5” (12.70 cm) bore with integral

pilot operated counterbalance valves.

Extension Cylinder: 3

⁄2” (8.89 cm) bore with integral

pilot operated counterbalance valves.

19Specifications 19

Rotation: 290 degree power (Worm Gear Drive)

Lifting Capacities: 9,000 lbs @ 10’ (4080 kg @ 3.03 m)

6,950 lbs @ 12’11” (3150 kg @ 3.94 m) 5,625 lbs @ 16’ (2550 kg @ 4.87 m)

Power Supply Requir

Controls: Proportional Radio Controls standard for all functions.

Stowed Height: 75” (190.5 cm) (Above Truck Frame)

Mounting Space Required: 32” (81.3 cm)

oximate Shipping Weight: 4,200 lbs (1590 kg)

Appr

ed: PTO & Pump

(8.0 gpm @ 3000 psi) (30.3 lpm @ 206 bars)

Page 24

20 9000 Owner’s Manual

10’

3.05m

16’

4.87m

12’11”

3.94m

10’

3.05m

16’

4.87m

12’11”

3.94m

10’

3.05m

25’4”

7.72m

22’6”

6.86m

CAPACITY

CHART

9000 lbs

4080 kg

6950 lbs

3150 kg

5625 lbs

2550 kg

0’

TRUCK

GROUND

0’

190 STATE STREET GARNER, IA 50438

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

9000

Capacity Chart - Decal PN 29559

Page 25

Chapter 5 - Decals

Decals of Note

21Decals 21

Crane Base Decals

Crane Outrigger Decals

Page 26

22 9000 Owner’s Manual

Crane Cover Decals

Electrocution Hazard Decal

Location: Crane Base Function: T

the 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

Crane Base Decals

Operation Hazard Decal

Location: Crane Base Function: T

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

o inform the operator and other

Operation Hazard Decal

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

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

ocedur

es and , the

Page 27

Crane Base Decals

23Decals 23

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 Function: T

the hazard associated with contact or proximity to electrical lines, the possible consequences should the hazar hazar PN: C1179

o infor

m the operator and other personnel in the work ar

d occur and how to avoid the

ea of

Page 28

24 9000 Owner’s Manual

Outrigger Decals

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.

Moving Outrigger Hazard Decal

Location: Outrigger Leg Function: T

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

to avoid the hazard PN: C5918

o inform the operator of the hazard

Crane Outrigger Decals

Page 29

25Decals 25

(USE WITH BODY PACKAGE)

DECAL-AL IGNMENT

DECAL-ELECTROCUTION 3.25x7.5

PART No.

ITEM

01 4188

4187

DESCRIPTION

QTY

THESE DECALS NOT SHOWN

DECAL-ELECTROCUTION 4.5x7.5

DECAL-S TELLAR APPROVED ATTACHMT

DECAL-DANGER MOVING O.R.

DECAL-DANGER

DECAL-ELECTROCUTION 2x2.75

DECAL-DANGER STOWING

DECAL-DANGER O.R.

DECAL-ELECTROCUTION 5x13

DECAL-DANGER

C4545

C4540

C454405

C454108

07 4189

4186

C4795

C591811

09104190

C1179

16973

DECAL ASME/ANSI B30.22/B30.5

DECAL WORM GEAR LUBRICATION

15172

9188

DECAL-OR PANEL

DECAL-I DENTIFICATION

DECAL-S ERVICE

DECAL-CAPACITY

DECAL-D IESEL FUEL ONLY

DECAL-S TELLAR 2x4.5

DECAL-F LOOD LIGHT

DECAL-S TELLAR 4x9.5

21 29559

18 C0568

C5911

C5910

19 4305

4214

DECAL CRANE OUTRIGGER

DECAL GREASE WORM DRIVE BEARINGS

4158

15171

13036

25 30487

TOP OF COVER

26 28841 DECAL OMNEX RADIO OPERATION 1

35234*27 DECAL STELLAR MADE IN THE USA 1

*THESE DECAL NOT INCLUDED WITH THE DECAL KIT

E-stop

Opt

Ext

Boom

Winch

tart/

Rot

top

Compressor

Speed Control

out

updnup

ccw

top

Start

PN 30488

Decal Kit Placement Kit 30488

Page 30

26 9000 Owner’s Manual

Page 31

Chapter 6 - Installation

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 9000 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.

