Stellar 6628 Telescopic Crane Owner’s Manual
Below you will find brief information for telescopic crane 6628 Telescopic Crane. This manual will help you understand the basic operation and maintenance of your new telescopic crane. The equipment has multiple safety features to help protect the operator and the environment. It is important to consult the manual before operating. It is also important to follow all safety instructions provided in the manual.
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O
WNER
’
S
M
ANUAL
Safety, Installation, Maintenance, and Operation
6628 Telescopic Crane
®
6628
31656
Subject to Change without Notification.
© 2008 Stellar Industries, Inc.
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811 www.stellarindustries.com
Manual Part No. 31709
Last Revision: 07/17/08
Date of Revision
September 1, 2005
September 19, 2005
September 9, 2006
November 7, 2006
March 1, 2007
April 12, 2007
6628 Manual Revisions
Section Revised
Chapter 7:
Assembly Drawings
Chapter 7:
Assembly Drawings
Chapter 7:
Assembly Drawings
Chapter 7:
Assembly Drawings
Chapter 8:
Hydraulics-Electrical
Chapter 8:
Hydraulics-Electrical
Chapter 5: Decals
Chapter 7:
Assembly Drawings
Description of Revision
Updated Main Boom and Extension Boom drawings to reflect engineering changes.
Updated Cable and Hook assembly drawings to reflect engineering changes.
Updated Cable and Hook assembly drawings to reflect engineering changes.
Updated Base assembly drawings and Hydraulic schematics to reflect engineering changes
Replaced Control Kit 18932 with Control Kit 10701
Updated Decal Kit. Updated assembly drawing for the extension cylinder per engineering changes.
Table of Contents i
Table of Contents
Lubrication Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Capacity Chart - Decal PN 31072. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Decal Kit Placement - PN 31654 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Extension Boom Assembly - PN 31649. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Main Cylinder Assembly - PN 31648 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Extension Cylinder Assembly - PN 37018. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Cable & Hook Assembly - PN 38183 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Basket Cable & Hook Assembly (Optional) - PN 48111 . . . . . . . . . . . . . . 42
Wire/Rope Sheave Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Control Kit (Power House 24) - PN 38989 . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Remote Control Assembly & Hydraulic System . . . . . . . . . . . . . . . . . . . . . 50
Chapter 9 - Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Chapter 10 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6 Function Hetronic Radio Remote Troubleshooting . . . . . . . . . . . . . . . . 55
4 & 7 Function Hetronic Radio Remote Troubleshooting . . . . . . . . . . . . . 57
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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6628 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.
Once you feel comfortable with the material contained in this manual, strive to exercise your knowledge as you safely operate and maintain the crane. This process is vital to the proper use of the unit.
Stellar manufactured cranes in general and may or may not apply to your specific model.
This manual is not binding. Stellar Industries,
Inc. reserves the right to change, at any time, any or all of the items, components, and parts deemed necessary for product improvement or commercial/production purposes. This right is kept with no requirement or obligation for immediate mandatory updating of this manual.
In closing:
If more information is required or technical assistance is needed, or if you feel that any part of this manual is unclear or incorrect, please contact the Stellar Customer Service
Department by phone at 800-321-3741 or email at [email protected].
A few notes on this manual:
A copy of this manual is provided with every crane and shall remain with the crane at all times. Information contained within this manual does not cover all maintenance, operating, or repair instructions pertinent to all possible situations.
Please be aware that some sections of this manual contain information pertaining to
ATTENTION
Failure to adhere to the instructions could result in property damage or even serious bodily injury to the operator or others close to the crane.
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
Order Parts
Warranty Information
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. The following information should be read and understood completely by everyone working with or near the crane before putting the unit into operation.
Please take note that Stellar Industries, Inc.
is not liable for accidents incurred by the crane because of non-fulfillment from the operator’s side of current rules, laws, and regulations.
GENERAL
It is the responsibility of the owner to instruct the operator in the safe operation of your equipment and to provide the operator with properly maintained equipment.
Trainees or untrained persons shall be under the direct supervision of qualified persons.
Do not operate equipment under the adverse influence of alcohol, drugs, or medication.
PERSONAL SAFETY
Keep clear of all moving parts.
Always wear the prescribed personal safety devices.
Always wear approved accident-prevention clothing such as: protective helmets, anti-slip shoes with steel toes, protective gloves, antinoise headphones, protective glasses, and reflective jackets with breathing apparatus.
Consult your employer regarding current safety regulations and accident-prevention equipment.
Do not wear rings, wristwatch, jewelry, loosefitting or hanging clothing such as ties, torn garments, scarves, unbuttoned jackets or unzipped overalls, which could get caught up in the moving parts of the crane.
Keep a first-aid box and a fire extinguisher readily available on the truck. Regularly check to make sure the fire extinguisher is fully charged and the first-aid kit is stocked.
Do not use controls and hoses as handholds.
These parts move and cannot provide stable support.
Never allow anyone to ride the crane hook or load.
MAINTENANCE SAFETY
Never modify or alter any of the equipment, whether mechanical, electrical, or hydraulic, without explicit approval from Stellar Industries.
Do not perform any maintenance or repair work on the crane unless authorized and trained to do so.
Release system pressure before attempting to make any adjustments or repairs.
Do not attempt service or repair when the PTO is engaged.
Failure to correctly plumb and wire the crane can cause a malfunction and damage to the crane and/or operator.
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.
The safety instruction plates, notices, load charts and any other sticker applied to the crane or service body must be kept legible and in good condition. If necessary, replace them.
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6628 Owner’s Manual
STABILITY
Know the crane components and their capabilities and limitations. Overloading the crane may result in serious injury to self and others, and damage to the equipment and immediate surroundings.
Never exceed manufacturer’s load ratings.
These ratings are based on the machine’s hydraulic, mechanical, and structural design rather than stability.
The supporting surface under the service truck must be able to support the weight of the machine and its load. Use outrigger pads if necessary.
Park the vehicle on level ground and extend the outriggers fully out and then down.
Keep feet and legs clear when lowering outrigger jacks.
Never operate the crane without making sure the outriggers are positioned on stable, flat ground.
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. If the crane is picking more than the maximum rated load, the overlord protection device may be malfunctioning.
Discontinue use immediately and contact
Stellar Customer Service for support.
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.
Do not leave a crane load suspended or unattended.
Do not walk under suspended loads.
Do not position any load over a person nor should any person be permitted to place him or herself under a load.
Do not use the boom or the winch to drag a load.
Do not use the crane boom to push downward onto anything.
ELECTROCUTION
Allow extra space for swaying power lines in windy conditions.
Keep a minimum of ten feet between any portion of the crane and an electrical line.
Add an additional 12" for every additional
30,000 Volts or less.
Remember - Death or serious injury can occur when working near power lines or during electrical storms.
Use a signal person when operating near electrical sources.
ENVIRONMENT
Do not operate the crane during electrical storms.
In extreme cold, allow adequate time to warm the truck before engaging the PTO. Do not rev the truck engine and over speed the hydraulic pumps as permanent damage to the pumps may occur. Follow the vehicle owner’s manual regarding operating the vehicle in such adverse conditions.
In dusty work areas, every effort must be taken to keep dust and sand out of the moving parts of the machinery.
In high humidity work areas, keep parts as dry as possible and well lubricated.
Be familiar with your remote control and how it works before operating the crane.
Safety 3
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.
4. Be familiar with the remote control and how it operates before attempting to lift a load.
5. Be prepared before beginning operation of the crane:
• All protective guards must be in place.
• Be aware of the surroundings: low branches, power lines, unstable ground.
• Be sure all safety devices provided are in place and in good operating condition.
• Be prepared for all situations. Keep fire extinguisher and first aid kit near.
• Be sure all regular maintenance has been performed.
• Visually inspect all aspects of the crane for physical damage.
• Check for fluid leaks.
• Make sure the outriggers are down and stable.
ATTENTION
Stellar Industries, Inc. is not liable for accidents incurred by the crane because of the operator’s non-fulfillment of current rules, laws and regulations.
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6628 Owner’s Manual
Operation 5
Chapter 2 - Operation
This chapter contains information regarding the operation of Stellar manufactured telescopic 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.
Unit Operation Overview
1. Engage the PTO
2. Turn on Power to Crane
3. Position Outriggers
4. Operate Crane
5. Store Outriggers
6. Turn Off Power to Crane
7. Disengage the PTO
Job-Site Set-Up
Thoroughly plan the lift before positioning the vehicle. Consider the following:
1. The vehicle should be positioned in an area free from overhead obstructions to eliminate the need for repositioning.
2. Position the vehicle so that it is impossible for any portion of the equipment to come within the minimum required safe distance of any power line. Maintain a clearance of at least 10 feet between any part of the crane, load line, or load, and any electrical line or apparatus carrying up to
50,000 volts. One foot additional clearance is required for every additional
30,000 volts or less. Remember to allow for winds that cause power lines to sway.
It is recommended that a signal person be used when the vehicle is set-up near power lines.
3. The vehicle should also be positioned on a firm and level surface that will provide adequate support for the outrigger loading. Use extreme caution when setting up near overhanging banks or excavations.
4. The parking brake must be set on the vehicle and the drive axle disengaged before performing a crane operation.
5. The outriggers must be extended to stabilize the truck before beginning operation.
1. Engage the PTO
A. Engage the parking brake.
B. Place the transmission in the
Neutral position.
C. Make certain the
PTO switch is in the
‘off’ position.
D. Start the vehicle engine.
PTO Switch
E. Depress the clutch on manual transmission vehicles.
F. Engage the PTO switch for cable and air type shifters. Turn on the dash switch for electrical operated style. Consult vehicle owner’s manual for location and operation of OEM style in-dash PTO switch.
G. Slowly release the clutch on a manual transmission vehicle.
H. Allow a few moments to warm the hydraulic system oil. In cold weather, it is especially important to let the system run for a few minutes before operating.
2. Turn on Power to Crane
Activate power to the crane and outriggers. The power switch is located on the control panel in the vehicle cab.
3. Position Outriggers
Once the PTO is engaged, extend the outriggers using the control levers or switches marked ‘outrigger’. These may be located on the crane base or in the compartment under the crane.
