Stellar Industries 28000 User Manual

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Subject to Change without Notification. © 2011 Stellar Industries, Inc.
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
Fax: 641-923-2811
www.stellarindustries.com
Last Revision: 08/31/12
28000 Manual Revisions
Date of Revision
November 6, 2008
May 7, 2010
Section Revised
Chapter 2:
Operation
Chapter 5: Decals Chapter 7:
Assembly Drawings
Chapter 8:
Hydraulics ­Electrical
Chapter 7:
Assembly Drawings
Chapter 8:
Hydraulics ­Electrical
Description of Revision
Updated drawings to reflect engineering changes. Updated drawings include: Decal Kit Placement, Reservoir Assembly, Base Assembly, Outrigger Assembly, Control Kit, Hydraulic Kit
Updated drawings to reflect engineering changes. Updated drawings include: Main Boom Assembly, Extension Boom Assembly, Control Kits, Hydraulic Kit
Table of Contents %
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
Chapter 1 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Chapter 2 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Unit Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Radio Remote Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Hook Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Crane Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Crane Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Operator Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Chapter 3 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Lubrication Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Torque Data Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Monthly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Quarterly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Inspection Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Chapter 4 - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Capacity Chart - Decal PN 16055 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Chapter 5 - Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Decals of Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Decals of Note Continued... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Decal Kit - PN 16658 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Chapter 6 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Installation Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
General Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Mounting Kit Drawing 16659 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Chapter 7 - Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Base Assembly - PN 47880 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Mast Assembly - PN 18073 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Main Boom Assembly - PN 55106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Main Boom Cylinder Assembly - PN 20694 . . . . . . . . . . . . . . . . . . . . . . . . . .30
Extension Boom Assembly - PN 55108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Extension Boom Cylinder Assembly - PN 50628 . . . . . . . . . . . . . . . . . . . . . .32
Outrigger Assembly - PN 48689 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Outrigger Cylinder Assembly - PN 48383 . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Reservoir Assembly - PN 41332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Optional 15 Ton Hook Kit - PN 55138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Chapter 8 - Hydraulics - Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Control Kit - PN 41919 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Control Kit (434 Mhz Option) - PN 51838 . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Control Kit (419 Mhz Option) - PN 55395 . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Hydraulic Kit - PN 48690 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Chapter 9 - Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Chapter 10 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
BMS-2 Receiver Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
%% 28000 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
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 n umber 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 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.
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 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.
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.
28000 Owner’s Manual
Set the parking brake and disengage the drive axle before attempting a lift.
LOAD SAFETY
Operate the crane in compliance with the load capacity chart at all times. Know the weight of the load being lifted. Do not rely on the overload device to determine maximum rated loads.
Never use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing. This would negate the safety feature.
Do not apply side loads to the booms. Do not leave a crane load suspended or unattended.
Do not walk under suspended loads.
Do not position any load over a person nor should any person be permitted to place him or herself under a load.
Do not use the boom or the winch to drag a load.
Do not use the crane boom to push downward onto anything.
ELECTROCUTION
Allow extra space for swaying power lines in windy conditions.
Keep a minimum of ten feet between any portion of the crane and an electrical line. Add an additional 12" for every additional 30,000 Volts or less.
Remember - Death or serious injury can occur when working near power lines or during electrical storms.
Use a signal person when operating near electrical sources.
ENVIRONMENT
Do not operate the crane during electrical storms.
In extreme cold, allow adequate time to warm the truck before engaging the PTO. Do not rev the truck engine and over speed the hydraulic pumps as permanent damage to the pumps may occur. Follow the vehicle owner’s manual regarding operating the vehicle in such adverse conditions.
In dusty work areas, every effort must be taken to keep dust and sand out of the moving parts of the machinery.
Crane Controls
1. Be familiar with the sequence and operation of the crane controls.
2. Each individual crane function should have control function decals. Replace them immediately if they are missing or illegible.
3. Keep hands, feet and control levers free from mud, grease and oil.
4. Be familiar with the remote control and how it operates before attempting to lift a load.
5. Be prepared before beginning operation of the crane:
• All protective guards must be in place.
• Be aware of the surroundings: low branches, power lines, unstable ground.
• Be sure all safety devices provided are in place and in good operating condition.
• Be prepared for all situations. Keep fire extinguisher and first aid kit near.
• Be sure all regular maintenance has been performed.
• Visually inspect all aspects of the crane for physical damage.
• Check for fluid leaks.
• Make sure the outriggers are down and stable.
ATTENTION
Stellar Industries, Inc. is not liable for
accidents incurred by the crane
because of the operator’s non-fulfillment
of current rules, laws and regulations
In high humidity work areas, keep parts as dry as possible and well lubricated.

Chapter 2 - Operation

Operation
This chapter contains information regarding the operation of Stellar manufactured articulating cranes. Please study the following pages to ensure your familiarity with the operation process. This understanding is vital to the safe and efficient operation of the crane.
Job-Site Set-Up
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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.
G. Slowly release the clutch on a manual
transmission vehicle. H. Allow a few moments to warm the hydraulic
system oil. In cold weather, it is especially important to let the system run for a few minutes before operating.
2. Turn on Power to Crane
Activate power to the crane and outriggers. The power switch is located on the control panel in the vehicle cab.
3. Position Outriggers
Once the PTO is engaged, extend the outriggers using the control levers or switches marked ‘outrigger’. These may be located on the crane base or in the compartment under the crane.
4.Operate Crane
A. Turn on necessary power to the crane. B. Activate toggle switch for desired crane function.
See the Hetronic Remote Manual for detailed information.
C. 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’.
PTO Switch

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.
28000 Owner’s Manual

Radio Remote Operation

The crane is operated by a radio control system which operates an electronic valve bank. The controller (as shown above) operates the following functions:
Main Boom Up and Down Outer Boom Up and Down Extension Boom In and Out Rotation Clockwise and Counter-Clockwise TireMan Clockwise and Counter-Clockwise TireMan Pad Clockwise and Counter-Clockwise TireMan Open and Close

Manual Operation

In case of radio failure, the crane can be operated using manual overrides located on the valve bank.
Note: If the crane does not operate, check the batteries located in the remote handle and replace if necessary.
Start Up Procedure
For a more detailed version of this procedure, please see the BMS-2 Remote Manual.
1. Be sure that all controls, joysticks or paddle levers are in the Off (neutral) position. NOTE: If any control, joy­stick or paddle lever is NOT in the Off (neutral) position when the Start/Horn button is pushed, the transmitter will not transmit.
2. Switch the transmitter "ON". A short buzzer signal will sound.
3. Wait for the second buzzer signal (approx. 3 seconds).
4. Turn the E-Stop to release.
5. Press the Start/Horn button.
6. The green LED on the transmitter control panel will flash.This indicates that the transmitter is working and is ready to use.
7. Check that the machine functions correspond with the transmitter functions. The receiver display will change according to which motion is activated.
Note About Battery Condition
The batteries included with this equipment may be rechargeable. To keep rechargeable batteries in optimal working condition, follow these simple guidelines:
Valve Manual Override Operation
1. Switch to Manual Operation:
Flip the toggle switch (shown below) up to “Manual”
2. Operate Levers on the Valve Bank:
Push or pull levers to operate listed function.
3. Switch Controls Off:
Flip the toggle switch to the middle “Off” position.
4. Have Unit Serviced.
1. Keep battery away from moisture. Store in a cool, dry location.
2. Do not store or carry battery so that metal objects can contact exposed metal end. Keep battery cap on when not in use.
3. The batteries should be recharged when they fail to produce sufficient power.
4. Never attempt to open the battery for any reason.
Operation 

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.

