Model 28000 ArticulAting crAne owners’ MAnuAl safety • operation • Maintenance • installation • Parts Stellar Industries, Inc. Subject to Change without Notification. © 2011 Stellar Industries, Inc. 190 State Street PO Box 169 Garner, IA 50438 800-321-3741 Fax: 641-923-2811 www.stellarindustries.
8000 Manual Revisions Date of Revision November 6, 2008 May 7, 2010 Section Revised Chapter 2: Operation Chapter 5: Decals Chapter 7: Assembly Drawings Chapter 8: Hydraulics Electrical Chapter 7: Assembly Drawings Chapter 8: Hydraulics Electrical Description of Revision Updated drawings to reflect engineering changes. Updated drawings include: Decal Kit Placement, Reservoir Assembly, Base Assembly, Outrigger Assembly, Control Kit, Hydraulic Kit Updated drawings to reflect engineering changes.
Table of Contents Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii Chapter 1 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Chapter 2 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Unit Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii 28000 Owner’s Manual 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. Though it is not intended to be a training manual for beginners, this manual should provide solid guidelines for the safe and proper usage of the crane.
Safety 1 Chapter 1 - Safety Please Read the Following Carefully! This portion of the manual contains information regarding all Stellar manufactured cranes. Some items contained within this chapter may not apply to your specific equipment. Safety should be the number 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.
2 28000 Owner’s Manual Set the parking brake and disengage the drive axle before attempting a lift. LOAD SAFETY Operate the crane in compliance with the load capacity chart at all times. Know the weight of the load being lifted. Do not rely on the overload device to determine maximum rated loads. Never use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing. This would negate the safety feature. Do not apply side loads to the booms.
Operation Chapter 2 - Operation This chapter contains information regarding the operation of Stellar manufactured articulating 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 Set-Up thoroughly plan the lift before positioning the vehicle. consider the following: 1.
4 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.
Operation Crane Precautions Crane Transport 1. Movement of the control levers should be slow and smooth to meter oil flow for safe operation. Avoid jerky and sudden movements. 2. The crane controls should be clearly marked with decals. If these are missing or illegible,replace immediately. (See Chapter 5: Decals) 3. Lift load slightly off the ground to check the safety of the cargo. Do not use stability to determine the safety. Consult the capacity charts and strictly adhere to them. 4.
6 28000 Owner’s Manual Operator Information OPERATOR REQUIREMENTS OPERATOR CONDUCT 1. Operation is limited to the following people: A. Designated individual. B. Trainees under direct supervision of the designated individual. C. Test or maintenance individual. D. Crane Inspector. 1. Operators will not engage in any operation that would cause them to divert attention away from the operation of the crane. 2. Operators are responsible for all operations under their direct control. 3.
Maintenance 7 Chapter 3 - Maintenance WARNING - Read the Following before performing any maintenance on the crane. 1. Only authorized service personnel are to perform maintenance on the crane. 2. Disengage the PTO before any service or repair is performed. 3. Do not disconnect hydraulic hoses while there is still pressure in those components. 4.
8 28000 Owner’s Manual Weekly Inspection Weekly Inspection should occur at the beginning of every work week. Each week, inspect the crane for all of the following: 1. Lubrication of points required by lubrication chart located in this chapter. 2. Proper operation of load hook safety latch. 3. Presence of this owner’s manual. Monthly Inspection Monthly Inspection should occur at the beginning of every work month. Each month, inspect the crane for all of the following: 1.
Maintenance Lubrication Recommendations Component Location Recommendation Engine Crankcase Hydraulic System Below –5*F -5*F to 90*F Above 90*F Open Gears Reservoir Bearings, grease (including turntable bearing inner race) Gun Precision XL EP 2 (NLGI 2) Worm Drive Gearbox Gearbox Precision Synthetic EP 00 (NLGI 00) Planetary Gearbox (including winch) Gearbox Traxon Synthetic 75W-90 (API GL-5) Wear Pad Lubrication Spray Gearshield NC Crankcase Crankcase Crankcase Compro 100 (ISO 100) Comp
10 28000 Owner’s Manual Holding Valve Inspection Procedure 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 valve is checked in the following manner: 1. Identify the cylinder in question. 2. Identify the holding valves and the cylinder direction in question. a. Cylinder Extend. b. Cylinder Retract. 3.
Maintenance 11 Inspection Checklist Use of this checklist is subject to terms of the Stellar Warranty information. Additional copies of this checklist can be obtained by contacting Stellar Customer Service at (800) 321-3741.