Installation Overview

Installation Guidelines (For more detail, please contact Stellar Customer Service)

Locate mounting brackets and clamp to

1. chassis 1” (min) from rear of cab (or desired location).

2. Set crane on chassis and check for interferences.

3. Using mounting bracket as a guide, mark holes to be drilled into truck frame.

4. Remove mounting brackets and drill holes.

5. Mount brackets using 3/4” Grade 8 bolts, flast washers, and nyloc nuts.

6. Lower crane onto mounting brackets.

7. Mount crane using 1” Grade 8 bolt, flat washers, and nyloc nuts.

8. Connect pressure and return lines per hydraulic kit.

9. Connect (+12V) Power and ground wires inside crane box.

10. Check reservoir for oil and fill if necessary

1. Operate crane several cycles.

Install Kit (PN 32307)

Page 32

28 9000 Owner’s Manual

Page 33

NOTE: ATTACH (2) 14" LONG PIECES OF WEATHERSTRIP, P/N 17162, TO COVER P/N 30005

.YTQNOITPIRCSEDTRAPMETI

10009 ESA

448821 2C6219 WASHER 0.75 SAE FLAT YELLOW GR8 20 3D1312 CAP SCR 0.63-11X3.50 HHGR8 2

COL

YN HH 11-36

.0 TUN62

205

.52X00

.2 REDNILY

70D5

0006 SS GEL REGGIRTUO71846

205.6X00.1 NIP69737 40

01-0027 DI 00.1 GNIR PANS01108

252.3X00

.1 NIP21

ANRE

TNI 00.1 GNIR PA

NS57830

1 11 D1295 CAP SCR 0.50-13X1.50 SH GR5 4 12 10974 VB 2 SECT W/PB VDM6-4-4-YE-HP 1 13 C0927 CAP SCR 0.31-18X2.25 HHGR5 2

NIZ TALF SSU 13

.0 REHSA

W343

41 15 26766 GUARD TTB 6000 GP BEARING 1 16 0484 CAP SCR 0.31-18 X 0.50 HHGR5 4

10009 ESAB REVOC5000371 2HSULF SS EGN

IH10

06C

NIZ )T( REBB

UR HCTAL6184C

1LABICE

D 79. MRALA

PUKCA

B5400D

2 21 D0896 CAP SCR #10-24X0.75 FHSH SS 3

5SS COLYN HH 42-01# TUN

94C22

TQNOITPIRCS

TRA

PMETI 23 D1711 CAP SCR #10-24X0.50 BTNHD SS 2 24 C6021 CAP SCR 0.25-20X0.75 BTNHD SS 10

21COLYN 5RGHH 02-52.0 T

3330

2 26 D0528 CAP SCR 0.25-20X1.25 BTNHD SS 2 27 D1345 FTG CPRSN 0.12NPT/0.25 TUBE 2 28 D1810 TBE AIR SAEJ844 TYPE A .25 (28") 1

131.0 EPIP RELPUOC GTF6522C92 1

THGIARTS TPN 8/1 KRE

2951c

1REBBUR 00.1 PMALC326713 32 30489 CAP CORDED BACKUP OMNEX 1 33 18611 SCREW #6-32X0.38 HH MACH SELF TAP 1

2TNALS REGGIRTUO MSA PAC0940343

35 30494 VB 6 SECT ELECT W/PROP STERLING 8 GPM 1

36 C0954 CAP SCR 0.38-16X4.50 HHGR5 2

2TALF 83.0 REHSAW643073

2COLYN HH 61-83.0 TUN7430

10009 EVIRD GNIWS GNIRAEB1923393 40 5841 CAP SCR 0.75-10X4.50 HHGR8 ZY 20 41 33941 MOTOR 9000, WHITE 500260C3120DEAAA 1

PN 29349

Chapter 7 - Assembly Drawings

Base Assembly - PN 29349

Note: Outrigger Cylinder

uses Stellar Seal Kit P/N 1099

29Assembly Drawings 29

Page 34

30 9000 Owner’s Manual

QNOITPIRCSEDTRA

0009 TSAM1

9721 20635 BUSHING 40DXR32 GARLOCK 4 3 C6219 WASHER 0.75 SAE FLAT YELLOW GR8 18 44974 CAP SCR 0.75-10X2.50 HHGR8 ZY 18 529352 CYLINDER ASM 6.00X28.63 1