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6628 Owner’s Manual
6 Function Hetronic Remote
4.Operate Crane
A. Turn on necessary power to the crane.
B. Activate toggle switch for desired crane function.
D. Activate the variable speed trigger to control the desired function.
E. When operation is complete, store remote handle in a safe, dry location.
5. Store Outriggers
Retract outriggers using the control levers or switches marked ‘outrigger’.
6. Turn Off Power to Crane
Deactivate power to crane and outriggers.
7. Disengage the PTO
A. On manual transmission vehicles, depress the clutch pedal completely.
B. Disengage the PTO switch.
C. If vehicle is a manual transmission, release the clutch pedal gradually.
NOTE: The radio control is an electrical device. Please handle with care!
1
Variable Speed Trigger on remote.
The crane should not function until the trigger has been activated. The speed of the crane will vary in direct correlation with how much or how little the trigger is engaged.
Manual Operation
If the remote control malfunctions, follow these steps to operate the crane manually:
1. Activate Flow Control. Turn the override screw on flow control counter-clockwise.
Full adjustment is between three and five turns.
2. Operate Solenoids. Slide the knurled sleeve out and then push or pull to operate, as shown below. Be sure the sleeve is in the center, locked, position before returning to remote operation.
3. Deactivate flow control. Turn the override screw clockwise until stopped. Full adjustment is between 3 and 5 turns.
4. Have unit serviced immediately to restore remote control functionality.
PULL
PUSH
WINCH
DOWN
WINCH
UP
EXTENSION
RETRACT
EXTENSION
EXTEND
MAIN
DOWN
ROT
CW
MAIN
UP
ROT
CCW
FLOW
CONTROL
Manual Override Pull
Function
The knurled sleeve is pulled all the way out together with the knob to manually override the pull solenoid function.
Manual Override Push
Function
The knurled sleeve should first be pulled to unlatch the ball latching mechanism and then, while holding the sleeve back, the override knob should be pushed all the way in to override the push solenoid.
Operation 7
Crane Precautions
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. Be constantly aware of the boom position when operating the controls.
5. The boom tip should be centered directly over the load before making the lift to avoid swinging.
6. Do not drag loads with the crane.
7. Do not attempt to lift fixed loads.
8. Do not load boom in a sideways direction.
9. Know the weight of the rigging and load to avoid overloading the crane.
10. Do not extend or rotate a load over anyone.
11. Wear protective gear such as hard hat, safety glasses, steel-toed boots, and gloves.
Hook Precautions
1. Hooks are designed and manufactured to lift specific loads. The specified rated load of a hook applies to loads held uniformly in direct tension and does not take into account shock loads, hook tip loading, side loading, bending, torsional, or related loads.
2. Do not attempt to lift a load that is larger than the load rating of the hook.
3. Never use a hook’s yield point as an indicator of its capacity.
4. Do not use a hook to lift personnel.
5. Know the rated load of the hook in use.
6. Never weld attachments to a finished hook in field applications. This will alter and destroy the design properties of the hook material.
7. Keep fingers, hands, body, and loose clothing from between the hook and the load.
8. Avoid shock loading.
9. Inspect the hook regularly for excessive wear and maintain it in safe operating condition.
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6628 Owner’s Manual
Operator Information
OPERATOR REQUIREMENTS
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.
2. Operators must meet the following physical qualifications:
A. Vision of at least 20/30 Snellen in one eye and 20/50 in the other, with or without corrective lenses.
B. Ability to distinguish colors if color differentiation is required.
C. Adequate hearing, with or without a hearing aid.
D. No physical or emotional defects that may create a hazard to the operator or others.
E. Normal depth perception and coordination.
3. In addition to the physical qualifications,
Operators must:
A. Demonstrate the ability to understand all decals, the owner’s manual, and any other information required for safe operation of the crane.
B. Be able to demonstrate the ability to safely control the crane.
C. Know all safety regulations.
D. Be responsible for maintenance requirements.
E. Understand and be fully capable of implementing all emergency procedures.
F. Understand the operating procedures as outlined by this manual, ANSI B30.5, and
Federal/State Laws.
OPERATOR CONDUCT
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. Operators will not leave a suspended load unattended.
4. Operators will be familiar with the equipment and the maintenance required for proper care.
HANDLING THE LOAD
1. Size of the load:
A. Do not load the crane beyond the rated capacity.
B. It is the responsibility of the operator to know the weight of the handled load.
2. Attaching the load:
A. Attach the load to the hook by means of slings or other approved devices.
B. Do not wrap the hoist rope around the load.
3. Moving the load:
A. Make certain that the crane is level and properly blocked.
B. Ensure that the load is secure and balanced within the sling before moving it.
C. Be sure that the crane is stable before moving the load. Use stabilizer pads to ensure the proper distribution of weight.
D. Do not drag the load sideways.
E. Make sure the hook is brought over the load to minimize swinging.
F. No suspended load should pass over a person.
G. Avoid sudden starts and stops when moving a load.
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. Before disconnecting hydraulic components, place the boom on the ground or have it supported, shut off the engine, release any air pressure on the hydraulic reservoir, and move pedals and control levers repeatedly through their operating positions to relieve all pressures.
5. Keep the crane and service body clean and free from grease build-up, oil and dirt to prevent slippery conditions.
6. Perform all safety and maintenance checks before each period of use.
7. Replace parts with Stellar Industries, Inc.
approved parts only.
8. Immediately repair or have repaired any components found to be inadequate.
Maintenance 9
Chapter 3 - Maintenance
Daily Inspection
Daily Inspection should occur each day before the crane is put into use. Each day, inspect the crane for all of the following:
1. Hydraulic oil level.
2. Loose parts or damage to structures or weld.
3. Cylinder movement due to leakage.
4. Hoses and gearboxes for evidence of oil leaks.
5. Controls, including hand throttle for malfunction or adjustment.
6. Truck hand brake operation.
7. All securing hardware such as cotter pins, snap rings, hairpins, and pin keepers for proper installation.
8. All safety covers for proper installation.
9. Cylinder holding valves for proper operation.
10. Wire rope for broken wires, extensive wear, distortion, and heat damage.
Maintenance Procedures
1. Position the crane where it will be out of the way of other operations or vehicles in the area.
2. Be sure boom is lowered to the ground or otherwise secured from dropping.
3. Place all controls in the off position and secure operating features from inadvertent motion.
4. Disconnect power source.
5. Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components.
6. Label or tag parts when disassembling.
Periodic Inspection
Periodic Inspection should occur while the crane is in use. For the duration of the usage, inspect the crane for all of the following:
1. Loose bolts and fasteners.
2. All pins, bearings, shafts, and gears for wear, cracks, or distortion to include all pivots, outriggers, sheave pins, and bearings.
3. Hydraulic systems for proper operating pressure.
4. Main frame mount bolts.
5. Cylinders for:
A. Damaged rods.
B. Dented barrels.
C. Drift from oil leaking internally.
D. Leaks at rod seals or holding valves.
6. PTO drive line system for proper alignment, lubrication, and tightness.
7. Hydraulic hose and tubing for evidence of damage such as blistering, crushing, or abrasion.
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6628 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. Frame bolt tightness - turn barrel nuts and mounting bolts during the first month of operation on new machines and then quarterly thereafter.
2. Cylinders and valves for leaks.
3. Lubrication.
4. Load hook for cracks or having more than
15 percent normal throat opening or 10 degrees twist.
5. Structural members for bends, cracks, or broken members.
6. All welds for breaks and cracks.
7. All pins and keepers for proper installation.
8. All control, safety, and capacity placards for readability and secure attachment.
9. Inspect all electrical wires and connections for worn, cut, or deteriorated insulation and bare wire. Replace or repair wires as required.
10. Tightness of all boom wear, pad-retaining bolts.
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. If operating in less than favorable conditions (excessive dust, moisture, etc.), be sure to check the filter gauge often for filter change notice.
Service
The following general suggestions should be helpful in analyzing and servicing your crane. Using the following systematic approach should be helpful in finding and fixing problems:
1. Determine the problem.
2. List and record possible causes.
3. Devise checks.
4. Conduct checks in a logical order to determine the cause.
5. Consider the remaining service life of components against the cost of parts and labor necessary to replace them.
6. Make the necessary repair.
7. Recheck to ensure that nothing has been overlooked.
8. Functionally test the new part in its system.
Inspection Checklist
For a more detailed outline of scheduled inspection points, refer to the Stellar
Inspection Checklist at the end of this chapter. This list is an excellent guide for the inspection tasks that will help maintain the quality of your Stellar product. Feel free to photocopy the checklist as needed.
ATTENTION
Every six (6) months, remove the hydraulic pump from the PTO and lubricate the splines using
Chelsea Lubricant #379831 or Stellar PN 20885. Failure to lubricate shaft splines will cause damage to the PTO and Hydraulic pump.
Maintenance 11
Lubrication Recommendations
Engine
Component Location
Crankcase
Recommendation
Apply Manufacturer’s
Recommendations
Hydraulic System
Below –5*F
-5*F to 90*F
Above 90*F
Open Gears
Reservoir
Hand
Gun
Petro-Canada Arctic MV 15 (ISO 22)
Petro-Canada HYDREX 32 (ISO 32)
Petro-Canada HYDREX 46 (ISO 46)
Precision XL3 Moly EP 2 (NLGI 2 grease with moly)
Precision XL EP 2 (NLGI 2) Bearings, grease
(including turntable bearing inner race)
Worm Drive Gearbox Gearbox Precision Synthetic EP 00 (NLGI 00)
Planetary Gearbox
(including winch)
Wear Pad Lubrication
Gearbox
Spray
Traxon Synthetic 75W-90 (API GL-5)
Gearshield NC
Compressor Fluids
Reciprocating Single Stage
Reciprocating Double Stage
Screw
-15ËšF to 86ËšF
-23ËšF to 100ËšF
32ËšF to 113ËšF
Crankcase
Crankcase
Crankcase
Compro 100 (ISO 100)
Compro 100 (ISO 100)
Compro XL-S 32 (ISO 32)
Compro XL-S 46 (ISO46)
Compro XL-S 68 (ISO68)
Greasing the Crane
Lubricate all grease gun points with
Extreme Pressure Grease - Stellar P/N: 22059.
