stellar labs 9628 Owner's Manual

Telescopic crane

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Owner's Manual

Safety, Installation, Maintenance, and Operation

Subject to Change without Notification.

9628 Telescopic Crane

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com

Manual Part No. 31711

Last Revision: 7/20/06

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Page 1 Owner’s Manual Safety, Installation, Maintenance, and Operation 9628 Telescopic Crane Stellar Industries, Inc. 190 State Street PO Box 169 Garner, IA 50438 800-321-3741 Fax: 641-923-2811 www.stellarindustries.com Manual Part No. 31711 Subject to Change without Notification. Last Revision: 7/20/06 © 2006 Stellar Industries, Inc.
Page 2 Introduction Stellar cranes are designed to provide safe and improvement or commercial/production dependable service for a variety of operations. purposes. This right is kept with no requirement With proper use and maintenance, Stellar or obligation for immediate mandatory updating cranes will operate at peak performance for of this manual.
Page 3: Table Of Contents
Table of Contents Chapter 1 - Safety Chapter 2 - Operation Chapter 3 - Maintenance Chapter 4 - Specifications Chapter 5 - Decals Chapter 6 - Installation Chapter 7 - Assembly Drawings Chapter 8 - Hydraulics/Electrical Chapter 9 - Replacement Parts Chapter 10 - Troubleshooting 10-1...
Page 4: Chapter 1 - Safety
Chapter 1 - Safety regulations and accident-prevention equipment. Please Read the Following Carefully! This portion of the manual contains information Do not wear rings, wristwatch, jewelry, loose- regarding all Stellar manufactured cranes. fitting or hanging clothing such as ties, torn Some items contained within this chapter may garments, scarves, unbuttoned jackets or not apply to your specific equipment.
Page 5 The safety instruction plates, notices, load charts Do not walk under suspended loads. and any other sticker applied to the crane or service body must be kept legible and in good Do not position any load over a person nor condition.
Page 6 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 7: Chapter 2 - Operation
Chapter 2 - Operation Job-Site Set-Up 1. Engage the PTO Thoroughly plan the lift before positioning A. Engage the parking the vehicle. Consider the following: brake. B. Place the 1. The vehicle should be positioned in an area transmission in the free from overhead obstructions to eliminate the Neutral position.
Page 8 6 Function Remote This radio remote is the standard for the 5520, 6620, 6628, 9620, 9628, 10620, and 10628 model Stellar Cranes. NOTE: The radio control is 4.Operate Crane an electrical device. Please A. Turn on necessary power to the crane.
Page 9 4 Function Remote This corded remote is the standard for the 3315 and 4420 model Stellar Cranes. 6 Function Remote This remote is the standard for the 14528 model Stellar Cranes. Chapter 2 - Operation...
Page 10 Manual Operation Crane Precautions 1. Movement of the control levers should be If the remote control malfunctions, follow slow and smooth to meter oil flow for safe these steps to operate the crane manually: operation. Avoid jerky sudden movements. 1. Activate Flow Control. Turn the override 2.
Page 11 Operator Information OPERATOR REQUIREMENTS OPERATOR CONDUCT 1. Operation is limited to the following 1. Operators will not engage in any operation people: that would cause them to divert attention away A. Designated individual. from the operation of the crane. B. Trainees under direct supervision of 2.
Page 12: Chapter 3 - Maintenance
Chapter 3 - Maintenance Daily Inspection WARNING - Read the Following before Daily Inspection should occur each day before performing any maintenance on the the crane is put into use. Each day, inspect crane. the crane for all of the following: 1.
Page 13 Weekly Inspection Weekly Inspection should occur at the Service beginning of every work week. Each week, The following general suggestions should inspect the crane for all of the following: be helpful in analyzing and servicing your 1. Lubrication of points required by lubrication crane.
Page 14 Stellar 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)
Page 15 Wire Rope Maintenance Wire Rope Inspection Points Only the surface wires of the rope need While inspection of the entire rope is required, to be inspected. This inspection will be attention should be directed to these critical concerned with discovering damage that points: may be an immediate hazard.
Page 16 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 Grade 8 Grade 5 Grade 9 or hydraulic component failure. The valve is checked in the following manner: 1.
Page 17 Stellar Industries Inspection Checklist for Telescopic Boom Cranes Use of this checklist is subject to terms of the Stellar Type of Inspection (check one) Warranty information. Additional copies of this checklist Daily Quarterly (if deficiency found) can be obtained by contacting Stellar Customer Service at (800) 321-3741 or by download at: Monthly Annual...
Page 18 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 19 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. Valves Control valve linkages for wear, smoothness of operation &...
Page 20 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 21 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 Pressure line(s) from control valve to each function Load holding valve pipe(s) and hose(s) Other...
Page 22 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 23 Inspection Notes Chapter 3 - Maintenance 3-12...
Page 24: Chapter 4 - Specifications
Chapter 4 - Specifications Model 9628 Crane SPECIFICATION SHEET Crane Rating: 55,000 ft-lbs (7.6 ton-meters) Standard Boom Length: 12’ 4” (3.28 m) from CL of Crane Boom Extension: 1st stage: Hydraulic 96" (244 cm) 2nd stage: Hydraulic 96" (244 cm) Maximum Horizontal Reach: 28’...
