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O
WNER
Safety, Installation, Maintenance, and Operation
Subject to Change without Notification.
© 2009 Stellar Industries, Inc.
'
S
14528 Telescopic Crane
Angle
Indicator
0
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
www.stellarindustries.com
M
ANUAL
14528
® ®
Manual Part No. 31713
Last Revision: 10/10/09
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Summary of Contents for stellar labs 14528
- Page 1 ’ WNER ANUAL Safety, Installation, Maintenance, and Operation 14528 Telescopic Crane 14528 ® ® Angle Indicator 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. Manual Part No. 31713 ©...
- Page 2 14528 Manual Revisions Date of Revision Section Revised Description of Revision September 1, 2005 Chapter 7: Updated Main Boom and Extension Boom drawings to Assembly Drawings reflect engineering changes. September 19, 2005 Chapter 7: Updated Cable and Hook assembly drawings to reflect Assembly Drawings engineering changes.
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Page 3: Table Of Contents
Table of Contents Table of Contents Introduction ............ii Chapter 1 - Safety. -
Page 4: Introduction
14528 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 14528 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.
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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 14528 Owner’s Manual...
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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
14528 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
14528 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 14528 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.
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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
14528 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
14528 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
14528 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 14528 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...
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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
14528 Owner’s Manual Inspection Notes... -
Page 25: Chapter 4 - Specifications
Specifications Chapter 4 - Specifications Model 14528 Crane SPECIFICATION SHEET Crane Rating: 70,000 ft-lbs (9.68 ton-meters) Standard Boom Length: 13’ (3.96 m) from CL of Crane Boom Extension: 1st stage: Hydraulic 90" (228.6 cm) 2nd stage: Hydraulic 90" (228.6 cm) Maximum Horizontal Reach: 28’... -
Page 26: Capacity Chart - Decal Pn 26204
14528 Owner’s Manual Capacity Chart - Decal PN 26204 Reach in Feet/Meters Capacity in Pounds/Kilograms 11000lbs 8075lbs 4990kg 3660kg 4675lbs 2120kg 14000lbs 6350kg 10400lbs 3400lbs 4720kg 1545kg 2825lbs 4575lbs 1280kg 14000lbs 2075kg 6350kg 14000lbs 6350kg 9350lbs 4240kg 3825lbs 1735kg 7025lbs... -
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 14528 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 14528 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...
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Page 32: Decal Kit Placement - Pn 27162
14528 Owner’s Manual Decal Kit Placement - PN 27162 14,15 14528 ® ® Angle Indicator **THESE DECALS NOT INCLUDED WITH THE DECAL KIT PN 27162 *USE THESE DECALS WITH BODY PACKAGE 12451 DECAL HOISTING PERSONNEL 41068 DECAL VB CONTROL MECH CRANE... -
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 14528 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 14528 crane is at least 25” x 22” (63.5 x 55.9 cm). 2. Use the detail below to drill 1.31” 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 14528 weighs approximately 3100 lbs (1406 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 14528 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.
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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. 14528 Stability Data Max Horizontal Reach: 336” (From the center of rotation to boom tip) Stability Test Weight: 2950 lbs. -
Page 38: Stability Capacity Chart
14528 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