Crane Transport

Before transporting the crane, do the following:
1. The crane must be in the stored position.
2. Outriggers must be securely stowed and not extended horizontally or vertically.
3. Hook and sheave assemblies must be securely fastened to prevent swinging.
4. All loose accessories, tools, and remote controls must be securely stored in their respective compartments or fasteners.
5. The PTO must be disengaged.
6. The parking brake must not be released until all of the above procedures are completed.
7. Do not drive the carrier vehicle while a load is present on the hook.
8. Do not drive the carrier vehicle with less than proper tire inflation.
9. Do not drive the carrier vehicle in areas where the vertical clearance is unknown.
10. Do not allow personnel to ride on the equipment during transport.

Hook Precautions

1. Hooks are designed and manufactured to lift specific loads. The specified rated load of a hook applies to loads held uniformly in direct tension and does not take into account shock loads, hook tip loading, side loading, bending, torsional, or related loads.
2. Do not attempt to lift a load that is larger than the load rating of the hook.
3. Never use a hook’s yield point as an indicator of its capacity.
4. Do not use a hook to lift personnel.
5. Know the rated load of the hook in use.
6. Never weld attachments to a finished hook in field applications. This will alter and destroy the design properties of the hook material.
7. Keep fingers, hands, body, and loose clothing from between the hook and the load.
8. Avoid shock loading.
9. Inspect the hook regularly for excessive wear and maintain it in safe operating condition.
The crane MUST be in the stored position before transporting.
28000 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 B30.2, 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 
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.
28000 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 the following:
a. Cracks or having more than 5%
normal throat opening.
b. Any visible bend or twist from the
plane of the unbent hook.
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.
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.
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.
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.

Lubrication Recommendations

Component Location Recommendation
Engine Crankcase Apply Manufacturer’s
Recommendations
Maintenance 
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.
 28000 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

Note: For Crane Tie Down Rods, see
Chapter 6: Installation Overview.
(Ft-Lb)
13 23 37 57
82 115 200 295 445 595 840 110
1460
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
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
When using the torque data in the charts above, the following rules should be observed.
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.

Inspection Checklist

Maintenance 
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.
 28000 Owner’s Manual

Daily Inspection

Frequency
D
D
D
D
D
D
D
D
D
D
D
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 legible. Check all safety devices for proper operation.
Control mechanisms for proper operation of all functions, leaks, & cracks.
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
D
D
D
Anti 2-Blocking
Operation Aid
Operation Aid
Operate anti 2-blocking device to check for proper operation.
Check presence of boom angle indicator.
Check overload device for proper operation.

Monthly Inspection

Maintenance 
Frequency
M
M
M
M
M
M
M
M
M
M
M
M
Key
Daily
Cylinders
Valves
Valves
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
M
M
M
M
M
M
M
M
M
M
Pump & Motor
PTO
Hyd Fluid
Hyd Lines
Hook
Rope
Manual
Chassis
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.
 28000 Owner’s Manual

Quarterly Inspection

Frequency
Q
Q
Q
Q
Q
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
Q
Hardware
Jib extension(s)
Other
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
Other
Quarterly Inspection Continued...
Maintenance 
Frequency
Q
Q
Q
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
Q
Q
Q
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 irregularities. Hydraulic filters for replacement per maintenance schedule.
 28000 Owner’s Manual

Annual Inspection

Frequency
A
A
A
A
A
A
A
A
A
A
A
A
Key
Daily
Monthly
Quarterly
Hyd System
Controls
Valves
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
A
A
A
Historic Data
Historic Data
Historic Data
Monthly inspection records.
Maintenance records.
Repair and modification records.

Inspection Notes

Maintenance 
 28000 Owner’s Manual

Chapter 4 - Specifications

Model 28000 Crane
SPECIFICATION SHEET
Crane Rating: 280,000 ft-lbs (38.71 ton meters)
Standard Boom Length: 13’ 2” (4.01 m) from CL of Crane
Boom Extension: Hydraulic 37" (94.0 cm)
Maximum Horizontal Reach: 16’ 3” (4.95 m) from CL of Crane
Maximum Vertical Lift: 25’ (7.62 m) (From Truck Frame)
Cylinder Specifications
Inner Lift Cylinder: 9” (22.9 cm) bore with integral pilot
operated counterbalance valves.
Outer Lift Cylinder: 7” (17.8 cm) bore with integral pilot
operated counterbalance valves.
Extension Cylinder: 6” (15.2 cm) bore with integral pilot
operated counterbalance valves.
Specifications 
Rotation: 315 degree power (planetary gear with pinion)
Lifting Capacities: 28,000 lbs @ 10’ (12,700 kg @ 3.05 m) (From CL of Truck) 17,200 lbs @ 16’ 3” (7,800 kg @ 4.95 m)
Power Supply Required: PTO & Pump
(16 gpm @ 4,200 psi) (60 lpm @ 290 bars)
Controls: Fully Proportional Paddle Controls for all
functions.
Stowed Height: 114” (289.6 cm) (Above Truck Frame)
Mounting Space Required: 48” (121.9 cm)
Approximate Shipping Weight: 13,000 lbs (5,895 kg)
 28000 Owner’s Manual
10’
3.05m
16’3”
4.95m
13’2”
4.01m
10’
3.05m
16’3”
4.95m
13’2”
4.01m
12’9”
3.89m
25’
7.62m
22’6”
6.86m
CAPACITY
CHART
28000 lbs
12700 kg
21300 lbs
9660 kg
17200 lbs
7800 kg
0’
0m
TRUCK
GROUND
0’
0m
16055
190 STATE STREET GARNER, IA 50438
PHONE: (800) 321-3741 FAX: (641) 923-2812
28000
66.00”
(167.6cm)
®