12 28000 Owner’s Manual Daily Inspection Frequency Key Inspection Description D Decals All load charts, safety & warning Decals, & control Decals are present and legible. Check all safety devices for proper operation. D Controls Control mechanisms for proper operation of all functions, leaks, & cracks. D Station Control mechanisms for proper operation of all functions, leaks, & cracks. D Hydsystem D Hook Presence & proper operation of hook safety latches.
Maintenance 13 Monthly Inspection Frequency Key Inspection Description M Daily All Daily Inspections. M Cylinders M Valves Visual inspection of cylinders for leakage at rod, fittings, & welds. Damage to rod & case. Holding valves for proper operation. M Valves Control valve for leaks at fittings & between sections. M Valves M General Control valve linkages for wear, smoothness of operation & tightness of fasteners. Relief valve for proper pressure settings.
14 28000 Owner’s Manual Quarterly Inspection Frequency Key Inspection Description Q Daily All daily inspections. Q Monthly Q Rotation Sys Q Hardware Base mounting bolts for proper torque. Q Structure All structural members for deformation, cracks, & corrosion. All monthly inspections. Rotation bearing for proper torque of all mounting bolts.
Maintenance 15 Quarterly Inspection Continued... Frequency Key Q Hyd Lines Inspection Description Hoses, fittings, & tubing for proper routing, leakage, blistering, deformation, & excessive abrasion.
16 28000 Owner’s Manual Annual Inspection Frequency Key Inspection Description A Daily All daily inspection items. A Monthly All monthly inspection items. A Quarterly All quarterly inspection items. A Hyd System A Controls A Valves Safety valve calibration for correct pressures & relief valve settings A Valves Valves for failure to maintain correct settings. A Rotation Sys A Lubrication Rotation drive system for proper backlash clearance & abnormal wear, deformation, & cracks.
Maintenance Inspection Notes 17
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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: (From Truck Frame) 25’ (7.62 m) Cylinder Specifications Inner Lift Cylinder: Outer Lift Cylinder: Extension Cylinder: 9” (22.9 cm) bore with integral pilot operated counterbalance valves. 7” (17.
20 28000 Owner’s Manual Capacity Chart - Decal PN 16055 CAPACITY CHART 10’ 3.05m 13’2” 4.01m 16’3” 4.95m 25’ 7.62m 22’6” 6.86m 12’9” 3.89m 10’ 3.05m 13’2” 4.01m 16’3” 4.95m 28000 lbs 21300 lbs 17200 lbs 12700 kg 9660 kg 7800 kg 0’ 0m TRUCK 28000 ® 66.00” (167.
Decals 21 Chapter 5 - Decals Decals of Note Operation Hazard Decal Function: To inform the operator of the need for proper training, familiarity with safe operating procedures, and the possible consequences of operation without training. PN: C4544 Operation Hazard Decal Function: To inform the operator of the hazard associated with overloading the crane, the possible consequences should the hazard occur, and how to avoid the hazard.
22 28000 Owner’s Manual Decals of Note Continued... Electrocution Hazard Decal 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. PN: C1179 Moving Outrigger Hazard Decal Function: To inform the operator of the hazard associated with outrigger operation, the possible consequences should the hazard occur, and how to avoid the hazard.
Decals 23 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. Do not remove any decals. Replace any decals that are missing, damaged, or not legible.
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Installation 25 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 for the installation of a Stellar 28000 Articulating Crane on a Stellar Service Body. Each installation is considered unique so certain portions of this chapter may or may not apply to your direct application.
26 28000 Owner’s Manual Mounting Kit Drawing 16659 PN 16659 ITEM 1 2 3 4 PART 8054 11677 14498 9180 DESCRIPTION MTG BLOCK 15000 PLATE MOUNTING 23000 TIE DOWN ROD WASHER 1.25 SAE FLAT YELLOW GR8 QTY. ITEM 4 5 4 6 8 7 16 PART 8834 8978 8202 DESCRIPTION NUT 1.25-7 HHGR8 TOP LOCKING NUT 1.25-7 HHGR8 FRAME SUPPORT 15000 CRANE QTY.
