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stellar labs 10621 Owner's Manual

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O
'
M
WNER
S
ANUAL
Safety, Installation, Maintenance, and Operation
10621 Telescopic Crane
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
www.stellarindustries.com
Subject to Change without Notification.
Last Revision:
© 2009 Stellar Industries, Inc.
10/10/09

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  • Page 1 ’ WNER ANUAL Safety, Installation, Maintenance, and Operation 10621 Telescopic Crane Stellar Industries, Inc. 190 State Street PO Box 169 Garner, IA 50438 800-321-3741 Fax: 641-923-2811 www.stellarindustries.com Subject to Change without Notification. Last Revision: © 2009 Stellar Industries, Inc. 10/10/09...
  • Page 2 10621 Manual Revisions Date of Revision Section Revised Description of Revision Chapter 8: October 22, 2008 Hydraulics-Electrical Updated Hydraulic Kit Versions to reflect engineering Chapter 9: changes (New Pressure Switch). Replacement Parts...

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Introduction ............ii Chapter 1 - Safety .

  • Page 4: Introduction

    10621 Owner’s Manual Introduction Stellar Cranes are designed to provide safe Please be aware that some sections of this and dependable service for a variety of manual contain information pertaining to operations. With proper use and Stellar manufactured cranes in general and...

  • Page 5: Chapter 1 - Safety

    Safety Chapter 1 - Safety Please Read the Following Carefully! This Do not wear rings, wristwatch, jewelry, loose- portion of the manual contains information fitting or hanging clothing such as ties, torn regarding all Stellar manufactured cranes. garments, scarves, unbuttoned jackets or Some items contained within this chapter unzipped overalls, which could get caught up may not apply to your specific equipment.
  • Page 6 10621 Owner’s Manual STABILITY Do not walk under suspended loads. Know the crane components and their capabilities and limitations. Overloading the Do not position any load over a person nor crane may result in serious injury to self and should any person be permitted to place him others, and damage to the equipment and or herself under a load.

  • Page 7: Crane Controls

    Safety 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.
  • Page 8 10621 Owner’s Manual...

  • Page 9: Chapter 2 - Operation

    Operation Chapter 2 - Operation Unit Operation Overview This chapter contains information regarding the operation of Stellar manufactured 1. Engage the PTO telescopic cranes. Please study the 2. Turn on Power to Crane following pages to ensure your familiarity 3. Position Outriggers with the operation process.

  • Page 10: Function Hetronic Remote

    10621 Owner’s Manual 6 Function Hetronic Remote 4.Operate Crane NOTE: The radio control is an electri- A. Turn on necessary power to the crane. cal device. Please handle with care! B. Activate toggle switch for desired crane function. D. Activate the variable speed trigger to control the desired function.

  • Page 11: Manual Operation

    Operation Manual Operation Crane Precautions 1. Movement of the control levers should be If the remote control malfunctions, follow these slow and smooth to meter oil flow for safe steps to operate the crane manually: operation. Avoid jerky and sudden movements.

  • Page 12: Operator Information

    10621 Owner’s Manual Operator Information OPERATOR REQUIREMENTS OPERATOR CONDUCT 1. Operation is limited to the following 1. Operators will not engage in any people: operation that would cause them to divert A. Designated individual. attention away from the operation of the B.

  • Page 13: Chapter 3 - Maintenance

    Maintenance Chapter 3 - Maintenance Daily Inspection WARNING - Read the Following before Daily Inspection should occur each day performing any maintenance on the before the crane is put into use. Each day, crane. inspect the crane for all of the following: 1.
  • Page 14 10621 Owner’s Manual Weekly Inspection Service Weekly Inspection should occur at the The following general suggestions should beginning of every work week. Each week, be helpful in analyzing and servicing your inspect the crane for all of the following: crane. Using the following systematic 1.

  • Page 15: Lubrication Recommendations

    Maintenance 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...

  • Page 16: Wire Rope Maintenance

    10621 Owner’s Manual Wire Rope Maintenance surface wires of the rope need to be inspected. This inspection will be concerned with discovering damage Wire Rope Inspection Points that may be an immediate hazard. The While inspection of the entire rope is...

