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Stellar Industries 28000 User's Manual

1. 27 Base Assembly PN 47880 27 Mast Assembly 18073 us ata dense py GR PEERS 28 Main Boom Assembly PN 55106 29 Main Boom Cylinder Assembly 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 PN 55138 36 Chapter 8 Hydraulics Electrical 37 Control PN 41919 Y Y 38 Control Kit 434 Mhz Option 51838 39 Control Kit 419 Mhz Option 55395 40 Hydraulic Kit PN 48690 4 Chapter 9 lt 43 Chapter 10 Troubleshooting 45 BMS 2 Receiver Troubleshooting 50 Warranty IntormatlOni 52 28000 Owner s Manual Introduction Stellar Cranes are designed to provide safe and dependable service for a variety of operations W
2. 36 28000 Owner s Manual Optional 15 Ton Hook Kit PN 55138 PN 55138 DESCRIPTION EXT BOOM 28000 HOOK 15 TON SWIVEL CROSBY 1028654 44069PC COLLAR 1 78X3 00X1 19 9142 PIN 0 56X2 50X0 19 10172 CAP SCR 0 50 13X1 00 HHGR8 ZY 160287 PIN TEAR DROP 1 75X7 06 D0790 IWASHER 0 50 FLAT GR8 Hydraulics Electrical 37 Chapter 8 Hydraulics Electrical WARNING Please read the following section before performing any work the hydrqoulic electricol system of your crane This section contains vital safety information and maintenance guidlines for your crane If questions should arise please contact Stellar Customer Service at 800 321 3741 Never modify or alter any of the equipment whether mechanical electrical or hydraulic without Stellar Industries approval Release system pressure before attempting to make adjustments or repairs Do not attempt service or repair when PTO is engaged Disassemble and assemble hydraulic components on a clean surface Clean all metal parts in a nonflammable cleaning fluid Then lubricate all components to aid in assembly Hydraulic fluid expands when heated This raises the pressure in an unventilated tank Release the tank pressure before removing the cap completely Failure to do so may cause the oil to shoot out of the tank very rapidly and cause severe burns Warning If hydraulic fluid escapes the boom or crane c
3. a ne Pe deg que 5 Operatorlntormoaltlor 26660546 6 Chapter 3 Maintenance 7 Lubrication Recommendations 9 Torque be eee RETRO ad aaa 10 Inspection 11 12 Monthly Inspectlori uu uy ote RIO E bed 13 QUareEnY INSOECTION ee eed EY ewes does 14 Annualinspection 0 0 16 Inspection NOTES 17 Chapter 4 Specifications 19 Capacity Chart Decal PN 16055 20 Chapter 5 Decals 21 Decals of NOTS qhu ec Ra P ahua 21 Decals of Note Continued 22 16658 5 5 he be ama 23 Chapter 6 Installation 25 Installation gt sce Rex wawas 25 Installation NONCE exa peste 25 General Installation 25 Mounting Kit Drawing 16659 26 Chapter 7 Assembly Drawings
4. 28000 ARTICULATING CRANE NewS TRUS LAG OWNERS MANUAL Safety Operation Maintenance Installation Parts Stellar Industries Inc 190 State Street PO Box 169 Garner IA 50438 800 321 3741 Fax 641 923 2811 Change without Notification 5 Inc www slellarindustiries com Last Revision 08 31 12 Subject to 2011 Stellar Industries In 28000 Manual Revisions 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 Table of Contents IMMOGQUCHOR ii Chapter 1 Safely EA yaw b em mm go oe ORE Tele med 1 Chapter 2 Operation 3 Unit Operation Overview 3 Operdtlor cease 4 Radio Remote Operation 4 Hook Precautlons 5 Crane sale ae ES 5 Crane
5. 2257 SNAP RING INSIDE 2 00 D0790 WASHER 0 50 FLAT GR8 10172 CAP SCR 0 50 13X1 00 HHGR8 ZY 10180PC COVER WEAR PAD 23000 C5902 WASHER 0 63 SAE FLAT YELLOW GR8 C1025 CAP SCR 0 63 11X2 00 HHGR8 ZY 25574 BUSHING 40DXR20 2 50X1 25 8819 BUSHING QSI 3235 16 o o 9 eo o 13343 BUSHING 40DXR16 GARLOCK o 17320 BUSHING 40DXR40 GARLOCK 40455 WEAR PAD 2 00 8 00 1 50 162667 PIN 2 00X8 19 D amp T 99967 PIN 2 50X9 38 D amp T 58052 SET SCREW 0 50 13 0 50 N S SN ISIS 5 N N BASE WELDMENT SHOWN AS REFERENCE Assembly Drowings Outrigger Assembly PN 48689 33 34 28000 Owner s Manual Outrigger Cylinder Assembly PN 48383 Note BUSHINGS ARE SHOWN FOR REFERENCE PN 48383 PART DESCRIPTION 48384 CYLINDER 7 00X19 25 15822 MANIFOLD DOUBLE 11 5000 PSI D1290 FTG ADAPT 8 6 F5OLO S 0279 FTG ADAPT 6 F5OLO S 19032 ASM 0 38 X 6 91 BUSHING 40DXR32 GARLOCK Assembly Drawings 35 Reservoir Assembly PN 41332 PN 41332 DESCRIPTION 41333 RSRVR 45GAL ORING 23000 C2126 MAGNETIC PLUG DRAIN 3 4 8241 FAN 16 00 PUSH 12 VOLT C0922 SCR 0 31 18X1 00 HHGR5 C6327 FILTER STRAINER 35GAL TF 2030 8240 COOLER OIL AL 15000 2300
6. 075 x 72 iret 13557 QUICK COUPLER 2FFN38 12SAE M 16700 HOSE HYD 0 50 x 30 se 13555 QUICK COUPLER 2FFI14 38SAE M 31665 HosE HYD O75 X 30 16493 HOSE HYD 0 38x 84 11674 5 0 38 x 102 _______ O l EN 10 iret iret 16663 HOSE HYD 0 38 X 288 4 28 FIG ADAPT 4 4 FLO 05 15815 HOSE HYD 0 38 X 240 7344 FTG ADAPT 12 8 F5OLO S 04 16662 HOSE HYD 0 38 X 42 1556 FTG ADAPT 90 8 C5OLO S 16661 HOSE HYD 0 38 x 180 2ret 2ret 14872 0 38 x 72 erer 48692 HOSE 28000 CRANE inch2 14 1 PART No DESCRIPTON gry 20525 TEE O RING F SL 12 R6LO S 5547 FTG ADAPT 6 8 5010 5 55394 SWITCH PRES OVERLD CD 11C 5500R WD PART No DESCRIPTION 42 28000 Owner s Manual Replacement Parts 43 Chapter 9 Replacement Parts HYDRAULIC SYSTEM COMPONENTS PART DESCRIPTION 39780 Oil pressure gauge Oil cooler Pressure transducer overload Hydraulic filter element Used in p n 42184 Counter balance valve Cylinders Counter balance valve Extension amp Outrigger cylinders Manifold asm dual 12 5000 psi Cylinder Valve bank 7 section Valve bank 5 section Relief valve 5 section valve bank Dump valve 7 section valve bank Oring 6 face seal hydraulic fit
7. A short buzzer signal will sound Wait for the second buzzer signal approx 3 seconds Turn the E Stop to release Press the Start Horn button The green LED on the transmitter control panel will flash This indicates that the transmitter is working and is ready to use 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 Do not store or carry battery so that metal objects can contact exposed metal end Keep battery cap on when not in use The batteries should be recharged when they fail to produce sufficient power 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 Have Unit Serviced Crane Precautions Movement of the control lev
