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stellar labs CDT 5521 Owner's Manual

Heavy-duty crane
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safety • Operation • Maintenance • troubleshooting
Models:
5521
7621
7628
9621
9628
10621
10628
12621
12628
14528
Subject to Change without Notification.
© 2013 Stellar Industries, Inc.
H
eavy
O
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
www.stellarindustries.com
-D
C
uty
' M
wners
anual
rane
®
TM
Last Revision: 04/29/13

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Summary of Contents for stellar labs CDT 5521

  • Page 1 eavy rane ’ M wners anual safety • Operation • Maintenance • troubleshooting Models: 5521 7621 7628 9621 9628 10621 10628 12621 12628 14528 ® Stellar Industries, Inc. 190 State Street PO Box 169 Garner, IA 50438 800-321-3741 Fax: 641-923-2811 Subject to Change without Notification.
  • Page 2 Heavy-Duty Crane Manual Revisions...

  • Page 3: Table Of Contents

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

  • Page 4: Introduction

    Stellar® Heavy-Duty Crane Owner’s Manual Introduction Stellar® Cranes are designed to provide Please be aware that some sections of this safe and dependable service for a variety manual contain information pertaining to of operations. With proper use and Stellar manufactured cranes in general and maintenance, these cranes will operate at may or may not apply to your specific peak performance for many years.

  • Page 5: Chapter 1 - Safety

    Safety Chapter 1 - Safety Please Read the Following Carefully! This fitting or hanging clothing such as ties, torn portion of the manual contains information garments, scarves, unbuttoned jackets or regarding all Stellar manufactured cranes. unzipped overalls, which could get caught up Some items contained within this chapter may in the moving parts of the crane.
  • Page 6 Stellar® Heavy-Duty Crane Owner’s Manual STABILITY Do not position any load over a person nor Know the crane components and their should any person be permitted to place him or capabilities and limitations. Overloading the herself under a load. crane may result in serious injury to self and others, and damage to the equipment and Do not use the boom or the winch to drag a immediate surroundings.

  • Page 7: Safety Decals Of Note

    Safety Safety Decals of Note DANGER DANGER ELECTROCUTION HAZARD This remote control box does THIS CRANE IS NOT INSULATED not provide you and others with DEATH OR SERIOUS INJURY protection against WILL RESULT FROM CONTACT ELECTROCUTION OR INADEQUATE CLEARANCE HAZARD •...
  • Page 8 Stellar® Heavy-Duty Crane Owner’s Manual DANGER DANGER FAILURE TO OBEY THE FOLLOWING FAILURE TO OBEY THE FOLLOWING WILL RESULT IN WILL RESULT IN DEATH OR SERIOUS INJURY DEATH OR SERIOUS INJURY • Follow all recommended inspections and INSTABILITY OR maintenance practices listed in the equipment manufacturer’s manuals.
  • Page 9 Safety DANGER DANGER TWO BLOCKING THE CRANE WILL CAUSE STOWING & UNFOLDING BOOM DEATH, SERIOUS INJURY WILL CAUSE DEATH OR SERIOUS INJURY OR PROPERTY DAMAGE Stand on the opposite side of the boom Do not allow the hook block to contact the boom tip by hoisting up, extending or when unfolding or stowing the crane.
  • Page 10 Stellar® Heavy-Duty Crane Owner’s Manual WARNING WARNING OVERLOAD HAZARD MOVEMENT HAZARD Tampering with overload device voids warranty. Failure to return the valve Overloaded crane may let the bank manual overrides to load down to the ground. the neutral position can Winch up, boom down, and result in unexpected extend out will be...

  • Page 11: Chapter 2 - Operation

    Operation Chapter 2 - Operation This chapter contains information regarding the operation of Stellar® Telescopic 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 Setup Thoroughly plan the lift by understanding your loads and distances before positioning the vehicle.