Capacity Chart - Decal PN 16055

Chapter 5 - Decals

Decals of Note

Decals 
Operation Hazard Decal Function: To inform the opera-
tor of the need for proper train­ing, familiarity with safe operat­ing procedures, and the possi­ble consequences of operation without training. PN: C4544
Operation Hazard Decal Function: To inform the opera-
tor of the hazard associated with overloading the crane, the possible consequences should the hazard occur, and how to avoid the hazard. PN: 4189
Operation Hazard Decal Function: To inform the opera-
tor and other personnel in the work area of the hazard associ­ated with improper maintenance and unauthorized modifications, the possible consequences should the hazard occur, and how to avoid the hazard. PN: 4190
Operation Hazard Decal Function: To inform the opera-
tor of the need for proper train­ing, familiarity with safe operat­ing procedures and , the possi­ble consequences without train­ing. PN: C4540
Foot Crush Hazard Decal Function: To inform the opera-
tor 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 Function: To inform the opera-
tor and other personnel in the work area of the hazard associ­ated with a moving boom, espe­cially while stowing and unfold­ing the crane, the possible con­sequences should the hazard occur, and how to avoid the haz­ard. PN: C4541
 28000 Owner’s Manual

Decals of Note Continued...

Electrocution Hazard Decal Function: To inform the operator and other personnel
in the work area of the hazard associated with contact or proximity to electrical lines, the possible conse­quences should the hazard occur and how to avoid the hazard. PN: C1179
Moving Outrigger Hazard Decal Function: To inform the operator of the hazard asso-
ciated with outrigger operation, the possible conse­quences should the hazard occur, and how to avoid the hazard. PN: C5918
Tire Man Hazard Decal Function: To inform the operator and other personnel in the work area
of the hazard associated with improper use of the Tire Man, the possi­ble consequences should the misuse occur and how to avoid these hazard. PN: 16732

Decal Kit - PN 16658

207 C1179 DECAL-DANGER ELECTROCUTION HORTL
DECAL- 28000 IDENTIFICATION
DECAL-DANGER OPERATION RESTRICTION
DESCRIPTION
DECAL-DANGER OPERATION CONDITION
PART No.ITEM
01 54597
THESE DECALS NOT SHOWN
PN 16658
(USE WITH BODY PACKAGE)
03 C4540
02 16055
04 4189
DECAL-DANGER
DECAL-CAPACITY
05 C4544
06 4190
DECAL-CAUTION
QTY
2
1
2
1
1
1
DECAL- TIRE MAN OVERLOAD POSITION
DECAL-GEARBOX OIL LEVEL
DECAL-GREASE WORM DRIVE
DECAL-AIR DRAIN
DECAL-DANGER FOOT
DECAL-CAUTION STAND CLEAR
DECAL SWITCH PANEL 28000 CRANE
DECAL-OUTRIGGER 28,000
DECAL-SWITCH PLATE 28,000
DECAL-DANGER ELECTROCUTION
DECAL-VB CONTROL 28000
DECAL STELLAR LOGO 4.00X9.50
DECAL-EXPLODING TANK
DECAL-STELLAR LOGO 2.00X4.50
DECAL-CONTROL HANDLE 28,000
DECAL-STELLAR ATTACHMENTS
DECAL ASME/ANSI B30.22/B30.5
C591118
10 C4795
08 C5918
09 C4541 DECAL-WARNING
11 4214
12 16620
DECAL-SERVICE
14 36248
13 43470
15 C4545
16 8998
17 8843
19 C5910
20 16657
22 43469
21 15172
23 16973
2261925
24 22618
26 16732
2
2
2
2
1
1
1
1
4
1
1
1
1
1
1
2
1
1
2
27 47404 DECAL COUPLERS 23000 1
28 54589 DECAL STELLAR LOGO 8.00x22.25 2
21
OPERATOR CONTROL
12
SS
CS
14
23
26
26
25
9
10
22
24
7
11
8
6
4
3
5
2
10
8
7
9
2
20
13
27
28
1
The following chapter highlights many decals of note on your Stellar 28000 and possibly
the TM14160. For a complete list of decals, please refer to the Decal Placement drawing
below. Remember: 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.
Decals 
 28000 Owner’s Manual
.YTQNOITPIRCSEDTRAPMETI.YTQNOITPIRCSEDTRAPMETI
8GNIKCOL POT 8RGHH 7-52.1 TUN43885400051 KCOLB GTM45081
2 11677 PLATE MOUNTING 23000 4 6 8978 NUT 1.25-7 HHGR8 16
4ENARC 00051 TROPPUS EMARF202878DOR NWOD EIT894413
49180 WASHER 1.25 SAE FLAT YELLOW GR8 16
PN 16659

Chapter 6 - Installation

Notice: Read this Page Before Installation of the Crane
Installation 

General Installation

This chapter is designed to serve as a general guide for the installation of a Stellar 28000 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

For more detail, please contact
Stellar Customer Service
1. Relocate any obstructions on the frame that will be in the way of mounting the crane.
2. Measure the inside of the frame rails and cut the frame support to this length. Ensure that the frame supports have a tight fit between the frame rails.
3. Set the crane on the chassis and allow a minimum of 2” from the cab.
4. Install the crane tie downs. Start at one corner and tighten both tie downs to 200 ft-lbs. Move to the diagonal set and tighten to 200 ft-lbs. Tighten the remaining 2 corners. Continue this pattern at 200 ft-lb increments until 650-700 ft­lbs is achieved. Be sure the mounting block stays perpendicular to the frame rail as they are tightened down.
5. Connect the pressure and return lines per the hydraulic kit.
6. Connect the (+12V) power and ground wires.
7. Check the reservoir for oil and fill if necessary.
8. Operate the crane for several cycles.
See the next page for a larger view
 28000 Owner’s Manual
.YTQNOITPIRCSEDTRAPMETI.YTQNOITPIRCSEDTRAPMETI
8GNIKCOL POT 8RGHH 7-52.1 TUN43885400051 KCOLB GTM45081
2 11677 PLATE MOUNTING 23000 4 6 8978 NUT 1.25-7 HHGR8 16
4ENARC 00051 TROPPUS EMARF202878DOR NWOD EIT894413
49180 WASHER 1.25 SAE FLAT YELLOW GR8 16
PN 16659