  • Page 17: Torque Data Chart

    Maintenance Holding Valve Inspection Procedure Torque Data Chart 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 Grade 5 Grade 8 Grade 9 valve is checked in the following manner: 1.

  • Page 18: Inspection Checklist

    10621 Owner’s Manual Inspection Checklist Type of Inspection (check one) Use of this checklist is subject to terms of the Daily Quarterly Stellar Warranty information. Additional copies of (if deficiency found) this checklist can be obtained by contacting Monthly Annual Stellar Customer Service at (800) 321-3741.

  • Page 19: Daily Inspection

    Maintenance Daily Inspection Frequency Inspection Description Status Decals All load charts, safety & warning Decals, & control Decals are present and legible. Check all safety devices for proper operation. Controls Control mechanisms for proper operation of all functions, leaks, & cracks. Station Control mechanisms for proper operation of all functions, leaks, &...

  • Page 20: Monthly Inspection

    10621 Owner’s Manual Monthly Inspection Frequency Inspection Description Status Daily All Daily Inspections. Cylinders Visual inspection of cylinders for leakage at rod, fittings, & welds. Damage to rod & case. Valves Holding valves for proper operation. Valves Control valve for leaks at fittings & between sections.

  • Page 21: Quarterly Inspection

    Maintenance Quarterly Inspection Frequency Inspection Description Status Daily All daily inspections. Monthly All monthly inspections. Rotation Sys Rotation bearing for proper torque of all mounting bolts. Hardware Base mounting bolts for proper torque. Structure All structural members for deformation, cracks, & corrosion. Base Outrigger beams &...
  • Page 22 10621 Owner’s Manual Quarterly Inspection Continued... Frequency Inspection Description Status Hyd Lines Hoses, fittings, & tubing for proper routing, leakage, blistering, deformation, & excessive abrasion. Pressure line(s) from pump to control valve Return line(s) from control valve to reservoir Suction line(s) from reservoir to pump...

  • Page 23: Annual Inspection

    Maintenance Annual Inspection Frequency Inspection Description Status Daily All daily inspection items. Monthly All monthly inspection items. Quarterly All quarterly inspection items. Hyd System Hydraulic fluid change per maintenance schedule. Controls Control valve calibration for correct pressures & relief valve settings. Valves Safety valve calibration for correct pressures &...

  • Page 24: Inspection Notes

    10621 Owner’s Manual Inspection Notes...

  • Page 25: Chapter 4 - Specifications

    Specifications Chapter 4 - Specifications Model 10621 Crane SPECIFICATION SHEET Crane Rating: 60,000 ft-lbs (8.29 ton-meters) Standard Boom Length: 11’0” (3.35 m) from CL of Crane Boom Extension: 1st stage: Hydraulic 60"(152.4 cm) 2nd stage: Hydraulic 60"(152.4 cm) Maximum Horizontal Reach: 21’0”(6.40 m) from CL of Crane...

  • Page 26: Capacity Chart - Decal Pn 45435

    10621 Owner’s Manual Capacity Chart - Decal PN 45435 Reach in Feet/Meters 10000 lbs Capacity in Pounds/Kilograms 4535 kgs 10000 lbs 7.01 m 4535 kgs 5425 lbs 6.40 m 2460 kgs 10000 lbs 4535 kgs 10000 lbs 5.49 m 3960 lbs...

  • Page 27: Chapter 5 - Decals

    Decals Chapter 5 - Decals Decals of Note Foot Crushing Hazard Decal Location: On each outrigger leg. Function: To inform the operator and other personnel in the work area of the hazard associated with the operation of the outriggers, the possible consequences should the hazard occur, and how to avoid the hazard.
  • Page 28 10621 Owner’s Manual Electrocution Hazard Decal Location: Each side of truck body, Front & Rear Bumper Function: To inform the operator and other personnel in the work area of the hazard associated with contact or proximity to electrical lines, the possible consequences should the hazard occur and how to avoid the hazard.
  • Page 29 Decals Two Block Hazard Decal Location: At Boom Tip Function: To inform the operator of the hazard associated with bringing the sheave(s) into contact with the hook, snatch block or load, the possible consequences should the hazard occur and how to avoid the hazard. PN: 12300 Instructional Decal Location: At Overload Switch Function: To inform the operator that...
  • Page 30 10621 Owner’s Manual Free Falling Manual Boom Decal Electrocution Hazard Decal Location: Inside Crane Compartment, on Location: Inside Crane Compartment, on Compartment Door Compartment Door Function: To inform the operator of the hazard Function: To inform the operator of the hazard...
  • Page 31 Decals Operation Hazard Decal Moving Boom Hazard Decal Location:Inside Crane Compartment, on Location:Inside Crane Compartment, on Compartment Door Compartment Door Function: To inform the operator of the need Function: To inform the operator and other for proper training, familiarity with safe personnel in the work area of the hazard operating procedures and, the possible associated with a moving boom, especially...

