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Page 18 | Stellar

®

 Small OTR Service Crane Owner’s Manual

Problem

Possible Cause

Possible Solution

Crane will not 
operate.

PTO is not engaged.

Engage PTO.  If PTO won't engage, refer to PTO 
manufacturer's manual for details.

Crane is not receiving proper 
hydraulic flow

Check hydraulic reservoir fluid level. 
 
Ensure PTO is engaged. 
 
Ensure Panic Bar E-Stop is not engaged. 
 
Verify selector switch is in crane mode and not 
stabilizer/off mode. 
 
Ensure dump valve is receiving proper electrical 
signal and operating properly. 
 
Verify hydraulic pump is producing proper flow. 
 
Ensure hydraulic oil is at the proper operating 
temperature. 
 
Verify engine speed control has been 
activated.

Crane is not receiving proper 
hydraulic pressure

Check hydraulic reservoir fluid level. 
 
Ensure PTO is engaged. 
 
Ensure Panic Bar E-Stop is not engaged. 
 
Verify selector switch is in crane mode and not 
stabilizer/off mode. 
 
Ensure dump valve is receiving proper electrical 
signal and operating properly. 
 
Verify hydraulic pump is producing proper 
pressure.

Crane does not have proper 
electrical power.

Check fuse and holder. 
 
Verify good ground. 
 
Verify good power supply. 
 
Verify proper voltage. 
 
Verify electrical wiring/connection integrity. 
 
Ensure manual/remote switch is working 
properly. 
 
Verify engine speed control has been 
activated.

Summary of Contents for Small OTR 2200

Page 1: ...www stellarindustries com Subject to Change without Notification 2021 Stellar Industries Inc Rev 1 PN 89711 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 2200 Model 3200 Model 6000 Model 4500 ...

Page 2: ...industries com Warranty Information warranty stellarindustries com 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 breat...

Page 3: ...alize 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 B...

Page 4: ... 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 ...

Page 5: ... 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 fulfillment 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 i...

Page 6: ...ower 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 flat 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 ...

Page 7: ...n the stabilizer makes solid contact with the ground release the control lever 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 Confirm that the stabilizers are pos...

Page 8: ...ionality immediately press down on the red Emergency Stop button Operating the Crane 1 Slowly pull the trigger and activate the main boom toggle up to un stow the crane from travel position 2 Once the crane is un stowed proceed with operating the proper toggles to perform the service Lifting the load Consider the following When performing a lift have the load as close to the ground as possible Nev...

Page 9: ...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...

Page 10: ... 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 Retract outriggers using the control levers or switches marked outrigger WARNING Step 10 Leave the worksite Step 6 Sto...

Page 11: ... Up and Down Extension Boom In and Out Rotation Clockwise and Counter Clockwise 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 DO NOT use the e stop as an on off button as it is intended solely for safety during emergencies The rechargeable battery ...

Page 12: ...equipment DANGER Electrocution Hazard Death or serious injury will result from inadequate clearance if crane load or vehicle becomes electrically charged Maintain safe clearance from high voltage power sources Never approach vehicle or load if equipment is near a high voltage power source C4545 WARNING Crush Hazard Keep clear of stabilizer legs during operation Failure to keep clear of moving stab...

Page 13: ...esult in death or serious injury Untrained Operator Hazard DANGER Electrocution Hazard Death or serious injury will result from inadequate clearance if crane load or vehicle becomes electrically charged Maintain safe clearance from high voltage power sources Never approach vehicle or load if equipment is near a high voltage power source 85504 charged from sources WARNING Keep clear of crane during...

Page 14: ...Page 10 Stellar Small OTR Service Crane Owner s Manual This page intentionally left blank ...

Page 15: ...ver modify or alter any of the equipment whether mechanical electrical or hydraulic without explicit approval from Stellar Industries Position the crane where it will be out of the way of other operations or vehicles in the area Stow the boom fully to prevent uncontrolled movement Place all controls in the off position and secure operating features from inadvertent motion Follow all company direct...