&D 52.31

5.2 NI

96 78377 PIN CAP 0.56X3.50X.25 4 8D0790 WASHER 0.50 FLAT GR8 4

ALC E

SOH

COL 83

AW32500

1 11 C0944 CAP SCR 0.38-16X1.75 HHGR5 2 12 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 4

PN 29350

Mast Assembly - PN 29350

Note: Main Lift Cylinder uses

Stellar Seal Kit P/N 38971

Page 35

.YTQNOITPIRCSEDTRAPMETI

10009 MOOB RENNI663821 229356 CYLINDER ASM 5.00X30.00 1 30635 BUSHING 40DXR32 GARLOCK 4 44381 BUSHING 32DXR32 2.00X2.00 GARLOCK 2 54380 BUSHING 32DXR24 2.00X1.50 GARLOCK 2

1T&D 31.01X05.2 ,NIP853926

1T&D 91.01X00.2 NIP90797

252.X05.3X65.0 P

773

252.X00.3X65.0 PAC NIP54159

RG TALF

05.0

REHSA

W0970

1 11 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 4

2THGIARTS TPN 8/1 KREZ2951c21

PN 29354

Main Boom Assembly - PN 29354

31Assembly Drawings 31

Note: Secondary Cylinder

uses Stellar Seal Kit P/N 38680

Page 36

32 9000 Owner’s Manual

.YTQ

OITPIRCSEDTR

METI

10009 MOOB RETUO5738

10009 MOOB TXE1329

39435 WEAR PAD 1.44X3.00 RND NYLATRON 6

100.73X05.3 REDNILYC063924 6

09 DAP RAEW REVOC155925 6D0790 WASHER 0.50 FLAT GR8 32 710666 CAP SCR 0.50-13X1.25 HHGR8 24 84380 BUSHING 32DXR24 2.00X1.50 GARLOCK 4

1T&D 31.21X00.2 NIP2400

2T&D 83.01X00.

2 NIP3400

201

1T&D 36.5X00.2 NIP2559211 8

2.X00.3X65.0 PAC N

IP541

521

13 26762 HOOK 7 TON SWIVEL CROSBY 1028632 1

.5X5

2.1 HCTIH N

IP2

91541 15 28496 COLLAR 1.28x1.75x1.00 2 16 8622 CLAMP HOSE/TUBE AG-2 4 17 0343 WASHER 0.31 USS FLAT ZINC 4

4COLYN HH

81-1

3.0 TUN24308

1 19 30483 WEAR PAD 0.34X3.00 RND 2 20 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 8 21 0249 BUSHING BPC-2022-20 1.25X1.25 3 22 c1592 ZERK 1/8 NPT STRAIGHT 1

PN 29359

Extension Boom Assembly - PN 29359

Note: Extension Cylinder uses

Stellar Seal Kit P/N 38679

Page 37

Chapter 8 - Hydraulics - Electrical

Do not rely on the hydraulic fluid to support

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 guidlines 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.

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.

33Hydraulics - Electrical 33

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.