  • Page 32: Decal Kit Placement - Pn 45434

    10621 Owner’s Manual Decal Kit Placement - PN 45434 14,15 10621 ® ® Angle Indicator PN 45434 **THESE DECALS NOT INCLUDED WITH THE DECAL KIT *USE THESE DECALS WITH BODY PACKAGE 25159 DECAL WARNING MANUAL OVERRIDES 12451 DECAL HOISTING PERSONNEL...

  • Page 33: Chapter 6 - Installation

    According to Federal Law (49 cfr part 571), general guide for the installation of a Stellar each final-stage manufacturer shall 10621 Telescopic Crane on a Stellar Service complete the vehicle in such a manner that Body. Each installation is considered unique...

  • Page 34: Installation Overview

    Installation Overview 1. Determine that the mounting location for the 10621 crane is at least 20” x 21” (50.8 x 50.8 cm). 2. Use the detail below to drill 1.06” diameter holes into the mounting plate. Run tap on the threads of the base to be sure they are clean.

  • Page 35: Installation Details

    3. Use a crane or lifting device capable of lifting the weight of the Stellar crane. The Stellar 10621 weighs approximately 2150 lbs (975 kg). Note: cranes are shipped with rotation positioned at 200 degrees of 400 degree system. This will allow for easy installation of the crane and permanent connection of all hydraulic and electrical components prior to repositioning into the crane saddle.
  • Page 36 10621 Owner’s Manual Installation Details Continued... 9. Secure the crane using the mounting hardware provided. Note: longer or shorter cap screws may be required – recommended thread engagement into crane base is 1.75” – use grade 8, zinc plated cap screws only.

  • Page 37: Stability Procedure

    2. Set outriggers so that they make contact with firm, level footings. 3. Operate the crane under partial load to assure operator proficiency and proper machine function. 10621 Stability Data Max Horizontal Reach: 252” (From the center of rotation to boom tip) Stability Test Weight: 3360 lbs.

  • Page 38: Stability Capacity Chart

    10621 Owner’s Manual Stability Capacity Chart STABILITY CAPACITY CHART For a decal version of this capacity chart, please contact Stellar Customer Service at (800) 321-3741...

  • Page 39: Chapter 7 - Assembly Drawings

    Assembly Drawings Chapter 7 - Assembly Drawings Base Assembly - PN 18027 GASKET SHOWN AS REFERENCE PN 18027 11453 BEARING SWING DRIVE CAST BASE 6620 C6069 MOTOR HYD ROSS MK080613AAAB D1307 CAP SCR 0.50-13X1.25 SH 44551PC GUARD TTB 6620 CRANE LZR 13959 CAP SCR 1.00-8 X .63 PLASTIC 0479...

  • Page 40: Mast Assembly - Pn 52272

    10621 Owner’s Manual Mast Assembly - PN 52272 DO NOT GREASE THESE BUSHINGS PN 52272 27813 COLLAR 0.38X0.75X0.38 UHMW C5902 WASHER 0.63 SAE FLAT YELLOW GR8 D1034 CAP SCR 0.63-11X3.00 HHGR8 0343 WASHER 0.31 USS FLAT ZINC C0933 CAP SCR 0.31-18X4.50 HHGR5 0342 NUT 0.31-18 HHGR5 NYLOC...

