Table of Contents
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28000
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wners
AnuAl
safety • operation • Maintenance • installation • Parts
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
Subject to Change without Notification.
www.stellarindustries.com
© 2013 Stellar Industries, Inc.
Last Revision: 01/23/13
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Table of Contents
Troubleshooting
Related Manuals for stellar labs Model 28000
Summary of Contents for stellar labs Model 28000
- Page 1 AnuAl safety • operation • Maintenance • installation • Parts Stellar Industries, Inc. 190 State Street PO Box 169 Garner, IA 50438 800-321-3741 Fax: 641-923-2811 Subject to Change without Notification. www.stellarindustries.com © 2013 Stellar Industries, Inc. Last Revision: 01/23/13...
- Page 2 28000 Manual Revisions Date of Revision Section Revised Description of Revision November 6, 2008 Chapter 2: Operation Chapter 5: Decals Updated drawings to reflect engineering Chapter 7: changes. Updated drawings include: Decal Kit Assembly Drawings Placement, Reservoir Assembly, Base Assembly, Chapter 8: Outrigger Assembly, Control Kit, Hydraulic Kit Hydraulics -...
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Page 3: Table Of Contents
Table of Contents Table of Contents Introduction ........................ii Chapter 1 - Safety......................1 Chapter 2 - Operation....................3 Unit Operation Overview ..................3 Manual Operation ....................4 Radio Remote Operation ..................4 Hook Precautions .....................5 Crane Transport......................5 Crane Precautions ....................5 Operator Information ....................6 Chapter 3 - Maintenance .....................7 Lubrication Recommendations................9 Torque Data Chart....................10 Inspection Checklist....................11... -
Page 4: Introduction
This manual is not binding. Stellar Industries, Inc. reserves the right to change, at any To promote this longevity, carefully study the time, any or all of the items, components,... -
Page 5: Chapter 1 - Safety
Release system pressure before attempting to make operation. any adjustments or repairs. Please take note that Stellar Industries, Inc. is not Do not attempt service or repair when the PTO is liable for accidents incurred by the crane because engaged. - Page 6 ATTENTION permanent damage to the pumps may occur. Follow the vehicle owner’s manual regarding Stellar Industries, Inc. is not liable for operating the vehicle in such adverse conditions. accidents incurred by the crane because of the operator’s non-fulfillment...
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Page 7: Chapter 2 - Operation
Operation Chapter 2 - Operation 1. Engage the PTO This chapter contains information regarding the A. Engage the parking operation of Stellar manufactured articulating brake. cranes. Please study the following pages to ensure B. Place the transmission in your familiarity with the operation process. This the Neutral position. -
Page 8: Manual Operation
28000 Owner’s Manual Radio Remote Operation Manual Operation In case of radio failure, the crane can be operated using manual overrides located on the valve bank. 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... -
Page 9: Hook Precautions
Operation Crane Precautions Crane Transport 1. Movement of the control levers should be Before transporting the crane, do the following: slow and smooth to meter oil flow for safe operation. Avoid jerky and sudden 1. The crane must be in the stored position. movements. -
Page 10: Operator Information
28000 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 11: Chapter 3 - Maintenance
6. Perform all safety and maintenance checks before each period of use. Periodic Inspection 7. Replace parts with Stellar Industries, Inc. Periodic Inspection should occur while the approved parts only. crane is in use. For the duration of the 8. - Page 12 Replace or repair wires as required. 10. Tightness of all boom wear, pad-retaining Stellar Industries recommends the first bolts. filter change to occur after the first 250 hours of service.* The second, and...
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Page 13: 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 14: Torque Data Chart
28000 Owner’s Manual 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 Note: For Crane Tie Down Rods, see hose or hydraulic component failure. The Chapter 6: Installation Overview. -
Page 15: Inspection Checklist
Maintenance 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. Owner/Company: Date Inspected: Contact Person:... -
Page 16: Daily Inspection
28000 Owner’s Manual 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 17: Monthly Inspection
Maintenance 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 18: Quarterly Inspection
28000 Owner’s Manual 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 19 Maintenance 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...
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Page 20: Annual Inspection
28000 Owner’s Manual 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 21: Inspection Notes
Maintenance Inspection Notes... - Page 22 28000 Owner’s Manual...