Page 38

34 9000 Owner’s Manual

PN 29556

Control Kit - PN 29556

Page 39

PN 29557

Hydraulic Kit - PN 29557

35Hydraulics - Electrical 35

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36 9000 Owner’s Manual

Page 41

Chapter 9 - Replacement Parts

37Replacement Parts 37

HYDRAULIC SYSTEM COMPONENTS

ART#DESCRIPTION

397OIL PRESSURE GAUGE

4960FLOW VALVE (PROPORTIONAL)

5369SEAL KIT (FLOW VALVE)

5367RELIEF VALVE

25368 SEAL KIT (RELIEF VALVE)

31077 SOLENOID VALVE (TANDEM)

31526 SEAL KIT (TANDEM SOLENOID VALVE)

25370 COIL (FLOW VALVE AND SOLENOID VALVES)

4587 PRESSURE SWITCH (OVERLOAD)

3941HYDRAULIC SWING MOTOR

2027O RING (#4 FACE SEAL) (HYDRAULIC FITTINGS)

2028O RING (#6 FACE SEAL) (HYDRAULIC FITTINGS)

2029O RING (#8 FA

2223O RING (#10 FACE SEAL) (HYDRAULIC FITTINGS)

1245O RING (#4 SAE PORT SIDE) (HYDRAULIC FITTINGS)

D1246 O RING (#6 SAE PORT

1247O RING (#8 SAE PORT SIDE) (HYDRAULIC FITTINGS)

1248O RING (#10 SAE PORT SIDE) (HYDRAULIC FITTINGS)

1099 SEAL KIT (OUTRIGGER CYLINDER)

38971 SEAL KIT (MAIN LIFT CYLINDER)

38680 SEAL KIT (SECONDARY CYLINDER)

38679 SEAL KIT (EXTENSION CYLINDER)

16154 MANIFOLD ASSEMBLY (MAIN AND SECONDARY CYLINDERS)

9803 COUNTERBALANCE VALVE (CYLINDERS)

29353 TUBE ASSEMBLY (MAIN LIFT CYLINDER)

29357 TUBE ASSEMBLY (SECONDARY CYLINDER)

13554 QUICK COUPLER-HYDRAULIC 0.38 FEMALE

13555 QUICK COUPLER-HYDRUALIC 0.38 MALE

13556 QUICK COUPLER-HYDRAULIC 0.50 FEMALE

13557 QUICK COUPLER-HYDRAULIC 0.50 MALE

CE SEAL) (HYDRAULIC FITTINGS)

SIDE) (HYDRAULIC FITTINGS)

ASSEMBLY COMPONENT PARTS

PART# DESCRIPTION

#0635 BUSHING 2.50" X 2.00"

4381 BUSHING 2.00" X 2.00"

4380 BUSHING 2.00" X 1.50"

#0249 BUSHING 1.25" X 1.25"

8377 PIN CAP 0.56" X 3.50" x 0.25"

5145 PIN CAP 0.56" X 3.00" x 0.25"

10172 CAP SCREW 0.50-13 X 1.00" GRADE 8

D0790 WASHER .50 SAE FLAT GRADE 8

C1592 GREASE ZERK 1/8 NPT STRAIGHT

9435 WEAR P

30483 WEAR PAD 0.34" X 3.00" ROUND

26762 HOOK 7-TON

5192 HITCH PIN 1.25" X 5.13"

28496 COLLAR - HOOK

38676 SAFETY LA

C6001 HINGE (VALVE BANK COVER)

C4816 LATCH RUBBER (VALVE BANK COVER)

#0110 SNAP RING 1.00" ID

#0108 SNAP RING 2.00" ID

30009 HOSE CLAMP (CRANE MAST)

8622 HOSE CLAMP (SECONDAR

AD 1.34" X 3.00" ROUND

TCH

LECTRICAL COMPONENTS

ART#DESCRIPTION

1661TOGGLE SWITCH (OMNEX RADIO REMOTE)

35433 E-STOP SWITCH (OMNEX RADIO REMOTE)

1662HANDLE / TRIGGER ASM (OMNEX RADIO REMOTE)

28832 CABLE BACK UP (OMNEX RADIO REMOTE)

1663BATTERY COVER (OMNEX RADIO REMOTE)

D0045 ALARM (OVERLOAD)

8837TRANSMITTER (OMNEX RADIO SYSTEM)

28836 RECEIVER (OMNEX RADIO SYSTEM)

COMPRESSOR COMPONENTS (SHD66 OPTIONAL)

ART#DESCRIPTION

3853 PILOT VALVE 145/175 PSI

4913SOLENOID VALVE (SHD66 COMPRESSOR)