Page 16: ... Rotation Gear Bearing Maintenance Rotation Worm Gear and Open Gear Teeth Use a heavy Moly Lube grease Stellar PN 4460 to lubricate the worm gear and open gear teeth of the rotation bearing Slowly rotate the crane while pumping the grease between the worm and rotation gear This should be greased every month or sooner depending on the usage of the crane Another way of applying the grease would be t...

Page 17: ... torque value using the tightening sequence shown above Step 4 Torque all bolts to the listed torque value using the tightening sequence shown above Rotation Gear Bearing Thread Tightening Procedure 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 clamp loads after torquing Anyt...

Page 18: ...ly the torque values in the charts by the factor 90 The use of Loctite does not affect the torque values listed above Torque values for socket head capscrews are the same as for Grade 8 capscrews Rotation Gear Bearing Thread Tightening Procedure 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 1...

Page 19: ...ne Owner s Manual Page 15 Face Seal A Stellar PN Hose Size Fitting Size Stellar PN O ring Boss B 4 C2027 D1245 6 C2028 D1246 8 C2029 D1247 10 32223 D1248 12 D1244 D1249 16 1 3 4 5 8 1 2 3 8 1 4 D1250 B A Face Seal O Ring Size Chart ...

Page 20: ...vot Areas EP2 Lithium Complex Grease Stellar PN 78090 Crane Pins Bushings Crane Pivot Points EP2 Lithium Complex Grease Stellar PN 78090 Component Location Recommendation Reciprocating Single Stage Compressor Crankcase ISO 100 compresser oil Reciprocating Double Stage Compressor Crankcase ISO 100 compresser oil Compressor Crankcase 15 F to 86 F Synthetic performing ISO 32 compresser oil 23 F to 10...

Page 21: ...PTO is engaged if equipped To determine if there is an electrical or hydraulic problem first try to operate the crane manually See Manual Operation at end of this chapter If the crane operates there will be an electrical problem to trace If the crane does not operate using the manual overrides there is a problem within the hydraulic circuit MODEL NO SERIAL NO DATE MADE IN THE U S A BY STELLAR INDU...

Page 22: ...ng proper flow Ensure hydraulic oil is at the proper operating temperature Verify engine speed control has been activated Crane is not receiving proper hydraulic pressure Check hydraulic reservoir fluid level Ensure PTO is engaged Ensure Panic Bar E Stop is not engaged Verify selector switch is in crane mode and not stabilizer off mode Ensure dump valve is receiving proper electrical signal and op...

Page 23: ... operates slowly Crane is not receiving proper hydraulic flow Check hydraulic reservoir fluid level Ensure PTO is engaged Ensure Panic Bar E Stop is not engaged Verify selector switch is in crane mode and not stabilizer off mode Ensure dump valve is receiving proper electrical signal and operating properly Verify hydraulic pump is producing proper flow Ensure hydraulic oil is at the proper operati...

Page 24: ...r properly Refer to mfg manual Crane will operate electrically but will not operate manually Remote Manual switch is in the Remote position Toggle the Remote Manual switch to the Manual position Ensure the switch is working properly Not all crane functions operate using the radio remote transmitter or crane operated intermittently Radio receiver displaying an error code Refer to radio system manuf...

Page 25: ...both directions blow past relief to remove air from system The temperature of the hydraulic oil is too low Perform maneuvers without loads for several minutes to warm up the oil Lack of oil in reservoir Add hydraulic oil Counter balance valves are not functioning properly Contact Stellar Customer Service for support Crane rotation is abnormal during operation Inadequate bearing lubrication Lubrica...

Page 26: ...icate bushings Damaged structure Inspect and repair replace as needed Broken worn pin Replace pin Stabilizers fail to operate Remote Manual switch is in the Remote position Toggle switch to the Manual position Remote Manual switch is malfunctioning Inspect and repair replace as needed Panic bar E Stop is engaged Models 9000 13500 Release Panic bar E Stop ...

Page 27: ...e knurled sleeve out and then push or pull to operate the desired function 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 Return the valve bank manual overrides to the neutral position Failure to return the valve bank manual overrides to the...

Page 28: ...Subject to Change without Notification 2021 Stellar Industries Inc ...

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