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Page 23: Chapter 4 - Specifications
Specifications Chapter 4 - Specifications Model 28000 Crane SPECIFICATION SHEET Crane Rating: 280,000 ft-lbs (38.71 ton meters) Standard Boom Length: 13’ 2” (4.01 m) from CL of Crane Boom Extension: Hydraulic 37" (94.0 cm) Maximum Horizontal Reach: 16’ 3” (4.95 m) from CL of Crane Maximum Vertical Lift: 25’... -
Page 24: Capacity Chart - Decal Pn 16055
28000 Owner’s Manual Capacity Chart - Decal PN 16055 10’ 13’2” 16’3” CAPACITY 3.05m 4.01m 4.95m CHART 25’ 7.62m 22’6” 6.86m 12’9” 3.89m 10’ 13’2” 16’3” 3.05m 4.01m 4.95m 28000 lbs 21300 lbs 17200 lbs 12700 kg 9660 kg 7800 kg 0’... -
Page 25: Chapter 5 - Decals
Decals Chapter 5 - Decals Decals of Note Operation Hazard Decal Operation Hazard Decal Operation Hazard Decal Function: To inform the opera- Function: To inform the opera- Function: To inform the opera- tor of the need for proper train- tor of the hazard associated tor and other personnel in the ing, familiarity with safe operat- with overloading the crane, the... -
Page 26: Decals Of Note Continued
28000 Owner’s Manual Decals of Note Continued... Electrocution Hazard Decal Moving Outrigger Hazard Decal Function: To inform the operator and other personnel Function: To inform the operator of the hazard asso- in the work area of the hazard associated with contact ciated with outrigger operation, the possible conse- or proximity to electrical lines, the possible conse- quences should the hazard occur, and how to avoid... -
Page 27: Decal Kit - Pn 16658
Decals Decal Kit - PN 16658 The following chapter highlights many decals of note on your Stellar 28000 and possibly the TM14160. For a complete list of decals, please refer to the Decal Placement drawing below. Remember: Decals are considered safety equipment. They must be maintained, as would other safety devices. - Page 28 28000 Owner’s Manual...
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Page 29: Chapter 6 - Installation
Installation Chapter 6 - Installation Notice: Read this Page Before Installation of the Crane General Installation Installation Notice This chapter is designed to serve as a general guide According to Federal Law (49 cfr part 571), each for the installation of a Stellar 28000 Articulating final-stage manufacturer shall complete the vehicle Crane on a Stellar Service Body. -
Page 30: Mounting Kit Drawing 16659
28000 Owner’s Manual Mounting Kit Drawing 16659 PN 16659 2 11677 PLATE MOUNTING 23000 6 8978 NUT 1.25-7 HHGR8 4 9180 WASHER 1.25 SAE FLAT YELLOW GR8... -
Page 31: Chapter 7 - Assembly Drawings
Assembly Drawings Chapter 7 - Assembly Drawings Base Assembly - PN 47880 30 31 NOTE: RADIO RECEIVER AND ALARM SHOWN FOR REFERNECE 16 17 PN 47880 18471 TURNTABLE BEARING 23000 18041 WASHER 0.88 SAE FLAT YELLOW GR9 17962 CAP SCR 0.88-9X4.50 HHGR9 ZY 41336PC PLATE SWITCH MTG 23000 0479 CAP SCR 0.25-20X0.75 HHGR5... -
Page 32: Optional Load Sensor Base - Pn 67062
