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stellar labs 7621 Owner's Manual

Heavy-duty telescopic cranes
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Models:
7621
7630
9621
9630
10621
10630
12621
12630
14530
Notice: A copy of this manual must remain with the equipment at all times.
For a printable download copy, please visit: www.stellarindustries.com
Subject to Change without Notification.
© 2017 Stellar Industries, Inc.
Safety • Operation • Maintenance • Troubleshooting
Stellar Industries, Inc.
190 State Street
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
www.stellarindustries.com
Heavy-Duty
Telescopic Cranes
Owner's Manual
PO Box 169
Last Revision: 2/14/17

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  • Page 1 Heavy-Duty Telescopic Cranes Owner’s Manual Safety • Operation • Maintenance • Troubleshooting Models: 7621 7630 9621 9630 10621 10630 12621 12630 14530 Notice: A copy of this manual must remain with the equipment at all times. For a printable download copy, please visit: www.stellarindustries.com Stellar Industries, Inc.
  • Page 2 Heavy-Duty Manual Revisions Date of Revsion Section Revised Description of Revision 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 service@stellarindustries.com Order Parts parts@stellarindustries.com...

  • Page 3: Table Of Contents

    Table of Contents Introduction ................................iv Chapter 1 - Operation ..............................1 General Operation ..............................1 Pre-Operation Inspection ............................1 Job Site Setup ................................. 2 Step 1: Disengage drive axle and set the parking brake.................. 2 Step 2: Engage the PTO............................2 Step 3: Turn on power to the crane.

  • Page 4: Introduction

    Introduction Stellar Cranes are designed to provide safe and dependable service for a variety ® of operations. With 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.

  • Page 5: Chapter 1 - Operation

    Chapter 1 - Operation Safety should be the n umber 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. This chapter contains information regarding the safety and operation of Stellar® manufactured EC Series Telescopic Cranes and should be read and understood completely by everyone working with or near the crane before putting the unit into operation.

  • Page 6: Job Site Setup

    Job Site Setup Thoroughly plan the lift by understanding the work site area and your loads before positioning the vehicle. For a complete and detailed description of job site setup, please refer to the AEM Safety Manual (Form C-70-2). Consider the following: •...

  • Page 7: Step 3: Turn On Power To The Crane

    Step 3: Turn on power to the crane. To initiate electrical power to the crane, activate the button labeled ‘Main Power’ on the VEC control panel. The VEC control panel is commonly mounted on the floor in the middle of the vehicle cab. Feel free to activate any other button functions needed for the job.

  • Page 8: Step 5: Operate The Crane

    Step 5: Operate the crane. Using the Radio Remote: To operate the crane using the radio remote control: 1. Activate and hold the desired toggle switch (See next page for details). 2. While holding the toggle, gently pull the variable speed trigger until the crane begins to move.
  • Page 9 Lifting the load: Lift the load slightly off the ground to check the safety of the cargo. Consider the following: • Make certain that the stabilizers are positioned on flat, stable ground. WARNING • Never exceed manufacturer’s load charts and ratings. These ratings are based on the machine’s hydraulic, mechanical, and structural design rather than stability.

  • Page 10: Step 6: Stow The Crane

    Step 6: Stow the crane. Once you have performed your lift and are ready to shut down the work site: • Retract all extensions. • Winch up to bring the snatch block within 3 feet of the boom tip. • Lower the crane boom down far enough so that the snatch block is within comfortable reach.

  • Page 11: Step 9: Release The Parking Brake

    Step 9: Release the parking brake. The parking brake must be released before moving the truck. WARNING Make certain that any air tanks are completely drained before moving the truck. Radio Remote Control Functions A. Optional Speed Control/Compressor Start/Stop Toggle: Push up to start or stop the optional speed control.

  • Page 12: Radio Remote Feedback And Boost Mode

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

  • Page 13: Radio Remote Control Features

    Radio Remote Control Features Radio Remote Sleep Mode The radio remote control enters sleep mode after about 15 seconds of inactivity. Activate a toggle switch to re-link the transmitter to the receiver. After re-linking, activate the desired toggle to continue operation. E-Stop Button The Radio remote control is equipped with an emergency stop button.

  • Page 14: Wire Rope/Sheave Configurations

    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 15: Personal Fall Protection With Stellar ® Equipment

    Personal Fall Protection with Stellar Equipment ® OSHA Provisions Before proceeding, all users must read, understand, and follow the provisions located in OSHA 29 CFR 1926.1423, specifically paragraphs (g) Anchorage criteria, (j) Anchoring to the load line, and (k) Training. Please note that OSHA sections 1926.502(d)(15) and 1926.502(e)(2) are cross-referenced in this section and need to be read, understood, and followed by each user.

  • Page 16: Safety Decals Of Note

    Safety Decals of Note Safety decals serve to inform the viewer of the hazard type, how to avoid the hazard, and the consequences of not avoiding the hazard. Decals are considered safety equipment. They must be maintained, as would other safety devices.

