Stellar labs 6000 Bedienungsanleitung

Articulating Crane

Owners’ Manual

Model 6000

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com Rev 1

PN 37810

Subject to Change without Notication.

Installation • Assembly Drawings • Parts

Page ii | Stellar®6000 Articulating Crane Owner’s Manual

P65 Warning / Serial Tag Location

MODELNO.SERIAL NO.

DATE

MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.

PNC5942

PATENTINFORMATION

http://www.stellarindustries.com/ip

MODEL NO.SERIAL NO.

DATE

MADE IN THE U.S.A. BY STELLAR INDUSTRIES, INC.

PN C5942

PATENT INFORMATION

http://www.stellarindustries.com/ip

Serial Tag

Location

WARNING

Operating, maintaining, and servicing a Stellar

product may expose you to chemicals including, but

not limited to, engine exhaust, carbon monoxide,

phthalates, and lead. These chemicals are known

to the State of California to cause cancer and birth

defects (or other reproductive harm). To keep your

exposure to a minimum, be sure to avoid breathing

exhaust and service your Stellar product in a well-

ventilated area while wearing gloves or washing

your hands frequently. For more information, go to

www.P65Warnings.ca.gov/passenger-vehicle. www.p65warnings.ca.gov

NOTICE

Cold Weather Performance

Although clear data on cold weather performance from every steel

manufacturer is not available for all types and thicknesses of steel, Stellar

Industries is confident that the weldments on our products will operate to

100% of their intended purpose to temperatures down to -40° F / C.

It is recommended it Stellar manufactured equipment needs to be used in

temperatures below -40° F / C, the operator should pull the unit into a

climate-controlled area and allow the weldments to warm up to and then

maintain a temperature above this level.

Stellar®6000 Articulating Crane Owner’s Manual | Page iii

Introduction ................................................................................................................................iv

Chapter 1 - Specications ............................................................................................................ 1

Capacity Chart - Decal PN 5165 ................................................................................................ 2

Chapter 2 - Installation.................................................................................................................. 3

General Installation .................................................................................................................... 3

Installer Notice ......................................................................................................................... 3

Torque Data Chart ................................................................................................................... 4

Installation Overview ............................................................................................................... 5

Mounting Kit Drawing .............................................................................................................. 5

Hydraulic Installation .................................................................................................................. 6

Face Seal/O-Ring Size Chart ..................................................................................................... 7

Hydraulic Kit - PN 13040 ............................................................................................................ 8

Control Kit - PN 52257 ............................................................................................................... 9

Decal Placement - PN 13356 ................................................................................................... 10

Chapter 3 - Assembly Drawings..................................................................................................11

Base Assembly - PN 22140 ......................................................................................................11

Gear Bearing - PN 4032........................................................................................................... 12

Stabilizer Valve Bank - PN 61040 ............................................................................................ 13

Mast Assembly - PN 22141 ...................................................................................................... 14

Valve Bank - PN 44530 ............................................................................................................ 15

Valve Bank (Alternate) - PN 125254 ........................................................................................ 16

Valve Bank (Alternate) - PN 125254 Parts List ........................................................................ 17

Main Boom Assembly - PN 22142 ........................................................................................... 18

Extension Boom Assembly - PN 22143 ................................................................................... 19

Radio Remote - PN 88454 ....................................................................................................... 20

Table of Contents

Page iv | Stellar®6000 Articulating Crane Owner’s Manual

Introduction

A copy of this manual is provided with every crane and can be found in the hard plastic manual

case that is installed on the chassis. A copy of this manual shall remain with the crane at all times.

Throughout the manual, three signal words will be used to bring attention to important items:

A NOTICE signal word indicates a practice not related to physical injury.

A WARNING signal word indicates a hazardous situation which, if not

avoided, could result in death or serious injury.

A DANGER signal word indicates a hazardous situation which, if not

avoided, will result in death or serious injury.

Information contained within this manual does not cover operation, maintenance, or

troubleshooting. Please refer to the Small OTR Crane Manual for details on these items.