Mounting Kit Drawing 16659

2
3
35
42
16
17
18
20
5
7
6
12
14
8
11
13
15
9
19
1
23
22
38
21
10
24
37
4
32
10
9
29
6
30
31
7
27
7
26
10
25
28
27
36
27
6
33
7
34
28
7
39
NOTE: RADIO RECEIVER AND ALARM SHOWN FOR REFERNECE
9
7
7
7
41
PN 47880
esaBNOITPIRCSEDTRAPMETI
100082 ESAB686841 2 18471 TURNTABLE BEARING 230001 3 18041 WASHER 0.88 SAE FLAT YELLOW GR916 4 17962 CAP SCR 0.88-9X4.50 HHGR9 ZY16 5 41336PC PLATE SWITCH MTG 230001 6 0479 CAP SCR 0.25-20X0.75 HHGR56
24TALF 52.0 REHSAW04307 100032 BV DRAUGCP480148 7COLYN HH 81-13.0 TUN24309
10 0343 WASHER 0.31 USS FLAT ZINC18 11 0485 CAP SCR 0.31-18X1.25 HHGR54 12 22921 E-STOP PANIC BAR 280001
100032 CINAP RAB2801431
14 22183 CAP SCR #8-32X0.75 BTNHD SS2 15 0488 CAP SCR 0.31-18X2.00 HHGR52 16 C6219 WASHER 0.75 SAE FLAT YEL LOW GR812 17 C1028 CAP SCR 0.75-10X3.00 HHG R8 ZY12 18 22935VALVE BLOCK CBCA-LAN-XTS 1 19 5591WASHER 0.31 SAE FLAT YELLOW GR84 20 C0930 CAP SCR 0.31-18X3.00 HHG R54 21 40827 VB 5 SECT HYDRO CONTROL HC-D3M/51
100032 AGNIZ RETLIF8331422
23 41339 CLAMP ZINGA FILTER 230001 24 0420 CAP SCR 0.31-18X0.75 HHGR54
200032 TNM BV TEKCARBCP9704452
26 0482 CAP SCR 0.25-20 X 3.00 HHGR 54 27 0333 NUT 0.25-20 HHGR5 NY LOC 15 28 0480 CAP SCR 0.25-20X1.00 HHGR58 29 44511 GUARD OUTRIG VB 230001
2SS TALF 91.0 REHSAW5812203 2SS COLYN HH 23-8# TUN6812213
32 C0922 CAP SCR 0.31-18X1.00 HHG R53 33 47425 CAP SCR 6MMX20MM HH CLASS 8.8 4 34 44078PC BRACKET V B MNT BASE 230002
100032 REVOC ETALPCP7331453
36 36243PC PLATE SWITC H MTG 28000 CRANE1 37 0437 CAP SCR 0.25-20X1.25 HHGR52 38 42802 VB 7 SECT DANFOSS PVG321 41 12869STRAIN RELIEF .50 NPT .24-.47 CABLE1 42 60505 GEAR BOX W/MOTOR 23/280001

Chapter 7 - Assembly Drawings

Base Assembly - PN 47880

Assembly Drawings 
 28000 Owner’s Manual
14
4
5
1
3
2
6
7
9
8
10
12
11
2
13
4
5
15
PN 18073
.YTQNOITPIRCSEDTRAPMETI
100082 TSAM304511
2 18041 WASHER 0.88 SAE FLAT YELLOW GR918 3 17963 CAP SCR 0.88-9X3.50 HHGR9 ZY16
28RG TALF 05.0 REHSAW0970D4
5 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY2 6 17964 CAP SCR 0.88-9X5.50 HHGR82 7 11297 PLATE INSPECTION MAST 230001 8 0484 CAP SCR 0.31-18 X 0.50 HHGR5 2 9 0343 WASHER 0.31 USS FLAT ZINC2
100082 PMALC ESOH3317101
11 11882 CAP SCR 0.38-16X1.75 SH ZC2
2KCOL 83.0 REHSAW325021
13 15755ZP PIN TEAR DROP 3.00X16.13 1
191.0X00.4X65.0 PAC NIP5133141
2KCOL 13.0 REHSAW225051

Mast Assembly - PN 18073

Assembly Drawings 
ITEMPART DESCRIPTIONQTY.
PN 55106
1 55103INNER BOOM 28000 REVISED 1 2 50628 CYLINDER ASM 7.00X38.25 1 3D0790WASHER 0.50 SAE FLAT YELLOW GR810 4 10172 CAP SCR 0.50-13X1.00 HHGR810 5c1592 ZERK 1/8 NPT STRAIGHT5 6 2227 BUSHING 48DXR48 GARLOCK6 7 0865 BUSHING 48DXR32 GARLOCK4 8 54374 BUSHING COMPOSITE MRP 3.00X2.504
9 41063ZPPIN 3.00X14.00 D&T 2 10 13315PIN CAP 0.56X4.00X0.19 6 11 15497 LINK WLDMT 28000 MAIN1 12 31056ZP PIN TEAR DROP 3.00X20.13 2 13 15495 LINK MAIN 280001 14 15763ZP TEAR DROP PIN 3.00X12.63 2 15 20694 CYLINDER ASM 28000 MAST 1
11
1
5
6
12
3
4
4
3
10
8
8
8
6
5
2
10
3
4
9
10
3
4
6
5
7
10
14
13
5
10
9
10
6
15
12

Main Boom Assembly - PN 55106

Note: Secondary Cylinder
uses Stellar Seal Kit PN 35650
Note: Main Lift Cylinder uses
Stellar Seal Kit PN 35651
 28000 Owner’s Manual
3
2
4
5
5
4
6
2
3
1
PRESSURE SWITCH IN THIS PORT
ITEM NO.PART NO.DESCRIPTION QTY
115598 CYLINDER 9.00x4.00x21.81 1 2 16153 FTG ADAPT 10-C5OLO-S2 32227BUSHING 48DXR48 GARLOCK 4 4 16157 TUBE ASM 0.63X7.88 YZ 2 5 16152 FTG ADAPT 10-F5OLO-S2 6 15995 MANIFOLD ASM DUAL T2A 5000PSI1
PN 20694

Main Boom Cylinder Assembly - PN 20694

11
5
3
13
8
1
8
15
13
3
5
8
14
13
3
5
18
3
5
2
5
3
13
8
6
4
17
16
19
17
4
6
7
9
5
3
13
9
10
12
13
3
5
5
3
13
9
9
15
13
3
5
10
ITEMPART DESCRIPTIONQTY.
1 55107 OUTER BOOM 28000 REVISED1 2 15388EXT BOOM 280001 3D0790 WASHER 0.50 SAE FLAT YELLOW GR814 4C6219 WASHER 0.75 SAE FLAT YELLOW GR836 5 10172 CAP SCR 0.50-13X1.00 HHGR814 6 4543 CAP SCR 0.75-10X2.00 HHGR8 36 7c1592 ZERK 1/8 NPT STRAIGHT1 8 54374 BUSHING COMPOSITE MRP 3.00X2.504
9 2227 BUSHING 48DXR48 GARLOCK4 10 0865 BUSHING 48DXR32 GARLOCK2 11 15608 CYLINDER 6.00x37.001 12 15769ZPPIN 3.00X9.13 D&T 1 13 13315PIN CAP 0.56X4.00X0.19 8 14 26973ZPPIN 3.00X15.00 SR/D&T1 15 55109ZPPIN 3.00X16.88 D&T 2 16 15778 WEAR PAD 3.00X5.00X2.442 17 15609PCPLATE WEAR PAD COVER 280006 18 15601 WEAR PAD 1.00X4.00X12.002 19 15779 WEAR PAD 3.00X5.00X1.754
PN 55108
Assembly Drawings 