Assembly Drawings Chapter 7 - Assembly Drawings Base Assembly - PN 47880 35 24 4 3 10 2 36 7 33 9 7 39 7 37 32 10 6 5 6 1 9 38 7 12 14 22 41 11 8 23 29 9 30 31 27 7 28 27 28 7 6 34 NOTE: RADIO RECEIVER AND ALARM SHOWN FOR REFERNECE 42 7 10 15 21 13 7 26 25 27 18 20 16 17 19 PN 47880 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 41 42 PART 486 86 18471 18041 17962 41336PC 0479 0340 4 10 8 4P C 0342 0343
28 28000 Owner’s Manual Mast Assembly - PN 18073 10 11 12 1 15 6 8 9 7 2 3 2 5 14 5 4 4 13 PN 18073 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PART 15403 18041 17963 D0790 10172 17964 11297 0484 0343 17133 11882 0523 15755ZP 13315 0522 DESCRIPTION MAST 28000 WASHER 0.88 SAE FLAT YELLOW GR9 CAP SCR 0.88-9X3.50 HHGR9 ZY WASHER 0.50 FLAT GR8 CAP SCR 0.50-13X1.00 HHGR8 ZY CAP SCR 0.88-9X5.50 HHGR8 PLATE INSPECTION MAST 23000 CAP SCR 0.31-18 X 0.50 HHGR5 WASHER 0.
Assembly Drawings Main Boom Assembly - PN 55106 12 6 1 3 4 5 4 10 3 6 8 6 5 6 8 7 11 12 8 4 3 10 5 10 4 3 10 9 14 10 9 2 5 Note: Secondary Cylinder uses Stellar Seal Kit PN 35650 13 10 Note: Main Lift Cylinder uses Stellar Seal Kit PN 35651 15 PN 55106 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PART 55103 50628 D0790 10172 c1592 2227 0865 54374 41063ZP 13315 15497 31056ZP 15495 15763ZP 20694 DESCRIPTION INNER BOOM 28000 REVISED CYLINDER ASM 7.00X38.25 WASHER 0.
30 28000 Owner’s Manual Main Boom Cylinder Assembly - PN 20694 2 5 6 PRESSURE SWITCH IN THIS PORT 4 3 5 1 4 2 3 PN 20694 ITEM NO. PART NO. 1 15598 2 16153 3 2227 4 16157 5 16152 6 15995 DESCRIPTION QTY CYLINDER 9.00x4.00x21.81 1 FTG ADAPT 10-C5OLO-S 2 BUSHING 48DXR48 GARLOCK 4 TUBE ASM 0.63X7.
Assembly Drawings 31 Extension Boom Assembly - PN 55108 5 5 3 13 8 3 13 8 8 1 15 6 13 3 4 5 17 16 5 8 19 14 13 17 3 18 4 3 3 13 9 9 5 5 15 6 13 5 3 13 2 7 9 11 Note: Cylinder uses Stellar Seal Kit PN 35649 10 9 10 12 13 3 5 PN 55108 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART DESCRIPTION QTY. 55107 OUTER BOOM 28000 REVISED 1 15388 EXT BOOM 28000 1 D0790 WASHER 0.50 SAE FLAT YELLOW GR8 14 C6219 WASHER 0.75 SAE FLAT YELLOW GR8 36 10172 CAP SCR 0.50-13X1.
32 28000 Owner’s Manual Extension Boom Cylinder Assembly - PN 50628 2 3 5 6 4 6 4 3 2 1 6 CYLINDER BUSHINGS SHOWN FOR REFERENCE ONLY 6 PN 50628 ITEM 1 2 3 4 5 6 PART 15604 16153 16158 16152 15995 2227 DESCRIPTION CYLINDER 7.00X38.25 FTG ADAPT 10-C5OLO-S T UB E A S M 0 . 6 3 X 1 6. 0 9 FTG ADAPT 10-F5OLO-S MANIFOLD ASM DUAL T2A 5000PSI BUSHING 48DXR48 GARLOCK QTY.
Assembly Drawings Outrigger Assembly - PN 48689 8 13 17 12 9 5 1 2 20 5 6 16 8 12 21 22 18 14 24 4 11 7 PN 48689 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 PART 4 04 50 15502 9994 4381 0635 48383 40837 8377 40459ZP 48 385ZP 2257 D0790 10172 10180PC C5902 C1025 25574 8819 13343 17320 40455 16266ZP 9996ZP 58052 12 13 23 19 24 13 8 15 3 10 DESCRIPTION O U T R I G GE R 23 0 0 0 OUTRIGGGER LEG 28000 C Y L I N D E R 4 . 0 0 X 5 0 .0 0 BUSHING 32DXR32 2.00X2.
34 28000 Owner’s Manual Outrigger Cylinder Assembly - PN 48383 5 6 4 2 4 5 3 3 1 Note: BUSHINGS ARE SHOWN FOR REFERENCE. 6 PN 48383 ITEM 1 2 3 4 5 6 PART 48384 15822 D1290 0279 19032 0635 DESCRIPTION QTY. CYLINDER 7.00X19.25 1 MANIFOLD DOUBLE T11A 5000 PSI 1 FTG ADAPT 8-6 F5OLO-S 2 FTG ADAPT 6-F5OLO-S 2 TUBE ASM 0.38 X 6.