C4914 PRESSURE RELIEF V

C0864 AIR PRESSURE SWITCH -HOBBS (SHD66 COMPRESSOR)

471LOW PRESSURE INTA

7472 HIGH PRESSURE INTAKE VALVE ASSEMBLY (SHD66 COMPRESSOR)

ALVE (SHD66 COMPRESSOR)

KE VALVE ASSEMBLY (SHD66 COMPRESSOR)

SERVICE KITS / FILTERS / LUBRICATION

ART#DESCRIPTION

4559 AIR FILTER (SHD66 COMPRESSOR)

C6227 HYDRAULIC RETURN FILTER (CRANE / COMPRESSOR)

37864 SERVICE KIT (CRANE / COMPRESSOR)

4460 MOLUBE GREASE-EXTERNAL GEAR TEETH FOR SWING GEAR BEARINGS)

C0087 SYNTHETIC COMPRESSOR OIL ( 1 QT )

MISCELLANEOUS COMPONENTS

PART# DESCRIPTION

12341 FLOOD LIGHTS (CRANE AND BODY)

5033 STROBE LIGHT (CRANE AND BODY)

Call 800-321-3741 to Order

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38 9000 Owner’s Manual

Page 43

Chapter 10 - Troubleshooting

This chapter will list a number of potential problems that may occur while operating the crane. Most problems are easily solved using the solutions portion of this chapter. If problems persist, please contact Customer Service at Stellar Industries 1-800-321-3741.

Problem: Crane will not operate. Solutions:

• Make sure that the parking brake is engaged.

• Make sure that the PTO is engaged.

• Make sure that there is 12V power going to the radio receiver. If there is no power going to the receiver, trace back to the power source and check for a blown fuse or loose ground connection. Refer to radio remote troubleshooting guide at the end of this chapter. Make sure that the transmitter batteries

• are fully charged. (Rechargeable batteries are good for 11 months or 200 charges)

• Make sure that the hydraulic pump is operating at its rated flow or GPMs. Check the flow by using the flow meter to determine the GPMs. It is possible that the hydraulic pump is getting weak. If this is suspected, contact Stellar Customer Service.

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

• Make sure that there is 12V power going to the radio receiver. If there is no power going to the r power source and check for a blown fuse or loose ground connection. Refer to radio remote troubleshooting guide at the end of this chapter.

• Make sure that the parking brake is

engaged.

• Make sure that the parking brake switch is working pr brake switch by performing a continuity test. If the switch is defective, simply replace it.

eceiver, trace back to the

operly. Check the parking

Problem: Not all crane functions operate using the radio remote transmitter or crane operates intermittently. Solutions:

• Make sure that the toggle switch is working properly. If the switch is defective, simply replace it.

• Make sure that there is power going from the valve bank coil solenoid or to the function that will not operate. If no power is going to the coil solenoid, check wiring connections on wire harness plug connector for broken wires, loose connection or poor crimp. If power is going to the solenoid valve, it may not be opening to allow hydraulic oil to the function that is not operating. Remove stem valve, thoroughly clean, lubricate, and reinstall valve. Do not over tighten. If the valve will not close, simply replace it.

Problem: Two functions operate at the same time while only toggling one function. Solutions:

Make sure that the solenoid valves

• manual override sleeves are all in the center position.

• Determine the function that is operating on its own. Check to see if there is power going to the solenoid valve fr function that should not be operating. If voltage is present at the solenoid valve without operating the function, the toggle switch has failed and is stuck in the “on” function. If no voltage is present, the solenoid valve may be partially open. Remove the stem valve, thoroughly clean, lubricate, and reinstall the valve. Do not over tighten. If valve will not close, simply replace it.

om a

39Troubleshooting 39

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40 9000 Owner’s Manual

Problem: Crane only operates at full speed. Solutions:

• Check to see if there is 12V power constantly going to the proportional valve. If 12 volts are showing up at the proportional valve without pulling on the transmitter trigger, the handle/trigger assembly may be defective. If 8 volts are showing at the proportional valve, it is possible that the valve is stuck open and will not close. Remove the valve, clean it thoroughly and reinstall. Do not over tighten. If the problem persists, replace the proportional valve.