Extension Boom Assembly - PN 55108

Note: Cylinder uses Stellar
Seal Kit PN 35649
 28000 Owner’s Manual
.YTQNOITPIRCSEDTRAPMETI
152.83X00.7 REDNILYC406511 2S-OLO5C-01 TPADA GTF351612 2 90.61X36.0 MSA EBUT851613
2S-OLO5F-01 TPADA GTF251614 515995MANIFOLD ASM DUAL T2A 5000PSI 1 62227BUSHING 48DXR48 GARLOCK 4
6
CYLINDER BUSHINGS SHOWN FOR REFERENCE ONLY
1
6
6
2
3
4
5
4
3
2
6
PN 50628

Extension Boom Cylinder Assembly - PN 50628

24
20
10
8
13
12
6
23
8
12
13
19
21
14
16
15
1
5
2
5
3
4
18
7
22
11
17
9
8
12
13
BASE WELDMENT SHOWN AS REFERENCE
24
.YTQNOITPIRCSEDTRAPMETI
200032 REGGIRTUO054041
2 15502 OUTRIGGGER LEG 280002
200.05X00.4 REDNILYC49993 4 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK4 5 0635 BUSHING 40DXR32 GARLOCK8
248384 MSA REDNILYC383846 7 40837 OUTRIGGER PAD 23000 96IN2 8 8377PIN CAP 0.56X3.50X0.19 12
2T&D 88.41X05.2 NIPPZ954049
2 T&D 00.41X05.2 NIPPZ5838401
400.2 EDISNI GNIR PANS752211 218RG TALF 05.0 REHSAW0970D21
13 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY12 14 10180PC COVER WEAR PAD 230002 15 C5902 WASHER 0.63 SAE FLAT YELLOW GR812 16 C1025 CAP SCR 0.63-11X2.00 HHGR8 ZY12 17 25574 BUSHING 40DXR20 2.50X1.254
261-5323-ISQ GNIHSUB918881 19 13343 BUSHING 40DXR16 GARLOCK4 20 17320 BUSHING 40DXR40 GARLOCK4 21 40455 WEAR PAD 2.00X8.00X1.502
2T&D 91.8X00.2 NIPPZ6626122
2T&D 83.9X05.2 NIPPZ699932
405.0X31-05.0 WERCS TES2508542
PN 48689

Outrigger Assembly - PN 48689

Assembly Drawings 
 28000 Owner’s Manual
Note: BUSHINGS ARE SHOWN FOR REFERENCE.
1
5
4
2
4
6
5
3
3
6
.YTQNOITPIRCSEDTRAPMETI 148384 CYLINDER 7.00X19.25 1 215822 MANIFOLD DOUBLE T11A 5000 PSI 1 3D1290 FTG ADAPT 8-6 F5OLO-S 2 40279 FTG ADAPT 6-F5OLO-S 2 519032 TUBE ASM 0.38 X 6.91 2 60635 BUSHING 40DXR32 GARLOCK 4
PN 48383

Outrigger Cylinder Assembly - PN 48383

Assembly Drawings 
7
33
10
9
8
3
6
6
49
13
11
12
23
1
14
9
PN 41332
.YTQNOITPIRCSEDTRAPMETI 1 41333RSRVR 45GAL ORING 230001 2C2126MAGNETIC PLUG DRAIN 3/4"1 3 8241 FAN 16.00 PUSH 12 VOLT1 4C0922 CAP SCR 0.31-18X1.00 HHGR56 5C6327FILTER STRAINER 35GAL TF-20301 6 8240COOLER OIL AL 15000/230001
6COLYN HH 81-13.0 TUN24307
8 0478 CAP SCR 0.25-20X0.50 HHGR512
42TALF 52.0 REHSAW04309 10 11149 GASKET ARCTIC FOX HEATER #A-6111 11 0519 WASHER 0.44 USS FLAT ZINC12 12 0501 CAP SCR 0.50-13X2.00 HHGR56 13 C6106 NUT 0.50-13 HHGR5 NYLOC 6 14 D1263 FTG HOSE BARB 0.38 HOSE X 0.38 90DG1
1EGUAG THGIS OMREHT3645151 16 42184 FILTER TANK TOP MPF1841AG7A10HBVR1 17 19242 FTG 20-20 MFS-MORB STRAIGHT1 18 47858 HOSE 1.25(881-JC-JC-20-20-20-26)1
1PMET RVRSR 00032 GTF7587491 20 C6021 CAP SCR 0.25-20X0.75 BTNHD SS4 21 30012 SHROUD RSRVER ASM 90001 22 0333 NUT 0.25-20 HHGR5 NYLOC 4 23 47859FTG 23000 RSRVR RETURN 1 24 0492 CAP SCR 0.38-16X0.75 HHGR54 25 54393 SWITCH TEMP NC TT-F5B-100R-MP1 26 C5552 FILTER STRAINER TFS-1220-01
1KLB 52.1X00.2 GNIHSUB7094C72
28 C1057
FTG 20-20XCLOSE MP-MP NIPPLE STRAIGHT BLK
2
252.1 LLAB EVLAV1155C92
2KLB GED 09 52.1 LE TS4964C03 31 C2282 FTG 1.25 NPT TO 1.25 BARB2 32 58284GASKET TANK TOP FILTER 1 33 11442PC PLATE COVER TANK HEATER FLANGE1
1KCEN/W MSA LLIF PAC9203643
34
19
2
5
16
17
32
18
15
21
20
22
25
24
28
29
31
30
30
29
28
26
27

Reservoir Assembly - PN 41332

 28000 Owner’s Manual
.YTQNOITPIRCSEDTRAPMETI
100082 MOOB TXE883511
2 41499 HOOK 15 TON SWIVEL CROSBY 10286541
291.1X00.3X87.1 RALLOCCP960443
191.0X05.2X65.0 PAC NIP24194 5 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY1 6 16028ZP PIN TEAR DROP 1.75X7.061
18RG TALF 05.0 REHSAW0970D7
PN 55138
3
6
2
5
7
4
3

