Stellar labs 9000 Bedienungsanleitung

Model 9000

Articulating Crane

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.

Rev 2

PN 37811

Installation • Assembly Drawings • Parts

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

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

Page ii | Stellar®9000 Articulating Crane Owner’s Manual

Model 9000 Manual Revisions

Date of Revsion Section Revised Description of Revision

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

Stellar®9000 Articulating Crane Owner’s Manual | Page iii

Table of Contents

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

Chapter 1 - Specications.....................................................................1

Model 9000 Specications .................................................................1

Capacity Chart - Decal PN 64835 ....................................................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

Hydraulic Pressure Settings .................................................................7

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

Hydraulic Kit - PN 61547 ......................................................................8

Control Kit (900 MHz Version) - PN 92662 ........................................10

Control Kit (434 MHz Version) - PN 92663 ........................................11

Decal Placement - PN 30488 ...........................................................12

Chapter 3 - Assembly Drawings .........................................................13

Base Assembly - PN 94131 ................................................................13

Base Assembly Rear Mount Australia Stop - PN 94132 ..................14

Gear Bearing - PN 63815 ..................................................................15

Valve Bank - PN 51658 ......................................................................16

Outrigger Valve Bank - PN 61642 ....................................................17

Valve Assembly - PN 66286 ..............................................................18

Mast Assembly - PN 29350 ................................................................19

Main Cylinder Assembly - PN 29352 ................................................20

Main Boom Assembly - PN 29354 ....................................................21

Outer Cylinder Assembly - PN 29356 ...............................................22

Extension Boom Assembly - PN 61204 .............................................23

Extension Cylinder Assembly - PN 73499 .........................................24

Stabilizer Assembly - PN 61089 .........................................................25

Reservoir Assembly - PN 86510 .........................................................26

Radio Transmitter - PN 89149/93084 ................................................27

Chapter 4 - Replacement Parts ..........................................................29

Page iv | Stellar®9000 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 Large 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

DANGER

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®9000 Articulating Crane Owner’s Manual | Page 1

Crane Rating: 90,000 ft-lbs (12.44 ton meters)

Standard Boom Length: 13’ 1” (3.99 m) from CL of Crane

Boom Extension: Hydraulic 41" (104 cm)

Maximum Horizontal Reach: 16’7” (5.05 m) from CL of Crane

Maximum Vertical Lift: 22’3” (6.78 m)

(From Truck Frame)

Cylinder Specications: Inner Lift Cylinder: 6” (15.24 cm) bore with integral

pilot operated counterbalance valves

Outer Lift Cylinder: 5” (12.7 cm) bore with integral

pilot operated counterbalance valves

Extension Cylinder: 3.5” (8.89 cm) bore with integral

pilot operated counterbalance valves

Rotation: 290 degree power

(planetary gear with pinion)

Lifting Capacities: 9,000 lbs @ 10’ (4080 kg @ 3.03 m)

(From CL of Truck) 5,425 lbs @ 16’7 (2460 kg @ 5.05 m)

Power Supply Required: PTO & Pump - 12 gpm @3,000 psi

(45.4 lpm @ 206 bar)

Controls: Fully Proportional Paddle Controls for all functions.

Stowed Height: 84” (213 cm)

(Above Truck Frame)

Mounting Space Required: 42” (107 cm)

Chassis RBM (Recommended): 1,080,000 in-lb

Approximate Shipping Weight: 4,800 lbs (2175 kg)

Chapter 1 - Specications

Model 9000 Specications

Page 2 | Stellar®9000 Articulating Crane Owner’s Manual

10’

3.05m

16’7”

5.05m

13’1”

3.99m

10’

3.05m

16’7”

5.05m

13’1”

3.99m

10’

3.05m

25’7”

7.80m

22’6”

6.86m

CAPACITY

CHART

9000 lbs

4080 kg

6880 lbs

3120 kg

5425 lbs

2460 kg

0’

CRANE

GROUND 0’

64835 - Rev A

190 STATE STREET GARNER, IA 50438

PHONE: (800) 321-3741 FAX: (641) 923-2812

WARNING

Do not exceed equipment load charts and ratings.

Failure to follow equipment load charts and ratings can result in death or serious injury.

Overload Hazard

Capacity Chart - Decal PN 64835

Stellar®9000 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 effect 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®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 Trafc 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.

Chapter 2 - Installation

General Installation

This chapter is designed to serve as a general guide for the installation of a Stellar 9000

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®9000 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 different 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®9000 Articulating Crane Owner’s Manual | Page 5

1. Relocate any obstructions on the frame that will be in the way of mounting the crane.

2. Measure the inside of the frame rails and cut the frame support to this length. Ensure that the frame

supports have a tight t between the frame rails.

3. Set the crane on the chassis and allow a minimum of 3” from the cab.

4. Make certain that the frame supports are installed square, cut to length in such a way as to support the

frame anges with the tie down rods are torqued.

5. Install the crane tie downs. Start at one corner and tighten both tie downs to 200 ft-lbs. Move to the

diagonal set and tighten to 200 ft-lbs. Tighten the remaining 2 corners. Continue this pattern at 200 ft-lb

increments until 375-400 ft-lbs is achieved. Be sure the mounting block stays perpendicular to the frame rail

as they are tightened down.

6. Connect the pressure and return lines per the hydraulic kit.

7. Connect the electrical power and ground wires. Ground preferrably connected to battery.

8. With the crane and outriggers in the stored position, check the reservoir for oil and ll if necessary.

9. Operate the crane for several cycles. Fully cycle the cylinder in both directions (blow past relief) to

remove any air from the system.

Installation Overview

Mounting Kit Drawing

.YTQNOITPIRCSEDTRAPMETI

160517 BASE 9000 FOLD OVER STABILIZER 1

258516 TIE DOWN ROD HIAB 12

358660 PLATE MOUNTING HIAB 1224

48202PCFRAME SUPPORT 15000 CRANE4

4221BAIHKCOLBGTM856855

66538 WASHER 1.00 SAE FLAT YELLOW GR8 16

618RGHH8-00.1TUN855167

861559NUT 1.00-8 HHGR8 TOP LOCKING8

PN 61405

Page 6 | Stellar®9000 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 affect 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 hydralic hose. The hose

should be installed so any bend is with this curvature.

WARNING

NOTICE

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