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6628 Owner’s Manual
Wire Rope Maintenance
Wire Rope Inspection Points
While inspection of the entire rope is required, attention should be directed to these critical points:
1. Pick-up Points for signs of wear due to stress from repeated lifts.
2. End Attachments for corrosion and broken wires at both ends of the rope.
3. Drums for signs of corrugation and wear that may lead to wire damage.
4. Sheaves to ensure that each sheave has the proper groove size and contour.
5. Abuse Points for heavy amounts of scuffing and scraping.
It is important to perform detailed inspections of all ropes associated with the crane. These inspections can be divided into two types:
1. Frequent Inspection
A. All running ropes should be inspected once each working day. These visual observations will be concerned with discovering damage that may be an immediate hazard. The following concerns should be addressed:
1. Distortion of the rope.
2. General corrosion.
3. Broken or cut strands.
B. Use caution while inspecting sections of rapid deterioration.
C. Use caution while inspecting boom hoist ropes. Proper inspection is critical but difficult.
2. Periodic Inspection
A. Inspection frequency will be determined by a qualified person and will be based on such factors as expected rope life, environment conditions, capacity of typical lifts, rates of usage, and exposure to shock loads. Periodic inspection needs to be performed at least annually.
B. Periodic inspections will be performed by a qualified individual and will cover the entire length of the rope. Only the surface wires of the rope need to be inspected. This inspection will be concerned with discovering damage that may be an immediate hazard. The following concerns should be addressed:
1. Distortion of the rope.
2. General corrosion.
3. Broken or cut strands.
4. Reduction of rope diameter.
5. Corroded or broken wires at end connections.
6. Corroded, cracked, bent, worn, or improperly applied end connections.
C. Use caution when inspecting the following:
1. Sections in contact with saddles, equalizer sheaves, or other sheaves where rope travel is limited.
2. Sections of the rope at or near ends with corroded or broken wires.
Wire Rope Replacement
Rope replacement guidelines are as follows:
1. Broken wires, including standing ropes with more than two broken wires in one lay or more than one broken wire at an end connection.
2. Wear of one-third the original diameter of the outside wires.
3. Distortion of the rope structure.
4. Evidence of heat damage.
5. Reductions from nominal diameters of more than 1/64 in. (0.4 mm) for diameters from 5/16 in.(19.0 mm) and 1/32 in. (0.8
mm) for diameters from 3/8 in. (9.5 mm) to and including 1/2 in. (13.0 mm).
Wire Rope Maintenance
Proper maintenance is key in ensuring a long lasting rope. These three tips will help:
1. Store the rope to prevent damage.
2. Avoid objects that may scrape, bend, or crush the wires of the rope.
3. Always keep the rope well-lubricated.
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. Place the machine so that the cylinder will be located in the appropriate testing position.
4. Pick the load (Do not exceed capacity, rated or stability).
5. Disengage hydraulics.
6. Operate crane functions.
A. If the cylinder creeps (lowering the load), replace the holding valve.
B. If the cylinder does not creep (load stays suspended), the valve is operational.
Gear-Bearing Bolt Maintenance
Anytime a gear-bearing bolt is removed, it must be replaced with a new bolt of the identical grade and size. 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!
Failure to replace gear-bearing bolts may result in bolt failure due to metal fatigue causing serious injury or even death.
Maintenance 13
Torque Data Chart
Grade 5
Grade 8
Grade 9
Size
(DIA-TPI)
5/16-18
3/8-16
7/16-14
1/2-13
9/16-12
5/8-11
3/4-10
7/8-9
1-8
1 1/8-7
1 1/4-7
1 3/8-6
1 1/2-6
Bolt DIA
(Inches)
0.3125
0.3750
0.4375
0.5000
0.5625
0.6250
0.7500
0.8750
1.000
1.1250
1.2500
1.3750
1.500
265
395
590
795
1120
1470
1950
Plain
(Ft-Lb)
17
31
49
75
110
150
Plated
(Ft-Lb)
13
23
37
57
82
115
200
295
445
595
840
110
1460
375
605
910
1290
1815
2380
3160
Plain
(Ft-Lb)
25
44
70
105
155
220
Plated
(Ft-Lb)
18
33
52
80
115
160
280
455
680
965
1360
1780
2370
Plated
(Ft-Lb)
22
39
63
96
139
192
340
549
823
1167
1646
2158
2865
When using the torque data in the charts above, the following rules should be observed.
1. Bolt manufacturer’s particular specifications should be consulted when provided.
2. Flat washers of equal strength must be used.
3. All torque measurements are given in foot-pounds. To convert to inch-pounds, multiply by 12.
4. Torque values specified are for bolts with residual oils or no special lubricants applied. If special lubricants of high stress ability, such as Never-Seez compound graphite and oil, molybdenum disulphite, colloidal copper or white lead are applied, multiply the torque values in the charts by the factor .90. The use of Loctite does not affect the torque values listed above.
5. Torque values for socket-head capscrews are the same as for Grade 8 capscrews.
14
6628 Owner’s Manual
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.
Type of Inspection (check one)
Daily
(if deficiency found)
Quarterly
Monthly
Annual
Owner/Company:
Contact Person:
Crane Make/Model:
Crane Serial:
Type of Inspection Information
Date Inspected:
Hour Meter Reading:
Inspected by: ( print
)
Signature of Inspector:
Daily and monthly inspections are to be performed by a “designated” person, who has been selected by the employer or the employer’s representative as being competent to perform specific duties.
Quarterly and annual inspections are to be performed by a “qualified” person who, by possession of a recognized degree in an applicable field or certificate of professional standing, or who, by extensive knowledge, training and experience has successfully demonstrated the ability to solve or resolve problems related to the subject matter and work.
One hour of normal crane operation assumes 20 complete cycles per hour. If operation exceeds 20 cycles per hour, inspection frequency should be increased accordingly.
Consult the Stellar Owner’s Manual for additional inspection items.
Before inspecting and operating the crane, make certain that t he crane is set up away from power lines and leveled with outriggers fully extended.
Daily (D): Before each day of operation, those items with a (D) must be inspected. This
inspection need not be recorded unless a deficiency is found.
Monthly (M): Monthly inspections or 100 hours of normal operation (which ever comes
first) includes all daily and monthly inspection items plus items designated with a (Q). This inspection must be recorded.
Quarterly (Q): Every three months or 300 hours of normal operation (which ever comes
first) includes all daily and monthly inspection items plus items designated with an (M).
This inspection must be recorded.
Annual (A): Each year or 1200 hours of normal operation (which ever comes first) includes
all items on this form which encompasses daily, monthly, and quarterly inspections plus those items designated by (A). this inspection must be recorded.
Maintenance 15
D
D
D
D
D
Frequency
D
D
D
D
D
D
D
D
D
Key
Decals
Controls
Station
Hydsystem
Hook
Rope
Pins
General
Operation
Remote Ctrls
Electrical
Daily Inspection
Inspection Description
All load charts, safety & warning Decals, & control Decals are present and legible.
Check all safety devices for proper operation.
Control mechanisms for proper operation of all functions, leaks, & cracks.
Control mechanisms for proper operation of all functions, leaks, & cracks.
Hydraulic system (hoses, tubes, & fittings) for leakage & proper oil level.
Presence & proper operation of hook safety latches.
Proper reeving of wire rope on sheaves & winch drum.
Proper engagement of all connecting pins & pin retaining devices.
Overall observation of crane for damage or missing parts, cracked welds & presence of safety covers.
During operation, observe crane for abnormal performance, unusual wear.
If observed, discontinue use & determine cause & severity of hazard.
Operate remote control devices to check for proper operation.
Operate all lights, alarms, etc. to check for proper operation.
Anti 2-Blocking Operate anti 2-blocking device to check for proper operation.
Operation Aid Check presence of boom angle indicator.
Operation Aid Check overload device for proper operation.
Status
M
M
M
M
M
16
6628 Owner’s Manual
Frequency
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
Key
Daily
Cylinders
Valves
Monthly Inspection
Inspection Description
All Daily Inspections.
Visual inspection of cylinders for leakage at rod, fittings, & welds. Damage to rod & case.
Holding valves for proper operation.
Control valve for leaks at fittings & between sections.
Valves
Valves
General
Electrical
Structure
Welds
Pins
Hardware
Wear Pads
Control valve linkages for wear, smoothness of operation & tightness of fasteners. Relief valve for proper pressure settings.
Bent, broken or significantly rusted/corroded parts.
Electrical systems for presence of dirt, moisture & frayed wires.
All structural members for damage.
All welds for breaks & cracks.
All pins for proper installation & condition.
All bolts, fasteners & retaining rings for tightness, wear & corrosion.
Condition of wear pads.
Pump & Motor
PTO
Hyd Fluid
Hydraulic pumps & motors for leakage at fittings, seals & between sections.
Check tightness of mounting bolts.
Transmission/PTO for leakage, abnormal vibration & noise, alignment & mounting bolt torque.
Quality of hydraulic fluid and for presence of water.
Hyd Lines
Hook
Hoses & tubes for leakage, abrasion damage, blistering, cracking, deterioration, fitting leakage, & secured properly.
Load hook for abnormal throat distance, twist, wear, & cracks.
Status
Rope
Manual
Chassis
Chassis
Station
Condition of load line.
Presence of operator's manuals with the unit.
Tire wear and air pressure.
Working backup alarm.
Fire extinguisher at cab or machinery housing.
Frequency
Q
Q
Q
Q
Q
Q
Key
Daily
Monthly
Rotation Sys
Hardware
Structure
Hardware
Maintenance 17
Quarterly Inspection
Inspection Description
All daily inspections.
All monthly inspections.
Rotation bearing for proper torque of all mounting bolts.
Base mounting bolts for proper torque.
All structural members for deformation, cracks, & corrosion.
Base
Outrigger beams & legs
Mast
Inner boom
Outer boom
Extension(s)
Jib boom
Jib extension(s)
Other
Other
Pins, bearings, shafts, gears, rollers, & locking devices for wear, cracks, corrosion, & distortion.