Optional 15 Ton Hook Kit - PN 55138

Chapter 8 - Hydraulics - Electrical

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
Hydraulics - Electrical 
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.
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.
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.
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.
Warning! If hydraulic fluid escapes, the boom or crane can fall immediately. Make sure the ground or blocking is supporting the boom before performing any maintenance or repair. Do not rely on the hydraulic fluid to support the boom or crane.
 28000 Owner’s Manual
PN 41919

Control Kit - PN 41919

PN 51838

Control Kit (434 Mhz Option) - PN 51838

Hydraulics - Electrical 
 28000 Owner’s Manual
PN 55395

Control Kit (419 Mhz Option) - PN 55395

PN 48690

Hydraulic Kit - PN 48690

Hydraulics - Electrical 
 28000 Owner’s Manual
HYDRAULIC SYSTEM COMPONENTS
PART# DESCRIPTION
39780 Oil pressure gauge 8240 Oil cooler 22934 Hydraulic rotation motor ( Crane rotation ) 22935 Valve block hydraulic motor (Crane rotation) 28485 Pressure transducer (overload) 41338 High pressure filter asm 47860 High pressure filter element (Used in p/n 41338) 18552 Fill cap assy with neck (Hydraulic reservoir) 15463 Thermo sight gauge (Hydraulic reservoir) 11149 Gasket - (Optional Artic heater cover) C6327 Filter Strainer ( Hydraulic reservoir ) 42184 Hydraulic return filter asm (Hydraulic reservoir) 47820 Hydraulic filter element (Used in p/n 42184) 47866 Control Handle - Valve bank (PVG32) C1090 Counter balance valve ( Cylinders) C6184 Counter balance valve (Extension & Outrigger cylinders) 15995 Manifold asm dual T2 - 5000 psi (Cylinder) 42802 Valve bank - 7 section 40827 Valve bank - 5 section 55401 Relief valve - (5 section valve bank) 50234 Dump valve - (7 section valve bank) 50235 Dump valve coil - (7 section valve bank) 47871 Valve - LMI system 13555 Hydraulic quick coupler 13554 Hydraulic quick coupler 13557 Hydraulic quick coupler 13556 Hydraulic quick coupler C2028 O ring ( # 6 face seal ) ( hydraulic fittings ) C2029 O ring ( # 8 face seal ) ( hydraulic fittings ) 32223 O ring (#10 face seal ) ( hydraulic fittings ) D1244 O ring (#12 face seal ) ( hydraulic fittings ) D1245 O ring (# 4 SAE port side ) ( hydraulic fittings ) D1246 O ring (# 6 SAE port side ) ( hydraulic fittings ) D1247 O ring (# 8 SAE port side ) ( hydraulic fittings ) D1248 O ring (#10 SAE port side ) ( hydraulic fittings ) D1249 O ring (#12 SAE port side ) ( hydraulic fittings ) D1250 O ring (#16 SAE port side ) ( hydraulic fittings ) 16158 Port tube asm - ( 15604 secondary cylinder ) 35647 Seal kit - Outrigger cylinder ( 9994 ) C6310 Seal kit - Outrigger cylinder ( 9993 ) 35651 Seal kit - Main lift cylinder ( 15598 ) 35650 Seal kit - Secondary cylinder ( 15604 ) 35649 Seal kit - Extension cylinder ( 15608 )
ASSEMBLY COMPONENTS
PART# DESCRIPTION
0635 Bushing 2.50" x 2.00" 0865 Bushing 3.00" x 2.00" 2227 Bushing 3.00" x 3.00" 4381 Bushing 2.00" x 2.00" 5739 Bushing 2.50" x 3.00" 8819 Bushing 2.00" x 1.00" 13343 Bushing 2.50" x 1.00" 13817 Bushing 2.50" x 1.50" 17320 Bushing 2.50" x 2.50" 25574 Bushing 2.50" x 1.75" 8377 Pin Cap 0.56 x 3.50" x .25 SS 8597 Pin Cap 0.69 x 4.00" x .25 SS 9142 Pin Cap 0.56 x 2.50" x .25 SS 10172 Cap Screw 0.50-13 x 1.00 Gr 8 D0790 Washer 0.50 Flat Gr 8 2257 Snap ring 2.00" Internal C5644 Grease Zerk 1/8 NPT 45 degree (Grease line kit option) C1592 Grease Zerk 1/8 NPT (Cylinders / pivot points) 40455 Wear Pad 2.00" x 8.00" x 1.50" 15779 Wear Pad 3.00" x 5.00" x 1.75" 15778 Wear Pad 3.00" x 5.00" x 2.44" 15601 Wear Pad 1.00" x 4.00" x 12.00" 17133 Hose clamp 39959 Gear bearing rotation kit 16054 Swivel link ( 15-ton hook ) 16052 Hook 15-ton Swivel
ELECTRICAL COMPONENTS
PART# DESCRIPTION
41922 Hetronic Nova radio system 47862 12v charger for Hetronic Nova radio system 47863 Battery for Hetronic Nova radio system 47867 Belt - Transmitter harness (waist) 8241 Fan 16.00 push 12 V ( Hydraulic reservoir ) 6394 Toggle switch ( Outrigger operation ) 8623 Toggle switch ( Outrigger operation ) C4815 Toggle switch ( Outrigger operation ) 54393 Temperature switch ( Hydraulic reservoir ) 22921 E-stop switch ( Crane panic bar ) 61562
CONTACT SWITCH (PANIC BAR) Switch inside E-stop housing (22921)
41367 LMI system (Load Moment Indicator) 31782 Wire harness - LMI & Lights 41368 Wire harness - LMI Cinch Retro D0045 Overload alarm
COMPRESSOR COMPONENTS (SHD245 OPTIONAL)
PART# DESCRIPTION
3853 Pilot valve 145/175 psi (SHD245 cprsr) C4913 Solenoid valve (SHD245 cprsr) C4914 Pressure Relief valve (SHD245 cprsr) C0864 Hobbs air pressure switch (SHD245 cprsr) 13731 Low pressure intake valve asm (SHD245 cprsr) 13733 High pressure intake valve asm (SHD245 cprsr)
SERVICE KITS / FILTERS / LUBRICATION
PART# DESCRIPTION
4562 Air filter (SHD245 cprsr) 32893 Service Kit - 200 hour (SHD245 cprsr) 4460 Molube grease-external gear teeth for swing gears
MISCELLANEOUS COMPONENTS
PART# DESCRIPTION
51263 Flood lights ( Crane & Body ) 5033 Stobe light ( Crane & Body ) 14022 Compartment light