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].

WARNING

NOTICE

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 [email protected]

Order Parts [email protected]

Warranty Information [email protected]

DANGER

Stellar®6000 Articulating Crane Owner’s Manual | Page 1

Chapter 1 - Specications

Model 6000 Crane

SPECIFICATION SHEET

Crane Rating: 60,000 ft-lbs (8.30 ton meters)

Standard Boom Length: 11’ (3.35 m) from CL of Crane

14’ (4.27 m) from CL of Truck

Boom Extension: Hydraulic 32” (81.3 cm)

Maximum Horizontal Reach: 14’ (4.27 m) from CL of Crane

17’ (5.18 m) from CL of Truck

Maximum Vertical Lift: 20’ (6.10 m) from Truck Frame

(From Truck Frame)

Cylinder Specications

Inner Lift Cylinder: 6” (15.24 cm) bore with integral pilot

operated counterbalance valves.

Outer Lift Cylinder: 5” (12.70 cm) bore with integral pilot

operated counterbalance valves.

Extension Cylinder: 3” (7.62 cm) bore with integral pilot

operated counterbalance valves.

Rotation: 290 degree power

(Worm Gear Drive)

Lifting Capacities: 10,000 lbs @ 9’ (4535 kg @ 2.74 m)

(From CL of Truck) 4,250 lbs @ 17’ (1930 kg @ 5.18 m)

Power Supply Required: PTO & Pump

(6.0 gpm @ 2850 psi)

(22.7 lpm @ 197 bars)

Controls: Proportional Radio Controls standard for all functions.

Stowed Height: 75” (190.5 cm) above Truck Frame

(Above Truck Frame)

Mounting Space Required: 32” (81.3 cm)

Approximate Shipping Weight: 3,150 lbs (1,430 kg)

Page 2 | Stellar®6000 Articulating Crane Owner’s Manual

Capacity Chart - Decal PN 5165

Stellar®6000 Articulating Crane Owner’s Manual | Page 3

Installer Notice

According to Federal Law (49 cfr part 571), each nal-stage manufacturer shall complete the

vehicle in such a manner that it conforms to the standards in e󰀨ect on the date of manufacture

of the incomplete vehicle, the date of nal completion, or a date between those two dates. This

requirement shall, however, be superseded by any conicting provisions of a standard that applies

by its terms to vehicles manufactured in two or more stages.

Therefore, the installer of Stellar® products are considered one of the manufacturers of the vehicle.

As such a manufacturer, the installer is responsible for compliance with all applicable federal l and

state regulations, as well as any OEM instructions such as chassis body builder guides. 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 Tra󰀩c and Motor Vehicle Safety Act and also

complies with recommended best practices from the chassis OEM.

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.

Chapter 2 - Installation

General Installation

This chapter is designed to serve as a general guide for the installation of a Stellar 2200 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.

This crane is designed for use with a Stellar Service Body installed on a vehicle that meets the

minimum chassis requirements of the crane. It is the installer’s responsibility to assure that the

crane is mounted on a platform that will support the maximum crane rating of this

crane.

Do not install this crane on a body not capable of handling the loads imposed on

it. Failure to do so may result in serious injury or death.

When installing welder units to the service bodies, it is highly recommended that

a surge protector is installed on the chassis batteries to protect the crane radio receiver, wiring and

other electronic devices from an unexpected electrical spike or surge. Failure to do so could result

in extensive damage to the service body and crane electrical circuit.

WARNING

NOTICE

Page 4 | Stellar®6000 Articulating Crane Owner’s Manual

When using the torque data in the

chart, the following rules should be

observed:

• Bolt manufacturer’s particular

specications should be consulted

when provided.

• Flat washers of equal strength must

be used.

• All torque measurements are given

in foot-pounds. To convert to inch-

pounds, multiply by 12.

• Torque values specied are for

bolts with residual oils or no special

lubricants applied.

• Torque values for socket-head

capscrews are the same as for Grade

8 capscrews.