28000 Owner’s Manual Optional Load Sensor Base - PN 67062 PN 67062 30 31 18041 WASHER 0.88 SAE FLAT YELLOW GR9 17962 CAP SCR 0.88-9X4.50 HHGR9 ZY 0479 CAP SCR 0.25-20X0.75 HHGR5 0485 CAP SCR 0.31-18X1.25 HHGR5 22183 CAP SCR #8-32X0.75 BTNHD SS 0488 CAP SCR 0.31-18X2.00 HHGR5 C6219... -
Page 33: Mast Assembly - Pn 18073
Assembly Drawings Mast Assembly - PN 18073 PN 18073 18041 WASHER 0.88 SAE FLAT YELLOW GR9 17963 CAP SCR 0.88-9X3.50 HHGR9 ZY 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 17964 CAP SCR 0.88-9X5.50 HHGR8 11297 PLATE INSPECTION MAST 23000 0484 CAP SCR 0.31-18 X 0.50 HHGR5 0343 WASHER 0.31 USS FLAT ZINC 11882... -
Page 34: Main Boom Assembly - Pn 55106
28000 Owner’s Manual Main Boom Assembly - PN 55106 Note: Secondary Cylinder uses Stellar Seal Kit PN 35650 Note: Main Lift Cylinder uses Stellar Seal Kit PN 35651 PN 55106 ITEM PART DESCRIPTION QTY. 55103 INNER BOOM 28000 REVISED 50628 CYLINDER ASM 7.00X38.25 D0790 WASHER 0.50 SAE FLAT YELLOW GR8... -
Page 35: Main Boom Cylinder Assembly - Pn 20694
Assembly Drawings Main Boom Cylinder Assembly - PN 20694 PRESSURE SWITCH IN THIS PORT PN 20694 ITEM NO. PART NO. DESCRIPTION 15598 CYLINDER 9.00x4.00x21.81 16153 FTG ADAPT 10-C5OLO-S 2227 BUSHING 48DXR48 GARLOCK 16157 TUBE ASM 0.63X7.88 YZ 16152 FTG ADAPT 10-F5OLO-S 15995 MANIFOLD ASM DUAL T2A 5000PSI... -
Page 36: Extension Boom Assembly - Pn 55108
28000 Owner’s Manual Extension Boom Assembly - PN 55108 3 13 Note: Cylinder uses Stellar Seal Kit PN 35649 13 3 PN 55108 ITEM PART DESCRIPTION QTY. 55107 OUTER BOOM 28000 REVISED 15388 EXT BOOM 28000 D0790 WASHER 0.50 SAE FLAT YELLOW GR8 C6219 WASHER 0.75 SAE FLAT YELLOW GR8 10172... -
Page 37: Extension Boom Cylinder Assembly - Pn 50628
Assembly Drawings Extension Boom Cylinder Assembly - PN 50628 CYLINDER BUSHINGS SHOWN FOR REFERENCE ONLY PN 50628 15995 MANIFOLD ASM DUAL T2A 5000PSI 2227 BUSHING 48DXR48 GARLOCK... -
Page 38: Outrigger Assembly - Pn 48689
28000 Owner’s Manual Outrigger Assembly - PN 48689 PN 48689 15502 OUTRIGGGER LEG 28000 4381 BUSHING 32DXR32 2.00X2.00 GARLOCK 0635 BUSHING 40DXR32 GARLOCK 40837 OUTRIGGER PAD 23000 96IN 8377 PIN CAP 0.56X3.50X0.19 & & 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 10180PC COVER WEAR PAD 23000 C5902 WASHER 0.63 SAE FLAT YELLOW GR8... -
Page 39: Outrigger Cylinder Assembly - Pn 48383
Assembly Drawings Outrigger Cylinder Assembly - PN 48383 Note: BUSHINGS ARE SHOWN FOR REFERENCE. PN 48383 48384 CYLINDER 7.00X19.25 15822 MANIFOLD DOUBLE T11A 5000 PSI D1290 FTG ADAPT 8-6 F5OLO-S 0279 FTG ADAPT 6-F5OLO-S 19032 TUBE ASM 0.38 X 6.91 0635 BUSHING 40DXR32 GARLOCK... -
Page 40: Reservoir Assembly - Pn 41332
28000 Owner’s Manual Reservoir Assembly - PN 41332 PN 41332 41333 RSRVR 45GAL ORING 23000 C2126 MAGNETIC PLUG DRAIN 3/4" 8241 FAN 16.00 PUSH 12 VOLT C0922 CAP SCR 0.31-18X1.00 HHGR5 C6327 FILTER STRAINER 35GAL TF-2030 8240 COOLER OIL AL 15000/23000 0478 CAP SCR 0.25-20X0.50 HHGR5 11149... -
Page 41: Optional 15 Ton Hook Kit - Pn 55138
Assembly Drawings Optional 15 Ton Hook Kit - PN 55138 PN 55138 41499 HOOK 15 TON SWIVEL CROSBY 1028654 10172 CAP SCR 0.50-13X1.00 HHGR8 ZY 16028ZP PIN TEAR DROP 1.75X7.06... - Page 42 28000 Owner’s Manual...