Chapter 9 - Replacement Parts

Replacement Parts 
Call 800-321-3741 to Order
 28000 Owner’s Manual

Chapter 10 - Troubleshooting

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.
• Make sure that the transmitter batteries are fully charged. (Rechargeable batteries are good for 11 months or 200 charges)
• Make sure that the hydraulic pump is operating at its rated flow or GPMs. Check the flow by using the flow meter to determine the GPMs. It is possible that the hydraulic pump is getting weak. If this is suspected, contact Stellar Customer Service.
Problem: Crane operates slowly. Solutions:
• Make sure that the crane is receiving the recommended GPMs to operate.
• Check the level of hydraulic fluid in the reservoir. Add fluid as needed.
• Check to see if the valve bank proportional valve is operating.
• Make sure the proportional valve is receiving
12V power when operating a function.
Problem: Crane will operate manually but will not operate electrically. Solutions:
• Make sure that there is 12V power going to the radio receiver. If there is no power going to the receiver, trace back to the power source and check for a blown fuse or loose ground connection.
• Make sure that the parking brake is engaged.
• Make sure that the parking brake switch is working properly. Check the parking brake switch by performing a continuity test. If the switch is defective, simply replace it.
• Make sure the “Power” LED is on outside the receiver door cover.  This light is the upper light on the receiver door. If the light does not come on, check wiring back to the fuse. If the fuse is OK, check system ground wires and connections.
• Make sure the green LED on the receiver door is lit green. This light will come on when the red e-stop is pulled upward and the toggle switch is activated on the transmitter. If the radio system does not link up and no green light is lit on the receiver - make sure that the battery is fully charged, check the battery contact points to make s ure they are not tarnished or corroded. Clean contact points and recharge or replace the battery.
• When battery voltage is acceptable, the power LED light on the transmitter will be solid.  If the voltage becomes low, the LED light will begin to blink and the battery will need to be charged or replaced.
If problems persist, please contact
Stellar Customer Service at:
1-800-321-3741
 28000 Owner’s Manual
Problem: Not all crane functions operate using the radio remote transmitter or crane operates intermittently. Solutions:
• Make sure that the function switch is working properly. If the switch is defective, simply replace it.
• Make sure that there is power going from the valve bank twin solenoid or to the function that will not operate. If no power is going to the twin solenoid, check wiring connections on wire harness plug connector for broken wires, loose connection or poor crimp. If power is going to the solenoid valve, it may not be opening to allow hydraulic oil to the function that is not operating. Check the twin solenoid for polarity, if solenoid does not magnetize, replace the twin solenoid.
Problem: Cylinder drifts outward or downward. Solutions:
• Check to see if there is air in the hydraulic system. Operate all cylinders connected to the hydraulic system. Start with the extension cylinder, then operate the main boom, winch, rotation, and ending with the hydraulic outriggers, if installed. When operating, extend each cylinder halfway out, retract all the way in, and then extend until the cylinder rod is at the end of its stroke. Operate cylinders slowly so air is pushed thru the system to the reservoir. Repeat this cycle 2-3 times.
• Make sure the holding valves are operating properly. Remove, clean, and then inspect each holding valve. When removing a holding valve, always relieve the pressure inside the cylinder by loosening jam nut of the holding valve and turning set screw inward/clockwise. Count the number of turns until the set screw is seated. When reinstalling the holding valve, make sure the valve is reset by turning the set screw the number of turns it took to relieve the pressure. Finish by tightening the jam nut.
• Check the cylinder rod for scratches. If a scratch is located on the cylinder rod, hydraulic fluid can pass thru and cause a loss of pressure. Replace cylinder rod or cylinder.
• Check to see if the piston seals are damaged. If they show signs of damage, install a new cylinder seal kit.
Problem: Outer “Extend” and Extension In and Out will not operate Manually or Remotely. Solutions:
• Check to see if the functional cut out connector,
located on the valve section is lit. Note: Functional cut out connectors will have an LED light on when electrical power is present
• Check to see if there is 12 volt power going to functional cut out connector.
• Check to make sure the Bosch relay is functioning properly. It is located just behind the panic bar E-stop switch. If functional cut out connector is lighting properly, check to make sure the connector is tight.
Troubleshooting continued...
Problem Possible Cause Possible Solution
Vibrations and jerking in hydraulic cylin­der during the first maneuvers.
The temperature of the hydraulic oil is too low.
lack of oil in reservoir.
Troubleshooting 
Perform maneuvers without loads for several minutes to warm up the oil.
Add hydraulic oil.
Vibrations with every function when oil is hot.
All crane movements are slow, loaded and unloaded.
The hydraulic extension is not extend­ing.
Crane rotation not regular Inadequate grease.
Lack of oil in reservoir.
air in hydraulic system.
Suction hose from oil tank crushed or obstructed.
Dump valve malfunctioning.
The pump is drawing in air.
Bad lubrication.
Wear pads are worn.
Sequence valve on extension cylinder has to be adjusted.
The truck is not level.
Worn rotation motor.
Add hydraulic oil to the tank.
Operate the control carrying the cylin­ders to stroke end several times in both directions.
Replace or clean the suction hose.
Manually override system to detect
Tighten suction hose connections.
Lubricate the wear pads
Replace wear pads.
Check to see if there is 12V power going to the extension function.
Grease gear bearing.
Level the truck.
Replace rotation motor.
Gear bearings worn.
The crane does not lift the loads on the load chart.
The crane lifts the load, but cannot hold it.
Noise coming from Articulation points. Lack of lubrication.
Defective hydraulic pump.
Incorrect settings of the valves.
Hydraulic cylinder seals are worn.
Incorrect relief setting.
Faulty holding valve.
Incorrect settings of the valves.
Hydraulic cylinder seals are worn.
Worn pin.
Worn bushing.
Replace gear.
Replace the pump.
Adjust valve settings.
Replace worn seals.
Contact Stellar customer service for proper setting. Replace holding valve.
Adjust valve settings.
Replace worn seals.
Grease articulation points.
Replace pin.
Replace bushing.
 28000 Owner’s Manual
Problem Possible Cause Possible Solution
Hydraulic legs do not hold under load. Defective holding valves
Worn seals in the stabilizer cylinder.
Crane does not function. Truck battery discharged
Electric connections are damaged or corroded.
Control handle turned off.
Crane does not function - Continued Battery charge low.
Burned fuses
Dump valve not operating properly.
PTO not fully engaged.
Control box lights do not operate (green LED out)
Discharged battery.
Burned fuses.
Disconnected electrical cord.
Corroded or loose electrical connec­tions.
Clean or replace holding valves.
Replace worn seals.
Charge battery.
Check electrical wiring, terminals, con­nections and their integrity.
Turn on control handle
Charge transmitter battery.
Replace the fuses.
Bypass electrical circuit
Check for full engagement.
Recharge battery.
Replace fuses.
Join correctly the connection, replace the electric coupling. Check electrical connections.
Faulty manual/remote switch.
A crane function does not work. Defective switch.
Faulty solenoid.
Locked valve cartridge.
Damaged electric connection.
Operations at high or low speed do not work.
Controls fail to respond with control box.
Operation slow down. Hydraulic oil supply is low.
Parameters of control box (receiver) set incorrectly or have failed.
Batteries dead in wireless handle.
Handle on/off button isn’t turned on.
Manual/remote switch is in manual position.
Hydraulic pump is operating at a reduced speed.
Replace switch.
Replace the switch.
Replace the solenoid.
Disassemble and clean the valve car­tridge. Check continuity of the circuit.
Contact Stellar customer service department.
Recharge or replace batteries in remote handle. Turn on on/off button on remote han­dle. Position manual/remote switch in remote position.
Add hydraulic oil.
Engine idle speed may be too slow, increase speed.
Relief valve is set too low.
Pump or cylinder is worn.
Check relief with gauge.
Replace cylinder seals.
Problem Possible Cause Possible Solution
Troubleshooting 
Operation slow down - con’t Pump is slipping due to excessive oil
temperature, this is a factor which will increase with worn components.
Filters are dirty.
Obstruction has occurred in boom hold­ing valve.
Operation slow down - con’t Defective flow valve. Replace valve.
Boom drifts when loaded and controls neutralized.
Unusual noise in operation. Cavitation is occurring due to low
Hydraulic oil is bypassing at piston seal.
Main or secondary cylinder holding valves are defective or contaminated.
hydraulic oil supply.
Restriction or collapse of suction line has occurred.
Suction line screen is clogged and requires replacement.
Check pump GPM with flow meter if it is suspected to be faulty.
Replace filters.
Replace or clean holding valve.
Replace cylinder.
Clean or replace holding valves.
Add oil and cycle cylinders to get air out of system.
Inspect suction line for damage.
Replace or clean screen.
Unusual noise in operation - con’t Bypass settings on relief valve are too
low.
Relief valve is damaged.
Outriggers fail to retract Control valve is inoperative.
Cylinder seals or holding valve are defective
Hydraulic lines are restricted or rup­tured.
Outriggers fail to retract-con’t Broken electrical wire going to outrig-
ger switch to the valve bank.
Outriggers yield or drift. Control valve is inoperative.
Contact customer service for correct relief setting.
Replace relief valve.
If outriggers retract using manual func­tion, it is a probable electrical problem ­check continuity.
Replace seals or holding valve.
Inspect and replace hydraulic lines.
Check continuity of circuit.
Clean or replace pulsar solenoid valve. Replace holding valve.
Cylinder or check valve is defective. Hydraulic lines are restricted or rup­tured.
Check hoses for damage and replace.
 28000 Owner’s Manual