  • Page 41: Main Boom - Pn 39800

    CAP SCR 0.38-16X1.25 HHGR5 12168 CAP SCR 0.38-16X9.00 HHGR5 4381 BUSHING BPC32DXR32 2.00X2.00 0340 WASHER 0.25 USS FLAT ZINC 0478 CAP SCR 0.25-20X0.50 HHGR5 0068 BUSHING BPC16DXR24 1.00X1.50 43476 INNER BOOM 10621/12621 13398PC PLATE WEAR PAD SUPPORT 9620 D1194PC PLATE ANGLE INDICATOR...

  • Page 42: Extension Boom Assembly - Pn 41546

    31132 SCREW #10-24X0.50 SH SS D0178 WASHER #10 SAE FLAT ZINC 35105 SWITCH LIMIT E1117-B9111-6C 43858 SHEAVE 10621 9.25 DIA .44R/1.88THK 43488PC PLATE CRADDLE 10621/12621 D0790 WASHER 0.50 SAE FLAT YELLOW GR8 10666 CAP SCR 0.50-13X1.25 HHGR8 0490 CAP SCR 0.31-18X3.50 HHGR5 0342 NUT 0.31-18 HHGR5 NYLOC...

  • Page 43: Extension Boom Assembly Flip Sheave - Pn 46309

    4974 CAP SCR 0.75-10X2.50 HHGR8 28859 CYLINDER EXT ASM 9620 13980P 13397PC PLATE 1ST EXT 9620 WEAR PAD 46310 EXT BOOM 2ND 10621/12621 FLIP SHEAVE 13400 PIN TEAR DROP 1.00X4.38 0530 CAP SCR 0.38-16X2.75 HHGR5 0347 NUT 0.38-16 HHGR5 NYLOC...

  • Page 44: Main Cylinder Assembly - Pn 43839

    10621 Owner’s Manual Main Cylinder Assembly - PN 43839 Manifold Assembly PN 41910 39425 MANIFOLD CBAL DOUBLE T11A WITH RELIEF 41906 VALVE C-BAL SUN CBCH-LJN 3500 C4961 PLUG STR HOLLOW HEX 0.38 6-HP5ON Cylinder Serial Tag Location Note: Main Cylinder uses...

  • Page 45: Extension Cylinder Assembly - Pn 28859

    Assembly Drawings Extension Cylinder Assembly - PN 28859 Cylinder Serial Tag Location Note: Upper/Lower Extension Cylinder uses Stellar Seal Kit P/N 20450 P/N 28859 13980P CYLINDER 13980 PAINTED 14442 TUBE ASM 0.38X23.25 EXT CYL 6620 14443 TUBE ASM 0.38X102.25 EXT CYL 6620 14115 MANIFOLD ASM 6620 EXT CBBD-LJN-XVN 14601 CAP SCR 0.38-16X2.25 SH ZC 11882 CAP SCR 0.38-16X1.75 SH ZC...

  • Page 46: Cable & Hook Assembly - Pn 44813

    10621 Owner’s Manual Cable & Hook Assembly - PN 44813 PN 44813 44641PC PLATE SNATCH BLOCK 10628/12628 43858 SHEAVE 10621 9.25 DIA .44R/1.88THK C0538 NUT 0.75-10 HHGR8 NYLOC C1030 CAP SCR 0.75-10X5.00 HHGR8 32086 CAP SCR 0.38-16X4.25 HHGR5 26762 HOOK 7 TON SWIVEL CROSBY 1028632...

  • Page 47: Wire Rope/Sheave Configurations

    Assembly Drawings Wire Rope/Sheave Configurations...
  • Page 48 10621 Owner’s Manual...

  • Page 49: Chapter 8 - Hydraulics - Electrical

    Hydraulics - Electrical Chapter 8 - Hydraulics - Electrical Hetronic Remote Assembly NOTE: P/N'S 25999 & 24958 ARE OPTIONAL COVERS FOR THE SWITCHES AND TRIGGER SEE NOTE 20088 CONTROL HANDLE HOUSING 4 FCTN HET 34107 CONTROL HANDLE FACE PLT 6 FCTN H2 24385 GUARD RADIO SWITCH 4 FCTN 35447...

  • Page 50: Control Kit - Pn 52268

    10621 Owner’s Manual Control Kit - PN 52268 PN 52268...

  • Page 51: Control Kit (Flip Sheave Version) - Pn 52269

    Hydraulics - Electrical Control Kit (Flip Sheave Version) - PN 52269 PN 52269...

