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Small OTR
Service Cranes
Owner's Manual
Safety • Operation • Maintenance • Troubleshooting
Model 3200
Model 2200
Model 4500
Model 6000
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.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
Subject to Change without Notification.
Rev 1
www.stellarindustries.com
© 2021 Stellar Industries, Inc.
PN 89711
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Table of Contents
Related Manuals for stellar labs Small OTR 2200
Summary of Contents for stellar labs Small OTR 2200
- Page 1 Small OTR Service Cranes Owner’s Manual Safety • Operation • Maintenance • Troubleshooting Model 3200 Model 2200 Model 4500 Model 6000 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 Small OTR Crane Manual Revisions Date of Revision Section Revised Description of Revision WARNING Operating, maintaining, and servicing a Stellar product may expose you to chemicals including, but not limited to, engine exhaust, carbon monoxide, phthalates, and lead. These chemicals are known to the State of California to cause cancer and birth defects (or other reproductive harm).
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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 hydraulic power source ................. 2 Step 3: Turn on electrical power ..................... -
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® Small OTR Service 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 Electrical Power
Step 3: Turn on electrical power Locate the desired function on the switch panel inside the cab and activate to power the equipment. Step 4: Position the stabilizers Once the PTO is engaged, locate the street side (SS) and curb side (CS) stabilizer control handles. -
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. Make certain that the red e-stop button is in the up position (disengaged). 2. To start up the remote control, follow the instructions provided in the remote control manufacturer’s manual. - Page 9 Step 5: Operate the crane (Cont.) • Never perform a lift that can induce a dynamic force greater than the capacity of the crane. • It is the responsibility of the operator to know the weight of the handled load to avoid overloading the crane.
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Page 10: Step 6: Stow The Crane
Step 6: Stow the crane When the job is complete, use the correct toggles to bring the crane gently down onto the crane rest. Step 7: Stow the stabilizers Retract outriggers using the control levers or switches marked ‘outrigger’. Step 8: Finalize Service Finalize the service by storing the safety cones, shutting drawers and compartments, and securing the load. -
Page 11: Radio Remote Control Functions
Radio Remote Control Functions The crane is operated by a radio control system which operates an electronic valve bank. The controller (as shown above) operates the following functions: Main Boom Up and Down Outer Boom Up and Down Extension Boom In and Out Rotation Clockwise and Counter-Clockwise •... -
Page 12: 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 13 Stabilizers WARNING Untrained Operator Hazard Read and understand all manuals and safety signs before operating or servicing this equipment. Failure to follow operating, maintenance, or safety instructions can result in death or serious injury. WARNING Crush Hazard Keep clear of crane during operation. Failure to keep clear of moving crane Decal Part Number: 85504 can result in death or serious injury.
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Page 15: Chapter 2 - Maintenance
Chapter 2 - Maintenance Maintenance is an important part of extending the life of any Stellar Crane. Performing ® key maintenance items on a scheduled program will prevent unnecessary downtime. General Maintenance Guidelines Before performing any maintenance to the crane, •... -
Page 16: 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 17: 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 clamp loads after torquing. WARNING Anytime a torqued gear-bearing bolt is removed, it must be replaced with a new bolt of the identical grade and size. -
Page 18: 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 19: 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 1” D1250 Stellar Small OTR Service Crane Owner’s Manual | Page 15 ®... -
Page 20: 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) -
Page 21: Chapter 3 - Troubleshooting
Chapter 3 - Troubleshooting This chapter will list a number of potential problems that may occur while operating the crane. Most problems are easily solved using the solutions portion of this chapter. If problems persist, please contact Customer Service at Stellar Industries 1-800-321-3741. Serial Tag Location ®... - Page 22 Problem Possible Cause Possible Solution Crane will not PTO is not engaged. Engage PTO. If PTO won't engage, refer to PTO operate. manufacturer's manual for details. Crane is not receiving proper Check hydraulic reservoir fluid level. hydraulic flow Ensure PTO is engaged. Ensure Panic Bar E-Stop is not engaged.
- Page 23 Crane will not Radio control system is not Ensure manual/remote switch in the 'Remote' operate. functioning. position. Ensure transmitter is properly started. Refer to the radio system manufacturer's manual for details. Verify receiver is getting proper electrical power. Ensure transmitter battery is charged. If error code is displayed, refer to the radio system manufacturer's manual for details.
- Page 24 Crane operates Crane does not have proper Check fuse and holder. slowly. electrical power. Verify good ground. Verify good power supply. Verify proper voltage. Verify electrical wiring/connection integrity. Ensure manual/remote switch is working properly. Verify engine speed control has been activated.
- Page 25 Single crane function Valve section shuttle ball is Locate a different valve section further down will not operate (will not releasing. stream from the valve section that is not not pressurize). functioning. Note: Use a function other than any rotation sections such as crane rotation, tireman rotation, or pad rotation.
- Page 26 Noise coming from Bushings are worn. Replace bushings. articulation points. Inadequate lubrication. Lubricate bushings. Damaged structure. Inspect and repair/replace as needed. Broken/worn pin. Replace pin. Stabilizers fail to Remote/Manual switch is in Toggle switch to the Manual position. operate. the Remote position. Remote/Manual switch is Inspect and repair/replace as needed.
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Page 27: 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. - Page 28 Subject to Change without Notification. © 2021 Stellar Industries, Inc.
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