8. the Crane Lubricate all grease gun points with Extreme Pressure Grease Stellar P N 22059 9 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 I
9. 6 15 2 cm bore with integral pilot operated counterbalance valves 315 degree power 28 000 Ibs 10 12 700 kg 3 05 m 17 200 Ibs 16 3 7 800 kg 4 95 m PTO amp Pump 16 4 200 psi 60 lom 290 bars Fully Proportional Paddle Controls for all functions 114 289 6 cm 48 121 9 13 000 Ibs 5 895 kg 20 28000 Owner s Manual Capacity Chart Decal PN 16055 CAPACITY 4 25 7 62 226 10 132 16 3 3 05m 4 01m 4 95m 28000 ene 21300 Ibs 17200 12700 ene 9660 kg 7800 66 00 167 6 GROUND 190 STATE STREET GARNER 50438 PHONE 800 321 3741 FAX 641 923 2812 Chapter 5 Decals 44 DANGER FAILURE TO OBEY THE FOLLOWING WILL RESULT IN DEATH OR SERIOUS INJURY Inspect equipment and its operation daily For equipment stability use only on solid level surface with outriggers rl waited properly Equipment must be level Operate all controls slowly and smoothly Never operate the equipment with personnel Operation Hazard Decal Function To inform the opera tor of the need for proper train ing familiarity with safe operat ing procedures and the possi ble consequences of operation without training PN C4544 DANGER AN UNTRAINED OPERATOR SUBJECTS HIMSELF AND OTHERS TO DEATH OR SERIOUS INJURY YOU MUST NOT OPERATE THIS EQUIPMENT UNLESS You have been trained in th
10. PN 48690 Ej ROTATION cow RETURN TO 1 4 2 36 RSRVR FTG INNER RETRACT INNER EXTEND OUTER RETRACT OUTER EXTEND 42 EXT RETRACT EXT EXTEND 42 EXTENSION ROTATION CW ROTATION CCW 4 ROTATION 2 TM CLAMP OPEN ID gt 21 33 TM ROTATION ccW I gt 3032 TM CLAMP CLOSE 1 gt 21 34 TM ROTATION gt 3031 PAD ROTATION CCW 30 32 TM PAD ROTATION CW 1 gt 30 31 PN 48690 22 14354 ADAPT 90 12 10 csoLo s 1 44 cave FIG ADAPT 8 610 5 21 47406 FTG BULK MSTR ORFS 8 WFSOLO WINL S 2 43 ADAPT 8 12 F5OLO S 20 ci855 FTG ADAPT 6 10 F5oLo s 2 42 cies4 FIG ADAPT 6 8 rsoto s 19 D1314 FTG ADAPT 4 60 1 1 casos ADAPT 6 8 rsoLo s 18 2536 FTG ADAPT 6 10 FSOLO S_ 7 40 Di302 FTG ADAPT 90 6 10 5010 5 1v FTG ADAPT MSTR FSTR 10 6 F5065 7 0882 6 5 1 cies Fre ADAPT 4 csoto S se see 6 90 MSTR FSTR 6 15 55677 HosE HYD 0 25 X 12 7 37 62248 FTG ADAPT 6 C6LO S 14 47423 5 0 38 x 288 7 se 62820 FTG 90 5 4 5 NWO FG 39895 HosE Hvo 0 25 x 108 35 44521 FTG ADAPT MSTR FSTR 5 4 F50G5 12 16627 0 50 x 24 13566 QUICK COUPLER 2FFN38 12SAE F 9104 5
11. WIRE HARNESS 28000 CRANE 1 50220 CONTROLLER ASSEMBLY 2 3 1 C4815 SWITCH TOGGLE ON OFF SWITCH TOGGLE ON OFF ON SCL P DBL T 1 SWITCH TOGGLE MOM ON OFF ON D0045 BACKUP ALARM 97 DECIBAL 10 C6072 RELAY BOSCH 20 30 AMP 3 2 m __ 40 28000 Owner s Manual Control Kit 419 Mhz Option PN 55395 PRESSURE SWITCH 2 2 ag fa 133 aa iez as aee ij 38 22 zz lez OPTIONAL TOO CIRCUIT Hi 8 d r E STOP COOLER O THERMOSTAT x gt Z BODY HARNESS CONNECTIONS Manual OFF N _ TO COMPR FAN Remote y CY CRANE BOLT SPEED CONTROL POWER FLOOD LIGHT Flood Lights 2 OVERLOAD POWER ALARM CRANE 4 CRANE POWER Speed Control COMPR CRANE SPEED CONTROL Tool Circuit REMOTE SPEED CONTROL PN 55395 DESCRIPTION 01 50219 CONTROLLER ASSEMBLY 2 3 HANDLE ASSEMBLY __ CONTROL BOX 04 41920 HARNESS 28000 CRANE 05 c4815 SWITCH TOGGLE ON OFF 06 8623 SWITCH TOGGLE ON OFF ON SGL P DBL T ov 6394 SWITCH TOGGLE MOM ON OFF ON EEG EE 10 4 C 4 D0045 BACKUP ALARM 97 DECIBAL RELAY BOSCH 20 30 AMP 07 10 11 Hydraulics Electrical 41 Hydraulic Kit
12. and dirt to prevent slippery conditions Perform all safety and maintenance checks before each period of use Replace parts with Stellar Industries Inc approved parts only 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 Period
13. 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 accident prevention 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 wit
14. truck before beginning operation NOTICE The parking brake must be fully engaged in order to operate any Stellar Equipment Unit Operation Overview Engage the PTO Turn on Power to Crane Position Outriggers Operate Crane Store Outriggers Turn Off Power to Crane Disengage the PTO 1 Engage the PTO A Engage the parking brake B Place the transmission in the Neutral position C Make certain the PTO switch is in the off position D Start the vehicle engine E Depress the clutch on manual transmission vehicles F Engage the PTO switch for cable and air type shifters Turn on the dash switch for electrical operated style Consult vehicle owner s manual for location and operation of OEM style in dash PTO switch G Slowly release the clutch on a manual transmission vehicle H Allow a few moments to warm the hydraulic system oil In cold weather it is especially important to let the system run for a few minutes before operating PTO Switch 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 desire
15. CAP 0 56 4 00 0 19 0522 WASHER 0 31 LOCK w o IS 55106 Note Secondary Cylinder uses Stellar Seal Kit PN 35650 Note Main Lift Cylinder uses Stellar Seal Kit PN 35651 DESCRIPTION INNER BOOM 28000 REVISED CYLINDER ASM 7 00X38 25 WASHER 0 50 SAE FLAT YELLOW GR8 CAP SCR 0 50 13X1 00 HHGR8 ZERK 1 8 NPT STRAIGHT BUSHING 48DXR48 GARLOCK BUSHING 48DXR32 GARLOCK BUSHING COMPOSITE 3 00X2 50 PIN 3 00X14 00 D amp T PIN CAP 0 56X4 00X0 19 LINK WLDMT 28000 MAIN PIN TEAR DROP 3 00X20 13 LINK MAIN 28000 TEAR DROP PIN 3 00X12 63 CYLINDER ASM 28000 MAST Assembly Drawings Boom Assembly 55106 29 30 28000 Owner s Manual Main Boom Cylinder Assembly PN 20694 PRESSURE SWITCH IN THIS PORT PN 20694 ITEM NO PART NO DESCRIPTION CYLINDER 9 00x4 00x21 81 FTG ADAPT 10 5 5 BUSHING 48DXR48 GARLOCK TUBE ASM 0 63X7 88 YZ FTG ADAPT 10 5 5 MANIFOLD ASM DUAL T2A 5000PSI Assembly Drawings 31 Extension Boom Assembly PN 55108 Note Cylinder uses Stellar Seal Kit PN 35649 PN 55108 PART DESCRIPTION QTY 55107 OUTER BOOM 28000 REVISED 15388 EXT BOOM 28000 DO790 WASHER 0 50 SAE FLAT YELLOW G
