Stellar Industries 28000 User Manual

Model 28000

ArticulAting crAne

owners’ MAnuAl

safety • operation • Maintenance • installation • Parts

Stellar Industries, Inc.

Subject to Change without Notification. © 2011 Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438 800-321-3741 Fax: [phone]

www.stellarindustries.com

Last Revision: 08/31/12

28000 Manual Revisions

Date of Revision	Section Revised	Description of Revision
November 6, 2008	Chapter 2:
	Operation
	Chapter 5: Decals	Updated drawings to reflect engineering
	Chapter 7:	changes. Updated drawings include: Decal Kit
	Assembly Drawings	Placement, Reservoir Assembly, Base Assembly,
	Chapter 8:	Outrigger Assembly, Control Kit, Hydraulic Kit
	Hydraulics -
	Electrical
May 7, 2010	Chapter 7:	Updated drawings to reflect engineering
	Assembly Drawings	changes. Updated drawings include: Main
	Chapter 8:	Boom Assembly, Extension Boom Assembly,
	Hydraulics -	Control Kits, Hydraulic Kit
	Electrical

Table of Contents i

Table of Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

ii 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 [e-mail].

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	[e-mail]
Order Parts	[e-mail]
Warranty Information	[e-mail]

Safety 1

Chapter 1 - 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 number one thought on every operator’s mind. Three factors should exist for safe operation: a qualified operator, well-maintained equipment, and the proper use of this equipment. The following information should be read and understood completely by everyone working with or near the crane before putting the unit into operation.

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

GENERAL

It is the responsibility of the owner to instruct the operator in the safe operation of your equipment and to provide the operator with properly maintained equipment.

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

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

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.

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.

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.

228000 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.

In high humidity work areas, keep parts as dry as possible and well lubricated.

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

Operation

3

Chapter 2 - 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

thoroughly plan the lift before positioning the vehicle. consider the following:

1.The vehicle should be positioned in an area free from overhead obstructions to eliminate the need for repositioning.

2.Position the vehicle so that it is impossible for any portion of the equipment to come within the minimum required safe distance of any power line. Maintain a clearance of at least 10 feet between any part of the crane, load line, or load, and any electrical line or apparatus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. Remember to allow for winds that cause power lines to sway. It is recommended that a signal person be used when the vehicle is set-up near power lines.

3.The vehicle should also be positioned on a firm and level surface that will provide adequate support for the outrigger loading. Use extreme caution when setting up near overhanging banks or excavations.

4.The parking brake must be set on the vehicle and the drive axle disengaged before performing a crane operation.

5.The outriggers must be extended to stabilize the truck before beginning operation.

NOTICE

The parking brake must be fully engaged in order to operate any Stellar Equipment.

Unit Operation Overview

1.Engage the PTO

2.Turn on Power to Crane

3.Position Outriggers

4.Operate Crane

5.Store Outriggers

6.Turn Off Power to Crane

7.Disengage the PTO

1. Engage the PTO

A.Engage the parking brake.

B.Place the transmission in the Neutral position.

C.Make certain the PTO switch is in the ‘off’ position.

D. Start the vehicle engine.

E.Depress the clutch on manual PTO Switch 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’.

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.

428000 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

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:

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.

Manual Operation

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

Valve Manual Override Operation

1.Switch to Manual Operation:

Flip the toggle switch (shown below) up to “Manual”

2.Operate Levers on the Valve Bank:

Push or pull levers to operate listed function.

3.Switch Controls Off:

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

4.Have Unit Serviced.

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.

Operation 5

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.

628000 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.

Maintenance 7

Chapter 3 - 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.

828000 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.

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

7.All pins and keepers for proper installation. photocopy the checklist as needed.

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.

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.

							Maintenance 9
	Lubrication Recommendations
	Component			Location			Recommendation
Engine			Crankcase			Apply Manufacturer’s
						Recommendations
Hydraulic System			Reservoir
Below –5*F						Petro-Canada Arctic MV 15 (ISO 22)
-5*F to 90*F						Petro-Canada HYDREX 32 (ISO 32)
Above 90*F						Petro-Canada HYDREX 46 (ISO 46)
Open Gears			Hand			Precision XL3 Moly EP 2 (NLGI 2 grease
						with moly)
Bearings, grease			Gun			Precision XL EP 2 (NLGI 2)
(including turntable bearing
inner race)
Worm Drive Gearbox			Gearbox			Precision Synthetic EP 00 (NLGI 00)
Planetary Gearbox			Gearbox			Traxon Synthetic 75W-90 (API GL-5)
(including winch)
Wear Pad Lubrication			Spray			Gearshield NC
Compressor Fluids
Reciprocating Single Stage			Crankcase			Compro 100 (ISO 100)
Reciprocating Double Stage			Crankcase			Compro 100 (ISO 100)
Screw			Crankcase
-15˚F to 86˚F						Compro XL-S 32 (ISO 32)
-23˚F to 100˚F						Compro XL-S 46 (ISO46)
	32˚F to 113˚F					Compro XL-S 68 (ISO68)

Greasing the Crane

Lubricate all grease gun points with Extreme Pressure Grease - Stellar P/N: 22059.