  • Page 17: Crane Compartment

    Crane Compartment DANGER Decal Part Number: 4186 Electrocution Hazard Decal Location: Crane Compartment Death or serious injury will Hazard Type: Electrocution Hazard result from touching tethered Consequences: Will result in death or serious injury. remote if crane, load, or vehicle Avoidance: Maintain safe clearance from high becomes electrically charged.

  • Page 18: Main Boom

    Main Boom WARNING Decal Part Number: 12451 Decal Location: Main Boom Fall Hazard Hazard Type: Fall Hazard Hoisting personnel on boom, Consequences: Can result in death or serious injury. hook, load, or loadline can result in death or serious injury. Avoidance: Never use the crane to hoist personnel.

  • Page 19: Crane Horse Head

    Crane Horse Head WARNING Boom Down Decal Part Number: 12300 Decal Location: Crane Horse Head Hazard Type: Misuse Hazard Consequences: Can result in death or serious injury. Avoidance: Never allow the hook block to contact the boom tip by hoisting up, extending or lowering Misuse Hazard the boom.
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  • Page 21: Chapter 2 - Maintenance

    Chapter 2 - Maintenance Maintenance is an important part of extending the life of any Stellar Telescopic Crane. ® Performing key maintenance items on a scheduled program will prevent unnecessary downtime. General Maintenance Guidelines Before performing any maintenance to the crane, •...

  • Page 22: Hydraulic Oil/Filter Maintenance

    Hydraulic Oil/Filter Maintenance Stellar Industries recommends the first filter change to occur after the first 250 hours of service. 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 23: Rotation Gear Bearing 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 24: Gear-Bearing Bolt Maintenance

    Gear-Bearing Bolt Maintenance 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 Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical grade and size.

  • Page 25: Rotation Gear Bearing Thread Tightening Procedure

    Rotation Gear Bearing Thread Tightening Procedure GRADE 5 GRADE 8 GRADE 9 Size Bolt DIA Plain Plated Plain Plated Plated (DIA-TPI) (Inches) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) 5/16-18 0.3125 3/8-16 0.3750 7/16-14 0.4375 1/2-13 0.5000 9/16-12 0.5625 5/8-11 0.6250 3/4-10 0.7500 7/8-9 0.8750...

  • Page 26: Rotation Gear Bearing Tilt Test

    It should not exceed the following tilt measurements: • Stellar Models 7621 - 12630 = 0.060” (1.524 mm) • Stellar Model 14530 = 0.070” (1.778 mm) Step 6: Return the crane to vertical position. The dial indicator should return to calibration.

  • Page 27: Rotation Gear Bearing Worm End Play & Backlash

    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 28: Face Seal/O-Ring Size Chart

    Face Seal/O-Ring Size Chart Hose Fitting Face Seal (A) O-ring Boss (B) Size Size Stellar Stellar ® ® 1/4” C2027 D1245 3/8” C2028 D1246 1/2” C2029 D1247 5/8” 32223 D1248 3/4” D1244 D1249 Page 24 | Stellar Heavy-Duty Telescopic Crane Owner’s Manual ®...

  • Page 29: Lubrication Recommendations

    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 Moly Grease 936SF Heavy (Stellar PN 4460)
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  • Page 31: Chapter 3 - Troubleshooting

    Chapter 3 - Troubleshooting This chapter will list a number of potential ® problems that may occur while operating the D AT E crane. Most problems are easily solved using PATENT INFORMATION the solutions portion of this chapter. If problems http://www.stellarindustries.com/ip persist, please contact Customer Service at M O D E L NO .
  • Page 32 will not operate. If no power is going to the coil solenoid, check wiring connections on wire harness plug connector for broken wires, loose connection or poor crimp. If power is going to the solenoid valve, it may not be opening to allow hydraulic oil to the function that is not operating.
  • Page 33 Customer Service for instructions. • Make sure the proportional valve is receiving 12V power when fully engaging the transmitter trigger. If there is not 12V power while pulling the trigger, check for loose connections inside the transmitter or replace the handle trigger assembly. If the proportional valve is receiving 12 volts, loosen the solenoid holding nut and check to see if the solenoid coil is magnetizing.

  • Page 34: Cdt

    Stellar Radio Remote Troubleshooting ® ™ Note: The System Error Light can have different flash patterns. Please note these patterns to assist Stellar Customer Service when troubleshooting the radio system. Symptom Probable Cause Remedy Check batteries to ensure a full Transmitter batteries fully charge.

  • Page 35: Synchronizing The Receiver And Transmitter

    Synchronizing the Receiver and Transmitter 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. NOTE: The star in the Stellar logo is the Learning Function button.

  • Page 36: Stellar ® Cdt Radio Error Code Troubleshooting

    Stellar ® CDT Radio Error Code Troubleshooting Error Input 1 (Pressure Transducer cylinder base end) Harness wire PD1 Problem: The Boom down, Extension out, and Winch up functions do not operate and the radio receiver is displaying Input error 1. Solutions: Check for broken or loose wires going to the transducer on the main lift cylinder.

  • Page 37: Manual Operation

    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. Operate Solenoids. Using the identification decal as a guide, slide the knurled sleeve out and then push or pull to operate the desired function.

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