16. a finished hook in field applications This will alter and destroy the design properties of the hook material Keep fingers hands body and loose clothing from between the hook and the load Avoid shock loading Inspect the hook regularly for excessive wear and maintain it in safe operating condition Operation 5 Crane Transport Before transporting the crane do the following The crane must be in the stored position Outriggers must be securely stowed and not extended horizontally or vertically Hook and sheave assemblies must be securely fastened to prevent swinging All loose accessories tools and remote controls must be securely stored in their respective compartments or fasteners The PTO must be disengaged The parking brake must not be released until all of the above procedures are completed Do not drive the carrier vehicle while a load is present on the hook Do not drive the carrier vehicle with less than proper tire inflation Do not drive the carrier vehicle in areas where the vertical clearance is unknown Do not allow personnel to ride on the equipment during transport The crane MUST be in the stored position before transporting 6 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 In
17. 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 warranty applicable 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 acc
18. 0 0342 NUTO 31 18 HH NYLOC 0478 SCR 0 25 20X0 50 HHGR5 0340 WASHER 0 25 FLAT 11149 GASKET ARCTIC FOX HEATER A 611 0519 WASHER 0 44 USS FLAT ZINC 0501 CAP SCR 0 50 13X2 00 HHGRS C6106 0 0 50 13 HHGR5 NYLOC 01263 FTG HOSE BARB 0 38 HOSE X 0 38 006 15463 SIGHT GAUGE 42184 FILTER TANK TOP MPF1841 AG7ATOHBVR 19242 20 20 MFS MORB STRAIGHT 47858 5 1 25 881 JC JC 20 20 20 26 47857 FTG 23000 RSRVR TEMP C6021 SCR 0 25 20X0 75 BTNHD SS 30012 SHROUD RSRVER ASM 9000 0333 NUT 0 25 20 HHGR5 NYLOC 47859 FTG 23000 RSRVR RETURN 0492 CAP SCR 0 38 16X0 75 HHGRS 54393 SWITCH TEMP NC TT F5B 100R MP C5552 FILTER STRAINER TFS 1220 0 C4907 5 2 00X1 25 BLK C1057 FIG 20 20XCLOSE MP MP NIPPLE STRAIGHT BLK C5511 VALVE BALL 1 25 C4694 STEL 1 25 90 DEG BLK C2282 1 25 NPT TO 1 25 BARB 58284 GASKET TANK TOP FILTER 11442PC PLATE COVER TANK HEATER FLANGE 63029 FILL ASM W NECK CO NJ amp CO N N NN o n
19. LED Solutions light will begin to blink and the battery will Make sure that the crane is receiving the need to be charged or replaced 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 If problems persist please contact valve is operating Stellar Customer Service at Make sure the proportional valve is receiving 1 800 321 3741 12V power when operating a function 46 28000 Owner s Manual Problem Not all crane functions operate using the radio remote transmitter or crane operates intermittently Solutions Problem Cylinder drifts outward or downward Solutions Check to see if there is air in the hydraulic 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 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 system Operate all cylinders connected to the hydraulic system Start with the extension cylinder then operate the main boom winch
20. R8 14 C6219 WASHER 0 75 SAE FLAT YELLOW GR8 36 10172 CAP SCR 0 50 13X1 00 HHGR8 14 4543 CAP SCR 0 75 10X2 00 HHGR8 c1592 ZERK 1 8 NPT STRAIGHT 54374 BUSHING COMPOSITE MRP 3 00X2 50 2227 BUSHING 48DXR48 GARLOCK 0865 BUSHING 48DXR32 GARLOCK 15608 CYLINDER 6 00x37 00 15769ZP PIN 3 00X9 13 D amp T 13315 PIN CAP 0 56X4 00X0 19 26973ZP PIN 3 00X15 00 SR D amp T 551097P PIN 3 00X16 88 D amp T 15778 WEAR PAD 3 00X5 00X2 44 15609PC PLATE WEAR PAD COVER 28000 15601 WEAR PAD 1 00X4 00X12 00 15779 WEAR PAD 3 00X5 00X1 75 5 T 32 28000 Owner s Manual Extension Boom Cylinder Assembly PN 50628 CYLINDER BUSHINGS SHOWN FOR REFERENCE ONLY PN 50628 DESCRIPTION CYLINDER 7 00X38 25 FTG ADAPT 10 C5OLO S TUBE ASM 0 63X16 09 FTG ADAPT 10 F5OLO S MANIFOLD ASM DUAL T2A 5000PSI BUSHING 48DXR48 GARLOCK 48689 DESCRIPTION 40450 OUTRIGGER 23000 15502 OUTRIGGGER LEG 28000 9994 CYLINDER 4 00X50 00 4381 BUSHING 32DXR32 2 00X2 00 GARLOCK 0635 BUSHING 40DXR32 GARLOCK 48383 CYLINDER ASM 48384 40837 OUTRIGGER PAD 23000 96 NM 00 N 2 8377 0 56X3 50X0 19 404597 PIN 2 50 14 88 D amp T 48385ZP PIN 2 50X14 00 D amp T
21. ROL Tool Circuit REMO SPEED CONTROL PN 41919 Le HANDLE ASSEMBLY CONTROL BOX 04 41920 WIRE HARNESS 28000 CRANE __ 1 05 4815 SWITCH TOGGLE ON OF 3 06 8623 SWITCH TOGGLE ON OFF ON SGL P DBL T 1 Ov 6394 SWITCH TOGGLE MOM ON OFF ON 2 08 41921 WIRE HARNESS 28000 LMI amp LIGHTS 1 09 20045 BACKUP ALARM 97 DECIBAL 1 al __ O O FM TO C CRANE BOLT OVERLOAD 09 ALARM 02 LIGHTS PRESSURE SWITCH r E STOP Hydraulics Electrical 39 Control Kit 434 Mhz Option PN 51838 ri CLAMP OPEN TOP CLOSE BOTTOM TOP BOTTOM ag d E 8 93 22 lez EIE 193 4 558 OPTIONAL TOO CIRCUIT BODY HARNESS CONNECTIONS COMPR FAN SPEED CONTROL POWER FLOOD LIGHT POWER CRANE ME Ut COMP SPEED CONTROL 2 OFF Remote CRANE Flood Lights L CRANE Speed Control L amp CRANE Tool Circuit L PN 51838 DESCRIPTION OR SS IN OR SS UP GROUND TO CRANE BOLT gt OVERLOAI 6 OR CS UP ALARM x ue B89988888 IR HANDLE ASSEMBLY CONTROL BOX 1
22. SAE FLAT YELLOW GR8 C0930 SCR 0 31 18X3 00 HHGR5 40827 5 SECT HYDRO CONTROL HC D3M 5 41338 FILTER ZINGA 23000 41339 CLAMP ZINGA FILTER 23000 0420 CAP SCR 0 31 18 0 75 HHGR5 44079PC BRACKET VB MNT 23000 0482 CAP SCR 0 25 20 X 3 00 HHGR5 0333 0 25 20 5 NYLOC 0480 CAP SCR 0 25 20X1 00 HHGR5 44511 GUARD OUTRIG VB 23000 22185 WASHER 0 19 FLAT SS 22186 NUT 48 32 HH NYLOC SS C0922 CAP SCR 0 31 18X1 00 5 47425 CAP SCR 6MMX20MM HH CLASS 8 8 44078PC BRACKET VB MNT BASE 23000 41337PC PLATE COVER 23000 36243PC PLATE SWITCH MTG 28000 CRANE 0437 SCR 0 25 20X1 25 HHGR5 42802 7 SECT DANFOSS PVG32 12869 STRAIN RELIEF 50 NPT 24 47 CABLE 60505 GEAR BOX W MOTOR 23 28000 TE jo ez 4 gt ARMIN Bow 5 gt 28 28000 Owner s Manual Mast Assembly PN 18073 PN 18073 DESCRIPTION MAST 28000 WASHER 0 88 SAE FLAT YELLOW GR CAP SCR 0 88 9X3 50 HHGR ZY WASHER 0 50 FLAT GR8 CAP SCR 0 50 13X1 00 HHGR8 ZY CAP SCR 0 88 9X5 50 HHGR8 PLATE INSPECTION MAST 23000 CAP SCR 0 31 18 X 0 50 HHGR5 WASHER 0 31 USS FLAT ZINC HOSE CLAMP 28000 CAP SCR 0 38 16X1 75 SH ZC WASHER 0 38 LOCK 157552 TEAR DROP 3 00X16 13 13315
23. 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 o