Inner boom pivot pin(s) & retainer(s)
Outer boom pivot pin(s) & retainer(s)
Inner boom cylinder pin(s) & retainer(s)
Outer boom cylinder pin(s) & retainer(s)
Extension cylinder pin(s) & retainer(s)
Jib boom pin(s) & retainer(s)
Jib cylinder pin(s) & retainer(s)
Jib extension cylinder pin(s) & retainer(s)
Boom tip attachments
Other
Status
Other
18
6628 Owner’s Manual
Frequency
Q
Q
Key
Hyd Lines
Quarterly Inspection Continued...
Inspection Description
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
Pumps&Motors Pumps and motors for loose bolts/fasteners, leaks, noise, vibration, loss of performance, heating and excess pressure.
Winch motor(s)
Status
Q
Q
Q
Q
Valves
Cylinders
Winch
Hyd Filter
Rotation motor(s)
Other
Hydraulic valves for cracks, spool return to neutral, sticking spools, relief valve failure.
Main control valve
Load holding valve(s)
Outrigger or auxiliary control valve(s)
Other
Hydraulic cylinders for drifting & leakage. Rods for nicks, scores, & dents.
Castor damage. Case & rod ends for damage & abnormal wear.
Outrigger cylinder(s)
Inner boom cylinder(s)
Outer boom cylinder(s)
Extension cylinder(s)
Rotation cylinder(s)
Jib lift cylinder(s)
Jib extension cylinder(s)
Other
Winch, sheaves, & drums for damage, abnormal wear, abrasion, & other irregularities.
Hydraulic filters for replacement per maintenance schedule.
A
A
A
A
A
A
A
A
Frequency
A
A
A
A
A
A
A
Key
Daily
Monthly
Quarterly
Hyd System
Controls
Valves
Valves
Rotation Sys
Lubrication
Hardware
Wear Pads
Loadline
Historic Data
Historic Data
Historic Data
Maintenance 19
Annual Inspection
Inspection Description
All daily inspection items.
All monthly inspection items.
All quarterly inspection items.
Hydraulic fluid change per maintenance schedule.
Control valve calibration for correct pressures & relief valve settings.
Safety valve calibration for correct pressures & relief valve settings
Valves for failure to maintain correct settings.
Rotation drive system for proper backlash clearance & abnormal wear, deformation, & cracks.
Gear oil change in rotation drive system per maintenance schedule.
Check tightness of all fasteners and bolts.
Wear pads for excessive wear.
Loadline for proper attachment to drum.
Monthly inspection records.
Maintenance records.
Repair and modification records.
Status
20
6628 Owner’s Manual
Inspection Notes
Specifications 21
Chapter 4 - Specifications
Crane Rating:
Standard Boom Length:
Boom Extension:
Maximum Horizontal Reach:
Maximum Vertical Lift:
(from crane base)
Boom Elevation:
Model 6628 Crane
SPECIFICATION SHEET
38,000 ft-lbs (5.25 ton-meters)
13’(3.96 m) from CL of Crane
1st stage: Hydraulic 90"(228.6 cm)
2nd stage: Hydraulic 90"(228.6 cm)
28’(8.53 m) from CL of Crane
29’4”(8.94 m)
-5 to +80 degrees
32.50” (82.6 cm) Stowed Height
(crane only)
Mounting Space Required
Approximate Shipping Weight
Controls
Winch Specification
Rope Diameter:
Line pull speed:
Max. single part line:
Max. double part line:
Rotation:
(worm gear)
Lifting Capacities
Power Supply Required
20 x 21 inches (50.8 x 53.3 cm)
1900 lbs (885 kg)
Radio control standard for all functions.
5/16"(.794 cm)
60 ft/min (18.29 m/min)
3000 lbs (1360 kg)
6000 lbs (2720 kg)
400 degree power
2925 lbs @ 13’(2440 kg @ 3.96m)
1850 lbs @ 20’6"(1540 kg @ 6.25m)
1350 lbs @ 28’(1130 kg @ 8.54m)
PTO & Pump
(8 gpm @ 2850 psi)
(30.3 lpm @ 197 bars)
*Subject to change without notification
22
6628 Owner’s Manual
Capacity Chart - Decal PN 31072
Reach in Feet/Meters
Capacity in Pounds/Kilograms
6000lbs
2720kg
4550lbs
2060kg
2550lbs
1155kg
6000lbs
2720kg
5950lbs
2700kg
1850lbs
840kg
3400lbs
1540kg
6000lbs
2720kg
6000lbs
2720kg
5125lbs
2325kg
3850lbs
1750kg
3275lbs
1485kg
2985lbs
1350kg
2500lbs
1135kg
2100lbs
950kg
1900lbs
860kg
1600lbs
725kg
1400lbs
635kg
1850lbs
840kg
1350lbs
610kg
2925lbs
1325kg
Weight of load handling devices are part of the load lifted and must be deducted from the capacity.
®
Maximum 1 - part line capacity is
3000lbs (1360kg). For greater loads, use 2 - part line.
6628
PN 31072
Chapter 5 - Decals
Decals of Note
Decals 23
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. PN: C4795
Moving Outrigger Hazard Decal
Location: On each outrigger
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
.
PN: C5918
Instructional Decal
Location: At Stow Hook area
Function: To caution the operator not to use the stow hook for any lifting applications. PN: 24712
24
6628 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.
PN: C4545
Instructional Decal
Location: At Overload Switch
Function: To inform the operator that tampering with the overload device may cause a unit failure.
PN: 28256
Decals 25
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
26
6628 Owner’s Manual
Free Falling Manual Boom Decal
Location: Inside Crane Compartment, on
Compartment Door
Function: To inform the operator of the hazard associated with free falling manual boom extensions, the possible consequences should the hazard occur, and how to avoid the hazard.
PN: 12452
Electrocution Hazard Decal
Location: Inside Crane Compartment, on
Compartment Door
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.
PN: C1179
Operation Hazard Decal
Location: Inside Crane Compartment, on
Compartment Door
Function: To inform the operator and other personnel in the work area of the hazard associated with improper maintenance and unauthorized modifications, the possible consequences should the hazard occur, and how to avoid the hazard.
PN: 4190
Operation Hazard Decal
Location: Inside Crane Compartment, on
Compartment Door
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.
PN: 4189
Decals 27
Moving Boom Hazard Decal
Location:Inside Crane Compartment, on
Compartment Door
Function: To inform the operator and other personnel in the work area of the hazard associated with a moving boom, especially while stowing and unfolding the crane, the possible consequences should the hazard occur, and how to avoid the hazard.
PN: C4541
Operation Hazard Decal
Location:Inside Crane Compartment, on
Compartment Door
Function: To inform the operator of the need for proper training, familiarity with safe operating procedures and, the possible consequences without training.
PN: C4540
Hoisting Decal:
Location: Inside Crane Compartment, on
Compartment Door
Function: To inform the operator of the hazard associated with lifting personnel with the boom, boom hook, the load or winch loadline, the possible consequences of lifting personnel, and how to avoid the hazard.
PN: 12451
Training Decal:
Location:Inside Crane Compartment, on
Compartment Door
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
28
6628 Owner’s Manual
Decal Kit Placement - PN 31654
PN 31654
Installation 29
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
6628 Telescopic 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. If a question should arise during the installation process, please contact Stellar Customer
Service at (800) 321 3741.
According to Federal Law (49 cfr part 571), each final-stage manufacturer shall complete the vehicle in such a manner that it conforms to the standards in effect on the date of manufacture of the incomplete vehicle, the date of final completion, or a date between those two dates. This requirement shall, however, be superseded by any conflicting provisions of a standard that applies by its terms to vehicles manufactured in two or more stages.
This crane is designed for use with a Stellar
Service Body installed on a vehicle that meets the minimum chassis requirements of the crane. Check with Stellar Industries before installing this crane on a body other than a Stellar Service Body.
WARNING!
The use of this crane on a body not capable of handling the loads imposed on it may result in serious injury or death.
Notice:
PTO and Pump installation instructions are provided by the corresponding manufacturers. For more information on which PTO and Pump fit your application, please contact your local Stellar Distributor or Stellar Customer Service.
Therefore, the installer of Stellar cranes and bodies is considered one of the manufacturers of the vehicle. As such a manufacturer, the installer is responsible for compliance with all applicable federal and state regulations. They are required to certify that the vehicle is in compliance with the Federal Motor Vehicle Safety Standards and other regulations issued under the
National Traffic and Motor Vehicle Safety
Act.
Please reference the Code of Federal
Regulations, title 49 - Transportation, Volume
5 (400-999), for further information, or visit http://www.gpoaccess.gov/nara/index.html
for the full text of Code of Federal
Regulations.
Optimal Service Body for the 6628 Crane:
T1-11 Service Body
Applicable Chassis:
Cab to Axle:
Body Length Nominal:
Body Height:
Body Width:
Compartment Depth:
Floor Width:
Net Weight:
16000 to 19000 GVWR
84” (213.36 cm)
133” (337.82 cm)
44” (111.76 cm)
94” (238.76 cm)
22” (55.88 cm)
50” (127 cm)
3220 lbs (1460.37 kg)
Optimal Service Body for the 6628 Crane:
T2-11 Service Body
Applicable Chassis:
Cab to Axle:
Body Length Nominal:
Body Height:
Body Width:
Compartment Depth:
Floor Width:
Net Weight:
19000 GVWR and up.
84” (213.36 cm)
133” (337.82 cm)
52” (132.08 cm)
94” (238.76 cm)
22” (55.88 cm)
50” (127 cm)
3600 lbs (1632.93 kg)
30
6628 Owner’s Manual
Installation Overview
1. Determine that the mounting location for the 6628 crane is at least 18” x 20” (45.7 x 50.8 cm).
2. Use the detail below to drill 1.06” diameter holes into the mounting plate. Run tap on the threads of the base to be sure they are clean.
3. Use a crane or lifting device capable of lifting the weight of the Stellar crane. The Stellar 6628 weighs approximately 1900 lbs (885 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.