BMS-2 Receiver Troubleshooting

Available on some systems. Consult BMS-2 Operator Manual for details.
Problem Probable Cause Correction
System will not initialize after normal start-up procedure.
The transmitter is turned on, but does not transmit (Power LED not flashing)
Transmitter is transmitting (Power LED flashing), but crane will not respond.
E-Stop reset
Joystick or paddle lever not in center position.
E-Stop switch engaged.
Battery fully discharged.
No power to the receiver.
Battery is discharged.
Coder board fuse.
Broken key switch.
Coder board failure.
E-Stop switch engaged.
Transmitter out of range.
Joystick, paddle lever or switch not in center position when transmitter turned on.
Push the Start button again. If the system is being initialized from an E-Stop condition, the Start button must be pressed twice - first to clear the E-Stop, then again, to start the system.
Be sure that all joysticks and paddle levers are in center position when the Start button is activated.
Pull out E-Stop switch. Restart system by pressing Start twice.
Check battery to ensure a full charge. Replace with fully charged battery if necessary.
Check the diagnostic Display on the side of the receiver to be sure power is applied. Ensure that the system is securely grounded to the negative battery terminal. The Display also indicates normal transmitter communication, interference, and E-Stop conditions.
Replace battery with a fully charged battery.
Check fuse and replace if necessary.
Check wiring on key switch. Replace key switch, wiring or contact element.
Contact Hetronic or your Dealer.
Pull out the E-Stop pushbutton and press the Start/Horn pushbutton.
Take the transmitter back into the range of the receiver. Press the Start/Horn pushbutton.
Ensure that all control devices are in center (neutral) position when the Start button is activated.
All crane/machine motions operate intermittently
Some crane/machine motions operate intermittently
Receiver power off.
Blown fuse in receiver.
E-Stop failure in transmitter.
E-Stop failure in receiver. Red E­Stop LED on decoder board is illuminated.
E-Stop module failure.
Receiver antenna loose or missing.
External antenna (if used) has loose connection, poor grounding or interference.
Connector wiring too close to power wiring.
Connector inside receiver is loose.
Crane/machine motion wiring may be loose.
Connector inside receiver is loose.
Turn on power to receiver.
Check all fuses. Replace if necessary.
Check E-Stop pushbutton for damage. Check wiring to contact element for broken or disconnected wires. Repair or replace E-stop pushbutton or wiring.
Check wiring on E-Stop module, decoder module, E-Stop decoder module. Secure any loose connections.
Replace E-Stop module.
Tighten or replace antenna.
Tighten antenna and ground connection. See "Connecting an External Antenna" Section for operational precautions.
Control wiring must be run separately from power wiring.
Check all connectors, reseat if necessary.
Check wiring from receiver to plug and from plug to crane/machine motion actuator.
Check all connectors, reseat if necessary.
Connector wiring too close to power wiring.
Control wiring must be run separately from power wiring.

Limited Warranty Statement
Stellar Industries, Inc. (Stellar) warrants products designed and manufactured by Stellar to be free from defects in material and workmanship under proper use and maintenance. Products must be installed and operated in accordance with Stellar’s written instructions and capacities. This warranty shall cover the following:
Stellar Cranes, Stellar Hooklift Hoists, Stellar Cable Hoists, Stellar Container Carriers, Stellar Service Trucks, and Stellar X-Tra-Lift Systems:
Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date ofmanufacture, 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 Manufactured 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.
Stellar Tarper Systems:
Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date of manufacture and Three (3) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond fifteen (15) month 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 warranty­applicable damage within fourteen (14) days of its occurrence. If at all possible, Stellar will ship the replacement part within 24-hours 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 Stellar-manufactured 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 Cranes, Stellar Hooklift Hoists, Stellar Cable Hoists, Stellar Container Carriers, Stellar Service Trucks, Stellar X-Tra-Lift Systems, and Stellar Tarper Systems shipped from Stellar’s factory after January 1st, 2010. The warranty is for the use of the original owner only and is 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 2010
Document Number: 37040
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