24. an 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 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 38 28000 Owner s Manual Control Kit PN 41919 COOLER THERMOSTAT gt FLOOD LIGHTS E 88 Jee 38 fez ds 22 ag Has ci CUNT B Lg ges OPTIONAL Too B OR SS IN 9 J on ss up T Flood Lights 92 or cs IN CRANE or CS UP Speed Control USE O s CRANE SPEED CONT
25. d 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 manual transmission release the clutch pedal gradually 4 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 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 joy stick or paddle lever is NOT in the Off neutral position when the Start Horn button is pushed the transmitter will not transmit Switch the transmitter ON
26. e Inspect and replace hydraulic lines Check continuity of circuit Clean or replace pulsar solenoid valve Replace holding valve Check hoses for damage and replace 50 28000 Owner s Manual BMS 2 Receiver Troubleshooting Available on some systems Consult BMS 2 Operator Manual for details 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 All crane machine motions operate intermittently Some crane machine motions operate intermittently E Stop reset 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 Joystick or paddle lever not in Be sure that all joysticks and paddle levers are in center position when the Start center position button is activated E Stop switch engaged Pull out E Stop switch Restart system by pressing Start twice Battery fully discharged Check battery to ensure a full charge Replace with fully charged battery if necessary No power to the receiver 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 interferenc
27. e and E Stop conditions Battery is discharged Replace battery with a fully charged battery Coder board fuse Check fuse and replace if necessary Broken key switch Check wiring on key switch Replace key switch wiring or contact element Coder board failure Contact Hetronic or your Dealer E Stop switch engaged Pull out the E Stop pushbutton and press the Start Horn pushbutton Transmitter out of range Take the transmitter back into the range of the receiver Press the Start Horn pushbutton Joystick paddle lever or switch Ensure that all control devices are in center neutral position when the Start button not in center position when is activated transmitter turned on Receiver power off Turn on power to receiver Blown fuse in receiver Check all fuses Replace if necessary E Stop failure in transmitter Check E Stop pushbutton for damage Check wiring to contact element for broken or disconnected wires Repair or replace E stop pushbutton or wiring E Stop failure in receiver Red E Check wiring on E Stop module decoder module E Stop decoder module Secure Stop LED on decoder board is any loose connections illuminated E Stop module failure Replace E Stop module Receiver antenna loose or Tighten or replace antenna missing External antenna if used has Tighten antenna and ground connection See Connecting an External Antenna loose connection poor grounding Section for operational precautions or inter
28. e Equipment WILL Void Warranty 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 possi ble consequences should the misuse occur and how to avoid these hazard PN 16732 Decals 23 Decal Kit 16658 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 PN 16658 DECAL STELLAR LOGO 8 00x22 25 2 mhe cs 400950 18 cs DECAL STELLARLOGO2 00x4 50 16 8998 DECAL AIR DRAIN __ io cas DECAL DANGERFOoT o cen DECAL WARNING o css DECAL CAUTIONSTAND CLEAR os 490 DECALDANGER OPERATION CONDITION THESE DECALS NOT SHOWN DECAL DANGER o se Decat 28000 2 24 28000 Owner s Manual Installation 25 Chapter 6 Installation Notice Read this Page Before Installation of the Crane 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 installati
29. e in operation con t Outriggers fail to retract Outriggers fail to retract con t Outriggers yield or drift Possible Cause Pump is slipping due to excessive oil temperature this is a factor which will increase with worn components Troubleshooting 49 Possible Solution Check pump GPM with flow meter if it is suspected to be faulty Replace filters Obstruction has occurred in boom hold Replace or clean holding valve Main or secondary cylinder holding valves are defective or contaminated Cavitation is occurring due to low hydraulic oil supply Restriction or collapse of suction line has occurred Suction line screen is clogged and requires replacement Bypass settings on relief valve are too low Relief valve is damaged Control valve is inoperative Cylinder seals or holding valve are defective Hydraulic lines are restricted or rup tured Broken electrical wire going to outrig ger switch to the valve bank Control valve is inoperative Cylinder or check valve is defective Hydraulic lines are restricted or rup tured 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 Contact customer service for correct relief setting Replace relief valve If outriggers retract using manual func tion it is a probable electrical problem check continuity Replace seals or holding valv
30. e parking brake is engaged Make sure the Power LED is on outside the Make sure that the PTO is engaged receiver door cover This light is the upper Make sure that there is 12V power going to light on the receiver door If the light does not the radio receiver If there is no power going come on check wiring back to the fuse If to the receiver trace back to the power the fuse is OK check system ground wires source and check for a blown fuse or loose and connections ground connection Make sure the green LED on the receiver Make sure that the transmitter batteries are door is lit green This light will come on when fully charged Rechargeable batteries are the red e stop is pulled upward and the toggle good for 11 months or 200 charges switch is activated on the transmitter If the Make sure that the hydraulic pump is radio system does not link up and no green operating at its rated flow or GPMs Check light is lit on the receiver make sure that the the flow by using the flow meter to determine battery is fully charged check the battery the GPMs It is possible that the hydraulic contact points to make s ure they are not pump is getting weak If this is suspected tarnished or corroded Clean contact points contact Stellar Customer Service and recharge or replace the battery When battery voltage is acceptable the power LED light on the transmitter will be Problem Crane operates slowly solid If the voltage becomes low the