4. Connect straps or chain from the lifting device to the lifting rings on the Stellar 6628.
5. Use four (4) 1” x 3” #8 bolts and four (4) #8 flat washers.
6. Install a washer on each bolt.
7. Apply Loctite Thread locker #277 to the bolts.
8. Using the lifting device, lower the Stellar 6628 just above the crane compartment and start the bolts.
Have someone assist in leveling the crane. Note: the rotation motor should be to the door side of crane
compartment and the boom should be extended back over the rear bumper.
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.
10. Torque the cap screws to 680 ft-lbs.
11. Remove supporting crane.
12. Hook-up hydraulics and electrical using the schematics provided in Chapter 8 - Hydraulics - Electrical.
Note: If questions should arise during any portion of this installation, please contact Stellar Customer
Service at (800) 321-3741.
The following pages will give a basic overview of the installation process for the Stellar 6628. Please read thru them entirely and obtain a clear understanding of the process before proceeding.
2
1
Ø1.063
4 Places
FRONT
Motor
Ø6.00
7.38
14.75
14.75
7.38
Hole Mounting Detail
ITEM NO. PART NO.
1
2
5199
6538
DESCRIPTION
CAP SCR 1.00X8X3.00 HHGR8 ZY
WASHER 1.00 SAE FLAT YELLOW GR8
QTY.
4
4
Installation 31
Installation Details
1. Determine that the mounting location for the 6628 crane is at least 18” x 20”
(45.7 x 50.8 cm).
2. Use the detail below to drill 1.06” diameter holes into the mounting plate.
Run tap on the threads of the base to be sure they are clean.
3. Use a crane or lifting device capable of lifting the weight of the Stellar crane. The Stellar
6628 weighs approximately 1900 lbs (885 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.
4. Connect straps or chain from the lifting device to the lifting rings on the Stellar 6628.
5. Use four (4) 1” x 3” #8 bolts and four (4) #8 flat washers.
6. Install a washer on each bolt.
7. Apply Loctite Thread locker #277 to the bolts.
The number of bolts used may vary from model to model.
8. Using the lifting device, lower the Stellar 6628 just above the crane compartment and start the bolts.
Have someone assist in leveling the crane. Note: the
rotation motor should be to the door side of crane compartment and the boom should be extended back over the rear bumper.
32
6628 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.
10. Torque the cap screws to 680 ft-lbs.
11. Remove supporting crane.
12. Hook-up hydraulics and electrical using the schematics provided in Chapter 8 -
Hydraulics - Electrical.
Note: If questions should arise during any portion of this installation, please contact Stellar
Customer Service at (800) 321-3741.
Installation 33
Stability Procedure
Definition of Stability for the Stellar Telescopic Crane Products:
A truck is stable until the load cannot be lifted off the ground with the winch, without tipping over the truck. Every Stellar crane installed must be tested for stability to determine the actual load capacity of the final truck package. The actual test data must be recorded and supplied with the truck at the time of in-service and should be kept with the truck at all times. The following procedure will test the truck package for stability and will provide a stability capacity chart. The load limit information shown on the stability capacity chart is formulated on 85% tipping.
Set Up:
1. Locate the truck on a test course in position for loading and engage travel brakes.
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.
6628 Stability Data
Max Horizontal Reach: 336” (From the center of rotation to boom tip)
Stability Test Weight: 1600 lbs.
Test Procedure
1. Rotate the crane into Zone 1 position.
2. With the crane fully retracted and the boom horizontal, winch the test weight off the ground. Note: Keep weight within six inches of the ground at all times.
3. Extend the boom outward until full extension has been reached or until the truck becomes unstable (Again, use the winch to keep the weight within six inches of the ground.)
4. If the boom goes full extension without becoming unstable, the crane is termed stable for this zone and 100% can be written in the Zone 1 data box.
5. If the truck becomes unstable prior to going full extension, retract the boom until the truck becomes stable and measure the horizontal reach in this position (center of rotation to boom tip). This is the stable horizontal reach for this zone. Stable horizontal reach divided by Maximum horizontal reach multiplied by 100 equals the percentage of rated capacity for this zone. Use the following formula to determine the percentage of rated capacity:
6. Record this number in the data box for Zone 1. This is the revised capacity due to stability for this zone.
7. Repeat this procedure for each zone until the worksheet is completed.
8. This is the revised capacity based on stability of this package.
34
6628 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
Assembly Drawings 35
Chapter 7 - Assembly Drawings
Base Assembly - PN 17375
6
7
8
9
4
5
10
3
11
14
11
13
12
P/N 17375
I T E M P A R T D E S C R I P T I O N
1 11453 BEARING SWING DRIVE CAST BASE 6620
2 1 1 5 4 2 S T O P 3 8 2 0 4 0 0 S L I D E
3C6069 MOTOR HYD ROSS MK080613AAAB
4 D 0 7 9 0 W A S H E R 0 .
5 0 F L A T G R 8
5D1307 CAP SCR 0.50-13X1.25 SH
6 1 2 7 3 0 G U A R D T T B 6 6 2 0 C R A N E
713959 CAP SCR 1.00-8 X .63 PLASTIC
8
9
0 3 4 0 W A S H E R 0 .
2 5 F L A T
0479 CAP SCR 0.25-20X0.75 HHGR5
10 21151 GASKET MOTOR 008-10056-1
11 D1345 FTG CPRSN 0.12NPT/0.25 TUBE
12 D1810 TBE AIR SAEJ844 TYPE A .25 (28")
1 3
1 4
C c
2
1
2
5
5
9
6
2
F T G
Z E R
C O
K
U P L E R P
1 / 8 N P T
I P E 0 .
1 3
S T R A I G H T
1
2
2
2
1
1
1
Q T Y .
1
1
2
1
1
2
2
GASKET SHOWN AS REFERENCE
2
1
36
6628 Owner’s Manual
Mast Assembly - PN 17376
1 4
6
4
5
7
8
9
9
1 0
1 6
1 5
P/N 17376
I E M
1
2
3
4
5
6
9 5
R
1
T
7
C 5 9 0 2
D
C
1
1
6
2
0
3
1
3
5
6
4
3
7
D E
M A
W
C A
W
C
A
A
A
C R I P T I O N
T 6 6 2 0 C R A N E
H
C R 0 . 6 3 - 1 1 X 3 . 0 0 H H G R 8 Z Y
S
E 0 . 6 3 S E F L A T Y
E R 0 . 3 8 F L A T G R 8
S R 0 . 3 8 - 1 6 1 . 7 5 H
L L O W G R 8
H G R 8
7
8
0
2
3
4
4
6
7
8 5
2 4 1 3 9
N U T 0 . 3 8 - 1 6 H H N Y L O C
V B 4 S C T L C T / P
C A S R 0 . 3 1 - 1 8 3 . 7 5
O
H
P S T
H G R 5
E L I N G 8 G P M
Q Y .
1
1 4
4
1
2
4
1 4
8
4
9
1 0
1 1
1 2
1
1
1
1
1
1
3
4
5
6
7
8
1 9
0 3 4 3
0 3 4 2
1 1 9 1 0
0 3 4 0
0
1 1 3 6 2
2
4
7
2
8
0
1 3
4 3 8 0
W
N
C
U
O
W A S
C A
E
S
R 0
R 0
. 2 5 F L A T
. 3 1 - 1 8 0 . 7 5 H H G R 5
W
A
I
T
N
H
0 .
E
C
E
3 1
R
H
R
- 1
6 6 2 0
K I
0 .
8
N
3 1 U
E
H H N
A S
A
S S F
T
Y L
I C
L T
O C
' S 3
Z I N C
0 0 0 #
C O L A R 0 . 3 8 X 0 . 7 5 X 0 . 3 8 U H M W
3 4
0
1
2
0
2
3
0
B U S H I N G 3 2 D X
R E
C A
E I V
C
R
R 0
R A
. 2
R
5 - 2 0
2 4 2 .
X 1 .
0 0 X 1
5 0 H
. 5 0 G
H G R 5
A L O C K
I O C O N T R O L 6 F C T N H 2
0 3 3 3 N U T 0 . 2 5 - 2 0 H H G R 5 N Y O C
1
2
4
1
2
1
8
4
2
2
1 2
1 7
1 3
1 2
1
1 8
3
2
1 2
1 9
1 1
Main Boom - PN 31647
Assembly Drawings 37
1
23
13
22
20
21
19
22
7
15
14
13
12
8
7
6
3
10
27
3
16
24
6
7
8
7
9
25
6
8
4
26
11
12
7
6
13
14
7
8
2
5
6
7
8
6
7
8
28
7
8
17
18
P/N 31647
7
8
5
6
9
1 0
I T E M
1
2
3
4
P A R T
3 4 7 6 7
D E S C R I P T I O N
I N N E R B O O M 6 6 2 8
31648 CYLINDER ASM 6628 INNER
4381 BUSHING 32DXR32 2.00X2.00 GARLOCK
0 0 6 8 B U S H I N G Q S -I 1 6 1 8 2 4
9 7 0 9 P I N 2 .
0 0 X 1 0 .
1 9 D & T
8377 PIN CAP 0.56X3.50X.25
D0790 WASHER 0.50 FLAT GR8
10172 CAP SCR 0.50-13X1.00 HHGR8 ZY
9 7 1 1
9 7 1 0
P I N 2 .
0 0 X 8 .
8 8 D & T
P I N 2 .
0 0 X 1 1 .
6 9 D & T
1
1
1
6
18
14
Q T Y .
1
1
4
2
I T E M
1 1
P A R T
9 7 1 2
D E S C R I P T I O N
P I N 1 .
0 0 X 8 .
3 8 D & T
12 7403 PIN CAP 0.44X2.50X.252
13 C6353 WASHER 0.38 FLAT GR8
14 9843 CAP SCR 0.38-16X0.75 HHGR8
15 D1194 PLATE ANGLE INDICATOR
16 C6106 NUT 0.50-13 HHGR5 NYLOC
17
18
9363 WEAR PAD 1.12X2.00 RND NYLATRON
9545 PLATE WEAR PAD SUPPORT
19 13435 BRKT ROPE GUIDE 9620
20 12168 CAP SCR 0.38-16X9.00 HHGR5
2
2
2
2
1
2
Q T Y .