  • Page 12: Step 1: Set The Parking Brake

    Stellar® Heavy-Duty Crane Owner’s Manual Step 1: Set the parking brake. The parking brake must be set before any operation. Step 2: Engage the PTO. 1. Make certain that the transmission is in neutral/park and that the PTO switch is in the ‘off’...

  • Page 13: Step 5: Operate The Crane

    Operation Step 5: Operate the crane. Operators should have a firm understanding very cautious when releasing the snatch of ANSI B30.5 - Section 5-3.2 Operating block. Maintain control to avoid personal Practices and AEM Safety Manual (Form C- injury or damage to any equipment. 70-2)prior to operation of the crane.

  • Page 14: Radio Remote Control Functions

    Stellar® Heavy-Duty Crane Owner’s Manual Radio Remote Control Functions A. Optional Speed Control/Compressor Mode’). If the remote loses connection Start/Stop Toggle: Push up to start or stop with the transmitter, use this button to the optional speed control. Push down to reconnect.

  • Page 15: Radio Remote Control Feedback And Boost Mode

    Operation Radio Remote Feedback and Boost Mode CDT Remote Feedback When the crane reaches 100% capacity, an If the crane starts to approach full capacity overload shutdown will be initiated. The or an overload situation, the Stellar CDT operator will need to set the load down sensory feedback system will respond: and reposition the truck or activate the Stellar CDT Boost Mode (If equipped).

  • Page 16: Radio Remote Control Features

    Stellar® Heavy-Duty Crane Owner’s Manual Radio Remote Control Features Radio Remote Sleep Mode Radio Remote Backup Cord The radio remote control enters sleep mode If the handheld transmitter has a system after about 15 seconds of inactivity. problem that makes the radio function un- Activate a toggle switch to re-link the usable, use of the back-up cord may be transmitter to the receiver.

  • Page 17: Step 6: Stow The Crane

    Operation Step 6: Stow the crane. Once you have performed your lift and are ready to shut down the work site: 1. Retract all extensions. 2. Winch up to bring the snatch block within 3 feet of the boom tip. 3.

  • Page 18: Wire Rope/Sheave Configurations

    Stellar® Heavy-Duty Crane Owner’s Manual Wire Rope/Sheave Configurations Standard 2-Part Line Sheave Flipped Down Capacities as shown on load chart. PIN "A" PIN "B" Single Part Line Sheave Flipped Down PIN "B" 1) Remove PIN “A” from boom tip. 2) Route wire rope through snatch block. 3) Pin wire rope to snatch block as shown with PIN “A”...

  • Page 19: Chapter 3 - Maintenance

    Maintenance Chapter 3 - Maintenance Maintenance is an important part of 6. Before performing any maintenance on extending the life of any Stellar® Telescopic hydraulic components, relieve hydraulic Crane. Greasing pivot points and rotation oil pressure from all hydraulic circuits. gear bearing on a scheduled maintenance Move pedals and control levers program will prevent unnecessary...

  • Page 20: Hydraulic Oil/Filter Maintenance

    Stellar® Heavy-Duty Crane Owner’s Manual Hydraulic Oil/Filter Maintenance Stellar Industries recommends the first filter change to occur after the first 250 hours of serv- ice. The second, and every subsequent change, should occur after every 1,000 hours of service. By following these guidelines, the hydraulic oil should last up to 6,500 hours. Note: These recommendations are based on normal working parameters.

  • Page 21: Rotation Gear Bearing Maintenance

    Maintenance Rotation Gear Bearing Maintenance Rotation Worm Gear and Open Gear Teeth Use a heavy Moly Lube grease (Stellar PN 4460) to lubricate the worm gear and open gear teeth of the rotation bearing. Slowly rotate the crane while pumping the grease between the worm and rotation gear.