• Do not use these values if a di󰀨erent torque value or tightening procedure is

given for a specic application. Torque values listed are for general use only. Check tightness of

fasteners periodically.

• Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with

identical grade.

• Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used,

these should only be tightened to the strength of the original.

• Tighten plastic insert or crimped steel-type lock nuts to approximately 110 percent of the dry

torque values shown in the chart below, applied to the nut, not to the bolt head. Tighten toothed or

serrated-type lock nuts to the full torque value. Note: “Lubricated” means coated with a lubricant

such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated

without lubrication. Tighten lubricated bolts to approximately 80% of dry bolts.

Size Bolt DIA Plain Plated Plain Plated Plated

(DIA-TPI) (Inches) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb) (Ft-Lb)

5/16-18 0.3125 17 13 25 18 22

3/8-16 0.3750 31 23 44 33 39

7/16-14 0.4375 49 37 70 52 63

1/2-13 0.5000 75 57 105 80 96

9/16-12 0.5625 110 82 155 115 139

5/8-11 0.6250 150 115 220 160 192

3/4-10 0.7500 265 200 375 280 340

7/8-9 0.8750 395 295 605 455 549

1-8 1.000 590 445 910 680 823

1 1/8-7 1.1250 795 595 1290 965 1167

1 1/4-7 1.2500 1120 840 1815 1360 1646

1 3/8-6 1.3750 1470 1100 2380 1780 2158

1 1/2-6 1.500 1950 1460 3160 2370 2865

GRADE 5 GRADE 8 GRADE 9

Torque Data Chart

NOTICE

Stellar®6000 Articulating Crane Owner’s Manual | Page 5

1. Locate mounting brackets and clamp to chassis1” (min) from rear of cab (or desired location).

2. Set crane on chassis and check for interferences.

3. Using mounting bracket as a guide, mark holes to be drilled into truck frame.

4. Remove mounting brackets and drill holes.

5. Mount brackets using 3/4” Grade 8 bolts, ast washers, and nyloc nuts.

6. Lower crane onto mounting brackets.

7. Mount crane using 1” Grade 8 bolt, at washers, and nyloc nuts.

8. Connect pressure and return lines per hydraulic kit.

9. Connect (+12V) Power and ground wires inside crane box.

10. Check reservoir for oil and ll if necessary.

11. Operate crane several cycles.

Installation Overview

Mounting Kit Drawing

Page 6 | Stellar®6000 Articulating Crane Owner’s Manual

Hydraulic Installation

Never modify or alter any of the equipment, whether mechanical, electrical, or hydraulic, without

Stellar Industries’ approval.

Do not touch or grab any hoses that could be under pressure. Release system

pressure before attempting to make adjustments or repairs.

Do not attempt service or repair when PTO is engaged.

Disassemble and assemble hydraulic components on a clean surface.

Clean all metal parts in a nonammable cleaning uid. Then lubricate all components to aid in

assembly.

Hydraulic uid expands when heated. This raises the pressure in an

unventilated tank. Release the tank pressure before removing the cap completely. Failure to do so

may cause the oil to shoot out of the tank very rapidly and cause severe burns.

Do not rely on the hydraulic uid to support the boom or crane. If hydraulic

uid escapes, the boom or crane can fall immediately. Make sure the ground or blocking is

supporting the boom before performing any maintenance or repair.

Contaminants in a hydraulic system a󰀨ect operation and will result in serious

damage to the system components. Dirty hydraulic systems are a major cause of component

failures.

If evidence of foreign particles is found in the hydraulic system, ush the system.

When installing metal hydraulic tubes, tighten all ttings nger tight. Then , in order, tighten the

ttings at the rigid end, the adjustable end, and the mounting brackets. After tubes are mounted,

install the hoses. Connect both ends of the hose with all ttings nger tight. Position the hose so

it does not rub the machine or another hose and has a minimum of bending and twisting. Tighten

ttings in both couplings.

Due to manufacturing methods, there is a natural curvature to a hydraulic hose. The hose should

be installed so any bend is with this curvature.

WARNING

NOTICE

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