1
2
6
2
2 5
26
2 7
28
I T E M P A R T D E S C R I P T I O N
21 27720 SPACER ROPE GUIDE 6620 UHMW
22
23
2 4
0347 NUT 0.38-16 HH NYLOC
0335 CAP SCR 0.38-16X1.25 HHGR5
0 3 4 0 W A S H E R 0 .
2 5 F L A T
C 5 6 0 6 C L A M P 0 .
2 5 B L K V I N Y L
0478 CAP SCR 0.25-20X0.50 HHGR5
1 9 1 6 6 C O R D R E E L 5 7 2 8
0425 MACHY WASHER 1.25ID 10GA
Q T Y .
2
4
2
2
1
2
1
2
38
6628 Owner’s Manual
Extension Boom Assembly - PN 31649
22
17
16
1
21
9
6
7
8
2
3
20
11 13
14
4
18
10
19
12 13 14 5
P/N 31649
I T E M
1
2
P
3
A
4 7
R
6
T
8
D E S
E X T
C R I P T I O N
B O O M 1 S T 6 6 2 8
3 4 7 6 9 E X T B O O M 2 N D 6 6 2 8
Q T Y .
1
1
4 1 2 8 2 4 P I N H I T C H 1 .
0 0 X 4 .
5 0
5 5 7 5 3 P I N 0 .
1 9 X 1 .
5 6 L Y N C H
69363 WEAR PAD 1.12X2.00 RND NYLATRON
79545 PLATE WEAR PAD SUPPORT
8 D 0 7 9 0 W A S H E R 0 .
5 0 F L A T G R 8
910172 CAP SCR 0.50-13X1.00 HHGR8 ZY
10 11545 SHEAVE 6620 6.75 DIA .31R/1.94 THK
11 13400 PIN TEAR DROP 1.00X4.38
12 13399 PIN TEAR DROP 1.00X3.81
13 0343 WASHER 0.31 USS FLAT ZINC
8
8
2
1
1
2
2
2
2
2
14 0484 CAP SCR 0.31-18 X 0.50 HHGR5
15 9991 WEAR PAD 0.25X2.00 RND NYLATRON
16 C6219 WASHER 0.75 SAE FLAT YELLOW GR8
4
1
17 4974 CAP SCR 0.75-10X2.50 HHGR8 ZY
18 27719 SPACER BOOM TIP 6620 UHMW
19 0490 CAP SCR 0.31-18X3.50 HHGR5
1
2
2
2 0 0 3 4 2 N U T 0 .
3 1 1 8 H H N Y L O C
21 0425 MACHY WASHER 1.25ID 10GA
22 37018 CYLINDER EXT ASM 6628 31073P RELIEF
2
2
1
15
15
5
Assembly Drawings 39
Main Cylinder Assembly - PN 31648
Note: Main Cylinder uses
Stellar Seal Kit P/N 35655
2
3
4
2
2
3
5
2
Cylinder
Serial Tag
Location
1
N O T E : B
F
U S
O R
H I
R
N G S S H O W N
E F E R E N C E
P/N 31648
I T E M
1
2
3
4
5
P A R T
3 1 0 7 4
D E S C R I P T I O N
C Y L I N D E R 4 .
5 0 X 2 1 .
3 8
0 2 7 9
1 2 1 5 8
1 3 0 8 0
4 3 8 1
F
T
M
T G
A N
A D
U B E
I F
A P T
O L D
6 F
A S M 0 .
5 O
A S M 6 6
L O
3 8 X 8 .
8 8
2 0
S
M A I N C Y L 6 6 2 0
I N N E R H O L D I N G
B U S H I N G 3 2 D X R 3 2 2 .
0 0 X 2 .
0 0 G A R L O C K
Q T Y .
1
4
2
1
4
40
6628 Owner’s Manual
Extension Cylinder Assembly - PN 37018
Note: Upper Extension
Cylinder uses Stellar Seal
Kit P/N C6304
7
6
1
Cylinder
Serial Tag
Location
8
9
10
9
2
4
3
5
6
Note: Lower Extension
Cylinder uses Stellar Seal
Kit P/N 20310
P/N 37018
I T E M P A R T D E S C R I P T I O N
131073P CYLINDER EXT 6628 2 STAGE 2.5/2.0
2 14115 MANIFOLD ASM 6620 EXT CBBD-LJN-XVN
311882 CAP SCR 0.38-16X1.75 SH ZC
414601 CAP SCR 0.38-16X2.25 SH ZC
531652 TUBE ASM 0.38X 72.86 EXT CYL 6628
6 C 4 6 6 0 H O S E C L A M P # 2 4 S S
737019 TUBE ASM 0.38X 104.34 EXT CYL 6628
8
9
26212 TUBE ASM 0.38X9.63 MAIN CYL 6620
C 1 8 5 4 F T G A D A P T 6 8 F 5 O L O S
10 C2238 VALVE RELIEF 750PSI 49040-750
Q T Y .
1
1
1
1
2
2
1
1
2
1
Assembly Drawings 41
Cable & Hook Assembly - PN 38183
11
14
16
13
15
12
23
19
8
17
18
22
21
20
5
6
2
3
2
1
5
6
6
10
4
9
6
P/N 38183
1 9
2 0
21
1 6
1 7
18
2 2
23
13
14
15
10
11
12
I T E M P A R T D E S C R I P T I O N
1 11934 SHEAVE 6620 6.50 DIA .31R/1.12 THK
237120PC PLATE 6620 SNATCH BLOCK
327812 SPACER 6620 SNATCH BLOCK UHMW
4 11666PC SPACER 5520 SNATCH BLOCK
54975 CAP SCR 0.75-10X3.50 HHGR8 ZY
6 C6219 WASHER 0.75 SAE FLAT YELLOW GR8
7C0538 NUT 0.75-10 HHGR8 NYLOC
817005 WIRE ROPE 5/16 6X19 IWRC-XIP 150FT
99263 PIN .38X3.00 QUICK RELEASE
25831 HOOK 5 TON SWIVEL CROSBY 1028623
11938 SWITCH LIMIT A2B FURNAS 3SE3170
33749 SCREW #10-24X1.75 SHGR8 ZINC
34354 ANTI 2 BLOCK COVER LH
D1711 CAP SCR #10-24X0.50 BTNHD SS
C4956 NUT #10-24 HH NYLOC SS
1
3
8
5
4
2
5
6
0530
3
4
0 3 4 7
3 7 6 0 1
0424
C H A I N 0 .
1 0 5 X 1 7
W E I G H T A N T I 2 B L O C K
CAP SCR 0.38-16X2.75 HHGR5
N U T
P I N
0 .
3 8 1 6 H H
1 .
0 0 X
N Y L
2 .
7 5 C O T T
O C
E R
MACHY WASHER 1.00ID 10GA
3 7 8 2 4 C O T T E R P I N . 1 2 5 X 1 .
0 0
37850 CONNECTOR QUICK LINK 0.13
7
1
1
2
2
1
1
1
1
1
1
1
1
1
4
1
3
1
6
1
3
Q T Y .
1
2
2
7
22
21
42
6628 Owner’s Manual
Basket Cable & Hook Assembly (Optional) - PN 48111
8
5
6
14
2
13
12
11
5
6
3
1
2
14
6
10
4
9
6
7
PN 48111
I T E
1
2
M P A R T
11934
D E S C R I P T I O N
SHEAVE 6620 6.50 DIA .31R/1.12 THK
3 7 1 2 0 P C P L A T E 6 6 2 0 S N A T C H B L O C K
327812 SPACER 6620 SNATCH BLOCK UHMW
411666PC SPACER 5520 SNATCH BLOCK
9
10
1 1
12
1
5 4975 CAP SCR 0.75-10X3.50 HHGR8 ZY
6C6219 WASHER 0.75 SAE FLAT YELLOW GR8
7 C 0 5 3 8 N U T 0 .
7 5 1 0 H H G R 8 N Y L O C
817005 WIRE ROPE 5/16 6X19 IWRC-XIP 120FT
3
3
3
9263
7
0424
7
6
8
0
2
1
4
PIN .38X3.00 Q U I C K R E
P I N 1 .
0 0 X 2 .
7 5 C O T T E R
MACHY WASHER 1.00ID 10GA
C O T T E R P I N . 1 2 5 X 1 .
0 0
L E A S E
25831 HOOK 5 TON SWIVEL CROSBY 1028623
14 43536PC BRACKET SNATCH BLOCK CRADLEA2B 5520
3
1
1
1
3
6
Q T Y .
1
2
2
1
1
2
2
2
7
12
13
Assembly Drawings 43
Wire Rope/Sheave Configurations
44
6628 Owner’s Manual
Chapter 8 - Hydraulics - Electrical
Control Kit - PN 10701
PN 10701
46
6628 Owner’s Manual
Control Kit (Power House 24) - PN 38989
P/N 38989
Hydraulic Kit - PN 13042
P/N 13042
48
6628 Owner’s Manual
Valve Bank - PN 24685
4
5
3
5
3
1
2
5
P/N 24685
Valve Identification
Valve Item #3 P/N 25371 GS0457
Valve Item #4 P/N 25372 GS0459
I T
1
E M
3
4
P
2
2
A
5
5
4
R
3
3
9
6
6
T
7
8
6 0 2
2
2
2
2
2
5
5
5
5
5
3
3
3
3
3
6
7
7
7
7
9
1
7 2
7 0
D
R
S
V
S
V
V
S
C
E
E
E
A
E
A
A
E
O
S
L
A L K
L
I
V E
A
L
L
V
A
I
I
C
E
V
L
V E
V E
L
L
R
F
E F L W
K
E
I
K
K
I T
S
S
K
1 2
P
I T 2
I
I
V
I
T
T
2
2
4
O L
T
V
T
O
2
5 3 6 7
D
I
A
O
L
2 4
L
9
N
5 3
C
C T R L P R
N
3
N
V
9
E
6 0
D
O L N D
7
P
I T 2 5 3 6 7
0 / 2
3
5 3
P
3 P
1
A
2
/
3
3
/
4 6
2
2
C
5
P
P
5
K
8 5 / 2 4 6 9 0
3 8 1
O S 4
O S 4
3
A
8
O
O
S
S
7
P / J P 0 4 C 3 1 5 0 N 0 - 8
1
2
R
4
4
D
W A Y T A N D G 0 4 5 7 1 W
W
A
A
Y
Y
T A
O
N
P
D
E N
G 0
G
4
0
5
4
7
5 9 1
M A L E 2 4 6 8 5 / 2 4 6 9 0
1
9 1
Q
1
T Y
3
1
H Y D R A U L I C S C H E M A T I C
Hydraulic Installation
1. After mounting, locate the pressure and return lines. Note: Pressure line is 3/8” hose; Return line is 1/2” 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.