Page 25 STELLAR 9628 Chapter 4 - Specificaitons...
Page 26: Chapter 5 - 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 27 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 28 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.
Page 29 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 associated with free falling manual boom associated with overloading the crane, the possible extensions, the possible consequences should the consequences should the hazard occur, and how to...
Page 30 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 for Function: To inform the operator and other proper training, familiarity with safe operating personnel in the work area of the hazard procedures and, the possible consequences associated with a moving boom, especially while...
Page 31 Decal Placement Chapter 5 - Decals...
Page 32 Chapter 7 - Assembly Drawings Base Assembly P/N 18027 ) " Chapter 7 - Assembly Drawings...
Page 33 Mast Assembly P/N 18028 Chapter 7 - Assembly Drawings...
Page 34 0343 WASHER 0.31 USS FLAT ZINC 0420 CAP SCR 0.31-18X0.75 HHGR5 27813 COLLAR 0.38X0.75X0.38 UHMW 27841 FLAT WINCH MTG 9628 2 SPEED 30750 CAP SCR 0.50-13X3.50 HHGR8 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 14066 RELAY LATCHING MODULE TSD LRM02 8649 SCREW #8X0.38 SHEET MTL PHIL PH...
Page 35 Main Boom P/N 23451 & & & & Chapter 7 - Assembly Drawings...
Page 36 Extension Boom Assembly P/N 23452 Chapter 7 - Assembly Drawings...
Page 37 Main Cylinder Assembly Note: Main Cylinder uses Stellar Seal Kit P/N 25081 Cylinder Serial Tag Location P/N 24144 Chapter 7 - Assembly Drawings...
Page 38 Extension Cylinder Assembly Cylinder Serial Tag Location Note: Upper/Lower Extension Cylinder uses Stellar Seal Kit P/N C6304 P/N 28856 Chapter 7 - Assembly Drawings...
Page 39 Cable & Hook Assembly P/N 24209 Chapter 7 - Assembly Drawings...
Page 40 Chapter 7 - Assembly Drawings...
Page 41: Chapter 6 - Installation
Installation Notice This chapter is designed to serve as a general According to Federal Law (49 cfr part 571), each guide for the installation of a Stellar 9628 final-stage manufacturer shall complete the Telescopic Crane on a Stellar Service Body.
Page 42 3. Use a crane or lifting device capable of lifting the weight of the Stellar crane. The Stellar 9628 weighs approximately 2850 lbs (1295 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 43 3. Use a crane or lifting device capable of lifting the weight of the Stellar crane. The Stellar 9628 weighs approximately 2850 lbs (1295 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 44 Installation Details Continued... 9. Secure the crane using the mounting hardware provided (see the detail on page 6-2). 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. 10.
Page 45 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. 9628 Stability Data Max Horizontal Reach: 339” (From the center of roation to boom tip) Stability Test Weight: 2270 lbs.
Page 46 STABILITY CAPACITY CHART For a decal version of this capacity chart, please contact Stellar Customer Service at (800) 321-3741 Chapter 6 - Installation...
Page 47: Chapter 8 - Hydraulics/Electrical
Chapter 8 - Hydraulics - Electrical Control Kit P/N 18932 Chapter 8 - Hydraulics-Electrical...
Page 48 2 SPEED WINCH POWER - ENABLE 2 SPEED WINCH PN 27974 27975 DECAL 2-SPEED OPERATION 27969 WIRE HARNESS 9628 2 SPEED WINCH 0333 NUT 0.25-20 HHGR5 NYLOC C6021 CAP SCR 0.25-20X0.75 BTNHD SS 6832 DECAL MAGNET COVER-2.94DIA 6629 MAGNET 70# 2.80 DIA 16255 BATTERY CHARGER W/BTRY 110-3.6V...
Page 49 Hydraulic Kit P/N 13971 Chapter 8- Hydraulics - Electrical...
Page 50 HOSE-HYD .38 X 20 1ref 27979 HOSE-HYD .38 X 13 1ref 13030 HOSE-HYD .38 X 39 2ref 13029 HOSE-HYD .38 X 22.50 2ref 13028 HOSE-HYD .38 X 17 2ref 27977 HOSE KIT,9628 2-SPEED (incl:2-8) ITEM PART No. DESCRIPTION Chapter 8 - Hydraulics/Elecrical...
Page 51 Valve Bank P/N 24685 Valve Identification Valve Item #3 P/N 25371-GS0457 Valve Item #4 P/N 25372-GS0459 Chapter 8 - Hydraulics/Elecrical...
Page 52 Hydraulic Installation 1. After mounting, locate the pressure and return lines. Note: Pressure line is 3/8” hose; Return line is 1/2” hose. Hoses are terminated using swivel fittings. 2. Install hydraulic lines per diagram below. Note: Outrigger valve supplies oil to crane using the Power Beyond feature.
Page 53 Hydraulic System Chapter 8 - Hydraulics-Electrical...
Page 54: Chapter 9 - Replacement Parts
Chapter 9 - Replacement Parts PART# DESCRIPTION SUGGESTED QTY 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 25372 SOLENOID VALVE OPEN G04591 25373 SEAL KIT - SOLENOID VALVE 25370...
Page 55: Chapter 10 - Troubleshooting
Chapter 10 - Troubleshooting Problem: Not all crane functions operate This chapter will list a number of using the radio remote transmitter or crane potential problems that may occur operates intermittently. while operating the crane. Most Solutions: problems are easily solved using •...
Page 56 Problem: Winch will not hold load. Problem: Winch “Up”, Main Cylinder Solutions: “Down”, 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. Solutions: Refer to the capacity chart.
Page 57 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 connected? •...
Page 58 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 Possible Cause LED is off Transmitter is off LED flashes Transmitter is operating in a normal mode LED will not light when any button is pushed, or LED...
Page 59 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 60 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, Twelve (12) month repair labor, and...
Page 61 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, Twelve (12) month repair labor, and...

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