• Check to see if the manual override on the proportional valve is turned out. Turn the manual override on the flow valve in.

Problem: Crane operates slowly. Solutions:

• Make sure that the crane is receiving the recommended GPMs to operate.

• Check the level of hydraulic fluid in the reservoir. Add fluid as needed. Check to see if the valve bank orifice is

• plugged. If so, replace the orifice. Call Stellar Customer Service for instructions.

• Make sure the proportional valve is receiving 12V power when fully engaging the transmitter trigger. If there is not 12V power while pulling the trigger loose connections inside the transmitter or replace the handle trigger assembly. If the proportional valve is receiving 12 volts, loosen the solenoid holding nut and check to see if the solenoid coil is magnetizing. If no polarity is present, replace the coil. If coil is magnetizing, remove the stem valve, thoroughly clean, lubricate, and reinstall the valve.

, check for

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 r 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.

eset

If problems persist, please contact

Stellar Customer Service at:

1-800-321-3741

Page 45

Omnex Diagnostics and Troubleshooting

Tether connection detected

Low battery. Unit will run approximately 10 hours after Battery light starts flashing.

Flashing rapidly for 10 seconds indicates a transmitter failure.

Normal Operation

The Active light will flash several times per second, indicating that the transmitter is sending signals to the receiver. The Active light will remain on momentarily whenever a function changes

On Power Up

Release the E-Stop button within 10 seconds to power up the transmitter, or the unit will power down.

Normal Operation

The transmitter is in Download Mode.

On Power Up

Press and release the E-Stop button within 10 seconds to power up the transmitter, or the unit will power down.

Stuck switch detected. Ensure that all switches are in a centered position. The transmitter will not power up when a function is ON.

On Power Down

Unit is still powered. Check for stuck switches, as the transmitter will not power down when a function is ON. Alternating flash means that the transmitter is in Calibration Mode.

Flash Legend

olid

low

Flash

ast

Flash

Red Yellow

Yellow

Red

ocumented in this section is a portion of the Omnex Installation/Configuration

Manual for the T150 Transmitter and R160 Receiver.

T150 Transmitter Diagnostics

41Troubleshooting 41

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42 9000 Owner’s Manual

Normal Operation

Transmitter is OFF I

f the transmitter is off, the receiver is operating properly.

Transmitter is ON When the transmitter is turned on, the Link light (fast flashing) and E-Stop (GREEN) indicates the receiver is operating properly

Transmitter is in Operation When a function is activated on the transmitter, the Fault light will turn on GREEN. This indicates the receiver is operating properly

Transmitter is OFF When a latched function is activated then the transmitter is turned off, the Fault light will stay on GREEN. If the system was intentionally designed this way, the receiver is operating properly, if not call for service.

ESTOP

FAULT LINK

STATUS

STOP

AULT LINK

TATUS

Indicator Lights Description Solution

Transmitter is ON The reason is the transmitter is not communicating with the receiver.

Refer to Trouble Shooting Chart #3 for solutions

Transmitter is ON A low battery condition has been detected.

To detect intermittent conditions caused by poor or corroded ground or power circuits, the GREEN light will continue to flash for 30 seconds after the condition has been removed.

Transmitter is ON An internal fault with the E-Stop has been

detected.

Inspect E-Stop wiring for short circuit. Disconnect E-Stop wire as close to the receiver output as possible. If the Status light changes to:

•

GREEN, a short occurs after disconnection point.

•

Stays flashing RED, send it in for service .

Transmitter is ON A short to ground or excessive current draw on an output. It is most likely caused by a wiring fault.

Ensure transmitter is functioning properly, check status of each output connection: Press each function button and observe Fault Light.

•

If GREEN, everything is OK.

•

If RED, there is a short in that connection.

Transmitter is ON The E-Stop output has been connected with one of the other outputs

Follow the wire and check for connections with other wires, disconnect to see if condition clears. If not, call for service.

Transmitter is OFF A wiring short to the battery has been detected.

Refer to Trouble Shooting Chart #1 for solutions

Transmitter is OFF The receiver has detected an internal fault.