3. Install hydraulic reservoir with return filter.
Attach pump pressure line to valve, return link to tank.
4. Fill system with hydraulic oil (Mobil DTE-
13M is recommended).
50
6628 Owner’s Manual
Hetronic Remote Assembly
1
NOTE: P/N'S 25999 & 24958 ARE OPTIONAL COVERS
FOR THE SWITCHES AND TRIGGER
2
8
9
3
6
SEE NOTE
4
I T E M P A R T D E S C R I P T I O N
1
2
20088 CONTROL HANDLE HOUSING 4 FCTN HET
34107 CONTROL HANDLE FACE PLT 6 FCTN H2
324385 GUARD RADIO SWITCH 4 FCTN
435447 CONTROL HANDLE GRIP W/TRIGGER HT H2
524958 RUBBER BOOT TRIGGER GUARD HET
622600 SWITCH TOGGLE HET RADIO 63019300
735441 BATTERY TUBE AA HETRONIC RADIO
816975 SWITCH E STOP ASM HETRONIC RADIO
934110 DECAL CONTROL HANDLE H2 6FCTN MECH
Q T Y .
1
1
1
1
1
1
1
6
1
Hydraulic System
7
5
Chapter 9 - Replacement Parts
12158
31651
31652
4380
4381
#0068
9363
9991
8377
7403
D0790
10172
11545
11934
17005
12824
9263
11938
19166
34102
35441
16975
22600
C6304
20310
14390
4587
6397
C2027
C2028
C2029
D1245
D1246
D1247
25895
25896
PART#
C6069
25367
25368
24960
25369
25371
25372
25373
25370
13080
9803
11991
14115
35655
HYDRAULIC SWING MOTOR
RELIEF VALVE
COIL - 12VDC
PRESSURE SWITCH
O'RING - # 4 SAE
O'RING - # 6 SAE
DESCRIPTION
SEAL KIT - RELIEF VALVE
FLOW CONTROL VALVE
SEAL KIT - FLOW CONTROL VALVE
SOLENOID VALVE TAND G04571
SOLENOID VALVE OPEN G04591
SEAL KIT - SOLENOID VALVE
MANIFOLD ASM - MAIN CYLINDER
C-BALANCE VALVE
PLUG - C-BALANCE
MANIFOLD ASM - EXTENSION CYLINDER
SEAL KIT - MAIN LIFT CYLINDER
SEAL KIT - EXTENSION CYLINDER (upper)
SEAL KIT - EXTENSION CYLINDER (lower)
O'RING - MANIFOLD ASM EXT. CYLINDER
HYD PRESSURE GAUGE
O'RING - # 4 FACE SEAL
O'RING - # 6 FACE SEAL
O'RING - # 8 FACE SEAL theO'RING - # 8 SAE
WORM GEAR - BEARING SWING DRIVE
BEARING & SEAL KIT - BEARING SWING DRIVE
TUBE ASM - MAIN CYLINDER
TUBE ASM - EXTENSION CYLINDER
TUBE ASM - EXTENSION CYLINDER
BUSHING 2.00"x1.50"
BUSHING 2.00"x2.00"
BUSHING
WEAR PAD 1.12" x 2.00"
WEAR PAD 2.50" ROUND
PIN CAP .56 X 3.50 X .25
PIN CAP .44 X 2.50 X .25
WASHER 0.50 FLAT GR8
CAP SCR. 0.50-13 X 1.00"
SHEAVE
SHEAVE
WIRE ROPE
HITCH PIN 1.00" X 4.50"
QUICK RELEASE PIN .38 X 3.00"
LIMIT SWITCH
CORD REEL
RADIO TRANSMITTER (HETRONIC RADIO)
BATTERY TUBE (AA) HOLDER (HETRONIC RADIO)
E-STOP SWITCH (HETRONIC RADIO)
TOGGLE SWITCH (HETRONIC RADIO)
12280 3.6V BATTERY
35264PC ANTI - 2 BLOCK WEIGHT
5753
19501
LYNCH PIN
5-TON HOOK SAFETY LATCH ASM.
SUGGESTED QTY
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
4
1
1
4
4
4
4
1
4
2
1
1
1
1
1
1
1
1
1
4
1
2
4
4
2
1
1
1
1
2
2
2
2
1
1
1
52
6628 Owner’s Manual
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. If there is no power going to the receiver, trace back to the power source and check for a blown fuse or loose ground connection. Refer to radio remote troubleshooting guide at the end of this chapter.
• Make sure that the transmitter batteries are fully charged. (Rechargeable batteries are good for 11 months or 200 charges)
• Make sure that the hydraulic pump is operating at its rated flow or GPMs. Check the flow by using the flow meter to determine the GPMs. It is possible that the hydraulic pump is getting weak. If this is suspected, contact Stellar Customer Service.
Problem: Crane will operate manually but will not operate electrically.
Solutions:
• Make sure that there is 12V power going to the radio receiver. If there is no power going to the receiver, trace back to the power source and check for a blown fuse or loose ground connection. Refer to radio remote troubleshooting guide at the end of this chapter.
• Make sure that the parking brake is engaged.
• Make sure that the parking brake switch is working properly. Check the parking brake switch by performing a continuity test. If the switch is defective, simply replace it.
Problem: Not all crane functions operate using the radio remote transmitter or crane operates intermittently.
Solutions:
• Make sure that the toggle switch is working properly. If the switch is defective, simply replace it.
• Make sure that there is power going from the valve bank coil solenoid or to the function that 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. Remove stem valve, thoroughly clean, lubricate, and reinstall valve. Do not over tighten. If the valve will not close, simply replace it.
Problem: Two functions operate at the same time while only toggling one function.
Solutions:
• Make sure that the solenoid valves are all in the center position.
• Determine the function that is operating on its own. Check to see if there is power going to the solenoid valve from a function that should not be operating. If voltage is present at the solenoid valve without operating the function, the toggle switch has failed and is stuck in the “on” function. If no voltage is present, the solenoid valve may be partially open. Remove the stem valve, thoroughly clean, lubricate, and reinstall the valve. Do not over tighten. If valve will not close, simply replace it.
Problem: Winch brake will not hold.
Solutions:
• Check to see if the back pressure on the return line of the winch is greater than 50 psi.
Try operating a function other than the winch. Operate the function both ways and then stop. Now operate the winch. If the brake still does not hold, contact Customer
Service at Stellar.
54
6628 Owner’s Manual
Problem: Winch will not hold load.
Solutions:
• Make sure that the object being lifted does not exceed the rated capacity of the winch.
Refer to the capacity chart. If the object is within the rated capacity, reposition the truck and try to lift the object without using the crane boom extensions.
• Make sure that the relief valve on the winch is set correctly. Readjust the relief valve if necessary.
Problem: Crane only operates at full speed.
Solutions:
• Check to see if there is 12V power constantly going to the proportional valve. If 12 volts are showing up at the proportional valve without pulling on the transmitter trigger, the handle/trigger assembly may be defective.
If 8 volts are showing at the proportional valve, it is possible that the valve is stuck open and will not close. Remove the valve, clean it thoroughly and reinstall. Do not over tighten. If the problem persists, replace the proportional valve.
• Check to see if the manual override on the proportional valve is turned out. Turn the manual override on the flow valve in.
Problem: Winch “Up”, Main Cylinder “Down”, and Extension Cylinder “Out” are the only functions that don’t operate.
Solutions:
• Make sure that the unit 2-block weight and chain on the end of the boom are straight so they slide easily along the wire rope cable.
• Make sure that the limit switch is working properly. Disconnect the two wires connected to the limit switch and tie them together. If all functions operate, replace the limit switch.
• Make sure that the cord for the cord reel is undamaged. Check the continuity of the cord. Disconnect the cord reel from the crane harness and bypass the harness connection. If the crane operates properly, replace cord reel.
Problem: Crane operates slowly.
Solutions:
• Make sure that the crane is receiving the recommended GPMs to operate.
• Check the level of hydraulic fluid in the reservoir. Add fluid as needed.
• Check to see if the valve bank orifice is plugged. If so, replace the orifice. Call Stellar
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. If no polarity is present, replace the coil. If coil is magnetizing, remove the stem valve, thoroughly clean, lubricate, and reinstall the valve.
Problem: Cylinder drifts outward or downward.
Solutions:
• Check to see if there is air in the hydraulic system. Operate all cylinders connected to the hydraulic system. Start with the extension cylinder, then operate the main boom, winch, rotation, and ending with the hydraulic outriggers, if installed. When operating, extend each cylinder halfway out, retract all the way in, and then extend until the cylinder rod is at the end of its stroke.
Operate cylinders slowly so air is pushed thru the system to the reservoir. Repeat this cycle
2-3 times.
• Make sure the holding valves are operating properly. Remove, clean, and then inspect each holding valve. When removing a holding valve, always relieve the pressure inside the cylinder by loosening jam nut of the holding valve and turning set screw inward/clockwise. Count the number of turns until the set screw is seated. When reinstalling the holding valve, make sure the valve is reset by turning the set screw the number of turns it took to relieve the pressure.
Finish by tightening the jam nut.
• Check the cylinder rod for scratches. If a scratch is located on the cylinder rod, hydraulic fluid can pass thru and cause a loss of pressure. Replace cylinder rod or cylinder.
• Check to see if the piston seals are damaged. If they show signs of damage, install a new cylinder seal kit.
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
• Is the E-Stop pushbutton pulled out?
• Are all the switches in their center
(neutral) position.
• Are the batteries in the transmitter fully charged?
• Is the transmitter inside its operating range?
PROBABLE CAUSE
Receiver
• Is the antenna plug securely connected?