Chapter 7 - Assembly Drawings Base Assembly - PN 26205 GASKET SHOWN AS REFERENCE PN 26205 25140 BEARING SWING DRIVE CAST BASE 14528 26206P MOTOR HYD ROSS MK080613AAAB D1295 CAP SCR 0.50-13X1.50 SH GR5 44551PC GUARD TTB 14528 CRANE LZR 26774 CAP SCR 1.25-7X0.63 PLASTIC... -
Page 40: Mast Assembly - Pn 41903
14528 Owner’s Manual Mast Assembly - PN 41903 PN 41903 4380 BUSHING 32DXR24 2.00X1.50 GARLOCK C6219 WASHER 0.75 SAE FLAT YELLOW GR8 4975 CAP SCR 0.75-10X3.50 HHGR8 ZY 44073 VB 4 SECT ELECT W/PROP STERLING12GPM 0343 WASHER 0.31 USS FLAT ZINC 7011 CAP SCR 0.31-18X5.50 HHGR5... -
Page 41: Main Boom - Pn 41902
CAP SCR 0.25-20X0.50 HHGR5 0335 CAP SCR 0.38-16X1.25 HHGR5 26753 SPACER ROPE GUIDE 14528 UHMW 26755 CAP SCR 0.38-16X10.00 HHGR5 D0178 WASHER #10 SAE FLAT ZINC D0894 SCREW #10-24X0.75 BTN HD SS 26751PC PLATE WEAR PAD SUPPORT 14528 D1194PC PLATE ANGLE INDICATOR... -
Page 42: Extension Boom Assembly - Pn 26757
26756 CYLINDER ASM 14528 EXT C6219 WASHER 0.75 SAE FLAT YELLOW GR8 4974 CAP SCR 0.75-10X2.50 HHGR8 ZY 24557 SHEAVE 14528 10.00 DIA .50R/1.94 THK 13399 PIN TEAR DROP 1.00X3.81 0343 WASHER 0.31 USS FLAT ZINC 0420 CAP SCR 0.31-18X0.75 HHGR5... -
Page 43: Main Cylinder Assembly - Pn 26197
Assembly Drawings Main Cylinder Assembly - PN 26197 Note: Main Cylinder uses Stellar Seal Kit P/N 35649 *CYLINDER BUSHINGS FOR REFERENCE ONLY PN 26197 26198 CYLINDER INNER 6.00X25.75 41514 TUBE ASM 0.38X9.00 MAIN CYL 14528 41910 MANIFOLD ASM DUAL 10-1CBAL-RLF-CHK... -
Page 44: Extension Cylinder Assembly - Pn 26756
24703 CYLINDER EXT 14528 2 STAGE 3.0/3.0 28840 MANIFOLD ASM14528 EXT CBBD-LJN-XVO 11882 CAP SCR 0.38-16X1.75 SH ZC 14601 CAP SCR 0.38-16X2.25 SH ZC 28842 TUBE ASM 0.50 X 72.69 EXT CYL 14528 28843 TUBE ASM 0.50X 119.75 EXT CYL 14528... -
Page 45: Cable & Hook Assembly - Pn 48597
Assembly Drawings Cable & Hook Assembly - PN 48597 PN 48597 48598PC PLATE SNATCH BLOCK 14528 24557 SHEAVE 14528 10.00 DIA .50R/1.94 THK 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 26761 WIRE ROPE .50 6X19 IWRC-XIP 120FT... -
Page 46: Valve Bank Assembly - Pn 44073
14528 Owner’s Manual Valve Bank Assembly - PN 44073 HYDRAULIC SCHEMATIC PN 44073 50914 VALVE SOLND 3 POS 4 WAY TAND 50915 VALVE SOLND 3 POS 4 WAY OPEN... -
Page 47: Wire Rope/Sheave Configurations
Wire Rope/Sheave Configurations... - Page 48 14528 Owner’s Manual...
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Page 49: Chapter 8 - Hydraulics - Electrical
Hydraulics - Electrical Chapter 8 - Hydraulics - Electrical Control Kit - PN 41654 PN 41654... -
Page 50: Wiring Harness - Pn 41655
14528 Owner’s Manual Wiring Harness - PN 41655 PN 41655... -
Page 51: Hydraulic Kit - Pn 26771
Hydraulics - Electrical Hydraulic Kit - PN 26771 PN 26771... -
Page 52: Hydraulic Installation
14528 Owner’s Manual Hydraulic Installation 1. After mounting, locate the pressure and return lines. Note: Pressure line is 1/2” hose; Return line is 3/4” 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
Hydraulics - Electrical Hydraulic System P/N 26209 Valve Identification Valve Item #3 P/N 31077-G0657A1 Valve Item #4 P/N 31078-G06591... - Page 54 14528 Owner’s Manual...
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Page 55: Chapter 9 - Replacement Parts
Replacement Parts Chapter 9 - Replacement Parts PART# DESCRIPTION SUGGESTED QTY 26206P HYDRAULIC SWING MOTOR 31075 RELIEF VALVE 42828 SEAL KIT - RELIEF VALVE 50913 FLOW CONTROL VALVE 50914 SOLENOID VALVE TAND G04571 50915 SOLENOID VALVE OPEN G04591 44532 COIL - 12VDC 16154 MANIFOLD ASM - MAIN CYLINDER 28840... - Page 56 14528 Owner’s Manual...
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Page 57: 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 58 14528 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.
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Page 59: 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 60: Transmitter Troubleshooting
14528 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 Possible Cause LED is off... -
Page 61: 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 62: 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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