Refer to Trouble Shooting Chart #1 for solutions

Transmitter is OFF Blown fuse detected.

Refer to Page 8 for instructions on how to open the receiver case to access fuse. Check wiring for shorts or bare spots. If fuses continue to blow, call for service.

Transmitter is ON A setup failure has occurred.

Either hold the Setup button for 5 seconds to return to Setup mode or cycle power to return to the normal operating mode.

Transmitter is OFF The receiver is powered incorrectly.

Most likely cause of this condition is that an output wire or the E-Stop wire has been connected to the power supply while the power wire is disconnected from the power supply.

Trouble Indicators

Note: In some cases, the indicator lights will be different depending on whether the transmitter is on or off. Please note the transmitter status in the “Description” column for each case.

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

AULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

STOP

FAULT LINK

TATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

ESTOP

FAULT LINK

STATUS

RED RED GREEN

REEN GREEN GREEN

REEN GREENGREEN GREEN

ED REDGREEN GREEN

RED RED GREEN

ED GREEN RED

GREEN RED GREEN RED

RED RED RED RED

RED RED RED ALT

RED RED RED

GREEN RED RED

GREEN GREEN GREEN

Flash Legend

Solid

Slow F

lash

Fast F

lash

R160 Receiver Diagnostics

Page 47

Start

Initial Condition: Turn transmitter off (all lights are off—press the E-Stop button) C

ycle power to receiver (turn off and back on)

What is the state

of the lights on

he receiver?

K state: Status—GREEN Link—RED Fault—OFF E

-Stop—RED

Note: If there is a short to ground on an output, it is not indicated at this stage. To test for short to ground, refer to the “*Fault Light is RED*” procedure at the bottom of this page and follow the instructions.

Problem state: Status—RED

Go to Chart 2

What is the

state of the E-

Stop light ?

OK state:

E-Stop—RED

Problem state:

E-Stop— Flashing RED

Is the Status light flashing

RED?

Fuse is blown, change fuse

1. Inspect wiring looking for short circuits (e.g. bare wires)

2. If problem re-occurs, call for service.

YES

Inspect E-Stop wiring looking for short circuits (e.g. bare wires) Disconnect the E-Stop output as close to the receiver output as possible. If the Status light changes to:

•

GREEN, there is a short is the wiring after the disconnection point.

•

Stays flashing RED, call for service .

What is the state of the Fault light ?

Fault Light is

OFF

Fault Light is

Flashing RED

*Fault Light is

RED*

Call for service.

There is a short to supply.

1. Disconnect A & B connectors from receiver and check all outputs for power (e.g. bare wires, improper connections) make the correct adjustments

2. Call for service.

There is a short to ground. Note: This should only occur when the transmitter is on and a function button is pressed. In this case the Status light will be GREEN and will turn RED at the same time as the Fault light.

Go to Chart 2 to test the transmitter. If the transmitter is functioning properly, proceed to check the status of each of the output connections: Press each of the function buttons and observe the Fault Light. If the light turn GREEN, everything is OK. If the Light turns RED, there is a short in that connection.

Test the Receiver—R160

Problem state: Status—flashing GREEN & RED

The system is wired incorrectly. Most likely cause is one of the input/output wires has been connected to the power source.

R160 Receiver Troubleshooting

43Troubleshooting 43

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44 9000 Owner’s Manual

What is the state of

the lights?

Active light is flashing rapidly and Battery light flashing slowly

Low Battery—Change Batteries

Note: Low batteries will last approximately 10 hours once the Low Battery light begins to flash. Replace batteries by next shift.

Battery light flashes for 10 seconds then all lights are OFF

Press and release E-Stop if the condition persists, then either there is a faulty EStop or transmitter failure—call for service

Test the Transmitter—T150

Turn off the receiver Ensure there are good batteries in the transmitter Turn on the transmitter

OK state: Active light—steady for about 3 seconds then goes to fast flash. Battery light—OFF E-Stop light—OFF

Go to Chart 3

Activate a

function

Does the Active

light go to solid

YELLOW?