31. e safe operation of this equipment Operation Hazard Decal Function To inform the opera tor of the need for proper train ing familiarity with safe operat ing procedures and the possi ble consequences without train ing PN C4540 Decals of Note 44 DANGER FAILURE TO OBEY THE FOLLOWING WILL RESULT IN DEATH OR SERIOUS INJURY INSTABILITY OR STRUCTURAL DAMAGE Read understand and follow the equipment load and work area charts Do not exceed winch or equipment ratings Weights of accessories attached to the boom or loadline must be deducted from the load chart ratings or be added to the load weight Do not exceed jib load ratings at reduced boom lengths 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 44 DANGER E OUTRIGGERS WILL CAUSE SERIOUS CRUSHING INJURY STAND CLEAR Foot Crush Hazard Decal Function To inform the opera tor and other personnel in the work area of the hazard associ ated with the operation of the outriggers the possible conse quences should the hazard occur and how to avoid the hazard PN C4795 Decals 21 44 DANGER FAILURE TO OBEY THE FOLLOWING WILL RESULT IN DEATH OR SERIOUS INJURY Follow all recommended ins maintenance practices listed in the equipment manufacturer s manuals If manuals are miss
32. ector 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 47 Troubleshooting continued Problem Vibrations and jerking in hydraulic cylin der during the first maneuvers Vibrations with every function when oil is hot All crane movements are slow loaded and unloaded The hydraulic extension is not extend ing Crane rotation not regular The crane does not lift the loads on the load chart Possible Cause The temperature of the hydraulic oil is too low lack of oil in reservoir 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 Inadequate grease The truck is not level Worn rotation motor Gear bearings worn Defective hydraulic pump Incorrect settings of the valves Hydraulic cylinder seals are worn The crane lifts the load but cannot hold Incorrect relief setting it Noise coming from Articulation points Faulty holding valve Incorrect settings of the valves Hydraulic cylinder seals are worn Lack of lubrication Possible Solution Perform maneuvers without loads for several minutes
33. electrical line carrying up to required for every additional 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 conse quences should the hazard occur and how to avoid the hazard PN C1179 _ d DANGER FAILURE TO OBEY THE FOLLOWING WILL RESULT IN DEATH SERIOUS INJURY INSTABILITY OR EQUIPMENT DAMAGE A MOVING OUTRIGGER WILL CAUSE SERIOUS CRUSHING INJURY Do not operate any outrigger unless you or a signal person can see that all personnel are clear of the outrigger and its ground contact point Moving Outrigger Hazard Decal Function To inform the operator of the hazard asso ciated with outrigger operation the possible conse quences should the hazard occur and how to avoid the hazard PN C5918 NEVER clamp an uninflated tired and then inflate Damage or injury will result NEVER use the unit for any jacking pulling or dragging NEVER drag the tire the unit is designed operation involving an object or another vehicle c NEVER use the outer cylinder to push objects with the Tireman Damage to the equipment will result AAA to lift and position NEVER operate the unit while persons not required for operation are in the work area NEVER handle tires filled with ballast Instability and structural failure will result Improper Operation of th
34. ers should be slow and smooth to meter oil flow for safe operation Avoid jerky and sudden movements The crane controls should be clearly marked with decals If these are missing or illegible replace immediately See Chapter 5 Decals 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 Be constantly aware of the boom position when operating the controls The boom tip should be centered directly over the load before making the liff to avoid swinging Do not drag loads with the crane Do not attempt to lift fixed loads Do not load boom in a sideways direction Know the weight of the rigging and load to avoid overloading the crane Do not extend or rotate a load over anyone Wear protective gear such as hard hat safety glasses steel toed boots and gloves Hook Precautions 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 Do not attempt to lift a load that is larger than the load rating of the hook Never use a hook s yield point as an indicator of its capacity Do not use a hook to lift personnel Know the rated load of the hook in use Never weld attachments to
35. essary WEM PART Operate the crane for several cycles t PN 1665 DESCRIPTION rreM PART DESCRIPTION 1 BLOCK 15000 4 5 8834 NUT 1 25 7 HHGR8 TOP LOCKING 8 PLATE MOUNTING 23000 4 6 8978 NUT 1 25 7 HHGR8 16 TIE DOWN ROD a 7 gB202 FRAME SUPPORT 15000 CRANE 4 4 9180 WASHER 1 25 SAE FLAT YELLOW GR8 16 26 28000 Owner s Manual Mounting Kit Drawing 16659 ITEM DESCRIPTION QTY 8054 MTG BLOCK 15000 4 58834 11817 PLATE MOUNTING23000 4 __6 8978 1 25 7HHGRB 46 3 14498 TIE DOWN ROD 8 7 8202 FRAME SUPPORT 15000 CRANE 4 WASHER 1 25 FLAT YELLOW GR8 Assembly Drawings 27 Chapter 7 Assembly Drawings Base Assembly PN 47880 NOTE RADIO RECEIVER AND ALARM SHOWN FOR REFERNECE PART _ DESCRIPTION 48686 5 28000 18471 TURNTABLE BEARING 23000 18041 WASHER 0 88 SAE FLAT YELLOW 17962 SCR 0 88 9 4 50 HHGR ZY 41336PC_ PLATE SWITCH MTG 23000 0479 CAP SCR 0 25 20X0 75 HHGR5 0340 WASHER 0 25 FLAT 41084PC GUARD VB 23000 0342 NUTO 31 18 HH NYLOC 0343 WASHER 0 31 USS FLAT ZINC 0485 CAP SCR 0 31 18X1 25 HHGR5 22921 PANIC BAR 28000 41082 BAR PANIC 23000 22183 CAP SCR 8 32X0 75 BTNHD SS 0488 CAP SCR 0 31 18 2 00 HHGR5 C6219 WASHER 0 75 SAE FLAT YELLOW GR8 C1028 CAP SCR 0 75 10X3 00 HHGR8 ZY 22935 BLOCK CBCA LAN XTS 5591 WASHER 0 31
36. f 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