• If there is an external antenna, is the antenna connection assembly outside the enclosure secure?
• Are the power supply and ground wires securely fastened?
• Are the signal wires separated from the power supply wires?
CORRECTION PROBLEM
System will not operate after normal start-up procedure.
E-Stop switch engaged
Batteries fully discharged
Transmitter is transmitting
(Power LED flashing), but crane will not respond
All crane motions operate intermittently
No power to the receiver
E-Stop switch engaged
Transmitter out of range
Receiver power off
E-Stop failure in transmitter
Pull out E-Stop switch.
Check batteries to ensure a full charge.
Replace with new batteries if necessary.
Check the diagnostic LED on the receiver to be sure power is applied. Ensure that the system is properly grounded.
Pull out the E-Stop push button and activated switch on transmitter.
Take the transmitter back into the range of the receiver.
Turn on power to receiver.
Check E-Stop pushbutton for damage. Check wiring to contact element for broken or disconnected wires. Repair or replace E-Stop push button or wiring.
Tighten or replace antenna.
Some crane motions operate intermittently
Receiver antenna is loose or missing
External antenna (if used) has loose connection, poor grounding or interference
Ground wiring is poor.
Conductor is too small, or receiver is grounded to chassis.
Crane motion wiring may be loose.
Tighten antenna and ground connection.
Ground wiring must be connected to machine power source ground. Minimum diameter of conductor ground is 12 AWG.
Check wiring from receiver to plug and from plug to crane motion actuator.
56
6628 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
LED is off
LED flashes
LED will not light when any button is pushed, or LED remains on continuously
Possible Cause
Transmitter is off
Transmitter is operating in a normal mode
Replace batteries. If this does not correct the problem, the transmitter must be returned for repair.
Transmitter Repairs
Notice: The transmitter electronic components are exposed when the back of the case is removed. Take caution to prevent dirt or other contaminants from entering the case. Do not allow the circuit to be scraped or damaged in any way.
Receiver Troubleshooting
The following steps should be followed when troubleshooting the receiver.
1. Check the LED indicator. If it is not lit: a. Make sure 12 VDC and ground is present at the connecting wires.
b. If using the AC power, check for AC power on the connecting wires.
c. If input power is present and the LED is off, check the fuse inside the receiver case.
d. If input power is present and the LED is off, and the fuse inside the receiver case is OK, contact Customer
Service at Stellar Industries.
2. Activate the transmitter by pressing any command switch.
a. If the receiver LED does not flash, test the transmitter.
b. Verify the identity code is the same for the transmitter and receiver. use the learn button to re-program the receiver for the transmitter.
c. Contact Customer Service at Stellar Industries.
3. Only some functions are operating: a. Check to make sure the common wires for the relays are connected properly. (See Installation drawings for details.
b. Check output voltage of the respective wires and the electrical circuits.
c. Check the fuses inside the receiver case.
d. Check the receiver label to verify the function has been programmed to the needs of the equipment.
4. You are experiencing intermittent operation: a. Check antenna connections and antenna location.
b. On AC systems, ensure noise suppression devices have been placed across the coils of all contacts.
c. Ensure you are inside the operating range of the receiver and have line of sight to the receiver antenna.
5. Operating Range is short: a. Check all antenna connections and transmitter operation.
b. On new installations, verify the receiver antenna is placed properly. If necessary, use an antenna mounting kit to relocate the antenna to a more favorable location.
Receiver Testing
LED on continuous
LED Indication
LED flashes
LED goes off
Receiver Action
Receiver operating voltage is present, no signal is being received.
Signal is being received that matches the decoders address.
Signal is being received, but address is wrong.
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. Is the emergency brake engaged?
3. Is the transmitter battery fully charged? (Note: When the battery is fully charged, there should be a quick beep sound from the transmitter when toggling a function. A longer or constant steady beep indicates that the battery charge is weak or going dead.)
4. Is the E-Stop switch button pulled out or engaged?
Check the receiver functions.
(Note: Remove the receiver cover located on the crane mast)
With the main power on, check the following functions:
1. Is the yellow light flashing in the upper left hand corner of the receiver?
a. Yes – i. Check the signal functions using the transmitter toggle functions - go to step 2.
b. No – i. Check the 7.5 fuse located inside the receiver. Replace the fuse if it has blown.
ii. If the 7.5 fuse is ok, check the crane power fuse. (Usually located under the chassis hood near the 300 amp continuous duty solenoid.)
2. Does the green light in the upper left hand corner of the receiver flash when operating a toggle switch on the transmitter?
a. Yes – i. Go to step 3.
b. No – i. Carefully remove the switch face plate housing from the transmitter and check the following areas:
1. Check to see if a jumper spade, from the CS458 TX-RF module, is loose or laying inside the transmitter, either laying on, or beneath the coder board.
2. Check for broken wires on the CS458 TX-RF Module. (Blue, Red, and White with blue stripes - Three wires total.
3. Check to make sure that the E-Stop 2 Wire connector plug (Located in the upper right hand corner of the coder board) isn’t loose or disconnected. (Usually a grey and white with brown stripe wire.)
4. Check for loose, corroded, or broken wires on the toggle switches. Note: If the green light inside the receiver flashed constantly without engaging a toggle switch, the coder board has failed or a toggle switch may be weak or broken.
3. Are the red LED function lights coming on when activating a toggle on the transmitter?
a. Yes – i. Go to Step 4.
b. No – i. The E-Stop switch or coder board has failed.
4. All lights are working properly?
a. Note: Radio system is functioning correctly - check the following areas: i. Check for loose ground wires.
ii. Check for loose or broken wires on the crane valve bank wiring harness.
iii. Check to make sure the flow control valve on the valve bank is actuating properly, using the trigger assembly of the transmitter.
iv. Check the anti-2-blocking electrical circuit (Limit switch, cord reel, and pressure switch - if applicable) for proper operation.
b. If problem cannot be determined, contact customer service at Stellar Industries.
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,
Twelve (12) month repair labor from the date recorded by Stellar as the in-service date, not to extend beyond twenty-four (24) month from date of manufacture, and
Thirty-six (36) month warranty on all Stellar Crane, Hooklift Hoist, Cable Hoist, and Container Carrier structural parts from the date recorded by
Stellar as the in-service date, not to extend beyond forty-eight (48) months from date of manufacture.
The in-service date will be derived from the completed warranty registration card. In the event a warranty registration card is not received by
Stellar, the factory ship date will be used.
Stellar’s obligation under this warranty is limited to, and the sole remedy for any such defect shall be, the repair and/or replacement (at Stellar’s option) of the unaltered part and/or component in question. Stellar after-sales service personnel must be notified by telephone, fax, or letter of any warranty-applicable damage within fourteen (14) days of its occurrence. If at all possible, Stellar will ship the replacement part within 24hours of notification by the most economical, yet expedient, means possible. Expedited freight delivery will be at the expense of the owner.
Warranty claims must be submitted and shall be processed in accordance with Stellar’s established warranty claim procedure. Stellar after-sales service personnel must be contacted prior to any warranty claim. A return materials authorization (RMA) account number must be issued to the claiming party prior to the return of any warranty parts. Parts returned without prior authorization will not be recognized for warranty consideration.
All damaged parts must be returned to Stellar freight prepaid; freight collect returns will be refused. Freight reimbursement of returned parts will be considered as part of the warranty claim.
Warranty service will be performed by any Stellar new equipment distributor, or by any Stellar-recognized service center authorized to service the type of product involved, or by the Stellar factory in the event of a direct sale. At the time of requesting warranty service, the owner must present evidence of date of delivery of the product. The owner shall be obligated to pay for any overtime labor requested of the servicing company by the owner, any field service call charges, and any towing and/or transportation charges associated with moving the equipment to the designated repair/service provider.
All obligations of Stellar and its authorized dealers and service providers shall be voided if someone other than an authorized Stellar dealer provides other than routine maintenance service without prior written approval from Stellar. In the case repair work is performed on a Stellarmanufactured product, original Stellar parts must be used to keep the warranty in force. The warranty may also be voided if the product is modified or altered in any way not approved, in writing, by Stellar.
The owner/operator is responsible for furnishing proof of the date of original purchase of the Stellar product in question. Warranty registration is the ultimate responsibility of the owner and may be accomplished by the completion and return of the Stellar product registration card provided with the product. If the owner is not sure of registration, he is encouraged to contact Stellar at the address below to confirm registration of the product in question. This warranty covers only defective material and workmanship. It does not cover depreciation or damage caused by normal wear and tear, accident, mishap, untrained operators, or improper or unintended use. The owner has the obligation of performing routine care and maintenance duties as stated in Stellar’s written instructions, recommendations, and specifications. Any damage resulting from owner/operator failure to perform such duties shall void the coverage of this warranty. The owner will pay the cost of labor and supplies associated with routine maintenance.
The only remedies the owner has in connection with the breach or performance of any warranty on the Stellar product specified are those set above. In no event will Stellar, the Stellar distributor/dealer, or any company affiliated with Stellar be liable for business interruptions, costs of delay, or for any special, indirect, incidental, or consequential costs or damages. Such costs may include, but are not limited to, loss of time, loss of revenue, loss of use, wages, salaries, commissions, lodging, meals, towing, hydraulic fluid, or any other incidental cost.
All products purchased by Stellar from outside vendors shall be covered by the warranty offered by that respective manufacturer only. Stellar does not participate in, or obligate itself to, any such warranty.
Stellar reserves the right to make changes in design or improvement upon its products without imposing upon itself the same upon its products theretofore manufactured.
This warranty will apply to all Stellar Hooklift Hoists, Stellar Cable Hoists, Stellar Container Carriers, Stellar Service Trucks, Stellar Truck-mounted
Cranes, and Stellar Compactors shipped from Stellar’s factory after March 1, 2008. The warranty is for the use of the original owner only and is not transferable without prior written permission from Stellar.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES, AS
SPECIFIED HEREIN. STELLAR INDUSTRIES, INC. IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Revision Date: July 2008 Document Number: 37040
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Key Features
- Telescopic boom
- Hydraulic system
- Remote control
- Outriggers
- Load charts
- Safety features