10 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.

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.

Torque Data Chart

Note: For Crane Tie Down Rods, see Chapter 6: Installation Overview.

Grade 5		Grade 8	Grade 9

Size	Bolt DIA	Plain				Plated			Plain				Plated				Plated
(DIA-TPI)	(Inches)	(Ft-Lb)				(Ft-Lb)			(Ft-Lb)				(Ft-Lb)				(Ft-Lb)
5/16-18	0.3125	17			13				25				18				22
3/8-16	0.3750	31			23				44				33				39
7/16-14	0.4375	49			37				70				52				63
1/2-13	0.5000	75			57				105				80				96
9/16-12	0.5625	110			82				155				115				139
5/8-11	0.6250	150			115				220				160				192
3/4-10	0.7500	265			200				375				280				340
7/8-9	0.8750	395			295				605				455				549
1-8	1.000	590			445				910				680				823
1 1/8-7	1.1250	795			595				1290				965				1167
1 1/4-7	1.2500	1120			840				1815				1360				1646
1 3/8-6	1.3750	1470			110				2380				1780				2158
1 1/2-6	1.500	1950			1460				3160				2370				2865

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

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.

Maintenance 11

Inspection Checklist

Use of this checklist is subject to terms of the Stellar Warranty information. Additional copies of this checklist can be obtained by contacting Stellar Customer Service at [phone].

Owner/Company:

Contact Person:

Crane Make/Model:

Crane Serial:

Type of Inspection (check one)

Daily (if deficiency found) Quarterly

	Monthly		Annual

Date Inspected:

Hour Meter Reading:

Inspected by: (print)

Signature of Inspector:

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.

12 28000 Owner’s Manual

Daily Inspection

Frequency	Key	Inspection Description	Status
D	Decals	All load charts, safety & warning Decals, & control Decals are present and
		legible.
		Check all safety devices for proper operation.
D	Controls	Control mechanisms for proper operation of all functions, leaks, & cracks.
D	Station	Control mechanisms for proper operation of all functions, leaks, & cracks.
D	Hydsystem	Hydraulic system (hoses, tubes, & fittings) for leakage & proper oil level.
D	Hook	Presence & proper operation of hook safety latches.
D	Rope	Proper reeving of wire rope on sheaves & winch drum.
D	Pins	Proper engagement of all connecting pins & pin retaining devices.
D	General	Overall observation of crane for damage or missing parts, cracked welds &
		presence of safety covers.
D	Operation	During operation, observe crane for abnormal performance, unusual wear.
		If observed, discontinue use & determine cause & severity of hazard.
D	Remote Ctrls	Operate remote control devices to check for proper operation.
D	Electrical	Operate all lights, alarms, etc. to check for proper operation.

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

DOperation Aid Check presence of boom angle indicator.

DOperation Aid Check overload device for proper operation.

Maintenance 13

Monthly Inspection

Frequency	Key	Inspection Description	Status
M	Daily	All Daily Inspections.
M	Cylinders	Visual inspection of cylinders for leakage at rod, fittings, & welds. Damage
		to rod & case.
M	Valves	Holding valves for proper operation.
M	Valves	Control valve for leaks at fittings & between sections.
M	Valves	Control valve linkages for wear, smoothness of operation & tightness of
		fasteners. Relief valve for proper pressure settings.
M	General	Bent, broken or significantly rusted/corroded parts.
M	Electrical	Electrical systems for presence of dirt, moisture & frayed wires.
M	Structure	All structural members for damage.
M	Welds	All welds for breaks & cracks.
M	Pins	All pins for proper installation & condition.
M	Hardware	All bolts, fasteners & retaining rings for tightness, wear & corrosion.
M	Wear Pads	Condition of wear pads.

MPump & Motor Hydraulic pumps & motors for leakage at fittings, seals & between sections.

		Check tightness of mounting bolts.
M	PTO	Transmission/PTO for leakage, abnormal vibration & noise, alignment &
		mounting bolt torque.
M	Hyd Fluid	Quality of hydraulic fluid and for presence of water.
M	Hyd Lines	Hoses & tubes for leakage, abrasion damage, blistering, cracking,
		deterioration, fitting leakage, & secured properly.
M	Hook	Load hook for abnormal throat distance, twist, wear, & cracks.
M	Rope	Condition of load line.
M	Manual	Presence of operator's manuals with the unit.
M	Chassis	Tire wear and air pressure.
M	Chassis	Working backup alarm.
M	Station	Fire extinguisher at cab or machinery housing.