37. ference Connector wiring too close to Control wiring must be run separately from power wiring power wiring Connector inside receiver is Check all connectors reseat if necessary loose Crane machine motion wiring may Check wiring from receiver to plug and from plug to crane machine motion be loose actuator Connector inside receiver is Check all connectors reseat if necessary loose Connector wiring too close to Control wiring must be run separately from power wiring power wiring 51 STELLAR SE INDUSTRIES INC 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 of manufacture Twelve 12 month repair labor from the date recorded by Stellar as the in service date not to extend beyond twenty four 24 month from date of manufacture and Thirty six 36 month warranty on all Stellar Manufactured structural parts from the date recorded
38. having more than 5 normal throat opening b Any visible bend or twist from the plane of the unbent hook Structural members for bends cracks or broken members All welds for breaks and cracks All pins and keepers for proper installation All control safety and capacity placards for readability and secure attachment 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 lubricate the splines using Chelsea Lubricant 379831 or Stellar PN 20885 Failure to lubricate shaft splines will cause damage to the 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 Consider the remaining service life of components against the cost of parts and labor necessary to replace them Make the necessary repair Recheck to ensure that nothing has been overlooked Functionally test the new part in its system Inspection Checklist For a more detailed outline of scheduled ins
39. hout 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 su
40. ic 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 alll 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 8 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 2 2 Lubrication of points required by lubrication chart located in this chapter Proper operation of load hook safety latch 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 Cylinders and valves for leaks Lubrication Load hook for the following a Cracks or
41. ing from this equipment contact manufacturer for replacement Do not modify or alter this equipment without written manufacturers approval Use only manufacturer approved attachments or parts on this equipment Equipment must be mounted on factory recommended chassis If remounted or rebullt the equipment must be recertified Operation Hazard Decal Function To inform the opera tor and other personnel in the work area of the hazard associ ated with improper maintenance and unauthorized modifications the possible consequences should the hazard occur and how to avoid the hazard PN 4190 44 DANGER STOWING amp UNFOLDING BOOM WILL CAUSE DEATH OR SERIOUS INJURY Stand on the opposite side of the boom when unfolding or stowing the equipment C4541 Moving Boom Hazard Decal Function To inform the opera tor and other personnel in the work area of the hazard associ ated with a moving boom espe cially while stowing and unfold ing the crane the possible con sequences should the hazard occur and how to avoid the haz ard PN C4541 22 28000 Owner s Manual Decals of Note Continued DANGER UTION HAZARD THIS EQUIPMENT IS NOT INSULATED WILL RESULT FROM CONTACT OR INADEQUATE CLEARANCE aintain safe clearances from electrical lines Allow for joes not provide protection from contact with or electrically charged conductor ince of at least 10 feet between any part of the load and
42. ith 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 par
43. ity 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 Only authorized service personnel are to perform maintenance on the crane Disengage the PTO before any service or repair is performed Do not disconnect hydraulic hoses while there is still pressure in those components 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 Keep the crane and service body clean and free from grease build up oil
44. ler 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 Relocate any obstructions on the frame that will be in the way of mounting the crane 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 Set the crane on the chassis and allow a minimum of 2 from the cab See the next page for a larger view 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 Ibs is achieved Be sure the mounting block stays perpendicular to the frame rail as they are tightened down Connect the pressure and return lines per the hydraulic kit Connect the 12V power and ground wires Check the reservoir for oil and fill if nec
45. lic 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 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 Operatio
46. n 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 The vehicle should also be positioned 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 The outriggers must be extended to stabilize the
47. 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 Frequency D 28000 Owner s Manual Daily Inspection Key dd c sss Description m load charts safety amp warning Decals amp control Decals are present and legible Check all safety devices for proper operation NELLE mechanisms for proper operation of all functions leaks amp cracks Station Control mechanisms for proper operation of all functions leaks amp cracks Hydsystem Hydraulic system hoses tubes amp fittings for leakage amp proper oil level Hook Presence amp proper operation of hook safety latches Rope Proper reeving of wire rope on sheaves amp winch drum 5 UA engagement of all connecting pins amp pin retaining devices General Overall observation of crane for damage
48. nstallation Overview Grade 5 Grade 8 X 4 lll S Grade 9 12 4 X Bolt DIA Plain Plated Plain Plated Plated DIA TPI Inches Fi 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 82 155 115 139 5 8 11 0 6250 115 220 160 192 3 4 10 0 7500 265 200 375 280 340 0 8750 395 295 605 455 549 1 000 590 445 910 680 823 1 1250 795 595 1290 965 1167 1 2500 1120 840 1815 1360 1646 1 3750 1470 110 2380 1780 2158 1 500 1950 1460 3160 2370 2865 Size 1 1 2 6 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 Hat washers of equal strength must be used 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 f
