Stellar labs 9000 Bedienungsanleitung

Large OTR

Service Cranes

Owner’s Manual

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com

Subject to Change without Notication.

Safety • Operation • Maintenance • Troubleshooting

Notice: A copy of this manual must remain with the equipment at all times.

For a printable download copy, please visit: www.stellarindustries.com

Model 9000 Model 13500

Model 23000 Model 28000

Model 17000

Page ii | Stellar®Large OTR Service Crane Owner’s Manual

Large OTR Crane Manual Revisions

Date of Revsion Section Revised Description of Revision

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]

Stellar®Large OTR Service Crane Owner’s Manual | Page iii

Table of Contents

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

Chapter 1 - Operation ...........................................................................1

General Operation .............................................................................1

Pre-Operation Inspection ...................................................................1

Job Site Setup ......................................................................................2

Step 1: Disengage drive axle and set the parking brake. .............2

Step 2: Engage the hydraulic power source. ..................................2

Step 3: Turn on electrical power. .......................................................3

Step 4: Position the stabilizers. ............................................................3

Step 5: Operate the crane. ...............................................................4

Step 6: Stow the crane. ......................................................................6

Step 7: Stow the stabilizers. ................................................................6

Step 8: Finalize Service........................................................................6

Step 9: Disengage the hydraulic power source. .............................6

Step 10: Leave the worksite. ..............................................................6

Radio Remote Control Functions ......................................................7

Safety Decals of Note ........................................................................8

Chapter 2 - Maintenance....................................................................11

General Maintenance Guidelines ..................................................11

Basic Crane Maintenance Schedule* ............................................11

Hydraulic Oil/Filter Maintenance ....................................................12

Washing the Crane ...........................................................................12

Paint Maintenance ...........................................................................12

PTO and Pump Maintenance .........................................................12

Rotation Gear Bearing Maintenance ............................................12

Gear-Bearing Bolt Maintenance .....................................................13

Rotation Gear Bearing Thread Tightening Procedure ..................13

Rotation Gear Bearing Thread Tightening Procedure ..................14

Face Seal/O-Ring Size Chart ...........................................................15

Lubrication Recommendations .......................................................16

Checking Gear Lube in Gear Box ...................................................17

Chapter 3 - Troubleshooting................................................................18

Manual Operation ............................................................................24

Page iv | Stellar®Large OTR Service Crane 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.

A few notes on this manual:

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 all maintenance, operating, or

repair instructions pertinent to all possible situations. Please be aware that some sections of

this manual contain information pertaining to Stellar® manufactured cranes in general and

may or may not apply to your specic 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].

WARNING

NOTICE

DANGER

Stellar®Large OTR Service Crane Owner’s Manual | Page 1

Chapter 1 - Operation

General Operation

Pre-Operation Inspection

Safety should be the n umber one thought on every operator’s mind. Three factors should

exist for safe operation: a qualied operator, well-maintained equipment, and the proper

use of this equipment.

This chapter contains information regarding the safety and operation of Stellar® Large OTR

Service Cranes and should be read and understood completely by everyone working with

or near the crane before putting the unit into operation.

Failure to follow operating, maintenance, or safety instructions can result

in death or serious injury.

It is the responsibility of the owner to instruct the operator in the safe operation of the

equipment and to provide the operator with properly maintained equipment.

Stellar® Crane operators must conform to the qualications specied in

ANSI B30.5 - Chapter 5-3 Operation. Trainees or untrained persons shall be under the direct

supervision of qualied persons.

Operators shall consult with the owner of the equipment regarding current safety

regulations and required personal protective equipment.

Please take note that Stellar Industries, Inc. is not liable for accidents incurred by the crane

because of non-fulllment from the operator’s side of current rules, laws, and regulations.

Before operating the equipment, make sure all regular maintenance has been performed.

Each day, inspect the crane for all of the following:

• Vehicle for standard checks such as proper tire ination and uid levels.

• Parking brake operation.

• Hydraulic reservoir for proper oil level.