  • Page 22: Torque Data Chart

    Stellar® Heavy-Duty Crane Owner’s Manual 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.
  • Page 23 Maintenance Rotation Gear Bearing Thread Tightening Procedure Step 1: Refer to the Torque Data Chart on the previous page to determine the proper torque value based on the size of bolt used. Step 2: Torque all bolts to approximately 40% of the specificed torque value using the tightening sequence shown above.
  • Page 24 Stellar® Heavy-Duty Crane Owner’s Manual Rotation Gear Bearing Tilt Test Step 1: Place crane in vertical position. Step 2: Place a dial indicator on the pinion cover plate at the back side of the mast. Step 3: Set the dial indicator to 0. Step 4: Lower the crane to the horizontal position.
  • Page 25 Maintenance Rotation Gear Bearing Worm End Play & Backlash Stellar® Telescopic Cranes have an integral base and worm drive rotation system. Backlash is the shortest distance between non-driving tooth surfaces in mating gears. Measure backlash using a feeler gauge at or near the pitch diameter and tangent to the gear. Locate High Tooth To set both Worm End Play and Backlash, first locate the high tooth on the gear.

  • Page 26: Lubrication Recommendations

    Stellar® Heavy-Duty Crane Owner’s Manual Lubrication Recommendations Crane Lubrication Component Location Recommendation Reservoir Below –5˚F High VI, low pour, ISO 22, AW hydraulic oil Hydraulic System -5˚F to 90˚F High VI, low pour, ISO 32, AW hydraulic oil Above 90˚F ISO 46, AW hydraulic oil Open Gear Teeth Crane Rotation Gear Lithium complex, NLGI 2 grease with moly...

  • Page 27: Chapter 4 - Troubleshooting

    Troubleshooting Chapter 4 - Troubleshooting This chapter will list a number of potential troubleshooting guide at the end of this chapter. problems that may occur while operating • Make sure that the parking brake is engaged. the crane. Most problems are easily solved •...
  • Page 28 Stellar® Heavy-Duty Crane Owner’s Manual Now operate the winch. If the brake still does Problem: Winch “Up”, Main Cylinder “Down”, and not hold, contact Customer Service at Stellar. Extension Cylinder “Out” are the only functions that don’t operate. Problem: Winch will not hold load. Solutions: Solutions: •...

  • Page 29: Stellar ® Cdt Radio Error Code Troubleshooting

    Troubleshooting Stellar® CDT™ Radio Remote Troubleshooting Symptom Probable Cause Remedy Check batteries to ensure a full Transmitter batteries fully charge. Replace with fully charged discharged batteries if necessary. System will not initialize after normal start-up procedure Check the receiver to be sure power No power to the receiver is applied.

  • Page 30: Synchronizing The Receiver And Transmitter

    Stellar® Heavy-Duty Crane Owner’s Manual Synchronizing the Receiver and Transmitter If the receiver and transmitter are not communicating, use the following procedure to re- synchronize the unit: YNCHRONIZING THE ECEIVER AND RANSMITTER DDRESS AND HANNELS 1. Press and hold the START switch on the transmitter while pressing and holding the Learning Function button on the receiver.
  • Page 31 Troubleshooting Stellar ® CDT Radio Error Code Troubleshooting Error Input 1 (Pressure Transducer cylinder Error Input 3 (Inclinometer) base end) Harness wire PD1 Problem: The crane will not lift the rated Problem: The Boom down, Extension out, load per the capacity chart and the Boom and Winch up functions do not operate and up, Extension out, and Winch up functions the radio receiver is displaying Input error 1.

  • Page 32: Manual Operation

    Stellar® Heavy-Duty Crane Owner’s Manual Models 5521-12628 Manual Operation If the remote control malfunctions, follow these steps to operate the crane manually: 1. Activate Flow Control. Turn the override screw on proportional flow control counter-clockwise. Full adjustment is between three and five turns. 2.

This manual is also suitable for:

Cdt 7621Cdt 7628Cdt 9621Cdt 9628Cdt 10621Cdt 10628 ... Show all

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