49. on 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 manufacturer the instal
50. or Grade 8 capscrews Maintenance 11 Inspection Checklist Use of this checklist is subject to terms of the Type of Inspection check one Stellar Warranty information Additional copies of Daily if deficiency founa L Quarterly this checklist can be obtained by contacting Stellar Customer Service at 800 321 3741 1 Monthly L Annual Contact Person Crane Make Model Crane Serial 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
51. or missing parts cracked welds amp presence of safety covers Operation During operation observe crane for abnormal performance unusual wear If observed discontinue use amp determine cause amp severity of hazard Remote Operate remote control devices to check for proper operation Electrical Operate all lights alarms etc to check for proper operation Anti 2 Blocking Operate anti 2 blocking device to check for proper operation Operation Aid Check presence of boom angle indicator Operation Aid Check overload device for proper operation Status Frequency M lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt Maintenance Monthly Inspection Key Inspection Description Doily All Doily Inspections Cylinders Visual inspection of cylinders for leakage at rod fittings amp welds Damage to rod amp case Valves Holding valves for proper operation Valves Control valve for leaks at fittings amp between sections Valves Control valve linkages for wear smoothness of operation amp tightness of fasteners Relief valve for proper pressure settings General Bent broken or significantly rusted corroded parts Electrical Electrical systems for presence of dirt moisture amp frayed wires BUM A structural members for damage Welds All welds for breaks amp cracks Pins All pins for proper installation amp condition No dus bolts fa
52. ount 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
53. pection 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 The second 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 filter gauge often for filter change notice Maintenance Lubrication Recommendations Component Engine Bearings grease including turntable bearing inner race Worm Drive Gearbox Planetary Gearbox including winch Wear Pad Lubrication Compressor Fluids Reciprocating Single Stage Reciprocating Double Stage Screw 15 F to 86 F 23 F to 100 F 32 to 113 F Location Recommendation Crankcase Apply Manufacturer s Recommendations Reservoir Petro Canada Arctic MV 15 ISO 22 Petro Canada HYDREX 32 ISO 32 Petro Canada HYDREX 46 ISO 46 Spray Gearshield NC Compro 100 ISO 100 Compro 100 ISO 100 Crankcase Compro XL S 32 ISO 32 Compro XL S 46 ISO46 Compro XL S 68 ISO68
54. pump to control valve Return line s from control valve to reservoir Suction line s from reservoir fo Pressure 5 from control valve to each function Load holding valve pipe s and hose s Other Q Pumps amp Motors Pumps and motors for loose bolts fasteners leaks noise vibration loss of performance heating and excess pressure Winch motor s Rotation motor s Q Valves Hydraulic valves for cracks spool return to neutral sticking spools relief valve failure 1 control valve Load holding valve s or auxiliary control valve s __ NN Castor damage Case amp rod ends for damage amp abnormal wear PO a Inner boom cylinder s Outer boom cylinder s Extension cylinder s Rotation cylinder s EN lift cylinder s 21 extension cylinder s Other Q Winch Winch sheaves amp drums for damage abnormal wear abrasion amp other irregularities Hyd Filter Hydraulic filters for replacement per maintenance schedule 16 Frequency A gt gt gt gt gt gt gt gt gt gt gt gt gt gt 28000 Owner s Manual Annual Inspection Key Inspection Description Doily All doily inspection items Monthly All monthly inspection items Quarterly All quarterly inspection items Hyd System Hydraulic fluid change per maintenance schedule valve calibration for correct pressures amp relief
55. re the outriggers are positioned on stable flat ground 2 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 hydrau
56. ric connection Possible Solution Clean or replace holding valves Replace worn seals Charge battery Check electrical wiring terminals con nections 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 Replace switch Replace the switch Replace the solenoid Disassemble and clean the valve car tridge Check continuity of the circuit Operations at high or low speed do not Parameters of control box receiver Contact Stellar customer service Work set incorrectly or have failed department Controls fail to respond with control Batteries dead in wireless handle box Handle on off button isn t turned on Manual remote switch is in manual position Operation slow down Hydraulic oil supply is low Hydraulic pump is operating at a reduced speed Relief valve is set too low Pump or cylinder is worn Recharge or replace batteries in remote handle Turn on on off button on remote han dle Position manual remote switch in remote position Add hydraulic oil Engine idle speed may be too slow increase speed Check relief with gauge Replace cylinder seals Problem Operation slow down neutralized Unusual noise in operation Unusual nois
57. 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 conn