• Hoses and gearboxes for evidence of oil leaks.

• Crane controls for excessive wear, cleanliness and proper operation.

• Operational aids such as decals for placement and legibility.

• All securing hardware such as cotter pins, snap rings, hairpins, and pin keepers for proper

installation.

• All safety guards for proper installation.

Replace/repair as necessary prior to operation. For a more detailed checklist of scheduled

inspection points, refer to the Stellar® Crane Inspection Log. This document is an essential

guide for the daily, monthly, quarterly and annual inspection tasks that will help maintain

the quality of your Stellar product.

WARNING

Page 2 | Stellar®Large OTR Service Crane Owner’s Manual

Step 2: Engage the hydraulic power source.

Step 1: Disengage drive axle and set the parking brake.

Job Site Setup

1. Make certain that the transmission is in neutral/park.

2. Engage the hydraulic power source. If using a PTO, consult the PTO manual for specic

instructions if needed. Note: Allow the hydraulic system oil to warm before operating

any of the hydraulic equipment, especially during cold weather.

The drive axle must be disengaged and the parking brake must be set before operating

any of the equipment.

Thoroughly plan the lift by understanding the work site area and your loads before

positioning the vehicle. For a complete and detailed description of job site setup, please

refer to the AEM Safety Manual (Form C-70-2). Consider the following:

• The vehicle should be positioned in an area free from bystanders and overhead

obstructions. Use a signal person if necessary.

• Always maintain safe clearance from high voltage power lines in

accordance with ANSI B30.5: 5-3.4.5 Operating Near Electric Power Lines. Death or

serious injury will result from inadequate clearance if crane, load, or vehicle becomes

electrically charged.

• Make certain that the vehicle is parked on stable, at ground as close to the job as

possible. The surface under the service truck must be able to support the weight of the

machine and its load.

• Use wheel chocks if parking the vehicle on a slope.

• Always park the vehicle with the grade. If cross-grade parking is required, the load

capacity must be decreased appropriately to mitigate tipping risk.

• Park the vehicle perpendicular and at the proper distance to the tire being serviced. The

vehicle’s proper distance will be determined by multiple variables and can be gured

from the crane load chart, size of tire, type of service being performing, and various

other factors.

• Never begin a lift without estimating the load weight andcalculating

the distance and position on the capacity chart.

• Once the vehicle is properly placed, secure the work area using safety cones.

• Do not operate the crane during electrical storms.

• 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.

DANGER

WARNING

Stellar® Large OTR Service Crane Owner’s Manual | Page 3

Step 3: Turn on electrical power.

Locate the desired function on the switch panel inside the cab and activate to power the

equipment.

Step 4: Position the stabilizers.

Extend the stabilizers using the control levers or switches marked ‘stabilizer’ or ‘outrigger’.

These may be located at the crane operation center outside the cab of the vehicle.

1a. Models: 9000/13500 The Stabilizer/Crane switch needs to be toggled to ‘Stabilizer’ to

operate the stabilizers.

1b. Models: 17000/23000/28000

The Remote/Manual switch

needs to be toggled to

‘Manual’ to operate the

stabilizers.

2. Locate the street side (SS)

and curb side (CS) stabilizer

control handles. Push the lever

down to lower or extend the

corresponding stabilizer leg.

When the stabilizer makes

solid contact with the ground,

release the control lever.

Note: On some models, level

the crane base using the level

provided.

Note: Some models may have and in/out extension levers or auxillary stabilizers.

Keep clear of stabilizer legs during operation. Moving stabilizers can

cause serious crushing injuries. Make certain that all personnel are clear of the stabilizer

and the ground contact point before operating.

Do not raise the rear tires of the truck off the ground with the stabilizers.

Conrm that the stabilizers are positioned on stable, at ground and that the truck is as

level as possible both front to rear and side to side. Use stabilizer pads to ensure the proper

distribution of weight.