  • Page 52: Hydraulic Kit - Pn 52476

    10621 Owner’s Manual Hydraulic Kit - PN 52476 24, 25 24, 25 PN 52476 52276...

  • Page 53: Valve Bank - Pn 52265

    Hydraulics - Electrical Valve Bank - PN 52265 HYDRAULIC SCHEMATIC PN 52265 25367 RELIEF VALVE 24685/24690 25368 SEAL KIT 25367 24960 VALVE FLW CTRL PRP/JP04C3150N 0-8 25369 SEAL KIT 24960/25381 25371 VALVE SOLND 3 POS 4 WAY TAND G04571 25373 SEAL KIT 25371/25372 44532 COIL 12VDC DUETSCH CAP012H...

  • Page 54: Hydraulic Installation

    10621 Owner’s Manual Hydraulic Installation 1. After mounting, locate the pressure and return lines. Note: Pressure line is 3/8” hose; Winch Case Drain Line is 3/8” hose; Return line is 1/2” hose. Hoses are terminated using swivel fittings. 2. Install hydraulic lines per diagram below.

  • Page 55: Winch Case Drain Installation

    Hydraulics - Electrical Winch Case Drain Installation Installing the winch case drain The winch case drain must run directly to the reservoir to ensure no back pressure in the line. Use 3/8” hydraulic hose and fittings rated for a minimum of 300 psi. Locate the winch case drain line at the bottom of the crane base as shown in Fig.

  • Page 56: Hydraulic System

    10621 Owner’s Manual Hydraulic System...

  • Page 57: Chapter 9 - Replacement Parts

    Replacement Parts Chapter 9 - Replacement Parts PART# DESCRIPTION C6069 HYDRAULIC SWING MOTOR 25367 RELIEF VALVE 25368 SEAL KIT - RELIEF VALVE 24960 FLOW CONTROL VALVE 25369 SEAL KIT - FLOW CONTROL VALVE 25371 SOLENOID VALVE TAND G04571 25373 SEAL KIT - SOLENOID VALVE 44532 COIL - 12VDC 41910...
  • Page 58 10621 Owner’s Manual 10621 Owner’s Manual...

  • Page 59: Chapter 10 - Troubleshooting

    Troubleshooting Chapter 10 - Troubleshooting This chapter will list a number of Problem: Not all crane functions operate using potential problems that may occur while the radio remote transmitter or crane operates intermittently. operating the crane. Most problems are Solutions: easily solved using the solutions portion •...
  • Page 60 10621 Owner’s Manual 10621 Owner’s Manual Problem: Winch will not hold load. Problem: Winch “Up”, Main Cylinder “Down”, Solutions: and Extension Cylinder “Out” are the only functions that don’t operate. • Make sure that the object being lifted does not exceed the rated capacity of the winch.

  • Page 61: Function Hetronic Radio Remote Troubleshooting

    Troubleshooting 6 Function Hetronic Radio Remote Troubleshooting If the system does not operate after normal start-up, follow the recommended troubleshooting sequence to help isolate the cause and determine corrective action. Transmitter Receiver • Is the E-Stop pushbutton pulled out? • Is the antenna plug securely •...

  • Page 62: Receiver Troubleshooting

    10621 Owner’s Manual 10621 Owner’s Manual Transmitter Troubleshooting Notice: When testing the transmitter, the receiver may become active resulting in system operation. Always assume the system is working and will respond when testing a transmitter. Status LED Troubleshooting LED Indication...

  • Page 63: 4 & 7 Function Hetronic Radio Remote Troubleshooting

    Troubleshooting 4 & 7 Function Hetronic Radio Remote Troubleshooting Problem: Transmitter will not communicate with the Receiver. (Note: Make sure the PTO is fully engaged when troubleshooting the problem.) 1. Is the main power switch on? (Control panel located inside the cab.) 2.

  • Page 64: Warranty Information

    Limited Warranty Statement Stellar Industries, Inc. (Stellar) warrants products designed and manufactured by Stellar to be free from defects in material and workmanship under proper use and maintenance. Products must be installed and operated in accordance with Stellar’s written instructions and capacities. The warranty period shall cover the following: Twelve (12) month warranty on parts from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) months from date of manufacture,...

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