58. s LMI amp Lights Wire harness LMI Cinch Retro Overload alarm COMPRESSOR COMPONENTS SHD245 OPTIONAL Pilot valve 145 175 psi SHD245 cprsr Solenoid valve SHD245 cprsr Pressure Relief valve SHD245 cprsr Hobbs air pressure switch SHD245 cprsr Low pressure intake valve asm SHD245 cprsr High pressure intake valve asm SHD245 SERVICE KITS FILTERS LUBRICATION MISCELLANEOUS COMPONENTS DESCRIPTION 51263 Flood lights Crane amp Body 5033 Stobe light Crane amp Body 14022 Compartment light 44 28000 Owner s Manual Troubleshooting 45 Chapter 10 Troubleshooting This chapter will list a number of Problem Crane will operate manually but potential problems that may occur will not operate electrically while operating the crane Most conne toblems are easil Ived using th Make sure that there is 12V power going to p SUY S9ee Using die the radio receiver If there is no power going solutions portion of this chapter If to the receiver trace back to the power problems persist please contact source and check for a blown fuse or loose Customer Service at Stellar Industries ground connection 1 800 321 3741 Make sure that the parking brake is engaged Make sure that the parking brake switch is working properly Check the parking brake Problem Crane will not operate switch by performing a continuity test If the switch is defective simply replace it Make sure that th
59. spector 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 capac
60. steners amp retaining rings for tightness wear amp corrosion WearPads Condition of wear pads Pump amp Motor Hydraulic pumps amp motors for leakage at fittings seals amp between sections Check tightness of mounting bolts Transmission PTO for leakage abnormal vibration amp noise alignment amp mounting bolt torque Hyd Fluid Quality of hydraulic fluid and for presence of water Hyd Lines Hoses amp tubes for leakage abrasion damage blistering cracking deterioration fitting leakage amp secured properly Hook MISSE MM 13 Status 14 28000 Owner s Manual Quarterly Inspection Frequency Key Inspection Description Q Daily All daily inspections ____ _ Inner boom Outer boom Extension s Jib boom extension s Other ca Hardware Pins bearings shafts gears rollers amp locking devices for wear cracks corrosion amp distortion Inner boom pivot pin s amp retainer s Outer boom pivot pin s amp retainer s Inner boom cylinder pin s amp retainer s wass 2 ______ 2 2 i sa NN 1 2 T Boom tip attachments ee Other Status Maintenance 15 Quarterly Inspection Continued Frequency Key Inspection Description Status Q Hyd Lines Hoses fittings amp tubing for proper routing leakage blistering deformation amp excessive abrasion Pressure line s from
61. t 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 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 Order Parts Warranty Information serviceGstellarindustries com parts stellarindustries com warranty stellarindustries com Chapter 1 Safety Safety 1 Please Read the Following Carefully This portion of the manual contains information regarding all Stellar manufactured cranes Some items contained within this chapter may not apply to your specific equipment Safety should be the number one thought on every operator s mind Three factors should exist for safe operation a qualified operator well maintained equipment and the proper use of this equipment The following information should be read and understood completely by everyone working with or near the crane before putting the unit into operation Please take note that Stellar Industries Inc is not liable for accidents incurred by the crane because of non fulfillment from the operator s side of current rules laws
62. tings C2029 32223 Oring 12 SAE port side hydraulic fittings Oring 16 SAE port side hydraulic fittings Seal kit Extension cylinder 15608 ASSEMBLY COMPONENTS 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 Bushing 2 50 x 1 00 Bushing 2 50 x 1 75 Pin Cap 0 56 x 2 50 x 25 55 40455 15779 15778 Wear Pad 3 00 x 5 00 x 2 44 15601 Wear Pad 1 00 x 4 00 x 12 00 7133 Hose clamp ivel link 8485 1338 7860 8552 5463 15995 2802 40827 5401 50234 50235 47871 3555 13554 3557 13556 C2028 Hose clamp O 39959 Gear bearing rotation kit 16054 Swivel link 15 ton hook 16052 Hook 15 ton Swivel PART 1922 7862 7863 7867 241 394 623 C4815 4393 2921 1562 1367 1782 41368 D0045 PART 3853 C4913 C4914 C0864 13731 13733 PART ELECTRICAL COMPONENTS DESCRIPTION Hetronic Nova radio system 12v charger for Hetronic Nova radio system Battery for Hetronic Nova radio system Belt Transmitter harness waist Fan 16 00 push 12 V Hydraulic reservoir Toggle switch Outrigger operation Toggle switch Outrigger operation Toggle switch Outrigger operation Temperature switch Hydraulic reservoir E stop switch Crane panic bar CONTACT SWITCH PANIC BAR Switch inside E stop housing 22921 LMI system Load Moment Indicator Wire harnes
63. to warm up the oil Add hydraulic oil Add hydraulic oil to the tank Operate the control carrying the cylin ders 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 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 48 28000 Owner s Manual Problem Possible Cause 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 connec tions Faulty manual remote switch A crane function does not work Defective switch Faulty solenoid Locked valve cartridge Damaged elect
64. valve settings BEN ii valve calibration for correct pressures amp relief valve settings Valves Valves for failure to maintain correct settings Rotation Sys Rotation drive system for proper backlash clearance amp abnormal wear deformation amp cracks oil change in rotation drive system per maintenance schedule B pd tightness of all fasteners and bolts Wear Pads Wear pads for excessive wear Loadline Loadline for proper attachment to drum Historic Data Monthly inspection records Historic Data Repair and modification records Status Maintenance 17 Inspection Notes 18 28000 Owner s Manual Specifications 19 Chapter 4 Specifications Model 28000 Crane SPECIFICATION SHEET Crane Rating Standard Boom Length Boom Extension Maximum Horizontal Reach Maximum Vertical Lift From Truck Frame Cylinder Specifications Inner Lift Cylinder Outer Lift Cylinder Extension Cylinder Rotation planetary gear with pinion Lifting Capacities From CL of Truck Power Supply Required Controls Stowed Height Above Truck Frame Mounting Space Required Approximate Shipping Weight 280 000 ft lbs 38 71 ton meters 13 2 4 01 m from CL of Crane Hydraulic 37 94 0 cm 16 3 4 95 m from CL of Crane 25 7 62 m 9 22 9 cm bore with integral pilot operated counterbalance valves 7 17 8 cm bore with integral pilot operated counterbalance valves

Stellar Industries 28000 User's Manual

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