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Page 43: Chapter 8 - Hydraulics - Electrical
Hydraulics - Electrical Chapter 8 - Hydraulics - Electrical WARNING! Please read the following section before performing any work on the hydraulic/electrical system of your crane. This section contains vital safety information and maintenance guidlines for your crane. If questions should arise, please contact Stellar Customer Service at 800-321-3741 Never modify or alter any of the Contaminants in a hydraulic system affect... -
Page 44: Control Kit - Pn 41919
28000 Owner’s Manual Control Kit - PN 41919 PN 41919... -
Page 45: Control Kit (434 Mhz Option) - Pn 51838
Hydraulics - Electrical Control Kit (434 Mhz Option) - PN 51838 PN 51838... -
Page 46: Control Kit (419 Mhz Option) - Pn 55395
28000 Owner’s Manual Control Kit (419 Mhz Option) - PN 55395 PN 55395... -
Page 47: Hydraulic Kit - Pn 48690
Hydraulics - Electrical Hydraulic Kit - PN 48690 19,36 17,18 17,18 17,18 17,18 17,18 17,18 17,18 29,35 43,44 24 24,39 37,42 37,42 37,42 37,42 37,39 20,45 20,45 30,32 21,33 21,34 30,31 30,32 30,31... -
Page 48: Optional Load Sensor Hydraulic Kit - Pn 66288
28000 Owner’s Manual Optional Load Sensor Hydraulic Kit - PN 66288 LS LINE TO PUMP. PORT 2 ON MODIFICATION TO RESERVOIR DRAIN PLUG PORT SHUTTLE VALVE CASE DRAIN 49,50 LINE TO LOAD 46,47,48 SENSE PUMP PLUG 17,18 17,18 17,18 17,18 17,18 17,18 17,18... -
Page 49: Chapter 9 - Replacement Parts
Replacement Parts Chapter 9 - Replacement Parts HYDRAULIC SYSTEM COMPONENTS ELECTRICAL COMPONENTS PART# DESCRIPTION PART# DESCRIPTION 39780 Oil pressure gauge 41922 Hetronic Nova radio system 8240 Oil cooler 47862 12v charger for Hetronic Nova radio system 22934 Hydraulic rotation motor ( Crane rotation ) 47863 Battery for Hetronic Nova radio system 22935... - Page 50 28000 Owner’s Manual...
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Page 51: Chapter 10 - Troubleshooting
If to the receiver, trace back to the power problems persist, please contact source and check for a blown fuse or loose Customer Service at Stellar Industries ground connection. • Make sure that the parking brake is engaged. 1-800-321-3741. - Page 52 28000 Owner’s Manual Problem: Not all crane functions operate Problem: Cylinder drifts outward or using the radio remote transmitter or crane downward. operates intermittently. Solutions: Solutions: • Check to see if there is air in the hydraulic • Make sure that the function switch is working system.
- Page 53 Troubleshooting Troubleshooting continued... Problem Possible Cause Possible Solution Vibrations and jerking in hydraulic cylin- The temperature of the hydraulic oil is Perform maneuvers without loads for der during the first maneuvers. too low. several minutes to warm up the oil. Add hydraulic oil.
- Page 54 28000 Owner’s Manual Problem Possible Cause Possible Solution Hydraulic legs do not hold under load. Defective holding valves Clean or replace holding valves. Worn seals in the stabilizer cylinder. Replace worn seals. Crane does not function. Truck battery discharged Charge battery. Electric connections are damaged or Check electrical wiring, terminals, con- corroded.
- Page 55 Troubleshooting Problem Possible Cause Possible Solution Operation slow down - con’t Pump is slipping due to excessive oil Check pump GPM with flow meter if it temperature, this is a factor which will is suspected to be faulty. increase with worn components. Filters are dirty.
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Page 56: Bms-2 Receiver Troubleshooting
28000 Owner’s Manual BMS-2 Receiver Troubleshooting Available on some systems. Consult BMS-2 Operator Manual for details. Problem Probable Cause Correction System will not initialize after E-Stop reset Push the Start button again. If the system is being initialized from an E-Stop normal start-up procedure. -
Page 58: 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. This warranty...
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