Assembly Drawings Reservoir Assembly - PN 41332 33 8 9 10 3 1 34 20 21 14 25 19 6 18 22 24 6 7 13 17 12 32 16 11 9 23 9 4 PN 41332 15 5 26 27 28 28 29 29 30 2 31 30 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 PART 41333 C2126 8241 C0922 C6327 8240 03 42 0478 0340 11149 0519 0501 C6106 D1263 15463 42184 19242 47858 47857 C6021 30012 0333 47859 0492 54393 C5552 C4907 DESCRIPTION RSRVR 45GAL ORING 23000 MAGNETIC PLUG DRAIN 3/4"
36 28000 Owner’s Manual Optional 15 Ton Hook Kit - PN 55138 6 3 4 7 5 2 3 PN 55138 ITEM 1 2 3 4 5 6 7 PART 15388 41499 44069PC 9142 10172 16028ZP D0 7 9 0 DESCRIPTION EXT BOOM 28000 HOOK 15 TON SWIVEL CROSBY 1028654 COLLAR 1.78X 3.00X1.19 P IN CAP 0.56X 2.50X0.19 CAP SCR 0.50-13X1.00 HHGR8 ZY PIN TEAR DROP 1.75X7.06 WASHER 0.50 FLAT GR8 QTY.
Hydraulics - Electrical 37 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 equipment, whether mechanical, electrical, or hydraulic, without Stellar Industries’ approval.
38 28000 Owner’s Manual Control Kit - PN 41919 PN 41919
Hydraulics - Electrical Control Kit (434 Mhz Option) - PN 51838 PN 51838 39
40 28000 Owner’s Manual Control Kit (419 Mhz Option) - PN 55395 PN 55395
Hydraulics - Electrical Hydraulic Kit - PN 48690 PN 48690 41
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Replacement Parts Chapter 9 - Replacement Parts PART# 39780 8240 22934 22935 28485 41338 47860 18552 15463 11149 C6327 42184 47820 47866 C1090 C6184 15995 42802 40827 55401 50234 50235 47871 13555 13554 13557 13556 C2028 C2029 32223 D1244 D1245 D1246 D1247 D1248 D1249 D1250 16158 35647 C6310 35651 35650 35649 PART# 0635 0865 2227 4381 5739 8819 13343 13817 17320 25574 8377 8597 9142 10172 D0790 2257 C5644 C1592 40455 15779 15778 15601 17133 39959 16054 16052 HYDRAULIC SYSTEM COMPONENTS DESCRIPTION Oil pre
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Troubleshooting 45 Chapter 10 - 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. Problem: Crane will not operate. Solutions: • Make sure that the parking brake is engaged. • Make sure that the PTO is engaged. • Make sure that there is 12V power going to the radio receiver.
46 28000 Owner’s Manual Problem: Not all crane functions operate using the radio remote transmitter or crane operates intermittently. Solutions: • Make sure that the function switch is working properly. If the switch is defective, simply replace it. • Make sure that there is power going from the valve bank twin solenoid or to the function that will not operate.
Troubleshooting 47 Troubleshooting continued... Problem Possible Cause Vibrations and jerking in hydraulic cylin- The temperature of the hydraulic oil is der during the first maneuvers. too low. Possible Solution Perform maneuvers without loads for several minutes to warm up the oil. Add hydraulic oil. lack of oil in reservoir. Vibrations with every function when oil Lack of oil in reservoir. is hot. air in hydraulic system. Add hydraulic oil to the tank.
48 28000 Owner’s Manual Problem Hydraulic legs do not hold under load. Crane does not function. Crane does not function - Continued Control box lights do not operate (green LED out) Possible Cause Defective holding valves Clean or replace holding valves. Worn seals in the stabilizer cylinder. Replace worn seals. Truck battery discharged Charge battery. Electric connections are damaged or corroded. Check electrical wiring, terminals, connections and their integrity. Control handle turned off.
Troubleshooting Problem Operation slow down - con’t 49 Possible Cause Possible Solution Pump is slipping due to excessive oil temperature, this is a factor which will increase with worn components. Check pump GPM with flow meter if it is suspected to be faulty. Filters are dirty. Replace filters. Obstruction has occurred in boom hold- Replace or clean holding valve. ing valve. Operation slow down - con’t Defective flow valve. Replace valve. Boom drifts when loaded and controls neutralized.
50 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 normal start-up procedure. E-Stop reset Push the Start button again. If the system is being initialized from an E-Stop condition, the Start button must be pressed twice - first to clear the E-Stop, then again, to start the system. Joystick or paddle lever not in center position.
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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.