YES

Either the switch/trigger is defective or the switch/trigger connection to the circuit board is broken.

Call for service

Complete the following steps in order:

1. Check battery orientation

2. Clean battery contacts

3. Check or Replace batteries

4. Call for service

Stuck switch:

1. Return all switches to neutral (OFF) position

2. Toggle the switch a few times

3. Call for service

No light comes on at any time

Both the Active light and the Battery light flash at the same time

The transmitter is in Calibration mode

1. Turn unit OFF, then turn back ON

2. If condition persists, call for service.

Battery light and Active light flash alternately.

T150 Transmitter Troubleshooting

Page 49

Testing the Transmitter / Receiver Communication

hat is the status of

he lights of both the

transmitter and

receiver?

Transmitter: Active light is flashing

Receiver: Status—GREEN Link—Flashing GREEN F

ault—OFF

E-Stop—GREEN

Transmitter: Active light is flashing

Receiver: Status—GREEN Link—RED Fault—OFF E-Stop—RED

There is no link between the transmitter and receiver

Do you have a

matched set? (i.e. the

transmitter and re-

ceiver should have

identical ID codes

YES

Was the transmitter

accidentally swapped

with another one on

the job site?

Search the job site for the correct transmitter.

POSSIBLY

Transmitter and receiver should be working properly. The problem may rest with the machine instead of the radio system

Call for service

Was it found?

Turn on the transmitter to check if the units function correctly. If not, proceed to Chart 1

YES

The transmitter code may need to be re-downloaded to the receiver

!!Caution!!

Note: Before you proceed with the Download ID procedure located on Page 8, great

care and caution must be adhered to.

If by accident, the transmitters have been switched with another unit, by downloading the ID code to a new receiver, it is possible for the transmitter to operate 2 units at the same time (if the original receiver unit is still on the job site). Therefore it must be certain that the transmitter / receiver pair are the correct set.

Secondly, once the download procedure is completed, ensure all other units on the job site are stopped. Test the operation of the newly configured set to ensure no other machines on the site work with the same transmitter.

Once you are certain that the transmitter / receiver pair are a unique set, continue normal operations.

Call for service.

R160 Receiver/T150 Transmitter Troubleshooting

45Troubleshooting 45

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46 9000 Owner’s Manual

Reprogramming the System Considerations

Potential reprogramming issues

If testing of the receiver and transmitter both yield positive results (Chart 1 & 2), then the transmitter and receiver will both go into Download/Calibration mode.

Possible issues will arise during Step 4, the download phase of reprogramming. In this case there are 2 symptoms to look for:

1. The Link light on the receiver will not turn GREEN when the power switch is toggled on the transmitter to download

2. The receiver will “time out” indicating that it didn’t receive a signal from the transmitter within the 30 seconds from the time the receiver was put into Setup Mode.

If all indications appear normal during the download phase, test the link by turning on the transmitter (note: the transmitter shuts off after transmitting the ID code in Step 4)

1. If the Link light on the receiver doesn’t turn GREEN, the receiver didn’t receive all of the information that was sent from the transmitter.

Possible Solutions

1. Try the Reprogramming steps again

2. If this doesn’t correct the problem, send both the transmitter and receiver in for service.

Note: you could try to determine whether the fault lies with the transmitter or receiver by completing the Reprogramming procedure with a different transmitter. If this step works, then the fault lies with the original transmitter. If not, the fault may lie with the receiver.

!!Caution!!

Note: Before attempting reprogramming with another transmitter, understand that re-

programming the receiver with another transmitter, could result in two receivers on the job site responding to the one transmitter. If the original transmitter was sent in for repair, disconnect the receiver (disconnect connector A) to continue using the machine without remote capability and without fear of inadvertently operating the machine with the other transmitter.

Connector A

Reprogramming Tips:

1. Use a pointy instrument to depress the Setup button on the receiver (i.e. a pen) as the button is relatively small

2. Follow each step as laid out in the procedure

3. Never lay the receiver circuit board down on anything metallic (there are contact points on the back which could contact the metal and damage the receiver)

Reprogramming Troubleshooting

Page 51

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