Stellar Industries 28000 User Manual
2
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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
800-321-3741
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.
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