WARNING

Page 4 | Stellar®Large OTR Service Crane Owner’s Manual

Using the Radio Remote:

To operate the crane using the radio remote control:

1. Make certain that the red e-stop button is in the up position (disengaged). On some

models (17000/23000/28000), toggle the Remote/Manual switch to “Remote”. On other

models (9000/13500), toggle the Crane/Stabilizer switch to “Crane” and the Crane

Manual/Crane Remote switch to “Crane Remote”.

2. To start up the remote control, follow the instructions provided in the remote control

manufacturer’s manual.

4. To operate the crane, activate and hold the desired paddle

(See Radio Remote Control page for details). The remote

control units for these models operate the crane functions

proportionally by controlling the oil ow entering the control

valve when a specic paddle is activated. The more

you engage the paddle, the faster the crane function will

operate.

Note: The Radio remote control is equipped with an

emergency stop button. If you encounter a situation that you

need to stop the crane functionality immediately, press down

on the red Emergency Stop button.

Operating the Crane:

1. Slowly activate the main boom paddle up to un-stow the crane from travel position.

2. Once the crane is un-stowed, proceed with operating the proper paddles to perform

the service.

Lifting the load:

Consider the following:

• When performing a lift, have the load as close to the ground as possible.

• Never exceed manufacturer’s capacity charts and ratings. These

ratings are based on the machine’s hydraulic, mechanical, and structural design rather

than stability. If there is a tire manipulator attached to your crane, use the manipulator

load chart, as the weight of the unit must be taken into account.

• Center the crane directly over the load to avoid side loading.

WARNING

Step 5: Operate the crane.

Stellar® Large OTR Service Crane Owner’s Manual | Page 5

• Make certain that the stabilizers are positioned on at, stable ground. If the terrain is

soft or loose, stabilizer pads may be required. In icy conditions, bolts can be added to the

holes in the stabilizer pads for additional traction.

• Never perform a lift that can induce a dynamic force greater than the capacity of the

crane.

• It is the responsibility of the operator to know the weight of the handled load to avoid

overloading the crane. Do not rely on the overload device to determine maximum

rated loads. If the crane is picking more than the maximum rated load, the overload

protection device may be malfunctioning. Discontinue use immediately and contact

Stellar Customer Service for support.

• Do not use a crane to lift personnel without factory approved lifting

device.

• Do not attempt to lift xed loads.

Moving the load:

Ensure that the load is secure and balanced before moving:

• Consult the Tire Industry Association (TIA) tire service training materials for proper tire

handling.

• Be sure that the crane is level and stable before moving the load.

• Always look for any changes to the surroundings since the job site setup. Be aware of

any new or missed overhead obstructions (branches, power lines, etc) and bystanders.

Use a signal person if necessary.

• Never operate the crane with personnel under any part the boom

or load. Do not extend or rotate a load over anyone. Never allow personnel to place

themselves under any part of the boom or load.

• Never leave a crane load suspended or unattended.

• Do not use the boom to drag a load.

• Do not use the crane boom to push downward onto anything.

• Avoid sudden starts and stops when moving a load.

WARNING

Page 6 | Stellar®Large OTR Service Crane Owner’s Manual

The parking brake must be released before moving the truck.

Make certain that any air tanks are completely drained before moving

the truck.

Step 9: Disengage the hydraulic power source.

• Disengage the hydraulic power source.

• Turn off all switches on the control panel.

• Stow the radio remote in the cab. If your truck has a docking station, secure the remote

prior to leaving the work site.

Step 8: Finalize Service

Step 7: Stow the stabilizers.

Finalize the service by storing the safety cones, shutting drawers and compartments, and

securing the load.

Models: 9000/13500 Toggle the Stabilizer/Crane switch needs to ‘Stabilizer’ and stow the

stabilizers.

Models: 17000/23000/28000 Toggle the Remote/Manual switch to ‘Manual’ and stow the

stabilizers.

WARNING

Step 10: Leave the worksite.

Step 6: Stow the crane.

When the job is complete, square up and center the tire manipulator over the bed. Lower

the crane onto the bed with the lowest crane height possible.

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